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    MOTOR KOMATSU 68E

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    Motor Komatsu 68e

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    SEBMO11501 SOP Js4 LENIN IOAN Ln KOMATSU 6SE-8SE SERIES 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 hal, since they are same as those of the conventional engines. ©2003 Komarsu All Rights Reserved Printed in Japan 05-03 (01) 00-1 a) 10. 1. 12. 13. 14, 15. 16. 20. 00-2 a) CONTENTS SPECIFICATIONS AND PERFORMANCE... CROSS SECTIONAL VIEWS.. COOLING WATER, LUBRICATING OIL AND FUEL OIL TROUBLESHOOTING . SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS MEASUREMENT, INSPECTION AND ADJUSTMENT .. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION... DISASSEMBLY AND REASSEMBLY... SERVICE DATA TIGHTENING TORQUE ... 10-1 FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM .. 44 FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM... 1241 GOVERNOR... 13-4 TURBOCHARGER 1441 SERVICE INFORMATION FOR CARB ULG REGULATION ... 151 ATTACHED DRAWING. 16-1 EPA CERTIFIED ENGINE. 20-1 68E-88E SERIES LIST OF REVISED PAGES ‘The affected pages are indicated by the use of the following marks. It is requested that necessary Mark Indication ‘Action required actions be taken to these pages according to the table below. Page to be newiy added Aad ‘@_| Page tobe replaced Replace () | Page tobe deleted Discard Pages having no marks are those previously revised ‘or made additions. LIST OF REVISED PAGES Mark Page TM®°" | fark Page TO! Mark Page TI O'| mark Page MEO! Mark Page Me ot eo or fe os mle 6 mile ms m fe oe eo 02 1 |e 32 le 67 a fe m5 mle 8s os a) |e 33) fe se) fe rte) | @ 8s 04 a) ec os a lo 35 m |e so fe 78 | o@ 88 ay eos a fo 38 mM |e on a le m9 i fe 88 eee fe 72 oOo et wy eo fe at le ss a fe re mm fo en em fe 42 fe sm Hy le re oy eC ee em mM fo 4 ew 1) fe 72 fe 82 en 45 |o e7 m |e 72 fe 98 a) 2 | o ot a) | 728 i fe oe ew o 6 fe 727 le 9s) er om fe st 7) | @ 98) et fe 52 fem ay [oo 8 er) emo le ss Mle nw 730 (1) o8 at) em miles mle wm 731) eon a fe 55 mle 74 lo 72 wr) eos a fo 58 mle 7s a 733) | oO 102 o m4 my fo sr om fe te 734) 103 o 58 Mle 77 Wy fo 735 eo eo 7 m6) | @ om e 2 le oe mle 7 mw lo m7 mle m2 23) |e 62 fe eo ens ee ee > 26 a) fe oe oo fe ee my fe a2 le ts ess mle zs mile 8 6 68E-88E SERIES 00-3 a) LIST OF REVISED PAGES mark Page RMP mare Page mE"! mark Page EMEC | Mark Page TE! | ark Page (ume Of er 2022) o ome mH |e 42 | o 2029 ee em fe es eo 22 le us e 2 le 6 a eo 4 “ar it) eons fo «8 4) © 2s eon wy le tt ers (|e 2 @ 128 (1) Oo 163 (1) e140) ea ay fe te @ 1242 (1) e 162 (1) e 23 mH |o 63 14) | 84a) o ms (| o 165 a) 2181) 0 m1 e 1 mH | o m2 @ 13220 (1) OQ 203 (1) e@ 1330 (1) 20-4 (1) e148 a) 25 (1) a ) © 6 | o 27 MH) e 7 (| o m8 e@ 138 (1) 20-9 (1) eRe 2040 (1) @ 1340) 2041 (1) eo | o 202 4) oe B12 2043 (1) oO 1813 (1) 2014 (1) oR 2045 (1) © 148 2046 (1) o 1346) zoa7(t) © ar ay | o 2018 41) 1318 (1) 2018 (1) 2020 (1) o 221) 00-4 a) 68E-88E SERIES LIST OF REVISED PAGES Applicable mac! 1@, Serial number (Current Production Model) Engine output Engine Machine model | Machine Serial No. | GuWipyntny Remarks 3088E-36 POTARS 70001 andup | 10.3(13.8y/2,460 3088-3H PCIER-B 10001 and up | 11.2(16.0V2,600 3D74E-3C PC20R-8 10001 and up 14,0{18.8)/2,600 3D82AE3E PCZERB 10001 and up | _17-7(28.7¥2,400 ‘3D82AE-3F PC27R-8 10001 and up 19,1{25.6/2,600 PC3OR-B 70001 and up | 20.6(27.6)72,500 aD84E-3F PC35R-8 36001 and up 20.6{27.6)/2,500 4084638 PosouU2 varra-taea2 | 29.4(99.4)2,000 4DB4E-3C PC5OUU-2 14993 and up 29.4{39.4)/2,800 PCAOR-B 30001 and up | 28.3(87.9)/2,500 ADBAE-20 PC45R-8 5001 and up 28.3{37.9)/2,500 Application Category Application code Usage Eng. Rev. type. Revolution speed (rpm) ot 7,500/1,800 Generator drive Constant cH 3,000/3,600 vw 2,000 - 3,000 General use Variable vA 3,000 - 3,600 4 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 tems. For details, see the Parts Book.) (Example) Update the part numbers and codes in this shop mnual: 172187-08520-»YM172187-08520 68E-88E SERIES 00-5 a) LIST OF REVISED PAGES Descrij (s) ive Breakdown of Model Name 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 (pm) 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 4 For engine application categary described in Chapter 1, Specifications and Performance. 00-6 a) 68E-88E SERIES 4, SPECIFICATIONS AND PERFORMANCE . SPECIFICATIONS AND PERFORMANCE 11 2088E: 12 1.2. 3D88E. 13 13° 3D74E 14 14 3D78AE 16 15 3D82AE 16 1.6 30826. wz 1.7 3D84E. 18 1.8 3D88E. 19 1.9. 4D82E: 110 1.10 4D84E: on 1.11 4D88E: 112 1.12 S3086E 113 1.13 SADB6E 114 68E-88E SERIES 1-1 @ 4, SPECIFICATIONS AND PERFORMANCE 1.1 2D68E tem Model) Grit 20886 oe = mi ar coinonnee fae) - | - | - | - | - - JOutput (1) IM: fi RW 574 6.25 6.84 743, 7.38 8.45 tax. rating wHey | (7-8) 65} @3) | gon | dog | (tp |Fuet injection ming He |(FID, B.7.0.c), oa ‘et iS lec MPa 3.24 + 0.1{33 + 1}, at 250 Mawétfectve| © 5106 Fan V-puley cia} ™ 9951 985 Bower a ae Icovering [aifference % 12 w|mance — [band % 2 8 7 6 8 l(a speed [Reenvary ie we z E |range) Fluctuation of = = evokiion om #0 tare: lfamtononon | yp, | wotos Ganon (eases) pressure lang foie poe) 1-2 68E-88E SERIES ay 4, SPECIFICATIONS AND PERFORMANCE 1.2 3D68E tem Model Unt S88E IRpprcaton = wa ype = Varical, #-oyle water-coted diesel engine [Combustion ayatom = Special sw pre-combusion camber Ne. cylinders — bore x Store im 3= 58x72 Displacement z O78 Firing oroer = 7=3-2-1 Revolution speed rom_| 2000[ 2700 [200 [2600 [2.800 [3.000 ri continuous ratna | fm, | = = = = — loutput int) Wax retng aw | 88 | 8a oS] Ha | a0 ey | is) | 2a | esa | oso | 16.1) Max revouiton speed atnoload | |, | 2.180% | 23752 | asrovs | 2700" | 270-9 | 3.100% Min. revolution speed at no oad . 3200 Dien afretation = ‘Counterciockwise (viewed Fom Tweed Power take off = Fiywhes! [Compression rato = 230 Fuelinjecton Sing (#10, 8.7.0.0) oo et Pe [Compression pressure 3.26.20.1{38 4 1), at 260 pm pression px woe 193 1), at 250 rp MPa Fuel injection pressure “3 ¢120"3 jection eet 18 "8120"%) Recommended diesel ga8 a = TSO 8277 DMA, BS 2665.A1 or A? (Celane No.5 in} Lubraaton ayer = orcad lubriaton with Woche pump Tubrestion ol capacity Maxetectve| 2a Recommended ubiating of = ‘APT rade CC cass or igh [Cooling system = Liquid cooling Radiator (Cooing water capacly z 0.9 (for engine ony) (Gootng Tan e No. ofbiede xaa) Pusher type, 5x $310 [rank V-puley dia Fan v-piley ia 105/985 [Governor = ‘Mechanical canstugal governor (AT seed pe) [Saring ayatom = Eleciical Dimensions LxWxH) mm GOT EXADI x 496 [ATS EXADI XA Dry weight (2) ‘a Tost ransiont spead z % si2 Icovering |ailerence ipeto~ |Steadystiespeed |] 2 Za 2 Imence [band x S(t soeed Recovery ire Eo = E|'ange) | uctuation of E[me Beer Tn 0 ie Rated open 0252005 2005 lose = 0.05 Lubcatin [Red operation Mea 25205) (80205) (85205) ol pressure fholem 3006 lang ma “1 Output conditions: Intake back pressure s 2,45 kPa (250 mmH,O}, Exhaust back pressure = 5,39 kPa (550 mmH,0}, 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 68E-88E SERIES 1-3 a) 4, SPECIFICATIONS AND PERFORMANCE 1.3 3D74E Nodal tem Unt 3074E [Applcation = vir [Type = Vertical, d-cydle water-cooled diesel engine [Combustion syatom = ‘Special swid pre-combuston chamber INo.cyinders bore x Some mm 3 Tax TB [Displacement z 71006 Finng order = 7232-7 Revolition speed vem | 2000 [2200 [~2a00 | 2800 [7600 | 3.000 [Continuous rating ket = = = = = = Jouput (+1) sd Ion tn ew | tio | ai] 32) as] i ey | caer | cea | a7 | 92 | eos | ea Max revolution speedatroteed |, | a.t80"% | 27s" | 25708 | 2780" | 2.970°% | 3.1808 Min. revolution speed aire fad $800 1 [recon af rotation = Countercackwise viewed from Thwheal Power take of = Flywheel [Compression rao = 230 2 Fuel injection timing He |(F10. 8. Fc), ceo et FS |compcessionpreaure MPa 343 £ 0.1384 1) at 250 pm a| {kgicm’) 6 ie MPa Fue injection pressure "(120° jection ps | eoem sa $0920) [Recommended diesel gas of = TSO 8217 DMA, BS 2869 AT or A2 (Celane No-aS min) Lubrication ayatem = Forced tubreation with Yrochaed pump Lubrication ai capacity a Mavetecive| —¢ 2410 [Recommended hibreating of = ‘APl grade OC class or higher [Gootng system = Liquid eooting/Radtator [Goaiing water capacity z 0.8 (or engine only) [Coating Tan re No, ofbiadexaie) Pusher type, $x 0310 [Crank V-palley cia? 7 Fan V-pulley dia" on10¢65 [Governar = Mechanical cenifugal governor (Al speed ype) [Staring eyatom = Eleiical [Dimensions Lx Wx A) mm EBT XAADK 602 [ATE X AAO x 502 Dry weight (2) [4 a5rf02 Teansiont speed % 522 [Governing |sterence pron” Seaaysatewpeed |G, Jy 2 z 2 glmence [ba Eu speed [Recovery ime Eo = Elrange) [Fluctuation of Efe Beet Tn 0 le 1; 025 20.05 0.2920.05 jo.34 £0.05) Lubrication [ate operation MPa 25205) 0205) 35205) ol pressure tile) 3006 Iaing mos “1 Output conditions: Intake back pressure = 2.45 kPa {250 mmH,O), Exhaust back pressure s 5.39 kPa (550 ‘mmH,0}, other conditions complying with JIS D 1005-1986, After minimum 30 hour's run-in. "2. Designation of engine dimension and dry weight in numerals. Engine with back plate/with flywheel housing 1-4 io) 68E-88E SERIES 1.4 3D78AE 4, SPECIFICATIONS AND PERFORMANCE hen ort SOTBAE ran = ai hips = Vera ace wate ao care eomaior ter = Bret dion aston a sere Denacerer 7 308 Fg oer = eee Ravan sped spa | amo | E80 a [a0 ar fninowne | | -|-1-1-1-1- cura en ; sr ia az as] 88 es} 3 om | crn | den | eta ges | can (Max. revolution speed at no load rom. 2,180" | 2,375" | 2,670" | 2,780°% | 2,970" | 3,180°9 |Min. revolution speed at no load ~ 3800 recon atten = area ed Fm Ta Power oF = Fie Gores ao = "30 2 |Fuelinjection timing 7 7 7 § Famine ves ze eet Set 5 lconpesson reser Ti 31405824 7 a 280ipm 2 tkalom’) : é wir ection p tegiom) 19.6°°$(120"%) Recorded cai oas at 150 aE DW BS BESTA rf Coane NOTE TIA) ater stom = oration pare fasta otcopoiy vavetoonel ! sana sont Recormanaibn ah = erates oa cooing son = Cad ong Radar Soto wae canaciy 7 1 fergie on coca ar “ Ne oumsewanl Pusher ype, 6 9285 rave aa Fan V-pulley dia] 91101910 Soener = canal ential gwar A eed Wa Sone = tear Soom WRATH am SAUTE 5 EK OTS Down a) is vaes aaa eS * — covering [atone pews" (Seaiy saad —1— J z 3 E\(ct'speed [Recovery ime we z Eleree castors? e fevtuton 15m a 2 0282005 Lubrication [Rated operation MPa (3.0205) tigre fam 3005 ta ae 4 (Output conditions: Intake back pressure = 2.45 kPa {250 mmH,O},Exhaust back pressure = 5,39 kPa (550, mmH,0},other conditions complying with JIS D 1005-1986. After minimum 30 hour's run-in. 2 Engine with back plate/with flywheel housing 68E-88E SERIES Designation of engine dimension and dry weight in numerals 15 a) 4, SPECIFICATIONS AND PERFORMANCE 1.5 3D82AE = Woda tem Uni SD82AE [Application = ar "Type = ‘Verioal, Zeeks water coated dasel engine | Combustion system = Direct injection system No, cyindars — bore x Stoke mm 382K eS Displacement 7 7.330 [Fring order = i=3-2-7 Revolition speed pm | 2000 | 2200-[ Za00 | 2600 | —2a00 [3.000 [Continuous rating mi-}-f-]-)-d- Output (4) a Maxcatne 70 | Ws | a0 | 205 | aS 8 eo | ero | eam | ess | ers) | 295) Max revolution speed at no load wpm | 2120°S | 2975°3 | 25703 | 2.780% | 2070°9 | a.180~2 |Win. reveluton speed at no Toad “ 00 Direcion of rotation = Cauniereiocavise (viewed War Rywhesly Power take off = Fiywhesl 1 [Compression ratio = 180 § [Fact injection timing 7 alaperec eg ie 14e1 168 5 MPa 3 | Compression pressure 3.048 0.4(8% 2 1), at 250 rom 3 Compression (aon 11 £1, MPa Fuel injection pressure 19.618 (2007 [Fs etin wor 42008) Recommended dasel gas ol = 150 8217 DMA, BS 2669 AT or AZ (Colane No-48 min) Tubricaton ayatem = Toreed luntaton wih wach pump bration al capaciy MaeFecwe |? B07 Recommended hibrcaing of = “BI grade CC class or Fighor [Cooling syster = quid cooling/Radiator Cooling water capacity a 78 forengine oni) Cooling fang otbiade xia) ™™ Pusher type, 6x 335 | crane Valley dar Cane PuY 28 anvgutey ia ang 110 |covernor = ‘Macharicalcontfuga governor (Allspeed type) Staring system = Electical Dimensions Lx WAT) mm ROB BOK 555 [528 X ABO KBE [Dey weiaht 2) kg *iariae Transient speed Governing [Atierence % s2 perfor [Steady sate speed % low De z z mance [and 8 ltaspeed [Recovery ire 36 x range) |Ftactution of é clon om 2 a} 0292005 Lubrication [Rated operation MPa (30205) ol pressure {halo $0.08 ang me “1 Output conditions: Intake back pressure 2.45 kPa (250 mmbH,O},Exhaust back pressure 5 6.39 KPa (550 ‘mm,0},other conditions complying with JIS D 1005-1986. After minimum 30 hour's runvin *2. Designation of engine dimension and dry weight in numerals. Engine with back plate/with flywheel housing 16 68E-88E SERIES 1.6 3D82E 4, SPECIFICATIONS AND PERFORMANCE tem Unt 3082 IRppicaTon = var Type = Vera, cycle water-cooled diesel engine [Combustion ayatom = Direct injection system INo.cyinders — bore x Stoke am 3 82x80) [Displacement z 7425 Firng order = i=3-2-7 iRevoltion speed vem | 20002200 [Bao [2600] 700 | 5.000 [Continuous rating wey = = = — = louput *4) cel IMac aw | 155] ves | ea] TOS | aS) wa 2 we) | gos | gan | ean | eon | aH | 1 Max. revolution speed atroioad | rpm | 2.160% | 2375~% | 2870“ | 2,780" | 2,970°% | 5.180" Min. revolution speed at no oad 800 [Direction of etation = Couniereiocavise (wewed Far Rywhesly iPower take of = Flywheel 2 [Compression rato = 780 3 Jruel jection tng alee eg 181 14s 1621 5 wPa § [Compression pressure 3.06 £ 0.481 £1}, at 250 rpm & [Comeression toon M1 £1, at 250 rp MPa [Fuel injection pressure 19.6°"3,200°% ection p tor 9.6°"$ (2003) [Recommended diesel gas of = TSO B27 DMA, BS 2869 AT or AZ (Celane No-45 min) [Cubration system = Forced ibrcaton with Vochord pump Lubrication of copaciy MaxieRecive| —t amie [ssa Recommended hibreaing of = ‘API grade CC dass or higher (Coating system = Liquid cooling/Radiator [Cooling water capacty z 2.0 (fr engine ony) [Cooling fan No-ofbiadexda) ™ Pusher type, 6x $325 (Crank V-pulley dia? 5 Fan V-pulley dia] ong 110 [Govemnar = Mecharical canlifugal governar (Allspeed ype) Staring system = Electreal [Dimensions LxWxH (2) mm 55 x 486 X 623 1564 x ABB XBT [Dry weiaht (2) ig 7367156 FWransient speed covering (aiference * a2 perfor [Steady sate speed 2 z gg|mance [band % 8 7 6 § |\tu speed [Recovery ime we % ange) |tactuation of ef [ctten tm a ie 0:3420.05 Lubrication [Rated operation MPa 85205) ot pressure ‘atem 30.06 ing G08} “1 Output conditions: Intake back pressure = 2.45 kPa {260 mmH,O} Exhaust back pressure = 6,39 kPa (550 mmH,0),other conditions complying with JIS D 1005-1986, After minimum 30 hour's rursin *2 Designation of engine dimension and dry weight in numerals. Engine with back plate/with fywheel housing 68E-88E SERIES 17 a) 4, SPECIFICATIONS AND PERFORMANCE 1.7 3D84E ‘Model 30846 [Recommended diesel 938 of en wreater = i Tipe = Veal, ce Wate ned selene combs so = Dieeijcion syste Ros inde = bore x Soe [an 3=84x90 Dsplaemert 7 195 [Firing order = 1-3-2-7 Reveaion peed wam_| Bae ag00 | B800 [Base (Continuous rating Ky - = = - = JOutput (*1) {A Naxraine wl | eae) a7] as} ao wm | cn | cam | esa | aoa | cnn | coo Mex revautonspeedatroloss |, | 175° | 2075°% | 2900" | 2000" | S00" | 9.005% [Min. revolution speed at no load ~ 3800 ~ [Drestonsfrotaton = rer vie (ewe Ta Ta Power te of = Fie »[oamresson rao = 80 Eeestsa™ eo aa eet 3 [Compression pressure MPa 3.24 £0.1{33 + 1}, at 250 spm 3 tkglom’} Fut econ pressure |e v20"§ 00°F) TS0 8217 DMA, BS 2868 AT or AZ (Cetane No.45 rin) [Lubrication system eread lubrication with rachod pump [Lubrication ol capacity MaeRecive| aT [Recommended lubricating oi [Coating system ‘API grade CC class or higher Liquid coolng/Radator [Coating water capacity z 2.0 (for engine only) [Cooling Tan No.of blade xia) ™ Pusher type, 6x $335 (Crank V-pulley dia? T Fan Vepulley dia) ort0rg 110 (Governor = ‘Mechanical central governor (All speed type) [Staring system = Elecirical [Dimensions Lx Wx AZ) ra ‘BEB X 4B X 623 564 KABE REDS [Dry weight (2) De 1387155 Transient speed % 512 [Governing |sifference perfor. Steady stale speed % @ 2 a Imance [bana full speed [Recovery tne we s range) Fluctuation oF om 228 revolution 034005 Lubrication [ated operation MPa 5405) oi pressure! gle} S005 raling os} “1 Output conditions: Intake back pressure = 2.45 kPa {250 mmH,O},Exhaust back pressure 5.39 kPa {550 ‘mmH,0},other conditions complying with JIS D 1005-1986. After minimum 30 hour's runein Designation of engine dimension and dry weight in numerals. Engine with back plate/with flywheel housing 1-8 ay 68E-88E SERIES 4, SPECIFICATIONS AND PERFORMANCE 1.8 3D88E ten Unit 3088 iRpphcaton = vr ype = Verical &ole water-ooted diesel engine [Combustion ayeiom = Direct ijecion system No, inders — bore x ORS ain T= 88x90 Displacement Z 7542 Fring order = i=3-2-1 Revoluion speed om | 2000] 2200 [200 | 2600] 2800 [3.000 [Continuous rating wey - = = — _ ]Output (*1) {Ph hance mW | 780] T99 | 218 | ws | wa] 27a 0 {HP} (24.1) (26.7) | {29.0} 31.5) {33.8} 36.3) Max revoliion speed atro lead |... | 275% | 2375" | 2800~% | 200° | 3000-3 | 3225" Nin revaluion speed at ro lad . 300 Dieston of atten = Toner clockwise (viewed Fem Tywhea Power take of = Fiwheel [Compression rao = 180 3 |uet injection tring 1 slaneroo deg wet wast 621 5 Pe } [compression pressure 3:43 £ 0.1958 1, at 250 rpm | [Compression {lem u i MPa Fuel injection pressure "$200" ection p oun 19.6""§ 200") Recommended diesel gas of = ISO BHT DMA, BS 2869 AT orA2 (Geiane No.45 min) Lubrcaton system = Forced bbicalon with Woche pump Tubreaton of capaciy WaneFecive | i a8 [sama Recommended lubicatng of = ‘AP grade CC case origher [Coon system = Liquid cooling Radiator Cooling water capaciy Z "2.0 (er engine oni) Cooling fan . No.otbiade xia)" Pusher type, 6 x 0335 Crank pale da? Fan V-pulley dia.| 11079110 [Governor = ‘Mechanical centrifugal governor (All speed type) Staring ayatem = Tectcal Dimensions LxWxH (2) mn BSEKAREK SIS 1564 x AEEXOTS Dry weight (*2) ka 138/155 rransient speed % 512 [Governing |diference perors [Steady slate speed % 2 2 a mance [band 8 |tutispeea [Recovery tne wee = E |rerge) Fluctuation of z e revoktion ‘om 25 é aa 005 Lubrication [Rated operation MP (3.5205) ol pressure {ialere} 35.06 ising me “1 Output conditions: Intake back pressure = 2.45 kPa {250 mmH,O},Exhaust back pressure < 5.39 kPa (650 mmH,0},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 68E-88E SERIES 1-9 a) 4, SPECIFICATIONS AND PERFORMANCE 1.9 4D82E i 5 hon Unt onze stanton = vit hee = Vera ye water coed eT ogi combustor ayo = Die eco saat orem bore x ST oa T= 8x90 Dsslacerent 7 1201 Feng oer = 1234-21 Revatutor speed iam _| B00 |Z a00— [2400 | 2500 [-Z800 [a 00 (Continuous rating fd - - - = - = JOutput (*1) {Ph Inova ai} a08 | 228} 228-255 | a9 | 05 "3 {HP} | (27.6) 30.3) 82.9) (35.5) (38.2) {40.9} ix evliton speed at no fad wom [280° | Bars | asrorg [2.700% | ag70°2 |, 100°% |Min. revolution speed at no load ~ $800 Dresten sf rotten = rr Toe we Fa Ts Power tace of = Fyre 1 |Compreetn rato = 180 §|Fuel injection timing ean pac eg ast teat rs | MPa [compresin pressure 08 £0914 1 at 280 opm £|[Comeression glen (31.41), at 250 Pa Font rjctonprestre = 3200°8 jection pr toon 19.6°"§{200"3) Recommended esa ga T= [TSO W217 OMA, BS R89 AT or 2 Catan NaS TRy Taco sa = vce bn wh Foes PO [Lotion o apecly Maneaie—| 7 38 Recorimended ubreatng of = APT rads cas Ther Costing system = Lil oeingfRadiator cooing water copay 7 27 (erengne on) cooing an * No. ofbiade xdia| Pusher type, 6 370 rank Vay Ba peeve eet ranvuley dia ™ gntovent0 |Governor = ‘Mechanical centrifugal governor (All speed tye). Staring tem = Elect [Dmersons Cx WAT) om TEXTES 650K TSS De weione 2) ia 1601170 Trarlan oped |Governing difference * 512 ret |Sieady state speed band = a 8 Recovery time ‘sec 6 Blt specs | Efe) ovcuton tom as H Osa T0a5 Lubrication [Rated operation MPa {3.5405} atoreceure gem) 3005 ang ae 1 Ouiput condone: Intake back pressure & 2.45 kPa (250 mmH,O) Exhaust back pressure = 6.38 KPa (650 rmm,0).thercondtons complying with JIS D 1008-1986. After minimum 30 hours ruin “2 Designation of engine mension and dy weight in numeral, Engine wih back patfwithfywhee! housing 1-10 68E-88E SERIES a) 4, SPECIFICATIONS AND PERFORMANCE 1.10 4D84E tem Unt 40846: TAppICaon = Wir Hype = Vertical, 4-aydle water-cooled diesel engine [Combustion syatarn = Direc injection system Ne, cylinders — bore x Stoke mm 3 84x90 Displacement z 7395 [Firing order = 234-27 Revoluton speed wpm | 2000 [2700] 2.400] 2.600 [2800 [5000 [Continuous rating mwyofyof, eye pepe (output 1) -— IMac a * we) | asa | G23 | osm | Gea | ara | aan Max. revolution speed at no load rpm |2190% | 2400~% | 25003 | 2010" | 2.905% | 3210% | in. revolution speed at na Toad $800 Direction of rattan = Gouriereiocewise (viewed Fam Hywel) Power take off = Flywhest 2 [Compression rato = 180 Fuel injecton timing 7 aconroo «eg wet a1 1681 is wPa § Compression pressure 8.24 £ 0.1(83 41), at 250 rpm flComeressiono toon (33 £1, at 250 rr MPa Fuelinjecton pressure 19.6°"8 200° "3,200" [Feinictono tor 9.6°"5 (2009) 196°"8 200") Recommended diesel gas al = TSO 8217 OMA, BS 2865 AT or A2 (Cetane No-aS min) Lubrication system = Freed bration with vochokd pump bration ol eapaniy Maeecive | —t 5823 Recommended lubricating of = ‘APlarade CC class or higher [Cootng system = Liquid e2aling/Radlator (Gooting water capacity z 2.7 (for engine oly) (Gooting Yar ‘3 io ofblade xia) Pusher type, 6 4 370 [FRR eyed vow no [covemor = Mechanical coninfugal governor (Allspeed pe) Siaring salem = Electical Dimensions Lx WA C2) mm TSI XAGEE NTS | 658 XAOS OTE [Dry weight (2) kg ‘60/170 Transient speed ‘Governing |atterence % 5 pet Seady sale peed band | —% w = Slat speng [Recovery time Bee # Fro [lucia on % is TH zO Lubrication [Rated operation MPa 65405) (ol pressure ‘kolem? 008 lang mos} *1 Output conditions: Intake back pressure = 2.45 KPa {250 mmH,O},Exhaust back pressure = 5.39 KPa (550 mmH,0},other conditions complying with JIS D 1005-1986, After minimum 30 hour's rursin "2. Designation of engine dimension and dry weight in numerals. Engine with back plate/with flywheel housing 68E-88E SERIES 4, SPECIFICATIONS AND PERFORMANCE 1.11 4D88E ‘Nodal 4088E | Recommended diesel gas oll arn Tappteaton = var Type = ‘Vere, Hoyele water-cadled dasel engine [Combustion system = Direct injection system No, cylinders ~ bore x STK mm 4=88x90 Displacement t Z108 | Firing order = 7=3-4-2-7 Revoldion speed em 2000] 2200 [ 2a00 | 2600 | 2800 | 3.000 |Continuous rating Kw - - = = - _ ‘Output (*1) Arh Wwoxvaing my 247} 285] 288] 313 | sa7 | 80 | ee) | 23) | 55) | Gee | zn | cs2) | (aa Max revolution speed at no load vn [2180°3 [2400 |2.500~S | 2810" [2.905-% | 3210" |Min- revolution speed at no load i ‘$800 Direchon afrotaton = Caunterciocvise (viewed fam fywhes Powertake of = Fiywheel 2 [Compression ratio = 18.0 [Fas igecton Uning eg wast test 1641 5 | Compression pressure Pe 343. 0.495. 1}, at 250 pm S| tkg!em’) Fuel injection pressure tea 496°" (2008) 196°" 2008) 150-8217 DMA, BS 2669 AT or A2 (Cetane No.45 min’) Lubrication system road lubrication with rachaid pump [Cooling system — Liquid cooling/Radiator Crank V-pulley dia. “uy Fan V-pulley dia.|_™" 9110/6110 Governor = ‘Mechanical centrifugal governor (All speed type) [Dry weight (-2) kg ‘160/170 Governing |diference % S12 serio | ieady state speed band | a Earl [zoe om Lubrication [ated operation MPa {3.5 40.5) seston ey se0 a ae 1-12 68E-88E SERIES 4, SPECIFICATIONS AND PERFORMANCE 112 S3D84E Item unit S3084E ORTON = vr fie = Wer ete water-coed dena eraine [combusTen system = Direct injection aytam No. einders~bore x Sake 7m I= 84x00 Danicerent Z 1486 Firg oer = qa3-2-1 Revolution speed pn | 2000 [2200 [2400 | 2600 [-2800| 3000 [Continuous rating wey = = = = = Output ("1) AF) Ivara ww] 200] 2x8] 250] 258] 201] 08 * {HP) | (28.2) (30.6) | (33.5) | (36.1) | (39.0) | (41.4) ax. revolution speed at no oad 2.75% [25754 | 2600~% | 2.000% | 302073 | 3240" [Min. revolution speed at no load e Drecon of retation = Carre (ewe Tar Tre Powe ake oF = Flywheel ¢|Comression alo = 80 |g |Fuel injection timing Else tro deg watt vazt wert 8 lcompressonproseure wey 98 £0 190-1, a 250pm Pa [Fuel injection pressure 13 (2008 "5 (20'S i kolo 196""8{200"°9) 19.6°°8(200"%) Recommended diesel gas of = [ISO 8247 DMA, BS 2868.A7 or AZ (Gatane No.5 min} Lubrication system = Forced ubeaton wih Yochad pump Lubreson of eapacy MaxETecwve | —E aang Recommended libra o = AP grade CC dass orhoher [cooing sytem = iui caning Radiator [Ecc water eapacty z 0 Tor engine ony [eccing fan wm No ofblade x di, Pusher ype, 8x 0335 [rank Vipulay ar noon Fan V-pulley dia.| 4110/9110 [Governor = ‘Mechanical centrifugal governor (All speed type) [Sarina stem = Electrical [Dimensions Lx WxHT2) 7m BEX SAOK E29 OSE BOXED Dry weight 2) ro Ta71160 Hrarsant apeed . [Governing difference % a2 Pero. Steady state speed band | —% a I = I a Bai spena Recovers ane we z Elonge) | Fucuaton of ‘om me 5 revoluton Lubrication [ated operation MPa (3.520.5) oi pressure uate 3006 lang mo (Output conditions: Intake back pressure = 2.45 kPa {250 mmH,0},Exhaust back pressure = 5,39 kPa (550 mmH,0},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 68E-88E SERIES 1-13 4, SPECIFICATIONS AND PERFORMANCE 1.13 S4D84E hem unit ‘SAD EAE onreation = va Type = Vercal, yoke water-cadled diesel engine [Combustion system = Direct injection system No, jinders ~bore x STORE ran a= 84x90 Displacement t 7995 [Firing order = 4-3-4-2-7 Revolution speed om | 2000 | 2200 [200 | 2800 | 2a00 [3.000 7a [continuous rating @ml-f-{[-[-[-][- jour aan ev [280 [305 | aes | as7 | 36 | at2 a {HP} | {37.5} (40.9) (44.9) 447.9) | (51.8) | {55.3} Max. revohtion speed at no load 2.175°3 | 2.75" | 2600" | 2,600" | 3.000°3 | 3225-3 IMin.revoltion speed at no load ” 800% Dredion afreation = Tountercockaiee ewed fom fywheal Power take off = Flywheel 2 |Compression ratio = 18.0 |S [Fuel injection timing 3 fue aeeien eg raat 1ait 1621 i loompresson prose we 2.94 40.1901, 20 rpm Fuel injection pressure teen 49.6" (2008) 19.6 ""§,200"3} Recommended diesel ga8 of = TSO BIIT DMR, BS ZBESAT orAz (Gatane No.5 min} [Lubrication system = Forced lubrication with trochoid pump: Cubrication ol capacity Mee fedive | ¢ 5523 Recommended Wbricalng of = ‘Abi grade CC class or higher [Cooling system = Liquid cooling/Radiator (Cootng water capaci z ZT (lr engine ony) ‘Cootng fan No. ofblade xia) ™ Pusher type, 6 @ 370 (crank V-puley a7 Fan V-pulley aia.| ort0/g 110 [Governor = ‘Mechanical centrifugal governor (All speed type) Staring system = Ereccal Dimensions L xW ATE mm BAT RABE RTI [BAD XADEE NTIS Dry weight (2) 9 eSrt75 | TFransient speed Governing |gifference * s12 perfor [Steady stats spoedband | z I z z 8 Recovery time ‘sec 6 £ (tu speed Eyer) ovcuon ia m et 1 034 E005 Lubrication [Rated operation MPa {3.5 40.5) ol pressure Asiom 3006 presse hating font os} “1 Output conditions: Intake back pressure = 2.45 kPa (250 mmH,O}, Exhaust back pressure = 5.39 kPa (550 mmH,0},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 68E-88E SERIES 2, CROSS SECTIONAL VIEWS 2. CROSS SECTIONAL VIEWS 2.1 Special swirl pre-combustion chamber system (Indirect injection system) 22 2.2 Direct injection system 24 68E-88E SERIES 241 2. CROSS SECTIONAL VIEWS 2.1 Special swirl pre-combustion chamber system (Indirect injection system) 3 2 1 4 1 | Wi 5 \ ‘ 7 5 rs 1 ' ; 7 ' \ 8 onal ; i 10 1) 2) 3) 4) 5) o Fuel injection pump Fuel injection valve Valve rocker arm cover Valve rocker arm Cylinder head 6) 7 8) 9) Piston Connecting rod Starting motor Crankshaft 10) Lubricating oil suction pipe 68E-88E SERIES 2, CROSS SECTIONAL VIEWS 11) Camshaft 68E-88E SERIES 23 a) 2. CROSS SECTIONAL VIEWS 2.2 Direct i 1) Fuel injection pump 5) Cylinder head 9) Crankshaft 2). Fuel injection valve 8) 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 a) 2, CROSS SECTIONAL VIEWS 11) Camshaft 68E-88E SERIES 25 a) 3. COOLING WATER, LUBRICATING OIL AND FUEL OIL 3. COOLING WATER, LUBRICATING OIL AND FUEL OIL 3.1. Cooling water. 32 3.2. Lubricating oi. 33 33. Fueloil 35 68E-88E SERIES 3-1 3. COOLING WATER, LUBRICATING OIL AND FUEL OIL 3.1 Cooling water 4. 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 cook 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 nea =e a LE | surtonk Bypase “cooing water pump 3-2 68E-88E SERIES (ty 3. COOLING WATER, LUBRICATING OIL AND FUEL OIL 3.2 Lubricating oil 41. Proper use of lubricating oil Use of proper lubricating ol brings about the following effects, (1) The friction part of the engine is protected from friction and wear. (2) The engine pars 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. (6) The engine parts are protected from sludge deposits For the above reasons, use lubricating oil API 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. ‘Ambien temperature al which the engine ie used, © Hdd Recommends SAE Service Grade 68E-88E SERIES 3-3 a) 3. COOLING WATER, LUBRICATING OIL AND FUEL OIL 2. Lubrication system diagram (1) Indirect injection system pooner Ton ' T L 1 aie aaa ae Tatoo aver Ffiettsvanel —[_Mesnecy }-7=[lae oearsnn feel ay ol pune Crank ural Seaingt crn Grae a elas Tape oar sa elie 5 a (2) Direct injection system {ooten) uo contr 4 = Tutboharner i ‘ T t 1 T wturbocharged 1 [eigen Some subneer® ft 1 ene i= | ‘Lub. ol fier I 1 wih ase vale) t_4 I Pressure i sentative Cynder body ana man galery t I [—-===-,| ! tuss.ot pump || [ete cear shat Crank iourat | | [PSIRR, nozatel ! ' 1 1 1 Valve rocker ' Lup, ot suction |] |_Sears toe | | Sim'ssar Crankpin | i Bie tained u tl T 7 ! er wibochged Y Y y Smee Y Ee otlpan 34 68E-88E SERIES (ty 3. COOLING WATER, LUBRICATING OIL AND FUEL OIL 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 At or Part 2 class A2, (Cetane Number: 45min.) Give your customers instructions on proper use of fuel ail, or the customers may suffer from troubles stated below. (1) Deposits on the exhaust valve Deposits on the exhaust valve cause unburnt oll mixture in exhaust gas and erosion of the exhaust valve seat, to occur in addition to poor compression, imperfect combustion, excessive fuel consump tion, ete. (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 oll, 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) Indirect injection system 1) Fuel injection valve 6) from fuel tank 2). Fuel injection pipe 7) Fuel feed pump 3) Fuel oll retum pipe 8) Fuel fiter 4) Fuel injection pump 9) to tank 5) Water separator (option) 68E-88E SERIES 3-5 a) 3. COOLING WATER, LUBRICATING OIL AND FUEL OIL (2) Direct injection system 41) Fuel injection valve 2). Fuel injection pipe 3) Fuel ol retum pipe 4) Fuel injection pump 5) Water separator (option) (ty 6) from fuel tank 7) Fuel feed pump 8) Fuel fiter 9) totank 10) Air-bleed pipe 68E-88E SERIES 4 TROUBLESHOOTING 4. TROUBLESHOOTING 4.1 Trouble causes and remedies 42 4.2 Trouble diagnosis through measurement of compression pressure. 46 68E-88E SERIES 4-1 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. cause N a oer ‘uring vin Poor ret to low seed urna ing Tpoper clarence ofirakaenhaust vale (© | Engine wi no sa ‘Seirad ofnakeesnaust valve (00 [0 [Atnarmat engine oie Blowout For eyindrhead gasket ofololo| res ° ‘Seized or en pong ° We son ing piston or indor ° Improper arangenent of ston rng nts Reverso assory of pision rings Wor erp and jul bearng oosened comeing ra bok sign rater Wapped i earbuston umber ‘Excessive gear backlash ofofolo Wor nseaeshau vale gue ‘vesive govemar lnpopc open Waste gate matuncion Wor ural boning Excoasve coang fect of itor Insult cootng waar ol ‘Slackeved fon bak oy 68E-88E SERIES 4 TROUBLESHOOTING cing nak Exconsve el eons one with water [Aju va dlarancs. (Reet Chenier 6, 62) ° ° Tap the valve eat (Refer to Chapin 7,72) ofefe omact repos Feslace he gaskot (Rafer o Chater 8, 62410) Race te pson ing. Relat Ghapler 7, 74-3 and 7-4-4) Prior ning and use ovarszo paris. (Rafer to Chapin 7. 72-3 end 7-4) ‘Core the ing ont postions, (RlertoChaple 7. 7-6) efofefelo Reacsomble coat (Roar to Chapter 77-448) TWeasara ad veplace, Rater to Ghaper7, 7 and Pp “ghen i he spoifd onus. Refero Chapa 10, 10-1) ‘Adj gear meshing (Rel to Chae, 7-242) easar and replace, Refer Chaper 7,749) ‘Repaand ast (Retort Graptar 13) ‘Adjust We va clearance (Reto Chapter 6) and ‘hack tring (aero ChaplerS) ihe wane gate ‘iassembla and na ‘Disassemble a inspect he pura bora, ‘Defective tarosat kaplclosd) (Refer to Chapler 6-3) ° Defective narmostat kept opened) (Rete to Chap 8 6) 0 fan bet Retro Chapa 63). ‘Chace water leakage om colng war system, (Refer fo Chapter and lean keg mater syst Rel Chapa 3,31). Repair or epac, ‘Adjust bl onsen (Refer lo Chapior 6, 63), efofe] o (Chacko place. (Retort Chapin 6 6) 68E-88E SERIES a) 4, TROUBLESHOOTING N TToutle syrotom | Stating atore eet NN Engin sats ~ bu saps soon During nave rok ne wean Poorer alow speed Wine ura ing Lage (| Enoine wana 0 | more ofhtneatng of Insult deter capi of woehad pump ‘lopged Weeaing oor Detective pase ntl valve Insuciont ecatng ol oval oo ate trang of ul etn pump ofo ° ° °° ofofolo ° ‘Wie entring in ue eye Clogged uate Clogged or races al pe ofofefolo efolofo ofolofo ‘Uneven njeton vine oul nacton pune ° ° ° xcossv uainocton volun oar apy pln or fl con nazz ° Clogged aR ° ex 104 at high omperatre ost high of 0 folo e| © felefolo Clogged exhaust pe Staring moor detec cyston] Aifexhaust gas stom ‘Atoraior doc! ‘Open-oetin wing ofofolo Bator vlogs drop 4-4 68E-88E SERIES a) 4 TROUBLESHOOTING Lubricating oil eating A Eg : 5 i elelslalglal {2 : Corectveacton o]é 5(é}s gle lela 3 fo esp vero ar Cha) 3 3 = ote nr 3 ha 3 zaps han anol STOLL] So [0 [ees a otro apa aa ST [own ° 0] fol | Jeeneneom oie oem ana Fear — 68E-88E SERIES a) 4, TROUBLESHOOTING 4.2 Trouble diagnosis through measurement of compression pressure 4 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 durabilly 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 tal value. 4 For the compression pressure limit values, refer to Chapter 6, 6.1 Measurement of compression pres- n when the compression pressure is less than the limit sure No. item | Cause Countermeasures Fiter element ofair |» Clogged filer element 7 Glean the fiter element 1 | cleaner + Broken fiter element + Replace thefiter element with a + Defective fiter element seal new one 2 | Valve clearance + Excessive valve clearance orno |+ Adjust the valve clearance (Re- 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? 73,7.3and7.8,) + Gylinder head gasket [+ Gas leak through the gasket |- Replace the gasket | Nozale gasket + Retighten the cylinder head 4 and nozale tothe specified torque. (Refer to Chapter 10, 10.1) ~ Intake/exhaust valve | Gas leak caused by wom valve |- Rap valve seats, 5 |* Valve seat seats or rapped foreign matter | (Refer to Chapter 7, 7.1.2) + 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, pistonring | size parts. (Refer to Chapter 7 + Cylinder and cylinder 72.3and 7.48) 4-6 68E-88E SERIES ay 5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS 5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS 5.1 Special service tools 52 5.2 Measuring instruments 55 68E-88E SERIES 5-1 5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS % Although main engine parts can be disassembled and reassembled only with standard service tools, itis. 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.| Too! name Applicable model and tool dimension llustration (Wnitmm) Moist “it . 2 e 20686, 388E wo) si) s | 8 | x 1 | Valve guide 3074E 20 [| 7 | 65 | 10 | extraction tool | |357@Ae 3082AE_| 20 | 75 | 65 | 10) 30826, 40825 | 1} * (S084 (sy4dee| 20 | 75 | 75 | 11 8088, 4088 vyeoote Locally manufacured (Unitmm) Dimension _ aw |e | a | a& Model [2D6eE, 3D68E 7 | | | 7 2 {Valve guide | ovae eo) 0 | 3] 18 insertion tool SO7@AE, aD82AE_| 72 | 60 | 13 | 19 [S082E, aD87E (sysosee, (Sjape4e | 15 | 65 | 14 | 20 [s08ee, De6e yeoor Locally manufacured (Unity a) ele ia |b Model 20886, 90886 zz | 62 | 2083 | 2038 e Connection rod 3 | bushing S074E 20 | 60 | 2193 | 2032 replacer soveaz,ade2ae | 25 | a [asi 26a2|| A 3082, ADEZE (s)aDe4e, s40e 16 | Digital thermometer Contact type Measures temperature of each part. 4) Probe Measures RPM of the rotary shaft by bringing the gage head into contact with the mortise. 8) Photoelectric type 16 Applies a reflecting tape on the cir- ccumference of the rotating parts to measure RPM, 1) Revolving body 2). Reflecting tape Tachometer High pressure fuel pipe clamping type Measures engine RPM's using pulse system, irelevantly to the center of. the rotary shaft and the circumfer- ence of the rotary object. 1) High-pressure pipe 68E-88E SERIES ) 5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS No, Instrument name Purpose of use IMustration 7 18 Cirout tester Compression gauge kit Measures the resistance, voltage, and continuity of electric circuits. Measures compression pressure. Model Code No. ‘Allmodel TOL-97190080 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT MEASUREMENT, INSPECTION AND ADJUSTMENT 6.1 Measuring the compression pressure. on 6.2 Adjusting the valve head clearance os 6.3 Checking the V-belt tension. 65 6.4 Measuring and checking the injection pressure and spray patterns ofthe fuel injection valve 66 6.5 Checking and adjusting the fuel injection timing 6-10 6.6 Adjusting the noJoad maximum (or minimum) revolutions. 613 6.7 Checking the cooling water system and radiator for water leakage 613 6.8 Checking the battery. eta 6.9 Checking the sensors 617 6.10 Checking the oll cooler 618 6.11 Checking the piston cooling nozzle 619 68E-88E SERIES 6-1 6. MEASUREMENT, INSPECTION AND ADJUSTMENT 6.1 1. Measuring Procedure (1) Warm up the engine. Remove the fuel injeo- tion pipe and fuel injection valve from the cylinder to be measured (2) Crank the engine before attaching the com- pression gauge adapter. %* Crank the engine when the regulator handle has been tured to "STOP" posi- tion (NO injection state). % Fro the compression gauge and com- pression gauge adapter, refer to Chap- ter, 6.2. (8) Attach the compression gauge adapter and compression gauge to the cylinder to be measured Never fall to attach the gasket to the tip of the adapter. (4) Crank the engine by the starting moter unti the reading of the compression gauge is stabilized, by taking steps shown in (2), *. Measuring the compression pressure Measuring the compression pressure 1) Compression gauge [Reference: List of Engine Compression Pressures] roaes _ |Comression pressure at 250m (MPa lem) | Dispersion of compression pressure [standard mit | «Ong cylinders (MPa fkgiem’) 2088E 3.242 0.1 (9321) 2.45 (25) 0.20-0.29 2-3} 3088E 3.244 0.1 (93+ 1} 2.45 (25) 0.20-0.29 2-3} 30748 3.43 £0.1 (35 1) 2.65 27) 0.20 -0.29 2-3} SD78AE 3.14 #04 (922 1} 2.45 (25) 0.20 - 0.29 {2-3} 3D82AE 3.040.181 1) 2.35 (24) 0.20 - 0.29 2-3} 3082E 3.042041 812 1} 2.35 (24) 0.20 - 0.29 {2-3} 30868 324 £0.1 332 1) 2.45 (25) 0.20 - 0.29 (2-3) 3088E 3.43 + 0.1 (35+ 1} 2.65 (27) 0.20 - 0.29 {2-3} 4D82E 3.04 £0.1 (81 1) 2.35 (24) 0.20 0.29 (2-3) 4D84E 3.24 40.1 (93 1} 2.45 (25) 0.20 - 0.29 {2-3} ‘40886 3.43 £0.1 (352 1) 2.65 27) 0.20 - 0.29 (2-3) ()3084E 2.94 40.1 (902 1} 2.35 (24) 0.20 - 0.29 {2-3} (40846, 2.944 0.1 (3021) 2.35 (24) (020-029 2-3} 6-2 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT [Reference: Variation of Compression Pressure with Engine Speed] (1) Indirect injection system 39240) 343,35) 294(20) 20686, 90686 245 (28) + 98 @0) Engine speed (rom) eos (2) Direct injection system 2.82 40) ape, 4084 a43.35) \ aotene 298.00) s0e2Ae, 0826, 4042E 245,05) \ Re ‘ (S)sbe4e, yosce 1.96 20) : i Engine speed (om) veows 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 a) 6. MEASUREMENT, INSPECTION AND ADJUSTMENT 6.2 Adjusting the valve head clearance (1) Inspect and adjust a valve head clearance while the engine is in cold state. Raise the piston in the cylinder to be mea- ‘ured to the top dead center (TDC) of com- pression. (8) Loosen the lock nut and adjusting screw. Make sure that the valve cap is free fram inclination or trapped dit. (4) Insert a thickness gauge in between the rocker arm and valve cap. Tighten the adjusting screw until the clearance listed below is attained. 2 ‘All models Intake/exhaust valve head clearance 0.18-0.25 mm 41) Adjusting serew 2). Lock nut 3), Valve clearance % If the valve cap is worn or otherwise ‘damaged on the head, replace it with a Make sure that the valve cap is nested ‘on the head of intake/exhaust valves. 4) Valve cap 5) Normal 6) Abnormal 6-4 (a) (Adjusting the vaive head clearancey 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT 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. oD} 2) 3) 4) 5) 6) 68E-88E SERIES Alternator Crankshaft pulley Cooling water pump Bar (For adjusting the tension of the V-belt) Alternator Adjuster (Adjustment of the V-belt tension) a) 6. MEASUREMENT, INSPECTION AND ADJUSTMENT 6.4 Measuring and checking the injection pressure and spray patterns of the fuel injection valve Measuring the injection pressure ‘+ Thoroughly remove carbon deposits from the injection nozzle before making measure- ment, Connect the fuel injection valve to the high pressure pipe of the nozzle tester. ‘While pumping the lever of the nozzle tester 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 Performance". (3) Ifthe measured injection pressure is lower than the specified value, replace the pres- sure adjusting shim with a thicker one. a Q (Measuring the injection pressure with a nozzle tester) 41) Injection nozzle 2) Nozzle tester injection pressure adjustment Increase the pressure adjusting shim the thickness by 0.1 ‘mm and the injection pressure is increased by 0.69-0.98 MPa {7-10 kalo? Increase the pressure adjusting shim the thickness by 0.1 ‘mm and the injection pressure is increased by about 1.86 MPa (19 kglom?). ‘Type of pressure shim thickness (mm) Indirect injec- tion system | 1:02, 0.3, 0.4, 0.6 Direct ines” |9 13, 0.15, 0.18, 04,05, 08 tion system 6-6 (ay 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT (indirect injection system) 1) 2) 3) 4) 5) 6) 68E-88E SERIES Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat Valve stop spacer Nozzle assembly 6a) Nozzle valve 6b) Nozzle body Nozzle case nut (Direct Injection system) » 2) 3) 4) 5) 6) 7 8) Fuel return pipe joint Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat Valve stop spacer Nozzle assembly 7a) Nozzle valve 7b) Nozzle bady 7e) Dowel pin Nozzle case nut 6. MEASUREMENT, INSPECTION AND ADJUSTMENT 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 pattems. Ifthe following trouble is found, clean or replace the nozzle, (1) Make sure that the pattern is neither stream nor sliver. (2) Ensure that fue! 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] 3 wo ‘Yro0ss 150" aa TTR TERT Bear ear aya [Abnormal spray patterns] Tndirect injection system) (Direct injection systemy (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. (8) Ol should not ooze from the injection hole when the pressure is raised to a litle less than the specified 1.96 MPa {20 kg/cm?) (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 ifthe leaking oil is stil excessive. 6-8 68E-88E SERIES ay 3. Nozzle valve sliding test 6, MEASUREMENT, INSPECTION AND ADJUSTMENT ‘Thoroughly wash the nozzle valve using clean diese! ol Hold the nozzle body vertically, and lft the nozzle valve approx. 1/3 ofits 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 oll and is pasted with the seal peel to shut off outer air, NN (Nozzle valve sliding check by gravity for indi- rect injection system) 4. Nozzle body identification number (Nozzle valve sliding check by gravity for direct injection system) YON—OSD YDI Tt No code: pnte ype Design code 5. bette be Sie shee cies Injection angle LL type: pinte wpe iovos) YANMAR —— gente Y DLL A— 150 P 24430 T [Cowen Size sie? ces Injecton ange Nzae insertion angle "GoseAanaled No code: no angle “Type: DLL (sem-ong ype) YANMAR, SF ~ enision (ndirect injection system) 68E-88E SERIES (Direct injection system) a) 6. MEASUREMENT, INSPECTION AND ADJUSTMENT 6.5 Chee! 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 fare numbered sequentially from cylinder No.1 from the flywheel side). (2) When the crankshaft is tured in the speci- fied direction, oil level rises at the tip of the delivery valve spring holder. At that time, stop the crankshaft, (3) Identity the timing mark stamped on the fly- wheel through the access hole of the fly- wheel housing, % For the fuel injection of each engine model, refer to Chapter 1, Specifications land Performance, 1) Crankshaft pulley 2) Cylinder No. 4 3) Flywheel housing 4) Access hole 5) Timing mark 6-10 g and adjusting the fuel injection timing 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT (4) Ifthe 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 + Increase the shim thickness to delay the injection timing, + Decrease the shim thickness to advance the injection timing 6) Adjusting shim 2. Direct injection system (1) Using the crankshaft pulley, tun 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- fied direction, the oil level rises at the tip of the delivery valve spring holder. At that time, stop the crankshaft. 1) Crankshaft pulley 2) Cylinder No. 4 68E-88E SERIES 6-11 6. MEASUREMENT, INSPECTION AND ADJUSTMENT (3) Identity the timing mark stamped on the fly- wheel through the access hole of the fiy- wheel housing, + 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) Ifthe measured injection timing differs from the specified timing, adjust the injection tim- ing by turning down the fuel injection pump toward the engine or to the opposite side after loosening the lock nut ofthe fuel injec- tion pump. + IFinjection timing is late, turn down the fuel injection pump away from the en- gine. + Ifthe injection timing is too early, turn the injection pump down toward the engine 7) Lock nut 68E-88E SERIES 6.6 Adjusting the no-load ma (1) First warm up the engine, Then, gradually increase the engine speed up to the no-load max. revolution (Refer to Chapter 1, Specif- cations and Performance). (2) Ifthe present no-load max. revolution differ from the specified one, adjust the no-load max. revolution adjusting bolt. (@) Set the engine fo the idling revolution, (Refer to Chapter 1, Specifications and Per- formance) by turing the no-load min, revolu- tion adjusting bok. % The illustration shows the partial per- spective view of the governor for the direct injection system. 1) Nodoad maximum revolution adjusting bolt 2) Increase 3) Decrease 4) No-load minimum revolution adjusting bolt 5) Increase 6) Decrease 7) Regulator handle 6.7 Checking the cooling water system and radiator for water leakage ‘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 upto the normal water level in the radiator. Attach the cap tester body to the radiator. (2) Start the cooling water pump, and set ito a pressure of 88.3 + 14.7 kPa (0.9 # 0.18 kal em’), Any lower reading of the pressure gauge on the cap tester indicates water leak from the cooling water system, Then, detect the potion where cooling water leaks from the cooling water system. 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 + 0.18 kg/cm}. Check to see if the cap is opened at the set pressure. If not, replace the cap because itis defective 7) Cap tester 8) Radiator cap 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT imum) revolutions (Checking the cooling water system for water leakage) (Checking the radiator cap) “ih 6. MEASUREMENT, INSPECTION AND ADJUSTMENT 6.8 Chee! g the battery 4. Structure of the battery 41) Terminal 2) Cap 3) Cover 4) Cathode plate 5) Separator 6) Glass mat 7) Anode plate 8) Battery case 2. Checking the battery (1) Electrolyte level Check the electrolyte level in each cell. ifthe level is low, add deionized water to bring the level to the UPPER level as illustrated at right. 9) Lower limit 10) Upper limit 11) Acceptable 12) Too low 13) Too high 14) Liquid level 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT (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 (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- lowing equation, as it changes by 0.0007 per 1°C. $20 = St + 0.0007 (t-20) Measured electrolyte temperature Measured specific gravity Specific gravity converted to 20°C (Measuring the remaining battery charge with hydromete 16) Float ¥ ” 68E-88E SERIES 6-15 6. MEASUREMENT, INSPECTION AND ADJUSTMENT Hydrometer and remaining battery charge Specific gravy | Discharged | Remaining (at2"c) tevel (4) | level (2%) 1260 ° 100 1210 25 75 1160 50 50 1.10 75 25 1.060 700 0 17) Rubber bulb 18) Glass tube 19) Float (3) Terminals Repair of clean the terminals if corroded of soiled. (4) Fittings Repair or replace the fitings 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 17 (ydrometery (How to read a hydromatery 68E-88E SERIES 6.9 Checking the sensors 1 ‘Checking the thermostat and thermoswitch (1) Thermostat Puta thermostat into water in a container. ‘While measuring water temperature, heat the water. Make sure that the thermostat functions at a temperature of 68.5 - 72.5°C. (80.5 ~ 83.5°C are used as option parts) (2) Thermoswitch Put a thermoswitch into an antifreeze or oil ina container, While measuring liquid tem- perature, heat the liquid. Ifthe tester shows continuity at a temperature of 107-113°C, the thermoswitch is acceptable. Lub. oll pressure switch Remove the connector from the lub. oil pressure switch, While running the engine, bring the tester probes into contact with the switch terminal and cylinder block. Ifthe tester shows continuity, the lub. oll pressure switch is defective 1) Thermometer 6) Thermoswitch 2) Thermostat 7) Thermometer 3) Toradiator 8) Tester probes 4) Cover 9) Cylinder block 5) Thermostat (flywheel side) 10) Tester probes 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT (Continuity test) 6. MEASUREMENT, INSPECTION AND ADJUSTMENT 6.10 Checking the oil cooler The oil cooler is ofthe core type and cooled by fresh water. Itis 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” (8) Cooling tube leak check Close either the inlet or outlet ofthe cooling tube. Apply an air pressure (0.49 MPa {5.0 kg/cm’) from the other end and check if airs leaking by immersing the tube in water. Ifleaking, repair or replace the cooling tube. 4 veooes 41). Joint for draining 4) Ollintet 2) Cooling water outlet 5) Oil outlet 3). To bypass valve 6) Cooling water inlet 6-18 68E-88E SERIES 6, MEASUREMENT, INSPECTION AND ADJUSTMENT 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 ‘Annozzle 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 (9 1.77mm) at the tip end of the steel pipe to be jet-sprayed. This jet spray comes into contact with the rear face ofthe piston for cooling it ‘Jet flow rate 1.3 eimin Jetting pressure | 0.34 MPa {3.5 kglom?) 41) 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 stee! pipe for loosening or freeing by vibration. Replace with a new part if defective, 68E-88E SERIES a 7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION 7.4 Cylinder head. 72 7.2. Cylinder block. 710 7.3 Valve rocker arm. 714 7.4 Piston and piston ring TAT 7.5 Connecting rod 723 7.8 Camshaft 728 7.7 Crankshaft 731 7.8 Gears. 7-34 7.9 Trochoid pump. 7-38 68E-88E SERIES 7-1 7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION * In maintaining various parts, make measurement according to the following measurement procedure. f 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 ofits use, be ‘sure to replace such a part beforehand. 7.1 Cylinder head 1 2 0 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 thickness gauge. (Unitemm) 2 vyeooe7 (Measuring the combustion surface distortion) (Cylinder head combustion Wear surface distortion | S'48%1 | yp ‘Allmodels [0.05 orless) 0.75 1) Straight-edge 2). Thickness gauge 3). Depth-Micrometer 4). Valve sinking depth ° 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, Intake\exhaust valve seats (1) Valve sinking ‘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, (Unitimm) a m= |e NS Sunde oom [Emon] 7 Tso] orsoas | 10 stansen] We Sanda ‘sem [Ete | oso] a0 | asas | 10 68E-88E SERIES 7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION (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. (unm) Se sep = (Unitemm) (Measuring the valve seat width) rae | sau oe stansars | "88" | sears | Weer 68E-88E SERIES 7? 0) 7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION [Valve Seat Correction Procedure] (1) When the seat surface is warn or roughened slightly, lap the seat surface withe a valve ‘compound mixed with oll to a smooth state, (2) When the seat surface is worn or roughened heavily, correct seat surface using a seat

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