Iseki SGR17, SCM49, SGR19, SCM54 Service Manual

SERVICE MANUAL

ISEKI LAWN MOWERS

LAWN MOWERS:

MOWER DECKS:

SCM48 & SCM54

2

SERVICE MANUAL FOR SGR19 & SGR17

FOREWARD

This service manual has been prepared to provide the information and suggestions necessary for
servicing the ISEKI SGR equipped with the hydrostatic transmission. These include construction, specifica­tions, removal and reinstallation of the components, disassembly and reassembly instructions, inspection
and adjustment instructions, troubleshooting, general precautions etc.

Figures mentioned in this manual are standard values established by ISEKI for the SGR, conse­quently when a non-ISEKI part has been installed on the machine or adjustments and repairs have been
made in a manner other than as specified in this manual, the pertinent values mentioned herein are no longer
valid. ISEKI does not assume responsibility for problems or damage caused by a value deviation due to
maladjustment or by the use of unauthorized parts.

Servicing procedures outlined in the manual contain sufficient informa­tion to return all component parts of a machine to new condition. In discussion of each
component part, it is assumed that a complete overhaul is being performed, conse­quently, complete disassembly and reassembly are outlined. The machine is relied
upon to decide how far disassembly must be carried out when complete overhaul is not
required.

Study unfamiliar service procedures thoroughly and understand them clearly
before attempting disassembly. Specific data essential for proper overhaul, such as
running clearances and torque values, have been provided in interline of inspection
and reassembling procedures of each group section.

This manual was compiled from latest information available at time of
publication, However ISEKI reserves the right to make changes at any time without
notice.

Whenever the terms “left” and “right” are used, this means as viewed by
the operator when seated in the operator’s seat.

Whenever servicing the machines, pay sufficient attention to the opera­tional safety to protect you and other persons around the machines from danger by
following carefully the instructions given in the manual. Never take chances!

3

ISEKI LAWN MOWERS

TABLE OF CONTENTS

FOREWARD ................................................................ 2

TABLE OF CONTENTS............................................... 3

CHAPTER 1. INTRODUCTION ................................... 5

1. GENERAL INFORMATION..................................... 5

a. Model name and identification numbers ......... 5

b. Chassis number.............................................. 5

c. Engine model name and serial number .......... 5

2. SPECIFICATIONS ................................................. 6

3. EXTERIOR VIEW AND DIMENSIONS ................... 7

4. PERIODIC INSPECTION TABLE............................ 8

5. FILLING DIAGRAM................................................. 9

CHAPTER 2. DISASSEMBLY OF MAJOR COMPO-

NENTS ....................................................................... 10

I. GENERAL PRECAUTIONS FOR SEPARATION

AND REINSTALLATION ....................................... 10

1. BEFORE OPERATION ......................................... 10

2. PRECAUTIONS TO BE FOLLOWED WHEN

INSTALLING COMMON PARTS........................... 10

a. Roller or ball bearings ................................... 10

b. Oil seals ........................................................ 10

c. O-rings ...........................................................11

d. Snap-rings .....................................................11

e. Spring (roll) pins.............................................11

f. Cotter pins .....................................................11

g. Bolts and nuts ................................................11

h. After installation, each grease fitting should be

filled with grease. .......................................... 12

i. Other precautions ......................................... 12

II. BEFORE STARTING DISASSEMBLY .................. 12

1. REMOVAL OF THE MOWER DESK..................... 12

2. REMOVAL AND REINSTALLATION OF MAJOR

FUNCTIONAL COMPONENTS ............................ 13

2.1. REMOVAL AND REINSTALLATION OF

ENGINE ........................................................ 13

REMOVAL..................................................... 13

REINSTALLATION........................................ 16

2.2. REMOVAL AND REINSTALLATION OF

FENDERAND STEP ..................................... 17

REMOVAL OF FENDER ............................... 17

REMOVAL OF STEP .................................... 17

REINSTALLATION........................................ 18

2.3. REMOVAL AND REINSTALLATION OF

TRANSMISSION CASE................................ 18

REMOVAL..................................................... 18

REINSTALLATION........................................ 19

CHAPTER 3. ENGINE ............................................... 20

1. INSPECTION OF ENGINE OIL ............................ 21

2. INSPECTION OF FAN BELT ................................ 21

3. INSPECTION AND ADJUSTMENT OF VAL VE

CLEARANCES...................................................... 22

4. INSPECTION AND ADJUSTMENT OF NOZZLE
OPENING PRESSURE AND INJECTION TIMING

...................................................................... 22

4.1. Adjustment of the valve opening pressure of

the injection nozzles ..................................... 22

4.2. Inspection of oil tightness of valve seats ...... 23

4.3. Spraying condition of injection nozzle........... 23

4.4. Inspection and adjustment of injection timing

...................................................................... 23

5. COMPRESSION AND UNLOADED IDLING.............

SPEEDS ............................................................... 25

5.1. Inspection of compression ............................ 25

5.2. Inspection and adjustment of the idling

speeds .......................................................... 25

6. INSPECTION OF WATER PUMP ......................... 25

6.1. Inspection of the pump and pulley ................ 25

6.2. Inspection of the bearing unit........................ 26

7. INSPECTION OF THERMOSTAT ......................... 26

III. ENGINE BODY ..................................................... 26

III.1. CYLINDER HEAD.............................................. 26

1. REMOVAL OF THE CYLINDER HEAD................. 27

2. DISASSEMBLY ..................................................... 28

3. INSPECTION ........................................................ 28

4. DISASSEMBLY AND INSPECTION OF THE

ROCKER ARM SHAFT ......................................... 31

5. INSPECTION OF THE PUSH RODS.................... 32

6. INSTALLATION OF THE CYLINDER HEAD ......... 32

III.2. GEAR CASE ...................................................... 34

1. EXPLODED VIEW ................................................ 34

2. REMOVAL OF THE GEAR CASE......................... 34

3. RE-INSTALLATION OF THE GEAR CASE ........... 35

III.3. CYLINDER BLOCK ........................................... 36

1. EXPLODED VIEWS.............................................. 36

2. DISASSEMBLY OF THE CYLINDER BLOCK ...... 37

3. INSPECTION OF CYLINDER BLOCK, CRANK-

SHAFT, CAMSHAFT, AND TAPPETS................... 38

4. INSPECTION OF PISTONS AND CONNECTING

RODS.................................................................... 43

5. ASSEMBLY OF PISTON AND CONNECTING ROD

...................................................................... 45

6. INSTALLATION OF CRANKSHAFT...................... 46

7. INSTALLATION OF PISTON/CONNECTING-ROD

ASSEMBLIES ....................................................... 47

8. INSTALLATION OF REAR OIL SEAL ................... 48

9. INSTALLATION OF STRAINER AND OIL PAN..... 48

10.INSTALLATION OF REAR PLATE AND FLYWHEEL

...................................................................... 49

11.INSTALLATION OF FRONT PLATE AND GEARS

...................................................................... 49

CHAPTER 4. TRANSMISSION & RELATED PARTS

......................................................................... 52

1. DRIVE TRAIN DIAGRAM...................................... 52

2. TRANSMISSION................................................... 52

4

SERVICE MANUAL FOR SGR19 & SGR17

3. REAR WHEEL DRIVING MECHANISM ............... 53

DISASSEMBLY............................................. 53

4. REAR TRANSMISSION CASE ............................. 54

INSPECTION................................................ 54

REASSEMBLY.............................................. 54

5. BRAKE SYSTEM .................................................. 56

5.1. CONSTRUCTION ......................................... 56

5.2. INSPECTION ................................................ 56

5.3. REASSEMBLY .............................................. 57

5.4. ADJUSTMENT OF BRAKE PEDAL AFTER

ASSEMBLING .............................................. 57

CHAPTER 5. HYDROSTATIC TRANSMISSION ....... 59

1. CONSTRUCTION AND NAMES OF MAJOR

COMPONENTS .................................................... 59

2. OPERATING DIAGARM OF HST ......................... 60

3. FUNCTION ........................................................... 61

3.1. VARIABLE TYPE PUMP............................... 61

3.2. FIXED TYPE MOTOR................................... 62

3.3. VALVES ........................................................ 62

4. DISASSEMBLY AND REASSEMBLY.................... 64

4.1. REQUIRED TOOLS...................................... 64

4.2. PRECAUTIONS FOR DISASSEMBLY ......... 64

4.3. DISASSEMBLY ............................................. 64

4.4. CRITERIA FOR REPLACING WORN PARTS

6968

4.5. PRECAUTION BEFORE REASSEMBLY ..... 70

4.6. REASSEMBLY .............................................. 70

4.7. PRECAUTIONS FOR REASSEMBLY .......... 74

4.8. LIST OF MAJOR COMPONENTS OF HST.. 76

4.9. PRECAUTIONS FOR INSTALLATION OF

HST UNIT ..................................................... 77

4.10.PRECAUTIONS AFTER INSTALLATION OF

HST UNIT ..................................................... 77

4.11.TROUBLESHOOTING.................................. 78

5. ADJUSTMENT OF HST........................................ 80

5.1. ADJUSTMENT OF NEUTRAL POSITION .... 80

5.2. ADJUSTMENT OF HST PEDALS ................ 80

5.3. ADJUSTMENT OF TRUNNION ARM

STOPPERS .................................................. 81

CHAPTER 6. HYDRAULIC SYSTEM ........................ 82

1. HYDRAULIC SYSTEM DIAGARMS ..................... 82

2. INSPECTION OF MAJOR COMPONENTS.......... 84

2.1 SUCTION FILTER ......................................... 84

2.2. HYDRAULIC PUMP (GEAR PUMP)............. 84

2.3. RELIEF VALVE ............................................. 84

2.4. RELIEF METAL (SUPPORT)........................ 85

2.5. OIL FILTER (Return filter assembly)............. 85

2.6. SOLENOID VALVE ASSEMBLY ................... 86

CHAPTER 7. POWER STEERING SYSTEM ............ 88

1. CONSTRUCTION ................................................. 88

2. WORKING PRINCIPLE ........................................ 89

2.1. When the steering wheel is in the neutral

position: ........................................................ 89

2.2. When the steering wheel is operated: .......... 89

3. SECTION OF MINI-ORBIT ROLL AND MAJOR

COMPONENTS .................................................... 90

4. DISASSEMBLY & REASSEMBLY ........................ 91

4.1. DISASSEMBLY ............................................. 91

4.2. REASSEMBLY .............................................. 92

5. MAJOR TROUBLES AND CAUSES, AND

COUNTERMEASURES ........................................ 94

CHAPTER 8. MANUAL STEERING SYSTEM .......... 97

1. CONSTRUCTION ................................................. 97

2. GEAR BOX ........................................................... 97

3. DISASSEMBLY ..................................................... 98

3.1. REMOVAL OF THE STEERING GEAR BOX

ASSEMBLY................................................... 98

3.2. DISASSEMBLY OF THE STEERING GEAR

BOX .............................................................. 98

3.3. INSPECTION ................................................ 98

3.4. REINSTALLATION AND ADJUSTMENT ...... 99

CHAPTER 9. ELECTRICAL ACCESSORIES ......... 100

1. WIRE HARNESS LAYOUT ................................. 100

2. WIRE HARNESS SEQUENCE ........................... 101

3. WIRING DIAGRAM............................................. 102

4. LIMITTER SWITCH FOR TRUNNION ARM ....... 103

5. STA RTER............................................................ 103

5.1. CONSTRUCTION ....................................... 103

5.2. REMOVAL AND DISASSEMBLY OF

STA RTE R ................................................... 104

5.3. INSPECTION OF COMPONENTS ............. 104

5.4. REASSEMBLY OF STARTER .................... 107

5.5. INSPECTION OF THE STARTER AFTER

REMOVAL FROM THE TRACTOR............. 108

5.6. PERFORMANCE TEST.............................. 108

5.7. INSTALLATION OF THE STARTER ........... 109

6. ALTERNATOR ..................................................... 110

6.1. EXPLODED VIEW, SPECIFICATIONS, AND

PERFORMANCE CURVES......................... 111

6.2. TROUBLESHOOTING................................. 111

6.3. REMOVAL AND DISASSEMBLY ................. 111

6.4. INSPECTION ...............................................113

6.5. RE-ASSEMBLY............................................116

7. GLOW PLUGS.....................................................117

7.1. SECTIONAL VIEW ......................................117

7.2. REMOVAL, INSPECTION, AND

RE-ASSEMBLY............................................117

CHAPTER 10. MOWER DECK ................................ 118

1. SPECIFICATIONS ...............................................118

2. FILLING DIAGRAM..............................................119

3. DISASSEMBLY AND REASSEMBLY ................. 120

3.1. GEAR BOX ................................................. 120

3.2. SIDE AND CENTER METAL (SUPPORTS) 122

4. TROUBLESHOOTING........................................ 124

CHAPTER 11. SERVICE STANDARDS .................. 125

1. SERVICE STANDARDS ..................................... 125

2. TIGHTENING TORQUE OF MAJOR

FASTENERS....................................................... 127

3. STANDARD BOLTS AND NUTS ......................... 128

4. BEARING NUTS ................................................. 128

5. LOCKING BOLTS AND NUTS ............................ 128

5

CHAPTER 1. INTRODUCTION

CHAPTER 1. INTRODUCTION

1.GENERAL INFORMATION

a. Model name and identification numbers

The name plate, which gives the maodel name, type,

production serial number, and production year
of the machine, is located on the left-hand side
of the chassis.

ISEKI & CO., LTD. MADE IN JAPAN

MODEL SGR19H

TYPE UE42

WEIGHT 477 kg

ENGINE 14.0 kw/2900 min

-1

NO. 000001 99
3-14 NISHI-NIPPORI 5-CHOME

ARAKAWA-KU TOKYO 116 JAPAN

1
2

3 4

(1) Model a=name: SGR19H in the exammple
(2) Type: E42 or UE42
(3) Production serial number: 000001 in the

example

(4) Production year by the last two digits

Fgi. 1-1

Fig. 1-2

b. Chassis number

The chassis number is punched on the left-hand side

of the chassis as shown below.

Fig. 1-3

c. Engine model name and serial number

• The engine name is cast into the right-hand side

wall of the cylinder block.

• The serial number is punched into the left-hand

side wall of the cylinder block.

E393

0.928L

123456

E393

0.928L

123456

1

2

3

Fig. 1-4

6

SERVICE MANUAL FOR SGR19 & SGR17

2. SPECIFICATIONS

These specifications are subject to change without notice.

SGR19H SGR17H

Dimensions ..................... Overall length ................ (mm) .............................................. 1935

(Ballast weight Overall width ................. (mm) .............................................. 1100

included) Overall height ................ (mm) .............................................. 1265

Weight........................................................................ (kg) ......................430............................................420

Engine............................. Model.......................................................... E393-G .................................... E383-G

Numbre of cylinders .................................................................. 3

Output .........kW(PS)/2900rpm ................... 14(19) ................................... 12.2(16.5)

Piston displacement ..........(cc) ......................928............................................828

Combustion chamber...................................................... Swirl chamber

Fuel tank capcity ................................................... (litres) ...............................................18.5

Transmission................... Main transmission .............................................HST (Hydro-Static Transmission)

Travelling speed ............. Forward........................ (km/h) ............................................0 – 16.8

Reverse ........................ (km/h) ............................................0 – 10.0

Wheelbase ............................................................... (mm) .............................................. 1365

Wheel tread..................... Front .............................. (mm) ............................................... 860

Rear................................ (mm) ............................................... 860

Tyre size.......................... Front ...................................................................................210/60D-8

Rear....................................................................................250/60D-14

Minimum ground clearance..................................... (mm) ..................................................

Steering system................................................................................Power steering................. Manual or Power steering

PTO................................. Front .............................. (mm) ........................................ 25 (6-spline)

(min-1) .............................................. 2440

........................................ Mid ................................ (mm) .................................25 (ASAE S431 T15)

(min-1) .............................................. 2440

........................................ Rear................................ (mm) .......................................22 (Key-type)

(min-1) .............................................. 2900

7

CHAPTER 1. INTRODUCTION

3.EXTERIOR VIEW AND DIMENSIONS

1935 mm

1965 mm

1100 mm

1265 mm

8

SERVICE MANUAL FOR SGR19 & SGR17

4.PERIODIC INSPECTION TABLE

R

: Inspection, replenishment, and adjustmentY: Cleaning and washing

K

: Replacement

★

: Consult your dealer.

Check points Inspection and servicing intervals Intervals Judgement

hours of operation after that criteria

50 100 150 200 250 300 350 400

Engine oil

R ★ KK★

Replace after initial 50 h Maintain the specified level.
and then every 100 h.

Air cleaner

YYYYYYYY

Clean after every 50 h.

Engine coolant

R

Replace every year. Maintain the specified level.

Fuel

R

Keep fuel tank always full.

Fuel strainer

RYYKY

Clean after every 100 h. There should be no dust or
Replace element after every water in filter.
300 h.

Fan belt

R

10 mm (0.4 in.) deflection

Electrolyte level

RRRRRRRR

Inspect after every 50 h. Level should be kept properly.

Engine oil filter

★★

Replace after initial 50 h.
Replace after every 300 h.

Transmission oil

R ★★

Replace after initial 50 h. Maintain the specified level.
and then after every 200 h.

Hydraulic oil filter

★★

Replace after initial 50 h. and
then replace after every 200 h.

Suction filter

★★

Clean after initial 50 h. and
then clean after every 200 h.

Brake pedal play

R

20 to 30 mm (0.8 to 1.2 in.)

Steering wheel

R ★

Check after every 300 h.

There should be no abnormality.

Ball joints of steering

R

Check after every 300 h. Loose

ball joints should be

system linkage re-tightened.
Tyre pressure

R

Front: 1.6 x 105 Pa (22.7 psi)
Rear: 1.6 x 10

5

Pa (22.7 psi)

Toe-in

★

Adjust aftger every 300 h. 2 to 4 mm (0.08 to 0.16 in.)

Wheel tightening nuts

R

There should be no loose nuts.

Grease-up

RRRRRRRR

Inject grease after evey 50 h.

Radiator screen

Y

There should be no clogging.

Radiator

Y

There should be no clogging.

Electrical apparatus

R

All should work properly.

Safety switches

R

All should work properly.

Air intake openings

Y

There should be no clogging.

Bolts and nuts

R

There should be no loose ones.

Rubber pipes

RRRR

Check after every 100 h.

Important:

• Above mentioned service intervals should be used as reference creteria. If working conditions are harder, earlier service is recommended.

• When special technology and special tools are required, consult your dealers.

Pre-

operation

9

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

5

4

6
3

2

1

7

5

Oil fillers
Oil drains
Greasing points

8
9

5.FILLING DIAGRAM

Quantity: litre

SGR19/17H-U SGR17H

1 Radiator 3.5

Reserve tank 0.6
2 Engine Engine oil 2.5
3 Transmission case HST oil 6.7 6.3

(SHELLDONAX TD)
4 Center pivot Grease As required
5 Knuckle arms Grease As required
6 Brake shaft/HST hub Grease As required
7 Fuel Diesel fuel 18.5
8 Cylinder ball end Grease As required
9 Drive shaft Grease As required

• Use oil of better than class CC.

• Use ISEKI’s recommended oil.

Ref. No. Filling points Lubricants

Fresh clean water

10

SERVICE MANUAL FOR SGR19 & SGR17

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

I. GENERAL PRECAUTIONS FOR SEPARATION AND REINSTALLATION

1. BEFORE OPERATION

a. Always be safety-conscious in selecting clothes

to wear and suitable tools to use.

b. Before disassembly, be sure that you familiarize

yourself with the assembled condition for sub­sequent reference in reassembly.

c. Keep parts and tools in proper order during op-

erations.

d. When servicing electrically live parts, be sure to

disconnect the negative battery terminal.

e. To prev ent oil or water leaks, use the liquid g as-

ket as required.

f. When reassembling disassembled parts, discard

used gaskets, O-rings, or oil seals and install
new ones.

g. When lifting up only the front or rear part of the

tractor, be sure to wedge the grounded wheels.

h. When the tractor is jacked up, be sure to support

the entire tractor with something like a stand.
Lifting it up with a jack only is a dangerously
unstable procedure.

i. When replacing parts, use authorized, genuine

ISEKI parts only. ISEKI assumes no responsi­bility for accidents, operating problems or dam­age caused by the use of imitation parts. Also,
the use of unauthorized parts will result in rela­tively poor machine performance.

2. PRECAUTIONS TO BE FOLLOWED
WHEN INSTALLING COMMON PARTS

a. Roller or ball bearings

• When a bearing is fitted in by the outer race, use
an installer which is specially designed to push
only the outer race and vice versa.

• The installer must be designed to install the bear­ing on the shaft in a parallel position.

•

When installing a bearing which appears the same
on both sides, install it so that the face which has
the identification number faces in a direction for
easy visual identification. All the bearings which
are to be installed in the transmission case should
be placed so that their identification number faces
outward.

• If a shaft or a hole where a bearing is to be in­stalled has a stopper, the bearing should be
pushed in completely until it is seated against
the stopper.

• Installed bearings should turn smoothly.

b. Oil seals

• Oil seal installer should be designed so as not to
deform the oil seals.

• During installation, be careful not to damage the
lips, and assure that it is pushed in parallel to the
shaft or hole.

• When oil seals are installed, there should be no
turnover of the lips nor dislocation of the springs.

• When a multi-lip seal is installed, the grooves
between lips should be filled with grease, not
adhesive.

11

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

• Use a lithium-based grease.

• There should be no oil or water leaks through
the installed soil seals.

c. O-rings

• O-rings should be coated with grease before in­stalling.

• Installed O-rings should have no slack or twist.

• Installed O-rings should maintain proper air
tightness.

d. Snap-rings

• Snap-ring installers should be designed so as not
to permanently deform the snap-rings.

• Installed snap-rings should be seated securely
in the groove.

• Be careful not to overload the snap-ring to the
extent that it is permanently deformed.

• How to install the snap-ring:

When installing a snap-ring, install it as shown
in the figure with its round edge side turned to­ward the part to be retained. This round edge is
formed when the snap-ring is pressed out.

Fig. 2-1

e. Spring (roll) pins

• Spring pins should be driven in properly and
tightly.

• Spring pins should be installed so that their seams
should face the direction from which the load is
applied.

Fig. 2-2

• The roll pins installed in the transmission or other
parts where much force is applied should be re­tained with wire.

f. Cotter pins

• When installed, cotter pins should be bent se­curely at the ends as shown in the figure.

Fig. 2-3

g. Bolts and nuts

• Special bolts are installed at several locations,
so be sure not to interchange them other bolts.

• Bolts and nuts should be tightened to their speci­fied torque with a torque wrench.

• When locking the bolts or nuts with wire or a
lock washer, be sure to wind the wir e paying suf­ficient attention to its winding direction and bend
the lock washer for secure locking.

• When locking bolts and nuts with an adhesive,
apply the adhesive on the thread and tighten se­curely .

Snap-ring

Snap-ring

Round edge side

Thrust force

F

F

F

12

SERVICE MANUAL FOR SGR19 & SGR17

• Apply an adhesive (THREE BOND TB1104) to
parts through which there is any possibility of
oil leaks, such as stud bolts and tapped-through
parts.

• Each lock nut must be tightened securely.

• When tightening bolts and nuts, refer to the tight­ening torque table.

h. After installation, each grease fitting

should be filled with grease.

• When installing grease fittings of types B and
C, be sure to turn the fitting tips in a direction
that will provide easy access for a grease gun.

i. Other precautions

• Be sure not to damage any finished surfaces or
parts.

• Always refrain from forcing installation.

• Each lever knob should be installed coated with
an adhesive (SUPER THREE CEMENT
TB1702)

• Each contact surface should be coated with an
adhesive (THREE BOND TB1215) and tight­ened evenly with bolts. Adhesiv e coated surfaces
should be installed within 30 minutes after ap­plication of the adhesive.
The contact surfaces should be flawless and free
from foreign matter,, and especially from grease
before application of the adhesive.

– Contact surfaces of the sleeve metal (support)

and front transmission case

– Contact surfaces of the hydraulic control le-

ver guide and cylinder case

• Precautions for applying adhesives

– The surface or the thread where an adhesive

is to be applied should be completely free of
chips and oil.

II.

BEFORE STARTING DISASSEMBLY

1. REMOVAL OF THE MOWER DESK

(1) Change the direction of the rear wheels when in

the lifted-up position.

Fig. 2-4

(2) Start the engine and lower the lift by the lift

switch.

Fig. 2-5

(3) Pull out the link pin and remove the support link.

Fig. 2-6

13

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

(4) Remove the fixed bolt and the stopper brackets.

Fig. 2-7

(5) Disconnect the universal joint of the drive shaft

from the front mower.

Fig. 2-8

(6) Move the mower deck rearward to detach it from

the linkage.

Fig. 2-9

(7) Start the engine and lift up the linkage. Then

remove the mower deck sideways from the
mower engine.

Fig. 2-10

2. REMOVAL AND REINSTALLATION OF
MAJOR FUNCTIONAL COMPONENTS

2.1. REMOVAL AND REINSTALLATION OF
ENGINE

REMOVAL

(1) Open the rear fender.

Fig. 2-11

(2) Disconnect the negative (-) post of the battery.

(3) Drain engine coolant through the drain plug.

14

SERVICE MANUAL FOR SGR19 & SGR17

Fig. 2-12

(4) Remove both the front side covers (RH and LH).

Fig. 2-13

(5) Remove the engine hood assembly.

Fig. 2-14

(6) Loosen the lock-nut for the inner wire of the

throttle wire and draw out the inner wire.

(7) Loosen the lock-nut for the throttle wire sheath

and then remove the sheath.

(8) Remove the air-intake pipe by loosening the air-

cleaner side and engine side clamps.

Fig. 2-15

(9) Remove the upper and lower hoses which con-

nect the radiator and engine.

– Remove the drain hose from the cylinder

block.

(10) Disconnect the wire harness from the engine by

removing bolts and nuts which holds it.

- Glow plug terminals

- Thermometer

- Oil pressure switch

- Starter

- Alternator

- Fuel cut-off

Fig. 2-16

15

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

Fig. 2-17

(11) Remove the fuel pipes.

– Remove the fuel return pipes from the noz-

zles.

(12) Remove the drive shaft.

Loosen the bolts of the joint installed on the shaft
end which is connected to the engine.

(13) Remove the control wire for the front PTO

clutch.

– Remove the tension wire from the tension

pulley arm.

(14) Remove the belt stopper.

– Remove the belt cover (PTO shield).
– Remove the two belts.

(15) Remove the snap-ring from the front PTO shaft.

Note:
Remove the spring from the tension pulley.

– Drive the front PTO shaft rearwards with a

plastic hammer or a mallet.

(16) Remove the engine stoppers which are clamped

on both sides of the frame with bolts.

– Remove the bolts which tighten the insulators:

two insulators on RH and LH and one in front.

Fig. 2-18

Fig. 2-19

Fig. 2-20

(17) Remove the engine by lifting it up using the en-

gine hangers.

16

SERVICE MANUAL FOR SGR19 & SGR17

Note:
Keep on pushing the engine forward while lift­ing it up to avoid damaging the radiator shr oud
and cooling fan.

REINSTALLATION

Note:
Reassemble in re verse order of disassembly . But
check every part and replace defective ones.

(1) Install the engine on the frame.

– Install both insulators so that they are bent

slightly outwards.

Note:

– The bolts which tighten the insulators on the

frame should be loosened in advance.

– Install both stoppers so that there is a clearance

of 1.5 to 4.5 mm on both sides in the engine
bracket.

– The engine should not be slanted either to the

right or to the left.

(2) Install the front PTO and related parts.

– Install the PTO pulley and shaft.
– Set the belt and tension pulley.
– Install the stopper and cover.

(3) Install the drive shaft.

(4) Install fuel pipes.

– Install the pipes on the injection pump.
– Install the fuel return pipes on the nozzles.

(5) Connect wire harness.

– Glow plug terminals
– Thermometer
– Oil pressure switch
– Starter
– Alternator
– Fuel cut-off unit

(6) Install radiator hoses.

(7) Install the air intake pipe, throttle wire, tension

arm wire, etc., and then check that they have been
installed securely.

– The front PTO clutch control wire should be

connected with the tension spring through the
wire holder and the hole at the right-hand bot­tom of the steering post.

Fig. 2-21

PTO
ON

0.2 to

0.3 mm

17

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

2.2. REMOVAL AND REINSTALLATION OF
FENDER AND STEP

REMOVAL OF FENDER

(1) Remove the five hairpins from the dumper and

the rear linkages.

Fig. 2-22

Fig. 2-23

(2) Remove the wire harness from the fender.

Fig. 2-24

(3) Remove the fender.

Fig. 2-25

(4) Remove the fuel tank.

Fig. 2-26

REMOVAL OF STEP

(1) Remove the connecting bolt from the brake pedal

and HST pedals. Also remove the dif-lock pedal
at the left-hand side.

Fig. 2-27

18

SERVICE MANUAL FOR SGR19 & SGR17

(2) Remove the four hairpins retaining the step on

the frame.

Fig. 2-28

REINSTALLATION

Reinstall in reverse order of removal.

2.3. REMOVAL AND REINSTALLATION OF
TRANSMISSION CASE

REMOVAL

(1) Remove the drain plug located on the bottom of

the transmission case.

(2) Remove the fender and step, referring to 3.2.

(3) Remove the battery and fuel tank, referring to

3.2.

Fig. 2-29

(4) Remove the drive shaft.

Fig. 2-30

(5) Remove the following oil hoses.

– Lifting cylinder connecting hose
– Solenoid valve connecting hose

Fig. 2-31

(6) Remove the brake rod linkage and parking brake

cable.

Fig. 2-32

19

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

(7) Remove the delivery pipe to the solenoid valve.

Fig. 2-33

(8) Remove the HST tension spring and the assem-

bly of the HST controlling rods.

Fig. 2-34

–

Hold the transmission case with jacks or other ap­propriate supports and hang the chassis with a hoist.

Fig. 2-36

– Remove the transmission tightening bolts.

Fig. 2-37

(10) Remove the HST unit.

– Remove the suction pipe and filter.
– Remove the HST unit tightening bolts. Then the

unit can be removed from the transmission case.

REINSTALLA TION

Reinstall in reverse order of removal, taking the
following precautions.

Reinstall in reverse order of removal, taking the
following precautions.

– Be sure to install O-rings for all hydraulic pipes.

– Each bolt and nut should be tightened to respec-

tive specified torque values referring to the tight­ening torque table.

Fig. 2-35

(9) Remove the transmission case along with the

HST unit from the chassis.

20

SERVICE MANUAL FOR SGR19 & SGR17

CHAPTER 3. ENGINE

I. SPECIFICATIONS

hese specifications are subject to change without notice.

E393-G E383-G

Type ............................................................................................................... 4-cycle, water-cooled, Diesel

with swirl type combustion chambers

Cylinder – bore × stroke .................................................... mm ..........3 – 74×72 .................................3 – 70×72

Total displacement............................................................... cc ............... 928............................................831

Engine performnce ......... Rated output............... ps(kW)/rpm .....19.0(14.0)/2900........................ 16.5(12.1)/2900

Maximum torque ..kg·m(N·m)/rpm ......5.4(53.0)/2300.......................... 4.7(46.1)/2300

Fuel consumption ...

g/sp-h/2900rpm ............................................. 215

Unloaded maximum speed ........... rpm ............................................ 3150

Unloaded minimum speed ............ rpm ............................................ 1250

Fuel .............................................................................................................................. Diesel fuel

Dry weight ........................................................................... kg .........................................85

Dimensions (L × W × H) ...................................................mm .............................. 520 × 400 × 554

Fuel injection order ....................................................................................................... 1 – 3 – 2

Direction of rotation ....................................................................................... Clockwise viewed from fan

Fuel injection system

Fuel injection pump ...... model ....................................................................... DN-PD+KCA-P

Plunger (dia. × stroke) ..... mm ................................ 5.0 × 6.0

Injection nozzle ...................................................................................... Throttle type

Governor................................................................................... Centrifugal, all-speed governor

Valve timing...................... Intake .........Opening ...........................................10° BTDC

Closing............................................. 45° A TDC

Exhaust ......Opening ...........................................46° BBDC

Closing............................................. 10° A TDC

Valve clearance (Intake/Exhaust) ............................mm ................................... 0.25

Fuel injection timing ........................................................................................ 23° BTDC

Compression pressure (at 300 rpm) ................... kg/cm2.....................................30

Oil pan capacity ....................................................... litre .........................Max. 2.5/ Min. 1.5

21

CHAPTER 3. ENGINE

II. INSPECTION AND ADJUSTMENT

1. INSPECTION OF ENGINE OIL

• Draw out the level gauge (dip stick) and wipe
the end clean. Then insert and draw out it again.
Check to see if the level is between the upper
and lower limits. If the level is low, refill oil
through the filler to the upper level.

Fig. 3-1

Note:

- W hen checking oil level, place the machine on
level ground.

- Bef ore checking oil level, stop the engine and
wait three minutes at least.

- W hen replenishing oil, use the same king of oil
as that in the engine.

• Oil capacities:

E393-G & E383-G: 2.5 litres

• Grades and viscosities of usable oil

Temperatures SAE No. API

°C

classifications

-20 – 30 10w-30 CC or over
below 0 10 ˝

0 – 25 20 ˝

Above 25 30 ˝

• Replacing intervals: After the initial 50 hours
of operation and then after every 100 hours.
Replace the oil filter cartridge after every 300
hours.

a. REPLACEMENT OF OIL FILTER

Remove the oil filter cartridge from the cylinder
block, using a cartridge wrench.

b. INSTALLATION OF OIL FILTER

Inject a small amount of engine oil into the car­tridge.
Apply engine oil to the O-ring of the cartridge.

Fig. 3-2

Tighten the cartridge by hand until the O-ring
comes into contact with the cylinder block sur­face and then give it three-fourth turn. After fill­ing with new oil, operate the engine more than
three minutes. Then check for oil leaks.

Fig. 3-3

2. INSPECTION OF FAN BELT

• Check belt deflection by apply a force of about
10 kgs to the center of the belt between the fan
pulley and alternator. Also check the belt for
damage such as cracks, peeling, wear, etc.

22

SERVICE MANUAL FOR SGR19 & SGR17

Specified deflection 5 – 10 mm

Fig. 3-4

• Adjustment:

When the deflection is more than specified, ten­sion the belt properly by moving the alternator.

3. INSPECTION AND ADJUSTMENT OF
VALVE CLEARANCES

3.1. Remove the cylinder head cover.

3.2. Turn the crankshaft by hand so that the piston in
No.1 cylinder reaches at TDC: align the
TDC notch in the crankshaft pulley with the pro­jection on the gear case.

Direction

of rotation

TDC

Injection
timing

Crankshaft

pulley

Fig. 3-5

Note:

When it is difficult to distinguish between TDC
in compression str oke and TDC in e xhaust stroke,
use height difference among the push rods as a
criterion for judgement. When the heights of the
push rods (No.1, 2,3, and 6 vie wed fr om the fan)
are about 5 mm lower than those of No.4 and 5,

the piston in No. 1 cylinder is at TDC in com­pression stroke.

3.3. Insert a feeler gauge of a specified thickness and
adjust the clearance with the adjusting screw.

Specified valve clearance (cold):

Intake 0.25 mm
Exhaust 0.25 mm

Fig. 3-6

4. INSPECTION AND ADJUSTMENT OF
NOZZLE OPENING PRESSURE AND IN­JECTION TIMING

4.1. Adjustment of the valve opening pressure
of the injection nozzles

• Measure the pressure of initial fuel injection on
a nozzle tester.

E393-G & E383-G:

Specified pressure 120 kg/cm

2

Fig. 3-9

23

CHAPTER 3. ENGINE

When the pressure is too high, adjust by reduc­ing shimming thickness for the nozzle, or replace
the nozzle assembly.

When the pressure is too low, adjust by increas­ing shimming thickness, or replace the nozzle
assembly.

4.2. Inspection of oil tightness of valve seats

Set a nozzle on a nozzle tester, and apply and
maintain a pressure of 100 – 110 kg/cm2. Check
it see if fuel leaks through the seat. If fuel oozes
out apparently, the nozzle is defective.

If a nozzle is not oil tight, disassemble it and
remove carbon deposit. If this is insufficient to
stop the oil leaking, replace the nozzle assem­bly.

4.3. Spraying condition of injection nozzle

closing of the valves.

(2) Remove the injection pipes.

Note:
To keep away dust, cap the openings of the in­jection nozzle, injection pump, and injection pipe.

Fig. 3-10

4.4. Inspection and adjustment of injection tim­ing

• Confirmation of injection timing, using No.1
cylinder

(1) Bring the piston in No.1 cylinder to TDC in com-

pression by aligning the marking on the crank­shaft pulley with the one on the timing gear case,
turning the crankshaft by hand. (Refer to Fig. 3-

5.)

Note:
Be sure not to take TDC in exhaust for that in
compression by checking for the opening and

Fig. 3-11

(3) Remove the delivery valve holder.

(4) Remove No.1 delivery spring and install a de-

livery holder.

Remove

Fig. 3-12

(5) Turn the crankshaft by hand to the point about

10° before the injection timing (turning the
crankshaft in either direction will do).

(6) Open the fuel cock and turn the key switch to

the “ON” position to activate the fuel pump.

Proper Defective Defective Defective

4°

24

SERVICE MANUAL FOR SGR19 & SGR17

(7) Make sure that fuel ejects from the delivery

holder. Turn the crankshaft slowly in correct di­rection (clockwise viewed from the fan) until fuel
ejection stops. The injection timing is just be­fore fuel ejection stops.

• When fuel ejection stops, the injection timing
point is passed. Turn the crankshaft in reverse
and repeat operation 6).

• Even when the injection timing point is passed,
there is no sign of fuel ejection stopping. The
point is BTDC in exhaust stroke. T urn the crank­shaft fully by 360°
and start operation.

• As a criterion of
“just before fuel
stops,” use the
time to take to re­fill the fuel in the
end of the delivery
holder after blow­ing it off. When it
takes 1 to 2 sec­onds to refill, it is
the fuel injection
timing point.

Fig. 3-13

(8) Check to see the timing mark on the flywheel or

the crankshaft pulley is aligned as shown in “3.2.
Adjustment of valve clearance.”

For reference:
The crank angle 1° is about 1 mm on the crank­shaft pulley and about 2.5 mm on the flywheel.

(9) Turn the ke y switch to “OFF” and close the fuel

cock.

(10) After checking to see the fuel injection timing is

correct, remove the delivery holder and install
the delivery spring and stopper. Then re-tighten
the delivery holder to the specified torque.

(11) Install the injection pipe and tighten the nut to

the specified torque.

Tightening torque 1.5 – 2.5 kgf·m

Fuel

Delivery

valve

Note:

- Supply fuel only when fuel injection timing is
measured [only for operation 6)].

- It is impossible to measure the fuel injection tim­ing by turning the crankshaft in reverse
(counterclockwise viewed from the fan).

- Dur ing this operation, be sure to keep dust out
of the fuel system.

• Adjustment of injection timing

When the injection timing is improper, it should
be corrected.
The injection timing can be adjusted by chang­ing the distance between the camshaft and pump
mounting surface with shims.

a. Remove the injection pump cover.

b. Remove the control link and starting spring from

the control rack.

c. Remove the injection pump.

- Shimming

A vailable adjusting shims: 0.1, 0.2, 0.3, 0.4 and

0.5 mm thick

For reference:
Injection timing shift with 0.1 mm thick shim­ming by crank angle:

Shimming +0.1 mm........... 1° delay

Shimming -0.1 mm............1° advance

d. Install the injection pump.

e. Confirm that the injection timing is proper by

the operation mentioned above. Until the proper
fuel injection timing is attained, repeat steps from
c. to e.

f. Install the control link and starting spring on the

control rack and then the injection pump cover.

Note:
During this operation, be careful to keep dust
out of the fuel system.

25

CHAPTER 3. ENGINE

5. COMPRESSION AND UNLOADED IDLING
SPEEDS

5.1. Inspection of compression

1) Remove the injection pipes.

2) Remove a injection nozzle.

Note:
Cap the injection nozzles, injection pump, and
injection pipes to avoid dust.

3) Install a compression gauge using an adaptor.

Fig. 3-14

4) Activate the starter and measure the compres­sion.

kg/cm

2

at 300 rpm

Standard Limit Difference

between cylinders

30 26 3

Note:

• Use a fully charged battery.

• Be sure to remove the fuel pipes in advance to
avoid fuel injection.

• Remove only the nozzle for the cylinder whose
compression is to be measured. Other nozzles
should be left installed.

Caution:
When cranking the engine, take care not to
touch rotating parts.

5.2. Inspection and adjustment of the idling
speeds

1) Check for idling speeds.

Specified value 1250 rpm

2) When the measured value deviates from the
specified value, correct with an adjusting
bolt.

Fig. 3-15

6. INSPECTION OF WATER PUMP

6.1. Inspection of the pump and pulley

Check the pump for noise or hitching by turning
the water pump pulley, applying load vertically
to the pump axis.

When noise or hitching occurs, replace the pump
assembly .

Fig. 3-16

26

SERVICE MANUAL FOR SGR19 & SGR17

6.2. Inspection of the bearing unit

Check the bearing unit for run-out. If the run­out is more than 0.2 mm, replace the pump as­sembly.

7. INSPECTION OF THERMOSTAT

• Inspection of activiating temperatures at which
the valve starts to open and opens fully
Put the thermostat in water and heat the water
gradually by stirring.
Check for the temperature at which the valve
starts to open and that at which the valve opens
fully .

Fig. 3-17

Starts-to-open 76.5±2°C
temperature

Full-open 90°C (194°F)
temperature [lift: more than 8 mm]

III. ENGINE BODY

III.1. CYLINDER HEAD

Fig. 3-18 (Exploded view of cylinder head)

27

CHAPTER 3. ENGINE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

(5) Removal of the rocker shaft assembly (Fig. 3-20).

(6) Removal of the push rods.

(7) Removal of the water by-pass hose.

(8) Removal of nozzles.

Fig. 3-22

• Remove the cap.

• Remove fuel-return pipes.

• Draw out the nozzle along with the gasket.

Note:
Be careful to keep the nozzle free from dust.

(9) Removal of glow plugs.

(10) Removal of the cylinder head.

• Loosen the cylinder head bolts in the sequence
shown in the figure.

• After the removal of the cylinder head, remove
the dowels and tappets.

Fig. 3-23

1. REMOVAL OF THE CYLINDER HEAD

(1) Removal of the cylinder head cover.

Fig. 3-19

(2) Disconnection of the injection piping.

• When the piping has been removed, cap the de­livery pipe holders, injection nozzles and injec­tion pipes at once to avoid dust.

Fig. 3-20

(3) Removal of the fan belt.

(4) Removal of the oil pipe.

Fig. 3-21

28

SERVICE MANUAL FOR SGR19 & SGR17

2. DISASSEMBLY

(1) Removal of the inlet manifold.

(2) Removal of the exhaust manifold.

(3) Removal of the thermostat housing.

(4) Removal of the valves.

Fig. 3-24

• Compress the valve spring along with the spring
seat with a spring compressor, and remove the
cotter spring seat retainer.

Note:
Removed valve and related parts should be put
aside in order of valve numbers.

(5) Removal of the valve oil seals.

Note:
Discard removed valve oil seals.

3. INSPECTION

(1) Inspection of the cylinder head for cracks.

• Remove carbon deposit from the bottom surface
of the cylinder head.

• Inspect the bottom surface and inlet and exhaust
ports using “COLOR CHECK.”

Fig. 3-25

(2) Inspection of the cylinder head for distortion

• Measure the flatness of the bottom surface of
the cylinder head by putting a straight rule di­agonally across the four corners on the bottom
face and check for clearance with thickness
gauges.

Standard value Usable limit

Distortion 0.075 mm 0.15 mm

• When the distortion exceeds the usable limit,
correct on a surface grinder.

• As the ground-down limit is 0.4 mm (0.016 in.),
replace a cylinder head assembly which required
more than the ground-down limit to correct.

Fig. 3-26

(3) Inspection of the clearance between the valve

guide and valve stem.

• Check the valve for play with a dial indicator. If
the play exceeds 0.15 mm for the inlet valve and

0.2 mm for the exhaust valve, replace both the

29

CHAPTER 3. ENGINE

Specified bore 7 mm

Fig. 3-29

(5) Inspection and correction of valve seats.

• Check for valve contacting width and depres­sion.

When the contact width is wider than specified,
correct with a 75° valve seat cutter. When the
valve depression is more than specified, replace
the cylinder head assembly.

Standard value Usable limit

Contact width 1.3 – 1.6 mm 2.0 mm

Valve depression 0.7 mm 1.4 mm

Valve guide

Cylinder head

7 mm

Contact

width

Subsidence

Fig. 3-30

• Apply polishing compound to the valve seat sur­face and lap with the valve while tapping the
valve to secure sufficiently contact with the
whole circumference.

valve and valve guide as an assembly. Measure
the play at a point 10 mm apart above the valve
oil seal when the valve lift is 0 mm.

Fig. 3-27

(4) Replacement of the valve guide.

• Drive out the valve guide upwards from the cyl­inder head bottom.

• Press in a new valve guide from the cylinder head
top, taking care not to damage the guide.

Fig. 3-28

Note:
Apply oil to the new valve guide ahead of time.

• Press in so that the distance from the cylinder
head top to the valve guide end becomes 7 mm.

• After installation, correct the bore diameter of
the valve guide to the specified value by reaming.

30

SERVICE MANUAL FOR SGR19 & SGR17

Fig. 3-31

Note:
After lapping, remove the polishing compound
completely.

(6) Inspection of valves.

• Measure the valve stem diameter with a microm­eter.

Standard value Usable limit

Inlet valve 7.00 mm 6.90 mm

Exhaust valve 7.00 mm 6.89 mm

III II I

Valve stem end

Fig. 3-32

• Check for valve thickness.

Standard value Usable limit

Valve thickness 0.8 mm 0.55 mm

When the valve thickness is less than the usable
limit, replace the valve.

Fig. 3-33

(7) Inspection of valve springs.

• Measure the free length of each valve spring with
calipers.

Standard value Usable limit

Free length 36.0 mm 35.0 mm

Tension 8.3 kgf 7.35 kgf

(when compressed to 31 mm)

• Put a spring upright on a surface table and meas­ure deviation from vertical.

Usable limit

Deviation from vertical 1.0 mm

Free length

Deviation from vertical

Fig. 3-34

(8) Inspection of intake and exhaust manifold con-

tact surfaces for flatness.

• Measure flatness with a straight rule and thick–
ness gauges.

Valve head thickness