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Jacobsen
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GP400
Jacobsen GP400 Service Manual
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W
ARNING
GB
United
Kingdom
SAFETY
, OPERAT
ION
& MAIN
TENAN
CE MANU
AL
A SIGNATURE CUT, TRUSTED FOR OVER 100 YEARS
W
ARNING:
If incorrectly used this machine can cause severe injury
. Those who use and maintain this machine must
be trained in its proper use, warned of its dangers and must read the entire manual before attempting to set up,
operate, adjust or service the machine.
10015205-A
RJL AGCD
Jacobsen GP400™ Ride on
Greens Mower
CA
T
® - C0.7 Diesel
GP400 Diesel (CA
T
® - C0.7)
Series: DDE / Product code:USA
D004E
2
Table of Contents
1.1 IMPORTANT
5
1.2 production identification
6
A. Maximum front axle load in Kg (for machines being driven on the highway)
6
B. Unladen weight, (No cutting implements or fuel (mass) in Kg
6
C. Maximum rear axle load in Kg (for machines being driven on the highway)
6
D. Power in Kw
6
E. Date code
6
F. Machine type (Designation)
6
G. Product code
6
H. Product name
6
I. Serial number
6
A. Weight of ROPS
7
B. Date Code
7
C. Standard Used
7
D. Part Number
7
E. Used on Product
7
F. Serial Number
7
1.3 GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS
8
1.3.1 DURING SERVICE LIFE
8
1.3.2 END OF SERVICE LIFE
8
1.4 parts manual
9
1. Website – www.jacobsen.com and select the “FIND A MANUAL” tab at the top, search our catalogue of current Jacobsen Turf Equipment for parts, and product information. Search by product name to access PDF version of the parts manual.
9
1.5 KEY NUMBERS
9
NOTES
10
2.1 how to operate safely
11
WARNING
11
2.2 SAFE OPERATION
11
A. Read the Operator’s Manual and other training material. If the operator or technician can not read this manual, the owner is responsible to describe this material to the operators and technicians. Manuals in additional languages may be available...
11
B. Read all of the instructions for this mower carefully. Know the controls and the correct operation of the equipment.
11
C. Children or persons who do not understand these instructions must not use the mower. The local regulations can limit the age of the operator.
11
D. Never use a mower near persons, including children or animals. — Parts could be ejected from the machine at high speed in certain circumstances. The hazard area, particularly in front of and behind the machine, must be cleared of any persons, an...
11
E. Any use of the machine without verification of the hazard area can lead to serious or fatal accidents.
11
F. Remember that the operator or owner is responsible for accidents or hazards that occur to other persons or their property.
11
G. Never carry passengers.
11
H. Never allow persons to operate or service the mower or its attachments without correct instructions.
11
I. Do not operate equipment while tired, sick or whilst under the influence of alcohol or drugs.
11
2.3 PREPARATION
11
A. When you operate the mower, wear correct clothing, slip resistant work shoes or boots, work gloves, hard hat, safety glasses and hearing protection. Long hair, loose clothing or jewelry can be caught in moving parts.
11
B. Do not operate the equipment with the Interlock System disconnected or the system does not operate correctly. Do not disconnect or prevent the operation of any switch.
11
C. Never operate equipment that is not in correct order or without decals, guards, shields, deflectors or other protective devices fastened. When you mow with a side discharge deck, DO NOT operate the cutting unit without the discharge chute installed.
11
D. Inspect the mower before you operate the mower. Check the tyre pressure, engine oil level, the radiator coolant level and the air cleaner indicator. Fuel is flammable. Use caution when you add the fuel to the mower.
11
E. Operate the mower in daylight or in good artificial light. Use caution when you operate the mower during bad weather. Never operate the mower with lightning in the area.
11
F. Inspect the area to select the accessories and attachments that are needed to correctly and safely do the job. Only use parts, accessories and attachments approved by Jacobsen.
11
G. Be careful of holes in the terrain and other hazards that are not visible.
11
H. Inspect the area where the equipment is operated. Remove all objects you can find before you operate. Be careful of obstructions above the ground (low tree limbs, electrical wires) and also underground obstacles (sprinklers, pipes, tree roots). En...
11
I. Inspect the cutting system before you start the mower. Make sure the blades are free to rotate. When you rotate one blade, other blades can rotate.
12
2.4 OPERATION
12
A. Never operate the engine without enough ventilation or in an enclosed area. The carbon monoxide in the exhaust fumes can increase to dangerous levels.
12
B. Never carry passengers. Keep other persons or animals away from the mower.
12
C. Disengage all drives and engage the park brake before you start the engine. Only start the engine with the operator in the seat. Never start the engine with persons near the mower.
12
D. Keep your legs, arms and body inside the operator compartment while the mower is in operation. Keep your hands and feet away from the cutting units.
12
E. Do not use on the slopes greater than the safe slope limit for the equipment.
12
F. To guard against over turning or loss of control:
12
G. When you drive in the reverse direction, look behind you and down to make sure the path is clear. Do not operate the cutting units when you drive in the reverse direction.
12
H. Use caution when you go near corners, trees or other objects that can prevent a clear view.
12
I. Equipment must meet the current regulations to be driven on the public roads.
12
J. Before you move across or operate on the paths or roads, turn off the PTO switch, lift the mowers and travel at decreased speed. Look for traffic.
12
K. Stop the blades when the mower is on any surface that is not grass.
12
L. Do not release the cut grass in the direction of persons or allow persons near the mower while in operation.
12
M. Do not operate the mower with damaged guards or without safety devices in position.
12
N. Do not change the engine governor setting or over-speed the engine. Never change or tamper with adjusters that are closed with a seal for the engine speed control.
12
O. Before you leave the operator compartment, for any reason:
12
P. When you hit an object or mower starts to cause the vibration that is not normal, inspect the mower for damage and make repairs.
12
Q. Decrease the throttle setting before you stop the engine.
12
R. Do not use this equipment for uses that the mower was not made for.
12
S. The machine and its cutting units are designed for use on maintained turf surfaces. Use of the machine with its cutting units engaged on hard and rough surfaces could rapidly decrease design life of components and potentially cause acute damage to...
12
2.5 ROPS AND CABIN
12
A. The ROPS/Cabin is a safety device. Keep the ROPS in the vertical and locked position. Always use the seat belt when you operate the mower. Make sure the seat belt can be released quickly in an emergency.
12
B. Only operate the mower with the ROPS in the folded position on flat and level surfaces when necessary. Do not operate the mower with the ROPS in the folded position on slopes, near sharp edges or near water. On a ROPS machine there is no roll over...
13
C. Check for clearance before you drive below objects. Do not contact tree branches, electrical wires or other objects with the ROPS/Cabin.
13
D. Do not use the seat belt with the ROPS in the folded position.
13
E. Inspect the ROPS/Cabin for damage. Keep hardware fastened.
13
F. Do not weld, drill, change or bend the structure. Replace a damaged ROPS/Cabin. Do not try to correct a damaged ROPS/Cabin frame.
13
G. Do not remove the ROPS/Cabin from the mower other than for maintenance access. Ensure to refit before use.
13
H. Ransomes Jacobsen must approve any changes to the ROPS/Cabins.
13
2.6 SAFE HANDLING OF FUELS
13
A. The fuel and the fuel vapors are flammable. Use caution when you add the fuel to the mower. The fuel vapors can cause an explosion.
13
B. Never use the containers that are not approved to keep or transfer fuel.
13
C. Never keep the mower or fuel containers near an open flame or any device that can cause the ignition of fuel or fuel vapors.
13
D. Never fill the fuel containers inside a vehicle or on a truck or trailer with a plastic liner. Always put the fuel container on the ground away from your vehicle before you fill the container.
13
E. Refuel the mower before you start the engine. When the engine is in operation or while the engine is hot, never remove the fuel cap or add fuel to the mower.
13
F. Refuel outdoors only and do not smoke when you add fuel. Extinguish all types of ignition.
13
G. The fuel nozzle must touch the rim of the fuel tank when you add fuel to the mower. Do not use a device to lock the fuel nozzle in the open position.
13
H. Do not over fill the fuel tank. Leave at least 1 inch (25 mm) below the filler neck.
13
I. Always tighten the fuel tank cap and container cap after you add fuel.
13
J. If the fuel spills on your clothing, change your clothing immediately.
13
2.7 MAINTENANCE AND STORAGE
13
A. Before you clean, adjust or repair this equipment, push PTO switch to the OFF position, lower the cutting unit to the ground, engage the park brake, stop the engine and remove the key.
13
B. Make sure the mower is parked on a solid and level surface.
13
C. Never work on a mower that is lifted only by a Jack. Always use Axle stands.
13
D. Never allow persons to service the mower or its attachments without correct instructions.
13
E. When the mower is parked, put into storage or left without an operator, lower the cutting device unless a positive mechanical lock is used. - Do not keep fuel near flames or drain the fuel inside a building.
13
F. Disconnect the battery before you service the mower. Always disconnect the negative battery cable before the positive battery cable. Always connect the positive battery cable before the negative battery cable.
13
G. Charge the battery in an area with good airflow. The battery can release hydrogen gas that is explosive. To prevent an explosion, keep any device that can cause sparks or flames away from the battery.
13
H. Disconnect the battery charger from the power supply before you connect or disconnect the battery charger to the battery. Wear protective clothing and use insulated tools when you service the battery.
13
I. Be careful and wear gloves when you check or service the cutting unit blades. Replace any damaged blades, do not try to correct a damaged blade.
13
J. Keep your hands and feet away from parts that move. Do not adjust the mower with the engine in operation, unless the adjustment needs the engine in operation.
14
K. Take care working on cutting units and moving parts with stored energy.
14
L. To prevent injury from the hot, high pressure oil, never use your hands to check for oil leaks. Use paper or cardboard to find leaks.
14
M. The hydraulic fluid pressure can have enough force to enter your skin. If hydraulic fluid has entered your skin, seek medical attention immediately.
14
N. When you service the hydraulic system, make sure the hydraulic fittings, tubes and hoses are tightened to the correct torque (where applicable). Make sure the hydraulic system is in good condition before you start the engine.
14
O. Keep the mower and the engine clean.
14
P. Allow the engine to become cool before storage and always remove the ignition key.
14
Q. Keep all nuts, bolts and screws tight to make sure the equipment is in safe condition.
14
R. DO NOT operate the machine if you have worn or damaged parts for safety. Replace damaged or worn decals. Only use parts, accessories and attachments approved by Ransomes Jacobsen.
14
S. To decrease the fire hazard, remove materials that burn from the engine, muffler, battery tray and fuel tank area.
14
T. Disconnect the battery and controller connectors before you weld on this mower.
14
2.8 WHEN YOU PUT THE MOWER ON TO TRAILER
14
A. Be careful when you load or unload the mower on a trailer. The trailer must be wider than the mower and can carry the weight of the mower.
14
B. Use a full-width ramp to load or unload the mower on a trailer.
14
C. Use appropriate securing methods to fasten the mower to the trailer. Both front and rear straps must be sent down and towards the sides of trailer.
14
D. Make sure that all latches are correctly fastened.
14
2.9 IMPORTANT SAFETY NOTES
15
WARNING
15
WARNING
15
WARNING
16
WARNING
16
WARNING
16
WARNING
16
WARNING
16
WARNING
16
WARNING
17
WARNING
17
CAUTION
17
CAUTION
17
3.1 ENGINE SPECIFICATION
18
CAT® - C0.7
18
Cycle
18
4 stroke
18
Number of Cylinders
18
3
18
Bore & Stroke
18
67mm x 68mm (2.64 in) - 72mm (2.83 in)
18
Displacement
18
0.762 Litres (46.5 in³)
18
Compression ratio
18
22.1:1
18
Gross Intermittent Power
18
13.3kW (17.8hp) @ 3600rpm
18
Maximum Speed:
18
3400 ± 50 RPM (No load)
18
3500 ± 50 RPM (No load)
18
Idle Speed:
18
1700 ± 100 RPM
18
1800 ± 50 RPM
18
Order of Firing
18
1-2-3
18
Direction of Rotation
18
Counter-clockwise (viewed from flywheel side)
18
Injection Pump
18
Bosch MD type mini pump
18
Injection Pressure
18
13.73 MPa (140kgf/cm²)
18
Injection Timing (Before T.D.C.)
18
21°
18
20°
18
Compression Ratio
18
23.5:1
18
Fuel:
18
No. 2-D Diesel fuel (ASTM D975)
18
Lubrication (API Classification)
18
Above CF grade
18
Oil Sump Capacity:
18
Maximum: 3.05 Litres / 5.36 pints - Minimum: 2.35 Litres / 4.13 pints
18
Dimensions (length x width x height)
18
480mm (18.9 in) x 371mm (14.6 in) x 528mm (20.8 in)
18
Dry Weight
18
71kg
18
Starting System
18
Cell starter (with glow plug)
18
Standard Starting Motor cold start limit
18
-20°C - (-4°F)
18
3.2 DIMENSIONS & weights
19
A
19
Width of Cut:
19
160 cm
19
63 inches
19
B
19
Overall Width Cutting:
19
188 cm
19
74 inches
19
Overall Width Transport (minimum):
19
186 cm
19
73.25 inches
19
C
19
Overall Height with ROPS Frame:
19
196.5 cm
19
77.38 inches
19
D
19
Overall Length Without Grass Boxes:
19
219 cm
19
86.2 inches
19
E
19
Overall Length With Grass Boxes:
19
250 cm
19
98.4 inches
19
F
19
Wheel Track:
19
121.7 cm
19
48 inches
19
G
19
Wheel Base 2 Wheel Drive:
19
133.2 cm
19
52.44 inches
19
G
19
Wheel Base 3 Wheel Drive:
19
125.5 cm
19
49.5 inches
19
H
19
Turning Circle 2 Wheel Drive:
19
368 cm
19
144.88 inches
19
H
19
Turning Circle 3 Wheel Drive:
19
393.8 cm
19
155 inches
19
Weight of Diesel Machine, No Fuel, Plus ROPS:
19
590kg
19
1390 lbs
19
Weight of one Cutting Unit 11 Knife
19
31.6 kg
19
69.6 lbs
19
Weight of one Brush & Groomer Kit:
19
7 kg
19
15.4 lbs
19
TYRE PRESSURE
20
Product
20
Front Wheel
20
Rear Wheel
20
Tyre Size
20
Tyre Type
20
Tyre Pressure
20
Tyre Size
20
Tyre Type
20
Tyre Pressure
20
GP400
20
20 x 10.00 - 10
20
OTR Smooth
20
0.7 bar
20
(10 psi)
20
20 x 10.00 - 10
20
OTR Smooth
20
0.7 bar
20
(10 psi)
20
3.3 MACHINE SPECIFICATION
20
Cutting unit drive: Direct Drive hydrostatic reel drive pump, bi-directional hydraulic gear motor with reel control and Backlap valves.
20
3.4 VIBRATION LEVEL
21
The machine was tested for hand/arm vibration levels. The operator was in the normal position to drive the vehicle, with two hands on the steering mechanism. The engine was in operation and the cutting device was in rotation, while the machine was no...
21
The Machinery Safety Directive 2006/42/EC
21
By compliance to:
21
The Lawnmower Standard BS EN ISO 5395
21
Referenced to Hand/Arm: BS EN ISO20643:2008
21
Information Supplied for Physical Agents Directive 2002/44/EC
21
By reference to:
21
Hand/Arm Standards: BS EN ISO 5349-1 (2001)
21
BS EN ISO 5349-2 (2002)
21
The machine was tested for Whole Body vibration levels. The operator was in the normal position to drive the vehicle, with two hands on the steering mechanism. The cutting device was in rotation with the machine driven in a straight line at 6 Km/hr o...
21
The Machinery Safety Directive 2006/42/EC
21
By compliance to:
21
Whole Body EN1032:2003
21
Information Supplied for Physical Agents Directive 2002/44/EC
21
By reference to:
21
Whole Body Standards BS EN ISO 2631-1 (1997)
21
measurements according to the requirements of BS EN ISO 5395
21
3.5 NOISE Level
22
When the machine was tested for sound power (Noise in the Environment).
22
3.6 SLOPES
22
DO NOT USE ON SLOPES GREATER THAN 16°. The 16° slope was calculated using static stability measurements according to the requirements of BS EN ISO 5395-2013
22
3.7 Cutting unit SPECIFICATION
23
NOTE: These cutting units are designed to cut grass of maximum height 12mm (15/32 in) down to the available height of cut range, removing no more than 1mm (3/64 in) to 2mm (5/64 in) with each pass.
23
3.8 CUTTING PERFORMANCE
24
3.9 RECOMMENDED LUBRICANTS
24
TEMPERATURE
24
VISCOSITY
24
Above 4°C (39°F)
24
SAE30
24
Below 4°C (39°F)
24
SAE5W-30 or SAE10W-30
24
3.10 ACCESSORIES
24
22 in. Segmented Roller 68673
24
NOTES
25
4.1 decals
26
4.2 INSTRUCTION DECALS
28
NOTES
29
5.1 Operator Workstation
30
5.2 INSTRUMENT PANEL
31
5.2.A STARTER KEY SWITCH
32
NOTICE
32
5.2.B THROTTLE CONTROL LEVER
32
5.2.C CUTTING UNIT SWITCH (pto)
32
5.2.D JOYSTICK
33
5.2.E working lights
33
5.2.F engine coolant temperature
33
5.2.G hour meter
33
5.2.H blocked hydraulic filter Warning light
34
5.2.I multifunction warning light
34
5.2.J multifunction warning light
34
5.2.K oil pressure warning light
34
5.2.L mow / transport lever
35
5.2.M Power outlet
35
5.2.N Horn button
35
5.3 parking brake
36
5.4 traction pedal
36
5.5 steering wheel
36
5.6 LIFT & LOWER RATE & SYNCHRONISATION control
37
5.7 FREE WHEEL
37
WARNING
37
6.1 DAILY INSPECTION
38
CAUTION
38
1. Perform a visual inspection of the entire machine, look for signs of wear, loose hardware and missing or damaged components. Check for fuel and oil leaks to ensure connections are tight and hoses and tubes are in good condition.
38
2. Check the fuel supply, radiator coolant level, crankcase oil level, hydraulic oil level and the air cleaner is clean. All fluids must be at the full mark with the engine cold.
38
3. Make sure all cutting implements are adjusted to the same height of cut.
38
4. Check all tyres for proper inflation. (Section 3.2).
38
6.2 OPERATOR PRESENCE AND SAFETY INTERLOCK SYSTEM
38
1. The operator presence & safety interlock system prevents the engine from starting unless the operator is seated, Park Brake is on, the Cutter Engage (PTO) switch is off, and the Traction Pedal is in the neutral position. The system stops the engin...
38
WARNING
38
2. Perform each of the following tests to ensure the operator presence & safety interlock system is functioning properly. Stop the test and have the system inspected and repaired if any of the tests fail as listed below:
38
6.3 OPERATING PROCEDURE
39
1. Under no circumstances must the engine be started without the operator seated on the machine.
39
CAUTION
39
NOTICE
39
CAUTION
40
Remove all debris from the site before mowing. Enter a new area cautiously always operate at
40
speeds that allow you to have complete control of the mower.
40
CAUTION
40
Before you clean, adjust, or repair this equipment, always disengage all drives, lower implements to the ground, engage parking brake, stop engine and remove key from ignition switch to prevent injuries.
40
WARNING
40
6.4 setting up THE MACHINE
41
WARNING
41
Check the hydraulic system. Make sure the connections are tight and all hoses and lines are in good condition before pressurizing the system. Hydraulic system should be allowed to warm-up and re-check connections for leaks.
41
WARNING
41
NOTICE
41
6.5 MOUNTING THE CUTTING HEADS
42
NOTICE
42
All Jacobsen Cutting Units are backlapped at the factory, but the Bedknife adjustment must
42
be performed before the unit is put into use. Refer to the Bedknife Adjustment Procedure as described
42
in section 8.8 & 8.13 in this manual.
42
CAUTION
42
1. Cut all shipping straps holding the front pull frames in place and position the pull frames so the up stop bumpers contact the up stop brackets. Set cutting head drive motors and hoses away from the lift arms.
42
2. With the reel enable switch in the “OFF” position, lower all three Cutting Unit lift arms and turn off the Unit and remove ignition key.
42
3. Align the Cutting Unit at the front of the yoke frame. Secure cutting head to either side of the yoke frame using the shoulder bolt (A) on each side of the cutting head.
42
4. To remove the Cutting Unit, undo shoulder bolts, applied in step 3.
42
6.6 REEL MOTOR MOUNTING
43
1. The cutting head motor mounting adapter, coupling and hardware are shipped in the step located above the left front wheel. Install a 1.49" i.d. x 07" (38mm x 1.7mm) O- ring on the male side of motor adapter plate and a 1.99" i.d. x.07” (50mm x 1...
43
2. Remove and discard screws holding the shipping cover to cutting head (retain the shipping cover to protect the bearings whenever the motor is removed from the cutting head).
43
3. Install coupler (A) on cutting head shaft.
43
4. Install motor adapter plate (B) positioning the male face and O-ring (C) toward the cutting head.
43
5. Install two (2) 5/16-18 x 1 1/2” screws (with washer and lock washer) loosely into the mounting holes.
43
6. Align the splines on the motor shaft with the coupler (A) and slide the motor into place rotating approximately 45° away from the mounting screws. With motor face against adapter plate (B), rotate the motor mounting flange into place engaging the...
43
7. Add lithium based lubricant to the bearing housings at BOTH ends of the reels bearings at both ends are partially packed with lubricant at the factory, but additional lubricant is required once assembled. Use a grease gun to add lubricant until it...
43
NOTICE
43
Check to MAKE SURE when the cutting heads are lowered to the turf, they must contact the turf evenly across the entire length of the cutting head. If the front cutting heads contact the level surface unevenly,
43
6.7 CUTTING CYLINDER LIFT & LOWER RATE & SYNCHRONISATION
44
The valves that control the rate and sequence in which the Cutting Units rise and fall are set at the factory, however they can be reset or altered using the following steps.
44
6.8 OPERATION OF THE MACHINE
44
6.9 STARTING THE ENGINE
45
6.10 DRIVING
45
6.11 MOWING procedure
45
NOTICE
46
6.12 HOW TO STOP THE ENGINE
46
1. Disengage drive to the Cutting Units with the Cutting Unit Switch.
46
2. Return the FWD/REV pedal to the neutral position.
46
3. Set the parking brake.
46
4. Move the throttle control lever to the SLOW position.
46
5. Turn the ignition key to OFF
46
CAUTION
46
6.13 HOW To remove A blockage from cutting units
46
1. Disengage the power to the cutting units with the cutting unit switch.
46
2. Keep the cutting units lowered to the ground (Wait for the remaining cutting cylinders to stop rotation).
46
3. Lift the cutting units into the “Transport Position”, lock in position use the transport latches fitted on your product.
46
4. Remove your foot from the forward/reverse pedal.
46
5. Set the parking brake.
46
6. Move the throttle control lever to the slow position.
46
7. Turn the ignition key to the off position and remove the key
46
NOTICE
46
8. Use the Jacobsen “Cutting Unit Tool” part number 4184540 See below or stout stick, put into the cutting cylinder between the blades
47
9. Rotate the cylinder with either the “Cutting Unit Tool” or “Stout Stick” until the obstruction has been removed.
47
10. Inspect all the cutting surfaces for damage, when necessary replace the damaged components.
47
6.14 BACKLAPPING
47
Jacobsen grinding paste:
47
6.15 Backlapping procedure
48
1. Apply an even coat of backlapping compound to the entire length of each blade of the reels.
48
2. While pressing the centre red button (A) on the reel valve pull yellow plunger (B) away from the valve.
48
3. Start the engine and set the throttle to low idle. Lower heads by operating the Joystick or paddle.
48
4. Slowly turn the restriction valve knob (C) clockwise until the desired reel rotation speed is attained. It should be slow enough so that the reel will not throw off the backlapping compound as it spins.
48
5. Once all the blades on the reel are uniformly sharp, shut off the engine and push yellow plunger (B) back towards the valve. Set the reel speed valve (C) to mow speed.
48
NOTICE
48
6.16 Transporting on a trailer OR FLATBED
48
6.17 SLINGING and jacking THE MACHINE
48
Slinging
48
When slinging the machine use the tie down loops front and rear.
48
Jacking
48
The machine has three jacking points, one at the rear chassis engine mount and two on
48
the front chassis wheel motor mounting.
48
6.18 Mowing on slopes
49
The mower has been designed for good traction and stability under normal mowing conditions. Use caution when operating on slopes, especially when the grass is wet. Wet grass reduces traction and steering control.
49
WARNING
49
To minimize the possibility of overturning, the
49
safest method for operating on hills and
49
terraces is to travel up and down the face of
49
the slope (vertically), not across the face
49
(horizontally). Avoid unnecessary turns, travel
49
at reduced speeds, and stay alert for hidden
49
hazards. To ensure best stability always load
49
the left hand storage rack first and cut with all
49
three units powered.
49
1. Always mow with the engine at full throttle, control forward speed using traction foot pedal to maintain proper cutting.
49
2. Use weight transfer control as required to improve weight distribution between decks and mower.
49
3. If the mower tends to slide or the tyres begin to mark the turf, angle mower into a less steep slope until traction is regained or tyre marking stops.
49
4. If mower continues to slide or mark the turf, the slope is too steep for safe operation. Do not make another attempt to climb, and back down slowly.
49
5. When descending a steep slope, always lower implements to the ground to reduce the risk of mower overturning.
49
Correct tyre pressure is essential for maximum traction. See 3.2 Specification.
49
WARNING
49
DO NOT USE ON SLOPES GREATER THAN 16°
49
WARNING
50
When the machine is being used, whether
50
cutting grass or not, on slopes, the ROPS
50
frame should be deployed and the seat belt
50
used. This rationale is based on the fact that
50
a seat belt must be worn with a ROPS to
50
comply with the Machiney Directive
50
2006/42/EC Sections 3.2.2, Seating & 3.4.3,
50
Rollover
50
Ransomes Jacobsen Limited recommends that
50
a local risk assessment is completed by the
50
owner/user of the machine to determine the risks
50
associated with working on slopes.
50
NOTES
51
7.1 maintenance & lubrication chart
52
MainTENANCE & LUBRICATION CHART
52
Interval
52
Item
52
First 50 hours
52
l Change Engine Oil & Filter.
52
l Check Fan Belt Tension.
52
l Change Hydraulic Oil Filter.
52
Daily
52
10 hours
52
l Check Engine Oil Level.
52
l Check Safety Interlock System.
52
l Check Engine Coolant Level
52
l Check Hydraulic Fluid Level
52
l Check Tyre Pressure.
52
l Check Air Filter Tell Tail Indicator*.
52
l Check for Hydraulic Leaks.
52
l Check Oil Cooler Screen.
52
l Check Oil Cooler Fins.
52
l Check Bedknife & Reel Blades.
52
l Walk-Around Inspection.
52
Weekly Every 50 hours
52
l Check for Loose Components.
52
l Check Fan Belt Tension.
52
l Check Engine Bay For Debris.
52
l Check Battery Condition. l Fuel Tank Water and Sediment - Drain.
52
Every 100 hours
52
l Change Engine Oil Filter.
52
l Check Fuel Filter For Water Contamination.
52
Every 200 hours
52
l Change Engine Oil.
52
l Change Inline Fuel Filter.
52
Every 250 hours
52
l Change Hydraulic Oil & Filters. l Alternator and Fan Belts - Inspect / Adjust.
52
Every 500 hours
52
l Change Air Filter Element*.
52
l Change Oil and Filter Element. l Check Safety Interlock System.
52
l Hoses and Clamps - Inspect / Replace.
52
l Radiator - Clean
52
End of season
52
Every 1000 hours
52
l Check Parking Brake Operation.
52
l Check Brake pads.
52
l Drain & Clean Fuel Tank
52
l Drain & Replace Engine Coolant
52
Lubricate all Grease fittings weekly
52
A = Lift Arm Pivot, B = Cutting Unit Pivot, C = Cutting Unit Bearing Housing, D = Steering Ram Ball Joint.
52
*Check more often in dirty conditions
52
IMPORTANT
52
Refer to Engine Manufacturers Manual for Additional Engine Maintenance Procedures
52
Fluid Requirements
53
Quantity
53
Type
53
A
53
Engine Oil (with filter)
53
3.0 litres
53
SAE10W 30
53
B
53
Hydraulic Oil (with filter)
53
23 litres
53
GreensCare ISO VG 46
53
C
53
Radiator Coolant
53
4.4 litres
53
50% Anti-Freeze
53
D
53
Fuel
53
55 litres
53
No 2-D (ASTM D975) Diesel
53
7.2 ENGINE ACCESS
54
The Fuel & Hydraulic Tanks can be raised for better access to the engine.
54
Support the tanks by pivoting the stay (B) beneath the tank and secure in the hole provided.
54
WARNING
54
CAUTION
54
7.3 ENGINE LUBRICATION
55
Check Engine Oil Level
55
Check the engine oil level before starting or more than five minutes after stopping the engine.
55
Change Engine Oil
55
CAUTION
55
CAUTION
55
7.4 AIR FILTER
56
CAUTION
56
Clean Air Filter Element
56
7.5 ENGINE: FAN BELT
56
The fan belt is adjusted so that it has sufficient tension to avoid undue stress on alternator bearings but does not slip on the alternator pulley. Use the following procedure to check the belt tension at the mid-point of the belt between crank shaft...
56
1. Loosen alternator bolt (A) and pivot bolt (B) on the underside of the alternator.
56
2. Move the alternator to tighten or loosen the belt so that a deflection of 7 to 9 mm is achieved at the mid-span with a load 10Kgf (98N/22lbs).
56
3. Re-tighten bolts.
56
7.6 ENGINE COOLANT _
57
CAUTION
57
7.7 AIR CLEANER
57
7.8 OIL COOLER and RADIATOR
58
7.9 prime the FUEL SYSTEM
58
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the with suitable containers before opening any compartment or disassembling an...
58
Use the following procedure to prime the fuel system:
58
If air enters the fuel system, the air must be purged from the fuel system before the engine can be started. Air can enter the fuel system when the following events occur:
58
CAUTION
58
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
60
Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
60
Dispose of all fluids according to local regulations and mandates.
60
7.10 replacing FUEL FILTERS
60
1. Stop the engine.
60
2. Open the air valve (A) at the top of the filter (B) to release system pressure.
60
3. Remove fuel filter cartridge (B). Clean any fuel that spills.
60
4. Assemble new filter cartridge to the filter base. Tighten the cartridge with your hand.
60
5. Loosen hose clamps (C). Loosen filter clamp (E) and replace pre-filter (D).
60
6. Bleed air from the fuel system - Close Air Valve (A).
60
7.11 BATTERY
61
WARNING
61
WARNING
61
WARNING
61
Wear eye protection when servicing battery.
61
CAUTION
61
7.12 HYDRAULIC SYSTEM
62
Check Hydraulic Oil Level
62
Check hydraulic oil level using sight gauge (C).
62
Change Hydraulic Oil
62
Change Hydraulic Oil Filter
62
IMPORTANT - Whenever the closed loop transmission circuit has been broken into, it is essential that the circuit is flushed prior to use. Absolute cleanliness must be observed when filling the hydraulic tank. Oil must be filtered through a 25 micron ...
62
7.13 Handbrake
63
Place the front axle on axle stands and remove the front wheels. Inspect the discs and pads for wear and replace
63
if necessary. Remove all debris from around the brake assembly and ensure the calliper is free to float.
63
7.14 Tyres
63
Keep tyres properly inflated to prolong tire life. Check inflation pressure while the tyres are cool. Use an accurate, low pressure tyre gauge.
63
Keep tires inflated to the air pressure specified. See Specifications 3.2
63
CAUTION
63
7.15 MACHINE MAINTENANCE general
64
When washing machine with pressure spray washers or steam cleaners, avoid washing bearing areas because cleaning solutions might penetrate bearing seals and cause premature bearing failure.
64
Storage
64
7.16 Lubrication of cutting unit
64
Cleaning
64
The cutting heads should be washed after use each days and dried as well as possible to prevent rust.
64
Lubrication
64
The lubrication fittings at each end of both the front and rear rollers, as well as the reel bearings at each end should be lubricated periodically (approximately once each week). Use only enough lubricant to keep the bearings from drying out. Too mu...
64
8.1 TRACTION CONTROL PEDAL
65
ADJUSTING MOW SPEED
65
8.2 ADJUSTING SPEED CONTROL SWITCH
66
The speed control sensor is positioned under the control panel. The mechanism is activated when the speed control lever is cycled from the transport and mow positions.
66
To set the sensor (A), position the control lever in the “mow” position, loosen nuts (B), and adjust sensor until a gap of 4mm is achieved. Tighten nuts. Cycle control lever to the “transport” position, to ensure bolt head is clear of switch.
66
To ensure correct set-up, the cylinders MUST only rotate when the switch is activated. i.e the Mow position.
66
8.3 Steering ARM ADJUSTMENT
66
Support the control arm to avoid a sudden drop while adjusting its height. Loosen the Locking Lever (A) to allow the steering wheel and control arm to be adjusted up or down. Tighten the locking lever when steering wheel is at the desired position.
66
WARNING
66
DO NOT attempt to adjust the control arm
66
position while the machine is moving.
66
The operator may loose control, causing
66
possible injury to themselves or bystanders.
66
8.4 REAR SWING OUT ARM
67
The rear swing out arm is to allow you easy access to the rear cutting head. The cutting heads must be in the raised position.
67
DO NOT swing the arm out with the cutting heads in the lowered position.
67
WARNING
67
8.5 LevELLING LINKAGE FOR THE FRONT CUTTING HEADS
68
WARNING
68
8.6 SEAT ADJUSTMENT
69
Milsco XB200
69
Pull out on the adjustment lever located under the left side of the seat. Slide the seat to the desired position and release the lever.
69
Grammer MSG 65
69
Safety
69
Weight adjustment
70
• To prevent damage to the health and material, the setting for the driver’s weight must be checked and adjusted as necessary before the vehicle is driven.
70
• When the minimum/maximum has been reached, you can notice an empty movement in the handle.
70
• When you have set the weight, fold the lever completely into the locking.
70
Fore/aft adjustment
71
The fore/aft adjustment is released by lifting the locking lever.
71
WARNING
71
Risk of accident.
71
Do not operate the locking lever while driving.
71
WARNING
71
Risk of crushing.
71
only touch the lever at the indented grip, do not reach back under the lever.
71
• After the adjustment, the locking lever must latch into the desired position with an audible click. It should not be possible to move the driver’s seat into another position when it is locked.
71
• Do not lift the locking lever with your leg or calf.
71
Lumbar support
71
The lumbar support increases both the seating comfort and the performance of the driver. By turning the adjustment knob upwards, the curvature in the upper part of the backrest cushion can be adjusted. By turning the knob downwards, the curvature in ...
71
0 = No curvature
71
1 = Max. curvature at the top
71
2 = Max. curvature at the bottom.
71
Backrest adjustment
71
Pull up the locking lever to release the backrest catch. When releasing the backrest catch, do not apply load to the backrest by pressing against it. By exerting pressure on or off the front or rear part of the seat pan it can be moved to the desired...
71
• It should not be possible to move the backrest into another position after it has been locked.
71
Armrests
72
WARNING
72
If the belt roller is fitted, do not install the armrest in the lowest position as otherwise the belt roller might not function correctly. Carry out a functional test of the belt roller.
72
Armrest adjustment
72
Maintenance
72
CAUTION
72
ATTENTION: Do not clean the seat with a pressure washer.
72
When the machine is being used off road, whether cutting grass or not, the seat belt should only be worn when a ROPS frame is in place and deployed.
73
This rationale is based on the fact that a seat belt must be worn with a ROPS to comply with the Machinery Directive 98/37/EC Sections 3.2.2, Seating & 3.4.3, Rollover.
73
Ransomes Jacobsen Limited recommends that a local risk assessment is completed by the owner / user of the machine to determine any exceptions to this seat belt wearing rule e.g. use of the machine next to water or on the highway.
73
8.7 Bedknife-To-Reel TrueSet™ Reel
74
CAUTION
74
To prevent personal injury and damage to the cutting edges, wear gloves and handle the reel
74
and bedknife with extreme care.
74
8.8 Bedknife Adjustment TrueSet™ Reel
75
8.9 Cutting Height TrueSet™ Reel
76
1. Set desired cutting height on the gauge (E).
76
2. Loosen the nuts on the front roller brackets (G) just enough to allow the adjuster knob (K) to raise or lower the front roller.
76
3. Place gauge (E) across bottom of front and rear rollers near one end of roller.
76
4. Slide the head of gauge screw (H) over the bedknife (L) and adjust the knob (K) to close the gap between the screw head and bedknife. Then tighten locknut (G).
76
5. Repeat Steps 4 and 5 on opposite end. Complete adjustment to one end before adjusting opposite end.
76
6. Tighten nuts (G) and recheck each end.
76
8.10 Reel Bearing TrueSet™ Reel
77
2. Apply a medium strength grade of Loctite to nut (P), then thread nut onto the reel shaft until the nut is 1-27/ 32” (46 mm) from the end of the reel shaft.
77
3. Fill reel bearing housings with NLGI - Grade O grease after adjusting spring.
77
8.10.1 Bedknife Adjuster Spring TrueSet™ Reel
77
8.11 knife Adjuster Tension TrueSet™ Reel _________________________
78
8.12 Grinding Bedknife TrueSet™ Reel
78
2. Press down on adjuster end of rod (T) to rotate other end of the adjuster out of the bedknife finger.
78
3. Rotate bedknife backing to access the reel and bedknife for grinding.
78
4. After grinding, assemble bedknife using reverse order of removal. Check adjustment of bedknife adjuster tension and reel to bedknife adjustment.
78
8.13 BEDKNIFE ADJUSTMENT Classic XP™ reels
79
Too much clearance between the bedknife and the blades will result in poor cutting quality.
79
Too little clearance will cause excessive wear to the cutting edges and may cause damage to the
79
bedknife, reel blades or other components.
79
WARNING
79
WARNING
79
8.14 HEIGHT OF CUT Classic XP™ reels
80
Any adjustment to the clearance between the reel blades and the bedknife should be done at the leading end of the reel first (the end at which each individual blade first crosses the bedknife). Then at the opposite end of the reel.
80
Too much clearance between the bedknife and the blades will result in poor cutting quality.
80
Too little clearance will cause excessive wear to the cutting edges and may cause damage to the
80
bedknife, reel blades or other components.
80
8.15 HEIGHT OF CUT Classic XP™ reels
81
Work Bench Setting.
81
All three cutting heads MUST be accurately set at the same height of cut to ensure an even cut.
81
WARNING
81
To avoid the possibility of serious injury, NEVER attempt any cutting head adjustments while the engine is running.
81
WARNING
81
NEVER rotate the cutting reel by pushing it with your hands or fingers.
81
Fingers can become caught between the reel and the frame resulting in serious injury.
81
Use a ratchet with a 9/16” socket on the end of the reel shaft to rotate it during adjustments and testing.
81
1. Direction/Speed Pedal
65
2. Transport Stop
65
3. Locknuts
65
4. Mow Stop
65
5. Locknuts
65
9.1 THREE WHEEL DRIVE KIT
82
9.2 PADDLE KIT _________________________________________________________
82
9.3 DEW WHIP KIT
83
9.4 GROOMER KIT
83
10.1 PROBLEM SOLVING GENERAL
84
NOTES
85
11.1 Quality of Cut Problem Solving
86
1. Blade Sharpness
86
2. Blade Speed
86
3. Mowing (Ground) Speed
86
4. Height-of-Cut (HOC)
86
5. Rake Angle
86
6. Caster/Roller and Roller Bearing Condition
86
7. Tyre pressures
86
8. General wear and tear of the machine
86
11.2 Step Cutting
86
11.3 SCALPING
87
11.4 STRAGGLERS
88
11.5 Streaks
89
11.6 Windrowing
90
11.7 CLUMPING
91
11.8 INSUFFICIENT MULCHING
92
11.9 torn crowns
93
11.10 LAYING UNCUT GRASS
94
NOTES
95
12.1 Electrical Fuses & relays
96
12.2 fuse and relay identification
97
13.1 Torques
98
14.1 GUARANTEE
99
4
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Jacobsen GP400 Specifications
General
Brand
Jacobsen
Model
GP400
Category
Lawn Mower
Language
English
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