Hustler Shibaura S773L N843 N843L Service Manual 109823 0209

SHIBAURA DIESEL ENGINE
MODELS: S773L, N843, N843L

WORKSHOP MANUAL
SUPPORTED BY HUSTLER TURF EQUIPMENT AND EXCEL INDUSTRIES, INC.
109823_2/09 c-2
FOREWORD
This workshop Manual includes repair and adjustment procedures required for the diesel engine models S773L, N843,
and N843L.
When servicing to keep the engine in the best condition, you will find this Manual very useful as a guidebook.
This Workshop Manual was prepared in Jul. 2008. Specifications contained in this Manual are subject to change without
notice for subsequent engineering changes.
t-1 109823 2/09
Table of Contents
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c-2
Section 1: Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Before beginning service or repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Avoid Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Prepare For Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Engine Starting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Prevent Battery Explosions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Avoid Acid Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Avoid High-pressure Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Understand Correct Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
General Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Fuel Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Wear Protective Clothing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Section 2: General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Notes Before Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Fundamental Instructions On Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Engine Sectional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Parts and Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Section 3: Disassembly And Inspection Of Engine. . . . . . . . . . . . . . . . . 3-1
Rocker arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Piston and piston ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Connecting rod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Disassembly, inspection and reassembly of bearing holder . . . . . . . . . . . . . . . . . .3-9
Crankshaft bearing (bushing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Flywheel and ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Cam shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Oil flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Water pump assembly and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Nozzle and holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Section 4: Engine Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Relief valve assembly with O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Crank shaft and bearing holder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Measure the end play of crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Rear plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
109823 2/09 t-2
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Piston and connecting rod assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Suction pipe Suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Oil pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Oil dipstick Dipstick guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Front plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Camshaft assembly Tachometer shaft plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Idle gear Oil pump assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Timing gear case Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Injection pump assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Engine stop solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Cap Push rod Rocker arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Oil pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Water pump assembly Bypass hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Glow plug, Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Section 5: Electrical Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Engine Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Engine Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Alternator (40 amp version) (No. 185046320). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Alternator diagnostic procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Starter Motor (M001T66081) (No. 185086551). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Section 6: Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Section 7: Servicing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
109823 2/09 1-1
SECTION 1: SAFETY
This safety alert symbol is used to call attention to a
message intended to provide a reasonable degree of
PERSONAL SAFETY for operators and other persons
during the normal operation and servicing of this
equipment.
BEFORE BEGINNING SERVICE OR REPAIR
1. Read and understand all instructions and safety
warnings in this manual and on any decals on the
equipment.
2. Make sure engine and work area are clean.
3. Place engine or machine on stable, level work
area and/or use an approved engine stand.
4. Stop engine and remove ignition key.
5. Allow engine to cool before preforming service.
6. Disconnect negative (-) battery cable before pre-
forming service or repair.
DANGERdenotes immediate hazards which WILL
result in severe personal injury or death.
WARNINGdenotes a hazard or unsafe practice which
COULD result in severe personal injury or death.
NOTE:emphasizes general information worthy of
special attention.
All operators and mechanics should read this manual, and
be instructed about safe operating and maintenance
procedures. If the operators or mechanics cannot read
and understand English, it is the owners responsibility to
explain this material to them.
To reduce the potential for injury, comply with these safety
instructions and always pay attention to the safety alert
symbol, which means DANGER or WARNINGpersonal
safety instructions. Failure to comply with the instructions
may result in personal injury or death.
AVOID FIRE HAZARDS
Be prepared if an accident or fire should occur.
Know where the first aid kit and the fire
extinguishers are located and how to use them.
Provide adequate ventilation when charging
batteries.
Do not smoke near battery.
Never check fuel level with an open flame.
Never use an open flame to look for leaks
anywhere on the equipment.
Never use an open flame as light anywhere on or
around the equipment.
When preparing engine for storage, remember
that inhibitor is volatile and therefore dangerous.
Seal and tape openings after adding the inhibitor.
Keep container tightly closed when not in use.
Inspect electrical wiring for worn or frayed
insulation. Install new wiring if wires are damaged.
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguishers available.
Keep emergency numbers for doctor, ambulance
service, hospital, and fire department near the
telephone.
ENGINE STARTING SAFETY
Do not start engine by shorting across starter
terminals.
Unauthorized modifications to the engine may
impair the function and/or safety and affect engine
life.
PREVENT BATTERY EXPLOSIONS
Battery gas can explode. Keep sparks and flames
away from batteries. Use a flashlight to check
battery electrolyte level.
1-2 109823 2/09
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery cable first
and replace it last.
AVOID ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in clothing
and cause blindness if splashed in eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripped electrolyte.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10-15 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs or veg-
etable oil.
3. Get medical attention immediately.
AVOID HIGH-PRESSURE FLUIDS
Escaping fluid (fuel or hydraulic oil) under
pressure can penetrate skin causing serious
injury. Hydraulic oil may cause infection in a minor
cut or opening in the skin. If exposed to hydraulic
fluid, see a doctor at once.
Before applying pressure to fuel or hydraulic
system, make sure all connections are tight and
all hoses and lines are in good condition. To find a
leak under pressure, use a piece of cardboard or
woodnever use your hands. Relieve all
pressure in the system before disconnecting or
working on hydraulic lines. To relieve pressure,
lower all attachments and shut off engine.
UNDERSTAND CORRECT SERVICE
Be sure you understand a service procedure
before you work on the machine.
Unauthorized modifications to the machine may
impair the function and/or safety and affect
machine life.
If it is necessary to make checks with the engine
running, always use two people - with the
operator at the controls, able to see the person
doing the checking. Use extra safety precautions.
Use caution when running engines to avoid
moving and hot parts.
Use the correct tool for the work. Do not use
makeshift tools or substitute parts.
GENERAL MAINTENANCE PRECAUTIONS
Do not perform work or service while under the
influence of alcohol, medication, or other
substances, or when fatigued.
Never run the engine in an enclosed area unless
exhaust is vented to the outside. Exhaust gases
contain carbon monoxide which is odorless and
deadly poison.
Never remove radiator cap while the engine is
running. Allow engine to cool and remove cap
slowly to relieve pressure.
Never attempt to make any adjustments or repairs
to the tractor drive system, mower deck or any
109823 2/09 1-3
attachment while the tractor engine is running or
deck clutch is engaged.
Repairs or maintenance requiring engine power
should be performed by trained personnel only.
Never work under the machine or attachment
unless it is safely supported with stands, blocks or
a hoist.
Always transport machine in a safe manner.
FUEL HANDLING
Fuel is extremely flammable and explosive under
certain conditions Do not smoke while you fill the
fuel tank, service fuel system or handle highly
flammable material.
Do not remove fuel cap or add fuel to tank when
engine is hot or running. Allow engine to cool for
several minutes.
Do not use open pans of gasoline or diesel fuel
for cleaning parts. Use good commercial,
nonflammable solvents.
Never refuel tractor while engine is running; never
refuel near an open flame or near devices which
can create a spark. Refuel outdoors preferably or
in well ventilated areas.
Immediately clean up any spilled fuel.
dispose of all fluids properly, and in an
environmently correct maner.
WEAR PROTECTIVE CLOTHING
Wear fairly tight fitting clothing and safety
equipment.
Always wear adequate eye protection when
servicing the hydraulic system and battery, or
when grinding mower blades and removing
accumulated debris.
Prolonged exposure to loud noise can cause
impairment or loss of hearing. Always wear
adequate ear protection, such as earplugs, when
operating this equipment as prolonged exposure
to uncomfortable or loud noises can cause
impairment or loss of hearing. Do not wear radios
or music headphones while operating the
machinery. Safe operation requires your full
attention.
1-4 109823 2/09
109823 2/09 2-1
SECTION 2: GENERAL
General Notes Before Service
1. Clean the exterior of the engine, drain oil, fuel and cooling water as necessary before disas-
sembly.
2. Keep the service shop clean, free from dust, and with adequate lighting.
3. Remove oil and grease from disassembled parts, and place them in groups on a clean table.
4. Be safety conscience; check equipment, tools and wear appropriate clothing.
5. Measurements are in the following format:
Fundamental Instructions On Service
1. Keep the engine clean, disassemble only those components that need to be disassembled.
The engine is built to close tolerances and clearances.
2. Retain replaced parts for the customer.
3. Always use machine model, serial number, part number and parts name when ordering ser-
vice parts.
4. Prelube all moving parts during reassembly.
5. Tighten bolts and nuts to specified torque with proper tools, unless otherwise instructed.
Type of measurement Units
Length in(mm)
Torque lbfft(Nm){kgfm}
Weight oz(g)
Temperature F(C)
Pressure
PSI(MPa){kgf/cm
2
}
2-2 109823 2/09
Torque Specifications
Bolt
Size
Grade No. Coarse Thread Fine Thread
Pitch
(mm)
Tightening torque Pitch
(mm)
Tightening torque
lbfft Nm lbfft Nm
M5 4T, 4.8 0.8 18.6-35.4 inlb
f
2.8-4.0 ----- -----
7T, 8T, 8.8 43.4-61.1 inlb
f
4.9-6.9
10T, 11T 59.3-83.2 inlb
f
6.7-9.4
M6 4T, 4.8 1.0 43.4-61.1 inlb
f
4.9-6.9
7T, 8T, 8.8 73.5-100.0 inlb
f
8.3-11.3
10T, 11T 106.2-141.6 inlb
f
12-16
M8 4T, 4.8 1.25 115.1-150.5 inlb
f
13-17 1.0 11.1-14.8 15-20
7T, 8T, 8.8 17.0-20.7 23-28 19.2-25.1 26-34
10T, 11T 20.7-26.6 28-36 22.1-29.5 30-40
M10 4T, 4.8 1.5 18.4-24.3 25-33 1.25 20.7-26.6 28-36
7T, 8T, 8.8 32.5-41.3 44-56 36.1-46.5 49-63
10T, 11T 39.8-51.6 54-70 42.8-54.6 58-74
M12 4T, 4.8 1.75 27.3-34.7 37-47 1.25 31.7-40.6 43-55
7T, 8T, 8.8 48.7-61.2 66-83 55.3-69.3 75-94
10T, 11T 67.9-85.6 92-116 73.0-93.7 99-127
M14 4T, 4.8 2.0 46.5-59.0 63-80 1.5 51.6-64.2 70-87
7T, 8T, 8.8 76.7-97.4 104-132 86.3-109.2 117-148
10T, 11T 102.5-129.1 139-175 109.9-135.7 149-184
M16 4T, 4.8 2.0 63.4-81.1 86-110 1.5 67.1-84.1 91-114
7T, 8T, 8.8 109.9-136.4 149-185 115.8-141.6 157-192
10T, 11T 151.2-188.1 205-255 163.0-198.4 221-269
M18 4T, 4.8 2.0 83.3-104.0-5.1 113-141 1.5 97.4-119.5 132-162
7T, 8T, 8.8 144.6-174.1 196-236 170.4-205.8 231-279
10T, 11T 202.8-245.6 275-333 219.8-270.7 298-367
M20 4T, 4.8 2.5 106.2-132.8 144-180 1.5 126.9-154.9 172-210
7T, 8T, 8.8 177.0-213.9 240-290 202.8-245.6 275-333
10T, 11T 267.7-325.3 363-441
109823 2/09 2-3
Engine Sectional Drawing
2-4 109823 2/09
Specifications
Notes: 1. The specifications above are subject to change without notice.
Items Specifications
Engine model S773L N843 N843L
Engine type 4-cycle water cooled in-line
overhead valve
4-cycle water cooled in-line
overhead valve
4-cycle water cooled in-line
overhead valve
No. of cylinders-bore
stroke in(mm)
3-3.031(77) 3.189(81) 3 - 3.307(84) x 3.54(90) 3 - 3.307(84) x 3.94(100)
Piston displacement cc 1131 1496 1662
Compression ratio 23.5 to 1 22.5 to 1 22.5 to 1
Combustion chamber type Special swirl chamber Special swirl chamber Special swirl chamber
*Rated output (Gross)
HP(kW)/rpm
25(18.3)/2800 30(22.6)/2800 34(25.1)/2800
Fuel used SAE No.2D, DIN 51601,
BS class A-1
SAE No.2D, DIN 51601,
BS class A-1
SAE No.2D, DIN 51601,
BS class A-1
Injection pump Bosch, PFR type Bosch, PFR type Bosch, PFR type
Injection nozzle Throttle type Throttle type Throttle type
Injection governor Centrifugal allspeed con-
trol
Centrifugal allspeed con-
trol
Centrifugal allspeed con-
trol
*Alternator, voltage. Output 12V40A 12V40A 12V40A
*Starter, Voltage. Output 12V1.2kW 12V2.0kW 12V2.0kW
Lubrication method Pressurized circulation by
trochoid pump
Pressurized circulation by
trochoid pump
Pressurized circulation by
trochoid pump
Engine oil used API grade CD API grade CD API grade CD
*Lubrication oil volume
US Qts(L)
5.2(4.9) 6.3(6) 6.3(6)
Cooling water volume
(Engine only) US Qts(L)
2.0(1.9) 2.9(2.7) 3.0(2.8)
*Engine dry weight lbs(Kg) 207(94) 331(150) 353(160)
Engine
dimen-
sions
*Overall length
in(mm)
19.69(500) 21.0(534) 21.0(534)
*Overall width
in(mm)
15.28(388) 18.1(459) 18.1(459)
*Overall height
in(mm)
23.31(592) 25.9(657) 27.1(689)
Air cleaner Dry type
109823 2/09 2-5
Engine Removal
Note: Asterisks (*). Items may vary depending on
the type of equipment in which the engine
is Installed.
1. If necessary, remove engine cover or
hood.
2. Remove the muffler and mounting
brackets from the engine.
3. Disconnect the wiring from the air
cleaner clogging sensor if so equipped.
4. Disconnect the wiring from the water
temperature sensor and water tempera-
ture switch.
5. Remove the radiator hoses from the
engine.
6. Disconnect the wiring from the alterna-
tor.
7. Disconnect the wiring from the starting
motor.
8. Remove the ground wire and bolt from
the cylinder head.
9. Disconnect the fuel return hose from
the fuel return line.
10. Disconnect the wiring from the engine
oil pressure switch.
11. Disconnect the wiring from the glow
plug connector.
12. Disconnect the wiring from the engine
stop solenoid.
13. Disconnect the fuel line from the injec-
tion pump.
14. Remove the throttle cable from the
engine
15. Disconnect the drain hose from the
drain cock.
16. Disconnect the oil hoses from the
hydraulic oil pump.
17. Remove the engine mounting hardware
and hoist the engine from the frame.
Fig. 2-1
1. Water temperature switch
2. Water temperature sensor
3. Radiator hose
4. Alternator
5. Starting motor
Fig. 2-2
1. Air cleaner clogging
sensor
2. Ground wire
3. Glow plug connector
4. Fuel return hose
Fig. 2-3
1. Engine stop solenoid
2. Throttle cable
3. Fuel hose
4. Hydraulic oil pump
5. Engine mounting
hardware
6. Drain cock
3
2
1
4
5
4
3
1 2
3
1
2
4
6
5
109823 2/09 2-6
Parts and Descriptions
Index Description
1 Alternator
2 Oil filter
3 Relief valve
4 Oil level gaugeGauge guide
5 Engine stop solenoidSeal washer
6 Fuel injection lines
7 Injection pump assembly and shim
Note:
1. Remove the injection fuel lines and engine stop solenoid before remov-
ing the injection pump.
2. Raise the injection pump and disconnect the governor link from the
control rack by removing the snap pin.
3. Injection timing is set by the shims between injection pump and block.
Note thickness and number when removing the injection pump.
4. Visually inspect the shim to determine if it is reusable or needs to be
replaced
5
1
2
4
3
6
7
109823 2/09 2-7
Index Description
8 Fuel return line
9 Injection nozzleGasket
10 Oil transfer pipeEye bolt Seal washer
11 ConnectorGlow plug
12 Oil pressure switch
13 Thermostat housingGasket
14 Valve coverO-ringIntake manifoldSpacer
15 Rocker arm assemblyO-ringCap
NOTE: Remove the caps from intake valves and exhaust valves.
16 Push rod
17 Cylinder head assemblyHead gasket
NOTE: Loosen the cylinder head bolts in several steps and remove the cylinder head
assembly.
18 Tappet
9
8
13
10
11
17
16
18
15
12
14
14
15
109823 2/09 2-8
Index Description
20 V-beltCooling fanFan holderFan pulley
21 Water pump assemblyGasket
22 Crankshaft pulley and nut
23 Not available
24 Timing gear case assemblyGasket
Note: Remove the engine stop solenoid and injection pump assembly first.
25 Idle gearOil pump assembly
26 Cam shaft assemblyPlate
Note: Remove the bolts and plate before pulling the camshaft assembly.
27 Front plateGasket
20
21
20
22
23
24
25
26
27
109823 2/09 2-9
Index Description
28 Oil panGasketSuction filterSuction pipe
29 Fly wheel
30 Rear plate or Flywheel cover
31 Oil seal
32 Piston and connecting rod assembly
NOTE:
1. Before extracting piston, remove the carbon deposit from the top of the
cylinder.
2. Keep pistons, connecting rods, caps and bearings grouped by cylinder
number and reassemble to their original locations.
33 Crank shaft and bearing holder assembly
Note: Remove the bolts for bearing holders, and remove the crankshaft and bearing
holder assembly as an assembly.
28
29
30
31
33 32
33
2-10 109823 2/09
109823 2/09 3-1
SECTION 3: DISASSEMBLY AND INSPECTION OF ENGINE
Caution: before starting disassembly
1. Check the cylinder block and cylinder head for wear, leakage or damage.
2. Clean oil passages with compressed air and check for clogging.
3. Thoroughly clean parts to remove dust, contaminated oil, carbon, and other foreign mate-
rial.
4. Remove carbon deposits on the piston, cylinder head, valves, etc. being careful not to dam-
age parts. (Especially for aluminum alloy parts.)
5. Valves, pistons, connecting rods, bearings and other parts, should be marked indicating
cylinder number and reassembled to the original cylinder location.
Rocker arm assembly
Disassembly
1. Screw in an M8 bolt at the front end of the rocker arm
shaft and extract the rocker arm shaft.
2. Take out the spring, shim and rocker arm from the
rocker arm bracket.
Inspection and service
1. Using a micrometer, check outside diameter of the
rocker arm shaft. If the shaft is worn beyond the
service limit, replace the part.
2. Measure the inside diameter of the rocker arm.
Check the clearance between the rocker arm and
rocker arm shaft. If the clearance is beyond the
service limit, replace the part.
Wear of rocker arm shaft in(mm)
Standard assembling value Service limit
0.4587-0.4594(11.65-11.67) Less than 0.4555(11.57)
Clearance between rocker arm and rocker arm shaft
in(mm)
0.0013-0.0027(0.0320.068) More than .008(0.2)
Fig. 3-1
1. Screw
2. Rocker arm shaft
3. Rocker arm
4. Spring
5. Shim
3
5
1
2
4
Fig. 3-2
Fig. 3-3
Clearance
3-2 109823 2/09
3. Check the valve cap-contact surface for uneven
wear and streaks. If wear is insignificant, grind flat
with oilstone or grinder, otherwise, replace.
Cylinder head assembly
Disassembly
1. Using a valve spring compressor, compress the
valve spring to remove the valve cotter, retainer,
spring and valve.
2. Remove the valve guide seal.
1. Check for distortion of cylinder head bottom surface
by using a straight edge. Using Fig. 3-5 as a guide,
and a feeler gage, check for distortion at the six
positionsA through F. If distortion exceeds the
repair value, correct using a surface grinder.
2. Valve guide and valve stem
a. Check the head and stem of each valve and
replace if burned, worn, or deformation is
excessive.
b. Measure the outside diameter at positions I, II, and
III on the valve stem with a micrometer and
replace if less than the service limit.
c. Replace a valve if its head thickness is less than
service limit.
Distortion at cylinder head bottom surface in(mm)
Standard assembling value Repair value
Less than 0.0020(0.05) More than 0.0047(0.12)
Wear of valve stem in(mm)
Intake valve Exhaust valve
Standard
assembling
value
Service limit Standard
assembling
value
Service limit
0.274-0.2744
(6.9556.97)
Less than
0.2712(6.89)
0.273-0.274
(6.946.955)
Less than
0.269(6.84)
Valve head thickness in(mm)
0.0305-0.0423(0.7751.075) Less than 0.0197(0.5)
Fig. 3-4
1. Valve guide seal
2. Spring
3. Retainer
4. Valve
5. Valve cotter
1
2
5
3
4
Fig. 3-5
Fig. 3-6
Fig. 3-7
I II III
Stem End
Head End
Thickness
109823 2/09 3-3
d. Replace the valve if the clearance between the
stem and guide exceeds the service limit.
3. Valve seat
a. Since the valve seat is corrected according to the
valve guide, be sure to check the valve guide for
wear condition first before correcting the seat.
b. Correct the seat to the standard assembling values
of the contact width and recess using seat cutters
of 15, 45and 75.
c. When the seat recess exceeds the service limit,
replace the cylinder head.
d. Coat the valve seat surface with compound and
lap the contact surface turning the valve.
e. Check that the valve contact surface is within the
standard value and the contact position is even.
f. When the cylinder head is replaced with a new
head, adjust the seat contact width and seat
recess to the specified values with a seat cutter
before lapping.
Clearance between valve stem and valve guide in(mm)
Intake valve Exhaust valve
Standard
assembling
value
Service limit Standard
assembling
value
Service limit
0.0012-
0.0024
(0.030.06)
More than
0.0079(0.2)
0.0016-
0.0030
(0.04-0.075)
More than
0.0100
(0.25)
Valve seat contact width in(mm)
In 0.059-0.083
(1.50-2.10)
More than
0.098(2.5)
Exhaust 0.063-0.071
(1.59-1.80)
More than
0.098(2.5)
Valve seat recess in(mm)
In,Ex 0.0335-0.0453
(0.851.15)
More than
0.0709(1.8)
Fig. 3-8
Clearance
Fig. 3-9
150
90
30
Contact
Width
Fig. 3-10
Fig. 3-11
Recess
Valve
Lapper
3-4 109823 2/09
4. Valve spring
a. Check the valve spring visually for damage.
b. Measure the squareness of the spring using a
square on a surface plate and replace if the
service limit is exceeded.
c. Check the free length and spring force with a
spring tester and replace if the service limit is
exceeded.
Reassembly
Reassemble components in the reverse order of
disassembly. When assembling the valve spring, retainer
and cotter, be especially careful not to damage the valve
guide seal. Tighten the glow plug to the proper torque5.6-
10.5 lb
f
ft(8-15 Nm) {0.8~1.5 kgfm}.
Cylinder block
1. Check for cracks, damage and distortion on the top
of the block in the same way as the cylinder head.
2. Measurement of cylinder bore
a. There should be no scratches, rust, corrosion, etc.
on the cylinder bore when checked visually.
b. Measure the cylinder bore at the top, center and
bottom respectively in the crankshaft direction (A)
and the direction at right angle to it (B). If the
repair value is exceeded, replace engine with long
block.
Standard
assembling
value
Service limit
Squareness in(mm) 0.047(1.2) More than
0.079(2)
Free length in(mm) 1.38(35) Less than
1.3(33.5)
Spring force (when
compressed to
1.20(30.4) in(mm))
17.9 lb
f
(79.8
N){8.1 kgfp}
Less than
15.4 lb
f
(68.6
N){7 kgf}
Distortion on cylinder block top surface in(mm)
Cylinder bore dia. in(mm)
3.0315-3.0322
(77-77.019)
More than 3.0394(77.2)
Fig. 3-12
Fig. 3-13
Squareness
Free Length
Replace with long block assembly
A B
Front
1
C Ring Sliding Range
109823 2/09 3-5
Piston and piston ring
Disassembly
1. Remove the piston ring using a piston ring tool.
2. Remove the snap ring and extract the piston pin.
Inspection
1. Piston
a. Check the piston for cracks, streaking and burnout
on the outside surface and replace if excessive.
b. Measure the longer diameter at 0.39in.(10 mm)
above the lower end of the piston skirt and bore of
the cylinder in the thrust direction, calculate the
clearance, and replace if the repair value is
exceeded.
c. Measure the piston pin hole diameter and piston
pin outside diameter and replace if the clearance
exceeds the service limit.
Piston skirt bottom longer dia . in(mm)
3.0288-3.0298
(76.9325-76.9575)
Less than
3.0197(76.7)
Clearance between cylinder and piston in(mm)
0.0023-0.0034
(0.05750.0865)
More than
0.0098(0.25)
Clearance between piston pin hole and piston pin
in(mm)
-0.0000~+0.0003
(-0.000~+0.008)
More than
0.0008(0.02)
Fig. 3-14
Fig. 3-15
Snap
Ring
Piston
Pin
1
1
Fig. 3-16
3-6 109823 2/09
2. Piston ring
a. Replace worn out or damaged piston rings, if any.
b. Insert a ring at a right angle to the least worn out
skirt of a cylinder, measure the clearance of ring
end gap with a thickness gauge and replace if the
end gap exceeds the service limit.
c. Measure the clearance between the piston ring
groove and ring and replace if the service limit is
exceeded.
d. Piston kit consisting of piston and piston rings are
available.
e. Piston ring installing procedure: Install the piston
ring to the piston as shown in Fig. 3-18.
3. Piston pin
Measure the outside diameter of the piston pin and replace
if the service limit is exceeded.
Piston ring end gap in(mm)
Standard assembling
value
Service limit
Top ring 0.00790.0138
(0.200.35)
More than
0.0393(1.0)
Second
ring
0.00790.0138
(0.200.35)
More than
0.0393(1.0)
Oil ring 0.00590.0138
(0.150.35)
More than
0.0393(1.0)
Clearance between piston ring groove and ring
in(mm)
Standard assembling
value
Service limit
Top ring 0.0031-0.0047(0.08
0.12)
More than
0.0098(0.25)
Second
ring
0.0020-0.0035(0.05
0.09)
More than
0.0098(0.25)
Oil ring 0.0008-0.0024(0.02
0.06)
More than
0.0059(0.15)
Piston kit
Size Part No.
S773L STD 115017610
N843 STD 115017541
N843L STD 115017491
Piston ring kit
Part No.
S773L 115107240
N843 & N843L 115107960
Fig. 3-17
1. Piston Ring
2. Piston
3. Ring End Gap
3
1
1
Fig. 3-18
Expander joint
(on the opposite side
to ring end gap)
Ring top mark
Piston pin outside dia. in(mm)
Standard assembling
value
Service limit
0.8266-0.8268
(20.996-21.002)
Less than 0.8260(20.98)
109823 2/09 3-7
Connecting rod
Inspection
1. Check for torsion, parallelism and damage.
Measure the torsion and parallelism using a connecting rod
aligner and correct or replace if the repair value is
exceeded.
2. Measure the bore of the connecting rod small end
bushing and replace if the clearance to the piston
pin exceeds the service limit.
3. Install the connecting rod to the crankshaft, measure
the axial play and replace the connecting rod if the
Connecting rod bearing
Inspection
1. Check the bearing for peeling, melting, uneven wear,
improper contact or other damage is noticed,
replace the bearing.
2. Measure the oil clearance between the crank pin and
bearing using plasti-gauge.
3. Remove oil, dust or other foreign matter stuck to the
bearing and crank pin.
4. Cut plasti-gauge to a length equal to the bearing
width and place it on the crank pin parallel to the
crankshaft axis, avoiding the oil hole.
5. Install the connecting rod bearing and connecting rod
cap and tighten to the specified torque.
Note: Never turn the connecting rod at this time.
6. Remove the connecting rod cap and measure the
plasti-gauge width with the scale printed on the
gauge envelope.
Note: Measure the widest part of the plasti-gauge.
7. If the oil clearance exceeds the service limit, replace
the bearing.
Torsion and parallelism of connecting rod in(mm)
Standard assem-
bling value
Repair value
Torsion (per
3.93(100)
Less than
0.0031(0.08)
More than
0.0079(0.20)
Parallelism
3.93(100)
Less than
0.0020(0.05)
More than
0.0059(0.15)
Tightening torque 20.3-23.8 lb
f
ft(2934 Nm)
{3.03.5 kgfm}
Fig. 3-19
1. Gauge
2. Piston pin
3. Torsion
4. Flat part of aligner
5. Pin
Clearance between bushing and piston pin in(mm)
Standard assembling
value
Service limit
0.00031-0.00010
(0.0080.025)
More than 0.0031(0.08)
Axial play of connecting rod and crank pin in(mm)
Standard assembling
value
Service limit
0.0039-0.0118
(0.10.3)
More than 0.028(0.7)
5
1
3
4
4 2
1
2
Clearance between crank pin and connecting rod bear-
ing (Oil clearance) in(mm)
Standard assembling
value
Service limit
0.0014-0.0033
(0.0350.085)
0.079(0.2)
Set a plasti-gauge Measure the oil clear-
ance
Fig. 3-20 Fig. 3-21
Plasti-gauge
Plasti-gauge
3-8 109823 2/09
Reassembly (piston and connecting rod)
1. Heat the piston to about 212F(100C) with a piston
heater or equivalent and install it aligning the
SHIBAURA mark in the piston and match mark at
(A) of the connecting rod.
2. Assemble the connecting rod cap such that the
match mark (A) on the cap is oriented to the same
side as the match mark (A) on the connecting rod.
3. When installing piston rings to the piston, the
indicator mark on the end surface of the ring is to be
pointing toward the top of the piston.
4. Install the piston rings to the piston facing the
stamped T mark upward.
5. When the connecting rod or piston and piston pin are
replaced, weight variation among cylinders with the
rod, piston and piston ring installed should be within
0.35 oz. (10 g).
Bearing code No. Crankshaft pin outside dia.
Finishing dimension
in(mm)
198517602 1.6128-1.6132
(40.964-40.975)
Fig. 3-22
Fig. 3-23
Fig. 3-24
A
A
Expander joint
(on the opposite side
to ring end gap)
Ring top mark
109823 2/09 3-9
Disassembly, inspection and reassembly of
bearing holder
Disassembly and inspection
Center bearing
1. Remove the bearing holder, and replace the bearing
if peeling, melting, uneven wear, or improper contact
is noticed.
2. Measure the oil clearance of the crankshaft center
journal and bearing using a plasti-gauge.
3. If the oil clearance exceeds the service limit
according to the result of the measurement, replace
the bearing and/or crank shaft.
Reassembly
Bearing holder, Center bearing
1. Install the bearing holder with identification cutting
mark at the center and the aluminum bearing holder
on the flywheel side, facing the stepped side to the
front side.
2. Install the bearing with oil groove to the upper side
and the one without oil groove to the lower side.
Note: Be sure that the oil holes of the bearing
holder and cylinder block are aligned.
Crankshaft bearing (bushing)
Clearance between crankshaft center journal and
bearing (Oil clearance) in(mm)
0.0012-0.0036
(0.03-0.092)
More than 0.008(0.2)
Bearing
size
Bearing part No. Crankshaft center
journal finishing
dia in(mm)
STD 198517572 (upper)
198517582 (lower)
1.8883-1.8888
(47.964 47.975)
Bearing holder tightening
torque
14-17.5 lb
f
ft(2025 Nm)
{2.02.5 kgfm}
Fig. 3-25
Bearing holder (Upper)
Upper Bearing
(with oil groove)
Oil groove
Upper Bearing
(without oil groove)
Bearing holder (Lower)
Cutting mark
Stepped side
3-10 109823 2/09
Inspection
1. Check the bearing and replace if peeling, melting,
uneven wear, improper contact, or other damage is
noticed.
2. Measure the oil clearance of the bearing and
crankshaft journal using a cylinder gauge and
micrometer.
3. If out of specification, replace the bearing and/or
crankshaft.
NOTE:
1. Measure the dimensions in the A and B
directions at positions 1 and 2 in
Fig. 3-27 avoiding the oil hole in the
bearing. Calculate the difference
between that measurement and the
maximum diameter of the crankshaft
journal (oil clearance).
2. When replacing the bushing, push it up
using a press or similar method. At this
time, align the oil holes and push it up
until the bushing end surface becomes
flush with the outside machined surface
of the cylinder block (see the arrow
mark in the figure at right).
3. If the crankshaft journal has been
ground, check the oil clearance before
reinstalling it.
Crankshaft
Clearance between crankshaft journal and bearing
(Oil clearance) in(mm)
0.0015-0.0042
(0.039-0.106)
More than
0.008(0.2)
Bearing
size
Bearing part
No.
Crankshaft journal
outside dia. Finish-
ing dimension
in(mm)
STD. 198517592 1.8883-1.8888
(47.964-47.975)
Fig. 3-26
Fig. 3-27
1 2
A
B
109823 2/09 3-11
Inspection
1. To measure run-out of the crankshaft, support the
crankshaft using a V block as shown inFig. 3-28.
Using a dial indicator as shown, measure the run-out
of the center to the crankshaft center journal, by
slowly rotating the shaft through one revolution. If
the service limit is exceeded, correct or replace.
2. Check the crankshaft oil seal for damage or wear on
the contact surface and oil hole for clogging.
3. Check the crankshaft journal and pin for damage,
irregular wear (ellipticity, conicalness), and shaft
diameter. If service limit is exceeded replace the
bearing (bushing) and/or crankshaft. Measure the
dimensions of the journal and pin in the AA and BB
directions at positions 1 and 2 (Fig. 3-29) avoiding
the oil holes.
Flywheel and ring gear
Irregular wear limit of crankshaft journal and
pin in(mm)
More than 0.0020(0.05)
Shaft dia. At crankshaft journal in(mm)
Size Outside dia. Fin-
ished dimension
Repair value
STD. 1.8883-1.8888
(47.964-47.975)
Less than
1.886(47.9)
Shaft dia. At crankshaft pin in(mm)
Size Outside dia. Fin-
ished dimension
Repair value
STD. 1.6128-1.6132
(40.964-40.975)
Less than
1.6102(40.90)
Crankshaft run-out in(mm)
Standard assembling
value
Service limit
Fig. 3-28
Fig. 3-29
A
B
A
B
2 1
2 1
Pin
Journal
3-12 109823 2/09
Inspection
Check the ring gear and replace if damaged or excessive
wear is noticed.
When the wear is limited to a small area, remove the, ring
gear, turn it about 90 degrees and shrinkage-fit to reuse it.
To shrinkage-fit the ring gear, heat it to 248-302F(120
150C) to allow it to expand.
Cam shaft assembly
Inspection
1. Check the journal and cam for wear and damage
and replace if the service limit is exceeded.
2. Correct insignificant uneven wear or scars on the
cam surface using oil stone or equivalent.
Timing gear
Inspection
1. If pitting or excessive wear is observed on the tooth
face of gears, replace the gear.
2. Measure the backlash of gears and replace if the
A. Height of intake/exhaust valve cams in(mm)
Standard assembling
value
Service limit
1.0459-1.0480
(26.565-26.62)
Less than 1.032(26.2)
B. Height of injection pump cams in(mm)
Standard assembling
value
Service limit
1.5701-1.5764
(39.88-40.04)
Less than 1.563(39.7)
Timing gear backlash in(mm)
Standard assembling
value
Service limit
0.0031(0.08) More than 0.0098(0.25)
Fig. 3-30
Fig. 3-31
Fig. 3-32
Fig. 3-33
A
B
A
B
Cam shaft gear
Idler gear
Crankshaft gear
Match mark
Match mark
109823 2/09 3-13
Oil flow
Fig. 3-34
1. Suction filter
2. Oil pump
3. Relief valve
4. Oil filter
5. Oil Pressure switch
1
2
3
4
5
3-14 109823 2/09
Oil pump
Disassembly
Removal from engine
1. Remove the snap ring.
2. Remove the collar, spring and shim.
3. Remove the idle gear, vane, and oil pump cover
together.
4. Extract the rotor and thrust washer.
5. Extract the oil pump cover from the idle gear.
Inspection and reassembly
1. Check the oil pump cover, rotor and vane and
replace if worn out or excessively damaged.
2. Check the clearance between the rotor and vane and
replace if the service limit 0.0098 in(0.25 mm) is
exceeded.
3. Reassemble in the reverse order of disassembly.
a. Install the crankshaft gear and idle gear aligning
the match mark.
b. Adjust the side clearance of the rotor and vane to
0.0039-0.0059 in(0.10.15 mm). (See Fig. 3-36)
Oil filter
Structure and Functions
1. The oil filter is a full flow cartridge type.
2. When (if) the filter is clogged the safety valve opens
and allows oil to flow, preventing seizures and other
engine related problems.
3. Oil, fed under pressure from the oil pump, enters at
point (A), is filtered by the element, and supplied to
the lubrication system from point (B). When the
element is clogged, the oil bypasses the filter
element.
Replacement
1. Replace the oil filter after first 50 hours and every
100 hours of operation thereafter.
2. Coat the filter mounting surface with oil and tighten
the filter by hand.
3. For engines with remote mounted oil filters, fill filter
with oil prior to installation.
4. Do not reuse the filter.
Fig. 3-35
1. Collar
2. Shim
3. Rotor
4. Thrust washer
5. Idle gear assembly
6. Oil pump cover
7. Spring
8. Snap ring
Fig. 3-36
Fig. 3-37
1
2
3
6
5
8
4
7
Clearance
A
B
Safety
Valve
109823 2/09 3-15
Water pump assembly and thermostat
1. Remove the set plate and gasket.
2. Inspect the water pump and replace if cracked, worn,
or damaged.
Note: The pump main body is aluminum die cast
and should be replaced as an assembly if
there are leaks or other problems.
Specification and inspection
Thermostat
1. Replace if the valve is opened slightly at room
temperature.
2. Immerse the thermostat in water, increase the water
temperature gradually and check the valve opening
temperature and valve lift. (See Fig. 3-38)
Note: 3 to 5 minutes are required for the valve to
open.
Reassembly
Reassemble the components in the reverse order of
disassembly.
Radiator
Inspection
1. Check the radiator, hose, and reservoir tank for
water leakage. Repair any damage found.
2. Check the radiator fins and remove dust, mud, or
other foreign material clogging the air passage.
3. Check the pressure valve and negative pressure
valve of the radiator cap for valve opening pressure
and sealing condition. Replace if defective.
4. Check the radiator hose and replace if damaged or
aged.
5. If the screen is clogged, remove and clean.
6. The cooling water level in the reserve tank should be
always between FULL and LOW.
Type Wax pellet
Opening temperature 163.4-170.6F
(73- 77C)
Full-opening temperature 188.6F(87C)
Valve lift 0.24 in.(6.0 mm)
Fig. 3-38
Fig. 3-39
3-16 109823 2/09
Fuel filter
Note: N843 and N843L engines (used in the
Hustler 3500 and 3700) have an electric
fuel pump.
Fuel flow
The fuel flows as shown in Fig. 3-40, from the tank,
pressurized by the injection pump to high pressure, and fed
to the nozzle and injected to the combustion chamber.
The fuel, after lubricating the nozzle needle, is returned to
the tank through the overflow pipe.
Note: S773L engine (used in the Hustler Diesel Z)
has a marine type squeeze ball located
between tank and Mechanical pump.
Squeeze ball us used for fuel priming
purposes
Inspection
If water, dust, or other foreign matter is observed in the
sediment bowl, clean and replace the filter if necessary.
Disassembly and reassembly
1. Remove the filter turning by the filter ring nut
counterclockwise.
Note: Be careful not to damage the O-ring between the ring nut and main body, coat with grease before
tightening.
2. Coat the area of the element to be mounted to the main body with grease and install the element by hand.
Governor
Structure and functions
1. Governor:
This governor is a mechanical all-speed governor. It is
installed in the gear case. The flyweight assembly is
installed to the camshaft and its movement is transmitted to
the control rack of the injection pump through the slider
control lever link. The spring which controls the movement
of the flyweight is connected to the arm COMPL and
tension lever. The spring tension is changed by changing
the governor lever to control the engine speed.
2. Maximum speed set bolt:
A bolt is mounted on the cylinder block. This bolt limits the
movement of the arm COMPL (unloaded maximum rpm).
This bolt has been adjusted and sealed at the factory.
3. Smoke set, start spring:
These are built into the cylinder block to regulate the fuel
injection amount at high-speed range. Regulation of the
fuel injection amount at middle speed range is made with a
torque control spring to obtain higher torque.
A start spring is placed between the gear case and link.
This spring automatically functions to increase the amount
of fuel injected when the engine is started. The smoke set
has been adjusted at the factory.
Injection pump
Disassembly, Inspection and Reassembly
Disassembly, inspection, and reassembly of injection
pump:
Note: Service of fuel injection pump is to be done
Fig. 3-40
1. Fuel Tank
2. Mechanical fuel pump
3. Nozzle and holder
4. Fuel filter
5. Injection pump
4 1
5
2
3
Fig. 3-41
Link
Tension lever
Start Spring
Arm COMPL
109823 2/09 3-17
by authorized service personnel, only. Any service done by unauthorized personnel, will void the
injection pump warranty.
Note: No service parts are available for the fuel injection pump.
Trouble-shooting
Nozzle and holder
Specifications
Structure and functions
The nozzle is a precision assembly used to inject the fuel, which is fed from the injection pump under pressure, to the
combustion chamber. It consists of the components as shown in Fig. 3-42 on page 3-18. The fuel is fed under pressure,
from the oil hole of the nozzle holder main body to the nozzle body. When the pressure exceeds the specified value, the
spring is compressed opening the valve, allowing the fuel to be injected into the combustion chamber. At the same time,
the fuel lubricates and cools the nozzle and nozzle body. Excess fuel is returned to the tank by the return line.
Symptom Possible Cause Check or Remedy
1. Engine does not
start.
1. Empty fuel tank or air mixed in fuel.
2. Defective engine stop solenoid.
1. Fill fuel tank, check for air entering
system, bleed air.
2. Check and replace the electric system.
2. Engine starts but
will not stop at
once.
1. Filter or lines clogged.
2. Air mixed in fuel.
3. Fuel tank filter cap air breather clogged.
4. Short-circuit or disconnected wire in
wiring harness to engine stop solenoid.
1. Replace or clean out.
2. Check fuel lines and connections.
3. Wash
4. Inspect and repair.
3. Engine output
unstable
1. Air mixed in fuel.
2. Water mixed in fuel.
1. Check fuel lines and connections.
2. Replace fuel, replace filter.
For additional trouble-shooting, refer to Section 6: Trouble-Shooting
Part No. 131406440 Pintle dia. 0.0394 in(1 mm)
Assembly No. 105148-1210 Valve opening 185.65-1778.16 PSI
(1.2812.26 MPa)
{115125 kgf/cm
2
}
Nozzle holder 105078-0100
Nozzle 105007-1170 (NP-DN4PDN117) Injection angle 4
Needle valve dia. 0.0866 in(2.2 mm) Nozzle type Throttle type
3-18 109823 2/09
1. Place the nozzle holder (body) in a vise and
disassemble turning the nozzle nut.
Note: Be careful not to drop the needle valve
when removing the nozzle.
2. Wash the nozzle and needle valve and check for
seizure and sticking in the nozzle, and fuel leakage
on the seat surface. Correct fuel leakage by lapping
the seat.
3. Check the nozzle spacer for defects; it must seal
against the nozzle body holder and the nozzle body.
4. Check the push rod for wear on the nozzle needle
valve contact surface and check the spring seat for
cracks.
Reassembly and adjustment
1. When assembling a new nozzle assembly, heat light
oil to 122-140F(5060C) and remove the rust
preventative from it for use in a nozzle tester.
2. Slide the needle valve into the nozzle body without
the spring and shims, to ensure that they slide
easily.
3. Invert the nozzle body; place the shim(s), spring,
needle valve, spacer and nozzle on the nozzle body
in this order. Install nozzle nut and tighten.
4. After assembly, check nozzle injection pressure.
a. Adjust by the adjusting shims so that the injection
is started at 1707.1 PSI (11.77 MPa) {120 kgf/cm
2
}
on all models.
b. The pressure increases or decreases about 142.1
PSI (0.98 MPa) {10 kgf/cm2} for shims of 0.00340
in(0.1 mm) thickness.
5. Injection condition
a. Small drops should not be mixed in the spray.
b. The injection pattern should be conical in shape.
c. Place white paper at about 11.8 in.(30 cm) from
the nozzle and confirm that the spray is
approximately circular when injected.
d. Lower the pressure 284.3 PSI (1.96 MPa) {20 kgf/
cm2} from the specified value of 1707.1 PSI (11.77
Mpa) {120 kgf/cm2} and check that the test oil
does not drip from the nozzle end.
Fig. 3-42
1. Nut
2. Nozzle
3. Nozzle body
4. Shim
5. Spring
6. Needle valve
7. Spacer
8. Nozzle nut
Fig. 3-43
1
3
4
}
5
6
7
8
2
1
3
4
5
6
7
Valve Closed
Valve open
fully opened
(main injection)
Fig. 3-44
1. Gasket
2. Nozzle nut; Torque:
21.7-36.2 lb
f
ft (3-5
kgfm)
3. Nozzle
4. Nozzle spacer
5. Needle valve
6. Spring
7. Shim
8. Nozzle body
9. Nut; Torque: 21.7-29.3
lb
f
ft (3-4 kgfm)
1
22
3
4
5
6
7
8
9
109823 2/09 4-1
SECTION 4: ENGINE RE-ASSEMBLY
Caution: before assembling engine;
1. Clean parts to be installed. (Especially oil passages, bearings, pistons, and cylinder bores
carefully.)
2. Coat the sliding and rotating parts of the cylinder bore, piston, bearing and other parts with
new oil before installing.
3. Use new gaskets. If necessary, use gasket sealants to prevent oil leakage.
4. Do not tighten bolts and nuts for aluminum alloy parts excessively. Tighten them to speci-
fied torque.
Relief valve assembly with O-Ring.
Relief valve, torque to:
41.3-48.3 lb
f
ft (5969 Nm) {6.07.0 kgfm}
Crank shaft and bearing holder assembly
Cylinder block to bearing holder torque
Notes: 1. Be careful not to damage the bushing in the
cylinder block by the crankshaft gear when
install the crankshaft and bearing holder
assembly.
2. Install the two hexagon socket head bolts
for the flywheel side bearing holder.
Measure the end play of crankshaft.
Relief valve torque
43.5-50.9 lb
f
ft (59-69 Nm) {6.0-7.0 kgfm}
Bearing holder bolts
A Hexagon socket
head bolt
17.5-20.3 lb
f
ft (2529 Nm)
{2.53.0 kgfm}
B Hexagon bolt 17.5-20.3 lb
f
ft (2529 Nm)
{2.53.0 kgfm}
Crankshaft end play
Standard value 0.004-0.012 (0.10.3)
Service limit More than 0.020(0.5)
Fig. 4-1
B
A
Fig. 4-2
4-2 109823 2/09
Oil seal
Coat the seal lip of the oil seal prior to installing the seal in
the block.
Rear plate
Note: Apply the liquid gasket around the M8
screw holes on the rear plate
Flywheel
Align the hole to the roll pin on the crankshaft.
Rear plate torque:
16.8-20.3 lb
f
ft (2429 Nm) {2.43.0 kgfm}
Fly wheel torque
49.7-54.6 lb
f
ft (7178 Nm) {7.28.0 kgfm}
Fig. 4-3
Roll pin
Liquid packing
Oil seal
Fig. 4-4
Rear Plate
Fig. 4-5
Fly Wheel
109823 2/09 4-3
Piston and connecting rod assembly
1. Coat the metal surface, piston and piston ring with
engine oil.
2. Turn the ring to distribute the oil in the ring groove,
and set the ring end gaps at 90 respectively
avoiding piston pin direction and the direction at a
right angle to the piston pin.
3. Insert the ring facing the connecting rod figure match
mark toward the injection pump side, using ring
pliers.
Note: Place the smallest connecting rod figure
match mark to the front cylinder position
so that the figures increase toward the rear
of the engine.
4. Tighten the connecting rod cap with the specified
torque and check for the axial play.
Notes: 1. After tightening, verify that the crankshaft
moves easily.
2. The connecting rod should move 0.004-.012
in (0.10.3 mm) in the axial direction.
Suction pipe Suction filter
1. Install an O-Ring on the suction pipe and insert the
suction pipe into the cylinder block.
2. Place the suction pipe end into the suction filter and
fasten the suction filter.
Connecting rod torque
20.3-23.8 lb
f
ft (2934 Nm) {3.03.5 kgfm}
Suction filter torque
79.7-115.1 lb
f
in (913 Nm) {0.91.3 kgfm}
Fig. 4-6
Fig. 4-7
Oil
Oil
Injection pump side
Fig. 4-8
Suction pump
Suction filter
4-4 109823 2/09
Oil pan
Start tightening the bolts of the oil pan from the center, then
tighten the opposing bolt on opposite side on the diagonal
and to specified torque. (See Fig. 4-9).
Oil dipstick Dipstick guide
Install the oil level gauge and gauge guide using two O-
Rings.
Front plate
Install the front plate together with the gasket.
Camshaft assembly Tachometer shaft plate
1. Install the tachometer shaft.
2. Install the cam shaft assembly (be careful with the
bearing).
3. Fix the tachometer shaft and cam shaft assembly
with the plate.
Note: When installing the timing gear case, align
the notch in the slider with the guide pin.
Bolt torque
7.4-9.6 lb
f
ft (1013 Nm) {1.01.3kgfm}
Plate torque
79.7-115.1 lb
f
in (913 Nm) {0.9-1.3 kgfm}
Fig. 4-9
Fig. 4-10
14 17 21 19
7
10
12
13
21
20
18
16
23
25
26 1 9 11 15 22 24
8 2 4 6
5
3
Guide pin
Slider
Camshaft
Idler gear
Plate
109823 2/09 4-5
Idle gear Oil pump assembly
1. Install a thrust washer to the idle gear shaft.
2. Install the idle gear assembly.
3. Align the match marks of the idle gear, crankshaft
gear and camshaft gear and install it to the idle gear
shaft.
4. Install the rotor.
5. Install the oil pump cover, shim, spring and collar and
fix with a snap ring.
Notes: 1. Coat both sides of the rotor and vane with
grease before installing them.
2. Do not turn the crankshaft until the timing
gear case is installed.
3. By turning the oil pump cover either
direction, set the spring pin insert hole to
the middle position and fit the gear case.
6. Adjust the shims so that the oil pump, rotor and vane
side clearance is 0.004-0.006 in (0.10.15 mm).
Timing gear case Cover
1. Loosen the lock nut and remove the low idle set bolt.
Install the start spring between the timing gear case
and governor link.
2. Insert the link into the cylinder block hole while
turning the governor lever to clockwise and hold it,
and then install the timing gear case.
3. Reinstall the low idle set bolt and secure the lock nut.
4. Install the covers.
Fig. 4-11
1. Thrust washer
2. Idle gear assy
3. Rotor
4. Oil pump cover
5. Shim
6. Snap ring
Fig. 4-12
1
2
3
4
5
6
Cam shaft gear
Idle gear
Crankshaft gear
Match mark
Match mark
Fig. 4-13
Shims
Idle gear
Fig. 4-14
Governor lever
Lock
Low idle adjusting bolt
A
nut
4-6 109823 2/09
Crankshaft pulley
Install the key into the crankshaft, and install the crankshaft
pulley and tighten with the nut.
Injection pump assembly
1. Install the shim, which was removed during
disassembly, connect the control rack of the injection
pump and link, and install the snap pin.
2. Tighten the injection pump bolts and nuts.
Notes: 1. When shim is not required, use a light
coat of silicone before installing.
2. The injection timing varies about 2
with 0.012in (0.3 mm) of shims.
3. Use a combination of shims (0.020 in
(0.5 mm)) with beading and a shim
(0.020 in (0.5 mm)) without beading
when you need adjusting shims more
than 0.0394 in (1.0 mm).
Oil filter
Coat the mounting surface with a small quantity of oil and
tighten by hand.
Engine stop solenoid
Tighten the engine stop solenoid lightly with pliers.
Crankshaft pulley torque
82.6-88.9 lbfft (118127 Nm) {1213 kgfm}
Injection pump torque
73.47-100.0 inlb
f
(8.311.3 Nm) {0.8511.5 kgfm}
Injection timing adjusting shim
Thickness in(mm) Part code
0.008 (0.2) 131437590
0.012 (0.3) 131437600
0.016 (0.4) 131437610
0.020 (0.5) 131437620
0.020 (0.5) *131437630
* Without beading
Fig. 4-15
Fig. 4-16
Snap pin
Injection pump
Shim
Link
109823 2/09 4-7
Cylinder head assembly
1. Set the piston at top dead center (TDC) and
measure the projection or depression from the face
of the cylinder block with a depth gauge or dial
indicator.
Notes: 1. Measure, holding the piston lightly by
hand.
2. Use the largest projection value to
determine head gasket usage.
2. Select a head gasket according to the measured
value.
Note: The last four digits of the part number are
stamped on the top surface of the head
gasket.
3. Tighten the cylinder head in several steps in the
order as shown in Fig. 4-18 and tighten to the
specified final torque
Notes: 1. Be careful not to damage the spring pin,
which positions the cylinder head
assembly.
2. Coat the cylinder head bolt threads with
grease containing disulfide
molybdenum.
Measured value in(mm) Head gasket part code No. Thickness when tight-
ened
0.0217-0.0256
(0.550.65)
111147560 t=0.047(1.2)
0.0256-0.0295
(0.650.75)
111147570 t=0.051(1.3)
Cylinder head tightening torque
34.3-34.6 lb
f
ft (49 52 Nm) {5.05.3 kgfm}
Fig. 4-17
Projection
Fig. 4-18
1
2
3
4
5
6
7
8 9
10
11
12
13
14
4-8 109823 2/09
Cap Push rod Rocker arm assembly
1. Install the cap to the valve stem end.
2. Install the push rod and rocker arm assembly.
Valve clearance adjustment
Loosen the locking nut of the intake and exhaust valve
rocker arm and adjust the valve clearance to 0.008 in (0.2
mm) by turning the adjust screws.
Notes: 1. Adjust the valve clearance while cold.
2. Be sure the tappet is in its lowest
position before making adjustment. To
be sure the tappet is in its lowest
position, bring the piston to top dead
center on the compression stroke.
(both valves closed)
Rocker arm assembly tightening torque
177.0-221.3. lb
f
in (2025 Nm) {2.02.5 kgfm}
Lock nut tightening torque
106.2-141.6 lb
f
in (1216 Nm) {1.21.6 kgfm}
Fig. 4-19
1
2
Fig. 4-20
Adjusting Screw
Push Rod
Valve Clearance
109823 2/09 4-9
Oil pressure switch
Oil pipe
Water pump assembly Bypass hose
1. Install and tighten the gasket and water pump
assembly .
2. Connect the thermostat case and water pump case
with bypass hose .
3. Install the radiator hose .
Valve cover
Tighten the valve cover evenly being careful not to damage
the O-ring.
Glow plug, Connector
Oil pressure switch tightening torque
88.5-106.2 lb
f
in (1012 Nm) {1.01.2 kgfm}
Eye bolt torque
M8 88.5-115.1 lb
f
in (1013 Nm)
{1.01.3 kgfm}
Head cover torque
88.5-106.2 lb
f
in (1012 Nm) {1.01.2 kgfm}
Glow plug nut torque
8.9-13.3 lb
f
in (11.5 Nm) {0.10.15 kgfm}
Fig. 4-21
Eye Bolt
Fig. 4-22
2
1
3
109823 2/09 4-16
109823_2/09 5-1
SECTION 5: ELECTRICAL SYSTEMS
WARNING: Before working on any component of the electrical system, the negative (-)
battery cable should be disconnected from the battery, as electrical shock or damage to
system components may occur. Some testing requires 12 - volt power; care should be taken
in cases where power is needed.
Fuel Shutoff Solenoid
Description and Location
The fuel shutoff solenoid, C, is located on the right side of
the engine, and is threaded into the rear of the fuel injection
pump, . The fuel shutoff solenoid contains a spring-
loaded plunger that pushes the injection pump control rack
to the closed (shut-off) position when the solenoid is not
energized. When the key switch is turned to the ON or
START position, the safety stop relay closes completing
the circuit that energizes the solenoid. This retracts the
plunger from the injection pump, and the injection pump
control rack moves into the position that allows the engine
to start.
Removal
1. Disconnect the negative () battery cable from the
battery.
2. Disconnect the wiring harness lead, from the fuel
shutoff solenoid.
3. Using a pair of pliers, carefully remove the fuel
shutoff solenoid, C ( page 5-1, Fig. 5-1), from the
engine.
4. Remove and discard the sealing washer, C ( page
5-1, Fig. 5-2), which seals the solenoid, ( page
5-1, Fig. 5-2), to the fuel injection pump.
Fig. 5-1
Fig. 5-2
2
1
2
1
5-2 109823_2/09
Testing
1. Using a suitable measuring device, measure the
protrusion distance, A ( page 5-2, Fig. 5-3), on the
solenoid. The distance should measure between
1.001.04 in.(25.5 - 26.4 mm). If the distance is not
within these specifications, the solenoid is defective
and needs replaced.
Note: When connecting the 12-volt power supply
to the solenoid body, be sure paint is
removed from the body. Otherwise, the
power will not be transferred to the
solenoid.
2. Use jumper wires to connect the positive (+) terminal
of a 12-volt power supply to the solenoid lead, C (
page 5-2, Fig. 5-4). Connect the negative terminal of
the 12-volt power supply to the solenoid body, (
page 5-2, Fig. 5-4). The plunger, ( page 5-2,
Fig. 5-4), should retract into the solenoid body.
3. Using a suitable measuring device, measure the
protrusion distance, B on the solenoid. The
distance should measure between 0.450.57 in.
(11.5 - 14.5 mm). If the distance is not within these
specifications or the plunger does not retract, the
solenoid is defective and needs replaced.
Installation
1. Assembly of the engine stop solenoid generally
follows the disassembly in reverse, using a new
sealing washer, C ( page 5-1, Fig. 5-2), on the
solenoid, ( page 5-1, Fig. 5-2).
Engine Glow Plugs
Description
The engine glow plugs C are located on the right side of
the engine cylinder head, near the fuel injectors.
The glow plugs are used to preheat the air in the pre-
combustion chamber. This aids in the starting of the engine
when cold.
Removal
1. Disconnect the negative () battery cable from the
battery.
2. Remove the three (3) nuts, C ( page 5-3, Fig. 5-6),
and washers securing the electrode bar, ( page
5-3, Fig. 5-6), from the glow plugs.
3. Remove the glow plugs from the engine cylinder
head.
Engine Glow Plug Testing
1. Clean carbon from the sheath end of the glow plug.
Note: Do not test resistance using the glow plug
sheath.
Fig. 5-3
Fig. 5-4
A
2
1
2
3
2
B
Fig. 5-5
1
109823_2/09 5-3
2. Using an ohmmeter, touch one test probe to the glow
plug electrode. Touch the other test probe to the
glow plug body (see page 5-3, Fig. 5-7).
3. Observe the ohmmeter. A resistance reading of 1.0
ohm is maximum for the standard glow plug. If the
resistance is higher than 1.0, the glow plug is
defective and needs replaced.
Installation
1. Thread the glow plugs into the engine cylinder head.
Torque each glow plug to 11.114.8 lb
f
ft (15-20
Nm) {1.52.0 kg
f
m}.
2. Install the electrode bar, , and the washers onto
the glow plugs. Secure with the three (3) nuts, C.
3. Connect the negative () battery cable to the battery.
Engine Oil Pressure Switch
Description and Location
The engine oil pressure switch, C ( page 5-3, Fig. 5-8), is
located in the front of the engine cylinder head.
The engine oil pressure switch closes (circuit completed)
when engine oil pressure is less than 4.25 psi (29.4 kPa).
This illuminates an indicator light on the instrument panel.
The closed engine oil pressure switch will be opened after
the engine is started. If the switch does not work after
started, the oil level inside the engine may be low or there
may be a problem with the oil pump.
Engine Oil Pressure Switch Testing
1. Using an ohmmeter, touch one test lead to the
pressure switch terminal, C ( page 5-3, Fig. 5-9),
and the other test lead to the threads of the switch
body, ( page 5-3, Fig. 5-9).
2. Observe the ohmmeter. There should be little or no
resistance, indicating continuity in the switch. If there
is no continuity, the switch is defective and needs
replaced.
Caution: Do not use high-pressure compressed
air for the following test, otherwise
damage may occur to the oil pressure
switch.
Note: The following test is not a calibrated test.
The purpose of the test is to see if the
switch contacts open at pressure.
3. While the test leads are connected to the switch,
pressurize the switch oil pressure port ( page 5-3,
Fig. 5-9), with low pressure 10.020.0 psi(69138
kPa) {0.71.4 kgf/c
2
} compressed air.
4. Observe the ohmmeter. While air pressure is being
supplied to the oil pressure port, the ohmmeter
should indicate high resistance, or no continuity. If
there is continuity, the switch is defective and needs
replaced.
Installation
Fig. 5-6
Fig. 5-7
1
2
Fig. 5-8
Fig. 5-9
1
1
2
3
5-4 109823_2/09
1. Install the oil pressure switch into the engine cylinder head and tighten to 10.814.4 lb
f
ft(14.719.6 Nm) (1.52.0
kgfm).
2. Install the ring terminal onto the oil pressure switch, and secure the terminal with the retaining screw, C, ( page
5-3, Fig. 5-9).
Alternator (40 amp version) (No. 185046320)
Charging circuit
Description
1. The charging circuit and internal connection are shown in page 5-4, Fig. 5-10. The charging system consists of an
IC (integrated circuit) regulator built in alternator, a battery and connecting wires. Because of the use of an IC, the
voltage regulator is very compact and is built into the alternator.
2. The field current flows directly from the diode trio to the field coil without passing through the external circuit. But to
help the initial voltage built up when the engine is started, the field current is supplied through the indicator lamp
from the battery.
3. Since the frequency pulse output of 1/10 the alternator speed develops on P terminal, this terminal is used for
speed detection.
Fig. 5-10
NOTE: Represent the alternator terminal
P
B
L
R
R
L
F
E
Stator coil
Field coil
IC regulator
Diode trio
Indicator lamp
Battery
R
L
B
P
R1
R6
R2 Tr2
Tr1
R5
D6
Dz
Key switch
a
109823_2/09 5-5
Construction
The principal components of the IC alternator are the stator,
the rotor, the rectifier assembly, the IC voltage regulator, the
front bracket, the rear bracket and the pulley.
The rectifier assembly consists of two heatsinks, one
positive and one negative, and diode trio.
The diode trio is used as field supply diode and is
connected to the field coil and the terminal L on the
alternator.
The built-in IC regulator is a solid-state unit so that it can
only be serviced as an assembly.
Alternator diagnostic procedures
Checking the regulator adjusting voltage.
1. In equipment without an ammeter, connect a
ammeter (50A capacity) at the position shown in
page 5-5, Fig. 5-12. In equipment with an ammeter,
make use of the ammeter on the equipment.
2. Connect a voltmeter between the terminal B of the
alternator and the ground. The reading on the
voltmeter should indicate the battery voltage. If the
voltmeter reading is zero, the wiring between the
terminal B and the battery is faulty.
3. With the test ammeter terminals short-circuited, start
the engine.
Caution: If the test ammeter is connected at the
position shown in page 5-5, Fig. 5-12,
make sure that no starting current is
applied to the ammeter when the engine is
started.
4. Remove the short circuit across the test ammeter
terminals and increase the engine speed
immediately to approx. 2000 rpm. Note the ammeter
reading.
5. If the ammeter reading is 5A or less, note the
voltmeter reading without changing the engine
speed (approx. 2000 rpm). The reading is the
adjusting voltage.
6. If the ammeter reading is more than 5A, continue to
charge the battery until the reading falls to less than
5A or replace the battery with one that is fully
charged.
7. An alternative method is to limit the charging current
by connecting a 1/4 ohm (25W) resistor in series with the battery.
Checking output
If the results of the of the regulator adjusting voltage are within specification, check alternator output:
1. Turn ignition switch to off position, disconnect the terminal B of the alternator and connect an ammeter (50A
capacity) at the position shown in page 5-5, Fig. 5-12.
2. Connect the voltmeter between the terminal B of the alternator and the ground. Confirm that the voltmeter
indicates the battery voltage.
3. Turn ignition switch to on position.
4. Start the engine and turn on all the lamps. Immediately accelerate the engine to 2000 rpm or more and note the
maximum value indicated on the ammeter.
5. If this value is more than 70% of the nominal output (refer to page 7-1, Section 7:Servicing Specifications), the
alternator can be considered as working satisfactorily.
Note: To make the above judgment more accurate, remove the alternator from the engine and check it on a
test bench.
Fig. 5-11
Fig. 5-12
Rotor
IC voltage regulator
Pulley
Bush
Stator
Front bracket
Rear bracket
Rectifier
V
B
L
R
A
Battery
Key switch
Alternator
5-6 109823_2/09
Disassembly
1. Mark both brackets and the stator with a scribe mark
for assembly.
2. Remove the four (4) through bolts. Pry between the
stator and front bracket with blade of a screwdriver.
Carefully separate the front bracket, pulley and
rotor assembly from the stator and rear bracket
assembly.
3. Place the rotor in a vise with soft jaws and remove
the pulley nutC, washer, pulley spacer and front
bracket from the rotor.
4. Unsolder three stator leads and remove the stator.
5. Remove the voltage regulator assembly and rectifier
assembly as a set.
Inspection of parts
1. Rotor
a. Slip ring surface inspection: Remove discoloration
or scratches on the slip ring surface with 400-600
grit sand paper. A badly roughened slip ring or a
slip ring worn beyond the service limit should be
replaced.
Fig. 5-13
1. Pulley nut
2. Pulley
3. Screw
4. Front bracket
5. Bearing
6. Bearing holder
7. Collar
8. Pulley spacer
9. Rotor
10. Bearing
Fig. 5-14
1
2
3
4
6
7
10
9
8
5
Lead Wires
Stator
Fig. 5-15
Core
Slip ring
109823_2/09 5-7
b. Check for continuity between both the slip rings,
page 5-7, Fig. 5-16. If there is no continuity, the
field coil is defective. Replace the rotor assembly.
c. Check for continuity between the slip ring and
shaft (or core), page 5-7, Fig. 5-17. If there is
continuity, the coil or slip ring is grounded.
Replace the rotor assembly.
2. Stator
a. Check for continuity between the leads of the
stator coil, page 5-7, Fig. 5-18. If there is no
continuity, the stator coil is defective. Replace the
stator assembly.
Fig. 5-16
Fig. 5-17
Fig. 5-18
5-8 109823_2/09
b. Check for continuity between any stator lead and
stator core, page 5-8, Fig. 5-19. If there is
continuity, the coil is grounded. Replace the stator
assembly
3. Rectifier Assembly
a. Positive heatsink: Check for continuity between
the positive (+) heatsink and stator coil lead
connection terminal with a circuit tester. If there is
continuity in both directions, the diode is short-
circuited. Replace the rectifier assembly.
b. Negative Heatsink: Check for continuity between
the negative () heatsink and stator coil lead
connection terminal with a circuit tester. If there is
continuity in both directions, the diode is short-
circuited. Replace the rectifier assembly.
Fig. 5-19
Fig. 5-20
Stator coil lead terminal
Positive heatsink
Rectifier Assembly
Fig. 5-21
Stator coil lead terminal
Negative heatsink
Rectifier Assembly
109823_2/09 5-9
c. Diode Trio: Using a circuit tester, check the three
(3) small diodes for continuity in both directions. If
there is either continuity or an open circuit in both
directions, the diode is defective. Replace the
rectifier assembly.
4. Brush and Brush Spring
a. Check the length of the brush. A brush worn down
to the wear limit line should be replaced.
b. Check the brush spring pressure and verify the
brush moves smoothly in the brush holder.
Reassembly
Reverse the disassembly procedure except for the
following:
1. Installing rotor.
a. Push brushes into brush holder, and insert a wire
to hold them in raised position before installing the
rectifier and regulator assembly.
b. Install rotor and remove wire.
Note: Since rear bearing and rear bracket fit is
tight, heat the bearing box in the rear
bracket to 122140F (5060C) before
installing rotor.
Note: Do not apply lubrication to bearing box for
bearing with resin band. Completely
remove any oil from the bearing box in the
rear bracket.
Fig. 5-22
Diode trio
Rectifier Assembly
Fig. 5-23
0.728 in.
(18.5 mm)
0.197 in.
(5 mm)
Wear limit line
Fig. 5-24
Brush
Wire
5-10 109823_2/09
Bench Check
To check the alternator on a test bench, proceed as follows:
1. Make connection as shown in the page 5-10, Fig. 5-25, except leave the load resistor disconnected.
2. Slowly increase the alternator speed and observe the voltage.
3. If the voltage is uncontrolled with speed and increases above 15.5V, check the alternator.
4. If voltage is below 15.5V, connect the load resistor as shown in page 5-10, Fig. 5-257.
5. Operate the alternator at 2500 rpm and adjust the load resistor as required to obtain maximum output.
6. Measure the output current. The output must be within the limits shown in the section on Service Specifications.
If the output is less than specified value the alternator should be disassembled and checked.
Precautions
1. Reversed battery connections will damage the alternator and/or wiring.
2. When connecting a booster battery, make certain to connect negative battery terminals together and positive
battery terminals together.
3. When a fast charger is used to charge the battery, the equipment battery cables should be disconnected.
4. Grounding of the alternator output terminal will damage the alternator and/or circuit.
5. Do not connect a load of over 1A to the terminal L.
6. If the alternator is operated with the terminal L and B short-circuited, if may damage the diode trio
Fig. 5-25
Voltmeter
Ammeter
Switch
Load resistor
Battery
Alternator
V
B
A
L
R
109823_2/09 5-11
Maintenance
Item/Model Name A007T03877(MITSUBISHI)
Nominal output (V-A) 1240
Polarity Negative ground
Weight lb. (kg) Approx. 8.2(3.7)
Rotational Direction (Viewed from the pulley) Clockwise
Load characteristic (cold) Terminal Voltage (V) 13.5
Current (A) Min. 30
Rotational Speed (RPM) 2500
Brush length Original in(mm) 0.728(18.5)
Limit in(mm) 2.0(50)
Brush spring tension Original lb(g) 1.041.30(470590)
Limit lb(g) 0.600(270)
Bearing Rear side ECS8
Front 6303DDG
Slip ring diameter
eccentric wear
To be repaired in(mm) 0.002(0.05)
Allowable limit in(mm) 0.008(0.2)
Slip rings surface condition If dirty or damaged polish with emery cloth
Rotor shaft bending To be repaired in(mm) 0.0028(0.07)
Field coil resistance (Ohms@5000rpm) 2.8
Adjusting voltage (Volts @5000rpm) 14.415.0
5-12 109823_2/09
Trouble Shooting
Symptom Part Cause Remedy
Wiring, ammeter Open or short circuit
Loose connection
Correct
No Defective coils, short to ground Replace
charging Alternator Defective rectifier Replace
Defective RF resistor Replace
Regulator Defective regulator Replace
Wiring Open or short circuit
Loose connection
Correct
Loose alternator drive belt Correct
Short circuit in rotor coil Replace
Insufficient Alternator Short circuit in stator coil Replace
charging Defective rectifier Replace
Insufficient brush contact, stained slip ring Correct
Battery Defective battery Replace
Over Battery Internal short Replace
charge Regulator Defective regulator Replace
Wiring Open circuit (broken wire) Replace
Loose or worn alternator drive belt Correct
or
Replac
e
Unstable Short circuit or broken wire in rotor Replace
charging Alternator Short circuit or broken wire in stator coil Replace
current Insufficient brush contact, stained slip ring Correct
Broken brush or brush spring Replace
Loose terminal connections Correct
Incorrect installation of alternator Correct
Abnormal Defective bearing Replace
noise from Alternator Rotor core and stator coil in contact Correct
alternator Defective diode Replace
Short in stator coil Replace
109823_2/09 5-13
Starter Motor (M001T66081) (No. 185086551)
Description
This starter features a reduction mechanism consisting of a planetary gearing system and permanent magnets for
magnetic field induction. Its reduction mechanism is comprised of an internal gear, three planetary gears, gear shafts
(with overrunning clutch fitted by spline) and armature shaft gear. The structure is different from that of direct drive type,
but the electrical wiring is the same between two types. The magnetic field is produced by six permanent magnets. The
magnets are mounted in the yoke and positioned according to polarity. They are permanently attached to the yoke and,
are not removable.
Fig. 5-26
1. Rear Bracket 7. Overrunning Clutch 13. Planetary Gears
2. Armature 8. Front Bracket 14. Rubber Cover
3. Switch 9. Bearing 15. Magnets
4. Internal Gear 10. Pinion 16. Yoke
5. Lever Packing 11. Gear Shaft 17. Brushes
6. Lever 12. Ball 18. Sleeve Bearing
1
2
3
4
5
6
7
8
9
11 12
13
14 15 16
17 18
10
5-14 109823_2/09
Disassembly
Reference page 5-14, Fig. 5-28.
Notes: 1. Before disassembling starter, put
alignment marks on the switch and yoke,
To aid in correct reassembly.
2. Do not clamp yoke in a vise or strike it
with a hammer during repair
operations. Permanent magnets
attached to yoke could be broken and
yoke dented or deformed if mishandled.
1. Remove switch terminal nut C and disconnect
connecting wire . Remove screws securing
switch and remove switch and plunger .
2. Remove brush holder securing screws and
through bolts . Remove rear bracket ( but do not
remove brush holder .
3. Install a socket (outer diameter 1.18 in.(30mm)) on
the armature commutator, see page 5-14, Fig. 5-27.
Then slide the brush holder onto the socket. Leave the socket in position in the brush holder for inspection and
reassembly.
4. Slide yoke away from front bracket .
5. Remove armature and ball . Do not lose ball when removing the armature.
6. Remove rubber cover from planetary gear assembly and remove lever packing and plate .
7. Remove planetary gears . Remove gear shaft/overrunning clutch assembly and lever as a unit from front
bracket .
8. To remove overrunning clutch :
a. Remove plastic cap . If the cap is too badly distorted or cracked, replace.
Fig. 5-27
Socket
1.18 in.
(30 mm)
11 12
Fig. 5-28
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15
16
17
18
21
22
20
23
19
13 23 14 15
16 18 19
18
20
109823_2/09 5-15
b. Slide a piece of tubing of suitable size over shaft
against stop ring ) (see page 5-14, Fig. 5-28
and page 5-15, Fig. 5-29).
c. Then tap the tubing with a hammer to remove the
stop ring and expose snap ring (see page 5-14,
Fig. 5-28 and page 5-15, Fig. 5-29). Remove the
tubing from the shaft.
d. Remove the snap ring and the stop ring and
separate the overrunning clutch (see page
5-14, Fig. 5-28 and page 5-15, Fig. 5-29) from the
gear shaft (see page 5-14, Fig. 5-28 and page
5-15, Fig. 5-29). If the snap ring is distorted, it will
be necessary to use a new one on reassembly.
Inspection
1. Armature
a. Inspect the armature coil for short-circuit with a
growler armature tester. Replace armature if
shorted.
b. Inspect armature coil for ground with a circuit
tester ( page 5-15, Fig. 5-30). Replace grounded
armature.
c. Inspect commutator for wear. If below the limit,
replace armature.
d. Inspect commutator for insulator depth. Correct if
below the limit.
e. Check gear teeth for wear or damage, and replace
armature as necessary.
2. Permanent magnets
a. Check permanent magnets for cracks, damage
and looseness, replace yoke assembly as
necessary.
3. Brushes
a. Check brushes for wear. Replace brushes if below
the limit.
b. Check brush spring pressure to make sure brush
moves smoothly in brush holder.
Fig. 5-29
Stop ring
Snap
ring
21
22
18
17
Fig. 5-30
Fig. 5-31
Hacksaw blade
Commutator
Commutator
0.020.03
Segment
No Good
Chamfered (0.50.8mm)
Good
Insulation
5-16 109823_2/09
c. To check brush holder assembly for grounds,
touch one probe of a circuit tester to holder plate
and the other probe to each of insulated holders.
Replace brush holder assembly if any continuity is
noted.
d. Overrunning clutch and pinion gear. While holding
clutch housing, rotate pinion. Pinion should rotate
smoothly in one direction (not necessarily easily),
but should not rotate in opposite direction. If the
clutch does not function properly, replace it. If
pinion gear is worn or burred, replace it.
Note: Overrunning clutch should not be cleaned
with grease dissolving solvents, since
these would dissolve the lubricant in the
clutch mechanism.
Reassembly and adjustment
To reassemble the starter, follow the reverse of
disassembling procedure.
1. Apply grease to the following parts during assembly:
(see page 5-16, Fig. 5-33)
a. Sleeve bearing and ball.
b. Sleeve bearing in internal gear.
c. Sleeve bearing in rear bracket.
d. Gear shaft
e. Sliding surface of lever and overrunning clutch.
f. Armature shaft gear, internal gear and planetary
gears.
g. Sliding surfaces of pinion and front bearing.
2. ) Armature shaft end play: no adjustment.
3. Pinion position adjustment.
After completing reassembly, check pinion position to be
sure that it is between 0.020 and 0.079 (0.5 and 2.0mm). To
adjust, proceed as follows:
a. Connect the starter to a battery, as shown in page
5-16, Fig. 5-34. Close switch. This will shift pinion
into cranking position.
Fig. 5-32
Fig. 5-33
a
b
c
e g f
d
Fig. 5-34
Terminal: S
Switch
Battery
109823_2/09 5-17
b. Push pinion back by hand and measure the
amount of the pinion movement as shown in page
5-17, Fig. 5-35. If the amount does not fall within
limit, adjust it by adding or removing shims which
are located between switch and front bracket.
Adding shims decreases the amount of the
movement.
Non-load test
1. After adjusting pinion position, from a test circuit with
a voltmeter and an ammeter, as shown in page
5-17, Fig. 5-36.
Note: Use wires as thick as possible and tighten
each terminal.
2. Close the switch and compare the R.P.M. current
and voltage readings with the specifications in page
7-1, Section 7:Servicing Specifications.
3. If any abnormality is noted, check it according to the
procedures on page 5-15, Inspection.
Fig. 5-35
0.0200.079
(.0.52.0mm)
Fig. 5-36
Switch
B
A
V
+
5-18 109823_2/09
Maintenance
Item Standard Value or Service Limit
Volts 11
No-load Characteristic Amps 110 Max
R.P.M. 2400 Min.
Commutator Outer Dia. 1.16in.(29.4mm)
Service Limit 1.14in.(28.8mm)
Brush Length 0.69in.(17.5mm)
Service Limit) 0.40in.(10mm)
Brush spring Tension 5.17.3 lb
f
(22.532.5 N)
Service Limit 2.3 lb
f
(10 N)
Pinion Movement (Pinion Gap) 0.0200.079 (0.52.0mm)
109823_2/09 5-19
Trouble shooting
Symptom Part Cause Remedy
Wiring Open circuit: loose battery connection,
loose connection at ignition switch or at
starter terminals.
Tighten connections.
Pinion does not advance
even though the key
switch is turned ON.
Key switch Defective ignition switch Replace
Starting motor Helical spline on pinion shaft is scored
and prevents the pinion from moving
Replace or correct
Magnet switch Improper movement of the plunger of the
magnet switch or disconnected wire or
short circuit of the coil.
Replace or correct
Pinion is engaged, the
motor rotates, but rota-
tion is not transmitted to
the engine.
Starting motor Defective clutch or broken reduction gear. Replace
Wiring Wire from batter to magnet switch discon-
nected. Loose connection between
magnet switch and motor.
Repair, retightening, or
replace the wire.
Locked ball bearing. Replace
Improper installation. Replace
Starting motor Worn out brush, improper contact of
brush spring.
Correct
Pinion is engaged with the
ring gear, starting motor
does not turn.
Stained commutator. Replace
Defective armature or field coil. Replace
Insufficient tightening of connections of
the field coil and brush
Replace
Broken holding coil Replace
Magnet switch Improper contact of contact Replace
Roughened contact surface of contact Replace
Battery Discharged Charge
Improper sliding of pinion shaft Replace
Starting motor Worn out pinion tooth top Correct
Motor starts rotating before
the pinion is engaged
with the ring gear.
Improper pinion pushing position Replace
Engine Worn out ring gear Replace
Magnet switch Defective magnet switch Replace
5-20 109823_2/09
109823_2/09 6-1
SECTION 6: TROUBLE-SHOOTING
Symptom Cause Remedy
Defective key switch Check electrical connection and contacts.
Insufficient charging or completely dis-
charged battery.
Charge.
No fuel. Check and refill fuel tank.
Air mixed in the fuel system. Tighten all fuel system connections.
Clogged fuel filter. Replace the fuel filter.
Engine does not start Irregular of improper fuel supply. Injection pump malfunction. Repair by
Bosch qualified repair shop.
Defective glow plug. Replace.
Improper viscosity of lubricating oil. Check and change.
Clogged air cleaner. Clean the air cleaner.
Low compression. Check and correct each part.
Defective engine stop solenoid. Check or replace wiring.
Air mixed in the fuel system. Discharge air from the fuel.
Uneven fuel injection. Injection pump problem. Have corrected in
a Bosch qualified repair shop or
replaced.
Irregular engine speed Clogged fuel filter. Replace the fuel filter.
Governor malfunction. Check and adjust.
Improper function of engine main body. Overhaul, check and correct each part.
No fuel in fuel tank. Refill fuel tank.
Engine stops during
operation
Clogged fuel filter. Replace the filter.
Air mixed in the fuel system. Tighten all fuel system connections.
Worn engine. Overhaul, repair or replace worn parts.
Insufficient coolant. Refill with coolant, and check for leaks and
repair.
Loose or slipping fan belt. Clean oil dust, etc. and retighten.
Fan belt failure. Replace.
Clogged radiator. Clean the radiator.
Engine overheats Clogged radiator fins. Clean.
Cooling water passage clogged with dust,
etc.
Flush cooling system.
Thermostat malfunction. Check and replace.
Insufficient lubricating oil. Check and fill as necessary.
Overload. Decrease the load.
Improper engine
exhaust color
Too much engine oil. Check and adjust the quantity.
Too low viscosity of engine oil. Check and change.
Improper injection timing.
Improper fuel. Check and change.
Improper engine
exhaust (black or
dark gray)
Excessive fuel injection.
Improper function of engine main body. Check a correct each part.
Overload. Reduce the load.
Clogged air cleaner. Clean the element.
Loose fan belt. Correct belt tension.
Wiring problem. Check and repair.
Improper charging Defective battery. Replace.
Defective alternator. Replace.
Loose or disconnected wires. Check and install or tighten.
6-2 109823_2/09
Dropped battery voltage. Charge the battery.
Starting motor does not
operate.
Defective safety switch. Replace.
Trouble in starting motor. Check and correct the starting motor.
Disconnected wire of fusible link. Replace.
Insufficient engine oil. Replenish to specified gauge level.
Oil pressure lamp does
not go out.
Trouble in oil pressure switch. Replace the switch.
Leak in lubricating system. Check and retighten.
Clogged oil filter. Replace with new one.
Short circuit to ground in wiring between oil
pressure lamp and oil pressure sensor.
Repair.
Oil pressure lamp does
not light up with the
key switch turned
ON. (Engine
stopped.)
Burnt out lamp. Replace the lamp.
Disconnected wire between battery and oil
pressure lamp.
Repair.
1
0
9
8
2
3

2
/
0
9
7
-
1
SECTION 7: SERVICING SPECIFICATIONS
* Unit for values without unit in the column of inspection item is in(mm).
Unit Part Inspection Items
Standard Dimension Standard Value
To be
Repaired
Allowable Limit
S773L N843(L) S773L N843(L) S773L N843(L) Remarks
E
n
g
i
n
e
C
y
l
i
n
d
e
r

H
e
a
d
Cylinder compression
PSI (MPa) {kgf/cm2}
More than
426.4 (2.94) {30}
More than
426.4 (2.94) {30}
Less than
361.1
(2.45){25}
Engine 250
rpm
Cylinder head bolt torque
lb
f
ft (Nm) {kgfm}
36.1-38.4 (4952)
{5.05.3}
36.1-38.4 (4952)
{5.05.3}
Coat threads
with engine oil.
Distortion of cylinder head
bottom surface
Less than
0.002(0.05)
Less than
0.002(0.05)
.005(0.12)
IN 0.0335-0.0453
(0.851.15)
Ex 0.0335-0.0453
(0.851.15)
IN 0.0335-0.0453
(0.851.15)
Ex 0.0335-0.0453
(0.851.15)
0.71(1.8) Valve sheet
angle 45
Width of valve
seat
Intake 0.059-0.083
(1.502.10)
0.059-0.083
(1.502.10)
0.098(2.5)
Exhaust 0.063-0.071
(1.591.80)
0.063-0.071
(1.591.80)
0.098(2.5)
R
o
t
a
t
i
n
g

A
s
s
e
m
b
l
y
C
y
l
i
n
d
e
r

B
l
o
c
k
Cylinder bore dia.
in(mm)
3.0315(77) 3.307(84) 3.307-3.308
(84-84.019)
3.3073.308
(8484.019)
3.0394
(77.2)
3.315
(84.2)
Distortion of cylinder block
upper face
Less than
0.0020(0.05)
Less than
0.0020(0.05)
0.0047(0.12)
P
i
s
t
o
n
Piston skirt bottom longer dia 3.0291(76.94) 3.3053(83.955) 3.02883.0294
(76.932576.9475)
3.30503.3056
(83.94883.963)
3.020
(76.7)
3.295
(83.7)
Clearance between cylinder
and piston
0.00010.0030
(0.002650.075)
0.00150.0028
(0.0380.072)
0.0010
(0.25)
0.0010
(0.25)
At 68F(20C)
Clearance between piston pin
hole and piston pin
-0.00000.0003
(-0.0000.008)
-0.00000.0001
(-0.0010.0027)
0.0008
(0.02)
0.0008
(0.02)
7
-
2
1
0
9
8
2
3

2
/
0
9
R
o
t
a
t
i
n
g

A
s
s
e
m
b
l
y
P
i
s
t
o
n

P
i
n
Piston pin outside dia. .82660.8568
(20.99621.002)
1.10211.1024
(27.99428.0)
0.8260
(20.98)
1.1012
(27.97)
Clearance between small end
bush and piston pin
0.00030.0010
(0.0080.025)
0.00040.0011
(0.0100.027)
0.0003
(0.08)
0.0003
(0.08)
Oil clearance
P
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Piston ring end
gap:
Top ring .00790.0138
(0.200.35)
0.00790.0138
(0.200.35)
0.0394
(1.0)
0.0394
(1.0)
2nd ring 0.00790.0138
(0.200.35)
0.00790.0157
(0.200.40)
0.0394
(1.0)
Oil ring 0.00590.0138
(0.150.35)
0.00980.0197
(0.250.50)
0.0394
(1.0)
0.0472
(1.2)
Clearance
between piston
ring groove and
ring
Top ring 0.00310.0047
(0.080.12)
0.00280.0043
(0.070.11)
0.0010
(0.25)
0.010
(0.25)
2nd ring 0.00200.0040
(0.050.09)
0.00160.0031
(0.040.08)
Oil ring 0.00080.0024
(0.020.06)
0.00080.0024
(0.020.06)
0.0060
(0.15)
Ring width Top ring 0.079(2) 0.079(2)
2nd ring 0.059(1.5) 0.059(1.5)
Oil ring 0.118(3) 0.157(4)
C
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R
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Torsion between small and
large end holes (per 3.937 in
(100 mm))
Less than
0.003(0.08)
Less than
0.003(0.08)
More than
0.0080(0.2)
Parallelism between small
and large end hole (per 3.937
in (100 mm))
Less than
0.0020(0.05)
Less than
0.0020(0.05)
More than
0.0059(0.15)
Axial play of connecting rod
and crank pin
0.00390.0118
(0.10.3)
0.00390.0118
(0.10.3)
0.0276
(0.7)
0.0276
(0.7)
Clearance between crank pin
and connecting rod metal
0.00140.0033
(0.0350.085)
0.00140.0033
(0.0350.085)
0.008
(0.2)
0.008
(0.2)
Oil clearance
Connecting rod tightening
torque
lb
f
ft(Nm) {kgfm}
21.425.1(2934)
{3.03.5}
36.139.8(4954)
{5.05.5}
To be
Repaired
Allowable Limit
1
0
9
8
2
3

2
/
0
9
7
-
3
R
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t
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A
s
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t
Diameter of journal 1.890(48) 2.677(68) 1.88831.88888
(47.96447.975)
2.67552.6760
(67.95767.970)
1.8858
(47.9)
2.6535
(67.4)
Diameter of crank pin 1.614(41) 2.0472(52) 1.61281.3132
(40.96440.975)
2.04582.0463
(51.96451.975)
1.6102
(40.9)
2.024
(51.4)
Roughness, main journal and
crank pin
1.6Z 1.6Z
Crankshaft run out Less than
0.0012(0.03)
Less than
0.0012(0.03)
More than
0.0024(0.06)
Axial play of crankshaft 0.00390.0118
(0.10.3)
0.00390.0118
(0.10.3)
0.0197
(0.5)
0.0197
(0.5)
Thickness of thrust washer 0.118(3.0) 0.1160.118
(2.953.00)
0.110
(2.8)
O.D. X. I.D. of journal bearing 2.008 x 1.890
(51 x 48)
2.677 x 2.835
(68 72)
Clearance between crank-
shaft journal and bearing
0.00150.0042
(0.0390.106)
0.00150.0042
(0.0390.106)
0.008
(0.2)
0.008
(0.2)
Oil clearance
I.D. X O.D. of center bearing 1.890 x 2.047
(48 x 52)
2.677 x 2.835
(68 x 72)
Clearance between crank-
shaft journal and center bear-
ing
0.00150.0036
(0.0390.092)
0.00170.0040
(0.044 - 0.102)
0.008
(0.2)
0.008
(0.2)
V
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For intake/
exhaust
1.04591.0480
(26.56526.62)
1.35641.3586
(34.45334.508)
1.0315
(26.2)
1.3425
(34.1)
For injec-
tion pump
1.57011.5764
(39.88 - 40.04)
1.6911.695
(42.9443.06)
1.563
(39.7)
1.685
(42.8)
Cam shaft run out Less than
0.0012(0.03)
Less than
0.0012(0.03)
More than
0.004(0.1)
More than
0.004(0.1)
Cam gear back-
lash
0.0031(0.08) 0.0031(0.08) 0.010
(0.25)
To be
Repaired
Allowable Limit
7
-
4
1
0
9
8
2
3

2
/
0
9
V
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Diameter of intake valve stem 0.2744
(6.97)
0.2744
(6.97)
0.27380.2744
(6.9556.97)
0.27380.2744
(6.9556.97)
0.2713
(6.89)
0.2713
(6.89)
Diameter of exhaust valve
stem
0.2738
(6.955)
0.2738
(6.955)
0.27320.2738
(6.946.955)
0.27320.2738
(6.946.955)
0.2693
(6.84)
0.2693
(6.84)
Clearance
between valve
stem and valve
guide
Intake 0.00120.0024
(0.03 0.06)
0.00120.0024
(0.03 0.06)
More than
0.0079
(0.2)
More than
0.0079
(0.2)
Exhaust 0.00180.0030
(0.0450.075)
0.00180.0030
(0.0450.075)
More than
0.0100
(0.25)
More than
0.0100
(0.25)
0.039(1.0) 0.039(1.0) 0.03050.0423
(0.7751.075)
0.03150.0433
(0.8- 1.1)
0.02
(0.5)
0.02
(0.5)
Valve clearance
(Intake/exhaust)
0.008(0.2) 0.008(0.2) 0.02(0.5)
Valve spring Spring
force
lb
f
(N){kgf}
(Com-
pressed to
1.20(30.4)
mounting
length)
17.9(79.8){8.1} 17.9(79.8){8.1} 15.4(68.6)
{7}
15.4(68.6)
{7}
Free length 1.4(35) 1.4(35) 1.32
(33.5)
1.32
(33.5)
Less than
0.047(1.2)
Less than
0.047(1.2)
0.08
(2.0)
0.08
(2.0)
P
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s
h

R
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d
Overall length 6.86(174.3) 7.00(177.8) 6.856.87
(174.1174.5)
6.997.01
(177.6178.0)
Outer diameter 0.25(6.3) 0.25(6.3)
R
o
c
k
e
r
A
r
m
Wear, rocker arm shaft 0.46(11.7) 0.589(14.96) 0.45870.4594
(11.65011.668)
0.58860.5894
(14.9514.97)
0.4555
(11.57)
0.5854
(14.87)
Clearance between rocker
arm and shaft
0.0013.00268
(0.0320.068)
0.00126.0027
(0.0320.068)
0.0079
(0.2)
0.0079
(0.2)
Oil clearance
To be
Repaired
Allowable Limit
1
0
9
8
2
3

2
/
0
9
7
-
5
L
u
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r
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S
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O
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P
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Discharge rate: gal/min(L/min)
Engine speed: 2500rpm Dis-
charge pressure:
42.671.1 PSI
(294490 kPa)
{35 kgf/cm}
Oil temperature:
122F176F
(50C80C)(SAE30)
4.28(16.2) 4.28(16.2)
Oil pressure switch operating
pressure PSI(kPa){kgf/cm2}
7.11(49.0){0.5} 4.26(29.4){0.3} 5.698.53(39.2
58.8){0.40.6}
2.845.69(19.6 -
39.2){0.20.4}
Relief pressure
PSI(kPa){kgf/cm}
49.7563.96
(343441)
{3.54.5}
35.5349.75
(245343)
{2.53.5}
Lubrication oil capacity US
Qt(L)
4.86(4.6) With
filter(+0.32
Qt.)(+ 0.3 L)
6.34(6)With fil-
ter(+0.53 Qt.)(+
0.5 L)
Tip clearance (rotor-to-vane) 0.0040.006
(0.10.15)
0.0040.006
(0.10.15)
0.0100
(0.25)
0.0100
(0.25)
Side clearance (rotor-to-
cover)
0.0040.006
(0.10.15)
0.0040.006
(0.10.15)
.008(0.2) .008(0.2)
F
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Type Bosch, PFR Type
Injection timing Before
T.D.C.
2527 1820
Piston dis-
placement
before
T.D.C.
0.27-.31in
3
(4.4115.123ml)
N843: 0.16-0.19in
3
(2.5943.187ml)
N843L: 0.19-0.24
in
3(
3.1953.923ml)
0.22-.26in
3
(3.529-
4.217ml)
I
n
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t
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n
N
o
z
z
l
e
Type S773L131406440, N843(L)(Nozzle) 105007-1170 (NP DN4PDN117)
Injection pressure
PSI(MPa){kgf/cm2}
1711.4(11.8){120} 2175.62349
(15.216.2)
{155165}
16361778
(11.28-12.26)
{115-125}
Angle of injection direction 4 4
Nozzle and holder tightening
torque lb
f
ft(Nm){kgfm}
43.550.9
(59.069.0)
{67}
36.137.3
(49.050.6)
{57}
With cylinder head installed
To be
Repaired
Allowable Limit
7
-
6
1
0
9
8
2
3

2
/
0
9
C
o
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Cooling method Forced circulation water cooling
Coolant water volume US
Qt(L)
2.0(1.9) 5.3(5)
Type 145206061
Thermostat open
temperature F(C)
167(75) 180(82)
Thermostat full-open
Temperature F(C)
189(87) 203(95)
V belt (fan) looseness
(load at center 11lb(5kg))
0.190.39(510) 0.190.39(510)
E
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S
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t
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M
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Type
185086670 M001T66081
No. of teeth of pinion gear 9 11
Shifting method of pinion Magnetic shifting
Wear of commutator diameter 1.16(29.4) 1.16(29.4) 1.13
(28.8)
Stepped wear of commutator 0.002(0.05) 0.002(0.05) 0.0079
(0.2)
0.0079
(0.2)
Bending allowance of arma-
ture shaft
0.002(0.05) 0.002(0.05) More than
0.003(0.08)
Length of brush 0.69(17.5) 0.69(17.5) 0.35(9) 0.35(9)
Spring force of brush
lb
f
(N){kgf}
5.067.31
(22.532.5)
{2.33.3}
5.067.31
(22.532.5)
{2.33.3}
Less than
1.98(8.8)
{0.9}
Less than
1.98(8.8)
{0.9
A
l
t
e
r
n
a
t
o
r
Type 185046440 A007T03877 12V40A
Outside diameter of slip ring 0.89(22.7) 0.89(22.7) 0.87
(22.1)
Length of brush 0.73(18.5) 0.73(18.5) 0.197(5.0)
Pulley tightening torque
lb
f
ft(Nm){kgfm}
42.858.3(5879)
{5.958.05}
42.858.3(5879)
{5.958.05}
To be
Repaired
Allowable Limit
i-1 109823_2/09
Index
A
Alternator (40 amp version) . . . . . . . . . . . . . . 5-4
Alternator Maintenance . . . . . . . . . . . . . . . . . . 5-11
Alternator Trouble shooting . . . . . . . . . . . . . . 5-12
C
Cam shaft assembly. . . . . . . . . . . . . . . . . . . . . 3-12
Camshaft Tachometer assembly . . . . . . . . . 4-4
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Connecting rod bearing . . . . . . . . . . . . . . . . . . 3-7
Crank shaft and bearing holder assembly . . 4-1
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Crankshaft bearing holder. . . . . . . . . . . . . . . . 3-9
Crankshaft bearings . . . . . . . . . . . . . . . . . . . . . 3-9
Crankshaft end play . . . . . . . . . . . . . . . . . . . . . 4-1
Crankshaft pulley installation . . . . . . . . . . . . . 4-6
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cylinder head assembly . . . . . . . . . . . . . . . . . 3-2,
4-7
E
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . 5-1
Engine glow plugs . . . . . . . . . . . . . . . . . . . . . . 5-2
Engine oil pressure switch . . . . . . . . . . . . . . . 5-3
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Engine Sectional Drawing . . . . . . . . . . . . . . . . 2-3
Engine stop solenoid . . . . . . . . . . . . . . . . . . . . 4-6
F
Flywheel and ring gear . . . . . . . . . . . . . . . . . . 3-11
Flywheel installation. . . . . . . . . . . . . . . . . . . . . 4-2
Front plate installation . . . . . . . . . . . . . . . . . . . 4-4
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Fuel shutoff solenoid . . . . . . . . . . . . . . . . . . . . 5-1
Fundamental Instructions On Service . . . . . . 2-1
G
General Notes Before Service . . . . . . . . . . . . 2-1
Glow plug, Connector . . . . . . . . . . . . . . . . . . . 4-9
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
I
Idle gear Oil pump assembly . . . . . . . . . . . . 4-5
Injection pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Injection pump assembly. . . . . . . . . . . . . . . . . 4-6
N
Nozzle and holder . . . . . . . . . . . . . . . . . . . . . . 3-17
O
Oil dipstick Dipstick guide installation . . . . 4-4
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Oil filter installation . . . . . . . . . . . . . . . . . . . . . 4-6
Oil flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Oil pan installation . . . . . . . . . . . . . . . . . . . . . . 4-4
Oil pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Oil pressure switch. . . . . . . . . . . . . . . . . . . . . . 4-9
Oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Oil seal installation. . . . . . . . . . . . . . . . . . . . . . 4-2
P
Parts and Descriptions . . . . . . . . . . . . . . . . . . 2-6
Piston and connecting rod assembly. . . . . . . 4-3
Piston and piston ring . . . . . . . . . . . . . . . . . . . 3-5
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Rear plate installation . . . . . . . . . . . . . . . . . . . 4-2
Relief valve assembly with O-Ring . . . . . . . . 4-1
Rocker arm assembly . . . . . . . . . . . . . . . . . . . 3-1
Rocker arm assembly, Cap Push rod . . . . 4-8
S
Sectional Drawing . . . . . . . . . . . . . . . . . . . . . . 2-3
Servicing Specifications . . . . . . . . . . . . . . . . . 7-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Starter Maintenance. . . . . . . . . . . . . . . . . . . . . 5-18
Starter motor (M001T66081) . . . . . . . . . . . . . 5-13
Starter Trouble shooting . . . . . . . . . . . . . . . . . 5-19
Suction pipe Suction filter installation . . . . 4-3
T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Timing gear case Cover installation . . . . . . 4-5
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Torque Specifications . . . . . . . . . . . . . . . . . . . 2-2
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . 6-1
V
Valve clearance adjustment . . . . . . . . . . . . . . 4-8
Valve cover installation . . . . . . . . . . . . . . . . . . 4-9
W
Water pump assembly Bypass hose . . . . . . 4-9
Water pump assembly and thermostat . . . . . 3-15

Hustler Shibaura S773L N843 N843L Service Manual 109823 0209

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Hustler Shibaura S773L N843 N843L Service Manual 109823 0209

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Hustler Shibaura S773L N843 N843L Service Manual 109823 0209

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SHIBAURA DIESEL ENGINE

MODELS: S773L, N843, N843L

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