Jacobsen G-Plex III Guide

Safety, Operation and Maintenance Manual
WARNING:Ifincorrectlyusedthismachinecancausesevere
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 January 2010
24789G-GB (rev.4)
Jacobsen G-Plex III
Series: FH - Engine type: Kubota D722
Product code: USAD002
Series: FJ - Engine type: Briggs & Stratton 350447
Product code: USAG002

©2010, Ransomes Jacobsen Limited. All Rights Reserved

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JACOBSEN G-PLEX III Series: FH & FJ
SAFETY AND OPERATORS MANUAL
1 CONTENTS
2 INTRODUCTION
2.1 IMPORTANT ................................................................. 4
2.2 PRODUCT IDENTIFICATION ........................................ 4
2.3 GUIDELINES FOR THE DISPOSAL OF PRODUCTS ... 4
3 SAFETY INSTRUCTIONS
3.1 OPERATING INSTRUCTIONS ...................................... 6
3.2 SAFETY SIGNS ............................................................. 6
3.3 STARTING THE ENGINE ............................................... 6
3.4 DRIVING THE MACHINE .............................................. 6
3.5 TRANSPORTING........................................................... 6
3.6 LEAVING THE DRIVING POSITION ............................. 7
3.7 SLOPES ........................................................................ 7
3.8 BLOCKED CUTTING CYLINDERS ............................... 7
3.9 ADJUSTMENTS, LUBRICATIONAND
MAINTENANCE............................................................. 7
4 SPECIFICATIONS
4.1 ENGINE SPECIFICATION.............................................. 9
4.2 MACHINE SPECIFICATION ......................................... 9
4.3 CUTTING UNIT.............................................................. 9
4.4 DIMENSIONS ................................................................. 9
4.5 VIBRATION LEVEL ..................................................... 10
4.6 SLOPES ....................................................................... 10
4.7 RECOMMENDED LUBRICANTS ................................. 11
4.8 FUEL RECOMMENDATIONS - DIESEL ...................... 11
4.9 FUEL RECOMMENDATIONS - GASOLINE................. 11
4.10 CUTTING UNIT SPECIFICATION................................ 12
4.11 CUTTING PERFORMANCE ......................................... 12
4.12 CONFORMITYCERTIFICATES ................................... 13
5 DECALS
5.1 SAFETYDECALS......................................................... 17
5.2 INSTRUCTION DECALS .............................................. 18
6 CONTROLS
6.1 CONTROLPANEL- DIESEL ........................................ 19
6.2 CONTROL PANEL - GASOLINE .................................. 20
6.3 CONTROL PEDALS ..................................................... 21
6.4 PARKING BRAKEPEDAL ............................................ 21
6.4A PARKINGBRAKE LEVER ............................................ 21
6.5 PADDLE/FOOT SWITCH MOW/LIFT .......................... 22
6.6 JOYSTICK MOW/LIFT ................................................. 22
7 OPERATION
7.1 DAILYINSPECTION ..................................................... 23
7.2.1 OPERATORPRESENCEAND SAFETYINTERLOCK
SYSTEM ....................................................................... 24
7.2.2 CONTROLLERERROR CODES................................... 24
7.3 OPERATINGPROCEDURE .......................................... 25
7.4 MOWING PROCEDURES............................................ 26
7.5 MOWING ON SLOPES ................................................ 27
8 SETUP
8.1 SET UP ......................................................................... 27
8.2 MOUNTING THE CUTTING HEADS............................. 31
8.3 REEL MOTOR MOUNTING .......................................... 32
8.4 CUTTING CYLINDER LIFT & LOWER RATE &
SYNCHRONISATION .................................................... 33
9 LUBRICATION & MAINTENANCE
9.1 LUBRICATIONAND MAINTENANCECHART ............. 35
9.2A LUBRICATION DIAGRAM - GASOLINE ...................... 36
9.2B LUBRICATION DIAGRAM - DIESEL ............................ 37
9.3 ENGINE ACCESS ......................................................... 38
9.4 ENGINE OIL LEVEL - GASOLINE ............................... 39
9.5 ENGINE OIL CHANGE- GASOLINE ............................. 39
9.6 ENGINE OIL FILTER- GASOLINE................................ 40
9.7 AIR FILTER - GASOLINE ............................................. 40
9.8 AIR CLEANER - GASOLINE ........................................ 41
9.9 ENGINE FUEL FILTER - GASOLINE ........................... 41
9.10 ENGINE OIL LEVEL - DIESEL ..................................... 42
9.11 ENGINE OIL CHANGE - DIESEL.................................. 43
9.12 ENGINE OIL FILTER - DIESEL .................................... 43
9.13 ENGINE FUEL FILTER - DIESEL ................................. 44
9.14 AIR FILTER - DIESEL................................................... 44
9.15 BLEEDING THE FUEL SYSTEM - DIESEL .................. 45
9.16 AIR CLEANER - DIESEL .............................................. 46
9.17 FAN BELT TENSION - DIESEL .................................... 46
9.18 TIRES............................................................................ 47
9.19 BRAKES ....................................................................... 47
9.20 HYDRAULIC OIL FILTER ............................................. 48
9.21 HYDRAULIC OIL .......................................................... 48
9.22 HYDRAULICSYSTEM .................................................. 49
9.23 HYDRAULIC PUMP BYPASS VALVE .......................... 49
9.24 FREE WHEELING OR TOWING UNIT ......................... 49
9.25 BATTERY ...................................................................... 50
9.26 JUMP STARTING ......................................................... 51
9.27 OIL COOLER GASOLINE MACHINE ........................... 52
9.28 RADIATORDIESELMACHINE..................................... 53
9.29 OIL COOLER & RADIATOR DIESELMACHINE.......... 54
10 ADJUSTMENT
10.1 CUTTINGHEAD MAINTENANCE ................................. 55
10.2 BEDKNIFEADJUSTMENT ........................................... 56
10.3 HEIGHT OF CUT .......................................................... 57
10.4 CONTROLARM ADJUSTMENT .................................. 58
10.5 REAR SWING OUT ARM ............................................. 59
10.6 LEVELLING LINKAGE FOR THE FRONT CUTTING
HEADS .......................................................................... 60
10.7 MOW/TRANSPORT SPEED CONTROL ...................... 61
10.8 SPEED CONTROLPEDAL ........................................... 62
10.9 SEATADJUSTMENT LEVER ....................................... 62
10.10 BACKLAPPING ............................................................ 63
11 SCHEMATICS
11.1 HYDRAULIC CIRCUIT .................................................. 67
11.2 ELECTRICAL CIRCUIT - GASOLINE .......................... 69
11.3 ELECTRICAL CIRCUIT - DIESEL ................................ 71
12 GUARANTEE / SALES & SERVICE ............................. 72
RansomesJacobsenLimited reserves therightto make designchanges withoutobligationto make thesechanges
on units previously sold and the information contained in this manual is subject to change without notice.
SECTION ................................................................... PAGE SECTION ................................................................... PAGE

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JACOBSEN G-PLEX III Series: FH & FJ
SAFETY AND OPERATORS MANUAL
2 INTRODUCTION
2.1IMPORTANT
IMPORTANT: This is a precision machine and the service obtained from it depends on the way it is
operatedandmaintained.
This SAFETY AND OPERATORS MANUAL should be regarded as part of the machine. Suppliers of both
newand second-handmachines are advised to retaindocumentary evidencethat this manual was provided
withthemachine.
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
intendeduse.
Before attempting to operate this machine, ALL operators MUST read through this manual and make
themselvesthoroughlyconversantwithSafetyInstructions,controls,lubricationandmaintenance.
Accident prevention regulations, all other generally recognized regulations on safety and occupational
medicine, and all road traffic regulations shall be observed at all times.
Anyarbitrary modificationscarriedoutonthismachinemayrelievethemanufacturerofliabilityforany resultingdamage
orinjury.
2006/42/EC
ThesearetheOriginalinstructions verifiedbyRansomesJacobsen Limited.
2.2 PRODUCTIDENTIFICATION
A Maximum front axle load in Kg (for machines
being driven on the highway)
B Gross weight (mass) in Kg
C Maximum rear axle load in Kg (for machines
being driven on the highway)
D Power in Kw
E Date code
F Machine type (Designation)
G Product code
H Productname
J Serialnumber
SerialPlateLocation
The serial plate A is located on the chassis under
theoperators seating position.
Kg Kw Kg Kg
West Road
Ransomes Europark
Ipswich IP3 9TT
England
ABCD E
FG
HJ

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JACOBSEN G-PLEX III Series: FH & FJ
SAFETY AND OPERATORS MANUAL
2 INTRODUCTION
2.3 GUIDELINES FOR THE DISPOSAL
OFSCRAPPRODUCTS
2.3.1 DURINGSERVICELIFE
Used oil, oil filters and engine coolant are
hazardous materials and should be handled in a
safeandenvironmentallyresponsibleway.
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.
Followingthe maintenanceprocedures laid outin
thismanual will ensurethat theimpactthe machine
hason the localenvironment is controlled.
When it has been identified that a turf care product
has no further functional value and requires
disposal,thefollowingactionsshouldbetaken.
2.3.2 ENDOFSERVICELIFE
Theseguidelines shouldbe used inconjunction with
applicableHealth,SafetyandEnvironmental
legislation and use of approved local facilities for
waste disposal and recycling.
• Position the machine in a suitable location
for any necessary lifting
equipmenttobeused.
• UseappropriatetoolsandPersonal
ProtectiveEquipment(PPE) and
take guidance from the technical
manualsapplicabletothe
machine.
• Removeandstoreappropriately:
1. Batteries
2. Fuelresidue
3. Enginecoolant
4. Oils
• Disassemblethe structureof the machine
referring to the technical
manualswhereappropriate.
Specialattentionshouldbe
made for dealing with ‘stored
energy’ within pressurised
elements of the machine or
tensionedsprings.
• Any items that still have a useful service life
as second hand components or
can be re-serviced should be
separatedand returnedtothe
relevantcentre.
• Otherwornoutitems should be separated
into material groups for
recycling and disposal
consistentwithavailable
facilities. More common
separationtypes areas follows:
• Steel
• Nonferrousmetals
• Aluminium
• Brass
• Copper
• Plastics
• Identifiable
• Recyclable
• Non recyclable
• Notidentified
• Rubber
• Electrical & Electronic Components
• Itemsthatcannotbeseparatedeconomically
into different material groups
shouldbe added tothe‘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.

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JACOBSEN G-PLEX III Series: FH & FJ
SAFETY AND OPERATORS MANUAL
3 SAFETY INSTRUCTIONS
Thissafety symbolindicates important safety
messages in this manual. When you see this
symbol, be alert to the possibility of injury, carefully
readthe messagethat follows, andinform other
operators.
3.1OPERATINGINSTRUCTIONS
• Ensure that the instructions in this book are
read and fully understood.
• Nopersonshould be allowed tooperatethis
machine unless they are fully acquainted with
all the controls and the safety procedures.
• Neverallowchildrenorpeopleunfamiliar with
these instructions to use this machine. Local
regulations may restrict the age of the
operator.
3.2SAFETYSIGNS
• 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
obtainablefromRansomesdealers.
3.3STARTINGTHEENGINE
• 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
adequateventilation.
3.4DRIVINGTHEMACHINE
• 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
• Alwaysobservethe Highway Codebothon
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.
• Rememberthat some peopleare deaf or
blind and that children and animals can be
unpredictable.
• Keeptravellingspeeds low enoughforan
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
obstructionsand/or bystanders. DONOT
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
orleftunattended,lowerthecutting means
unless the transport locks are being used.
• Whilemowing,alwayswearsubstantial
footwear and long trousers. Do not operate
theequipmentwhen barefoot orwearing
opensandals.
• Check the grass catcher frequently for
wear or deterioration. After striking a
foreign object. Inspect. the lawnmower for
damage and make repairs before restarting
andoperatingtheequipment.
• If the machine starts to vibrate abnormally,
checkimmediately.
3.5TRANSPORTING
• Ensure that the cutting units are securely
fastened in the transport position. Do not
transportwithcuttingmechanismrotating.
• Drive the machine with due consideration of
road and surface conditions, inclines and
localundulations.
• Sudden decelerating or braking can cause
the rear wheels to lift.
• Remember that the stability of the rear of
the machine is reduced as the fuel is used.

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JACOBSEN G-PLEX III Series: FH & FJ
SAFETY AND OPERATORS MANUAL
3 SAFETY INSTRUCTIONS
3.6 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 thestarterkey.
3.7SLOPES
TAKEEXTRACAREWHENWORKINGON
SLOPES
• Localundulationsand sinkage will changethe
general slope. Avoid ground conditions which
can cause the machine to slide.
• Keepmachine speedslow onslopes and
during tight turns.
• Sudden decelerating or braking can cause
the rear wheels to lift. Remember there is no
such thing as a “safe” slope.
• Travelon grassslopes requiresparticular
care.
DO NOT USE ON SLOPES GREATER THAN 15°
IMPORTANT: When working on any slope set the
weight transfer, if fitted to its maximum (+) setting.
3.8BLOCKEDCUTTINGCYLINDERS
• Stopthe engineandmake sureall moving
parts are stationary.
• Apply brakes and disengage all drives.
• Releaseblockages 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
theothers to rotate.
3.9ADJUSTMENTS,LUBRICATIONAND
MAINTENANCE
• Stopthe engineandmake sureall moving
parts are stationary.
• Apply brakes and disengage all drives.
• Readallthe 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,leavesorexcessivegrease.
• Replace worn or damaged parts for safety.
• When working underneath lifted parts or
machines, make sure adequate support Is
provided.
• Donotdismantlethemachinewithout
releasing or restraining forces which can
causepartsto move suddenly.
• Donotalterenginespeedabovemaximum
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.
• Whenrefuelling, STOP THE ENGINE, DO
NOTSMOKE. Add fuelbefore startingthe
engine, never add fuel while the engine is
running.
• Use a funnel when pouring fuel from a can
intothe 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.
• Refueloutdoors only anddo not smokewhile
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.
• Neverstore the equipmentwithfuel 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
bedone outdoors.
• Donot spillfuel onto hotcomponents.
• Whenservicing batteries, DONOTSMOKE,
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
allowedtocoolsufficientlytopreventdamage
tothe block andexhaustmanifold. Never
force water into any electrical components,
the air cleaner or exhaust muffler as water
could enter the engine cylinder and cause
damage.

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JACOBSEN G-PLEX III Series: FH & FJ
SAFETY AND OPERATORS MANUAL
3 SAFETY INSTRUCTIONS
DANGER-Indicatesanimminentlyhazardous
situation which, if not avoided, WILL result in death
orserious injury.
WARNING-Indicatesapotentiallyhazardous
situationwhich,if not avoided, COULD resultin
deathor serious injury.
CAUTION-Indicatesapotentiallyhazardous
situationwhich, if notavoided, MAY resultinminor
ormoderate injury andproperty damage. Itmay
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.
Ear Protection Should be Worn When
Operating Machines with Operator Ear Noise
Levels above 90dB(A)Leq.
WARNING
Hydraulic Fluid escaping under pressure
can penetrate skin and do serious
damage. Immediate medical assistance
mustbesought.
WARNING
Batteries produce explosive gases and
contain corrosive acid and supply levels
of electrical current high enough to cause
burns.
WARNING
Battery posts, terminals and related
accessories contain lead and lead
compounds
WASHHANDSAFTERHANDLING
WARNING
California Proposition 65
EngineExhaust,someofitsconstituents,
and certain vehicle components contain
or emit chemicals known to the state of
California to cause cancer and birth
defects or other
WARNING
DONOTUSEONSLOPESGREATERTHAN15°
WARNING
When carrying out any welding on the
machine the battery and controller must
be disconnected before starting.
Underno circumstances should the
controller be opened as this will
invalidate all warranties and could result
in a malfunction.

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JACOBSEN G-PLEX III Series: FH & FJ
SAFETY AND OPERATORS MANUAL
4 SPECIFICATIONS
4.1 ENGINESPECIFICATION
TYPE:TYPE: Kubota 13.2KW @ 3200 RPM,
3 cylinder Diesel engine, 4
stroke, water cooled, 719cc
with 12V electric start.
Model: D722-E3B-RNUK-1
MaximumSpeed: 3350 RPM ±50 rpm (No load)
IdleSpeed: 1500 RPM ±50rpm
Oil Sump Capacity:3.2 litres
Firing Order: 1, 2, 3.
Fuel: No. 2-D Diesel fuel (ASTM
D975)
4.1.1 ENGINESPECIFICATION
TYPE:TYPE: Briggs & Stratton 13.2KW @
3400RPM, V twingasoline
engine, 4 stroke, air cooled,
719cc with 12V electric start.
Model: Vanguard350447 Type 1294
MaximumSpeed: 3400 RPM (Noload)
IdleSpeed: 1500RPM
Oil Sump Capacity:1.4 litres
Fuel: UnleadedGasolineMinimum85
octane
4.2 MACHINESPECIFICATION
Frameconstruction:
Heavy duty fabricated steel
chassis.
Transmission: Variabledisplacement
hydrostatic pump with high
speedlowtorquewheelmotors.
Cuttingunitdrive: Direct drive hydrostatic and reel
drivepumps, bi-directional
hydraulic gear motor with reel
controlvalveandbacklapcontrol
valve.
Speeds:
Cutting: 6 km/h
Transport: 12 kp/h
Reverse: 3 kp/h
Steering: Rear Wheel Steering. Power
Steering, 2.5 turns lock to lock
330mm dia. Steering Wheel
Groundpressure: 1.0 kg/cm
Brakes, Service: Positivehydrostatic braking.
Parking: 152 mm Calliper Disk
Capacities:
CoolingSystem: 3.8 litres
FuelTank: 31 litres
HydraulicTank: 18.2 litres
TotalSystem 25.7 litres
Battery: 12volt,Type 093
Alternator Diesel40 amp
Gasoline15amp
4.3 CUTTINGUNIT
Type: Three559mmwidesteerable
floatinghead.
Reel: 127mm diameter, 7 / 9 / 11
knife.
Rolls: Smooth rear roll, smooth or
grooved front /rear rolls optional.
Bedknife to reel
adjustment: Opposedsetscrew.
Height of cut
adjustment: Micro-adjusters on front roll.
Height of cut: 2.5mmto16mmStandardblade
2mmto16mmTournament
blade.

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JACOBSEN G-PLEX III Series: FH & FJ
SAFETY AND OPERATORS MANUAL
4.4 DIMENSIONS
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