Ransomes Mastiff 91 Safety, Operation & Maintenance Manual
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Ransomes Mastiff 91 Safety, Operation & Maintenance Manual

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Safety, Operation & Maintenance Manual
Ransomes Mastiff 91 - Honda GX390 UT2 LXE4
Series: FN4 & FP4
Product code: LDEA330 & LDEA340
WARNING: If incorrectly used this machine can
cause severe injury. Those who use and maintain
this machine must be trained in its proper use,
warned of its dangers and must read the entire
manual before attempting to set up, operate, adjust
or service the machine.
GB
RJL 100 January 2015
United
Kingdom
WARNING
25081G-GB (Rev.0)
®

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  • Page 1 25081G-GB (Rev.0) ® Safety, Operation & Maintenance Manual Ransomes Mastiff 91 - Honda GX390 UT2 LXE4 Series: FN4 & FP4 Product code: LDEA330 & LDEA340 WARNING WARNING: If incorrectly used this machine can cause severe injury. Those who use and maintain...

  • Page 2: Table Of Contents

    Removing The Landroll Assembly ....... 31 Balance Bar (Walk Behind Machines Only) ....32 Seat (Steering Seat) ............. 32 Steering Control Cable (Steering Seat) ......32 Testing Gear Selection ..........33 Adjusting Gear Selector ..........33 © 2015, Ransomes Jacobsen Limited. All Rights Reserved...

  • Page 3: Introduction 2

    INTRODUCTION 2 IMPORTANT __________________________________________________________ The Ransomes Mastiff is a petrol-engine chain driven Cylinder mower. The cutting cylinder is chain driven. An OPC safety system is fitted. IMPORTANT: Follow the maintenance schedule indicated in this manual. In service performance will depend on the level of maintenance given.

  • Page 4: Product Identification

    2 INTRODUCTION PRODUCT IDENTIFICATION ___________________________________________ Maximum front axle load in Kg (for the machines driven on West Road the highway) Ransomes Europark Ipswich IP3 9TT Gross weight in Kg England Maximum rear axle load in Kg (for the machines driven...

  • Page 5: Guidelines For The Disposal Of Scrap Products

    If an item is not easily separated into different material groups, the material must be added to the “General discarded materials” area. • Do not burn discarded materials. The machinery records must show that the machine is not in operation and is discarded. Supply this serial number to Ransomes Jacobsen Warranty Department to close their records. en-5...

  • Page 6: Parts Manual

    2 INTRODUCTION PARTS MANUAL ______________________________________________________ In compliance with the ISO14001 standard, Ransomes Jacobsen Limited does not send a paper parts manual with every product. The parts manuals are available on-line or from Ransomes Jacobsen. Website – www.ransomesjacobsen.com. Select the “”GENUINE PARTS” tab followed by the “ON-LINE PARTS LOOK-UP”...

  • Page 7: Assembly

    INTRODUCTION 2 ASSEMBLY___________________________________________________________ Remove the sides and top of the container from the mower. Leave the mower on the base. Remove the plastic cover and cable ties that hold the handles in position. assembly the handle assembly (A) to the primary frame. Fit the top of the handles (B) and tighten the clamps (C).

  • Page 8: Safety

    Know the location and correct operation of controls. Operators without experience must receive instruction from another person that knows the correct operation of the equipment before you operate the mower. Only use parts, accessories and attachments approved by Ransomes Jacobsen. SAFE OPERATION Read the Operator’s Manual and other training material.

  • Page 9: Operation

    SAFETY 3 OPERATION Never operate the engine without enough ventilation or in an enclosed area. The carbon monoxide in the exhaust fumes can increase to dangerous levels. Never carry passengers. Keep other persons or animals away from the mower. Disengage all drives and engage the parking brake before you start the engine. Only start the engine with the operator in the seat.

  • Page 10: Rops

    3 SAFETY SAFE HANDLING OF FUELS The fuel and the fuel vapors are flammable. Use caution when you add the fuel to the mower. The fuel vapors can cause an explosion. Never use the containers that are not approved to keep or transfer fuel. Never keep the mower or fuel containers near an open flame or any device that can cause the ignition of fuel or fuel vapors.

  • Page 11: When You Put The Mower On A Trailer

    SAFETY 3 WHEN YOU PUT THE MOWER ON A TRAILER Be careful when you load or unload the mower on a trailer. Trailer must be wider than the mower and can carry the weight of the mower. Use a full-width ramp to load or unload the mower on a trailer. Use straps, chains, cables or ropes to fasten the mower to the trailer.

  • Page 12: Important Safety Notes

    By following all instructions in this manual, you increase the life of your machine and keep its maximum performance. Adjustments and maintenance must always be done by an approved technician. If additional information or service is needed. Contact your Authorized Ransomes Jacobsen Dealer, who knows the latest methods to service this equipment and can give that service.
  • Page 13 SAFETY 3 WARNING California Proposition 65 Engine Exhaust, Some Of Its Constituents, And Some Vehicle Components Contain Or Release Chemicals Known To The State Of California To Cause Cancer And Birth Defects Or Other Reproductive Harm. WARNING Explosive Gases Are Released By Batteries. The Battery Contains Corrosive Acid And Supply An Electrical Current That Is High Enough To Cause Burn Injuries To The Body.
  • Page 14 3 SAFETY WARNING Never Mow If There Is A Risk Of Lightning Or You Hear Thunder. If You Are In The Middle Of Mowing, Stop In A Safe Place, Turn Off The Engine And Go Inside a Building. CAUTION Personal Protective Equipment (PPE), For Example Safety Glasses, Leather Work Shoes Or Boots, A Hard Hat, Leather Work Gloves And Ear Protection Must Be Used After The Owner/User Completes A Local Risk Assessment Of The Mower, To Prevent Injury.
  • Page 15 SAFETY 3 NOTES en-15...

  • Page 16: Decals

    4 DECALS 4.1 SAFETY DECALS EC___________________________________________________ 009034910Read Operator's Manual. 009034890Keep a Safe Distance from the Machine. 009034920Stay Clear of Hot Surfaces. 009034940Caution Rotating Blades. 009034900Do Not Remove Safety Shields While Engine is Running. 009114100Danger of Explosion if the Battery Terminals are Short Circuited.

  • Page 17: Instruction Decals

    DECALS 4 4.2 INSTRUCTION DECALS _________________________________________________ 009034760 - Decal - Noise 100dB 4329286 - Decal - Ignition 009034990 - Decal - Forward / Reverse 4157021 - Decal - Throttle 009039700 - Decal - Parking Brake 4329286 009034990 en-17...

  • Page 18: Controls

    5 CONTROLS 5.1 THROTTLE CONTROL (A)_______________________________________________ Move the throttle lever forward to increase the engine speed which in turn engages the centrifugal clutch thus driving the machine. The direction of travel and blade engagement is determined by the gearbox selection levers noted in 5.4 & 5.5 OPERATOR PRESENCE CONTROL (B) Pushing the OPC down on the top handlebar allows the operator to engage the transmission, forward / reverse of...

  • Page 19: Choke Control

    CONTROLS 5 CHOKE CONTROL ____________________________________________________ Move the choke lever to the closed position to start the engine. Cold NOTE The choke may not be needed if the engine is warm or the air temperature is high. FUEL TAP ___________________________________________________________ The fuel tap (B) is turned on by moving the lever to the right. The tap is in the ‘off’...

  • Page 20: Operation

    6 OPERATION 6.1 DAILY INSPECTION _____________________________________________________ CAUTION THE DAILY INSPECTION SHOULD BE PERFORMED ONLY WHEN THE ENGINE IS OFF AND ALL FLUIDS ARE COLD. LOWER IMPLEMENTS TO THE GROUND, ENGAGE PARKING BRAKE, STOP ENGINE AND REMOVE IGNITION KEY. Perform a visual inspection of the entire unit, look for signs of wear, loose hardware and missing or damaged components.

  • Page 21: Operator Presence And Safety Interlock System

    OPERATION 6 OPERATOR PRESENCE AND SAFETY INTERLOCK SYSTEM _________________ The engine can be started but drive cannot be engaged until the operator presence system has been engaged. When the primary drive is engaged the machine will move forward, the cylinder will only rotate if the cylinder clutch is engaged.

  • Page 22: Operating Procedure

    6 OPERATION OPERATING PROCEDURE ______________________________________________ CAUTION To help prevent injury, always wear safety glasses, leather work shoes or boots, a hard hat and ear protection Under no circumstances should the engine be started with the operator presence system engaged. Do not operate the machine or attachments with loose, damaged or missing components. Whenever possible mow when grass is dry First mow in a test area to become thoroughly familiar with the operation of the machine and control levers.

  • Page 23: Before Starting The Engine For The First Time

    OPERATION 6 CAUTION Before you clean, adjust, or repair this equipment, always disengage all drives, lower implements to the ground, engage parking brake, stop engine and remove key from ignition switch to prevent injuries. Stop and inspect the equipment for damage immediately after striking an obstruction or if the machine begins to vibrate abnormally.

  • Page 24: Starting The Engine

    6 OPERATION STARTING THE ENGINE ________________________________________________ Electric Start Apply the brake.Turn starter switch (F) clockwise to the first position, then turn further clockwise to the start position and engine will start. If engine fails to start within 10 seconds, wait a further 30 seconds before attempting to start the engine again.

  • Page 25: Stopping The Machine

    OPERATION 6 Before starting the engine, check or set the following points: Check that the cylinder and landroll drive clutches are disengaged and the brake is applied. Turn the fuel tap B ‘on’ by positioning the lever vertically downwards. Move the choke control lever to the left for cold starting.

  • Page 26: How To Remove A Blockage From Cutting Units

    NOTE Make sure correctly selected PPE is worn before you clear the obstruction. use the Ransomes Jacobsen “Cutting Unit Tool” part number 4184540 See below or stout stick, put into the cutting cylinder between the blades. Rotate the cylinder with either the “Cutting Unit Tool” or “Stout Stick” until the obstruction has been removed.
  • Page 27 OPERATION 6 NOTES en-27...

  • Page 28: Adjustments

    7 ADJUSTMENTS 7.1 HEIGHT OF CUT ADJUSTMENT __________________________________________ The cutting height is determined by the position of the front rolls in relation to the bottom blade; variation of this setting is made by adjusting the front roll: Loosen the bolts securing the front roll brackets on both sides of the machine.

  • Page 29: Cylinder To Bottom Blade Adjustment

    ADJUSTMENTS 7 CYLINDER TO BOTTOM BLADE ADJUSTMENT_____________________________ To check that the cutting cylinder is set correctly to the bottom blade: tilt the machine back, hold a thin piece of paper between the edge of the blade and spiral cutters, and turn the cylinder manually.

  • Page 30: Chain Tensioners

    7 ADJUSTMENTS CHAIN TENSIONERS __________________________________________________ Automatic adjustment Self adjusting Chain Tensioners need No adjustment. BRAKE _____________________________________________________________ If adjustment is necessary: Slacken the locknut (A). Turn the adjusting screw (B) anti-clockwise. Re-tighten the locknut. Make certain that after adjusting there is still some slack movement on the lever to avoid the brake shoes rubbing against the landroll when the brake is disengaged.

  • Page 31: Removing The Cutting Cylinder And Bottom Blade Assembly

    ADJUSTMENTS 7 REMOVING THE CUTTING CYLINDER AND BOTTOM BLADE ASSEMBLY _______ Remove the chaincase and the cylinder drive chain. Tilt the machine back until it rests on the handles. Ensure ithe machine is fully supported before continuing Remove the front roll by extracting the pivot studs (A) and adjusting bolts (B) from both sides of the machine.

  • Page 32: Balance Bar (Walk Behind Machines Only)

    7 ADJUSTMENTS 7.10 BALANCE BAR (WALK BEHIND MACHINES ONLY) _________________________ When the machine is used without the grassbox fitted, the balance bar (Fig. 39), fitted at the base of the handle, must be removed and fitted to the grassbox arms. 7.11 SEAT (STEERING SEAT) _______________________________________________ The seat is adjustable forwards or backwards.

  • Page 33: Testing Gear Selection

    ADJUSTMENTS 7 7.13 TESTING GEAR SELECTION ____________________________________________ Perform the following tests to determine the correct function of the gear selection mechanism; do not use the machine until any failures have been rectified Select forward drive (A) using the gear lever, check the gear lever is still free to move and does not catch in the gate.
  • Page 34 7 ADJUSTMENTS Change the length of the gear lever by rotating the clevis joint until the holes in the clevis joint (K) and the hole in the bell crank (L) align. Refit the locating pin and repeat the checks detailed in section 9.13.
  • Page 35 ADJUSTMENTS 7 NOTES en-35...

  • Page 36: Maintenance And Lubrication

    8 MAINTENANCE AND LUBRICATION 8.0 MAINTENANCE & LUBRICATION CHART __________________________________ MACHINE SERVICE INTERVAL CHART 9 MAINTENANCE AND LUBRICATION CHART Interval Item Section  First 20 8.2.1 Change Engine Oil hours  Daily 8.2.1 Check Engine Oil Level. 10 hours 8.3.1 ...
  • Page 37 MAINTENANCE AND LUBRICATION 8 8.2.1 8.2.6 8.2.1 8.2.2 8.2.5 8.3.4 en-37...

  • Page 38: Lubrication

    8 MAINTENANCE AND LUBRICATION LUBRICATION ________________________________________________________ Before using the machine for the first time lubricate all points. For recommended lubricants see section 8.1. Should the number of working hours that the machine is in use during the indicated period exceed the number quoted in brackets, then use the recommended ‘working hour’...

  • Page 39: Machine

    MAINTENANCE AND LUBRICATION 8 8.1.2 MACHINE __________________________________________________________ LUBRICATE THE FOLLOWING WITH ENGINE OIL: Cutting cylinder bearings (A). Front rolls, or side rolls, where fitted (B). Landroll bearing housings (C). Outer landrolls on 91cm (36in) machine. CAUTION Contact With Engine Oil Can Damage Your Skin.

  • Page 40: Gearbox

    8 MAINTENANCE AND LUBRICATION 8.1.5 Gearbox ___________________________________________________________ CHECK OIL LEVEL Release screws on both sides of cover and remove cover over gearbox and clutch shaft. Remove filler plug (C) and using the straight dipstick check level of oil. Top up, if necessary, to level indicated on the dipstick with recommended oil.

  • Page 41: Maintenance

    MAINTENANCE AND LUBRICATION 8 MAINTENANCE 8.2.1 Cooling fins and Air intake ____________________________________________ Check to ensure that the air blower and cooling fins (A) Linkages and exhaust (B) are kept free of all grass clippings and debris. This is essential to allow the free passage of air so that the cooling system functions correctly.

  • Page 42: Battery

    8 MAINTENANCE AND LUBRICATION BATTERY ____________________________________________________________ Before you service the battery, make sure the ignition switch is in the OFF position and the key is removed. CAUTION When you service the battery, use correctly insulated tools. Wear applicable eye protection and clothing. Discard used batteries as shown in your local regulations.

  • Page 43: Clean Fuel Filter

    MAINTENANCE AND LUBRICATION 8 CLEAN FUEL FILTER __________________________________________________ Drain the fuel tank Turn the fuel valve lever to the ON position. Loosen the carburetor drain bolt. Drain the fuel from the carburetor and fuel tank into an approved container. CAUTION Contact With Fuel Can Damage Your Skin.

  • Page 44: Problem Solving

    9 PROBLEM SOLVING 9.1 PROBLEM SOLVING GENERAL FAULT REMEDY variations in the height of cut grass across the Front rolls are not square with bottom blade. width of cut Make necessary adjustment as per instruction in section 7.1 Grass is cut unevenly in wavy or hummocky Alignment of cutting cylinder has been upset, fashion probably through running into an obstruction.
  • Page 45 PROBLEM SOLVING 9 NOTES en-45...

  • Page 46: Schematics

    10 SCHEMATICS 10.1 ELECTRICAL CIRCUIT_________________________________________________ OIL_ALT EXT (-) EXT (+) en-46...
  • Page 47 SCHEMATICS 10 12.1 ELECTRICAL CIRCUIT Starter Solenoid (Battery Positive) Starter Solenoid (Actuator) Starter Motor Battery Engine Ground Ignition Coil Spark Plug Emergency Kill Switch Ignition Switch Start Control Stop Relay Gear Switch Operator Presence Control Delay Unit Operator Presence Control Switch Fuse 2 Power Diode Fuse 1...

  • Page 48: Torques

    11 TORQUES 11.1 TORQUES ____________________________________________________________________ FINE PITCH METRIC THREADS COARSE PITCH METRIC THREADS Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade (mm) 10.9 12.9 (mm) 10.9 12.9 (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) 1152 1055 1266 1327...

  • Page 49: Specification

    SPECIFICATIONS 12 12.1 ENGINE SPECIFICATION _______________________________________________ Honda Manufacture Honda GX390 UT2 LXE4 Model ID Air Cooled 4 Stroke Overhead valve Single Cylinder Type 389 cm³ Petrol with 2:1 Reduction Unit 8.7kW @ 3600 rpm 11.7 hp @ 3600rpm Net Power 2550 ±...

  • Page 50: Machine Specification

    12 SPECIFICATIONS 12.3 MACHINE SPECIFICATION______________________________________________ Chassis: Pressed steel welded fabrication. Transmission: Gearbox with half speed reverse to heavy duty roller chains to Land roll and cutting cylinder. Clutches: Main centrifugal clutch. Separate Land roll clutch. and Cylinder clutch. Front roll: One piece steel roll runningon ball bearings.

  • Page 51: Vibration Level

    Information Supplied for Physical Agents Directive 2002/44/EC By reference to: Hand/Arm Standards: BS EN ISO 5349-1 (2001) BS EN ISO 5349-2 (2002) Series FN1 & FP1 Ransomes Mastiff Max. LH or RH Accelerations m/s² Hand / Arm Acceleration Mean Value of X, Y, Z Aeq Level 4.64 ±...

  • Page 52: Noise Level

    12 SPECIFICATIONS 12.5 NOISE LEVEL ________________________________________________________ When the machine was tested for sound pressure (Operator Ear). The Machinery Safety Directive 2006/42/EC Exposure Of Workers To The Risks Arising From Physical Agents (Noise) Directive 2003/10/EC By compliance to: The Lawnmower Standard BS EN ISO 5395:2013 Sound Pressure Standard EN ISO 3746: 2010 Measured Sound Pressure 87 dB(A) ±...

  • Page 53: Recommended Lubricants

    An EC Certificate of Incorporation is included in this manual. 10.3 GROOVED ROLL LMSE167-Grooved Front Roll Assembly Refer to parts manual 10.4 BRUSH KIT LMAB 997 - Brush Kit, Mastiff 91 Refer to parts manual 10.5 TIP-OVER GRASSBOX LMAB885 - Standard Grass-box. LMAA768D - Self Emptying Grass-box.

  • Page 54: Certificates Of Conformity

    12 SPECIFICATIONS 10.6 SIDE ROLLS Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, England, IP3 9TT LDEA330 LDEA340 Ransomes mastiff 91 Walk Behind Reel Mower FN100301 - FN999999 FP100301 - FP999999 Honda GX390 UT2 LXE4 8.7 kW @ 3000 RPM...
  • Page 55 BS ISO 2631-1:1997 (Vibration W/B) ANSI B71.4-2012 Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, England, IP3 9TT 1st December 2014 Signature of the person empowered to draw up the declaration on behalf of the manufacturer, holds the technical documentation and is authorised to compile the technical file, and who is established in the Community.
  • Page 56 12 SPECIFICATIONS Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, England, IP3 9TT Product Code Serial Number Description LMAB029 Trailing Seat We undertake to transmit, in response to a reasoned request by the national authorities, relevant information on the partly completed machinery. This shall be by hardcopy and shall be without prejudice to the intellectual property rights of the manufacturer of the partly completed machinery.
  • Page 57 These accessories have been designed to be fitted to the La quasi-macchina non deve essere messa in servizio finché la macchina finale in cui deve essere incorporata non è stata dichiarata conforme, nel caso, alle disposizioni della Direttiva Ransomes Mastiff 91 2006/42/CE. LDEA230 / LDEA240 LDEA330 / LDEA340 Dalinai užbaigto mechanizmo negalima paleisti kol kiti mechanizmai, kurie dar bus prijungti, nebus patvirtinti kaip atitinkantys 2006/42/EC Direktyvos reikalavimus.
  • Page 58 12 SPECIFICATIONS ERKLÆRING Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, England, IP3 9TT Product Code Serial Number Description LMAC253 Steering Seat We undertake to transmit, in response to a reasoned request by the national authorities, relevant information on the partly completed machinery. This shall be by hardcopy and shall be without prejudice to the intellectual property rights of the manufacturer of the partly completed machinery.
  • Page 59 La quasi-macchina non deve essere messa in servizio finché la macchina finale in cui deve essere incorporata non è stata dichiarata conforme, nel caso, alle disposizioni della Direttiva Ransomes Mastiff 91 2006/42/CE. LDEA230 / LDEA240 Dalinai užbaigto mechanizmo negalima paleisti kol kiti mechanizmai, kurie dar bus prijungti, nebus patvirtinti kaip atitinkantys 2006/42/EC Direktyvos reikalavimus.

  • Page 60: Guarantee

    13 GUARANTEE WARRANTY Warranty is subject to specific terms and conditions, e.g. wearing parts, unapproved modifications, etc. are not included. For a full set of warranty conditions, contact your local dealer or distributor. SERVICE A network of authorised Sales and Service dealers has been established and these details are available from your supplier.
  • Page 62 Europe & Rest of The World Except North & South America Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, IP3 9TT English Company Registration No. 1070731 www.ransomesjacobsen.com North & South America Jacobsen, A Textron Company 11108 Quality Drive, Charlotte, NC 28273, USA...

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