Perkins 3000 Series

WORKSHOP MANUAL

3012/CV12

12 cylinder diesel engines for industrial

applications

The contents of this manual are applicable to both

CV12 and 3000 Series - 3012 engines.

Publication TSD 3420, Issue 3

© Perkins Group Limited 2000, all rights reserved.

Published in September 2000 by Technical Publications.

Perkins Engines Company Limited, Lancaster Road,

Shrewsbury SY1 3NX, England

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Contents

10 General information

Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... .13

Bank and cylinder bore identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .13

Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .13

General safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .14

Safety .  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .15

Useful information   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .16

Approved lubricants and fluids ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... .21

11 Specifications

Basic engine data  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .23

Recommended specific applied torques  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .26

Recommended nominal applied torques  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .28

12 Cylinder head assembly

General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 29

Pedestal rocker cover

12-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .31

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Pedestal rocker assembly

12-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 32

12-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  33

Rocker box cover

12-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 34

Rocker box

12-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 34

12-6 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  35

12-7 To inspect and to correct  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  36

Tappet clearances

12-8 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  38

Cylinder head assembly

12-9 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 40

12-10 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  44

12-11 To clean and to inspect the cylinder head  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  45

12-12 To correct a valve seat   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  46

12-13 To remove a valve seat insert .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  47

12-14 To fit a valve seat insert ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  48

12-15 To inspect the valve guides  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  49

12-16 To renew a valve guide  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  50

12-17 To inspect the bridge pieces and guides  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  51

12-18 To renew a bridge piece guide   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  51

12-19 To recondition a fuel injector sleeve   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  52

12-20 To renew a fuel injector sleeve  ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  53

Valves, valve springs and valve rotators

12-21 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  57

12-22 To inspect and to correct  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  57

Push rods

12-23 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 58

12-24 To inspect   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  58

Fits and clearances - Cylinder heads, rocker assemblies and valves  . ... ... ... ... ...  59

Cylinder heads, rocker assemblies and valves (continued)  . ... ... ... ... ... ... ... ... ...  60

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13 Pistons and connecting rods

General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 61

Big end bearings

13-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .63

13-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .64

Piston and connecting rod assembly

13-3 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .65

13-4 To dismantle and to assemble  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .68

Piston rings

13-5 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .70

Piston and rings

13-6 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .71

Connecting rod

13-7 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .71

Fits and clearances - Pistons and connecting rods

Pistons - 4 rings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... .72

Piston rings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .72

Pistons - 3 rings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... .74

Piston rings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .74

Connecting rods  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 76

14 Crankshaft assembly

General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 77

Crankshaft pulley, damper and alternator pulley

14-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78

Front oil seal

14-2 To renew  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .79

Rear oil seal

14-3 To renew  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .81

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Crankshaft

14-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 83

14-5 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  88

14-6 To clean and inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  88

Main bearings and thrust washers

14-7 To inspect  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  88

Fits and clearances  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  89

15 Timing gears and timing case

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  91

Timing gears and auxiliary drive shaft

15-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 92

15-2 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  98

Double idler gear

15-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  98

Auxiliary drive gear

15-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  98

Timing case

15-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 99

15-6 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 100

Fits and clearances  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 101

16 Crankcase and cylinder liners

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 105

Crankcase

16-1 To fit to and to remove from a build stand  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 107

16-2 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 110

16-3 To clean, to inspect and to correct . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 114

16-4 To test under pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 115

Cylinder liner

16-5 To clean and inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 115

Fits and clearances  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 116

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17 Camshafts and engine timing

General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...119

Camshafts

17-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...121

17-2 To clean and inspect . ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ...125

Engine timing

17-3 To check the valve timing .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...126

17-4 To check/adjust the timing of the fuel injection pump  ... ... ... ... ... ... ... ... ... ... ...127

Fits and clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...128

18 Induction and exhaust system

General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...129

Turbocharger

18-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...129

18-2 To dismantle and to assemble  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...131

18-3 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...134

Exhaust manifold

18-4 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135

Induction manifold

18-5 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135

Fits and clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...136

19 Lubrication system

General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137

Lubricating oil sump - early engines

19-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139

19-2 To clean and inspect . ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ...139

Sump adaptor - early engines

19-3 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139

19-4 To clean and inspect . ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ...140

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Single piece lubricating oil sump

19-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 140

19-6 To clean and inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 141

Lubricating oil pump

19-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 142

19-8 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 143

19-9 To clean and inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 144

Heat exchanger (oil to coolant) - early engines

19-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 145

19-11 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146

19-12 To clean and to inspect  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146

Mounting adaptor for the heat exchanger - early engines

19-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 147

Heat exchanger (oil to coolant)

19-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 148

19-15 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 149

19-16 To clean and to inspect  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 150

Relief valve

19-17 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 151

20 Fuel system

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 153

Primary fuel filter

20-1 How to clean the primary fuel filter   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 156

Fuel filter canisters

20-2 How to renew the canisters of the main fuel filter  .. ... ... ... ... ... ... ... ... ... ... ... .. 156

Fuel filter head

20-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157

Mechanical fuel lift pump

20-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 158

20-5 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 159

20-6 To test  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 160

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Fuel injectors

20-7 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...161

20-8 To dismantle and to assemble  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...162

20-9 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...163

20-10 To set and to test   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...165

Fuel injection pump and governor

20-11 To remove and to fit   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...166

20-12 To dismantle and to assemble   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...171

20-13 To inspect  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...187

20-14 To calibrate the fuel injection pump   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...189

20-15 To test the fuel injection pump   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...190

Sizes of spacers (A) available for the tappets  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 192

Sizes of lower spring plates (A) available  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...193

Fuel system

20-16 How to eliminate air from the fuel system  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...194

21 Cooling system

General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...195

Radiator

21-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...197

21-2 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...197

Thermostats

21-3 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...198

21-4 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...198

Coolant pump

21-5 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...199

21-6 To dismantle and to assemble  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...200

21-7 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...202

Fan

21-8 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...203

Fan belts and tensioner pulley

21-9 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...204

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Fan adaptor

21-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 205

21-11 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 207

21-12 To clean and to inspect  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 210

22 Flywheel and flywheel housing

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 211

Flywheel

22-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 211

22-2 To inspect  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 211

Starter ring

22-3 To renew  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 212

Flywheel housing

22-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 212

23 Electrical equipment

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 215

Alternator

23-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 218

23-2 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 220

23-3 To clean . ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 221

23-4 To inspect and to correct the rotor . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 221

23-5 To remove and to fit the rectifier  ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 222

23-6 To test the main diodes with an ohmmeter or a test lamp . ... ... ... ... ... ...  ... ... .. 222

23-7 To test the auxiliary diodes  ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... .. 223

23-8 To remove and to fit the D+ and F- wires  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223

23-9 To check and to renew the carbon brushes ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223

23-10 To inspect the stator and the housing .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223

23-11 To inspect the bearings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224

23-12 To renew the bearing at the slip ring end   ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224

23-13 To renew the bearing at the drive end .  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224

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Starter motor

23-14 To remove and to fit   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...225

23-15 To dismantle and to assemble the solenoid switch . ... ... ... ... ... ... ... ... ... ... ...226

23-16 To dismantle and to assemble the starter motor . ... ... ... ... ... ... ... ... ... ... ... ...228

23-17 To clean  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...230

23-18 To inspect and to correct . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...230

23-19 To test  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...231

23-20 To fit the main starter cables ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...232

Electrical switches

23-21 To test  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...233

Engine stop solenoid (energised to run)

23-22 To adjust the linkage ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...234

Early 3012 engines  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...235

24 Auxiliary equipment

General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...237

25 Running-in and test

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...239

Running-in and test

25-1 To run the engine .. ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...239

25-2 To check the consumption rate of the engine lubricating oil  . ... ... ... ... ... ... ... ...240

26 Special tools

List of special tools  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...241

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General information

10

Introduction

This workshop manual has been designed to provide    Engine identification

assistance in the service and the overhaul of Perkins

3012 (CV12) engines.  Most of the general

information, which is included in the User’s Handbook

(Sections 1 to 9), has not been repeated in this

Workshop Manual and the two publications should be

used together.

The engine number is stamped on the data plate

which is fastened to the right side of the crankcase.

For early engines, a typical engine number is

6A27487U 59426V, which consists of these codes:

6A

=

Engine family

Read the ’Safety precautions’ and remember them.

They are given for your protection and must be

applied at all times.

27487   =

Engine number

U

=

Country of manufacture

Build line number

Year of manufacture

Danger is indicated in the text by two methods:

59426   =

Warning!  This indicates that there is a possible

V

=

danger to the person.

Engines produced after August 1994, have a new

engine number system.  For these engines, a typical

number is: SGD 12 0012 U 1572 Y, which consists of

these codes:

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.

SG

D

=

=

=

=

=

=

=

Engine application

Engine type

Bank and cylinder bore identification

12

0012

U

Number of engine cylinders

Engine specification number

The country of manufacture

Build line number

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 left and

’B’ bank to the right when viewed from the front end.

1572

Y

The cylinders are numbered from the front of the

crankcase, A1 to A6 and B1 to B6.

Year of manufacture

Units such as the fuel injection pump and

turbochargers have their own data plates.

To ensure that you use the correct information for

your specific engine type, refer to ’Engine

identification’ below.

If you need parts, service or information for your

engine, you must give the complete engine number to

your Perkins distributor.

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General safety precautions

Read and use the instructions relevant to lift

equipment which are given on page 15.

These safety precautions are important.

Reference must also be made to the local regulations

in the country of operation.

Always use a safety cage to protect the operator

when a component is to be pressure tested in a

tank of water. Fit safety wires to secure the plugs

which seal the hose connections of a component

which is to be pressure tested.

Only use these engines in the type of application

for which they have been designed.

Do not allow compressed air to contact your skin.

If compressed air enters your skin, obtain medical

help immediately.

Do not change the specification of the engine.

Do not smoke when you put fuel in the tank.

Clean away fuel which has been spilt. Material

which has been contaminated by fuel must be

moved to a safe place.

Turbochargers operate at a high speed and at

high temperatures. Keep fingers, tools and other

items away from the inlet and outlet ports of the

turbocharger and prevent contact with hot

surfaces.

Do not put fuel in the tank while the engine runs

(unless it is absolutely necessary).

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).

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 make adjustments that you do not

understand.

Do not wear clothing which is contaminated by

lubricating oil. Do not put material which is

contaminated with oil into the pockets.

Ensure that the engine does not run in a location

where it can cause a concentration of toxic

emissions.

Discard used lubricating oil in a safe place to

prevent contamination.

Other persons must be kept at a safe distance

while the engine or equipment is in operation.

Ensure that the control lever of the transmission

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

engine is started.

Do not permit loose clothing or long hair near

moving parts.

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.

Keep away from moving parts during engine

operation. Warning! The fan cannot be seen

clearly while the engine runs.

Do not operate the engine if a safety guard has

been removed.

Fit only genuine Perkins parts.

Do not remove the filler cap of the cooling system

while the engine is hot and while the coolant is

under pressure as dangerous hot coolant can be

discharged.

Fuel and oil pipes MUST be inspected for cracks

or damage before they are fitted to the engine.

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.

Disconnect the battery terminals before a repair is

made to the electrical system.

Only one person must control the engine.

Ensure that the engine is operated only from the

control panel or from the operator’s position.

Be extremely careful if emergency repairs must be

made in adverse conditions.

If your skin comes into contact with high pressure

fuel, obtain medical assistance immediately.

14

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Safety

.

Engine lift equipment

Use only the lift equipment which is designed for the

engine.  The part number for the lift adaptor to use for

the 3012 engine is: 21825 822.

Use lift equipment or obtain assistance to lift heavy

engine components such as the cylinder block,

cylinder head, flywheel housing, crankshaft and

flywheel.

Check the engine lift brackets for security before the

engine is lifted.

A

Asbestos joints

Viton seals

Some joints and gaskets contain compressed

asbestos fibres in a rubber compound or in a metal

outer cover.  The ’white’ asbestos (Chrysotile) which

is used is a safer type of asbestos and the danger of

damage to health is extremely small.

Some seals used in engines and in components fitted

to engines are made from Viton.

Viton is used by many manufacturers and is a safe

material under normal conditions of operation.

If Viton is burned, a product of this burnt material is an

acid which is extremely dangerous.  Never allow this

burnt material to come into contact with the skin or

with the eyes.

Contact with asbestos particles normally occurs at

joint edges or where a joint is damaged during

removal, or where a joint is removed by an abrasive

method.

If it is necessary to come into contact with

components which have been burnt, ensure that the

precautions which follow are used:

To ensure that the risk is kept to a minimum, the

procedures given below must be followed when an

engine which has asbestos joints is dismantled or

assembled.

Ensure that the components have cooled.

Work in an area with good ventilation.

Do NOT smoke.

Use Neoprene gloves and discard the gloves

safely after use.

Wash the area with a calcium hydroxide solution

and then with clean water.

Use a hand scraper to remove the joints - do NOT

use a rotary wire brush.

Disposal of gloves and components which are

contaminated, must be in accordance with local

regulations.

Ensure that the joint to be removed is wet with oil

or water to contain any loose particles.

Spray all asbestos debris with water and place it in

a closed container which can be sealed for safe

disposal.

If there is contamination of the skin or eyes, wash the

affected area with a continuous supply of clean water

or with a calcium hydroxide solution for 15-60

minutes.  Obtain immediate medical attention.

Environmental protection

There is legislation to protect the environment from

the incorrect disposal of used lubricating oil.  To

ensure that the environment is protected, consult your

Local Authority who can give advice.

Perkins Engines Company Limited

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Useful information

To clean components

It is important that the work area is kept clean and that

the components are protected from dirt and other

debris.  Ensure that dirt does not contaminate the fuel

system.

Before a component is removed from the engine,

clean around the component and ensure that all

openings, disconnected hoses and pipes are sealed.

Remove, clean and inspect each component

carefully.  If it is usable, put it in a clean dry place until

needed.  Ball and roller bearings must be cleaned

thoroughly and inspected.  If the bearings are usable,

they must be flushed in low viscosity oil and protected

with clean paper until needed.

Before the components are assembled, ensure that

the area is as free from dust and dirt as possible.

Inspect each component immediately before it is

fitted, wash all pipes and ports and pass dry

compressed air through them before connections are

made.

Use suitable gloves for protection when components

are degreased or cleaned with trichloroethylene,

white spirit, etc.  Degreasing solutions which are

basically trichloroethane are not recommended.

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Leave to soak until all contamination has been

Suitable fluids to clean and to protect

components

removed.

Warning!  Full information for the use of all the

products listed below and for their safe disposal, and

especially for the health and safety of the personnel

who use them, will be found in the Manufacturer’s

data.

Subsequently, the components must be thoroughly

flushed in clean water.  If necessary, a suitable

corrosion inhibitor can be added to the last quantity of

water.

Warning!  Protection for the eyes and for the skin

Ardrox 667: Ardrox Limited, Brentford, Middlesex.

must be used always during the use of this product.

Maxan 774:Henkel Chemicals Limited, Edgeware

Crodafluid CR2: Croda Chemicals Limited, Goole,

Road, London.

Yorkshire.

These products are basically methylene chloride and

are safe to use on most metals for the removal of

carbon and to remove paint.  They can damage

rubber and most plastic materials.

This product is basically an acid solution with a

corrosion inhibitor.  It is used to remove corrosion

from components that are made of ferrous metals.

Method of use

Method of use

Crodafluid CR2 must be contained in a tank that is

made from a material which is not affected by acid.

Before the process begins, the components must be

degreased before they are lowered completely into

the Crodafluid solution.  For medium to heavy

deposits of corrosion, the solution can be heated to

70°C.  Inspect the components now and then to check

the results of the process.  Surface corrosion can be

removed in a short period of time.  The last operation

is to wash thoroughly the components in clean water.

The components to be degreased must be lowered

completely into the degreasing solution.  Allow

enough time to elapse for the components to be

thoroughly cleaned.  Subsequently, the components

must be thoroughly flushed in clean water.  In use,

maintain a layer of water at least 76 mm (3 inches)

deep above the cleaning fluid to ensure that vapour

and toxic gases are not released.

Warning!  Do NOT smoke near the container.

Protection for the eyes and for the skin must be used

always during the use of these fluids, and the

container must be in a place with good ventilation.

Warning!  Protection for the eyes and for the skin

must be used always during the use of this product.

Diverspray 30:  Diversey Limited, Northampton.

Duroclean 150 powder: Diversey Limited,

Northampton.

This product is a moderate and basically alkaline

compound with corrosion inhibitors.  It is either

sprayed over the components to clean them, or is

contained in a tank, for the immersion and agitation of

the components.

This product is basically an alkaline degreasing

solution and is safe to use on brass, copper and

ferrous metals.  It must not be used on aluminium,

lead, tin or zinc.

Diverspray 30 may be added to water to wash

components if a corrosion inhibitor is necessary.  It is

used after other processes, such as corrosion

removal, are finished.

Method of use

It is recommended that Duroclean 150 is used with a

maximum concentration of 50 grams for each litre of

water.  The components to be degreased must be

lowered completely into the degreasing solution

which is heated to 65°C.

Perkins Engines Company Limited

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NALCO 2568 Powder: NALCO Limited, PO Box 11,

Hose connections

Winnington Avenue, Northwich  CW8 4DX

Do not use a screwdriver to remove hoses by force

because adaptors or pipe connections can be

damaged.  Cut through the hose and then cut the

ends of the hose from the adaptor or pipe connection.

This product (which is supplied only in quantities of 25

kg) is an inhibited sulphamic acid and can be used for

the removal of hard deposits from the tube stack of

the oil cooler.

When a new hose is fitted, a suitable rubber lubricant

can be used instead of antifreeze, water or french

chalk.  Never lubricate a hose with oil or grease.

Warning!  The solution must be made and used in

accordance with the manufacturer’s instructions.

The NALCO 2568 powder should be mixed with clean

fresh water in the ratio which follows:

Gaskets, joints and ’O’ rings

Discard all used items if an engine or a component is

dismantled and fit only new and correct parts.

15 - 40 kg/Tonne of water

(15 - 40 lb/100 UK gallons of water)

If a jointing compound is needed, ’Hylomar PL 32’

jointing compound is recommended for use, but on

metal joints ONLY.  Only a thin application is needed,

an excessive quantity of compound can restrict the

flow of fluids in pipes and passages.

When the action of the solution is finished, dip the

tube stack in a solution made from: 0,5 kg (1 lb) of

sodium carbonate to 25 litres (5 UK gallons) of hot

water.  The final operation is to dry the inside of the

tubes with compressed air.

Caution:  ’Hylomar’ jointing compound must NOT be

used in contact with any fibre joints as the solvent

contained in ’Hylomar’ can damage the joint material.

Oil seals

Apply petroleum jelly to oil seals before they are fitted,

and do not damage the lip of the seal on sharp edges. 

Unless other specifications apply, fit the seal with the

edge of the lip toward the bearing.

Apply a small amount of a suitable lubricant to ’O’ ring

seals to prevent damage during assembly.

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Locking devices

Split pins, lock plates and tab washers which have

been used must be discarded.  Various methods to

retain securely the nuts of an engine are shown (A).

Stiffnuts can be used again only if they have not lost

their grip and the original torque is needed to turn

them.

There must be a minimum protrusion of one full

thread of the bolt or stud through the stiffnut when it is

tightened fully. Discard all stiffnuts which have nylon

or fibre inserts.

Application of thread locking compounds

Remove all oil, grease and dirt from engine parts

before thread locking compounds are applied to

them.  Most thread locking compounds have a date by

which they must be used, ensure that the compounds

used are within those dates.

Fits and clearances

The dimensions given in section 11C are acceptable

limits.  The components which have measurements

within these limits are acceptable for a complete

period of service.

Certain components which are worn by more than

these limits can be corrected in accordance with a

Service Reclamation Scheme (SRS).  Information

about the Service Reclamation Schemes is available

from the Service Department at Perkins Engines

(Shrewsbury) Limited.

A

122

Applied torques

The specifications for applied torques, which are

given in section 11B, apply to some bolts and nuts

where damage or failure can occur if they are

incorrectly tightened.  Where joints are fitted, for

example, between the cylinder head and the

crankcase, it is also important that bolts and nuts are

tightened evenly and gradually as instructed in the

assembly sequence. The torque wrenches, listed

below, are suitable for the torque load requirements of

the 3012/CV12 engine, and are available from

Perkins Distributors.

8 to 54 Nm (6 to 40 lbf ft), 21825 846

30 to 150 Nm (20 to 110 lbf ft), 21825 991

70 to 310 Nm (50 to 230 lbf ft), 21825 992

Perkins Engines Company Limited

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Checks for cracks

When possible, it is recommended that components

which are affected by high stresses such as the

crankshaft, the connecting rods, the gears and the

cylinder liners are tested for cracks during overhaul.

They should also be checked for cracks when they

have been affected by an excessive load or impact. It

is recommended that ferrous components are tested

by the electro-magnetic method if possible. Portable

electro-magnetic test equipment is available from

Radalloyd Limited, Oadby, Leicester. Non-ferrous

components can be tested by the use of a dye

penetrant process such as ’Ardrox 996’, available

from Ardrox Limited, Brentford, Middlesex. The dye

penetrant must conform to one of the standards listed

below:

MIL-STD 271-E

MIL-L 25135

B.S. 5750

D.T.D. 929

Exchange units

It is recommended that unserviceable units are

returned, as complete as the new exchange unit, with

covers fitted to all openings and the joint faces

protected.  When necessary, protect the unit, both

inside and outside, from corrosion.

Parts

To ensure maximum reliability, fit only genuine

PERKINS parts supplied by a PERKINS distributor.

These parts are made to the latest specification and

have a guarantee for 12 months.  The use of parts,

such as filter elements, which do not conform to

PERKINS standards, may reduce the life of the

engine and can affect the warranty.

If you need parts, spares or information for your

engine, give the complete engine number to your

Perkins distributor.  This will ensure that the correct

parts can be obtained.

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Approved lubricants and fluids

Equivalent lubricants and fluids of other manufacturers are acceptable

Product or specification

Manufacturer

Alternator

Cleaning fluid for diodes

Grease for diodes

Fluid grade 8-23

Applied Chemicals Limited

Applied Chemicals Limited

Silicon MS200, MS4 and MS5

Camshafts

Anti-seize compound

Anti-scuffing paste

Rocol J166

Rocol

Rocol Limited

Cooling system

Lips of oil seal in coolant pump

Hose and ‘O’ rings

Shell Alvania R3 Grease

Liner lubricant

Shell Oils

Morris’s Shrewsbury

I.C.I Limited

Compound for cleaning the system

Lissapol ‘N’, 1%

(10 cc/ltr - 45 cc/Imp. gallon)

Lissapol ‘NDB’, 2%

(20 cc/ltr - 90 cc/Imp. gallon)

To remove hard deposits from the oil

cooler

NALCO 2568 powder

(in 25 kg drums only)

NALCO Limited

Exhaust system

Anti-seize compound for threads

Copaslip

Slip Group Rocol Limited

Rocol J166

Joints

Jointing compound

Hylomar Silicone Sealant

Marston Bentley Limited

Adhesive and Sealants

Division, Wigan

Sealant and thread locking

Loctite AVV, 241, 270, 290,

542 and 601

Douglas Kane Sealants

Morris’s Shrewsbury Shell

Oils Various

Lubrication system

‘O’ rings and relevant bores

Liner lubricant

Morris’s Shrewsbury

Starter motor

Cleaning fluid for commutators

Lubricant for splines

 ‘O’ ring lubricant

White spirit

Aeroshell DID5598

Glycerine

Shells Oils

Various

Lubricator wick

Mineral oil

SAE 5W/20

Perkins Engines Company Limited

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Specifications

11

Basic engine data

Engine

Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12

Cylinder arrangement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 degree included angle ‘V’

Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four stroke

Induction system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged and charge cooled

Combustion system   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection

Nominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 mm (5.315 in)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 mm (5.984 in)

Compression ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,11 litres (1593.24 in³)

Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  14.5:1

Firing order  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6, B1, A3, B4, A5, B2, A1, B6, A4, B3, A2, B5

Tappet clearances (hot or cold)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engines before ‘build line number’ 8281

(6C27437/29):

Inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 mm (0.016 in)

Exhaust valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 mm (0.020 in)

Engines from ‘build line number’ 8281

(6C27437/29):

Inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2 mm (0.008 in)

Exhaust valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 mm (0.020 in)

Direction of rotation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-clockwise from the rear of the engine

Injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As stamped on engine data plate

Rated power output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 to 740 kW

Maximum rated speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 rev/min

Dry weight of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2120 kg (4674 lb)

(Approximate)

Dry weight of electropak

(Approximate)

3012 TG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2365 kg (5214 lb)

3012 TAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2315 kg (5103 lb)

Perkins Engines Company Limited

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Cooling system

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid cooled

Coolant pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal unit, gear-driven

Capacities for coolant

Engine and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 litres (15 UK gallons)

Engine/radiator pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  122,7 litres (27 UK gallons)

Coolant system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Up to 69 kN/m² (10 lbf/in²)

Temperature (normal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° to 100°C

Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Two, single element, wax capsule type

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1220 mm (48 in) diameter, 8 blades, belt driven

Approved coolant  . . . . . . . . . . . . . . . . . . .See section 5 - ‘Engine fluids’ in the User’s Handbook TSD 3138

Fuel system

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Low-pressure supply to injection pump

with return of spill fuel to the tank

Fuel injection pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 element in-line unit

Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Mechanical, servo assisted, integral with fuel injection

pump, constant speed for operation of generators

(for other applications, variations are fitted)

Fuel lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical, operated by camshaft

Fuel supply pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  140 to 210 kN/m² (20 to 30 lbf/in²)

Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axial supply, low spring type, six spray holes

Injection pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 bar (early engines 240 bar)

Main fuel filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Two screw-on type canisters

Approved fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Centrifugal type

Approved fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See section 5 - ‘Engine fluids’ in the User’s

Handbook TSD 3138

24

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Lubrication system

Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet sump

Capacities

Sump maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 litres (12 UK gallons)

Sump minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 litres (7.3 UK gallons)

System total. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.8 litres (16.2 UK gallons)

Pressure

Normal load conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  448 kN/m² (65 lbf/in²)

Minimum at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  345 kN/m² (50 lbf/in²)

Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spur gear type, gear driven

Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spring loaded plunger, not adjustable

Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  488 kN/m² (71 lbf/in²)

Oil-to-coolant heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tube stack and body, with baffle plates

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three screw-on type canisters

Maximum recommended temperature

of oil in sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  125°C

Approved lubricating oil . . . . . . . . . . . . . . See section 5 - ‘Engine fluids’ in the User’s Handbook TSD 3138

Induction and exhaust systems

Aspiration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure charged by two turbochargers

Air charge coolers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Two, air to air type, integral with radiator

Air filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Two, paper element type

Electrical equipment

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt 40 ampere

Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt - flange fitted (certain engines have two starter motors)

Stop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt, energised-to-run

Engine protection switches . . . . . . . . . . . . . . . . . . . . . . 24 volt instrument sender/switches for oil pressure,

coolant temperature and coolant level

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11

Recommended specific applied torques

Caution:  The torque loads listed below apply to threads in an oil wet condition, unless the use of thread

locking compound is recommended.

Application of a torque specification is NOT enough to ensure that the relevant components are retained

securely as an assembly.  It is important to conform also to the recommendations for assembly and, if given,

the sequence in which the bolts or nuts must be tightened.  This information is given in the relevant section of

this publication.

If a bolt or nut is retained with a locking washer, lock plate or split pin, the specification for a torque load can

be exceeded, if necessary, by the MINIMUM amount that is needed for correct assembly.

Nm

lbf ft

Alternator

Nut, pulley

95

70

Auxiliary drive shaft

Nut, flange

(18 mm  27 A/F)

(22 mm  32 A/F)

200

300

300

221

Camshafts

200 to 250

217

148 to 184

160

Bolts, camshaft gear

‘A’ bank

‘B’ bank

Screws, countersunk head, thrust plate

24

18

Connecting rods

Nuts, big end bearing

60

44

(Caution - refer to operation 13-1)

Crankcase

Bolts, main bearing cap

Front, centre and rear

Others

177

488

131

360

Side bolts, main bearing cap

Front, centre and rear

Others

114

177

315

84

131

232

Studs, cylinder head

Crankshaft

Bolts, damper and pulley

Cap screws, flywheel

80

59

315

232

Cylinder heads

Bolts, cylinder head to crankcase

Bolts in induction ports only

All other long bolts

200

240

148

148

(plus a further 90°)

(plus a further 90°)

Nuts, cylinder head to crankcase (earlier engines)

200

148

Bolts, rocker box to cylinder head

46

35

23

40

34

26

17

30

Cap screws, rocker box to cylinder head

Bolts, rocker box cover to rocker box

Lock nut, adjustment screw, bridge piece

26

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Nm

40

lbf ft

30

Lock nut, adjustment screw, tappet

Bolt, location, rocker shaft

15

11

Coolant Gallery

Bolts and nuts

23

17

Coolant pump

Lock nut, bearing

Nut, drive gear

100

88

74

65

Exhaust manifolds

Bolts

46

34

Fan adaptor

Nuts, bearing

280

207

Flywheel housing

Bolts, flywheel housing to timing case

Bolts, (2) flywheel housing to crankcase

(later engines with steel crankcase/timing case joints)

80

95

59

70

Fuel filter head

Bolts, bracket to crankcase

Fuel injection pump

Cap screws, adjustable coupling (earlier engines)

Special bolts, adjustable coupling (later engines)

Nut, hub, camshaft

70

46

52

34

149

122

46

110

90

Holders, delivery valve

Bolts, pump to mounting

34

Nuts, coupling, plate, spring

120

88

Fuel injectors

Cap screws, clamp

60

80

27

17

80

59

20

12

Cap nut, nozzle

Connection, spill pipe, new type (directly onto fuel injector)

Connection, spill pipe, new type (directly onto fuel injector)

Fuel lift pump (mechanical)

Nut, cam to auxiliary drive shaft

54

45

40

33

High pressure fuel pipes

Nuts, high pressure fuel pipes

Gears

Bolts, auxiliary drive gear

Bolts, compound idler gear

Bolts, axle, double idler gear

Bolts, axle, idler gear, main

Bolt, axle, idler gear, coolant pump

Bolt, axle, idler gear, oil pump

58

43

30

40

135

135

135

135

100

100

100

100

Induction manifolds

Bolts, induction manifolds

46

34

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Nm

lbf ft

Lubricating oil pump

Bolts, casing

23

17

89

Nut, drive gear

120

Lubricating oil sump

Bolts

55

325

115

47

41

240

85

Insert, drain plug

Drain plug (sump with insert - early engines only)

Drain plug (single piece sump without insert)

35

Timing case

Bolts, timing case to crankcase

Bolts and nut (early engines)

Bolts and cap screws (later engines)

Bolts, timing case to sump

Bolts (early engines)

95

70

135

100

55

75

40

55

Bolts (later engines with steel joints)

Recommended nominal applied torques

Where instructions are not given for the correct torque to be applied to nuts and bolts, the figures which follow

should be used.

Bolt size

M5

Nm

6

lbf ft

4.5

7

M6

9.5

23

M8

17

M10

M12

M14

M16

M18

M20

M22

M24

46

34

80

59

127

198

273

387

526

669

94‘

146

201

285

388

493

28

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Cylinder head assembly

12

General description

The four cylinder heads, which are all the same, are

made from high quality cast iron and are retained by

bolts or by studs on early engines. They are machined

on the top and bottom faces for the rocker box and the

cylinder head gaskets respectively.  Joint faces are

machined on the inner and outer sides for the

induction and the exhaust manifolds.  There are

passages for coolant in the cylinder head around the

valve guides and the pockets for the fuel injectors.

The valve guides (A6) are made from an alloy of high

quality nickel chromium and are a press fit in the

cylinder head.  The valve seat inserts (A7) are cooled

and pressed into recesses which are machined in the

cylinder heads.

A

375

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The inlet valves (A9) are made from steel forgings.

The exhaust valves (A8) are made from solid

’Nimonic’ material.  The valves are retained with

collets, springs and spring seat washers.  Exhaust

valves are fitted with valve rotators instead of upper

spring seat washers.  Each set of two valves is

actuated by a bridge piece (A5) which moves on a

guide.  There is an adjustment screw and a lock nut

on the outer arm of each bridge piece.  A nitrided

button is inserted in the top face of each bridge piece

and connects with its rocker lever (A4).  Each rocker

lever is operated by the camshaft through a push rod

(A2) and a tappet (A1).

Three fuel injectors in each cylinder head are retained

by clamps and cap screws.  The connections for the

fuel supply and the surplus fuel are sealed at the

rocker box covers and the walls of the rocker boxes

respectively, to prevent leakage of oil and the entry of

dirt.

Note:   For the illustration (A), inlet and exhaust valves

are shown under the same bridge piece.

The rocker levers (A4) have adjustment screws and

lock nuts for the tappet clearances.  For early

engines, they are assembled on a rocker shaft in

each rocker box and are separated by the springs.

The rocker boxes are held in the correct positions on

the cylinder heads by spring dowels and are retained

with socket head cap screws and bolts, tightened to a

specific torque.  The rocker box covers are made from

castings of aluminium and are retained by bolts.  The

new rocker box covers of these engines are retained

with an extra bolt at each end.

A

375

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