All 252 pages of this Perkins 3012, CV12 workshop manual PDF (OEM #TSD 3420, Issue 3) focus entirely on repairing and maintaining these heavy-duty 12 cylinder diesel engines for industrial applications. Inside, you get complete teardown procedures for the crankshaft, timing gears, and cylinder head assemblies to rebuild your motor from the block up. Open to detailed system diagrams, exploded parts views of the fuel injection pump, and clearance tables specifically for the pistons and connecting rods. Adjust your tappet clearances to exact factory tolerances, and verify the correct nominal applied torques before sealing the rocker box cover. Stop hunting through forums for reliable engine data. Grab this bookmarked download, pull it up on your tablet in the shop, and get your diesel running right on the first try.
What's Inside This Perkins 3012, CV12 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 13-22 | Introduction, Bank and Cylinder Bore Identification, Engine Identification, Safety, Useful Information, Approved Lubricants and Fluids |
| Specifications | 23-28 | Basic Engine Data, Recommended Specific Applied Torques, Recommended Nominal Applied Torques |
| Cylinder Head Assembly | 29-60 | General Description, Pedestal Rocker Cover, Pedestal Rocker Assembly, Rocker Box Cover, Tappet Clearances, Valves, Valve Springs and Valve Rotators, Push Rods |
| Pistons and Connecting Rods | 61-76 | General Description, Big End Bearings, Piston and Connecting Rod Assembly, Piston Rings, Piston and Rings, Fits and Clearances - Pistons and Connecting Rods, Pistons - 3 Rings |
| Crankshaft Assembly | 77-90 | General Description, Crankshaft Pulley, Damper and Alternator Pulley, Front Oil Seal, Rear Oil Seal, Crankshaft, Main Bearings and Thrust Washers, Fits and Clearances |
| Timing Gears and Timing Case | 91-104 | General Description, Timing Gears and Auxiliary Drive Shaft, Double Idler Gear, Timing Case, Fits and Clearances |
| Crankcase and Cylinder Liners | 105-118 | General Description, Crankcase, Cylinder Liner, Fits and Clearances |
| Camshafts and Engine Timing | 119-128 | General Description, Camshafts, Engine Timing, Fits and Clearances |
| Induction and Exhaust System | 129-136 | General Description, Exhaust Manifold, Fits and Clearances |
| Lubrication System | 137-152 | General Description, Lubricating Oil Sump - Early Engines, Single Piece Lubricating Oil Sump, Lubricating Oil Pump, Heat Exchanger (Oil to Coolant) - Early Engines |
| Fuel System | 153-194 | General Description, Primary Fuel Filter, Fuel Filter Head, Mechanical Fuel Lift Pump, Fuel Injectors, Fuel Injection Pump and Governor |
| Cooling System | 195-210 | General Description, Radiator, Thermostats, Coolant Pump, Fan, Fan Belts and Tensioner Pulley, Fan Adaptor |
| Flywheel and Flywheel Housing | 211-214 | General Description, Starter Ring |
| Electrical Equipment | 215-236 | General Description, Alternator, Starter Motor, Electrical Switches, Engine Stop Solenoid (Energised to Run), Early 3012 Engines |
| Auxiliary Equipment | 237-238 | - |
| Running-In and Test | 239-240 | To Run the Engine, Load or Power Rating, Rev/min, Duration, To Check the Consumption Rate of the Engine Lubricating Oil |
| Special Tools | 241-252 | List of Special Tools |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tappet clearances (hot or cold) - Engines before 'build line number' 8281 (6C27437/29): Inlet valves | 0,4 mm (0.016 in) | p. 23 |
| Tappet clearances (hot or cold) - Engines before 'build line number' 8281 (6C27437/29): Exhaust valves | 0,5 mm (0.020 in) | p. 23 |
| Fuel injectors - Cap screws, clamp | 60 Nm (80 lbf ft) | p. 27 |
| Fuel injectors - Cap nut, nozzle | 80 Nm (59 lbf ft) | p. 27 |
| Main fuel filters | Two screw-on type canisters | p. 24 |
| Lubricating oil sump capacity (maximum) | 55 litres (12 UK gallons) | p. 25 |
| Coolant capacity, engine/radiator pack | 122.7 litres (27 UK gallons) | p. 24 |
| Fuel injector injection pressure | 250 bar (early engines 240 bar) | p. 24 |
| Piston top ring maximum permissible worn gap | 1.397 mm (0.055 in) | p. 73 |
| Bolts, rocker box to cylinder head torque | 46 Nm (34 lbf ft) | p. 26 |
| Bolts, main bearing cap torque (front, centre, rear) | 177 Nm (131 lbf ft) | p. 26 |
| Maximum recommended oil temperature in sump | 125 °C | p. 25 |
Perkins 3012, CV12 Common Problems This Manual Covers
Perkins 3012 or CV12 engine sudden loss of oil pressure while operating under heavy load.
Drain the lubricating oil sump and verify it held the maximum capacity of 55 litres (12 UK gallons) listed on page 25. Remove the sump to inspect the oil pump pickup screen for blockage before checking the main bearings for wear.
Manual Section: Lubrication System p. 25Engine fires briefly then dies or fails to start despite cranking at normal speed.
Measure the fuel supply pressure at the filter head. Verify the reading falls between 140 to 210 kN/m² (20 to 30 lbf/in²) as specified on page 24. Replace both screw-on type main fuel filter canisters if pressure drops below this range.
Manual Section: Fuel System p. 24Heavy crankcase breathing and excessive blow-by noted from the breather tube during normal operation.
Remove the cylinder head and extract the pistons to measure ring end gaps. Check page 73 and replace the rings if the top ring gap exceeds the maximum permissible worn gap of 1,397 mm (0.055 in). Install a new cylinder head gasket during reassembly.
Manual Section: Pistons and Connecting Rods p. 73Loud tapping noise from the top end when starting cold or idling after warmup.
Remove the rocker box cover to check and adjust the tappet clearances. Set the exhaust valves to 0,5 mm (0.020 in) per the tappet clearance table on page 23. Torque the rocker box cover bolts to 46 Nm (34 lbf ft) when reinstalling the cover.
Manual Section: Cylinder Head Assembly p. 73High water temperature alarm sounds and radiator pushes out fluid under heavy load conditions.
Drain and flush the cooling system completely. Refill the system and verify it takes the full engine and radiator pack coolant capacity of 122.7 litres (27 UK gallons) as noted on page 24. Inspect the thermostats and water pump for proper operation.
Manual Section: Cooling System p. 24Frequently Asked Questions
What are the torque specifications for the Perkins 3012 fuel injection pump mounting bolts?
The bolts retaining the fuel injection pump to its mounting should be tightened to a torque of 46 Nm (34 lbf ft). This specification is listed in the manual's recommended specific applied torques. p. 27
How do I adjust the tappet clearance on a Perkins 3012/CV12 engine?
Tappet clearances for engines before 'build line number' 8281 are 0.4 mm (0.016 in) for inlet valves and 0.5 mm (0.020 in) for exhaust valves. For engines from 'build line number' 8281, inlet valves are 0.2 mm (0.008 in) and exhaust valves are 0.5 mm (0.020 in). The procedure for checking and adjusting tappet clearances is detailed in operation 12-8. p. 23
What are the torque specifications for the Perkins 3012 rocker box bolts and cap screws?
Bolts for the rocker box to the cylinder head should be tightened to 46 Nm (34 lbf ft), while cap screws for the rocker box to cylinder head are 35 Nm (26 lbf ft). Bolts for the rocker box cover to the rocker box require a torque of 23 Nm (17 lbf ft). p. 26
How do I adjust the linkage for the Perkins CV12 engine stop solenoid?
To adjust the linkage, connect a 24 volt DC supply to energize the solenoid. Then, adjust the lock nut (B1) until its rear face is aligned with the front of the rod (B2) as shown in the illustration on page 234. This procedure ensures correct operation of the stop control. For Early 3012 engines, adjust the lock nut (B1) until it is 8-10 mm (0.3-0.4 in) from the rear face of the rod (B3) as shown on page 235. p. 234
What are the replacement specifications for Perkins 3012 fuel injectors?
Perkins 3012 fuel injectors are axial supply, low spring type, with six spray holes, and have an injection pressure of 250 bar (240 bar for early engines). When replacing, new copper sealing washers should be used, as described in operation 20-7. p. 24
What do I get after purchasing this Perkins 3012, CV12 manual?
You get a 252-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Can I print specific sections of this Perkins 3012, CV12 Workshop Manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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