Perkins 3000 Series

USER’S HANDBOOK

3012/CV12      12 cylinder diesel engines for industrial

applications

The contents of this handbook are applicable to both

CV12 and 3000 Series - 3012 engines.

Publication TSD 3138 (issue 13)

©Proprietary information of Perkins Group Limited, all rights reserved

The information is correct at the time of print.

Published in May 2001 by Technical Publications,

Perkins Engines Company Limited, Lancaster Road,

Shrewsbury, Shropshire SY1 3NX, England

1

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Contents

1 General information

Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5

How to care for your engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5

Engine identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6

Perkins companies  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7

Safety precautions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  8

2 Engine views

Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9

Location of engine parts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9

3 Operation instructions

Preparations for a new or an overhauled engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   11

How to start a new or overhauled engine or an engine which has been in storage  . . . .   12

Normal start procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  13

How to start the engine in low ambient temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . .   13

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   13

How to stop the engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  13

4 Preventive maintenance

Preventive maintenance periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   15

Schedule for engines in normal use  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   16

Schedule for engines in intermittent use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   17

Coolant level  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18

Lubricating oil level  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18

Restriction indicator   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19

How to renew the elements of the air filters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   19

How to drain the primary fuel filter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19

How to check the drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   20

How to renew the fan belts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20

How to renew the alternator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   20

How to check the specific gravity of the coolant  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  21

How to check the pH value of the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  21

How to renew the engine lubricating oil  .  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  22

How to renew the canisters of the oil filter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  22

Continued

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This document has been printed from SPI². Not for Resale

How to clean the primary fuel filter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  23

How to renew the canister of the main fuel filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  23

How to check/adjust the timing of the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . .  24

Fuel injector fault  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

How to remove the fuel injectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

How to correct the fuel injector sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25

How to fit the fuel injectors   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25

How to eliminate air from the fuel system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  27

How to check the tappet clearances  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  28

Turbochargers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29

How to drain the coolant system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29

How to clean the coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29

How to fill the coolant system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29

5 Engine fluids

Diesel fuel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  31

Coolant   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Lubricating oil   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  32

Recommended oils for Europe  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  33

Recommended oils for remainder of the world  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  34

Warranty  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  34

6 Fault diagnosis

Problems and possible causes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  36

Code list of possible causes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  37

7 Engine preservation

Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  39

Short period storage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  39

Long period storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  39

Removal from storage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Approved products for engine preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  41

8 Parts and Service

Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  43

Service literature  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  43

Training  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  43

Service Bulletins  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  43

9 Engine data

3012 diesel engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  45

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General information

1

Introduction

The 3012 heavy duty diesel engine is the latest

development from Perkins Engines Company

How to care for your engine

Limited, a world leader in the design and manufacture

of high performance diesel engines.

This handbook has been written to assist you to

maintain and operate your engine correctly.

More than fifty years of diesel production experience,

together with the use of the latest technology, have

been used in the manufacture of your engine to give

you reliable and economic power.

To obtain the best performance and the longest life

from your engine, you must ensure that the

maintenance operations are done at the intervals

shown in ‘Preventive maintenance’. If the engine is

operated in a very dusty environment or other

adverse conditions, certain maintenance intervals will

have to be reduced. Renew the filter elements and the

lubricating oil regularly to ensure that the inside of

your engine remains clean.

To ensure that you use the correct information for

your specific engine type, refer to ‘Engine

identification’ on page 6.

Danger is indicated in the text by two methods:

Warning!  This indicates that there is a possible

danger to the person.

Ensure that all adjustments and repairs are done by

personnel who have had the correct training. Perkins

distributors have this type of personnel available. You

can also obtain parts and service from your Perkins

distributor. If you do not know the address of your

nearest distributor, enquire at one of the Perkins

companies listed on page 7.

Caution:  This indicates that there is a possible

danger to the engine.

Note:  Is used where the information is important, but

there is not a danger.

The left and right sides of the engine are as seen from

the rear (flywheel) end. Where reference is made to

‘A’ and ‘B’ banks of cylinders: ‘A’ bank is to the right

and ‘B’ bank is to the left when viewed from the rear

end.

Read the ‘Safety precautions’ and remember

them. They are given for your protection and must

be applied at all times.

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Engine identification

If you need parts, service or information for your

engine, you must give the complete engine number to

your Perkins distributor.

The engine number is stamped on the data plate

which is fastened to the left side of the crankcase.

For early engines, a typical engine number is:

6A27487U 59426U, which consists of these codes:

6A

=

Engine family

27487   =

Engine number

U

=

Country of manufacture

Build line number

Year of manufacture

59426   =

U

=

Engines made after August 1994, have a new engine

number system. For these engines, a typical number

is: SGJ 12 0029 U 3254 C, which consists of these

codes:

SG

J

=

=

=

=

=

=

=

Engine application

Engine type

12

Number of engine cylinders

Engine specification number

Country of manufacture

Build line number

0029

U

3254

C

Year of manufacture

Units such as the fuel injection pump and

turbochargers have their own data plates.

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Perkins companies

Korea

Perkins Engines (Korea)

Textile Center 12F

Daechi 3 dong 944-31

Kangnam-Ku

Australia

Perkins Engines Australia Pty. Limited,

Suite 4, 13A Main Street,

Mornington, Victoria 3931, Australia.

Telephone: 0061 (0)597 51877

Telex: Perkoil AA 30816

Seoul, 135-283

Korea

Telephone: (822) 528 3377

Fax: (822) 528 3378

Fax: 0061 (0)597 1305

China

Singapore

Perkins Engines (Tianjin) Limited,

Jinwei Road,

Perkins Engines (Asia Pacific) Pte. Limited,

20 Harbour Drive,

Beichen District, Tianjin,

300402

#07-06A, PSA Vista,

Singapore 117612.

China

Telephone: (86) (22) 2699 2288

Fax: (86) (22) 2699 3784

Telephone: (65) 874 7712

Fax: (65) 874 7722

United Kingdom

France

Perkins Engines Company Limited,

Lancaster Road, Shrewsbury, SY1 3NX,

England.

Perkins France SAS,

"Parc des reflets",

165 Avenue du Bois de la Pie,

95700 Roissy Charles de Gaulle, France.

Telephone: 0033 (01) 49-90-7171

Fax: 0033 (01) 49-90-7190

Telephone: 0044 (0)1743 212000

Telex: 35171 PESL G

Fax: 0044 (0)1743 212700

United States of America

Germany

Perkins Engines - North America

12025, Tech Center Drive

Livonia

Michigan 48150

USA

Perkins Motoren G.m.b.H.,

Saalaeckerstrasse 4,

63801 Kleinostheim,

Germany.

Telephone: 0049 6027 5010

Fax: 0049 6027 501124

Telephone: 001 313 266 5427

Fax: 001 313 266 2700

Italy

Perkins Engines Latin America Inc,

Suite 620,

Motori Perkins S.p.A.,

Via Socrate 8

999, Ponce de Leon Boulevard,

Coral Gables,

Florida 33134,

22070 Casnate con Bernate (Como), Italy.

Telephone: 0039 (0)31 564625/564633

Fax: 0039 (0)31 565480/564145/396001

USA.

Telephone: 001 305 442 7413

Telex: 32501 Perken G

Fax: 001 305 442 7419

Japan

Perkins Engines, Inc. Japan Branch,

8 Fl, 2-2-19 Akasaka, Minato-ku,

Tokyo 107-0052, Japan.

Telephone: 0081 (0)3 3560 3877

Fax: 0081 (0)3 3560 3878

In addition to the above companies, there are

Perkins distributors in most countries. Perkins

Engines Company Limited, Shrewsbury or one of

the above companies can provide details.

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Safety precautions

Disconnect the battery terminals before a repair is

made to the electrical system.

These safety precautions are important.

Only one person must control the engine.

Reference must also be made to the local regulations

in the country of operation.

Ensure that the engine is operated only from the

control panel or from the operator’s position.

If your skin comes into contact with high-pressure

fuel, obtain medical assistance immediately.

Only use these engines in the type of application

for which they have been designed.

Diesel fuel and lubricating oil (especially used

lubricating oil) can damage the skin of certain

persons. Protect your hands with gloves or a

special solution to protect the skin.

Do not change the specification of the engine.

Do not smoke when you put fuel in the tank.

Clea, n away fuel which has been spilt. Material

which has been contaminated by fuel must be

moved to a safe place.

Do not wear clothing which is contaminated by

lubricating oil. Do not put material which is

contaminated with oil into the pockets.

Do not put fuel in the tank while the engine runs

(unless it is absolutely necessary).

Discard used lubricating oil in a safe place to

prevent contamination.

Do not clean, add lubricating oil, or adjust the

engine while it runs (unless you have had the

correct training; even then extreme caution must

be used to prevent injury).

Ensure that the control lever of the transmission

drive is in the ‘out-of-drive’ position before the

engine is started.

Do not make adjustments that you do not

understand.

The combustible material of some components of

the engine (for example certain seals) can

become extremely dangerous if it is burned. Never

allow this burnt material to come into contact with

the skin or with the eyes.

Ensure that the engine does not run in a location

where it can cause a concentration of toxic

emissions.

Other persons must be kept at a safe distance

while the engine or equipment is in operation.

Fuel and oil pipes MUST be inspected for cracks

or damage before they are fitted to the engine.

Do not permit loose clothing or long hair near

moving parts.

Fit only genuine Perkins parts.

Keep away from moving parts during engine

operation. Warning!  Some moving parts cannot

be seen clearly while the engine runs.

Do not operate the engine if a safety guard has

been removed.

Do not remove the filler cap of the cooling system

while the engine is hot and while the coolant is

under pressure, because dangerous hot coolant

can be discharged.

Do not use salt water or any other coolant which

can cause corrosion in the closed coolant circuit.

Do not allow sparks or fire near the batteries

(especially when the batteries are on charge)

because the gases from the electrolyte are highly

flammable. The battery fluid is dangerous to the

skin and especially to the eyes.

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Engine views

2

Introduction

Perkins engines are built for specific applications and

the views which follow do not necessarily match your

engine specification.

Location of engine parts

Front and left side view of the 3012 engine

1 ‘B’ bank air cleaner

2 ‘B’ bank turbocharger

3 Exhaust manifold

4 Coolant pump

5 Canisters of the lubricating oil filter

6 Crankcase breather

7 Fan

8 Thermostat housings

8

1

2

3

7

4

6

5

A

482

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Rear and right side view of the 3012 engine

1 ‘A’ bank turbocharger

2 Alternator

6 Starter motor

7 Flywheel housing

8 Flywheel

3 Dipstick

4 Filler cap for lubricating oil

5 Lubricating oil sump

9 Canisters of the fuel filter

10 ‘A’ bank air cleaner

10

1

9

8

2

3

7

4

6

5

B

483

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Operation instructions

3

Preparations for a new or an overhauled

engine

Every new engine supplied by Perkins Engines

Company Limited, Shrewsbury, is run-in before it

leaves the factory.

1

1  Check that all protection covers and blanking plugs

have been removed.

2  Fit all components that were removed for storage

or for transport.

3  Ensure that drain plugs for coolant and for

lubricating oil are securely fitted.

4  Where necessary, connect the remote control

linkages, the pressure gauge pipes, the air inlet pipes

and the wiring loom.

2

A

57

5  Connect the fuel pipes.

6  Connect the exhaust pipes.

7  Fill the fuel tank(s) with the correct grade of fuel

(see page 31).

1

8  Fill the cooling system with the approved coolant

mixture (see page 31).

9  Fill the sump to the H mark on the dipstick with the

correct grade of lubricating oil (see page 32).

10  Clean the area around the plug (A1) on the

governor housing of the injection pump and remove

1

the plug. Add approximately 0,2 litres (  /  pint) of

3

clean engine oil of the correct grade (see page 32) to

the governor housing. Fit and tighten the plug

securely.

B

58

11  Add oil to the turbochargers as follows: Clean the

area around the blanking plug (B1) on the bearing

housing of each turbocharger. Remove the plugs (B1)

1

and add 0,2 litre (  /  pint) of engine oil of the correct

3

grade to each turbocharger. Fit and tighten the plugs.

12  Eliminate air from the fuel system (see page 27).

13  Lubricate all of the control linkages and check the

linkages for free movement.

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How to start a new or overhauled engine

or an engine which has been in storage

Prepare to start the engine as given in paragraphs 1

to 13 on page 11.

If an engine has been in storage for a period of more

than one month, add clean lubricating oil to the fuel

injection pump and to the turbochargers. If the engine

has been in storage for less than one month, but the

fuel injection pump has been removed and fitted, add

lubricating oil to the fuel injection pump. The

procedure is described on page 11, paragraphs 10

and 11. Use clean engine oil of the same grade and

specification as that already in the system.

Start procedure

Ensure that the stop control is in the STOP position

and that the speed control lever is in the IDLE

position. Press the start button for 10 seconds and

then release it for 10 seconds, then press it for 20

seconds and release it for 20 seconds. Oil pressure

MUST be indicated on the gauge. Move the stop

control lever to the RUN position and proceed as for

a normal start.

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Normal start procedures

Precautions

Service checks each day before first engine start

The precautions that follow will help to ensure a long

and fault-free life for the engine:

1  Check that the level of coolant is just at the bottom

of the filler extension in the radiator. Fill, if necessary,

to the required level with the approved coolant

mixture. If there is a large loss of coolant find the

reason.

Variable speed engines

1  Do not operate the engine at high speeds and loads

until the coolant has reached a minimum temperature

of 78°C.

2  Check the engine oil level. With the engine

stopped the oil level must be at the H mark on the

dipstick. If necessary, add oil of the same grade and

specification as that already in the system. Do NOT

add more oil than is necessary.

2  Do not allow the engine to run at idle speed for

prolonged periods.

3  Do not exceed the maximum no load speed.

4  Never allow an engine to continue to run if the oil

pressure is below 170 kN/m² (25 lbf/in²) at rated

speed.

3  Ensure that the fuel tank is full.

4  Check the air restriction indicator.

5  Fill the fuel tank(s) at the end of each day to prevent

condensation.

Caution:  If a fuel injection pump or turbocharger has

been removed from an engine, it must be primed with

clean engine oil of the correct grade before the engine

is first started. See page 11, paragraphs 10 and 11.

Constant speed engines

1  Do not operate the engine with a full load until the

coolant has reached a minimum temperature of 78°C.

Variable speed engines

2  Do not allow the engine to run with no load for

prolonged periods.

Perform the daily service checks then proceed as

follows:

3  Ensure that the fuel tank(s) are full to prevent

condensation.

Turn on the fuel supply.

Move the stop control to the RUN position.

Move the speed control lever to the maximum speed    How to stop the engine

position.

Variable speed engines

Press the start button and release it when the engine

starts.

1  Put the gear lever into the NEUTRAL position.

2  Operate the engine at approximately 800 rev/min

for 3 minutes to allow the turbochargers to reduce

speed and temperature.

Move the speed control lever to the idle position.

Constant speed engines

Perform daily service checks then proceed as follows:

Turn on the fuel supply.

3  Move the stop control to the STOP position.

Constant speed engines

Move the stop control to the RUN position.

1  Operate the engine for 3 minutes at idle speed with

no load to allow the turbochargers to reduce speed

and temperature.

Press the start button and release it when the engine

starts.

2  Move the switches for the engine protection

devices to the OFF position.

How to start the engine in low ambient

temperatures

3  Move the stop control to the STOP position.

4  Turn off the fuel supply.

An excess fuel device, within the fuel injection pump,

works as a starting aid when ambient temperatures

are below 0°C.

Before the engine is started, push fully in, the control

rod of the excess fuel device. Press the start button

and release it when the engine starts. The control rod

returns automatically to its original position when the

engine starts.

Caution:  The excess fuel device must not be used at

the same time as other cold starting aids as the extra

fuel will make the engine more difficult to start.

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Preventive maintenance

4

Preventive maintenance periods

These preventive maintenance periods apply to

average conditions of operation. Check the periods

given by the manufacturer of the equipment in which

the engine is installed. If necessary, use the shorter

periods. When the operation of the engine must

conform to the local regulations, these periods and

procedures may need to be adapted to ensure correct

operation of the engine.

The service intervals can be reduced for operation in

adverse conditions. The intervals must not be

extended unless Perkins Engines Company Limited

have approved the changes as indicated in the

Perkins Warranty. It is good preventive maintenance

to check for leakage and loose fasteners at each

service. These maintenance periods apply only to

engines that are operated with fuel and lubricating oil

which conform to the specifications given in this

handbook.

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4

Schedule for engines in normal use

The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.

A - Every 10 hours or daily

B - Every 400 hours or 12 months

C - Every 1200 hours or 24 months

A

B

C

Operation

Check the amount of coolant

Check the level of the lubricating oil

Check the restriction indicators for the air filters and, when necessary, renew the filter

elements

Drain the water/sediment from the primary fuel filter

Check the condition and the tension of all drive belts

Check the specific gravity and the pH value of the coolant

Renew the lubricating oil

Renew the canisters of the lubricating oil filter

Renew the canister of the main fuel filter

Clean the primary fuel filter

Ensure that the mounting nuts for the turbochargers are tightened securely

Check that the air charge cooler and the radiator are clean and free from debris

Check the timing of the fuel injection pump

Check that the drive coupling bolts of the fuel injection pump are tightened to 120 Nm

(88 lbf ft)

Ensure that the fuel injectors are checked and corrected or renewed, if necessary*

Ensure that the tappet clearances are checked and adjusted, if necessary*

*  By a person who has had the correct training.

In addition to the operations listed above, the operations listed below must be applied at 12 month

intervals:

Drain and flush the coolant system and renew the coolant mixture

Check the turbochargers, ensure that they are checked and corrected if necessary*

Ensure that the alternator is checked and corrected if necessary*

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4

Schedule for engines in intermittent use

For engines which are in use for a total of less than 400 hours in every twelve months, the schedule below

must be used:

The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.

A - Monthly

B - Every 200 hours or 12 months

C - Every 1000 hours or 24 months

A

B

C

Operation

Check the amount of coolant

Check the level of the lubricating oil

Check the restriction indicators for the air filters and, when necessary, renew the filter

elements

Start and run the engine with 30% load (minimum), until normal temperature of

operation is reached

Drain the water/sediment from the primary fuel filter

Check the condition and the tension of all drive belts

Check the specific gravity and the pH value of the coolant

Renew the lubricating oil

Renew the canisters of the lubricating oil filter

Renew the canister of the main fuel filter

Clean the primary fuel filter

Ensure that the mounting nuts for the turbochargers are tightened securely

Check the timing of the fuel injection pump

Check that the drive coupling bolts of the fuel injection pump are tightened to 120 Nm

(88 lbf ft)

Ensure that the fuel injectors are checked and corrected or renewed, if necessary*

Ensure that the tappet clearances are checked and adjusted, if necessary*

*  By a person who has had the correct training.

In addition to the operations listed above, the operations listed below must be applied at 12 month

intervals:

Drain and flush the coolant system and renew the coolant mixture

Check the turbochargers, ensure that they are checked and corrected if necessary*

Check that the air charge cooler and the radiator are clean and free from debris

Ensure that the alternator is checked and corrected if necessary*

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4

Coolant level

Remove the filler cap from the radiator and check that

the level of the coolant mixture just touches the

bottom of the filler tube inside the radiator. If

necessary, add coolant until the level of the coolant

reaches the filler tube. Fit the filler cap.

Caution:  If coolant is added to the system during

service, it must consist of the same original mixture as

used to fill the system.

Warning!  On a hot engine release the filler cap

carefully as the system will be under pressure.

Lubricating oil level

At the periods given in the service schedule use the

dipstick to check the amount of lubricating oil in the

sump. While the engine runs, the oil level must be

above the L mark. With the engine stopped the oil

level must be at the H mark on the dipstick. If

necessary, put more oil into the sump. Use the same

grade and specification as that already in the system.

Do NOT overfill.

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4

Restriction indicator

Each air filter is fitted with an indicator (A) which gives

a visual warning when the filter needs a service.

When the red warning indicator is seen through the

clear panel after the engine has stopped, the air filter

element must be renewed.

After a clean element has been fitted, press the reset

button on the restriction indicator.

How to renew the elements of the air

filters

A

37

The two air filters (B) contain paper elements. These

must not be washed. Renew the paper elements as

follows:

1  Loosen the clamp and remove the end cover (B1).

Remove the wing nut (B2), withdraw and discard the

filter element (B3).

2  Clean, thoroughly, the inside of the casing of the air

filter. Fit a new filter element and fit the end cover.

3  Reset the restriction indicator.

Repeat this procedure for the other air filter.

How to drain the primary fuel filter

3

1  Remove the drain plug from the base of the filter

bowl and allow any water or sediment to drain from

the unit.

2

1

2  Fit the drain plug and tighten it securely.

B

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4

How to check the drive belts

Check all drive belts and renew a belt if it is worn or

damaged. Where more than one belt is used between

two pulleys, all of the belts must be renewed together.

Maximum belt life will be obtained only if the belts are

kept at the correct tensions.

1

2

Check the belt tension at the centre of the longest free

length, for example, position (A5) to check the fan

drive belts.

5

Use a ‘Gates "Krikit" V-belt tension gauge’ or similar

tool to check the tension of the belts.

4

3

A

The correct tension for all belts is 400 to 489 N (90 to

100 lbf). Where more than one belt is used between

two pulleys, check/adjust the tension on the tightest

belt.

59

Note:  When new belts are fitted they must be

checked again after the engine has been run for 15

minutes and, if necessary, adjusted to the correct

tension.

1

How to adjust the tension of the fan belts

1  To adjust the tension of the fan belts, loosen the

nuts on the adjustment bolt. Loosen the large lock nut

(B1) on the belt tensioner and turn the adjustment bolt

(B2) until the correct tension is obtained.

2

B

2  Tighten the lock nut and check the tension of the

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belts again.

How to renew the alternator belt

3  Run the engine for 15 minutes and then check the

belt tension again.

1  Remove the fan belts from the crankshaft pulley as

given on this page.

Check the tension of new belts every week for four

weeks and then at the intervals specified in the

service schedule

2  Loosen the adjustment bolts to release the tension

on the alternator belt and remove the old belt. Check

that the pulley grooves are clean and fit a new belt.

Adjust the belt to the correct tension. Fit the fan belts

as given on this page.

How to adjust the tension of the alternator belt

1  Loosen the alternator pivot bolt (A1), the

adjustment link bolt (A3) and the adjustment bolt (A2).

Move the alternator to obtain the correct belt tension

and tighten the bolts.

2  Run the engine for 15 minutes and then check the

belt tension again.

Check the tension of new belts every week for four

weeks and then at the intervals specified in the

service schedule.

How to renew the fan belts

1  To renew the fan belts, remove the six bolts which

fasten the fan to the pulley and push the fan forward

into the radiator cowl.

2  Release the tension on the belts and remove the

old belts. Ensure that the pulley grooves are free from

grease and dirt. Fit a new set of belts.

3  Fit the fan and tighten the bolts securely. Adjust the

fan belts to the correct tension.

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