Maintenance Manual Vedlighold elseshåndbog. Fairway 405. Series: CH - Engine type: Kubota V1505-TTB-EC-S1 Product code: JGPP G-DK (rev.

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1 24496G-DK (rev.5) Maintenance Manual Vedlighold elseshåndbog Fairway 405 Series: CH - Engine type: Kubota V1505-TTB-EC-S1 Product code: JGPP010 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. ADVARSEL: Denne maskine kan forårsage alvorlig personskade, hvis den bruges forkert. Alle, der bruger og vedligeholder denne maskine, skal være korrekt uddannet til dette, skal advares om farerne og læse hele instruktionsbogen, før maskinen forberedes, bruges, justeres eller serviceres. RJL 100 July 2009

2 2009, Ransomes Jacobsen Limited. All Rights Reserved

3 1 CONTENTS JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL 1 CONTENTS 2 INTRODUCTION 2.1 PRODUCT IDENTIFICATION SPARES STOCKING GUIDE HOW TO USE THE PARTS MANUAL SAFETY INSTRUCTIONS 3.1 OPERATING INSTRUCTIONS SAFETY SIGNS STARTING THE ENGINE DRIVING THE MACHINE TRANSPORTING LEAVING THE DRIVING POSITION SLOPES BLOCKED CUTTING CYLINDERS ADJUSTMENTS, LUBRICATION AND MAINTENANCE... 5/6 4 SPECIFICATION 4.1 ENGINE SPECIFICATION MACHINE SPECIFICATION DIMENSIONS VIBRATION LEVEL SLOPES RECOMMENDED LUBRICANTS CUTTING UNIT SPECIFICATION CUTTING PERFORMANCE (AREA) TORQUES LUBRICATION AND MAINTENANCE LUBRICATION AND MAINTENANCE CHART... 9/ ENGINE: FIRST 50 WORKING HOURS AND EVERY 100 WORKING HOURS MACHINE: LUBRICATE THE FOLLOWING POINTS WITH SHELL DARINA R2 GREASE WEEKLY (EVERY 40 WORKING HOURS): MACHINE: EVERY 400 WORKING HOURS HYDRAULIC TEST PORTS ENGINE MAINTENANCE: EVERY 100 HRS ENGINE MAINTENANCE: EVERY 400 HRS... 14/ MACHINE MAINTENANCE END OF SEASON SERVICING ADJUSTMENTS 6.1 SPEED LIMITER REAR WHEEL TOE-IN STEERING SHAFT ALTERNATOR STANDARD FOOT BRAKE & BRAKE BANDS TROUBLESHOOTING 7.1 GENERAL SCHEMATICS 8.1 HYDRAULIC CIRCUIT... 20/ ELECTRICAL CIRCUIT MAIN... 22/ ELECTRICAL CIRCUIT INSTRUMENT ELECTRICAL CIRCUIT FUSES/RELAYS & COMPONENTS... 25/26/27 PARTS LIST... PARTS-1 GB-1

4 2 INTRODUCTION JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL 2.1 PRODUCT IDENTIFICATION A D C B E A B C D E Machine Name Serial Number Year of Manufacture Machine Weight Engine Power 2.2 SPARES STOCKING GUIDE To keep your equipment fully operational and productive, Ransomes suggests you maintain a stock of the more commonly used maintenance items. We have included part numbers for the additional support materials and training aids. Service Parts Part No D escription Part No. Description Engine Oil Filter W Hydraulic Filter (Suction) Engine Fuel Filter Electric Fuel Pump Air Cleaner Element In-line Fuel Filter Ignition Switch Service Support Material Part No D escription Part No. Description Engine Parts Manua l Engine Operators Manual - Engine Service Manual 24496G 24495G - Machine Maintenance and Parts Manual Machine Safety and Operators Manual Machine Manual Service GB-2

5 2 INTRODUCTION JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL 2.3 HOW TO USE THE PARTS MANUAL ITEM NUMBER Each part which is identified in the illustrations has an item number. Parts which do not have an item number may not be readily identified in the illustration but are usually closely associated with the immediately adjacent part. ASSEMBLIES A complete assembly, e.g. a wheel motor or hydraulic motor or roll assembly, is listed as a complete item with subsequent individual components listed separately. The assembly is listed under it's part number with component parts being listed offset to the right, e.g:- ITEM RANSOMES DESCRIPTION QTY REMARKS PART NO MBG2504 BRACKET MBG3848 LATCH SCREW, M8 x 20, SCKT CSK HD NUT, M8 NYLOC Wl001 Set Of Wheels Wheel & Hub Assy 1 (Rear) Tyre Rim Hub Assy Cap Lubricator Wheel & Tyre 2 (Front) Tyre 2 It may not be possible to illustrate every item. With certain items purchased from outside suppliers some component parts may not be available from Ransomes and may need to be specially ordered from the supplier. QUANTITIES Quantities shown are for one assembly or sub-assembly. USING THE PARTS LIST Determine the function and application of the part required. Turn to the main index page and select the appropriate section. Locate the part on the illustration and parts list and read off the quantity from the appropriate MODEL column. NUMERICAL INDEX This is a summary of all part numbers used in the manual arranged in numerical sequence and showing the page and item number under which the parts appear. ORDERING OF SPARE PARTS When ordering replacement parts, it is most important to quote the SERIAL NUMBER of the machine, PART NUMBER, DESCRIPTION and QUANTITY required. Any arbitrary modifications carried out on this machine may relieve the manufacturer of liability for any resulting damage or injury. ABBREVIATIONS N/A Not Available AR As Required GB-3

6 3 SAFETY INSTRUCTIONS JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL 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 usethis 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. 3.3 STARTING THE ENGINE 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 adequate ventilation. 3.4 DRIVING THE MACHINE 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 Always observe the Highway Code both on 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. Remember that some people are deaf or blind and that children and animals can be unpredictable. Keep travelling speeds low enough for an 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 obstructions and/or bystanders. DO NOT 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 or left unattended, lower the cutting means unless the transport locks are being used. While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. Check the grass catcher frequently for wear or deterioration. After striking a foreign object. Inspect the lawnmower for damage and make repairs before restarting and operating the equipment. If the machine starts to vibrate abnormally, check immediately. 3.5 TRANSPORTING Ensure that the cutting units are securely fastened in the transport position. Do not transport with cutting mechanism rotating. Drive the machine with due consideration of road and surface conditions, inclines and local undulations. 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. GB-4

7 3 SAFETY INSTRUCTIONS JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL 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 the starter key. 3.7 SLOPES TAKE EXTRA CARE WHEN WORKING ON SLOPES Local undulations and sinkage will change the general slope. Avoid ground conditions which can cause the machine to slide. Keep machine speeds low on slopes 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. Travel on grass slopes requires particular 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. 3.8 BLOCKED CUTTING CYLINDERS Stop the engine and make sure all moving parts are stationary. Apply brakes and disengage all drives. Release blockages 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 the others to rotate. 3.9 ADJUSTMENTS, LUBRICATION AND MAINTENANCE 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. GB-5

8 3 SAFETY INSTRUCTIONS JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL 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. WARNING Hydraulic Fluid escaping under pressure can penetrate skin and do serious damage. Immediate medical assistance must be sought. IMPORTANT: Transport speed is for highway use only. Never select transport speed on grass areas or uneven or unsurfaced roads or tracks. The operating instruction for the Cutting Units are contained in a separate Publication. WARNING California Proposition 65 Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the state of California to cause cancer and birth defects or other reproductive harm WARNING Batteries produce explosive gases and contain corrosive acid and supply levels of electrical current high enough to cause burns. WARNING DO NOT USE ON SLOPES GREATER THAN 15 WARNING Before releasing transport latches it is important that all cutting units are fully raised. 1. Park the machine on level ground. 2. With the engine running at operating speed raise the cutting units to their maximum position by operating lift levers whilst seated in the driving position. 3. Disengage drives, stop the engine and make sure all moving parts are stationary. Apply brakes and remove the starter key. 4. transport latches can now be released. GB-6

9 4 SPECIFICATIONS JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL 4.1 ENGINE SPECIFICATION TYPE: Kubota 34.7KW 3000 RPM, 4 cylinder (in line) Turbo charged Diesel engine, 4 stroke, water cooled, 1498cc (91.44 cu.in) with 12V electric start. Model: V1505-TE Maximum Speed: 3000 ± 50 RPM (No load) Idle Speed: 1500 RPM Oil Sump Capacity:6.4 litres (11.26 Imp.pints) Fuel: No. 2-D Diesel fuel (ASTM D975) 4.2 MACHINE SPECIFICATION Frame construction:heavy duty formed steel chassis with box section frame rails. Cutting unit drive: Fixed displacement hydraulic motors directly coupled to cutting unit. Transmission: Full time 4-wheel drive. Direct coupled variable displacement pump to direct coupled 29 cu in front, 21 cu in rear wheel motors. Speeds: Cutting: 0-12km/h (0-7.5 mph) FORWARD Transport: 0-14km/h (0-8.7mph) FORWARD Reverse: Steering: Tyres: Front - Rear km/h (0-4 mph) Hydrostatic power steering, with adjustable tilt steering wheel. Front x ply rating turf Rear - 20 x ply rating turf Pressures: All tyres 14p.s.i. (1 kg/cm 2 ) Ground pressure: 14p.s.i. (1 kg/cm 2 ) Brakes: Fuel Tank Capacity: Hydrostatic braking with mechanical type band parking brakes, 260mm x 45mm (10.25in x 1.75in) on front wheels litres 4.3 DIMENSIONS Width of cut: 4.0 metres (158in) Overall width: 4.31 metres(170in) Overall width: 2.52 metres (99.2in) (transport) Overall height: 1.6 metres (63in) Overall length: 2.75metres (113.4in) Overall weight of machine: 1860kg (4100lb) 4.4 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. Standard ISO 5349: 1986 Mechanical vibration. Guidelines for the measurement and the assessment of human exposure to handtransmitted vibration. 405 TURBO SeriesCH Hand / Arm Acceleration level X Aeq Max LH or RH 2 Accelerations m/s Y Aeq Z Aeq Dominant Value Standard ISO : 1985 Evaluation of human exposure to whole body vibration -- Part 1: General requirements. 405 TURBO SeriesCH Whole Body Acceleration level Floor Location 2 Accelerations m/s Seat Location 2 Accelerations m/s x y z x y z Mean SLOPES DO NOT USE ON SLOPES GREATER THAN 15 The slope 15 was calculated using static stability measurements according to the requirements of EN 836. Hydraulic Tank Capacity: 37.8 litres Battery: Exide 093 (SAE 500) GB-7

10 4 SPECIFICATIONS JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL 4.6 RECOMMENDED LUBRICANTS Engine oil: Hydraulic Oil: Grease: Should be to MIL-L-2104C or to A.P.I. Classification SE/SF/SG grades. [10W-30] To A.P.I. Classification CE/SF grades SAE 10W-30 Shell Darina R2, or equivilant. 4.7 CUTTING PERFORMANCE 46 cuts per meter at 12 km/hr with 7-knife cutting head units. 72 cuts per meter at 12 km/hr with 11-knife cutting head units. 4.8 CUTTING PERFORMANCE (AREA) 4.32 hectares/hr. at 12 km/hr. (10.67 acres/hr at 7.5 mph) 10% allowance is included for normal overlaps and turning at the end of each cut. 4.9 TORQUES Dia (mm) FINE PITCH METRIC THREADS ( Nm) ( Nm) ( Nm) ( Nm) (Nm) Dia (mm) CORSE PITCH METRIC THREADS ( Nm) ( Nm) ( Nm) ( Nm) (Nm) Dia (in) A UNC THREADS S T V X ( lbf. ft) ( lbf. ft) ( lbf. ft) ( lbf. ft) (lbf. ft) 1/ / / / / / / / / / / / / Dia (in) A UNF THREADS S T V X ( lbf. ft) ( lbf. ft) ( lbf. ft) ( lbf. ft) (lbf. ft) 1/ / / / / / / / / / / / / GB-8

11 5 LUBRICATION AND MAINTENANCE JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL LUBRICATION AND MAINTENANCE CHART Black bullet points are operator checks and white bullet points are workshop maintenance procedures First 50 hours Daily Every 50 hours Every 100 hours Every 400 hours Every 600 hours End of Season ENGINE Check Oil Level C hange Oil Clean Air Filter Element Change Air Filter Element C hange Oil Filter Cartridge Replace Fuel Filters MACHINE Check Interlock System Check/Top-up Coolant Level Check/Drain Water Seperator Check Tyre Pressure Check Hydraulic Fluid Level Check/Clean Engine Bay, Bug Screen & Radiator Check Nuts & Bolts For Tightness Check Hydraulic Fittings For Tightness Check Rear Wheel Toe-in Check Battery Condition Check Belt Tension Change Hydraulic Oil & Filter Drain & Clean Fuel Tank Drain & Flush Cooling System Check Parking Brake Adjustment *Service more often in dirty conditions Lubricate the Grease Fittings with Shell Darina R2 grease weekly (SEE CHART) GB-9

12 5 LUBRICATION AND MAINTENANCE JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL LUBRICATION Fig.3 Lubricate every 40 working hours at arrows (except lubricate all reel fittings daily). Coupling between reel and hydraulic motor should be half full of non-tracking grease. FLUID REQUIREMENTS QUANTITY TYPE ENGINE OIL (with filter) 6.4 Litres 10W 30 (SE/SF/SG) HYDRAULIC OIL (with filter) 37.9 Litres 10W 30 (CE-SF) RADIATOR COOLANT 6.8 Litres 50% ANTI-FREEZ E GB-10

13 5 LUBRICATION AND MAINTENANCE JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL LUBRICATION 5.1 ENGINE: First 50 working hours and every 100 working hours. Change Engine Oil. (a) Warm up the engine first and then shut it off. Remove oil drain plug from the bottom of the crankcase and wipe it off. (b) Replace the drain plug and fill engine with 6.4 litres of oil(with filter). Fig.1 A Oil Fill, B DIPSTICK Change Engine Oil Filter (A(Fig.2)) (a) Remove single-unit cartridge (A) (b) Clean area on crankcase. (c) Apply thin coat of oil to cartridge gasket before installing. (d) Tighten filter by hand only. (e) Check for oil leaks around the cartridge gasket after engine is started. Fig.1 Fig MACHINE: Lubricate the following points. Weekly or every 40 working hours. 1. Lubricate the following with Shell Darina R2 grease. (Fig.3) (a) (b) (c) (d) (e) (f) (g) (h) Lift arm pivots. Rear Axle centre pivot. Steering rams-inner pivots. Steering ram rod end. Steering Track Rod, Rod End. Cutter deck, roller ends. Cutter deck, wheels. Lift arm yoke pivots. GB-11

14 5 LUBRICATION AND MAINTENANCE JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL LUBRICATION 5.3 MACHINE: Every 600 Working Hours. Change Hydraulic Oil 1. Remove drain plug from bottom of Hydraulic tank and wipe off plug. (A(Fig.4)) 2. Allow tank to drain and replace plug. 3. Refill tank with approx 38 litres of SAE 10W-30 Oil through one of the brass plugs. (B(Fig.5)) 4. Hydraulic Oil should be filled to half way up the sight tube. (A(Fig.5)). IMPORTANT-Whenever the closed loop transmission circuit has been broken into, it is essential that the circuit is flushed prior to use. Absolute cleanliness must be observed when filling the hydraulic tank. Oil must be filtered through a 25micron filter before entering the hydraulic tank. Fig4 Change Hydraulic Oil Filter (A)(Fig.6)) 1. Wipe filter canister and housing to remove any dirt present. 2. Place a suitable drip tray under the filter. 3. Unscrew filter and dispose of safely. 4. Replace with new filter canister. 5. Coat the top outside lip of the filter canister with a thin film of oil, fill filter with clean hydraulic fluid and refit the filter canister. 6. Filter should be replaced before refilling hydraulic tank. Fig.5 Fig.6 GB-12

15 5 LUBRICATION AND MAINTENANCE JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL LUBRICATION 5.4 HYDRAULIC TEST PORTS If any problems are experienced with the hydraulic system service ports are provided to enable pressures to be checked. All tests, unless stated otherwise, should be carried out with the hydraulic oil at normal working temperature. TEST PORTS (Fig.7,8,9): 1. Deck drive pressure: 207 bar (3000 psi). (A(Fig.7)) 2. Four wheel drive pressure: 207 bar (3000 psi). (A/B(Fig.8)). 3. Lift and power steering pressure: 83 bar (1200 psi). (A(Fig.9)). Fig.7 NOTE: Any servicing of the hydraulic system must be carried out by trained service personnel. Fig.8 Fig.9 GB-13

16 5 LUBRICATION AND MAINTENANCE JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL MAINTENANCE 5.5 ENGINE MAINTENANCE: Every 100 hrs Fuel System: Use Diesel fuel No.2-D (ASTM D975) See engine manufacturer's manual for additional information. Water Separator - If water is not removed from the fuel, extensive damage can be done to the fuel injection system. 1. With engine off, open vent (A) at top of water separator. 2. Open drain valve (B) at bottom of water seperator to allow any water to drain out. 3. If water is present, it will drain first. When fuel emerges from the valve (B), close the valve. Close the vent (A). Fig.10 NOTE: Failure to drain water reduces fuel filter efficiency. Bleeding air from fuel system (Fig.11) 1. Turn the ignition switch to the ON position (don't start engine). 2. Open air vent (A) on side of injection pump to allow air to escape. 3. Retighten air vent. 4. Turn ignition to OFF. Fig ENGINE MAINTENANCE: Every 400 hrs Replace In-line fuel (A) (Fig.12) Cleaning the air filter Remove loose dirt from element with compressed air working from the clean to dirty side, using compressed air max 6 bar, with nozzle 5cm from element. Change air filter (Or every 6 cleanings) (Fig.13) 1. Raise bonnet. 2. Remove end cap of air filter cartridge. 3. Remove accumulated dust or dirt. 4. Remove filter element (A) (pull straight out firmly) 5. install new filter element (press firmly against rear shoulder) 6. Replace end cap and fasten with clips Fig.12 NOTE: Extensive damage to engine can result from an inadequate air supply. GB-14

17 5 LUBRICATION AND MAINTENANCE JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL MAINTENANCE 5.6 ENGINE MAINTENANCE: Every 400 hrs Changing fuel filter (Fig.14) 1. Unscrew filter (A) from filter head. 2. Remove water (B) separator from filter and discard filter. 3. Fit water separator to new filter and refit filter to head. 4. Bleed air from system as describe in section 5.5. Fig.14 Fig MACHINE MAINTENANCE Battery. Keep fluid levels above battery plates. WARNING Wear eye protection when servicing battery. Other Regular Service. Verify proper operation of safety interlock switches (Neutral switch, Seat switch, etc.) Ensure nuts and bolts remain tight. Keep tyre pressure at 1kg/cm 2 (14psi). Follow the engine manufacturer s maintenance recommendations. If a label becomes worn or removed, see the LABELS section of this manual or the tractor Parts Manual for replacement information. NOTE: When washing machine with pressure spray washers or steam cleaners, avoid washing bearing areas because cleaning solutions might penetrate bearing seals and cause premature bearing failure. Storage Store petrol or diesel fuel in an approved container in a cool dry place. Keep the machine and fuel containers in a locked storage place to prevent tampering and to keep children from playing with them. Do not store fuel or petrol/diesel fuel powered equipment in any closed area where heating appliances, pilot lights or any sort of open flame is present. Before storing, allow the engine to cool, and drain fuel completely from fuel tanks and containers. Maximum safety and best mowing results can only be expected if the mower is maintained and operated properly. WARNING Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING GB-15

18 5 LUBRICATION AND MAINTENANCE JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL MAINTENANCE 5.8 END OF SEASON or when required Change Hydraulic Oil 1. Remove drain plug from bottom of Hydraulic tank and wipe off plug. (A(Fig.15)) 2. Allow tank to drain and replace plug. 3. Refill tank with approx 38 litres of SAE 10W-30 Oil through one of the brass plugs. (B(Fig.16)) 4. Hydraulic Oil should be filled to half way up the sight tube. (A(Fig.16)). IMPORTANT-Whenever the closed loop transmission circuit has been broken into, it is essential that the circuit is flushed prior to use. Absolute cleanliness must be observed when filling the hydraulic tank. Oil must be filtered through a 25micron filter before entering the hydraulic tank. Change Hydraulic Oil Filter (A)(Fig.17)) 1. Wipe filter canister and housing to remove any dirt present. 2. Place a suitable drip tray under the filter. 3. Unscrew filter and dispose of safely. 4. Replace with new filter canister. 5. Coat the top outside lip of the filter canister with a thin film of oil, fill filter with clean hydraulic fluid and refit the filter canister. 6. Filter should be replaced before refilling hydraulic tank. Change Coolant. 1. Completely drain the cooling water from the radiator and flush the cooling system with flushing detergent. 2. Check for leaks or loose connections at the radiator, cylinder head gasket, etc. 3. Mix antifreeze coolant and water at the specified ratio before pouring into the engine. Fig.15 Fig.16 Note: When topping up the cooling system fill with 50/50 solution. Fig.17 GB-16

19 6 ADJUTMENTS JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL ADJUSTMENTS 6.1 SPEED LIMITER The transport and mow speeds are factory set and should not need altering. NOTE: Textron Turf Care cannot be held responsible for loss of performance or machine damage if these speeds are adjusted outside the speeds shown in the machine specification. 6.2 REAR WHEEL TOE-IN The rear wheels should toe in 3.2mm(1/8") from the front to the back of the wheel. (Fig.18) 1. Loosen locknuts D at rosejoints inside each of the rear wheels. 2. For each wheel, rotate tie rod C until the toe-in is correct. 3. Tighten locknuts D. 6.3 STEERING SHAFT Fig.18 Casting B should just contact pin A on both sides. (Fig.18) 1. Loosen nut F. 2. Verify steering balance by rotating steering shaft G in its cylinder to produce full steering right and left. 3. Tighten nut F. 6.4 ALTERNATOR The fan belt is adjusted so that it can be deflected 5mm (0.2in) with a force of 5 kg (11 lbs) applied midway between the crankshaft and alternator pulley. (Fig.19) To adjust: 1. Loosen alternator bolts A. 2. Move the alternator to tighten or loosen fan belt. 3. Tighten bolts A. Fig.19 GB-17

20 6 ADJUTMENTS JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL ADJUSTMENTS 6.5 STANDARD FOOT BRAKE & BRAKE BANDS Adjust so that both brakes lock evenly when the parking brake foot pedal is depressed. Loosen nuts A and turn nuts B on the two cables (Fig.20). Also, adjust nuts A (Fig.21) for each wheel so that neither brake band drags when the parking brake is disengaged. Fig.20 Fig.21 GB-18

21 7 TROUBLESHOOTING JACOBSEN 405 Series: CH MAINTENANCE AND PARTS MANUAL GENERAL The troubleshootijng chart below lists basic problems that may occur during start-up and operation. For more detailed information regarding the hydraulic and electrical systems contact your area Jacobsen Distributor. Symptoms Possible Causes Action Section 1. Glow Plug has not timed out. 1. Reset ignition switch and allow glow plug to time out before cranking engine. 2. Battery low on charge defective. or 2. Inspect condition of connections. battery and battery Engine will not start. 3. Fuel tank empty or fuel contaminated. 3. Fill tank with fresh fuel. from lines. 4. Blown Fuse. 4. Replace Fuse. Change filter, Bleed air 5. Defective Starter Relay. 5. Test and replace relay if neccesary. 6.Forward/Reverse pedal latch depressed. 6. Ensure Forward/Reverse not depressed. pedal neutral latch 7. Mow switch set to cut. 7. Set mow switch to off. 1. Fuel tank empty or fuel contaminated. 1. Fill tank with fresh fuel. from lines. Change filter, Bleed air Engine hard to start or runs poorly. 2. Air Cleaner blocked or dirty. 2. Check air cleaner, replace as neccesary. 3. Injectors, fuel pump. 3. Consult engine manual. 4. Other Engine Problem 4. Consult engine troubleshooting guide. Engine Stops. 1. Fuel tank empty 1. Fill with fresh fuel and bleed lines 2. Interlocks not set before leaving operators seat 2. Set mow switch to off. Ensure forward/reverse neutral latch is not depressed. 1. Coolant level low 1. Inspect required. and add 50/50antifreeze solution if Engine Overheating. 2. Radiator air intake restricted 2. Clean wire mesh guard at radiator. Battery not holding charge. Battery light on. 3. Waterpump/alternator belt or fan belt loose or broken. 1. Loose or terminals. 2. Low electrolyte battery. 3. Alternator broken. corroded battery level in belt loose or 3. Inspect waterpump/alternator Tighten if neccesary. 1. Inspect required. belt and fan belt. terminals, clean and tighten as 2. Refill battery with distelled water 3. Inspectwaterpump/alternator neccesary. belt. Tighten if 4. Alternator defective. 4. See engine manual. 1. Cylinder to bottom blade not adjusted properly. 1. Inspect cylinder to bottom blade adjustment 2. Engine speed too low. 2. Check engine speed, run engine at full throttle. Cylinders cut unevenly. Poor quality of cut. 3. Cylinder speed not adjusted for turf conditions. 4. Cylinder direction lever set in reverse. 5. Ground adjusted weight incorrectly 3. Adjust cylinder speed for best cut. 4. Set cylinder direction lever to forward rotation. 5. Adjust ground weight control ground weight is achieved. valve until correct GB-19

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