Perkins D3.152 - Workshop Manual

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Contents3
General Information5
Safety Precautions7
Asbestos Joints7
Engine Identification8
Engine Views11
Front/Left Side of 3.152 Engine12
Rear/Right Side of 3.152 Engine12
Front/Left Side of D3.152 Engine13
Rear/Right Side of D3.152 Engine13
Front/Left Side of 3.1522 Engine14
Rear/Right Side of 3.1522 Engine14
Front/Left Side of T3.1524 Engine15
Rear/Right Side of T3.1524 Engine15
Front Left Side of 3HD46 Mk2 Engine16
Rear Right Side of 3HD46 Mk2 Engine16
Technical Data17
Engine Data18
Approximate Dry Engine Weights18
Typical Dry Installed Engine Weights18
Rating Details18
Recommended Torque Tensions19
Component Data and Dimensions20
Connecting Rod Alignment24
Engine Check and Fuel Pump Mark Angles - Static Timing30
Fault Diagnosis32
Fault Diagnosis Chart33
Code List of Possible Causes33
Cylinder Head34
To Remove Cylinder Head35
To Remove Valves35
Valve and Valve Seat Overhaul36
Rocket Shaft Assembly37
Valve Guides37
Valve Seat Inserts38
Tappets40
Combustion Chamber Caps and Joints (3.152)40
Cylinder Head Inspection40
Cylinder Head Fasteners41
Cylinder Head Tightening Sequence41
Cylinder Head Stud/Setscrew Positions41
To Fit Valves42
To Fit Cylinder Head42
Valve and Spring Assemblies42
To Adjust Tappet Clearances44
Crankcase Vent Valve - 3.1522 Only44
Pistons and Connecting Rods45
To Remove Pistons and Connecting Rods45
To Remove Pistons from Connecting Rods46
To Renew Small End Bush46
To Assemble Piston and Connecting Rod46
To Fit New Rings47
Laminated Compression Rings48
To Fit Three Segment Type49
To Fit Four Segment Type49
To Fit Spring Loaded Scraper Ring49
To Fit Piston and Connecting Rod50
Cylinder Block and Liners53
To Remove Cylinder Liners54
Preparation to Fit New Cylinder Liners55
To Fit New Service Liners - Flanged55
To Fit Factory Liners56
To Fit New Liners - Plain56
Oversize Cylinder Liners56
Coolant Restriction Plugs56
Crankshaft and Main Bearings57
To Fit New Main Bearings and Thrust Washers58
To Remove Crankshaft59
Balance Weights60
Crankshaft Overhaul60
To Fit Crankshaft61
Crankshaft Rear End Rope Oil Seal62
Crankshaft Rear End Lip Seal (Earlier Type)63
Crankshaft Rear End Lip Seal (Later Type)64
Timing Case and Drive65
Camshaft Bush - No.1 Bearing66
To Remove Timing Case Cover66
To Renew Crankshaft Front Oil Seal66
Timing Gears67
To Remove Idler Gear and Hub67
To Fit Idler Gear and Hub68
To Remove Camshaft Gear68
To Fit Camshaft Gear68
To Remove Fuel Injection Pump Gear68
To Fit Injection Pump Gear69
To Remove Camshaft69
To Fit Camshaft69
To Remove Timing Case69
To Fit Timing Case70
New Timing Case70
Timing71
Gear Timing Marks72
Fuel Injection Pump Timing Marks72
To Set Engine Timing72
To Check Valve Timing72
To Check DPA Fuel Injection Pump Timing by Use of Pump Rotor Marks73
To Check Fuel Injection Pump Timing by Use of Tools MS.67B and Adaptor PD.67B-1 and PD.67-274
To Check Mark Angle of DPA Fuel Injection Pump by Use of Tool MS.67B and Adaptor PD.67-375
To Check Mark Angle of Stanadyne Fuel Injection Pump by Use of Tool MS.67B and Adaptor PD.67B-1 and PD.67B-675
Lubrication System77
Lubrication Circuit78
Lubricating Oil Diagram78
Lubricating Oil Pressure79
Lubricating Oil Filter79
To Renew Lubricating Oil Filter Element79
To Renew Lubricating Oil Filter Canister80
Lubricating Oil Relief Valve80
To Remove Lubricating Oil Sump80
To Fit Lubricating Oil Sump80
To Remove Lubricating Oil Pump81
To Dismantle Lubricating Oil Pump81
Lubricating Oil Pump Inspection81
To Assemble Lubricating Oil Pump81
To Fit Lubricating Oil Pump82
Cooling System83
To Check and Adjust Fan Belt Tension84
To Drain Cooling System84
To Remove Water Pump84
To Dismantle Water Pump85
To Assemble Water Pump85
To Fit Pump to Engine86
Thermostat87
Fuel System88
Fuel Filters89
To Renew Fuel Filter Element (Current Engines)89
To Renew Fuel Filter Element (Earlier Engines)90
To Remove Air from Fuel System90
Fuel Lift Pump91
To Test Fuel Lift Pump When Fitted to Engine91
To Check Pressure Output of Fuel Lift Pump When Fitted to Engine92
To Remove Fuel Lift Pump92
To Dismantle Fuel Lift Pump92
To Assemble Fuel Lift Pump93
To Fit Fuel Lift Pump93
Fuel Injection Pump93
To Remove Fuel Injection Pump94
To Set Maximum no Load Speed94
To Fit Fuel Injection Pump94
High Pressure Fuel Pipes94
Flywheel and Flywheel Housing96
To Remove and Fil Flywheel97
Flywheel Ring Gear97
Alignment of Flywheel Housing98
Electrical System99
Electrical Equipment100
Alternators100
Precautions100
Maintenance100
To Test Alternator on Engine101
Alternator Output Test - Regulator Disconnected101
Starter Motor102
To Test Regulator102
To Test Dynamo on Engine102

Perkins D3.152 - Workshop Manual

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