Iseki SGR19 Service Manual
  1. Manuals
  2. Brands
  3. Iseki Manuals
  4. Lawn Mower
  5. SGR19
  6. Service manual

Iseki SGR19 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

I S E K I L A W N M O W E R S
S E R V I C E
M A N U A L
LAWN MOWERS:
MOWER DECKS:
SCM48 & SCM54

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SGR19 and is the answer not in the manual?

Questions and answers

Related Manuals for Iseki SGR19

Summary of Contents for Iseki SGR19

  • Page 1 I S E K I L A W N M O W E R S S E R V I C E M A N U A L LAWN MOWERS: MOWER DECKS: SCM48 & SCM54...

  • Page 2: Foreward

    Figures mentioned in this manual are standard values established by ISEKI for the SGR, conse- quently 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repairs have been made in a manner other than as specified in this manual, the pertinent values mentioned herein are no longer valid.

  • Page 3: Table Of Contents

    ISEKI LAWN MOWERS TABLE OF CONTENTS FOREWARD ..............2 4. INSPECTION AND ADJUSTMENT OF NOZZLE OPENING PRESSURE AND INJECTION TIMING TABLE OF CONTENTS ..........3 ..............22 4.1. Adjustment of the valve opening pressure of CHAPTER 1. INTRODUCTION ........5 the injection nozzles ........
  • Page 4 SERVICE MANUAL FOR SGR19 & SGR17 3. REAR WHEEL DRIVING MECHANISM ....53 4. DISASSEMBLY & REASSEMBLY ......91 DISASSEMBLY ..........53 4.1. DISASSEMBLY ..........91 4. REAR TRANSMISSION CASE ......54 4.2. REASSEMBLY ..........92 INSPECTION ..........54 5. MAJOR TROUBLES AND CAUSES, AND REASSEMBLY ..........

  • Page 5: Chapter 1. Introduction

    3 - 1 4 N I S H I - N I P P O R I 5 - C H O M E ARAKAWA-KU TOKYO 116 JAPAN Fig. 1-3 ISEKI & CO., LTD. MADE IN JAPAN c. Engine model name and serial number (1) Model a=name: SGR19H in the exammple (2) Type: E42 or UE42 •...

  • Page 6: Specifications

    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 ................

  • Page 7: Exterior View And Dimensions

    CHAPTER 1. INTRODUCTION 3.EXTERIOR VIEW AND DIMENSIONS 1935 mm 1965 mm...

  • Page 8: Periodic Inspection Table

    SERVICE MANUAL FOR SGR19 & SGR17 4.PERIODIC INSPECTION TABLE : Inspection, replenishment, and adjustment : Cleaning and washing : 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...

  • Page 9: Filling Diagram

    As required Knuckle arms Grease As required Brake shaft/HST hub Grease As required Fuel Diesel fuel 18.5 Cylinder ball end Grease As required Drive shaft Grease As required • Use oil of better than class CC. • Use ISEKI’s recommended oil.

  • Page 10: Chapter 2. Disassembly Of Major Components

    SERVICE MANUAL FOR SGR19 & SGR17 CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS I. GENERAL PRECAUTIONS FOR SEPARATION AND REINSTALLATION 1. BEFORE OPERATION 2. PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING COMMON PARTS a. Always be safety-conscious in selecting clothes a. Roller or ball bearings to wear and suitable tools to use.

  • Page 11: O-Rings

    CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS • Use a lithium-based grease. • Spring pins should be installed so that their seams should face the direction from which the load is • There should be no oil or water leaks through applied.

  • Page 12: After Installation, Each Grease Fitting Should Be Filled With Grease

    SERVICE MANUAL FOR SGR19 & SGR17 II. BEFORE STARTING DISASSEMBLY • Apply an adhesive (THREE BOND TB1104) to parts through which there is any possibility of 1. REMOVAL OF THE MOWER DESK oil leaks, such as stud bolts and tapped-through parts.

  • Page 13: Removal And Reinstallation Of Major Functional Components

    CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS (4) Remove the fixed bolt and the stopper brackets. (7) Start the engine and lift up the linkage. Then remove the mower deck sideways from the mower engine. Fig. 2-7 (5) Disconnect the universal joint of the drive shaft Fig.
  • Page 14 SERVICE MANUAL FOR SGR19 & SGR17 (8) Remove the air-intake pipe by loosening the air- cleaner side and engine side clamps. Fig. 2-12 (4) Remove both the front side covers (RH and LH). Fig. 2-15 (9) Remove the upper and lower hoses which con- nect the radiator and engine.
  • Page 15 CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS (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.

  • Page 16: Reinstallation

    SERVICE MANUAL FOR SGR19 & SGR17 Note: (7) Install the air intake pipe, throttle wire, tension Keep on pushing the engine forward while lift- arm wire, etc., and then check that they have been ing it up to avoid damaging the radiator shroud installed securely.

  • Page 17: Removal And Reinstallation Of Fenderand Step

    CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS 2.2. REMOVAL AND REINSTALLATION OF (3) Remove the fender. FENDER AND STEP REMOVAL OF FENDER (1) Remove the five hairpins from the dumper and the rear linkages. Fig. 2-25 (4) Remove the fuel tank. Fig.

  • Page 18: Reinstallation

    SERVICE MANUAL FOR SGR19 & SGR17 (2) Remove the four hairpins retaining the step on (4) Remove the drive shaft. the frame. Fig. 2-30 (5) Remove the following oil hoses. – Lifting cylinder connecting hose Fig. 2-28 – Solenoid valve connecting hose REINSTALLATION Reinstall in reverse order of removal.

  • Page 19: Reinstallation

    CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS (7) Remove the delivery pipe to the solenoid valve. – Hold the transmission case with jacks or other ap- propriate supports and hang the chassis with a hoist. Fig. 2-33 Fig. 2-36 (8) Remove the HST tension spring and the assem- –...

  • Page 20: Chapter 3. Engine

    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 ...............

  • Page 21: Inspection Of Engine Oil

    CHAPTER 3. ENGINE II. INSPECTION AND ADJUSTMENT a. REPLACEMENT OF OIL FILTER 1. INSPECTION OF ENGINE OIL Remove the oil filter cartridge from the cylinder block, using a cartridge wrench. • Draw out the level gauge (dip stick) and wipe the end clean.

  • Page 22: Inspection And Adjustment Of Valve Clearances

    SERVICE MANUAL FOR SGR19 & SGR17 the piston in No. 1 cylinder is at TDC in com- Specified deflection 5 – 10 mm pression stroke. 3.3. Insert a feeler gauge of a specified thickness and adjust the clearance with the adjusting screw.

  • Page 23: Inspection Of Oil Tightness Of Valve Seats

    CHAPTER 3. ENGINE When the pressure is too high, adjust by reduc- closing of the valves. ing shimming thickness for the nozzle, or replace the nozzle assembly. (2) Remove the injection pipes. When the pressure is too low, adjust by increas- Note: ing shimming thickness, or replace the nozzle To keep away dust, cap the openings of the in-...
  • Page 24 SERVICE MANUAL FOR SGR19 & SGR17 (7) Make sure that fuel ejects from the delivery Tightening torque 1.5 – 2.5 kgf·m holder. Turn the crankshaft slowly in correct di- rection (clockwise viewed from the fan) until fuel Note: ejection stops. The injection timing is just be- - Supply fuel only when fuel injection timing is fore fuel ejection stops.

  • Page 25: Compression And Unloaded Idling

    CHAPTER 3. ENGINE 5. COMPRESSION AND UNLOADED IDLING 5.2. Inspection and adjustment of the idling SPEEDS speeds 5.1. Inspection of compression 1) Check for idling speeds. 1) Remove the injection pipes. Specified value 1250 rpm 2) When the measured value deviates from the 2) Remove a injection nozzle.

  • Page 26: Inspection Of The Bearing Unit

    SERVICE MANUAL FOR SGR19 & SGR17 6.2. Inspection of the bearing unit Check the bearing unit for run-out. If the run- out is more than 0.2 mm, replace the pump as- sembly. 7. INSPECTION OF THERMOSTAT • Inspection of activiating temperatures at which Fig.

  • Page 27: Removal Of The Cylinder Head

    CHAPTER 3. ENGINE 1. REMOVAL OF THE CYLINDER HEAD (5) Removal of the rocker shaft assembly (Fig. 3-20). (1) Removal of the cylinder head cover. (6) Removal of the push rods. (7) Removal of the water by-pass hose. (8) Removal of nozzles. Fig.

  • Page 28: Disassembly

    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. 3-25 (2) Inspection of the cylinder head for distortion •...
  • Page 29 CHAPTER 3. ENGINE valve and valve guide as an assembly. Measure Specified bore 7 mm the play at a point 10 mm apart above the valve oil seal when the valve lift is 0 mm. Valve guide Cylinder head Fig. 3-29 Fig.
  • Page 30 SERVICE MANUAL FOR SGR19 & SGR17 Valve head thickness Fig. 3-33 (7) Inspection of valve springs. Fig. 3-31 • Measure the free length of each valve spring with Note: calipers. After lapping, remove the polishing compound Standard value Usable limit completely.

  • Page 31: Disassembly And Inspection Of The Rocker Arm Shaft

    CHAPTER 3. ENGINE Fig. 3-35 Usable limit Fig. 3-37 Surface flatness (both for intake 0.2 mm (3) Inspection of the rocker arm shaft for wear and exhaust manifolds) • Measure diameter at four points where the shaft When the deviation exceeds the usable limit, bears respective rocker arms.

  • Page 32: Inspection Of The Push Rods

    SERVICE MANUAL FOR SGR19 & SGR17 Standard value Usable limit Clearance 0.01 – 0.05 mm 0.2 mm Fig. 3-41 6. INSTALLATION OF THE CYLINDER HEAD Fig. 3-39 (5) Reassembly of the rocker arm shaft assembly (1) Installation of the cylinder head •...
  • Page 33 CHAPTER 3. ENGINE • Place the cylinder head softly on the cylinder (4) Installation of the leak hoses. block. • Apply engine oil to the threads of the cylinder head bolts. • Tighten the cylinder head bolts in the sequence as shown in Fig.

  • Page 34: Iii.2. Gear Case

    SERVICE MANUAL FOR SGR19 & SGR17 (7) Installation of the injection pipes sure to adjust the valve clearances. • Install injection pipes for respective cylinders (10) Installation of the head cover. and tighten them securely. Note: (8) Install water by-pass hose.

  • Page 35: Re-Installation Of The Gear Case

    CHAPTER 3. ENGINE Note: Note which bolt is to be installed in which place for later reference and remember to remove the Injection pump bolts which also tighten the case from behind. gear Camshaft gear Idle gear Crankshaft gear Fig. 3-53 •...

  • Page 36: Iii.3. Cylinder Block

    SERVICE MANUAL FOR SGR19 & SGR17 III.3. CYLINDER BLOCK 1. EXPLODED VIEWS Fig. 3-55...

  • Page 37: Disassembly Of The Cylinder Block

    CHAPTER 3. ENGINE 2. DISASSEMBLY OF THE CYLINDER (10) Remove the water pump spacer. BLOCK (11) Remove the oil filter. (1) Install the engine on a engine stand. (12) Remove the oil pan and oil strainer. (13) Clean the cylinder bores of carbon deposit. Remove carbon deposit from the upper part of the cylinder bore with a scraper, taking care not to damage the cylinder walls.

  • Page 38: Inspection Of Cylinder Block, Crankshaft, Camshaft, And Tappets

    SERVICE MANUAL FOR SGR19 & SGR17 3. INSPECTION OF CYLINDER BLOCK, (15) Removal of the flywheel. CRANKSHAFT, CAMSHAFT, AND TAPPETS • Chock the flywheel. • Removal of the flywheel. (1) Inspection of the cylinder block • Inspect the cylinder block for damage.
  • Page 39 ISEKI LAWN MOWERS 12 mm 10 mm Fig. 3-64 (2) Inspection of the crankshaft Fig. 3-63 • Check the crankshaft journals for oil clearance. - Measure cylinder bore diameter at a point of 12 to 14 mm below the cylinder block top surface a.
  • Page 40 SERVICE MANUAL FOR SGR19 & SGR17 c. Tighten the bearings on the connecting rods to the specified torque. Fig. 3-66 Standard value Usable limit 0.029 – 0.080 mm 0.12 mm Fig. 3-68 f. If the oil clearance of a journal is in excess of...
  • Page 41 ISEKI LAWN MOWERS oil clearance again. When the clearance exceeds Pilot bearing Ring gear the usable limit ever after new bearing have been installed, polish the pin and use undersize bear- ings. Undersize bearings 0.5; 1.0 mm When the ground-down limit of 1.0 mm (0.039 in.) is enough for correction, replace both crank-...
  • Page 42 SERVICE MANUAL FOR SGR19 & SGR17 • Inspection of the pilot bearing • Cam height Check for noise or hitching by turning it. Re- place a defective bearing with a new one. Measure the height with a micrometer. Standard value Usable limit •...

  • Page 43: Inspection Of Pistons And Connecting Rods

    ISEKI LAWN MOWERS Clearance between journal and bearing: pitting, cracks, etc. Defective tappets should be replaced with new ones. Standard value Usable limit 0.05 – 0.105 mm 0.12 mm Pitting Cracking Proper contact If the clearance exceeds the usable limit, replace the camshaft with a new one.
  • Page 44 SERVICE MANUAL FOR SGR19 & SGR17 Fig. 3-81 Fig. 3-83 Measure the gaps of each piston ring with thick- ness gauges. Clean ring grooves using a used piston ring. Measure the clearance at the outer circumference with thickness gauges as shown in the figure.

  • Page 45: Assembly Of Piston And Connecting Rod

    • Set the piston and the connecting rod so that the Standard value Usable limit front mark on the piston and “ISEKI” marking on the connecting rod are turned in the same di- Twist 0.05 mm or less 0.2 mm...

  • Page 46: Installation Of Crankshaft

    SERVICE MANUAL FOR SGR19 & SGR17 Chrome-plated Chrome-plated Fig. 3-89 Fig. 3-91 Coil expanders • Install the other snap ring securely in the groove. • Install the rings with their gaps 120° apart from each other as shown in the figure.

  • Page 47: Installation Of Piston/Connecting-Rod Assemblies

    ISEKI LAWN MOWERS Fig. 3-95 7. INSTALLATION OF PISTON/CON- NECTING-ROD ASSEMBLIES • Install bearings on the connecting-rod big end Fig. 3-93 and bearing cap with the bearing projections (2) Apply engine oil to upper bearing surfaces and seated securely in respective notches in the big bring the crankshaft softly in contact with them.

  • Page 48: Installation Of Rear Oil Seal

    SERVICE MANUAL FOR SGR19 & SGR17 • Apply silicone compound to the outer circum- ference of the rear oil seal and drive it in evenly to avoid slanted installation. • Make sure that the crankshaft turns smoothly. • The projection of the rear oil seal after installa- tion should be 1.5 mm.

  • Page 49: Installation Of Rear Plate And Flywheel

    ISEKI LAWN MOWERS Note: Temporarily tighten the flywheel. Be careful not to damage the O-ring. Chock the flywheel, and then tighten the bolts to the specified torque. 10. INSTALLATION OF REAR PLATE AND FLYWHEEL Specified torque 9.5 kgf·m • Installation of the rear plate 11.
  • Page 50 SERVICE MANUAL FOR SGR19 & SGR17 Specified torque 0.8 kgf·m (6 ft·lbs) Fig. 3-105 • Sub-assemble the pump cam and the thrust plate Fig. 3-108 in advance, paying attention to thrust plate di- rection. • Install the idle gear. Apply engine oil to the bore of the gear in ad- vance.
  • Page 51 CHAPTER 4. TRANSMISSION & RELATED PARTS • Install the water pump spacer. • Install the water pump with a new packing and tighten to the specified torque. Specified torque 1.9 kgf·m Fig. 3-110 • Installation of the oil pan Apply liquid gasket to the cylinder block sur- face in shape of a string of Ø3 –...

  • Page 52: Chapter 4. Transmission & Related Parts

    SERVICE MANUAL FOR SGR19 & SGR17 CHAPTER 4. TRANSMISSION & RELATED PARTS 1. DRIVE TRAIN DIAGRAM ENGINE HST UNIT REAR PTO (Optional) BRAKE FRONT PTO (Optional) Fig. 4-1 2. TRANSMISSION Fig. 4-2...

  • Page 53: Rear Wheel Driving Mechanism

    CHAPTER 4. TRANSMISSION & RELATED PARTS 3. REAR WHEEL DRIVING MECHANISM Fig. 4-3 DISASSEMBLY (4) Remove the tightening bolts and separate the transmission assembly. (1) Remove the transmission assembly from the chassis, referring to component removal. (2) Remove the left wheel shaft from the transmis- sion assembly.

  • Page 54: Rear Transmission Case

    SERVICE MANUAL FOR SGR19 & SGR17 4. REAR TRANSMISSION CASE • Install the oil seal and the shaft into the case. • Install the collars. INSPECTION Note: (1) Check the gears for damage and tooth bearing. Install the collar (26×35×03) with the chamfered side turned upwards.
  • Page 55 CHAPTER 4. TRANSMISSION & RELATED PARTS a. Measuring tools • Holder of drive pinion set • Dial guage setting tool φ48 Fig. 4-9 (5) Adjustment of drive pinion backlash Adjust the backlash between the drive pinion and 4 – φ11 unit: mm the ring gear by shimming.

  • Page 56: Brake System

    SERVICE MANUAL FOR SGR19 & SGR17 5. BRAKE SYSTEM Plate 5.1. CONSTRUCTION (1) Input gear (12T) (4) Washer (31×42×1) (2) Collar (31×38×11) A, B: Shimming points (3) Snap-ring Fig. 4-13 (6) Install the left wheel assembly and HST unit. Fig. 4-15 5.2.

  • Page 57: Reassembly

    CHAPTER 4. TRANSMISSION & RELATED PARTS 5.3. REASSEMBLY (2) Install the actuator ball. Reassemble in reverse order of disassembly, tak- ing the following precautions mentioned below: (1) Install the brake discs and seperator plates • Before reinstalling new brake discs, immerse them in oil for a few minutes.
  • Page 58 SERVICE MANUAL FOR SGR19 & SGR17 ADJUSTMENT OF THE BRAKES make sure the brake arm returns to the previous position without fail. (1) Brake arm (3) Foot brake adjustment Make sure that the brake arm is in the vertical position or slanted a little forward and does not a.

  • Page 59: Chapter 5. Hydrostatic Transmission

    CHAPTER 5. HYDROSTATIC TRANSMISSION CHAPTER 5. HYDROSTATIC TRANSMISSION 1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS (1) Case (37) Snap-ring (81) O-ring (92) Plug (2) Port block (38) Snap-ring (82) O-ring (93) Spring (3) Cylinder block (41) Spring holder (89) Oil seal case (94) Plug (4) Slant board (42) Oil seal...

  • Page 60: Operating Diagarm Of Hst

    SERVICE MANUAL FOR SGR19 & SGR17 2. OPERATING DIAGARM OF HST Fig. 5-2...

  • Page 61: Function

    CHAPTER 5. HYDROSTATIC TRANSMISSION 3. FUNCTION 3.1. VARIABLE TYPE PUMP Nine pistons are housed in the cylinder block, which is connected to the engine and revolves as the engine does, while the slant board does not. When the slant board and shaft are perpendicular to each other, cylinder displacement volumes A and B do not vary, so no delivery or suction takes place.

  • Page 62: Fixed Type Motor

    SERVICE MANUAL FOR SGR19 & SGR17 3.2. FIXED TYPE MOTOR Nine pistons are housed in the cylinder block. A valve plate with two arched ports, Ps and Pd, is in contact with one end of the cylinder block. The ports are connected to the delivery pipe or the suction pipe respectively.
  • Page 63 CHAPTER 5. HYDROSTATIC TRANSMISSION HIGH PRESSURE RELIEF VALVE A direct type both-direction relief valve is installed across the main passages A and B. The valve con- trols the pressure in both passages. When the pressure in the passage A is higher, surface “a” of the poppet receives pressure which pushes the poppet overcoming the force of the spring and opens the valve: to the left as shown in the figure.

  • Page 64: Disassembly And Reassembly

    SERVICE MANUAL FOR SGR19 & SGR17 CHECK VALVE The check valves are installed symmetrically in both sides across the charge passage “C.” The check valve prevents the fluid from the high pressure passage “A” from flowing back into the charge passage “C” and replenish the charge fluid in the passage “B.” But the fluid flows back through the neutral orifice in accordance with the pressure applied to passage “C.”...
  • Page 65 CHAPTER 5. HYDROSTATIC TRANSMISSION 4.3. DISASSEMBLY c. Remove the valve plates (6 and 7). Note: Insert the blade end of a conventional (1) Remove the port block. screw driver into the groove and lift up the valve plate as shown in the figure below to remove a.
  • Page 66 SERVICE MANUAL FOR SGR19 & SGR17 Fig. 5-13 Fig. 5-15 Components of the cylinder block assembly (Both blocks have the same components.) (5) Remove motor-side thrust bearing (13) from the case (1). • (3) Cylinder block ......... 1 • (5) Pistons ..........9 •...
  • Page 67 CHAPTER 5. HYDROSTATIC TRANSMISSION Fig. 5-17 Fig. 5-19 b. Remove the snap-ring (37) and hit the end of b. Remove the snap-ring (37), which is inside the the shaft (8) with a plastic hammer as shown in case, and hit the end of the shaft (9) with a plas- the figure blow and extract the shaft from the tic hammer as shown in the figure below in or- case (1).
  • Page 68 SERVICE MANUAL FOR SGR19 & SGR17 Fig. 5-21 (8) Disassembly of the port block a. Remove the plug (33) for the check valve and take out the springs (21) and poppets (30) out of the port block (2). b. Remove the valve sub-assembly (27).

  • Page 69: Criteria For Replacing Worn Parts

    CHAPTER 5. HYDROSTATIC TRANSMISSION 4.4 . CRITERIA FOR REPLACING WORN PARTS Friction parts which have worn and exceed the specified limit should be replaced with new ones. Name Inspection items Standard value Usable limit Piston a. Diameter of cylinder block Clearance: δ...

  • Page 70: Precaution Before Reassembly

    SERVICE MANUAL FOR SGR19 & SGR17 4.5. PRECAUTION BEFORE REASSEMBLY a. Wash disassembled parts in fresh cleansing oil and blow them with compressed air. b. Handle the cleaned parts carefully to avoid dam- age such as dents, scratches, etc. c. All removed sealing parts should be discarded and replaced with new ones.
  • Page 71 CHAPTER 5. HYDROSTATIC TRANSMISSION b. Press the bore plug (11) into the case (1) and install the snap-ring (37) on the outside. Fig. 5-26 Tightening torqe 17.2±2 N·m of screw (71) Fig. 5-28 * As for oil seal installation, refer to page 75. (3) Reassembly of the slant board and thrust bear- •...
  • Page 72 SERVICE MANUAL FOR SGR19 & SGR17 When installing the cylinder block, apply work- ing fluid to the pistons ahead of time. * As for the details of the cylinder block, refer to Fig. 5-1. Fig. 5-30 d. Installl the thrust bearing onto the slant board assembly, which includes the swash plate (4) and bush (17).
  • Page 73 CHAPTER 5. HYDROSTATIC TRANSMISSION b. Install the valve sub-assembly (28). e. After being reassembled, make sure that the shafts (8 & 9) turn smoothly using an adjustable Apply grease to the valve ahead of time to pre- end wrench. vent it from falling. c.

  • Page 74: Precautions For Reassembly

    SERVICE MANUAL FOR SGR19 & SGR17 4.7. PRECAUTIONS FOR REASSEMBLY ø47.5 ø47 a. Installation of shaft bearings Press in the bearings using the jigs mentioned in the drawing below. Bench Install bearing until it comes into contact with shaft. (Unit: mm) Fig.
  • Page 75 CHAPTER 5. HYDROSTATIC TRANSMISSION e. Installation of oil seals g. Pressed-in parts in the port block • Press the oil seal (61) into the cover until the oil Note: seal end becomes flush with the cover surface. • The oil seal (42) should be installed with the dust ø35 lip turned outward.

  • Page 76: List Of Major Components Of Hst

    SERVICE MANUAL FOR SGR19 & SGR17 4.8. LIST OF MAJOR COMPONENTS OF HST (1) Case (21) Spring (53) Pin (80) Shim B (2) Port block (22) Spring (54) Cradle bearing (81) O-ring (3) Cylinder block (27) Valve (55) Socket head bolt...

  • Page 77: Precautions For Installation Of Hst Unit

    CHAPTER 5. HYDROSTATIC TRANSMISSION 4.9. PRECAUTIONS FOR INSTALLATION OF (2) OIL TEMPERATURE HST UNIT It is a very important factor at what temperature (1) INSTALLATION OF SHAFTS a hydraulic system operates. High operating temperaure will cause working oil to deteriorate a.

  • Page 78: Troubleshooting

    SERVICE MANUAL FOR SGR19 & SGR17 List of criteria for judging oil deterioration (Draw some oil out of the HST case into a test tube and compare the sample with fresh oil.) Appearance Smell Condition Countermeasure Transparent and with no discolouration...
  • Page 79 CHAPTER 5. HYDROSTATIC TRANSMISSION Trouble Presumable cause Countermeasure 4. Insufficient delivery of charge When cold: Warm up sufficiently. pump due to abnormal oil When hot: Stop the engine and wait temperature until the machine cools down. Then start. HST produces abnormal noise. 1.

  • Page 80: Adjustment Of Hst

    SERVICE MANUAL FOR SGR19 & SGR17 5. ADJUSTMENT OF HST 5.1. ADJUSTMENT OF NEUTRAL POSITION (1) Place the lawn mower on level, hard ground. Put the adjusting rod. Then tighten it temporarily tyre chocks in the position a little apart from the with the lock-nu.

  • Page 81: Adjustment Of Trunnion Arm Stoppers

    CHAPTER 6. HYDRAULIC SYSTEM 5.3. ADJUSTMENT OF TRUNNION ARM STOPPERS The trunnion arm should be adjusted to turn for- ward by 21.5° and 13° in reverse by respective stopper bolts as shown. 13° 21.5° Around 32 mm Fig. 5-48 These stopper bolts prevent the respective HST pedals from being depressed beyond the operat- ing limits of the slant board of the HST motor.

  • Page 82: Chapter 6. Hydraulic System

    SERVICE MANUAL FOR SGR19 & SGR17 CHAPTER 6. HYDRAULIC SYSTEM 1. HYDRAULIC SYSTEM DIAGRAMS (SGR17 with manual steering system) K182-032-000-0B Cylinder assembly for mower lift + 0.5 K200-069-000-0A kgf/cm Solenoid valve assembly P103-521-300-0D Return filter assembly 10 µm K250-044-000-0 55 kgf/cm 12 litres/min.
  • Page 83 CHAPTER 6. HYDRAULIC SYSTEM (Type U of SGR19/17) 1689-408-220-0A Cylinder assembly for Power steering K182-032-000-0B Cylinder assembly for mower lift 5-port orbit roll K200-069-000-0A + 0.5 kgf/cm Solenoid valve assembly P103-521-300-0D Return filter assembly 10 µm 15±1 kgf/cm kgf/cm 12 litres/min. 50°C Relief metal (Support) K130-003-000-0C...

  • Page 84: Inspection Of Major Components

    SERVICE MANUAL FOR SGR19 & SGR17 2. INSPECTION OF MAJOR COMPO- rubber parts in clean diesel fuel or kerosene. In- NENTS spect all parts and repair or replace defective parts with new ones. 2.1 SUCTION FILTER Delivery pressure: 55 kgf/cm...

  • Page 85: Relief Metal (Support)

    CHAPTER 6. HYDRAULIC SYSTEM 2.4. RELIEF METAL (SUPPORT) Relief pressure 5.4 Mpa (55 kgf/cm at 10 liters/min. and 50°C From gear pump From gear pump Fig. 6-5 2.5. OIL FILTER (Return filter assembly) The filter cartridge is attached on the HST unit. Bypass relief valve in the base Opening pressure 1.5 MPa (1.5 kgf/cm...

  • Page 86: Solenoid Valve Assembly

    SERVICE MANUAL FOR SGR19 & SGR17 Fig. 6-6 2.6. SOLENOID VALVE ASSEMBLY (K200-069-000-00) Fig. 6-7...
  • Page 87 CHAPTER 7. POWER STEERING SYSTEM INSPECTION Normally the operation of the solenoid valve should be checked on the machine, but as for wear of each part or oil leaks it should be removed from the machine and checked according to the standards men- tioned below.

  • Page 88: Chapter 7. Power Steering System

    SERVICE MANUAL FOR SGR19 & SGR17 CHAPTER 7. POWER STEERING SYSTEM 1. CONSTRUCTION The steering unit (mini-orbit roll) controls hydraulic power and activates the rear wheels directly through the power steering cylinder. It features minimized vibration at the steering wheel because vibration of the rear wheels is not directly transmitted to the steering wheel.

  • Page 89: Working Principle

    CHAPTER 7. POWER STEERING SYSTEM 2. WORKING PRINCIPLE turned to right; Fig. 7-5 when the wheel is turned to left. While the steering wheel is being turned, The orbit roll has 5 ports as shown in Fig. 7-2. some fluid from the pump goes to a cylinder port: Port EF is connected to another actuator circuit.

  • Page 90: Section Of Mini-Orbit Roll And Major Components

    SERVICE MANUAL FOR SGR19 & SGR17 3. SECTION OF MINI-ORBIT ROLL AND MAJOR COMPONENTS Section A — A Section C — C PARTS LIST OF MINI-ORBIT ROLL Ref. Description Q’ty Remarks Ref. Description Q’ty Remarks Control valve assembly End cap...

  • Page 91: Disassembly & Reassembly

    CHAPTER 7. POWER STEERING SYSTEM 4. DISASSEMBLY & REASSEMBLY Note: The spool/sleeve assembly is composed of sleeve (3), spool (4), pin (8), centring spring (6), Disassemble or reassemble the mini-orbit roll re- thrust spring (7), and spring retaining ring (9). ferring to the parts list and the drawing in Fig.

  • Page 92: Reassembly

    SERVICE MANUAL FOR SGR19 & SGR17 4.2. REASSEMBLY with the flat surface turned downward. Inspect all disassembled parts for contact sur- (7) Installation of oil seal (12) faces for flaws and burr. The parts which have such defects should be replaced with new ones a.
  • Page 93 CHAPTER 7. POWER STEERING SYSTEM alternatively. Make the end of the spool/sleeve assembly and the end of the G-rotor side of the housing be flush. In this state, the assembly should turn smoothly. (12) Fit O-ring (22) into housing (2). (13) Put spacer plate (24) on the housing and align the bolt holes and oil holes in the housing and spacer plate.

  • Page 94: Major Troubles And Causes, And Countermeasures

    SERVICE MANUAL FOR SGR19 & SGR17 5. MAJOR TROUBLES AND CAUSES, AND COUNTERMEASURES When the system should suffer troubles, confront them in accordance with the countermeasures men- tioned below. In such cases, analyse the trouble properly and check the whole hydraulic system besides the orbit-roll and control valves.
  • Page 95 CHAPTER 7. POWER STEERING SYSTEM Troubles Presumable causes Countermeasures 5. Chassis a. Excessively worn mechanical parts Lubricate joints or replace defective ones with new ones. Steering wheel does not 1. Hydraulic system return to neutral position a. Excessively high back pressure Correct.
  • Page 96 SERVICE MANUAL FOR SGR19 & SGR17 Troubles Presumable causes Countermeasures Abnormal vibration is 1. Hydraulic system observed. Trapped air Bleed system of air. 2. Chassis Worn joints Replace with new ones. Abnormal noises 1. Hydraulic system (abnormal relief noise a. A specific hydraulic apparatus...

  • Page 97: Chapter 8. Manual Steering System

    CHAPTER 8. MANUAL STEERING SYSTEM CHAPTER 8. MANUAL STEERING SYSTEM 1. CONSTRUCTION Fig. 8-1 2. GEAR BOX Fig. 8-2...

  • Page 98: Disassembly

    SERVICE MANUAL FOR SGR19 & SGR17 3. DISASSEMBLY 3.1. REMOVAL OF THE STEERING GEAR BOX ASSEMBLY – Remove the drag rod from the drag arm. – Remove the steering wheel cap and remove the steering wheel. Fig. 8-3 – Remove the bolts which tighten the steering gear...

  • Page 99: Reinstallation And Adjustment

    CHAPTER 9. ELECTRICAL ACCESSORIES 3.4. REINSTALLATION AND ADJUSTMENT Reassmebly of the steering gear box – Install the control flange (for gear backlash ad- justment) offset downwards as illustrated. Install two RBB’s and retain them with the snap ring. The outside RBB has a seal on one side only. Install it with the seal turned outward.

  • Page 100: Chapter 9. Electrical Accessories

    SERVICE MANUAL FOR SGR19 & SGR17 CHAPTER 9. ELECTRICAL ACCESSORIES 1. WIRE HARNESS LAYOUT Fig. 9-1...

  • Page 101: Wire Harness Sequence

    CHAPTER 9. ELECTRICAL ACCESSORIES 2. WIRE HARNESS SEQUENCE Fig. 9-2...

  • Page 102: Wiring Diagram

    SERVICE MANUAL FOR SGR19 & SGR17 3. WIRING DIAGRAM Fig. 9-3...

  • Page 103: Limitter Switch For Trunnion Arm

    CHAPTER 9. ELECTRICAL ACCESSORIES 4. LIMITTER SWITCH FOR TRUNNION Neutral stay Neutral plate Limitter switch When pedal is depressed by 20 mm Fig. 9-4 5. STARTER 5.1. CONSTRUCTION Fig. 9-5...

  • Page 104: Removal And Disassembly Of Starter

    SERVICE MANUAL FOR SGR19 & SGR17 5.2. REMOVAL AND DISASSEMBLY OF STARTER REMOVAL OF STARTER 1) Remove the negative (-) battery cable. 2) Remove the starter wiring. • Disconnect the wire harness from terminal 30 by removing the nut. Fig. 9-8 •...
  • Page 105 CHAPTER 9. ELECTRICAL ACCESSORIES • Measure the commutator diameter with vernier armature coil core. If there is no continuity, the calipers. armature coil is normal. Standard value Usable limit 30 mm 29 mm Fig. 9-11 2) Inspection of armature coil for short circuit •...
  • Page 106 SERVICE MANUAL FOR SGR19 & SGR17 8) Inspection of the brush holder • Inspect for insulation across positive (+) side and negative (-) side of the brush holder. If there is no continuity, the brush holder is normal. Fig. 9-17 6) Inspection of the brushes •...

  • Page 107: Reassembly Of Starter

    CHAPTER 9. ELECTRICAL ACCESSORIES 5.4. REASSEMBLY OF STARTER 1) Installation of the armature • Apply grease to the armature bearing and then install the armature on the starter yoke. 2) Installation of the brushes and brush holder Fig. 9-23 • Lift up and hold the spring and install the brush. Fig.

  • Page 108: Inspection Of The Starter After Removal From The Tractor

    SERVICE MANUAL FOR SGR19 & SGR17 5) Installation of the gear and clutch • In the state of the pull-in test, the gear should remain pushed out when the lead is disconnected • Install the clutch assembly on the starter hous- from terminal C.

  • Page 109: Installation Of The Starter

    CHAPTER 9. ELECTRICAL ACCESSORIES Fig. 9-34 2) Braking test Install the starter on a test bench and apply brake. Measure each value while the starter is thus pre- vented from spinning. Each value should be as shown below: Voltage 8.0 V Current 230A or less at 1180 rpm or over...

  • Page 110: Alternator

    SERVICE MANUAL FOR SGR19 & SGR17 6. ALTERNATOR 6.1. EXPLODED VIEW, SPECIFICATIONS, AND PERFORMANCE CURVES • Exploded view Fig. 9-36 • Specifications • Output performance curves Under a constant supply of 13.5 V and at atmospheric temperature of 25°C Nominal voltage...

  • Page 111: Troubleshooting

    CHAPTER 9. ELECTRICAL ACCESSORIES 6.2. TROUBLESHOOTING Check fan belt. GOOD Replace belt. Check diode. GOOD Replace diode Check stator. assembly. GOOD Replace stator Check brushes. assembly. GOOD Replace brush Check IC regulator. assembly. Replace regulator assembly. 6.3. REMOVAL AND DISASSEMBLY b.
  • Page 112 SERVICE MANUAL FOR SGR19 & SGR17 Fig. 9-42 f. Removal of the brushes Remove the four nuts and bushes which tighten Fig. 9-40 the drive end frame and rear end frame. Then the brush assembly is removed. d. Removal of the IC regulator Remove the three screws which tighten the IC regulator.

  • Page 113: Inspection

    CHAPTER 9. ELECTRICAL ACCESSORIES Note: The bearing is a high speed type, so be sure to use a specified one by ISEKI when replacing. Never give it shock. k. Removal of the baring which is installed on the slip ring side Remove the bearing using a puller as illustrated.
  • Page 114 SERVICE MANUAL FOR SGR19 & SGR17 If it is smeared with oil, clean with alcohol- e. Continuity test of the stator coils soaked cloth. Check for continuity across respective coil ter- b. Continuity test of the rotor coil minals with a tester. If there is no continuity, re- place the stator.
  • Page 115 CHAPTER 9. ELECTRICAL ACCESSORIES Note: the brush holder. If the length is less than the The rectifier cannot be judged by the resistance usable limit, replace. value shown in forward direction, because the diode shows greatly different forward current flow in accordance with voltage applied, that is, the tester type and resistance range applied greatly affect resistance reading.

  • Page 116: Re-Assembly

    SERVICE MANUAL FOR SGR19 & SGR17 j. Inspection of the IC regulator Fig. 9-58 • Connect the removed IC regulator, variable DC power supply, voltmeter, and a lamp as illus- trated. (Keep SW1 and SW2 turned off.) • Set the power supply at 12V.

  • Page 117: Glow Plugs

    CHAPTER 10. MOWER DECK Fig. 9-61 Note: - The clearance between the brush holder and the Fig. 9-60 connector should be 1 mm or more. 2) Installation of the brush holder - Rubber packing for the brush holder should not be deformed or pinched.

  • Page 118: Chapter 10. Mower Deck

    SERVICE MANUAL FOR SGR19 & SGR17 CHAPTER 10. MOWER DECK 1. SPECIFICATIONS Models SCM48 SCM54 Type Rotary mower with rear discharge Cutting width 1220 mm 1369 mm Number of blades Blade driving method Drive shaft and drive belt Belts SB88-W800...

  • Page 119: Filling Diagram

    CHAPTER 10. MOWER DECK 2. FILLING DIAGRAM All the shafts mentioned below have a grease fitting on their end. Grease them periodically. The gear case should also be serviced periodically for oil replenishment and replacement. SCM54 SCM48 Fig. 10-1 Ref. No. Filling points Lubricants Quantity (cc)

  • Page 120: Disassembly And Reassembly

    SERVICE MANUAL FOR SGR19 & SGR17 3. DISASSEMBLY AND REASSEMBLY (1) As for the detachment of the mower deck from the lawn mower, refer to Chapter 2. (2) Remove the belt covers and other necessary parts to check the belts and other components for wear or damage or inspect or service each part if required.
  • Page 121 CHAPTER 10. MOWER DECK 3.1.2. BACKLASH ADJUSTMENT (1) Prepare the jig as show in the drawing to measure the backlash at R25 mm of the output shaft. Fig. 10-3 (2) Reassemble the gear box assembly and place it sideways and lock the input shaft in order to prevent it from turning.

  • Page 122: Side And Center Metal (Supports)

    SERVICE MANUAL FOR SGR19 & SGR17 3.2. SIDE AND CENTER METAL (SUPPORTS) 3.2.1. CONSTRUCTION Fig. 10-5 Assembled center metal (support) Adjusting shims (0.1, 0.2 mm) Adjusting shims (0.1, 0.2 mm) Fig. 10-6...
  • Page 123 CHAPTER 10. MOWER DECK Assembled side metal (support) Fig. 10-7 3.2.2. DISASSEMBLY AND REASSEMBLY Disassemble, inspect, and reassemble the supports in accordance with the following insturctions, refer- ring to the drawing above. - Inspect the oil seals for wear and deformation. (Oil seals are fundamentally consumable parts, so disas- semble ones should be replaced with new ones.) - When installing an oil seal, take care not to allow the lips of the oil seal to turn up or the oil seal to be installed slanted.

  • Page 124: Troubleshooting

    SERVICE MANUAL FOR SGR19 & SGR17 4. TROUBLESHOOTING Problems Causes Countermeasures Blades do not turn. • Broken belt • Replace. Blade speed does not • Slippery belt • Adjust tension spring. rise. • Replace belt when it is worn out where it contacts the pulley.

  • Page 125: Chapter 11. Service Standards

    CHAPTER 11. SERVICE STANDARDS CHAPTER 11. SERVICE STANDARDS 1. SERVICE STANDARDS Service Items Nominal Value Usable Limit Remarks when assembled 1.1. CHASSIS Brake system Brake disc 3.5 mm 2.9 mm Separator plate 1.52 mm 1.6 mm Max. speed Forward 16.8 km/h Reverse 10.0 km/h Braking distance...
  • Page 126 SERVICE MANUAL FOR SGR19 & SGR17 Service Items Nominal Value Usable Limit Remarks when assembled Rear 160 Kpa (1.6 kgf/cm 1.2. ENGINE Fan belt Belt deflection 5 – 10 mm 10 kg Valve clearance Intake 0.25 mm Cold Exhaust 0.25 mm...

  • Page 127: Tightening Torque Of Major Fasteners

    CHAPTER 11. SERVICE STANDARDS 2. TIGHTENING TORQUE OF MAJOR FASTENERS Locations Tightened parts kgf·m Cylinder head Cylinder head bolts 6.0±0.5 Rocker shaft 1.9±0.5 Injection nozzles 4.5±0.5 Glow plugs 1.75±0.25 Glow plug connectors 0.1 – 0.15 Hangers 4.1±0.6 Cylinder block Bearing caps 5.0±0.5 Front plate (M8)

  • Page 128: Standard Bolts And Nuts

    SERVICE MANUAL FOR SGR19 & SGR17 3. STANDARD BOLTS AND NUTS Size 4T bolts and nuts 7T bolts and nuts 7/9 bolts and nuts 30 – 40 50 – 60 60 – 70 60 – 80 90 – 110 100 – 130 130 –...

Table of Contents

Save PDF