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Table Of Contents - Nanni N4.40 Workshop Manual

Table Of Contents

Table of Contents

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Table of Contents

Safety Information5

Before You Start Your Service5

Safe Operation6

Prevent A Fire6

Technical Data8

Engine Specifications8

Tightening Torque8

General Information15

Table Of Contents15

Engine Identification16

Model Name And Engine Serial Number16

Cylinder Number18

General Precautions19

Maintenance Check List20

Engine Oil Classification (Api Classification)22

Check And Maintenance23

Daily Check Points23

Check Of Engine Oil Level23

Check Of Coolant Level And Replenishment24

Check Points For The Initial 50 Hours25

Change Of Engine Oil25

Replacement Of Oil Filter Cartridge26

Check Points For Every 50 Hours27

Check Of Fuel Hoses And Clamp Bands27

Check Points For Every 100 Hours28

Cleaning Of Air Cleaner Element28

Cleaning Of Fuel Filter (Element Type Only)28

Check Of Battery Electrolyte Level / Fan Belt Tension28

Fan Belt Damage And Wear29

Check Points For Every 150 Hours30

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 Hours32

Change Of Engine Oil (For 124 Mm (4.88 In.) Depth Oil Pan)32

Check Of Radiator Hoses And Clamp Bands34

Check Points For Every 400 Hours35

Check Of Intake Air Line35

Replacement Of Fuel Filter Cartridge (Cartridge Type)36

Replacement Of Fuel Filter Element (Element Type)36

Check Points For Every 500 Hours37

Cleaning Of Water Jacket And Radiator Interior37

Replacement Of Fan Belt38

Check Points For Every 1 Or 2 Months39

Check Points For Every Year40

Battery Specific Gravity40

Replacement Of Air Cleaner Element40

Check Points For Every 800 Hours41

Check Points For Every 1500 Hours42

Nozzle Fume Condition42

Fuel Injection Pressure42

Valve Seat Tightness43

Nozzle Holder44

Check Points For Every 3000 Hours45

Check Of Injection Pump46

Check Points For Every 2 Years48

Replacement Of Intake Air Line48

Replacement Of Battery48

Replacement Of Radiator Hoses And Clamp Bands48

Change Of Radiator Coolant (L.l.c.)50

Special Tools52

Diesel Engine Compression Tester52

Oil Pressure Tester52

Injection Pump Pressure Tester53

Valve Guide Replacing Tool54

Bushing Replacing Tools54

Flywheel Stopper54

Crankshaft Bearing 1 Replacing Tool55

Socket Wrench For Crank Pulley Nut55

Auxiliary Socket For Fixing Crankshaft Sleeve56

Balancer Metal Replacing Tool (For Removing)58

Balancer Metal Replacing Tool (For Fitting)59

Idle Gear 2 Puller60

Built-In Dynamic Balancer (Balancer Model Only)64

Half-Floating Head Cover65

Cooling System66

Bottom Bypass System66

Smoke Detector Device (Srd)67

Turbocharger System69

Boost Compensator69

Troubleshooting71

Engine Body Troubles71

Electronic Governor Troubles78

Blinking Pattern Of Glow Lamp79

Servicing Specifications80

Tightening Torques Of Screws, Bolts And Nuts For General Use90

Tightening Torques Of The Screws, Bolts And Nuts For Special Use91

Checking, Disassembling And Servicing92

Engine Body Checking And Adjustment92

Compression Pressure92

Checking And Adjusting92

Valve Clearance94

Lubricating System Checking And Adjustment95

Engine Oil Pressure95

Cooling System Checking And Adjustment95

Fan Belt Tension95

Radiator Cap Air Leakage96

Radiator Water Leakage96

Opening-Temperature Of Thermostat Valve97

Fuel System Checking And Adjustment98

Injection Timing98

Fuel Tightness Of Pump Element101

Fuel Tightness Of Delivery Valve102

Electrical System Checking And Adjustment106

Battery Voltage106

Magnetic Switch Test108

Magnetic Switch Continuity Test108

Alternator-On Unit Test109

Glow Plug Lead Terminal Voltage109

Glow Plug Continuity109

Turbocharger Checking And Adjustment110

Engine Stop Solenoid110

Turbine Side110

Radial Clearance110

Electronic Governor Checking And Adjustment111

Speed Sensor111

Water Temperature Sensor111

Oil Pressure Switch112

Glow Plug Harness114

Speed Switch114

Emergency Stop Switch115

Slow Down Switch115

Disassembly And Assembly116

Draining Engine Oil And Coolant116

External Components117

Air Cleaner, Muffler And Others117

Turbocharger117

Cylinder Head And Valves118

Injection Pipes118

Nozzle Holder Assembly And Glow Plug119

Service Procedure Of Nozzle Heat Seal120

Rocker Arm And Push Rod120

Cylinder Head121

Thermostat Assembly123

Water Pump Assembly123

Gear Case And Timing Gears124

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 Plate127

Fan Drive Pulley129

Idle Gear 2 And Hydraulic Pump Base Assembly (For Side Pto Model)130

Crankshaft Oil Slinger131

Camshaft And Balancer Shaft (For Balancer Model)132

Fuel Camshaft And Fork Lever Assembly133

Piston And Connecting Rod134

Oil Pan And Oil Strainer134

Piston Ring And Connecting Rod137

Flywheel And Crankshaft139

Bearing Case Cover139

Main Bearing Case Assembly141

Cylinder Head And Valves Servicing144

Top Clearance144

Cylinder Head Surface Flatness145

Cylinder Head Flaw145

Valve Recessing146

Clearance Between Valve Stem And Valve Guide147

Replacement Of Valve Guide147

Valve Seating148

Correction Of Valve And Valve Seat149

Valve Lapping150

Free Length And Tilt Of Valve Spring150

Setting Load Of Valve Spring150

Oil Clearance Between Rocker Arm And Rocker Arm Shaft151

Push Rod Bend151

Oil Clearance Between Tappet And Tappet Guide Bore151

Timing Gears Servicing152

Timing Gear Backlash152

Side Clearance Of Idle Gear153

Side Clearance Of Camshaft153

Camshaft Bend153

Oil Clearance Of Camshaft Journal155

Oil Clearance Between Idle Gear Shaft And Idle Gear Bushing156

Replacement Of Idle Gear Bushing156

Side Clearance Of Balancer Shaft (For Balancer Model Only)156

Balancer Shaft Bend (For Balancer Model Only)156

Oil Clearance Of Balancer Shaft Journal157

Piston And Connecting Rod Servicing158

Piston Pin Bore I.d.158

Oil Clearance Between Piston Pin And Small End Bushing158

Replacement Of Small End Bushing158

Connecting Rod Alignment159

Piston Ring Gap160

Clearance Between Piston Ring And Groove161

Crankshaft Servicing162

Side Clearance Of Crankshaft162

Crankshaft Bend162

Oil Clearance Between Crankpin And Crankpin Bearing163

Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 1164

Replacement Of Crankshaft Bearing 1164

Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 2165

Replacement Of Crankshaft Sleeve166

Cylinder Servicing167

Cylinder Wear167

Cylinder Correction (Oversize)168

Oil Pump Servicing169

Rotor Lobe Clearance169

Clearance Between Rotor And Cover169

Starter Servicing169

Commutator And Mica170

Brush Holder171

Armature Coil172

Alternator Servicing172

Ic Regulator174

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