24888G-GB (rev.0) Fitting Instructions Ransomes HR6010 Lighting Kit LMAC388 Jacobsen HR6010 Euro Lighting Kit LMAC388 For use on Product code: LHAM002 WARNING 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. GB United Kingdom RJL 100 November 2011
2011, Ransomes Jacobsen Limited. All Rights Reserved
1 CONTENTS FITTING INSTRUCTIONS - LMAC388 Section Page 2.1 Important... 4 2.2 Product Identification... 4 2.3 Guidelines For The Disposal Of Scrap Products... 5 2.3.1 During Service Life... 5 2.3.2 End Of Service Life... 5 3.1 Operating Instructions... 6 3.2 Safety Signs... 6 3.9 Adjustments, Lubrication, Maintenance & Cleaning... 6 4.1 Preparation... 8 4.2 Description... 8 4.3 Control Panel... 9 4.4 Front Frame... 10 4.5 Front Lights... 10 4.6 Number Plate Bracket & Lights... 14 4.7 Rear Lights And Reflectors... 15 4.8 Mirrors... 15 4.9 Front Light Beam Setup... 16 Parts List... 20 GB-3
2 INTRODUCTION HR 3300T FITTING INSTRUCTIONS - LMAC260 2.1 IMPORTANT IMPORTANT: This is a precision machine and the service obtained from it depends on the way it is operated and maintained. This SAFETY AND OPERATORS MANUAL should be regarded as part of the machine. Suppliers of both new and second-hand machines are advised to retain documentary evidence that this manual was provided with the machine. This machine is designed solely for use in customary grass cutting operations. Use in any other way is considered as contrary to the intended use. Compliance with and strict adherence to the conditions of operation, service and repair as specified by the manufacturer, also constitute essential elements of the intended use. Before attempting to operate this machine, ALL operators MUST read through this manual and make themselves thoroughly conversant with Safety Instructions, controls, lubrication and maintenance. Accident prevention regulations, all other generally recognized regulations on safety and occupational medicine, and all road traffic regulations shall be observed at all times. Any arbitrary modifications carried out on this machine may relieve the manufacturer of liability for any resulting damage or injury. It is important that during the life of the machine wearing and replaceable parts are disposed of in an environmentally responsible way using the resources available in the country where it is used. There are guidelines in this manual for the eventual decommissioning of the mower once it has no further use. Hardware provided. 2.2 PRODUCT IDENTIFICATION A B C D E F G H J Maximum front axle load in Kg (for machines being driven on the highway) 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 West Road Ransomes Europark Ipswich IP3 9TT England A B C D E Kg Kg Kg Kw F G H J GB-4
2 INTRODUCTION HR 3300T FITTING INSTRUCTIONS - LMAC260 2.3 GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS 2.3.1 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. 2.3.2 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 in a suitable location for any necessary lifting equipment to be used. Use appropriate tools and Personal Protective Equipment (PPE) and take guidance from the technical manuals applicable to the machine. Any items that still have a useful service life as second hand components or can be re-serviced should be separated and returned to the relevant centre. 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: Steel Non ferrous metals Aluminium Brass Copper Plastics Identifiable Recyclable Non recyclable Not identified Rubber Electrical & Electronic Components Items 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 Jacobsen Warranty department to close off relevant records. Remove and store appropriately: 1. Batteries 2. Fuel residue 3. Engine coolant 4. Oils Disassemble the structure of 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. GB-5
3 SAFETY INSTRUCTIONS HR 3300T FITTING INSTRUCTIONS - LMAC260 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. 3.1 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. 3.2 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. 3.9 ADJUSTMENTS, LUBRICATION, MAINTENANCE & 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. 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 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 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 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 to cool sufficiently to prevent damage to the block and exhaust manifold. Never force water into any electrical components, GB-6
3 SAFETY INSTRUCTIONS HR 3300T FITTING INSTRUCTIONS - LMAC260 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 select transport speed on grass areas or uneven or unsurfaced roads or tracks. GB-7
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 4.1 PREPARATION CAUTION: Read the rotary mower s manual and become familiar with the rotary mower, the controls and proper use of the equipment. 4.2 DESCRIPTION The following instruction details the process of installing the Lighting Kit LMAC388 to the HR6010 machine. 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 rotary 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 any adjustments or modifications. 3. 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. GB-8
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 4.3 CONTROL PANEL Raise the seat plate and disconnect the negative terminal of the battery prior to commencing work to install the Lighting Kit. Ensure that the seat plate is supported in the raised position by the stay provided. Instrument Pane (Fig.1) Connect the main harness to the switches on the instrument panel as follows:- Lights Switch (A) connector: wires coloured Blue, Brown & Red. Switch Back Lamp: wires coloured Black & Red. C D A B Beacon Switch (B) connector: Wires coloured Blue/Yellow & Purple/Brown. Switch Back Lamp: wires coloured Black & Blue Yellow. Fig. 1 Directional Indicator Switch (C) connector: wires coloured Green/White, Green Brown & Green/Red. Switch Back Lamp: wires coloured: Green/ white &Green/Red. Hazard Switch (D) connector: wires coloured: Green/Red, Green/white, Green/Brown, Red/Black, White/Orange, Grey/Yellow & Grey/Red. Switch Back Lamp: one connection only, coloured Black. GB-9
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 4.4 FRONT FRAME 1. If the machine does not have a Front Frame (Hard Point) fitted already fit the Front Frame in the kit to the Operators Platform (Fig.2). This should be done using the four M10x45 Hex.Hd bolts, M10 plain washers and M10 lockwashers and two M8x40 Hex.Hd bolts, M8 plain washers and M8 lockwashers detailed in the parts section. All M10 bolts here should be torqued to 52 Nm. Fig. 2 4.5 FRONT LIGHTS 1. Insert the Work Light adjustment screws into the tabs on the light assembly. These should be inserted from the rear of the lamp and then the plastic collar turned approx 120 so that the plastic tab locks into place. Note the orientation of the adjuster screw in Fig. 3 (the spherical end of the screws should be towards the front of the light) and that they should be attached to tabs A, B and C only as shown on Fig. 4 2. Before they are assembled the Front Light units need to be correctly set up to suit Left- Hand drive (UK use) or Right Hand drive (European use). B Fig. 3 A Check that the Front Lights are set correctly for the region that the machine will be used in. For Left-Hand drive use the screw at the top centre of the light should be in position 1 on Fig. 5. Position 2 is for Right-Hand drive use. C Fig. 4 GB-10
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 1 2 X Y Y Fig. 5 Fig. 6 5. If the light is not correctly set it can easily be altered by removing screw X and slackening screws Y, rotating the two parts to the correct position and then retightening/replacing the screws (Fig. 6). 6. Once the light is set place the plastic grommets supplied and firmly push each one into the relevant holes in the LH & RH Light Bracket (Figs. 7 & 8). Note that Fig. 7 shows the adjuster screw removed from the light for clarity only. Assemble the spherical ends of the adjuster screws on the lamp assemblies into the grommets. Fig. 7 When doing this ensure that the marking TOP on the bulb holder will be at the top and that the makers name (e.g. Hella ) on the lens will be upright once the lights are fully assembled. Refer to the diagrams in the parts list section of this manual for the orientation of the LH & RH Light Brackets. Fig. 8 GB-11
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 5. Attach the Sidelights to the LH & RH Light Bracket using the nuts and washers attached. (Fig, 9). Caution - Do not overtighten the nuts. 6. Locate the Front Light Wiring Harnesses in the kit (Fig. 18). Thread connector A all the way down through the vertical tubes of the Front Frame - one on each side. 7. Plug the connectors marked A into the relevant connector on the machine s main wiring harness. These can be found inside the Steering Tower and should be marked LH and RH to indicate which side they are to be connected to. D Fig. 9 A 8. Replace the Steering Tower Cover and fasten in place using the six M6x16 Pan.Hd screws and hardware removed in Step 4.5.1. B C 9. Attach the LH and RH Front Light assemblies built so far and the Light Backing Plates to the Front Frame using the four M6x65 Hex.Hd bolts, M6 plain washers and M6 lockwashers detailed in the parts section (Fig. 11. It will be necessary to thread harness connector D through the large hole in the Light Backing Plate prior to assembling it to the Front Frame. Fig. 10 Caution - Be careful not to damage the harness running down the centre of the upright tube. Fig. 11 GB-12
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 10. Attach one of the two green indicator repeater lights to the LH and RH lighting assemblies. Note that the repeater should be inserted so that the lens is facing towards the rear of the machine (Fig. 12). 11. Referring to Fig. 10 connect the harnesses to the relevant lighting component as follows - B - Indicator Repeater Lamp C - Sidelight/Indicator Lamp D - Main/Work Lamp Fig. 12 12. Attach the plastic covers to the front LH & RH light assemblies and fix in place with the six M5x16 Pan.Hd screws, M5 plain washers and M5 lockwashers detailed in the parts section (Fig. 13). 13. Do not attach the rear cover onto the front light assemblies yet. The front lights beams need to be set up before this cover is fitted. This is covered later in this fitting instruction. Fig. 13 14. The link (Fig. 14) is used to connect both front lights onto the existing vehicle loom. Once in place draw the loose cables together and cable tie to the main vehicle loom Fig. 14 GB-13
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 4.6 NUMBER PLATE BRACKET & LIGHTS 1 Locate the number plate wiring harness in the kit (Fig. 15). A A 2. Thread the ends A through the two Ø15 holes in the Number Plate Bracket. Note that it is important that they are threaded through in the direction shown (Fig. 15). 3. Undo the small screw on each of the Number Plate Light Housings and remove the cover. B 4. Thread the two terminal connectors through the rubber grommet in the rear of each housing and connect the terminals to the spade connectors inside. Note that it may be necessary to increase the size of the hole in the grommet so that the terminals will go through. C D Fig.15 5. Insert a bulb (supplied in the kit) into each housing, replace the cover and tighten the cover screw. E 7. Remove the nuts from the housing mounting studs, thread the studs through the Number Plate Bracket and reassemble the nuts on the other side (Fig. 16). Caution - Do not overtighten the nuts. 8. Attach the Number Plate Bracket to the underside of the rear bumper using the M6x20 Hex.Hd screws, M6 plain washers and M6 lockwashers detailed in the parts section. A Fig. 16 B 10. Ensure that the wire between the Number Plate and the main wiring harness is clipped up out of the way of any moving parts using tie wraps or similar. GB-14
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 4.7 REAR LIGHTS AND REFLECTORS 1. Connect the Rear light harness to the rear lights (B & C) B 2. Attach the Reflectors (A) and rear lights (B & C) to either side of the machine on the rear mudguards using the four M4x16 pan.hd screws (D), M4 plain washers (F) and M6 Nuts (E) detailed in Fig.17. C E F D A Fig. 17 4.8 MIRRORS 1. Attach the mirrors (Fig.18) to either side of the Front Frame using the four M6x65 Hex.Hd bolts, M6 plain washers and M6 lockwashers detailed in the parts section. Note - The illustration shows the mirrors attached to the side of the Front Frame, however they can also be attached from the front if desired. Caution - Be careful not to damage the harness running down the centre of the upright tube. Fig. 18 GB-15
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 4.9 FRONT LIGHT BEAM SETUP 1. Reconnect the negative terminal of the battery. 2. Ensure that the seat plate is closed and secured in place with the relevant hardware. 3. There are two methods that can be used to set the front light beams. The first is to use a beam setting device, such as the Sealey HBS2001 Headlamp Beam Setter. The second is to manually check the beam setting. A 3. If using the method 2, position the machine on a flat, level surface adjacent to a vertical white wall. 4. Park the machine as close as possible to the wall with the front lights facing it. Draw a vertical line A on the wall corresponding to the centreline of the machine (Fig. 19). Fig. 19 5. Reverse the machine straight back until the headlights are 7.62m (25 feet) from the wall. A B 6. Draw a horizontal line B on the wall corresponding to the headlight centreline (Fig. 20). The distance of the line from the floor will depend upon which lighting kit is being fitted as follows (distance in mm) - Fig. 2 0 Lighting Kit Vertical Distance LMAC388 1048.5 7. Draw two more horizontal lines C & D below the line B (Fig. 21). The distance that lines C & D are from B will depend upon which lighting kit is being fitted as follows (distance in mm) - A B D C Lighting Kit B to C B to D LMAC388 27.4 28.8 Fig. 21 GB-16
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 8. Draw two vertical lines E corresponding to the headlight centrelines (Fig. 22). The distance that lines E are from line A will depend upon which lighting kit is being fitted as follows (distance in mm) - E A E Lighting Kit A to E LMAC388 475 B D C 9. Draw two more vertical lines either to the left F for UK/right-hand drive, or right G for European/left-hand drive of the headlight centrelines E (Fig. 23). The distance that lines F or G are from line E will depend upon which lighting kit is being fitted as follows (distance in Fig. 22 mm) - Lighting Kit Distance LMAC388 21 10. Start the machine and turn on the headlights. FE G A FE G B D C Fig. 23 GB-17
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 11. Adjust the Light Adjustment Screws A, B & C until the Maximum Intensity Hotspot is in area 1 for UK/right-hand drive, or area 2 for European/left-hand drive (Figs. 24 & 25). The adjustments screws should also be adjusted so that the light lens is in the correct position relative to the plastic cover at the front. 1 2 1 2 12. Once this is complete attach the Front Light Rear Covers to the Front Lights using the six No.6x9.5 Pan.Hd screws detailed in the parts section (Fig. 26). Fig. 24 Fig. 25 Fig. 26 GB-18
4 FITTING INSTRUCTIONS FITTING INSTRUCTIONS - LMAC388 GB-19
PARTS MANUAL LMAC388 KIT-LIGHTS Illustration Number: Parts explosion Parts-20
PARTS MANUAL LMAC388 KIT-LIGHTS ITEM PART NO. DESCRIPTION QTY. 1 002952633 End Cap-50 X 50 X 5 2 2 008194180 Mirror 2 3 008231536 Relector 2 4 008231811 Light - Number Plate 2 5 009096170 Mirror Stem 1 6 009096180 Mirror Stem 1 7 4127604 Assembly Left Hand Rear Light 1 * 4281511 Lens 1 8 4127605 Assembly - Right Hand Rear Light 1 * 4281512 Lens 1 9 4161623 Side Indicator Lamp 2 10 4161780 Work / Headlamp 2 11 4161942 Backplate - Bumper 1 12 4161943 Backplate - Bumper 1 13 4165803 Rear Cover - Work / Headlamp 2 14 4170900 Weldment - RH Light Bracket 1 15 4170901 Weldment - LH Light Bracket 1 16 4172461 Indicator Repeater Lens 2 17 4175360 Weldment - RH Front Light Backing 1 18 4175361 Weldment - LH Front Light Backing (72") 1 19 4175367 Front Cover - Light Cluster RH (72") 1 20 4175368 Front Cover - Light Cluster LH (72") 1 21 4175520 Spacer-20 X 7 X 50 4 22 4189285 Weldment Front Hardpoint 1 23 4190743 Nameplate - Bumper 1 24 4190745 Nameplate - Bumper 1 25 450008 Bolt - Hex M6 X 65 12 26 450191 Screw - Hex M8 X 20 2 27 450195 Screw - Hex M8 X 40 4 28 450217 Screw - Hex M10 X 40 2 29 450377 Nut - Hex M6 Nyloc 2 30 450378 Nut - Hex M8 Nyloc 14 31 450379 Nut - Hex M10 Nyloc 2 32 450387 Washer - M4 X 9 X 0.9 16 33 450389 Washer - M6 X 12.5 X 1.8 16 34 450390 Washer - M8 X 17 X 1.8 32 35 450391 Washer - M10 X 21 X 2.2 4 36 450409 Washer - Slw M5 4 37 450410 Washer - Slw M6 12 38 450519 Screw - Pan Hd M4 X 16 8 39 450528 Screw - Pan Hd M5 X 16 4 40 450543 Screw - Pan Hd M6 X 25 2 41 450526 Screw - Pan Hd M5 X 12 6 Parts-21
PARTS MANUAL LMAC388 KIT-LIGHTS Illustration Number: Parts explosion Parts-22
PARTS MANUAL LMAC388 KIT-LIGHTS ITEM PART NO. DESCRIPTION QTY. 42 452717 Nut - Hex M4 Nyloc 8 43 4158720 Stiffener Cab Support 2 44 450411 Washer - Slw M8 2 45 450392 Washer - M12 X 24 X 2.7 10 46 450016 Bolt - Hex M8 X 40 10 47 450048 Bolt - Hex M12 X 40 10 48 452438 Nut - Hex M12 Flange Nyloc 10 * 4161625 Flasher Relay Unit 1 Parts-23
Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, IP3 9TT English Company Registration No. 1070731 www.ransomesjacobsen.com Jacobsen, A Textron Company 11108 Quality Drive, Charlotte, NC 28273, USA www.jacobsen.com