Great Dane Chariot Brutus Gbkh2752S Users Manual

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200315 03/06/2006

TCU20866

Chariot Brutus

GBKW2552S, GBKH2752S

GBKW2561S, GBKH2761S

OPERATOR’S MANUAL

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.

Auburn Consolidated Industries Inc.

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

Introduction - 1

INTRODUCTION

Introduction

Using Your Operator’s Manual

This manual is an important part of your machine and should remain with

the machine when you sell it.

Use the safety and operating information in the machine operator’s

manual to operate and service the machine safely and correctly.

An engine manufacturer’s owner’s manual has been provided with your

machine. This will provide maintenance and troubleshooting information

for the engine installed in your machine.

Specifications and design are subject to change without notice.

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.

NOTE: General information is given throughout the manual that may

help the operator in the operation or service of the machine.

Product Identification

Record Identification Numbers

Chariot Brutus

GBKW2552S S/N 637910000

GBKH2752S S/N 638010000

GBKW2561S S/N 638310000

GBKH2761S S/N 638410000

If you need to contact an Authorized Service Center for information on

servicing, always provide the product model and serial numbers.

You will need to locate the model and serial numbers for the machine and

for the engine of your machine and record the information in the spaces

provided.

DATE OF PURCHASE:

_________________________________________

DEALER NAME:

_________________________________________

DEALER PHONE:

_________________________________________

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.

Safety Labels - 2

SAFETY LABELS

MODEL NUMBER (POWER UNIT) (A):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

SERIAL NUMBER (POWER UNIT) (A):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ENGINE MODEL NUMBER(B):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ENGINE SERIAL NUMBER (B):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ENGINE SPECIFICATION NUMBER (B):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

MOWER DECK MODEL NUMBER (C):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

MOWER DECK SERIAL NUMBER (C):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ROPS SERIAL NUMBER (D):

Safety Labels

Understanding The Machine Safety Labels

The machine safety labels shown in this section are placed in important

areas on your machine to draw attention to potential safety hazards.

On your machine safety labels, the words DANGER, WARNING, and

CAUTION are used with this safety-alert symbol. DANGER identifies the

most serious hazards.

The operator’s manual also explains any potential safety hazards

whenever necessary in special safety messages that are identified with

the word, CAUTION, and the safety-alert symbol.

DANGER

To avoid injury from rotating blades, stay clear of deck edge.

Safety Labels - 3

SAFETY LABELS

DANGER

Do not mow without discharge chute or entire grass catcher in place.

DANGER

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

• Cigarettes, flames or sparks could cause battery to explode. Always

shield eyes and face from battery. Do not charge or use booster cables or

adjust post connections without proper instruction and training.

• Contains sulfuric acid. Avoid contact with the skin, eyes or clothing. In

event of accident, flush with water and call a physician immediately. Keep

out of reach of children.

WARNING

To avoid injury from tipover, drive across slopes, not up and down. If

machine stops going uphill, stop blades and back down slowly.

Safety Labels - 4

SAFETY LABELS

WARNING

To avoid injury from rotating belts, keep all shields and guards in place.

WARNING

Hot surface

CAUTION

• Operator training required

• Read operator’s manual

• Keep shields in place

• Never carry riders

• Keep people a safe distance away

• Maintain all safety devices

• Before leaving machine:

• Stop engine

• Set park brake

• Remove key

WARNING

AVOID CRUSHING

• Keep Rollover Protective Structure fully extended

• Do not jump if machine tips

• Use seat belt

When Structure must be down

• DO NOT use seat belt

• Drive with extra care

WARNING

Seat belts are not to be mounted in this hole, because seat will not meet

SAE J386 test requirements. Failure to comply with warning could cause

serious injury or death.

Safety - 5

SAFETY

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.

Emission Compliance Period

If your engine has the emission compliance category listed on the

emission control system certification or air index label, this indicates the

number of operating hours for which the engine has been certified to meet

EPA and/or CARB emission requirements. The following table provides

the engine compliance period in hours associated with the category found

on the certification label.

Certification

Your product has been tested and evaluated by the manufacturer and

conforms with American National Standard B-71.4, “Safety Specifications”

for commercial turf care equipment.

Canadian Electromagnetic Compatibility (EMC)

Compliance

This spark ignition system complies with Canadian ICES-002.

Safety

Operator Training Required

• Read the operator’s manual and other training material. If the operator

or mechanic cannot read English, it is the owner’s responsibility to explain

this material to them. This publication is available in other languages.

• Become familiar with the safe operation of the equipment, operator

controls, and safety signs.

• All operators and mechanics should be trained. The owner of the

machine is responsible for training the users.

• Never let children or untrained people operate or service the equipment.

Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for accidents or injuries

occurring to themselves, other people, or property.

• Operate the machine in an open, unobstructed area under the direction

of an experienced operator.

Preparation

• Evaluate the terrain to determine what accessories and attachments are

needed to properly and safely perform the job. Only use accessories and

attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety glasses and

hearing protection. Long hair, loose clothing or jewelry may get tangled in

moving parts.

• Inspect the area where the equipment is to be used and remove all

objects such as rocks, toys and wire which can be thrown by the machine.

• Use extra care when handling gasoline and other fuels. They are

flammable and vapors are explosive.

a.Use only an approved container.

b.Never remove gas cap or add fuel when engine is running. Do not

smoke.

c.Never refuel or drain the machine indoors.

• Check that the operator’s presence controls, safety switches and shields

are attached and functioning properly. Do not operate unless they are

functioning properly.

Operating Safely

• Never run an engine in an enclosed area where dangerous carbon

monoxide fumes can collect.

• Only operate in good light, keeping away from holes and hidden

hazards.

• Be sure all drives are in neutral and parking brake is engaged before

starting engine. Only start engine from the operator’s position. Use seat

belts if provided.

• Slow down and use extra care on hillsides. Be sure to travel in the

recommended direction on hillsides. For this machine, drive across

hillsides, not up and down. Turf conditions can affect the machine’s

stability. Use caution while operating near drop-offs.

• Slow down and use caution when making turns and when changing

directions on slopes.

• Never raise deck with the blades running.

• Never operate with the PTO shield, or other guards, not securely in

place. Be sure all interlocks are attached, adjusted properly, and

functioning properly.

• Never operate with the discharge deflector raised, removed or altered,

unless using a grasscatcher. Do not operate mower without discharge

chute or entire grasscatcher in place.

• Do not change the engine governor setting or overspeed the engine.

Operating the engine at excessive speed can increase the hazard of

personal injury.

• Stop on level ground, lower implements, disengage drives, engage

parking brake, and shut off engine before leaving the operator’s position

for any reason including emptying the grasscatchers or unclogging the

chute.

• Stop equipment and inspect blades after striking objects or if an

abnormal vibration occurs. Make necessary repairs before resuming

operations.

• Keep hands and feet away from the cutting units.

• Look behind and down before backing up to be sure of a clear path.

• Never carry passengers and keep pets and bystanders away.

• Slow down and use caution when making turns and crossing roads and

sidewalks. Stop blades if not mowing. Watch for traffic when operating

near or crossing roadways.

Agency Category Hours

EPA C 250

EPA B 500

EPA A 1000

CARB Moderate 125

CARB Intermediate 250

CARB Extended 500

Safety - 6

SAFETY

• Be aware of the mower discharge direction and do not point it at anyone.

• Do not operate the machine while under the influence of alcohol or

drugs.

• Use care when loading or unloading the machine into or off of a trailer or

truck.

• Use care when approaching blind corners, shrubs, trees, or other

objects that may obscure vision.

• Inspect machine before you operate. Be sure hardware is tight. Repair

or replace damaged, badly worn, or missing parts. Be sure guards and

shields are in good condition and fastened in place. Make any necessary

adjustments before you operate.

• Before using, always visually inspect to see that the blades, blade bolts

and the mower assembly are not worn and damaged. Replace worn and

damaged blades and bolts in sets to preserve balance.

• Keep safety labels visible when installing accessories and attachments.

• Do not wear radio or music headphones. Safe service and operation

require your full attention.

• When machine is left unattended, stored, or parked, lower the mower

deck unless a positive mechanical lock is used.

Using a Spark Arrestor

The engine in this machine is not equipped with a spark arrestor muffler. It

is a violation of California Public Resource Code Section 4442 to use or

operate this engine on or near any forest-covered, brush-covered or

grass-covered land unless the exhaust system is equipped with a spark

arrestor meeting any applicable local or state laws. Other states or federal

areas may have similar laws.

A spark arrestor for your machine may be available from your authorized

dealer. An installed spark arrestor must be maintained in good working

order by the operator.

Checking Mowing Area

• Clear mowing area of objects that might be thrown. Keep people and

pets out of mowing area.

• Low-hanging branches and similar obstacles can injure the operator or

interfere with mowing operation. Before mowing, identify potential

obstacles such as low-hanging branches, and trim or remove those

obstacles.

• Study mowing area. Set up a safe mowing pattern. Do not mow where

traction or stability is doubtful.

• Test drive area with mower lowered but not running. Slow down when

you travel over rough ground.

Parking Safely

1.Stop machine on a level surface, not on a slope.

2.Move motion control levers out to the neutral lock position.

3.Disengage mower blades.

4.Lower attachments to the ground.

5.Lock the park brake.

6.Stop the engine.

7.Remove the key.

8.Wait for engine and all moving parts to stop before you leave the

operator’s seat.

9.Close fuel shut-off valve, if your machine is equipped.

10.Disconnect the negative battery cable or remove the spark plug wire

(for gasoline engines) before servicing the machine.

Rotating Blades are Dangerous

HELP PREVENT SERIOUS OR FATAL ACCIDENTS:

• Rotating blades can cut off arms and legs, and throw objects. Failure to

observe safety instructions could result in serious injury or death.

• Keep hands, feet and clothing away from mower deck when engine is

running.

• Be alert at all times, drive forward carefully. People, especially children

can move quickly into the mowing area before you know it.

• Do not mow in reverse.

• Shut off blades when you are not mowing.

• Park machine safely before leaving the operator station for any reason

including emptying the catchers or unplugging the chute.

Safety - 7

SAFETY

Protect Children

• Death or serious injury can occur when young children associate having

fun with a lawn mowing machine simply because someone has given

them a ride on a machine.

• Children are attracted to lawn mowing machines and mowing activities.

They don’t understand the dangers of rotating blades or the fact that the

operator is unaware of their presence.

• Children who have been given rides in the past may suddenly appear in

the mowing area for another ride and be run over or backed over by the

machine.

• Tragic accidents with children can occur if the operator is not alert to the

presence of children, especially when a child approaches a machine from

behind. Before and while backing up, stop mower blades and look down

and behind the machine carefully, especially for children.

• Never carry children on a machine or attachment, even with the blades

off. Do not tow children in a cart or trailer. They can fall off and be

seriously injured or interfere with safe machine operation.

• Never use the machine as a recreational vehicle or to entertain children.

• Never allow children or an untrained person operate the machine.

Instruct all operators not to give children a ride on the machine or in an

attachment.

• Keep children indoors, out of the mowing area, and in the watchful eye

of a responsible adult, other than the operator, when a mower is being

operated.

• Stay alert to the presence of children. Never assume that children will

remain where you last saw them. Turn the machine off if a child enters the

work area.

Avoid Tipping

• Slopes are a major factor related to loss-of-control and tip-over

accidents, which can result in severe injury or death. Operation on all

slopes requires extra caution.

• If you feel uneasy on a hillside, do not mow it.

• Mow across slopes, not up and down.

• Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven

terrain could overturn the machine. Tall grass can hide obstacles.

• Choose a low ground speed so you will not have to stop or shift while on

a slope.

• Do not mow or operate machine on wet grass. Tires may lose traction.

Tires may lose traction on slopes even though the brakes are functioning

properly.

• Avoid starting, stopping or turning on a slope. If the tires lose traction,

disengage the blades and proceed slowly, straight down the slope.

• Keep all movement on slopes slow and gradual. Do not make sudden

changes in speed or direction, which could cause the machine to roll over.

• Use extra care while operating machine with grasscatchers or other

attachments, they can affect stability of the machine. Do not use on steep

slopes.

• Do not mow near drop-offs, ditches, embankments, or bodies of water.

The machine could suddenly roll over if a wheel goes over the edge or the

edge caves in.

• Follow the manufacturer’s recommendations for wheel weights or

counterweights for added stability when operating on slopes or using front

or rear mounted attachments. Remove weights when not required.

• Drive machine very slowly and avoid quick stops when attachment is

removed.

• Transport machine with decks lowered to improve stability.

Use Seat Belt Properly

• Use a seat belt when operating with the folding Roll-Over Protective

Structure (ROPS) in the upright position to minimize chance of injury from

an accident, such as an overturn.

• Do not use a seat belt when operating with the folding ROPS in the

folded position. Return the folding ROPS to the upright position as soon as

possible.

• Never modify, disassemble or attempt to repair the seat belt.

• Replace entire seat belt if mounting hardware, buckle, belt, or retractor

show signs of damage.

• Inspect seat belt and mounting hardware at least once a year. Look for

signs of loose hardware or belt damage, such as cuts, fraying, extreme or

unusual wear, discoloration, or abrasion. Replace only with replacement

parts approved by your Great Dane.

• Layers of heavy clothing can interfere with proper positioning of the seat

belt and can reduce the effectiveness of the seat belt.

Keep ROPS Installed Properly

• Make certain all parts of the ROPS are installed correctly if the ROPS

structure is loosened or removed for any reason. All ROPS hardware

should be tightened to the proper torque per manufacturer’s

recommendations.

• Any alteration of the ROPS must be approved by the manufacturer. The

protection provided by the ROPS will be impaired if the ROPS is subjected

to structural damage, is involved in an overturn incident, or is in any way

altered by welding, bending, drilling, or cutting.

• Never attempt to repair a damaged or altered ROPS. It must be

replaced to maintain the manufacturer’s certification of the structure.

Safety - 8

SAFETY

Keep Riders Off

• Only allow the operator on the machine. Keep riders off.

• Riders on the machine or attachment may be struck by foreign objects

or thrown off the machine causing serious injury.

• Riders obstruct the operator’s view resulting in the machine being

operated in an unsafe manner.

Avoid High Pressure Fluids

• Hydraulic hoses and lines can fail due to physical damage, kinks, age,

and exposure. Check hoses and lines regularly. Replace damaged hoses

and lines.

• Hydraulic fluid connections can loosen due to physical damage and

vibration. Check connections regularly. Tighten loose connections.

• Escaping fluid under pressure can penetrate the skin causing serious

injury. Avoid the hazard by relieving pressure before disconnecting

hydraulic or other lines. Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard. Protect hands and body from

high pressure fluids.

• 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.

Driving Safely on Public Roads

Avoid personal injury or death resulting from a collision with another

vehicle on public roads:

• Use safety lights and devices. Slow moving machines when driven on

public roads are hard to see, especially at night.

• Whenever driving on public roads, use flashing warning lights and turn

signals according to local regulations. Extra flashing warning lights may

need to be installed.

Checking Wheel Hardware

• A serious accident could occur causing serious injury if wheel hardware

is not tight.

• Check wheel hardware tightness often during the first 100 hours of

operation.

• Wheel hardware must be tightened to specified torque using the proper

procedure anytime it is loosened.

Wear Appropriate Clothing

• Always wear safety goggles, or safety glasses with side shields, and a

hard hat when operating the machine.

• Wear close fitting clothing and safety equipment appropriate for the job.

• While mowing, always wear substantial footwear and long trousers. Do

not operate the equipment when barefoot or wearing open sandals.

• Wear a suitable protective device such as earplugs. Loud noise can

cause impairment or loss of hearing.

Maintenance and Storage

• Never operate machine in a closed area where dangerous carbon

monoxide fumes can collect.

• Disengage drives, lower implement, lock parking brake, stop engine and

remove key or disconnect spark plug (for gas engines). Wait for all

movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives, mufflers, and engine to

help prevent fires. Clean up oil or fuel spillage.

• Let engine cool before storing and do not store near flame.

Safety - 9

SAFETY

• Shut off fuel while storing or transporting. Do not store fuel near flames

or drain indoors.

• Park machine on level ground. Never allow untrained personnel to

service machine. Understand service procedure before doing work.

• Use jack stands or lock service latches to support components when

required. Securely support any machine elements that must be raised for

service work.

• Before servicing machine or attachment, carefully release pressure from

any components with stored energy, such as hydraulic components or

springs.

• Release hydraulic pressure by lowering attachment or cutting units to

the ground or to a mechanical stop and move hydraulic control levers back

and forth.

• Disconnect battery or remove spark plug (for gas engines) before

making any repairs. Disconnect the negative terminal first and the positive

last. Reconnect positive first and negative last.

• Use care when checking blades. Wrap the blades or wear gloves, and

use caution when servicing them. Only replace blades. Never straighten

or weld them.

• Keep hands, feet, clothing, jewelry and long hair away from moving

parts. If possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away from spark and

flames. Unplug charger before connecting or disconnecting from battery.

Wear protective clothing and use insulated tools.

• Keep all parts in good working condition and all hardware tightened.

Replace all worn or damaged decals.

• Check grasscatcher components and the discharge guard frequently

and replace with manufacturer’s recommended parts, when necessary.

Grasscatcher components are subject to wear, damage, and deterioration

which could expose moving parts or allow objects to be thrown.

• Keep all nuts and bolts tight, especially blade attachment bolts, to be

sure the equipment is in safe working condition.

• Check brake operation frequently. Adjust and service as required.

• On multi-bladed machines, take care as rotating one blade can cause

other blades to rotate.

Prevent Fires

• Remove grass and debris from engine compartment and muffler area,

before and after operating machine, especially after mowing or mulching

in dry conditions.

• Empty the grasscatcher completely before storing.

• Always shut off fuel when storing or transporting machine, if the

machine has a fuel shutoff.

• Do not store machine near an open flame or source of ignition, such as

a water heater or furnace.

• Check fuel lines, tank, cap, and fittings frequently for cracks or leaks.

Replace if necessary.

Tire Safety

Explosive separation of a tire and rim parts can cause serious injury or

death:

• Do not attempt to mount a tire without the proper equipment and

experience to perform the job.

• 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.

• Check tires for low pressure, cuts, bubbles, damaged rims or missing

lug bolts and nuts.

Handling Fuel Safely

To avoid personal injury or property damage, use extreme care in

handling fuel. Fuel is extremely flammable and fuel vapors are

explosive:

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container. Use only non-metal, portable fuel

containers approved by the Underwriter’s Laboratory (U.L.) or the

American Society for Testing & Materials (ASTM). If using a funnel, make

sure it is plastic and has no screen or filter.

Operating - 10

OPERATING

• Never remove the fuel tank cap or add fuel with the engine running.

Allow engine to cool before refueling.

• Never add fuel to or drain fuel from the machine indoors. Move machine

outdoors and provide adequate ventilation.

• Clean up spilled fuel immediately. If fuel is spilled on clothing, change

clothing immediately. If fuel is spilled near machine, do not attempt to start

the engine but move the machine away from the area of spillage. Avoid

creating any source of ignition until fuel vapors have dissipated.

• Never store the machine or fuel container where there is an open flame,

spark, or pilot light such as on a water heater or other appliance.

• Prevent fire and explosion caused by static electric discharge. Static

electric discharge can ignite fuel vapors in an ungrounded fuel container.

• Never fill containers inside a vehicle or on a truck or trailer bed with a

plastic liner. Always place containers on the ground away from your

vehicle before fueling.

• Remove fuel-powered equipment from the truck or trailer and refuel it on

the ground. If this is not possible, then refuel such equipment with a

portable container, rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container

opening at all times until the fueling is complete. Do not use a nozzle lock-

open device.

• Never overfill fuel tank. Replace fuel tank cap and tighten securely.

• Replace all fuel container caps securely after use.

• For gasoline engines, do not use gas with methanol. Methanol is

harmful to your health and to the environment.

Handling Waste Product 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.

• See your local Recycling Center or authorized dealer to learn how to

recycle or get rid of waste products.

• A Material Safety Data Sheet (MSDS) provides specific details on

chemical products: physical and health hazards, safety procedures, and

emergency response techniques. The seller of the chemical products

used with your machine is responsible for providing the MSDS for that

product.

Operating

Daily Operating Checklist

oMake sure all necessary guards and shields are safely and securely

attached. Check for loose, missing, or damaged parts.

oRemove mower deck belt shields. Clean grass and debris from belt

area.

oRemove grass and debris from machine and mower deck.

oTest park brake.

oTest safety systems.

oInspect battery terminals and hold-downs.

oInspect for oil leaks.

oCheck engine and hydraulic oil levels.

oInspect all belts for damage or cracking.

oInspect engine air filter.

oInspect mower level.

oAdjust cutting height if necessary.

oInspect wheel bolt torque. Tighten if necessary.

oCheck tire air pressure. Check tires for damage or cracking.

oInspect front caster spindles/wheels.

Avoid Damage to Plastic and Painted Surfaces

• Do not wipe plastic parts unless rinsed first.

• Insect repellent spray may damage plastic and painted surfaces. Do not

spray insect repellent near machine.

Operating - 11

OPERATING

• Be careful not to spill fuel on machine. Fuel may damage surface. Wipe

up spilled fuel immediately.

• Prolonged exposure to sunlight will damage the hood surface.

Operator Station Controls

A- Motion Control Levers

B- Park Brake Lever

C- Seat Adjustment Lever

D- Hourmeter

E- Ignition Key Switch

F- PTO Knob

G- Choke (Carbureted Engines Only)

H- Throttle Lever

I - Mower Deck Lift/Lower Lever

J - Height-of-Cut (HOC) Adjustment Pin

K- Mower Deck Transport Position Lock Lever

Miscellaneous Controls

A- Hydraulic Pump Free-Wheel Valves

Mounting and Dismounting Machine Safely

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

Raising the Seat:

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Slide seat to full rear position.

3.Remove two locknuts (A) and capscrews securing the flanges at the

rear of the seat frame (B) to the machine.

4.Lift seat frame and tilt forward until it rests against the hinge stops.

Lowering the Seat:

1.Stand on the side of the machine.

2.Slowly lower seat frame. Secure with cap screws and locknuts, removed

earlier.

3.Adjust seat as necessary for operator comfort.

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.

Operating - 12

OPERATING

Adjusting Seat

Front-to-Back Adjustment

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Sit on the operator seat.

3.To adjust the seat front to back, push and hold the seat adjustment lever

(A) away from the seat.

4.Slide forward or backward to desired position.

5.Release lever.

Seat Height Adjustment

1.Sit on the operator seat.

2.To lower the seat, turn knob (B) counterclockwise.

3.To raise the seat, turn knob (B) clockwise.

Using Seat Belt

1.Sit in seat.

2.Pull belts across your lap and insert seat belt buckle (A) into latch (B)

until it locks.

3.To release seat belt, press red button (C) until buckle comes out of latch.

Raising and Lowering ROPS

Raising ROPS

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Remove spring pin (A) from drilled pin (B) on left and right side of ROPS.

3.Remove drilled pin from left and right side of ROPS.

CAUTION: Avoid injury! Never adjust seat while machine is

moving. Stop machine before adjusting seat to prevent loss of

machine control.

CAUTION: Avoid injury! Always wear seat belt when

operating machine with non-folding Roll-Over Protective

Structure (ROPS) or folding ROPS in upright position. Do not

jump from machine if machine tips.

•If folding ROPS must be folded to operate in a low

clearance area, do not use seat belt. Raise ROPS and use

seat belt as soon as conditions permit.

Operating - 13

OPERATING

4.Push ROPS into upright position.

5.Install drilled pin (B) into holes on left and right side of ROPS, and

secure in place with spring pins (A).

6.Check the ROPS bolt torque if the ROPS is loose.

Lowering ROPS

1.Park machine safely. (See Parking Safely in the SAFETY section).

2.Remove spring pin (A) from drilled pin (B) on left and right side of ROPS.

3.Remove drilled pin from left and right side of ROPS.

4.Pull ROPS rearward to lower.

5.Install drilled pins and spring pins back into hole in ROPS to secure in

place.

Adjusting Mower Deck Cutting Height

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.)

2.Move the mower deck lift lever (A) to the transport position (D).

3.Position the HOC adjustment pin (C) in the proper hole for the desired

height-of-cut.

4.Pull back and hold the mower deck lift lever (A) and release the

transport position lock lever (B).

5.Allow the mower deck lift lever (A) to rest against the HOC adjustment

pin (C).

Adjusting Mower Deck Anti-Scalp Wheels

1.Park machine safely. (See Parking Safely in the SAFETY section.)

NOTE: The flattest cut can be achieved by having all anti-scalp

wheels adjusted off the ground. Check anti-scalp wheel adjustments

each time the mower deck cutting height is changed.

It is recommended that all anti-scalp wheels be kept off the ground to

minimize scuffing.

2.Inflate tires to correct pressure.

3.Adjust mower deck to desired cutting height.

CAUTION: Avoid injury! Use roll-over protection system

(ROPS) in lowered position only when low clearance

operation is necessary.

•Do not use seat belt when ROPS is in lowered position.

•Do not operate machine on slope with ROPS in folded

position.

•Raise ROPS and fasten seat belt as soon as conditions

permit.

CAUTION: Avoid injury! Rotating blades are dangerous and

can cut fingers and toes. Stop engine, lock the park brake,

and wait for blade to stop rotating before adjusting cutting

height.

CAUTION: Avoid injury! Fingers and loose clothing can get

caught in rotating parts. Do not operate machine without all

mower deck belt shields installed.

Operating - 14

OPERATING

NOTE: The rear anti-scalp wheels are located under the rear of the

mower deck.

4.Adjust anti-scalp wheel (A) to one of two positions (B).

• 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.

5.Install wheel with attaching hardware.

6.Adjust all wheels to same height.

Testing Safety Systems

The safety systems installed on your machine should be checked before

each machine use. Be sure you have read the machine operator manual

and are completely familiar with the operation of the machine before

performing these safety system checks.

Use the following checkout procedures to check for normal operation of

machine.

If there is a malfunction during one of these procedures, do not operate

machine. See your authorized dealer for service.

Perform these tests in a clear open area. Keep bystanders away.

Testing Safety Systems

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 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.

• Left side motion control lever inward.

• Both motion control levers inward.

1.Move motion control lever(s) out of the neutral detent position (standard

levers) or neutral lock position (optional “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.

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.Do not run an engine in an enclosed area without

adequate ventilation.•

•Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the

exhaust fumes out.

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.Do not run an engine in an enclosed area without

adequate ventilation.•

•Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the

exhaust fumes out.

Operating - 15

OPERATING

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.

3.Pull PTO knob up to engage.

4.Raise slightly off the seat.

Result: The engine must stop.

Testing the Park Brake

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 & Brakes section.

Using the Park Brake

Locking Park Brake:

• Raise and pull rearward park brake lever (A) to lock the park brake.

Unlocking Park Brake:

• Lower park brake lever (A) forward to unlock the park brake.

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.

CAUTION: Avoid injury! If the engine should stop while

operating on an incline, the mower can free wheel. If this

should occur:•lock the park brake,

•start the engine,

•unlock the park brake,

•resume operation.

Operating - 16

OPERATING

Using the Key Switch

NOTE: Machine will only start if the following conditions exist:

• Park brake is locked.

• PTO is disengaged.

• Motion control levers are in the neutral detent position (standard

levers) or neutral lock position (optional “over the lap” levers).

• To turn ignition off, turn key to the STOP position (A).

• To turn ignition on, turn key to the run position (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:

1.Move throttle lever (A) to the 1/2- to 3/4-throttle position.

2.Pull PTO knob (B) up to engage mower deck.

3.Move throttle lever (A) forward to the fast detent position (C) for mowing.

Disengage PTO:

• Push PTO knob (B) down.

Using the Throttle Lever

• Push throttle lever (A) all the way forward to the full-throttle detent

position (B) when mowing.

• Move throttle lever (A) to the 1/2-throttle position (C) when starting and

warming the engine.

• Pull throttle lever (A) rearward to the slow position (D) to idle engine. Do

not run engine at slow idle any longer than necessary.

Using the Hourmeter

NOTE: The machine is equipped with an electric start. The hourmeter

will continue to run with the key switch left in the run position.

• The hourmeter (A) shows the number of hours the machine has run.

• 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.

STOP

Operating - 17

OPERATING

Using the Choke

Engage Choke:

• Pull choke knob (A) out.

Disengage Choke:

• Push choke knob (A) in.

Using the Motion Control Levers

NOTE: Two types of control levers are available - standard “center

steer” levers and optional “over the lap” levers. The operation of

both styles of levers is the same except as noted.

The functions of the motion control levers are:

• Dual function neutral position.

•Steering.

• Acceleration.

•Braking.

Neutral Detent Position - Standard “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.

• Motion control levers must be in the neutral detent position, the PTO

switch disengaged and the park brake locked to start the engine.

Neutral Lock Position - Optional “Over the Lap” Levers

Picture Note: Motion control levers (A) shown in the neutral lock

position.

• Motion control levers must be in the neutral lock position, the PTO

switch disengaged and the park brake locked to start the engine.

• Forward and reverse movement of the motion control levers is

prevented when levers are moved to the neutral lock position.

• Operator can exit mower with the engine running when the PTO switch

is disengaged, the motion control levers are in the neutral lock position

and the park brake is locked.

• Motion control levers must be in the neutral lock position to safely enter

and exit the operator seat.

Neutral Position - Optional “Over the Lap” Levers

Picture Note: Motion control levers (A) shown in the neutral

position.

• Machine speed, motion, and direction can be controlled when the

engine is running, operator is on the seat and the park brake is unlocked.

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.

Operating - 18

OPERATING

Forward and Reverse Motion:

1.Move throttle lever to the full-throttle position.

2.Unlock the park brake.

3.Optional “over the lap” levers: Move both motion control levers from the

neutral lock position inward to the neutral position.

4.Push the control levers forward to begin forward motion.

• The farther forward the control levers are moved, the faster the

machine will travel.

• Forward speed range: 0-14 km/h (0-9 mph).

5.Pull both control levers rearward at the same time to begin reverse

motion.

• Reverse speed range: 0-6 km/h (0-4 mph).

6.To stop motion, move both motion control levers forward or rearward

until the machine comes to a stop.

NOTE: The motion control linkages are adjustable. If adjustment is

required, see Checking and Adjusting Motion Control Linkages in

the Service Transmission section.

Forward:

• Push both motion control levers forward at the same time.

Reverse:

• Pull both control levers past center rearward at the same time.

Gentle Left Turn:

• Push right control lever farther forward than the left control lever.

Gentle Right Turn:

• Push left control lever farther forward than the right control lever.

CAUTION: Avoid injury! Children or bystanders can be

injured or killed by moving machine and rotating blades.

Before traveling forward or rearward:•

•Carefully check area around machine.

•Disengage mower before backing up.

Operating - 19

OPERATING

Sharp Left Turn:

• Push right control lever forward and pull left control lever rearward at the

same time.

Sharp Right Turn:

• Push left control lever forward and pull right control lever rearward at the

same time.

Starting the Engine

1.Sit on the operator seat.

2.Lock the park brake.

3.Move both motion control levers to the neutral detent position (standard

levers) or neutral lock position (optional “over the lap” levers).

4.Push PTO knob (A) down to disengage PTO.

5.Move throttle lever to set engine speed:

• Cold engine: Set throttle lever at the 1/2- to 3/4-throttle position.

• Warm/Hot engine: Set throttle lever to the 1/2-throttle position.

6.Position choke knob (D):

• Cold engine: Pull knob up and hold in choke position.

• Warm/Hot engine: If necessary, pull knob up and hold in choke

position.

7.Turn key switch to start position (B).

If the engine does not start, wait 10 seconds.

• Turn key to start position again for no more than 5 seconds.

• Repeat the procedure if necessary.

8.Release key to run position (C) when engine starts.

9.With engine started:

• Push choke knob to off position.

• Move throttle lever to full-throttle position.

• Unlock the park brake.

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.Do not run an engine in an enclosed area without

adequate ventilation.

•Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the

exhaust fumes out.

IMPORTANT: Avoid damage! Starter may be damaged if starter is

operated for more than 20 seconds at a time:

• Wait two minutes before trying again if engine does not start.

IMPORTANT: Avoid damage! Unnecessary engine idling can

cause engine overheating, carbon build-up, and poor

performance.

STOP

Operating - 20

OPERATING

Engaging Mower

1.Adjust mower deck to desired cutting height.

2.Start engine.

3.Move throttle lever to the 1/2 - 3/4 throttle position.

4.Unlock the park brake.

5.Move both motion control levers to the neutral position.

NOTE: In cold weather or with a new machine, it may be necessary to

engage the choke at the same time as the PTO knob to prevent the

engine from stalling.

6.Pull PTO knob (A) up to engage mower deck.

7.Move throttle lever to full-throttle position.

NOTE: The travel speed and turn rate will vary with the amount that

the control levers are moved.

8.Push motion control levers forward slowly. Mow at a safe travel speed.

Stopping the Engine

1.Move the motion control levers to the neutral detent position (standard

levers) or neutral lock position (optional “over the lap” levers).

2.Lock the park brake.

3.Push PTO switch down to disengage.

4.Move throttle lever to 1/4-throttle position and run for 30 seconds, then

move throttle to slow position.

5.Turn key switch to STOP position (A).

6.Remove key.

Transporting Machine

Use a heavy-duty trailer to transport your machine. Trailer must have

signs and lights required by law.

1.Raise the mower deck lift lever to the transport position.

2.Drive machine on trailer.

3.Stop engine and lock the park brake.

4.Remove key.

5.Fasten machine to trailer with heavy-duty straps, chains or cables. Both

front and rear straps must be directed down and outward from machine.

Mowing Tips

• Mow grass with throttle lever in the full fast position.

• Cut grass when it is dry.

• Keep mower deck and discharge chute clean.

• Mow with sharp blades.

• Properly level mower deck for a smooth cut.

• Mow grass high and often.

• Use a travel speed that fits the conditions:

CAUTION: Avoid injury! Clear mowing area of all bystanders

when operating this machine.

Thrown objects could cause serious injury or death.

Keep hands and feet away from blades and discharge

opening.

Do not mow in reverse unless absolutely necessary.

IMPORTANT: Avoid damage! To help prevent damage to PTO

clutch:

• Do not engage PTO with throttle in the fast position.

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.

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.

CAUTION: Avoid injury! Use extra care when loading or

unloading the machine into a trailer or truck.

Close fuel shut-off valve, if your machine is equipped.

IMPORTANT: Avoid damage! Transmission damage may occur if

the machine is moved or towed incorrectly:

• Move unit by hand only.

• Do not use another vehicle to move unit.

• Do not tow unit.

STOP

Service Intervals - 21

SERVICE INTERVALS

• Mow tall or wet grass twice. Cut grass at half desired height – then cut

at desired height.

• Travel slow when mowing tall, thick or wet grass.

• Avoid damaging grass by slipping or skidding machine drive wheels.

Practice smooth control lever movements.

• When performing sharp turns, do not allow inside machine drive wheel

to stop and twist on grass.

Mowing Travel Speeds

Use slow travel speed for:

• Trimming.

• Working in close quarters.

• Mowing tall grass.

Use faster travel speeds for:

• Normal mowing on level ground.

Dismounting to Inspect Mower

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.

Service Intervals

Servicing Your Machine

Please use the following timetables to perform routine maintenance on

your machine.

Break-In (After First 8 Hours of Operation)

NOTE: The following initial break-in items must be performed and

verified to validate the warranty (dealer service invoice accepted).

• Change engine oil and filter.

• Check drive belt tension.

• Check mower deck drive belt tension.

• Check transmission neutral adjustment.

• 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 HOC shafts (four places).

• Lubricate front caster wheel spindles.

• Remove debris from the underside of the mower deck.

Every 50 Hours or Weekly (Whichever Comes First)

• Change engine oil and filter. See the engine manufacturer’s owner’s

manual provided with your machine for the complete procedure.

• Grease caster wheel spindle bearings (two places).

• Grease mower deck thrust arms (two places).

• Remove debris from the underside of the mower deck.

• Check drive belt tension.

• Check tire pressure.

• Clean engine air filter.

• Check wheel nut torque.

Every 160 Hours or Monthly (Whichever Comes First)

• Check transmission oil level.

• Lubricate mower deck idler pulley pivots (three places).

• Lubricate seat platform hinges (two places)

• Lubricate pump control arms (five places).

• Lubricate control lever pivot shafts (two places).

• Lubricate throttle cable.

• Lubricate choke control cable.

Annually

• Inspect all spindle bearings (6). Replace as needed.

• Inspect all mower deck idler pulleys (3). Replace as needed.

• 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.

• 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.

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.

IMPORTANT: Avoid damage! Operating in extreme conditions

may require more frequent service intervals:

• Engine components may become dirty or plugged when

operating in extreme heat, dust or other severe conditions.

• Engine oil may lose efficiency if vehicle is operated constantly

at slow or low engine speeds or with frequent short trips.

Service Lubrication - 22

SERVICE LUBRICATION

Service Lubrication

Grease

Use a general all-purpose grease with an NLGI grade No.2 rating.

Wet or high speed conditions may require use of a special-use grease.

Contact your Servicing dealer for information.

Spray Lubricant

Use a general-purpose petroleum-based spray lubricant.

Lubrication Points

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Grease caster wheel spindle bearings (B).

3.Grease HOC shafts (C) (two points on each side of the machine).

4.Grease mower deck thrust arms (D), located at the rear of the mower

deck.

5.Apply grease to three spindle bearings.

IMPORTANT: Avoid damage! The recommended grease is

effective within an average air temperature range of -29 to 135

degrees C (-20 to 275 degrees F).

If operating outside that temperature range, contact your

servicing dealer for a special-use grease.

CAUTION: Avoid injury! Rotating parts can catch fingers,

loose clothing, or long hair. Wait for engine and all moving

parts to stop before leaving operator’s station to adjust or

service machine.

Service Engine - 23

SERVICE ENGINE

6.Grease traction drive belt tension arm pivot (G).

7.Grease mower deck drive belt tension arm (H).

NOTE: Use spray lubricant to lubricate the following items:

8.Lubricate mower deck idler pulleys (K-M).

9.Lubricate hydraulic pump control arms (N).

10.Lubricate control lever pivot shaft (O).

11.Lubricate seat platform hinges (P).

12.Lubricate throttle control cable (Q).

13.Lubricate choke control cable (R).

Service Engine

Engine Warranty 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 establishment or

individual. Warranty repairs must be performed by an authorized servicing

dealer.

Avoid Fumes

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:

• See the engine manufacturer’s owner’s manual provided with your

machine for the correct specifications.

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.Do not run an engine in an enclosed area without

adequate ventilation.•

•Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the

exhaust fumes out.

Service Engine - 24

SERVICE ENGINE

Checking Engine Oil Level

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.Remove dipstick (A). Wipe with a clean cloth.

4.Install dipstick and allow the cap to rest on the end of the tube. Do not

tighten the cap.

5.Remove dipstick and check oil level on dipstick. Oil must be between the

ADD and FULL marks.

• If oil is low, add oil to bring oil level no higher than the FULL mark on

dipstick.

• If oil level is above the FULL mark, drain to proper level.

6.Install and tighten dipstick.

Changing Engine Oil and Filter

1.Run engine to warm oil.

2.Park machine safely. (See Parking Safely in the SAFETY section).

3.Put container under drain tube.

4.Open drain valve (A) using a 10 mm socket, 1 ft extension, swivel and 3/

8 in. drive ratchet.

5.Allow oil to drain into an oil drain pan.

6.After oil drains, close drain valve.

7.Remove oil filter using an appropriate filter wrench. Turn filter

counterclockwise to remove.

8.Apply a film of clean engine oil on gasket of new filter.

9.Install filter. Turn filter clockwise until gasket makes contact with

mounting surface. Tighten 1/2 to 3/4 turn after gasket contact.

10.Clean area around the dipstick.

11.Unscrew and remove dipstick.

12.Add approximately 1.4 L (1.5 qt) of oil.

13.Install and tighten dipstick.

14.Start engine and run at slow throttle for approximately two minutes.

Check for leaks around filter and drain valve.

15.Stop engine.

16.Check oil level:

• Remove dipstick. Wipe with a clean cloth.

• Install dipstick and allow the cap to rest on the end of the tube. Do not

tighten the cap.

• Remove dipstick and check oil level on dipstick. Oil level should be

between the ADD and FULL marks. Add oil if needed.

17.Install and tighten dipstick.

CAUTION: Avoid injury! Touching hot surfaces can burn

skin. The engine, components, and fluids will be hot if the

engine has been running. Allow the engine to cool before

servicing or working near the engine and components.

IMPORTANT: Avoid damage! Failure to check the oil level

regularly could lead to serious engine problems if oil level is low:

• Check oil level before operating.

• Keep oil level between the FULL and the ADD marks.

• Check oil level when engine is stopped, level, and is cooled so

oil has had time to drain into the sump.

IMPORTANT: Avoid damage! Dirt and debris in oil may cause

damage to the engine. Clean area around opening before

removing plug or 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.

IMPORTANT: Avoid damage! Change the oil more often if the

vehicle is used in extreme conditions:

• Extremely dusty conditions.

• Frequent slow or low-speed operation.

• Frequent short trips.

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.

MODEL Oil Capacity With Filter (Dry)

Kawasaki Engines 1.8 L (1.9 qt)

Kohler Engines 2.0 L (2.1 qt)

Service Engine - 25

SERVICE ENGINE

Cleaning Engine Air Intake Screen and Fan

Keep air intake screens and engine cooling fins clear of debris to ensure

proper cooling. See the engine manufacturer’s owner’s manual provided

with your machine for the complete procedure.

Checking and Cleaning Air Filter Elements

NOTE: It may be necessary to check the air filter more frequently if

operating machine in dusty conditions.

Check and clean air filter elements at the intervals recommended in the

Service Intervals section. See the engine manufacturer’s owner’s manual

provided with your machine for the complete procedure.

Cleaning Engine Oil Cooler - Kohler Engines

Keep engine oil cooler fins clear of debris to ensure proper cooling. See

the engine manufacturer’s owner’s manual provided with your machine for

the complete procedure.

Checking Spark Plug

Check spark plugs at the intervals recommended in the Service Intervals

section. See the engine manufacturer’s owner’s manual provided with

your machine for the complete procedure.

Adjusting Carburetor

NOTE: Carburetor is calibrated by the engine manufacturer and is

not adjustable.

If engine is operated at altitudes above 1829 m (6,000 ft), some

carburetors may require a special high altitude main jet. See your

authorized dealer.

If engine is hard to start or runs rough, check the TROUBLESHOOTING

section of this manual.

Possible engine surging will occur at high throttle with transmission in “N”

neutral and mower engagement lever disengaged. This is a normal

condition due to the emission control system.

After performing the checks in the troubleshooting section and your

engine is still not performing correctly, contact your authorized dealer.

Replacing Fuel Filter

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.

Picture Note: Kawasaki engine shown.

4.Locate fuel hose (A) coming from fuel tank, disconnect it from the inlet

side of fuel filter (B) and drain gasoline into a properly marked container.

5.Remove fuel filter from fuel hose (C) going to engine. Discard filter.

6.Connect a new fuel filter to hoses. Make sure fuel filter is installed with

arrow pointing in direction of fuel flow.

CAUTION: Avoid injury! Compressed air can cause debris to

fly a long distance.•

•Clear work area of bystanders.

•Wear eye protection when using compressed air for

cleaning purposes.

•Reduce compressed air pressure to 210 kPa (30 psi).

IMPORTANT: Avoid damage! An obstructed air intake screen can

cause engine damage due to overheating. Keep air intake screen

and other external surfaces of the engine, including cooling fins,

clean at all times to allow adequate air intake.

CAUTION: Avoid injury! Touching hot surfaces can burn

skin. The engine, components, and fluids will be hot if the

engine has been running. Allow the engine to cool before

servicing or working near the engine and components.

IMPORTANT: Avoid damage! Dirt and debris can enter the engine

through a damaged filter element:

• Do not wash paper element.

• Do not attempt to clean paper element by tapping against

another object.

• Do not use pressurized air to clean element.

• Replace element only if it is very dirty, damaged or the seal is

cracked.

CAUTION: Avoid injury! Touching hot surfaces can burn

skin. The engine, components, and fluids will be hot if the

engine has been running. Allow the engine to cool before

servicing or working near the engine and components.

IMPORTANT: Avoid damage! Do not clean spark plugs with

abrasives.

CAUTION: Avoid injury! Fuel vapors are explosive and

flammable:•Do not smoke while handling fuel.

•Keep fuel away from flames or sparks.

•Shut off engine before servicing.

•Cool engine before servicing.

•Work in a well-ventilated area.

•Clean up spilled fuel immediately.

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.

Service Transmission - 26

SERVICE TRANSMISSION

Service Transmission

Hydraulic Oil

Use only 5W-50 or 15W-50 all synthetic oil.

Checking Hydraulic Oil Level

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Unscrew and remove hydraulic reservoir cap/dipstick (A) from hydraulic

oil reservoir.

3.Wipe dipstick with a clean cloth.

4.Install dipstick and allow the cap to rest on the end of the tube. Do not

tighten the cap.

5.Remove dipstick and check oil level. Oil level should be at top mark on

dipstick.

6.If necessary, add oil through oil reservoir filler neck.

7.Install cap on filler neck.

Changing Hydraulic Oil and Filter

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.

4.Remove cap (A) from oil reservoir tank filler neck.

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.

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.

IMPORTANT: Avoid damage! Dirt and debris in oil may cause

damage to the transaxle. Clean area around opening before

removing dipstick.

CAUTION: Avoid injury! Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid the hazard by

relieving pressure before disconnecting hydraulic or other

lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and

body from high pressure fluids.

Use caution when filling and draining hydraulic oil. During

periods of machine operation the hydraulic oil reservoir can

get hot. Allow engine and oil reservoir to cool before

servicing.

IMPORTANT: Avoid damage! 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.

Service Transmission - 27

SERVICE TRANSMISSION

11.Start engine.

12.Move throttle lever to 3/4-throttle position.

13.Unlock the park brake.

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

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Clean hydraulic oil cooler fins (A) on each hydraulic pump with a rag,

brush, or compressed air.

Removing and Installing Traction Drive Belt

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Remove mower deck drive belt.

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).

5.Install new drive belt.

6.Install mower deck drive belt as shown.

Checking and Adjusting Motion Control Linkages

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.Do not run an engine in an enclosed area without

adequate ventilation.

•Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the

exhaust fumes out.

CAUTION: Avoid injury! Help prevent serious bodily injury.

Remain alert to other people and the surroundings when

operating the machine.

CAUTION: Avoid injury! Compressed air can cause debris to

fly a long distance.

•Clear work area of bystanders.

•Wear eye protection when using compressed air for

cleaning purposes.

•Reduce compressed air pressure to 210 kPa (30 psi).

IMPORTANT: Avoid damage! To ensure proper cooling, keep the

cooling fins clean at all times. Operating the machine with

obstructed cooling fins could cause damage due to overheating.

CAUTION: Avoid injury! Fingers and hands can be pinched or

crushed. Keeps hands clear of sheave and belt pinch points

when servicing belt.

CAUTION: Avoid injury! Do not attempt this adjustment

unless you are a qualified and properly trained technician.

Improper adjustment can result in an unsafe machine.

Service Transmission - 28

SERVICE TRANSMISSION

Check Neutral Creep

NOTE: Check and adjust motion control linkages with the machine

parked on a hard, level surface.

1.Start 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.

5.Loosen nut (A), and move the dampener (B) in adjusting slot backward

or forward to stop machine creep.

• If machine creeps forward, slide dampener to the rear of the adjusting

slot. Tighten nut.

• 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.

7.Remove pin (C) and disconnect swivel (D) from each traction control rod

(E), and rotate the swivel.

8.Rotate swivel (D) to adjust:

• To stop forward creep, rotate each swivel (D) counterclockwise one

rotation.

• To stop rearward creep, rotate each swivel (D) clockwise one rotation.

9.Connect swivel to traction control rod.

10.Repeat as needed to stop machine creep.

11.Lower seat.

12.Lower the rear of the machine to the ground.

13.Check maximum speed drift.

Check Maximum Speed Drift

1.Check neutral creep, and adjust as needed.

2.Sit on the seat, and 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.

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.

Do not run an engine in an enclosed area without adequate

ventilation.

•Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the

exhaust fumes out.

Service Transmission - 29

SERVICE TRANSMISSION

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).

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 - 30

SERVICE TRANSMISSION

Hydraulic System Hose Routing

A- Hydraulic Reservoir

B- Oil Filter

C- Right Hydraulic Pump

D- Right Wheel Motor

E- Left Wheel Motor

F- Left Hydraulic Pump

Service Steering & Brakes - 31

SERVICE STEERING & BRAKES

Hydraulic System Schematic

A- Control Input Shaft

B- Pump Block

C- Charge Pump

D- Charge System Check Valve

E- Right Hydraulic Pump

F- Manual Bypass (Free-Wheel) Valve

G- Right Wheel Motor

H- Cooling Orifice

I - Charge Relief Valve

J - Left Wheel Motor

K- Left Hydraulic Pump

L- Oil Filter

M- Hydraulic Reservoir

Service Steering & Brakes

Service Steering & Brakes - 32

SERVICE STEERING & BRAKES

Removing and Installing 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.

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 Parking Safely in the SAFETY section.)

2.Raise and securely support the front of the mower deck.

3.Remove locknut (A), cap screw (B), two trash guards (C) and wheel and

tire assembly (D).

4.Remove bearings (E) and spacer tube (F) from wheel.

5.Wipe clean and inspect bearings (E). Replace bearings as needed.

6.Install spacer tube (F), press bearings (E) into wheel and tire assembly.

7.Install wheel and tire assembly (D), two trash guards (C), cap screw (B)

and locknut (A).

Adjusting Front Caster Spindle Bearing

NOTE: Adjustment required only if the front caster wheel shimmies

during travel.

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Remove dust cover (A) from top of spindle.

CAUTION: Avoid injury! The machine may fall or slip from an

unsafe lifting device or supports, injuring anyone beneath it.

• Remove key before raising machine.

• Use a safe lifting device rated for the load to be lifted.

• Lower machine onto stable supports or jack stands and

block wheels before servicing.

CAUTION: Avoid injury! The machine may fall or slip from an

unsafe lifting device or supports, injuring anyone beneath it.

•Remove key before raising machine.

•Use a safe lifting device rated for the load to be lifted.

•Lower machine onto stable supports or jack stands and

block wheels before servicing.

Service Steering & Brakes - 33

SERVICE STEERING & BRAKES

3.Remove cotter pin (B).

4.Turn castle nut (C) 1/4 turn clockwise.

5.Install a new cotter pin. Do not loosen the castle nut to align cotter pin

hole, tighten to align.

6.Replace dust cover.

7.Test machine to determine if shimmy is still present. Repeat adjustment

as necessary.

Servicing Caster Spindle Bearings

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Raise and securely support the front of the mower deck.

3.Remove cap (A), cotter pin (B), castle nut (C), caster yoke and wheel

assembly (D) and caster bushing (E).

NOTE: It is not necessary to remove the bearing races (F and G),

unless the bearings need to be replaced.

4.Remove seal (H) and lower bearing (I).

5.Remove upper bearing (J).

6.Clean and inspect bearings (I and J); pack with clean grease. Replace

bearings if needed.

7.Install lower bearing (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.

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.

CAUTION: Avoid injury! The machine may fall or slip from an

unsafe lifting device or supports, injuring anyone beneath it.

•Remove key before raising machine.

•Use a safe lifting device rated for the load to be lifted.

•Lower machine onto stable supports or jack stands and

block wheels before servicing.

Service Mower - 34

SERVICE MOWER

• 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.)

2.Move both motion control levers (A) from the neutral lock to the neutral

steer position.

3.Check levers for equal alignment.

• Check gap (B) between the levers. The recommended gap is 3-6 mm

(1/8-1/4 in.).

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 the neutral position

and check for the recommended gap of 3-6 mm (1/8-1/4 in.).

• If positions of the control levers are unequal, an adjustment is

necessary.

Alignment Procedure

1.Adjust position of motion control levers:

• Loosen cap screws (C).

• Slide both levers forward or rearward to desired position on control

arm until levers are aligned.

• Tighten cap screws.

Adjusting Park Brake

1.Park machine safely. (See Parking Safely in the SAFETY section.)

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.

Service Mower

Removing and Installing Mower Deck Foot Plate

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.

CAUTION: Avoid injury! Always operate the mower with the

foot plate installed. Operating with the foot plate removed can

cause serious injury.

Service Mower - 35

SERVICE MOWER

Removing Foot Plate

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Raise foot plate (A) using hole (B).

3.Remove and retain hardware (C) securing foot plate (A) on both sides of

machine.

4.Remove foot plate.

Installing Foot Plate

1.Install foot plate (A) using hardware (C) saved earlier.

2.Lower foot plate.

Removing and Installing Mower Deck Belt Shields

Removing Belt Shields

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Lower mower deck to the lowest cutting height position.

3.Remove knob (A).

4.Remove belt shield (B).

Installing Belt Shields

1.Install belt shield (B).

2.Install knob (A).

Leveling Mower Deck

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:

• Blade sharpness.

• Blade damage.

• Bent blades.

Checking Level (Side-to-Side)

NOTE: Mower deck anti-scalp wheels should not contact the ground.

1.Lower deck to the 76 mm (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.

CAUTION: Avoid injury! Help prevent serious personal injury.

Do not operate the mower without the belt shields installed.

CAUTION: Avoid injury! Rotating blades are dangerous.

Before adjusting or servicing mower:

•Remove ignition key or disconnect battery negative (-)

cable to prevent engine from starting accidently.

•Always wear gloves when handling mower blades or

working near blades.

Service Mower - 36

SERVICE MOWER

Picture Note: Discharge chute raised for photo clarity.

3.Position right mower blade (A) (discharge side) in the side-to-side

position.

4.Measure from outside blade tip to the ground.

• The difference between both measurements should be no greater

than 3 mm (1/8 in.).

5.If side-to-side level is not within specifications, an adjustment is

necessary.

Adjusting Level (Side-to-Side)

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.

• 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.

Adjusting Level (Front-to-Rear)

NOTE: Adjust side-to-side mower level before adjusting front-to-rear

level.

1.Loosen jam nut (D) on deck lift assist rod.

2.While positioned in front of the machine, adjust mower level:

• Turn hex nut (E) counterclockwise (F) to lower front of mower deck.

• Turn hex nut (E) clockwise (G) to raise front of mower deck.

3.Tighten jam nuts.

4.Check front-to-rear mower level.

IMPORTANT: Avoid damage! Adjust the left and right deck lift

assist rods equally.

Service Mower - 37

SERVICE MOWER

Checking and Adjusting Cutting Height

Checking Thrust Arm-to-Stop Rod Clearance (Transport Position)

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Set mower deck to transport (fully raised) position.

3.Check clearance (A) from the top of the thrust arms (B) to the bottom of

the thrust arm stop rod (C). The clearance should be 3 mm (1/8 in.).

Adjust Thrust Arm-to-Stop Rod Clearance (Transport Position)

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Loosen jam nut (A).

NOTE: If correct adjustment cannot be obtained by adjusting the lift

handle connecting rod, further movement can be gained by

adjusting the chain U-bolts.

Adjust all four chain U-bolts equally. All four chains should be tight.

Tighten the U-bolt of the loose chain to correct.

3.Adjust deck lift handle connecting rod (B) while viewing adjusting

mechanism from rear of machine.

• To lower deck, turn nut (C) counterclockwise.

• To raise deck, turn nut (C) clockwise.

4.Tighten jam nut (A).

Adjusting Deck Lift Assist Spring Tension

NOTE: Deck lift assist spring tension is adjusted at the factory. If the

effort required to raise or lower the mower deck is not satisfactory,

an adjustment may be necessary.

Check Spring Tension

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Raise the mower deck lift lever to the transport position.

3.Measure distance (A) between the washers (B) on each deck lift spring

assembly.

• The recommended factory setting is approximately 1 mm (1/32 in.)

gap between the spring coils at the lowest HOC setting.

Adjust Assist Spring Tension

NOTE: Do not overtighten the deck lift assist springs. If the springs

are compressed too tightly, the mower deck will float too freely.

Decrease deck lift assist spring tension if operating in rough terrain.

While positioned in front of the machine:

• Turn hex nut (C) clockwise to increase deck lift spring tension and

reduce the effort to raise and lower the mower deck.

• Turn hex nut (C) counterclockwise to decrease deck lift spring tension

and increase the effort to raise and lower the mower deck.

Checking and Adjusting Mower Deck Drive Belt

Tension

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Adjust the mower deck for the lowest cutting height, and lower the deck.

3.Raise foot platform.

CAUTION: Avoid injury! Rotating blades are dangerous.

Before adjusting or servicing mower:

•Remove ignition key or disconnect battery negative (-)

cable to prevent engine from starting accidently.

•Always wear gloves when handling mower blades or

working near blades.

Service Mower - 38

SERVICE MOWER

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 lb) is applied to the

center of the longest span.

When properly adjusted, there would be approximately a 2 mm (1/16 in.)

gap between the spring coils.

• To increase belt tension: Turn nut (C) clockwise.

• To decrease belt tension: Turn nut (C) counterclockwise.

6.Tighten jam nut (A).

7.Lower foot platform.

Removing and Installing Mower Deck Drive Belt

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Raise foot platform.

3.Remove mower deck drive belt covers.

4.Release mower deck drive belt tension by turning the tension adjuster

nut (A) counterclockwise.

5.Remove mower deck drive belt (B).

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.

Checking and Replacing Mower Blades

CAUTION: Avoid injury! Fingers and hands can be pinched or

crushed. Keeps hands clear of sheave and belt pinch points

when servicing belt.

CAUTION: Avoid injury! Do not work near raised mower deck

unless it is safely supported.

•Mower blades are sharp. Wrap blades or wear gloves

when servicing.

•Before performing any service function, wait for all

moving parts to stop turning.

•Disconnect battery or remove spark plug wire before

making repairs.

Service Mower - 39

SERVICE MOWER

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.

• Support with jack stands and/or wooden blocks.

4.Check mower blades:

• Mower blades should be sharp and free of any damage.

• Inspect blades; sharpen/balance or replace as necessary.

Replacing Mower Blades

1.Use two long-handled 15/16 in. wrenches to loosen nut (A).

2.Remove nut (A), blade bolt (B), three 1/4 in. washers (C) and blade (D).

3.Install replacement blade:

• Blade wing must face toward top of mower deck.

• Install blade bolt (B), blade (D), three 1/4 in. washers (C) and nut (A).

• Tighten blade nut to 81 N•m (60 lb-ft).

4.Lower machine.

5.Adjust mower deck to a desirable cutting height.

Sharpening Blades

• Sharpen blades with grinder, hand file, or electric blade sharpener.

• Keep original bevel (A) when grinding.

• Blade should have 0.40 mm (1/64 in.) cutting edge (B) or less.

• Balance blades before installing.

Balancing Blades

1.Clean blade.

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

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Remove mower blade. (See Checking and Replacing Mower Blades.)

IMPORTANT: Avoid damage! When replacing mower blades,

always use genuine Great Dane Service Parts.

IMPORTANT: Avoid damage! When installing the blade:

• Make sure the blade is properly seated on the spindle.

• Make sure the concave side of the large washer faces towards

the blade.

CAUTION: Avoid injury! Mower blades are dangerous!

•Always wear gloves while working on blades.

•Always wear safety eye protection when grinding.

CAUTION: Avoid injury! Mower blades are sharp. Always

wear gloves when handling mower blades or working near

blades.

Service Electrical - 40

SERVICE ELECTRICAL

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 (I).

6.Clean entire assembly.

7.Install a new lower bearing (F) and spacer (G) on the spindle shaft (E).

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 N•m (50 lb-ft).

12.Install mower blade, blade washers and blade bolt assembly. Tighten

nut to 81 N•m (60 lb-ft). (See Checking and Replacing Mower Blades.)

Service Electrical

WARNING: Battery posts, terminals and related accessories contain lead

and lead components, chemicals known to the State of California to cause

cancer and reproductive harm. Wash hands after handling.

Service the Battery Safely

Removing and Installing the Battery

Removing:

1.Park machine safely. (See Parking Safely in the SAFETY section.)

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).

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.

CAUTION: Avoid injury! The battery produces a flammable

and explosive gas. The battery may explode:

•Do not smoke near battery.

•Wear eye protection and gloves.

•Do not allow direct metal contact across battery posts.

•Remove negative cable first when disconnecting.

•Install negative cable last when connecting.

Service Electrical - 41

SERVICE ELECTRICAL

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

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Disconnect and remove battery.

3.Wash battery with a solution of four tablespoons of baking soda to one

gallon of water. Be careful not to get the soda solution into the battery

cells.

4.Rinse the battery with plain water and dry.

5.Clean terminals and battery cable ends with wire brush until bright.

6.Install battery.

7.Attach cables to battery posts using washers and nuts (H).

8.Apply petroleum jelly or silicone spray to terminals to prevent corrosion.

Using Booster Battery

A- Booster Battery

B- Disabled Vehicle Battery

1.Connect positive (+) booster cable to booster battery (A) positive (+)

post (C).

2.Connect the other end of positive (+) booster cable to the disabled

vehicle battery (B) positive (+) post (D).

3.Connect negative (–) booster cable to booster battery negative (–) post

(E).

4.Connect the other end (F) of negative (–) booster cable to a metal part of

the disabled machine engine block away from battery.

5.Start the engine of the disabled machine and run machine for several

minutes.

6.Carefully disconnect the booster cables in the exact reverse order:

negative cable first and then the positive cable.

Replacing Fuse

One 20-amp fuse is located behind the seat area.

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Remove defective fuse (A) from socket.

3.Check metal clip in fuse window and discard fuse if clip is broken.

4.Install new fuse in socket.

Burnishing the PTO Clutch

NOTE: The clutch will only require burnishing if a new clutch has

been installed.

1.Start and run the engine at 1/2 throttle.

2.Engage and disengage the PTO clutch five times (ten seconds on, ten

seconds off).

3.Move throttle lever to 3/4 throttle.

4.Engage and disengage the PTO clutch five times (ten seconds on, ten

seconds off).

CAUTION: Avoid injury! The battery produces a flammable

and explosive gas. The battery may explode:

•Do not smoke or have open flame near battery.

•Wear eye protection and gloves.

•Do not jump start or charge a frozen battery. Warm

battery to 16°C (60°F).

•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.

IMPORTANT: Avoid damage! Electric charge from booster battery

can damage machine components. Do not install negative

booster cable to machine frame. Install only to the engine block.

Install negative booster cable away from moving parts in the

engine compartment, such as belts and fan blades.

IMPORTANT: Avoid damage! When replacing fuses - use only a

20-amp fuse or you may damage the circuit.

Service Electrical - 42

SERVICE ELECTRICAL

Wiring Schematic

Service Miscellaneous - 43

SERVICE MISCELLANEOUS

Service Miscellaneous

Using Proper Fuel

Use regular grade unleaded fuel with an octane rating of 87 octane or

higher. Fuel blends containing up to 10% ethanol or up to 15% MTBE

reformulated fuel are acceptable. Do not use fuel or additives containing

methanol as engine damage can occur.

Always use fresh, clean fuel that is purchased in a quantity that can be

used within approximately 30 days, or add fuel stabilizer.

Fuel is blended to give best seasonal performance. To avoid engine

performance problems such as hard starting or vapor lock, use in-season

fuel. Use fuel during warm weather that was purchased during that

season, and use fuel during cold weather that was purchased during that

season.

Fuel can become stale in machines with engines that are used seasonally

or infrequently during a season. Stale fuel can produce varnish and plug

carburetor components which can affect engine performance.

Keep fuel storage container tightly covered and in a cool area out of direct

sunlight. Fuel can break down and degrade if not sealed properly or

exposed to sun and heat.

Condensation may collect in the fuel tank because of a variety of

operating or environmental conditions and, over time, may affect your

machine’s operation. Fill fuel tank at the end of daily use and store fuel in

plastic containers to reduce condensation.

For best year-round performance and fuel-handling, add stabilizer to fuel

immediately after fuel purchase. Such practice helps prevent engine

performance problems and allows fuel storage in the machine all year

without draining.

Filling Fuel Tank

Fill fuel tank at the end of each day’s operation to prevent condensation

and freezing during cold weather.

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Allow engine to cool.

3.Remove any trash from area around fuel tank cap.

4.Remove fuel tank cap slowly to allow any pressure built up in tank to

escape.

5.Fill fuel tank only to bottom of filler neck.

6.Install fuel tank cap.

Checking Tire Pressure

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Check tires for damage.

3.Check tire pressure with an accurate gauge.

4.Add air, if necessary:

Removing and Installing Rear Drive Wheels

Removing:

1.Park machine safely. (See Parking Safely in the SAFETY section.)

CAUTION: Avoid injury! Fuel vapors are explosive and

flammable:

•Shut engine off before filling fuel tank.

•Do not smoke while handling fuel.

•Keep fuel away from flames or sparks.

•Fill fuel tank outdoors or in well ventilated area.

•Clean up spilled fuel immediately.

•Use clean approved non-metal container to prevent

static electric discharge.

•Use clean approved plastic funnel without screen or

filter to prevent static electric discharge.

IMPORTANT: Avoid damage! Dirt and water in fuel can cause

engine damage:

• Clean dirt and debris from the fuel tank opening.

• Use clean, fresh, stabilized fuel.

• 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.

CAUTION: Avoid injury! Explosive separation of tire and rim

parts is possible when they are serviced incorrectly:

•Do not attempt to mount a tire without the proper

equipment and experience to perform the job.

•Do not inflate the tires above the recommended

pressure.

•Do not weld or heat a wheel and tire assembly. Heat can

cause an increase in air pressure resulting in an

explosion. Welding can structurally weaken or deform

the wheel.

•Do not stand in front or over the tire assembly when

inflating. Use a clip-on chuck and extension hose long

enough to allow you to stand to one side.

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)

Troubleshooting - 44

TROUBLESHOOTING

2.Slightly loosen five 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.

2.Install and tighten wheel nuts in numbered sequence shown for safe

wheel installation. Tighten alternately until recommended torque value is

reached.

• Tighten nuts to 100 N•m (75 lb-ft).

3.Lower machine.

Cleaning and Repairing Plastic Surfaces

Your authorized dealer has the professional materials needed to properly

remove surface scratches from any plastic surfaces, do not attempt to

paint over marks or scratches in plastic parts.

1.Wash surface with clean water and a mild liquid automotive washing

soap.

2.Dry thoroughly to avoid water spots.

Cleaning and Repairing Metal Surfaces

Cleaning:

Follow automotive practices to care for your vehicle painted metal

surfaces. Use a high-quality automotive wax regularly to maintain the

factory look of your vehicle’s painted surfaces.

Repairing Minor Scratches (surface scratch):

1.Clean area to be repaired thoroughly.

2.Use automotive polishing compound to remove surface scratches.

3.Apply wax to entire surface.

Repairing Deep Scratches (bare metal or primer showing):

1.Clean area to be repaired with rubbing alcohol or mineral spirits.

2.Use paint stick with factory-matched colors available from your

authorized dealer to fill scratches. Follow directions included on paint stick

for use and for drying.

3.Smooth out surface using an automotive polishing compound. Do not

use power buffer.

4.Apply wax to surface.

Troubleshooting

Using Troubleshooting Chart

If you are experiencing a problem that is not listed in this chart, see your

authorized dealer for service.

When you have checked all the possible causes listed and you are still

experiencing the problem, see your authorized dealer.

CAUTION: Avoid injury! The machine can fall or slip from an

unsafe lifting device or supports.

•Use a safe lifting device rated for the load to be lifted.

•Lower machine onto jack stands or other stable

supports and block wheels before servicing.

IMPORTANT: Avoid damage! Place jack stands under frame, not

under transmission or engine, when raising or supporting

machine.

IMPORTANT: Avoid damage! Improper care of machine plastic

surfaces can damage that surface:

• Do not wipe plastic surfaces when they are dry. Dry wiping will

result in minor surface scratches.

• Use a soft, clean cloth (bath towel, diaper, automotive mitt).

• Do not use abrasive materials, such as polishing compounds,

on plastic surfaces.

• Do not spray insect repellent near machine.

IMPORTANT: Avoid damage! Do not use rubbing compound on

painted surfaces.

Troubleshooting - 45

TROUBLESHOOTING

Engine

Electrical System

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.

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.

Choke adjusted incorrectly. See your

Great Dane servicing dealer.

Engine Will Not Slow Idle Bent or kinked throttle cable.

Bent governor control.

Incorrect governor idle control.

Carburetion problems. See your Great

Dane servicing dealer.

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.

Choke adjusted incorrectly. See your

Great Dane 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.

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.

Engine Uses Too Much Oil Find and correct oil leaks.

Incorrect engine oil.

Plugged oil filter.

Plugged air intake filter.

Engine Backfires Through

Muffler

Throttle should be at low idle for several

seconds before turning off machine.

Leaking/damaged exhaust manifold

gasket.

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.

If 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 terminals are dirty.

Dead cell in battery.

If Check

Troubleshooting - 46

TROUBLESHOOTING

Machine

Park Brake

Steering

Mower Deck

PTO Clutch Does Not

Engage

Blown 20-amp fuse (main power

circuit).

Faulty PTO switch.

Faulty PTO clutch.

Loose PTO clutch connections.

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.

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.

If Check

Park Brake Not Working

Correctly

Brakes out of adjustment - adjust

linkage.

Brake drums wet.

Worn brake shoes.

Brake cable damaged.

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 damaged or worn.

If Check

Machine Will Not Follow a

Straight Path

Steering tracking out of adjustment.

Machine Moves to the Left or

Right With Engine Running

and Transmission in Neutral

Pump linkage (neutral position) out of

adjustment.

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.

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.

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.

Sharpen or replace blades.

Change mowing pattern.

Check tire pressure.

If Check

Storage - 47

STORAGE

Storage

Storing Safety

Preparing Machine for Storage

1.Repair any worn or damaged parts. Replace parts if necessary. Tighten

loose hardware.

2.Repair scratched or chipped metal surfaces to prevent rust.

3.Remove grass and debris from machine.

4.Clean under the deck and remove grass and debris from inside chute

and bagger.

5.Wash the machine and apply wax to metal and plastic surfaces.

6.Run machine for five minutes to dry belts and pulleys.

7.Apply light coat of engine oil to pivot and wear points to prevent rust.

8.Lubricate grease points and check tire pressure.

Preparing Fuel and Engine For Storage

Fuel:

If you have been using “Stabilized Fuel,” add stabilized fuel to tank until

the tank is full.

NOTE: Filling the fuel tank reduces the amount of air in the fuel tank

and helps reduce deterioration of fuel.

If you are not using “Stabilized Fuel:”

1.Park machine safely in a well-ventilated area. (See Parking Safely in the

SAFETY section.)

NOTE: Try to anticipate the last time the machine will be used for the

season so very little fuel is left in the fuel tank.

2.Turn on engine and allow to run until it runs out of fuel.

3.For machines equipped with key switch, turn key to off position.

4.Mix fresh fuel and fuel stabilizer in separate container. Follow stabilizer

instructions for mixing.

5.Fill fuel tank with stabilized fuel.

6.Run engine for a few minutes to allow fuel mixture to circulate through

carburetor on gas engine or fuel injectors on diesel engine.

Engine:

Engine storage procedure should be used when vehicle is not to be used

for longer than 60 days.

1.Change engine oil and filter while engine is warm.

2.Service air filter if necessary.

3.Clean debris from engine air intake screen.

4.On gas engines:

• Remove spark plugs. Put 30 mL (1 oz) of clean engine oil in cylinders.

• Install spark plugs, but do not connect spark plug wires.

• Crank the engine five or six times to allow oil to be distributed.

5.Clean the engine and engine compartment.

6.Remove battery.

7.Clean the battery and battery posts. Check the electrolyte level, if your

battery is not maintenance free.

8.Close fuel shut-off valve, if your machine is equipped.

9. Store the battery in a cool, dry place where it will not freeze.

NOTE: The stored battery should be recharged every 90 days.

10. Charge the battery.

11. Store the vehicle in a dry, protected place. If vehicle is stored outside,

put a waterproof cover over it.

Removing Machine From Storage

1.Check tire pressure.

2.Check engine oil level.

3.Check battery electrolyte level, if your battery is not maintenance free.

Charge battery if necessary.

4.Install battery.

5.On gas engines: Check spark plug gap. Install and tighten plugs to

specified torque.

6.Lubricate all grease points.

7.Open fuel shut-off valve, if your machine is equipped.

8.Run the engine 5 minutes without the mower or any attachments

running to allow oil to be distributed throughout engine.

9.Be sure all shields and guards or deflectors are in place.

Assembly

Bag of Parts

Prepare for Assembly

• Remove machine from the shipping crate:

• Remove box containing operator seat.

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.

•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.

IMPORTANT: Avoid damage! Stale fuel can produce varnish and

plug carburetor or injector components and affect engine

performance.

• Add fuel conditioner or stabilizer to fresh fuel before filling tank.

IMPORTANT: Avoid damage! Prolonged exposure to sunlight

could damage the hood surface. Store machine inside or use a

cover if stored outside.

Qty. Description

1Key

1 Operator’s Manual

1 PDR Check List

Assembly - 48

ASSEMBLY

• Cut plastic tie straps fastening the front wheels to the shipping crate.

• Cut plastic tie straps holding the discharge chute up.

• Cut plastic tie straps securing the motion control levers to the

machine.

Check Fluid Levels

NOTE: Refer to the Service sections of the operator’s manual for

information regarding check locations and proper fluid levels.

• Check engine oil level.

• Check hydraulic oil level.

Check Tire Pressure

1.Check tires for damage.

2.Check tire pressure with an accurate gauge.

3.Add or remove air, if necessary.

Install Motion Control Levers

1.Remove hardware from control arms.

NOTE: The control lever mounting brackets have six holes. The

levers can be installed in the top four holes, or for a lower lever

position, install the levers in the lower four holes.

2. Raise the seat and prop it in the upright position.

NOTE: It is easiest during installation if the bottom rear bolts are

loosely installed first prior to installation of the front bolts.

3. Align motion control levers (A) with control arms. Install hardware and

tighten.

3.Check motion control lever alignment.

• Move both motion control levers forward.

Install Seat

CAUTION: Avoid injury! Explosive separation of tire and rim

parts is possible when they are serviced incorrectly:

•Do not attempt to mount a tire without the proper

equipment and experience to perform the job.

•Do not inflate the tires above the recommended

pressure.

•Do not weld or heat a wheel and tire assembly. Heat can

cause an increase in air pressure resulting in an

explosion. Welding can structurally weaken or deform

the wheel.

•Do not stand in front or over the tire assembly when

inflating. Use a clip-on chuck and extension hose long

enough to allow you to stand to one side.

Assembly - 49

ASSEMBLY

1.Remove and retain the two locknuts and cap screws securing the

flanges at the rear of the seat frame to the machine.

2.Pivot seat frame (A) forward until it rests on the hinge stops.

3.Remove and retain the seat pivot shoulder bolts (B) and nuts.

4.Remove protective covers from seat screws.

NOTE: The seat mounting hardware is attached to the seat plate with

tie straps.

5.Install seat (C) to the seat frame (A), using four 5/16-18 locknuts and

heavy flat washers (D). Tighten locknuts to 27 N•m (20 lb-ft).

6.Connect wire harness to seat safety switch (E).

7.Secure front of seat frame to machine with seat pivot shoulder bolts and

nuts, removed earlier. Tighten to 81 N•m (60 lb-ft).

8.Secure rear of seat frame to machine with capscrews and locknuts,

removed earlier.

Install ROPS

1.Support rear of bumper with wooden blocks or jack.

2.Loosen nut (A) securing the rear battery hold-down rod and disengage

hooked end (B) from bumper.

3.Remove all bumper mounting bolts and retaining hardware except for

the lower left cap screw (C) at each side of the machine. Discard any

assembly washers, retain bolts and locknuts for later use.

4.Fold ROPS to the upright operating position and install lock pins (D) and

spring pins (E).

Specifications - 50

SPECIFICATIONS

NOTE: Using a tapered drift will aid in the alignment of mounting

holes and ease installation of cap screws.

5.Lay ROPS on the ground, slide it up to the bumper and align the

appropriate hole in the ROPS flange with the lower rear mounting holes in

the machine frame and bumper. Install an M10 cap screw, removed

earlier, through the hole from the inside and secure loosely with an M10

locknut (F).

6. Remove cap screw (C).

NOTE: Take care when raising ROPS to avoid damaging paint on

bumper.

7.Using the lower rear bolts as a pivot, raise ROPS to the vertical position,

and install remaining cap screws and locknuts (F) on each side. Tighten all

ROPS mounting hardware to 80 N•m (59 lb-ft).

8.Engage hooked end (B) of rear battery hold-down rod in slot in bumper

and tighten nut to secure.

Lubricate Machine

Lubricate all moving parts before operating the machine. See Lubrication

Points in the Service Lubrication section.

Check Mower Deck Level

The mower deck is assembled and adjusted at the factory. After machine

is completely assembled, check the mower front-to-rear and side-to-side

deck level.

Check Safety System

For a complete checkout procedure of the safety interlock system, see

Testing the Safety Interlock System in the Operating section.

Initial Adjustments

1.Check free-wheel valves on both pump assemblies to make sure that

the valves are closed. Tighten valves to 108-163 N•m (80-120 lb-ft).

2.Raise the rear of the machine until the drive wheels are off the ground.

Support the machine with jackstands.

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 control linkage.

Specifications

Engine

NOTE: See engine manufacturer’s owner’s manual provided with

your machine for engine specifications.

Battery

Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt

CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340 amp

Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 minutes

BCI Group Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Tires

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 x 5.0-6

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 x 9.50-12

Inflation Front (Maximum) . . . . . . . . . . . . . . . . . . 110-138 kPa (16-20 psi)

CAUTION: Avoid injury! Machine component is heavy. Use a

safe lifting device or get an assistant to help lift and hold

component into place for installation.

CAUTION: Avoid injury! Clear area of all bystanders before

performing this service procedure.

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

•Move the machine to an outside area before running the

engine.

•Do not run an engine in an enclosed area without

adequate ventilation.

•Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the

exhaust fumes out.

Getting Quality Service - 51

GETTING QUALITY SERVICE

Inflation Rear (Maximum) . . . . . . . . . . . . . . . . . . . . .69-97 kPa (10-14 psi)

Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 N•m (75 lb-ft)

Capacities

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.2 L (8 gal)

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54 L (3.75 qt)

Net Weight - Chariot (With Mower Deck and Without

Fuel)

23-hp Kohler Engine/48-in. Deck . . . . . . . . . . . . . . . . . . . 499 kg (1100 lb)

25-hp Kawasaki Engine/52-in. Deck . . . . . . . . . . . . . . . . . 508 kg (1119 lb)

27-hp Kohler Engine/52-in. Deck . . . . . . . . . . . . . . . . . . 510 kg (1124 lb)

25-hp Kawasaki Engine/61-in. Deck . . . . . . . . . . . . . . . . 519 kg (1144 lb)

27-hp Kohler Engine/61-in. Deck . . . . . . . . . . . . . . . . . . 521 kg (1149 lb)

Travel Speeds

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-18 km/h (0-11 mph)

Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 km/h (0-5 mph)

Dimensions

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.)

48-Inch Mower Deck

Mower Type. . . . . . . . . . . . . . . . . . . . . . . . . Mulch, Bag or Side Discharge

Cutting Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Blade Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 N•m (60 lb-ft)

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 m (48 in.)

Cutting Height (approximate) . . . . . . . . . . . . . . . 25 to 127 mm (1 to 5 in.)

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 N•m (60 lb-ft)

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 N•m (60 lb-ft)

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55 m (61 in.)

Cutting Height (approximate) . . . . . . . . . . . . . . . 25 to 127 mm (1 to 5 in.)

Height Adjustment Increments . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2 in.)

Getting Quality Service

Service Literature

If you would like to order a copy of the Parts Catalog or Operator Manual

for this machine, contact your dealer. Parts catalogs and operator manuals

are also available online at GreatDaneMowers.com.

Parts

We recommend Great Dane quality parts available at your Great Dane

dealer.

Part numbers may change, use part numbers listed below when you order.

If a number changes, your dealer will have the latest number.

When you order parts, your Great Dane dealer needs your machine serial

number and engine serial number. These are the numbers that you

recorded in the Product Identification section of this manual.

Great Dane Quality Continues with Quality Service

Great Dane provides a process to handle your questions or problems,

should they arise, to ensure that product quality continues with your

authorized Great Dane dealer’s parts and service support.

Follow the steps below to get answers to any questions you may have

about your product.

1.Refer to your attachment and machine operator manuals.

2.Contact your authorized Great Dane dealer with unanswered questions.

ENGINE AND RELATED COMPONENTS - KAWASAKI - 52

ENGINE AND RELATED COMPONENTS - KAWASAKI

ENGINE AND RELATED COMPONENTS - KAWASAKI - 53

ENGINE AND RELATED COMPONENTS - KAWASAKI

Ref. No. Part No. Description Qty. Remarks

1 14M7166 LOCK NUT 4 M8

2 19M7897 SCREW 4 M8 X 35

3 200318 PULLEY 1 ENGINE TO PUMP

4 GDA10017 CLUTCH 1 MAG-STOP ELECTRIC

5 D18056 SPACER 1

6 D14208 LOCK WASHER 1

7 19H2531 CAP SCREW 1 7/16" X 3"

8 TCA16240 DRAIN VALVE 1

9 D18145 SHAFT KEY 1

10 D18379 CLAMP 1

11 M76926 TUBE 1

12 M78480 TIE BAND 2

13 M136651 GASKET 2 25 HP

14 GD10128 MUFFLER 1 25 HP

15 H137328 LOCK NUT 2

16 03M7184 BOLT 2 M8 X 20

17 D22236 ANGLE 1

18 12M7065 LOCK WASHER 4 M8

19 14M7273 NUT 4 M8

20 200316 BRACKET 1

21 03M7017 BOLT 2 M10 X 25

22 14M7518 FLANGE NUT 2 M10

ENGINE AND RELATED COMPONENTS - KOHLER 27 HP - 54

ENGINE AND RELATED COMPONENTS - KOHLER 27 HP

ENGINE AND RELATED COMPONENTS - KOHLER 27 HP - 55

ENGINE AND RELATED COMPONENTS - KOHLER 27 HP

NOTES

Ref. No. Part No. Description Qty. Remarks

1 14M7396 LOCK NUT 4 M8

2 19M8317 SCREW 4 M8 X 40

3 200311 PULLEY 1 ENGINE TO PUMP

4 GDA10122 CLUTCH 1 MAG-STOP ELECTRIC

5 GDU10312 SPACER 1

6 D14208 LOCK WASHER 1

7 D24022 BOLT 1

8 TCA15389 HOSE 1 OIL DRAIN

9 D18145 SHAFT KEY 1

10 230687 FITTING PLUG 1

11 M78480 TIE BAND 2

12 M132446 GASKET 2

13 D28121 MUFFLER 1

14 12M7065 LOCK WASHER 4 M8

15 14M7273 NUT 4 M8

16 200316 BRACKET 1 M8

17 03M7017 BOLT 2 M10 X 25

18 14M7518 FLANGE NUT 2 M10

FUEL DELIVERY SYSTEM COMPONENTS - 56

FUEL DELIVERY SYSTEM COMPONENTS

Ref. No. Part No. Description Qty. Remarks

1 181251 FILLER CAP 1

2 M88753 HOSE 1

3 R56101 CLIP 2

4 GDA10012 FUEL TANK 1

5 D18144 BUSHING 1

6 GDU10026 FUEL PICKUP 1 (INCLUDES M145626)

7 M63277 LOCK NUT 2 7.925 MM (5/16")

8 E53830 CLAMP 2

9 M63277 LOCK NUT 2 7.925 MM (5/16")

10 N10213 LOCK NUT 1 7.925 MM (5/16")

11 D14235 BOLT 2 7.925 MM X 63.5 MM (5/16"X 2-1/2")

12 GDU10028 STRAP 2

13 24H1776 WASHER 2 5/16" X 47/64" X .065

OVER THE LAP CONTROL ASSEMBLY - 57

OVER THE LAP CONTROL ASSEMBLY

Ref. No. Part No. Description Qty. Remarks

1 TCU14989 TUBE 2

2 M131171 GRIP 2

3 GDU10047 STRAP 2

4 19M8320 SCREW 4 M10 X 45

5 14M7518 FLANGE NUT 4 M10

6 03M7195 BOLT 2 M10 X 45

7 M85516 LOCK NUT 2 M10

8 TCU13271 ARM 2

9 GDU10275 COVER 1

10 37M7059 SCREW 3 M5 X 12

ELECTRICAL AND RELATED COMPONENTS - 58

ELECTRICAL AND RELATED COMPONENTS

ELECTRICAL AND RELATED COMPONENTS - 59

ELECTRICAL AND RELATED COMPONENTS

Ref. No. Part No. Description Qty. Remarks

1 57M7120 FUSE 1 20 AMP

2 D18334 SWITCH 2 NEUTRAL

3 M110159 NUT 1

4 AM101561 SWITCH 1 IGNITION

5 TCU17401 KEY 1

6 24M7349 WASHER 2 21 X 37 X 3 MM

7 GDA10060 WIRING LEAD 1 KAWASAKI

8 GDA10055 WIRING HARNESS 1 KAWASAKI

9 GDA10109 WIRING HARNESS 1 CARBURETED KOHLER

10 GDA10110 WIRING LEAD 1 GROUND (FUEL PUMP) KOHLER

11 M78480 TIE BAND 3

12 AM123716 RELAY 2

13 21M7246 SCREW 3 M6 X 16

14 14M7397 LOCK NUT 3 M6

15 AM118802 SWITCH 1 BLADE ENGAGEMENT

16 AM129887 HOUR METER 1

17 D14304 BOLT 2

18 D14305 LOCK NUT 2

19 D38001 SWITCH 1 PARK BRAKE

20 D28055 SWITCH 1 SEAT

21 GDA10017 CLUTCH 1 1" HUB

22 GDA10122 CLUTCH 1 1.125" HUB

23 D14288 SCREW 4

24 M63431 LOCK NUT 4

25 H122207 FLANGE NUT 2

26 AM101006 DIODE 5 1000V -3AMP

27 TCU17832 DIODE 1 400V - 6AMP

28 D38018 WIRING HARNESS 1

29 D28082 CLAMP 3

30 03M7184 BOLT 2 M8 X 20

31 14M7396 LOCK NUT 2 M8

32 GDA10037 WIRING HARNESS 1 MAIN CHASSIS

33 D28118 BATTERY CABLE 1 POSITIVE WITH BOOT

34 D28119 BATTERY CABLE 1 NEGATIVE WITH BOOT

35 03M7184 BOLT 2 M8 X 20

36 14M7396 LOCK NUT 2 M8

37 AM124356 WET CHARGED BATTERY 1

38 GDU10204 HOLDER 1

39 D23047 HOOK BOLT 2

** 14M7396 LOCK NUT 1 M8 MAIN STARTER (KAWASAKI)

40 200302 SEAT RELAY HARNESS 1

41 102770 RELAY 1 ISO MINI

42 963101 SCREW 1 12/24 SELF DRILLING

CONSOLE AND CONTROL ASSEMBLY - 60

CONSOLE AND CONTROL ASSEMBLY

CONSOLE AND CONTROL ASSEMBLY - 61

CONSOLE AND CONTROL ASSEMBLY

NOTES

Ref. No. Part No. Description Qty. Remarks

1 GDA10083 CONSOLE 1

2 19M7785 SCREW 5 M10 X 25

3 14M7396 LOCK NUT 7 M8

4 D14133 CAP SCREW 2

5 N10217 LOCK NUT 2

6 GDU10046 BRACKET 1 RH SEAT PLATE

7 GDU10045 BRACKET 1 LH SEAT PLATE

8 19M7867 SCREW 4 M8 X 25

9 14M7396 LOCK NUT 16 M8

10 GDA10097 PIVOT 1 LH CONTROL

11 GDA10098 PIVOT 1

12 M44508 BUSHING 4

13 M46676 THRUST WASHER 4

14 GDU10253 ARM 2

15 AA34134 BALL BEARING 2

16 24M7388 WASHER 6 10 X 16 X 1 MM

17 03M7195 BOLT 2 M10 X 45

18 M85516 LOCK NUT 2

19 19H1936 CAP SCREW 2 3/8" X 3/4"

20 GX10707 EXTENSION SPRING 2

21 D14236 SCREW 2

22 14H778 NUT 4 .190"

23 TCA13253 PIVOT 1

24 03M7184 BOLT 2 M8 X 20

25 M78480 TIE BAND 1

26 GDA10081 CONTROL LEVER 1 LH

27 GDA10080 CONTROL LEVER 1 RH

28 D18093 GRIP 2

29 03M7184 BOLT 8 M8 X 20

30 19H3693 SCREW 2 3/8" X 1 1/4"

31 TCU17400 ROD 2 CONTROL

32 D33002 SWIVEL 2 ADJUSTER

33 24M7106 WASHER 8 10 X 18 X 2.500 MM

34 11M7082 COTTER PIN 2 2.500 X 25 MM

35 TCA15322 GAS OPERATED CYLINDER 2

36 GDA10136 BRACKET 1

37 J16931 PIN 4

38 D28255 ACCELERATOR 1

39 D38146 CABLE 1 CHOKE

40 14H1080 NUT 1 3/8"

41 M63431 LOCK NUT 2

42 19M7867 SCREW 2 M8 X 25

43 E53830 CLAMP 2

Hydrostatic drive system Components - 62

HYDROSTATIC DRIVE SYSTEM COMPONENTS

Hydrostatic drive system Components - 63

HYDROSTATIC DRIVE SYSTEM COMPONENTS

NOTES

Ref. No. Part No. Description Qty. Remarks

1 D24028 FITTING 6

2 BULK HOSE AR (21") CASE RETURN, (MAKE FROM TY22503)

3 BULK HOSE AR (5") CASE RETURN, (MAKE FROM TY22503)

4 BULK HOSE AR (11-1/4") CASE RETURN, (MAKE FROM TY22503)

5 BULK HOSE AR (11-1/4") CHARGE INLET, (MAKE FROM TY22503)

6 BULK HOSE AR (5") CHARGE INLET, (MAKE FROM TY22503)

7 BULK HOSE AR (29") CHARGE INLET, (MAKE FROM TY22503)

8 D18379 CLAMP 12

9 D14197 FITTING 4

10 M86863 TEE FITTING 2

11 D28026 HOSE 2 HIGH PRESSURE (SHORT)

12 GDA10089 HYDRAULIC HOSE 2 HIGH PRESSURE (LONG)

13 D24026 FITTING 4

14 MT2119 NUT 2 PATCH LOCK

15 200313 PUMP 1 HYDROSTATIC (BDP - 12) RH

16 200312 PUMP 1 HYDROSTATIC (BDP - 12) LH

D19000 SEAL KIT 1

17 GDA10022 DIPSTICK 1

18 TCA15373 HYDRAULIC RESERVOIR 1

19 D18207 KEY 2

20 GDA10137 OIL FILTER 1

21 GDA10100 WHEEL MOTOR 2

AZ45116 GASKET KIT 1

M78480 TIE BAND 4

TRACTION DRIVE AND BRAKES - 64

TRACTION DRIVE AND BRAKES

TRACTION DRIVE AND BRAKES - 65

TRACTION DRIVE AND BRAKES

Ref. No. Part No. Description Qty. Remarks

1 GDA10036 PIVOT 1

2 D25059 ARM 1 IDLER

3 D18076 BUSHING 2

4 D18205 FITTING 1

5 D14104 SNAP RING 1

6 24H1441 WASHER 1

7 GDA10032 IDLER 1

8 03M7192 BOLT 3 M10 X 30

9 14M7518 FLANGE NUT 6 M10

10 19H1801 CAP SCREW 1 3/8" X 2"

11 24H1305 WASHER 1 13/32" X 13/16" X .065"

12 D14010 LOCK NUT 1

13 19M8162 SCREW 2 M10 X 40

14 14M7152 NUT 2 M10

15 14M7517 LOCK NUT 2 M10

16 D18071 EXTENSION SPRING 1

17 D28019 LEVER 1 PARKING BRAKE

18 37M7059 SCREW 4 M5 X 12

19 200326 BRACKET 1

20 D25014 RETAINER 1

21 D23062 SPACER 2 Includes O-ring

22 D28099 PUSH PULL CABLE 1 RH BRAKE

23 D28100 PUSH PULL CABLE 1 LH BRAKE

24 19H1900 CAP SCREW 8 5/16" X 3/4"

25 24H1136 WASHER 8 11/32" X 11/16" X .065"

26 19M8319 SCREW 3 M8 X 50

27 H137328 LOCK NUT 5

28 19M8008 CAP SCREW 2 M8 X 25

29 14M7151 NUT 2 M8

30 TCU10037 NUT 10 12.700 MM

31 GDA10000 TIRE AND WHEEL ASSEMBLY 2 23 X 9.5 X 12

32 GDU10096 SUPPORT 1

33 03M7199 BOLT 6 M12 X 35

34 H137329 LOCK NUT 6 M12

35 200312 PUMP 1 RH HYDROSTATIC

36 200313 PUMP 1 LH HYDROSTATIC

37 03M7192 BOLT 4 M10 X 30

38 TCA15316 PULLEY 2

39 D18067 SHAFT KEY 2

40 D25146 ARM 1 RH PUMP

41 D25147 ARM 1 LH PUMP

42 D13336 PLATE 2

43 19H2975 CAP SCREW 4 1/4" X 1-1/4"

44 34M5722 SPRING PIN 2 5 X 30 MM

45 D28125 V-BELT 1

46 22H907 SET SCREW 2 5/16" X 7/8"

47 GDA10100 MOTOR 2

48 19H1930 CAP SCREW 8 1/2" X 2-1/2"

49 H32811 LOCK NUT 8

50 MT2119 NUT 2 PATCH LOCK

51 D18207 KEY 2

52 TCA15373 HYDRAULIC RESERVOIR 1

53 GDA10022 DIPSTICK 1

54 GDA10137 OIL FILTER 1

55 GDU10184 BRACKET 1

56 19M7785 SCREW 2 M10 X 25

57 D28029 BRAKE SHOE 2

58 D28088 BRAKE DRUM 2

59 24H1776 WASHER 3 5/16" X 47/64" X 065"

60 200330 FAN SHIELD 1

61 200331 DECK STOP BUSHING 2

62 967387 CAP SCREW 2 1/2-13 X 2.00

63 967192 WHIZ LOCKNUT 2 1/2-13

Hydraulic Schematic - 66

HYDRAULIC SCHEMATIC

Seat Components - 67

SEAT COMPONENTS

Ref. No. Part No. Description Qty. Remarks

1 192068 SUSPENSION SEAT 1

181749 KIT 1 SEAT ADJUSTER

181461 ARM REST 1 SINGLE SUSPENSION W/HDWR

181074 SEAT SWITCH 1

2 24H1887 WASHER 4 11/32" X 1" X 0.134"

3 TCU17356 PAD 1 CUT TO LENGTH

4 200324 SEAT PLATE (YELLOW) 1

5 135139 BOLT 1 1/2 X 1.06 X 3/8-16

6 K40003 LOCK NUT 1

7 03M7184 BOLT 1 M8 X 20

8 E83830 CLAMP 3

9 14M7396 LOCK NUT 1 M8

10 M63277 LOCK NUT 4

11 14M7518 FLANGE NUT 4 M10

12 GDA10136 BRACKET 1

13 19M7786 SCREW 4 M10 X 30

14 181572 SEAT BELT 1 RETRACTABLE MALE + FEM.

15 960703 FLAT WASHER 4

16 960079 BOLT 2

17 964025 LOCK NUT 2

FRAME ASSEMBLY

FRAME ASSEMBLY - 69

FRAME ASSEMBLY

* NOTE: See authorized servicing engine dealer for engines and engine related service items. Always reference the

engine model number when ordering parts.

NOTES

Ref. No. Part No. Description Qty. Remarks

1 200338 FRAME 1

2 14M7396 LOCK NUT 1 M8

3 E53830 CLAMP 1

4 GDU10222 PLATE 1

5 03M7199 BOLT 4 M12 X 35

6 H137329 LOCK NUT 8

7 03M7197 BOLT 4 M12 X 25

8 JD7844 LUBRICATION FITTING 2

9 200329 PLATFORM 2

10 135139 LOCK NUT 2

11 964022 LOCK NUT 2

12 GDU10165 FENDER 1 LH

13 GDU10164 FENDER 1 RH

14 03M7017 BOLT 7 M10 X 25

15 03M7085 BOLT 1 M10 X 30

16 14M7518 FLANGE NUT 21 M10

17 19M7865 SCREW 3 M8 X 16

18A TCU20372 BUMPER 1 KOHLER ENGINE

18B TCU20695 BUMPER 1 KAWASAKI ENGINE

19 GDU10285 PLATE 2

20 GDU10184 BRACKET 1

21 GDU10170 BRACKET 1

22 191257 TRACTION TAPE 2

FRONT CASTER ASSEMBLY - 70

FRONT CASTER ASSEMBLY

FRONT CASTER ASSEMBLY - 71

FRONT CASTER ASSEMBLY

NOTES

Ref. No. Part No. Description Qty. Remarks

1 200334 YOKE 1 CASTER

2 TCU14490 ROUND RETAINER 2

3 AA21840 BALL BEARING 2

4 TCU13871 SPACER 1

5 TCA13769 TIRE AND WHEEL ASSEMBLY 1 13" CASTER

6 19M7978 CAP SCREW 1

7 14M7276 NUT 1 M16

8 TCU13454 SPACER 1

9 E14625 SEAL 1

10 JD8933 BEARING CONE 2

11 145553 BEARING CUP 2

12 24H180 WASHER 1

13 11M7083 COTTER PIN 1 3.200 X 50 MM

14 A12188 LOCK NUT 1

15 TCU14490 ROUND RETAINER 1

16 JD7844 LUBRICATION FITTING 1

17 TCU13604 RIM 1 13"

18 TCU15970 TIRE 1 13 X 5.00-5, 4 PLY

19 AM30795 TIRE VALVE STEM 1

ROPS - 72

ROPS

NOTES

Ref. No. Part No. Description Qty. Remarks

1 TCA16051 ROPS 1

Notes - 73

NOTES

SPINDLE ASSEMBLY - 74

SPINDLE ASSEMBLY































SPINDLE ASSEMBLY - 75

SPINDLE ASSEMBLY

NOTES

Ref. No. Part No. Description Qty. Remarks

1 200041 Spindle Assembly 1 Includes items 2, 3, 4, 5, 6, 14

2 200046 Ball Bearing 2

3 200042 Housing 1

4 200044 Spacer 1 1.000 x 1.250 x 2.772

5 200043 Shaft, Spindle 1

6 200045 Bolt 3 3/8-16

7 D13055 Nut, Pulley (Special) 3

8 D18209 Pulley, Cutter Housing, 48" Deck 3

D18084 Pulley, Cutter Housing, 52" Deck 3

D18211 Pulley, Cutter Housing, 61" Deck 3

9 D13024 Spacer, Pulley 3

10 967347 Bolt, Blade 3 5/8-18 x 7-3/4 HHCS

11 960502 Nut 18 3/8-16 Std Hex GR5

12 D18055 Spacer, Blade Bolt 9

13 GDU10230 16.5" Blade, 48" Deck 3

GDU10231 18.0" Blade, 52" Deck 3

GDU10232 21.0" Blade, 61" Deck 3

14 200047 Zerk, Grease S/O 3

DECK LIFT ASSEMBLY - 76

DECK LIFT ASSEMBLY

DECK LIFT ASSEMBLY - 77

DECK LIFT ASSEMBLY

NOTES

Ref. No. Part No. Description Qty. Remarks

1 TCU18697 BEARING CAP 8

2 GDA10093 ARM 1

3 GDU10242 PLATE 1

4 19M7796 SCREW 1 M6 X 30

5 H137327 LOCK NUT 1

6 GDA10092 ARM 1

7 19M7803 SCREW 8 M8 X 70

8 14M7396 LOCK NUT 8 M8

9 JD7849 LUBRICATION FITTING 4

10 GDA10101 LEVER 1

11 W10728 BUSHING 1

12 R58806 SNAP RING 1

13 D18079 GRIP 2

14 200339 LEVER 1

15 TCA15049 LEVER 1

16 TCU17371 TORSION SPRING 1

17 03M7204 BOLT 3 M12 X 60

18 TCU15816 SPACER 2

19 D28155 PIN FASTENER 1

20 D25107 ROD 1

21 D23049 SWIVEL 1

22 14H1039 NUT 2 5/8"

23 24H1111 WASHER 3 17/32" X 1-1/16" X .090"

24 11M7015 COTTER PIN 2 3.200 X 25 MM

25 GDU10162 STUD 1

26 14H1058 NUT 5 3/4"

27 GDU10238 SWIVEL 1

28 TCU17245 SWIVEL 1

29 24H1236 WASHER 1 13/16" X 2" X .149"

30 D28200 COMPRESSION SPRING 1

31 TCA13510 LINK CHAIN 4

32 GDU10048 U-BOLT 4

33 H137329 LOCK NUT 11

34 N10215 LOCK NUT 16

35 19M8162 SCREW 4 M10 X 40

36 24H1413 WASHER 6 57/64" X 1-3/8" X 0.048"

37 A15147 SPRING LOCKING PIN 1

48" AND 52" CUTTING DECK - 78

48" AND 52" CUTTING DECK

48" AND 52" CUTTING DECK - 79

48" AND 52" CUTTING DECK

Ref. No. Part No. Description Qty. Remarks

1 GDA10104 MOWER DECK 1 48"

GDA10088 MOWER DECK 1 52"

2 D18209 PULLEY 3 CUTTER HOUSING 48"

D18084 PULLEY 3 CUTTER HOUSING 52"

3 D13024 SPACER 3

4 D13055 NUT 3

5 200041 SPINDLE 3

6 19M7786 BOLT 18 M10 X 1.5 X30 HHFCS

7 E63526 Nut 18 M10 X 438 HHSFN

8 D18055 SPACER 9

9 967347 BOLT 3 5/8-11 X 2.25

10 14H1083 NUT 3 5/8"

11 GDU10230 BLADE 3 48" HIGH LIFT

GDU10231 BLADE 3 52" HIGH LIFT

12 TCU14540 BUSHING 2

13 GDU10119 STRAP 1

14 TCU16092 V-BELT 1 ENGINE TO BLADES 48"

TCU16093 V-BELT 1 ENGINE TO BLADES 52"

15 TCU18744 WHEEL 4 GAGE

16 GDU10251 COVER 1 LH 48"

GDU10249 COVER 1 LH 52"

17 GDU10252 COVER 1 RH 48"

GDU10250 COVER 1 RH 52"

18 M119352 KNOB 2

19 GDA10084 ARM 1 LH

20 GDA10085 ARM 1 RH

21 D18076 BUSHING 4

22 JD7844 LUBRICATION FITTING 3

23 19H2380 SCREW 2 1/4" X 1"

24 D24008 LOCK NUT 2

25 TCA13292 PIN FASTENER 2

26 03M7185 BOLT 2 M8 X 25

27 14M7396 LOCK NUT 2 M8

28 GDA10103 PIVOT 2

29 03H1729 BOLT 2 1/4" X 1

30 H122207 FLANGE NUT 2

31 TCA15346 ARM 1

32 D18032 PULLEY 1

33 03H1658 BOLT 1 3/8" X 2-1/4"

34 24H1305 WASHER 1 13/32" X 13/16" X .065"

35 K40003 LOCK NUT 4

36 03H1836 BOLT 1 3/8" X 3-1/2"

37 AM127235 CHUTE 1

38 M132768 TORSION SPRING 1

39 H141123 PUSH NUT 1

40 03H2040 BOLT 1

41 D13005 HOOK BOLT 1 48"

D23058 HOOK BOLT 1 52"

42 D28025 SPRING 1

43 D14010 LOCK NUT 1

44 N10215 LOCK NUT 1

45 TCA14548 PULLEY 1

46 GDU10180 SPACER 1

47 03H1838 BOLT 1 3/8" X 5"

48 D28050 IDLER 1

49 GDU10181 SPACER 1

50 D24040 BOLT 2

51 E62934 FLANGE NUT 2

61" CUTTING Deck - 80

61" CUTTING DECK

61" CUTTING Deck - 81

61" CUTTING DECK

Ref. No. Part No. Description Qty. Remarks

1 GDA10077 MOWER DECK 1 61"

2 D18211 PULLEY 3 CUTTER HOUSING 61"

3 D13024 SPACER 3

4 D13055 NUT 3

5 200041 SPINDLE 3

6 19M7786 BOLT 18 M10 X 1.5 X30 HHFCS

7 E63526 NUT 18 M10 X 438 HHSFN

8 D18055 SPACER 9

9 967347 BOLT 3 5/8-11 X 2.25

10 14H1083 NUT 3 5/8"

11 GDU10232 BLADE 3 61" HIGH LIFT

12 TCU14540 BUSHING 2

13 GDU10119 STRAP 1

14 E62934 FLANGE NUT 4

15 TCU18744 WHEEL 6 GAGE

16 D24040 BOLT 4

17 GDU10187 COVER 1 LH 61"

18 M119352 KNOB 2

19 GDA10084 ARM 1 LH

20 GDA10085 ARM 1 RH

21 D18076 BUSHING 4

22 JD7844 LUBRICATION FITTING 3

23 19H2380 SCREW 2 1/4" X 1"

24 D24008 LOCK NUT 2

25 TCA13292 PIN FASTENER 2

26 03M7185 BOLT 2 M8 X 25

27 14M7396 LOCK NUT 2 M8

28 GDA10103 PIVOT 2

29 03H1729 BOLT 2 1/4" X 1

30 H122207 FLANGE NUT 2

31 TCA15346 ARM 1

32 D18032 PULLEY 1

33 03H1658 BOLT 1 3/8" X 2-1/4"

34 24H1305 WASHER 1 13/32" X 13/16" X .065"

35 K40003 LOCK NUT 4

36 03H1836 BOLT 1 3/8" X 3-1/2"

37 AM127488 CHUTE 1

38 M132768 TORSION SPRING 1

39 H141123 PUSH NUT 1

40 03H2040 BOLT 1

41 D23058 HOOK BOLT 1 61"

42 D28025 SPRING 1

43 D14010 LOCK NUT 1

44 N10215 LOCK NUT 1

45 TCA14548 PULLEY 1

46 GDU10180 SPACER 1

47 03H1838 BOLT 1 3/8" X 5"

48 D28050 IDLER 1

49 GDU10181 SPACER 1

61" CUTTING Deck - 82

61" CUTTING DECK

LABELS

LABELS - 83

LABELS

NOTES

Ref. No. Part No. Description Qty. Remarks

1 181023 Decal 1 HYDRO OIL SPECS.

2 D28167 Decal 1 THROTTLE CONSOLE

3 D28181 Decal 1 NO STEP

4 GDU10254 Decal 1 CHARIOT

5 200343 LABEL 1 BRUTUS

6 GDU10256 LABEL 2 PUPPY PAW

7 GDU10257 LABEL 1 GREAT DANE BLACK

8 GDU10258 LABEL 1 GREAT DANE WHITE

9 GDU10259 LABEL 1 MOTION CONTROL OTL KIT

10 GDU10260 LABEL 1 MOTION CONTROL CONSOLE

11 GDU10262 LABEL 1 BELT PATH 48", 52", 61" DECK

12 GDU10267 LABEL 1

13 GDU10268 LABEL 1

14 GDU10269 LABEL 1

15 M17554 LABEL 2 WARNING - HOT SURFACES

16 M127610 LABEL 1 IGNITION

17 M131739 LABEL 2 DANGER BLADE CONTACT

18 M131748 LABEL 1 DANGER THROWN OBJECTS

19 M137637 LABEL 1 DISCHARGE

20 TCU51051 LABEL 1 DANGER, ROTATING BLADES

21 TCU14840 LABEL 1 GENERAL CAUTION

22 TCU14862 LABEL 1 PARK BRAKE DIRECTION

23 TCU13514 LABEL 4 ROPS WARNING - ENGLISH

24 TCU13515 LABEL 4 ROPS WARNING - SPANISH

25 TCU20576 LABEL 4 ROPS CERTIFICATION - SPANISH

26 TCU14885 LABEL 1 DANGER, EXPLOSIVE GASES/POISON

27 TCU15908 LABEL 1 CUT HEIGHT

28 TCU151051 LABEL 1 DANGER, ROTATING BELTS

29 TCU20575 LABEL 4 ROPS CERTIFICTATION

30 TCU15907 LABEL 1 WARNING SLOPE

LABELS - 84

Great Dane Chariot Brutus Gbkh2752S Users Manual

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