Nanni 5.280HE Workshop Manual
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Nanni 5.280HE Workshop Manual

Diesel marine engine
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WORKSHOP MANUAL
Diesel Marine Engine
5.280HE—4.200HE—4.220HE—4.195HE
60300075
Mis à jour 01/2013

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Summary of Contents for Nanni 5.280HE

  • Page 1 WORKSHOP MANUAL Diesel Marine Engine 5.280HE—4.200HE—4.220HE—4.195HE 60300075 Mis à jour 01/2013...
  • Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA Diesel Engine 03- M Series. It is divided into two parts, “Mechanism” and “Servicing” for each section. Mechanism Information on the Features and New Mechanisms are described.
  • Page 3 SAFETY INSTRUCTIONS 03-M Series, WSM SAFETY INSTRUCTIONS SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself 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 unit.
  • Page 4 SAFETY INSTRUCTIONS 03-M Series, WSM SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. SAFETY WORKING •...
  • Page 5 SAFETY INSTRUCTIONS 03-M Series, WSM VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. DISPOSE OF FLUIDS PROPERLY •...

  • Page 6: Specifications

    SPECIFICATIONS 03-M Series, WSM SPECIFICATIONS Model D1503-M D1703-M D1803-M Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83 × 92.4 mm (3.27 × 3.64 in.) 87 × 92.4 mm (3.43 × 3.64 in.) 87 × 102.4 mm (3.43 × 4.03 in.) Total Displacement 1499 cm (91.47 cu.in.)
  • Page 7 SPECIFICATIONS 03-M Series, WSM Model V2203-M V2403-M Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87 × 92.4 mm (3.43 × 3.64 in.) 87 × 102.4 mm (3.43 × 4.03 in.) Total Displacement 2197 cm (134.07 cu.in.) 2434 cm (148.53 cu.in.)
  • Page 8 DIMENSIONS 03-M Series, WSM DIMENSIONS KiSC issued 08, 2012 A...
  • Page 9 DIMENSIONS 03-M Series, WSM KiSC issued 08, 2012 A...

  • Page 10: Table Of Contents

    MECHANISM CONTENTS 1. ENGINE BODY ....................M-1 [1] HOLLOW CORE ..................M-1 [2] PISTON...................... M-1 [3] BUILT-IN DYNAMIC 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.

  • Page 11: Engine Body

    03-M Series, WSM DIESEL ENGINE 1. ENGINE BODY [1] HOLLOW CORE The cylinder block has a hollow core (1) already cast inside the cylinder-to-cylinder water jacket. In this core, there is a pair of vertical cooling passages (right and left) as well as multiple horizontal cooling channels that interconnect these cooling passages.

  • Page 12: Half-Floating Head Cover

    03-M Series, WSM DIESEL ENGINE [4] HALF-FLOATING HEAD COVER 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. (1) Cylinder Head Cover (2) Rubber Packing W1013327...

  • Page 13: Cooling System

    03-M Series, WSM DIESEL ENGINE 2. COOLING SYSTEM [1] BOTTOM BYPASS SYSTEM Bottom bypass system is introduced in 03-M Series for improving the cooling performance of the radiator. While the temperature of coolant in the engine is low, the thermostat is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.

  • Page 14: Fuel System

    03-M Series, WSM DIESEL ENGINE 3. FUEL SYSTEM [1] GOVERNOR The governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. This engine employs an all-speed governor which controls the centrifugal force of the steel ball (1) weight, produced by rotation of the fuel camshaft (5), and the tension of the governor spring 1 (7) and 2 (8) are balanced.
  • Page 15 03-M Series, WSM DIESEL ENGINE At Idling When the speed control lever is set at the idling position after the engine starts, the governor spring 1 (7) does not work at all and the governor spring 2 (8) does only act slightly. The governor sleeve (2) is pushed leftward by a centrifugal force of steel ball (1).
  • Page 16 SERVICING CONTENTS 1. GENERAL ......................S-1 [1] ENGINE IDENTIFICATION................S-1 (1) Model Name and Engine Serial Number ..........S-1 (2) Cylinder Number ...................S-2 [2] GENERAL PRECAUTION .................S-3 [3] TIGHTENING TORQUES ................S-4 (1) Tightening Torques for Special Use Screws, Bolts and Nuts ....S-4 (2) Tightening Torques for General Use Screws, Bolts and Nuts ....S-4 [4] TROUBLESHOOTING ................S-5 [5] SERVICING SPECIFICATIONS ..............S-8 [6] MAINTENANCE CHECK LIST..............S-16...
  • Page 17 [2] DISASSEMBLING AND ASSEMBLING ..........S-94 5. FUEL SYSTEM....................S-95 [1] CHECKING AND ADJUSTING .............. S-95 (1) Injection Pump..................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...............

  • Page 18: General

    03-M Series, WSM DIESEL ENGINE 1. GENERAL [1] ENGINE IDENTIFICATION (1) Model Name and Engine Serial Number When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced.

  • Page 19: Cylinder Number

    03-M Series, WSM DIESEL ENGINE (2) 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 side. W1011077 KiSC issued 08, 2012 A...

  • Page 20: General Precaution

    03-M Series, WSM DIESEL ENGINE [2] GENERAL PRECAUTION • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools.

  • Page 21: Tightening Torques

    03-M Series, WSM DIESEL ENGINE [3] TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque. (1) Tightening Torques for Special Use Screws, Bolts and Nuts NOTE •...

  • Page 22: Troubleshooting

    03-M Series, WSM DIESEL ENGINE [4] TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel – Start Air in the fuel system Vent air S-21 Water in the fuel system Change fuel and S-21, 28 repair or replace fuel system Fuel hose clogged...
  • Page 23 03-M Series, WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Either White or Blue Excessive engine oil Reduce to specified S-18 Exhaust Gas Is level Observed Piston ring and liner worn or stuck Repair or replace S-50, 64, 65, 80, 81, 88 Incorrect injection timing Adjust...
  • Page 24 03-M Series, WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Replenish S-18 Oil strainer clogged Clean S-63 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace – Excessive oil clearance of crankshaft bearing Replace S-67, 84, 85, 86,...

  • Page 25: Servicing Specifications

    03-M Series, WSM DIESEL ENGINE [5] SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm / 500 mm 0.0020 in. / 19.69 in. Compression Pressure 3.53 to 4.02 MPa / 2.55 MPa / −1 −1 (rpm)
  • Page 26 03-M Series, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Timing (Intake Valve) D1503-M Open 0.14 rad (8 °) – before T.D.C. Close 0.35 rad (20 °) – after B.D.C. D1703-M Open 0.21 rad (12 °) –...
  • Page 27 03-M Series, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Timing Gear Crank Gear to Idle Gear Backlash 0.0415 to 0.1122 mm 0.15 mm 0.00163 to 0.00442 in. 0.0059 in. Idle Gear to Cam Gear Backlash 0.0415 to 0.1154 mm 0.15 mm 0.00163 to 0.00454 in.
  • Page 28 03-M Series, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Balancer Shaft Journal 1 to Balancer Shaft Clearance 0.030 to 0.111 mm 0.20 mm Bearing 1 (Balancer Model Only) 0.00118 to 0.00437 in. 0.0079 in. Balancer Shaft Journal 1 O.D.
  • Page 29 03-M Series, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Piston Pin to Small End Bushing Clearance 0.014 to 0.038 mm 0.15 mm 0.00055 to 0.00150 in. 0.0059 in. Piston Pin O.D. 25.002 to 25.011 mm – 0.98433 to 0.98469 in.
  • Page 30 03-M Series, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.040 to 0.104 mm 0.20 mm 2 (Serial No.: above 3S0001) 0.00157 to 0.00409 in. 0.0079 in. Crankshaft Journal O.D. 59.921 to 59.940 mm –...
  • Page 31 03-M Series, WSM DIESEL ENGINE LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 98 kPa 49 kPa 1.0 kgf/cm 0.5 kgf/cm 14 psi 7 psi At Rated Speed 294 to 441 kPa 245 kPa 3.0 to 4.5 kgf/cm 2.5 kgf/cm 42.7 to 64.0 psi...
  • Page 32 03-M Series, WSM DIESEL ENGINE FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump Injection Timing 0.297 to 0.331 rad – (17 to 19 °) before T.D.C. Injection Nozzle Injection Pressure 13.73 to 14.71 MPa – 140 to 150 kgf/cm 1991 to 2133 psi Injection Nozzle Valve Seat Valve Seat...

  • Page 33: Maintenance Check List

    03-M Series, WSM DIESEL ENGINE [6] MAINTENANCE CHECK LIST To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the table below. Service Interval Reference Every Item page 1 or 2 1 year 800 1500 3000 months...
  • Page 34 03-M Series, WSM DIESEL ENGINE CAUTION • When changing or inspecting, be sure to level and stop the engine. NOTE Lubricating Oil With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low- sulfur fuel on-road vehicle engines.

  • Page 35: Check And Maintenance

    03-M Series, WSM DIESEL ENGINE [7] CHECK AND MAINTENANCE (1) Daily Check Points Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies between the two notches.
  • Page 36 03-M Series, WSM DIESEL ENGINE Checking and Replenish Coolant 1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B).

  • Page 37: Check Points Of Initial 50 Hours

    03-M Series, WSM DIESEL ENGINE (2) Check Points of Initial 50 Hours Changing Engine Oil CAUTION • Be sure to stop the engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3.

  • Page 38: Check Points Of Every 50 Hours

    03-M Series, WSM DIESEL ENGINE (3) Check Points of Every 50 Hours Checking Fuel Hoses and Clamp Bands 1. If the clamp (1) is loose, apply oil to the threads and securely retighten it. 2. The fuel hose (2) is made of rubber and ages regardless of the period service.

  • Page 39: Check Points Of Every 100 Hours

    03-M Series, WSM DIESEL ENGINE (4) Check Points of Every 100 Hours Cleaning Air Cleaner Element 1. Remove the air cleaner element. 2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm 30 psi).
  • Page 40 03-M Series, WSM DIESEL ENGINE Fan Belt Damage and Wear 1. 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.

  • Page 41: Check Point Of Every 150 Hours

    03-M Series, WSM DIESEL ENGINE (5) Check Point of Every 150 Hours Changing Engine Oil (for 90 mm (3.54 in.) Depth Oil Pan) CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2.
  • Page 42 03-M Series, WSM DIESEL ENGINE Replacing Oil Filter Cartridge (for 90 mm (3.54 in.) Depth Oil Pan) CAUTION • Be sure to stop the engine before replacing filter cartridge. 1. Remove the oil filter cartridge (1) with the filter wrench. 2.

  • Page 43: Check Points Of Every 200 Hours

    03-M Series, WSM DIESEL ENGINE (6) Check Points of Every 200 Hours Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan) CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2.
  • Page 44 03-M Series, WSM DIESEL ENGINE Replacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil Pan) CAUTION • Be sure to stop the engine before replacing filter cartridge. 1. Remove the oil filter cartridge (1) with the filter wrench. 2.

  • Page 45: Check Points Of Every 400 Hours

    03-M Series, WSM DIESEL ENGINE (7) Check Points of Every 400 hours Replacing Fuel Filter Cartridge (Cartridge Type) Water and dust in fuel are collected in the filter cartridge. So, change the filter cartridge every 400 hours service. 1. Remove the used filter cartridge with filter wrench. 2.

  • Page 46: Check Points Of Every 500 Hours

    03-M Series, WSM DIESEL ENGINE (8) Check Points of Every 500 Hours Cleaning Water Jacket and Radiator Interior CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
  • Page 47 03-M Series, WSM DIESEL ENGINE Anti-Freeze • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times. •...
  • Page 48 03-M Series, WSM DIESEL ENGINE Replacing Fan Belt 1. Remove the alternator (1). 2. Remove the fan belt (2). 3. Replace new fan belt. 4. Install the alternator (1). 5. Check the fan belt tension. 7.0 to 9.0 mm / 98 N or 10 kgf Deflection (A) Factory spec.

  • Page 49: Check Points Of Every 1 Or 2 Months

    03-M Series, WSM DIESEL ENGINE (9) Check Points of Every 1 or 2 Months Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

  • Page 50: Check Point Of Every Year

    03-M Series, WSM DIESEL ENGINE Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

  • Page 51: Check Point Of Every 800 Hours

    03-M Series, WSM DIESEL ENGINE (11) Check Point of Every 800 Hours Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover. 2. Align the “1TC” mark line (3) on the flywheel and projection (2) on the housing so that the No.1 piston comes to the compression or overlap top dead center.

  • Page 52: Check Points Of Every 1500 Hours

    03-M Series, WSM DIESEL ENGINE (12) Check Points of Every 1500 Hours CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
  • Page 53 03-M Series, WSM DIESEL ENGINE Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction. •...

  • Page 54: Check Points Of Every 3000 Hours

    03-M Series, WSM DIESEL ENGINE (13) Check Points of Every 3000 Hours Checking Injection Pump (Fuel Tightness of Pump Element) 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4.

  • Page 55: Check Points Of Every 2 Years

    03-M Series, WSM DIESEL ENGINE (14) Check Points of Every 2 Years Replacing Intake Air Line 1. Loosen the clamp (2). 2. Remove the intake air hose (1) and clamp (2). 3. Replace new intake air hose (1) and new clamp (2). 4.
  • Page 56 03-M Series, WSM DIESEL ENGINE Replacing Fuel Hoses and Clamp Bands 1. Loosen the clamp (1) and remove the fuel hose (2). 2. Replace new fuel hose (2) and new clamp (2). 3. Tighten the clamp (1). CAUTION • Stop the engine when attempting the check and change prescribed above.
  • Page 57 03-M Series, WSM DIESEL ENGINE Changing Radiator Coolant (L.L.C.) CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Stop the engine and let cool down. 2.
  • Page 58 03-M Series, WSM DIESEL ENGINE Changing Radiator Coolant (L.L.C.) (Continued) (Anti-freeze) • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times. •...

  • Page 59: Special Tools

    03-M Series, WSM DIESEL ENGINE [8] SPECIAL TOOLS Diesel Engine Compression Tester Code No: 07909-30208 (Assembly)07909-31251 (G) 07909-30934 (A to F)07909-31271 (I) 07909-31211 (E and F)07909-31281 (J) 07909-31231 (H) Application: Use to measure diesel engine compression and diagnostics of need for major overhaul. (1) Gauge (7) Adaptor F (2) L Joint...
  • Page 60 03-M Series, WSM DIESEL ENGINE NOTE • The following special tools are not provided, so make them referring to the figure. Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm , 4267 psi) Copper gasket...
  • Page 61 03-M Series, WSM DIESEL ENGINE Bushing Replacing Tools Application: Use to press out and to press fit the bushing. 1. For small end bushing 162 mm (6.38 in.) 35 mm (1.38 in.) 27 mm (1.06 in.) 35 mm dia. (1.38 in. dia.) 27.90 to 27.95 mm dia.
  • Page 62 03-M Series, WSM DIESEL ENGINE Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. 1. Extracting tool (D1503, D1703, V2203: Serial No.: below 3R9999) 135 mm (5.31 in.) 72 mm (2.83 in.) 40 mm radius (1.57 in.
  • Page 63 03-M Series, WSM DIESEL ENGINE Socket Wrench for Crank Pulley Nut (46 mm Deep Socket Wrench) Application: Use to loosen and tighten the fan drive pulley mounting nut. 100 mm (3.94 in.) 25.0 mm (0.98 in.) 27.0 mm (1.06 in.) 45.0 mm dia.
  • Page 64 03-M Series, WSM DIESEL ENGINE Auxiliary Socket for Fixing Crankshaft Sleeve (Continued) Application: Use to fix the crankshaft sleeve of the diesel engine. 42.0 mm (1.6535 in.) 30.5 to 30.6 mm (1.2008 to 1.2047 in.) 23.0 mm (0.9055 in.) 20.0 mm (0.7874 in.) 2.0 mm (0.0787 in.) 31.911 to 31.950 mm dia.
  • Page 65 03-M Series, WSM DIESEL ENGINE Balancer Metal Replacing Tool (for Removing) Application: Use to remove the metal bearing. 25 mm dia. (0.98 in. dia.) 41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.) 10 mm (0.39 in.) 24.959 to 24.980 mm dia. (0.9826 to 0.9835 in. dia.) Chamfer 0.3 mm (0.01 in.) 21.947 to 21.960 mm dia.
  • Page 66 03-M Series, WSM DIESEL ENGINE Balancer Metal Replacing Tool (for Fitting) Application: Use to press fit the metal bearing. 0.52 rad (30 °) 5 mm (0.20 in.) 10 mm (0.39 in.) 3.3 to 3.7 mm (0.130 to 0.146 in.) Chamfer 0.3 mm (0.01 in.) 43.934 to 43.950 mm dia.

  • Page 67: Engine Body

    03-M Series, WSM DIESEL ENGINE 2. ENGINE BODY [1] CHECKING AND ADJUSTING Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine and disconnect the 2P connector from the stop solenoid in order not to inject fuel. 3.
  • Page 68 03-M Series, WSM DIESEL ENGINE Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover. 2. Align the “1TC” mark line (3) on the flywheel and projection (2) on the housing so that the No.1 piston comes to the compression or overlap top dead center.

  • Page 69: Disassembling And Assembling

    03-M Series, WSM DIESEL ENGINE [2] DISASSEMBLING AND ASSEMBLING (1) Draining Oil and Coolant Draining Engine Oil 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3. Remove the drain plug (1) to drain oil. 4.

  • Page 70: Cylinder Head And Valves

    03-M Series, WSM DIESEL ENGINE (3) Cylinder Head and Valves Cylinder Head Cover 1. Remove the lead (1). 2. Remove the breather hose (2). 3. Remove the head cover screws (3). 4. Remove the cylinder head cover (4). (When reassembling) •...
  • Page 71 03-M Series, WSM DIESEL ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe assembly (5). 2. Remove the nozzle holder assemblies (2) using a 21 mm deep socket wrench. 3. Remove the copper gasket (3) and heat seal (4). 4.
  • Page 72 03-M Series, WSM DIESEL ENGINE Cylinder Head 1. Loosen the pipe clamp (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of (n or r) to (a). 3. Lift up the cylinder head (3) to detach. 4.
  • Page 73 03-M Series, WSM DIESEL ENGINE Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).

  • Page 74: Timing Gears, Camshaft And Fuel Camshaft

    03-M Series, WSM DIESEL ENGINE (4) Timing Gears, Camshaft and Fuel Camshaft Injection Pump 1. Remove the stop solenoid (1) and hi-idling body (2). 2. Remove the engine stop lever (3) and stop solenoid guide (5). 3. Remove the fuel injection pump assembly (4). IMPORTANT •...
  • Page 75 03-M Series, WSM DIESEL ENGINE Governor Springs and Speed Control Plate NOTE • Specific tool (1) : 1.2 mm diameter hard wire with its end hooked, overall length 200 mm (7.87 in.). The tip of wire is bent like the hook to hang governor springs.
  • Page 76 03-M Series, WSM DIESEL ENGINE Governor Springs and Speed Control Plate (Continued) (When reassembling) • Hook the small spring (4) first and then the large governor spring (2) on the speed control plate (6). • Put the specific tool (1) from the injection pump side to catch the large governor spring (2).
  • Page 77 03-M Series, WSM DIESEL ENGINE Fan Drive Pulley 1. Lock the flywheel not to turn using the flywheel stopper. 2. Remove the fan drive pulley mounting nut (1) using 46 mm deep socket wrench (2). 3. Remove the fan drive pulley (3) with gear puller (4). 4.
  • Page 78 03-M Series, WSM DIESEL ENGINE Crankshaft Oil Slinger 1. Remove the crankshaft collar (3). 2. Remove the O-ring (2). 3. Detach the crankshaft oil slinger (1). (When reassembling) • Insert the crankshaft collar (3) after install the gear case to cylinder body.
  • Page 79 03-M Series, WSM DIESEL ENGINE Camshaft and Balancer Shaft (For Balancer Model) 1. Remove the camshaft set screws and draw out the camshaft (1). 2. Remove the balancer shaft 1 (2) set bolts and draw out the balancer shaft 1 (2). 3.

  • Page 80: Piston And Connecting Rod

    03-M Series, WSM DIESEL ENGINE Crank Gear 1. Draw out the crank gear (1) with a puller (2). 2. Remove the feather key. (1) Crank Gear (2) Gear Puller W1025476 (5) Piston and Connecting Rod Oil Pan and Oil Strainer 1.
  • Page 81 03-M Series, WSM DIESEL ENGINE Pistons 1. Completely clean carbon (1) in the cylinders. 2. Remove the connecting rod cap (3). 3. Turn the flywheel and bring the piston to top dead center. 4. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
  • Page 82 03-M Series, WSM DIESEL ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings (4), (5), (6) using a piston ring tool. 2. Remove the piston pin (1), and separate the connecting rod (7) from the piston (2). (When reassembling) •...

  • Page 83: Crankshaft

    03-M Series, WSM DIESEL ENGINE (6) Crankshaft Flywheel 1. Fit the stopper to the flywheel (1). 2. At first, remove two pieces of the flywheel screws (2). 3. Insert two pieces of the flywheel guide screws (3) in the holes. 4.
  • Page 84 03-M Series, WSM DIESEL ENGINE Crankshaft NOTE • Before disassembling, check the side clearance of crankshaft. Also check it during reassembling. For D1503-M, D1703-M and V2203-M 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly, taking care not to damage the crankshaft bearing 1 (3).
  • Page 85 03-M Series, WSM DIESEL ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (8), and remove the main bearing case assembly being careful with thrust bearing and crankshaft bearing. 2. Remove the main bearing case 1, 2 as above. (When reassembling) •...

  • Page 86: Servicing

    03-M Series, WSM DIESEL ENGINE [3] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. Move the piston up and stick a strip of fuse (2) on the piston head at three position with grease. 3.
  • Page 87 03-M Series, WSM DIESEL ENGINE Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying. 4.
  • Page 88 03-M Series, WSM DIESEL ENGINE Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (See page “SPECIAL TOOLS”.) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
  • Page 89 03-M Series, WSM DIESEL ENGINE Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
  • Page 90 03-M Series, WSM DIESEL ENGINE Free Length and Tilt of Valve Spring 1. Measure the free length (A) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
  • Page 91 03-M Series, WSM DIESEL ENGINE Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.

  • Page 92: Timing Gears, Camshaft And Fuel Camshaft

    03-M Series, WSM DIESEL ENGINE (2) Timing Gears, Camshaft and Fuel Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3.
  • Page 93 03-M Series, WSM DIESEL ENGINE Camshaft Side Clearance 1. Set a dial indicator with its tip on the camshaft. 2. measure the side clearance by moving the cam gear to the front to rear. 3. If the measurement exceeds the allowable limit, replace the camshaft stopper.
  • Page 94 03-M Series, WSM DIESEL ENGINE Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft.
  • Page 95 03-M Series, WSM DIESEL ENGINE Balancer Shaft Side Clearance (for Balancer Model Only) 1. Set a dial indicator with tip on the balancer shaft. 2. Measure the side clearance by moving the balancer shaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the balancer shaft.

  • Page 96: Piston And Connecting Rod

    03-M Series, WSM DIESEL ENGINE Oil Clearance of Balancer Shaft Journal (for Balancer Model Only) 1. Measure the balancer shaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for balancer shaft with an inside micrometer or cylinder gauge. 3.
  • Page 97 03-M Series, WSM DIESEL ENGINE Oil Clearance between Piston Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.
  • Page 98 03-M Series, WSM DIESEL ENGINE Clearance between Piston Ring and Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge or depth gauge. 3.

  • Page 99: Crankshaft

    03-M Series, WSM DIESEL ENGINE (4) Crankshaft Side Clearance of Crankshaft 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
  • Page 100 03-M Series, WSM DIESEL ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 101 03-M Series, WSM DIESEL ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate oil clearance. 3.
  • Page 102 03-M Series, WSM DIESEL ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 (Continued) (Reference) • Undersize dimensions of crankshaft journal (Serial No.: below 3R9999) 0.2 mm 0.4 mm Undersize 0.008 in. 0.016 in. 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius Dimension A 0.1102 to 0.1260 in.
  • Page 103 03-M Series, WSM DIESEL ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 1. Put a strip of plastigage on the center of the journal. 2. Install the bearing case and tighten the baring case screws 1 to the specified torque, and remove the bearing case again. 3.
  • Page 104 03-M Series, WSM DIESEL ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Continued) (Reference) • Undersize dimensions of crankshaft journal (Serial No.: below 3R9999) 0.2 mm 0.4 mm Undersize 0.008 in. 0.016 in. 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius Dimension A 0.1102 to 0.1260 in.

  • Page 105: Cylinder

    03-M Series, WSM DIESEL ENGINE Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve (3). 2. Set the sleeve guide (2) to the crankshaft (5). 3. Set the stopper (1) to the crankshaft (5) as shown in figure. 4. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft (5) as shown in figure.
  • Page 106 03-M Series, WSM DIESEL ENGINE Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. 83.250 to 83.272 mm D1503-M 3.27756 to 3.27843 in. Factory D1703-M spec. D1803-M 87.250 to 87.272 mm V2203-M 3.43504 to 3.43591 in.

  • Page 107: Lubricating System

    03-M Series, WSM DIESEL ENGINE 3. LUBRICATING SYSTEM [1] CHECKING Engine Oil Pressure 1. Remove the engine oil pressure switch, and set a oil pressure tester (Code No.: 07916-32032). (Adaptor screw size : PT 1/8) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

  • Page 108: Servicing

    03-M Series, WSM DIESEL ENGINE [2] SERVICING Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge. 2. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 3.

  • Page 109: Cooling System

    03-M Series, WSM DIESEL ENGINE 4. COOLING SYSTEM [1] CHECKING AND ADJUSTING Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbs). 2.
  • Page 110 03-M Series, WSM DIESEL ENGINE Radiator Water Leakage 1. Pour a specified amount of water into the radiator. 2. Set a radiator tester and an adapter and raise the water pressure to the specified pressure. 3. Check the radiator for water leaks. 4.

  • Page 111: Disassembling And Assembling

    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.

  • Page 112: Fuel System

    03-M Series, WSM DIESEL ENGINE 5. FUEL SYSTEM [1] CHECKING AND ADJUSTING (1) Injection Pump Injection Timing 1. Remove the stop solenoid. 2. Remove the injection pipes and nozzle. 3. Set the speed control lever to maximum fuel discharge position. (Reference) •...

  • Page 113: Injection Nozzle

    03-M Series, WSM DIESEL ENGINE Fuel Tightness of Pump Element 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (1) jetted with the proper injection pressure to the injection pump pressure tester (2).
  • Page 114 03-M Series, WSM DIESEL ENGINE (2) Injection Nozzle CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
  • Page 115 03-M Series, WSM DIESEL ENGINE Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction. •...

  • Page 116: Electrical System

    03-M Series, WSM DIESEL ENGINE 6. ELECTRICAL SYSTEM [1] CHECKING (1) Starter Motor Test CAUTION • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2.

  • Page 117: Alternator

    03-M Series, WSM DIESEL ENGINE Magnet Switch Continuity Test 1. Check the continuity across the C terminal (1) and the B terminal (2) with a circuit tester, pushing in the plunger. 2. If not continuous or if a certain value is indicated, replace the magnet switch.

  • Page 118: Engine Stop Solenoid

    03-M Series, WSM DIESEL ENGINE Glow Plug Continuity 1. Remove the glow plug. 2. Measure the resistance with a circuit tester between the glow plug terminal and the glow plug housing. 3. If the factory specification is not indicated, glow plug is faulty. Approx.

  • Page 119: Disassembling And Assembling

    03-M Series, WSM DIESEL ENGINE [2] DISASSEMBLING AND ASSEMBLING (1) Starter (1) Through Bolt (2) Brush (3) Yoke (4) Armature (5) Overrunning Clutch (6) Idle Gear (7) End Frame (8) Brush Holder (9) Magnet Switch Cover (10) Plunger (11) Housing (12) C Terminal Nut (13) B Terminal Nut W1222714...

  • Page 120: Alternator

    03-M Series, WSM DIESEL ENGINE (2) Alternator (1) Pulley (2) Drive End Frame (3) Stator (4) Bearing (5) Retainer Plate (6) Rotor (7) Bearing (8) Rear End Frame (9) Rectifier (10) IC Regulator (11) Brush Holder (12) Rear End Cover W1224079 1.

  • Page 121: Servicing

    03-M Series, WSM DIESEL ENGINE [3] SERVICING (1) Starter Overrunning Clutch 1. Check the pinion and if worn or damage, replace the clutch assembly. 2. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction. 3.
  • Page 122 03-M Series, WSM DIESEL ENGINE Armature Coil 1. Check the continuity across the commutator and armature coil core with resistance range of circuit tester. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with resistance range of circuit tester.

  • Page 123: Alternator

    03-M Series, WSM DIESEL ENGINE (2) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1019790 Stator 1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester. 2.
  • Page 124 03-M Series, WSM DIESEL ENGINE Rectifier 1. Check the continuity across each diode of rectifier with resistance range of circuit tester. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction. IMPORTANT •...
  • Page 125 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 publication of this document. Nanni Diesel reserves the right to amend this document without notice...

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