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详细描述
项目 零配件号码 最近的部分号码 描述
1 CV13727/1 Z 2 CV13727/1 Z 涡轮增压器
25 CV378 8 CV378 图钉
26 CV235 8 CV235 螺帽
27 2131 A010 8 2131 A010 垫圈
28 CV13795 2 CV13795 密封垫 -排气
29 KRP1249 1 KRP1249 修补装备 -涡轮增压器
30 CV13728 2 CV13728 手风箱
31 ST43604 6 ST43604 螺拴
32 CV1343 6 CV1343 公制的螺帽
33 2131 A012 6 2131 A012 垫圈
34 CV5654 1 CV5654 托架
35 CV5655 1 CV5655 托架
36 CV235 12 CV235 螺帽
37 2131 A010 12 2131 A010 垫圈
项目 零配件号码 最近的部分号码 描述
2 1 壳
3 OE45224 1 OE45224 联结器
4 CV3017 1 CV3017 锁紧螺母
5 OE45510 1 OE45510 壳
21 1 壳
22 OE45275 4 OE45275 砂箱夹
23 OE45220 12 OE45220 螺拴
24 CV2533 6 CV2533 图钉
项目 零配件号码 最近的部分号码 描述
6 1 壳
7 OE45507 1 OE45507 背板
8 OE45508 1 OE45508 密封O型圈
9 OE41325 2 OE41325 圈
10 OE45230 1 OE45230 间隔器
11 OE45234 1 OE45234 桥环
12 OE45283 1 OE45283 止推瓦
13 OE45509 3 OE45509 螺旋
14 2 瓦
15 OE45235 3 OE45235 圈
16 OE45281 1 OE45281 复缘
17 CV3005 1 CV3005 圈
18 OE45280 1 OE45280 轮
19 CV9940 1 CV9940 轮
20 OE45188 1 OE45188 锁紧螺母
项目 零配件号码 最近的部分号码 描述
1 CV13732 1 CV13732 油管
2 OE9691 2 OE9691 夹
3 OE9692 2 OE9692 衬套
4 ST46076 1 ST46076I 栓塞
5 ST49851 1 ST49851 垫圈
6 ST44444 2 ST44444 固定螺钉
7 2134 A008 2 2134 A008 垫圈
8 DV807 2 OE50898 密封垫
9 ST46007 1 ST46007 套筒
10 ST46032 1 ST46032 螺帽
11 CV12871 1 CV12871 油管
12 ST46008 1 ST46008 套筒
13 ST46033 1 ST46033 螺帽
14 ST46183 1 ST46183 TEEPIECE
15 OE9691 1 OE9691 夹
16 ST46269 1 ST46269 异径管接合器
17 ST46008 1 ST46008 套筒
18 ST46033 1 ST46033 螺帽
19 ST49459 1 ST49459 承接器
20 ST49891 1 ST49891 垫圈
21 CV13733 1 CV13733 油管
24 2314 C044 2 2314 C044 固定螺钉
25 2134 A008 2 2134 A008 垫圈
26 ST20557 1 ST20557 承接器
27 CV13729 1 CV13729 油管
28 OE9691 1 OE9691 夹
29 OE9692 1 OE9692 衬套
30 CV1726 1 CV1726 距离块
31 ST46076 1 ST46076I 栓塞
32 ST49851 1 ST49851 垫圈
33 ST44444 2 ST44444 固定螺钉
34 2134 A008 2 2134 A008 垫圈
35 ST43506 1 ST43506 螺拴
36 2134 A008 1 2134 A008 垫圈
37 ST46007 1 ST46007 套筒
38 ST46032 1 ST46032 螺帽
39 ST49449 1 ST49449 承接器
40 ST49853 1 ST49853 垫圈
41 CV17106 1 CV17106 油管
42 OE50899 2 OE50899 切片密封垫的板
43 2314 C044 2 2314 C044 固定螺钉
44 2134 A008 2 2134 A008 垫圈
45 CV20236 1 CV20236I 密封垫
46 ST43556 2 ST43556 螺拴
47 2134 A010 2 2134 A010 垫圈
48 ST49891 1 ST49891 垫圈
49 CV7361 2 CV7361 距离块
50 ST43511 2 ST43511 螺拴
51 2134 A008 2 2134 A008 垫圈
项目 零配件号码 最近的部分号码 描述
1 CV17435 24 CV21058 进气门
2 OE43638 24 OE43638 位子
3 CV11403 24 CV11403 阀弹簧
4 OE43262 24 OE43262 位子
5 OE42571 48 OE42571 阀筒夹
6 CV17434 24 排气阀
7 OE43638 24 OE43638 位子
8 CV11403 24 CV11403 阀弹簧
9 CV18761 24 CV18761 回转的人
10 OE42570 48 OE42570 阀筒夹
Contents
1 General information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
How to care for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Perkins companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety pr ecautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Engine views
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Location of engine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Operation instructions
Pr epar ations 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 temper atures . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pr ecautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to stop the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Preventive maintenance
Pr eventive maintenance periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Schedule for engines in nor mal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Schedule for engines in intermittent use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubr icating oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Restriction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to renew the elements of the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to drain the prim ary 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 lubr icating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to renew the canisters of the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Continued
3
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 tim ing of the fuel injec tion 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 injec tor s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to eliminate air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How to check the tappet clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Alter nator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to drain the c oolant s ystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to clean the c oolant 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 poss ible 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 liter ature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9 Engine data
3012 diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4
This document has been printed from SPI². Not for Resale
1
General information
Introduction
The 3012 heavy duty diesel engine is the latest
development from Perkins Engines Company
1
How to care for your engine
Limited, a world leader in the design and manufacture
of high performance diesel engines.
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 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.
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.
This handbook has been written to assist you to
maintain and operate your engine correctly.
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
advers e 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.
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.
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.
5
This document has been printed from SPI². Not for Resale
1
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
59426 = Build line number
U = Year of manufacture
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 = Engine application
J = Engine type
12 = Number of engine cylinders
0029 = Engine specification number
U = Country of manufacture
3254 = Build line number
C = Year of manufacture
Units such as the fuel injection pump and
turbochargers have their own data plates.
6
This document has been printed from SPI². Not for Resale
Perkins companies
Australia
Perkins Engines Australia Pty. Limited,
Suite 4, 13A Main Street,
Mornington, Victoria 3931, Australia.
Telephone: 0061 (0)597 51877
Telex: Perkoil AA 30816
Fax: 0061 (0)597 1305
China
Perkins Engines (Tianjin) Limited,
Jinwei Road,
Beichen District, Tianjin,
300402
China
Telephone: (86) (22) 2699 2288
Fax: (86) (22) 2699 3784
France
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
Germany
Perkins Motoren G.m.b.H.,
Saalaeckerstrasse 4,
63801 Kleinostheim,
Germany.
Telephone: 0049 6027 5010
Fax: 0049 6027 501124
Italy
Motori Perkins S.p.A.,
Via Socrate 8
22070 Casnate con Bernate (Como), Italy.
Telephone: 0039 (0)31 564625/564633
Fax: 0039 (0)31 565480/564145/396001
Japan
Perkins Engines, Inc. Japan Branch,
8 Fl, 2-2-19 Akasaka, Minato-ku,
Tokyo 107-0052, Japan.
Telephone: 0081 (0)3 3560 3877
Korea
Perkins Engines (Korea)
Textile Center 12F
Daechi 3 dong 944-31
Kangnam-Ku
Seoul, 135-283
Korea
Telephone: (822) 528 3377
Fax: (822) 528 3378
Singapore
Perkins Engines (Asia Pacific ) Pte. Limited,
20 Harbour Drive,
#07-06A, PSA Vista,
Singapore 117612.
Telephone: (65) 874 7712
Fax: (65) 874 7722
United Kingdom
Perkins Engines Company Limited,
Lancaster Road, Shrewsbury, SY1 3NX,
England.
Telephone: 0044 (0)1743 212000
Telex: 35171 PESL G
Fax: 0044 (0)1743 212700
United States of America
Perkins Engines - North America
12025, Tech Center Drive
Livonia
Michigan 48150
USA
Telephone: 001 313 266 5427
Fax: 001 313 266 2700
Perkins Engines Latin America Inc,
Suite 620,
999, Ponc e de Leon Boulevard,
Coral Gables,
Florida 33134,
USA.
Telephone: 001 305 442 7413
Telex: 32501 Perken G
Fax: 001 305 442 7419
In addition to the above companies, there are
1
Fax: 0081 (0)3 3560 3878
Perkins distributors in most countries. Perkins
Engines Company Limited, Shrewsbury or one of
the above companies can provide details.
7
This document has been printed from SPI². Not for Resale
1
Safety precautions
These safety precautions are important.
Reference must also be made to the local regulations
in the country of operation.
l Only use these engines in the type of application
for which they have been designed.
l Do not change the specification of the engine.
l Do not smoke when you put fuel in the tank .
l Clean away fuel which has been spilt. Material
which has been contaminated by fuel must be
moved to a safe place.
l Do not put fuel in the tank while the engine runs
(unless it is absolutely necessary).
l 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).
l Do not make adjustments that you do not
understand.
l Ensure that the engine does not run in a location
where it c an cause a concentration of toxic
emissions.
l Other persons must be kept at a safe distance
while the engine or equipment is in operation.
l Do not permit loose clothing or long hair near
moving parts.
l Keep away from moving parts during engine
operation. Warning! Some moving parts cannot
be seen clearly while the engine runs.
l Do not operate the engine if a safety guard has
been removed.
l 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.
l Do not use salt water or any other c oolant which
can cause corrosion in the closed coolant circ uit.
l 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.
l
l
l
l
l
l
l
l
l
l
l
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.
If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.
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 wear clothing which is contaminated by
lubricating oil. Do not put material which is
contaminated with oil into the pockets.
Discard used lubricating oil in a safe place to
prevent contamination.
Ensure that the control lever of the transmission
drive is in the ‘out-of-drive’ position before the
engine is started.
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.
Fuel and oil pipes MUST be inspected for cracks
or damage before they are fitted to the engine.
Fit only genuine Perkins parts.
8
This document has been printed from SPI². Not for Resale
2
Engine views
Introduction
2
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 Thermos tat housings
8
1
7
2
3
A
6
5
4
482
9
This document has been printed from SPI². Not for Resale
2
Rear and right side view of the 3012 engine
1 ‘A’ bank turbocharger
2 Alternator
3 Dipstick
4 Filler cap for lubricating oil
5 Lubricating oil sump
6 Starter motor
7 Flywheel housing
8 Flywheel
9 Canisters of the fuel filter
10 ‘A’ bank air cleaner
10
1
9
2
8
7
4
3
B
6
5
483
10
This document has been printed from SPI². Not for Resale
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Operation instructions
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Every new engine supplied by Perkins Engines
Company Limited, Shrewsbury, is run-in before it
leaves the factory.
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
link ages, the pressure gauge pipes, the air inlet pipes
and the wiring loom.
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).
8 Fill the cooling system with the approv ed 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
clean engine oil of the correct grade (see page 32) to
the governor housing. Fit and tighten the plug
securely.
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)
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
link ages for free movement.
A
B
1
2
1
57
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