Shibaura SG280E Workshop Manual Download Page 3

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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

Summary of Contents for SG280E

Page 1: ...SLOPE MOWER 2011 4 MODEL SG280E...

Page 2: ...1...

Page 3: ...ubleshooting 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...

Page 4: ...ling 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...

Page 5: ...4 Section 1 Overview 1 1 Specifications 1 2 Overall view part names 1 3 Maintenance precautions and procedures...

Page 6: ...oled 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 Trans...

Page 7: ...6 Body and operation areas 1 2 Overall view part names Fig 1 2 1 Fig 1 2 2...

Page 8: ...7 Fig 1 2 3 Total elapsed time Seat swing lever...

Page 9: ...n 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...

Page 10: ...9...

Page 11: ...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...

Page 12: ...tion 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...

Page 13: ...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...

Page 14: ...11 Model N843 2 2 Cross section diagrams Fig 2 2 1...

Page 15: ...12 Model N843 Fig 2 2 2...

Page 16: ...ings 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 sta...

Page 17: ...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 an...

Page 18: ...n 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 avo...

Page 19: ...ngine 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...

Page 20: ...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...

Page 21: ...emoving the connecting rods and pistons 1 Remove the bolts and then remove the rod cap 2 Pull the connecting rods and pistons out as a single unit from the cylinder head and store them after confirmin...

Page 22: ...19 2 Remove the anchor bolts from the bearing assembly holder on the crank shaft and then slide the crank shaft off in the direction of the flywheel Fig 2 4 21...

Page 23: ...formation on the bottom surface of the cylinder head Insert a straight edge underneath the cylinder head and then insert a thickness gauge in locations A through F shown in the figure on the right to...

Page 24: ...head thickness mm Assembly standard Usage limit 0 925 to 1 075 0 5 or less If the clearance between the valve and valve guide exceeds the usage limit replace the valve Clearance between valve and valv...

Page 25: ...Measure the external diameter of the rocker arm shaft Replace the shaft if the measurement exceeds the usage limit Rocker arm shaft wear Assembly standard Usage limit 14 95 to 14 97 14 87 or less 2 Me...

Page 26: ...ther damage Internal diameter of cylinder block Assembly standard Usage limit 84 000 to 84 019 84 200 or more 4 Pistons and piston rings 1 Replace pistons that have significant cracking striations or...

Page 27: ...sage limit 1 0 or more Assembly standard 0 20 to 0 40 Ring 2 Usage limit 1 0 or more Assembly standard 0 20 to 0 40 Oil ring Usage limit 1 0 or more 4 Measure the clearance between the piston ring gro...

Page 28: ...vel Distortion parallelism in connecting rods mm Assembly standard Required repair level Distortion per 100mm 0 08 or less 0 20 or more Parallelism per 100mm 0 05 or less 0 15 or more 2 Measure the in...

Page 29: ...ing the head of the piston on the combustion chamber side with the mark at part A on the connecting rod as shown in the figure on the right Pay careful attention to the numerical mark on part A of the...

Page 30: ...e usage limit replace the metal Thrust washer Inspect the bearing holder and thrust washer If there are signs of wear poor contact or burnout or if the thickness exceeds the usage limit replace the th...

Page 31: ...d replace it if it shows signs of peeling melting burnout or poor contact 2 Measure in directions A and B at locations 1 and 2 as shown in the figure on the right and then calculate the difference oil...

Page 32: ...Replace the gear if there is significant wear in the teeth 2 Measure the backlash in the gear Replace the gear if the measurement exceeds the usage limit Timing gear backlash mm Assembly standard Usa...

Page 33: ...e if they show significant wear or damage 2 If the clearance between the rotor and vane exceeds the usage limit replace the rotor and vane Clearance between rotor and vane mm Assembly standard Usage l...

Page 34: ...age and significant wear If there is sign of damage or wear replace the ring gear If the ring gear shows signs of only partial wear you can continue to use it by first removing it turning it approxima...

Page 35: ...bolt 3 Measure the allowance in the crankshaft axis direction Allowance in crankshaft axis direction mm Assembly standard Required repair level 0 1 to 0 4 0 5 or more 2 Oil seal and rear plate 1 Asse...

Page 36: ...od tightening torque N m 49 to 53 9 5 0 to 5 5 kgf m Allowance in connecting rod axis direction mm Assembly standard Usage limit 0 1 to 0 3 0 7 5 Suction pipe and suction filter 1 Install the O ring o...

Page 37: ...ar crankshaft gear and cam shaft gear and then install them on the idle gear shaft 4 Assemble the rotor 5 Install the oil pump cover shim spring and collar and fix the clip 6 Adjust the shim so that t...

Page 38: ...ft pulley Tightening torque for crankshaft pulley nut N m 274 4 to 333 2 28 to 34kgf m 11 Injection pump assembly 1 Insert the shim that was removed during disassembly connect the control rack on the...

Page 39: ...elivery holder 5 From the condition in step 4 carefully rotate the crankshaft in the clockwise direction until the flow of fuel from the deliver holder stops If reading of the piston position before u...

Page 40: ...k 2 Select a head gasket according to the measurement results Engine model Measured value mm Gasket part code Thickness when tightened mm 0 45 to 0 60 111147491 1 3 N 843 0 60 to 0 70 111147501 1 4 3...

Page 41: ...assembly Rocker arm assembly tightening torque N m 27 4 to 39 2 2 8 to 4 0 kgf m 16 Adjusting valve clearance Loosen the nut and adjust the adjusting screw so that valve clearance is 0 2mm for both in...

Page 42: ...e and holder tightening torque N m 58 8 to 68 6 6 0 to 7 0 kgf m 21 Return pipe and injection pipe Install the return pipe and then install the injection pipe Injection pipe tightening torque N m 14 7...

Page 43: ...ns Model A007T03877 Mitsubishi Direction of rotation Right when viewed from the pulley Adjusting voltage 14 5 to 15 0V Rated output 12V 40A Parts list No Part code Part name 1 185046320 Alternator ass...

Page 44: ...17 Packing 8 185846618 Armature 9 185846621 Ball set 10 185866391 Shaft clutch 11 Plug set 12 Clutch pinion 13 Gear 14 Washer 15 Gear shaft 16 Gear 17 Yoke 18 185416490 Brush 19 185416500 Brush holder...

Page 45: ...etracted Solenoid tightening torque N m 14 7 to 19 6 1 5 to 2 0 kgf m 4 Glow plug Measure the continuity between the center electrode and the body Replace the glow plug if it does not show the standar...

Page 46: ...rnor Inspect and adjust the governor Engine speed is irregular Defective engine Inspect and repair related parts No fuel in the fuel tank Add fuel Clogged fuel filter Replace the fuel filter Air in th...

Page 47: ...0 degrees centigrade Pistons Clearance between piston pin hole and pin 0 00004 to 0 00043 0 02 External diameter of pin 27 27 996 to 28 0 27 98 Clearance between rod small end and pin 0 01 to 0 025 0...

Page 48: ...iameter 68x72 Clearance between crank journal and center bearing 2 3 and 4 0 044 to 0 102 0 2 Oil clearance Primary moving parts Crankshaft Bearing holder upper and lower tightening torque N m 49 to 5...

Page 49: ...ge pressure 0 29 to 0 49Mpa Oil temperature 50 to 80 C SAE30 0 44 Oil pressure switch working pressure Mpa 0 029 0 019 to 0 039 Relief valve working pressure Mpa 0 35 to 0 45 Lubricant volume liters 5...

Page 50: ...p pressure valve start pressure Mpa 0 068 to 0 088 Cooling components Cooling Radiator cap negative pressure valve start pressure Mpa 0 004 to 0 005 Model M001T66081 18508 6551 Mitsubishi Electric Num...

Page 51: ...48 Section 3 Hydraulic and Power Systems 3 1 Hydraulic system diagram 3 2 Functions 3 3 Power system...

Page 52: ...49 Section 3 Hydraulic and Power Systems Overall circuit diagram 3 1 Hydraulic system diagram Fig 3 1 1 Forward Reverse...

Page 53: ...50 HST 2WD 4WD 2WD 4WD 2WD 4WD 3 2 Functions Fig 3 2 1...

Page 54: ...ince twice the volume of oil is sent to the rear wheel motor the driving motor is operated at high speed and the sub transmission shifts to high The front wheel motor forms a rotating circuit dark blu...

Page 55: ...like the flow of oil during 2WD the oil is supplied completely separately to the front and rear driving motors and therefore the sub transmission shifts to low Normally this low speed is used for mowi...

Page 56: ...erentially This circuit is protected by a safety valve relief valve inside the steering unit that will open if the system is overloaded Pressure setting 5 39Mpa 55kfg cm 2 The SG280E uses a mechanical...

Page 57: ...preferentially This circuit is protected by a safety valve relief valve inside the steering unit that will open if the system is overloaded The relief valve in the steering unit also functions to pro...

Page 58: ...ulley on the PTO shaft directly below via a belt This mower uses a tension method to engage disengage power via belt tension which is controlled smoothly by operating the mower clutch lever The power...

Page 59: ...56...

Page 60: ...56 Section 4 Electric Components 4 1 Layout diagram 4 2 Safety system electric components...

Page 61: ...18508 6551 Motor assembly M001T66081 7 38520 1410 Switch assembly brake switch 19 18524 6060 Engine oil mano contact 8 38520 1860 Switch assembly starter 20 38572 0360 Thermo switch water temperature...

Page 62: ...ngine and the engine to start When the HST pedal is pressed the switches go off and the engine cannot be started When starting the engine the HST pedal must not be pressed in neutral position and the...

Page 63: ...code Related electric components 5A Safety relay solenoid relay seat timer alternator 5A Pilot lamp water temperature thermometer 5A 38541 0070 Electric components from external terminal 1 30A 38541 0...

Page 64: ...ere should be no continuity 2 When a voltage of 12V is applied between A and B there should be continuity between D and C If the conditions detailed in 1 and 2 above are not met replace the relay 4 Se...

Page 65: ...f the driver leaves the seat such as in an emergency while the engine is running the engine will stop 2 Inspection 1 Connect a tester to the switch to check that there is no continuity 2 Check that th...

Page 66: ...moving the switch 1 Remove the battery terminal 2 Remove the spring from the switch 3 Remove the switch connector from the main harness 4 Remove the adjustment nuts and then remove the switch 3 Inspec...

Page 67: ...allowing the engine to be started 2 Removing the switch 1 Remove the battery terminal 2 Remove the spring from the switch 3 Remove the switch wiring from the main harness 4 Remove the adjustment nuts...

Page 68: ...0 Water temperature switch 38572 0360 1 Installation location and operation The water temperature switch is installed on the engine thermostat case If the engine starts to overheat the water temperatu...

Page 69: ...ater temperature sensor to a tester and measure the resistance value Replace the water temperature sensor if it does not show the standard resistance value Water temperature C Standard resistance valu...

Page 70: ...66 Section 5 Disassembling Assembling and Adjusting 5 1 Engine 5 2 Power steering 5 3 HST 5 4 Driving motor 5 5 Hydraulic hoses and pipes 5 6 Front accelerator 5 7 Control valve...

Page 71: ...nnectors 3 Remove the bolts and nuts at the hinge on the bonnet and then remove the bonnet 4 Drain the coolant from the radiator in the engine Loosen the band and pull out the flat head pin 5 Remove t...

Page 72: ...t from the engine side cable for tachometer 10 Remove the belt covers upper and lower on the PTO shaft drive and then remove the V belt 11 Set the fuel cock to Closed and then remove the fuel hose fee...

Page 73: ...t fix the engine mount 2 each on left and right sides 14 Connect a hoist line to the hangers 2 locations on the engine and use a chain block to lift out the engine assembly 2 Removing the engine Fig 5...

Page 74: ...1 Oil pump Direction of rotation Left when viewed from the shaft 2 Steering Type Full hydraulic non load reaction Stroke mm 187 3 Steering cylinder Inner diameter 35 Regulated stream flow liters min...

Page 75: ...Gerotor 1 8 Pin 1 Unused No 9 Steering retaining link 1 27 Plate 1 10 Thrust needle bearing 1 28 O ring 1 11 Bearing race 2 29 Cap screw 7 12 Oil seal 1 30 Name plate 1 13 Oil seal 1 31 Rivet 2 14 Re...

Page 76: ...O ring 1 10 Backup ring 2 11 05240 0380 O ring 1 12 02091 0012 Nut 1 13 34496 0433 Bush 2 14 34496 0436 Bush 1 15 03650 0035 C retaining ring for hole 1 16 34496 0437 Round R retaining ring 1 17 34496...

Page 77: ...f input revolutions 1400 to 2600rpm Slope angle 0 to 16deg Max working pressure 20 09 21 07Mpa 205 to 215 kgf cm2 Internal case pressure 0 098Mpa 1 kgf cm2 Piston pump 2x 0 to 16 4 cm3 rev Pumping cap...

Page 78: ...cket head bolt 14 Trunnion pin 45 Bolt 15 Trunnion 46 Socket head bolt 16 Spring pin 47 Bore plug 17 Ball bearing 48 Spring washer 18 Needle bearing 49 Name plate 19 Poppet 50 Drive screw 20 Spring 51...

Page 79: ...e cylinder block will have the same capacity Therefore neither intake nor exhaust is performed and the pump does not operate If the center of the shaft axis and the swash plate are tilted the capacity...

Page 80: ...pump to the drive motor Oil fed by the gear pump is supplied to the HST unit via the check valve The remaining oil passes through the low pressure relief valve cools the pump inside the case and is t...

Page 81: ...tion When the pedal is returned to the neutral position reversal of the load pressure causes the valve to return quickly to neutral position This allows the gradual closing of the valve for a smooth s...

Page 82: ...ow when driving in reverse When the HST pedal is pressed backward the variable pump operates and discharges oil The oil flowing to the drive motor flows in the opposite direction as for forward drivin...

Page 83: ...P2 Low pressure supply check valve function If the P1 or P2 pressure drops below the P charge pressure poppet A is lifted and P charge oil is supplied to either P1 or P2 2 Low pressure relief valve T...

Page 84: ...swash plate to 0 degrees move the neutral arm linked to the HST trunnion shaft forward back to first align the stop conditions of the rear wheels To do this loosen the bolt and then turn the boss to...

Page 85: ...ng this procedure 1 Separate the wiring for the safety switch loosen the two installation bolts on the switch bracket and then adjust by sliding the bracket so that electricity flows when the HST peda...

Page 86: ...del ORB S 205 3AT Discharge rate 205cm3 rev Output torque 330N m Fig 5 4 1 Fig 5 4 2 No in diagram Name 13 Needle bearing seal 14 Backup ring 15 X ring 19 Key 20 O ring 22 Spring 23 Steel ball 27 Squa...

Page 87: ...l bolts M8 3 Remove the seal case from the main unit Fig 5 4 3 Disassembly Fig 5 4 4 CAUTION 1 If the seal case is difficult to remove use the bolts to turn it See the figure below 2 Carefully store t...

Page 88: ...emove the square ring 5 Remove the O ring check spring and steel ball 6 Use a precision driver to remove the dust seal 7 Use a precision driver to remove the X ring Fig 5 4 8 Fig 5 4 9 Fig 5 4 10 Fig...

Page 89: ...from each part Wash each part and blow dry with compressed air Fig 5 4 13 Assembly Fig 5 4 14 CAUTION 1 Apply a thin layer of grease to the sliding part of the X ring 2 Be careful to avoid applying to...

Page 90: ...they will not fall out when the drain check is turned upside down Insert the O ring 5 Install the square ring on the main unit Apply a small amount of grease to help install the square ring securely...

Page 91: ...62 to the remaining four bolts and tighten all to the specified torque Tightening torque for hexagonal socket head bolts 43 to 45 N m Tightening torque for grooved hexagonal nuts 150 to 200 N m 8 Hamm...

Page 92: ...88 2 Rear wheel motor 1 Specifications 2 Cross section diagram Model OMSB200 Flow rate 60 liters min Continuous torque 470Nm Fig 5 4 23 Fig 5 4 24 Intermediate plate Brake lock...

Page 93: ...10 Dust seal ring 36 Disk valve 11 Brake shaft 37 Balance plate 12 O ring 38 Guide pin 13 Washer 39 O ring 14 Locking ring snap ring 40 O ring 15 Locking ring snap ring 41 Spacer 16 Bush 42 Spring wa...

Page 94: ...essary 2 Motor 1 End cover valve housing 1 Clamp the motor in a vise and then remove the four bolts 2 Lift and remove the end cover Fig 5 4 26 Fig 5 4 26 Fig 5 4 27 Fig 5 4 28 CAUTION 1 Clean the moto...

Page 95: ...marks before removing the disk valve Alignment mark for the disk valve and the channel plate Alignment mark for the disk valve and the valve drive Fig 5 4 31 CAUTION 1 Make alignment marks before remo...

Page 96: ...he shaft seal and dust seal out of the bearing housing and assemble them in the orientation shown in the figure on the right Fig 5 4 34 CAUTION 1 Pay careful attention to the orientation of the seal r...

Page 97: ...llowing the disassembly procedure in reverse order Use the rated torque when tightening screws 25 Screw 25 tightening torque 74 5 to 80 4N m 7 6 to 8 2kgf m Castle nut 3 tightening torque 84 3N m 8 6k...

Page 98: ...40 0551 Oil pipe P 4 A4040 0561 Oil pipe T 5 A4040 0590 Oil pipe L 6 A4040 0580 Oil pipe R 7 A4040 0571 Oil pipe EF 8 A4047 0930 Oil hose male seat G1 4 L 1000 9 A4047 1850 Oil hose male seat G1 4 L 9...

Page 99: ...7 0830 Oil hose male seat G1 4 L 320 6 A4040 0620 Oil pipe B2 7 A4040 0630 Oil pipe B1 8 A4047 1860 Oil hose male seat G1 2 L 500 A1 9 A4047 0820 Oil hose male seat G1 2 L 550 A2 10 A4047 1870 Oil hos...

Page 100: ...96 3 Front drive system No Part code Part name Remarks 1 A4040 0620 Oil pipe 2 A4040 0630 Oil pipe 3 A4040 0600 Oil pipe 4 A4040 0610 Oil pipe 5 A4047 0850 Oil hose G3 8 L 650 Fig 5 5 3...

Page 101: ...m G 1 4 3 8 1 2 Tightening torque 39 2 4 0 49 0 5 0 58 8 6 0 Locknut width mm 19 22 27 High pressure hose union nut tightening torque N m kgf m G 1 4 3 8 1 2 Tightening torque 24 5 2 5 49 0 5 0 58 8...

Page 102: ...ter pin method that is supported by the pivot shaft The PTO shaft for the mower drive is built into the pivot shaft for a structure in which power is transmitted from the engine to the mower 5 6 Front...

Page 103: ...the front tires 4 Remove the nut and spring washer from the front of the PTO shaft drive and then remove the pulley and plate together as a single unit Remove the grease nipple first 5 Pull out the pi...

Page 104: ...aft clamp from the rear of the pivot shaft and then pull out the shaft from the rear 10 Remove the front axle from the main unit 1 Pivot shaft bush Replace the bush if there is rattling or play at the...

Page 105: ...ent amount of grease after assembly is complete 1 After tightening the shaft end nuts on the pivot shaft tighten them so that the end of the front axle swings at 147 to 157N m 15 to 16kgf m 2 Tie rod...

Page 106: ...rs 2mm washer so that the pulley is centered on the engine side Use up to 2 washers 2 Press the center of the belt at 49N 5kgf and adjust the lock nut on the wire to create a sag of about 10mm Perform...

Page 107: ...y unit 1 34001 5632 Control assembly 1 2 34029 3654 Spool section 1 3 34029 3655 Spool section 1 4 34020 3652 Seal kit 1 5 34029 3653 Link assembly 2 6 Clevice pin 6 7 Link 2 8 Washer 6 9 Split pin 6...

Page 108: ...104 2 Main control valve 1 Specifications Part No 34001 4770 Rated flow 15 liters min Name Control valve Max working pressure 6 9MPa 70kgf cm 2 2 Structure Fig 5 7 2...

Page 109: ...105 Section 6 Wiring Diagram 6 1 Wiring diagram...

Page 110: ...106 6 1 Main circuit diagram...

Page 111: ...107 Fig 6 1 1...

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Shibaura SG280E, Workshop Manual

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