Sebm011501 PDF

SEBM011501
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
1. SPECIFICATIONS AND PERFORMANCE................................................................ 1-1
2. CROSS SECTIONAL VIEWS..................................................................................... 2-1
3. COOLING WATER, LUBRICATING OIL AND FUEL OIL ......................................... 3-1
4. TROUBLESHOOTING ............................................................................................... 4-1
5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS ........................... 5-1
6. MEASUREMENT, INSPECTION AND ADJUSTMENT ............................................. 6-1
7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION....... 7-1
8. DISASSEMBLY AND REASSEMBLY ....................................................................... 8-1
9. SERVICE DATA ......................................................................................................... 9-1
10. TIGHTENING TORQUE ........................................................................................... 10-1
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM .......................... 11-1
12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM .............................. 12-1
13. GOVERNOR ............................................................................................................. 13-1
14. TURBOCHARGER ................................................................................................... 14-1
15. SERVICE INFORMATION FOR CARB ULG REGULATION .................................. 15-1
16. ATTACHED DRAWING............................................................................................ 16-1
20. EPA CERTIFIED ENGINE........................................................................................ 20-1
00-2 68E-88E SERIES

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68E-88E SERIES 00-3

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00-4 68E-88E SERIES

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Applicable machine, Serial number (Current Production Model)
Engine output
Engine Machine model Machine Serial No. Remarks
(kW{HP}/rpm)
3D68E-3G PC12R-8 10001 and up 10.3{13.8}/2,450
3D68E-3H PC15R-8 10001 and up 11.2{15.0}/2,600
3D74E-3C PC20R-8 10001 and up 14.0{18.8}/2,600
3D82AE-3E PC25R-8 10001 and up 17.7{23.7}/2,400
3D82AE-3F PC27R-8 10001 and up 19.1{25.6}/2,600
PC30R-8 10001 and up 20.6{27.6}/2,500

3D84E-3F
PC35R-8 35001 and up 20.6{27.6}/2,500
4D84E-3B PC50UU-2 12772-14992 29.4{39.4}/2,800
4D84E-3C PC50UU-2 14993 and up 29.4{39.4}/2,800

PC40R-8 30001 and up 28.3{37.9}/2,500
4D84E-3D
PC45R-8 5001 and up 28.3{37.9}/2,500
Application Category
Application code Usage Eng. Rev. type. Revolution speed (rpm)
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
★ For engine application category described in Chapter 1, Specifications and Performance.
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
68E-88E SERIES 00-5

(1)
Descriptive Breakdown of Model Name
(S) D (A) —
Shipping identifier
Model subdivision
Cylinder bore (mm)
Model code
Number of cylinders (3 or 4)
Turbocharger
Application Category
Application code Usage Eng. Rev. type. Revolution speed (rpm)
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
★ For engine application category described in Chapter 1, Specifications and Performance.
00-6 68E-88E SERIES

(1)
1. SPECIFICATIONS AND PERFORMANCE
1.1 2D68E..................................................................................................................................................... 1-2

1.2 3D68E..................................................................................................................................................... 1-3
1.3 3D74E..................................................................................................................................................... 1-4
1.4 3D78AE .................................................................................................................................................. 1-5
1.5 3D82AE .................................................................................................................................................. 1-6
1.6 3D82E..................................................................................................................................................... 1-7
1.7 3D84E..................................................................................................................................................... 1-8
1.8 3D88E..................................................................................................................................................... 1-9
1.9 4D82E................................................................................................................................................... 1-10
1.10 4D84E................................................................................................................................................... 1-11
1.11 4D88E................................................................................................................................................... 1-12
1.12 S3D84E ................................................................................................................................................ 1-13
1.13 S4D84E ................................................................................................................................................ 1-14
68E-88E SERIES 1-1

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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
Fuel injection timing

deg 14 ± 1
(FID, B. T. D. C)
MPa
Compression pressure 3.24 ± 0.1{33 ± 1}, at 250 rpm
{kg/cm2}
MPa +1.0
Fuel injection pressure
{kg/cm2} 11.8 0 {120 +100 }
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 1.6/0.6
Max/Effective
Recommended lubricating oil — API grade CC class or higher
Cooling system — Liquid cooling/Radiator
Cooling water capacity l 0.6 (for engine only)
Cooling fan
mm Descharge type, 5 x 290
No. of blade x dia.
Crank V-pulley dia./
mm 95/ 85
Fan V-pulley dia.
Governor — Mechanical centrifugal governor (All speed type)
Starting system — Electrical
Dimensions L x W x H (*2) mm 373.5 x 417 x 498 / 383.5 x 417 x 498
Dry weight (*2) kg 55/65
Transient speed
% Z12
Governing difference
perfor- Steady state speed
% Z9 Z8 Z7 Z6
mance band
Performance
(full speed Recovery time sec Z6

range) Fluctuation of
rpm Z30
revolution
0.25 ± 0.05 0.29 ± 0.05 0.34 ± 0.05
Lubrica- Rated operation
MPa {2.5 ± 0.5} {3.0 ± 0.5} {3.5 ± 0.5}
tion oil
{kg/cm2} X0.06
pressure Idling
{X0.6}
*1 Output conditions: Intake back pressure Z 2.45 kPa {250 mmH2O}, Exhaust back pressure Z 5.39 kPa {550
mmH2O}, other conditions complying with JIS D 1005-1986. After minimum 30 hour’s run-in.
*2 Designation of engine dimension and dry weight in numerals.
Engine with back plate/with flywheel housing
1-2 68E-88E SERIES

(1)
1.2 3D68E
Model
Unit 3D68E
Item
Application — VM
No. cylinders – bore x Stroke mm 3 – 68 x 72
Firing order — 1–3–2–1
kW
{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}
rpm
Specifications

deg 14 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10
Fuel injection pressure 11.8 {120 }
{kg/cm2} 0 0
l 2.4/1.0
Max/Effective
Recommended lubricating oil — APl grade CC class or higher
Cooling fan
mm Pusher type, 5 x 310
No. of blade x dia.
mm 105/ 85
Fan V-pulley dia.
Transient speed
% Z12
% Z9 Z8 Z7 Z6
mance band
Performance

rpm Z30
revolution
0.25 ± 0.05 0.29 ± 0.05 0.34 ± 0.05
Rated operation
Lubrication MPa {2.5 ± 0.5} {3.0 ± 0.5} {3.5 ± 0.5}
oil pressure {kg/cm2} X0.06
Idling
{X0.6}
68E-88E SERIES 1-3

(1)
1.3 3D74E
Model
Unit 3D74E
Item
Application — VM
kW
{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}
rpm
Specifications

deg 14 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10
{kg/cm2} 0 0
l 2.4/1.0
Max/Effective
Cooling fan
No. of blade x dia.
mm 110/ 85
Fan V-pulley dia.
Transient speed
% Z12
% Z9 Z8 Z7 Z6
mance band
Performance

rpm Z30
revolution
0.25 ± 0.05 0.29 ± 0.05 0.34 ± 0.05
Rated operation
Lubrication MPa {2.5 ± 0.5} {3.0 ± 0.5} {3.5 ± 0.5}
Idling
{X0.6}
1-4 68E-88E SERIES

(1)
1.4 3D78AE
Model
Unit 3D78AE
Item
Application — VM
Combustion system — Direct injection system
kW
{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}
rpm
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10
{kg/cm2} 0 0
l 3.6/1.3 5.0/1.7
Max/Effective
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Dimensions L x W x H (*2) mm 520.5 x 489 x 565 / 528 x 489 x 565
Transient speed
% Z12
% Z9 Z8 Z7 Z6
mance band
Performance

rpm Z25
revolution
0.29 ± 0.05
Rated operation
Lubrication MPa {3.0 ± 0.5}
Idling
{X0.6}
*1 Output conditions: Intake back pressure Z 2.45 kPa {250 mmH2O},Exhaust back pressure Z 5.39 kPa {550
mmH2O},other conditions complying with JIS D 1005-1986. After minimum 30 hour’s run-in.
68E-88E SERIES 1-5

(1)
1.5 3D82AE
Model
Unit 3D82AE
Item
Application — VM
kW
{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}
rpm
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa
Fuel injection pressure 19.6 +1.00 {200 +100 }
{kg/cm2}
Lubrication oil capacity Max/Effective l 5.0/1.7
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Dimensions L x W x H (*2) mm 520.5 x 489 x 565 / 528 x 489 x 565
Transient speed
% Z12
% Z9 Z8 Z7 Z6
mance band
Performance

rpm Z25
revolution
0.29 ± 0.05
Rated operation
Idling
{X0.6}
1-6 68E-88E SERIES

(1)
1.6 3D82E
Model
Unit 3D82E
Item
Application — VM
kW
{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
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10
{kg/cm2} 0 0
Lubrication oil capacity Max/Effective l 4.7/1.8 6.9/2.1
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Dimensions L x W x H (*2) mm 556 x 486 x 623 / 564 x 486 x 623
Transient speed
% Z12
% Z8 Z7 Z6
mance band
Performance

rpm Z25
revolution
0.34 ± 0.05
Rated operation
Idling
{X0.6}
68E-88E SERIES 1-7

(1)
1.7 3D84E
Model
Unit 3D84E
Item
Application — VM
kW
{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}
rpm
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10
{kg/cm2} 0 0
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Transient speed
% Z12
% Z9 Z8 Z7
mance band
Performance

rpm Z25
revolution
0.34 ± 0.05
Rated operation
Idling
{X0.6}
1-8 68E-88E SERIES

(1)
1.8 3D88E
Model
Unit 3D88E
Item
Application — VM
kW
{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}
rpm
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10
{kg/cm2} 0 0
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Transient speed
% Z12
% Z9 Z8 Z7
mance band
Performance

rpm Z25
revolution
0.34 ± 0.05
Rated operation
Lubrication MP {3.5 ± 0.5}
Idling
{X0.6}
68E-88E SERIES 1-9

(1)
1.9 4D82E
Model
Unit 4D82E
Item
Application — VM
Firing order — 1–3–4–2–1
kW
{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}
rpm
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10
{kg/cm2} 0 0
Cooling fan
mm Pusher type, 6 370
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Dimensions L x W x H (*2) mm 632 x 448.5 x 618 / 658 x 498.5 x 618
Transient speed
Governing difference % Z12
perfor-
Steady state speed band % Z8 Z7 Z6
mance
Performance
Recovery time sec Z6

(full speed
rpm Z25
revolution
0.34 ± 0.05
Rated operation
Idling
{X0.6}
1-10 68E-88E SERIES

(1)
1.10 4D84E
Model
Unit 4D84E
Item
Application — VM
kW
{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}
rpm
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10 +1.0 +10
Fuel injection pressure 19.6 {200 } 19.6 {200 }
{kg/cm2} 0 0 0 0
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Transient speed
perfor-
mance
Performance

(full speed
rpm Z25
revolution
0.34 ± 0.05
Rated operation
Idling
{X0.6}
68E-88E SERIES 1-11

(1)
1.11 4D88E
Model
Unit 4D88E
Item
Application — VM
kW
{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}
rpm
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa +1.0 +10 +1.0 +10
Fuel injection pressure 19.6 {200 } 19.6 {200 }
{kg/cm2} 0 0 0 0
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Transient speed
perfor-
mance
Performance

(full speed
rpm Z25
revolution
0.34 ± 0.05
Rated operation
Idling
{X0.6}
1-12 68E-88E SERIES

(1)
1.12 S3D84E
Model
Unit S3D84E
Item
Application — VM
kW
{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}
rpm
Min. revolution speed at no load Z800 +500
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa
{kg/cm2} 19.6 +1.00 {200 +100 } 19.6 +1.00 {200 +100 }
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Transient speed
perfor- Steady state speed band % Z9 Z8 Z8
mance
Performance

rpm Z22
revolution
0.34 ± 0.05
Rated operation
Idling
{X0.6}
68E-88E SERIES 1-13

(1)
1.13 S4D84E
Model
Unit S4D84E
Item
Application — VM
kW
{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}
rpm
Min. revolution speed at no load Z800 +500
Specifications

deg 12 ± 1 14 ± 1 16 ± 1
(FID, B. T. D. C)
MPa
{kg/cm2}
MPa
{kg/cm2} 19.6 +1.00 {200 +100 } 19.6 +1.0
0 {200 +100 }
Cooling fan
No. of blade x dia.
mm 110/ 110
Fan V-pulley dia.
Transient speed
perfor- Steady state speed band % Z9 Z8 Z7
mance
Performance

rpm Z22
revolution
0.34 ± 0.05
Rated operation
Idling
{X0.6}
1-14 68E-88E SERIES

(1)
2. CROSS SECTIONAL VIEWS
2.1 Special swirl pre-combustion chamber system (Indirect injection system) ............................................. 2-2
2.2 Direct injection system ............................................................................................................................ 2-4
68E-88E SERIES 2-1

(1)
2.1 Special swirl pre-combustion chamber system

(Indirect injection system)
1 5
10
YE0001
1) Fuel injection pump 6) Piston

2) Fuel injection valve 7) Connecting rod
3) Valve rocker arm cover 8) Starting motor
4) Valve rocker arm 9) Crankshaft
5) Cylinder head 10) Lubricating oil suction pipe
2-2 68E-88E SERIES

(1)
11
YE0002
11) Camshaft
68E-88E SERIES 2-3

(1)
2.2 Direct injection system
3
2
10
YE0004
1) Fuel injection pump 5) Cylinder head 9) Crankshaft

2) Fuel injection valve 6) Piston 10) Lubricating oil suction pipe
3) Valve rocker arm cover 7) Starting motor
4) Valve rocker arm 8) Connecting rod
2-4 68E-88E SERIES

(1)
11
YE0005
11) Camshaft
68E-88E SERIES 2-5

(1)
3. COOLING WATER, LUBRICATING OIL AND FUEL OIL
3. COOLING WATER, LUBRICATING OIL AND FUEL

OIL
3.1 Cooling water .......................................................................................................................................... 3-2

3.2 Lubricating oil.......................................................................................................................................... 3-3
3.3 Fuel oil .................................................................................................................................................... 3-5
68E-88E SERIES 3-1

(1)
3.1 Cooling water
1. Proper use of cooling water

Impurities in cooling water are deposited in the engine and radiator in the form of scale and cause rusting.
For this reason, heat conduction of the cooling system and cooling water flow are impaired, and cause cool-
ing functions to reduce and the engine to over-heat. Therefore, drain the cooling water at intervals of 400
hours or one year. Never use hard water as the cooling water.
In order to prevent the cooling water from freezing in cold weather, be sure to use an antifreeze agent. For
further information on and proper usage and type of rust-preventive agents, antifreezes, and cleaning
agents, contact your nearest dealer.
2. Cooling water system diagram

Indirect injection system and direct injection system.
Cylinder head Thermo-

stat
Bypass
Radiator
Sub-tank
Cylinder block
Cooling water pump
Lub. oil cooler (option)

YE0314
3-2 68E-88E SERIES

(1)
3.2 Lubricating oil
1. Proper use of lubricating oil

Use of proper lubricating oil brings about the following effects.
(1) The friction part of the engine is protected from friction and wear.
(2) The engine parts is protected from rusting and corrosion.
(3) The high temperature part of the engine is effectively cooled.
(4) The engine is protected from leakage of combustion gas.
(5) The engine parts are protected from sludge deposits.
For the above reasons, use lubricating oil APl Service Classification Class CC or better.
[Reference:Lubricating oil to be used at ambient temperature]

Select the viscosity of lubricating oil depending on ambient temperature at which the engine is used,
according to SAE Service Grade shown below.
SAE 5W-20
SAE 20W-40
SAE 10W-30
SAE 10W
SAE 20W
SAE 20W-20
SAE 20W-30
SAE 20W-40
-30 -20 -10 0 10 20 30 40 ( C)
Ambient temperature at which the engine is used, C
: Recommended SAE Service Grade

YE0315
68E-88E SERIES 3-3

(1)
2. Lubrication system diagram

(1) Indirect injection system
Lub. oil cooler (Option)
Lub. oil filter Pressure Main gallery Idle gear shaft Fuel injection
(w/ bypass valve) regulating valve pump
Lub. oil pump Oil pressure Crank journal Camshaft

switch bearing
Crankpin Valve rocker

arm shaft
Lub. oil suction Valve rocker

pipe (strainer) arm
Tappet/cam
faces
Oil pan
YE0316
(2) Direct injection system
(Option)
Lub. oil cooler Turbocharger
(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
Gears face Valve rocker

Lub. oil suction arm shaft Crankpin Piston
pipe (strainer)
Valve rocker w/turbocharged

arm engine only
Tappet/cam
faces
Oil pan
YE0317
3-4 68E-88E SERIES

(1)
3.3 Fuel oil

1. Proper use of diesel gas oil
Use a diesel gas oil equivalent to or better than ISO 8217 DMA BS 2869 Part 1 class A1 or Part 2 class A2.
(Cetane Number: 45min.) Give your customers instructions on proper use of fuel oil, or the customers may
suffer from troubles stated below.
(1) Deposits on the exhaust valve
Deposits on the exhaust valve cause unburnt oil mixture in exhaust gas and erosion of the exhaust
valve seat, to occur in addition to poor compression, imperfect combustion, excessive fuel consump-
tion, etc.
(2) Deposits in the piston ring groove
Deposits in the piston ring groove cause blow-by gas, poor lubrication, imperfect combustion, excessive
fuel consumption, contamination of lubricating oil, premature wear, etc. of the cylinder liner and piston
ring.
(3) Clogging or corrosion of nozzle hole in fuel injection valve
Imperfect combustion causes the fuel injection mechanism to wear and corrode and the nozzle to be
clogged.
2. Fuel system diagram

1
2
9 4
8
5
6
7 YE0010
1) Fuel injection valve 6) from fuel tank

2) Fuel injection pipe 7) Fuel feed pump
3) Fuel oil return pipe 8) Fuel filter
4) Fuel injection pump 9) to tank
5) Water separator (option)
68E-88E SERIES 3-5

(1)
(2) Direct injection system
1
2
9 4
10
8
5
6
7 YE0011
1) Fuel injection valve 6) from fuel tank

2) Fuel injection pipe 7) Fuel feed pump
3) Fuel oil return pipe 8) Fuel filter
4) Fuel injection pump 9) to tank
5) Water separator (option) 10) Air-bleed pipe
3-6 68E-88E SERIES

(1)
4. TROUBLESHOOTING
4. TROUBLESHOOTING
4.1 Trouble causes and remedies ................................................................................................................ 4-2

4.2 Trouble diagnosis through measurement of compression pressure ....................................................... 4-6
68E-88E SERIES 4-1

(1)
4. TROUBLESHOOTING
4.1 Trouble causes and remedies

The following table summarizes the symptoms and causes of general troubles. If any symptom of trouble is
found, a corrective action shall be taken before the said symptom develops into a serious accident.
Carefully read Chapter 6, Measurement, Inspection and Adjustments, and Chapter 7, Measuring Procedures,
Service Data and Countermeasures, Familiarize yourself with Chapter 6 and Chapter 7, which practice is
extremely important for extending the service life of the engine.
4-2 68E-88E SERIES

(1)
4. TROUBLESHOOTING
68E-88E SERIES 4-3

(1)
4. TROUBLESHOOTING
4-4 68E-88E SERIES

(1)
4. TROUBLESHOOTING
68E-88E SERIES 4-5

(1)
4. TROUBLESHOOTING
4.2 Trouble diagnosis through measurement of compression

pressure
★ 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.
No. Item Cause Countermeasures

• Filter element of air • Clogged filter element • Clean the filter element.
1 cleaner • Broken filter element • Replace the filter element with a
• Defective filter element seal new one.
• Valve clearance • Excessive valve clearance or no • Adjust the valve clearance (Re-
2
clearance fer to Chapter 6, 6.2.)
• Valve timing • Improper valve timing • Adjust the valve clearance (Re-
• Improper valve clearance fer to Chapter 6, 6.2)
3 • Inspect and adjust the valve
rocker arm. (Refer to Chapter 7,
7.3, 7.3 and 7.8.)
• Cylinder head gasket • Gas leak through the gasket • Replace the gasket.
• Nozzle gasket • Re-tighten the cylinder head
4 and nozzle to the specified
torque. (Refer to Chapter 10,
10.1.)
• Intake/exhaust valve • Gas leak caused by worn valve • Rap valve seats.
• Valve seat seats or trapped foreign matter (Refer to Chapter 7, 7.1.2.)
5
• Seizure of valves • Replace the intake/exhaust
valves.
• Piston • Gas leak caused by scratches • Perform honing and use over-
6 • Piston ring and wear of piston, piston ring size parts. (Refer to Chapter 7,
• Cylinder and cylinder 7.2.3 and 7.4.8.)
4-6 68E-88E SERIES

(1)
5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS
5. SPECIAL SERVICE TOOLS AND MEASURING

INSTRUMENTS
5.1 Special service tools ............................................................................................................................... 5-2

5.2 Measuring instruments ........................................................................................................................... 5-5
68E-88E SERIES 5-1

(1)
★ 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.
5.1 Special service tools
No. Tool name Applicable model and tool dimension Illustration
(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
Valve guide 3D74E 9 60 13 19

2
insertion tool
3D78AE, 3D82AE 12 60 13 19
d1
3D82E, 4D82E d2
(S)3D84E, (S)4D84E 15 65 14 20
3D88E, 4D88E YE0013
(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
5-2 68E-88E SERIES

(1)
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
68E-88E SERIES 5-3

(1)
Model Code No.

Piston inser-
8 tion tool (Inser- All model 95550-002476
tion of piston)
NOTE: The above piston insertion tool is applicable
to pistons 60-125 mm in diameter.
YE0019
Piston ring
9 Sold on market
replacer
YE0020
5-4 68E-88E SERIES

(1)
5.2 Measuring instruments
No. Instrument name Purpose of use Illustration
Measures bent shafts, distorted flat

1 Dial gauge
surface, gaps, etc.
YE0021
Measures the limited small portions

2 Test indicator and deep portions unmeasurable
with dial gauge.
YE0022
Used together with the dial

3 Magnetic stand gauge:holds the dial gauge at differ-
ent angles.
YE0023
Measures the outside diameter of the

4 Micrometer crankshaft, piston, and piston pin,
etc.
YE0024
Measures the inside diameter of the

5 Cylinder gauge cylinder liner, connecting rod metal,
etc. YE0025
Measures the outside diameter,

6 Vernier callipers depth, thickness, width, etc. of vari-
ous items.
YE0026
7 Depth Micrometer Measures the sinkage of the valve.
YE0027
68E-88E SERIES 5-5

(1)
Measures inclination of valve spring,

8 Square
squareness of engine parts, etc.
YE0028
9 V-block Measures bent shaft.
YE0029
YE0030
Used for tightening bolts and nuts to

10 Torque wrench
the specified torques.
YE0031
Measures gaps between the piston

rings and mating ring grooves and
11 Thickness gauge
around shaft couplings during instal-
lation
YE0032
Checks the fresh water system for

12 Cap tester
leakage.
YE0033
Checks the antifreeze for concentra-

13 Battery coolant tester tion and the battery electrolyte for
specific gravity, and charging state.
YE0034
5-6 68E-88E SERIES

(1)
Checks the fuel injection valve for

14 Nozzle tester spray patterns and injection pres-
sure.
YE0035
Measures temperature of each part.

15 Digital thermometer
1) Probe 1
YE0036
Measures RPM of the rotary shaft by

Contact type bringing the gage head into contact
with the mortise.
YE0037
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
Measures engine RPM’s using pulse

system, irrelevantly to the center of 1
High pressure fuel the rotary shaft and the circumfer-
pipe clamping type ence of the rotary object.
1) High-pressure pipe
YE0039
68E-88E SERIES 5-7

(1)
Measures the resistance, voltage,

17 Circuit tester
and continuity of electric circuits.
YE0040
Measures compression pressure.
18 Compression gauge kit Model Code No.

All model TOL-97190080
YE0041
5-8 68E-88E SERIES

(1)
6. MEASUREMENT, INSPECTION AND ADJUSTMENT
6.1 Measuring the compression pressure..................................................................................................... 6-2

6.2 Adjusting the valve head clearance ........................................................................................................ 6-4
6.3 Checking the V-belt tension .................................................................................................................... 6-5
6.4 Measuring and checking the injection pressure and spray patterns of the fuel injection valve............... 6-6
6.5 Checking and adjusting the fuel injection timing ................................................................................... 6-10
6.6 Adjusting the no-load maximum (or minimum) revolutions ................................................................... 6-13
6.7 Checking the cooling water system and radiator for water leakage ..................................................... 6-13
6.8 Checking the battery ............................................................................................................................. 6-14
6.9 Checking the sensors ........................................................................................................................... 6-17
6.10 Checking the oil cooler ......................................................................................................................... 6-18
6.11 Checking the piston cooling nozzle ...................................................................................................... 6-19
68E-88E SERIES 6-1

(1)
6.1 Measuring the compression pressure

1. Measuring Procedure
(1) Warm up the engine. Remove the fuel injec-
tion pipe and fuel injection valve from the
cylinder to be measured.
(2) Crank the engine before attaching the com- 1
pression gauge adapter.
★ Crank the engine when the regulator
handle has been turned to "STOP" posi-
tion (NO injection state).
★ Fro the compression gauge and com-
pression gauge adapter, refer to Chap-
ter 5, 5.2.
YE0042
(3) Attach the compression gauge adapter and
compression gauge to the cylinder to be
measured. Measuring the compression pressure
★ Never fail to attach the gasket to the tip 1) Compression gauge
of the adapter.
(4) Crank the engine by the starting moter until
the reading of the compression gauge is
stabilized, by taking steps shown in (2), ★.
[Reference: List of Engine Compression Pressures]
Compression pressure at 250 rpm (MPa {kg/cm2}) Dispersion of compression pressure

Model
among cylinders (MPa {kg/cm2})
Standard LImit
2D68E 3.24 ± 0.1 {33 ± 1} 2.45 {25} 0.20 – 0.29 {2 – 3}
3D68E 3.24 ± 0.1 {33 ± 1} 2.45 {25} 0.20 – 0.29 {2 – 3}
3D74E 3.43 ± 0.1 {35 ± 1} 2.65 {27} 0.20 – 0.29 {2 – 3}
3D78AE 3.14 ± 0.1 {32 ± 1} 2.45 {25} 0.20 – 0.29 {2 – 3}

3D82AE 3.04 ± 0.1 {31 ± 1} 2.35 {24} 0.20 – 0.29 {2 – 3}
3D82E 3.04 ± 0.1 {31 ± 1} 2.35 {24} 0.20 – 0.29 {2 – 3}
3D84E 3.24 ± 0.1 {33 ± 1} 2.45 {25} 0.20 – 0.29 {2 – 3}

3D88E 3.43 ± 0.1 {35 ± 1} 2.65 {27} 0.20 – 0.29 {2 – 3}
4D82E 3.04 ± 0.1 {31 ± 1} 2.35 {24} 0.20 – 0.29 {2 – 3}
4D84E 3.24 ± 0.1 {33 ± 1} 2.45 {25} 0.20 – 0.29 {2 – 3}

4D88E 3.43 ± 0.1 {35 ± 1} 2.65 {27} 0.20 – 0.29 {2 – 3}
(S)3D84E 2.94 ± 0.1 {30 ± 1} 2.35 {24} 0.20 – 0.29 {2 – 3}
(S)4D84E 2.94 ± 0.1 {30 ± 1} 2.35 {24} 0.20 – 0.29 {2 – 3}
6-2 68E-88E SERIES

(1)
[Reference: Variation of Compression Pressure with Engine Speed]

3D74E
3.92 {40}
Compression pressure
3.43 {35}
(MPa {kg/cm2})
2.94 {30}
2D68E, 3D68E
2.45 {25}
1.96 {20}
200 250 300 350 400

Engine speed (rpm) YE0318
(2) Direct Injection system
3D88E, 4D88E
3.92 {40}
3D84E, 4D84E
Compression pressure
3.43 {35}
(MPa {kg/cm2})
3D78AE
2.94 {30}
3D82AE, 3D82E, 4D82E

2.45 {25}
(S)3D84E, (S)4D84E
1.96 {20}
200 250 300 350 400

Engine speed (rpm) YE0319
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.
68E-88E SERIES 6-3

(1)
6.2 Adjusting the valve head clearance

(1) Inspect and adjust a valve head clearance
while the engine is in cold state.
(2) Raise the piston in the cylinder to be mea-
sured to the top dead center (TDC) of com-
pression.
(3) Loosen the lock nut and adjusting screw.
Make sure that the valve cap is free from
inclination or trapped dirt.
(4) Insert a thickness gauge in between the
rocker arm and valve cap. Tighten the
adjusting screw until the clearance listed
below is attained. YE0045
All models
Intake/exhaust valve head 1

0.15 – 0.25 mm
clearance
3 2
1) Adjusting screw
2) Lock nut
3) Valve clearance
★ If the valve cap is worn or otherwise

damaged on the head, replace it with a
new one. YE0046
★ Make sure that the valve cap is nested
on the head of intake/exhaust valves. (Adjusting the valve head clearance)
4) Valve cap
5) Normal
4
6) Abnormal
5 6
YE0047
6-4 68E-88E SERIES

(1)
6.3 Checking the V-belt tension

Push the center of the V-belt between the alter-
nator and cooling water pump with a finger. If
the deflection is 10-15 mm, the V-belt tension is
acceptable. If not, adjust the V-belt tension
using the adjuster at the alternator.
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
(Adjustment of the V-belt tension)
68E-88E SERIES 6-5

(1)
6.4 Measuring and checking the injection pressure and spray

patterns of the fuel injection valve
1. Measuring the injection pressure
★ Thoroughly remove carbon deposits from
the injection nozzle before making measure-
ment.
(1) Connect the fuel injection valve to the high
pressure pipe of the nozzle tester.
(2) While pumping the lever of the nozzle tester 2
slowly, read the pressure gauge on the noz-
zle tester the moment the nozzle starts fuel
injection.
★ For injection pressure of each engine,
refer to Chapter 1, "Specifications and 1
Performance".
(3) If the measured injection pressure is lower
YE0050
than the specified value, replace the pres-
sure adjusting shim with a thicker one. (Measuring the injection pressure with a nozzle
tester)
1) Injection nozzle
2) Nozzle tester
Type of pressure shim

injection pressure adjustment
thickness (mm)
Increase the pressure adjusting shim the thickness by 0.1

Indirect injec-
0.1, 0.2, 0.3, 0.4, 0.5 mm and the injection pressure is increased by 0.69-0.98
tion system
MPa {7-10 kg/cm2}.
Increase the pressure adjusting shim the thickness by 0.1

Direct injec-
0.13, 0.15, 0.18, 0.4, 0.5, 0.8 mm and the injection pressure is increased by about 1.86
tion system
MPa {19 kg/cm2}.
6-6 68E-88E SERIES

(1)
[Reference:Structure of fuel injection valve]
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
6) Nozzle assembly (Direct Injection system)

6a) Nozzle valve 1) Fuel return pipe joint
6b) Nozzle body 2) Nozzle holder
7) Nozzle case nut 3) Pressure adjusting shim
4) Nozzle spring
5) Nozzle spring seat
6) Valve stop spacer
7) Nozzle assembly
7a) Nozzle valve
7b) Nozzle body
7c) Dowel pin
8) Nozzle case nut
68E-88E SERIES 6-7

(1)
2. Checking the spray patterns

While pumping the lever of the nozzle tester 4-6 times per second at the specified injection pressure (Refer
to Chapter 1, specifications and performance), check the spray patterns. If the following trouble is found,
clean or replace the nozzle.
(1) Make sure that the pattern is neither stream nor sliver.
(2) Ensure that fuel is sprayed conically around the nozzle center line and that a fuel injection spreading
angle is 5-10° in the indirect injection system or approx. 150° in the direct injection system.
[Normal spray pattern]
YE0053
YE0054
(Indirect Injection system) (Direct Injection system)
[Abnormal spray patterns]
YE0055
YE0056
(Indirect injection system) (Direct injection system)
(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.
6-8 68E-88E SERIES

(1)
3. Nozzle valve sllding test

Thoroughly wash the nozzle valve using clean diesel oil. Hold the nozzle body vertically, and lift the nozzle
valve approx. 1/3 of its length with one hand.
Check to see if the nozzle falls smoothly by itself gravity when released. If so, the nozzle valve is good. In
case of a new nozzle, remove the seal peel, and immerse it in clean diesel oil or the like to clean the inner
and outer surfaces and to thoroughly remove rust-preventive oil before using the nozzle.
Note that a new nozzle is coated with rust-preventive oil and is pasted with the seal peel to shut off outer air.
YE0057
YE0058
(Nozzle valve sliding check by gravity for indi- (Nozzle valve sliding check by gravity for direct
rect injection system) injection system)
4. Nozzle body identification number
Design code Design code

Size : size P
: size S
No code: pintle type Injection angle
D: throttle type
Nozzle insertion angle
Code A: angled
Size : size P No code: no angle
: size S
Type: DLL (semi-long type)
Injection angle
YANMAR
Type: pintle type
YANMAR Identification
number
Identification
number
YE0320
YE0321
68E-88E SERIES 6-9

(1)
6.5 Checking and adjusting the fuel injection timing

1. Indirect injection system
(1) Using the crankshaft pulley, turn the engine
in the specified direction. Check the injec-
tion timing at the delivery valve of the fuel
injection pump for cylinder No.1. (Cylinders
are numbered sequentially from cylinder
No.1 from the flywheel side).
(2) When the crankshaft is turned in the speci- 1
fied direction, oil level rises at the tip of the
delivery valve spring holder. At that time,
stop the crankshaft. YE0061
(3) Identify the timing mark stamped on the fly-
wheel through the access hole of the fly-
wheel housing.
★ For the fuel injection of each engine 2
model, refer to Chapter 1, Specifications
and Performance.
2) Cylinder No. 1
3) Flywheel housing
YE0062
4) Access hole
5) Timing mark
3
4
YE0063
YE0064
6-10 68E-88E SERIES

(1)
(4) If the present injection timing differs from the

specified timing, remove the fuel injection
pump, and adjust the timing by increasing or
decreasing the adjusting shim thickness
between the fuel injection pump and gear
case.
• Increase the shim thickness to delay the
injection timing.
• Decrease the shim thickness to advance
the injection timing.
6) Adjusting shim 6
YE0065
2. Direct injection system

(1) Using the crankshaft pulley, turn the engine
in the specified direction. Check the injec-
tion timing at the delivery valve of the fuel
injection pump for cylinder No.1. (Cylinders
are numbered sequentially from cylinder
No.1 from the flywheel side).
(2) When the crankshaft is turned in the speci- 1

fied direction, the oil level rises at the tip of
the delivery valve spring holder. At that time,
stop the crankshaft.
YE0061
2
2) Cylinder No. 1
YE0067
68E-88E SERIES 6-11

(1)
(3) Identify the timing mark stamped on the fly-

wheel through the access hole of the fly-
wheel housing. 3
★ For fuel injection timing for each engine
model, refer to Chapter 1, Specifications
and Performance.
3) Flywheel housing
4) Access hole
5) Timing mark
4
YE0063
(4) If the measured injection timing differs from

the specified timing, adjust the injection tim- YE0064
ing by turning down the fuel injection pump

toward the engine or to the opposite side
after loosening the lock nut of the fuel injec-
tion pump.
• If injection timing is late, turn down the
fuel injection pump away from the en-
gine.
• If the injection timing is too early, turn the
injection pump down toward the engine.
7) Lock nut
7
YE0322
6-12 68E-88E SERIES

(1)
6.6 Adjusting the no-load maximum (or minimum) revolutions

(1) First warm up the engine. Then, gradually
increase the engine speed up to the no-load
max. revolution (Refer to Chapter 1, Specifi- 1
cations and Performance). 3 2
(2) If the present no-load max. revolution differ
from the specified one, adjust the no-load
max. revolution adjusting bolt.
(3) Set the engine to the idling revolution,
(Refer to Chapter 1, Specifications and Per-
formance) by turing the no-load min. revolu-
4
tion adjusting bolt.
★ The illustration shows the partial per-
spective view of the governor for the
5
direct injection system.
7 6
1) No-load maximum revolution
adjusting bolt
2) Increase
3) Decrease
4) No-load minimum revolution YE0071
adjusting bolt
5) Increase 6) Decrease
7) Regulator handle
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
(Checking the radiator cap)
68E-88E SERIES 6-13

(1)
6.8 Checking the battery

1. Structure of the battery
1 2
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
2. Checking the battery

(1) Electrolyte level
Check the electrolyte level in each cell. If the
level is low, add deionized water to bring the
level to the UPPER level as illustrated at
right.
9) Lower limit
10) Upper limit 10
11) Acceptable 9
12) Too low
13) Too high YE0075
14) Liquid level
11 12 13
14
YE0076
6-14 68E-88E SERIES

(1)
(2) Battery charge

Using a battery tester or hydrometer, check
the state of the battery. If the battery is dis-
charged, recharge it.
• Measurement with a battery tester

To check the battery with a battery
tester, securely hold the (+) terminal of
the battery with the red clip of the bat-
tery tester and the (–) terminal with the
black clip. Judge battery charge level
from the indicator position:
Green zone: normal
Yellow zone: somewhat discharged
Red zone: abnormal or much
discharged 15
YE0077
(Measuring the battery charge with battery
15) Battery tester tester)
• Measurement with a hydrometer

When using a hydrometer, correct the
measured specific gravity according to
the temprerature. The specific gravity of
the electrolyte of the battery is the stan-
dard when measured at 20°C. Correct
the specific gravity according to the fol-
16
lowing equation, as it changes by
0.0007 per 1°C.
S20 = St + 0.0007 (t – 20)
Measured electrolyte
temperature
Measured specific gravity
Specific gravity converted to

20°C YE0078
(Measuring the remaining battery charge with

hydrometer)
16) Float
68E-88E SERIES 6-15

(1)
Hydrometer and remaining battery charge
Specific gravity Discharged Remaining

17
(at 2°C) level (%) level (%)
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
(How to read a hydrometer)
(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.
(5) Appearance of the battery

Replace the battery if cracked or deformed.
Clean it using fresh water if contaminated.
6-16 68E-88E SERIES

(1)
6.9 Checking the sensors

1. Checking the thermostat and thermoswitch
(1) Thermostat
Put a thermostat into water in a container. 1
While measuring water temperature, heat

the water. Make sure that the thermostat
functions at a temperature of 69.5 – 72.5°C.
(80.5 – 83.5°C are used as option parts) 2
(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
2. Lub. oil pressure switch

Remove the connector from the lub. oil pressure
4
switch.
While running the engine, bring the tester
probes into contact with the switch terminal and
5
cylinder block. If the tester shows continuity, the
lub. oil pressure switch is defective.
6
1) Thermometer 6) Thermoswitch
2) Thermostat 7) Thermometer
3) To radiator 8) Tester probes YE0082
4) Cover 9) Cylinder block

5) Thermostat (flywheel side) 7
10) Tester probes
YE0083
9
10
YE0084
(Continuity test)
68E-88E SERIES 6-17

(1)
6.10 Checking the oil cooler

The oil cooler is of the core type and cooled by fresh water. It is installed as a standard component on turbo-
charged engines in the Present series.
(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
1) Joint for draining 4) Oil inlet

2) Cooling water outlet 5) Oil outlet
3) To bypass valve 6) Cooling water inlet
6-18 68E-88E SERIES

(1)
6.11 Checking the piston cooling nozzle

The piston cooling nozzle is installed as a standard component on turbocharged engines in the Present
series.
(1) Piston cooling nozzle function

A nozzle made of a steel pipe is installed below the main gallery in the cylinder body. The lubricating oil
from the main gallery is constricted at the nozzle hole ( 1.77mm) at the tip end of the steel pipe to be
jet-sprayed. This jet spray comes into contact with the rear face of the piston for cooling it.
Jet flow rate 1.3 l/min
Jetting pressure 0.34 MPa {3.5 kg/cm2}
2
YE0086
1) Piston 4) Main gallery

2) Cooling nozzle 5) Spray
3) Ball valve
(2) Checking the piston cooling nozzle

• Check the nozzle hole at the tip end for clogging with dirt or foreign matter, and clean it.
• Check the brazed portion of the steel pipe for loosening or freeing by vibration. Replace with a new
part if defective.
68E-88E SERIES 6-19

(1)
7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION
7. MEASURING PROCEDURES, SERVICE DATA AND

CORRECTIVE ACTION
7.1 Cylinder head.......................................................................................................................................... 7-2

7.2 Cylinder block ....................................................................................................................................... 7-10
7.3 Valve rocker arm................................................................................................................................... 7-14
7.4 Piston and piston ring ........................................................................................................................... 7-17
7.5 Connecting rod ..................................................................................................................................... 7-23
7.6 Camshaft .............................................................................................................................................. 7-28
7.7 Crankshaft ............................................................................................................................................ 7-31
7.8 Gears .................................................................................................................................................... 7-34
7.9 Trochoid pump...................................................................................................................................... 7-36
68E-88E SERIES 7-1

(1)
★ 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.
7.1 Cylinder head

1
1. Distortion and inspection of the combustion
surface
(1) Remove intake/exhaust valves and fuel
injection valve from the engine. Clean the
surface of the cylinder head.
(2) Place a straight-edge along each of thr four
sides and each diagonal of the cylinder
head. Measure the clearance between the
straight-edge and combustion surface with a 2 YE0087
thickness gauge. (Measuring the combustion surface distortion)
(Unit:mm)
Cylinder head combustion Wear

Standard
surface distortion limit 3
All models 0.05 or less 0.15
1) Straight-edge
2) Thickness gauge
3) Depth-Micrometer
4) Valve sinking depth
(3) Visually check to see if the combustion sur-

face is free from discoloration, cracks, and
crazing. In addition, use the color check kit
for cracks and crazing. YE0088
(Measuring the valve sinkage)

2. Intake\exhaust valve seats
(1) Valve sinking 4
Over long periods of use and repeated lap-
pings, combustion efficiency may drop.
Measure the sinking depth and replace the
valve and valve seat if the valve sinking
depth exceeds the standard value.
(Unit:mm)
2D68E
3D74E
3D68E
Stan- Wear Wear

Standard
dard limit limit
Intake
Valve 0.3–0.5 1.0 0.4–0.6 1.0
valve
sinking
depth Exhaust 0.75–
1.0 0.75–0.95 1.0
valve 0.95 YE0089
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
7-2 68E-88E SERIES

(1)
(2) Width and angle of the valve seat

Remove carbon deposits from the seat sur-
face. Measure width and angle of the seat
using vernier calipers and an angle gauge.
(Unit:mm)
2D68E
3D74E
3D68E
Wear Wear
Standard Standard
limit limit
Valve Intake 1.5 1.65 1.44 1.98

seat width Exhaust 1.41 1.91 1.77 2.27
Valve Intake 120° — 120° —
seat
angle Exhaust 90° — 90° —
YE0090
(Unit:mm) (Measuring the valve seat width)
3D82E,4D82E,
3D78A
(S)3D84E,(S)4D84E
3D82AE
3D88E,4D88E
Wear Wear
Standard Standard
limit limit
Valve Intake 1.36–1.53 1.98 1.07–1.24 1.74

seat width Exhaust 1.66–1.87 2.27 1.24–1.45 1.94
Valve Intake 120° — 120° —
seat
angle Exhaust 90° — 90° —
68E-88E SERIES 7-3

(1)
[Valve Seat Correction Procedure]

(1) When the seat surface is worn or roughened
slightly, lap the seat surface withe a valve
compound mixed with oil to a smooth state.
(2) When the seat surface is worn or roughened 1
heavily, correct seat surface using a seat
grinder or seat cutter, and finish it according
to step (1).
1) Seat grinder
2) Grindstone
3) Seat width 2 YE0091
4) Valve seat
[Procedure for Using The Seat Grinder and Seat

Cutter]
(1) Correct the roughened seat surface with a
seat grinder or seat cutter.
3
Seat grinder Angle ( ) θ
Intake valve 30°
Exhaust valve 45°
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).
7-4 68E-88E SERIES

(1)
[Extraction of Valve seat]

1
2D68E,3D68E All
Without
3D74E VM
valve seat
Direct injection system CL and VM
3D74E(IDI) CH and VH
With valve
Direct injection system CH and VH
seat
Turbocharged engine All
(1) Grind the circumference of the intake/

exhaust valve head being or having been 2
used to the dimension smaller than the
valve seat outer diameter.
YE0093
(2) Grind the circumference of the stem end of
the valve to the same dimension as the fit-
ting diameter of the cotter.
(3) Weld the intake/exhaust valve head with the
valve seat at three positions.
(4) Hit the stem end of the intake/exhaust valve 3
to extract the valve seat.
1) Grind (Grind to the same dimension

as the fitting diameter of the cotter)
4
2) Grind to a smaller dimension than
the outer diameter of the valve seat.
3) Weld the valve with valve seat at YE0094
three positions
4) Valve seat
[Insertion of valve seat]

(1) Put the valve seat in a container which con-
tains liquefied nitrogen, or ether or alcohol
with dry ice to cool it sufficiently.
(2) Heat the cylinder head around the portion 4
for valve seat insertion to 80 – 100°C with a
dryer.
(3) With the new intake/exhaust valve, securely
insert the sufficiently cooled valve seat into
the cylinder head by tapping the head of the
intake/exhaust valve.
(4) Stand the cylinder head until the entire cylin-
der head is cooled to normal temperature.
YE0095
(Insertion of valve seat)
68E-88E SERIES 7-5

(1)
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.
(2) Valve stem and valve guide

Oil clearance is difference between the valve guide inside diameter measured with a three-point
micrometer (capable of measuring inside diameter between 4 mm and 8 mm) or a cylinder gauge
(capable of measuring 6 mm or greater inside diameter) and the stem outside diameter measured with
a micrometer. When oil clearance is near the limit, replace both the intake/exhaust valve and valve
guide with new ones.
(Unit:mm)
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
(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
7-6 68E-88E SERIES

(1)
(3) Thickness of valve head

Measure the thickness of the valve head
with a micrometer.
When the measured value is near the wear
limit, replace the valve with a new one.
(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
(Unit:mm) 1) Seat width

3D82E,4D82E 2) Valve diameter
3D78AE
(S)3D84E,(S)4D84E 3) Seat angle
3D82AE
3D88E,4D88E
4) Thickness
Wear Wear
Standard Standard
limit limit
Thick- Intake 1.244–

0.50
1.244–
0.50
ness of valve 1.444 1.444
valve Exhaust
head 1.35–1.55 0.50 1.35–1.55 0.50
valve
68E-88E SERIES 7-7

(1)
[Replacing the Valve Guide]

(1) Extract the valve guide from the cylinder
head using the valve guide extraction tool.
★ For the valve guide extraction tool, refer 1
to Chapter 5, 5.1.
(2) In a container containing liquefied nitrogen,
ether or alcohol together with dry ice, put the
valve guide to cool it. Then hit the suffi-
ciently cooled valve guide to fit into the cylin- 2
der head using the valve guide insertion
tool. 3
★ For the valve guide insertion tool, refer YE0098
to Chapter 5,5.1.
(3) After inserting the valve guide, finish the
inside of the valve guide with a reamer.
(4) Check the projection of the valve guide.
(Unit:mm)
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
Standard Wear limit Standard Wear limit (Valve guide projection)

Valve guide
12 — 15 —
projection 4
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.)
1) Valve guide insertion tool

2) Valve guide projection
3) Valve guide
4) Valve stem seal
5) Cylinder head
7-8 68E-88E SERIES

(1)
5. Checking the valve spring

(1) Visually check to see if the valve spring is
free from flaws and corrosion.
(2) Measure the free length (length of the
spring) and inclination (squareness of the
side of the coil).
(Unit:mm)
2D68E
3D74E
3D68E
Wear Wear
Standard Standard
limit limit
Free length 28 — 37.4 —

Inclination — 0.8 — 1.0 YE0101
Valve
Tension (kg) (Measuring the free length)
spring
(when com- 1.14– 2.37/1.87
— —
pressed to 1.40 (*1)
by 1mm)
*1 Tension at variable pitch

(Unit:mm)
3D82E,4D82E
3D78AE (S)3D84E
3D82AE (S)4D84E
3D88E,4D88E
Wear Wear
Standard Standard
limit limit
Free length 44.4 — 42 — YE0102
Inclination — 1.1 — 1.1 (Measuring the valve spring inclination)

Valve
Tension (kg)
spring 2.36/
(when com- 3.61/2.71
— 3.101 —
pressed to (*1)
(*1)
by 1mm)
1
*1 Tension at variable pitch
3
2
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.
68E-88E SERIES 7-9

(1)
7.2 Cylinder block

1
1. Checking the cylinder block
(1) Visually check to see if the cylinder block is
free from water leak, oil leak and cracks.
If any cylinder block is suspected to be
cracked, check it by color check.
(2) Replace the cylinder block if badly damaged
and incorrectable.
(3) Thoroughly clean each oil hole. Make sure
that it is not clogged.
2. Measuring the bore and distortion of the cyl-

inder
Measure the bore of each cylinder with a cylin-
der gauge. Measure the cylinder at point a,
approx. 20 mm below the crest of the liner, and
at points b and c at equal pitch (a – b = b – c).
Obtain distortion (roundness and cylindricity of
each cylinder) from the measured values as fol-
lows:
• Roundness: YE0104
Difference between max. and min. bore val-
(Measuring the cylinder bore)
ues on the same cross section of each liner.
• Cylindricity:
1) Cylinder gauge
Difference between max. and min. bore val-
ues in the same direction of each liner.
20
Honing (honing and boring) is required when the a
measured value exceeds the limit.
★ For oversized piston and piston ring, refer to
this chapter, 7.4, 8.
b
YE0105
(Cylinder bore measuring positions)
NOTE: Measurement should be made at a, b and c

in the directions of A and B.
7-10 68E-88E SERIES

(1)
(Unit:mm)
2D68E
3D74E
3D68E
Cylinder bore 68.000–68.030 68.20 74.000–74.030 74.20

Cylinder roundness 0.00–0.01 0.03 0.00–0.01 0.03
Cylindricity 0.00–0.01 0.03 0.00–0.01 0.03
(Unit:mm)
3D82AE
3D78AE 3D82E
4D82E
Cylinder bore 78.000–78.030 78.20 82.000–82.030 82.20
Cylindricity 0.00–0.01 0.03 0.00–0.01 0.03
(Unit:mm)
(S)3D84E 3D88E
(S)4D84E 4D88E
Cylinder bore 84.000–84.030 84.20 88.000–88.030 88.20
Cylindricity 0.00–0.01 0.03 0.00–0.01 0.03
68E-88E SERIES 7-11

(1)
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
2D68E,3D68E 129400-92400 63–70
3D74E 129400-92410 70–76 1) Flex-Hone 4) Diesel oil

2) Power drill 5) Honing liquid
3D78AE,3D82AE
3D82E,4D82E 3) Engine oil
129400-92420 76–89
(S)3D84E
(S)4D84E
3D88E,4D88E 129400-92430 83–95
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.
7-12 68E-88E SERIES

(1)
4. Overhaul of cylinder (Reference)
Service life of sleeveless cylinder block (H3)

(H3 = 3H1)
Time for boring and honing (H2)

(H2 = 1.5H1)
Time for honing (H1)
Increase in lub.oil Increase in lub.oil Increase in lub.oil Increase in lub.oil

consumption consumption consumption consumption
or blow-by or blow-by or blow-by or blow-by
Honing Boring
Consideration
on the applicability
of oversized
pistons and piston rings
YE0339
68E-88E SERIES 7-13

(1)
7.3 Valve rocker arm

1. Measuring the outside diameter of rocker arm
shaft and inside diameter of rocker arm
Oil clearance is the difference between the
rocker arm inside diameter measured with a cyl-
inder gauge and the rocker arm shaft outside
diameter measured with a micrometer. When
the oil clearance is near the limit, replace the
rocker arm shaft and rocker arm with new ones.
YE0110
(Measuring the rocker arm shaft outside
diameter)
YE0111
(Measuring the rocker arm inside diameter)
(Unit:mm)
3D78AE,3D82AE
3D82E,4D82E
2D68E,3D68E 3D74E
(S)3D84E,(S)4D84E
3D88E,4D88E
Standard Wear limit Standard Wear limit Standard Wear limit

Rocker arm
15.966–
shaft outside 9.972–9.987 9.95 11.966–11.984 11.95 15.95
15.984
Intake/ diameter
exhaust
Rocker arm
rocker 16.000–
bushing inside 10.000–10.020 10.09 12.000–12.020 12.09 16.09
arm 16.020
diameter
Oil clearance 0.013–0.048 0.14 0.016–0.054 0.14 0.016–0.054 0.14
7-14 68E-88E SERIES

(1)
2. Checking push rod bend, measuring tappet

outside diameter and checking contact sur-
face
Put the push rod on the stool, and measure the
gap between the push rod and stool to make
sure the push rod is in close contact with the
stool. Also, measure the outside diameter of the
tappet with amicrometer.
1) Thickness gauge
1
YE0112
(Measuring the push rod bend)
(Unit:mm)
3D78AE,3D82AE
3D82E,4D82E
2D68E,3D68E 3D74E
(S)3D84E,(S)4D84E
3D88E,4D88E
Wear Wear Wear

Standard Standard Standard
limit limit limit
Push rod bending 0.03 or less — 0.03 or less — 0.03 or less —
Tappet stem out-

17.950–17.968 17.93 20.927–20.960 20.90 11.975–11.990 11.93
side diameter
Tappet Tappet guide hole

18.000–18.018 18.05 21.000–21.021 21.05 12.000–12.018 12.05
inside diameter
Oil clearance 0.032–0.068 0.12 0.040–0.094 0.15 0.010–0.043 0.12
68E-88E SERIES 7-15

(1)
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.
(2) Wear of intake/exhaust valve rocker arm

and valve cap
Check the intake/exhaust valve rocker arm
for their contact surfaces with valve cap. If
any of them is abnormally worn or partially
flaked, replace it.
(3) Check the portion where the valve clear- YE0113

ance adjusting screw is in contact with the
(Measuring the tappet outside diameter)
push rod. If the portion is worn and flaked,
replace the pushrod or adjusting screw.
2) Normal contact surface

3) Abnormal contact surface
4) Adjusting screw
5) Check of contact surface
6) Push rod
7) Check of contact surface
of rocker arm
3 2 YE0114
(Checking the tappet contact surface)
YE0115
7-16 68E-88E SERIES

(1)
7.4 Piston and piston ring

1. Checking the piston
(1) Remove carbon deposits from the head and
combustion surface of the piston so as not
to impair the piston. Check to see if there is
any crack or damage.
(2) Check the circumference and ring groove of
the piston, and replace if worn or damaged.
1
1) Measurement position
22~25mm
YE0116
2. Measuring the piston outside diameter

To measure the piston outside diameter, mea-
sure the long diameter of the oval hole in vertical
direction to the pin hole and at a position 22-25
mm from the lower end of the piston.
YE0117
(Measuring the piston outside diameter)
(Unit:mm)
2D68E 3D82E (S)3D84E 3D88E
3D74E 3D78AE 3D82AE
3D68E 4D82E (S)4D84E 4D88E
Wear Wear Wear Wear Wear Wear Wear

Standard Standard Standard Standard Standard Standard Standard
limit limit limit limit limit limit limit
Piston outside 67.960– 73.940– 77.950– 81.950– 81.945– 83.945– 87.945–

67.90 73.90 77.90 81.90 81.90 83.90 87.90
diameter 67.990 73.970 77.980 81.980 81.975 83.975 87.975
Minimum clear-
ance between 0.025– 0.045– 0.035– 0.035– 0.040– 0.040– 0.040–
— — — — — — —
piston and cylin- 0.055 0.075 0.065 0.065 0.070 0.070 0.070
der
68E-88E SERIES 7-17

(1)
3. Shapes of piston rings
Model 2D68E, 3D68E, 3D74E

1
Application VM CH,VH
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
4. Measuring the ring groove width, ring width,

and end clearance
To measure the piston ring groove width, first
measure the width of the piston ring. Then,
insert the piston ring into the ring groove that
has been carefully cleaned. Insert a thickness
gauge in between the piston ring and groove to
measure the gap between them. Obtain the ring
groove width by adding ring width to the mea-
sured side clearance.
YE0123
(Measuring the side clearance)
1) Width
2) Thickness
3) Side clearance
4) Ring
5) Piston 1 3
5 4
YE0323
2 YE0124
7-18 68E-88E SERIES

(1)
To measure the end clearance, push the piston

ring into the sleeve using the piston head, insert 6
a thickness gauge in end clearance to measure.
If the sleeve is worn, measure the end clearance
after pushing the piston ring to the portion of the
7
sleeve which is less worn (approx. 30 mm from
the lower end of the lseeve).
8
6) End clearance
7) Approx. 30mm
9
8) Piston ring
9) Cylinder block
YE0125
(Measuring the end clearance of piston ring)
(Unit:mm)
3D82E, 4D82E
2D68E
3D74E 3D78AE (S)3D84E 3A88E, 4D88E
3D68E
(S)4D84E
Wear Wear Wear Wear Wear

Standard Standard Standard Standard Standard
limit limit limit limit limit
Ring groove 1.550– 1.550– 2.035– 2.065– 2.060–
— — — — —
width 1.570 1.570 2.050 2.080 2.075
1.470– 1.470– 1.940– 1.970– 1.970–
Ring width — — — — —
1.490 1.490 1.960 1.990 1.990
Top ring
Min.side 0.060– 0.060– 0.075– 0.075– 0.070–
— — — — —
clearance 0.100 0.100 0.110 0.110 0.105
End clear- 0.100– 0.200– 0.200– 0.200– 0.200–
1.5 1.5 1.5 1.5 1.5
ance 0.250 0.400 0.400 0.400 0.400
Ring groove 1.540– 1.520– 2.025– 2.035– 2.025–
— — — — —
width 1.555 1.535 2.040 2.050 2.040
1.430– 1.410– 1.975– 1.970– 1.970–
1.450 1.430 1.990 1.990 1.990
2nd ring
Min.side 0.090– 0.090– 0.035– 0.045– 0.035–
— — — — —
clearance 0.125 0.125 0.065 0.080 0.070
End clear- 0.150– 0.200– 0.250– 0.200– 0.200–
1.5 1.5 1.5 1.5 1.5
ance 0.350 0.400 0.400 0.400 0.400
Ring groove 3.010– 3.010– 3.015– 4.015– 4.015–
— — — — —
width 3.025 3.025 3.030 4.030 4.030
2.970– 2.970– 2.970– 3.970– 3.970–
2.990 2.990 2.990 3.990 3.990
Oil ring
Min.side 0.020– 0.020– 0.025– 0.025– 0.025–
— — — — —
clearance 0.055 0.055 0.060 0.060 0.060
End clear- 0.150– 0.150– 0.200– 0.200– 0.200–
1.5 1.5 1.5 1.5 1.5
ance 0.350 0.350 0.400 0.400 0.400
68E-88E SERIES 7-19

(1)
5. Reassembly of piston ring

(1) Using the piston ring replacer, insert the pis-
ton ring into the ring groove, with the manu-
facture’s mark near the joint of the piston
ring facing up to the combustion chamber
side. After fitting the piston ring, make sure
1
that the piston ring moves freely.
(2) Stagger the piston rings joints at 120° inter-

vals, making sure that they are not aligned
2
along the piston. Apply lube oil to the cir-
cumference of the piston.
3
7
6
YE0126
6. Measuring the outside diameter of the piston

pin and the pin hole diameter
Measure outside diameter of the piston pin and
pin hole diameter. Replace the piston pin if the
wear limit is exceeded.
Apply lubricating oil to the piston pin before
inserting it into the piston.
YE0128
(Measuring point of the piston pin O.D.)
1) The side with manufacturer's

mark shall face upward.
2) Top ring 5) Top ring
3) 2nd ring 6) Oil ring
4) Oil ring 7) 2nd ring
YE0127
(Measuring the piston pin outside diameter)
7-20 68E-88E SERIES

(1)
(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
7. [Reference] Top clearance

(Unit:mm)
2D68E
3D74E
3D68E
Wear Wear
Standard Standard
limit limit
Top 0.610– 0.658–
— —
(Unit:mm)
3D82E,4D82E
3D78AE (S)3D84E
3D82AE (S)4D84E
3D88E,4D88E
Wear Wear
Standard Standard
limit limit
Top 0.650– 0.660–
— —
68E-88E SERIES 7-21

(1)
8. List of the oversized piston and piston ring

(0.25OS: Oversized by 0.25 mm)
Size Piston ass’y code

Model Piston ring ass’y code
classification (including piston ring ass’y)
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
7-22 68E-88E SERIES

(1)
7.5 Connecting rod

m
0m
1. Visual inspection 10
Inspect the portion near the boundary of the
chamfered portion and I-beam section of the big m
0m 1
10
and small ends of the connecting rod as well as
the portion near the oil hole of the bushing at the
small end for cracks, deformation, and discolor-
ation.
2. Measuring the twist and parallelism 3

Measuring the twist and parallelism by use of
the connecting rod aligner.
2
(Unit:mm)
All models
Standard Wear limit

YE0130
Twist and 0.03 or less (Measuring the twist and parallelism)
0.08
parallelism per 100 mm
1) Parallelism
2) Mandrel
3) Twist
4) Connecting rod aligner 4
YE0131
(Measuring the twist with connecting rod
aligner)
68E-88E SERIES 7-23

(1)
3. Measuring the crankpin and bushing clear-

ance
To measure the oil clearance of the crankpin
and bushing, measure the inside diameter of the
crankpin metal and outside diameter of the
crankpin, and obtain the difference between
them.
If the measured oil clearance exceeds or near
the wear limit, replace the crankpin metal. If the
crankpin is excessively or unevenly worn, grind
the crankpin, and use an oversized crankpin 1
metal.
★ To measure the inside diameter of the
crankpin metal, reassemble the crankpin
metal to the connecting rod and tighten the
rod bolt to the specified torque, making sure
each metal is fitted on the correct position.
(Unit: Nm {kgm})
3D82E,4D82E YE0132
2D68E
3D68E
3D78AE (S)3D84E (Measuring the inside diameter of the crankpin
3D82AE (S)4D84E metal)
3D74E
3D88E,4D88E
1) Cylinder gauge
Specified torque
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
7-24 68E-88E SERIES

(1)
4. Measuring the oil clearance between the pis-

ton pin bushing and piston pin
To measure of oil clearance between the piston
pin bushing and piston pin, measure the inside
diameter of the piston pin bushing and outside
diameter of the piston pin, and obtain the differ-
ence between them.
(Unit:mm)
2D68E
3D74E
3D68E
Wear Wear
Standard Standard
limit limit
2
Piston pin
bushing 20.025– 21.025–
20.10 21.10
inside 20.038 21.038
diameter
Piston
pin Piston pin
19.991– 20.991–
side outside 19.90 20.90
20.000 21.000
diameter
YE0133
Oil clear- 0.025– 0.025–
ance 0.047
0.2
0.047
0.2 (Measuring the inside diameter of the piston pin
bushing)
(Unit:mm) 2) Cylinder gauge

3D82E,4D82E
3D78AE (S)3D84E
3D82AE (S)4D84E
3D88E,4D88E
Wear Wear
Standard Standard
limit limit
Piston pin
bushing 23.025– 26.025–
23.10 26.10
inside 23.038 26.038
diameter
Pis-
ton pin Piston pin
22.991– 25.987–
side outside 22.90 25.90
23.000 26.000
diameter
Oil clear- 0.025– 0.025–
0.2 0.2
ance 0.047 0.051
68E-88E SERIES 7-25

(1)
5. Checking the crankpin metal for contact

Apply a blue ink or a minium to the crankpin
metal upper surface. Attach the crankpin metal
to the connecting rod, and tighten the rod bolt to
the crankshaft to the specified torque (Refer to
this section 3) to check the metal for contact. If
the contact surface occupies 75% or more of the 1
total surface, the crankpin metal is acceptable in 2
terms of contact.
1) Crankpin metal
2) Assemble so that the punched mark of
large end faces the uel injection pump.
YE0134
6. Assembling the piston and connecting rod 3

Assemble the piston with the connecting rod,
with the mark at the big end of the connecting
rod facing the fuel injection pump. Reassemble
the piston so that the recess of the combustion
4
chamber is on the side of the fuel injection pump
as seen from the top.
5
3) Camshaft side
4) I.D. mark
5) Fuel injection pump side
6) Combustion chamber recess
7) Yanmar mark 7
YE0136
(Direct injection system piston)
6
4
5
YE0135
(Indirect injection system piston)
7-26 68E-88E SERIES

(1)
7. Side gap of the connecting rod

After attaching the connecting rod to the crank-
shaft, tighten the rod bolt to the specified torque
(see this section 3). Measure the side gap by
inserting a thickness gauge into the side gap. If
the standard is exceeded, replace the crankpin
metal or connecting rod.
(Unit:mm)
All models 1
Side gap 0.2–0.4 2
YE0137
(Measuring the connecting rod side gap)
1) Crankshaft
2) Thickness gauge
8. Oversized crankpin metal

(0.25 mm oversized)
Crankpin metal
Metal thickness
Part code No. (mm)
Standard
2D68E,3D68E 119260-23350 1.625
3D74E 119620-23350 1.625
3D78AE
119810-23350 1.625
3D82AE
3D82E,4D82E
(S)3D84E
129150-23350 1.625
(S)4D84E
3D88E,4D88E
68E-88E SERIES 7-27

(1)
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
2. Checking the camshaft for appearance

Check the camshaft for the contact surface of
the tappet to the cam, seizure and wear of the
bearing, and damage of the cam gear.
3
YE0138
3. Measuring the bend of the camshaft

Support the camshaft with V blocks. Using a dial 4
gauge, measure the runout of the journal at the
center of the camshaft, while rotating the cam-
shaft.
Take 50% of the measured runout as bend.
(Unit:mm)
All models
Standard Wear limit
Camshaft bend 0.02 or less 0.05
5
1) Camshaft gear YE0139

2) Thrust metal (Measuring the camshaft bend)
3) Side gap
4) Dial gauge
5) V block
7-28 68E-88E SERIES

(1)
4. Measuring the intake/exhaust cam height

(Unit:mm)
3D78AE,3D82AE
2D68E 3D82E,4D82E
3D74E
3D68E (S)3D84E,(S)4D84E
3D88E,4D88E
Intake
29.970–30.030 29.75 33.950–34.050 33.75 38.635–38.765 38.40
Cam cam
height Exhaust
29.970–30.030 29.75 33.950–34.050 33.75 38.635–38.765 38.40
cam
YE0141
YE0140
(Measuring the cam height)
6) Micrometer
7) Cam height
68E-88E SERIES 7-29

(1)
5. Measuring the outside diameter of the cam

shaft bearing
Measure the outside diameter of the camshaft
with a micrometer. Calculate the oil clearance 3
from measured camshaft outside diameter and 2
the camshaft bushing inside diameter measured
with a cylinder gauge after inserting the cam- 1
shaft bushing into the cylinder block.
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
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 —
6. Extracting the camshaft bushing

Extract the bushing with camshaft bushing tool
(refer to Chapter 5, 5.1.)
7-30 68E-88E SERIES

(1)
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
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. If the
crankshaft is slightly damaged, correct it by re-
grinding.
3. Checking the metal

Check the metal for flaking, melting, seizure,
and the state of the contact face. Replace the
metal if found defective.
YE0144
(Color check inspection)
4. Bend of the crankshaft
Support the crankshaft with V-blocks at both
ends of the journals; measure the runout at the
center journal with a dial gauge while rotating
3
the crankshaft to check the extent of crankshaft
bend.
(Unit:mm)
All models
4
Standard
5
Bend 0.02 or less
3) Bend
4) Deflection
5) Dial gauge 6 6
6) Set the V-block YE0145
(Measuring the crankshaft bend)
68E-88E SERIES 7-31

(1)
5. Measurement of crankpin and journal

Measure the outside diameter, roundness, taper
angle of the crankpin and the journal. If uneven
wear or roundness exceeds the wear limit but
measured outside diameter is within the limit,
use the crankpin and journal after correcting
them by regrinding.Replace them with new
ones, if any of the limit is exceeded.
An oversized crankpin metal by 0.25 mm is
available. (See this Chapter 7.5,8.)
YE0146
7
7) Crank journal
8 YE0147
8) Crankpin
(Measuring position of the crankpin and crank

journal)
(Unit:mm)
2D68E
3D74E
3D68E
Crankpin Crankpin outside diameter 35.970–35.980 35.91 39.970–39.980 39.91
Crankshaft journal out-
39.970–39.980 39.90 43.970–43.980 43.90
side diameter
Crank
Bearing metal thickness 1.487–1.500 — 1.987–2.000 —
journal
Crank journal and
0.033–0.059 0.15 0.033–0.059 0.15
bushing oil clearance
(Unit:mm)
3D82E,4D82E
3D78AE
(S)3D84E,(S)4D84E
3D82AE
3D88E,4D88E
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
7-32 68E-88E SERIES

(1)
6. Precautions in mounting the metal cap

(1) The lower metal (cap side) has no oil groove.
(2) The upper metal (cylinder block side) has an oil groove.
(3) Check the cylinder block alignment No.
(4) Place the relief mark "FW" of the cap on the flywheel side.
(5) Place the main bearing meal on the flywheel side.
3 1
YE0148
1) Main bearing metal 4) Main bearing cap (basic)

2) Main bearing cap 5) Thrust metal (flywheel side)
3) Main bearing cap bolt 6) Main bearing metal (basic)
7. Undersized main metal by 0.25 mm and the oversized thrust metal by 0.25 mm
Main metal Thrust metal

Metal thickness (mm) Metal thickness (mm)
Part code Part code
Standard Standard
2D68E,3D68E 719260-02870 1.625 119260-02940 2.125
3D74E 719620-02870 2.125 119620-02940 2.125
3D78AE,3D82AE 119810-02870 2.125 119810-02940 2.125
3D82E,4D82E
(S)3D84E,(S)4D84E 129150-02870 2.125 129150-02940 2.125
3D88E,4D88E
68E-88E SERIES 7-33

(1)
7.8 Gears
1. Checking gears
Inspect the gears and replace if the teeth are damaged, worn, or chipped.
2. Measuring the backlash

Apply a dial gauge onto the pitch circle of the gear, and measure the backlash.
(Unit:mm)
3D78AE,3D82AE
2D68E
3D82E,4D82E
3D68E
(S)3D84E,(S)4D84E
3D74E
3D88E,4D88E
Crankshaft gear, Camshaft gear, Idle
0.04–0.12 0.07–0.15
Backlash gear and Fuel injection pump drive gear
Lub.oil pump gear 0.11–0.19
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
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
1) Idle gear shaft 2) Bushing 3) Idle gear
7-34 68E-88E SERIES

(1)
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
(View the gear case)
1) Fuel injection pump drive gear 4) PTO gear (option)

2) Idle gear 5) Crankshaft gear
3) Camshaft gear 6) Lub. oil pump gear
68E-88E SERIES 7-35

(1)
7.9 Trochoid pump

1. Clearance between outer rotor and pump
body
Insert a thickness gauge between the outer rotor
and pump body to measure the clearance. 1
(Unit:mm)
All models
2
Standard Wear limit
Clearance between 3
outer rotor and 0.10–0.16 0.25
pump body
1) Outer rotor
YE0152
2) Pump body
3) Thickness gauge (Measuring the clearance between outer rotor
and pump body)
2. Clearance between outer rotor and inner ro-

tor
Insert a thickness gauge between the top of the
inner rotor tooth and the top of the outer rotor 1
tooth to measure the clearance.
(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
(Measuring the clearance between outer rotor

and inner rotor)
7-36 68E-88E SERIES

(1)
3. Side clearance between pump body and inner

rotor, outer rotor
Place a straight-edge against the end of the
pump and insert a thickness gauge between the 4
straight-edge and the rotors to measure the side
clearance.
4) Straight edge
5) Pump body 5
6) Thickness gauge
YE0154
(Measuring the clearance between the pump

body and inner-, outer-rotor)
(Unit:mm)
3D78AE,3D82AE
2D68E
3D78AE 3D82E,4D82E
3D68E
3D82AE (S)3D84E,(S)4D84E
3D74E
3D88E,4D88E
Pump body and inner-,
0.03–0.09 0.13 0.05 – 0.10 0.15 0.03 – 0.09 0.15
outer-rotor side clearance
4. Clearance between rotor shaft and side cover hole

Measure the rotor shaft outside diameter and the side cover hole diameter, and calculate the difference
between the hole diameter, and calculate the difference between the hole diameter and the outside diame-
ter.
(Unit:mm)
All models
Standard Wear limit
Clearance between rotor
0.013 – 0.043 0.2
shaft and side cover hole
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.
68E-88E SERIES 7-37

(1)
8. DISASSEMBLY AND REASSEMBLY
8.1 Disassembly ........................................................................................................................................... 8-2

8.2 Precautions before and during reassembly ............................................................................................ 8-7
68E-88E SERIES 8-1

(1)
★ 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"
Step Removal Parts Remarks
1) Thoroughly remove sand, dust, dirt

and soil from the surface of the
1 engine. —
2) Drain cooling water and lubricating
oil from the engine.
1) Remove turbocharger and

exhaust manifold .
2 —
2) Remove intake manifold and
surge tank .
1) Close the fuel cock valve of the fuel 1) If nozzle seat is left on the cylinder head, remove the
tank.
cylinder head before extracting nozzle seat .
2) Remove high-pressure fuel pipe .
2) To prevent dust from entering fuel injection nozzle ,
3) Remove fuel return pipe .
fuel injection pump and high-pressure fuel pipe ,
4) Loosen the tightening nut on fuel
3 seal their respective threads with a tape or the like.
injection nozzle retainer and
3) Whenever extracting fuel injection nozzle , replace
extract the retainer and fuel injection
nozzle protector with a new one.
nozzle .
★ Fuel injection nozzle for Indirect
injection system is screwed type.
4 1) Remove bonnet assembly . —
1) Remove valve rocker arm shaft 1) Attach a tag to push rod for each cylinder No. to put
assembly . the push rod in order.
2) Remove push rod . 2) remove valve cap from the intake/exhaust valve
head.
5 3) Note that tappet of the indirect injection system can
be removed at the same time when push rod is
extracted.
4) Attach a tag to tappet for each cylinder No. to put the
tappet in order.
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 .
8-2 68E-88E SERIES

(1)
1) Remove lubricating oil filter assem-

bly .
7 —
2) Extract dispstick from the oil dip-
stick hole.
1) Disconnect fuel return pipes to

8 . —
2) Remove fuel filter .
1) Disconnect cooling water pipe

from the cooling water pump.
9 —
2) Remove thermostat assembly .
3) Remove cooling water pump .
1) Remove cylinder head tightening 1) Lay a cardboard or the like on the floor and place cylin-
bolt . der head assembly on it so as not to damage the
2) Remove cylinder head assembly . combustion surface.
2) Order of loosening the cylinder head tightening bolts
3) Remove cylinder head gasket .
2-cylinder
Camshaft side
Gear case side

Flywheel side
Fuel injection pump side

YE0325
3-cylinder
10 Camshaft side
Gear case side

Flywheel side
Fuel injection pump side YE0066
4-cylinder
Camshaft side
Gear case side
Flywheel side
Fuel injection pump side

YE0326
68E-88E SERIES 8-3

(1)
3) To remove the intake/exhaust valves from cylinder head

assembly , take the following steps.
(1) Using valve spring composer (see Chapter 5. 5-1),
compress valve spring and remove valve cotter
.
10
1
YE0156
1) Valve spring compressor
(2) Remove valve retainer and valve spring .

(3) Remove intake retainer and exhaust valve .
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 starting motor from fly-

15 —
wheel housing .
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 .
8-4 68E-88E SERIES

(1)
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 .
20 1) Remove gear case flange . —
21 1) Remove lubricating oil strainer . —
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
68E-88E SERIES 8-5

(1)
Apply a dial gauge to the end of crankshaft . force the

crankshaft on both sides in the axial direction to mea-
sure the thrust gap. Alternatively, insert a thickness
gauge directly between the base thrust metal and the
thrust surface of the crankshaft to measure the gap. If
the limit size is exceeded, replace the thrust metal with a
new one.
(Unit:mm)
23 All models
2) Notice on the removal of thrust metal .

(1) When removing thrust metal , ascertain the posi-
tion and direction where thrust metal is installed in
relation to the cap.
(2) Make sure that the thrust metal groove is outward in
relation to the cap.
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 .
8-6 68E-88E SERIES

(1)
8.2 Precautions before and during reassembly

To reassemble engine components, reverse the procedure of diassembly. However, follow the precautions
below particularly before and during reassembly.
(1) Cleaning the component

Use particular care to clean the cylinder block, cylinder head, crankshaft, and camshaft. Ensure that they
are free from chips, dust, sand, and other foreign matter.
(2) Parts to be replaced during reassembly

Be sure to replace the following parts with new ones during assembly.
(1) Valve stem seal
(2) Head gasket packing
(3) Nozzle protector of the fuel injection valve
(4) Various copper packings, O-rings and gasket packings.
(3) Measuring the side gap around crankshaft

Apply a dial gauge to the end of the crankshaft.
Force the crankshaft on both sides in the axial
direction to measure the thrust gap. Alterna-
tively, insert a thickness gauge directly between
the base thrust metal and the thrust surface of
the crankshaft to measure the gap. If the limit
size is exceeded, replace the thrust metal with a
new one.
(Unit:mm)
All models
1
1) Dial gauge
2
2) Crankshaft YE0157
(Measurement of side gap around crankshaft)
68E-88E SERIES 8-7

(1)
(4) Gear train

After haveng installed each gear, make sure that marks (A) , (B) and (C) of the idle gear align with marks of
the fuel injection pump drive gear, camshaft gear and crankshaft gear as shown below.
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
(Viewed from gear case)
(5) Where to use liquid packings

1. Between the cylinder block and gear case flange
2. Between the gear case flange and gear case cover
3. Between the cylinder block and oil seal case (indirect injection system only)
4. Oil pan installation surface
★ Use Three Bond No. 005 (Yanmar part code: 97777-001212) as the liquid packing.
★ Apply the liquid packing so as not to form any break on the midway. Otherwise, oil leakage, etc.,
may result.
(6) Coating the lubricating oil on intake/exhaust

valve stem
Apply lubricating oil down to the lower surface
1
(hatched portion in the figure) of the valve guide
before reassembling the valve stem.
1) Valve guide
YE0160
8-8 68E-88E SERIES

(1)
(7) Reassembly of the piston ring

1. Insert the piston ring into the ring groove,
where the side with the manufacturer’s mark
on the matching ends facing up (to the com-
bustion chamber side), using a piston ring
replacer. After fitting the piston ring, make
sure it moves easily and smoothly.
2. Assemble the piston rings to the cylinder,
2
staggering the piston rings joints at 120 in-
tervals, making sure that they are not aligned
YE0161
along the piston. Apply lube oil to the circum-
ference of the piston.
2) The side with the manufacturer's

mark shall face upward. 3
3) Top ring
4) 2nd ring
5) Oil ring 4
YE0162
YE0163
68E-88E SERIES 8-9

(1)
(8) Coating the lubricating oil to pushrod adjust-

ing screw contact
Apply lubricating oil to the hatched portion of the
push rod as shown in the figure, before reas-
sembly.
6
6) Apply lubricating oil
YE0164
(9) Assembly direction of piston and connecting rod
3D78AE,3D82AE,3D82E,4D82E
2D68E,3D68E,3D74E
(S)3D84E,(S)4D84E,3D88E,4D88E
I.D. mark I.D. mark

Camshaft side
Camshaft side
Nozzle side
Nozzle side
Piston
Cylinder
size mark Flywheel side YE0327 Cylinder Flywheel side
size mark YE0328
Embossed mark Embossed mark

(Flywheel side) (Flywheel side)
Connecting rod
Alignment mark Alignment mark
YE0329 YE0330
8-10 68E-88E SERIES

(1)
(10) Order of tightening cylinder heads and tightening torque

Tighten cylinder heads in numerical order shown below to the specified torque.
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.
68E-88E SERIES 8-11

(1)
9. SERVICE DATA
9. SERVICE DATA
9.1 Cylinder head.......................................................................................................................................... 9-2

9.2 Cylinder block ......................................................................................................................................... 9-3
9.3 Valve rocker arm..................................................................................................................................... 9-3
9.4 Piston...................................................................................................................................................... 9-4
9.5 Piston ring............................................................................................................................................... 9-5
9.6 Connecting rod ....................................................................................................................................... 9-6
9.7 Camshaft ................................................................................................................................................ 9-6
9.8 Crankshaft .............................................................................................................................................. 9-7
9.9 Side gap and backlash ........................................................................................................................... 9-7
9.10 Others ..................................................................................................................................................... 9-8
68E-88E SERIES 9-1

(1)
9. SERVICE DATA
9.1 Cylinder head

(Unit: mm)
Model 3D82E,4D82E
2D68E 3D78AE
3D74E (S)3D84E,(S)4D84E
3D68E 3D82AE
3D88E,4D88E
Wear Wear Wear Wear

Standard Standard Standard Standard
Item limit limit limit limit
Cylinder head combustion

0.05 or less 0.15 0.05 or less 0.15 0.05 or less 0.15 0.05 or less 0.15
surface distortion
Valve seat Intake 120° — 120° — 120° — 120° —

angle Exhaust 90° — 90° — 90° — 90° —
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
Intake Open B.T.D.C 5–15° — 7–17° — 10–20° — 10–20° —

valve
timing Close A.B.D.C 37–47° — 35–45° — 40–50° — 40–50° —
Exhaust Open B.B.D.C 37–47° — 40–50° — 51–61° — 51–61° —

valve
timing Close A.T.D.C 5–15° — 8–18° — 13–23° — 13–23° —
Free length 28 — 37.4 — 44.4 — 42 —

Inclination — 0.8 — 1.0 — 1.1 — 1.1
Valve Tension
spring (N {kg}) 23.2 {2.37} 35.4 {3.61} 23.1 {2.36}
11.7–13.7
(when com- — (variable pitch) — (variable pitch) — (variable pitch) —
{1.14–1.40}
pressed to /18.3 {1.87} /26.6 {2.71} /30.4 {3.101}
1mm length)
Intake & exhaust valve
0.15–0.25 — 0.15–0.25 — 0.15–0.25 — 0.15–0.25 —
clearance
9-2 68E-88E SERIES

(1)
9. SERVICE DATA
9.2 Cylinder block

(Unit: mm)
2D68E
Model 3D74E 3D78AE
3D68E
Item Wear Wear Wear

limit limit limit
Cylinder bore 68.000–68.030 74.000–74.030 78.000–78.030
L mark 68.020–68.030 74.020–74.030 78.020–78.030
68.20 74.20 78.20
Cylinder bore M mark 68.010–68.020 74.010–74.020 78.010–78.020
S mark 68.000–68.010 74.000–74.010 78.000–78.010
Cylinder roundness 0.00–0.01 0.03 0.00–0.01 0.03 0.00–0.01 0.03
Cylindricity 0.00–0.01 0.03 0.00–0.01 0.03 0.00–0.01 0.03
3D82AE
Model (S)3D84E 3D88E
3D82E
(S)4D84E 4D88E
4D82E
Item Wear Wear Wear

limit limit limit
Cylinder bore 82.000–82.030 84.000–84.030 88.000–88.030
L mark 82.020–82.030 84.020–84.030 88.020–88.030
82.20 84.20 88.20
Cylinder bore M mark 82.010–82.020 84.010–84.020 88.010–88.020
S mark 82.000–82.010 84.000–84.010 88.000–88.010
Cylinder roundness 0.00–0.01 0.03 0.00–0.01 0.03 0.00–0.01 0.03
Cylindricity 0.00–0.01 0.03 0.00–0.01 0.03 0.00–0.01 0.03
9.3 Valve rocker arm

(Unit: mm)
3D78AE,3D82AE
Model 2D68E 3D82E,4D82E
3D74E
3D68E (S)3D84E,(S)4D84E
3D88E,4D88E
Item Wear Wear Wear

limit limit limit
Rocker arm
shaft outside 9.972–9.987 9.95 11.966–11.984 11.95 15.966–15.984 15.95
dia.
Intake &
Exhaust Rocker arm
rocker arm bushing inside 10.000–10.020 10.09 12.000–12.020 12.09 16.000–16.020 16.09
dia.
Oil clearance 0.013–0.048 0.14 0.016–0.054 0.14 0.016–0.054 0.14
Pushrod bending 0.03 or less — 0.03 or less — 0.03 or less —
Tappet stem out-
17.950–17.968 17.93 20.927–20.960 20.90 11.975–11.990 11.93
side dia.
Tappet Tappet guide
18.000–18.018 18.05 21.000–21.021 21.05 12.000–12.018 12.05
hole inside dia.
Oil clearance 0.032–0.068 0.12 0.040–0.094 0.15 0.010–0.043 0.12
68E-88E SERIES 9-3

(1)
9. SERVICE DATA
9.4 Piston
(Unit: mm)
2D68E
Model 3D74E 3D78AE 3D82AE
3D68E
Item Wear Wear Wear Wear

Standard Standard Standard Standard
limit limit limit limit
67.940– 73.940– 77.950– 81.950–
Piston outside dia.
67.990 73.970 77.980 81.980
67.980– 73.960– 77.970– 81.970–
L mark
67.990 73.970 77.980 81.980
67.975– 73.955– 77.965– 81.965–
ML mark 67.90 73.90 77.90 81.90
Piston out- 67.980 73.960 77.970 81.970
side dia. 67.970– 73.950– 77.960– 81.960–
MS mark
67.975 73.955 77.965 81.965
67.960– 73.940– 77.950– 81.950–
S mark
67.970 73.950 77.960 81.960
Min. clearance between
0.025–0.055 — 0.045–0.075 — 0.035–0.065 — 0.035–0.065 —
piston and cylinder
Top clearance 0.610–0.730 — 0.658–0.778 — 0.650–0.770 — 0.650–0.770 —
Piston pin 19.991– 20.991– 22.991– 22.991–
19.90 20.90 22.90 22.90
outside dia. 20.000 21.000 23.000 23.000
Piston and Piston pin 20.000– 21.000– 23.000– 23.000–
20.02 21.02 23.02 23.02
piston pin hole dia. 20.008 21.008 23.008 23.008
Oil clear-
0.000–0.017 0.12 0.000–0.017 0.12 0.000–0.017 0.12 0.000–0.017 0.12
ance
(Unit: mm)
3D82E (S)3D84E 3D88E
Model 4D82E (S)4D84E 4D88E
Item Wear Wear Wear

limit limit limit
Piston outside dia. 81.945–81.975 83.945–83.975 87.945–87.975
L mark 81.965–81.975 83.965–83.975 87.965–87.975
Piston out- ML mark 81.960–81.965 81.90 83.960–83.965 83.90 87.960–87.965 87.90

side dia. MS mark 81.955–81.960 83.955–83.960 87.955–87.960
S mark 81.945–81.955 83.945–83.955 87.945–87.955
Min. clearance between piston and
0.040–0.070 — 0.040–0.070 — 0.040–0.070 —
cylinder
Top clearance 0.660–0.780 — 0.660–0.780 — 0.660–0.780 —
Piston pin outside dia. 25.987–26.000 25.90 25.987–26.000 25.90 25.987–26.000 25.90
Piston and
Piston pin hole dia. 26.000–26.009 26.02 26.000–26.009 26.02 26.000–26.009 26.02
piston pin
Oil clearance 0.000–0.022 0.12 0.000–0.022 0.12 0.000–0.022 0.12
9-4 68E-88E SERIES

(1)
9. SERVICE DATA
9.5 Piston ring

(Unit: mm)
Model 2D68E
3D74E 3D78AE
3D68E
Item Standard Wear limit Standard Wear limit Standard Wear limit
Ring groove
1.550–1.570 — 1.550–1.570 — 2.035–2.050 —
width
Ring width 1.470–1.490 — 1.470–1.490 — 1.940–1.960 —
Top ring
Min.side
0.060–0.100 — 0.060–0.100 — 0.075–0.110 —
clearance
End clearance 0.100–0.250 1.5 0.200–0.400 1.5 0.200–0.400 1.5
Ring groove
1.540–1.555 — 1.520–1.535 — 2.025–2.040 —
width
Ring width 1.430–1.450 — 1.410–1.430 — 1.975–1.990 —
2nd ring
Min.side
0.090–0.125 — 0.090–0.125 — 0.035–0.065 —
clearance
End clearance 0.150–0.350 1.5 0.200–0.400 1.5 0.250–0.400 1.5
Ring groove
3.010–3.025 — 3.010–3.025 — 3.015–3.030 —
width
Ring width 2.970–2.990 — 2.970–2.990 — 2.970–2.990 —
Oil ring
Min.side
0.020–0.055 — 0.020–0.055 — 0.025–0.060 —
clearance
End clearance 0.150–0.350 1.5 0.150–0.350 1.5 0.200–0.400 1.5
(Unit: mm)
Model 3D82AE
(S)3D84E 3D88E
3D82E
(S)4D84E 4D88E
4D82E
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
68E-88E SERIES 9-5

(1)
9. SERVICE DATA
9.6 Connecting rod

(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
Crankpin
bushing inside 39.000–39.016 — 43.000–43.016 — 46.000–46.016 — 51.000–51.010 —
dia.
Crankpin
Crank- metal thick- 1.487–1.500 — 1.487–1.500 — 1.487–1.500 — 1.492–1.500 —
pin side ness
Crankpin out-
35.970–35.980 35.91 39.970–39.980 39.91 42.952–42.962 42.91 47.952–47.962 47.91
side diameter
Oil clearance 0.033–0.059 0.15 0.033–0.059 0.15 0.038–0.090 0.16 0.038–0.074 0.16
Piston pin
bushing inside 20.025–20.038 20.10 21.025–21.038 21.10 23.025–23.038 23.10 26.025–26.038 26.10
diameter
Piston
pin side Piston pin out-
19.991–20.000 19.90 20.991–21.000 20.90 22.991–23.000 22.90 25.987–26.000 25.90
side dia.
Oil clearance 0.025–0.047 0.2 0.025–0.047 0.2 0.025–0.047 0.2 0.025–0.051 0.2
Less than 0.03 Less than 0.03 Less than 0.03 Less than 0.03
Twist and parallelism 0.08 0.08 0.08 0.08
per 100 mm per 100 mm per 100 mm per 100 mm
9.7 Camshaft
(Unit: mm)
Model 3D78AE,3D82AE
2D68E 3D82E,4D82E
3D74E
3D68E (S)3D84E,(S)4D84E
3D88E,4D88E
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 —
9-6 68E-88E SERIES

(1)
9. SERVICE DATA
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
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 —
9.9 Side gap and backlash

(Unit: mm)
Model All models
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
68E-88E SERIES 9-7

(1)
9. SERVICE DATA
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
9-8 68E-88E SERIES

(1)
10. TIGHTENING TORQUE
10.1 Main bolt/nut ......................................................................................................................................... 10-2

10.2 Standard bolt and nut ........................................................................................................................... 10-3
68E-88E SERIES 10-1

(1)
10.1 Main bolt/nut

(Unit: Nm{kgm})
3D82E,4D82E
Model
2D68E 3D78AE (s)3D84E,
No. Item 3D74E
3D68E 3D82AE (s)4D84E
Torque
3D88E,4D88E
37.3–41.2 58.8–63.7 66.7–70.6 85.3–91.2
Lubricating oil applied
1 Cylinder head bolt {3.8–4.2} {6.0–6.5} {6.8–7.2} {8.7–9.3}
(Thread dia. x pitch)
(M8 x 1.25) (M9 x 1.25) (M9 x 1.25) (M10 x 1.25)
22.6–27.5 22.6–27.5 37.3–41.2 44.1–54.0
Connecting rod Lubricating oil applied
2 {2.3–2.8} {2.3–2.8} {3.8–4.2} {4.5–5.5}
bolt (Thread dia. x pitch)
(M7 x 1.0) (M7 x 1.0) (M8 x 1.0) (M9 x 1.0)
80.4–86.3 78.5–88.3 83.4–88.3 83.4–88.3
Flywheel clamp- Lubricating oil applied
3 {8.2–8.8} {8.0–9.0} {8.5–9.0} {8.5–9.0}
ing bolt (Thread dia. x pitch)
(M10 x 1.25) (M10 x 1.25) (M10 x 1.25) (M10 x 1.25)
52.0–55.9 78.5–83.4 76.5–80.4 96.1–100.0
Metal cap clamp- Lubricating oil applied
4 {5.3–5.7} {8.0–8.5} {7.8–8.2} {9.8–10.2}
ing bolt (Thread dia. x pitch)
(M9 x 1.25) (M10 x 1.25) (M10 x 1.5) (M12 x 1.5)
S48C: S48C:
112.8–122.6 112.8–122.6
Crankshaft {11.5–12.5} {11.5–12.5} 112.8–122.6 112.8–122.6
Lubricating oil applied
5 V-pulley clamping FC25: FC25: {11.5–12.5} {11.5–12.5}
(Thread dia. x pitch)
bolt 83.4–93.2 83.4–93.2 (M14 x 1.5) (M14 x 1.5)
{8.5–9.5} {8.5–9.5}
(M12 x 1.5) (M12 x 1.5)
Lubricating oil not 49.0–53.0 49.0–53.0 6.9–8.8 6.9–8.8
Fuel injection noz-
6 applied {5.0–5.4} {5.0–5.4} {0.7–0.9} {0.7–0.9}
zle nut
(Thread dia. x pitch) (M20 x 1.5) (M20 x 1.5) (M6 x 1.0) (M6 x 1.0)
Lubricating oil not 58.8–68.6 58.8–68.6
Timer clamping
7 applied — — {6.0–7.0} {6.0–7.0}
nut
(Thread dia. x pitch) (M12 x 1.75) (M12 x 1.75)
8 Glow plug applied {1.5–2.0} {1.5–2.0} — —
9 Stub shaft bolt applied {5.5–6.5} {5.5–6.5} — —
68.6–73.5 68.6–73.5 44.1–49.0 44.1–49.0
Governor weight Lubricating oil applied
10 {7.0–7.5} {7.0–7.5} {4.5–5.0} {4.5–5.0}
support nut (Thread dia. x pitch)
(M12 x 1.25) (M12 x 1.25) (M12 x 1.25) (M12 x 1.25)
High pressure Lubricating oil not 29.4–34.3 29.4–34.3 29.4–34.3 29.4–34.3
11 pipe sleeve applied {3.0–3.5} {3.0–3.5} {3.0–3.5} {3.0–3.5}
clamping nut (Thread dia. x pitch) (M12 x 1.5) (M12 x 1.5) (M12 x 1.5) (M12 x 1.5)
10-2 68E-88E SERIES

(1)
10.2 Standard bolt and nut

a Lubricating oil not applied
(Unit: Nm{kgm})
Tightening
Item Thread dia. x pitch Remarks
torque
9.8–11.8 1) When bolting the aluminum parts, tighten
M6 x 1
{1.0–1.2} the bolts with 80% of the tightening
torque specified in the Table.
22.6–28.4
M8 x 1.25 2) 4T bolt and lock nut should be tightened
Hexagon headed bolt (7T) {2.3–2.9}
with 60% of the torque shown in the
and nut 44.1–53.9 table.
M10 x 1.5
{4.5–5.5}
78.4–98.1
M12 x 1.75
{8.0–10.0}
9.8
1/8
{1.0}
19.6
1/4
{2.0}
PT plug —
29.4
3/8
{3.0}
58.8
1/2
{6.0}
12.7–16.7
M8
{1.3–1.7}
24.5–34.3
M12
{2.5–3.5}
Pipe joint bolt —
39.2–49.0
M14
{4.0–5.0}
49.0–53.9
M16
{5.0–5.5}
68E-88E SERIES 10-3

(1)
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION

SYSTEM
11.1 Exploded view (YPFR type) .................................................................................................................. 11-2

11.2 Disassembly ......................................................................................................................................... 11-3
11.3 Inspection ............................................................................................................................................. 11-5
11.4 Reassembly .......................................................................................................................................... 11-7
68E-88E SERIES 11-1

(1)
11.1 Exploded view (YPFR type)
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
10) Plunger guide inner roller

11) Plunger guid roller pin
12) Plunger roller guide 2
21
13) Plunger positioning shim 3
14) Plunger spring lower retainer 4
5
15) Plunger spring
16) Plunger spring upper retainer
17) Fuel control pinion
6
18) Plunger 20
19) Injection timing adjusting shim 7
20) Fuel control rack 19

8
21) Fuel injection pump body
22) Plunger barrel packing
23) Plunger barrel
18
24) Delivery valve holder
25) Delivery valve packing
26) Delivery valve 17
27) Delivery valve spring
16
28) O-ring
29) Delivery valve spring holder 15
14
13
12
11
9
10
YE0171
11-2 68E-88E SERIES

(1)
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.
(1) Remove the fuel injection pump.
(2) Extract the plunger guide stopper pin and

remove the plunger guide stopper and plunger
barrel stopper
YE0172
(3) Remove the right plunger roller guide assembly.
YE0173
(4) Remove the plunger spring and plunger spring

lower retainer.
YE0174
68E-88E SERIES 11-3

(1)
(5) Remove the plunger spring upper retainer and

the fuel control pinion.
YE0175
(6) Remove the delivery valve spring holder and

then remove fuel control rack, delivery valve
holder, delivery valve spring and delivery valve.
YE0176
(7) Remove the plunger barrel assembly.
(8) Remove the other plungers by repeating the YE0177

above steps.
a Never loosen the eccentric screw for adjust-
ing and set screw for the fuel injection vol-
ume adjusting plate.
11-4 68E-88E SERIES

(1)
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.
(1) Plunger guide outer roller, inner roller and

plunger roller guide.
Inspect for wear and scratches with the plunger
guide outer roller, inner roller and plunger roller
guide. If a gap between the fuel injection pump
camshaft and plunger guide outer roller exceeds 4 3 2
0.3 mm, replace the plunger roller guide assem- YE0178
bly with a new one.
1) Plunger roller guide

2) Plunger guide outer roller
3) Plunger guide inner roller
4) Plunger guide roller pin
(2) Fuel control rack and fuel control pinion

1. Inspect for bending of fuel control rack and YE0180
wear or deformation of engaged surface of
YE0179
fuel control pinion and fuel control rack.
(Fuel control rack) (Fuel control pinion)
2. Check to see if the fuel control rack moves
smoothly. If not, replace the fuel control rack
with a new one.
(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)
2. To test the plunger, hold the plunger barrel

tilted approx. 60° and check to see if it slides
down smoothly. If so, the plunger is accept-
able. While turning the plunger, repeat the
test several times. If any plunger slides down 6
too quickly (slowly) or jams in the midway,
correct it or replace the whole plunger as-
sembly.
6) Approx. 60°
YE0182
(Fall by gravity test of plunger)
68E-88E SERIES 11-5

(1)
(4) 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. 1
1) Seat
2) Suck-back collar
YE0183
2. Stop up the hole in the bottom of the delivery

valve holder and keep the seat as it is. Insert
the delivery valve to 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.
YE0184
(Inspection of 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 per-
fectly falls by gravity, when the finger is
released from the bottom hole.
If so, the delivery valve is acceptable. If not,
replace it.
YE0185
(Fall by gravity test of delivery valve)
11-6 68E-88E SERIES

(1)
11.4 Reassembly
(1) Insert the plunger barrel packing into the
fuel injection pump body.
(2) Insert the plunger barrel assembly.
YE0186
(3) Fit the delivery valve assembly, delivery

valve spring and delivery valve spring
holder.
(Unit: Nm{kgm})
Delivery valve spring 39.2–44.1
holder tightening torque. {4.0–4.5}
YE0187
(4) Reassemble the fuel control rack and fuel

control pinion.
a Ensure that the match mark of the fuel
control rack aligns with that of the fuel
control pinion.
a Make sure that the fuel control rack
moves smoothly over all the strokes.
YE0188
68E-88E SERIES 11-7

(1)
(5) Fit the plunger mounted with the plunger

spring upper retainer, plunger spring and
plunger spring lower retainer.
a Ensure that the match mark of the
plunger aligns with that of the fuel con-
trol pinion.
YE0189
1) Matching marks
1
YE0190
(6) Insert the plunger adjusting shim. Press the

plunger guide assembly by hand. While
aligning the plunger guide stopper pin with
the mating hole of the stopper pin of the fuel
injection pump body, attach the plunger
guide stopper pin.
YE0191
11-8 68E-88E SERIES

(1)
12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM
12. FUEL INJECTION PUMP FOR DIRECT INJECTION

SYSTEM
12.1 Exploded view (YPES type) .................................................................................................................. 12-2

12.2 Special service tools for disassembly and reassembly......................................................................... 12-4
12.3 Disassembly ......................................................................................................................................... 12-5
12.4 Inspection ........................................................................................................................................... 12-10
12.5 Reassembly ........................................................................................................................................ 12-12
68E-88E SERIES 12-1

(1)
12.1 Exploded view (YPES type)
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
12-2 68E-88E SERIES

(1)
1) Delivery valve spring holder 26) Bottom cover

2) Holder stopper 27) Gasket
3) O-ring 28) Pump side cover
4) Delivery valve stopper 29) Plunger guide assembly
5) Delivery valve spring 30) Plunger guide roller pin
6) Delivery valve 31) Plunger roller guide
7) Delivery valve packing 32) Plunger guide outer roller
8) Delivery valve holder 33) Plunger guide inner roller
9) Delivery valve assembly 34) Plunger adjusting shim
10) Plunger barrel 35) Adjusting bolt
11) Plunger 36) Plunger spring lower retainer
12) Plunger assembly 37) Plunger spring
13) Fuel injection pump body 38) Plunger spring upper retainer
14) Control rack stopper 39) Control sleeve
15) Plunger guide stopper 40) Stop screw
16) Plug 41) Fuel control pinion
17) Plug 42) Circlip
18) Bearing 43) Spacer
19) Fuel injection pump camshaft 44) Control rack spring
20) Woodruff key 45) Rack bushing
21) Bearing 46) Control rack
22) Bearing holder 47) Plunger barrel stopper
23) Oil seal 48) O-ring
24) Adjusting packing 49) Check bolt
25) O-ring 50) Deflector
68E-88E SERIES 12-3

(1)
12.2 Special service tools for disassembly and reassembly
No. Name of tool Shape and size Application

Side clearance measuring gauge Measurement of camshft side
clearance
Code No. 158090-51050
YE0193
Plunger insertion tool
Code No. 158090-51100

2
YE0194 YE0195
Tappet holder tool
Code No. 158090-51200

3
YE0196
YE0197
Rack lock screw
4 Code No. 158090-51510

YE0198
Governor weight extractor tool
Code No.
Governor
158090-
weight for 3
51400
5 pcs.
Governor
158090-
weight for 4
51450
pcs.
YE0199 YE0200
12-4 68E-88E SERIES

(1)
12.3 Disassembly
(1) Remove the bottom cover from the fuel
injection pump to drain lubricating oil from
the fuel injection pump.
(2) Turn the fuel injection pump upside down to

drain fuel oil.
YE0201
(3) Take out the governor weight assembly

using the governor weight extractor tool
(special service tool)
a For separating the governor assembly
from the fuel injection pump, refer to
Chapter 13,13.3.
YE0202
(4) Remove the fuel feed pump.

a Do not disassemble the fuel feed pump.
YE0203
(5) Remove the fuel injection pump side cover.
YE0204
68E-88E SERIES 12-5

(1)
(6) While turning the fuel injection pump cam-

shaft, raise the plunger guide up to the max.
stroke. Insert the tappet holders (special
service tool) between the plunger spring
lower retainer and fuel injection pump body.
YE0205
(Special service tool: Tappet Holder)

(7) Extract the woodruff key from the fuel injec-
tion pump camshaft.
(8) Extract the fuel injection pump camshaft

bearing horizontally by inserting a screw-
driver into the two grooves on the face
where the bearing holder of the fuel injection
pump camshaft is installed.
a Carefully avoid allowing the thread of
the fuel injection pump camshaft to
damage the oil seal.
a Carefully avoid allowing the adjusting
packings and oil seal between the pump YE0206
body and bearing holder to be lost.
(9) Turn the fuel injection pump upside down.

Move all plunger guides toward the plunger.
Then, turn aside the fuel injection pump.
While turning the fuel injection pump cam-
shaft, find a position where the cams of
each cylinder does not interfere with the
plunger guide outer roller and place the
camshaft in the position.
(10) Apply a plate against the governor end side

of the camshaft. While tapping the plate, YE0207
extract a set of the camshaft and drive bear-
ing.
(11) Remove the plunger guide stopper.
YE0208
12-6 68E-88E SERIES

(1)
(12) By using the handle of a hammer, etc., push

up the plunger guide from the bottom of the
pump and take out the tappet holders (spe-
cial service tool).
a Use particular care to remove the tappet
holder. Carefully prevent the plunger
guide, plunger, etc., from jumping out.
This is because the plunger spring is
powerful enough to force them out.
YE0209
(13) Take out the plunger guide assembly.

a Do not erect the fuel injection pump
body, wherever possible. Otherwise, the
plunger guide assembly falls off. There-
fore, hold the fuel injection pump body
tilted and remove the plunger guide
assembly.
YE0210
(14) Take out the plunger, plunger spring and

plunger spring lower retainer from the lower
part of the fuel injection pump.
a Separate these parts for each cylinder.
YE0211
(15) Remove the stop screw from the fuel control

pinion.
a When the stop screw of the fuel control
pinion is loosened, the fuel control pin-
ion is separated from the control sleeve.
Before loosening, therefore, make sure
that the match mark of the fuel control
pinion aligns with that of the control
sleeve. If the match mark is difficult to
identify or the match mark offsets, put
new match marks. This practice helps
adjusting injection volume later on.
YE0212
68E-88E SERIES 12-7

(1)
a Separate all these parts for each cylin-

der.
1
1) Small screw on control pinion 4
2
2) Control pinion
3) Control sleeve
3
4) Match mark
YE0213
(16) Remove the fuel control pinion, control

sleeve and plunger spring upper retainer.
a Separate all these parts for each cylin-
der.
YE0214
(17) Remove the control rack stopper. Extract

the control rack.
a Carefully prevent the control rack spring
and spacer on the control rack from
being missing.
YE0215
YE0216
12-8 68E-88E SERIES

(1)
(18) Loose the bolt for the holder stopper.

Remove the delivery valve spring holder.
YE0217
(19) Take out the delivery valve assembly.

a Carefully prevent small parts such as
the delivery valve packing, delivery
valve spring and delivery valve stopper
from being missing.
a Clearly separate the delivery valve
assembly for each cylinder.
YE0218
(20) Take out the plunger barrel toward the upper

part of the fuel injection pump.
a Keep the plunger barrel just picked up
together with the plunger which has
been taken out.
YE0219
68E-88E SERIES 12-9

(1)
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
(Fall by gravity test of delivery valve)
12-10 68E-88E SERIES

(1)
(3) Plunger guide, plunger barrel, etc.

1. Check to see if the sliding surface of the
plunger guide is free form excessive wear.
2. Check to see if the set of the plunger barrel
gas uneven contact, burrs, the mark of blow-
by gas or other defects etc. If so, correct or
replace the plunger barrel. Otherwise, lubri-
cating oil in use will be thinned.
3. If the surface of the plunger guide outer roller
indicates wear, flaking, etc., replace the out-
er roller.
4. If the plunger guide has the circumference YE0223
and roller pin hole worn or scratched, etc.,

replace it with a new one. (Plunger guide assembly)
5. If the plunger guide assembly has a combi-
nation of the pin and roller that indicates
chatters, replace the plunger guide assem-
bly.
(4) Fuel injection pump camshaft and bearing

1. Fuel injection pump camshaft
Check for damage and wear of the camshaft
surface, deformation of keyway and defor-
mation of threads on both ends. If the cam-
shaft proves to be defective, replace it.
2. Bearing
If the taper roller and outer race has flaking,
wear, or any other damage on the surface,
replace the bearing. YE0224
a When replacing the fuel injection pump
camshaft, replace the bearing at the
same time.
(5) Control rack and fuel control pinion

1. Check the control rack for bends and the
wear and deformation of the portion where it
is engaged with the fuel control pinion.
2. Check to see if the portion where the control
rack is engaged with the fuel control pinion is
free from wear and deformation.
a If the control rack is in trouble with the
teeth face and sliding part, it encounters
increased resistance, causing the YE0225
engine to be out of order (such as
uneven revolutions and abrupt revolu-
tion changes).
68E-88E SERIES 12-11

(1)
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
(2) Insert the delivery valve assembly, delivery

valve spring and delivery valve stopper from
the top of the fuel injection pump in that
order.
a Replace the delivery valve packing and
O-ring with new ones before reassem-
bling the fuel injection pump.
(3) Fit the control rack and tighten the control

rack stopper.
a Never fail to install the control rack
spring. YE0227
a Make sure that the control rack moves

smoothly over the full stroke.
(4) Insert a rack lock screw (special service

tool) into the thread hole of the control rack
stopper and fix the control rack.
(5) Peep through the bottom of the fuel injection

pump and align the match mark of the con-
trol rack with that of the fuel control pinion.
YE0228
3
1) Pinion/rack match mark
2) Control rack
YE0229
3) Fuel control pinion
(Matching mark on the control rack and fuel con-

trol pinion)

(1)
(6) While holding the fuel control pinion by one

hand so that its match mark may not be out
of position, reassemble the control sleeve
and lightly tighten the stop screw of the fuel
control pinion.
a Reassemble the control sleeve in the
direction in which the holes around the
control sleeve face the stop screw. At 1
the same time, align the match mark
with that of fuel control pinion.
YE0230
1) Match mark
(Fuel control pinion/control sleeve match mark)

(7) Mount the plunger spring upper retainer.
a Mount the plunger spring upper retainer
so that its recess faces downward.
a Once again, ascertain that the control
rack moves smoothly.
(8) Mount the plunger spring.
YE0231
(9) Mount the plunger spring lower retainer on

the top of the plunger. While aligning the
match mark of the plunger flange with that of
the control sleeve, reassemble the plunger
from the bottom of the fuel injection pump
using a plunger insertion tool (special ser-
vice tool).
a Never reassemble the plunger in
reverse. Otherwise, fuel injection vol-
ume increases excessively to the point
where fuel injection volume becomes
uncontrollable.
YE0232
(Insertion of plunger with a special service tool:
Plunger insertion tool)
YE0233
(Special service tool: Plunger insertion tool)

(1)
(10) Insert the plunger guide assembly into the

fuel injection pump from its bottom. Push up
the plunger guide using the handle of a
hammer, etc., and put a tappet holder (spe-
cial service tool) in between the lower spring 1
retainer and fuel injection pump body. 2
a While keeping the plunger guide detent
groove facing upward, align with the
mating screw hole of the plunger guide
stopper on the fuel injection pump body. YE0234
1) Stop screw hole

2) Detent groove
a Check to see if the control rack moves

freely. If not, the plunger spring inter-
feres with something else. In this case,
hold the plunger spring in position using
a screwdriver.
a When replacing the plunger guide
assembly with a new one, insert the
standard shim, and temporarily tighten
it.
YE0235
(11) Make sure that the plunger guide detent

groove is in position. Tighten the plunger
guide stopper.
YE0236
(12) Place the bearings on both ends of the fuel

injection pump camshaft. Insert the bearings
while tapping them from driving side.
a Turn the fuel injection pump upside
down. Move the plunger guide toward
the plunger spring and drive in the fuel
injection pump camshaft.
YE0237

(1)
(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.
(14) Drive the woodruff key into the fuel injection

pump camshaft.
YE0238
(15) Turn the fuel injection pump camshaft, and

extract the tappet holder (special service
tool).
(16) Fix the fuel injection pump. Using a mallet,

tap the end of the fuel injection pump cam-
shaft to adjust the side clearance of the fuel
injection pump camshaft using an adjusting
packing and a side clearance gauge (spe-
cial service tool).
(Unit: mm)
YE0239
All models
Camshaft side clearance 0.02–0.05
[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
(Special service tool: Side clearance gauge)

(17) Mount the fuel injection pump side cover.
YE0241

(1)
(18) Mount the fuel injection pump bottom cover.
YE0242
(19) Tighten the delivery valve spring holder to

the specified torque.
(Unit: Nm{kgm})
All models
34.3–39.2
Tightening torque
{3.5–4.0}
a Tighten the delivery valve spring holder
by hand as far as possible. If the bolt get
hard to run part way, the packing or
delivery valve may be out of position.
YE0243
Remove, correct, and start tightening
again.
a Never tighten the delivery valve holder
exc essi vely. Ex cess ive tightening
causes the control rack to malfunction.
(20) Tighten the holder stopper to the specified

torque.
(Unit: Nm{kgm})
All models
2.9
Tightening torque
{0.3}
a Never tighten the delivery holder exces- YE0244
siverly. Otherwise, it upsets, causing oil
to leak through it.
(21) Mount the fuel feed pump.
YE0245

(1)
13. GOVERNOR
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
68E-88E SERIES 13-1

(1)
13. GOVERNOR
13.1 Exploded views of governor for indirect injection system
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
13-2 68E-88E SERIES

(1)
13. GOVERNOR
1) Governor case 18) Governor sleeve

2) Governor spring 19) Shifter
3) Control lever 20) Governor lever (A)
4) Angleich spring assembly 21) Governor lever (B)
5) Stop nut 22) Snap pin
6) Angleich spring 23) Governor link
7) Shifter 24) Snap pin
8) Shim set 25) Shaft retainer
9) Bushing 26) Governor lever shaft
10) Tension lever 27) Control lever handle
11) Governor weight assembly 28) Control lever shaft
12) Bushing 29) O-ring
13) Shim set 30) Shaft retainer
14) Pin 31) Hex. nut
15) Governor weight support 32) Governor case cover
16) Governor support nut 33) FO limiter assembly
17) Governor weight 34) Mounting bolt
35) Governor lever assembly
68E-88E SERIES 13-3

(1)
13. GOVERNOR
13.2 Exploded views of governor for direct injection system
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
13-4 68E-88E SERIES

(1)
13. GOVERNOR
1) Stop lever return spring 18) Governor weight support

2) Stop lever 19) Governor support nut
3) Governor lever shaft 20) Governor sleeve
4) Circlip 21) Shifter
5) O-ring 22) Governor lever
6) O-ring 23) Governor lever assembly
7) Governor case 24) Tension lever
8) Circlip 25) Bushing
9) Mounting bolt 26) Bushing
10) Control lever shaft 27) Hex. nut
11) Governor spring 28) Angleich spring
12) Snap pin 29) Shifter
13) Governor link 30) Stop nut
14) Control rack 31) Angleich assembly
15) Governor weight 32) Control lever
16) Governor weight assembly 33) FO limiter assembly
17) Pin 34) Governor case cover
68E-88E SERIES 13-5

(1)
13. GOVERNOR
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)
(2) Remove the control lever hex. nut and pull

out the control lever from the control lever
shaft.
YE0250
(3) Remove the governor case mounting bolt.

Remove the governor case from the fuel
injection pump while gently tapping the gov-
ernor case with a wooden hammer. Create a
gap between the governor case and fuel
injection pump by moving only the moving
parts of the governor lever.
YE0251
13-6 68E-88E SERIES

(1)
13. GOVERNOR
(4) Pull out the governor link snap pin by insert-

ing long nosed pliers between the fuel injec-
tion pump and governor case.
YE0252
(5) Separate the governor and fuel injection

pump by sliding the governor case and fuel
injection pump apart and pulling out the
snap pin of the governor link from the con-
trol rack.
YE0253
YE0254
(6) Remove the stop lever return spring from

the governor lever shaft. (For direct injec-
tion)
YE0255
68E-88E SERIES 13-7

(1)
13. GOVERNOR
(7) Use long nosed pliers to unhook the gover-

nor spring from the tension lever and control
lever shaft.
YE0256
(8) Remove the shaft retainer on the governor

lever shaft. (for indirect injection)
Remove the circlips on both ends of the
governor lever shaft. (for direct injection)
YE0257
(9) Put a rod 8 mm in dia. or less in one end of

the governor lever shaft and tap the gover-
nor lever shaft until the O-ring comes out the
other side of the governor case.
YE0258
(10) After you remove the O-ring , lightly tap the

end of the shaft that you removed the O-ring
from, and extract the governor lever shaft.
YE0259
13-8 68E-88E SERIES

(1)
13. GOVERNOR
YE0260
YE0261
(11) Remove the governor link from the governor

lever.
a The governor assembly consists of the
governor lever, tension lever and angle-
ich, and is normally not disassembled.
YE0262
YE0263
68E-88E SERIES 13-9

(1)
13. GOVERNOR
(12) When you need to pull out the stop lever,

remove the stop lever shaft stop pin, and
lightly tap the inside of the governor case.
(For direct injection)
YE0264
(13) When you need to pull out the control lever

shaft, lightly tap the end of the shaft with a
wooden hammer, and extract the control
lever.
a Do not remove the FO limiter assembly
from the governor case unless neces-
sary.
a On models with torque springs, first
remove the box nut, stop nut, and then
the torque spring assembly.
YE0265
(14) Pull out the governor sleeve on the end of

the fuel injection pump camshaft by hand.
YE0266
(15) Fix the bearing holder with a vise to hold the

fuel injection pump camshaft. Loosen the
governor support nut with a box spanner a
few turns.
a When the taper fit comes apart after you
have removed the nut, the governor
weight may fly out. Be careful.
YE0267

(1)
13. GOVERNOR
(16) Remove the governor weight assembly from

the fuel injection pump camshaft using the
governor weight extractor (special service
tool).
YE0270
(Governor weight extractor)
YE0268
YE0269

(1)
13. GOVERNOR
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
(2) Replace the governor weight assembly if the

contact surface with governor sleeve is
extremely worn.
(3) Replace if there is governor weight support
and pin wear or the the caulking is loose.
(4) Replace if the governor weight suppout
stopper is excessively worn.
2. Inspection of governor sleeve

(1) Replace the governor sleeve if the contact
surface with governor weight is worn or 6
there is pitching. 4
(2) Replace the governor sleeve if the contact
surface with shifter is excessively worn or
there is pitching.
(3) If the governor sleeve does not move
smoothly on the fuel injection pump cam-
shaft due to governor sleeve inner dia. wear
5
or other reasons, replace. YE0272
4) Governor weight contact surface

5) Sleeve inner dia.
6) Shifter contact surface
3. Inspection of governor lever shaft assembly

(Unit: mm)
(1) Measure the clearance between the gover-
nor lever shaft and bushing, and replace if it Standard
Standard Limit
is near the wear limit. clearance
Governor lever -0.005
shaft outer dia 8 -0.014
0.065–0.124 0.5
(2) Inspect the shifter contact surface, and if it is Bushing inner +0.11
8 +0.06
worn or scorched, remove the spring pin to dia.
disassemble and replace the shifter only.
(3) Check link parts for bends or kinks that will
cause malfunctioning, and replace if it is
faulty.
a Side gap on top of governor lever shaft.

(Unit: mm)
Standard side gap 0.4
a Replace the governor lever, tension

lever, bushing, shifter and angleich
spring as an assembly.

(1)
13. GOVERNOR
4. Inspection of springs
(1) Check the governor spring and other
springs and replace if they are broken, set-
tled or corroded.
YE0273
5. Inspection of angleich spring assembly

(1) Inspect the sliding surface of shifter and
replace if it is faulty.
(2) Replace the angleich spring assembly if the
angleich spring is broken.
1
2
YE0274
6. Inspection of torque spring assembly

(1) Inspect the tip of the piston and contact sur-
3
face for wear and replace if it is faulty.
(2) Replace the assembly if the torque spring is
broken.
1) Angleich spring
4
2) Shifter
3) Torque spring
4) Contact surface
5) Piston 5 YE0275

(1)
13. GOVERNOR
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.
(1) Fix the bearing holder with a vise to hold the

fuel injection pump camshaft. Insert the gov-
ernor weight assembly in the taper portion
at the end of the fuel injection pump cam-
shaft. Mount the washer, and tighten the
YE0276
governor weight support nut with the speci-
fied torque.
(Unit: Nm {kgm})
Governor weight
support
68.6–73.5
Indirect injection system
{7.0–7.5}
44.1–49.0
Direct injection system
{4.5–5.0}
(2) Open the governor weight to the outside,

YE0277
and insert the sleeve in the end of the fuel
injection pump camshaft.
a Make sure that the sleeve moves
smoothly after inserting it.
(3) After the stop lever is disassembled, mount

the stop lever return spring on the stop
lever, tap the stop lever lightly with a
wooden hammer to insert it, and tighten the
stop lever stop pin. (For direct injection)
(4) After the control lever shaft is removed,

lightly tap and insert the control lever shaft
and washer from inside the governor case, YE0278
using an appropriate plate.
(5) If the governor has been disassembled, tap

in the spring pin.
YE0279

(1)
13. GOVERNOR
(6) Mount the governor lever assembly to the

governor link.
a Make sure that the correct governor link
mounting holes are used and that it is
mounted in the correct direction.
a Make sure that the governor link moves
smoothly.
YE0280
(7) Put the governor lever shaft assembly in the

governor case, insert the governor lever
shaft and tap it in until the O-ring groove
comes out the opposite side of the governor
case. (For direct injection)
a Fit the O-ring beforehand to the side
you tap in.
YE0281
YE0282
a Make sure to insert the governor lever

shaft in the correct direction.
a Don’t forget to mount the washers on

both sides of the governor lever.
YE0283

(1)
13. GOVERNOR
(8) After you have mounted the O-ring, tap the

governor lever in the opposite direction, and
mount the circlip on the grooves at both
ends. (For direct injection)
a After mounting the governor lever
assembly, make sure the governor lever
assembly moves smoothly.
YE0284
YE0285
(9) Fit the stop lever return spring to the end of

the governor lever shaft. (For direct injec-
tion)
YE0286
(10) Hook the governor spring on the control

lever shaft and tension lever hook with long
nosed pliers.
YE0287

(1)
13. GOVERNOR
(11) Pull the governor link as far as possible

towards the governor case mounting sur-
face, insert the covernor link pin in the fuel
control rack pin hole and fit the snap pin on
it.
(12) Mount the governor case to the fuel injection

pump while lightly tapping it with a wooden
hammer, and tighten the tightening bolt.
YE0288
(13) Mount the governor case cover.

On models with idle subspring, insert the
adjusting spring and adjusting rod on the
governor case cover adjusting bolt.
a If the angleich spring assembly has
been removed, tighten the nut tempo-
rarily. The nut should be securely tight-
ened after adjustment.
YE0289
(14) Insert the control lever in the control lever

shaft and tighten the nut.
a Move the control lever back and forth to
make sure that the entire link moves
smoothly.
YE0290

(1)
14. TURBOCHARGER
14. TURBOCHARGER
14.1 Specifications........................................................................................................................................ 14-2

14.2 Construction.......................................................................................................................................... 14-3
14.3 Waste gate valve adjusting method...................................................................................................... 14-5
14.4 Exploded view of turbocharger (with waste gate) ................................................................................. 14-7
14.5 Tightening torque.................................................................................................................................. 14-8
14.6 Service standards ................................................................................................................................. 14-8
68E-88E SERIES 14-1

(1)
14. TURBOCHARGER
14.1 Specifications
Applicable engine model (S)3D84E(CL,VM) (S)3D84E(CH,VH)

(application) (S)4D84E(CL) (S)4D84E(VM,CH,VH)
Turbocharger model RHB31 RHB51
Turbocharger specification Standard (w/waste gate)
Turbine type Radial flow
Blower (compressor) type Centrifugal
Lubrication method External lubrication
Max. continuous allowable rpm 250,00 rpm 180,000 rpm
Max. continuous allowable gas

750°C
inlet temperature
Dry weight 2.4 kg 4.2 kg
NOTE: VM and VH applications are provided with the waste gate.
14-2 68E-88E SERIES

(1)
14. TURBOCHARGER
14.2 Construction
E B
YE0291
No. Part name No. Part name No. Part name

1 Turbine shaft 8 M5 hexagon bolt 15 Bearing housing
2 Oil thrower 9 M5 spring washer 16 Retaining ring
3 Turbine side seal ring 10 Compressor side clamp 17 M3 countersunk flat head screw
4 Seal plate 11 Turbine housing 18 Compressor wheel
5 Journal bearing 12 M6 hexagon bolt 19 Shaft end nut
6 Thrust bearing 13 Turbine side clamp 20 Heat protector
7 Compressor housing 14 Lock washer
A) Air outlet D) Gas inlet

B) Air inlet E) Gas outlet
C) Oil outlet F) Oil inlet
68E-88E SERIES 14-3

(1)
14. TURBOCHARGER
NOTE: A waste gate valve is adopted in the turbo-

charger for VM or VH (variable speed) appli-
cation.
a The waste gate valve is a turbocharger speed

control system to maintain the intake air pres-
sure at a constant level by bypassing a part of 1
the exhaust gas for driving the turbocharger by
using the intake air pressure on the compressor
side. It consists of a control ass'y separated
from the turbocharger and a valve ass'y built in
the turbine housing.
1) Waste gate control ass'y

2) Waste gate valve ass'y
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.
14-4 68E-88E SERIES

(1)
14. TURBOCHARGER
14.3 Waste gate valve adjusting method

Since turbochargers for VM and VH applications are provided the waste gate valve each, adjustment of the
waste gate valve opening pressure and lift is indispensable at the time of overhaul or inner parts replacement.
Omission of this adjustment will adversely affect the engine performance.
NOTE: If the adjustment is impossible, leave off inner parts replacement but replace the whole turbocharger
ass’y.
(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
Dial gauge Capable of measuring 0 to 10 mm (A flat head type is desirable.)
Either mercury column or electric type (capable of measuring 0 to

Manometer
200 kPa {1,500 mmHg})
Capable of gradually adjusting in a range between 0 and 196 kPa { 0

Pressure regulating valve and 2 kg/cm2} (for controlling the pressure applied to the waste gate
actuator)
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.
1) Pressure regulating valve 5) Manometer 9) Clip

2) Pressure gauge 6) Waste gate valve 10) Dial gauge
(490 kPa {5 kg/cm2}) 7) Adapter 11) Rod
3) Pressure reducing valve 8) Hose 12) Waste gate actuator
4) Compressed air
68E-88E SERIES 14-5

(1)
14. TURBOCHARGER
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.
(2) Waste gate actuator leak test

Apply 118 kPa {1.2 kg/cm2} to the actuator and hold the state for 1 minute. The actuator is good if the
pressure then is 108 kPa {1.1 kg/cm2} or more.
14-6 68E-88E SERIES

(1)
14. TURBOCHARGER
14.4 Exploded view of turbocharger (with waste gate)
YE0294
No. Part name No. Part name

1 Turbine shaft 17 Bolt
2 Thrust bushing 18 Lock plate
3 Oil thrower 19 Bearing housing
4 Seal ring 20 Retaining ring
5 Seal ring 21 Screw
6 Seal ring (turbine side) 22 Screw
7 Lock nut 23 Lock washer
8 Impeller 24 Heat protector
9 Seal plate 25 Liquid gasket
10 Journal bearing 26 Waste gate actuator
11 Thrust bearing 27 Hose
12 Compressor housing 28 Adapter
13 Flanged bolt 29 Clip
14 Spring washer 30 Retaining ring
15 Clamp 31 Waste gate valve
16 Turbine housing 32 Link plate
68E-88E SERIES 14-7

(1)
14. TURBOCHARGER
14.5 Tightening torque

Tightening torque (Nm{kgcm})
Part No. Part name Size
RHB31 RHB51
7 Lock nut — 0.88–1.07 {9 – 11} 1.76–2.16 {18 – 22}
Flanged
13 M5 3.92–4.90 {40 – 50} 3.92–4.90 {40 – 50}
bolt
M6 11.77–12.75 {120 – 130}
17 Bolt 11.77–12.75 {120 – 130}
M8 26.97–28.93 {275 – 295}
21 Screw M3 1.18–1.37 {12 – 14} 1.18–1.37 {12 – 14}
22 Screw M3 1.18–1.37 {12 – 14} 1.18–1.37 {12 – 14}
14.6 Service standards

J
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
14-8 68E-88E SERIES

(1)
15. SERVICE INFORMATION FOR CARB ULG REGULATION
15. SERVICE INFORMATION FOR CARB ULG

REGULATION
15.1 Limiting the high idle and low idle adjustment screw ............................................................................ 15-2
15.2 Limiting the fuel volume limiter screw ................................................................................................... 15-3
68E-88E SERIES 15-1

(1)
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
a Do not adjust the high idle adjustment

screw unless necessary.
a The illustration shows the partial per-
spective view of the governor for the
direct injection system.
15.1.2 Low idle speed

After warming up the engine, set the low idling
speed (Refer to Chapter 1, Specifications and Per-
formance) by turning the low idle adjustment screw.
6) Low idle adjustment screw

7) Increase 6
8) Decrease
9) regulator handle
7
9 8
YE0333
15-2 68E-88E SERIES

(1)
15.2 Limiting the fuel volume limiter screw

1) After limiting the fuel volume, lock the fuel vol-
ume limiter screw with the lock nut by using the 1
special tool. 2
2) Then, insert the plug firmly to prevent re-adjust-
ment and oil leakage. 3
1) Fuel volume limiter screw

2) Lock nut
3) Plug
a Do not adjust the fuel volume limiter screw

unless necessary.
YE0334
68E-88E SERIES 15-3

(1)
16. ATTACHED DRAWING
16.1 Exploded views of engine components ................................................................................................ 16-2

16.2 Exploded views of engine components ................................................................................................ 16-4
68E-88E SERIES 16-1

(1)
16.1 Exploded views of engine components
YE0296
16-2 68E-88E SERIES

(1)
No. Engine Component No. Engine Component
1 Exhaust manifold 27 Fuel filter
2 Intake manifold 28 Cooling water pipe
3 High-pressure fuel pipe 29 Thermostat assembly
4 Fuel return pipe 30 Cooling water pump
5 Fuel injection nozzle retainer 31 Cylinder head tightening bolt
6 Fuel injection nozzle 32 Cylinder head assembly
7 Nozzle seat 33 Cylinder head gasket
9 Nozzle protector 34 Valve spring
10 Bonnet assembly 35 Valve cotter
11 Valve rocker arm shaft assembly 36 Valve retainer
12 Push rod 37 Intake valve
13 Valve cap 38 Exhaust valve
14 Fan mounting bolt 54 Flywheel housing
15 Fan 55 Starting motor
16 Adjusting bolt 56 Flywheel mounting bolt
17 V-belt 57 Flywheel
18 Alternator 58 Oil seal case
19 Spacer 66 Piston
20 V-pulley 67 Connecting rod
22 Dipstick 74 Turbocharger (S3D84E, S4D84E)
23 – 26 Fuel return pipe 75 Surge tank (S3D84E)
68E-88E SERIES 16-3

(1)
16.2 Exploded views of engine components
YE0297
16-4 68E-88E SERIES

(1)
No. Engine Component No. Engine Component

8 Fuel injection pump 52 Mounting bolt
21 Oil filter assembly 53 Camshaft assembly
39 V-pulley clamping bolt 59 Tappet
40 Crankshaft V-pulley 60 Oil pan
41 Gear case 61 Spacer
42 Oil pan mounting bolt 62 Gear case flange
43 Gear case mounting bolt 63 Lubricating oil strainer
44 Stiffner bolt 64 Crank pin side cap
45 Oil seal 65 Crankshaft
46 Fuel injection pump drive gear 68 Crank pin metal
47 Lubricating oil pump 69 Main bearing cap bolt
48 Idle gear shaft 70 Main bearing cap
49 Idle gear 71 Lower main bearing metal
50 Camshaft gear 72 Upper main bearing metal
51 Thrust bearing 73 Thrust metal
68E-88E SERIES 16-5

(1)
20. EPA CERTIFIED ENGINE
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
68E-88E SERIES 20-1

(1)
20.1 Applicable machine, serial number (EPA certified engine)
Engine output
Engine Machine model Machine Serial No. Remarks
(kW{HP}/rpm)
2D68E-N3C PC09-1 10001 and up 6.2{8.4}/2,200
PC09-1
2D68E-N3CB 10001 and up 6.2{8.4}/2,200
(KUE & KUC)
2D68E-N3A PC10MR-1 30001 and up 6.6{8.9}/2,300
2D68E-N3B PC10UU-3 10001 and up 6.6{8.9}/2,200
3D68E-3K PC15MR-1 10001 and up 11.2{15.0}/2,600

3D68E-3KJ PC15MRX-1 (KUC) 10001 and up 11.2{15.0}/2,600
3D74E-N3AB PC20MR-1 10001 and up 14{18.7}/2,600
3D74E-N3AB PC20UU-3 10001 and up 14{18.7}/2,600
PC20MRX-1
3D74E-N3AJ 10001 and up 14{18.7}/2,600
(KUE & KUC)
3D78AE-3GB WA20-2 11270 and up 16.2{21.7}/2,450
3D82AE-3HB PC27MR-1 11113 and up 19.1{25.6}/2,600

3D82AE-3HC PC27MR-1 (KUC) 11113 and up 19.1{25.6}/2,600
3D82AE-3HB PC28UU-3 30831 and up 19.1{25.6}/2,600
3D84E-3DB WA30-5 18970 and up 21.3{28.6}/2,500
3D84E-3KB PC30MR-1 14277 and up 20.6{27.6}/2,500
3D84E-3KB PC30UU-3 11589 and up 20.6{27.6}/2,500
3D84E-3LB1 PC35MR-1 3229 and up 20.6{27.6}/2,500
3D84E-3LN PC35MRX-1 (KUC) 3229 and up 20.6{27.6}/2,500

3D84E-3MB1 PC38UU-3 8157 and up 20.6{27.6}/2,500
S3D84E-3BB WA40-3 13530 and up 27.2{36.5}/2,500
S3D84E-3BB WA50-3 20642 and up 27.2{36.5}/2,500
4D88E-3HB PC40MR-1 5501 and up 29.1{38.9}/2,450
4D88E-3HB PC45MR-1 3001 and up 29.1{38.9}/2,450
4D88E-3GB PC58UU-3 20001 and up 29.4{39.4}/2,400

4D88E-3CQ PC58SF-1 1001 and up 29.4{39.4}/2,400
20-2 68E-88E SERIES

(1)
20.2 EPA certification plate attaching location

• Direct injection system engine: 3 cylinders • Direct injection system engine: 4 cylinders
1
1
YE0298
YE0299
(View from top) (View from top)
1) Certification Plate 1) Certification Plate
• Swirl pre-combustion system engine
YE0300
1) Certification Plate
68E-88E SERIES 20-3

(1)
20.3 Differences with the current production model

In order to reduce the exhaust gas emission and ensure meeting the EPA standards, the following changes for
improving which have been made.
Direct injection system engine Swirl pre-combustion system engine

No.
VM VM
1 Fuel injection timing —
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.
3 Fuel injection pipe changes —
4 Fuel injection pump —
5 Fuel injection valve —
6 Cylinder head —
7 Piston —
Restricting seals for fuel injection quantity and

8
engine speed.
The EPA certification plate is attached to the engine.

9 For details on the contents and location for the plate,
see [section 20.2].
• Notice
FIC, FID explanation
Symbol Unit Terminology Explanation
The timing at which the plunger barrel suction port closed

Fuel compression and the fuel compression starts. (B.T. D.C.)
FIC
starting (Had been adjusted by Yanmar fuel injection pump manu-
facturing plant)
Degree (B.T. D.C.)
The timing at which the fuel starts to be discharged from
Fuel delivery the delivery valve outlet port. (B.T. D.C.)
FID
starting [Adjustable (visually adjusting) on engine installing fuel
injection pump]
20-4 68E-88E SERIES

(1)
20.4 Fuel injection timing adjustment

20.4.1 Driving Part Structure of Fuel Injection Pump
(1) Current production engine model
• Structure of driving parts: A driving gear is installed directly at the edge of the fuel injection pump
cam shaft.
• Fuel injection timing adjustment.
Direct injection system engine

FID method, adjusted by turning the fuel injection pump to the right
N-series Swirl system pre-combustion
or lefthand around the fuel injection pump cam shaft.
engine
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
Fig. 1 Current production engine model: Direct injection system engine

N-series (Swirl pre-combustion system)
1) End nut
2) Fuel injection pump driving gear
68E-88E SERIES 20-5

(1)
2 5
3
YE0302
(Pump case integrated in gear case)
Fig. 2 Current production engine model: Swirl pre-combustion system engine

(Not including N-series)
1) Fuel Injection timing adjusting shim 4) Gear case

2) Fuel injection pump driving gear (Thermal insert) 5) Aligning mark
3) Gear case
20-6 68E-88E SERIES

(1)
(2) EPA certified engine

(2-1) Direct injection system engine
• Driving part structure: the fuel injection pump coupling is fitted to the end of the fuel injection
pump cam shaft. After the FIC is adjusted, the fuel injection pump coupling is locked to the pump
body not to turn the fuel injection pump cam shaft using the lock bolts. (Adjusted by fuel injection
pump manufacturing plant of Yanmar)
• Fuel injection timing adjustment: Adjusted by using the FIC fixed method.
YE0303
Fig. 3 EPA certified engine: Direct injection system engine
1) FIC lock bolt

2) End nut
3) Fuel injection pump coupling
68E-88E SERIES 20-7

(1)
(2-2) Swirl pre-combustion system engine

• Driving part structure: The coupling is attached to the end of the fuel injection pump cam shaft
(shrinkage fit), the driving gear is attached to the coupling with bolts.
• Fuel injection timing adjustment: Adjusted by a FIC fixed method.
i) Attach the driving gear to the couping temporarily and fix the gear so that it does not turn
using the jig.
(Alignment mark for driving gear: No.1 cylinder at top compression position of engine)
ii) Turn the fuel injection pump cam shaft to the clookwise viewed from the gear side and
examine the FIC position of the No.1 cylinder.
iii) Turn the fuel injection pump cam shaft to the clockwise further more (fuel injection timing x
1/2 deg.) to decide the position of the fuel injection timing on the fuel injection pump. After
that, fix the driving gear to the coupling with 4 bolts. (Adjusted by fuel injection pump manu-
facturing plant of Yanmar)
3 Bolt (M7) tightening torque (not apply lub. oil): 13.7 ± 2 Nm {1.4 ± 0.2 kgm}
1 2
6
4
8
5
9
YE0304
Fig. 4 EPA certified engine: Swirl pre-combusiton system engine

1) No.1 cylinder 6) Fuel injection pump driving gear fixed pin hole
2) Fuel injection timing shim (0.8 mm regularly) (Tool to prevent turning)
3) Gear attaching bolt (4-M7) 7) Gear case
4) Coupling (Shrinkage fit) 8) Aligning mark
5) Fuel injection pump driving gear 9) Cam shaft driving pin hole (Coupling, for jig)
(2-3) Swirl pre-combustion system engine (2D68E-N, 3D68E-N, 3D74E-N only)

• Driving part structure: Driving gear is attached directly to the end of the fuel injection pump cam
shaft as in the current production model, however, the method for marking to install on the engine
differs from the current production model.
• Fuel injection timing adjustment: Adjusted by the FIC fixed method
i) Using the marking tool, turn the fuel injection pump cam shaft to the clockwise viewed from
the gear side to find the FIC position (A°) for the No.1 cylinder.
ii) Turn the cam shaft further more to the clockwise from the FIC position (B°: fuel injection tim-
ing of engine x 1/2 deg.), decide the position for fuel injection timing on the fuel injection
pump and mark the installing mark on the engine. The position for the installing mark is 45 ±
1 degrees from the center of the fuel injection pump with the fuel injection timing adjusting
shim. (Had been adjusted by pump manufacturning plant of Yanmar)
20-8 68E-88E SERIES

(1)
1) No.1 cylinder, FIC key way location

2) Marking for adjusting shim 1
(Shim thickness differs for each fuel 4
injection pump.) 5
3) Flange marking tool
2
4) Marking
5) Direction of rotation
YE0305
Fig. 5 The adjustment point of the fuel injection

timing
2 6
1
YE0306
(Flange attachment method)
Fig. 6 EPA certified engine: Swirl pre-combustion system engine (2D68E-N, 3D68E-N, 3D74E-N only)
1) No.1 cylinder 3) Timing seal line

2) Marking for adjustment shim 4) End nut
(Shim thickness differs for each 5) Fuel injection pump driving gear
fuel injection pump.)
6) Key way location
68E-88E SERIES 20-9

(1)
20.4.2 Fuel Injection Timing Adjustment

(1) Installing the fuel injection pump in factory
Procedure
i) Align the fuel injection pump with the mark shown in figure 7 and install on to the gear case.
a Align the mark on the fuel injec-
tion pump with the center mark
(5th mark from the top) on the
gear case.
1
1) Fuel injection pump flange

2
2) Gear case YE0307
Fig. 7 Aligning the mark on the fuel injection

pump and gear case
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

2) Cam gear
3) PTO gear
7
4) Crank gear 3
5) Direction of revolution
4
6) Lub. oil pump gear 6 5
7) Idler gear YE0308
Fig. 8 Aligning the timing of the gear train.

(1)
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
Fig. 9 Fuel injection pump coupling driving gear unit
1) End nut 2) Coupling, gear, bolt assembly.
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}
vii) Remove the FIC lock bolt. (See figure 3.)

The fuel injection timing adjustment is completed.
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.

(1)

Procedure
i) Install the fuel injection pump/governor assembly (pump case integrated in gear case) to the
body of the engine. (Figure 4)
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

2) Cam gear
3) PTO gear 7
3
4) Crank gear
5) Directon of revolution 4
6 5
6) Lub. oil pump gear
YE0310
7) Ldler gear
Fig. 10 Aligning the timing make of the gear

train.
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.

(1)
(1-3) Swirl pre-combustion system engine (2D68E-N, 3D68E-N, 3D74E-N only)

Procedure
i) Align the fuel injection pump with the mark shown in figure 11 and install on the gear case.
a Aligning the marks on the fuel injection pump and gear case is the same for all these mod-
els.
1) Fuel injection pump flange 2

2) Gear case YE0311
Fig. 11 Aligning the marks on the fuel injection

pump and gear case
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

2) Cam gear
3) PTO gear 7
3
4) Crank gear
5) Direction of revolution 4
6 5
6) Lub. oil pump gear
YE0312
7) Idler gear
Fig. 12 Aligning the timing marks of the gear

train
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.

(1)
(2) Replacing the fuel injection pump on the local.

When the pump has become old and worn, replace the pump in the following manner.

a The fuel injection pump as the service part is the same as that used in the standard engine
(without coupling) (see fig. 1)
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.

• Replacing only the fuel injection
pump
As with the standard engine, injec-
tion timing adjusting shims (1) are 1
inserted between the gear case and
the fuel injection pump for adjust-
ment. Check the injection timing
with the FID method.
1) Adjusting shim YE0313
Fig. 13 Adjusting the injection timing
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
• Replacing the fuel injection pump cam shaft

Procedure
i) Remove the cam shaft, coupling, drive gear and bearing for EPA.
ii) Assemble the fuel injection pump cam shaft assembly (cam shaft, drive gear, bearing) for
the current production engine and adjust the injection timing with the shims and check the
injection timing with the FID method.

(1)
(2-3) Swirl pre-combustion system (2D68E-N, 3D68E-N, 3D74E-N only)

Replace with the fuel injection pump assembly for EPA.
Procedure
i) Replace the injection timing adjusting shims for the fuel injection pump.
Remove the adjusting shims for the failured fuel injection pump and measure its thickness.
Replace with the new shims of the same thickness as measured ones.
a The fuel injection pump shim thickness for EPA use differs for each fuel injection pump.
ii) Check the injection timing with FID method.

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

(1)
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
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
Firing order 1 – 2 – 1 (No.1 cylinder on flywheel side)

Power take off Flywheel
Direction of rotation Counterclockwise (viewed from flywheel)
Cooling system l Radiator [Cooling water capacity (engine only): 0.6]
Cooling fan Pusher type• 260 x 5 blades
V-pulley dia. 105/85 (Crank/Cooling fan)
Lubrication system Forced lubrication with trochoid pump
Electric starting (Starter: 12V-0.8kW, Alternator: 12V-15A)
Starting system
[Battery capacity (recommendation): 12V-28Ah (5 hours rate)]
Applicable fuel oil Diesel fuel oil [ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.)]
Applicable lub. oil API grade, class CC or higher grade
Lubricating oil capacity (Oil pan) l Max/Effective: 1.6/0.6
Engine operation Continuous degree Z25° (front, back / left, right)
Permissible inclination
angle Instantaneous degree Z30° (front, back / left, right) (Note) Operating time: 3 minutes max.
Dimensions (L x W x H) mm 400 x 401 x 495

Dry weight kg 65
NOTE: Engine dimensions and weight:

• Flywheel housing for direct couple with power machinery
• Radiator fan equipped (Radiator not included)

(1)
(2) 3D68E
Model unit 3D68E
No. of cylinders 3
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 timing degree B.T.D.C. :14 ± 1.5 (FID)
MPa +0.98 +10
{kg/cm2} 0
Firing order 1 – 3 – 2 – 1 (No.1 cylinder on flywheel side)

Radiator [Cooling water capacity (engine only): 0.9l] [Cooling fan:
Cooling system l Pusher type• 310 x 5 blades, V-pulley dia.: 105/85 (Crank/Cooling
fan)]
Starting system
Dimensions (L x W x H) mm (*1) 474 x 401 x 495 / (*2) 466 x 401 x 495

Dry weight kg (*1) 81 / (*2) 70

• (*1) Flywheel housing, (*2) Back plate equipment for direct couple with power machinery.

(1)
(3) 2D68E-N
Model unit 2D68E-N
No. of cylinders 2
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
MPa
Fuel injection pressure 11.8 +0.98 {120 +10
0}
{kg/cm2} 0
Firing order 1 – 2 – 1 (No.1 cylinder on flywheel side)

Cooling system l Radiator [Cooling water capacity (engine only): 0.6]
Cooling fan Pusher type• 260 x 5 blades
V-pulley dia. 105/85 (Crank/Cooling fan)
Starting system

Dry weight kg (*1) 63 / (*2) 52


(1)
(4) 3D74E-N
Model unit 3D74E-N
No. of cylinders 3
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 timing degree B.T.D.C :14 ± 2.0 (FID)
MPa +0.98 +10
{kg/cm2} 0

Radiator [Cooling water capacity (engine only): 0.9l] [Cooling fan:
Cooling system l Pusher type• 310 x 5 blades, V-pulley dia.: 110/85 (Crank / Cooling
fan)]
Starting system

Dry weight kg (*1) 105 / (*2) 85


(1)
(5) 3D78AE
Model unit 3D78AE
Combustion system Direct injection
No. of cylinders 3
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
B.T.D.C.
:12 ± 1.0 (FID)
MPa +0.98 +10
{kg/cm2} 0

Radiator [Cooling water capacity (engine only): 1.8l]
Cooling system l
(Cooling fan: Pusher type• 335 x 6 blades)
V-pulley dia. (Crank / Cooling fan) 110/110
Starting system
Max/Effective:
5.0/2.2
Permissible inclina-
tion angle Instantaneous degree Z30° (front, back / left, right) (Note) Operating time: 3 minutes max.

Dry weight kg (*1) 128 / (*2) 117


(1)
(6) 3D82AE
Model unit 3D82AE
No. of cylinders 3
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
B.T.D.C.
:11 ± 1.0 (FID)
MPa
Fuel injection pressure 19.61 +0.98 {200 +10
0}
{kg/cm2} 0

Cooling system l
Starting system
Max/Effective:
5.0/2.2

Dry weight kg (*1) 128 / (*2) 117


(1)
(7) 3D84E
Model unit 3D84E
No. of cylinders 3
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
B.T.D.C.
:12 ± 1.0 (FID)
MPa +0.98 +10
{kg/cm2} 0

Cooling system l
Starting system
Dimensions (L x W x H) mm 556 x 486 x 623

Dry weight kg 142

• Flywheel housing for direct couple with power machinery

(1)
(8) S3D84E
Model unit S3D84E
Aspiration Exhaust gas turbocharged
No. of cylinders 3
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
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
{kg/cm2} 0

Cooling system l
Starting system

Dry weight kg (*1) 155 / (*2) 142


(1)
(9) 4D88E
Model unit 4D88E
No. of cylinders 4
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 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
Firing order 1 – 3 – 4 – 2 – 1 (No.1 cylinder on flywheel side)

Cooling system l
Starting system
Lubricating oil capacity (Oil pan) l Max/Effective: 5.8/2.3 Max/Effective: 8.6/4.2

Dry weight kg (*1) 170 / (*2) 160


(1)

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SEBM011501

1. SPECIFICATIONS AND PERFORMANCE................................................................ 1-1

2. CROSS SECTIONAL VIEWS..................................................................................... 2-1

3. COOLING WATER, LUBRICATING OIL AND FUEL OIL ......................................... 3-1

4. TROUBLESHOOTING ............................................................................................... 4-1

5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS ........................... 5-1

6. MEASUREMENT, INSPECTION AND ADJUSTMENT ............................................. 6-1

7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION....... 7-1

8. DISASSEMBLY AND REASSEMBLY ....................................................................... 8-1

9. SERVICE DATA ......................................................................................................... 9-1

10. TIGHTENING TORQUE ........................................................................................... 10-1

13. GOVERNOR ............................................................................................................. 13-1

14. TURBOCHARGER ................................................................................................... 14-1

15. SERVICE INFORMATION FOR CARB ULG REGULATION .................................. 15-1

16. ATTACHED DRAWING............................................................................................ 16-1

20. EPA CERTIFIED ENGINE........................................................................................ 20-1

00-2 68E-88E SERIES

The affected pages are indicated by the use of the

Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

68E-88E SERIES 00-3

Time of Time of Time of Time of Time of

00-4 68E-88E SERIES

Applicable machine, Serial number (Current Production Model)

3D68E-3G PC12R-8 10001 and up 10.3{13.8}/2,450

3D68E-3H PC15R-8 10001 and up 11.2{15.0}/2,600

3D74E-3C PC20R-8 10001 and up 14.0{18.8}/2,600

3D82AE-3E PC25R-8 10001 and up 17.7{23.7}/2,400

3D82AE-3F PC27R-8 10001 and up 19.1{25.6}/2,600

PC30R-8 10001 and up 20.6{27.6}/2,500

4D84E-3B PC50UU-2 12772-14992 29.4{39.4}/2,800

4D84E-3C PC50UU-2 14993 and up 29.4{39.4}/2,800

Application code Usage Eng. Rev. type. Revolution speed (rpm)

★ For engine application category described in Chapter 1, Specifications and Performance.

68E-88E SERIES 00-5

Descriptive Breakdown of Model Name

Cylinder bore (mm)

Application code Usage Eng. Rev. type. Revolution speed (rpm)

★ For engine application category described in Chapter 1, Specifications and Performance.

00-6 68E-88E SERIES

1. SPECIFICATIONS AND PERFORMANCE

1.1 2D68E..................................................................................................................................................... 1-2

68E-88E SERIES 1-1

Fuel injection timing

(full speed Recovery time sec Z6

1-2 68E-88E SERIES

Fuel injection timing

(full speed Recovery time sec Z6

68E-88E SERIES 1-3

Fuel injection timing

(full speed Recovery time sec Z6

1-4 68E-88E SERIES

Fuel injection timing

(full speed Recovery time sec Z6

68E-88E SERIES 1-5

Fuel injection timing

(full speed Recovery time sec Z6

1-6 68E-88E SERIES

Fuel injection timing

(full speed Recovery time sec Z6