GB Installation Instructions Jacobsen GP400 Three Wheel Drive Kit
Contents
1. of the machine PART NUMBER DESCRIPTION and QUANTITY required Any arbitrary modifications carried out on this machine may relieve the manufacturer of liability for any resulting damage or injury ABBREVIATIONS N A Not Available ARAs Required Parts 6 PARTS MANUAL GP 400 GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS DURING SERVICE LIFE Used oil oil filters and engine coolant are hazardous materials and should be handled in a safe and environmentally responsible way In the event of a fluid leak contain the spill to prevent it entering the ground or drainage system Local legislation will dictate how such spills are to treated Following the maintenance procedures laid out in this manual will ensure that the impact the machine has on the local environment is controlled When it has been identified that a turf care product has no further functional value and requires disposal the following actions should be taken END OF SERVICE LIFE These guidelines should be used in conjunction with applicable Health Safety and Environmental legislation and use of approved local facilities for waste disposal and recycling Position the machine suitable location for necessary lifting equipment be used e Use appropriate tools and Personal Protective Equipment PPE and take guidance from the technical manuals applicable to the machine Remove store appropriately 1 Batteries 2 Fuel residue 3 Engine c2. without releasing or restraining forces which can cause parts to move suddenly Do not alter engine speed above maximum quoted in Engine Specification Do not change the engine governor settings or overspeed the engine Operating the engine at excessive speed may increase the hazard of personal injury When refuelling STOP THE ENGINE DO NOT SMOKE Add fuel before starting the engine never add fuel while the engine 15 running Use a funnel when pouring fuel from a can into the tank Do not fill the fuel tank beyond the bottom of the filler neck Replace all fuel tank and container caps securely Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refuelling If fuel is spilled do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapours have dissipated Allow the engine to cool before storing in any enclosure Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark If the fuel tank has to be drained this should be done outdoors Do not spill fuel onto hot components When servicing batteries DO NOT SMOKE and keep naked lights away Do not place any metal objects across the terminals When Pressure Washing the Mower Turn the engine off and remove the starter key If the engine has been running it should be allowed t
3. 25006G GB Rev 3 Installation Instructions Jacobsen GP400 Three Wheel Drive Kit LMAC418 WARNING If incorrectly used this machine can cause severe DJA COB S MN injury Those who use and maintain this machine should Textron 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 When Performance Matters United Kingdom RJL 100 March 2014 2014 Ransomes acobsen Limited All Rights Reserved h AOON CONTENTS GP 400 INSTALLATION INSTRUCTIONS LMAC418 INTRODUCTION 4 SAFRE TPTY INSTRUCTIONS seein 8 HONS 10 PARTS LIST PARTS MANUAL GP 400 PRODUCT IDENTIFICATION Machine Serial Plate A W Maximum front axle load Kg for machines being 22 West Road 5 i RA gM Ransomes Europark driven on the highway Ipswich IP3 9TT a A Textron Company England Gross weight mass in Kg Maximum rear axle load in Kg for machines being driven on the highway Power in Kw Date code Machine type Designation Product code Product name Serial number Serial Plate Location The serial plate is located on the chassis at the rear of the machine Chassis Stamping The Serial number and date code A are stamped on the chassis rear axle support plate ROPS Serial Plat
4. and fully understood No person should be allowed to operate this machine unless they are fully acquainted with all the controls and the safety procedures Never allow children or people unfamiliar with these instructions to use this machine Local regulations may restrict the age of the operator SAFETY SIGNS It is essential all safety labels are kept legible if they are missing or illegible they must be replaced If any part of the machine is replaced and it originally carried a safety label a new label must be affixed to the replacement part New safety labels are obtainable from Ransomes dealers ADJUSTMENTS LUBRICATION MAINTENANCE amp CLEANING Stop the engine and make sure all moving parts are stationary Apply brakes and disengage all drives Read all the appropriate servicing instructions Use only the replacement parts supplied by the original manufacturer When adjusting the cutting cylinders take care not to get hands and feet trapped when rotating cylinders Make sure that other people are not touching any cutting units as rotation of one cylinder can cause the others to rotate To reduce the fire hazard keep the engine silencer and battery compartments free of grass leaves or excessive grease Replace worn or damaged parts for safety GP 400 INSTALLATION INSTRUCTIONS LMAC418 When working underneath lifted parts or machines make sure adequate support Is provided Do not dismantle the machine
5. any adjustments or modifications 3 this opportunity to thoroughly inspect the equipment and perform other maintenance The Right and Left Front and Rear of the machine are referenced from the operator s right and left when seated in the operator s seat facing the direction of forward travel 4 2 DESCRIPTION The following instruction details the process of installing the Three Wheel drive kit LMAC418 to the GP 400 machine en 10 4 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 4 3 FITTING INSTRUCTIONS WARNING e f any part of this instruction is not understood contact your Jacobsen dealer for clarification before proceeding e These Instructions will alert you to certain things you should do very carefully to avoid hurting yourself or others Never perform service or maintenance on or near a hot engine Always allow ample time for the engine to cool Severe burns can result if engine has not been allowed to cool Allow time for the hydraulic oil to cool Installation of this kit requires handling of hydraulic oil Hot hydraulic oil can Cause severe burns WARNING When raising the vehicle for repairs or maintenance ALWAYS use jack stands to provide adequate support NEVER rely on hydraulic or mechanical jacks for support If not supported properly the vehicle may fall unexpectedly resulting in serious personal injury or death 1 Block the front tyres and raise re
6. ar of mower Figure 1 Figure 1 en 11 4 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 2 Remove rear fork and wheel assembly Retain the wheel and hardware for reinstallation on new fork and hub assembly 3 Install the hydraulic motor part 008006930 into the new rear fork assembly part 894728 as indicated Figure 2 using the supplied hardware Tighten the retaining bolts part 451110346 to approximately 90 113 Nm 67 83 ft lbs Motor Hub Standard or Castled Nut Torqued to 400 540Nm Then secure Split Pin Figure 2 4 Using previously retained hardware install the new rear fork assembly Tighten the lower nut until washer will not turn by hand then back off nut until washer will turn freely Prevent lower nut from turning then install and tighten upper nut to 68 Nm 50 ft lbs 5 Using previously retained hardware install and secure steering cylinder to the rear fork 6 Install two elbows part W158007 05 into the hydraulic motor as shown in Figure 3 Figure 3 7 Install and secure tyre Tighten retaining nuts to approximately 95 140 Nm 70 100 ft lbs 8 Lower the mower 9 Mount the flushing valve part 4187320 to the bracket 4268492 as indicated Figure 4 using two M8 x 55 bolts washers and nuts Figure 4 en 12 4 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 Figure 4 Figure 5 10 Undo the lock nut on the flushing valve turn the ad
7. c fluid reservoir is filled at the factory with GreensCare 46 en 19 PARTS MANUAL GP 400 LMAC418 FRONT MOTORS BOTTOM TEE CONNECT ING CAP TEE UNDER SEAT PLATE CAP RH FRONT WHEEL MOTOR PORT Parts 20 PARTS MANUAL GP 400 PARTNO DESCRIPTION ary 00 REMARKS 000 002540050 1 5 008006930 MOTOR HYD 158056 01 TEE 3 4 SAE 13 16 ORFS 4248590 BRACKET 3WD HOSE CLAMP 450019 BOLT HEX M8 x 55 451110346 BOLT HEX 1 2 13 x 2 3 4 450171 SCRW HEX x 20 450377 NUT HEX M6 NYLOC 450378 NUT HEX M8 NYLOC 450389 WSHR M6E x 12 5 x 1 8 450390 WSHR M8 x 17 x 1 8 452200176 LOCKWSHR 1 2 x 873 x 125 450738 CAPSCRW SCKT M10 x 25 844679 6 WHEEL HUB 894728 6 WLDMT 3WD FORK 923213 CUSHIONED P CLIP 4187320 3WD VALVE 4268492 BRACKET 3WD VALVE 4250912 HYDRAULIC HOSE 4268493 HYDRAULIC HOSE 4147141 HYDRAULIC HOSE 4240304 HYDRAULIC HOSE 4268495 HYDRAULIC HOSE 4268494 HYDRAULIC HOSE 002498400 TEE M F M 11 16 ORS 158007 01 90 M M 11 16 ORS x 9 16 SAE 158007 05 90 M M 1 ORS x 7 8 SAE 844071 TEE 1 ORFS 002568020 CAP 11 16 ORS 158059 04 FITTING 45 ORS ORB ADJ N NNa NH HBR HB PO PO HB PO A Parts 21 150 9001 Quality Management ISO 14001 Environmental Management OHSAS 18001 Occupational Health and Safety Management Europe amp Rest o
8. e gt ROPS Serial Plate Location Weight of ROPS West Road Date Code C TALE TABS Ratan Standard Used Part Number Used on Product K g Serial Number B The serial plate is located on the ROPS cross beam between the seat and engine cover Parts 4 PARTS MANUAL GP 400 SPARES STOCKING GUIDE To keep your equipment fully operational and productive Ransomes suggests you maintain a stock of the more commonly used maintenance items We have included part numbers for the additional support materials and training aids SERVICE SUPPORT MATERIAL 97898 72020 Kubota Diesel Engine Parts MS 2263 Briggs amp Stratton Gasoline Engine Manual Parts Manual 689 8916 1 Kubota Diesel Engine Operators MS 5156 5 03 Briggs amp Stratton Gasoline Engine Manual Operators Manual 25000G and Maintenance 4466061 Hydraulic Oil Filter Element Parts 5 PARTS MANUAL GP 400 HOW TO USE THE PARTS MANUAL ITEM NUMBER Each part which is identified in the illustrations has an item number Parts which do not have an item number may not be readily identified in the illustration but are usually closely associated with the immediately adjacent part ASSEMBLIES A complete assembly e g a wheel motor or hydraulic motor or roll assembly is listed as a complete item with subseq
9. e 11 from machine completely and by using hose 4250912 supplied within kit reconnect to tee piece and return tank fitting Orientate hose to position indicated in Figure 12 en 15 4 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 Figure 13 19 Install and secure hydraulic hose 4268495 connecting top left T piece of flushing valve to lower of front motor drive piping A Figure 13 Figure 14 20 Install and secure hydraulic hose 4268494 connecting top right T piece of flushing valve to lower T piece of the pump B Figure 14 Figure 15 21 Remove cap from the upper on the pump Install and secure hydraulic hose 4240304 Figure 16 connecting the upper T piece of the pump with the bottom left elbow on the flushing valve A Figure 15 en 16 4 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 Figure 16 22 Secure 11 16 ORFS D Figures 16 part 002498400 to existing cross Reinstall and secure original hose to the end of the T piece E Figures 16 4147141 linstall and secure to connector the T piece branch part and connect to bottom right hand connector B Figures 17 of the flushing valve Figure 17 Figure 18 17 23 24 25 26 27 28 29 30 31 32 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 Install and secure these two hoses connecting the bottom elbow on the wheel motor to
10. f The World Except North amp South America Ransomes Jacobsen Limited West Road Ransomes Europark Ipswich IP3 9TT English Company Registration No 1070731 www ransomesjacobsen com North amp South America Jacobsen A Textron Company 11108 Quality Drive Charlotte NC 28273 USA www Jacobsen com ee A Textron Company
11. juster IN one revolution and lock the lock nut Figure 5 11 Raise fuel tank frame and secure with support rod A Figure 6 Figure 6 12 Install and secure the flushing valve bracket to the ROPS rear left bracket on the chassis using M10 x 25 cap screw bolts en 13 13 14 15 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 Disconnect the case drain tube from the front right wheel motor and install and secure 11 16 ORFS cap part 002498400 to the end of the elbow in the motor A Figure 7 Cap the tee piece under the seat B Figure 7 with 11 16 ORFS cap part 002498400 Disconnect the hose A Figure 8 from the T piece on the pump and remove hose completely from the lower T Piece connecting the front 2 wheel motors located underneath the seat plate and discard hose Remove cap at position B Figure 8 and fit to position C Figure 8 NOTICE ENSURE fittings are clean to prevent contamination in hydraulic system Fig Figure 9 en 14 4 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 15 At the top of the flushing valve install two T pieces Figure 9 1 ORFS part 544071 Figure 10 16 the bottom face of the flushing valve install and secure elbows 158007 01 and orientate as shown Figure 10 Figure 11 17 Remove hose A Figure 11 from cross B Fit tee from kit C to cross B then temporarily refit hose A to tee C Figure 12 18 Replace hose A in Figur
12. o cool sufficiently to prevent damage to the block and exhaust manifold Never force water into any electrical components SAFETY INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 the air cleaner or exhaust muffler as water could enter the engine cylinder and cause damage DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury and property damage It may also be used to alert against unsafe practices IMPORTANT Transport speed is for highway use only Never se lect transport speed on grass areas or uneven or un surfaced roads or tracks en 9 4 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 4 1 PREPARATION CAUTION Read the mower s manual and become familiar with the mower the controls and proper use of the equipment Stay alert for potential hazards and follow all safety precautions Read all instructions completely and make sure you understand them before proceeding with the assembly 1 the mower on a flat and level surface fully lower the implements to the ground engage parking brake stop the engine and remove key from ignition switch 2 Wait for all movement to stop before making
13. oolant 4 Oils Disassemble the structure the machine referring to the technical manuals where appropriate Special attention should be made for dealing with stored energy within pressurised elements of the machine or tensioned springs Any items that still have a useful service life as second hand components re serviced should be separated and returned to the relevant centre e Other worn out items should be separated into material groups for recycling and disposal consistent with available facilities More common separation types are as follows e Steel e Non ferrous metals e Aluminium e Brass e Copper ePlastics eIdentifiable e Recyclable e Non recyclable e Not identified e Rubber e Electrical amp Electronic Components ltems that cannot be separated economically into different material groups should be added to the General waste area Do not incinerate waste Finally update machinery records to indicate that the machine has been taken out of service and scrapped Provide this serial number to Ranmsomes Jacobsen Warranty department to close off relevant records Parts 7 3 SAFETY INSTRUCTIONS This safety symbol indicates important safety mes sages in this manual When you see this symbol be alert to the possibility of injury carefully read the message that follows and inform other operators 3 1 en 8 OPERATING INSTRUCTIONS Ensure that the instructions in this book are read
14. the top left T piece on the flushing valve and the top elbow on the wheel motor to the top right T piece on the flushing valve Secure the nylon sleeve with cable ties Figure 18 Reposition the fuel pump to the tank retaining bolt to the rear of the current position BE SURE all hardware and hydraulic connections are tight Secure and tidy up all lose hoses with cable ties Fit the bracket hose clamp C Figure 19 part 4248590 to the ROPS rear right bracket A Figure 19 Feed the hydraulic hoses parts 4147141 and 4240403 through the cushioned p clip B Figure 19 part 523213 Fit the p clip to the bracket hose clamp as indicated in Figure 19 Figure 19 Lower and secure the fuel tank frame Check hydraulic oil level and fill as necessary Recommended hydraulic oil is listed on the right Start the mower and check for proper operation Check for any oil leaks and repair as necessary Recheck hydraulic oil level and fill as necessary en 18 4 FITTING INSTRUCTIONS GP 400 INSTALLATION INSTRUCTIONS LMAC418 f a hydraulic oil leak is suspected use a piece of cardboard or wood NOT your hands to check for leaks e Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin causing serious injury If injured by escaping fluid see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately NOTICE HYDRAULIC OIL The hydrauli
15. uent individual components listed separately The assembly is listed under it s part number with component parts being listed offset to the right e g ITEM PART DESCRIPTION QTY REMARKS 4295 MBG2504 Bracket 1 4296 848 2 4298 450865 Screw 20 Sckt 2 4300 450378 Nut 8 2 4301 WI001 Set Of Wheels 1 4301 1 008162130 e Wheel 8 Hub Assy 1 Rear 4301 2 008170390 e Tyre 1 4301 3 008161830 e e Rim 1 4301 4 008169140 e e Hub Assy 1 4301 5 008169150 e e 1 4301 6 002993010 e e Lubricator 1 4301 7 008161990 e Wheel amp Tyre 2 Front 4301 8 008170780 e Tyre 2 It may not be possible to illustrate every item With certain items purchased from outside suppliers some component parts may not be available from Ransomes and may need to be specially ordered from the supplier QUANTITIES Quantities shown are for one assembly or sub assembly USING THE PARTS LIST Determine the function and application of the part required Turn to the main index page and select the appropriate section Locate the part on the illustration and parts list and read off the quantity from the appropriate MODEL column NUMERICAL INDEX This is a summary of all part numbers used in the manual arranged in numerical sequence and show ing the page and item number under which the parts appear ORDERING OF SPARE PARTS When ordering replacement parts it is most important to quote the SERIAL NUMBER
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