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10-1

l1em Threaddia. x piteh Tightening torque RemarXs


M6x 1 1.0-1.2 1) When bolting the aluminum parts, tighten
Hexagon headed boIt
M8){ 125 2.3-2.9
Ihe bolts with 80% 01the tightening torque
specified in !he Table.
(7T)!lOO nut
M10 J I ; 1.5 4.5-5.5
2}4T bolt and lock nut should be lightened
M12x 1.75 8.0-10.0
wilh 60% 01the torque shown in the table.
1/8 1.0
1/4 2.0
PT plug
318 3.0
1 1 2 6.0
MB 1.3-1.7
Pipejoint bolt
M12 2.5-3.5
M14 4.0-5.0
M16 5.0-5.5
(Unit: kgt-m)
*:Lubricating011 notapplied
10-2 Standard bolt and nut
~
3TNE7BA
314TNE82,
No ltem 2I3TNE66 3TNE74
3TNE82A
314TNE84(T).
oe
314TNEBa
1 Cylinder head bolt
IJ .A>ricaling olapplied 3.8-4.2 6.0-6.5 6.8-7.2 8.7-9.3
(Threadda. xpik:h) (M8x 1.25) (M9 x 1.25) (M9x 1.25) (MIO x 1.25)
2 Connecting red bolt
Wlricaling oilapplled 2.3-2.8 2.3-2.8 3.8-4.2 4.5-5.5
(ThreadIia.x piten) (M7 x 1.0) (M7 x 1.0) (M8 x 1.0) (M9 x 1.0)
3
Flywheel clamping L.ubricafugoil appied 8.2-8.8 8.0-9.0 8.5-9.0 8.5-9.0
boft (Threadda. )(pl1ch) (Ml0x 1.25) (Ml0 x 1.25) (M10 x 1.25) {MI O x 1.25}
4
Metal cap clamplng LubrcatingolIapplied 5.3-5.7 8.0-8.5 7.6-8.2 9.8-10.2
bolt (Ttvead da.x pitch) (M9x 1.25) (Ml0 x 1.25) (Ml0xl.5) (M12)( 1.5)
._
Crankshaft V-pulley Lubri<;atirlg01appll8(j
S48C: 11.5-12.5 S48C:".5-12.5 11.5-12.5 11.5-12.5
5 FC25: 8.5-9.5 FC25: 6.5-9.5 (M14x1.5) (M14 x 1.5)
clamping bol! (Threaddia. )( pilch)
(M12x 1.5) (M12 x 1.5)
6
Fuel injection W:>ricating oiI not applied 5.0-5.4 5.0-5.4 0.7-0.9 0.7-0.9
nozzle nut (Threaddia. x pilch) (M20 x 1.5) (M20x 1.5) (M6 x 1.0) (M6 x 1.0)
7 Timar clamping nut
~g oi not appI ied
- -
6.0-7.0 6.0-7.0
(Thread dia. xpitch) {M12 x 1.75) (M12xl.75)
8 Glowplug
Lubricating oiI not applled 1.5-2.0 1.5-2.0
{Threa{j dia. >< pitchI (Ml0 x 1.25) (Ml0 x 1.25)
- -
9 Stub shaft boI t
LubricangoiI not applied 5.5-6.5 5.S-6.5
(Threaddia x p~ch) (Ml0 x 1.S) (Ml0 x 1.5)
- -
10
Govemor weight Lubricating oiI no! applied 7.0-7.5 7.0-7.5 4.5-5.0 4.5-5.0
supportnut (Thread dia. x pitch) (M12 x 1.25) (M12x 1.25) (M12 "X 1.25) (M12 x 1.25)
11
High pressure pipe Lubricating oil not appried 3.0-3.5 3.0-3.5 3.0-3.5 3.0-3.5
sleeve clamping nut (Threadda.)C pitch) (M12 x 1.5) (M12 x 1.5) (M12 " 1.5) (M12 x 1.5)
(Unit: kgf-m)
10. Tightening Torque
10-1 Main boltlnut
10. TlgIltBnIIlf TtlflllIf
8-9
(11) .Afler having reassembled 1hecylinder
heads, carryout conflrmation running
to see Hthey are free from leakage of
water and 011.
<:
3TNE78A
314TNE82
213TNE68 3TNE74
3TNE82A
314TNE84(T)
3/4TNE88
Tightening
3.8 ~4.2 6.0-6.5 6.8-7.2 8.7-9.3
torque
(kgf-m)
FO puma side
1
cr:
(4cyIlnder )
~
.
(3cyfinder)
~
.;
el>
-+---t- -;---.--- ~
g
O
FOpumpsidc
Camshaft side
(j)
<D
@
-8
@
.
@ ~

<ID
@
~
FO pump sde
Camshalt side
<ID
@
Camshaft sida
~
41

"O
v;

Q)
W
4i
<1)
( 2cylinder)
.,
~
ni
l

1.)
lij
:

@
<!I
O
Tighten cylinder heads in numerical arder shown below to the specified torque.
(10) Order of tightenlng cyUnder heads
and tightenlng torque
8. DIsassembIy IntI RI88IItHfIbJy
Alignment mar!<
14---Embossedmark
(Fiywheel side)
8-8
Rywheel siete
Cy~nder
size mar\(
1.0. mark
<1)
'O
.;
!2
N
N
o
Z
Cylnder
size ma/f( Flywheel 6ide
1.0. mar k
3TNE78A,3TNE82A,~4TNE82
3/4lNE84(T), 3f4TNE88
213TNE68, 3TNE74
(9) Assembly directlon of plston and connecUngrod
Apply lubficating oil
Appty J ubrca11ngoil to thehatched portiOn
of Ihe push rodas shown inthe figure, before
reassembly.
(8) Coatlng the lubrlcatlng oil to
pushrod adJ ustlngscrew eontact
,. Dfsassem tJfy andReassembly
8-5
Step RemovaJ Parts Remarks
Apply adial gauge 10the endof crankshaft @ . force
Ihe crankshaft on both sides in the axial direclion 10
measure thethrust gap. AJ ternatillely, nsenathlckness
gauga directly between the base Ihrust metal and the
thrust suriace of {he crankshaft lo measure the gap.
Ifthe limitsize is exceeded, (aplace Ihethrust metatwith
a newone.
(mm)
--
Al! models
-_
Thrusl gap 0.090 - 0.271
2. Notice on the removal of thrust metal @.
{1) When removing thrust metal @ , ascertatn the
position anddirection wnere thrust metal is installed
in relation to the cap.
(2) Make surethat tne thrust metal groove ts outward in
relalion lo the cap.
24 1. Removepiston @ andconnecling 1. To selectillely remolle a desired pistan and connecting
rod @ asserroiy. rod assembly without extracling crankshafl @ , take
the steps itamizad below:
(t) Hemove carbn deposits fromlhe upper wall of the
cylinder using fine sandpaper, taking care not to
damage the inner surtace of the cylinder.
(2}While turning the crankshaft, with the crankpin side
cap ~ removed, raisethe pisten up10ths lop dead
center (TDe).
(3) Extract the pistorVconnecting rod assembly while
tapping the connecting rod at the largeendwilh
the handle of a plastic hammer or the like.
25 1. Bernove lappet @J .
8. O l s a s s e m 1 J 1 y a m i R n s s e m t J / y
8 2
2. Remove cylindef head assen1J ly
@.
3. Remove cylinder headgasket @.
Camshah siete
~

@

a>
"O
.;
'" @

@
'i
~
- - -
III
oC
@
@ @ (j)
o
.t
ii
u.

@ ~
Fuel injection pump side
Camshalt side
~ e
@ @

a>
@
"O
.;;
<D

@ @
.
1
Q)
.
-
-
~ ..c
@ @ @
@
< ID
~ ~
ir

@ @
Q >
o
Fuer inecliOn pump side
t. Lay a cardbOard or the like on the floor and place
cylinder head assernbly @ on it so as net to damage
the combuslion surtace.
2. Order 01 loosening the cyllncler head tighlening bcns
1. Remove cylinder head tightening
boll .
10
9 1. D isconnect cooling water pipe @
from the oool;ng water purT'p.
2. Removethermostat assembly @.
3. Remove coollng water pump @.
2. Remove fuel filter @.
8 1. D isconnect fuel retum pipeS @ to
@.
7 1. Remove lubricating oil filter assem-
bly @l.
2. EXlractdlpstick @ fromtheoildip-
stick hole.
1. Never tum down alternator @ vigorously toward Ihe
cyllnder block. Otherwise, your finger may be nipped
and alternator @ broken.
6 1. Remove tan mounting balt @ I
andthenremovefan ~.
2. Loosenadjuslingboll @ torlheV-
belt adjuster, and lhen remove V-
beh 4]).
3. Remove allernator @.
4. Remove the spacer for cooIing fan
@ and V-pulle)' @.
Step Removal Parts
Remarks
Camshalt side
~
o
:2
.;
@) @ '"
Q ~
Q )
- -
t1I
s:
@
< D
Q
~
t;
,
ro
111
C)
Fuer injeeticn pump side
8. Dlsassembly Ind Reassemflly
7-26
Direction 01rolation
*PTO (oplion)
Camshaft gear
Fue! injection pump drive gear
(V1ewthe gear case)
4. Geartran
After ins1alling each gear, make sure that
aligning marks @,@ano 01the diegear
are aligned with those of the fuel injection
pump gear, cam gear and crank gear .'
7. Mnsating Procedure. Servlce Data 1M COrree/TveAclion
7-25
(DirectInjecllon systsm)
(rndJ rectInjectlon systern)
(2) Make sure that the ol hale of the idlegear
shaft ano bushing is a through hale.
r.
3TNE 78A182A.
213TNE 68, 3/4TNE 02.
3TNE 74 3i4TNE 84(T).
3t4TNE 88
Wear Wear
Slandard r . Standard r '1
umt um
Shaft outside 19.959
19.93
45.950
45.93
dia. -19.980 -45.975
Idle Bushing 20.000 46.000
46.0B
inside da. -20.021
-
-46.025 gear
Ol clearance
0.020
0.15
0.025
0.15
-0.062 -0.075
3. Checking and measuring the idllng
gear shaft and idling gear
(1) Measure the bushing nsdediameter ano
the idle gear shaft autside diameter, and
replace the bushing 01" idling gear snan it
the ail clearance exceeds the wear limit.
(mm)
-------......_
3TNE 78A182A.
2/3TNE68. 314TNE 82
........----.., 3TNE7"
314TNE 84!T),
314TNE 88

Crrishaft gear,
Camshaft gear.
0.04-0.12 0.07-0.15
8ack-
!dieggar and
lash
Fue! injection
pumpdrivegear
L.O. pumpgear 0.11-0.19
(mm)
2. Mes8urlng too backrash
Apply adial gauge ontothepitch cuele ofthe
gear, and measure Ihe backlash.
1. Checking gears
Inspectthegears andreplace if theteethare
damaged, wom. or chipped.
7. Measurfau Procedure, Serv/ce Dsls Bnd Cart8ctlve A&lion
7-8. Gears
(Measuring the crankshaft bend)
V-block V-bleck
Dial gauge
Dellectien
----. . . . . . . . . _
Al! models
"~. . . . . . . . . . '"
- . . . . . . . .
Standard
<. . ,
Bene! 0. 02or J ess
(mm)
4. Bend 01the crankshaft
Support the crankshatt with V- blocks at
botnendsofthe journals; measuretherunout
at the center journal with a dial gauge while
rotating tne crankshaft to check the extent
of crankshaft bend.
3. Ctlecking the metal
Checkthametal forflaking, melting, saizure.
and the state of the contact face. Replace
the metal i1found defective.
(Color check lnspectlon)
7-22
2. Color check of crankshaft
Clean the crankshaft and check it using a
color check kit or a magnaflux inspector,
Replace the crankshaft if cracked or badly
damaged. I f the cranksnart is slightly dam-
aged. correet it by re- grinding.
Craokahaf t
Thrust gap
AII models
- - - - - - - 0. 090-0. 271
(mm)
1. Side gap around the crankshaft
Before extracting the crankshaft and when
reassembling it, bring -a dial gauge Into
contact to the end of the crankshaft Force
the crankshaft to both sides in me axial
direction to rneasure the thrust gap. A1ter-
natively, insert a thickness gauge directly
into athrust gapbstween the thrust metal in
thestandard part anderankshaftto measure
the side gap.
If the limit is exceeded, replace the thrust
metal with a new ona.
7-7. Crankshaft
7. MUsurlng PrDC4r1ure,Serrla Data aooCorrecfive Aman
7-19
(Measuringtheconnecting rod slde gap)
0.2-0.4 Side gap
AII modsls
(mm)
7. Sldegap01the connecting rod
After attaching the connecting rod lo the
crankshaft, tighten the rod bolt tothe speci-
fiedtorqua (see this seetion3). Measurethe
side gapby insertngathekness gauge into
the side gap. lf the standard 15excesded,
replaee the crankpn metal or connecting
rod.
1.0. mark
Combustion
chamber recess
(Indirect InjecUonsystemplston)
Camshalt sicle
,
(Dlrect Injectlon systemplston)
6. ASsembling,heplstonandconnectlng
rod
Assemble the piston with the connectng
rod, with tne mark at the big end of the
connectingrodfacingthefuel injectionpump.
Reassemble the pistonso thatthe recess of
thecombustion chamber is onthesideofthe
fuel injection pump as seen fromthe topo
Crankpin metal
Assemblsso
!hatIhlit PlJ ndled
mark01larga
end faces !he
fuel~cction
pump.
7. MJasuring Proctdure, Serv ce Data and Corre&UVBA&/ion
7-17
I~
3/4TNE82,
2I3TNE68 3TNE7BA 314lNE84(T1,
STNE74 3TNE82A 3/4TNE88
SpeclfiBd torque
Aod bolt ligllten-
ingtorqU9
2.3-2.8 3.8~4.2 4,5-5,5
(AppIy lube oil
to the roo batt)
(kgf-m)
(
Measuringthe inside diameter of )
the crankpln metal
3. Measuring the crankpln and bushlng
clearance
To measure th oi!clearance 01the crank-
pin and bushing, measure the lnslde diam-
eter 01 the crankpin metal and outside di-
ameter of the crankpin, and obtainthe difter-
ence between them.
If the measured oH clearance exceeds or
near the wear limit, replace the
crankpin metal. If the crankpin is exoes-
sively or unevenly wom, grind the crankpin,
and use an oversized crankpin metal.
* romeasure tne insidediameterofthe cfank-
pin metal, resssemote tne crankpin metal
ro tne connecttnq rod and tighten tne roo
bolt to tbe speciea torque, making sure
each metal is tittea on the corree! postuon.
(
Measutingthetwist with)
connecting red aligner
(Measurlngthe twfst and paranensrn)
~"-i
Al! rnodals
Standard
Wear
limil
Twis1and paraUelism
0.03 or lass
0.08
per 100 mm
(mm)
2_ .Measuring the twlst and parallellsm
Measure the twist and parallelism by use of
the connecting red a1igner.
1. Visual Inspection
Inspect the portion nearthe boundary ofthe
chamferedportion and I-beamsectionofthe
bigand small ends of the connecting roo as
well as the portion near the oi! hale of the
bushlng at the small end for cracks, detor-
mation. and discoloration.
7. Measuring Procedure, Service Dais ami COlrect;veAtlion
7-5. Connecting rod
1-11
*1. Designation of engine dimension and dryweight in numerals.
CUCH applica1ion: engina with flywheel housing
VMNH application: angine with back plate/with flywheel hausing
-
Modal
4TNE88
118m Unt
Application - Cl VM
Type - Vertical. 4-cycle water-cooled diesel em:lne
Combus1ionsyslem
- Oirect ~ction s~
No. of cylinders - Bore x Stroke mm 4-8ax90
Dlsplacement e 2..189
Fring order
-
1- 3- 4- 2- 1
RevQlutionspeed rpm 1500 1600 2000 2200 2400 2.000 2800 3000
-
Continuous
kW(HP)
16.4 19.6
- - -
- - -
Output*
rating ( 22. 0) (26.3)
-
18.0 21.6 24.1 26.5 28.S 31.3 33.7 36.0
Max. rating kW(HP)
(24. t) (29.0) (32.3) (35.5) (38.6) (42.0) (45.2) (48.3)
Max. rsvoufion speed al
1575~ 1870sg 2180o s : ; 2400+s g
2590"~ 2810s g 2995"~
3210+5g
no load
Min. revolution speed at
rpm
no load
~1200 ~800
Direction 01rotation - Counterclockwise (viewed from flywt1eel)
Power take off - Flywheel
e n
Compression ratio - 18.0
z
O
Fue! injection timng
~
(FID, b.T.O.C.)
deg 101 121 14t 161
o
Compression pressure MPa
e
3.43O.1(351). al 250 rpm
(3 (kg Vcni)
Ul
Fuel nJ ecHonpressure MPa
19.6+1.~(200+'~) 19.6+l.g (200+1~)
o .
sn
I(kgf/cm2)
Recommended diesel gas oil
-
ISO ~17 DMA. BS 2869Al or A2 (Cetane No. 45 mio.
lubrlcation svstem - Forced lubrication with trochoid pump
lubrcating oil capacity
e 5.8/2.3 7.912.5
MaxJ Effective
Recommended lubric81ing oi! - API grade CC csassor hig_her
Cooling system - Liquid cooling/Radiator
Cooling water capacity 2.7 (for ertgine onJ y)
._
e
Coolingfan
mm Pusher type. 6 x ~370
No. of blade x dla.
Crank V-pulley dia.!
mm ~120/~ 911019110
Fan V-pulley dia.
Governor
- Machanical centrif~al~vemor (AII SQ_ged tvDe)
Starting system
- Electrica'
*1Dimensions L x W x H
mm 683x498.5)( 618 632 x498.5 x618(658 x498.5 x618
! f e1Ory weight k g 184 160 /170
Transient speed
% :;;10 ~8 ~12
dfference
LU Governing
S1eadystate
1
o
perform- % ss s 4 s s ~ !J
z speed band
~
anCQ
a:
(tull speed
Recoll8ry tlme sec s s s s
~
ranga)
-
a:
Fluctuatian of
rpm ~15 525
Ul
revolut;on
CL
Rated opereton
MPa
0.29: : 0.05 0.34O.O5
L O; pres s . (3.0o.S) J .3.5O.~
Idling
(kgl/cm2)
~0.06(~.6)
*Output conditions: Intakeback pressurs ::;250 mmAq,Exhausl back pressure $550 mmAq, .
otherconditionsoomlllyingwith J ISDl00s....:19B6. Afterminimum30hour'srun;n.
1-11. 4TNE88
1. Spe &lication ssn d p.n "n n an ce
6-3
Abnormal
2. Make sure that the valve cap 15nested en
the head 01intakelexhaust valves.
*: 1. J I tne va/ve cap is wom or etherwise
damaged on me head, replaes I t wlth a
new one.
0.15- 0.25
Intake/exhaust valve
head cfeaarance
AII models
(AdJ ustlng the valve head clearance)
(mm)
Lock nut
Ac:fJ Uslingscrew
(4) Insert a thickness gauge in between the
rccker armand vave cap. Tighten the
adjusting screw until the clearance listad
below 15attalned.
(3) Loosen the J ocknut and adjusting screw.
Maka surs that the valve cap is free from
inclination or trapped dirt.
Norm91
(2) Raiga the piston in the cylinder lo be
measured lo the top dead center (TOe)
of compresson.
(1) Inspect and adjusta vavehead cJ earance
while the angine is in cold state.
6-2. Adjusting the valve head
clearance
6. Measurement. I nspectlon and A dJ ustment
6 9
(4) If the measured injeerion timing differs
fromthe specified timing, adjust the njec-
tion timing byturning down the fuel injec-
tion pump toward the engine or to
the opposte sida after loosening the lock
nut of the fuel injection pump.
1 1 injection timing ts late, turn down the
fuel In~tion pumpawayfrom theengine.
11the injection timing too ear1y,turn the
injection pump down toward the englne.
Timing mark
Acoesshale
(2) When thecrankshaft is turnedintoo speci-
fieddreccn, the olllevel risesat the tip of
the delivery valve spring holder. Al tnat
time, stop the crankshaft.
(3) Identify the timing mark stamped on the
flywheel through the access hola ct tila
flywhBel housing.
*: ForfuelinjectiontimingforeachenginemodeJ,
reter to cnepter 1 , Specifications and
Performance.
2. Olrect In,ecdan system
(1) Using the crankShaft pUlley. turn the en-
gine In the specified direction. Check ttte
inj9Ctiontiming at the dellvery valve of the
fuellnjection pump for cyUnderNO.1.(Cyl-
inders are numbered se-quentially frorn
cylinder No. 1fromthe flywheel soe).
6. Measurement, InspectlDII BRdAdjuSlmeDl