Great Dane GDRZ61-28KHE Lawn Mower User Manual
Contents
1. CN NE 3 16B 018060 Chute Pivot Rod 52 and 61 3 17 018077 Spring Chute Torsion 3 012086 Discharge Chute 48 Deck 3 18B 012007 Discharge Chute 52 Deck 3 21B 018037 4 21C 018036 22 ie 22 014101 Spindle 5 8 Bolt 23 D18055 Spindle Blade Spacer 1 4 GREAT DANE 6 63 x Figure 4 8 ain ITEM NO PART DESCRIPTION 4 1 015031 Engine Deck 4 2 018004 Belt Engine to Hydro Pumps 4 3 018066 Wheel Motor Parker Ross 4 4 013021 Bushing Footplate Pivot 4 9 D18044 Pulley Idler Engine to Pumps 4 10 015027 Idier Mount Weldment 4 11 014104 Snap ring 1 4 12A 015032 Idler Arm Weldment Pumps 4 16 D18000 Blade Clutch Warner Electric 4 17 D14081 Nut Hex Head 5 16 18 4 18 D12043 Clutch Bumper Support 4 19 018068 Clutch Bumper GREAT DANE VI gt ES _ HI Ll a m NOTE VIEW FROM FRONT 37 27 28 26 ITEM PART NO DESCRIPTION 5 1A D15052 Oil Reservoir 5 1B D18081 Cap Oil Reservoir not shown 5 2 018010 Hose LP Oil Return 5 3 D13029 Drive Control Rod 5 4 D18072 Spring Hydro Pump Forward 5 9 D18010 Hose LP Oil Fill 5 10 014195 Fitting Oil Return 5 11 D18106 Ball Rod End 5 16 24 Female 5 12 D14196 Fitting HP Pump to Motor 5 18 D2. D12051 Replaced By D22215 2 1 D12052 Battery Tray Support 012066 Bracket Wheel MotorMount 2 1 D14215 Lug Stud Drive Wheel D15025 Side Support LH D15026 Side Support RH D15031 Engine Deck Weldment D18110 Rear Wheel Hub for the 18 x 8 50 D18134 Rubber Gromments D18192 Tire 18x8 50 8 D18193 Tire 18x7 50 8 D18195 Rim 18x8 50 8 D18198 Rim 18x7 50 8 NIN 012002 012098 012106 013011 013022 013036 013039 015022 015023 01504 016000 01600 035033 Console Old style w toggle PTO switch Console Current style Retainer Tab PTO Switch od Pivot lip Swivel Platform J hook rake Bushing rake Latch Bushing high Plate Weldment andle Mount Weldment rake Pedal Weldment LH pring Platform Update H Parking brake kit H Brake Bracket Weldment Y D13003 D13023 D13024 D1515 01800 018076 03300 038035 03806 038066 038067 038068 Caster Wheel Bearing Sleeve Spacer J Hook Flat Idler Spindle Top Pulley Spacer Pin 48 Chute Pin dler Arm Bearing Bushing aster Support Bushing pacer 13 Caster Wheel Tapered Roller Bearings w race 13 Caster Wheel 13 Caster Wheel Seal 13 Caster Tire 13 Caster Spacer Tube 3 Caster Stop Tube Y D12027 D12064 D13010 D14160 racket Clutch Mount ear Cover for Hydro Pulley pacer Engine Crankshaft asher 1 4 Heavy Washer D14215 D15025 D15026 D15031
3. D18110 D18134 D18192 D18193 D18195 D18198 p D12002 D12098 D12106 D13011 D13022 D13036 D13039 D15022 D15023 D15047 D16000 D16001 D35033 013003 D13023 D13024 D18076 033007 D38035 038066 038067 38068 D12027 D12064 D13010 D14160 8 Washer 1 4 Thick Platform Bolt olt m6x14 for Pump Pulle Weldment lunger OPC Actuator 018003 Idler Arm Bearing Bushing ey M5xM28 Hydro Pump Pulley ey Sq 1 4 Taper Engine Pulley ternal Flare Fitting iting Straight Fitting Tee Oil Fill To Pumps Lever Pump Release otational Support Hose LP Tank to Pump Hose Pump to Tee Square Head Set Screw w Patch 1 4 20 x 1 2 uel Tank Shut Off Valve rommet Fuel Tank Valve Cap Oil Drain Tee 032070 Mount Not shown Kawasaki units only Module Mount Not shown Kawasaki units only Be D18017 Wiring Pigtail Kohler D18184 Wiring Harness Kawasaki Manual Start 038182 Wiring Harness Kawasaki Electric Start Kawasaki Wiring Pigtail ET
4. not operate in slippery conditions Lean forward when mowing uphill Before crossing gravel drives sidewalks or roads disengage the cutter blades and wait for them to stop Do not run engine indoors Keep engine free of accumulated grass leaves and excessive lubricants to avoid fires Don t smoke around the mower at any time This has caused serious injury Keep all nuts and bolts tight to be sure of safe working conditions Machine should be stopped and inspected for damage after striking a foreign object Repair any damage before restarting Before leaving the operator s position or leaving mower unattended disengage cutter blades stop engine and remove starting key Always park the machine on level surface and apply parking brake Block the wheels when parking on sloping surface Before any servicing disengage cutter blades stop engine remove starting key and spark plug wires This machine is not meant for highway or street use It is nota recreational vehicle Don t try to show off other words always be careful SAFETY INTERLOCK SYSTEM The Great Dane Surfer has been designed to be inherently safe In addition there are these safety systems Before starting engine you must turn OFF the cutter blade clutch switch An operator must be standing on the platform to engage the cutter blades machines with pull start you must cycle blade clutch switch OFF then ON Completely letting go of control leve
5. 18011 Hose LP Oil Fill from Reservoir 5 19 014199 Fitting Oil Drain Tee 5 20 014195 Fitting Oil Return 5 25 D18095 Hydro Hose High Pressure 5 26 D18167 Mount Only Oil Filter 5 27 018094 Oil Fiter Great Dane 25 Micron 33 D15012 Neutral Adjust Weld RH 34 D15020 Neutral Mounting Bracket 35 D18047 Plastic Knob Male 36 GREAT DANE ELECTRIC WIRE SCHEMATIC LULA LD m Mt LOCATED Oh wEuTRAL 1 BRIGGS STRATTON DIAGRAM a staat switch reto KOHLER DIAGRAM Figure 6 DANGER NUFFLEN amp ADJACENT ARO OS FAHRER 1 6 Figure 7 ITEM NO PART NO DESCRIPTION ITEM NO PART NO DESCRIPTION 6 1 Briggs amp Stratton Wiring Recoil D18027 Decal Great Dane Logo D18019 Main Wiring Harness D18023 Decal Oi Reservoir 018018 Briggs Wiring Pigtail 018021 Decal Throttle Control 018014 Clutch Pigtail Harness D18080 Decal Neutral Adjust D18109 Hour Meter Optional Decal Danger Decal 48 Logo Kohler Wiring Electric Start Decal 52 Logo D18020 Main Wiring Harness Decal 61 Logo OPC Switch Cutter Blades Battery Cable Red Positive Battery Cable Black Negative Hour Meter Optional 13 Illustrated Parts Book Addendum Surfer Parts not shown in manual Description Figure
6. GREAT DANE ZERO TURN SURFER TECHNICAL MANUAL COMMERCIAL MOWERS GDSZ48 14KA GDSZ48 16BV GDSZ52 16BV GDSZ52 18BV GDSZ52 22KHE GDSZ61 22KHE GREAT DANE POWER EQUIPMENT INC PATENTS PENDING JAN 1997 JEFFERSONVILLE INDIANA 47130 U S A FORM 001002 97 TABLE OF CONTENTS SUBJECT PAGE Safety Guidelines 2 Common Accidents you must avoid Safety Interlock System Hydraulic Safety 3 Assembly of Machine 3 Initial Adjustments Initial run in Operating Instructions 3 Field Servicing amp Adjustments 4 Tire Pressure Height of Cut Belt Tension Free Wheeling Hydro Air Bleeding Spindle Disassembly Battery Servicing 5 Recommended Maintenance Check List Initial Break in SAFETY GUIDELINES COMMON ACCIDENTS YOU MUST AVOID CONTACT WITH ROTATING BLADES THROWN OBJECTS OPERATING WITHOUT GUARDS IN PLACE RUNNING OVER SOMEBODY OVERTURNING ON STEEP SLOPES Memorize the above and do yourself a favor read remember and follow these safety instructions Before Operating Do not let children or youngsters operate this machine Do not let others run the machine before they carefully read these instructions Do not carry excess baggage including passengers Police the work area and pick up and remove debris such as wires sticks glass rocks and scrap materials Wear safety goggles sturdy work shoes and close fitting clothes Never operate machine in r bare feet sandals or sneakers Keep all safety devices guard
7. Kohler Command Twin Cylinder Electric D18047 Plastic Knob Male D18095 Hydro Hose High Pressure D18095 Hydro Hose High Pressure D18133 Hose Retainer D 1 12 D16010 Engine Deck Power Unit Assembly 1 13A 016011 Cutter Deck Cutter Deck Assembly 61 1 138 016012 Cutter Deck Cutter Deck Assembly 52 1 13C 016013 Cutter Deck Cutter Deck Assembly 48 Figure 2 J ITEM NO PART NO DESCRIPTION 2 1A D15015 Drive Lever Weldment LH 2 1B D18093 Drive Lever Grip 2 2 D18069 Stationary Bar with Grip 2 7 D18097 Fuel Tank Cap 2 8 D18096 Fuel Tank 6 Gallon 2 9 D13005 J Hook 2 10 D15038 Footplate Grating Weldment 2 15 018049 Throttle Cable 2 16 018135 Battery Carrier with Lid 2 17 D18136 Battery Carrier Strap 2 22 D12094 Brake Release Lever 2 23 D35034 Brake Mounting Bracket 2 24 D18140 Spring Brake Release 2 25 D14031 Bolt Hex Head 3 8 x 5 1 2 Grade 5 2 18 A D C 1 A B C nn JONES PART DESCRIPTION ITEM NO PART DESCRIPTION 30 018034 Spindle Wire Clip 31 D18045 Spindle Bearings 6305 32 011000 Spindle House Casting 33 D18033 Spindle Bearing Spacer 035018 Caster Yoke Widmt 13 D38009 3 11C 018007 Belt Engine to 61 Deck 3 46 D13008 Bushing 20 3 12 D18046 Female 3 47 018057 Caster Quick Pin 3 13 013005 3 14A 018088
8. e proper procedure specified with the charging system neutralizing any acid spills install battery and securely tighten wires RECOMMENDED MAINTENANCE CHECK LIST DAILY 1 Check engine oil level 2 Remove and clean engine air filter 3 Blow clean engine blower screen and fins 4 Clean out debris under belt cover 5 Inspect all belts for damage 6 Sharpen and balance cutter blades WEEKLY or every 40 hours Change engine oil Grease caster wheel bearings 2 places Grease caster wheel pivot bearings 2 places Scrape clean underside of cutter deck Check belt tension Check tire pressure Check battery acid level Clean engine air filter MONTHLY or every 160 hours 1 Clean spark plugs 2 Replace engine oil filter 3 Check hydro reservoir oil level Lubricate the following with WD 40 or LPS 2 1 Idler pulley pivots 3 places 2 Hydro pump control arms 6 places 3 Platform OPC push rod 4 Platform hinges 2 places 5 Traction control lever pivot shaft 4 places 6 Throttle control cable 7 Choke control cable ANNUALLY Remove and replace all spindle bearings Remove and replace main cutter deck idler pulley Remove caster wheel roller bearings clean and relube Remove and replace caster pivot bearing bushings Replace three belts Run in and adjust tension for new belt Thoroughly clean top and underside of power unit Replace hydro
9. from 1 to 3 inches Adjust caster wheel spacers to keep cutter deck tilted slightly down at the front Vary number of spacers between cutter blade and spindle for higher height of cut BELT TENSION ADJUSTMENT The belt drive from the engine to the hydro is self adjusting normally requiring no maintenance The belt from the engine to the cutter deck and the right hand spindle drive belt should be tightened only so that you can deflect the belt about 1 2 inch when pulling about 10 Ibs If the belt is too tight you may damage the engine or the spindle bearings Too loose and the belt will wear prematurely FREE WHEELING move machine without having the engine running rotate the dump valve levers of the left hand side of the hydro pump about one turn counterclockwise Levers must be returned to original closed position to drive the machine HYDRO AIR BLEED PROCEDURE When any of the hydro components or hoses are disconnected or removed and when the hydro oil is changed entrapped air must be bled from the system Disconnect small hose line from each pump going to the oil filter When oil starts to flow in a steady stream from end of hose plug the hose When oil starts to flow in a steady stream from disconnected open port on the pump reconnect hose to pump Secure machine a safe area away from bystanders and facing a wall Raise drive wheels off the ground and block caster wheels Run full fo
10. ng the lever on the left side of bar OPERATING INSTRUCTIONS Read and understand the Safety Guidelines before attempting to operate Check fuel tank Check engine oil level Open fuel valve Adjust stationary bar half way back and tighten left side lever for moderate mowing speed Travel control levers must be in neutral Electric blade clutch switch must be OFF Stand on platform Set throttle and choke as required Turn key switch ON and pull start or electric start Wide open throttle Engage cutter blade switch Grasp stationary bar with both hands Push both levers forward smoothly and evenly to go straight ahead To make turns pull same side control lever back To stop return both levers to neutral reverse pull both levers back Apply parking brake when leaving machine Do not park on slopes To hand push the machine open dump valve levers about one full turn SERVICING amp ADJUSTMENTS TIRE PRESSURE When mowing on relatively smooth ground keep rear wheel tire pressure low such as 14 to 16 psi When mowing on rough ground increase tire pressure to 20 to 24 psi This will produce a nicer level of cut that the front caster wheels are foam filled and never need air HEIGHT OF CUT Rear wheels may be located in three or four positions Use midpoint position for average cut from 2 to 4 inches Highest hole position to cut from 3 to 5 inches Lowest hole position to cut
11. oil filter with original Great Dane service part Check all bolts and nuts for tightness Remove and clean battery box Replace spark plug ONN VERY IMPORTANT NOTE FOLLOWING ITEMS REQUIRED TO VALIDATE Dealer service invoice accepted INITIAL BREAK IN PERIOD 1 Change engine oil and replace engine filter at 8 hours 2 Dump hydro oil and replace with synthetic Aeroshell W or Mobil 1 15 W50 about 4 qts at 40 hours 3 Replace hydro oil filter at 40 hours 4 Adjust new belt tension at 4 hours 8 hours and again at 24 hours GREATSDANE ZERO TURN SURFER TECHNICAL MANUAL PARTS MANUAL COMMERCIAL MOWERS GDSZ48 16BV GDSZ52 16BV GDSZ52 18BV GDSZ52 18KHE GDSZ52 22KHE GDSZ61 22KHE GREAT DANE POWER EQUIPMENT INC MARCH 1998 SELLERSBURG IN 47172 U S A Table of Contents For Illustrated Parts Lists GREAT DANE SURFER Description Figure Page Mower Profile 1 2 Control System Power Unit Top View 2 4 Cutter Deck Assembly 3 6 Drive System Power Unit Underside 4 8 Hydraulic System 5 10 Wiring Schematics 6 12 Decals 7 13 13 12 11 9 AB Figure 1 ITEM NO PART NO DESCRIPTION 1 1A D18156 Engine 16 HP Briggs amp Stratton Vanguard Twin Cylinder Recoil 1 18 D18157 Engine 18 HP Briggs amp Stratton Vanguard Twin Cylinder Recoil 1 1C D18158 Engine 18 HP Kohler Command Twin Cylinder Electric 1 1D D18159 Engine 22 HP
12. rs will brake machine to instant stop HYDRAULIC SAFETY hydraulic system servicing should be done by a qualified technician Relieve all pressure in the system before disconnecting any hoses Keep body and hands away from pin holes that may eject hydraulic fluid under high pressure Make sure all hydraulic connections are tight and hoses in good condition High pressure hydraulic fluid may have sufficient force to penetrate skin and cause serious injury Seek medical attention immediately Treatment must be done a doctor ASSEMBLY OF MACHINE Please note the Great Dane Surfer is shipped completely assembled and has been tested at the factory After you have removed all crating and packaging materials carefully follow these steps Remove battery from machine if one is installed and service observing precautions in Section on Battery Servicing Check hydraulic fluid level Should be about 5 inches below the top of the oil filler pipe Use 10W 30 engine oil during initial operating period Check engine oil for proper level Check rear wheel tire pressure Use high pressures up to 24 psi for mowing on rough ground and down to 14 psi for fairly smooth terrain Note front caster wheel tires must be foam filled and thus never require air servicing Remove belt cover and check all belt tension Lubricate all moving parts see Maintenance Check List Locate rear drive wheel mounting bracket for general heigh
13. rward speed for about a minute and then reverse speed for another minute Continue to cycle until cavitations sound quiets down and full power is restored SPINDLE DISASSEMBLY To replace ball bearings in the spindle assembly there is no need to remove assembly from cutter deck Carefully clean all debris around the spindle assembly Remove the blade bolt and flanged nut Slide off pulley and spacer washer If pulley is seized on spline shaft soak with solvent Do not use hammer or wheel puller Remove wire clip ring at top of bearing around the shaft Use sharp tool to extract Lower the entire shaft from the bottom of the spindle with lower bearing and spacer sleeve Discard old bearings at this time Clean entire assembly Reinstall in reverse order Place new bearing on shaft lower flange slide on the spacer sleeve Slide the shaft assembly up into the spindle housing keeping shaft carefully centered The lower bearing can easily bind since clearance is only 002 inch Do not hammer into position If the bearing seizes take apart again and carefully reposition until the assembly slides easily and smoothly into housing Carefully center and install top bearing Insert wire clip any spacers and pulley BATTERY SERVICING Carefully fill each cell to the proper level with electrolyte observing great caution when handling acid Severe chemical burns may result Charge battery in open well ventilated area and us
14. s and shields in good condition and in place The discharge chute must be installed and spring loaded down except when grass catcher is in place Do not touch engine muffler It may be extremely hot and cause severe burns Although the Great Dane Surfer has a built in safety system it is recommended to disengage power to the cutter blades and engage the parking brake before leaving the platform for a brief time When leaving the machine out of sight disengage power to cutter blades shut off engine apply parking brakes and take the starting key with you Watch out for traffic when crossing or near roadways Never direct discharge chute toward bystanders windows buildings or cars Precautions when Handling Gasoline Use an approved gasoline container Never remove fuel cap or add gasoline to a running or hot engine Allow engine to cool for several minutes before refueling tank Never refuel indoors Avoid spilling gasoline anywhere Wipe up any spilled gasoline Do not smoke while handling gasoline During Operation Using the machine demands attention To prevent loss of control Mow only in daylight or when there is good lighting Watch for pot holes rocks and any hidden hazard Keep away from drop offs ditches creeks ponds and other hazards Reduce speed when making sharp turns and especially on hillsides Always be sure of your footing Keep a firm hold on the stationary handle at all times Do
15. t of cut in your region Fill fuel tank with regular 80 octane gasoline Open shut off valve under gas tank You are now ready for initial running of the machine INITIAL ADJUSTMENTS Set the rear of the machine on jack stands or blocks to raise rear wheels off of ground and block caster wheels Start engine Let run for several minutes to warm hydraulic fluid Observe that wheels rotate in the correct direction when control levers are moved back and forth wheels do not stop rotating when controls are in neutral adjust the NEUTRAL stop wing bolts at the rear of the power unit between the two hydro pumps Engage cutter blade clutch Be sure area is clear of debris Run blades for several minutes Shut off engine and remove jack stands Remove start key Check all belts for proper tension Test run the machine in a level area If machine drifts to the right or left when both control levers are full forward adjust swivel nuts at the top of control rods to change length of control rod so that machine travels in a straight line Please remember the neutral adjustment and straight drive adjustments will need to be repeated after several hours of operation Test function of the three safety interlock Systems Adjust safe maximum drive speed by unlocking and adjusting the stationary bar to limit amount of forward movement of the control levers Secure the stationary bar firmly by tighteni
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