Shibaura E673l User Manual

Shibaura Diesel Engine  
Operation Manuals  
E673L  
S773L  
N843  
N843L  
N844L  
N844L-T  
Supported by  
Hustler Turf Equipment Company  
and  
Excel Industries, Inc.  
109821_0508  
1
FOREWORD  
The IHI Shibaura Machinery Corporation (ISM) industrial diesel engines are a product of ISM's long years of experience,  
advanced technology. Shibaura takes great pride in the superior durability and operating economy of these engines.  
In order to get the fullest use and benefit from your industrial engine, it is important that you operate and maintain it correctly.  
This Manual is designed to help you do this.  
Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of  
trouble-free and economical engine operation.  
Should your engine require servicing, please contact your nearest Authorized Hustler Turf Dealer. He knows your engine best  
and is ready to meet your needs.  
All information, illustrations, and specifications contained in this Manual are based on the latest product information available  
at the time of publication.  
Shibaura reserves the right to make changes in this Manual at any time without prior notice.  
CALIFORNIA  
Proposition 65 Warning  
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other  
reproductive harm.  
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California  
to cause cancer and birth defects or other reproductive harm. Wash hands after handling.  
109821_0508  
3
FEDERAL and CALIFORNIA EMISSIONS WARRANTY  
WARRANTY STATEMENT  
IHI Shibaura Machinery Corporation (ISM) warrants that your 2004 and later non-road diesel engine was designed, built and  
equipped to conform to applicable U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARB)  
regulations and is free from defects in materials and workmanship which cause it to fail to conform with such regulations, for the  
following period of operation:  
For a period of two (2) years or 1,500 hours of operation, whichever occurs first, after the date of delivery to the initial  
retail owner of any variable speed non-road diesel engine rated at less than 19kW (25hp) and any constant-speed non-  
-1  
road diesel engine rated at less than 37 kW (50hp) with rated speed greater than or equal to 3,000 min  
.
For a period of five (5) years or 3,000 hours of operation, whichever occurs first, after the date of delivery to the initial  
owner for all other non-road diesel engines.  
WARRANTY INFORMATION  
The model year, class of diesel engine, and emission application for your engine are identified on the emission control infor-  
mation label affixed to the right hand side of your engine's timing gear case.  
Any emission control system parts that are proven defective during normal use will be repaired or replaced during the war-  
ranty period.  
The warranty repair or replacement will be performed by any Authorized Hustler Turf Dealer or the distributor of the original  
equipment manufacturer, with no charge for parts or labor (including diagnosis).  
As the engine owner, you are responsible to perform all the required maintenance listed in your owner's manual.  
ISM will not deny an emission warranty claim solely because you have no record of maintenance; however, a claim may be  
denied if your failure to perform maintenance resulted in the failure of a warranted part. Receipts covering regular maintenance  
should be retained in the event of questions and these receipts should be passed on to each subsequent owner of the engine.  
It is recommended that replacement parts used for maintenance or repairs be ISM Service Parts to maintain the quality origi-  
nally designed into your emission certified engine. The use of non-ISM parts does not invalidate the warranty on other compo-  
nents unless the use of such parts causes damage to warranted parts.  
ISM wishes to assure that the emission control systems warranty is being properly administered. If you believe you have not  
received the service to which you are entitled to under this warranty, you should contact your Authorized Hustler Turf Distribu-  
tor.  
EXCEPTIONS  
Please note that Emission Warranty does not cover the following:  
1. Diagnosis or inspection expenses that do not result in eligible claim.  
2. Consequential damage such as loss of time, inconvenience, loss of use of the engine or equipment.  
3. Replacement parts used for required maintenance.  
4. Conditions resulting from tampering, misuse, abuse, improper adjustment, engine alteration, use of add-on or modified  
parts, use of replacement parts that are not the same in performance and durability as the approved parts, accident, failure to  
use recommended fuel or oil, use of unapproved fuel or oil additives, or not performing required maintenance.  
5. Damages or repair costs caused by the Owner's unreasonable delay in making the engine available for inspection and repair.  
6. Replacement parts used for required or scheduled maintenance.  
PARTS COVERED  
This emission control system warranty applies to the following emission control parts.  
• Fuel Injection Pump  
• Fuel Injectors  
• Intake Manifold  
• Exhaust Manifold Turbocharger (if equipped)  
• Positive Crankcase Ventilation system parts (including PCV Valve and Oil Filler Cap)  
4
109821_0508  
TABLE OF CONTENTS  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Engine external views  
Engine main parts nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
General information  
3.1  
Engine data and specifications. . . . . . . . . . . . . . . . . . . . . . . . .7  
ISM engine after service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Fuel, lubricant and coolant  
5.1  
5.2  
5.3  
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9  
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10  
Engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10  
6.1  
6.2  
6.3  
6.4  
6.5  
6.6  
6.7  
6.8  
Check before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10  
Engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Check and operation after the engine start-up . . . . . . . . . . . .13  
Precautions during engine operation . . . . . . . . . . . . . . . . . . .13  
Engine stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15  
Run-in (break-in) for new engine . . . . . . . . . . . . . . . . . . . . . .15  
Engine care for over cooling. . . . . . . . . . . . . . . . . . . . . . . . . .15  
Starting the engine after being left  
unused for a long period of time. . . . . . . . . . . . . . . . . . . . . . .15  
Periodic inspection and maintenance  
7.1  
7.2  
7.3  
7.4  
7.5  
7.6  
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15  
Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17  
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Engine electricals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Engine assembly and others . . . . . . . . . . . . . . . . . . . . . . . . .20  
Engine care in cold season . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22  
8.1  
8.2  
8.3  
8-4  
8-5  
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22  
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22  
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22  
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22  
Engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22  
Engine maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23  
Simple engine troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25  
109821_0508  
5
In the caution area, we tell you about something that can  
damage your engine or equipment. Many times, this damage  
would not be covered by your warranty, and it could be costly.  
But the caution will tell you what to do to help avoid the dam-  
age.  
1. Safety  
Introduction  
This Operation Manual contains the information you will  
need to operate the engine correctly. Check that you have the  
correct Operation Manual for your engine.  
2. Engine external views  
Read the book carefully before operating or servicing  
the engine. Incorrect operation or servicing of the engine  
could result in personal injury or material damage as well as  
damaging the engine itself. If you do not understand or are  
uncertain on any operation in this book, contact your  
dealer who can explain or demonstrate the procedure for  
you.  
Engine main parts nomenclatures  
1. Stop solenoid  
2. Oil filler cap  
3. Nozzle and holder  
4. Fan  
5. Engine control lever  
6. Oil dipstick  
7. Oil sump  
Warning and Caution  
In this manual and on the engine you will find the follow-  
ing special warning symbols.  
8. Injection pump  
9. Oil drain plug  
10. Flywheel  
Safety Warnings  
11. Oil filter  
12. Water drain cock  
13. Air intake  
14. Head cover  
15. Exhaust manifold  
16. Starting motor  
17. Alternator  
WARNING: This means there is something that could  
hurt you or other people.  
In the warning area, we tell you what the hazard is. Then  
we tell you what to do to help avoid or reduce the hazard.  
Please read these warnings. If you don't, you or others could  
be hurt.  
18. Crankshft pulley  
19. Belt  
Engine or Equipment Damage Warnings  
CAUTION: This means there is something that could  
damage your engine or equipment.  
2
4
3
13  
14  
1
12  
5
15  
16  
8
19  
11  
18  
6
17  
9
7
10  
6
109821_0508  
3. General Information  
3.1.Engine data and specifications  
Model Name  
E673L  
S773L  
N843  
N843L  
N844L  
N844L-T  
Engine Type  
Four cycle, water-cooled, in-line overhead valve type  
Swirl chamber  
Combustion type  
No.of cylinder-bore×stroke (mm)  
Engine displacement (L)  
Compression ratio  
3 - 67×72  
0.761  
3 - 77×81  
1.131  
3 - 84×90  
1.496  
3 - 84×100  
1.662  
4 - 84×100  
2.216  
4 - 84×100  
2.216  
23.5  
23.5  
22.5  
22.5  
22.5  
22.5  
16.5hp/3000  
(12.3kW/3000)  
18.5hp/3600  
24.7hp/3000  
(18.4kW/3000)  
29.1hp/3600  
29.4hp/2600  
(21.9kW/2600)  
30.8hp/3600  
32.6hp/2600  
(24.3kW/2600)  
34.2hp/3600  
44.9hp/2600  
(33.5kW/2600)  
46.3hp/3600  
54.7hp/2600  
(40.8kW/2600)  
56.8hp/3600  
42.4kW/3000  
* Max output  
(13.8kW/3600)  
(21.7kW/3600)  
(23.0kW/3000)  
(25.5kW/3000)  
(35.0kW/3000)  
13.8hp/3000  
(10.3kW/3000)  
15.4hp/3600  
23.3hp/3000  
(17.4kW/3000)  
24.8hp/3600  
16.6hp/1500  
(12.4kW/1500)  
19.7hp/1800  
N/A  
N/A  
N/A  
N/A  
25.3hp/1500  
(18.9kW/1500)  
29.6hp/1800  
31.1hp/1500  
(23.2kW/1500)  
37.8hp/1800  
* Rated output  
(11.5kW/3600)  
(18.5kW/3600)  
(14.7kW/1800)  
(22.1kW/1800)  
(28.2kW/1800)  
Overall length (in) (mm)  
17.4 (443)  
15.2 (385)  
17.8 (453)  
15.1 (384)  
21.0 (534)  
18.1 (459)  
21.0 (534)  
18.1 (459)  
25.1 (637)  
17.8 (453)  
25.3 (642)  
20.3 (516)  
* Engine  
Overall width (in) (mm)  
Overall height (in) (mm)  
dimension  
21.5 (546)  
165.3 (75)  
23.6 (600)  
191.8 (87)  
25.9 (657)  
27.1 (689)  
28.1 (713)  
27.5 (698)  
* Engine dry weight (lbs.) (kg)  
Direction of rotation  
330.7 (150)  
352.7 (160)  
429.9 (195)  
447.5 (203)  
Counter clockwise (Look at Flywheel side)  
2.85 (2.7) 2.96 (2.8)  
Pressurized circulation by trochoid pump  
2.85 (2.7) 6.34 (6.0)  
Quality better than CD class(API)  
Coolant volume (Engine only) (qt) (L)  
Lubrication method  
1.37 (1.3)  
3.28 (3.1)  
2.00 (1.9)  
5.18 (4.9)  
3.80 (3.6)  
8.66 (8.2)  
3.80 (3.6)  
8.66 (8.2)  
Lub. Oil volume (qt) (L)  
Specified engine oil (API grade)  
* Alternator (V-A)  
12-14  
12-15  
12-40  
12-1.7  
* Starting Motor (V-kW)  
Specified fuel  
12-0.8  
12-2.0  
SAE NO. 2-D, DIN 51601, BS Class A-1  
Centrifugal all-speed control  
Governor  
NOTE:  
1. The specifications above are subject to partial changes without notice.  
2. Asterisked (*) items may vary depending on the type of equipment in which the engine is installed.  
4. Shibaura Engine Service  
(1) Shibaura Engine After Service  
Please feel free to contact your Hustler Turf Equipment  
Dealer which is authorized by Shibaura for periodic inspec-  
tion and maintenance.  
When ordering service or spare parts always quote the  
engine model name and serial number.  
(2) Engine Identification  
Model Name  
The engine serial number and engine model are stamped  
on the front upper right side of the cylinder body.  
XXXXXXXXXXX  
serial no.  
3/04  
IHI Shibaura Machinery Corporation  
Serial Number  
Assembled Months / Years  
109821_0508  
7
Number 1-D and Number 2-D). This blended fuel is usually  
called Number 2-D also, but can be used in colder tempera-  
tures than Number 2-D fuel which has not been "winterized".  
Check with the service station operator to be sure you get the  
properly blended fuel.  
Note that diesel fuel may foam during a fill-up. This can  
cause the automatic pump nozzle to shut off even though your  
tank is not full.  
5. Fuel, Lubricant & Coolant  
5.1 Fuel  
(1) Fuel Selection  
The following specific characteristics are required for the  
diesel fuel.  
1. Must be free from minute dust particles.  
2. Must have adequate viscosity.  
3. Must have high cetane value.  
4. Must have high fluidity at low temperature.  
5. Must have low sulfur content.  
6. Must have little residual carbon.  
CAUTION: Do not use home heating oil or gaso-  
line in your diesel engine; either may cause engine  
damage.  
(3) Handling of the Fuel  
Diesel fuels  
Fuel containing dust particles or water will cause engine  
failure. Therefore, the following notice must be observed.  
1. Prevent dust particles or water from entering when filling  
the fuel tank.  
Applicable Standard  
Recommendation  
NO. 2  
JIS (Japanese Industrial Standard  
DIN (Deutsche Industrie Normen)  
When fueling is done from an oil drum directly, keep the  
drum stationary for a period of time to allow the sediment  
to go to the bottom of the drum.  
Din 51601  
NO. 2-D  
SAE (Society of Automotive Engi-  
neers) Based on SAE-J-313C  
2. Always fully fill the fuel tank. Drain the sedimented par-  
ticles in the fuel tank frequently by opening the tank  
drain and draining the fuel into approved fuel containers.  
BS (British Standard)  
Based on BS/2869-1970  
Class A-1  
(4) Water in Fuel  
(2) Fuel Requirements  
During refueling, it is possible for water (and other con-  
taminants) to be pumped into your fuel tank along with the  
diesel fuel. This can happen if a service station does not regu-  
larly inspect and clean its fuel tanks, or if a service station  
receives contaminated fuel from its supplier(s).  
To protect your engine from contaminated fuel, there is a  
fuel filter system on the engine or equipment which allows  
you to drain excess water.  
CAUTION: The fuel injection pump, injector or  
other parts of the fuel system and the engine can  
be damaged if you use any fuel or fuel additive  
other than those specifically recommended by  
Shibaura. Such damage is not Shibaura's responsi-  
bility, and is not covered by the Warranty. To help  
avoid fuel system or engine damage, please be  
aware of the following:  
Some service stations mix used engine oil with  
diesel fuel. Some manufacturers of large diesel  
engines allow this; however, for your diesel  
engine, do not use diesel fuel which has been con-  
taminated with engine oil. Besides causing engine  
damage, such fuel can also affect emission control.  
Before using any diesel fuel, check with the ser-  
vice station operator to see if the fuel has been  
mixed with engine oil.  
Do not use any fuel additive (other than as recom-  
mended under "Biocide" in this section). At the  
time this manual was printed, no other fuel addi-  
tive was recommended. (See your authorized  
dealer to find out if this has changed.)  
WARNING: The water/diesel fuel mixture is  
flammable, and could be hot. To help avoid per-  
sonal injury and/or property damage, do not touch  
the fuel coming from the drain valve, and do not  
expose the fuel to open flames or sparks.  
Be sure you do not overfill the container. Heat  
(such as from the engine) can cause the fuel to  
expand. If the container is too full, fuel could be  
forced out of the container. This could lead to a  
fire and the risk of personal injury and/or vehicle  
or equipment damage.  
(5) Biocides  
Your engine is designed to use either Number 1-D or  
Number 2-D diesel fuel. However, for better fuel economy,  
use Number 2-D diesel fuel whenever possible. At tempera-  
tures less than -7°C, (20°F), Number 2-D fuel may pose oper-  
ating problems (see "Cold Weather Operation" which  
follows). At colder temperatures, use Number 1-D fuel (if  
available) or use a "winterized" Number 2-D (a blend of  
In warm or humid weather, fungus and/or bacteria may  
form in diesel fuel if there is water in the fuel.  
CAUTION: Fungus or bacteria can cause fuel sys-  
tem damage by plugging the fuel lines, fuel filters  
or injector. They can also cause fuel system corro-  
sion.  
8
109821_0508  
If fungus or bacteria has caused fuel system problems, you  
should have your authorized dealer correct these problems.  
Then, use a diesel fuel biocide to sterilize the fuel system (fol-  
low the biocide manufacturer's instructions). Biocides are  
available from your dealer, service stations, parts stores and  
other automotive places. See your authorized dealer for  
advice on using biocides in your area and for recommenda-  
tions on which biocides you should use.  
(1) Engine Oil Selection  
Quality better than CD grade by API classification engine  
oil must be used for the Shibaura engines.  
(2) Oil Viscosity  
Engine oil viscosity largely affect engine startability, per-  
formance, oil consumption, speed of wear and occurrence of  
seizure, etc.  
(6) Smoke Suppressants  
Using lubricants with viscosity rated according to the  
atmospheric temperature is important.  
Because of extensive testing of treated fuel versus  
untreated fuel, the use of a smoke suppressant additive is not  
recommended because of the greater possibility of stuck rings  
and valve failure, resulting from excessive ash deposits.  
CAUTION:  
1. Using a mixture of different brand or quality oils  
will adversely affect the original oil quality; there-  
fore, never mix different brands or different types  
of oils.  
5.2 Lubricant  
2. Don't use API, CA, CB grade and reconstituted  
engine oil.  
3. Engine damage due to improper maintenance, or  
using oil of the improper quality and/or viscosity,  
is not covered by the warranty.  
The quality of engine oil may largely affect engine perfor-  
mance, startability and engine life.  
Use of unsuitable engine oil will result in piston ring, pis-  
ton and cylinder seizure and accelerate the sliding surface  
wear causing increased oil consumption, lowered output and,  
finally engine failure. To avoid this, use the specified engine  
oil.  
ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE  
6$(ꢀꢆꢂ  
ꢀꢀꢀ6$(ꢀꢁꢂꢃꢁꢂ:  
SINGLE GRADE  
6$(ꢀꢄꢂ:  
6$(ꢀꢅꢂ  
᧬ഒ ᧭᧱ഒ  
᧩᧯᧬ഒ ᧩᧮᧬ഒ ᧩᧭᧱ഒ  
(-4F)  
᧮᧱ഒ  
᧯᧬ഒ  
AMBIENT  
TEMPERATURE  
᧩᧮᧮ᨂ  
᧤᧱ᨂ᧥ ᧤᧯᧮ᨂ᧱᧵ᨂ᧳᧳ᨂ᧴᧲ᨂ᧥  
6$(ꢀꢂ:ꢇꢅꢂ  
6$(ꢀꢄꢂ:ꢇꢅꢂ  
MULTI GRADE  
6$(ꢀꢄꢈ:ꢇꢆꢂ  
FIG-1  
109821_0508  
9
5.3 Coolant  
Drain oil to the max. oil level if oil level is above the  
max. level mark.  
Use 50/50 mix Ethylene Glycol and water for coolant and  
replace it periodically. (Refer to section 8.2)  
Add oil to the max. oil level if oil level is below the  
min. level mark.  
3. Also check the sample oil on the dipstick for fouling and  
degrees of viscosity.  
6. Engine Operation  
CAUTION: Oil level check must be made ten or  
twenty minutes after the engine has been stopped.  
When the oil level check is necessary while the  
engine is running, stop the engine and keep it sta-  
tionary ten or twenty minutes until the oil thor-  
oughly flows down to the oil pan.  
Engine Exhaust Gas Caution  
(Carbon Monoxide)  
WARNING: Do not breathe exhaust gas because  
it contains carbon monoxide, which by itself has  
no color or odor. Carbon monoxide is a dangerous  
gas. It can cause unconsciousness and can be  
lethal.  
If at any time you think exhaust fumes are entering  
the cab, have the cause determined and corrected  
as soon as possible. If you must drive under these  
conditions, drive only with all windows fully open.  
Protect against carbon monoxide entry into the  
cab. The best way is to keep the engine exhaust  
system, cab and cab ventilation system properly  
maintained. We recommend that the exhaust sys-  
tem and cab be inspected by competent technician:  
Each time the vehicle has an oil change.  
Whenever a change is noticed in the sound of  
the exhaust system.  
Max. Level  
Min. Level  
Whenever the exhaust system, underbody or cab  
is damaged or becomes corroded.  
See the "Maintenance Schedule" in this manual for  
parts requiring inspection.  
Engine oil replenishment  
Changing the oil  
To allow proper operation of your vehicle's venti-  
lation system, keep the air inlet grille clear of  
snow, leaves or other obstructions at all times. Do  
not run the engine in confined areas (such as  
garages or next to building) any more than needed  
to move the vehicles or the equipment.  
Keep the exhaust tailpipe area clear of snow and  
other material to help reduce the buildup of  
exhaust gases under the vehicle or the equipment.  
This is particularly important when parked in bliz-  
zard conditions.  
1. Before adding engine oil, place the unit on a level sur-  
face, then remove the dipstick to provide crankcase venti-  
lation.  
2. MODELS E673L, S773L, N844L, N844L-T ONLY  
Add engine oil slowly. Pouring the oil too quickly can  
result in the oil overflowing into the air breather valve  
and then into the air intake manifold. Cranking the  
engine with oil in the manifold will severely damage the  
engine.  
NOTE: If oil has entered the air intake manifold it will be  
necessary to clean the oil from the cylinders. To clean the  
cylinders, remove the fuel injection nozzles and turning  
the engine with the starter until all oil is exhausted.  
When changing the engine oil, add the exact amount  
specified in the engine owner’s manual.  
NOTE: Use CD grade or better by API classification  
engine oil.  
MODELS N843 & N843L ONLY — Add oil at the oil  
fill shown.  
6.1 Check Before Operation  
WARNING: For safety's sake, conduct the inspec-  
tion before start-up with the engine stopped.  
(1) Engine Oil Level  
1. Place the engine on a level surface.  
2. Remove the dipstick from the crankcase, wipe it with a  
clean shop towel or cloth.  
When changing the engine oil, add the exact amount  
specified in the engine owner’s manual.  
Use CD grade or better by API classification engine oil.  
3. Wait about fifteen minutes until the oil gets down to the  
oil pan. Then check the oil level with a dipstick. A certain  
period of time is required before the engine oil com-  
pletely flows down from the oil filler to the crankcase.  
Insert it fully and remove it gently again.  
Check the oil level by the level marks on the dipstick.  
The oil level must be between the "Max." level mark and  
the "Min." level mark as illustrated.  
Take care not to add too much engine oil.  
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