Ransomes EC Hydro Midsize Setup, Parts And Maintenance Manual
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Ransomes EC Hydro Midsize Setup, Parts And Maintenance Manual

Ransomes EC Hydro Midsize Setup, Parts And Maintenance Manual

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Setup, Parts and Maintenance Manual
Power Unit Models:
930325A EC Power Unit 15HP Kawasaki Hydro
(Safety & Operation Manual 4122451)
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.
RJ 100 / 092003
EC Hydro Midsize
4122450-GB (rev.A)

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  • Page 1 4122450-GB (rev.A) Setup, Parts and Maintenance Manual EC Hydro Midsize Power Unit Models: 930325A EC Power Unit 15HP Kawasaki Hydro (Safety & Operation Manual 4122451) WARNING: If incorrectly used this machine can cause severe injury. Those who use and maintain this machine should be...
  • Page 2 © 2002, Ransomes Jacobsen Limited. All Rights Reserved...

  • Page 3: Table Of Contents

    Your safe use of this Ransomes product is one of our prime design objectives. Many safety features are built in, but we also rely on your good sense and care to achieve accident-free operation. For best protection, study the manuals thoroughly.

  • Page 4: Safety

    SAFETY Hydro Midsize NOTICE !!! This symbol means: ATTENTION! Unauthorized modifications may present extreme BECOME ALERT! safety hazards to operators and bystanders and could also result in product damage. Your safety and the safety of others is involved. Textron Golf, Turf & Specialty Products strongly warns against, rejects and disclaims any modifica- Signal word definitions tions, add-on accessories or product alterations that...

  • Page 5: Assembly/Set-Up Instructions

    ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize GENERAL NOTE: FRONT, REAR, RIGHT HAND AND LEFT HAND REFERENCES BELOW ARE WITH RESPECT TO AN OPERATOR AT THE CONTROLS. 1. UNCRATE - Place both power unit and cutterdeck crates on a level surface. Remove sides and top from both the power unit and cutterdeck crates.
  • Page 6 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize 4. Unbolt upper handle B from shipping bracket C. Unbolt shipping bracket C from lower handle D. Retain fasteners removed for later use. 5. Bolt upper handle B to lower handle D with (2) 3/8-16 X 1" bolts and nuts at location E bolts removed in the previous step and (2) 3/8-16 X 1-1/2"...
  • Page 7 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize 7. Unbolt shipping bracket from crate. 8. Open the bypass valves X on each pump by rotating handle counter-clockwise two revolutions. 9. Remove the power unit from the crate and support the rear of the power unit with a jack stand.
  • Page 8 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize 11. Cut and remove tie wrap G from the traction control lever H. 12. Locate the two longest rods removed in Step 2. Install the two traction control rods through the traction control lever H, flatwasher and traction lock J and secure with hairpin.
  • Page 9 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize 14. Attach spring to pump arm and then to bolt L. Repeat for other side. 15. Connect speed control rod M to the speed control levers N and secure with hairpin. Repeat for other side. 16. Set the speed control levers to neutral and adjust the swivel on the lower end of the speed control rod M so they engage the very top of the slot on the neutral plates P and secure with flatwasher...
  • Page 10 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize 17. Insert threaded end of brake rod Q through the slot on the engine deck and attach the other end to the brake control arm R and secure in place with hairpin as shown. 18. Connect swivel on threaded end of brake rod Q to the brake arm T and secure in place with flatwasher and hairpin as shown.
  • Page 11 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize 19. Close bypass valve X by rotating clockwise until firmly seated. 20. Remove the battery cover and the battery from the machine. Fill the battery to the bottom of the vent wells with electrolyte and trickle charge for several hours.
  • Page 12 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize 21. Attach cutterdeck per the instructions on the following pages then return to Step 22 of this section. 22. Fill engine with oil. (See engine manual for specifications.) 23. Fill fuel tank with clean, fresh unleaded fuel. GASOLINE IS HIGHLY FLAMMABLE! •...
  • Page 13 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize FIXED CUTTERDECK ATTACHMENT 1. Remove the cutterdeck from the crate. 2. Unbolt the caster wheels and the shipping brackets from the crate. 3. Remove the shipping bracket from the caster wheel by loosening the caster bolt and sliding the shipping bracket off and retighten caster bolt.
  • Page 14 ASSEMBLY/SET-UP INSTRUCTIONS Hydro Midsize 6. Remove belt cover and set aside. 7. Block the rear of the cutterdeck with the appropriate height block for the desired height of cut B. See Support Block Chart below. " 5 " 5 " 5 "...

  • Page 15: Lubrication

    LUBRICATION Hydro Midsize MACHINE LUBRICATION Every 50 Working Hours - Lubricate the following points with grease: 1) Caster wheel pivots (2 points) 2) Neutral eccentric pin (2 points) 3) Idler pivot bearings: a) Engine to cutterdeck belt tensioner b) Cutterdeck belt tensioner c) Hydro drive belt tensioner NOTE: The spindles used on these machines use a superior sealed bearing which does not require relubrication.
  • Page 16 LUBRICATION Hydro Midsize ENGINE DAILY Remove the dipstick S and check that the oil level reaches the full mark. If necessary, top off with fresh oil. To obtain the correct oil level, the machine must be level. See engine manufacturer’s manual for proper oil viscosity and grade.

  • Page 17: Maintenance

    MAINTENANCE Hydro Midsize The maintenance schedule detailed is for average operating conditions. Under extreme conditions (dusty, dirty or more than 8 hrs continuous use) maintain more frequently. Engine (daily) Check the engine for oil leaks. Cooling Fins and Air Intake screen (daily) Ensure that the cooling fins and air intake screen I are cleaned daily.
  • Page 18 Do not straighten bent blades. Replace with new Ransomes blades. If lift portion of blade is worn thin replace with a new Ransomes blade. • ALWAYS replace with Ransomes blades—do not use another manufacturer’s blades as this could be dangerous. • Replace cracked or bent blades.
  • Page 19 MAINTENANCE Hydro Midsize HYDRAULIC RESERVOIR CHECK, DRAIN AND FILL Check level every 100 hours or when a leak has occurred. To check level: Remove reservoir cap. Add 10W30 oil until the oil level reaches the bottom of the filler tube. Do not overfill. EVERY 500 HOURS: Change hydraulic oil and filter.

  • Page 20: Service Chart

    SERVICE CHART Hydro Midsize NOTE: CHANGE ENGINE OIL AND FILTER AFTER FIRST 5 HOURS OF OPERATION. & & Consult the manufacturer’s manual for your engine for further information and instructions. GB-18...

  • Page 21: Service Record

    SERVICE RECORD Hydro Midsize NOTES _______________________________________________________________ ____________________________________________________ ________________________________________________________________________ _______________________________________________________________ ____________________________________________________________ ____________________________________________________ ________________________________________________________________________ _______________________________________________________________ ____________________________________________________________ _______________________________________________________________ ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ & & r i f t l i GB-19...

  • Page 22: Adjustments

    ADJUSTMENTS Hydro Midsize NOTE: Make all adjustments with the engine shut off, spark plug wire disconnected and mower drive disengaged. TRACTION DRIVE HYDROSTAT ADJUSTMENTS: The following adjustments must be done in order. STEP 1 - Set Neutral Neutral is set at the factory. If it should require adjustment, raise the wheels off the ground by setting the machine on jackstands or blocks.
  • Page 23 ADJUSTMENTS Hydro Midsize Speed Control Lever Friction The speed control lever is held where set by friction pads. If the setting will not hold, tighten nuts E to increase friction on the speed control lever. PARKING BRAKE - Apply parking brakes and open the bypass valves on the hydraulic pumps.
  • Page 24 ADJUSTMENTS Hydro Midsize OPERATOR PRESENT CONTROLS The operator present (OP) controls should be ad- justed to control the operation of the plunger of the operator present switch (located under the right side of the control panel). Depressing OP levers F should depress the plunger;...
  • Page 25 ADJUSTMENTS Hydro Midsize TRACKING WIDTH ADJUSTMENT The tracking width originally set from the factory can be increased an additional 83 mm overall by performing the following steps. 1. Loosen wheel lug nuts on both drive tires. 2. Raise rear of unit so that drive tires are off the ground.

  • Page 26: Belt Replacement

    BELT REPLACEMENT Hydro Midsize PTO BELT 1. Rotate idler arm using a 3/8" ratchet or breaker bar and remove belt. CUTTERDECK BELT 1. Remove PTO belt. 2. Rotate idler arm using a 3/8" ratchet or breaker bar and remove belt. 3.
  • Page 27 PARTS SECTION Hydro Midsize PARTS SECTION GB-25...
  • Page 28 UPPER ENGINE DECK ASSY Hydro Midsize FIGURE 1 Parts-26...

  • Page 29: Upper Engine Deck Assy

    UPPER ENGINE DECK ASSY Hydro Midsize 4122450-01 FIGURE 1 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 2721520 CAP-FUEL GASOLINE 3.5 1 4116345 TANK-FUEL (INCLUDES ITEMS 3 & 4) 48310 S BUSHING,FUEL TANK 38540 S FUEL SHUT-OFF VALV 1 88042N HOSE CLAMP 48016-8A HOSE,.25IDX.50ODX17"...
  • Page 30 LOWER ENGINE DECK ASSY/CLUTCH Hydro Midsize FIGURE 2 Parts-28...

  • Page 31: Lower Engine Deck Assy/Clutch

    LOWER ENGINE DECK ASSY/CLUTCH Hydro Midsize 4122450-02 FIGURE 2 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 2721647 PULLEY-4.50E.O.D. 64163-31 WASHER, 25/64 X 1 X 12 5 2721110 CLUTCH-ELECTRIC (INCLUDES ITEM 30) 2721331.7 WLDMT-CLUTCH STOP 2721642 BELT-HA 49.0 2722244 PULLEY- A SECTION 4.50 2 38304-03 BRG-FLANGED PLASTIC 1 4121540...
  • Page 32 DRIVE WHEELS Hydro Midsize FIGURE 3 Parts-30...

  • Page 33: Drive Wheels

    DRIVE WHEELS Hydro Midsize 4122450-03 FIGURE 3 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 2721105.2 WLDMT-ENGINE DECK 2721620.7 WLDMT-HUB 2721956 ASSY-WHEEL 16 X 7.50 X 8 2 2721956-01 TIRE-16X7.50 X 8 MLTI TRC 1 2721956-02 WHEEL W/ DUAL VALVES 1 64267-01 NUT-HEX FLANGED 1/2-208 64025-06...
  • Page 34 PARKING BRAKE Hydro Midsize FIGURE 4 Parts-32...

  • Page 35: Parking Brake

    PARKING BRAKE Hydro Midsize 4122413-04 FIGURE 4 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 2721637 WLDMT-BRAKE SHAFT 33103 SWIVEL 64168-2 COTTER-HAIRPIN.08X1.192 64141-4 NUT-WLF 3/8-16 64123-171 BOLT-HEX 3/8-16X3-1/2 2188131 SPRING-EXTENSION 2183071-01 SPACER-15.88X10.32X16 2 64171-2 WAVE WASHER 2188145 BEARING-.75ID 4-10 64123-54 BOLT, 5/16-18X3/4 HEX 4-11 64141-6...
  • Page 36 ELECTRIC START UPPER HANDLE Hydro Midsize FIGURE 5 Parts-34...

  • Page 37: Electric Start Upper Handle

    ELECTRIC START UPPER HANDLE Hydro Midsize 4122450-05 FIGURE 5 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION PL5029 GRIP-HANDLE 5-2 * 2308121 ADHESIVE-3 GRAM TUBE 1 (USE WITH PL5029 GRIP) 128010 KEY SWITCH 64152-46 SCR-SLT HH 10-24X1/2 4122157 S UP HNDL W/LBS 2303023 CONNECTOR-OP 4122104...
  • Page 38 TRACTION CONTROLS Hydro Midsize FIGURE 6 Parts-36...

  • Page 39: Traction Controls

    TRACTION CONTROLS Hydro Midsize 4122450-06 FIGURE 6 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 6-47 38404-01 GRIP,CONTROL LEVER 2722426 GRIP-TRACTION LOCK 6-48 2308076-02 BEARING-PLASTIC 38189 SPRING-COMPRESSION 2 6-49 64192-04 SET SCREW 5/16-18X5/8 2 64061-37 ROLL PIN-1/8 X 1.00 SS 6-50 2303058 ECCENTRIC SHAFT W/ZRK 2...
  • Page 40 ELECTRIC START BATTERY Hydro Midsize FIGURE 7 Parts-38...

  • Page 41: Electric Start Battery

    ELECTRIC START BATTERY Hydro Midsize 4115262-07 FIGURE 7 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 64229-02 LOCKNUT-NYLON 5/16-18 2 64163-29 WASHER 128035 COVER-BATTERY 2721105.2 WLDMT-ENGINE DECK 64123-54 BOLT, 5/16-18X3/4 HEX 112386 BOOT-BATTERY TERM POS 1 108055 BATTERY 108061-16 CABLE-BTTRY 31.5 BLACK 64025-02 NUT-HEX 5/16-18 7-10...
  • Page 42 HYDRAULICS Hydro Midsize FIGURE 8 Parts-40...

  • Page 43: Hydraulics

    HYDRAULICS Hydro Midsize 4115262-08 FIGURE 8 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION SERVICEABLE HYDRAULIC O-RINGS 58026-01 3-WAY CONNECTOR 108029 PLUG, MAGNETIC 158058-04 FITTING-90 BARB, ADJ. 108205-02 ELBW-MALE 45 8X8 37-ORB 4 88042-04 CLAMP-HOSE 5/8" 2720396 FLTR, 25 MCRN SM CAM 1 69060-01 FTG-BARB 9/16 X 3/8 ST 69216.7...
  • Page 44 DECALS Hydro Midsize FIGURE 9 Parts-42...

  • Page 45: Decals

    009034760 DECAL-NOISE 100 2000664 LABEL-HYDRAULIC MS EEC 1 2000655 LABEL-READ OPRTRS EEC 2 2000650 LABEL-BATTERY EEC 2721030 DECAL-RANSOMES 2000685-01 LBL-RED/WHITE STRPE 55" 1 (SIDE DISCHARGE LENGTH 28.4") (REAR DISCHARGE LENGTH 28.5") 2000638 LABEL-CON WASHER EEC1 2000760 LABEL-HANDS/ROCKS EC 1 9-10...

  • Page 46: Hyrogear Pump

    HYROGEAR PUMP Hydro FIGURE 10 Midsize Parts-44...
  • Page 47 HYDROGEAR PUMP Hydro 2721734-14 FIGURE 10 Midsize 4112782 PUMP-HYDRO LH ILLUSTRATED AS SHOWN 2721615 PUMP-HYDRO RH ILLUSTRATED AS SHOWN EXCEPT GROUP A IS ROTATED 180° AROUND THE CENTERLINE OF THE PUMP. ITEM HYDROGEAR PART NO. TEXTRON PART NO. DESCRIPTION 10-1 70516 ----- HOUSING KIT...
  • Page 48 CUTTERDECK MOUNTING Hydro Midsize FIGURE 11 Parts-46...

  • Page 49: Cutterdeck Mounting

    CUTTERDECK MOUNTING Hydro Midsize 4122450-11 FIGURE 11 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 11-1 2721991.7 PLATE-NUT 11-2 64246-04 NUT-WHIZ M12-1.75 11-3 64141-4 NUT-WLF 3/8-16 11-4 64163-82 WSHR-FLAT.406X1.44X9GA 2 11-5 64123-50 BOLT-HEX 3/8-16X1 11-6 64263-018 BLT-FLG HD M12-1.75 X 30 Parts-47...
  • Page 50 ELECTRICAL DIAGRAM Hydro Midsize FIGURE 12 Parts-48...

  • Page 51: Electrical Diagram

    ELECTRICAL DIAGRAM Hydro Midsize 2721734-12 FIGURE 12 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 12-1 2721110 CLUTCH-ELECTRIC (INCLUDES ITEM 2) 12-2 2720949 ASSY-CLUTCH WIRE 12-3 108208 SWITCH DBL POLE 12-4 128010 KEY SWITCH 12-5 2308094 SWITCH-NCNC DBL POLE 12-6 148082-20 FUSE 20 AMP 12-7...

  • Page 52: Electrical Schematic

    ELECTRICAL SCHEMATIC Hydro 4115262-13 FIGURE 13 Midsize Parts-50...
  • Page 54 World Class Quality, Performance and Support Equipment from Ransomes Jacobsen Limited is built to exacting standards ensured by ISO 9001 registration at all our manufacturing locations. A worldwide dealer network and factory-trained technicians backed by Ransomes Jacobsen Parts Xpress provide reliable, high-quality product support.

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