Perkins 3000 Series USER S HANDBOOK. This document has been printed from SPI². Not for Resale. 12 cylinder diesel engines for industrial applications

Transcription

1 This document has been printed from SPI². Not for Resae Perkins 3000 Series USER S HANDBOOK 3012/CV12 12 cyinder diese engines for industria appications The contents of this handbook are appicabe to both CV12 and 3000 Series engines. Pubication TSD 3138 (issue 13) Proprietary information of Perkins Group Limited, a rights reserved The information is correct at the time of print. Pubished in May 2001 by Technica Pubications, Perkins Engines Company Limited, Lancaster Road, Shrewsbury, Shropshire SY1 3NX, Engand 1

2 2 This document has been printed from SPI². Not for Resae

3 Contents 1 Genera information Introduction How to care for your engine Engine identification Perkins companies Safety precautions Engine views Introduction Location of engine parts Operation instructions Preparations for a new or an overhaued engine How to start a new or overhaued engine or an engine which has been in storage Norma start procedures How to start the engine in ow ambient temperatures Precautions How to stop the engine Preventive maintenance Preventive maintenance periods Schedue for engines in norma use Schedue for engines in intermittent use Cooant eve Lubricating oi eve Restriction indicator How to renew the eements of the air fiters How to drain the primary fue fiter How to check the drive bets How to renew the fan bets How to renew the aternator bet How to check the specific gravity of the cooant How to check the ph vaue of the cooant How to renew the engine ubricating oi How to renew the canisters of the oi fiter Continued This document has been printed from SPI². Not for Resae 3

4 How to cean the primary fue fiter How to renew the canister of the main fue fiter How to check/adjust the timing of the fue injection pump Fue injector faut How to remove the fue injectors How to correct the fue injector seeves How to fit the fue injectors How to eiminate air from the fue system How to check the tappet cearances Turbochargers Aternator How to drain the cooant system How to cean the cooant system How to fi the cooant system Engine fuids Diese fue Cooant Lubricating oi Recommended ois for Europe Recommended ois for remainder of the word Warranty Faut diagnosis Probems and possibe causes Code ist of possibe causes Engine preservation Introduction Short period storage Long period storage Remova from storage Approved products for engine preservation Parts and Service Introduction Service iterature Training Service Buetins Engine data 3012 diese engine This document has been printed from SPI². Not for Resae

5 This document has been printed from SPI². Not for Resae 1 Genera information 1 Introduction The 3012 heavy duty diese engine is the atest deveopment from Perkins Engines Company Limited, a word eader in the design and manufacture of high performance diese engines. More than fifty years of diese production experience, together with the use of the atest technoogy, have been used in the manufacture of your engine to give you reiabe 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 possibe danger to the person. Caution: This indicates that there is a possibe danger to the engine. Note: Is used where the information is important, but there is not a danger. How to care for your engine This handbook has been written to assist you to maintain and operate your engine correcty. To obtain the best performance and the ongest ife from your engine, you must ensure that the maintenance operations are done at the intervas shown in Preventive maintenance. If the engine is operated in a very dusty environment or other adverse conditions, certain maintenance intervas wi have to be reduced. Renew the fiter eements and the ubricating oi reguary to ensure that the inside of your engine remains cean. Ensure that a adjustments and repairs are done by personne who have had the correct training. Perkins distributors have this type of personne avaiabe. You can aso 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 isted on page 7. The eft and right sides of the engine are as seen from the rear (fywhee) end. Where reference is made to A and B banks of cyinders: A bank is to the right and B bank is to the eft when viewed from the rear end. Read the Safety precautions and remember them. They are given for your protection and must be appied at a times. 5

6 This document has been printed from SPI². Not for Resae 1 Engine identification If you need parts, service or information for your engine, you must give the compete engine number to your Perkins distributor. The engine number is stamped on the data pate which is fastened to the eft side of the crankcase. For eary engines, a typica engine number is: 6A27487U 59426U, which consists of these codes: 6A = Engine famiy = Engine number U = Country of manufacture = Buid ine number U = Year of manufacture Engines made after August 1994, have a new engine number system. For these engines, a typica number is: SGJ U 3254 C, which consists of these codes: SG = Engine appication J = Engine type 12 = Number of engine cyinders 0029 = Engine specification number U = Country of manufacture 3254 = Buid ine number C = Year of manufacture Units such as the fue injection pump and turbochargers have their own data pates. 6

7 This document has been printed from SPI². Not for Resae Perkins companies Austraia Perkins Engines Austraia Pty. Limited, Suite 4, 13A Main Street, Mornington, Victoria 3931, Austraia. Teephone: 0061 (0) Teex: Perkoi AA Fax: 0061 (0) China Perkins Engines (Tianjin) Limited, Jinwei Road, Beichen District, Tianjin, China Teephone: (86) (22) Fax: (86) (22) France Perkins France SAS, "Parc des refets", 165 Avenue du Bois de a Pie, Roissy Chares de Gaue, France. Teephone: 0033 (01) Fax: 0033 (01) Germany Perkins Motoren G.m.b.H., Saaaeckerstrasse 4, Keinostheim, Germany. Teephone: Fax: Itay Motori Perkins S.p.A., Via Socrate Casnate con Bernate (Como), Itay. Teephone: 0039 (0) / Fax: 0039 (0) /564145/ Japan Perkins Engines, Inc. Japan Branch, 8 F, Akasaka, Minato-ku, Tokyo , Japan. Teephone: 0081 (0) Fax: 0081 (0) Korea Perkins Engines (Korea) Textie Center 12F Daechi 3 dong Kangnam-Ku Seou, Korea Teephone: (822) Fax: (822) Singapore Perkins Engines (Asia Pacific) Pte. Limited, 20 Harbour Drive, #07-06A, PSA Vista, Singapore Teephone: (65) Fax: (65) United Kingdom Perkins Engines Company Limited, Lancaster Road, Shrewsbury, SY1 3NX, Engand. Teephone: 0044 (0) Teex: PESL G Fax: 0044 (0) United States of America Perkins Engines - North America 12025, Tech Center Drive Livonia Michigan USA Teephone: Fax: Perkins Engines Latin America Inc, Suite 620, 999, Ponce de Leon Bouevard, Cora Gabes, Forida 33134, USA. Teephone: Teex: Perken G Fax: 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 detais. 7

8 This document has been printed from SPI². Not for Resae 1 Safety precautions These safety precautions are important. Reference must aso be made to the oca reguations in the country of operation. Ony use these engines in the type of appication for which they have been designed. Do not change the specification of the engine. Do not smoke when you put fue in the tank. Cean away fue which has been spit. Materia which has been contaminated by fue must be moved to a safe pace. Do not put fue in the tank whie the engine runs (uness it is absoutey necessary). Do not cean, add ubricating oi, or adjust the engine whie it runs (uness you have had the correct training; even then extreme caution must be used to prevent injury). Do not make adjustments that you do not understand. Ensure that the engine does not run in a ocation where it can cause a concentration of toxic emissions. Other persons must be kept at a safe distance whie the engine or equipment is in operation. Do not permit oose cothing or ong hair near moving parts. Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen ceary whie the engine runs. Do not operate the engine if a safety guard has been removed. Do not remove the fier cap of the cooing system whie the engine is hot and whie the cooant is under pressure, because dangerous hot cooant can be discharged. Do not use sat water or any other cooant which can cause corrosion in the cosed cooant circuit. Do not aow sparks or fire near the batteries (especiay when the batteries are on charge) because the gases from the eectroyte are highy fammabe. The battery fuid is dangerous to the skin and especiay to the eyes. Disconnect the battery terminas before a repair is made to the eectrica system. Ony one person must contro the engine. Ensure that the engine is operated ony from the contro pane or from the operator s position. If your skin comes into contact with high-pressure fue, obtain medica assistance immediatey. Diese fue and ubricating oi (especiay used ubricating oi) can damage the skin of certain persons. Protect your hands with goves or a specia soution to protect the skin. Do not wear cothing which is contaminated by ubricating oi. Do not put materia which is contaminated with oi into the pockets. Discard used ubricating oi in a safe pace to prevent contamination. Ensure that the contro ever of the transmission drive is in the out-of-drive position before the engine is started. The combustibe materia of some components of the engine (for exampe certain seas) can become extremey dangerous if it is burned. Never aow this burnt materia to come into contact with the skin or with the eyes. Fue and oi pipes MUST be inspected for cracks or damage before they are fitted to the engine. Fit ony genuine Perkins parts. 8

9 2 Engine views 2 Introduction Perkins engines are buit for specific appications and the views which foow do not necessariy match your engine specification. Location of engine parts Front and eft side view of the 3012 engine 1 B bank air ceaner 2 B bank turbocharger 3 Exhaust manifod 4 Cooant pump 5 Canisters of the ubricating oi fiter 6 Crankcase breather 7 Fan 8 Thermostat housings A This document has been printed from SPI². Not for Resae

10 This document has been printed from SPI². Not for Resae 2 Rear and right side view of the 3012 engine 1 A bank turbocharger 2 Aternator 3Dipstick 4 Fier cap for ubricating oi 5 Lubricating oi sump 6 Starter motor 7 Fywhee housing 8 Fywhee 9 Canisters of the fue fiter 10 A bank air ceaner B

11 This document has been printed from SPI². Not for Resae 3 Operation instructions 3 Preparations for a new or an overhaued engine Every new engine suppied by Perkins Engines Company Limited, Shrewsbury, is run-in before it eaves the factory. 1 Check that a protection covers and banking pugs have been removed. 2 Fit a components that were removed for storage or for transport. 3 Ensure that drain pugs for cooant and for ubricating oi are securey fitted. 4 Where necessary, connect the remote contro inkages, the pressure gauge pipes, the air inet pipes and the wiring oom. 5 Connect the fue pipes. 6 Connect the exhaust pipes. 7 Fi the fue tank(s) with the correct grade of fue (see page 31). 8 Fi the cooing system with the approved cooant mixture (see page 31). 9 Fi the sump to the H mark on the dipstick with the correct grade of ubricating oi (see page 32). 10 Cean the area around the pug (A1) on the governor housing of the injection pump and remove the pug. Add approximatey 0,2 itres ( 1 / 3 pint) of cean engine oi of the correct grade (see page 32) to the governor housing. Fit and tighten the pug securey. 11 Add oi to the turbochargers as foows: Cean the area around the banking pug (B1) on the bearing housing of each turbocharger. Remove the pugs (B1) and add 0,2 itre ( 1 / 3 pint) of engine oi of the correct grade to each turbocharger. Fit and tighten the pugs. 12 Eiminate air from the fue system (see page 27). 13 Lubricate a of the contro inkages and check the inkages for free movement. 1 2 A 57 B

12 This document has been printed from SPI². Not for Resae 3 How to start a new or overhaued 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 cean ubricating oi to the fue injection pump and to the turbochargers. If the engine has been in storage for ess than one month, but the fue injection pump has been removed and fitted, add ubricating oi to the fue injection pump. The procedure is described on page 11, paragraphs 10 and 11. Use cean engine oi of the same grade and specification as that aready in the system. Start procedure Ensure that the stop contro is in the STOP position and that the speed contro ever is in the IDLE position. Press the start button for 10 seconds and then reease it for 10 seconds, then press it for 20 seconds and reease it for 20 seconds. Oi pressure MUST be indicated on the gauge. Move the stop contro ever to the RUN position and proceed as for a norma start. 12

13 Norma start procedures Precautions 3 Service checks each day before first engine start 1 Check that the eve of cooant is just at the bottom of the fier extension in the radiator. Fi, if necessary, to the required eve with the approved cooant mixture. If there is a arge oss of cooant find the reason. 2 Check the engine oi eve. With the engine stopped the oi eve must be at the H mark on the dipstick. If necessary, add oi of the same grade and specification as that aready in the system. Do NOT add more oi than is necessary. 3 Ensure that the fue tank is fu. 4 Check the air restriction indicator. Caution: If a fue injection pump or turbocharger has been removed from an engine, it must be primed with cean engine oi of the correct grade before the engine is first started. See page 11, paragraphs 10 and 11. Variabe speed engines Perform the daiy service checks then proceed as foows: Turn on the fue suppy. Move the stop contro to the RUN position. Move the speed contro ever to the maximum speed position. Press the start button and reease it when the engine starts. Move the speed contro ever to the ide position. Constant speed engines Perform daiy service checks then proceed as foows: Turn on the fue suppy. Move the stop contro to the RUN position. Press the start button and reease it when the engine starts. How to start the engine in ow ambient temperatures An excess fue device, within the fue injection pump, works as a starting aid when ambient temperatures are beow 0 C. Before the engine is started, push fuy in, the contro rod of the excess fue device. Press the start button and reease it when the engine starts. The contro rod returns automaticay to its origina position when the engine starts. Caution: The excess fue device must not be used at the same time as other cod starting aids as the extra fue wi make the engine more difficut to start. The precautions that foow wi hep to ensure a ong and faut-free ife for the engine: Variabe speed engines 1 Do not operate the engine at high speeds and oads unti the cooant has reached a minimum temperature of 78 C. 2 Do not aow the engine to run at ide speed for proonged periods. 3 Do not exceed the maximum no oad speed. 4 Never aow an engine to continue to run if the oi pressure is beow 170 kn/m² (25 bf/in²) at rated speed. 5 Fi the fue tank(s) at the end of each day to prevent condensation. Constant speed engines 1 Do not operate the engine with a fu oad unti the cooant has reached a minimum temperature of 78 C. 2 Do not aow the engine to run with no oad for proonged periods. 3 Ensure that the fue tank(s) are fu to prevent condensation. How to stop the engine Variabe speed engines 1 Put the gear ever into the NEUTRAL position. 2 Operate the engine at approximatey 800 rev/min for 3 minutes to aow the turbochargers to reduce speed and temperature. 3 Move the stop contro to the STOP position. Constant speed engines 1 Operate the engine for 3 minutes at ide speed with no oad to aow the turbochargers to reduce speed and temperature. 2 Move the switches for the engine protection devices to the OFF position. 3 Move the stop contro to the STOP position. 4 Turn off the fue suppy. 13 This document has been printed from SPI². Not for Resae

14 This document has been printed from SPI². Not for Resae

15 This document has been printed from SPI². Not for Resae 4 Preventive maintenance 4 Preventive maintenance periods These preventive maintenance periods appy to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is instaed. If necessary, use the shorter periods. When the operation of the engine must conform to the oca reguations, these periods and procedures may need to be adapted to ensure correct operation of the engine. The service intervas can be reduced for operation in adverse conditions. The intervas must not be extended uness Perkins Engines Company Limited have approved the changes as indicated in the Perkins Warranty. It is good preventive maintenance to check for eakage and oose fasteners at each service. These maintenance periods appy ony to engines that are operated with fue and ubricating oi which conform to the specifications given in this handbook. 15

16 This document has been printed from SPI². Not for Resae 4 Schedue for engines in norma use The preventive maintenance operations must be appied at the interva (hours or months) which occurs first. A - Every 10 hours or daiy B - Every 400 hours or 12 months C - Every 1200 hours or 24 months * By a person who has had the correct training. In addition to the operations isted above, the operations isted beow must be appied at 12 month intervas: A B C Operation Check the amount of cooant Check the eve of the ubricating oi Check the restriction indicators for the air fiters and, when necessary, renew the fiter eements Drain the water/sediment from the primary fue fiter Check the condition and the tension of a drive bets Check the specific gravity and the ph vaue of the cooant Renew the ubricating oi Renew the canisters of the ubricating oi fiter Renew the canister of the main fue fiter Cean the primary fue fiter Ensure that the mounting nuts for the turbochargers are tightened securey Check that the air charge cooer and the radiator are cean and free from debris Check the timing of the fue injection pump Check that the drive couping bots of the fue injection pump are tightened to 120 Nm (88 bf ft) Ensure that the fue injectors are checked and corrected or renewed, if necessary* Ensure that the tappet cearances are checked and adjusted, if necessary* Drain and fush the cooant system and renew the cooant mixture Check the turbochargers, ensure that they are checked and corrected if necessary* Ensure that the aternator is checked and corrected if necessary* 16

17 Schedue for engines in intermittent use 4 For engines which are in use for a tota of ess than 400 hours in every tweve months, the schedue beow must be used: The preventive maintenance operations must be appied at the interva (hours or months) which occurs first. A - Monthy B - Every 200 hours or 12 months C - Every 1000 hours or 24 months A B C Operation Check the amount of cooant Check the eve of the ubricating oi Check the restriction indicators for the air fiters and, when necessary, renew the fiter eements Start and run the engine with 30% oad (minimum), unti norma temperature of operation is reached Drain the water/sediment from the primary fue fiter Check the condition and the tension of a drive bets Check the specific gravity and the ph vaue of the cooant Renew the ubricating oi Renew the canisters of the ubricating oi fiter Renew the canister of the main fue fiter Cean the primary fue fiter Ensure that the mounting nuts for the turbochargers are tightened securey Check the timing of the fue injection pump Check that the drive couping bots of the fue injection pump are tightened to 120 Nm (88 bf ft) Ensure that the fue injectors are checked and corrected or renewed, if necessary* Ensure that the tappet cearances are checked and adjusted, if necessary* * By a person who has had the correct training. In addition to the operations isted above, the operations isted beow must be appied at 12 month intervas: Drain and fush the cooant system and renew the cooant mixture Check the turbochargers, ensure that they are checked and corrected if necessary* Check that the air charge cooer and the radiator are cean and free from debris Ensure that the aternator is checked and corrected if necessary* 17 This document has been printed from SPI². Not for Resae

18 This document has been printed from SPI². Not for Resae 4 Cooant eve Remove the fier cap from the radiator and check that the eve of the cooant mixture just touches the bottom of the fier tube inside the radiator. If necessary, add cooant unti the eve of the cooant reaches the fier tube. Fit the fier cap. Caution: If cooant is added to the system during service, it must consist of the same origina mixture as used to fi the system. Warning! On a hot engine reease the fier cap carefuy as the system wi be under pressure. Lubricating oi eve At the periods given in the service schedue use the dipstick to check the amount of ubricating oi in the sump. Whie the engine runs, the oi eve must be above the L mark. With the engine stopped the oi eve must be at the H mark on the dipstick. If necessary, put more oi into the sump. Use the same grade and specification as that aready in the system. Do NOT overfi. 18

19 Restriction indicator 4 Each air fiter is fitted with an indicator (A) which gives a visua warning when the fiter needs a service. When the red warning indicator is seen through the cear pane after the engine has stopped, the air fiter eement must be renewed. After a cean eement has been fitted, press the reset button on the restriction indicator. How to renew the eements of the air fiters The two air fiters (B) contain paper eements. These must not be washed. Renew the paper eements as foows: 1 Loosen the camp and remove the end cover (B1). Remove the wing nut (B2), withdraw and discard the fiter eement (B3). 2 Cean, thoroughy, the inside of the casing of the air fiter. Fit a new fiter eement and fit the end cover. 3 Reset the restriction indicator. Repeat this procedure for the other air fiter. How to drain the primary fue fiter 1 Remove the drain pug from the base of the fiter bow and aow any water or sediment to drain from the unit. 2 Fit the drain pug and tighten it securey. A B This document has been printed from SPI². Not for Resae

20 This document has been printed from SPI². Not for Resae 4 How to check the drive bets Check a drive bets and renew a bet if it is worn or damaged. Where more than one bet is used between two pueys, a of the bets must be renewed together. Maximum bet ife wi be obtained ony if the bets are kept at the correct tensions. Check the bet tension at the centre of the ongest free ength, for exampe, position (A5) to check the fan drive bets. Use a Gates "Krikit" V-bet tension gauge or simiar too to check the tension of the bets. The correct tension for a bets is 400 to 489 N (90 to 100 bf). Where more than one bet is used between two pueys, check/adjust the tension on the tightest bet. Note: When new bets are fitted they must be checked again after the engine has been run for 15 minutes and, if necessary, adjusted to the correct tension. How to adjust the tension of the fan bets 1 To adjust the tension of the fan bets, oosen the nuts on the adjustment bot. Loosen the arge ock nut (B1) on the bet tensioner and turn the adjustment bot (B2) unti the correct tension is obtained. 2 Tighten the ock nut and check the tension of the bets again. 3 Run the engine for 15 minutes and then check the bet tension again. Check the tension of new bets every week for four weeks and then at the intervas specified in the service schedue How to adjust the tension of the aternator bet 1 Loosen the aternator pivot bot (A1), the adjustment ink bot (A3) and the adjustment bot (A2). Move the aternator to obtain the correct bet tension and tighten the bots. 2 Run the engine for 15 minutes and then check the bet tension again. Check the tension of new bets every week for four weeks and then at the intervas specified in the service schedue A 59 How to renew the aternator bet 1 2 B 60 1 Remove the fan bets from the crankshaft puey as given on this page. 2 Loosen the adjustment bots to reease the tension on the aternator bet and remove the od bet. Check that the puey grooves are cean and fit a new bet. Adjust the bet to the correct tension. Fit the fan bets as given on this page. 3 5 How to renew the fan bets 1 To renew the fan bets, remove the six bots which fasten the fan to the puey and push the fan forward into the radiator cow. 2 Reease the tension on the bets and remove the od bets. Ensure that the puey grooves are free from grease and dirt. Fit a new set of bets. 3 Fit the fan and tighten the bots securey. Adjust the fan bets to the correct tension. 20

21 This document has been printed from SPI². Not for Resae How to check the specific gravity of the cooant Drain some cooant from the cooing system after the engine has been stopped and before the formation of sediment. Proceed as foows: 1 For mixtures which contain inhibited ethyene gyco: (a) Put a hydrometer, and a reiabe thermometer, into the antifreeze mixture and check the readings on both instruments. (b) Compare the readings obtained with the chart and adjust the strength of the mixture as necessary. 2 For mixtures which contain inhibited propyene gyco: (a) Open the cover of the refractometer, check that the cear pane is cean and use a sma syringe to appy three or four drops of the cooant mixture to the cear pane. (b) Spread the cooant over the fu area of the cear pane and cose the cover. Hod the refractometer horizontay with the cear pane at the top and inspect the sampe through the viewer. (c) Compare the reading with the chart in the instructions; adjust the strength of the mixture as necessary. Caution: The cear pane must be ceaned thoroughy before use. Some of the fuid which was tested earier can remain on the cear pane and this wi affect the reading of the sampe. C A B Specific gravity chart A = Percentage anti-freeze by voume B = Specific gravity C = Mixture temperature in Centigrade D = Mixture temperature in Fahrenheit D Protection against frost is as foows: Antifreeze/water (% by voume) Protection down to ( C) 50/ /40-40 How to check the ph vaue of the cooant The ph vaue of the cooant must not be ess than ph7 or more than ph9.5. The ph vaue can be found by the use of a ph meter or test papers, which are avaiabe from pharmaceutica manufacturers. If these imits are exceeded the ph vaue may be adjusted by the addition of a corrosion inhibitor to the same specification as that aready in use. If this is not possibe, the system must be drained, fushed and fied with new cooant. 21

22 This document has been printed from SPI². Not for Resae 4 How to renew the engine ubricating oi 1 Operate the engine unti it is warm. 2 Stop the engine, remove the sump drain pug and drain the ubricating oi from the sump. Fit the drain pug, compete with a new seaing washer, and tighten the pug to a torque of 47 Nm (35 bf ft). If the pug is fitted to a stee insert, tighten the pug to a torque of 115 Nm (85 bf ft). 3 Renew the three oi fiter canisters as given beow. 4 Cean the area around the oi fier cap (A2) and remove the cap. Fi the sump to the H mark on the dipstick (A1) with cean new ubricating oi of an approved grade as given on page 32. Do NOT overfi. 5 Operate the engine and check for eakage from the fiter canisters. When the engine has cooed, check the oi eve on the dipstick and put more oi into the sump, if necessary. How to renew the canisters of the oi fiter Three screw-on type canisters are fitted to the fiter head which is integra with the bottom of the engine oi cooer. 1 Put a tray under the canisters to retain the spit ubricating oi. Use a strap wrench to remove each canister. 2 Check that the seaing rings (B1) are correcty fitted to the new canisters and cean the contact faces of the fiter head. 3 Lubricate the top of each canister sea with cean engine ubricating oi and fi each canister with the approved grade of ubricating oi. 4 Fit the new canisters to their adaptors and tighten each canister unti its seaing ring is just in contact with the face of the fiter head. Continue to tighten each canister by a further 1 1 / 4 turns. Do NOT overtighten. 1 2 A 61 B

23 How to cean the primary fue fiter 4 1 Remove the three bots (A1) and remove the fiter bow (A2). 2 Cean a of the components with paraffin and dry them with a compressed air jet. 3 Fit the bow to the fiter head, together with a new seaing ring. Aign the camp ring (A3) and fasten it with the three bots. Eary engines can be fitted with fiters that have eements which can be ceaned. These eements shoud be removed, ceaned with fue oi and dried with a compressed air jet. How to renew the canister of the main fue fiter The main fue fiter is at the rear of the engine on the B bank side and has two canisters. Both canisters must be renewed at the same time Cean the area around the fiter and remove the fue fiter canisters. If necessary, use a strap wrench. Discard the canisters. 2 Check that the seaing ring (B1) is fitted correcty to each new canister and cean the contact faces of the fiter head. 3 Lubricate the top of the canister sea (B1) with cean fue oi and renew the seaing ring (B2) on the adaptor. 4 Fit the new canisters to their threaded adaptors and tighten each canister unti the seaing ring just comes into contact with the fiter head. Continue to tighten each canister by a further 1 1 / 4 turns by hand. Do NOT overtighten. After the fue fiter canisters have been renewed, eiminate air from the ow pressure fue system as given on page A B This document has been printed from SPI². Not for Resae

24 This document has been printed from SPI². Not for Resae 4 How to check/adjust the timing of the fue injection pump If it becomes necessary to check and adjust the timing of the fue injection pump, the procedure which foows is recommended: 1 Ensure that the stop contro is in the STOP position. 2 Remove the high-pressure fue pipes and the rocker cover from the cyinder head for A4, A5 and A6 cyinders. 3 Remove the cover from the fywhee housing as shown (A). 4 Turn the crankshaft by hand, in the norma direction of rotation, unti the reevant number for injection timing (see the engine data pate) aigns with the timing pointer at the same time as the vaves of A6 cyinder are cosed, ie. A6 piston at TDC on its compression stroke. 5 Check that the timing mark (B1), on the hub of the fue injection pump, aigns with the pointer (B2). 6 If the timing mark (B1) does not aign with the pointer, check that the fue pump drive shaft and the couping are secure and are not damaged, then proceed as foows: 7 Set the timing position as in paragraph 4 above, and oosen the four cap screws (C1), or for ater engines specia bots, on the injection pump adjustabe couping. 8 Turn the hub in the norma direction of rotation by hand, to just past the timing position. Then turn the hub back unti the timing mark and pointer aign; For earier engines tighten the four cap screws (C1) to 69 Nm (51 bf ft). For ater engines tighten the four specia bots to 46 Nm (34 bf ft). 9 Turn the engine in reverse direction for a quarter of a turn (90 ) and then forward, in the norma direction of rotation, unti the fywhee timing pointer is again aigned with the correct timing point (stamped on the engine data pate). Check that the timing marks of the fue injection pump are correcty aigned. A B 68 1 C 69 24

25 Fue injector faut 4 A fue injector faut can cause an engine misfire. In order to find which injector is defective, operate the engine at a fast ide speed. Loosen and tighten the union nut of the high-pressure fue pipe at each injector. When the union nut of the defective injector is oosened, it has itte or no effect on the engine speed. Warning! Ensure that the fue does not spray onto your skin. How to remove the fue injectors 1 Disconnect and remove the high-pressure pipes and the spi pipes. For eary engines, remove the reevant rocker box cover. Reease the connection for the eak-off fue from the fue injector and remove it through the wa of the rocker box. For ater engines, remove the reevant pedesta rocker cover. 2 Reease the reevant camp and withdraw the fue injector. To remove a tight fue injector, use the Side Hammer, (A1) and the reevant Adaptor (A2): for M18 threads or for M14 threads. Caution: Ensure that the copper fue injector seeve is not oosened in the cyinder head during the use of the side hammer. How to correct the fue injector seeves To improve the condition of the injector seeves, use the Reamer/facer too for the injector seeve. Grease must be appied to both of the cutters before use, to retain carbon and meta partices. Do not remove more meta than is absoutey necessary to correct the seat face. The maximum permissibe depth of the seat face, measured from the top face of the cyinder head, is 104,25 mm (4.104 in). Note: The Reamer/facer too is assembed from these toos: , and How to fit the fue injectors 1 Check that the new injector is fitted with a new O ring sea in the machined groove near to the top of the stem and check that the seeve for each fue injector is cean. 2 If reevant, remove the connection for the eak-off fue from each fue injector and fit carefuy each fue injector into its seeve, with the threaded hoe for the eak-off fue toward the outer wa of the rocker box. DO NOT use a seaing washer between the injector and the seating face of the injector seeve. 2 A 93 3 Fit the assemby of the meta cup and rubber sea against the head of each connection for eak-off fue and fit a new copper washer onto the thread. For eary engines, insert each connection through the openings in the outer was of the rocker boxes and fit the connection into its fue injector, finger-tight. 4 Fit the camps to the reevant fue injectors, compete with a spherica washer for each camp. Fit the cap screws through the washers and the camps and tighten them to 60 Nm (44 bf ft). For eary engines, when a the cap screws of the camps are tight, tighten the connections for eak-off fue to 27 Nm (20 bf ft). 5 Check that the joint face of each rocker box is cean. Fit a new joint for each rocker box cover and aign correcty the bot hoes. 1 Continued 25 This document has been printed from SPI². Not for Resae

26 This document has been printed from SPI². Not for Resae 4 6 Fit carefuy each rocker box cover and fit the eight bots, compete with pain and spring washers. Tighten the bots to 27 Nm (20 bf ft). For ater engines, fit a new O ring around the groove near the top of each fue injector. Fit the pedesta rocker cover and tighten ighty a of the bots. Tighten eveny a of the bots, in the sequence shown (A), to a torque of 11 Nm (8 bf ft). 7 For a engines, fit new copper seaing washer to the connections for eak-off fue and fit the pipes between the fue injectors and the connection bock for the eak-off fue. Tighten securey each banjo bot connection and each union nut. 8 Fit each high-pressure fue pipe between its deivery vave and its fue injector. Tighten by hand each nut. DO NOT bend a pipe to make it fit between its connections. Tighten securey each nut to 45 Nm (33 bf ft). Note: The identification of each high-pressure fue pipe is made by the cyinder number which is stamped on the union nut which is fitted to the fue injector. 9 Fit new rubber dampers around each high-pressure fue pipe. Fit the shrouds over the rubber dampers and retain securey each shroud to its induction manifod with bots and spring washers. 10 Eiminate air from the high-pressure fue system as given on page Run the engine and check for eaks A 70 26

27 How to eiminate air from the fue system If air enters the fue system, the injection pump pressure may become insufficient to operate the injector vaves and the engine may stop, misfire or fai to start. To eiminate air from the system, use the reevant procedure which foows: Low pressure system 1 Loosen the ow pressure reief vaves (A1) on the fue injection pump and operate the priming punger (B1) of the fue ift pump. When fue, free from air, fows from the reief vaves, tighten the unions. 2 Cean away fue that has been spied. High pressure system Air in the high pressure system must be reeased at the injectors. 1 Move the stop contro to the RUN position and operate the starter motor. 2 Loosen the nut of the high-pressure fue pipe at one of the injectors. When fue, free from air, is reeased, tighten the nut to a torque of 45 Nm (33 bf ft). DO NOT OVERTIGHTEN. Warning! Ensure that fue does not spray onto your skin. 3 Repeat the procedure for the remainder of the fue injectors. 4 If the engine starts during this operation but runs erraticay, continue to eiminate air from each injector unti the high pressure system is free from air or unti the engine runs correcty. 5 Return the stop contro to the STOP position. 6 Cean away any fue that has been spied. 1 4 A 71 1 B This document has been printed from SPI². Not for Resae

28 This document has been printed from SPI². Not for Resae 4 How to check the tappet cearances The tappet cearance is measured between the rocker evers and the top of the vave bridge pieces. See page 45 for the size of the cearances. Each vave bridge piece contros two vaves. An adjustment screw and ock nut is fitted to each bridge piece to ensure that equa force is appied to both vaves from the rocker arm. Before the tappet cearances are adjusted, the vave bridge pieces MUST be checked and adjusted if necessary. Check and adjust the vave bridge pieces and tappet cearances whie the fue injectors are removed for service. Caution: Numbers A1 and B1 cyinders are at the front (fan end) of the engine. 1 Remove the air fiters, the high pressure fue pipes and the fue injector eak-off pipes. 2 Remove the rocker covers. 3 Turn the crankshaft in the norma direction of rotation unti the inet vave of number A1 cyinder has just opened and the exhaust vave of the same cyinder has not cosed competey. Check and, if necessary, adjust the vave bridge pieces of ony the cyinder numbers which foow: Inet: Exhaust: A2, A4, A6, B1, B3, B5 A3, A5, A6, B1, B4, B5 To adjust the vave bridge pieces, proceed as foows: Loosen the ock nut and the adjustment screw on the reevant bridge piece. Use the rocker ever to appy pressure to the bridge piece, then turn the adjustment screw unti it is just in contact with the tip of the vave stem (A). Hod the adjustment screw in this position with a screwdriver and tighten the ock nut to a torque of 40 Nm (30 bf ft). Use a torque wrench with a ring spanner adaptor. Note that the reading on the torque wrench must be adjusted to compensate for the extra ength caused by the ring spanner adaptor. Check the tappet cearance AFTER the bridge pieces have been adjusted. When the cearance has been set correcty (B), tighten the ock nut to a torque of 40 Nm (30 bf ft). 4 Turn the crankshaft 360, in the norma direction of rotation unti the inet vaves of number A6 cyinder have just opened and the exhaust vaves of the same cyinder have not cosed competey. Check and, if necessary, adjust the vave bridge pieces of ony the cyinder numbers which foow: Inet: A1, A3, A5, B2, B4, B6 Exhaust: A1, A2, A4, B2, B3, B6 A B Check the tappet cearance AFTER the bridge pieces have been adjusted. When the cearance has been set correcty (B), tighten the ock nut to a torque of 40 Nm (30 bf ft). 5 When a of the bridge pieces and tappet cearances have been checked/adjusted, appy oi to the rocker evers, the bridge pieces and the vave springs. Fit the rocker covers, the fue pipes and the air fiters

29 Turbochargers How to cean the cooant system 4 At the periods given in the service schedue, disconnect and remove the pipes from between the air fiters and the turbochargers. Turn, rapidy, the rotor assemby of each turbocharger, check for freedom of movement and for sounds of interference. Deposits must not be removed from the turbine whees nor the compressor whees or the baance of the assembies wi be adversey affected. Aternator At the periods specified in the service schedue cean the outside of the aternator and ensure that the ventiation hoes are cean. Contamination near to the diodes can cause sparks and must be removed with an approved ceaning fuid. A recommended fuid is Eectronic Ceaning Fuid, Grade 8-23, avaiabe in aeroso containers or in arger quantities from Appied Chemicas Limited, Uxbridge, Middesex. The aternator must be checked and corrected, if necessary, by a person who has had the correct training, at the periods given in the service schedue. How to drain the cooant system Drain and fush the cooant system every 12 months or ess. The system must be drained as soon as possibe after the engine is stopped and before any deposits in the cooant have faen to the bottom. 1 Ensure that the engine is eve. 2 Carefuy remove the header tank fier cap, especiay if the engine is hot. Warning! Take care during remova of the fier cap as the cooant system wi be under pressure. 3 Remove the cooant drain pugs from the front eft side and the rear right side of the engine. Ensure that the drain hoes are not restricted. 4 Fush the system with cean water. 5 Fit the engine and radiator drain pugs. 6 Fit a cooant drained abe if the cooant system is not to be fied immediatey. The cooant system must be drained and fushed through with cean water unti it fows cear from a of the drain taps. If the system has become contaminated, it must be ceaned. Use cean water with 1% of Symperonic N. This is equivaent to 10m/itre or 45 m/uk gaon. 1 Fi the system with cean water, at the same time add the necessary amount of Symperonic N at the fier cap. 2 Operate the engine unti the cooant reaches the norma temperature of operation, then operate the engine at maximum rated speed for 10 minutes. Caution: In very cod ambient conditions, the thermostat may not open to aow fu circuation of the ceaning fuid. If this occurs the engine must be operated on oad. The thermostat is open when the pipe between the thermostat housing and the radiator is hot. If the pipe is coo, the thermostat vave is cosed. 3 Stop the engine and drain immediatey the cooant from a of the drain taps or pugs. Warning! Take care during remova of the fier cap as the cooant system wi be under pressure. 4 Aow the engine to coo, then fi the system with cean water. Aow a minimum of 5 itres (1 UK gaon) to drain from the system before the drain taps are cosed. 5 Operate the engine as in operation 2, but maintain maximum speed for 5 minutes ony. 6 Repeat the operations in paragraphs 3, 4 and 5. 7 Drain the system competey and cose the drain taps. Fi the system with the correct cooant mixture. How to fi the cooant system Fi the system sowy, with the approved cooant mixture, unti the cooant is just in contact with the bottom of the fier extension tube in the radiator. Operate the engine unti the cooant reaches the norma temperature of operation. Stop the engine, check the cooant eve and, if necessary, add extra cooant. Warning! Take care during remova of the fier cap as the cooant system wi be under pressure. 29 This document has been printed from SPI². Not for Resae

30 This document has been printed from SPI². Not for Resae

31 5 Engine fuids 5 Diese fue Diese fue must conform to the specifications given beow: On highway BS EN maximum suphur content 0.05%; minimum cetane number 49 and minimum cetane index 46. Low suphur fues must conform to a ubricity performance such that when tested using HFRR (CEC F-06-A96) the wear scar meets a maximum of 460 microns. Off highway BS 2869: Part Cass A2 - maximum suphur content 0.20%; minimum cetane number 45 and minimum cetane index 45. The use of fues which do not conform to the above standards can cause damage and/or reduced engine ife and coud affect the warranty. Further detais can be obtained from the Service Department at Perkins Engines Company Limited, Shrewsbury. Cooant Cooant mixture The cooant approved for use in a diese engines manufactured by PE(S)L is a mixture of 50% inhibited ethyene gyco, or inhibited propyene gyco, and 50% cean soft water. Mixtures which contain methano are NOT approved. The corrosion inhibitor in the anti-freeze or cooant concentrate, must be based on sodium nitrite, sodium benzoate, sodium borate, sodium metasiicate and benzotriazoe. Amines or phosphates must not be used. If operators are in doubt, they shoud consut their source of suppy. In addition, a products which are used shoud conform to BS For marine engines and engines which have auminium water-cooed exhaust manifods, ony BASF 007/400F or Perkins anti-freeze are approved. The Perkins anti-freeze, part numbers (1 itre) and (5 itre), can be obtained from the Perkins wordwide distributor network. Caution: Do NOT use sat water or any other cooant which can cause corrosion in the cosed cooant circuit. Corrosion inhibitor If anti-freeze is not avaiabe and is not required then cean soft water, with 1% of PE(S)L corrosion inhibitor, may be used. This ratio is equivaent to 0,5 itres of corrosion inhibitor to 50 itres (11 UK gaons) of water. The corrosion inhibitor is avaiabe from the Perkins wordwide distributor network, part number (1 itre). The use of this product shoud be controed in accordance with the manufacturer s instructions. For CHP (combined heat and power) sets an aternative inhibitor, part number OE45765, is recommended at a strength of 3%. Water quaity Soft water means de-ionised water, distied water, rain water, or water from a mains suppy which has a maximum combined choride and suphate eve of 150 mg/itre and a maximum tota hardness of 250 mg/itre. 1 If soft water is not used, the cooing system may be affected by the formation of hard deposits which can cause the engine to overheat. This is especiay important for engines which have cooant added frequenty. 2 The use of products which are not approved for the cooing system may cause serious probems. Cooant mixtures with insufficient corrosion inhibitor can cause erosion and/or corrosion of the cooing system components. 31 This document has been printed from SPI². Not for Resae