Ransomes 3WD Conversion Kit 63353 Accessories Manual

Ransomes
Brand
Ransomes
Model
3WD Conversion Kit 63353
Type
Accessories Manual
This kit is intended for use with Eclipse
®
322 riding greens
mowers.
1. Park the mower on a flat and level surface, verify the
parking brake is engaged, turn the ignition switch to the
OFF position, and remove the key.
a. Wait for all movement to stop before making any
adjustments or modifications.
b. Allow sufficient time for the unit to cool down.
c. Take this opportunity to thoroughly inspect the
equipment and perform other required maintenance.
2. Refer to the Parts & Maintenance manual of the
Eclipse 322 mower as an aid in the disassembly and
assembly of components.
3. Field Test Kit 4222802 is required to update the
software revision level of controllers to use the 3WD kit.
Preparation ___________________________________________________________________
1. Use Field Test Kit (4222802) to install the following
software updates.
a. RCU: 7861$G.S19
b. LDU: 6928$F.S19
c. MCU: 7027$C.S19
d. SCU: 69A21245C01.epf
e. TCU: 69E21118C04.epf
NOTE:
3WD controller included in this kit has the correct
software revision loaded at the factory, and does not need
to be updated.
2. Disconnect 12 volt and 48 volt battery connectors.
3. Open rear hood. Remove hardware (A) and lift
controller cover (B) off mower. Retain hardware,
discard controller cover.
4. Tag and disconnect harness connector and motor/
power cables from steering controller (C).
5. Remove hardware (D) and lift controller bracket (E) off
mower frame.
6. Remove hardware (U), left (V), and right (W) cowlings.
NOTE:
On diesel units, remove air cleaner intake duct
before removing right cowling (W).
Figure 1
Figure 2
CAUTION
Before you install this kit, read the mower’s manuals to
become familiar with the mower, the controls, and
proper use of the equipment.
Stay alert for potential hazards and follow all safety
precautions. Read all instructions completely and make
sure you understand them before proceeding with the
assembly.
!
WARNING
Before you attempt to clean, adjust, or repair any of this
equipment, disengage all drives, shut down the engine
and allow the unit to cool. Remove the key from the
ignition switch to prevent accidental starting and
potential bodily injuries.
!
E
A
A
B
C
D
U
U
V
W
INSTRUCTION SHEET
Battery and Diesel Hybrid 3WD Conversion Kit 62827
Gas Hybrid 3WD Conversion Kit 63353
Litho in U.S.A. 5-2012
Part No. 4257274-Rev A
© 2012 Jacobsen, A Textron Company/Textron Innovations Inc.
2
Gas Genset Modification ________________________________________________________
The gas genset needs to be modified to provide clearance
for the rear wheel motor.
1. Cut template on page 11 out and place as shown on
rear surface of gas genset engine plate. Align edges of
template with edge of plate. Long edge of template
should be on rear edge of engine plate
2. Trace a line along the edge of the template. Remove
template.
3. Using traced line as a guide, trim corner off engine
plate, with a cut-off wheel or similar tool.
4. Remove any burrs or sharp edges using a file. Paint
exposed metal using a high quality gloss black paint.
5. Remove and retain nuts (AH). Discard screws (AJ).
6. Loosen muffler clamp (AK). Slide muffler (AL) off
engine manifold outlet pipe.
7. Remove hardware (AP) and manifold (AS). Retain
hardware and gaskets (AR). Discard manifold.
NOTE:
Inspect gaskets for damage before assembling
new manifold. If gaskets are damaged, order replacement
gaskets from you local Briggs & Stratton dealer, Part
Number 691613.
8. Assemble new exhaust manifold (Item 42) to engine
using hardware (AP) and gaskets (AR). Adjust position
of manifold as required to make certain manifold rests
flat against engine mounting surface. Torque hardware
to 150 in. lbs. (12 ft. lbs.) (17 Nm).
9. Slide clamp (AK) and muffler (AL) onto manifold outlet
pipe. Secure muffler using two M8-1.25 x 40 mm
screws (Item 39), 1/4 in. spacers (Item 40), 1/2 in.
spacers (Item 41), and nuts (AH). Tighten clamp.
Figure 3
Steering Yoke _________________________________________________________________
1. Chock or block the front wheels to prevent the mower
from moving. Using the two locations indicated (+),
raise rear of mower so rear tire is approximately 10 in.
(254 mm) off the ground. Place jack stands to support
the weight of the mower.
2. Locate and disconnect steering chain master link.
Remove steering chain (F) from both sprockets. Loosen
hardware (G) and lift large sprocket (H) off steering
yoke. Remove key (J).
3. Support rear tire. Loosen hardware (K) on both sides of
rear axle (L). Remove and discard tire and axle.
4. Support steering fork (M). Remove retaining ring (N)
and bushing (P). Lower steering yoke out of mower.
Remove bushings (R and S) and spacer (T). Discard
retaining ring (N), steering yoke (M), and plastic
bushing (S). Retain metal bushings (P and R) and
spacer (T).
5. Remove steering tube bushings (AG).
Figure 4
Template
Long edge
39
40
41
AJ
AK
AP
AP
AR
AR
AS
42
AH
AL
WARNING
Make sure the mower is parked on a solid and level
surface. Never work on a mower that is supported only
by the jack. Always use jack stands.
!
M
F
J
AG
AG
N
R
R
G
K
K
S
H
★
★
L
P
T
3
Rear Axle Assembly
1. Press new steering tube bushings (Item 22) into
mower frame. Fill cavity between bushings with clean
Lubriplate
®
grease.
NOTE:
Yoke assembly is pre-assembled at the factory.
Exploded view (Figure 6) is shown for reference only.
2. Assemble spacer (T), one metal busing (R), plastic
bushing (Item 5), and another metal bushing (R) to
steering yoke.
3. Grease steering yoke shaft with Lubriplate
®
grease.
Slide steering yoke into tube on frame. Secure yoke
with bushing (P) and retaining ring (Item 6).
4. Secure 3WD motor harness to main mower harness
behind steering motor using cable tie (Item 45). Leave
6 in. (152 mm) of excess slack between steering yoke
and cable tie.
5. Harness should be routed around rear side of steering
yoke tube and towards left rear corner of mower frame.
Rotate steering yoke by hand for full left and full right
turn. Adjust harness in clips (Item 15) as required so
harness does not interfere with the movement of
steering yoke, does not rub against any sharp edges,
and is not pinched between moving and stationary
parts of mower. See Figure 11
.
6. Raise rear of mower slightly, remove jack stands, and
lower mower to the ground.
7. Insert key (J) into slot in steering yoke (Item 2).
Assemble large sprocket (H) onto steering yoke shaft.
Use a straight edge to align large sprocket with motor
sprocket and tighten hardware (G).
8. Assemble chain (F) to mower. Position master link so it
will be accessible for service.
9. Assemble magnet portion of new sensor (Item 29) to
yoke (Item 2). Secure using M4-0.7 x 12 mm socket
head screw (Item 28).
10.Assemble rear fender (Item 44) to yoke (Item 2) using
two M8-1.25 x 25 mm hex flange screws (Item 43) and
hex flange nuts (Item 4).
Figure 5
Figure 6
NOTICE
To prevent damage, do not allow steering stop to
contact steering sensors when moving yoke.
F
J
44
43
4
R
R
G
H
P
T
5
6
22
22
28
29
21
21
4216820 Rev A
45
Secure motor harness
to mower harness,
leaving 6 in. (152 mm)
slack in motor harness
1
2
3
4
7
8
9
10
13
●
●
●
15
23
24
25
26
38
35
4
Controller Assembly____________________________________________________________
1. Assemble controller bracket (E) to mower frame using
hardware (D).
2. Remove hardware (X and Y) and steering controller
support brackets (Z). Retain hardware (X), discard
screws (Y) and support brackets (Z).
3. Assemble 3WD controller (Item 11) to controller
bracket using two M6-1 x 30 mm socket head screws
(Item 12) and hardware (X). Torque hardware to 53 in.
lb. (6 Nm).
4. Assemble new steering sensor (Item 29) and sensor
mount (Item 30) to controller brace (Item 14) using two
M5-0.8 x 25 mm socket head screws (Item 31), flat
washers (Item 32), lockwashers (Item 33), and four
nuts (Item 34).
5. Lower controller brace and sensor assembly between
steering and 3WD controllers. Magnetic portion of
sensor assembled to steering yoke should be centered
in large hole of sensor mount (Item 30).
6. Assemble controller brace (Item 14) to steering
controller (C) and 3WD controller (Item 11) using two
M6-1 x 30 mm socket head screws (Item 12), flange
nuts (Item 36), and hardware (X). Adjust position of
controller brace as required to allow an air gap of 1/8 to
3/16 in. (3.2 to 4.8 mm) between magnetic portion of
sensor and sensor body. Torque hardware to 53 in. lb.
(6 Nm).
Figure 7
Steering Proximity Switch _______________________________________________________
1. Disconnect steering proximity switch connectors (AM).
2. Remove and discard left and right steering proximity
switches (AN).
3. Seal ends of electrical connectors (AM) with electrical
tape.
Figure 8
B+
B-
U
V
W
11
12
12
36
14
E
Y
Z
D
C
X
X
X
29
30
31
32
33
34
34
B+
B-
U
V
W
AM
AN
AN
5
Steering Sensor Wiring
1. Insert Purple wire of jumper harness (Item 37) into
terminal 9 of steering controller connector.
a. Using a small flat blade screwdriver, gently pry on
opposite corners of red wedge lock of steering
controller connector until it is released from, but not
completely out of the connector housing.
b. Remove sealing plug from terminal 9 of steering
controller connector.
c. Insert contact on the end of purple wire into terminal
9 of the steering controller connector. Push wire in
until an audible click is heard.
d. Gently pull on the wire to ensure the contact is
secured in position.
e. While squeezing the two locking latches, push red
wedge lock into the closed position.
2. Approximately 2 inches (50 mm) from the steering
controller connector, locate the Red wire (From
terminal 3 of steering controller connector), and the
Green/Brown wire (From terminal 4 of steering
controller connector) in the wire harness.
3. Cut the Red and Green/Brown wires. Strip
approximately 1/4 in. (6 mm) of insulation off ends of
wires.
4. Twist the ends of the two red wires together and crimp
to Red wire of jumper harness (Item 37).
5. Twist the ends of the two Green/Brown wires together
and crimp to Black wire of jumper harness (Item 37).
6. Apply heat to butt-splice connections until heat-shrink
seals wires.
7. Route new jumper harness (Item 37) to steering
sensor (Item 29 - Figure 7)
8. Assemble motor/power cables and harness connector
to steering controller (C).
Figure 9
Figure 10
NOTICE
To prevent damage to wire contact and/or connector
housing, do not attempt to insert contact with the
wedge lock in the closed position.
NOTICE
To prevent damage to the steering sensor, do not
splice into the Red wire with White stripe from
terminal 1 of steering controller connector.
Approximately
2 in. (50 mm)
1/4 in.
(6 mm)
37
Grn/Brn
Wires
Red
Wires
Red
Wire
Pur
Wire
Grn/Brn
Wire
6
Harness Assembly _____________________________________________________________
1. Route end of motor harness to 3WD controller. The six
wire connector (AA) should be in left rear corner of
frame, near the ground wires.
2. Connect cable labeled 1 to of motor harness to 3WD
controller terminal U. Torque controller screw to 53 in.
lb. (6 Nm).
3. Connect cable labeled 2 to of motor harness to 3WD
controller terminal V. Torque controller screw to 53 in.
lb. (6 Nm).
4. Connect cable labeled 3 to of motor harness to 3WD
controller terminal W. Torque controller screw to 53 in.
lb. (6 Nm).
5. Connect 23 pin connector (AC) of 3WD control harness
(Item 16) to 3WD controller (Item 11).
6. Route control harness (Item 16) to left rear corner of
frame. Connect 6 pin connector (AB) of control harness
to mating connector (AA) on motor harness.
7. Route control harness (Item 16) along existing main
harness forward towards ROPS, then towards right side
of mower along seat cross member of frame.
8. Locate unused eight pin connector labeled J93 and
three pin connector labeled J94 on main harness.
Connectors will be located behind and to the right of the
seat. Remove protective caps and connect
corresponding control harness connectors (AD) to main
harness connectors.
9. Assemble long red cable (AE) on 3WD power harness
(Item 17) to Traction B+ stud on PDU.
10.Route power harness (Item 17) to left rear corner of
mower frame. Connect black cable (AG) of power
harness to one of the two ground studs.
11.Route power harness to 3WD controller. Connect red
cable to B+ terminal and black cable to B- terminal of
3WD controller.
12.Secure power harness, motor harness, and control
harness as required to prevent harness contacting
moving parts or interfering with operation of mower.
Figure 11
B+
B-
UV
W
16
AD
AG
AE
17
B+
B-
U
V
W
AA
AB
AC
Part of Motor
Item 7
7
Final Assembly
1. Assemble new controller cover (Item 19) to mower
using hardware (A).
2. Connect 12V and 48V battery connectors.
3. Start unit in Maintenance Mode and verify software
revisions on the LDU. Make certain 3WD mode is
enabled on LDU.
a. RCU: Rev G
b. LDU: Rev F
c. MCU: Rev C
d. SCU: C01
e. 3WD: C02
f. TCU: C04
4. Assemble left (V) and right (W) cowlings to mower
using hardware (U). See Figure 2.
5. Apply 3WD decal (Item 18) to left cowling, right
cowling, and rear hood, centered under the existing
Eclipse 322 decal.
Figure 12
Figure 13
3WD Electrical Schematic
Figure 14
B+
B-
U
V
W
19
20
20
A
A
4181860
18
18
18
3WD
3WD
3WD
J93-1
J93-2
J93-3
J93-4
J93-5
J93-6
J93-7
J93-8
To Mower Harness
Traction Power
5V Sensor Supply
Motor Encoder (B)
Motor Encoder (A)
CAN-Shield
Analog Ground
J110-1
J110-2
J110-3
J110-4
J110-5
J110-6
J110-7
J110-8
J110-9
J110-10
J110-11
J110-12
J94-A
J94-B
J94-C
Rd/Wh
Ye
Gn
Bk
Traction Motor Temp
CAN-Low
J110-13
J110-14
J110-15
J110-16
J110-17
J110-18
J110-19
J110-20
J110-21
J110-22
CAN High
B+
B-
Rd
Bk
VU
J110-23
3WD
Controller
Motor Temp
Motor Encoder In 1 (A)
Motor Encoder In 2 (B)
5V Sensor Supply
Analog Ground
J72-1
J72-2
J72-3
J72-4
J72-5
Rd/Wh
Bu/Wh
Wh/Bk
Rd
Wh
Bk
Gn
Bk
Bk
Wh
Rd
Wh/Bk
Bu/Wh
Bg
Bk
Bn
Ye
Gn
J72-6
W
WV U
3WD
Motor
Ye
Ground Ring
Terminal
Traction B+
Stud on PDU
8
Updated Steering Controller Schematic____________________________________________
Figure 15
SHLD
CAN Gnd
CAN High
CAN Low
(Splice C) Switched 48V-1
(Splice B) Traction Power
GC2
GC2
Power
LORD Brake neg
5V Sensor Supply
Motor Encoder (1)
Motor Encoder (2)
CAN-Gnd
Steering Sensor Signal
Analog Ground
J65-1
J65-2
J65-3
J65-4
J65-5
J65-6
J65-7
J65-8
LORD Output Sensor 1A
LORD Output Sensor 1B
J65-9
J65-10
J65-11
Proximity Switch 2
J65-12
5V Sensor Supply
Motor Encoder (1)
Motor Encoder (2)
Analog Ground
Motor Temp
J55-1
J55-2
J55-3
J55-4
J55-5
J55-6
J57-C
J57-A
J57-B
Steering Motor Temp
LORD Output Sensor 2A
Proximity Switch 1
CAN-Low
J65-13
J65-14
J65-15
J65-16
J65-17
J65-18
J65-19
LORD Output Sensor 2B
J65-20
J65-21
J65-22
CAN High
W
B+
B-
V
WV
U
U
J65-23
Steering
Controller
5V Power
Sensor 1A
LORD Brake neg
Sensor 1B
Sensor 2A
Sensor 2B
48V Power
Analog Ground
J56-1
J56-2
J56-3
J56-4
J56-5
J56-6
J56-7
J56-8
Rd/Wh
Bn/Ye
Rd
Gn/Bn
Wh
Gy
Bk
Wh
Pu
Bk
Rd
Wh
Gy
Vt/Bu
Gn/Bn
Wh/Gn
Gn
Vt/Bu
Wh
Wh/Pk
Bk
Ye
R
Q
Rd
Wh
Bk
Gn/Bn
Wh
Bk
Bn/Ye
Rd/Bu
Steering
LORD
Steering
Motor
Power
Signal
Ground
Steering
Sensor
J105-C
J105-A
J105-B
Gn/Bn
Rd
Wh/Pk
Gn/Bn
Rd
Wh/Gn
Gn/Bn
Pu
Rd
Steering Controller +48V
9
Parts List
Support
If you encounter any problems while installing this kit,
contact your Jacobsen Dealer, or contact the Jacobsen
Customer Care department.
Jacobsen, A Textron Company
11108 Quality Drive
Charlotte, NC 28273
800-848-1636
http://www.Jacobsen.com
Item Part No. Qty. Description Serial Numbers/Notes
1
4255670 1
Stop, Power Steering
2
4231280 1
Yoke, 3WD Steering
3 452390 2 Screw, M8-1.25 x 30 mm Hex Flange
4 450453 4 Nut, M8-1.25 Hex Flange
5 4211340 1 Bushing, Thrust
6 458466 1 Retaining Ring
7 4258090 1 Motor, Wheel
8 452398 6 Screw, M10-1.5 x 20 mm Hex Flange
9 N/S 1 Rear Wheel Assembly
4163860 1 • Tire, 10 x 10.5 - 10 4 Ply Smooth
4247411 1 • Rim, 10” x 7”
360111 1 • Inflation Valve
10 353914 4 Wheel Bolt, 1/2-20 x 3/4
11 4233561 1 Controller, 3WD Traction
12 450714 4 Screw, M6-1 x 30 mm Hex Socket
13 4245911 6 Tie Clip, Double Head
14 4255671 1 Brace, Controller
15 4257272 4 Mount, Tie Clip Push-In
16 4233060 1 Harness, 3WD Motor Control
17 4233040 1 Harness, 3WD Power
18 4257350 1 Decal, 3WD
19 4222680 1 Cover, Controller
20 4181860 1 • Decal, Read Manual
21 4216820 1 Decal, Tow
22 4168103 2 Bushing, Steering Tube
23 4260414 1 Cover, Wheel Motor
24 4261990 2 Screw, 3/8-16 x 1” Button Head
25 453011 2 Flat Washer, 3/8
26 4167640 1 Cable Tie, Fir Tree
27 N/S 1 Template, Gas Genset
28 450687 1 Screw, M4-0.7 x 12 mm Hex Socket
29 4233560 1 Sensor, Steering Non-Contact Sensor
30 4236642 1 Mount, Sensor
31 450699 2 Screw, M5-0.8 x 25 mm Hex Socket
32 450388 2 Flat Washer, M5
33 450409 2 Lockwasher, M5
34 450322 4 Nut, M5-0.8 Hex
35 445783 2 Nut, 3/8-16 Whizlock Flange
36 450452 4 Nut, M6-1 Hex Flange
37 4260690 1 Jumper, Steering Sensor
38 4222500 1 Plug, Fir-Tree
39 452381 2 Screw, M6-1 x 40 mm Hex Flange 63353 Only
40 3005971 2 Spacer, 1/4” 63353 Only
41 3005970 2 Spacer, 1/2” 63353 Only
42 4264310 1 Manifold, Gas Engine 63353 Only
43 452389 2 Screw, M8-1.25 x 25 mm Hex Flange
44 4263311 1 Fender, Rear
45 473142 1 Cable Tie, 3/16 x 14”
10
This Page Intentionally Blank
11
Gas Engine Plate Template
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
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  • Page 12 12

Ransomes 3WD Conversion Kit 63353 Accessories Manual

Ransomes
Brand
Ransomes
Model
3WD Conversion Kit 63353
Type
Accessories Manual
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