FIELD KIT FITTING INSTRUCTIONS FOR TR3

Transcription

1 24795G-GB (rev.1) FIELD KIT FOR TR3 Rear Roller Brush Kit LMAC185-TR3-F for "Fairway" style Cutting Units Series: AAG, AAH, AAJ, AAK IMPORTANT NOTE - TR3 ONLY Grassboxes cannot be used with these Cutting Units when Rear Roller Brushes are fitted. 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, adjust or service the machine. RJL 100/July 2008

2 2008, Ransomes Jacobsen Limited. All Rights Reserved GB-2

3 1 CONTENTS CONTENTS PAGE 2 SAFETY INSTRUCTIONS 2.1 OPERATING INSTRUCTIONS SAFETY SIGNS STARTING THE ENGINE DRIVING THE MACHINE TRANSPORTING LEAVING THE DRIVING POSITION SLOPES BLOCKED CUTTING CYLINDERS ADJUSTMENTS, LUBRICATION AND MAINTENANCE PREPARATION 3.1 PREPARATION IMPORTANT NOTE CUTTING CYLINDER 4.1 MODIFYING EXISTING CUTTING CYLINDER NEW CUTTING CYLINDER PART NUMBERS ASSEMBLY INSTRUCTIONS 5.1 ASSEMBLE REAR ROLLER BRUSH AND MOUNTING PLATES ASSEMBLE NON-DRIVE SIDE BEARING HOUSING ASSEMBLE PULLEY TO CUTTING CYLINDER SHAFT ASSEMBLE PULLEY TO BRUSH SHAFT AND ADJUST DRIVE BELT ASSEMBLE BELT & TENSIONER ASSEMBLE BELT GUARD AND TEST & REPLACE THE PIVOT ARM MOUNTING BRACKETS - FRONT LH UNIT REPLACE THE PIVOT ARM MOUNTING BRACKETS - FRONT RH UNIT REPLACE THE PIVOT ARM MOUNTING BRACKETS - CENTRE UNIT PARTS LISTS LMAC185 KIT FOR 26" RH DRIVE CUTTING UNIT & LMAC186 KIT FOR 26" RH DRIVE CUTTING UNIT & GB-3

4 2 SAFETY INSTRUCTIONS This safety symbol indicates important safety messages 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. 2.1 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. 2.2 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 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. 2.4 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 out 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. 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 substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. 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. If the machine starts to vibrate abnormally, check immediately. 2.5 TRANSPORTING Ensure that the cutting units are securely fastened in the transport position. Do not transport with cutting 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. 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 safe slope. Travel on grass slopes requires particular care. 2.8 BLOCKED CUTTING CYLINDERS Stop the engine and make sure all moving parts are stationary. Apply brakes and disengage all drives. GB-4

5 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. 2.9 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 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. 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. GB-5

6 3 PREPARATION 3.1 PREPARATION 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. b. 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 1. In order to maintain a balanced cutting unit when rear roller brushes are fitted it is necessary to also fit the new pivot arm mounting brackets supplied with this kit. GB-6

7 4 CUTTING CYLINDER 4.1 MODIFYING EXISTING CUTTING CYLINDER 1. If the Rear Roller Brush Kit is to be fitted the cutting cylinder shaft needs to be bored at 12 mm diameter to a depth of mm. 2. Make sure that the bore is absolutely vertical! 3. Tap a thread in the new hole 13mm full thread minimum: M14 x 1.5 RH when fitting kit LMAC183 or LMAC185 to a RH Drive Cutting Unit. 4. Or, fit a new cutting cylinder as shown in the table below 4.2 NEW CUTTING CYLINDER PART NUMBERS Part No Description Used On MBF0469B.07 Wldmt-Cyl 26" x 5K RH Drive TR3 MBF0325B.07 MBF0326B.07 Wldmt-Cyl 26" x 7K RH Drive Wldmt-Cyl 26" x 11K RH Drive Fairway 305 Fairway 405 TR3 Fairway 305 Fairway 405 TR3 MBF0894A.07 Wldmt-Cyl 26" x 5K LH Drive TR3 MBF0895A.07 Wldmt-Cyl 26" x 7K LH Drive TR3 MBF0896A.07 Wldmt-Cyl 26" x 11K LH Drive TR3 GB-7

8 5 ASSEMBLY INSTRUCTIONS 5.1 ASSEMBLE REAR ROLLER BRUSH AND MOUNTING PLATES 1. Remove rear roller scraper cable and store. It will not be used any more. 2. Remove bolts for rear roller brackets and fit studs (13), plates (14), mounting plates (12 and 24), washers (30) and locknuts (29). 3. Assemble brush shaft (16 and 17) with flange bearings (15) to mounting plates (12 and 24) using bolts (25), washers (36) and locknuts (28). 4. Adjust brush shaft (16 and 17) to the rear roller and fix it using the bearing collars. GB-8

9 5 ASSEMBLY INSTRUCTIONS 5.2 ASSEMBLE NON-DRIVE SIDE BEARING HOUSING 1. Apply Loctite 270 to the splined adapter (5) thread, and screw it into the cutting cylinder. 2. Fit the lubricator (1), pivot stud (39) and nut (27) to the bearing housing (21). 3. Fit the bearing (23) to the bearing housing (21). 4. Add thrust ring (4) and approximately 5-off spring washers (22) into the bearing housing (21) in back-toback order to obtain the correct pre-tension for the cutting cylinder bearing. Remove the taper roller bearing outer race from the original bearing housing and re-assemble it to the new bearing housing (21). The original spring kit is no longer used. 5. Assemble splined adapter (7) to drive shaft (8). From June 2008 this is a one piece drive shaft (7). 6. Assemble one circlip (40) to drive shaft (8) or (7) in groove nearest splined adapter. 7. Assemble drive shaft (8) with splined adapter (7) or one piece part (7) and sleeve (6) to bearing housing (21) and bolt to the unit frame using the original hardware. 8. Assemble second circlip (40) to drive shaft (8) or (7). 9. Fit cover (3) with countersunk screws (32). GB-9

10 5 ASSEMBLY INSTRUCTIONS 5.3 ASSEMBLE PULLEY TO CUTTING CYLINDER SHAFT 1. Fit key (37) to the drive shaft. 2. Install the variator pulley (11) to the drive shaft using the conical flange lock (10). From June Fit pulley (18) using drive shaft using pin (35). 5.4 ASSEMBLE PULLEY TO BRUSH SHAFT AND ADJUST DRIVE BELT 1. Make final adjustment of the brush shaft (16 and 17) in relation to the rear roller. 2. Fit pulley (18) to the brush shaft using pin (35). 3. Grease all lubricators. From June 2008 Both pulleys are (18) GB-10

11 5 ASSEMBLY INSTRUCTIONS 5.5 ASSEMBLE BELT GUARD AND TEST 1. Fit drive belt and adjust it by the drive pulley variation (11). a. Loosen grub screws (A). b. Rotate the movable flange part of the pulley (B) until correct belt tension is obtained. c. Tighten grub screws (A). 2. Fit belt cover (41) using distance piece (19), countersunk screw (33), screw (26), bolt (38), washer (30), lockwasher (31) and locknut (29). IMPORTANT NOTE: Ensure that the full belt guards shown in the illustration below are fitted. The drive belt and pulleys must be fully covered during operation. 3. Fit decal (2) to belt cover (41). 4. Make test run and check all parts for proper fitting. LOCATION OF DECAL ON BELT COVER GB-11

12 5 ASSEMBLY INSTRUCTIONS (from June 2008) 5.5 FITTING OF VEE BELT & IDLER TENSIONER 1. Complete the assembly of the kit as per sections 5.1 to Remove screws from bottom block and replace with studs (26) & (8), one screw at a time. 3. Fit plate welded assembly (10) to these with washers and nyloc nuts. 3. Assemble tensioner bracket (11) to plate w/a (10) with grubscrews (37) as shown next page. 4. Fit tensioner (20) to tensioner bracket (11) with screw & washers as shown next page. 5. Assembly vee belt (9) as shown below. 6. Align brush to rear roller and tight mounting screws of flange bearings and brackets. 7. Adjust tensioner (20) on vee belt (9) as required. GB-12

13 5 ASSEMBLY INSTRUCTIONS (from June 2008) 5.5 ASSEMBLE BELT GUARD AND TEST 1. Fit guard support (19) to plate w/a (10). 2. Fit belt cover (41) to guard support (19) with screws and washers as shown below. 3. Fit decal (2) to belt cover (41). 4. Make test run and check all parts for proper fitting. GB-13

14 5 ASSEMBLY INSTRUCTIONS Illustration No. LMAC185_TR3_Front-LH GB-14

15 5 ASSEMBLY INSTRUCTIONS ITEM PART No DESCRIPTION QTY REMARKS Nut-Hex 1/2-20 Nyloc Wshr-.526/.506 x 1-1/4 x 12GA Spacer-1/2 x 3/4 x 1/ Wldmt-Pivot Arm LH Bracket LH-Pivot Arm Bracket RH-Pivot Arm Bracket LH-Front Pivot Arm Bracket RH-Front Pivot Arm Screw-Hex M10 x Washer-M10 x 21 x Lockwasher-M10 x 15.9 x Scrw-Hex 1/2-20 x 1-1/ REPLACE THE PIVOT ARM MOUNTING BRACKETS 1. Remove screw (12), nut (1), washer (2) and spacer (3) from pivot arm (4), and retain for future use. 2. Remove pivot arm (4) from brackets (5) and (6), and retain for future use. 3. Remove screws (9), washers (10) and lockwashers (11) to release brackets (5) and (6) from the cutting unit. Retain the hardware for future use. 4. Store brackets (5) and (6) in a safe place; they will not be required when the cutting unit is fitted with Rear Roller Brushes. 5. Assemble brackets (7) and (8) to the cutting unit using the hardware removed at Assemble pivot arm (4) to the cutting unit using the hardware removed at GB-15

16 5 ASSEMBLY INSTRUCTIONS Illustration No. LMAC185_TR3_Front-RH GB-16

17 5 ASSEMBLY INSTRUCTIONS ITEM PART No DESCRIPTION QTY REMARKS Nut-Hex 1/2-20 Nyloc Wshr-.526/.506 x 1-1/4 x 12GA Spacer-1/2 x 3/4 x 1/ Wldmt-Pivot Arm RH Bracket LH-Pivot Arm Bracket RH-Pivot Arm Bracket LH-Front Pivot Arm Bracket RH-Front Pivot Arm Screw-Hex M10 x Washer-M10 x 21 x Lockwasher-M10 x 15.9 x Scrw-Hex 1/2-20 x 1-1/ REPLACE THE PIVOT ARM MOUNTING BRACKETS 1. Remove screw (12), nut (1), washer (2) and spacer (3) from pivot arm (4), and retain for future use. 2. Remove pivot arm (4) from brackets (5) and (6), and retain for future use. 3. Remove screws (9), washers (10) and lockwashers (11) to release brackets (5) and (6) from the cutting unit. Retain the hardware for future use. 4. Store brackets (5) and (6) in a safe place; they will not be required when the cutting unit is fitted with Rear Roller Brushes. 5. Assemble brackets (7) and (8) to the cutting unit using the hardware removed at Assemble pivot arm (4) to the cutting unit using the hardware removed at GB-17

18 5 ASSEMBLY INSTRUCTIONS Illustration No. LMAC185_TR3_Centre GB-18

19 5 ASSEMBLY INSTRUCTIONS ITEM PART No DESCRIPTION QTY REMARKS Nut-Hex 1/2-20 Nyloc Wshr-.526/.506 x 1-1/4 x 12GA Spacer-1/2 x 3/4 x 1/ Wldmt-Pivot Arm, Centre Bracket LH-Centre Pivot Bracket RH-Centre Pivot Bracket LH-Centre Pivot Arm Bracket RH-Centre Pivot Arm Screw-Hex M10 x Washer-M10 x 21 x Lockwasher-M10 x 15.9 x Scrw-Hex 1/2-20 x 1-1/ REPLACE THE PIVOT ARM MOUNTING BRACKETS 1. Remove screw (12), nut (1), washer (2) and spacer (3) from pivot arm (4), and retain for future use. 2. Remove pivot arm (4) from brackets (5) and (6), and retain for future use. 3. Remove screws (9), washers (10) and lockwashers (11) to release brackets (5) and (6) from the cutting unit. Retain the hardware for future use. 4. Store brackets (5) and (6) in a safe place; they will not be required when the cutting unit is fitted with Rear Roller Brushes. 5. Assemble brackets (7) and (8) to the cutting unit using the hardware removed at Assemble pivot arm (4) to the cutting unit using the hardware removed at GB-19

20 6 PARTS LIST LMAC185 Kit for 26" RH Drive Cutting Unit Illustration No. LMAC185-2 GB-20

21 6 PARTS LIST LMAC185 Kit for 26" RH Drive Cutting Unit ITEM PART No DESCRIPTION QTY REMARKS LMAC185 Kit-Rear Roller Brush 1 For 26" RH Drive Cutting Unit Lubricator-M6 Str Decal-Belt Cover Thrust Ring Splined Drive, M14 RH Thread Sleeve 1 LMSE199 Shaft-Splined Drive 1 comprising Splined Drive, M12 RH Thread Shaft, Drive Pulley, M12 RH Thd Drive Belt Taper Lock, Drive Pulley Pulley Mounting Plate LH Stud M8 x Plate, Tapped M Flange Bearing Brush Shaft (723mm Lg) 1 For 22" Cutting Unit Brush Shaft (823 mm Lg) 1 For 26" Cutting Unit Pulley, Brush Distance Piece Housing-Cyl, LH Sprg-Disc 30 x 50 x Brg-Align 17 x 47 x Mounting Plate Bolt-Hex M6 x Scrw-Hex M8 x Nut-Hex M10 Thin Nut-Hex M6 Nyloc Nut-Hex M8 Nyloc Wshr-M8 x 17 x Lockwshr-M8 x x Scrw-Csk M5 x Scrw-Sckt Csk M8 x Scrw-Pan Hd No.12 x Pin-Tension 5 x Wshr-1/4 x 5/8 x Key-5 x 5 x Bolt-Crg M8 x MBE2659 Pivot Stud Circlip-Exp 17 x 1 T Belt Guard 1 GB-21

22 6 PARTS LIST LMAC186 Kit for 26" LH Drive Cutting Unit Illustration No. LMAC186-2 GB-22

23 6 PARTS LIST LMAC186 Kit for 26" LH Drive Cutting Unit ITEM PART No DESCRIPTION QTY REMARKS LMAC186 Kit-Rear Roller Brush 1 For 26" LH Drive Cutting Unit Lubricator-M6 Str Decal-Belt Cover Thrust Ring Splined Drive, M14 LH Thread Sleeve Splined Drive, M12 LH Thread Shaft, Drive Pulley, M12 LH Thd Drive Belt Taper Lock, Drive Pulley Pulley Mounting Plate LH Stud M8 x Plate, Tapped M Flange Bearing Brush Shaft (723mm Lg) 1 For 22" Cutting Unit Brush Shaft (823 mm Lg) 1 For 26" Cutting Unit Pulley, Brush Distance Piece Belt Guard RH Housing-Cyl, RH Sprg-Disc 30 x 50 x Brg-Align 17 x 47 x Mounting Plate Bolt-Hex M6 x Scrw-Hex M8 x Nut-Hex M10 Thin Nut-Hex M6 Nyloc Nut-Hex M8 Nyloc Wshr-M8 x 17 x Lockwshr-M8 x x Scrw-Csk M5 x Scrw-Sckt Csk M8 x Scrw-Pan Hd No.12 x Pin-Tension 5 x Wshr-1/4 x 5/8 x Key-5 x 5 x Bolt-Crg M8 x MBE2659 Pivot Stud Circlip-Ext 17 x 1 T 2 GB-23

24 6 PARTS LIST LMAC185 Kit for 26" RH Drive Cutting Unit (from June 2008) GB-24

25 6 PARTS LIST LMAC185 Kit for 26" RH Drive Cutting Unit (from June 2008) ITEM PART No DESCRIPTION QTY REMARKS LMAC185 Kit-Rear Roller Brush 1 For 26" RH Drive Cutting Unit Lubricator-M6 Str Decal-Belt Cover Thrust Ring Splined Drive, M14 RH Thread Sleeve Drive Shaft Stud M8/M Vee Belt Plate LH W/A Tensioner Bracket W/A Mounting Plate Stud M8 x Plate, Tapped M Flange Bearing Brush Shaft (723mm Lg) 1 For 22" Cutting Unit Brush Shaft (823 mm Lg) 1 For 26" Cutting Unit Pulley, Brush Guard Support Tensioner Housing-Cyl, LH Sprg-Disc 30 x 50 x Brg-Align 17 x 47 x Mounting Plate Stud M10/M Scrw-Hex M8 x Nut-Hex M10 Thin Nut-Hex M6 Nyloc Nut-Hex M8 Nyloc Wshr-M8 x 17 x Screw M10 x Scrw-Csk M5 x Screw M6 x Scrw-Pan Hd No.12 x Pin-Tension 5 x Wshr-1/4 x 5/8 x Grubscrew M6 x Nut-Hex M10 Nyloc 1 39 MBE2659 Pivot Stud Circlip-Exp 17 x 1 T Brush Guard W/A 1 GB-25

26 6 PARTS LIST LMAC186 Kit for 26" LH Drive Cutting Unit (from June 2008) GB-26

27 6 PARTS LIST LMAC186 Kit for 26" LH Drive Cutting Unit (from June 2008) ITEM PART No DESCRIPTION QTY REMARKS LMAC186 Kit-Rear Roller Brush 1 For 26" LH Drive Cutting Unit Lubricator-M6 Str Decal-Belt Cover Thrust Ring Splined Drive, M14 LH Thread Sleeve Drive Shaft Stud M8/M Vee Belt Plate RH W/A Tensioner Bracket W/A Mounting Plate Stud M8 x Plate, Tapped M Flange Bearing Brush Shaft (723mm Lg) 1 For 22" Cutting Unit Brush Shaft (823 mm Lg) 1 For 26" Cutting Unit Pulley, Brush Guard Support Tensioner Housing-Cyl, RH Sprg-Disc 30 x 50 x Brg-Align 17 x 47 x Mounting Plate Bolt-Hex M6 x Stud M10/M Nut-Hex M10 Thin Nut-Hex M6 Nyloc Nut-Hex M8 Nyloc Wshr-M8 x 17 x Screw M10 x Scrw-Csk M5 x Scrw-Sckt Csk M8 x Scrw-Pan Hd No.12 x Pin-Tension 5 x Wshr-1/4 x 5/8 x Grubscrew M6 x Nut-Hex M10 Nyloc 2 39 MBE2659 Pivot Stud Circlip-Ext 17 x 1 T Brush Guard W/A 1 GB-27

28 Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, IP3 9TT English Company Registration No Jacobsen, A Textron Company Quality Drive, Charlotte, NC 28273, USA