This is a very practical manual

1. Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2014/3/30
Profile:
CEX, EW60C [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

2. Service Information
Document Title: Function Group: Information Type: Date:
Engine, identification 200 Service Information 2014/3/30
Profile:
CEX, EW60C [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

3. Service Information
Document Title: Function Group: Information Type: Date:
Engine, tightening torque 200 Service Information 2014/3/30
Profile:
CEX, EW60C [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
nut
M 18 × 1.5 113 ~ 123 (83 ~ 90) Not applied
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)
M 6 × 1.0 9.8 ~ 11.8 (7 ~ 9)
Screw (7T) and nut


Use 80% of the value at left
when the tightening part is
aluminium.
Use 60% of the value at left
for 4T screws and lock nuts.
M 8 × 1.25 22.6 ~ 28.4 (17 ~ 21)
M 10 × 1.5 44.1 ~ 53.9 (33 ~ 40)
M 12 × 1.75 78.4 ~ 98 (58 ~ 72)
M 14 × 1.5 127.5 ~ 147.1 (94 ~ 108)
M 16 × 1.5 215.7 ~ 235.4 (157 ~ 174)
1/8 9.8 (7)
PT plug
1/4 19.6 (14)
3/8 29.4 (22)
1/2 58.5 (43)
M 8 12.7 ~ 16.7 (9 ~ 12)
Pipe joint screw
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.

4. Service Information
Document Title: Function Group: Information Type: Date:
Precautions 200 Service Information 2014/3/30
Profile:
CEX, EW60C [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.

5. Service Information
Document Title: Function Group: Information Type: Date:
Maintenance standards 200 Service Information 2014/3/30
Profile:
CEX, EW60C [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
(kgf/cm2)
(psi)
(bar)
21.6 ~ 22.6
(220 ∼ 230)
(3129 ∼ 3271)
(21.6 ~ 225.6)
Compression at 250 rpm MPa
(kgf/cm2)
(psi)
(bar)
3.43 ±0.09
(35 ±1)
(498 ±14)
(34.3 ±0.98)
2.74 ±0.09
(28 ±1)
(398.2 ±14.2)
(27.4 ±0.98)
Coolant capacity (engine only) 4.2 (1.1)
Liters (US gal)
High 11.6 (3)
Lubricating oil capacity (oil pan)
Low 5.2 (1.4)
Oil pressure switch operating pressure MPa
(kgf/cm2)
(psi)
0.04 ~ 0.06
(0.4 ~ 0.6))
(5.8 ~ 8.8))
Valve opening temperature °C (°F) 82 (179.6)
Thermostat
Full opening lift (temperature) mm (inch) / °C (°F) 8 (0.32) or more / 95
(203)
Coolant Temperature Switch °C (°F) 107 ~ 113 (225 ~ 235)

6. Service Information
Document Title: Function Group: Information Type: Date:
Special tools 200 Service Information 2014/3/30
Profile:
CEX, EW60C [GB]
Special tools
Special tools
Special tools
Tool name Applicable model and tool size Illustration
Valve guide tool (for extracting valve
guide)
Part number: 14527850 Drift




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
guide)
Part number: 14527851 Drift




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
(for removal/installation of
connecting rod bushing)
Part number: 14527852 Drift




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
removal/installation of valve spring)
Part number: 8931-00060 Press tool
Stem seal inserter (for inserting stem
seal)
Part number: 14527853 Drift






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/
installation of lubrication oil filter)
Available on the market

7. Camshaft bushing tool (for
removing camshaft bushing)
Part number: 8931-00080 Installation
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
piston)
The above piston insertion tool is
applicable to 60 ~ 125 mm (2.362 ~
4.921 in) diameter piston.
Piston ring replacer (for removal/
installation of piston ring)
Available on the market
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

8. 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
of the revolving shaft
1 : 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

9. Service Information
Document Title: Function Group: Information Type: Date:
Component locations 200 Service Information 2014/3/30
Profile:
CEX, EW60C [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 Coolant temperature sensor 15 Engine oil cooler
2 Fuel control PWM valve (Governor) 9 Coolant pump 16 Engine oil filter
3 Fuel filter 10 Crankshaft V-pulley 17 Engine oil drain plug
4 Fuel return line 11 V-belt 18 Engine oil dipstick
5 Fuel supply line 12 Side filler port (engine oil) 19 Oil pressure switch
6 Top filler port (engine oil) 13 Fuel injection pump 20 Fuel feed pump
7 Thermostat 14 Speed sensor

10. Figure 2
Component locations, flywheel side
21 Lifting bracket 26 Starter motor
22 Rocker arm cover 27 Cylinder block
23 EGR vavle 28 Exhaust manifold
24 Flywheel 29 Alternator
25 Oil pan

11. Service Information
Document Title: Function Group: Information Type: Date:
Engine characteristic curve 210 Service Information 2014/3/30
Profile:
CEX, EW60C [GB]
Engine characteristic curve
Figure 1
Engine characteristic curve (Gross power)

12. Service Information
Document Title: Function Group: Information Type: Date:
Cylinder head, description 211 Service Information 2014/3/30
Profile:
CEX, EW60C [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

13. Service Information
Document Title: Function Group: Information Type: Date:
Exploded view, cylinder
head
211 Service Information 2014/3/30
Profile:
CEX, EW60C [GB]
Exploded view, cylinder head

14. 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

15. 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

16. Service Information
Document Title: Function Group: Information Type: Date:
Cylinder head,
disassembly/assembly
211 Service Information 2014/3/30
Profile:
CEX, EW60C [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:

17. 


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
Adjustment, V-belt tension
A.
B.
C.
Bar
Adjuster
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

18. 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

19. 

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.

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Please download this document
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21. Service Information
Document Title: Function Group: Information Type: Date:
Cylinder head, parts
inspection and
measurement
211 Service Information 2014/3/30
Profile:
CEX, EW60C [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.
2.
Straight edge
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.