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Nanni 4.195HE, Workshop Manual

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Nanni 4.195HE Workshop Manual Download Page 111

S-94

03-M Series, WSM

DIESEL  ENGINE

[2] DISASSEMBLING  AND ASSEMBLING

CAUTION

• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.

Otherwise, hot water way gush out, scalding nearby people.

Thermostat Assembly

1. Remove the thermostat cover mounting screws, and remove the

thermostat cover (1).

2. Remove the thermostat assembly (3).

(When reassembling)

• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the

thermostat cover side of the thermostat cover gasket (2).

W1105115

(1) Thermostat Cover
(2) Thermostat Cover Gasket

(3) Thermostat Assembly

KiSC issued 08, 2012 A 

Summary of Contents for 4.195HE

Page 1: ...60300075 Mis jour 01 2013 Diesel Marine Engine 5 280HE 4 200HE 4 220HE 4 195HE WORKSHOP MANUAL...

Page 2: ...g General includes general precautions check and maintenance and special tools There are troubleshooting checking and adjusting disassembling and assembling and servicing which cover procedures precau...

Page 3: ...tself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safety regulations before you attempt to repair or use this uni...

Page 4: ...g Otherwise hot water will spout out from radiator Only remove radiator cap when cool enough to touch with bare hands Slowly loosen the cap to first stop to relieve pressure before removing completely...

Page 5: ...ations when disposing of oil fuel coolant electrolyte and other harmful waste PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin clothing and cause b...

Page 6: ...l Injection Pump Bosch Type Mini Pump Governor All speed mechanical governor Direction of Rotation Counter Clockwise viewed from flywheel side Injection Nozzle Bosch Throttle Type Mini Nozzle OPD Inje...

Page 7: ...unter Clockwise viewed from flywheel side Injection Nozzle Bosch Throttle Type Mini Nozzle OPD Injection Timing 0 314 rad 18 before T D C Firing Order 1 3 4 2 Injection Pressure 13 73 MPa 140 kgf cm2...

Page 8: ...6 03 M Series WSM DIMENSIONS DIMENSIONS KiSC issued 08 2012 A...

Page 9: ...7 DIMENSIONS 03 M Series WSM KiSC issued 08 2012 A...

Page 10: ...YNAMIC BALANCER BALANCER MODEL ONLY M 1 4 HALF FLOATING HEAD COVER M 2 2 COOLING SYSTEM M 3 1 BOTTOM BYPASS SYSTEM M 3 3 FUEL SYSTEM M 4 1 GOVERNOR M 4 For not above mentioned engine mechanism informa...

Page 11: ...he molybdenum disulfide 1 serves as a solid lubricant like a Graphite or Teflon This material helps resist metal wears even with little lube oil W1013114 3 BUILT IN DYNAMIC BALANCER BALANCER MODEL ONL...

Page 12: ...VER The rubber packing 2 is fitted in to maintain the cylinder head cover 1 0 5 mm 0 02 in or so off the cylinder head 1 This arrangement helps reduce noise coming from the cylinder head W1013327 1 Cy...

Page 13: ...the thermostat is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine When the temperature exceeds the thermostat valve opening level the thermostat...

Page 14: ...battery current into the engine stop solenoid 16 the plunger 17 is actuated to arrow direction Since the steel ball 1 have no centrifugal force the control rack 14 is pushed to the right by the start...

Page 15: ...ed is dropped and fork lever 2 9 is pulled to the right by the governor springs 1 7 and 2 8 increasing fuel injection Though fork lever 2 9 becomes ineffective in increasing fuel injection when it is...

Page 16: ...28 8 Check Points of Every 500 Hours S 29 9 Check Points of Every 1 or 2 Months S 32 10 Check Point of Every Year S 33 11 Check Point of Every 800 Hours S 34 12 Check Points of Every 1500 Hours S 35 1...

Page 17: ...mp S 95 2 Injection Nozzle S 97 6 ELECTRICAL SYSTEM S 99 1 CHECKING S 99 1 Starter S 99 2 Alternator S 100 3 Glow Plug S 100 4 Engine Stop Solenoid S 101 2 DISASSEMBLING AND ASSEMBLING S 102 1 Starter...

Page 18: ...dicates 2001 and A indicates January So 1A indicates that the engine was manufactured in January 2001 W1010477 Alphabet or Number Year Alphabet or Number Year 1 2001 F 2015 2 2002 G 2016 3 2003 H 2017...

Page 19: ...Cylinder Number The cylinder numbers of 03 M Series diesel engine are designated as shown in the figure The sequence of cylinder numbers is given as No 1 No 2 No 3 and No 4 starting from the gear case...

Page 20: ...attery first Remove oil and dirt from parts before measuring Use only KUBOTA genuine parts for parts replacement to maintain engine performance and to ensure safety Gaskets and O rings must be replace...

Page 21: ...e assembly retaining nut Camshaft set screw Hi idling body Balancer shaft set bolt M6 1 0 M11 1 25 M9 1 25 M10 1 25 M12 1 25 M8 1 0 M8 1 25 M8 1 25 M30 1 5 M8 1 25 M10 1 25 M20 1 5 PT 1 8 M12 1 5 M8 1...

Page 22: ...haft camshaft piston cylinder or bearing Repair or replace Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder Improper valve timing Correct or r...

Page 23: ...ing Repair or replace S 57 96 Deficient nozzle injection Repair or replace nozzle S 54 97 Compression leak Check the compression pressure and repair S 50 Air cleaner dirty or clogged Clean or replace...

Page 24: ...lief valve defective Replace Engine Overheated Engine oil insufficient Replenish S 20 Fan belt broken or elongated Replace or adjust S 23 31 Coolant insufficient Replenish S 19 Radiator net and radiat...

Page 25: ...less Top Clearance 0 55 to 0 70 mm 0 0217 to 0 0276 in Valve Clearance When Cold 0 18 to 0 22 mm 0 0071 to 0 0087 in Valve Seat Width Intake Width Exhaust 2 12 mm 0 0835 in 2 12 mm 0 0835 in Valve Sea...

Page 26: ...e Length Setting Load Setting Length Tilt 41 7 to 42 2 mm 1 6417 to 1 6614 in 117 6 N 35 0 mm 12 0 kgf 35 0 mm 26 4 lbs 1 3780 in 41 2 mm 1 6220 in 100 0 N 35 0 mm 10 2 kgf 35 0 mm 22 5 lbs 1 3780 in...

Page 27: ...Idle Gear Side Clearance 0 12 to 0 48 mm 0 0047 to 0 0189 in 0 9 mm 0 0354 in Idle Gear Shaft to Idle Gear Bushing Idle Gear Shaft Idle Gear Bushing Clearance O D I D 0 025 to 0 066 mm 0 00098 to 0 00...

Page 28: ...Balancer Shaft Journal 3 Balancer Shaft Bearing 3 Clearance O D I D 0 020 to 0 094 mm 0 00079 to 0 00370 in 21 947 to 21 960 mm 0 86406 to 0 86457 in 21 980 to 22 041 mm 0 86535 to 0 86776 in 0 20 mm...

Page 29: ...1 to 59 940 mm 2 35910 to 2 35984 in 51 980 to 52 039 mm 2 04646 to 2 04878 in 59 980 to 60 039 mm 2 36142 to 2 36374 in 0 20 mm 0 0079 in Crankshaft Journal to Crankshaft Bearing 1 Serial No above 3S...

Page 30: ...00 to 47 046 mm 1 85039 to 1 85221 in 0 20 mm 0 0079 in Crankshaft Serial No below 3R9999 D1503 M D1703 M V2203 M D1803 M V2403 M Side Clearance 0 15 to 0 35 mm 0 0059 to 0 0138 in 0 15 to 0 31 mm 0 0...

Page 31: ...0 0055 in 0 2 mm 0 0079 in Outer Rotor to Pump Body Clearance 0 11 to 0 19 mm 0 0043 to 0 0075 in 0 25 mm 0 0098 in Inner Rotor to Cover Clearance 0 105 to 0 150 mm 0 00413 to 0 00591 in 0 20 mm 0 00...

Page 32: ...ressure is 12 75 MPa 130 kgf cm2 1849 psi the valve seat must be fuel tightness Starter Commutator Mica Brush Brush Holder and Holder Support O D Under Cut Length Resistance 30 0 mm 1 181 in 0 50 to 0...

Page 33: ...Engine oil depending on the oil pan 1 Oil pan depth 90 mm 3 54 in S 20 24 2 Oil pan depth 124 mm 4 88 in S 20 26 Cleaning air cleaner element Replace the element after 6 times cleanings S 22 Cleaning...

Page 34: ...road vehicle engine runs on a high sulfur fuel it is advisable to employ the CF CD or CE lubricating oil with a high total base number If the CF 4 or CG 4 lubricating oil is used with a high sulfur f...

Page 35: ...iscosity from the previous drain old oil Never mix two different types of oil NOTE Q Be sure to inspect the engine locating it on a horizontal place If placed on gradients accurately oil quantity may...

Page 36: ...t brand cannot be identified drain out all of the remaining coolant and refill with a totally new brand of coolant mix CAUTION Do not remove the radiator cap until coolant temperature is below its boi...

Page 37: ...ter cartridge 1 Remove the oil filter cartridge 1 with the filter wrench 2 Apply a slight coat of oil onto the new cartridge gasket 3 To install the new cartridge screw it in by hand Over tightening m...

Page 38: ...bleeding fuel system 1 Fill the tank with fuel and open the fuel cock 4 B only 2 Loosen the air vent plug 3 of the fuel filter a few turns 3 Screw back the plug when bubbles do not come up any more 4...

Page 39: ...uel filter keeping out dust and dirt 5 Bleed the fuel system IMPORTANT Q If dust and dirt enter the fuel the fuel injection pump and injection nozzle will wear quickly To prevent this be sure to clean...

Page 40: ...Check the fan belt for damage 2 If the fan belt is damaged replace it 3 Check if the fan belt is worn and sunk in the pulley groove 4 If the fan belt is nearly worn out and deeply sunk in the pulley...

Page 41: ...oil of different maker or viscosity from the previous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification CD CE CF CF 4 CG 4 Use...

Page 42: ...n by hand Over tightening may cause deformation of rubber gasket 4 After the new cartridge has been replaced the engine oil normally decrease a little Thus see that the engine oil does not leak throug...

Page 43: ...oil of different maker or viscosity from the previous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification CD CE CF CF 4 CG 4 Use...

Page 44: ...UBOTA genuine filter or its equivalent W1023046 Checking Radiator Hoses 1 Check to see if the radiator hoses are properly fixed every 200 hours of operation or every six months whichever comes first 2...

Page 45: ...before screwing on 3 Then tighten enough by hand 4 Loosen the air vent plug to let the air out 5 Start engine and check for fuel leakage W1050548 Replacing Fuel Filter Element Element Type 1 Close th...

Page 46: ...r instruction 6 After flushing fill with clean water and anti freeze until the coolant level is just below the port Install the radiator cap 1 securely 7 Fill with coolant up to FULL A mark on the rec...

Page 47: ...c A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system NOTE Q The above data represents industrial standards that nec...

Page 48: ...lternator 1 2 Remove the fan belt 2 3 Replace new fan belt 4 Install the alternator 1 5 Check the fan belt tension W1052220 Deflection A Factory spec 7 0 to 9 0 mm 98 N or 10 kgf 0 28 to 0 35 in 98 N...

Page 49: ...be slightly lower than the specified level to prevent overflow 2 Connect the battery to the charging unit following the manufacture s instructions 3 As the electrolyte generates gas while charging re...

Page 50: ...varies with temperature To be exact the specific gravity decreases by 0 0007 with an increase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 00...

Page 51: ...lockwise to see if the piston is at the compression top dead center or the overlap position Now referring to the table below readjust the valve clearance 1 The piston is at the top dead center when bo...

Page 52: ...tester handle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holde...

Page 53: ...ssembling the nozzle be sure to adjust the fuel injection pressure W1018491 Tightening torque Nozzle holder 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Overflow pipe retaining nut 19 6 to 24...

Page 54: ...op the starter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 73 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel back about...

Page 55: ...ttery start with the positive terminal first Never check battery charge by placing a metal object across the posts 1 Disconnect the negative terminal and positive terminal 2 Remove the battery holder...

Page 56: ...hen bubbles do not come up any more 4 Open the air vent cock on top of the fuel injection pump 5 If equipped electrical fuel feed pump turn the key to AC position and pump the fuel up for 10 to 15 sec...

Page 57: ...ion 6 After flushing fill with clean water and anti freeze until the coolant level is just below the port Install the radiator cap 1 securely 7 Fill with coolant up to FULL A mark on the recovery tank...

Page 58: ...g pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system NOTE Q The above data represents industri...

Page 59: ...easure diesel engine compression and diagnostics of need for major overhaul W1024200 Oil Pressure Tester Code No 07916 32032 Application Use to measure lubricating oil pressure W1024318 1 Gauge 2 L Jo...

Page 60: ...0 67 in dia L 6 10 to 6 20 mm dia 0 2402 to 0 2441 in dia M 8 mm 0 31 in N 4 mm 0 16 in O 11 97 to 11 99 mm dia 0 4713 to 0 4720 in dia P PF 1 2 Q 23 mm 0 91 in R 17 mm 0 67 in S 4 mm 0 16 in T 12 00...

Page 61: ...A 162 mm 6 38 in B 35 mm 1 38 in C 27 mm 1 06 in D 35 mm dia 1 38 in dia E 27 90 to 27 95 mm dia 1 098 to 1 100 in dia F 25 00 to 25 01 mm dia 0 984 to 0 985 in dia A 175 mm 6 89 in B 40 mm 1 57 in C...

Page 62: ...in dia H 51 8 to 51 9 mm dia 2 039 to 2 043 in dia A 130 mm 5 12 in B 72 mm 2 83 in C 40 mm radius 1 57 in radius D 9 mm 0 35 in E 4 mm 0 16 in F 20 mm 0 79 in G 20 mm dia 0 79 in dia H 68 mm dia 2 6...

Page 63: ...00 mm 3 94 in B 25 0 mm 0 98 in C 27 0 mm 1 06 in D 45 0 mm dia 1 77 in dia E 35 0 mm dia 1 38 in dia F 62 5 mm dia 2 46 in dia G 46 0 mm 1 81 in A 80 0 mm 3 1496 in B 60 1 to 60 3 mm 2 3661 to 2 3740...

Page 64: ...17 to 3 1437 in dia V 10 0 mm 0 3937 in W 0 04 mm dia 0 0016 in dia X 140 mm 5 5118 in Y 120 mm 4 7244 in Z 110 mm 4 3307 in a 50 0 mm 1 9685 in b 39 9 to 40 0 mm 1 5709 to 1 5748 in c 25 0 mm 0 9843...

Page 65: ...947 to 21 960 mm dia 0 8641 to 0 8646 in dia D 0 52 rad 30 O 28 mm 1 10 in E 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia P 29 mm 1 14 in F 43 934 to 43 950 mm dia 1 7297 to 1 7303 in dia Q 5 mm 0...

Page 66: ...n dia T 60 mm dia 2 36 in dia G 60 mm dia 2 36 in dia U 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia H 37 mm 1 46 in V 44 950 to 44 975 mm dia 1 7697 to 1 7707 in dia I 21 947 to 21 960 mm dia 0 86...

Page 67: ...elow the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again 8 If the compression pressure is still less than the allowa...

Page 68: ...f the piston is at the compression top dead center or the overlap position Now referring to the table below readjust the valve clearance 1 The piston is at the top dead center when both the IN and EX...

Page 69: ...remove radiator cap while operating or immediately after stopping Otherwise hot water will spout out from the radiator Wait for more than ten minutes to cool the radiator before opening the cap 1 Prep...

Page 70: ...ipes 1 Loosen the screws on the pipe clamps 1 2 Detach the injection pipes 2 When reassembling Blow out dust inside the pipes W1060970 Tightening torque Cylinder head cover screw 6 9 to 11 3 N m 0 7 t...

Page 71: ...ust be changed when the injection nozzle is removed for cleaning or for service W1021255 Rocker Arm and Push Rod 1 Remove the rocker arm bracket mounting bolts 2 Detach the rocker arm assembly 1 3 Rem...

Page 72: ...r Tighten them uniformly or the head may deform in the long run W1021755 Tappets 1 Remove the tappets 1 from the crankcase When reassembling Visually check the contact between tappets 1 and cams for p...

Page 73: ...m to assure proper fit with a plastic hammer IMPORTANT Q Don t change the combination of valve and valve guide hole W1022102 Thermostat Assembly 1 Remove the thermostat cover mounting screws and remov...

Page 74: ...e hi idling body gasket 6 with a new one Before fitting the stop lever 3 to the gear case install the stop solenoid guide 5 first into position Then attach the stop lever and use it to see if it funct...

Page 75: ...and bolts 3 Using the specific tool 1 undo the large governor spring 2 from the fork lever 3 4 Using the specific tool 1 undo the small governor spring 4 from the fork lever 3 5 Set the speed control...

Page 76: ...ong because otherwise it may get deformed permanently Using the specific tool 1 hook the large governor spring 2 onto the fork lever 3 Make sure both the governor springs 2 4 are tight on the fork lev...

Page 77: ...the gear case 1 3 Remove the O rings 2 When reassembling Replace the gear case gasket and O rings 2 Apply liquid gasket Three Bond 1215 or equivalent to both side of hour meter gear case gasket if equ...

Page 78: ...etach the idle gear 2 When reassembling Check to see each gear is aligned with its aligning mark Idle gear 2 and crank gear 5 cam gear 3 and balancer gear 4 Cam gear 3 and idle gear 2 Idle gear 2 and...

Page 79: ...er holder mounting screws 2 4 Draw out the fuel camshaft assembly 5 6 and fork lever assembly 3 4 7 at the same time When reassembling After installation check to see that the fork lever 1 3 and 2 4 a...

Page 80: ...l strainer 3 and O ring 4 When reassembling After cleaning the oil strainer 3 check to see that the filter mesh in clean and install it Visually check the O ring 4 apply engine oil and install it Secu...

Page 81: ...rk 1 on the No 1 piston Place the piston rings with their gaps at 0 79 rad 45 from the piston pin s direction as shown in the figure Carefully insert the pistons using a piston ring compressor 6 When...

Page 82: ...il ring gap 11 Apply engine oil to the piston pin When installing the connecting rod 7 to the piston 2 immerse the piston 2 in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin 1 to the pi...

Page 83: ...r 5 to remove it IMPORTANT Q The length of inside screws 6 and outside screws 3 are different Do not take a mistake using inside screws and outside screws When reassembling Fit the bearing case gasket...

Page 84: ...third cylinder 4 Repeat the above steps to draw out all the crankshaft For V2403 M 1 Remove the main bearing case screw 2 1 2 Turn the crankshaft to set the crank pin of the 4th cylinder to the horiz...

Page 85: ...stall them in order of makings A B for 3 cylinders and A B C for 4 cylinders from the gear case side Match the alignment numbers 1 and mark 2 on the main bearing case When installing the main bearing...

Page 86: ...n the crankpin and bearing and between the piston pin and bushing W1020190 Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Place a straightedge on the cylinder head s four sides A B...

Page 87: ...eplace the cylinder head W10768800 Clearance between Valve Stem and Valve Guide 1 Remove carbon from the valve guide section 2 Measure the valve stem O D with an outside micrometer 3 Measure the valve...

Page 88: ...r during replacement W10278890 Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact 2 If the valve does not seat all the way around the val...

Page 89: ...t them with valve lapping tool 4 Check the valve seating with prussian blue The valve seating surface should show good contact all the way around W10283500 Valve Lapping 1 Apply compound evenly to the...

Page 90: ...il Clearance between Rocker Arm and Rocker Arm Shaft 1 Measure the rocker arm shaft O D with an outside micrometer 2 Measure the rocker arm I D with an inside micrometer and then calculate the oil cle...

Page 91: ...ppet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet W1029366 Push rod alignment Allowab...

Page 92: ...ec 0 0415 to 0 1122 mm 0 00163 to 0 00442 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory spec 0 0415 to 0 1154 mm 0 00163 to 0 00454 in Allowable limit 0 15 mm 0...

Page 93: ...ure the camshaft alignment 4 If the measurement exceeds the allowable limit replace the camshaft W1031413 Cam Height 1 Measure the height of the cam at its highest point with an outside micrometer 2 I...

Page 94: ...used idle gear bushing using an idle gear bushing replacing tool See page SPECIAL TOOLS When installing 1 Clean a new idle gear bushing and idle gear bore and apply engine oil to them 2 Press in a new...

Page 95: ...lignment 1 Support the balancer shaft with V blocks on the surface plate and set a dial indicator with its tip on the intermediate journal at high angle 2 Rotate the balancer shaft on the V block and...

Page 96: ...ory spec 43 934 to 43 950 mm 1 72969 to 1 73032 in Balancer shaft bearing 1 I D Factory spec 43 980 to 44 045 mm 1 73150 to 1 73406 in Oil clearance of balancer shaft journal 2 Factory spec 0 030 to 0...

Page 97: ...od oil hole matches the bushing hole W1032140 Piston Ring Gap 1 Insert the piston ring into the lower part of the liner the least worn out part with the piston 2 Measure the ring gap with a feeler gau...

Page 98: ...hand 1 Install the piston pin into the connecting rod 2 Install the connecting rod on the connecting rod alignment tool 3 Put a gauge over the piston pin and move it against the face plate 4 If the ga...

Page 99: ...termediate journal 3 Measure the crankshaft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft W1033001 Crankshaft side clearance Factory spec D1503 M D1703 M V2203 M 0...

Page 100: ...e connecting rod screws are tightened Reference Undersize dimensions of crankpin W1033106 Oil clearance between crankpin and crankpin bearing Factory spec 0 025 to 0 087 mm 0 00098 to 0 00343 in Allow...

Page 101: ...l No below 3R9999 Serial No above 3S0001 W1033717 Oil clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 040 to 0 118 mm 0 00157 to 0 00409 in Allowable limit 0 20 mm 0 0079...

Page 102: ...5 mm relief 0 0394 to 0 0591 in relief Dimen sion C D1503 M V1703 M V2203 M 51 721 to 51 740 mm 2 0363 to 2 0370 in 51 521 to 51 540 mm 2 0284 to 2 0291 in D1803 M V2403 M 59 721 to 59 740 mm 2 35122...

Page 103: ...re NOTE Q Be sure not to move the crankshaft while the bearing case screws are tightened Serial No below 3R9999 Serial No above 3S0001 W1083821 Oil clearance between crankshaft and crankshaft bearing...

Page 104: ...02913 in D1803 M V2403 M 59 721 to 59 740 mm 2 35122 to 2 35197 in 59 521 to 59 540 mm 2 34335 to 2 34410 in 0 8 S The crankshaft journal must be fine finished to higher than Holes to be de burred and...

Page 105: ...itions see figure with a cylinder gauge to find the maximum and minimum I D s 2 Get the difference Maximum wear between the maximum and the minimum I D s 3 If the wear exceeds the allowable limit bore...

Page 106: ...spec D1503 M 83 250 to 83 272 mm 3 27756 to 3 27843 in D1703 M D1803 M V2203 M V2403 M 87 250 to 87 272 mm 3 43504 to 3 43591 in Allowable limit D1503 M 83 400 mm 3 2835 in D1703 M D1803 M V2203 M V2...

Page 107: ...strainer clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Foreign matter in the relief valve When reassembling After checking the engine oil pressure tighten the engin...

Page 108: ...t a strip of plastigage onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the width of the press gauge with a sheet of gauge 4 If the...

Page 109: ...rn out and deeply sunk in the pulley groove replace it W1020602 CAUTION When removing the radiator cap wait at least ten minutes after the engine has stopped and cooled down Otherwise hot water may gu...

Page 110: ...pend the thermostat in the water by a string with its end inserted between the valve and seat 2 Heating the water gradually read the temperature when the valve opens and leaves the string 3 Continue h...

Page 111: ...ush out scalding nearby people Thermostat Assembly 1 Remove the thermostat cover mounting screws and remove the thermostat cover 1 2 Remove the thermostat assembly 3 When reassembling Apply a liquid g...

Page 112: ...087 rad 5 of crank angle from 0 175 rad 10 to 0 436 rad 25 before mark 1TC Calculate the angle which the center of the window points out If the calculation differs from specified injection timing add...

Page 113: ...ssure 6 Stop the starter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 73 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel b...

Page 114: ...handle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adj...

Page 115: ...ssembling the nozzle be sure to adjust the fuel injection pressure W1260248 Tightening torque Nozzle holder 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Overflow pipe retaining nut 19 6 to 24...

Page 116: ...erminal It is the terminal which connects the cable from the motor to the magnet switch W1019297 Magnetic Switch Test 1 Disconnect the battery negative cable from the battery 2 Disconnect the battery...

Page 117: ...he engine 2 When the engine is operating measure the voltage between two battery terminals If the voltage is between 13 8 V and 14 8 V the alternator is operating normally 3 If the results of alternat...

Page 118: ...rom switch 4 to the battery positive terminal 4 Connect the jumper leads from the engine stop solenoid body to the battery negative terminal 5 When switch 4 is turn on the plunger pull into the soleno...

Page 119: ...he housing 11 9 Remove the idle gear 6 and the overrunning clutch 5 10 Remove the magnet switch cover 9 11 Remove the plunger 10 NOTE Q Do not damage to the brush and commutator When reassembling Appl...

Page 120: ...rive end frame 2 9 Remove the retainer plate 5 10 Press out the bearing 4 from drive end frame 2 with a press and jig 11 Lightly secure the rotor with a vise to prevent damage and remove the bearing 7...

Page 121: ...dusty clean it with emery paper 2 Measure the brush length A with vernier caliper 3 If the length is than the allowable limit replace the yoke assembly and brush holder W1156360 Brush Holder 1 Check...

Page 122: ...ide micrometer at several points 3 If the minimum O D is less than the allowable limit replace the armature 4 If the difference of the O D s exceeds the allowable limit correct the commutator on a lat...

Page 123: ...continuity across the slip ring and core with resistance range of circuit tester 4 If infinity is not indicated replace it W1020094 Slip Ring 1 Check the slip ring for score 2 If scored correct with...

Page 124: ...multimeter Because it s very hard to check the continuity of rectifier by using it W1020452 IC Regulator 1 Check the continuity across the B terminal and the F terminal of IC regulator with resistanc...

Page 125: ...22 30 60 Fax 33 0 5 56 22 30 79 E mail contact nannidiesel com 2010 Nanni Industries SAS The pictures text and information contained in this document are based on product characteristics at time of pu...

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