Chariot / Chariot LX
GDRZ48-17KAE, GDRZ48-19KAE, GDRZ52-23KAE, GDRZ52-25KAE, GDRZ52-25KHE,
GDRZ61-25KAE, GDRZ61-25KHE, GDRZ61-25KAE, GDRZ61-25KHE, GDRZ61-26KHE,
GDRZ61-27KHE, GDRZ61-28KHE, GDRZ72-27KHE, GDRZ72-28KHE
TCU17095
H2
OPERATOR’S MANUAL
cWARNING:The Engine Exhaust
from this product contains chemicals known
to the State of California to cause cancer,
birth defects or other reproductive harm.
California Proposition 65 Warning
OMTCU17095 J2
North American Version
Litho in U.S.A.
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PRODUCT IDENTIFICATION
Product Identification
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
MOWER DECK MODEL NUMBER (C):
Record Identification Numbers
Chariot
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
MOWER DECK SERIAL NUMBER (C):
GDRZ48-17KAE, GDRZ48-19KAE, GDRZ52-23KAE,
GDRZ52-25KAE, GDRZ52-25KHE,
GDRZ61-25-KAE, GDRZ61-25KHE Serial No. (010001 - )
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
Chariot LX
GDRZ61-25KAE, GDRZ61-25KHE, GDRZ61-26KHE,
GDRZ61-27KHE, GDRZ61-28KHE, GDRZ72-27KHE,
GDRZ72-28KHE Serial No. (010001 - )
If you need to contact an Authorized Service Center for
information on servicing, always provide the product model
and serial 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:
_________________________________________
B
C
A
MX15355
MODEL NUMBER (POWER UNIT) (A):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
SERIAL NUMBER (POWER UNIT) (A):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ENGINE MODEL NUMBER(B):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ENGINE SERIAL NUMBER (B):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ENGINE SPECIFICATION NUMBER (B):
Product Identification
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TABLE OF CONTENTS
Table of Contents
Safety .....................................................................................................................................................................................1
Operating .............................................................................................................................................................................10
Replacement Parts...............................................................................................................................................................22
Service Intervals...................................................................................................................................................................23
Service Lubrication...............................................................................................................................................................24
Service Engine .....................................................................................................................................................................26
Service Transmission............................................................................................................................................................31
Service Steering & Brakes....................................................................................................................................................37
Service Mower......................................................................................................................................................................41
Service Electrical..................................................................................................................................................................51
Service Miscellaneous..........................................................................................................................................................57
Troubleshooting ....................................................................................................................................................................59
Storage.................................................................................................................................................................................64
Assembly..............................................................................................................................................................................65
Specifications .......................................................................................................................................................................68
Index.....................................................................................................................................................................................70
Service Record GD ..............................................................................................................................................................71
All information, illustrations and
specifications in this manual are based
on the latest information at the time of
publication. The right is reserved to
make changes at any time without
notice.
COPYRIGHT© 2002
Deere & Co.
John Deere Worldwide Commercial and
Consumer Equipment Division
All rights reserved
Previous Editions
COPYRIGHT©
OMTCU17095 J2 - English
Table of Contents
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SAFETY
Safety
DANGER
Understanding The Machine Safety Labels
Safety-Alert Symbol
The machine safety labels shown in this section are placed
in important areas on your machine to draw attention to
potential safety hazards.
M131739, MX15340
To avoid injury from rotating blades, stay clear of deck
edge.
On your machine safety labels, the words DANGER,
WARNING, and CAUTION are used with this safety-alert
symbol. DANGER identifies the most serious hazards.
The operator’s manual also explains any potential safety
hazards whenever necessary in special safety messages
that are identified with the word, CAUTION, and the safety-
alert symbol.
DANGER
DANGER
M137637, MX15340
Do not mow without discharge chute or entire grass catcher
in place.
TCU51336, MX15340
To avoid injury to children, stop mower when children are
near. Do not mow in reverse. Look behind when backing.
Never carry riders, especially children.
Safety - 1
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SAFETY
DANGER
WARNING
MX15340, TCU15907
M131748, MX15340
To avoid injury from tipover, drive across slopes, not up and
down. If machine stops going uphill, stop blades and back
down slowly.
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.
WARNING
DANGER: EXPLOSIVE GASES / POISON:
CAUSES SEVERE BURNS
TCU51051, MX15340
TCU14885, MX15274
To avoid injury from rotating belts, keep all shields and
guards in place.
•
Cigarettes, flames or sparks could cause battery to
explode. Always shield eyes and face from battery. Do not
charge or use booster cables or adjust post connections
without proper instruction and training.
•
Contains sulfuric acid. Avoid contact with the skin, eyes
or clothing. In event of accident, flush with water and call a
physician immediately. Keep out of reach of children.
Safety - 2
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SAFETY
WARNING
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.
M117554, MX15274
Hot surface
Emission Compliance Period
CAUTION: HELP AVOID INJURY
If your engine has the emission compliance category listed
on the emission control system certification or air index
label, this indicates the number of operating hours for which
the engine has been certified to meet EPA and/or CARB
emission requirements. The following table provides the
engine compliance period in hours associated with the
category found on the certification label.
Agency
EPA
Category
Hours
250
C
EPA
B
500
EPA
A
1000
125
CARB
CARB
CARB
Moderate
Intermediate
Extended
TCU14840, MX15340
250
•
•
•
•
•
•
•
Operator training required
Read operator’s manual
Keep shields in place
500
Certification
Never carry riders
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.
Keep people a safe distance away
Maintain all safety devices
Before leaving machine:
•
•
•
Stop engine
Set park brake
Remove key
Canadian Electromagnetic Compatibility
(EMC) Compliance
This spark ignition system complies with Canadian ICES-
002.
Safety - 3
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SAFETY
•
Be sure all drives are in neutral and parking brake is
Operator Training Required
locked before starting engine. Only start engine from the
operator’s position.
•
The owner of the machine is responsible for training the
users and mechanics of the machine.
•
Do not change the engine governor settings or
•
The owner/user can prevent and is responsible for
overspeed the engine. Operating the engine at excessive
speed can increase the hazard of personal injury.
accidents or injuries occurring to themselves, other people,
or property.
•
Do not operate mower without discharge chute or entire
•
Do not allow operation or service of the machine by
grass catcher in place. Never operate with the discharge
deflector raised, removed, or altered, unless using a grass
catcher.
untrained adults.
•
Do not let children operate the machine. Local
regulations may restrict the age of the operator.
•
Check brake action before you operate. Adjust or
service brakes as necessary.
•
Read the operator’s manual and study the safety and
operation sections before operating the machine.
•
•
Stop machine if anyone enters the area.
•
If the operator of the machine cannot read or
If you hit an object or if abnormal vibration occurs, stop
understand this manual, it is the machine’s owner
responsibility to explain this material to the operator.
and inspect the machine. Make repairs before you operate.
Keep machine and attachments properly maintained and in
good working order.
•
Operate the machine in an open, unobstructed area
under the direction of an experienced operator.
•
Be aware of the mower discharge direction and make
sure that no one is in the path of the discharge direction.
•
•
Learn the use of all controls.
•
•
•
Do not leave machine unattended when it is running.
Only operate during daylight or with good artificial light.
Stop the blades rotating before crossing surfaces other
Operator experience is required to learn the moving,
stopping, turning and other operating characteristics of the
machine.
than grass.
Operating Safely
•
Use only accessories and attachments approved by the
manufacturer of the machine. Keep safety labels visible
when installing accessories and attachments.
•
Do not operate machine if you are under the influence of
drugs or alcohol.
•
Check before each use that operator presence controls
are functioning correctly. Test safety systems. Do not
operate unless they are functioning correctly.
•
Always wear seat belt if machine has a standard ROPS
or a folding ROPS in the upright position.
•
•
Never raise mower decks when blades are running.
Slow down and be careful of traffic when operating near
MIF
or crossing roadways. Stop blades before crossing roads or
sidewalks. Use care when approaching blind corners,
shrubs, trees, or other objects that may obscure vision.
•
Only allow responsible adults, who are familiar with the
instructions to operate the machine. Local restrictions may
restrict the age of the operator.
•
Do not wear radio or music headphones. Safe service
and operation require your full attention.
•
Inspect machine before you operate. Be sure hardware
is tight. Repair or replace damaged, badly worn, or missing
parts. Replace faulty silencers. Be sure guards and shields
are in good condition and fastened in place. Make any
necessary adjustments before you operate.
•
Disengage drive to attachments when transporting or
not in use.
•
Reduce the throttle setting during engine run-out and, if
the engine is provided with a fuel shut-off valve, turn the
fuel off at the conclusion of mowing.
•
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.
•
When machine is left unattended, stored, or parked,
lower the mower deck unless a positive mechanical lock is
used.
Safety - 4
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SAFETY
7. Wait for engine and all moving parts to stop before you
leave the operator’s seat.
Using a Spark Arrestor
The engine in this machine is not equipped with a spark
arrestor muffler. It is a violation of California Public
Resource Code Section 4442 to use or operate this engine
on or near any forest-covered, brush-covered or grass-
covered land unless the exhaust system is equipped with a
spark arrestor meeting any applicable local or state laws.
Other states or federal areas may have similar laws.
8. Disconnect the negative battery cable or remove the
spark plug wire before servicing the machine.
Rotating Blades are Dangerous
HELP PREVENT SERIOUS OR FATAL ACCIDENTS:
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
MIF
•
•
Rotating blades can cut off arms and legs.
Keep hands, feet and clothing away from mower deck
when engine is running.
MIF
•
Be alert at all times, drive forward carefully. People,
•
Evaluate the terrain to determine what accessories and
especially children can move quickly into the mowing area
before you know it.
attachments are needed to properly and safely perform the
job.
•
Before backing up, shut off PTO and look down and
•
Clear mowing area of objects that might be thrown.
behind the machine carefully, especially for children.
Keep people and pets out of mowing area.
•
•
•
Do not mow in reverse.
•
Low-hanging branches and similar obstacles can injure
Shut off blades when you are not mowing.
the operator or interfere with mowing operation. Before
mowing, identify potential obstacles such as low-hanging
branches, and trim or remove those obstacles.
Park machine safely before inspecting or unplugging
mower or bagger for any reason including emptying the
catchers or unplugging the chute.
•
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 PTO.
3. Lower attachments to the ground.
4. Lock the park brake.
5. Stop the engine.
6. Remove the key.
Safety - 5
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SAFETY
PROTECT CHILDREN:
•
Transport machine with decks lowered to improve
stability.
•
Drive machine very slowly and avoid quick stops when
attachment is removed.
•
Drive across a hill, not up and down. Be careful when
you change direction on a slope. If necessary, turn slowly
and in the downhill direction.
•
Mowing when grass is wet can cause reduced traction
and sliding.
Keep Riders Off
•
Never assume that children will remain where you last
saw them. Children are attracted to mowing activity, stay
alert to the presence of children.
•
Keep children indoors when you are mowing. Turn the
machine off if a child enters the mowing area.
•
Use extra care when you come to blind corners, shrubs,
trees, or other objects that may block your vision.
•
Do not let children or an untrained person operate the
machine.
•
Do not carry or let children ride on any attachment or
MIF
machine even with the blades off. Do not tow children in a
cart or trailer.
•
•
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.
Avoid Tipping
•
Riders obstruct the operator’s view resulting in the
machine being operated in an unsafe manner.
Checking Wheel Bolts
•
A serious accident could occur causing serious injury if
wheel bolts are not tight.
•
Check wheel bolt 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.
MIF
•
Slopes are a major factor related to loss-of-control and
tip-over accidents, which can result in severe injury or
death.
•
Do not drive where machine could slip or tip.
•
Stay alert for holes and other hidden hazards in the
terrain.
•
•
Keep away from drop-offs, ditches, and embankments.
Slow down before you make a sharp turn or operate on
a slope.
Safety - 6
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SAFETY
Wear Appropriate Clothing
Practice Safe Maintenance
MIF
MIF
•
Always wear safety goggles, or safety glasses with side
•
Only qualified, trained adults should service this
shields, and a hard hat when operating the machine.
machine.
•
Wear close fitting clothing and safety equipment
•
Understand service procedure before doing work. Keep
appropriate for the job.
area clean and dry.
•
While mowing, always wear substantial footwear and
•
Never lubricate, service, or adjust machine while it is
long trousers. Do not operate the equipment when barefoot
or wearing open sandals.
moving. Keep safety devices in place and in working
condition. Keep hardware tight.
•
Wear a suitable protective device such as earplugs.
•
Keep hands, feet, clothing, jewelry, and long hair away
Loud noise can cause impairment or loss of hearing.
from any moving parts, to prevent them from getting
caught.
•
Lower attachments to the ground before servicing
Driving Safely on Public Roads
machine. Disengage all power and stop the engine. Lock
park brake and remove the key. Let machine cool.
•
Disconnect battery or remove spark plug wire (for
gasoline engines) before making any repairs.
•
Before servicing machine, carefully release pressure
from any components with stored energy, such as hydraulic
components.
•
Keep all nuts and bolts tightened, especially blade
attachment bolts.
•
Securely support any machine elements that must be
raised for service work. Use jack stands or lock service
latches to support components when needed.
MIF
•
Never run engine unless park brake is locked.
•
Use safety lights and devices. Slow moving machines
•
Keep all parts in good condition and properly installed.
when driven on public roads are hard to see, especially at
night.
Fix damage immediately. Replace worn or broken parts.
Replace all worn or damaged safety and instruction decals.
•
Whenever driving on public roads, use flashing warning
•
Grass catcher components are subject to wear,
lights and turn signals according to local regulations. Extra
flashing warning lights may need to be installed.
damage, and deterioration which could expose moving
parts or allow objects to be thrown. Check components
frequently and replace with manufacturer’s recommended
parts when necessary.
•
To prevent fires, remove any buildup of grease, oil, or
debris from the machine, especially the engine
compartment.
Safety - 7
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SAFETY
•
Charge batteries in an open, well-ventilated area, away
Prevent Fires
from sparks. Unplug battery charger before connecting or
disconnecting from the battery. Wear protective clothing
and use insulated tools.
•
Do not modify machine or safety devices. Unauthorized
modifications may impair its function and safety.
Avoid High-Pressure Fluids
•
Remove grass and debris from engine compartment
and muffler area, before and after operating machine,
especially after mowing or mulching in dry conditions.
•
To reduce fire hazard, keep engine and engine
compartment free of grass, leaves, or excessive grease.
•
•
Allow engine to cool before storing in any enclosure.
Never remove fuel cap, or add fuel with engine running
MIF
•
Hydraulic hoses and lines can fail due to physical
or hot. Allow engine to cool for several minutes.
damage, kinks, age, and exposure. Check hoses and lines
regularly. Replace damaged hoses and lines.
•
Never store equipment with fuel in the tank inside a
building where fumes may reach an open flame or spark.
•
Hydraulic fluid connections can loosen due to physical
damage and vibration. Check connections regularly.
Tighten loose connections.
Tire Safety
•
Escaping fluid under pressure can penetrate the skin
causing serious injury. Avoid the hazard by relieving
pressure before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
•
Search for leaks with a piece of cardboard. Protect
hands and body from high-pressure fluids.
•
If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a
knowledgeable medical source.
MIF
Explosive separation of a tire and rim parts can cause
serious injury or death:
•
Do not attempt to mount a tire without the proper
equipment and experience to perform the job.
•
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
Safety - 8
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SAFETY
•
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
Fuel and fuel vapors are highly flammable:
•
Static electric discharge can ignite gasoline vapors in an
ungrounded fuel container. Remove the fuel container from
the bed of a vehicle or the trunk of a car and place on the
ground away from the vehicle before filling. Keep nozzle in
contact with container opening while filling. Do not use a
nozzle lock-open device.
•
When practical, remove equipment from trailers or truck
beds and refuel them on the ground. If this is not possible,
use a portable, plastic fuel container to refuel equipment on
a truck bed or trailer.
•
Do not refuel machine while you smoke, when machine
•
For gasoline engines, do not use gas with methanol.
is near an open flame or sparks, or when engine is running.
Stop engine and allow to cool before filling.
Methanol is harmful to your health and to the environment.
•
Never remove the fuel cap or add fuel with the engine
running.
Handling Waste Products and Chemicals
•
Never fill fuel tank or drain fuel from a machine in an
enclosed area. Fill fuel tank outdoors.
•
Prevent fires. Clean up spilled fuel immediately. If fuel is
spilled on clothing, change clothing immediately.
•
Do not store fuel in container or machine with fuel in
tank in a building where fumes may reach an open flame or
spark.
•
Prevent fire and explosion caused by static electric
discharge. Use only non-metal, portable fuel containers
approved by the Underwriters Laboratories (UL) or the
American Society for Testing and Materials (ASTM). If
using a funnel, make sure it is plastic and has no screen or
filter.
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.
Safety - 9
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OPERATING
Operating
H - Throttle Lever
I - Mower Deck Lift/Lower Lever
J - Height-of-Cut (HOC) Adjustment Pin
K - Mower Deck Transport Position Lock Lever
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.
Miscellaneous Controls
❏ Remove grass and debris from machine and mower
deck.
❏ Test park brake.
❏ Test safety systems.
❏ Inspect battery terminals and hold-downs.
❏ Inspect for oil leaks.
❏ Check engine and hydraulic oil levels.
❏ Inspect all belts for damage or cracking.
❏ Inspect engine air filter.
A
❏ Inspect mower level.
MX13124
❏ Adjust cutting height if necessary.
❏ Inspect wheel bolt torque. Tighten if necessary.
A - Hydraulic Pump Free-Wheel Valves
❏ Check tire air pressure. Check tires for damage or
cracking.
Testing Safety Systems
❏ Inspect front caster spindles/wheels.
Operator Station Controls
A
B
C
K
D
I
c
CAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
J
F
H
G
E
Move the machine to an outside area before
running the engine.
MX15290
A - Motion Control Levers
B - Park Brake Lever
C - Seat Adjustment Lever
D - Hourmeter
E - Ignition Key Switch
F - PTO Knob
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.
G - Choke (Carbureted Engines Only)
Operating - 10
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OPERATING
The safety systems installed on your machine should be
Testing Seat Switch
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.
Procedure 1:
1. Sit on the operator seat with the motion control levers in
the neutral detent position (standard levers) or neutral lock
position (optional “over the lap” levers).
Use the following checkout procedures to check for normal
operation of machine.
2. Unlock the park brake.
If there is a malfunction during one of these procedures, do
not operate machine. See your authorized dealer for
service.
3. Push PTO knob down to disengage.
4. Turn key switch to the start position.
5. Raise slightly off the seat.
Perform these tests in a clear open area. Keep bystanders
away.
Result: The engine must stop.
Procedure 2:
Testing PTO Switch
1. Start engine.
1. Sit on the operator seat with the motion control levers in
the neutral detent position (standard levers) or neutral lock
position (optional “over the lap” levers).
2. Lock the park brake.
2. Lock the park brake.
c
CAUTION: Avoid injury! Before engaging
mower, make sure that area is clear of
bystanders, especially children.
3. Pull PTO knob up to engage.
4. Turn key switch to the start position.
Result: The engine must not crank.
3. Pull PTO knob up to engage.
4. Raise slightly off the seat.
Result: The engine must stop.
Testing Park Brake Switch
1. Sit on the operator seat with the motion control levers in
the neutral detent position (standard levers) or neutral lock
position (optional “over the lap” levers).
Testing the Park Brake
2. Push PTO knob down to disengage.
3. Unlock the park brake.
4. Turn key switch to the start position.
Result: The engine must not crank.
Testing Neutral Start Switch
NOTE: Repeat this test three times, with the motion
control levers in the following positions:
MIF
•
•
•
Right side motion control lever inward.
Left side motion control lever inward.
Both motion control levers inward.
1. Stop machine on a 17° slope (30% grade). Stop the
engine and lock the park brake.
Result: Park brake must hold the machine stationary.
(Machine should move no more that 61 cm (24 in.) in one
hour.) If machine moves more than that, brakes need to be
adjusted. See Adjusting Park Brake in the Service Steering
& Brakes section.
1. Move motion control lever(s) out of the neutral detent
position (standard levers) or neutral lock position (optional
“over the lap” levers).
2. Lock the park brake.
3. Push PTO knob down to disengage.
4. Turn key switch to the start position.
Result: The engine must not crank.
Operating - 11
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OPERATING
Lowering the Seat:
Mounting and Dismounting Machine Safely
1. Stand on the side of the machine.
2. Push operator seat back and slowly lower seat frame.
A
Adjusting Seat
Front-to-Back Adjustment
1. Sit on the operator seat.
MX15340
Do not step on the mower deck when mounting and
dismounting the machine. Mount the machine from the
front using the foot plate (A). Park machine safely (see
Parking Safely in the Safety section) before dismounting.
B
A
MX15280
Keep the foot plate clean.
Picture Note: Chariot LX suspension seat shown.
2. To adjust the seat front to back, push and hold the seat
adjustment lever (A) away from the seat.
Raising and Lowering Operator Seat
3. Slide forward or backward to desired position.
4. Release lever.
c
CAUTION: Avoid injury! The seat is heavy and
can cause injury if it falls. When performing
any service function under the operator seat,
make sure the seat is tilted forward and rests
against the hinge stops.
Seat Height Adjustment (Chariot LX only)
1. Sit on the operator seat.
2. To lower the seat, turn knob (B) counterclockwise.
3. To raise the seat, turn knob (B) clockwise.
Raising the Seat:
1. Park machine safely. (See Parking Safely in the Safety
section.)
Adjusting Mower Deck Cutting Height
2. Slide seat to full rear position.
c
CAUTION: Avoid injury! Before adjusting
cutting height, stop engine and lock the park
brake.
Cutting height can be adjusted from approximately 25-125
mm (1-5 in.). Each hole adjusts the height-of-cut (HOC) in
approximately 12 mm (1/2 in.) increments.
A
The deck can also be raised and locked in a transport
position, to provide maximum ground clearance when
moving the machine from one area to another.
1. Park machine safely. (See Parking Safely in the Safety
section.)
MX15282
3. Lift seat frame (A) and tilt forward until it rests against
the hinge stops.
Operating - 12
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OPERATING
2. Adjust mower deck to desired cutting height.
A
NOTE: The rear anti-scalp wheels are located under the
rear of the mower deck.
B
D
C
MX13149
B
A
2. Move the mower deck lift lever (A) to the transport
position (D).
C
MX15281
3. Position the HOC adjustment pin (C) in the proper hole
for the desired height-of-cut.
3. Adjust anti-scalp wheel (A) to one of two positions (B).
4. Pull back and hold the mower deck lift lever (A) and
release the transport position lock lever (B).
•
Remove screw (C), nut and washer.
•
Adjust wheel up or down so it is approximately 6-13
mm (1/4-1/2 in.) above mowing surface.
4. Install wheel with attaching hardware.
5. Adjust all wheels to same height.
A
Using the Park Brake
C
c
CAUTION: Avoid injury! Children or bystanders
may attempt to move or operate an unattended
machine.
MX13155
Always lock the park brake and remove the
key before leaving the machine unattended.
5. Allow the mower deck lift lever (A) to rest against the
HOC adjustment pin (C).
Locking Park Brake:
Adjusting Mower Deck Anti-Scalp Wheels
c
CAUTION: Avoid injury! If the engine should
stop while operating on an incline, the mower
will free-wheel. If this should occur, lock the
park brake, start the engine, unlock the park
brake and resume operation.
c
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 flattest cut can be achieved by having all
anti-scalp wheels adjusted off the ground. Check anti-
scalp wheel adjustments each time the mower deck
cutting height is changed.
It is recommended that all anti-scalp wheels be kept off
the ground to minimize scuffing.
1. Inflate tires to correct pressure.
Operating - 13
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OPERATING
Using the Key Switch
NOTE: Machine will only start if the following
conditions exist:
A
•
•
•
Park brake is locked.
PTO is disengaged.
Motion control levers are in the neutral detent
position (standard levers) or neutral lock position
(optional “over the lap” levers).
A
MX15275
•
Raise and pull rearward park brake lever (A) to the lock
B
STOP
park brake.
Unlocking Park Brake:
C
MIF
•
•
•
To turn ignition off, turn key to the STOP position (A).
A
To turn ignition on, turn key to the run position (B).
To start engine, turn key to the start position (C). Once
engine begins to run, release key back to the run position.
Using the PTO
MX15292
•
Lower park brake lever (A) forward to unlock the park
Engage PTO:
brake.
B
A
C
MX15284
1. Move throttle lever (A) to the 1/2- to 3/4-throttle position.
2. Pull PTO knob (B) up to engage mower deck.
3. Move throttle lever (A) forward to the fast detent position
(C) for mowing.
Disengage PTO:
•
Push PTO knob (B) down.
Operating - 14
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OPERATING
Using the Throttle Lever
Using the Choke (Carbureted Engines Only)
Engage Choke:
A
B
A
C
D
MX15284
•
Push throttle lever (A) all the way forward to the full-
MX15284
throttle detent position (B) when mowing.
•
Pull choke knob (A) out.
•
Move throttle lever (A) to the 1/2-throttle position (C)
when starting and warming the engine.
Disengage Choke:
Push choke knob (A) in.
•
Pull throttle lever (A) rearward to the slow position (D) to
•
idle engine. Do not run engine at slow idle any longer than
necessary.
Using the Motion Control Levers
Using the Hourmeter
c
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.
NOTE: The machine is equipped with an electric start.
The hourmeter will continue to run with the key switch
left in the run position.
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.
A
NOTE: Two types of control levers are available -
standard “center steer” levers and optional “over the
lap” levers. The operation of both styles of levers is the
same except as noted.
The functions of the motion control levers are:
MX15284
•
•
•
•
Dual function neutral position.
Steering.
•
The hourmeter (A) shows the number of hours the
machine has run.
Acceleration.
•
The service interval chart gives necessary service
intervals. Use the hourmeter and service interval chart in
the Service Intervals section to determine when machine
will need service.
Braking.
See the service interval chart in the engine manufacturer’s
owners manual supplied with your machine to determine
when the engine will need service.
Operating - 15
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OPERATING
Neutral Detent Position - Standard “Center Steer”
Neutral Position - Optional “Over the Lap” Levers
Levers
NOTE: When the control levers are in the neutral detent
position, the control lever rollers (A) located on each
side of the control console will be seated in the
notches in the console.
A
MX15293
Picture Note: Motion control levers (A) shown in
the neutral position.
A
•
Machine speed, motion, and direction can be controlled
when the engine is running, operator is on the seat and the
park brake is unlocked.
MX15341
•
Motion control levers must be in the neutral detent
position, the PTO switch disengaged and the park brake
locked to start the engine.
Forward and Reverse Motion:
Neutral Lock Position - Optional “Over the Lap” Levers
c
CAUTION: Avoid injury! Children or bystanders
may be injured by run over and rotating blades.
Before traveling forward or rearward:
A
• Carefully check the area around the
machine.
• Disengage the mower before backing up.
1. Move throttle lever to the full-throttle position.
2. Unlock the park brake.
3. Optional “over the lap” levers: Move both motion control
levers from the neutral lock position inward to the neutral
position.
4. Push the control levers forward to begin forward motion.
MX15276
•
The farther forward the control levers are moved, the
Picture Note: Motion control levers (A) shown in
the neutral lock position.
faster the machine will travel.
•
Forward speed range: 0-14 km/h (0-9 mph).
•
Motion control levers must be in the neutral lock
5. Pull both control levers rearward at the same time to
begin reverse motion.
position, the PTO switch disengaged and the park brake
locked to start the engine.
•
Reverse speed range: 0-6 km/h (0-4 mph).
•
Forward and reverse movement of the motion control
6. To stop motion, move both motion control levers forward
or rearward until the machine comes to a stop.
levers is prevented when levers are moved to the neutral
lock position.
NOTE: The motion control linkages are adjustable. If
adjustment is required, see Checking and Adjusting
Motion Control Linkages in the Service Transmission
section.
•
Operator can exit mower with the engine running when
the PTO switch is disengaged, the motion control levers are
in the neutral lock position and the park brake is locked.
•
Motion control levers must be in the neutral lock position
to safely enter and exit the operator seat.
Operating - 16
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OPERATING
Forward:
Gentle Right Turn:
MX13114
MX13117
•
Push both motion control levers forward at the same
•
Push left control lever farther forward than the right
time.
control lever.
Reverse:
Sharp Left Turn:
MX13115
MX13118
•
Pull both control levers past center rearward at the same
•
Push right control lever forward and pull left control lever
time.
rearward at the same time.
Gentle Left Turn:
Sharp Right Turn:
MX13116
MX13119
•
Push right control lever farther forward than the left
•
Push left control lever forward and pull right control lever
control lever.
rearward at the same time.
Operating - 17
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OPERATING
Starting the Engine
IMPORTANT: Avoid damage! Starter may be
damaged if starter is operated for more than 20
seconds at a time:
c
CAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
•
Wait 2 minutes before trying again if the engine
does not start.
Move the vehicle to an outside area before
running the engine.
Do not run an engine in an enclosed area
without adequate ventilation.
STOP
C
• 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.
B
1. Sit on the operator seat.
2. Lock the park brake.
MIF
7. Turn key switch to start position (B).
If the engine does not start, wait 10 seconds.
Turn key to start position again for no more than 5
seconds.
3. Move both motion control levers to the neutral detent
position (standard levers) or neutral lock position (optional
“over the lap” levers).
•
A
•
Repeat the procedure if necessary.
IMPORTANT: Avoid damage! Unnecessary engine
idling may cause engine damage. Excessive idling
can cause engine overheating, carbon buildup and
poor performance.
8. Release key to run position (C) when engine starts.
9. With engine started:
•
•
•
Push choke knob to off position.
Move throttle lever to full-throttle position.
Unlock the park brake.
MX15284
4. Push PTO knob (A) down to disengage PTO.
5. Move throttle lever to set engine speed:
•
Cold engine: Set throttle lever at the 1/2- to 3/4-
throttle position.
•
Warm/Hot engine: Set throttle lever to the 1/2-throttle
position.
6. Carbureted Engines Only: Position choke knob (D):
•
Cold engine: Pull knob up and hold in choke position.
•
Warm/Hot engine: If necessary, pull knob up and
hold in choke position.
Operating - 18
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OPERATING
Engaging Mower
Stopping the Engine
IMPORTANT: Avoid damage! To help prevent engine
backfiring, throttle lever should be set at the 1/4-
throttle position and run for 30 seconds prior to
stopping the engine.
c
CAUTION: Avoid injury! Clear mowing area of
all bystanders when operating this machine.
Thrown objects could cause serious injury or
death.
Do not stop engine when mower is on a slope of
more than 30° for an extended period of time. Oil
may run through valve train into carburetor and
muffler.
Keep hands and feet away from blades and
discharge opening.
Do not mow in reverse unless absolutely
necessary.
1. Move the motion control levers to the neutral detent
position (standard levers) or neutral lock position (optional
“over the lap” levers).
IMPORTANT: Avoid damage! To help prevent
damage to the PTO clutch:
2. Lock the park brake.
•
Do not engage PTO with throttle in the fast
3. Push PTO switch down to disengage.
position.
4. Move throttle lever to 1/4-throttle position and run for 30
seconds, then move throttle to slow position.
1. Adjust mower deck to desired cutting height.
2. Start engine.
A
A
STOP
MIF
MX15284
5. Turn key switch to STOP position (A).
3. Move throttle lever to the 1/2- to 3/4-throttle position.
4. Unlock the park brake.
c
CAUTION: Avoid injury! Children or bystanders
may attempt to move or operate an unattended
machine.
5. Move both motion control levers to the neutral position.
NOTE: In cold weather or with a new machine, it may
be necessary to engage the choke at the same time as
the PTO knob to prevent the engine from stalling.
Always lock the park brake and remove the key
before leaving the machine unattended.
6. Pull PTO knob (A) up to engage mower deck.
7. Move throttle lever to full-throttle position.
6. Remove key.
NOTE: The travel speed and turn rate will vary with the
amount that the control levers are moved.
8. Push motion control levers forward slowly. Mow at a safe
travel speed.
Operating - 19
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OPERATING
clockwise (closed position). Tighten valve to 9-14 N•m (80-
120 lb-in.).
Using Hydraulic Pump Free-Wheel Valves
6. Lock the park brake.
c
CAUTION: Avoid injury! With the free-wheel
valves open, the machine will have
unrestricted motion.
Transporting Machine
• The machine may free-wheel out of control if
the free-wheel valves are opened with the
machine on an incline.
c
CAUTION: Avoid injury! Use caution when
loading or unloading machine into a trailer or
truck.
• Park the machine on a level surface before
opening the free-wheel valves.
IMPORTANT: Avoid damage! Transmission damage
may occur if the machine is moved or towed
incorrectly:
IMPORTANT: Avoid damage! Transmission damage
may occur if the machine is moved or towed
incorrectly:
•
•
•
Move unit by hand only.
•
•
•
Move unit by hand only.
Do not use another vehicle to move unit.
Do not tow unit.
Do not use another vehicle to move unit.
Do not tow unit.
Use a heavy-duty trailer to transport your machine. Trailer
must have signs and lights required by law.
NOTE: The hydraulic pump free-wheel valves must be
fully turned clockwise (closed) during normal vehicle
operation.
1. Raise the mower deck lift lever to the transport position.
2. Drive machine on trailer.
When the machine needs to be moved without starting or
running the engine, use the hydraulic pump free-wheel
valves:
3. Stop engine and lock the park brake.
4. Remove key.
1. Lock the park brake.
5. Fasten machine to trailer with heavy-duty straps, chains
or cables. Both front and rear straps must be directed down
and outward from machine.
NOTE: The pumps are located under the machine,
behind the mower deck.
Mowing Tips
•
•
•
•
•
•
•
Mow grass with throttle lever in the full-throttle position.
Cut grass when it is dry.
Keep mower deck and discharge chute clean.
Mow with sharp blades.
A
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.
MX13120
Picture Note: Left pump shown.
•
•
Travel slow when mowing tall, thick or wet grass.
Avoid damaging grass by slipping or skidding
2. Turn free-wheel valve (A) on both pumps one full turn
counterclockwise (open position).
machine drive wheels. Practice smooth control lever
movements.
3. Unlock the park brake.
•
When performing sharp turns, do not allow inside
4. Push machine to desired location. Due to hydraulic
system drag, machine will move slowly.
machine drive wheel to stop and twist on grass.
5. Turn free-wheel valve (A) on both pumps one full turn
Operating - 20
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OPERATING
Mowing Travel Speeds
Use slow travel speed for:
•
•
•
Trimming.
Working in close quarters.
Mowing tall grass.
Use faster travel speeds for:
Normal mowing on level ground.
•
Dismounting to Inspect Mower
c
CAUTION: Avoid injury! Help prevent serious
injury. Keep hands and feet away from blades
and the discharge opening.
Do not step on either side of the mower deck
when mounting and dismounting the machine.
Mount and dismount the machine using the
front foot plate.
1. Park machine on a hard, level surface.
2. Push PTO knob down to disengage mower.
3. Move motion control levers to the neutral detent position
(standard levers) or neutral lock position (optional “over the
lap” levers).
4. Lock the park brake.
5. Stop engine and remove key. Always wait for mower
blades to stop turning before leaving operator seat.
Avoid Damage to Plastic and Painted
Surfaces
•
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.
•
Operating - 21
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REPLACEMENT PARTS
Replacement Parts
Parts
We recommend Great Dane quality parts available at your
Great Dane dealer.
Part numbers may change. Use part numbers listed below
when you order. If a number changes, your dealer will have
the latest number.
When you order parts, your Great Dane dealer needs your
machine model and serial numbers and engine serial
number. These are the numbers that you recorded in the
Product Identification section of this manual.
Part Numbers
Item
Part Number
AM124356
D18097
Battery
Fuel Tank Cap
Oil Reservoir Cap
Oil Filter (Hydraulic System)
Traction (Hydro) Drive Belt
Mower Deck Drive Belt:
GDA10022
M16053
D28030
•
•
•
1.22 m (48 in.) Deck
1.32 m (52 in.) Deck
1.55 m (61 in.) Deck
TCU16092
TCU16093
GDU10228
Engine to Deck Drive Belt:
1.83 m (72 in.) Deck
Spindle Drive Belt:
1.83 m (72 in.) Deck
Mower Blades:
•
GDU10229
D28028
•
•
•
•
•
1.22 m (48 in.) Deck
1.32 m (52 in.) Deck
1.55 m (61 in.) Deck
1.83 m (72 in.) Deck
GDU10230
GDU10231
GDU10232
GDU10233
(Part numbers are subject to change without notice. Part
numbers may be different outside the U.S.A.)
Replacement Parts - 22
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SERVICE INTERVALS
Service Intervals
Remove debris from the underside of the mower deck.
Servicing Your Machine
IMPORTANT: Avoid damage! Operating in extreme
conditions may require more frequent service
intervals:
Every 50 Hours or Weekly (Whichever Comes
First)
Change engine oil and filter. See the engine manufacturer’s
owner’s manual provided with your machine for the
complete procedure.
•
Engine components may become dirty or
plugged when operating in extreme heat, dust or
other severe conditions.
Grease caster wheel spindle bearings (two places).
Grease mower deck thrust arms (two places).
Remove debris from the underside of the mower deck.
Check drive belt tension.
•
Engine oil and spark plugs may lose efficiency if
vehicle is operated constantly at slow or low engine
speeds or with frequent short trips.
Please use the following timetables to perform routine
maintenance on your machine.
Check tire pressure.
NOTE: The following initial break-in items must be
performed and verified to validate the warranty (dealer
service invoice accepted).
Clean engine air filter.
Check wheel nut torque.
Break-In (After First 8 Hours of Operation)
Every 160 Hours or Monthly (Whichever
Comes First)
Change engine oil and filter.
Check drive belt tension.
Check transmission oil level.
Lubricate mower deck idler pulley pivots (three places).
Lubricate seat platform hinges (two places)
Lubricate pump control arms (five places).
Lubricate control lever pivot shafts (two places).
Lubricate throttle cable.
Check mower deck drive belt tension (48-, 52- and 61-Inch
Mower Deck).
Check engine-to-deck drive belt tension (72-Inch Mower
Deck).
Check spindle drive belt tension (72-Inch Mower Deck).
Check transmission neutral adjustment.
Check wheel nut torque.
Lubricate choke control cable (Carbureted Engines Only).
Check and adjust (as needed) park brake.
Remove debris from the underside of the mower deck.
Annually
Inspect all spindle bearings (6). Replace as needed.
Inspect all mower deck idler pulleys (3). Replace as
needed.
Every 25 Hours or Weekly (Whichever Comes
First)
Remove and inspect caster wheel roller bearings; clean
and pack with grease. Replace as needed.
Grease mower deck thrust arms (two places).
Grease spindle bearings (three places).
Grease traction drive belt tension arm.
Grease mower deck drive belt tension arm.
Remove and inspect caster pivot bearings; clean and pack
with grease. Replace as needed.
Inspect drive belts. Replace as needed. Run-in and adjust
tension.
Grease engine-to-deck drive belt tension arm (72-Inch
Mower Deck).
Clean power unit.
Change hydraulic oil and filter (annually or 500 hours
whichever comes first).
Grease HOC shafts (four places).
Lubricate spindle drive belt tension arm (72-Inch Mower
Deck).
Check all bolts and nuts; tighten as needed.
Remove battery. Clean battery and holder.
Replace spark plugs.
Lubricate front caster wheels (Chariot LX).
Lubricate front caster wheel spindles.
Service Intervals - 23
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SERVICE LUBRICATION
Service Lubrication
Grease
IMPORTANT: Avoid damage! If operating outside
that temperature range, contact your servicing
dealer for a special-use grease.
D
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.
MX15319
Spray Lubricant
•
Grease mower deck thrust arms (D), located at the rear
Use a general-purpose petroleum-based spray lubricant.
of the mower deck.
Lubrication Points
E
B
F
A
MX15287
•
Apply grease to three spindle bearings (E), until grease
is expelled from vent (F) on spindle housings.
MX15286
•
•
Chariot LX only: Grease caster wheel bearings (A).
Grease caster wheel spindle bearings (B).
G
MX15320
•
Grease traction drive belt tension arm pivot (G).
C
MX15289
•
Grease HOC shafts (C) (two points on each side of the
machine).
Service Lubrication - 24
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SERVICE LUBRICATION
NOTE: Use spray lubricant to lubricate the following
items:
K
L
H
M
MX15288
•
48-, 51- and 61-Inch Mower Deck: Grease mower deck
MX15335
drive belt tension arm (H).
Picture Note: 48-, 52- and 61-inch mower decks.
K
I
J
L
M
MX15331
Picture Note: 72-inch mower deck.
MX15331
•
72-Inch Mower Deck:
•
Lubricate mower deck idler pulleys (K-M).
•
•
Grease engine-to-deck drive belt tension arm (I).
Apply spray lubricant to the spindle drive belt tension
arm (J).
O
N
N
P
R
Q
MX15290
•
•
•
•
•
Lubricate hydraulic pump control arms (N).
Lubricate control lever pivot shaft (O).
Lubricate seat platform hinges (P).
Lubricate throttle control cable (Q).
Carbureted Engines Only: Lubricate choke control cable
(R).
Service Lubrication - 25
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SERVICE ENGINE
Service Engine
1. Park machine safely. (See Parking Safely in the Safety
section.)
Engine Warranty Maintenance Statement
Maintenance, repair, or replacement of the emission control
devices and systems on this engine, which are being done
at the customer’s expense, may be performed by any non-
road engine repair establishment or individual. Warranty
repairs must be performed by an authorized Great Dane
servicing dealer.
2. Allow engine to cool.
3. Clean area around dipstick to prevent debris from falling
into crankcase.
4. Remove dipstick (A). Wipe with a clean cloth.
5. Install dipstick and allow the cap to rest on the end of the
tube. Do not tighten the cap.
Avoid Fumes
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.
c
CAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
6. Remove dipstick and check oil level on dipstick. Oil must
be between the ADD and FULL marks.
Move the machine to an outside area before
running the engine.
•
If oil is low, add oil to bring oil level no higher than the
Do not run an engine in an enclosed area
without adequate ventilation.
FULL mark on dipstick.
•
If oil level is above the FULL mark, drain to proper
• Connect a pipe extension to the engine
exhaust pipe to direct the exhaust fumes out of
the area.
level.
7. Install and tighten dipstick.
• Allow fresh outside air into the work area to
clear the exhaust fumes out.
Changing Engine Oil and Filter
Engine Oil
c
CAUTION: Avoid injury! Help prevent serious
personal injury. Allow the engine, exhaust pipe
and muffler to cool before performing this
service function.
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
Use oil that meets the following specification:
IMPORTANT: Avoid damage! Change the oil more
often if the machine is used in extreme conditions:
•
See the engine manufacturer’s owner’s manual provided
with your machine for the correct specifications.
•
•
•
Extremely dusty conditions.
Frequent slow or low-speed operation.
Frequent short trips.
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:
1. Run engine to warm oil.
2. Park machine safely. (See Parking Safely in the Safety
section).
•
Check oil level before operating.
•
Check oil level when the engine is cold and not
running.
•
•
Keep level between the FULL and ADD marks.
Shut off engine before adding oil.
NOTE: Check oil twice a day if you run engine over 4
hours in a day.
Make sure engine is cool when checking engine oil
level.
Service Engine - 26
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SERVICE ENGINE
MODEL
Oil Capacity With Filter (Dry)
Kawasaki
Engines
1.8 L (1.9 qt)
Kohler Engines
2.0 L (2.1 qt)
Checking and Cleaning Air Filter Elements
A
c
CAUTION: Avoid injury! Touching hot surfaces
can burn skin. The engine and components will
be hot if the engine has been running. Allow
the engine to cool before servicing.
MX15321
3. Put container under drain tube.
4. Open drain valve (A) using a 10 mm socket, 1 ft
extension, swivel and 3/8 in. drive ratchet.
5. Allow oil to drain into an oil drain pan.
6. After oil drains, close drain valve.
IMPORTANT: Avoid damage! Dirt and debris can
enter the engine through a damaged filter element:
•
Do not wash paper element.
7. Remove oil filter using an appropriate filter wrench. Turn
filter counterclockwise to remove.
•
Do not attempt to clean paper element by tapping
against another object.
8. Apply a film of clean engine oil on gasket of new filter.
•
Do not use pressurized air to clean element.
9. Install filter. Turn filter clockwise until gasket makes
contact with mounting surface. Tighten 1/2 to 3/4 turn after
gasket contact.
•
Replace element only if it is very dirty, damaged
or the seal is cracked.
10.Clean area around the dipstick.
11.Unscrew and remove dipstick.
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.
IMPORTANT: Avoid damage! To prevent extensive
engine wear or damage, always maintain the proper
engine oil level. Never operate the engine with the
oil level below the ADD mark or over the FULL mark.
12.Add approximately 1.4 L (1.5 qt) of oil.
13.Install and tighten dipstick.
Cleaning Engine Air Intake Screen and Fan
IMPORTANT: Avoid damage! The engine is air-
cooled and requires a large amount of air intake
when running. Reduced air intake can cause
overheating:
14.Start engine and run at slow throttle for approximately
two minutes. Check for leaks around filter and drain valve.
15.Stop engine.
16.Check oil level:
•
•
Keep air intake screen and cooling fins clean.
Keep covers and screens in place.
•
Remove dipstick. Wipe with a clean cloth.
•
Install dipstick and allow the cap to rest on the end of
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.
the tube. Do not tighten the cap.
•
Remove dipstick and check oil level on dipstick. Oil
level should be between the ADD and FULL marks. Add
oil if needed.
17.Install and tighten dipstick.
Cleaning Engine Oil Cooler - Kohler Engines
Keep engine oil cooler fins clear of debris to ensure proper
cooling. See the engine manufacturer’s owner’s manual
provided with your machine for the complete procedure.
Service Engine - 27
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SERVICE ENGINE
Checking Spark Plug
B
c
CAUTION: Avoid injury! Touching hot surfaces
can burn skin. The engine and components will
be hot if the engine has been running. Allow
the engine to cool before servicing.
Check spark plugs at the intervals recommended in the
Service Intervals section. See the engine manufacturer’s
owner’s manual provided with your machine for the
complete procedure.
A
C
MX15300
Picture Note: Kawasaki engine shown.
Adjusting Carburetor - Carbureted Engines
4. Disconnect fuel hose (A) from the outlet side of fuel filter
(B), and drain gasoline into a properly marked container.
NOTE: Carburetor is calibrated by the engine
manufacturer and is not adjustable.
5. Remove fuel filter from inlet fuel hose (C). Discard filter.
If engine is operated at altitudes above 1829 m (6000
ft), some carburetors may require a special high
altitude main jet.
IMPORTANT: Avoid damage! When installing a new
fuel filter, the filter arrow must be pointing in the
direction of fuel flow. Make sure clamps are installed
properly.
If engine is hard to start or runs rough, see Troubleshooting
section of this manual.
Possible engine surging will occur at high throttle with
transmission in neutral and mower disengaged. This is a
normal condition due to the emission control system.
6. Connect a new fuel filter to hoses. Make sure fuel filter is
installed with arrow pointing in direction of fuel flow.
After performing checks in Troubleshooting section and
your engine is still not performing correctly, contact the
local engine manufacturer’s authorized servicing dealer.
Replacing Fuel Filter - Fuel Injected Engines
c
CAUTION: Avoid injury! Fuel vapors are
explosive and flammable:
Replacing Fuel Filter - Carbureted Engines
• Do not smoke while handling fuel.
• Keep fuel away from flames or sparks.
• Shut off engine before servicing.
• Cool engine before servicing.
c
CAUTION: Avoid injury! Fuel vapors are
explosive and flammable:
• Do not smoke while handling fuel.
• Keep fuel away from flames or sparks.
• Shut off engine before servicing.
• Cool engine before servicing.
• Work in a well-ventilated area.
• Clean up spilled fuel immediately.
1. Park machine safely. (See Parking Safely in the Safety
section.)
• Work in a well-ventilated area.
• Clean up spilled fuel immediately.
2. Allow engine to cool.
3. Place a drain pan under hoses to catch any fuel that
may be left in hoses.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Allow engine to cool.
3. Place a drain pan under hoses to catch any fuel that
may be left in hoses.
Service Engine - 28
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SERVICE ENGINE
Troubleshooting the Kohler Electronic Fuel
Injection System
c
CAUTION: Avoid injury! Fuel system under
pressure. Wear personal eye protection when
disconnecting fuel hoses to guard against
spraying fuel.
B
C
A
A
MX15301
4. Disconnect fuel hose (A) from the outlet side of fuel filter
(B), and drain gasoline into a properly marked container.
MX15334
5. Remove fuel filter from inlet fuel hose (C). Discard filter.
Chariot LX models equipped with Kohler engines with the
Electronic Fuel Injection (EFI) system will include an MIL
(Malfunction Indicator Light) (A). This light will indicate
potential problems with the EFI system.
IMPORTANT: Avoid damage! When installing a new
fuel filter, the filter arrow must be pointing in the
direction of fuel flow. Make sure clamps are installed
properly.
The light will come on when the key switch is moved to the
run position, but should go out once the engine has started.
Use only approved replacement parts: fuel filter
(Bosch P/N D28256) and clamps (P/N D18439).
If the light remains on after the engine has started, or if the
engine fails to start, there may be a problem with the EFI
system or its related electrical system.
6. Connect a new fuel filter to hoses using new clamps.
Make sure fuel filter is installed with arrow pointing in
direction of fuel flow.
The MIL can also be used to access diagnostic codes to
aid service. These codes can be accessed only by an
authorized Kohler EFI servicing dealer.
Priming Fuel Injectors - Fuel Injected Engines
When troubleshooting a problem with the Kohler EFI
system, basic engine operating problems must be
eliminated before faulting the EFI system components.
What appears to be an EFI problem could be something as
simple as a fuel tank with debris in the bottom or a plugged
vent. Be sure the engine is in good mechanical operating
condition and other systems are operating properly before
attempting to troubleshoot the EFI system.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Allow engine to cool.
3. Fill fuel tank.
4. Turn key switch to run position and leave it in the run
position for 15 seconds.
The EFI system is a 12 VDC negative ground system,
designed to operate down to a minimum of 7.0 volts. If the
system voltage drops below this level, the operation of
voltage sensitive components such as the ECU, fuel pump
and injectors will be intermittent or disrupted, causing
erratic operation or hard starting. A fully charged, 12-volt
battery with a minimum of 250 cold cranking amps is
important in maintaining steady and reliable system
operation. Battery condition and state of charge should
always be checked first when troubleshooting an
operational problem.
5. Start the engine. If the engine will not start, repeat step
4 two times.
Service Engine - 29
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SERVICE ENGINE
Keep in mind that EFI-related problems are more often
caused by the wiring harness or connections than by the
EFI components. Even small amounts of corrosion or
oxidation on the terminals can interfere with the milliampere
currents used in system operation. Cleaning the
connectors and grounds will solve problems in many cases.
In an emergency situation, simply disconnecting and
reconnecting the connectors may clean up the contacts
enough to restore operation, at least temporarily.
IMPORTANT: Avoid damage! When performing
voltage or continuity tests, avoid putting excessive
pressure on or against the connector pins. Flat
probes are recommended for testing to avoid
spreading or bending the terminals.
If the MIL indicates a problem with the EFI system, first
disconnect the Electronic Control Unit (ECU) connector
and test for continuity between the component connector
terminals and the corresponding terminals in the ECU
connector using an ohmmeter. Little or no resistance
should be measured, indicating that the circuit is good.
If the condition cannot be corrected by checking the
electrical system and connections, the EFI system must be
serviced by an authorized Kohler EFI servicing dealer.
Service Engine - 30
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SERVICE TRANSMISSION
Service Transmission
Hydraulic Oil
A
Use only 5W-50 or 15W-50 all synthetic oil.
Checking Hydraulic Oil Level
IMPORTANT: Avoid damage! Check oil level in
reservoir tank when oil is cold.
Do not overfill oil reservoir tank. Oil will expand
during operation and could overflow.
1. Park machine safely. (See Parking Safely in the Safety
section.)
MX15294
4. Remove cap (A) from oil reservoir tank filler neck.
A
B
MX15294
MX15312
2. Unscrew and remove hydraulic reservoir cap/dipstick (A)
from hydraulic oil reservoir.
5. Turn hydraulic oil filter (B) counterclockwise to remove.
6. Allow hydraulic oil to drain into a drain pan with at least a
3.8 L (1.0 gal) capacity.
3. Wipe dipstick with a clean cloth.
4. Install dipstick and allow the cap to rest on the end of the
tube. Do not tighten the cap.
7. Apply a film of clean oil on gasket of new filter.
8. Install filter. Turn filter clockwise until gasket makes
contact with mounting surface. Tighten 1/2 to 3/4 turn after
gasket contact.
5. Remove dipstick and check oil level. Oil level should be
at top mark on dipstick.
6. If necessary, add oil through oil reservoir filler neck.
7. Install cap on filler neck.
NOTE: Reservoir capacity is approximately 1.9 L (2.0
qt). Total system capacity is approximately 3.5 L (3.75
qt).
Changing Hydraulic Oil and Filter
9. Fill oil reservoir with approximately 1.9 L (2.0 qt) of oil.
10.Install reservoir cap.
IMPORTANT: Avoid damage! Contamination of
hydraulic fluid could cause transmission damage or
failure. Do not open oil reservoir cap unless
absolutely necessary.
Severe or unusual conditions may require a more
frequent service interval.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Allow engine and hydraulic oil reservoir to cool.
3. Clean area around reservoir filler cap, and remove filler
cap from reservoir.
Service Transmission - 31
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SERVICE TRANSMISSION
c
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.
A
MX13120
• Allow fresh outside air into the work area to
clear the exhaust fumes out.
2. Clean hydraulic oil cooler fins (A) on each hydraulic
pump with a rag, brush, or compressed air.
11.Start engine.
12.Move throttle lever to 3/4-throttle position.
13.Unlock the park brake.
Removing and Installing Traction Drive Belt
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Remove mower deck drive belt (48-, 52 and 61-inch
mower decks), or engine-to-deck drive belt (72-inch mower
decks).
c
CAUTION: Avoid injury! Help prevent serious
bodily injury. Remain alert to other people and
the surroundings when operating the machine.
14.Run engine in full forward position for several minutes
and then cycle motion control levers forward and rearward
several times. Check for leaks around filter.
F
F
15.Stop engine. Check oil level. Add oil as necessary.
E
Cleaning Hydraulic Pump Cooling Fins
B
c
CAUTION: Avoid injury! Help prevent injury
from foreign particles when using compressed
air for cleaning purposes, clear area of
bystanders, and wear personal eye protection
to guard against flying debris.
C
A
D
MX9232
Picture Note: Drive belt routing as viewed from top
of machine.
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.
A - 1/2 in. Square Opening
B - Tension Arm
C - Traction Drive Belt
D - Engine Drive Sheave
E - Tension Idler Sheave
F - Hydraulic Pump Sheave
1. Park machine safely. (See Parking Safely in the Safety
section.)
3. Using a 1/2 in. drive breaker bar and extension, insert
end of extension in 1/2 in. drive square opening (A) in
tension arm, and carefully move tension arm (B) counter-
clockwise to release belt tension.
4. Remove drive belt (C).
Service Transmission - 32
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SERVICE TRANSMISSION
5. Install new drive belt.
6. Install mower deck drive belt as shown.
A
Checking and Adjusting Motion Control
Linkages
B
c
CAUTION: Avoid injury! Do not attempt this
adjustment unless you are a qualified and
properly trained technician.
MX15350
Check Neutral Creep
5. Loosen nut (A), and move the dampener (B) in adjusting
slot backward or forward to stop machine creep.
c
CAUTION: Avoid injury! Engine exhaust fumes
can cause sickness or death:
• If it is necessary to run an engine in an
enclosed area, use an exhaust pipe extension
to remove the fumes.
•
If machine creeps forward, slide dampener to the
rear of the adjusting slot. Tighten nut.
•
If machine creeps backward, slide dampener to the
front of the adjusting slot. Tighten nut.
6. Check for creep, and if the machine still creeps,
continue with the next step.
• Always try to work in a well-ventilated area.
NOTE: Check and adjust motion control linkages with
the machine parked on a hard, level surface.
1. Start engine.
2. Set throttle lever to full-throttle position.
3. Unlock the park brake.
D
4. If the rear drive wheels begin to creep, an adjustment is
required.
C
C
D
Neutral Creep Adjustment
E
E
1. Stop engine and lock the park brake.
2. Move both motion control levers to neutral detent
position (standard levers) or neutral lock position (optional
“over the lap” levers).
MX15351
7. Remove pin (C) and disconnect swivel (D) from each
traction control rod (E), and rotate the swivel.
3. Raise the rear wheels off the ground and securely
support the rear of the machine.
8. Rotate swivel (D) to adjust:
•
To stop forward creep, rotate each swivel (D)
NOTE: When tilting the seat forward, do not tilt the seat
so far forward that it moves the motion control levers
out of the neutral detent position.
counterclockwise one rotation.
•
To stop rearward creep, rotate each swivel (D)
clockwise one rotation.
4. Tilt operator seat forward and support the seat frame.
9. Connect swivel to traction control rod.
10.Repeat as needed to stop machine creep.
11.Lower seat.
12.Lower the rear of the machine to the ground.
13.Check maximum speed drift.
Check Maximum Speed Drift
1. Check neutral creep, and adjust as needed.
Service Transmission - 33
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SERVICE TRANSMISSION
2. Sit on the seat, and start the engine.
3. Operate machine to bring the hydraulic oil to normal
operating temperature.
4. Move the machine in a level, wide-open area, such as
an empty parking lot.
5. Run the engine at full throttle.
6. Move and hold both control levers to the full forward
position. Observe the machine travel. If the machine does
not travel in a straight line, adjustment is required. Note the
direction the machine moves.
Maximum Speed Drift Adjustment
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Tilt operator seat forward and support the seat frame.
NOTE: If the machine travels to the left, adjust the right
speed drift screw (A). If the machine travels to the
right, adjust the left speed drift screw (B).
A
B
C
D
MX15351
3. Adjust the appropriate speed drift screw (A or B) as
follows:
a. Loosen jam nut (C or D).
b. Adjust the screw (A or B) one turn clockwise.
c. Tighten the jam nut (C or D).
4. Lower the seat platform.
5. Perform Check Maximum Speed Drift procedure to
check adjustment. Repeat the adjustment procedure as
needed.
Service Transmission - 34
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SERVICE TRANSMISSION
Hydraulic System Schematic
E
G
D
B
C
F
A
H
D
I
D
B
C
A
H
F
D
J
I
K
L
M
MX15333
H - Cooling Orifice
I - Charge Relief Valve
J - Left Wheel Motor
K - Left Hydraulic Pump
L - Oil Filter
A - Control Input Shaft
B - Pump Block
C - Charge Pump
D - Charge System Check Valve
E - Right Hydraulic Pump
M - Hydraulic Reservoir
F - Manual Bypass (Free-Wheel) Valve
G - Right Wheel Motor
Service Transmission - 36
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SERVICE STEERING & BRAKES
Service Steering
&
Brakes
Remove and Install Front Caster Wheels
A
Removing
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Lift front of machine with a safe lifting device.
B
C
E
B
F
D
E
A
C
MX15324
3. Remove locknut (A), capscrew (B), two trash guards (C)
and wheel and tire assembly (D).
4. Remove bearings (E) and spacer tube (F) from wheel.
C
5. Wipe clean and inspect bearings (E). Replace bearings
as needed.
MX15323
3. Remove hex nut (A) and wheel bolt (B).
6. Install spacer tube (F), press bearings (E) into wheel
and tire assembly.
4. Remove wheel (C) from assembly yoke.
7. Install wheel and tire assembly (D), two trash guards
(C), capscrew (B) and locknut (A).
Installing
1. Install replacement wheel (C).
2. Install wheel bolt (B) and hex nut (A).
3. Tighten nut.
Servicing Front Caster Wheel Roller Bearings
- Chariot LX
1. Park machine safely. (See Parking Safely in the Safety
section.)
4. Lower machine.
2. Raise and securely support the front of the mower deck.
Servicing Front Caster Wheel Roller Bearings
- Chariot
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Raise and securely support the front of the mower deck.
Service Steering & Brakes - 37
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SERVICE STEERING & BRAKES
A
A
B
D
E
F
MX15286
2. Remove dust cover (A) from top of spindle.
B
C
C
F
E
D
MX15339
3. Remove locknut (A), capscrew (B) and wheel assembly
(C).
4. Remove spacers (D), seals (E) and bearings and
bearing races (F) from wheel.
5. Clean and inspect bearings (F) and pack with clean
grease. Replace bearings with races as needed.
MX15316
6. Install bearings and races (F) and new seals (E).
3. Remove cotter pin (B).
7. Install wheel assembly (C), two spacers (D), capscrew
(B) and locknut (A). Tighten locknut until rolling resistance
is felt.
4. Turn castle nut (C) 1/4 turn clockwise.
5. Install a new cotter pin. Do not loosen the castle nut to
align cotter pin hole, tighten to align.
Adjusting Front Caster Spindle Bearing
6. Replace dust cover.
7. Test machine to determine if shimmy is still present.
Repeat adjustment as necessary.
NOTE: Adjustment required only if the front caster
wheel shimmies during travel.
1. Park machine safely. (See Parking Safely in the Safety
section.)
Servicing Caster Spindle Bearings
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Raise and securely support the front of the mower deck.
Service Steering & Brakes - 38
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SERVICE STEERING & BRAKES
2. The control lever gap is pre-set at the factory. If the gap
requires adjustment, see your authorized Great Dane
servicing dealer.
A
B
Height Adjustment Procedure
C
The position of the control levers can be varied higher or
lower by approximately 25 mm (1 in.) depending on the
holes chosen for mounting the lever.
J
F
L
G
I
H
E
D
MX15352
•
To mount in the high position, mount the levers to the top
four holes in the mounting bracket.
MX15325
•
To mount in the low position, mount the levers to the
3. Remove cap (A), cotter pin (B), castle nut (C), caster
yoke and wheel assembly (D) and caster bushing (E).
bottom four holes in the mounting bracket.
NOTE: It is not necessary to remove the bearing races
(F and G), unless the bearings need to be replaced.
Checking and Aligning Motion Control Levers
- Optional “Over the Lap” Levers
4. Remove seal (H) and lower bearing (I).
5. Remove upper bearing (J).
Check Alignment:
6. Clean and inspect bearings (I and J); pack with clean
grease. Replace bearings if needed.
1. Park machine safely. (See Parking Safely in the Safety
section.)
7. Install lower bearing (I).
8. Install caster bushing (E) into a new seal (H).
9. Install seal assembly (H).
A
10.Carefully install caster yoke and wheel assembly (D).
NOTE: Do not overtighten castle nut (C). Tighten castle
nut only enough to install the cotter pin (B). The caster
wheel yoke assembly must be free to rotate.
B
11.Install castle nut (C), cotter pin (B) and cap (A).
12.Apply grease to lubrication fitting (L).
Checking and Aligning Motion Control Levers
- Standard “Center Steer” Levers
MX13126
2. Move both motion control levers (A) from the neutral lock
to the neutral steer position.
Check Alignment:
3. Check levers for equal alignment.
1. Park machine safely. (See Parking Safely in the Safety
section.)
•
Check gap (B) between the levers. The
recommended gap is 3-6 mm (1/8-1/4 in.).
Service Steering & Brakes - 39
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SERVICE STEERING & BRAKES
NOTE: If the ends of the levers strike against each
other while in the neutral position, move the levers to
the neutral lock position and carefully bend them
outward. Move them back to the neutral position and
check for the recommended gap of 3-6 mm (1/8-1/4 in.).
A
B
•
If positions of the control levers are unequal, an
adjustment is necessary.
Alignment Procedure
1. Adjust position of motion control levers:
MX13130
2. Loosen set screw (A).
3. Turn knob (B) clockwise several times.
4. Tighten set screw down in the lower slot.
5. Test park brake.
C
MX15353
•
•
Loosen capscrews (C).
Slide both levers forward or rearward to desired
position on control arm until levers are aligned.
•
Tighten capscrews.
Adjusting Park Brake
IMPORTANT: Avoid damage! Due to initial brake
wear, the park brake should be checked and
adjusted after the first 25 hours of use.
A park brake that is adjusted too tightly could
damage the transmission or cause premature brake
wear.
1. Park machine safely. (See Parking Safely in the Safety
section.)
Service Steering & Brakes - 40
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SERVICE MOWER
Service Mower
Removing and Installing Mower Deck Belt
Shields
Removing and Installing Mower Deck Foot
Plate
c
CAUTION: Avoid injury! Help prevent serious
personal injury. Do not operate the mower
without the belt shields installed.
c
CAUTION: Avoid injury! Help prevent serious
personal injury. Do not operate the mower
without the foot plate installed.
Removing Belt Shields
Removing Foot Plate
1. Park machine safely. (See Parking Safely in the Safety
section.)
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Lower mower deck to the lowest cutting height position.
A
NOTE: Two retaining knobs are used on each cover on
the 72-inch mower deck.
B
B
MX15314
A
MX15302
2. Raise foot plate (A) using hole (B).
Picture Note: 48-, 52- and 61-inch mower deck belt
shield.
A
C
B
A
MX15315
MX15303
Picture Note: 72-inch mower deck belt shield.
3. Remove knob(s) (A).
3. Remove and retain hardware (C) securing foot plate (A)
on both sides of machine.
4. Remove foot plate.
4. Remove belt shield (B).
Installing Foot Plate
Installing Belt Shields
1. Install belt shield (B).
2. Install knob(s) (A).
1. Install foot plate (A) using hardware (C) saved earlier.
2. Lower foot plate.
Service Mower - 41
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SERVICE MOWER
4. Measure from outside blade tip to the ground.
Leveling Mower Deck
•
The difference between both measurements should
be no greater than 3 mm (1/8 in.).
c
CAUTION: Avoid injury! Rotating blades are
dangerous. Before adjusting or servicing
mower:
5. If side-to-side level is not within specifications, an
adjustment is necessary.
• Disconnect spark plug wire(s) to prevent
engine from starting accidently.
Adjusting Level (Side-to-Side)
• Always wear gloves when handling mower
blades or working near blades.
B
NOTE: Mower deck anti-scalp wheels should not
contact the ground.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Inflate tires to the correct pressure.
3. Raise the mower deck lift lever to transport position.
4. Inspect mower blades for:
MX15285
•
•
•
Blade sharpness.
Blade damage.
Bent blades.
1. Adjust four chain U-bolts (B) (two on each side of deck)
until deck is within 3 mm (1/8 in.) of level from side to side.
Checking Level (Front-to-Rear)
Checking Level (Side-to-Side)
1. Lower mower deck to the 76 mm (3 in.) cutting height
position.
NOTE: Mower deck anti-scalp wheels should not
contact the ground.
2. Position right mower blade (discharge side) in the
straight forward (front-to-rear) position.
1. Lower deck to the 76 mm (3 in.) cutting height position.
3. Measure from right front blade tip to the ground.
NOTE: Position the left mower blade in the sideways
(left-to-right) position.
4. Turn blade 180° and measure from right rear blade tip to
the ground.
Use a short ruler or a leveling gauge to check the
mower blade level.
2. Measure from outside blade tip to the ground.
C
A
M40137
•
The height (C) of the rear blade tip should be 3-6 mm
(1/8-1/4 in.) higher than the front blade tip.
MX10371
5. If the front-to-rear level is not within specifications, an
adjustment is necessary.
Picture Note: Discharge chute raised for photo
clarity.
3. Position right mower blade (A) (discharge side) in the
side-to-side position.
Service Mower - 42
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SERVICE MOWER
Adjusting Level (Front-to-Rear)
IMPORTANT: Avoid damage! Adjust the left and
right deck lift assist rods equally.
C
NOTE: Adjust side-to-side mower level before
adjusting front-to-rear level.
Chariot LX model is equipped with a deck lift assist rod
on each side of machine. Adjust both sides of the
mower deck equally.
A
B
MX15342
D
F
E
2. Check clearance (A) from the top of the thrust arms (B)
to the bottom of the thrust arm stop rod (C). The clearance
should be 3 mm (1/8 in.).
Adjust Thrust Arm-to-Stop Rod Clearance (Transport
Position)
G
MX15285
1. Loosen jam nut (D) on deck lift assist rod.
2. While positioned in front of the machine, adjust mower
level:
•
Turn hex nut (E) counterclockwise (F) to lower front
of mower deck.
A
C
•
Turn hex nut (E) clockwise (G) to raise front of mower
deck.
3. For Chariot LX model, repeat for other side. Verify that
the adjustment on right and left sides is equal.
B
MX13148
4. Tighten jam nuts.
1. Loosen jam nut (A).
5. Check front-to-rear mower level.
NOTE: If correct adjustment cannot be obtained by
adjusting the lift handle connecting rod, further
movement can be gained by adjusting the chain U-
bolts.
Checking and Adjusting Cutting Height
Adjust all four chain U-bolts equally. All four chains
should be tight. Tighten the U-bolt of the loose chain to
correct.
c
CAUTION: Avoid injury! Rotating blades are
dangerous. Before adjusting or servicing
mower:
2. Adjust deck lift handle connecting rod (B) while viewing
adjusting mechanism from rear of machine.
• Disconnect spark plug wire(s) to prevent
engine from starting accidentally.
•
•
To lower deck, turn nut (C) counterclockwise.
To raise deck, turn nut (C) clockwise.
• Always wear gloves when handling mower
blades or working near blades.
3. Tighten jam nut (A).
Checking Thrust Arm-to-Stop Rod Clearance
(Transport Position)
1. Set mower deck to transport (fully raised) position.
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SERVICE MOWER
Adjusting Deck Lift Assist Spring Tension
Checking and Adjusting Mower Deck Drive
Belt Tension - 48-, 52- and 61-Inch Mower
Deck
NOTE: Deck lift assist spring tension is adjusted at the
factory. If the effort required to raise or lower the
mower deck is not satisfactory, an adjustment may be
necessary.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Adjust the mower deck for the lowest cutting height, and
lower the deck.
Check Spring Tension
1. Park machine on a hard, level surface.
2. Stop engine and lock park brake.
3. Raise foot platform.
3. Raise the mower deck lift lever to the transport position.
C
C
A
B
A
B
B
MX15317
MX15285
4. Loosen jam nut (A).
4. Measure distance (A) between the washers (B) on each
deck lift spring assembly.
5. Check the mower deck drive belt (B) tension. The belt
should deflect a maximum of 13 mm (1/2 in.) when a force
of 4.5 kg (10 lb) is applied to the center of the longest span.
•
The recommended factory setting is approximately 1
mm (1/32 in.) gap between the spring coils at the lowest
HOC setting.
When properly adjusted, there would be approximately a 2
mm (1/16 in.) gap between the spring coils.
Adjust Assist Spring Tension
•
•
To increase belt tension: Turn nut (C) clockwise.
To decrease belt tension: Turn nut (C)
NOTE: The Chariot LX is equipped with two deck lift
assist spring assemblies. Both deck lift assist springs
must be adjusted equally.
counterclockwise.
6. Tighten jam nut (A).
7. Lower foot platform.
Do not overtighten the deck lift assist springs. If the
springs are compressed too tightly, the mower deck
will float too freely.
Checking and Adjusting Engine-to-Deck Drive
Belt Tension - 72-Inch Mower Deck
Decrease deck lift assist spring tension if operating in
rough terrain.
1. Park machine safely. (See Parking Safely in the Safety
section.)
While positioned in front of the machine:
•
Turn hex nut (C) clockwise to increase deck lift spring
2. Adjust the mower deck for the lowest cutting height, and
lower the deck.
tension and reduce the effort to raise and lower the mower
deck.
3. Raise foot platform.
•
Turn hex nut (C) counterclockwise to decrease deck lift
spring tension and increase the effort to raise and lower the
mower deck.
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SERVICE MOWER
•
To increase belt tension: Turn nut (B) clockwise.
•
To decrease belt tension: Turn nut (B)
counterclockwise.
Removing and Installing Mower Deck Drive
Belt - 48-, 52- and 61-Inch Mower Deck
1. Park machine safely. (See Parking Safely in the Safety
section.)
A
2. Raise foot platform.
3. Remove mower deck drive belt covers.
MX15328
4. Check the engine-to-deck drive belt tension. The belt
should deflect a maximum of 13 mm (1/2 in.) when a force
of 4.5 kg (10 lb) is applied to the center of the longest span.
When properly adjusted, there would be approximately a 2
mm (1/16 in.) gap between the spring coils.
A
•
To increase belt tension: Turn nut (A) clockwise.
•
To decrease belt tension: Turn nut (A)
counterclockwise.
B
Checking and Adjusting Spindle Drive Belt
Tension - 72-Inch Mower Deck
1. Park machine safely. (See Parking Safely in the Safety
section.)
MX15317
2. Adjust the mower deck for the lowest cutting height, and
lower the deck.
4. Release mower deck drive belt tension by turning the
tension adjuster nut (A) counterclockwise.
3. Raise foot platform.
5. Remove mower deck drive belt (B).
A
B
MX15327
4. Check the spindle drive belt (A) tension. The belt should
deflect a maximum of 13 mm (1/2 in.) when a force of 4.5
kg (10 lb) is applied to the center of the longest span.
When properly adjusted, there would be approximately an
2 mm (1/16 in.) gap between the spring coils.
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SERVICE MOWER
A
B
C
A
H
MX15328
3. Release engine-to-deck drive belt tension by turning the
tension adjuster nut (A) counterclockwise.
D
G
F
A
E
MX15318
A - PTO Clutch Sheave
B - Mower Deck Drive Belt
C - Tension Idler Sheave
D - Left Spindle Sheave
E - Center Spindle Sheave
F - Idler Sheave
B
C
G - Right Spindle Sheave
H - Idler Sheave
6. Install new mower deck drive belt (B) as shown.
7. Adjust belt tension.
D
E
8. Install mower deck drive belt covers.
9. Lower foot platform.
MX15329
A - PTO Clutch Sheave
B - Mower Deck Drive Belt
C - Tension Idler Sheave
D - Tension Idler Sheave
E - Center Spindle Sheave
Removing and Installing Engine-to-Deck
Drive Belt - 72-Inch Mower Deck
1. Park machine safely. (See Parking Safely in the Safety
section.)
4. Remove engine-to-deck drive belt (B).
5. Install new engine-to-deck drive belt (B) as shown.
6. Adjust drive belt tension.
2. Remove mower deck drive belt covers.
7. Install mower deck drive belt covers.
8. Lower foot platform.
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SERVICE MOWER
Removing and Installing Spindle Drive Belt -
Checking and Replacing Mower Blades
72-Inch Mower Deck
1. Park machine safely. (See Parking Safely in the Safety
section.)
c
CAUTION: Avoid injury! Help prevent serious
personal injury. Do not work near a raised
mower deck unless it is safely supported.
2. Raise foot platform.
Never start the engine or engage the PTO
switch when performing this service
procedure.
3. Remove mower deck drive belt covers.
Blades are sharp and could cause personal
injury. Wear appropriate clothing including
gloves when working near the underside of a
raised mower deck.
C
Before performing any service function, wait
for all moving parts to stop turning.
A
IMPORTANT: Avoid damage! When replacing mower
blades, always use genuine Great Dane Service
Parts.
NOTE: Only replace blades. Never straighten or weld
them.
B
MX15327
4. Remove engine-to-deck drive belt (A).
Checking Mower Blades
5. Release spindle drive belt tension by turning tension
adjustment nut (B) counterclockwise.
1. Park machine safely. (See Parking Safely in the Safety
Section).
6. Remove spindle drive belt (C).
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.
B
A
•
Support with jack stands and/or wooden blocks.
4. Check mower blades:
Mower blades should be sharp and free of any
damage.
•
E
•
Inspect blades; sharpen/balance or replace as
necessary.
C
D
MX15330
A - Tension Idler Sheave
B - Left Spindle Sheave
C - Spindle Drive Belt
D - Center Spindle Sheave
E - Right Spindle Sheave
7. Install new spindle drive belt (C) as shown.
8. Adjust drive belt tension.
9. Install engine-to-deck drive belt and adjust belt tension.
10.Install mower deck drive belt covers.
11.Lower foot platform.
Service Mower - 47
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SERVICE MOWER
Replacing Mower Blades
A
A
B
C
D
MX8333
•
•
Keep original bevel (A) when grinding.
Blade should have 0.40 mm (1/64 in.) cutting edge (B)
or less.
B
•
Balance blades before installing.
MX15357
1. Use two long-handled 15/16 in. wrenches to loosen nut
(A).
Balancing Blades
2. Remove nut (A), blade bolt (B), three 1/4 in. washers (C)
and blade (D).
c
CAUTION: Avoid injury! Mower blades are
sharp. Always wear gloves when handling
mower blades or working near blades.
3. Install replacement blade:
•
Blade wing must face toward top of mower deck.
1. Clean blade.
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 toward the blade.
•
Install blade bolt (B), blade (D), three 1/4 in. washers
(C) and nut (A).
•
Tighten blade nut to 81 N•m (60 lb-ft).
4. Lower machine.
5. Adjust mower deck to a desirable cutting height.
M61524
2. Put blade on nail in a vise. Turn blade to horizontal
position.
Sharpening Blades
3. Check balance. If blade is not balanced, heavy end of
blade will drop.
c
CAUTION: Avoid injury! Mower blades are
dangerous!
4. Grind bevel of heavy end. Do not change blade bevel.
• Always wear gloves while working on
blades.
Replacing Mower Spindle Bearings - 48-, 52-
and 61-Inch Mower Decks
• Always wear safety eye protection when
grinding.
1. Park machine safely. (See Parking Safely in the Safety
section.)
•
Sharpen blades with grinder, hand file or electric blade
sharpener.
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SERVICE MOWER
2. Remove mower blade. (See Checking and Replacing
Mower Blades.)
12.Install mower blade, blade washers and blade bolt
assembly. Tighten nut to 81 N•m (60 lb-ft). (See Checking
and Replacing Mower Blades.)
A
Replacing Mower Spindle Bearings - 72-Inch
Mower Deck
B
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Remove engine-to-deck drive and spindle drive belts.
C
3. Remove mower blade. (See Checking and Replacing
Mower Blades.)
D
A
E
I
F
B
C
H
G
H
D
G
F
E
I
N
MX15354
3. Remove nut (A), pulley (B) and spacer (C).
M
4. Remove retaining ring (D), spindle shaft (E), lower
bearing (F) and spacer (G) from spindle housing (H).
Discard bearing.
5. Remove and discard upper bearing (I).
6. Clean entire assembly.
L
7. Install a new lower bearing (F) and spacer (G) on the
spindle shaft (E).
K
IMPORTANT: Avoid damage! The clearance between
the lower bearing and the housing is only 0.05 mm
(0.002 in.). Do not force bearing into housing.
J
8. Install the spindle shaft (E), lower bearing (F) and
spacer (G) into the spindle housing (H).
MX9222
4. Remove pulleys:
Right and Left Spindles (A): Remove nut (B),
spacer (C) and pulley (D).
Center Spindle (E): Remove nut (F), drive pulley (G)
and spindle pulley (H).
9. Install the upper bearing (I) and retaining ring (D).
10.Install spacer (C).
•
11.Install pulley (B) and nut (A). Tighten nut to 61 N•m (50
lb-ft).
•
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SERVICE MOWER
5. Remove retaining ring (I), spindle shaft (J), lower
bearing (K) and spacer (L) from spindle housing (M).
Discard bearing.
6. Remove and discard upper bearing (N).
7. Clean entire assembly.
8. Install a new lower bearing (K) and spacer (L) on the
spindle shaft (J).
IMPORTANT: Avoid damage! The clearance between
the lower bearing and the housing is only 0.05 mm
(0.002 in.). Do not force bearing into housing.
9. Install the spindle shaft (J), lower bearing (K) and spacer
(L) into the spindle housing (M).
10.Install the upper bearing (N) and retaining ring (I).
11.Install upper pulleys:
•
Right and Left Spindles (A): Install pulley (D),
spacer (C) and nut (B). Tighten nut to 81 N•m (60 lb-ft).
•
Center Spindle (E): Install spindle pulley (H), drive
pulley (G) and nut (F). Tighten nut to 81 N•m (60 lb-ft).
12.Install mower blade, blade washers and blade bolt
assembly. Tighten nut to 81 N•m (60 lb-ft). (See Checking
and Replacing Mower Blades.)
Service Mower - 50
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SERVICE ELECTRICAL
Service Electrical
Installing:
1. Install battery (H) using J-bolts (G), bracket (F), washers
and nuts (E).
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.
2. Connect the positive battery cable (D) first, then the
negative cable (B).
3. Apply petroleum jelly or silicone spray to the terminals to
prevent corrosion.
Removing and Installing the Battery
4. Slide covers (A and C) over battery terminals.
c
CAUTION: Avoid injury! The battery produces a
flammable and explosive gas. The battery may
explode:
Cleaning Battery and Terminals
• Do not smoke near battery.
c
CAUTION: Avoid injury! The battery produces a
flammable and explosive gas. The battery may
explode:
• Wear eye protection and gloves.
• Do not allow direct metal contact across
battery posts.
• Do not smoke near battery.
• Remove negative cable first when
disconnecting.
• Wear eye protection and gloves.
• Do not allow direct metal contact across
battery posts.
• Install negative cable last when connecting.
• Remove negative cable first when
disconnecting.
Removing:
1. Park machine safely. (See Parking Safely in the Safety
section.)
• Install negative cable last when connecting.
1. Disconnect and remove battery.
2. Wash battery with a solution of four tablespoons of
baking soda to one gallon of water. Be careful not to get the
soda solution into the battery cells.
F
E
E
3. Rinse the battery with plain water and dry.
4. Clean terminals and battery cable ends with wire brush
until bright.
G
G
5. Install battery.
H
H
6. Attach cables to battery posts using washers and nuts
(H).
A
B
D
C
7. Apply petroleum jelly or silicone spray to terminals to
prevent corrosion.
H
MX15326
2. Slide black cover (A) away from the negative battery
terminal and disconnect the negative battery cable (B).
3. Slide red cover (C) away from the positive battery
terminal and disconnect the positive battery cable (D).
4. Remove nuts (E) and washers from both sides of the
bracket (F).
5. Remove bracket (F) and J-bolts (G).
6. Remove battery (H).
Service Electrical - 51
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SERVICE ELECTRICAL
3. Connect negative booster cable to booster battery
negative post (E).
Using Booster Battery
4. Connect the other end (F) of negative booster cable to a
unpainted metal part of the disabled machine’s engine,
away from battery.
5. Start the engine of the disabled machine and run
machine for several minutes.
6. Carefully disconnect the booster cables in the exact
reverse order: negative cable first and then the positive
cable.
Replacing Fuse - Carbureted Engines
MIF TS204
IMPORTANT: Avoid damage! When replacing fuses -
use only a 20-amp fuse or you may damage the
circuit.
c
CAUTION: Avoid injury! The battery produces a
flammable and explosive gas. The battery may
explode:
One 20-amp fuse is located behind the seat area.
• Do not attempt to jump start a frozen
battery. Warm to 16 degrees C (60 degrees F).
• Do not smoke near battery.
• Wear eye protection and gloves.
• Keep sparks and flames away.
A
• 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.
• Do not cross jump the battery, damage to
electronic modules will result.
MX15336
F
C
E
1. Remove defective fuse (A) from socket.
2. Check metal clip in fuse window and discard fuse if clip
is broken.
D
3. Install new fuse in socket.
Replacing Fuses - Fuel Injected Engines
B
A
IMPORTANT: Avoid damage! When replacing fuses -
use only fuses of the same rating or you may
damage the circuit.
M71044
A - Booster Battery
B - Disabled Vehicle Battery
1. Connect positive booster cable to booster battery (A)
positive post (C).
2. Connect the other end of positive booster cable to the
disabled vehicle battery (B) positive post (D).
Service Electrical - 52
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SERVICE ELECTRICAL
B
C
A
MX15337
Chariot LX models equipped with Kohler EFI engines have
three additional fuses:
•
One 10-amp fuse (A), used to protect the fuel pump
circuit.
•
One 20-amp fuse (B), used to protect the main power
circuit.
•
One 30-amp fuse (C), used to protect the charge circuit.
1. Remove defective fuse from socket.
2. Check metal clip in fuse window and discard fuse if clip
is broken.
3. Install new fuse into socket.
Burnishing the PTO Clutch
NOTE: The clutch will only require burnishing if a new
clutch has been installed.
1. Start and run the engine at 1/2 throttle.
2. Engage and disengage the PTO clutch five times (ten
seconds on, ten seconds off).
3. Move throttle lever to 3/4 throttle.
4. Engage and disengage the PTO clutch five times (ten
seconds on, ten seconds off).
Service Electrical - 53
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SERVICE MISCELLANEOUS
Service Miscellaneous
Checking Tire Pressure
Filling Fuel Tank
Use regular grade 87 octane unleaded fuel. (For gasoline
engines only.)
c
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.
MIF
• Clean up spilled fuel immediately.
• Use clean, approved non-metal container to
prevent static electric discharge.
c
CAUTION: Avoid injury! Explosive separation of
a tire and rim parts can cause serious injury or
death:
• Use clean, approved plastic funnel without
screen or filter to prevent static electric
discharge.
• DO NOT attempt to mount a tire without the
proper equipment and experience to perform
the job.
IMPORTANT: Avoid damage! Dirt and water in fuel
can cause engine damage:
• 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.
•
•
•
Clean dirt and debris from the fuel tank opening.
Use clean, fresh, stabilized fuel.
Fill the fuel tank at the end of each day’s
operation to keep condensation out of the fuel tank.
•
Use a non-metallic funnel with a plastic mesh
• 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.
strainer when filling the fuel tank or container.
NOTE: Capacity of fuel tank is 30.2 L (8 gal).
1. Stop engine and let it cool several minutes before
adding fuel.
• Check tires for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
2. Remove any grass or debris from top of fuel tank.
1. Check tires for damage.
2. Check tire pressure with an accurate gauge.
3. Add air, if necessary:
A
Tire Size
Pressure
Front: 13 x 5.0-6
110-138 kPa (16-20 psi)
Rear - Chariot: 23 x 9.5-12 69-97 kPa (10-14 psi)
Rear - Chariot LX: 24 x 12- 69-97 kPa (10-14 psi)
12
MX15309
3. Remove fuel tank cap (A).
4. Fill tank with fuel only to bottom of filler neck.
5. Install fuel tank cap.
Service Miscellaneous - 57
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SERVICE MISCELLANEOUS
Remove and Install Rear Drive Wheels
Cleaning and Repairing Metal Surfaces
Removing:
Cleaning:
1. Park machine safely. (See Parking Safely in the Safety
section.)
Follow automotive practices to care for your machine’s
painted metal surfaces. Use a high-quality automotive wax
regularly to maintain the factory look of your machine’s
painted surfaces.
Repairing Minor Scratches (Surface Scratch):
1. Clean area to be repaired thoroughly.
IMPORTANT: Avoid damage! Do not use rubbing
compound on painted surfaces.
2. Use automotive polishing compound to remove surface
scratches.
3. Apply wax to entire surface.
Repairing Deep Scratches (Bare Metal or Primer
Showing):
A
B
1. Clean area to be repaired with rubbing alcohol or
mineral spirits.
MX15322
2. Slightly loosen five wheel nuts (A).
3. Lift machine with a safe lifting device.
4. Remove wheel nuts.
2. Use factory-matched colors available from your Great
Dane dealer to fill scratches. Follow directions included on
container for use and for drying.
3. Smooth out surface using an automotive polishing
compound. Do not use power buffer.
5. Remove wheel and tire assembly (B).
4. Apply wax to surface.
Installing Rear Drive Wheels/Tightening Hardware:
1. Install new wheel and tire assembly.
M77000
2. Install and tighten wheel nuts in numbered sequence
shown for safe wheel installation. Tighten alternately until
recommended torque value is reached.
•
Tighten nuts to 100 N•m (75 lb-ft).
3. Lower machine.
Service Miscellaneous - 58
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TROUBLESHOOTING
Troubleshooting
Using Troubleshooting Chart
If you are experiencing a problem that is not listed in this
chart, see your Great Dane servicing dealer for service.
When you have checked all the possible causes listed and
you are still experiencing the problem, see your Great Dane
servicing dealer.
Engine
If
Check
Engine Will Not Start or Is Hard to Start
Motion control levers not in the neutral detent (or neutral lock)
position.
Park brake lever unlocked.
Key switch not in proper position.
PTO engaged.
Loose or corroded starter cable connections.
Stale or improper fuel/fuel level.
Plugged fuel filter.
EFI Engines Only: Air in fuel line.
Plugged air intake filter.
Spark plug wire is loose or disconnected.
Spark plug not gapped correctly.
Blown 20-amp fuse (main power circuit).
Carbureted Engines Only: Blown fusible link (charging circuit).
Electrical problem - dead battery.
Carbureted Engines Only: Choke adjusted incorrectly. See your
Great Dane servicing dealer.
EFI Engines Only: Blown 10-amp fuse (fuel pump circuit).
EFI system problem - check EFI electrical system and connections.
If problem continues, have system serviced by an authorized Kohler
EFI servicing dealer.
Engine Will Not Slow Idle
Bent or kinked throttle cable.
Carbureted Engines Only: Bent governor control.
Carbureted Engines Only: Incorrect governor idle control.
Carbureted Engines Only: Carburetion problems. See your Great
Dane servicing dealer.
Troubleshooting - 59
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TROUBLESHOOTING
If
Check
Engine Runs Rough or Stalls
Plugged fuel filter.
Plugged air intake system.
Fuel cap vent dirty.
Stale or improper fuel/fuel level.
Spark plug not gapped correctly.
Replace spark plug.
Carbureted Engines Only: Choke adjusted incorrectly. See your
Great Dane servicing dealer.
EFI system problem - check EFI electrical system and connections.
If problem continues, have system serviced by an authorized Kohler
EFI servicing dealer.
Engine Knocks
Engine oil level low.
Reduce load. (Slower ground speed.)
Fuel is bad. Fill tank with fresh fuel, correct octane.
Idle speed too slow.
EFI system problem - check EFI electrical system and connections.
If problem continues, have system serviced by an authorized Kohler
EFI servicing dealer.
Engine Overheats
Clean cooling fins.
Low oil level.
Do not operate at slow idle. Operate at full-throttle setting.
Cooling air intake screen is dirty.
Plugged air intake filter.
Operating at too fast ground speed for conditions.
Engine Lacks Power
Plugged air intake system.
Plugged fuel filter.
Improper type of fuel. Drain tank and fill with correct fuel.
Clean cooling fins to help prevent overheating.
Replace spark plug.
EFI system problem - check EFI electrical system and connections.
If problem continues, have system serviced by an authorized Kohler
EFI servicing dealer.
Engine Uses Too Much Oil
Find and correct oil leaks.
Incorrect engine oil.
Plugged oil filter.
Plugged air intake filter.
Troubleshooting - 60
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TROUBLESHOOTING
If
Check
Engine Backfires Through Muffler
Throttle should be at low idle for several seconds before turning off
machine.
Leaking/damaged exhaust manifold gasket.
EFI system problem - check EFI electrical system and connections.
If problem continues, have system serviced by an authorized Kohler
EFI servicing dealer.
High Fuel Consumption
Improper type of fuel.
Plugged air intake system.
Operating at too fast ground speed for conditions.
Improper valve clearance. See your Great Dane servicing dealer.
Restricted air intake system.
EFI system problem - check EFI electrical system and connections.
If problem continues, have system serviced by an authorized Kohler
EFI servicing dealer.
Electrical System
If
Check
Starter Will Not Work
Dead battery.
Blown 20-amp fuse (main power circuit).
Blown fusible link (charging circuit).
Loose or corroded battery or ground connections.
Loose or corroded starter cable connections.
Neutral start switches faulty or not adjusted properly. See your
Great Dane servicing dealer.
Key switch or starter faulty. See your Great Dane servicing dealer.
PTO engaged.
Motion control levers and park brake lever not in proper position.
Battery Will Not Charge
Loose or corroded battery or ground connections.
Blown fusible link (charging circuit).
Battery cables and terminals are dirty.
Dead cell in battery.
PTO Clutch Does Not Engage
Blown 20-amp fuse (main power circuit).
Faulty PTO switch.
FaultyPTO clutch.
Loose PTO clutch connections.
Troubleshooting - 61
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TROUBLESHOOTING
If
Check
Starter Turns Slowly
Loose or corroded battery or ground connections.
Low battery power - charge battery.
Engine oil viscosity too heavy.
Hydraulic pump linkages failed and are engaged.
Machine
If
Check
Excessive Machine Vibration
Engine speed too slow.
Machine Will Not Move With Engine Running
Park brake locked.
Transmission hydraulic oil level low.
Transmission oil cold - allow engine to warm.
Traction drive belt slipping.
Hydraulic pump free-wheel valves open.
Traction drive belt damaged or worn.
Hydrostatic pump and/or wheel motor problems. See your Great
Dane servicing dealer.
Machine Creeps With Engine Running and Motion Needs shift control linkage adjustment.
Control Levers in a Neutral Position
Park Brake
If
Check
Park Brake Not Working Correctly
Brakes out of adjustment - adjust linkage.
Brake drums wet.
Worn brake shoes.
Brake cables damaged.
Steering
If
Check
Steering Not Working
Park brake locked.
Hydraulic pump free-wheel valves partially open.
Improper tire Inflation.
Hydrostatic transmission oil low.
Traction drive belt slipping.
Traction drive belt damaged or worn.
Machine Will Not Follow a Straight Path
Steering tracking out of adjustment.
Troubleshooting - 62
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TROUBLESHOOTING
If
Check
Machine Moves to the Left or Right With Engine
Running and Transmission in Neutral
Pump linkage (neutral position) out of adjustment.
Mower Deck
If
Check
Discharge Chute Plugged
Grass is wet - mow grass only when dry.
Raise cutting height.
Mow at full throttle.
Ground speed too fast for conditions.
Correct installation of deck drive belt.
Mower Deck Vibrates
Run engine at full throttle.
Loose hardware.
Check/replace mower deck drive belt.
Check/replace spindle drive belt (72-inch mower deck).
Blades bolts are loose.
Blades are bent or worn.
Sharpen and balance blades.
Remove belt shields and check for debris on sheaves.
Check sheaves for proper alignment or damage. See your Great
Dane servicing dealer.
Mower Blades Do Not Engage
Mower deck drive belt slipping or broken.
Spindle drive belt slipping or broken (72-inch mower deck).
Mower deck belt tension spring not installed or broken.
PTO switch failure.
20-amp fuse is blown (main power circuit).
Loose electrical connections.
Faulty PTO clutch.
Mower Mows Unevenly
Mower deck not properly leveled.
Ground speed too fast for conditions.
Run engine at full throttle.
Reduce ground speed when making turns.
Blades are bent or worn.
Sharpen or replace blades.
Change mowing pattern.
Check tire pressure.
Troubleshooting - 63
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STORAGE
Storage
Engine:
Storing Safety
Engine storage procedure should be used when vehicle is
not to be used for longer than 60 days.
1. Change engine oil and filter while engine is warm.
2. Service air filter if necessary.
c
CAUTION: Avoid injury! Fuel vapors are
explosive and flammable. Engine exhaust
fumes contain carbon monoxide and can cause
serious illness or death:
3. Clean debris from engine air intake screen.
• Run the engine only long enough to move
the machine to or from storage.
4. Remove spark plugs. Put 30 mL (1 oz.) of clean engine
oil in cylinders.
• Do not store vehicle with fuel in the tank
inside a building where fumes may reach an
open flame or spark.
5. Crank the engine five or six times to allow oil to be
distributed.
6. Install spark plugs.
• Allow the engine to cool before storing the
machine in any enclosure.
7. Clean the engine and engine compartment.
8. Remove battery.
9. Clean the battery and battery posts.
Preparing Machine for Storage
10.Store the battery in a cool, dry place where it will not
freeze.
1. Repair any worn or damaged parts. Replace parts if
necessary. Tighten loose hardware.
NOTE: The stored battery should be recharged every
90 days.
2. Repair scratched or chipped metal surfaces to prevent
rust.
11.Charge the battery.
3. Clean under the deck and remove grass and debris from
inside chute.
12.Store the machine in a dry, protected place. If machine
is stored outside, put a waterproof cover over it.
4. Wash the machine and apply wax to metal surfaces.
5. Run machine for five minutes to dry belts and pulleys.
Removing Machine From Storage
6. Apply light coat of engine oil to pivot and wear points to
prevent rust.
1. Check tire pressure.
2. Check engine oil level.
3. Charge battery if necessary.
4. Install battery.
Preparing Fuel and Engine for Storage
Fuel:
5. Check spark plug gap. Install and tighten plugs to
specified torque.
If you have been using “Stabilized Fuel”, add stabilized fuel
to tank until the tank is full.
6. Lubricate all grease points.
NOTE: Filling the fuel tank reduces the amount of air in
the fuel tank and helps reduce deterioration of fuel.
7. Run the engine 5 minutes without the mower or any
attachments running to allow oil to be distributed
throughout engine.
If you are not using “Stabilized Fuel”:
1. Park machine safely in a well-ventilated area.
8. Be sure all shields and guards or deflectors are in place.
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. Turn key to off position.
4. Mix fresh fuel and fuel stabilizer in separate container.
Follow stabilizer instructions for mixing.
5. Fill fuel tank with stabilized fuel.
6. Run engine for a few minutes to allow fuel mixture to
circulate through fuel system.
Storage - 64
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ASSEMBLY
Assembly
7. Install cap on filler neck.
Bag of Parts
Qty.
1
Description
Check Engine Oil Level
Key
Remove dipstick from tube by unscrewing it. Wipe it clean.
8. Install dipstick and allow the cap to rest on the end of the
tube. Do not tighten the cap.
1
Operator’s Manual
PDR Check List
1
9. Remove dipstick. Check oil level on dipstick; oil level
should be between the ADD and FULL marks.
•
If oil is low, add oil to bring oil level no higher than the
Prepare for Assembly
FULL mark on dipstick.
•
Remove machine from the shipping crate:
•
If oil level is above the FULL mark, drain to proper
•
Remove box containing operator seat.
level.
•
Cut plastic tie straps fastening the front wheels to the
10.Install and tighten dipstick.
shipping crate.
•
•
Cut plastic tie straps holding the discharge chute up.
Cut plastic tie straps securing the motion control
Check Tire Pressure
levers to the machine.
c
CAUTION: Avoid injury! Explosive separation of
a tire and rim parts can cause serious injury or
death:
Check Hydraulic Oil Level
• DO NOT attempt to mount a tire without the
proper equipment and experience to perform
the job.
IMPORTANT: Avoid damage! Check all fluid levels
before attempting to start the machine. Machine
should be parked on a hard, level surface with the
key switch in the STOP position.
• 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.
1. Park machine safely. (See Parking Safely in the Safety
section.)
A
• 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.
1. Check tires for damage.
2. Check tire pressure with an accurate gauge.
MX15294
3. Check that tires have correct pressure. Add air, if
necessary:
2. Unscrew and remove hydraulic reservoir cap/dipstick (A)
from hydraulic oil reservoir.
Tire Size
Pressure
3. Wipe dipstick with a clean cloth.
Front: 13 x 5.0-6
110-138 kPa (16-20 psi)
4. Install dipstick and allow the cap to rest on the end of the
tube. Do not tighten the cap.
Rear - Chariot: 23 x 9.5-12 69-97 kPa (10-14 psi)
5. Remove dipstick and check oil level. Oil level should be
at top mark on dipstick.
Rear - Chariot LX: 24 x 12- 69-97 kPa (10-14 psi)
12
6. If necessary, add oil through oil reservoir filler neck.
Assembly - 65
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ASSEMBLY
Install Motion Control Levers
B
A
D
A
C
C
MX15344
2. Pivot seat frame (A) forward until it rests on the hinge
stops.
NOTE: The seat mounting hardware is attached to the
seat plate with tie straps.
3. Install seat (B) to the seat frame, using four 5/16-18
locknuts and heavy flat washers (C). Tighten locknuts to 27
N•m (20 lb-ft).
MX15343
1. Remove hardware from control arms.
NOTE: The control lever mounting brackets have six
holes. The levers can be installed in the top four holes,
or for a lower lever position, install the levers in the
lower four holes.
4. Connect wire harness to seat safety switch (D).
Lubricate Machine
2. Align motion control levers (A) with control arms. Install
hardware and tighten.
Lubricate all moving parts before operating the machine.
See Lubrication Points in the Service Lubrication section.
3. Check motion control lever alignment.
•
Move both motion control levers forward.
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.
Install Seat
1. Remove protective covers from seat screws.
Check Safety System
For a complete checkout procedure of the safety interlock
system, see Testing the Safety Interlock System in the
Operating section.
Assembly - 66
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ASSEMBLY
Initial Adjustments
c
CAUTION: Avoid injury! Clear area of
bystanders before performing this service
procedure.
1. Check free-wheel valves on both pump assemblies to
make sure that the valves are closed. Tighten valves to
108-163 N•m (80-120 lb-ft).
2. Raise the rear of the machine until the drive wheels are
off the ground. Support the machine with jackstands.
c
CAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
Move the vehicle to an outside area before
running the engine.
Do not run an engine in an enclosed area
without adequate ventilation.
• 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.
3. Start and run the engine until it reaches normal
operating temperature.
4. Move control levers to the forward position and observe
drive wheel rotation; the drive wheels should rotate in the
correct direction.
5. Move the control levers to the reverse position and
observe drive wheel rotation; the drive wheels should rotate
in the correct direction.
6. Move PTO clutch switch to on position; mower clutch
should engage. Run blades for several minutes.
7. Move PTO clutch switch to off position and shut the
engine off.
8. Check all belts for proper tension.
9. Start the engine and test drive the machine in an open
area. Drive the machine forward; if the machine drifts to the
right or left, adjust the transmission control linkage.
Assembly - 67
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SPECIFICATIONS
Specifications
Net Weight - Chariot LX (With Mower Deck
and Without Fuel)
Engine
NOTE: See engine manufacturer’s owner’s manual
provided with your machine for engine specifications.
25-hp Kawasaki Engine/61-in. Deck . . . . 501 kg (1104 lb)
25-hp Kohler Engine/61-in. Deck . . . . . . . 501 kg (1104 lb)
26-hp Kohler Engine/61-in. Deck . . . . . . . 501 kg (1104 lb)
27-hp Kohler Engine/61-in. Deck . . . . . . . 500 kg (1103 lb)
28-hp Kohler Engine/61-in. Deck . . . . . . . 501 kg (1104 lb)
27-hp Kohler Engine/72-in. Deck . . . . . . . 545 kg (1202 lb)
28-hp Kohler Engine/72-in. Deck . . . . . . . 545 kg (1202 lb)
Battery
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 amp
Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . .90 minutes
BCI Group Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Travel Speeds
Tires - Chariot
Forward . . . . . . . . . . . . . . . . . . . . . . . 0-14 km/h (0-9 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . 0-8 km/h (0-5 mph)
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 x 5.0-6
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 x 9.50-12
Inflation Front (Maximum). . . . . . . 110-138 kPa (16-20 psi)
Inflation Rear (Maximum) . . . . . . . . 69-97 kPa (10-14 psi)
Wheel Nut Torque. . . . . . . . . . . . . . . . . . 100 N•m (75 lb-ft)
Dimensions - Chariot
Wheel Base . . . . . . . . . . . . . . . . . . . . . 1.10 m (43.375 in.)
Track Width . . . . . . . . . . . . . . . . . . . . . . . .1.21 m (47.5 in.)
Overall Height . . . . . . . . . . . . . . . . . . . . 1.09 m (42.75 in.)
Overall Length (with Kawasaki Engines) . .1.92 m (75.5 in.)
Overall Length (with Kohler Engines). . . 1.97 m (77.75 in.)
Overall Width (with 48-in. Deck). . . . . . . . . . 1.50 m (59 in.)
Overall Width (with 52-in. Deck). . . . . . . . . . 1.63 m (64 in.)
Overall Width (with 61-in. Deck). . . . . . 1.86 m (73.375 in.)
Tires - Chariot LX
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 x 5.0-6
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 x 12-12
Inflation Front (Maximum). . . . . . . 110-138 kPa (16-20 psi)
Inflation Rear (Maximum) . . . . . . . . 69-97 kPa (10-14 psi)
Wheel Nut Torque. . . . . . . . . . . . . . . . . . 100 N•m (75 lb-ft)
Dimensions - Chariot LX
Capacities
Wheel Base . . . . . . . . . . . . . . . . . . . . . 1.27 m (49.875 in.)
Track Width . . . . . . . . . . . . . . . . . . . . . . . . . 1.35 m (53 in.)
Overall Height . . . . . . . . . . . . . . . . . . . . . . . 1.22 m (48 in.)
Overall Length (with Kawasaki Engines) 2.00 m (78.75 in.)
Overall Length (with Kohler Engines). . . . . . 2.06 m (81 in.)
Overall Width (with 61-in. Deck). . . . . . 1.86 m (73.375 in.)
Overall Width (with 72-in. Deck). . . . . . . 2.13 m (83.75 in.)
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.2 L (8 gal)
Hydraulic System . . . . . . . . . . . . . . . . . . . . 3.54 L (3.75 qt)
Net Weight - Chariot (With Mower Deck and
Without Fuel)
17-hp Kawasaki Engine/48-in. Deck . . . . 479 kg (1055 lb)
19-hp Kawasaki Engine/48-in. Deck. . . . . 479 kg (1055 lb)
23-hp Kawasaki Engine/52-in. Deck. . . . . 489 kg (1079 lb)
25-hp Kawasaki Engine/52-in. Deck. . . . . 489 kg (1079 lb)
25-hp Kohler Engine/52-in. Deck . . . . . . . 489 kg (1079 lb)
25-hp Kawasaki Engine/61-in. Deck. . . . . 489 kg (1079 lb)
25-hp Kohler Engine/61-in. Deck . . . . . . . 489 kg (1079 lb)
48-Inch Mower Deck
Mower Type . . . . . . . . . . . . . Mulch, Bag or Side Discharge
Cutting Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . .81 N•m (60 lb-ft)
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . 1.22 m (48 in.)
Cutting Height (approximate) . . . . 25 to 127 mm (1 to 5 in.)
Specifications - 68
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SPECIFICATIONS
Height Adjustment Increments . . . . . . . . . . 13 mm (1/2 in.)
52-Inch Mower Deck
Mower Type . . . . . . . . . . . . .Mulch, Bag or Side Discharge
Cutting Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . 81 N•m (60 lb-ft)
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . 1.32 m (52 in.)
Cutting Height (approximate) . . . 25 to 127 mm (1 to 5 in.)
Height Adjustment Increments . . . . . . . . . . 13 mm (1/2 in.)
61-Inch Mower Deck
Mower Type . . . . . . . . . . . . .Mulch, Bag or Side Discharge
Cutting Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . 81 N•m (60 lb-ft)
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . 1.55 m (61 in.)
Cutting Height (approximate) . . . 25 to 127 mm (1 to 5 in.)
Height Adjustment Increments . . . . . . . . . . 13 mm (1/2 in.)
72-Inch Mower Deck
Mower Type . . . . . . . . . . . . .Mulch, Bag or Side Discharge
Cutting Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . 81 N•m (60 lb-ft)
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . 1.83 m (72 in.)
Cutting Height (approximate) . . . 25 to 127 mm (1 to 5 in.)
Height Adjustment Increments . 13 mm (1/2 in.) increments
(Specifications and design subject to change without
notice.)
Specifications - 69
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INDEX
Index
Front Caster Spindle Bearings, Service ..........................38
Fuel Tank, Filling .............................................................57
Fuse, Replace
A
B
Balancing Blades ............................................................ 48
Battery, Cleaning ............................................................ 51
Battery, Specifications .................................................... 68
Blades, Sharpen ............................................................. 48
Brake, Testing Park ........................................................ 11
G
H
C
Hydraulic Oil, Check Level ..............................................31
Cutting Height, Adjusting Mower Deck ........................... 12
K
D
Deck Level, Check Mower .............................................. 66
Dimensions, Chariot LX .................................................. 68
L
M
Motion Control Levers, Using ..........................................15
Mower Blades, Sharpen ..................................................48
Mower Deck Anti-Scalp Wheels, Adjusting .....................13
E
Engine, Starting .............................................................. 18
F
Index - 70
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INDEX
Mower Deck, Troubleshooting ........................................ 63
Mowing Travel Speeds ................................................... 21
T
Throttle Lever, Using .......................................................15
Tire Specifications, Chariot LX ........................................68
Troubleshooting, Electrical ..............................................61
Troubleshooting, Steering ...............................................62
N
Neutral Start Switch, Test ............................................... 11
O
P
Park Brake, Adjust .......................................................... 40
Park Brake, Testing ........................................................ 11
Parts, Replacement ........................................................ 22
Plastic and Painted Surfaces, Avoid Damage ................ 21
V
Valves, Using Hydraulic Pump Free-Wheel ....................20
W
Wheels
Wheels, Adjusting Mower Deck Anti-Scalp .....................13
Wiring Schematic, Fuel Injected Engine (26 HP) ............55
Wiring Schematic, Fuel Injected Engine (28 HP) ............56
R
S
Service, Lubrication ........................................................ 24
Spindle Bearings, Replace - 72-Inch Mower Deck ......... 49
Storage, Preparing Machine ........................................... 64
Index - 71
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