Safety, Operation and Maintenance Manual. Jacobsen MH G-US (Rev.2) WARNING

Transcription

1 25077G-US (Rev.2) Safety, Operation and Maintenance Manual Jacobsen MH5 Frame With Oil Cooler, Less Cutting Units Series: KT Product Code LBMA405 Frame Less Oil Cooler And Cutting Units Series: KU Product Code LBMA406 Sportcutter 8 inch 8 knife Left Hand floating Head Cutting Unit Series: AD2 Product Code: LMAC603-L Sportcutter 8 inch 8 knife Right Hand floating Head Cutting Unit Series: AE2 Product Code: LMAC603-R Sportcutter 8 inch 6 knife Left Hand floating Head Cutting Unit Series: AB2 Product Code: LMAC604-L Sportcutter 8 inch 6 knife Right Hand floating Head Cutting Unit Series: AC2 Product Code: LMAC604-R Verticut Left Hand floating Head Cutting Unit Series: AF2 Product Code: LMAC605-L Verticut Right Hand floating Head Cutting Unit Series: AG2 Product Code: LMAC605-R Frame With Oil Cooler And 8"- 8k Floating Head Units Series: JB2 Product code: LKDA304 WARNING WARNING: 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. US United States of America RJL 100 February 2015

2 Section Page Section Page INTRODUCTION 2.1 Important Product Identification Guidelines For The Disposal Of Scrap Products During Service Life End Of Service Life Parts Manual... 6 SAFETY 3.1 Operating Safety Operating Instructions Safety Signs Starting The Engine Transporting Slopes Blocked Cutting Units Adjustments, Lubrication, Maintenance & Cleaning SPECIFICATIONS 4.1 Dimensions & Weights Machine Specification Hydraulic Specification Cutting Unit Specification Recommended Lubricants Cutting Performance (Area) Cutting Performance (Frequency) DECALS 5.1 Safety Decals Instruction Decals CONTROLS 6.1 Cutting Cylinder Drive OPERATION 7.1 Daily Inspection Operating Procedure Attaching The Mower To The Tractor Removing The Machine From The Tractor Mowing Transporting Cutting Performance Unblocking Cutting Units Backlapping MAINTENANCE AND LUBRICATION 8.1 Maintenance & Lubrication Chart Lubrication During Overhaul ADJUSTMENT 9.1 Height Of Cut Adjustment Cutting Reel Adjustment QUALITY OF CUT 10 Quality Of Cut Troubleshooting Washboarding Marcelling Step Cutting Scalping Stragglers Streaks Windrowing Rifling Or Tramlining Mismatched Cutting Units GUARANTEE 11.1 Warranty Ransomes Jacobsen Limited reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. 2015, Ransomes Jacobsen Limited. All Rights Reserved

3 INTRODUCTION IMPORTANT The Jacobsen Hydraulic 5 is a tractor mounted reel mower. The cutting units are driven by a two-port hydraulic pump, driven by the Tractor output shaft. IMPORTANT: Do the maintenance indicated in this manual to make sure that the quality of cut is kept at a high level. This Manual is part of the machine and must stay with the machine always. The suppliers of new, or used, machines need to keep this documentation and supply the owners with a copy. You must use the machine to cut the grass only and not for any other purpose. The Compliance with these conditions of The operation, service and repair specified by the manufacturer, are understood to be part of the correct use. ALL operators MUST read through this manual and understand the Safety Instructions, controls, lubrication and maintenance procedures. Make sure that you obey all safety and road traffic regulations. You must not make any changes to the machine that are not approved by the manufacturer. This type of change can release the manufacturer from the liability for any damage or injury. Discard of worn parts in alignment with all local environment protection regulations. Use the local systems available in the country where the machine is used, for these recycled materials. When the machine is at its end of life, there are guidelines in this manual for the removal of the machine from use. Use only Jacobsen Genuine spare parts to meet the machine type approval regulations specified by the European Union. 2006/42/EC These instructions are the Original instructions confirmed by Ransomes Jacobsen Limited en-3

4 2 INTRODUCTION 2.2 PRODUCT IDENTIFICATION A B C D E F G H J Maximum front axle load in Kg (for all machines being driven on the highway) Weight-Mass in Kg Maximum rear axle load in Kg (for all machines being driven on the highway) Power Rating in Kw Date code Machine type (Name) Product code Product name Serial number West Road Ransomes Europark Ipswich IP3 9TT England A B C D E Kg Kg Kg Kw F G H J Location of Serial number plate The serial number plate (A) is found on the main frame upper tractor mount. A Cutting Unit The cutting unit serial plate (B) is located on the unit top plate. B Kg Kg Kg Kw West Road Ransomes Europark Ipswich IP3 9TT England en-4

5 INTRODUCTION GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS DURING SERVICE LIFE All the used fluids and parts must be controlled as hazardous materials material. Recommended procedures must be followed for their safe removal. If a fluid leak occurs, contain the spill to make sure that the leak does not flow into the ground or drainage system. Follow the regulations in force to make sure that leaks are controlled. The maintenance procedures in this manual make sure that the damage that the machine can cause in the local environment is controlled. When the machine completes its full service life, the following actions must be taken END OF SERVICE LIFE These guidelines must be used with applicable Health, Safety and Environmental laws. Always use the approved local waste disposal and agencies for recycled materials. Park the machine in an applicable area to use all of the necessary lifting equipment. Use correct tools and Personal Protective Equipment (PPE) and take instruction from the technical manuals applicable to the machine. Remove and store correctly 1. Batteries 2. Fuel 3. Engine coolant 4. Oils Read the Technical Manual before you begin to disassemble the machine. Plan the disassembly, give attention to parts that are in a state of mechanical pressure or contain stored energy e.g springs. Items that continue to have a service life must be separated and returned to the local dealer. Items that are worn must be separated into the material groups and removed according to the agencies for the recycled materials that are available. Common examples. Steel Non ferrous metals Aluminium Brass Copper Plastic materials Identified Can be recycled Can not be recycled Not identified Rubber Electrical and Electronic Components Some parts are not easily separated e.g Hydraulic hose. These materials must be added to the General discarded materials area. Do not burn discarded materials. Change the machinery records to show that the machine is not in operation and is discarded. Supply this serial number to The Jacobsen Warranty Department to close their records. en-5

6 2 INTRODUCTION 2.4 PARTS MANUAL To meet the standard ISO14001, Jacobsen does not send a paper parts manual with every product. To refer to the parts list for this mower you have four options: 1. Website Select the GENUINE PARTS tab followed by the ONLINE PARTS LOOK-UP tab. These pages will show the parts list and the line drawings you need to help with the identification of spare parts. 2. Website Select the CUSTOMER CARE tab followed by the MANUALS tab. You have the option to view or Download a PDF version of the parts manual. 3. Complete the form included in the technical manual pack supplied with the machine for one of the two options below a. A disc that contains an electronic copy of the Parts Book. b. A paper copy of the parts manual. en-6

7 SAFETY HOW TO OPERATE SAFELY! WARNING EQUIPMENT THAT IS NOT OPERATED CORRECTLY OR BY PERSONNEL WITHOUT TRAINING CAN BE DANGEROUS. Know the location and correct use of all controls. Before any use of the machine, personnel without training must receive instruction from personnel with experience in the machines operation Safe operation a) Read the instructions carefully. Know the controls and the correct use of the equipment; b) Children or persons who do not understand these instructions must not use the machine. The Local regulations will set the age of the operator; c) Never use a machine near persons, including children or animals; d) Remember that the operator or user is responsible for accidents or hazards that occur to other persons or their property. e) Do not carry passengers; f) All drivers must get instruction. That instruction must include: - A need for careful attention when you use a ride-on class machine. - The loss of traction on slopes or in a condition of decreased traction, is not always corrected by an application of the brakes. Reasons for the loss of control. i) Not enough wheel grip; ii) Driving at more than the safe speed for the conditions iii) You over brake or brake suddenly. iv) The type of machine is wrong for the job; v) No attention given to the ground conditions or operating slopes; vi) Incorrect hitch and load distribution Preparation a) When you operate the machine, always wear strong footwear and long trousers. Do not operate the equipment without the correct footwear. b) Inspect the area you are to cut. Objects or any particles in the area are a safety risk. Remove these objects. These objects can damage the blades or cause injury to any person near. c) WARNING - Diesel and Petrol are flammable. - Store in clean applicable metal containers. - Refuel outdoors only and do not smoke when you add fuel; - Refuel the machine before you start the engine. When the engine is hot, do not remove the fuel tank cap or add fuel to the tank. - If any fuel spills, do not try to start the engine, but move the machine away from the area. Until the fuel vapors have gone keep any supply of ignition at a distance. - Replace all fuel tank and container caps correctly; d) Replace any damaged or broken silencers. e) Visually inspect the machine use. Check the blades, blade bolts and the deck assembly for wear or damage. Replace all the blades in a group to keep the balance; f) On those machines with many blades, be careful when you rotate one blade, it can cause other blades to rotate Operation a) Do not operate the engine in a closed space. The gas Carbon Monoxide is part of the exhaust gas mix. In a closed space this gas can reach dangerous levels b) Use a mower only in daylight or in good artificial light; c) Before you start the engine, disengage all blade attachment clutches and shift into neutral; d) Do not use on slopes of more than the recommended angle; NOTE The recommended angle is calculated as shown in BS EN ISO :2013 clause 4.6.1, 4.6.2, en-7

8 3 SAFETY e) Remember there is no safe slope. Operate with caution on grass slopes. To guard against a turn over - Do not stop or start suddenly when you operate on a slope. - To operate on a down slope, prevent sharp movements on the controls and always keep the machine in gear. - Go slowly when you operate on slopes and when you make tight turns; - Look for any changes in the cutting surface that can change the mowers balance. - Never use the mower to move across a slope on a diagonal line. Unless the machine is for this purpose; f) When you pull a load or use accessories, be careful. - Use only approved drawbars; - Any load must not change your full control of the machine. - Do not turn suddenly. Be careful when you move in a reverse direction; - Use the counterweight or wheel weights recommended in the instruction handbook; g) Be careful of those around you and the users of the road when you move across or near roadways; h) Stop the blades before you move across any surface different from grass; i) Do not allow the deck outlets to point at other persons. Do not allow persons near a machine that you operate. j) Do not operate the machine with damaged guards or without safety devices in position; k) Do not change the engine governor settings or operate at more than the specified engine turns. If you operate the engine at more than the suppliers set speed, you increase the hazard of personal injury; l) When you leave the position for operation, disengage the drive and lower the attachments to the ground. - Engage neutral and set the parking brake; - Stop the engine and remove the key; m) Before you check, clean or work on the machine. Disengage the drive to the attachments, stop the engine and remove the ignition key: - When you hit an object, inspect the machine for damage and make the repairs before you restart and operate the equipment; - If the machine starts to make a sound that is not normal or begins to cause vibration, check immediately; n) When the machine is not in operation or during transport. Disengage the drive to the attachments. Before you refuel or you make height adjustment, unless the adjustment is made with the operator in the seat. Stop the engine and disengage drive to attachments. Decrease the throttle setting during the engine run-out. If the engine has a fuel valve, turn the fuel valve to the OFF position at the end of operation Maintenance and storage a) Keep all nuts, bolts and screws tight to make sure the equipment is in safe work condition; b) Do not store the equipment with fuel in the tank. The Fuel vapour can become a danger in closed spaces. c) When you store in a closed space, allow the engine to become cool first; d) Replace worn or damaged parts for safety; e) If the fuel tank is drained, drain in an area with good ventilation. and: a) On those machines with many blades, be careful when you rotate one blade, it can cause other blades to rotate.; b) When the machine is parked for an extended period or put into storage, lower the cutting device unless a positive mechanical lock is used. en-8

9 SAFETY Important Safety Notes This safety alert symbol indicates possible hazards. DANGER: Indicates a condition state that WILL cause death or injury. WARNING: Indicates a condition state that CAN cause death or injury. CAUTION: Indicates a condition state that can cause injury and damage to property. Also indicates work procedures that are not safe. IMPORTANT: Only drive the machine at the road speed when you are on a highway. You must not select road speed on grass areas, rough roads or gravel tracks. Some of the illustrations in this manual can show shields, guards or plates removed for accuracy. You must not operate this equipment without these devices fastened in position. WARNING 1. To leave the position for operation, for any reason: a. Return the traction pedal to the Neutral position. b. Disengage all drives. c. Lower all equipment to the ground. d. Engage the parking brake. e. Stop the engine and remove the ignition key. 2. Keep your hands, feet and clothing away from moving parts. Wait for all movement to stop before you clean, adjust or service the machine. 3. Keep all persons and animals away from the area of operation. 4. Never carry any passengers, unless a seat is supplied for that purpose. 5. Never operate the equipment without a correctly fastened grass deflector in position. If you follow all the instructions in this manual, you increase the life of your machine and keep its maximum performance. Adjustments and maintenance must always be done by an approved technician. For additional service information or service instruction, contact your Authorized Ransomes Jacobsen Dealer. en-9

10 3 SAFETY WARNING If the Machine, Has An Operator Ear Sound Level Of More Than 85 Db(A) Leq. You Must Wear Applicable Ear Protection. WARNING To Prevent Injury From The Hydraulic Oil, Which Is At High Pressure And Work Temperature, Do Not Use The Hands To Check For Oil Leaks. Make Sure That You Use A Piece Of Paper Or Cardboard. Hydraulic Oil At High Pressure Has Enough Force To Enter Through The Skin. If The Fluid Enters Through The Skin, The Fluid Must Be Removed Within Hours. Immediately Get Attention By A Medical Professional Or Gangrene May Result. CAUTION Personal Protective Equipment (PPE), for example Safety Glasses, Footwear, Hard Hats, Work Gloves And Ear Protection Must Be Used. Ransomes Jacobsen Recommends That The Owner Of The Machine Completes The Local Risk Assessment And Supplies All The Necessary PPE. All Persons Who Use This Machine Must Accept Training By An Approved Person. The Training Must Include All Of The Machine Systems, Controls and The Safety Devices Before These Persons Use The Machine. en-10

11 SPECIFICATIONS ENGINE SPECIFICATION The Hydraulic 5 is driven by the tractor power take off shaft. 4.2 DIMENSIONS & WEIGHTS A Width of Cut: 135 inch 343 cm B Overall Width Cutting: 142 inch 361 cm C Overall Width Transport (minimum): 98.5 inch 250 cm D Overall Length: 43.7 inch 111 cm E Overall Height 38.6 inch 98 cm Weight of Machine, Hydraulic Tank Full 1323 lb 600 kg Weight of one 8 Knife Cutting Unit (Floating) lb 95 kg Weight of one Verticut Cutting Unit lb 95 kg 4.3 MACHINE SPECIFICATION Frame construction: Cutting unit drive: Transmission: Tractor Requirements: Minimum Tractor Power: Type, Welded and bolted hollow box section frame; Fixed displacement hydraulic motors with cutting cylinder drive control levers for forward and reverse Backlapping. PTO from tractor to gearbox mounted on main frame, through tandem hydraulic pump to hydraulic valve then to cutting unit hydraulic motors. Lift System Attaches to tractors with category 1 or 2 three point linkage. Standard 1.38 inch (35mm). diameter, 6-spline 540 rpm power take off shaft. 40hp (29.5 kw) en-11

12 4 SPECIFICATIONS 4.4 CUTTING UNIT SPECIFICATION Sportcutter Verticut Construction Heavy-duty pressed steel bolted construction Reel Length 30 inch (762mm) 30 inch (762mm) Number of Knives 6 N/A Number of Blades N/A 54 Reel Diameter (New) 7.75 inch (197mm) N/A Minimum Reel Diameter (Before Replacement) 7.0 inch (178mm) N/A Floating Head Height of Cut (Standard Blade) Floating Head Height of Cut (Thin Blade) 0.5 inch inch (12.7mm mm) 0.35 inch inch (9mm - 32mm) N/A N/A Rear Roll Height of Cut Adjustment Transmission Maximum Reel Speed at 540 rpm PTO Speed 2.4 inch (60mm) Diameter Adjustable screw system on front & rear roll By hydraulic motor through gear & pinion to reel. 1240rpm NOTE These cutting units are made to cut grass of maximum height 4 inch (100mm) down to the available height of cut range. 4.5 CUTTING PERFORMANCE 10 acre / hour at 7.5 mph 4.1 hectares / hour at 12 km 10% allowance is included for normal overlaps and turning at the end of each cut. 6-blade Floating Head: 6-blade Floating Head: 8-blade Floating Head: 8-blade Floating Head: 53 cuts/y at 5 mph 58 cuts/m at 8 km/h 71 cuts/y at 5 mph 78 cuts/m at 8 km/h. en-12

13 SPECIFICATIONS 4 en-13

14 5 DECALS 5.1 SAFETY DECALS EC A B C D E F 5.2 INSTRUCTION DECALS EC A en-14

15 5 DECALS Safety Decals A Read Operator's Manual. B Keep a Safe Distance from the Machine. C Caution Rotating Blades. D Avoid Fluid Escaping Under Pressure. Read Operators Manual for Service Procedures. E Do Not Remove Safety Shields While Engine is Running. F Caution Power Take Off Shaft Instruction Decals A. Cutting Cylinder Forward / Neutral / Reverse en-15

16 6 CONTOLS 6.16 CUTTING CYLINDER DRIVE The levers A and B operate the cutting cylinder drive. The direction of drive is indicated by the decal illustrated. Directions are given from the Operators seated position Lever A controls cylinders 1, 2 and 4. Lever B controls cylinders 3 and 5. Select the cutting pattern required and select accordingly. To operate: (a) Pull the lever forward to engage drive for grass cutting. (b) (c) Push the lever rearward for reverse drive which is used for Backlapping or clearing of cylinders. When drive is not required the lever should be in the neutral (N) position. 4 REAR 1 5 CUTTING CYLINDER LAY OUT 2 3 FRONT en-16

17 OPERATION DAILY INSPECTION CAUTION The Daily Inspection Should Be Performed Only When The Tractors Engine Is Off And All Fluids Are Cold. Lower Implements To The Ground, Engage Tractors Parking Brake, Stop Engine And Remove Ignition Key. 1. Perform a visual inspection of the entire unit, look for signs of wear, loose hardware and missing or damaged components. Check for oil leaks to ensure connections are tight and hoses and tubes are in good condition. 2. All fluids must be at the full mark when cold. See 8 - MAINTENANCE and LUBRICATION 3. Make sure all cutting units are adjusted to the same height of cut. en-17

18 7 OPERATION 7.2 OPERATING PROCEDURE CAUTION To Help Prevent Injury, Always Wear Safety Glasses, Leather Work Shoes Or Boots, A Hard Hat And Ear Protection. 1. Do not operate with loose, damaged or missing components. Whenever possible mow when grass is dry 2. First mow in a test area to become thoroughly familiar with the operation of the controls. 3. Study the area to determine the best and safest operating procedure. Consider the height of the grass, type of terrain, and condition of the surface. Each condition will require certain adjustments or precautions. 4. Never direct discharge of material toward bystanders, nor allow anyone near the machine while in operation. The owner/operator is responsible for injuries inflicted to bystanders and/or damage to their property. 5. Use discretion when mowing near gravel areas (roadway, parking areas, cart paths, etc.). Stones discharged from the implement may cause serious injuries to bystanders and/or damage the equipment. CAUTION Remove All Debris From The Site Before Mowing. Enter A New Area Cautiously Always Operate At Speeds That Allow You To Have Complete Control Of The Mower. 6. Disengage the cutter motors and raise the implements when crossing paths or roads. Look out for traffic. 7. Stop and inspect the equipment for damage immediately after striking an obstruction or if the machine begins to vibrate abnormally. Have the equipment repaired before resuming operation. CAUTION Before You Clean, Adjust, Or Repair This Equipment, Always Disengage All Drives, Lower Implements To The Ground, Engage Tractor Parking Brake, Stop Engine And Remove Key From Ignition Switch To Prevent Injuries. 10. Do not operate with loose, damaged or missing components. en-18

19 OPERATION ATTACHING THE MOWER TO THE TRACTOR P.T.O. SHAFT A standard P.T.O. shaft is provided and this will have to be shortened in length to suit the tractor being used. It is essential that no more than is necessary is cut off as maximum engagement of the sliding portion is needed to prevent excessive wear. Adequate removal of sharp edges and chamfering of the cut ends must be carried out. NOTE On certain tractors it will be impossible to lift the machine to the maximum height on the three point linkage without the sliding part of the P.T.O. shaft disengaging. Stops must be set correctly on the tractor lift quadrant to limit the lift height to prevent the disengagement of the P.T.O. shaft. 1. Stop the tractor engine. 2. Connect the tractor lower lift arms to the 2-hitch points (A) on the main crossbeam, using the lower hole in the hitch plates to fit the connecting pins and spring clips. B Connect the tractor top link (B) to the machine. IMPORTANT Select the pair of holes in the 'A' frame which allows the top link to take up as near a horizontal position as possible. C 3. Fit pin (B) and secure with pin and spring ring. 4. Extend the top link and remove the stabiliser pin from the rear of the unit pivot support plates. Stow this pin in the holes in the lugs at the front of the main crossbeam and secure with spring pins. A 5. Shorten the top link until the 'A' frame becomes vertical. Attach the jubilee clip (supplied) to the top link up against the end of the turn buckle and tighten securely in this position. 6. Connect up P.T.O. shaft (C) to the machine and tractor.connect lift hose QRC to Tractor QRC. en-19

20 7 OPERATION 7. Start the tractor engine and lift the machine fully by means of the tractor lifting quadrant lever. 8. Switch off the engine. 9. Adjust the tractor RH lift rod length to level the main crossbeam of the machine. 10. Measure the height of the crossbeam from the ground at each end to ensure the machine is level. 11. Adjust the length of the check chains so that there is a minimum of slack when the tractor arms are fully raised. This will prevent excessive side swing of the machine when transporting. NOTE If external tractor check chains are fitted, they should be adjusted so that no part of the lift arms can foul against the hydraulic pump or any of the fittings when the machine is in the cutting position. This will prevent excessive side swing of the machine when transporting. Before this adjustment can be made, the height of cut of all three units must be set accurately with the machine on a level, hard surface (see page 23). The A frame must be vertical. On the area to be cut, make an initial cut of approximately 20 metres. Examine the finish of cut across the width of the swathe - it is likely that the 2-front units will be cutting lower than the rear unit. If necessary, to obtain an even cut, extend the top link by 1½ to 2 turns. IMPORTANT Do not lengthen the top link by more than 3 turns; the need for adjustment in excess of this indicates that the height of cut settings on the units were not equal initially. Any subsequent changes in height of cut will not effect the length of the top link; but it is important that is the units are set up by using spacers between the ground and bottom blade, the top link should be shortened to its original length, ie. until the turnbuckle contacts the jubilee clip. After resetting the height of cut by this method, the top link should again be lengthened by the same amount. NOTE Alternatively, the height of cut setting on the individual units can of course be adjusted slightly to obtain an even finish without altering the length of the top link. en-20

21 OPERATION REMOVING THE MACHINE FROM THE TRACTOR To remove the machine from the tractor, reverse the attachment instructions. 1. The stabiliser pin (A) must be in place over the rear unit trailing arm (B) before the machine is removed from the tractor 3-point linkage; this ensures that the machine is stable when removed from the tractor. 2 The stabiliser pin MUST always be removed from over the rear unit trailing arm (A) for all mowing and transporting operations. When not used store the pin in location (B) to prevent loss. B A REMEMBER: It is not necessary at anytime when assembling or removing the mower from the tractor to dismantle, or disturb, any hydraulic pipe joints or components. should servicing be necessary during use, it must be carried out by a trained service person. NOTE This instruction applies to the centre and wing units en-21

22 7 OPERATION 7.5 MOWING 1. Start the tractor and lower the lift arms. 2. Engage the tractor P.T.O. 3. Select tractor gear ready to move off. 4. Move the mower control levers forwards to engage the forward drive to the cutting units. CAUTION Always put the drive controls in the neutral position and switch off the engine before dismounting from the tractor. CAUTION IMPORTANT Do not reverse the tractor with the machine lowered. Always lift the machine on the tractor 3 - point linkage before moving in reverse, and when obstructions are met during cutting. 7.6 TRANSPORTING 1. Move the cutting cylinder control levers to neutral. 2. Raise the machine fully by operating the tractor lift lever. 3. Put the tractor P.T.O drive in neutral to avoid unnecessary circulation of oil in the hydraulic system. It is imperative that the P.T.O. drive is disengaged and the valve control lever is in neutral before the machine is lifted. No automatic cut out of the hydraulic drive is provided and damage will occur to the machine components if the P.T.O. is not disengaged. IMPORTANT The tractor P.T.O. drive MUST NOT be re-engaged until the machine is returned to the cutting position. en-22

23 OPERATION CUTTING PERFORMANCE NOTE Due to the low power requirement of the Hydraulic 5 it is quite acceptable to use the tractor with the engine speed reduced to as low as 900 rpm. This may be necessary when sparse grass of uneven height is being cut. It is also convenient for maneuvering, noise and improves operator comfort, and reduces tractor engine wear. Slow cutting cylinder speeds reduce cylinder and bottom blade wear. It is necessary to use increased engine speeds to achieve satisfactory cutting and grass discharge in wet, lush grass conditions or where higher cuts/yard are required at reasonable forward speeds. 7.8 HOW TO REMOVE A BLOCKAGE FROM CUTTING UNITS CAUTION It is important to note: there will be remaining hydraulic pressure within the system that can cause the cutting cylinder to rotate when the obstruction is removed. Therefore keep your hands, feet and clothing away from cutting units at all times. 1) Disengage the power to the cutting units with the cutting unit switch. 2) Keep the cutting units lowered to the ground (Wait for the remaining cutting cylinders to stop rotation). 3) Lift the cutting units into the Transport Position, lock in position use the transport latches fitted on your product. 4) Remove your foot from the forward/reverse pedal. 5) Set the parking brake. 6) Move the throttle control lever to the slow position. 7) Turn the ignition key to the off position and remove the key. NOTE Make sure correctly selected PPE is worn before you clear the obstruction. 8) use the Ransomes Jacobsen Cutting Unit Tool part number See below or stout stick, put into the cutting cylinder between the blades. 9) Rotate the cylinder with either the Cutting Unit Tool or Stout Stick until the obstruction has been removed. 10) Inspect all the cutting surfaces for damage, when necessary replace the damaged components. en-23

24 7 OPERATION 7.9 BACKLAPPING Backlapping is a process which will lightly grind the reel to the bedknife whilst mounted on the mower. If significant amounts of metal are to be removed then the cutting unit should be reground on a specialised grinding machine. Before any Backlapping is carried out, Ransomes Jacobsen recommends that the Backlapping process should be risk assessed as a workshop process by the manager of the machine. Backlapping should only be carried out by trained staff. Jacobsen recommend that grinding paste is only applied to the reel when it is stationery, the engine is off and the parking brake applied. When applying grinding paste the reel should only be rotated by appropriately sized piece of wood and not by hand. Place reels in the most accessible position for applying the paste. After applying the grinding paste the person Backlapping should return to the seat, engage the relevant controls and run the reels in reverse. When the desired finish is achieved switch off the mower, clean off any surplus paste, reset the reel to bedknife and return the controls to the normal mow positions. Jacobsen grinding paste: Grinding Paste Part Number 80 grit grinding paste, 4.5kg tin grit grinding paste, 4.5kg tin grit grinding paste, 9kg tin grit grinding paste, 9kg tin PROCEDURE 1. Apply an even coat of Backlapping compound to the entire length of each blade of the reel. 2. Start the tractor and set the tractor P.T.O. to allow reels to rotate at a slow speed. 3. Slowly adjust the P.T.O. speed 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. 4. Once all the blades on the reel are uniformly sharp, shut off the engine and move the PTO to the off position. 7. Wash all of the Backlapping compound from all of the heads. Once they are thoroughly cleaned and dry, apply a light film of oil to the cutting edges to help prevent rust. 8. After Backlapping, the reel to bedknife adjustment should be made again. en-24

25 MAINTENANCE AND LUBRICATION MAINTENANCE & LUBRICATION CHART MACHINE MAINTENANCE CHART Interval Item Section First 50 hours Daily 10 hours Weekly Every 50 hours End of season Every 1000 hours Change P.T.O. gearbox Oil Check Hydraulic Fluid Level. Check for Play in Trailing Arm Spherical Bearing. Check for Loose Components. Check for Hydraulic Leaks. Check P.T.O. Gearbox Oil Lubricate all Cutting Unit Grease Fittings. Lubricate P.T.O. Lubricate Control Valve Linkage. Change Hydraulic Oil & Filter. Lubricate Cutting Unit Gearboxes. Change P.T.O. gearbox Oil Lubricate all Grease fittings weekly A = Centre Lift Arm Pivot, B =Cutting Unit Pivot, C = Cutting Unit Bearing Housing, (see diagram) FLUID REQUIREMENTS Quantity Type A Hydraulic Oil (with filter) 21.6 US gal (82 litres) ISO VG 46 B P.T.O. Gearbox 1.1 US pint (0.52 litres) Shell Spirax G90 C Cutting Unit Gearboxes 3.4 US ounce (0.1Litre) Shell Alvania HDX2 D General Lubrication - Lithium Based General Purpose Grease similar to Shell Darina R2 E Power Take Off Shaft - Rocol GP1 Grease en-25

26 8 MAINTENANCE AND LUBRICATION 8.2 LUBRICATION Sportcutter For recommended lubricants see section 8.1 B Should the number of working hours that the machine is in use during the indicated period exceed the number quoted in brackets, then use the recommended working hour guide as the lubrication schedule. Before using the machine for the first time: 1. Lubricate all points. 2. Check, and if necessary fill the pump gearbox (B) to the correct level (C). 3. Check hydraulic oil when cold and if necessary, fill the hydraulic tank with ISO VG46 hydraulic oil until the level of the oil is midway up the filler filter (A). Check oil level in sight glass (C) is at the midway position. Circulate the oil through the hydraulic system, re-check the oil level and top up, if necessary. C C A 4. Lubricate both ends of the Power Take Off shaft where it connects to the tractor PTO and the pump drive gearbox with Rocol Anti-seize (dry Molybdenum) paste. Daily (Every 8 working hours) Lubricate the trailing arm spherical bearing (unit number 1, centre) using Rocol GP 1 grease. Weekly (Every 50 working hours) A NOTE: Lubricate more frequently in very wet or dusty conditions. B 1. (a) (b) (c) Lubricate the following points using grease. Cutting cylinder bearing housing (A) Height adjustment tubes (B). Cutting cylinder bearing housing pivot (C). 2. Lubricate the following points using Rocol AntiSeize: Cutting cylinder adjusting screws D). (a) en-26 C D

27 MAINTENANCE AND LUBRICATION 8 3. Using general purpose grease, lubricate the valve lever pivot bolt (A) and the connecting link (B). A B 4. Lubricate the rear unit trailing arm spherical bearing. A First 50 working hours Change P.T.O. gearbox oil. 1. Remove Filler/breather plug (B), sight gauge (C) and drain plug (A) and drain oil into an appropriate container. B 2. Clean sight gauge and drain plug before replacing them. Refill gearbox with correct oil to the correct level. Clean and replace filler/breather. A C CAUTION Contact With Oil Can Damage Your Skin. Use Gloves When Working With any Oil. If You Come In Contact With Oil, Wash It Off Immediately. CAUTION Dispose Of Used Oil In Accordance With Local Regulations en-27

28 8 MAINTENANCE AND LUBRICATION 8.3 DURING OVERHAUL When rebuilding a cutting unit after it has been dismantled for overhaul: 1. Clean the cutting unit gearboxes and repack to approximately ½ full - 0.1lites with Shell Alvania HDX2 grease. 2. Lubricate cutting cylinder adjusting screws and clamp pivots with Molybdenum Disulphide grease. Weekly (Every 50 working hours) Make general check on all nuts, bolts and screws to ensure that these are tight. (a) (b) (c) After grass cutting the machine should be thoroughly cleaned down to remove all accumulations of grass clippings and debris. Turn the cutting cylinders to clean the cutting edges. Brush a little oil onto the cutters to prevent rusting. A few turns of the cylinders will soon spread the oil onto the bottom blade. NOTE: DO NOT turn the cylinders by hand. the end of season overhaul the hydraulic motors should be removed and the gearbox cleaned out. (b) (a) Repack the gearboxes with Shell Alvania HDX2 grease to half fill the box approximate quantity kg per gearbox). The oil filter is a screw on type. Remove the old filter, drain the contents and dispose of responsibly. Wet the sealing O ring on the new filter with some old oil and refit to a firm hand tight. Do not over tighten..(b) Remove and clean the Hydraulic Tank strainer. CAUTION Contact With Oil Can Damage Your Skin. Use Gloves When Working With any Oil. If You Come In Contact With Oil, Wash It Off Immediately. CAUTION Dispose Of Used Oil In Accordance With Local Regulations en-28

29 ADJUSTMENT HEIGHT OF CUT ADJUSTMENT Sportcutter The height of cut can be set from 12mm (15/32 in) to 85mm (3 11/32 in). There are two methods of adjustment. Method 1. For quick adjustment. A B Three settings at 2 7/16 in (62mm), 2 29/32in(73mm), 3 11/32in (85mm) maximum intervals are provided in the mounting bracket (A). To adjust: (a) Slacken the nut (B) until the locating collars (C) are free. C (b) Move the cutting unit up or down to the required setting and tighten the nut and bolt securely. Method 2. For finer adjustment. When the mounting brackets are positioned in the lower setting the height of cut can be adjusted from 12mm (15/ 32in) up to 63mm (2 31/64in) by means of the rear roll adjusters. To adjust: A B (a) (b) (c) Slacken the screws (B) which clamp the skids to the side frames. Turn the adjusters (A) clockwise to reduce the height of cut, and anticlockwise to increase the height of cut. Tighten the screws securely. Adjust both sides equally. Verticut 10 VERTICUT REEL ADJUSTMENT The position of the reel must not be altered after being set. Any changes required in height must only be made by moving the front and rear rolls. VERTICUT UNITS: Normal settings of the blades is that the tips should be 3mm (1/8in) above the ground. The blade tips MUST NOT penetrate the top surface of the soil. A To adjust: B 1. Release bolt and nut (B) at front end. 2. Turn adjusters (A) above rear roll clockwise to reduce height of cut and anticlockwise to increase height of cut. 3. Tighten nut (B) at front of skid. en-29

30 9 ADJUSTMENT 9.2 CUTTING REEL ADJUSTMENT To check that the cutting cylinder is set correctly to the bottom blade: 1. Hold a thin piece of paper between the edge of the bottom blade and the spiral cutters, and turn the cylinder manually. 2. The paper should be cut cleanly along the length of the bottom blade; if it is not, some adjustment is necessary - BUT DO NOT OVER TIGHTEN. To Adjust: 1. Slacken the clamp pin locknut's (A). 2. Turn the adjuster (B) anticlockwise to move the cylinder closer to the bottom blade. Make an 1/8 of a turn alternately to each adjuster. Second position B A 3. Re-tighten the clamp pin locknut's securely and re-check the setting. NOTE The cutting cylinder setting should be checked every 4 working hours. If, after adjusting correctly, the paper is not cut cleanly, the cylinder and bottom blade can be back lapped (See section 7.9). en-30

31 10 QUALITY OF CUT 10 QUALITY OF CUT TROUBLESHOOTING It is recommended that a test cut be performed to evaluate the mower s performance before beginning repairs. An area should be available where test cuts can be made. This area must provide known and consistent turf conditions to allow accurate evaluation of the mower s performance. Another test cut should be performed after the completion of the repairs and/or adjustments to verify the mower s performance. Before performing a test cut to diagnose cut appearance and mower performance, the following items must be verified to ensure an accurate test cut. 1. Mowing (Ground) Speed. 2. Reel Bearing Condition and Pre-Load (End Play) Adjustment. 3. Reel and Bedknife Sharpness. 4. Bedknife Alignment to Reel. 5. Reel-to-Bedknife Contact. 6. Height-of-Cut (HOC). 7. Roller and Roller Bearing Condition WASHBOARDING Washboarding is a cyclical pattern of varying cutting heights, resulting in a wave-like cut appearance. In most cases, the wave tip-to-tip distance is approximately 6 8 in. (15 20 cm). Colour variation (light-to-dark) may also be noticed. This condition is usually caused by a rocking motion in the cutting unit(s). This condition is found mostly on mowers with multiple (suspended) cutting units, but other causes can produce the same result. Washboarding may also be caused by variations in the turf. NOTE: Arrow indicates direction of travel. TN0159 Probable Cause Mowing (ground) speed is too fast. Grass build-up on roller. Roller is out of round. Mowing in the same direction. Use of a groomer on cleanup pass. Remedy Reduce mowing (ground) speed. Clean the roller and use scrapers or brushes. Replace roller. Change mowing direction regularly. Groomers must be used only in a straight line. en-31

32 10 QUALITY OF CUT 10.2 MARCELLING Marcelling, like wash boarding, is a cyclical pattern of varying cutting heights, resulting in a wave-like cut appearance. In most cases, the wave tip-to-tip distance is 2 in. (5 cm) or less. NOTE: Arrow indicates direction of travel. TN0220 Probable Cause Mowing (ground) speed is too fast. HOC (height-of-cut) setting is too low for turf conditions. Cutting reel diameter is worn. Remedy Reduce mowing (ground) speed. Check/adjust HOC to turf conditions. Check cutting reel diameter and replace if worn. en-32

33 10 QUALITY OF CUT 10.3 STEP CUTTING Step cutting occurs when grass is cut taller on one side of a reel than the other or one cutting unit to another. This is usually caused by mechanical wear or an incorrect roller or HOC (height-of-cut) adjustment. NOTE: Arrow indicates direction of travel. TN0221 Probable Cause HOC (height-of-cut) settings are different from one side of a reel to the other or from one cutting unit to another. Worn front roller bearings. Reel-to-bedknife contact is different from one side of the cutting unit to the other or from one cutting unit to another. Cutting reel movement is restricted. Variations in turf density. Machine weight distribution is uneven. Remedy Check HOC adjustment of cutting units. Check/replace front roller bearings. Check reel-to-bedknife contact. Check/remove cutting reel movement obstruction. Change mowing direction. Check/adjust tire inflation pressure. en-33

34 10 QUALITY OF CUT 10.4 SCALPING Scalping is a condition in which areas of grass are cut noticeably shorter than the surrounding areas, resulting in a light green or even brown patch. This is usually caused by an excessively low height-of-cut (HOC) setting and/or uneven turf. NOTE: Arrow indicates direction of travel. TN0222 Probable Cause HOC (height-of-cut) settings are lower than normal. Improper reel-to-bedknife adjustment. Turf too uneven for the mower to follow. Cutting too much grass at one time. Mowing (ground) speed is too fast. Remedy Check/adjust the HOC settings. Adjust reel-to-bedknife setting for desired HOC. Change mowing direction. Mow more often. Reduce mowing (ground) speed. en-34

35 10 QUALITY OF CUT 10.5 STRAGGLERS Stragglers are scattered blades of uncut or poorly cut grass. NOTE: Arrow indicates direction of travel. TN0223 Probable Cause Bedknife improperly adjusted. Dull reel or bedknife cutting edges. Mowing (ground) speed is too fast. Grass is too tall. Mowing in the same direction. Nicks in reel or bedknife. Remedy Adjust reel-to-bedknife setting. Sharpen or replace reel blade and bedknife as necessary. Reduce mowing (ground) speed. Mow more often. Change mowing direction regularly. Grind, sharpen or replace reel blades and bedknife as necessary. en-35

36 10 QUALITY OF CUT 10.6 STREAKS A streak is a line of uncut grass. This is usually caused by a nicked or bent bedknife. NOTE: Arrow indicates direction of travel. TN0224 Probable Cause Remedy Damaged bedknife. Damaged or unevenly worn reel. Loose or missing bedknife fasteners. Turning too aggressively. Cutting units don t overlap around turns or on side hills. Tire mats down grass before it is cut. Wet grass is matted down before it is cut. Replace bedknife. Inspect reel. Replace as needed. Check bedknife screws. Tighten loose screws; replace missing screws. Turn less aggressively to allow cutting units to overlap. Change mowing direction or pattern on side hills. Check/adjust tire inflation pressure. Mow when grass is dry. en-36

37 10 QUALITY OF CUT 10.7 WINDROWING Windrowing is the deposit of clippings concentrated at one end of cutting unit(s) or between two cutting units, forming a line in the direction of travel. NOTE: Arrow indicates direction of travel. TN0225 Probable Cause Remedy Grass is too tall. Mowing while grass is wet. Grass built up on roller(s). Grass collecting on bedknife. Mow more often. Mow when grass is dry. Clean roller(s) and scraper(s). Adjust reel-to-bedknife setting. en-37

38 10 QUALITY OF CUT 10.8 RIFLING OR TRAMLINING Rifling or tramlining is a pattern of varying cutting heights, resulting in a wave-like cut appearance, usually due to heavy contact points across a reel and/or bedknife. NOTE: Arrow indicates direction of travel. Probable Cause Reel and/or bedknife unevenly worn. Missing, loose, or over torqued bedknife screws. Mowing (ground) speed is too fast. Remedy Inspect bedknife and reel. Sharpen or replace reel and bedknife as necessary. Install, replace or tighten bedknife screws to proper torque setting. Reduce mowing (ground) speed MISMATCHED CUTTING UNITS Mismatched cutting units is a pattern of varying cutting heights, resulting in a stepped cut appearance, usually due to mismatched HOC (height-of-cut) adjustment from one cutting unit to another. NOTE: Arrow indicates direction of travel. Probable Cause HOC inconsistent from one cutting unit to another. Difference in mower ride height side to side. Remedy Check/adjust HOC on cutting units. Check/adjust tire inflation pressure. en-38

39 GUARANTEE GUARANTEE WARRANTY Warranty is subject to specific terms and conditions, e.g. wearing parts, unapproved modifications, etc. are not included. For a full set of warranty conditions, contact your local dealer or distributor. SERVICE A network of authorised Sales and Service dealers has been established and these details are available from your supplier. When service attention, or spares, are required for the machine, within or after the warranty period your supplier or any authorised dealer should be contacted. Always quote the registered serial number of the machine. If any damage is apparent when delivery is made, report the details at once to the supplier of the machine. en-39

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42 Europe & Rest of The World Except North & South America Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, IP3 9TT English Company Registration No North & South America Jacobsen, A Textron Company Quality Drive, Charlotte, NC 28273, USA