Nanni N4.40 Instruction manual

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

TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the 03-M-E3B, the 03-M-DI-E3B and the 03-M-E3BG series. It contains 4 parts:
"Information", "General", "Mechanism" and "Servicing".
Information
This section contains information below.
• Safety First
• Specification
• Dimensions
• Wiring Diagram
General
This section contains information below.
• Engine Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
Mechanism
This section contains information on the structure and the function 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 manual does not include.
Servicing
This section contains information below.
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.
January, 2009
© KUBOTA Corporation 2009
KiSC issued 06, 2009 A

I INFORMATION
KiSC issued 06, 2009 A

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

INFORMATION
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
I-1
1. SAFETY FIRST
M00000003INI0001US1
BEFORE YOU START SERVICE
• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a stable and level ground.
• Let the temperature of the engine decrease before
you start a job.
• Stop the engine, then remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE" tag in the operator
station.
M00000003INI0002US1
START SAFELY
• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch
• Do not make unauthorized modifications to the
engine. This 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 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.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
KiSC issued 06, 2009 A

INFORMATION
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
I-2
OPERATE SAFELY
• Do not use the machine after you consume alcohol
or medication or when you are tired.
• Put on applicable clothing and safety equipment.
• Use applicable tools only. Do not use alternative
tools or parts.
• When 2 or more persons do servicing, make sure
that you do it safely.
• Do not touch the hot parts or parts that turn when the
engine operates.
• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.
• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten 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 repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.
• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.
• Be careful about electric shock. The engine
generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.
M00000003INI0004US1
PREVENT A FIRE
• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.
• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.
• Make sure that you do not spill fuel on the engine.
M00000003INI0005US1
KiSC issued 06, 2009 A

INFORMATION
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
I-3
KEEP A GOOD AIRFLOW IN THE WORK AREA
• If the engine is in operation, make sure that the area
has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.
M00000003INI0006US1
DISCARD FLUIDS CORRECTLY
• Do not discard fluids on the ground, down the drain,
into a stream, pond, or lake. Obey related
environmental protection 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 battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.
M00000003INI0008US1
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher ready at all
times.
• Keep the emergency contact telephone numbers
near your telephone at all times.
M00000003INI0009US1
KiSC issued 06, 2009 A

19/02/2009
Fiche N4.40GB
TECHNICAL DATA
ENGINE MODEL N4.40
(Since serial number: KTF08040093)
ENGINE SPECIFICATIONS
Number of cylinders: 4
Displacement: 1999 cc
Bore - Stroke: 83 X 92.4 mm
Compression ratio: 23/1
Max. pres. difference between cyl. : 10%
Compression pressure: 36 to 38 bars
Maximum speed without load: 3050 rpm
Maximum speed in load: 2800 rpm
Idle speed in forward gear: 850 rpm
Firing order: 1 - 3 - 4 - 2
Rotation: Anti clockwise (Flywheel)
INJECTION
Combustion chamber: E-TCVS
Type of injector: BOSCH JET
Fuel injection pressure: 140 to 150 Mpa
Injection pump manufacturer:
BOSCH Mini
Injection timing: 18° before TDC
TIGHTENING TORQUE
Arm head cover cap nuts: 6.9 to 8.8 Nm
Cylinder 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 bearing caps bolts: 68 to 73 Nm
Nozzle holder assembly: 50 Nm to 68 Nm
Glow Plug : 22 Nm
LUBRIFICATION
Oil pressure at idle RPM: 1 bar
Oil pressure at maximum load: 3 to 4.5 b
Recommended oil: 15W 40API CD
Oil pan capacity: 9.5 litres
Gearbox model:
Oil capacity: depending on type
Recommended oil:
DIAGRAMS
Valve clearance (cold):
Inlet: 0.18 to 0.22 mm
Exhaust: 0.18 to 0.22 mm
Valve recessing: + 0.05 to - 0.15 mm
PISTON RINGS
Piston ring gap:
Piston top compression: 0.20 to 0.35 mm
Intermediate: 0.30 to 0.45 mm
Oil control: 0.25 to 0.45 mm
Limit: 1.25mm
CYLINDER HEAD
Cylinder head surface flatness: 0.05 mm
SEA WATER PUMP
Water flow: 33 litres per minutes
GLOW PLUGS
Resistance : 0.8 ohms

G GENERAL
KiSC issued 06, 2009 A

CONTENTS
1. ENGINE IDENTIFICATION .......................................................................................................... G-1
[1] MODEL NAME AND ENGINE SERIAL NUMBER.................................................................. G-1
[2] E3B ENGINE .......................................................................................................................... G-3
[3] CYLINDER NUMBER............................................................................................................. G-3
2. GENERAL PRECAUTIONS.......................................................................................................... G-4
3. MAINTENANCE CHECK LIST ..................................................................................................... G-5
4. CHECK AND MAINTENANCE ..................................................................................................... G-8
[1] DAILY CHECK POINTS ......................................................................................................... G-8
[2] CHECK POINTS FOR THE INITIAL 50 HOURS.................................................................. G-10
[3] CHECK POINTS FOR EVERY 50 HOURS .......................................................................... 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 HOURS........................................................................ G-22
[9] CHECK POINTS FOR EVERY 1 OR 2 MONTHS ................................................................ G-24
[10]CHECK POINTS FOR EVERY YEAR .................................................................................. G-25
[11]CHECK POINTS FOR EVERY 800 HOURS ........................................................................ G-26
[12]CHECK POINTS FOR EVERY 1500 HOURS ...................................................................... G-27
[13]CHECK POINTS FOR EVERY 3000 HOURS ...................................................................... G-30
[14]CHECK POINTS FOR EVERY 2 YEARS............................................................................. G-33
5. SPECIAL TOOLS ....................................................................................................................... G-37
GENERAL
KiSC issued 06, 2009 A

GENERAL
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
G-1
1. ENGINE IDENTIFICATION
[1] MODEL NAME AND ENGINE SERIAL NUMBER
You must identify the engine model name and serial number
before you start a job.
When you get in touch with the manufacturer, always tell your
engine model name and serial number.
The 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)
Alphabet or
Number Year Alphabet or Number Year
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model Name and Serial
Number
KiSC issued 06, 2009 A

GENERAL
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
G-2
(Continued)
Month of manufacture
* Alphabetical letters "I" and "O" are not used.
e.g. D1803
(a)
- 7
(b)
B
(c)
A001
(d)
M00000003GEG0001US1
Month Engine Lot Number
January A0001 ~ A9999 B0001 ~ BZ999
February C0001 ~ C9999 D0001 ~ DZ999
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 ~ S9999 T0001 ~ TZ999
October U0001 ~ U9999 V0001 ~ VZ999
November W0001 ~ W9999 X0001 ~ XZ999
December Y0001 ~ Y9999 Z0001 ~ ZZ999
(a) Engine Model Name : D1803
(b) Year : 7indicates 2007
(c) Month : Aor Bindicates January
(d) Lot Number : (0001 ~ 9999 or A001 ~ Z999)
KiSC issued 06, 2009 A

GENERAL
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
G-3
[2] E3B ENGINE
[Example : Engine Model Name D1803-M-E3B-XXXX or D1803-M-DI-E3B-XXXX]
The emission controls previously implemented in various countries to prevent air pollution will be stepped up as
Nonroad Emission Standards continue to change. The timing or applicable date of the specific Nonroad Emission
regulations depends on the engine output classification.
Over the past several years, Kubota has been supplying diesel engines that comply with regulations in the
respective countries affected by Nonroad Emission regulations. For Kubota Engines, E3B will be the designation that
identifies engine models affected by the next emission phase (See the table below).
When servicing or repairing ###-E3B series engines, use only replacement parts for that specific E3B engine,
designated by the appropriate E3B Kubota Parts List and perform all maintenance services listed in the appropriate
Kubota Operator's Manual or in the appropriate E3B Kubota Workshop Manual. Use of incorrect replacement parts
or replacement parts from other emission level engines (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 engine head cover to identify Output classification and Emission Control Information. E3B engines are
identified with "ET" at the end of the Model designation, on the US EPA label. Please note : E3B is not marked on the
engine.
M00000003GEG0002US1
[3] CYLINDER NUMBER
You can see the cylinder numbers of KUBOTA diesel engine in
the figure. The sequence of cylinder numbers is No.1, No.2, No.3
and No.4 and it starts from the gear case side.
M00000003GEG0003US1
Category (1) Engine output classification EU regulation
K From 19 to less than 37 kW STAGE IIIA
J From 37 to less than 75 kW STAGE IIIA
I From 75 to less than 130 kW STAGE IIIA
Category (2) Engine output classification EPA regulation
ET
Less than 19kW Tier 4
From 19 to less than 56 kW Interim Tier 4
From 56 to less than 75 kW Tier 3
From 75 to less than 130 kW Tier 3
(1) EU regulation engine output classification category
(2) "E3B" engines are identified with "ET" at the end of the Model designation, on
the US EPA label.
"E3B" designates Tier 3 and some Interim Tier 4 / Tier 4 models, depending on
engine output classification.
KiSC issued 06, 2009 A

GENERAL
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
G-4
2. GENERAL PRECAUTIONS
• When you disassemble, carefully put the parts in a clean area
to make it easy to find the parts. You must install the screws,
bolts and nuts in their initial position to prevent the reassembly
errors.
• When it is necessary to use special tools, use KUBOTA special
tools. Refer to the drawings when you make special tools that
you do not use frequently.
• Before you disassemble or repair machine, make sure that you
always disconnect the ground cable from the battery 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-rings when you assemble
again. Apply grease (1) to new O-rings or oil seals before you
assemble.
• When you assemble the external or internal snap rings, make
sure that the sharp edge (3) faces against the direction from
which force (2) is applied.
• Make sure that you try to operate the engine after you repair or
assemble it. Do not try to give a heavy load immediately, if not,
you can cause serious damage to the engine.
M00000003GEG0004US1
(1) Grease
(2) Force
(3) Sharp Edge
(A) External Snap Ring
(B) Internal Snap Ring
KiSC issued 06, 2009 A

GENERAL
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM
G-5
3. MAINTENANCE CHECK LIST
To make sure that the engine operates safely for a long time, refer to the table below to do regular inspections.
[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]
 Change the engine oil and replace the oil filter cartridge after the first 50 hours of operation.
* The items above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA nonroad
emission regulation. As the owner of the engine, you are responsible for the performance of the required maintenance
above.
M00000003GEG0005US1
Item
Service Interval
Every
50
hrs
100
hrs
150
hrs
200
hrs
400
hrs
500
hrs
1 or 2
months 1 year 800 hrs
1500
hrs
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 the element after 6-times
cleanings)

* Cleaning of fuel filter (Element type) 
Check of battery electrolyte level 
Check of fan belt tension and damage 
Replacement of oil
filter cartridge
(1) Oil pan depth
(90 mm, 3.5 in.) 
(2) Oil pan depth
(124 mm, 4.88 in.) 
Check of radiator hoses and clamp bands 
* Check of intake air line 
Replacement of fuel filter cartridge 
Cleaning of water jacket and radiator
interior 
Replacement of fan belt 
Recharge of battery 
* Replacement of air cleaner element 
Check of valve clearance 
* Check of injection nozzle 
* Check of turbocharger 
* Check of injection pump 
* Replacement of intake air line 
Replacement of battery 
Replacement of radiator hoses and clamp
bands 
* Replacement of fuel hoses and clamps 
Change of radiator coolant (L.L.C.) 
KiSC issued 06, 2009 A