Hunting for a Perkins 3.152 shop manual PDF? This 128-page factory shop manual (OEM TPD 1091 1208E) covers the whole 3.152 diesel engine family: 3.152, D3.152, 3.1522, 3.1524, T3.1524, D3.152M, and the 3HD46. You get full overhaul procedures for the cylinder head, pistons and connecting rods, crankshaft and main bearings, timing gear, fuel system, cooling system, and turbocharger, plus marine engine maintenance and the approved service tool list. A fault diagnosis chart and a technical data section stacked with torque tensions and component dimensions back up every job. Pull the cylinder head nuts down to 81 Nm cold, then set tappet clearance at 0.30 mm on your 3.152 or D3.152. Bad clearances kill good engines. This PDF is bookmarked with a real text layer: search any spec from your phone or laptop, right at the engine.
What's Inside This Perkins 3.152 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-8 | Introduction, Safety Precautions, Asbestos Joints, Engine Identification, Running-In Procedure |
| Engine Views | 9-14 | Engine, D3.152 Engine, T3.1524 Engine, 3HD46 Mk2 Engine |
| Technical Data | 15-29 | Engine Data, Recommended Torque Tensions, Component Data and Dimensions |
| Fault Diagnosis | 31-32 | Fault Diagnosis Chart |
| Cylinder Head | 33-44 | To Remove Cylinder Head, Valve and Valve Seat Overhaul |
| Pistons and Connecting Rods | 45-54 | To Remove Pistons and Connecting Rods, To Fit New Rings |
| Cylinder Block and Liners | 55-58 | To Remove Cylinder Liners |
| Crankshaft and Main Bearings | 59-66 | To Fit New Main Bearings and Thrust Washers, To Remove Crankshaft, Crankshaft Overhaul |
| Timing Case and Drive | 67-72 | To Remove Timing Case Cover, To Remove Idler Gear and Hub |
| Timing | 73-78 | To Set Engine Timing |
| Lubrication System | 79-84 | Lubrication Circuit, Lubricating Oil Filters |
| Cooling System | 85-90 | To Check and Adjust Fan Belt Tension, To Dismantle Water Pump |
| Fuel System | 91-98 | Fuel Filters, To Remove Air From Fuel System, Fuel Lift Pump |
| Flywheel and Flywheel Housing | 99-102 | To Remove and Fit Flywheel |
| Electrical System | 103-106 | Alternators |
| Turbocharger | 107-114 | Maintenance |
| Marine Engines | 115-118 | Preventive Maintenance |
| Approved Service Tools | 119-124 | Valve Guide Remover and Replacer, Piston Ring Squeezer, Piston Height and Valve Depth Gauge, Fuel Injection Pump Timing Tool, Valve Seat Cutter Kit |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head nuts (cold) | 81 Nm (60 lbf ft) 8,3 kgf m | p. 17 |
| Cylinder head nuts/setscrews (cold) | 95 Nm (70 lbf ft) 9,7 kgf m | p. 17 |
| Tappet clearance (cold) - 3.152, D3.152 | 0,30 mm (0.012 in) | p. 16 |
| Tappet clearance (hot or cold) - 3.1522, 3.1524, T3.1524 (Inlet) | 0,20 mm (0.008 in) | p. 16 |
| Atomiser flange nuts | 16 Nm (12 lbf ft) 1,7 kgf m | p. 17 |
| Atomiser clamp nuts | 12 Nm (9 lbf ft) 1,2 kgf m | p. 17 |
| Fuel injection pump with tapered shaft nut | 81 Nm (60 lbf ft) 8,3 kgf m | p. 17 |
| Thermostat | 13,6 Nm (10 lbf ft) 1,4 kgf m | p. 17 |
| Thermostat adaptor (where fitted) | 13,6 Nm (10 lbf ft) 1,4 kgf m | p. 17 |
| Starter cable resistance | 0.0017 ohms maximum | p. 29 |
| Static pressure - no delivery | 41/69 kN/m2 (6/10 lbf/in2) 0,4/0,7 kgf/cm2 | p. 27 |
| Pressure output | 0.3 kgf/cm2 (4.5 lbf/in2) or 31 kN/m2 | p. 95 |
Perkins 3.152 Series Common Problems This Manual Covers
Perkins 3.152 diesel cranks but will not start, or fires only after long cranking
Check for air in the fuel system first. Loosen the filter vent screws and work the lift pump priming lever until fuel runs free of bubbles, following the bleed procedure starting on page 91. Test lift pump delivery; if output falls below 0.3 kgf/cm2 (4.5 lbf/in2), the figure on page 95, replace the pump.
Manual Section: Fuel System p. 91Heavy black smoke and low power under load, worse at full throttle
Check the air filter element first; a blocked element over-fuels the engine. Inspect the atomisers and have their spray pattern tested per the fuel system procedures. When refitting, note that page 97 prints the high pressure pipe union torque three ways that do not agree — '30 Nm (15 lbf ft) 2,1 kgf m'. The lbf ft and kgf m figures both work out to about 20 Nm, so tighten the union nuts in small increments to roughly 20 Nm rather than 30 and atomiser flange nuts to 16 Nm (12 lbf ft) per page 98, then run the fault chart on page 31 to rule out exhaust restriction.
Manual Section: Fuel System p. 91Oil pressure gauge reads low at operating temperature, warning light flickers at idle
Verify oil level and grade before condemning the engine. Renew the oil filter and inspect the relief valve, both covered in the lubrication section starting on page 79. If pressure stays low, drop the sump and inspect the bearings; measure crankshaft end clearance against the 0.05/0.38 mm limit on page 22.
Manual Section: Lubrication System p. 79Heavy crankcase breathing and oil mist from the vent on high-hour engine
Test compression on all three cylinders to confirm ring or bore wear. Remove the pistons and measure the bores; wear beyond 0.18 mm means new liners, per the limit on page 18. Check top ring clearance with a new ring in the groove; more than 0.18 mm, the spec on page 19, calls for new pistons and rings.
Manual Section: Pistons and Connecting Rods p. 45Engine runs hot under sustained load, temperature gauge climbs and radiator pushes coolant
Check fan belt tension and clear the radiator core of debris first. Drain and refill with clean coolant; engine-only capacity is 4.8 litres, listed on page 26. Test the thermostat in heated water: a wax type must start opening at 81/84°C. Replace it if it stays shut; water pump overhaul is covered from page 85.
Manual Section: Cooling System p. 85Frequently Asked Questions
How do I reset the Perkins 3.152 fuel system after running out of diesel?
To reset the fuel system after running out of fuel, you must remove air from the system. This involves opening the vent plug on the fuel filter, operating the fuel lift pump priming lever, and loosening the vent screw on the fuel injection pump governor control cover until fuel flows free of air. Detailed steps for this procedure are provided on page 93. p. 93
What are the torque specifications for Perkins 3.152 cylinder head nuts and main bearings?
The torque specification for cylinder head nuts (cold) is 81 Nm (60 lbf ft) or 8,3 kgf m. For main bearing setscrews, the torque is 150 Nm (110 lbf ft) or 15,0 kgf m. p. 17
What valve clearance should I set on a Perkins 3.152 or D3.152 engine?
For 3.152 and D3.152 engines, the tappet clearance for both inlet and exhaust valves is 0,30 mm (0.012 in) with the engine cold. p. 43
What is the lubricating oil pressure for the Perkins 3.152 series engines?
The minimum lubricating oil pressure is 207 kN/m2 (30 lbf/in2) or 2,1 kgf/cm2 at maximum engine speed and normal engine temperature. p. 16
How do I check the fan belt tension on a Perkins 3.152 engine?
With thumb pressure of approximately 10 kgf (22 lbf), press the fan belt down at the center of the longest free length. The belt movement should be 10 mm (3/8 in). p. 86
How is this Perkins 3.152 Shop Manual delivered?
Immediate download of the complete 128-page searchable Shop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Can I print a copy of this Perkins 3.152 Shop Manual for the shop?
Print away. There is no DRM and no page limit. Many buyers print one chapter at a time and leave the rest on a tablet.
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