Shibaura SG280E Workshop Manual

SLOPE MOWER

2011-4

MODEL

SG280E

1

2

We have developed a riding slope mower that improves efficiency

and reduces labor for work on sloped lawns.

This manual describes the structure and functions of the SG280E, as

well as its operation and troubleshooting measures, so that you can

make the most of its capabilities.

Please make the most of the information provided here to enhance

your sales and service activities, and to correctly operate this slope

mower.

Specifications and other details in this manual are subject to change without prior notice.

IHI Shibaura Machinery Corporation

TURF CARE EQUIPMENT DIVISION

April 2011, First Edition

Introduction

3

Contents

Section 1 Overview ·············································································································

3

1-1 Specifications ·············································································································

4

1-2 Overall view [part names] ··························································································· 5

1-3 Maintenance precautions and procedures ································································· 7

Section 2 Engine ················································································································· 9

2-1 Engine specifications ·································································································· 10

2-2 Cross-section diagrams ····························································································· 11

2-3 General precautions for disassembly/assembly ························································ 13

2-4 Disassembling the engine ·························································································· 14

2-5 Disassembling, inspecting, and assembling primary parts ········································ 20

2-6 Assembling the engine ······························································································· 32

2-7 Electric components ··································································································· 40

2-8 Troubleshooting ·········································································································· 43

2-9 Engine standard maintenance chart ·········································································· 44

Section 3 Hydraulic and Power Systems·············································································· 48

3-1 Hydraulic system diagram···························································································· 49

3-2 Functions······················································································································ 50

3-3 Power system··············································································································· 55

Section 4 Electric Components····························································································· 56

4-1 Layout diagram ············································································································ 57

4-2 Safety system, electric components ············································································ 58

Section 5 Disassembling, Assembling, and Adjusting ·························································· 66

5-1 Engine ·························································································································· 67

5-2 Power steering ············································································································· 70

5-3 HST ······························································································································ 73

5-4 Driving motor················································································································ 82

5-5 Hydraulic hoses and pipes··························································································· 94

5-6 Front axle ····················································································································· 98

5-7 Control valves ·············································································································· 103

Section 6 Wiring Diagram ····································································································· 105

6-1 Wiring diagram ············································································································· 106

4

Section 1

Overview

1-1 Specifications

1-2 Overall view [part names]

1-3 Maintenance precautions and

procedures

5

Section 1 Overview

Model

SG280E

Total length (mm)

2495

Total width (mm)

1590

Total height (mm)

1900 (ROPS)/1200 (steering wheel)

Wheelbase (mm)

1500

Front wheels (mm)

1310

Track

tread

Rear wheels (mm)

1310

Dimensions

Minimum ground clearance (mm)

Reference: 140 (with mower deck in lowest position)

Front wheel size

21x11.00-10

Wheels

Rear wheel size

21x11.00-10

Mass (kg)

800

Model

N843

Type

4-cycle water-cooled diesel

Number of cylinders

3

Total stroke volume (cc)

1496

Engine

Rated output kw (HP)/rpm

20.6 (27.6)/2400

Brakes

Dry, internal expansion

Steering

Full hydraulic power steering (with tilt steering)

Transmission

Includes sub-transmission HST

Forward (transmission)

Dual transmission (2WD/4WD)

Num-

ber of

gears

Reverse (transmission)

Dual transmission (2WD/4WD)

Forward (km/h)

L: 0 to 9.0 (4WD) H: 0 to 18.0 (2WD)

Body

Speed

Reverse (km/h)

L: 0 to 6.0 (4WD) H: 0 to 12.0 (2WD)

Fuel tank capacity (liters)

26.0

Battery

55B24L

Engine oil (liters)

3.5

Hydraulic oil (liters)

23.0

Radiator coolant (liters)

4.0

1-1 Specifications

6





 Body and operation areas

1-2 Overall view [part names]

Fig.1-2-1

Fig.1-2-2

7

Fig.1-2-3

Total

elapsed

time

Seat swing lever

8

1. Pre-maintenance precautions

1. Wash the mower clean, and then drain oil, fuel, coolant, and other fluids prior to disassembly as

necessary.

2. Keep the maintenance workplace free from dust and brightly lit at all times.

3. Remove all oil and grease from disassembled parts, and then arrange the parts by group on a clean

work stand.

4. Check all work clothes, equipment, and tools to ensure a safe working environment.

2. Basic procedures for pre-maintenance precautions

1. The engine, HST, and hydraulic system are precision equipment. They should be kept clean and

disassembled only when necessary.

2. Parts that have become defective due to wear should be stored temporarily so that they can be

shown to the customer. Model, equipment number, part code number, and part name should be

clearly identified for placing an order.

3. During assembly, it is necessary to oil all movable parts and create an initial oil film for normal

lubrication.

4. Use appropriate tools to tighten bolts and nuts to an appropriate torque, unless specified otherwise.

5. Be sure to turn off the engine before performing inspection, maintenance, or repair work.

 Tightening torque chart

* See the bolt head marks on the following page for strength divisions.

Coarse thread

Fine thread

Screw

dimen-

sions

* Strength

division

Screw

pitch

Tightening torque

(kgf⋅m)

Tightening torque

(N⋅m)

Screw

pitch

Tightening torque

(kgf⋅m)

Tightening torque

(N⋅m)

4.8 0.15 to 0.21 1.47 to 2.06

8.8 0.27 to 0.37 2.65 to 3.63

M4

10.9

0.7

0.36 to 0.50 3.53 to 4.90

4.8 0.29 to 0.41 2.84 to 4.02

8.8 0.50 to 0.70 4.90 to 6.86

M5

10.9

0.8

0.68 to 0.96 6.66 to 9.41

4.8 0.50 to 0.70 4.90 to 6.86

8.8 0.85 to 1.15 8.33 to 11.3

M6

10.9

1.0

1.20 to 1.60 11.8 to 15.7

4.8 1.30 to 1.70 12.7 to 16.7 1.55 to 2.05 14.7 to 20.1

8.8 2.30 to 2.90 22.5 to 28.4 2.70 to 3.50 26.5 to 34.3

M8

10.9

1.25

2.90 to 3.70 28.4 to 36.3

1.0

3.10 to 4.10 30.4 to 40.2

4.8 2.60 to 3.40 25.4 to 33.3 2.90 to 3.70 28.4 to 36.3

8.8 4.50 to 5.70 44.1 to 55.9 5.00 to 6.40 49.0 to 62.7

M10

10.9

1.5

5.50 to 7.10 53.9 to 69.6

1.25

5.90 to 7.50 57.8 to 73.5

1-3 Maintenance precautions and procedures

Fig.1-2-4

Parking lever

9

8

Coarse thread

Fine thread

Screw

dimen-

sions

* Strength

division

Screw

pitch

Tightening torque

(kgf⋅m)

Tightening torque

(N⋅m)

Screw

pitch

Tightening torque

(kgf⋅m)

Tightening torque

(N⋅m)

4.8 3.80 to 4.80 37.2 to 47.0 4.40 to 5.60 43.1 to 54.9

8.8 6.70 to 8.50 65.7 to 83.3 7.60 to 9.60 74.5 to 94.1

M12

10.9

1.75

9.40 to 11.8 92.1 to 115.6

1.25

10.10 to 12.90 99.0 to 126.4

4.8 6.40 to 8.20 62.7 to 80.4 7.10 to 8.90 69.6 to 87.2

8.8 10.60 to 13.40 103.9 to 131.3 11.90 to 15.10 116.6 to 150.9

M14

10.9

2.0

14.20 to 17.80 139.2 to 174.4

1.5

15.00 to 19.00 147.0 to 186.2

4.8 8.80 to 11.20 86.2 to 109.8 9.30 to 11.70 91.1 to 114.7

8.8 15.20 to 18.80 149.0 to 184.2 16.00 to 19.60 156.8 to 192.1

M16

10.9

2.0

21.00 to 26.00 205.8 to 254.8

1.5

22.50 to 27.50 220.5 to 269.5

4.8 11.6 to 14.40 113.7 to 141.1 13.40 to 16.60 131.3 to 162.7

8.8 20.00 to 24.00 196.0 to 235.2 23.50 to 28.50 230.3 to 279.3

M18

10.9

2.0

28.00 to 34.00 274.4 to 333.2

1.5

30.50 to 37.50 298.9 to 367.5

4.8 14.70 to 18.30

144.1 to 179.3

17.50 to 21.50 171.5 to 210.7

8.8 24.50 to 29.50

240.1 to 289.1

28.00 to 34.00 274.0 to 333.0

M20

10.9

2.5

37.00 to 45.00

363.0 to 441.0

1.5

40.50 to 49.50 396.9 to 485.1



Conversion chart

kgf⋅

⋅⋅

⋅m →

→→

→ N⋅

⋅⋅

⋅m

.0 .1 .2 .3 .4 .5 .6 .7 .8 .9

0 0.98 1.96 2.94 3.92 4.90 5.88 6.86 7.84 8.82

1 9.8 10.8 11.8 12.7 13.7 14.7 15.7 16.7 17.6 18.6

2 19.6 20.6 21.6 22.5 23.5 24.5 25.5 26.5 27.4 28.4

3 29.4 30.4 31.4 32.3 33.3 34.3 35.3 36.3 37.2 38.2

4 39.2 40.2 41.2 42.1 43.1 44.1 45.1 46.1 47.0 48.0

5 49.0 50.0 51.0 51.9 52.9 53.9 54.9 55.9 56.8 57.8

6 58.8 59.8 60.8 61.7 62.7 63.7 64.7 65.7 66.6 67.6

7 68.6 69.6 70.6 71.5 72.5 73.5 74.5 75.5 76.4 77.4

8 78.4 79.4 80.4 81.3 82.3 83.3 84.3 85.3 86.2 87.2

9 88.2 89.2 90.2 91.1 92.1 93.1 94.1 95.1 96.0 97.0

Conversion example

1kgf⋅

⋅⋅

⋅m = 9.8N⋅

⋅⋅

⋅m 1kgf/cm

2

= 0.098Mps

2.4kgf⋅

⋅⋅

⋅m = 23.5N⋅

⋅⋅

⋅m

.1 .2 .3 .4 .5

1

2

23.5

3

4

Fig.1-3-1

9

Section 2

Engine

2-1 Engine specifications

2-2 Cross-section diagrams

2-3 General precautions for disassembly/assembly

2-4 Disassembling the engine

2-5 Disassembling, inspecting, and assembling

primary parts

2-6 Assembling the engine

2-7 Electric components

2-8 Troubleshooting

2-9 Engine standard maintenance chart

10

Section 2 Engine

N843

Type

Water-cooled 4-cycle stand-alone diesel

Cooling method

Forced-circulation cooling

Cylinder layout

Vertical in-line

Combustion

chamber type

Special excess flow type

Number of cylinders

3

Inner diameter x

stroke

84x90mm

Total stroke volume

1496cc

Compaction ratio

22.2:1

Rated output

20.6kw (27.6HP)/2400rpm

Lubricant quantity

3.5

2-1 Engine specifications

11

Model N843

2-2 Cross-section diagrams

Fig.2-2-1

12

Model N843

Fig.2-2-2

13

1) During an overhaul

Wear in cylinders, pistons, rings, and valves lead directly to the need for an engine overhaul. External indications of

such wear take a variety of forms, making it difficult to make a certain judgment. Therefore, the best method is to

perform inspections and maintenance on a regular basis, record the results, and then make a judgment based on that

data.

External indications of wear and/or damage to cylinders and pistons often include the following, in various combinations:

 Reduced compression pressure

 Increased consumption of engine oil

 Increased consumption of fuel

 Poor start up

 Reduced output

 Increased engine noise

 Increased blow-by of explosive gas into the cylinder block, and increased gas from the air breather

Primary indicators for the need of an overhaul include the following:

1. Reduced functioning of battery and starting motor

2. Wear on cylinders, pistons, and piston rings

3. No valve clearance

4. Reduced functioning of injection pump

5. Defective nozzle and valve during injection

2) General precautions during an overhaul

 When disassembling the engine, use an engine stand and a work stand for the disassembled parts, and arrange the

parts in order according to the disassembly procedure.

 When disassembling the engine, pay careful attention to the assembly marks so that the engine can be assembled

back the way it was. If some parts do not have assembly marks, add marks as necessary.

 When disassembling and/or washing the engine, always be careful to check for defects that would not be noticed

after disassembly and/or washing is complete.

 During disassembly and assembly, use the correct tools to avoid damaging parts. In addition, be sure to lubricate

movable parts, and use a torque wrench to tighten parts that have a specific tightening torque.

 Replace gaskets and packing. Use fluid packing when necessary to prevent leaks.

 Use appropriate tools to tighten bolts and nuts to an appropriate torque, unless specified otherwise.

2

-

3

General precautions for disassembly/

assembly

14

1. Removing the nozzle and glow plugs

1) Remove the high-pressure pipes .

* Clean to remove all debris before disassembly.

2) Remove the fuel return pipe .

3) Remove the injection nozzle assembly .

4) Remove the connector , and then remove the glow

plugs.

2. Removing the head cover (intake manifold)

 Remove the cap nut  and bolts , and then remove the

head cover .

3. Removing the oil pipe

 Remove the eye bolt , and then remove the oil pipe .

4. Removing the water pump assembly

1) Remove the bolt , and then remove the fan , holder

, and pulley .

2-4 Disassembling the engine

Fig.2-4-4

Fig.2-4-1

Fig.2-4-2

Fig.2-4-3

15

2) Remove the bypass hose  and lower hose  from the

water pump .

3) Remove the bolt , and then remove the water pump

 and gasket  from the engine.

4) Remove the bolt , and then remove the plate  and

the gasket  from the water pump .

5. Removing the rocker arms and push rods

1) Remove the bolts, and then remove the rocker arm

assembly .

CAUTION: Pay careful attention to the lengths of

the bolts.

2) Pull the push rods out of the cylinders.

CAUTION: Carefully store the caps from the tops of

the valves, to avoid losing them. (See

Fig. 2-4-8.)

6. Removing the exhaust manifold

 Remove the nut  and bolt , and then remove the

exhaust manifold .

7. Removing the cylinder heads

 Equally loosen the bolts  two or three times to remove

them, and then remove the cylinder head.

Fig.2-4-8

Fig.2-4-7

Fig.2-4-5

Fig.2-4-6

16

8. Removing the tappet

 Pull the tappets  up and out of the cylinder block.

9. Removing the injection pump assembly

1) Remove the engine stop solenoid .

2) Remove the bolts and nuts  holding the injection

pump .

3) Slowly lift the injection pump  over the stud bolts ,

and then pull out the snap pin  and remove it from the

link .

CAUTION: Check the number and thickness of

shims inserted on the installation

surface for injection.

Fig.2-4-10

Fig.2-4-11

Fig.2-4-12

Fig.2-4-9

17

10. Removing the crank shaft pulley

1) Remove the lock nut , and then pull out the crank

shaft pulley .

2) Remove the key  from the crank shaft .

11. Removing the timing gear case assembly

 Remove the bolts , and then remove the timing gear

case .

12. Removing the idle gear and oil pump assembly

1) Remove the E clip , and then remove the oil pump

assembly  and idle gear .

<

<<

>>

>

No. Name



E clip



Collar



Spring



Shim



Oil pump cover



Rotor



Spring



Idle gear



Thrust washer

Fig.2-4-16

Fig.2-4-13

Fig.2-4-14

Fig.2-4-15

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Shibaura SG280E Workshop Manual

Shibaura SG280E Workshop Manual

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