Ransomes Frontline 960 (Engine Type: Perkins 404C-22T). Parts and Maintenance Manual (2002)

24598G (rev.0)

Parts and Maintenance Manual

Nomenclature Des Pieces De Rechange

& Manuel De Maintenance

Onderhouds - En Onderdelenhandleiding

Wartungsanleitung Und Stückliste

Manuale Per La Manutenzione E Dei Ricambi

Frontline 960

Series: LQ

Engine Type: Perkins 404C-22T

Product Codes: LHAM001

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.

AVERTISSEMENT : Risque de blessures graves en cas

d’utilisation incorrecte de la machine. Les opérateurs et le

personnel d’entretien doivent être formés et conscients des

dangers encourus. Ils doivent lire avec attention le manuel

avant d’essayer de monter, d’utiliser, de régler ou maintenir la

machine.

WAARSCHUWING: Bij verkeerd gebruik kan deze machine

ernstig lichamelijk letsel veroorzaken. Degenen die de machine

gebruiken en onderhouden moeten worden getraind in het

juiste gebruik ervan, worden gewaarschuwd voor de

gevaren ervan en behoren de volledige handleiding

aandachtig te lezen alvorens de machine bedrijfs-klaar te

maken, te bedienen, af te stellen en/of te onderhouden.

WARNHINWEIS: Wenn diese Maschine nicht ordnungsgemäß

verwendet wird, können ernsthafte Verletzungen verursacht

werden. Personen, die diese Maschine verwenden und

warten, müssen in ihrer richtigen Verwendung ausgebildet

sein, auf die Gefahren aufmerksam gemacht worden sein

und die Anleitung ganz gelesen haben, bevor sie versuchen,

die Maschine aufzustellen, zu bedienen, einzustellen oder

zu warten.

AVVERTENZA: Questa macchina può causare gravi infortuni

se viene utilizzata in modo errato. Prima di accingersi ad

approntare, usare, mettere a punto o eseguire la manutenzione

di questa macchina, coloro che la utilizzano ed i responsabili

della manutenzione devono essere addestrati all’impiego della

macchina, devono essere informati dei pericoli, e devono

leggere l’intero manuale.

RJ 100 / 082002

CONTENTS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

CONTENTS

INTRODUCTION

2.1

PRODUCT IDENTIFICATION

2.2

SPARES STOCKING GUIDE

2.3

HOW TO USE THE PARTS MANUAL

SAFETY INSTRUCTIONS

3.1

OPERATING INSTRUCTIONS

3.2

SAFETY SIGNS

3.3

STARTING THE ENGINE

3.4

DRIVING THE MACHINE

3.5

TRANSPORTING

3.6

LEAVING THE DRIVING POSITION

3.7

SLOPES

3.8

BLOCKED CUTTING CYLINDERS

3.9

ADJUSTMENTS, LUBRICATION AND MAINTENANCE

5/6

SPECIFICATION

4.1

ENGINE SPECIFICATION

4.2

MACHINE SPECIFICATION

4.3

DIMENSIONS

4.4

VIBRATION LEVEL

4.5

SLOPES

4.6

RECOMMENDED LUBRICANTS

4.7

CUTTING PERFORMANCE (AREA)

4.8

TORQUES

LUBRICATION AND MAINTENANCE

LUBRICATION AND MAINTENANCE CHARTS

9/10

5.1

ENGINE: FIRST 50 WORKING HOURS AND EVERY 250 WORKING HOURS

5.2

MACHINE: LUBRICATE THE FOLLOWING POINTS WITH SHELL

DARINA R2 GREASE WEEKLY (EVERY 40 WORKING HOURS):

5.3

MACHINE: EVERY 400 WORKING HOURS

5.4

HYDRAULIC TEST PORTS

5.5

ENGINE MAINTENANCE: EVERY 250 HRS

5.6

ENGINE MAINTENANCE: EVERY 400 HRS

5.7

MACHINE MAINTENANCE

5.8

END OF SEASON SERVICING

ADJUSTMENTS

6.1

SPEED LIMITER

6.2

REAR WHEEL TOE-IN

6.3

ALTERNATOR

CUTTER DECK ADJUSTMENTS

7.1

CUTTER DECK TENSION

7.2

BLADE SHARPENING & REMOVAL

TROUBLESHOOTING

8.1

GENERAL

SCHEMATICS

9.1

HYDRAULIC CIRCUIT

9.2

ELECTRICAL CIRCUIT INSTRUMENT

9.3

ELECTRICALCIRCUIT MAIN

9.4

ELECTRICAL FUSES/RELAYS

23/24

PARTS LIST

PARTS-1

GB-1

INTRODUCTION

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

2.1 PRODUCT IDENTIFICATION

A Machine Name

B Serial Number

C Year of Manufacture

D Machine Weight

E 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

Description

Part No.

Description

Engine Oil Filter

178025

Hydra

26560017

Engine Fuel Filter

4126806

Electric Fuel Pump

4123044

Air Cleaner Element

5001182

In-line Fuel Filter

008089620

Hydra

Service Support Material

Part No

Description

Part No.

Description

Machine Maintenance

Engine Parts Manual

24598G

and Parts Manual

Engine Operators

Machine Safety and

24597G

Manual

Operators Manual

Engine Service

Machine Service

Manual

GB-2

INTRODUCTION

FRONTLINE 960 Series: LQ

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.

4295

MBG2504

BRACKET

4296

MBG3848

LATCH

4298

450865

SCREW, M8 x 20, SCKT CSK HD

4300

450378

NUT, M8 NYLOC

4301

Wl001

Set Of Wheels

4301.1

008162130

• Wheel & Hub Assy

(Rear)

4301.2

008170390

• • Tyre

4301.3

008161830

• • Rim

4301.4

008169140

• • Hub Assy.

4301.5

008169150

• • Cap

4301.6

002993010

• • Lubricator

4301.7

008161990

• Wheel & Tyre

(Front)

4301.8

008170780

• • Tyre

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.

Spare Parts can also be ordered direct from the TEXTRON DIRECT web site at www.textrondirect.com

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

SAFETY INSTRUCTIONS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

This safety symbol indicates important safety

•

Remember that some people are deaf

messages in this manual. When you see this

or blind and that children and animals

symbol, be alert to the possibility of injury, carefully

can be unpredictable.

read the message that follows, and inform other

•

Keep travelling speeds low enough for

operators.

an emergency stop to be effective and

safe at all times, in any conditions.

3.1 OPERATING INSTRUCTIONS

•

Remove or avoid obstructions in the

•

Ensure that the instructions in this book

area to be cut, thus reducing the

are read and fully understood.

possibility of injury to yourself and/or

•

No person should be allowed to operate

bystanders.

this machine unless they are fully

•

When reversing, take special care to

acquainted with all the controls and the

ensure that the area behind is clear of

safety procedures.

obstructions and/or bystanders. DO

•

Never allow children or people unfamiliar

NOT carry passengers.

with these instructions to usethis

•

Keep in mind that the operator or user is

machine. Local regulations may restrict

responsible for accidents or hazards

the age of the operator.

occurring to other people or their

property.

3.2 SAFETY SIGNS

•

When the machine is to be parked,

•

It is essential all safety labels are kept

stored or left unattended, lower the

legible, if they are missing or illegible they

cutting means unless the transport

must be replaced. If any part of the

locks are being used.

machine is replaced and it originally

•

While mowing, always wear substantial

carried a safety label, a new label must be

footwear and long trousers. Do not

affixed to the replacement part. New

operate the equipment when barefoot or

safety labels are obtainable from

wearing open sandals.

Ransomes dealers.

•

Check the grass catcher frequently for

wear or deterioration. After striking a

3.3 STARTING THE ENGINE

foreign object. Inspect the lawnmower

•

Before starting the engine check that the

for damage and make repairs before

brakes are applied, drives are in neutral,

restarting and operating the equipment.

guards are in position and intact, and

•

If the machine starts to vibrate

bystanders are clear of the machine.

abnormally, check immediately.

•

Do not run the engine in a building without

adequate ventilation.

3.5 TRANSPORTING

•

Ensure that the cutting units are

3.4 DRIVING THE MACHINE

securely fastened in the transport

•

Before moving the machine, check to

position. Do not transport with cutting

ensure that all parts are in good working

mechanism rotating.

order, paying particular attention to

•

Drive the machine with due

brakes, tyres, steering and the security of

consideration of road and surface

cutting blades.

conditions, inclines and local

•

Replace faulty silencers, mow only in

undulations.

daylight or good artificial light

•

Sudden decelerating or braking can

•

Always observe the Highway Code both

cause the rear wheels to lift.

on and off the roads. Keep alert and

•

Remember that the stability of the rear

aware at all times. Watch out for traffic

of the machine is reduced as the fuel is

when crossing or near roadways.

used.

•

Stop the blades rotating before crossing

surfaces other than grass.

GB-4

SAFETY INSTRUCTIONS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

3.6 LEAVING THE DRIVING POSITION

•

To reduce the fire hazard, keep the engine,

•

Park the machine on level ground.

silencer and battery compartments free of

grass, leaves or excessive grease.

•

Before leaving the driving position, stop

•

Replace worn or damaged parts for safety.

the engine and make sure all moving

•

When working underneath lifted parts or

parts are stationary. Apply brakes and

machines, make sure adequate support Is

disengage all drives. Remove the starter

provided.

key.

•

Do not dismantle the machine without

releasing or restraining forces which can

3.7 SLOPES

cause parts to move suddenly.

TAKE EXTRA CARE WHEN WORKING ON

•

Do not alter engine speed above maximum

SLOPES

quoted in Engine Specification. Do not

•

Local undulations and sinkage will change

change the engine governor settings or

the general slope. Avoid ground

overspeed the engine. Operating the engine

at excessive speed may increase the hazard

conditions which can cause the machine

of personal injury.

to slide.

•

When refuelling, STOP THE ENGINE, DO

•

Keep machine speeds low on slopes and

NOT SMOKE. Add fuel before starting the

during tight turns.

engine, never add fuel while the engine is

•

Sudden decelerating or braking can

running.

cause the rear wheels to lift. Remember

•

Use a funnel when pouring fuel from a can

there is no such thing as a “safe” slope.

into the tank.

•

Travel on grass slopes requires particular

•

Do not fill the fuel tank beyond the bottom of

care.

the filler neck.

•

Replace all fuel tank and container caps

DO NOT USE ON SLOPES GREATER THAN 15°

securely.

•

Store fuel in containers specifically designed

for this purpose.

IMPORTANT: When working on any slope set the

•

Refuel outdoors only and do not smoke while

weight transfer, if fitted to its maximum (+) setting.

refuelling.

•

If fuel is spilled, do not attempt to start the

3.8 BLOCKED CUTTING CYLINDERS

engine but move the machine away from the

•

Stop the engine and make sure all moving

area of spillage and avoid creating any

parts are stationary.

source of ignition until fuel vapours have

•

Apply brakes and disengage all drives.

dissipated.

•

Release blockages with care. Keep all parts

•

Allow the engine to cool before storing in any

of the body away from the cutting edge.

enclosure.

Beware of energy in the drive which can

•

Never store the equipment with fuel in the

cause rotation when the blockage is

tank inside a building where fumes may

released.

reach an open flame or spark.

•

Keep other people away from the cutting

•

If the fuel tank has to be drained, this should

units as rotation of one cylinder can cause

be done outdoors.

the others to rotate.

•

Do not spill fuel onto hot components.

•

When servicing batteries, DO NOT SMOKE,

3.9 ADJUSTMENTS, LUBRICATION AND

and keep naked lights away.

MAINTENANCE

•

Do not place any metal objects across the

•

Stop the engine and make sure all moving

terminals.

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.

GB-5

SAFETY INSTRUCTIONS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

DANGER - Indicates an imminently hazardous

IMPORTANT: Transport speed is for highway

situation which, if not avoided, WILL result in

use only. Never select transport speed

death or serious injury.

on grass areas or uneven or unsurfaced

roads or tracks.

WARNING - Indicates a potentially hazardous

situation which, if not avoided, COULD result

The operating instruction for the Cutting Units are

in death or serious injury.

contained in a separate Publication.

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

California Proposition 65

Engine Exhaust, some of its constituents,

Hydraulic Fluid escaping under pressure

and certain vehicle components contain or

can penetrate skin and do serious

emit chemicals known to the state of

damage. Immediate medical assistance

California to cause cancer and birth defects or

must be sought.

other reproductive harm

WARNING

Batteries produce explosive gases and

DO NOT USE ON SLOPES GREATER THAN 15°

contain corrosive acid and supply levels

of electrical current high enough to cause

burns.

WARNING

Before releasing transport latches it is

important that all cutting units are fully raised.

Park the machine on level ground.

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.

Disengage drives, stop the engine and

make sure all moving parts are

stationary. Apply brakes and remove

the starter key.

transport latches can now be released.

GB-6

SPECIFICATIONS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

4.1

ENGINE SPECIFICATION

4.3

DIMENSIONS

Width of cut:

TYPE:

Perkins 45KW (60HP) @ 2800

9'8" Model

2.95 metres (116in)

RPM, 4 cylinder (in line) vertical

10'7" Model

3.23 metres (127in)

Diesel engine, 4 stroke, water

Overall width:

metres (in)

cooled, 2200cc (135.2 cu.in)

Overall width:

1.55 metres (61in)

with 12V electric start.

(transport)

Model:

404C-22T

Overall height:

1.35 metres (53in)

Maximum Speed:

3000 ± 25 RPM (No load)

Overall length:

3.1 metres (122in)

Idle Speed:

1250 ± 50 RPM

Overall weight of

Oil Sump Capacity:10.6 litres (18.65 Imp.pints)

machine:

Fuel:

No. 2-D Diesel fuel (ASTM D975)

9'8" Model

1554 kg (3426 lb)

10'7" Model

1577 kg (3476lb)

4.2

MACHINE SPECIFICATION

4.4

VIBRATION LEVEL

The machine was tested for whole body and hand/

Frame construction:Heavy duty formed steel chassis

arm vibration levels. The operator was seated in the

with box section frame rails.

normal operating postion with both hands on the

Cutting unit drive:

Fixed displacement hydraulic

steering mechanism. The engine was running and

motors coupled to cutting means

the cutting device was rotating with the machine

through drive belt.

stationary.

Transmission:

Full time 4-wheel drive. Direct

coupled variable displacement

Standard ISO 5349: 1986 Mechanical vibration.

pump to direct coupled 280cc

Guidelines for the measurement and the

(17.1 cu in) front, 237cc (14.5 cu

Max LH or RH

in) rear wheel motors.

FRONTLINE 960

Accelerations m/s²

Speeds:

SeriesLQ

Cutting:

0 - 12km/h (0 - 7.5 mph)

Hand / Arm Acceleration

XAeq

Y Aeq

Z Aeq

leve l

FORWARD

0.6

0..33

0.19

Transport:

0 - 22km/h (0 - 13.7mph)

Dominant Value

0.64

FORWARD

Reverse:

0 - 12km/h (0 - 7.5 mph)

Steering:

Hydrostatic power steering, with

assessment of human exposure to hand-transmitted

adjustable tilt steering wheel.

vibration.

Tyres:

Front -

Front - 24 x 13 - 12 4 ply rating

Standard ISO 2631-1: 1985 Evaluation of human

turf

Rear -

Rear - 20 x 10.00 - 8 6 ply rating

FRONTLIN E

turf

960

Floor Locatio n

Seat Location

SeriesLQ

Pressures:

Front tyres20 p.s.i. (1.4 kg/cm²)

Accelerations m/s²

Whole Bod y

Rear tyres14 p.s.i. (1 kg/cm²)

Acceleratio n

leve l

Ground pressure:

14p.s.i. (1 kg/cm²)

Mea n

0.06

0.05

0.18

0.05

0.02

Brakes, Service:

Positive hydrostatic braking.

Parking:

Fail safe, Oil immersed wet disc

exposure to whole body vibration -- Part 1: General

brakes.

requirements.

Fuel Tank

Capacity:

45.4 litres (10 Imp. galls) 12 US

4.5

SLOPES

galls

Hydraulic Tank

DO NOT USE ON SLOPES GREATER THAN 15°

Capacity:

18.8 litres (4.14 Imp. galls) 5 US

The slope 15° was calculated using static stability

galls

measurements according to the requirements of

EN 836.

Battery:

Exide 065

GB-7

SPECIFICATIONS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

4.6

RECOMMENDED LUBRICANTS

Engine oil:

Should be to MIL-L-2104C or to

A.P.I. Classification SE/SF/SG

grades. [10W-30]

Hydraulic Oil:

Shell Tellus 46

Grease:

Shell Darina R2, or equivilant.

4.7

CUTTING PERFORMANCE (AREA)

9'8" Model

3.2 hectares/hr. at 12 km/hr. ( 7.9 acres/hr at 7.5

mph)

10'7" Model

3.5 hectares/hr. at 12 km/hr. ( 8.65 acres/hr at 7.5

mph)

10% allowance is included for normal overlaps and

turning at the end of each cut.

4.8

TORQUES

FINE PITCH METRIC THREAD S

CORSE PITCH METRIC THREAD S

GRAD E

(mm

)

(mm

)

(Nm

)

(Nm)

(Nm

)

(Nm)

106

100

113

159

191

104

146

175

179

252

302

165

232

278

103

137

274

385

462

129

257

362

434

209

279

557

783

940

188

251

502

706

847

281

375

750

1055

1266

256

341

683

960

1152

354

472

944

1327

1593

325

434

868

1220

1464

514

686

1371

1928

2314

476

635

1269

1785

2142

715

954

1908

2683

3219

646

862

1723

2424

2908

964

1286

2572

3616

4340

822

1097

2193

3084

3701

1196

1594

3189

4484

5381

1129

1506

3012

4235

5082

UNF THREAD S

UNC THREAD S

GRAD E

Dia (in)

(lbf.

)

(lbf.

)

(lbf.

125

152

112

135

131

141

179

217

117

127

161

195

183

197

250

303

162

175

222

269

118

319

344

437

529

106

288

310

394

477

188

509

550

697

845

171

464

500

635

769

279

757

817

1036

1255

256

695

749

950

1152

405

1099

1186

1504

1823

363

984

1062

1347

1632

563

1529

1650

2093

2535

511

1387

1497

1899

2300

759

2061

2224

2821

3418

670

1820

1963

2490

3017

996

2703

2917

3699

4482

889

2414

2605

3303

4002

GB-8

LUBRICATION AND MAINTENANCE

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

LUBRICATION AND MAINTENANCE CHART

B lack bullet points are operator checks and w hite bullet points are w orkshop maintenance procedure s

Firs t

Every

End

Daily

Every

250

400

600

50 hours

hours

Season

ENGINE (Service As Per Engine

Manual)

C heck/Top-up Oil Leve l

C hange Oil

C lean Air Filter Element & Particle

Collector

C hange Air Filter Elemen t

C hange Oil Filter C artridg e

Replace Fuel Filters

MACHIN E

C heck Interlock Syste m

C heck/Top-up C oolant Leve l

C heck Tyre Pressure

C heck/Top-up Hydraulic Fluid

C heck/C lean & Remove Grass fro m

E ngine C ompartment, Pum p

Conpartment, Bug Screen & Radiator

C heck Nuts & Bolts For Tightnes s

C heck Hydraulic Fittings For Tightnes s

C heck Rear Wheel Toe-in

C heck Battery C onditio n

C heck Fan Belt Tensio n

C hange Hydraulic Oil & Filte r

Drain & Clean Fuel Tank

Drain & Flush Cooling System

*Service more often in dirty condition s

Lubricate the Grease Fittings with Shell Darina R2 grease weekly (SEE CHAR

)

GB-9

LUBRICATION AND MAINTENANCE

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

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

10.6 litres of oil(with filter).

Fig.1

A Oil Fill, B Dipstick, C Oil fill

Fig.1

Change Engine Oil Filter (A)

(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.

5.2

MACHINE: Lubricate the following

points. Weekly or every 40 working

hours.

1. Lubricate the following with Shell Darina R2

grease. (Fig.3)

(a)

Lift arm pivots.

(b)

Rear Axle centre pivot.

(c)

Steering rams-inner pivots.

(d)

Steering ram rod end.

(e)

Steering Track Rod, Rod End.

(f)

Lift arm yoke pivots.

(g)

Belt pulleys.

(h)

Deck Castor wheels

GB-11

LUBRICATION AND MAINTENANCE

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

LUBRICATION

5.3

MACHINE: Every400 Working Hours.

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

Fig.4

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.

Hydraulic oil type requirements:

Shell Tellus 46

Fig.5

Change Hydraulic Oil Filter (CHARGE) (Fig.6)

Wipe filter canister and housing to remove any dirt

present.

Place a suitable drip tray under the filter.

Un-screw filter canister and remove the filter

element and dispose of safely.

Replace with new filter element.

Coat the top outside lip of the filter canister with a

thin film of oil and refit the filter canister.

Filter should be replaced before refilling hydraulic

tank.

Fig.6

GB-12

LUBRICATION AND MAINTENANCE

FRONTLINE 960 Series: LQ

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):

Front Cutter Deck Pressure: 220 bar

(3200 psi). (A(Fig.7)).

Lift Pressure : 63.5 bar (920 psi).

(B(Fig.7)).

RH & LH Cutter Deck Pressure: 210 bar

Fig.7

(3045 psi). (A(Fig.8 & 9)).

FWD Transmission Pressure : 250 bar

(3625 psi). (A(Fig.10)).

REV Transmission Pressure : 210 bar

(3045 psi). (B (Fig.10)).

Charge Pressure : 15.8 - 19.3 bar

(230-280 psi). (Either A or B(Fig.10))

NOTE: Any servicing of the hydraulic system

must be carried out by trained service

personnel.

Fig.8

Fig.9

Fig.10

GB-13

LUBRICATION AND MAINTENANCE

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

MAINTENANCE

5.5

ENGINE MAINTENANCE: Every 250 hrs

Fuel System:

Use Diesel fuel No.2-D (ASTM D975)

See engine manufacturer's manual for additional

information.

Changing fuel filter (Fig.10)

Unscrew filter screw (A) from filter head.

Bleed air from system as described in

section 5.5

Fig.10

Bleeding air from fuel system

Turn the ignition switch to the ON position

(dont start engine)

Open air vent A onto top of fuel filter to

allow air to escape.(Fig.10)

Retighten air vent.

Open air vent (A) on side of injector pump

to allow air to escape.(Fig.11)

Retighten air vent

Turn ignition to OFF.

Fig.11

GB-14

LUBRICATION AND MAINTENANCE

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

MAINTENANCE

5.6

ENGINE MAINTENANCE: Every 400 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.

Fig.12

To close the cover reverse operation.

NOTE: Extensive damage to engine can result

from an inadequate air supply.

5.7

MACHINE MAINTENANCE

bearing seals and cause premature bearing failure.

Storage

•

Store petrol or diesel fuel in an approved

Battery.

container in a cool dry place.

Keep fluid levels above battery plates.

•

Keep the machine and fuel containers in a

locked storage place to prevent tampering

WARNING

and to keep children from playing with

them.

Wear eye protection when servicing battery.

•

Do not store fuel or petrol/diesel fuel

powered equipment in any closed area

where heating appliances, pilot lights or

Other Regular Service.

any sort of open flame is present.

•

Verify proper operation of safety interlock

•

Before storing, allow the engine to cool,

switches (Neutral switch, Seat switch,

and drain fuel completely from fuel tanks

etc.)

and containers.

•

Ensure nuts and bolts remain tight.

•

Maximum safety and best mowing results

•

Keep tyre pressure at 1kg/cm² (14psi).

can only be expected if the mower is

•

Follow the engine manufacturer’s

maintained and operated properly.

maintenance recommendations.

•

If a label becomes worn or removed, see

WARNING

the LABELS section of this manual or the

tractor Parts Manual for replacement

Battery posts, terminals and related

information.

accessories contain lead and lead

compounds.

NOTE: When washing machine with pressure spray

washers or steam cleaners, avoid washing bearing

WASH HANDS AFTER HANDLING

areas because cleaning solutions might penetrate

GB-15

LUBRICATION AND MAINTENANCE

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

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

Fig.13

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.

Hydraulic oil type requirements:

Shell Tellus 46

Change Hydraulic Oil Filter(Fig.6 Ref to pg 12)

Wipe filter canister and housing to remove any dirt

present.

Place a suitable drip tray under the filter.

Un-screw filter canister and remove the filter

element and dispose of safely.

Fig.14

Replace with new filter element.

Coat the top outside lip of the filter canister with a

thin film of oil and refit the filter canister.

Filter should be replaced before refilling hydraulic

tank.

Change Coolant.

Completely drain the cooling water from

the radiator and flush the cooling system

with flushing detergent. Drainplugs A.

Check for leaks or loose connections at

the radiator, cylinder head gasket, etc.

Mix antifreeze coolant and water at the

specified ratio before pouring into the

engine.

Note:

When topping up the cooling system fill

Fig.15

with 50/50 solution.

GB-16

ADJUSTMENTS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

ADJUSTMENTS

6.1

SPEED LIMITER

NOTE: Textron Turf Care cannot be held responsible

The transport and mow speeds are factory set and

for loss of performance or machine damage if these

should not need altering.

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:

Loosen alternator bolts A.

Move the alternator to tighten or loosen fan

belt.

Tighten bolts A.

Check belt tension and condition of belt every 250

hours.

Fig.17

GB-17

CUTTER DECK ADJUSTMENTS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

CUTTER DECK ADJUSTMENTS

7.1

CUTTER DECK BELT TENSION

Check all belts regularly during the first 5, 10 and 15

hours of operation, and then after every 50 hours of

operation. If necessary adjust as follows:

CENTER DECK

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 adjust-

ment bolt E.

WING DECKS

1. Adjust belt tension to 3/8” (10 mm) deflection at

10 lbs (5 kg) force at the middle of the long rear

span H. If necessary, adjust as follows:

2. Loosen locking nut on adjustment bolt L.

3. Loosen two bolts I fastening the idler plate to

the cutter deck.

4. Turn adjustment bolt L until proper tension is

obtained.

5. Retighten bolts I and lock nut on adjustment

bolt L.

GB-18

CUTTER DECK ADJUSTMENTS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

CUTTER DECK ADJUSTMENTS

7.2

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 Ran-

somes 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

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.

GB-19

TROUBLESHOOTING

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

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.

Symptom s

Possible Causes

Action

Section

1. Reset ignition switch and alow glow plug

1. Glow Plug has not

time out before cranking engine.

2. Battery

defective

connections.

3. Fuel tank empty or

3. Fill tank withfreshfuel. Change

contaminated .

from

Engine will not start.

4. Blown Fuse.

4. Replace Fuse.

5. Defective Starter Relay.

5. Test and replace relay if neccesary.

6.Forward/Reverse pedal

6. Ensure Forward/Reverse pedal neutral

depressed.

not depressed .

7. Mow switch set

7. Set mow switchto off.

1. Fuel tank empty or

1. Fill tank withfreshfuel. Change

contaminated .

from

Engine hard

2. Air Cleaner blocked or dirty

2. Check air cleaner, replace as neccesary.

or runs poorl.

3. Injectors,

3. Cons

4. Other Engine Problem

4. Consult engine

1. Fuel

1. Fill withfreshfuel and bleed

Engine Stops.

2. Set mow switchto off. Ensure

leaving operators seat

neutral

1. Coolant level

required

Engine Overheating.

2. Radiator air intake restricted

2. Clean wire mesh guard at radiator.

3. Waterpump/alternator belt or

3. Inspect waterpump/alternator belt and

fan belt

ighten if neccesary.

1. Loose or corroded battery

1. Inspect terminals, clean and

terminals

required

2. Low electrolyte level

Battery not holding

2. Refill battery with diste

battery.

charge. Battery

on.

3. Alternator belt

broken.

neccesary.

4. Alternator defective

4. See engine manual.

1. Cylinder

1. Inspect cylinder

adjusted properl.

2. Engine speed too

2. Check engine speed, run engine at full throt

3. C

3. Adjust cylinder speed

unevenly. Poo r

for

quality of cut.

4. Cylinder direction

4. Set cylinder direction lever to

in reverse

5. Ground weight incorrect

5. Adjust ground weight control valve until correct

adjusted

ground weight is achieved .

GB-20

SCHEMATICS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

9.2

ELECTRICAL CIRCUIT INSTRUMENT

KEY TO WIRING DIAGRAM

Key Switch

Split to Main Harness No.3

OFFPosition

Split to Main Harness No.4

HEATER Position

RUN Position

START Position

CABLE COLOUR CODE

Split to Main Harness No.2

Split to Main Harness No.1

Red

2WD Switch

Green

2WD Lamp

Orange

Glow Indicator Lamp

Grey

Battery Lamp

Black

Oil Temperature Lamp

White

Oil Pressure Lamp

Pink

Cutting Deck Switch Lamp

Violet

Cutting Deck Switch

Yellow

Fuel Guage

Blue

Temperature Guage

Brown

Beacon Switch (Optional)

Light Green

Hazard Swicth

Lights

E.G. R/W = Red/White

Direction Indicators

GB-22

SCHEMATICS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

9.3

ELECTRICAL CIRCUIT MAIN

KEY TO WIRING DIAGRAM

Lamp Timer

Fuel Level Sender

RH Deck Kill Switch

Cab Supply

Water Temperture Sender

RH Cutter Deck Valve

Front Lamps

Engine Oil Pressure Switch

LH Cutter Deck Valve

Flasher Unit

Horn Relay

Centre Cutter Deck Valve

Fuse Holder

Horn

Seat Delay Module

Split to Rear Lights

Start Reley

Brake Release Engine Kill

Brake Lights Switch

Alarm Relay

Engine Fule Soleniod

Connection

Seat Switch

Split to Beacon

Split to Console No.4

Park Switch

Accessory Supply

Transport Deck Disable

Diff Lock Switch

Air Seat Supply

Switch

Fuel Pump

Heated Jacket Supply

Glow Plug Relay

Starter

Water Temp Sender

Glow Plugs

Battery

Alternator

Centre Relay

Relay Flasher

LH Deck Relay

Accessory Control Relay

Deck enable Switch

Accessory Relay

Diff Lock Valve

Hourmeter

4WD Relay

Switch Hydraulic Oil

RH Deck Relay

Tempature

Centre Deck Switch

LH Deck Kill Switch

GB-23

SCHEMATICS

FRONTLINE 960 Series: LQ

MAINTENANCE AND PARTS MANUAL

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.

Fuse C - 40 Amp Cab Fuse.

Relay D - Glow Plug Relay.

SECONDARY FUSES

The secondary fuse panel is situated under the front

tower cover.

FUSE BLOCK 1

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

Fuse A - 20Amp - Accessory.

Fuse B - 20Amp - Air Seat.

Fuse C - 20Amp - Heated Jacket.

Fuse D - Spare.

Fuse E - Spare.

Fuse F - Spare.

FUSE BLOCK 3

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-24

TABLE DES MATIERES

FRONTLINE 960 Série : LQ

MANUEL DE MAINTENANCE

ET NOMENCLATURE DES PIECES DE RECHANGE

TABLE DES MATIERES

INTRODUCTION

2.1

IDENTIFICATION DU PRODUIT

2.2

STOCKAGE DES PIECES DE RECHANGE

2.3

UTILISATION DE LA NOMENCLATURE

CONSIGNES DE SECURITE

3.1

NOTICE DE FONCTIONNEMENT

3.2

VIGNETTES DE SECURITE

3.3

DEMARRAGE DU MOTEUR

3.4

CONDUITE DE LA MACHINE

3.5

TRANSPORT

3.6

AVANT DE QUITTER LE POSTE DE CONDUITE

3.7

PENTES

3.8

BLOCAGE DES PLATEAUX DE COUPE

3.9

REGLAGES, GRAISSAGE ET MAINTENANCE

5/6

SPECIFICATIONS

4.1

SPECIFICATIONS DU MOTEUR

4.2

SPECIFICATIONS DE LA MACHINE

4.3

DIMENSIONS

4.4

NIVEAU DES VIBRATIONS

4.5

PENTES

4.6

LUBRIFIANTS RECOMMANDES

4.7

RENDEMENT DE COUPE (SURFACE)

4.8

COUPLES DE SERRAGE

GRAISSAGE ET MAINTENANCE

TABLEAU DE MAINTENANCE ET DE GRAISSAGE

9/10

5.1

MOTEUR : 50 PREMIERES HEURES D’HORAMETRE PUIS TOUTES LES 250 HEURES

D’HORAMETRE

5.2

MACHINE : GRAISSAGE DES COMPOSANTS SUIVANTS. HEBDOMADAIREMENT OU

TOUTES LES 40 HEURES D’HORAMETRE

5.3

MACHINE : TOUTES LES 400 HEURES D’HORAMETRE

5.4

ORIFICES D’ESSAIS HYDRAULIQUES

5.5

MAINTENANCE DU MOTEUR : TOUTES LES 400 HEURES D’HORAMETRE

5.6

MAINTENANCE DU MOTEUR : TOUTES LES 400 HEURES D’HORAMETRE

5.7

MAINTENANCE DE LA MACHINE

5.8

FIN DE SAISON (OU SELON LA DEMANDE)

REGLAGES

6.1

LIMITEUR DE VITESSE

6.2

PINCEMENT DES ROUES ARRIERE

6.3

ALTERNATEUR

REGLAGE DES PLATEAUX DE COUPE

7.1

TENSION DE LA COURROIE DES PLATEAUX DE COUPE

7.2

AFFUTAGE ET DEPOSE DES LAMES

DEPISTAGE DES DEFAUTS

8.1

GENERALITES

SCHEMATIQUE

9.1

CIRCUIT HYDRAULIQUE

9.2

COMPOSANTS DU CIRCUIT ELECTRIQUE

9.3

CIRCUIT ELECTRIQUE PRINCIPAL

F-1

INTRODUCTION

FRONTLINE 960 Série : LQ

MANUEL DE MAINTENANCE

ET NOMENCLATURE DES PIECES DE RECHANGE

2.1

IDENTIFICATION DU PRODUIT

A Nom de la machine

B Numéro de série

C Date de fabrication

D Poids de la machine

E Puissance moteur

2.2

STOCKAGE DES PIECES DE RECHANGE

Afin d’assurer le fonctionnement et la rentabilité maximum de la machine, Ransomes recommande de

conserver les pièces de rechange les plus courantes. Les numéros de certaines pièces sont également inclus

pour les manuels et aides à la formation.

Pièces de rechange

No. Pièce

Description

No. Pièce

Description

Filtre à huile moteur

178025

Filtre hydra

26560017

Filtre à carburant moteur

4126806

Pompe électrique à carburant

4123044

Elément d'épurateur d'air

5001182

Filtre à carburant en

008089620

Filtre hydra

(Charge)

Documents d'appui

No. Pièce

Description

No. Pièce

Description

Manuel de

Nomenclature de s

maintenance et

pièces de rechange

24598 G

nomenclature de s

de moteur

pièces de rechange

Manuel de l'utilisateur

Manuel de sécurité et

24597 G

de moteur

de l'opérateur

Manuel de service de

moteur

la machin e

F-2

INTRODUCTION

FRONTLINE 960 Série : LQ

MANUEL DE MAINTENANCE

ET NOMENCLATURE DES PIECES DE RECHANGE

2.3

UTILISATION DE LA NOMENCLATURE

NUMERO D'ARTICLE

Chaque pièce, identifiée sur les illustrations, est accompagnée d'un numéro. Il peut s'avérer difficile d'identifier

les pièces ne possédant pas de numéro, mais celles-ci sont généralement étroitement associées à la pièce

immédiatement adjacente.

ENSEMBLES/BLOCS

Un bloc complet, par exemple : un bloc moteur de roue, de moteur hydraulique ou de rouleau, est représenté

par le bloc entier et ses composant s sont représentés séparément. Le bloc parait sous son numéro de pièce et

les composants sont décalés vers la droite sur la liste, par exemple :

ARTICLE NO. PIECE

DESCRIPTION

QTE

REMARQUES

RANSOMES

4295

MBG2504

BRIDE

4296

MBG3848

VERROU

4298

450865

VIS A TETE FRAISEE M8 x 20

4300

450378

ECROU M8, NYLOC

4301

Wl001

Jeu de roues

4301.1

008162130

• Roue & moyeu

(Arrière)

4301.2

008170390

• • Pneu

4301.3

008161830

• • Jante

4301.4

008169140

• • Moyeu

4301.5

008169150

• • Chapeau

4301.6

002993010

• • Graisseur

4301.7

008161990

• Roue & moyeu

(Avant)

4301.8

008170780

• • Pneu

Il se peut que l'illustration de tous les articles ne soit pas possible. Pour certains articles achetés à des

fournisseurs externes, il se peut que des composants ne soient pas disponibles chez Ransomes et que ceux-ci

doivent être commandés spécialement auprès du fournisseur.

QUANTITES

Les quantités indiquées s'appliquent à un ensemble ou sous-ensemble.

UTILISATION DE LA LISTE DE PIECES

Déterminez la fonction et l'application de la pièce requise. Repérez l'index principal et sélectionnez la section

appropriée. Identifiez la pièce sur l'illustration et la nomenclature, puis notez la quantité dans la colonne

adjacente intitulée MODELE.

INDEX NUMERIQUE

Il s'agit d'un récapitulatif de tous les numéros de pièces utilisés dans le manuel, classés numériquement, et

indiquant la page et le numéro d'article sous lesquels les pièces paraissent.

COMMANDE DES PIECES DE RECHANGE

Lors de la commande des pièces de rechange, stipulez le NUMERO DE SERIE de la machine, le NUMERO DE

LA PIECE, la DESCRIPTION et la QUANTITE requise.

00Le fabriquant n'est pas responsable des accidents ou endommagements pouvant résulter de modifications

apportées à la machine sans son accord préalable.

ABBREVIATIONS

N/D Non Disponible

SC Selon la Commande

F-3

Ransomes Frontline 960 (Engine Type: Perkins 404C-22T). Parts and Maintenance Manual (2002) - page 1