2 Engine With Mounting and Equipment

Service Information
Document Title: Function Group: Information Type: Date:

Engine, description 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
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Engine, description
 The engine is a 4–cycle, 4–cylinder, direct injected, water cooled diesel engine.
 The engine produces powerful performance using direct injection type combustion chamber.
Figure 1
Engine, top side view
1 Cooling fan 7 Fuel pipe 13 Engine data plate

2 Thermostat housing 8 Intake manifold 14 Rocker arm cover
3 Fuel return line Flywheel 9 Fuel supply line to 15 Start motor
fuel injection
pump
4 Hose for thermostat element 10 Fuel return line 16 Exhaust manifold
5 Oil filler port 11 Fuel filter 17 Engine data plate
6 Fuel injection pump 12 Fuel supply line to 18 Alternator
fuel filter
Figure 2
Engine, front side view
1 Engine oil filter 5 Hose for thermostat element 9 Alternator

2 Cooling water pump 6 Fuel return line 10 Fan pulley
3 Engine oil filler port 7 Thermostat housing 11 Starter motor
4 Fuel injection pump 8 Adjuster 12 Crankshaft V-pulley
Figure 3
Engine, rear side view
1. Alternator
2. Lifting bracket
3. Fuel filler
4. Engine oil filter
5. Flywheel
6. Oil drain valve (M22 x 1.5P)
Figure 4
Engine, starter motor side view
1 Thermostat housing 7 Starter motor

2 Lifting eye 8 Engine oil pan
3 Exhaust manifold 9 Crankshaft V-pully
4 Rocker arm cover 10 V-belt
5 Cylinder block 11 Alternator
6 Flywheel housing
Figure 5
Engine, fuel filter side view
1 Intake manifold 6 C. W. switch 11 Engine oil dipstick
2 Fuel supply line 7 Oil filler port 12 Injection pump lubricant pipe
3 Fuel return line 8 Fuel injection pump 13 Oil pressure switch
4 Fuel injection pipe 9 Engine oil filter 14 Fuel filter
5 Thermostat housing 10 Engine oil drain valve
Service Information

Engine, description 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Engine, description
D3.4D Engine
The D3.4D configuration is a four stroke, straight four cylinder, direct injected, water cooled diesel engine.
The engine produces powerful performance using direct injection type combustion chamber.
The valve mechanism receives its movement from the camshaft via rods and rocker arms. Turning direction is counter-
clockwise seen from the flywheel. Firing order is 1-3-4-2 and the first cylinder is on the flywheel side.
The lubrication system consists of forced lubrication with trochoid pump.
The cooling of the engine is performed by a high capacity radiator and a hydraulic oil cooler.
Figure 1
Engine, D3.4D
Service Information

Engine, identification 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Engine, identification
Identification plate
The engine model, serial number and performance data are stamped on an identification plate which is attached on the
cylinder head cover. The engine model designation and serial number must be indicated when ordering spare parts.
Figure 1
Engine identification
Service Information

Engine, tightening torque 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Engine, tightening torque

Tightening torque, unit: Nm (lbf ft)
Item Nominal size Tighten torque Lubricating oil application (thread

portion, and seat surface)
Cylinder head screw M 11 × 1.25 103.1 ~ 112.9 (76 ~ 83) Applied
Connecting rod screw M10 × 1.0 53.9 ~ 58.8 (40 ~ 43) Applied
Flywheel set screw M14 × 1.5 186.2 ~ 205.8 (137 ~ 152) Applied
Bearing cap set screw M 11 × 1.25 108.1 ~ 117.9 (80 ~ 87) Applied
Crankshaft pulley set screw M14 × 1.5 107.9 ~ 127.5 (80 ~ 94) Applied
Fuel injection nozzle set screw M 8 × 1.25 22.6 ~ 28.4 (17 ~ 21) Not applied
Fuel feed pump drive gear set M 18 × 1.5 113 ~ 123 (83 ~ 90) Not applied
nut
High-pressure fuel lines screw M 12 × 1.5 19.6 ~ 24.5 (174 ~ 217) Not applied
Fuel return pipe joint screw M 6 × 1.0 7.8 ~ 9.8 (70 ~ 86) Not applied
Tightening torque for standard screws and nuts, unit: Nm (lbf ft)
Item Nominal size Tighten torque Lubricating oil application (thread

portion, and seat surface)
Screw (7T) and nut M 6 × 1.0 9.8 ~ 11.8 (7 ~ 9)
M 8 × 1.25 22.6 ~ 28.4 (17 ~ 21)  Use 80% of the value at left
when the tightening part is
M 10 × 1.5 44.1 ~ 53.9 (33 ~ 40)
aluminium.
M 12 × 1.75 78.4 ~ 98 (58 ~ 72)  Use 60% of the value at left
M 14 × 1.5 127.5 ~ 147.1 (94 ~ 108) for 4T screws and lock nuts.
M 16 × 1.5 215.7 ~ 235.4 (157 ~ 174)
PT plug 1/8 9.8 (7)
1/4 19.6 (14)
3/8 29.4 (22)
1/2 58.5 (43)
Pipe joint screw M8 12.7 ~ 16.7 (9 ~ 12)
M 10 19.6 ~ 25.5 (14 ~ 19)
M 12 24.5 ~ 34.3 (18 ~ 25)
M 14 39.2 ~ 49 (29 ~ 36)
M 16 49 ~ 58.8 (36 ~ 43)
NOTE!
Lubricating oil is not applied to threaded portion and seat surface.
Service Information

Precautions 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Precautions
Make preparation as follows before starting engine inspection and service.
WARNING
Risk of personal injury. Very heavy object.
Be sure to fix the engine securely to prevent injury or damage due to parts falling during the work.
WARNING
Risk of personal injury! Wear safety glasses and use protective gloves.
Always wear glasses or a protective face shield when using compressed air or steam to prevent any foreign matter
from getting into the eyes.
 Fix the engine on a horizontal base.

 Remove the coolant hoses, fuel oil pipes, wire harness, control wires etc. connecting the driven machine and
engine, and drain coolant, lubricating oil and fuel.
 Remove soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as not to let
any foreign matter enter the engine.
 Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the
standard or limit shall be replaced.
 Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of use
should be replaced even when the measured value then satisfies the standard or limit.
Service Information

Troubleshooting chart 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Troubleshooting chart
The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take
corrective action before it develops into a serious problem so as not to shorten the engine service life.
Engine troubleshooting chart
Trouble symptoms Causes Corrective actions

Engine does not start Improper clearance of inlet/exhaust valve Adjust the valve clearance
Seizure of inlet/exhaust valve Correct or replace
Seized or broken piston ring Replace the piston ring
Worn piston ring, piston or cylinder Perform honing and use oversize parts
Seized crankpin metal or bearing Repair or replace
Foreign matter trapped in combustion chamber Disassemble and repair
Improper open/close timing of intake/exhaust Adjust the valve clearance
valves
Improper properties of lubricating oil Use proper lubricating oil
Water entrance in fuel system Perform draining from the fuel filter
Clogged fuel filter Clean or replace
Air entrance in fuel system Perform air bleeding
Clogged or cracked fuel pipe Clean or replace
Insufficient fuel supply to fuel injection pump Check the fuel tank cock, fuel tank, fuel
pipe and fuel feed pump
Priming failure (foreign matter trapped in the Disassemble and clean
valve inside the priming pump)
Starting motor defect Repair or replace
Alternator defect Repair or replace
Open circuit in wiring harness Repair
Battery voltage drop Inspect and charge the battery
Engine starts, but stops Improper clearance of inlet/exhaust valve Adjust the valve clearance
soon. Seized crankpin metal or bearing Repair or replace
Exhaust smoke none.
Improper arrangement of piston rings joint Correct the ring joint positions
Defective governor Make adjustment
Insufficient lubricating oil level Add proper lubricating oil
Engine starts, but stops Seizure of inlet/exhaust valve Correct or replace
soon. Seized or broken piston ring Replace the piston ring
Exhaust smoke excessive.
Clogged air filter Clean
Insufficient engine output. Improper clearance of inlet/exhaust valve Adjust the valve clearance
Exhaust color : ordinary Compression leakage from valve seat Lap the valve seat
Blowout from cylinder head gasket Replace the gasket
Worn crankpin and journal bearing Measure and replace
Improper properties of fuel oil Use proper fuel oil
Clogged strainer at fuel feed pump inlet Clean the strainer
Insufficient engine output. Seized or broken piston ring Replace the piston ring
(Exhaust color : white) Worn piston ring, piston or cylinder Perform honing and use oversize parts
Reverse assembly of piston ring Reassemble correctly
Worn inlet/exhaust valve guide Measure and replace
valves
Timing of fuel injection pump too late Check and adjust
Uneven injection volume of fuel injection pump Check and adjust
Poor spray pattern from fuel injection nozzle Check and adjust
Insufficient engine output. Compression leakage from valve seat Lap the valve seat
(Exhaust color : black) Seizure of inlet/exhaust valve Correct or replace
valves
Insufficient cooling effect of radiator, Repair or replace thermostat and fan
Defective thermostat (kept opened) or slipping belt
fan belt
Insufficient coolant level Check leakage from cooling system
Slackened fan belt Adjust the belt tension
Defective thermostat Check or replace
Engine used at high temperature or at high Study output drop and load matching
altitude
Clogged exhaust pipe Clean
Poor exhaust color : white Seized or broken piston ring Replace the piston ring
(During work) Worn piston ring, piston or cylinder Perform honing and use oversize parts
valves
Excessive cooling effect of radiator, Repair or replace
Defective thermostat (kept closed)
Timing of fuel injection pump too early Check and adjust
Poor exhaust color : black Compression leakage from valve seat Lap the valve seat
(During work) Seizure of inlet/exhaust valve Correct or replace
valves
Excessive fuel injection volume Check and adjust
altitude
High knocking sound during Timing of fuel injection pump too early Check and adjust
compression
Abnormal engine sound Improper clearance of inlet/exhaust valve Adjust the valve clearance
Compression leakage from valve seat Lap the valve seat
Loosened connecting rod screw Tighten to specified torque
Excessive gear backlash Adjust gear and repair
valves
Uneven combustion sound Improper properties of fuel oil Use proper fuel oil
Hunting during idling Seized or broken piston ring Replace the piston ring
Hunting during work Seizure of inlet/exhaust valve Correct or replace
Large engine vibration Seizure of inlet/exhaust valve Correct or replace
Difficulty in returning to low Defective governor Make adjustment
speed
Excessive fuel consumption Compression leakage from valve seat Lap the valve seat
Excessive cooling effect of radiator, Repair or replace
altitude
Excessive lubricating oil Seized or broken piston ring Replace the piston ring
consumption Worn piston ring, piston or cylinder Perform honing and use oversize parts
Leakage from lubricating oil piping system Repair
Lubricating oil diluted by Seizure of inlet/exhaust valve Correct or replace
fuel Seized or broken piston ring Replace the piston ring
Lubricating oil mixed with Blowout from cylinder head gasket Replace the gasket
water Cracked water jacket Repair or replace
Low lubricating oil pressure Worn crankpin and journal bearing Measure and replace
Cracked water jacket Repair or replace
Leakage from lubricating oil piping system Repair
Insufficient delivery capacity of trochoid pump Check and repair
Clogged lubricating oil filter Clean or replace
Defective pressure regulating valve Check, adjust or replace
Insufficient lubricating oil level Add proper lubricating oil
Excessive blow-by gas Compression leakage from valve seat Lap the valve seat
Clogged lubricating oil filter Clean or replace
Overheating of coolant Blowout from cylinder head gasket Replace the gasket
fan belt
Cracked water jacket Repair or replace
altitude
Low coolant temperature Excessive cooling effect of radiator, Repair or replace
Air inlet pressure drop Improper clearance of inlet/exhaust valve Adjust the valve clearance
altitude
Air inlet pressure rise Excessive fuel injection volume Check and adjust
Exhaust temperature rise Improper clearance of inlet/exhaust valve Adjust the valve clearance
fan belt
Service Information

Maintenance standards 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Maintenance standards
Engine service standard
Inspection item Unit Standard Limit

Intake / Exhaust Valve Clearance mm (inch) 0.15 ∼ 0.25
(0.006 ∼ 0.010)
Fuel injection pressure MPa 21.6 ~ 22.6
(kgf/cm2) (220 ∼ 230)
(psi) (3129 ∼ 3271)
(bar) (21.6 ~ 225.6)
Compression at 250 rpm MPa 3.43 ±0.09 2.74 ±0.09
(kgf/cm2) (35 ±1) (28 ±1)
(psi) (498 ±14) (398.2 ±14.2)
(bar) (34.3 ±0.98) (27.4 ±0.98)
Coolant capacity (engine only) Liters (US gal) 4.2 (1.1)
Lubricating oil capacity (oil pan) High 11.5 (3)
Low 5 (1.3)
Oil pressure switch operating pressure MPa 0.04 ~ 0.06
(kgf/cm2) (0.4 ~ 0.6))
(psi) (5.8 ~ 8.8))
Thermostat Valve opening temperature °C (°F) 82 (179.6)
Full opening lift (temperature) mm (inch) / °C (°F) 8 (0.32) or more / 95
(203)
Coolant Temperature Switch °C (°F) 107 ~ 113 (225 ~ 235)
Service Information

Maintenance standards 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Maintenance standards
Engine service standard
Inspection item Unit Standard Limit

Intake / Exhaust Valve Clearance mm (inch) 0.15 ∼ 0.25
(0.006 ∼ 0.010)
Fuel injection pressure MPa 21.6 ~ 22.6
(kgf/cm2) (220 ∼ 230)
(psi) (3129 ∼ 3271)
(bar) (21.6 ~ 225.6)
Compression at 250 rpm MPa 3.43 ±0.09 2.74 ±0.09
(kgf/cm2) (35 ±1) (28 ±1)
(psi) (498 ±14) (398.2 ±14.2)
(bar) (34.3 ±0.98) (27.4 ±0.98)
Coolant capacity (engine only) Liters (US gal) 4.2 (1.1)
Lubricating oil capacity (oil pan) High 11.6 (3)
Low 5.2 (1.4)
Oil pressure switch operating pressure MPa 0.04 ~ 0.06
(kgf/cm2) (0.4 ~ 0.6))
(psi) (5.8 ~ 8.8))
Thermostat Valve opening temperature °C (°F) 82 (179.6)
Full opening lift (temperature) mm (inch) / °C (°F) 8 (0.32) or more / 95
(203)
Coolant Temperature Switch °C (°F) 107 ~ 113 (225 ~ 235)
Service Information

Special tools 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Special tools
Special tools
Special tools
Tool name Applicable model and tool size Illustration

Valve guide tool (for extracting valve Part number: 14527850 Drift
guide)
 l1 : 20 mm (0.787 in)
 l2 : 75 mm (2.953 in)
 d1 : 6.5 mm (0.256 in)
 d2 : 10 mm (0.394 in)
Valve guide tool (for inserting valve Part number: 14527851 Drift
guide)
 l1 : 7 mm (0.276 in)
 l2 : 60 mm (2.362 in)
 d1 : 13 mm (0.512 in)
 d2 : 16 mm (0.630 in)
Connecting rod bushing replacer Part number: 14527852 Drift

(for removal/installation of
connecting rod bushing)  l1 : 20 mm (0.787 in)
 l2 : 100 mm (3.937 in)
 d1 : 30 mm (1.181 in)
 d2 : 33 -0.3/-0.6 mm
(1.299 -0.012/-0.024 in)
Valve spring compressor (for Part number: 8931-00060 Press tool

removal/installation of valve spring)
Stem seal inserter (for inserting stem Part number: 14527853 Drift
seal)
 l1 : 11.8 mm (0.465 in)
 l2 : 65 mm (2.559 in)
 l3 : 4 mm (0.157 in)
 d1 : 15.2 mm (0.598 in)
 d2 : 21 mm (0.827 in)
 d3 : 12 mm (0.472 in)
Filter wrench (for removal/ Available on the market

installation of lubrication oil filter)
Camshaft bushing tool (for Part number: 8931-00080 Installation
removing camshaft bushing) tool
 l1 : 18 mm (0.709 in)
 l2 : 70 mm (2.756 in)
 d1 : 50 -0.3/-0.6 mm (1.967
-0.012/-0.024 in)
 d2 : 53-0.3/-0.6 mm (2.087
-0.012/-0.024 in)
Flex–hone (for re–honing of cylinder

liner)  Applicable bore : 89 ~ 101 mm
(3.504 ~ 3.976 in)
Piston insertion tool (for inserting The above piston insertion tool is
piston) applicable to 60 ~ 125 mm (2.362 ~
4.921 in) diameter piston.
Piston ring replacer (for removal/ Available on the market
installation of piston ring)
Measuring tools
Measuring tools
Instrument name Application Illustration

Dial gauge Measurements of shaft bending, strain
and gap of surface
Test indicator Measurements of narrow or deep
portions that cannot be measured by
dial gauge.
Magnetic stand For holding the dial gauge when
measuring using a dial gauge, standing
angles adjustable
Micrometer For measuring the outside diameter of
crankshaft, pistons, piston pins, etc.
Cylinder gauge For measuring the side diameters of
cylinder liners, rod metal, etc.
Callipers For measuring outside diameters, depth,
thickness and width
Depth micrometer For measuring of valve sink
Square For measuring valve spring inclination
and straightness of parts
V–block For measuring shaft bend
Torque wrench For tightening nuts and screws to the

specified torque
Feeler gauge For measuring gaps between ring and
ring groove, and shaft joints during
assembly
Cap tester For checking water leakage
Battery/coolant tester For checking concentration of antifreeze
and the battery electrolyte charge status
Nozzle tester For measuring injection spray pattern of
fuel injection nozzle and injection
pressure
Digital thermometer For measuring temperature
Speedometer (contact type) For measuring revolution by contacting
the mortise in the revolving shaft
Speedometer (photoelectric type) For measuring revolution by sensing the
reflecting mark on the outer periphery 1 : Revolving shaft
of the revolving shaft 2 : Reflection mark
Circuit tester For measuring resistance voltage and
continuity of electrical circuits
Compression gauge kit Part number: 14546935
For measuring compression pressure
Service Information

Periodic inspection and 200 Service Information 2014/4/2 0
maintenance procedure
Profile:
CEX, ECR88 [GB]
Periodic inspection and maintenance procedure

Check before daily operation
Be sure to check the following points before starting the engine every day.
If any problem is found, do not use the machine before the engine repairs have been completed.
 Oil leak from the lubrication system

 Fuel leak from the fuel system
 Coolant leak from the cooling system
 Damaged parts
 Loosened or lost screws
 Fuel, radiator rubber hoses cracked, loosened clamp
Thermostat and Thermal Switch Inspection
Figure 1
Thermostat
1. Cover
2. Thermostat
3. Thermostat switch
A. To radiator
1. Thermostat
Place the thermostat in a container filled with water.
Heat it while measuring the water temperature, and see that the thermostat is actuated at the temperature of
following table.
Valve opening temperature, °C (°F) Full open lift, mm (°C, °F)

69.5 ~ 72.5 (157.1 ~ 162.5) 8 mm or more (85 °C, 185 °F)
NOTE!
Valve opening temperature is scribed on the flange.
Figure 2
Thermostat inspection
1. Thermometer
2. Thermostat
Figure 3
Thermostat switch inspection
1. Thermometer
2. Tester probes
2. Thermostat switch
Place the thermostat switch in a container filled with antifreeze or oil. Heat it while measuring the fluid temperature.
The switch is normal if the multi-meter shows continuity when the fluid temperature is 107 ~ 113 °C (225 ~ 235 °F).
 Inspection and replacement of fuel pipe and cooling pipes/hoses.
 Regularly check the rubber hoses of the fuel system and cooling system. If cracked or degraded, replace
them with new ones. Replace the rubber hoses at least every 2 years.
 Lapping the intake and exhaust valves
 The adjustment is necessary to maintain proper contact of the valves and seats.
 Fuel injection timing inspection and adjustment
Sensor inspection
 Oil pressure switch

Disconnect the connector from the oil pressure switch. Keep the multi-meter probes in contact with the switch
terminal and cylinder block while operating the engine. If is abnormal if circuit is closed.
 Thermostat switch
Coolant leak check in cooling system
 Check coolant leakage from the cooling system visually. If any problem is found, Inspect as follows :
Figure 5
Water leak check in coolant system
1. Cap tester
 Fill coolant to the normal level in the radiator, and install the cap tester on the radiator.
 Operate the manual pump to set the pressure to 0.9 ± 0.15 kgf/cm2(12.8 ± 2.1 psi). If the cap tester
pressure gage reading drops then, coolant is leaking from the cooling system. Check and repair the
coolant leaking point.
Radiator cap inspection
Figure 6
Radiator cap inspection
1. Radiator cap
 Install the radiator cap on the cap tester. Set the tester pressure to 0.9 ± 0.15 kgf/cm2(12.8 ± 2.1 psi) and check that
the cap relief valve is opened. If the relief valve does not open, replace the cap since it is abnormal.
Service Information

Component locations 200 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Component locations
Component position, engine D3.4D. The following figures show the position of a number of components on engine D3.4D.
Figure 1
Component locations, front side
1 Water separator 8 V-belt

2 Fuel filter 9 Side filler port (engine oil)
3 Fuel return line 10 Fuel injection pump
4 Fuel supply line 11 Engine oil filter
5 Top filler port (engine oil) 12 Engine oil drain plug
6 Engine coolant pump 13 Engine oil dipstick
7 Crankshaft V-pulley 14 Oil pressure switch
Figure 2
Component locations, flywheel side
15 Lifting bracket (engine cooling fan end 20 Starter motor

16 Rocker arm cover 21 Cylinder block
17 EGR vavle 22 Exhaust manifold
18 Flywheel 23 Alternator
19 Oil pan
Service Information

Engine characteristic curve 210 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Engine characteristic curve

Engine performance curve
Figure 1
Engine performance curve
A. Torque (kg·m)
B. Power (PS)
C. Speed (rpm)
D. Fuel consumption (g/ps·hr)
Service Information

Engine characteristic curve 210 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]

Figure 1
Service Information

Troubleshooting 210 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Troubleshooting
General about troubleshooting
When a malfunction is suspected or has been confirmed, it is important to identify the cause as soon as possible.
The starting point for all troubleshooting is that there is some type of trouble symptom or malfunction.
Malfunctions can be indicated by:
 generation of error codes

 detection of a malfunction symptom.
Troubleshooting work
The first step in troubleshooting is to gather information from the operator concerning the malfunction symptoms, see
Electrical and information system, Collection of basic data. Then, attempt to pin-point the cause by checking in a certain
order, for more information, see Electrical and information system, troubleshooting strategy.
The different checking steps are:
 Check error codes

 Check parameters
 Perform basic check
Troubleshooting information
The following is included in Electrical and information system and is used when troubleshooting:
1. Troubleshooting strategy
Describes troubleshooting work, step by step.
2. Troubleshooting, assistive devices
Brief summary of the assistive devices that are available for troubleshooting.
3. Functional checks and tests, VCADS Pro
Brief description of VCADS Pro. For a detailed description, see VCADS Pro User’s Manual.
4. Error code information
Contains information regarding error code design, lists of all error codes and error code information about each
error code.
5. Components, troubleshooting and specifications
Contains methods and measuring values for troubleshooting of components. Also includes wiring diagrams and
certain specifications.
6. Parameters
Incorrectly set parameters may cause malfunction symptoms. The parameter list includes all limit and command
values for parameters.
7. Control units, functional description
Describes the functions of the control units, inputs and outputs as well as communication between the various
control units.
8. Control units, active and passive measuring
Contains measuring values for active and passive measuring of the ECUs.
9. Software functions
Describes the pre-requisite conditions for the control and monitoring functions that are performed by the software
in the ECUs.
Service Information

Compression pressure 210 Service Information 2014/4/2 0
inspection
Profile:
CEX, ECR88 [GB]
Compression pressure inspection

Compression pressure drop is one of major causes of increasing blow-by gas (lubricating oil contamination or increased
lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the
following factors:
1. Degree of clearance between piston and cylinder

2. Degree of clearance at intake/exhaust valve seat
3. Gas leak from nozzle gasket or cylinder head gasket
In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use of the engine.
A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or
worn or broken piston ring. Measure the compression pressure to diagnose presence of any abnormality in the engine.
Compression pressure measurement method
1. After warming up the engine, remove the fuel injection nozzle from the cylinder to be measured.
Figure 1
Measuring the compression pressure
1. Compression gauge
2. Crank the engine before installing the compression gauge adapter.
 Perform cranking with the stop handle at the stop position (no injection state).
3. Install the compression gauge and compression gauge adapter at the cylinder to be measured.
NOTE!
Do not forget to install a gasket at the tip end of the adapter.
4. Crank the engine by the starting motor until the compression gage reading is stabilized.
Standard compression pressure
 Standard: 3.43 ±0.098 MPa (35 ±1 kgf/cm2) (498 ±14 psi) (34.32 ±0.98 bar)
 Limit: 2.74 MPa (28 kgf/cm2) (398 psi) (27.4 bar)
 Dispersion among cylinders: 0.19 ~ 0.29 MPa (2 ~ 3 kgf/cm2) (28 ~ 43 psi) (1.96 ~ 2.94 bar)
Engine speed and compression pressure

Figure 2
Engine speed and compression pressure
 P: Compression pressure
 N: Engine speed
Check items
When the measured compression pressure is below the limit value, inspect each part by referring to the table below.
Compression pressure check items
Item Cause Corrective action

Air cleaner element
 Clogged element  Clean the element.
 Broken element  Replace the element.
 Defect at element seal portion
Valve clearance
 Excessive or no clearance  Adjust the valve clearance.
Valve timing
 Incorrect valve clearance  Adjust the valve clearance.
Cylinder head gasket

 Gas leak from gasket  Replace the gasket.
 Retighten the cylinder head screws
to the specified torque.
Inlet/exhaust valve
Valve seat  Gas leak due to worn valve seat or  Lap the valve seat.
foreign matter  Replace the inlet/exhaust valve.
 Sticking valve
Piston
Piston ring  Gas leak due to scoring or wear  Perform honing or boring/honing
Cylinder and use an oversized part.
Service Information

Adjusting operation 210 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Adjusting operation
Perform adjusting operation as follows after the maintenance job:
 Supply the fuel oil, lubricating oil and coolant.
NOTE!
Check the levels of the lubricating oil and coolant again after test running (for about 5 minutes) and add as required.
 Start the engine, and carry out idling at a low revolution (700 ~ 900 rpm) for a few minutes.
 Run in the engine for about five minutes at the rated revolution (no–load). Check for coolant, fuel or oil leaks and
existence of abnormal vibration or noise. Also check the oil pressure, coolant temperature and exhaust gas color.
 Adjust the no–load minimum and maximum revolutions according to the specifications.
 Perform loaded operation as required.
Long storage
Observe the following instructions when the engine is to be stored for a long period without operation:
 Always drain coolant in a cold season or before extended storage. (This is unnecessary when antifreeze is used.)
NOTE!
Negligence of water draining will cause the water remaining inside the engine to freeze and expanded, damaging the engine
cooling system components.
 Coolant draining procedure
1. Remove the radiator cap.

2. Loosen the draining cock under the radiator to drain coolant.
3. Loosen the drain cock on the side of the engine block to drain coolant.
4. After draining coolant, tighten the radiator cap and drain plug and cocks.
 Remove all mud, dust, oil deposits and thoroughly clean the engine and attached components.
 Perform the nearest periodic inspection before the storage.
 Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
 Disconnect the battery cable from the battery negative terminal.
 Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing or
entrance.
 Select a well–ventilated location without moisture and dust for storage.
 Perform battery recharging once a month during storage to compensate for self–discharge.
Checking and adjusting radiator fan V-belt

Figure 1
Checking and adjustment, radiator fan V-belt
1. Radiator fan
2. V-belt
3. Crankshaft V-pulley
4. Press with thumb
5. Deflection
6. Alternator
7. Set screw
When there is not enough tension in the V-belt, the V-belt will slip making it impossible for the alternator to generate power
and water pump and cooling fan will not work causing the engine to overheat. Check and adjust the V-belt tension
(deflection) in the following manner.
 Press the V-belt with your thumb [approximately 98N (10kgf)] at the middle of the V-belt span to check the tension
(deflection).
Available positions to check and adjust the V-belt tension (deflection) are at the A, B or C direction as shown in the
illustration right.
You may choose a position whichever you can easily carry out the check and adjustment on the machine unit.
 "New V-belt" refers to a V-belt which has been used less than 5 minutes on a running engine.
 "Used V-belt" refers to a V-belt which has been used on a running engine for 5 minutes or more.
 The specified deflection to be measured at each position should be as follows.
V-belt deflection, unit: mm (in)
Direction A B C
For used V-belt 10 ~ 14 7 ~ 10 9 ~ 13
(0.39 ~ 0.55) (0.28 ~ 0.39 (0.35 ~ 0.51)
For new V-belt 8 ~ 12 5~8 7 ~ 11
(0.31 ~ 0.47) (0.20 ~ 0.31) (0.28 ~ 0.43)
Figure 2
Adjustment, V-belt tension
A. Bar
B. Adjuster
C. Alternator
 If necessary, adjust the V-belt tension (deflection).

To adjust the V-belt tension, loosen the set screw and move the alternator to tighten the V-belt.
After replacing with a new V-belt and adjusting it, run the engine for 5 minutes and readjust the deflection to the
value in the table above.
 Visually check the V-belt for cracks, oiliness or wear.
If any, replace the V-belt with a new one.
 Inspection and adjustment: Injection pressure and spray pattern of fuel injection valve
Figure 3
Injection pressure measurement
1. Nozzle tester
2. Injection nozzle
 Injection pressure measurement

: 225 ± 5 kgf/cm2 (3200 ± 71 psi)
Remove carbon deposit at the nozzle hole thoroughly before measurement.
 Connect the fuel injection valve to the high pressure pipe of the nozzle tester.
 Operate the nozzle tester lever slowly and read the pressure at the moment when the fuel injection from
the nozzle starts.
 If the measured injection pressure is lower than the standard level, replace the pressure adjusting shim
with a thicker one.
Injection pressure adjustment
Type of pressure adjusting shim thickness, mm Injection pressure adjustment

(in)
0.13(0.0051), 0.15(0.0059), 0.18(0.0071), 0.4(0.0157), The injection pressure is increased by
0.5(0.0197), 0.8(0.0315) approximately 19 kgf/cm2 (270 psi) when the
adjusting shim thickness is increased by 0.1 mm
(0.004).
Figure 4
Exploded view, fuel injection valve
1 Nozzle holder
2 Pressure adjusting shim
3 Nozzle spring
4 Nozzle spring seat
5 Dowel pin
6 Valve stop spacer
7 Nozzle valve
8 Nozzle body
9 Nozzle case nut (tightening torque : 4.25 ± 0.25 kgf·m (30.7 ± 1.8 lbf·ft)
 Spray pattern inspection

After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat
oil-tightness.
1. Seat oil tightness check
 After injecting a few times, increase the pressure gradually.

 Hold the pressure for about 5 seconds at a little before the valve opening pressure of 20 kgf/cm2
(285 psi), and check to see that oil does not drip from the tip end of the nozzle.
 If extreme oil leak from the overflow joint exists during injection by the nozzle tester, check after
retightening. If excessive oil is leaking, replace the nozzle assembly.
Figure 5
Uniform spray pattern from each nozzle (normal)
2. Spray and injection states
 Operate the nozzle tester lever at a rate of once or twice a second and check for abnormal
injection.
 If normal injection as shown below cannot be obtained, replace the fuel injection valve.
- No extreme difference in angle (θ)
- No extreme injection angle difference (α)
- Finely atomized spray
- Excellent spray departure
Figure 6
Non-uniform spray pattern from each nozzle (abnormal)
 Nozzle valve sliding test

Wash the nozzle valve in clean fuel oil.
Place the nozzle body vertically and insert the nozzle into the body to about 1/3 of its length.
The valve is normal if it smoothly falls by its own weight into the body.
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!
New nozzle is coated with rust-preventive oil and is pasted with the seal peel to shut off outer air.
Figure 7
Nozzle valve sliding check by gravity
 The type of nozzle can be determined from the number inscribed on the outside of the nozzle body.
Figure 8
Nozzle body identification number
A. Identification number
 Nozzle body identification number

Symbol Description Remarks
Y YANMAR
DLL Type (DLL : semi-long type)
A Nozzle insertion angle
Code A : angled
No code : no angle
150 Injection angle
P Nozzle size : size P, size S
244JO Design code
 Measuring and adjusting valve clearance

Make measurement and adjustment while the engine is cold.
Figure 9
Valve clearance measurement
A. No.1 cylinder
B. Crankshaft pulley
C. Top mark
D. Rotational direction
1. Valve clearance measurement
 Remove the rocker cover on cylinder head.

 Turn the crankshaft to bring the piston of the No.1 cylinder to its compression top dead center
while watching the rocker arm motion, timing scale and the top mark position of the crankshaft
pulley.
(Position where both the intake and exhaust valves are closed.)
NOTE!
The crankshaft shall be turned clockwise as viewed from the pulley side.
NOTE!
The No.1 cylinder position is on the flywheel side and the ignition order shall be 1-3-4-2-1 at
180° intervals.
NOTE!
Since the intake and exhaust valve rocker arms are operated the same and there is a clearance
between the arm and valve generally at the top dead center, the position can be checked by
means of the play when the arm head is held with a hand. Also see that the crankshaft pulley top
mark is positioned at zero on the timing scale. If there is no valve clearance, inspection in the
disassembled state is necessary since the valve seat may be worn abnormally.
 Insert a thickness gage between the rocker arm and valve cap in case of 2-valve cylinder head, or
insert between the rocker arm and the valve bridge in case of 4-valve head, and record the
measured valve clearance. (Use it as the data for estimating the wear state.)
Figure 10
Valve clearance
1. Valve bridge
2. Valve clearance
3. Rocker arm
 Turn the crankshaft 180° then and make adjustment for the No.3 cylinder. Then adjust the No.4
and No.2 cylinders in this order.
The cylinder to be adjusted first does not have to be the No.1 cylinder. Select and adjust the
cylinder where the piston is the nearest to the top dead center after turning, and make
adjustment for other cylinders in the order of ignition by turning the crankshaft 180° each time.
2. Valve clearance inspection and adjustment
 In case of 4-valve cylinder head loosen the lock nut and adjusting screw of rocker arm. Be careful
that excessive tension isn"t applied to the valve bridge, and loosen a lock nut of valve bridge.
Figure 12
Adjustment, screw
1. Adjusting screw
2. Wrench
3. Valve bridge
A. Loosen
NOTE!
When loosening a lock nut of a valve bridge, loosen the lock nut while holding the valve bridge
with a wrench so that the valve bridge can not lean.
 Insert a 0.2 or 0.3 mm thickness gage between the rocker arm and valve cap / valve bridge, and
adjust the valve clearance. Tighten the adjusting screw.
Recheck the valve clearance.
Figure 13
Adjustment, valve clearance
1. Adjusting screw
2. Valve bridge
3. Rocker nut
A. Hold
B. Clearance 0
C. Adjust clearance to 0
 Apply oil to the contact surface between adjusting screw and push rod.
Figure 14
Adjustment, valve clearance
 Turn the crankshaft 180° then and make adjustment for the No.3 cylinder. Then adjust the No.4
and No.2 cylinders in this order.
The cylinder to be adjusted first does not have to be the No.1 cylinder. Select and adjust the
cylinder where the piston is the nearest to the top dead center after turning, and make
adjustment for other cylinders in the order of ignition by turning the crankshaft 180° each time.
Adjusting the no-load maximum or minimum speed
 After warming the engine, gradually raise the speed and set it at the no-load maximum revolution.
Figure 15
Adjustment, governor lever and accelerator device
1 Low idle limiting screw

2 Governor lever
3 Accelerating cable bracket
4 Accelerating cable fixing nut
5 Accelerating cable bracket
6 High idle limiting screw
H High
L Low
 If the no-load maximum revolution is out side the standard range, adjust it by turning the high idle limiting screw.
 Then set the no-load minimum speed by adjusting the low idle limiting screw.
Service Information

Cylinder head, description 211 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Cylinder head, description

The cylinder head, which covers all cylinders, is a sixteen valve cylinder head.
The cylinder head has two inlet valves and two exhaust valves for each cylinder.
Figure 1
Cylinder head with valve mechanism
1. Cylinder head 7. Spring guide

2. Exhaust valve 8. Guide
3. Inlet valve 9. Spring
4. Plug 10. Seal
5. Yoke 11. Guide
6. Valve collet
Service Information

Exploded view, cylinder 211 Service Information 2014/4/2 0
head
Profile:
CEX, ECR88 [GB]
Exploded view, cylinder head

Figure 1
Exploded view, cylinder head
1 Crankcase breather cover 19 Cylinder head

2 Diaphragm spring 20 Intake valve
3 Diaphragm cup 21 Exhaust valve
4 Crankcase breather diaphragm 22 Cylinder head gasket
5 Oil fill cap 23 Fuel injector nozzle protector
6 Valve cover nut 24 Fuel injector nozzle seat
7 Valve cover nut O-ring 25 Valve spring
8 Valve cover gasket 26 Valve bridge guide
9 Support bolt 27 Spring retainer
10 Rocker arm shaft support 28 Valve keepers
11 Wave washer 29 Valve bridge
12 Fuel injector retainer bolt 30 Valve bridge seat
13 Valve adjusting screw (primary) 31 Valve adjusting screw lock nut (secondary)
14 Valve adjusting screw lock nut (primary) 32 Valve adjusting screw (secondary)
15 Rocker arm shaft aligning stud 33 Push rod
16 Fuel injector retainer 34 Rocker arm shaft
17 Valve stem seal 35 Crankcase breather components
18 Valve guide 36 Valve cover
Service Information

Cylinder head, 211 Service Information 2014/4/2 0
disassembly/assembly
Profile:
CEX, ECR88 [GB]
Cylinder head, disassembly/assembly

Op nbr 2111
Disassemble in the order of the numbers shown in the illustration. (service point)
1. Remove the alternator assembly. (service point 1)
2. Remove the fan, pulley and V–belt.
3. Remove the thermostat case. (service point 2)
4. Remove the fuel filter and fuel oil piping. (service point 3)
5. Remove the oil level gauge assembly.
6. Remove the oil filter. (service point 4)
7. Remove the fuel injection pipes. (service point 5)
8. Remove the intake manifold assembly.
9. Remove the exhaust manifold assembly.
10. Remove the rocker cover.
11. Remove the rocker shaft assembly, push rods and valve caps. (service point 6)
12. Remove the cylinder head assembly and head gasket. (service point 7)
13. Remove the fuel injection valves and fuel return pipe. (service point 8)
14. Remove the intake/exhaust valves, stem seals and valve springs. (service point 9)
15. Remove the rocker arms from the rocker shaft.

For assembly, reverse the procedure.
Service points
Point 1
Disassembly :
 Loosen the mounting screw while supporting the alternator.
NOTE!
Do not tilt the alternator towards the cylinder block in a haste since it may damage the alternator or pinch a finger.
Reassembly:
 The belt deflection shall be checked according to Inspection after initial 50 hours operation.
 Replace the belt with a new one if cracked, worn or damaged.
Figure 2
A. Bar
B. Adjuster
C. Alternator
 Carefully prevent the belt from being smeared with oil or grease.
Point 2
Reassembly :
 Check the thermostat function.
Point 3
Reassemble :
 Replace the fuel filter element with a new one.
Disassemble :
 Cover the fuel pipe opening with tape to prevent intrusion of foreign matters.
Point 4
Reassemble :
 Replace the oil filter with a new one.

 After fully tightening the filter manually, retighten it with a filter wrench by 3/4 turn.
Point 5
Disassemble :
 Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of foreign
matter.
Point 6
Disassemble :
 Keep the removed push rods by attaching tags showing corresponding cylinder numbers.
Reassemble :
 Always apply oil to the contact portions of the push rods and valve clearance adjusting screws.
Point 7
Disassemble :
 Loosen the cylinder head screws in two steps in the illustrated order.
Figure 3
Head screw disassembly order
1. Fan side
 Place the cylinder head assembly on cardboard to prevent any damage to the combustion face.
Reassemble :
 Replace the head gasket with a new one.
Figure 4
Head screw tightening order
1. Fan side
 Uniformly install the head screws manually after applying oil on the threads and seat portions.
 They shall be tightened in two steps in the reverse of the order for disassembly.
Tightening torque :
 First step : 5 ~ 6 kgf·m (36.1 ~ 43.3 lbf·ft)

 Second step : 10.5 ~ 11.5 kgf·m (75.8 ~ 83.0 lbf·ft)
Point 8
Disassemble :
 Carefully remove the fuel injection valve so as not to leave the tip end protector from being left inside the cylinder.
Reassemble :
 Replace the fuel injection valve protector with a new one.
Point 9
Disassemble :
 When removing each inlet/exhaust valve from the cylinder head, use a valve spring compressor and compress the
valve spring and remove the valve cotter.
Figure 5
Valve spring compressor
 Keep each removed inlet/exhaust valve after attaching a tag showing the corresponding cylinder number.
 If cotter burr is seen at the shaft of each inlet/exhaust valve stem, remove it with an oilstone and extract the valve
from the cylinder head.
Reassemble :
 Replace the stem seal with a new one when an intake/exhaust valve is disassembled.
 Carefully install each valve after oil application so as not to damage the stem seal.
 Different stem seals are provided for the intake and exhaust valves. Do not confuse them since those for exhaust
valves are marked with yellow paint.
 After assembling the intake/exhaust valve, stem seal, valve spring, seat, and cotter, tap the head of the valve stem
lightly for settling.
 Do not forget to install the valve cap.
Service Information

Cylinder head, parts 211 Service Information 2014/4/2 0
inspection and
measurement
Profile:
CEX, ECR88 [GB]
Cylinder head, parts inspection and measurement

Cylinder head
Clean the cylinder head, mainly the combustion surface, valve seats and intake/exhaust ports, remove carbon deposit and
bonding agent, and check the surface state.
Figure 1
Distortion at combustion surface
1. Straight edge
2. Feeler gauge
 Appearance check
Check mainly discoloration and cracks. If a crack is suspected, perform dye check.
 Combustion surface distortion
Apply a straightedge in two diagonal directions and on four sides of the cylinder head, and measure distortion with
a feeler gage
Combustion surface distortion, unit: mm (in)
Standard Limit
Distortion 0.05 (0.002) or less 0.15 (0.0059)
 Valve sink
Measure with the valve inserted to the cylinder head.
Figure 2
Valve sink
1. Depth micrometer
Combustion surface distortion, unit: mm (in)
Standard Limit
Valve sink Inlet 0.36 ∼ 0.56 (0.0142 ∼ 0.0220) 0.8 (0.0315)
Exhaust 0.35 ∼ 0.55 (0.0138 ∼ 0.0217) 0.8 (0.0315)
Figure 3
Valve sink depth
1. Valve sinking depth
 Seat contact
Apply a thin coat of bluing on the valve seat. Insert the valve in the cylinder and push it against the seat to check
seat contact.
Standard : Continuous contact all around
Figure 4
Valve seat contact
1. Seat
 Valve guide
Mainly check damage and wear on the inside wall. Apply supply part number 129907–11800 when
replacing the part.
Figure 5
Valve guide inside diameter
1. Measuring positions
 Valve stem clearance
Valve stem clearance, unit: mm (in)
Standard Limit
Inlet valve Stem outside diameter 6.945 ~ 6.960 (0.2734 ~ 0.2740) 6.900 (0.2717)
Guide inner diameter 7.000 ~ 7.015 (0.2756 ~ 0.2762) 7.080 (0.2787)
Clearance 0.040 ~ 0.070 (0.0016 ~ 0.0028) 0.170 (0.0067)
Exhaust valve Stem outside diameter 6.940 ~ 6.955 (0.2732 ~ 0.2738) 6.900 (0.2717)
Guide inner diameter 7.000 ~ 7.015 (0.2756 ~ 0.2762) 7.080 (0.2787)
Clearance 0.045 ~ 0.075 (0.0018 ~ 0.0030) 0.170 (0.0067)
Figure 6
Valve stem outside diameter
1. Measuring positions
 Inlet/exhaust valve
Mainly clean and check damage and wear at the valve stem and seat.
Figure 7
Valve head thickness
1. Thickness
 Seat contact : see Seat contact.
 Stem outside diameter : see Valve stem clearance, unit: mm (in).
 Valve head thickness
Valve head thickness, unit : mm (in)
Standard Limit
Inlet 1.71 (0.0673) 1.00 (0.0394)
Exhaust 1.65 (0.0650) 1.00 (0.0394)
 Valve stem bend

Limit : 0.01 mm (0.0004 in)
Figure 8
Valve bend and length
1. Length
 Overall length
Valve overall length, unit: mm (in)
Standard Limit
Inlet 115 (4.53) 114.5 (4.50)
Exhaust 115 (4.53) 114.5 (4.50)
 Valve spring
Mainly inspect damage and corrosion.
Figure 9
Valve spring free length
Valve spring, unit: mm (in)
Standard Limit
Free length 47.5 (1.87) –
Inclination – 1.2 (0.047)
Figure 10
Valve spring inclination
 Valve rocker arm

Mainly inspect valve head cap contact surface, inside surface defects and wear. Slight surface defects shall be
corrected with an oilstone
Figure 11
Rocker arm hole diameter
Rocker arm hole diameter, unit : mm (in)
Standard Limit
Arm hole diameter 18.50 ~ 18.52 (0.7283 ~ 0.7291) 18.57 (0.7311)
Shaft outside diameter 18.47 ~ 18.49 (0.7272 ~ 0.7280) 18.44 (0.7260)
Clearance 0.01 ~ 0.05 (0.0004 ~ 0.0020) 0.13 (0.005)
 Valve rocker arm shaft

Mainly inspect seizure and wear at the surface in sliding contact with the arm. The rocker shaft diameter shall be as
specified in above.
Figure 12
Rocker shaft outside diameter
 Push rod
Mainly inspect the surface in contact with the tappet and adjusting screw. Slight defects shall be corrected with an
oilstone.
Bend limit : 0.03 mm (0.0012 in) or less
Figure 13
Push rod bend
1. Thickness gauge
 Valve clearance adjusting screw

Mainly inspect the surface in contact with the push rod. Slight defects shall be corrected with an oilstone.
 Rocker arm spring

Mainly inspect surface defects and corrosion.
Valve seat correction

NOTE!
Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it exceeds the limit,
replace the valve or valve guide first to make the clearance satisfy the standard. After correction, wash the valve and the
cylinder head sufficiently with diesel oil to remove all grinding powder or compound.
Figure 14
Cylinder head correction angle
1. Seat angle
2. Seat width
3. Seat cutter
 If the seat surface is slightly roughened : perform lapping (A) and (B) noted below.
Figure 15
Seat grinder
1. Grinder
2. Grindstone
 If the seat is heavily roughened but the width is almost normal, correct with a seat grinder or seat cutter first. Then
perform lapping (A) and (B) noted below.
Seat cutter angle, unit: degree
Inlet Exhaust
Seat cutter angle 120 90
 If the seat is heavily roughened and the width is much enlarged, grind the seat inner surface with a seat grinder
whose center angle is 40°, then grind the seat outer surface with a grinder whose center angle is 150° to make the
seat width match the standard. Then perform seat correction as described above, and then carry out lapping (A)
and (B) noted below.
Grinding wheel angle, unit: degree
θ1 θ2
Grinding wheel angle 40 150
Figure 16
Valve lapping
NOTE!
(A) : Lap the valve and seat with a mixture of valve compound and engine oil.
NOTE!
(B) : Lap with engine oil only.
Valve guide replacement
 Use a valve guide extraction tool and extract the valve guide from the cylinder head.
Figure 17
Valve guide replacement
1. Cylinder head
2. Valve guide
3. Projection
4. Valve guide extracting & inserting tool
 Put liquid nitrogen or ether (or alcohol) with dry ice added in a container and put the valve guide for replacement
(Part No. 129907–11800) in it for cooling. Then insert it in with a valve guide inserting tool.
 Check the inside diameter and finish to the standard inside diameter as required with a reamer.
 Check the projection from the cylinder head.
Projection: 9.7 ~ 10.0 mm (0.3819 ~ 0.3937 in)
Valve stem seal replacement

Always use a new seal after the intake/exhaust valve disassembly. Since the exhaust valve is marked with yellow paint, do not
confuse the intake and exhaust valves.
Figure 18
Stem seal insertion
1. Valve stem seal inserting tool

2. Stem seal
3. Valve guide
4. Cylinder head
 Apply engine oil to the lip.

 Push with the inserting tool for installation.
 Measure and check the projection of valve stem seal to keep proper clearance between valve guide and stem seal.
Projection: 11.7 ~ 12.0 mm (0.4606 ~ 0.4724 in)
Figure 19
Measurement and check the projection of valve stem seal
1. Stem seal
2. Valve guide
A. Clearance
B. Valve guide projection
C. Stem seal projection
Service Information

Cylinder block, description 212 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Cylinder block, description

The cylinder block is made of cast iron. To obtain a better noise reduction the cylinder block and the gear case have a high
stiffness.
Figure 1
Cylinder block and timing gear casing
1. Cylinder block
2. Timing gear casing
Service Information

Cylinder block, disassembly 212 Service Information 2014/4/2 0
and assembly
Profile:
CEX, ECR88 [GB]
Cylinder block, disassembly and assembly

Op nbr 00000
Disassemble in the order of the numbers in the illustration.
1. Perform steps 1 to 12 in the cylinder head disassembly procedure.
2. Perform steps 1 to 12 in the gear train disassembly procedure.
3. Remove the oil pan. (service point 1)
4. Remove the lubricating oil suction pipe.
5. Remove the piston with rod. (service point 2)
6. Remove the mounting flange. (service point 3)
7. Remove the bearing metal caps. (service point 4)
8. Remove the crankshaft. (service point 5)
9. Remove the tappets.
10. Remove the pistons and rings. (service point 6)
11. Remove the oil seal from the mounting flange. (service point 7)
Service points
Point 1 Oil pan
Disassembly :
 Sealant is applied to the oil pan mounting surface on the block. Carefully operate so as not to damage or distort
the bonding surface.
Reassembly :
 Apply sealant (Part No. 977770–01212) before reassembly.
Point 2 Piston with rod

Disassembly :
 Measure the connecting rod side gap.

Standard : 0.20 ~ 0.40 mm (0.0079 ~ 0.0157 inch)
 Carefully remove the carbon deposit on top of the cylinder so as not to damage the inner side of the cylinder.
 Set the piston at the BDC (Bottom Dead Center) position and remove the connecting rod cap. Then set the piston at
the TDC (Top Dead Center) position, and push the connecting rod big end with the wooden shaft of a hammer.
Proceed carefully so as not to cause the cylinder block to catch the rod big end. Set the rod caps and crankpin
metals in their correct combinations.
Reassembly :
 Apply oil especially carefully to the sliding contact surfaces of the pistons, rods and rings.
 Use the piston insertion tool to insert each piston with rod in the cylinder block and install the bearing metal cap.
 Tightening torque (Rod screw): 53.93 ~ 58.83 N m (5.5 ~ 6 kgf m) (39.7 ~ 152.4 lbf ft) (lubrication oil
applied)
Point 3 Mounting flange

Disassembly :
 Place the engine on a stable base with the cylinder block upper surface facing down, and remove the mounting
flange carefully so as not to damage the combustion surface.
Reassembly :
 Apply sealant (Part No. 977770–01212) and install the mounting flange by matching the two dowel pins. After
assembly, raise the engine with its mounting flange on the bottom side.
WARNING
Unforeseen injury may arise due to falling or slipping when raising or reversing the engine. Carefully operate so as
not to lose balance.
Point 4 Journal bearing cap
Disassembly :
Figure 2
Measurement (1), crankshaft side gap
 Before removing the journal bearing, measure the crankshaft side gap. Measure it in either method because there
are the next two methods. Standard : 0.11 ~ 0.21 mm (0.0043 ~ 0.0083 inch)
1. Install a dial gauge on the cylinder block, and move a crankshaft in front and back, and measure the side
gap as shown in the left figure.
Figure 3
Measurement (2), crankshaft side gap
A. Cylinder block
B. Standard width
C. Thrust face
2. Put a thickness gauge in the clearance between thrust metal and crankshaft directly, and measure it.
Crankshaft side gap, unit: mm (inch)
Standard Limit
Crankshaft side gap 0.13 ~ 0.23 (0.0051 ~ 0.0091) 0.28 (0.0110)
Reassembly :
 If the side gap exceeds the standard, replace the thrust metal with an oversize one.
Standard thickness, unit: mm (inch)
0.25 Oversize 129900–02370 (Upper)

129900–02360 (Lower)
Standard thickness, mm (inch) 2.055 ~ 2.105 (0.0809 ~ 0.0829 )
Disassembly :
 Remove the bearing caps, cap side bearings, and thrust metals. Place each thrust metal with identification of the
position and direction.
Reassembly :
 Carefully install each thrust metal so that the grooved one is positioned away from the cap.
 Do not confuse the upper and lower main bearing metals. The upper main bearing metal (block side) has an oil
hole, and the lower one does not. The “wheel and arrow” marks on the cap shall face the flywheel.
 Bearing cap mounting screw tightening torque: 107.87 ~ 117.68 N m (11 ~ 12 kgf m) (79.4 ~ 86.6 lbf ft)
(lubrication oil applied)
Point 5 Crankshaft
Disassembly :
 Remove the crankshaft. Remove each main bearing metal upper (block side) and pair it with the metal cap side
lower metal.
WARNING
The parts are heavy. Take appropriate safety precautions.
Carefully prevent damage to the bearing or finger injury when removing the crankshaft because it is heavy.
Point 6 Piston pin and rings
Disassembly :
 Use the piston ring replacer, remove the piston rings.

 Remove the circlip and remove the piston pin by pushing it out.
Reassembly :
 Install each piston ring on the piston, with the punched manufacturer’s mark facing upward.
Figure 4
Piston ring
1. Make the punched manufacture’s mark face upward
 The piston ring joints shall be staggered at by 120° intervals. Do not position the top ring joint vertical to the piston
pin. The coil expander joint shall be opposite to the oil ring joint.
Figure 5
Ring joints
1. Oil ring joint

2. Second ring joint
3. Expander joint
4. Top ring joint
 When installing the piston pin to the rod and piston, the punched match mark on the big end of the connecting
rod shall be opposite to the size mark on the piston top.
Figure 6
Assembly direction of connecting rod and piston
1. Engraved mark
A. Camshaft side
B. Flywheel side
 Install the piston in the cylinder block with the punched mark on the big end of the rod on the nozzle side. (The
embossed mark at the connecting rod I-beam section shall be on the flywheel side.)
Point 7 Oil seal

Reassembly :
 Replace the oil seal with a new one whenever disassembled. Apply lithium grease at the time of assembly.
Service Information

Cylinder block, parts 212 Service Information 2014/4/2 0
inspection and
measurement
Profile:
CEX, ECR88 [GB]
Cylinder block, parts inspection and measurement

Cylinder block
Especially clean head surface, cylinder bores and oil holes, and check after removing any carbon deposit and bonding agent.
 Appearance inspection
Check if there is any discoloration or crack. If crack is suspected, perform dye check. Sufficiently clean the oil holes
and check they are not clogged.
Figure 2
Cylinder bore measurement positions
 Cylinder bore and distortion
Measure at 20 mm (0.7874 in) below the crest of the liner, at 20 mm (0.7874 in) from the bottom end and at the
center.
NOTE!
Measure in two directions A and B at points a, b and c.
 Roundness : Maximum value of the difference between the measured values in the same cross section.
 Cylindricity : Maximum value of the difference between the measured values in the same direction.
Cylinder block, roundness and cylindricity, unit: mm (in)
Standard Limit
Bore 94.000 ~ 94.030 (3.7008 ~ 3.7020) 94.130 (3.7059)
Roundness 0.01 (0.0004) or less 0.03 (0.0012)
Cylindricity 0.01 (0.0004) or less 0.03 (0.0012)
 If the limit is exceeded or any surface defect is found, repair by boring and honing. Use an oversized piston (and
new piston rings) as required.
Piston and related parts
Piston assembly part No. (including Piston ring assembly part Boring dimension,
piston ring assembly) No. mm (in)
0.25 Oversize 129900–22700 129901–22950 φ94.250 ∼ 94.280
(φ3.7106 ~ 3.7118)
0.50 Oversize 129900–22920 129901–22970 φ94.500 ∼ 94.530
(φ3.7205 ~ 3.7217)
Crankshaft
 Mainly check seizure and wear of the crankpins and journals. Since the crankshaft gear is shrink–fitted, heat from
180 ~ 200 °C (356 ~ 392 °F) when extraction is necessary.
Figure 3
Inspection by dye check
 Shaft portion dye check
After washing the crankshaft, inspect it by means of dye check or a magnetic flux test. Replace it if cracked or
heavily damaged. Slight defects shall be corrected by grinding.
Figure 4
Crankshaft bend measurement
1 Bend 4 V–block
2 Deflection 5 V–block
3 Dial gauge
 Crankshaft bend
Support the crankshaft journals at both ends with V–blocks. Use a dial gauge and measure the run-out at the center
journal while rotating the shaft to inspect the bend.
Standard: 0.02 mm (0.0008 in) or less.
Figure 5
Measuring position of crankshaft and crank journal
1. Crankshaft journal
2. Crankpin
 Crankpin and journal measurement

Measure the outside diameter, roundness and taper at each crankpin and journal. Correct by grinding if unevenly
wear, roundness exceeding the limit or insufficient outside diameter is found. Replace if the defect is excessive.
Crankpin standard, unit: mm (in)
Standard Limit
Pin outside diameter 57.952 ~ 57.962 (2.2816 ~ 2.2820) 57.902 (2.2796)
Metal thickness 1.492 ~ 1.500 (0.0587 ~ 0.0591) –
Oil clearance 0.038 ~ 0.074 (0.0015 ~ 0.0029) 0.150 (0.0059)
 If the oil clearance exceeds the limit, use an undersized bearing.
0.25 US bearing, unit: mm (in)
Part Number 129900 - 23350

Standard thickness 1.617 ~ 1.625 (0.0637 ~ 0.0640)
Pin machining dimension φ57.702 ~ 57.712 (φ2.2717 ~ 2.2721)
Crank journal, unit: mm (in)
Standard Limit
Journal outside diameter 64.952 ~ 64.962 (2.5572 ~ 2.5576) 64.902 (2.5552)
Metal thickness 1.995 ~ 2.010 (0.0785 ~ 0.0791) –
Oil clearance 0.038 ~ 0.068 (0.0015 ~ 0.0027) 0.150 (0.0059)
 If the clearance limit is exceeded, use an undersized bearing.

0.25 US crank journal bearing
Part No. 129900 ~ 02320 (Upper)

129900 ~ 02330 (Lower)
Standard thickness, mm (in) 2.120 ~ 2.135 (0.0835 ~ 0.0841)
Journal bearing machining dimension, mm (in) φ64.702 ~ 64.712 (φ2.5473 ~ 2.5477)
Figure 6
Crankshaft R machining
A. Super polishing
1. Thrust face
2. Crank journal
3. Crank pin
 Dimension R and finishing precision of crankshaft journal and pin

As for grinding processing of journal and pin, machine it by using the grinding wheel of the dimension R of below
table.
Surface finishing precision standard on journal and pin:
Ry = 0.8S super polishing
Surface finishing precision standard on the thrust side of crankshaft arm:
0.25 Finishing precision standard
Finishing precision standard of dimension R, mm 4.0 +0.3/0 (0.1575 +0.0118/0)

(in)
NOTE!
If the oil clearance is excessive though the thicknesses of the journal and crankpin metals are normal or if partial uneven
wear is observed, regrind the crankshaft and use an oversized metals.
NOTE!
If rust or surface roughening exists on the rear side of the metals, coat it with thin film of ink. Then assemble the crankpin
metal to the connecting rod, and tighten the rod screw to the specified torque to check the metal for contact. If the contact
surface occupies 75% or more, the metal is normal. If the contact surface is insufficient, the metal interference is insufficient.
Replace the metal with a new one.
Thrust metal inspection
 Inspect any damage or wear.

 Measure side gap and thrust metal thickness.
Side gap and thrust metal thickness, unit: mm (in)
Standard Limit
Side gap 0.13 ~ 0.23 (0.0051 ~ 0.0091) –
Thickness 1.930 ~ 1.980 (0.0760 ~ 0.0780) 1.850 (0.0728)
 If the side gap is exceeded, use an oversized thrust metal.

0.25 Oversize thrust metal, unit: mm (in)
0.25 Oversize 129900 ~ 02370 (Upper)

129900 ~ 02360 (Lower)
Standard thickness 2.055 ~ 2.105 (0.0809 ~ 0.0828)
Piston
Figure 7
Piston outside diameter measurement
 Especially clean the combustion surface, circumference, ring grooves and piston pin bosses, and check after
removing any carbon deposit. Any burr at a ring groove or snap ring groove shall be removed. If crack is suspected,
inspect using color check.
 Piston outside diameter measurement

Measure the long diameter at 22 mm (0.8661 in) from the bottom end of the piston of the oval hole in the vertical
direction to the piston pin hole.
Piston outside diameter, unit : mm (in)
Standard Limit
Thickness 93.945 ~ 93.955 (3.6986 ~ 3.6990) 93.900 (3.6969)
Clearance between piston and cylinder – 0.050 (0.0020) ~ 0.080 (0.0031)
 If the clearance between piston and cylinder exceeds the limit, use an oversized piston.
Figure 8
Piston pin outside diameter
 Measure at positions a, b and c in directions A and B.
 Piston pin hole measurement.

Measure the outside diameter of piston pin and the inside diameter of piston pin hole. Calculate the clearance
between piston pin and piston pin hole. If any data exceeds the limit, replace the part with a new one.
Figure 9
Piston pin hole
 Measure at positions a and b in directions A and B.
Piston pin hole outside diameter, unit: mm (in)
Standard Limit
Pin hole diameter 30.000 ~ 30.009 (1.1811 ~ 1.1815) 30.039 (1.1826)
Pin outside diameter 29.989 ~ 30.000 (1.1807 ~ 1.1811) 29.959 (1.1795)
Oil clearance 0.000 ~ 0.020 (0.0000 ~ 0.0008) 0.080 (0.0031)
Figure 10
Ring components
1. Top ring
2. Second ring
3. Oil ring
 Piston ring, ring groove and end clearance measurement.
 Piston ring groove width
1. Measure the width of the piston ring.

2. Insert the piston ring into the ring groove.
3. Insert a feeler gauge in between the piston ring and groove to measure the gap between them.
4. Obtain the ring groove width by adding ring width to the measured side clearance.
 End clearance
1. Push the piston ring into the sleeve using the piston head.
2. Insert a feeler gauge in end clearance to measure.
3. The ring shall be pushed in to approximately 30 mm (1.181 in) above the bottom end of the
cylinder.
 For the top ring, measure only the piston ring joint end clearance in normal state.
Figure 11
Measurement, side clearance
1. Width
2. Thickness
Figure 12
Measurement, ring joint clearance
1. Piston ring
2. Cylinder block
3. Head surface
A. Joint end clearance

B. Approximately 30 mm (1.181 in)
Piston rings dimension, unit: mm (in)
Standard Limit
Top ring Ring groove width 2.040 ~ 2.060 (0.0803 ~ 0.0811) –
Ring width 1.940 ~ 1.960 (0.0764 ~ 0.0772) 1.920 (0.0756)
Side clearance 0.080 ~ 0.120 (0.0031 ~ 0.0047) –
End clearance 0.250 ~ 0.450 (0.0098 ~ 0.0177) 0.540 (0.0213)
Second ring Ring groove width 2.080 ~ 2.095 (0.0819 ~ 0.0825) 2.195 (0.0864)
Ring width 1.970 ~ 1.990 (0.0776 ~ 0.0783) 1.950 (0.0768)
Side clearance 0.090 ~ 0.125 (0.0035 ~ 0.0049) 0.245 (0.0096)
End clearance 0.450 ~ 0.650 (0.0177 ~ 0.0256) 0.730 (0.0287)
Oil ring Ring groove width 3.015 ~ 3.030 (0.1187 ~ 0.1193) 3.130 (0.1232)
Ring width 2.970 ~ 2.990 (0.1169 ~ 0.1177) 2.950 (0.1161)
Side clearance 0.025 ~ 0.060 (0.0010 ~ 0.0024) 0.180 (0.0071)
End clearance 0.250 ~ 0.450 (0.0098 ~ 0.0177) 0.550 (0.0217)
Connecting rod
Figure 13
Measurement, twist and parallelism
1. Mandrel
A. Parallelism
B. Twist
 Appearance inspection
Inspect the portion near the boundary of the chamfered portion and I–beam section of the big 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 discoloration.
 Twist and parallelism measurement
Use a connecting rod aligner and measure the twist and bend.
Rod, twist and parallelism measurement, unit: mm (in)
Standard Limit
Twist and parallelism 0.03 (0.0012) or less per 100 (3.94) 0.08 (0.0031)
Figure 14
Twist measurement using a connecting rod aligner
1. Connecting rod aligner

Figure 15
Connecting rod small end
1. Cylinder gauge
 Rod small end measurement

Measure the pin outside diameter according to procedure described above.
Connecting rod small end measurement, unit: mm (in)
Standard Limit
Piston pin bushing inside diameter 30.025 ~ 30.038 (1.1821 ~ 1.1826) 30.068 (1.1838)
Piston pin outside diameter 29.987 ~ 30.000 (1.1806 ~ 1.1811) 29.959 (1.1795)
Oil clearance 0.025 ~ 0.051 (0.0010 ~ 0.0020) 0.109 (0.0043)
 If the bushing is to be replaced because the oil clearance exceeds the limit, use spare part number 129900–23910.
 Rod big end measurement

Measure the crankpin and bushing according to procedure described above.
Connecting rod big end measurement, unit: mm (in)
Standard Limit
Rod bushing inside diameter 57.952 ~ 57.962 (2.2816 ~ 2.2820) 30.068 (1.1838)
Crank pin outside diameter 58.000 ~ 58.026 (1.1806 ~ 1.1811) –
Metal thickness 1.492 ~ 1.500 (0.0587 ~ 0.0591) –
Clearance 0.038 ~ 0.074 (0.0015 ~ 0.0029) 0.150 (0.0059)
Tappet
 Mainly check the tappet contact surface with the cam and push rod. Slight surface defects shall be corrected with
an oilstone.
Tappet measurement, unit : mm (in)
Standard Limit
Stem outside diameter 11.975 ~ 11.990 (0.4715 ~ 0.4720) 11.955 (0.4707)
Tappet hole inside diameter 12.000 ~ 12.018 (0.4724 ~ 0.4731) 12.038 (0.4739)
Oil clearance 0.010 ~ 0.043 (0.0004 ~ 0.0017) 0.083 (0.0033)
Cylinder bore correction

Figure 17
Honing cross hatch
 Slight uneven wear, flaws, etc. shall be corrected by honing only. If the cylinder is unevenly worn, partially flawed or
otherwise damaged and cannot be repaired simply by honing, rebore the cylinder first and then hone.
 Items to be prepared for honing
 Flex–Hone
 Electric drill
 Honing fluid (50 : 50 mixture of lube oil and diesel oil)
 Apply the honing fluid to the Flex–Hone and run the electric drill at 300 to 1200 rpm. Then insert the Flex–Hone
into the cylinder bore while running it, and move it up and down for about 30 seconds, to obtain honing mark with
a cross hatch angle of 30 to 40°.
NOTE!
Avoid faster revolution than 1200 rpm since it may cause breakdown.
NOTE!
Do not insert or extract the Flex–Hone in stopped state because the cylinder will be damaged.
Figure 18
Cylinder bore honing and boring process
T1 Time for honing (H1) 3 Honing

T2 Boring and honing (1.5 H1) A Increase in L.O.C. or blow-by gas
T3 Service life of cylinder block (3 H1) B Increase in L.O.C. or blow-by gas
1 Honing C Increase in L.O.C. or blow-by gas
2 Boring D Increase in L.O.C. or blow-by gas
 L.O.C. : Lubrication Oil Consumption

Piston pin bushing replacement
 Replace bushing by using the special service tool.

See Special tools.
Oil seal replacement
 Replace oil seal, when mounting flange is removed. Extract the used seal.
 Insert a new oil seal with the seal insertion tool.
 Apply lithium grease.
Service Information

Valves, adjusting 214 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Valves, adjusting
Op nbr 214-012
The 4-valve cylinder head operates two valves with a single rocker arm by employing a valve bridge between the
two valves. Clearance between the valve bridge and valves must be set before adjusting the clearance between the
rocker arm and valve bridge.
NOTICE
Valve adjustment with the engine running is not allowed since the valves may strike the piston, causing severe
damage.
1. Place the machine in the service position B, See 091 Service positions.
2. Open the engine hood
3. Remove clamp mounting screw (1).
Figure 1
4. Loosen nuts (1), (2) of the delivery pipes and then remove the delivery pipes.
Figure 2
5. Remove 4 rubber seals.
Figure 3
6. Remove 4 mounting screws of the engine rocker arm cover.
Figure 4
7. Remove the engine rocker arm cover.
Figure 5
NOTE!
If adjusting each cylinder individually, the cylinder to be adjusted first does not have to be the No. 1 cylinder. Select
and adjust the cylinder where the piston is nearest to the top dead center after turning, and make adjustment for
other cylinders in the order of firing by turning the crankshaft 180° each time.
8. Remove the rubber plug and rotate the crankshaft clockwise as seen from the coolant pump end, to bring No.1
piston to TDC on the compression stroke while watching the rocker arm motion and the timing grid on the
flywheel. (Position where both the intake and exhaust valves are closed.)
Figure 6
9. Make sure there is clearance (5) between valve bridge (1) and rocker arm (3).
Figure 7
1. Valve bridge
2. Valves
3. Rocker arm
4. Clearance between the valve bridge and valves
5. Clearance between the valve bridge and the rocker arm
NOTE!
Do not loosen or tighten the valve adjusting screw lock nut without holding the valve bridge. Always hold the valve
bridge using a wrench to prevent bending of the valve stems.
10. Loosen valve bridge adjusting screw lock nut (1) while holding bridge (3) with a wrench (2).
Figure 8
1. Valve bridge adjusting screw lock nut

2. Wrench
3. Bridge
11. To assure the valve bridge contacts the rear valve, apply light, downward finger pressure (4) on valve bridge (3) and
loosen valve bridge adjusting screw (1) until there is visible clearance between the adjusting screw and the front
valve.
12. To assure the valve bridge has equal contact with the front and rear valves, apply light downward pressure (4) on
valve bridge (3), adjust valve bridge adjusting screw (1), so there is “zero” clearance between the adjusting screw
and the front valve.
Figure 9
1. Valve bridge adjusting screw

2. Wrench
3. Bridge
13. Tighten lock nut (1), while holding the valve bridge with a wrench. Verify that the valve clearance (2) is zero.
Figure 10
1. Valve bridge adjusting screw

2. Valve clearance
NOTE!
There is a tendency for the clearance to decrease slightly when the lock nut is tightened. It is suggested that the
initial clearance adjustment is made slightly on the “loose “ side before tightening the lock nut.
14. To adjust the actual valve clearance between the rocker arm and the valve bridge, insert a feeler gauge (1) of the
correct thickness between rocker arm (2) and valve bridge (3). Record the results and use this value as an indication
of wear.
Figure 11
1. Feeler gauge
2. Rocker arm
3. Valve bridge
15. If adjustment is required, proceed to the next step.
16. Loosen valve adjusting screw lock nut (5) and valve adjusting screw (4) on rocker arm (3) and check clearance gap
(2) for evidence of dirt or wear.
Figure 12
1. Valve bridge
2. Valve clearance gap
3. Rocker arm
4. Valve adjusting screw
5. Valve adjusting screw lock nut
17. Adjust valve clearance (2) by turning adjusting screw (4) until there is a slight “drag” on the feeler gauge when
sliding it between the rocker arm and the valve bridge.
18. Hold adjusting screw (4) while tightening the valve adjusting screw lock nut (5). Recheck the clearance.
19. Apply oil to the contact surface between the adjusting screw and push rod.
20. Rotate the crankshaft to measure and adjust the set of valves. Continue until all valves are measured and adjusted.
21. Restore the machine to the operating condition.

NOTE!
Use only new bronze washers, O-rings and seals.
Service Information

Engine timing gear, 215 Service Information 2014/4/2 0
description
Profile:
CEX, ECR88 [GB]
Engine timing gear, description

The engine is controlled by timing gears. The timing gears are on the front of the engine in the timing case. The camshaft
gear and the injector pump gear are driven by the crankshaft gear via an intermediate pulley.
Figure 1
1. Fuel injection pump gear

2. Camshaft gear
3. Idler gear
4. Lubrication oil pump gear
5. Crankshaft gear
6. PTO (Power Take-Off, optional)
7. Direction of rotation
Service Information

Camshaft, description 215 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Camshaft, description
The function of the camshaft is to control the flow of intake air and exhaust gasses in the combustion chambers of the
engine. Tappets work off the lobes of the camshaft and drive the push rods to operate the valves. There are six tappets in
this engine. Springs on the valves return them to their closed position. The camshaft is mounted on four bearing journals.
Figure 1
Camshaft and components
1. Gear case
2. Push rod
3. Tappet
4. Camshaft
5. Camshaft gear key
6. Camshaft end plate
7. Screw
8. Camshaft gear
Service Information

Gear train and camshaft, 215 Service Information 2014/4/2 0
disassembly and assembly
Profile:
CEX, ECR88 [GB]
Gear train and camshaft, disassembly and assembly

Op nbr 00000
Disassemble in the order of the numbers in the illustration.
1. Perform steps 1 to 12 of the cylinder head disassembly procedure.
2. Remove the coolant pump.
3. Remove the crankshaft pulley. (service point 1)
4. Remove the gear case cover. (service point 2)
5. Remove the fuel injection pump. (service point 3)
6. Remove the idle gear assembly. (service point 4)
7. Remove the PTO (Power Take-Off) drive gear. (service point 5)
8. Remove the PTO (Power Take-Off) lubrication pipe.
9. Remove the starting motor.
10. Remove the flywheel. (service point 6)
11. Remove the camshaft assembly. (service point 7)
12. Remove the gear case. (service point 8)
13. Remove the seal from the gear case cover. (service point 9)

Service point
Point 1
Disassembly :
 Remove the crankshaft pulley using a gear puller after removing the crankshaft pulley set screw. When removing
the pulley using the gear puller, use a pad and carefully operate so as not to damage the thread. Set the gear puller
securely to prevent the pulley from being damaged.
Reassembly :
 Apply lithium grease to the oil seal lips. For the oil seal with double lips dust seal, further slightly apply engine oil
on the lips so as not to damage them.
 Clean by wiping off any oil on both taper surface using detergent.
 Be sure to use the crankshaft pulley installing tool so as not to damage the oil seal lips.
 When installing the crankshaft pulley, apply lube oil to the set screw to tighten and carefully assemble so as not to
damage the oil seal.
Tightening torque : 107.87 ~ 127.48 N m (11 ~ 13 kgf m) (79.4 ~ 93.9 lbf ft)
Point 2
Reassembly :
 When installing the gear case cover, do not forget to install the two reinforcing screws at the center.
Figure 1
Gear train
1. Fuel injection pump drive gear

2. Camshaft gear
3. Idle gear
4. Lubrication oil pump gear
5. Crankshaft gear
6. PTO (Power Take-Off) gear
7. Direction of rotation
 Measure the backlash of each gear.
Gear train measurement, unit : mm (inch)
Standard Limit
Crankshaft gear, camshaft gear, fuel injection pump 0.08 ~ 0.14 (0.0031 ~ 0.0055) 0.16 (0.0063)
gear, idle gear, PTO (Power Take-Off) gear
Lubricating oil pump gear 0.09 ~ 0.15 (0.0035 ~ 0.0059) 0.17 (0.0067)
 Apply sealant and install the gear case cover by correctly positioning the two dowel pins.
Point 3
Disassembly :
 Remove the fuel injection pump drive gear mounting nut, remove the gear using the gear puller, and remove the
fuel injection pump. Do not forget to remove the stay on the rear side. When extracting the gear using the gear
puller, use a pad at the shaft and carefully operate so as not to damage the thread.
Reassembly :
 Drive gear nut tightening torque: 112.77 ~ 122.58 N m (11.5 ~ 12.5 kgf m) (83 ~ 90 lbf ft)
Point 4
Reassembly :
 Assemble crankshaft gear A, fuel injection pump drive gear B and camshaft gear C at the same time by aligning
with idle gear A, B and C marks.
 Install the idle gear shaft with the oil hole facing upward.
Point 5
Reassembly :
 Install the PTO (Power Take-Off) drive gear with its inner spline side facing the flywheel.
Point 6
Disassembly :
 Install a screw as a handle in the hole at the end face of the flywheel and remove carefully so as not to damage the
ring gear.
Reassembly :
 Flywheel mounting screw tightening torque : 186.32 ~ 205.94 N m (19 ~ 21 kgf m) (137.2 ~ 151.6 lbf ft) (lubrication
oil applied)
Point 7
Disassembly :
 Measure the camshaft side gap.
Figure 2
Camshaft side gap
1. Camshaft gear
2. Thrust bearing
A. Side gap
Camshaft side gap measurement, unit: mm (inch)
Standard Limit
Side gap 0.05 ~ 0.20 (0.0020 ~ 0.0079) 0.30 (0.1181)
 If the measured side gap exceeds the limit, replace the thrust bearing.
 Since the camshaft gear is shrink–fit, heat it to 180 ~ 200 °C (356 ~ 392 °F) for extraction.
NOTE!
Do not heat directly with flame to prevent damage.
 For camshaft removal, raise the engine with its mounting flange at the bottom. After removing the thrust bearing
mounting screw from the camshaft gear hole, extract the camshaft carefully so as not to damage the bearing
bushing.
 Rotate the camshaft a few turns before extracting it to prevent the tappet from being caught by the cam.
 After removing the camshaft, set the engine horizontal and fix it on the base.
WARNING
Unforeseen injury may arise due to falling or slipping when raising or reversing the engine. Carefully operate so as
not to lose balance.
Point 8
Reassembly :
 Do not forget to install the oil pan mounting screws on the bottom side when installing the gear case.
 Apply sealant (Part No. 977770–01212) and install the gear case by matching the two dowel pins.
Point 9
Reassembly :
 Replace the oil seal whenever disassembled.

 Apply lithium grease at the time of assembly.
Service Information

Gear train and camshaft, 215 Service Information 2014/4/2 0
parts inspection and
measurement
Profile:
CEX, ECR88 [GB]
Gear train and camshaft, parts inspection and measurement

Camshaft
Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and gear damage.
 Shaft bend measurement

Support the camshaft with V blocks. Rotate the camshaft and measure the run out at the center of the camshaft
and at each journal with a dial gauge. Half of the run out is the bend.
Figure 1
Camshaft bend
1. Dial gauge
2. V–block
Camshaft bend measurement, unit : mm (inch)
Standard Limit
Bend 0.0 ~ 0.02 (0.0 ~ 0.0008) 0.05 (0.0020)
 Intake/exhaust cam height measurement
Figure 2
Cam height
H Cam height
1 Micrometer
Cam height measurement, unit : mm (inch)
Standard Limit
Cam height 43.400 ~ 43.600 43.150 (1.6988)
(1.7087 ~ 1.7165)
 Camshaft outside diameter and bearing hole diameter measurement

Measure the camshaft outside diameter with a micrometer. The oil clearance shall be calculated by subtracting the
measured camshaft outside diameter from the camshaft bushing inside diameter after insertion to the cylinder
measured with a cylinder gauge.
Figure 3
Camshaft outside diameter
1. Flywheel side
2. Micrometer
Camshaft outside diameter measurement, unit: mm (inch)
Standard Limit
Gear end Camshaft outside diameter 49.925 ~ 49.950 (1.9656 ~ 1.9665) 49.890 (1.9642)
Bushing inner diameter 49.990 ~ 50.055 (1.9681 ~ 1.9707) 50.130 (1.9736)
Oil clearance 0.040 ~ 0.130 (0.0016 ~0.0051) 0.240 (0.0094)
Intermediate Camshaft outside diameter 49.910 ~ 49.935 (1.9650 ~ 1.9659) 49.875 (1.9636)
position Bushing inner diameter 50.000 ~ 50.025 (1.9685 ~ 1.9695) 50.100 (1.9724)
Oil clearance 0.065 ~ 0.115 (0.0026 ~ 0.0045) 0.225 (0.0089)
Flywheel end Camshaft outside diameter 49.925 ~ 49.950 (1.9656 ~ 1.9665) 49.890 (1.9642)
Bushing inner diameter 50.000 ~ 50.025 (1.9685 ~ 1.9695) 50.100 (1.9724)
Oil clearance 0.050 ~ 0.100 (0.0020 ~ 0.0039) 0.210 (0.0083)
Idle gear
 Idle gear mainly check the bushing seizure and wear, and gear damage.
Figure 4
Idle gear
1 Shaft
2 Idle gear
D1 Shaft diameter
D2 Inside diameter
 Shaft outside diameter and bushing inside diameter measurement

Idle gear measurement, unit: mm (inch)
Standard Limit
Bushing inside diameter 46.000 ~ 46.025 (1.8110 ~ 1.8120) 46.075 (1.8140)
Clearance 0.025 ~ 0.075 (0.0010 ~0.0030) 0.175 (0.0070)
PTO (Power Take-Off) drive gear
 PTO (Power Take-Off) drive gear

Mainly check sticking of bearings on both sides, gear damage and looseness, and gear shaft damage and wear.
Camshaft bushing replacement
 Replace the bushing using the special service tool.

See Special tools.
 Replace the oil seal with a new one when the gear case cover is disassembled. Extract the used seal.
 Insert a new oil seal using the seal inserting tool.
 Apply lithium grease to the oil seal lips. For the oil seal with double lips dust seal, further, slightly apply engine oil
on the oil seal lip so as not to damage them, when installing the pulley.
NOTE!
Pay attention not to drop any oil on the taper surface of the crankshaft. If dropped, clean wiping off using
detergent.
 Carefully install the crankshaft pulley so as not to damage the oil seal lips. Especially for the engine installed the oil
seal with double lips dust seal, be sure to use the crankshaft pulley installing tool.
Figure 5
1 Oil seal with double lips dust seal

2 Knurled head
3 Crankshaft pulley installing tool
4 Guiding
A Detail of crankshaft pulley installing tool
B Detail of oil seal with double lips dust seal
Service Information

Crankshaft, description 216 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Crankshaft, description
The forged crankshaft is provided with integrated balancing weights. The gear that drives the engine timing gear and the
flange for the flywheel is keyed to the crankshaft.
Figure 1
Crankshaft, description
1 Fly wheel 5 Crankshaft gear

2 Crankshaft 6 Crankshaft pulley
3 Parallel pin 7 Connecting rod
4 Crankshaft gear key 8 Piston
Service Information

Engine mounting 218 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Engine mounting
Engine mounting
Figure 1
1. Cushion
2. Bracket
3. Frame
4. Screw
5. Washer
6. Nut
7. Screw
8. Nut
9. Screw
10. Screw
Cushion
NOTE!
Check the color markings for cushion installation.
– Front (fan end) : Blue color marking.
– Rear (flywheel end) : white color marking.
NOTE!
Convex part should be directed downward when install the cushions.
Tightening torque, unit: kgf·m (lbf·ft)
No. Tightening torque

4 118 ±1 (86.5 ±7)
Assembly after coated with Loctite.
7 64 ±7 (47 ±5)
9 Assembly after coated with Loctite.
10
Service Information

Lubricating system, 220 Service Information 2014/4/2 0
description
Profile:
CEX, ECR88 [GB]
Lubricating system, description

 Engine lubricating oil is supplied to the contact faces of rotating components such as crankshaft, camshaft, piston,
inlet/exhaust valve, rocker arm and timing gear by means of forced lubrication from the oil pump.
Lubricating oil flow diagram
Figure 1
Lubrication oil flow
Structure, lube oil pump

Figure 2
Structure, lube oil pump
1 Gear case 4 Lubrication oil pump

2 Crankshaft 5 Pressure regulating valve
3 Outer rotor 6 Punch mark
Service Information

Lubricating system, 220 Service Information 2014/4/2 0
description
Profile:
CEX, ECR88 [GB]
Lubricating system, description

The oil pump transports the lubricating oil from the sump through the cooler to the oil filter. From there, the lubricating oil
reaches the main distribution channel. The main distribution channel supplies oil to the crankshaft, camshaft and rocker
shaft via lubricant bores. The injection pump is lubricated via an oil line. To protect the system from over pressure, there is a
pressure relief valve in the tank return line. If the oil filter is blocked, the oil flows through a bypass valve to the main
distribution channel. If the oil pressure is too low, the oil pressure sensor gives a warning signal to the engine oil control
lamp in the I-ECU.
Figure 1
Engine lubrication system
1. Oil pan
2. Lubrication oil pump
3. Pressure limiting valve
4. Oil filter
5. Oil cooler
6. Bypass valve
7. Injection pump
8. Rocker shaft
9. Oil pressure sensor
10. Camshaft
11. Crankshaft
Service Information

Lubrication system, 220 Service Information 2014/4/2 0
disassembly and assembly
Profile:
CEX, ECR88 [GB]
Lubrication system, disassembly and assembly

Op nbr 00000
1. Loosen the belt, and remove the radiator pulley, fan and V–belt.
2. Remove the crankshaft pulley.
3. Remove the gear case cover.
4. Remove the lubricating oil pump assembly from the gear case. (point 1)
5. Remove the pressure regulating valve from the lubricating oil pump body. (point 2)
Service point
Point 1
Disassembly :
 Check if the pump rotates smoothly and see that there is no play between the shaft and gear, and inner rotor.
Reassembly :
 Install the outer rotor in the gear case so that the punch mark on the end face is seen.
 For installation on the gear case, tighten four screws uniformly in several steps.
NOTE!
Always check if the pump rotates smoothly after installation on the gear case. Running the engine when the pump
rotation is heavy may cause the pump to be burnt.
 When replacing the lubricating oil pump, replace the whole assembly.
Point 2
Disassembly–Reassembly :
 Only wash the pressure regulating valve. Disassembly is unnecessary unless any abnormality in operation is
detected.
Service Information

Lubrication system, parts 220 Service Information 2014/4/2 0
inspection and
measurement
Profile:
CEX, ECR88 [GB]
Lubrication system, parts inspection and measurement

Outer rotor
 Measure oil clearance between the outer rotor and inside diameter of the gear case hole.
Figure 1
Oil clearance
1. Gear case
2. Outer rotor
 Measure side clearance between the outer rotor and gear case side.
Figure 2
Side clearance
Outer rotor measurement, unit: mm (inch)
Standard Limit
Oil clearance 0.100 ~ 0.155 (0.004 ~ 0.006) 0.25 (0.010)
Side clearance 0.050 ~ 0.100 (0.002 ~ 0.004) 0.15 (0.006)
Rotor shaft clearance

Measure the outside diameter of rotor shaft and the shaft hole diameter of gear case. Calculate the clearance from that
difference.
Figure 3
Lube oil pump bearing
1. Rotor shaft
2. Gear case
3. Shaft outer diameter
4. Bearing inner diameter
Rotor shaft measurement, unit: mm (inch)
Standard Limit
Bearing inside diameter 13.000 ~ 13.020 (0.5118 ~ 0.5126) 13.050 (0.5138)
Rotor Clearance 0.015 ~ 0.065 (0.0006 ~ 0.0026) 0.105 (0.0041)
Service Information

Fuel system, description 230 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Fuel system, description

A fuel supply hose deliveres fuel from the bottom of the tank to the water separator. The fuel then flows through a hose to
the electric fuel pump. A tube deliveres fuel under pressure from the fuel lift pump to fuel filter . Fuel which has been filtered
by the fuel filter is directed through tubes to the fuel injection pump and to the thermo start plug in the intake manifold. A
tube from the fuel injectors returns surplus fuel from the injectors to the fuel filter and into a line and hose which returns it
to the fuel tank.
Fuel system, diagram
Figure 1
Fuel system
1 Diesel fuel tank 12 Engine crankcase

2 Water separator 13 Tappet
3 Electric fuel pump 14 High pressure gallery
4 Fuel filter 15 Overflow orifice
5 Air bleed orifice 16 Accumulator
6 Fuel supply line 17 Timer piston
7 Low pressure gallery 18 Mono-plunger
8 Pressure control valve 19 Distributor shaft
9 Trochoid pump 20 Fuel return line
10 Oil seal 21 High-pressure fuel injection lines
11 Fuel injection pump cam 22 Fuel injector
Service Information

Fuel system, description 230 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Fuel system, description

Tier 3
For machines equipped with engine ECU The fuel system is controlled electronically by the engine control unit (ECU). The
ECU receives signals from the ignition key, the speed control switch and a number of sensors on the engine, to help govern
the function of the fuel system.
When the engine is running (and during the initial crank mode) an electric fuel pump is activated in order to pump fuel from
the tank through a water separator and further to the fuel filter. From there a tube delivers the fuel to a Trochoid pump
through a pressure control valve. The Trochoid pump builds up pressure before the fuel is carried to the fuel injection, where
a Mono-Plunger works to deliver fuel via the distributor shaft through high-pressure lines to the fuel injectors. Excess fuel is
carried through a high-pressure gallery and returned to the fuel tank by a fuel return line. Should the system contain air, an
air bleed orifice is placed on top of the fuel filter for automatic air bleeding.
Fuel level is monitored by a sensor, and a software function handles driver information via the I-ECU.
Fuel system, diagram
Figure 1
Fuel system
1 Diesel fuel tank 12 Engine crankcase

2 Water separator 13 Tappet
3 Electric fuel pump 14 High pressure gallery
4 Fuel filter 15 Overflow orifice
5 Air bleed orifice 16 Accumulator
6 Fuel supply line 17 Timer piston
7 Low pressure gallery 18 Mono-plunger
8 Pressure control valve 19 Distributor shaft
9 Trochoid pump 20 Fuel return line
10 Oil seal 21 High-pressure fuel injection lines
11 Fuel injection pump cam 22 Fuel injector
Service Information

Fuel filters, replacing 233 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Fuel filters, replacing

Op nbr 233-014
A reduction in engine power can be caused by a clogged fuel filter. If the filter becomes clogged quickly, check fuel for
contamination and clean the fuel tank if necessary.
1. Place the machine in the service position B. See 091 Service positions.
2. Open the engine hood.
3. Turn shut–off valve (1) of the water separator to OFF position to cut fuel supply.
Figure 1
4. Loosen fuel filter with a filter wrench and remove.
Figure 2
Removal, filter
5. Clean the sealing surface of the filter head.
6. Lightly oil the rubber seal of the new filter, or moisten with diesel fuel.
7. Screw the new filter on by hand until the seal makes contact, then tighten another half turn.
8. Turn shut–off valve of the water separator to ON position and turn engine starting switch to ON position for two
minute to feed fuel into the engine.
9. Close the engine hood.

Service Information

Fuel tank, description 234 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Fuel tank, description
Figure 1
Structure, fuel tank
1 Cap 6 Spring washer 11 Drain cock valve 16 Fuel filler port

2 Screen filter 7 Shim 12 Hydraulic oil tank 17 Level gauge
3 Fuel tank 8 Shim 13 Fuel return port Screw
4 Screw 9 Fuel drain plug 14 Fuel supply port
5 Plain washer 10 O-ring 15 Fuel level sender
NOTE!
When mounting the tank, adjust the height by use of shim (7, 8).
NOTE!
When mounting to the frame, adjust the gap "D" : 5 mm (Upper and lower parts are same).
Tightening torque
 Level gauge (18): 1.5 ± 0.2 kgf·m (10.8 ± 1.4 lbf·ft)

 Screw (4): 11.3 ± 1.8 kgf·m (81.6 ± 7.9 lbf·ft)
 Drain cock valve (11): 1.6 ~ 1.9 kgf·m (11.6 ~ 13.7 lbf·ft)
Service Information

Fuel tank, description 234 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Fuel tank, description
Figure 1
Structure, fuel tank
1 Fuel cap 4 Fuel tank

2 Screen filter 5 Shim & Washer with screw
3 Level gauge 6 Drain cock valve
NOTE!
When mounting the tank, adjust the height by using shim
NOTE!
When mounting to the frame, adjust the gap "D" : 5 mm (Upper and lower parts are same).
Tightening torque
 Level gauge (3): 15 ±2 Nm (11 ±1.5 lbf ft)

 Screw (5): 111 ±11 Nm (81.6 ±8 lbf ft)
 Drain cock valve (6): 16 ~ 19 Nm (12 ~ 14 lbf ft)
Service Information

Fuel filler pump, 234 Service Information 2014/4/2 0
description
Profile:
CEX, ECR88 [GB]
Fuel filler pump, description

 The pump outlet is plumbed directly to the fuel tank to reduce the risk of introducing contamination.
 The master switch must be in the ON position to operate the fuel filler pump.
NOTE!
The filter at the end of fuel filler pump inlet hose is a strainer, and will not filter impurities from the fuel. When filling use
CLEAN fuel only!
NOTE!
Do not operate the fuel filler pump without fuel or for extended periods of time.
NOTE!
Drain the fuel from the suction hose before putting it in the storage compartment.
NOTE!
In case the pump has been disassembled, assemble the pump so the that the sharp portion of the vane faces the
counterclockwise direction.
Figure 1
Structure, fuel filler pump (35 liter/min.)
Service Information

Fuel lines, description 235 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Fuel lines, description

The fuel level sensor is installed in the fuel tank.
When the fuel level gauge indicates EMPTY, there is still approximately 10 Liter (2.64 gal) remaining.
Fuel supply flow
Fuel tank (1) → Water separator (3) → Fuel feed pump (10) → Fuel filter (2) → Fuel injection pump (9) → Fuel injector (6)
Fuel return flow
Injector return line (7) → Fuel return hose (5, 11) → Fuel tank (1)
Figure 1
Fuel line
1. Fuel tank
2. Fuel filter
3. Water separator
4. Fuel pipe
5. Fuel return hose
6. Fuel injector
7. Injector return line
8. Thermostat element line (coolant)
9. Fuel injection pump
10. Fuel feed pump
11. Fuel return hose
12. Fuel suction hose
13. Fuel tank drain valve
Service Information

Fuel injection pump, 236 Service Information 2014/4/2 0
description
Profile:
CEX, ECR88 [GB]
Fuel injection pump, description

Fuel injection pump
The fuel injection pump is a very important component of the engine. It is capable of making very precise fuel delivery
adjustments according to the varied loads applied to the engine.
All of the fuel injection pump components are very precisely machined. It is extremely important to follow good service
practices and maintain cleanliness when servicing the fuel injection pump.
The fuel injection pump is a distributor type pump which consists of a single fuel supply plunger, a distributor shaft, a
hydraulic head and a pump housing. The hydraulic head has a delivery valve for each cylinder. The fuel injection pump
housing contains a governor and an internal camshaft.
The fuel is pressurized by the up and down motion of the camshaft-driven single plunger. It is then distributed to the proper
fuel injector by the rotating distributor shaft.
Trochoid fuel pump
The trochoid fuel pump is located on the side of the fuel injection pump, however is not a fuel supply pump. The function of
this pump is to raise the pressure of the fuel supplied by the electric fuel supply pump to the internal fuel pressure required
by the fuel injection pump.
Figure 1
Fuel injection pump
1. Fuel injection pump

2. Cold-start device
3. Monoplunger
4. Pressure valve
5. Stop solenoid valve
6. Trochoid fuel pump
Service Information

Fuel injection pump/ 236 Service Information 2014/4/2 0
governor, description
Profile:
CEX, ECR88 [GB]
Fuel injection pump/governor, description

Fuel injection pump
The fuel injection pump is a very important component of the engine. It is capable of making very precise fuel delivery
adjustments according to the varied loads applied to the engine.
All of the fuel injection pump components are very precisely machined. It is extremely important to follow good service
practices and maintain cleanliness when servicing the fuel injection pump.
The fuel injection pump is a distributor type pump which consists of a single fuel supply plunger, a distributor shaft, a
hydraulic head and a pump housing. The hydraulic head has a delivery valve for each cylinder. The fuel injection pump
housing contains a governor and an internal camshaft.
The fuel is pressurized by the up and down motion of the camshaft-driven single plunger. It is then distributed to the proper
fuel injector by the rotating distributor shaft.
Trochoid fuel pump
The trochoid fuel pump is located on the side of the fuel injection pump, however is not a fuel supply pump. The function of
this pump is to raise the pressure of the fuel supplied by the electric fuel supply pump to the internal fuel pressure required
by the fuel injection pump.
Electronically controlled governor
Electronically controlled engine is quipped with an electronically controlled governor called "Eco Governor". Combined with
the rack actuator (4). engine speed sensor (6), and other parts, the electronically controlled governor communicates with the
engine controller (E-ECU), whereby the engine speed and fuel injection rate are controlled.
When the key is turned on or off, corresponding signal is sent to the E-ECU.
Thus the E-ECU controls the rack actuator to provide a sufficient injection rate when the engine is tarted up (the key is
turned on) or cut the fuel supply and stop then engine when the key is turned off.
Figure 1
Fuel injection pump
1. Cold-start device
2. Solenoid valve connector
3. Rack actuator connector
4. Rack actuator
5. Engine speed sensor connector
6. Engine speed sensor
7. Trochoid fuel pump
8. Fuel injector pump
Service Information

Stop solenoid, description 236 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Stop solenoid, description

The fuel injection pump is equipped with a stop solenoid that controls the fuel flow inside the fuel injection pump.
With the starter switch in the OFF position, no current flows to the stop solenoid and the solenoid plunger is extended
holding the fuel injection pump fuel rack in the “closed” position, thus not allowing fuel to flow through the injection pump
and to the engine.
When the starter switch is turned to the START position, the “pull coil” inside the solenoid is activated and pulls the solenoid
plunger into the solenoid. This releases the fuel injection pump fuel rack, allowing fuel to flow through the injection pump
and allowing the engine to start and run.
When the starter switch is returned to the ON or RUN position, the “pull coil” no longer receives current and the “hold coil”
inside the solenoid is activated. The “hold coil” holds the solenoid plunger in the RUN position, allowing fuel to continue
flowing and the engine to continue running.
To stop the engine, the key switch is turned to the OFF position. Current no longer flows to the stop solenoid “hold coil” and
the solenoid plunger extends and moves the injection pump fuel rack to the “closed” position, shutting off the fuel flow and
stopping the engine.
Failure of the stop solenoid could result in the engine not starting, the engine stopping suddenly, the engine not continuing
to run with the key switch returned to the ON or RUN position, or the engine failing to stop when the key switch is turned to
the OFF position. Use a multimeter or continuity light to check for 12 volts at the stop solenoid connector in the correct
sequence.
Service Information

Cold start device, 236 Service Information 2014/4/2 0
description
Profile:
CEX, ECR88 [GB]
Cold start device, description

The engine is equipped with a cold start device. The cold start device is located in the upper section of the fuel injection
pump and is connected to the engine's cooling system.
The cold start device improves engine starting at lower temperatures. At engine cooling system temperatures below 5° C
(41° F), the cold start device advances the fuel injection timing and slightly increases the fuel injection volume.
For approximately the first 5 minutes of operation, the idle speed of the engine will be slightly elevated.
When the cold start device is activated, there may be a slight increase in the exhaust smoke of the engine during warm up.
Figure 1
Cold start device
1. Coolant channel
2. Thermo element
3. Piston
4. Plunger barrel
5. Plunger
6. Sub port
7. Fuel inlet
X: Difference injection timing A to B

Service Information

Cold start device, 236 Service Information 2014/4/2 0
description
Profile:
CEX, ECR88 [GB]
Cold start device, description

Tier 3 engine
The engine is equipped with a cold start device. The cold start device is located in the upper section of the fuel injection
pump.
The cold start device improves engine starting at lower temperatures. this is consists of a fuel injection pump complete with
solenoid valve.
When the engine is started with the cooling water sensor detecting a low water temperature of 10°C (50°F) or lower and the
E-ECU receives the corresponding signal, then the E-ECU causes the cold start device's solenoid valve to increase the
injection rate and advance the injection timing.
Because of this, the engine speed increases while the cold start device is operating. When the water temperature becomes
10°C (50°F) or higher, the device is tuned off and the engine returns to the normal speed.
When the cold start device is activated, there may be a slight increase in the exhaust smoke of the engine during warm up.
Figure 1
Cold start device
Service Information

Injectors, description 237 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Injectors, description
 When fuel oil pumped by the fuel injection pump reaches the injection nozzle, it pushes up the nozzle valve (held
down by a spring), and is injected into the combustion chamber at high pressure.
 The fuel is atomized by the nozzle to mix uniformly with the air in the combustion chamber. How well the fuel is
mixed with high temperature air directly affects combustion efficiency, engine performance and fuel economy.
 Accordingly, the fuel injection nozzles must be kept in top condition to maintain performance and operating
efficiency.
Functioning of fuel injection nozzle
 Fuel from the fuel injection pump passes through the oil port in the nozzle holder and enters the nozzle body
reservoir.
 When oil reaches the specified pressure, it pushes up the nozzle valve (held by the nozzle spring), and is injected
through the small hole on the tip of the nozzle body.
 The nozzle valve is automatically pushed down by the nozzle spring and closed after fuel is injected.
 Oil that leaks from between the nozzle valve and nozzle body goes from the hole on top of the nozzle spring
through the oil leakage fitting and back into the fuel tank.
 Adjustment of injection starting pressure is effected with the adjusting shims.
Figure 1
Exploded view, fuel injection valve
1 Nozzle holder
2 Pressure adjusting shim
3 Nozzle spring
4 Nozzle spring seat
5 Dowel pin
6 Valve stop spacer
7 Nozzle valve
8 Nozzle body
9 Nozzle case nut (tightening torque : 41.67 ±2.45 N m (4.25 ±0.25 kgf m) (30.7 ±1.8 lbf ft)
Figure 2
Fuel injection nozzle
1. Nozzle valve
2. Nozzle body
3. Injection hole
4. F.O. reservoir
5. Hole
A. Nozzle angle
Service Information

Intake and exhaust system, 250 Service Information 2014/4/2 0
description
Profile:
CEX, ECR88 [GB]
Intake and exhaust system, description
Figure 1
Intake and exhaust system, structure
1 Intake manifold 9 Pipe 17 Screw 25 Clamp

2 Hose 10 U-bolt 18 Screw 26 Screw
3 Air cleaner 11 Nut 19 Screw 27 Clamp
4 Clamp 12 Hose 20 Exhaust manifold 28 Vacuator
5 Pipe 13 Clamp 21 Bracket 29 Indicator
6 Pipe 14 Bracket 22 Pipe
7 Muffler 15 Screw 23 Screw
8 Screw 16 Screw 24 Clamp
Tightening torque
1. Screw (15, 16, 17, 18, 23) : 3.3 ± 0.3 kgf·m (23.8 ± 0.3 lbf·ft)
2. Screw (8) : 6.7 ± 0.7 kgf·m (46.9 ± 5.1 lbf·ft)
3. Screw (19) : 2.6 ± 0.6 kgf·m (18.8 ± 2.2 lbf·ft)
4. Nut (11, 26) : 1.2 ± 0.1 kgf·m (8.7 ± 0.9 lbf·ft)
5. Clamp (4, 13, 24, 25) : 0.5 ~ 0.6 kgf·m (3.6 ~ 4.3 lbf·ft)
Service Information

Inlet system, description 250 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Inlet system, description

 The air required for combustion is filtered by the air cleaner filter, and then supplied to the engine combustion
chamber.
 For operator convenience the clogging of the inlet system is sensed and activates a warning lamp on the dash
board.
Figure 1
Inlet system
1. Inlet hose+tube
2. Clamp screw (tightening torque : 2 Nm, 7.2 lbf ft)
3. Air cleaner
4. Flange screw (tightening torque : 12 ±1 Nm, 8.5 ±0.7 lbf ft)
5. Air sensor connector
Service Information

Exhaust system, description 250 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Exhaust system, description

1. The exhaust system is designed so that exhaust noise is remarkably reduced when the exhaust gas is passed
through the manifold and muffler.
Figure 1
Exhaust system
1. Screw (tightening torque : 32 ±3 Nm, 24 ±2 lbf ft)

4. Screw (tightening torque : 25.5 ±3 Nm, 18.7 ±2 lbf ft)
5. Exhaust manifold
6. Muffler
Service Information

Exhaust Gas Recirculation 250 Service Information 2014/4/2 0
(EGR), description
Profile:
CEX, ECR88 [GB]
Exhaust Gas Recirculation (EGR), description

EGR (Exhaust Gas Recirculation) lowers the combustion temperature and reduces N0x which is a composition subject to
emission control regulations by introducing a part of exhaust gas into the intake air.
The amount and timing of exhaust that is introduced into the intake is calculated by the E-ECU. The calculation of the rate of
exhaust gas recirculation depends upon the engine speed and load. Once the E-ECU has determined this rate, the E-ECU
controls a step motor which pushes a rod varying the opening of a valve that the exhaust flow to the intake manifold.
EGR valve controls the exhaust gas recirculation flow rate depending on the engine speed/load signals from the E-ECU. It is
installed on the top of the exhaust manifold.
Figure 1
1. Exhaust manifold
2. EGR pipe
3. EGR valve
4. Intake manifold
5. Cooling water hose, EGR valve inlet
6. Cooling water hose, EGR valve outlet
Each EGR valve has four built-in coils. The power to each of the four coil is either ON or OFF at any given time. Depending
on which coil is ON and which coil is OFF, the step motor rotates to determine the valve lift. The power to each coil is turned
ON/OFF by the E-ECU based on the engine speed and fuel injection rate. The resistances of these coils should be as
specified below when measured between each pair of pins shown. If any of the actually measured values is beyond the
standard range, replace the entire EGR valve assembly.
Standard resistance value
Terminal Resistance (Ω)

1–2 15 ±2 at 20°C (68°F)
2–3
4–5
5–6
Figure 2
EGR valve connectors
Service Information

Cooling system, description 260 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Cooling system, description

The engine is liquid cooled by means of a cooling system. The cooling system consists of a radiator, radiator cap, engine
cooling fan, engine coolant pump, thermostat and expansion tank.
Engine cooling fan
The engine cooling fan is driven by a V-belt which is powered by the crankshaft V-pulley. The purpose of the engine cooling
fan is to circulate air through the radiator.
Engine coolant pump
The engine coolant pump circulates the engine coolant through the cylinder block and the cylinder head and returns the
engine coolant to the radiator.
Radiator
The radiator acts as a heat exchanger. As the engine coolant circulates through the cylinder block, it absorbs heat. The heat
in the engine coolant is dissipated in the radiator. As the engine cooling fan circulates air through the radiator, the heat is
transferred to the air.
Radiator cap
The radiator cap controls the cooling system pressure. The cooling system is pressurized to raise the boiling point of the
engine coolant. As the engine coolant temperature rises, the system pressure and the coolant volume increases. When the
pressure reaches a preset value, the release valve in the radiator cap opens and the excess engine coolant flows into the
expansion tank. As the engine coolant temperature is reduced, the system pressure and volume is reduced and the vacuum
valve in the radiator cap opens allowing the engine coolant to flow from the expansion tank back into the radiator.
Expansion tank
The expansion tank contains the overflow of engine coolant from the radiator. If engine coolant needs to be added to the
system, add it to the expansion tank and not the radiator.
Thermostat
A thermostat is placed in the cooling system to prevent the engine coolant from circulating into the radiator until the engine
coolant temperature reaches a preset temperature. When the engine is cold, no engine coolant flows through the radiator.
Once the engine reaches it's operating temperature, the thermostat opens and allows the engine coolant to flow through
the radiator. By letting the engine warm up as quickly as possible, the thermostat reduces engine wear, deposits and
emissions.
Cooling system diagram
Figure 1
1 Thermostat 5 Coolant pump

2 Bypass 6 Cylinder block
3 Radiator 7 Cylinder head
4 Sub-tank
Service Information

Cooling system, description 260 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Cooling system, description

The engine is liquid cooled by means of a cooling system. The cooling system consists of a radiator, radiator cap, engine
cooling fan, engine coolant pump, thermostat and expansion tank.
Engine cooling fan
The engine cooling fan is driven by a V-belt which is powered by the crankshaft V-pulley. The purpose of the engine cooling
fan is to circulate air through the radiator.
Engine coolant pump
The engine coolant pump circulates the engine coolant through the cylinder block and the cylinder head and returns the
engine coolant to the radiator.
Radiator
The radiator acts as a heat exchanger. As the engine coolant circulates through the cylinder block, it absorbs heat. The heat
Radiator cap
The radiator cap controls the cooling system pressure. The cooling system is pressurized to raise the boiling point of the
engine coolant. As the engine coolant temperature rises, the system pressure and the coolant volume increases. When the
pressure reaches a preset value, the release valve in the radiator cap opens and the excess engine coolant flows into the
expansion tank. As the engine coolant temperature is reduced, the system pressure and volume is reduced and the vacuum
valve in the radiator cap opens allowing the engine coolant to flow from the expansion tank back into the radiator.
Expansion tank
The expansion tank contains the overflow of engine coolant from the radiator. If engine coolant needs to be added to the
system, add it to the expansion tank and not the radiator.
Thermostat
A thermostat is placed in the cooling system to prevent the engine coolant from circulating into the radiator until the engine
coolant temperature reaches a preset temperature. When the engine is cold, no engine coolant flows through the radiator.
Once the engine reaches it's operating temperature, the thermostat opens and allows the engine coolant to flow through
the radiator. By letting the engine warm up as quickly as possible, the thermostat reduces engine wear, deposits and
emissions.
Figure 1
1 Cylinder head 4 Coolant expansion tank 7 Cylinder block

2 Thermostat 5 Radiator & Hydraulic oil cooler
3 Engine coolant pump 6 Engine oil cooler
Service Information

Cooling system, 260 Service Information 2014/4/2 0
disassembly/assembly
Profile:
CEX, ECR88 [GB]
Cooling system, disassembly/assembly

Op nbr 00000
1. Remove the alternator.
2. Remove the fan, V–belt and pulley.
3. Remove the thermostat cover.
4. Remove the coolant pump.
5. Remove the thermostat.

NOTE!
Service points
Point 1
Disassembly–reassembly :
 Check to see that the coolant pump bearing is free from abnormal noise, sticking or play and water leakage from
the bearing. If replacement is necessary, replace the coolant pump assembly.
Point 2
Disassembly :
 Check the thermostat function, referring to the inspection method.

Service Information

Radiator, description 261 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Radiator, description
Description
The cooling unit cells and tanks are made of aluminium. The hydraulic oil cooler is installed to the radiator frame.
The radiator acts as a heat exchanger. As the engine coolant circulates through the cylinder block it absorbs heat. The heat
Figure 1

Figure 2
1 Thermostat 5 Coolant pump

2 Bypass 6 L.O. cooler
3 Radiator 7 Cylinder block
4 Sub-tank 8 Cylinder head
Service Information

Coolant, checking anti- 261 Service Information 2014/4/2 0
freeze resistance
Profile:
CEX, ECR88 [GB]
Coolant, checking anti-freeze resistance

Op nbr 261-002
88890105 Refractometer
WARNING
Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant
may rush out and cause severe burns.
1. Check the freezing protection with 88890105 Refractometer.

Open the cover on the refractometer and place a few drops of the coolant on the glass surface. Close the cover and
read off the value against strong light source.
Read off the value on the ethylene scale. The coolant should be taken from the filling point on the expansion tank.
Figure 1
2. The machine is delivered with a coolant mixture for optimal cooling and corrosion characteristics.
That is why the same coolant mixture shall be filled, regardless of ambient temperature conditions. See 160 Coolant
and 160 Coolant with freezing and corrosion protection.
Figure 2
NOTE!
Volvo Construction Equipment concentrated coolant with anti-freeze must not be mixed with other brands
of anti-freeze or additives as this type of mixture could have negative effects.
Service Information

Coolant, changing 261 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Coolant, changing
Op nbr 261-004
WARNING
Risk of burns - stop the diesel engine and allow it to cool down before starting any work.
WARNING
Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling
system.
1. Place the machine in the service position B, See 091 Service positions.
Draining coolant
2. Open the engine hood and slowly remove the radiator cap
3. Open coolant drain valve and drain all coolant into a suitable container.
NOTE!
Prepare a suitable container.
Figure 1
NOTE!
The cooling system is not protected from freezing after draining. There may still be pockets of coolant in the
system.
NOTE!
Handle and take care of waste oil/fluids in an environmentally safe manner.
NOTE!
Volvo Construction Equipment concentrated coolant with anti-freeze must not be mixed with other brands
of anti-freeze or additives as this type of mixture could have negative effects.
NOTE!
Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S.
Refilling coolant into drained cooling system
4. Refill coolant through the filling port on the top of the radiator
Figure 2
NOTE!
Cooling system refill volume is approximately 7 litres (1.8 US gal).
5. Start and run the engine to operating temperature and top up with coolant so that the cooling system is
completely filled with coolant and is free of air.
6. Check the coolant level after the engine has been run to operating temperature and then cooled down.
Figure 3
NOTE!
Never fill or top up the cooling system with cold coolant when the engine is warm. This can cause cracking of the
engine block and the cylinder head.
Service Information

Thermostat, check 262 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Thermostat, check
1. Place the thermostat in a container filled with water.
Figure 1
1. Thermometer
2. Thermostat
2. Heat it while measuring the water temperature, and see that the thermostat is actuated at the temperature of
following table.
Concerning the operating temperature, see 262 Coolant pump, thermostat, specifications.
NOTE!
Valve opening temperature is scribed on the flange.
Figure 2
1. Thermometer
2. Thermostat
3. Tester probes
3. Place the thermostat in a container filled with antifreeze or oil.
Heat it while measuring the fluid temperature.
NOTE!
The switch is normal if the multi-meter shows continuity when the fluid temperature is 107 ~ 113 °C (225 ~ 235 °F).
Service Information

Fan belt and/or alternator 263 Service Information 2014/4/2 0
belt, checking and
adjusting tension
Profile:
CEX, ECR88 [GB]
Fan belt and/or alternator belt, checking and adjusting tension

When there is not enough tension in the V-belt, the V-belt will slip making it impossible for the alternator to generate
power. The water pump and cooling fan will not work which will cause the engine to overheat. Check and adjust the V-belt
tension (deflection) in the following manner.
Op nbr 263-013
1. Press the V-belt with your thumb (approximately 98 Nm (10 kgfm) at the middle of the V-belt span to check the
tension (deflection).
Available positions to check and adjust the V-belt tension (deflection) are in the A, B and C locations shown.
Choose a position where the adjustment can be easily carried out.
Figure 1
Checking and adjustment, radiator fan V-belt
1. Radiator fan
2. V-belt
3. Crankshaft V-pulley
4. Checking the tension
5. Deflection
6. Alternator
7. Set screw
NOTE!
A “new V-belt” refers to a V-belt which has been used on a running engine less than 5 minutes. A “used V-belt”
refers to a V-belt which has been used on a running engine more than 5 minutes.
The specified deflection to be measured at each position is listed in the table below.
V-belt deflection, unit: mm (inch)
Direction A B C
For used V-belt 10 – 14 (0.39 – 0.55) 7 – 10 (0.28 – 0.39) 9 – 13 (0.35 – 0.51)
For new V-belt 8 – 12 (0.31 – 0.47) 5 – 8 (0.20 – 0.31) 7 – 11 (0.28 – 0.43)
2. If necessary, adjust the V-belt tension (deflection). To adjust the tension, loosen the set screw and move the
alternator to tighten the V-belt.
Figure 2
A. Bar
B. Tensioner
C. Alternator
3. After replacing the V-belt, and adjusting it, run the engine for 5 minutes and readjust the deflection to the value in
the table above.
4. Visually check the V-belt for cracks and wear. If necessary, replace the V-belt.
Service Information

Engine speed control 275 Service Information 2014/4/2 0
switch, description
Profile:
CEX, ECR88 [GB]
Engine speed control switch, description

 The operator can easily control the engine speed, and maximum working horsepower by turning the engine speed
control switch if the V-ECU is in the operating position.
 The switch also controls the engine speed according to the built-in program of V-ECU.
 The engine speed control switch changes the PWM input to V-ECU according to the position (step) selected.
Engine speed control switch
No. Wire specification Signal

1 0.85 R Power (B+)
2 0.85 W Output
3 0.85 SB Ground
4 0.85 R/W 12 V (Illumination)
5 0.85 BN GND (Illumination)
Figure 1
Engine speed control switch
Service Information

Engine control 275 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Engine control
Figure 1
Adjustment, engine throttle lever
1. Low speed
2. High speed
Idle rpm
Low idle rpm High idle rpm B mm (in) C degree

930 2280 200 (7.9) 24
Service Information

Engine control 275 Service Information 2014/4/2 0
Profile:
CEX, ECR88 [GB]
Engine control
 The electric signal is generated and sent to V-ECU (3) when the operator controls speed control switch (4). Then the
V-ECU determines proper RPM and request it to E-ECU (2).
 The E-ECU communicates with engine (1) and adjusts the rack position of the fuel injection pump depending on the
signal from V-ECU, thus regulating the engine speed and power.
Idle RPM
Low idle rpm High idle rpm

960 ±30 2150 ±30
Figure 1
Many thanks for your purchase.
Happy every day.
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2 Engine With Mounting and Equipment

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Service Information

Document Title: Function Group: Information Type: Date:

Go back to Index Page

1 Cooling fan 7 Fuel pipe 13 Engine data plate

1 Engine oil filter 5 Hose for thermostat element 9 Alternator

1 Thermostat housing 7 Starter motor

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Engine, tightening torque

Item Nominal size Tighten torque Lubricating oil application (thread

Item Nominal size Tighten torque Lubricating oil application (thread

Document Title: Function Group: Information Type: Date:

 Fix the engine on a horizontal base.

Document Title: Function Group: Information Type: Date:

Trouble symptoms Causes Corrective actions

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Inspection item Unit Standard Limit

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Inspection item Unit Standard Limit

Document Title: Function Group: Information Type: Date:

Tool name Applicable model and tool size Illustration

Connecting rod bushing replacer Part number: 14527852 Drift

Valve spring compressor (for Part number: 8931-00060 Press tool

Filter wrench (for removal/ Available on the market

Flex–hone (for re–honing of cylinder

Instrument name Application Illustration

Torque wrench For tightening nuts and screws to the

Document Title: Function Group: Information Type: Date:

Periodic inspection and maintenance procedure

 Oil leak from the lubrication system

Thermostat and Thermal Switch Inspection

Valve opening temperature, °C (°F) Full open lift, mm (°C, °F)

 Inspection and replacement of fuel pipe and cooling pipes/hoses.

 Lapping the intake and exhaust valves

 Fuel injection timing inspection and adjustment

 Oil pressure switch

Radiator cap inspection

Document Title: Function Group: Information Type: Date:

1 Water separator 8 V-belt

15 Lifting bracket (engine cooling fan end 20 Starter motor

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Engine characteristic curve

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Engine characteristic curve

Document Title: Function Group: Information Type: Date:

 generation of error codes

 Check error codes

Document Title: Function Group: Information Type: Date:

Compression pressure inspection

1. Degree of clearance between piston and cylinder

2. Crank the engine before installing the compression gauge adapter.

Standard compression pressure

Engine speed and compression pressure

Item Cause Corrective action

Cylinder head gasket

Document Title: Function Group: Information Type: Date:

 Supply the fuel oil, lubricating oil and coolant.