Great Dane GDRZ25KAE Lawn Mower User Manual
Contents
1. 18 Oil Level Checking Engine 13 Oil Level Checking Transmission 15 Oil Changing Engine 13 Oil TRANSMISSION suier nennir ee 15 Operating Checklist Daily 6 Park Brake USING 7 Part Numbers Replacement 10 Parts Replacement 10 Plug Checking Spark 14 Safety Systems Testing 6 5 Service Interval Chart 11 Service Record 36 Spark Plug CHECKING neir 14 Specifications OR 34 Storage Preparing Fuel and Engine for 31 Storage Preparing Machine 31 Storage Removing Machine 31 Storing Safety 31 Testing Safety Systems 6 Tire Pressure CHECK 33 Transmission oere aneura aa ee 15 Transmission Oil Level C2. the item referred to is hidden from view Special Messages Your manual contains special messages to bring attention to potential safety concerns machine damage as well as helpful operating and servicing information Please read all the information carefully to avoid injury and machine damage A CAUTION Avoid injury This symbol and text highlight potential hazards or death to the operator or bystanders that may occur if the hazards or procedures are ignored GDRZ26KHE Serial No 459000 460999 If you need to contact an Authorized Service Center for information on servicing always provide the product model and serial numbers You will need to locate the model and serial numbers for the machine and for the engine of your machine and record the information in the spaces provided DATE OF PURCHASE DEALER NAME DEALER PHONE 9204 MODEL NUMBER SERIAL NUMBER POWER UNIT B ENGINE SERIAL NUMBER B IMPORTANT Avoid damage This text is used to tell the operator of actions or conditions that might result in damage to the machine NOTE General information is given throughout the manual that may help the operator in the operation or service of the machine Record Identification Numbers Chariot GDRZ25KAE Serial No 455000 455999 GDRZ25KHE Serial No 457000 458999 ENGINE SPECIFICATION NUMBER C Introduction TABLE OF CONTE
3. 18 on uae 7303 WOO WN stud lt a H dais ANIDNA i HOLIMS Old ONNOYD ANIDNA YOLOANNGO YA THO i H LIMS Old SSAINYVH NIYIN OL SLOANNOD HOLIMS Ol SLOANNOSD 6182 SSANHVH Old 9299 Service Electrical 25 SERVICE MISCELLANEOUS Filling Fuel Tank Use regular grade 87 octane unleaded fuel Add fuel stabilizer to fuel before using it in your machine to prevent engine damage due to stale fuel Follow directions on stabilizer container A CAUTION Avoid injury Fuel vapors are explosive and flammable e Shut engine off before filling fuel tank Do smoke while handling fuel e Keep fuel away from flames or sparks e Fill fuel tank outdoors or in well ventilated area Clean up spilled fuel immediately e Use clean approved non metal container to prevent static electric discharge e Use clean approved plastic funnel without screen or filter to prevent static electric discharge IMPORTANT Avoid damage Dirt and water in fuel can cause engine damage Clean dirt and debris from the fuel tank opening e Use clean fresh stabilized fuel e Fill the fuel tank at the end of each day s operation to keep condensation out of the fuel tank e Use a non metallic fu
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5. attachments are needed to properly and safely perform the job e Clear mowing area of objects that might be thrown Keep people and pets out of mowing area Study mowing area Set up a safe mowing pattern Do not mow where traction or stability is doubtful e Test drive area with mower lowered but not running Slow down when you travel over rough ground Parking Safely Stop machine on a level surface not on a slope Disengage PTO Lower attachments to the ground Lock park brake Stop engine oOo a A OON Remove key 7 Wait for engine and all moving parts to stop before you leave the operator s station Rotating Blades are Dangerous HELP PREVENT SERIOUS OR FATAL ACCIDENTS e Rotating blades can cut off arms and legs Keep hands feet and clothing away from mower deck when engine is running e Be alert at all times drive forward carefully People especially children can move quickly into the mowing area before you know it Before backing up shut off PTO and look down and behind the machine carefully especially for children e Do not mow in reverse Shut off blades when you are not mowing e Do not operate machine if you are under the influence of drugs or alcohol e Park machine safely before inspecting or unplugging mower or bagger PROTECT CHILDREN Never assume that children will remain where you last saw them Child
6. GREATDANE Chariot GDRZ25KAE GDRZ25KHE GDRZ26KHE OPERATOR S MANUAL A WARNING The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm California Proposition 65 Warning OMGD10001 B2 002 1 05 North American Version Litho in U S A INTRODUCTION Using Your Operator s Manual This manual is an important part of your machine and should remain with the machine when you sell it An engine manufacturer s owner s manual has been provided with your machine This will provide maintenance and troubleshooting information for the engine installed in your machine Reading your operator s manual will help you and others avoid personal injury or damage to the machine Information given in this manual will provide the operator with the safest and most effective use of the machine Sections in your operator s manual are placed in a specific order to help you understand all the safety messages and learn the controls so you can operate this machine safely You can also use this manual to answer any specific operating or servicing questions The machine shown in this manual may differ slightly from your machine but will be similar enough to help you understand our instructions RIGHT HAND and LEFT HAND sides are determined by facing in the direction the machine will travel when going forward When you see a broken line
7. 2 Move control levers to forward travel position 3 Move PTO clutch switch to off position 4 Lock park brake 5 Turn key switch to start position Result The engine must not crank Testing Seat Safety Switch 1 Operator must be seated in the seat seat safety switch engaged 2 Move control levers to neutral position 3 Start the engine 2 Unlock park brake 3 Move PTO clutch switch to on position mower deck drive engaged 4 Turn key switch to start position Result The engine must not crank Using the Park Brake Move park brake lever to the raised locked position to lock the park brake This will also engage the park brake safety switch Starting the Engine A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the vehicle to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation e Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area e Allow fresh outside air into the work area to clear the exhaust fumes out A CAUTION Avoid injury Before engaging mower clear area of bystanders especially children 1 Open the fuel shutoff valve 2 Operator must be seated in the seat seat safety switch engaged 3 Lock park brake Move control levers to neutral position 4 5 Move PTO clutch switch to off
8. 9295 9214 e This product is designed for professional and commercial users e Operation training is required e Carefully read safety instructions e Know function of controls before operating e Practice with cutter blades off until confident e Clear mowing area of all debris Keep all guards covers and shields in place while working e Do not disable or bypass any safety device Always wear safety goggles while operating e Always park machine on level surface e Avoid contact with cutter blades They may be rotating e Keep children and others clear from area Set ground speed control to safe speed Slowly and smoothly move speed control levers to start and stop machine e Reduce speed and avoid sharp turns e careful on slopes do not mow where stability or traction is in doubt e To obtain additional operator manual and safety instructions contact your Great Dane dealer or write Great Dane Power Equipment 4700 New Middle Rd Jeffersonville IN 47130 USA Emission Control System Certification Label Small Off Road Gas Engines NOTE Tampering with emission controls and components by unauthorized personnel may result in severe fines or penalties Emission controls and components can only be adjusted by EPA and or CARB authorized service centers Contact your Great Dane Equipment Retailer concerning emission controls and component questions The presence of an emissions label
9. Cleaning Air Intake Screen and Engine Fins IMPORTANT Avoid damage The engine is air cooled and requires a large amount of air intake when running Reduced air intake can cause overheating e Keep air intake screen and cooling fins clean e Keep covers and screens in place Keep air intake screens and engine cooling fins clear of debris to ensure proper cooling See the engine manufacturer s owner s manual provided with your machine for the complete procedure Checking and Cleaning Air Filter Elements A CAUTION Avoid injury Touching hot surfaces can burn skin The engine and components will be hot if the engine has been running Allow the engine to cool before servicing Service Engine 13 SERVICE ENGINE IMPORTANT Avoid damage Dirt and debris can enter the engine through a damaged filter element Do not wash paper element Do not attempt clean paper element by tapping against another object Do not use pressurized air to clean element e Replace element only if it is very dirty damaged or the seal is cracked Replacing Fuel Filter Check and clean air filter elements at the intervals recommended in the Service Intervals section See the engine manufacturer s owner s manual provided with your machine for the complete procedure Checking Spark Plug A CAUTION Avoid injury Fuel vapors are explosive and flammable Do smoke while
10. Assembly 32 ASSEMBLY Check Tire Pressure A CAUTION Avoid injury Explosive separation of tire and rim parts is possible when they are serviced incorrectly e Do not inflate the tires above the recommended pressure Do not stand in front or over the tire assembly when inflating Use a clip on chuck and extension hose long enough to allow you to stand to one side 1 Check tires for damage 2 Check tire pressure with an accurate gauge 3 Check that tires have equal pressure add or remove air if necessary Tire Size Pressure Front 13 5 0 6 110 139 kPa 16 20 psi Rear 23 x 9 5 12 69 83 kPa 10 12 psi Level Mower Deck Before operating the machine level the mower deck Initial Adjustments A CAUTION Avoid injury Clear area of bystanders before performing this service procedure 1 Check free wheeling valves on both pump assemblies to make sure that the valves are closed 2 Raise the rear of the machine until the drive wheels are off the ground Support the machine with jackstands A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the vehicle to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation e Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area Allo
11. Dimensions Wheel Base 1 27 m 50 in Overall Height 1 11 m 44 in Overall Length All Models 1 98 m 78 in Overall Width with 52 Inch Mower Deck 1 57 62 in Overall Width with 61 Inch Mower Deck 1 80 71 in 52 Inch Mower Deck Mower Side Discharge Cutting 3 Blade Bolt Torque 80 Nem 60 lb ft Cutting Width 1 32 52 Cutting Height approximate 25 152 mm 1 6 Height Adjustment 13 1 2 in increments 61 Inch Mower Deck Mower Side Discharge Cutting Blades 3 Blade Bolt Torque 80 Nem 60 lb ft Cutting Width 1 55 61 Cutting Height approximate 25 to 152 mm 1 6 Height 4 13 1 2 in increments Specifications and design subject to change without notice Specifications 34 INDEX A Air Cleaner Elements Replacing 13 Air Cleaner Elements Servicing 13 B Battery and Terminals Cleaning 24 Battery Removing and Installing 23 Belt Replacing Mower Drive Primary
12. use grease Contact your Servicing dealer for information Spray Lubricant Use a general purpose petroleum based spray lubricant 9252 e Lubricate mower deck idler pulleys A D Lubrication Points MX9206 e Grease caster wheel bearings e Grease caster wheel pivot bearings e Grease HOC shafts e Grease mower deck thrust arms D located at the rear of the mower deck MX9408 e Lubricate hydraulic pump control arms e Lubricate control lever pivot shaft Lubricate seat platform hinges e Grease mower deck spindle bearings if equipped Lubricate throttle control cable D e Lubricate choke control cable Service Lubrication 12 SERVICE ENGINE Avoid Fumes A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the vehicle to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation e Connect a pipe extension the engine exhaust pipe to direct the exhaust fumes out of the area e Allow fresh outside air into the work area to clear the exhaust fumes out Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes Use oil that meets the following specification API Service Classification SG or higher Checking Engi
13. 5 Install a new blade if the difference between the two measurements is more than 3 mm 1 8 in Servicing Mower Blades CAUTION Avoid injury Mower blades sharp Always wear gloves when handling mower blades or working near blades Removing and Installing Mower Blades 1 Park machine safely See Parking Safely in the Safety section 9231 2 Remove nut A blade blade washers and bolt D 3 Install blade B blade washers C bolt D and secure using nut A Tighten nut to 80 Nem 60 lb ft Balancing Mower Blades 1 Clean blade M61524 2 Put blade on nail in a vise Turn blade to horizontal position 3 Check balance If blade is not balanced heavy end of blade will drop 4 Grind bevel of heavy end Do not change blade bevel Sharpening Blades A CAUTION Avoid injury Always wear safety eye protection when grinding Sharpen blades with grinder hand file or electric blade sharpener Service Mower 20 SERVICE MOWER cf i Q Pe M61830 e Keep original bevel when grinding Blade should have 0 40 mm 1 64 in cutting edge or less Balance blades before installing Replacing Mower Spindle Bearings 1 Park machine safely See Parking Safely in the Safety section 2 Remove mower deck drive and spindle drive belt 3
14. feet clothing jewelry and long hair away from any moving parts to prevent them from getting caught Lower attachments to the ground before servicing machine Disengage all power and stop the engine Lock park brake and remove the key Let machine cool Disconnect battery or remove spark plug wire before making any repairs e Before servicing machine carefully release pressure from components with stored energy such as hydraulic components Keep all nuts and bolts tightened especially blade attachment bolts Securely support any machine elements that must be raised for service work Lock service latches before working on machine with raised attachments e Never run engine unless park brake is locked e Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Replace all worn or damaged safety and instruction decals e To prevent fires remove any buildup of grease oil or debris from the machine especially the engine compartment e Charge batteries an open well ventilated area away from sparks Unplug battery charger before connecting or disconnecting from the battery Wear protective clothing and use insulated tools e Do modify machine or safety devices Unauthorized modifications may impair its function and safety e Do not wear radio or music headphones while servicing the machine Safe service requires your full attention Avoi
15. 19 Blades Checking Mower 20 Blades Servicing 20 Brake Using Park 7 Carburetor Adjusting 14 Chart Service Interval 11 Cleaning Air Intake Screen 13 Daily Operating Checklist 6 Engine Oil Level Checking 13 Engine and Fuel Storage Preparing 31 Engine Starting cccccccccceceseeeeeeeeeeeeeeeeeeeeeseneeeseneeeeeaees 7 Engine Troubleshooting 28 F Filter Changing Engine 13 Filter Changing Transmission 15 Fu l Safety Fuel Storage re 31 Fuel Tank Filling 26 G E RETo TE e EEEE ETETETT 12 L Leveling Mower Side to Side 18 M Mower Blades Checking 20 Mower Blades Servicing 20 Mower Drive Primary Belt Replacing 19 Mower Level Side to Side Adjusting
16. Deck Drive Belts e 1 32 m 52 in Deck D28031 1 55 61 in Deck D28028 Mower Blades e 53 21 in 018036 e 45 18 in 018037 Part numbers are subject to change without notice Part Numbers may be different outside the U S A Replacement Parts 10 SERVICE INTERVALS Servicing Your Machine IMPORTANT Avoid damage Operating in extreme conditions may require more frequent service intervals e Engine components may become dirty plugged when operating in extreme heat dust or other severe conditions Engine oil and spark plugs may lose efficiency if vehicle is operated constantly at slow or low engine speeds or with frequent short trips Please use the following timetables to perform routine maintenance on your machine NOTE The following initial break in items must be performed and verified to validate the warranty dealer service invoice accepted Break In After First 8 Hours of Operation Change engine oil and filter Check drive belt tension Check transmission neutral adjustment Check wheel nut torque Break In After First 24 Hours of Operation Check drive belt tension Break In After First 40 Hours of Operation Change transmission oil and filter Every 40 Hours Change engine oil Grease HOC shafts five places Grease caster wheel pivot bearings two places Grease caster wheel bearings two places Grease mower deck thrust arms
17. Remove mower blade 9222 4 Remove upper pulleys Side Spindles Remove nut A spacer and pulley e Center Spindle Remove nut D drive pulley and spindle pulley F 5 Remove spindle shaft G lower bearing H and spacer 1 from spindle housing J Discard bearing 6 Remove and discard upper bearing 7 Clean entire assembly 8 Install new lower bearing and spacer 1 on the spindle shaft G IMPORTANT Avoid damage The clearance between the lower bearing and the housing is only 0 05 mm 0 002 in Do not force bearing into housing 9 Install the spindle shaft G lower bearing H and spacer 1 into the spindle housing J 10 Install the upper bearing Service Mower 21 SERVICE MOWER 11 Install upper pulleys Side Spindles Install pulley spacer and nut A Tighten nut to 80 Nem 60 lb ft e Center Spindle Install spindle pulley F drive pulley and nut D Tighten nut to 80 Nem 60 lb ft 12 Install mower blade Tighten nut to 80 Nem 60 lb ft Replacing Mower Deck Idler Pulleys 1 Park machine safely See Parking Safely in the Safety section 2 Remove the mower deck drive and spindle drive belts 9252 3 Remove mower deck drive tension idler pulleys A B mower deck drive fixed idler pulley C and spindle drive tension idler pulley D
18. battery cell caps 7 Install battery Cleaning Battery and Terminals A CAUTION Avoid injury The battery produces a flammable and explosive gas The battery may explode Do not smoke near battery e Wear eye protection and gloves Do not allow direct metal contact across battery posts e Remove negative cable first when disconnecting e Install negative cable last when connecting 1 Disconnect and remove battery 2 Wash battery with a solution of four tablespoons of baking soda to one gallon of water Be careful not to get the soda solution into the battery cells 3 Rinse the battery with plain water and dry 4 Clean terminals and battery cable ends with wire brush until bright 5 Install battery 6 Attach cable clamps to battery posts 7 Apply petroleum jelly or silicone spray to terminal to prevent corrosion Replacing Fuses IMPORTANT Avoid damage When replacing fuses use only 20 amp fuses or you may damage the circuit Two 20 amp fuses to protect the electric start and charging circuit are located behind the seat area 1 Remove defective fuse A electric start circuit or B charging circuit from socket 2 Check metal clip in fuse window and discard fuse if clip is broken 3 Install new fuse into socket Check and Adjust PTO Clutch Air Gap NOTE If clutch is not equipped with adjusting nuts B no adjustment is required 1 Park th
19. cause loss of control or damage the machine 1 Adjust mower deck to desired cutting height 2 Start and warm up engine at half throttle 3 Move PTO clutch switch to on position 4 Move throttle lever to wide open position 5 Unlock park brake NOTE The travel speed and turn rate will vary with the amount that the control levers are moved MX9220 6 Drive the machine To drive the machine forward Push both control levers forward smoothly and evenly To turn the machine Pull the control lever back on the same side as the direction of the desired turn Push the other lever forward To stop the machine Return both control levers to the neutral position To drive the machine in reverse Pull both control levers back evenly Stopping the Machine NOTE If the operator leaves the seat without placing the PTO switch in the off position the mower blades will stop as soon the operator leaves the seat 1 Move the PTO clutch switch to the off position 2 Return both control levers to the neutral position A CAUTION Avoid injury Children or bystanders may attempt to move or operate an unattended machine Always lock the park brake and remove the key before leaving the machine unattended 3 Lock park brake 4 Move the throttle lever to the half speed position and let the engine run at low throttle for a few seconds 5 Turn the key switch to the stop position 6 Rem
20. fuel stabilizer in separate container Follow stabilizer instructions for mixing 5 Fill fuel tank with stabilized fuel 6 Run engine for a few minutes to allow fuel mixture to circulate through carburetor Engine Engine storage procedure should be used when vehicle is not to be used for longer than 60 days 1 Change engine oil and filter while engine is warm 2 Service air filter if necessary 3 Clean debris from engine air intake screen 4 Remove spark plugs Put 30 mL 1 oz of clean engine oil in cylinders 5 Crank the engine five or six times to allow oil to be distributed 6 Install spark plugs 7 Clean the engine and engine compartment 8 Remove battery 9 Clean the battery and battery posts Check the electrolyte level 10 Move fuel shut off valve to off position 11 Store the battery in a cool dry place where it will not freeze NOTE The stored battery should be recharged every 90 days 12 Charge the battery 13 Store the vehicle in a dry protected place If vehicle is stored outside put a waterproof cover over it Removing Machine From Storage 1 Check tire pressure 2 Check engine oil level 3 Check battery electrolyte level Charge battery if necessary 4 Install battery 5 Check spark plug gap Install and tighten plugs to specified torque 6 Lubricate all grease points 7 Turn fuel shut off valve to on position 8 Run the engine 5 minutes without the mower
21. handling fuel e Keep fuel away from flames or sparks e Shut off engine before servicing Cool engine before servicing e Work in a well ventilated area Clean up spilled fuel immediately A CAUTION Avoid injury Touching hot surfaces can burn skin The engine and components will be hot if the engine has been running Allow the engine to cool before servicing 1 Park machine safely See Parking Safely in the Safety section 2 Turn fuel shutoff valve to off position 3 Disconnect the fuel hose from the outlet side of the fuel filter and drain gasoline into a properly marked container 4 Remove the fuel filter from the inlet fuel hose Discard filter Check spark plugs at the intervals recommended in the Service Intervals section See the engine manufacturer s owner s manual provided with your machine for the complete procedure Adjusting Carburetor NOTE Carburetor is calibrated by the engine manufacturer and is not adjustable If engine is operated at altitudes above 1829 m 6 000 ft some carburetors may require a special high altitude main jet If engine is hard to start or runs rough see the troubleshooting section of the engine manufacturer s owner s manual provided with your machine Possible engine surging will occur at high throttle with transmission in neutral and mower disengaged This is a normal condition due to the emission control system After
22. position 6 Move throttle lever to half speed position 7 Adjust choke as required 4 Move PTO clutch switch to on position 5 Operator rises slightly off the seat Result The engine must stop Testing PTO Clutch Safety Switch 1 Operator must be seated in the seat seat safety switch engaged IMPORTANT Avoid damage Starter may be damaged if starter is operated for more than 20 seconds at a time Wait 2 minutes before trying again if the engine does not start 8 Turn key switch to start position for no more than 5 seconds Release key to the run position when engine starts If the engine does not start wait 10 seconds e Turn key to start position again for more than 5 Operating 7 OPERATING seconds e Repeat the procedure if necessary IMPORTANT Avoid damage Unnecessary engine idling may cause engine damage Excessive idling can cause engine overheating carbon build up and poor performance 9 Let the engine run at half speed position for several minutes to warm up before operating the machine Reduce choke setting as the engine warms up Operating the Machine A CAUTION Avoid injury Learn the use of the control levers Practice at half throttle until becoming proficient and comfortable with the operation of the machine Do not move control levers from forward to reverse or reverse to forward position rapidly Sudden direction changes could
23. signifies that the engine has been certified with the United States Environmental Protection Agency EPA and or California Air Resources Board CARB The emissions warranty applies only to those engines marketed by Great Dane that have been certified by the EPA and or CARB and used in the United States and Canada in off road mobile equipment Emission Compliance Period Small Off Road Gas Engines If your engine has the emission compliance category listed on the emission control system certification or air index label this indicates the number of operating hours for which the engine has been certified to meet EPA and or CARB emission requirements The following table provides the engine compliance period in hours associated with the category found on the certification label Agency Category Hours EPA 250 500 1000 Moderate 125 CARB Intermediate 250 CARB Extended 500 Operating Safely Inspect machine before you operate Be sure hardware is tight Repair or replace damaged badly worn or missing parts Be sure guards and shields are in good condition and fastened in place Make any necessary adjustments before you operate e Do not operate mower without discharge chute or entire grass catcher in place e Check before each use that operator presence controls are functioning correctly Test safety systems Do not operate unless they are functioning corr
24. two places Grease mower deck spindle bearings three places if equipped Remove debris from the underside of the mower deck Check drive belt tension Check tire pressure Check battery electrolyte level Clean engine air filter Check wheel nut torque Every 160 Hours Clean and inspect spark plugs Change engine oil filter Check transmission oil level Lubricate mower deck idler pulley pivots three places Lubricate seat platform hinges two places Lubricate pump control arms five places Lubricate control lever pivot shafts two places Lubricate throttle cable Lubricate choke control cable Every 500 Hours Change transmission oil and filter Annually Replace all spindle bearings 6 Replace all mower deck idler pulleys 3 Remove caster wheel roller bearings clean and lubricate Replace drive belts Run in and adjust tension Clean power unit Replace hydraulic oil filter Check all bolts and nuts tighten as needed Remove battery Clean battery and holder Replace spark plugs Service Intervals 11 SERVICE LUBRICATION Grease NOTE Use spray lubricant to lubricate the following items IMPORTANT Avoid damage If operating outside that temperature range contact your Servicing dealer for special use grease Use general all purpose grease with NLGI grade No 2 rating Wet or high speed conditions may require use of a special
25. 4 Install new idler pulleys 5 Install spindle drive and mower deck drive belts 6 Adjust belt tension Service Mower 22 SERVICE ELECTRICAL WARNING Battery posts terminals and related accessories contain lead and lead components chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Removing and Installing the Battery A CAUTION Avoid injury The battery produces a flammable and explosive gas The battery may explode Do not smoke near battery e Wear eye protection and gloves Do not allow direct metal contact across battery posts e Remove negative cable first when disconnecting e Install negative cable last when connecting Removing 1 Park the vehicle safely See Parking Safely in the safety section 9209 2 Slide black cover A away from the negative battery terminal and disconnect the negative battery cable B 3 Slide red cover C away from the positive battery terminal and disconnect the positive battery cable D 4 Loosen the cap screws and nuts E on both sides of the battery tray 5 Remove battery F and isolator pad G Installing 1 Place isolator pad G in the battery tray 2 Install battery F in the battery tray making sure that the isolator pad G is between the bottom and sides of the battery tray 3 Tighten the cap screws and nuts E to secure the
26. FICATIONS Engine NOTE See engine manufacturer s owner s manual provided with your machine for engine specifications Battery AY e 2 0 gee ene nee re 12 volt COAT 235 amp 0 Reserve 25 minutes BCI Group Size U1 Tires We ea Sea 13x5 0 6 Rodi tock ett ed 23 x 9 50 12 Inflation 110 139 kPa 16 20 psi Inflation 69 83 kPa 10 12 psi Wheel Nut 68 Nem 50 16 9 Capacities Fuel Tanks oe veces ats chided aes 30 2 L 8 gal Hydraulic System Low Profile 4 3 L 4 5 qt High Profile Tank 5 2 L 5 5 qt Hydraulic Oil Reservoir Low Profile 2 8 L 3 qt High Profile Tank 3 8 L 4 qt Net Weight With Mower Deck and Without Fuel 23 hp Kawasaki engine 52 in deck 510 kg 1125 Ib 25 hp Kohler engine 52 deck 533 kg 1175 Ib 23 hp Kawasaki engine 61 in deck 535 kg 1180 Ib 25 hp Kawasaki engine 61 in deck 535 kg 1180 Ib 25 hp Kohler engine 61 in deck 535 kg 1181 Ib 26 hp Kohler engine 61 in deck 544 kg 1200 Ib Travel Speeds 0 16 km h 0 10 mph Reverse 0 8 0 5
27. NTS Safety a 1 Operating aves 6 Replacement Pans ei areca eae 10 Service literals 11 12 Semice ENA 13 15 18 Sence Elecro 23 Service Miscellaneous crena anei a 26 Troubleshooting ENA 28 a ach Sats 31 AASSOIMIDI 32 amp kane A R 34 9 35 Service RECO 36 All information illustrations and specifications in this manual are based on the latest information at the time of publication The right is reserved to make changes at any time without notice COPYRIGHT 2002 Deere amp Co John Deere Worldwid
28. are explosive and flammable Engine exhaust fumes contain carbon monoxide and can cause serious illness or death e Run the engine only long enough to move the machine to or from storage Do not store vehicle with fuel the tank inside a building where fumes may reach an open flame or spark e Allow the engine to cool before storing the machine in any enclosure Preparing Machine for Storage 1 Repair any worn or damaged parts Replace parts if necessary Tighten loose hardware 2 Repair scratched or chipped metal surfaces to prevent rust 3 Clean under the deck and remove grass and debris from inside chute and bagger 4 Wash the machine and apply wax to metal and plastic surfaces 5 Run machine for five minutes to dry belts and pulleys 6 Apply light coat of engine oil to pivot and wear points to prevent rust Preparing Fuel and Engine for Storage Fuel If you have been using Stabilized Fuel add stabilized fuel to tank until the tank is full NOTE Filling the fuel tank reduces the amount of air in the fuel tank and helps reduce deterioration of fuel If you are not using Stabilized Fuel 1 Park machine safely in a well ventilated area NOTE Try to anticipate the last time the machine will be used for the season so very little fuel is left in the fuel tank 2 Turn on engine and allow to run until it runs out of fuel 3 Turn key to off position 4 Mix fresh fuel and
29. ation of hydraulic fluid could cause transmission damage or failure Do not open oil reservoir cap unless absolutely necessary Severe or unusual conditions may require a more frequent service interval NOTE Whenever hydraulic components are removed from the system hoses are disconnected or the system has been drained trapped air must be removed from the hydraulic system Service Transmission 16 SERVICE TRANSMISSION 1 Park machine safely See Parking Safely in the Safety section 2 Check hydraulic oil level Adjust as necessary A CAUTION Avoid injury Machine must be safely supported on jackstands before removing or installing wheels Do not use a hoist or floor jack to support the machine 3 Raise drive wheels off the ground and block caster wheels NOTE The pumps are located under the machine behind the mower deck MX9226 Picture Note Left pump shown 4 Open free wheeling valves A one full turn counterclockwise and start engine 5 Slowly move the control levers in both forward and reverse directions five to six times As the air is purged from the unit the oil level will drop 6 Turn off engine and check oil level Adjust as necessary 7 Close the free wheeling valves and tighten to 9 14 Nem 80 120 Ib in 8 Start engine and slowly move the control levers in both forward and reverse directions five to six times 9 Turn off engine and lower machine to
30. battery in the battery tray Do not overtighten 4 Connect the positive battery cable D first then the negative cable B 5 Apply general purpose grease or silicone spray to the terminals to prevent corrosion 6 Slide covers A and C over battery terminals Checking Battery Electrolyte Level A CAUTION Avoid injury Battery electrolyte contains sulfuric acid It is poisonous and can cause serious burns e Wear eye protection and gloves e Keep skin protected e If electrolyte is swallowed get medical attention immediately e If electrolyte is splashed into eyes flush immediately with water for 15 30 minutes and get medical attention e If electrolyte is splashed onto skin flush immediately with water and get medical attention if necessary NOTE Add only distilled water to replace normal electrolyte loss 1 Park the vehicle safely See Parking Safely in the safety section 2 Remove battery from vehicle and set it on a level surface 3 Remove battery cell caps Make sure cap vents are not plugged MIF 4 Check electrolyte level Electrolyte A should be Service Electrical 23 SERVICE ELECTRICAL approximately halfway between bottom of filler neck B and top of plates C IMPORTANT Avoid damage Do not overfill battery Electrolyte can overflow when battery is charged and cause damage 5 Add only distilled water if necessary 6 Install
31. d High Pressure Fluids Hydraulic hoses and lines can fail due to physical damage kinks age and exposure Check hoses and lines regularly Replace damaged hoses and lines Hydraulic fluid connections can loosen due to physical Safety 4 damage and vibration Check connections regularly Tighten loose connections e Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids e f an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Prevent Fires e Never remove fuel cap or add fuel with engine running or hot Allow engine to cool for several minutes Never store equipment with fuel in the tank inside a building where fumes may reach an open flame or spark Allow engine to cool before storing in any enclosure e To reduce fire hazard keep engine free of grass leaves or excessive grease Tire Safety Explosive separation of a tire and rim parts can cause serious injury or death Do attempt to mount a tire without the proper equipment and ex
32. e Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT 2001 OMGD10001 B2 English Table of Contents SAFETY DANGER Understanding The Machine Safety Labels MIF The machine safety labels shown in this section are placed in important areas on your machine to draw attention to potential safety hazards On your machine safety labels the words DANGER WARNING and CAUTION are used with this safety alert symbol DANGER identifies the most serious hazards The operator s manual also explains any potential safety hazards whenever necessary in special safety messages that are identified with the word CAUTION and the safety alert symbol DANGER POISON MX9292 MX9204 Shield eyes explosive gases can cause blindness or injury e No sparks flames smoking Sulfuric acid can cause blindness or severe burns e Flush eyes immediately with water get medical help fast e Keep out of the reach of children e Do not tip Keep vent caps tight and level 9293 9214 e Keep hands and feet away CAUTION 9294 9214 Do not operate mower without chute deflector mulching plate or complete grass catcher assembly in position Do not remove grass catcher mulching plate or raise the chute deflector until engine and blade s have stopped Safety 1 CAUTION
33. e Move unit by hand only Do not use another vehicle to move unit Do not tow unit 1 Park machine safely See Parking Safely in the Safety section NOTE The pumps are located under the machine behind the mower deck MX9226 Picture Note Left pump shown 2 Turn free wheeling valves A on both pumps one full turn counterclockwise open position 3 Unlock park brake 4 Push machine to desired location Due to internal hydraulic system resistance the machine will move slowly 5 Turn free wheeling valves A on both pumps one full turn clockwise closed position Tighten the valves to 9 14 Nem 80 120 Ib in 6 Lock park brake Operating 9 REPLACEMENT PARTS Parts We recommend Great Dane quality parts available at your Great Dane dealer Part numbers may change Use part numbers listed below when you order If number changes your dealer will have the latest number When you order parts your Great Dane dealer needs your machine model and serial numbers and engine serial number These are the numbers that you recorded in the Product Identification section of this manual Part Numbers Item Part Number Battery D18169 Fuel Tank Cap D18097 Oil Reservoir Cap D18081 Oil Filter Hydraulic System D18094 Traction Hydro Drive Belt D28030 Engine to Blade Belts 1 32 52 in Deck D28032 1 55 61 in Deck D28029 Mower
34. e longest span To Increase Belt Tension Turn nut mower deck drive belt or D spindle drive belt clockwise To Decrease Belt Tension Turn nut mower deck drive belt or D spindle drive belt counterclockwise Removing and Installing Mower Deck Drive Belts 1 Park machine safely See Parking Safely in the Safety section 2 Raise foot platform 3 Remove mower deck drive belt covers 9217 4 Release mower deck drive belt tension by turning the tension adjuster nut A counterclockwise 5 Remove mower deck drive belt B 6 Release spindle drive belt tension by turning tension adjustment nut C counterclockwise 7 Remove spindle drive belt D 8 Install new spindle drive belt D and adjust drive belt tension 9 Install new mower deck drive belt B and adjust drive belt tension 10 Install mower deck drive belt covers 11 Lower foot platform Service Mower 19 SERVICE MOWER Checking for Bent Mower Blades A CAUTION Avoid injury Mower blades are sharp Always wear gloves when handling mower blades or working near blades 1 Park machine safely See Parking Safely in the Safety section 2 Lower mower deck to mowing position 2 P MIF 3 Measure distance A between blade tip and flat ground surface 4 Turn blade 180 Measure distance between the other blade tip and flat ground surface
35. e vehicle safely See Parking Safely in the safety section 9290 2 Check the air gap at the three openings A around the clutch using a feeler gauge The air gap should be within 0 012 0 584 mm 0 005 0 023 in If the gap is not within specifications adjust the air gap 3 Adjust the air gap to 0 34 mm 0 12 in by tightening or loosening the three adjustment nuts Service Electrical 24 SERVICE ELECTRICAL Kohler Wiring Schematic 290810 Nid AVTIH AYMY Nid 18 Esn G 30010 N ONYE ON SI 28 pmu an we 0001 0 1 ON ON 1545 HOLIMS Mud A 9 829 98 Awad EAEAN NOWAOS Houma ee OC E LINOHID 109 98 9 98 gt 1545 H108 i ter 1 i HOLMIO Old g SIHOLIMS ra NOH
36. ectly Do not change the engine governor setting or overspeed the engine Check brake action before you operate Adjust or service brakes as necessary Safety 2 Stop machine if anyone enters the area e Never raise mower decks when blades are running e If you hit an object stop and inspect the machine Make repairs before you operate Keep machine and attachments properly maintained and in good working order Do not leave machine unattended when it is running e Only operate during daylight or with good artificial light Slow down and be careful of traffic when operating near or crossing roadways Stop blades before crossing roads or sidewalks Use care when approaching blind corners shrubs trees or other objects that may obscure vision Be aware of the mower discharge direction and make sure that no one is in the path of the discharge direction Use only accessories and attachments approved by the manufacturer of the machine Wear close fitting clothing and safety equipment appropriate for the job Always wear safety goggles or safety glasses with side shields when operating the mower e Wear a suitable protective device such as earplugs Loud noise can cause impairment or loss of hearing e Do not wear radio or music headphones Safe service and operation requires your full attention Checking Mowing Area e Evaluate the terrain to determine what accessories
37. ed for several weeks or more Obtain fresh fuel Engine Will Not Start Park brake not locked Control levers are not in neutral position PTO clutch switch is in on position Fuel shutoff valve in off position Spark plug wire s loose or disconnected Improper fuel Plugged fuel filter Electrical problem See Electrical Troubleshooting section Engine Will Not Idle Operator rising off the seat Engine Stops Or Misses When Operating On Hillsides Fuel tank less than half full of fuel Operator rising off of the seat Engine Backfires Operator rising off of the seat Troubleshooting 28 TROUBLESHOOTING Electrical If Check Starter Does Not Work Or Will Not Turn Engine Park brake is not locked PTO clutch switch is in on position Battery terminals are corroded Battery not charged 20 amp fuse is blown Battery Will Not Charge Dead cell in the battery Battery cables and terminals are dirty Low engine speed or excessive idling Machine Operation If Check Machine Vibrates Too Much Or Rattles Excessively Attachment drive belts worn or damaged Traction drive belt damaged or worn Dirt on drive sheaves Machine Will Not Move With Engine Running Park brake locked Transmission hydraulic oil level low Free wheeling valves are open Traction drive belt damaged or worn Machine Will Not Follow a Straight Path Stee
38. ed height of position D 8 Measure the distance from the top of the mower deck to the ground at positions C and D The height at position C must be 3 6 mm 1 8 1 4 in higher than position D e If adjustment is required proceed to Step 9 e f no adjustment is required proceed to Adjust Cutting Height 9 Loosen the nut I and slide cap screw J in the slot until the desired height at position C is obtained Tighten the nut Adjust Cutting Height 1 Set the cutting height to 89 mm 3 1 2 in and lower mower to cutting position 2 2 Turn right blade so that the blade tip is pointing out of the middle of the discharge chute 3 Measure from outside blade tip to flat ground surface If the blade height A is not 89 mm 3 1 2 in adjust the cutting height Service Mower 18 SERVICE MOWER 9285 4 Loosen the jam nut on the link rod assembly and turn the sleeve C until the blade height is 89 mm 3 1 2 in Tighten the jam nut Checking and Adjusting Mower Deck Drive Belt Tension 1 Park machine safely See Parking Safely in the Safety section 2 Adjust the mower deck for the lowest cutting height and lower the deck 9217 3 Check the mower deck drive A and spindle drive belt tension The belts should deflect a maximum of 13 mm 1 2 in when a force of 4 5 kg 10 Ib is applied to the center of th
39. ground Check oil level and adjust as necessary Mower should move in forward and reverse at normal speed if not repeat procedure Service Transmission 17 SERVICE MOWER Adjusting Mower Level A CAUTION Avoid injury Mower blades are sharp Always wear gloves when handling mower blades or working near blades 1 Park machine safely See Parking Safely in the Safety section 2 Inflate drive rear tires to 69 83 kPa 10 12 psi and caster front tires to 110 139 kPa 16 20 psi 3 Adjust cutting height to 50 mm 2 in and lower mower to cutting position H T 9288 4 Measure the distance from the top of the mower deck to the ground at positions A and B The height at position A must be 3 6 mm 1 8 1 4 in higher than position B e If adjustment is required proceed to Step 5 e If no adjustment is required proceed to Step 6 5 Loosen jam nuts E and F on the swivel adjuster rod Turn the jam nuts as required to obtain the desired height of position A 6 Measure the distance from the top of the mower deck to the ground at positions B and D The heights of position B and D should be equal 3 mm 1 8 in e If adjustment is required proceed to Step 7 e If no adjustment is required proceed to Step 8 9221 7 Loosen jam nuts the swivel adjuster rod Turn the jam nuts as required to obtain the desir
40. hecking 15 Transmission Oil Changing 15 Index 35 Notes Record Service Dates SERVICE RECORD GD Engine Oil and Filter Change Lubricate Machine Air Cleaner Element Clean Replace Service Record GD 37
41. ion 2 Remove battery from machine and set it on a level surface 3 Remove battery cell caps Make sure cap vents are not plugged MIF 4 Fill the battery e Only use battery acid with a 1 265 specific gravity Slowly add acid A to each cell The solution should 6 Charge the battery for a minimum of 30 minutes at 5 10 amps If your battery charger has a Deep Cycle or Maintenance Free setting use this setting to charge the battery Failure to charge the battery before use will reduce battery performance and life 7 Install the battery in the machine Check Fluid Levels IMPORTANT Avoid damage Check all fluid levels before attempting to start the machine Machine should be parked on a hard level surface with the key switch in the STOP position Check Engine Oil Level Oil level should be between the ADD and FULL marks on the dipstick Add oil as necessary Check Transmission Oil Level Hydraulic oil level should be to the top of the FULL COLD mark on the reservoir dipstick Add oil as necessary If your mower has no dipstick make sure that oil is 76 mm 3 in from the top of the filler pipe Lubricate Machine Lubricate all moving parts before operating the machine see Lubrication Points in Service Lubrication section Check Safety System For a complete checkout procedure of the safety interlock system see Testing the Safety Interlock System in the Operating section
42. ition The wheels should stop rotating If the wheels continue to rotate adjust the neutral adjustment knob s A located on each side of the seat until wheel s stop rotating 9250 6 Adjust neutral switch activator as needed The switches should be engaged when the control levers are in the neutral position 7 Shut engine off 8 Lower the machine to the ground Removing and Installing Traction Drive Belt 1 Park machine safely See Parking Safely in the Safety section 2 Remove mower deck drive belt 9216 Picture Note Drive belt routing as viewed from the top of machine Disconnect tension spring A from the anchor pin Remove drive belt B Install new drive belt B Connect tension spring A to anchor pin OO O Install mower deck drive belt Bleeding Hydraulic System A CAUTION Avoid injury Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids Use caution when filling and draining hydraulic oil During periods of machine operation the hydraulic oil reservoir can get hot Allow engine and oil reservoir to cool before servicing IMPORTANT Avoid damage Contamin
43. ne Oil Level IMPORTANT Avoid damage Failure to check the oil level regularly could lead to serious engine problems if oil level is low e Check oil level before operating e Check oil level when the engine is cold and not running e Keep level between the FULL and the ADD marks e Shut off engine before adding oil NOTE Check oil twice a day if you run engine over 4 hours in a day Make sure engine is cold when checking engine oil level 1 Park machine safely See Parking Safely in the Safety section 2 Clean area around dipstick to prevent debris from falling into crankcase 3 Remove dipstick Wipe with a clean cloth 4 Install and tighten dipstick 5 Remove dipstick and check oil level on dipstick Oil must be between ADD and FULL marks If oil is low add oil to bring oil level no higher than FULL mark on dipstick Do not overfill 6 Install and tighten dipstick Changing Engine Oil and Filter MX9413 NOTE An oil drain tube is provided with your machine Attach the tube to the oil drain fitting on your engine and open the valve A to drain the used oil Close the valve and remove the drain tube from the fitting after the oil has been drained Store the drain tube after use Change engine oil and filter at the intervals recommended in the Service Intervals section See the engine manufacturer s owner s manual provided with your machine for the complete procedure
44. ne safely See Parking Safely in the Safety section 2 Allow engine and hydraulic reservoir to cool 3 Clean area around the reservoir filler cap and remove the filler cap from the reservoir MX9233 4 Turn hydraulic filter A counterclockwise to remove and drain oil into a properly marked container with a capacity of at least 7 5 L 2 0 gal 5 Apply a film of clean oil to gasket of new filter 6 Install filter Turn filter clockwise until gasket makes contact with the mounting surface Tighten 1 2 to 3 4 turn after contact 7 Fill reservoir with approximately 2 8 L 3 qt low profile tank or 3 8 L 4 qt high profile tank of oil 8 Install reservoir cap 9 Bleed air from hydraulic system Adjusting Transmission Neutral Position 1 Park machine safely See Parking Safely in the Safety section A CAUTION Avoid injury Machine must be safely supported on jackstands before removing or installing wheels Do not use a hoist or floor jack to support the machine 2 Raise drive wheel off the ground and securely support the machine and block caster wheels 3 Start and run the engine until it reaches normal operating temperature 4 Observe wheel movement as control levers are moved back and forth The wheels should travel in the correct direction as the levers are moved Service Transmission 15 SERVICE TRANSMISSION Mx9244 5 Move control levers to neutral pos
45. nnel with a plastic mesh strainer when filling the fuel tank or container Checking Wheel Nuts Tighten rear wheel nuts in an alternating pattern to 68 Nem 50 Ib ft Servicing Caster Wheel Roller Bearings 1 Park machine safely See Parking Safely in the Safety section 2 Raise and securely support the front of the mower deck Sas hile MX9223 3 Remove lock nut A bolt B two spacers C and wheel assembly D 4 Remove seals E bearings F and spacer tube G from wheel 5 Clean and inspect bearings F and pack with clean grease Replace bearings as needed 6 Install spacer tube G bearings F and new seals E 7 Install wheel assembly D two spacers C bolt B and lock nut A Servicing Caster Pivot Bearings 1 Park machine safely See Parking Safely in the Safety section 2 Raise and securely support the front of the mower deck Service Miscellaneous 26 SERVICE MISCELLANEOUS 9224 3 Remove cap A cotter castle nut caster yoke and wheel assembly D and caster bushing E NOTE It is not necessary to remove the bearing races F and G unless the bearings need to be replaced 4 Remove seal and lower bearing 1 5 Remove upper bearing J 6 Clean and inspect bearings 1 and J pack with clean grease Replace bearings if needed 7 Install lower bearing 1 and a new seal 8 I
46. nstall upper bearing J NOTE Do not overtighten castle nut C Tighten castle nut only enough to remove excess play from bearings Align crossdrill and nut to allow installation of the cotter pin B The caster wheel yoke assembly must be free to rotate 9 Install caster bushing E on yoke shaft and install caster yoke and wheel assembly D castle nut C and cotter pin B 10 Apply grease to lubrication fitting L until you can see grease at the top bearing J Install grease cap A Service Miscellaneous 27 TROUBLESHOOTING Using Troubleshooting Chart If you are experiencing a problem that is not listed in this chart see your Great Dane dealer for service When you have checked all the possible causes listed and you are still experiencing the problem see your Great Dane dealer Engine NOTE This engine troubleshooting chart covers items that are unique to the machine operation See the engine manufacturer s owner s manual provided with your machine for detailed engine troubleshooting procedures If Check Poor Engine Performance Dirt in fuel system or fuel is old obtain fresh fuel from another supplier before suspecting machine problems Suppliers blend fuels differently and changing suppliers will generally solve any performance problems Fuel blended with alcohol or ether may contribute to performance problems by causing gum and varnish deposits especially if fuel is stor
47. or any attachments running to allow oil to be distributed throughout engine 9 Be sure all shields and guards or deflectors are in place Storage 31 ASSEMBLY Install Seat and Control Lever Handles 1 Install seat on platform and secure using nuts provided in small parts bag 2 Connect seat safety switch to wiring harness 3 Install handles on control levers and secure using sleeves cap screws and nuts provided in small parts bag Activate and Charge Battery be 6 mm 1 4 in above plates B but NO HIGHER than 6 mm 1 4 in from the bottom of the filler neck C 5 Install the battery caps before charging the battery IMPORTANT Avoid damage Wait 20 minutes before charging the battery to allow the plates to absorb the acid so they will take a charge well Battery must be charged before operation Adding acid without charging will result in battery damage A CAUTION Avoid injury Battery electrolyte contains sulfuric acid It is poisonous and can cause serious burns e Wear eye protection and gloves e Keep skin protected e If electrolyte is swallowed get medical attention immediately e If electrolyte is splashed into eyes flush immediately with water for 15 30 minutes and get medical attention e If electrolyte is splashed onto skin flush immediately with water and get medical attention if necessary 1 Park the vehicle safely See Parking Safely in the Safety sect
48. ove key Adjusting Cutting Height Cutting height can be adjusted from approximately 25 152 mm 1 6 in Each hole adjusts the height of cut HOC in 13 mm 1 2 in increments The deck can also be raised and locked in a transport position to provide maximum ground clearance when moving the machine from one area to another 9215 1 Push the mower deck lift lower pedal A forward to raise and latch the deck in the transport position 2 Position the HOC adjustment pin B in the proper hole for the desired height of cut Operating 8 OPERATING 3 Depress and hold the mower deck lift lIower pedal A and release the transport position lock lever 4 Release the mower deck lift lower pedal A and allow the pedal to rest against the HOC pin Using the Fuel Shutoff Valve 9409 Move the fuel shutoff valve to the on position for normal operation Move the valve to the off position when the machine is not in use and during transport Moving the Machine Manually A CAUTION Avoid injury With the free wheeling valve open the machine will have unrestricted motion e The machine may free wheel out of control if the free wheeling valve is opened with the machine on an incline e Park the machine on a level surface before opening the free wheeling valve IMPORTANT Avoid damage Transmission damage may occur if the machine is moved or towed incorrectly
49. performing the checks in the troubleshooting section and your engine is still not performing correctly contact the local engine manufacturer s authorized servicing dealer IMPORTANT Avoid damage When installing a new fuel filter the filter arrow must be pointing in the direction of fuel flow 5 Connect a new fuel filter to hoses 6 Turn fuel shutoff valve to ON position Service Engine 14 SERVICE TRANSMISSION Avoid Fumes A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the vehicle to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation e Connect a pipe extension the engine exhaust pipe to direct the exhaust fumes out of the area Allow fresh outside air into the work area to clear the exhaust fumes out Transmission Oil Use only Quaker State 5W 50 Mobil 1 15W 50 all synthetic oil Checking Transmission Oil Level 1 Park machine safely See Parking Safely in the Safety section 2 Remove the hydraulic reservoir cap The oil level should be 76 mm 3 in from the top of the filler pipe Add oil as needed Changing Transmission Oil and Filter IMPORTANT Avoid damage Contamination of hydraulic fluid could cause transmission damage or failure Do not open oil reservoir cap unless absolutely necessary 1 Park machi
50. perience to perform the job Always maintain the correct tire pressure Do not inflate the tires above the recommended pressure Never weld or heat a wheel and tire assembly The heat can cause an increase in air pressure resulting in a tire explosion Welding can structurally weaken or deform the wheel e When inflating tires use a clip on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly Check tires for low pressure cuts bubbles damaged rims or missing lug bolts and nuts Handling Fuel Safely Fuel and fuel vapors are highly flammable and explosive e Do not refuel machine while you smoke when machine is near an open flame or sparks or when engine is running Stop engine and allow to cool before filling e Never remove the fuel cap or add fuel with the engine running e Never fill fuel tank or drain fuel from a machine enclosed area Fill fuel tank outdoors e Prevent fires Clean up spilled fuel immediately e Do not store machine with fuel in tank a building where fumes may reach an open flame or spark Prevent fire and explosion caused by static electric discharge Use only non metal portable fuel containers approved by the Underwriter s Laboratory U L or the American Society for Testing amp Materials ASTM If using a funnel make sure it is plastic and has no screen or filter MIF e Static elec
51. ren are attracted to mowing activity stay alert to the presence of children e Keep children indoors when you are mowing Turn the machine off if a child enters the mowing area Use extra care when you come to blind corners shrubs trees or other objects that may block your vision e Do not let children or an untrained person operate the machine e Do not carry or let children ride on any attachment or machine even with the blades off Do not tow children a cart or trailer Avoid Tipping e Slopes a major factor related to loss of control and tip over accidents which can result in severe injury or death Safety 3 e Drive across hill not up and down If necessary turn slowly and in the downhill direction Do not shift to neutral and coast downhill e Avoid starting and stopping on a slope If machine stops disengage mower blades and back down slowly e Do not drive where machine could slip or tip Stay alert for holes and other hidden hazards in the terrain Keep away from drop offs ditches and embankments Slow down before you make a sharp turn or operate a slope On gear models choose a low gear so that shifting and stopping will not be necessary while on the slope e Transport machine with decks lowered to improve stability e Drive machine very slowly and avoid quick stops when attachment is removed e Mowing when grass is wet can cause reduced trac
52. ring tracking out of adjustment Machine Moves To The Left Or Right With Engine Running And Transmission In Neutral Pump linkage neutral position out of adjustment Mower If Check Discharge Chute Plugged Travel speed too fast Grass too long Grass too wet Engine rpm not at wide open throttle Restricted air flow Belt installed incorrectly Patches Of Grass Uncut Travel speed too fast Engine rpm not at wide open throttle Mower deck needs cleaning Troubleshooting 29 TROUBLESHOOTING If Check Belt Slipping Debris in sheaves Worn belt Too Much Vibration Debris on mower deck or in sheaves Damaged sheaves or sheaves out of alignment Damaged drive belt Blades out of balance Blades Scalping Grass Cutting too low Mower wheels not adjusted correctly Turning speed too fast Ridges in terrain Rough or uneven terrain Low tire pressure Mower Loads Down Engine Engine rpm too low Travel speed too fast Debris wrapped around mower spindles Uneven Cut Mower deck not leveled properly Travel speed too fast Blades dull Mower wheels not adjusted correctly Tire pressure unequal Grass Tips Are Jagged And Turn Grayish Brown After Mowing Dull mower blades Mower deck not leveled properly Troubleshooting 30 STORAGE Storing Safety A CAUTION Avoid injury Fuel vapors
53. ter Ammeter Testing Safety Systems A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the vehicle to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation e Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area Allow fresh outside air into the work area to clear the exhaust fumes out Use the following checkout procedure to check for normal operation of machine If there is a malfunction during one of these procedures do not operate machine See your Great Dane dealer for service Perform these tests in a clear open area Keep bystanders away Operating 6 OPERATING Testing Park Brake Safety Switch 1 Operator must be seated in the seat seat safety switch engaged 2 Move control levers to neutral position 3 Move PTO clutch switch to off position 4 Unlock park brake 5 Turn key switch to start position Result The engine must not crank Testing Park Brake Stop the machine on a maximum 17 slope Stop the engine and lock the park brake Result Park brake must hold the machine stationary If the machine moves more than 61 cm 24 in in one hour brakes need to be adjusted See your Great Dane dealer Testing Neutral Start Safety Switch 1 Operator must be seated in the seat seat safety switch engaged
54. tion and sliding Keep Riders Off e Only allow the operator on the machine Keep riders off e Riders the machine or attachment may be struck by foreign objects or thrown off the machine causing serious injury e Riders obstruct the operator s view resulting in the machine being operated in an unsafe manner Checking Wheel Bolts e serious accident could occur causing serious injury if wheel bolts are not tight Check wheel bolt tightness often during the first 100 hours of operation Wheel hardware must be tightened to specified torque using the proper procedure anytime it is loosened Driving Safely on Public Roads Avoid personal injury or death resulting from a collision with another vehicle on public roads Use safety lights and devices Slow moving machines when driven on public roads are hard to see especially at night e Use extra care when loading or unloading the machine into a trailer or truck e Whenever driving on public roads use flashing warning lights and turn signals according to local regulations Extra flashing warning lights may need to be installed Practice Safe Maintenance e Only qualified trained adults should service this machine Understand service procedure before doing work Keep area clean and dry Never lubricate service or adjust machine while it is moving Keep safety devices in place and in working condition Keep hardware tight e Keep hands
55. tric discharge can ignite gasoline vapors in an ungrounded fuel container Remove the fuel container from the bed of a vehicle or the trunk of a car and place on the ground away from the vehicle before filling Keep nozzle in contact with container opening while filling When practical remove equipment from trailers or truck beds and refuel them on the ground If this is not possible use a portable plastic fuel container to refuel equipment on a truck bed or trailer e For gasoline engines do not use gas with methanol Methanol is harmful to your health and to the environment Safety 5 OPERATING Daily Operating Checklist 1 Test safety systems 1 Check tire pressure 1 Check fuel level Check engine oil level 1 Remove and clean engine air filter 1 Check transmission oil reservoir level 1 Remove grass and debris from machine Inspect all belts for damage Sharpen and balance mower blades 1 Check area below machine for any fuel or oil leaks Operating Controls 9206 Park Brake Lever B Height of Cut HOC Adjustment Pin Mower Deck Lift Lower Pedal D Mower Deck Transport Position Lock Lever E Fuel Shutoff Valve F Steering Control Levers G Console Clean engine cooling air intake screen and cooling fins Console Controls 9205 Throttle Lever Key Switch Choke Lever PTO Clutch Switch Hourme
56. w fresh outside air into the work area to clear the exhaust fumes out 3 Start and run the engine until it reaches normal operating temperature 4 Move control levers to the forward position and observe drive wheel rotation the drive wheels should rotate in the correct direction 5 Move the control levers to the reverse position and observe drive wheel rotation the drive wheels should rotate in the correct direction NOTE Neutral position and transmission linkage adjustments will needed to be recheck after several hours of operation 6 Release control levers the levers should return to the neutral position and wheel rotation should stop If the wheels do not stop adjust the neutral adjustment knob on each side of the seat 7 Move PTO clutch switch to on position mower clutch should engage Run blades for several minutes 8 Move PTO clutch switch to off position and shut the engine off 9 Check all belts for proper tension 10 Start the engine and test drive the machine in an open area Drive the machine forward if the machine drifts to the right or left adjust the transmission control linkage PTO Clutch Run in Procedure 1 Start and run the engine at half throttle 2 Engage and disengage the PTO clutch five times ten seconds on ten seconds off 3 Move throttle lever to 3 4 throttle 4 Engage and disengage the PTO clutch five times ten seconds on ten seconds off Assembly 33 SPECI
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