Professional Documents
Culture Documents
DIESEL ENGINE
As a part of revision of this shop manual, special descriptions of the engines certified by the
EPA (Environmental Protection Agency) are added to the latter half of the manual (Chapter
20).
For the descriptions other than the above, see the first half, since they are same as those of
the conventional engines.
© 2003
All Rights Reserved
Printed in Japan 05-03 (01)
00-1
(1)
GENERAL
CONTENTS
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM .......................... 11-1
12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM .............................. 12-1
Engine output
Engine Machine model Machine Serial No. Remarks
(kW{HP}/rpm)
Application Category
CL 1,500/1,800
Generator drive Constant
CH 3,000/3,600
VM 2,000 – 3,000
General use Variable
VH 3,000 – 3,600
Notice
Pease update the part numbers and codes in this shop manual as follows.
[Method of updating]
Add YM in front of the part number and code.
(Note:This does not apply to all items. For details, see the Parts Book.)
(Example)
Update the part numbers and codes in this shop mnual: 172187-08520oYM172187-08520
(S) D (A) —
Shipping identifier
Model subdivision
Model code
Number of cylinders (3 or 4)
Turbocharger
Application Category
CL 1,500/1,800
Generator drive Constant
CH 3,000/3,600
VM 2,000 – 3,000
General use Variable
VH 3,000 – 3,600
1.1 2D68E
Model
Unit 2D68E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Special swirl pre-combustion chamber
No. of cylinders – bore x Stroke mm 2 – 68 x 72
Displacement l 0.523
Firing order — 1–2
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 5.74 6.25 6.84 7.43 7.94 8.46
Max. rating
{HP} {7.8} {8.5} {9.3} {10.1} {10.8} {11.5}
Max. revolution speed at no load 2,180 +500 2,375 +500 2,570 +500 2,780 +500 2,970 +500 3,180 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 23.0
Specifications
1.2 3D68E
Model
Unit 3D68E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Special swirl pre-combustion chamber
No. cylinders – bore x Stroke mm 3 – 68 x 72
Displacement l 0.784
Firing order — 1–3–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 8.6 9.4 10.3 11.2 12.0 12.9
Max. rating
{HP} {11.5} {12.6} {13.8} {15.0} {16.1} {17.3}
Max. revolution speed at no load 2,180 +500 2,375 +500 2,570 +500 2,780 +500 2,970 +500 3,180 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 23.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity
l 2.4/1.0
Max/Effective
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 0.9 (for engine only)
Cooling fan
mm Pusher type, 5 x 310
No. of blade x dia.
Crank V-pulley dia./
mm 105/ 85
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 463.5 x 401 x 496 / 473.5 x 401 x 496
Dry weight (*2) kg 70/81
Transient speed
% Z12
Governing difference
perfor- Steady state speed
% Z9 Z8 Z7 Z6
mance band
Performance
1.3 3D74E
Model
Unit 3D74E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Special swirl pre-combustion chamber
No. cylinders – bore x Stroke mm 3 – 74 x 78
Displacement l 1.006
Firing order — 1–3–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 11.0 12.1 13.2 14.3 15.5 16.6
Max. rating
{HP} {14.8} {16.2} {17.7} {19.2} {20.8} {22.3}
Max. revolution speed at no load 2,180 +500 2,375 +500 2,570 +500 2,780 +500 2,970 +500 3,180 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 23.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity
l 2.4/1.0
Max/Effective
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 0.9 (for engine only)
Cooling fan
mm Pusher type, 5 x 310
No. of blade x dia.
Crank V-pulley dia./
mm 110/ 85
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 469.1 x 440 x 502 / 476.6 x 440 x 502
Dry weight (*2) kg 85/102
Transient speed
% Z12
Governing difference
perfor- Steady state speed
% Z9 Z8 Z7 Z6
mance band
Performance
1.4 3D78AE
Model
Unit 3D78AE
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 3 – 78 x 84
Displacement l 1.204
Firing order — 1–3–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 13.2 14.6 15.9 17.2 18.5 19.9
Max.rating
{HP} {17.7} {19.6} {21.3} {23.1} {24.8} {26.7}
Max. revolution speed at no load 2,180 +500 2,375 +500 2,570 +500 2,780 +500 2,970 +500 3,180 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity
l 3.6/1.3 5.0/1.7
Max/Effective
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 1.8 (for engine only)
Cooling fan
mm Pusher type, 6 x 335
No. of blade x dia.
Crank V-pulley dia./
mm 110/ 110
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 520.5 x 489 x 565 / 528 x 489 x 565
Dry weight (*2) kg 112/128
Transient speed
% Z12
Governing difference
perfor- Steady state speed
% Z9 Z8 Z7 Z6
mance band
Performance
1.5 3D82AE
Model
Unit 3D82AE
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 3 – 82 x 84
Displacement l 1.330
Firing order — 1–3–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 14.6 16.0 17.5 19.0 20.5 21.9
Max.rating
{HP} {19.6} {21.5} {23.5} {25.5} {27.5} {29.5}
Max. revolution speed at no load 2,180 +500 2,375 +500 2,570 +500 2,780 +500 2,970 +500 3,180 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
1.6 3D82E
Model
Unit 3D82E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 3 – 82 x 90
Displacement l 1.425
Firing order — 1–3–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 15.5 16.9 18.4 19.9 21.3 23.2
Max.rating
{HP} {20.8} {22.7} {24.7} {26.7} {28.6} {31.1}
Max. revolution speed at no load rpm 2,160 +500 2,375 +500 2,570 +50
0 2,780 +500 2,970 +500 3,180 +500
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity Max/Effective l 4.7/1.8 6.9/2.1
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 2.0 (for engine only)
Cooling fan
mm Pusher type, 6 x 335
No. of blade x dia.
Crank V-pulley dia./
mm 110/ 110
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 556 x 486 x 623 / 564 x 486 x 623
Dry weight (*2) kg 138/155
Transient speed
% Z12
Governing difference
perfor- Steady state speed
% Z8 Z7 Z6
mance band
Performance
1.7 3D84E
Model
Unit 3D84E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 3 – 84 x 90
Displacement l 1.496
Firing order — 1–3–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 16.4 18.1 19.7 21.3 23.0 24.6
Max.rating
{HP} {22.0} {24.3} {26.4} {28.6} {30.8} {33.0}
Max. revolution speed at no load 2,175 +500 2,375 +500 2,600 +500 2,800 +500 3,000 +500 3,225 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity Max/Effective l 4.7/1.8
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 2.0 (for engine only)
Cooling fan
mm Pusher type, 6 x 335
No. of blade x dia.
Crank V-pulley dia./
mm 110/ 110
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 556 x 486 x 623 / 564 x 486 x 623
Dry weight (*2) kg 138/155
Transient speed
% Z12
Governing difference
perfor- Steady state speed
% Z9 Z8 Z7
mance band
Performance
1.8 3D88E
Model
Unit 3D88E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 3 – 88 x 90
Displacement l 1.642
Firing order — 1–3–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 18.0 19.9 21.6 23.5 25.2 27.1
Max.rating
{HP} {24.1} {26.7} {29.0} {31.5} {33.8} {36.3}
Max. revolution speed at no load 2,175 +500 2,375 +500 2,600 +500 2,800 +500 3,000 +500 3,225 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity Max/Effective l 4.7/1.8 6.9/2.1
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 2.0 (for engine only)
Cooling fan
mm Pusher type, 6 x 335
No. of blade x dia.
Crank V-pulley dia./
mm 110/ 110
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 556 x 486 x 623 / 564 x 486 x 623
Dry weight (*2) kg 138/155
Transient speed
% Z12
Governing difference
perfor- Steady state speed
% Z9 Z8 Z7
mance band
Performance
1.9 4D82E
Model
Unit 4D82E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 4 – 82 x 90
Displacement l 1.901
Firing order — 1–3–4–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 20.6 22.6 24.5 26.5 28.5 30.5
Max.rating
{HP} {27.6} {30.3} {32.9} {35.5} {38.2} {40.9}
Max. revolution speed at no load 2,160 +500 2,375 +500 2,570 +500 2,780 +500 2,970 +500 3,180 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity Max/Effective l 5.8/2.3
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 2.7 (for engine only)
Cooling fan
mm Pusher type, 6 370
No. of blade x dia.
Crank V-pulley dia./
mm 110/ 110
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 632 x 448.5 x 618 / 658 x 498.5 x 618
Dry weight (*2) kg 160/170
Transient speed
Governing difference % Z12
perfor-
Steady state speed band % Z8 Z7 Z6
mance
Performance
1.10 4D84E
Model
Unit 4D84E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 3 – 84 x 90
Displacement l 1.995
Firing order — 1–3–4–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 21.9 24.1 26.3 28.5 30.7 32.9
Max.rating
{HP} {29.4} {32.3} {35.3} {38.2} {41.2} {44.1}
Max. revolution speed at no load 2,180 +500 2,400 +500 2,590 +500 2,810 +500 2,995 +500 3,210 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity Max/Effective l 5.8/2.3
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 2.7 (for engine only)
Cooling fan
mm Pusher type, 6 370
No. of blade x dia.
Crank V-pulley dia./
mm 110/ 110
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 632 x 498.5 x 618 / 658 x 498.5 x 618
Dry weight (*2) kg 160/170
Transient speed
Governing difference % Z12
perfor-
Steady state speed band % Z9 Z8 Z7
mance
Performance
1.11 4D88E
Model
Unit 4D88E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 4 – 88 x 90
Displacement l 2.189
Firing order — 1–3–4–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 24.1 26.5 28.8 31.3 33.7 36.0
Max.rating
{HP} {32.3} {35.5} {38.6} {42.0} {45.2} {48.3}
Max. revolution speed at no load 2,180 +500 2,400 +500 2,590 +500 2,810 +500 2,995 +500 3,210 +500
rpm
Min. revolution speed at no load Z800
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.45 min.)
Lubrication system — Forced lubrication with trochoid pump
Lubrication oil capacity Max/Effective l 5.8/2.3 7.9/2.5
Recommended lubricating oil — APl grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 2.7 (for engine only)
Cooling fan
mm Pusher type, 6 370
No. of blade x dia.
Crank V-pulley dia./
mm 110/ 110
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 632 x 498.5 x 618 / 658 x 498.5 x 618
Dry weight (*2) kg 160/170
Transient speed
Governing difference % Z12
perfor-
Steady state speed band % Z9 Z8 Z7
mance
Performance
1.12 S3D84E
Model
Unit S3D84E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 3 – 84 x 90
Displacement l 1.496
Firing order — 1–3–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 21.0 22.8 25.0 26.9 29.1 30.9
Max.rating
{HP} {28.2} {30.6} {33.5} {36.1} {39.0} {41.4}
Max. revolution speed at no load 2,175 +500 2,375 +500 2,600 +500 2,800 +500 3,020 +500 3,240 +500
rpm
Min. revolution speed at no load Z800 +500
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
1.13 S4D84E
Model
Unit S4D84E
Item
Application — VM
Type — Vertical, 4-cycle water-cooled diesel engine
Combustion system — Direct injection system
No. cylinders – bore x Stroke mm 4 – 84 x 90
Displacement l 1.995
Firing order — 1–3–4–2–1
Revolution speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Continuous rating — — — — — —
{HP}
Output (*1)
kW 28.0 30.5 33.5 35.7 38.6 41.2
Max.rating
{HP} {37.5} {40.9} {44.9} {47.9} {51.8} {55.3}
Max. revolution speed at no load 2,175 +500 2,375 +500 2,600 +500 2,800 +500 3,000 +500 3,225 +500
rpm
Min. revolution speed at no load Z800 +500
Direction of rotation — Counterclockwise (viewed from flywheel)
Power take off — Flywheel
Compression ratio — 18.0
Specifications
2.1 Special swirl pre-combustion chamber system (Indirect injection system) ............................................. 2-2
2.2 Direct injection system ............................................................................................................................ 2-4
1 5
10
YE0001
11
YE0002
11) Camshaft
3
2
10
YE0004
11
YE0005
11) Camshaft
Radiator
Sub-tank
Cylinder block
For the above reasons, use lubricating oil APl Service Classification Class CC or better.
SAE 5W-20
SAE 20W-40
SAE 10W-30
SAE 10W
SAE 20W
SAE 20W-20
SAE 20W-30
SAE 20W-40
Lub. oil filter Pressure Main gallery Idle gear shaft Fuel injection
(w/ bypass valve) regulating valve pump
Tappet/cam
faces
Oil pan
YE0316
(Option)
(w/turbocharged
Oil pressure engine only)
switch
Fuel injection
pump
Lub. oil filter
(with bypass valve)
Pressure
regulating valve
Cylinder body and main gallery
Lub. oil pump Idle gear shaft Camshaft Crank journal Piston
bearing cooling nozzle
Tappet/cam
faces
Oil pan
YE0317
1
2
9 4
8
5
6
7 YE0010
1
2
9 4
10
8
5
6
7 YE0011
4. TROUBLESHOOTING
★ For the compression pressure measuring procedure, refer to chapter 6, 6.1.Measurement of compression
pressure.
Reduction in compression pressure of the cylinder is one of major causes of an increase in blow-by gas (which
causes contamination and increased consumption of lubricating oil, and other trouble) as well as the engine
starting failure.The compression pressure is influenced by the following factors:
1. Degree of clearance between the piston and cylinder.
2. Degree of clearance around intake/exhaust valve seats.
3. Gas leak through the nozzle gasket or cylinder head gasket.
In addition, the compression pressure decreases as the engine parts are worn and lose durability through use of
the engine for a long period.
Scratches on the cylinder or piston caused by dust or foreign matter through the soiled air cleaner element, and
wear or breakage of piston ring also decrease the compression pressure.
For this reason, diagnose the engine status by measuring the compression presure.
(1) Causes and contermeasures to be taken when the compression pressure is less than the limit
value.
★ For the compression pressure limit values, refer to Chapter 6, 6.1 Measurement of compression pres-
sure.
★ Although main engine parts can be disassembled and reassembled only with standard service tools, it is
recommended to provide the following special service tools and measuring instruments for more efficient
and accurate work, correct maesurement, diagnosis, and troubleshooting.
(Unit:mm)
Dimension
l1 l2 d1 d2
2
Model
d2
2D68E, 3D68E 20 55 5 8 1
Valve guide 3D74E 20 75 6.5 10
1
extraction tool
3D78AE, 3D82AE 20 75 6.5 10
3D82E, 4D82E d1
(S)3D84E, (S)4D84E 20 75 7.5 11
3D88E, 4D88E YE0012
★ Locally manufacured
(Unit:mm)
Dimension
l1 l2 d1 d2 2
Model
2D68E, 3D68E 7 60 11 17 1
★ Locally manufacured
(Unit:mm)
Dimension
l1 l2 d1 d2
Model
2
2D68E, 3D68E 22 62 20 -0.3
-0.6 22 -0.3
-0.6 d2
Connection rod 1
-0.3 -0.3
3 bushing 3D74E 20 80 21 -0.6 23 -0.6
replacer -0.3 -0.3
3D78AE, 3D82AE 25 85 23 -0.6 26 -0.6
d1
3D82E, 4D82E
-0.3 -0.3 YE0014
(S)3D84E, (S)4D84E 20 100 26 -0.6 29 -0.6
3D88E, 4D88E
★ Locally manufacured
Valve spring
compressor Model Code No.
4
(Replacement All model 129100-92630
of valve spring)
YE0015
Filter wrench
(Removal and
5 Sold on market
installation of
Lub.oil filter)
YE0016
(Unit:mm)
Dimension
l1 l2 d1 d2
Model
2
Camshaft bush- 2D68E, 3D68E 13 60 36 -0.3
-0.6 39 -0.3
-0.6 d2
ing tool 1
-0.3 -0.3
6 (Extraction of 3D74E 14 60 40 -0.6 43 -0.6
camshaft bush-
ing)
3D78AE, 3D82AE 18 70 45 -0.3
-0.6 48 -0.3
-0.6
d1
3D82E, 4D82E
-0.3 -0.3 YE0017
(S)3D84E, (S)4D84E 18 70 45 -0.6 48 -0.6
3D88E, 4D88E
★ Locally manufactured
Flex-Hone
(for honing cyl- Model Code No.
inder liner) 2D68E, 3D68E 129400-92400
★ For the
3D74E 129400-92410
usage pro-
7 3D78AE, 3D82AE 129400-92420
cedure of
the Flex- 3D82E, 4D82E
Hone, refer (S)3D84E, (S)4D84E 129400-92430
to Chapter 3D88E, 4D88E
7,7.2,3.
YE0018
Piston ring
9 Sold on market
replacer
YE0020
YE0023
YE0027
YE0028
YE0029
YE0030
YE0031
YE0033
YE0035
YE0036
1
Applies a reflecting tape on the cir-
cumference of the rotating parts to
measure RPM.
Photoelectric type
Tachometer
1) Revolving body
16 2) Reflecting tape 2 YE0038
1) High-pressure pipe
YE0039
YE0040
YE0041
3D74E
3.92 {40}
Compression pressure
3.43 {35}
(MPa {kg/cm2})
2.94 {30}
2D68E, 3D68E
2.45 {25}
1.96 {20}
3D88E, 4D88E
3.92 {40}
3D84E, 4D84E
Compression pressure
3.43 {35}
(MPa {kg/cm2})
3D78AE
2.94 {30}
2. Action to be taken when the measured compression pressure is below the limit value.
Trouble occurs in a part of the engine. For troubleshooting, refer to Chapter 4, 4.2 trouble diagnosis through
measurement of compression pressure.
All models
4) Valve cap
5) Normal
4
6) Abnormal
5 6
YE0047
1) Alternator
2) Crankshaft pulley
3) Cooling water pump
4) Bar (For adjusting the 10~15mm
tension of the V-belt)
5) Alternator
6) Adjuster 1
3
2
YE0048
5
YE0049
1
1
3 2
4
5
3
6a
6
6b
4
5
7
6
YE0051 7a
( Indirect Injection system) 7c
7
1) Nozzle holder 7b
2) Pressure adjusting shim
3) Nozzle spring
8
4) Nozzle spring seat
5) Valve stop spacer YE0052
YE0053
YE0054
YE0055
YE0056
(3) Place a sheet of white paper 300 mm below the nozzle. The injection spray should form a perfect circle.
(4) No oil should drip from the nozzle after injection.
(5) Oil should not ooze from the injection hole when the pressure is raised to a little less than the specified
1.96 MPa {20 kg/cm2}.
(6) Test the injection with a nozzle tester; retighten and test again if there is excessive oil leak from the
overflow coupling. Replace the nozzle as a set if the leaking oil is still excessive.
YE0057
YE0058
(Nozzle valve sliding check by gravity for indi- (Nozzle valve sliding check by gravity for direct
rect injection system) injection system)
YANMAR Identification
number
Identification
number
YE0320
YE0321
(Indirect injection system) (Direct injection system)
1) Crankshaft pulley
2) Cylinder No. 1
3) Flywheel housing
YE0062
4) Access hole
5) Timing mark
3
4
YE0063
YE0064
6) Adjusting shim 6
YE0065
2
1) Crankshaft pulley
2) Cylinder No. 1
YE0067
3) Flywheel housing
4) Access hole
5) Timing mark
4
YE0063
7) Lock nut
7
YE0322
6.7 Checking the cooling water system and radiator for water
leakage
1. Checking the cooling water system and radi-
ator for water leakage
★ The cooling water system can be checked
effectively while the engine is warm.
(1) Supply cooling water up to the normal water
level in the radiator. Attach the cap tester
body to the radiator.
(2) Start the cooling water pump, and set it to a
pressure of 88.3 ± 14.7 kPa {0.9 ± 0.15 kg/
cm 2 }. Any lower reading of the pressure 8
gauge on the cap tester indicates water leak
YE0072
from the cooling water system. Then, detect
the potion where cooling water leaks from (Checking the cooling water system for water
the cooling water system. leakage)
2. Checking the radiator cap
Attach the radiator cap to a cap tester. Set the
tester to a pressure of 88.3 ± 14.7 kPa {0.9 ±
0.15 kg/cm2}. Check to see if the cap is opened
at the set pressure. If not, replace the cap,
because it is defective.
7) Cap tester
8) Radiator cap
9
YE0073
3
1) Terminal
2) Cap
3) Cover
4
4) Cathode plate
5
5) Separator
6) Glass mat 8 6
7) Anode plate
8) Battery case 7
YE0074
9) Lower limit
10) Upper limit 10
11) Acceptable 9
12) Too low
13) Too high YE0075
11 12 13
14
YE0076
Measured electrolyte
temperature
1.260 0 100 18
1.210 25 75
1.160 50 50 19
1.110 75 25
1.060 100 0
YE0079
(Hydrometer)
17) Rubber bulb
18) Glass tube
19) Float
YE0080
(3) Terminals
Repair or clean the terminals if corroded or
soiled.
(4) Fittings
Repair or replace the fittings if corroded. Re-
tighten them if loosened.
(2) Thermoswitch
Put a thermoswitch into an antifreeze or oil
in a container. While measuring liquid tem-
perature, heat the liquid. If the tester shows
YE0081
continuity at a temperature of 107-113°C,
the thermoswitch is acceptable.
3
6
1) Thermometer 6) Thermoswitch
2) Thermostat 7) Thermometer
3) To radiator 8) Tester probes YE0082
YE0083
9
10
YE0084
(Continuity test)
(1) Replace the packing at the joint and O-rings at the time of reassembly after disassembly.
(2) When the oil cooler is disassembled and cleaned for periodic inspection, remove the scale by using
descaling agent "Unicon 146"
(3) Cooling tube leak check
Close either the inlet or outlet of the cooling tube. Apply an air pressure (0.49 MPa {5.0 kg/cm2}) from
the other end and check if air is leaking by immersing the tube in water. If leaking, repair or replace the
cooling tube.
6 2
5 3
4 YE0085
2
YE0086
★ In maintaining various parts, make measurement according to the following measurement procedure. If any
trouble is found and if any part deviates from the standard size, replace it with a new one. However, if any
part within the limit is expected to deviate from the standard presumably because of the record of its use, be
sure to replace such a part beforehand.
1) Straight-edge
2) Thickness gauge
3) Depth-Micrometer
4) Valve sinking depth
3D82E,4D82E
3D78AE
(S)3D84E,(S)4D84E
3D82AE
3D88E,4D88E
Wear Wear
Standard Standard
limit limit
Intake 0.296–
Valve 1.0 0.306–0.506 1.0
valve 0.496
sinking
depth Exhaust
0.3–0.5 1.0 0.3–0.5 1.0
valve
(Unit:mm)
2D68E
3D74E
3D68E
Wear Wear
Standard Standard
limit limit
YE0090
(Unit:mm) (Measuring the valve seat width)
3D82E,4D82E,
3D78A
(S)3D84E,(S)4D84E
3D82AE
3D88E,4D88E
Wear Wear
Standard Standard
limit limit
1) Seat grinder
2) Grindstone
3) Seat width 2 YE0091
4) Valve seat
4
(2) When the seat width is enlarged from the
initial value, correct it by grinding the seat
YE0092
surface with a 70° seat grinder or seat cut-
ter. Then, grind the seat to the standard (Valve seat correction angle)
width with a 15° grinder.
★ When using a seat cutter, evenly apply
pressure taking care of avoiding uneven
cutting.
(3) Knead valve compound with oil and finish the valve seat by lapping.
★ It any valve requires correction, be sure to measure the oil clearance between the valve stem out-
side dia. and valve guide inside dia. If the oil clearance exceeds the limit, replace the valve or valve
guide before correcting the valve seat surface. (For oil clearance between the valve and valve
guide, refer to section 3 in this chapter.)
(4) Finally, lap the valve using only oil.
★ After the valve seat is corrected, thoroughly clean the valve and cylinder head using diesel oil or the
like. Thoroughly remove the valve compound or grindstone powder.
★ For slightly poor contact, take steps (3) and (4).
3D74E(IDI) CH and VH
With valve
Direct injection system CH and VH
seat
Turbocharged engine All
three positions
4) Valve seat
3. Intake/exhaust valve
(1) Wear and vend of the valve stem
Replace a valve stem if bent or worn badly. In this case, replace the valve guide at the same time.
2D68E
3D74E
3D68E
Wear Wear
Standard Standard
limit limit
5.460– 6.960–
Stem O.D. 5.4 6.9
5.475 6.975
Intake 5.500– 7.005–
Guide I.D. 5.58 7.08
valve 5.515 7.020
Oil 0.025– 0.030–
0.18 0.18
clearance 0.055 0.060
5.445– 6.945–
Stem O.D. 5.4 6.9
5.460 6.960
Exhaust 5.500– 7.005– YE0096
Guide I.D. 5.58 7.08
valve 5.515 7.020 (Measuring the valve stem outside diameter)
Oil 0.040– 0.045–
0.18 0.18
clearance 0.070 0.075
(Unit:mm)
3D82E,4D82E
3D78AE
(S)3D84E,(S)4D84E
3D82AE
3D88E,4D88E
Wear Wear
Standard Standard
limit limit
6.945–
Stem O.D. 6.9 7.955–7.975 7.9
6.960
Intake 7.000–
Guide I.D. 7.08 8.010–8.025 8.1
valve 7.015
Oil 0.040–
0.18 0.035–0.070 0.2
clearance 0.070
6.940–
Stem O.D. 6.9 7.955–7.970 7.9
6.955
Exhaust 7.015–
Guide I.D. 7.08 8.015–8.030 8.1
valve 7.045
Oil 0.045–
0.18 0.045–0.075 0.2
clearance 0.075
(Unit:mm)
2D68E
3D74E
3D68E
Wear Wear 1
Standard Standard
limit limit 4
Thick- Intake 0.85–1.15 0.50 0.99–1.29 0.50 2
ness of valve
valve Exhaust 3 YE0097
head 0.95–1.25 0.50 0.95–1.25 0.50
valve
2D68E
3D74E
3D68E 2
Standard Wear limit Standard Wear limit
Valve guide
7 — 9 —
projection
(Unit:mm)
3D82E,4D82E
3D78AE
(S)3D84E,(S)4D84E
3D82AE
3D88E,4D88E YE0099
3
4. Valve stem seal
5
[Time of Replacement]
(1) When oil loss is found excessive
(2) When the valve stem seal is removed
(3) When intake/exhaust valves are removed
[Precautions on Installation]
Make sure that the entire surface of valve stem is
smooth, and sufficiently apply lubricating oil to the
valve stem before reassembling intake/exhaust
valves.
YE0100
(Hatched portion indicates where to apply lubri-
cating oil.)
(Unit:mm)
2D68E
3D74E
3D68E
Wear Wear
Standard Standard
limit limit
Wear Wear
Standard Standard
limit limit
4 YE0103
6. Checking valve spring holder and cotter (Measuring the inclination of valve spring)
Check contact of the inner surface of the valve
spring holder with the circumference of the cot- 1) Inclination
ter as well as contact of the inner circumference 2) Free length
of the cotter with the notch on the head of the 3) Square
valve stem. If such contact is uneven or if the
4) Suface plate
cotter sinks, replace the cotter with a new one.
YE0105
(Unit:mm)
2D68E
3D74E
3D68E
(Unit:mm)
3D82AE
3D78AE 3D82E
4D82E
(Unit:mm)
(S)3D84E 3D88E
(S)4D84E 4D88E
3. Honing
(1) Practice of honing
Honing or boring the cylinder if unevenly
worn, flawed, otherwise damaged. Slight
uneven worn, flaws, etc. may well be only
honing with a Flex-Hone. However, signifi-
cant uneven wear should be first bored and
then honed. It is important to take into care-
ful consideration as to whether the cylinder
can attain perfect roundness after honing,
boring, or both, considering maximum wear.
In addition, carefully study as to whether
prepared oversized pistons and piston rings
are applicable. (For the oversized piston
YE0106
and piston ring, refer to this chapter 7.4,8.)
(Flex-Hone)
(2) Procedure for using the Flex-Hone
It is common practice to use the Flex-Hone
for honing. The procedure for using it
appears in the following table. Any material
must allow for approx.1/1,000 mm when 1
honed with the Flex-Hone.
2
1) Necessary items
3 4
Flex-Hone, power drill, and honing fluid. 50% 50%
Flex-Hone Applicable
Model
Code No. bore (mm) 5 YE0107
YE0108
2) Handling procedure
Apply the honing fluid to the Flex-Hone. Insert the Flex-Hone into the cylinder while turning it, move
it up and down for about 30 sec for a cross hatch angle of 30-40°. Extract the Flex-Hone while turn-
ing it.
★ Use the Flex-Hone at a speed of 300-1,200 rpm. Use of the Flex-Hone at a higher speed may
be hazardous.
★ Never insert into or extract from the cylinder the Flex-Hone, with the power drill left stopped.
Honing Boring
Consideration
on the applicability
of oversized
pistons and piston rings
YE0339
YE0111
(Unit:mm)
3D78AE,3D82AE
3D82E,4D82E
2D68E,3D68E 3D74E
(S)3D84E,(S)4D84E
3D88E,4D88E
1) Thickness gauge
1
YE0112
(Unit:mm)
3D78AE,3D82AE
3D82E,4D82E
2D68E,3D68E 3D74E
(S)3D84E,(S)4D84E
3D88E,4D88E
3. Other checks
(1) Valve rocker arm shaft spring
Check to see if the rocker arm shaft spring
is free from corrosion and wear. If not,
replace it with a new one.
YE0115
1
1) Measurement position
22~25mm
YE0116
YE0117
(Unit:mm)
2D68E 3D82E (S)3D84E 3D88E
3D74E 3D78AE 3D82AE
3D68E 4D82E (S)4D84E 4D88E
2
Top ring
YE0119 YE0120
3
3D78AE, 3D82AE
3D82E, 4D82E
Model YE0118
(S)3D84E, (S)4D84E
3D88E, 4D88E
1) Top ring
CH,VH with
Application CL,VM 2) 2nd ring
turbocharged.
(Common to all models)
3) Oil ring
Top ring (Common to all models)
YE0121 YE0122
YE0123
1) Width
2) Thickness
3) Side clearance
4) Ring
5) Piston 1 3
5 4
YE0323
2 YE0124
6) End clearance
7) Approx. 30mm
9
8) Piston ring
9) Cylinder block
YE0125
(Unit:mm)
3D82E, 4D82E
2D68E
3D74E 3D78AE (S)3D84E 3A88E, 4D88E
3D68E
(S)4D84E
7
6
YE0126
YE0128
YE0127
(Unit:mm)
2D68E, 3D68E 3D74E
Wear Wear
Standard Standard
limit limit
Piston pin
19.991– 20.991–
outside 19.90 20.90
20.000 21.000
diameter
Piston
and piston Piston pin 20.000– 21.000–
20.02 21.02
pin hole dia. 20.008 21.008
Oil clear- 0.000– 0.000–
0.12 0.12
ance 0.017 0.017
8
(Unit:mm) 9
3D82E,4D82E
3D78AE (S)3D84E YE0129
3D82AE (S)4D84E
(Insertion of piston pin)
3D88E,4D88E
Wear Wear
Standard Standard
limit limit 8) Apply oil to piston pin
Piston pin 9) Circlip
22.991– 25.987–
outside 22.90 25.90
23.000 26.000
diameter
Piston
and pis- Piston pin 23.000– 26.000–
23.02 26.02
ton pin hole dia. 23.008 26.009
Oil clear- 0.000– 0.000–
0.12 0.12
ance 0.017 0.022
(Unit:mm)
3D82E,4D82E
3D78AE (S)3D84E
3D82AE (S)4D84E
3D88E,4D88E
Wear Wear
Standard Standard
limit limit
Top 0.650– 0.660–
— —
clearance 0.770 0.780
VM
2D68E
CH 0.250S 119265-22930 119265-22950
3D68E
VH
VM
3D74E CH 0.250S 119623-22900 119623-22950
VH
CL
VM
3D78AE 0.250S 119818-22910 119818-22950
CH
VH
CL
3D82AE 0.250S 119813-22900 129003-22950
VM
CL
0.250S 129003-22900 129003-22950
3D82E VM
4D82E CH
0.250S 129003-22910 129003-22950
VH
CL
0.250S 129002-22900 129002-22950
(S)3D84E VM
(S)4D84E CH
0.250S 129002-22910 129002-22950
VH
3D88E CL
0.250S 129001-22900 129001-22950
4D88E VM
1) Parallelism
2) Mandrel
3) Twist
4) Connecting rod aligner 4
YE0131
(Measuring the twist with connecting rod
aligner)
Rod bolt
tightening
torque 22.6–27.5 37.3–41.2 44.1–53.9
(Apply lub. {2.3–2.8} {3.8–4.2} {4.5–5.5}
oil to the
rod bolt)
(Unit:mm)
3D82E,4D82E
2D68E 3D78AE
3D74E (S)3D84E,(S)4D84E
3D68E 3D82AE
3D88E,4D88E
Standard Wear limit Standard Wear limit Standard Wear limit Standard Wear limit
Crankpin
39.000– 43.000– 46.000– 51.000–
bushing — — — —
39.016 43.016 46.016 51.010
inside dia.
Crankpin
1.487– 1.487– 1.487– 1.492–
Crank- metal thick- 1.500
—
1.500
—
1.500
—
1.500
—
pin side ness
Crankpin out- 35.970– 39.970– 42.952– 47.952–
35.91 39.91 42.91 47.91
side diameter 35.980 39.980 42.962 47.962
0.033– 0.033– 0.038– 0.038–
Oil clearance 0.15 0.15 0.16 0.16
0.059 0.059 0.090 0.074
1) Crankpin metal
2) Assemble so that the punched mark of
large end faces the uel injection pump.
YE0134
YE0136
6
4
5
YE0135
(Unit:mm)
All models 1
YE0137
1) Crankshaft
2) Thickness gauge
7.6 Camshaft
1
1. Camshaft side gap
2
Before extracting the camshaft, bring a dial
gauge into contact with the camshaft gear and
measure the side gap around the camshaft. If
the measured value exceeds the limit, replace
the thrust metal with a new one.
(Unit:mm)
All models
Side gap 0.05–0.25
(Unit:mm)
All models
Standard Wear limit
Camshaft bend 0.02 or less 0.05
5
YE0141
YE0140
(Measuring the cam height)
6) Micrometer
7) Cam height
1) Gear side
2) Intermediate bearing
3) Flywheel side YE0142
(Unit:mm)
3D78AE,3D82AE
2D68E 3D82E,4D82E
3D74E
3D68E (S)3D84E,(S)4D84E
3D88E,4D88E
Wear Wear Wear
Standard Standard Standard
limit limit limit
Camshaft
Gear journal out- 35.940–35.960 35.85 39.940–39.960 39.85 44.925–44.950 44.85
side side diameter
Oil clearance 0.040–0.085 — 0.040–0.085 — 0.040–0.130 —
Camshaft
Inter- journal out- 35.910–35.935 35.85 39.910–39.935 39.85 44.910–44.935 44.85
mediate side diameter
Oil clearance 0.065–0.115 — 0.065–0.115 — 0.065–0.115 —
Camshaft
Fly- journal out- 35.940–35.960 35.85 39.940–39.960 39.85 44.925–44.950 44.85
wheel side diameter
side
Oil clearance 0.040–0.125 — 0.040–0.0125 — 0.050–0.100 —
7.7 Crankshaft
1. Side gap around the crankshaft
Before extracting the crankshaft and when reas-
sembling it, bring a dial gauge into contact ot the
end of the crankshaft. Force the crankshaft to
both sides in the axial direction to measure the
thrust gap. Alternatively, insert a thickness
gauge directly into a thrust gap between the
thrust metal in the standard part and crankshaft
to measure the side gap.
If the limit is exceeded, replace the thrust metal
with a new one.
(Unit:mm)
All modelss
1
Thrust gap 0.090–0.271
2 YE0143
1) Dial gauge
2) Crankshaft
3) Bend
4) Deflection
5) Dial gauge 6 6
6) Set the V-block YE0145
(Measuring the crankshaft bend)
YE0146
7
7) Crank journal
8 YE0147
8) Crankpin
(Unit:mm)
3D82E,4D82E
3D78AE
(S)3D84E,(S)4D84E
3D82AE
3D88E,4D88E
Standard Wear limit Standard Wear limit
Crankpin Crankpin outside diameter 42.952–42.962 42.91 47.952–47.962 47.91
Crankshaft journal outside
46.952–46.962 46.91 53.952–53.962 53.91
diameter
Crank
Bearing metal thickness 1.987–2.000 — 1.995–2.010 —
journal
Crank journal and
0.038–0.093 0.25 0.038–0.068 0.15
bushing oil clearance
3 1
YE0148
7. Undersized main metal by 0.25 mm and the oversized thrust metal by 0.25 mm
7.8 Gears
1. Checking gears
Inspect the gears and replace if the teeth are damaged, worn, or chipped.
3. Checking and measuring the idling gear shaft and idling gear
(1) Measure the bushing inside diameter and the idle gear shaft outside diameter, and replace the bushing
or idling gear shaft if the oil clearance exceeds the wear limit.
(Unit:mm)
3D78AE,3D82AE
2D68E
3D82E,4D82E
3D68E
(S)3D84E,(S)4D84E
3D74E
3D88E,4D88E
Standard Wear limit Standard Wear limit
Shaft outside dia. 19.959–19.980 19.93 45.950–45.975 45.93
Idle gear Bushing inside dia. 20.000–20.021 — 46.000–46.025 46.08
Oil clearance 0.020–0.062 0.15 0.025–0.075 0.15
(2) Make sure that the oil hole of the idle gear shaft and bushing is a through hole.
3
2
1
1
2
3 YE0150
YE0149
4. Gear train
After installing each gear, make sure that aligning marks (A), (B) and (C) of the idle gear are aligned with
those of the fuel injection pump gear, cam gear and crank gear.
3
2
YE0151
1) Outer rotor
YE0152
2) Pump body
3) Thickness gauge (Measuring the clearance between outer rotor
and pump body)
(Unit:mm) 2
All models
Standard Wear limit
3
Clearance between
outer rotor and inner — 0.15
rotor
1) Inner rotor
2) Outer rotor
3) Thickness gauge
YE0153
4) Straight edge
5) Pump body 5
6) Thickness gauge
YE0154
5. Others
(1) Check for looseness of drive gear/rotor shaft fitting, and replace the entire assembly if loose or wobbly.
(2) Push the oil pressure regulating valve piston from the oil hole side, and replace the entire assembly if
the piston does not return due to spring breakage, etc.
(Engine with oil cooler only)
(3) Make sure that the rotor shaft rotates smoothly and easily when the drive gear is rotated.
★ Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application.
Therefore, description in this Chapter is started with the steps to be taken just after the peripheral parts
have been removed.
Perform the procedure, with reference to the attached drawings, "Engine Component Exploded View".
8.1 Disassembly
★ For the number following the part name, refer to 16. ATTACHED DRAWING 1 and 2, "Exploded Views of
Engine Components"
1) Remove fan mounting bolt , and 1) Never turn down alternator vigorously toward the cyl-
then remove fan . inder block. Otherwise, your finger may be nipped and
2) Loosen adjusting bolt for the V- alternator broken.
belt adjuster, and then remove V-
6
belt .
3) Remove alternator .
4) Remove the spacer for cooling fan
and V-pulley .
3-cylinder
10 Camshaft side
4-cylinder
Camshaft side
Gear case side
Flywheel side
10
1
YE0156
1) Remove crankshaft V-pulley clamp- 1) Extrace crankshaft V-pulley by hitting the bolt of the
ing bolt . puller using a plastic hammer or the like.
11
2) Using a puller, extract crankshaft V-
pulley .
1) Remove oil pan mounting bolt 1) Never fail to removes stiffner bolt at the center of the
under gear case . gear case.
12 2) Remove gear case mounting bolt 2) When removing the gear case, carefully protect oil seal
. from damage.
3) Remove gear case .
1) Remove the nut from fuel injection 1) Before removing fuel injection pump , make sure of
pump drive gear . Extract fuel the position of the arrow of the pump body for adjusting
13 injection pump drive gear using a fuel injection timing as well as the position of the scribed
puller. line of the gear case flange. (Applies only to direct injec-
tion system.)
14 1) Remove lubricating oil pump . —
1) Remove flywheel mounting bolt . 1) Carefully protect the ring gear from damage.
16
2) Remove flywheel .
1) Remove flywheel housing . 1) Carefully protect the oil seal from damage.
2) Remove oil seal case with a
17 screwdriver or the like by utilizing
grooves on both sides of oil seal
case .
1) Remove oil pan and spacer . 1) Put the cylinder block with the attaching surface of the
cylinder head facing down.
2) Carefully protect the combustion surface of the cylinder
18 block from damage.
3) For indirect injection system, be careful to the possibility
of the tappet to drop off when the cylinder block is turned
upside down, because the tappet is cylindrical in shape.
1) Remove idle gear shaft , and 1) Turn the cylinder block aside and carefully prevent tap-
then remove idle gear . pet from jamming on the cam.
2) Remove mounting bolt of thrust 2) Preheat camshaft gear and camshaft assembly to
19 180 – 200°C which are shrink fitted, before removing
bearing through the hole of the
them.
camshaft gear . Remove cam-
shaft assembly .
1) Remove crankpin side cap of the 1) Before extracting piston , remove carbon deposits
connecting rod. from the upper wall of the cylinder using fine sandpaper,
• While turning crankshaft , while taking care not to damage the inner surface of the
place piston in the bottom cylinder.
22 dead center (B.D.C.). 2) Make sure that cap No. of connecting rod agrees with
cylinder No.
3) Take care not to let crankpin metal fall when removing
connecting rod crankpin side cap .
1) Remove main bearing cap bolt . 1) Before extracting crankshaft , measure the side gap
While shaking main bearing cap , around it.
remove main bearing cap
together with lower main bearing
metal .
2) Extract crankshaft , taking care
not to damage it.
3) Remove upper main bearing metal
.
23
2
YE0157
1) Dial gauge
2) Crankshaft
23 All models
Thrust gap 0.090–0.271
1) Remove piston and connecting 1) To selectively remove a desired piston and connecting
rod assembly. rod assembly without extracting crankshaft , take the
steps itemized below:
(1) Remove carbon deposits from the upper wall of the
cylinder using fine sandpaper, taking care not to
damage the inner surface of the cylinder.
24 (2) While turning the crankshaft, with the crankpin side
cap removed, raise the piston up to the top dead
center (T.D.C.).
(3) Extract the piston/connecting rod assembly while
tapping the connecting rod at the large end with
the handle of a plastic hammer or the like.
25 1) Remove tappet .
1
1) Dial gauge
2
2) Crankshaft YE0157
1) Camshaft gear
5
2) PTO gear (option)
1 3) Crankshaft gear
4) Lubricating oil pump gear
6
5) Fuel injection pump drive
2 gear
6) Idle gear
YE0159
1) Valve guide
YE0160
YE0162
YE0163
YE0164
3D78AE,3D82AE,3D82E,4D82E
2D68E,3D68E,3D74E
(S)3D84E,(S)4D84E,3D88E,4D88E
Camshaft side
Nozzle side
Nozzle side
Piston
Cylinder
size mark Flywheel side YE0327 Cylinder Flywheel side
size mark YE0328
Connecting rod
Alignment mark Alignment mark
YE0329 YE0330
2-cylinder
4 2
3 YE0331
1) Camshaft side
3-cylinder
2) Gear case side
3) Fuel injection
1
pump side
4) Flywheel side
4 2
3 YE0169
4-cylinder
4 2
3 YE0170
(Unit: Nm {kgm})
3D82E,4D82E
2D68E,3D68E 3D74E 3D78AE,3D82AE (S)3D84E,(S)4D84E
3D88E,4D88E
Tightening torque 37.3–41.2 {3.8–4.2} 58.8–63.7{6.0–6.5} 66.7–70.6 {6.8–7.2} 85.3–91.2 {8.7–9.3}
(11) After having reassembled the cylinder heads, carry out confirmation running to see if they are free
from leakage of water and oil.
9. SERVICE DATA
Valve seat Intake 1.15 1.65 1.44 1.98 1.36–1.53 1.98 1.07–1.24 1.74
width Exhaust 1.41 1.91 1.77 2.27 1.66–1.87 2.27 1.24–1.45 1.94
Valve stem out-
5.460–5.475 5.4 6.960–6.975 6.9 6.945–6.960 6.9 7.955–7.975 7.9
side dia.
Intake
Valve guide
valve 5.500–5.515 5.58 7.005–7.020 7.08 7.000–7.015 7.08 8.010–8.025 8.1
inside dia.
Oil clearance 0.025–0.055 0.18 0.030–0.060 0.18 0.040–0.070 0.18 0.035–0.070 0.2
Valve stem out-
5.445–5.460 5.4 6.945–6.960 6.9 6.940–6.955 6.9 7.955–7.970 7.9
side dia.
Exhaust
Valve guide
valve 5.500–5.515 5.58 7.005–7.020 7.08 7.000–7.015 7.08 8.015–8.030 8.1
inside dia.
Oil clearance 0.040–0.070 0.18 0.045–0.075 0.18 0.045–0.075 0.18 0.045–0.075 0.2
Valve guide projection 7 — 9 — 12 — 15 —
Intake valve 0.3–0.5 1.0 0.4–0.6 1.0 0.296–0.496 1.0 0.306–0.506 1.0
Valve sink- VM:0.75–0.95
ing depth Exhaust valve 0.75–0.95 1.0 CH:0.40–0.60 1.0 0.3–0.5 1.0 0.3–0.5 1.0
VH:0.40–0.60
Thickness Intake valve 0.85–1.15 0.5 0.99–1.29 0.5 1.244–1.444 0.5 1.244–1.444 0.5
of valve
head Exhaust valve 0.95–1.25 0.5 0.95–1.25 0.5 1.35–1.55 0.5 1.35–1.55 0.5
3D82AE
Model (S)3D84E 3D88E
3D82E
(S)4D84E 4D88E
4D82E
9.4 Piston
(Unit: mm)
2D68E
Model 3D74E 3D78AE 3D82AE
3D68E
(Unit: mm)
3D82E (S)3D84E 3D88E
Model 4D82E (S)4D84E 4D88E
(Unit: mm)
Model 3D82AE
(S)3D84E 3D88E
3D82E
(S)4D84E 4D88E
4D82E
Item Standard Wear limit Standard Wear limit Standard Wear limit
Ring groove
2.05–2.080 — 2.065–2.080 — 2.060–2.075 —
width
Ring width 1.970–1.990 — 1.970–1.990 — 1.970–1.990 —
Top ring
Min.side
0.075–0.110 — 0.075–0.110 — 0.070–0.105 —
clearance
End clearance 0.200–0.400 1.5 0.200–0.400 1.5 0.200–0.400 1.5
Ring groove
2.035–2.050 — 2.035–2.050 — 2.025–2.040 —
width
Ring width 1.970–1.990 — 1.970–1.990 — 1.970–1.990 —
2nd ring
Min.side
0.045–0.080 — 0.045–0.080 — 0.035–0.070 —
clearance
End clearance 0.200–0.400 1.5 0.200–0.400 1.5 0.200–0.400 1.5
Ring groove
4.015–4.030 — 4.015–4.030 — 4.015–4.030 —
width
Ring width 3.970–3.990 — 3.970–3.990 — 3.970–3.990 —
Oil ring
Min.side
0.025–0.060 — 0.025–0.060 — 0.025–0.060 —
clearance
End clearance 0.200–0.400 1.5 0.200–0.450 1.5 0.200–0.400 1.5
9.7 Camshaft
(Unit: mm)
Model 3D78AE,3D82AE
2D68E 3D82E,4D82E
3D74E
3D68E (S)3D84E,(S)4D84E
3D88E,4D88E
Item Standard Wear limit Standard Wear limit Standard Wear limit
Camshaft jour-
35.940–35.960 35.85 39.940–39.960 39.85 44.925–44.950 44.85
Gear side nal outside dia.
Oil clearance 0.040–0.085 — 0.040–0.085 — 0.040–0.130 —
Camshaft jour-
35.910–35.935 35.85 39.910–39.935 39.85 44.910–44.935 44.85
Intermediate nal outside dia.
Oil clearance 0.065–0.115 — 0.065–0.115 — 0.065–0.115 —
Camshaft jour-
Flywheel 35.940–35.960 35.85 39.940–39.960 39.85 44.925–44.950 44.85
nal outside dia.
side
Oil clearance 0.040–0.125 — 0.040–0.125 — 0.050–0.100 —
9.8 Crankshaft
(Unit: mm)
Model 3D82E,4D82E
2D68E 3D78AE
3D74E (S)3D84E,(S)4D84E
3D68E 3D82AE
3D88E,4D88E
Wear Wear Wear Wear
Item Standard Standard Standard Standard
limit limit limit limit
Crankshaft jour- 39.970– 43.970– 46.952– 53.952–
39.90 43.90 46.91 53.91
nal outside dia 39.980 43.980 46.962 53.962
Crank
Bearing metal
journal 1.487–1.500 — 1.987–2.000 — 1.987–2.000 — 1.995–2.000 —
thickness
Oil clearance 0.033–0.059 0.15 0.033–0.059 0.15 0.038–0.093 0.25 0.038–0.068 0.15
Bend 0.02 or less — 0.02 or less — 0.02 or less — 0.02 or less —
Item Standard
Crankshaft 0.090–0.271
Camshaft 0.05–0.25
Side gap
Connecting rod 0.2–0.4
Idle gear 0.1–0.3
(Unit: mm)
3D78AE,3D82AE
2D68E
3D82E,4D82E
Item Model 3D68E (S)3D84E,(S)4D84E
3D74E 3D88E,4D88E
Crankshaft gear, Camshaft gear,
Idle gear and Fuel injection pump 0.04–0.12 0.07–0.15
Backlash drive gear
Lub. oil pump gear 0.11–0.19 0.11–0.19
9.10 Others
Model 3D82E,4D82E
2D68E 3D78AE
3D74E (S)3D84E,(S)4D84E
3D68E 3D82AE
Item 3D88E,4D88E
High speed
Lub. oil pump operation 11.9 (at 3,600 rpm) 19.6 (at 3,600 rpm) 25.0 (at 3,000 rpm)
discharge l/min 15.8 (at 3,600 rpm)
Low speed 2.5 (at 750 rpm) 4.4 (at 800 rpm) 8.0 (at 800 rpm)
volume
operation
Pressure control valve kPa 294–392 294–392 294–392 294–392
opening pressure {kg/cm2} {3.0–4.0} {3.0–4.0} {3.0–4.0} {3.0–4.0}
Lub. oil pressure switch kPa 39–59 39–59 39–59 39–59
operating pressure {kg/cm2} {0.4–0.6} {0.4–0.6} {0.4–0.6} {0.4–0.6}
45 55
Cooling water pump (at 4,320–4,380 rpm) (at 4,320–4,380 rpm) 35 70
l/min
discharge volume 32 40 (at 3,220–3,280 rpm) (at 3,220–3,280 rpm)
(at 3,320–3,380 rpm) (at 3,320–3,380 rpm)
Opening
Thermostat tempera- °C 69.5–72.5 69.5–72.5 69.5–72.5 69.5–72.5
valve opening ture
temperature Min. 4.5 Min. 8.0 Min. 8.0 Min. 8.0
Lift height mm
(at 85°C and above) (at 85°C and above) (at 85°C and above) (at 85°C and above)
Thermoswitch ON 107–113 107–113 107–113 107–113
operating °C
temperature OFF 100 and above 100 and above 100 and above 100 and above
29
1) Label
2) Pin 28
3) Fuel injection volume adjusting plate 27
4) Eccentric screw for adjusting
26
5) Set screw 25
6) Plunger barrel stopper
24
7) Plunger guide stopper
23
8) Plunger guide stopper pin
9) Plunger guide outer roller 22 1
14
13
12
11
9
10
YE0171
11.2 Disassembly
To disassemble the fuel injection pump, classify dis-
assembled parts for each cylinder and carefully
avoid allowing them to be mixed with one another.
Identifiably classify paired parts supplied as assem-
blies, such as "plunger and plunger barrel" for each
cylinder. Use particular care to prevent the assembly
from going to pieces and being scattered.
YE0173
YE0174
YE0175
YE0176
11.3 Inspection
Before inspection, thoroughly clean the parts, using
new diesel oil. Be careful to avoid damage to the 1
sliding surface of the plunger and delivery valve, etc.
(3) Plunger
1. Thoroughly clean the plunger. If any plunger
lead is scratched or discolored, replace the
plunger assembly with a new one. 5
5) Lead
YE0181
(Plunger)
6) Approx. 60°
YE0182
1) Seat
2) Suck-back collar
YE0183
YE0184
YE0185
11.4 Reassembly
(1) Insert the plunger barrel packing into the
fuel injection pump body.
YE0186
YE0187
YE0188
YE0189
1) Matching marks
1
YE0190
YE0191
2
1
48
49 3
50 4
5
6
7 9
8
42
43 10
44 12
45
11
41 46
40 39 13
38 14
15
37
36 47
30 35 16
34
31 17
32
33
18
29 19
20
21
27
28
26
25
24
23
22
YE0192
YE0193
YE0194 YE0195
YE0196
YE0197
Code No.
Governor
158090-
weight for 3
51400
5 pcs.
Governor
158090-
weight for 4
51450
pcs.
YE0199 YE0200
12.3 Disassembly
(1) Remove the bottom cover from the fuel
injection pump to drain lubricating oil from
the fuel injection pump.
YE0201
YE0202
YE0203
YE0204
YE0205
YE0208
YE0209
YE0210
YE0211
YE0213
YE0214
YE0215
YE0216
YE0217
YE0218
YE0219
12.4 Inspection
Before inspection, thoroughly clean the parts, using new diesel oil. Be careful to avoid damage to the sliding
surface of the plunger and delivery valve, etc.
(1) Plunger
1. Thoroughly clean the plunger. If any plunger
lead is scratched or discolored, replace the
plunger assembly with a new one.
2. To test the plunger, hold the plunger barrel
tilted approx. 60° and check to see if it slides
1
down smoothly. If so, the plunger is accept-
able. While turning the plunger, repeat the
test several times. If any plunger slides down
too quickly (slowly) or jams in the midway,
correct it or replace the whole plunger as-
sembly.
1) Approx. 60° YE0220
(Fall by gravity test of plunger)
(2) Delivery valve
1. If the suck-back collar or seat of the delivery
valve is found scratched, dented, worn, or
otherwise damaged, replace the whole deliv-
ery valve assembly.
2. Stop up the hole in the bottom of the delivery
valve holder and keep the seat as it is. Insert
the delivery valve in the holder. While releas-
ing your upper finger, check to see if the de-
l iv er y v al ve s pr in gs ba ck . I f s o, i t i s
acceptable. If not, replace it.
YE0221
(Check for delivery valve)
3. Likewise as described in item 2, stop up the
hole in the bottom of the delivery valve hold-
er and check to see if the delivery valve falls
by gravity perfectly, when the bottom hole’s
finger is released. If so, the delivery valve is
acceptable. If not, replace it.
YE0222
12.5 Reassembly
(1) Put the plunger barrel into the fuel injection
pump from its top.
a Make sure that the plunger barrel stop-
per is snugly fitted with the key way.
YE0226
YE0228
3
1) Pinion/rack match mark
2) Control rack
YE0229
3) Fuel control pinion
YE0231
YE0233
YE0235
YE0236
YE0237
(13) Fit the oil seal to the inner side of the bear-
ing holder. Mount the bearing holder.
a Apply lubricating oil to the fuel injection
pump camshaft and oil seal of the fuel
injection pump camshaft in advance so
as not to damage the oil seal.
YE0238
[Adjustment Procedure]
If a clearance is found small, remove the
adjusting packing.
If a clearance is found large, add one or
more adjusting packing.
Thickness of adjusting packing: 0.5, 0.4,
0.3, and 0.15mm.
YE0240
YE0241
YE0242
YE0245
13. GOVERNOR
13.1 Exploded views of governor for indirect injection system ..................................................................... 13-2
13.2 Exploded views of governor for direct injection system ........................................................................ 13-4
13.3 Disassembly ......................................................................................................................................... 13-6
13.4 Inspection ........................................................................................................................................... 13-12
13.5 Reassembly ........................................................................................................................................ 13-14
34
33
2
3
1
32
30
31 29 5
28
7
27 6
26
25
9
8
12
13 10
18
17
14 11
19
24 21
22 20
23 15
16
35 YE0246
1
2
4
5
34
9 7
33
32
31 10
11
30
27
29
28
12
26
13
14
25
20 15
24 21 16
22 17
19
23
18 YE0247
13.3 Disassembly
Disassembly and reassembly can be carried out
similarly for Indirect injection system and Direct
injection system.
(1) Remove the governor case.
a Loosen the stop nut on models with
angleich assembly.
YE0248
1) Circlip
1
2) Angleich case
2
3) Angleich spring
7 3
4) Shifter
5) Shim 6 4
6) Washer 5
7) Stop nut
YE0249
(Angieich assembly)
YE0250
YE0251
YE0252
YE0253
YE0254
YE0255
YE0256
YE0257
YE0258
YE0259
YE0260
YE0261
YE0262
YE0263
YE0264
YE0265
YE0266
YE0267
YE0270
YE0268
YE0269
13.4 Inspection
1. Inspection of governor weight assembly
(1) Replace the governor weight if it does not 1
open and close smoothly.
3
1) Governor weight
2) Governor weight support
3) Pin 2
YE0271
4. Inspection of springs
(1) Check the governor spring and other
springs and replace if they are broken, set-
tled or corroded.
YE0273
1
2
YE0274
1) Angleich spring
4
2) Shifter
3) Torque spring
4) Contact surface
5) Piston 5 YE0275
13.5 Reassembly
Inspect all parts after disassembly and replace any
parts as necessary. Before starting reassembly,
clean all parts and put them in order.
Make sure to readjust the unit after reassembly to
obtain the specified performance.
YE0279
YE0280
YE0281
YE0282
YE0283
YE0284
YE0285
YE0286
YE0287
YE0288
YE0289
YE0290
14. TURBOCHARGER
14.1 Specifications
14.2 Construction
E B
YE0291
YE0292
(Exploded view of turbocharger w/waste gate)
(1) Turbine
The exhaust gas from the engine is accelerated at the nozzle portion in the turbine housing and blown
onto the turbine impeller to rotate the turbine shaft. This is called the turbine. A seal ring and heat insu-
lating plate are installed to prevent the bearing from being adversely influenced by the gas.
(2) Compressor
The compressor wheel installed on the turbine shaft is rotated with the shaft to suck and compress air
for feeding into the intake manifold. This is called the blower or compressor.
(3) Bearing
1. Thrust bearing
As the turbine shaft is constantly applied with a thrust force, this bearing prevents the shaft from
being moved by the thrust force.
2. Radial (journal bearing)
A floating journal bearing is adopted. Because the bearing moves with the turbine shaft as oil films
are formed both inside and outside of the bearing, the bearing sliding speed is slower than the tur-
bine shaft speed as compared with the ordinary fixed type bearing.
The dynamic stability is improved as a result.
3. Compressor side sealing mechanism
To prevent the intake air and oil from leaking, a seal ring and a seal plate is provided to form a dou-
ble wall structure on the rear side of the compressor wheel.
(1) Checking the waste gate valve pressure and lift characteristics
1. Equipment
Prepare the equipment shown in the figure below.
2. Measuring instruments and devices
Used for suppressing the air supply pressure at 490 kPa {5 kg/cm2}
Pressure reducing valve
or less
Pressure gauge Bourdon tube pressure gauge (0 to 981 kPa {0 to10 kg/cm2})
12
11
9
2
10
8
1 3 4
Pc
6
5 YE0293
NOTE: Pc (control pressure) is 80 to 100 kPa {600 to 750 mmHg} which varies with the set output.
3. Check method
i) Set the manometer control pressure (Pc) applied to the waste gate actuator to 0 and set the
dial gauge to the zero point.
ii) Gradually open the pressure regulating valve and measure the Pc value when the actuator rod
is operated by 2 mm.
iii) For the hysteresis, let the rod move to 3 mm first. Then gradually close the pressure regulating
valve, measure the pressure when the rod is moved to 2 mm and obtain the difference from the
pressure measured in ii) above.
4. Precautions
i) Set the dial gauge on the extension line of the actuator rod.
ii) The piping and joints shall completely be free from leak.
iii) Fix the turbocharger and dial gauge securely.
iv) An electric manometer, if used, shall have sufficient precision.
v) Even when an electric manometer is used, preparation of a mercury column type manometer is
recommended for calibration and daily check.
vi) The speed for increasing/decreasing Pc by means of the pressure regulating valve shall be
very slow near the measuring point. If the 2 mm position is exceeded, restart from the begin-
ning.
vii) Do not apply over 490 kPa {5 kg/cm2} to the actuator.
YE0294
F
B D C A H2 H1
E G1 G2
YE0295
(Unit :mm)
Standard dimension Wear limit
RHB31 RHB51 RHB31 RHB51
Turbine shaft journal outside diameter (A) 6.257 – 6.263 7.99 – 8.00 6.25 7.98
Turbine shaft
Turbine shaft seal ring groove width (E) 1.038 – 1.062 1.25 – 1.28 1.07 1.29
Compressor side seal ring groove width (G1) 1.02 – 1.03 1.22 – 1.23 1.04 1.31
Compressor side seal ring groove width (G2) 0.82 – 0.83 1.02 – 1.03 0.84 1.11
Turbine shaft runout 0.002 0.002 0.005 0.011
Journal bearing inside diameter (C) 6.275 – 6.285 8.01 – 8.03 6.29 8.04
Bearing
Journal bearing outside diameter (D) 9.940 – 9.946 12.32 – 12.33 9.93 12.31
Bearing housing inside diameter (B) 9.995 – 10.005 12.40 – 12.41 10.01 12.42
Thrust bearing width (J) 3.59 – 3.61 3.99 – 4.01 3.58 3.98
fixing area bearing
Thrust
Thrust bushing groove dimension (K) 3.632 – 3.642 4.04 – 4.05 3.65 4.07
Turbine side (bearing housing) (F) 11.00 – 11.018 15.00 – 15.02 11.03 15.05
Seal ring
Compressor side (seal ring) (H1) 9.987 – 10.025 12.40 – 12.42 10.04 12.45
Compressor side (seal ring) (H2) 7.968 – 8.00 10.00 – 10.02 8.01 10.05
Rotor play in axial direction 0.022 – 0.053 0.03 – 0.06 0.07 0.09
Rotor play in radial direction 0.061 – 0.093 0.08 – 0.13 0.12 0.17
15.1 Limiting the high idle and low idle adjustment screw ............................................................................ 15-2
15.2 Limiting the fuel volume limiter screw ................................................................................................... 15-3
Introduction
This chapter describes only the items designated as special specifications for servicing the engine under 23 HP
that complies with CARB ULG regulation (Regulation for small Utility engines and Lawn & Garden from Califor-
nia Air Resource Board, effects to the engines manufactured on Jan. 1st 1995 and later).
15.1 Limiting the high idle and low idle adjustment screw
15.1.1 High idle speed
(1) First warm up the engine. Then, gradually 1 2 3
increase the engine speed up to the high
idle speed (Refer to Chapter 1, Specifica- 4
tions and Performance).
(2) If the present high idle speed differ from the 5
specified one, adjust the high idle speed
using the high idle adjustment screw.
(3) After locking the adjustment screw with the
lock nut by using the special tool, insert the
plug firmly to prevent re-adjustment and oil
leakage.
1) Decrease
2) Increase
3) Plug
4) Lock nut
5) High idle adjustment screw
YE0332
YE0333
YE0334
YE0296
17 V-belt 57 Flywheel
19 Spacer 66 Piston
YE0297
20.1 Applicable machine, serial number (EPA certified engine) ................................................................... 20-2
20.2 EPA certification plate attaching location.............................................................................................. 20-3
20.3 Differences with the current production model ..................................................................................... 20-4
20.4 Fuel injection timing adjustment ........................................................................................................... 20-5
20.5 Secifications........................................................................................................................................ 20-16
Engine output
Engine Machine model Machine Serial No. Remarks
(kW{HP}/rpm)
PC09-1
2D68E-N3CB 10001 and up 6.2{8.4}/2,200
(KUE & KUC)
PC20MRX-1
3D74E-N3AJ 10001 and up 14{18.7}/2,600
(KUE & KUC)
1
1
YE0298
YE0299
YE0300
1) Certification Plate
In order to insure that the EPA emission standards are met, changes have been made in the adjusting
method for the fuel injection timing to make it more precise. (The timing deviation is reduced.)
2
• Fuel injection timing is adjusted by a FIC fixed method; a FID method is not used.
• See [section 20.4.2] for details on adjustment of the fuel injection timing.
6 Cylinder head —
7 Piston —
• Notice
FIC, FID explanation
Swirl pre-combustion system engine FID method, adjusted by changing the shim thickness between the
(Not including N-series) body of the fuel injection pump and the pump case.
YE0301
1) End nut
2) Fuel injection pump driving gear
2 5
3
YE0302
YE0303
1 2
6
4
8
5
9
YE0304
YE0305
2 6
1
YE0306
Fig. 6 EPA certified engine: Swirl pre-combustion system engine (2D68E-N, 3D68E-N, 3D74E-N only)
k Before installing the fuel injection pump, confirm that the FIC lock is still attached. The correct
fuel injection pump cam shat on the assembly line side does not turn. Do not use the pump if
k
there is the problem.
The marks on the gear case and the fuel injection pump have no relation to the fuel injection
timing and are the same on all engine models.
The installing angle for the pump is fixed (all the engines are same).
ii) Attach the fuel injection pump driving gear to the fuel injection pump coupling to allow rotating
freely on its outer surface without bolt fixing.
iii) Align the timing mark of each gear, crank, idler, cam and fuel injection pump drive gear and
install them.
k When aligning the timing marks, put the piston for the No.1 cylinder in the top compres-
sion position, align the letters on the gears and assemble. No.1 cylinder is from the fly-
wheel side.
1
2
iv) Align the crankshaft with the FIC fuel injection angle (B.T.D.C). To reduce the deviation in the
fuel injection timing, the equivalent crank angle is determined by measuring the piston stroke of
the cylinders noted below and calculating the average value. The piston stroke is determined
by measuring the T.D.C. when the piston is in the top position.
[Piston stroke measuring cylinder No.]
• 3-cylinder engine: No.1, 3 cylinders
• 4-cylinder engine: No.1, 2 cylinders
NOTE: The procedures described in iv) are performed automatically in the factories.
v) Keeping the gear backlash fix the fuel injection pump driving gear to the fuel injection pump
coupling by automatically tightning the 2 bolts (marked E) in the factories.
3 Bolt tightening torque (not apply lub. oil): 34.32 ± 1.96Nm {3.5 ± 0.2kgm}
2
YE0309
vi) Tighten the remaining 2 fixing bolts for the fuel injection pump driving gear by hand.
3 Bolt tightening torque (not apply lub. oil): 34.32 ± 1.96Nm {3.5 ± 0.2kgfm}
k After removing the FIC lock bolts, do not separate the fuel injection pump coupling and
the fuel injection pump driving gear. If they are separated, this will confuse the FIC setup
k
and it will be necessary to adjust the fuel injection timing from the beginning.
If the fuel injection pump should have to be removed the fuel injection pump, loosen the
end nuts to do it.
k Check to see that the fuel injection pump coupling and driving gear are firmly attached
before installing them to the engine body. Do not use them if loose.
ii) Align the timing mark for the crankshaft, idler, camshaft, and the fuel injection pump driving
gear and then assemble them.
a When aligning the timing marks, put the piston for the No.1 cylinder in the top compression
position, align the letters on the gears and assemble. No.1 cylinder is from the flywheel
side.
1
2
k The fuel injection timing is set (FIC) by aligning the timing mark of the gear train. Do not
k
adjust with the FID method.
Do not separate the fuel injection pump coupling and the fuel injection pump driving gear.
If they are separated, this will confuse the FIC setup and it will be necessary to adjust the
fuel injection timing from the beginning.
ii) Align the timing marks of each gear, crank, idler, cam, and fuel injection pump driving gear and
install them.
a When aligning the timing marks, put the piston for the No.1 cylinder in the top compression
position, align the letters on the gears and assemble. No.1 cylinder is from the flywheel
side.
.
1
2
3 Fuel injection pump drive gear installation nut tightening torque (apply lub. oil):
63.8 ± 5 Nm {6.5 ± 0.5 kgfm}
k The fuel injection timing is adjusted (FIC) by aligning the timing marks of the gear train.
Do not adjust the injection timing using the FID method.
Procedure
i) Remove the current pump from the gear case.
Loosen the end nuts to remove the fuel injection pump.
(Leave the fuel injection pump coupling and driving gear as a semi-assembly in the gear case.)
k Do not separate the fuel injection pump coupling and driving gear. Do not touch the
attachent bolts (4 bolts with E marked).
ii) Align the fuel injection pump for service with the aligning marks on the gear case and the pump
to install on the gear case (See figure 7).
iii) Attach the fuel injection pump coupling and driving gear semi-assembly to the pump.
3 Tightening torque (apply lub. oil): 63.8 ± 5 Nm {6.5 ± 0.5 kgm}
Replacing the fuel injection pump is completed. Check the fuel injection timing with the
FID method.
Procedure
i) Insert the standard shim (0.8 mm), and check the injection timing with the FID method.
a The standard shim thickness of the fuel injection pump for EPA use is 0.8 mm for all
models.
k Do not separate the fuel injection pump coupling and driving gear.
ii) If the fuel injection timing is out of specified adjust by changing the thickness of the shims.
• Greater shim thickness: injection timing is delayed
• Lesser shim thickness: injection timing is fast
20.5 Secifications
(1) 2D68E
Model unit 2D68E
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Swirl pre-combustion
Aspiration Natural aspiration
No. of cylinders 2
Cylinder bore x Stroke mm 68 x 72
Displacement l 0.522
Application – VM
Engine speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Net —
Continuous {HP}
rating kW
Gross —
{HP}
Output
kW 5.7 6.2 6.8 7.4 7.9 8.5
Net
Rated output {HP} {7.7} {8.4} {9.2} {10.0} {10.6} {11.4}
(max.) kW 5.9 6.4 7.1 7.7 8.3 8.8
Gross
{HP} {7.9} {8.7} {9.5} {10.4} {11.0} {11.9}
High rpm 2,180 ± 25 2,375 ± 25 2,590 ± 25 2,780 ± 25 2,995 ± 25 3,195 ± 25
Idle engine speed
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
Fuel injection timing degree B.T.D.C. 14 ± 1.5 (FID)
MPa +0.98 +10
Fuel injection pressure 11.8 {120 0}
{kg/cm2} 0
(2) 3D68E
Model unit 3D68E
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Swirl pre-combustion
Aspiration Natural aspiration
No. of cylinders 3
Cylinder bore x Stroke mm 68 x 72
Displacement l 0.784
Application – VM
Engine speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Net —
Continuous {HP}
rating kW
Gross —
{HP}
Output
kW 8.6 9.4 10.3 11.2 12.0 12.9
Net
Rated output {HP} {11.5} {12.6} {13.8} {15.0} {16.1} {17.3}
(max.) kW 8.8 9.7 10.6 11.5 12.4 13.4
Gross
{HP} {11.8} {12.9} {14.2} {15.5} {16.7} {17.9}
High rpm 2,180 ± 25 2,375 ± 25 2,570 ± 25 2,780 ± 25 2,995 ± 25 3,195 ± 25
Idle engine speed
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
Fuel injection timing degree B.T.D.C. :14 ± 1.5 (FID)
MPa +0.98 +10
Fuel injection pressure 11.8 {120 0}
{kg/cm2} 0
(3) 2D68E-N
Model unit 2D68E-N
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Swirl pre-combustion
Aspiration Natural aspiration
No. of cylinders 2
Cylinder bore x Stroke mm 68 x 72
Displacement l 0.522
Application – VM
Engine speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Net —
Continuous {HP}
rating kW
Gross —
{HP}
Output
kW 5.7 6.3 6.8 7.4 7.9 8.5
Net
Rated output {HP} {7.7} {8.4} {9.2} {10.0} {10.6} {11.3}
(max.) kW 5.9 6.5 7.1 7.7 8.3 8.9
Gross
{HP} {7.9} {8.7} {9.5} {10.4} {11.1} {11.8}
High rpm 2,180 ± 25 2,375 ± 25 2,590 ± 25 2,780 ± 25 2,995 ± 25 3,195 ± 25
Idle engine speed
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
Fuel injection timing degree B.T.D.C. :14 ± 2.0 (FID)
MPa
Fuel injection pressure 11.8 +0.98 {120 +10
0}
{kg/cm2} 0
(4) 3D74E-N
Model unit 3D74E-N
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Swirl pre-combustion
Aspiration Natural aspiration
No. of cylinders 3
Cylinder bore x Stroke mm 74 x 78
Displacement l 1.006
Application – VM
Engine speed rpm 2,000 2,200 2,400 2,600 2,800 3,000
kW
Net —
Continuous {HP}
rating kW
Gross —
{HP}
Output
kW 11.0 12.1 13.2 14.3 15.5 16.6
Net
Rated output {HP} {14.8} {16.3} {17.7} {19.2} {20.7} {22.2}
(max.) kW 11.3 12.4 13.6 14.7 15.9 17.1
Gross
{HP} {15.1} {16.7} {18.1} {19.7} {21.3} {22.9}
High rpm 2,180 ± 25 2,390 ± 25 2,590 ± 25 2,795 ± 25 3,010 ± 25 3,195 ± 25
Idle engine speed
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
Fuel injection timing degree B.T.D.C :14 ± 2.0 (FID)
MPa +0.98 +10
Fuel injection pressure 11.8 {120 0}
{kg/cm2} 0
(5) 3D78AE
Model unit 3D78AE
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Direct injection
Aspiration Natural aspiration
No. of cylinders 3
Cylinder bore x Stroke mm 78 x 84
Displacement l 1.204
Application – VM
Engine speed rpm 2,000 2,200 2,400 2,600 2,700 2,800 3,000
Continu-
kW
ous rat- Net —
{HP}
ing
Output kW 13.2 14.6 16.0 17.2 17.9 18.5 19.9
Rated Net
{HP} {17.7} {19.5} {21.3} {23.1} {24.0} {24.8} {26.6}
output
(max.) kW 13.7 15.0 16.4 17.9 18.6 18.8 20.1
Gross
{HP} {18.2} {20.1} {22.0} {24.0} {24.9} {25.2} {26.9}
2,180 2,375 2,570 2,780 2,890 2,995 3,180
High rpm
Idle engine speed ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
B.T.D.C.
Fuel injection timing degree B.T.D.C. :11 ± 1.0 (FID)
:12 ± 1.0 (FID)
MPa +0.98 +10
Fuel injection pressure 19.61 {200 0}
{kg/cm2} 0
(6) 3D82AE
Model unit 3D82AE
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Direct injection
Aspiration Natural aspiration
No. of cylinders 3
Cylinder bore x Stroke mm 82 x 84
Displacement l 1.330
Application – VM
Engine speed rpm 2,000 2,200 2,400 2,500 2,600 2,800 3,000
kW
Continu- Net {HP}
—
ous rat-
ing kW
Gross —
{HP}
Output
kW 14.6 16.0 17.5 18.2 19.0 20.4 21.9
Rated Net
{HP} {19.6} {21.5} {23.5} {24.5} {25.4} {27.4} {29.4}
output
(max.) kW 15.0 16.5 18.0 18.8 19.2 20.7 22.2
Gross
{HP} {20.1} {22.1} {24.2} {25.2} {25.7} {27.8} {29.8}
2,180 2,375 2,570 2,675 2,780 2,995 3,180
High rpm
Idle engine speed ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
B.T.D.C.
Fuel injection timing degree B.T.D.C. :12 ± 1.0 (FID)
:11 ± 1.0 (FID)
MPa
Fuel injection pressure 19.61 +0.98 {200 +10
0}
{kg/cm2} 0
(7) 3D84E
Model unit 3D84E
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Direct injection
Aspiration Natural aspiration
No. of cylinders 3
Cylinder bore x Stroke mm 84 x 90
Displacement l 1.496
Application – VM
Engine speed rpm 2,000 2,200 2,400 — 2,600 2,800 3,000
kW
Continu- Net {HP}
—
ous rat-
ing kW
Gross —
{HP}
Output
kW 16.4 18.1 19.7 21.3 23.0 24.6
Rated Net —
{HP} {22.0} {24.3} {26.4} {28.6} {30.9} {33.0}
output
(max.) kW 16.7 18.5 20.2 21.9 23.7 25.5
Gross —
{HP} {22.5} {24.8} {27.1} {29.4} {31.7} {34.2}
2,180 2,400 2,590 2,810 2,995 3,210
High rpm —
Idle engine speed ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
B.T.D.C.
Fuel injection timing degree B.T.D.C. :11 ± 1.0 (FID)
:12 ± 1.0 (FID)
MPa +0.98 +10
Fuel injection pressure 19.61 {200 0}
{kg/cm2} 0
(8) S3D84E
Model unit S3D84E
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Direct injection
Aspiration Exhaust gas turbocharged
No. of cylinders 3
Cylinder bore x Stroke mm 84 x 90
Displacement l 1.496
Application – VM
Engine speed rpm 2,000 2,200 2,400 — 2,600 2,800 3,000
kW
Continu- Net {HP}
—
ous rat-
ing kW
Gross —
{HP}
Output
kW 21.0 22.8 25.0 26.8 29.1 30.9
Rated Net —
{HP} {28.1} {30.6} {33.5} {36.0} {38.9} {41.4}
output
(max.) kW 21.2 23.2 25.5 27.4 29.8 31.7
Gross —
{HP} {28.4} {31.2} {34.2} {36.8} {39.9} {42.5}
2,200 2,420 2,615 2,835 2,995 3,270
High rpm —
Idle engine speed ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
B.T.D.C. B.T.D.C B.T.D.C
Fuel injection timing degree
:10 ± 1.0 (FID) :11 ± 1.0 (FID) :12 ± 1.0 (FID)
MPa +0.98 +10
Fuel injection pressure 19.61 {200 0}
{kg/cm2} 0
(9) 4D88E
Model unit 4D88E
Type Vertical, 4-cycle water-cooled diesel engine
Combustion system Direct injection
Aspiration Natural aspiration
No. of cylinders 4
Cylinder bore x Stroke mm 88 x 90
Displacement l 2.189
Application – VM
Engine speed rpm 2,000 2,200 2,400 2,600 2,800
kW
Continu- Net {HP}
—
ous rat-
ing kW
Gross —
{HP}
Output
kW 24.05 26.48 28.83 31.26 33.69
Rated Net
{HP} {32.2} {35.5} {38.7} {41.9} {45.2}
output
(max.) kW 24.47 27.04 29.54 32.11 34.76
Gross
{HP} {32.8} {36.3} {39.6} {43.1} {46.6}
High rpm 2,180 ± 25 2,400 ± 25 2,590 ± 25 2,810 ± 25 2,995 ± 25
Idle engine speed
Low rpm Z800
Fuel injection pump Bosch inline (integrated mechanical governor)
Fuel injection timing degree B.T.D.C. :9 ± 1.0 (FID) B.T.D.C. :11 ± 1.0 (FID)
MPa +0.98
Fuel injection pressure 19.61 {200 +100 }
{kg/cm2} 0