Jacobsen GP400 & Jacobsen G-PLEX III Fitting Instructions
Contents
1. FITTING INSTRUCTION MANUAL REMOVE EXISTING FOOTPEDAL MOW SPEED ARRANGEMENT Remove Footpedal but retain all pivot hardware including bushings collars brackets Disconnect mow transport speed cable from mechanism and remove from machine Including switch Parts no longer required Remove pivot hardware for brake locking plate Retain hardware Unscrew footplate and discard Retain hardware ASSEMBLE NEW FOOT PLATE Assemble transport speed stop and bolt arrangement which acts as bellcrank stop Secure footplate to chassis Note It is benefical to secure footpedal bracket A to footpedal prior to commencing fitting of the automatic mow speed mechanism Assemble all hardware transport stop spring fixing point bellcrank stop SeeParts Breakdown Re assemble brake locking plate pivot ASSEMBLE AUTOMATIC MOW SPEED MECHANISM Assemble mechanism as detailed opposite Also use parts breakdown plus exploded diagram for further information regarding this assembly GB 7 3 FITTING INSTRUCTIONS JACOBSEN GP400 8 G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL FIT MECHANISM TO MACHINE Remove outer ram pivot pin from RH lift ram Retain Hardware removed Offer mechanism built up previously and assemble to underside of footplate Note G Plex a split pin and washer to be assemblied either side of lockout link when connected to inner ram pin A Secure Bellcrank pivot to under side2. engine to cool before storing in any enclosure JACOBSEN GP400 amp G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL e 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 be drained this should be done outdoors e Do not spill fuel onto hot components When servicing batteries DO NOT SMOKE and keep naked lights away e Do not place any metal objects across the terminals 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 CAUTION N Refer to local legislation and standards for the appropriate use of personal protective equipment and the disposal of waste WARNING Battery posts terminals and related accessories contain lead and lead compounds WASH HANDS AFTER HANDLING WARNING DISCONNECT THE BATTERY BEFORE WORKING ON THE ELECTRICS WARNING Batteries produce explosive gases and contain corrosive acid and supply levels of electrical current high enough to cause burns GB 5 3 FITTING INSTRUCTIONS 3 1 PREPARATIO
3. of footplate Re connect ram pin Note GP400 Locate pin 84382 A from kit and replace inboard ram pin Locate lockout link B between split pins amp washers C Secure Bellcrank pivot to under side of footplate Re connect outer ram pin FIT SPRING Loop spring through bellcrank assy and extend spring over fixng point Refer to adjustment section 4 1 1 for clarification Secure spring in place with nut FIT NEW FOOTPEDAL Mount new footpedal using all existing hardware removed previously GB 8 FITTING INSTRUCTIONS JACOBSEN GP400 8 G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL REMOVE MOW CABLE Remove control panel Cut all cable ties securing cable to old mechainsm Remove Cable lever from control panel and discard Re assemble control panel to Machine MOW SWITCH G Plex Using switch bypass wire loop out switch as mow switch is no longer required and secure harness under footplate 3 11 MOW SWITCH GP400 1 Using switch bypass A loop out switch as mow switch is no longer required GB 9 4 ADJUSTMENTS JACOBSEN GP400 8 G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL 4 1 SPEED CONTROL PEDAL This procedure MUST be performed as specified and only by properly trained service personnel Adjusting the speed control screw out increasing length will reduce the mow speed Adjusting the speed control s
4. Estimated time for 3 8 mph 6 1 Km hr will be approximately 8 8 to 9 2 seconds If there is a significant difference in the times listed above you can adjust the mow speed as follows GB 11 4 PARTS LIST JACOBSEN GP400 amp G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL GB 12 4 PARTS LIST JACOBSEN GP400 8 G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL ITEM PART NO DESCRIPTION QTY OO 001090016 002993063 4115061 4119282 450120398 450192 450216 450219 450378 450379 450453 450454 450473 452564 515268 923221 548159 548168 829500 840003 841487 893359 454000297 4152177 843821 4227580 Scrw Hex 3 8 16 x 2 Lubricator Traction Pedal RH Footplate Nut Hex Nyloc 3 8 16 Scrw Hex M8 x 25 Scrw Hex M10 x 35 Scrw Hex M10 x 50 Nut Hex M8 Nyloc Nut Hex M10 Nyloc Nut Hex M8 Verbus Ripp Nut Hex M10 Verbus Ripp Scrw Hex M8 x 30 Verbus Ripp Bolt Crg M8 x 25 Bushing Spacer Washer Washer Spring Tread Control Panel Lockout Link Ballcrank Ay Lockout Split Pin 1 8 x 1 1 4 Switch Bypass Harness G Plex III Pin Cylinder Pivot GP400 Link Mow Mode Switch Bypass GP400 GB 13 6 NOTES JACOBSEN GP400 amp G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL NOTES GB 14 ISO9001 ISO14001 OHSAS 18001 gt Ransomes Jacobsen Limited West Road Ransomes Europark Ipswich England IPS 9TT Engl
5. M 24794G GB rev 1 Fitting Instructions Automatic Mow Speed Selection Kit LMAC236 Jacobsen GP400 amp Jacobsen G PLEX III adjust or service the machine WARNING If incorrectly used this machine can cause severe injury 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 United Kingdom RJ 100 March 2011 2011 Ransomes Jacobsen Limited All Rights Reserved 1 CONTENTS JACOBSEN GP400 8 G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL CONTENTS PAGE 1 CONTENT e 3 2 Pili eecT A 2 1 OPERATING INSTRUCTIONS P 4 2 2 GNS ae iesu ER RR EIL 4 2 3 STARTING THE ENGINE stu tetris 4 2 4 BDRZIRETTNENMZC FINE a ao EPE 4 25 TRANG PORTIN oosa O i noz ata 4 2 6 LEAVING THE DRIVING POSITION assess ccc 4 2 7 ESL o 4 2 8 BLOGREBCUNTNN CTENOERC i ACRE ZA 5 2 9 ADJUSTMENTS LUBRICATION 8 MAINTENANCE 9 3 FITTING INSTRUG TIONS oaa osea iiie cate ace agent cuu 6 4 ADJUSTMENTS reia aa N a 10 5 PARTS E oE E 12 6 NOTES 2 A zie t 14 GB 3 2 SAFETY INSTRUCTIONS This safety symbol indicates important safety messages in this manual When you see this symbol be a
6. N CAUTION Read the tractor s manual and become familiar with the tractor 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 Park the tractor 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 a Wait for all movement to stop before making any adjustments or modifications Take 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 3 2 IMPORTANT NOTE CAUTION WAN Contact with diesel fuel amp Gasoline can damage your skin Use gloves when working with diesel fuel amp Gasoline If you come in contact with diesel fuel amp Gasoline wash it off immediately WARNING e Catch fuel and dispose of properly e To avoid a fire hazard clean up any spilled fuel CAUTION Dispose of used diesel fuel amp Gasoline in accordance with local regulations GB 6 JACOBSEN GP400 amp G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL 3 FITTING INSTRUCTIONS JACOBSEN GP400 8 G PLEX AUTOMATIC MOW SPEED SELECTION
7. crew in shortening length will increase mow speed Determine which direction to adjust the mow speed Figure 4 1 1 screw Loosen the locking nut and adjust speed 1 Mow Speed Adjustment Screw control screw snug up the locking nut and run the 2 Locking Nut time test again repeat as necessary When correct mow speed has been obtained tighten the locking nut See Fig 4 1 1 TO SET BELLCRANK STOP SCREW NOTICE The bellcrank stop screw has been set at the factory and should NOT require adjustment If stop screw is loosened or removed it MUST be properly installed and adjusted prior to unit operation Remove the screws securing the center foot panel Fe SPRUE RES ia and remove panel this will allow access to the Figure 4 1 2 lockout link angle 1 Bellcrank Stop Screw 2 Center Foot Panel Loosen the nut on the bellcrank stop screw just enough to allow the screw to be slid to the left of the slot See Fig 4 1 3 Figure 4 1 3 1 Bellcrank 2 Lockout Link Angle 3 Lockout Link slot 4 Bellcrank Stop Screw GB 10 4 ADJUSTMENTS JACOBSEN GP400 8 G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL Rotate bellcrank clockwise as viewed from above and hold the bushing on the lockout link angle to the left end of the lockout link slot See Fig 4 1 4 Slide the bellcrank stop screw to the left of the slot located in the foot panel See Fig 4 1 2 making sure the bellcrank contacts the stop screw W
8. ish Company Registration No 1070731 www ransomesjacobsen com
9. ith the screw held tightly against the bellcrank tighten the stop screw nut Install the center foot panel Figure 4 1 4 Position Bushing to Left of Slot 4 2 MOW TRANSPORT SPEED CONTROL When cuiting heads are raised completely the wheel drive speed range is 0 7 5 mph 0 12 Km hr Speed is controlled by use of the direction speed control pedal as described in control pedals section When cutting heads are lowered the forward movement of the direction speed control pedal is restricted by the automatic mow speed control linkage the bellcrank stop screw contacts the foot pedal tab which rotates the pedal upward This in turn reduces the ground speed of the unit for mowing The mow speed range is 0 3 8 mph 0 6 1 Km hr 43 ADJUSTING MOW SPEED To determine mow speed run a time check on how fast the unit travels in a distance of 50 15 24 M Prepare a level surface with enough room to start and end beyond the 50 marks Place a stake in the ground where you want to begin timing the unit Measure and place another stake at a distance of 50 15 24 M Lower the cutting heads and press the direction pedal forward so the unit is traveling at full throttle the cutting heads should be in the neutral position when timing the unit Begin timing the unit when the center of the front tire aligns with the first stake Stop timing when the center of the front tire aligns with the stake placed at 50 15 24 M
10. lert to the possibility of injury carefully read the message that follows and inform other operators 2 1 2 2 OPERATING INSTRUCTIONS Ensure that the instructions in this book are read 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 2 3 STARTING THE ENGINE 2 4 GB 4 Before starting the engine check that the brakes are applied drives are in neutral guards are in position and intact and bystanders are clear of the machine Do not run the engine in a building without adequate ventilation DRIVING THE MACHINE Before moving the machine check to ensure that all parts are in good working order paying particular attention to brakes tyres steering and the security of cutting blades Replace faulty silencers mow only in daylight or good artificial light Always observe the Highway Code both on and off the roads Keep alert and aware at all times Watch ou
11. t for traffic when crossing or near roadways Stop the blades rotating before crossing surfaces other than grass Remember that some people are deaf or blind and that children and animals can be unpredictable Keep travelling speeds low enough for an emergency stop to be effective and safe at all times in any conditions Remove or avoid obstructions in the area to be cut thus reducing the possibility of injury to yourself and or bystanders JACOBSEN GP400 amp G PLEX AUTOMATIC MOW SPEED SELECTION FITTING INSTRUCTION MANUAL e When reversing take special care to ensure that the area behind is clear of obstructions and or bystanders DO NOT carry passengers Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property When the machine is to be parked stored or left unattended lower the cutting means unless the transport locks are being used While mowing always wear substaniial footwear and long trousers Do not operate the equipment when barefoot or wearing open sandals e Check the grass catcher frequently for wear or deterioration After striking a foreign object Inspect the lawnmower for damage and make repairs before restarting and operating the equipment e If the machine starts to vibrate abnormally check immediately 2 5 TRANSPORTING e Ensure that the cutting units are securely fastened in the transport position Do not transport with cu
12. 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 When working underneath lifted parts or machines make sure adequate support Is provided Do not dismantle the machine 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 over speed 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 is 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
13. tting mechanism rotating Drive the machine with due consideration of road and surface conditions inclines and local undulations 2 6 LEAVING THE DRIVING POSITION Park the machine on level ground e Before leaving the driving position stop the engine and make sure all moving parts are stationary Apply brakes and disengage all drives Remove the starter key 2 7 SLOPES TAKE EXTRA CARE WHEN WORKING ON SLOPES Local undulations and sinkage will change the general slope Avoid ground conditions which can cause the machine to slide Keep machine speeds low on slopes and during tight turns Remember there is no such thing as a sale slope e Travel on grass slopes requires particular care 2 8 BLOCKED CUTTING CYLINDERS e Stop the engine and make sure all moving parts are stationary e Apply brakes and disengage all drives 2 SAFETY INSTRUCTIONS Release blockages with care Keep all parts of the body away from the cutting edge Beware of energy in the drive which can cause rotation when the blockage is released Keep other people away from the cutting units as rotation of one cylinder can cause the others to rotate ADJUSTMENTS LUBRICATION AND MAINTENANCE 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
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