GDSZ48-14KA
GDSZ48-16BV
GDSZ52-16BV
GDSZ52-18BV
GDSZ52-22KHE
GDSZ61-22KHE
PATENTS PENDING JAN 1997
FORM D01002-97
GREAT DANE POWER EQUIPMENT, INC.
JEFFERSONVILLE, INDIANA 47130 U.S.A.
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SAFETY GUIDELINES
During Operation
.Using the machine demands attention.
COMMON ACCIDENTS YOU MUST AVOID
To prevent loss of control:
* Mow only in daylight or when there is
good lighting
* Watch for pot holes, rocks, and any
hidden hazard
.CONTACT WITH ROTATING BLADES .THROWN OBJECTS
.OPERATING WITHOUT GUARDS IN PLACE
.RUNNING OVER SOMEBODY
.OVERTURNING ON STEEP SLOPES
* Keep away from drop-offs, ditches, creeks, ponds and
other hazards.
Memorize the above and do yourself a favor; read, remember
and follow these safety instructions.
* Reduce speed when making sharp turns
and especially on hillsides.
* Always be sure of your footing. Keep a firm hold on the
stationary handle at all times.
Before Operating
.Do not let children or youngsters operate this machine.
.Do not let others run the machine before they carefully read
these instructions.
* Do not operate in slippery conditions.
* Lean forward when mowing uphill.
.Before crossing gravel drives, sidewalks or
roads, disengage the cutter blades and wait for them to stop.
.Do not run engine indoors.
.Do not carry excess baggage including passengers.
.Police the work area and pick up and remove debris such as
wires, sticks, glass, rocks and scrap materials.
.Wear safety goggles, sturdy work shoes, and close fitting
clothes. Never operate machine in
.Keep engine free of accumulated grass, leaves and excessive
lubricants to avoid fires.
.Don't smoke around the mower at any time. This has caused
serious injury-
r'bare feet, sandals or sneakers.
.Keep all nuts and bolts tight to be sure of safe working
conditions.
-Keep all safety devices, guards and shields in good condition
and in place.
.Machine should be stopped and inspected for damage after
striking a foreign object. Repair any damage before restarting-
.Before leaving the operator's position or leaving mower
unattended, disengage cutter blades, stop engine and remove
starting key.
.Always park the machine on level surface and apply parking
brake. Block the wheels when parking on sloping surface-
.Before any servicing, disengage cutter blades, stop engine,
remove starting key and spark plug wires.
.The discharge chute must be installed and
spring loaded down, except when grass catcher is in place.
.Do not touch engine muffler. It may be
extremely hot and cause severe burns. .Although the Great
Dane Surfer has a built-in
safety system, it is recommended to disengage power to the
cutter blades and engage the parking brake before leaving
the platform for a brief time.
.When leaving the machine out of sight, disengage power to
cutter blades, shut off engine, apply parking brakes and take
the starting key with you.
.This machine is not meant for highway or street use. It is not a
recreational vehicle. Don't try to show off.
.In other words. always be careful.
.Watch out for traffic when crossing or near roadways.
.Never direct discharge chute toward bystanders, windows,
buildings or cars.
SAFETY INTERLOCK SYSTEM
The Great Dane Surfer has been designed to be
inherently safe. In addition, there are these safety systems:
Precautions when Handling Gasoline
.Before starting engine, you must turn "OFF" the cutter blade
clutch switch.
.Use an approved gasoline container
Never remove fuel cap or add gasoline to a running or hot
engine. Allow engine to cool for several minutes before
refueling tank.
.An operator must be standing on the platform to engage the
cutter blades (machines with pull start, you must cycle blade
clutch switch "OFF" then "ON").
.Never refuel indoors.
.Avoid spilling gasoline anywhere.
.Wipe up any spilled gasoline
.Completely letting go of control levers will brake machine to
instant stop.
.Do not smoke while handling gasoline
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.If wheels do not stop rotating when controls are.~ in neutral, adjust
the NEUTRAL stop wing bolts at the rear of the power unit,
between the two hydro pumps.
HYDRAULIC SAFETY
.All hydraulic system servicing should be done by a qualified
technician.
.Engage cutter blade clutch. Be sure area is clear
of debris. Run blades for several minutes.
.Shut off engine and remove jack stands.
Remove start key.
.Relieve all pressure in the system before disconnecting any
hoses.
.Keep body and hands away from pin holes that may eject
hydraulic fluid under high pressure.
.Check all belts for proper tension.
.Test run the machine in a level area. If machine
drifts to the right or left when both control levers
are full forward, adjust swivel nuts at the top of
control rods to change length of control rod so
that machine travels in a straight line. Please remember, the
neutral adjustment and straight
.Make sure all hydraulic connections are tight and hoses in
good condition.
High pressure hydraulic fluid may have sufficient force to
penetrate skin and cause serious injury. Seek medical attention
immediately. Treatment must be done a doctor.
drive adjustments will need to be repeated after several hours of
operation.
ASSEMBLY OF MACHINE
Please note the Great Dane Surfer is shipped completely
assembled and has been tested at the factory.
After you have removed all crating and packaging materials,
carefully follow these steps:
.Test function of the three safety interlock Systems.
.Remove battery from machine, if one is installed and service
observing precautions in Section on Battery Servicing.
.Check hydraulic fluid level. Should be about 5 inches below
the top of the oil filler pipe. Use 10W-30 engine oil during
initial operating period.
.Adjust safe maximum drive speed by unlocking
and adjusting the stationary bar to limit amount
of forward movement of the control levers.
Secure the stationary bar firmly by tightening the ~ lever on the left
side of bar.
.Check engine oil for proper level.
.Check rear wheel tire pressure. Use high pressures up to 24
psi for mowing on rough ground, and down to 14 psi for fairly
smooth terrain. Note, front caster wheel tires must be foam
filled and thus never require air servicing.
.Remove belt cover and check all belt tension. .Lubricate all
moving parts (see Maintenance
OPERATING INSTRUCTIONS
Read and understand the Safety Guidelines before attempting to
operate.
.Check fuel tank
.Check engine oil level
Check List).
.Open fuel valve
.Adjust stationary bar half way back and tighten left side lever
for moderate mowing speed
.Locate rear drive wheel mounting bracket for general height of
cut in your region.
.Fill fuel tank with regular, 80 octane gasoline. .Open shut-off
valve under gas tank.
.Travel control levers must be in neutral
.Electric blade clutch switch must be OFF
.Stand on platform
You are now ready for initial running of the machine.
.Set throttle and choke as required
.Turn key switch ON and pull start or electric start .Wide open
throttle
.Engage cutter blade switch
.Grasp stationary bar with both hands
.Push both levers forward smoothly and evenly to go straight
ahead
INITIAL ADJUSTMENTS
.Set the rear of the machine on jack stands or blocks to raise
rear wheels off of ground and block caster wheels.
.Start engine. Let run for several minutes to warm hydraulic
fluid.
.To make turns, pull same side control lever back .To stop,
return both levers to neutral
.To reverse, pull both levers back
.Apply parking brake when leaving machine. Do not park on
slopes
.Observe that wheels rotate in the correct direction when
control levers are moved back and forth.
.To hand push the machine, open dump valve levers about one
full turn.
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.When oil starts to flow in a steady stream from disconnected
open port on the pump, reconnect hose to pump.
.Secure machine in a safe area, away from bystanders and
facing a wall. Raise drive wheels off the ground and block
caster wheels
Run full forward speed for about a minute and
then reverse speed for another minute. Continue
to cycle until cavitations sound quiets down and full power is
restored.
SERVICING & ADJUSTMENTS
TIRE PRESSURE
.When mowing on relatively smooth ground, keep rear wheel
tire pressure low, such as 14 to 16 psi. When mowing on
rough ground, increase
tire pressure to 20 to 24 psi. This will produce a nicer level of
cut.
.Note that the front caster wheels are foam filled and never
need air .
SPINDLE DISASSEMBLY
HEIGHT OF CUT
.Rear wheels may be located in three or four positions. Use
midpoint position for average cut from 2 to 4 inches. Highest
hole position to cut from 3 to 5 inches. Lowest hole position
to cut from 1 to 3 inches.
To replace ball bearings in the spindle assembly, there is no
need to remove assembly from cutter deck
.Adjust caster wheel spacers to keep cutter deck tilted slightly
down at the front.
.Carefully clean all debris around the spindle assembly
.Remove the blade, bolt and flanged nut
.Vary number of spacers between cutter blade
and spindle for higher height of cut.
.Slide off pulley and spacer washer. If pulley is seized on spline
shaft, soak with solvent. Do not use hammer or wheel puller
.Remove wire clip ring at top of bearing around the shaft. Use
sharp tool to extract
BELT TENSION ADJUSTMENT
.Lower the entire shaft from the bottom of the spindle with
lower bearing and spacer sleeve
The belt drive from the engine to the hydro -'pumps is self
adjusting, normally requiring no
maintenance.
.Discard old bearings at this time.
.Clean entire assembly
.Reinstall in reverse order. Place new bearing on shaft lower
flange, slide on the spacer sleeve
.The belt from the engine to the cutter deck and the right hand
spindle drive belt should be tightened only so that you can
deflect the belt about 1/2 inch when pulling about 10 Ibs. If
the belt is too tight, you may damage the engine or the
spindle bearings. Too loose, and the belt will wear
prematurely.
.Slide the shaft assembly up into the spindle housing keeping
shaft carefully centered. The lower bearing can easily bind
since clearance is only .002 inch. Do not hammer into
position. If the bearing seizes, take apart again and carefully
reposition until the assembly slides easily and smoothly into
housing
.Carefully center and install top bearing
FREE WHEELING
.Insert wire clip, any spacers and pulley
.To move machine without having the engine running, rotate
the dump valve levers of the left hand side of the hydro
pump about one turn counterclockwise. Levers must be
returned to original closed position to drive the machine.
BATTERY SERVICING
HYDRO AIR BLEED PROCEDURE
.Carefully fill each cell to the proper level with electrolyte,
observing great caution when handling acid. Severe chemical
burns may
When any of the hydro components or hoses are
disconnected or removed and when the hydro oil is changed
entrapped air must be bled from the system.
Disconnect small hose line from each pump going to the oil
filter
result.
.Charge battery in open, well ventilated area and use proper
procedure specified with the charging system.
.After neutralizing any acid spills, install battery and securely
tighten wires.
.When oil starts to flow in a steady stream from end of hose,
plug the hose
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RECOMMENDED MAINTENANCE CHECK LIST
DAILY
1. Check engine oil level
2. Remove and clean engine air filter
3. Blow clean engine blower screen and fins
4. Clean out debris under belt cover
5. Inspect all belts for damage
6. Sharpen and balance cutter blades
WEEKLY (or every 40 hours}
1 .Change engine oil
2. Grease caster wheel bearings (2 places)
3. Grease caster wheel pivot bearings (2 places)
4. Scrape clean underside of cutter deck
5. Check belt tension
6. Check tire pressure
7. Check battery acid level
8. Clean engine air filter
MONTHLY {or every 160 hours}
1. Clean spark plugs
2. Replace engine oil filter
3. Check hydro reservoir oil level
Lubricate the following with WD 40 or LPS-2:
1. Idler pulley pivots (3 places)
2. Hydro pump control arms (6 places)
3. Platform OPC push rod
4. Platform hinges (2 places)
5. Traction control lever pivot shaft (4 places)
6. Throttle control cable
7. Choke control cable
ANNUALLY
1. Remove and replace all spindle bearings
2. Remove and replace main cutter deck idler pulley
2. Remove caster wheel roller bearings, clean and relube
3. Remove and replace caster pivot bearing bushings
4. Replace three belts. Run-in and adjust tension for new belt
5. Thoroughly clean top and underside of power unit
6. Replace hydro oil filter with original Great Dane service part
7. Check all bolts and nuts for tightness
8. Remove and clean battery box
9. Replace spark plug.
VERY IMPORTANT NOTE: FOLLOWING ITEMS REQUIRED TO VALIDATE
(Dealer service invoice accepted)
INITIAL BREAK-IN PERIOD
1. Change engine oil and replace engine filter at 8 hours
2. Dump hydro oil and replace with synthetic Aeroshell W or Mobil 1, 15-W50 (about 4 qts) at 40 hours
3. Replace hydro oil filter at 40 hours
4. Adjust new belt tension at 4 hours, 8 hours and again at 24 hours
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Illustrated Parts Book Addendum: Surfer
Parts not shown in manual
Part no. Description
Page no. Figure #
D12051 Replaced By D22215
D12052 Battery Tray Support
D12066 Bracket, Wheel Motor Mount
D14215 Lug Stud, Drive Wheel
D15025 Side Support LH
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
D15026 Side Support RH
D15031 Engine Deck Weldment
D18110 Rear Wheel Hub (for the 18 x 8.50)
D18134 Rubber Gromments
D18192 Tire, 18x8.50-8
D18193 Tire, 18x7.50-8
D18195 Rim, 18x8.50-8
D18198 Rim, 18x7.50-8
D12002 Console, Old style w/ toggle PTO switch
D12098 Console, Current style
D12106 Retainer Tab, PTO Switch
D13011 Rod, Pivot
D13022 Slip Swivel, Platform J-hook
D13036 Brake Bushing
D13039 Brake Latch Bushing
D15022 Thigh Plate Weldment
D15023 Handle Mount Weldment
D15047 Brake Pedal Weldment LH
D16000 Spring Platform Update
D16001 LH Parking brake kit
4
4
4
4
4
4
4
4
4
4
4
4
4
2
2
2
2
2
2
2
2
2
2
2
2
2
D35033 LH Brake Bracket Weldment
D13003 Caster Wheel Bearing Sleeve
D13023 Spacer, J-Hook Flat Idler
D13024 Spindle - Top Pulley Spacer
D15151 Pin, 48" Chute Pin
D18003 Idler Arm - Bearing Bushing
D18076 Caster Support Bushing
D33007 Spacer, 13" Caster Wheel
D38035 Tapered Roller Bearings w/ race - 13" Caster Wheel
D38065 13" Caster Wheel Seal
D38066 13" Caster Tire
6
6
6
6
6
6
6
6
6
6
6
6
3
3
3
3
3
3
3
3
3
3
3
3
D38067 13" Caster Spacer Tube
D38068 13" Caster Stop Tube
D12027 Bracket, Clutch Mount
8
8
8
8
4
4
4
4
D12064 Rear Cover for Hydro Pulley
D13010 Spacer - Engine Crankshaft
D14160 Washer, 1/4" Heavy Washer
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D14204 3/8 Washer, 1/4" Thick - Platform Bolt
D14213 Bolt, m6x14 for Pump Pulley
D15009 O.P.C. Weldment
8
8
8
8
8
8
8
4
4
4
4
4
4
4
D15036 Plunger, OPC Actuator
D18003 Idler Arm - Bearing Bushing
D18067 Key, M5xM28 Hydro Pump Pulley
D18145 Key Sq. 1/4" Taper, Engine Pulley
D14043 Internal Flare Fitting
D14197 Fitting, Straight
D14198 Fitting - Tee - Oil Fill To Pumps
D14212 Lever - Pump Release
D15010 Rotational Support
10
10
10
10
10
10
10
10
10
10
10
10
10
5
5
5
5
5
5
5
5
5
5
5
5
5
D18009 Hose, LP Tank to Pump
D18010 Hose, Pump to Tee
D18059 Square Head Set Screw w/Patch 1/4-20 x 1/2
D18098 Fuel Tank - Shut Off Valve
D18144 Grommet, Fuel Tank Valve
D18174 Cap - Oil Drain Tee
D32070 Capacitor Mount (Not shown, Kawasaki units only)
D32071 Module Mount (Not shown, Kawasaki units only)
D18017 Wiring Pigtail, Kohler
12
12
12
12
6
6
6
6
D18184 Wiring Harness, Kawasaki Manual Start
D38182 Wiring Harness, Kawasaki Electric Start
D38027 Kawasaki Wiring Pigtail
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