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Great Dane GBKH2752S Lawn Mower User Manual

1. en em em et Control Input Shaft Pump Block Charge Pump Charge System Check Valve Right Hydraulic Pump Manual Bypass Free Wheel Valve Right Wheel Motor Cooling Orifice Charge Relief Valve J Left Wheel Motor K Left Hydraulic Pump L Oil Filter M Hydraulic Reservoir Service Steering amp Brakes Service Steering amp Brakes 31 SERVIGE STEERING amp BRAKES Removing and Installing Front Caster Wheels Removing 1 Park machine safely See Parking Safely in the SAFETY section A CAUTION Avoid injury The machine may fall or slip from an unsafe lifting device or supports injuring anyone beneath it Remove key before raising machine Use a safe lifting device rated for the load to be lifted Lower machine onto stable supports or jack stands and block wheels before servicing 2 Lift front of machine with a safe lifting device 3 Remove locknut A cap screw B two trash guards C and wheel and tire assembly D 4 Remove bearings E and spacer tube F from wheel 5 Wipe clean and inspect bearings E Replace bearings as needed 6 Install spacer tube press bearings E into wheel and tire assembly 7 Install wheel and tire assembly D two trash guards cap screw and locknut A Adjusting Front Caster Spindle Bearing NOTE Adjustm
2. JCT ET pl PROTECTIVE STAUCTURE a mp apres nalacken snd F llt MOFA r DES must Se eed by EE EE GE rePri al 0584 Pert 142442 Wemt 3256 LES fe El Far ut Great Dass Chale LE Basic Cormoam Misc 1 8 CAUSES SEVERE BURKE Cream acid Bez AC yad d gl up vu Ir de FLER ES a pied _ GA ESTRUCTURA de le Sasiriulr una ever raria Sim Las rodar da daher Ser ail par pn brite RIPS ligand de Pris 112152 PPS fea lica 131142 1540 Pact uta D 4 Medan Mach EE Ll 61 CUTTING DECK AA SELL LIUM SCH LAG 1 122111 flera Es Lug rs 11 11 41 Kies decks pel 094 org d ML ll BE 181023 D28167 D28181 GDU10254 200343 GDU10256 GDU10257 GDU10258 GDU10259 GDU
3. same time Cold engine Set throttle lever at the 1 2 to 3 4 throttle position Sharp Right Turn e Warm Hot engine Set throttle lever to the 1 2 throttle position 6 Position choke knob D Cold engine Pull knob up and hold in choke position Warm Hot engine If necessary pull knob up and hold in choke position IMPORTANT Avoid damage Starter may be damaged if starter is operated for more than 20 seconds at a time Wait two minutes before trying again if engine does not start Push left control lever forward and pull right control lever rearward at the same time Starting the Engine CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine Do not run an engine in an enclosed area without 7 Turn key switch to start position B adequate ventilation If the engine does not start wait 10 seconds Connect pipe extension to the engine exhaust pipe to Tum k in f h d direct the exhaust fumes outofihearen e Turn key to start position again for no more than 5 seconds Allow fresh outside air into the work area to clear the Repeat the procedure if necessary exhaust fumes out IMPORTANT Avoid damage Unnecessary engine idling can 1 Sit on the operator seat cause engine overheating carbon build up and poor 2 Lock the park brake performance 3 Move both motion c
4. Extremely dusty conditions Frequent slow low speed operation Frequent short trips 1 Run engine to warm oil 2 Park machine safely See Parking Safely in the SAFETY section 3 Put container under drain tube 4 Open drain valve A using a 10 mm socket 1 ft extension swivel and 3 8 in drive ratchet 5 Allow oil to drain into an oil drain pan 6 After oil drains close drain valve 7 Remove oil filter using an appropriate filter wrench Turn filter counterclockwise to remove 8 Apply a film of clean engine oil on gasket of new filter 9 Install filter Turn filter clockwise until gasket makes contact with mounting surface Tighten 1 2 to 3 4 turn after gasket contact 10 Clean area around the dipstick 11 Unscrew and remove dipstick IMPORTANT Avoid damage To prevent extensive engine wear or damage always maintain the proper engine oil level Never operate the engine with the oil level below the add mark or over the full mark 12 Add approximately 1 4 L 1 5 qt of oil 13 Install and tighten dipstick 14 Start engine and run at slow throttle for approximately two minutes Check for leaks around filter and drain valve 15 Stop engine 16 Check oil level Remove dipstick Wipe with a clean cloth Install dipstick and allow the cap to rest on the end of the tube Do not tighten the cap Remove dipstick and check oil level on dipstick Oil level should be betwee
5. GREAT DANE Chariot Brutus GBKW2552S GBKH2752S GBKW2561S GBKH2761S OPERATOR S MANUAL 200315 03 06 2006 INTRODUCTION 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 Use the safety and operating information in the machine operator s manual to operate and service the machine safely and correctly 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 A WA R N N G The Engine Exhaust Specifications and design are subject to change without notice from this product contains chemicals known Special Messages to the State of California to cause cancer 3 Your manual contains special messages to bring attention to potential birth defects or other reproductive harm safety concerns machine damage as well as helpful operating and _ servicing information Please read all the information carefully to avoid California Proposition 65 Warning injury and machine damage 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 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 i
6. Neutral Position Park Brake Park Brake Not Working Brakes out of adjustment adjust Correctly linkage Mower Mows Unevenly Brake drums wet Worn brake shoes Brake cable damaged Steering Park brake locked Hydraulic pump free wheel valves partially open Steering Not Working Improper tire Inflation Hydrostatic transmission oil low Traction drive belt slipping Traction drive belt damaged or worn Troubleshooting 46 Machine Moves to the Left or Right With Engine Running and Transmission in Neutral Discharge Chute Plugged Pump linkage neutral position out of adjustment Grass is wet mow grass only when dry Raise cutting height Mow at full throttle Ground speed too fast for conditions Correct installation of deck drive belt Run engine at full throttle Loose hardware Check replace mower deck drive belt Blades bolts are loose Blades are bent or worn Sharpen and balance blades Remove belt shields and check for debris on sheaves Check sheaves for proper alignment or damage See your Great Dane servicing dealer Mower deck drive belt slipping or broken Mower deck belt tension spring not installed or broken PTO switch failure 20 amp fuse is blown main power circuit Loose electrical connections Faulty PTO clutch Mower deck not properly leveled Ground speed too fast for conditions Run engine at full throttle Reduce ground spe
7. NOTE See authorized servicing engine dealer for engines and engine related service items Always reference the engine model number when ordering parts FRONT CASTER ASSEMBLY FRONT CASTER ASSEMBLY 70 8 200334 TCU14490 AA21840 TCU13871 TCA13769 19M7978 14M7276 TCU13454 E14625 JD8933 145553 24H180 11M7083 A12188 TCU14490 JD 7844 TCU13604 TCU15970 AM30795 FRONT CASTER ASSEMBLY ay YOKE ROUND RETAINER BALL BEARING SPACER TIRE AND WHEEL ASSEMBLY CAP SCREW NUT SPACER SEAL BEARING CONE BEARING CUP WASHER COTTER PIN LOGK NUT ROUND RETAINER LUBRICATION FITTING RIM TIRE TIRE VALVE STEM NOTES 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 FRONT CASTER ASSEMBLY 71 CASTER 13 CASTER M16 3 200 X 50 MM 13 13 X 5 00 5 4 PLY ROPS MP35897 Ref No PartNo Description Remarks 16051 ROPS e SS SE NOTES ROPS 72 NOTES Notes 73 SPINDLE ASSEMBLY SPINDLE ASSEMBLY 74 8 200041 200046 200042 200044 200043 200045 D13055 D18209 D18084 D18211 D13024 967347 960502 D18055 SPINDLE ASSEMBLY Deseription _ Spindle Assembly Ball Bearing Housing Spacer Shaft Spindle Bolt Nut Pulley Special Pulley Cutter Housing 48 Deck Pulley Cutter Housing 52 Deck Pulley Cutter Housing 61 Deck Spacer Pulley Bolt B
8. Assembly 49 SPECIFICATIONS CAUTION Avoid injury Machine is heavy Use safe lifting device or get an assistant to help lift and hold component into place for installation NOTE Using tapered drift will aid in the alignment of mounting holes and ease installation of cap screws 5 Lay ROPS on the ground slide it up to the bumper and align the appropriate hole in the ROPS flange with the lower rear mounting holes in the machine frame and bumper Install an M10 cap screw removed earlier through the hole from the inside and secure loosely with an M10 locknut 6 Remove cap screw C NOTE Take care when raising ROPS to avoid damaging paint on bumper 7 Using the lower rear bolts as a pivot raise ROPS to the vertical position and install remaining cap screws and locknuts on each side Tighten all ROPS mounting hardware to 80 59 Ib ft 8 Engage hooked end B of rear battery hold down rod in slot in bumper and tighten nut to secure Lubricate Machine Lubricate all moving parts before operating the machine See Lubrication Points in the Service Lubrication section Check Mower Deck Level The mower deck is assembled and adjusted at the factory After machine is completely assembled check the mower front to rear and side to side deck level Check Safety System For a complete checkout procedure of the safety interlock system see Testing the Safety Interlock
9. IMPORTANT Avoid damage Contamination 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 1 Park machine safely See Parking Safely in the SAFETY section 2 Allow engine and hydraulic oil reservoir to cool 3 Clean area around reservoir filler cap and remove filler cap from reservoir 5 Turn hydraulic oil filter B counterclockwise to remove 6 Allow hydraulic oil to drain into drain pan with at least 3 8 L 1 0 gal capacity 7 Apply a film of clean oil on gasket of new filter 8 Install filter Turn filter clockwise until gasket makes contact with mounting surface Tighten 1 2 to 3 4 turn after gasket contact NOTE Reservoir capacity approximately 1 9 2 0 qt Total system capacity is approximately 3 5 3 75 qt 9 Fill oil reservoir with approximately 1 9 L 2 0 qt of oil 10 Install reservoir cap Service Transmission 26 SERVIGE TRANSMISSION CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation Connect 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
10. Neutral Creep Adjustment 1 Stop engine and lock the park brake 2 Move both motion control levers to neutral detent position standard levers or neutral lock position optional over the lap levers 3 Raise the rear wheels off the ground and securely support the rear of the machine NOTE When tilting the seat forward do not tilt the seat so far forward that it moves the motion control levers out of the neutral detent position 4 Tilt operator seat forward and support the seat frame 5 Loosen nut A and move the dampener B in adjusting slot backward or forward to stop machine creep machine creeps forward slide dampener to the rear of the adjusting slot Tighten nut f machine creeps backward slide dampener to the front of the adjusting slot Tighten nut 6 Check for creep and if the machine still creeps continue with the next step 7 Remove pin C and disconnect swivel D from each traction control rod E and rotate the swivel 8 Rotate swivel D to adjust To stop forward creep rotate each swivel D counterclockwise one rotation To stop rearward creep rotate each swivel D clockwise one rotation 9 Connect swivel to traction control rod 10 Repeat as needed to stop machine creep 11 Lower seat 12 Lower the rear of the machine to the ground 13 Check maximum speed drift Check Maximum Speed Drift 1 Check neutral creep and adjust as needed 2 Sit on the seat and
11. 3 Check clearance A from the top of the thrust arms B to the bottom of the thrust arm stop rod C The clearance should be 3 mm 1 8 in Adjust Thrust Arm to Stop Rod Clearance Transport Position 1 Park machine safely See Parking Safely in the SAFETY section 2 Loosen jam nut A NOTE If correct adjustment cannot be obtained by adjusting the lift handle connecting rod further movement can be gained by adjusting the chain U bolts Adjust all four chain U bolts equally All four chains should be tight Tighten the U bolt of the loose chain to correct 3 Adjust deck lift handle connecting rod B while viewing adjusting mechanism from rear of machine To lower deck turn nut C counterclockwise To raise deck turn nut C clockwise 4 Tighten jam nut A Adjusting Deck Lift Assist Spring Tension NOTE Deck lift assist spring tension is adjusted at the factory If the effort required to raise or lower the mower deck is not satisfactory an adjustment may be necessary Check Spring Tension 1 Park machine safely See Parking Safely in the SAFETY section 2 Raise the mower deck lift lever to the transport position ir n 3 Measure distance A between the washers B on each deck lift spring assembly The recommended factory setting is approximately 1 mm 1 32 in gap between the spring coils at the lowest HOC setting Adjust Assist Spring Tension NOTE Do not overt
12. carefully bend them outward Move them back to the neutral position Cnn and check for the recommended gap of 3 6 mm 1 8 1 4 in 5 Test park brake f positions of the control levers are unequal an adjustment is necessary Alignment Procedure Service Mower 1 Adjust position of motion control levers Removing and Installing Mower Deck Foot Plate A CAUTION Avoid injury Always operate the mower with the foot plate installed Operating with the foot plate removed can cause serious injury Service Mower 34 SERVICE MOWER Removing Foot Plate 1 Park machine safely See Parking Safely in the SAFETY section 3 Remove and retain hardware C securing foot plate A on both sides of machine 4 Remove foot plate Installing Foot Plate 1 Install foot plate A using hardware C saved earlier 2 Lower foot plate Removing and Installing Mower Deck Belt Shields CAUTION Avoid injury Help prevent serious personal injury Do not operate the mower without the belt shields installed Removing Belt Shields 1 Park machine safely See Parking Safely in the SAFETY section 2 Lower mower deck to the lowest cutting height position 3 Remove knob A 4 Remove belt shield B Installing Belt Shields 1 Install belt shield B 2 Install knob A Leveling Mower Deck 4h CAUTION Avoid injury Rotating blades are dangerous Before adjusting or servi
13. over the lap levers 2 Lock the park brake 3 Push PTO knob down to disengage 4 Turn key switch to the start position Result The engine must not crank Operating 14 OPERATING Testing Seat Switch Locking Park Brake Procedure 1 1 Sit on the operator seat with the motion control levers in the neutral A CAUTION Avoid injury If the engine should stop while detent position standard levers or neutral lock position optional over the operating on an incline the mower can free wheel If this lap levers should occur lock the park brake 2 Unlock the park brake Start the engine 3 Push PTO knob down to disengage unlock the park brake 4 Turn key switch to the start position resume operation 5 Raise slightly off the seat Result The engine must stop Procedure 2 1 Start engine 2 Lock the park brake 3 Pull PTO knob up to engage 4 Raise slightly off the seat Result The engine must stop Testing the Park Brake Raise and pull rearward park brake lever A to lock the park brake Unlocking Park Brake 1 Stop machine on 17 slope 30 grade Stop the engine and lock the park brake Result Park brake must hold the machine stationary Machine should move no more that 61 cm 24 in in one hour If machine moves more than that brakes need to be adjusted See Adjusting Park Brake in the Service Steering amp Brakes section Lower park brake lever A forward to unlo
14. CUTTER HOUSING 61 M10 X 1 5 X30 5 M10 X 438 HHSFN 5 8 11 X 2 25 5 8 61 HIGH LIFT GAGE LH 61 LH RH 1 4 X 1 M8 X 25 M8 1 4 X 1 3 8 X 2 1 4 13 32 X 13 16 X 065 3 8 X 3 1 2 3 8 X 5 clear m dari d PELIGRO FEF 14 2 13 150306 j lax las alejada fel bods ie price de care des WARE o geg A fra kis aj M Quer Et 61 CUTTING Deck 82 4 HOT SURFACE ee pur op ded AS LII gar A DANGER as EXPLOSIVE GATES CHEZ Canes OF Spark d cagse gtiery 2 PTES aad from batir Go not ase adjunt pos DANE ls salig cece light Gr awer delas eres Trek dea cp bindes avi harc rien or ADVERTENCIA Parc evitu ks ata la mi d ra maquina er rur a Trine wer EE Hatia uri GT se mieri se suhr una LI TL drcum on rit ess rre ay LABELS ETA de ale Leere rama del EE
15. machine Check Fluid Levels NOTE Refer to the Service sections of the operator s manual for information regarding check locations and proper fluid levels Check engine oil level Check hydraulic oil level Check Tire Pressure CAUTION Avoid injury Explosive separation of tire and rim parts is possible when they are serviced incorrectly Do not attempt to mount a tire without the proper equipment and experience to perform the job Do not inflate the tires above the recommended pressure Do not weld or heat a wheel and tire assembly Heat cause an increase in air pressure resulting in an explosion Welding can structurally weaken or deform the wheel 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 Add or remove air if necessary Install Motion Control Levers 1 Remove hardware from control arms Remove This Hardware NOTE The control lever mounting brackets have six holes The levers can be installed in the top four holes or for a lower lever position install the levers in the lower four holes 2 Raise the seat and prop it in the upright position NOTE It is easiest during installation if the bottom rear bolts are loosely installed first prior to installation of the front bolts 3 Align motion con
16. BAND RELAY SCREW LOGK NUT SWITCH HOUR METER BOLT LOCK NUT SWITCH SWITCH CLUTCH CLUTCH SCREW LOCK NUT FLANGE NUT DIODE DIODE WIRING HARNESS CLAMP BOLT LOCK NUT WIRING HARNESS BATTERY CABLE BATTERY CABLE BOLT LOCK NUT WET CHARGED BATTERY HOLDER HOOK BOLT LOCK NUT SEAT RELAY HARNESS RELAY SCREW Description 1 sch eck eck NM NM ND PO WH eck gt NM NN SH a sch py Remarks 20 AMP NEUTRAL IGNITION 21 X 37 X 3 KAWASAKI KAWASAKI CARBURETED KOHLER GROUND FUEL PUMP KOHLER M6 X 16 M6 BLADE ENGAGEMENT PARK BRAKE SEAT 1 HUB 1 125 HUB 1000V 3AMP 400V GAMP M8 X 20 M8 MAIN CHASSIS POSITIVE WITH BOOT NEGATIVE WITH BOOT M8 X 20 M8 M8 MAIN STARTER KAWASAKI ISO MINI 12 24 SELF DRILLING ELECTRICAL AND RELATED COMPONENTS 59 CONSOLE AND CONTROL ASSEMBLY MP35883 CONSOLE AND CONTROL ASSEMBLY 60 CONSOLE AND CONTROL ASSEMBLY Description GDA10083 19M7785 14M7396 D14133 N10217 GDU10046 GDU10045 19M7867 14M7396 GDA10097 GDA10098 M44508 M46676 GDU10253 AA34134 24M7388 03M7195 M85516 19H1936 GX10707 D14236 14H778 TCA13253 03M7184 M78480 GDA10081 GDA10080 D18093 03M7184 19H3693 TCU17400 D33002 24M7106 11M7082 TCA15322 GDA10136 J16931 D28255 D38146 14H1080 M63431 19M7867 E53830 CONSOLE SC
17. Close fuel shut off valve if your machine is equipped 9 Store the battery in a cool dry place where it will not freeze NOTE The stored battery should be recharged every 90 days 10 Charge the battery IMPORTANT Avoid damage Prolonged exposure to sunlight could damage the hood surface Store machine inside or use a cover if stored outside 11 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 if your battery is not maintenance free Charge battery if necessary 4 Install battery 5 On gas engines Check spark plug gap Install and tighten plugs to specified torque 6 Lubricate all grease points 7 Open fuel shut off valve if your machine is equipped 8 Run the engine 5 minutes without the mower or any attachments running to allow oil to be distributed throughout engine 9 Be sure all shields and guards or deflectors are in place Assembly Bag of Parts Qty Description 1 Key 1 Operator s Manual 1 PDR Check List Prepare for Assembly e Remove machine from the shipping crate e Remove box containing operator seat otorage 47 ASSEMBLY Cut plastic tie straps fastening the front wheels to the shipping crate Cut plastic tie straps holding the discharge chute up Cut plastic tie straps securing the motion control levers to the
18. LOCK NUT E53830 CLAMP M63277 LOCK NUT N10213 LOCK NUT D14235 BOLT GDU10028 STRAP 24H1776 WASHER INCLUDES M145626 7 925 MM 5 16 7 925 5 16 7 925 MM 5 16 7 925 MM X 63 5 MM 5 16 X 2 1 2 NNN EFE Q py sch 5 16 X 47 64 X 065 FUEL DELIVERY SYSTEM COMPONENTS 56 OVER THE LAP CONTROL ASSEMBLY MP35884 Qty Remarks TCU14989 TUBE M131171 GRIP GDU10047 STRAP 19M8320 SCREW 14M7518 FLANGE NUT 03M7195 BOLT M85516 LOGK NUT 13271 0010275 37 7059 SCREW M10 X 45 M10 M10 45 M10 1 2 3 4 5 6 7 8 9 0 OVER THE LAP CONTROL ASSEMBLY 57 ELECTRICAL AND RELATED COMPONENTS MAIN HARNESS 22 85 5 B PELA COR CIRCUIT 349 SWITCH COMA d gt MP35882 i T 5 X 40 ELECTRICAL AND RELATED COMPONENTS 58 ELECTRICAL AND RELATED COMPONENTS 57M7120 D18334 M110159 AM101561 TCU17401 24M7349 GDA10060 GDA10055 GDA10109 GDA10110 M78480 AM123716 21M7246 14M7397 AM118802 AM129887 D14304 D14305 D38001 D28055 GDA10017 GDA10122 D14288 M63431 H122207 AM101006 TCU17832 D38018 D28082 03M7184 14M7396 GDA10037 D28118 D28119 03M7184 14M7396 AM124356 GDU10204 D23047 14M7396 200302 102770 963101 FUSE SWITCH NUT SWITCH KEY WASHER WIRING LEAD WIRING HARNESS WIRING HARNESS WIRING LEAD TIE
19. System in the Operating section Initial Adjustments CAUTION Avoid injury Clear area of all bystanders before performing this service procedure 1 Check free wheel valves on both pump assemblies to make sure that the valves are closed Tighten valves to 108 163 Nem 80 120 Ib ft 2 Raise the rear of the machine until the drive wheels are off the ground Support the machine with jackstands CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine not run an engine in enclosed area without adequate ventilation Connect 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 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 6 Move PTO clutch switch to on position mower clutch should engage Run blades for several minutes 7 Move PTO clutch switch to off position and shut the engine off 8 Check all belts for proper tension 9 Start the engine and test drive the machine
20. TROUBLESHOOTING section of this manual Possible engine surging will occur at high throttle with transmission in N neutral and mower engagement lever disengaged This is a normal condition due to the emission control system After performing the checks in the troubleshooting section and your engine is still not performing correctly contact your authorized dealer Replacing Fuel Filter A CAUTION Avoid injury Fuel vapors are explosive and flammable Do not smoke while handling fuel Keep fuel away from flames or sparks Shut off engine before servicing Cool engine before servicing Work in a well ventilated area Clean up spilled fuel immediately 1 Park machine safely See Parking Safely in the SAFETY section 2 Allow engine to cool 3 Place drain pan under hoses to catch any fuel that may be left in hoses Picture Note Kawasaki engine shown 4 Locate fuel hose A coming from fuel tank disconnect it from the inlet side of fuel filter and drain gasoline into properly marked container 5 Remove fuel filter from fuel hose C going to engine Discard filter IMPORTANT Avoid damage When installing new fuel filter the filter arrow must be pointing in the direction of fuel flow Make sure clamps are installed properly 6 Connect new fuel filter to hoses Make sure fuel filter is installed with arrow pointing in direction of fuel flow Service Engine 25 SERVIGE TRAN
21. clear the exhaust fumes out 11 Start engine 12 Move throttle lever to 3 4 throttle position 13 Unlock the park brake CAUTION Avoid injury Help prevent serious bodily injury Remain alert to other people and the surroundings when operating the machine 14 Run engine in full forward position for several minutes and then cycle motion control levers forward and rearward several times Check for leaks around filter 15 Stop engine Check oil level Add oil as necessary Cleaning Hydraulic Pump Cooling Fins CAUTION Avoid injury Compressed air can cause debris to fly a long distance Clear work area of bystanders Wear eye protection when using compressed air for cleaning purposes Reduce compressed air pressure to 210 kPa 30 psi IMPORTANT Avoid damage To ensure proper cooling keep the cooling fins clean at all times Operating the machine with obstructed cooling fins could cause damage due to overheating 1 Park machine safely See Parking Safely in the SAFETY section 2 Clean hydraulic oil cooler fins A on each hydraulic pump with a rag brush or compressed air Removing and Installing Traction Drive Belt 1 Park machine safely See Parking Safely in the SAFETY section 2 Remove mower deck drive belt CAUTION Avoid injury Fingers and hands can be pinched or crushed Keeps hands clear of sheave and belt pinch points when servicing belt Picture Note Drive belt routing a
22. for drying 3 Smooth out surface using an automotive polishing compound Do not use power buffer 4 Apply wax to surface Troubleshooting Using Troubleshooting Chart If you are experiencing a problem that is not listed in this chart see your authorized dealer for service When you have checked all the possible causes listed and you are still experiencing the problem see your authorized dealer Troubleshooting 44 Engine Will Not Start or Is Hard to Start Engine Will Not Slow Idle Engine Runs Rough or Stalls Engine Knocks Engine Overheats TROUBLESHOOTING Engine Lacks Power Motion control levers not in the neutral detent or neutral lock position Park brake lever unlocked Key switch not in proper position PTO engaged Loose or corroded starter cable connections Engine Uses Too Much Oil Stale or improper fuel fuel level Plugged fuel filter Plugged air intake filter Spark plug wire is loose or discontte od Engine Backfires Through Muffler Spark plug not gapped correctly Blown 20 amp fuse main power circuit Carbureted Engines Only Blown High Fuel Consumption fusible link charging circuit Electrical problem dead battery Choke adjusted incorrectly See your Great Dane servicing dealer Bent or kinked throttle cable Bent governor control Incorrect governor idle control Electrical System Carburetion problems See your Great Dane servicing dealer Plugged fuel f
23. or death Operation on all slopes requires extra caution f you feel uneasy on a hillside do not mow it Mow across slopes not up and down Watch for holes ruts bumps rocks or other hidden objects Uneven terrain could overturn the machine Tall grass can hide obstacles Choose a low ground speed so you will not have to stop or shift while on a slope Do not mow or operate machine on wet grass Tires may lose traction Tires may lose traction on slopes even though the brakes are functioning properly Avoid starting stopping or turning on a slope If the tires lose traction disengage the blades and proceed slowly straight down the slope Keep all movement on slopes slow and gradual Do not make sudden changes in speed or direction which could cause the machine to roll over Use extra care while operating machine with grasscatchers or other attachments they can affect stability of the machine Do not use on steep slopes Do not mow near drop offs ditches embankments or bodies of water The machine could suddenly roll over if a wheel goes over the edge or the edge caves in Follow the manufacturer s recommendations for wheel weights or counterweights for added stability when operating on slopes or using front or rear mounted attachments Remove weights when not required Drive machine very slowly and avoid quick stops when attachment is removed e Transport machine with decks lowered to improve
24. 10260 GDU10262 GDU10267 GDU10268 GDU10269 M17554 M127610 M131739 M131748 M137637 TCU51051 TCU14840 TCU14862 TCU13514 TCU13515 TCU20576 TCU14885 TCU15908 TCU151051 TCU20575 TCU15907 LABELS PartNo Description A HR Lh A eck eck sch sch gt sch sch odo NOTES LABELS 83 HYDRO OIL SPECS THROTTLE CONSOLE NO STEP CHARIOT BRUTUS PUPPY PAW GREAT DANE BLACK GREAT DANE WHITE MOTION CONTROL OTL KIT MOTION CONTROL CONSOLE BELT PATH 48 52 61 DECK WARNING HOT SURFACES IGNITION DANGER BLADE CONTACT DANGER THROWN OBJECTS DISCHARGE DANGER ROTATING BLADES GENERAL CAUTION PARK BRAKE DIRECTION ROPS WARNING ENGLISH ROPS WARNING SPANISH ROPS CERTIFICATION SPANISH DANGER EXPLOSIVE GASES POISON CUT HEIGHT DANGER ROTATING BELTS ROPS CERTIFICTATION WARNING SLOPE LABELS 84
25. 149 M10 X 40 57 64 X 1 3 8 X 0 048 48 AND 52 CUTTING DECK MP35894 48 AND 52 CUTTING DECK 78 Ref 1590 Ol N GDA10104 GDA10088 D18209 D18084 D13024 D13055 200041 19M7786 E63526 D18055 967347 14H1083 GDU10230 GDU10231 TCU14540 GDU10119 TCU16092 TCU16093 TCU18744 GDU10251 GDU10249 GDU10252 GDU10250 M119352 GDA10084 GDA10085 D18076 JD 7844 19H2380 D24008 TCA13292 03M7185 14M7396 GDA10103 03H1729 H122207 15346 018032 03H1658 24H1305 K40003 03H1836 AM127235 M132768 H141123 03H2040 D13005 D23058 D28025 D14010 N10215 TCA14548 GDU10180 03H1838 D28050 GDU10181 D24040 E62934 48 AND 52 CUTTING DECK Description MOWER DECK MOWER DECK PULLEY PULLEY SPAGER NUT SPINDLE BOLT Nut SPAGER BOLT NUT BLADE BLADE BUSHING STRAP V BELT V BELT WHEEL COVER COVER COVER COVER KNOB ARM ARM BUSHING LUBRICATION FITTING SCREW LOCK NUT PIN FASTENER BOLT LOCK NUT PIVOT BOLT FLANGE NUT ARM PULLEY BOLT WASHER LOCK NUT BOLT CHUTE TORSION SPRING PUSH NUT BOLT HOOK BOLT HOOK BOLT SPRING LOCK NUT LOCK NUT PULLEY SPAGER BOLT IDLER SPAGER BOLT FLANGE NUT d ck d A sch sch sch sch ech J sch ck sch N WWW 48 AND 52 CUTTING 79 Remarks 48 52 CUTTER HOUSING 48 CUTTER HOUSING 52 M10 X 1 5 X30 HHF
26. 8 14 7166 19M7897 200318 GDA10017 D18056 D14208 19H2531 TCA16240 D18145 D18379 M76926 M78480 M136651 GD10128 H137328 03M7184 D22236 12M7065 14M7273 200316 03M7017 14M7518 LOGK NUT SCREW PULLEY CLUTCH SPACER LOCK WASHER CAP SCREW DRAIN VALVE SHAFT KEY CLAMP TUBE TIE BAND GASKET MUFFLER LOCK NUT BOLT ANGLE LOCK WASHER NUT BRACKET BOLT FLANGE NUT MN po gt NNa NN HAH HAH dk do kh M8 M8 X 35 ENGINE TO PUMP MAG STOP ELECTRIC 7 16 X 3 25 HP 25 HP M8 X 20 M8 M8 M10 X 25 M10 ENGINE AND RELATED COMPONENTS KAWASAKI 53 ENGINE AND RELATED COMPONENTS KOHLER 27 HP MP35878 A ENGINE AND RELATED COMPONENTS KOHLER 27 HP 54 ENGINE AND RELATED COMPONENTS KOHLER 27 HP ay 14M7396 LOGK NUT M8 19M8317 SCREW M8 40 200311 PULLEY ENGINE TO PUMP GDA10122 CLUTCH MAG STOP ELECTRIC GDU10312 SPAGER D14208 LOGK WASHER D24022 BOLT 15389 HOSE OIL DRAIN D18145 SHAFT KEY 230687 FITTING PLUG M78480 TIE BAND M132446 GASKET D28121 MUFFLER 12M7065 LOGK WASHER M8 14M7273 NUT M8 200316 M8 03M7017 BOLT M10 X 25 14M7518 FLANGE NUT M10 NN NOTES ENGINE AND RELATED COMPONENTS KOHLER 27 HP 55 FUEL DELIVERY SYSTEM COMPONENTS MP35879 Description Oy Bes 0 181251 FILLER CAP M88753 HOSE R56101 CLIP GDA10012 FUEL TANK D18144 BUSHING GDU10026 FUEL PICKUP M63277
27. Be sure you have read the machine operator manual and are completely familiar with the operation of the machine before performing these safety system checks Use the following checkout procedures to check for normal operation of machine If there is a malfunction during one of these procedures do not operate machine See your authorized dealer for service Perform these tests in a clear open area Keep bystanders away Testing PTO Switch 1 Sit on the operator seat with the motion control levers in the neutral detent position standard levers or neutral lock position optional over the lap levers 2 Lock the park brake 3 Pull PTO knob up to engage 4 Turn key switch to the start position Result The engine must not crank Testing Park Brake Switch 1 Sit on the operator seat with the motion control levers in the neutral detent position standard levers or neutral lock position optional over the lap levers 2 Push PTO knob down to disengage 3 Unlock the park brake 4 Turn key switch to the start position Result The engine must not crank Testing Neutral Start Switch NOTE Repeat this test three times with the motion control levers in the following positions e Right side motion control lever inward Left side motion control lever inward Both motion control levers inward 1 Move motion control lever s out of the neutral detent position standard levers or neutral lock position optional
28. CS M10 X 438 HHSFN 5 8 11 X 2 25 5 8 48 HIGH LIFT 52 HIGH LIFT ENGINE TO BLADES 48 ENGINE TO BLADES 52 GAGE LH 48 LH 52 RH 48 RH 52 LH RH 1 4 X 1 M8 X 25 M8 1 4 X 1 3 8 X 2 1 4 13 32 X 13 16 X 065 3 8 X 3 1 2 3 8 X 5 61 CUTTING DECK MP2352R09A 61 CUTTING Deck 80 Ref CO CO O1 B GDA10077 D18211 D13024 D13055 200041 19M7786 E63526 D18055 967347 14H1083 GDU10232 TCU14540 GDU10119 E62934 TCU18744 D24040 GDU10187 M119352 GDA10084 GDA10085 D18076 JD7844 19H2380 D24008 TCA13292 03M7185 14M7396 GDA10103 03H1729 H122207 TCA15346 D18032 03H1658 24H1305 K40003 03H1836 AM127488 M132768 H141123 03H2040 D23058 D28025 D14010 N10215 TCA14548 GDU10180 03H1838 D28050 GDU10181 61 CUTTING DECK MOWER DECK PULLEY SPACER NUT SPINDLE BOLT NUT SPACER BOLT NUT BLADE BUSHING STRAP FLANGE NUT WHEEL BOLT COVER KNOB ARM ARM BUSHING LUBRICATION FITTING SCREW LOCK NUT PIN FASTENER BOLT LOCK NUT PIVOT BOLT FLANGE NUT ARM PULLEY BOLT WASHER LOCK NUT BOLT CHUTE TORSION SPRING PUSH NUT BOLT HOOK BOLT SPRING LOCK NUT LOCK NUT PULLEY SPACER BOLT IDLER SPACER 61 CUTTING Deck 81 CO CO CO lt CO sch o sch sch sch S sch ld sch IAD NO NP A N P P sch Remarks 61
29. ORT BOLT LOCK NUT PUMP PUMP BOLT PULLEY SHAFT KEY ARM ARM PLATE CAP SCREW SPRING PIN V BELT SET SCREW MOTOR CAP SCREW LOCK NUT NUT KEY HYDRAULIC RESERVOIR DIPSTICK OIL FILTER BRACKET SCREW BRAKE SHOE BRAKE DRUM WASHER FAN SHIELD DECK STOP BUSHING CAP SCREW WHIZ LOCKNUT TRACTION DRIVE AND BRAKES 65 O10 CO sch P sch sch PND sch 393 SH ech ech ASH a sch BQ NN 00 Description Remarks M10 30 M10 3 8 X 2 13 32 13 16 X 065 M10 X 40 M10 M10 PARKING BRAKE 5 12 Includes LH BRAKE 5 16 X 3 4 11 32 X 11 16 X 065 M8 X 50 12 700 MM 23 9 5 12 M12 X 35 M12 RH HYDROSTATIC LH HYDROSTATIC M10 X 30 RH PUMP LH PUMP 1 4 X 1 1 4 5 X 30 MM 5 16 X 7 8 1 2 X 2 1 2 PATCH LOCK M10 X 25 5 16 X 47 64 X 065 1 2 13 X 2 00 1 2 13 HYDRAULIC SCHEMATIC mmm em em om Oen em em em Control Input Shaft B Pump Block C Charge Pump D Charge System Check Valve E Right Hydraulic Pump Manual Bypass Free Wheel Valve G Right Wheel Motor MP35887 Hydraulic Schematic 66 Cooling Orifice Charge Relief Valve J Left Wheel Motor K Left Hy
30. REW LOCK NUT CAP SCREW LOCK NUT BRACKET BRACKET SCREW LOCK NUT PIVOT PIVOT BUSHING THRUST WASHER ARM BALL BEARING WASHER BOLT LOCK NUT CAP SCREW EXTENSION SPRING SCREW NUT PIVOT BOLT TIE BAND CONTROL LEVER CONTROL LEVER GRIP BOLT SCREW ROD SWIVEL WASHER COTTER PIN GAS OPERATED CYLINDER BRACKET PIN ACCELERATOR CABLE NUT LOCK NUT SCREW CLAMP NOTES CONSOLE AND CONTROL ASSEMBLY 61 Qty O 1 1 4 4 2 2 6 2 2 2 2 2 4 1 2 1 1 1 2 8 2 2 2 8 2 2 1 4 1 1 1 2 2 2 Remarks M10 X 25 M8 RH SEAT PLATE LH SEAT PLATE M8 X 25 M8 LH CONTROL 10 X 16 X 1 MM M10 X 45 3 8 X 3 4 190 M8 X 20 LH M8 X 20 3 8 X 1 1 4 CONTROL ADJUSTER 10 X 18 X 2 500 MM 2 500 X 25 MM HYDROSTATIC DRIVE SYSTEM COMPONENTS MP35885 Hydrostatic drive system Components 62 BE HYDROSTATIC DRIVE SYSTEM COMPONENTS D18379 D14197 M86863 D28026 GDA10089 D24026 MT2119 200313 200312 D19000 GDA10022 TCA15373 D18207 GDA10137 GDA10100 AZ45116 M78480 FITTING BULK HOSE BULK HOSE BULK HOSE BULK HOSE BULK HOSE BULK HOSE CLAMP FITTING TEE FITTING HOSE HYDRAULIC HOSE FITTING NUT PUMP PUMP SEAL KIT DIPSTICK HYDRAULIG RESERVOIR KEY OIL FILTER WHEEL MOTOR GASKET KIT TIE BAND P A pA Ref No PartNo Description Qty Re
31. Rear 1 Lower mower deck to the 76 mm 3 in cutting height position 2 Position right mower blade discharge side in the straight forward front to rear position 3 Measure from right front blade tip to the ground 4 Turn blade 180 and measure from right rear blade tip to the ground The height of the rear blade tip should be 3 6 mm 1 8 1 4 in higher than the front blade tip 5 If the front to rear level is not within specifications an adjustment is necessary Adjusting Level Front to Rear NOTE Adjust side to side mower level before adjusting front to rear level 1 Loosen jam nut D on deck lift assist rod 2 While positioned in front of the machine adjust mower level Turn hex nut E counterclockwise to lower front of mower deck e Turn hex nut E clockwise to raise front of mower deck 3 Tighten jam nuts 4 Check front to rear mower level Service Mower 36 SERVICE MOWER Checking and Adjusting Cutting Height CAUTION Avoid injury Rotating blades are dangerous Before adjusting or servicing mower Remove ignition key or disconnect battery negative cable to prevent engine from starting accidently Always wear gloves when handling mower blades or working near blades Checking Thrust Arm to Stop Rod Clearance Transport Position 1 Park machine safely See Parking Safely in the SAFETY section 2 Set mower deck to transport fully raised position
32. Replace worn and damaged blades and bolts in sets to preserve balance Keep safety labels visible when installing accessories and attachments Do not wear radio or music headphones Safe service and operation require your full attention When machine is left unattended stored or parked lower the mower deck unless a positive mechanical lock is used Using a Spark Arrestor The engine in this machine is not equipped with a spark arrestor muffler It is a violation of California Public Resource Code Section 4442 to use or operate this engine on or near any forest covered brush covered or grass covered land unless the exhaust system is equipped with a spark arrestor meeting any applicable local or state laws Other states or federal areas may have similar laws A spark arrestor for your machine may be available from your authorized dealer An installed spark arrestor must be maintained in good working order by the operator Checking Mowing Area Clear mowing area of objects that might be thrown Keep people and pets out of mowing area Low hanging branches and similar obstacles can injure the operator or interfere with mowing operation Before mowing identify potential obstacles such as low hanging branches and trim or remove those obstacles Study mowing area Set up a safe mowing pattern Do where traction or stability is doubtful Test drive area with mower lowered but not running Slow down
33. SMISSION Service Transmission Hydraulic Oil Use only 5W 50 or 15W 50 all synthetic oil Checking Hydraulic Oil Level IMPORTANT Avoid damage Check oil level in reservoir tank when oil is cold Do not overfill oil reservoir tank Oil will expand during operation and could overflow 1 Park machine safely See Parking Safely in the SAFETY section IMPORTANT Avoid damage Dirt and debris in oil may cause damage to the transaxle Clean area around opening before removing dipstick 2 Unscrew and remove hydraulic reservoir cap dipstick A from hydraulic oil reservoir 3 Wipe dipstick with a clean cloth 4 Install dipstick and allow the cap to rest on the end of the tube Do not tighten the cap 5 Remove dipstick and check oil level Oil level should be at top mark on dipstick 6 If necessary add oil through oil reservoir filler neck 7 Install cap on filler neck Changing Hydraulic Oil and Filter 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
34. a safe lifting device Support with jack stands and or wooden blocks 4 Check mower blades Mower blades should be sharp and free of any damage Inspect blades sharpen balance or replace as necessary Replacing Mower Blades Keep original bevel A when grinding Blade should have 0 40 mm 1 64 in cutting edge B or less Balance blades before installing Balancing Blades A CAUTION Avoid injury Mower blades are sharp Always wear gloves when handling mower blades or working near blades 1 Clean blade 1 Use two long handled 15 16 in wrenches to loosen nut A 2 Remove nut A blade bolt B three 1 4 in washers C and blade D 3 Install replacement blade Blade wing must face toward top of mower deck IMPORTANT Avoid damage When installing the blade Make sure the blade is properly seated on the spindle Make sure the concave side of the large washer faces towards the blade Install blade bolt B blade D three 1 4 in washers and nut A Tighten blade nut to 81 Nem 60 Ib ft 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 Lower machine 4 Grind bevel of heavy end Do not change blade bevel 5 Adjust mower deck to a desirable cutting height Replacing Mower Spindle Bearings Sharpening Blades 1 Park machine safely See Parking Safely in the SAFETY secti
35. aintain 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 To avoid personal injury or property damage use extreme care in handling fuel Fuel is extremely flammable and fuel vapors are explosive Extinguish all cigarettes cigars pipes and other sources of ignition Use only an approved fuel container 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 oafety 9 OPERATING Never remove the fuel tank cap or add fuel with the engine running Handling Waste Product and Chemicals Allow engine to cool before refueling Never add fuel to or drain fuel from the machine indoors Move machine outdoors and provide adequate ventilation Clean up spilled fuel immediately If fuel is spilled on clothing change clothing immediately If fuel is spilled near machine do not attempt to s
36. al injury Stop on level ground lower implements disengage drives engage parking brake and shut off engine before leaving the operator s position for any reason including emptying the grasscatchers or unclogging the chute e Stop equipment and inspect blades after striking objects or if an abnormal vibration occurs Make necessary repairs before resuming operations Keep hands and feet away from the cutting units Look behind and down before backing up to be sure of a clear path Never carry passengers and keep pets and bystanders away Slow down and use caution when making turns and crossing roads and sidewalks Stop blades if not mowing Watch for traffic when operating near or crossing roadways Safety 5 SAFETY Be aware of the mower discharge direction and do not point it at anyone Do not operate the machine while under the influence of alcohol or drugs Use care when loading or unloading the machine into or off of a trailer or truck Use care when approaching blind corners shrubs trees or other objects that may obscure vision 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 Before using always visually inspect to see that the blades blade bolts and the mower assembly are not worn and damaged
37. ank at the end of each day s operation to keep Removing and Installing Rear Drive Wheels condensation out of the fuel tank Removing Use a non metallic funnel with a plastic mesh strainer when filling the fuel tank or container 1 Park machine safely See Parking Safely in the SAFETY section Fill fuel tank at the end of each day s operation to prevent condensation and freezing during cold weather 1 Park machine safely See Parking Safely in the SAFETY section Service Miscellaneous 43 TROUBLESHOOTING 2 Slightly loosen five wheel nuts A CAUTION Avoid injury The machine can fall or slip from an unsafe lifting device or supports Use a safe lifting device rated for the load to be lifted Lower machine onto jack stands or other stable supports and block wheels before servicing IMPORTANT Avoid damage Place jack stands under frame not under transmission or engine when raising or supporting machine 3 Lift machine with a safe lifting device 4 Remove wheel nuts 5 Remove wheel and tire assembly Installing Rear Drive Wheels Tightening Hardware 1 Install new wheel and tire assembly 2 Install and tighten wheel nuts in numbered sequence shown for safe wheel installation Tighten alternately until recommended torque value is reached e Tighten nuts to 100 75 Ib ft 3 Lower machine Cleaning and Repairing Plastic Surfaces Your authorized dealer has the professio
38. c roads Use safety lights and devices Slow moving machines when driven on public roads are hard to see especially at night 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 Checking Wheel Hardware A serious accident could occur causing serious injury if wheel hardware is not tight Check wheel hardware 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 Wear Appropriate Clothing Always wear safety goggles or safety glasses with side shields and a hard hat when operating the machine Wear close fitting clothing and safety equipment appropriate for the job While mowing always wear substantial footwear and long trousers Do not operate the equipment when barefoot or wearing open sandals Wear a suitable protective device such as earplugs Loud noise can cause impairment or loss of hearing Maintenance and Storage Never operate machine in a closed area where dangerous carbon monoxide fumes can collect Disengage drives lower implement lock parking brake stop engine and remove key or disconnect spark plug for gas engines Wait for all movement to stop before adjusting cleaning or repairing Clean grass and debris from cutting units drives mufflers and engi
39. cing mower Remove ignition key or disconnect battery negative cable to prevent engine from starting accidently Always wear gloves when handling mower blades or working near blades NOTE Mower deck anti scalp wheels should not contact the ground 1 Park machine safely See Parking Safely in the SAFETY section 2 Inflate tires to the correct pressure 3 Raise the mower deck lift lever to transport position 4 mower blades for Blade sharpness Blade damage Bent blades Checking Level Side to Side NOTE Mower deck anti scalp wheels should not contact the ground 1 Lower deck to the 76 mm in cutting height position NOTE Position the left mower blade in the sideways left to right position Use a short ruler or a leveling gauge to check the mower blade level 2 Measure from outside blade tip to the ground Service Mower 35 SERVICE MOWER Picture Note Discharge chute raised for photo clarity 3 Position right mower blade A discharge side in the side to side position 4 Measure from outside blade tip to the ground The difference between both measurements should be no greater than 3 mm 1 8 in 5 1 side to side level is not within specifications an adjustment is necessary Adjusting Level Side to Side 1 Adjust four chain U bolts two on each side of deck until deck is within 3 mm 1 8 in of level from side to side Checking Level Front to
40. ck the park brake Using the Park Brake 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 Operating 15 OPERATING Using the Key Switch NOTE Machine will only start if the following conditions exist e Park brake is locked is disengaged e Motion control levers are in the neutral detent position standard levers or neutral lock position optional over the lap levers To turn ignition off turn key to the STOP position A To turn ignition on turn key to the run position To start engine turn key to the start position Once engine begins to run release key back to the run position Using the PTO Engage PTO 1 Move throttle lever A to the 1 2 to 3 4 throttle position 2 Pull PTO knob B up to engage mower deck 3 Move throttle lever A forward to the fast detent position C for mowing Disengage PTO Push PTO knob down Using the Throttle Lever Push throttle lever A all the way forward to the full throttle detent position B when mowing Move throttle lever A to the 1 2 throttle position C when starting and warming the engine Pull throttle lever A rearward to the slow position D to idle engine Do not run engine at slow idle any longer than necessary Using the Hourmeter NOTE The mac
41. correctly without draining Do attempt to mount a tire without the proper equipment and experience to perform the job Filling Fuel Tank Do not inflate the tires above the recommended pressure 4h CAUTION Avoid injury Fuel vapors are explosive and flammable Do not weld or heat a wheel and tire assembly Heat can cause an increase in air pressure resulting in an explosion Welding can structurally weaken or deform Shut engine off before filling fuel tank the wheel Do not smoke while handling fuel 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 fuel away from flames or sparks Fill fuel tank outdoors or in well ventilated area Clean up spilled fuel immediately 1 Park machine safely See Parking Safely in the SAFETY section Use clean approved non metal container to prevent 2 Check tires for damage EES 3 Check tire pressure with an accurate gauge Use clean approved plastic funnel without screen or filter to prevent static electric discharge PRE NE ooo IMPORTANT Avoid damage Dirt and water fuel can cause engine damage Front 13 x 5 0 6 110 138 kPa 16 20 psi Rear Chariot 23 x 9 5 12 69 97 kPa 10 14 psi Clean dirt and debris from the fuel tank opening Use clean fresh stabilized fuel Fill the fuel t
42. d nuts tighten as needed Remove battery Clean battery and holder Replace spark plugs Service Intervals 21 SERVICE LUBRICATION Service Lubrication Grease IMPORTANT Avoid damage The recommended grease is effective within an average air temperature range of 29 to 135 degrees C 20 to 275 degrees F If operating outside that temperature range contact your servicing dealer for a special use grease Use a general all purpose grease with an NLGI grade No 2 rating Wet or high speed conditions may require use of a special use grease Contact your Servicing dealer for information Spray Lubricant Use a general purpose petroleum based spray lubricant Lubrication Points A CAUTION Avoid injury Rotating parts can catch fingers loose clothing or long hair Wait for engine and all moving parts to stop before leaving operator s station to adjust or service machine 1 Park machine safely See Parking Safely in the SAFETY section 4 Grease mower deck thrust arms D located at the rear of the mower deck 2 Grease caster wheel spindle bearings B 5 Apply grease to three spindle bearings Service Lubrication 22 SERVICE ENGINE 9 Lubricate hydraulic pump control arms N 10 Lubricate control lever pivot shaft O 11 Lubricate seat platform hinges P 12 Lubricate throttle control cable Q 13 Lubricate choke control cable R Service Engine Engine Warranty Maintena
43. draulic Pump L Oil Filter M Hydraulic Reservoir MP35880 192068 181749 181461 181074 24H1887 TCU17356 200324 135139 K40003 03M7184 E83830 14M7396 M63277 14M7518 GDA10136 19M7786 181572 960703 960079 964025 Seat Components 67 SEAT COMPONENTS Description SUSPENSION SEAT KIT ARM REST SEAT SWITCH WASHER PAD SEAT PLATE YELLOW BOLT LOCK NUT BOLT CLAMP LOCK NUT LOCK NUT FLANGE NUT SCREW SEAT BELT FLAT WASHER BOLT LOCK NUT Serie NDA AA A HS HS S SEAT ADJUSTER SINGLE SUSPENSION W HDWR 11 32 X 1 X 0 134 CUT TO LENGTH 1 2 X 1 06 X 3 8 16 M8 X 20 M8 M10 M10 X 30 RETRACTABLE MALE FEM FRAME ASSEMBLY MP35888 8 200338 14M7396 E53830 GDU10222 03M7199 H137329 03M7197 JD 7844 200329 135139 964022 GDU10165 GDU10164 03M7017 03M7085 14M7518 19M7865 TCU20372 TCU20695 GDU10285 GDU10184 GDU10170 191257 FRAME ASSEMBLY FRAME LOCK NUT CLAMP PLATE BOLT LOGK NUT BOLT LUBRIGATION FITTING PLATFORM LOGK NUT LOGK NUT FENDER FENDER BOLT BOLT FLANGE NUT SCREW BUMPER BUMPER PLATE BRACKET BRACKET TRACTION TAPE NOTES FRAME ASSEMBLY 69 A 14 00 Parto Description Remaks _ M12 X 35 M12 X 25 LH RH M10 X 25 M10 X 30 M10 M8 X 16 KOHLER ENGINE KAWASAKI ENGINE
44. e Parking Safely in the SAFETY section 2 Move the mower deck lift lever A to the transport position D 3 Position the HOC adjustment pin C in the proper hole for the desired height of cut 4 Pull back and hold the mower deck lift lever A and release the transport position lock lever B 5 Allow the mower deck lift lever A to rest against the HOC adjustment pin C Adjusting Mower Deck Anti Scalp Wheels 1 Park machine safely See Parking Safely in the SAFETY section A CAUTION Avoid injury Fingers and loose clothing can get caught in rotating parts Do not operate machine without all mower deck belt shields installed NOTE The flattest cut can be achieved by having all anti scalp wheels adjusted off the ground Check anti scalp wheel adjustments each time the mower deck cutting height is changed It is recommended that all anti scalp wheels be kept off the ground to minimize scuffing 2 Inflate tires to correct pressure 3 Adjust mower deck to desired cutting height Operating 13 OPERATING NOTE The rear anti scalp wheels are located under the rear of the mower deck 4 Adjust anti scalp wheel A to one of two positions B e Remove screw nut and washer Adjust wheel up or down so it is approximately 6 13 mm 1 4 1 2 in above mowing surface 5 Install wheel with attaching hardware 6 Adjust all wheels to same height Testing Safety Systems A CAUTION Avoid injur
45. e park brake 4 Remove key 5 Fasten machine to trailer with heavy duty straps chains or cables Both front and rear straps must be directed down and outward from machine Mowing Tips Mow grass with throttle lever in the full fast position Cut grass when it is dry Keep mower deck and discharge chute clean Mow with sharp blades Properly level mower deck for a smooth cut Mow grass high and often Use a travel speed that fits the conditions Operating 20 SERVICE INTERVALS Mow tall or wet grass twice Cut grass at half desired height then cut at desired height Travel slow when mowing tall thick or wet grass Avoid damaging grass by slipping or skidding machine drive wheels Practice smooth control lever movements When performing sharp turns do not allow inside machine drive wheel to stop and twist on grass Mowing Travel Speeds Use slow travel speed for Trimming Working in close quarters Mowing tall grass Use faster travel speeds for Normal mowing on level ground Dismounting to Inspect Mower A CAUTION Avoid injury Help prevent serious injury Keep hands and feet away from blades and the discharge opening Do not step on either side of the mower deck when mounting and dismounting the machine Mount and dismount the machine using the front foot plate 1 Park machine on a hard level surface 2 Push PTO knob down to disengage mower 3 Move moti
46. ed when making turns Blades are bent or worn Sharpen or replace blades Change mowing pattern Check tire pressure STORAGE Storage Storing Safety CAUTION Avoid injury Fuel vapors are explosive and flammable Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Run the engine only long enough to move the machine to or from storage not store vehicle with fuel in the tank inside building where fumes may reach an open flame or spark 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 Remove grass and debris from machine 4 Clean under the deck and remove grass and debris from inside chute and bagger 5 Wash the machine and apply wax to metal and plastic surfaces 6 Run machine for five minutes to dry belts and pulleys 7 Apply light coat of engine oil to pivot and wear points to prevent rust 8 Lubricate grease points and check tire pressure 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 safel
47. ence tue LE 1 21 m 47 5 in Overall eee ES eds 1 09 m 42 75 in Overall Length with Kawasaki Engines 1 92 m 75 5 in Overall Length with Kohler Engines 1 97 77 75 Overall Width with 48 in Deck 1 50 m 59 in Overall Width with 52 in Deck 1 63 m 64 in Overall Width with 61 in Deck 1 86 m 73 375 in 48 Inch Mower Deck Mower Mulch Bag or Side Discharge CUMING Sr eee 3 Blade Bolt Torque 81 Nem 60 Ib ft VICI errar 1 22 m 48 in Cutting Height approximate 25 to 127 mm 1 to 5 in Height Adjustment 5 13 mm 1 2 in 52 Inch Mower Deck Mower Mulch Bag or Side Discharge Blades o p e E Need 3 Blade Bolt Torque 81 60 Ib ft CUNN WIG rr E 1 32 m 52 in Cutting Height approximate 25 to 127 mm 1 to 5 in Height Adjustment Increments 13 mm 1 2 in 61 Inch Mower Deck Mower Mulch Bag or Side Discharge Cutting Blade St dE EE 3 Blade Torque 24 ie bode ane EE 81 Nem 60 lb ft Wah ds dada eos AS 1 55 m 61 in Cutting Heigh
48. ent required only if the front caster wheel shimmies during travel 1 Park machine safely See Parking Safely in the SAFETY section 3 Remove hex nut A and wheel bolt B 4 Remove wheel C from assembly yoke Installing 1 Install replacement wheel 2 Install wheel bolt and hex nut 3 Tighten nut 4 Lower machine Servicing Front Caster Wheel Roller Bearings Chariot 1 Park machine safely See Parking Safely in the SAFETY section A CAUTION Avoid injury The machine may fall or slip from an unsafe lifting device or supports injuring anyone beneath it Remove key before raising machine Use safe lifting device rated for the load to be lifted 2 REMOVE dust cover 4 rem top Lower machine onto stable supports or jack stands and block wheels before servicing 2 Raise and securely support the front of the mower deck Service Steering amp Brakes 32 SERVIGE STEERING amp BRAKES 3 Remove cotter pin B 4 Turn castle nut C 1 4 turn clockwise 5 Install a new cotter pin Do not loosen the castle nut to align cotter pin hole tighten to align 6 Replace dust cover 7 Test machine to determine if shimmy is still present Repeat adjustment as necessary Servicing Caster Spindle Bearings 1 Park machine safely See Parking Safely in the SAFETY section A CAUTION Avoid injury The machine may fall or slip from an unsafe lifting device or supports injur
49. enter Steer Levers NOTE When the control levers are in the neutral detent position the control lever rollers A located on each side of the control console will be seated in the notches in the console Motion control levers must be in the neutral detent position the PTO switch disengaged and the park brake locked to start the engine Neutral Lock Position Optional Over the Lap Levers Picture Note Motion control levers A shown in the neutral lock position Motion control levers must be in the neutral lock position the PTO switch disengaged and the park brake locked to start the engine Forward and reverse movement of the motion control levers is prevented when levers are moved to the neutral lock position Operator can exit mower with the engine running when the PTO switch is disengaged the motion control levers are in the neutral lock position and the park brake is locked Motion control levers must be in the neutral lock position to safely enter and exit the operator seat Neutral Position Optional Over the Lap Levers Picture Note Motion control levers A shown in the neutral position Machine speed motion and direction can be controlled when the engine is running operator is on the seat and the park brake is unlocked Operating 17 OPERATING Forward and Reverse Motion Reverse CAUTION Avoid injury Children or bystanders can be injured or killed by moving machine and
50. essurized air to clean element Replace element only if it is very dirty damaged or the seal is cracked NOTE It may be necessary to check the air filter more frequently if operating machine in dusty conditions 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 Cleaning Engine Oil Cooler Kohler Engines Keep engine oil cooler 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 Spark Plug A CAUTION Avoid injury Touching hot surfaces can burn skin The engine components and fluids will be hot if the engine has been running Allow the engine to cool before servicing or working near the engine and components IMPORTANT Avoid damage Do not clean spark plugs with abrasives 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 5 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 See your authorized dealer If engine is hard to start or runs rough check the
51. higher or lower by approximately 25 mm 1 in depending on the holes chosen for mounting the lever Service Steering amp Brakes 33 SERVICE MOWER To mount in the high position mount the levers to the top four holes in the mounting bracket Loosen screws To mount in the low position mount the levers to the bottom four holes in the mounting bracket Slide both levers forward or rearward to desired position on control arm until levers are aligned lighten cap screws Checking and Aligning Motion Control Levers M Beak Optional Over the Lap Levers justing Park Brake IMPORTANT Avoid damage Due to initial brake wear the park 1 Park machine safely See Parking Safely in the SAFETY section brake should be checked and adjusted after the first 25 hours of use A park brake that is adjusted too tightly could damage the transmission or cause premature brake wear 1 Park machine safely See Parking Safely in the SAFETY section 2 Move both motion control levers A from the neutral lock to the neutral steer position 3 Check levers for equal alignment Check B between the levers The recommended gap is 3 6 mm 1 8 1 4 in 2 Loosen set screw A NOTE If the ends of the levers strike against each other while in the 3 Turn knob B clockwise several times neutral position move the levers to the neutral lock position and 4 Tigh in the
52. hine is equipped with an electric start The hourmeter will continue to run with the key switch left in the run position e The hourmeter A shows the number of hours the machine has run e The service interval chart gives necessary service intervals Use the hourmeter and service interval chart in the Service Intervals section to determine when machine will need service See the service interval chart in the engine manufacturer s owners manual supplied with your machine to determine when the engine will need service Operating 16 OPERATING Using the Choke Engage Choke Pull choke knob out Disengage Choke Push choke knob in Using the Motion Control Levers 4h CAUTION Avoid injury Learn use of the motion control levers and practice at half throttle until becoming proficient and comfortable with the operation of the machine Do not move motion control levers from forward to reverse or reverse to forward position rapidly Sudden direction changes could cause loss of control or damage the machine NOTE Two types of control levers are available standard center steer levers and optional over the lap levers The operation of both styles of levers is the same except as noted The functions of the motion control levers are Dual function neutral position Steering Acceleration Braking Neutral Detent Position Standard C
53. ighten the deck lift assist springs If the springs are compressed too tightly the mower deck will float too freely Decrease deck lift assist spring tension if operating in rough terrain While positioned in front of the machine Turn hex nut C clockwise to increase deck lift spring tension and reduce the effort to raise and lower the mower deck Turn hex nut C counterclockwise to decrease deck lift spring tension and increase the effort to raise and lower the mower deck 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 3 Raise foot platform Service Mower 37 SERVICE MOWER A CAUTION Avoid injury Fingers and hands can be pinched or crushed Keeps hands clear of sheave and belt pinch points when servicing belt 5 Remove mower deck drive belt B 4 Loosen jam nut A 5 Check the mower deck drive belt B tension The belt 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 the longest span When properly adjusted there would be approximately a 2 mm 1 16 in gap between the spring coils To increase belt tension Turn nut C clockwise To decrease belt tension Turn nut C counterclockwise 6 Tighten jam nut A 7 Lower foot platform Removing and Installing Mower Deck Drive Belt 1 Par
54. ilter Starter Will Not Work Plugged air intake system Fuel cap vent dirty Stale or improper fuel fuel level Spark plug not gapped correctly Replace spark plug Choke adjusted incorrectly See your Great Dane servicing dealer Engine oil level low Reduce load Slower ground speed Fuel is bad Fill tank with fresh fuel correct octane Idle speed too slow Clean cooling fins Low oil level Do not operate at slow idle Operate at Battery Will Not Charge full throttle setting Cooling air intake screen is dirty Plugged air intake filter Operating at too fast ground speed for conditions Troubleshooting 45 Plugged air intake system Plugged fuel filter Improper type of fuel Drain tank and fill with correct fuel Clean cooling fins to help prevent overheating Replace spark plug Find and correct oil leaks Incorrect engine oil Plugged oil filter Plugged air intake filter Throttle should be at low idle for several seconds before turning off machine Leaking damaged exhaust manifold gasket Improper type of fuel Plugged air intake system Operating at too fast ground speed for conditions Improper valve clearance See your Great Dane servicing dealer Restricted air intake system Dead battery Blown 20 amp fuse main power circuit Blown fusible link charging circuit Loose or corroded battery or ground connections Loose or corroded starter cable connect
55. in an open area Drive the machine forward if the machine drifts to the right or left adjust the transmission control linkage Specifications Engine NOTE See engine manufacturer s owner s manual provided with your machine for engine specifications Battery x Ss OS demand hd ar 12 volt qo D Lr 340 amp Reserve Capacity 90 minutes BOL GMN E aa a a 51 Tires EE EEE EN 13 x 5 0 6 EE NE SD EG dm ta 23 x 9 50 12 Inflation Front Maximum 110 138 kPa 16 20 psi Specifications 50 GETTING QUALITY SERVICE Inflation Rear Maximum 69 97 kPa 10 14 psi Wheel Nut Torque 100 Nem 75 Ib ft Capacities BUG TAK EE p 30 2 L 8 gal Hydraulic System 3 54 L 3 75 at Net Weight Chariot With Mower Deck and Without Fuel 23 hp Kohler Engine 48 in Deck 499 kg 1100 Ib 25 hp Kawasaki Engine 52 in Deck 508 kg 1119 Ib 27 hp Kohler Engine 52 in Deck 510 kg 1124 Ib 25 hp Kawasaki Engine 61 in 519 kg 1144 Ib 27 hp Kohler Engine 61 in Deck 521 kg 1149 Ib Travel Speeds FOWA se ee a SE 0 18 km h 0 11 mph RENE EEE AAA 0 8 km h 0 5 mph Dimensions Wheel Bassas 1 10 m 43 375 in WAG a e un v
56. ing 6 Install fuel tank cap methanol as engine damage can occur Always use fresh clean fuel that is purchased in quantity that can be Checking Tire Pressure used within approximately 30 days or add fuel stabilizer Fuel is blended to give best seasonal performance To avoid engine performance problems such as hard starting or vapor lock use in season fuel Use fuel during warm weather that was purchased during that season and use fuel during cold weather that was purchased during that season Fuel can become stale in machines with engines that are used seasonally or infrequently during season Stale fuel can produce varnish and plug carburetor components which can affect engine performance Keep fuel storage container tightly covered and cool area out of direct sunlight Fuel can break down and degrade if not sealed properly or exposed to sun and heat Condensation may collect in the fuel tank because of a variety of operating or environmental conditions and over time may affect your machine s operation Fill fuel tank at the end of daily use and store fuel in plastic containers to reduce condensation For best year round performance and fuel handling add stabilizer to fuel immediately after fuel purchase Such practice helps prevent engine CAUTION Avoid injury Explosive separation of tire and rim performance problems and allows fuel storage in the machine all year parts is possible when they are serviced in
57. ing Fuse One 20 amp fuse is located behind the seat area 2 Remove defective fuse A from socket 3 Check metal clip in fuse window and discard fuse if clip is broken 4 Install new fuse in socket Burnishing the PTO Clutch NOTE The clutch will only require burnishing if a new clutch has been installed 1 Start and run the engine at 1 2 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 Service Electrical 41 SERVIGE ELECTRICAL Wiring Schematic HZRLUMGS TELLA 141 51 LNO Ur LN NI III Old 5 1 HOLLINEN 901915 Jk Service Electrical 42 SERVIGE MISCELLANEOUS 2 Allow engine to cool Service Miscellaneous 3 Remove any trash from area around fuel tank cap Using Proper Fuel 4 Remove fuel tank cap slowly to allow any pressure built up in tank to escape Use regular grade unleaded fuel with an octane rating of 87 octane or higher Fuel blends containing up to 1096 ethanol or to 15 5 Fill fuel tank only to bottom of filler neck reformulated fuel are acceptable Do not use fuel or additives contain
58. ing anyone beneath it Remove key before raising machine Use a safe lifting device rated for the load to be lifted Lower machine onto stable supports or jack stands and block wheels before servicing 2 Raise and securely support the front of the mower deck 3 Remove cap A cotter pin B castle nut C 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 H and lower bearing 1 5 Remove upper bearing J 6 Clean and inspect bearings I and J pack with clean grease Replace bearings if needed 7 Install lower bearing 1 8 Install caster bushing E into a new seal H 9 Install seal assembly H 10 Carefully install caster yoke and wheel assembly D NOTE Do not overtighten castle nut C Tighten castle nut only enough to install the cotter pin B The caster wheel yoke assembly must be free to rotate 11 Install castle nut C cotter pin B and cap A 12 Apply grease to lubrication fitting 1 Checking and Aligning Motion Control Levers Standard Center Steer Levers Check Alignment 1 Park machine safely See Parking Safely in the SAFETY section 2 The control lever gap is pre set at the factory If the gap requires adjustment see your authorized Great Dane servicing dealer Height Adjustment Procedure The position of the control levers can be varied
59. ions Neutral start switches faulty or not adjusted properly See your Great Dane servicing dealer Key switch or starter faulty See your Great Dane servicing dealer PTO engaged Motion control levers and park brake lever not in proper position Loose or corroded battery or ground connections Blown fusible link charging circuit Battery cables and terminals are dirty Dead cell in battery TROUBLESHOOTING Machine Will Not Follow Steering tracking out of adjustment Straight Path PTO Clutch Does Not Blown 20 amp fuse main power Engage circuit Faulty PTO switch Faulty PTO clutch Loose PTO clutch connections Starter Turns Slowly Loose or corroded battery or ground Mower Deck connections Low battery power charge battery Engine oil viscosity too heavy Hydraulic pump linkages failed and are engaged Machine mw Excessive Machine Vibration Engine speed too slow Machine Will Not Move With Park brake locked Engine Running Mower Deck Vibrates Transmission hydraulic oil level low Transmission oil cold allow engine to warm Traction drive belt slipping Hydraulic pump free wheel valves open Traction drive belt damaged or worn Hydrostatic pump and or wheel motor problems See your Great Dane servicing dealer Mower Blades Do Not Machine Creeps With Engine Needs shift control linkage adjustment Engage Running and Motion Control Levers
60. k machine safely See Parking Safely in the SAFETY section A PTO Clutch Sheave B Mower Deck Drive Belt C Tension Idler Sheave D Left Spindle Sheave E Center Spindle Sheave F Idler Sheave G Right Spindle Sheave H Idler Sheave 2 Raise foot platform 3 Remove mower deck drive belt covers 6 Install new mower deck drive belt as shown 7 Adjust belt tension 8 Install mower deck drive belt covers 9 Lower foot platform Checking and Replacing Mower Blades A CAUTION Avoid injury Do not work near raised mower deck unless it is safely supported 4 Release mower deck drive belt tension by turning the tension adjuster Mower blades are sharp Wrap blades or wear gloves nut A counterclockwise when servicing Before performing any service function wait for all moving parts to stop turning Disconnect battery or remove spark plug wire before making repairs Service Mower 38 SERVICE MOWER A CAUTION Avoid injury Mower blades are dangerous NOTE Only replace blades Never straighten or weld them Always wear gloves while working on blades Checking Mower Blades Always wear safety eye protection when grinding 1 Park machine safely See Parking Safely in the Safety Section Sharpen blades with grinder hand file or electric blade sharpener 2 Raise the mower deck to the transport position also the 12 7 cm 5 in cutting height position 3 Raise front of machine with
61. lade Nut Spacer Blade Bolt Qty C0 CO CO 03 py 00 Includes items 2 3 4 5 6 14 1 000 x 1 250 x 2 772 3 8 16 5 8 18 x 7 3 4 HHCS 3 8 16 Std Hex GR5 GDU10230 GDU10231 GDU10232 16 5 Blade 48 Deck 18 0 Blade 52 Deck 21 0 Blade 61 Deck 200047 Zerk Grease 5 NOTES SPINDLE ASSEMBLY 75 CO CO CO CO DECK LIFT ASSEMBLY MP35892 DEGK LIFT ASSEMBLY 76 8 TCU18697 GDA10093 GDU10242 19M7796 H137327 GDA10092 19M7803 14M7396 JD 7849 GDA10101 W10728 R58806 D18079 200339 TCA15049 TCU17371 03M7204 TCU15816 D28155 D25107 D23049 14H1039 24H1111 11M7015 GDU10162 14H1058 GDU10238 TCU17245 24H1236 D28200 13510 GDU10048 H137329 N10215 19M8162 24H1413 A15147 DECK LIFT ASSEMBLY BEARING CAP ARM PLATE SCREW LOCK NUT ARM SCREW NUT LUBRIGATION FITTING LEVER BUSHING SNAP RING GRIP LEVER LEVER TORSION SPRING BOLT SPAGER PIN FASTENER ROD SWIVEL NUT WASHER COTTER PIN STUD NUT SWIVEL SWIVEL WASHER COMPRESSION SPRING LINK CHAIN U BOLT LOCK NUT LOCK NUT SCREW WASHER SPRING LOCKING PIN NOTES DECK LIFT ASSEMBLY 77 A NM PE OO E Description Remarks 0 M12 X 60 5 8 17 32 X 1 1 16 X 090 3 200 X 25 MM 3 4 13 16 X 2 X
62. lade blade washers and blade bolt assembly Tighten disconnect the negative battery cable B nut to 81 N m 60 Ib ft See Checking and Replacing Mower Blades 3 Slide red cover C away from the positive battery terminal and disconnect the positive battery cable D d Remove nuts E and washers from both sides of the bracket Service Electrical 5 Remove bracket F and J bolts G 6 Remove battery H WARNING Battery posts terminals and related accessories contain lead and lead components chemicals known to the State of California to cause Service Electrical 40 SERVICE ELECTRICAL Installing 1 Install battery using J bolts bracket washers and nuts E 2 Connect the positive battery cable D first then the negative cable B 3 Apply petroleum jelly or silicone spray to the terminals to prevent corrosion 4 Slide covers and over battery terminals Cleaning Battery and Terminals 1 Park machine safely See Parking Safely in the SAFETY section 2 Disconnect and remove battery 3 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 4 Rinse the battery with plain water and dry 5 Clean terminals and battery cable ends with wire brush until bright 6 Install battery 7 Attach cables to battery posts using washers and nuts 8 Apply petroleum jelly or silicone spray to terminals to p
63. marks 024028 21 22503 5 CASE RETURN MAKE FROM 22503 11 1 4 CASE RETURN MAKE FROM TY22503 11 1 4 CHARGE INLET MAKE FROM TY22503 5 CHARGE INLET MAKE FROM 22503 29 CHARGE INLET MAKE FROM TY22503 HIGH PRESSURE SHORT HIGH PRESSURE LONG PATCH LOCK HYDROSTATIC BDP 12 RH HYDROSTATIC BDP 12 LH NOTES Hydrostatic drive system Components 63 TRAGTION DRIVE AND BRAKES NN y x Dach 35886 20 TRACTION DRIVE AND BRAKES 64 CO CO 0 0 D25059 D18076 D18205 D14104 24H1441 GDA10032 03M7192 14M7518 19H1801 24H1305 D14010 19M8162 14M7152 14M7517 D18071 D28019 37M7059 200326 D25014 D23062 D28099 D28100 19H1900 24H1136 19M8319 H137328 19M8008 14M7151 TCU10037 GDA10000 GDU10096 03M7199 H137329 200312 200313 03M7192 TCA15316 D18067 D25146 D25147 D13336 19H2975 34M5722 D28125 22H907 GDA10100 19H1930 H32811 MT2119 D18207 TCA15373 GDA10022 GDA10137 GDU10184 19M7785 D28029 D28088 24H1776 200330 200331 967387 967192 TRAGTION DRIVE AND BRAKES ARM BUSHING FITTING SNAP RING WASHER IDLER BOLT FLANGE NUT CAP SCREW WASHER LOCK NUT SCREW NUT LOCK NUT EXTENSION SPRING LEVER SCREW RETAINER SPACER PUSH PULL CABLE PUSH PULL CABLE CAP SCREW WASHER SCREW LOCK NUT CAP SCREW NUT NUT TIRE AND WHEEL ASSEMBLY SUPP
64. mowing machines and mowing activities They don t understand the dangers of rotating blades or the fact that the operator is unaware of their presence Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine Tragic accidents with children can occur if the operator is not alert to the presence of children especially when a child approaches a machine from behind Before and while backing up stop mower blades and look down and behind the machine carefully especially for children Never carry children on a machine or attachment even with the blades off Do not tow children in a cart or trailer They can fall off and be seriously injured or interfere with safe machine operation Never use the machine as a recreational vehicle or to entertain children Never allow children or an untrained person operate the machine Instruct all operators not to give children a ride on the machine or in an attachment Keep children indoors out of the mowing area and in the watchful eye of a responsible adult other than the operator when a mower is being operated e Stay alert to the presence of children Never assume that children will remain where you last saw them Turn the machine off if a child enters the work area Avoid Tipping Slopes are a major factor related to loss of control and tip over accidents which can result in severe injury
65. mponents 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 Keep oil level between the FULL and the ADD marks Check oil level when engine is stopped level and is cooled so oil has had time to drain into the sump NOTE Check oil twice a day if you run engine over 4 hours in a day Make sure engine is cool when checking engine oil level 1 Park machine safely See Parking Safely in the SAFETY section 2 Allow engine to cool IMPORTANT Avoid damage Dirt and debris in oil may cause damage to the engine Clean area around opening before removing plug or dipstick 3 Remove dipstick Wipe with a clean cloth 4 Install dipstick and allow the cap to rest on the end of the tube Do not tighten the cap IMPORTANT Avoid damage To prevent extensive engine wear or damage always maintain the proper engine oil level Never operate the engine with the oil level below the add mark or over the full mark 5 Remove dipstick and check oil level on dipstick Oil must be between the ADD and FULL marks f oil is low add oil to bring oil level no higher than the FULL mark on dipstick If oil level is above the FULL mark drain to proper level 6 Install and tighten dipstick Changing Engine Oil and Filter IMPORTANT Avoid damage Change the oil more often if the vehicle is used in extreme conditions
66. n the ADD and FULL marks Add oil if needed 17 Install and tighten dipstick Oil Capacity With Filter Dry 1 8 L 1 9 at MODEL Kawasaki Engines Kohler Engines 2 0 L 2 1 qt Service Engine 24 SERVICE ENGINE Cleaning Engine Air Intake Screen and Fan A CAUTION Avoid injury Compressed air can cause debris to fly a long distance Clear work area of bystanders Wear eye protection when using compressed air for cleaning purposes Reduce compressed air pressure to 210 kPa 30 psi IMPORTANT Avoid damage An obstructed air intake screen can cause engine damage due to overheating Keep air intake screen and other external surfaces of the engine including cooling fins clean at all times to allow adequate air intake 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 components and fluids will be hot if the engine has been running Allow the engine to cool before servicing or working near the engine and components IMPORTANT Avoid damage Dirt and debris can enter the engine through a damaged filter element e Do not wash paper element Do not attempt to clean paper element by tapping against another object Do not use pr
67. nal materials needed to properly remove surface scratches from any plastic surfaces do not attempt to paint over marks or scratches in plastic parts IMPORTANT Avoid damage Improper care of machine plastic surfaces can damage that surface Do not wipe plastic surfaces when they are dry Dry wiping will result in minor surface scratches Use a soft clean cloth bath towel diaper automotive mitt Do not use abrasive materials such as polishing compounds on plastic surfaces Do not spray insect repellent near machine Wash surface with clean water and mild liquid automotive washing soap 2 Dry thoroughly to avoid water spots Cleaning and Repairing Metal Surfaces Cleaning Follow automotive practices to care for your vehicle painted metal surfaces Use a high quality automotive wax regularly to maintain the factory look of your vehicle s painted surfaces Repairing Minor Scratches surface scratch 1 Clean area to be repaired thoroughly IMPORTANT Avoid damage Do not use rubbing compound on painted surfaces 2 Use automotive polishing compound to remove surface scratches 3 Apply wax to entire surface Repairing Deep Scratches bare metal or primer showing 1 Clean area to be repaired with rubbing alcohol or mineral spirits 2 Use paint stick with factory matched colors available from your authorized dealer to fill scratches Follow directions included on paint stick for use and
68. nce Statement Maintenance repair or replacement of the emission control devices and systems on this engine which are being done the customer s expense may be performed by any non road engine repair establishment or individual Warranty repairs must be performed by an authorized servicing dealer 7 Grease mower deck drive belt tension arm H NOTE Use spray lubricant to lubricate the following items Avoid Fumes A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation 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 Engine Oil Use oil viscosity based on the expected air temperature range during the 8 Lubricate mower deck idler pulleys K M period between oil changes Use oil that meets the following specification e See the engine manufacturer s owner s manual provided with your machine for the correct specifications Service Engine 23 SERVICE ENGINE Checking Engine Oil Level 4h CAUTION Avoid injury Touching hot surfaces can burn skin The engine components and fluids will be hot if the engine has been running Allow the engine to cool before servicing or working near the engine and co
69. ne to help prevent fires Clean up oil or fuel spillage Let engine cool before storing and do not store near flame oafety 8 SAFETY e Shut off fuel while storing or transporting Do not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Understand service procedure before doing work Use jack stands or lock service latches to support components when required Securely support any machine elements that must be raised for service work Before servicing machine or attachment carefully release pressure from any components with stored energy such as hydraulic components or springs Release hydraulic pressure by lowering attachment or cutting units to the ground or to a mechanical stop and move hydraulic control levers back and forth Disconnect battery or remove spark plug for gas engines before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blades or wear gloves and use caution when servicing them Only replace blades Never straighten or weld them e Keep hands feet clothing jewelry and long hair away from moving parts If possible do not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from bat
70. nformation is given throughout the manual that may help the operator in the operation or service of the machine Product Identification Record Identification Numbers Chariot Brutus GBKW2552S S N 637910000 GBKH2752S S N 638010000 GBKW2561S S N 638310000 All information illustrations and 27615 9 996410000 specifications in this manual are based on If you need to contact an Authorized Service Center for information on the latest information at the time of servicing always provide the product model and serial numbers publication The right is reserved to make changes any time without notice You will need to locate the model and serial numbers for the machine and COPYRIGHTO 2006 for the engine of your machine and record the information in the spaces Auburn Consolidated Industries Inc provided All rights reserved COPYRIGHTO 2006 DATE OF PURCHASE DEALER NAME DEALER PHONE Introduction 1 SAFETY LABELS 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 To avoid injury Para evitar wom raja nng causadas blades las cuchillas olg ar ai deck mantenerse alejado del borde de la plakalonna de corte Ab ei LA m m od MODEL NUMBER POWER UNIT To avoid injury from rotating blades sta
71. ng 11 OPERATING Using Seat Belt Adjusting Seat Front to Back Adjustment 1 Park machine safely See Parking Safely in the SAFETY section 2 Sit on the operator seat CAUTION Avoid injury Never adjust seat while machine is moving Stop machine before adjusting seat to prevent loss of machine control CAUTION Avoid injury Always wear seat belt when operating machine with non folding Roll Over Protective Structure ROPS or folding ROPS in upright position Do not jump from machine if machine tips If folding ROPS must be folded to operate low clearance area do not use seat belt Raise ROPS and use seat belt as soon as conditions permit 3 adjust the seat front to back push and hold the seat adjustment lever A away from the seat 4 Slide forward or backward to desired position 5 Release lever Seat Height Adjustment 1 Sit on the operator seat 2 To lower the seat turn knob B counterclockwise 3 To raise the seat turn knob B clockwise 1 Sit in seat 2 Pull belts across your lap and insert seat belt buckle A into latch B until it locks 3 release seat belt press red button C until buckle comes out of latch Raising and Lowering ROPS Raising ROPS 1 Park machine safely See Parking Safely in the SAFETY section 2 Remove spring pin from drilled pin B on left and right side of ROPS 3 Remove drilled pin from left and right side of ROPS Opera
72. ng belts keep all shields and guards in place WARNING Hot surface CAUTION HELP AVOID INJURY AYUDAR EVITAR Ze waning ee raqulara entrenamiento dal aparador Rand nual Leer e manual del operader anar les on gg lugar Mantener laz una distancia prudente Mantener los de tad an buen estado Operator training required SAFETY LABELS Read operator s manual Keep shields in place Never carry riders Keep people a safe distance away Maintain all safety devices Before leaving machine Stop engine Set park brake Remove key WARNING ET il machine ups bse weal belt W nin mel Sp exlra care AVOID CRUSHING Keep Rollover Protective Structure fully extended Do not jump if machine tips Use seat belt When Structure must be down DO NOT use seat belt Drive with extra care WARNING d WARNING SEAT BELTS BE MOUNTED THIS HOLE BECAUSE SEAT WILL MOT MEET 1388 TEST REQUIREMENTS FAILURE TO COMPLY WITH WARNING COULD CAUSE SERIOUS INJURY OR DEATH Seat belts are not to be mounted in this hole because seat will not meet SAE J386 test requirements Failure to comply with warning could cause serious injury or death Safety Labels 4 SAFETY Emission Control System Certification Label NOTE Tampering with emission controls and comp
73. nged exposure to sunlight will damage the hood surface Operator Station Controls A Motion Control Levers B Park Brake Lever C Seat Adjustment Lever D Hourmeter E Ignition Key Switch F PTO Knob G Choke Carbureted Engines Only H Throttle Lever I Mower Deck Lift Lower Lever Do not step on the mower deck when mounting and dismounting the machine Mount the machine from the front using the foot plate A Park machine safely See Parking Safely in the SAFETY section before dismounting Keep the foot plate clean Raising and Lowering Operator Seat A CAUTION Avoid injury The seat is heavy and can cause injury if it falls When performing any service function under the operator seat make sure the seat is tilted forward and rests against the hinge stops J Height of Cut HOC Adjustment Pin Ss Raising the Seat K Mower Deck Transport Position Lock Lever 1 Park machine safely See Parking Safely in the SAFETY section Miscellaneous Controls 2 Slide seat to full rear position 3 Remove two locknuts A and capscrews securing the flanges at the rear of the seat frame B to the machine A Hydraulic Pump Free Wheel Valves 4 Lift seat frame and tilt forward until it rests against the hinge stops Lowering the Seat 1 Stand on the side of the machine 2 Slowly lower seat frame Secure with cap screws and locknuts removed earlier 3 Adjust seat as necessary for operator comfort Operati
74. o not smoke c Never refuel or drain the machine indoors Check that the operator s presence controls safety switches and shields are attached and functioning properly Do not operate unless they are functioning properly Operating Safely Never run an engine in an enclosed area where dangerous carbon monoxide fumes can collect Only operate in good light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine Only start engine from the operator s position Use seat belts if provided Slow down and use extra care on hillsides Be sure to travel in the recommended direction on hillsides For this machine drive across hillsides not up and down Turf conditions can affect the machine s stability Use caution while operating near drop offs Slow down and use caution when making turns and when changing directions on slopes Never raise deck with the blades running Never operate with the PTO shield or other guards not securely in place Be sure all interlocks are attached adjusted properly and functioning properly Never operate with the discharge deflector raised removed or altered unless using a grasscatcher Do not operate mower without discharge chute or entire grasscatcher in place Do not change the engine governor setting or overspeed the engine Operating the engine at excessive speed can increase the hazard of person
75. on 2 Remove mower blade See Checking and Replacing Mower Blades Service Mower 39 SERVICE ELECTRICAL cancer and reproductive harm Wash hands after handling Service the Battery Safely CAUTION Avoid injury The battery produces flammable and explosive gas The battery may explode not smoke near battery Wear eye protection and gloves not allow direct metal contact across battery posts Remove negative cable first when disconnecting Install negative cable last when connecting Removing and Installing the Battery Removing 1 Park machine safely See Parking Safely in the SAFETY section 3 Remove nut A pulley B and spacer 4 Remove retaining ring D spindle shaft E lower bearing F and spacer G from spindle housing H Discard bearing 5 Remove and discard upper bearing 1 6 Clean entire assembly 7 Install a new lower bearing and spacer on the spindle shaft E 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 8 Install the spindle shaft E lower bearing F and spacer G into the spindle housing H 9 Install the upper bearing 1 and retaining ring D 10 Install spacer C 11 Install pulley B and nut A Tighten nut to 61 Nem 50 Ib ft 2 Slide black cover A away from the negative battery terminal and 12 Install mower b
76. on control levers to the neutral detent position standard levers or neutral lock position optional over the lap levers 4 Lock the park brake 5 Stop engine and remove key Always wait for mower blades to stop turning before leaving operator seat Service Intervals Servicing Your Machine IMPORTANT Avoid damage Operating in extreme conditions may require more frequent service intervals Engine components may become dirty or plugged when operating in extreme heat dust or other severe conditions Engine oil 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 Break In After First 8 Hours of Operation NOTE The following initial break in items must be performed and verified to validate the warranty dealer service invoice accepted Change engine oil and filter Check drive belt tension Check mower deck drive belt tension Check transmission neutral adjustment e Check wheel nut torque Check and adjust as needed park brake Remove debris from the underside of the mower deck Every 25 Hours or Weekly Whichever Comes First Grease mower deck thrust arms two places Grease mower deck thrust arms two places Grease spindle bearings three places Grease traction drive belt tension arm Grease mower deck drive belt tension a
77. onents 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 signifies that the engine has been certified with the United States Environmental Protection Agency EPA and or California Air Resources Board 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 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 Certification Your product has been tested and evaluated by the manufacturer and conforms with American National Standard B 71 4 Safety Specifications for commercial turf care equipment Canadian Electromagnetic Compatibility EMC Compliance This spark ignition system complies with Canadian ICES 002 Safety Operator Training Required Read the operator s manual and
78. ontrol levers to the neutral detent position standard 8 Release key to run position C when engine starts levers or neutral lock position optional over the lap levers 9 With engine started Push choke knob to off position Move throttle lever to full throttle position Unlock the park brake Operating 19 OPERATING Engaging Mower CAUTION Avoid injury Clear mowing area of all bystanders when operating this machine Thrown objects could cause serious injury or death Keep hands and feet away from blades and discharge opening Do not mow in reverse unless absolutely necessary IMPORTANT Avoid damage To help prevent damage to PTO clutch Do not engage PTO with throttle in the fast position 1 Adjust mower deck to desired cutting height 2 Start engine 3 Move throttle lever to the 1 2 3 4 throttle position 4 Unlock the park brake 5 Move both motion control levers to the neutral position NOTE In cold weather or with a new machine it may be necessary to engage the choke at the same time as the PTO knob to prevent the engine from stalling 6 Pull PTO knob A up to engage mower deck 7 Move throttle lever to full throttle position NOTE The travel speed and turn rate will vary with the amount that the control levers are moved 8 Push motion control levers forward slowly Mow at a safe travel speed Stopping the Engine IMPORTANT Avoid damage To help prevent engine backfi
79. other training material If the operator or mechanic cannot read English it is the owner s responsibility to explain this material to them This publication is available in other languages Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner of the machine is responsible for training the users Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator he owner user can prevent and is responsible for accidents or injuries occurring to themselves other people or property Operate the machine in an open unobstructed area under the direction of an experienced operator Preparation Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by the manufacturer Wear appropriate clothing including hard hat safety glasses and hearing protection Long hair loose clothing or jewelry may get tangled in moving parts Inspect the area where the equipment is to be used and remove all objects such as rocks toys and wire which can be thrown by the machine Use extra care when handling gasoline and other fuels They are flammable and vapors are explosive a Use only an approved container b Never remove gas cap or add fuel when engine is running D
80. revent corrosion Using Booster Battery CAUTION Avoid injury The battery produces a flammable and explosive gas The battery may explode Do not smoke or have open flame near battery Wear eye protection and gloves Do not jump start or charge a frozen battery Warm battery to 16 C 60 F not connect the negative booster cable to the negative terminal of the discharged battery Connect at a good ground location away from the discharged battery A Booster Battery B Disabled Vehicle Battery 1 Connect positive booster cable to booster battery A positive post C 2 Connect the other end of positive booster cable to the disabled vehicle battery B positive post D 3 Connect negative booster cable to booster battery negative post E IMPORTANT Avoid damage Electric charge from booster battery can damage machine components Do not install negative booster cable to machine frame Install only to the engine block Install negative booster cable away from moving parts in the engine compartment such as belts and fan blades 4 Connect the other end of negative booster cable to a metal part of the disabled machine engine block away from battery 5 Start the engine of the disabled machine and run machine for several minutes 6 Carefully disconnect the booster cables in the exact reverse order negative cable first and then the positive cable Replac
81. ring throttle lever should be set at the 1 4 throttle position and run for 30 seconds prior to stopping the engine Do not stop engine when mower is on slope of more than 30 for an extended period of time Oil may run through valve train into carburetor and muffler 1 Move the motion control levers to the neutral detent position standard levers or neutral lock position optional over the lap levers 2 Lock the park brake 3 Push PTO switch down to disengage 4 Move throttle lever to 1 4 throttle position and run for 30 seconds then move throttle to slow position 5 Turn key switch to STOP 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 6 Remove key Transporting Machine A CAUTION Avoid injury Use extra care when loading or unloading the machine into a trailer or truck Close fuel shut off valve if your machine is equipped IMPORTANT Avoid damage Transmission damage may occur if the machine is moved or towed incorrectly Move unit by hand only Do not use another vehicle to move unit Do not tow unit Use a heavy duty trailer to transport your machine Trailer must have signs and lights required by law 1 Raise the mower deck lift lever to the transport position 2 Drive machine on trailer 3 Stop engine and lock th
82. rm Grease HOC shafts four places Lubricate front caster wheel spindles Remove debris from the underside of the mower deck Every 50 Hours or Weekly Whichever Comes First e Change engine oil and filter See the engine manufacturer s owner s manual provided with your machine for the complete procedure Grease caster wheel spindle bearings two places Grease mower deck thrust arms two places Remove debris from the underside of the mower deck Check drive belt tension Check tire pressure Clean engine air filter Check wheel nut torque Every 160 Hours or Monthly Whichever Comes First Check transmission oil level 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 Annually Inspect all spindle bearings 6 Replace as needed Inspect all mower deck idler pulleys 3 Replace as needed e Remove and inspect caster wheel roller bearings clean and pack with grease Replace as needed e Remove and inspect caster pivot bearings clean and pack with grease Replace as needed Inspect drive belts Replace as needed Run in and adjust tension Change hydraulic oil and filter annually or 500 hours whichever comes first Check all bolts an
83. rotating blades Before traveling forward or rearward Carefully check area around machine Disengage mower before backing up 1 Move throttle lever to the full throttle position 2 Unlock the park brake 3 Optional over the lap levers Move both motion control levers from the neutral lock position inward to the neutral position 4 Push the control levers forward to begin forward motion The farther forward the control levers are moved the faster the machine will travel Forward speed range 0 14 km h 0 9 mph Gentle Left Turn Pull both control levers past center rearward at the same time 5 Pull both control levers rearward at the same time to begin reverse motion e Reverse speed range 0 6 km h 0 4 mph 6 To stop motion move both motion control levers forward or rearward until the machine comes to a stop NOTE The motion control linkages are adjustable If adjustment is required see Checking and Adjusting Motion Control Linkages in the Service Transmission section Forward Push right control lever farther forward than the left control lever Gentle Right Turn Push both motion control levers forward at the same time Push left control lever farther forward than the right control lever Operating 18 OPERATING Sharp Left Turn 4 Push PTO knob A down to disengage PTO Push right control lever forward and pull left control lever rearward at the
84. s viewed from top of machine A 1 2 in Square Opening B Tension Arm C Traction Drive Belt D Engine Drive Sheave E Tension Idler Sheave F Hydraulic Pump Sheave 3 Using a 1 2 in drive breaker bar and extension insert end of extension in 1 2 in drive square opening A in tension arm and carefully move tension arm B counter clockwise to release belt tension 4 Remove drive belt C 5 Install new drive belt 6 Install mower deck drive belt as shown Checking and Adjusting Motion Control Linkages CAUTION Avoid injury Do not attempt this adjustment unless you are a qualified and properly trained technician Improper adjustment can result in an unsafe machine Service Transmission 27 SERVICE TRANSMISSION Check Neutral Creep CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation Connect 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 NOTE Check and adjust motion control linkages with the machine parked on hard level surface 1 Start engine 2 Set throttle lever to full throttle position 3 Unlock the park brake 4 1 the rear drive wheels begin to creep an adjustment is required
85. se battery to explode Always shield eyes and face from battery Do not charge or use booster cables or adjust post connections without proper in struction and training Keep vent caps tight and level Cigarettes flames or sparks could cause battery to explode Always shield eyes and face from battery Do not charge or use booster cables or adjust post connections without proper instruction and training Contains sulfuric acid Avoid contact with the skin eyes or clothing In event of accident flush with water and call a physician immediately Keep out of reach of children WARNING AWARNING avoid injury from drive across slopes not up and down machine stops going uphill stop blades and back down slowly ADVERTENCIA Para evitar las lesiones causadas por la volcadura de la m quina viajar en sentido transversal en vez de hacia arriba y abajo Si la m quina se para mientras se sube una endiente detener las cuchillas y bajar entamente en retroceso To avoid injury from tipover drive across slopes not up and down machine stops going uphill stop blades and back down slowly Safety Labels 3 WARNING da WARNING To avoid injury from rotating belts keep all shields and guards place di ADVERTENCIA Para evitar ser lesionado por las correas en movi miento mantener todos los escudos y protectores en su lugar To avoid injury from rotati
86. ssible then refuel such equipment with a portable container rather than from a fuel dispenser nozzle ORemove mower deck belt shields Clean grass and debris from belt area Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fueling is complete Do not use a nozzle lock Remove grass and debris from machine and mower deck open device OTest park brake Never overfill fuel tank Replace fuel tank cap and tighten securely OTest safety systems Replace all fuel container caps securely after use Olnspect battery terminals and hold downs For gasoline engines do not use gas with methanol Methanol is Olnspect for oil leaks harmful to your health and to the environment OCheck engine and hydraulic oil levels Olnspect all belts for damage or cracking Olnspect engine air filter Olnspect mower level OAgjust cutting height if necessary Olnspect wheel bolt torque Tighten if necessary OCheck tire air pressure Check tires for damage or cracking Olnspect front caster spindles wheels Avoid Damage to Plastic and Painted Surfaces Do not wipe plastic parts unless rinsed first Insect repellent spray may damage plastic and painted surfaces Do not spray insect repellent near machine Operating 10 OPERATING Be careful not to spill fuel on machine Fuel may damage surface Wipe Mounting and Dismounting Machine Safely up spilled fuel immediately Prolo
87. stability Use Seat Belt Properly Use a seat belt when operating with the folding Roll Over Protective Structure ROPS in the upright position to minimize chance of injury from an accident such as an overturn Do not use a seat belt when operating with the folding ROPS in the folded position Return the folding ROPS to the upright position as soon as possible Never modify disassemble or attempt to repair the seat belt Replace entire seat belt if mounting hardware buckle belt or retractor show signs of damage seat belt and mounting hardware at least once a year Look for signs of loose hardware or belt damage such as cuts fraying extreme or unusual wear discoloration or abrasion Replace only with replacement parts approved by your Great Dane Layers of heavy clothing can interfere with proper positioning of the seat belt and can reduce the effectiveness of the seat belt Keep ROPS Installed Properly Make certain all parts of the ROPS are installed correctly if the ROPS structure is loosened or removed for any reason All ROPS hardware should be tightened to the proper torque per manufacturer s recommendations Any alteration of the ROPS must be approved by the manufacturer The protection provided by the ROPS will be impaired if the ROPS is subjected to structural damage is involved in an overturn incident or is in any way altered by welding bending drilling or cutting Ne
88. start the engine 3 Operate machine to bring the hydraulic oil to normal operating temperature 4 Move the machine in a level wide open area such as an empty parking lot 5 Run the engine at full throttle 6 Move and hold both control levers to the full forward position Observe the machine travel If the machine does not travel in a straight line adjustment is required Note the direction the machine moves Maximum Speed Drift Adjustment 1 Park machine safely See Parking Safely in the SAFETY section 2 Tilt operator seat forward and support the seat frame Service Transmission 28 SERVICE TRANSMISSION NOTE If the machine travels to the left adjust the right speed drift screw If the machine travels to the right adjust the left speed drift screw 3 Adjust the appropriate speed drift screw A or B as follows a Loosen jam nut C or D b Adjust the screw A or B one turn clockwise Tighten the jam nut or D 4 Lower the seat platform 5 Perform Check Maximum Speed Drift procedure to check adjustment Repeat the adjustment procedure as needed Service Transmission 29 SERVICE TRANSMISSION Hydraulic System Hose Routing A Hydraulic Reservoir B Oil Filter C Right Hydraulic Pump D Right Wheel Motor E Left Wheel Motor F Left Hydraulic Pump Service Transmission 30 SERVIGE STEERING amp BRAKES Hydraulic System Schematic gt
89. t approximate 25 to 127 mm 1 to 5 in Height Adjustment Increments 13 mm 1 2 in Getting Quality Service Service Literature If you would like to order a copy of the Parts Catalog or Operator Manual for this machine contact your dealer Parts catalogs and operator manuals are also available online at GreatDaneMowers com 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 a number changes your dealer will have the latest number When you order parts your Great Dane dealer needs your machine serial number and engine serial number These are the numbers that you recorded in the Product Identification section of this manual Great Dane Quality Continues with Quality Service Great Dane provides a process to handle your questions or problems should they arise to ensure that product quality continues with your authorized Great Dane dealer s parts and service support Follow the steps below to get answers to any questions you may have about your product 1 Refer to your attachment and machine operator manuals 2 Contact your authorized Great Dane dealer with unanswered questions Getting Quality Service 51 ENGINE AND RELATED COMPONENTS KAWASAKI MP35877 ENGINE AND RELATED COMPONENTS KAWASAKI 52 ENGINE AND RELATED COMPONENTS KAWASAKI ay
90. tart the engine but move the machine away from the area of spillage Avoid creating any source of ignition until fuel vapors have dissipated Never store the machine or fuel container where there is an open flame spark or pilot light such as on a water heater or other appliance Waste products such as used oil fuel coolant brake fluid and batteries can harm the environment and people Do not use beverage containers for waste fluids someone may drink from them See your local Recycling Center or authorized dealer to learn how to recycle or get rid of waste products A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques The seller of the chemical products used with your machine is responsible for providing the MSDS for that product Prevent fire and explosion caused by static electric discharge Static electric discharge can ignite fuel vapors in an ungrounded fuel container Never fill containers inside a vehicle or on a truck or trailer bed with a Operating plastic liner Always place containers on the ground away from your Daily Operating Checklist vehicle before fueling OMake sure all necessary guards and shields are safely and securely Remove fuel powered equipment from the truck or trailer and refuel it on attached Check for loose missing or damaged parts the ground If this is not po
91. tery Wear protective clothing and use insulated tools Keep all parts in good working condition and all hardware tightened Replace all worn or damaged decals Check grasscatcher components and the discharge guard frequently and replace with manufacturer s recommended parts when necessary Grasscatcher components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Keep all nuts and bolts tight especially blade attachment bolts to be sure the equipment is in safe working condition Check brake operation frequently Adjust and service as required On multi bladed machines take care as rotating one blade can cause other blades to rotate Prevent Fires Remove grass and debris from engine compartment and muffler area before and after operating machine especially after mowing or mulching in dry conditions Empty the grasscatcher completely before storing Always shut off fuel when storing or transporting machine if the machine has a fuel shutoff Do not store machine near an open flame or source of ignition such as a water heater or furnace Check fuel lines tank cap and fittings frequently for cracks or leaks Replace if necessary Tire Safety Explosive separation of a tire and rim parts can cause serious injury or death Do not attempt to mount a tire without the proper equipment and experience to perform the job e Always m
92. ting 12 OPERATING 4 Push ROPS into upright position 5 Install drilled B into holes on left and right side of ROPS and secure in place with spring pins A 6 Check the ROPS bolt torque if the ROPS is loose Lowering ROPS CAUTION Avoid injury Use roll over protection system ROPS in lowered position only when low clearance operation is necessary Do not use seat belt when ROPS is lowered position Do not operate machine on slope with ROPS in folded position Raise ROPS and fasten seat belt as soon as conditions permit 1 Park machine safely See Parking Safely in the SAFETY section 2 Remove spring pin A from drilled pin on left and right side of ROPS 3 Remove drilled pin from left and right side of ROPS 4 Pull ROPS rearward to lower 5 Install drilled pins and spring pins back into hole in ROPS to secure in place Adjusting Mower Deck Cutting Height CAUTION Avoid injury Rotating blades are dangerous and can cut fingers and toes Stop engine lock the park brake and wait for blade to stop rotating before adjusting cutting height Cutting height can be adjusted from approximately 25 125 mm 1 5 in Each hole adjusts the height of cut HOC in approximately 12 mm 1 2 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 1 Park machine safely Se
93. trol levers A with control arms Install hardware and tighten 3 Check motion control lever alignment Move both motion control levers forward Install Seat Assembly 48 ASSEMBLY 1 Remove and retain the two locknuts and cap screws securing the Install ROPS flanges at the rear of the seat frame to the machine 1 Support rear of bumper with blocks or jack 2 Loosen nut A securing the rear battery hold down rod and disengage hooked end B from bumper 3 Remove all bumper mounting bolts and retaining hardware except for the lower left cap screw C at each side of the machine Discard any assembly washers retain bolts and locknuts for later use 2 Pivot seat frame A forward until it rests on the hinge stops 3 Remove and retain the seat pivot shoulder bolts B and nuts 4 Remove protective covers from seat screws NOTE The seat mounting hardware is attached to the seat plate with tie straps 4 Fold ROPS to the upright operating position and install lock pins D and spring pins E 5 Install seat to the seat frame using four 5 16 18 locknuts and heavy flat washers D Tighten locknuts to 27 Nem 20 Ib ft 6 Connect wire harness to seat safety switch E 7 Secure front of seat frame to machine with seat pivot shoulder bolts and nuts removed earlier Tighten to 81 Nem 60 Ib ft 8 Secure rear of seat frame to machine with capscrews and locknuts removed earlier
94. ver attempt to repair a damaged or altered ROPS It must be replaced to maintain the manufacturer s certification of the structure oafety 7 SAFETY Keep Riders Off Only allow the operator on the machine Keep riders off Riders on the machine or attachment may be struck by foreign objects or thrown off the machine causing serious injury Riders obstruct the operator s view resulting in the machine being operated in an unsafe manner Avoid 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 damage and vibration Check connections regularly Tighten loose connections 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 e Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids 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 Driving Safely on Public Roads Avoid personal injury or death resulting from a collision with another vehicle on publi
95. when you travel over rough ground Parking Safely 1 Stop machine on a level surface not on a slope 2 Move motion control levers out to the neutral lock position 3 Disengage mower blades 4 Lower attachments to the ground 5 Lock the park brake 6 Stop the engine 7 Remove the key 8 Wait for engine and all moving parts to stop before you leave the operator s seat 9 Close fuel shut off valve if your machine is equipped 10 Disconnect the negative battery cable or remove the spark plug wire for gasoline engines before servicing the machine Rotating Blades are Dangerous HELP PREVENT SERIOUS OR FATAL ACCIDENTS Rotating blades cut off arms and legs and throw objects Failure to observe safety instructions could result in serious injury or death Keep hands feet and clothing away from mower deck when engine is running Be alert at all times drive forward carefully People especially children can move quickly into the mowing area before you know it Do not mow in reverse Shut off blades when you are not mowing Park machine safely before leaving the operator station for any reason including emptying the catchers or unplugging the chute oafety 6 SAFETY Protect Children Death or serious injury can occur when young children associate having fun with lawn mowing machine simply because someone has given them ride on machine Children are attracted to lawn
96. y Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation 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 The safety systems installed on your machine should be checked before each machine use Be sure you have read the machine operator manual and are completely familiar with the operation of the machine before performing these safety system checks Use the following checkout procedures to check for normal operation of machine If there is a malfunction during one of these procedures do not operate machine See your authorized dealer for service Perform these tests in a clear open area Keep bystanders away Testing Safety Systems A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation 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 The safety systems installed on your machine should be checked before each machine use
97. y clear of deck edge ROPS SERIAL NUMBER D Safety Labels Understanding The Machine Safety Labels 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 Safety Labels 2 SAFETY LABELS DANGER DANGER Do not mow without dis charge chute or entire grass in place PELIGRO No usar la maquina sin el tubo de _ descarg o sin el regogedor de pasto en sur lugar Do not mow without discharge chute or entire grass catcher in place DANGER Para avitar subir causadas por cuchillas giratorias 1 thrown objects stay clicar of deck edge and keep others away De not mow wch begt discharge chute or Ho usar la mag de desarga o el res de paso an su lugar To avoid injury from rotating blades and thrown objects stay clear of deck edge and keep others away Do not mow without discharge chute or entire grass catcher in place DANGER ADANGER EXPLOSIVE GASES Cigarettes flames or sparks POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with the skin eyes or clothing In event of accident flush with water and call a physician immi diately Keep out of reach of children could cau
98. y in a well ventilated area See Parking Safely in the SAFETY section 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 For machines equipped with key switch turn key to off position IMPORTANT Avoid damage Stale fuel can produce varnish and plug carburetor or injector components and affect engine performance Add fuel conditioner or stabilizer to fresh fuel before filling tank 4 Mix fresh fuel and 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 on gas engine or fuel injectors on diesel engine 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 gas engines Remove spark plugs Put 30 mL 1 oz of clean engine oil in cylinders Install spark plugs but do not connect spark plug wires Crank the engine five or six times to allow oil to be distributed 5 Clean the engine and engine compartment 6 Remove battery 7 Clean the battery and battery posts Check the electrolyte level if your battery is not maintenance free 8

Great Dane GBKH2752S Lawn Mower User Manual

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