Ransomes G - PLEX WD series Service manual

Service Course Manual
G - PLEX
WD, ZV & DP SERIES
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

SECTION 1
SPECIFICATIONS
E NG INE S P E C IF IC A TION
T YP E :T Y P E : K ubota 15.5K W @ 3600 R P M,
3 cylinder Dioes el engine, 4
stroke, water cooled, 719cc
with 12V electric start.
Model: D722-E
Maximum S peed: 3400 R P M (No load)
Idle S peed: 1500 R P M
Oil S ump C apacity:3.2 litres
F iring Order: 1, 3, 4, 2.
Fuel: No. 2-D Diesel fuel (AS TM D975)
E NG INE S P E C IF IC A T IO N
T YP E :T Y P E : B riggs & S tratton 13.5K W @
3600 R P M, V twin gas oline
engine, 4 s troke, air cooled,
719cc with 12V electric start.
Model: V anguard 350447 T ype 1294
Maximum S peed: 3400 R P M (No load)
Idle S peed: 1500 R P M
Oil S ump C apacity:1.4 litres
F uel: Unleaded G asoline Minimum 85
octane
MAC HINE S P E C IF IC A TION
F rame construction:
Heavy duty fabricated steel
chas s is.
Trans mission:
Variable displacement
hydrostatic pump with high
speed low torque wheel motors .
C utting unitdrive:
Direct drive hydros tatic and reel
drive pumps, bi-directional
hydraulic gear motor with reel
control valve and backlap control
valve.
S peeds:
C utting: 6 km/h
Trans port: 12 kp/h
R everse: 3 kp/h
S teering: R ear Wheel S teering. P ower
S teering, 2.5 turns lock to lock
330mm dia. S teering Wheel
G round pres s ure: 1.0 kg/cm
B rakes, S ervice: P os itive hydos tatic braking.
P arking: 152 mm C aliper Dis k
C apacities :
C ooling S ystem: 3.8 litres
F uel T ank: 31 litres
Hydraulic Tank: 18.2 litres
Total S ys tem 25.7 litres
B attery: 12 volt, T ype 093
Alternator Dies el 40a mp
G asoline 15amp
C UTT ING UNIT
Type: T hree 559mm wide steerable
floating head.
R eel: 127mm diameter, 7 / 9 / 11
knife.
R olls: S mooth rear roll, smooth or
grooved front/rear rolls optional.
B edknife to reel
adjustment: Opposed s et screw.
Height of cut
adjustment: Micro-adjusters on front roll.
height of cut: 2.5mm to 16mm S tandard blade
2mm to 16mm T ournament
blade.
DIME NS IONS
Width of cut: 1.57 metres
Overall width with reels: 1.9 metres
Overallheight: 1.3 metres
Overall length with reels: 2.1 metres
Overall length with catchers : 2.5 metres
Overall weightof machine
With R eels
Diesel: 630kg
G asoline: 574kg
Without R eels
Diesel: 535kg
G asoline: 478kg
Wheel Track: 1.2 metres
Wheel B as e: 1.3 metres
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VIB R A TION L E V E L
The machine was tested for whole body and hand/
arm vibration levels. The operator was s eated in the
normal operating postion with both hands on the
steering mechanism. The engine was running and
the cutting device was rotating with the machine
stationary.
S tandard IS O 5349: 1986 Mechanic al vibration.
G uidelines for the meas urement and the
as s es s ment of human expos ure to hand-
trans mitted vibration.
S tandard IS O 2631-1: 1985 E valuation of human
ex pos ure to whole body vibration -- P art 1:
G eneral requirements .
C UTT ING P E R F OR MANC E
C utting F requency
7-knife reel - 7.4mm at 6km/h
9-knife reel - 5.7mm at 6km/h
11-knife reel - 4.7mm at 6km/h
S L OP E S
DO NOT US E ON S LOP E S G R E ATE R T HAN 15°
The slope 15° was calculated using static stability
meas urements according to the requirements of
E N 836.
R E C OMME NDE D L UB R IC A NTS
E ngine oil:
Diesel: S hould be to MIL-L -2104C
or to A.P .I. C lassification C D
G asoline: A.P .I. C las s ification S E /S F
Hydraulic Oil: G reens C are 68
G rease: Lithium based.
ERUTAREPMETTYISOCSIVLIO
)F°93(C°4EVOBA03EAS
)F°93(C°4WOLEB 0 3-W01ro03-W5EAS

2
SECTION 2
CONTROLS
T
CONTROLS
Figure11
1. Voltmeter
2. HourMeter
3. HeadlightSwitch
4. EngineOil Warning Light
5. IgnitionSwitch
6. Throttle
7. TurfProtectionSystem(optional)
8. Pre–HeatSwitchandGlow Plug Light
9. TemperatureGaugeAndWarningLight
10. ReelEnableSwitch
Voltmeter - indicates battery condition.
Headlight Switch - turns the headlights on and
off.
Engine Oil Warning Light - will come on when
the engine oil pressure is too low for
operation.
Ignition Switch - has four positions:
OFF-prevents allelectrical functions
from operating. Switch must be in the
OFF position to remove the key.
ON-fornormaloperation.
START-engagesthestarter.Release
the key after engine starts (the switch
automaticallyreturns toON).
ACC. - has no function on this unit.
NOTICE
•If the engine fails to start, or if it
“dies” for any reason, the ignition
switch must be returned to the OFF
positionbeforerestarting is
attempted. This feature prevents
damage to the starter and flywheel
teeth that can occur if the

CONTROLPEDALS
The Direction/Speed Pedal (See Fig. 12) controls
speedanddirection. Depress frontof pedalto go
forward,depress back ofpedaltogobackward.
Increasedmovementofthepedalwillincreasespeed.
To slow and stop the unit, release the pedal
completely.Properbrakingisprovidedbyhydrostatic
pressure. If more braking is required, press on the
brakepedal.
WARNING
• DONOT attempttoforce thedirection
control pedal to the neutral (stop) position or
tochange directionsbefore coming toa
complete stop. Abrupt stops or changes in
direction may cause injury.
starter is engaged while the engine is running.
Wait 30 seconds before restarting
engine.
WARNING
•When the ignition is switched on, if the
units are in the lowered position they will
raise. It should be ensured that operators/
bystandersareclearofallmovingparts
before the ignition switch is switched on.
Throttle - Pushall the wayforward fornormal engine
operating speed, and all the way back for
idle.
Hour Meter - records the number of hours the engine
has run. Use the hour meter to manage a
goodscheduledmaintenanceprogram(refer
totheMaintenanceGuide).
Pre–Heat Switch and Glow Plug Light - With key
switchON,push up/forward and hold the
pre–heat switch until the glow plug light
goes out.
Temperature Gauge and Warning Light - gauge
indicatescoolanttemperatureandlight
warnsofoverheatsituation.
Turf Protection System - can be installed as an
option to warn the operator if a leak in the
hydraulic system is detected.
Reel Enable Switch - This switch must be in the on
position (1) in order for the reels to rotate.
The switch must be in the off position (0) for
the unit to be started.
1
2
Figure12
1.Direction/SpeedPedal
2. Brake Pedal
NOTICE
• Toreducefatigueduring
normalforwardoperation,the
operator’sheelshould rest on
thefloorboardnexttothepedal
(not on the lower part of the
pedal).
PARKINGBRAKEPEDAL
The Parking Brake can be engaged by
depressingthe brakepedal untilthe unit
is at a complete stop. Once the unit is
stoped, push the parking brake latch
fowardtoholdthebrakepedal.
Disengagetheparkingbrakeby
depressingandreleasingthebrake
pedal.
1
2
Figure13
1. Brake Pedal
2. Park Brake Latch
PADDLE/FOOTSWITCHMOW/LIFT
TheMow/LiftPaddle/Footswitch
lowers and raises the cutting heads.
To Lower the Heads: Depress the
footswitchoroperatethepaddle.Ifreel
enable switch is on, reel rotation starts
whentheheadsarelowered.
To Raise the Heads: Depress the
footswitchoroperate the paddle. Reel
rotationstops when theheads are
raised.

ZX Models Only. NOTICE
• The paddle/footswitch will not operate
if the rear unit has not completed its
raise/lower cycle.
Figure14
1.PaddleControl(Mow/Raise)
2.FootswitchControl(Mow/Raise)
3.IllustrationofPaddle/FootswitchOperation
ADJUSTMENTS
WARNING
•Adjustmentproceduresmustbe
performedasspecifiedbyproperlytrained
service personnel ONLY. If assistance is
needed, contact your local Jacobsen
TextronDealer.
•Toavoid thepossibilityof seriousinjury,
switch the reel enable switch to the off
position, lower the heads, stop the
engine,remove thekey andset the
parkingbrake BEFORE makingany
adjustment.
•The rear swing out arm is to allow you
easy access to the rear cutting head.
The cutting heads MUST BE in the raised
position. DO NOT swing the arm out
with the cutting heads in the lowered
position.
•NEVER rotate the cutting reel by pushing
it with your hands or fingers. Fingers can
becomecaughtbetweenthereelandthe
frame resulting in serious injury. Use a
ratchet with a 9/16” socket on the end of
the cutting head shaft to rotate the reel
duringadjustment andtesting(See Fig.
15).
1
Cutting Head Shown
with
Rear Rotary Brush
Accessory mounted
Figure15
1. Rotate Cutting Reel with this Screw Head
BEDKNIFEADJUSTMENT
Forthis adjustment, thebacklap valvecontrol
lever must be in the center “neutral” position
so that the reels can be rotated manually.
WARNING
· To avoid the possibility of serious
injury, NEVER attempt any cutting
head adjustment while the engine is
running.
Any adjustment to the clearance between the
reelbladesand thebedknife shouldbedoneat
the leading end of the reel first (the end at which
eachindividualbladefirstcrossesthebedknife).
Thenat theopposite endof the reel.
1. Loosen the lower adjustment screws at
eachendby turningthem approximately
1/4turn counterclockwise(SeeFigure
16).
2. Whilerotating thereel backwards, turn
theupperadjustmentscrews(leading
end first) until there is approximately
(.025mm-.075mm)clearance.After
adjustingboth ends,recheck the leading
end.

NOTICE
•Toomuchclearancebetweenthebedknife
and the blades will result in poor cutting
quality. Too little clearance will cause
excessivewear tothecuttingedgesand
may cause damage to the bedknife, reel
bladesorothercomponents.
1
2
Figure16
1.UpperAdjustmentScrew
2.LowerAdjustmentScrew
3. Rotatethereelforward.Thereel must turn
freely and you should just be able to hear
the reel blades making slight contact with
thebedknife.
4. Afterthe bedknife is properlyadjusted,
tighten the lower adjustment screw at each
end.
5. Test the cutting head by holding two strips
ofnewsprintperpendiculartothebedknife.
Rotatethe reel witha wrench.Thereel
must turn freely and each blade on the
reel should cut one of the two strips of
paper.
HEIGHTOFCUT
NOTICE
• All three cutting heads MUST be accurately
set at the same height of cut to insure an
evencut.
• Bedknifeadjustmentmustbemadebefore
setting the height of cut.
1. Set the height of cut on the gauge block by
turning the wingnut until the distance
betweenthe bottom ofthe screwheadand
the top of the gauge block equals the
desired height of cut (See Fig. 18).
2. Loosen the locking nut on one of the front
roller adjusting brackets just enough to
allowadjustment (SeeFig.17).
1
Cutting Head Shown
with
Rear Rotary Brush
Accessory mounted
Figure17
1. Loosen Locking Nut
3. Hold the gauge block across the
bottomofboththe front and rear
rollersneartherolleradjustment
bracketandadjust thefront roller
until the cutting edge of the
bedknife comes up to touch the
bottomofthegaugescrewhead
(SeeFig. 18).
Front Roller Rear Roller
Bedknife
Gauge Block
Gauge
Screw
Head
Set Height Of Cut
(Part No. 892010)
Figure18
HeightofCutAdjustment
4. Tightenthe locking nutandrepeat
theprocedureat the otherend.
Afteradjustment hasbeen made at
both ends, go back and recheck
bothends.
5. Make sure all three cutting heads
areset withoutchangingthe height
ofthegaugescrew.
SEATADJUSTMENTLEVER
Pullout onthe adjustment leverlocated
under the left side of the seat. Slide the seat
tothedesired position andrelease the lever.
1
Figure19
1.SeatAdjustmentLever

OPERATION
840228
Readandfamiliarizeyourselfwiththe
followingwarningsbeforeoperatingtheunit.
WARNING
•Thisisheavyequipment.Improper
use, or operating the unit in areas
that may cause it to overturn, could
cause serious injury or death of you
theoperatororbystanders.
•READandunderstandthe
operator’smanualbefore
attempting to operate this unit.
•AllowONLYtrainedandauthorized
persons to operate this unit.
NEVERallowchildrentooperate
this unit. Local regulations may
restrictthe ageof theoperator.
•Neveroperatetheunitwhilepeople,
especially children, or pets are
nearby.
•Keep in mind that the operator or
user is responsible for accidents or
hazardsoccurringtootherpeople
orproperty.
•BEFORE using the unit, always
inspectit forproblems. If something
is wrong, DO NOT USE IT. Fix the
problembeforeusingtheunitto
preventpossibleinjury.
•WHILE using the unit, if something
is found to be wrong, STOP using
it. Fix the problem before the unit is
usedagain.
•RuntheengineONLYwherethere
isenough fresh air topreventthe
buildupofcarbonmonoxidefumes.
Carbonmonoxideiscolorless,
odorlessanddeadly.NEVERrun
the unit in an enclosed space
where exhaust fumes will collect.
•NEVER use the unit in or near an
areawheretheremaybeexplosive
dustor fumes.The electricaland
exhaust systems of this unit will
make sparks that can ignite
explosivematerials.
•ALWAYSusegood judgement
whenoperatingonornearhillsor
slopes. NEVER start or stop
suddenly, you may cause unstable
operatingconditions.NEVER
changedirectionsabruptlyormake
sharp turns on slopes. ALWAYS
drivestraightup and down theface
of slopes, NEVER across the face.
•When refueling, ALWAYS stop the
engineand donot allowsparks or
openflamesanywherenearthe
unit.DO NOToverfillthefuel tank.
Fuelis extremelyflammableand
highlyexplosiveundercertain
conditions. Clean up any spilled
fuelandallowthevaporsto
dissipatebeforeoperatingtheunit.
Store fuel in containers specifically
CONTROLARMADJUSTMENT
Supportthecontrolarmtoavoid a sudden drop
while adjusting its height. Loosen the Locking
Lever to allow the steering wheel and control
armto beadjusted up ordown. Tightenthe
lockinglever whensteeringwheel isatthe
desiredposition.
1
Figure21
1.ControlArmHeightLockingLever
WARNING
•DO NOT attempt to adjust the control
arm position while the unit is moving.
Operatormayloose control, causing
possibleinjury to themselvesor
bystanders.
HYDRAULICPUMPBYPASSVALVE
The Bypass Valve allows the unit to be pushed
ortowed. Turnthe handle onthe bottom ofthe
pumpcounterclockwise(asviewed fromthe
bottomof the pump)toopenthevalve.After
movingtheunit,close the valve byturning the
handleclockwise.
1
Figure22
1.BypassValveHandle
NOTICE
• Thebypassvalvemustbe tightly
closedfornormaloperationora
significant loss of speed will occur and

3
SECTION 3
ENGINE
STARTINGTHEENGINE
When starting a diesel engine for the first time, after
prolongedstorage orif thefuel tankis allowedto run
dry, the fuel system must be bled before attempting
tostart theengine.Refer toBleeding The Fuel
System in the maintenance and parts manual.
After bleeding thesystem (ifrequired):
1. Operatormust be properlyseatedin the
operator’sseat.
2. Makesurefoot is offdirection/speedcontrol
pedal. The reel enable switch must be in
theoff position beforethe engine willstart.
3. Pushhandthrottleleverforwardtoa
“MIDDLE” position.
4. Insert key in ignition switch and turn to ON
position.
5. Pushandholdthepre–heatswitchforward.
The red indicator light will come on. When
the light goes out, release the pre–heat
switchand startthe engine(If theengine
hasbeenrunningandisalreadywarm,
there should be no need to pre heat the
glowplugs).
6. After the engine starts, allow it to warm up
for at least one minute.
NOTICE
• Thestartermotorshouldneverberunfor
morethan 10seconds. If theengine does
notstart afteroperatingthe starterfor 10
seconds, stop the starter. Wait for 30
seconds and repeat the start sequence.
• Donotuseether or starterfluid; severe
enginedamagemayoccur.
7. After the engine starts, check the following:
·Make sure the oil pressure light goes off
·The exhaust should be colorless or slightly
dark when engine is under load
NOTICE
• Ifthe oillightor watertemperature light and
buzzercome on duringoperation, stop the
engineimmediately.Toavoidseriousengine
damage,findandfixtheproblembefore
restarting.
ENGINEBREAK-IN
Allnew engines require abreak-inperiod. The
servicelifeofyourengineisdependentuponhow
yourengineis operatedduring thefirst 50hours
ofoperation.
1. ALWAYS idle and warm up your
engine for at least one minute. In cold
weather,allowtheenginetowarmup
completelybeforeoperatingtheunit.
2. NEVERoverloadtheengine.
3. Changeengine oil after the first 50
hours:
Withthe enginestoppedand warm,
drainthecrankcaseandremoveoil
filter. Install a new oil filter and refill the
crankcasewithproper oil.
WARNING
·Thisoilchange mustbe performedas
specifiedandonly by properly trained
servicepersonnel.
4. RefertotheMaintenanceGuidefor
futureserviceintervals.

ENGINEACCESS
The rear section of the unit can be raised for better
access to the engine. Loosen the two handknobs
abovethe rearfork.Raisethefueltankframe.
Supportit bypivoting therod beneaththe fuel tank
down and securing it in the cup next to the fork pivot
(SeeFig. 23).
WARNING
·DONOT remove thefueltank cap whilethe
tank is in the raised position.
Figure23
RearSectionofUnitRaised
DAILYSERVICEGUIDE
ENGINEOILLEVEL
Damagetoenginesduetoimproper
maintenance or use of incorrect oil quality
and/or viscosity is not covered by the
enginewarranty(refertotheengine
operator’smanualforcrankcasecapacity
andrecommendedoilgradeandweight).
Unit must be on a level surface to obtain an
accurateoillevelreading.Theoillevelmust
be kept between the two marks on the
dipstick. NOTICE
•DONOToverfill. Engine
overheatinganddamagemay
result.
Figure26
1. Dipstick
1
Figure27
1. Oil Filler Port

IMPORTANT!
WERECOMMENDTHATTHEFILTERELEMENTBEREPLACEDBEFOREENGINE
PERFORMANCEISAFFECTED.THISMAYOCCURAT250HOURSOFSERVICEUNDERVERY
DUSTYCONDITIONSORAT500HOURSUNDERNORMALOPERATINGCONDITIONS. WEDO
NOTRECOMMENDCLEANINGTHEFILTERELEMENTBECAUSEOFTHEPOSSIBILITYOF
DAMAGINGIT. CHECKINGTHEELEMENT
To check for damage, pin holes, etc. shine a light source into the end of the element. If light
CANNOT beseen throughthe paper, anew element shouldbe installed.Likewise,if pinholesof
brightlight appear inthepaper, the elementshouldbe replaced.
INSTALLINGELEMENT
1. Clean the dust from inside the filter housing with a damp cloth. Make sure that dust does
not enter the engine air intake.
2. Check the soft gasket material at both ends of the element to be sure it is not damaged.
3. Insert the open end of the element into the housing and press it onto the air intake pipe at
the back of the housing. Make sure the filter element fits over the pipe snugly and is pushed
all the way on to prevent any dust from getting past the filter.
4. Installthe air cleanercover overthe element withthe dust collectorpointing DOWN (dust
collectorempties automaticallywhenproperly installed).Securethe coverwiththe twowire
bails (See Fig. 29).
1
2
3
3
Figure29
1.Cover
2. Dust Collector
3. Wire Bails

BLEEDINGTHEFUELSYSTEM
WARNING
•Thisproceduremustbeperformedas
specifiedandonly by properly trained
servicepersonnel.
The fuel system must be bled when:
•Starting the engine for the first time
•Thefuel tank becomescompletely
empty
•Theenginehasnotbeen used foran
extended period of time
•Thefuelfilterand/orfuellineshavebeen
loosened,removedorreplaced.
Primaryfuelfilter PN 825619
Secondaryfuelfilter element (See Fig.
25) PN 840161
1. Fill the fuel tank.
2. Openthe air venton topofthe fuelfilter
(SeeFig. 25).
3. Withoutpreheatingtheglow plugs, turn
the ignition switch to START to operate
the fuel pump. Allow the starter to run the
pump until a steady stream of fuel is
coming out of the fuel filter air vent. Stop
the starter and close the air vent.
1
2
Figure25
1. Fuel Filter Air Vent
2.Secondaryfuelfilter
4. Openthe airvent on top of the
injectionpump,openairventonly
whenengineisNOTrunning(See
Fig.26).
1
Figure26
1. Injection Pump Air Vent
5. Withoutpreheating the glow plugs,
turn the ignition switch to START to
operatethefuel pump. Allowthe
starter to run the pump until a steady
stream of fuel is coming out of the
injectionpump airvent. Stopthe
starter and close the air vent.
WARNING
• Catchfuelanddisposeofproperly.
•Toavoidafirehazard,cleanupany
spilledfuel.

4
SECTION 4
DRIVE TRAIN
THIS SECTION INTENTIONALLY LEFT BLANK

5
SECTION 5
BRAKE SYSTEM
PARKINGBRAKE PEDAL
The Parking Brake can be engaged by depressing the brake pedal until the unit is at a
completestop. Once the unitis stoped, pushtheparking brakelatchfoward toholdthe
brake pedal. Disengage the parking brake by depressing and releasing the brake
pedal.
It isimportant to noteonthe ZXseriesmachines and machinesthat have beenupdated
using kit LMAB 973, the parking brake must be depressed to unable the machine to
start.
1. Brake Pedal
2. Park Brake Latch
1
2

6
SECTION 6
STEERING
THIS SECTION INTENTIONALLY LEFT BLANK