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109823 2/09

2-6

Parts and Descriptions

Index

Description

Alternator

Oil filter

Relief valve

Oil level gauge•Gauge guide

Engine stop solenoid•Seal washer

Fuel injection lines

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

Содержание N843

Страница 1: ...SHIBAURA DIESEL ENGINE MODELS S773L N843 N843L WORKSHOP MANUAL SUPPORTED BY HUSTLER TURF EQUIPMENT AND EXCEL INDUSTRIES INC...

Страница 2: ...esel 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 Speci...

Страница 3: ...moval 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...

Страница 4: ...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 Elect...

Страница 5: ...y instructions and always pay attention to the safety alert symbol which means DANGER or WARNING personal safety instructions Failure to comply with the instructions may result in personal injury or d...

Страница 6: ...ydraulic 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 wood never use your hands Relieve all pressu...

Страница 7: ...ercial 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 area...

Страница 8: ...1 4 109823 2 09...

Страница 9: ...asurements 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 tolerance...

Страница 10: ...4 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 M1...

Страница 11: ...109823 2 09 2 3 Engine Sectional Drawing...

Страница 12: ...AE No 2 D 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 all speed con tro...

Страница 13: ...rom 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 Di...

Страница 14: ...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...

Страница 15: ...witch 13 Thermostat housing Gasket 14 Valve cover O ring Intake manifold Spacer 15 Rocker arm assembly O ring Cap NOTE Remove the caps from intake valves and exhaust valves 16 Push rod 17 Cylinder hea...

Страница 16: ...ft pulley and nut 23 Not available 24 Timing gear case assembly Gasket Note Remove the engine stop solenoid and injection pump assembly first 25 Idle gear Oil pump assembly 26 Cam shaft assembly Plate...

Страница 17: ...E 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 locatio...

Страница 18: ...2 10 109823 2 09...

Страница 19: ...rew 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 micro...

Страница 20: ...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 R...

Страница 21: ...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 Cle...

Страница 22: ...he 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 re...

Страница 23: ...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 di...

Страница 24: ...in mm Standard assembling value Service limit Top ring 0 0079 0 0138 0 20 0 35 More than 0 0393 1 0 Second ring 0 0079 0 0138 0 20 0 35 More than 0 0393 1 0 Oil ring 0 0059 0 0138 0 15 0 35 More than...

Страница 25: ...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...

Страница 26: ...lling 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 upw...

Страница 27: ...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...

Страница 28: ...e 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 w...

Страница 29: ...f 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...

Страница 30: ...ce 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 servic...

Страница 31: ...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...

Страница 32: ...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...

Страница 33: ...ed 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 f...

Страница 34: ...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 movem...

Страница 35: ...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 enteri...

Страница 36: ...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...

Страница 37: ...f valve torque to 41 3 48 3 lbf ft 59 69 N m 6 0 7 0 kgf m Crank shaft and bearing holder assembly Cylinder block to bearing holder torque Notes 1 Be careful not to damage the bushing in the cylinder...

Страница 38: ...ply 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 lbf ft 24 29 N m 2 4 3 0 kgf m Fly wheel torque...

Страница 39: ...o 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 mo...

Страница 40: ...ket 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 plat...

Страница 41: ...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 1 0 15 mm Timing gear case Cover 1 Loosen the lock nut and remove th...

Страница 42: ...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...

Страница 43: ...he 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 p...

Страница 44: ...rning 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...

Страница 45: ...e 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 lbf in 10 12 N m 1 0 1 2 kgf m Ey...

Страница 46: ...109823 2 09 4 16...

Страница 47: ...hes 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...

Страница 48: ...tance should measure between 0 45 0 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 As...

Страница 49: ...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 o...

Страница 50: ...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...

Страница 51: ...mediately 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 v...

Страница 52: ...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 sur...

Страница 53: ...y 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 b...

Страница 54: ...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...

Страница 55: ...sembly 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...

Страница 56: ...mits 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...

Страница 57: ...RPM 2500 Brush length Original in mm 0 728 18 5 Limit in mm 2 0 50 Brush spring tension Original lb g 1 04 1 30 470 590 Limit lb g 0 600 270 Bearing Rear side ECS8 Front 6303DDG Slip ring diameter ecc...

Страница 58: ...Regulator Defective regulator Replace Battery Defective battery Replace Over Battery Internal short Replace charge Regulator Defective regulator Replace Wiring Open circuit broken wire Replace Loose o...

Страница 59: ...fferent 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 positione...

Страница 60: ...der 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 in...

Страница 61: ...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 commu...

Страница 62: ...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 bearin...

Страница 63: ...he 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 term...

Страница 64: ...d 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 1 7 3 lbf 22 5 3...

Страница 65: ...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...

Страница 66: ...5 20 109823_2 09...

Страница 67: ...uel 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 r...

Страница 68: ...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 Shor...

Страница 69: ...15 IN 0 0335 0 0453 0 85 1 15 Ex 0 0335 0 0453 0 85 1 15 0 71 1 8 Valve sheet angle 45 Width of valve seat Intake 0 059 0 083 1 50 2 10 0 059 0 083 1 50 2 10 0 098 2 5 Exhaust 0 063 0 071 1 59 1 80 0...

Страница 70: ...08 Oil ring 0 0008 0 0024 0 02 0 06 0 0008 0 0024 0 02 0 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 Connecting Rods Torsion between small...

Страница 71: ...Clearance between crank shaft journal and bearing 0 0015 0 0042 0 039 0 106 0 0015 0 0042 0 039 0 106 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...

Страница 72: ...2 0 5 Valve clearance Intake exhaust 0 008 0 2 0 008 0 2 0 02 0 5 Valve spring Spring force lbf 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...

Страница 73: ...0100 0 25 Side clearance rotor to cover 0 004 0 006 0 1 0 15 0 004 0 006 0 1 0 15 008 0 2 008 0 2 Fuel System Injection Pump Type Bosch PFR Type Injection timing Before T D C 25 27 18 20 Piston dis pl...

Страница 74: ...ed 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 Spri...

Страница 75: ...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...

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