Great Dane Lawn Mower GSRKA1952S User Manual

Great Dane Surfer®

GSRKA1952S

GSRKW2352S

OPERATOR’S MANUAL

200772 REV. 12/18/2006

North American Version

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Introduction

Using Your Operator’s Manual

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

the machine when you sell it.

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

manual to operate and service the machine safely and correctly.

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

machine. This will provide maintenance and troubleshooting information

for the engine installed in your machine.

Specifications and design are subject to change without notice.

Special Messages

WARNING:The Engine Exhaust

from this product contains chemicals known

to the State of California to cause cancer,

birth defects or other reproductive harm.

Your manual contains special messages to bring attention to potential

safety concerns, machine damage as well as helpful operating and

servicing information. Please read all the information carefully to avoid

injury and machine damage.

California Proposition 65 Warning

CAUTION: Avoid injury! This symbol and text highlight

potential hazards or death to the operator or

bystanders that may occur if the hazards or

procedures are ignored.

IMPORTANT: Avoid Damage! This text is used to tell the operator

of actions or conditions that might result in damage to the

machine.

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.

NOTE: General information is given throughout the manual that may

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

Auburn Consolidated Industries, Inc.

Previous Editions

Product Identification

Record Identification Numbers

Surfer

GSRKA1952S Serial Number (636810001-)

GreatDane, Surfer, Brutus, Chariot,

Scamper, and Super Surfer are trademarks

of Auburn Consolidated Industries, Inc.

GSRKW2352S Serial Number (635410001-)

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.

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SAFETY LABELS

DATE OF PURCHASE:

Safety Labels

_________________________________________

DEALER NAME:

_________________________________________

DEALER PHONE:

_________________________________________

PRODUCT IDENTIFICATION NUMBER:

Model Number

_________________________________________

Serial Number

_________________________________________

ENGINE MODEL, SPECIFICATION, AND SERIAL NUMBER:

Model Number

_________________________________________

Specification

MX20097

_________________________________________

Serial Number

WARNING (A)

_________________________________________

Hot Surface.

WARNING (B)

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

Safety Labels

Understanding The Machine Safety Labels

DANGER (C)

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

DANGER (D)

To avoid injury from rotating blades and thrown objects, stay clear of deck

edge and keep others away. Do not mow without discharge chute or entire

grass catcher in place.

DANGER (E)

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

WARNING (F)

Shield missing, DO NOT Operate.

Safety-Alert Symbol

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

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

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

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

most serious hazards.

The operator’s manual also explains any potential safety hazards

whenever necessary in special safety messages that are identified with

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

CAUTION: (G)

Before operating read operators manual and safety instructions.

CAUTION: HELP AVOID INJURY (H)

• Operator training required

Safety Labels - 2

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SAFETY

• Read operator’s manual

• Keep shields in place

• Never carry riders

Agency

Category

Hours

250

EPA

• Keep people a safe distance away

• Maintain all safety devices

• Before leaving machine:

• Stop engine

EPA

500

EPA

1000

125

CARB

Moderate

Intermediate

Extended

250

• Set park brake

• Remove key

500

CAUTION (I)

Certification

Be safe! To avoid a fire hazard remove all leaves, grass and debris from

engine, hydro pumps and motors, pulleys, belts, hoses, engine deck and

cutter deck.

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.

DANGER/POISON (J)

• Shield Eyes: Explosive gases can cause blindness or injury.

Safety

• NO

Operator Training Required

• Sparks

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

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

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

• Flames

• Smoking

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

controls, and safety signs.

• Sulfuric acid can cause blindness or severe burns.

• Flush eyes immediately with water. Get medical help fast.

• Keep out of reach of children.

• Do not tip.

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

machine is responsible for training the users.

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

Local regulations may restrict the age of the operator.

• Do not open battery.

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

occurring to themselves, other people, or property.

WARNING (K)

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

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

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

of an experienced operator.

Emission Control System Certification Label

Preparation

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.

• Evaluate the terrain to determine what accessories and attachments are

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

attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety glasses and hearing

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

parts.

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).

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

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

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.

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

flammable and vapors are explosive.

a. Use only an approved container.

Emission Compliance Period

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

smoke.

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.

c. Never refuel or drain the machine indoors.

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

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

functioning properly.

Operating Safely

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

monoxide fumes can collect.

Safety - 3

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SAFETY

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

hazards.

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.

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

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

belts if provided.

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

recommended direction on hillsides. For this machine, drive across

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

stability. Use caution while operating near drop-offs.

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.

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

directions on slopes.

Checking Mowing Area

• Never raise deck with the blades running.

• Evaluate the terrain to determine what accessories and attachments are

needed to properly and safely perform the job.

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

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

functioning properly.

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

pets out of mowing area.

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

unless using a grasscatcher. Do not operate mower without discharge

chute or entire grasscatcher in place.

• 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.

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

Operating the engine at excessive speed can increase the hazard of

personal injury.

Parking Safely

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

2. Disengage mower blades.

3. Lock the park brake.

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

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

for any reason including emptying the grasscatchers or unclogging the

chute.

4. Stop the engine.

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

abnormal vibration occurs. Make necessary repairs before resuming

operations.

5. Remove the key.

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

operator’s station.

• Keep hands and feet away from the cutting units.

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

• Never carry passengers and keep pets and bystanders away.

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

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

(for gasoline engines) before servicing the machine.

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

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

near or crossing roadways.

Rotating Blades are Dangerous

HELP PREVENT SERIOUS OR FATAL ACCIDENTS:

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

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

drugs.

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

truck.

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

that may obscure vision.

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

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

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

adjustments before you operate.

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

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

damaged blades and bolts in sets to preserve balance.

• Keep safety labels visible when installing accessories and attachments.

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

observe safety instructions could result in serious injury or death.

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

require your full attention.

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

running.

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

deck unless a positive mechanical lock is used.

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

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

Safety - 4

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SAFETY

• Do not mow in reverse.

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

properly.

• Shut off blades when you are not mowing.

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

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

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

including emptying the catchers or unplugging the chute.

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

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

Protect Children

• Use extra care while operating machine with grasscatchers or other

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

slopes.

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

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

edge caves in.

• Follow the manufacturer’s recommendations for wheel weights or

counterweights for added stability when operating on slopes or using front

or rear mounted attachments. Remove weights when not required.

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

removed.

• Transport machine with decks lowered to improve stability.

Keep Riders Off

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

fun with a lawn mowing machine simply because someone has given

them a ride on a machine.

• 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.

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

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

operator is unaware of their presence.

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

operated in an unsafe manner.

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

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

machine.

Avoid High Pressure Fluids

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

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

and lines.

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

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

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

and behind the machine carefully, especially for children.

• Hydraulic fluid connections can loosen due to physical damage and

vibration. Check connections regularly. Tighten loose connections.

• Escaping fluid under pressure can penetrate the skin causing serious

injury. Avoid the hazard by relieving pressure before disconnecting

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

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

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

seriously injured or interfere with safe machine operation.

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

high pressure fluids.

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

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

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

attachment.

• 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.

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

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

operated.

Checking Wheel Hardware

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

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

work area.

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

is not tight.

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

operation.

Avoid Tipping

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

procedure anytime it is loosened.

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

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

slopes requires extra caution.

Wear Appropriate Clothing

• Mow across slopes, not up and down.

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

hard hat when operating the machine.

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

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

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

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

a slope.

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

not operate the equipment when barefoot or wearing open sandals.

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

Safety - 5

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SAFETY

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

cause impairment or loss of hearing.

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

Replace if necessary.

Maintenance and Storage

Tire Safety

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

death:

• Never operate machine in a closed area where dangerous carbon

monoxide fumes can collect.

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

experience to perform the job.

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

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

movement to stop before adjusting, cleaning or repairing.

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

help prevent fires. Clean up oil or fuel spillage.

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

• 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.

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

or drain indoors.

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

service machine. Understand service procedure before doing work.

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

bolts and nuts.

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

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

service work.

Handling Fuel Safely

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

handling fuel. Fuel is extremely flammable and fuel vapors are

explosive:

• Before servicing machine or attachment, carefully release pressure from

any components with stored energy, such as hydraulic components or

springs.

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

• Release hydraulic pressure by lowering attachment or cutting units to the

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

and forth.

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

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

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

sure it is plastic and has no screen or filter.

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

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

last. Reconnect positive first and negative last.

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

Allow engine to cool before refueling.

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

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

or weld them.

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

outdoors and provide adequate ventilation.

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

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

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

creating any source of ignition until fuel vapors have dissipated.

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

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

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

flames. Unplug charger before connecting or disconnecting from battery. •

Wear protective clothing and use insulated tools.

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

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

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

Replace all worn or damaged decals.

• Check grass catcher components and the discharge guard frequently

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

Grass catcher components are subject to wear, damage, and deterioration

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

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

sure the equipment is in safe working condition.

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

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

other blades to rotate.

Prevent Fires

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

before and after operating machine, especially after mowing or mulching

in dry conditions.

• Empty the grass catcher completely before storing.

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

has a fuel shutoff.

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

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

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

water heater or furnace.

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

Safety - 6

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OPERATING

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

vehicle before fueling.

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

up spilled fuel immediately.

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

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

portable container, rather than from a fuel dispenser nozzle.

• Prolonged exposure to sunlight will damage the hood surface.

Operator Station Controls

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

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

open device.

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

• Replace all fuel container caps securely after use.

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

to your health and to the environment.

Handling Waste Product and Chemicals

• Waste products, such as, used oil, fuel, coolant, brake fluid, and

batteries, can harm the environment and people:

• Do not use beverage containers for waste fluids - someone may drink

from them.

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

recycle or get rid of waste products.

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

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

emergency response techniques. The seller of the chemical products

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

product.

Picture Note:

A-Speed Control Bar Lock

B-Speed Control Bar

C-Left Motion Control Lever

D-Right Motion Control Lever

E-Hydrostatic Oil Reservoir Cap and Dipstick

F-Ignition Key Switch

G-Fuel Tank Cap

Operating

Daily Operating Checklist

Make sure all necessary guards and shields are safely and securely

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

H-PTO Switch

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

area.

I-Hour Meter

J-Choke

Remove grass and debris from machine and mower deck.

K-Throttle Lever

Remove grass and debris from operator station foot plate, pump drive

belt compartment, hydraulic pump and pump mounting plate.

L-Park Brake Lever

Test park brake.

Miscellaneous Controls

Test safety systems.

Check battery.

Check for oil leaks.

Check engine oil and hydraulic oil levels.

Check all belts for damage or cracking.

Check engine air filter.

Check mower level.

Adjust cutting height if necessary.

Check wheel bolt torque. Tighten if necessary.

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

Check and adjust speed control linkages and lock.

A-Free-Wheeling Valves

Avoid Damage to Plastic and Painted Surfaces

• Do not wipe plastic parts unless rinsed first.

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

spray insect repellent near machine.

Operating - 7

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OPERATING

Mounting and Dismounting Machine Safely

CAUTION: Avoid injury! Machine must be safely supported

on jack stands before removing or installing wheels. Do not

use a hoist or floor jack to support the machine.

2.Using a suitable lifting device, lift the rear of the machine.

1. Step on operator’s platform (A) at the rear of machine to mount the

machine.

3.Loosen bolts (A).

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

3. Step off operator’s platform to dismount machine.

4.Loosen and remove bolts (B).

5.Move deck (C) up or down to desired height and tighten bolts (A) to 47-

54 N•m (35-40 lb-ft).

4. Keep operator’s platform and suspension springs clean and free of

debris.

6.Insert bolts (B) into holes and tighten to 95-108 N•m (70-80 lb-ft).

Raising and Lowering Thigh Pad

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

7.Remove lynch pin (D) and spacer bushing (E).

IMPORTANT:Do not allow washer (G) to set on caster yoke. It

must be on top of height-of-cut spacer bushings (H).

2. Adjust the pad (A) as required by lifting or lowering the pad to where it is

comfortable.

NOTE: Adjust caster wheel spacers to keep mower deck tilted

slightly down at the front.

8.Adjust caster wheel spacers (F) to compensate front HOC accordingly.

Adjusting Cutting Height

Cutting height can be adjusted from approximately 38-114 MM. (1-1/2 - 4-

1/2 in.). Each hole adjusts the height of cut (HOC) in 12 MM. (1/2 in.)

increments.

Setting Cutting Height

NOTE: Before setting cut height, ensure the tires are all set at the

correct tire pressures.

CAUTION: Avoid injury! Before adjusting cutting height, stop

engine and lock the park brake.

1.Check tire pressure. Inflate front caster wheels to 172-207 CPA (25-30

psi). Inflate rear tires to 69-83 CPA (10-12 psi).

Operating - 8

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OPERATING

Rear of Deck

Front Casters

Rear Deck

Nominal Height C-Spacers C-Spacers Height of Cut

Deck Rake

Hole Position

Top

Bottom

(inches)

4.5

3.5

0.5

3.5

2.5

0.5

2.5

1.5

0.5

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.

Do not run an engine in an enclosed area without adequate

ventilation.

• Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

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

exhaust fumes out.

The safety systems installed on your machine should be checked before

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

and are completely familiar with the operation of the machine before

performing these safety system checks.

HOLE LOCATIONS

To adjust the rear height of cut, use the chart above and match the hole

locations on the chart up to the hole locations on the picture.

Use the following checkout procedures to check for normal operation of

machine.

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

machine. See your authorized dealer for service.

To adjust the front height of cut, use the chart above and insert the number

of C-spacers to correspond to the number on the chart to achieve the

height of cut you desire.

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

Testing PTO Switch

1. Stand on operator’s platform with motion control levers in the neutral

position.

2. Lock park brake.

3. Pull PTO switch up to engage.

4. Turn key switch to the start position.

Result: The engine must not crank.

Testing Park Brake Switch

1. Push PTO switch down to disengage.

2. Unlock park brake.

3. Turn key switch to the start position.

Result: The engine must not crank.

Testing Neutral Switch (Start)

1. Lock park brake.

NOTE: Rake is described as the amount that the rear of the deck is

above the front of the deck. Your best cut will occur when you have

at least some rake on the deck.

2. Push PTO switch down to disengage.

3. Push one motion control lever forward.

Testing Safety Systems

Operating - 9

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OPERATING

4. Turn key switch to the start position.

2. Repeat procedure with machine facing uphill.

Result: The engine must not crank.

Result: Park brake must hold the machine stationary. (Machine should

move no more that 61cm (24 in.) in one hour.) If machine moves more

than that, brakes need to be adjusted. See your authorized dealer or refer

to Adjusting Park Brake in the SERVICE STEERING AND BRAKES

section.

Testing Neutral Switch (Run)

1. Lock park brake.

2. Push PTO switch down to disengage.

3. Start engine.

Using Park Brake

Locking Park Brake

4. Push one motion control lever forward.

5. Repeat procedure using the other lever.

6. Repeat procedure pushing each motion control lever rearward.

Result: The engine must stop when either lever is moved from neutral

position.

Testing Operator Presence Switch

NOTE: Ensure OPC switch bracket is depressed when standing on

operator’s station.

1. Stand on operator’s platform with motion control levers in the NEUTRAL

position.

2. Start engine.

3. Unlock park brake.

Raise park brake lever (A) to lock park brake.

4. Step completely off operator’s platform.

Result: The engine must stop.

Unlocking Park Brake:

Lower park brake lever (A) to unlock park brake.

NOTE: Ensure OPC switch bracket is depressed when standing on

operator’s station.

Using the PTO

5. Stand on operator’s platform with motion control levers in the NEUTRAL

position and start engine.

Engage PTO:

1. Stand on operator’s platform with motion control levers in the neutral

position.

CAUTION: Avoid injury! Thrown objects can be dangerous.

Before operating the attachment:

2. Start engine.

3. Release park brake.

Clear area of bystanders, especially children.

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

Pick up objects which may be thrown by the attachment.

6. Pull PTO switch up to engage.

7. Step completely off operator’s platform.

Result: The engine must stop.

Testing the Park Brake

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

6. Move throttle lever forward to the fast position for mowing.

Disengage PTO:

1. Push PTO knob (A) down.

2. Set park brake.

1. Stop machine on a 17° slope (30% grade) facing downhill. Stop the

engine and lock the park brake.

Operating - 10

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OPERATING

Neutral Position

Using the Throttle

MX12847

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

position.

• Push throttle lever (A) forward to the fast position (B) when mowing.

• Move throttle lever (A) to the half fast position (C) when starting and

warming the engine.

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

is running and park brake is unlocked.

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

not run engine at slow idle any longer than necessary for cooldown after

mowing.

• Operator can exit the mower with the engine running when the park

brake is locked and the PTO switch is disengaged.

Forward and Reverse Motion:

Using the Hourmeter

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

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

CAUTION: Avoid injury! Children or bystanders may be

injured by runover and rotating blades. Before traveling

forward or rearward:

• Carefully check the area around the machine.

• Disengage the mower before backing up.

1. Move throttle lever to the fast position.

2. Unlock park brake.

3. Push motion control levers forward to begin forward motion. The further

forward the control levers are moved, the faster the machine will travel.

• Forward speed range: 0–14.8 km/h (0–9.2 mph)

4. Pull both motion control levers rearward at the same time to begin

reverse motion.

•Reverse speed range: 0–6.4 km/h (0–4 mph)

• Hourmeter (A) shows number of hours the machine has been operated.

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

until the machine comes to a stop.

• Use hourmeter and SERVICE INTERVAL section to determine when

machine needs service.

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

required, see Checking and Adjusting Motion Control Linkages in

the SERVICE TRANSMISSION section.

Using the Motion Control Levers

The functions of the motion control levers are:

Forward:

CAUTION: Avoid injury! Learn use of the motion control

levers and practice at half throttle until becoming proficient

and comfortable with the operation of the machine.

Do not move motion control levers from forward to reverse or

reverse to forward position rapidly. Sudden direction

changes could cause loss of control or damage the machine.

• Steering.

• Acceleration.

• Deceleration.

Operating - 11

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OPERATING

• Push left motion control lever further forward than the right motion control

lever.

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

Sharp Left Turn:

Reverse:

• Push right motion control lever forward and pull left motion control lever

rearward at the same time.

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

Gentle Left Turn:

Sharp Right Turn:

• Push right motion control lever further forward than the left motion control

lever.

• Push left motion control lever forward and pull right motion control lever

rearward at the same time.

Gentle Right Turn:

Operating - 12

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OPERATING

Starting Engine

IMPORTANT: Avoid damage! To help prevent damage to PTO

clutch:

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

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

Move the machine to an outside area before running the

engine.

1. Adjust mower deck to desired cutting height.

2. Start engine.

Do not run an engine in an enclosed area without adequate

ventilation.

• Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

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

exhaust fumes out.

1. Stand on operator’s platform.

2. Lock park brake.

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

4. Unlock park brake.

NOTE: In cold weather or with a new machine, allow engine to reach

operating temperature before engaging PTO to prevent engine from

stalling.

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

6. Move throttle lever to the fast position (C).

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

the motion control levers are moved.

3. Put motion control levers (A) in the NEUTRAL position.

4. Push PTO switch knob (B) down to disengage PTO.

7. Push motion control levers (D) forward slowly. Mow at a safe travel

speed.

5. Move throttle lever (C) to set engine speed at the 1/2 to 3/4 fast

position.

Stopping the Engine

6. Position choke knob (D):

IMPORTANT: Avoid damage! To help prevent engine backfiring,

throttle lever should be set at the half-speed position prior to

stopping the engine.

• Cold engine: Pull knob up to the CHOKE position.

• Warm/Hot engine: If necessary, pull knob up to the CHOKE position.

7. Turn key switch (E) to the START position.

8. Release key to the RUN position when engine starts.

9. With engine started:

Do not stop engine when mower is on a slope of more than 30

degrees for an extended period of time. Oil may run through valve

train into carburetor and muffler.

1. Lock park brake.

• Push choke knob to the OFF position.

• Move throttle lever to the FAST position.

• Unlock park brake.

2. Reduce engine speed to half-throttle.

3. Turn key switch to STOP position (C).

4. Remove key.

Engaging Mower

Using Pump Free-Wheel Valves

CAUTION: Avoid injury! Clear mowing area of all bystanders

when operating this machine. Thrown objects could cause

serious injury or death.

CAUTION: Avoid injury! With the free-wheeling valve open,

the machine will have unrestricted motion.

Keep hands and feet away from blades and discharge

opening.

• The machine may free-wheel out of control if the free-

wheeling valve is opened with the machine on an incline.

Do not mow in reverse unless absolutely necessary.

• Park the machine on a level surface before opening the

free-wheeling valve.

Operating - 13

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OPERATING

• Mow with sharp blades.

IMPORTANT: Avoid Damage! Transmission damage may occur if

the machine is towed or moved incorrectly:

• Properly level mower deck for a smooth cut.

• Mow grass high and often.

• Move machine by hand only.

• Do not use another vehicle to move machine.

• Do not tow machine.

• Use a travel speed that fits the conditions:

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

at desired height.

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

NOTE: The pump free-wheel valves must be turned fully clockwise

(closed) during normal machine operation.

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

Practice smooth control lever movements.

When the machine needs to be moved without starting the engine, use the

pump free-wheel valves:

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

to stop and twist on grass.

1. Lock park brake.

NOTE: The pumps (A) are located in the back of the machine, behind

Mowing Travel Speeds

Use slow travel speeds for:

the rear shield (B).

• Slopes.

• Trimming.

• Close quarters.

• Tall grass.

Use faster travel speeds for:

• Normal mowing on level ground.

Dismounting to Inspect Mower

CAUTION: Avoid injury! Help prevent serious injury. Keep

hands and feet away from blades and the discharge opening.

• Do not step on either side of the mower deck when

mounting and dismounting the machine. Mount and

dismount the machine using the front foot plate.

2. Turn both pump free-wheel valves (C) counterclockwise approximately

one full turn (open position).

3. Unlock park brake.

1. Park machine on a hard, level surface.

2. Disengage PTO.

4. Push machine to desired location. Due to hydraulic system drag,

machine will move slowly.

3. Move motion control levers to the neutral position.

4. Lock park brake.

5. Turn pump free-wheel valves (C) on both pumps one full turn clockwise

(closed position). Tighten valves to 11 N•m (100 lb-in.).

6. Lock park brake.

5. Stop engine and remove key. Wait for mower blades to stop turning

before leaving operator’s position.

Transporting Machine on a Trailer

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

signs and lights required by law.

CAUTION: Avoid injury! Use extra care when loading or

unloading the machine into a trailer or truck.

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

1. Drive machine onto a trailer.

2. Stop engine and lock park brake.

3. Remove key.

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

front and rear straps must be directed downward and outward from

machine.

Mowing Tips

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

• Cut grass when it is dry.

• Keep mower deck and discharge chute clean.

Operating - 14

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SERVICE INTERVALS

Yearly

Service Intervals

• Change fuel filter.

• Clean battery.

Servicing Your Machine

• Change engine oil and filter at least once per season.

• Change hydraulic oil and filter at least once per season.

• Replace spark plugs.

IMPORTANT: Avoid Damage! Operating in extreme conditions

may require more frequent service intervals:

• Engine components may become dirty or plugged when

operating in extreme heat, dust or other severe conditions.

• Engine oil may lose efficiency if vehicle is operated constantly at

slow or low engine speeds or with frequent short trips.

Service Lubrication

Grease

Please use the following timetables to perform routine maintenance on

your machine.

IMPORTANT: Avoid Damage! The recommended grease is

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

degrees C (-20 to 275 degrees F).

Servicing Engine

See engine manufacturer’s owner’s manual provided with your machine

for engine service information.

• If operating outside that temperature range, contact your

servicing dealer for a special-use grease.

Break-In (After First 10 Hours)

• Check air pressure in tires.

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.

• Check wheel bolt torque.

• Check and adjust park brake.

• Change engine oil and filter.

Lubricating Front Caster Spindles and Wheels

• Check mower deck drive belt tension.

• Check hydraulic pump drive belt.

• Check transmission neutral adjustment.

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.

Every 40 Hours

• Check air pressure in tires.

• Check wheel bolt torque.

• Check and adjust park brake.

• Change engine oil and filter.

• Check foam and paper air cleaner elements.

• Clean engine shrouds as needed.

• Lubricate front caster spindles and wheels.

• Lubricate mower deck idler pivot.

• Check mower deck drive belt tension.

• Lubricate hydraulic pump idler pivot.

• Check hydraulic pump drive belt.

• Check hydraulic fluid level.

• Lubricate two spindle grease fittings (A) and two wheel grease fittings

(B).

• If operating machine in extremely dusty or dirty conditions:

• Clean behind engine shrouds and exposed fins.

• Remove screws on blower fan screen and clean behind.

Lubricating Pump Idler Pivot

Every 100 Hours

• Lubricate mower deck spindles.

• Clean and gap spark plugs.

• Check hydraulic pump drive belt.

• Clean behind engine shrouds and exposed fins.

• Remove screws on blower fan screen and clean behind.

Every 500 Hours

• Change hydraulic oil and filter.

Service Intervals - 15

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SERVICE ENGINE

machine for the correct specifications.

• Lubricate one pump idler pivot grease fitting (A).

Checking Engine Oil Level

Lubricating Mower Deck Spindles

IMPORTANT: Avoid Damage! Failure to check the oil level

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

Check oil level before operating.

Keep oil level between the FULL and the ADD marks.

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

has had time to drain into the sump.

NOTE: Check oil twice a day if you run engine over 4 hours in a day.

Make sure engine is cool when checking engine oil level.

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

2. Allow engine to cool.

3. Clean area around dipstick to prevent debris from falling into crankcase.

• Lubricate three mower deck spindle grease fittings (A).

Lubricating Mower Deck Idler Pivot

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

NOTE: Allow dipstick cap to rest on threads of filler tube when

checking oil level. Do not tighten dipstick cap when checking oil

level.

• Lubricate one deck idler pivot grease fitting (A).

5. Install dipstick and allow the cap to rest on the threads of the tube. Do

not tighten the cap.

Service Engine

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.

Avoid Fumes

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.

NOTE: Refer to engine manufacturers operating manual for correct

type and grade of oil.

Do not run an engine in an enclosed area without adequate

ventilation.

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

dipstick.

• Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

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

Use oil viscosity based on the expected air temperature range during the

period between oil changes.

Use oil that meets the following specification:

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

Service Engine - 16

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SERVICE ENGINE

17. Check oil level:

• Remove dipstick cap. Wipe dipstick clean.

CAUTION: Avoid injury! Touching hot surfaces can burn

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

engine has been running. Be cautious and wear protective

clothing when servicing or working near a hot engine and

components.

NOTE: Allow dipstick cap to rest on threads of filler tube when

checking oil level. Do not tighten dipstick cap when checking oil

level.

• Insert dipstick and allow cap to rest on threads of filler. Do not tighten

cap.

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

machine is used in extreme conditions:

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.

Extremely dusty conditions.

Frequent slow or low-speed operation.

Frequent short trips.

• Remove dipstick. Add oil as needed to bring level to the full mark

without overfilling.

1. Clean area around dipstick cap and filter.

18. Insert dipstick. Tighten cap.

2. Start engine and run until it reaches normal operating temperature.

Cleaning Engine Air Intake Screen and Fan

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

CAUTION: Avoid injury! Compressed air can cause debris to

fly a long distance.

Clear work area of bystanders.

Wear eye protection when using compressed air for

cleaning purposes.

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

IMPORTANT: Avoid damage! An obstructed air intake screen can

cause engine damage due to overheating. Keep air intake screen

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

clean at all times to allow adequate air intake.

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.

4. Insert drain tube over oil drain fitting (A)

5. Put oil drain pan under drain tube.

Checking and Cleaning Air Filter Elements

6. Loosen drain plug.

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

8. After oil drains, install and securely tighten drain plug.

9. Turn oil filter (B) counterclockwise to remove.

CAUTION: Avoid injury! Touching hot surfaces can burn

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

engine has been running. Allow the engine to cool before

servicing or working near the engine and components.

10. Apply a film of clean engine oil to gasket of new filter.

IMPORTANT: Avoid Damage! Do not use wrench to tighten oil

filter.

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

through a damaged filter element:

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

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

• Do not wash paper element.

• Do not attempt to clean paper element by tapping against

another object.

12. Raise thigh pad.

13. Remove dipstick cap.

• Do not use pressurized air to clean element.

NOTE: Refer to engine manufacturers operating manual for correct

type and grade of oil.

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

cracked.

13. Add approximately 1.7 L (1.75 qt.) of oil.

14. Insert dipstick. Tighten cap.

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.

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

Check for leaks around filter and drain valve.

16. Stop engine.

Service Engine - 17

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SERVICE TRANSMISSION

Checking Spark Plug

CAUTION: Avoid injury! Touching hot surfaces can burn

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

engine has been running. Allow the engine to cool before

servicing or working near the engine and components.

Check spark plugs at the intervals recommended in the Service Intervals

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

your machine for the complete procedure.

Cleaning Engine Oil Cooler - Kohler Engines

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

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

the complete procedure.

3. Slide hose clamps (A) away from fuel filter (B).

Adjusting Carburetor

4. Place drain pan under hoses to catch any fuel that may be left in the

hoses.

Carburetor is calibrated by the engine manufacturer and is not adjustable.

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

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

authorized dealer.

5. Disconnect hoses from fuel filter (B).

6. Install new fuel filter (B).

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

section of this manual.

• Make sure fuel filter (B) is installed with arrow pointing in direction of

fuel flow.

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

neutral and mower engagement lever disengaged. This is a normal

condition due to the emission control system.

7. Connect hoses to new fuel filter (B).

8. Install hose clamps (A).

After performing the checks in the troubleshooting section and your

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

9. Start engine and check for fuel leaks.

Replacing Fuel Filter

Service Transmission

Hydraulic Oil

CAUTION: Avoid injury! Fuel vapors are explosive and

flammable:

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

Checking Hydraulic Oil Level

• Do not smoke while handling fuel.

• Keep fuel away from flames or sparks.

• Shut off engine before servicing.

• Cool engine before servicing.

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.

• Work in a well-ventilated area.

• Clean up spilled fuel immediately.

1. Park machine safely. (Refer to Parking Safely in SAFETY section.)

IMPORTANT: Avoid Damage! When installing a new fuel filter, the

filter arrow must be pointed in the direction of the fuel flow.

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

2. Allow engine to cool.

2. Clean area around reservoir dipstick cap (A).

Service Transmission - 18

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SERVICE TRANSMISSION

3. Remove dipstick cap (A). Wipe dipstick clean.

IMPORTANT: Avoid Damage! Do not add oil beyond FULL mark.

Oil capacity after draining may be less than dry fill capacity.

Check oil level before filling completely.

NOTE: NOTE: Do not tighten dipstick cap when checking oil level.

4. Insert dipstick into reservoir filler neck (B). Do not tighten cap.

5. Remove dipstick. Check oil level on dipstick. Oil level should be in

crosshatch area between ADD and FULL marks.

NOTE: Dry fill capacity for hydraulic system is 3.1L (3.3 qt.).

10. Fill oil reservoir with approximately 1.9L (2 qt.) of oil.

11. Insert dipstick. Tighten cap.

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

dipstick.

12. Start engine.

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

6. Insert dipstick. Tighten cap.

13. Move throttle lever to 1/2 to 2/3 position.

14. Unlock park brake.

Changing Hydraulic Oil and Filter

CAUTION: Avoid injury! Help prevent serious bodily injury.

Remain alert to other people and the surroundings when

operating the machine.

CAUTION: Avoid injury! Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid the hazard

by relieving pressure before disconnecting hydraulic or other

lines. Tighten all connections before applying pressure.

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

body from high pressure fluids.

15. Cycle motion control levers forward and rearward several times.

Check for leaks around filter.

16. Stop engine. Check oil level. Add oil as necessary to bring oil level to

FULL mark on dipstick.

Use caution when filling and draining hydraulic oil. During

periods of machine operation the hydraulic oil reservoir can

get hot. Allow engine and oil reservoir to cool before

servicing.

Cleaning Hydraulic Oil Pump Cooling Fins

CAUTION: Avoid injury! Compressed air can cause debris to

fly a long distance.

IMPORTANT: Avoid Damage! Contamination of hydraulic fluid

could cause transmission damage or failure. Do not open oil

reservoir cap unless absolutely necessary.

• Clear work area of bystanders.

• Wear eye protection when using compressed air for

cleaning purposes.

Severe or unusual conditions may require a more frequent

service interval.

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

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

2. Allow engine and hydraulic oil reservoir to cool.

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

cooling fins clean at all times. Operating the machine with

obstructed cooling fins could cause damage due to overheating.

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

3. Clean area around reservoir dipstick cap and oil filter.

4. Turn oil filter (A) counterclockwise to remove.

5. Allow hydraulic oil to drain into a drain pan with a capacity of at least

3.8L (1.0 gal).

2. Remove four cap screws (A).

6. Apply a film of clean hydraulic oil to gasket of new filter.

3. Remove rear shield (B) to access hydraulic pumps (C).

7. Install new filter. Turn filter clockwise until gasket makes contact with

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

4. Clean hydraulic oil cooling fins on each hydraulic pump with a rag,

brush or compressed air.

8. Remove dipstick cap from hydraulic reservoir filler neck.

5. Clean area around hydraulic pumps and frame.

Service Transmission - 19

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SERVICE TRANSMISSION

Checking and Replacing Pump Traction Drive Belt

CAUTION: Avoid injury! Fingers or loose clothing can get

caught in rotating parts. Stop engine and wait for all moving

parts to stop before servicing.

NOTE: The traction drive belt will not require a tension adjustment.

Belt is self-adjusted using a spring tensioner.

Checking Traction Drive Belt:

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

3. Remove two cap screws (A).

4. Remove rear shield (B).

CAUTION: Avoid injury! Tensioning spring is under high

tension. Wear gloves and safety glasses, and use a spring

puller to install and remove spring.

2. Remove two cap screws (A).

3. Remove rear shield (B).

MX20167

Picture Note: Traction drive belt idler pulley bottom view.

5. Insert 1/2 in. breaker bar into hole (C) and rotate idler pulley (D) forward

to ease tension on traction drive belt.

6. Remove traction drive belt (E).

Installing Traction Drive Belt:

MX20111

NOTE: Install the traction drive belt (E) in front of spring latch on

4. Inspect belt (C) through frame openings (D) for excessive wear,

damage or stretching.

frame (F).

Removing Traction Drive Belt:

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

2. Remove mower deck drive belt. (See Replacing Mower Deck Drive Belt

in the SERVICE MOWER section.)

Service Transmission - 20

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SERVICE TRANSMISSION

1. Install traction drive belt (E) on drive sheaves (G) as shown. Ensure that

traction drive belt is positioned in front of anchor cap screw (F).

5. Stand on the operator’s platform and, with the park brake released,

move the motion control levers (B).

2. Insert 1/2 in. breaker bar into hole (C) and rotate idler pulley (D) forward

for additional clearance to install traction drive belt.

6. Observe wheel movement as motion control levers are moved back and

forth. Wheels should travel in the correct direction as the levers are

moved.

3. Install rear shield.

7. Move motion control levers to neutral position. If rear wheels continue to

rotate, a return to neutral (RTN) adjustment is required.

4. Install mower deck drive belt.

Checking and Adjusting Motion Control Linkages

Adjusting Motion Control Return to Neutral (RTN) Linkages:

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

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.

Move the machine to an outside area before running the

engine.

1. Stop engine.

Do not run an engine in an enclosed area without adequate

ventilation.

2. Lock park brake.

Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

3. Lift machine with a safe lifting device centered under rear tire support

frame.

Allow fresh outside air into the work area to clear the

exhaust fumes out.

4. Start the machine with motion control levers in neutral.

5. Stand on the operator’s platform and release park brake.

NOTE: Check and adjust motion control linkages with the machine

parked on a hard, level surface.

6. If rear wheels rotate when motion control levers are in neutral, a neutral

adjustment is required.

Checking Motion Control Linkages:

7. Stop engine.

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

MX20161

Picture Note: Side frame removed for picture clarity.

8. Slightly loosen cap screw (A) to allow rotation of neutral return plate.

• If wheel is rotating forward, rotate neutral return plate counterclockwise

until wheel rotation stops.

2. Rotate speed control bar (A) to full forward position.

• If wheel is rotating in reverse, rotate neutral return plate clockwise until

wheel rotation stops.

3. With engine off, move motion control levers (B) until they contact the

speed control bar (A). A slight deflection should be seen in the linkage rod

(C).

9. Tighten cap screw (A).

10. Recheck neutral. If wheels continue to rotate, readjust.

NOTE: Check machine tracking after making adjustments.

11. With the engine running, operate the motion control levers to verify

adjustment.

Start the engine and run until it reaches normal operating temperature.

• If engine will not crank over after adjustments are made, adjust the

neutral switch.

CAUTION: Avoid injury! Be aware of bystanders.

Service Transmission - 21

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SERVICE TRANSMISSION

Checking and Adjusting Transmission Tracking

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.

Do not run an engine in an enclosed area without adequate

ventilation.

• Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

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

exhaust fumes out.

NOTE: Check and adjust transmission tracking on a hard, level

surface.

Checking Transmission Tracking:

Picture Note: Arrow shows direction of speed control bar (A)

movement when decreasing forward speed.

1. Check and adjust motion control linkages. See Checking and Adjusting

Motion Control Linkages in the SERVICE TRANSMISSION section.

2. Loosen lock lever (B) on speed control bar (A).

2. Start engine and run until it reaches normal operating temperature.

• To decrease forward speed, pull speed control bar (A) toward the

operator’s station.

3. Move machine to an open, level area for operation.

• To increase forward speed, push speed control bar (A) forward (away

from operator’s station).

3. Tighten lock lever (B).

Adjusting Reverse Speed:

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

2. Loosen jam nut (C) on cap screw (D) on each side of machine.

• To decrease reverse speed, turn cap screw (D) counterclockwise.

• To increase reverse speed, turn cap screw (D) clockwise.

3. Tighten jam nut (C) on cap screw (D) on each side of machine.

Adjust Neutral Switch

4. Drive machine forward, pushing both control levers (A) all the way to

speed control bar (B).

5. If machine does not drive in a straight line, an adjustment is required.

Adjusting Transmission Tracking:

1. Adjust appropriate control rod swivel (C) located on each side of

machine.

• If machine tracks to the right, remove spring pin (D) and rotate left

control rod swivel one turn clockwise. Install spring pin (D).

• If machine tracks to the left, remove spring pin (D) and rotate right

control rod swivel one turn clockwise. Install spring pin (D).

Picture Note: Side frame removed for picture clarity.

2. Check transmission tracking again and adjust as required until machine

drives in a straight line.

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

2. Loosen nuts (A).

Adjusting Forward and Reverse Speeds

Adjusting Forward Speed:

3. Adjust neutral switch (B).

• If neutral switch sensitivity needs to be increased, adjust switch (B)

down in slots.

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

• If neutral switch sensitivity needs to be decreased, adjust switch (B) up

in slots.

4. Tighten nuts (A).

Service Transmission - 22

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SERVICE STEERING & BRAKES

Service Steering & Brakes

Adjusting Park Brake

Testing Park Brake:

CAUTION: Avoid injury! Help prevent serious personal injury.

Do not operate the mower without the mower deck shield

installed.

1. Inflate tires to correct pressures.

Removing Mower Deck Shield:

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

2. Stop machine on a maximum 17° slope.

3. Lock park brake.

2. Remove two knobs (A).

• A properly adjusted park brake must prevent the drive wheels from

turning.

3. Lift shield (B) and pull forward to disengage from under tabs (C) on the

frame.

• If the drive wheels turn, a brake adjustment will be necessary.

4. Remove mower deck shield (B).

Adjusting Park Brake:

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

CAUTION: Avoid injury! Help prevent serious personal injury.

Do not operate the mower without the belt shields installed.

2. Unlock park brake.

Adjusting Drive Belt Tension

1. Park machine safely.

2. Adjust mower deck to the 76 mm (3 in.) cutting height position.

3. Remove mower deck shield.

4. Remove rue clip (B).

5. Turn brake linkage yoke in one-turn increments on the brake link rod (C)

clockwise to increase braking force; counterclockwise to decrease braking

force.

6. Install rue clip (B).

4. Measure length (C) of tension spring from inside of hook to inside of

hook. The spring should measure 21.6 to 22.6 cm (8-1/2 in. to 8-7/8 in.).

7. Test park brake. Adjust again, if required.

• To add tension to spring: Loosen jam nut (B). Turn nut (A) clockwise.

Tighten jam nut (B).

Service Mower

Removing and Installing Mower Deck Shield

• To release tension from spring: Loosen jam nut (B). Turn nut (A)

counterclockwise. Tighten jam nut (B).

Service Steering & Brakes - 23

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SERVICE MOWER

Replacing Mower Deck Drive Belt

Removing Mower Deck Drive Belt:

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

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

3. Remove mower deck shield.

4. Remove both mower deck belt shields.

CAUTION: Avoid injury! Tensioning spring is under high

tension. Wear gloves and safety glasses, and use a spring

puller to install and remove spring.

1. Install replacement drive belt (A) as shown on mower deck drive belt

label. Make sure drive belt is installed properly on PTO clutch sheave,

spindle sheaves and idler pulleys.

2. Tighten idler pulley retaining bolt to 34 N•m (25 lb-ft) ensuring idler

pulley belt is captured between idler pulley flange and belt guide.

5. Release mower deck drive belt tension by turning adjuster nut (A)

counterclockwise until two threads remain protruding through adjuster nut

(A).

6. Disconnect idler spring (B) from idler arm (C) using a spring puller tool.

3. Connect idler tension spring and adjust tension. The length (B) of the

tension spring should measure 21.6 to 22.6 cm (8-1/2 in. to 8-7/8 in.) from

inside of hook to inside of hook.

4. Install both mower deck belt shields.

5. Install mower deck shield.

6. Adjust mower deck to desired cutting height.

Checking for Bent Mower Blades

7. Loosen idler pulley retaining nut (D) just enough to allow idler pulley (E)

to tilt, allowing belt (F) to clear fixed belt guide (G).

CAUTION: Avoid injury! Mower blades are sharp. Always

wear gloves when handling mower blades or working near

blades.

8. Remove mower deck drive belt (F).

Replace blades if defective. Never straighten or weld them.

Installing Mower Deck Drive Belt:

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

2. Raise mower to highest position to access blades.

NOTE: If necessary, see drive belt installation label on mower deck.

Service Mower - 24

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SERVICE MOWER

Picture Note: Mower deck with side discharge used for illustration.

3. Measure distance (A) between blade tip and flat ground surface.

4. Rotate blade 180° and measure distance between other blade tip and

flat ground surface.

5. Install new blade if the difference between the two measurements is

more than 3 mm (1/8 in.).

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

2. Install replacement blade:

6. Repeat for all blades.

• Blade wing must face toward top of mower deck.

Checking and Replacing Mower Blades

IMPORTANT: Avoid Damage! When installing the blade:

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

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

unless it is safely supported.

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

the blade.

Mower blades are sharp. Wrap blades or wear gloves when

servicing.

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

• Tighten blade bolt to 163 N•m (120 lb-ft).

3. Lower machine.

Before performing any service function, wait for all moving

parts to stop turning.

Disconnect battery or remove spark plug wire before making

repairs.

4. Adjust mower deck to a desirable cutting height.

Sharpening Blades

IMPORTANT: Avoid Damage! When replacing mower blades,

always use genuine Great Dane Service Parts.

CAUTION: Avoid injury! Mower blades are dangerous!

Always wear gloves while working on blades.

Always wear safety eye protection when grinding.

NOTE: Only replace blades. Never straighten or weld them.

Checking Mower Blades

1. Park machine safely. (See Parking Safely in the Safety Section).

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

2. Raise the mower deck to the transport position (also the 12.7 cm [5 in.]

cutting height position).

3. Raise front of machine with a safe lifting device.

• Support with jack stands and/or wooden blocks.

4. Check mower blades:

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

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

Replacing Mower Blades

MIF

• Keep original bevel (A) when grinding.

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

Service Mower - 25

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SERVICE ELECTRICAL

• Balance blades before installing.

Balancing Blades

CAUTION: Avoid injury! Battery electrolyte contains sulfuric

acid. It is poisonous and can cause serious burns:

• Wear eye protection and gloves.

• Keep skin protected.

CAUTION: Avoid injury! Mower blades are sharp. Always

wear gloves when handling mower blades or working near

blades.

• If electrolyte is swallowed, get medical attention

immediately.

1. Clean blade.

• If electrolyte is splashed into eyes, flush immediately

with water for 15-30 minutes and get medical attention.

• If electrolyte is splashed onto skin, flush immediately

with water and get medical attention if necessary.

The battery produces a flammable and explosive gas. The

battery may explode:

• Do not smoke near battery.

• Wear eye protection and gloves.

• Do not allow direct metal contact across battery posts.

• Remove negative cable first when disconnecting.

• Install negative cable last when connecting.

Checking the Battery (Sealed Batteries)

2. Put blade on nail in a vise. Turn blade to horizontal position.

3. Check balance. If blade is not balanced, heavy end of blade will drop.

4. Grind bevel of heavy end. Do not change blade bevel.

NOTE: Do not attempt to open, add fluid or service battery. Any

attempt to do so will void warranty.

• Keep battery and terminals clean.

• Keep battery bolts tight.

Service Electrical

• Keep small vent holes open.

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.

IMPORTANT: Avoid Damage! The battery comes fully charged. If

the machine is not used by the service expiration date indicated

on the battery, charge the battery.

Service the Battery Safely

Recharge, if necessary, at 6–10 amperes for 1 hour.

Removing and Installing Battery

Removing:

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

2. Slide back black cover (A) and disconnect negative (-) battery cable (B).

Service Electrical - 26

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SERVICE ELECTRICAL

3. Slide back red cover (C) and disconnect positive (+) battery cable (D).

A - Booster Battery

4. Loosen nut on front long carriage bolt (E).

B - Disabled Vehicle Battery

5. Remove rear long carriage bolt (F) and nut.

6. Lift and slide battery (G) out from back of battery tray (H).

7. Inspect isolator pad (I). Replace as needed.

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).

Installing:

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

(E).

1. Place isolator pad (I) in battery tray (H). Ensure that isolator pad is on

the bottom and sides of battery tray.

2. Install battery (G) in battery tray (H) with positive terminal in rear.

3. Install rear long carriage bolt (F) and nut. Do not overtighten.

IMPORTANT: Avoid Damage! Electric charge from booster battery

can damage machine components. Do not install negative

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

4. Tighten nut on long carriage bolt (E) to secure battery (G) in battery tray

(H). Do not overtighten.

Install negative booster cable away from moving parts in the

engine compartment, such as belts and fan blades.

5. Apply dielectric grease to terminals to prevent corrosion.

6. Connect the positive (+) battery cable (D) and install cover (C).

7. Connect negative (-) battery cable (B) and install cover (A).

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

of the disabled machine engine block away from battery.

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

minutes.

Cleaning Battery and Terminals

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

negative cable first and then the positive cable.

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

2. Disconnect and remove battery.

Replacing Fuse

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

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

The electric start circuit is protected by one 20 Amp fuse.

4. Rinse the battery with plain water and dry.

IMPORTANT: Avoid Damage! Help prevent machine circuit

damage. Make sure replacement fuse is the correct size.

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

6. Apply general purpose grease or silicone spray to terminal to prevent

corrosion.

1. Locate electric start fuse holder under console on right side of machine.

7. Install battery.

Using Booster Battery

CAUTION: Avoid injury! The battery produces a flammable

and explosive gas. The battery may explode:

Do not smoke or have open flame near battery.

Wear eye protection and gloves.

Do not jump start or charge a frozen battery. Warm

battery to 16°C (60°F).

Do not connect the negative (-) booster cable to the

negative (-) terminal of the discharged battery. Connect at

a good ground location away from the discharged battery.

• Open fuse holder (A) and remove socket with fuse.

Service Electrical - 27

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SERVICE MISCELLANEOUS

• Check metal clip in fuse window. Discard fuse if clip is broken.

exposed to sun and heat.

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

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

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

plastic containers to reduce condensation.

• Install new 20 Amp fuse in socket.

• Install socket with fuse in cover. Ensure that plastic tab of fuse holder is

securely fastened to fuse socket.

Adjusting Operator Presence Switch

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

immediately after fuel purchase. Such practice helps prevent engine

performance problems and allows fuel storage in the machine all year

without draining.

1. Remove the OPC plate covering the operator presence switch by

removing the two 3/8-16 x 1.25 carriage bolts securing it in place.

2. Carefully cut the wire tie securing the harness to the plate.

Filling Fuel Tank

3. Loosen the two # 10 pan head screws (A) securing the safety switch (B)

in place and slide the switch in or out as necessary.

CAUTION: Avoid injury! Fuel vapors are explosive and

flammable:

4. Install the safety plate removed in step one and tie the harness to the

plate again.

• Shut engine off before filling fuel tank.

• Do not smoke while handling fuel.

NOTE: The switch is properly adjusted when there is 3/8” - 1/2” clearance

between the rubber bumper and the support plate when there is not any

pressure applied to the plate. The foot plate can be adjusted by tightening

or loosening the jam nut (C) and either tightening (lower) or loosening the

compression (raise) on the bolt holding the compression spring in place.

Re-tighten the jam nut after desired platform height is attained.

• Keep fuel away from flames or sparks.

• Fill fuel tank outdoors or in well ventilated area.

• Clean up spilled fuel immediately.

• Use clean approved non-metal container to prevent

static electric discharge.

• Use clean approved plastic funnel without screen or

filter to prevent static electric discharge.

Important: Avoid damage! Dirt and water in fuel can cause engine

damage:

• Clean dirt and debris from the fuel tank opening.

• Use clean, fresh, stabilized fuel.

• Fill the fuel tank at the end of each day’s operation to keep

condensation out of the fuel tank.

Use a non-metallic funnel with a plastic mesh strainer when filling

the fuel tank or container.

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

and freezing during cold weather.

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

2. Allow engine to cool.

Service Miscellaneous

Using Proper Fuel

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

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

escape.

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

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

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

methanol as engine damage can occur.

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

6. Install fuel tank cap.

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

used within approximately 30 days, or add fuel stabilizer.

Removing and Installing Rear Drive Wheels

Removing:

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

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

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

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

season.

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

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

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

carburetor components which can affect engine performance.

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

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

Service Miscellaneous - 28

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SERVICE MISCELLANEOUS

2. Lift machine with a safe lifting device centered under tire support frame

3. Remove nut (A) and wheel cap screw (B).

(A) on the side where tire is being removed.

4. Remove wheel and spacers from yoke assembly (C).

Installing:

1. Install replacement wheel and original spacers.

2. Install wheel cap screw (B) and nut (A).

3. Tighten nut until wheel develops slight rolling resistance.

4. Lower machine.

Tightening Rear Drive Wheel Hardware

1. Tighten rear wheel nuts to 102 N•m (75 lb-ft).

3. Remove wheel nuts (B).

4. Remove wheel.

Installing:

1. Install wheel with valve stem (C) facing out.

2. Install and tighten wheel nuts alternately until recommended torque

value is reached.

• Tighten nuts to 102 N•m (75 lb-ft).

3. Lower machine.

MX10287

2. Tighten wheel nuts in numbered sequence shown for safe wheel

installation. Tighten alternately until recommended torque value is

reached.

Removing and Installing Front Caster Wheels

Removing:

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

2. Lift front of machine with a safe lifting device.

Checking Tire Pressure

Service Miscellaneous - 29

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TROUBLESHOOTING

6. Repack bearings with clean grease.

7. Install bearings (E) and wheel spacer (F) (if removed), and new seals

(D).

CAUTION: Avoid injury! Explosive separation of tire and rim

parts is possible when they are serviced incorrectly:

8. Install wheel assembly (C), cap screw (B) and locknut (A).

Do not attempt to mount a tire without the proper

equipment and experience to perform the job.

9. Use a grease gun to fill hub until grease just appears at one of the seals

(D).

Do not inflate the tires above the recommended pressure.

10. Lower machine.

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

cause an increase in air pressure resulting in an

explosion. Welding can structurally weaken or deform the

wheel.

Cleaning and Repairing Plastic Surfaces

Your authorized dealer has the professional materials needed to properly

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

paint over marks or scratches in plastic parts.

Do not stand in front or over the tire assembly when

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

enough to allow you to stand to one side.

IMPORTANT: Avoid Damage! Improper care of machine plastic

surfaces can damage that surface:

1.1. Check tires for damage.

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

result in minor surface scratches.

2. Check tire pressure with an accurate gauge.

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

3. Add air, if necessary:

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

plastic surfaces.

Tire Size

Pressure

Do not spray insect repellent near machine.

Front: 11 x 4 - 5

Rear: 18 x 8.5 - 8

138–173 kPa (20-25 psi)

69–97 kPa (10–14 psi)

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

soap.

Servicing Caster Wheel Roller Bearings

2. Dry thoroughly to avoid water spots.

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

Cleaning and Repairing Metal Surfaces

Cleaning:

2. Raise and securely support front of machine.

Follow automotive practices to care for your vehicle painted metal

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

factory look of your vehicle’s painted surfaces.

Repairing Minor Scratches (surface scratch):

1. Clean area to be repaired thoroughly.

IMPORTANT: Avoid damage! Do not use rubbing compound on

painted surfaces.

2. Use automotive polishing compound to remove surface scratches.

3. Apply wax to entire surface.

Repairing Deep Scratches (bare metal or primer showing):

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

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

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

for use and for drying.

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

use power buffer.

4. Apply wax to surface.

Troubleshooting

Using Troubleshooting Chart

3. Remove locknut (A), cap screw (B), and wheel assembly (C).

4. Remove seals (D) and bearings (E) from wheel.

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

authorized dealer for service.

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

experiencing the problem, see your authorized dealer.

5. Clean and inspect bearings (E). Replace as needed.

Troubleshooting - 30

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TROUBLESHOOTING

Engine

Check

Engine Knocks

• Engine oil level low.

Check

• Reduce load. (Slower ground speed.)

Poor Engine Performance

Fuel:

• Fuel is bad. Fill tank with fresh fuel,

correct octane.

• Dirt in fuel system or fuel is old.

Replace fuel with fresh stabilized fuel.

Obtain fuel from another supplier

before suspecting machine problems.

Suppliers blend fuels differently and

changing suppliers will generally solve

any performance problems.

• Idle speed too slow.

Engine Overheats

• Clean cooling fins.

• Low oil level.

• Do not operate at slow idle. Operate

at fast idle.

• Fuel blended with alcohol or ether

may contribute to performance

problems by causing gum and varnish

deposits, especially if fuel is stored for

several weeks or more. Obtain fresh

fuel.

• Cooling air intake screen is dirty.

• Plugged carburetor air intake filter.

• Plugged air intake filter.

• Operating at too fast ground speed for

conditions.

Engine Will Not Start Or Is

Hard To Start

• Park brake lever not in the proper

position.

Engine Lacks Power

• Reduce load.

• OPC switch not depressed. Stand on

platform or adjust switch.

• Plugged air intake system.

• Plugged fuel filter.

• Check that motion control levers are in

neutral and neutral switches are

correctly adjusted.

• Improper type of fuel. Drain tank and

fill with correct fuel.

• PTO engaged.

• Clean cooling fins to help prevent

overheating.

• Stale or improper fuel/fuel level.

• Plugged fuel filter.

• Replace spark plugs.

• Plugged air intake filter.

Engine Uses Too Much Oil

• Find and correct oil leaks.

• Incorrect engine oil.

• Spark plug wires loose or

disconnected.

• Plugged oil filter.

• Spark plugs not gapped correctly.

• Blown fuse.

• Plugged air intake filter.

• Worn engine components.

• Electrical problem – dead battery.

Engine Backfires Through

Muffler

• Throttle lever should be at low idle for

thirty seconds before turning off

machine.

• Choke adjusted incorrectly. See your

authorized dealer.

Engine Will Not Slow Idle

• Carburetion problems. See your

authorized dealer.

High Fuel Consumption

• Improper type of fuel.

• Plugged air intake system.

• Bent or kinked throttle cable.

• Bent governor control.

• Operating at too fast ground speed for

conditions.

• Incorrect governor idle control.

• Improper valve clearance. See your

authorized dealer.

Engine Runs Rough or Stalls • Plugged fuel filter.

• Plugged air intake system.

• Restricted air intake system.

Fuel cap vent dirty.

Other Symptoms

• See engine manufacturer’s owner’s

manual provided with your machine for

additional information.

• Stale or improper fuel/fuel level.

• Spark plugs not gapped correctly.

• Replace spark plugs.

Electrical System

• Choke adjusted incorrectly. See your

authorized dealer.

Troubleshooting - 31

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TROUBLESHOOTING

Park Brake

Check

Starter Will Not Work

• Blown fuse.

Park Brake Not Working

Correctly

• Park brake out of adjustment – adjust

linkage.

• OPC Switch faulty or not adjusted

properly.

• Park brake switch is faulty.

Steering

• Loose or corroded battery

connections.

Check

• Neutral switches faulty or not adjusted

properly. See your authorized dealer.

Steering Not Working

• Pump free-wheel valves partially

open.

• Key switch or starter faulty. See your •

authorized dealer.

• Improper tire inflation.

• Hydrostatic transmission oil level low.

• Traction drive loose or broken.

• Hydraulic pump or wheel motor faulty.

• PTO engaged.

• Motion control levers and park brake

lever not in proper position.

Battery Will Not Charge

• Loose or corroded connections.

• Blown fuse or fusible link. See your

authorized dealer.

PTO Switch Does Not Work

Starter Turns Slowly

• Blown fuse.

• PTO switch faulty.

• Loose or corroded battery

connections.

• Low battery power-charge battery.

• Engine oil viscosity too heavy.

• Hydraulic pump linkage out of

adjustment-pumps engaged.

Machine

Check

Excessive Machine Vibration • Engine speed too slow.

• Deck drive belt not tensioned

correctly.

• Mower blades not balanced.

Machine Will Not Move With

Engine Running

• Park brake locked.

• Transmission oil level low.

• Transmission oil cold – allow engine to

warm up.

• Pump drive belt slipping or broken.

• Pump drive belt spring broken.

• Pump free-wheel valves open.

• Transmission problems. See your

authorized dealer.

Machine Creeps With Engine • Needs motion control linkage

Running and Motion Control

Levers in a Neutral Position

adjustment.

• Needs Adjustment.

Troubleshooting - 32

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STORAGE

Mower Deck

Storage

Check

Storing Safety

Discharge Chute Plugged

• Grass is wet-mow grass only when

dry.

CAUTION: Avoid injury! Fuel vapors are explosive and

flammable. Engine exhaust fumes contain carbon monoxide

and can cause serious illness or death:

• Raise cutting height.

• Mow with engine at full fast throttle.

• Ground speed too fast for conditions.

• Correct installation of deck drive belt.

Run the engine only long enough to move the machine to

or from storage.

Do not store vehicle with fuel in the tank inside a building

where fumes may reach an open flame or spark.

Mower Deck Vibrates

• Run engine at fast throttle.

• Loose hardware.

Allow the engine to cool before storing the machine in

any enclosure.

• Check/replace deck drive belt.

• Blade bolts are loose.

Preparing Machine for Storage

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

loose hardware.

• Blades are bent or worn.

• Sharpen and balance blades.

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

3. Remove grass and debris from machine.

• Remove belt shields and clean

debris from sheaves.

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

and bagger.

• Check sheaves for proper alignment

or damage. See authorized dealer.

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

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

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

8. Lubricate grease points and check tire pressure.

Mower Blades Do Not

Engage

• Deck drive belt slipping or broken.

• Deck belt tension spring not installed

or broken.

• PTO switch faulty.

• Fuse blown.

Preparing Fuel and Engine For Storage

Fuel:

• Loose electrical connections.

• PTO clutch faulty.

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

the tank is full.

Mower Mows Unevenly

• Mower deck not properly leveled.

• Ground speed too fast for conditions.

• Run engine at fast throttle.

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

and helps reduce deterioration of fuel.

If you are not using “Stabilized Fuel:”

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

the SAFETY section.)

• Reduce ground speed when making

turns.

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.

• Sharpen or replace blades.

• Change mowing pattern.

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

• Check air pressure in all traction unit

tires.

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

• Anti-scalp rollers not adjusted

correctly.

IMPORTANT: Avoid Damage! Stale fuel can produce varnish and

plug carburetor or injector components and affect engine

performance.

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

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

instructions for mixing.

5. Fill fuel tank with stabilized fuel.

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

carburetor on gas engine or fuel injectors on diesel engine.

Engine:

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

for longer than 60 days.

Storage - 33

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ASSEMBLY

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

2. Service air filter if necessary.

Assembly

Check Hydraulic Oil Level

3. Clean debris from engine air intake screen.

4. On gas engines:

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

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

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

5. Clean the engine and engine compartment.

6. Remove battery.

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

battery is not maintenance free.

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

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

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

1. Clean area around dipstick cap (A).

10. Charge the battery.

2. Remove dipstick cap (A). Wipe dipstick clean.

NOTE: Do not tighten dipstick cap when checking oil level.

3. Insert dipstick in filler neck (B). Do not tighten cap.

IMPORTANT: Avoid Damage! Prolonged exposure to sunlight

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

cover if stored outside.

4. Remove dipstick. Check oil level on dipstick. Oil level should be

between the ADD and FULL marks on dipstick.

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

put a waterproof cover over it.

• If oil is level is below ADD mark, fill to proper level.

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

5. Insert dipstick. Tighten cap.

Removing Machine From Storage

1. Check tire pressure.

2. Check engine oil level.

Check Engine Oil Level

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

Charge battery if necessary.

1. Lift thigh pad.

4. Install battery.

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

specified torque.

6. Lubricate all grease points.

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

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

running to allow oil to be distributed throughout engine.

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

2. Clean area around dipstick cap (A).

3. Remove dipstick cap (A) from tube. Wipe dipstick clean.

NOTE: Do not tighten dipstick cap when checking oil level.

4. Insert dipstick in tube. Do not tighten cap.

5. Remove dipstick. Check oil level on dipstick. Oil level should be

between the ADD and FULL marks.

• If oil is level is below ADD mark, fill to proper level.

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

6. Insert dipstick. Tighten cap.

Assembly - 34

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SPECIFICATIONS

Connect Battery

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic

Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Contact

CAUTION: Avoid injury! Prevent Battery Explosions:

Tires

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 x 8.5 - 8

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 x 4 - 5

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

Inflation Front (Maximum) . . . . . . . . . . . . . . . . . . 138–173 kPa (20-25 psi)

• Keep sparks, lighted matches, and open flame away

from the top of battery. Battery gas can explode.

• Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm

battery to 16 degrees C (60 degrees F).

Battery

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

CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270-amp

Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 minutes

BCI Group Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U1

Capacities

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 L (6 gal)

Hydraulic Oil (With Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 L (3.3 qt.)

Engine Oil (With Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt.)

Travel Speeds at Full Engine RPM

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–14 km/h (0–8.7 mph)

Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–6.4 km/h (0–4 mph)

Dimensions

Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 m (44 in.)

Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 m (48 in.)

Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47 m (65.5 in.)

Overall Width (with chute up) . . . . . . . . . . . . . . . . . . . . . . . 1.35 m (53 in.)

Overall Width (with chute down) . . . . . . . . . . . . . . . . . . . 1.64 m (64.5 in.)

1. Connect positive (red) cable to battery positive (+) terminal. Install red

terminal cover (A).

2. Connect negative (black) cable to battery negative (-) terminal. Install

black terminal cover (B).

Check Machine Safety Systems

Recommended Lubricants

Perform safety system check to make sure the electronic safety interlock

circuit is functioning properly.

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . See Applicable Engine Manual

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . 5W-50 or 15W-50 All Synthetic Oil

Grease: (This may change for high-speed applications such as

cutting units)

Specifications

Engine

. . . . . . . . . . . . . . . . All-Purpose Grease with an NLGI Grade No. 2 Rating

Note: See engine manufacturer’s owner’s manual provided with your

machine for engine specifications.

(Specifications and design subject to change without notice.)

Drivetrain

Getting Quality Service

Service Literature

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dual Hydrostatic

Pumps . . . . . . . . . . . . . . . . . .Hydro-Gear PG-1KDA-D61 - PG-1HDA-D41

Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . . .Hydro-Gear HGD-12-7172

Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Infinitely Variable

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

for this machine, contact your Great Dane Dealer. Parts catalogs and

operator manuals are also available online at GreatDaneMowers.com.

Electrical System

Parts

Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Amp

Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flywheel

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solenoid Shift

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.

Fuel System

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

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

recorded in the Product Identification section of this manual.

Fuel Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, Regular Unleaded

Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . On Right Side of Operator

Fuel Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.7 L (6.0 gal)

Great Dane Quality Continues with Quality Service

Steering and Brakes

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

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

Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Control Levers

Specifications - 35

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GETTING QUALITY SERVICE

authorized Great Dane dealer’s parts and service support.

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

about your product.

Refer to your attachment and machine operator manuals.

Contact your authorized Great Dane dealer with unanswered questions.

Part Numbers

Item

Part Number

Mower Blades:

52-Inch Deck

GDU10231

Hydraulic Oil Filter

Battery

GDU10137

191832

Fuse - 20 amp

57M7120

Belts:

GDU10025

TCU18848

Hydraulic Drive Belt

52-Inch Mower Deck Belt

(Part numbers are subject to change without notice. Part Numbers may be

different outside the U.S.A.)

Getting Quality Service - 36

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SERVICE MISCELLANEOUS

Wiring Schematics

Service Miscellaneous

Service Miscellaneous - 37

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SERVICE MISCELLANEOUS

Hydraulic Schematics

Service Miscellaneous

Charge Relief Valve

Left Hydrostatic Pump Assembly

Pump Block

Right Hydrostatic Pump Assembly

Right Wheel Motor

Inlet Filter

Charge Pump

System Charge Check Shock Valve (Reverse)

Manual Bypass

Hydraulic Reservoir

Left Wheel Motor

Cooling Orifice

System Charge Check Shock Valve (Forward)

Service Miscellaneous - 38

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SERVICE MISCELLANEOUS

Service Miscellaneous - 39

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MAIN FRAME ASSEMBLY

Frame Assembly - 40

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MAIN FRAME ASSEMBLY

ITEM

PART NO

D24020

M63431

JD26

QTY

DESCRIPTION

SCREW, 8-32X .50 PAN PHL Y

NUT, 8-32 ELASTIC STOP

NUT, 1/2-20 LUG Y

102770

200601

200672

N/A

RELAY, ISO MINI ELEC.

ASSY, TIRE/WHL 18/8.5X8 YELLOW

SPACER, .625X.120X.400 Y

ASSEMBLY, CONSOLE

N/A

POWER UNIT

200741

200658

200775

200737

200739

251907

960032

960044

960113

963019

964003

964016

967115

967192

D13029

GUARD, FOOT

PIN, CVS SPG 3/8" YOKE SPEC Y

WEIGHT, CAST DRILLED

FENDER, LH

FENDER, RH

YOKE, 3/8-24 RH ADJUSTABLE

BOLT, 5/16-18 X 3.25 HEX 5 Y

BOLT, 3/8-16 X 1.00 FGH 8 Y

BOLT, 1/2-13 X 1.25 HEX 5 Y

BOLT, 3/8-16 X 1.00 CRG 5 SN Y

NUT, 5/16-24 STD HEX GR5 Y

LOCKNUT, 3/8-16 WHIZ Y

LOCKNUT, 5/16-18 NYLOC Y

LOCKNUT, 1/2-13 WHIZ GR5 Y

ROD, CONTROL 5/16 X 26 Y

Frame Assembly - 41

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FUEL, HYDRAULIC AND HANDLE ASSEMBLY

Fuel, Hydraulc and Handle Assembly - 42

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FUEL, HYDRAULIC AND HANDLE ASSEMBLY

ITEM

PART NO

D13028

D13308

D13309

D18093

D24028

TCA15373

GDA10066

gda10137

M68342

tca15021

TCA15122

TCA15195

TCU21265

34H60

QTY

DESCRIPTION

SWIVEL ADJUSTER

BASE, LOCK LEVER Y

LEVER, LOCK Y

GRIP, CONTROL

FTG, 90 9/16 MOR X 3/8 HOSE

WLDT, RESERVIOR HYDRAULIC

ELBOW, FITTING

FILTER, OIL

CLAMP, HOSE (RED) #

TANK, FUEL ASSY

CAP, FILLER OIL

WLDT, PIVOT ROD Y

HOSE, 1/4" ID LOW PERM FUEL 50

PIN, SPRING

19M7865

111886

SCREW, FL M8X1.25X16

P-CLIP, .500 INSULATED

PIN, HAR .091 X 1.63 5/16-1/2 Y

BRG, FLG .500X.620X.500 BRNZ

BRACKET, FUEL TANK MOUNTING

HANDLE, SUPPORT

121080

200116

200603

200654

200762

WLDT, RH CONTROL LEVER

FTG, 90 9/16 MOR X 9/16 MJIC

BOLT, 1/4-20 X .750 HEX 5 Y

BOLT, 3/8-16 X 1.00 HEX 5 Y

NUT, 1/4-20 STD HEX GR5 Y

WASHER, .375 REG FLAT Y

BOLT, 3/8-16 X 1.00 CRG 5 SN Y

BOLT, 3/8-16 X 1.00 CRG 5 Y

LOCKNUT, 1/4-20 NYLOC Y

LOCKNUT, 3/8-16 NYLOC Y

WLDT, LH CONTROL LEVER

313270

960001

960046

960500

960702

963019

963020

964048

968087

200763

Fuel, Hydraulc and Handle Assembly - 43

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ENGINE, HYDRAULIC AND MAINFRAME ASSEMBLY

19 H.P.

23 H.P.

Engine, Hydraulic And Mainframe Assembly - 44

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ENGINE, HYDRAULIC AND MAINFRAME ASSEMBLY

ITEM

PART NO

QTY

DESCRIPTION

D18379

D18394

M86863

TCA15874

TCA15078

TCA16240

11H237

200612

200616

N/A

CLAMP, HOSE - 1/2" PINCH

HOSE ASSEMBLY

FTG, TUN 3/8 HOSE

HUB, REAR WHEEL

MOTOR, WHEEL HGM-12P-7172

FITTING, OIL DRAIN

PIN, COT .125 X 2.00 EXTP Y

WLDT, BRAKE SHAFT

WLDT, RH BRAKE ARM

ENGINE, KAWASAKI 19HP FH580V

ENGINE, KAWASAKI 23 HP FH680V

ASSEMBLY, LH HYD PUMP

ASSEMBLY, RH HYD PUMP

FTG, ADP 3/4-16FJIC X 7/8-14MOR

FTG, ADP MJIC-FSWJIC 6500-08-08

FTG, ADP JIC-ORB 2062-10-8S

SHIM, .020X.787X1.102

N/A

231104

231046

231647

24M7158

960025

960026

960044

960046

963053

967034

967115

967155

968087

TCU19166

200709

191125

191365

181073

191601

200785

BOLT, 5/16-18 X 1.50 HEX 5 Y

BOLT, 5/16-18 X 1.75 HEX 5 Y

BOLT, 3/8-16 X 1.00 FGH 8 Y

BOLT, 3/8-16 X 1.00 HEX 5 Y

BOLT, 3/8-16 X 1.25 CRG 5 Y

NUT, 5/16-18 JAM GR5 Y

LOCKNUT, 5/16-18 NYLOC Y

PIN, ROL .156 X 1.00

LOCKNUT, 3/8-16 NYLOC Y

NUT, 3/4-20 CASTLE

PLATE, WHEEL SPACER

MUFFLER, 23 HP ONLY

SHIELD, EXHAUST - 23 HP ONLY

FILTER, KAWASAKI OIL

GASKET, MUFFLER GASKET

WELDMENT, FRAME

Engine, Hydraulic And Mainframe Assembly - 45

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CLUTCH, PUMP COMPONENTS AND FOOT PLATE ASSEMBLY

Clutch, Pump Components and Foot Plate Assembly - 46

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CLUTCH, PUMP COMPONENTS AND FOOT PLATE ASSEMBLY

ITEM

PART NO

D14160

D14213

D14252

D18038

D18056

D18067

D18071

D18145

D18314

D38128

GDA10004

GDA10005

GDU10025

TCA15316

111910

QTY

DESCRIPTION

WASHER, .250 WIDE HEAVY FLAT Y

BOLT, M6 X 1.00 X 10 HEX 8.8 Y

BOLT, 7/16-20X3.00 HEX 5 Y

SWITCH

SPACER, .468 X 1.38 X .375 Y

KEY, M5 X M5 X M30 RD

SPRING, EXT .900X.135X4.50 Y

KEY, .250 X .250 X .995 TPR

PULLEY, V-BELT 4.00X.379 W/BRG

SPRING, COM 1.22X.162X2.50 Y

WLDT, PIVOT IDLER MOUNT

WLDT, IDLER ARM

BELT,PUMP DRIVE

ASSY, PUMP PULLEY W/SET SCREW

CABLE TIE, .15 X 8.50

150052

191179

200318

200665

200666

N/A

BUSHING, MACH .750X1.25X.048 Y

BRG, FLG .750 X 1.00 X .750 BRNZ

PULLEY, V-BELT 4.78PD X 1.000 W/KEY

CLUTCH ASSY, OGURA

PLATE, CLUTCH DOG

ASSEMBLY, FOOT PLATE

COVER, OPC

200769

200770

403490

959995

960022

960046

960052

960055

960078

960602

960702

963020

963033

960502

964013

967115

967340

968087

WASHER, SPRING

SNAP RING, .750 X .042 EXT

FTG, 1/4-28 STRGT GREASE ZERK

BOLT, 5/16-18 X .750 HEX 5 Y

BOLT, 3/8-16 X 1.00 HEX 5 Y

BOLT, 3/8-16 X 2.50 HEX 5 Y

BOLT, 3/8-16 X 3.25 HEX 5 Y

BOLT, 7/16-14 X .750 HEX 5 Y

WASHER, .375 MED SPRG LOCK Y

WASHER, .375 REG FLAT Y

BOLT, 3/8-16 X 1.00 CRG 5 Y

Bolt,3/8-16x3/4 Car Gr5 LNnk

NUT, 3/8-16 STD HEX GR5 Y

LOCKNUT, 10-24 NYLOC Y

LOCKNUT, 5/16-18 NYLOC Y

SCREW, 10-24 X .625 PAN PHL MAC Y

LOCKNUT, 3/8-16 NYLOC Y

Clutch, Pump Components and Foot Plate Assembly - 47

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HYDRAULIC COMPONENTS

Hydraulic Components - 48

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HYDRAULIC COMPONENTS

ITEM

PART NO.

TCA15122

TCA15373

D18379

QTY

DESCRIPTION

CAP

HYDRAULIC RESERVOIR W/DECALS

HOSE CLAMP

TCA15078

D14196

WHEEL MOTOR

ELBOW FITTING, PUMP END

O-RING

R26375

231647

90° FITTING, UPPER W/O-RING

STRAIGHT ADAPTER, LOWER W/O-RING

90° FITTING, LOWER

OIL FILTER

231104

231046

—

GDA10137

GDA10066

313270

ELBOW FITTING

14M7517

19M7784

M86863

LOCK NUT, M10 X 1.5

CAP SCREW, M10 X 1.5 X 20

TEE FITTING

D24028

FITTING

D18394

HOSE, HIGH PRESSURE

HOSE, BULK RETURN

ADAPTER

TY22552

GDA10065

M78480

TIE STRAPS

Hydraulic Components - 49

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FUELCOMPONENTS/WIRING HARNESS

FUEL COMPONENTS

WIRING HARNESS

200704 Wiring Harness

Fuel Components - 50

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FUEL COMPONENTS/WIRING HARNESS

FUEL COMPONENTS

ITEM

PART NO.

TCA15021

181251

QTY

DESCRIPTION

FUEL TANK

CAP, FUEL

D18144

GROMMET

TCA15048

M68342

FUEL PICKUP

CLAMP

M88753

HOSE, FUEL, 10 FT. 1/4 IN. SAE 30-R7

NUT

14M7400

AM116304

03M7191

19M7865

200603

FILTER

CAP SCREW

BRACKET

WIRING HARNESS

ITEM

PART NO.

200704

QTY

DESCRIPTION

HARNESS, WIRING

Fuel Components - 51

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CONSOLE AND BATTERY ASSEMBLY

Console and Battery Assembly - 52

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CONSOLE AND BATTERY ASSEMBLY

iTEM

PART NO

D18079

D28159

TCU16323

03H1832

111886

121080

180640

180842

181148

191832

N/A

QTY

DESCRIPTION

GRIP, PVC .250 X 1.00 X 3.63

STRIP, BATTERY INSULATOR

LABEL. PARK BRAKE DIRECTION

BOLT, 5/16-18 X 6.00 CRG 2 Y

P-CLIP, .500 INSULATED

PIN, HAR .091 X 1.63 5/16-1/2 Y

SOLENOID, 12 V STARTER

CABLE, 12” STARTER

CABLE, BATTERY STARTER - 48”

BATTERY, 12V-U1-CCA270MIN

ASSEMBLY, CONTROL PANEL

PAD, THIGH

200606

200787

200614

200615

200671

200690

200692

200705

181148

963020

960000

960001

960047

960600

963001

964040

964048

967115

967185

968087

200745

TRAY, BATTERY

LEVER, BRAKE

LINK. BRAKE

BUSHING, BRAKE PIVOT

WLDT, THIGH PAD BRACKET

BUSHING, .364X.540X1.250 Y

SWITCH, NO-NO-NC GREY PLUNGER

CABLE, BATTERY STARTER - 51”

BOLT, 3/8-16 X 1.00 CRG 5 Y

BOLT, 1/4-20 X .500 HEX 5 Y

BOLT, 1/4-20 X .750 HEX 5 Y

BOLT, 3/8-16 X 1.25 HEX 5 Y

WASHER, .250 MED SPRG LOCK Y

BOLT, 1/4-20 X .625 WSH Y

LOCKNUT, 1/4-20 WHIZ Y

LOCKNUT, 1/4-20 NYLOC Y

LOCKNUT, 5/16-18 NYLOC Y

BOLT, 5/16-18 X 2.00 CRG 5 Y

LOCKNUT, 3/8-16 NYLOC Y

WELDMENT, CONSOLE

Console and Battery Assembly - 53

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FOOT PLATE/CONSOLE COMPONENTS

FOOT PLATE COMPONENTS

CONSOLE COMPONENTS

Foot Plate/Console Components - 54

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FOOT PLATE/CONSOLE COMPONENTS

FOOT PLATE COMPONENTS

ITEM

PART NO

200618

200619

200655

200691

200693

200767

960001

960023

960701

963019

964048

967115

968087

QTY

DESCRIPTION

PLATE, PLATFORM

PLATE, PLATFORM TAB LH

BUMPER, MINER GBR-6

WEDGE, PLATFORM

PLATE, PLATFORM TAB RH

ANCHOR, OPC

BOLT, 1/4-20 X .750 HEX 5 Y

BOLT, 5/16-18 X 1.00 HEX 5 Y

WASHER, .313 REG FLAT Y

BOLT, 3/8-16 X 1.00 CRG 5 SN Y

LOCKNUT, 1/4-20 NYLOC Y

LOCKNUT, 5/16-18 NYLOC Y

LOCKNUT, 3/8-16 NYLOC Y

CONSOLE COMPONENTS

ITEM

PART NO

D18021

D18427

D24020

M63431

TCA15051

TCU14840

TCU16481

136574

QTY

DESCRIPTION

DECAL, THROTTLE

CABLE, CHOKE

SCREW, 8-32X .50 PAN PHL Y

NUT, 8-32 ELASTIC STOP

CABLE, THROTTLE

DECAL, GENERAL CAUTION

DECAL, PTO & KEY SWITCH

SWITCH, PTO ENGAGEMENT

NUT, 3/8 UNF HEX GR 5 ZN

SWITCH, KEY - 3 POSITION

METER, HOUR - LCD ALT. (ENM)

TOP, CONSOLE

14H846

180620

192296

200743

Foot Plate/Console Components - 55

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DECK ASSEMBLY

46 42 35

Deck Assembly - 56

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DECK ASSEMBLY

ITEM

PART NO

D13024

D13055

QTY

DESCRIPTION

SPACER, 1.500X1.000X.510

NUT, 7/8-14

D18032

D18055

Pulley, Flat 5.0x.38 w/BRG

WASHER, BLADE

D18084

D23058

D24019

D28050

PULLEY, SPLINE SPINDLE OFFSET

J-BOLT, 3/8-16 X 4.00 Y

WASHER, .402X2.00X.055 FEND Y

PULLEY, FLAT 5.00X.375 W/BRG

PIVOT, RETAINER WELD

BLADE, 18“

DECAL, 52

NUT-1/4“ FLANGE PREVAILING TOR

RETAINER #

KNOB, LOCKING

SPRING,CHUTE GUARD

DECAL, DANGER

SPRING, TENSION

GDA10103

GDU10231

GDU10268

H122207

H141123

M119352

M132768

M137637

M131739

N242189

TCA15346

TCA16387

TCU14540

TCU18344

TCU18742

TCU18744

TCU18848

TCU18852

TCU51051

03H1658

03H1729

03H1809

03H1836

160169

200041

999538

200747

N/A

200749

200155

959995

960046

960502

963053

964016

964022

964501

967347

968087

ARM, IDLER

CHUTE DISCHARGE ASST #

BRG, FLG M10XM25XM27 FLUTED

STRAP, IDLER PULLEY

SPACER

WHEEL, GAGE

BELT, 52“ DECK

DECAL, DANGER

DECAL, WARNING

BOLT, 3/8-16X2.25 CRG 5 Y

BOLT, 1/4-20X1.00 SQU SN Y

BOLT, 3/8X4 SHT NK RD HD

BOLT, 3/8-16X3.50 CRG 5 Y

DECAL, WARNING - SHIELD

ASSY, SPINDLE HOUSING

TRIM 1/4

WLDT, 52” FIXED DECK

ASSEMBLY, WHEEL & STRUT

ASSEMBLY, SHIELD & DECALS - 19 H.P.

ASSEMBLY, SHIELD & DECALS - 23 H.P.

FTG, 1/4-28 STRGT GREASE ZERK

BOLT, 3/8-16 X 1.00 HEX 5 Y

NUT, 3/8-16 STD HEX GR5 Y

BOLT, 3/8-16 X 1.25 CRG 5 Y

LOCKNUT, 3/8-16 WHIZ Y

LOCKNUT, 3/8-16 CROWN Y

WASHER, .406 X .813 X .065 FLAT Y

BOLT, 5/8-11 X 2.25 HEX 8 Y

LOCKNUT, 3/8-16 NYLOC Y

Deck Assembly - 57

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WHEEL AND STRUT ASSEMBLY/PUMP COMPONENTS

WHEEL AND STRUT ASSEMBLY

PUMP COMPONENTS

Wheel and Strut Assembly/Pump Components - 58

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WHEEL AND STRUT ASSEMBLY/PUMP COMPONENTS

WHEEL AND STRUT ASSEMBLY

ITEM

PART NO

QTY

DESCRIPTION

D13008

D18076

161397

164145

191049

200729

200731

200664

963011

964000

959995

BUSHING, 1.03 X 1.50 X .179 Y

BRG, FLG 1.00X1.25X1.00

PIN, LNC .438 X 2.00 Y

C-SPACER, 1.00 X 1.77 X .500

TUBE, RD 1.00X.500X4.76

WLDT, CASTER MOUNT BRACKET

WLDT, FR WHEEL FORK

WHEEL, FRONT CARLISLE11X4X5

BOLT, 1/2-13X6.00 CRG Y

LOCKNUT, 1/2-13 CROWN Y

FTG, 1/4-28 STRGT GREASE ZERK

PUMP COMPONENTS

ITEM

PART NO

D14196

D24028

D38157

TCA14966

TCA14965

191256

QTY

DESCRIPTION

FTG, ADP JIC-ORB 6801-08-08

FTG, 90 9/16 MOR X 3/8 HOSE

ALIGNABALL, 5/16-24 RH THD

PUMP, RH HYDRO PG-1GRQ

PUMP, LH HYDRO PG-1GRQ

SWITCH, PLUNGER DP - N.O. - N.C.

BOLT, 5/16-18 X 1.00 HEX 5 Y

LOCKNUT, 10-24 NYLOC Y

LOCKNUT, 5/16-18 NYLOC Y

SCREW, 10-24 X .625 PAN PHL MAC Y

960023

964013

967115

967340

Wheel and Strut Assembly/Pump Components - 59

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SPINDLE ASSEMBLY

Spindle Assembly - 60

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SPINDLE ASSEMBLY

ITEM

PART NO

200262

200046

200042

200044

200262

200045

D13055

N/A

QTY

DESCRIPTION

Spindle Assembly - Includes items 2, 3, 4, 5, 6, 14

Ball Bearing

Housing

Spacer - 1.000 x 1.250 x 2.772

Shaft, Spindle

Bolt, 3/8-16 x 1.25 Rib

Nut, Pulley (Special)

Pulley, Cutter Housing - See Mower Assembly Pages

Spacer, Pulley

D13024

967347

960502

D18055

GDU10231

200047

Bolt, Blade - 5/8-11 x 2.25 Grade 8

Nut, 3/8-16 Std Hex Gr5

Spacer, Blade Bolt

18.0" Blade, 52" Deck

Zerk, Grease S/O

Spindle Assembly - 61

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DECAL LOCATIONS

S/N

Decal Locations - 62

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DECAL LOCATIONS

1. D18197

4. M117554

6. TCU15907

2. D18372

3. GDU10256

5. TCU18852

7. M137637

MAY BE COVERED BY ONE

OR MORE OF THE FOLLOWING

WARNING

Shield Missing.

8. M131739

PATENT(S):

5,343,678; 5,507,138; 5,600,944;

5,765,347; 5,964,082; 6,085,504;

6,094,897; 6,189,305; 6,189,304;

13. TCU15910

DO NOT Operate.

6,404,515; 6,625,965; 6,862,872

200037

9. 160169

12. 200037

11. GDU10268

10. TCU16323

14. GDU10257

15. D18021

��

WARNING

ADVERTENCIA

�

��

To avoid injury

from rotating

belts, keep all

shields and

Para evitar ser

lesionado por las

correas en movimiento,

mantener todos los

escudos y protectores

en su lugar.

��

guards in place

��

17. TCU51051

��

16. TCU16481

18. D18023

19. TCU14840

Decal Locations - 63

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