Shibaura N843L Instruction manual

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.
DANGER—denotes immediate hazards which WILL
result in severe personal injury or death.
WARNING—denotes 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 owner’s 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 WARNING—“personal
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
wood—never 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 lbf•ft(Nm){kgfm}
Weight oz(g)
Temperature °F(°C)
Pressure PSI(MPa){kgf/cm2}

2-2 109823 2/09
Torque Specifications
Bolt
Size Grade No. Coarse Thread Fine Thread
Pitch
(mm) Tightening torque Pitch (mm) Tightening torque
lbf•ft N•m lbf•ft N•m
M5 4T, 4.8 0.8 18.6-35.4 in•lbf2.8-4.0 ----- -----
7T, 8T, 8.8 43.4-61.1 in•lbf4.9-6.9
10T, 11T 59.3-83.2 in•lbf6.7-9.4
M6 4T, 4.8 1.0 43.4-61.1 in•lbf4.9-6.9
7T, 8T, 8.8 73.5-100.0 in•lbf8.3-11.3
10T, 11T 106.2-141.6 in•lbf12-16
M8 4T, 4.8 1.25 115.1-150.5 in•lbf13-17 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.2–D, DIN 51601,
BS class A-1 SAE No.2–D, DIN 51601, BS class A-1 SAE 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-
trol Centrifugal all–speed con- trol Centrifugal all–speed con- trol
*Alternator, voltage. Output 12V–40A 12V–40A 12V–40A
*Starter, Voltage. Output 12V–1.2kW 12V–2.0kW 12V–2.0kW
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
45
43
12
3
124
6
5

109823 2/09 2-6
Parts and Descriptions
Index Description
1 Alternator
2 Oil filter
3 Relief valve
4 Oil level gauge•Gauge guide
5 Engine stop solenoid•Seal 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
43
6
7

109823 2/09 2-7
Index Description
8 Fuel return line
9 Injection nozzle•Gasket
10 Oil transfer pipe•Eye bolt •Seal washer
11 Connector•Glow plug
12 Oil pressure switch
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 head assembly•Head 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-belt•Cooling fan•Fan holder•Fan pulley
21 Water pump assembly•Gasket
22 Crankshaft 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
Note: Remove the bolts and plate before pulling the camshaft assembly.
27 Front plate•Gasket
20
21
20
22
23
24
25 26
27

109823 2/09 2-9
Index Description
28 Oil pan•Gasket•Suction filter•Suction 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 ø 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)
Standard assembling value Service limit
0.0013-0.0027(0.032–0.068) 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.
Inspection and service
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
positions—A 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 ø in(mm)
Intake valve Exhaust valve
Standard
assembling
value
Service limit Standard
assembling
value
Service limit
0.274-0.2744
(6.955–6.97) Less than 0.2712(6.89) 0.273-0.274 (6.94–6.955) Less than 0.269(6.84)
Valve head thickness in(mm)
Standard assembling value Service limit
0.0305-0.0423(0.775–1.075) 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
III III
Stem End
Head End
Thickness