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Nanni N4.40, Workshop Manual

The Nanni N4.40 Workshop Manual is a comprehensive guide to maintaining and servicing your engine. This manual provides detailed instructions on how to troubleshoot and repair issues, ensuring optimal performance. Download your free copy from manualshive.com to keep your Nanni N4.40 running smoothly.

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Summary of Contents for N4.40

Page 1: ...N4 40 Starting serial number KTF08040093 WORK SHOP MANUAL ENGINE BASE NANNI INDUSTRIES S A S Zone Industrielle 11 avenue MARIOTTE B P 107 33260 LA TESTE FRANCE 60300209...

Page 2: ...ion of the unit Before you continue with the subsequent sections make sure that you read this section Refer to Workshop Manual Code No 9Y021 01870 for the diesel engine mechanism that this workshop ma...

Page 3: ...I INFORMATION KiSC issued 06 2009 A...

Page 4: ...CONTENTS 1 SAFETY FIRST I 1 2 SPECIFICATION I 4 3 DIMENSIONS I 15 4 WIRING DIAGRAM I 21 INFORMATION KiSC issued 06 2009 A...

Page 5: ...s can cause damage and decrease the engine life M00000003INI0003US1 SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels on the machine itself to wa...

Page 6: ...hten all connections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in fuel lines can cause serious injury Do not disconnect or re...

Page 7: ...on regulations when you discard oil fuel coolant electrolyte and other dangerous waste M00000003INI0007US1 PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric acid in b...

Page 8: ...ylinder head bolts M11 93 to 98 Nm Flywheel bolts M12 98 to 107 Nm Connecting rod bolts with coll 38 Nm Without coll 48 Nm Rocker arm bracket nuts 26 Nm Main bearing caps bolts 46 to 50 Nm Main bearin...

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Page 14: ...G GENERAL KiSC issued 06 2009 A...

Page 15: ...RS G 12 4 CHECK POINTS FOR EVERY 100 HOURS G 13 5 CHECK POINTS FOR EVERY 150 HOURS G 15 6 CHECK POINTS FOR EVERY 200 HOURS G 17 7 CHECK POINTS FOR EVERY 400 HOURS G 20 8 CHECK POINTS FOR EVERY 500 HOU...

Page 16: ...engine serial number is an identified number for the engine It appears after the engine model number and it shows the month and year of manufacture as below Year of manufacture To be continued Alphab...

Page 17: ...99 March E0001 E9999 F0001 FZ999 April G0001 G9999 H0001 HZ999 May J0001 J9999 K0001 KZ999 June L0001 L9999 M0001 MZ999 July N0001 N9999 P0001 PZ999 August Q0001 Q9999 R0001 RZ999 September S0001 S999...

Page 18: ...gines for example E2B engines may result in emission levels out of compliance with the original E3B design and EPA or other applicable regulations Please refer to the emission label located on the eng...

Page 19: ...ery first Remove oil and dirt from parts before you measure Use only KUBOTA genuine parts for replacement to keep the machine performance and to make sure of safety You must replace the gaskets and O...

Page 20: ...3000 hrs 2 years Check of fuel hoses and clamp bands Change of engine oil depending on the oil pan 1 Oil pan depth 90 mm 3 5 in 2 Oil pan depth 124 mm 4 88 in Cleaning of air cleaner element replace t...

Page 21: ...h 90 mm 3 5 in 2 Oil pan depth 124 mm 4 88 in Cleaning of air cleaner element replace the element after 6 times cleanings Cleaning of fuel filter Element type Check of battery electrolyte level Check...

Page 22: ...recommended If high sulfur fuel sulfur content 0 50 5000 ppm to 1 0 10000 ppm is used as a diesel fuel change the engine oil and oil filter at shorter intervals approximately half DO NOT USE Fuels th...

Page 23: ...n the remaining oil Do not mix 2 different types of oil NOTE When you examine the engine oil level make sure that you put it in a level position If not you cannot measure oil quantity accurately Make...

Page 24: ...clean and soft water Case 2 If the coolant decreases by leak add coolant of the same manufacturer and brand in the specified mixture ratio clean soft water and L L C If you cannot identify the coolant...

Page 25: ...Do not mix 2 different types of oil Engine oil must have the properties of API classification CF CF 4 CG 4 CH 4 CI 4 Use the correct SAE Engine Oil by reference to the ambient temperature 90 mm 3 5 i...

Page 26: ...e new cartridge by hand Do not tighten too much because it can cause deformation of the rubber gasket 4 After you replace the cartridge the engine oil usually decrease by a small level Make sure that...

Page 27: ...e fuel cock 4 B only 3 Loosen the air vent plug 3 of the fuel filter by a few turns 4 Tighten the plug when the bubbles do not come up 5 Open the air vent cock 5 on top of the fuel injection pump 6 En...

Page 28: ...lter again Make sure that you keep out dust and dirt 7 Bleed the fuel system IMPORTANT If dust and dirt go into the fuel the fuel injection pump and injection nozzle can wear out quickly To prevent th...

Page 29: ...Fan Belt Damage and Wear 1 Examine the fan belt for damage 2 If the fan belt has a damage replace it 3 Examine if the fan belt is worn out and sunk in the pulley groove 4 If it is replace it M0000000...

Page 30: ...ne on the dipstick 2 IMPORTANT When you use an oil of different brand or viscosity from the previous drain the remaining oil Do not mix 2 different types of oil Engine oil must have the properties of...

Page 31: ...2 Apply a thin layer of oil on the new cartridge gasket 3 Install the new cartridge by hand Do not tighten too much because it can cause deformation of the rubber gasket 4 After you replace the cartri...

Page 32: ...e upper line on the dipstick 2 IMPORTANT When you use an oil of different brand or viscosity from the previous drain the remaining oil Do not mix 2 different types of oil Engine oil must have the prop...

Page 33: ...2 IMPORTANT When you use an oil of different brand or viscosity from the previous drain the remaining oil Do not mix 2 different types of oil Engine oil must have the properties of API classification...

Page 34: ...T CAUTION Make sure that you stop the engine before you replace the oil filter cartridge 1 Remove the oil filter cartridge 1 with the filter wrench 2 Apply a thin layer of oil on the new cartridge gas...

Page 35: ...he engine oil 1 Start and warm up the engine for approximately 5 minutes 2 Put an oil pan below the engine 3 Remove the drain plug 1 at the bottom of the engine and drain the oil fully 4 Tighten the d...

Page 36: ...BOTA genuine filters or its equivalent M00000003GEG0027US1 Replacement of Fuel Filter Cartridge Cartridge Type The fuel filter cartridge collects water and dust in the fuel In service replace the fuel...

Page 37: ...until the coolant level is immediately below the port Install the radiator cap 1 correctly 8 Fill with the coolant until the FULL A mark on the recovery tank 4 9 Start and operate the engine for a few...

Page 38: ...hows the minimum glycol content necessary in the concentrated anti freeze When the coolant level decreases because of evaporation add clean soft water only to keep the anti freeze mixing ratio less th...

Page 39: ...ity of electrolyte must be lower than the specified level to make sure that it does not spill 2 Connect the battery to the charging unit obey the manufacturer instructions 3 When you charge remove all...

Page 40: ...ccurate the specific gravity decreases by 0 0007 when temperature increases by 1 C decreases by 0 0004 when temperature increases by 1 F increases by 0 0007 when temperature decreases by 1 C increases...

Page 41: ...rad 15 to see if the piston is at the compression top dead center or the overlap position Refer to the table below to adjust the valve clearance 1 again The piston is at the compression top dead cente...

Page 42: ...Set the injection nozzle to a nozzle tester and examine the condition of the fumes from the nozzle 2 If the fume condition is defective replace the injection nozzle assembly M00000003GEG0039US1 Fuel I...

Page 43: ...tester 2 Increase the fuel pressure and keep it at 12 75 MPa 130 0 kgf cm2 1849 psi for 10 seconds 3 If you find a fuel leakage replace the nozzle piece M00000003GEG0042US1 Valve Seat Tightness D1803...

Page 44: ...zle in clean fuel oil Install the push rod 4 correctly in its direction After you assemble the nozzle adjust the fuel injection pressure M00000003GEG0044US1 Tightening torque Nozzle holder 35 to 39 N...

Page 45: ...ace the gasket with a new one Compressor Side 1 Examine the inlet hose 4 of the compressor cover 5 for air leakage 2 Examine the suction side of the intake hose for loose connections or cracks 3 If yo...

Page 46: ...injection pressure to the injection pump pressure tester 1 5 Crank the engine with the starter to increase the pressure 6 Stop the starter when the fuel jets from the injection nozzle Then turn the f...

Page 47: ...p pressure tester 1 5 Crank the engine with the starter to increase the pressure 6 Stop the starter when the fuel jets from the injection nozzle Then turn the flywheel manually and increase the pressu...

Page 48: ...etal across the terminals to do a test on the battery charge Use a voltmeter or hydrometer to do a test on the battery charge 1 Disconnect the negative terminal and positive terminal 2 Remove the batt...

Page 49: ...me up 5 Open the air vent cock 5 on top of the fuel injection pump 6 Engine with the electrical fuel feed pump Turn the key to the AC position and supply the fuel with the pump for 10 to 15 seconds En...

Page 50: ...is immediately below the port Install the radiator cap 1 correctly 8 Fill with the coolant until the FULL A mark on the recovery tank 4 9 Start and operate the engine for a few minutes 10 Stop the en...

Page 51: ...radiator pressure cap that lets the pressure collect in the cooling system to get a higher boiling point NOTE The above data is the industrial standards that shows the minimum glycol content necessary...

Page 52: ...ug D1803 M DI V2403 M DI V2403 M DI T Code No 07909 39081 Assembly 07909 31291 K 07909 31301 L 07909 31311 M Application To measure the diesel engine compression and to make a decision for a large ove...

Page 53: ...1 2 C Copper gasket D Flange Material Steel E Hex nut 27 mm 1 1 in across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut I 17 mm dia 0 67 in dia J 8 mm di...

Page 54: ...99 in dia G 25 mm dia 0 98 in dia H 7 70 to 8 00 mm dia 0 304 to 0 314 in dia I 5 mm 0 2 in J 20 mm dia 0 79 in dia K 13 5 to 13 8 mm dia 0 532 to 0 543 in dia L 8 90 to 9 10 mm 0 351 to 0 358 in C1 C...

Page 55: ...0 mm radius 1 6 in radius D 10 mm 0 39 in E 20 mm 0 79 in F 20 mm dia 0 79 in dia G 64 80 to 64 90 mm dia 2 552 to 2 555 in dia H 59 80 to 59 90 mm dia 2 355 to 2 358 in dia A 130 mm 5 12 in B 72 mm 2...

Page 56: ...be continued A 80 0 mm 3 15 in B 60 10 to 60 30 mm 2 367 to 2 374 in C 80 0 mm dia 3 15 in dia D 85 0 mm dia 3 35 in dia E 60 10 to 60 30 mm dia 2 367 to 2 374 in dia F 26 30 to 26 40 mm 1 036 to 1 0...

Page 57: ...to 3 143 in dia V 10 0 mm 0 394 in W 0 04 mm dia 0 002 in dia X 140 mm 5 51 in Y 120 mm 4 72 in Z 110 mm 4 33 in a 50 0 mm 1 97 in b 39 90 to 40 00 mm 1 571 to 1 574 in c 25 0 mm 0 984 in d 90 0 mm di...

Page 58: ...N 21 947 to 21 960 mm dia 0 86406 to 0 86456 in dia D 25 mm dia 0 98 in dia O 36 mm 1 4 in E 46 950 to 46 975 mm dia 1 8485 to 1 8494 in dia P 5 mm 0 2 in F 0 52 rad 30 Q 29 0 mm 1 14 in G 43 934 to...

Page 59: ...ia 2 4 in dia S 36 mm 1 4 in F 10 mm 0 39 in T 60 mm dia 2 4 in dia G 0 52 rad 30 U 46 950 to 46 975 mm dia 1 8485 to 1 8494 in dia H 21 947 to 21 960 mm dia 0 86406 to 0 86456 in dia V 44 950 to 44 9...

Page 60: ...in radius D M20 Pitch 2 0 E 10 mm 0 39 in F 20 mm 0 79 in G 5 mm 0 2 in H 95 mm 3 7 in I 125 mm 4 92 in J 0 87 rad 50 K 5 mm 0 2 in L 60 mm radius 2 4 in radius M M20 Pitch 2 0 N 30 mm 1 2 in O 10 mm...

Page 61: ...1 ENGINE KiSC issued 06 2009 A...

Page 62: ...CER BALANCER MODEL ONLY 1 M2 3 HALF FLOATING HEAD COVER 1 M3 2 COOLING SYSTEM 1 M4 1 BOTTOM BYPASS SYSTEM 1 M4 3 FUEL SYSTEM 1 M5 1 GOVERNOR 1 M5 2 SMOKE REDUCTION DEVICE S R D 1 M5 4 TURBOCHARGER SYS...

Page 63: ...oise Molybdenum disulfide MoS2 The molybdenum disulfide 1 is a solid lubricant like Graphite or Teflon This material helps not to wear the metal even with little lube oil M00000003ENM0001US1 1 Molybde...

Page 64: ...one second inertia etc But all engines have many parts that moves and thus cannot be fully free from vibration The 4 cylinder engine can attach the balance weight on the crankcase to absorb the secon...

Page 65: ...TING HEAD COVER The rubber packing is attached to keep the cylinder head cover approximately 0 5 mm 0 02 in off the cylinder head This decreases the noise from the cylinder head M00000003ENM0003US1 1...

Page 66: ...ys closed This lets the coolant flow through the bypass pipe and around the engine When the temperature is more than the thermostat valve opening level the thermostat 1 opens up fully The hot coolant...

Page 67: ...p in normal operating temperature as well as on sharp acceleration As this adjustment is performed and sealed before the fuel limitation is set the adjustment in the field cannot be performed without...

Page 68: ...engine in normal operating temperature and then excessive injection of fuel is controlled On sharp acceleration in normal operating temperature the lever acts as a damper and the rack of the fuel inj...

Page 69: ...ives sufficient power to the engine M00000003ENM0010US1 When the boost pressure drops fuel supply decreases to decrease black emission The system can decrease the emission in low boost pressures at qu...

Page 70: ...System 1 S25 4 Fuel System 1 S28 5 Electrical System 1 S36 6 Turbocharger 1 S40 7 Electronic Governor 1 S41 2 DISASSEMBLING AND ASSEMBLING 1 S46 1 Draining Engine Oil and Coolant 1 S46 2 External Com...

Page 71: ...the specified fuel I 4 Fuel leakage because of loose injection pipe retaining nut Tighten the retaining nut 1 S48 Incorrect injection timing Adjust 1 S28 1 S30 The fuel camshaft is worn out Replace 1...

Page 72: ...S68 1 S90 1 S91 1 S97 Incorrect valve clearance Adjust 1 S24 The solenoid is defective Replace 1 S40 1 S54 1 S55 1 S56 The starter does not operate Discharged battery Charge G 24 G 25 Starter is defec...

Page 73: ...orn out Replace the turbocharger assembly 1 S47 The turbocharger shaft is bent Replace the turbocharger assembly 1 S47 The turbocharger fin or other part has a damage because of unwanted materials Rep...

Page 74: ...pair or replace The injection pump is defective Repair or replace 1 S31 1 S32 1 S33 1 S54 1 S55 1 S56 The injection nozzle is defective Repair or replace the nozzle 1 S34 1 S35 1 S36 1 S49 There is co...

Page 75: ...g is worn out Replace 1 S65 1 S66 1 S71 1 S93 1 S94 1 S95 There is an oil leakage because of the seal or packing is defective Replace The fuel is mixed into the lubricant oil The plunger of the inject...

Page 76: ...oil pressure is high The type of oil used is incorrect Use the specified type of oil I 4 G 10 The relief valve is defective Replace The engine is overheated The engine oil is not sufficient Fill up ag...

Page 77: ...led water and charge G 13 G 24 The fan belt slips Adjust belt tension or replace G 13 G 14 G 23 The wires connection is incorrect Connect again The rectifier is defective Replace 1 S73 1 S104 The alte...

Page 78: ...NS0005US1 Cause Corrections Refer to Checking Starter Operating but Not Cranking the Engine Examine operation of the solenoid Solenoid Examine harness of the solenoid Solenoid Examine harness of the g...

Page 79: ...mperature is abnormal Water temperature sensor 1 Long and 5 Short Emergency stop switch operated Emergency stop switch 2 Long and 1 Short Abnormality of speed sensor Speed sensor 2 Long and 2 Short So...

Page 80: ...V2403 M V2403 M T D1703 M BG V2003 M BG V2003 M T BG V2203 M BG V2403 M BG 0 575 to 0 675 mm 0 0227 to 0 0265 in Top Clearance D1803 M DI V2403 M DI V2403 M DI T 0 60 to 0 70 mm 0 024 to 0 027 in Cyl...

Page 81: ...3 M V2403 M DI T V2003 M BG V2203 M BG V2403 M BG Open Close 0 21 rad 12 before T D C 0 63 rad 36 after B D C Valve Timing Intake Valve V2403 M T V2003 M T BG Open Close 0 35 rad 20 before T D C 0 79...

Page 82: ...mm 1 62 in 100 N 35 0 mm 10 2 kgf 35 0 mm 22 5 lbf 1 38 in 1 0 mm 0 039 in Rocker Arm Shaft to Rocker Arm Rocker Arm Shaft Rocker Arm Oil Clearance O D I D 0 016 to 0 045 mm 0 00063 to 0 0017 in 13 97...

Page 83: ...0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in Idle Gear Side Clearance 0 12 to 0 48 mm 0 0048 to 0 018 in 0 9 mm 0 04 in Idle G...

Page 84: ...86 in 0 30 mm 0 012 in Balancer Shaft Balancer Model Only Bend 0 02 mm 0 0008 in Balancer Shaft Journal 1 to Balancer Shaft Bearing 1 Balancer Model Only Balancer Shaft Journal 1 Balancer Shaft Bearin...

Page 85: ...403 M DI V2403 M DI T V2003 M BG V2003 M T BG Ring Gap 0 20 to 0 35 mm 0 0079 to 0 013 in 1 25 mm 0 0492 in Top Ring D1703 M D1803 M V2203 M V2403 M D1703 M BG V2203 M BG V2403 M BG Ring Gap 0 25 to 0...

Page 86: ...in 47 000 to 47 046 mm 1 8504 to 1 8522 in 0 20 mm 0 0079 in Crankshaft Side Clearance 0 15 to 0 31 mm 0 0059 to 0 012 in 0 5 mm 0 02 in Cylinder Bore Standard D1503 M V2003 M V2003 M BG V2003 M T BG...

Page 87: ...0 008 in Item Factory Specification Allowable Limit Fan Belt Tension 7 0 to 9 0 mm 0 28 to 0 35 in deflection at 98 N 10 kgf 22 lbf of force Thermostat Valve D1503 M D1703 M D1803 M V2003 M V2203 M V...

Page 88: ...DI V2403 M DI V2403 M DI T Fuel Tightness 18 63 MPa 190 0 kgf cm2 2702 psi Delivery Valve D1503 M D1703 M D1803 M V2003 M V2203 M V2403 M V2403 M T D1703 M BG V2003 M BG V2003 M T BG V2203 M BG V2403...

Page 89: ...1703 M V2003 M V2203 M D1803 M DI D1703 M BG V2003 M BG V2003 M T BG V2203 M BG Brush D1803 M V2403 M V2403 M DI V2403 M T V2403 M DI T Brush V2403 M BG Brush Holder and Holder Support O D O D Undercu...

Page 90: ...E If the tightening torque is not specified refer to the table below for the none specified torques values M00000003ENS0013US1 Indication on top of bolt No grade or 4T 7T Indication on top of nut No g...

Page 91: ...7 2 4 to 2 8 18 to 20 Mounting nut of fan drive pulley M30 1 5 138 to 156 14 0 to 16 0 102 to 115 Mounting screw of bearing case cover M8 1 25 24 to 27 2 4 to 2 8 18 to 20 Glow plug M10 1 25 20 to 24...

Page 92: ...asure the compression pressure 8 Do the steps 5 through 7 again for each cylinder 9 If the measurement is below the allowable limit apply a small quantity of oil to the cylinder wall through the nozzl...

Page 93: ...6 Crank the engine with the starter to measure the compression pressure 7 Do the steps 5 through 6 again for each cylinder 8 If the measurement is below the allowable limit examine the cylinder wall...

Page 94: ...he piston is at the compression top dead center or the overlap position Refer to the table below to adjust the valve clearance 1 again The piston is at the compression top dead center when both the IN...

Page 95: ...he specified torque M00000003ENS0019US1 3 Cooling System Fan Belt Tension 1 Push the belt halfway between the fan drive pulley and alternator pulley at a specified force 98 N 10 kgf 22 lbf to measure...

Page 96: ...rement is less than the factory specification replace the radiator cap M00000003ENS0023US1 Radiator Water Leakage 1 Fill a specified quantity of water into the radiator 2 Increase the water pressure t...

Page 97: ...surement is out of the factory specifications replace the thermostat M00000003ENS0025US1 Opening temperature When the valve starts to open Factory spec D1503 M D1703 M D1803 M V2003 M V2203 M V2403 M...

Page 98: ...gle at which the center of the window points out The flywheel has a mark 1TC and 4 lines that shows every 0 09 rad 5 of crank angle from 0 17 rad 10 to 0 44 rad 25 before mark 1TC 7 If the result is d...

Page 99: ...ation of these shims for adjustment The 0 175 mm 0 00689 in thick shim has only a thin layer on the lower face Thus do not use the 0 175 mm 0 00689 in thick shim as the top shim of the combination inj...

Page 100: ...gasket is not necessary to assemble The shims are available in thickness of 0 175 mm 0 00689 in 7 0 20 mm 0 0079 in 3 0 25 mm 0 0098 in 4 0 30 mm 0 012 in 5 and 0 35 mm 0 014 in 6 Make a combination o...

Page 101: ...of Pump Element D1803 M DI V2403 M DI V2403 M DI T 1 Remove the solenoid 2 Remove the injection pipes and glow plugs 3 Set the injection pump pressure tester to the injection pump 4 Set the injection...

Page 102: ...3 73 MPa 140 0 kgf cm2 1991 psi 7 Turn the flywheel back about half a turn to keep the plunger free and keep the flywheel at this position 8 Measure the time for the pressure to decrease from 13 73 to...

Page 103: ...he flywheel back about half a turn to keep the plunger free and keep the flywheel at this position 8 Measure the time for the pressure to decrease from 18 63 to 17 65 MPa 190 0 to 180 0 kgf cm2 2702 t...

Page 104: ...nozzle to a nozzle tester and examine the condition of the fumes from the nozzle 2 If the fume condition is defective replace the injection nozzle assembly M00000003GEG0039US1 Fuel Injection Pressure...

Page 105: ...tester 2 Increase the fuel pressure and keep it at 12 75 MPa 130 0 kgf cm2 1849 psi for 10 seconds 3 If you find a fuel leakage replace the nozzle piece M00000003GEG0042US1 Valve Seat Tightness D1803...

Page 106: ...you are spattered with it clean with water immediately Keep open sparks and flames away from the battery at all times Hydrogen gas mixed with oxygen becomes very explosive IMPORTANT Do not disconnect...

Page 107: ...level You must read the hydrometer at the highest electrolyte level Reference The specific gravity changes with temperature To be accurate the specific gravity decreases by 0 0007 when temperature in...

Page 108: ...rom the battery 2 Disconnect the positive cable from the battery 3 Disconnect the leads from the starter B terminal 4 Remove the starter from the engine 5 Connect a jumper lead from the starter S term...

Page 109: ...le the alternator Examine each component part to find out the problem Refer to DISASSEMBLING AND ASSEMBLING and SERVICING for the alternator M00000003ENS0046US1 Glow Plug Lead Terminal Voltage 1 Turn...

Page 110: ...plunger the solenoid is defective IMPORTANT Do not apply the current to the pulling coil for more than 2 seconds when you examine M00000003ENS0049US1 6 Turbocharger Turbine Side 1 Examine the exhaust...

Page 111: ...ct the connector of the water temperature sensor 1 2P 2 Examine the condition of the harness 3 If the harness is defective replace it with a new one 4 Turn the key switch to the ACC position 5 Measure...

Page 112: ...between the terminal of the connector harness side and chassis 5 If the measurement is not in the factory specification the ECU is defective Then replace the ECU with a new one 6 If the measurement i...

Page 113: ...s of the connector solenoid side 2 If the measurement is not in the factory specification the solenoid is defective Then replace the solenoid with a new one 3 If the measurement is in the factory spec...

Page 114: ...nt is not in the factory specification the ECU is defective Then replace the ECU with a new one 6 If the measurement is in the factory specification the ECU is correct In this case the alternator is d...

Page 115: ...e resistance between the terminals of the slow down switch when the slow down switch turn on or off 5 If the measurements are in the factory specifications the ECU is defective Then replace the ECU wi...

Page 116: ...n the dipstick 2 IMPORTANT Do not mix different types of oil Use the correct SAE Engine Oil by reference to the ambient temperature M00000003ENS0063US1 Draining Coolant CAUTION Do not remove the radia...

Page 117: ...clean engine oil through the oil filter port of the turbocharger Before you start the engine make sure that the air cleaner is in the correct position 1 Remove the inlet hose 1 2 Remove the joint bolt...

Page 118: ...mbling Blow out dust in the pipes M00000003ENS0068US1 Tightening torque Cylinder head cover screw 6 87 to 11 2 N m 0 700 to 1 15 kgf m 5 07 to 8 31 lbf ft 1 Breather Hose 2 Cylinder Head Cover 3 Head...

Page 119: ...e assembly 2 Remove the nozzle holder assemblies 2 3 Remove the glow plugs 1 When reassembling Replace the copper gasket with a new one M00000003ENS0070US1 Tightening torque Nozzle holder assembly 49...

Page 120: ...do the above procedure again When reassembling Change the heat seal and injection nozzle gasket when you remove the injection nozzle to clean or for servicing M00000003ENS0071US1 Rocker Arm and Push...

Page 121: ...er head screw 93 2 to 98 0 N m 9 50 to 10 0 kgf m 68 8 to 72 3 lbf ft Gasket Markand Code Number Model D1503 M D1703 M D1803 M D1803 M DI V2003 M V2203 M V2403 M V2403 M T V2403 M DI V2403 M DI T 15 1...

Page 122: ...y If it is defective replace the tappets IMPORTANT Do not change the combination of tappet and tappet guide M00000003ENS0074US1 Gasket Dimension Number Piston Protrusion D1503 M D1703 M D1803 M V2003...

Page 123: ...US1 Thermostat Assembly 1 Remove the thermostat cover mounting screws and remove the thermostat cover 1 2 Remove the thermostat assembly 3 When reassembling Replace the thermostat cover gasket 2 with...

Page 124: ...body 1 and solenoid guide 6 install the injection pump first into position Replace the hi idling body gasket 5 with a new one Before you attach the stop lever 3 to the gear case install the solenoid g...

Page 125: ...5 install the injection pump first into position Replace the hi idling body gasket with a new one Before you attach the boost compensator assembly 2 to the gear case make sure that the solenoid guide...

Page 126: ...install the injection pump first into position Replace the hi idling body gasket with a new one Before you attach the smoke reduction device 2 to the gear case make sure that the solenoid guide 5 is...

Page 127: ...ed control plate 6 3 Use the specific tool 1 to release the large governor spring 3 from the fork lever 2 4 Use the specific tool 1 to release the small governor spring 4 from the fork lever 2 5 Set t...

Page 128: ...o much because it can cause permanent deformation Set the large governor spring 3 on the fork lever 2 with the specific tool Make sure that the 2 governor springs 3 4 are tight on the fork lever 2 Tig...

Page 129: ...in deep socket wrench 3 3 Remove the fan drive pulley 2 with a gear puller 4 4 Remove the feather key When reassembling Apply grease to the splines of coupling M00000003ENS0082US1 Tightening torque M...

Page 130: ...When reassembling Replace the washer 6 and gear case cover gasket with new ones Replace the hour meter gear case gasket with a new one M00000003ENS0083US1 Tightening torque Set screw of idle gear 2 s...

Page 131: ...se 1 Apply a thin layer of engine oil to the oil seal Then install the oil seal not to come off the lip Before you install the gear case gasket apply an adhesive that does not become dry M00000003ENS0...

Page 132: ...1 and pull out the balancer shaft 1 2 3 Remove the set bolts of the balancer shaft 2 and pull out the balancer shaft 2 3 When reassembling When you install the balancer shafts 2 and 3 put the first an...

Page 133: ...er shaft Make sure also that they can turn smoothly in the holder 7 M00000003ENS0091US1 Oil Pump 1 Remove the nut 2 Pull out the oil pump drive gear 2 with a gear puller 1 3 Remove the 4 mounting scre...

Page 134: ...ner 1 and O ring 4 When reassembling After you clean the oil strainer 1 make sure that the filter mesh is clean and install it Visually examine the O ring 4 apply engine oil and install it Install the...

Page 135: ...linder and piston Align the position of each piston by the its mark For example mark 1 on the No 1 piston Set the piston rings with their gaps at 0 79 rad 45 from the direction of the piston pin see t...

Page 136: ...rection of the piston pin Then set the second ring and the oil ring with their gaps B C at 2 09 rad 120 from the top ring gap A See the figure Install the pistons with a piston ring compressor 7 caref...

Page 137: ...on the piston 6 set the expander joint 10 on the opposite side of the oil ring gap 11 Apply engine oil to the piston pin 9 Put the piston 6 fully in 80 C 176 F oil for 10 to 15 minutes Align the mark...

Page 138: ...opposite side of the oil ring gap 11 Apply engine oil to the piston pin 8 Put the piston 5 fully in 80 C 176 F oil for 10 to 15 minutes Align the FW mark 9 that points to the flywheel with the mark 7...

Page 139: ...ws 5 and external screws 3 are different Make sure that you use the correct one at the correct position When reassembling Attach the bearing case gasket 1 and the bearing case cover gasket 2 in the co...

Page 140: ...teps again to pull out the crankshaft completely V2403 M V2403 M DI V2403 M T V2403 M DI T V2403 M BG 1 Remove the screw 2 1 of the main bearing case 2 Turn the crankshaft to set the crankpin of the f...

Page 141: ...l the thrust bearing point the oil groove 8 externally Install the main bearing case assemblies in the initial positions Since the diameters of the main bearing cases are different install them in the...

Page 142: ...e the idle gear 7 and the overrunning clutch 6 10 Remove the magnet switch cover 10 11 Remove the plunger 11 NOTE Do not cause damage to the brush and commutator When reassembling Apply grease DENSO N...

Page 143: ...drive end frame 2 9 Remove the retainer plate 5 10 Push out the bearing 4 from the drive end frame 2 with a press and jig 11 Lightly hold the rotor with a vise to prevent damage and remove the bearin...

Page 144: ...ances between the crankpin and bearing Also examine that between the piston pin and bushing NOTE After you examine the top clearance make sure that you assemble the cylinder head with a new cylinder h...

Page 145: ...r you correct M00000003ENS0106US1 Cylinder Head Flaw 1 Prepare an air spray red check 2 Clean the surface of the cylinder head with detergent 2 3 Apply some red permeative liquid 1 on the cylinder hea...

Page 146: ...S0108US1 Valve recessing Factory spec D1503 M D1703 M D1803 M V2003 M V2203 M V2403 M V2403 M T D1703 M BG V2003 M BG V2003 M T BG V2203 M BG V2403 M BG 0 05 protrusion to 0 15 recessing mm 0 002 prot...

Page 147: ...tool See page SPECIAL TOOLS When installing 1 Clean the new valve guide and valve guide bore and apply engine oil to them 2 Press fit the new valve guide with the valve guide replacing tool 3 Ream acc...

Page 148: ...is not fully around the seat or the contact is less than 70 of the factory specification correct the valve seat See the next section 3 If the valve contact width cannot get the factory specification...

Page 149: ...mm 0 0835 in 3 After you correct the seat examine that the valve seating is flat Apply a thin layer of compound between the valve face and valve seat and lap them with a valve lapping tool 4 Examine...

Page 150: ...e valve spring on a surface plate and put a square on the side of the valve spring 4 Make sure that the full side is in contact with the square 5 Turn the valve spring to measure the maximum tilt A 6...

Page 151: ...S1 Oil Clearance between Tappet and Tappet Guide Bore 1 Measure the tappet O D with an external micrometer 2 Measure the tappet guide bore I D with a cylinder gauge 3 Calculate the oil clearance 4 If...

Page 152: ...m 0 0059 in Backlash between idle gear and injection pump gear Factory spec 0 04150 to 0 1154 mm 0 001634 to 0 004543 in Allowable limit 0 15 mm 0 0059 in Backlash between crank gear and oil pump gear...

Page 153: ...t is more than the allowable limit replace the camshaft stopper M00000003ENS0121US1 Camshaft Bend 1 Hold the 2 end journals of camshaft with V blocks on the surface plate 2 Set a dial indicator with i...

Page 154: ...tory spec D1503 M D1703 M BG 33 27 mm 1 310 in V2003 M V2403 M DI T V2003 M BG V2203 M BG 33 47 mm 1 318 in D1703 M D1803 M V2203 M V2403 M V2403 M T D1803 M DI V2403 M DI V2003 M T BG V2403 M BG 33 9...

Page 155: ...M V2403 M D1803 M DI V2403 M DI V2403 M BG 33 90 mm 1 335 in V2403 M T D1703 M BG V2003 M BG V2203 M BG 33 27 mm 1 310 in V2403 M DI T 33 00 mm 1 299 in Allowable limit D1503 M V2003 M V2003 M T BG 33...

Page 156: ...or with its point on the balancer shaft 2 Move the balancer shaft to the front and rear to measure the side clearance 3 If the measurement is more than the allowable limit replace the balancer shaft M...

Page 157: ...3 950 mm 1 7297 to 1 7303 in Balancer shaft bearing 1 I D Factory spec 43 980 to 44 045 mm 1 7315 to 1 7340 in Oil clearance of balancer shaft journal 2 Factory spec 0 0300 to 0 111 mm 0 00119 to 0 00...

Page 158: ...the piston pin also M00000003ENS0131US1 Replacement of Small End Bushing When removing 1 Press out the used small end bushing with the replacing tool See page SPECIAL TOOLS When installing 1 Clean a...

Page 159: ...l the connecting rod on the alignment tool of the connecting rod 3 Put a gauge on the piston pin and move it against the face plate 4 If the gauge does not touch fully against the face plate measure t...

Page 160: ...M BG V2203 M BG V2403 M BG 0 25 to 0 40 mm 0 0099 to 0 015 in Allowable limit 1 25 mm 0 0492 in Second ring Factory spec D1503 M D1703 M D1803 M V2203 M V2403 M D1803 M DI V2403 M DI D1703 M BG V2003...

Page 161: ...9 in Second ring Factory spec D1503 M D1703 M D1803 M V2003 M V2203 M V2403 M V2403 M T V2403 M ID T D1703 M BG V2003 M BG V2003 M T BG V2203 M BG V2403 M BG 0 0930 to 0 128 mm 0 00367 to 0 00503 in D...

Page 162: ...on the surface plate 2 Set a dial indicator with its point on the middle journal 3 Turn the crankshaft slowly and read the variation on the indicator 4 If the measurement is more than the allowable l...

Page 163: ...onnecting rod screws do not move the crankshaft Reference Undersize dimensions of crankpin M00000003ENS0138US1 Oil clearance between crankpin and crankpin bearing Factory spec 0 025 to 0 087 mm 0 0009...

Page 164: ...ring 1 2 points to the exhaust manifold side see the figure Then press fit the new bearing 1 2 with the replacing tool M00000003ENS0140US1 Oil clearance between crankshaft journal and crankshaft beari...

Page 165: ...e Undersize dimensions of crankshaft journal M00000003ENS0141US1 Oil clearance between crankshaft and crankshaft bearing 2 Factory spec 0 0400 to 0 104 mm 0 00158 to 0 00409 in Allowable limit 0 20 mm...

Page 166: ...to between 150 and 200 C 302 and 392 F 5 Install the sleeve to the crankshaft with the auxiliary socket for pushing 4 see the figure Refer to SPECIAL TOOLS NOTE Make sure that the large chamfer of th...

Page 167: ...ylinder Refer to Cylinder Correction Oversize M00000003ENS0143US1 Cylinder I D Factory spec D1503 M V2003 M V2003 M BG V2003 M T BG 83 000 to 83 022 mm 3 2678 to 3 2685 in D1703 M D1803 M V2203 M V240...

Page 168: ...c D1503 M V2003 M V2003 M BG V2003 M T BG 83 250 to 83 272 mm 3 2776 to 3 2784 in D1703 M D1803 M V2203 M V2403 M V2403 M T D1803 M DI V2403 M DI V2403 M DI T D1703 M BG V2203 M BG V2403 M BG 87 250 t...

Page 169: ...sembly of the oil pump M00000003ENS0146US1 7 Starter Overrunning Clutch 1 Examine the pinion and if it is worn or damaged replace the clutch assembly 2 Examine that the pinion turns freely and smoothl...

Page 170: ...n 5 Measure the mica undercut 6 If the undercut is less than the allowable limit correct it with a saw blade and chamfer the segment edges To be continued Commutator O D Factory spec D1503 M D1703 M V...

Page 171: ...replace the brush holder assembly M00000003ENS0150US1 Mica undercut Factory spec D1503 M D1703 M D1803 M V2003 M V2203 M V2403 M V2403 M T D1803 M DI V2403 M DI V2403 M DI T D1703 M BG V2003 M BG V20...

Page 172: ...tester 4 If electricity does not flow replace the armature assembly M00000003ENS0151US1 Field Coil 1 Examine the continuity across the lead 1 and brush 2 with a circuit tester 2 If electricity does n...

Page 173: ...nce range of circuit tester 4 If it does not show infinity replace the rotor assembly M00000003ENS0155US1 Slip Ring 1 Examine the slip ring for score 2 If there is score correct with an emery paper or...

Page 174: ...t if the diode in the rectifier conducts electricity only in one direction M00000003ENS0158US1 IC Regulator 1 Examine the continuity across the B terminal 2 and the F terminal 1 of IC regulator with t...

Page 175: ...RY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ksos pub kubota co jp KUBOTA Corporation Printed in Japan 2009 06 S EI EI e C...

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