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Dodge 2008 LC22 Challenger SRT8 Automobile User Manual

1. Item Part Number Battery AM124356 Fuel Tank Cap D18097 Oil Reservoir Cap GDA10022 Oil Filter Hydraulic System M16053 Traction Hydro Drive Belt D28030 Mower Deck Drive Belt e 1 22 m 48 in Deck TCU16092 e 1 32 m 52 in Deck TCU16093 e 1 55 m 61 in Deck GDU10228 Engine to Deck Drive Belt e 1 83 m 72 in Deck GDU10229 Spindle Drive Belt e 1 83 m 72 in Deck D28028 Mower Blades e 1 22 m 48 in Deck GDU10230 e 1 32 m 52 in Deck GDU10231 e 1 55 m 61 in Deck GDU10232 e 1 83 m 72 in Deck GDU10233 Part numbers are subject to change without notice Part numbers may be different outside the U S A Replacement Parts 22 SERVICE INTERVALS Servicing Your Machine IMPORTANT Avoid damage Operating in extreme conditions may require more frequent service intervals e Engine components may become dirty or plugged when operating in extreme heat dust or other severe conditions Engine oil and spark plugs may lose efficiency if vehicle is operated constantly at slow or low engine speeds or with frequent short trips Please use the following timetables to perform routine maintenance on your machine NOTE The following initial break in items must be performed and verified to validate the warranty dealer service invoice accepted Break In After First 8 Hours of Operation Change engine oil and filter Check drive belt tension Check mo
2. 3 e MX15332 A Hydraulic Reservoir B Oil Filter C Right Hydraulic Pump D Right Wheel Motor E Left Wheel Motor F Left Hydraulic Pump Service Transmission 35 SERVICE TRANSMISSION Hydraulic System Schematic MX15333 H Cooling Orifice A Control Input Shaft Charge Relief Valve B Pump Block J Left Wheel Motor C Charge Pump K Left Hydraulic Pump D Charge System Check Valve L Oil Filter E Right Hydraulic Pump M Hydraulic Reservoir F Manual Bypass Free Wheel Valve G Right Wheel Motor Service Transmission 36 SERVICE STEERING 8 BRAKES Remove and Install Front Caster Wheels Removing 1 Park machine safely See Parking Safely in the Safety section 2 Lift front of machine with a safe lifting device MX15323 3 Remove hex nut A and wheel bolt B 4 Remove wheel C from assembly yoke Installing 1 Install replacement wheel C 2 Install wheel bolt B and hex nut A 3 Tighten nut 4 Lower machine Servicing Front Caster Wheel Roller Bearings Chariot 1 Park machine safely See Par
3. MX15275 e Raise and pull rearward park brake lever A to the lock park brake Unlocking Park Brake MX15292 e Lower park brake lever A forward to unlock the park brake Using the Key Switch NOTE Machine will only start if the following conditions exist e Park brake is locked e PTO is disengaged e Motion control levers are in the neutral detent position standard levers or neutral lock position optional over the lap levers MIF To turn ignition off turn key to the STOP position A e To turn ignition on turn key to the run position B To start engine turn key to the start position C Once engine begins to run release key back to the run position Using the PTO Engage PTO MX15284 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 e Push PTO knob B down Operating 14 OPERATING Using the Throttle Lever MX15284 e 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 e 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
4. 5 Release spindle drive belt tension by turning tension adjustment nut B counterclockwise 6 Remove spindle drive belt C MX15330 A Tension Idler Sheave B Left Spindle Sheave C Spindle Drive Belt D Center Spindle Sheave E Right Spindle Sheave 7 Install new spindle drive belt C as shown 8 Adjust drive belt tension 9 Install engine to deck drive belt and adjust belt tension 10 Install mower deck drive belt covers 11 Lower foot platform Checking and Replacing Mower Blades A CAUTION Avoid injury Help prevent serious personal injury Do not work near a raised mower deck unless it is safely supported Never start the engine or engage the PTO switch when performing this service procedure Blades are sharp and could cause personal injury Wear appropriate clothing including gloves when working near the underside of a raised mower deck Before performing any service function wait for all moving parts to stop turning IMPORTANT Avoid damage When replacing mower blades always use genuine Great Dane Service Parts NOTE Only replace blades Never straighten or weld them Checking Mower Blades 1 Park machine safely See Parking Safely in the Safety Section 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 a safe lifting device e Support with jack stands
5. GREATGDANE Chariot Chariot LK GDRZ48 17KAE GDRZ48 19KAE GDRZ52 23KAE GDRZ52 25KAE GDRZ52 25KHE GDRZ61 25KAE GDRZ61 25KHE GDRZ61 25KAE GDRZ61 25KHE GDRZ61 26KHE GDRZ61 27KHE GDRZ61 28KHE GDRZ72 27KHE GDRZ72 28KHE OPERATOR S MANUAL AA WARNING The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm California Proposition 65 Warning OMTCU17095 J2 North American Version Litho in U S A INTRODUCTION Using Your Operator s Manual This manual is an important part of your machine and should remain with the machine when you sell it An engine manufacturer s owner s manual has been provided with your machine This will provide maintenance and troubleshooting information for the engine installed in your machine Reading your operator s manual will help you and others avoid personal injury or damage to the machine Information given in this manual will provide the operator with the safest and most effective use of the machine Sections in your operator s manual are placed in a specific order to help you understand all the safety messages and learn the controls so you can operate this machine safely You can also use this manual to answer any specific operating or servicing questions The machine shown in this manual may differ slightly from your machine but will be similar enough to help you understand our
6. 11 Install castle nut C cotter pin B and cap A 12 Apply grease to lubrication fitting L 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 higher or lower by approximately 25 mm 1 in depending on the holes chosen for mounting the lever MX15352 e To mount in the high position mount the levers to the top four holes in the mounting bracket To mount in the low position mount the levers to the bottom four holes in the mounting bracket Checking and Aligning Motion Control Levers Optional Over the Lap Levers Check Alignment 1 Park machine safely See Parking Safely in the Safety section MX13126 2 Move both motion control levers A from the neutral lock to the neutral steer position 3 Check levers for equal alignment e Check gap B between the levers The recommended gap is 3 6 mm 1 8 1 4 in Service Steering amp Brakes 39 SERVICE STEERING 8 BRAKES NOTE If the ends of the levers strike against each other while in the neutral position move the levers to the neutral lock position and carefully bend them outward Move them back to
7. 1 Park machine safely See Parking Safely in the Safety section 2 Remove engine to deck drive and spindle drive belts 3 Remove mower blade See Checking and Replacing Mower Blades MX9222 4 Remove pulleys Right and Left Spindles A Remove nut B spacer C and pulley D e Center Spindle E Remove nut E drive pulley G and spindle pulley H Service Mower 49 SERVICE MOWER 5 Remove retaining ring spindle shaft J lower bearing K and spacer L from spindle housing M Discard bearing 6 Remove and discard upper bearing N 7 Clean entire assembly 8 Install a new lower bearing K and spacer L on the spindle shaft J IMPORTANT Avoid damage The clearance between the lower bearing and the housing is only 0 05 mm 0 002 in Do not force bearing into housing 9 Install the spindle shaft J lower bearing K and spacer L into the spindle housing M 10 Install the upper bearing N and retaining ring 1 11 Install upper pulleys e Right and Left Spindles A Install pulley D spacer C and nut B Tighten nut to 81 Nem 60 Ib ft e Center Spindle E Install spindle pulley H drive pulley G and nut F Tighten nut to 81 Nem 60 lb ft 12 Install mower blade blade washers and blade bolt assembly Tighten nut to 81 Nem 60 Ib ft See Checking and Replacing Mower Blades Service Mower 50 SERVICE ELECTRICAL W
8. 3 Pull PTO knob up to engage 4 Raise slightly off the seat Result The engine must stop Testing the Park Brake MIF 1 Stop machine on a 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 Operating 11 OPERATING Mounting and Dismounting Machine Safely AN o MX15340 Fa rat 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 Raising the Seat 1 Park machine safely See Parking Safely in the Safety section 2 Slide seat to full rear position MX15282 3 Lift seat frame A and tilt forward until it rests against the hinge stops Lowering the Seat 1 Stand on the side of the machine 2 Push operator seat back and slowly lower seat frame
9. 9 Remove dipstick Check oil level on dipstick oil level should be between the ADD and FULL marks e If oil is low add oil to bring oil level no higher than the FULL mark on dipstick e If oil level is above the FULL mark drain to proper level 10 Install and tighten dipstick Check Tire Pressure A CAUTION Avoid injury 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 maintain the correct tire pressure DO NOT inflate the tires above the recommended pressure Never weld or heat a wheel and tire assembly The heat can cause an increase in air pressure resulting in a tire explosion Welding can structurally weaken or deform the wheel 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 e Check tires for low pressure cuts bubbles damaged rims or missing lug bolts and nuts 1 Check tires for damage 2 Check tire pressure with an accurate gauge 3 Check that tires have correct pressure Add air if necessary Tire Size Pressure 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 Rear Chariot LX 24 x 12 12 69 97 kPa 10 14 psi Assembly 65 ASSEMBLY Install Motion Cont
10. IMPORTANT Avoid damage Dirt and debris can enter the engine through a damaged filter element e Do not wash paper element e Do not attempt to clean paper element by tapping against another object e Do not use pressurized air to clean element e 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 owners manual provided with your machine for the complete procedure Cleaning Engine Air Intake Screen and Fan IMPORTANT Avoid damage The engine is air cooled and requires a large amount of air intake when running Reduced air intake can cause overheating e Keep air intake screen and cooling fins clean e Keep covers and screens in place Keep air intake screens and engine cooling fins clear of debris to ensure proper cooling See the engine manufacturer s owner s manual provided with your machine for the complete procedure 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 Service Engine 27 SERVICE ENGINE Checking Spark Plug A CAUTION Avoid injury Touching hot
11. e Allow engine to cool before storing in any enclosure Never remove fuel cap or add fuel with engine running or hot Allow engine to cool for several minutes e Never store equipment with fuel in the tank inside a building where fumes may reach an open flame or spark Tire Safety MIF 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 Always maintain the correct tire pressure Do not inflate the tires above the recommended pressure Never weld or heat a wheel and tire assembly The heat can cause an increase in air pressure resulting in a tire explosion Welding can structurally weaken or deform the wheel Safety 8 SAFETY 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 e Check tires for low pressure cuts bubbles damaged rims or missing lug bolts and nuts Handling Fuel Safely Fuel and fuel vapors are highly flammable e Do not refuel machine while you smoke when machine is near an open flame or sparks or when engine is running Stop engine and allow to cool before filling e Never remove the fuel cap or add fuel with the engine running e Never fill fuel tank or drain fuel from a machine in an enclosed area Fill fuel tank outdoors e P
12. In an emergency situation simply disconnecting and reconnecting the connectors may clean up the contacts enough to restore operation at least temporarily IMPORTANT Avoid damage When performing voltage or continuity tests avoid putting excessive pressure on or against the connector pins Flat probes are recommended for testing to avoid spreading or bending the terminals If the MIL indicates a problem with the EFI system first disconnect the Electronic Control Unit ECU connector and test for continuity between the component connector terminals and the corresponding terminals in the ECU connector using an ohmmeter Little or no resistance should be measured indicating that the circuit is good If the condition cannot be corrected by checking the electrical system and connections the EFI system must be serviced by an authorized Kohler EFI servicing dealer Service Engine 30 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 MX15294 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 th
13. Park Brake Switch Test ooccccccccncccccccnncnnncncnnononononnnnnnns 11 Park Brake Adjust ooocccccnnccoccoocccccncncccnnnnnnrnnnncccnnanccnnnns 40 Park Brake Testing ooccconinnnnccccccccccncccnnnnnncnnnncccnnnnncnnnns 11 Park Brake Troubleshooting occcoccccccinnnocccccccnninccnnnns 62 Park Brake USING utopia reddit 13 Part Numbers Replacement cccceeeeeeeeeeeeeeeeeeees 22 Parts Replacement issssssssessssssrrrreneseestrrrrnnrnrnnseererene 22 Plastic and Painted Surfaces Avoid Damage 21 R Rear Drive Wheels Remove and Install 58 S Safety Systems Testing ooooooconccccnnnccnnoncnconcccnanananinacanano 10 Safety MO A aan gagap ewa danuka AAK ena eg aai dee 8 Safety Alert Symbol sanane aan anane a nenen n nane a nenen 1 Seat Switch Test a aranen naa e eea a anara naar a nenen ae 11 Seat Adjusting ccoooccccnnccconncccnonnccnnnccnnanncnnanncnnanacananncnnnno 12 Seat Install ooooconnoccccnnonoccccnononocnnnonocnnnnonnnncnnnnnnnnnnnnos 66 Seat Raise and LOWE ccccccscceccessseeeessstteeeesessneeeees 12 Service Interval Chart oooooocccccconoccccnconooncnnnononnnoncnnnnnncnnnns 23 Service RECOM miii tii Ka da 71 Service Lubrication ooomoccccnnnocccconcnononcnnnonnonnnnnnannncnnnns 24 Spark Arrestor Using ooocconnccconoccccnocccconncnnonacananacaninancnannrs 5 Spark Plugs Checking naen eaaa
14. 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 4 Connect the other end F of negative booster cable to a unpainted metal part of the disabled machine s engine 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 Replacing Fuse Carbureted Engines IMPORTANT Avoid damage When replacing fuses use only a 20 amp fuse or you may damage the circuit One 20 amp fuse is located behind the seat area MX15336 1 Remove defective fuse A from socket 2 Check metal clip in fuse window and discard fuse if clip is broken 3 Install new fuse in socket Replacing Fuses Fuel Injected Engines IMPORTANT Avoid damage When replacing fuses use only fuses of the same rating or you may damage the circuit Service Electrical 52 SERVICE ELECTRICAL MX15337 Chariot LX models equipped with Kohler EFI engines have three additional fuses One 10 amp fuse A used to protect the fuel pump circuit One 20 amp fuse B used to protect the main power circuit One 30 amp fuse C used
15. Belt Shields Removing and Installing 41 Mower Deck Cutting Height Adjusting 0annnaanaei 12 Mower Deck Drive Belt Check Adjust Tension 48 In 44 Mower Deck Drive Belt Check Adjust Tension 52 In 44 Mower Deck Drive Belt Check Adjust Tension 61 In 44 Mower Deck Drive Belt Remove Install 48 In 45 Mower Deck Drive Belt Remove Install 52 In 45 Mower Deck Drive Belt Remove Install 61 In 45 Mower Deck Foot Plate Removing and Installing 41 Mower Deck Level Check 0oooooocnccnccccccncccncnnnnonononononononos 66 Mower Deck Level coccccooonnncccncccconococcccnconanononononanacnnnnna 42 Index 70 INDEK Mower Deck Troubleshooting ccccccccinnnocccccccnniccccnnns 63 Mower Dismounting to Inspect seeen 21 Mower Engaging ccccconocccccnononnncncnancnccncnanancnncnannncnnncnnnns 19 MOWING TiPS saa Aan SAN ea aaa wak Kas baia ANE e WA ANA 20 Mowing Travel Speeds saanane aae anana anana nenen 21 N Neutral Start Switch Test 11 O Oil Level Checking Engine 26 Oil and Filter Changing Engine 26 OIL ENGINE iia rita lineas 26 Oil HydrauliC ee kaag Ia KAKE pa a KEN Aa a tia 31 Operating Checklist Daily 10 P PTO Clutch Burnishing coococnncccccncccconacininacaninacananacanannos 53 PTOS Witch TeSt aucem h raai a ia 11 PTO Switch Using coooocccnnccccnnccccnoncccnnancnanna conca ranccananors 14
16. Park Brake Lever C Seat Adjustment Lever D Hourmeter E Ignition Key Switch F PTO Knob G Choke Carbureted Engines Only 90 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 e Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area e Allow fresh outside air into the work area to clear the exhaust fumes out Operating 10 OPERATING 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 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
17. Plugged oil filter Plugged air intake filter Troubleshooting 60 TROUBLESHOOTING If Check Engine Backfires Through Muffler Throttle should be at low idle for several seconds before turning off machine Leaking damaged exhaust manifold gasket EFI system problem check EFI electrical system and connections If problem continues have system serviced by an authorized Kohler EFI servicing dealer High Fuel Consumption 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 EFI system problem check EFI electrical system and connections If problem continues have system serviced by an authorized Kohler EFI servicing dealer Electrical System H Check Starter Will Not Work 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 connections 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 Battery Will Not Charge Loose or corroded battery or ground connections Blown fusible link charging circuit Battery cables and te
18. and or wooden blocks 4 Check mower blades e Mower blades should be sharp and free of any damage e Inspect blades sharpen balance or replace as necessary Service Mower 47 SERVICE MOWER Replacing Mower Blades A F es La MX15357 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 e Blade wing must face toward top of mower deck IMPORTANT Avoid damage When installing the blade e Make sure the blade is properly seated on the spindle e Make sure the concave side of the large washer faces toward the blade e Install blade bolt B blade D three 1 4 in washers C and nut A e Tighten blade nut to 81 Nem 60 lb ft 4 Lower machine 5 Adjust mower deck to a desirable cutting height Sharpening Blades A CAUTION Avoid injury Mower blades are dangerous e Always wear gloves while working on blades e Always wear safety eye protection when grinding e Sharpen blades with grinder hand file or electric blade sharpener e MX8333 e Keep original bevel A when grinding e Blade should have 0 40 mm 1 64 in cutting edge B or less e Balance blades before installing Balancing Blades A CAUTION Avoid injury Mower blades are sharp Always wear gloves when handling mower blades or worki
19. establishment or individual Warranty repairs must be performed by an authorized Great Dane servicing dealer 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 e Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area e Allow fresh outside air into the work area to clear the exhaust fumes out Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes Use oil that meets the following specification e See the engine manufacturer s owners manual provided with your machine for the correct specifications Checking Engine Oil Level IMPORTANT Avoid damage Failure to check the oil level regularly could lead to serious engine problems if oil level is low e Check oil level before operating e Check oil level when the engine is cold and not running e Keep level between the FULL and ADD marks Shut off engine before adding oil NOTE Check oil twice a day if you run engine over 4 hours in a day Make sure engine is cool when checking engine oil level 1 Park machine safely See Parking Safely in the Safety section 2 Allow engine to cool 3 Clean area around dipstick to preven
20. instructions RIGHT HAND and LEFT HAND sides are determined by facing in the direction the machine will travel when going forward When you see a broken line the item referred to is hidden from view Special Messages Your manual contains special messages to bring attention to potential safety concerns machine damage as well as helpful operating and servicing information Please read all the information carefully to avoid injury and machine damage A CAUTION Avoid injury This symbol and text highlight potential hazards or death to the operator or bystanders that may occur if the hazards or procedures are ignored IMPORTANT Avoid damage This text is used to tell the operator of actions or conditions that might result in damage to the machine NOTE General information is given throughout the manual that may help the operator in the operation or service of the machine Introduction PRODUCT IDENTIFICATION Record Identification Numbers Chariot MOWER DECK MODEL NUMBER C GDRZ48 17KAE GDRZ48 19KAE GDRZ52 23KAE GDRZ52 25KAE GDRZ52 25KHE MOWER DECK SERIAL NUMBER C GDRZ61 25 KAE GDRZ61 25KHE Serial No 010001 Chariot LX GDRZ61 25KAE GDRZ61 25KHE GDRZ61 26KHE GDRZ61 27KHE GDRZ61 28KHE GDRZ72 27KHE GDRZ72 28KHE Serial No 010001 If you need to contact an Authorized Service Center for information on servicing always provide the product model and serial numb
21. 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 Right side motion control lever inward e Left side motion control lever inward e Both motion control levers inward 1 Move motion control lever s out of the neutral detent position standard levers or neutral lock position optional 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 Testing Seat Switch Procedure 1 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 Unlock the park brake 3 Push PTO knob down to disengage 4 Turn key switch to the start position 5 Raise slightly off the seat Result The engine must stop Procedure 2 1 Start engine 2 Lock the park brake A CAUTION Avoid injury Before engaging mower make sure that area is clear of bystanders especially children
22. to protect the charge circuit 1 Remove defective fuse from socket 2 Check metal clip in fuse window and discard fuse if clip is broken 3 Install new fuse into 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 53 SERVICE ELECTRICAL Wiring Schematic Carbureted Engines Sa PIT wor yov a 0617 ts HOLIMS TVHLNIN P691 OV1E WE HOLIMS IWVELNIN Wor MOTISA WEI L3IHS LNO Dee 1 907 spent IJ DEL v091 mO1134 TON MOTISA WY LNAN NI L4IHS LNO PO9I MOTIZA MH AUVd uo eye1q NI yo seg SCHO PONTE aE oeh HOLIMS 1V3S ebo NMGHA AHalIva Hee MAUVAS JINON A O OIONTIOS Tana ANTIOH LYVLS stat uo a O ezg Een AWI38 3dO PODI NMOHE Sara ui 440 HOLIMS Old ano NO E Si SS Uvas NO H uwas 440 H
23. 60 lb ft Cutting Wd 1 22 m 48 in Cutting Height approximate 25 to 127 mm 1 to 5 in Specifications 68 SPECIFICATIONS Height Adjustment Increments 13 mm 1 2 in 52 Inch Mower Deck Mower Type Mulch Bag or Side Discharge Cutting Blades 3 Blade Bolt Torque 81 Nem 60 lb ft Cutting Width aaua 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 Type Mulch Bag or Side Discharge Cutting Blades 3 Blade Bolt Torque 81 Nem 60 lb ft Cutting Width uaaa 1 55 m 61 in Cutting Height approximate 25to 127 mm 1 to 5 in Height Adjustment Increments 13 mm 1 2 in 72 Inch Mower Deck Mower Type Mulch Bag or Side Discharge Cutting Blades 3 Blade Bolt Torque 81 Nem 60 lb ft Cutting Width 1 83 m 72 in Cutting Height approximate 25 to 127 mm 1 to 5 in Height Adjustment Increments 13 mm 1 2 in increments Specifications and design subject to change without notice Specifications 69 INDEK A Air Cleaner Elements Checking and Cleaning 27 ASSOMDIY sawa rara ea saa anae a aa cdt Di 65 B Balancing Blades AA 48 Battery Cleaning saeeaeseeaaee aana anana nana anana naene 51 Battery Re
24. 885 MX15274 e 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 e 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 injury from tipover drive across slopes not up and down If machine stops going uphill stop blades and back down slowly A 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 po detener las cuchillas y bajar Be en retroceso MX15340 TCU15907 To avoid injury from tipover drive across slopes not up and down lf machine stops going uphill stop blades and back down slowly WARNING A ADVERTENCIA Para evitar ser lesionado por las correas en movi miento mantener AWARNING To avoid injury trom rotating belts keep all shields and guards in place todos los escudos y protectores en su lugar det BE r TCU51051 MX15340 To avoid injury from rotating belts keep all shields and guards in place Safety 2 WARNING SAFETY A WARNING Hot surface CAUTION
25. 95 J2 English Table of Contents SAFETY Understanding The Machine Safety Labels Safety Alert Symbol The machine safety labels shown in this section are placed in important areas on your machine to draw attention to potential safety hazards On your machine safety labels the words DANGER WARNING and CAUTION are used with this safety alert symbol DANGER identifies the most serious hazards The operator s manual also explains any potential safety hazards whenever necessary in special safety messages that are identified with the word CAUTION and the safety alert symbol DANGER di DANGER A PELIGRO Para evitar las lesiones parar la segadora cuando hay ni os en las careanias e Ho corter en retroceso Q Mirar hacla atr s mientras 86 hage retroceder la m quina Runga llgvar pasajaras especialmento los ni os carry riders especially children TCU51336 MX15340 To avoid injury to children stop mower when children are near Do not mow in reverse Look behind when backing Never carry riders especially children DANGER A DANGER A PELIGRO To avoid injury Para evitar Lily from rotating lesiones causadas bladas slay por las cuchillas k clear af deck mantenerse alejado edge del borde de la plelalorma de corte M131739 MX15340 To avoid injury from rotating blades stay clear of deck edge DANGER
26. ARNING Battery posts terminals and related accessories contain lead and lead components chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Removing and Installing the Battery A CAUTION Avoid injury The battery produces a flammable and explosive gas The battery may explode Do not smoke near battery e Wear eye protection and gloves e Do not allow direct metal contact across battery posts e Remove negative cable first when disconnecting e Install negative cable last when connecting Removing 1 Park machine safely See Parking Safely in the Safety section MX15326 2 Slide black cover A away from the negative battery terminal and disconnect the negative battery cable B 3 Slide red cover C away from the positive battery terminal and disconnect the positive battery cable D 4 Remove nuts E and washers from both sides of the bracket F 5 Remove bracket F and J bolts G 6 Remove battery H Installing 1 Install battery H using J bolts G bracket F 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 A and C over battery terminals Cleaning Battery and Terminals A CAUTION Avoid injury The battery produces a flammable and explosive g
27. Adjusting Seat Front to Back Adjustment 1 Sit on the operator seat MX15280 Picture Note Chariot LX suspension seat shown 2 To adjust the seat front to back push and hold the seat adjustment lever A away from the seat 3 Slide forward or backward to desired position 4 Release lever Seat Height Adjustment Chariot LX only 1 Sit on the operator seat 2 To lower the seat turn knob B counterclockwise 3 To raise the seat turn knob B clockwise Adjusting Mower Deck Cutting Height A CAUTION Avoid injury Before adjusting cutting height stop engine and lock the park brake 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 in increments The deck can also be raised and locked in a transport position to provide maximum ground clearance when moving the machine from one area to another 1 Park machine safely See Parking Safely in the Safety section Operating 12 OPERATING d MX13149 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 pS MX13155 5 Allow the mower deck lift lever A to rest against the HOC adjustment pin C Adjusting M
28. CE MOWER MX15328 4 Check the engine to deck drive belt 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 e To increase belt tension Turn nut A clockwise e To decrease belt tension Turn nut A counterclockwise Checking and Adjusting Spindle Drive Belt Tension 72 Inch Mower Deck 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 MX15327 4 Check the spindle drive belt A 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 an 2 mm 1 16 in gap between the spring coils e To increase belt tension Turn nut B clockwise e To decrease belt tension Turn nut B counterclockwise Removing and Installing Mower Deck Drive Belt 48 52 and 61 Inch Mower Deck 1 Park machine safely See Parking Safely in the Safety section 2 Raise foot platform 3 Remove mower deck drive belt covers bh MX15317 4 Release mower deck drive belt tension by turning the tension adjuster nut A counterclockwise 5 Remove mower deck d
29. M117554 MX15274 HELP AVOID INJURY Emission Compliance Period Emission Control System Certification Label NOTE Tampering with emission controls and components by unauthorized personnel may result in severe fines or penalties Emission controls and components can only be adjusted by EPA and or CARB authorized service centers Contact your Great Dane Equipment Retailer concerning emission controls and component questions The presence of an emissions label signifies that the engine has been certified with the United States Environmental Protection Agency EPA and or California Air Resources Board CARB The emissions warranty applies only to those engines marketed by Great Dane that have been certified by the EPA and or CARB and used in the United States and Canada in off road mobile equipment If your engine has the emission compliance category listed on the emission control system certification or air index label this indicates the number of operating hours for which the engine has been certified to meet EPA and or CARB emission requirements The following table provides the engine compliance period in hours associated with the category found on the certification label Agency Category Hours EPA C 250 A A F a a a E AYUDA GE E PA B 500 Abed gah a a da onago apara Koop shie elds in 1 placa lt Mantan Ll e on su Jugar EPA A 1000 eg e bal ERA ES CEE CARB Mode
30. OLM Old A Ve MET um 0014 sees Y aa OTE Pa Kl HOLIMS NOILINDI NIN ROOM r EENG HERR SIS lo GI g L a F OS MOVIE PONTE Bar MOVIE Sat Av 909 Y3LYVLS NOILLINO Lid HOLVLS L UY 9mid AUVAS JINON NOLLINO 3411934 YHOLVINDSY re Wo y YO 9b LWN OS 01 EELER EI Tons TUVIS INON NAN E LOSLOLINY Nid tN INON 3301 DIVA LINDH NOLLISO4 IER z Nu 340 d HOLIMS NOLLINO MX15338 Service Electrical 54 SERVICE ELECTRICAL Wiring Schematic 26 HP Fuel Injected Engine Deen Lag ie El ALLY el Taran Szen Ll ajonnos Pl eau r E mig E HOTS NOUNS TS Ken voz Bnd MX15345 ITAD HOIDINNOD O L ASW Service Electrical 55 SERVICE ELECTRICAL Wiring Schematic 28 HP Fuel Injected Engine e LAND EH HOLAS VALAN sh IAS NO Samoni 6 al AE Datei Ca agin Ra SES UN KE WT dD er Ee
31. OS p44 oons ll f EEE a E d o EEIEE sovna OSA OS OL voL asna TENT SEN DECH KEN AAA YOLDANNOD SONDA EEN NOUINS EES NOILINDL Indino 7 savas STAD YOLANNOD I L ISW MX15356 Service Electrical 56 SERVICE MISCELLANEOUS Filling Fuel Tank Use regular grade 87 octane unleaded fuel For gasoline engines only A CAUTION Avoid injury Fuel vapors are explosive and flammable e Shut engine off before filling fuel tank e Do not smoke while handling fuel e Keep fuel away from flames or sparks e Fill fuel tank outdoors or in well ventilated area e Clean up spilled fuel immediately e Use clean approved non metal container to prevent static electric discharge e Use clean approved plastic funnel without screen or filter to prevent static electric discharge Checking Tire Pressure MIF IMPORTANT Avoid damage Dirt and water in fuel can cause engine damage e Clean dirt and debris from the fuel tank opening e Use clean fresh stabilized fuel e Fill the fuel tank at the end of each day s operation to keep condensation out of the fuel tank Use a non metallic funnel with a plastic mesh strainer when filling the fuel tank or container NOTE Capacity of fuel tank is 30 2 L 8 gal 1 Stop engine and let it cool several minutes before adding fuel 2 Remove a
32. OTING If Check Engine Runs Rough or Stalls Plugged fuel filter Plugged air intake system Fuel cap vent dirty Stale or improper fuel fuel level Spark plug not gapped correctly Replace spark plug Carbureted Engines Only Choke adjusted incorrectly See your Great Dane servicing dealer EFI system problem check EFI electrical system and connections If problem continues have system serviced by an authorized Kohler EFI servicing dealer Engine Knocks Engine oil level low Reduce load Slower ground speed Fuel is bad Fill tank with fresh fuel correct octane Idle speed too slow EFI system problem check EFI electrical system and connections If problem continues have system serviced by an authorized Kohler EFI servicing dealer Engine Overheats Clean cooling fins Low oil level Do not operate at slow idle Operate at full throttle setting Cooling air intake screen is dirty Plugged air intake filter Operating at too fast ground speed for conditions Engine Lacks Power 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 EFI system problem check EFI electrical system and connections If problem continues have system serviced by an authorized Kohler EFI servicing dealer Engine Uses Too Much Oil Find and correct oil leaks Incorrect engine oil
33. a ANAK Ka SANAN a BA Na DE ag A NA Nga ON 24 H Hourmeter Using bs 15 Hydraulic Oil YAA AAN A ANA NA A MENE a a a EN EEN 31 Hydraulic Oil Change saaeesanen ane ane aane anana nane 31 Hydraulic Oil Check Level aaaananan anane nenen anane 31 Hydraulic Pump Free Wheel Valves Using 20 Hydraulic Pump Clean Cooling Fins 32 Hydraulic System Hose Routing oooccccccoooccccconconccnccnnnnss 35 Hydraulic System Schematic coooooccccccnooccccccnoonnnnnnnnnnnos 36 K Key Switch Using cceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseaeeeeneees 14 L Labels Safety sits ccicee tetas aida 1 Linkages Check and Adjust Motion Control 33 Lubrication Points ccccccceeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeess 24 M Machine Transporting conocccccnnnoncccnnnnccccnnnnnnnrnnanonnnn nos 20 Metal Surfaces Repairing and Cleaning n se 58 Motion Control Levers Check and Align c eeeee 39 Motion Control Levers Installing oooooconnn nnnnnn 66 Motion Control Levers USING cooooccccccnnocccnccnoonnnnnnnnnnnos 15 Motion Control Linkages Check and Adjust 33 Mower Blades Balance ccsccccceceeesseeeeeeteeesseeeeeees 48 Mower Blades Check and Replace ssie 47 Mower Blades Sharpen ccccccsscccccsssseeceeessnteeeeesenaes 48 Mower Deck Anti Scalp Wheels Adjusting 13 Mower Deck
34. aaa nenen anana anana nane 28 Specifies onien TENANE a ida 68 Specifications 48 Inch Mower Deck cceeeeeeeees 68 Specifications 52 Inch Mower Deck cceeceeseeeees 69 Specifications 61 Inch Mower Deck c cceeeeseeeees 69 Specifications 72 Inch Mower Deck ccccceeeeeeees 69 Spindle Bearings Replace 72 Inch Mower Deck 49 Spindle Bearings Replace 48 52 and 61 In Decks 48 Spindle Drive Belt Check and Adjust Tension 45 47 Spindle Drive Belt Remove and Install 47 Steering Troubleshooting cccoonccccnnncccnonccconcccnanccaninncanano 62 Storage Preparing Fuel and Engine 64 Storage Preparing Machine cc ccccceessseessesneeees 64 Storage Removing Machine eseeeeseeereerrsere 64 Storing Safety occoncccconiciccnocinnnannnnannncnnn cnn nano cnn oca nana cnn 64 T Testing Park Brake AA 11 Testing Safety Systems anaa aaanee naa ne naa a nenen anane 10 Throttle Lever Using cccccccccccnnnnconconccccncncccnnnanananancncnnos 15 Tire Pressure CHECKING 57 Tire Specifications Chariot coooocccccnnooccccnnononannnconnnnnnnos 68 Tire Specifications Chariot LN 68 Traction Drive Belt Remove and Install 32 Transporting Machine sssesessesaneneananenaanen e nananenan 20 Travel Speeds MOWING 0saseanee anana ane aane a naa nnene 21 Troubleshooti
35. amaged or worn Machine Will Not Follow a Straight Path Steering tracking out of adjustment Troubleshooting 62 TROUBLESHOOTING If Check Machine Moves to the Left or Right With Engine Running and Transmission in Neutral Pump linkage neutral position out of adjustment Mower Deck If Check Discharge Chute Plugged 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 Mower Deck Vibrates Run engine at full throttle Loose hardware Check replace mower deck drive belt Check replace spindle drive belt 72 inch mower deck 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 Blades Do Not Engage Mower deck drive belt slipping or broken Spindle drive belt slipping or broken 72 inch mower deck 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 Mows Unevenly Mower deck not properly leveled Ground speed too fast for conditions Run engine at full throttle Reduce ground speed when making turns Blades are bent or worn Sh
36. arpen or replace blades Change mowing pattern Check tire pressure Troubleshooting 63 STORAGE Storing Safety A 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 e Do not store vehicle with fuel in the tank inside a 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 Clean under the deck and remove grass and debris from inside chute 4 Wash the machine and apply wax to metal surfaces 5 Run machine for five minutes to dry belts and pulleys 6 Apply light coat of engine oil to pivot and wear points to prevent rust Preparing Fuel and Engine for Storage Fuel If you have been using Stabilized Fuel add stabilized fuel to tank until the tank is full NOTE Filling the fuel tank reduces the amount of air in the fuel tank and helps reduce deterioration of fuel If you are not using Stabilized Fuel 1 Park machine safely in a well ventilated area NOTE Try to anticipate the last time the machine will be used for the season so very little fue
37. as The battery may explode e Do not smoke near battery e Wear eye protection and gloves e Do not allow direct metal contact across battery posts e Remove negative cable first when disconnecting e Install negative cable last when connecting 1 Disconnect and remove battery 2 Wash battery with a solution of four tablespoons of baking soda to one gallon of water Be careful not to get the soda solution into the battery cells 3 Rinse the battery with plain water and dry 4 Clean terminals and battery cable ends with wire brush until bright 5 Install battery 6 Attach cables to battery posts using washers and nuts H 7 Apply petroleum jelly or silicone spray to terminals to prevent corrosion Service Electrical 51 SERVICE ELECTRICAL Using Booster Battery MIF TS204 A CAUTION Avoid injury The battery produces a flammable and explosive gas The battery may explode e Do not attempt to jump start a frozen battery Warm to 16 degrees C 60 degrees F Do not smoke near battery e Wear eye protection and gloves e Keep sparks and flames away e Do 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 e Do not cross jump the battery damage to electronic modules will result M71044 A Booster Battery B Disabled Vehicle
38. atform hinges two places Lubricate pump control arms five places Lubricate control lever pivot shafts two places Lubricate throttle cable Lubricate choke control cable Carbureted Engines Only Annually Inspect all spindle bearings 6 Replace as needed Inspect all mower deck idler pulleys 3 Replace as needed Remove and inspect caster wheel roller bearings clean and pack with grease Replace as needed 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 Clean power unit Change hydraulic oil and filter annually or 500 hours whichever comes first Check all bolts and nuts tighten as needed Remove battery Clean battery and holder Replace spark plugs Service Intervals 23 SERVICE LUBRICATION Grease IMPORTANT Avoid damage 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 MX15319 e Grease mower deck thrust arms D located at the rear Use a general purpose petroleum based spray lubricant g purp P pray of the mower deck Lubrication Points MX15287 e Apply grease to three spindle bear
39. awasaki Engine 61 in Deck 501 kg 1104 Ib 25 hp Kohler Engine 61 in Deck 501 kg 1104 Ib 26 hp Kohler Engine 61 in Deck 501 kg 1104 Ib 27 hp Kohler Engine 61 in Deck 500 kg 1103 Ib 28 hp Kohler Engine 61 in Deck 501 kg 1104 Ib 27 hp Kohler Engine 72 in Deck 545 kg 1202 Ib 28 hp Kohler Engine 72 in Deck 545 kg 1202 Ib Travel Speeds Forward 0 14 km h 0 9 mph Reverse 0 2 2 0 eee eee eee 0 8 km h 0 5 mph Dimensions Chariot Wheel Base 1 10 m 43 375 in Track Width 1 21 m 47 5 in Overall Height 1 09 m 42 75 in Overall Length with Kawasaki Engines 1 92 m 75 5 in Overall Length with Kohler Engines 1 97 m 77 75 in 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 Dimensions Chariot LX Wheel Base 2 0 1 27 m 49 875 in Track Width 1 35 m 53 in Overall Height 1 22 m 48 in Overall Length with Kawasaki Engines 2 00 m 78 75 in Overall Length with Kohler Engines 2 06 m 81 in Overall Width with 61 in Deck 1 86 m 73 375 in Overall Width with 72 in Deck 2 13 m 83 75 in 48 Inch Mower Deck Mower Type Mulch Bag or Side Discharge Cutting Blades 0 0 uaaa 3 Blade Bolt Torque 81 Nem
40. bystanders may be injured by run over and rotating blades Before traveling forward or rearward e Carefully check the area around the machine e Disengage the 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 e The farther forward the control levers are moved the faster the machine will travel e Forward speed range 0 14 km h 0 9 mph 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 Operating 16 OPERATING Forward MX13114 e Push both motion control levers forward at the same time Reverse MX13115 e Pull both control levers past center rearward at the same time Gentle Left Turn MX13116 e Push right control lever farther forward than the left control lever Gentle Right Turn MX13117 e Push left control lever far
41. codes to aid service These codes can be accessed only by an authorized Kohler EFI servicing dealer When troubleshooting a problem with the Kohler EFI system basic engine operating problems must be eliminated before faulting the EFI system components What appears to be an EFI problem could be something as simple as a fuel tank with debris in the bottom or a plugged vent Be sure the engine is in good mechanical operating condition and other systems are operating properly before attempting to troubleshoot the EFI system The EFI system is a 12 VDC negative ground system designed to operate down to a minimum of 7 0 volts If the system voltage drops below this level the operation of voltage sensitive components such as the ECU fuel pump and injectors will be intermittent or disrupted causing erratic operation or hard starting A fully charged 12 volt battery with a minimum of 250 cold cranking amps is important in maintaining steady and reliable system operation Battery condition and state of charge should always be checked first when troubleshooting an operational problem Service Engine 29 SERVICE ENGINE Keep in mind that EFl related problems are more often caused by the wiring harness or connections than by the EFI components Even small amounts of corrosion or oxidation on the terminals can interfere with the milliampere currents used in system operation Cleaning the connectors and grounds will solve problems in many cases
42. di PELIGRO No usar la ADANGER M137637 MX15340 Do not mow without discharge chute or entire grass catcher in place Safety 1 SAFETY DANGER A DANGER A PELIGRO To avoid injury from Para evitar sufrir lesiones rotating blades and thrown objects stay clear of deck edge and keep others away Do not mow without discharge chute or entire grass catcher causadas por cuchillas giratorias y objetos lanzados manteerse alejado del borde de la plataforma de corte y mantener a las demas personas alejadas dela maquina No usar la maquina sin el tubo de desarga o sin el recogedor in place de paso en su lugar MINA M131748 MX15340 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 EXPLOSIVE GASES POISON CAUSES SEVERE BURNS ADANGER POISON EXPLOSIVE GASES 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 in struction and training Keep vent caps tight and level 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 imme diately Keep out of reach of children TCU14
43. e a drain pan under hoses to catch any fuel that may be left in hoses MX15300 Picture Note Kawasaki engine shown 4 Disconnect fuel hose A from the outlet side of fuel filter B and drain gasoline into a properly marked container 5 Remove fuel filter from inlet fuel hose C Discard filter IMPORTANT Avoid damage When installing a new fuel filter the filter arrow must be pointing in the direction of fuel flow Make sure clamps are installed properly 6 Connect a new fuel filter to hoses Make sure fuel filter is installed with arrow pointing in direction of fuel flow Replacing Fuel Filter Fuel Injected Engines A CAUTION Avoid injury Fuel vapors are explosive and flammable Do not smoke while handling fuel e Keep fuel away from flames or sparks e Shut off engine before servicing e Cool engine before servicing e Work in a well ventilated area e Clean up spilled fuel immediately 1 Park machine safely See Parking Safely in the Safety section 2 Allow engine to cool 3 Place a drain pan under hoses to catch any fuel that may be left in hoses Service Engine 28 SERVICE ENGINE A CAUTION Avoid injury Fuel system under pressure Wear personal eye protection when disconnecting fuel hoses to guard against spraying fuel MX15301 4 Disconnect fuel hose A from the outlet side of fuel filter B and drain gasoline into a prope
44. e 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 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 MX15294 4 Remove cap A from oil reservoir tank filler neck MX15312 5 Turn hydraulic oil filter B counterclockwise to remove 6 Allow hydraulic oil to drain into a drain pan with at least a 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 is approximately 1 9 L 2 0 qt Total system capacity is approximately 3 5 L 3 75 qt 9 Fill oil reservoir with approximately 1 9 L 2 0 qt of oil 10 Install reservoir cap Service Transmission 31 SERVICE TRANSMISSION A CAUTION Avoid i
45. earn the use of all controls e Operator experience is required to learn the moving stopping turning and other operating characteristics of the machine Operating Safely MIF e Only allow responsible adults who are familiar with the instructions to operate the machine Local restrictions may restrict the age of the operator e Inspect machine before you operate Be sure hardware is tight Repair or replace damaged badly worn or missing parts Replace faulty silencers Be sure guards and shields are in good condition and fastened in place Make any necessary adjustments before you operate e Before using always visually inspect to see that the blades blade bolts and the mower assembly are not worn and damaged Replace worn and damaged blades and bolts in sets to preserve balance e Be sure all drives are in neutral and parking brake is locked before starting engine Only start engine from the operator s position Do not change the engine governor settings or overspeed the engine Operating the engine at excessive speed can increase the hazard of personal injury Do not operate mower without discharge chute or entire grass catcher in place Never operate with the discharge deflector raised removed or altered unless using a grass catcher e Check brake action before you operate Adjust or service brakes as necessary e Stop machine if anyone enters the area e If you hit an object or if abnormal v
46. el Bolts e A serious accident could occur causing serious injury if wheel bolts are not tight e Check wheel bolt tightness often during the first 100 hours of operation e Wheel hardware must be tightened to specified torque using the proper procedure anytime it is loosened Safety 6 SAFETY Wear Appropriate Clothing Y EA gt aa MB mm MIF e Always wear safety goggles or safety glasses with side shields and a hard hat when operating the machine e Wear close fitting clothing and safety equipment appropriate for the job e While mowing always wear substantial footwear and long trousers Do not operate the equipment when barefoot or wearing open sandals e Wear a suitable protective device such as earplugs Loud noise can cause impairment or loss of hearing Driving Safely on Public Roads S lt 7 ES AR ait e A y e Use safety lights and devices Slow moving machines when driven on public roads are hard to see especially at night MIF e Whenever driving on public roads use flashing warning lights and turn signals according to local regulations Extra flashing warning lights may need to be installed Practice Safe Maintenance MIF e Only qualified trained adults should service this machine e Understand service procedure before doing work Keep area clean and dry e Never lubricate service or adjust machine while it is movin
47. ers You will need to locate the model and serial numbers for the machine and for the engine of your machine and record the information in the spaces provided DATE OF PURCHASE DEALER NAME DEALER PHONE MX15355 MODEL NUMBER POWER UNIT A SERIAL NUMBER POWER UNIT A ENGINE MODEL NUMBER B ENGINE SERIAL NUMBER B ENGINE SPECIFICATION NUMBER B Product Identification TABLE OF CONTENTS Safety A A RSs Nang a TE A Cate Gg r a ga a Ba ab E a aka O 1 Operation tas 10 Replacement Paris oia at iba 22 Service Jrlepvale eege A cae We ca See ve A AA A Dhaka E 23 Service LubricaliON eendeiteg anak b pa R aa AA pana aan aan AE kaa Aak Nan ab da ank a BEN EE ah a DA E hacias ade espia sisas 24 e NIE e Un 26 Service Transmission novere AE AA NANG GA AB aa ge ae aga AGA Daha AB PG A E E 31 elle KETTEN 37 SEIVICS TE 41 NS EE 51 Service TE TEE TEE 57 leiren e WEE 59 MOMO it lO ITA SENG NANA AS Ta 64 ASSOMDIY EE 65 ee EE 68 nie TEE 70 Serice Record GO aaa kaag A A cae Ba ag sia Ba a A at daw a S AE ace AA EE AAA E eal aaa a A dd 71 All information illustrations and specifications in this manual are based on the latest information at the time of publication The right is reserved to make changes at any time without notice COPYRIGHTO 2002 Deere A Co John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHTO OMTCU170
48. g Keep safety devices in place and in working condition Keep hardware tight e Keep hands feet clothing jewelry and long hair away from any moving parts to prevent them from getting caught e Lower attachments to the ground before servicing machine Disengage all power and stop the engine Lock park brake and remove the key Let machine cool e Disconnect battery or remove spark plug wire for gasoline engines before making any repairs e Before servicing machine carefully release pressure from any components with stored energy such as hydraulic components e Keep all nuts and bolts tightened especially blade attachment bolts e Securely support any machine elements that must be raised for service work Use jack stands or lock service latches to support components when needed e Never run engine unless park brake is locked e Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Replace all worn or damaged safety and instruction decals e Grass catcher components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Check components frequently and replace with manufacturer s recommended parts when necessary e To prevent fires remove any buildup of grease oil or debris from the machine especially the engine compartment Safety 7 SAFETY e Charge batteries in an open well ventilated area a
49. g Level Front to Rear IMPORTANT Avoid damage Adjust the left and right deck lift assist rods equally NOTE Adjust side to side mower level before adjusting front to rear level Chariot LX model is equipped with a deck lift assist rod on each side of machine Adjust both sides of the mower deck equally MX15285 1 Loosen jam nut D on deck lift assist rod 2 While positioned in front of the machine adjust mower level e Turn hex nut E counterclockwise F to lower front of mower deck e Turn hex nut E clockwise G to raise front of mower deck 3 For Chariot LX model repeat for other side Verify that the adjustment on right and left sides is equal 4 Tighten jam nuts 5 Check front to rear mower level Checking and Adjusting Cutting Height A CAUTION Avoid injury Rotating blades are dangerous Before adjusting or servicing mower e Disconnect spark plug wire s to prevent engine from starting accidentally Always wear gloves when handling mower blades or working near blades Checking Thrust Arm to Stop Rod Clearance Transport Position 1 Set mower deck to transport fully raised position MX15342 2 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 V b a a D eu lm E e
50. g 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 motion 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 Avoid Damage to Plastic and Painted Surfaces e Do not wipe plastic parts unless rinsed first e Insect repellent spray may damage plastic and painted surfaces Do not spray insect repellent near machine e Be careful not to spill fuel on machine Fuel may damage surface Wipe up spilled fuel immediately Operating 21 Parts REPLACEMENT PARTS We recommend Great Dane guality parts available at your Great Dane dealer Part numbers may change Use part numbers listed below when you order lfa number changes your dealer will have the latest number When you order paris your Great Dane dealer needs your machine model and serial numbers and engine serial number These are the numbers that you recorded in the Product Identification section of this manual Part Numbers
51. he engine is provided with a fuel shut off valve turn the fuel off at the conclusion of mowing e When machine is left unattended stored or parked lower the mower deck unless a positive mechanical lock is used Safety 4 SAFETY 7 Wait for engine and all moving parts to stop before you 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 Re Y S gt SS e Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job MIF e Clear mowing area of objects that might be thrown Keep people and pets out of mowing area e 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 e Study mowing area Set up a safe mowing pattern Do not mow where tract
52. his 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 A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the vehicle to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation e Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area e Allow fresh outside air into the work area to clear the exhaust fumes out 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 in an open area Drive the machine forward if the machine drifts to the right or left adjust the transmission c
53. ibration occurs stop and inspect the machine Make repairs before you operate Keep machine and attachments properly maintained and in good working order Be aware of the mower discharge direction and make sure that no one is in the path of the discharge direction Do not leave machine unattended when it is running e Only operate during daylight or with good artificial light e Stop the blades rotating before crossing surfaces other than grass e Use only accessories and attachments approved by the manufacturer of the machine Keep safety labels visible when installing accessories and attachments Do not operate machine if you are under the influence of drugs or alcohol e Check before each use that operator presence controls are functioning correctly Test safety systems Do not operate unless they are functioning correctly e Always wear seat belt if machine has a standard ROPS or a folding ROPS in the upright position e Never raise mower decks when blades are running e Slow down and be careful of traffic when operating near or crossing roadways Stop blades before crossing roads or sidewalks Use care when approaching blind corners shrubs trees or other objects that may obscure vision Do not wear radio or music headphones Safe service and operation require your full attention e Disengage drive to attachments when transporting or not in use Reduce the throttle setting during engine run out and if t
54. ing 27 Engine Oil and Filter Changing s es 26 Engine Warranty Maintenance Statement 0seeeseeee 26 Engine and Fuel Storage Preparing seses 64 Engine Checking Oil Level ccsecececeeseeeeeeeeeeeteaes 26 Engine Specifications sranane anana na ana nen ananan 68 Engine Starting z saas esri pani a ANA La GAE n a ENE Kn Kas 18 Engine Stopping sasa sas aia as aaa aaa ak aaa GA aa sn aaa 19 Engine Troubleshooting A 59 Engine to Deck Belt Check Adjust Tension 72 In 44 Engine to Deck Drive Belt Remove Install 72 In 46 F Filter Changing Engine Oil and n 26 Front Caster Spindle Bearings Adjust cceeee 38 Front Caster Spindle Bearings Service 38 Front Caster Wheels Remove and Install 37 Front Caster Wheels Service Bearings Chariot 37 Front Caster Wheels Service Bearings Chariot LX 37 Fuel Filter Replacing Fuel Injected Engines 28 Fuel Filter Replacing Carbureted Engines 28 Fuel Injectors Prime 29 Fuel Sate asa aaa aa aa aga NA AE aga nae ean ie 9 Fuel Tank Filling ss awanan as ani a agen aga Kusa KENA NAHEN naga GENE 57 Fuse Replace Carbureted Engines seaeeea eaaa a nean n anaa a anane 52 Fuses Replacing Carbureted Engines 52 Fuses Replacing Fuel Injected Engines 52 G GIO ASO aaa knek a Da
55. ings E until grease is expelled from vent F on spindle housings P d e Chariot LX only Grease caster wheel bearings A MX15286 e Grease caster wheel spindle bearings B MX15320 e Grease traction drive belt tension arm pivot G MX15289 e Grease HOC shafts C two points on each side of the machine Service Lubrication 24 SERVICE LUBRICATION MX15288 e 48 51 and 61 Inch Mower Deck Grease mower deck drive belt tension arm H MX15331 e 72 Inch Mower Deck e Grease engine to deck drive belt tension arm I e Apply spray lubricant to the spindle drive belt tension arm J NOTE Use spray lubricant to lubricate the following items MX15335 Picture Note 48 52 and 61 inch mower decks MX15331 Picture Note 72 inch mower deck e Lubricate mower deck idler pulleys K M MX15290 e Lubricate hydraulic pump control arms N e Lubricate control lever pivot shaft O e Lubricate seat platform hinges P e Lubricate throttle control cable Q e Carbureted Engines Only Lubricate choke control cable R Service Lubrication 25 SERVICE ENGINE Engine Warranty Maintenance Statement Maintenance repair or replacement of the emission control devices and systems on this engine which are being done at the customer s expense may be performed by any non road engine repair
56. ion Standard Center 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 MX15341 e 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 MX15276 Picture Note Motion control levers A shown in the neutral lock position e Motion control levers must be in the neutral lock position the PTO switch disengaged and the park brake locked to start the engine e Forward and reverse movement of the motion control levers is prevented when levers are moved to the neutral lock position e 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 e 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 MX15293 Picture Note Motion control levers A shown in the neutral position e Machine speed motion and direction can be controlled when the engine is running operator is on the seat and the park brake is unlocked Forward and Reverse Motion A CAUTION Avoid injury Children or
57. ion or stability is doubtful e Test drive area with mower lowered but not running Slow down when you travel over rough ground Parking Safely Stop machine on a level surface not on a slope Disengage PTO Lower attachments to the ground Lock the park brake Stop the engine oa A OO N Remove the key leave the operators seat 8 Disconnect the negative battery cable or remove the spark plug wire before servicing the machine Rotating Blades are Dangerous HELP PREVENT SERIOUS OR FATAL ACCIDENTS Ya MIF e Rotating blades can cut off arms and legs e Keep hands feet and clothing away from mower deck when engine is running e Be alert at all times drive forward carefully People especially children can move quickly into the mowing area before you know it e Before backing up shut off PTO and look down and behind the machine carefully especially for children Do not mow in reverse e Shut off blades when you are not mowing e Park machine safely before inspecting or unplugging mower or bagger for any reason including emptying the catchers or unplugging the chute Safety 5 SAFETY PROTECT CHILDREN e Never assume that children will remain where you last saw them Children are attracted to mowing activity stay alert to the presence of children e Keep children indoors when you are mowing Turn the
58. king Safely in the Safety section 2 Raise and securely support the front of the mower deck N E BS ei EE 6 gt OS MX15324 3 Remove locknut A capscrew 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 F press bearings E into wheel and tire assembly 7 Install wheel and tire assembly D two trash guards C capscrew B and locknut A Servicing Front Caster Wheel Roller Bearings Chariot LX 1 Park machine safely See Parking Safely in the Safety section 2 Raise and securely support the front of the mower deck Service Steering 4 Brakes 37 SERVICE STEERING 8 BRAKES N N N N N Ae N N N N l a Ae Los MX15339 3 Remove locknut A capscrew B and wheel assembly C 4 Remove spacers D seals E and bearings and bearing races F from wheel 5 Clean and inspect bearings F and pack with clean grease Replace bearings with races as needed 6 Install bearings and races F and new seals E 7 Install wheel assembly C two spacers D capscrew B and locknut A Tighten locknut until rolling resistance is felt Adjusting Front Caster Spindle Bearing NOTE Adjustment required only if the front caster wheel shimmies d
59. l is left in the fuel tank 2 Turn on engine and allow to run until it runs out of fuel 3 Turn key to off position 4 Mix fresh fuel and 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 fuel system Engine Engine storage procedure should be used when vehicle is not to be used for longer than 60 days 1 Change engine oil and filter while engine is warm 2 Service air filter if necessary 3 Clean debris from engine air intake screen 4 Remove spark plugs Put 30 mL 1 oz of clean engine oil in cylinders 5 Crank the engine five or six times to allow oil to be distributed 6 Install spark plugs 7 Clean the engine and engine compartment 8 Remove battery 9 Clean the battery and battery posts 10 Store the battery in a cool dry place where it will not freeze NOTE The stored battery should be recharged every 90 days 11 Charge the battery 12 Store the machine in a dry protected place If machine is stored outside put a waterproof cover over it Removing Machine From Storage Check tire pressure Check engine oil level Charge battery if necessary Install battery a A U N Check spark plug gap Install and tighten plugs to specified torque 6 Lubricate all grease points 7 Run the engine 5 minutes without the mower or a
60. ly 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 e 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 48 52 and 61 Inch Mower Deck 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 MX15317 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 e To decrease belt tension Turn nut C counterclockwise 6 Tighten jam nut A 7 Lower foot platform Checking and Adjusting Engine to Deck Drive Belt Tension 72 Inch Mower Deck 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 44 SERVI
61. machine is equipped with an electric start The hourmeter will continue to run with the key switch left in the run position MX15284 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 Using the Choke Carbureted Engines Only Engage Choke MX15284 e Pull choke knob A out Disengage Choke e Push choke knob A in Using the Motion Control Levers A 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 e Dual function neutral position e Steering e Acceleration e Braking Operating 15 OPERATING Neutral Detent Posit
62. machine off if a child enters the mowing area e Use extra care when you come to blind corners shrubs trees or other objects that may block your vision e Do not let children or an untrained person operate the machine e Do not carry or let children ride on any attachment or machine even with the blades off Do not tow children in a cart or trailer Avoid Tipping MIF e Slopes are a major factor related to loss of control and tip over accidents which can result in severe injury or death e Do not drive where machine could slip or tip e Stay alert for holes and other hidden hazards in the terrain e Keep away from drop offs ditches and embankments e Slow down before you make a sharp turn or operate on a slope e Transport machine with decks lowered to improve stability e Drive machine very slowly and avoid quick stops when attachment is removed e Drive across a hill not up and down Be careful when you change direction on a slope If necessary turn slowly and in the downhill direction e Mowing when grass is wet can cause reduced traction and sliding Keep Riders Off MIF e Only allow the operator on the machine Keep riders off e Riders on the machine or attachment may be struck by foreign objects or thrown off the machine causing serious injury e Riders obstruct the operator s view resulting in the machine being operated in an unsafe manner Checking Whe
63. mission damage may occur if the machine is moved or towed incorrectly e Move unit by hand only Do not use another vehicle to move unit e Do not tow unit Use a heavy duty trailer to transport your machine Trailer must have signs and lights required by law a A U N o a Raise the mower deck lift lever to the transport position Drive machine on trailer Stop engine and lock the park brake Remove key Fasten machine to trailer with heavy duty straps chains r cables Both front and rear straps must be directed down nd outward from machine Mowing Tips Mow grass with throttle lever in the full throttle 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 e Mow tall or wet grass twice Cut grass at half desired height then cut at desired height e Travel slow when mowing tall thick or wet grass e 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 Operating 20 OPERATING Mowing Travel Speeds Use slow travel speed for Trimming e Working in close quarters e Mowing tall grass Use faster travel speeds for e Normal mowing on level ground Dismountin
64. move and Install aane eeea aran enene nenen 51 Battery Specifications 0sseaaneane anana nean a reenen 68 Battery Using Booster AA 52 Belt Shields Removing and Installing Mower Deck 41 Blades Balance ccccccccconncnncnccccoonononcnconnncnnnnnnnnoncnnnnnnnos 48 Blades Check and Replace Mower 47 Blades Sharpen occccconocccnncoooonnnnconnnnnnnconnnnnnnccnnnnnnnncnnns 48 Brake Testing Park ooooconnnnccncoccccccnccccccnnnnnonnnnccnnnnnccnnnns 11 C Carburetor Adjusting nenen anana nenen n een 28 Certification ta dida 3 EI e 1 Chart Service Interval metir asa ana abaini 23 Choke USING coros Na RA KS AKA KAE TA AG AWAN Ba aa EN AA gi KA 15 Controls Miscellaneous 10 Cutting Height Adjusting Mower Deck naranata 12 D Daily Operating Checklist cccccceeeseeeeeseeeeeeeneeeteaes 10 Deck Anti Scalp Wheels Adjusting Mower 13 Deck Belt Shields Removing and Installing Mower 41 Deck Cutting Height Adjusting Mower sesse 12 Deck Level Check MOWED ccccccccccseeeeeeeeeeeeseeeneeeeeeees 66 Deck Lift Assist Spring Adjust Tension n 44 Dimensions Chariot ooooncccncnncncncnnnnnncnnnnnnnnnnnnonononononnnnns 68 Dimensions Chariot lx 68 E Electrical System Troubleshooting sses 61 Emission Compliance Period eseese 3 Emission Control System Certification Label 3 Engine Air Intake Screen and Fan Clean
65. n gt a E MX13148 1 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 2 Adjust deck lift handle connecting rod B while viewing adjusting mechanism from rear of machine To lower deck turn nut C counterclockwise e To raise deck turn nut C clockwise 3 Tighten jam nut A Service Mower 43 SERVICE MOWER 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 on a hard level surface 2 Stop engine and lock park brake 3 Raise the mower deck lift lever to the transport position MX15285 4 Measure distance A between the washers B on each deck lift spring assembly e 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 The Chariot LX is equipped with two deck lift assist spring assemblies Both deck lift assist springs must be adjusted equally Do not overtighten the deck lift assist springs If the springs are compressed too tight
66. 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 IMPORTANT Avoid damage To help prevent engine backfiring 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 a 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 MIF 5 Turn key switch to STOP position A 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 Operating 19 OPERATING Using Hydraulic Pump Free Wheel Valve
67. ng Electrical saanane anana nane nn en nenen 61 Troubleshooting Engines essasee ea aane nan aenn eaaa nean 59 Troubleshooting Kolher Fuel Injection System 29 Troubleshooting Mower Deck ooooccococccccccccccccccncananncnnccos 63 Troubleshooting Park Brake 62 Troubleshooting Steering cccccceeeseeeeeeeeeteneeeeeeeeeees 62 V Valves Using Hydraulic Pump Free Wheel 20 WwW Warranty Maintenance Statement Engine 26 Weights Chariot akasa gisi TAA SA NGANG DANG NGERAK AKUN AK 68 Weights Chariot LX aa ea aane aaa eee a naen a anana nane 68 Wheels Remove and Install Rear Drive ccceeeeeeeeeeeeeeees 58 Wheels Adjusting Mower Deck Anti Scalp 13 Wheels Remove and Install Front Caster ssseneeene 37 Wiring Schematic Carbureted Engines cceeee 54 Wiring Schematic Fuel Injected Engine 26 HP 55 Wiring Schematic Fuel Injected Engine 28 HP 56 Index 71 Record Service Dates SERVICE RECORD GD Engine Oil and Filter Change Lubricate Machine Air Cleaner Element Clean Replace Service Record GD 72
68. ng near blades 1 Clean blade M61524 2 Put blade on nail in a vise Turn blade to horizontal position 3 Check balance If blade is not balanced heavy end of blade will drop 4 Grind bevel of heavy end Do not change blade bevel Replacing Mower Spindle Bearings 48 52 and 61 Inch Mower Decks 1 Park machine safely See Parking Safely in the Safety section Service Mower 48 SERVICE MOWER 2 Remove mower blade See Checking and Replacing Mower Blades MX15354 3 Remove nut A pulley B and spacer C 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 6 Clean entire assembly 7 Install a new lower bearing F and spacer G 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 I and retaining ring D 10 Install spacer C 11 Install pulley B and nut A Tighten nut to 61 Nem 50 bm 12 Install mower blade blade washers and blade bolt assembly Tighten nut to 81 Nem 60 lb ft See Checking and Replacing Mower Blades Replacing Mower Spindle Bearings 72 Inch Mower Deck
69. njury 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 e Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area e Allow fresh outside air into the work area to clear the exhaust fumes out 11 Start engine 12 Move throttle lever to 3 4 throttle position 13 Unlock the park brake A 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 A CAUTION Avoid injury Help prevent injury from foreign particles when using compressed air for cleaning purposes clear area of bystanders and wear personal eye protection to guard against flying debris 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 MX13120 2 Clean hydraulic oil cooler fi
70. nnecessary engine idling may cause engine damage Excessive idling can cause engine overheating carbon buildup and poor performance 8 Release key to run position C when engine starts 9 With engine started e Push choke knob to off position MX15284 Move throttle lever to full throttle position 4 Push PTO knob A down to disengage PTO 5 Move throttle lever to set engine speed e Cold engine Set throttle lever at the 1 2 to 3 4 throttle position e Unlock the park brake e Warm Hot engine Set throttle lever to the 1 2 throttle position 6 Carbureted Engines Only Position choke knob D e Cold engine Pull knob up and hold in choke position e Warm Hot engine If necessary pull knob up and hold in choke position Operating 18 OPERATING Engaging Mower Stopping the Engine A 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 the PTO clutch Do not engage PTO with throttle in the fast position 1 Adjust mower deck to desired cutting height 2 Start engine MX15284 3 Move throttle lever to the 1 2 to 3 4 throttle position 4 Unlock the park brake 5 Move both motion control levers to the
71. ns 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 48 52 and 61 inch mower decks or engine to deck drive belt 72 inch mower decks MX9232 Picture Note Drive belt routing as 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 Service Transmission 32 SERVICE TRANSMISSION 5 Install new drive belt 6 Install mower deck drive belt as shown Checking and Adjusting Motion Control Linkages A CAUTION Avoid injury Do not attempt this adjustment unless you are a qualified and properly trained technician Check Neutral Creep A CAUTION Avoid injury Engine exhaust fumes can cause sickness or death e If itis necessary to run an engine in an enclosed area use an exhaust pipe extension to remove the fumes e Always try to work in a well ventilated area NOTE Check and adjust motion control linkages with the machine parked on a hard level surface 1 S
72. nter or authorized dealer to learn how to recycle or get rid of waste products e 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 Safety 9 OPERATING H Throttle Lever Daily Operating Checklist UU Make sure all necessary guards and shields are safely and securely attached Check for loose missing or damaged parts LJ Remove mower deck belt shields Clean grass and debris from belt area deck L Test park brake l Test safety systems LI Inspect battery terminals and hold downs LI Inspect for oil leaks LJ Check engine and hydraulic oil levels LI Inspect all belts for damage or cracking LI Inspect engine air filter LI Inspect mower level Ly Adjust cutting height if necessary E Inspect wheel bolt torque Tighten if necessary l Check tire air pressure Check tires for damage or cracking L Inspect front caster spindles wheels Operator Station Controls Remove grass and debris from machine and mower Mower Deck Lift Lower Lever J Height of Cut HOC Adjustment Pin K Mower Deck Transport Position Lock Lever Miscellaneous Controls A Hydraulic Pump Free Wheel Valves Testing Safety Systems L MX152 A Motion Control Levers B
73. ny attachments running to allow oil to be distributed throughout engine 8 Be sure all shields and guards or deflectors are in place Storage 64 ASSEMBLY Bag of Parts Qty Description 1 Key 1 Operator s Manual 1 PDR Check List Prepare for Assembly Remove machine from the shipping crate e Remove box containing operator seat e Cut plastic tie straps fastening the front wheels to the shipping crate e Cut plastic tie straps holding the discharge chute up e Cut plastic tie straps securing the motion control levers to the machine Check Hydraulic Oil Level IMPORTANT Avoid damage Check all fluid levels before attempting to start the machine Machine should be parked on a hard level surface with the key switch in the STOP position 1 Park machine safely See Parking Safely in the Safety section MX15294 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 Check Engine Oil Level Remove dipstick from tube by unscrewing it Wipe it clean 8 Install dipstick and allow the cap to rest on the end of the tube Do not tighten the cap
74. ny grass or debris from top of fuel tank E Eo 3 Remove fuel tank cap A MX15309 4 Fill tank with fuel only to bottom of filler neck 5 Install fuel tank cap A CAUTION Avoid injury Explosive separation of a tire and rim parts can cause serious injury or death es DO NOT attempt to mount a tire without the proper equipment and experience to perform the job e Always maintain the correct tire pressure DO NOT inflate the tires above the recommended pressure Never weld or heat a wheel and tire assembly The heat can cause an increase in air pressure resulting in a tire explosion Welding can structurally weaken or deform the wheel e When inflating tires use a clip on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly e Check tires for low pressure cuts bubbles damaged rims or missing lug bolts and nuts 1 Check tires for damage 2 Check tire pressure with an accurate gauge 3 Add air if necessary Tire Size Pressure 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 Rear Chariot LX 24 x 12 69 97 kPa 10 14 psi 12 Service Miscellaneous 57 SERVICE MISCELLANEOUS Remove and Install Rear Drive Wheels Removing 1 Park machine safely See Parking Safely in the Safety section MX15322 2 Slightly loosen five
75. ontrol linkage Assembly 67 SPECIFICATIONS Engine NOTE See engine manufacturer s owner s manual provided with your machine for engine specifications Battery Molt eech 12 volt CGA Std e rata das 340 amp Reserve Capacity a 90 minutes BOl GIOUPESIZE 5 isisi pa Bea e DEET dek a E 51 Tires Chariot Oli ral ERA AR e ENRE 13 x 5 0 6 Rear tee Ge Dak aaa bk a ON Ae hee aa a 23 x 9 50 12 Inflation Front Maximum 110 138 kPa 16 20 psi Inflation Rear Maximum 69 97 kPa 10 14 psi Wheel Nut Torque 100 Nem 75 lb ft Tires Chariot LX Pon saa A PER a Ee A 13 x 5 0 6 ROAM een Beat EAS eege 24 x 12 12 Inflation Front Maximum 110 138 kPa 16 20 psi Inflation Rear Maximum 69 97 kPa 10 14 psi Wheel Nut Torque 100 Nem 75 lb ft Capacities Fuel Tank 30 2 L 8 gal Hydraulic System 0 3 54 L 3 75 qt Net Weight Chariot With Mower Deck and Without Fuel 17 hp Kawasaki Engine 48 in Deck 479 kg 1055 Ib 19 hp Kawasaki Engine 48 in Deck 479 kg 1055 Ib 23 hp Kawasaki Engine 52 in Deck 489 kg 1079 lb 25 hp Kawasaki Engine 52 in Deck 489 kg 1079 Ib 25 hp Kohler Engine 52 in Deck 489 kg 1079 Ib 25 hp Kawasaki Engine 61 in Deck 489 kg 1079 Ib 25 hp Kohler Engine 61 in Deck 489 kg 1079 Ib Net Weight Chariot LX With Mower Deck and Without Fuel 25 hp K
76. ower Deck Anti Scalp Wheels 2 Adjust mower deck to desired cutting height NOTE The rear anti scalp wheels are located under the rear of the mower deck A MX15281 3 Adjust anti scalp wheel A to one of two positions B Remove screw C nut and washer Adjust wheel up or down so it is approximately 6 13 mm 1 4 1 2 in above mowing surface 4 Install wheel with attaching hardware 5 Adjust all wheels to same height 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 Locking Park Brake A CAUTION Avoid injury Fingers or loose clothing can get caught in rotating parts Stop engine and wait for all moving parts to stop before servicing A CAUTION Avoid injury If the engine should stop while operating on an incline the mower will free wheel If this should occur lock the park brake start the engine unlock the park brake and resume operation 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 1 Inflate tires to correct pressure Operating 13 OPERATING w
77. rate 125 TOU14840 MKTSSAO CARB Intermediate 250 e Operator training required CARB Extended 500 e Read operators manual e Keep shields in place a Certification e Never carry riders e Keep people a safe distance away e Maintain all safety devices e Before leaving machine Your product has been tested and evaluated by the manufacturer and conforms with American National e Stop engine e Set park brake Remove key 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 3 SAFETY Operator Training Required The owner of the machine is responsible for training the users and mechanics of the machine e The owner user can prevent and is responsible for accidents or injuries occurring to themselves other people or property e Do not allow operation or service of the machine by untrained adults e Do nat let children operate the machine Local regulations may restrict the age of the operator e Read the operators manual and study the safety and operation sections before operating the machine e If the operator of the machine cannot read or understand this manual it is the machine s owner responsibility to explain this material to the operator e Operate the machine in an open unobstructed area under the direction of an experienced operator e L
78. reep 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 Service Transmission 33 SERVICE TRANSMISSION 2 Sit on the seat and 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 NOTE If the machine travels to the left adjust the right speed drift screw A If the machine travels to the right adjust the left speed drift screw B MX15351 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 c Tighten the jam nut C 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 34 SERVICE TRANSMISSION Hydraulic System Hose Routing
79. revent fires Clean up spilled fuel immediately If fuel is spilled on clothing change clothing immediately e Do not store fuel in container or machine with fuel in tank in a building where fumes may reach an open flame or spark e Prevent fire and explosion caused by static electric discharge Use only non metal portable fuel containers approved by the Underwriters Laboratories UL or the American Society for Testing and Materials ASTM If using a funnel make sure it is plastic and has no screen or filter e Static electric discharge can ignite gasoline vapors in an ungrounded fuel container Remove the fuel container from the bed of a vehicle or the trunk of a car and place on the ground away from the vehicle before filling Keep nozzle in contact with container opening while filling Do not use a nozzle lock open device e When practical remove equipment from trailers or truck beds and refuel them on the ground If this is not possible use a portable plastic fuel container to refuel equipment on a truck bed or trailer e For gasoline engines do not use gas with methanol Methanol is harmful to your health and to the environment Handling Waste Products and Chemicals 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 e See your local Recycling Ce
80. rive belt B Service Mower 45 SERVICE MOWER MX15318 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 6 Install new mower deck drive belt B as shown 7 Adjust belt tension 8 Install mower deck drive belt covers 9 Lower foot platform Removing and Installing Engine to Deck Drive Belt 72 Inch Mower Deck 1 Park machine safely See Parking Safely in the Safety section 2 Remove mower deck drive belt covers 3 Z MX15328 Release engine to deck drive belt tension by turning the tension adjuster nut A counterclockwise OON DO A DNA 9 RES MX15329 A PTO Clutch Sheave B Mower Deck Drive Belt C Tension Idler Sheave D Tension Idler Sheave E Center Spindle Sheave Remove engine to deck drive belt B Install new engine to deck drive belt B as shown Adjust drive belt tension Install mower deck drive belt covers Lower foot platform Service Mower 46 SERVICE MOWER Removing and Installing Spindle Drive Belt 72 Inch Mower Deck 1 Park machine safely See Parking Safely in the Safety section 2 Raise foot platform 3 Remove mower deck drive belt covers MX15327 4 Remove engine to deck drive belt A
81. rlier 2 Lower foot plate Removing and Installing Mower Deck Belt Shields A 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 NOTE Two retaining knobs are used on each cover on the 72 inch mower deck MX15302 Picture Note 48 52 and 61 inch mower deck belt shield MX15303 Picture Note 72 inch mower deck belt shield 3 Remove knob s A 4 Remove belt shield B Installing Belt Shields 1 Install belt shield B 2 Install knob s A Service Mower 41 SERVICE MOWER Leveling Mower Deck A CAUTION Avoid injury Rotating blades are dangerous Before adjusting or servicing mower e Disconnect spark plug wire s to prevent engine from starting accidently e 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 Inspect mower blades for e Blade sharpness e Blade damage e Bent blades Checking Level Side to Side NOTE Mower deck anti scalp wheels should not contac
82. rly marked container 5 Remove fuel filter from inlet fuel hose C Discard filter IMPORTANT Avoid damage When installing a new fuel filter the filter arrow must be pointing in the direction of fuel flow Make sure clamps are installed properly Use only approved replacement parts fuel filter Bosch P N D28256 and clamps P N D18439 6 Connect a new fuel filter to hoses using new clamps Make sure fuel filter is installed with arrow pointing in direction of fuel flow Priming Fuel Injectors Fuel Injected Engines 1 Park machine safely See Parking Safely in the Safety section 2 Allow engine to cool 3 Fill fuel tank 4 Turn key switch to run position and leave it in the run position for 15 seconds 5 Start the engine If the engine will not start repeat step 4 two times Troubleshooting the Kohler Electronic Fuel Injection System MX15334 Chariot LX models equipped with Kohler engines with the Electronic Fuel Injection EFI system will include an MIL Malfunction Indicator Light A This light will indicate potential problems with the EFI system The light will come on when the key switch is moved to the run position but should go out once the engine has started If the light remains on after the engine has started or if the engine fails to start there may be a problem with the EFI system or its related electrical system The MIL can also be used to access diagnostic
83. rminals are dirty Dead cell in battery PTO Clutch Does Not Engage Blown 20 amp fuse main power circuit Faulty PTO switch FaultyPTO clutch Loose PTO clutch connections Troubleshooting 61 TROUBLESHOOTING If Check Starter Turns Slowly Loose or corroded battery or ground connections Low battery power charge battery Engine oil viscosity too heavy Hydraulic pump linkages failed and are engaged Machine If Check Excessive Machine Vibration Engine speed too slow Machine Will Not Move With Engine Running Park brake locked 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 Machine Creeps With Engine Running and Motion Control Levers in a Neutral Position Needs shift control linkage adjustment Park Brake If Check Park Brake Not Working Correctly Brakes out of adjustment adjust linkage Brake drums wet Worn brake shoes Brake cables damaged Steering If Check Steering Not Working Park brake locked Hydraulic pump free wheel valves partially open Improper tire Inflation Hydrostatic transmission oil low Traction drive belt slipping Traction drive belt d
84. rol Levers PN MX15343 1 Remove hardware from control arms 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 Align motion control levers A with control arms Install hardware and tighten 3 Check motion control lever alignment e Move both motion control levers forward Install Seat 1 Remove protective covers from seat screws MX15344 2 Pivot seat frame A forward until it rests on the hinge stops NOTE The seat mounting hardware is attached to the seat plate with tie straps 3 Install seat B to the seat frame using four 5 16 18 locknuts and heavy flat washers C Tighten locknuts to 27 Nem 20 Ib ft 4 Connect wire harness to seat safety switch D 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 System in the Operating section Assembly 66 ASSEMBLY Initial Adjustments A CAUTION Avoid injury Clear area of bystanders before performing t
85. s A CAUTION Avoid injury With the free wheel valves open the machine will have unrestricted motion e The machine may free wheel out of control if the free wheel valves are opened with the machine on an incline e Park the machine on a level surface before opening the free wheel valves IMPORTANT Avoid damage Transmission damage may occur if the machine is moved or towed incorrectly e Move unit by hand only e Do not use another vehicle to move unit e Do not tow unit NOTE The hydraulic pump free wheel valves must be fully turned clockwise closed during normal vehicle operation When the machine needs to be moved without starting or running the engine use the hydraulic pump free wheel valves 1 Lock the park brake NOTE The pumps are located under the machine behind the mower deck KI MUI MX13120 Picture Note Left pump shown 2 Turn free wheel valve A on both pumps one full turn counterclockwise open position 3 Unlock the park brake 4 Push machine to desired location Due to hydraulic system drag machine will move slowly 5 Turn free wheel valve A on both pumps one full turn Cc 1 lockwise closed position Tighten valve to 9 14 Nem 80 20 Ib in 6 Lock the park brake Transporting Machine A CAUTION Avoid injury Use caution when loading or unloading machine into a trailer or truck IMPORTANT Avoid damage Trans
86. surfaces can burn skin The engine and components will be hot if the engine has been running Allow the engine to cool before servicing 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 Carbureted Engines NOTE Carburetor is calibrated by the engine manufacturer and is not adjustable If engine is operated at altitudes above 1829 m 6000 ft some carburetors may require a special high altitude main jet If engine is hard to start or runs rough see Troubleshooting section of this manual Possible engine surging will occur at high throttle with transmission in neutral and mower disengaged This is a normal condition due to the emission control system After performing checks in Troubleshooting section and your engine is still not performing correctly contact the local engine manufacturer s authorized servicing dealer Replacing Fuel Filter Carbureted Engines A CAUTION Avoid injury Fuel vapors are explosive and flammable Do not smoke while handling fuel e Keep fuel away from flames or sparks e Shut off engine before servicing e Cool engine before servicing e Work in a well ventilated area e Clean up spilled fuel immediately 1 Park machine safely See Parking Safely in the Safety section 2 Allow engine to cool 3 Plac
87. t debris from falling into crankcase 4 Remove dipstick A Wipe with a clean cloth 5 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 6 Remove dipstick and check oil level on dipstick Oil must be between the ADD and FULL marks e If oil is low add oil to bring oil level no higher than the FULL mark on dipstick e H oil level is above the FULL mark drain to proper level 7 Install and tighten dipstick Changing Engine Oil and Filter A CAUTION Avoid injury Help prevent serious personal injury Allow the engine exhaust pipe and muffler to cool before performing this service function IMPORTANT Avoid damage Change the oil more often if the machine is used in extreme conditions e Extremely dusty conditions e Frequent slow or low speed operation e Frequent short trips 1 Run engine to warm oil 2 Park machine safely See Parking Safely in the Safety section Service Engine 26 SERVICE ENGINE 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 Remo
88. t the ground 1 Lower deck to the 76 mm 3 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 4 Mis 2 lex TF MX10371 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 s The difference between both measurements should be no greater than 3 mm 1 8 in 5 If side to side level is not within specifications an adjustment is necessary Adjusting Level Side to Side MX15285 1 Adjust four chain U bolts B 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 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 M40137 e The height C 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 Service Mower 42 SERVICE MOWER Adjustin
89. tart engine 2 Set throttle lever to full throttle position 3 Unlock the park brake 4 If the rear drive wheels begin to creep an adjustment is required 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 MX15350 5 Loosen nut A and move the dampener B in adjusting slot backward or forward to stop machine creep e If machine creeps forward slide dampener to the rear of the adjusting slot Tighten nut e If 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 MX15351 7 Remove pin C and disconnect swivel D from each traction control rod E and rotate the swivel 8 Rotate swivel D to adjust e To stop forward creep rotate each swivel D counterclockwise one rotation e 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 c
90. the neutral position and check for the recommended gap of 3 6 mm 1 8 1 4 in e If positions of the control levers are unequal an adjustment is necessary Alignment Procedure 1 Adjust position of motion control levers MX13130 2 Loosen set screw A 3 Turn knob B clockwise several times 4 Tighten set screw down in the lower slot 5 Test park brake MX15353 e Loosen capscrews C e Slide both levers forward or rearward to desired position on control arm until levers are aligned e Tighten capscrews Adjusting Park Brake IMPORTANT Avoid damage Due to initial brake wear the park 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 Service Steering amp Brakes 40 SERVICE MOWER Removing and Installing Mower Deck Foot Plate A CAUTION Avoid injury Help prevent serious personal injury Do not operate the mower without the foot plate installed Removing Foot Plate 1 Park machine safely See Parking Safely in the Safety section 74 SE f 9 h MX15315 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 ea
91. ther forward than the right control lever Sharp Left Turn MX13118 e Push right control lever forward and pull left control lever rearward at the same time Sharp Right Turn MX13119 e Push left control lever forward and pull right control lever rearward at the same time Operating 17 OPERATING Staring Me Engine IMPORTANT Avoid damage Starter may be damaged if starter is operated for more than 20 seconds at a time A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause e Wait 2 minutes before trying again if the engine serious illness or death does not start Move the vehicle to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation e Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area e Allow fresh outside air into the work area to clear the exhaust fumes out 1 Sit on the operator seat 2 Lock the park brake MIF 3 Move both motion control levers to the neutral detent 7 Turn key switch to start position B position standard levers or neutral lock position optional If the engine does not start wait 10 seconds over the lap levers e Turn key to start position again for no more than 5 seconds e Repeat the procedure if necessary IMPORTANT Avoid damage U
92. uring travel 1 Park machine safely See Parking Safely in the Safety section p gt SE 2 Remove dust cover A from top of spindle MX15286 MX15316 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 2 Raise and securely support the front of the mower deck Service Steering 4 Brakes 38 SERVICE STEERING 8 BRAKES MX15325 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 5 Remove upper bearing J 6 Clean and inspect bearings and J pack with clean grease Replace bearings if needed 7 Install lower bearing I 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
93. ve 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 e Install dipstick and allow the cap to rest on the end of the tube Do not tighten the cap e Remove dipstick and check oil level on dipstick Oil level should be between the ADD and FULL marks Add oil if needed 17 Install and tighten dipstick MODEL Oil Capacity With Filter Dry Kawasaki 1 8L 1 9 qt Engines Kohler Engines 2 0 L 2 1 qt Checking and Cleaning Air Filter Elements A CAUTION Avoid injury Touching hot surfaces can burn skin The engine and components will be hot if the engine has been running Allow the engine to cool before servicing
94. way from sparks Unplug battery charger before connecting or disconnecting from the battery Wear protective clothing and use insulated tools e Do not modify machine or safety devices Unauthorized modifications may impair its function and safety Avoid High Pressure Fluids MIF e Hydraulic hoses and lines can fail due to physical damage kinks age and exposure Check hoses and lines regularly Replace damaged hoses and lines e Hydraulic fluid connections can loosen due to physical damage and vibration Check connections regularly Tighten loose connections e Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure e Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids e If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Prevent Fires allt a Remove grass and debris from engine compartment and muffler area before and after operating machine especially after mowing or mulching in dry conditions e To reduce fire hazard keep engine and engine compartment free of grass leaves or excessive grease
95. wer deck drive belt tension 48 52 and 61 Inch Mower Deck Check engine to deck drive belt tension 72 Inch Mower Deck Check spindle drive belt tension 72 Inch Mower Deck Check transmission neutral adjustment 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 spindle bearings three places Grease traction drive belt tension arm Grease mower deck drive belt tension arm Grease engine to deck drive belt tension arm 72 Inch Mower Deck Grease HOC shafts four places Lubricate spindle drive belt tension arm 72 Inch Mower Deck Lubricate front caster wheels Chariot LX Lubricate front caster wheel spindles Remove debris from the underside of the mower deck Every 50 Hours or Weekly Whichever Comes First Change engine oil and filter See the engine manufacturer s owners 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 Lubricate mower deck idler pulley pivots three places Lubricate seat pl
96. wheel nuts A 3 Lift machine with a safe lifting device 4 Remove wheel nuts 5 Remove wheel and tire assembly B Installing Rear Drive Wheels Tightening Hardware 1 Install new wheel and tire assembly M77000 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 Nem 75 lb ft 3 Lower machine Cleaning and Repairing Metal Surfaces Cleaning Follow automotive practices to care for your machine s painted metal surfaces Use a high quality automotive wax regularly to maintain the factory look of your machine 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 factory matched colors available from your Great Dane dealer to fill scratches Follow directions included on container for use and for drying 3 Smooth out surface using an automotive polishing compound Do not use power buffer 4 Apply wax to surface Service Miscellaneous 58 TROUBLESHOOTING Using Troubleshooting Chart If you are e
97. xperiencing a problem that is not listed in this chart see your Great Dane servicing dealer for service When you have checked all the possible causes listed and you are still experiencing the problem see your Great Dane servicing dealer Engine If Check Engine Will Not Start or Is Hard to Start 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 Stale or improper fuel fuel level Plugged fuel filter EFI Engines Only Air in fuel line Plugged air intake filter Spark plug wire is loose or disconnected Spark plug not gapped correctly Blown 20 amp fuse main power circuit Carbureted Engines Only Blown fusible link charging circuit Electrical problem dead battery Carbureted Engines Only Choke adjusted incorrectly See your Great Dane servicing dealer EFI Engines Only Blown 10 amp fuse fuel pump circuit EFI system problem check EFI electrical system and connections If problem continues have system serviced by an authorized Kohler EFI servicing dealer Engine Will Not Slow Idle Bent or kinked throttle cable Carbureted Engines Only Bent governor control Carbureted Engines Only Incorrect governor idle control Carbureted Engines Only Carburetion problems See your Great Dane servicing dealer Troubleshooting 59 TROUBLESHO

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