Lawn Mowers - Mower Decks - SCMB48 & Scma54 Collectors - SBC550X & 600X

LAWN MOWERS:
MOWER DECKS:
SCMB48 & SCMA54

COLLECTORS:
SBC550X & 600X

ISEKI LAWN MOWERS
FOREWORD
This service manual has been prepared to provide the information and suggestions necessary
for servicing the ISEKI SXG Lawn Mower. 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 SXG,
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mentioned herein are no longer valid.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!
1
SERVICE MANUAL FOR SXG323&326
TOTAL CONTENTS
LAWN MOWERS
CHAPTER 1. GENERAL INFORMATION ...................................................................................... 11
CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS .......................................................... 17
CHAPTER 3. ENGINE ACCESSORIES ......................................................................................... 27
CHAPTER 4. ENGINE .................................................................................................................... 33
CHAPTER 5. LUBRICATION SYSTEM .......................................................................................... 67
CHAPTER 6. COOLING SYSTEM.................................................................................................. 73
CHAPTER 7. FUEL SYSTEM ......................................................................................................... 75
CHAPTER 8. TRANSMISSION AND RELATED PARTS ............................................................... 87
CHAPTER 9. REAR AXLE ............................................................................................................. 93
CHAPTER 10. HYDROSTATIC TRANSMISSION .......................................................................... 95
CHAPTER 11. HYDRAULIC SYSTEM ......................................................................................... 117
CHAPTER 12. POWER STEERING SYSTEM ............................................................................. 121
CHAPTER 13. ELECTRICAL ACCESSORIES ............................................................................ 127
MOWER DECKS
CHAPTER 1. FOR SAFETY LABELS .............................................................................................. 5
CHAPTER 2. SPECIFICATIONS ...................................................................................................... 7
CHAPTER 3. ATTACHING AND DETACHING THE MOWER DECK .............................................. 9
CHAPTER 4. MOWER OPERATION .............................................................................................. 11
CHAPTER 5. INSPECTION AND MAINTAINANCE OF MAJOR PARTS ...................................... 17
CHAPTER 6. DISASSEMBLY AND REASSEMBLY OF GEAR BOX ............................................ 25
CHAPTER 7. INSPECTION OF MOWER DECK SCMA TYPE ...................................................... 29
CHAPTER 8. TROUBLESHOOTING.............................................................................................. 33
COLLECTORS
CHAPTER 1. SAFETY LABELS....................................................................................................... 5
CHAPTER 3. NAME OF MAJOR COMPONENTS ........................................................................... 9
CHAPTER 4. DETACHING AND ATTACHING THE COLLECTOR ............................................... 11
CHAPTER 5. COLLECTOR OPERATION ...................................................................................... 15
CHAPTER 7. ASSEMBLY INSTRUCTION ..................................................................................... 21
2
CHAPTER 1
CHAPTER 2
CHAPTER 3
CHAPTER 4
CHAPTER 5
CHAPTER 6
CHAPTER 7
CHAPTER 8
CHAPTER 9
CHAPTER 10
ISEKI LAWN MOWERS CHAPTER 11
SXG323 & 326 CHAPTER 12
CHAPTER 13
ISEKI LAWN MOWERS
TABLE OF CONTENTS
FOREWORD ..................................................................................................................................... 1
TOTAL CONTENTS .......................................................................................................................... 2
TABLE OF CONTENTS .................................................................................................................... 5
CHAPTER 1. GENERAL INFORMATION ...................................................................................... 11

1. MODEL NAME AND IDENTIFICATIONS NUMBERS .............................................................. 11
2. SPECIFICATIONS ................................................................................................................... 12
3. EXTERIOR VIEW .................................................................................................................... 13
4. PERIODIC INSPECTION TABLE ............................................................................................ 14
5. FILLING DIAGRAM.................................................................................................................. 15
CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS .......................................................... 17

1. GENERAL PRECAUTIONS FOR SEPARATION AND REINSTALLATION ............................. 17
1.1. BEFORE OPERATION ..................................................................................................... 17
1.2. PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING COMMON PARTS ............... 17
2. DISASSEMBLY OF FUNCTIONAL BLOCKS .......................................................................... 20
2.1. REMOVAL OF THE MOWER DECK ................................................................................ 20
2.2. DETACHING THE COLLECTOR ...................................................................................... 21
2.2.1. DETACHING THE HIGH DUMP COLLECTOR .......................................................... 21
2.2.2. DETACHING THE LOW DUMP COLLECTOR ........................................................... 21
2.3. REMOVAL OF MAJOR FUNCTIONAL COMPONENTS .................................................. 22
2.3.1. REMOVAL OF FENDER(WING) PANEL .................................................................... 22
2.3.2. REMOVAL OF FLOOR STEP, COVER AND FUEL TANK .......................................... 22
2.3.3. REMOVAL OF STEERING HEEL,METER PANEL ..................................................... 23
2.3.4. REMOVAL OF RADIATOR ......................................................................................... 23
2.3.5. REMOVAL OF ENGINE .............................................................................................. 24
2.3.6. REMOVAL OF REAR AXLE CASE ............................................................................. 24
2.3.7. REMOVAL OF TRANSMISSION CASE...................................................................... 25
2.3.8. REMOVAL OF FRONT AXLE CASE AND STEERING CYLINDER............................ 25
3. REINSTALLATION ................................................................................................................... 26
CHAPTER 3. ENGINE ACCESSORIES ......................................................................................... 27

1. RADIATOR ............................................................................................................................... 27
2. COOLING FAN AND BELT ...................................................................................................... 28
3. AIR CLEANER ......................................................................................................................... 29
4. FUEL SYSTEM ........................................................................................................................ 29
5. TROUBLE SHOOTING ............................................................................................................ 31
5
CHAPTER 4. ENGINE .................................................................................................................... 33

1. ENGINE ................................................................................................................................... 33
1.1. SPECIFICATIONS ............................................................................................................ 33
1.2. PERFORMANCE CURVES .............................................................................................. 34
2. INSPECTION AND ADJUSTMENT.......................................................................................... 35
2.1. INSPECTION OF ENGINE OIL ........................................................................................ 35
2.2. INSPECTION OF FAN BELT ............................................................................................ 35
2.3. INSPECTION AND ADJUSTMENT OF VALVE CLEARANCES ....................................... 36
2.3.1. Remove the cylinder head cover. ............................................................................... 36
2.3.2. 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 pro-jection on the
gear case. ................................................................................................................... 36
2.3.3. Insert a feeler gauge of a specified thickness and adjust the clearance with
the adjusting screw...................................................................................................... 36
2.4. INSPECTION AND ADJUSTMENT OF NOZZLE OPENING PRESSURE AND
INJECTION TIMING.......................................................................................................... 36
2.4.1. Adjustment of the valve opening pressure of the injection nozzles. ........................... 36
2.4.2. Inspection of oil tightness of valve seats .................................................................... 37
2.4.3. Spraying condition of injection nozzle ......................................................................... 37
2.4.4. Inspection and adjustment of injection timing ............................................................. 37
2.5. COMPRESSION AND UNLOADED IDLING SPEEDS ..................................................... 39
2.5.1. Inspection of compression .......................................................................................... 39
2.5.2. Inspection and adjustment of the idling speeds .......................................................... 39
2.6. INSPECTION OF WATER PUMP ..................................................................................... 39
2.6.1. Inspection of the pump and pulley .............................................................................. 39
2.6.2. Inspection of the bearing unit ...................................................................................... 40
2.7. INSPECTION OF THERMOSTAT ..................................................................................... 40
3. ENGINE BODY ........................................................................................................................ 40
3.1. CYLINDER HEAD ............................................................................................................. 40
3.1.1. REMOVAL OF THE CYLINDER HEAD ...................................................................... 41
3.1.2. DISASSEMBLY ........................................................................................................... 42
3.1.3. INSPECTION .............................................................................................................. 42
3.1.4. DISASSEMBLY AND INSPECTION OF THE ROCKER ARM SHAFT ....................... 45
3.1.5. INSPECTION OF THE PUSH RODS ......................................................................... 46
3.1.6. INSTALLATION OF THE CYLINDER HEAD............................................................... 46
3.2. GEAR CASE ..................................................................................................................... 48
3.2.1. EXPLODED VIEW ...................................................................................................... 48
3.2.2. REMOVAL OF THE GEAR CASE............................................................................... 48
3.2.3. RE-INSTALLATION OF THE GEAR CASE................................................................. 49
3.3. CYLINDER BLOCK .......................................................................................................... 50
3.3.1. EXPLODED VIEW ...................................................................................................... 50
3.3.2. DISASSEMBLY OF THE CYLINDER BLOCK ............................................................ 51
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ISEKI LAWN MOWERS
3.3.3. INSPECTION OF CYLINDER BLOCK,CRANKSHAFT, CAMSHAFT,

AND TAPPETS ............................................................................................................ 52
3.3.4. INSPECTION OF PISTONS AND CONNECTING RODS. ......................................... 57
3.3.5. ASSEMBLY OF PISTON AND CONNECTING ROD .................................................. 59
3.3.6. INSTALLATION OF CRANKSHAFT............................................................................ 60
3.3.7. INSTALLATION OF PISTON/CON-NECTING-ROD ASSEMBLIES ........................... 61
3.3.8. INSTALLATION OF REAR OIL SEAL ......................................................................... 62
3.3.9. INSTALLATION OF STRAINER AND OIL PAN .......................................................... 62
3.3.10. INSTALLATION OF REAR PLATE AND FLYWHEEL ............................................... 62
3.3.11. INSTALLATION OF FRONT PLATE AND GEARS .................................................... 63
CHAPTER 5. LUBRICATION SYSTEM .......................................................................................... 67

1. GENERAL DESCRIPTION ...................................................................................................... 67
1.1. LUBRICATION DIAGRAM ................................................................................................ 67
1.2. RELIEF VALVE ................................................................................................................. 68
1.3. OIL FILTER ....................................................................................................................... 68
1.4. EXPLODED VIEW OF OIL PUMP .................................................................................... 69
2. REMOVAL, DISASSEMBLY, INSPECTION AND RE-INSTALLATION OF OIL PUMP ............ 70
2.1. REMOVAL OF OIL PUMP................................................................................................. 70
2.2. DISASSEMBLY OF OIL PUMP ......................................................................................... 70
2.3. INSPECTION .................................................................................................................... 70
2.4. INSTALLATION OF OIL PUMP ......................................................................................... 71
3. OIL FILTER .............................................................................................................................. 71
3.1. REMOVAL OF OIL FILTER ............................................................................................... 71
3.2. INSTALLATION OF OIL FILTER ....................................................................................... 71
CHAPTER 6. COOLING SYSTEM.................................................................................................. 73

1. COOLING SYSTEM DIAGRAM ............................................................................................... 73
2. THERMOSTAT ......................................................................................................................... 73
2.1. REMOVAL OF THERMOSTAT.......................................................................................... 73
2.2. INSTALLATION OF THERMOSTAT.................................................................................. 73
2.3. INSPECTION OF THERMOSTAT ..................................................................................... 73
3.WATER PUMP .......................................................................................................................... 74
3.1. REMOVAL OF WATER PUMP .......................................................................................... 74
3.2. INSTALLATION OF WATER PUMP .................................................................................. 74
3.3. INSPECTION OF WATER PUMP ..................................................................................... 74
CHAPTER 7. FUEL SYSTEM ......................................................................................................... 75

1. INJECTION PUMP CONSTRUCTION..................................................................................... 75
2. REMOVAL, DISASSEMBLY, INSPECTION, RE-ASSEMBLY, AND INSTALLATION............... 76
2.1. REMOVAL OF INJECTION PUMP ................................................................................... 77
2.2. DISASSEMBLY OF INJECTION PUMP ........................................................................... 77
7
2.3. INSPECTION .................................................................................................................... 79

2.4. RE-ASSEMBLY................................................................................................................. 79
3. INJECTION NOZZLES AND HOLDERS.................................................................................. 81
3.1. REMOVAL OF INJECTION NOZZLES AND HOLDERS .................................................. 81
3.2. INSPECTION OF INJECTION NOZZLES ........................................................................ 81
3.3. DISASSEMBLY AND WASHING OF INJECTION NOZZLES ........................................... 82
3.4. INSTALLATION OF INJECTION NOZZLES AND HOLDERS .......................................... 83
3.5. INSTALLATION OF INJECTION NOULES AND HOLDERS ............................................ 83
4. GOVERNOR ............................................................................................................................ 84
4.1. GOVERNOR CONSTRUCTION ....................................................................................... 84
4.2. GOVERNOR OPERATION ............................................................................................... 86
CHAPTER 8. TRANSMISSION AND RELATED PARTS ............................................................... 87

1. DRIVE TRAIN DIAGRAM ........................................................................................................ 87
2. TRANSMISSION...................................................................................................................... 88
3. REAR WHEEL DRIVING MECHANISM (GE type) .................................................................. 88
4. BRAKE SYSTEM DISASSEMBLY ........................................................................................... 90
5. PRECAUTIONS FOR REASSEMBLY ..................................................................................... 90
6. BRAKE ADJUSTMENT ............................................................................................................ 90
7. DIF-LOCK ADJUSTMENT ...................................................................................................... 91
CHAPTER 9. REAR AXLE ............................................................................................................. 93

1. CONSTRUCTION .................................................................................................................... 93
CHAPTER 10. HYDROSTATIC TRANSMISSION .......................................................................... 95

1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS ............................................... 95
2. OPERATING DIAGRAM OF HST ............................................................................................ 96
3. FUNCTION .............................................................................................................................. 97
3.1. VARIABLE TYPE PUMP ................................................................................................... 97
3.2. FIXED TYPE MOTOR....................................................................................................... 98
3.3. VALVES ............................................................................................................................ 98
4. DISASSEMBLY AND REASSEMBLY .................................................................................... 100
4.1. REQUIRED TOOLS ........................................................................................................ 100
4.2. PRECAUTIONS FOR DISASSEMBLY ........................................................................... 100
4.3. TROUBLESHOOTING .................................................................................................... 101
4.4. DISASSEMBLY ............................................................................................................... 103
4.5. CRITERIA FOR REPLACING WORN PARTS ................................................................ 106
4.6. PRECAUTION BEFORE REASSEMBLY ....................................................................... 107
4.7. REASSEMBLY ................................................................................................................ 107
4.8. PRECAUTIONS FOR REASSEMBLY .............................................................................111
4.9. LIST OF MAJOR COMPONENTS OF HIST ................................................................... 113
4.10. PRECAUTIONS FOR INSTALLATION OF HST UNIT .................................................. 113
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ISEKI LAWN MOWERS
4.11. PRECAUTIONS AFTER INSTALLATION OF HST UNIT .............................................. 113

5. ADJUSTMENT OF HIST ........................................................................................................ 114
CHAPTER 11. HYDRAULIC SYSTEM ......................................................................................... 117

1. HYDRAULIC SYSTEM DIAGRAMS ...................................................................................... 117
2. INSPECTION OF MAJOR COMPONENTS........................................................................... 119
2.1. SUCTION FILTER........................................................................................................... 119
2.2. HYDRAULIC PUMP (GEAR PUMP) ............................................................................... 119
2.3. RELIEF VALVE FUNCTION............................................................................................ 119
2.4. RELIEF METAL (support) ............................................................................................... 120
2.5. OIL FILTER (Relief metal (support) ................................................................................ 120
CHAPTER 12. POWER STEERING SYSTEM ............................................................................. 121

1. CONSTRUCTION .................................................................................................................. 121
2. WORKING PRINCIPLE ......................................................................................................... 122
2.1. When the steering wheel is in neutral position: .............................................................. 122
2.2. When the sterrring wheel is operated: ............................................................................ 122
3. MAJOR TROUBLES AND CAUSES, AND COUNTERMEASURES ..................................... 123
CHAPTER 13. ELECTRICAL ACCESSORIES ............................................................................ 127

1. ELECTRICAL COMPORNENS AND WIRE HARNESS ........................................................ 127
2. WIRING DIAGRAM (E TYPE)................................................................................................ 129
3. WIRING DIAGRAM (GE TYPE) ............................................................................................. 130
4. STARTER .............................................................................................................................. 131
4.1. CONSTRUCTION ........................................................................................................... 131
4.2. REMOVAL AND DISASSEMBLY OF STARTER ............................................................. 132
4.3. INSPECTION OF COMPONENTS ................................................................................. 132
4.4. REASSEMBLY OF STARTER ........................................................................................ 135
4.5. INSPECTION OF THE STARTER AFTER REMOVAL FROM THE TRACTOR ............. 136
4.6. PERFORMANCE TEST .................................................................................................. 136
4.7. INSTALLATION OF THE STARTER ............................................................................... 137
5. ALTERNATOR........................................................................................................................ 138
5.1. EXPLOTED VIEW, SPECIFICATIONS, AND PERFORMANCE CURVES..................... 138
5.2. TROUBLESHOOTING .................................................................................................... 139
5.3. REMOVAL AND DISASSEMBLY .................................................................................... 139
5.4. INSPECTION .................................................................................................................. 141
5.5. RE-ASSEMBLY............................................................................................................... 144
6. GLOW PLUGS ....................................................................................................................... 145
6.1. SECTIONAL VIEW ......................................................................................................... 145
6.2. REMOVAL, INSPECTION, AND RE-ASSEMBLY ........................................................... 146
9
10
CHAPTER 1. GENERAL INFORMATION

1. MODEL NAME AND IDENTIFICATIONS NUMBERS b. Engine model name and serial number
a. Model name plate • The engine name is cast into the left-hand side
wall of the cylinder block. 1
The model name plate, which gives the model • The serial number is punched into the left-hand
name, type, production serial number, and pro- side wall of the cylinder block.
duction year of the machine, is located on the
right-hand side of the chassis.
1
SXG323H 1
E42
2 510kg 2 112
14.0kW/2600min -1 123
3 4
3
Fig. 1-1
(1) Model
(2) Type
(3) Production serial number
(4) Production year
Fig. 1-3
(1) Model
(2) Displacement
(3) Production serial number
Fig. 1-2
(A) Model name plate
(B) Engine plate
(C) Punched model name and serial number on
the right side of the chassis
SXG323 H000001
Chassis production serial number
Manufacturer’s model name
11
2. SPECIFICATIONS
LAWN MOWER
Model SXG 326 H SXG 323 H

E42 GE42 E42 GE42
Dimensions Overall length 2110 mm (83.1 in.)
Overall width 1170 mm (46.1 in.) 1100 mm (43.3 in.)
Overall height 1320 mm (52 in.) 1290 mm (50.8 in.)
525 kg (1157 530 kg (1168
Weight 510 kg (1124 lb.) 515 kg (1135 lb.)
lb.) lb.)
Engine Model E3112-G07 E3112-G06
Type Vertical, Water-cooled, 4-cycle, diesel
Combustion
Swirl chamber type
chamber
No, of cylinders 3
Total
1123
displacement
15.4 kw (21ps) 14.0 kw (19 ps)
Output (net)
2600 min-1 (rpm) 2600 min-1 (rpm)
Fuel Diesel fuel
Fuel tank Capacity 21 liters (4.6 imp. gal.)
Main
Transmission HST (Hydrostatic transmission)
transmission
Rear axle Chain drive
Travel Forward 0-16.5 km/h (0-10.3 mph) 0-14.5 km/h (0-9 mph)
Speeds Reverse 0-10 km/h (0-6.3 mph)
Wheel base 1450 mm (57.1 in.) 1365 mm (53.7 in.)

Wheel Tread Front 930 mm (36.6 in.) 910 mm (35.8 in.)
Rear 860 mm (33.9 in.)
Driving
2WD
system
Steering
Power steering
system
Brake system Dry internal-shoe expanding
No. of Brake 1 (Before dif.) 2 (After dif.) 1 (Before dif.) 2 (After dif.)
Tyre size Front 18 x 8.50-8 16 x 6.5-8
Rear 26 x 10.50-12 23 x 10.50-12
PTO Front 1750 min-1 (rpm)
PTO Clutch Belt tension clutch
Minimum
Lawn mower 140 mm (5.5 in.) 110 mm (4.3 in.)
ground
clearance Mower lift 150 mm (5.9 in.) 130 mm (5.1 in.)
12
3. EXTERIOR VIEW
Fig. 1-4
13
4. PERIODIC INSPECTION TABLE
c:Inspection, replenishment, and adjustment U:Cleaning and washing

z:Replacement :Consult your dealer.
Inspection and servicing intervals
Pre- hours of operation
Check points Intervals after that Judgement criteria
operation
50 100 150 200 250 300 350 400
Replace after initial 50 h
Engine oil c z z Maintain the specified level.
and then every 100 h.
Air cleaner U U U U U U U U Clean after every 50h.
Engine coolant c Replace every year. Maintain the specified level.
Fuel c Keep fuel tank always full.
Clean after every 100h. There should be no dust or
Fuel strainer c U U z U Replace element after water in filter.
every 300h.
13.8~14.8mm
Fan belt c
(0.54~0.58 in.) deflection
Electrolyte level c c c c c c c c Inspect after every 50h. Level should be kept properly.
Replace after initial 50h.
Engine oil filter Replace after every 300h.
Replace after initial 50h
Transmission oil c Maintain the specified level.
and then after every 200h.
Replace after initial 50h.
Hydraulic oil filter and then replace after every 200h.
Clean after initial 50h.
Suction filter and then replace after every 200h.
Replace after initial 50h
Chain case maintain the specified level
and then after every 200h.
Brake pedal play c 20 to 30 mm (0.8 to 1.2h.)
Steering wheel c Check after every 300h. There should be no abnormality.
Ball joints of steering Loose ball joints should be
c Check after every 300h.
system linkage re-tightened.
SXG326
Front: 1.5 x 105Pa (22psi)
Rear: 1.4 x 105Pa (20psi)
Tire pressure c
SXG323
Front: 1.4 x 105Pa (20psi)
Rear: 1.9 x 105Pa (28psi)
Toe-in Adjust after every 300h. 1 to 5mm(0.04 to 0.20in.)
Wheel tightening nuts c There should be no loose nuts.
Grease-up c c c c c c c c Inject grease after every 50h.
Radiator screen U There should be no clogging.
Radiator U There should be no clogging.
Electrical apparatus c All should work properly.
Safety switches c All should work properly.
Air intake openings U All should work properly.
Bolts and nuts c There should be no loose ones.
Rubber pipes c c c c Check after every 100h.
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 dealer.
14
5. FILLING DIAGRAM
8 7 6 2 7 1

12 12 1
8 9
3 9
13 10
5 13
14 4
Oil fillers
Oil drains
11 Greasing points
Fig. 1-5
Ref.No Filling points Lubricants Quantity: litre (imp.gal)

Radiator 3.5 (0.77)
1 LLC50%
Reserve tank 0.6 (0.13)
2 Engine Engine Oil 2.6 (0.57)
3 Transmission case HST OIL(SHELLDONAX TD) 8.0 (1.76)
4 Chain case (RH) Gear oil (SAE80) 1.1 (0.24)

5 Chain case (LH) Gear oil (SAE80) 1.1 (0.24)
6 Centre pivot Grease As required
7 Knuckle arms Grease As required
8 Cylinder ball end Grease As required
9 HST pedal hub Grease As required
10 Brake shaft Grease As required
11 HST link hub Grease As required
Brake shaft
12 Grease As required
ÚOnly G type
13 Mower link Grease As required
14 Fuel tank Diesel fuel 21 (4.62)
15
16
CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

1. GENERAL PRECAUTIONS FOR SEPARATION AND REINSTALLATION
1.1. BEFORE OPERATION 1.2. 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. 2
• When a bearing is fitted in by the outer race, use an
installer which is specially designed to push only the
b. Before disassembly, be sure that you familiarize outer race and vice versa.
yourself with the assembled condition for
subsequent reference in reassembly. • The installer must be designed to install the bearing
on the shaft in a parallel position.
c. Keep parts and tools in proper order during
operations. •When installing a bearing which appears the same on
both sides, install it so that the face which has the
d. When servicing electrically live parts, be sure to identification number faces in a direction for easy
disconnect the negative battery terminal. visual identification. All the bearings which are to be
installed in the transmission case should be placed so
e. To prevent oil or water leaks, use the liquid that their identification number faces outward.
gasket as required.
• If a shaft or a hole where a bearing is to be installed
f. When reassembling disassembled parts, discard has a stopper, the bearing should be pushed in
used gaskets, O-rings, or oil seals and install new completely until it is seated against the stopper.
ones.
• Installed bearings should turn smoothly.
g. When lifting up only the front or rear part of the
tractor, be sure to wedge the grounded wheels. b. Oil seals
• Oil seal installer should be designed so as not to
h. When the tractor is jacked up, be sure to support deform the oil seals.
the entire tractor with something like a stand.
Lifting it up with a jack only is a dangerously • During installation, be careful not to damage the lips,
unstable procedure. and assure that it is pushed in parallel to the shaft or
hole.
i. When replacing parts, use authorized, genuine
ISEKI parts only. ISEKI assumes no responsibility • When oil seals are installed, there should be no
for accidents, operating problems or dam-age turnover of the lips nor dislocation of the springs.
caused by the use of imitation parts. Also, the use
of unauthorized parts will result in relatively poor • When a multi-lip seal is installed, the grooves
machine performance. between lips should be filled with grease, not
adhesive.
• Use a lithium-based grease.
• There should be no oil or water leaks through the

installed soil seals.
17
c. O-rings
• O-rings should be coated with grease before • The roll pins installed in the transmission or other
installing. parts where much force is applied should be retained
with wire.
• Installed O-rings should have no slack or twist.
f. Cotter pins(Split pin)
• Installed O-rings should maintain proper air •When installed, cotter pins should be bent securely at
tightness. the ends as shown in the figure.
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 Fig. 2-3

extent that it is permanently deformed.
g. Bolts and nuts
•How to install the snap-ring: • Special bolts are installed at several locations, so be
When installing a snap-ring, install it as shown in sure not to interchange them other bolts.
the figure with its round edge side turned toward • Bolts and nuts should be tightened to their specified
the part to be retained. This round edge is formed torque with a torque wrench.
when the snap-ring is pressed out. • When locking the bolts or nuts with wire or a lock
washer, be sure to wind the wire 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.
•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.

Fig. 2-1
• When tightening bolts and nuts, refer to the tightening
e. Spring (roll) pins torque table.
• Spring pins should be driven in properly and
tightly. h. After installation, each grease fitting should
• Spring pins should be installed so that their be filled with grease.
seams should face the direction from which the
load is applied. • 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.
Fig. 2-2
18
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 2

adhesive (THREE BOND TB1215) and
tightened evenly with bolts. Adhesive 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 leve
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.
19
2. DISASSEMBLY OF FUNCTIONAL BLOCKS
2.1. REMOVAL OF THE MOWER DECK
(1) Start the engine and lower the mower deck by (5) Dismount the front linkage from the mower deck.
the lift lever. Turn the key switch OFF.
(2) Set the direction of the rear gauge wheels side
ways in the lifted-up position.
Fig. 2-7
(6) Start the engine and raise the mower linkage the
Fig. 2-4 lift lever.
(3) Disconnect the universal joint of the front drive (7) Turn the steering wheel to the right until the
shaft from the lawn mower. stopper.
(8) Turn the key switch OFF.
(9) Depress the discharge cover.
(10) Remove the mower deck sideways from left side

of lawn mower.
Fig. 2-5
(4) Disconnect the linkage from the mower deck.
Fig. 2-8
Fig. 2-6
20
2.2. DETACHING THE COLLECTOR
2.2.1. DETACHING THE HIGH DUMP 2.2.2. DETACHING THE LOW DUMP
COLLECTOR COLLECTOR
(1) Set the collector lowest position by using lift (1) Set the collector lowest position by using lift and
and dump lever. dump lever.
(2) Remove the hoses from lift and dump cylinders. (2) Remove the hose from dump cylinder
(3) Separate the connection of grass limit sensor and (3) Separate the connection of grass limit sensor and
safety switch wiring, it is located in right hand safety switch wiring, it is located in right hand
side on lawn mower. side on lawn mower. 2
(4) Support the container with wood and stand. (4) Remove cylinder upper pins.
(5) Remove right and left cylinder lower pins. (5) Remove dump fulcrum pin.
(6) Remove right and left lift fulcrum pin. (6) Push the lawn mower forward with using unload
(7) Set the collector lowest position by using lift and ever in the step.
Push the lawn mower forward with using unload (7) Separate the collector frame and lawn mower.
lever in the step. (8) Separate the cylinder stay and lawn mower.
Fig. 2-11
Fig. 2-9
Fig. 2-10
21
2.3. REMOVAL OF MAJOR FUNCTIONAL

COMPONENTS
2.3.2. REMOVAL OF FLOOR STEP, COVER
2.3.1. REMOVAL OF FENDER(WING) PANEL AND FUEL TANK
(1) Disconnect the wire harness of seat and remove (1) Remove the center cover of step.
the seat.
(2) Remove the knob of collector and mower deck.
(3) Remove the height adjust dial.
(4) Pull the pins of fender out and remove the fender.
Fig. 2-14
(2) Remove the cover of steering column.
Fig. 2-12
Fig. 2-15
Fig. 2-13 (3) Remove the HST pedal and step.

Important:
The negative battery cable should be disconnected
ahead of time to prevent short circuit.
Fig. 2-16
22
2.3.4. REMOVAL OF RADIATOR

(4) Disconnect the fuel hose.
(5) Remove the fuel tank. (1) Drain the coolant in radiator.
(2) Disconnect the radiator hose from engine.
(3) Disconnect the fan cover from radiator.
(4) Remove the radiator.
Fig. 2-17
2.3.3. REMOVAL OF STEERING HEEL,METER

PANEL
(1) Remove the steering wheel.
Fig. 2-20
Fig. 2-18
(2) Disconnect the wire harness from meter panel.
(3) Remove the meter panel.
Fig. 2-19
23
2.3.5. REMOVAL OF ENGINE

(7) Detach the engine from bracket
(1) Disconnect the drive shaft from engine.
Fig. 2-21 Fig. 2-24
2.3.6. REMOVAL OF REAR AXLE CASE

(2) Separate the fan cover from radiator.
(3) Disconnect the hydraulic hose and radiator hose
(1) Remove the rear tyre.
from engine.
(2) Drain the oil in rear axle case.
(4) Disconnect the wire harness from engine.
(5) Separate the fuel hose from engine.
Fig. 2-25
Fig. 2-22 (3) Detach the rear axle case from transmission case
and chassis.
(6) Disconnect the front PTO belt from engine.
Fig. 2-26
Fig. 2-23
24
2.3.7. REMOVAL OF TRANSMISSION CASE

(1) Drain the oil in the transmission case. (7) Detach the transmission case from bracket.
Fig. 2-27 Fig. 2-29
(2) Disconnect the wire cable of dif-lock from 2.3.8. REMOVAL OF FRONT AXLE CASE AND
transmission case. STEERING CYLINDER
(1) Disconnect the hose of steering cylinder.

(3) Remove the hydraulic control valve and pipe. (2) Remove the steering cylinder.
(4) Disconnect the brake linkage from transmission

case.
(5) Disconnect the drive shaft from transmission case.
(6) Disconnect the HST linkage from transmission

case.
Fig. 2-30
(3) Remove the pin of front axle.
Fig. 2-28
Fig. 2-31
25
(4) Detach the front axle from bracket. (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.
&IG - The front PTO ciutch control wire should be

connected with the tension spring through the
3. REINSTALLATION wire holder and the hole at the right-hand bot-
tom of the steering post.
Note:
Reassemble in reverse order of disassembly.But
check every part and replace defective once.
(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 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 or 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.
&IG
(3) Install the driver shaft.
(4) Install fuel pipes.

- Install the pipes on the injection pump.
- Install the fuel return pipes on the nozzles.
26
CHAPTER 3. ENGINE ACCESSORIES

1. RADIATOR Take care not to spill antifreeze on painted parts.
(1) CONSTRUCTION (3) INSPECTION FOR RADIATOR WATER LEAKS
Water leaks are liable to occur at the fitting portion

between the upper tank and the core section or
between the lower tank and the core section.
Test the radiator for leaks with compressed air in a

manner as shown below.
3
Fig. 3-1
Fig. 3-2
(2) REMOVAL AND RE-ASSEMBL
Or check for leaks with a radiator cap tester as
Remove and reassemble the radiator in accordance shown as below.
with the instruction of "DISASSEMBLY OF FUNC-
TIONAL BLOCKS."
Note:
Coolant should be replaced if it becomes contam-
inated with rust or sludge.Before adding new
coolant, flush inside of the radiator and engine
block with clean water
PRECAUTION FOR FILLING ANTI FREEZE

Fig. 3-3
Follow manufacturer's instructions for mixing ratio
of antifreeze. Note:
Never allow the test pressure to exceed
Antifreeze should be blended well with water before 1kgf/cm 2(14.2 psi) in both cases.
filling.
When the coolant level is lowered due to evaporation,

maintain the level by adding water, not by using an
antifreeze solution.
When the coolant level is lowered due to leaks,

maintain the level by adding an antifreeze solution of
the same mixing ratio.
27
(4) INSPECTION FOR RADIATOR CLOGIGING (5) VISUAL INSPECTION OF THE EXTERIOR
PARTS
Inside:
When the radiator exterior is corroded, cracked, or
Clean the radiator inside as shown below. badly damaged and the radiator core fins are crushed
or damaged, replace the radiator. Also replace dam-
aged or fatigued water hoses. Retighten loose hose
clamps securely if water is leaking through the hose
clamps, or replace them if necessary.
2. COOLING FAN AND BELT
(1) SPECIFICATION
Cooling fan.................320 mm (12.6 inches) 5 blades
Drive.....................................................................Belt
Pulley ratio.............................Crank/Fan101/78=1.29
(2) ADJUSTMENT OF BELT
To adjust belt tension, loosen the alternator pivot bolt

Fig. 3-4 and nut and tensioning bracket bolt. Pull outward on
top the alternator to correctly tension belt and tighten
Clean with a detergent. the bolt first and then tighten the pivot bolt.
Outside: Note:
Clean the radiator screen (wire mesh). Do not pry against the alternator housing or pul-
After the tractor has been operated in dusty condi- ley. Carefully pry against the alternator-mounting
tions, check the screen daily and clean if necessary. flange to prevent damage.
Clean the radiator cores by applying water spray or Belt deflection at“X” 13.8 to 14.8 mm
compressed air so as to form a right angle with the point
radiator cores, moving water application in parallel.
Note:
When cleaning the radiator cores with pressurized
water be sure to apply it at a right angle to the
cores. Slanted applications might deform their
cooling fins.
Clean the radiator cores by applying water spray or

compressed air so as to form a right angle with the
radiator cores, moving water application in parallel.
Note:
When cleaning the radiator cores with pressurized
Fig. 3-5
water be sure to apply it at a right angle to the
cores. Slanted applications might deform their
cooling fins.
28
3. AIR CLEANER Using compressed air [not exceeding 200 kPa (30
psi)] from the inside of the element, remove loose
(1) REMOVAL AND REASSEMBLY dirt, grass, chaff, etc.
Release clips on the cover. Remove the element. Be careful not to damage element pleats with air
Examine the element and seals for damage and brit- flow.
tleness. If the element is damaged in any way, it must
be replaced. Reassemble in reverse order of removal If the element is coated with oil or soot:
and clip securely.
a. Prepare solution of warm water and nonfoam-
ing detergent.
b. Soak the element for thirty minutes.

3
c. Agitate the element in solution until oil and
soot are loosened.
d. Rinse the element until rinse water is clear.
e. Allow the element to completely dry. Do not

Fig. 3-6 dry by using compressed air or heat.
(2) INSPECTION After cleaning (or washing) the element examine for
pinholes, punctures, or tears. If the element paper,
Inspect the air cleaner visually for cracks, deforma- canister or seal show any signs of physical damage,
tion, or other damage. the element must be replaced.
Check the rubber packing at each joint, rubber pipes Note:

and the evacuator valve. Replace an element, which has already been
washed five times.
Inspect the paper element.
4. FUEL SYSTEM
(3) CLEANING ELEMENT
(1) FUEL CIRCUIT
Fig. 3-7
The element may be cleaned (if in serviceable condi-
tion) using the following procedures. Fig. 3-8
29
(2) INSPECTION
Use only clean diesel fuel of cor rect grade.

Introduction of water or dirt into the fuel tank or
other part of the fuel system can cause repeated
plugging of the fuel filter and possible injection
pump and injector damage.
(3) FUEL FILTER
To replace the fuel filter element or clean sediment,

turn the fuel valve to the OFF position (top).
Inspect the filter element sediment bowl and O-ring.
Examine the small O-ring in the filter head and

replace as necessary.
Fig. 3-10
Caution:
Fuel emitted from loosened injection lines is
under high pressure. Keep hands and face away
when the engine is cranked. Clean all spilled
fuel following air-bleeding procedure.
Important:
When turning key switch ON, don,t start engine.
Fig. 3-9
(4) AIR-BLEEDING
PROCEDURE:
a. Turn key switch“ON”.

b. Fill the fuel tank.
c. Turn the fuel valve (1) to "ON".
d. Loosen the air-bleeding screw (2) and let air
bubbles out.
e. Loosen the air-bleeding screw of the fuel injec-
tion pump and let air bubbles out of the pump.
30
5. TROUBLE SHOOTING
Problems and probable causes Countermeasures
Overheating:
Low coolant level Replenish coolant and inspect water leaks.

Fatigued pressure valve spring Replace radiator cap.
Loose or broken fan belt Adjust belt tension or replace.
Oily fan belt Replace.
Poor thermostat Replace.
Poor water pump or water leaks Repair or replace. 3
Clogged water passages Clean radiator and water passages.
Improper injection timing Adjust injection timing.
Clogged air ways Clean radiator exterior.
Fuel gas enters water jacket due to broken cylinder Inspect cylinder head and replace cylinder gasket.
gasket.
Over-cooling:
Poor thermostat Replace.

Excessive low atmospheric temperature Decrease area of radiator working by masking
radiator.
Loss of coolant:
Leaking radiator Repair or replace.

Loosely clamped or broken water hose Re-tighten or replace hose.
Fatigued pressure valve spring Replace radiator cap.
Leaking water pump Repair or replace.
Water leakage through cylinder head gasket Inspect cylinder head and replace gasket.
Cracked cylinder head or body Replace.
Noisy cooling fan:
Poor water pump bearing Replace.

Loose or bent fan Re-tighten or replace.
Unbalanced fan Replace.
Poor fan belt Replace.
31
32
CHAPTER 4. ENGINE
CHAPTER 4. ENGINE
1. ENGINE
1.1. SPECIFICATIONS
SXG SXG
Engine models E3112-G06 E3112-G07
4-cycle, over-head valve, diesel with swirl type combustion
Type
chambers
Cylinder- Bore Stroke mm (in) 3-78.2X78 (3-3.08X3.1)
Total displacement cc (cu.in.) 1123 (68.53)
Compression ratio 22.5
Rated output ps (kW) at 2600rpm 19.2 (14.1) 21.1 (15.5)
4
Cooling method Water cooling
Fuel consumption g/ps-h 199
High idling speed rpm 2865 +/- 50
Low idling speed rpm 1175 +/- 50
Fuel Diesel fuel
Fuel injection system
Fuel injection pump Bosch, PFR type pump
Model ND-PFR3M (marking : 6264)
Plunger (dia. x stroke) mm (in.) 5.75X7.0X (0.23X0.28)
Injection nozzle Throttle type
Governor Centrifugal, all-speed governor
Lubrication system Forced lubrication

Oil pump Trochoid type
Valve timing
Intake Opening 10° BTDC
Closing 46° ABDC
Exhaust Opening 46° BBDC
Closing 10° ATDC
Valve clearance mm (in.) 0.25 (0.0098)
Fuel injection timing 19° BTDC
Injector
Maker DENSO CO., LTD
Type DN0PD620
Injection nozzle opening pressure 120
kgf/cm2(Mpa) (11.8 )
Compression pressure kg/cm2
30 (427)
(psi)/300 rpm
33
1.2. PERFORMANCE CURVES
(1) SXG326 (E3112-G07)
Fig. 4-1
(2) SXG323 (E3112-G06)
Fig. 4-2
34
CHAPTER 4. ENGINE
2. INSPECTION AND ADJUSTMENT a. REPLACEMENT OF OIL FILTER
2.1. INSPECTION OF ENGINE OIL Remove the oil filter cartridge from the cylinder
• Draw out the level gauge (dip stick) and wipe block, using a cartridge wrench.
the end clean. Then insert and draw out it
again. Check to see if the level is between the b. INSTALLATION OF OIL FILTER
upper and lower limits. If the level is low, refill
oil through the filler to the upper level. Inject a small amount of engine oil into the car-
tridge.
Apply engine oil to the O-ring of the cartridge.
&IG
&IG
Note:
-When checking oil level, place the machine on Tighten the cartridge by hand until the O-ring
level ground. comes into contact with the cylinder block sur-
-Before checking oil level, stop the engine and face and then give it three-fourth turn.After fill-
wait three minutes at least. ing with new oil, operate the engine more than
three minutes. Then check for oil leaks.
• /IL CAPACITIES
%% LITRES
• 'RADES AND VISCOSITIES OF USABLE OIL
4EMPERATURES !0)
3!% .O
# °
° & #LASSIFICATIONS

W ## OR OVER

"ELOW
↑

&IG

↑

!BOVE
↑
2.2. INSPECTION OF FAN BELT

• Check belt deflection by apply a force of about
10 kg to the center of the belt between the fan
pulley and alternator. Also check the belt for
damage such as cracks, peeling, wear, etc.
35
3PECIFIED DEFLECTION MM )NSERT A FEELER GAUGE OF A SPECIFIED THICK
NESS AND ADJUST THE CLEARANCE WITH THE
ADJUSTING SCREW
Specified valve clearance (cold):
)NTAKE MM
%XHAUST MM
&IG
• Adjustment:
When the deflection is more than specified, ten-
sion the belt properly by moving the alternator.
2.3. INSPECTION AND ADJUSTMENT OF

VALVE CLEARANCES
&IG
2EMOVE THE CYLINDER HEAD COVER
2.4. INSPECTION AND ADJUSTMENT OF
4URN THE CRANKSHAFT BY HAND SO THAT THE NOZZLE OPENING PRESSURE AND
PISTON IN .O CYLINDER R EACHES AT 4$# INJECTION TIMING
ALIGN THE 4$# NOTCH IN THE CRANKSHAFT
PULLEY WITH THE Pro JECTION ON THE GEAR !DJUSTMENT OF THE VALVE OPENING PRESSURE
CASE OF THE INJECTION NOZZLES
• Measure the pressure of initial fuel injection on a

nozzle tester.
%%
3PECIFIED PRESSURE KGCM
&IG
Note:
When it is difficult to distinguish between TDC in
compression stroke and TDC in exhaust stroke,
use height difference among the push rods as a
criterion for judgment. When the heights of the &IG
push rods (No.1, 2,3, and 6 viewed from the fan)
are about 5 mm lower than those of No.4 and 5,
the piston in No.1 cylinder is at TDC in compres-
sion stroke.
36
CHAPTER 4. ENGINE
• When the pressure is too high, adjust by reduce- (2) Remove the injection pipes.
ing shimming thickness for the nozzle, or
replace the nozzle assembly. Note:
To keep away dust, cap the openings of the in-
• When the pressure is too low, adjust by increas- jection nozzle, injection pump, and injection pipe.
ing shimming thickness, or replace the nozzle
assembly.
)NSPECTION 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 assem- 4
bly. &IG
3PRAYING CONDITION OF INJECTION NOZZLE (3) Remove the delivery valve holder.
(4) Remove No.1 delivery spring and install a deliv-

ery holder.
&IG
)NSPECTION AND ADJUSTMENT OF INJECTION

TIMING
• Confirmation of injection timing, using No.1

cylinder
(1) Bring the piston in No.1 cylinder to TDC in &IG

compression by aligning the marking on the
crankshaft pulley with the one on the timing (5) Turn the crankshaft by hand to the point about
。
gear case, turning the crankshaft by hand. 10 before the injection timing (turning the
crankshaft in either direction will do).
Note:
Be sure not to take TDC in exhaust for that in (6) Open the fuel cock and turn the key switch to the
compression by checking for the opening and “ON”position to activate the fuel pump.
closing of the valves.
37
(7) Make sure that fuel ejects from the delivery

4IGHTENING TORQUE KGF･M
holder. Turn the crankshaft slowly in correct
direction (clockwise viewed from the fan) until
fuel ejection stops. The injection timing is just Note:
before fuel ejection stops. -Supply fuel only when fuel injection timing is
measured (only for operation 6)].
• When fuel ejection stops, the injection timing -It is impossible to measure the fuel injection tim-
point is passed. Turn the crankshaft in reverse ing by turning the crankshaft in reverse (counter-
and repeat operation (6). clockwise viewed from the fan).
• Even when the injection timing point is passed, -During this operation, be sure to keep dust out of
there is no sign of fuel ejection stopping. The the fuel system.
point is BTDC in exhaust stroke. Turn the crank-
shaft fully by 360" and start operation. • Adjustment of injection timing
• As a criterion of “just before fuel stops," use
the time to take to refill the fuel in the end of the When the injection timing is improper, it should
delivery holder after blowing it off. When it be corrected.
takes 1 to 2 seconds to refill, it is the fuel injec- The injection timing can be adjusted by chang-
tion timing point. ing 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
Available adjusting shims: 0.1, 0.2, 0.3, 0.4 and
&IG 0.5 mm thick.
(8) Check to see the timing mark on the flywheel or For reference:
the crankshaft pulley is aligned as shown in Injection timing shift with 0.1 mm thick shim-
“3.2. Adjustment of valve clearance.” ming by crank angle:
For reference: Shimming +0.1 mm 1°delay

The crank angle 1°is about 1mm on the crank- Shimming -0.1 mm 1°advance
shaft pulley and about 2.5 mm on the flywheel.
d. Install the injection pump.
(9) Turn the key switch to“OFF”and close the fuel
cock. e. Confirm that the injection timing is proper by the
operation mentioned above. Until the proper fuel
(10)After checking to see the fuel injection timing is injection timing is attained, repeat steps from c. to
correct, remove the delivery holder and install e.
the delivery spring and stopper. Then re-tighten
the delivery holder to the specified torque. f. Install the control link and starting spring on the
control rack and then the injection pump cover.
(11)Install the injection pipe and tighten the nut to
the specified torque. Note:
During this operation, be careful to keep dust out
of the fuel system.
38
CHAPTER 4. ENGINE
2.5. COMPRESSION AND UNLOADED )NSPECTION AND ADJUSTMENT OF THE IDLING
IDLING SPEEDS SPEEDS
)NSPECTION OF COMPRESSION (1) Check for idling speeds.
(1) Remove the injection pipes. 3PECIFIED VALUE ± RPM
(2) Remove an injection nozzle. (2) When the measured value deviates from the
specified value, correct with an adjusting bolt.
Note:
Cap the injection nozzles, injection pump, and
injection pipes to avoid dust.
(3) Install a compression gauge using an adaptor.
&IG
2.6. INSPECTION OF WATER PUMP
)NSPECTION OF THE PUMP AND PULLEY

&IG
Check the pump for noise or hitching by turning
(4) Activate the starter and measure the compres- the water pump pulley, applying load vertically
sion. to the pump axis.
+GCM AT RPM
$IFFERENCE BETWEEN When noise or hitching occurs, replace the pump
3TANDARD ,IMIT
CYLINDERS assembly.

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.
&IG
Caution:
When cranking the engine, take care not to
touch rotating parts.
39
)NSPECTION OF THE BEARING UNIT
Check the bearing unit for run-out. If the run out

is more than 0.2 mm (0.008 in.), replace the
pump assembly.
2.7. INSPECTION OF THERMOSTAT
• Inspection of activating 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 &IG
starts to open and that at which the valve opens
fully. 3TARTS TO OPEN
±°
#
TEMPERATURE
&ULL OPEN °# °&

3. ENGINE BODY
TEMPERATURE ;LIFT MORE THAN MM =
3.1. CYLINDER HEAD
&IG %XPLODED VIEW OF CYLINDER HEAD
40
CHAPTER 4. ENGINE
2%-/6!, /& 4(% #9,).$%2 (%!$ (5) Removal of the rocker shaft assembly.
(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.
&IG
(2) Disconnection of the injection piping.
• When the piping has been removed, cap the 4

delivery pipe holders, injection nozzles and &IG
injection pipes at once to avoid dust. • 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

&IG shown in the figure.
(3) Removal of the fan belt. • After the removal of the cylinder head, remove
the dowels and tappets.
(4) Removal of the oil pipe.
&IG
&IG
41
$)3!33%-",9
(1) Removal of the inlet manifold.
(2) Removal of the exhaust manifold.
(3) Removal of the thermostat housing.
(4) Removal of the valves.

&IG
(2) Inspection of the cylinder head for distortion
• Measure the flatness of the bottom surface of the

cylinder head by putting a straight rule diagonal-
ly across the four corners on the bottom face and
check for clearance with thickness gauges.
3TANDARD VALUE 5SABLE LIMIT

$ISTORITION MM MM
&IG
• When the distortion exceeds the usable limit,
• Compress the valve spring along with the spring correct on a surface grinder.
seat with a spring compressor, and remove the • As the ground-down limit is 0.4 mm (0.016 in.),
cotter spring seat retainer. replace a cylinder head assembly, which required
more than the ground-down limit to correct.
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.
).30%#4)/.
(1) Inspection of the cylinder head for cracks. &IG
• Remove carbon deposit from the bottom surface (3) Inspection of the clearance between the valve
of the cylinder head. guide and valve stem.
• Inspect the bottom surface and inlet and exhaust
ports using "COLOR CHECK."
42
CHAPTER 4. ENGINE
• Check the valve for play with a dial indicator. If • Press in so that the distance from the cylinder
the play exceeds 0.15 mm (0.0059 in.) for the head top to the valve guide end becomes 7mm.
inlet valve and 0.2 mm (0.008 in.) for the • After installation, correct the bore diameter of
exhaust valve, replace both the valve and valve the valve guide to the specified value by ream-
guide as an assembly. Measure the play at a point ing.
10 mm (0.39 in.) apart above the valve oil seal
when the valve lift is 0 mm (0 in.). 3PECIFIED BORE MM
4
&IG &IG
(4) Replacement of the valve guide. (5) Inspection and correction of valve seats.
• Drive out the valve guide upwards from the • Check for valve contacting width and depress-
cylinder head bottom. sion.
• Press in a new valve guide from the cylinder
head top, taking care not to damage the guide. When the contact width is wider than specified,
correct with a 45° valve seat cutter. When the
valve depression is more than specified, replace
the cylinder head assembly.

#ONTACT WIDTH MM MM
6ALVE DEPRESSION MM MM
&IG
&IG • Apply polishing compound to the valve seat sur-

face and lap with the valve while tapping the
Note: valve to secure suff iciently contact with the
Apply oil to the new valve guide ahead of time. whole circumference.
43
&IG
(7) Inspection of valve springs.
• Measure the free length of each valve spring

with calipers.

&IG
&REE LENGTH MM MM
Note:
After lapping, remove the polishing compound KFG KFG
4ENSION
completely. (When compressed to 36mm)
(6) Inspection of valves.

• Put a spring upright on a surface table and meas-
• Measure the valve stem diameter with a microm- ure deviation from vertical.
eter.
3TANDARD VALUE 5SABLE LIMIT 5SABLE LIMIT
)NLET VALVE MM MM

$EVIATION FROM VERTICAL MM
%XHAUST VALVE MM MM
&IG
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• Check for valve thickness.
(8) Inspection of intake and exhaust manifold con-
tact surfaces for flatness.
6ALVE THICKNESS MM MM
• Measure flatness with a straight rule and thick-
When the valve thickness is less than the usable ness gauges.
limit, replace the valve.
44
CHAPTER 4. ENGINE
&IG
&IG
5SABLE LIMIT (3) Inspection of the rocker arm shaft for wear.
3URFACE FLATNESS BOTH FOR INTAKE • Measure diameter at four points where the shaft
MM
AND EXHAUST MANIFOLDS bears respective rocker arms.
4
When the deviation exceeds the usable limit, • When wear is in excess of the usable limit,
replace the manifold. replace the shaft.
$)3!33%-",9 !.$ ).30%#4)/. /& 3TANDARD VALUE 5SABLE LIMIT

4(% 2/#+%2 !2- 3(!&4
$IAMETER MM MM
(1) Disassembly of the rocker arm shaft assembly.
• Put an identification mark on the front side top

of the rocker arm shaft for later reference.
• Remove snap rings C and remove arm brackets.
• Put away the brackets in order.
&IG
(4) Inspection of the clearance between the rocker

arms and rocker arm shaft
&IG • Measure the bore diameter of each rocker arm

and calculate the difference from the diameter of
the rocker arm shaft.
(2) Inspection of the rocker arm shaft for bending.
When the difference exceeds the usable limit,
• Check for bending with a dial gauge. replace the assembly of the rocker arm shaft and
rocker arms.
5SABLE LIMIT
3HAFT BENDING MM
45

#LEARANCE MM MM
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(%!$
(5)Reassembly of the rocker arm shaft assembly
(1) Installation of the cylinder head
• Arrange the rocker arms so that the sides where
identification markings were put when disas- • Clean the bottom surface of the cylinder head
sembled are turned forward. Make sure that the and the top surface of the cylinder block.
shaft is placed with the end having an off-set • Drive in dowels.
positioning tapped hole turned forward. • Insert tappets.
• Put a new gasket with its "TOP" mark turned
upward.
• A gasket of different models has a different iden-
tification marking: notches in the left top corner
as shown below.
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).30%#4)/. /& 4(% 053( 2/$3
• Check both ends of each push rod for wear.

Replace excessively worn rods with new ones.
• Check push rods for bending.

Place a rod on a surface table and measure bend-
ing with thickness gauges.
5SABLE LIMIT
0USH ROD BENDING MM
&IG
46
CHAPTER 4. 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.IV-31 to the specified torque.
• Be sure to tighten the bolts step by step: first to 2

kgf-m (14 ft-lbs), second to 4 kgf-m (29 ft-lbs),
and then lastly to the following torques.
Specified torque 5.5 - 6.5kgf･m

Fig. 4-45
(5) Installation of the push rods

4
Fig. 4-43
(2) Installation of the glow plugs. Fig. 4-46
(3) Installation of the injection nozzles. (6) Installation of the rocker arm assembly
• Be sure to use new packing and tighten the noz- • Loosen all rocker arm adjusting screws.
zles to the specified torque. • Install the rocker arm assembly and tighten it to
the specified torque.
Specified torque 4.0 - 5.5 kgf･m
Specified torque 1.4-2.4 kgf･m
Fig. 4-44
Fig. 4-47
47
(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. The head cover seal and gasket is made of rubber,
(9) Adjustment of the valve clearances. so take care not to tighten the head cover exces-
sively.
When the cylinder head has been removed, be
3.2. GEAR CASE
3.2.1. EXPLODED VIEW
Fig. 4-48
3.2.2. REMOVAL OF THE GEAR CASE • Remove the return spring from the control lever.
• Remove the hydraulic pump if installed.
• Remove the cooling fan. • Remove the hydraulic pump drive gear.
• Remove the fan belt. • Remove the gear case.
• Remove the crankshaft pulley.
• Remove the alternator.
• Remove the injection pump cover and then
remove the starting spring, setting spring, and
control link from the rack.
Fig. 4-50
Fig. 4-49
48
CHAPTER 4. ENGINE
Note:
Note which bolt is to be installed in which place
for later reference and remember to remove the
bolts which also tighten the case from behind.
Fig. 4-53
• Install the gear case.

Fig. 4-51
4
Fig. 4-52
Fig. 4-54
• Discard removed packings and oil seals and use
new ones during re-assembly. • Connect the rack of the injection pump and the
control link with a setting spring. After installa-
Note: tion, confirm their smooth working by moving
It is recommended not to disassemble the oil the rack several times.
pump assembly, relief valve, governor, and related • Install the starting spring. Take care not to drop
parts, which are installed inside the gear case the spring.
except when required. • Install the injection pump cover, using new pack-
ing.
3.2.3. RE-INSTALLATION OF THE GEAR CASE • Install the crankshaft pulley and tighten to the
specified torque.
• Install the idle gear.
• Specified torque 17.0 - 20.8 kgf･m
• Apply oil to the bore surface of the idle gear and
install taking care to align the timing marks with • Install the alternator.
those of other gears.
• Install the fan belt and cooling fan.
49
3.3. CYLINDER BLOCK
3.3.1. EXPLODED VIEW
Fig. 4-55
50
CHAPTER 4. ENGINE
3.3.2. DISASSEMBLY OF THE CYLINDER (10) Remove the water pump spacer.
BLOCK
(11) Remove the oil filter.
(1) Install the engine on an 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.
Fig. 4-56 4
(2) Drain engine oil.
(3) Remove the cylinder head (Refer to page 41).
(4) Remove the tappets. Fig. 4-58
(5) Remove the gear case (Refer to page 48). (14) Removal of the pistons and connecting rods.
(6) Remove the camshaft. • Remove the nuts, which tighten the connecting
bearing cap.
• Remove the piston/connecting rod assembly

toward the cylinder head.
Fig. 4-57
(7) Remove the injection pump and then remove the

pump cam. Fig. 4-59
(8) Remove the solenoid. • Put aside removed piston/connecting rod assem-
blies, connecting rod bearing caps, and bearings
(9) Remove the water pump. in order in accordance with respective cylinders.
51
(15) Removal of the flywheel. 3.3.3. INSPECTION OF CYLINDER

BLOCK, CRANKSHAFT, CAMSHAFT,
• Chock the flywheel. AND TAPPETS
• Removal of the flywheel. (1) Inspection of the cylinder block
• Inspect the cylinder block for damage.
Check for damage visually.

Use "COLOR CHECK" if necessary to check
for cracks and other damage. Repair damage if
possible or replace.
• Inspect the cylinder block top surface for flat-

ness.
Check the top surface for distortion with a

straight rule and thickness gauges in diagonal
Fig. 4-60 ways as shown in the figure.
(16) Remove the rear plate.
(17) Removal of the crankshaft.
• Remove bearing caps.
Fig. 4-62
Standard value Usable limit

0.08 mm
or less 0.15 mm
If distortion exceeds the usable limit, correct on

Fig. 4-61 a surface grinder. But the ground-down limit is
0.4 mm (0.016 in.). A cylinder block, which can-
• Put aside removed bearing caps and bearings in not be corrected within the ground-down limit,
order of bearing numbers. should be replaced with a new one.
• Remove the crankshaft. • Check the cylinder bores for wear.
(18) Remove the oil pressure switch.
52
CHAPTER 4. ENGINE
Fig. 4-65
Fig. 4-63 (2) Inspection of the crankshaft
- Measure cylinder bore diameter at a point of 12 • Check the crankshaft journals for oil clearance.
to 14 mm (0.47 - 0.55 in.) below the cylinder
block top surface in two directions: one is in a. Clean the journals and bearings. 4
alignment with the crankshaft axis and the other
is at right angles to the crankshaft axis. b. Install the upper bearings and crankshaft on the
cylinder block.
Wear limit 0.2 mm
c. Put plasti-gauge over the journal width.
- If wear is in excess of 0.2 mm (0.008 in.), cor-
rect by honing.
- Honing should be done to fit an oversize piston,

which should be done at a specialist's work-
shop.
Oversize 0.5; 1.0 mm
- Honing accuracy should be to the extent that

bore diameters measured in two directions at A
and B and in three levels at a, b, and c differ less Fig. 4-66
than 0.02 mm (0.0008 in.) from each other.
d. Install the bearings on respective bearing caps.
Install the assembled and tighten them to the
specified torque.
Specified torque 4.5 kgf･m
While tightening, the crankshaft should be held

securely so as not to turn.
e. Loosen the tightening bolts and remove the bear-

ing caps carefully. Then measure the most
stretched parts of the plasti-gauges.
Fig. 4-64
53
c. Tighten the bearings on the connecting rods to

Fig. 4-67

0.029 - 0.090 mm 0.12 mm
f. If the oil clearance of a journal is in excess of

the usable limit, replace the bearings with new
ones and check for oil clearance again. When the Fig. 4-69
clearance exceeds the usable limit ever after new
bearings have been installed, polish the journal Specified torque 2.7 - 3.3 kgf･m
and use undersize bearings.
Note:
Undersize bearings 0.5, 1.0 mm Hold the crankshaft securely so as not to turn
while tightening.
When the ground-down limit of 1.0 mm (0.039
in.) is not enough for correction, replace both d. Loosen the tightening bolts and remove the con-
crankshaft and bearings with new ones. necting-roil bearing caps carefully.
• Check the pins on the crankshaft for oil clear- e. Measure the most stretched parts of the plasti-
ance. gauges.
a. Clean the crankshaft pins, connecting-rod big

ends, and bearings.
b. Place plasti-gauge over the pin width.
Fig. 4-70

0.025 - 0.072 mm 0.12 mm
Fig. 4-68
f. If the oil clearance exceeds the usable limit, re-
place the bearings with new ones and check for
54
CHAPTER 4. ENGINE
oil clearance again. When the clearance exceeds

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-
shaft and bearings with new ones. Fig. 4-72
• Thrust clearance • Replacement of the ring gear
Install the connecting rod on the crank pin and Hammer the circumference of the ring gear
measure the thrust play with thickness gauges. evenly via a holding rod to remove the ring gear.
If the play exceeds the usable limit, replace the
connecting rod.
4
0.04 - 0.215 mm 0.30 mm
Fig. 4-73
Heat up a new ring gear with a torch, and then

drive it onto the flywheel.
Fig. 4-71
(3) Inspection of the flywheel
Check the friction surface for cracks and other

damage. If defective, correct or replace with a
new flywheel.
Check the ring gear teeth for excessive wear and
other damage. If defective, replace the ring gear Fig. 4-74
with a new one.
Note:
- Install the ring gear with the chamfered side
turned toward the starter.
- After installation, make sure the ring gear is in
tight contact with the flywheel.
55
(4) Inspection of the camshaft
• Check the journals and cams for wear and other

damage.
A worn or defective shaft should be replaced

with a new one.
Fig. 4-77
Measure the bore diameter of each bearing. And

calculate the difference between the cam journal
diameter and bearing bore diameter.
Clearance between journal and bearing:
Fig. 4-75 Standard value Usable limit

0.05 - 0.105 mm 0.120 mm
• Cam height
If the clearance exceeds the usable limit, replace
Measure the height with a micrometer. the camshaft with a new one.

27 mm 26.6 mm
Fig. 4-78
• Thrust play of the camshaft

Fig. 4-76
Install the thrust plate and cam gear on the
• Measurement of journal wear camshaft. Push the thrust plate fully against the
cam gear and measure the clearance between the
Measure the diameter of each journal. thrust plate and journal with thickness gauges.

33 mm 32.75 mm
If wear is in excess of the usable limit, replace

the camshaft with a new one.
56
CHAPTER 4. ENGINE

0.05 - 0.174 mm 0.3 mm Replace the tappets, which have clearances in
excess of the usable limit.
If the clearance exceeds the usable limit, replace Standard value Usable limit
the thrust plate. 0.02 - 0.062 mm 0.1 mm
3.3.4. INSPECTION OF PISTONS AND CON-

NECTING RODS.
• Push a piston ring into the cylinder, using a pis-

ton as a pushing tool, to a point past the position
where the ring would be during operation i.e. to
the lower end of the cylinder wall.
Fig. 4-79 4
(5) Inspection of tappets
• Check the contact surface with the camshaft for

pitting, cracks, etc. Defective tappets should be
replaced with new ones.
Fig. 4-81
Measure the gaps of each piston ring with thick-

ness gauges.
Fig. 4-80
• Check the outer diameter for wear.

20 mm 19.95 mm
Replace the tappets having diameters less than Fig. 4-82

the usable limit.
Replace the rings whose gaps are in excess of
• Clearance of the tappets with the cylinder block the usable limit.
Measure the bore diameter of each tappet hole in

the cylinder block and the outer diameter of each
tappet. Then calculate the difference.
57

No.1
compression 0.25 - 0.40 mm 1.5 mm
ring
No.2
ring
Oil ring 0.25 - 0.40 mm 1.0 mm
• Inspection of piston ring clearance in ring

grooves.
Fig. 4-84
When the pin has excessive play in the hole at

room temperature, replace the piston or the pis-
ton pin.
• Inspection of the clearance between the connect-

ing-rod small end and piston pin
Fig. 4-83
Clean ring grooves using a used piston ring.

Measure the clearance at the outer circumference
with thickness gauges as shown in the figure.
Standard value Usable limit Fig. 4-85
No.1 0.08 - 0.12 mm (E3000)
compression 0.3 mm
ring 0.06 - 0.10 mm (E3112)
No.2
ring Fig. 4-86
Oil ring 0.02 - 0.06 mm 0.15 mm
Calculate the difference between the bore in the
When the clearance exceeds the usable limit, small end and piston pin diameter.
replace both piston and rings as an assembly.
• Inspection of the piston pin
Clearance 0.008 - 0.2 mm 0.05 mm
The interference between the piston-pin and pis-
ton-pin hole should be such that the pin can be
pushed in smoothly at room temperature. When the clearance exceeds the usable limit,
replace the connecting rod or the piston pin.
58
CHAPTER 4. ENGINE
• Connecting-rod twist • Install a snap ring in one end of the piston pin
hole.
Find the twist and parallelism between the big
end and small end of the connecting rod. • Set the piston and the connecting rod so that the
front mark on the piston and "ISEKI" marking
Standard value Usable limit on the connecting rod are turned in the same
direction.
Twist 0.05 or less 0.2 mm
• Apply engine oil to the piston pin and push it
Parallelism 0.05 or less 0.15 mm
into the hole by hand.
If either of the measured values exceeds the

specified value, replace the connecting rod.
Fig. 4-89
• Install the other snap ring securely in the groove.
Fig. 4-87
Fig. 4-90
(2) Installation of piston rings

Fig. 4-88
• Install the rings using a piston ring expander
with their "T" marks turned upwards. But the oil
3.3.5. ASSEMBLY OF PISTON AND CONNECT- rings have no markings, so they can be installed
ING ROD with either side up.
(1) Assembly of the piston and connecting rod
59
• The gaps of the ring and ring expander of the oil Note:
ring should be set apart 180" from each other. Bearings and bearing fitting surfaces on the cyl-
inder block should be free from any foreign ma-
Note: tter.
As No.1 and No.2 compression rings have differ-
ent cross sections, take care not to install them in The projection of each bearing should be se-
wrong order. curely seated in its notch in the cylinder block.
Fig. 4-93
Fig. 4-91
(2) Apply engine oil to upper bearing surfaces and
• Install the rings with their gaps 120" apart from bring the crankshaft in contact with them.
each other as shown in the figure.
Fig. 4-94
(3) Install the lower bearings, which have no oil

grooves or holes, on bearing caps.
Fig. 4-92
Note:
Bearings and bearing fitting surfaces on the bear-
3.3.6. INSTALLATION OF CRANKSHAFT ing caps should be free from any foreign matter.
(1) Install the upper bearings, which have oil

grooves or oil holes, in cylinder block.
60
CHAPTER 4. ENGINE
(4) Then install bearing cap seals (B). Drive them in • Install the connecting rod bearing cap having the
until they subside 0 - 0.3 mm (0 - 0.012 in.) from same number that the connecting rod has.
the cylinder block end. Fill the gaps with sili-
cone compound. Tighten the journal bearing cap
to the specified torque.
Specified torque: 4.5 - 5.5 kgf･m
Fig. 4-97
4
• Tighten the connecting rod bearing cap to the
Fig. 4-95 specified torque.
3.3.7. INSTALLATION OF PISTON/CON-NECT-

ING-ROD ASSEMBLIES
• Install bearings on the connecting-rod big end

and bearing cap with the bearing projections
seated securely in respective notches in the big
end and bearing cap. Apply engine oil to the
bearing surfaces.
• Clean the cylinder bores and crankshaft, and
apply engine oil to them.
• Set the crankshaft at BDC.
• Turn the front mark on the piston head towards
the front and make sure that the piston ring gaps
are 120°apart from each other. Then insert the Fig. 4-98
piston/connecting rod assembly, compressing the
piston rings with a piston ring compressor, into Specified torque: 2.7 - 3.3 kgf･m
the cylinder until the connecting rod bearing
comes into contact with the crankpin. The crankshaft should turn smoothly.
Fig.4-96
61
3.3.8. INSTALLATION OF REAR OIL SEAL
Fig. 4-99 Fig. 4-101
• Apply silicone compound to the outer circum- Note:

ference of the rear oil seal and drive it in evenly Be careful not to damage the O-ring.
to avoid slanted installation.
3.3.10. INSTALLATION OF REAR PLATE AND
• Make sure that the crankshaft turns smoothly. FLYWHEEL
• The projection of the rear oil seal after installa- • Installation of the rear plate
tion should be 1.5 mm (0.059 in.). Set the rear plate guided by the straight pins and
tighten it to the specified torque.
Specified torque M10: 3.5 - 4.7 kgf･m
Fig. 4-100
3.3.9. INSTALLATION OF STRAINER AND OIL Fig. 4-102

PAN
• Installation of the flywheel
• Install the O-ring in the groove in the hole for oil Apply engine oil to the seats and threads of
strainer installation. tightening bolts.
• Apply engine oil to the outer surface of the

strainer pipe and install it by turning to avoid
dislocation of the O-ring.
62
CHAPTER 4. ENGINE
• Install the crankshaft gear on the crankshaft with

the side bearing the front mark turned forward.
• Apply engine oil to the camshaft bearing parts

and install the camshaft assembly. Then tighten
to the specified torque.
Fig. 4-103
Temporarily tighten the flywheel. 4

Chock the flywheel, and then tighten the bolts to
Specified torque 8.5 - 10.5 kgf･m Fig. 4-105
• Sub-assemble the pump cam and the thrust plate

3.3.11. INSTALLATION OF FRONT PLATE AND in advance, paying attention to thrust plate direc-
GEARS tion.
• Install the front plate.

Apply silicone compound to the contact surfaces
of the cylinder block and bearing cap.
Install new packing and tighten the front plate to
Fig. 4-106
• Insert the starting spring pin into the cylinder

block and install the starting spring.
Fig. 4-104
• Install key on the crankshaft.
63
Fig. 4-107
Fig. 4-109
• Install the injection cam gear assembly.
• Installation of the injection pump.
• Retain the injection pump cam shaft with the
thrust plate and tighten the gear to the specified Tighten the bolts to the specif ied torque in
torque. sequence as shown in the figure.
Specified torque 0.6 - 1.0 kgf-m Specified torque 1.4 - 2.4 kgf･m
Note:
Remember to install adjusting shims.
Fig. 4-108
• Install the idle gear.

Fig. 4-110
Apply engine oil to the bore of the gear in
advance. • Installation of the oil pan
Align respective timing marks with those of
other gears. Apply liquid gasket (THREE BOND1207D) to
the cylinder block surface in shape of a string of
φ3 - 3.5 mm (φ0.12 - 0.14 in.) as illustrated.
Then install the oil pan and tighten to the speci-
fied torque.
64
CHAPTER 4. ENGINE
• Install the water by-pass hose.
• Install the generator.
• Install the fan.
Set the fan belt on the fan pulley.
Install the spacer and the fan.
Fig. 4-111
• Install the oil pan with the recessed part turned

forward.
Fig. 4-112
• Install the gear case referring to page 49.
• Install the cylinder head referring to page 46.
• Install the water pump spacer.
• Install the water pump with new packing and

tighten to the specified torque.
Fig. 4-113
65
66
CHAPTER 5. LUBRICATION SYSTEM

1. GENERAL DESCRIPTION
1.1. LUBRICATION DIAGRAM
Fig. 5-1
67
1.2. RELIEF VALVE WKURXJK WKH RLO JDOOHU \ WR WKH RXWVLGH FLUFXPIHU
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/HDNHG RLO WKURXJK WKH Y DOYH LV VSUD\HG LQVLGH
WKH JHDUER[ DQG DOVR OXEULFDWHV JHDUV
Fig. 5-3 Oil filter
:KHQ DQ HOHPHQW LV FOR JJHG ZLWK GXVW WKH RLO

UHDFKLQJ WKH RXWVLGH FLUFXPIHUHQFH FKDPEHU LQ
WKH RLO I LOWHU LV QRW DOOR ZHG WR SDVV VPRRWKO \
WKURXJK WKH HOHPHQW $V D UHVXOW RLO VXSSO\ WR WKH
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* Oil filter cartridge should be replaced with a
Fig. 5-2 Relief valve new one after every 300 hours of operation.
1.3. OIL FILTER
SPECIFICATIONS
CONSTRUCTION AND OPERATION
7KLV ILOWHU LV D FDUWULGJH W\SH DV VKRZQ LQ )LJ

7KH RLO IURP WKH RLO SXPS LV IHG LQWR WKH UHOLHI
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OHYHO E\ WKH UHOLHI YDOYH DQG GHOLYHUHG
68
1.4. EXPLODED VIEW OF OIL PUMP
Fig. 5-4
69
2. REMOVAL, DISASSEMBLY, INSPECTION

AND RE-INSTALLATION OF OIL PUMP
2.1. REMOVAL OF OIL PUMP
'UDLQ RLO
5HPRYH WKH JHDU FDVH 5HIHU WR SDJH
5HPRYH WKH RLO SXPS
Fig. 5-6
0HDVXUH WKH FOHDUDQFH EHWZ HHQ WKH LQQHU URWRU

DQG RXWHU URWRU
:KHQ WKH FOHDUDQFH H[FHHGV WKH XVDEOH OLPLW

UHSODFH WKH SXPS DVVHPEO\
Fig. 5-5
2.2. DISASSEMBLY OF OIL PUMP
5HPRYH WKH RLO FR YHU WLJKWHQLQJ EROWV 7KHQ WKH

FRYHU LQQHU URWRU DQG RXWHU URWRU DUH GLVDVVHP
EOHG
2.3. INSPECTION
5HPRYH WKH RLO SXPS JHDU DQG FRYHU
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GDPDJHG UHSODFH WKH SXPS DVVHPEO\ ZLWK D QHZ
RQH
&OHDUDQFH RI WKH LQQHU DQG RXWHU URWRUV ZLWK WKH Fig. 5-7
FRYHU
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DQG RXWHU URWRU ZLWK WKLFNQHVV JDXJHV

70
Fig. 5-10
Fig. 5-8
3.2. INSTALLATION OF OIL FILTER
2.4. INSTALLATION OF OIL PUMP
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71
72
CHAPTER 6. COOLING SYSTEM
CHAPTER 6. COOLING SYSTEM

1. COOLING SYSTEM DIAGRAM
Fig. 6-1
*In this section, only the thermostat and the 2.3. INSPECTION OF THERMOSTAT
water pump, which are directly mounted on the
engine, are explained. About the radiator, refer • Inspection of activating temperatures at which 6
to chapter 4. the valve starts to open and opens fully.
Put the thermostat in water and heat the water
2. THERMOSTAT gradually by stirring.
Check for the temperature at which the valve
2.1. REMOVAL OF THERMOSTAT starts to open and that at which the valve opens
fully.
• Drain coolant.
• Remove the radiator hoses.
• Remove the water outlet.
• Remove the thermostat.
2.2. INSTALLATION OF THERMOSTAT
• Discard the removed O-ring and install a new

one.
Fig. 6-2
73
Replace the thermostat whose specified temper-

atures deviate from specified values.
Note:
- Keep in mind that the valve reaction to tempera- • Remove the cooling fan and pulley.
ture change is sometimes delayed by 3 to 5 min-
utes. • Install the pulley, belt, and cooling fan.
- Be careful not to heat the thermostat directly.
Place something under the thermostat in the 3.3. INSPECTION OF WATER PUMP
water container or hang it in the water.
• Inspection of the pump and pulley
3. WATER PUMP
Check the pump for noise or hitching by turning
3.1. REMOVAL OF WATER PUMP the water pump pulley, applying load vertically
to the pump axis.
When noise or hitching occurs, replace the pump

assembly.
Fig. 6-3
• Drain coolant.
Fig. 6-4
• Remove the cooling fan and pulley.
• Inspection of the bearing unit
• Remove the water by-pass hose
Check the bearing unit for run-out. If the run out
• Remove the water pump. is more than 0.2 mm (0.008 in.), replace the
pump assembly.
• Remove the water pump spacer.
3.2. INSTALLATION OF WATER PUMP
• Install the water pump spacer with new packing.
• Install the water pump with new packing and

tighten to the specified torque.
74
CHAPTER 7. FUEL SYSTEM

1. INJECTION PUMP CONSTRUCTION
The illustrations used in this section show the 3-cylinder type.
The construction is the same as that of the 2-cylinder type
except in cylinder number.
Fig. 7-1
兟Specifications
Pump type NP-PFR2MD60/1NP6
Element 䪻 6.0 mm, counter-clockwise leading: 12 mm (0.472 in.)
Pre-stroke 1.9±0.05 mm (0.075±0.002 in.)
Rack stroke 10 mm (0.394 in.)
Allowable max. speed Np=2750 rpm
75
2. REMOVAL, DISASSEMBLY, INSPECTION, RE-ASSEMBLY, AND INSTALLATION
兟The injection pump is a precision component, so handle it carefully.
兟Before disassembling the pump, wash it clean of dust and oil.
兟While disassembling, put aside the disassembled parts in order of disassembly and in accordance with respective
cylinders. Reinstall the same parts to the same cylinders. Especially the combinations of the plunger and plunger
arrel, and the delivery valve and delivery valve seat must not be changed.
兟Figures in parentheses following parts name in the text show reference numbers in Fig. 7-2 or tool numbers.
(1) Pump housing

(5) Plunger assembly
(12) Delivery valve assembly
(13) Delivery valve spring
(16) Gasket
(17) Delivery valve holder
(20) O-ring
(30) Sleeve flange
(31) Pin
(32) O-ring
(37) Socket head bolt
(39) Washer
(40) Tappet assembly
(44) Pin
(45) Snap ring
(50) Plunger spring
(51) Spring seat
(52) Spring seat
(53) Shim
(60) Control rack
(65) Plate
(66) Screw
(77) Control sleeve
(93) Eye bolt
(94) Gasket
(152) Plug
(170) Bolt
(171) Gasket
Fig. 7-2
76
2.1. REMOVAL OF INJECTION PUMP
兟Remove the injection pipes.
兟Remove the injection pump side cover. Then remove

the control rack along with the starting spring, setting
spring, and control link out of the injection pump.
兟Remove the tightening bolts.
2.2. DISASSEMBLY OF INJECTION PUMP
1) Remove snap ring (45) from pump housing (1).
Fig. 7-5
4) Remove plunger (5) and spring seat (52).
NOTE: Keep removed plungers in clean fuel in order of

cylinders.
Fig. 7-3
2) Push up tappet (40) and pull out pin (44).
7
Fig. 7-6
5) Pull out plunger spring (50).
Fig. 7-4
3) Pull out shim (53) along with the tappet.
Fig. 7-7
6) Move the pin, which is press-installed in the control
lack, to the center of the slot opened in plate (65).
77
NOTE: The control sleeve cannot be removed without

shifting the control rack in the center position.
Fig.7-11
11) Hold pump housing (1) in a vise and remove the de-
livery valve holder from the sleeve flange.
Fig. 7-8
7) Remove control sleeve (77) along with spring seat
(51).
Fig. 7-12
12) Pull out delivery valve spring (13).
Fig. 7-9
13) Remove delivery valve assembly (12) along with
8) Remove four screws (66) which tighten the plate. gasket (16).
Fig. 7-10 Fig. 7-13

9) Remove the plate. 14) Pull out the plunger barrel from each sleeve flange.
Assemble remove plunger barrels with respective
10) Remove control rack (60). plungers, which have already been removed, and
keep the assemblies in clean fuel.
78
3) Control rack
Replace a control rack which is bent or has abnormally

worn teeth.
Fig. 7-14
NOTE: Never change the combination of each plunger
and plunger barrel.
Fig. 7-16
15) The sleeve flange can be removed with a special 4) Replace a control sleeve whose recess, where the
tool. But do so only when required. brim of the plunger or the ball of PFR-MD type is to
When a sleeve flange has been removed, take the be seated, is abnormally worn.
assembled pump to a specialist and have it checked
for functioning and adjusted before installing it on 5) Plunger assembly
the engine.
兟When the notched part in the plunger is damaged, dis-
2.3. INSPECTION colored, or worn, replace the assembly of the plunger
and plunger barrel.
1) Pump housing
Check the pump housing for cracks, wear, or damaged 7

screw threads. If defective, replace the housing.
2) Tappets
Replace a tappet whose roller and roller pin have any

damage, abnormal wear, exfoliation, seizure, etc.
Fig. 7-17
兟After washing well in clean fuel, place the assembly
slanted at 60° and then pull up the plunger. When the
plunger comes down without any hitch, the assembly
is normal.
Fig. 7-15
79
2.4. RE-ASSEMBLY
兟Re-assemble the injection pump in reverse order of

disassembly, taking the following precautions.
1) Tighten the delivery holder to the specified torque.
Specified torque 4.0 - 4.5 kgf兟m
2) Apply adhesive to the threads of the four bolts (66)

which tighten the pump housing plate (65).
Fig. 7-18
6) Delivery valve assembly
兟Replace an assembly which has any damage, dents,

wear, etc. on the piston and seat surfaces.
兟Wash the delivery valve sufficiently in clean fuel.

While it is still wet after washing, close the opening
with a finger and push it in to see that it pushes back
positively.
Fig. 7-20
3) When installing the plunger into the plunger barrel,
be sure to turn the notch in the plunger in the op-
posite direction of the control rod: towards the posi-
tioning pin of the plunger.
Fig. 7-19
7) Gaskets and O-rings
Be sure to discard removed gaskets and 0-rings. Install

new ones during re-assembling.
8) Other parts
Also check other parts carefully and replace damaged or

Fig. 7-21
worn ones.
NOTE: When the plunger is installed wrongly, its flange
cannot be seated in the groove of the control
sleeve.
80
4) Install the shim with the chamfered side turned to- 7) After installation, make sure that the control rod
wards the tappet. moves smoothly.
3. INJECTION NOZZLES AND HOLDERS
3.1. REMOVAL OF INJECTION NOZZLES AND

HOLDERS
兟Removal of the injection pipes and leak-off pipes.
After removing the injection pipes, cap the openings of

the delivery holders, nozzles, and injection pipes.
Fig. 7-22
5) When inserting pin (44) into the tappet, feel for the
position where the plunger flange is seated in the
groove of the control sleeve by turning the control
rod little by little.
Fig. 7-25
兟Loosen the retaining nuts.
Use a box wrench or open-end wrench of 22 mm (0.866 7

in.).
NOTE: Be careful not to loosen the hexagonal part

[19mm (0.748 in.)] of the holder body. If done
so, the holder becomes disassembled.
3.2. INSPECTION OF INJECTION NOZZLES

Fig. 7-23
6) Adjust the groove in the pin so it is in level, using a 兟Spraying test
screw driver and install the snap ring.
Use fuel with a specific gravity of 0.82 - 0.84 and a tem-
perature of approximately 20°C (68°F).
Wash the holder and nozzle in clean fuel.
Also wash a nozzle tester and install the nozzle and
nozzle holder on it as shown in Fig. 7-28 Inject fuel and
observe spraying. It is the best to use a stroboscope to
judge accurately.
Fig. 7-24
81
But it can be considered to be normal if the spraying pat- 3.3. DISASSEMBLY AND WASHING OF INJECTION
tern is focused and free from scattering. NOZZLES
Fig. 7-26
兟Injection-starting pressure
Injection-starting pressure should be 120 kgf/cm2 (1707

psi). If it is not so, adjust by shimming.
Fig. 7-27
兟Oil tightness of the valve seat 兟Removal of the packing ring.
Apply a pressure of 100 - 110 kgf/cm2 (1422 - 1565 psi) Loosen the joint nut without removing the nozzle from
to the nozzle on a nozzle tester to check for oil leakage. the engine.
兟Visual inspection NOTE: Take care not to damage the packing ring and
the washer-contacting surface of the nozzle
After washing the nozzles, check the needle valve seat holder.
for damage, or carbon deposit, and the injection orifice
for clogging. 兟Hold the nozzle/holder assembly in a vice by the hex-
agonal part [19 mm (0.75 in.)] of the nozzle body with
the nozzle turned upwards.
Then loosen the retaining nut with a box wrench [21
mm (0.83 in.)].
兟Remove the retaining nut while holding the nozzle by

hand.
兟Remove the nozzle assembly and distance piece.
兟Remove the holder body from the vise and remove

other parts.
NOTE: Handle the nozzle, distance piece, and nozzle

holder body carefully not to damage their end
surfaces, as they are made tight for high-pres-
sure fuel.
82
When a nozzle is found functioning poorly through spray 3.4. INSTALLATION OF INJECTION NOZZLES AND
test, wash it. If its original function is not restored by HOLDERS
washing, replace it.
兟Before installation, wash all parts in clean diesel fuel
兟Nozzle washing or cleansing oil.
First wash the nozzle in clean gasoline, and then wash it 兟Put the adjusting shim, spring, pressure pin, and dis-
again in clean diesel fuel before assembling it. tance piece on the nozzle holder body in this order.
If the nozzle is seized, soak it in cleaning liquid after Lastly place the nozzle assembly and retain with the
washing. Then wash it again. retaining nut.
兟Nozzle replacement
NOTE: When installing the pressure pin and distance
piece, pay attention to their directions.
Replace the assembly of the needle valve and nozzle
body.
兟Hold the nozzle holder body in a vise and tighten the
Before installing a new nozzle, move the needle valve
retaining nut to the specified torque.
sufficiently in the nozzle body in clean diesel fuel
warmed up at 50 - 60°C (122 - 140°F) to remove the
anti-corrosive completely. Specified torque 3.5 - 4.0 kgf兟m
兟Needle valve sliding

Incorrect tightening torque will lead to fuel leakage or
Move the needle valve in and out of the nozzle body
nozzle seizure.
several times in clean diesel fuel to make sure of its
smooth movement. 兟Remove the assembly from the vise and install a new
Slant the nozzle body by about 60°, pull out the needle
washer, the packing ring, and nut. (Be sure to discard
valve by about one-third of its length, and release it.
the removed washer and install a new one.)
When it comes down smoothly, it is normal. Perform
three tests with the needle valve turned by 120°at each 兟Check each assembly on a nozzle tester for spraying,
test.
valve-opening pressure, etc.
Valve-opening pressure should be adjusted with an
If the needle valve does not move smoothly, replace the
adjusting shim. 7
assembly of the needle valve and nozzle holder.
3.5. INSTALLATION OF INJECTION NOULES AND
HOLDERS
兟Install the nozzle gasket into the cylinder head.
兟Screw in the retaining nut by hand.
兟Tighten the retaining nut to the specified torque, using

a box wrench [21 mm (0.83 in.)].
Specified torque 4 䢯 5 kgf兟m
兟When using an air tool to tighten the nut, make its

Fig. 7-28
tightening speed as slow as possible.
83
4. GOVERNOR 5) The floating arm end is connected with a pin to the

control link, which is connected with the control rack
4.1. GOVERNOR CONSTRUCTION of the injection pump.
1) Flyweights are installed on the injection pump cam 6) A tension arm end is connected with the governor
gear and turn along with the injection pump cam spring, which is connected with a control arm. The
shaft. control arm is further connected with a control lever.
2) A thrust piece is installed on the camshaft and can 7) An“Angleichung”(adaptation) device, which will be
slide along the shaft. explained later, is installed on the tension arm. The
Angleichung pin end is in contact with the control
link pin, which is connected with the control lever.
8) A setting spring is installed at the connecting point

of the control link and control rod to eliminate free
play of the rod in direction of movement and to se-
cure the connection.
9) A starting spring is installed on the control link.
10) A return spring is installed on the control lever,

which is limited in movement with two adjusting
screws.
Fig. 7-29
3) A tension arm and a floating arm are installed to
turn on a common pin.
4) A sintered piece is cast in the center of the float-

ing arm and in contact with the thrust piece, which
slides as the injection pump camshaft turns.
Fig. 7-30
84
兟Be careful not to hit the nozzle body with a wrench,

which may cause fuel leakage.
兟Place the packing ring in position and tighten the joint

nut to the specified torque.
Specified torque 2 - 2.5 kgf兟m
兟Install the injection pipe and leak-off pipe and tighten

them to the specified torque.
2.5 kgf兟m
Specified torque
or less
85
4.2. GOVERNOR OPERATION
1) The control lever is released in the engine starting

position and is set in the idling position by the return
spring.
In this state no centrifugal force is applied to the
governor, so the control rack of the injection pump
is shifted by the starting spring to the position for
increased fuel supply.
2) Once the engine is stated, the governor controls en-

gine speeds automatically.
When engine speeds exceeds preset value, the
thrust plate moves by means of the centrifugal force
of the flyweights and shifts the control rack to de-
crease fuel supply providing smooth rotation. When
engine speeds come down below the specified
value, the force of the governor spring and starting
spring surpasses the centrifugal force and the thrust
peace is pushed back. Then the control rack is shift-
ed to increase fuel and thus restore engine speeds.
Engine speeds are maintained at a constant level in
his way.
Fig. 7-31
3) When the control lever is set in the full load posi-
tion, tension of the tension spring is increased and
the tension arm is in contact with the full load stop-
per. Meanwhile, the floating arm, control link, and
control rod work to control fuel supply so as to avoid
exceeding a preset maximum engine speed. Thus
full-load, maximum speed operation is possible.
When load is eliminated during loaded operation,
engine speeds increase, which lead to increased
centrifugal force of the flyweights. Then the trust
piece pushes the floating arm and the control rod
is shifted to decrease fuel. Thus over-racing is pre-
vented.
86
CHAPTER 8. TRANSMISSION AND RELATED PARTS

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UGE TYPE 7. DIF-LOCK ADJUSTMENT
8 notches
Brake cable Brake rod
m
0.3m
A
Fig. 8-15
ADJUST BRAKE ROD
(1) Depress the brake pedal until the stopper.

Fig. 8-16
(2) Adjust the length of brake rod so that distance of
(1) Make sure the Arm/Diff(4) to move
spring is 0.3mm. completely and fasten the adjusting plate(1)
by the bolts(2).
(3) After adjusting the brake rod, be sure to check
free-play of brake arm and confirm distance of a
screw(A) is within 18mm.
ADJUST CABLE OF PARKING LEVER
(1) Pull up the parking lever until 8 notch. 8

(2) Adjust the length of left and right brake rod so
that each distance of spring of spring is 0.3mm.
(3) After releasing the parking brake, be sure to

check free-play of brake cable.
Fig. 8-17
(2) After re-installing the dif-lock wire cable, be

sure to be able to depress dif-lock pedal until
the stopper.
91
92
CHAPTER 9. REAR AXLE
CHAPTER 9. REAR AXLE

1. CONSTRUCTION
Fig. 9-1
DISASSEMBLY (3) Remove the gear and chain and tension plate.
(1) Drain the oil in the rear axle case.
Fig. 9-4
9
Fig. 9-2 (4) Detach the rear axle case from chassis.
(5) Remove the snap ring on the wheel shaft.
(2) Separate the rear axle case.
Fig. 9-5
Fig. 9-3
93
(6) Remove the wheel shaft. (9) Remove the snap ring on shaft.
Fig. 9-6 Fig. 9-9
(7) Remove the snap ring on the bearing. (10) Remove the shaft from case.
Fig. 9-7 Fig. 9-10
(8) Remove the bearing from the rear axle case.
Fig. 9-8
94
CHAPTER 10. HYDROSTATIC TRANSMISSION

1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS
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䎋䎔䎘䎌䎱䏈䏈䏇䏏䏈䏅䏈䏄䏕䏌䏑䏊䎋䎖䎘䎌䎲䏌䏏䏖䏈䏄䏏
䎋䎔䎙䎌䎥䏘䏖䏋䎋䎖䎙䎌䎲䏌䏏䏖䏈䏄䏏
䎋䎔䎚䎌䎥䏘䏖䏋䎋䎖䎚䎌䎲䏌䏏䏖䏈䏄䏏
䎋䎔䎛䎌䎶䏓䏕䏌䏑䏊䎋䎖䎛䎌䎲䏌䏏䏖䏈䏄䏏䏆䏄䏓
䎋䎔䎜䎌䎶䏓䏕䏌䏑䏊䎋䎖䎜䎌䎲䏌䏏䏖䏈䏄䏏䏆䏄䏓
䎋䎕䎓䎌䎶䏓䏕䏌䏑䏊䎋䎗䎓䎌䎺䏄䏖䏋䏈䏕
10
Fig.10-1
95
2. OPERATING DIAGRAM OF HST
Fig. 10-2
96
3. FUNCTION
3.1. VARIABLE TYPE PUMP
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.
Fig. 10-3
10
Fig. 10-4
97
Fig. 10-5
Fig. 10-6
98
10
Fig. 10-7
99
Fig. 10-8
4. DISASSEMBLY AND REASSEMBLY
100
4.3.
10
101
102
4.4. DISASSEMBLY (2) Remove the cylinder block assembly.
(1) Remove the port block.

a. Remove the bolts.
Fig. 10-12
Components of the cylinder block assembly

Fig. 10-9 (Both blocks have the same components.)
b. Separate the port block from cylinder block. • Cylinderblock . . . . . . . . . . . . . . . . . . . . . . . . . . 1

• Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
• Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
• Spring holders . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fig. 10-10
c. Remove the cylinder block assembly(pump Fig. 10-13

side).
(3) Remove the slant board assembly, which in
Remove the cylinder block assembly(motor
cludes the swash plate and bushing from the case
10
side).
and then take out the thrust bearing bush and
sliding piece .
Fig. 10-11
103
Fig.10-14 Fig. 10-16
(4) Remove motor-side thrust bearing from the b. Remove the snap-ring and hit the end of the shaft
case . with a plastic hammer as shown in the figure
blow and extract the shaft from the case .
Fig.10-15
Fig. 10-17
(5) Removal of the shafts
• Removal of motor shaft
• Removal of the pump shaft
a. Remove the snap-ring and pry off the bore plug
a. Remove the four screws and take out cover pin with a conventional screw driver.
and O-ring from the case .
104
Fig. 10-20
Fig. 10-18
(7) Disassembly of the port block
b. Remove the snap-ring which is inside the case,
and hit the end of the shaft with a plastic ham- a. Remove the plug for the check valve and take out
mer as shown in the figure below in order to the springs and poppets out of the port block .
extract the shaft out of the case .
b. Remove the valve sub-assembly .
Fig. 10-19 Fig. 10-21
(6) Disassembly of the trunnion shaft 10

a. Remove the snap-ring and hit the end of trunnion
shaft with a plastic hammer as shown in the fig-
ure below in order to extract it out of the case.
b. Remove the bearing .
105
4.5. CRITERIA FOR REPLACING WORN PARTS
106
4.6. 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.
d. All fasteners should be tightened to specified
values.
e. Apply lithium-based grease to oil seals and O-
rings: especially to the lips of oil seals.
4.7. REASSEMBLY Fig. 10-23
(1) Reassembly of the trunnion shaft (2) Reassembly of the shafts
a. Install the snap-ring into the case . • Assembly of the pump-side shaft
Install the oil seal .
a. Install the pump shaft assembly, which is com-
b. Install the trunnion shaft assembly, which is posed of the shaft ball bearing and snapring into
composed of the trunnion shaft sub-assembly the case and retain the shaft with the snap-ring .
and the ball bearing .
Fig. 10-24 10
Fig. 10-22
b. Install the two pins and O-ring and then the
c. Install the washer and ball bearing and retain the cover assembly, which is composed of the cover
shaft with the snap-ring . and oil seal . Tighten the cover with the screws .
107
• Reassembly of the motor side shaft (3) Reassembly of the slant board and thrust bearing
a. Install the motor shaft assembly, which is com- a. Install the thrust bearing into the case .
posed of the shaft ball bearing and snapring into
the case and retain the shaft with the snap-ring . Install the thrust bearing with the side bearing
no marking turned towards the pistons.
Fig. 10-25
Fig. 10-27
b. Press the bore plug into the case and install the
snap-ring on the outside. b. Install the two bushes in the case .
c. Install the sliding piece onto the trunnion shaft .
Fig. 10-26
Fig. 10-28
d. Installl the thrust bearing onto the slant board

assembly, which includes the swash plate and
bush . Install the slant board so that the groove in
the slant board is aligned with the sliding piece.
Install the thrust bearing so that the side having

no marking is turned towards the pistons.
108
Fig. 10-31
Fig. 10-29
b. Install the valve sub-assembly .
(4) Installation of the cylinder blocks
Apply grease to the valve ahead of time to pre-
a. Install the cylinder block assembly, which is vent it from falling.
composed of the cylinder block pistons springs
and spring holders respectively onto the motor c. Install the springs pins and gasket onto the case.
and pump shafts.
Apply grease to the springs ahead of time in or-
When installing the cylinder block, apply work- der to prevent them from falling.
ing fluid to the pistons ahead of time.
10
Fig. 10-32
Fig. 10-30
d. Install the port block assembly onto the case and
(5) Reassembly of the port block tighten the eight socket-head bolts .
Tightening torque of
a. Install the port block assembly with the copper
socket-head bolt (50) 49.0 +
- 5 N･m
alloy side turned towards you and install the
valve plates .
Apply grease to the valve plate ahead of time to

prevent it from falling.
The valve plate with two notches should be
installed on the pump.
109
Fig. 10-33
e. After being reassembled, make sure that the

shafts turn smoothly using an adjustable end
wrench.
Fig. 10-35
Fig. 10-34
110
4.8. PRECAUTIONS FOR REASSEMBLY
a. Installation of shaft bearings
Press in the bearings using the jigs mentioned in

the drawing below.
Fig. 10-37
c. Swash plate (slant board) assembly

• Press the bush into the slant board so that the
bush end becomes flush with the surface of the
swash plate.
Fig. 10-36
b. Bore plug installation
Note:
• Press in the bore plug until its top sinks to 4.2
mm deep from the case surface. 10
• Prepare pressing-in jigs in accordance with the
dimensions mentioned on the drawing. Fig. 10-38
d. Trunnion shaft assembly
Fig. 10-39
111
e. Installation of oil seals g. Pressed-in parts in the port block
• Press the oil seal into the cover until the oil seal Note:
end becomes flush with the cover surface. • The oil seal should be installed with the dust lip
turned outward.
• Install the bearing until the end protrudes by 2.5
mm beyond the port block surface.
• Prepare pressing-in jigs in accordance with the
dimensions mentioned on the drawing.
Fig. 10-40
• Press in the oil seal until the oil seal end sinks to
12.5 mm below the case surface.
Fig. 10-41
f, Port block assembly
As for the pressed-in parts, refer to paragraph g.
Fig. 10-43
Fig. 10-42
112
4.9. LIST OF MAJOR COMPONENTS OF HIST
Fig. 10-44
4.10. PRECAUTIONS FOR INSTALLATION OF 4.11. PRECAUTIONS AFTER INSTALLATION

HST UNIT OF HST UNIT
(1) INSTALLATION OF SHAFTS (1) STARTING
a. The input shaft (output shaft) and the driving a. Fill the HST case with working fluid.
shaft (driven shaft) of the two shaft type HST
should be aligned correctly. The deviation of b. After the installation of the HST system, oper-
centering should be less than 0.05 mm. ate the control lever or pedal slowly several
times in order to bleed the system of air com-
b. When mounting or dismounting the two shaft pletely. 10
type HST onto or from the machine, prevent the • When air-bleeding is incomplete, trapped air
input and output shaft end from excessive thrust bubbles make noise. Repeat the above air-bleed-
load. ing operation until such noise is elimiated.
• When excessive air is trapped inside the system,
(2) INSTALLATION OF TRUNNION SHAFT the output shaft may not turn. But when the con-
trol lever is held at the maximum angle under
Provide a stopper in place before the maximum idling speed for a while, the shaft will begin
inclination of the trunnion shaft when there is a turning. This may cause the machine to start
fear of application of stronger force to the trun- abruptly, so a safety measure should be provided
nion shaft than HST operating force. such as jacking up the drive wheels.
c. At first make sure there are no abnormal noises

or vibrations generated at low speed and then
113
acceralate to the specified speed. 5. ADJUSTMENT OF HIST
(2) OIL TEMPERATURE
It is a very important factor at what temperature Warning:

a hydraulic system operates. High operating tem- After a long time of use, the neutral position of
peraure will cause working oil to deteriorate the HST unit can shift, which will cause various
faster, that is, oil is oxidized faster. On the other troubles such as difficulty in stopping the lawn
hand excessively low operating temperature in- mower, changing over between forward travel
creases oil viscosity resulting in poor mechani- and reverse travel, etc., which is very dangerous.
cal efficiency of the HST.
Important:
Consequently abide by the following items: • When the HST unit is out of order, ask your deal-
ers to repair it.
a. When starting the machine at 10°C or colder • The adjustment of the neutral position of the HST
temperature, wait until oil temperature becomes unit should be done by your dealers.
higher than 10°C by warm-up operation or us-
ing an oil heater. Then start operation. When there is no alternative but for the user to adjust
it, follow the next instructions:
b. Normal operating temperature: 20°C to 60°C The neutral arm of the HST unit is located around
the centre under the step.
c. Maximum operating temperature With this arm the neutral position can be adjusted.
The maximum operating temperature should be
80° C. This limit is determined form the viscoci-
ty, oxidation-proof property of working oil and
deterioration of O-rings and oil seals.
Consequently operation at higher than 80°C will
shorten the service life of the HST and working
oil.
(3) PERIODICAL INSPECTION AND CHANG-

ING INTERVALS OF WORKING OIL
As the system operates, deposits like sludge ac-

cumulate within circuits and oil tank and work-
ing oil deteriorates, which will prevent the sys- Fig. 10-45 (1) Lawn mower (3) Front wheel
tem from smooth operation in the end. (2) Tyre chocks (4) Rear wheel
Consequently working oil should be checked
periodically to replace it timely with new one. a. Place the lawn mower on level, hard ground Put
As it is very difficult to judge how oil has dete- tyre chocks in the positions a little apart from the
riorated visually, a rule of thumb is given below. front wheels and rear wheels as shown in the fig-
Normally the oil should be replaced after the ure.
intial 50 hours of operaton and then every year
(before the new season begins) when the b. Shift the PTO lever to the OFF position (N).
machine is used for less than 250 hours or every
250 hours of operation. c. Stop the engine and remove the starter key.
As water and sludge will be deposited in the cir-
cuits and oil tank when replacing the working d. Apply the parking brakes (UGE) or locking brake
oil, the whole system should be flushed clean (UE).
before filling it with new oil
e. Loosen the lock nut of the adjust rod.
114
f. When the lawn mower creeps forward, tilt the k. Next, align both HST pedals in height by adjust-
adjust nut slightly toward A and when ing the effective length of the HST rod with the
creeps reverse, tilt toward B by manipulating the two lock nuts. Be sure to tighten the lock nuts
add just nut. Then tighten it temporarily with the securely after adjustment.
lock nut.
l. Loosen the lock nut of the crank plate stopper bolt
A B and screw in the bolt slightly to shorten the effec-
tive length.
m. Free the Neutral arm and depress HST pedal.
n. Then adjust the effective length of the stopper

bolt until the head comes into contact with the
stopper and tighten it with the lock nut.
Fig. 10-46
g. Start the engine and turn the throttle lever to the
intermediate position between r and t posi-
tions.
h. Release the parking brake. Fig. 10-48 (1) HST pedal (3) Lock nut
(2) Stopper bolt (4) Crank plate
i. When the lawn mower does not start moving, it
shows that the neutral position is properly set.
j. Stop the engine and apply the parking brakes.

Tighten the adjust nut securely.
10
Fig. 10-47 (1) HST rod. (3) Trunnion arm

(2) Lock nuts.
115
116
Fig. 11-1
１７２８−４０８−２６０
ＣＹＬＩＮＤＥＲＡＳＳＹＣ（ＰＢ）ＣＯＬＬＥＣＴＯＲ
１７２８−５０８−２７０
Ｘ
Ｘ
ＯＰＥＮ
ＶＡＬＶＥ／１Ｓ−２ＤＡＳＳＹ
Ｂ３
Ａ３
ＬＲ１７２８−４０７−２００ＣＯＬＬＥＣＴＯＲ
φ ．６ φ ．６
ＣＯＭＮＴＲＯＬＬＥＲＬＩＦＴ
／ＳＴＲＥＥＲＩＮＧＡＳＳＹＢ２
３２ｃｃ／ｒｅｖ
ＲＥＬＥＡＦＰＲＥＳＳＵＲＥ：Ａ２
６．０∼６．５ＭＰａ φ ．６ φ ．６
（６１．２∼６６．３ｋｇｆ／ｃｍ２）
Ａ１
Ｘ
φ ．６ φ ．６
1. HYDRAULIC SYSTEM DIAGRAMS
ＰＴＥ（ＰＢ）Ｋ１８２−０３２−０００
ＣＹＬＩＮＤＥＲＡＳＳＹ
ＰＴ（ｆｏｒＭＯＷＥＲＬＩＦＴＩＮＧ）
117
ＣＨＡＲＧＥＦＩＬＴＥＲ
Ｐ１０３−５２１−３００
１０μ
Ｋ５１０−００５−０００
ＨＳＴ／ＳＸＧ／２１ＡＳＳＹ
Ｂ
ＨＩＧＨＰＲＥＳＳＵＲＥ
ＧＥＡＲＰＵＭＰＧＥＡＲＲＡＴＩＯＩＮＰＵＴＲＥＬＥＡＦ
ＬＥＦＴＨＡＮＤ０∼２１．５２２．６ＭＰａ
Ｋ１３０−０１８−０００３１／３４＝０．９１２ｃｃ／ｒｅｖ（２３０ｋｇｆ／ｃｍ２）２１．５
５．２ｃｃ／ｒｅｖＲＯＴＡＴＩＯＮ φ１．３ｃｃ／ｒｅｖ
１１．１Ｌ／ｍｉｎＥＮＧ（ＣＣＷ）
（ＥＦＦＩＣＩＥＮＣＹ０．９）
φ０．５
２６００ｒｐｍＬＯＷＰＲＥＳＳＵＲＥ
ＲＥＬＥＡＦ
ＳＵＣＴＩＯＮＦＩＬＴＥＲ０．４９ＭＰａ
（５ｋｇｆ／ｃｍ２）
１６８２−５０８−３００
２００ＭＥＳＨＴ
CHAPTER 11. HYDRAULIC SYSTEM
11
Fig. 11-2
Steering control
ＤＥ
Pump port(A)
118
Tank port(B)
Left port(E)
Right port(D)
E port(C)
Ｂ
Ａ
2. INSPECTION OF MAJOR COMPONENTS parts with new ones.

2.1. SUCTION FILTER Delivery pressure: 6.87Mpa (70 kgf/cm 2) with fluid
heated at 50°C (Maximum pressure: 85 kgf/cm 2 )
The filter is installed under the transmission case. It
has a reusable wire element, which should be washed
clean periodically.
2.2. HYDRAULIC PUMP (GEAR PUMP)
Check all disassembled parts for damage and wash

undamaged and usable parts except for rubber parts
in clean diesel fuel or kerosene. Inspect all parts and
repair or replace defective
Mini-orbit roll
Gear pump
Fig. 11-3
2.3. RELIEF VALVE FUNCTION
This device functions as a flow-distributor of the

pressurized fluid from the pump and the built-in
relief vavel stabilises the pressure in the mini-orbit
roll. It is installed on the mini-orbit roll.
11
119
2.4. RELIEF METAL (support)
6.0-6.5Mpa
Relief pressure
(61.2-66.3kgf/cm2)
2.5. OIL FILTER (Relief metal (support)
The filter cartridge is attached on the HST unit.
Bypass relief valve in the base
1.5Mpa
Opening pressure
(1.5kgf/cm2)
Replace the cartridge with a new one after the initial 50

hours of operation and the after every 200hours of
operation.
120
CHAPTER 12. POWER STEERING SYSTEM

1. CONSTRUCTION
Control(steering)
Pump port(A)
Tank port(B) ＰＬ
Left port(E)
ＴＲ
Ｅ Right port(D)
E port(C)
ＣＹＬＩＮＤＥＲＡＳＳＹ
ＣＯＮＴＲＯＬＬＥＲＬＲ
／ＳＴＲＥＥＲＩＮＧＡＳＳＹ
３２ｃｃ／ｒｅｖ
ＲＥＬＥＡＦＰＲＥＳＳＵＲＥ：
６．０∼６．５ＭＰａＰＴＥ（ＰＢ）
（６１．２∼６６．３ｋｇｆ／ｃｍ２） 12
Fig. 12-1
121
2. WORKING PRINCIPLE
Fig. 12-2
Fig. 12-4 (when the steering wheel is turned to right)
Fig. 12-3: when the steering wheel is in neutral
Fig. 12-5 (when the steering wheel is turned to left)
122
3. MAJOR TROUBLES AND CAUSES, AND COUNTERMEASURES
12
123
124
12
125
126
CHAPTER 13. ELECTRICAL ACCESSORIES

1. ELECTRICAL COMPORNENS AND WIRE HARNESS
1) UE TYPE 2) UGE TYPE
RELAYS
Fig. 13-1 Fig. 13-3
Fig. 13-2 Fig. 13-4

FUSE
13
Fig. 13-5 Fig. 13-6
127
3) ALL TYPE
Fig. 13-7
Fig. 13-9
Fig. 13-8
Engine
Fig. 13-10 Fig. 13-11
128
2. WIRING DIAGRAM (E TYPE)
13
Fig. 13-12
129
3. WIRING DIAGRAM (GE TYPE)
Fig. 13-13
130
4. STARTER
Fig. 13-14
13
131
4.2. 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. 13-17
• Remove the connector from terminal 50.
• Remove the starter from the engine. 4) Removal of the clutch assembly.
DISASSEMBLY OF STARTER • Remove the clutch assembly from the magnet

switch.
1) Removal of the lead from terminal C.
5) Removal of the steel ball and spring
Fig. 13-15
2) Removal of the starter yoke/armature assembly Fig. 13-18
6) Removal of the brush holder
• Remove the starter yoke/armature assembly and
O-ring by removing the two through bolts. • Lift up the brush spring and take out the brush.
• Remove the commutator end frame and an O-
ring.
Fig. 13-19
• Disconnect the brush holder from the starter
Fig. 13-16 yoke.
3) Removal of the starter housing
7) Removal of the armature
• Disconnect the starter housing from the magnet-
ic switch. • Remove the armature from the starter yoke.
• Remove the drive pinion.
• Remove the idle gear and retainer with roller. 4.3. INSPECTION OF COMPONENTS
1) Inspection of the armature coil grounding
• Check continuity across the commutator and an
132
armature coil core. If there is no continuity, the • Measure the commutator diameter with vernier
armature coil is normal. calipers.
30 mm 29 mm
Fig. 13-20
2) Inspection of armature coil for short circuit
• Turn the armature coil on a armature coil tester

while holing a piece of iron closely above the
armature. If the iron piece does not vibrate nor is Fig. 13-23
attracted to the armature, the armature is nor- • Measure mica depth against segment top.
mal.
Note: 0.5-0.8 mm 0.2 mm

The armature coil surfaces should be cleaned
ahead of time.
Fig. 13-24
Fig. 13-21 4) Inspection of field coils for short circuit
3) Inspection of the commutator
• Inspect for continuity across the lead from termi-
• Inspect the commutator surfaces for dirt, burn- nal C and field coil brush. If there is continuity,
ing, damage, etc. Minor damage can be correct- the coils are normal.
ed with sandpaper of #400 or higher no.
• Inspect the commutator for run-out with a dial

gauge on a V-block.
0.02 mm 0.05 mm
Fig. 13-25
5) Inspection offield coils for grounding
Inspect continuity across the field coil brush and
field coil. If there is no continuity, the coils are 13
normal.
Fig. 13-22
133
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. 13-26
6) Inspection of the brushes
• Measure brush length in the middle.

Fig. 13-29
15.0 mm 10.0 mm 9) Inspection of the clutch
• Inspect the gear for wear and damage.

• Make sure that the gear locks when turned in
diving direction and turns smoothly in the re-
verse direction.
Fig. 13-27
• Correct the contact surfaces of the brushes on
the sandpaper wrapped around the commutator.
7) Inspection of brush spring tension Fig. 13-30

• There should be no hitching when the bearing is
• Measure spring tension with a spring balance turned manually by applying some force to it
and read the balance at the moment when the with fingers.
spring is about to leave the brush. • It should not make abnormal noises when turned
abruptly.
1785-2415 gr 1200 gr
Fig. 13-31
11) Replacement of the bearing
• Remove the bearing or install it as illustrated.

Fig. 13-28
134
4.4. 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. 13-32
• Lift up and hold the spring and install the brush.
Fig. 13-33 Fig. 13-36

12) Inspection of the magnetic switch • Install the commutator end frame using an O-
• Inspect for continuity across terminal 50 and ter- ring.
minal C. If there is continuity, the switch is nor-
mal. 3) Installation of the starter yoke/armature
• Install the starter yoke on the magnetic switch

using an O-ring.
Fig. 13-34
• Inspect for continuity across terminal 50 and
magnetic switch body. If there is continuity, the
switch is normal. Fig. 13-37
4) Installation of the steel ball and spring
• Apply grease to the ball ahead of time and in-

stall the ball and spring.
Fig. 13-35
13
Fig. 13-38
135
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.
ing.
• Apply grease to the roller/retainer assembly and
idle gear and then install.
• Install the drive pinion on the armature shaft.
• Apply grease to each gear.
Fig. 13-41
3) Plunger-return test
• In the state of the coil holding test, the pinion

should retract when the connection is removed as
Fig. 13-39 illustrated.
6) Installation of the starter housing
• Install the starter housing on the magnetic

switch.
• Install the two through bolts.
7) Connection of the lead of terminal C
4.5. INSPECTION OF THE STARTER AFTER

REMOVAL FROM THE TRACTOR Fig. 13-42
4.6. PERFORMANCE TEST
Note:
Each step should be performed within three to Note:
five seconds to prevent damage. • Hold the starter securely in a vise.
• In unloaded test use thick wires because of high
1) Pull-in test current.
• Make sure the pinion is pushed out when the 1) Unloaded test
starter is connected as illustrated.
Drive the starter independently with a specified
battery without any load and check for spinning
speed, voltage, and current. Values should be as
shown below:
Voltage 11.5 V
Current 90A or less
Speed 3000 rpm or more
Fig. 13-40
2) Coil holding test
136
Fig. 13-43
2) Braking test
Install the starter on a test bench and apply

brake. Measure each value while the starter is
thus prevented from spinning. Each value should
be as shown below:
Voltage 8.0 V
Current 230A or less
at 1180 rpm or over
Torque 0.65 kgf･or over
Fig. 13-44
4.7. INSTALLATION OF THE STARTER
1) Connect the wiring.
• Connect the lead to terminal 30 and tighten it

with the nut.
• Install the connector on terminal 50.
2) Install the starter on the engine.
3) Connect the negative (-) battery cable.

13
137
5. ALTERNATOR
5.1. EXPLOTED VIEW, SPECIFICATIONS, AND PERFORMANCE CURVES
Fig. 13-45
Fig. 13-46
138
Fig. 13-48
13
Fig. 13-47
139
Fig. 13-51
Fig. 13-49 f. Removal of the brushes
d. Removal of the 1C regulator
Remove the four nuts and bushes which tighten
Remove the three screws which tighten the 1C the drive end frame and rear end frame. Then the
regulator. Then the regulator is removed. brush assembly is removed.
Note:
As screws ofdifferent length are usedfor respec-
tive terminals, they should be set aside in order
for later reference after disassembly. A wrongly
used screw may come into contact with the end
frame and cause the regulator out of control,
which will lead to battery overcharging and re-
sult in serious damage in the end.
Fig. 13-52
Note:
When removing the bushes, take care not to
stretch the wire from the stator.
g. Removal of the rear end frame
Remove the rear end frame using a puller as il-

lustrated.
Fig. 13-50
e. Removal of the rectifier
Remove the four screws which tighten the leads

for the rectifier and stator. Then the rectifier is
removed.
Fig. 13-53
h. Place the drive end frame on blocks as illustrated
to make it level and push out the rotor on a press.
140
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.
Fig. 13-54
Note:
Take care not to allow the rotor to fall to avoid
damaging the slip ring and fan.
i. Removal of the retainer plate
Remove the four screws which tighten the re- Fig. 13-57
tainer plate. Then the plate is removed.
5.4. INSPECTION
a. Inspection of the rotor slip rings
Measure the outer diameter of the rings. If the

measured value exceeds the usable limit, replace
with a new one.
14.4 mm 14.0 mm
Fig. 13-55
j. Removal of the bearing which is installed on the
drive end side
Place the drive end frame level on blocks as il-

lustrated and put ajig on the bearing. Then push
out the bearing on a press.
Fig. 13-58
• Make sure that the slip ring surface is smooth,
clean, and free from oil. If the surface is rough-
ened, polish with a f ine sand paper (#500 -
#600). 13
Fig. 13-56
141
If it is smeared with oil, clean with alcohol- c. 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.
Check for continuity across the slip rings. If
there is no continuity, replace the rotor.
Fig. 13-62
f. Insulation test of the stator coils
Fig. 13-59
c. Insulation test of the rotor coil Check continuity across one of the stator termi-
nals and stator core. If there is continuity, re-
Check for continuity across a slip ring and the place the stator.
rotor core or the shaft. If there is continuity, re-
place the rotor.
Fig. 13-63
g. Inspection of the rectifier

Fig. 13-60
d. Inspection of the bearings Set the tester at KQ range and check continuity
across respective terminals. The diode should
Noisy or hitching bearings should be replaced show continuity only in one direction.
with new ones.
Fig. 13-61
Fig. 13-64
142
Note: the brush holder. If the length is less than the

The rectifier cannot bejudged 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. Consequently the diode
should be considered normal when the resistance
difference between the forward direction and
reverse direction is large enough. Never apply
MQ, range of the tester, which may damage the
diode.
h. Inspection of the brushes

Fig. 13-65
Measure the length of the brush exposed above Standard value Usable limit
10.5 mm 4.5 mm
i. Specified tightening torques and service stan-

dard
13
Fig. 13-66
143
j. Inspection of the IC regulator
Fig. 13-67
• Connect the removed 1C regulator, variable DC
power supply, voltmeter, and a lamp as illustrat-
ed. (Keep SW1 and SW2 turned off.)
• Set the power supply at 12V.
• Turn on SW1. Make sure that LI (in place of the

charge lamp) is lit bright and L2 (in place of the
rotor coil) is also lit.
• Then turn on SW2 with SW1 on. Make sure that

LI is turned off and L2 remains lit.
• When the power supply output is changed gradu- Fig. 13-68

ally from 12V until 14.5±0.6 at about 25° C
with both SW1 and SW2 turned on, L2 should 5.5. RE-ASSEMBLY
turn off and LI should remain turned off.
Re-assemble in reverse order of disassembly, fol-
After above test, check the diode between ter- lowing the next precautions.
minal B and F.
a. Pressing in the bearings
• Set the tester at KQ range and check for conti-
nuity across terminals B and F. Check by chang- Press in the bearing with a hand press carefully
ing the polarity of the tester. There should be to avoid slanted installation.
continuity in one direction and no continuity in
the other direction. At room temperature, it is very hard to press in
the bearing due to interference. So it is recom-
mendable to heat up the whole frame at about
100°C.
Note:
When installing the bearing, use ajig which is
designed to press only the outer race. Support the
frame at the bearing box not at the stay.
144
Fig. 13-70
Fig. 13-69 Note:
2) Installation of the brush holder • The clearance between the brush holderandthe
connector should be 1 mm or more.
Install the brush holder sideways along with the • Rubberpackingfor the brush holder should not
IC regulator. be deformed or pinched.
• As the terminals have screws different in length,
6. GLOW PLUGS be sure not to confuse them when installing.
6.1. SECTIONAL VIEW
Fig. 13-71
13
145
6.2. REMOVAL, INSPECTION, AND RE-ASSEMBLY
a. Troubleshooting
b. Removal electrode. If there is no resistance, it indicates a

short circuit, so replace the glow plug. If the re-
• Remove the connector by loosening the glow sistance is infinite, it shows that pre-heating coil
plug nut installed on the cylinder head. is burnt out, so replace the glow plug.
Standard value 1.2-2.5 Ω
• Remove the glow plug.
d. Re-installation
c. Inspection
• Install the glow plug.
• Check for continuity across the sheath and cen-
ter • Install the nut on the glow plug and connect the
connector.
146
CHAPTER 1
CHAPTER 2
CHAPTER 3
CHAPTER 4
CHAPTER 5
CHAPTER 6
CHAPTER 7
CHAPTER 8
MOWER DECK
SCMB48 & SCMA54
MOWER DECK
CONTENTS
CONTENTS ....................................................................................................................................... 3
CHAPTER 1. FOR SAFETY LABELS .............................................................................................. 5
CHAPTER 3. ATTACHING AND DETACHING THE MOWER DECK .............................................. 9

1. ATTACHING THE MOWER DECK............................................................................................. 9
2. DETACHING THE MOWER DECK .......................................................................................... 10
CHAPTER 4. MOWER OPERATION .............................................................................................. 11

1. BEFORE OPERATION ........................................................................................................... 11
2. CUTTING HEIGHT ADJUSTMENT ......................................................................................... 11
3. STARTING MOWING OPERATION ........................................................................................ 12
4. EMERGENCY STOP .............................................................................................................. 13
5. STOPPING MOWING OPERATION ....................................................................................... 13
6. EFFICIENT MOWING ............................................................................................................. 14

1. INSPECTION AND REPLACEMENT OF BEVEL GEAR CASE ............................................. 17
2. INSPECTION AND REPLACEMENT OF FRONT BELT ......................................................... 18
3. INSPECTION & REPLACEMENT OF BLADES ..................................................................... 18
4. INSPECTION OF GAUGE WHEELS ...................................................................................... 20
5. INSPECTION OF ROLLERS ................................................................................................... 20
6. CLEANING OF MOWER DECK ............................................................................................. 20
7. FILLING DIAGRAM ................................................................................................................. 21
8. PERIODICAL INSPECTION TABLE ....................................................................................... 22
9. STORAGE OF MOWER DECK .............................................................................................. 23
CHAPTER 6. DISASSEMBLY AND REASSEMBLY OF GEAR BOX ............................................ 25

1. CONSTRUCTION ................................................................................................................... 25
2. DISASSEMBLY AND REASSEMBLY ..................................................................................... 27
3. BACKLASH ADJUSTMENT ..................................................................................................... 27
CHAPTER 7. INSPECTION OF MOWER DECK SCMA TYPE ...................................................... 29
3
4
CHAPTER 1. FOR SAFETY LABELS
CHAPTER 1. FOR SAFETY LABELS

SAFETY LABELS
SCMB48 & 54
1
5
Shut off the engine and remove the

starter key before performing
maintenance or repair work.
・Maintenance of the caution labels

- The labels should always be clearly seen,
that is, nothing should obscure them.
- When they have become dirty, wash them
with soapy water and wipe off with soft
cloth.
- If any of them are torn or lost, order new
labels from your dealer.
- A new label should be placed in the same
place where the old one was located.
- When sticking on a new label, clean the
place to enable the label to stick and squeeze
out all air bubbles trapped under it.
- When replacing a part with a caution label
stuck on, a new caution label should also be
ordered.
6
CHAPTER 2. SPECIFICATIONS
Models SCMB48 SCMA54
Type Rotary mower with rear discharge
Cutting width 1220mm 1372mm

2
Number of blades 2
Blade driving method Shaft drive
Overlap of Blades 112mm 60mm
Dimensions
Overall length 885mm
Overall width 1275mm 1430mm
Overall height 380mm 395mm

Weight Mower Deck 96kg
Linkage 9kg
Blade rotating speeds 68.9 m/s 67.7 m/s
(Gear box input speed ) 1978rpm 1808rpm
(Gear box output speed ) 1830rpm 1519rpm
Adjustable in 7 stages by pin shifting and cutting

Cutting height Adjustment
height dial
Cutting height 25-115mm
Blade Length 666mm 716mm
7
1. SCMB48 & SCMA54

(1) Mower deck
(2) Drive shaft
(3) Pulley cover
(4) Joint cover
(5) Yoke cover
(6) Water hose plug
(7) Carry handle with step
(8) V-belt
(9) Input bearing case
(10) Output bearing case
(11) Tension pulley
(12) Coupling
(13) Bevel gear case(LH)
(14) Bevel gear case(RH)
(15) Discharge cover
(16) Blade(LH)
(17) Blade(RH)
(18) Gauge wheel
(19) Roller
(20) Shaft cover
(21) Air intake cover
8
CHAPTER 3. ATTACHING AND DETACHING THE MOWER DECK
CHAPTER 3. ATTACHING AND DETACHING THE MOWER DECK

1. ATTACHING THE MOWER DECK
Warning:
When attaching or detaching the mower deck to the lawn mower:
· Place the lawn mower on level, hard ground.
· Apply the parking brake securely.
· Shift the PTO lever to the STOP ( ) position.
· Do not start the engine except for operating the lift. 3
(1) Lift lever (2) Lower Chute (3) Gauge wheel

(4) Ring clip (5) Rear link (6) Drive shaft
(7) Front link (8) Lock nut (9) Height adjust dial
(10) PTO Cover (11) Joint Cover
9
a. Start the engine and push down the rear half

(u) the lift lever(1) to raise the mower link in
the highest position. Important:
· When installing and removing the mower deck,
b. Set the gauge wheels(3) of the mower deck in turn clockwise(-) the high adjust dial(9) fully to
the lowest position. lower the mower deck.
c. Before installing the mower deck, set the rear · After installing the mower deck, be sure that the
gauge wheels(3) sideways. ground clearance of the bottom surface of the
mower deck is 150mm.
· When the mower deck is leaning to forward or

backward, adjust length of the front link(7).
In case of leaning to forward:

Make length of the front link(7) shorter
In case of leaning to backward:

Make length of the front link(7) longer
2. DETACHING THE MOWER DECK
Detach the mower deck in reverse order of

attaching: Remove the drive shaft first and then
d. Depress the lower chute(2) and keep it down the mower deck.
with ring clip(4).
e. Place the mower deck underneath the lawn

mower.
Caution:
f. Insert the discharge cover of mower deck into Be sure to disconnect the universal joint on the
chute of lawn mower. PTO shaft of the lawn mower.
g. Move the lift lever(1) forward and depress
rear link(5). Important:
Be sure to keep the removed parts.
h. Install the rear link(5) into mower deck with
pin.
i. Install drive shaft(6) into lawn mower.
J. Install the front link(7) into lawn mower and

mower deck.
k. Start the engine and move the lift lever

backward to raise the mower deck.
l. Set the gauge wheels(3) of the mower deck

straightly.
m. Return the lower chute (2) by removing the

ring clip.
10
CHAPTER 4. MOWER OPERATION

"%&/2% /0%2!4)/.
Caution:
· Become familiar with haw to operate the lawn
mower and understand safety instructions by
reading this manual carefully.
· Make sure that all safety covers and guards are
installed in position.
· Make sure that the blade nuts are tightened
securely.
· Make sure that the belt is tensioned evenly as
specified.
· Before moving the lawn mower into the 4
working site, check the whole area and get rid of
all obstacles such as stones, wood, empty tins,
bottles, wires, etc to assure safe operation.
· Make sure that the mower operation will not
cause any injury to children, animals, bystanders,
or damage to trees, buildings, etc.
· Check the place to mow for bumps, ditches, b. Select one of the setting holes to get the required
mounds, steps, slopes, inclination, softness, cutting height, insert the pin, and retain it with
water pools, etc. ahead of time to avoid the spring clip pin. The label showing the relation
accidents such as turnover, fall, side-sliding of ships between the setting holes and cutting
the lawn mower. heights is stuck on the mower deck.
c. Also set the cutting height of the gauge wheels by
#544).' (%)'(4 !$*534-%.4 re-setting the setting hole for the setting pin with
the spring clip pin removed.
a. Start the engine and raise the mower deck by
the lift lever. Then stop the engine. d. The right and left gauge wheels should be set to
the same cutting height.
e. Push down the (d) of the lift lever to lower the

mower deck.
Caution:
Before operating the lift lever, be seated in the
operator's seat and make sure of the safety con
dictions when lowering the mower deck.
11
3. STARTING MOWING OPERATION

a. Start the engine and turn the throttle lever to
the intermediate position between the low
speed (t) and high speed (r) positions.
d. Push down the HST forward travel pedal gradually

to drive the lawn mower into the working site.
Before starting to move the lawn mower, be sure to

lock the rear gauge wheels either in vertical or
b. Push down the rear half (u) of the lift lever slanted positions.
Fig.5-2-䷵ button to raise the mower deck.
e. Release the HST pedal gradually to stop the lawn

mower
f. Push forward (d) of the lift lever to lower the

mower on the ground.
g. Shift the PTO lever to the ON ( ) position.
Important:
· When engaging the PTO clutch, slow down the
engine speed sufficiently for safety.
c. Release the parking brake.

Caution:
· Whenever you encounter with any trouble of the
mower, ask your dealer for repair immediately
12
Warning:
· As soon as the PTO lever is shifted to the ON · When the operator leaves the seat, the safety system
( ) Position, the mower blades start rotating automatically stops the engine. When leaving the lawn
and eject cut grass or stones through the mower to remove obstacles such as twigs, pebbles, etc.
discharge opening. Consequently, before the PTO lever must be shifted to the OFF position and
operating the PTO lever make sure that there the parking brake applied.
is no people, animals, or physical properties
like buildings cars, etc. within a range where
ejected grass or stones may reach.
· The mower blades should be turned only on 5. STOPPING MOWING OPERATION
turf or grassland with the mower deck
lowered. a. Release the HST pedal.
b. Turn the throttle lever Fig.5-3-䷵ to the low speed
position (t) to reduce engine speeds.
h. Turn the throttle lever to the high speed (r) c. Apply the parking brakes Fig.5-4-䷵, or locking
position to raise engine speed. brake pedal Fig.5-5-䷵.
i. As the HST forward travel pedal is depressed 4
gradually, the lawn mower starts to travel.
Caution:
Be sure to start mowing at sufficiently low
speeds and increase traveling speed gradually.
Important:
The screens of the air-intake openings provided
under the steering wheel, the upper net provided
underside the engine hood and the radiator
screen should be kept clean. Never keep on
operating with clogged screens, or the engine
may be overheated, which may result in engine d. Shift the PTO lever to the STOP ( ) position
seizure.
e. Turn the key switch to the STOP ($) position to
stop the engine
4. EMERGENCY STOP
· When any of the following abnormalities is

encountered, stop the lawn mower and mower
deck immediately. Caution:
- Abnormal noise Park the lawn mower on level, hard ground and make
- Abnormal vibration sure that the parking brakes or locking brake pedal
- Abnormal smell are applied securely.
- Blade hitting an obstacle
- The lawn mower hitting an obstacle Important:
· Never attempt to stop the engine abruptly when it is
· The cause of trouble should be located and running at high speeds.
corrected immediately. If not, consult your Be sure to let the engine idle for about 5 minutes after
dealers. long operation and then stop the engine.
Never attempt to keep on operating the lawn Abrupt engine stopping may lead to overheating
mower without locating and correcting the cause causing seizure.
of trouble.
13
%&&)#)%.4 -/7).' &OR MOWING HIGHLY MOIST GRASS OR ON WET

GROUND
Important: i. If turf damage by the tyres could result, wait until the
· Be sure to mow at full throttle (r). grass and land have dried sufficiently.
· Choose an adequate traveling speed in ii. Wet grass requires a higher grass cutting height
accordance with the height or other conditions setting than when mowing dry grass, as the cutting
of grass to be cut. height is often lower than expected during operation.
· When the screens for the air-intake openings iii. Select a sufficiently slow traveling speed and avoid
and radiator are clogged with dust, clean them sudden starts, turns, and stops. If not, the turf may be
at once. Never go on operating with clogged damaged.
screens.
· Mowing is desirable when the grass is &OR MOWING LOW MOISTURE CONTENT GRASS OR
WHEN THRER IS MUCH DEAD GRASS
dew-free: in the afternoon or late afternoon,
thus preventing the mower from heavy
i. Advance should be in a direction where the dust does
clogging. not hit the operator by taking into consideration the
· Always keep the mower deck clean. direction of the wind.
· Check the blade ends for damage. ii. When the air-intake screens are clogged, clean them
· Repeated mowing is recommended before the at once.
grass grows to high.
· Cutting grass too closely may damage the Important:
grass. · When operating the lawn mower in dusty
Too maintain a green lawn, never mow more circumstances, keep on paying attention to the coolant
than one-third off the height of the grass in one temperature warning lamp.
mowing. Never continue operating when screens are clogged, or
engine breakdown may result.
· A slower traveling speed will result in
improved mowing. Avoid selecting such a
traveling speed that causes the lawn mower to
bounce.
· Short, fast turns will damage turf. Slow down
sufficiently when turning.
· Frequent sharpening of the mower blades
results in beautiful famishment and less load
on equipment, which leads to economical
operation.
&OR MOWING TALL GRASS
i. Mow grass twice.
First, mow the grass to a height low enough

for the next finishing pass. Then finish to the
desired grass height.
The second traveling pass should be shifted
side ways by 20 cm (8 in.) or so, or travel
perpendicular to the first passes, which will
result in a beautiful even finish.
ii. When trying to finish in one pass, select a

sufficiently slow traveling speed. It may also
be required to set the cutting width to half or
one-third of that for normal operation.
14
(ELPFUL MOWING HINTS

· Be sure to mow at full throttle.
· Choose an adequate traveling speed in

accordance with height of grass to be cut.
· Low cutting height will lead to poor mowing

efficiency and rapid blade wear.
· When screens for air-intake openings are

clogged
with dust, clean them at once. Never go on
operating with clogged screens.
· Mowing plan and method.
· When mowing a large are, the following

method is recommended. 4
· Travel clockwise in spirals two or three times,
towards the center.
· Then continue traveling counterclockwise to

the end.
· In this way, scattering of cut grass onto

adjacent passes and mower clogging are
prevented and even mowing is achieved.
· When mowing irregular-shaped land, divide it

roughly into square area and apply same
method as above.
Important:
When adjustment of the cutting height is required
during operation, shift the PTO clutch lever to the
off position, raise the mower to the highest
position with the lift lever, stop the engine, shift
the trans mission range shift lever to the neutral
position, push down the master brake pedal, and
apply the parking brake. Then adjust the cutting
height.
15
16
CHAPTER 5. INSPECTION AND MAINTAINANCE OF MAJOR PARTS
Caution:
• When servicing the lawn mower, place it on level,
hard ground. b. Check to see if a small amount of oil overflows
• Stop the engine and remove key from the starter
switch.
through the plug hole. If so, the level is normal.
• Apply the parking brake securely. (GE TYPE) If not, replenish with gear oil SAE80 through
• Apply the parking lock securely. (E TYPE) the plug hole using an oil pitcher or the like.
• Move the lift lever forward (d) to lower the mower Oil Gear oil SAE 80
to the ground. Capacity Both bevel gear cases 300 cc (0.07
• Move the PTO lever to the STOP position ( ). imp.gal.)
• Service the lawn mower after the engine has
cooled down sufficiently.
With these items in mind, confirm the safety Important:
conditions for maintenance operation without fail Before replacing the level plug, be sure to wrap
ahead of time. the threads with sealing tape without fail, or oil
may leak through the plug.
1. INSPECTION AND REPLACEMENT OF
BEVEL GEAR CASE 5
• Replacement of oil
• Inspection of oil level in the bevel gear case
Important:
Important: Replace oil after the initial 50 hours of operation
Check the oil level after every 50 hours of operation. and then after every 200 hours of operation.
a. Bevel gear case (LH) and (RH) : Remove the a. Remove the level plug (2) and oil filler plug (3).
level plugs (2) located on the back side of the Then drain all oil by tilting the gear case.
bevel gear case.
b. Wrap the threads of the oil filler plug (3) with
sealing tape and screw it in and supply with
fresh oil through the level plug hole using an oil
pitcher.
c. Wrap the threads of the level plug with sealing

tape and re-install it.
Important:
All oil spilt on the gear case mount should be
wiped off completely with cloth. If it is not, the
belt may be smeared with oil and become
slippery.
d. Re-install the belt covers.
17
2. INSPECTION AND REPLACEMENT OF

FRONT BELT b. Check the belt for damage and dirt.
If it is smeared with oil or dirt, or wet with water,
a. Remove the pulley cover (1) installed on the wipe it clean with a dry cloth. When damaged, install
mower deck. a new belt.
Caution:
Never forget to replace all the removed covers.
• Replacement of the front belt

a. Remove the pulley cover (1) installed on the
mower deck.
b. Loosen the nuts (8) of the tension rod and loosen
the tension rod (7).
c. Remove the front belt (4) and install a new belt.
Important:
• Be sure to install the belt as illustrated.
• An improperly installed belt will not work as
expected but also may result in the belt breaking
b. Inspect the front belt tension. right away.
Check if the front belt (4) is tensioned properly. • Be sure to use the following ISEKI’s genuine belts:
When its tension is correct, the clearances SCMA 54 8665-201-052-10 BELT / VB 038
between coils of the tension spring (6) should SCMB 48 8674-203-200-00 BELT / VC0GB 035 SET
be 1.1 to 1.2 mm
d. Make sure that the belt is seated properly on the
groove of each pulley and apply tension to it by
expanding the tension, referring to the paragraph
for “Inspection of belt tension.”
e. Re-install the pulley cover (1).
Caution:
Never forget to replace the removed pulley cover.
3. INSPECTION & REPLACEMENT OF

BLADES
• Inspection of blades a phase position LH & RH.
a. Make sure that blade (LH)(1) and blade (RH)(2) are
at right angles to each other.
Important:
Stretch front belt (4) on a specified value with the
tension rod (7) when the tension power of front
belt (4) is insufficient because the down of the
performance of the lawn mower.
• Inspection of front belt

a. Remove the pulley cover (1) installed on the
mower deck.
18
b. When these blades are not at right angles to • Low cutting height or the operation just after soil
each other, straighten them by following ways. has been applied will wear blades rapidly. The
blades should be checked more frequently.
a. New Blade
b. Blade with rounded edge
c. Excessively worm blades

are very dangerous. So
replace such blades with
new ones at once.
1. Remove one of the bolt (3) of blade (8). c. The blade bolt should be tightened to the
specified
2. Remove the collar (9) assembly. torque with the blades chocked respectively.
Tightening torque: 1000kg•cm (72 ft•lb)
5
3. Install the collar (9) assembly so that blade
(LH)(1) and blade (RH)(2) are at right angles
to each other. Danger:
Be sure to use new bolts when replacing blade
4. Fix wood between blade and mower deck to with a new one.
tighten the bolt (3) Tightening torque: 1000
kg•fcm (72ft.lb) Important:
Make sure that the blades are not in contact with the
5. After installing the blade, be sure to confirm mower deck by turning them by hand.
that it has no trouble by turning the blade with
hand. d. There are two kinds of blades for respective
mower decks. Be sure to install blades in the
proper positions.
Danger:
Do not touch the blade. Before handling the Parts code Punched ID
blade, put on the glove. SCMA 54
Left 8665-306-001-10 I 8665 C
• Inspection of blades Right 8665-306-002-10 I 8665 D
a. Turn the mower deck upside down.
SCMB 48
Left 8674-306-001-00 I 8674 A
Caution: Right 8674-306-002-00 I 8674 B
When turning the mower deck upside down,
take care not to allow it to hit your feet. e. Connect the mower deck to the lawn mower
properly, referring to the paragraph for “attaching
b. Check the mower blades for deformation and and detaching the mower deck”
damage.
Important:
• If the blade ends have become round due to
wear, enlarged clearance between blades leave
uncut grass behind. The blade should be
checked timely and worn ones should be
replaced immediately.
19
4. INSPECTION OF GAUGE WHEELS

6. CLEANING OF MOWER DECK
As the gauge wheels are installed on the rear
ends of the mower deck, they are more
a. Remove belt cover, and clear the grass and dust
vulnerable to being hit and deformed by
accumulated
obstacles than any other part. When a gauge
under the cover before operation, or shorter
wheel (1) does not turn smoothly or is
service life of the belts and damage to bearings
deformed, replace it with a new gauge wheel
and oil seals will be caused.
immediately.
Caution:
Be sure to replace the removed cover after
cleaning.
5. INSPECTION OF ROLLERS
Make sure that the rollers (1) turn smoothly.
b. Pour the water into mower deck from water hose

plugs (1) and turn the blade.
c. After mowing, clear the underside of the mower

deck and blades of accumulated grass and dirt.
Especially after operation in wet grass, wash
them without fail, or accumulated wet grass and
dirt will cause performance deterioration.
Important: Caution:
• When the gauge wheels and rollers are hard to When pouring the water into mower deck to clean,
turn, disassemble them and clean them. be revolution of engine low.
• After re-assembly, be sure to grease them
sufficiently:
20
7. FILLING DIAGRAM
All the shafts mentioned below have grease fitting on their end. Grease them up periodically. The gear case
should also be serviced periodically for oil replenishment and replacement.
Ref. No. Filling points Lubricants Quantity

1 Bevel gear case (LH) ASSY Gear oil SAE 80 300 cc (0.07 imp.gal.)
2 Bevel gear case (RH) ASSY Gear oil SAE 80 300 cc (0.07 imp.gal.)
3 Coupling Grease As required
4 Gauge wheel ASSY Grease As required
5 Wheel fork ASSY Grease I Inject until greaseoverflows
6 Universal joint ASSY Grease Inject until grease overflows
7 Front arm SET Grease As required
8 Tension arm ASSY Grease Inject until grease overflows
21
INSPECTION AND MAINTENANCE OF MAJOR PARTS
8. PERIODICAL INSPECTION TABLE
‫ۑ‬:Inspection, replenishment, and adjustment ‫ڹ‬: Cleaning and washing

‫ە‬: Replacement
Inspection and servicing
Check points intervals (hours of operation) Intervals after that Judgement criteria
50 100 150 200 250
Deformed, broken, worn,
Blade and cracked ones should
be replaced.
Bevel gear case Replace after initial 50 h. and Maintain the specified
(LH) and (RH) then after every 200 h. level.
Belt tension Spring coil clearance
Roller and gauge They should turn

wheels smoothly.
There should be no grass
Belt cover inside Clean alter every 50 h.
or dust accumulated.
Criteria for replacement:
· Deep crack over half the
Belt Clean after every 50 h.
thickness of belt.
· Worn out side wall canvas
Greasing points Grease up after every 50 h.
Bolls and nuts There should be no loose ones.
There should be no lost or

Pins and crimps
deformed ones.
Important:
• Above mentioned service intervals should be used as reference criteria. If working conditions are
harder, earlier service is recommended.
• When special technology and special tools are required, consult your dealer.
22
9. STORAGE OF MOWER DECK
When the mower deck is to be stored for a long period of time, service the deck as mentioned below
before storing it.
a. Clean the mower deck. Take special care to remove grass and dirt from the blades and underside of the
mower deck.
b. Remove grass or other objects tangled around the rollers and shafts.
c. Remove the belt covers, and clean the mower deck top. Be sure to remove grass and other objects tangled
around the pulleys and shaft.
d. Check the belt. If the belt is normal, loosen the tension pulley.
e. Remove all rust and touch up where paint bas peeled off with touch-up paint supplied by ISEKI.
f. Be sure to replace all the removed parts.
g. Lost pins and clips should be replaced with new ones.
h. Check each part for damage and repair or replace damaged ones with new ones for the next operation. 5
Important:
Insist on ISEKI genuine parts when replacing.
i. Grease up all grease points.
j. All loose bolts and nuts should be tightened properly and lost ones should be replaced with new ones.
k. Store the mower deck in a dry place with wooden blocks placed under it and cover with tarpaulin or the
like.
Caution:
When storing the mower deck installed on the lawn mower, be sure to lower it on ground to prevent
unexpected accidents caused by manipulation of the lift lever by children or unauthorized people
23
24
CHAPTER 6. DISASSEMBLY AND REASSEMBLY OF GEAR BOX

(1) As for the detachment of the mower deck from the lawn mower.
(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.
1. CONSTRUCTION
1) Location of Gear box and adjusting shims
2) Gear Box (right hand) and shaft
25
3) Gear box (left hand)
26
2. DISASSEMBLY AND REASSEMBLY f. Inspect the disassembled parts for items men tined
below and replace defective parts with new ones.
a. Detach the gear case from mower deck.
b. Remove the bolts and metal cover. - Abnormal wear and flaws of bevel gears.
c. Remove the gear and bearing. - Wear or abnormal deformation of oil seals: as oil
seal are consumable parts, disassembled ones should
be replaced with new ones.
- Wear and abnormal noise of bearings.
d. Remove the oil seal and snap spring
6
3. BACKLASH ADJUSTMENT
SCMA48 & 54
e. Remove the bevel gear
27
SCMB48 & 54
Front Belt and Belt tension
Blade and Blade hub
28
CHAPTER 7. INSPECTION OF MOWER DECK SCMA TYPE

INTRUCTION FOR check and adjustment of SCMA54/48 SHAFT DRIVE
傜Instruction for check傝
1. To loosen NUT x 5pcs, and to remove BELT COVER.
傜Check points傝
1. Miss-alignment of shaft at COUPLING/A

2. Miss-alignment of shaft at COUPLING/B and COUPLING/C
3. Surface of both side of fitting area for GEARBOX
4. The number of SHIM at A and its half thickness of SHIM at B.
29
1. Inspection and adjustment of COUPLING
2. To put 3 x SNAP RING beside the groove to make space to move COUPLING.
3. To check if 3 x COUPLING can be moved by hand or not.
4. If they can be moved by hand, alignment of shaft will be OK and no need for adjustment.
To place the SNAP RING in correct position and install the belt cover, then finish.
5. If the COUPLING cannot be moved by hand, please adjust alignment by using 4 typs of shims.
They will be used in circled positons. Details will be explained in following pages.
傜Instruction for adjustment傝
1凛 In case that COUPLING/A cannot be moved by hand, first of all loosen TENSION ROD to loosen belt.
2凛 Loosen NUT for fixing METAL/OUTPUT and move COUPLING/A forward. At this time, scrap the old
type SHIM.
30
3凛 Adjust height and angle of METAL/OUTPUT with SHIM to correct alignment of shaft.
FYI: Standard thickness of SHIM will be 1mm for both sides.
4凛 If the shaft does not meet in horizontal direction, disassemble METAL/OUTPUT and ream 4 fitting holes
from 䪛9 to 11mm.
5凛 Thickness of SHIM will be within 2.5mm. 凚If there is more than 2.5mm of gap, please inform ISEKI凛
6凛 When fixing METAL/OUTPUT, make sure the gap of belt line within 2mm.
7凛 When setting up TENSION ROD, make sure the gap of TENSION SPRING between 1.1到1.2mm.
2. COUPLING/B & C cannot be moved, or ALL 3 COUPLING cannot be moved. 7
31
1凛 Loosen TENSION ROD to loosen belt.
2凛 Loosen NUT for fixing METAL/OUTPUT and move COUPLING/A forward.

At this time, scrap the old type SHIM.
3凛 Loosen 8 x NUT for METAL/BLADE/LH(LH gearbox) and METAL/BLADE/RH (RH gearbox).

Adjust height and angle of gearbox both side with SHIM to correct alignment of shaft.
4凛 If the shaft does not meet in horizontal direction, disassemble METAL/BLADE and ream 8 fitting holes
from 䪛11 to 12mm.
6凛 Fix METAL/BLADE/LH and METAL/BLADE/RH to the MOWER DECK with 8 x NUT.

And check if COUPLING/B and COUPLING/C can be moved by hand.
7凛 Adjust height and angle of METAL/OUTPUT with SHIM to correct alignment of

shaft.
FYI: Standard thickness of SHIM will be 1mm for both sides.
8凛 If the shaft does not meet in horizontal direction, disassemble METAL/OUTPUT and ream 4 fitting holes
from 䪛9 to 11mm.
10凛When fixing METAL/OUTPUT, make sure the gap of belt line within 2mm.
11凛When setting up TENSION ROD, make sure the gap of TENSION SPRING between 1.1到1.2mm.
32
CHAPTER 8. TROUBLESHOOTING
Troubles Presumable causes Remedies
• Improper discharging • Front PTO belts and drive • Check belt and correct.
• Blades are installed upside down. • Re-install them correctly.
• Grass is too moist. • Wait until grass becomes dry.
• Too tall grass • Mow it in two steps.
• Too fast traveling speed • Slow down sufficiently.
• Too low engine speed • Run engine at full throttle (r).
• Clogged discharge or mower deck • Clean.
inside • Mow it in two steps or
narrow cutting width.
• Too dense grass • Slow down sufficiently.
• Improperly installed blades • Install blades properly.
• Grass is not mowed. • Front PTO belts and drive • Adjust belt tension spring or
replace belt with new one.
• Too fast traveling speed • Slow down.
• Too low engine speed • Run engine at full throttle (r).
• Worm or broken blades • Replace them with new ones.
• Blades are installed upside down. • Re-install them correctly.
• Improperly installed blades • Install blades properly.
• Uneven cutting
• Mower is not parallel to ground. • Adjust mower mounting.
heights
• Worn blades • Replace them with new ones.
• Clogged grass inside of mower deck • Clean. 8
• Improperly adjusted gauge wheels • Adjust them properly.
• Too tall grass • Mow it in two steps.
• Two blades are not installed on the same • Correct by shimming and set
level and correct angle. the blades properly.
• Deformed blades • Replace them with new ones.
• Turf is peeled off • Too low cutting height. • Correct it with gauge wheels.
in some places. • Mower is not parallel to ground. • Adjust mower mounting.
• Too fast turning speed • Turn slowly.
• Too bumpy ground • Shift mowing direction.
• Excessive noise and

• Broken or unbalanced blades • Replace them with new ones.
vibration
• Loose blade tightening nuts • Re-tighten them to 1300 kgf•cm
• Tension of timing belt is poor. • Adjust tension of timing belt
properly.
33
Troubles Presumable causes Remedies
• Excessive noise and • Clogged grass inside of mower or

• Clean.
vibration foreign
matter caught in a pulley
• Broken belt • Replace it with a new one.
• Tension of timing belt is poor. • Adjust tension of timing belt properly.
• Deformed or interfering belt cover • Repair it.
• Damaged gears • Consult your dealers.
• Too low engine output • Too low engine speed • Mow at full throttle (r).
• Foreign matter caught between blade • Clean.
and blade support
• Foreign matter caught in a pulley • Clean.
• Defective engine • Consult your dealers
• Gauge wheels do not turn. • Foreign matter caught in shaft • Clean.

• Broken wheel • Replace it with a new one.
• Short of grease • Inject grease.
• Blades do not rotate. • Loose blade tightening nuts • Re-tighten them to 1300 kgf• cm.
• Foreign matter caught in blades or • Clean.
blade supports • Replace it with a new one.
• Broken blade pulley • Replace it with a new one.
• Broken belt • Consult your dealers.
• Broken gears • Adjust PTO cable or replace
• Front PTO belt is slipping or broken. belt with a new one.
• Inside of the mower deck is clogged

• Mower does not rise. • Clean.
with
• too much grass or mud
• Defective hydraulic system • Consult your dealers.
34
CHAPTER 1
CHAPTER 2
CHAPTER 3
CHAPTER 4
CHAPTER 5
CHAPTER 6
CHAPTER 7
CHAPTER 8
COLLECTOR
SBC600X & SBC550X
COLLECTOR
CONTENTS
CONTENTS ....................................................................................................................................... 3
CHAPTER 1. SAFETY LABELS....................................................................................................... 5
CHAPTER 3. NAME OF MAJOR COMPONENTS ........................................................................... 9

1. SBC600X-HQE4 (High dump collector) ..................................................................................... 9
2. SBC550X-LE4 (Low dump collector) ......................................................................................... 9
CHAPTER 4. DETACHING AND ATTACHING THE COLLECTOR ............................................... 11

1. DETACHING THE HIGH DUMP COLLECTOR (SBC600X-HQE4) ......................................... 11
2. ATTACHING THE HIGH DUMP OLLECTOR (SBC600X-HQE4) ............................................. 12
3. DETACHING THE LOW DUMP COLLECTOR (SBC550X-LE4) ............................................. 13
4 ATTACHING THE LOW DUMP COLLECTOR (SBC550X-LE4) .............................................. 14
CHAPTER 5. COLLECTOR OPERATION ...................................................................................... 15

1. BERORE OPERATION ............................................................................................................ 15
2. ADJUSTMENT OF THE GRASS LIMIT SENSOR ................................................................... 15
3. INSPECTION BEFORE OPERATION ..................................................................................... 15
4. CLEANING A COLLECTOR..................................................................................................... 16
5. EFFICIENT COLLECTING ...................................................................................................... 16

1. INSPECTION OF CYLINDER .................................................................................................. 17
2. INSPECTION OF HYDRAULIC HOSES.................................................................................. 17
3. FILLING DIAGRAM.................................................................................................................. 18
4. PERIODICAL INSPECTION TABLE ........................................................................................ 19
5. STORING THE COLLECTOR.................................................................................................. 20
CHAPTER 7. ASSEMBLY INSTRUCTION ..................................................................................... 21

1. SBC600X-LQE4 (High dump collector).................................................................................... 21
2. SBC550X-LE (Low dump collector) ......................................................................................... 39
3
4
CHAPTER 1. SAFETY LABELS
CHAPTER 1. SAFETY LABELS

High dump collector
Low dump collector
• Maintenance of the caution labels

- The labels should always be clearly seen, that is, nothing should obscure them.
- When they have become dirty, wash them with soapy water and wipe off with soft cloth.
- If any of them are torn or lost, order new labels from your dealer.
- A new label should be placed in the same place where the old one was located.
- When sticking on a new label, clean the place to enable the label to stick and squeeze out all air
bubbles trapped under it.
- When replacing a part with a caution label stuck on, a new caution label should also be ordered.
5
(1) Link caution label

(Code No. 8664-905-003-0) (4) Hot-part caution label
(Code No. 8595-901-007-0)
Stay clear of the container rear frame while

the close of the rear door.
(5) Discharge label

(Code No. 8595-901-005-0)
Stay clear of the collector frame while the container dumping.
container dumping
(2) Collector caution label

(Code No. 8664-955-002-0)
Stay away of the discharge opening of the

mower deck because stones or other hard
objects ejected from the mower may hit
you.
(3) Maintenance label (6) Maintenance label

(Code No. 1593-901-015-0) (Code No. 1593-901-015-0)
Stop the engine and remove key from the

starter switch before performing
Stay clear of the heated parts while they maintenance or repair work.
are hot.
6
SPECIFICATIONS
7
8
CHAPTER 3. NAME OF MAJOR COMPONENTS
CHAPTER 3. NAME OF MAJOR COMPONENTS

1.SBC600X-HQE4 (High dump collector)
(1) Collector frame

(2) Container
(3) Lift link
(4) Dump link
(5) Lift cylinder
(6) Dump cylinder
(7) Lift hose
3
(8) Dump hose
(9) Container limit sensor
(10) Container cover
(11) Side cover
(12) Rear cover
(13) Cleaning stick
2. SBC550X-LE4 (Low dump collector)
(1) Collector frame

(2) Container
(3) Dump cylinder
(4) Dump hose
(5) Container limit sensor
(6) Container cover
(7) Rear cover
(8) Cleaning stick
9
10
CHAPTER 4. DETACHING AND ATTACHING THE COLLECTOR
Warning:
When attaching or detaching the
collector to the lawn mower:
· Place the lawn mower on level, hard
ground.
· Apply the parking brake securely.
· Shift the PTO lever to the STOP ( )
position.
· Do not start the engine except for
operation the lift.
(4) Guide
1. DETACHING THE HIGH DUMP 4
COLLECTOR e. Adjust the height of rear position of the
(SBC600X-HQE4) container ASSY (2) by the rear stay adjuster
(5), and then lock the rear stay adjuster (5) by
a. Place the lawn mower on level, hard
fastening the nut.
ground, and then apply the parking brake
(GE TYPE) or the parking lock (E TYPE).
b. Start the engine. Move the collector lift

lever (1) backward, and lift the container
ASSY (2) to 20 cm from the lowest
position.
c. Set the collector base ASSY (3) under the

container ASSY (2). Move the collector lift
lever (1) forward to put the container
ASSY (2) on the collector base ASSY (3).
(5) Rear stay adjustor
f. Stop the engine. Move the container lift lever

(1) for-ward and backward two or three times
to decrease the residual oil pressure into the
lift cylinder ASSY (6).
g. Remove the hair pin (8) from the bottom of

the lift cylinder ASSY (6), and then remove
the pin (16x61) (7).
h. Move the bottom of the lift cylinder ASSY (6)

from the collector frame (10) to the collector
(1) Collector lift lever (2) Container ASSY base ASSY (3). Set it to the collector base
(3) Collector base ASSY (OPTION) ASSY (3) with adjusting the front adjustor bolt
(9), and then lock the collector base ASSY(3)
d. Be sure to put the front bottom of the by fastening the nut of the front adjustor bolt
container ASSY(2) on the guide (4) of the (9).
collector base ASSY (3).
11
m. Move the container ASSY (2) which is put on

the collector base ASSY (3) backward slowly
to separate from the lawn mower.
n. Insert the pin (16x65) COMP (14) in the holes

of the upper frame COMP (16), and put the
hairpin (8) to the pin (16x65) COMP (14).
(6) Lift cylinder ASSY (9) Front Adjustor bolt

(7) Pin (16x61) (10) Collector frame
(8) Hairpin
i. Release four hydraulic pressure hoses from

the hose guide (11).
j. Remove all four quick couplers (13).

k. Separate the grass limit sensor coupler (12).
(8) Hairpin (15) Guide bar
(10) Collector frame (16) Upper frame COMP
(14) Pin (16x65) COMP
2. ATTACHING THE HIGH DUMP

OLLECTOR (SBC600X-HQE4)
Attach the collector in reverse order of
detaching.
Note:
When connecting the quick couplers to the dump
and lift ports of the valve ASSY, make sure that
colors of caps for the quick couplers and colors of
the ports are same.
Important:
Be sure to keep the removed parts.
(11) Hose guide (13) Quick coupler Danger:

(12) Grass limit sensor coupler Use the strong and stable stand.
l. Remove four hairpins (8) and four pin (16x65)
COMP (14).
Note:
If it is difficult to remove pin (16x65) COMP
(14), insert the stick or screw driver in the guide
bar (15) of collector frame (10), and then try to
remove the pin (16x65) COMP (14) while
shaking the stick or screw driver.
12
SBC600XH & SBC550XL

c. Remove Nut (M8) (3) and pin (20x410) COMP
3. DETACHING THE LOW DUMP (2) and hook plate (1) from the collector frame
COLLECTOR (SBC550X-LE4) (4).
1) In case of detaching the collector ASSY
a. Support the container with wood (1) and

stand(2).
(1) Hook plate (5) Cylinder ASSY

(2) Pin (20x410) COMP (6) Pin (16x55) COMP
(3) Nut (M8) (7) Split pin 4
(4) Collector frame
d. After removing the collector ASSY (4), insert

pin (2) and pin COMP (6) of cylinder ASSY (5)
(1) Wood (4) Dump fulcrum pin by using plate (1).
(2) Stand (5) Collector frame
(3) Cylinder upper pin (6) Cylinder stay e. Set the split pin (7) and nut (3).
b. Remove the hoses from dump ports (7) of
the valve ASSY.
c. Separate the grass limit sensor coupler from
safety switch wiring, where is located in
right hand side on lawn mower.
d. Remove cylinder upper pins (3).
e. Remove dump fulcrum pin (4).
f. Separate the collector frame (5) from the

lawn mower. Note:
When attaching the collector ASSY, the hook plate
g. Separate the cylinder stay (6) from the lawn (1) assembles with pin (20X410) COMP (2).
mower. When detaching the collector ASSY, hang the
cylinder ASSY (5) on the hook plate (1).
2) In case of detaching the container

4 ATTACHING THE LOW DUMP
a. Support the container with wood and stand. COLLECTOR (SBC550X-LE4)
b. Remove pin (16x65) COMP (6) and split Attach the collector in reverse order of detaching.
pin (7) from the cylinder ASSY (5) and
then separate the cylinder ASSY (5) from Important:
the frame collector (4). Be sure to keep the removed parts.
Danger:
Use the strong and stable stand.
13
14
CHAPTER 5. COLLECTOR OPERATION
CHAPTER 5. COLLECTOR OPERATION

1. BERORE OPERATION 3. INSPECTION BEFORE OPERATION
• Before operating, inspect the points that follow.

Caution:
· Become familiar with how to operate the
lawn mower and understand safety
instructions by reading this manual
carefully.
· Make sure that all safety covers and guards
are installed in position.
· Before operating the collector, be sure to
confirm that collector move up and down
smoothly. a. Make sure that the engine stops as soon as
· When operating the collector, be sure to operator starts to lift the container
confirm that hydraulic hose is not pulled (SBC600X-H) or dump the container
and interfered. (SBC550X-L) when the mower deck operating.
5
2. ADJUSTMENT OF THE GRASS LIMIT
SENSOR
a. Filler level of container depends on the Danger:
adjustment of the adjuster bolt (1). Safety switch prevents the blades from starting
during lifting the container (SBC600X-H) or
b. Check the buzzer of grass limit sensor. dumping the container (SBC550X-L) to keep
Turn the starter switch to the ON operator’s safety. Be sure to check that the safety
position (Do not start engine), and then system is normal.
move the PTO lever to the ON ( )
position. Be sure to check that the buzzer b. The container (SBC600X-H) dose not dump
sounds when pushing the sensor plate (3). until the container is lifted at the middle
position. Make sure that the door (1) of the
container (SBC600X-H) is locked by the lock
plate (2) until the container is lifted at the
middle position, when moving the container
dump lever backward.
(1) Adjuster bolt (3) Sensor plate

(2) Adjustment position label
(1) Door (2) Lock plate
Important:
Caution: Pay attention when moving the collector dump
After checking the buzzer, be sure to turn lever. If operator moves the collector dump lever
starter switch and PTO lever to OFF position. backward before moving the collector lift lever
backward with container located at the lowest
position, container (SBC600X-H) may hit the
lawn mower.
15
4. CLEANING A COLLECTOR
If net of container is clogged with grass, the

collecting power would go down. Clean the
net of container frequently.
Danger:
It is a danger to operate the lawn mower with
damaged rear net. Repair it or replace it with
a new one.
5. EFFICIENT COLLECTING
Important:
• Keep rear net of container clean always.
When mowing the wet or long grass, filling

rate of container would go down. Slow down
the lawn mower.
Adjust the grass limit sensor as a necessary

(refer to page).
Stop operating the lawn mower as soon as the

buzzer sounds and dump grass of container.
Danger:
Dump grass of container on level, hard
ground.
16

1. INSPECTION OF CYLINDER
(1) lock nut (2) adjust adapter
a. Cylinder of collector(SBC550X-L) can be

adjusted its length.
b. Adjust the length of cylinder so that its length

is the shortest with collector located lowest
position.
6
Caution:
· Container would be damaged by making length
of cylinder too longer.
Be careful to adjust its length.
2. INSPECTION OF HYDRAULIC HOSES
a. When operating the collector, be sure to

confirm that hydraulic hose is not pulled and
interfered.
b. When the hydraulic hose is damaged, exchange

it as soon as possible.
Danger:
It is danger to operate the lawn mower with
damaged hydraulic hose.
It may cause that collector falls or hydraulic
hose burst suddenly.
17
3. FILLING DIAGRAM
Grease up the points mentioned below periodically.
SBC600X-HQE4 (High dump collector)
SBC550X-LE4 (Low dump collector)
18
4. PERIODICAL INSPECTION TABLE
SBC600X-HQ and SBC550X-L

何 : Inspection, replenishment, and adjustment 伽 : Cleaning and washing
余 : Replacement 使 : Consult your dealer.
Inspection and servicing
operatio
Check points intervals (hours of operation) Intervals Judgement
after that criteria
Pre 50 100 150 200 250
Greasing points 何何何何何 Greas up after every 50hrs
Bolts and nuts 何
Pins and clips 何
Rear net 何
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.
6
19
5. STORING THE COLLECTOR
When the collector is to be stored for a long period of time, service the collector as mentioned below before
storing it.
a. Clean the collector. Take special care to remove grass and dirt from the container net.
b. Remove grass or other objects tangled around the link and hydraulic hose.
c. Remove all rust and touch up where paint has peeled off with touch-up paint supplied by ISEKI.
d. Be sure to replace all the removed parts.
e. Lost pins and clips should be replaced with new ones.
f. Check each part for damage and repair or replace damaged ones with new ones for the next operation.
Important:
Insist on ISEKI genuine parts when replacing.
g. Grease up all grease points.
h. All loose bolts and nuts should be tightened properly and lost ones should be replaced with new ones.
i. Store the collector in a dry place with wooden blocks placed under it and cover with tarpaulin or the like.
Caution:
When storing the collector installed on the lawn mower, be sure to lower it on ground to prevent
unexpected accidents caused by manipulation of the lift and dump lever by children or unauthorized
people.
20
CHAPTER 7. ASSEMBLY INSTRUCTION

1. SBC600X-LQE4 (High dump collector)
Assembly of Collector ASSY
1. Assemble FRAME/COLLECTOR SET,1 to the frame of the machine by tightening

BOLT/M12X25/7T(8pcs.),63 and WASHER/LOCK/M12(8 pcs.) ,65.
Tightening BOLT 7T/M12䡔䠎䠑
torque 79.4䡚93.1 N䞉䡉 810䡚950 䡇䡃䡂䞉䠿䡉
No Parts name Standards Pieces

䠄䠍䠅 FRAME/COLLECTOR SET 1
䠄䠍䠐䠅 TUBE/䠕䠎䠓 COMP 1
䠄䠍䠑䠅 SPRING/HE108 2
䠄䠑䠎䠅 BOLT/S/M10X20 M10X20 8
䠄䠒䠏䠅 BOLT 7T/M12䡔䠎䠑 M12X25 8
䠄䠒䠑䠅 WASHER/LOCK M12 8
2. Attach TUBE/927 COMP,14 to FRAME/COLLECTOR SET,1 by BOLT/S/M10X20 (8pcs.), 62.
Note:
The side of TUBE/927 COMP on which serial number plate should face forward.
3. Attach SPRING/HE108 ,15 to FRAME/COLLECTOR SET
21
4. Assemble the container box.

(9) PLATE/SENSOR/H SET 1
(10) FRAME/LH/H SET 1
(11) FRAME/RH/H SET 1
(21) FRAME/REAR COMP 1
(22) FRAME/LOWER COMP 1
(77) CONTAINER/FRONT SET 1
(61) BOLT/SP/M8x45/7T 7T 4
(72) NUT/WASHER/M8 12
(60) BOLT/SP/M8x16 M8X16 4
5. Temporally fix FRAME/LH/H SET,10 and FRAME/RH/H SET,11 to FRAME/LOWER COMP,

22 by BOLT/SP/M8x45/凩 T(4 pcs.) ,61.
Note:
As for FRAME/LOWER COMP, the side to which PLATE/SENSOR/H SET is attached should be front.
6. Temporally fix FRAME/REAR COMP, 21 by NUT/WASHER/M8, 72(4 pcs.).
7. Temporally fix CONTAINER/FRONT SET,77 by BOLT/SP/M8x16, 60(4 pcs.) and
NUT/WASHER/M8,72 (2 pcs.).
8. Temporally fix PLATE/SENSOR/H SET, 9 by 72 NUT/WASHER/M8, 72(6 pcs.)
Note:
Put the harness of PLATE/SENSOR/H SET, 9 through the holes of CONTAINER/FRONT COMP,20
FRAME/LOWER COMP, 22.
Note:
Check if all of the BOLTs and NUTs are fixed temporally, then fix them firmly.
Tightening BOLT 7T/M䠔䡔䠐䠑

4T bolt's torque to prevent the deformation of tube.
22

(23䠅 FRAME/COVER/LH COMP 1
(24䠅 FRAME/COVER/RH COMP 1
(37) PIN COMP 2
FRAME/REAR/UPPER
(25) COMP 1
FRAME/REAR/LOWER
(26) COMP 1
(28) NET/REAR 1
(61) BOLT/SP/M8x45/7T M8x45 8
(72) NUT/WASHER/M8 2
(55) BOLT/SP/M8x35 M8x35 3
(27䠅 COLLAR/12䡔20䡔41 2
(64) BOLT/M12X65 M12X65 2
(65) SW/M12 M12 2
(70) NUT/M12 M12 2 7
Tightening NUT/M12
torque 41.2䡚58.8 N䞉m 420䡚600 kgf䞉cm
9. Assemble FRAME/COVER/RH COMP to the upper part of FRAME/COVER/LH COMP,23 and

FRAME/COVER/R COMP,24 by BOLT/SP/M8x45/7T,61(4 pcs.).
10. And assemble FRAME/REAR/LOWER,26 to the lower part by BOLT/SP/M8x45/7T,61( 4pcs.).
*Fix the lower part also by PIN COMP,37 and adjust by slotted hole to be rightly locked
11. Assemble NET/REAR,28 by BOLT/SP/M8x35 ,55( 3pcs.) and NUT/WASHER/M8 ,72( 2pcs.).
Note:
Don't forget to assemble COLLAR/12x20x41,27.
Don't mistake FRAME/REAR/UPPER COMP,25 for FRAME/REAR/LOWER COMP,26.
Check if assembled FRAME/COVER COMP is swinging a bit by hands.
12. Get together assembled FRAME/COVER COMP with assembled FRAME/LH SET and FRAME/RH
SET.
23

(35) PLATE/U/819x25 1
(36) PLATE/U/819x25 2
(61) BOLT/SP/M8x35 M8x35 6
13. Attach PLATE/U/819x25 ,35 and

PLATE/U/819x25 ,36 to FRAME
COVER ASSY by
BOLT/SP/M8X35 ,61 (6 Pcs.).
Note:
PLATE/U/819x25 ,36 should not tilt upward
when tightening by bolts.

(5) BRACKET/LINK/LH SET 1
(6) BRACKET/LINK/RH SET 1
(69) WASHER/M16 M16 2
(66) SW/M16 M16 2
(71) NUT/M16 M16 2
tightening NUT/M16
14. Assemble BRACKET/LINK/LH SET ,5 and BRACKET/LINK/RH SET ,6 to CONTAINER

ASSY by WASHER/M16 ,69 , SW/M16 ,66 and NUT/M16 ,71.
Note:
Be aware of the assembly direction of BRACKET/LH SET and RH SET.
A pin welded on the brackets should face to the inner side of the container.
24

(8) CYLINDER/D/H SET 2
(43) PIN/16x61 2
(45) HOSE/HYDRO/2250 ASSY 4
(69) WASHER/M16 M16 2
(74) PIN/COTTER/3x30 3x30 2
(68) WASHER/M12 M12 2
(105) PIN/COTTER/3x25 3x25 2
tightening HOSE/HYDRO/2250 ASSY

16. Attach HOSE/HYDRO/凤凤凧凢 ASSY ,45 to CYLINDER/D/H SET ,8.

Note:
Distinguish RED taped hose and BLUE taped one.
17. Fix the upper part of CYLINDER/L/DUMP SET ,8 with PIN/凣凨刪凨凣 , 43
WASHER/M16 ,69 and PIN/COTTER/3x30 ,74. And fix the lower part with WASHER/M12 ,68
PIN/COTTER/凥刪凤凧 ,105.
Note:
Grease nipples of CYLINDER/D/H SET ,8 should face to the travel direction.
Unless or until the container is attached to the machine, cylinder should be assembled in the middle hole of
the bracket with pin. Fix the cylinder with a pin from top-to-bottom.
25

tightenin NUT/M12
(2) LINK/A SET 2 g torque 41.2~58.8 N䞉m 420~600 kgf䞉
(3) LINK/B SET 䠄LH䠃RH) 2
cm
(12) LINK/C SET 2
(81) FRAME/UPPER/LH SET 1
(82) FRAME/UPPER/RH SET 1
(27) COLLAR (12X20X41) 8
18. Attach LINK/C SET ,12 to a pivot of FRAME/COVER and BRACKET/LINK with
WASHER/M16 ,凨凫 and PIN/COTTER/3x30 ,74.
Note:
LINK/C SET should be fixed with PIN/COTTER/凥刪凥凢 from BRACKET/LINK side first.
Be aware of the assembly direction of LINK/C SET.
19. Place a wooden stand under the container. Check if PLATE/SENSOR/H SET doesn't touch the
ground.
20. Attach LINK/A SET ,2 and LINK/B SET ,3 to BRACKET/LINK SET LH/RH ,5,6.
21. Attach LINK/B SET凚 L/R凛 to FRAME/UPPER/SET ,81,82 so as it to be fixed outside of cable stay.
Be aware of the assembly direction of LINK/B SET.
22. Attach LINK/A SET ,2 to FRAME/UPPER/SET ,81,82. Be aware of the assembly direction of
LINK/B SET.
Note: Support the container by stands which should be put under both LH and RH sides of the container.
Note: Don't confuse FRAME/UPPER SET LH with FRAME/UPPER SET RH.
Note: COLLAR/12x20x41 ,27(7 pcs) should be inserted to each pivot of link with BOLT/M12x65,64
and then attach it to the container. BOLT/M12x65 ,64 should be inserted from outside and fix with
SW/M12 ,65 and NUT/M12 ,70.
26

(38) CABLE/LOCK 2
(39) BAR COMP 1
(40) PLATE/I/38x80 COMP 2
(64) BOLT/M12X65 M12X65 8
(65) SW/M12 M12 8
(67) WASHER/M6 M6 4
(70) NUT/M12 M12 8
(72) NUT/WASHER/M8 M8 4
(73) PIN/COTTER/2.5x20 2.5x20 4
23. Couple together LINK/B SET ,3 with BAR COMP ,39 7

Note: Attach PLATE/I/凥凪刪凪凢 ,40 COMP from outside and tighten it with LINK/B SET.
Note: When assembling BAR COMP ,39, the part winding like 'L' should be upward
凜Check if assembled link is swinging a bit on each pivot by hands.
24. Fix CABLE/LOCK ,38 with WASHER/M6 ,67 and PIN/COTTER/凤几凧刪凤凢 ,70.
凜 Hang hoses (4 pcs.) on TUBE/凫凤凩 COMP ,14
25. Put the container and link ASSY on collector base(OPT).

26. Assemble FRAME/UPPER SET ,81,82 to FRAME/COLLECTOR/SET
with PIN凚 16x65凛 COMP凚 4 pcs.凛 and PIN/HAIR凚 4 pcs.).
Note: Make sure that pins and corresponding holes are placed properly. If not, adjust the position of the
container by adjuster bolt.
27

CYLINDER/L/H SET 2
HOSE/HYDRO/ 4
tightening HOSE/HYDRO/ 250 ASSY

torque 34.3 39.2 N 350 400
27. Attach HOSE/HYDRO/ ASSY ,41 to the adapters of CYLINDER/L/H SET ,7.
Note:
Attach the hose with green taped to the adapter, the one with black taped to the adapter.

PIN/ 2
PIN/ 2
PIN/HAIR 2
WASHER/M12 M12 2
WASHER/M16 M16 2
PIN/COTTER/ 2
PIN/ 2
STAY/GUARD SET 2
GUARD/CYLINDER COMP 2
PIN/COTTER/3x25 3x25 2
28. Fix cylinder ASSY and LINK/B SET with inserting PIN/16 46 ,44 and fix it with
WASHER/M16 ,69 and PIN/COTTER/ ,74.
29. Fix the lower part of cylinder with inserting PIN/ ,43 and PIN/HAIR ,46.
30. Attach STAY/GUARD SET ,93 to the upper part of cylinder ASSY.
Note: Before above procedure, insert GUARD/CYLINDER COMP, 94 to the grommet part.
Note: Apply grease to the inside of grommet.
Note: make sure STAY GUARD SET ,93 is fixed around the cylinder.
31. Fix GUARD/CYLINDER COMP ,94 with inserting PIN/ ,91 and fix it with
WASHER/M12 ,68 and PIN/COTTER/ ,105.
28

䠄䠍䠒䠅 LOCK/LIFT SET 2
32. Attach LOCK/LIFT SET ,16 to FRAME/UPPER SET ,81, 82.

Note:
PIN/COTTER/凥刪凥凢 should be fixed from font.
Note:
Check if LOCK/LIFT moves smoothly.

䠄䠑䠎䠅 BAND/WIRE/䠎䠑䠌 4 7
䠄䠑䠏䠅 HARNESS/H ASSY 1
䠄䠓䠕䠅 BOLT/SP/M6X30 6
䠄䠔䠌䠅 NUT/WASHER/M6 6
䠄䠔䠒䠅 COVER/LINK/A 2
33. Join HARNESS/H ASSY ,53 to the connector of PLATE/SENSOR/H SET ,9.
34. Place the harness along the clampers welded on FRAME/LOWER COMP ,22.
35. Put the hose for dumping though COVER/LINK/A.
Note:
Clamp by BAND/WIRE/凤凧凢 ,52 with hoses (approx.250 mm from the pivot)
36. Attach COVERLINK/A ,86 by BOLT/SP/M6X30 ,79 and NUT/WASHER/M6 ,80.
Note:
Make sure that hose and harness doesn't twist in COVER/LINK/A. Clamp Hydraulic hose ,RH side of lift
cylinder, and HARNESS/H ASSY ,53 with BAND/WIRE /250 ,52.
Don't clamp with FRAME/COLLECTOR COMP.
29

䠄䠍䠅 FRAME/COLLECTOR SET 1
䠄䠍䠕䠅 SWITCH/LEVER ASSY 1
䠄䠑䠏䠅 HARNESS/H ASSY 1
䠄䠑䠕䠅 BOLT/SP/M6X20 M6X20 1
37. Attach SWITCH/LEVER ASSY ,19 with BOLT/SP/M6X20 ,59.

Note:
Clamp the harness linked with SWITCH/LEVER ASSY ,19 and plate on which SWITCH/LEVER ASSY ,19
is attached by BAND/WIRE/㸰㸳㸮 ,52 Maintain the harness of SWITCH/LEVER ASSY and HARNESS/H
ASSY ,53 in the clamper welded on FRAME/COLLECTOR SET ,1.
Don't clamp the parts that will separate when detaching the collector.
tightening HOSE/HYDRO/2250 ASSY

30

TUBE/ COMP 1
HOSE/HYDRO/ ASSY 4
HOSE/HYDRO/ ASSY 4
BOLT/SP/M X16 M8X16 4
BOLT/SP/M6X16 M6X16 8
COUPLER/ORIFICE/BLUE
ASSY 1
COUPLER/ORIFICE/RED
ASSY 1
COVER/CENTER/REAR SET 1
COVER/CENTER/FRONT SET 1
COVER/SIDE/LH COMP 1
COVER/SIDE/RH COMP 1
COUPLER/BLACK ASSY 1
COUPLER/GREEN ASSY 1
38.Temporarily assemble COVER/SIDE/LH COMP ,89 and COVER/SIDE/RH COMP by

BOLT/SPM8X16 ,60
39. Assemble COVER/CENTER/REAR SET ,87 by BOLT/SP/M6X16 ,76.
Then, tighten firmly COVER/SIDE/LH COMP ,89 and COVER/SIDE/RH COMP ,90.
Note:
Front bolt should be tightened with COVER/CENTER/FRONT SET ,88.
40. Hold the hoses on lift cylinder ASSY ASSY in GUARD/HOSE of FRAME/COLLECTOR SET ,1.
Note:
The hoses in the lower part of lift cylinder should be put deeply in the GUARD/HOSE and hoses in the upper
shallowly in the GUARD/HOSE. 7
41. Join COUPLER/ORIFICE/RED ASSY ,84 and HOSE/HYDRO/ ASSY , .
Note:
Join a hose with red colored tape to the one with red cap.
42. Join COUPLER/ORIFICE/BLUE ASSY ,83 and HOSE/HYDRO/ ASSY ,45.
Note:
Join a hose with blue colored tape and the one with blue cap.
43. Join COUPLER/GREEN ASSY ,103 and HOSE/HYDRO/ ASSY ,41.
Note:
Join a hose with green colored tape and the one with green cap.
44. Join COUPLER/BLACK ASSY ,102 and HOSE/HYDRO/ ASSY ,41.
Note:
Join a hose with black colored tape and the one with black cap.
45. Allocate hoses in the GUIDE PLATE welded on COVER/CENTER/REAR ,87.
Note:
Allocate HOSE/HYDRO/ ASSY ,45 behind TUBE/ COMP ,14.
Note:
Allocate hoses not violently to be twisted and not touch the sharp-edged part.
Note:
Allocate HOSE/HYDRO/ ASSY ,45 not to interfere with the pivot nut of lift arm with the collector
lowest position.
31
* In case of not use of the collector base (OPT), follow the instructions below.
a. If the hoist is not available;
1) Set wood pieces and stands as shown in illustration below, and put the container on the stands with wood
pieces.
2) Move lawn mower backward, and attach the UPPER FRAME SETS, 81 and 82 to the
FRAME/COLLECTOR SET, 1, by 4 pcs of PIN (16x65) COMP and 4 pcs of hair pin.
* If it is difficult to insert pin (16x65) COMP in the hole, try to reinsert the pin (16x65) COMP while
adjusting the height of stands with wood pieces and inserting the stick or screw driver in the hook of
UPPER FRAME SETS, 81 and 82.
b. If the hoist is available;

1) Set wood pieces under the container, and hang them by slings via these wood pieces. Make sure the
balance of container.
2) Set a wood piece between the linkages and upper frame sets, and hang it by sling via the wood piece.
Make sure the balance of container.
3) Lift up the container by hoisting the balance with slings. Attach the UPPER FRAME SETS,81 and 82 to
the FRAME/COLLECTOR SET, 1, by 4 pcs of PIN (16x65) COMP and 4 pcs of hair pin.
* If it is difficult to insert pin (16x65) COMP in the hole, try to reinsert the pin (16x65) COMP while
swinging the container and inserting the stick or screw driver in the hook of UPPER FRAME
SETS, 81 and 82.
32
[Hydraulic hose allocation]
[How to allocate pipes of CONTROL VALVE] 7
33

䠄䠐䠓䠅 ADAPTER/PF䠍/䠐 4
䠄䠐䠔䠅 PIPE/LIFT/A COMP 1
䠄䠐䠕䠅 PIPE/LIFT/B COMP 1
䠄䠑䠌䠅 PIPE/DUMP/A COMP 1
䠄䠑䠍䠅 PIPE/DUMP/B COMP 1
䠄䠔䠑䠅 GROMMET/10x18x20 4
䠄䠕䠎䠅 BOLT/SP/M8X25 M8X25 4
䠄䠕䠑䠅 STAY/COUPLER COMP 1
䠄䠕䠒䠅 COVER/COUPLER 1
䠄䠕䠓䠅 PLATE COMP 2
䠄䠍䠌䠐䠅 BOLT/S/M8X35 M8X35 2
tightening ADAPTER/PF䠍/䠐䠃PT䠍/䠐
46. At first, male coupler of above pat 83, 84 ,102, 103 and their adapter should be replaced to the above
parts 48, 49, 50, 51.
Note:
There are two types of Adapter: with orifice and without orifice
Attach adapter with orifice to PIPE DUMP/A COMP ,50 and PIPE DUMP/A COMP ,51.
Attach the one without orifice to PIPE/LIFT/A COMP ,48 and PIPE/LIFT/B COMP ,49.
Note:
It's difficult to distinguish between the above parts 48 and 50 , also 49 and 51.
So, put them on the level ground and judge by the difference that they are winding or not.
47. Remove plugs on the port in the machine 凚 A3傎 B3傎 A2傎 B2凛 and attach ADAPTER/PF1/4, 47.
48. Attach PIPE/LIFT/A COMP ,48 to PORT A2 so as the pipe of quick coupler to be vertical.
48. Attach PIPE/LIFT/B COMP ,49 to PORT B2 so as the pipe of quick coupler to be vertical.
48. Attach PIPE/DUMP/A COMP ,48 to PORT A3so as the pipe of quick coupler to be vertical.
48. Attach PIPE/DUMP/B COMP ,48 to PORT B3 so as the pipe of quick coupler to be vertical.
Note:
To tighten by spanner, attach pipes all the way back.
Put hoses to the control valve between
PIPE/LIFT/A COMP ,48 and PIPE/DUMP/A COMP ,50
and attach the above pipe 48 to 51.
34
52. Attach STAY/COUPLER COMP ,95 according to the

model.
53. Attach COVER/COUPLER ,95 by BOLT/SP/M8X25 ,92.
Note:
Be aware of the attachment place of STAY/COUPLER
COMP. It differs according to the model.
Note:
Adjust the corresponding holes of COVER/COUPLER and
quick coupler adapter. Then, fix firmly STAY/COUPLER
COMP.
54. Attach GROMMET/10X18X20, 85 to each
pipe(48,49,50,51) And then fix the pipes by PLATE
COMP ,97 and BOLT/S/M8X35 ,104.
Note:
GROMMET should be in the lowest end of ADAPTER.
Note:
Make sure PIPE is fixed properly by bolts.
55. Connect each COUPLER ASSY(83,84,102,104) to the
corresponding color label of caps.

䠄䠎䠕䠅 COVER/CONTAINER/FRONT 1
䠄䠏䠌䠅 COVER/CONTAINER/REAR 1
䠄䠏䠍䠅 COVER/CONTAINER/SIDE/LH 1
䠄䠏䠎䠅 COVER/CONTAINER/SIDE/RH 1
䠄䠏䠏䠅 BOLT/SP/M8X20䠄BLACK䠅 M8X20 17
䠄䠏䠐䠅 BOLT/SP/M8X40䠄BLACK䠅 M8X40 2
䠄䠓䠑䠅 GUIDE/REAR 1
䠄䠍䠌䠍䠅 WASHER/09x28x03 2
35
56. Attach COVER/CONTAINER/FRONT ,29 by BOLT/SP/M8X20凚 BLACK COLOR凛 ,33.

Note:
As for rear 3 fixing places, Fix together with COVER/CONTAINER/REAR ,30.
57. Fix the upper part of COVER/CONTAINER/REAR僔 with 34 BOLT/SP/MAX40凚 BLACK
COLOR凛 ,34 (2 pcs) and BOLT/SP/MAX20凚 BLACK COLOR凛 , 33 (3 pcs).
58. Attach COVER/CONTAINER/SIDE/LH ,31 and COVER/CONTAINER/SIDE/RH ,32

by BOLT/SP/M8X20凚 BLACK COLOR凛 ,33.
Note:
Fix GUIDE/REAR ,75 together with the lower part of COVER/CONTAINER/REAR,30.(3places.)
Note:
WASHER/凢凫刪凤凪刪凢凥凥処 ,101 should be inserted with BOLT/SP/M8X40 (2 places).
59. Insert BAR ,18 to COVER/CENTER/FRONT SET ,88.

Note:
Let BAR ,18 touch the stopper to prevent it falling off.
60. Attach 凾凳凴凷凾 /凾击凸分 /出 ,58 to the groove of lever guide.
Note:
Clean up the place where the label will be attached before attaching it.
61.Start the engine with idling and lift the collector, then pull out the collector base(OPT).
36
* In case of not use of the collector base (OPT),

61-1. Start the engine with idling and move the lawn mower forward, and then remove the stands and
wood pieces from under the container.
62. Loosen BOLT/SP/M12X25. Let the collector be close to the flame and fix again. with lift cylinder pin
and cam comp pulled down.
Note:
Fix the outer and inner cam with the same height.
Note:
If the collector is already close to the flame, loosen BOLT/SP/M12X25 and make sure there is no play in the 7
cylinder. Then, fix again with cam comp pulled down
62. Attach WEIGHT/凤凢 ,98 to the chassis COMP by BOLT/M12x90 ,99 and SW/M12 ,65
and also WASHER/13x32x3 ,100.
37
Note:
Check if neither hydraulic hoses and harnesses touch nor get close to the rear tire.
63. Operation check
Turn the key swath to 'ON' position. Shift PTO lever to ON position and push PLATE/SENSOR/H
SET ,9.
Then check if the horn sounds.(This is the confirmation of grass limit sensor.凛
Start the engine and shift PTO lever to ON position with the collector kept lifted. Then check if the
engine stops.
Make sure dumping doesn't work even if you operate the dump lever with the collector down.
Note:
If not, check the harness, switches and hoses are properly assembled
64. Increase the engine rev. from 1800 to 2000 RPME and evacuate the air in the pipe by repeating the
lifting and dumping operation a number of times.
65. Check oil level of the transmission. If it is not good, add some oil.
38
2. SBC550X-LE (Low dumpcollector)

Assembly of Collector ASSY
1) Attach the STAY/CYLINDER COMP (21) to the

rear frame of the lawn mower, and tighten 4 pcs of
BOLT/7T (36) and 4 pcs of WASHER/LOCK/M12
(37).
No. PARTS NAME QTY

21 STAY/CYLINDER COMP 1
36 BOLT 7T/M1䠎X䠎䠑 4
37 WASHER LOCK䠋M12 4
No. PARTS NAME QTY

1 FRAME SET 1
4 SPRING/HE䠍䠌䠔 2
36 BOLT 7T/M䠍䠎䡔䠎䠑 8
37 WASHER LOCK䠋M12 8
2) Attach 2pcs of SPRING/HE108 (4) to the FRAME

SET (1).
3) Attach the FRAME SET (1) to the lawn mower, and
tighten 8 pcs of BOLT/7T (36) and 8 pcs of 7
WASHER/LOCK/M12 (37).
4) Attach the COVER/SUB ASSY (9) to the

FRAME/UPPER ASSY (8), and tighten 3 pcs of
NUT/WASHER/M6 (39).
5) Attach the FRAME/UPPER ASSY (8) to

FRAME SET (1). Pass the PIN/20X410 COMP
(7) through PLATE/HOOK (43) and fix them by
1pc of NUT/WASHER/M8 (40).
No. PARTS NAME QTY

8 FRAME/UPPER ASSY 1
9 COVER/SUB ASSY 1
39 NUT/WASHER/M6 3
7 PIN/䠎䠌䡔䠐䠍䠌 COMP 1
43 PLATE/HOOK 1
40 NUT/WASHER/M䠔 1
39
6) Attach the FRAME/SIDE/LH COMP (10) and

FRAME/SIDE/RH COMP (11) to the
FRAME/UPPER ASSY (8), and tighten BOLT/S/7T (35).
Note:
Make sure that the FRAME/SIDE/LH COMP (10) and
FRAME/SIDE/RH COMP
(11) do not attach to opposite sides.
No. PARTS NAME QTY

10 FRAME/SIDE/LH COMP 1
11 FRAME/SIDE/RH COMP 1
35 BOLT/S/䠓T/M䠌8x35 4
7) Attach the PLATE/SENSOR SET (3) to the FRAME/LOWER

COMP (13), and tighten
2 pcs of the NUT/WASHER/M8 (40).
Note:
Pass the harness of PLATE/SENSOR SET (3) through the hole of
FRAME/LOWER COMP (13).
No. PARTS NAME QTY

13 FRAME/LOWER COMP 1
3 PLATE/SENSOR SET 1
8) Attach the FRAME/LOWER COMP (13) to

FRAME/SIDE/LH COMP (10) and
FRAME/SIDE/RH COMP (11), and tighten 4 pcs of
BOLT/SP/7T (34).
40
9) Attach the FRAME/REAR COMP (12) to

BOLT/SP/7T (34).
10) Attach the PLATE/COVER/FRONT COMP (19) to
NUT/WASHER/M8 (42).
No. PARTS NAME QTY

10 FRAME/SIDE/LH COMP 1
11 FRAME/SIDE/RH COMP 1
12 FRAME/REAR COMP 1
34 BOLT/SP/䠓T/M䠌8x40 8
19 PLATE/COVER/FRONT COMP 1
11) Attach the top hole of CYLINDER/L SET (2) to FRAME/UPPER ASSY (8) by the PIN/16X65 COMP (24) and
PIN/SNAP (25).
12) Attach the lower hole of CYLINDER/L SET (2) to hole of STAY/CYLINDER COMP(21) by the PIN/16X65 (23),
WASHER/M16 (38) and PIN/COTTER (41).
Note:
It is possible to attach the PIN/16X65 (23) and PIN/16X65 COMP (24) from either left side or right side.
Note:
Attach the PIN/16X65 COMP (24) as shown in the left illustration, and make sure that the CYLINDER/L SET(2) does not
rotate when it moves.
No. PARTS NAME QTY
2 CYLINDER/L SET 1
24 PIN/䠍䠒䡔䠒䠑 COMP 1 7
25 PIN/SNAP 1
23 PIN/䠍䠒䡔䠒䠑 COMP 1
38 WASHER/M16 1
41 PIN/COTTER/䠏䡔䠏䠌 1
Note:
If the door of collector ASSY does not close completely
after attaching the CYLINDER/L SET (2), adjust the
length of NUT/CYLINDER (2-2) by loosening NUT (2-1).
Note:
The attaching hole of STAY/CYLINDER COMP (21) is
different from the kind of the lawn mower.
No. PARTS NAME QTY
6 SWITCH/LEVER ASSY 1
33 BOLT/SP/M䠌䠒䡔䠎䠌 1
28 HARNESS/L ASSY 1
SXG19, SXG22 A
SXG323, SXG326 B
41
13) Attach the SWITCH/LEVER ASSY (6) to

FRAME SET (1), and tighten BOLT/SP
(33).
14) Attach the HARNESS/L ASSY (28).
Note:
When attaching the HARNESS/L ASSY (28),
make sure to clamp the HARNESS/L ASSY
(28) to as shown in the circle marks of
illustration below, in order to not damage the
harness when operating the collector.
15) Connect the coupler from the lawn mower

and HARNESS/L ASSY (28).
16) Insert the NET/REAR (14) between the FRAME/SIDE/LH COMP (10) and FRAME/SIDE/RH COMP (11).
No. PARTS NAME QTY

14 NET/REAR 1
42
17) Attach the COVER/REAR (16) and

PLATE/REAR COMP (20) to
COVER/FRONT (15), and tighten 3 pcs
of BOLT/SP/M08X20 (17)
18) Attach the COVER/FRONT (15) to the top

of the container, and tighten 4 pcs of
BOLT/SP/M08X20 (17).
19) Fix the top of the COVER/REAR (16) by

2 pcs of BOLT/SP/M8X40 (18), and the
rear of the COVER/REAR (16) by 3 pcs of
BOLT/SP/M8X20 (17), with putting
GUIDE/REAR (42).
No. PARTS NAME QTY

18 BOLT/SP/M08x䠐䠌 2
42 GUIDE/REAR 1
17 BOLT/SP/M08x20 3
20) Attach the HOSE/HYDRO/650 ASSY (22) to CYLINDER/L SET (2).

21) Attach 2 pcs of ADAPTER/G1/4 (26) to the "A3" and "B3"ports of valve ASSY.
22) Connect the HOSE/HYDRO/650 ASSY (22) to the top adaptor of CYLINDER/L SET (2) with "B3" port, and the
lower adaptor with "A3" port.
Note:
When connecting the HOSE/HYDRO/650 ASSY (22) to ports, pay attention to the connecting positions.
Note:
Fix the HOSE/HYDRO/650 ASSY (22) by BAND/250 (27).
No. PARTS NAME QTY

2 CYLINDER/L SET 1
22 HOSE/HYDRO/䠒䠑䠌 ASSY 2
26 ADAPTER/G1/4 2
27 BAND/䠎䠑䠌 5
43
23) Insert the BAR (5) in the pipe of FRAME SET (1).
No. PARTS NAME QTY

5 BAR 1
24) Stick the ORNAMENTS (29)

(30) and LABEL/LIFT/L (32) as
shown in the illustration below.
Be sure to clean up the surfaces
before sticking.
No. PARTS NAME QTY

29 ORNAMENT/SBC550/LH 1
30 ORNAMENT/SBC550/RH 1 25) Grease up points (the circle marks of illustration
32 LABEL/LIFT/L 1 below) the CYLINDER/L SET (24) and
FRAME/UPPER ASSY (8).
Note:
Make sure that the hydraulic hose and harness are not
pulled or interfered to rear tires when all parts for the
collector ASSY are attached to the lawn mower. 26) Test
the operation of the collector ASSY.
a. Start the engine, and make sure that the collector
ASSY operates normally when moving the collector
lift lever.
b. Make sure that the buzzer of the grass limit sensor
sounds when turning the starter switch to the ON
position (Do not start the engine), moving the PTO
lever to the ON position, and pushing the
PLATE/SENSOR SET (3).
c. Make sure that the engine stops when starting the
engine and moving the PTO lever to the ON position
with opening the door of container.
Important:
If above test does not operate normally, make sure that
the harness and switch are connected surely.
44
3. Assembly position of the PLATE/HOOK (43)

όFor assembly, refer to "ASSEMBLY INSTRUCTIONS FOR HOOK OF DUMP CYLINDER
(SBC550X)".
No. PARTS NAME
7 PIN/䠎䠌䡔䠐䠍䠌 COMP
43 PLATE/HOOK
1) Assembly when attaching the collector ASSY
2) Assembly when detaching the collector ASSY
Note:
Connect the PIN/20x410 COMP (7) and CYLINDER/L SET (2) by PLATE/HOOK (43).
Note:
7
The removed parts when detaching the collector ASSY can be set to the lawn mower.
Pay attention to the loss of the removed parts.
4. Completion Drawing of Collector ASSY
45
46
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47
48
SXG323
SXG326
SCMB48
SCMA54
SBC550X
SBC600X
Overseas Business Division

5-3-14, Nishi-Nippori, Arakawa-ku,
Tokyo 116-8541, Japan
Phone: (03) 5604-7658
Fax: (03) 5604-7703
SM-SXG326/-EN-10
1203-01-300
Printed in Japan

Lawn Mowers - Mower Decks - SCMB48 & Scma54 Collectors - SBC550X & 600X

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Lawn Mowers - Mower Decks - SCMB48 & Scma54 Collectors - SBC550X & 600X

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LAWN MOWERS:

SCMB48 & SCMA54

SBC550X & 600X

ISEKI LAWN MOWERS CHAPTER 11

SXG323 & 326 CHAPTER 12

TOTAL CONTENTS .......................................................................................................................... 2

TABLE OF CONTENTS .................................................................................................................... 5

CHAPTER 1. GENERAL INFORMATION ...................................................................................... 11

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS .......................................................... 17

CHAPTER 3. ENGINE ACCESSORIES ......................................................................................... 27

CHAPTER 4. ENGINE .................................................................................................................... 33

3.3.3. INSPECTION OF CYLINDER BLOCK,CRANKSHAFT, CAMSHAFT,

CHAPTER 5. LUBRICATION SYSTEM .......................................................................................... 67

CHAPTER 6. COOLING SYSTEM.................................................................................................. 73

CHAPTER 7. FUEL SYSTEM ......................................................................................................... 75

2.3. INSPECTION .................................................................................................................... 79

CHAPTER 8. TRANSMISSION AND RELATED PARTS ............................................................... 87

CHAPTER 9. REAR AXLE ............................................................................................................. 93

CHAPTER 10. HYDROSTATIC TRANSMISSION .......................................................................... 95

4.11. PRECAUTIONS AFTER INSTALLATION OF HST UNIT .............................................. 113

CHAPTER 11. HYDRAULIC SYSTEM ......................................................................................... 117

CHAPTER 12. POWER STEERING SYSTEM ............................................................................. 121

CHAPTER 13. ELECTRICAL ACCESSORIES ............................................................................ 127

CHAPTER 1. GENERAL INFORMATION

Model SXG 326 H SXG 323 H

Wheel base 1450 mm (57.1 in.) 1365 mm (53.7 in.)

4. PERIODIC INSPECTION TABLE

c:Inspection, replenishment, and adjustment U:Cleaning and washing

Ref.No Filling points Lubricants Quantity: litre (imp.gal)

3 Transmission case HST OIL(SHELLDONAX TD) 8.0 (1.76)

4 Chain case (RH) Gear oil (SAE80) 1.1 (0.24)

CHAPTER 2. DISASSEMBLY OF MAJOR COMPONENTS

1.1. BEFORE OPERATION 1.2. PRECAUTIONS TO BE FOLLOWED WHEN

a. Always be safety-conscious in selecting clothes a. Roller or ball bearings

• Use a lithium-based grease.

• There should be no oil or water leaks through the

• Installed snap-rings should be seated securely in

• Be careful not to overload the snap-ring to the Fig. 2-3

• When locking bolts and nuts with an adhesive, apply

•Apply an adhesive (THREE BOND TB1104) to parts

• Each lock nut must be tightened securely.

• Be sure not to damage any finished surfaces or

•Always refrain from forcing installation.

• Each contact surface should be coated with an 2

2. DISASSEMBLY OF FUNCTIONAL BLOCKS

2.1. REMOVAL OF THE MOWER DECK

(9) Depress the discharge cover.

(10) Remove the mower deck sideways from left side

(4) Disconnect the linkage from the mower deck.

2.2. DETACHING THE COLLECTOR

2.3. REMOVAL OF MAJOR FUNCTIONAL

Fig. 2-13 (3) Remove the HST pedal and step.

2.3.4. REMOVAL OF RADIATOR

2.3.3. REMOVAL OF STEERING HEEL,METER

2.3.5. REMOVAL OF ENGINE

Fig. 2-21 Fig. 2-24

2.3.6. REMOVAL OF REAR AXLE CASE

2.3.7. REMOVAL OF TRANSMISSION CASE

Fig. 2-27 Fig. 2-29

(1) Disconnect the hose of steering cylinder.

(4) Disconnect the brake linkage from transmission

(5) Disconnect the drive shaft from transmission case.

(6) Disconnect the HST linkage from transmission

&IG - The front PTO ciutch control wire should be

)NSPECTION OF OIL TIGHTNESS OF VALVE SEATS

)NSPECTION AND ADJUSTMENT OF INJECTION

(1) Bring the piston in No.1 cylinder to TDC in &IG

)NSPECTION OF COMPRESSION (1) Check for idling speeds.

(1) Remove the injection pipes. 3PECIFIED VALUE ± RPM

)NSPECTION OF THE PUMP AND PULLEY

)NSPECTION OF THE BEARING UNIT

&ULL OPEN °# °&

&IG %XPLODED VIEW OF CYLINDER HEAD