YEARS OF MOWING EXCELLENCE

YEARS OF MOWING EXCELLENCE

2004, Ransomes Jacobsen Limited. All Rights Reserved

1 CONTENTS RANSOMES HR3806 Series: DZ MAINTENANCE AND 1 CONTENTS 2 INTRODUCTION 2.1 PRODUCT IDENTIFICATION... 2 2.2 SPARES STOCKING GUIDE... 2 2.3 HOW TO USE THE... 3 2.4 GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS... 4 3 SAFETY INSTRUCTIONS 3.1 OPERATING INSTRUCTIONS... 5 3.2 SAFETY SIGNS... 5 3.3 STARTING THE ENGINE... 5 3.4 DRIVING THE MACHINE... 5 3.5 TRANSPORTING... 5 3.6 LEAVING THE DRIVING POSITION... 6 3.7 SLOPES... 6 3.8 BLOCKED CUTTING CYLINDERS... 6 3.9 ADJUSTMENTS, LUBRICATION AND MAINTENANCE... 6 4 SPECIFICATION 4.1 ENGINE SPECIFICATION... 8 4.2 MACHINE SPECIFICATION... 8 4.3 DIMENSIONS... 8 4.4 VIBRATION LEVEL... 9 4.5 SLOPES... 10 4.6 RECOMMENDED LUBRICANTS... 10 4.7 CUTTING PERFORMANCE (AREA)... 10 4.8 TORQUES...10 5 LUBRICATION AND MAINTENANCE LUBRICATION AND MAINTENANCE CHARTS... 11 5.1 ENGINE: FIRST 50 WORKING HOURS AND EVERY 250 WORKING HOURS... 12 5.2 MACHINE: LUBRICATE THE FOLLOWING POINTS WITH SHELL DARINA R2 GREASE WEEKLY (EVERY 40 WORKING HOURS):... 12 5.3 MACHINE: EVERY 400 WORKING HOURS... 13 5.4 HYDRAULIC TEST PORTS... 14 5.5 ENGINE MAINTENANCE: EVERY 250 HRS... 15 5.6 ENGINE MAINTENANCE: EVERY 400 HRS... 16 5.7 MACHINE MAINTENANCE... 16 5.8 END OF SEASON SERVICING... 17 6 ADJUSTMENTS 6.1 SPEED LIMITER... 18 6.2 REAR WHEEL TOE-IN... 18 6.3 ALTERNATOR... 18 7 CUTTER DECK ADJUSTMENTS 7.1 CUTTER DECK TENSION... 19 7.2 BLADE SHARPENING & REMOVAL... 21 8 TROUBLESHOOTING 8.1 GENERAL... 22 9 SCHEMATICS 9.1 HYDRAULIC CIRCUIT... 23 9.2 ELECTRICAL CIRCUIT INSTRUMENT... 24 9.3 ELECTRICALCIRCUIT MAIN - PRE 2006... 26 9.4 ELECTRICAL FUSES/RELAYS... 28 9.5 ELECTRICAL CIRCUIT MAIN - POST 2006... 30 PARTS LIST... PARTS-1 GB-1

2 INTRODUCTION RANSOMES HR3806 Series: DZ MAINTENANCE AND 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 16271-32090 Engine Oil Filter 4123044 Air Cleaner Element 13351-43011 Engine Fuel Filter 178025 Hydraulic Filter (Suction) 13351-43610 In-line Fuel Filter 008089620 Hydraulic Filter (Charge) 68371-50211 Electric Fuel Pump Cutter Blade Service Support Material Part No D escription Part No. Description 97898-02690 Engine Parts Manual 16622-8916-5 97897-01643 Engine Manual Engine Manual Operators Service 24715G-GB Machine Safety & Operation Manual GB-2

2 INTRODUCTION RANSOMES HR3806 Series: DZ MAINTENANCE AND 2.3 HOW TO USE THE 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. 4295 MBG2504 BRACKET 1 4296 MBG3848 LATCH 2 4298 450865 SCREW, M8 x 20, SCKT CSK HD 2 4300 450378 NUT, M8 NYLOC 2 4301 Wl001 Set Of Wheels 1 4301.1 008162130 Wheel & Hub Assy 1 (Rear) 4301.2 008170390 Tyre 1 4301.3 008161830 Rim 1 4301.4 008169140 Hub Assy. 1 4301.5 008169150 Cap 1 4301.6 002993010 Lubricator 1 4301.7 008161990 Wheel & Tyre 2 (Front) 4301.8 008170780 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

2 INTRODUCTION RANSOMES HR3806 Series: DZ MAINTENANCE AND 2.4 GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS When it has been identified that a turf care product has no further functional value and requires disposal, the following actions should be taken. These guidelines should be used in conjunction with applicable Health, Safety and Environmental legislation and use of approved local facilities for waste disposal and recycling. Position the machine in a suitable location for any necessary lifting equipment to be used. Use appropriate tools and Personal Protective Equipment (PPE) and take guidance from the technical manuals applicable to the machine. Remove and store appropriately: 1. Batteries 2. Fuel residue 3. Engine coolant 4. Oils Disassemble the structure of the machine referring to the technical manuals where appropriate. Special attention should be made for dealing with stored energy within pressurised elements of the machine or tensioned springs. Other worn out items should be separated into material groups for recycling and disposal consistent with available facilities. More common separation types are as follows: o Steel o o o Non ferrous metals Aluminium Brass Copper Plastics Identifiable Recyclable Non recyclable Not identified Rubber Items that cannot be separated economically into different material groups should be added to the General waste area. Do not incinerate waste. Finally update machinery records to indicate that the machine has been taken out of service and scrapped. Any items that still have a useful service life as second hand components or can be re-serviced should be separated and returned to the relevant centre. GB-4

3 SAFETY INSTRUCTIONS RANSOMES HR3806 Series: DZ MAINTENANCE AND 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-5

3 SAFETY INSTRUCTIONS RANSOMES HR3806 Series: DZ MAINTENANCE AND 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-6

3 SAFETY INSTRUCTIONS RANSOMES HR3806 Series: DZ MAINTENANCE AND 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-7

4 SPECIFICATIONS RANSOMES HR3806 Series: DZ MAINTENANCE AND 4.1 ENGINE SPECIFICATION TYPE: Kubota 28KW @ 3000 RPM, 4 cylinder (in line) vertical Diesel engine, 4 stroke, water cooled, 1498cc with 12V electric start. Model: V1505- BBS-EC-1 Maximum Speed: 3000 ± 50 RPM (No load) Idle Speed: 1500 +100/-0 RPM Oil Sump Capacity:6 litres 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 coupled to cutting means through drive belt. Transmission: Speeds: Cutting: Transport: Reverse: Steering: Ground pressure: 1 kg/cm 2 Full time 4-wheel drive. Direct coupled variable displacement pump to direct coupled 280cc front, 237cc rear wheel motors. 0-12km/h FORWARD 0-22km/h FORWARD 0-12km/h Hydrostatic power steering, with adjustable tilt steering wheel. 4.3 DIMENSIONS Width of cut: 1.52 meter 1.60 meter 1.80 meter Overall width (transport) 1.52 metre Rear Discharge Deck 1.56meters 1.60 meter Side Discharge Deck Chute down 1.92meters Chute up 1.75meters 1.82 meter Side Discharge Deck Chute down 2.16meters Chute up 1.88meters 1.82 meter rear Discharge Deck 1.86meters Overall height: 1.35 metres Overall length of machine with: 1.52 meter Deck 3.14meters 1.60 meter Deck 3.19meters 1.82 meter Deck 3.26meters Overall weight of machine with: 1.52 meter Deck 1240 kg 1.60 meter Deck 1266 kg 1.82 meter Deck 1311 kg Brakes, Service: Positive hydrostatic braking. Parking: Fail safe, Oil immersed wet disc brakes. Fuel Tank Capacity: 45.4 litres Hydraulic Tank Capacity: 18.8 litres Battery: Exide 065 TYRES Product Tyre Type Front Pressure Tyre Type Rear Pressure HR3806 24 x 13.00-12 Maxxis tread pattern C-165S 4pr Maxxis Turfmaxx (Kevlar) tread pattern C-165S 4pr 0 psi 1.37 bar 20-22 psi 1.37-1.50 bar 20 x 10.00-8 Titan Turf Trac 6pr Maxxis Turfmaxx (Kevlar) tread pattern C-165S 4pr 14-20 psi 1.00-1.37 bar 20-22 psi 1.37-1.50 bar GB-8

4 SPECIFICATIONS RANSOMES HR3806 Series: DZ MAINTENANCE AND 4.4 VIBRATION LEVEL The machine was tested for whole body and hand/ arm vibration levels. The operator was seated in the normal operating position 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. RANSOMES HR3806 SeriesDZ with 1.52m (60") rear Discharge Deck Hand / Arm Acceleration level X Aeq Max LH or RH 2 Accelerations m/s Y Aeq Z Aeq 0.319 0..231 0.229 Dominant Value 0.319 Standard ISO 2631-1: 1985 Evaluation of human exposure to whole body vibration -- Part 1: General requirements. RANSOMES HR3806 SeriesDZ with 1.52m (60") Rear Discharge Deck Whole Body Acceleration level Floor Location 2 Accelerations m/s Seat Location 2 Accelerations m/s x y z x y z Mean 0.0172 0.0155 0.0779 0.0531 0.0242 0.0467 RANSOMES HR3806 SeriesDZ with 1.60m (63") Side Discharge Deck Hand / Arm Acceleration level X Aeq Max LH or RH 2 Accelerations m/s Y Aeq Z Aeq 0.429 0..326 0.232 Dominant Value 0.429 RANSOMES HR3806 SeriesDZ with 1.60m (63") Side Discharge Deck Whole Body Acceleration level Floor Location 2 Accelerations m/s Seat Location 2 Accelerations m/s x y z x y z Mean 0.0168 0.0238 0.0801 0.0447 0.0181 0.0564 RANSOMES HR3806 SeriesDZ with 1.82m (72") Side Discharge Deck Hand / Arm Acceleration level X Aeq Max LH or RH 2 Accelerations m/s Y Aeq Z Aeq 0.580 0..266 0.210 Dominant Value 0.580 RANSOMES HR3806 SeriesDZ with 1.82m (72") Side Discharge Deck Whole Body Acceleration level Floor Location 2 Accelerations m/s Seat Location 2 Accelerations m/s x y z x y z Mean 0.0192 0.0248 0.101 0.0427 0.0247 0.0266 RANSOMES HR3806 SeriesDZ with 1.82m (72") Rear Discharge Deck Hand / Arm Acceleration level X Aeq Max LH or RH 2 Accelerations m/s Y Aeq Z Aeq 0.455 0..275 0.241 Dominant Value 0.455 RANSOMES HR3806 SeriesDZ with 1.82m (72") Rear Discharge Deck Whole Body Acceleration level Floor Location 2 Accelerations m/s Seat Location 2 Accelerations m/s x y z x y z Mean 0.0150 0.0285 0.0641 0.0523 0.0298 0.0490 RANSOMES HR3806 SeriesDZ with 1.52m (60") Envirodeck Hand / Arm Acceleration level X Aeq Max LH or RH 2 Accelerations m/s Y Aeq Z Aeq 0.580 0..395 0.589 Dominant Value 0.589 RANSOMES HR3806 SeriesDZ with 1.52m (60") Envirodeck Whole Body Acceleration level Floor Location 2 Accelerations m/s Seat Location 2 Accelerations m/s x y z x y z Mean 0.0185 0.0296 0.0883 0.0355 0.0230 0.0461 RANSOMES HR3806 SeriesDZ with 1.82m (72") Envirodeck Hand / Arm Acceleration level X Aeq Max LH or RH 2 Accelerations m/s Y Aeq Z Aeq 0.437 0..408 0.267 Dominant Value 0.437 RANSOMES HR3806 SeriesDZ with 1.82m (72") Envirodeck Whole Body Acceleration level Floor Location 2 Accelerations m/s Seat Location 2 Accelerations m/s x y z x y z Mean 0.0146 0.0191 0.125 0.0232 0.0278 0.0232 GB-9

4 SPECIFICATIONS RANSOMES HR3806 Series: DZ MAINTENANCE AND 4.5 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. 4.6 RECOMMENDED LUBRICANTS Engine oil: TEMPERATURE ABOVE 25 C (77 F) SAE30 0 C to 25 C (32 F to 77 F) SAE20 Should be to MIL-L-2104C or to A.P.I. ClassificationCD grades. [10W-30] OIL VISCOSITY or or SAE10W-30 SAE10W-40 SAE10W-30 SAE10W-40 4.7 CUTTING PERFORMANCE (AREA) 152cm Model: 1.44 hectares/hr. at 12 km/hr. 160cm Model: 1.52 hectares/hr. at 12 km/hr. 182cm Model: 1.73 hectares/hr. at 12 km/hr. 10% allowance is included for normal overlaps and turning at the end of each cut. BELOW 0 C (32 F) SAE10W or SAE10W-30 SAE10W-40 Hydraulic Oil: Shell Tellus 46 Grease: Shell Darina R2, or equivalent. 4.8 TORQUES Dia (mm) FINE PITCH METRIC THREADS GRADE 4.6 GRADE 4.8 GRADE 8.8 GRADE 10.9 GRADE 12.9 ( Nm) ( Nm) ( Nm) ( Nm) (Nm) 6 0 0 0 0 0 8 12 16 32 45 54 10 24 31 63 88 106 12 42 57 113 159 191 14 67 90 179 252 302 16 103 137 274 385 462 20 209 279 557 783 940 22 281 375 750 1055 1266 24 354 472 944 1327 1593 27 514 686 1371 1928 2314 30 715 954 1908 2683 3219 33 964 1286 2572 3616 4340 36 1196 1594 3189 4484 5381 Dia (mm) CORSE PITCH METRIC THREADS GRADE 4.6 GRADE 4.8 GRADE 8.8 GRADE 10.9 GRADE 12.9 ( Nm) ( Nm) ( Nm) ( Nm) (Nm) 6 5 6 12 17 21 8 11 15 30 42 51 10 22 30 59 84 100 12 39 52 104 146 175 14 62 82 165 232 278 16 96 129 257 362 434 20 188 251 502 706 847 22 256 341 683 960 1152 24 325 434 868 1220 1464 27 476 635 1269 1785 2142 30 646 862 1723 2424 2908 33 822 1097 2193 3084 3701 36 1129 1506 3012 4235 5082 Dia (in) GRADE A UNF THREADS GRADE S GRADE T GRADE V GRADE X ( lbf. ft) ( lbf. ft) ( lbf. ft) ( lbf. ft) (lbf. ft) 1/4 3. 8 10. 4 11. 3 14. 3 17. 3 5/16 7. 7 20. 8 22. 5 28. 5 34. 5 3/8 13. 9 37. 7 40. 7 51. 6 62. 5 7/16 21. 9 59. 5 64. 2 81. 4 98. 6 1/2 33. 7 91. 5 98. 7 125 152 9/16 48. 2 131 141 179 217 5/8 67. 4 183 197 250 303 3/4 118 319 344 437 529 7/8 188 509 550 697 845 1 279 757 817 1036 1255 1 1/8 405 1099 1186 1504 1823 1 1/4 563 1529 1650 2093 2535 1 3/8 759 2061 2224 2821 3418 1 1/2 996 2703 2917 3699 4482 Dia (in) GRADE A UNC THREADS GRADE S GRADE T GRADE V GRADE X ( lbf. ft) ( lbf. ft) ( lbf. ft) ( lbf. ft) (lbf. ft) 1/4 3. 4 9. 2 9. 9 12. 6 15. 2 5/16 7 18. 9 20. 4 25. 8 31. 3 3/8 12. 3 33. 5 36. 1 45. 8 55. 5 7/16 19. 7 53. 5 57. 8 73. 2 88. 7 1/2 30. 1 81. 6 88 112 135 9/16 43. 3 117 127 161 195 5/8 59. 8 162 175 222 269 3/4 106 288 310 394 477 7/8 171 464 500 635 769 1 256 695 749 950 1152 1 1/8 363 984 1062 1347 1632 1 1/4 511 1387 1497 1899 2300 1 3/8 670 1820 1963 2490 3017 1 1/2 889 2414 2605 3303 4002 GB-10

5 LUBRICATION AND MAINTENANCE RANSOMES HR3806 Series: DZ MAINTENANCE AND LUBRICATION AND MAINTENANCE CHART MAINTENANCE AND LUBRICATION CHART First 50 hours Daily 10 hours Every 50 hours Weekly l Change Engine Oil & Oil Filter l Check Fan Belt Tension l Check Engine Oil Level l Check Safety Interlock System l Check Coolant Level l Check Hydraulic Fluid Level l Check Tyre Pressure l Check Engine Bay for Debris l Check for Loose components l Check for Hydraulic Leaks l Check Battery Condition l Check Fan Belt Tension l Clean Air Filter Element * Every 100 hours Every 250 hours Monthly Every 500 hours Quarterly l Change Engine Oil & Oil Filter l Change Air Filter Element l Replace Fuel Filters Every 1000 hours Annually End of Season l Change Engine Oil & Oil Filter l Change Air Filter Element * l Replace Fuel Filters l Change Hydraulic Oil & Filters l Drain & Clean Fuel Tank l Drain & Flush Cooling System Lubricate all Grease fittings with Shell Darina R2 or equivilent Grease Weekly (See Chart) * Service more often in dirty conditions GB-11

5 LUBRICATION AND MAINTENANCE RANSOMES HR3806 Series: DZ MAINTENANCE AND LUBRICATION Fig.1 l Lubricate every 50 working hours at arrows FLUID REQUIREMENTS QUANTITY TYPE ENGINE OIL (with filter) 6.0 Litres 10W 30 (CD) HYDRAULIC OIL (with filter) 37.0 Litres Shell Tellus 46 RADIATOR COOLANT 5.5 Litres 50% ANTI-FREEZ E GB-12

5 LUBRICATION AND MAINTENANCE RANSOMES HR3806 Series: DZ MAINTENANCE AND LUBRICATION 5.1 ENGINE: First 50 working hours and every 250 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 the correct grade to the correct level on the dipstick (B) Change Engine Oil Filter (V) (a) Remove cartridge (V) (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.2 Fig.3 5.2 MACHINE: Lubricate the following points. Weekly or every 50 working hours. 1. Lubricate the following with Shell Darina R2 grease. (Fig.1) (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. Lift arm yoke pivots. Belt pulleys. Deck Castor wheels GB-13

5 LUBRICATION AND MAINTENANCE RANSOMES HR3806 Series: DZ MAINTENANCE AND LUBRICATION 5.3 MACHINE 1. Drain Oil reservoir by removing drain plug H on bottom of hydraulic oil reservoir. 2. Ensure that plug is clean and reinstall in tank. 3. Unscrew both filter elements G and discard. 4. Clean the rubber seal through which the filter elements pass. 5. Apply a thin film of oil to the seals of the new filters and install. 6. Remove plug K and add the recommended oil Fig 5) until the indicator on the oil level gauge J is centered in the green area of the gauge. Avoid operation in either red zone as insufficient oil could damage hydraulic components. Too much oil could lead to oil overflowing the reservoir as it heats up. 7. Reinstall plug K. 8. Start the tractor and allow to run at 1/4 throttle for approximately 5 minutes. 9. Allow oil to cool and recheck the oil level and adjust as required. Fig.4 Hydraulic oil type requirements: Shell Tellus 46 IMPORTANT: Absolute cleanliness must be observed when filling the hydraulic tank. Oil must be filtered through a 25 micron filter before entering the hydraulic tank. Change Hydraulic Oil Filter (CHARGE) (Fig.6) 1. Wipe filter canister and housing to remove any dirt present. 2. Place a suitable drip tray under the filter. 3. Un-screw filter canister and remove the filter element and dispose of safely. 4. Replace with new filter element. 5. Coat the top outside lip of the filter canister with a thin film of oil and refit the filter canister. 6. Filter should be replaced before refilling hydraulic tank. Fig.5 Fig.6 GB-14

5 LUBRICATION AND MAINTENANCE RANSOMES HR3806 Series: DZ MAINTENANCE AND 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): 1. Front Cutter Deck Pressure: 220 bar (3200 psi). (A(Fig.7)). Lift Pressure : 63.5 bar (920 psi). (B(Fig.7)). 2. FWD Transmission Pressure : 250 bar (3625 psi). (A(Fig.8)). Fig.7 3. REV Transmission Pressure : 210 bar (3045 psi). (B (Fig.8). 4. Charge Pressure : 15.8-19.3 bar (230-280 psi). (Either A or B(Fig.8) NOTE: Any servicing of the hydraulic system must be carried out by trained service personnel. Fig.8 GB-15

5 LUBRICATION AND MAINTENANCE RANSOMES HR3806 Series: DZ MAINTENANCE AND MAINTENANCE 5.5 ENGINE MAINTENANCE: Every 500 hrs Fuel System: Use Diesel fuel No.2-D (ASTM D975) See engine manufacturer's manual for additional information. Changing fuel filter (Fig.10) 1. Unscrew filter screw (A) from filter head. 2. Bleed air from system as described in section 5.5 Fig.9 Bleeding air from fuel system 1. Turn the ignition switch to the ON position (dont start engine) 2. Open air vent A onto top of fuel filter to allow air to escape.(fig.9) 3. Retighten air vent. 4. Open air vent (A) on side of injector pump to allow air to escape.(fig.10) 5. Retighten air vent 6. Turn ignition to OFF. Fig.10 GB-16

5 LUBRICATION AND MAINTENANCE RANSOMES HR3806 Series: DZ MAINTENANCE AND MAINTENANCE 5.6 ENGINE MAINTENANCE: Every 100 hrs Cleaning the air filter. To remove the cover, pull the yellow finger on the cover towards you. Take hold of the cover firmly and twist it to the left. Pull the cover towards you to open the housing. Remove old filter gently, then clean inside of the housing carefully. 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. The element should be cleaned no more than 6 times. In any case we recommend replacing the main element once a year irrespective of how many times it has been cleaned. To close the cover reverse operation. Fig.12 NOTE: Extensive damage to engine can result from an inadequate air supply. 5.7 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-17

5 LUBRICATION AND MAINTENANCE RANSOMES HR3806 Series: DZ MAINTENANCE AND MAINTENANCE 5.8 END OF SEASON or when required 1. Drain Oil reservoir by removing drain plug H on bottom of hydraulic oil reservoir. 2. Ensure that plug is clean and reinstall in tank. 3. Unscrew both filter elements G and discard. 4. Clean the rubber seal through which the filter elements pass. 5. Apply a thin film of oil to the seals of the new filters and install. 6. Remove plug K and add the recommended oil Fig 5) until the indicator on the oil level gauge J is centered in the green area of the gauge. Avoid operation in either red zone as insufficient oil could damage hydraulic components. Too much oil could lead to oil overflowing the reservoir as it heats up. 7. Reinstall plug K. 8. Start the tractor and allow to run at 1/4 throttle for approximately 5 minutes. 9. Allow oil to cool and recheck the oil level and adjust as required. Fig.13 Hydraulic oil type requirements: Shell Tellus 46 Change Hydraulic Oil Filter(Fig.6 Ref to pg 12) 1. Wipe filter canister and housing to remove any dirt present. 2. Place a suitable drip tray under the filter. 3. Un-screw filter canister and remove the filter element and dispose of safely. 4. Replace with new filter element. 5. Coat the top outside lip of the filter canister with a thin film of oil and refit the filter canister. 6. Filter should be replaced before refilling hydraulic tank. Fig.14 Change Coolant. 1. Completely drain the cooling water from the radiator and flush the cooling system with flushing detergent. Drainplugs A. 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. Note: When topping up the cooling system fill with 50/50 solution. Fig.15 GB-18

6 ADJUSTMENTS RANSOMES HR3806 Series: DZ MAINTENANCE AND 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 have 1/8" (3.2mm) toe-in from the front of the wheel to the back of the wheel. Adjust as follows: 1. Loosen locknuts N at balljoints near both rear wheels. 2. Rotate the tie rod O until wheels are correctly positioned. Adjust both tie rods an equal amount. 3. Re-tighten locknuts. The tires should then be 1/ 8" closer at the front than the rear. Fig.16 6.3 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.17) To adjust: 1. Loosen alternator bolts S & T. 2. Move the alternator to tighten or loosen fan belt. 3. Tighten bolts S & T. Check belt tension and condition of belt every 250 hours. Fig.17 GB-19

7 CUTTER DECK ADJUSTMENTS RANSOMES HR3806 Series: DZ MAINTENANCE AND CUTTER DECK ADJUSTMENTS 7.1 HEIGHT OF CUT ADJUSTMENT The cutting height is determined by the position of the blades in relation to the caster wheels. Changes to this height are made at (4) points and can be made in any order. Make adjustment selections for each deck from the height of cut chart for that deck included in this section. NOTES Cutting height must be set the same for all three decks. The actual height may vary slightly from the chart value because of tire pressure or condition. Fig.18 HEIGHT OF CUT ADJUSTMENT (CENTRE DECK) 1. Raise the deck. 2. Remove the quick pin Q from the top of the caster wheel pivot spindle 3. Remove the caster wheel from caster support M. 4. Select either Position 1 or Position 2 for wheel mounting bracket. To change, remove (4) mounting bolts R, move to the alternate location and bolt in place. 5. Place the selected size and number of spacers below the caster support. Both A- size (6.5 mm) and B-size (12.5 mm) spacers are provided. Place the remaining spacers above the caster support. 6. Replace the quick pin. 7. Place pin P into the proper hole of bracket for the selected height of cut. Fig.19 CENTER DECK HEIGHT OF CUT CHART GB-20

7 CUTTER DECK ADJUSTMENTS RANSOMES HR3806 Series: DZ MAINTENANCE AND CUTTER DECK ADJUSTMENTS 7.2 BELT TENSION 1. Adjust belt tension to 1/2 (13 mm) deflection at 10 lbs (5 kg) force at the middle of the long rear span D. If necessary, adjust as follows: 2. Loosen locking nut on adjustment bolt E. 3. Loosen (4) bolts G fastening the motor mounting plate to the cutter deck (3 visible in photo). 4. Turn adjustment bolt E until proper tension is obtained. 5. Retighten (4) bolts G and lock nut on adjustment bolt E. Fig.20 7.3 BLADE SHARPENING & REMOVAL When required, the cutter blades may be sharpened either by filing or grinding. It is essential that the balance of the blades are maintained. NOTE: Always replace blades with original Ransomes blades, do not use another manufacturers blades. Service the blades with the tractor turned off, and the decks securely supported. Do not overheat or weaken the blades. If blade becomes cracked or bent, replace with a new blade to ensure safe operation f lift portion of blade is worn thin replace with a new blade to ensure safe operation Place block of wood W between blade and deck baffle to prevent blade from turning during removal Keep hands clear of rotating blades Fig.21 Removing Blades 1. Remove the nut N from the top of the blade spindle bolt 2. Remove the blade spindle bolt with the washer and blade. 3. Replace the blade, washer and blade spindle bolt. 4. Tighten to 100-140 ft-lbs (135-190 N-M) Fig.22 GB-21

8 TROUBLESHOOTING RANSOMES HR3806 Series: DZ MAINTENANCE AND 8.1 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 or defective. 2. Inspect condition of connections. battery and battery Engine will not start. 3. Fuel tank empty contaminated. or fuel 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 contaminated. or fuel 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 corroded battery terminals. 2. Low electrolyte battery. 3. Alternator broken. level in belt loose or 3. Inspect waterpump/alternator Tighten if neccesary. 1. Inspect required. terminals, clean and 2. Refill battery with distelled 3. Inspectwaterpump/alternator neccesary. belt and tighten as water fan belt. belt. Tighten if 4. Alternator defective. 4. See engine manual. GB-22

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND 9.1 HYDRAULIC CIRCUIT 1. Transmission Pump 2. 3 Section Pump 3. Transmission Valve 4. RF Wheel Motor 5. LF Wheel Motor 6. LR Wheel Motor 7. RR Wheel Motor 8. Brake Valve 9. Aux Brake Valve 10. Oil Cooler 11. Filter Head 12. Reservoir/Tank 13. Steer Valve 14. Steer Ram 15. Lift Valve 17. Lift Cylinder 19. Front Cutter Deck Valve 20. Charge Filter 21. Front Cutter Deck Motor 25. Inlet Manifold GB-23

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND 9.2 ELECTRICAL CIRCUIT INSTRUMENTs & LIGHTS 1 Connector No 1 2 Connector No 2 3 Connector No 3 4 Front RH Side & Direction Lamps 5 Front LH Side & Direction Lamps 6 LH Head Lamp 7 RH Head Lamp 8 Cutter Deck Relay 9 Flasher 10 Cutter Master Relay 11 Starter Relay 12 Horn Relay 13 Alarm Relay 14 Fuse Holder No 1 14.1 Fuse 10 Amp - Fuel Pump / Alternator 14.2 Fuse 20 Amp - Main Ignition 14.3 Fuse 10 Amp - Horn 14.4 Fuse 10 Amp - Glow Plug Relay 14.5 Fuse 10 Amp - Beacon 15 Fuse Holder No 2 15.1 Fuse 20 Amp - Accessory 15.2 Fuse 20 Amp - Air Seat 15.3 Fuse 20 Amp - Heated Jacket 44 Seat Delay Module 50 Light Switch 51 Direction Indicator Switch Connector 54 Hazard Warning Switch 61 Accessory Relay 62 Front Lamps Ground 63 Front Lamps Connector 64 Flasher Unit 65 Fuse Holder No 3 65.1 Fuse 10 Amp - LH Head Lamp 65.2 Fuse 10 Amp - RH Head Lamp 65.3 Fuse 10 Amp - RH Side Lamp 65.4 Fuse 10 Amp - LH Side Lamp 65.5 Fuse 10 Amp - Hazard Lights 65.6 Fuse 10 Amp - Indicators 66 Connector to Main Harness 68 Connector to Main Harness 69 Registration Plate Connectoin 70 Accessory Control Relay 77 Connector Rear Lamps RH 78 Connector Rear Lamps LH 79 Rear Lamps Connection 80 Key Switch Connector 81 Cutter Deck Switch Pilot Lamp, Twin 12 Volt 82 Glow Plug Indicator Lamp Lens 83 Battery Warning Lamp Lens 84 Oil Temperature Warning Lamp Lens 85 Oil Pressure Warning Lamp Lens 86 Temperatur Gauge 87 Fuel Gauge GB-24

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND CABLE COLOUR CODE 89 Beacon Indicator Lamp 90 Cutter Deck Switch Connector 91 Cutter Deck Switch Lamp Connector 92 Beacon Switch Connector 93 Beacon Switch lamp Connector 94 Beacon Switch 95 Hazard Switch Connector 96 Hazard Switch Ground 97 Light Switch Connector 98 Light Switch Lamp Connector 99 Direction Indicator Switch Connector 100 Direction Indicator Warning Lamp Connector 101 Key Switch Connector 102 Registration Plate Lamp No 1 103 Registration Plate Lamp No 2 A B Rear Lighting Harness Front Lighting Harness R Red G Green O Orange S Grey B Black W White K Pink P Violet Y Yellow U Blue N Brown LG Light Green E.G. R/W = Red/White GB-25

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND 9.3 ELECTRICAL CIRCUIT MAIN - PRE 2006 1 Connector No 1 2 Connector No 2 3 Connector No 3 16 Horn 18 Cutter Deck Switch 20 Lamp Timer 21 Hydraulic Oil Temperature Switch 23 Seat Switch 24 4 WD Valve 26 Fuel Solinoid 27 Engine Oil Pressure Switch 28 Fuel Pump 29 Glow Plug Relay 30 Back Start 31 Glow Plugs 32 Cutter Deck Valve 33 Fuel Level Sender 34 Starter Motor 37 Alternator OP 38 Alternator Motor 39 Water Temperature Switch 40 Water Temperature 41 Hour Meter 45 Deck Enable Switch 46 System I/P 47 Cab Supply 48 Heaters & Accessories I/P 49 Diode Module Connector 52 Parking Brake Switch 53 Beacon Supply 55 Cab Supply 56 Accessory Supply I/P 57 Air Seat Supply 58 Heated Jacket Supply 59 Diff Lock Switch 60 Oil Filter Switch 67 Brake Light Switch 68 Connector to Main Harness 71 Starter Main Terminal 72 System I/P Battery 73 Cab Supply I/P Battery 74 Heaters & Accessory I/P Battery 75 Brake Release / Engine Kill Switch 76 Forward / Reverse Pedal Switch 88 Fuel Solenoid Diode 89 Beacon Indicator Lamp GB-26

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND 9.3 ELECTRICAL CIRCUIT MAIN - PRE 2006 CABLE COLOUR CODE R G O S B W K P Y U N LG Red Green Orange Grey Black White Pink Violet Yellow Blue Brown Light Green E.G. R/W = Red/White GB-27

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND 9.4 FUSE POSITIONS - MAIN FUSES MAIN FUSES The main fuse panel is situated under the front of the engine bonnet. Fuse A - 40Amp Link Fuse - System Fuse. Fuse B - 40Amp Link Fuse - Glow Plug and Accessory. Fuse C - 40 Amp Cab Fuse. Relay D - Glow Plug Relay - Item 29 pages 26 & 30. Fig.23 SECONDARY FUSES The secondary fuse panel is situated under the front tower cover. FUSE BLOCK 1 - Item 14 Pages 26 & 30. Fuse A - 10Amp - Fuel pump/alternator. Fuse B - 20Amp - Main Ignition. Fuse C - 10Amp - Horn. Fuse D - 10Amp - Glow Plug Relay. Fuse E - 10Amp - Beacon Fuse F - Spare. FUSE BLOCK 2 - Item 15 Pages 26 & 30. Fuse A - 20Amp - Accessory. Fuse B - 20Amp - Air Seat - Pre 2006. Fuse B - 10Amp - Air Seat - Post 2006. Fuse C - 20Amp - Heated Jacket - Pre 2006. Fuse D - Spare. Fuse E - Spare. Fuse F - Spare. Fig.24 FUSE BLOCK 3 - Item 65 Pages 26 & 30. Fuse A - 10Amp - LH Headlamp. Fuse B - 10Amp - RH Headlamp. Fuse C - 10Amp - RH Side Lights. Fuse D - 10Amp - LH Side Lights. Fuse E - 10Amp - Hazards. Fuse F - 10Amp - Indicators /Brake Lights GB-28

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND RELAY POSITIONS RELAY POSITIONS Relays are situated under the front tower cover Relay A - Flasher Relay. Relay B - RH Deck Relay Relay C - Centre Deck Relay. Relay D - LH Deck Relay Relay E - 4 Wheel Drive Relay Relay F - Start Relay. Relay G - Horn Relay. Relay H - Alarm Relay. Relay I - Accessory Relay. Relay J - Accessory Control Relay. Relay K - Seat Delay Relay. Fig.25 GB-29

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND 9.5 ELECTRICAL CIRCUIT MAIN - POST 2006 GB-30

9 SCHEMATICS RANSOMES HR3806 Series: DZ MAINTENANCE AND 9.5 ELECTRICAL CIRCUIT MAIN - POST 2006 1 Connector No 1 2 Connector No 2 3 Connector No 3 16 Horn 18 Cutter Deck Switch 20 Lamp Timer 21 Hydraulic Oil Temperature Switch 23 Seat Switch 24 4 WD Valve 26 Fuel Solinoid 27 Engine Oil Pressure Switch 28 Fuel Pump 29 Glow Plug Relay 30 Back Start 31 Glow Plugs 32 Cutter Deck Valve 33 Fuel Level Sender 34 Starter Motor 37 Alternator OP 38 Alternator Motor 39 Water Temperature Switch 40 Water Temperature 41 Hour Meter 45 Deck Enable Switch 46 System I/P 47 Cab Supply 48 Heaters & Accessories I/P 49 Diode Module Connector 52 Parking Brake Switch 53 Beacon Supply 55 Cab Supply 56 Accessory Supply I/P 57 Air Seat Supply 59 Diff Lock Switch 60 Oil Filter Switch 67 Brake Light Switch 68 Connector to Main Harness 71 Starter Main Terminal 72 System I/P Battery 73 Cab Supply I/P Battery 74 Heaters & Accessory I/P Battery 75 Brake Release / Engine Kill Switch 76 Forward / Reverse Pedal Switch 88 Fuel Solenoid Diode 89 Beacon Indicator Lamp CABLE COLOUR CODE R Red G Green O Orange S Grey B Black W White K Pink P Violet Y Yellow U Blue NBrown LG Light Green E.G. R/W = Red/White GB-31

1 SISÄLTÖ RANSOMES HR3806 -sarja: DZ HUOLTOA JA OSIA KOSKEVA KÄYTTÖOPAS 1 SISÄLTÖ 2 JOHDANTO 2.1 TUOTTEEN TUNNISTETIEDOT... 2 2.2 VARAOSIEN VARASTOINTIOPAS... 2 2.3 VARAOSAOPPAAN KÄYTT... 3 3 TURVAOHJEET 3.1 KÄYTTÖOHJEET... 4 3.2 VAROITUSKILVET... 4 3.3 MOOTTORIN KÄYNNISTYS... 4 3.4 RUOHONLEIKKURIN KÄYTTÄMINEN... 4 3.5 RUOHONLEIKKURIN KULJETTAMINEN... 4 3.6 RUOHONLEIKKURIN PYSÄYTTÄMINEN... 5 3.7 RINTEET... 5 3.8 SUOJATUT LEIKKUUTASOT... 5 3.9 SÄÄDÖT, VOITELU JA HUOLTO... 5 4 TEKINISET TIEDOT 4.1 MOOTTORIN TEKNISET TIEDOT... 7 4.2 KONEEN TEKNISET TIEDOT... 7 4.3 MITAT...7 4.4 TÄRINÄTASO... 8 4.5 RINTEET... 9 4.6 SUOSITELLUT VOITELUAINEET... 9 4.7 LEIKKUUSUORITUS (ALUE)... 9 4.8 VÄÄNTÖNOPEUDET... 9 5 VOITELU JA HUOLTO VOITELU- JA HUOLTOKAAVIO... 10 5.1 MOOTTORI: ENSIMMÄISTEN 50 TYÖTUNNIN JÄLKEEN JA AINA 250 TYÖTUNNIN VÄLIAJOIN... 12 5.2 KONE: VOITELE SEURAAVAT PAIKAT. VIIKOTTAIN TAI AINA 40 TYÖTUNNIN VÄLIAJOIN... 12 5.3 KONE: AINA 400 TYÖTUNNIN VÄLIAJOIN... 13 5.4 HYDRAULITESTIAUKOT... 14 5.5 MOOTTORIN HUOLTO: AINA 250 TUNNIN VÄLIAJOIN... 15 5.6 MOOTTORIN HUOLTO: AINA 400 TUNNIN VÄLIAJOIN... 16 5.7 KONEEN HUOLTO... 16 5.8 SESONGIN PÄÄTTYESSÄ TAI TARPEEN VAATIESSA... 17 6 SÄÄDÖT 6.1 NOPEUSRAJOITIN... 18 6.2 TAKAPYÖRÄN AURAUSKULMA... 18 6.3 VAIHTOJÄNNITEGENERAATTORI... 18 7 LEIKKUUTASON SÄÄDÖT 7.1 LEIKKUUTASON HIHNAN KIREYS... 19 7.2 TERIEN TEROITUS JA IRROTUS... 20 8 VIANHAKU 8.1 YLEISTÄ... 22 9 KAAVIOT 9.1 HYDRAULIPIIRI... 23 9.2 SÄHKÖPIIRI-INSTRUMENTTI... 24 9.3 PÄÄSÄHKÖPIIRI - PRE 2006... 26 9.5 PÄÄSÄHKÖPIIRI - POST 2006... 30 FI-1

2 JOHDANTO RANSOMES HR3806 -sarja: DZ HUOLTOA JA OSIA KOSKEVA KÄYTTÖOPAS 2.1 TUOTTEEN TUNNISTETIEDOT A D C B E A B C D E Koneen nimi Sarjanumero Valmistusvuosi Koneen paino Moottorin teho 2.2 VARAOSIEN VARASTOINTIOPAS Jotta laite toimisi asianmukaisesti ja tehokkaasti, Ransomes suosittelee, että pidät varastossa yleisimmin käytettyjä huoltotarvikkeita. Taulukossa on myös muun tuki- ja koulutusmateriaalin osanumerot. Huolto-osat Osanro Kuvaus Osanro Kuvaus 16271-32090 Moottorin öljysuodati n 178025 13351-43011 4123044 Moottorin polttoainesuodatin Ilmanpuhdistimen elementti 68371-50211 13351-43610 008089620 Hydraulinesteen suodatin (imu) Sähköinen polttoainepumppu Linjakytketty polttoainesuodatin Hydraulinesteen suodatin (syöttö) Huoltotukimateriaali Osanro Kuvaus Osanro Kuvaus 97898-02690 Moottorin osien käyttöopas 24684G-FI Koneen huoltoa ja osia koskeva käyttöopas 16622-89163 Moottorin käyttäjän käyttöopas 97897-01643 Moottorin huolto käyttöopas FI-2

2 JOHDANTO RANSOMES HR3806 -sarja: DZ HUOLTOA JA OSIA KOSKEVA KÄYTTÖOPAS 2.3 VARAOSAOPPAAN KÄYTTÖ NUMERO Kaikilla kuviin merkityillä osilla on numero. Osia, joilla ei ole numeroa, voi olla vaikea hahmottaa kuvasta, mutta ne liittyvät yleensä läheisesti viereiseen osaan. LAITTEISTOT Laitteistot, kuten pyörän käyttömoottori, hydraulimoottori ja telalaitteisto, ovat luettelossa yhtenä osana, ja niiden yksittäiset komponentit luetellaan erikseen heti niiden alla. Laitteisto on luettelossa osanumeronsa kohdalla, ja yksittäiset komponentit luetellaan sen alla oikealle sisennettynä, kuten alla olevassa esimerkissä. NUMERO OSANUMERO KUVAUS MÄÄRÄ HUOMAUTUKSET RANSOMES 4295 MBG2504 KANNATIN 1 4296 MBG3848 SALPA 2 4298 450865 RUUVI, M8 x 20, SCKT CSK HD 2 4300 450378 MUTTERI, M8 NYLOC 2 4301 Wl001 Pyörät 1 4301.1 008162130 Pyörän ja pyöränavan kokoonpano 1 (Takaosa) 4301.2 008170390 Rengas 1 4301.3 008161830 Vanne 1 4301.4 008169140 Navan kokoonpano 1 4301.5 008169150 Tulppa 1 4301.6 002993010 Voiteluainelaite 1 4301.7 008161990 Pyörä ja rengas 2 (Etuosa) 4301.8 008170780 Rengas 2 Kaikkia osia ei ehkä ole mahdollista kuvata. Ransomes ei toimita joidenkin muilta toimittajilta hankittujen osien komponentteja. Kyseiset komponentit, on tällöin tilattava erikseen näiden osien toimittajalta. MÄÄRÄT Oppaassa mainittavat määrät koskevat yhtä laitteistoa tai laitteiston osaa. VARAOSALUETTELON KÄYTTÖ Määritä tarvittavan osan tehtävä ja käyttötarkoitus. Avaa hakemiston pääsivu ja valitse asianmukainen kohta. Etsi osa kuvasta ja osaluettelosta sekä katso määrä oikeasta MALLI-sarakkeesta. NUMEERINEN HAKEMISTO Tämä on yhteenveto kaikista tässä oppaassa käytettävistä osanumeroista. Hakemisto etenee numerojärjestyksessä ja osoittaa kunkin osan sivunumeron ja numeron. VARAOSIEN TILAAMINEN Varaosia tilattaessa on erittäin tärkeää mainita laitteen SARJANUMERO, OSANUMERO, KUVAUS ja tarvittava MÄÄRÄ. Tähän laitteeseen tehtävät mielivaltaiset muutokset voivat vapauttaa valmistajan kaikesta vastuusta koskien näistä muutoksista aiheutuvia vahinkoja ja vammoja. LYHENTEET E/S Ei saatavissa AR Tarvittaessa FI-3

3 TURVAOHJEET RANSOMES HR3806 -sarja: DZ HUOLTOA JA OSIA KOSKEVA KÄYTTÖOPAS Tämä turvallisuustunnus on merkkinä tässä käyttäjän käsikirjassa olevista tärkeistä, turvallisuutta koskevista viesteistä. Kun näet tämän tunnuksen, ole valppaana mahdollisen loukkaantumisen varalta, lue huolellisesti senjälkeinen viesti ja ilmoita asiasta muille koneen käyttäjille. 3.1 KÄYTTÖOHJEET Varmista, että tätä konetta käyttävät ovat lukeneet tämän käsikirjan sisältämät ohjeet ja ymmärtäneet ne täysin. Tätä ruohonleikkuria saavat käyttää vain sen hallintalaitteisiin ja turvatoimenpiteisiin perusteellisesti tutustuneet henkilöt. Älä koskaan anna lasten tai henkilöiden, jotka eivät ole tutustuneet koneen käyttöohjeisiin, käyttää tätä ruohonleikkuria. Noudata virallisia määräyksiä koneenkäyttäjän ikärajoitusten suhteen. 3.2 VAROITUSKILVET On tärkeää, että kaikki varoituskilvet pidetään puhtaina ja hyvässä kunnossa. Irronneet ja epäselviksi kuluneet varoituskilvet on uusittava. Jos koneen jokin varoituskilvellä varustettu osa uusitaan, uuteen osaan on kiinnitettävä uusi varoituskilpi. Uusia varoituskilpiä on saatavissa Ransomes-myyjiltä. 3.3 MOOTTORIN KÄYNNISTYS Ennen kuin käynnistät moottorin varmista, että koneen käyttimet ovat neutraaliasennossa, suojukset ovat paikoillaan ja ehjät. Varmista myös, että ruohonleikkurin liikeradalla ei ole ihmisiä. Älä anna moottorin käydä sisätiloissa, joissa ei ole riittävää tuuletusta. 3.4 RUOHONLEIKKURIN KÄYTTÄMINEN Ennen kuin siirrät ruohonleikkuria tarkasta, että sen kaikki osat ovat hyvässä kunnossa, ja kiinnitä erityisesti huomiota jarruihin, renkaisiin, ohjaukseen ja leikkuriterien turvalliseen kiinnitykseen. Vaihda vialliset äänenvaimentimet uusiin. Käytä ruohonleikkuria ainoastaan päivänvalossa tai hyvin valaistuilla nurmikentillä. Noudata aina liikennesääntöjä sekä yleisillä teillä että muualla. Ole tarkkaavainen kuljettaessasi ruohonleikkuria. Tarkkaile liikennettä ylittäessäsi tietä tai kuljettaessasi ruohonleikkuria ajotien vieressä. Pysäytä leikkuriterien pyörintä, ennen kuin siirrät ruohonleikkurin nurmikolta tielle. Ota huomioon, että jotkut ihmiset saattavat olla näkö- tai kuulovammaisia. Muista myös, että lapset ja eläimet saattavat toimia arvaamattomasti. Kuljeta ruohonleikkuria riittävän pienellä nopeudella voidaksesi pysäyttää sen hätätilanteissa nopeasti ja turvallisesti kaikissa olosuhteissa. Siirrä ruohonleikkausta vaikeuttavat esineet pois leikattavalta alueelta mikäli mahdollista, tai kierrä ne, välttääksesi onnettomuuksia, jotka saattavat aiheuttaa vammoja joko itsellesi tai lähettyvillä oleville muille ihmisille. Toimi erityisen varovasti ohjatessasi ruohonleikkuria taaksepäin ja varmista, että koneen takana ei ole esteitä eikä ihmisiä. ÄLÄ kuljeta matkustajia ruohonleikkurilla. Pidä mielessäsi, että ruohonleikkurin käyttäjä on vastuussa sen käytöstä sekä ruohonleikkurin muille ihmisille tai heidän omaisuudelleen aiheuttamista vahingoista. Laske leikkurit alas, kun pysäköit ruohonleikkurin, panet sen varastoon tai jätät sen seisomaan ilman valvontaa. Käytä aina ruohoa leikatessasi tukevia jalkineita ja pitkiä housuja. Älä käytä laitetta sandaalit jalassa tai paljain jaloin. Tarkasta silppusäiliön kunto säännöllisesti. Jos ruohonleikkuri törmää johonkin esineeseen, tarkasta, että kone ei ole rikkoutunut. Korjaa mahdolliset vauriot, ennen kuin jatkat ruohonleikkurin käyttöä. Jos ruohonleikkuri alkaa täristä epänormaalisti, etsi vika välittömästi. 3.5 RUOHONLEIKKURIN KULJETTAMINEN Varmista, että leikkurit ovat kuljetusasennossa. Älä siirrä ruohonleikkuria leikkurimekanismin pyöriessä. Kun siirrät ruohonleikkuria, kiinnitä huomiota tienpintaan ja maasto-olosuhteisiin, rinteiden kaltevuuteen ja maastossa esiintyviin kohoumiin ja kuoppiin. Äkkinäinen kiihdytys tai jarrutus voi nostaa ruohonleikkurin takapyörät ylös. Muista, että laitteen takaosan vakaus vähenee polttoaineen kuluessa. FI-4