Textron RANSOMES G-Plex II Manuel utilisateur

RANSOMES

Parts and Maintenance Manual

Nomenclature Des Pieces De Rechange & Manuel De Maintenance

Onderhouds - En Onderdelenhandleiding

Sicherheits und Bedienungs anleitung

Manuale d’istruzioni per I’uso e la Sicurezza

RANSOMES

AVVERTENZA: Questa macchina può causare gravi infortuni

se viene utilizzata in modo errato. Prima di accingersi ad

approntare, usare, mettere a punto o eseguire la

manutenzione di questa macchina, coloro che la utilizzano

ed i responsabili della manutenzione devono essere

addestratiall’impiegodellamacchina,devonoessereinformati

dei pericoli, e devono leggere l’intero manuale.

Part No. 24210G (rev.0)(RJ 100 062000)

FNL DI

WARNHINWEIS:WenndieseMaschinenicht ordnungsgemäß

verwendet wird, können ernsthafte Verletzungen verursacht

werden. Personen, die diese Maschine verwenden und

warten, müssen in ihrer richtigen Verwendung ausgebildet

sein, auf die Gefahren aufmerksam gemacht worden sein

und die Anleitung ganz gelesen haben, bevor sie versuchen,

die Maschine aufzustellen, zu bedienen, einzustellen oder

zu warten.

WAARSCHUWING: Bij verkeerd gebruik kan deze machine

ernstig lichamelijk letsel veroorzaken. Degenen die de ma-

chine gebruiken en onderhouden moeten worden getraind

in het juiste gebruik ervan, worden gewaarschuwd voor de

gevaren ervan en behoren de volledige handleiding

aandachtig te lezen alvorens de machine bedrijfs-klaar te

maken, te bedienen, af te stellen en/of te onderhouden.

AVERTISSEMENT : Risque de blessures graves en cas

d’utilisation incorrecte de la machine. Les opérateurs et le

personnel d’entretien doivent être formés et conscients des

dangers encourus. Ils doivent lire avec attention le manuel

avant d’essayer de monter, d’utiliser, de régler ou maintenir

lamachine.

WARNING: If incorrectly used this machine can cause se-

vereinjury. Those who use and maintain this machine should

be trained in its proper use, warned of its dangers and should

read the entire manual before attempting to set up, operate,

adjust or service the machine.

G-Plex II

Series: WD - Engine type: Kubota model D722B

Product codes:LHAH001

GB-1

RANSOMES G PLEX II Series :WD

MAINTENANCE AND PARTS MANUAL

INDEX

Service and Maintenance Pages

Page

Adjustments .......................................7

Air Cleaner .....................................17–18

Ammeter ............................................5

Backlapping ...................................19–20

Battery...............................................18

Bedknife Adjustment..........................8

Bleeding The Fuel System ...............12

Cleaning Radiator .............................17

Control Pedals ...................................6

Controls............................................. 5

Cutting Head Levaling .......................9

Cutting Head Maintenance ...............19

Cutting Head Serial Number..............3

Cutting Head Timing.........................11

Dipstick, Engine Oil ..........................15

Engine Access ..................................14

Engine Break–In ...............................13

Engine Cooling System ....................17

Engine Oil Filter ................................15

Engine Oil Level ...............................15

Fuel Recommendations....................13

Fuses ................................................18

Headlight Switch ................................5

Height Of Cut.....................................8

Hour Meter .........................................5

Hydraulic Diagram ............................22

Hydraulic Pump Bypass Valve ..........6

Hydraulic System...........................16–17

Identification Numbers.......................3

Ignition Switch....................................5

Jump Starting....................................18

Leveling Linkage, Front Heads..........9

Lube Chart ........................................21

Maintenance Guide...........................13

Model Number ...................................3

Mow/Transport Speed Control........9–10

Mowing Speed Adjustment .............9–10

Oil Filter (hydraulic) ..........................17

Oil type, hydraulic .............................16

Oil Warning Light, Engine .................5

Parking Brake ....................................6

Pedals

Mow/Lift .............................................6

Page

Brake..................................................6

Speed/Direction .................................9

Pre–Heat Switc ..................................5

Rear Swingout Arm............................7

Serial Number....................................3

Service and Maintenance .................13

Specifications.....................................4

Starting The Engine

Diesel ................................................12

Gasoline............................................11

Storage .............................................20

Temperature Gauge ..........................5

Throttle...............................................5

Tire Pressure ....................................19

Towing The Unit................................13

Troubleshooting ................................23

Turf Protection System (accessory) .17

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RANSOMES G PLEX II Series :WD

MAINTENANCE AND PARTS MANUAL

Index To Parts Pages

Section Title Page

1CHASSIS AND COVERS.................................................................... 120

2POWER ASSY DIESEL....................................................................... 122

3RADIATOR (DIESEL) .......................................................................... 124

4AIR CLEANER (DIESEL).................................................................... 126

5FUEL SYSTEM.................................................................................... 128

6OIL COOLER MOUNTING................................................................... 130

7HEAD LIFT AND PUMP CONTROL LINKAGE .................................. 132

8HYDRAULIC PUMP AND VALVES..................................................... 134

9HYDRAULIC LIFT CIRCUIT................................................................ 136

10 HYDRAULIC REEL CIRCUIT ............................................................. 138

11 HYDRAULIC WHEEL DRIVE CIRCUIT .............................................. 140

12 HYDRAULIC POWER STEERING ...................................................... 142

13 CONTROL ARM .................................................................................. 144

14 LIFT ASSEMBLY - FRONT CUTTING HEADS................................... 146

15 LIFT ASSEMBLY - REAR CUTTING HEAD ....................................... 148

16 MOW / RAISE PEDAL AND SPEED CONTROL PEDAL ................... 152

17 MOW SPEED CONTROL .................................................................... 154

18 BRAKE PEDAL................................................................................... 156

19 SEAT.................................................................................................... 158

20 DECALS .............................................................................................. 160

21 CONTROL PANEL AND ELECTRICAL COMPONENTS .................. 162

22 ELECTRICAL COMPONENTS ........................................................... 166

23 WHEELS AND REAR HUB ................................................................ 168

24 COUNTER WEIGHT AND MOTOR MOUNTING ................................. 170

25 REEL ASSEMBLY - 1.......................................................................... 172

26 REEL ASSEMBLY - 2.......................................................................... 174

27 REAR ROLLER................................................................................... 176

28 REAR ROLLER................................................................................... 178

29 CUTTING HEAD.................................................................................. 180

30 ACCESORY - ROTARY REAR BRUSH 892327................................. 184

31 ACCESORY - FRONT ROLL SCRAPER 892329............................... 186

32 ACCESORY......................................................................................... 188

33 ACCESORY......................................................................................... 190

34 GROOMER ACCESORY ..................................................................... 192

35 VERTICUTTER ACCESORY .............................................................. 196

36 ACCESORY - REAR ROLLER SCRAPER......................................... 200

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RANSOMES G PLEX II Series :WD

MAINTENANCE AND PARTS MANUAL

DIESEL ENGINES

The diesel engine’s serial number is stamped into

the block directly below the injector pump (See Fig.

4).

Figure 4

1. Diesel Engine Serial Number

CUTTING HEAD SERIAL NUMBERS

Identification numbers for each individual cutting

head are on the nameplate decal located on the

right side panel (See Fig. 5).

NAME PLATE

DECAL

Figure 5

IDENTIFICATION

THESE IDENTIFICATION NUMBERS MUST

APPEAR ON ALL CORRESPONDENCE

CONCERNING THIS UNIT.

MODEL NUMBER & SERIAL NUMBER

Both the Model Number and Serial Number are on

the identification nameplate decal located on the

right rear frame. See figure 1.

Figure 1

1. Identification Nameplate Decal

ENGINE IDENTIFICATION NUMBERS

To gain access to the engine, loosen the two hand

knobs above the rear fork.Raise the fuel tank frame

(rear section) and pivot the rod beneath the fuel

tank down and secure it in the cup next to the fork

(See Fig. 2). DO NOT remove fuel tank cap while

tank is in raised position.

Figure 2

Fuel Tank in Raised Position

1. Support Rod

2. Hand Knobs

GB-4

RANSOMES G PLEX II Series :WD

MAINTENANCE AND PARTS MANUAL

SPECIFICATIONS

(subject to change without notice)

Engine Kubota model D722B-1, 18 hp. three

cylinder, liquid cooled diesel engine

High Idle Speed 3400 RPM

Low Idle Speed 1500 RPM

(See engine manual for additional

specifications)

Speed (maximum):

Transport 12 Km/h

Mowing 6.1 Km/h

Reverse 3 Km/h

Hydraulic System:

Traction Drive Pump Sundstrand 15-

Series

Traction Motors: Parker-Ross ME10

Reel Drive Pump: J.S. Barnes W900

.488 in3/Rev (8cc/Rev)

Reel Motors: J.S. Barnes W600

.73 in3/Rev (12cc/Rev)

Reservoir Capacity: 18.2 L

Total System Capacity: 25.7 L

Ransomesr Turf Protector™

9.7 L PN 65363

18.9 L PN 65352

208 L PN 65354

(Alt. Texaco Rando HDZ-32)

See oil selection guide

Hydraulic Filters

2 ea, 25 micron (suction) PN 522972

Dimensions:

Width Of Cut: 1.6m

Overall Width (w/reels and catchers): 1.9m

Overall Length (w/reels and catchers):

2.5m

Overall Height: 1.25m

Wheel Base: 1.26m

Front Wheel Tread (width): 1.2m

Weight w/o reels: 535 kg

Weight w/reels: 631 kg

Fuel Tank Capacity: 31 L

Coolant Capacity: 3.8 L

Battery 12 volt

BCI Group Size 24

Cold Cranking Amps (min.) 430

Reserve Capacity Minutes (min.) 70

Ground Terminal Polarity Negative

with SAE taper posts

Brakes Positive Hydrastatic Braking

6” (152 mm) Caliper Disk Parking Brake

Eletrical:Alternator: 40 AMP

Steering:Rear Wheel Steering

Power Steering, 2.5 turns lock to lock

13” (330mm) dia. Steering Wheel

Tyres: 20 x 10.00 - 10 Smooth tread

VIBRATION LEVEL

The machine was tested for whole body and hand/

arm vibration levels. The operator was seated in

the normal operating postion with both hands on the

steering mechanism. The engine was running and

the cutting device was rotating with the machine

stationary.

Hand / Arm acceleration level : 2.0 m/s2

Whole body acceleration level

X axis : 0.051 m/s2

Y axis : 0.085m/s2

Z axis : 0.204 m/s2

WARNING

•This manual deals with service and

maintenance functions. These functions

must be performed as specified and must

be done by properly trained service

personnel only.

GB-5

RANSOMES G PLEX II Series :WD

MAINTENANCE AND PARTS MANUAL

CONTROLS

(Diesel Models)

Figure 7

1. Ammeter

2. Hour Meter

3. Headlight Switch

4. Engine Oil Warning Light

5. Ignition Switch

6. Throttle

7. Turf Protection System (optional)

8. Pre–Heat Switch and Glow Plug

Light

9. Temperature Gauge And

Warning Light

10. Reel Enable Switch

Ammeter - indicates amount of electrical flow at the

battery. Under normal operating conditions

the needle will be on the plus (+) side of

the meter, showing that current is being

supplied to the battery.

At idle speed, the indicator may be at zero

or on the negative (-) side. A continuous

negative reading at normal operating

speed indicates a malfunction in the

charging system that should be checked

immediately.

Headlight Switch - turns the headlights on and off.

Engine Oil Warning Light - will come on when the

engine oil pressure is too low for operation.

Ignition Switch - has four positions:

OFF - prevents all electrical functions from

operating. Switch must be in the OFF

position to remove the key.

ON - for normal operation.

START - engages the starter. Release the

key after engine starts (the switch

automatically returns to ON).

ACC. - has no function on this unit.

NOTICE

•If the engine fails to start, or if it “dies” for

any reason, the ignition switch must be

returned to the OFF position before

restarting is attempted. This feature

prevents damage to the starter and

flywheel teeth that can occur if the starter

is engaged while the engine is running.

Throttle - Push all the way forward for normal

engine operating speed, and all the way

back for idle.

Hour Meter - records the number of hours the

engine has run. Use the hour meter to

manage a good scheduled maintenance

program (refer to the Maintenance Guide).

Pre–Heat Switch and Glow Plug Light -With key

switch ON, push up/forward and hold the

pre–heat switch until the glow plug light

goes out (Diesel Only).

Temperature Gauge and Warning Light -gauge

indicates coolant temperature and light

warns of overheat situation (Diesel Only).

Turf Protection System - can be installed as an

option to warn the operator if a leak in the

hydraulic system is detected.

REAR SWING OUT ARM

NOTICE

GB-6

RANSOMES G PLEX II Series :WD

MAINTENANCE AND PARTS MANUAL

CONTROL PEDALS

The Direction/Speed Pedal (See Fig. 8) controls

speed and direction. Depress front of pedal to go

forward, depress back of pedal to go backward.

Increased movement of the pedal will increase

speed.

To slow and stop the unit, release the pedal

completely. Proper braking is provided by

hydrostatic pressure. If more braking is required,

press on the brake pedal.

WARNING

•DO NOT attempt to force the direction

control pedal to the neutral (stop) position

or to change directions before coming to a

complete stop. Abrupt stops or changes in

direction may cause injury.

Figure 8

1. Direction/Speed Pedal

2. Brake Pedal

PARKING BRAKE PEDAL

The Parking Brake can be engaged by depressing

the brake pedal until the unit is at a complete stop.

Once the unit is stoped, push the parking brake

latch foward to hold the brake pedal. Disengage the

parking brake by depressing and releasing the brake

pedal.

Figure 9

1. Brake Pedal

2. Park Brake Latch

NOTICE

•To reduce fatigue during normal forward

operation, the operator’s heel should rest

on the floorboard next to the pedal (not on

the lower part of the pedal).

The Mow/Lift Pedal (See Fig. 10) lowers and raises

the cutting heads.

To Lower the Heads: Depress the front of the pedal

into the lowered head position. If reel enable switch

is on, reel rotation starts when the heads are

lowered.

To Raise the Heads: Depress the back of the pedal

into the raised head position. Reel rotation stops

when the heads are raised.

Figure 10

1. Mow/Lift Pedal

HYDRAULIC PUMP BYPASS VALVE

The Bypass Valve allows the unit to be pushed or

towed. Turn the handle on the bottom of the pump

counterclockwise (as viewed from the bottom of the

pump) to open the valve. After moving the unit,

close the valve by turning the handle clockwise.

Figure 11

1. Bypass Valve Handle

NOTICE

•The bypass valve must be tightly closed

for normal operation or a significant loss of

speed will occur and may cause serious

damage to the hydrostatic pump.

GB-7

RANSOMES G PLEX II Series :WD

MAINTENANCE AND PARTS MANUAL

•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. DO NOT swing the arm out with

the cutting heads in the lowered position.

WARNING

•To avoid the possibility of serious injury,

ALWAYS be properly seated in the

operator’s seat while the engine is running.

•To avoid the possibility of serious injury,

ALWAYS switch the reel enable switch to

the off position, stop the engine, remove

the key, and set the parking brake each

time you leave the operators seat.

1. The grass catcher MUST BE removed

before you swing the arm out.

2. Release the draw latch (See Fig. 12).

3. Pull the handle and swing the rear arm and

cutting head out.

4. Once you are properly seated in the

operator’s seat, restart the unit and lower

the cutting heads.

5. Shut off the unit and remove the rear

cutting head for service.

6. Once you have completed your servicing,

secure the cutting head to the rear arm.

7. Once you are properly seated in the

operator’s seat, restart the unit and raise

the cutting heads.

8. Shut off the unit and swing the rear arm

back under the unit and secure the arm

with the draw latch (See Fig. 12).

WARNING

•NEVER attempt to drive the unit while the

rear arm is not secured by the draw latch.

Driving the unit with the rear arm out, will

result in damage to the unit, or causing

serious injury or death of you the operator

or bystanders.

Figure 12

1. Draw Latch

2. Handle

ADJUSTMENTS

WARNING

•Adjustment procedures must be performed

as specified by properly trained service

personnel ONLY. If assistance is needed,

contact your local Ransomes/Cushman/

Ryan Dealer.

•To avoid the possibility of serious injury,

switch the reel enable switch to the off

position, lower the heads, stop the engine,

remove the key, and set the parking brake

BEFORE making any adjustment.

•NEVER rotate the cutting reel by pushing

it with your hands or fingers. Fingers can

become caught between the reel and the

frame resulting in serious injury. Use a

ratchet with a 9/16” socket on the end of the

cutting head shaft to rotate the reel during

adjustment and testing (See Fig. 13).

Cutting Head Shown

with

Rear Rotary Brush Ac

cessory mounted

Figure 13

1. Rotate Cutting Reel with this Screw Head

GB-8

RANSOMES G PLEX II Series :WD

MAINTENANCE AND PARTS MANUAL

BEDKNIFE ADJUSTMENT

For this adjustment, the backlap valve control lever

must be in the center “neutral” position so

that the reels can be rotated manually.

WARNING

•To avoid the possibility of serious injury,

NEVER attempt any cutting head

adjustment while the engine is running.

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.

1. Loosen the lower adjustment screws at

each end by turning them approximately 1/

4 turn counterclockwise (See Figure 14).

2. While rotating the reel backwards, turn the

upper adjustment screws (leading end

first) until there is approximately .001²

(.025mm) clearance. After adjusting both

ends, recheck the leading end.

NOTICE

•Too much clearance between the bedknife

and the blades will result in poor cutting

quality. Too little clearance will cause

excessive wear to the cutting edges and

may cause damage to the bedknife, reel

blades or other components.

Figure 14

1. Upper Adjustment Screw

2. Lower Adjustment Screw

3. Rotate the reel forward. The reel must turn

freely and you should just be able to hear

the reel blades making slight contact with

the bedknife.

4. After the bedknife is properly adjusted,

tighten the lower adjustment screw at each

end.

5. Test the cutting head by holding two strips

of newsprint perpendicular to the bedknife.

Rotate the reel with a wrench. The reel

must turn freely and each blade on the reel

should cut one of the two strips of paper.

HEIGHT OF CUT

NOTICE

•All three cutting heads MUST be

accurately set at the same height of cut to

insure an even cut.

•Bedknife adjustment must be made before

setting the height of cut.

1. Set the height of cut on the gauge block

(Part No. 892010) by turning the wingnut

until the distance between the bottom of

the screw head and the top of the gauge

block equals the desired height of cut (See

Fig. 16).

2. Loosen the locking nut on one of the front

roller adjusting brackets just enough to

allow adjustment (See Fig. 15).

Cutting Head Shown

with

Rear Rotary Brush Ac

cessory mounted

Figure 15

1. Loosen Locking Nut

3. Hold the gauge block across the bottom of

both the front and rear rollers near the

roller adjustment bracket and adjust the

front roller until the cutting edge of the

bedknife comes up to touch the bottom of

the gauge screw head (See Fig. 16).

Front Roller

Rear Roller

Bedknife

Gauge Block

Gauge

Screw

Head

Set Height Of Cut

(Part No. 892010)

Figure 16

Height of Cut Adjustment

4. Tighten the locking nut and repeat the

procedure at the other end. After

adjustment has been made at both ends,

go back and recheck both ends.

5. Make sure all three cutting heads are set

without changing the height of the gauge

screw.

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