Textron RANSOMES G-Plex II User manual

RANSOMES
¨
Parts and Maintenance Manual
Nomenclature Des Pieces De Rechange & Manuel De Maintenance
Onderhouds - En Onderdelenhandleiding
Sicherheits und Bedienungs anleitung
Manuale d’istruzioni per I’uso e la Sicurezza
RANSOMES
AVVERTENZA: Questa macchina può causare gravi infortuni
se viene utilizzata in modo errato. Prima di accingersi ad
approntare, usare, mettere a punto o eseguire la
manutenzione di questa macchina, coloro che la utilizzano
ed i responsabili della manutenzione devono essere
addestratiall’impiegodellamacchina,devonoessereinformati
dei pericoli, e devono leggere l’intero manuale.
GB
Part No. 24210G (rev.0)(RJ 100 062000)
FNL DI
WARNHINWEIS:WenndieseMaschinenicht ordnungsgemäß
verwendet wird, können ernsthafte Verletzungen verursacht
werden. Personen, die diese Maschine verwenden und
warten, müssen in ihrer richtigen Verwendung ausgebildet
sein, auf die Gefahren aufmerksam gemacht worden sein
und die Anleitung ganz gelesen haben, bevor sie versuchen,
die Maschine aufzustellen, zu bedienen, einzustellen oder
zu warten.
WAARSCHUWING: Bij verkeerd gebruik kan deze machine
ernstig lichamelijk letsel veroorzaken. Degenen die de ma-
chine gebruiken en onderhouden moeten worden getraind
in het juiste gebruik ervan, worden gewaarschuwd voor de
gevaren ervan en behoren de volledige handleiding
aandachtig te lezen alvorens de machine bedrijfs-klaar te
maken, te bedienen, af te stellen en/of te onderhouden.
AVERTISSEMENT : Risque de blessures graves en cas
d’utilisation incorrecte de la machine. Les opérateurs et le
personnel d’entretien doivent être formés et conscients des
dangers encourus. Ils doivent lire avec attention le manuel
avant d’essayer de monter, d’utiliser, de régler ou maintenir
lamachine.
WARNING: If incorrectly used this machine can cause se-
vereinjury. 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.
G-Plex II
Series: WD - Engine type: Kubota model D722B
Product codes:LHAH001

©2000, Textron Inc. All Rights Reserved

GB-1
RANSOMES G PLEX II Series :WD
MAINTENANCE AND PARTS MANUAL
GB
INDEX
Service and Maintenance Pages
Page
Adjustments .......................................7
Air Cleaner .....................................17–18
Ammeter ............................................5
Backlapping ...................................19–20
Battery...............................................18
Bedknife Adjustment..........................8
Bleeding The Fuel System ...............12
Cleaning Radiator .............................17
Control Pedals ...................................6
Controls............................................. 5
Cutting Head Levaling .......................9
Cutting Head Maintenance ...............19
Cutting Head Serial Number..............3
Cutting Head Timing.........................11
Dipstick, Engine Oil ..........................15
Engine Access ..................................14
Engine Break–In ...............................13
Engine Cooling System ....................17
Engine Oil Filter ................................15
Engine Oil Level ...............................15
Fuel Recommendations....................13
Fuses ................................................18
Headlight Switch ................................5
Height Of Cut.....................................8
Hour Meter .........................................5
Hydraulic Diagram ............................22
Hydraulic Pump Bypass Valve ..........6
Hydraulic System...........................16–17
Identification Numbers.......................3
Ignition Switch....................................5
Jump Starting....................................18
Leveling Linkage, Front Heads..........9
Lube Chart ........................................21
Maintenance Guide...........................13
Model Number ...................................3
Mow/Transport Speed Control........9–10
Mowing Speed Adjustment .............9–10
Oil Filter (hydraulic) ..........................17
Oil type, hydraulic .............................16
Oil Warning Light, Engine .................5
Parking Brake ....................................6
Pedals
Mow/Lift .............................................6
Page
Brake..................................................6
Speed/Direction .................................9
Pre–Heat Switc ..................................5
Rear Swingout Arm............................7
Serial Number....................................3
Service and Maintenance .................13
Specifications.....................................4
Starting The Engine
Diesel ................................................12
Gasoline............................................11
Storage .............................................20
Temperature Gauge ..........................5
Throttle...............................................5
Tire Pressure ....................................19
Towing The Unit................................13
Troubleshooting ................................23
Turf Protection System (accessory) .17

GB-2
RANSOMES G PLEX II Series :WD
MAINTENANCE AND PARTS MANUAL
GB
Index To Parts Pages
Section Title Page
1CHASSIS AND COVERS.................................................................... 120
2POWER ASSY DIESEL....................................................................... 122
3RADIATOR (DIESEL) .......................................................................... 124
4AIR CLEANER (DIESEL).................................................................... 126
5FUEL SYSTEM.................................................................................... 128
6OIL COOLER MOUNTING................................................................... 130
7HEAD LIFT AND PUMP CONTROL LINKAGE .................................. 132
8HYDRAULIC PUMP AND VALVES..................................................... 134
9HYDRAULIC LIFT CIRCUIT................................................................ 136
10 HYDRAULIC REEL CIRCUIT ............................................................. 138
11 HYDRAULIC WHEEL DRIVE CIRCUIT .............................................. 140
12 HYDRAULIC POWER STEERING ...................................................... 142
13 CONTROL ARM .................................................................................. 144
14 LIFT ASSEMBLY - FRONT CUTTING HEADS................................... 146
15 LIFT ASSEMBLY - REAR CUTTING HEAD ....................................... 148
16 MOW / RAISE PEDAL AND SPEED CONTROL PEDAL ................... 152
17 MOW SPEED CONTROL .................................................................... 154
18 BRAKE PEDAL................................................................................... 156
19 SEAT.................................................................................................... 158
20 DECALS .............................................................................................. 160
21 CONTROL PANEL AND ELECTRICAL COMPONENTS .................. 162
22 ELECTRICAL COMPONENTS ........................................................... 166
23 WHEELS AND REAR HUB ................................................................ 168
24 COUNTER WEIGHT AND MOTOR MOUNTING ................................. 170
25 REEL ASSEMBLY - 1.......................................................................... 172
26 REEL ASSEMBLY - 2.......................................................................... 174
27 REAR ROLLER................................................................................... 176
28 REAR ROLLER................................................................................... 178
29 CUTTING HEAD.................................................................................. 180
30 ACCESORY - ROTARY REAR BRUSH 892327................................. 184
31 ACCESORY - FRONT ROLL SCRAPER 892329............................... 186
32 ACCESORY......................................................................................... 188
33 ACCESORY......................................................................................... 190
34 GROOMER ACCESORY ..................................................................... 192
35 VERTICUTTER ACCESORY .............................................................. 196
36 ACCESORY - REAR ROLLER SCRAPER......................................... 200

GB-3
RANSOMES G PLEX II Series :WD
MAINTENANCE AND PARTS MANUAL
GB
DIESEL ENGINES
The diesel engine’s serial number is stamped into
the block directly below the injector pump (See Fig.
4).
1
Figure 4
1. Diesel Engine Serial Number
CUTTING HEAD SERIAL NUMBERS
Identification numbers for each individual cutting
head are on the nameplate decal located on the
right side panel (See Fig. 5).
NAME PLATE
DECAL
Figure 5
IDENTIFICATION
THESE IDENTIFICATION NUMBERS MUST
APPEAR ON ALL CORRESPONDENCE
CONCERNING THIS UNIT.
MODEL NUMBER & SERIAL NUMBER
Both the Model Number and Serial Number are on
the identification nameplate decal located on the
right rear frame. See figure 1.
1
Figure 1
1. Identification Nameplate Decal
ENGINE IDENTIFICATION NUMBERS
To gain access to the engine, loosen the two hand
knobs above the rear fork.Raise the fuel tank frame
(rear section) and pivot the rod beneath the fuel
tank down and secure it in the cup next to the fork
(See Fig. 2). DO NOT remove fuel tank cap while
tank is in raised position.
1
2
Figure 2
Fuel Tank in Raised Position
1. Support Rod
2. Hand Knobs

GB-4
RANSOMES G PLEX II Series :WD
MAINTENANCE AND PARTS MANUAL
GB
SPECIFICATIONS
(subject to change without notice)
Engine Kubota model D722B-1, 18 hp. three
cylinder, liquid cooled diesel engine
High Idle Speed 3400 RPM
Low Idle Speed 1500 RPM
(See engine manual for additional
specifications)
Speed (maximum):
Transport 12 Km/h
Mowing 6.1 Km/h
Reverse 3 Km/h
Hydraulic System:
Traction Drive Pump Sundstrand 15-
Series
Traction Motors: Parker-Ross ME10
Reel Drive Pump: J.S. Barnes W900
.488 in3/Rev (8cc/Rev)
Reel Motors: J.S. Barnes W600
.73 in3/Rev (12cc/Rev)
Reservoir Capacity: 18.2 L
Total System Capacity: 25.7 L
Ransomesr Turf Protector™
9.7 L PN 65363
18.9 L PN 65352
208 L PN 65354
(Alt. Texaco Rando HDZ-32)
See oil selection guide
Hydraulic Filters
2 ea, 25 micron (suction) PN 522972
Dimensions:
Width Of Cut: 1.6m
Overall Width (w/reels and catchers): 1.9m
Overall Length (w/reels and catchers):
2.5m
Overall Height: 1.25m
Wheel Base: 1.26m
Front Wheel Tread (width): 1.2m
Weight w/o reels: 535 kg
Weight w/reels: 631 kg
Fuel Tank Capacity: 31 L
Coolant Capacity: 3.8 L
Battery 12 volt
BCI Group Size 24
Cold Cranking Amps (min.) 430
Reserve Capacity Minutes (min.) 70
Ground Terminal Polarity Negative
with SAE taper posts
Brakes Positive Hydrastatic Braking
6” (152 mm) Caliper Disk Parking Brake
Eletrical:Alternator: 40 AMP
Steering:Rear Wheel Steering
Power Steering, 2.5 turns lock to lock
13” (330mm) dia. Steering Wheel
Tyres: 20 x 10.00 - 10 Smooth tread
VIBRATION LEVEL
The machine was tested for whole body and hand/
arm vibration levels. The operator was seated 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.
Hand / Arm acceleration level : 2.0 m/s2
Whole body acceleration level
X axis : 0.051 m/s2
Y axis : 0.085m/s2
Z axis : 0.204 m/s2
WARNING
•This manual deals with service and
maintenance functions. These functions
must be performed as specified and must
be done by properly trained service
personnel only.

GB-5
RANSOMES G PLEX II Series :WD
MAINTENANCE AND PARTS MANUAL
GB
CONTROLS
(Diesel Models)
4
2
7
6
5
3
1
10
8
9
Figure 7
1. Ammeter
2. Hour Meter
3. Headlight Switch
4. Engine Oil Warning Light
5. Ignition Switch
6. Throttle
7. Turf Protection System (optional)
8. Pre–Heat Switch and Glow Plug
Light
9. Temperature Gauge And
Warning Light
10. Reel Enable Switch
Ammeter - indicates amount of electrical flow at the
battery. Under normal operating conditions
the needle will be on the plus (+) side of
the meter, showing that current is being
supplied to the battery.
At idle speed, the indicator may be at zero
or on the negative (-) side. A continuous
negative reading at normal operating
speed indicates a malfunction in the
charging system that should be checked
immediately.
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 all electrical functions from
operating. Switch must be in the OFF
position to remove the key.
ON - for normal operation.
START - engages the starter. Release the
key after engine starts (the switch
automatically returns to ON).
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 position before
restarting is attempted. This feature
prevents damage to the starter and
flywheel teeth that can occur if the starter
is engaged while the engine is running.
Throttle - Push all the way forward for normal
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 good scheduled maintenance
program (refer to the Maintenance Guide).
Pre–Heat Switch and Glow Plug Light -With key
switch ON, push up/forward and hold the
pre–heat switch until the glow plug light
goes out (Diesel Only).
Temperature Gauge and Warning Light -gauge
indicates coolant temperature and light
warns of overheat situation (Diesel Only).
Turf Protection System - can be installed as an
option to warn the operator if a leak in the
hydraulic system is detected.
REAR SWING OUT ARM
NOTICE

GB-6
RANSOMES G PLEX II Series :WD
MAINTENANCE AND PARTS MANUAL
GB
CONTROL PEDALS
The Direction/Speed Pedal (See Fig. 8) controls
speed and direction. Depress front of pedal to go
forward, depress back of pedal to go backward.
Increased movement of the pedal will increase
speed.
To slow and stop the unit, release the pedal
completely. Proper braking is provided by
hydrostatic pressure. If more braking is required,
press on the brake pedal.
WARNING
•DO NOT attempt to force the direction
control pedal to the neutral (stop) position
or to change directions before coming to a
complete stop. Abrupt stops or changes in
direction may cause injury.
1
2
Figure 8
1. Direction/Speed Pedal
2. Brake Pedal
PARKING BRAKE PEDAL
The Parking Brake can be engaged by depressing
the brake pedal until the unit is at a complete stop.
Once the unit is stoped, push the parking brake
latch foward to hold the brake pedal. Disengage the
parking brake by depressing and releasing the brake
pedal.
1
2
Figure 9
1. Brake Pedal
2. Park Brake Latch
NOTICE
•To reduce fatigue during normal forward
operation, the operator’s heel should rest
on the floorboard next to the pedal (not on
the lower part of the pedal).
The Mow/Lift Pedal (See Fig. 10) lowers and raises
the cutting heads.
To Lower the Heads: Depress the front of the pedal
into the lowered head position. If reel enable switch
is on, reel rotation starts when the heads are
lowered.
To Raise the Heads: Depress the back of the pedal
into the raised head position. Reel rotation stops
when the heads are raised.
1
Figure 10
1. Mow/Lift Pedal
HYDRAULIC PUMP BYPASS VALVE
The Bypass Valve allows the unit to be pushed or
towed. Turn the handle on the bottom of the pump
counterclockwise (as viewed from the bottom of the
pump) to open the valve. After moving the unit,
close the valve by turning the handle clockwise.
1
Figure 11
1. Bypass Valve Handle
NOTICE
•The bypass valve must be tightly closed
for normal operation or a significant loss of
speed will occur and may cause serious
damage to the hydrostatic pump.

GB-7
RANSOMES G PLEX II Series :WD
MAINTENANCE AND PARTS MANUAL
GB
•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.
WARNING
•To avoid the possibility of serious injury,
ALWAYS be properly seated in the
operator’s seat while the engine is running.
•To avoid the possibility of serious injury,
ALWAYS switch the reel enable switch to
the off position, stop the engine, remove
the key, and set the parking brake each
time you leave the operators seat.
1. The grass catcher MUST BE removed
before you swing the arm out.
2. Release the draw latch (See Fig. 12).
3. Pull the handle and swing the rear arm and
cutting head out.
4. Once you are properly seated in the
operator’s seat, restart the unit and lower
the cutting heads.
5. Shut off the unit and remove the rear
cutting head for service.
6. Once you have completed your servicing,
secure the cutting head to the rear arm.
7. Once you are properly seated in the
operator’s seat, restart the unit and raise
the cutting heads.
8. Shut off the unit and swing the rear arm
back under the unit and secure the arm
with the draw latch (See Fig. 12).
WARNING
•NEVER attempt to drive the unit while the
rear arm is not secured by the draw latch.
Driving the unit with the rear arm out, will
result in damage to the unit, or causing
serious injury or death of you the operator
or bystanders.
1
2
Figure 12
1. Draw Latch
2. Handle
ADJUSTMENTS
WARNING
•Adjustment procedures must be performed
as specified by properly trained service
personnel ONLY. If assistance is needed,
contact your local Ransomes/Cushman/
Ryan Dealer.
•To avoid the possibility of serious injury,
switch the reel enable switch to the off
position, lower the heads, stop the engine,
remove the key, and set the parking brake
BEFORE making any adjustment.
•NEVER rotate the cutting reel by pushing
it with your hands or fingers. Fingers can
become caught between the reel and the
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 during
adjustment and testing (See Fig. 13).
1
Cutting Head Shown
with
Rear Rotary Brush Ac
cessory mounted
Figure 13
1. Rotate Cutting Reel with this Screw Head

GB-8
RANSOMES G PLEX II Series :WD
MAINTENANCE AND PARTS MANUAL
GB
BEDKNIFE ADJUSTMENT
For this adjustment, the backlap valve control 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 reel
blades and the bedknife should be done at the
leading end of the reel first (the end at which each
individual blade first crosses the bedknife). Then at
the opposite end of the reel.
1. Loosen the lower adjustment screws at
each end by turning them approximately 1/
4 turn counterclockwise (See Figure 14).
2. While rotating the reel backwards, turn the
upper adjustment screws (leading end
first) until there is approximately .001²
(.025mm) clearance. After adjusting both
ends, recheck the leading end.
NOTICE
•Too much clearance between the bedknife
and the blades will result in poor cutting
quality. Too little clearance will cause
excessive wear to the cutting edges and
may cause damage to the bedknife, reel
blades or other components.
1
2
Figure 14
1. Upper Adjustment Screw
2. Lower Adjustment Screw
3. Rotate the reel forward. The reel must turn
freely and you should just be able to hear
the reel blades making slight contact with
the bedknife.
4. After the bedknife is properly adjusted,
tighten the lower adjustment screw at each
end.
5. Test the cutting head by holding two strips
of newsprint perpendicular to the bedknife.
Rotate the reel with a wrench. The reel
must turn freely and each blade on the reel
should cut one of the two strips of paper.
HEIGHT OF CUT
NOTICE
•All three cutting heads MUST be
accurately set at the same height of cut to
insure an even cut.
•Bedknife adjustment must be made before
setting the height of cut.
1. Set the height of cut on the gauge block
(Part No. 892010) by turning the wingnut
until the distance between the bottom of
the screw head and the top of the gauge
block equals the desired height of cut (See
Fig. 16).
2. Loosen the locking nut on one of the front
roller adjusting brackets just enough to
allow adjustment (See Fig. 15).
1
Cutting Head Shown
with
Rear Rotary Brush Ac
cessory mounted
Figure 15
1. Loosen Locking Nut
3. Hold the gauge block across the bottom of
both the front and rear rollers near the
roller adjustment bracket and adjust the
front roller until the cutting edge of the
bedknife comes up to touch the bottom of
the gauge screw head (See Fig. 16).
Front Roller Rear Roller
Bedknife
Gauge Block
Gauge
Screw
Head
Set Height Of Cut
(Part No. 892010)
Figure 16
Height of Cut Adjustment
4. Tighten the locking nut and repeat the
procedure at the other end. After
adjustment has been made at both ends,
go back and recheck both ends.
5. Make sure all three cutting heads are set
without changing the height of the gauge
screw.