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Great Dane GDRZ61-28KHE Lawn Mower User Manual

1. 1 32 m 52 in Overall 1 14 m 45 Overall Length Model 647 1 6 m 65 5 in Overall Length Model 657 and Model 667 1 7 m 68 5 in Overall Width 48 inch deck with chute up 1 36 m 53 5 in Overall Width 48 inch deck with chute down 1 57 m 62 in Overall Width 54 inch deck with chute up 1 46 m 57 5 in Overall Width 54 inch deck with chute down 1 73 m 68 in Overall Width 60 inch deck with chute up 1 61 m 63 5 in Overall Width 60 inch deck with chute down 1 88 m 74 in Recommended Lubricants Engine Oil deres Acie See Applicable Engine Manual Hydraulic Oil 5W 50 15W 50 All Synthetic Grease This may change for high speed applications such as cutting units Lue Sar Ee ta di All Purpose Grease with an NLGI Grade No 2 Rating Specifications and design subject to change without notice Specifications 38 GETTING QUALITY SERVICE 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 Great Dane 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
2. GREAT DANE Super Surfer Series Il GSKH1848S GSKH2352S GSKH2561S GSKW1948S GSKW2352S GSKA1948S OPERATOR S MANUAL 200036 REV 04 11 2007 North American Version A WARNING the Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm California Proposition 65 Warning AII information illustrations and specifications in this manual are based on the latest information at the time of publication The right is reserved to make changes at any time without notice COPYRIGHT 2007 Auburn Consolidated Industries Inc All rights reserved Previous Editions COPYRIGHT 2002 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 in
3. 4 2 2 2 Il f 2 Side Kawasaki Only lt gt LH Side Battery Electrical Harness and Components 64 BATTERY ELECTRICAL HARNESS AND COMPONENTS Ref No Part No Description Qty Remarks 1 TCA15061 Wiring Harness 1 Main Kohler 200204 Wiring Harness 1 Main Kawasaki 2 19M7372 Cap Screw 2 M5 x 0 8 x 16 3 14M7360 Nut 2 M5 x 0 8 4 AM123716 Relay 2 5 57M7120 Fuse 2 20A 6 24H1283 Washer 1 7 AM129887 Hour Meter 1 8 TCU13098 Clip 1 9 TCA15075 Key Switch 1 10 M110159 Nut 1 11 TCU17401 Ignition Key 1 12 AM118802 Switch PTO 1 13 M72685 Spacer 1 14 D28159 Isolator Pad 1 Battery 15 200085 Battery Box 1 16 D18318 Cable Positive 1 17 191227 Cable Negative 1 18 14M7396 Flange Nut 2 M8x 1 25 19 03M7184 Carriage Bolt 2 M8 x 1 25 x 20 20 03M7184 Carriage Bolt 4 8 x 1 25 x 20 21 H110730 Flange Nut 2 5 16 22 03H1832 Cap Screw 2 5 16 x 6 23 14M7396 Nut 4 8 24 Dry Charged Battery 1 25 200074 Adapter Assy Kawasaki 1 26 200069 Solenoid Mounting Plate 1 27 180640 Start Solenoid 1 28 180842 Starter Cable 1 12 29 200924 Fusible Link 1 30 960001 Capscrew 1 4 x 75 2 31 964040 Locknut 1 4 Whiz 2 M78480 Tie Strap AR Not shown NOTES Battery Electrical Harness and Components 65 CASTER WHEELS AND REAR WHEELS Caster Wheels and Rear Wheels 66 CASTER WHEELS AND WHEELS Ref No Part No Description Qty Remark
4. 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 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 connecti
5. 1 Park machine safely See Parking Safely in the SAFETY section 2 Allow engine to cool Service Engine 20 SERVICE TRANSMISSION MX20149 3 Slide hose clamps A away from fuel filter B 4 Place drain pan under hoses to catch any fuel that may be left in the hoses 5 Disconnect hoses from fuel filter B 6 Install new fuel filter B Make sure fuel filter B is installed with arrow pointing in direction of fuel flow 7 Connect hoses to new fuel filter B 8 Install hose clamps A 9 Start engine and check for fuel leaks Service Transmission Hydraulic Oil Use only 5W 50 or 15W 50 all synthetic oil Checking Hydraulic Oil Level IMPORTANT Avoid Damage Check oil level in reservoir tank when oil is cold Do not overfill oil reservoir tank Oil will expand during operation and could overflow 1 Park machine safely Refer to Parking Safely in SAFETY section HYDRO RESERVOIR MX20114 2 Clean area around reservoir dipstick cap A 3 Remove dipstick cap A Wipe dipstick clean NOTE Do not tighten dipstick cap when checking oil level 4 Insert dipstick into reservoir filler neck B Do not tighten cap 5 Remove dipstick Check oil level on dipstick Oil level should be in crosshatch area between ADD and FULL marks If oil is low add oil to bring oil level no higher than FULL mark on dipstick If oil is above FULL mark drain oil to proper
6. A CAUTION Avoid injury Prevent Battery Explosions Keep sparks lighted matches and open flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a frozen battery it may explode Warm battery to 16 degrees C 60 degrees F SULFURIC ACID FLUSH EYES IMMEDIATELY M GAUSE WITH WATER GET MEDICALHEL FAST wml MAMED TEMEN IDE IMMEDIATE 5 ULF E TUE L GRANDE Ely 1 Connect positive red cable to battery positive terminal Install red terminal cover A 2 Connect negative black cable to battery negative terminal Install black terminal cover B 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 Machine Safety Systems Perform safety system check to make sure the electronic safety interlock circuit is functioning properly Specifications Engine Note See engine manufacturer s owner s manual provided with your machine for engine specifications Drivetrain SPY Ove Ee Dual Hydrostatic PUMPS urease Rte ene Hydro Gear BDP 10A Wheel Motors Hydro Gear HGD 12 1792 Number of Speeds Infinitely Variable Electrical System Chargi
7. M Hydraulic Reservoir Hydraulic Schematic 54 PLATFORM COMPONENTS Ref No Part No Description Qty Remarks 1 D18038 Park Brake Switch 1 2 D38128 Com Spring 1 22x 162x2 5 1 3 200299 Platform Weldment 1 4 200618 Platform Plate 1 5 200619 Platform Tab LH Plate 1 6 200655 Miner GBR 6 Bumper 2 7 200691 Platform Wedge 2 8 200693 Platform Tab Plate 1 9 200767 Anchor 1 10 200770 Spring Washer 1 11 200935 Cover 1 12 960001 Bolt 4 1 4 20 x 750 Hex Gr 5 13 963074 Carriage Bolt 2 5 16 18 x 1 00 14 960046 Bolt 2 3 8 16 x 1 00 Hex Gr 5 15 960055 Bolt 1 3 8 16 x 3 25 Hex Gr 5 16 960502 Nut 1 3 8 16 Hex Gr 5 17 960701 Washer 2 3 8 Reg Flat 18 963019 Carriage Bolt 6 3 8 16 x 1 00 19 963033 Carriage Bolt 2 3 8 16 x 3 4 20 964013 Locknut 2 10 24 Nylock 21 964048 Locknut 4 1 4 20 Nyloc 22 967115 Locknut 2 5 16 18 Nyloc 23 967340 Screw 2 10 24 x 625 PAN PHL MAC 24 968087 Locknut 10 3 8 16 Nyloc Platform Components 55 F UEL TANK AND LINES 0 a 20229 Fuel Tank and Lines 56 FUEL TANK AND LINES Ref No Part No Description Qty Remarks 1 TCA15021 Fuel Tank 1 2 181251 Cap Fuel 1 No Lanyard 3 D18144 Grommet 1 4 TCA15048 Fuel Pickup 1 5 M68342 Clamp 5 6 M88753 Hose Fuel 1 4 in SAE 30 R7 AR 10 Ft Hose 7 14M7400 Nut 4 8 AM116304 Filter 1 9 03M7191 Cap Screw 4 10 19M7865 Cap Screw 6 11 TCU18489 Bracket 1 N
8. cap screw locknut A 9 Use a grease gun to fill hub until grease just appears at one of the seals E 10 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 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 1 Wash surface with clean water and a mild liquid automotive washing soap Service Miscellaneous 33 TROUBLESHOOTING 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 If Check IMPORTANT Avoid damage Do not use rubbing compound on painted surfaces 2 Use automotive polishing compound to remove surface scratches 3 App
9. Loose hardware Check replace deck drive belt Blade bolts are loose Blades are bent or worn Sharpen and balance blades Remove belt shields and clean debris from sheaves Check sheaves for proper alignment or damage See authorized dealer Mower Blades Do Not Engage Deck drive belt slipping or broken Deck belt tension spring not installed or broken PTO switch faulty Fuse blown Loose electrical connections PTO clutch faulty Mower Mows Unevenly Mower deck not properly leveled Ground speed too fast for conditions Run engine at fast throttle Reduce ground speed when making turns Sharpen or replace blades Change mowing pattern Check air pressure in all traction unit tires Anti scalp rollers not adjusted correctly Storage Storing Safety CAUTION Avoid injury Fuel vapors are explosive and flammable Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Run the engine only long enough to move the machine to or from storage Do not store vehicle with fuel in the tank inside a building where fumes may reach an open flame or spark Allow the engine to cool before storing the machine in any enclosure Preparing Machine for Storage 1 Repair any worn or damaged parts Replace parts if necessary Tighten loose hardware 2 Repair scratched or chipped metal surfaces to prevent rust
10. Keep original bevel A when grinding Blade should have 0 40 mm 1 64 in cutting edge or less Balance blades before installing Balancing Blades A CAUTION Avoid injury Mower blades are sharp Always wear gloves when handling mower blades or working near blades 1 Clean blade 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 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 Service Electrical 29 SERVICE ELECTRICAL CAUTION Avoid injury Battery electrolyte contains sulfuric acid It is poisonous and can cause serious burns Wear eye protection and gloves Keep skin protected If electrolyte is swallowed get medical attention immediately If electrolyte is splashed into eyes flush immediately with water for 15 30 minutes and get medical attention If electrolyte is splashed onto skin flush immediately with water and get medical attention if necessary The battery produces a flammable and explosive gas The battery may explode Do not smoke near battery Wear eye protection and gloves Do
11. 2 to 3 4 turn after gasket contact 9 Remove dipstick cap from hydraulic reservoir filler neck Service Transmission 21 SERVICE TRANSMISSION IMPORTANT Avoid Damage Do not add oil beyond FULL mark Oil capacity after draining may be less than dry fill capacity Check oil level before filling completely NOTE Dry fill capacity for hydraulic system is 3 1L 3 3 qt 10 Fill oil reservoir with approximately 1 9L 2 qt of oil 11 Insert dipstick Tighten cap 12 Start engine 13 Move throttle lever to 1 2 to 2 3 position 14 Unlock park brake A CAUTION Avoid injury Help prevent serious bodily injury Remain alert to other people and the surroundings when operating the machine 15 Cycle motion control levers forward and rearward several times Check for leaks around filter 16 Stop engine Check oil level Add oil as necessary to bring oil level to FULL mark on dipstick Cleaning Hydraulic Oil Pump Cooling Fins CAUTION Avoid injury Compressed air can cause debris to fly a long distance Clear work area of bystanders Wear eye protection when using compressed air for cleaning purposes Reduce compressed air pressure to 210 kPa 30 psi IMPORTANT Avoid Damage To ensure proper cooling keep the cooling fins clean at all times Operating the machine with obstructed cooling fins could cause damage due to overheating 1 Park machine safely See Pa
12. 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 IMPORTANT Avoid Damage Stale fuel can produce varnish and plug carburetor or injector components and affect engine performance Add fuel conditioner or stabilizer to fresh fuel before filling tank 4 Mix fresh fuel and fuel stabilizer in separate container Follow stabilizer instructions for mixing 5 Fill fuel tank with stabilized fuel 6 Run engine for a few minutes to allow fuel mixture to circulate th
13. 5 Stop engine and remove key Wait for mower blades to stop turning before leaving operator s position Operating 16 SERVICE INTERVALS Service Intervals Servicing Your Machine IMPORTANT Avoid Damage Operating in extreme conditions may require more frequent service intervals Engine components may become dirty or plugged when operating in extreme heat dust or other severe conditions Engine oil may lose efficiency if vehicle is operated constantly at slow or low engine speeds or with frequent short trips Please use the following timetables to perform routine maintenance on your machine Servicing Engine See engine manufacturer s owner s manual provided with your machine for engine service information Break In After First 10 Hours Check air pressure in tires Check wheel bolt torque Check and adjust park brake Change engine oil and filter Check mower deck drive belt tension Check hydraulic pump drive belt Check transmission neutral adjustment Every 40 Hours Check air pressure in tires Check wheel bolt torque Check and adjust park brake Change engine oil and filter Check foam and paper air cleaner elements Clean engine shrouds as needed Lubricate front caster spindles and wheels Lubricate mower deck lift pivot tubes Lubricate mower deck idler pivot Lubricate mower deck push arms Check mower deck drive belt tension Lubricate
14. 61 Deck 3 14 959995 Zerk Grease 5 1 NOTES Mower Deck Spindles 73 LABELS AND DECALS AWARNING MANUFACTURED UNDER THE A DANGER To meld iguy ton pone ee saves FOLLOWING PATENT S Do not mow No usar la non 5 964 082 5 765 347 5 600 944 herde chute 5 507 138 5 809 756 6 085 504 orenlire descargao sin A ADVERTENCIA 6 094 897 6 189 305 6 189 304 ehe depasto en vial dos ne Yar eA mio AND OTHER PATENT S sur lugar transversal en vez de hacia arriba j abajo PENDING Si la m quina se para mientas s er UNA Tia da WARNING d ADVERTENCIA SUPER SURFER Series Il 5 AXCAUTION AATENCION HELP AVOID INJURY AYUDAR A EVITAR LESIONES Operator training required Sa requiere entrenamianto del aperador Road operator s manual Lear o manual del operador Keep shields in place Manianer Ing escudos en su higar Never carry riders Iavar pasaj ros Keep people a sata distance away Mantener a lag dam s personas a una distancia prudente Maintala all safety devices Mantener 105 dispositivos de sai uridad an buen estado Before ieavin hi Antes de de la maquina Stop engine park braka Remove key Apsparel motor Apilear of estconamiecto tallava A ADVERTENCIA AWARNING To avoid injury from rotating belts keep all shlelds and DANGER PELIGRO ACAUTION guards in piace To avoid injury Para evit
15. 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 Never mow on inclines exceeding 15 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
16. blades always use genuine Great Dane Service Parts NOTE Only replace blades Never straighten or weld them Checking Mower Blades 1 Park machine safely See Parking Safely in the Safety Section 2 Raise the mower deck to the transport position also the 12 7 cm 5 in cutting height position 3 Raise front of machine with a safe lifting device 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 Remove blade bolt A three 1 4 in washers and blade 2 Install replacement blade Blade wing must face toward top of mower deck IMPORTANT Avoid Damage When installing the blade Make sure the blade is properly seated on the spindle Make sure the concave side of the large washer faces towards the blade Install blade bolt A blade B and three 1 4 in washers C Tighten blade bolt to 163 N m 120 Ib ft 3 Lower machine 4 Adjust mower deck to a desirable cutting height Sharpening Blades A Avoid injury Mower blades are dangerous Always wear gloves while working on blades Always wear safety eye protection when grinding Sharpen blades with grinder hand file or electric blade sharpener MIF Service Mower 28 SERVICE ELECTRICAL
17. 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 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
18. engine Set park brake Remove key CAUTION 1 Be safe To avoid a fire hazard remove all leaves grass and debris from engine hydro pumps and motors pulleys belts hoses engine deck and cutter deck DANGER POISON J Shield Eyes Explosive gases can cause blindness or injury NO Sparks Flames Smoking Sulfuric acid can cause blindness or severe burns Flush eyes immediately with water Get medical help fast Keep out of reach of children Do not tip Do not open battery WARNING K To avoid injury from tipover drive across slopes not up and down If machine stops going uphill stop blades and back down slowly 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 t
19. 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 frequ
20. hydraulic pump idler pivot Check hydraulic pump drive belt Check hydraulic fluid level If operating machine in extremely dusty or dirty conditions Clean behind engine shrouds and exposed fins Remove screws on blower fan screen and clean behind Every 100 Hours Lubricate mower deck spindles Clean and gap spark plugs Check hydraulic pump drive belt Clean behind engine shrouds and exposed fins Remove screws on blower fan screen and clean behind Every 500 Hours Change hydraulic oil and filter Yearly Change fuel filter Clean battery Change engine oil and filter at least once per season Change hydraulic oil and filter at least once per season Replace spark plugs Service Lubrication Grease IMPORTANT Avoid Damage The recommended grease is effective within an average air temperature range of 29 to 135 degrees C 20 to 275 degrees F If operating outside that temperature range contact your servicing dealer for a special use grease Use a general all purpose grease with an NLGI grade No 2 rating Wet or high speed conditions may require use of a special use grease Contact your Servicing dealer for information Lubricating Front Caster Spindles and Wheels CAUTION Avoid injury Fingers loose clothing get caught rotating parts Stop engine and wait for all moving parts to stop before servicing MX15286 Lubricat
21. jam nut B Turn nut A counterclockwise Tighten jam nut B Replacing Mower Deck Drive Belt Removing Mower Deck Drive Belt 1 Park machine safely See Parking Safely in the SAFETY section 2 Lower mower deck to the lowest cutting height position 3 Remove mower deck shield 4 Remove both mower deck belt shields CAUTION Avoid injury Tensioning spring is under high tension Wear gloves and safety glasses and use a spring puller to install and remove spring Service Mower 26 SERVICE MOWER MX20118 5 Release mower deck drive belt tension by turning adjuster nut A counterclockwise until two threads remain protruding through adjuster nut A 6 Disconnect idler spring B from idler arm C using a spring puller tool MX20120 7 Loosen idler pulley retaining nut D just enough to allow idler pulley E to tilt allowing belt F to clear fixed belt guide G 8 Remove mower deck drive belt F Installing Mower Deck Drive Belt NOTE If necessary see drive belt installation label on mower deck MX20160 1 Install replacement drive belt A as shown on mower deck drive belt label Make sure drive belt is installed properly on PTO clutch sheave spindle sheaves and idler pulleys 2 Tighten idler pulley retaining bolt to 34 N m 25 Ib ft ensuring idler pulley belt is captured between idler pulley flange and belt guide MX20118 3 Connect i
22. level 6 Insert dipstick Tighten cap Changing Hydraulic Oil and Filter A CAUTION Avoid injury Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids Use caution when filling and draining hydraulic oil During periods of machine operation the hydraulic oil reservoir can get hot Allow engine and oil reservoir to cool before servicing IMPORTANT Avoid Damage Contamination of hydraulic fluid could cause transmission damage or failure Do not open oil reservoir cap unless absolutely necessary Severe or unusual conditions may require a more frequent Service interval 1 Park machine safely Refer to Parking Safely in the SAFETY section 2 Allow engine and hydraulic oil reservoir to cool MX13362 3 Clean area around reservoir dipstick cap and oil filter 4 Turn metal cap A on bottom of hydraulic reservoir counterclockwise to remove 5 Allow hydraulic oil to drain into a drain pan with a capacity of at least 3 8L 1 0 gal 6 Turn oil filter B counterclockwise to remove 7 Apply a film of clean hydraulic oil to gasket of new filter 8 Install new filter Turn filter clockwise until gasket makes contact with mounting surface Tighten 1
23. post 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 IMPORTANT Avoid Damage Electric charge from booster battery can damage machine components Do not install negative booster cable to machine frame Install only to the engine block Install negative booster cable away from moving parts in the engine compartment such as belts and fan blades 4 Connect the other end 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 The electric start circuit is protected by one 20 Amp fuse IMPORTANT Avoid Damage Help prevent machine circuit damage Make sure replacement fuse is the correct size 1 Locate electric start fuse holder under console on right side of machine Open fuse holder A and remove socket with fuse Check metal clip in fuse window Discard fuse if clip is broken Install new 20 Amp fuse in socket Install socket with fuse in cover Ensure that plastic tab of fuse holder is securely fastened to fuse socket Service Miscellaneous Using Proper Fuel Use regular grad
24. 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
25. 03H1836 Bolt 1 3 8 16 x 4 00 CHCS 18 AM128170 Discharge Chute 1 48 deck AM128243 Discharge Chute 1 52 and 61 deck 19 M132768 Spring Torsional Discharge Chute 1 20 H141123 Clip Retainer 1 21 03H1809 Bolt 1 3 8 16 x 3 3 4 CHCS 22 D23058 J Hook 1 23 N242189 Spring Deck Belt Tension 1 24 14H1090 Nut 1 3 8 16 Nyloc 25 N10215 Nut 1 3 8 16 PTHN 26 D28050 Pulley Flat Blade to Blade 1 27 TCU18742 Spacer Blade to Blade Pulley 1 28 03H1480 Bolt 1 3 8 16 x 1 1 4 CHCS 29 03H1853 Bolt 4 61 deck only 1 2 x 4 1 2 x 13 CHCS 30 E62934 Flange Lock Nut 4 61 deck only 1 2 13 31 JD7844 Grease Zerk 1 32 200095 Bracket Chute Support 1 48 Only NOTES Mower Deck 71 MOWER DECK SPINDLES Mower Deck Spindles 72 MOWER DECK SPINDLES Ref No Part No Description Qty Remarks 1 200262 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 200196 Shaft Spindle 1 6 200045 Bolt 6 3 8 16 x 1 25 Rib 7 967333 Nut Pulley 3 3 4 16 Flange 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 967348 Bolt Blade 3 5 8 11 x 2 Grade 8 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
26. 8 x 1 25 8 12M7065 Lock Washer 4 5 16 9 D18427 Cable Choke 1 10 TCA15051 Cable Throttle 1 11 D24020 Bolt Throttle Cable 2 0 164 x 1 2 12 M63431 Lock Nut Throttle Cable 2 0 164 13 14H846 Nut Choke Cable 1 3 8 14 TCU15761 Bracket Muffler Support Rh 1 15 TCU15762 Bracket Muffler Support Lh 1 16 12H303 Washer Helical Spring Lock 4 17 14M7273 Nut 4 8 18 19 7139 Screw Hex 1504017 4 M8 x 1 25 x 20 19 19M7865 Screw Hex Fl 2 M8 x 1 25 x 16 20 19M8040 Screw Flanged Metric 2 M6 x 60 HS Head Marked 10 9 21 191365 Shield Heat 1 22 M146170 Spacer 2 23 14M7298 Nut 1 8 1 25 Flange NOTE See authorized Kawsaki servicing engine dealer for engines and engine related service items Always reference the engine model number when ordering parts NOTES KOHLER LOGIC 5 MX20146 3009 NOLIN C ALON 1102852 DI ALN o Ze en PELLE 2 310000 1 NDILINDI 12 p e AZILIVE Hi ONS Tn 2 T NCW NOLLINDI HOLIAS 1914 Saved HILIAS LAIHS WALNAN HOLIAS 4 LAIHS WWALNEN UO ayoq 430 A p 0370 ALAVIS ON ADV 11538 9991 15478 IN SI 089 JN SI 0920 NOWACI HOLIAS SI COE vaan i 11 13 MIDI AVTRI 98 3 SB om L LEE 3a Be pm 9891 3078 330 KOHLE
27. 9 Thrust Arm LH 52 Deck 1 TCA14878 Thrust Arm RH 52 Deck 1 TCA14881 Thrust Arm LH 61 Deck 1 TCA14880 Thrust Arm RH 61 Deck 1 18 M83541 Bushing 4 19 JD8744 Grease Zerk 3 20 19H3280 Bolt 2 3 4 16 x 3 HHCS 21 D24008 Nut 2 3 4 16 PTHN 22 TCA13292 Pivot Pin Thrust Arm 2 23 03M7185 Bolt 2 1 4 20 x 1 CHCS 24 14M7396 Nut 2 1 4 20 25 M137523 Pin Clevis 2 26 TCU15892 Bushing 2 27 H143731 Nut Push 2 28 M88183 Ring Locking 2 NOTES Mower Deck Lift Linkage 69 MOWER DECK Mower Deck 70 MOWER Ref Description Qty Remarks 1 TCA15385 Mower Deck 48 S O 1 TCA15386 Mower Deck 52 S O 1 TCA15387 Mower Deck 61 S O 1 2 TCU14540 Bushing 2 3 TCU18344 Support Strap 1 4 TCU18847 Belt Engine to Blades 48 Deck 1 TCU18848 Belt Engine to Blades 52 Deck 1 TCU18849 Belt Engine to Blades 61 Deck 1 5 TCU18744 Roller Anti Scalp 2 48 and 52 deck TCU18744 Roller Anti Scalp 6 61 deck 6 200082 Belt Cover LH 1 48 and 52 deck TCU18413 Belt Cover LH 1 61 deck 7 200084 Belt Cover RH 1 48 deck TCU18411 Belt Cover RH 1 52 deck TCU18413 Belt Cover RH 1 61 deck 8 M119352 Knob Belt Cover 2 9 GDA10103 Pivot Anti Scalp Roller 2 10 03H1729 Bolt 2 1 4 20 x 1 CHCS 11 H122207 Nut 2 1 4 20 PTFHN 12 TCA15346 Arm Idler Engine to Blade 1 13 D18032 Pulley Flat Tension ldler 1 14 03H1658 Bolt 1 3 8 16 x 2 1 4 CHCS 15 24H1305 Washer 1 3 8 SAE 16 K40003 Nut 4 3 8 16 PTHN 17
28. E CONTROLS AND LINKAGE 3 ER N vat I h 1 Y i Oa v Vis x 27 2 D Y IS DE X 24 i i 21 EA Let i 1 7 7 2 1 et 25 A ir J x 19 7 DE Fa 700 3 x 26 29 33 5 T Sy 7 4 u 28 N 33 ez 1 32 T x DS 32 31 N Boc SE v 2 Fo I Il 1 lt vif p Sa SJ Il 5 34 PR S 30 EN i 76 lt S EE VE Drive Controls and Linkage 46 DRIVE CONTROLS AND LINKAGE Ref No Part No Description Qty Remarks 1 D18069 Speed Limiter 1 2 200080 Steering Controller RH 1 200081 Steering Controller LH 1 3 D13029 Control Rod 2 4 14M7303 Flange Nut 2 M6x 1 0 5 J16913 Spring Pin 2 6 D13028 Swivel 2 7 D38157 Rod End 2 8 D18093 Grip 2 9 19M7547 Cap Screw Reverse Stop 2 M6 x 1 0 x 55 10 14M7400 Flange Lock Nut 3 M10 x 1 5 11 D13308 Base Speed Control Lock 1 12 D13309 Handle 1 13 34H60 Spring Pin 1 5 32 x 1 14 TCA15195 Shaft Pivot 1 15 19M7862 Cap Screw 1 M6 x 1 0 x 20 16 14M7397 Lock Nut 1 M6 x 1 0 17 19M7785 Cap Screw 3 M10 x 1 5 x 25 18 191256 Switch Neutral 2 19 19H1905 Cap Screw 2 5 16 18 x 1 20 200116 Bushing 4 21 14H650 Jam Nut 2 5 16 24 22 19M7372 Cap Screw 2 M5 x 0 8x 16 23 14M7360 Nut 2 M5 x 0 8 24 D14081 Lock Nut 2 5 16 18 25 TCU19201 Arm Control RTN 2 26 TCU19202 Arm Return 2 27 TCU18929 Arm RH Inner RTN 2 TCU18931 Arm LH Inne
29. LLINDI 3115 V mr T 310004 NOLLINDI HOLIAS WADALY Td HOLIAS Fal 141HS WALNGN quo 24040 NI 330 31915 431311535 an Lv 1N538 ON SI 28 IN SI 0 8 NOWWOD HOLIAS SI 062 LINDAID 109 AVT3M 08 3 58 0891 3976 Ss OOD Service Miscellaneous 40 Kawasaki Wiring Schematics SERVICE MISCELLANEOUS Service Miscellaneous mom aia im monde 0 ION sf 000099 gi Ha e g 83 sn tonc Bane MOE aom ana en un E ACC DEL ew 5609 _ us decine O LDS are I 300 Service Miscellaneous 41 SERVICE MISCELLANEOUS Hydraulic Schematics Service Miscellaneous Left Hydrostatic Pump Assembly Charge Relief Valve Pump Block Right Hydrostatic Pump Assembly Charge Pump Right Wheel Motor System Charge Check Shock Valve Reverse Inlet Filter Manual Bypass Hydraulic Reservoir Left Wheel Motor Cooling Orifice System Charge Check Shock Valve Forward Service Miscellaneous 42 SERVICE MISCELLANEOUS Service Miscellaneous 43 MAIN FRAME TRACTION DECK CONSOLE AND PLATFORM Main Frame Traction De
30. Neutral Switch Run 1 Lock park brake 2 Push PTO switch down to disengage 3 Start engine 4 Push one motion control lever forward 5 Repeat procedure using the other lever 6 Repeat procedure pushing each motion control lever rearward Result The engine must stop when either lever is moved from neutral position Operating 11 OPERATING Testing Operator Presence Switch NOTE Ensure OPC switch bracket is depressed when standing on operator s station 1 Stand on operator s platform with motion control levers in the NEUTRAL position 2 Start engine 3 Unlock park brake 4 Step completely off operator s platform Result The engine must stop NOTE Ensure OPC switch bracket is depressed when standing on operator s station 5 Stand on operator s platform with motion control levers in the NEUTRAL position and start engine CAUTION Avoid injury Thrown objects can be dangerous Before operating the attachment Clear area of bystanders especially children Pick up objects which may be thrown by the attachment 6 Pull PTO switch up to engage 7 Step completely off operator s platform Result The engine must stop Testing the Park Brake MIF 1 Stop machine on 17 slope 30 grade facing downhill Stop the engine and lock the park brake 2 Repeat procedure with machine facing uphill Result Park brake must hold the machine stationary Mach
31. OTES Fuel Tank and Lines 57 KOHLER ENGINE AND RELATED COMPONENTS KOHLER Engine and Related Components 58 KOHLER ENGINE AND RELATED COMPONENTS Ref No Part No Description Qty Remarks 1 D28121 Muffler 1 2 Gasket 1 3 TCA15389 Oil Drain Hose 1 4 X6PMTX S Oil Drain Plug 1 5 03M7188 Carriage Bolt Engine Mounting 1 M8 x 1 25 x 40 6 19M8317 Cap Screw Engine Mounting 3 M8 x 1 25 x 40 7 14M7396 Flange Lock Nut Engine Mounting 4 M8 x 1 25 8 14M7298 Flange Nut Muffler 4 M8 x 1 25 9 D18427 Cable Choke 1 10 D18359 Cable Throttle 1 11 D24020 Bolt Throttle Cable 2 0 164 x 1 2 12 63431 Lock Nut Throttle Cable 2 0 164 13 14H846 Nut Choke Cable 1 3 8 14 12M7032 Washer 1 NOTE See authorized KOHLER servicing engine dealer for engines and engine related service items Always reference the engine model number when ordering parts KOHLER Engine and Related Components 59 NOTES KAWASAKI ENGINE AND RELATED COMPONENTS KAWASAKI ENGINE AND RELATED COMPONENTS Ref No Part No Description Qty Remarks 1 TCA15321 Muffler 1 2 191601 Gasket Kit 2 Includes ltems 2 8 amp 17 3 TCA16240 Oil Drain Fitting 1 4 TCU19288 Shield Muffler 1 5 03M7188 Carriage Bolt Engine Mounting 1 M8 x 1 25 x 40 6 19M8317 Cap Screw Engine Mounting 3 M8 x 1 25 x 40 7 14M7396 Flange Lock Nut Engine Mounting 4 M
32. R Logic Schematic 62 KI8N3SSV YALdVAV KAWASAKI LOGIC SCHEMATIC Wi rr EE lt RE wma Ww i MEN Vane vanni OM RES OL NO REDEN TS 0 1648 ond ON WANA SEUSS 3 META LOS DIG SOOV NAC 30000 m LM Orio NON WO UU monens Ca VEIS ALDE 16001 Nd SVELSAS VIE KONS ZN sa DG 3 A zk Lg DO LOOWOO NA Bum LI CO STH SZH 34094 3904 30448 dV 02 9 SIN EP Pr he ab m 8 eee SELSAS EO HOLD Old IRITE 9 GONTIOSWSIBNIS Kawasaki Logic Schematic 63 BATTERY ELECTRICAL HARNESS AND COMPONENTS
33. Side to Side NOTE Mower deck anti scalp wheels should not contact the ground 1 Adjust mower deck to 76 mm 3 in cutting height position NOTE Discharge chute raised for clarity E nn ii MX20139 2 Position right mower blade A discharge side perpendicular to direction of travel NOTE Use a short ruler or a leveling gauge to check the mower blade level 3 Measure distance B from outside blade tip to the ground 4 Position left mower blade perpendicular to direction of travel 5 Measure from outside blade tip to the ground difference between both measurements should be no greater than 3 mm 1 8 in 6 If side to side level is not within the tolerance an adjustment is necessary Adjusting Level Side to Side NOTE When adjusting U bolts maintain a minimum clearance of 3 mm 1 8 in between mower deck and stop pads MX20099 Adjust four U bolts C two on each side of deck until deck is within 3 mm 1 8 in of level from side to side Operating 9 OPERATING MX20100 a Loosen jam nuts D and adjust nuts E on each U bolt until side to side level is reached b Tighten jam nuts D Checking Level Front to Rear 1 Set height of cut HOC to the 76 mm 3 in cutting height position NOTE The height of the rear blade tip should be between 3 6 mm 1 8 1 4 in higher than the front blade tip MX20122 2 Po
34. Stop blades if not mowing Watch for traffic when operating near or crossing roadways 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 wit
35. ake 4 Remove key 5 Fasten machine to trailer with heavy duty straps chains or cables Both front and rear straps must be directed downward 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 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 speeds for Slopes Trimming Close quarters Tall grass Use faster travel speeds for Normal mowing on level ground Dismounting to Inspect Mower CAUTION Avoid injury Help prevent serious injury Keep hands and feet away from blades and the discharge opening Do not step on either side of the mower deck when mounting and dismounting the machine Mount and dismount the machine using the front foot plate 1 Park machine on a hard level surface 2 Disengage PTO 3 Move motion control levers to the neutral position 4 Lock park brake
36. ar from rotating lesiones causadas blades stay por las cuchillas REMOVE ALL LEAVES GRASS AND DEBRIS FROM clear of deck mantenerse alejado ENGINE HYDRO PUMPS AND MOTORS PULLEYS edge del horde de la BELTS HOSES ENGINE DECK AND CUTTER DECK pl lalorma de carte 11 BE SAFE TO AVOID A FIRE HAZARD To avoid injury from Para evitar sufrir lesiones ry rotating blades and causadas por cuchillas giratorias I m thrown objects stay y objetos lanzados mantenerse clear 01 deck edge alejado del barde de la and keep others away plataforma de corte mantener gt Do not mow without las dem s alejadas I Li discharge chute or de la maquina No usar la entire grass catcher maquina sin el tubo de in place descarga sin el 12600500 de paste en su ugar HYDRO OIL RESERVOIR USE ONLY QUAKER STATE 5W50 SYNTHETIC OIL 4 tv RIGHT TURN VIRAJE A DERECHA OR EQUIVALENT WARNING HOT SURFACE m VIRAJE DA RI gn OFF ACAUTION BEFORE OPERATING OPER READ ATORS 1 8 MANUAL AND SAFETY INSTRUCTIONS Labels and Decals 74 LABELS AND DECALS Ref No Part No Description Qty Remarks 1 GDU10257 Decal 1 Great Dane 2 M137637 Decal 1 Danger Rotating Blades 3 D28181 Decal 1 No Step 61 only 4 1841115907 Decal 1 Warning Avoid Tipover 5 TCU15909 Decal 1 Patent 6 TCU19020 Decal 1 Super Surfer Se
37. bring oil level no higher than the FULL mark on dipstick If oil level is above the FULL mark drain to proper level 7 Install and tighten dipstick Changing Engine Oil and Filter A CAUTION Avoid injury Touching hot surfaces can burn skin The engine components and fluids will be hot if the engine has been running Be cautious and wear protective clothing when servicing or working near a hot engine and components IMPORTANT Avoid Damage Change the oil more often if the machine is used in extreme conditions Extremely dusty conditions Frequent slow or low speed operation Frequent short trips 1 Clean area around dipstick cap and filter 2 Start engine and run until it reaches normal operating temperature 3 Park machine safely See Parking Safely in the SAFETY section MX201858 4 Put oil drain pan under drain tube 5 Remove plug A 6 Allow oil to drain into an oil drain pan 7 After oil drains install and securely tighten drain plug A MX20149 8 Turn oil filter B counterclockwise to remove 9 Apply a film of clean engine oil to gasket of new filter IMPORTANT Avoid Damage Do not use wrench to tighten oil filter 10 Install filter Turn filter clockwise until gasket makes contact with mounting surface Tighten 1 2 to 3 4 turn after gasket contact 11 Raise thigh pad 12 Remove dipstick cap NOTE Refer to engine manufacturers operati
38. ce Fuel Dirt in fuel system or fuel is old Replace fuel with fresh stabilized fuel Obtain fuel from another supplier before suspecting machine problems Suppliers blend fuels differently and changing suppliers will generally solve any performance problems Fuel blended with alcohol or ether may contribute to performance problems by causing gum and varnish deposits especially if fuel is stored for several weeks or more Obtain fresh fuel Engine Runs Rough or Stalls Plugged fuel filter Plugged air intake system Fuel cap vent dirty Stale or improper fuel fuel level Spark plugs not gapped correctly Replace spark plugs Choke adjusted incorrectly See your authorized dealer Engine Knocks Engine oil level low Reduce load Slower ground speed Fuel is bad Fill tank with fresh fuel correct octane dle speed too slow Engine Overheats Clean cooling fins Low oil level Do not operate at slow idle Operate at fast idle Cooling air intake screen is dirty Plugged carburetor air intake filter Plugged air intake filter Operating at too fast ground speed for conditions Troubleshooting 34 TROUBLESHOOTING If Check If Check Engine Lacks Power Reduce load Plugged air intake system Plugged fuel filter Improper type of fuel Drain tank and fill with correct fuel Clean cooling
39. change use part numbers listed below when you order If anumber 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 Refer to your attachment and machine operator manuals Contact your authorized Great Dane dealer with unanswered questions Part Numbers Part Number Mower Blades 48 Inch Deck GDU10230 54 Inch Deck GDU10231 DU10232 60 Inch Deck GPU 1023 Hydraulic Oil Filter GDU10137 Battery TY25221 Fuse 20 amp 57M7120 Belts Hydraulic Drive Belt GDU10025 48 Inch Mower Deck Belt TCU18847 TCU18848 54 Inch Mower Deck Belt TCU18849 60 Inch Mower Deck Belt Part numbers are subject to change without notice Part Numbers may be different outside the U S A Getting Quality Service 39 SERVICE MISCELLANEOUS Wiring Schematics Service Miscellaneous 3009 NOLLWODT 79 ALON 4 maler J1NdOW 7 NH
40. chine safely Refer to Parking Safely in the SAFETY section 2 Lift machine with a safe lifting device centered under tire support frame A on the side where tire is being removed 3 Remove wheel nuts B 4 Remove wheel Installing 1 Install wheel with valve stem C facing out 2 Install and tighten wheel nuts alternately until recommended torque value is reached Tighten nuts to 102 75 Ib ft 3 Lower machine Removing and Installing Front Caster Wheels Removing 1 Park machine safely Refer to Parking Safely in the SAFETY section 2 Lift front of machine with a safe lifting device 3 Remove nut A and wheel cap screw B 4 Remove wheel and spacers from yoke assembly Installing 1 Install replacement wheel and original spacers 2 Install wheel cap screw B and nut A 3 Tighten nut until wheel develops slight rolling resistance 4 Lower machine Tightening Rear Drive Wheel Hardware 1 Tighten rear wheel nuts to 102 Nem 75 Ib ft 0 0 Oo 2 Tighten wheel nuts numbered sequence shown for safe wheel installation Tighten alternately until recommended torque value is reached Service Miscellaneous 32 SERVICE MISCELLANEOUS Checking Tire Pressure A 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 prope
41. ck Console and OPC Platform 44 MAIN FRAME TRACTION DECK CONSOLE AND PLATFORM Ref No Part No Description Qty Remarks 1 TCA14936 Frame 1 W 48 52 Deck TCA14946 Frame 1 W 61 Deck 2 D15356 Fender Left 1 D15355 Fender Right 1 3 200038 Weight 2 4 19M7270 Cap Screw 6 M8 x 1 25 x 65 5 19M7803 Cap Screw 6 M8 x 1 25 x 70 6 14M7396 Nut 12 M8 x 1 25 7 JD7842 Lubrication Fitting 4 8 200218 Deck Shield Assembly 1 48 and 52 deck TCA15350 Deck Shield Assembly 1 61 deck 9 M119352 Knob 2 10 14M7299 Nut 6 M12 x 1 75 11 14912 Control Console 1 12 TCA14919 Side Bracket Left 1 13 TCA14918 Side Bracket Right 1 14 TCA15348 Handle Mount 1 15 D15368 Plate Thigh Pad 1 16 TCA15060 Pad Thigh 1 17 TCA15371 Shield 1 18 D15305 Plate 1 19 TCA14856 Engine Traction Deck 1 20 03M7191 Carriage Bolt 6 M10 x 1 5 x 25 21 14M7400 Flange Nut Locking 6 M10 x 1 5 22 19H1948 Cap Screw 4 1 4 x 3 4 23 129302 Lock Washer 4 1 4 24 19M7784 Cap Screw Flange Head 6 M10 x 1 5 x 20 25 19M7785 Cap Screw 4 M10 x 1 5 x 25 26 14M7400 Flange Nut Locking 4 M10 x 1 5 27 19M7784 Cap Screw Flange Head 4 M10 x 1 5 x 20 28 734037 4 3 8 16 3 4 29 19 7784 Screw Flange Head 2 M10 x 1 5 x 20 30 14M7400 Flange Nut Locking 2 10 1 5 31 19 7784 Screw Flange Head 6 M10 x 1 5 x 20 32 M115279 Plug 1 Optional light switch hole Main Frame Traction Deck Console and OPC Platform 45 DRIV
42. ction 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 Safety Labels MX20097 WARNING A Hot Surface WARNING B To avoid injury from rotating belts keep all shields and guards in place DANGER C To avoid injury from rotating blades stay clear of deck edge DANGER D 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 E Do not mow without discharge chute or entire grass catcher in place MX20138 DANGER F To avoid injury to children stop mower when children are near Do not mow in reverse Look behind when backing Never carry riders especially children CAUTION G Before operating read operators manual and safety instructions Safety Labels 2 SAFETY CAUTION HELP AVOID INJURY H 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
43. dler tension spring and adjust tension The length B of the tension spring should measure 21 6 to 22 6 cm 8 1 2 in to 8 7 8 in from inside of hook to inside of hook 4 Install both mower deck belt shields 5 Install mower deck shield 6 Adjust mower deck to desired cutting height Checking for Bent Mower Blades CAUTION Avoid injury Mower blades are sharp Always wear gloves when handling mower blades or working near blades Replace blades if defective Never straighten or weld them 1 Park machine safely See Parking Safely in the SAFETY section 2 Raise mower to highest position to access blades Service Mower 27 SERVICE MOWER MX20122 Picture Note Mower deck with side discharge used for illustration 3 Measure distance A between blade tip and flat ground surface 4 Rotate blade 180 and measure distance between other blade tip and flat ground surface 5 Install new blade if the difference between the two measurements is more than mm 1 8 in 6 Repeat for all blades Checking and Replacing Mower Blades 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 IMPORTANT Avoid Damage When replacing mower
44. doors 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 Safety 6 OPERATING 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 Pr
45. e machine on a level surface before opening the free wheeling valve IMPORTANT Avoid Damage Transmission damage may occur if the machine is towed or moved incorrectly Move machine by hand only Do not use another vehicle to move machine Do not tow machine NOTE The pump free wheel valves must be turned fully clockwise closed during normal machine operation When the machine needs to be moved without starting the engine use the pump free wheel valves 1 Lock park brake NOTE The pumps A are located in the back of the machine behind the rear shield B d CAUTION MX20094 2 Turn both pump free wheel valves C counterclockwise approximately one full turn open position 3 Unlock park brake 4 Push machine to desired location Due to hydraulic system drag machine will move slowly 5 Turn pump free wheel valves C on both pumps one full turn clockwise closed position Tighten valves to 11 N m 100 Ib in 6 Lock park brake Transporting Machine on a Trailer Use a heavy duty trailer to transport your machine Trailer must have signs and lights required by law 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 1 Raise mower deck to the transport position 2 Drive machine onto a trailer 3 Stop engine and lock park br
46. e to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area Allow fresh outside air into the work area to clear the exhaust fumes out The safety systems installed on your machine should be checked before each machine use Be sure you have read the machine operator manual and are completely familiar with the operation of the machine before performing these safety system checks Use the following checkout procedures to check for normal operation of machine clf 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 Stand on operator s platform with motion control levers in the neutral position 2 Lock park brake 3 Pull PTO switch up to engage 4 Turn key switch to the start position Result The engine must not crank Testing Park Brake Switch 1 Push PTO switch down to disengage 2 Unlock park brake 3 Turn key switch to the start position Result The engine must not crank Testing Neutral Switch Start 1 Lock park brake 2 Push PTO switch down to disengage 3 Push one motion control lever forward 4 Turn key switch to the start position Result The engine must not crank Testing
47. e two spindle grease fittings A and two wheel grease fittings B Service Intervals 17 SERVICE ENGINE Lubricating Deck Lift Pivot Points MX20104 Lubricate two front deck lift pivot grease fittings A and two rear deck lift pivot grease fittings B Lubricating Pump Idler Pivot CSS MX15095 Lubricate one pump idler pivot grease fitting A Lubricating Mower Deck Spindles MX15287 Lubricate three mower deck spindle grease fittings A Lubricating Mower Deck Idler Pivot MX20106 Lubricate one deck idler pivot grease fitting A Lubricating Mower Deck Push Arms MX20107 Lubricate two push arm grease fittings A one located on each side of the machine Service Engine Avoid Fumes A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area Allow fresh outside air into the work area to clear the exhaust fumes out Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes Use oil that meets the following specification See the engine manufacturer s owner s manual provided with your machine fo
48. e unleaded fuel with an octane rating of 87 octane or higher Fuel blends containing up to 1096 ethanol or up to 1596 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 stora
49. en nut on long carriage bolt E to secure battery G in battery tray H Do not overtighten 5 Apply dielectric grease to terminals to prevent corrosion 6 Connect the positive battery cable D and install cover 7 Connect negative battery cable B and install cover A Cleaning Battery and Terminals 1 Park machine safely See Parking Safely in the SAFETY section 2 Disconnect and remove battery 3 Wash battery with solution of four tablespoons of baking soda to one gallon of water Be careful not to get the soda solution into the cells 4 Rinse the battery with plain water and dry 5 Clean terminals and battery cable ends with wire brush until bright 6 Apply general purpose grease or silicone spray to terminal to prevent corrosion 7 Install battery Using Booster Battery CAUTION Avoid injury The battery produces 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 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 Service Electrical 30 SERVICE MISCELLANEOUS A Booster Battery B Disabled Vehicle Battery 1 Connect positive booster cable to booster battery A positive
50. ently 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 amp Materials ASTM If using a funnel make sure it is plastic and has no screen or filter 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 out
51. er the machine will travel Forward speed range 0 14 8 km h 0 9 2 mph 4 Pull both motion control levers rearward at the same time to begin reverse motion Reverse speed range 0 6 4 km h 0 4 mph 5 To stop motion move both motion control levers forward or rearward until the machine comes to a stop NOTE The motion control linkages are adjustable If adjustment is required see Checking and Adjusting Motion Control Linkages in the SERVICE TRANSMISSION section Operating 13 OPERATING Forward MX12788 Push both motion control levers forward at the same time Reverse MX12789 Pull both motion control levers past center rearward at the same time x 12790 Push right motion control lever further forward than the left motion control lever Gentle Left Turn MEM Gentle Right Turn in y MX12791 Push left motion control lever further forward than the right motion control lever Sharp Left Turn MX12792 Push right motion control lever forward and pull left motion control lever rearward at the same time Sharp Right Turn MX12793 Push left motion control lever forward and pull right motion control lever rearward at the same time Operat
52. fins to help prevent overheating Replace spark plugs Starter Turns Slowly Loose or corroded battery connections Low battery power charge battery Engine oil viscosity too heavy Hydraulic pump linkage out of adjustment pumps engaged Machine Engine Uses Too Much Oil Find and correct oil leaks Incorrect engine oil Plugged oil filter Plugged air intake filter Worn engine components If Check Excessive Machine Vibration Engine speed too slow Deck drive belt not tensioned correctly Mower blades not balanced Engine Backfires Through Muffler Throttle lever should be at low idle for thirty seconds before turning off machine High Fuel Consumption Improper type of fuel Plugged air intake system Operating at too fast ground speed for conditions Improper valve clearance See your authorized dealer Restricted air intake system Machine Will Not Move With Engine Running Park brake locked Transmission oil level low Transmission oil cold allow engine to warm up Pump drive belt slipping or broken Pump drive belt spring broken Pump free wheel valves open Transmission problems See your authorized dealer Other Symptoms See engine manufacturer s owner s manual provided with your machine for additional information Machine Creeps With Engine Running and Motion Contr
53. for damage or cracking Check and adjust speed control linkages and lock 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 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 20138 Picture Note A Speed Control Bar Lock B Speed Control Bar C Left Motion Control Lever D Right Motion Control Lever E Hydrostatic Oil Reservoir Cap and Dipstick F Ignition Key Switch G Fuel Tank Cap H PTO Switch l Optional Light Switch Location J Hourmeter Operating 7 OPERATING K Choke L Throttle Lever M Park Brake Lever Mower Deck Controls MX20093 A Mower Deck Lift Levers B Height of Cut HOC Pin Miscellaneous Controls MX20094 A Free Wheeling Valves Mounting and Dismounting Machine Safely MX20095 1 Step on operator s platform A at the rear of machine to mount the machine 2 Park machine safely See Parking Safely in the SAFETY section 3 Step off operator s platform to dismount machine 4 Keep operator s platform and suspension springs clean and free of debris Raising and Lowering Thigh Pad 1 Park machine safely See Parking Safely i
54. ge in the machine all year without draining Filling Fuel Tank A 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 filtrer to prevent static electric discharge Service Miscellaneous 31 SERVICE MISCELLANEOUS Important Avoid damage Dirt and water in fuel can cause engine damage Clean 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 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 Removing and Installing Rear Drive Wheels Removing 1 Park ma
55. h 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 Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Clear mowing area of objects that might be thrown Keep people and pets out of mowing area Study mowing area Set up a safe mowing pattern Do not mow where traction or stability is doubtful 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 Disengage mower blades 3 Lock the park brake 4 Stop the engine 5 Remove the key 6 Wait for engine and all moving parts to stop before you leave the operator s station 7 Close fuel shut off valve if your machine is equipped 8 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 Ma 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 whe
56. he emission compliance category listed on the emission control system certification or air index label this indicates the number of operating hours for which the engine has been certified to meet EPA and or CARB emission requirements The following table provides the engine compliance period in hours associated with the category found on the certification label Agency Category Hours EPA 250 500 1000 Moderate 125 CARB Intermediate 250 CARB Extended 500 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 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 Ope
57. ine should move no more that 61cm 24 in in one hour If machine moves more than that brakes need to be adjusted See your authorized dealer or refer to Adjusting Park Brake in the SERVICE STEERING AND BRAKES section Using Park Brake Locking Park Brake MX20102 Raise park brake lever A to lock park brake Unlocking Park Brake Lower park brake lever A to unlock park brake Using the PTO Engage PTO 1 Stand on operator s platform with motion control levers in the neutral position 2 Start engine 3 Release park brake 4 Move throttle lever to the 1 2 to 3 4 fast position Y rj vaga Or OFF CAUTION A BEFORE OPERATING READ OPERATORS MANUAL AND SAFETY INSTRUCTIONS MX12854 5 Pull PTO knob A up to engage mower deck 6 Move throttle lever forward to the fast position for mowing Disengage PTO 1 Push PTO knob A down 2 Set park brake Operating 12 OPERATING Using the Throttle MX12847 Push throttle lever A forward to the fast position B when mowing Move throttle lever A to the half fast position C when starting and warming the engine Pull throttle lever A backward to the slow position D to idle engine Do not run engine at slow idle any longer than necessary for cooldown after mowing Using the Hourmeter NOTE The machine is equipped with an electric start The hourmeter will continue to run with the key switch in the run pos
58. ing 14 OPERATING Starting Engine Engaging Mower CAUTION Avoid 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 1 Stand on operator s platform 2 Lock park brake MX20091 3 Put motion control levers A in the NEUTRAL position 4 Push PTO switch knob B down to disengage PTO 5 Move throttle lever to set engine speed at the 1 2 to 3 4 fast position 6 Position choke knob D Cold engine Pull knob up to the CHOKE position Warm Hot engine If necessary pull knob up to the CHOKE position 7 Turn key switch E to the START position 8 Release key to the RUN position when engine starts 9 With engine started Push choke knob to the OFF position Move throttle lever to the FAST position Unlock park brake 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 pre
59. intake Keep air intake screens and engine cooling fins clear of debris to ensure proper cooling See the engine manufacturer s owner s manual provided with your machine for the complete procedure Checking and Cleaning Air Filter Elements A CAUTION Avoid injury Touching hot surfaces can burn skin The engine components and fluids will be hot if the engine has been running Allow the engine to cool before servicing or working near the engine and components IMPORTANT Avoid damage Dirt and debris can enter the engine through a damaged filter element 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 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 Checking Spark Plug A CAUTION Avoid injury Touching hot surfaces can burn skin The engine components and fluids will be hot if the engine has been running Allow the engine to cool before servicing or working near the engine and components Check spark plugs at the intervals recommended in the Service In
60. ion of travel 4 Measure from the front of the blade tip to the ground 5 If blade tip height is not within 73 79 mm 2 7 8 3 1 8 in an adjustment is needed Operating 10 OPERATING Adjusting Overall Cutting Height NOTE When adjusting U bolts maintain a minimum clearance of 3 mm 1 8 in between mower deck and stop pads Adjust both sides of the mower deck equally All lift chains must remain taut MX20099 1 Adjust four U bolts A two on each side of deck until blade tip height is within 73 79 mm 2 7 8 3 1 8 in of the 76 mm 3 in setting Adjusting Mower Deck Anti Scalp Wheels NOTE The flattest cut can be achieved by having all anti scalp wheels adjusted off the ground Check anti scalp wheel adjustments each time the mower deck cutting height is changed It is recommended that all anti scalp wheels be kept off the ground to minimize scuffing 1 Inflate tires to correct pressure 2 Adjust mower deck to desired cutting height MX15658 3 Adjust anti scalp wheel A to one of three positions D Remove screw E nut C and washer B Adjust wheel up or down so it is approximately 6 13 mm 1 4 1 2 in above mowing surface 4 Install wheel with attaching hardware 5 Adjust all wheels to the same height Testing Safety Systems CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machin
61. ition MX20091 Hourmeter A shows number of hours the machine has been operated Use hourmeter and SERVICE INTERVAL section to determine when machine needs service Using the Motion Control Levers The functions of the motion control levers are 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 Steering Acceleration Deceleration Neutral Position MX20091 Picture Note Motion control levers A shown in the neutral position Machine speed motion and direction can be controlled when the engine is running and park brake is unlocked Operator can exit the mower with the engine running when the park brake is locked and the PTO switch is disengaged Forward and Reverse Motion CAUTION Avoid injury Children or bystanders may be injured by runover and rotating blades Before traveling forward or rearward Carefully check the area around the machine Disengage the mower before backing up 1 Move throttle lever to the fast position 2 Unlock park brake 3 Push motion control levers forward to begin forward motion The further forward the control levers are moved the fast
62. jam nut C on cap screw D on each side of machine Adjust Neutral Switch MX20161 Picture Note Side frame removed for picture clarity 1 Park machine safely See Parking Safely in the SAFETY section 2 Loosen nuts 3 Adjust neutral switch B If neutral switch sensitivity needs to be increased adjust switch down in slots If neutral switch sensitivity needs to be decreased adjust switch up in slots 4 Tighten nuts A Service Steering amp Brakes Adjusting Park Brake Testing Park Brake 1 Inflate tires to correct pressures MX12874 2 Stop machine on a maximum 17 slope 3 Lock park brake A properly adjusted park brake must prevent the drive wheels from turning f the drive wheels turn a brake adjustment will be necessary Adjusting Park Brake 1 Park machine safely Refer to Parking Safely in the SAFETY section 2 Unlock park brake 3 Loosen jam nut A 4 Remove hair pin and washer B 5 Turn brake linkage rod C in one turn increments clockwise to increase braking force counterclockwise to decrease braking force 6 Install hair pin and washer B 7 Tighten jam nut A 8 Test park brake Adjust again if required Service Steering amp Brakes 25 SERVICE MOWER Service Mower Removing and Installing Mower Deck Shield CAUTION Avoid injury Help prevent serious personal injury Do not operate the mower withou
63. jury and machine damage A CAUTION Avoid injury This symbol and text highlight potential hazards or death to the operator or bystanders that may occur if the hazards or procedures are ignored IMPORTANT Avoid Damage This text is used to tell the operator of actions or conditions that might result in damage to the machine NOTE General information is given throughout the manual that may help the operator in the operation or service of the machine Product Identification Record Identification Numbers Super Surfer GSKH18 48S Serial Number 636510001 GSKH23 52S Serial Number 636610001 GSKH25 61S Serial Number 636710001 GSKW1948S Serial Number 636410001 GSKW2352S Serial Number 637010001 GSKA1948S Serial Number 6373010001 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 PRODUCT IDENTIFICATION NUMBER Model Number Serial Number SAFETY LABELS ENGINE MODEL SPECIFICATION AND SERIAL NUMBER Model Number Specification Serial Number Safety Labels Understanding The Machine Safety Labels Safety Alert Symbol The machine safety labels shown in this se
64. ly 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 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 Engine Will Not Start Or Is Hard To Start Park brake lever not in the proper position Check that motion control levers are in neutral and neutral switches are correctly adjusted engaged Stale or improper fuel fuel level Plugged fuel filter Plugged air intake filter Spark plug wires loose or disconnected Spark plugs not gapped correctly Blown fuse Electrical problem dead battery Choke adjusted incorrectly See your authorized dealer Engine Will Not Slow Idle Carburetion problems See your authorized dealer Bent or kinked throttle cable Bent governor control Incorrect governor idle control Engine If Check Poor Engine Performan
65. n 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 Safety 4 SAFETY 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 Protect Children 18014 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
66. n the SAFETY section MX20096 2 Raise and lower thigh pad A as required Adjusting Mower Deck Cutting Height The mower deck height adjustment consists of seven different cutting heights The cutting heights range from 38 114 mm 1 1 2 4 1 2 in in 13 mm 1 2 in increments CAUTION Avoid injury Before adjusting cutting height stop engine and lock the park brake 1 Park machine safely See Parking Safely in the SAFETY section 2 Disengage PTO Operating 8 OPERATING 3 Stop engine and lock park brake 20099 4 Remove retaining ring A from pin 5 Push down on deck lift lever 6 Remove pin 7 Place pin in desired height hole 0 8 Release deck lift lever 9 Install retaining ring A 10 Repeat procedure for opposite side Leveling Mower Deck CAUTION Avoid injury Rotating blades are dangerous Before adjusting or servicing mower Disconnect spark plug wire s or battery negative cable to prevent engine from starting accidently Always wear gloves when handling mower blades or working near blades NOTE Mower deck anti scalp wheels should not contact the ground 1 Park machine safely See Parking Safely in the SAFETY section 2 Inflate tires to the correct pressure 3 Inspect mower blades for Blade sharpness Blade damage Bent blades Checking Level
67. ng 15 Amp Ignitiohe rette Y debo de see NN Ede Flywheel Starter woo tao aa ce Pec s er Solenoid Shift Fuel System Fuel Typen r ket ed se Gasoline Regular Unleaded Fuel Tank On Right Side of Operator Fuel Capacity is Sene 22 7 L 6 0 gal Steering and Brakes Steetirg uice Ae ihe fete dat a ad Dual Control Levers urere epp ede bim Hydraulic Parle Brake oe a Tire Contact Tires Rear Model 647 20 x 8 8 with 48 in deck Front ebrei Rie NUDO tend metus cir asalto edel 13 5 6 Rear Models 657 667 20 10 8 with 54 in and 60 in deck Inflation Rear Maximum 69 97 kPa 10 14 psi Inflation Front Maximum 110 138 kPa 16 20 psi Battery Voltage eese Sak eere cfe tte ee 12 volt o Mr 340 amp Reserve Capacity 67 minutes BGI Group Size xx op re pepe Eie dere U1L Capacities Fuel Tanks ve ere dco ue bres 22 7 L 6 gal Hydraulic Oil With 3 1 L 3 3 qt Engine Oil With Filter 1 9 L 2 0 qt Travel Speeds at Full Engine RPM Forward icis e e Rex 0 14 8 km h 0 9 2 mph Reverse uns hits ee pirke Seeds 0 6 4 km h 0 4 mph Dimensions Wheel Base
68. ng manual for correct type and grade of oil 13 Add approximately 1 7 L 1 75 qt of oil Service Engine 19 SERVICE ENGINE 14 Insert dipstick Tighten cap 15 Start engine and run at slow throttle for approximately two minutes Check for leaks around filter and drain valve 16 Stop engine 17 Check oil level Remove dipstick cap Wipe dipstick clean NOTE Allow dipstick cap to rest on threads of filler tube when checking oil level Do not tighten dipstick cap when checking oil level Insert dipstick and allow cap to rest on threads of filler Do not tighten cap IMPORTANT Avoid Damage To prevent extensive engine wear or damage always maintain the proper engine oil level Never operate the engine with the oil level below the add mark or over the full mark Remove dipstick Add oil as needed to bring level to the full mark without overfilling 18 Insert dipstick Tighten cap Cleaning Engine Air Intake Screen and Fan A CAUTION Avoid injury Compressed air can cause debris to fly a long distance Clear work area of bystanders Wear eye protection when using compressed air for cleaning purposes Reduce compressed air pressure to 210 kPa 30 psi IMPORTANT Avoid damage An obstructed air intake screen can cause engine damage due to overheating Keep air intake screen and other external surfaces of the engine including cooling fins clean at all times to allow adequate air
69. not allow direct metal contact across battery posts Remove negative cable first when disconnecting Install negative cable last when connecting Checking the Battery Sealed Batteries NOTE Do not attempt to open add fluid or service battery Any attempt to do so will void warranty Keep battery and terminals clean Keep battery bolts tight Keep small vent holes open IMPORTANT Avoid Damage The battery comes fully charged If the machine is not used by the service expiration date indicated on the battery charge the battery Recharge if necessary at 6 10 amperes for 1 hour Removing and Installing Battery Removing 1 Park machine safely See Parking Safely in the SAFETY section FLUSH EYES EI WITH WATER GET MEDIGALKELD FAST 2 Slide back black cover A and disconnect negative battery cable B 3 Slide back red cover and disconnect positive battery cable 0 4 Loosen nut on front long carriage bolt E 5 Remove rear long carriage bolt F and nut 6 Lift and slide battery G out from back of battery tray H 7 Inspect isolator pad 1 Replace as needed Installing 1 Place isolator pad 1 in battery tray H Ensure that isolator pad is on the bottom and sides of battery tray 2 Install battery G in battery tray H with positive terminal in rear 3 Install rear long carriage bolt F and nut Do not overtighten 4 Tight
70. oduct 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 Make sure all necessary guards and shields are safely and securely attached Check for loose missing or damaged parts Remove mower deck belt shields Clean grass and debris from belt area LI Remove grass and debris from machine and mower deck Remove grass and debris from operator station foot plate pump drive belt compartment hydraulic pump and pump mounting plate C Test park brake Test safety systems Check battery Check for oil leaks Check engine oil and hydraulic oil levels Check all belts for damage or cracking Check engine air filter Check mower level Adjust cutting height if necessary Check wheel bolt torque Tighten if necessary Check tire air pressure Check tires
71. ol Levers in a Neutral Position Needs motion control linkage adjustment Needs Adjustment Electrical System Park Brake If Check Starter Will Not Work Blown fuse Park brake switch is faulty Loose or corroded battery connections Neutral switches faulty or not adjusted properly See your authorized dealer Key switch or starter faulty See your authorized dealer PTO engaged Motion control levers and park brake lever not in proper position If Check Park Brake Not Working Correctly Park brake out of adjustment adjust linkage Steering Battery Will Not Charge Loose or corroded connections Blown fuse or fusible link See your authorized dealer If Check Steering Not Working PTO Switch Does Not Work Blown fuse PTO switch faulty Troubleshooting 35 Pump free wheel valves partially open Improper tire inflation Hydrostatic transmission oil level low Traction drive loose or broken Hydraulic pump or wheel motor faulty Mower Deck STORAGE If Check Discharge Chute Plugged Grass is wet mow grass only when dry Raise cutting height Mow with engine at full fast throttle Ground speed too fast for conditions Correct installation of deck drive belt Mower Deck Vibrates Run engine at fast throttle
72. ons before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids 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 Such information is available from Deere amp Company Medical Department in Moline Illinois U S A Information may be obtained in the United States and Canada only by calling 1 800 822 8262 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 Safety 5 SAFETY 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
73. ow rotation of neutral return plate If wheel is rotating forward rotate neutral return plate counterclockwise until wheel rotation stops If wheel is rotating in reverse rotate neutral return plate clockwise until wheel rotation stops 9 Tighten cap screw A 10 Recheck neutral If wheels continue to rotate readjust 11 With the engine running operate the motion control levers to verify adjustment If engine will not crank over after adjustments are made adjust the neutral switch Checking and Adjusting Transmission Tracking A CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machine to an outside area before running the engine Do not run an engine in an enclosed area without adequate ventilation Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area Allow fresh outside air into the work area to clear the exhaust fumes out NOTE Check and adjust transmission tracking on a hard level surface Checking Transmission Tracking 1 Check and adjust motion control linkages See Checking and Adjusting Motion Control Linkages in the SERVICE TRANSMISSION section 2 Start engine and run until it reaches normal operating temperature 3 Move machine to an open level area for operation MX20109 4 Drive machine forward pushing both control levers A all the way to
74. pulley bottom view 5 Insert 1 2 breaker bar into hole and rotate idler pulley 0 forward to ease tension on traction drive belt 6 Remove traction drive belt E Installing Traction Drive Belt NOTE Install the traction drive belt E in front of anchor cap screw F MX20168 1 Install traction drive belt E on drive sheaves G as shown Ensure that traction drive belt is positioned in front of anchor cap screw F 2 Insert 1 2 in breaker bar into hole and rotate idler pulley D forward for additional clearance to install traction drive belt 3 Install rear shield 4 Install mower deck drive belt 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 NOTE Check and adjust motion control linkages with the machine parked on a hard level surface Checking Motion Control Linkages 1 Park machine safely See Parking Safely in the SAFETY section MX20109 2 Rotate speed control bar A to full forward position 3 With engine off move mo
75. r 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 1 Check tires for damage 2 Check tire pressure with an accurate gauge 3 Add air if necessary Tire Size Pressure Front 13 x 5 6 110 138 kPa 16 20 psi Rear 20 x 10 8 69 97 kPa 10 14 psi Rear 20 x5 3C 69 97 kPa 10 14 psi Servicing Caster Wheel Roller Bearings 1 Park machine safely See Parking Safely in the SAFETY section 2 Raise and securely support front of machine p 3 Remove locknut screw two seal spacers and wheel assembly D NOTE Bearing races G are pressed in place and will be damaged when removed Do not remove bearing races G unless they need to be replaced with new 4 Remove seals E bearings F and if needed bearing races G from wheel 5 Clean and inspect bearings F and races G Replace as needed 6 Repack bearings with clean grease 7 Install bearings F and races G if removed and new seals E 8 Install wheel two seal spacers
76. r RTN 2 28 TCU18932 Arm LH Outer RTN 2 TCU18930 Arm RH Outer RTN 2 29 TCU19203 Spacer 2 30 TCU19204 Spring 2 31 TCU19209 Screw 2 5 16 x 1 patch lock 32 TCU19205 Washer 4 33 TCU19206 Washer Nylon 4 34 TCU19207 Lock Nut 2 5 16 24 35 TCU19208 Spacer 2 36 24H1305 Washer 1 406 x 812 x 065 Flat Included with new Hydrostatic Pump NOTES Drive Controls and Linkage 47 PARK BRAKE 2 2 x 17 fa Sx 20 27 Su 1 4 e w I a 14 m 1 N Sa gt lt x lt lt a ran 15 Park Brake 48 PARK BRAKE Ref No Part No Description Qty Remarks 1 D18038 Switch 1 2 19M7373 Cap Screw 2 M5 x 0 8 x 20 3 14M7360 Nut 2 M5 x 0 8 4 K40003 Lock Nut 1 3 8 16 5 19H1801 Cap Screw 1 3 8 16 2 6 TCU12713 Spacer 1 7 GDU10037 Bushing 1 8 AM105809 Swivel 1 9 TCU20956 Rod 1 10 D12352 Lever 1 11 14H846 Nut 2 3 8 12 416931 Spring Pin 1 13 34 268 Roll Pin 1 14 TCA15174 Arm 1 15 TCA15070 Shaft 1 16 24H1413 Bushing 5 0 891 x 1 375 x 0 048 17 D18079 Grip 1 18 24H1341 Washer 1 17 32 x 15 16 x 0 060 19 19M3804 Cap Screw 1 M10 x 1 5 x 40 20 14M7518 Flange Lock Nut 1 10 1 5 21 24 1305 Washer 1 22 M94087 Spacer Plate 3 23 TCU20955 Turn Buckle 1 NOTES Park Brake 49 HYDROSTATIC PUMP DRIVE AND _ lt gt Hydrostatic P
77. r the correct specifications Service Engine 18 SERVICE ENGINE Checking Engine Oil Level IMPORTANT Avoid Damage Failure to check the oil level regularly could lead to serious engine problems if oil level is low Check oil level before operating Keep oil level between the FULL and the ADD marks Check oil level when engine is stopped level and is cooled so oil has had time to drain into the sump NOTE Check oil twice a day if you run engine over 4 hours in a day Make sure engine is cool when checking engine oil level 1 Park machine safely See Parking Safely in the SAFETY section 2 Allow engine to cool 3 Clean area around dipstick to prevent debris from falling into crankcase MX20155 4 Remove dipstick A Wipe with a clean cloth NOTE Allow dipstick cap to rest on threads of filler tube when checking oil level Do not tighten dipstick cap when checking oil level 5 Install dipstick and allow the cap to rest on the threads of the tube Do not tighten the cap IMPORTANT Avoid Damage To prevent extensive engine wear or damage always maintain the proper engine oil level Never operate the engine with the oil level below the add mark or over the full mark 6 Remove dipstick and check oil level on dipstick Oil must be between the ADD and FULL marks NOTE Refer to engine manufacturers operating manual for correct type and grade of oil If oil is low add oil to
78. rate 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 Safety 3 SAFETY Only operate in good light keeping away from holes and hidden hazards Be sure all drives 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
79. ries Il 7 M134406 Decal 1 Warning Hot Surface 8 9 TCU16323 Decal 1 Park Brake 10 TCU14840 Decal 1 General Caution 11 TCU51051 Decal 2 Danger Rotating Belts 12 M131739 Decal 2 Danger Blade Contact 13 D18372 Decal 1 Caution Fire Hazard 14 M131748 Decal 1 Danger Thrown Objects 15 GDU10267 Decal 1 48 16 GDU10268 Decal 1 52 17 GDU10269 Decal 1 61 18 TCU15910 Decal 1 Directional Control 19 TCU 15911 Decal 1 Cut Height LH TCU15912 Decal 1 Cut Height RH 20 D18021 Decal 1 Throttle 21 D18023 Decal 1 Hydro Oil Reservoir 22 M117554 Decal 2 Warning Hot Surface Reservoir 134406 Decal 1 Warning Hot Surface Belt Cover 23 TCU16481 Decal 1 Ignition 24 TCU18852 Decal 1 Belt Path NOTES Labels and Decals 75
80. rk 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 Check Hydraulic Oil Level HYDRO _RESERVONR 1 Clean area around dipstick cap A 2 Remove dipstick cap A Wipe dipstick clean NOTE Do not tighten dipstick cap when checking oil level 3 Insert dipstick in filler neck B Do not tighten cap 4 Remove dipstick Check oil level on dipstick Oil level should be between the ADD and FULL marks on dipstick If oil is level is below ADD mark fill to proper level If oil level is above FULL mark drain to proper level 5 Insert dipstick Tighten cap Check Engine Oil Level 1 Lift thigh pad 2 Clean area around dipstick cap A 3 Remove dipstick cap A from tube Wipe dipstick clean NOTE Do not tighten dipstick cap when checking oil level 4 Insert dipstick in tube Do not tighten cap 5 Remove dipstick Check oil level on dipstick Oil level should be between the ADD and FULL marks If oil is level is below ADD mark fill to proper level If oil level is above the FULL mark drain to proper level 6 Insert dipstick Tighten cap Assembly 37 SPECIFICATIONS Connect Battery
81. rking Safely in the SAFETY section MX20126 2 Remove four cap screws A 3 Remove rear shield B to access hydraulic pumps C 4 Clean hydraulic oil cooling fins on each hydraulic pump with a rag brush or compressed air 5 Clean area around hydraulic pumps and frame Checking and Replacing Pump Traction Drive Belt CAUTION Avoid injury Fingers or loose clothing can get caught in rotating parts Stop engine and wait for all moving parts to stop before servicing NOTE The traction drive belt will not require a tension adjustment Belt is self adjusted using a spring tensioner Checking Traction Drive Belt 1 Park machine safely See Parking Safely in the SAFETY section MX20126 2 Remove four cap screws A 3 Remove rear shield B MX20111 4 Inspect belt C through frame openings D for excessive wear damage or stretching Removing Traction Drive Belt 1 Park machine safely See Parking Safely in the SAFETY section 2 Remove mower deck drive belt See Replacing Mower Deck Drive Belt in the SERVICE MOWER section Service Transmission 22 SERVICE TRANSMISSION MX20126 3 Remove four cap screws A 4 Remove rear shield B CAUTION Avoid injury Tensioning spring is under high tension Wear gloves and safety glasses and use a spring puller to install and remove spring MX20167 Picture Note Traction drive belt idler
82. rough 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 Storage 36 ASSEMBLY 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 02 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 IMPORTANT Avoid Damage Prolonged exposure to sunlight could damage the hood surface Store machine inside or use a cover if stored outside 11 Store the vehicle in a dry protected place If vehicle is stored outside put a waterproof cover over it Removing Machine From Storage 1 Check tire pressure 2 Check engine oil level 3 Check battery electrolyte level if your battery is not maintenance free Charge battery if necessary 4 Install battery 5 On gas engines Check spa
83. s 1 TCA15122 Cap 1 2 TCA15373 Hydraulic Reservoir 1 Includes decals 3 D18379 Hose Clamp 12 4 TCA15078 Wheel Motor 2 5 D14196 Elbow Fitting Pump End 4 Includes O ring 6 TCA14966 Pump LH 1 Includes items 25 35 on page 5 7 TCA14965 Pump RH 1 Includes items 25 35 on page 5 8 14M7518 Nut 4 M10 x 1 5 9 03M7192 Carriage Bolt Pump Mounting 4 M10 x 1 5 x 30 10 GDA10137 Oil Filter 1 11 GDA10066 Elbow Fitting 1 12 313270 Elbow Fitting 1 13 14M7517 Lock Nut Reservoir Mounting 2 M10 x 1 5 14 19M7784 Cap Screw Reservoir Mounting 2 M10 x 1 5 x 20 15 M86863 Tee Fitting 2 16 D24028 Fitting 4 17 D18394 Hose High Pressure 4 18 TY22552 Hose Return AR 25 ft bulk cut to length 19 GDA10065 Adapter 1 20 R26375 O Ring 8 Included with fitting 21 231647 90 Fitting Upper 2 Includes O ring 22 231104 Straight Adapter Lower 2 Includes O ring 23 231046 90 Fitting Lower 2 24 D18206 Key 2 25 200950 Hub 2 26 24M7158 Washer 2 27 11H237 Cotter Pin 2 28 TCU19166 Castle Nut 2 M78480 Tie Straps AR Not shown 29 D14280 Bolt 8 3 8 16 x 1 NOTES Hydrostatic Components 53 HYDRAULIC SCHEMATIC A Left Hydrostatic Pump Assembly B Pump Block __ Charge Pump System Charge Check Shock Valve Reverse E Manual Bypass F Left Wheel Motor G Cooling Orifice H System Charge Check Shock Valve Forward Charge Relief Valve MX20151 J Right Hydrostatic Pump Assembly K Right Wheel Motor Inlet Filter
84. s 1 TCU17863 Spacer Caster Bushing 2 2 E14625 Seal 2 3 D38035 Bearing Assembly Caster Wheel 4 Cup and cone 4 D28051 Bearing Assembly Caster Yoke 4 Cup and cone 5 11M7083 Cotter Pin 2 6 A12188 Castle Nut 2 1 14 7 M135582 Cap Bearing 2 8 JD7844 Grease Fitting 2 9 D25004 Yoke 2 10 D33007 Spacer Caster Wheel 4 11 D28097 Cap Screw 2 3 4 16 x 8 12 D24008 Nut 2 3 4 16 13 D38009 Caster Wheel and Tire Assembly 2 Includes items 3 and 17 14 TCA15086 Caster Arm 2 15 19M7785 Cap Screw 12 M10 x 1 5 x 25 16 14M7518 Nut 12 M10 x 1 5 17 D38065 Seal 4 18 TCA15147 Wheel and Tire Assembly Rear 2 48 deck 20 x 8 8 tire TCA15148 Wheel and Tire Assembly Rear 2 52 amp 61 deck 20 x 10 8 tire 4026 Lug Nut Rear Wheel 8 Not shown NOTES Caster Wheels and Rear Wheels 67 MOWER LINKAGE Mower Deck Lift Linkage 68 MOWER LINKAGE Ref No Part No Description Qty Remarks 1 D18225 Grip 2 2 E63526 Nut 4 M10 Nut 3 GDA10010 Lift Arm LH Rear 1 GDA10009 Lift Arm RH Rear 1 4 P46402 Snap Ring 4 5 24H1413 Washer 16 6 R27434 Snap Ring 4 7 N10215 Nut 8 3 8 8 150749 Chain Deck Lift 4 9 19M8162 Cap Screw 4 M10 x 1 5 x 40 10 GDU10048 U Bolt 4 11 12 14H1058 Nut 8 3 4 13 TCU15817 Rod Deck Lift 2 14 200075 Swivel 4 15 GDA10008 Lift Arm LH Front 1 GDA10007 Lift Arm RH Front 1 16 E63526 Nut 4 M10x 1 5 17 TCA14877 Thrust Arm LH 48 Deck 1 TCA14876 Thrust Arm RH 48 Deck 1 TCA1487
85. sition right mower blade F discharge side parallel to the direction of travel 3 Measure distance G from front blade tip to the ground 4 Turn blade 180 and measure from rear blade tip to the ground 5 If the front to rear level is not within the tolerance an adjustment is necessary Adjusting Level Front to Rear IMPORTANT Avoid damage Adjust the left and right deck lift assist rods equally NOTE Adjust side to side mower level before adjusting front to rear level Adjust both sides of the mower deck equally All lift chains must remain taut MX20099 1 Loosen jam nut H on both deck lift assist rods 2 Adjust front to rear mower level Turn nut I on both sides clockwise to raise front of mower deck or counterclockwise to lower front of mower deck 3 Verify that the adjustment on right and left sides is equal 4 Tighten jam nuts H 5 Check front to rear mower level Checking and Adjusting Cutting Height CAUTION Avoid injury Rotating blades are dangerous Before adjusting or servicing mower Disconnect spark plug wire s or battery negative cable to prevent engine from starting accidentally Always wear gloves when handling mower blades or working near blades Checking Overall Cutting Height 1 Inflate tires to correct pressure 2 Lower mower deck to the 76 mm 3 in cutting height 3 Position right mower blade discharge side parallel to the direct
86. speed control bar B 5 If machine does not drive in a straight line an adjustment is required Adjusting Transmission Tracking 1 Adjust appropriate control rod swivel C located on each side of machine If machine tracks to the right remove spring pin D and rotate left control rod swivel one turn clockwise Install spring pin D If machine tracks to the left remove spring pin D and rotate right control rod swivel one turn clockwise Install spring pin D 2 Check transmission tracking again and adjust as required until machine drives in a straight line Adjusting Forward and Reverse Speeds Adjusting Forward Speed Park machine safely See Parking Safely in the SAFETY section Service Transmission 24 SERVICE STEERING 48 BRAKES MX20115 Picture Note Arrow shows direction of speed control bar A movement when decreasing forward speed 2 Loosen lock lever B on speed control bar A To decrease forward speed pull speed control bar A toward the operator s station increase forward speed push speed control bar A forward away from operator s station 3 Tighten lock lever B Adjusting Reverse Speed 1 Park machine safely See Parking Safely in the SAFETY section 2 Loosen jam nut C on cap screw D on each side of machine To decrease reverse speed turn cap screw D counterclockwise To increase reverse speed turn cap screw 0 clockwise 3 Tighten
87. t the mower deck shield installed Removing Mower Deck Shield 1 Park machine safely See Parking Safely in the SAFETY section MX20105 2 Remove two knobs A 3 Lift shield B and pull forward to disengage from under tabs C on the frame 4 Remove mower deck shield B Installing Mower Deck Shield 1 Insert rear of shield B under tabs on frame and lower shield into position 2 Secure with knobs A Removing and Installing Mower Deck Drive Belt Shields CAUTION Avoid injury Help prevent serious personal injury Do not operate the mower without the belt shields installed Removing Belt Shields 1 Park machine safely See Parking Safely in the SAFETY section MX20117 2 Remove belt shield locking knobs A 3 Remove belt shields B by sliding shield from mower deck stud Installing Belt Shields 1 Install belt shields B by sliding shield over mower deck stud 2 Install belt shield locking knobs A Adjusting Drive Belt Tension 1 Park machine safely 2 Adjust mower deck to the 76 mm 3 in cutting height position 3 Remove mower deck shield MX20118 4 Measure length C of tension spring from inside of hook to inside of hook The spring should meaure 21 6 to 22 6 cm 8 1 2 in to 8 7 8 in To add tension to spring Loosen jam nut B Turn nut A clockwise Tighten jam nut B To release tension from spring Loosen
88. tervals 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 Adjusting Carburetor 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 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 pointed in the direction of the fuel flow
89. tion control levers B until they contact the speed control bar A A slight deflection should be seen in the linkage rod NOTE Check machine tracking after making adjustments Start the engine and run until it reaches normal operating temperature CAUTION Avoid injury Be aware of bystanders 5 Stand on the operator s platform and with the park brake released move the motion control levers B 6 Observe wheel movement as motion control levers are moved back and forth Wheels should travel in the correct direction as the levers are moved 7 Move motion control levers to neutral position If rear wheels continue to rotate a return to neutral RTN adjustment is required Service Transmission 23 SERVICE TRANSMISSION Adjusting Motion Control Return to Neutral RTN Linkages CAUTION Avoid injury Fingers or loose clothing can get caught in rotating parts Stop engine and wait for all moving parts to stop before servicing 1 Stop engine 2 Lock park brake 3 Lift machine with a safe lifting device centered under rear tire support frame 4 Start the machine with motion control levers in neutral 5 Stand on the operator s platform and release park brake 6 If rear wheels rotate when motion control levers are in neutral a neutral adjustment is required 7 Stop engine MX20161 Picture Note Side frame removed for picture clarity 8 Slightly loosen cap screw A to all
90. ump Drive and PTO 50 HYDROSTATIC PUMP DRIVE AND Ref No Part No Description Qty Remarks 1 GDU10025 V Belt 1 2 15316 Pulley Pump 2 Set screws included 3 D28091 Pulley Engine Drive 1 4 GDA10017 PTO Clutch 1 All Units Except KAl 5 GDA10006 Bracket 1 All Units Except KAl 6 D18314 Idler 1 7 GDA10004 Idier Post 1 8 D18403 Bushing 2 9 GDA10005 Idler Arm 1 10 D18071 Spring Idler 1 11 D14213 Cap Screw 2 12 E63526 Flange Nut 1 10 1 5 13 403490 Ring 1 14 19H3031 Cap Screw 1 3 8 x 2 1 2 15 14M7400 Lock Nut 3 M10x1 5 16 03M7191 Carriage Bolt 1 M10 x 1 5 x 25 17 D24022 Cap Screw PTO Clutch 1 7 16 x 2 5 Kohler D14252 Cap Screw PTO Clutch 1 7 16 x 3 Kawasaki 18 D14208 Washer Split Lock 1 19 22H907 Set Screw 4 20 D14160 Washer 2 21 D18067 Key Special 2 M5 x 28 22 19M7810 Cap Screw Spring Anchor 1 M10 x 1 5 x 80 23 24H1305 Washer 1 24 03M7191 Carriage Bolt 2 M10 x 1 5x 25 25 JD7842 Grease Fitting 1 26 K40003 Lock Nut 2 27 D44003 Washer 1 28 D18145 Key Special 1 29 D18056 Spacer PTO Clutch 1 30 200665 PTO Clutch 1 31 200666 Clutch Dog Plate 1 32 960078 Bolt Hex 2 7 16 14 x 750 33 960022 Bolt Hex 2 5 16 18 x 750 34 967115 Locknut 2 5 16 18 NOTES Hydrostatic Pump Drive and PTO 51 HYDROSTATIC COMPONENTS MX20223 Hydrostatic Components 52 HYDROSTATIC COMPONENTS Ref No Part No Description Qty Remark
91. vent damage to PTO clutch Do not engage with throttle in the fast position 1 Adjust mower deck to desired cutting height 2 Start engine MX20091 3 Move throttle lever A to the 1 2 to 3 4 fast position 4 Unlock park brake NOTE In cold weather or with a new machine allow engine to reach operating temperature before engaging PTO to prevent engine from stalling 5 Pull PTO knob B up to engage mower deck 6 Move throttle lever to the fast position NOTE The travel speed and turn rate will vary with the amount that the motion control levers are moved 7 Push motion control levers 0 forward slowly Mow at a safe travel speed Stopping the Engine IMPORTANT Avoid damage To help prevent engine backfiring throttle lever should be set at the half speed position prior to stopping the engine Do not stop engine when mower is on slope of more than 30 degrees for an extended period of time Oil may run through valve train into carburetor and muffler 1 Lock park brake 2 Reduce engine speed to half throttle 3 Turn key switch to STOP position 4 Remove key Operating 15 OPERATING Using Pump Free Wheel Valves CAUTION Avoid injury With the free wheeling open the machine will have unrestricted motion machine may free wheel out of control if the free wheeling valve is opened with the machine on an incline Park th

Great Dane GDRZ61-28KHE Lawn Mower User Manual

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