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N4.40
Nanni N4.40 User Manual
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ENGINE
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
1-M3
[3]
HALF-FLOATING HEAD COVER
The rubber packing is attached to
keep the cylinder
head cover app
roximately 0.5 mm (0.02 in.) o
ff the
cylinder head. This decrea
ses the noise from the
cylinder head.
M00000003ENM0003US1
(1)
Cylinder Head Cover
(2)
R
ubber Packing
KiSC issued 06, 2009 A
64
66
Table of Contents
Default Chapter
2
Safety First
2
Safety Information
5
Before You Start Your Service
5
Prevent a Fire
6
Safe Operation
6
Technical Data
8
Tightening Torque
8
Lubrication
8
Engine Specifications
8
Diagrams
9
Table of Contents
15
General Information
15
1 Engine Identification
16
Model Name and Engine Serial Number
16
Cylinder Number
18
E3B Engine
18
2 General Precautions
19
3 Maintenance Check List
20
Engine Oil Classification (API Classification)
22
4 Check and Maintenance
23
Daily Check Points
23
Check of Engine Oil Level
23
Check of Coolant Level and Replenishment
24
Check Points for the Initial 50 Hours
25
Change of Engine Oil
25
Replacement of Oil Filter Cartridge
26
Check Points for Every 50 Hours
27
Check of Fuel Hoses and Clamp Bands
27
Check Points for Every 100 Hours
28
Cleaning of Air Cleaner Element
28
Cleaning of Fuel Filter (Element Type Only)
28
Check of Battery Electrolyte Level / Fan Belt Tension
28
Fan Belt Damage and Wear
29
Check Points for Every 150 Hours
30
Change of Engine Oil (for 90 MM (3.5 In.) Depth Oil Pan)
30
Replacement of Oil Filter Cartridge (for 90 MM (3.5 In.)
31
Check Points for Every 200 Hours
32
Change of Engine Oil (for 124 MM (4.88 In.) Depth Oil Pan)
32
Check of Radiator Hoses and Clamp Bands
34
Check Points for Every 400 Hours
35
Check of Intake Air Line
35
Replacement of Fuel Filter Cartridge (Cartridge Type)
36
Replacement of Fuel Filter Element (Element Type)
36
Check Points for Every 500 Hours
37
Cleaning of Water Jacket and Radiator Interior
37
Anti-Freeze
38
Replacement of Fan Belt
38
Check Points for Every 1 or 2 Months
39
Check Points for Every Year
40
Battery Specific Gravity
40
Replacement of Air Cleaner Element
40
Check Points for Every 800 Hours
41
Check Points for Every 1500 Hours
42
Nozzle Fume Condition
42
Fuel Injection Pressure
42
Valve Seat Tightness
43
Nozzle Holder
44
Check Points for Every 3000 Hours
45
Check of Injection Pump
46
Check Points for Every 2 Years
48
Replacement of Intake Air Line
48
Replacement of Battery
48
Replacement of Radiator Hoses and Clamp Bands
48
Change of Radiator Coolant (L.L.C.)
50
5 Special Tools
52
Diesel Engine Compression Tester
52
Oil Pressure Tester
52
Injection Pump Pressure Tester
53
Bushing Replacing Tools
54
Flywheel Stopper
54
Valve Guide Replacing Tool
54
Crankshaft Bearing 1 Replacing Tool
55
Socket Wrench for Crank Pulley Nut
55
Auxiliary Socket for Fixing Crankshaft Sleeve
56
Balancer Metal Replacing Tool (for Removing)
58
Balancer Metal Replacing Tool (for Fitting)
59
Idle Gear 2 Puller
60
Mechanism
62
Engine Body
63
Piston
63
Built-In Dynamic Balancer (Balancer Model Only)
64
Half-Floating Head Cover
65
Bottom Bypass System
66
Cooling System
66
Fuel System
67
Governor
67
Smoke Detector Device (SRD)
67
Boost Compensator
69
Turbocharger System
69
Servicing
70
Engine Body Troubles
71
Troubleshooting
71
Electronic Governor Troubles
78
Blinking Pattern of Glow Lamp
79
Servicing Specifications
80
Tightening Torques of Screws, Bolts and Nuts for General Use
90
Dimensions
91
Tightening Torques of the Screws, Bolts and Nuts for Special Use
91
Checking and Adjusting
92
Checking, Disassembling and Servicing
92
Compression Pressure
92
Engine Body Checking and Adjustment
92
Valve Clearance
94
Cooling System Checking and Adjustment
95
Engine Oil Pressure
95
Fan Belt Tension
95
Lubricating System Checking and Adjustment
95
Radiator Cap Air Leakage
96
Radiator Water Leakage
96
Opening-Temperature of Thermostat Valve
97
Fuel System Checking and Adjustment
98
Injection Timing
98
Fuel Tightness of Pump Element
101
Fuel Tightness of Delivery Valve
102
Battery Voltage
106
Electrical System Checking and Adjustment
106
Magnetic Switch Continuity Test
108
Magnetic Switch Test
108
Motor Test
108
Alternator-On Unit Test
109
Glow Plug Continuity
109
Glow Plug Lead Terminal Voltage
109
Engine Stop Solenoid
110
Radial Clearance
110
Turbine Side
110
Turbocharger Checking and Adjustment
110
Electronic Governor Checking and Adjustment
111
Speed Sensor
111
Water Temperature Sensor
111
Oil Pressure Switch
112
Solenoid
113
Alternator
114
Glow Plug Harness
114
Speed Switch
114
Battery
115
Emergency Stop Switch
115
Slow down Switch
115
Disassembly and Assembly
116
Draining Engine Oil and Coolant
116
Air Cleaner, Muffler and Others
117
External Components
117
Turbocharger
117
Cylinder Head and Valves
118
Injection Pipes
118
Nozzle Holder Assembly and Glow Plug
119
Rocker Arm and Push Rod
120
Service Procedure of Nozzle Heat Seal
120
Cylinder Head
121
Tappets
122
Thermostat Assembly
123
Valves
123
Water Pump Assembly
123
Gear Case and Timing Gears
124
Injection Pump (for Non Turbocharger Model)
124
Injection Pump (for Turbocharger Model)
125
Injection Pump (for Smoke Reduction Device)
126
Governor Springs and Speed Control Plate
127
Fan Drive Pulley
129
Idle Gear 2 and Hydraulic Pump Base Assembly (for Side PTO Model)
130
Crankshaft Oil Slinger
131
Gear Case
131
Idle Gear
131
Camshaft
132
Camshaft and Balancer Shaft (for Balancer Model)
132
Crank Gear
133
Fuel Camshaft and Fork Lever Assembly
133
Oil Pump
133
Oil Pan and Oil Strainer
134
Piston and Connecting Rod
134
Pistons
135
Piston Ring and Connecting Rod
137
Bearing Case Cover
139
Flywheel and Crankshaft
139
Main Bearing Case Assembly
141
Starter
142
Alternator
143
Cylinder Head and Valves Servicing
144
Top Clearance
144
Cylinder Head Flaw
145
Cylinder Head Surface Flatness
145
Valve Recessing
146
Clearance between Valve Stem and Valve Guide
147
Replacement of Valve Guide
147
Valve Seating
148
Correction of Valve and Valve Seat
149
Free Length and Tilt of Valve Spring
150
Setting Load of Valve Spring
150
Valve Lapping
150
Oil Clearance between Rocker Arm and Rocker Arm Shaft
151
Oil Clearance between Tappet and Tappet Guide Bore
151
Push Rod Bend
151
Timing Gear Backlash
152
Timing Gears Servicing
152
Camshaft Bend
153
Side Clearance of Camshaft
153
Side Clearance of Idle Gear
153
Cam Height
154
Oil Clearance of Camshaft Journal
155
Balancer Shaft Bend (for Balancer Model Only)
156
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
156
Replacement of Idle Gear Bushing
156
Side Clearance of Balancer Shaft (for Balancer Model Only)
156
Oil Clearance of Balancer Shaft Journal
157
Oil Clearance between Piston Pin and Small End Bushing
158
Piston and Connecting Rod Servicing
158
Piston Pin Bore I.D.
158
Replacement of Small End Bushing
158
Connecting Rod Alignment
159
Piston Ring Gap
160
Clearance between Piston Ring and Groove
161
Crankshaft Bend
162
Crankshaft Servicing
162
Side Clearance of Crankshaft
162
Oil Clearance between Crankpin and Crankpin Bearing
163
Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1
164
Replacement of Crankshaft Bearing 1
164
Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2
165
Replacement of Crankshaft Sleeve
166
Cylinder Servicing
167
Cylinder Wear
167
Cylinder Correction (Oversize)
168
Clearance between Rotor and Cover
169
Oil Pump Servicing
169
Rotor Lobe Clearance
169
Starter Servicing
169
Commutator and Mica
170
Brush Holder
171
Brush Wear
171
Alternator Servicing
172
Armature Coil
172
Field Coil
172
Rotor
173
Slip Ring
173
Stator
173
IC Regulator
174
Rectifier
174
5
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Nanni N4.40 Specifications
General
Brand
Nanni
Model
N4.40
Category
Engine
Language
English
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