Page 3 - Important Safety Information; WARNING
1 Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to ...
Page 5 - Index
Diesel Engine Index 3 Index Introduction About the Manual................................................... 4 How to Use the Manual ......................................... 4 Illustrations............................................................. 6 Symbols .........................................
Page 6 - About the Manual; How to Use the Manual
Diesel Engine Introduction 4 About the Manual This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine-related problems and to provide recommended repair procedures. The material in this manual covers all Signature engines. The manual is divided into sections. Eac...
Page 7 - Symbols
Diesel Engine Introduction 5 Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: WARNING – Serious personal injury or extensive property damage can result if the warning...
Page 8 - Illustrations
Diesel Engine Introduction 6 Illustrations Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. The...
Page 9 - Engine Identification; Engine Dataplate
Diesel Engine Engine Identification 7 Engine Identification Engine Dataplate The engine dataplate shows specific information about the engine. The engine serial number (ESN) and control parts list (CPL) provide information for ordering parts and for service needs. NOTE: The engine dataplate must not...
Page 10 - Specifications
Diesel Engine Engine Identification 8 Specifications Performance D20/25/30/32/33S-3 450/450Plus,460/460Plus Standard - SAEJ1995 Air Cleaner - without but with 3.0kPa intake restriction Muffler - without but with 10.0kPa exhaust restriction Alternator - without Test Condition Fan - without Rated Powe...
Page 11 - Engine Diagrams; Engine Views
Diesel Engine Engine Identification 9 Engine Diagrams Engine Views The following illustrations show the locations of the major external engine components, filters, and other service and maintenance points. Some external components will be at different locations for different engine models. 1. Intake...
Page 22 - Procedures and Techniques; Troubleshooting Symptoms Charts
Diesel Engine Troubleshooting Symptoms 20 Procedures and Techniques A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known about a complaint, the faster and easier the problem can be solved. The Troubleshooting Symptom Charts are organize...
Page 23 - Engine Will Not Crank or Cranks Slowly
Diesel Engine Troubleshooting Symptoms 21 Engine Will Not Crank or Cranks Slowly This is symptom tree T-002. Cause Correction Defective wiring of starting circuit Troubleshoot and repair starting circuit wiring including relays and switches. OK Specific gravity of battery electrolytr is low, or Batt...
Page 24 - Engine Cranks But Will Not Start (No Exhaust Smoke)
Diesel Engine Troubleshooting Symptoms 22 Engine Cranks But Will Not Start (No Exhaust Smoke) This is symptom tree T-003. Cause Correction Fuel level low in the tank Fill the supply tank. OK Improper fuel is being used Drain fuel and replace with correct fuel. OK Clogged fuel tank air breather hole ...
Page 25 - Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Diesel Engine Troubleshooting Symptoms 23 Engine Difficult to Start or Will Not Start (Exhaust Smoke) This is symptom tree T-004. Cause Correction Starting aid malfunctioning or heater mount Does not become warm Replace the starting aid. OK Crank speed is too slow (minimum crank Speed: 150 rpm) Veri...
Page 27 - Engine Has Poor Respones
Diesel Engine Troubleshooting Symptoms 25 Engine Has Poor Respones This is symptom tree T-005. Cause Correction Clogged air cleaner element Clean or replace the air cleaner element OK Clogged fuel tank air breather hole Clean the fuel tank breather. OK Clogged prefilter Clean or replace the fuel fil...
Page 28 - Engine Stops During Operation
Diesel Engine Troubleshooting Symptoms 26 Engine Stops During Operation This is symptom tree T-006. Cause Correction Chassis powertrain is damaged or overloaded Refer to the OEM’s service manuals. OK Fuel level low in the tank Fill the supply tank. OK Clogged fuel tank air breather hole Clean the fu...
Page 29 - Engine Runs Rough or Misfires
Diesel Engine Troubleshooting Symptoms 27 Engine Runs Rough or Misfires This is symptom tree T-007. Cause Correction Fuel level low in the tank Fill the supply tank. OK Clogged fuel tank air breather hole Clean the fuel tank breather. OK Low idle speed is adjusted too low Adjust the low idle speed. ...
Page 30 - Engine Power Output Low
Diesel Engine Troubleshooting Symptoms 28 Engine Power Output Low This is symptom tree T-008. Cause Correction Improper fuel is being used Drain and replace the fuel with the correct fuel. OK Clogged air cleaner element Clean or replace the air cleaner element. OK Clogged fuel tank air breather hole...
Page 33 - Lubricating Oil Consumption Excessive
Diesel Engine Troubleshooting Symptoms 31 Lubricating Oil Consumption Excessive This is symptom tree T-010. Cause Correction Lubricating oil leak (external) Inspect the engine the external oil leaks. Tighten the capscrews, pipe plugs, and fittings. Replace the gaskets if necessary. OK Intake system ...
Page 34 - Lubricating Oil Contaminated
Diesel Engine Troubleshooting Symptoms 32 Lubricating Oil Contaminated This is symptom tree T-011. Cause Correction Breather or breather hose is clogged Clean the breather and breather hose. OK Lubricating oil filter is clogged Replace the filter. OK Turbocharger turbine oil seal is damaged Replace ...
Page 35 - Fuel consumption Is Excessive
Diesel Engine Troubleshooting Symptoms 33 Fuel consumption Is Excessive This is symptom tree T-012. Cause Correction Overloading from malfunctioning accessories Check and repair the accessories. Refer to the OEM’s service manuals. OK Operator technique is not correct Refer to the operation and maint...
Page 36 - Coolant Contamination
Diesel Engine Troubleshooting Symptoms 34 Coolant Contamination This is symptom tree T-013. Cause Correction Coolant is rusty Review the coolant change interval. Drain and flush the system. Fill the system with the Correct mixture of coolant and water. OK Lubricating oil cooler for powertrain is dam...
Page 37 - Coolant Loss
Diesel Engine Troubleshooting Symptoms 35 Coolant Loss This is symptom tree T-013.1 Cause Correction Radiator or cab heater is leaking Inspect the radiator heater, hoses, and connection to locate the leak. If oil is present in the coolant, check for a transmission or lubricating oil cooler leak. OK ...
Page 38 - Lubricating Oil Pressure Is Low
Diesel Engine Troubleshooting Symptoms 36 Lubricating Oil Pressure Is Low This is symptom tree T-014. Cause Correction Lubricating oil lever is below specification Check the oil level. Verify the dipstick calibration and the oil pan capacity. Fill the system to the specified level. OK Oil level or p...
Page 39 - Oil Level Rises
Diesel Engine Troubleshooting Symptoms 37 Oil Level Rises This is symptom tree T-015. Cause Correction Rear crankshaft seal or seal surface is damaged Repair or replace seal and surface OK Auxiliary equipment has damaged pump seal Replace the auxiliary pump. Refer to the OEM’s service manual. OK Inj...
Page 40 - Coolant Temperature above Normal
Diesel Engine Troubleshooting Symptoms 38 Coolant Temperature above Normal This is symptom tree T-016. Cause Correction Coolant level is below specification Inspect the engine and radiator for external coolant leaks. OK Fan belt is slipping or the fan pulley is worn Replace the fan belt or pulley. O...
Page 41 - Excessive Noise
Diesel Engine Troubleshooting Symptoms 39 Excessive Noise This is symptom tree T-017. Cause Correction Belt is squeaking due to insufficient tension or abnormally high loading Check and adjust belt tension. Make sure all the pulleys rotate freely. OK Air leakage between the turbocharger and head Tig...
Page 43 - Engine Vibration Excessive
Diesel Engine Troubleshooting Symptoms 41 Engine Vibration Excessive This is symptom tree T-018. Cause Correction Engine mounting bolts are loose or the engine mounting cushion is broken Replace the engine mounting bolts or cushion. OK Engine and powertrain is out of alignment Repair the alignment. ...
Page 44 - Complete Engine; Engine Disassembly
Diesel Engine Complete Engine 42 Complete Engine Engine Disassembly Service Tool Part No. Part Name Quantity 3375193 or 3375194 Unit Repair Stand or Engine Overhaul Stand 1 3163625 Bracket 1 3163292 Valve Spring Compressor 1 3397890 Flange Puller 1 3823137 Piston Ring Expansion Tool 1 Engine Removal...
Page 50 - CAUTION
Diesel Engine Complete Engine 48 Spill Tube Remove the spring hose clamps and hose. Remove the spill tube. Injector CAUTION Be careful not to damage the tip of the injector when removing. Remove the mounting capscrew, washer, and injector. NOTE: When removing the injector, clean around the injector,...
Page 63 - Engine Assembly
Diesel Engine Complete Engine 61 Engine Assembly Service Tools Part No. Part Name Quantity 3375193 or 3375194 Unit Repair Stand or Engine Overhaul Stand 1 3163625 Bracket 1 3163292 Valve Spring Compressor 1 3823137 Piston Ring Expansion Tool 1 3397773 Piston Ring Compressor 1 Setting the Unit in the...
Page 89 - Rocker Levers; Adjusting Valve Clearance
Diesel Engine Engine Testing 87 Rocker Levers Adjusting Valve Clearance Remove the cylinder head cover. Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of No. 4 cylinder, bring the No.1 cylinder into compression top dead center position Align the TOP en...
Page 91 - Measuring Compression Pressure
Diesel Engine Engine Testing 89 Complete Engine Measuring Compression Pressure WARNING Exhaust manifold and muffler are hot. Do not touch the exhaust manifold or muffler or personal injury will occur. WARNING To avoid personal injury, keep hands, long hair, jewelry, and loose fitting or torn clothin...
Page 93 - Testing and Adjusting the Fan Belt
Diesel Engine Engine Testing 91 Crank the engine with the starting motor. Read the gauge when the pointer is stabilized. Engine Compression kPa psi 1965 MIN 285 2944 NOM 427 Testing and Adjusting the Fan Belt Tansion Testing the Fan Belt Tension Check the amount the fan belt deflects when pushed wit...
Page 94 - Fuel System; Checking and Adjusting Fuel
Diesel Engine Engine Testing 92 Fuel System Checking and Adjusting Fuel Injection Timing There are two methods for checking and adjusting the fuel injection timing of an injection pump. • The “MATCH MARK ALIGNMENT” method, which is used when the injection pump is installed on the original engine and...
Page 97 - Injector; Testing
Diesel Engine Engine Testing 95 Remove the dial gauge. Install the distributor head bolt and new copper washer into the injection pump. Tighten the bolt. Torque Value: 17 N•m [13 ft-lb] Stamp a match mark on the injection pump and the timing gear case. Adjusting the Idle Move the governor control le...
Page 99 - Disassembly
Diesel Engine Engine Testing 97 Disassembly Remove the copper sealing washer and discard. Clamp the nozzle holder in a soft jawed vise and remove the nozzle nut. Remove the nozzle needle valve and intermediate plate. NOTE: To avoid damage, place the injector nozzle and needle valve in a suitable bat...
Page 100 - Assembly
Diesel Engine Engine Testing 98 Assembly NOTE: Make sure all mating surfaces and pressure faces are clean and lubricated with fuel oil before assembly. WARNING Install the same thickness of shims that were removed in disassembly. Use the pressure spring to make sure the shims are installed flat. Ins...
Page 102 - Lubricating System; Measuring Oil Pressure
Diesel Engine Engine Testing 100 Lubricating System Measuring Oil Pressure WARNING When measuring the oil pressure, be careful not to get caught in rotating parts. always remove or install plug or oil pressure gauges with the engine stopped. Remove the oil pressure sensor, and install the pressure g...
Page 104 - Rocker Arm Shaft, Push Rod and Tappets
Diesel Engine Specifications 102 Rocker Arm Shaft, Push Rod and Tappets Ref Inspection Item Standard Remarks VALVE ROCKER ARM SHAFT Diameter of Shaft 19 mm [0.75 in] Tolerance: -0.020 mm [-0.0008 in] Diameter of Rocker Arm Shaft Hole Nominal: 19 mm [0.75 in] Tolerance: 0.030 mm [0.0012 in] 0.010 mm ...
Page 106 - Cylinder Block
Diesel Engine Specifications 104 Cylinder Block Ref Inspection Item Standard Remarks CYLINDER BLOCK 1 Surface Flatness (Warpage Limit) 0.00 to 0.08 mm [0.00 to 0.003 in] Repair Limit: 0.15 mm [0.006 in] STD 70.000 mm [2.756 in] Repair Limit: 70.200 mm [2.764 in] U/S 0.25 69.750 mm [2.746 in] Repair ...
Page 107 - Camshaft and Camshaft Bushing
Diesel Engine Specifications 105 Camshaft and Camshaft Bushing Ref Inspection Item Standard Remarks CAMSHAFT Naturally Aspirated Naturally Aspirated 1 Bend of Shaft — 0.03 mm [0.0012 in] Intake 42.69 mm [1.681 in] Repair Limit: 42.20 mm [1.661 in] 2 Cam Height Exhaust 43.04 mm [1.694 in] Repair Limi...
Page 108 - Crankshaft
Diesel Engine Specifications 106 Crankshaft Ref Inspection Item Standard Remarks CRANKSHAFT 1 Thrust Clearance 0.131 to 0.351 mm [0.0052 to 0.0138 in] Repair Limit: 0.40 mm [0.016 in] STD 70.000 mm [2.756 in] Repair Limit: 69.86 mm [2.750 in] U/S 0.25 69.75 mm [2.746 in] Repair Limit: 69.61 mm [2.74...
Page 109 - Timing Gear
Diesel Engine Specifications 107 Timing Gear Ref Inspection Item Standard Remarks TIMING GEAR Naturally Aspirated and Turbocharged A Crankshaft gear and idler gear 0.08 mm to 0.19 mm [0.0031 in to 0.007 in] B Camshaft gear and idler gear 0.08 mm to 0.19 mm [0.0031 in to 0.007 in] C Injection pump ge...
Page 110 - Flywheel
Diesel Engine Specifications 108 Flywheel Ref Inspection Item Standard Remarks FLYWHEEL 1 Face Runout of Flywheel Housing — Repair Limit: 0.30 mm [0.012 in] 2 Radial Runout of Flywheel Housing — Repair Limit: 0.35 mm [0.014 in] 3 Face Runout of Flywheel — Repair Limit: 0.15 mm [0.0059 in] 4 Radial R...
Page 111 - Cylinder
Diesel Engine Specifications 109 Cylinder Ref Inspection Item Standard Remarks CYLINDER Bore STD ID: 95.00 mm [3.740 in] Tolerance: 0.022 mm [0.0008 in] Repair Limit: ID: 95.15 mm [3.746 in] Roundness of Cylinder — 1 Cylindricity of Cylinder — Repair Limit: 0.02 mm [0.0008 in] 18900020
Page 112 - Piston
Diesel Engine Specifications 110 Piston Ref Inspection Item Standard Remarks PISTON 1 Diameter STD ID: 95.00 mm [3.740 in] Repair Limit: ID: 94.85 mm [3.734 in] 2 Top 0.06 to 0.10 mm [0.0024 to 0.0039 in] 2.0 mm [0.079 in]* Repair Limit: 0.15 mm [0.0059 in] 3 Second 2.0 mm [0.079 in]* Repair Limit: ...
Page 113 - Connecting Rod, Piston Ring and Piston Pin
Diesel Engine Specifications 111 Connecting Rod, Piston Ring and Piston Pin Ref Inspection Item Standard Remarks PISTON PIN Outer Diameter Nominal OD: 30.00 mm [1.181 in] — 1 Clearance 0.004 to 0.018 mm [0.0002 to 0.0007 in] Clearance Limit: 0.05 mm [0.002 in] PISTON RING A Top 0.30 to 0.45 mm [0.01...
Page 114 - Oil Pump
Diesel Engine Specifications 112 Oil Pump Ref Inspection Item Standard Remarks 1 Axial 0.030 to 0.085 mm [0.0012 to 0.0033 in] Clearance Limit: 0.10 mm [0.0039 in] 2 Clearance of Pump Gear Radial 0.045 to 0.090 mm [0.0018 to 0.0035 in] Clearance Limit: 0.13 mm [0.0051 in] 18900017
Page 115 - Regulator Valve
Diesel Engine Specifications 113 Regulator Valve Ref Inspection Item Standard Remarks Tolerance Standard Size Shaft Hole Standard Clearance Clearance Limit 1 Clearance Between Valve and Body 11 mm [0.43 in] -0.050mm-0.077mm [0.002 in][0.003 in] 0.020 mm -0.020mm [0.0008 in][0.0008 in] 0.030 to 0.097...
Page 117 - Capscrew Markings and Torque Values; Capscrew Markings and Torque Values - Metric
Diesel Engine Specifications 115 Capscrew Markings and Torque Values CAUTION When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the gra...
Page 119 - Fraction, Decimal, Millimeter Conversions
Diesel Engine Specifications 117 Fraction, Decimal, Millimeter Conversions Fraction inch mm Fraction inch mm 1/64 0.0156 0.397 33/64 0.5156 13.097 1/32 0.0313 0.794 17/32 0.5313 13.494 3/64 0.0469 1.191 35/64 0.5469 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.0781 1.984 37/64 0.5781 14.684 3/...
Page 122 - Weight and Measures - Conversion Factors
Diesel Engine Specifications 120 Weight and Measures - Conversion Factors Quantity U.S. Customary Metric From U.S. Customary To Metric Multiply By From Metric To U.S. Customary Multiply By Unit Name Abbreviation Unit Name Abbr. sq. inch in 2 sq. millimeters mm 2 645.16 0.001550 sq. centimeters cm 2 ...
Page 123 - SPECIAL TOOLS
Diesel Engine Special Tools 121 SPECIAL TOOLS Style Tool No. Tool name ST 434 Vacuum Gauge ST 537 Dial Depth Gauge ST 1111-3 Seal Leakage Tester ST 1273 Pressure Gauge 3162745 Injector/Connector Removal tool
