G-Plex III - Course Book 2007 PDF

Service Course Manual
G-Plex III (with Plus+1 Controller)

Series: FH - Engine type: Kubota D722
Product codes: USAD002
Series: FJ - Engine type: Briggs & Stratton Model 356447, Type 0123
Product codes: USAG002
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.
GB
English
2007
RANSOMES JACOBSEN SERVICE TRAINING
G-PLEX III - FH & FJ SERIES
SECTION 1 - CONTENTS
CONTENTS 1
INTRODUCTION 2
CONTROLS 3
ENGINE 4
DRIVE TRAIN 5
BRAKE SYSTEM 6
STEERING 7
WHEELS & TYRES 8
CHASSIS 9
HYDRAULICS 10
ELECTRICAL SYSTEM 11
PREVENTATIVE MAINTENANCE 12
ATTACHMENTS AND OPTIONS 13
NOTES 14
SECTION 2 - INTRODUCTION
1 Introduction ….…………………...……………..……………………………………… 2-3

2 Specifications …………………………………………………………………………… 2-3
Product Identification ……………………………………………………………… 2-3
Engine Specification ……………………………………………………………… 2-4
2
Machine Specification ……………………………………………………………… 2-4
Cutting Units ………………………………………………………………………… 2-4
Dimensions …………….…………………………………………………………… 2-5
Overall weight of machine ………………………………………………………… 2-5
Vibration Level ……………………………………………………………… 2-6
RANSOMES JACOBSEN SERVICE TRAINING G-PLEX III – FH & FJ SERIES
1 INTRODUCTION
This is a precision machine and the service obtained from it depends on the way it is operated and
maintained.
The SAFETY AND OPERATORS MANUAL should be regarded as part of the machine. Suppliers of both new
and second-hand machines are advised to retain documentary evidence that this manual was provided with
the machine.
This machine is designed solely for use in customary grass cutting operations. Use in any other way is
considered as contrary to the intended use. Compliance with and strict adherence to the conditions of
operation, service and repair as specified by the manufacturer, also constitute essential elements of the
intended use.
Before attempting to operate or maintain this machine, ALL operators and/or technicians MUST read through
the SAFETY AND OPERATORS MANUAL and make themselves thoroughly conversant with Safety Instructions,
controls, lubrication and maintenance.
Accident prevention regulations, all other generally recognized regulations on safety and occupational
medicine, and all road traffic regulations shall be observed at all times.
Any arbitrary modifications carried out on this machine may relieve the manufacturer of liability for any
resulting damage or injury.
It is important that during the life of the machine wearing and replaceable parts are disposed of in an
environmentally responsible way using the resources available in the country where it is used. There are
guidelines in the above manual for the eventual decommissioning of the mower once it has no further use.
Use the appropriate PARTS CATALOGUE when ordering replacement parts. Follow the installation
instructions shipped with service parts or kits. When ordering parts, always give the serial number and
product number and description of the parts needed.
2 SPECIFICATIONS
Product Identification
Product code: USAD002 ………………….. Series: FH - Engine type: Kubota D722

Product code: USAG002 ………………….. Series: FJ - Engine type: Briggs & Stratton 350447
An identification plate, like the one shown, listing the serial number, is attached to the frame of the tractor
under the seat. Always provide the serial number of the unit when ordering replacement parts or requesting
service information.
A B
C
D E
A - Machine Name
B - Serial Number
C - Year of Manufacture
D - Machine Weight
E - Engine Power
2-3
Engine Specification – Diesel Engine Specification – Gasoline (Petrol)
Make ………………………………………… Kubota Make …………………………… Briggs & Stratton

Model ...................................... D722-E2B-CSM-1 Model .................... Vanguard 350447 Type 1294
Power ………………………. 13.2 kW @ 3200 rpm Power ………………………. 13.2 kW @ 3400 rpm
Type ...................................... 3 cylinder, 4 stroke Type ........................................... V twin, 4 stroke
Displacement ……………………………….. 719cc Displacement ……………………………….. 719cc
Maximum Speed …………….. 3400 rpm (no load) Maximum Speed …………….. 3400 rpm (no load)
Idle Speed ……………………. 1500 rpm (no load) Idle Speed ……………………. 1500 rpm (no load)
Firing Order ………………………………… 1, 2, 3
Fuel Type ……. No. 2-D Diesel fuel (ASTM D975) Fuel Type .Unleaded Gasoline, minimum 85 octane
Engine Oil ………………. above 4°C (39°F) SAE30 Engine Oil ………………. above 4°C (39°F) SAE30
Engine Oil .. below 4°C (39°F) SAE5W-30 or 10W-30 Engine Oil .. below 4°C (39°F) SAE5W-30 or 10W-30
Oil Sump Capacity ………………………. 3.2 litres Oil Sump Capacity ………………………. 1.4 litres
Air Filter …………. Dry type with service indicator Air Filter …………. Dry type with service indicator
Cooling System …………………… Liquid Cooled Cooling System …………………… Liquid Cooled
Machine Specifications
Frame construction: Heavy duty fabricated steel chassis.
Transmission: Variable displacement hydrostatic pump with high speed low torque wheel motors.
Cutting unit drive: Direct drive hydrostatic and reel drive pumps, bi-directional hydraulic gear motor
with reel control valve and backlap control valve.
Speeds: Cutting: 6 km/h
Transport: 12 km/h
Reverse: 3 km/h
Steering: Rear Wheel Power Steering, 2.5 turns lock to lock 330mm Ø Steering Wheel
Ground pressure: 1.0 kg/cm
Brakes: Service: Positive Hydrostatic Braking
Parking: 152 mm Calliper Disk
Capacities:
Cooling System: 3.8 litres 50/50 mixture anti-freeze and water
Fuel Tank: 31 litres
Hydraulic Tank: 18.2 litres GreensCare 68
Total System: 25.7 litres
Battery: 12 volt, Type 093
Alternator Diesel: 40 amp
Gasoline: 15 amp
Cutting Units
Type: Three 559mm wide steerable floating head.
Reel: 127mm diameter, 7 / 9 / 11 knife.
Rolls: Smooth rear roll, smooth or grooved front /rear rolls optional.
Bedknife to reel adjustment: Opposed set screw.
Height of cut adjustment: Micro-adjusters on front roll.
Height of cut: 2.5mm to 16mm Standard blade
2mm to 16mm Tournament blade.
Cutting frequency: 7-knife reel: 7.4 mm at 6 km/h
9-knife reel: 5.7 mm at 6 km/h
11-knife reel: 4.7 mm at 6 km/h
2-4
Dimensions
Overall weight of machine
With Reels
Diesel: 630kg
Gasoline: 574kg
Without Reels
Diesel: 535kg
Gasoline: 478kg
2-5
Vibration Level
When the machine was tested for hand/arm vibration

levels, the operator was seated in the normal operating Max LH or RH
position with both hands on the steering mechanism. Jacobsen G-Plex III Accelerations m/s²
The engine was running and the cutting device was Series: FH, FJ
rotating with the machine stationary. Hand / Arm Acceleration Mean Value of X,Y Z Aeq
level
The Machinery Safety Directive 98/37/EC 0.50

By compliance to:
The Lawnmower Standard EN836:1997
Referenced to hand/Arm: EN1033:1996
Information Supplied for Physical Agents

Directive 2002/44/EC
Max LH or RH Foot
By reference to:
Accelerations m/s²
Hand/Arm Standards: BS EN ISO 5349-1 (2001) Jacobsen G-Plex III
BS EN ISO 5349-2 (2001) Series: FH, FJ
Whole Body Mean Value of X,Y Z Aeq
Acceleration level
When the machine was tested for Whole Body Vibration
1.16
levels, the operator was seated in the normal operating
position with both hands on the steering mechanism.
The cutting device was rotating with the machine driven
in a straight line at 6 km/h on a level freshly cut lawn.
The Machinery Safety Directive 98/37/EC

By compliance to: Seat Location
Whole Body EN1032:2003
Jacobsen G-Plex III Accelerations m/s²
Series: FH, FJ
Information Supplied for Physical Agents Whole Body Mean Value of X,Y Z Aeq
Directive 2002/44/EC Acceleration level
By reference to: 0.85
Whole Body Standards BS EN ISO 2631-1 (1997)
2-6
SECTION 3 - CONTROLS
1 Control Panel - Diesel …..……………..……………………………………………… 3-3

2 Control Panel – Gasoline (Petrol) …...……………………………………………… 3-4
3 Control Pedals …………………………………………………………………… 3-5
4 Parking Brake Pedal …………………………………………………………………… 3-5
5 Paddle/Footswitch Mow/Lift …………………………………………………………… 3-5
6 Operator Presences and Safety Interlock System ………………………………… 3-6
3
1. CONTROL PANEL - DIESEL
A - Temperature Gauge D - Reel Enable Switch

Gauge indicates coolant temperature and This switch must be in the on position (1) in
light warns of overheat situation. order for the reels to rotate. The switch
must be in the off position (0) for the unit to
B - Ignition Switch be started.
Has four positions:
OFF - prevents all electrical functions E - Working Light Switch
from operating. Switch must be in The Working light Switch turns the two
the OFF position to remove the working lamps on and off.
key.
ON - Illuminates the red indicator lamp. F - Mow / Transport Lever
This position is also for normal This lever limits the maximum traction
operation. speed for cutting.
START - Activates the glow plugs &
automatically cranks the engine, G - Throttle
after the glow plugs have Push all the way forward for normal engine
preheated. Release the key after operating speed, and all the way back for
engine starts (the switch idle.
automatically returns to ON).
ACC. - has no function on this unit. H - Hour Meter
Records the number of hours the engine
NOTE: If the engine fails to start, or if it has run. Use the hour meter to manage a
“dies” for any reason, the ignition good scheduled maintenance program
switch must be returned to the OFF (refer to Table 12-1 - Lubrication and
position before restarting is attempted. Maintenance Chart).
This feature prevents damage to the
starter and flywheel teeth that can occur J - Warning Light
if the starter is engaged while the engine a) Flashes when glow plugs are on
is running. Wait 30 seconds before b) On when the engine oil pressure is too
restarting engine. low for operation or the engine
overheats.
C - 12 Volt Power Outlet
Provides a 12 volt power supply for
accessories.
3-3
2. CONTROL PANEL – GASOLINE (PETROL)
A - Hour Meter
Records the number of hours the engine D - Reel Enable Switch
has run. Use the hour meter to manage a This switch must be in the on position (1) in
good scheduled maintenance program order for the reels to rotate. The switch
(refer to Table 12-1 - Lubrication and must be in the off position (0) for the unit to
Maintenance Chart). be started.
B - Ignition Switch E - Working Light Switch

Has four positions: The Working light Switch turns the two
OFF - prevents all electrical functions working lamps on and off.
from operating. Switch must be in
the OFF position to remove the F - Mow / Transport Lever
key. This lever limits the maximum traction
ON - Illuminates the red indicator lamp. speed for cutting.
This position is also for normal
operation. G - Throttle
START - Engages the starter. Release the Push all the way forward for normal engine
key after engine starts (the switch operating speed, and all the way back for
automatically returns to ON). idle.
ACC. - has no function on this unit.
H - Choke
NOTE: If the engine fails to start, or if it Pull the choke control out to start the
“dies” for any reason, the ignition engine. In warm weather, move the choke
switch must be returned to the OFF control slowly to the off position. In cold
position before restarting is attempted. weather allow the engine to run smoothly
This feature prevents damage to the before moving the choke control to the off
starter and flywheel teeth that can occur position.
if the starter is engaged while the engine
is running. Wait 30 seconds before J - Warning Light
restarting engine. a) On when the engine oil pressure is too
low for operation or the engine
C - 12 Volt Power Outlet overheats.
Provides a 12 volt power supply for
accessories.
3. CONTROL PEDALS
3-4
The Direction/Speed Pedal controls speed and

direction. Depress front of pedal to go forward, depress
back of pedal to go backward. Increased movement of
the pedal will increase speed. To slow and stop the
unit, release the pedal completely. Proper braking is
provided by hydrostatic pressure. If more braking is
required, press on the brake pedal.
WARNING
DO NOT attempt to force the direction control pedal to
the neutral (stop) position or to change directions before
coming to a complete stop. Abrupt stops or changes in
direction may cause injury.
NOTE: To reduce fatigue during normal forward operation, the operator’s heel should rest on the floorboard
next to the pedal (not on the lower part of the pedal).
4. PARKING BRAKE PEDAL
The Parking Brake can be engaged by depressing the

brake pedal until the unit is at a complete stop. Once
the unit is stopped, push the parking brake latch
forward to hold the brake pedal. Disengage the parking
brake by depressing and releasing the brake pedal.
5. PADDLE/FOOTSWITCH MOW/LIFT
The Mow/Lift Paddle/Footswitch lowers and raises the

cutting heads.
To Lower the Heads: Depress the footswitch or operate the
paddle. If reel enable switch is on, reel rotation starts when
the heads are lowered.
To Raise the Heads: Depress the footswitch or operate the
paddle. Reel rotation stops when the heads are raised.
3-6
6. OPERATOR PRESENCES AND SAFETY INTERLOCK SYSTEM
1. The operator presence & safety interlock system prevents the engine from starting unless the parking
brake is engaged, the mowing device is off and the operator is in the seat. The system also stops the
engine if the operator leaves the seat with the mowing device engaged or the parking brake
disengaged.
WARNING
Never operate the equipment with the operator presence
& safety interlock system disengaged or malfunctioning.
Do not disconnect or bypass any switch.
2. Perform each of the following tests to ensure the operator presence & safety interlock system is
functioning properly. Stop the test and have the system inspected and repaired if any of the tests fail
as listed below:
• The engine does start in test 1;
• The engine does not start during tests 2 or 3;
• The engine Stops during test 4.
3. Refer to the chart below for each test and follow the check (9) marks across the chart. Shut engine off
between each test.
Test 1: Represents normal starting procedure. The operator is seated, parking brake is engaged, the
operator’s feet are off the pedals and the mower engagement device is off. The engine should
start.
Test 2: The engine must not start if the mower engage device is on.
Test 3: The engine must not start if the parking brake is not applied.
Test 4: Start the engine in the normal manner, then turn mower engage device on and lift your weight
off the seat.
Parking Mower
Operator Engine
Test Brake Switch
Seated Starts
Pedal on On Panel
Yes No Yes No On Off Yes No
1 9 9 9 9
2 9 9 9 9
3 9 9 9 9
4 9 9 9
Lift your weight off seat. The cutting units must stop rotating

within seven (7) seconds
Table 3-1 – Safety Interlock Test Chart
3-7
SECTION 4 - ENGINE
1 Starting the Engine …..……………..…………..……………………………………… 4-3

2 Engine Access …..................................……………………………………………… 4-3
3 Engine Oil Level - Diesel ……………………………………………………………… 4-3
4 Engine Oil Change - Diesel …………………………………………………………… 4-4
5 Engine Oil Filter - Diesel ………………………….…………………………………… 4-4
6 Engine Fuel Filter - Diesel ……………………………….…………………………… 4-4
7 Engine Fuel Feed System - Diesel …………………….…………………………… 4-5
8 Bleeding te Fuel System - Diesel ……………………………….…………………… 4-6
9 Air Filter - Diesel ……………………………...............................…………………… 4-6
10 Engine Oil Level - Gasoline (Petrol) ……………………………….………………… 4-7
11 Engine Oil Change - Gasoline (Petrol) ………………………………….…………… 4-8
12 Engine Oil Filter - Gasoline (Petrol) ……………………………….………………… 4-8 4
13 Air Filter - Gasoline (Petrol) …………………………….…………………………… 4-9
14 Engine Fuel Filter - Gasoline (Petrol) ………………………………………………… 4-9
15 Engine Fuel Feed System - Gasoline (Petrol) ……………………………………… 4-10
16 Fan Belt Tension - Diesel ……………………………….…………………………… 4-11
17 Radiator - Diesel …………………………................…….…………………………… 4-11
18 Oil Cooler - Gasoline (Petrol) ……………………………….………………………… 4-12
SECTION 4 - ENGINE
1 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.
Under no circumstances should the engine be started without the operator seated on the machine.
Do not run the engine in a building without adequate ventilation.
2 ENGINE ACCESS
The rear section of the unit (Fuel & Hydraulic Tanks)
can be raised for better access to the engine.
1. Raise the seat platform.
2. Loosen the lock bolt above the rear fork.
3. Raise the fuel tank frame.
4. Support the frame by pivoting the rod beneath the
fuel tank down and securing it in the cup next to the
fork pivot (See Figure 4-1).
WARNING
Figure 4-1 – Rear Section of Unit
DO NOT remove the fuel tank cap
while the tank is in the raised position.
3 ENGINE OIL LEVEL - DIESEL

Damage to engines due to improper maintenance or 1
use of incorrect oil quality and/or viscosity is not
covered by the engine warranty. Unit must be on a
level surface to obtain an accurate oil level reading.
The oil level must be kept between the two marks on
the dipstick.
Figure 4-2 – Dipstick

NOTE
DO NOT overfill. 1
Engine overheating and damage may result.
Figure 4-3 – Oil Filler Port
4-3
SECTION 4 - ENGINE
4 ENGINE OIL CHANGE - DIESEL

Change engine oil.
1. After first warming up the engine remove the
drain plug and drain all the oil from the crankcase CAUTION
sump.
2. Clean plug and replace. Dispose of used engine oil in accordance with local
3. Remove the filler cap (Figure 4-3) and refill with regulations.
fresh oil up to the maximum level on the dipstick
(Figure 4-2). See Specification for oil grade and
amount.
4 Replace filler cap securely.
CAUTION
NOTE Contact with engine oil can damage your skin.
Use gloves when working with engine oil.
DO NOT overfill. If you come in contact with engine oil, wash it off
Engine overheating and damage may result. immediately.
5 ENGINE OIL FILTER - DIESEL

Change oil filter cartridge
1. Remove cartridge from engine by unscrewing and
discard.
2. Clean area on crankcase.
3. Apply a thin film of clean oil to the rubber gasket.
Screw in the new cartridge by hand until the seal
contacts the crankcase, then tighten 1/2 turn more.
4. After replacing the new cartridge the engine oil level
will drop, run the engine for a short period and after
ensuring that no leaks appear, top up with fresh oil
to the level indicated on the dipstick.
NOTE 1
DO NOT use a wrench when installing the filter,
use hand pressure ONLY. Figure 4-4 – Oil Filter Canister
6 ENGINE FUEL FILTER - DIESEL

Replace fuel filter element
1. Unscrew locking ring and remove filter element and
discard.
2. Place new filter element in filter bowl locating on
spring. Position bowl against gasket in filter head
and fit locking ring.
3. Vent the fuel system.
In-line fuel filter
1
1. Release clamp bands either side of in-line filter and
remove fuel pipes.
2. Fit new in-line filter to fuel pipes, noting direction of Figure 4-5 – Engine Fuel
flow and replace clamp bands Filter
Figure 4-6 – In-Line Fuel Filter
4-4
SECTION 4 - ENGINE
7 ENGINE FUEL FEED SYSTEM - DIESEL
3 - In-Line Fuel Filter

4 - Weight in Fuel Tank
5 - Electric Fuel Pump
6 - Fuel Tank
7 - Fuel Cap With Gauge
9 - In-Line Fuel Filter (Bleeding)
10 - Fuel Pick-Up Assembly
12 - In-Line Fuel T-Piece
16 - Fuel Filter Assembly
Figure 4-7 – Engine Fuel System (Diesel)
4-5
SECTION 4 - ENGINE
8 BLEEDING THE FUEL SYSTEM - DIESEL
WARNING 1
This procedure MUST be performed as specified and

only by properly trained service personnel.
The fuel system must be bled when:

Starting the engine for the first time.
The fuel tank becomes completely empty.
The engine has not been used for an extended 2
period of time.
The fuel filter and/or fuel lines have been loosened,
removed or replaced. 1 – Fuel Filter Air Vent
2 – Secondary Fuel Filter
1. Fill the fuel tank.
Figure 4-8 – Fuel System Bleeding
2. Open the air vent on top of the fuel filter (See Figure
4-8).
3. Without preheating the glow plugs, turn the ignition
switch to START to operate the fuel pump. Allow the
starter to run the pump until a steady stream of fuel
is coming out of the fuel filter air vent. Stop the
starter and close the air vent.
4. Open the air vent on top of the injection pump, open 1
air vent only when engine is NOT running (See
Figure 4-9).
5. Without preheating the glow plugs, turn the ignition
switch to START to operate the fuel pump. Allow the
starter to run the pump until a steady stream of fuel
is coming out of the injection pump air vent. Stop
the starter and close the air vent. Figure 4-9 – Injection Pump Air Vent
WARNING CAUTION
• Catch fuel and dispose of properly, in accordance Contact with diesel fuel can damage your skin.
with local regulations. Use gloves when working with diesel fuel.
• To avoid a fire hazard, clean up any spilled fuel. If you come in contact with diesel fuel, wash it off
immediately.
9 AIR FILTER - DIESEL
NOTE IMPORTANT
Check the air filter condition indicator situated on the We recommend that the filter element be replaced
underside of the outlet elbow at regular intervals. before engine performance is affected. This may occur
If the indicator shows red either clean or replace the air at 250 hours of service under very dusty conditions or
filter element. at 500 hours under normal operating conditions. We do
not recommend cleaning the filter element, because of
the possibility of damaging it.
Clean Air Filter Element
1. As the element of the air cleaner employed on this engine is a dry type, never apply oil to it.
2. Open the evacuator valve once a week under ordinary conditions - or daily when used in a dusty place -
to get rid of large particles of dust and dirt.
4-6
SECTION 4 - ENGINE
3. Avoid touching the element except when cleaning.

4. When dry dust adheres to the element, blow
compressed air from the inside, turning the element. 3
Pressure of compressed air must be under 7 bar
(100 psi).
5. When carbon or oil adheres to the element, soak
3
the element in detergent for 15 minutes, then wash
it several times in water, rinse with clean water and 1
dry it naturally. After the element is fully dried,
inspect inside of the element with a light and check
if it is damaged or not (referring to the instructions 2
on the label attached to the element).
1 – Cover; 2 – Evacuator Valve; 3 – Clips
Figure 4-10 – Engine Air Cleaner
Checking The Element
To check for damage, pin holes, etc. shine a light source into the end of the element. If light CANNOT be
seen through the paper, a new element should be installed. Likewise, if pinholes of bright light appear in the
paper, the element should be replaced.
Installing Element
1. Clean the dust from inside the filter housing with a damp cloth. Make sure that dust does not enter the
engine air intake.
2. Check the soft gasket material at both ends of the element to be sure it is not damaged.
3. Insert the open end of the element into the housing and press it onto the air intake pipe at the back of the
housing. Make sure the filter element fits over the pipe snugly and is pushed all the way on to prevent any
dust from getting past the filter.
4. Install the air cleaner cover [1] over the element with the dust collector [2] pointing DOWN (dust collector
empties automatically when properly installed). Secure the cover with the two wire clips [3].
10 ENGINE OIL LEVEL - GASOLINE
Damage to engines due to improper maintenance or

use of incorrect oil quality and/or viscosity is not 1
covered by the engine warranty (refer to the engine
2
operator's manual for crankcase capacity and
recommended oil grade and weight).
Unit must be on a level surface to obtain an accurate oil

level reading.
The oil level must be kept between the two marks on

the dipstick.
NOTE 1 – Oil Filler Port

DO NOT overfill.
2 – Dipstick
Engine overheating and damage may result. Figure 4-11 – Engine Oil Check
4-7
SECTION 4 - ENGINE
11 ENGINE OIL CHANGE- GASOLINE

Change engine oil
1. After first warming up the engine remove the drain 1
plug (Figure 4-13) and drain all the oil from the
crankcase sump. 2
2. Clean plug and replace.
3. Remove the filler cap (Figure 4-12) and refill with
fresh oil up to the maximum level on the dipstick
(Figure 4-12). See Specification for oil grade and
amount.
4. Replace filler cap securely.
NOTE 1 – Oil Filler Port

2 – Dipstick
DO NOT overfill. Figure 4-12 – Engine Oil Check
Engine overheating and damage may result.
CAUTION
Dispose of used engine oil in accordance with local
regulations.
CAUTION
Contact with engine oil can damage your skin.
Use gloves when working with engine oil. If
you come in contact with engine oil, wash it off 1 – Drain Plug
immediately. Figure 4-13 – Engine Oil Check
12 ENGINE OIL FILTER- GASOLINE

Change Engine Oil Filter
1. Drain engine oil and remove oil filter.
2. Before installing new filter, lightly oil filter gasket with
fresh, clean oil.
3. Screw filter on by hand until gasket contacts filter
head. Tighten ½ to ¾ turn more.
4. Add fresh oil. Fill to FULL line on dipstick.
5. Start and run engine at idle and check for leaks.
6. Stop engine, leave for 15 minutes, recheck oil level.
Add oil if required.
A – Oil Filter
Figure 4-14 – Engine Oil Check
4-8
SECTION 4 - ENGINE
13 AIR FILTER - GASOLINE
NOTE
DO NOT use bent or dented air cleaner housing.
DO NOT use bent or dented air cleaner elements.
IMPORTANT
We recommend that the filter element be replaced before
engine performance is affected. This may occur at 250
hours of service under very dusty conditions or at 500
hours under normal operating conditions. We do not
recommend cleaning the filter element, because of the
possibility of damaging it.
A - Cover, B - Clips, C - Plate, D – Knob,
E - Cartridge, F - Foam Pre-Cleaner, G - Body
Checking the element
To check for damage, pin holes, etc. shine a light Figure 4-15 – Engine Air Filter
source into the end of the element. If light CANNOT be
seen through the paper, a new element should be
installed. Likewise, if pinholes of bright light appear in 1 2
the paper, the element should be replaced (See Figure
4-15).
Pre-Cleaner
To clean the pre cleaner, separate it from the cartridge
and wash in liquid detergent and water.
Squeeze dry in a clean cloth.
CAUTION
DO NOT use pressurised air or solvents to clean
cartridge. Pressurised air can damage cartridge; solvents 1 - Pre-Cleaner
will dissolve cartridge. 2 – Air Cleaner Element
Figure 4-16 – Engine Air Cleaner
Removing / Installing Air Cleaner
1. Unhook clips on both sides of cover and remove cover.
2. Remove knob and plate. Carefully remove air cleaner assembly to prevent debris from entering
carburettor.
3. Reassemble clean (or new) pre-cleaner on clean (or new) cartridge.
4. Reinstall air cleaner assembly, plate and knob.
5. Replace cover and reattach clips to body.
14 ENGINE FUEL FILTER - GASOLINE

Replace fuel filter
1. Release clamp bands either side of in-line filter and remove fuel pipes.
2. Fit new in-line filter to fuel pipes and replace clamp bands.
Figure 4-17 – Fuel Filter
4-9
SECTION 4 - ENGINE
15 ENGINE FUEL FEED SYSTEM - GASOLINE
4 - Fuel In-Tank Weight

6 - Fuel Tank
7 - Fuel Cap With Gauge
9 - In-Line Fuel Filter (Bleeding)
10 - Fuel Pick-Up Assembly
* In-Line Fuel Filter
Figure 4-18 – Engine Fuel System (Gasoline)
4-10
SECTION 4 - ENGINE
16 FAN BELT TENSION - DIESEL

The tension on the belt is correct when the belt can be
depressed 7 to 9mm (0.28 - 0.35in) under a load of 10kgf
(22lbs) midway between the crankshaft pulley and the
alternator pulley.
To adjust:
1. Release the two bolts (A ) holding the alternator and
adjust alternator until the tension is correct.
2. Re-tighten the bolts securely after adjusting.
Figure 4-19 – Fuel Filter
17 RADIATOR - DIESEL MACHINE

Check Engine Coolant Level
1. The level of coolant in the expansion tank should be
between the MAX and MIN level indicators when
cold.
2. If topping up is required, remove the plastic cap and
top up using the correct antifreeze mixture.
1
3. Replace the plastic cap when finished.
Changing Coolant
1. To drain coolant, open cock on engine block and
remove hose from radiator.
2. Close drain cock on engine block and replace hose
back on to radiator. Ensure all hose clips are tight.
3. Refill the cooling system with the correct anti-freeze
mixture. Fill system through expansion tank. 2
4. The level of coolant in the expansion tank should be
between the MAX and MIN level indicators when
cold. 1 – Radiator Cap
2 – Expansion Tank
5. Run the engine for approximately 5 minutes or until
Figure 4-20 – Radiator Level
the thermostat opens.
6. Check level of coolant in expansion tank and top up
if necessary.
CAUTION
CAUTION
Contact with anti-freeze can damage your skin. Use
Dispose of used anti-freeze in accordance with gloves when working with anti-freeze. If you come in
local regulations. contact with anti-freeze, wash it off immediately.
Cleaning
1. Release the 8 screws A holding the radiator / oil cooler screen B to the cowling. (See Figure 4-19)
2. Remove screen and clean.
3. Remove any debris from inside of cowling and around oil cooler C and radiator D. (See Figure 4-20)
4. Replace screen, secure with screws.
4-11
SECTION 4 - ENGINE
B D
C
Figure 4-21 – Bug Screen Figure 4-22 – Oil Cooler / Radiator
18 OIL COOLER - GASOLINE MACHINE

Cleaning
1. Release the catch A (Figure 4-21) retaining the oil
cooler screen.
2. Slide the screen B (Figure 4-22) towards the rear of
the machine and remove. A
3. Clean screen and check oil cooler for debris.
4. Replace screen in the runners and slide into
position.
5. Secure using latch A.
Figure 4-23 – Bug Screen Latch
Figure 4-24 – Bug Screen
4-12
SECTION 5 - DRIVE TRAIN
1 Transmission Pump Mounting (Diesel) …..………………………………………… 5-3

2 Transmission Pump Mounting (Gasoline) …..………………………………………… 5-4
3 Mow / Transport Speed Control …...………………………………………………… 5-4
4 Hydraulic Pump Bypass Valve ……………………………………………………… 5-6
5 Free Wheeling or Towing Unit ………………………………………………………… 5-6
5
1 TRANSMISSION PUMP MOUNTING - DIESEL

In the diesel-powered machine the hydraulic pump is directly mounted to a bellhousing and is driven by a
nylon and steel coupling set. When replacing the coupling, great care has to be taken to maintain a 1mm gap
between the pump spigot and the coupling clamp hub (see Figure 5-2). The capscrew in the clamp hub has
to be torqued to 58 Nm.
25 - Bellhousing
25a - Coupling Hub
25b - Coupling Flange
Figure 5-1 – Pump Mounting - Diesel
Figure 5-2 – Transmission Pump Coupling
5-3
2 TRANSMISSION PUMP MOUNTING - GASOLINE
In the gasoline-powered machine the hydraulic pump is directly mounted to a bellhousing and is driven by a
steel coupling and rubber spider set.
3 MOW / TRANSPORT SPEED CONTROL

The direction/speed pedal, 1 (Figure 5-2), controls speed and direction. Depressing the front of the pedal
causes the machine to go forward, depressing the back of pedal to go backward. Increased movement of the
pedal will increase the speed. The pedal is connected to the transmission pump control linkage via the
transmission control cable 12 (Figure 5-3).
1. Direction/Speed Pedal
2. Transport Stop
3. Locknuts
4. Mow Stop
5. Locknuts
Figure 5-2 – Directional/Speed Control Pedal
Adjusting mow speed

To determine mow speed, run a time check on how fast the unit travels in a distance of 50’ (15.24 m).
Prepare a level surface with enough room to start and end beyond the 50’ marks.
Place a stake in the ground where you want to begin timing the unit. Measure and place another stake at a
distance of 50’ (15.24 m). Lower the cutting heads and press the direction pedal forward so the unit is
travelling at full throttle (the cutting heads should be in the neutral position when timing the unit).
Begin timing the unit when the centre of the front tire aligns with the first stake. Stop timing when the centre
of the front tire aligns with the stake placed at 50’ (15.24 m). Estimated time for 3.8 mph (6.1 km/hr) will be
approximately 8.8 to 9.2 seconds. If there is a significant difference in the times listed above, you can adjust
the mow speed as follows.
5-4
To Adjust Transport Speed Stop:

a. Loosen locknuts (3).
b. Adjust bolt (2).
c. Tighten locknuts (3).
To Adjust Mow Speed Stop.
a. Loosen locknuts (5).
b. Adjust screw (4).
c. Tighten locknuts (5).
Figure 5-3 – Pump Control Linkage
Adjusting pump neutral

The control linkage controls the direction and volume of the pump output. The neutral setting of the pump is
achieved via setting of the eccentric bolt 4 (Figure 5-3).
5-5
4 HYDRAULIC PUMP BYPASS VALVE

The bypass valve allows the unit to be pushed or
towed. Use the pin on the key fob in the valve at the
bottom of the pump to rotate counter clockwise (as
viewed from the bottom of the pump) to open the valve.
NOTE
The bypass valve must be tightly closed for normal
operation or a significant loss of speed will occur and
may cause serious damage to the hydrostatic pump.
1
After moving the unit, close the valve by turning the
Figure 5-4 – Pump Bypass Valve
valve clockwise.
5 FREE WHEELING OR TOWING UNIT

To prevent damage to the pump or wheel motors when FREE WHEELING or TOWING:
1. Engine must be OFF and cool.
2. Turn hydraulic pump bypass valve on the bottom of the pump 180° counter clockwise to open position (as
viewed from the bottom).
3. FREE WHEEL or TOW unit slowly, below 2 mph (3.2 Km/h).
4. Before starting engine, BE SURE to turn the pump bypass valve clockwise to fully closed position.
NOTE
If the pump bypass valve is not completely closed, a
significant loss of speed will occur. Operating the unit
when the pump is not completely closed, may cause
damage to the pump.
5-6
SECTION 6 - BRAKE SYSTEM
1 Specifications …………………...……………..……………………………………… 6-3

2 Parking Brake Pedal …...……………………………………………………………… 6-3
3 Brake Adjustment ……………………………………………………………………… 6-3
6
SECTION 6 - BRAKE SYSTEM
1 SPECIFICATIONS
Service Brakes : Positive hydrostatic braking
Parking Brakes : 152 mm Calliper Disk
2 PARKING BRAKE PEDAL

The parking brake can be engaged by depressing the
brake pedal until the unit is at a complete stop. Once 1
the unit is stopped, push the parking brake latch
forward to hold the brake pedal.
2
Disengage the parking brake by depressing and
releasing the brake pedal.
1 – Brake Pedal
2 – Park Brake Latch
Figure 6-1 – Brake Pedal
3 BRAKE ADJUSTMENT
Place the front axle on axle stands and remove the
front wheels. Inspect the discs and pads for wear and
replace if necessary. Remove all debris from around
the brake assembly and ensure the calliper is free to
float
To Adjust
a. Release the locknuts A on either end of the brake A B A
rod B.
b. Rotate the brake rod B clockwise when viewed form
the operating position.
c. Check the foot pedal can be pushed down to the first
notch before resistance is felt.
d. Check the brake switch for clearance between the
Figure 6-2 – Brake Adjustment
plunger and chassis when the brake is applied.
6-3
SECTION 7 - STEERING
1 Specifications …………………...……………..……………………………………… 7-3

2 Control Arm Adjustment …...………………………………………………………… 7-3
3 Power Steering Layout ………………………………………………………………… 7-3
7
SECTION 7 - STEERING
1 SPECIFICATIONS
Rear wheel hydraulic powered steering, 2.5 turns lock to lock, with a 330mm diameter steering wheel.
2 CONTROL ARM ADJUSTMENT

Support the control arm to avoid a sudden drop while
adjusting its height. Loosen the locking lever to allow
the steering wheel and control arm to be adjusted up or
1
down. Tighten the locking lever when steering wheel is
at the desired position.
WARNING
DO NOT attempt to adjust the control arm position while
the machine is moving. The operator may loose control,
causing possible injury to themselves or bystanders.
Figure 7-1 – Control Arm Height Locking Lever
3 POWER STEERING LAYOUT
Figure 7-2 – Power Steering Layout
7-3
SECTION 8 - WHEELS AND TYRES
1 Specifications …………………...……………..……………………………………… 8-3

2 Ground Speeds and Pressure …..…………………………………………………… 8-3
3 Tyre Pressure …………..……………………………………………………………… 8-3
8
SECTION 8 - WHEELS AND TYRES
1 SPECIFICATIONS
Part Number
Wheel Assembly, Complete 892312
* Tyre 20 x10.00-10 893184
* Rim 10 x 8.50 892687
* Valve Stem 886735
Wheel Nut 7/16"-20 x 60 Deg 450990638 Torque 65Nm
2 GROUND SPEEDS AND PRESSURE
Cutting Mode: 6 km/h

Transport Mode: 12 km/h
Reverse: 3 km/h
Ground Pressure: 1.0 kg/cm
3 TYRE PRESSURE
Keep tyres properly inflated to prolong tyre life. CAUTION
Check inflation pressure while the tyres are cool.
Caution must be used when inflating a low pressure tire
Use an accurate, low pressure tire gauge. to the recommended pressure. Check pressure with a
low pressure tire gauge before connecting an air hose to
Check tyre pressure daily to the air pressure a partly inflated tire.
specified below: Due to the low air volume requirements of a small tire,
over inflation may be reached in a matter of a few
20 x 10 - 10 Turf Tires – 0.62 bar (9 psi) seconds, which could cause the tire to explode.
8-3
SECTION 13 - ATTACHMENTS AND OPTIONS
1 Specifications …………………...……………..……………………………………… 13-3
9
1 SPECIFICATIONS
Frame construction: Heavy duty fabricated steel tube chassis.
13-3
SECTION 10 - HYDRAULIC SYSTEM
10A Hydraulic Service Procedures …..…………………………………………………… 10A-3

10B Repair, Service Tools and Materials ………………………………………………… 10B-9
10C Component Location …………………………………………………………………… 10C-13
10D Transmission Circuit …………………………………………………………………… 10D-17
Specifications ……………………………………………………………………….. 10D-17
Circuit Description ………………………………………………………………….. 10D-17
Hydraulic Diagram - All Drives in Neutral ………………………………………. 10D-19
Hydraulic Diagram - Transmission Forward .…………………………………… 10D-21
Hydraulic Diagram - Transmission Reverse ………….………………………… 10D-23
Hydraulic Diagram - Transmission Forward 3WD ……………………………… 10D-25
Hydraulic Diagram - Transmission Reverse 3WD ……………………………… 10D-27
10E Steering Circuit ………………………………………………………………………… 10E-29
Specifications ……………………………………………………………………….. 10E-29
Circuit Description ………………………………………………………………….. 10E-29
Hydraulic Diagram - Steering ………………..……………………………………. 10E-31
10F Cutting Circuit ………………………………………………………………………….. 10F-33
Specifications ……………………………………………………………………….. 10F-33
Circuit Description ………………………………………………………………….. 10F-33
Backlapping Procedure …………………………………………………………….. 10F-35
Hydraulic Diagram – Reels Engaged Forward ………………..…………………. 10F-37
Hydraulic Diagram – Reels Engaged (Back-lap) ………………..………………. 10F-39
10G Lifting Circuit ……………………………………………………………………………. 10G-41
Specifications ……………………………………………………………………….. 10G-41
Circuit Description ………………………………………………………………….. 10G-41
Cutting Cylinder Lift & Lower Rate & Synchronisation ……………………….. 10G-43
Hydraulic Diagram – Lower Units ……………………………..…………………. 10G-45
Hydraulic Diagram – Lift Units ………………..………………..…………………. 10G-47
10H DP Series (Diesel) …............................................………………………………….. 10H-49

Hydraulic Diagram – Master …………........................………………………….. 10H-51
10
SECTION 10A – HYDRAULIC SERVICE PROCEDURES
1 HYDRAULIC SYSTEM SAFETY
Four kinds of hazards exist when working on hydraulic systems:

Injection of fluid into the skin
Burns from the hot, high pressure spray of fluid
Lacerations and crushing from failing, unsupported cutting units, etc.
Bruises, cuts or abrasions from flailing hydraulic lines
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Use proper safety equipment, including safety glasses, at all times. Take the following general
precautions whenever servicing a hydraulic system.
Key points and supporting information

Always wear eye protection and appropriate protective clothing when working on hydraulic systems.
Block up cutting units, such as a wing decks, when you must work on the hydraulic system with the unit
raised. Never rely on hydraulics to keep you safe in this kind of situation.
Never service the hydraulic system while the machine's engine is running unless absolutely necessary,
such as when bleeding the system.
Do not remove cylinders until the working units are resting on the floor or ground, on safety stands or on
blocks. Be sure the machine's engine is shut off during this procedure.
Before disconnecting oil lines, relieve all hydraulic pressures by operating valves or connecting pressure
measuring lines.
Be sure that all pipe or hose connections are tight and the hoses are not damaged. Escaping oil under
pressure is a fire hazard and can penetrate the skin causing serious injury. Keep hands and body away
from pinhole leaks and nozzles which eject fluids under pressure. Use a piece of cardboard or paper
when searching for leaks. Do NOT use your hand. If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.
Always lower cutting units to the ground before leaving the machine.
When transporting the machine, lock the transport latches to hold cutting units (if fitted) solidly in place.
Some hydraulic pumps, motors and valves are heavy. Before removing them, provide a means of
support such as a chain hoist, floor jack or blocks.
10A
To insure adequate control of the unit, keep the hydraulics in proper adjustment.
Be sure to couple hoses correctly. If the hoses are interchanged, equipment may operate in reverse and
this could result in serious injury.
Always repair components with external leaks and clean up any spilled oil as this may cause a bad fall.
Use care in storing and handling fluids to keep out dirt and moisture. Store inside when possible. If
stored outside, lay oil barrels on their sides. If not possible, tilt slightly so bung is at the high side. Keep
oil bungs drawn tight. Revise oil containers and funnels in fuel after use. Store in clean area or cover to
keep out dirt. When adding oil, clean all dirt from around the filler cap before removing it.
Always filter replacement oil while re-filling or topping-up hydraulic reservoirs.
Always be sure that all belts, pulling and rotating shafts are covered with appropriate guards.
Personal safety
Unintended movement of the machine may cause injury to the technician or bystanders. To protect
against unintended movement, secure the machine while servicing.
Prior to making adjustment or repairs on the hydraulic system, make sure the cutting units are
completely lowered or properly supported by axle stands, not by the oil. Never work under a hydraulic
attachment that is supported by the oil system.
10A-3
The hydraulic system may hold pressure for a long period of time after the engine has been shut down.
Removal of plugs or lines may result in oil and the component shooting out with explosive force. Always
release system pressure BEFORE making repairs or adjustments.
Never attempt to service or repair a hydraulic system if you do not know what you are doing. They are
unforgiving and can cause serious injuries or death.
Never take chances.
Fluid under pressure

Pressurised hydraulic oil escaping the system through a leak can be almost invisible. Escaping
hydraulic fluid under pressure can have sufficient force to penetrate your skin, causing serious injury
and/or infection.
Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the system before
removing hoses, fittings, gauges, or components.
If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury IMMEDIATELY, or gangrene may result.
Immediately after the injection, the person experiences only a slight stinging sensation and may not
think much about it. Several hours later, however, the wound begins to throb and severe pain begins.
By the time a doctor is seen, it is often too late, and the individual loses a finger or entire arm.
Never use your hand or any other body part to check for leaks in a pressurised line. Use a piece of
cardboard or wood when searching for suspect leaks.
Figure 10A-1 - Injury caused by high-pressure fluid Figure 10A-2 - Detecting pinhole leaks
The injury in Figure 8A-1 occurred when a hose carrying high-pressure fluid ruptured. The injured
person was wearing leather gloves at the time. The wound could not be sutured due to tissue damage
by the oil. The wound was gradually closed over weeks.
Oil escaping to atmosphere presents a considerable burning hazard. In addition, it can cause severe
eye injury or total eye loss.
This fluid may also be hot enough to cause burns.
Pressurized oil leaks spraying on a hot engine can be an invitation to disaster. Accumulated oil and fuel
from leaks on the machine can result in a fire that can spread with explosive speed. Keep the machine
clean and free of leaks.
Testing any hydraulic component to atmosphere is extremely hazardous - the outcome is totally
unpredictable! Always error on the side of safety, and keep the oil contained.
10A-4
The safe and effective way to test hydraulic cylinders is to use a flowmeter and a pressure gauge. A
flowmeter has an indicator that shows if oil is bypassing, and more importantly, it keeps the oil where it
belongs - safely within the confines of the transmission lines!
Figure 10A-3 – Piston seal bypass
The use of a flowmeter and/or a pressure gauge is the

only safe way to indicate whether oil is bypassing the
piston seal.
Figure 10A-4 – Safe cylinder bypass detecting
Flammable cleaning solvents

Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area
where a source of ignition may be present.
2 HYDRAULIC TROUBLESHOOTING AND TESTING
This machine is equipped with hydrostatic transmission. Pushing or towing this machine can cause
damage to the transmission. The hydrostatic transmission pump is equipped with a bypass valve, which,
when opened, allows the machine to be pushed or towed a short distance.
Do NOT push or tow the machine faster than 1.5 km/hr for 1.5 km (1 mph for 1 m), otherwise internal
transmission damage may occur.
The bypass valve MUST be open whenever the machine is pushed or towed.
However, running the engine with the bypass valve open will cause the transmission to overheat;
therefore it must be closed immediately after towing is completed.
When troubleshooting a hydraulic problem:

1. Know the hydraulic system for the machine:
Study the schematics, operator’s manual, service manual and service bulletins
Know how the system is suppose to work and what the relief valve settings and pump output flows
should be
2. Talk to the operator(s) and fitters:
How did the machine act just prior and during malfunctioning?
Under which circumstances was the machine used?
Was any service performed or did anyone else attempt the repair the machine?
When preventative and major maintenance was last performed?
10A-5
3. Inspect the machine:

Check the hydraulic fluid level and condition. Is the fluid dirty or smelly?
Check if filter(s) are blocked?
Check for overheating. Does the oil have a burnt smell? Is the oil cooler plugged or caked with dirt?
Look for bent or collapsed fluid pipes and hoses. Check for leaks, loose fasteners, cracked welds,
binding pivot points, damaged linkage, etc.
4. Operate the machine:
Operate the machine in conditions simulating when the malfunction occurred. Verify what the operator
described.
Are gauges or warning lights operating correctly?
Do the controls feel spongy or stick?
Check for unusual sounds, smells or smoke. At what speeds or operating cycles does this occur?
5. List possible causes:
Note what was reported by the operator and verified by you.
List what you found during your inspection.
Remember that there may be more than one cause leading to the failure or malfunction.
6. Determine which cause is most likely the problem:
Look at your list of possible causes and determine which are the most likely
7. Test your findings:
Operate the machine with a hydraulic tester connected to the suspected malfunctioning circuit.
It may be necessary to replace or adjust a component to verify your findings.
8. Verify results:
Verify the problem and solution by replicating the original problem.
3 HYDRAULIC HOUSE TROUBLESHOOTING

Three kinds of hazards exist:
burns from the hot, high pressure spray
injection of fluid into the skin
bruises, cuts or abrasions from flailing hydraulic lines
The goal of troubleshooting is to identify the cause, or causes, of a hose failure, and then to take the
appropriate corrective action. Here is a list of some common causes of premature hose failure and some
everyday solutions to correct the problems:
Hose abrasion
Solution – Reroute the hose to keep it

away from abrasive sources or guard
the hose with a protective sleeve.
Figure 10A-5 – Hose abrasion
Hose burst away from hose ends
Solution – Inspect system operating

pressure and select a hose that
meets or exceeds the system’s
maximum pressure. Try rerouting the
hose to prevent excessive flexing
and/or to keep the hose from
exceeding its minimum bend radius.
Figure 10A-6 – Hose burst
10A-6
Hose burst at coupling
Solution – Increase the hose

assembly’s length to accommodate
contraction under pressure; increase
the hose bend radius or install bend
restrictors; or replace the hose
assembly with a properly crimped
assembly.
Figure 10A-7 – Hose burst at coupling
4 GENERAL INSTRUCTIONS
Follow these general procedures when working on hydraulic systems.
Remove the component

Prior to performing major repairs, remove the component from the vehicle/machine.
Chock the wheels on the vehicle or lock the mechanism to inhibit movement.
Be aware that hydraulic fluid may be under high pressure and/or hot. Inspect the outside of the pump
and fittings for damage.
Cap hoses after removal to prevent contamination.
Keep it clean
Cleanliness is a primary means of assuring satisfactory component life, on either new or repaired units.
Clean the outside of the component thoroughly before disassembly.
Take care to avoid contamination of the system ports.
Cleaning parts by using a clean solvent wash and air drying is usually adequate.
As with any precision equipment, you must keep all parts free of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material.
If left unattended, cover the component with a protective layer of plastic.
Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam in the oil, sludge, or
small metal particles.
If there are signs of contamination in the hydraulic fluid, replace all filters, drain the hydraulic system,
and fill with the correct hydraulic fluid.
Flush the lines before replacing the hydraulic fluid.
Lubricate moving parts

During assembly, coat all moving parts with a film of clean hydraulic oil.
This assures that these parts will be lubricated during start-up.
Replace all O-rings and gaskets

We recommend you replace all O-rings, seals, and gaskets during repair.
Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.
Secure the unit

For major repair, place the component in a stable position.
It will be necessary to secure the component while removing and torqueing any endcap bolts.
10A-7
5 START-UP PROCEDURE FOR A NEW HYDROSTAT

Prior to installing the pump, inspect for damage that may have occurred during shipping.
1. Ensure the machine, hydraulic oil, and system components (reservoir, hoses, valves, fittings, and oil
cooler) are clean and free of any foreign material.
2. Install new system filter element(s) if necessary. Check that inlet line fittings are properly tightened and
free of air leaks.
3. Install the pump. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port.
4. Fill the housing by adding filtered oil to the upper case drain port.
5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a 10-micron filler filter.
Ensure inlet line from reservoir to pump is filled.
After start-up the oil level in the reservoir may drop due to filling of the system components. Check the level
in the reservoir to maintain a full oil level throughout the start-up.
Warning - Damage to hydraulic components may occur if the oil supply is not maintained.
6. Disconnect the pump from control linkage.

7. Use a common method to disable the engine to prevent the engine from starting. Crank the starter for
several seconds. Do not to exceed the engine manufacturer’s recommendation. Wait 30 seconds and
then crank the engine a second time as stated above. This operation helps remove air from the system
lines. Refill the reservoir to recommended full oil level.
8. When charge pressure begins to appear, enable and start engine. Let the engine run for a minimum of
30 seconds at low idle to allow the air to work itself out of the system. Check for leaks at all line
connections and listen for cavitation. Check for proper fluid level in reservoir.
Caution - Air entrapment in oil under high pressure may damage hydraulic components. Do not run at
maximum pressure until system is free of air and fluid has been thoroughly filtered.
9. When adequate charge pressure is established, increase engine speed to normal operating rpm to
further purge residual air from the system.
10. Shut off engine. Connect pump control. Start engine, checking to be certain pump remains in neutral.
Run engine at normal operating speed and carefully check for forward and reverse control operation.
11. Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system
contaminants out of loop. Normal charge pressure fluctuation may occur during forward and reverse
operation.
12. Check that the reservoir is full. Remove charge pressure gauge. The pump is now ready for operation.
6 HYDRAULIC SYSTEM CAPACITY

2
Reservoir Capacity 18.0L
Total System Capacity 25.5L
3
To check the hydraulic fluid level, locate the sight glass
on the tower portion of the reservoir. Visually inspect to
see if there is 1/2" (13mm) (at ambient temperature) of 1
fluid visible above the lower portion of the sight glass. If
not, unscrew the reservoir cap and fill to proper level.
1 – Sight Glass
2 – Reservoir Cap
3 – Tower
Figure 10A-8 – Engine Oil Check
10A-8
7 HYDRAULIC OIL FILTER

The hydraulic oil MUST be drained and replaced when:
250 hours of operation occurs.

Yearly.
After a major component failure.
If you notice the presence of water or foam in the oil.
A rancid odour is detected (indicating excessive heat).
Always replace the hydraulic filters when changing

oil. NOTE
When replacing the hydraulic oil filter, apply a light DO NOT use wrench when replacing the filter, use hand
film of clean oil to the rubber seal. Screw filter on pressure ONLY.
until the seal contacts the oil filter base, then tighten
1/2 turn more.
CAUTION
To drain the hydraulic oil, remove the hydraulic oil
filters. Dispose of used hydraulic oil in accordance with local
regulations.
Once the hydraulic oil is replaced, the air must be
purged from the system. Operate the unit for five
minutes to stabilize the oil level.
Once the air is purged and the oil level is stabilized,
fill the tank to its proper level. CAUTION
The hydraulic fluid reservoir is filled at the factory
Contact with hydraulic oil can damage your skin.
with biodegradable hydraulic oil. Use gloves when working with hydraulic oil.
If you come in contact with hydraulic oil, wash it off
If desired, mineral oil may be used in place of the immediately.
biodegradable hydraulic oil.
When changing to mineral oil, drain the reservoir

and replace the hydraulic oil filters. The system does
not have to be flushed out when changing over. As a NOTE
mineral oil alternative to the biodegradable hydraulic
Use of mineral oil will compromise all biodegradable
oil, a straight-viscosity ISO 68 type fluid is properties of the biodegradable hydraulic oil.
recommended for higher temperature environment.
10A-9
SECTION 10B – REPAIR, SERVICE TOOLS AND MATERIALS
Tools required: Standard automotive hand tools, including torque wrench, seal drivers, circlip
pliers and bearing driver.
Tachometer (Photo/Mechanical)
Obtain from local supplier or,
Graham and White Instruments
135 Hatfield Road
St. Albans
Herts
AL1 4LZ
United Kingdom
Tel: 01727 841692
Part number Description

A810957 Hydraulic Flow meter equipped with loading valve.
A808947 Fittings kit (7/8” JIC to assorted ORFS sizes)
A810938 Pressure Gauge test kit. 1 x 0 - 6000 psi (0 – 400 bar) gauge,
1 x 0 - 600 psi (0 – 40 bar) gauge, 2 x rubber covers for gauges and 1 x micro-
bore connector hose.
A810954 0 - 600 psi (0 – 40 bar) pressure gauge
A810955 0 - 6000 psi (0 – 400 bar) pressure gauge
A810939 Micro-bore connector hose for pressure gauges
2695493 Flushing Filter. Flow capacity 230 litres/min, pressure capacity 6085 psi (414
bar), filtration 10 micron and condition indicator gauge.
2695483 Replacement element for flushing filter
A810953 Belt tension tester
Cleaning Materials: Stoddard or equivalent solvent

Detergent and water
Loctite “Locquic” Primer “T”
Lubricants: See section 11
Other service items: Seal and repair kits (available from Textron distributors)
Liquid gasket
Loctite 242 Blue
10B
Note: When testing system pressures, calibrate pressure gauges and flow meters
frequently to ensure accuracy, at least annually.
10B-11
SECTION 10C – COMPONENT LOCATION
TRANSMISSION AND STEERING COMPONENTS
Steering Pump
Steering Cylinder
10C
Transmission Pump LH Wheel Motor
RH Wheel Motor
Figure 10C-9 – Location of transmission and steering components
10C-13
LIFT / LOWER AND CUUTING COMPONENTS
Rear Lift Cylinder
Sequencing Valves Front Lift Cylinder
Soft Drop Valve
Cutting Pump Flow Divider
Lift / Lower Valve
Cutting Valve
Reel Motor
Backlap Valve
Figure 10C-10 – Location of lift / lower and cutting components
10C-14
Lift Cylinder (Right) Lift Cylinder (Centre) Steering Cylinder
Hydraulic Circuit
Bottom Valve B B Top Valve
Soft Drop
(Master)
Sequence
Valve Delay
Flow Divider/Combiner
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Lift Cylinder (Left)
Relief
Valve
88 +-5 bar
P 1275 +-75 psi Hot Oil Shuttle
PB P
2 mm
T 4 l/min
(0.08”)
1 gal/min US
P T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
(Engine 3400 rpm) Relief Valve
Valve 18.3 l/min 10-15 bar
210 bar RH
4.9 gal/min US 150-210 psi
3020 psi
Wheel Motors
Cutting Me10
Pump Implement
22 l/min [6.5 cc] Relief Valve
P
5.8 gal/min US 55 bar LH
Transport: 300 rpm
800 psi
Mowing: 110-140 rpm
M G Reverse: 140-170 rpm
(actual measurements)
Oil
Backlap Valve Cooler
Filter Filter
25 µm 25 µm
2 3 1
Reel Drive Motors Reservoir

2000 +- 100 rpm
9.8 cc
SECTION 10D – TRANSMISSION CIRCUIT
SPECIFICATIONS
Pump: Sundstrand series 15, 15 cc/rev maximum, 51 litres/min @ 3400 rpm engine speed.
Charge Pump: Integral part of transmission pump. 5.4 cc/rev, 18.3 litres/min @ 3400 rpm engine
speed.
Charge Relief Valve: 10.3 bar (150 psi)
Wheel Motors: Parker Ross ME10 169 cc.
Optional 3WD: Parker Ross ME21 338 cc.
CIRCUIT DESCRIPTION
NOTE: All hydraulic pump outputs and pressures are given with the engine at maximum rpm and with the oil
at working temperature.
The foot pedal mounted on the right hand side of the operator’s platform is linked to the transmission pump
by cable. A simple spring return system is provided to ensure the pump returns to a neutral position.
Movement of the pedal results directly in a corresponding movement of the transmission pump’s swash-
plate. The transmission system is not protected by any form of shock or relief valve. This is considered
unnecessary, as overloading the system will result in spinning the slick tyres.
Oil from the transmission pump goes to a T-piece, which supplies both front motors, before returning to the
pump via another T-piece. The front right hand motor has an oil shuttle that sets up an exchange of oil at a
rate of 4 litres/minute, joining the oil going to the steering circuit. This oil is replaced within the transmission
pump by cooler, filtered oil by the 5.4cc gerotor charge pump. Oil is drawn into the charge pump from the
hydraulic reservoir (GreensCare 68 grade or equivalent) via a 25 micron suction filter. This works whether
forward or reverse drive is selected.
Distinction between transport and mow speeds is made by sliding a stop bolt underneath the foot pedal to
restrict the latter’s movement. This is accomplished by another, hand-operated, cable and selection lever.
Third wheel drive is available as an optional accessory. A rear wheel motor of twice the capacity of the front
motors is connected in what is the return line to the pump in forward drive. As the oil has already driven the
front wheels in parallel this larger motor rotates at the same speed. A check valve ensures that the rear 10D
motor can freewheel during severe hydrostatic braking on steep descents or when reversing.
10D-17
SECTION 10D – TRANSMISSION CIRCUIT
10D-18
All Drives in Neutral

Soft Drop Sequence

Valve Delay
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Relief
Valve
P
PB P
2 mm
T
(0.08”)
Hot Oil Shuttle
P T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
Valve 18.3 l/min 10-15 bar RH
Wheel Motors
Cutting Me10
Pump Implement
P
5.8 gal/min US LH
Oil
Filter Filter
25 µm 25 µm
Pressure
Return
3 2 1 Case
Charge
Suction
Transmission Forward
Soft Drop Sequence

Valve Delay
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Relief
Valve
P Hot Oil Shuttle

PB P
2 mm
T 4 l/min
(0.08”)
1 gal/min US
P T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
Wheel Motors
Cutting Me10
Pump Implement
P
Transport: 300 rpm
800 psi
Mowing: 110-140 rpm
M Reverse: 140-170 rpm
Oil
Filter Filter
25 µm 25 µm
Pressure
Return
3 2 1 Case
Charge
Suction
Transmission Reverse
Soft Drop Sequence

Valve Delay
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Relief
Valve
P Hot Oil Shuttle

PB P
2 mm
T 4 l/min
(0.08”)
1 gal/min US
P T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
Wheel Motors
Cutting Me10
Pump Implement
P
Transport: 300 rpm
800 psi
Mowing: 110-140 rpm
M Reverse: 140-170 rpm
Oil
Filter Filter
25 µm 25 µm
Pressure
Return
3 2 1 Case
Charge
Suction
3WD Circuit
Soft Drop
(Forward)
Sequence
Valve Delay
Valves
Valve Pressure
Lift/Lower
R L Return
A A
Case
B A Steering
Charge
Valve Suction
A B
Lift Valve
Relief
Valve
P
T PB P
P T RH
T
Reel
Drive Wheel Motors
Transmission Pump Me10
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
(Engine 3400 rpm) Relief Valve LH
Valve 18.3 l/min 10-15 bar Transport: 300 rpm
4.9 gal/min US 150-210 psi Mowing: 110-140 rpm
Reverse: 140-170 rpm
Cutting Rear Wheel Motor

Pump Implement Me21
22 l/min [6.5 cc] Relief Valve 3WD
P
5.8 gal/min US 55 bar
800 psi
Oil
Filter Filter
25 µm 25 µm
1 mm
3 2 1 (0.04”)
0.5 mm Flushing Valve

Reel Drive Motors Reservoir (0.02”) .... l/min
.... gal/min US
3WD Circuit
Soft Drop
(Reverse)
Sequence
Valve Delay
Valves
Valve Pressure
Lift/Lower
R L Return
A A
Case
B A Steering
Charge
Valve Suction
A B
Lift Valve
Relief
Valve
P
T PB P
P T RH
T
Reel
Drive Wheel Motors
Transmission Pump Me10
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
(Engine 3400 rpm) Relief Valve LH
Valve 18.3 l/min 10-15 bar Transport: 300 rpm
4.9 gal/min US 150-210 psi Mowing: 110-140 rpm
Reverse: 140-170 rpm
Cutting Rear Wheel Motor

Pump Implement Me21
22 l/min
27.2 l/min
[6.5 cc] Relief Valve 3WD
P
7.2 gal/min US
5.8 55 bar
800 psi
Oil
Filter Filter
25 µm 25 µm
1 mm
(0.04”)
3 2 1
0.5 mm Flushing Valve

Reel Drive Motors Reservoir (0.02”) .... l/min
.... gal/min US
SECTION 10E – STEERING CIRCUIT
SPECIFICATIONS
Pump: Charge pump of the Sundstrand series 15 transmission pump. 5.4 cc/rev, 18.3
litres/min @ 3400 rpm engine speed.
Steering Valve: Eaton five port valve.
Steering Relief Valve: Implement valve fitted to the Sundstrand series 15 transmission pump. 55 bar (800
psi)
Steering Cylinder: Double acting hydraulic cylinder.
CIRCUIT DESCRIPTION
Oil is drawn into the charge pump from the hydraulic reservoir via a 25 micron suction filter. The oil is
displaced by the at a rate of 18.3 litres/min, at an engine speed of 3400 rpm.
From the charge pump the oil flows to the “P” port of the Eaton steering valve. When turning the steering
wheel oil is fed from the valve to the double acting cylinder at the rear of the machine. Oil displaced from the
other side of the cylinder returns to the hydraulic reservoir via port “T” of the steering valve. The maximum
pressure available for steering is 55 bar. An implement relief valve, located inside the transmission pump,
controls this pressure.
If the steering wheel is not being turned the oil flows freely out of the “T” port of the steering valve, via the oil
cooler, to the hydraulic reservoir. The hot oil from the transmission circuit’s shuttle valve joins this circuit
before the steering valve and is therefore also cooled.
10E
10E-29
SECTION 10E – STEERING CIRCUIT
10E-30
Steering to One Side

Soft Drop Sequence

Valve Delay
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Relief
Valve
P Hot Oil Shuttle

PB P
2 mm
T 4 l/min
(0.08”)
1 gal/min US
P T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
Wheel Motors
Cutting Me10
Pump Implement
P
800 psi
Oil
Filter Filter
25 µm 25 µm
Pressure
Return
3 2 1 Case
Charge
Suction
SECTION 10F – CUTTING CIRCUIT
SPECIFICATIONS
Pump: Casappa series PLP20 single section, fixed displacement, gear pump. 6.5 cc/rev,
22.1 litres/min @ 3400 rpm engine speed.
Reel Drive Relief Valve: Variable cartridge type valve in the reel drive valve block. 210 bar (3020 psi)
Reel Motors: Casappa series PLM10 bi-directional gear motors. 9.8 cc/rev, 2200 rpm @ 3400
rpm engine speed.
CIRCUIT DESCRIPTION
Oil is drawn into the cutting pump from the hydraulic reservoir via a 25 micron suction filter. This oil is
displaced by the gear pump (6.5cc) at a rate of 22.1 litres/min, at an engine speed of 3400rpm.
From the pump the oil flows to the “P” port of the reel drive valve. If reel drive is not electrically enabled the
oil passes through the solenoid valve and from the “T” port it returns to the hydraulic reservoir via the
lift/lower valve and the oil cooler.
If the reel drive is enabled (and the units lowered) the solenoid valve closes and the oil then flows from “M”
port to the reel motors via the backlap valve. If forward drive has been selected in the back-lap valve, the oil
goes to the front right hand unit, the front left hand unit and then to the centre unit before returning to the
back-lap valve, the lift/lower valve, the cooler and the reservoir.
Within the reel drive valve is a variable speed control that comprises a needle valve and a pilot operated
spool valve. Rotating the knurled head of the needle valve allows a proportion of the oil to return to the
reservoir, thus reducing reel speed. The pilot operated pressure compensating spool valve ensures that the
selected speed is maintained regardless of changes in loading.
If one of the reels becomes jammed (by a tee peg, etc.) the pressure within the circuit will quickly increase
until it reaches 207 bar, at which point the relief valve will open, allowing oil to return to the reservoir via the
cooler. All reels will then stop rotating.
10F
SAFETY NOTE: To avoid the possibility of serious injury, switch the reel enable switch to off, stop the
engine, remove the key and set the parking brake before attempting to release any lodged obstructions.
NEVER rotate the reel by pushing with your hands or fingers, as energy can be released suddenly, resulting
in serious injury. Instead, use a suitable length of softwood to ease the obstruction free.
10F-33
10F-34
BACKLAPPING PROCEDURE
Backlapping on a regular basis will help keep the cutting edges sharp and extend the life of the reel.
Backlapping may be performed on one cutting head only, two heads, or all three heads simultaneously. If
backlapping one or two cutting heads is desired, back off slightly on the bedknife–to–reel clearance on the
head(s) not requiring backlapping. This will eliminate contact between bedknife and reel, avoiding the
possibility of damaging the reel or bedknife during the backlap process. Always make bedknife adjustments
with the engine off.
Throughout this Operators manual you will find warnings and advice that indicates that the only safe place
from which to operate this machine is from the driver’s seat.
The only exception to this rule is when the cutting units are being sharpened using the backlap feature. In
this situation the requirement to observe the blades and apply the appropriate amount of grinding paste
dictates that the person responsible for sharpening the machine must be in front of the cutting unit as it
rotates in reverse.
Ransomes Jacobsen Ltd. strongly recommends that the following points are considered before and during
backlapping:
Before
• Select a well ventilated area to clear engine emissions.
• Risk-assess the process to be followed and implement any protective measures judged appropriate.
• Ensure a colleague is working in the area, but at a safe distance from the machine.
During
• Use Personal Protective Equipment, particularly hand and eye protection, in addition to the normal
workshop clothing that should be worn.
• Use a long handled brush to apply grinding paste.
• Keep hands and loose clothing clear of rotating cylinder.
Ransomes Jacobsen Ltd. recommends that the best way to keep the cutting cylinder and blade on your
mower sharp is to use a regular grinding regime.
NOTE: Make sure the bedknife adjustment is correct before backlapping. Refer to Bedknife Adjustment.
WARNING
ALWAYS open the restriction valve before setting the
reel control lever to BACKLAP position.
DO NOT set the reel control lever to the BACKLAP
position before opening the needle valve in the bypass
circuit. This will cause the reels to start turning
IMMEDIATELY at full speed.
Keep hands, feet and clothing away from all three reels
whenever the reel control lever is placed in the backlap
position. When backlap restriction valve is closed or
being closed, all three reels will rotate in the backlap
direction.
10F-35
1. Open the restriction valve on the reel valve by turning

the knob counterclockwise as far as it will go. 1
2. Set the reel control lever to the right for the backlap
position.
3
3. Start the engine and set the throttle to low idle. Switch
the reel enable switch to the on position. Lower heads 2
by operating the paddle or the foot switch.
4. Slowly turn the restriction valve knob clockwise until

the desired reel rotation speed is attained. It should be
slow enough so that the reel will not throw off the
backlapping compound as it spins.
5. Apply an even coat of backlapping compound to the 1. Restriction Valve

entire length of each blade of the reel. Use a brush 2. Backlap Valve
with a long enough handle to keep you away from the 3. Reel Control Lever
rotating blades. For best results, use a handle length A. Mow Position
which will permit application of compound while B. Backlap Position
standing in front of the unit. N. Neutral Position
6. Once all the blades on the reel are uniformly sharp, shut off the engine and switch the reel enable switch
to the off position. Set the reel valve control to the mow position and close the restriction valve (all the
way clockwise).
NOTE: To ensure proper reel rotation, make sure the restriction valve is completely closed.
7. Wash all of the backlapping compound from all of the heads. Once they are thoroughly cleaned and dry,
apply a light film of oil to the cutting edges to help prevent rust.
8. After backlapping, the bedknife adjustment should be made again.
10F-36
Reels Engaged Forward

Soft Drop Sequence

Valve Delay
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Relief
Valve
88 +-5 bar
P 1275 +-75 psi
PB P
2 mm
T
(0.08”)
Hot Oil Shuttle
P T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
210 bar RH
3020 psi
Wheel Motors
Cutting Me10
Pump Implement
P
800 psi
Oil
Filter Filter
25 µm 25 µm
Pressure
Return
3 2 1 Case
Charge
Suction
2000 +- 100 rpm
9.8 cc
Reels Engaged Backlap

Soft Drop Sequence

Valve Delay
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Relief
Valve
88 +-5 bar
P 1275 +-75 psi
PB P
2 mm
T
(0.08”)
Hot Oil Shuttle
P T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
210 bar RH
3020 psi
Wheel Motors
Cutting Me10
Pump Implement
P
800 psi
Oil
Cooler
Backlap Valve Filter Filter
25 µm 25 µm
Pressure
Return
3 2 1 Case
Charge
Suction
SECTION 10G – LIFTING CIRCUIT
SPECIFICATIONS
Pump: Casappa series PLP20 single section, fixed displacement, gear pump. 6.5 cc/rev,
22.1 litres/min @ 3400 rpm engine speed.
Lift/Lower Relief Valve: Variable cartridge type valve in the lift/lower valve block. 88 bar (1275 psi)
Lift Cylinders: Front: Double acting hydraulic cylinder, 1¾” bore x 3” stroke.
Centre: Double acting hydraulic cylinder, 1½” bore x 3” stroke.
CIRCUIT DESCRIPTION
When the reel drive is not selected the oil flows freely through the reel drive valve (from the “T” port) and is
available to the “P” port of the lift/lower valve. Unactivated, the oil flows freely through the solenoid-operated
lift/lower valve to the hydraulic reservoir, via the oil cooler.
When raising the units by activating either the foot pedal or the hand paddle, the lift solenoid is energised,
thus moving the spool to feed oil out of the “A” port and opening the check valve as it does so. The oil then
flows to the rear of all three lift cylinders (two front and one centre), which extend and raise the units. The
flow combiner/divider ensures that the front cylinders lift at equal speed by controlling the rate that oil is
displaced from the cylinders. The return oil goes though valve port “B” before returning to the oil cooler and
reservoir. If the Operator continues to press the foot pedal or hold the hand paddle the pressure would build
until the 210 bar relief valve opens. When the pedal or paddle is released the oil is trapped between the
cylinders and the pilot-operated check valve, preventing the units from dropping.
Pressing the foot pedal or the hand paddle again energises the lower solenoid on the lift valve, moving the
spool and allowing oil to flow out of port “B”. At the same time the pilot-operated check valve in port “A” is
lifted off its seat via an internal pilot line. Oil flows to the front of all three lift cylinders via the flow
combiner/divider, ensuring the two front units lower at the same rate. Oil displaced from the cylinders has to
pass through the opened check valve in port “A” before returning to the oil cooler and reservoir.
The “soft-drop” valve (adjustable needle flow control valve) in the front cylinder circuit, allows for speed
adjustment for the lowering of the front units. The setting guide for this valve is approximately one complete 10G
turn closed from fully open. Sequencing of the rear unit, both during raising and lowering, is done by two
separate adjustable needle flow control valves. Setting is done after the soft-drop valve has been set, with
the oil at working temperature. Close both valves first, then adjust the top valve 1½ turns out and the bottom
valve 1 full turn out. (See full instructions overleaf.)
Flotation of the units whilst cutting is not restricted in any way by the cylinders, as they locate in slots in the
unit arms, allowing full articulation.
NOTE: Unlike previous models, the lifting circuit is independent from the steering circuit. Therefore the
machine can be steered on the greens while the cutting units are lifted.
10G-41
10G-42
CUTTING CYLINDER LIFT & LOWER RATE & SYNCHRONISATION

The valves that control the rate and sequence in which the
cutting units rise and fall are set at the factory as 1
described below, however they can be reset or altered
using the following steps:
1. Attach a 400 bar (6000 psi) hydraulic pressure gauge
to the port on the cylinder reel drive valve (see Figure
10G-1).
2. Ensure the parking brake is engaged, start the
machine and run the engine at full throttle (3200 ± 100
rpm) for 15-20 mins to ensure that the oil is at the
optimum temperature of 40ºC (105ºF).
3. Screw the front units lower valve (found under the Figure 10G-1 – Gauge Port
battery cover) out counter-clockwise all the way and then
in clockwise one complete turn (see Figure 10G-2).
4. Screw both the centre unit lift and lower valves (found
at the rear of the machine) clockwise in all the way(see
Figure 10G-3).
5. Then screw the top valve out counter-clockwise one and
a half turns. This valve controls the lifting of the centre
unit.
6. Then screw the bottom valve out counter-clockwise one
turn. This valve controls the lowering of the centre unit.
7. The pressure relief valve setting on the lift valve needs
to be set to 88 ± 5 bar (1275 ± 75 psi). To check this
raise and hold the cutting cylinders with the hand
paddle or foot pedal and note the peak pressure Figure 10G-2 – Front Unit ‘Soft-Drop’ Valve
reading on the pressure gauge attached to the cylinder
reel drive valve when the units are fully raised.
If the gauge displays a pressure outside the limits
specified above the pressure needs to be corrected.
8. This is done by first losening the nut on the pressure
relief valve (1) see Figure 10G-4) and then adjusting
the valve setting screw (2). Screw the screw in to
increase the pressure and out to decrease the
pressure. Adjust the screw half a turn at a time and re-
check the pressure by raising and lowering the cutting
cylinders. Once the optimum pressure is reached,
retighten the locking nut (1) to secure the setting. (The
engine should be OFF whenever the relief valve is set.) Figure 10G-3 – Centre Unit Lift & Lower Valves
9. Cycle the cutting units to check the synchronisation.

The centre cutting unit should lower and lift slightly 2
after the front cutting units.
If the cylinders drop too quickly or are not synchronised
correctly then they should be adjusted accordingly.
If it is not possible to get the sequencing of the rear
cutting unit correct this may be because the front
cutting units are set to lower too slowly. Try increasing 1
the speed of drop slightly.
7. Once the cutting units are lifting and lowering correctly
tighten each of the grubscrews found on the valves to
Figure 10G-4 – Pressure Relief Valve
lock the settings. Then re-check the pressure as in step
7 and adjust if necessary.
8. Finally remove the pressure gauge fitted in step 1 and replace the dust cap of the port.
10G-43
Lower Units
Soft Drop Sequence

Valve Delay
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Relief
Valve
88 +-5 bar
NOTE: P 1275 +-75 psi
Pressure measured at G: PB P
2 mm
T
At the start of the cycle the pressure measured will be 88 bar (lift (0.08”)
pressure), then 300 bar (combined pressure) and finally 210 bar Hot Oil Shuttle
P T
(reel drive pressure) (1275 psi, then 4300 psi and then 3020 psi).
T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
210 bar RH
3020 psi
Wheel Motors
Cutting Me10
Pump Implement
P
800 psi
M G
Oil
Filter Filter
25 µm 25 µm
Pressure
Return
3 2 1 Case
Charge
Suction
Lift Units
Soft Drop Sequence

Valve Delay
Valves
Valve
Lift/Lower
R L
A A
B A Steering
Valve
A B
Lift Valve
Relief
Valve
NOTE: 88 +-5 bar
Pressure measured at G: P 1275 +-75 psi
At the start of the cycle reels continue to turn for 2 seconds, PB P
2 mm
T
therefore the combined pressure of the reel valve plus the lift relief (0.08”)
valve pressure will read as 300 bar (4300 psi), thereafter only the lift Hot Oil Shuttle
P T
valve relief pressure is measured as 88 bar (1275 psi).
T
Reel
Drive
Transmission Pump
Valve
l/min [ cc]
5115
13 .5 gal/min US
Charge
Relief Charge Pump
210 bar RH
3020 psi
Wheel Motors
Cutting Me10
Pump Implement
P
800 psi
M G
Oil
Filter Filter
25 µm 25 µm
Pressure
Return
3 2 1 Case
Charge
Suction
RANSOMES JACOBSEN SERVICE TRAINING G-PLEX III – DP SERIES
SECTION 10H – HYDRAULIC DIAGRAM - MASTER
CIRCUIT DESCRIPTION
DP Series machines are fitted with a bi-directional relief valve (no pressure switch) and use a timed lift/lower
PIC module.
10H
10H-49
Lift ram Lift ram
Divider
(right) (centre) Hydraulic Circuit (Master)
combiner
valve
2 Steering
.050 valve R L
Sequence Steering ram
valve
A B
Lift ram
(left)
Lift
valve
Cylinder drive T P .081

valve T PB P
T
Transmission Pump
48.45 Lpm Hot oil shuttle
Relief Cutting 4 Lpm
valve Pump (150-210 psi)
Charge pump
210 Bar 26.27 Lpm Charge relief RH
18.3 Lpm
3000 psi valve
P (800 psi) TRW ME10
Implement
M G relief valve LH
Oil
Cooler
Filter Filter Accessory

Cylinder drive motors 2100 Rpm 25 micron 25 micron rear wheel
motor
Tank
G-PlexIII
SECTION 11 - ELECTRIC SYSTEM
11A Electrical Service Procedures ……..……………….…………………………………… 11A-3

11B Repair, Service and Diagnostic Tools ……..………………………………………… 11B-5
11C Component Location ………………………...………………………………………… 11C-7
11D Electronic Microcontroller …………………...………………………………………… 11D-3
11E FH Series (Diesel) ……………………………………………………………………… 11E-5
Circuit Voltage Measurements ………….……………………………………….. 11E-5
Electric Diagram - Master ….…………..………………………………………….. 11E-5
Electric Diagram - Hot Circuit ………….……..……………………………………. 11E-7
Electric Diagram - Ignition On ……………………………………………………… 11E-9
Electric Diagram - Crank Engine ……..…………..…….………………………… 11E-11
Electric Diagram - Engine Running ………………….…………………………… 11E-13
Electric Diagram - Mowing – Lower Units ………….…….……………………… 11E-15
Electric Diagram - Mowing – Raising Units ……….……..……………………… 11E-15
Electric Diagram - Ignition Off …………………..……..………………………….. 11E-17
11F FJ Series (Gasoline / Petrol) ……………….………………………………………… 11F-5
Electric Diagram - Master …..…………………………….……………………….. 11F-5
Electric Diagram - Hot Circuit …………….………………………………………. 11F-7
Electric Diagram - Ignition On ……………………………..……………………… 11F-9
Electric Diagram - Crank Engine …………………………….…………………… 11F-11
Electric Diagram - Engine Running ……………………………………………… 11F-13
Electric Diagram - Mowing – Lower Units …………………….………………… 11F-15
Electric Diagram - Mowing – Raising Units ……………………………………… 11F-15
11G DP Series (Diesel) ……………………………………………………………………… 11G-5

Electric Diagram - Hot Circuit ……………………………………………………. 11G-7
Electric Diagram - Ignition On ……………….…………………………………… 11G-9
Electric Diagram - Crank Engine ……………………….………………………… 11G-11
Electric Diagram - Engine Running (Brake applied) ………..……..…………… 11G-13
Electric Diagram - Drive (PTO off) ……………………………………………….. 11G-17
Electric Diagram - Mowing – Lower Units ……………………………………… 11G-15
Electric Diagram - Mowing – Raising Units …….……………………………… 11G-15
11
SECTION 11A – ELECTRICAL SERVICE PROCEDURES
1. ELECTRICAL SYSTEM SAFETY
Electric current can cause injury in three main ways:

Cardiac arrest due to the electrical effect on the heart.
Muscle, nerve, and tissue destruction from a current passing through the body.
Thermal burns from contact with the electrical source.
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Use proper safety equipment at all times. Try to understand the electrical system enough to
avoid shocks, flashes or burns.
Key points and supporting information

Always wear eye protection and appropriate protective clothing when working on electric systems.
Be sure that the floor and bench areas are clean and free from debris, spares and spills and well lighted
and ventilated.
Pay particular attention to instructions regarding the disabling of a vehicle. Always remove the negative
battery cable first, using insulated tools. Never operate an engine with a spark plug removed. Fuel may
be blown out of the cylinder and a high-tension arc could ignite it.
Electrical shock occurs when a person comes in contact with two conductors of a circuit or when the
body becomes part of the electrical circuit. In either case, a severe shock can cause the heart and lungs
to stop functioning.
Also, severe burns may occur where current enters and exits the body.
Prevention is the best medicine for electrical shock. Respect all voltages, have knowledge of the
principles of electricity, and follow safe work procedures.
Batteries produce explosive gases and contain corrosive acid and supply levels of electrical current high
enough to cause burns.
Always check the polarity of each battery terminal and be sure to rewire the batteries correctly.
When servicing batteries, do not smoke, and keep naked flames away.
Do not place any metal objects across the battery terminals.
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS
AFTER.
Keep top of battery clean and free of corrosion by washing with a solution of baking soda and water OR
ammonia and water. Rinse with clean water. 11A
Batteries with heavy corrosion should be removed and cleaned with solution.
Battery electrolyte is an acidic solution and should be handled with care. If electrolyte is splashed on
any part of the body, immediately flush the exposed area with liberal amounts of water and obtain
medical aid immediately.
Always insulate any tools used within the battery area in order to prevent sparks or battery explosion
caused by shorting the battery terminals or associated wiring.
Always use specified replacement parts. Never use replacement parts of lesser quality.
Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is
supported by a jack. Lift the vehicle in accordance with the manufacturer’s instructions.
Always test-drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe
area that is free of both vehicular and pedestrian traffic.
Always replace damaged or missing warning, caution or information labels.
Always ensure the safety circuit is intact, connected and working as per manufacturer’s specifications.
Do not take chances.
11A-3
SECTION 11A – ELECTRICAL SERVICE PROCEDURES
2. ELECTRICAL TROUBLESHOOTING AND TESTING
Most electrical problems are simple, such as a loose connection or damaged wire, rather than mysterious
and complex. In any product, components will eventually fail to perform properly as the result of normal
use, age, wear or abuse. It is virtually impossible to anticipate all possible component failures or the
manner in which each component may fail.
The 5 Step Troubleshooting Approach consists of the following:

Preparation
Step 1 Observation
Step 2 Define Problem Area
Step 3 Identify Possible Causes
Step 4 Determine Most Probable Cause
Step 5 Test and Repair
Follow-up
When troubleshooting an electrical problem:

1. Know the electrical system for the machine:
Study the schematics, operator’s manual, service manual and service bulletins
Know how the system works and where the fuses, relays, switches and other components are.
2. Talk to the operator:
Was equipment running when problem occurred?
How did the machine act just prior and during malfunctioning?
Under which circumstances was the machine used?
Does the Operator know what caused the problem, and if so, what, in their opinion, caused the
problem?
Was any service performed or did anyone else attempt the repair the machine?
When preventative and major maintenance was last performed?
3. Operate the machine:
If possible, operate the machine in conditions simulating when the malfunction occurred. Verify what the
operator described.
Are gauges or warning lights operating correctly?
Check to ensure there is power
Check with the key switch in the ON position, then with the machine running.
Do the safety circuits work properly? (i.e., machine should not start with the park brake released, etc.)
4. Inspect the machine:
Verify that no safety switches or relays are bypassed.
Check all wiring connections.
Look for corrosion and broken or bare wires.
Check for overheated components or wiring.
5. List possible causes:
Note what was reported by the operator and verified by you.
List what you found during your inspection.
Remember that there may be more than one cause leading to the failure or malfunction. Do not assume
that all problems are solved after completing one, always test the circuit and operation prior to returning
the equipment to service.
6. Determine which cause is most likely the problem.
Look at your list of possible causes and determine which are the most likely.
7. Test your findings.
Check the suspected circuit(s) or switch(es) with a continuity tester or digital Volt/Ohm multi–meter.
It may be necessary to replace or adjust a component to verify your findings.
8. Verify results:
Verify the problem and solution by replicating the original problem.
11A-4
SECTION 11B – REPAIR, SERVICE AND DIAGNOSTIC TOOLS
Tools required: Digital Multimeter

Jumper Wires
60 amp Ammeter
Battery Tester
Tachometer (Photo/Mechanical)
Obtain from local supplier or,
Graham and White Instruments
135 Hatfield Road
St. Albans
Herts
AL1 4LZ
United Kingdom
Tel: 01727 841692
Cleaning Materials: Baking Soda and Water

Water repellent (WD40)
Other service items: Electrical Insulation Compound
Diagnostic Tools: Sauer Danfoss P+1 Microcontroller P1D Diagnostic File

Gateway from Computer USB port to Controller P/N 4150557
Intermediate connector Gateway to Vehicle Harness P/N 4143951
11B
Figure 11B-1 – CAN and RJ adaptors
11B-5
MACHINE
Dash Micro Switch
11C
Micro Switch
Plus 1 Controller
11C-7
DASH
Temperature Gauge (Diesel Only) Ignition Switch Accessory Socket

Hourmeter (Petrol Only)
Rocker Switch - Mow Warning Lamp Rocker Switch - Worklamp
INSTRUMENT PANEL
Time Delay
(Diesel Only)
Plus+1
40 Amp
Controller
Strip Fuse
Fuse Box
40 Amp
Glowplug Fuse
Starter Relay
Glow Plug Relay (Diesel)

Engine Stop Relay (Gas)
Warning Buzzer
11C-8
FUSE BOX
Brown Wire
12V un-switched
from Battery
Green Wire / Orange Trace
Feeds: Air Seat
Green Wire / Brown Trace 10 Amp Fuse

Feeds: Logic Controller
Black Connector P11
20 Amp Fuse
Green Wire
Feeds: Temperature Gauge,
Alternator, PTO Switch,
Fuel Pump 10 Amp Fuse
Green Wire / Black Trace
Feeds: Accessory Socket
10 Amp Fuse
Blue Wire
Feeds: Light Switch
15 Amp Fuse
White Wires
12V switched
from Key Switch
Seat Switch Hourmeter

Gasoline Only
Head Lamp
11C-9
SECTION 11D – PLUS+1 Micro Controller
1. Description
The controller system is responsible for controlling the engine start and stop functions using the safety
interlock circuit as well as the hydraulic lift/lower and reel engagement circuits. Although there is interaction
between the different control areas the specification will first detail engine control, then the reel controls, then
consider the alarm functions and finally the Backlap mode.
2. Engine control
The engine RPM control is managed by a traditional cable control. The controller system is used to ensure
certain conditions (safety functions) are met before the engine can start, as well as stopping the engine if
certain events occur.
3. Engine start sequence

If the following conditions are met, the engine start sequence can begin:
Sensor State
Seat Switch Closed (Operator Present)

Park Brake Closed (Brake Engaged)
Mow (PTO) Switch and/or Disengaged
Reel Interlock Switch Disengaged
Start-Signal Active (key switch)
Table 9-1 - Engine start, sensor conditions
The key switch has three positions, off, on, and crank. The positions off and on (run) are latching and the
crank is sprung-return to on.
If the sensors are not in the correct configuration for the Start Sequence at power up an Error Code will be
flashed on the Red LED. See Section 8 for further explanation.
The controller is powered at the on position, when the key is turned to crank the engine start sequence is
initialised. The operator must hold the crank position until the engine starter motor engages and the engine
fires. The glow plugs will be energised for a period of time dependent upon the water temperature, see
section 5. After this time, the Fuel Solenoid will be engaged (energised to stop system, no voltage to Fuel
Solenoid when engine is running) and will remain engaged unless an Engine shutdown condition occurs.
Finally the starter-motor will be run, and will continue to run until the start-signal is deactivated. The hour
meter is hardwired to the fuel solenoid controller output thus giving an accurate reflection of engine hours
run. 11D
If the engine is stopped and restarted given that the water temperature is above 90°C, the Glow Plugs will be
energised for a period of 1 sec before the fuel solenoid engages and the starter motor runs.
For a PETROL (GAS) ENGINE, there are no glow plugs and the water temperature sensor is not fitted. The
start sequence therefore is the engagement of the fuel solenoid and the starter motor.
It is intended that the controller system will automatically detect which type of engine is fitted to the vehicle
the first time power is applied. This will be achieved by energising the glow plug output and checking to see if
any current is drawn. If not, it is assumed that a petrol engine is fitted and a parameter in the EEPROM
(program) memory will be written to reflect this. If the controller needs to be changed between machines the
Service Tool will need to be used to change the engine type parameter setting to suit the engine fitted. One
is assigned to petrol, two is assigned to diesel.
11D-11
4. Engine fault conditions

The fuel solenoid controls whether the engine is running or not and as such this output will be used to stop
the engine if certain conditions occur. The Fuel Shut Down Timer controls the Fuel Solenoid, it is this
component which is controlled by the controller output.
If the Seat-Switch is opened for more than 3 seconds and the park-brake is disengaged, the fuel solenoid will
be energised (via the Fuel Shut Down Timer) and the engine will be stopped. The red led on the controller
will show an Error Flash Code 3 if this situation occurs.
If the Engine Oil Pressure is too low, the alarm lamp & buzzer will be triggered. If this fault does not clear
within 60 seconds, the reels will be stopped, then raised and mow operation will be inhibited. If the fault does
not clear within a further 60 seconds then the engine will be shutdown and Error Flash Code 1 will be shown.
In Backlap mode if the park brake is disengaged then the engine will stop after a time period of 2 seconds.
5. Water temperature sensor

The water temperature sensor will not be used to prevent the starting or stopping of the engine. The water
temperature sensor will be used for the following functions:
To determine the period of time that the glow plugs are energised for. There are 3 pre-set time periods
depending on engine water temperature. The set time periods for activating the glow plugs are for 1
second, 5 second and 10 seconds.
If the water temperature exceeds a given value equal to 105°C (221°F) and the machine is not already in cut
mode the reels will be prevented from being operated. If the machine is in the cut mode the reels will stop
and the units will be raised. This will enable the operator to be aware that a problem has occurred and take
additional load from the engine. Before the reels are shut off both the alarm lamp and buzzer will be
operated for a 60sec period, beeping at a rate of twice per second. Once the reels have stopped and the
units are raised an error flash code 3 will be shown on the LED.
6. Cutting unit control

The lift/lower function cannot be activated without the seat switch closed, i.e unless the operator is in the
seat and the seat switch is made.
The raise / lower command is a single digital input to the controller system. The operator will press the switch
once to lower the decks and once to raise the decks, this can from either the foot or paddle control. It will be
assumed by the controller that on system start up the decks are in a raised position. Upon detecting a lower
command, the Lower Solenoid will be energised for 2 seconds (variable parameter). Upon detecting a raise
command, the Raise Solenoid will be energised for 2 seconds. If the raise / lower command switch is held,
the appropriate solenoid will remain energised until the raise / lower switch is released.
Once the units have been lowered, the reels can be started and stopped by pressing and releasing the PTO
switch and switching the Speed Control lever from the transport to mow speed setting. If the reels are
operating, and a raise command is issued, the reels will be stopped after a delay of 1.5secs and the units will
be raised.
Once the units are lowered again, the reels will automatically be re-started immediately with no delay.
When a fault condition has occurred the reels cannot be restarted until the PTO switch has been switch off
then on again after the fault has been cleared.
The operator can leave the seat when the park brake is engaged without the engine stopping, however if the
reels are running they will stop. When this occurs they cannot be restarted until the operator is back in the
seat and the PTO switch is switch off then on again.
11D-12
7. Alarm
The controller system will have two outputs assigned to the alarm, these will be used to control both a lamp
and a warning buzzer.
Conditions are ignored for the relevant delay period before any response other than the Lamp / LED / Buzzer
alert occurs.
Under the following conditions the alarm will activate:
Condition Signal Priority Action after delay period

Reels stopped and raised after
Oil pressure low Constant lamp and buzzer 1 60 seconds and then engine
shutdown after further 60
seconds delay
Water temperature Lamp and buzzer will beep
2 Reels stopped and raised
too high twice every second
Start condition glow
Solid lamp (no buzzer) N/A N/A
plugs on
Table 9-2 - Alarm conditions
During the start sequence only the conditions for low oil pressure and excessive water temperature will be
ignored.
The Lamp output will be high when the ignition is on and the crank signal has not been activated. When the
crank signal is activated and all engine enable conditions are met, then the Lamp will flash once a second
until the engine is started (signalling that glow plugs are on).
8. Controller Indicator LED

The red LED mounted on the controller is used to indicate when the action has been taken according to the
relevant conditions shown in the table in Section 2.3.
Table 3 relates to when the engine is not running and a fault prevents engine starting.
The controller is equipped with two indicating LED’s:

Red and Green.
Green is used to indicate power
Red is used to indicate fault conditions
Condition Signal Priority
Seat switch open One flash every two seconds 1

Park brake disengaged Two flashes every two seconds 2
Cutter(PTO) switch on Three flashes every two seconds 3
Table 9-3 - Faults preventing engine start
The flash codes 1 and 2 will be shown until the condition is cleared, flash code 3 will be shown until power is
cycled.
11D-13
Table 4 relates to when the engine is running and a fault occurs.
Condition Signal Priority
Oil pressure low One flash every two seconds 1

Water temperature too high Two flashes every two seconds 2
Seat switch shutdown Three flashes every two seconds 3
Table 9-4 - Faults when engine is running
Flash code 1 and 3 will be shown until power is cycled. Flash code 2 will be shown until the condition is
cleared.
9. Backlap control function

It is necessary to rotate the cylinders in the reverse direction to permit the use of a lapping paste to sharpen
both the cylinder blades and bottom blade. The reverse rotation is selected by means of a manually operated
spool valve. To enable the Backlap function to operate the following conditions must be met.
Sensor State
Seat Switch Closed (Operator Present)

Park Brake Closed (Brake Engaged)
Mow (PTO) Switch and/or Disengaged
Reel Interlock Switch Disengaged
Engine Oil Pressure Within operating limits
Backlap switch Closed (Engaged)
Table 9-5 - Backlap start conditions
This should enable the machine to be started and, provided the operator is in the seat and the reels lowered,
they should be able to engage the mow switch. Having selected Backlap the reels will rotate in reverse.
It will then be possible for the operator to dismount and apply lapping paste for a period up to 5 minutes,
after which time, if the operator has not re-seated, the reels will stop automatically, but the engine will
continue to run. To restart the reels the operator will need to be seated and return the PTO switch to the
disengaged position and then switch it back to the engaged position at which point the reels will restart.
Note: In Backlap mode if the park brake is disengaged then the engine will stop immediately.
When the machine is in Backlap mode and the operator changes the mode to normal cutting mode, the
cutters will stop and need to be restarted as per the normal cutter start conditions.
10. Data logging

The last 50 “Error” shutdowns that the controller performs are logged by the controller.
The term ‘Shutdown’ as far as logging is concerned, refers to an engine shutdown caused by the park brake
and seat switch condition in normal mode, an engine shutdown caused by the park brake condition in
Backlap mode, a cutter shutdown caused by low oil pressure (which then goes on to shut off the engine if
remaining high for a further 60s) and a cutter shutdown caused by high engine temperature.
The controller will log this data against the total hours run. The total hours run will be clocked with reference
to the time that the fuel solenoid is engaged. This information can be retrieved using the Service Diagnostic
Tool. The information is translated using some different legends, for example different shutdowns have been
given different numeric values.
The Shutdown legend is as shown:
11D-14
Numeric Value Shutdown Condition
1 Oil Pressure Cutter Shutdown

2 Park Brake/Seat Switch Engine Shutdown
3 Backlap Mode/Park Brake Engine Shutdown
4 High Engine Temperature Cutter Shutdown
Table 9-6 - Shutdown conditions
The controller will also store the following information:
Information Logged
1 The total hours run

2 The number of hours the cutters are running
3 The number of lift/lower signals
4 The number of times the machine is started
Table 9-7 – Information logged and stored
11. List of Inputs & Outputs
Inputs Types Used Configuration Assignment
C1P5 AIN/CAN Shield Yes Analogue* Start/Stop Cutters

C1P6 DIN Yes Digital Starter Signal
C1P7 DIN Yes Digital Seat Switch
C1P10 DIN/AIN/FreqIN Yes Digital Backlap Enable
C1P11 DIN/AIN/FreqIN Yes Digital Park Brake
C1P12 DIN/AIN/FreqIN Yes Digital Engine Oil Pressure
C2P1 DIN/AIN/FreqIN Yes Analogue Engine Water Temp
C2P2 DIN/AIN/FreqIN Yes Digital Raise/Lower Switch
Outputs Types Used Configuration Assignment
C2P3 DOUT Yes Digital Glow Plug

C2P4 DOUT Yes Digital Starter Motor
C2P5 DOUT Yes Digital Fuel Sol
C2P6 DOUT Yes Digital Alarm lamp
C2P7 DOUT Yes Digital Raise Solenoid
C2P8 DOUT Yes Digital Lower Solenoid
C2P9 DOUT Yes Digital Cut Solenoid
C2P10 DOUT Yes Digital Alarm Buzzer
Comms and Power
C1P1 Power Ground

C1P2 Power Supply
C2P11 Power Supply
C2P12 Power Supply
C1P3 CAN High
C1P4 CAN Low
C1P8 Sensor Power Supply
C1P9 Sensor Power Ground
* Configured as Analogue but actually Digital using threshhold value
Table 9-8 – Input & Outputs
11D-15
12. Signal characteristics
Sensor or Input Characteristic
Crank signal Digital Active with 12V

Cutter switch Digital Active with 5V
Park brake Digital Active with 5V
Raise / lower Digital Active with 5V
Seat switch Digital Active with 5V
Engine oil pressure Digital 5V high when pressure OK
Engine water temperature Analogue 0 – 12V
Enable Backlap Digital Active with ground
Table 9-9 - Signal characteristics
11D-16
RANSOMES JACOBSEN SERVICE TRAINING G-PLEX III – FH SERIES (DIESEL)
SECTION 11E –CIRCUIT DIAGRAMS
CIRCUIT VOLTAGE MEASUREMENTS
NOTE: Prior to any electrical testing, first determine the Battery Reference Voltage reading, and ensure that
all tests are performed with a good ground.
Component Wire Voltage

HOT CIRCUIT Starter Solenoid Black BRV
Alternator O/P Brown BRV
Key Switch Brown BRV
Fuse Box – Terminal 7 Brown BRV
Glow Plug (Heater) Fuse (40A) Brown BRV
Glow Plug Relay – Terminal 30 Brown/Red BRV
Starter Relay – Terminal 30 Brown BRV
Shut-down Timer Brown BRV
KEY SWITCHED CIRCUIT Key Switch White BRV
Fuse Box – Terminals 8 - 12 White BRV
Fuse Box – Terminal 2 Green/Orange BRV
Fuse Box – Terminal 3 Green/Brown BRV
Fuse Box – Terminal 4 Green BRV
Fuse Box – Terminal 5 Green/Black BRV
Fuse Box – Terminal 6 Blue BRV
Controller (Black) - Terminal 11 Green/Brown BRV
PTO Switch – Terminal 2 Green BRV
Fuel Pump Green BRV
Air Seat Connector Green/Orange BRV
Accessory Socket Green/Brown BRV
Light Switch – Terminal 2 Blue BRV
CONTROLLED CIRCUIT Controller (Black) – Terminal 1 Blue/Green 0-12 V
Controller (Black) – Terminal 6 Orange/Black 12 V
Controller (Black) – Terminal 11 Green/Brown BRV
Controller (Black) – Terminal 12 Green/Brown 12 V
Controller (Gray) – Terminal 1 Black Ground
Controller (Gray) – Terminal 2 Green/Brown 12 V
Controller (Gray) – Terminal 8 Yellow 5V
Controller (Gray) – Terminal 12 Blue/Brown 0-5 V
Alarm Lamp Orange/Black 12 V
PTO Switch – Terminal 6 Yellow 5V
Foot Pedal Switch Yellow 5V
Paddle Switch Yellow 5V
Seat Switch Yellow 5V
Park Brake Switch
Water Temperature Sender
Yellow
Blue/Green
5V
0-12 V
11E
Oil Pressure Sensor Blue/Brown 0-5 V
SAFETY CIRCUIT Controller (Gray) – Terminal 6 Yellow/Blue 0V
= PTO & Reel Interlock Switch Yellow/Blue 0V
Controller (Gray) – Terminal 7 Yellow/Brown 5V
= Seat Switch Yellow/Brown 5V
Controller (Gray) – Terminal 11 Yellow/Slate 0V
= Park Brake Switch Yellow/Slate 0V
CRANK CIRCUIT Key Switch White/Red BRV
Controller (Gray) – Terminal 6 White/Red BRV
Controller (Black) – Terminal 3 Light Green 12 V
Controller (Black) – Terminal 4 Light Green/Red 12 V
Controller (Black) – Terminal 5 Light Green/Brown 12 V
Hour Meter Light Green/Brown 12 V
Shut Down Timer Light Green/Brown 12 V
Glow Plug Relay Light Green 12 V
Starter Relay Light Green/Red 12 V
Glow Plugs Brown/Blue 12 V
Starter Solenoid White/Red 12 V
Table 9-10a
11E-13
RANSOMES JACOBSEN SERVICE TRAINING G-PLEX III – FH SERIES (DIESEL)
SECTION 11E –CIRCUIT DIAGRAMS
CIRCUIT VOLTAGE MEASUREMENTS (Continued)
Component Wire Voltage

LIFT / LOWER CIRCUIT Paddle Switch Yellow/Black 5V
or Foot Pedal Switch Yellow/Black 5V
and PTO Switch Blue/Yellow 5V
then Lower Solenoid White/Blue 5V
and Reel Solenoid White/Pink 5V
Paddle Switch Yellow/Black 5V

or Foot Pedal Switch Yellow/Black 5V
then Raise Solenoid White/Black 5V
and Reel Solenoid White/Pink 0V
KEY SWITCH OFF Key Switch White 0V
Controller (Black) - Terminal 5 Light/Green 0V
Shut Down Timer Light Green/Brown 0V
Shut Down Timer (for 7 sec) Brown/Orange BRV
Fuel Solenoid (for 7 sec) Brown/Orange BRV
Table 9-10b
11E-14
10 11 G-PLEX III
TEMPERATURE GAUGE ALARM LAMP
(WITH ALARM O/P) FH SERIES
I GP 12V 1.0 G SP#7 O/B 1.0 1.0 B SP#2
6 DIESEL POWERED
BATTERY GROUND 1.0 B SP#2 12
5
5 Amp O/P N/C ALARM BUZZER
4
SENDER I/P Var 1.0 U/G SP#8
3
IGP ALARM I/P 12V 1.0 G SP#7 LG/K 1.0 1.0 B SP#2
2
ILLUMINATION 12V 1.0 U
1
9 Y/B 1.0
HOUR METER Y/O 1.0
1.0 LG/N W/U 1.0
1
1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)
SP#11
POWER GROUND 1.0 B SP#2 Y/S 1.0
1
POWER 12V 1.0 G/N Y/U 1.0
2
CHANNEL H 0.5 Red B/Y 1.0
3
CHANNEL L 0.5 Blue
4 0
START/STOP CUTTERS I/P 5V 1.0 Y/U
13
5
STARTER I/P 12V 1.0 W/R REEL ENABLE SWITCH 18 2.0 G/B
6 1 1
(PTO SWITCH) SP#2
SEAT SWITCH I/P 5V 1.0 Y/N 1 ACCESSORY 2.0 B
7 2
SENSOR POWER SUPPLY 5V 1.0 Y SP#6 SP#7 G 1.0 2
SOCKET
8
SENSOR GROUND 1.0 B/Y 3 1.0 R/B
9
BACKLAP I/P 5V 1.0 Y/O 4
10
PARK BRAKE I/P 5V 1.0 Y/S U/Y 1.0 5
11
ENGINE OIL PRESS I/P Var 1.0 U/N 6 1.0 Y SP#6 34 1.0 G/O
12 1
SP#2 B 1.0 7 8 1.0 R/B AIR SEAT 1.0 B SP#9
2
CONNECTOR
U/Y 1.0
ENGINE WATER TEMP I/P Var 1.0 U/G SP#8

1
RAISE / LOWER I/P 5V 1.0 Y/B U/N 1.0
2
GLOW PLUG O/P 12V 1.0 LG
3
START SOLENOID O/P 12V 1.0 LG/R
4 17
FUEL SOLENOID O/P 12V 1.0 LG/N
5 SHUTDOWN TIMER
ALARM LAMP O/P 12V 1.0 O/B
6
RAISE SOLENOID O/P 12V 1.0 W/B SP#2 B 1.0 1.0 N/O N/O 1.0
7 GND O/P
LOWER SOLENOID O/P 12V 1.0 W/U N 1.0 1.0 LG/N
8
+ve TRIG
MOW SOLENOID O/P 12V 1.0 W/K
9
ALARM BUZZER O/P 12V 1.0 LG/K
10
POWER 12V 1.0 G/N
11 36
POWER 12V 1.0 G/N
12
N 1.0 7 1
HEATER FUSE 87a
W 2.0 8 10A 2 1.0 G/O N 3.0 40A 3.0 N/R N/R 3.0 3.0 N/U N/U 3.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G SP#7 LG 1.0 86 85 1.0 B SP#2
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 4.5
SP#3
14 16
W 2.0 12 15A 6 2.0 U SP#1
0.5 Red LIGHT SWITCH GLOW PLUG RELAY
1 0
0.5 Blue TWISTED PAIR
2
LG 6
3 1
FUSE BOX 1
5
37 U 2.0 2 2.0 U/R SP#5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
ELECTRIC DIAGRAM CAN ADAPTOR W
15
MASTER P/N 4150557 STARTER RELAY
W/R
SERVICE TOOL I/P RUN ST
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 27 5 4.5 4.5 2

SP#1
PADDLE SWITCH LOWER RAISE CUT / REEL FUEL 36 3.0 BRN 2.0 15
FH SERIES SOLENOID SOLENOID SOLENOID PUMP 1.0 17
Y/B 1.0 1.0 1.0 Y SP#7 G 1.0
DIESEL POWERED 2
SP#6 Y 1.0 NO 9 1.0 1.0 11
1
M 10 1.0 1.0 12
GND
1 2 1 2 1 2 SP#9 B 1.0 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0 1.0 17
1.0
1.0
1.0
1.0
1.0
1.0
FOOT SWITCH 13 1.0 2.0 18
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
22 PARK BRAKE SWITCH SP#5 7 1.0 G/N
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 Y/U NC BACKLAP SWITCH
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 31 SP#6
YEL 1.0 22
REEL INTERLOCK SP#8 U/G 1.0 WATER TEMP
SWITCH SENSOR
1.0 U/Y
1.0 27
IGP
30 10 1.0 1.0 13
SP#7
OIL PRESSURE 10 1.0 GRN 1.0 6
1.0 U/N U/N 1.0
SENSOR 1.0 4
35 29
FUEL SOLENOID GLOW PLUGS OO
10 1.0 1.0 31
1.0 N/O N/O 1.0 N/U 3.0
SP#8
7 1.0 U/G
1.0 23
1 3.0 1.0 24
GND
32 1.0 1.0 25
SP#9
33 1.0 BLK 1.0 27
ROTOR O/P
3.0 N/U 2.0 34
4
2.0 W/R
ALTERNATOR
4.5 4.5 3
SP#7 OO
STARTER G 1.0 19 1.0 1.0 8
Wire Colour Chart SP#10
SOLENOID 20 1.0 Y/B
B - Black
2 4.5 N
1 G - Green
MAIN STARTER K - Pink
GROUND POINT
TERMINAL LG - Light Green
SP#2 B 2.0
28 2 W/R
N - Brown OO
SP#9 B 3.0 BATTERY 7 1.0 1.0 17
O - Orange SP#11
9 1.0 LG/N
R - Red
S - Slate/Gray
U - Blue
V - Violet ELECTRIC DIAGRAM
39
W - White
ENGINE GROUND MASTER
2 of 2
10 11 G-PLEX III
I GP 12V 1.0 G SP#7 O/B 1.0 1.0 B SP#2
6 DIESEL POWERED
5
4
3
2
1
9 Y/B 1.0
HOUR METER Y/O 1.0
1.0 LG/N W/U 1.0
1
1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)
SP#11
1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
3
4 17
5 SHUTDOWN TIMER
6
7 GND O/P
8
+ve TRIG
9
10
POWER 12V 1.0 G/N
11 36
POWER 12V 1.0 G/N
12
N 1.0 7 1
HEATER FUSE 87a
W 2.0 8 10A 2 1.0 G/O N 3.0 40A 3.0 N/R N/R 3.0 3.0 N/U N/U 3.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G SP#7 LG 1.0 86 85 1.0 B SP#2
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 4.5
SP#3
14 16
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
5
37 U 2.0 2 2.0 U/R SP#5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
15
HOT CIRCUIT P/N 4150557 STARTER RELAY
W/R
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 27 5 4.5 4.5 2

SP#1
Y/B 1.0 1.0 1.0 Y SP#7 G 1.0
DIESEL POWERED 2
SP#6 Y 1.0 NO 9 1.0 1.0 11
1
M 10 1.0 1.0 12
GND
1 2 1 2 1 2 SP#9 B 1.0 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0 1.0 17
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 31 SP#6
YEL 1.0 22
SWITCH SENSOR
1.0 U/Y
1.0 27
IGP
30 10 1.0 1.0 13
SP#7
1.0 U/N U/N 1.0
SENSOR 1.0 4
35 29
10 1.0 1.0 31
1.0 N/O N/O 1.0 N/U 3.0
SP#8
7 1.0 U/G
1.0 23
1 3.0 1.0 24
GND
32 1.0 1.0 25
SP#9
33 1.0 BLK 1.0 27
ROTOR O/P
3.0 N/U 2.0 34
4
2.0 W/R
ALTERNATOR
4.5 4.5 3
SP#7 OO
STARTER G 1.0 19 1.0 1.0 8
SOLENOID 20 1.0 Y/B
B - Black
2 4.5 N
1 G - Green
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown OO
SP#9 B 3.0 BATTERY 7 1.0 1.0 17
O - Orange SP#11
9 1.0 LG/N
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND HOT CIRCUIT
2 of 2
10 11 G-PLEX III
I GP 12V 1.0 G SP#7 O/B 1.0 1.0 B SP#2
6 DIESEL POWERED
5
4
3
2
1
9 Y/B 1.0
HOUR METER Y/O 1.0
1.0 LG/N W/U 1.0
1
1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)
SP#11
1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
3
4 17
5 SHUTDOWN TIMER
6
7 GND O/P
8
+ve TRIG
9
10
POWER 12V 1.0 G/N
11 36
POWER 12V 1.0 G/N
12
N 1.0 7 1
HEATER FUSE 87a
W 2.0 8 10A 2 1.0 G/O N 3.0 40A 3.0 N/R N/R 3.0 3.0 N/U N/U 3.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G SP#7 LG 1.0 86 85 1.0 B SP#2
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 4.5
SP#3
14 16
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
5
37 U 2.0 2 2.0 U/R SP#5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
15
IGNITION ON P/N 4150557 STARTER RELAY
W/R
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 27 5 4.5 4.5 2

SP#1
Y/B 1.0 1.0 1.0 Y SP#7 G 1.0
DIESEL POWERED 2
SP#6 Y 1.0 NO 9 1.0 1.0 11
1
M 10 1.0 1.0 12
GND
1 2 1 2 1 2 SP#9 B 1.0 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0 1.0 17
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 31 SP#6
YEL 1.0 22
SWITCH SENSOR
1.0 U/Y
1.0 27
IGP
30 10 1.0 1.0 13
SP#7
1.0 U/N U/N 1.0
SENSOR 1.0 4
NOTE:
35 29 Safety circuit is
FUEL SOLENOID GLOW PLUGS indicated as follows: OO
10 1.0 1.0 31
1.0 N/O N/O 1.0 N/U 3.0
SP#8
7 1.0 U/G
1 Nobody in the seat.
2 Parking brake dis-
engaged.
1.0 23
3 PTO switch off.
1 3.0 1.0 24
4 Reel interlock GND
32 1.0 1.0 25
switch off ( lever in SP#9
33 1.0 BLK 1.0 27
ROTOR O/P transport position).
3.0 N/U 2.0 34
4
2.0 W/R
ALTERNATOR
4.5 4.5 3
SP#7 OO
STARTER G 1.0 19 1.0 1.0 8
SOLENOID 20 1.0 Y/B
B - Black
2 4.5 N
1 G - Green
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown OO
SP#9 B 3.0 BATTERY 7 1.0 1.0 17
O - Orange SP#11
9 1.0 LG/N
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND IGNITION ON
2 of 2
10 11 G-PLEX III
I GP 12V 1.0 G SP#7 O/B 1.0 1.0 B SP#2
6 DIESEL POWERED
5
4
3
2
1
9 Y/B 1.0
HOUR METER Y/O 1.0
1.0 LG/N W/U 1.0
1
1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)
SP#11
1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
3
4 17
5 SHUTDOWN TIMER
6
7 GND O/P
8
+ve TRIG
9
10
POWER 12V 1.0 G/N
11 36
POWER 12V 1.0 G/N
12
N 1.0 7 1
HEATER FUSE 87a
W 2.0 8 10A 2 1.0 G/O N 3.0 40A 3.0 N/R N/R 3.0 3.0 N/U N/U 3.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G SP#7 LG 1.0 86 85 1.0 B SP#2
(BLACK)
W 2.0 11 10A 5 2.0 G/B 4.5
SP#3
14 16
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
5
37 U 2.0 2 2.0 U/R SP#5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
15
CRANK ENGINE P/N 4150557 STARTER RELAY
W/R
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 27 5 4.5 4.5 2

SP#1
Y/B 1.0 1.0 1.0 Y SP#7 G 1.0
DIESEL POWERED 2
SP#6 Y 1.0 NO 9 1.0 1.0 11
1
M 10 1.0 1.0 12
GND
1 2 1 2 1 2 SP#9 B 1.0 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0 1.0 17
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
22 PARK BRAKE SWITCH 7 1.0
SP#5 U/R 1.0 G/N
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 31 SP#6
YEL 1.0 22
SWITCH SENSOR
1.0 U/Y
1.0 27
IGP
30 10 1.0 1.0 13
SP#7
1.0 U/N U/N 1.0
SENSOR 1.0 4
NOTE:
35 29 Safety circuit is
FUEL SOLENOID GLOW PLUGS indicated as follows: OO
10 1.0 1.0 31
1.0 N/O N/O 1.0 N/U 3.0
SP#8
7 1.0 U/G
1 Body in the seat.
2 Parking brake
engaged.
1.0 23
3 PTO switch off.
1 3.0 1.0 24
4 Reel interlock GND
32 1.0 1.0 25
33 1.0 BLK 1.0 27
ROTOR O/P transport position).
3.0 N/U 2.0 34
4
2.0 W/R
ALTERNATOR
4.5 4.5 3
SP#7 OO
STARTER G 1.0 19 1.0 1.0 8
SOLENOID 20 1.0 Y/B
B - Black
2 4.5 N
1 G - Green
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown OO
SP#9 B 3.0 BATTERY 7 1.0 1.0 17
O - Orange SP#11
9 1.0 LG/N
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND CRANK ENGINE
2 of 2
10 11 G-PLEX III
I GP 12V 1.0 G SP#7 O/B 1.0 1.0 B SP#2
6 DIESEL POWERED
5
4
3
2
1
9 Y/B 1.0
HOUR METER Y/O 1.0
1.0 LG/N W/U 1.0
1
1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)
SP#11
1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
3
4 17
5 SHUTDOWN TIMER
6
7 GND O/P
8
+ve TRIG
9
10
POWER 12V 1.0 G/N
11 36
POWER 12V 1.0 G/N
12
N 1.0 7 1
HEATER FUSE 87a
W 2.0 8 10A 2 1.0 G/O N 3.0 40A 3.0 N/R N/R 3.0 3.0 N/U N/U 3.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G SP#7 LG 1.0 86 85 1.0 B SP#2
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 4.5
SP#3
14 16
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
5
37 U 2.0 2 2.0 U/R SP#5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
15
ENGINE RUNNING P/N 4150557 STARTER RELAY
W/R
DRIVE TO GREEN
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 27 5 4.5 4.5 2

SP#1
Y/B 1.0 1.0 1.0 Y SP#7 G 1.0
DIESEL POWERED 2
SP#6 Y 1.0 NO 9 1.0 1.0 11
1
M 10 1.0 1.0 12
GND
1 2 1 2 1 2 SP#9 B 1.0 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0 1.0 17
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
SP#5 U/R 1.0 G/N
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 31 SP#6
YEL 1.0 22
SWITCH SENSOR
1.0 U/Y
1.0 27
IGP
30 10 1.0 1.0 13
SP#7
1.0 U/N U/N 1.0
SENSOR 1.0 4
35 29
10 1.0 1.0 31
1.0 N/O N/O 1.0 N/U 3.0
SP#8
7 1.0 U/G
1.0 23
1 3.0 1.0 24
GND
32 1.0 1.0 25
SP#9
33 1.0 BLK 1.0 27
ROTOR O/P
3.0 N/U 2.0 34
4
2.0 W/R
ALTERNATOR
4.5 4.5 3
SP#7 OO
STARTER G 1.0 19 1.0 1.0 8
SOLENOID 20 1.0 Y/B
B - Black
2 4.5 N
1 G - Green
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown OO
SP#9 B 3.0 BATTERY 7 1.0 1.0 17
O - Orange SP#11
9 1.0 LG/N
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND ENGINE RUNNING
DRIVE TO GREEN
2 of 2
10 11 G-PLEX III
I GP 12V 1.0 G SP#7 O/B 1.0 1.0 B SP#2
6 DIESEL POWERED
5
4
3
2
1
9 Y/B 1.0
HOUR METER Y/O 1.0
1.0 LG/N W/U 1.0
1
1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)
SP#11
1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
3
4 17
5 SHUTDOWN TIMER
6
7 GND O/P
8
+ve TRIG
9
10
POWER 12V 1.0 G/N
11 36
POWER 12V 1.0 G/N
12
N 1.0 7 1
HEATER FUSE 87a
W 2.0 8 10A 2 1.0 G/O N 3.0 40A 3.0 N/R N/R 3.0 3.0 N/U N/U 3.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G SP#7 LG 1.0 86 85 1.0 B SP#2
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 4.5
SP#3
14 16
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
5
37 U 2.0 2 2.0 U/R SP#5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
15
MOWING - LOWER UNITS P/N 4150557 STARTER RELAY
W/R
USING PADDLE
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 27 5 4.5 4.5 2

SP#1
Y/B 1.0 1.0 1.0 Y SP#7 G 1.0
DIESEL POWERED 2
SP#6 Y 1.0 NO 9 1.0 1.0 11
1
M 10 1.0 1.0 12
GND
1 2 1 2 1 2 SP#9 B 1.0 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0 1.0 17
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
SP#5 U/R 1.0 G/N
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 31 SP#6
YEL 1.0 22
SWITCH SENSOR
1.0 U/Y
1.0 27
IGP
30 10 1.0 1.0 13
SP#7
1.0 U/N U/N 1.0
SENSOR 1.0 4
35 29
10 1.0 1.0 31
1.0 N/O N/O 1.0 N/U 3.0
SP#8
7 1.0 U/G
1.0 23
1 3.0 1.0 24
GND
32 1.0 1.0 25
SP#9
33 1.0 BLK 1.0 27
ROTOR O/P
3.0 N/U 2.0 34
4
2.0 W/R
ALTERNATOR
4.5 4.5 3
SP#7 OO
STARTER G 1.0 19 1.0 1.0 8
SOLENOID 20 1.0 Y/B
B - Black
2 4.5 N
1 G - Green
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown OO
SP#9 B 3.0 BATTERY 7 1.0 1.0 17
O - Orange SP#11
9 1.0 LG/N
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND MOWING - LOWER UNITS
USING PADDLE
2 of 2
10 11 G-PLEX III
I GP 12V 1.0 G SP#7 O/B 1.0 1.0 B SP#2
6 DIESEL POWERED
5
4
3
2
1
9 Y/B 1.0
HOUR METER Y/O 1.0
1.0 LG/N W/U 1.0
1
1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)
SP#11
1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
3
4 17
5 SHUTDOWN TIMER
6
7 GND O/P
8
+ve TRIG
9
10
POWER 12V 1.0 G/N
11 36
POWER 12V 1.0 G/N
12
N 1.0 7 1
HEATER FUSE 87a
W 2.0 8 10A 2 1.0 G/O N 3.0 40A 3.0 N/R N/R 3.0 3.0 N/U N/U 3.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G SP#7 LG 1.0 86 85 1.0 B SP#2
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 4.5
SP#3
14 16
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
5
37 U 2.0 2 2.0 U/R SP#5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
15
MOWING - RAISE UNITS P/N 4150557 STARTER RELAY
W/R
USING FOOT PEDAL
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 27 5 4.5 4.5 2

SP#1
Y/B 1.0 1.0 1.0 Y SP#7 G 1.0
DIESEL POWERED 2
SP#6 Y 1.0 NO 9 1.0 1.0 11
1
M 10 1.0 1.0 12
GND
1 2 1 2 1 2 SP#9 B 1.0 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0 1.0 17
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
SP#5 U/R 1.0 G/N
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 31 SP#6
YEL 1.0 22
SWITCH SENSOR
1.0 U/Y
1.0 27
IGP
30 10 1.0 1.0 13
SP#7
1.0 U/N U/N 1.0
SENSOR 1.0 4
35 29
10 1.0 1.0 31
1.0 N/O N/O 1.0 N/U 3.0
SP#8
7 1.0 U/G
1.0 23
1 3.0 1.0 24
GND
32 1.0 1.0 25
SP#9
33 1.0 BLK 1.0 27
ROTOR O/P
3.0 N/U 2.0 34
4
2.0 W/R
ALTERNATOR
4.5 4.5 3
SP#7 OO
STARTER G 1.0 19 1.0 1.0 8
SOLENOID 20 1.0 Y/B
B - Black
2 4.5 N
1 G - Green
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown OO
SP#9 B 3.0 BATTERY 7 1.0 1.0 17
O - Orange SP#11
9 1.0 LG/N
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND MOWING - RAISE UNITS
USING FOOT PEDAL
2 of 2
10 11 G-PLEX III
I GP 12V 1.0 G SP#7 O/B 1.0 1.0 B SP#2
6 DIESEL POWERED
5
4
3
2
1
9 Y/B 1.0
HOUR METER Y/O 1.0
1.0 LG/N W/U 1.0
1
1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)
SP#11
1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
3
4 17
5 SHUTDOWN TIMER
6
7 GND O/P
8
+ve TRIG
9
10
POWER 12V 1.0 G/N
11 36
POWER 12V 1.0 G/N
12
N 1.0 7 1
HEATER FUSE 87a
W 2.0 8 10A 2 1.0 G/O N 3.0 40A 3.0 N/R N/R 3.0 3.0 N/U N/U 3.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G SP#7 LG 1.0 86 85 1.0 B SP#2
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 4.5
SP#3
14 16
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
5
37 U 2.0 2 2.0 U/R SP#5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
15
IGNITION OFF P/N 4150557 STARTER RELAY
W/R
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 27 5 4.5 4.5 2

SP#1
Y/B 1.0 1.0 1.0 Y SP#7 G 1.0
DIESEL POWERED 2
SP#6 Y 1.0 NO 9 1.0 1.0 11
1
M 10 1.0 1.0 12
GND
1 2 1 2 1 2 SP#9 B 1.0 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0 1.0 17
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 31 SP#6
YEL 1.0 22
SWITCH SENSOR
1.0 U/Y
1.0 27
IGP
30 10 1.0 1.0 13
SP#7
1.0 U/N U/N 1.0 NOTE:
SENSOR 1.0 4
When the ignition
35 switch is switched off,
29 or a safety switch has
FUEL SOLENOID
GLOW PLUGS opened, the input to OO
(SEE NOTE) 10 1.0 1.0 31
1.0 N/O N/O 1.0 N/U 3.0 the Shutdown Timer is SP#8
7 1.0 U/G
cut. The Timer will
then operate the
output to the fuel 1.0 23
solenoid for 7 sec 1 3.0 1.0 24
(approx), shutting off GND
32 1.0 1.0 25
fuel supply to the SP#9
33 1.0 BLK 1.0 27
ROTOR O/P
3.0 N/U engine. . 2.0 34
4
2.0 W/R
ALTERNATOR
4.5 4.5 3
SP#7 OO
STARTER G 1.0 19 1.0 1.0 8
SOLENOID 20 1.0 Y/B
B - Black
2 4.5 N
1 G - Green
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown OO
SP#9 B 3.0 BATTERY 7 1.0 1.0 17
O - Orange SP#11
9 1.0 LG/N
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND IGNITION OFF
2 of 2
RANSOMES JACOBSEN SERVICE TRAINING G-PLEX III – FJ SERIES (GASOLINE)
SECTION 11F –CIRCUIT DIAGRAMS
11F
11F-37
11 G-PLEX III
ALARM LAMP
FJ SERIES
O/B 1.0 1.0 B SP#2
GASOLINE POWERED
12
ALARM BUZZER
LG/K 1.0 1.0 B SP#2
9 Y/B 1.0
HOUR METER Y/O 1.0
RUN I/P 12V 1.0 LG/N W/U 1.0
1
BATTERY GROUND 1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)

1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SENSOR POWER SUPPLY 5V 1.0 Y SP#6 G 1.0 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0
ENGINE WATER TEMP I/P

1
2
GLOW PLUG O/P
3
4
FUEL SOLENOID O/P 12V 1.0 LG/N SP#11 LG/N 1.0
5
6
RAISE SOLENOID O/P 12V 1.0 W/B
7
LOWER SOLENOID O/P 12V 1.0 W/U
8
9
10
POWER 12V 1.0 G/N 16
11
POWER 12V 1.0 G/N ENGINE STOP RELAY
12
N 1.0 7 2A 1 87a 1.0 B/G B/G 1.0
W 2.0 8 10A 2 1.0 G/O B 1.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G LG/N 1.0 86 85 1.0 B SP#2 N 2.0
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 1.0 B 4.5
SP#3
14
W 2.0 12 15A 6 2.0 U SP#1
0.5 Red LIGHT SWITCH
1 0
2
LG 6
3 1
FUSE BOX 1
15
5
37 U 2.0 2 2.0 U/R SP#5 STARTER RELAY
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
MASTER P/N 4150557
W/R
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 5 4.5 4.5 2
SP#1
PADDLE SWITCH LOWER RAISE CUT / REEL BRN 2.0 15
FJ SERIES SOLENOID SOLENOID SOLENOID 2.0 4
GASOLINE POWERED Y/B 1.0 1.0 1.0 Y
2
SP#6 Y 1.0 NO 1.0 11
1
10 1.0 1.0 12
GND
1 2 1 2 1 2 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 SP#6
YEL 1.0 22
REEL INTERLOCK
SWITCH
1.0 U/Y
1 3.0 1.0 23
GND
32 1.0 1.0 24
SP#9
30 33 1.0 BLK 1.0 25
1.0 U/N U/N 1.0
OIL LIGHT 2.0 34
SWITCH
36
1.0 LG/N LG/N 1.0
FUEL SOLENOID OO
19 1.0 1.0 8
SP#10
20 1.0 Y/B
4
35 ALTERNATOR
B/G 1.0
ENGINE KILL
ROTOR O/P OO
7 1.0 1.0 16
SP#11
1.0 B/G 10 1.0 1.0 36
LG/N
2.0 W/R
2.0 N N 2.0
4.5 4.5
3 Wire Colour Chart

STARTER B - Black
2 SOLENOID G - Green
1
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown
SP#9 B 3.0 BATTERY
O - Orange
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND MASTER
2 of 2
11 G-PLEX III
ALARM LAMP
FJ SERIES
O/B 1.0 1.0 B SP#2
GASOLINE POWERED
12
ALARM BUZZER
LG/K 1.0 1.0 B SP#2
9 Y/B 1.0
HOUR METER Y/O 1.0
RUN I/P 12V ? 1.0 LG/N W/U 1.0
1
BATTERY GROUND 12V - 1.0 B SP#2 W/K 1.0
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)

1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
GLOW PLUG O/P
3
4
5
6
7
8
9
10
11
12
N 1.0 7 1 87a 1.0 B/G B/G 1.0
W 2.0 8 10A 2 1.0 G/O B 1.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G LG/N 1.0 86 85 1.0 B SP#2 N 2.0
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 1.0 B 4.5
SP#3
14
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
15
5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
HOT CIRCUIT P/N 4150557
W/R
(also ENGINE OFF)
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 5 4.5 4.5 2
SP#1
2
SP#6 Y 1.0 NO 1.0 11
1
10 1.0 1.0 12
GND
1 2 1 2 1 2 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 SP#6
YEL 1.0 22
REEL INTERLOCK
SWITCH
1.0 U/Y
1 3.0 1.0 23
GND
32 1.0 1.0 24
SP#9
30 33 1.0 BLK 1.0 25
1.0 U/N U/N 1.0
OIL LIGHT 2.0 34
SWITCH
36
1.0 LG/N LG/N 1.0
FUEL SOLENOID OO
19 1.0 1.0 8
SP#10
20 1.0 Y/B
4
35 ALTERNATOR
B/G 1.0
ENGINE KILL
ROTOR O/P OO
7 1.0 1.0 16
SP#11
1.0 B/G 10 1.0 1.0 36
LG/N
2.0 W/R
2.0 N N 2.0
4.5 4.5
3 Wire Colour Chart

STARTER B - Black
1
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown
SP#9 B 3.0 BATTERY
O - Orange
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND HOT CIRCUIT
(also ENGINE OFF)
2 of 2
11 G-PLEX III
ALARM LAMP
FJ SERIES
O/B 1.0 1.0 B SP#2
GASOLINE POWERED
12
ALARM BUZZER
LG/K 1.0 1.0 B SP#2
9 Y/B 1.0
HOUR METER Y/O 1.0
RUN I/P 12V ? 1.0 LG/N W/U 1.0
1
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)

1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
GLOW PLUG O/P
3
4
5
6
7
8
9
10
11
12
N 1.0 7 1 87a 1.0 B/G B/G 1.0
W 2.0 8 10A 2 1.0 G/O B 1.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G LG/N 1.0 86 85 1.0 B SP#2 N 2.0
(BLACK) 85
W 2.0 11 10A 5 2.0 G/B 1.0 B 4.5
SP#3
14
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
15
5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
IGNITION ON P/N 4150557
W/R
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 5 4.5 4.5 2
SP#1
2
SP#6 Y 1.0 NO 1.0 11
1
10 1.0 1.0 12
GND
1 2 1 2 1 2 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

22 PARK BRAKE SWITCH NO NO SP#4
SP#5 7 1.0 G/N
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 SP#6
YEL 1.0 22
REEL INTERLOCK
SWITCH
1.0 U/Y
1 3.0 1.0 23
GND
32 1.0 1.0 24
SP#9
30 33 1.0 BLK 1.0 25
1.0 U/N U/N 1.0
OIL LIGHT 2.0 34
SWITCH
NOTE:
36
1.0 LG/N LG/N 1.0 Safety circuit is
FUEL SOLENOID indicated as follows: OO
19 1.0 1.0 8
SP#10
20 1.0 Y/B
1 Nobody in the seat.
4 2 Parking brake dis-
35 ALTERNATOR engaged.
B/G 1.0
ENGINE KILL 3 PTO switch off.
ROTOR O/P 4 Reel interlock OO
7 1.0 1.0 16
1.0 B/G 10 1.0 1.0 36
LG/N
transport position).
2.0 W/R
2.0 N N 2.0
4.5 4.5
3 Wire Colour Chart

STARTER B - Black
1
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown
SP#9 B 3.0 BATTERY
O - Orange
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND IGNITION ON
2 of 2
11 G-PLEX III
ALARM LAMP
FJ SERIES
O/B 1.0 1.0 B SP#2
GASOLINE POWERED
12
ALARM BUZZER
LG/K 1.0 1.0 B SP#2
9 Y/B 1.0
HOUR METER Y/O 1.0
RUN I/P 12V ? 1.0 LG/N W/U 1.0
1
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)

1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
GLOW PLUG O/P
3
4
5
6
7
8
9
10
11
12
N 1.0 7 1 87a 1.0 B/G B/G 1.0
W 2.0 8 10A 2 1.0 G/O B 1.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G LG/N 1.0 86 85 1.0 B SP#2 N 2.0
(BLACK)
W 2.0 11 10A 5 2.0 G/B 1.0 B 4.5
SP#3
14
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
15
5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
CRANK ENGINE P/N 4150557
W/R
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 5 4.5 4.5 2
SP#1
2
SP#6 Y 1.0 NO 1.0 11
1
10 1.0 1.0 12
GND
1 2 1 2 1 2 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 SP#6
YEL 1.0 22
REEL INTERLOCK
SWITCH
1.0 U/Y
1 3.0 1.0 23
GND
32 1.0 1.0 24
SP#9
30 33 1.0 BLK 1.0 25
1.0 U/N U/N 1.0
OIL LIGHT 2.0 34
SWITCH
NOTE:
36
1.0 LG/N LG/N 1.0 Safety circuit is
FUEL SOLENOID indicated as follows: OO
19 1.0 1.0 8
SP#10
20 1.0 Y/B
1 Body in the seat.
4 2 Parking brake
35 ALTERNATOR engaged.
B/G 1.0
ENGINE KILL 3 PTO switch off.
ROTOR O/P 4 Reel interlock OO
7 1.0 1.0 16
1.0 B/G 10 1.0 1.0 36
LG/N
transport position).
2.0 W/R
2.0 N N 2.0
4.5 4.5
3 Wire Colour Chart

STARTER B - Black
1
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown
SP#9 B 3.0 BATTERY
O - Orange
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND CRANK ENGINE
2 of 2
11 G-PLEX III
ALARM LAMP
FJ SERIES
O/B 1.0 1.0 B SP#2
GASOLINE POWERED
12
ALARM BUZZER
LG/K 1.0 1.0 B SP#2
9 Y/B 1.0
HOUR METER Y/O 1.0
RUN I/P 12V ? 1.0 LG/N W/U 1.0
1
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)

1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
GLOW PLUG O/P
3
4
5
6
7
8
9
10
11
12
N 1.0 7 1 87a 1.0 B/G B/G 1.0
W 2.0 8 10A 2 1.0 G/O B 1.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G LG/N 1.0 86 85 1.0 B SP#2 N 2.0
(BLACK)
W 2.0 11 10A 5 2.0 G/B 1.0 B 4.5
SP#3
14
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
15
5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
ENGINE RUNNING P/N 4150557
W/R
DRIVE TO GREEN
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 5 4.5 4.5 2
SP#1
2
SP#6 Y 1.0 NO 1.0 11
1
10 1.0 1.0 12
GND
1 2 1 2 1 2 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

NO NO SP#4
U/R 1.0
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 SP#6
YEL 1.0 22
REEL INTERLOCK
SWITCH
1.0 U/Y
1 3.0 1.0 23
GND
32 1.0 1.0 24
SP#9
30 33 1.0 BLK 1.0 25
1.0 U/N U/N 1.0
OIL LIGHT 2.0 34
SWITCH
36
1.0 LG/N LG/N 1.0
FUEL SOLENOID OO
19 1.0 1.0 8
SP#10
20 1.0 Y/B
4
35 ALTERNATOR
B/G 1.0
ENGINE KILL
ROTOR O/P OO
7 1.0 1.0 16
SP#11
1.0 B/G 10 1.0 1.0 36
LG/N
2.0 W/R
2.0 N N 2.0
4.5 4.5
3 Wire Colour Chart

STARTER B - Black
1
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown
SP#9 B 3.0 BATTERY
O - Orange
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND ENGINE RUNNING
DRIVE TO GREEN
2 of 2
11 G-PLEX III
ALARM LAMP
FJ SERIES
O/B 1.0 1.0 B SP#2
GASOLINE POWERED
12
ALARM BUZZER
LG/K 1.0 1.0 B SP#2
9 Y/B 1.0
HOUR METER Y/O 1.0
RUN I/P 12V ? 1.0 LG/N W/U 1.0
1
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)

1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
GLOW PLUG O/P
3
4
5
6
7
8
9
10
11
12
N 1.0 7 1 87a 1.0 B/G B/G 1.0
W 2.0 8 10A 2 1.0 G/O B 1.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G LG/N 1.0 86 85 1.0 B SP#2 N 2.0
(BLACK)
W 2.0 11 10A 5 2.0 G/B 1.0 B 4.5
SP#3
14
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
15
5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
MOWING - LOWER UNITS P/N 4150557
W/R
USING PADDLE
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 5 4.5 4.5 2
SP#1
2
SP#6 Y 1.0 NO 1.0 11
1
10 1.0 1.0 12
GND
1 2 1 2 1 2 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

PARK BRAKE SWITCH NO NO SP#4
22 7 1.0
SP#5 U/R 1.0 G/N
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 SP#6
YEL 1.0 22
REEL INTERLOCK
SWITCH
1.0 U/Y
1 3.0 1.0 23
GND
32 1.0 1.0 24
SP#9
30 33 1.0 BLK 1.0 25
1.0 U/N U/N 1.0
OIL LIGHT 2.0 34
SWITCH
36
1.0 LG/N LG/N 1.0
FUEL SOLENOID OO
19 1.0 1.0 8
SP#10
20 1.0 Y/B
4
35 ALTERNATOR
B/G 1.0
ENGINE KILL
ROTOR O/P OO
7 1.0 1.0 16
SP#11
1.0 B/G 10 1.0 1.0 36
LG/N
2.0 W/R
2.0 N N 2.0
4.5 4.5
3 Wire Colour Chart

STARTER B - Black
1
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown
SP#9 B 3.0 BATTERY
O - Orange
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND MOWING - LOWER UNITS
USING PADDLE
2 of 2
11 G-PLEX III
ALARM LAMP
FJ SERIES
O/B 1.0 1.0 B SP#2
GASOLINE POWERED
12
ALARM BUZZER
LG/K 1.0 1.0 B SP#2
9 Y/B 1.0
HOUR METER Y/O 1.0
RUN I/P 12V ? 1.0 LG/N W/U 1.0
1
2
W/B 1.0
8 Y/N 1.0
LOGIC CONTROLLER A
(GRAY)

1
2
3
CHANNEL L 0.5 Blue
4 0
13
5
6 1 1
(PTO SWITCH) SP#2
7 2
SOCKET
8
9
10
11
12 1
2
CONNECTOR
U/Y 1.0

1
2
GLOW PLUG O/P
3
4
5
6
7
8
9
10
11
12
N 1.0 7 1 87a 1.0 B/G B/G 1.0
W 2.0 8 10A 2 1.0 G/O B 1.0
7
30 87
W 2.0 9 30A 3 2.0 G/N W/R 2.0
LOGIC CONTROLLER B
W 1.0 10 10A 4 1.0 G LG/N 1.0 86 85 1.0 B SP#2 N 2.0
(BLACK)
W 2.0 11 10A 5 2.0 G/B 1.0 B 4.5
SP#3
14
W 2.0 12 15A 6 2.0 U SP#1
1 0
2
LG 6
3 1
FUSE BOX 1
15
5
KEY SWITCH
3 1.0 U 87a
PROGRAM
PORT 4 N 2.0 2.0 W/R
30 87
OFF
ACC
RUN
START
5
W 6 1.0 U LG/R 1.0 86 85 1.0 B SP#2
AC
40
N SP#2 B 1.0 7 8 1.0 U
MOWING - RAISE UNITS P/N 4150557
W/R
USING FOOT PEDAL
P/N 4143951
1 of 2
1.0 6
G-PLEX III 20 23 24 25 5 4.5 4.5 2
SP#1
2
SP#6 Y 1.0 NO 1.0 11
1
10 1.0 1.0 12
GND
1 2 1 2 1 2 8 1.0 1.0 15
SP#2
1 2.0 BLK 1.0 16
19 14 1.0
1.0
1.0
1.0
1.0
1.0
1.0
B
B
B
W/B
W/K
W/U
1.0 Y/B Y/B 1.0 1.0 Y SP#6
32
1.0 Y/O SP#10 NO WORK LAMP 5 4.5 1.0 6
SP#3
SP#9
SP#9
SP#9
1.0 W/U SP#5 U/R 1.0 6 2.0 WHT 2.0 6
1
1.0 W/K SP#9 B 1.0 6 2.0 2.0 6
2
1.0 W/B
1.0 Y/N Y/N 1.0 1.0 Y SP#6 Y/O 1.0 1.0 B/Y
33 8 1.0
WORK LAMP 7 1.0 2.0 6

PARK BRAKE SWITCH NO NO SP#4
22 7 1.0
SP#5 U/R 1.0 G/N
21 SEAT SWITCH 1
1.0 Y/S 1.0 1.0 Y SP#6 26 SP#9 B 1.0
2
1.0 B/Y
14 2.0 1.0 32
SP#5
U/R 1.0 33
Y/U 1.0 1.0 U/Y

1.0 19
NO 8 1.0 1.0 20
SV
13 1.0 1.0 21
38 SP#6
YEL 1.0 22
REEL INTERLOCK
SWITCH
1.0 U/Y
1 3.0 1.0 23
GND
32 1.0 1.0 24
SP#9
30 33 1.0 BLK 1.0 25
1.0 U/N U/N 1.0
OIL LIGHT 2.0 34
SWITCH
36
1.0 LG/N LG/N 1.0
FUEL SOLENOID OO
19 1.0 1.0 8
SP#10
20 1.0 Y/B
4
35 ALTERNATOR
B/G 1.0
ENGINE KILL
ROTOR O/P OO
7 1.0 1.0 16
SP#11
1.0 B/G 10 1.0 1.0 36
LG/N
2.0 W/R
2.0 N N 2.0
4.5 4.5
3 Wire Colour Chart

STARTER B - Black
1
GROUND POINT
SP#2 B 2.0
28 2 W/R
N - Brown
SP#9 B 3.0 BATTERY
O - Orange
R - Red
S - Slate/Gray
U - Blue
39
W - White
ENGINE GROUND MOWING - RAISE UNITS
USING FOOT PEDAL
2 of 2
RANSOMES JACOBSEN SERVICE TRAINING G-PLEX III – DP SERIES
SECTION 11G –CIRCUIT DIAGRAMS
CIRCUIT DESCRIPTION
DP Series machines are fitted with a bi-directional relief valve (no pressure switch) and use a timed lift/lower
PIC module.
1. Lift/Lower and Reel Motor issues related to PIC Module, Relays and Latching Diodes
Description of Problem Possible Cause
No lift or lower and no rotation of the reels Mow switch, pedal/paddle switch or PIC module faulty
Lifting action stops before lifting is complete Remove jumper link under PIC module
Reel motors rotate while units lower, then stop White Diode in Yellow/Blue wire failed open
and reel motors rotate while units lift, then stop or
i.e. units work off PIC Module only Raise Relay faulty
Reel motors do not rotate when units lower White Diode in Orange wire failed open or
and reel motors rotate while units lift, then stop Black Diode in Purple wire failed open or
Lower Relay faulty
Reel motors run when units are lowering and Black Diode in Green wire failed open
lowered, but stop Immediately when the pedal/
paddle switch is activated
and Reel motors do not run when units are raised
Units work as normal, but engine labours White Diode in Yellow/Blue wire failed closed
Units work correctly, but lower cycle does not White Diode in Orange wire failed closed or
switch off Black Diode in Purple wire failed closed
Units will not lower, but rotate for the time of the Black Diode in Green wire failed closed
PIC module
Table 9-11 – Latching Circuit Characteristics
Note:
All DP-Series machines fitted with the latest PIC Module have a 5 second optional lift function built into the module
(production units were set to 2 seconds). If a customer wishes to increase the lift duration, the small two-pin jumper
wire plug, located in the control panel, should be removed. The latest PIC Module can be identified by the suppliers
part number 010189-00 on the label, indicating it has been programmed to operate as above, Ransomes Jacobsen
part number 4133067.
11G
The two-pin jumper wire plug feeds an additional 12V input into the PIC Module to ensure a raise time of 2 seconds.
With plug removed the time will revert to 5 seconds raise duration. In order for this change to become active, the PIC
Module has to be cycled, i.e. ignition off and on again.
11G-53
Y
1
R
2
(WATER TEMP GAUGE)
G
RELAY MODULE 3
R O W/B W/R
+ W/Y W/B 4 SPLIT TO
W/R MAIN #1
B Y PREHEAT 5
LAMP 6
PREHEAT
- W/U
SIG TIMER
4 6
U W/P W/Y
5 1 13
W C NO W/G
5
G
7
HEADLIGHT 3
W/O
G
SWITCH 8
W/Y W
B
B W/P PREHEAT G 9
SWITCH W/P
3 10
W/Y W/Y
WATER TEMP HEADLIGHT
BUZZER SW LIGHT 2 1
B O
R
W
O
W/U
WATER TEMP U N N N
LAMP 1
5 20A
2
B
N
N
W N
3 1
2
30A
N
3
WATER TEMP N
B
GAUGE 4
5 SPLIT TO
R B MAIN #2
1 3
87a 87a 6
G W/G W/R W VOLT B G
87 30 87 30 METER 7
Y R R
20A W/N W/R B W/Y
85 86 85 86 8
STARTER RELAY PREHEAT

W/N RELAY 9
7
B W/G B O
5 1 10
O
W/R SHUT DOWN

8 TIMER
R/G R/O
6 2
B B W/G
REEL GND O/P
ENABLE U W/Y
SWITCH
+VE TRIG
HOUR
B R/O METER
B B W/B WHT/ORA
REEL ENABLE 2 1
SWITCH LIGHT
OIL PRESS
O
B LIGHT
W/Y
3A
N/Y N/Y O O
N/Y
LOWER RAISE
RELAY 3A RELAY
87a Y/U 87a
P R P P Y
87 30 87 30
6A
B N/Y B G G Y Y
85 86 85 86
6A
R Y
R R 1
R/G R R/W
2
W/Y Y Y W/G
3
OFF
ACC
RUN
R R (A)
KEY SW
START
4
O SPLIT TO
W 5
AC
MAIN #3
R R (E)
20A 6
I/P
N
B W/Y
Y 7
RUN
Y O B
G 8
20A G
ST
W/G
20A
W/R 9
W/G
10
R R
1
R/N
2
R/N
R
B
G
O
R/W
R
W/Y
With the 2 pole plug connected the time

1 2 3 4 5 6 7 8 9 for raise will be 2 seconds. With plug removed Hot 1 of 2
the time will revert to 5 seconds raise duration.
LIFT / LOWER MODULE

ALTERNATOR
ROTOR O/P
Hot 2 of 2
Y
N
Y
1
R
2
G
3
W/R W/R FOOT
4 SW
W/R
5 R R/W
SPLIT TO
INST PNL #1 W/U NO
WATER TEMP GLOW
6 PLUG
SENDER
W/G PADDLE
7 FUEL SOL
SW
W/O
8 OIL PRESS
R R/W
SENDER
W NO
9
W/P W/P B
10
HEADLIGHT
W/P B
HEADLIGHT
N
1
N
N N N
2
N
3
STARTER
PC
MOTOR
N
4
SPLIT TO 5
G
INST PNL #2
HC
6
SOL
RAISE SOL
STARTER
G G B
7
9
3 W/D SOL
O O B
10
LOWER SOL
BATTERY
B
B
Y
1 ENGINE
GND
R/W
2
3 REEL SOL
W/G Y
SEAT SW
R (A) R (A) W
4
C NO
SPLIT TO 5
INST PNL #3 R W/R
6
C NO
W/Y BACKLAP
7 M SWITCH
B FUEL PUMP
PARKING BRAKE/
8
NEUTRAL SW
W/R R R/W
9
NO
10
Y
1
R
2
(WATER TEMP GAUGE)
G
RELAY MODULE 3
R O W/B W/R
W/R MAIN #1
B Y PREHEAT 5
LAMP 6
PREHEAT
- W/U
SIG TIMER
4 6
U W/P W/Y
5 1 13
W C NO W/G
5
G
7
HEADLIGHT 3
W/O
G
SWITCH 8
W/Y W
B
B W/P PREHEAT G 9
SWITCH W/P
3 10
W/Y W/Y
BUZZER SW LIGHT 2 1
B O
R
W
O
W/U
WATER TEMP U N N N
LAMP 1
5 20A
2
B
N
N
W N
3 1
2
30A
N
3
WATER TEMP N
B
GAUGE 4
5 SPLIT TO
R B MAIN #2
1 3
87a 87a 6
87 30 87 30 METER 7
Y R R
20A W/N W/R B W/Y
85 86 85 86 8

W/N RELAY 9
7
B W/G B O
5 1 10
O
W/R SHUT DOWN

8 TIMER
R/G R/O
6 2
B B W/G
REEL GND O/P
ENABLE U W/Y
SWITCH
+VE TRIG
HOUR
B R/O METER
B B W/B WHT/ORA
REEL ENABLE 2 1
SWITCH LIGHT
OIL PRESS
O
B LIGHT
W/Y
3A
N/Y N/Y O O
N/Y
LOWER RAISE
RELAY 3A RELAY
87a Y/U 87a
P R P P Y
87 30 87 30
6A
B N/Y B G G Y Y
85 86 85 86
6A
R Y
R R 1
R/G R R/W
2
W/Y Y Y W/G
3
OFF
ACC
RUN
R R (A)
KEY SW
START
4
O SPLIT TO
W 5
AC
MAIN #3
R R (E)
20A 6
I/P
N
B W/Y
Y 7
RUN
Y O B
G 8
20A G
ST
W/G
20A
W/R 9
W/G
10
R R
1
R/N
2
R/N
R
B
G
O
R/W
R
W/Y

1 2 3 4 5 6 7 8 9 for raise will be 2 seconds. With plug removed Ignition 1 of 2
LIFT / LOWER MODULE

ALTERNATOR
ROTOR O/P
Ignition 2 of 2
Y
N
Y
1
R
2
G
3
W/R W/R FOOT
4 SW
W/R
5 R R/W
SPLIT TO
INST PNL #1 W/U NO
WATER TEMP GLOW
6 PLUG
SENDER
W/G PADDLE
7 FUEL SOL
SW
W/O
8 OIL PRESS
R R/W
SENDER
W NO
9
W/P W/P B
10
HEADLIGHT
W/P B
HEADLIGHT
N
1
N
N N N
2
N
3
STARTER
PC
MOTOR
N
4
SPLIT TO 5
G
INST PNL #2
HC
6
SOL
RAISE SOL
STARTER
G G B
7
9
3 W/D SOL
O O B
10
LOWER SOL
BATTERY
B
B
Y
1 ENGINE
GND
R/W
2
3 REEL SOL
W/G Y
SEAT SW
R (A) R (A) W
4
C NO
SPLIT TO 5
INST PNL #3 R W/R
6
C NO
W/Y BACKLAP
7 M SWITCH
B FUEL PUMP
PARKING BRAKE/
8
NEUTRAL SW
W/R R R/W
9
NO
10
Y
1
R
2
(WATER TEMP GAUGE)
G
RELAY MODULE 3
R O W/B W/R
W/R MAIN #1
B Y PREHEAT 5
LAMP 6
PREHEAT
- W/U
SIG TIMER
4 6
U W/P W/Y
5 1 13
W C NO W/G
5
G
7
HEADLIGHT 3
W/O
G
SWITCH 8
W/Y W
B
B W/P PREHEAT G 9
SWITCH W/P
3 10
W/Y W/Y
BUZZER SW LIGHT 2 1
B O
R
W
O
W/U
WATER TEMP U N N N
LAMP 1
5 20A
2
B
N
N
W N
3 1
2
30A
N
3
WATER TEMP N
B
GAUGE 4
5 SPLIT TO
R B MAIN #2
1 3
87a 87a 6
87 30 87 30 METER 7
Y R R
20A W/N W/R B W/Y
85 86 85 86 8

W/N RELAY 9
7
B W/G B O
5 1 10
O
W/R SHUT DOWN

8 TIMER
R/G R/O
6 2
B B W/G
REEL GND O/P
ENABLE U W/Y
SWITCH
+VE TRIG
HOUR
B R/O METER
B B W/B WHT/ORA
REEL ENABLE 2 1
SWITCH LIGHT
OIL PRESS
O
B LIGHT
W/Y
3A
N/Y N/Y O O
N/Y
LOWER RAISE
RELAY 3A RELAY
87a Y/U 87a
P R P P Y
87 30 87 30
6A
B N/Y B G G Y Y
85 86 85 86
6A
R Y
R R 1
R/G R R/W
2
W/Y Y Y W/G
3
OFF
ACC
RUN
R R (A)
KEY SW
START
4
O SPLIT TO
W 5
AC
MAIN #3
R R (E)
20A 6
I/P
N
B W/Y
Y 7
RUN
Y O B
G 8
20A G
ST
W/G
20A
W/R 9
W/G
10
R R
1
R/N
2
R/N
R
B
G
O
R/W
R
W/Y

1 2 3 4 5 6 7 8 9 for raise will be 2 seconds. With plug removed Start Engine 1 of 2
LIFT / LOWER MODULE

ALTERNATOR
ROTOR O/P
Start Engine 2 of 2
Y
N
Y
1
R
2
G
3
W/R W/R FOOT
4 SW
W/R
5 R R/W
SPLIT TO
INST PNL #1 W/U NO
WATER TEMP GLOW
6 PLUG
SENDER
W/G PADDLE
7 FUEL SOL
SW
W/O
8 OIL PRESS
R R/W
SENDER
W NO
9
W/P W/P B
10
HEADLIGHT
W/P B
HEADLIGHT
N
1
N
N N N
2
N
3
STARTER
PC
MOTOR
N
4
SPLIT TO 5
G
INST PNL #2
HC
6
SOL
RAISE SOL
STARTER
G G B
7
9
3 W/D SOL
O O B
10
LOWER SOL
BATTERY
B
B
Y
1 ENGINE
GND
R/W
2
3 REEL SOL
W/G Y
SEAT SW
R (A) R (A) W
4
C NO
SPLIT TO 5
INST PNL #3 R W/R
6
C NO
W/Y BACKLAP
7 M SWITCH
B FUEL PUMP
PARKING BRAKE/
8
NEUTRAL SW
W/R R R/W
9
NO
10
Y
1
R
2
(WATER TEMP GAUGE)
G
RELAY MODULE 3
R O W/B W/R
W/R MAIN #1
B Y PREHEAT 5
LAMP 6
PREHEAT
- W/U
SIG TIMER
4 6
U W/P W/Y
5 1 13
W C NO W/G
5
G
7
HEADLIGHT 3
W/O
G
SWITCH 8
W/Y W
B
B W/P PREHEAT G 9
SWITCH W/P
3 10
W/Y W/Y
BUZZER SW LIGHT 2 1
B O
R
W
O
W/U
WATER TEMP U N N N
LAMP 1
5 20A
2
B
N
N
W N
3 1
2
30A
N
3
WATER TEMP N
B
GAUGE 4
5 SPLIT TO
R B MAIN #2
1 3
87a 87a 6
87 30 87 30 METER 7
Y R R
20A W/N W/R B W/Y
85 86 85 86 8

W/N RELAY 9
7
B W/G B O
5 1 10
O
W/R SHUT DOWN

8 TIMER
R/G R/O
6 2
B B W/G
REEL GND O/P
ENABLE U W/Y
SWITCH
+VE TRIG
HOUR
B R/O METER
B B W/B WHT/ORA
REEL ENABLE 2 1
SWITCH LIGHT
OIL PRESS
O
B LIGHT
W/Y
3A
N/Y N/Y O O
N/Y
LOWER RAISE
RELAY 3A RELAY
87a Y/U 87a
P R P P Y
87 30 87 30
6A
B N/Y B G G Y Y
85 86 85 86
6A
R Y
R R 1
R/G R R/W
2
W/Y Y Y W/G
3
OFF
ACC
RUN
R R (A)
KEY SW
START
4
O SPLIT TO
W 5
AC
MAIN #3
R R (E)
20A 6
I/P
N
B W/Y
Y 7
RUN
Y O B
G 8
20A G
ST
W/G
20A
W/R 9
W/G
10
R R
1
R/N
2
R/N
R
B
G
O
R/W
R
W/Y

1 2 3 4 5 6 7 8 9 for raise will be 2 seconds. With plug removed Engine Running & Brake Applied 1 of 2
LIFT / LOWER MODULE

ALTERNATOR
ROTOR O/P
Engine Running & Brake Applied 2 of 2
Y
N
Y
1
R
2
G
3
W/R W/R FOOT
4 SW
W/R
5 R R/W
SPLIT TO
INST PNL #1 W/U NO
WATER TEMP GLOW
6 PLUG
SENDER
W/G PADDLE
7 FUEL SOL
SW
W/O
8 OIL PRESS
R R/W
SENDER
W NO
9
W/P W/P B
10
HEADLIGHT
W/P B
HEADLIGHT
N
1
N
N N N
2
N
3
STARTER
PC
MOTOR
N
4
SPLIT TO 5
G
INST PNL #2
HC
6
SOL
RAISE SOL
STARTER
G G B
7
9
3 W/D SOL
O O B
10
LOWER SOL
BATTERY
B
B
Y
1 ENGINE
GND
R/W
2
3 REEL SOL
W/G Y
SEAT SW
R (A) R (A) W
4
C NO
SPLIT TO 5
INST PNL #3 R W/R
6
C NO
W/Y BACKLAP
7 M SWITCH
B FUEL PUMP
PARKING BRAKE/
8
NEUTRAL SW
W/R R R/W
9
NO
10
Y
1
R
2
(WATER TEMP GAUGE)
G
RELAY MODULE 3
R O W/B W/R
W/R MAIN #1
B Y PREHEAT 5
LAMP 6
PREHEAT
- W/U
SIG TIMER
4 6
U W/P W/Y
5 1 13
W C NO W/G
5
G
7
HEADLIGHT 3
W/O
G
SWITCH 8
W/Y W
B
B W/P PREHEAT G 9
SWITCH W/P
3 10
W/Y W/Y
BUZZER SW LIGHT 2 1
B O
R
W
O
W/U
WATER TEMP U N N N
LAMP 1
5 20A
2
B
N
N
W N
3 1
2
30A
N
3
WATER TEMP N
B
GAUGE 4
5 SPLIT TO
R B MAIN #2
1 3
87a 87a 6
87 30 87 30 METER 7
Y R R
20A W/N W/R B W/Y
85 86 85 86 8

W/N RELAY 9
7
B W/G B O
5 1 10
O
W/R SHUT DOWN

8 TIMER
R/G R/O
6 2
B B W/G
REEL GND O/P
ENABLE U W/Y
SWITCH
+VE TRIG
HOUR
B R/O METER
B B W/B WHT/ORA
REEL ENABLE 2 1
SWITCH LIGHT
OIL PRESS
O
B LIGHT
W/Y
3A
N/Y N/Y O O
N/Y
LOWER RAISE
RELAY 3A RELAY
87a Y/U 87a
P R P P Y
87 30 87 30
6A
B N/Y B G G Y Y
85 86 85 86
6A
R Y
R R 1
R/G R R/W
2
W/Y Y Y W/G
3
OFF
ACC
RUN
R R (A)
KEY SW
START
4
O SPLIT TO
W 5
AC
MAIN #3
R R (E)
20A 6
I/P
N
B W/Y
Y 7
RUN
Y O B
G 8
20A G
ST
W/G
20A
W/R 9
W/G
10
R R
1
R/N
2
R/N
R
B
G
O
R/W
R
W/Y

1 2 3 4 5 6 7 8 9 for raise will be 2 seconds. With plug removed
Drive to Green, PTO Switch ON 1 of 2
LIFT / LOWER MODULE
ALTERNATOR
ROTOR O/P
Drive to Green, PTO Switch ON 2 of 2
Y
N
Y
1
R
2
G
3
W/R W/R FOOT
4 SW
W/R
5 R R/W
SPLIT TO
INST PNL #1 W/U NO
WATER TEMP GLOW
6 PLUG
SENDER
W/G PADDLE
7 FUEL SOL
SW
W/O
8 OIL PRESS
R R/W
SENDER
W NO
9
W/P W/P B
10
HEADLIGHT
W/P B
HEADLIGHT
N
1
N
N N N
2
N
3
STARTER
PC
MOTOR
N
4
SPLIT TO 5
G
INST PNL #2
HC
6
SOL
RAISE SOL
STARTER
G G B
7
9
3 W/D SOL
O O B
10
LOWER SOL
BATTERY
B
B
Y
1 ENGINE
GND
R/W
2
3 REEL SOL
W/G Y
SEAT SW
R (A) R (A) W
4
C NO
SPLIT TO 5
INST PNL #3 R W/R
6
C NO
W/Y BACKLAP
7 M SWITCH
B FUEL PUMP
PARKING BRAKE/
8
NEUTRAL SW
W/R R R/W
9
NO
10
Y
1
R
2
(WATER TEMP GAUGE)
G
RELAY MODULE 3
R O W/B W/R
W/R MAIN #1
B Y PREHEAT 5
LAMP 6
PREHEAT
- W/U
SIG TIMER
4 6
U W/P W/Y
5 1 13
W C NO W/G
5
G
7
HEADLIGHT 3
W/O
G
SWITCH 8
W/Y W
B
B W/P PREHEAT G 9
SWITCH W/P
3 10
W/Y W/Y
BUZZER SW LIGHT 2 1
B O
R
W
O
W/U
WATER TEMP U N N N
LAMP 1
5 20A
2
B
N
N
W N
3 1
2
30A
N
3
WATER TEMP N
B
GAUGE 4
5 SPLIT TO
R B MAIN #2
1 3
87a 87a 6
87 30 87 30 METER 7
Y R R
20A W/N W/R B W/Y
85 86 85 86 8

W/N RELAY 9
7
B W/G B O
5 1 10
O
W/R SHUT DOWN

8 TIMER
R/G R/O
6 2
B B W/G
REEL GND O/P
ENABLE U W/Y
SWITCH
+VE TRIG
HOUR
B R/O METER
B B W/B WHT/ORA
REEL ENABLE 2 1
SWITCH LIGHT
OIL PRESS
O
B LIGHT
W/Y
3A
N/Y N/Y O O
N/Y
LOWER RAISE
RELAY 3A RELAY
87a Y/U 87a
P R P P Y
87 30 87 30
6A
B N/Y B G G Y Y
85 86 85 86
6A
R Y
R R 1
R/G R R/W
2
W/Y Y Y W/G
3
OFF
ACC
RUN
R R (A)
KEY SW
START
4
O SPLIT TO
W 5
AC
MAIN #3
R R (E)
20A 6
I/P
N
B W/Y
Y 7
RUN
Y O B
G 8
20A G
ST
W/G
20A
W/R 9
W/G
10
R R
1
R/N
2
R/N
R
B
G
O
R/W
R
W/Y

Lower Units (Paddle) onto Green PTO ON 1 of 2
LIFT / LOWER MODULE
ALTERNATOR
ROTOR O/P
Lower Units (Paddle) onto Green PTO ON 2 of 2
Y
N
Y
1
R
2
G
3
W/R W/R FOOT
4 SW
W/R
5 R R/W
SPLIT TO
INST PNL #1 W/U NO
WATER TEMP GLOW
6 PLUG
SENDER
W/G PADDLE
7 FUEL SOL
SW
W/O
8 OIL PRESS
R R/W
SENDER
W NO
9
W/P W/P B
10
HEADLIGHT
W/P B
HEADLIGHT
N
1
N
N N N
2
N
3
STARTER
PC
MOTOR
N
4
SPLIT TO 5
G
INST PNL #2
HC
6
SOL
RAISE SOL
STARTER
G G B
7
O O B
10
LOWER SOL
BATTERY
B
B
Y
1 ENGINE
GND
R/W
2
3 REEL SOL
W/G Y
SEAT SW
R (A) R (A) W
4
C NO
SPLIT TO 5
INST PNL #3 R W/R
6
C NO
W/Y BACKLAP
7 M SWITCH
B FUEL PUMP
PARKING BRAKE/
8
NEUTRAL SW
W/R R R/W
9
NO
10
Y
1
R
2
(WATER TEMP GAUGE)
G
RELAY MODULE 3
R O W/B W/R
W/R MAIN #1
B Y PREHEAT 5
LAMP 6
PREHEAT
- W/U
SIG TIMER
4 6
U W/P W/Y
5 1 13
W C NO W/G
5
G
7
HEADLIGHT 3
W/O
G
SWITCH 8
W/Y W
B
B W/P PREHEAT G 9
SWITCH W/P
3 10
W/Y W/Y
BUZZER SW LIGHT 2 1
B O
R
W
O
W/U
WATER TEMP U N N N
LAMP 1
5 20A
2
B
N
N
W N
3 1
2
30A
N
3
WATER TEMP N
B
GAUGE 4
5 SPLIT TO
R B MAIN #2
1 3
87a 87a 6
87 30 87 30 METER 7
Y R R
20A W/N W/R B W/Y
85 86 85 86 8

W/N RELAY 9
7
B W/G B O
5 1 10
O
W/R SHUT DOWN

8 TIMER
R/G R/O
6 2
B B W/G
REEL GND O/P
ENABLE U W/Y
SWITCH
+VE TRIG
HOUR
B R/O METER
B B W/B WHT/ORA
REEL ENABLE 2 1
SWITCH LIGHT
OIL PRESS
O
B LIGHT
W/Y
3A
N/Y N/Y O O
N/Y
LOWER RAISE
RELAY 3A RELAY
87a Y/U 87a
P R P P Y
87 30 87 30
6A
B N/Y B G G Y Y
85 86 85 86
6A
R Y
R R 1
R/G R R/W
2
W/Y Y Y W/G
3
OFF
ACC
RUN
R R (A)
KEY SW
START
4
O SPLIT TO
W 5
AC
MAIN #3
R R (E)
20A 6
I/P
N
B W/Y
Y 7
RUN
Y O B
G 8
20A G
ST
W/G
20A
W/R 9
W/G
10
R R
1
R/N
2
R/N
R
B
G
O
R/W
R
W/Y

Raise Units (Foot) PTO ON 1 of 2
LIFT / LOWER MODULE
ALTERNATOR
ROTOR O/P
Raise Units (Foot) PTO ON 2 of 2
Y
N
Y
1
R
2
G
3
W/R W/R FOOT
4 SW
W/R
5 R R/W
SPLIT TO
INST PNL #1 W/U NO
WATER TEMP GLOW
6 PLUG
SENDER
W/G PADDLE
7 FUEL SOL
SW
W/O
8 OIL PRESS
R R/W
SENDER
W NO
9
W/P W/P B
10
HEADLIGHT
W/P B
HEADLIGHT
N
1
N
N N N
2
N
3
STARTER
PC
MOTOR
N
4
SPLIT TO 5
G
INST PNL #2
HC
6
SOL
RAISE SOL
STARTER
G G B
7
O O B
10
LOWER SOL
BATTERY
B
B
Y
1 ENGINE
GND
R/W
2
3 REEL SOL
W/G Y
SEAT SW
R (A) R (A) W
4
C NO
SPLIT TO 5
INST PNL #3 R W/R
6
C NO
W/Y BACKLAP
7 M SWITCH
B FUEL PUMP
PARKING BRAKE/
8
NEUTRAL SW
W/R R R/W
9
NO
10
SECTION 12 - PREVENTATIVE MAINTENANCE
1 Lubrication and Maintenance Chart …..……………..……………………………… 12-3

2 Lubrication Diagram …...……………………………………………………………… 12-4
3 Battery Care ……………………………………………………..……………………… 12-6
12
1. LUBRICATION AND MAINTENANCE CHART
Interval Item Section
First 5-8 hours

Gasoline
Change Gasoline Engine Oil * Filter 5
First 50 hours Change Diesel Engine Oil * Filter 11
Diesel Check Diesel Fan Belt Tension 17
First 50hours
All
Change Hydraulic Oil Filter 20
Daily 10 hours
Gasoline
Check Gasoline Engine Oil Level 4
Daily 10 hours Check Diesel Engine Oil Level 10
Diesel Check Diesel Air Filter Element 14
Check Tyre Pressure 18
Check for Hydraulic Leaks -
Check Bedknife & Reel Blades Ops Man
Daily 10 hours Check Hydraulic Fluid Level 22
All Check Safety Interlock System 3.6
Check Coolant Level -
Check Oil Cooler Screen -
Clean Oil Cooler Fins -
Every 25 hours
Gasoline
Check & Clean Gasoline Air Filter Element * 7
Every 50 hours
Weekly Change Gasoline Engine Oil 5
Gasoline
Every 50 hours
Weekly Check Diesel Fan Belt Tension 17
Diesel
Every 50 hours Check for Loose components -
Weekly Check Engine Bay for Debris -
All Check Battery Condition 25
Every 100 hours
Gasoline
Change Gasoline Oil Filter 6
Every 100 hours Change Diesel Engine Oil 11
Diesel Check Diesel Fuel Filter for Water Contamination 13
Every 200 hours
Diesel
Change Diesel Engine Filter 12
Every 200 hours
All
Change inline Fuel Filter 13
Every 250 hours
Gasoline
Check & Adjust Gasoline Valve Clearance -
Every 250 hours
All
Change Hydraulic Oil & Filters 2
Every 400 hours Change Diesel Air Filter Element * 14
Diesel Change Diesel Fuel Filter Element 13
End of Season
or
1000 hours
Drain & Replace Diesel Engine Coolant 28
Diesel
End of Season
or Check Brake Linings 19
1000 hours Drain & Clean Fuel Tank -
All
Lubricate all Grease fittings with Shell Darina R2 or equivalent Grease Weekly (See Chart) 2
* Check more often in dirty conditions
IMPORTANT
Refer to Engine Manufacturers Manual for Additional Engine Maintenance Procedures
Table 12-1 - Lubrication and Maintenance Chart
12-3
2a LUBRICATION DIAGRAM - GASOLINE
Figure 12-2 - Lubrication Diagram – Gasoline (Petrol)
12-4
2b LUBRICATION DIAGRAM - DIESEL
Figure 12-3 - Lubrication Diagram – Diesel
12-5
3 BATTERY CARE
The factory installed battery is "Low Maintenance."
Add liquid only as required. WARNING
UNTRAINED/UNAUTHORIZED persons should NEVER
NOTE attempt to service or recharge the battery in this unit.
Keep top of battery clean and free of corrosion by Battery electrolyte is an acidic solution and should be
washing with a solution of baking soda and water OR handled with care. If electrolyte is splashed on any part
ammonia and water. Rinse with clean water. Batteries of the body, immediately flush the exposed area with
with heavy corrosion should be removed and cleaned liberal amounts of water and obtain medical aid
with solution. immediately.
Battery cables should be disconnected before using

a "Fast Charger”.
WARNING
DO NOT allow flames or sparks near the battery when
connecting for jump starting or charging.
Hydrogen gas is produced during the charging process

and can be explosive. Provide adequate ventilation to
prevent possible explosion.
WARNING
Wear eye protection when servicing battery.
WARNING
CAUTION
Battery posts, terminals and related accessories
contain lead and lead compounds. Dispose of used batteries in accordance with local
WASH HANDS AFTER HANDLING. regulations.
12-6
1 Attachments and Options ……………………..……………………………………… 13-3
13
1 ATTACHMENTS AND OPTIONS
Option Part Number

Backlap Kit ……………………………………….
OPS Frame ………………………………………
Smooth Rollers ………………………………….
Grooved Rollers …………………………………
Turf Groomers …………………………………..
Vertical Mowers …………………………………
Spikers …………………………………………….
Rear Roller Brushes …………………………….
MagKnife …………………………………………
3 Wheel Drive ……………………………………
.
SECTION 14 - NOTES
14
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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G-Plex III - Course Book 2007 PDF

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Service Course Manual

G-Plex III (with Plus+1 Controller)

WARNING: If incorrectly used this machine can cause

WHEELS & TYRES 8

ATTACHMENTS AND OPTIONS 13

1 Introduction ….…………………...……………..……………………………………… 2-3

Product code: USAD002 ………………….. Series: FH - Engine type: Kubota D722

Engine Specification – Diesel Engine Specification – Gasoline (Petrol)

Make ………………………………………… Kubota Make …………………………… Briggs & Stratton

Overall weight of machine

When the machine was tested for hand/arm vibration

The Machinery Safety Directive 98/37/EC 0.50

Information Supplied for Physical Agents

The Machinery Safety Directive 98/37/EC

1 Control Panel - Diesel …..……………..……………………………………………… 3-3

1. CONTROL PANEL - DIESEL

A - Temperature Gauge D - Reel Enable Switch

2. CONTROL PANEL – GASOLINE (PETROL)

B - Ignition Switch E - Working Light Switch

The Direction/Speed Pedal controls speed and

4. PARKING BRAKE PEDAL

The Parking Brake can be engaged by depressing the

The Mow/Lift Paddle/Footswitch lowers and raises the

6. OPERATOR PRESENCES AND SAFETY INTERLOCK SYSTEM

Table 3-1 – Safety Interlock Test Chart

1 Starting the Engine …..……………..…………..……………………………………… 4-3

1 STARTING THE ENGINE

3 ENGINE OIL LEVEL - DIESEL

Figure 4-2 – Dipstick

Figure 4-3 – Oil Filler Port

4 ENGINE OIL CHANGE - DIESEL

5 ENGINE OIL FILTER - DIESEL

6 ENGINE FUEL FILTER - DIESEL

Figure 4-6 – In-Line Fuel Filter

7 ENGINE FUEL FEED SYSTEM - DIESEL

3 - In-Line Fuel Filter

8 BLEEDING THE FUEL SYSTEM - DIESEL

This procedure MUST be performed as specified and

The fuel system must be bled when:

9 AIR FILTER - DIESEL

3. Avoid touching the element except when cleaning.

10 ENGINE OIL LEVEL - GASOLINE

Damage to engines due to improper maintenance or

Unit must be on a level surface to obtain an accurate oil

The oil level must be kept between the two marks on

NOTE 1 – Oil Filler Port

11 ENGINE OIL CHANGE- GASOLINE

NOTE 1 – Oil Filler Port

12 ENGINE OIL FILTER- GASOLINE

13 AIR FILTER - GASOLINE

14 ENGINE FUEL FILTER - GASOLINE

Figure 4-17 – Fuel Filter

15 ENGINE FUEL FEED SYSTEM - GASOLINE

4 - Fuel In-Tank Weight

16 FAN BELT TENSION - DIESEL

Figure 4-19 – Fuel Filter

17 RADIATOR - DIESEL MACHINE

Figure 4-21 – Bug Screen Figure 4-22 – Oil Cooler / Radiator

18 OIL COOLER - GASOLINE MACHINE

Figure 4-23 – Bug Screen Latch

Figure 4-24 – Bug Screen

1 Transmission Pump Mounting (Diesel) …..………………………………………… 5-3

1 TRANSMISSION PUMP MOUNTING - DIESEL

250 hours of operation occurs.