Wsm 05-E2B SERIES Dokumentacja

N4.40 (Before serial number KTF08040093) WORK SHOP MANUAL ENGINE BASE NANNI INDUSTRIES S.A.S – Zone Industrielle 11 avenue MARIOTTE B.P.107 – 33260

S-4703-E2B SERIES, WSMDIESEL ENGINE(7) StarterW12227141. Unscrew the C terminal nut (3), and disconnect the connecting lead.2. Remove the two through

S-4803-E2B SERIES, WSMDIESEL ENGINE(8) AlternatorW12240791. Remove the pulley (1).2. Remove the rear end cover (12).3. Remove the brush holder (11).4

S-4903-E2B SERIES, WSMDIESEL ENGINE[3] SERVICING(1) Cylinder Head and ValvesTop Clearance1. Remove the cylinder head.2. Move the piston up and stick

S-5003-E2B SERIES, WSMDIESEL ENGINECylinder Head Flaw1. Prepare an air spray red check.2. Clean the surface of the cylinder head with the detergent (

S-5103-E2B SERIES, WSMDIESEL ENGINEReplacing Valve Guide(When removing)1. Press out the used valve guide using a valve guide replacing tool.(See page

S-5203-E2B SERIES, WSMDIESEL ENGINECorrecting Valve and Valve SeatNOTEQ• Before correcting the valve and seat, check the valve stemand the I.D. of va

S-5303-E2B SERIES, WSMDIESEL ENGINEFree Length and Tilt of Valve Spring1. Measure the free length (B) of valve spring with vernier calipers.If the me

S-5403-E2B SERIES, WSMDIESEL ENGINEPush Rod Alignment1. Place the push rod on V blocks.2. Measure the push rod alignment.3. If the measurement exceed

S-5503-E2B SERIES, WSMDIESEL ENGINEIdle Gear Side Clearance1. Set a dial indicator with its tip on the idle gear.2. Measure the side clearance by mov

S-5603-E2B SERIES, WSMDIESEL ENGINECam Height1. Measure the height of the cam at its highest point with an outsidemicrometer.2. If the measurement is

S-5703-E2B SERIES, WSMDIESEL ENGINEOil Clearance between Idle Gear Shaft and Idle Gear Bushing1. Measure the idle gear shaft O.D. with an outside mic

S-5803-E2B SERIES, WSMDIESEL ENGINEOil Clearance between Piston Pin and Small End Bushing1. Measure the piston pin O.D. where it contacts the bushing

S-5903-E2B SERIES, WSMDIESEL ENGINEPiston Ring Gap1. Insert the piston ring into the lower part of the liner (the least wornout part) with the piston

S-6003-E2B SERIES, WSMDIESEL ENGINE(4) CrankshaftSide Clearance of Crankshaft1. Set a dial indicator with its tip on the end of the crankshaft.2. Mea

S-6103-E2B SERIES, WSMDIESEL ENGINEOil Clearance between Crankpin and Crankpin Bearing1. Clean the crankpin and crankpin bearing.2. Put a strip of pl

S-6203-E2B SERIES, WSMDIESEL ENGINEOil Clearance between Crankshaft Journal and CrankshaftBearing 11. Measure the O.D. of the crankshaft journal with

S-6303-E2B SERIES, WSMDIESEL ENGINEReplacing Crankshaft Bearing 1(When removing)1. Press out the used crankshaft bearing 1 using a crankshaftbearing

S-6403-E2B SERIES, WSMDIESEL ENGINEOil Clearance between Crankshaft Journal and CrankshaftBearing 21. Put a strip of plastigage on the center of the

S-6503-E2B SERIES, WSMDIESEL ENGINEReplacing Crankshaft Sleeve1. Remove the used crankshaft sleeve (3).2. Set the sleeve guide (2) to the crankshaft

S-6603-E2B SERIES, WSMDIESEL ENGINE(5) CylinderCylinder Wear1. Measure the I.D. of the cylinder at the six positions (see figure)with a cylinder gaug

CONTENTSGENERAL1. ENGINE IDENTIFICATION... G-1[1] MODEL NAME AND ENGINE

S-6703-E2B SERIES, WSMDIESEL ENGINECorrecting Cylinder (Oversize)1. When the cylinder is worn beyond the allowable limit, bore andhone it to the spec

S-6803-E2B SERIES, WSMDIESEL ENGINEClearance between Rotor and Cover1. Put a strip of plastigage onto the rotor face with grease.2. Install the cover

S-6903-E2B SERIES, WSMDIESEL ENGINEBrush Wear1. If the contact face of the brush is dirty or dusty, clean it with emerypaper.2. Measure the brush len

S-7003-E2B SERIES, WSMDIESEL ENGINEField Coil1. Check the continuity across the lead (1) and brush (2) with acircuit tester.2. If it dose not conduct

S-7103-E2B SERIES, WSMDIESEL ENGINESlip Ring1. Check the slip ring for score.2. If scored, correct with an emery paper or on a lathe.3. Measure the O

EDITOR:KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPANPHONE : (81)72-241-1129FA

G-103-E2B SERIES, WSMG GENERAL1. ENGINE IDENTIFICATION[1] MODEL NAME AND ENGINE SERIAL NUMBERWhen contacting the manufacture, always specify yo

G-203-E2B SERIES, WSMG GENERAL• Month of manufacturee.g. D1703-4A0001“4” indicates 2004 and “A” indicates January.So, 4A indicates that the engine wa

G-303-E2B SERIES, WSMG GENERAL2. GENERAL PRECAUTIONS• During disassembly, carefully arrange removed parts in a cleanarea to prevent confusion later.

G-403-E2B SERIES, WSMG GENERAL3. MAINTENANCE CHECK LISTTo maintain long-lasting and safe engine performance, make it a rule to carry out regular in

G-503-E2B SERIES, WSMG GENERALCAUTION• When changing or inspecting, be sure to level and stop the engine.Q NOTELubricating OilWith the emission contr

G-603-E2B SERIES, WSMG GENERAL4. CHECK AND MAINTENANCE[1] DAILY CHECK POINTSChecking Engine Oil Level1. Level the engine.2. To check the oil leve

G-703-E2B SERIES, WSMG GENERALChecking and Replenish Coolant1. Without recovery tank :Remove the radiator cap (1) and check to see that the coolantle

TO THE READERThis Workshop Manual has been prepared to provide servicing personnel withinformation on the mechanism, service and maintenance of 03-E

G-803-E2B SERIES, WSMG GENERAL[2] CHECK POINTS OF INITIAL 50 HOURSChanging Engine OilCAUTION• Be sure to stop engine before changing engine oil.

G-903-E2B SERIES, WSMG GENERALReplacing Oil Filter CartridgeCAUTION• Be sure to stop the engine before replacing filter cartridge.1. Remove the oil f

G-1003-E2B SERIES, WSMG GENERAL[3] CHECK POINTS OF EVERY 50 HOURSChecking Fuel Hoses and Clamp Bands1. If the clamp (2) is loose, apply oil to t

G-1103-E2B SERIES, WSMG GENERAL[4] CHECK POINTS OF EVERY 100 HOURSCleaning Air Cleaner Element1. Remove the air cleaner element.2. Use clean dry

G-1203-E2B SERIES, WSMG GENERALFan Belt Damage and Wear1. Check the fan belt for damage.2. If the fan belt is damaged, replace it.3. Check if the fan

G-1303-E2B SERIES, WSMG GENERAL[5] CHECK POINTS OF EVERY 150 HOURSChanging Engine Oil (for 90 mm (3.54 in.) Depth Oil Pan)CAUTION• Be sure to st

G-1403-E2B SERIES, WSMG GENERALReplacing Oil Filter Cartridge (for 90 mm (3.54 in.) Depth OilPan)CAUTION• Be sure to stop the engine before replacing

G-1503-E2B SERIES, WSMG GENERAL[6] CHECK POINTS OF EVERY 200 HOURSChanging Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan)CAUTION• Be sure to s

G-1603-E2B SERIES, WSMG GENERALReplacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth OilPan)CAUTION• Be sure to stop the engine before replacin

G-1703-E2B SERIES, WSMG GENERAL[7] CHECK POINTS OF EVERY 400 HOURSReplacing Fuel Filter Cartridge (Cartridge Type)Water and dust in fuel are col

103-E2B SERIES, WSMSAFETY INSTRUCTIONSSAFETY INSTRUCTIONSBEFORE SERVICING AND REPAIRING• Read all instructions and safety instructions in thismanua

G-1803-E2B SERIES, WSMG GENERAL[8] CHECK POINTS OF EVERY 500 HOURSCleaning Water Jacket and Radiator InteriorCAUTION• Do not remove the radiator

G-1903-E2B SERIES, WSMG GENERALAnti-Freeze• There are two types of anti-freeze available: use the permanenttype (PT) for this engine.• Before adding

G-2003-E2B SERIES, WSMG GENERAL[9] CHECK POINTS OF EVERY 1 OR 2 MONTHSRechargingCAUTION• When the battery is being activated, hydrogen and oxy

G-2103-E2B SERIES, WSMG GENERALBattery Specific Gravity1. Check the specific gravity of the electrolyte in each cell with ahydrometer.2. When the ele

G-2203-E2B SERIES, WSMG GENERAL[11] CHECK POINTS OF EVERY 800 HOURSValve ClearanceIMPORTANTQ• Valve clearance must be checked and adjusted when

G-2303-E2B SERIES, WSMG GENERAL[12] CHECK POINTS OF EVERY 1500 HOURSCAUTION• Check the injection pressure and condition after confirming that th

G-2403-E2B SERIES, WSMG GENERALNozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out parts in

G-2503-E2B SERIES, WSMG GENERAL[13] CHECK POINTS OF EVERY 3000 HOURSChecking Turbocharger(Turbine Side)1. Check the exhaust port (2) and inlet p

G-2603-E2B SERIES, WSMG GENERALInjection Timing1. Remove the injection pipes and nozzle.2. Set the speed control lever to maximum fuel discharge posi

G-2703-E2B SERIES, WSMG GENERALChecking Injection Pump(Fuel Tightness of Pump Element)1. Remove the engine stop solenoid.2. Remove the injection pipe

203-E2B SERIES, WSMSAFETY INSTRUCTIONSSAFETY STARTING• Do not start the engine by shorting across starterterminals or bypassing the safety start swit

G-2803-E2B SERIES, WSMG GENERAL[14] CHECK POINTS OF EVERY 2 YEARSReplacing Intake Air Line1. Loosen the clamp (2).2. Remove the intake air hose

G-2903-E2B SERIES, WSMG GENERALReplacing Fuel Hoses and Clamp Bands1. Loosen the clamp (2) and remove the fuel hose (1).2. Replace new fuel hose (1)

G-3003-E2B SERIES, WSMG GENERALChanging Radiator Coolant (L.L.C.)CAUTION• Do not remove the radiator cap when the engine is hot. Thenloosen cap slig

G-3103-E2B SERIES, WSMG GENERALChanging Radiator Coolant (L.L.C.) (Continued)(Anti-freeze)• There are two types of anti-freeze available: use the per

G-3203-E2B SERIES, WSMG GENERAL5. SPECIAL TOOLSDiesel Engine Compression TesterCode No: 07909-30208 (Assembly) 07909-31251 (G)07909-30934 (A to F) 0

G-3303-E2B SERIES, WSMG GENERALNOTEQ• The following special tools are not provided, so make them referring to the figure.Injection Pump Pressure Test

G-3403-E2B SERIES, WSMG GENERALBushing Replacing ToolsApplication: Use to press out and to press in the bushing.1. For small end bushing2. For idle g

G-3503-E2B SERIES, WSMG GENERALCrankshaft Bearing 1 Replacing Tool(D1403/D1503/D1703/V1903/V2003-T/V2203-E2B)Application: Use to press out and press

G-3603-E2B SERIES, WSMG GENERALAuxiliary Socket for Fixing Crankshaft SleeveApplication: Use to fix the crankshaft sleeve of the diesel engine.W10276

G-3703-E2B SERIES, WSMG GENERALAuxiliary Socket for Fixing Crankshaft Sleeve (Continued)Application: Use to fix the crankshaft sleeve of the diesel e

303-E2B SERIES, WSMSAFETY INSTRUCTIONSVENTILATE WORK AREA• If the engine must be running to do some work, makesure the area is well ventilated. Neve

CONTENTSMECHANISM1. ENGINE BODY ... M-1[1] HALF-FLOATING

M-103-E2B SERIES, WSMDIESEL ENGINE1. ENGINE BODY[1] HALF-FLOATING HEAD COVERThe rubber packing is fitted in to maintain the cylinderhead cover 0.5

M-203-E2B SERIES, WSMDIESEL ENGINE2. FUEL SYSTEM[1] GOVERNORThe governor serves to keep engine speed constantby automatically adjusting the amount o

CONTENTSSERVICING1. TROUBLESHOOTING ...S-12. SERVICING SPECIFICATI

S-103-E2B SERIES, WSMDIESEL ENGINE1. TROUBLESHOOTINGW1014322Symptom Probable Cause SolutionReference PageEngine Does Not StartNo fuel Replenish fuel

S-203-E2B SERIES, WSMDIESEL ENGINEW1011567Symptom Probable Cause SolutionReference PageEngine Revolution Is Not SmoothFuel filter clogged or dirty Re

S-303-E2B SERIES, WSMDIESEL ENGINEW1012032Symptom Probable Cause SolutionReference PageDeficient Output Incorrect injection timing Adjust S-20Engine’

S-403-E2B SERIES, WSMDIESEL ENGINEW1012501Symptom Probable Cause SolutionReference PageHigh Oil Pressure Different type of oil Use specified type of

S-503-E2B SERIES, WSMDIESEL ENGINE2. SERVICING SPECIFICATIONSENGINE BODYW1013874Item Factory Specification Allowable LimitValve Clearance (When Col

S-603-E2B SERIES, WSMDIESEL ENGINEENGINE BODY (Continued)W1013874Item Factory Specification Allowable LimitValve Timing (Intake Valve)[D1403-E2B][D1

19/02/2009 Fiche N4.40GB TECHNICAL DATA ENGINE MODEL N4.40 (up to serial number: KTF08040092) ENGINE SPECIFICATIONS Number of cylinders: 4 Displ

S-703-E2B SERIES, WSMDIESEL ENGINEENGINE BODY (Continued)W1013874Item Factory Specification Allowable LimitTappet to Tappet GuideTappetTappet GuideO

S-803-E2B SERIES, WSMDIESEL ENGINEENGINE BODY (Continued)W1013874Item Factory Specification Allowable LimitCamshaft Journal to Cylinder Block Bore

S-903-E2B SERIES, WSMDIESEL ENGINEENGINE BODY (Continued)W1013874Item Factory Specification Allowable LimitCrankshaft Journal to Crankshaft Bearing

S-1003-E2B SERIES, WSMDIESEL ENGINEENGINE BODY (Continued)W1013874LUBRICATING SYSTEMW1013973Item Factory Specification Allowable LimitCrankshaft[D1

S-1103-E2B SERIES, WSMDIESEL ENGINECOOLING SYSTEMW1013874FUEL SYSTEMW1013973Item Factory Specification Allowable LimitFan Belt Tension 7.0 to 9.0 m

S-1203-E2B SERIES, WSMDIESEL ENGINEELECTRICAL SYSTEMW1013874Item Factory Specification Allowable LimitStarterCommutatorMicaBrushO.D.Under CutLength3

S-1303-E2B SERIES, WSMDIESEL ENGINE3. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, seve

S-1403-E2B SERIES, WSMDIESEL ENGINE[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS ANDNUTSNOTEQ• For “*” marked screws, bolts and nuts on

S-1503-E2B SERIES, WSMDIESEL ENGINE4. CHECKING, DISASSEMBLING AND SERVICING[1] CHECKING AND ADJUSTING(1) Engine BodyCompression Pressure1. Run t

S-1603-E2B SERIES, WSMDIESEL ENGINEValve ClearanceIMPORTANTQ• Valve clearance must be checked and adjusted when engineis cold.1. Remove the head cove

S-1703-E2B SERIES, WSMDIESEL ENGINE(2) Lubricating SystemEngine Oil Pressure1. Remove the engine oil pressure switch, and set an oil pressuretester (

S-1803-E2B SERIES, WSMDIESEL ENGINEFan Belt Damage and Wear1. Check the fan belt for damage.2. If the fan belt is damaged, replace it.3. Check if the

S-1903-E2B SERIES, WSMDIESEL ENGINEThermostat Valve Opening Temperature1. Suspend the thermostat in the water by a string with its endinserted betwee

S-2003-E2B SERIES, WSMDIESEL ENGINE(4) Fuel SystemInjection Timing1. Remove the injection pipes and nozzle.2. Set the speed control lever to maximum

S-2103-E2B SERIES, WSMDIESEL ENGINEFuel Tightness of Pump Element1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. I

S-2203-E2B SERIES, WSMDIESEL ENGINECAUTION• Check the nozzle injection pressure and condition after confirming that there is nobody standing in thedi

S-2303-E2B SERIES, WSMDIESEL ENGINENozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out part

S-2403-E2B SERIES, WSMDIESEL ENGINEBattery Specific Gravity1. Check the specific gravity of the electrolyte in each cell with ahydrometer.2. When the

S-2503-E2B SERIES, WSMDIESEL ENGINEMotor TestCAUTION• Secure the starter to prevent it from jumping up and downwhile testing the motor.1. Disconnect

S-2603-E2B SERIES, WSMDIESEL ENGINEAlternator on Unit Test(Before testing)• Before alternator on unit test, check the battery terminalconnections, ci

S-2703-E2B SERIES, WSMDIESEL ENGINE(6) TurbochargerTurbine Side1. Check the exhaust port (2) and inlet port (3) side of the turbinehousing (1) to see

S-2803-E2B SERIES, WSMDIESEL ENGINE[2] DISASSEMBLING AND ASSEMBLING(1) Draining Oil and CoolantDraining Engine Oil1. Start and warm up the engine f

S-2903-E2B SERIES, WSMDIESEL ENGINETurbocharger (equipped with Turbocharger Model)CAUTION• While the engine is running and or just after it stops, th

S-3003-E2B SERIES, WSMDIESEL ENGINE(3) Cylinder Head and ValvesCylinder Head Cover1. Remove the lead (1).2. Remove the breather hose (2).3. [a] D1403

S-3103-E2B SERIES, WSMDIESEL ENGINEInjection Pipes1. Loosen the screws on the pipe clamps (1).2. Detach the injection pipes (2).(When reassembling)•

S-3203-E2B SERIES, WSMDIESEL ENGINERocker Arm and Push Rod1. Remove the rocker arm bracket screws (D1403/D1503/D1703/D1903/V2203-E2B) or nuts (V2203-

S-3303-E2B SERIES, WSMDIESEL ENGINECylinder Head1. Loosen the pipe clamp (2), and remove the water return pipe (1).2. Remove the cylinder head screw

S-3403-E2B SERIES, WSMDIESEL ENGINEThermostat Assembly1. Remove the thermostat cover mounting screws, and remove thethermostat cover (1).2. Remove th

S-3503-E2B SERIES, WSMDIESEL ENGINE(4) Gear Case and Timing GearsInjection Pump1. Remove the injection pump cover (3) with the engine stop lever(2).2

S-3603-E2B SERIES, WSMDIESEL ENGINESpeed Control Plate1. Remove the speed control plate and governor spring 1 (2) and 2(1).(When reassembling)• Be ca

S-3703-E2B SERIES, WSMDIESEL ENGINEFan Drive Pulley1. Lock the flywheel not to turn using the flywheel stopper.2. [D1403/D1503/D1703/V1903/V2003-T/V2

S-3803-E2B SERIES, WSMDIESEL ENGINEGear Case1. Remove the hour meter gear case (if equipped).2. Remove the gear case (1).3. Remove the O-rings (2).(W

S-3903-E2B SERIES, WSMDIESEL ENGINEFuel Camshaft and Fork Lever Assembly1. Remove the fuel feed pump.2. Detach the fuel camshaft stopper (1).3. Remov

S-4003-E2B SERIES, WSMDIESEL ENGINE(5) Piston and Connecting RodOil Pan and Oil Strainer1. Remove the oil pan mounting screws.2. Remove the oil pan (

S-4103-E2B SERIES, WSMDIESEL ENGINEPistons (To be continued)1. Completely clean carbon (1) in the cylinders.2. Remove the connecting rod cap (3).3. T

S-4203-E2B SERIES, WSMDIESEL ENGINEPistons (Continued)(When reassembling)• Before inserting piston into the cylinder, apply enough engine oilto the p

S-4303-E2B SERIES, WSMDIESEL ENGINEPiston Ring and Connecting Rod1. Remove the piston rings (1), (2), (3) using a piston ring tool.2. Remove the pist

S-4403-E2B SERIES, WSMDIESEL ENGINE(6) Flywheel and CrankshaftFlywheel1. Fit the stopper to the flywheel (1).2. At first, remove two pieces of the fl

S-4503-E2B SERIES, WSMDIESEL ENGINECrankshaftNOTEQ• Before disassembling, check the side clearance ofcrankshaft. Also check it during reassembling.1

S-4603-E2B SERIES, WSMDIESEL ENGINEMain Bearing Case Assembly1. Remove the two main bearing case screws 1 (8), and remove themain bearing case assemb