Great Dane Lawn Mower GSKH1848S User Manual

Super Surfer Series II

GSKH1848S, GSKH2352S, GSKH2561S

GSKW1948S, GSKW2352S, GSKA1948S

OPERATOR’S MANUAL

200036 REV. 04/11/2007

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.

NOTE: General information is given throughout the manual that may

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

Product Identification

Record Identification Numbers

Super Surfer

GSKH18-48S Serial Number (636510001-)

GSKH23-52S Serial Number (636610001-)

GSKH25-61S Serial Number (636710001-)

GSKW1948S Serial Number (636410001-)

GSKW2352S Serial Number (637010001-)

GSKA1948S Serial Number (6373010001-)

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.

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.

Auburn Consolidated Industries, Inc.

DATE OF PURCHASE:

Previous Editions

_________________________________________

DEALER NAME:

_________________________________________

DEALER PHONE:

_________________________________________

PRODUCT IDENTIFICATION NUMBER:

Model Number

_________________________________________

Serial Number

_________________________________________

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SAFETY LABELS

ENGINE MODEL, SPECIFICATION, AND SERIAL NUMBER:

Safety Labels

Model Number

_________________________________________

Specification

_________________________________________

Serial Number

_________________________________________

Safety Labels

Understanding The Machine Safety Labels

MX20097

WARNING (A)

Hot Surface.

WARNING (B)

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

DANGER (C)

Safety-Alert Symbol

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

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

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

DANGER (D)

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

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

most serious hazards.

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.

The operator’s manual also explains any potential safety hazards

whenever necessary in special safety messages that are identified with

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

DANGER (E)

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

MX20138

DANGER (F)

To avoid injury to children, stop mower when children are near. Do not

mow in reverse. Look behind when backing. Never carry riders, especially

children.

CAUTION: (G)

Before operating read operators manual and safety instructions.

Safety Labels - 2

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SAFETY

CAUTION: HELP AVOID INJURY (H)

• Operator training required

• Read operator’s manual

• Keep shields in place

• Never carry riders

Agency

Category

Hours

250

EPA

500

EPA

1000

125

• Keep people a safe distance away

• Maintain all safety devices

• Before leaving machine:

• Stop engine

CARB

Moderate

Intermediate

Extended

250

500

• Set park brake

Certification

• Remove key

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.

CAUTION (I)

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.

Safety

DANGER/POISON (J)

Operator Training Required

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

• 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.

• NO

• Sparks

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

controls, and safety signs.

• Flames

• Smoking

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

machine is responsible for training the users.

• 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.

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

Local regulations may restrict the age of the operator.

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

occurring to themselves, other people, or property.

• Do not open battery.

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

of an experienced operator.

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.

Preparation

• Evaluate the terrain to determine what accessories and attachments are

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

attachments approved by the manufacturer.

Emission Control System Certification Label

NOTE: Tampering with emission controls and components by

unauthorized personnel may result in severe fines or penalties.

Emission controls and components can only be adjusted by EPA

and/or CARB authorized service centers. Contact your Great Dane

Equipment Retailer concerning emission controls and component

questions.

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

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

parts.

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

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

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).

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

flammable and vapors are explosive.

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.

a. Use only an approved container.

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

smoke.

Emission Compliance Period

c. Never refuel or drain the machine indoors.

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.

• 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.

MX18014

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. Such information is available from Deere

& Company Medical Department in Moline, Illinois, U.S.A. Information

may be obtained in the United States and Canada only by calling 1-800-

822-8262.

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

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

operated.

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

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

work area.

Checking Wheel Hardware

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

is not tight.

Avoid Tipping

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

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

slopes requires extra caution. Never mow on inclines exceeding 15°.

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

operation.

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

procedure anytime it is loosened.

• Mow across slopes, not up and down.

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

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

Wear Appropriate Clothing

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

hard hat when operating the machine.

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

a slope.

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

Safety - 5

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SAFETY

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

• Empty the grasscatcher completely before storing.

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

not operate the equipment when barefoot or wearing open sandals.

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

has a fuel shutoff.

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

cause impairment or loss of hearing.

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

water heater or furnace.

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

Replace if necessary.

Maintenance and Storage

Tire Safety

• Never operate machine in a closed area where dangerous carbon

monoxide fumes can collect.

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

death:

• 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.

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

experience to perform the job.

• Always maintain the correct tire pressure. Do not inflate the tires above

the recommended pressure. Never weld or heat a wheel and tire

assembly. The heat can cause an increase in air pressure resulting in a

tire explosion. Welding can structurally weaken or deform the wheel.

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

help prevent fires. Clean up oil or fuel spillage.

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

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

or drain indoors.

• 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.

• 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.

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

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

• 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.

• 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 grasscatcher components and the discharge guard frequently and

replace with manufacturer’s recommended parts, when necessary.

Grasscatcher components are subject to wear, damage, and deterioration

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

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

sure the equipment is in safe working condition.

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

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

other blades to rotate.

Prevent Fires

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

before and after operating machine, especially after mowing or mulching

in dry conditions.

Safety - 6

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OPERATING

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.

Avoid Damage to Plastic and Painted Surfaces

• Do not wipe plastic parts unless rinsed first.

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

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

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

spray insect repellent near machine.

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

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

vehicle before fueling.

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

up spilled fuel immediately.

• Prolonged exposure to sunlight will damage the hood surface.

• 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.

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.

MX20138

Picture Note:

A-Speed Control Bar Lock

B-Speed Control Bar

Operating

Daily Operating Checklist

C-Left Motion Control Lever

D-Right Motion Control Lever

E-Hydrostatic Oil Reservoir Cap and Dipstick

F-Ignition Key Switch

Make sure all necessary guards and shields are safely and securely

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

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

area.

G-Fuel Tank Cap

Remove grass and debris from machine and mower deck.

H-PTO Switch

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

belt compartment, hydraulic pump and pump mounting plate.

I-Optional Light Switch Location

J-Hourmeter

Test park brake.

Operating - 7

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OPERATING

K-Choke

Mounting and Dismounting Machine Safely

L-Throttle Lever

M-Park Brake Lever

Mower Deck Controls

MX20095

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

machine.

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

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

MX20093

A-Mower Deck Lift Levers

B-Height-of-Cut (HOC) Pin

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

debris.

Miscellaneous Controls

Raising and Lowering Thigh Pad

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

MX20094

A-Free-Wheeling Valves

MX20096

2. Raise and lower thigh pad (A) as required.

Adjusting Mower Deck Cutting Height

The mower deck height adjustment consists of seven different cutting

heights. The cutting heights range from 38-114 mm (1-1/2-4-1/2 in.) in 13

mm (1/2 in.) increments.

CAUTION: Avoid injury! Before adjusting cutting height,

stop engine and lock the park brake.

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

2. Disengage PTO.

Operating - 8

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OPERATING

3. Stop engine and lock park brake.

NOTE: Discharge chute raised for clarity.

MX20139

MX20099

2. Position right mower blade (A) (discharge side) perpendicular to

direction of travel.

4. Remove retaining ring (A) from HOC pin (B).

5. Push down on deck lift lever (C).

6. Remove HOC pin.

NOTE: Use a short ruler or a leveling gauge to check the mower

blade level.

7. Place HOC pin in desired height hole (D).

8. Release deck lift lever (C).

3. Measure distance (B) from outside blade tip to the ground.

4. Position left mower blade perpendicular to direction of travel.

5. Measure from outside blade tip to the ground.

9. Install retaining ring (A) in HOC pin (B).

10. Repeat procedure for opposite side.

• The difference between both measurements should be no greater than

3 mm (1/8 in.).

Leveling Mower Deck

6. If side-to-side level is not within the tolerance, an adjustment is

necessary.

CAUTION: Avoid injury! Rotating blades are dangerous.

Before adjusting or servicing mower:

Adjusting Level (Side-to-Side)

NOTE: When adjusting U-bolts, maintain a minimum clearance of 3

Disconnect spark plug wire(s) or battery negative (-) cable

to prevent engine from starting accidently.

mm (1/8 in.) between mower deck and stop pads.

Always wear gloves when handling mower blades or

working near blades.

NOTE: Mower deck anti-scalp wheels should not contact the ground.

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

2. Inflate tires to the correct pressure.

3. Inspect mower blades for:

• Blade sharpness.

• Blade damage.

• Bent blades.

Checking Level (Side-to-Side)

MX20099

NOTE: Mower deck anti-scalp wheels should not contact the ground.

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

Adjust four U-bolts (C) (two on each side of deck) until deck is within 3 mm

(1/8 in.) of level from side-to-side.

Operating - 9

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OPERATING

MX20100

MX20099

a. Loosen jam nuts (D) and adjust nuts (E) on each U-bolt until side-to

side level is reached.

1. Loosen jam nut (H) on both deck lift assist rods.

2. Adjust front-to-rear mower level:

b. Tighten jam nuts (D).

• Turn nut (I) on both sides clockwise to raise front of mower deck, or

counterclockwise to lower front of mower deck.

Checking Level (Front-to-Rear)

3. Verify that the adjustment on right and left sides is equal.

4. Tighten jam nuts (H).

1. Set height-of-cut (HOC) to the 76 mm (3 in.) cutting height position.

NOTE: The height of the rear blade tip should be between 3-6 mm (1/

8-1/4 in.) higher than the front blade tip.

5. Check front-to-rear mower level.

Checking and Adjusting Cutting Height

CAUTION: Avoid injury! Rotating blades are dangerous.

Before adjusting or servicing mower:

•Disconnect spark plug wire(s) or battery negative (-)

cable to prevent engine from starting accidentally.

•Always wear gloves when handling mower blades or

working near blades.

Checking Overall Cutting Height

1. Inflate tires to correct pressure.

MX20122

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

2. Position right mower blade (F) (discharge side) parallel to the direction

of travel.

3. Position right mower blade (discharge side) parallel to the direction of

travel.

3. Measure distance (G) from front blade tip to the ground.

4. Measure from the front of the blade tip to the ground.

4. Turn blade 180° and measure from rear blade tip to the ground.

5. If blade tip height is not within 73-79 mm (2-7/8-3-1/8 in.), an

adjustment is needed.

5. If the front-to-rear level is not within the tolerance, an adjustment is

necessary.

Adjusting Level (Front-to-Rear)

IMPORTANT: Avoid damage: Adjust the left and right deck lift

assist rods equally.

NOTE: Adjust side-to-side mower level before adjusting front-to-rear

level.

Adjust both sides of the mower deck equally.

All lift chains must remain taut.

Operating - 10

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OPERATING

Adjusting Overall Cutting Height

Testing Safety Systems

NOTE: When adjusting U-bolts, maintain a minimum clearance of 3

mm (1/8 in.) between mower deck and stop pads.

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Adjust both sides of the mower deck equally.

All lift chains must remain taut.

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.

Use the following checkout procedures to check for normal operation of

machine.

MX20099

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

machine. See your authorized dealer for service.

1. Adjust four U-bolts (A) (two on each side of deck) until blade tip height is

within 73-79 mm (2-7/8-3-1/8 in.) of the 76 mm (3 in.) setting.

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

Adjusting Mower Deck Anti-Scalp Wheels

Testing PTO Switch

NOTE: The flattest cut can be achieved by having all anti-scalp

wheels adjusted off the ground. Check anti-scalp wheel adjustments

each time the mower deck cutting height is changed.

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

position.

2. Lock park brake.

It is recommended that all anti-scalp wheels be kept off the ground to

minimize scuffing.

3. Pull PTO switch up to engage.

4. Turn key switch to the start position.

Result: The engine must not crank.

1. Inflate tires to correct pressure.

2. Adjust mower deck to desired cutting height.

Testing Park Brake Switch

1. Push PTO switch down to disengage.

2. Unlock park brake.

3. Turn key switch to the start position.

Result: The engine must not crank.

Testing Neutral Switch (Start)

1. Lock park brake.

2. Push PTO switch down to disengage.

3. Push one motion control lever forward.

4. Turn key switch to the start position.

Result: The engine must not crank.

MX15658

3. Adjust anti-scalp wheel (A) to one of three positions (D).

• Remove screw (E), nut (C) and washer (B).

Testing Neutral Switch (Run)

1. Lock park brake.

• Adjust wheel up or down so it is approximately 6–13 mm (1/4–1/2 in.)

above mowing surface.

2. Push PTO switch down to disengage.

3. Start engine.

4. Install wheel with attaching hardware.

5. Adjust all wheels to the same height.

4. Push one motion control lever forward.

5. Repeat procedure using the other lever.

6. Repeat procedure pushing each motion control lever rearward.

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

position.

Operating - 11

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OPERATING

Testing Operator Presence Switch

Using Park Brake

NOTE: Ensure OPC switch bracket is depressed when standing on

operator’s station.

Locking Park Brake

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

position.

2. Start engine.

3. Unlock park brake.

4. Step completely off operator’s platform.

Result: The engine must stop.

NOTE: Ensure OPC switch bracket is depressed when standing on

operator’s station.

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

position and start engine.

MX20102

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

CAUTION: Avoid injury! Thrown objects can be dangerous.

Before operating the attachment:

Unlocking Park Brake:

Clear area of bystanders, especially children.

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

Pick up objects which may be thrown by the attachment.

Using the PTO

6. Pull PTO switch up to engage.

7. Step completely off operator’s platform.

Result: The engine must stop.

Engage PTO:

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

position.

2. Start engine.

Testing the Park Brake

3. Release park brake.

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

MIF

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

engine and lock the park brake.

MX12854

2. Repeat procedure with machine facing uphill.

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

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.

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

Disengage PTO:

1. Push PTO knob (A) down.

2. Set park brake.

Operating - 12

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OPERATING

Using the Throttle

Neutral Position

MX12847

MX20091

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.

Using the Hourmeter

Forward and Reverse Motion:

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.

MX20091

•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:

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 - 13

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OPERATING

Forward:

Gentle Right Turn:

MX12791

MX12788

• 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:

MX12792

MX12789

• 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:

MX12790

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

lever.

MX12793

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

rearward at the same time.

Operating - 14

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OPERATING

Starting Engine

Engaging Mower

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

CAUTION: Avoid injury! Clear mowing area of all bystanders

when operating this machine. Thrown objects could cause

serious injury or death.

Move the machine to an outside area before running the

engine.

Keep hands and feet away from blades and discharge

opening.

Do not run an engine in an enclosed area without adequate

ventilation.

Do not mow in reverse unless absolutely necessary.

• Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

IMPORTANT: Avoid damage! To help prevent damage to PTO

clutch:

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

exhaust fumes out.

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

1. Stand on operator’s platform.

1. Adjust mower deck to desired cutting height.

2. Lock park brake.

2. Start engine.

MX20091

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

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

4. Unlock park brake.

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

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

position.

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

operating temperature before engaging PTO to prevent engine from

stalling.

6. Position choke knob (D):

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

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

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

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

9. With engine started:

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.

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

speed.

• Push choke knob to the OFF position.

• Move throttle lever to the FAST position.

• Unlock park brake.

Stopping the Engine

IMPORTANT: Avoid damage! To help prevent engine backfiring,

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

stopping the engine.

Do not stop engine when mower is on 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.

2. Reduce engine speed to half-throttle.

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

4. Remove key.

Operating - 15

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OPERATING

Using Pump Free-Wheel Valves

3. Stop engine and lock park brake.

4. Remove key.

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

the machine will have unrestricted motion.

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

front and rear straps must be directed downward and outward from

machine.

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

wheeling valve is opened with the machine on an incline.

Mowing Tips

• Park the machine on a level surface before opening the

free-wheeling valve.

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

• Cut grass when it is dry.

• Keep mower deck and discharge chute clean.

• Mow with sharp blades.

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.

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

(closed) during normal machine operation.

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

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

pump free-wheel valves:

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

Practice smooth control lever movements.

1. Lock park brake.

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

to stop and twist on grass.

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

the rear shield (B).

Mowing Travel Speeds

Use slow travel speeds for:

• Slopes.

• Trimming.

• Close quarters.

• Tall grass.

Use faster travel speeds for:

• Normal mowing on level ground.

Dismounting to Inspect Mower

MX20094

CAUTION: Avoid injury! Help prevent serious injury. Keep

hands and feet away from blades and the discharge opening.

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

one full turn (open position).

• 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.

3. Unlock park brake.

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

machine will move slowly.

1. Park machine on a hard, level surface.

2. Disengage PTO.

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.).

3. Move motion control levers to the neutral position.

4. Lock park brake.

6. Lock park brake.

Transporting Machine on a Trailer

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

signs and lights required by law.

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

before leaving operator’s position.

CAUTION: Avoid injury! Use extra care when loading or

unloading the machine into a trailer or truck.

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

1. Raise mower deck to the transport position.

2. Drive machine onto a trailer.

Operating - 16

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SERVICE INTERVALS

Every 500 Hours

Service Intervals

• Change hydraulic oil and filter.

Servicing Your Machine

Yearly

IMPORTANT: Avoid Damage! Operating in extreme conditions

may require more frequent service intervals:

• Change fuel filter.

• Clean battery.

• Engine components may become dirty or plugged when

operating in extreme heat, dust or other severe conditions.

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

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

• Replace spark plugs.

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

slow or low engine speeds or with frequent short trips.

Please use the following timetables to perform routine maintenance on

your machine.

Service Lubrication

Servicing Engine

Grease

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

for engine service information.

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).

Break-In (After First 10 Hours)

• Check air pressure in tires.

• If operating outside that temperature range, contact your

servicing dealer for a special-use grease.

• Check wheel bolt torque.

Use a general all-purpose grease with an NLGI grade No.2 rating.

• Check and adjust park brake.

• Change engine oil and filter.

Wet or high speed conditions may require use of a special-use grease.

Contact your Servicing dealer for information.

• Check mower deck drive belt tension.

• Check hydraulic pump drive belt.

• Check transmission neutral adjustment.

Lubricating Front Caster Spindles and Wheels

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 lift pivot tubes.

• Lubricate mower deck idler pivot.

• Lubricate mower deck push arms.

• Check mower deck drive belt tension.

• Lubricate hydraulic pump idler pivot.

• Check hydraulic pump drive belt.

• Check hydraulic fluid level.

MX15286

• 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.

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.

Service Intervals - 17

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SERVICE ENGINE

Lubricating Deck Lift Pivot Points

Lubricating Mower Deck Idler Pivot

MX20106

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

MX20104

Lubricating Mower Deck Push Arms

• Lubricate two front deck lift pivot grease fittings (A) and two rear deck lift

pivot grease fittings (B).

Lubricating Pump Idler Pivot

MX20107

• Lubricate two push arm grease fittings (A), one located on each side of

the machine.

MX15095

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

Service Engine

Lubricating Mower Deck Spindles

Avoid Fumes

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.

Do not run an engine in an enclosed area without adequate

ventilation.

• Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

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

exhaust fumes out.

Engine Oil

MX15287

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

period between oil changes.

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

Use oil that meets the following specification:

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

machine for the correct specifications.

Service Engine - 18

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SERVICE ENGINE

Checking Engine Oil Level

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

machine is used in extreme conditions:

IMPORTANT: Avoid Damage! Failure to check the oil level

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

Extremely dusty conditions.

Frequent slow or low-speed operation.

Frequent short trips.

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.

1. Clean area around dipstick cap and filter.

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.

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

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

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

MX201858

4. Put oil drain pan under drain tube.

5. Remove plug (A).

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

MX20155

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

7. After oil drains, install and securely tighten drain plug (A).

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

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

level.

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

not tighten the cap.

IMPORTANT: Avoid Damage! To prevent extensive engine wear or

damage, always maintain the proper engine oil level. Never

operate the engine with the oil level below the add mark or over

the full mark.

6. Remove dipstick and check oil level on dipstick. Oil must be between

the ADD and FULL marks.

NOTE: Refer to engine manufacturers operating manual for correct

type and grade of oil.

MX20149

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

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

dipstick.

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

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

7. Install and tighten dipstick.

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

filter.

Changing Engine Oil and Filter

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

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

11. Raise thigh pad.

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.

12. Remove dipstick cap.

NOTE: Refer to engine manufacturers operating manual for correct

type and grade of oil.

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

Service Engine - 19

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SERVICE ENGINE

14. Insert dipstick. Tighten cap.

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.

Checking Spark Plug

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. Allow the engine to cool before

servicing or working near the 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

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.

cap.

IMPORTANT: Avoid Damage! To prevent extensive engine wear or

damage, always maintain the proper engine oil level. Never

operate the engine with the oil level below the add mark or over

the full mark.

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.

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

without overfilling.

Adjusting Carburetor

18. Insert dipstick. Tighten cap.

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

Cleaning Engine Air Intake Screen and Fan

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.

CAUTION: Avoid injury! Compressed air can cause debris to

fly a long distance.

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

section of this manual.

Clear work area of bystanders.

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.

Wear eye protection when using compressed air for

cleaning purposes.

After performing the checks in the troubleshooting section and your

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

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

Replacing Fuel Filter

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.

CAUTION: Avoid injury! Fuel vapors are explosive and

flammable:

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.

• Do not smoke while handling fuel.

• Keep fuel away from flames or sparks.

• Shut off engine before servicing.

• Cool engine before servicing.

Checking and Cleaning Air Filter Elements

• Work in a well-ventilated area.

• Clean up spilled fuel immediately.

CAUTION: Avoid injury! Touching hot surfaces can burn

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

engine has been running. Allow the engine to cool before

servicing or working near the engine and components.

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

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

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

through a damaged filter element:

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

2. Allow engine to cool.

• Do not wash paper element.

• Do not attempt to clean paper element by tapping against

another object.

• Do not use pressurized air to clean element.

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

cracked.

NOTE: It may be necessary to check the air filter more frequently if

Service Engine - 20

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SERVICE TRANSMISSION

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

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

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

crosshatch area between ADD and FULL marks.

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

dipstick.

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

6. Insert dipstick. Tighten cap.

Changing Hydraulic Oil and Filter

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.

MX20149

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

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

hoses.

5. Disconnect hoses from fuel filter (B).

6. Install new fuel filter (B).

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.

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

fuel flow.

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

8. Install hose clamps (A).

IMPORTANT: Avoid Damage! Contamination of hydraulic fluid

could cause transmission damage or failure. Do not open oil

reservoir cap unless absolutely necessary.

9. Start engine and check for fuel leaks.

Severe or unusual conditions may require a more frequent

service interval.

Service Transmission

Hydraulic Oil

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

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

2. Allow engine and hydraulic oil reservoir to cool.

Checking Hydraulic Oil Level

IMPORTANT: Avoid Damage! Check oil level in reservoir tank

when oil is cold.

Do not overfill oil reservoir tank. Oil will expand during operation

and could overflow.

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

MX13362

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

4. Turn metal cap (A) on bottom of hydraulic reservoir counterclockwise to

remove.

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

3.8L (1.0 gal).

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

MX20114

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

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

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

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

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

9. Remove dipstick cap from hydraulic reservoir filler neck.

Service Transmission - 21

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SERVICE TRANSMISSION

Checking and Replacing Pump Traction Drive Belt

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.

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: 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.

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

Belt is self-adjusted using a spring tensioner.

12. Start engine.

Checking Traction Drive Belt:

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

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

14. Unlock park brake.

CAUTION: Avoid injury! Help prevent serious bodily injury.

Remain alert to other people and the surroundings when

operating the machine.

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

Check for leaks around filter.

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

FULL mark on dipstick.

Cleaning Hydraulic Oil Pump Cooling Fins

MX20126

CAUTION: Avoid injury! Compressed air can cause debris to

fly a long distance.

2. Remove four cap screws (A).

• Clear work area of bystanders.

3. Remove rear shield (B).

• Wear eye protection when using compressed air for

cleaning purposes.

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

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

cooling fins clean at all times. Operating the machine with

obstructed cooling fins could cause damage due to overheating.

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

MX20111

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

damage or stretching.

Removing Traction Drive Belt:

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

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

in the SERVICE MOWER section.)

MX20126

2. Remove four cap screws (A).

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

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

brush or compressed air.

5. Clean area around hydraulic pumps and frame.

Service Transmission - 22

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SERVICE TRANSMISSION

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

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

for additional clearance to install traction drive belt.

3. Install rear shield.

4. Install mower deck drive belt.

Checking and Adjusting Motion Control Linkages

CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the

engine.

MX20126

Do not run an engine in an enclosed area without adequate

ventilation.

3. Remove four cap screws (A).

Connect a pipe extension to the engine exhaust pipe to

direct the exhaust fumes out of the area.

4. Remove rear shield (B).

Allow fresh outside air into the work area to clear the

exhaust fumes out.

CAUTION: Avoid injury! Tensioning spring is under high

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

puller to install and remove spring.

NOTE: Check and adjust motion control linkages with the machine

parked on a hard, level surface.

Checking Motion Control Linkages:

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

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:

MX20109

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

NOTE: Install the traction drive belt (E) in front of anchor cap screw

(F).

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).

NOTE: Check machine tracking after making adjustments.

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

CAUTION: Avoid injury! Be aware of bystanders.

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

move the motion control levers (B).

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

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

moved.

MX20168

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

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

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

Service Transmission - 23

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SERVICE TRANSMISSION

Adjusting Motion Control Return to Neutral (RTN) Linkages:

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

surface.

Checking Transmission Tracking:

CAUTION: Avoid injury! Fingers or loose clothing can get

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

parts to stop before servicing.

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

Motion Control Linkages in the SERVICE TRANSMISSION section.

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

1. Stop engine.

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

2. Lock park brake.

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

frame.

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

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

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

adjustment is required.

7. Stop engine.

MX20109

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:

MX20161

Picture Note: Side frame removed for picture clarity.

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

machine.

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

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

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

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

until wheel rotation stops.

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

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

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

wheel rotation stops.

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

drives in a straight line.

9. Tighten cap screw (A).

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

Adjusting Forward and Reverse Speeds

Adjusting Forward Speed:

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

adjustment.

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

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

neutral switch.

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.

Service Transmission - 24

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SERVICE STEERING & BRAKES

4. Tighten nuts (A).

Service Steering & Brakes

Adjusting Park Brake

Testing Park Brake:

1. Inflate tires to correct pressures.

MX20115

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

movement when decreasing forward speed.

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

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

operator’s station.

MX12874

2. Stop machine on a maximum 17° slope.

3. Lock park brake.

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

from operator’s station).

3. Tighten lock lever (B).

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

turning.

Adjusting Reverse Speed:

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

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.

Adjusting Park Brake:

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

2. Unlock park brake.

Adjust Neutral Switch

MX20116

3. Loosen jam nut (A).

4. Remove hair pin and washer (B).

MX20161

Picture Note: Side frame removed for picture clarity.

5. Turn brake linkage rod (C) in one-turn increments clockwise to increase

braking force; counterclockwise to decrease braking force.

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

6. Install hair pin and washer (B).

7. Tighten jam nut (A).

2. Loosen nuts (A).

3. Adjust neutral switch (B).

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

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

down in slots.

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

in slots.

Service Steering & Brakes - 25

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SERVICE MOWER

MX20117

Service Mower

2. Remove belt shield locking knobs (A).

Removing and Installing Mower Deck Shield

3. Remove belt shields (B) by sliding shield from mower deck stud.

Installing Belt Shields:

CAUTION: Avoid injury! Help prevent serious personal injury.

Do not operate the mower without the mower deck shield

installed.

1. Install belt shields (B) by sliding shield over mower deck stud.

2. Install belt shield locking knobs (A).

Adjusting Drive Belt Tension

Removing Mower Deck Shield:

1. Park machine safely.

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

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

3. Remove mower deck shield.

MX20105

2. Remove two knobs (A).

MX20118

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

frame.

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

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

4. Remove mower deck shield (B).

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

Tighten jam nut (B).

Installing Mower Deck Shield:

1. Insert rear of shield (B) under tabs on frame and lower shield into

position.

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

counterclockwise. Tighten jam nut (B).

2. Secure with knobs (A).

Replacing Mower Deck Drive Belt

Removing and Installing Mower Deck Drive Belt Shields

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.

CAUTION: Avoid injury! Help prevent serious personal injury.

Do not operate the mower without the belt shields installed.

Removing Belt Shields:

4. Remove both mower deck belt shields.

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

CAUTION: Avoid injury! Tensioning spring is under high

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

puller to install and remove spring.

Service Mower - 26

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SERVICE MOWER

Installing Mower Deck Drive Belt:

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

MX20118

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

counterclockwise until two threads remain protruding through adjuster nut

(A).

MX20160

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

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.

MX20120

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

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

8. Remove mower deck drive belt (F).

MX20118

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

CAUTION: Avoid injury! Mower blades are sharp. Always

wear gloves when handling mower blades or working near

blades.

Replace blades if defective. Never straighten or weld them.

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

2. Raise mower to highest position to access blades.

Service Mower - 27

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SERVICE MOWER

MX20122

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

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

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

flat ground surface.

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

more than 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

Service Mower - 28

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SERVICE ELECTRICAL

• Keep original bevel (A) when grinding.

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

• Balance blades before installing.

Balancing Blades

CAUTION: Avoid injury! Mower blades are sharp. Always wear

gloves when handling mower blades or working near blades.

1. Clean blade.

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

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

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

Service Electrical

WARNING: Battery posts, terminals and related accessories contain lead

and lead components, chemicals known to the State of California to cause

cancer and reproductive harm. Wash hands after handling.

Service the Battery Safely

Service Electrical - 29

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SERVICE ELECTRICAL

CAUTION: Avoid injury! Battery electrolyte contains sulfuric

acid. It is poisonous and can cause serious burns:

• Wear eye protection and gloves.

• Keep skin protected.

• If electrolyte is swallowed, get medical attention

immediately.

• If electrolyte is splashed into eyes, flush immediately

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

• If electrolyte is splashed onto skin, flush immediately

with water and get medical attention if necessary.

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

The battery produces a flammable and explosive gas. The

battery may explode:

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.

• 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.

Installing:

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.

Checking the Battery (Sealed Batteries)

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

attempt to do so will void warranty.

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

(H). Do not overtighten.

• Keep battery and terminals clean.

• Keep battery bolts tight.

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).

• Keep small vent holes open.

Cleaning Battery and Terminals

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.

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

2. Disconnect and remove battery.

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

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.

Removing and Installing Battery

Removing:

4. Rinse the battery with plain water and dry.

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

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

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

corrosion.

7. Install battery.

Using Booster Battery

CAUTION: Avoid injury! The battery produces 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.

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

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

Service Electrical - 30

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SERVICE MISCELLANEOUS

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

• Install new 20 Amp fuse in socket.

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

securely fastened to fuse socket.

Service Miscellaneous

Using Proper Fuel

Use regular 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.

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

used within approximately 30 days, or add fuel stabilizer.

A - Booster Battery

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.

B - Disabled Vehicle Battery

1. Connect positive (+) booster cable to booster battery (A) positive (+)

post (C).

2. Connect the other end of positive (+) booster cable to the disabled

vehicle battery (B) positive (+) post (D).

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.

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

(E).

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

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

exposed to sun and heat.

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.

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 negative booster cable away from moving parts in the

engine compartment, such as belts and fan blades.

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.

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.

Filling Fuel Tank

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

negative cable first and then the positive cable.

CAUTION: Avoid injury! Fuel vapors are explosive and

flammable:

Replacing Fuse

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

• Shut engine off before filling fuel tank.

• Do not smoke while handling fuel.

IMPORTANT: Avoid Damage! Help prevent machine circuit

damage. Make sure replacement fuse is the correct size.

• Keep fuel away from flames or sparks.

• Fill fuel tank outdoors or in well ventilated area.

• Clean up spilled fuel immediately.

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

• 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.

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

Service Miscellaneous - 31

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SERVICE MISCELLANEOUS

Installing:

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

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

damage:

2. Install and tighten wheel nuts alternately until recommended torque

value is reached.

• Clean dirt and debris from the fuel tank opening.

• Use clean, fresh, stabilized fuel.

• Tighten nuts to 102 N•m (75 lb-ft).

3. Lower machine.

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

condensation out of the fuel tank.

Removing and Installing Front Caster Wheels

Removing:

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

the fuel tank or container.

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

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

and freezing during cold weather.

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

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

2. Allow engine to cool.

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

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

escape.

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

6. Install fuel tank cap.

Removing and Installing Rear Drive Wheels

Removing:

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

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

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).

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

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

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

installation. Tighten alternately until recommended torque value is

reached.

3. Remove wheel nuts (B).

4. Remove wheel.

Service Miscellaneous - 32

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SERVICE MISCELLANEOUS

Checking Tire Pressure

CAUTION: Avoid injury! Explosive separation of tire and rim

parts is possible when they are serviced incorrectly:

Do not attempt to mount a tire without the proper

equipment and experience to perform the job.

Do not inflate the tires above the recommended pressure.

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

cause an increase in air pressure resulting in an

explosion. Welding can structurally weaken or deform the

wheel.

3. Remove locknut (A), cap screw (B), two seal spacers (C) and wheel

assembly (D).

NOTE: Bearing races (G) are pressed in place and will be damaged

when removed. Do not remove bearing races (G) unless they need to

be replaced with new.

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.

4. Remove seals (E), bearings (F) and if needed, bearing races (G) from

wheel.

1. Check tires for damage.

5. Clean and inspect bearings (F) and races (G). Replace as needed.

6. Repack bearings with clean grease.

2. Check tire pressure with an accurate gauge.

3. Add air, if necessary:

7. Install bearings (F) and races (G) (if removed), and new seals (E).

8. Install wheel assembly (D), two seal spacers (C), cap screw (B) and

locknut (A).

Tire Size

Pressure

Front: 13 x 5-6

Rear: 20 x 10-8

Rear: 20 x5.3C

110–138 kPa (16–20 psi)

69–97 kPa (10–14 psi)

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

(E).

10. Lower machine.

Cleaning and Repairing Plastic Surfaces

Servicing Caster Wheel Roller Bearings

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.

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

2. Raise and securely support front of machine.

IMPORTANT: Avoid Damage! Improper care of machine plastic

surfaces can damage that surface:

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

result in minor surface scratches.

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

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

plastic surfaces.

Do not spray insect repellent near machine.

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

soap.

Service Miscellaneous - 33

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TROUBLESHOOTING

2. Dry thoroughly to avoid water spots.

Check

Cleaning and Repairing Metal Surfaces

Cleaning:

Engine Will Not Start Or Is

Hard To Start

• Park brake lever not in the proper

position.

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.

• Check that motion control levers are in

neutral and neutral switches are

correctly adjusted.

Repairing Minor Scratches (surface scratch):

• PTO engaged.

1. Clean area to be repaired thoroughly.

• Stale or improper fuel/fuel level.

• Plugged fuel filter.

IMPORTANT: Avoid damage! Do not use rubbing compound on

painted surfaces.

• Plugged air intake filter.

• Spark plug wires loose or

disconnected.

2. Use automotive polishing compound to remove surface scratches.

3. Apply wax to entire surface.

• Spark plugs not gapped correctly.

• Blown fuse.

Repairing Deep Scratches (bare metal or primer showing):

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

• Electrical problem – dead battery.

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.

• Choke adjusted incorrectly. See your

authorized dealer.

Engine Will Not Slow Idle

• Carburetion problems. See your

authorized dealer.

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

use power buffer.

• Bent or kinked throttle cable.

• Bent governor control.

4. Apply wax to surface.

• Incorrect governor idle control.

Troubleshooting

Engine Runs Rough or Stalls • Plugged fuel filter.

• Plugged air intake system.

Using Troubleshooting Chart

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

authorized dealer for service.

Fuel cap vent dirty.

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

experiencing the problem, see your authorized dealer.

• Stale or improper fuel/fuel level.

• Spark plugs not gapped correctly.

• Replace spark plugs.

Engine

• Choke adjusted incorrectly. See your

authorized dealer.

Check

Poor Engine Performance

Fuel:

Engine Knocks

• Engine oil level low.

• 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.

• Reduce load. (Slower ground speed.)

• Fuel is bad. Fill tank with fresh fuel,

correct octane.

• Idle speed too slow.

Engine Overheats

• Clean cooling fins.

• Low oil level.

• 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.

• Do not operate at slow idle. Operate

at fast idle.

• Cooling air intake screen is dirty.

• Plugged carburetor air intake filter.

• Plugged air intake filter.

• Operating at too fast ground speed for

conditions.

Troubleshooting - 34

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TROUBLESHOOTING

Check

Engine Lacks Power

• Reduce load.

Starter Turns Slowly

• Loose or corroded battery

connections.

• Plugged air intake system.

• Plugged fuel filter.

• Low battery power-charge battery.

• Engine oil viscosity too heavy.

• Improper type of fuel. Drain tank and

fill with correct fuel.

• Hydraulic pump linkage out of

adjustment-pumps engaged.

• Clean cooling fins to help prevent

overheating.

Machine

• Replace spark plugs.

Check

Engine Uses Too Much Oil

• Find and correct oil leaks.

• Incorrect engine oil.

Excessive Machine Vibration • Engine speed too slow.

• Plugged oil filter.

• Deck drive belt not tensioned

correctly.

• Plugged air intake filter.

• Worn engine components.

• Mower blades not balanced.

Machine Will Not Move With

Engine Running

• Park brake locked.

Engine Backfires Through

Muffler

• Throttle lever should be at low idle for

thirty seconds before turning off

machine.

• Transmission oil level low.

• Transmission oil cold – allow engine to

warm up.

High Fuel Consumption

• Improper type of fuel.

• Pump drive belt slipping or broken.

• Pump drive belt spring broken.

• Pump free-wheel valves open.

• Plugged air intake system.

• Operating at too fast ground speed for

conditions.

• Improper valve clearance. See your

authorized dealer.

• Transmission problems. See your

authorized dealer.

• Restricted air intake system.

Machine Creeps With Engine • Needs motion control linkage

Running and Motion Control

Levers in a Neutral Position

adjustment.

Other Symptoms

• See engine manufacturer’s owner’s

manual provided with your machine for

additional information.

• Needs ? Adjustment.

Park Brake

Electrical System

Check

Park Brake Not Working

Correctly

• Park brake out of adjustment – adjust

linkage.

Starter Will Not Work

• Blown fuse.

• 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.

• PTO engaged.

• Hydrostatic transmission oil level low.

• Traction drive loose or broken.

• Hydraulic pump or wheel motor faulty.

• 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

• Blown fuse.

• PTO switch faulty.

Troubleshooting - 35

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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 - 36

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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 - 37

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SPECIFICATIONS

Connect Battery

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

Fuel System

CAUTION: Avoid injury! Prevent Battery Explosions:

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

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

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

• 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.

Steering and Brakes

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

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

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

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

battery to 16 degrees C (60 degrees F).

Tires

Rear (Model 647). . . . . . . . . . . . . . . . . . . . . . . . 20 x 8-8 (with 48 in. deck)

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 x 5-6

Rear (Models 657, 667). . . . . . . . . .20 x 10-8 (with 54 in. and 60 in. deck)

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

Inflation Front (Maximum) . . . . . . . . . . . . . . . . . .110–138 kPa (16–20 psi)

Battery

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

CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340-amp

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

BCI Group Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U1L

Capacities

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

terminal cover (A).

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)

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

black terminal cover (B).

Travel Speeds at Full Engine RPM

Check Mower Deck Level

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–14.8 km/h (0–9.2 mph)

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

The mower deck is assembled and adjusted at the factory. After machine

is completely assembled, check the mower front-to-rear and side-to-side

deck level.

Dimensions

Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 m (52 in.)

Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 m (45 in.)

Overall Length (Model 647) . . . . . . . . . . . . . . . . . . . . . . . . 1.6 m (65.5 in.)

Overall Length (Model 657 and Model 667) . . . . . . . . . . . 1.7 m (68.5 in.)

Overall Width (48 inch deck with chute up) . . . . . . . . . . 1.36 m (53.5 in.)

Overall Width (48 inch deck with chute down) . . . . . . . . . . 1.57 m (62 in.)

Overall Width (54 inch deck with chute up) . . . . . . . . . . 1.46 m (57.5 in.)

Overall Width (54 inch deck with chute down) . . . . . . . . . . 1.73 m (68 in.)

Overall Width (60 inch deck with chute up) . . . . . . . . . . 1.61 m (63.5 in.)

Overall Width (60 inch deck with chute down) . . . . . . . . . . 1.88 m (74 in.)

Check Machine Safety Systems

Perform safety system check to make sure the electronic safety interlock

circuit is functioning properly.

Specifications

Engine

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

machine for engine specifications.

Drivetrain

Recommended Lubricants

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

Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydro-Gear BDP-10A

Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . . .Hydro-Gear HGD-12-1792

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

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)

Electrical System

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

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

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

(Specifications and design subject to change without notice.)

Specifications - 38

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GETTING QUALITY SERVICE

Getting Quality Service

Service Literature

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

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

operator manuals are also available online at GreatDaneMowers.com.

Parts

We recommend Great Dane quality parts available at your Great Dane

dealer.

Part numbers may change, use part numbers listed below when you order.

If a number changes, your dealer will have the latest number.

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

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

recorded in the Product Identification section of this manual.

Great Dane Quality Continues with Quality Service

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

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

authorized Great Dane dealer’s parts and service support.

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

about your product.

Refer to your attachment and machine operator manuals.

Contact your authorized Great Dane dealer with unanswered questions.

Part Numbers

Item

Part Number

Mower Blades:

48-Inch Deck

54-Inch Deck

60-Inch Deck

GDU10230

GDU10231

GDU10232

Hydraulic Oil Filter

Battery

GDU10137

TY25221

57M7120

Fuse - 20 amp

Belts:

GDU10025

TCU18847

TCU18848

TCU18849

Hydraulic Drive Belt

48-Inch Mower Deck Belt

54-Inch Mower Deck Belt

60-Inch Mower Deck Belt

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

different outside the U.S.A.)

Getting Quality Service - 39

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SERVICE MISCELLANEOUS

Wiring Schematics

Service Miscellaneous

Service Miscellaneous - 40

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SERVICE MISCELLANEOUS

Service Miscellaneous

Kawasaki Wiring Schematics

Service Miscellaneous - 41

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SERVICE MISCELLANEOUS

Hydraulic Schematics

Service Miscellaneous

Left Hydrostatic Pump Assembly

Pump Block

Charge Relief Valve

Right Hydrostatic Pump Assembly

Charge Pump

Right Wheel Motor

Inlet Filter

System Charge Check Shock Valve (Reverse)

Manual Bypass

Hydraulic Reservoir

Left Wheel Motor

Cooling Orifice

System Charge Check Shock Valve (Forward)

Service Miscellaneous - 42

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SERVICE MISCELLANEOUS

Service Miscellaneous - 43

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MAIN FRAME, TRACTION DECK, CONSOLE AND OPC PLATFORM

Main Frame, Traction Deck, Console and OPC Platform - 44

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MAIN FRAME, TRACTION DECK, CONSOLE AND OPC PLATFORM

Ref. No.

Part No.

TCA14936

TCA14946

D15356

Description

Qty.

Remarks

W/ 48"-52" Deck

W/ 61" Deck

Frame -

Fender, Left

D15355

200038

Fender, Right

Weight

19M7270

19M7803

14M7396

JD7842

Cap Screw

Nut

Lubrication Fitting

Deck Shield Assembly

Knob

M8 x 1.25 x 65

M8 x 1.25 x 70

M8 x 1.25

200218

48" and 52" deck

61" deck

TCA15350

M119352

14M7299

TCA14912

TCA14919

TCA14918

TCA15348

D15368

TCA15060

TCA15371

D15305

TCA14856

03M7191

14M7400

19H1948

12H302

19M7784

19M7785

14M7400

19M7784

T34037

19M7784

14M7400

19M7784

M115279

Nut

M12 x 1.75

Control Console

Side Bracket, Left

Side Bracket, Right

Handle Mount

Plate, Thigh Pad

Pad, Thigh

Shield

Plate

Engine/Traction Deck

Carriage Bolt

Flange Nut, Locking

Cap Screw

Lock Washer

Cap Screw, Flange Head

Cap Screw

Flange Nut, Locking

Cap Screw, Flange Head

Cap Screw

Cap Screw, Flange Head

Flange Nut, Locking

Cap Screw, Flange Head

Plug

M10 x 1.5 x 25

M10 x 1.5

1/4" x 3/4"

1/4"

M10 x 1.5 x 20

M10 x 1.5 x 25

M10 x 1.5

M10 x 1.5 x 20

3/8"-16 x 3/4"

M10 x 1.5 x 20

M10 x 1.5

M10 x 1.5 x 20

Optional light switch hole

Main Frame, Traction Deck, Console and OPC Platform - 45

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DRIVE CONTROLS AND LINKAGE

Drive Controls and Linkage - 46

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DRIVE CONTROLS AND LINKAGE

Ref. No.

Part No.

D18069

200080

200081

D13029

14M7303

J16913

D13028

D38157

Description

Speed Limiter

Steering Controller, RH

Steering Controller, LH

Control Rod

Flange Nut

Qty.

Remarks

M6 x 1.0

Spring Pin

Swivel

Rod End

Grip

D18093

19M7547

14M7400

D13308

D13309

34H60

TCA15195

19M7862

14M7397

19M7785

191256

19H1905

200116

14H650

Cap Screw, Reverse Stop

Flange Lock Nut

Base, Speed Control Lock

Handle

M6 x 1.0 x 55

M10 x 1.5

25*

26*

27*

Spring Pin

5/32 x 1

Shaft, Pivot

Cap Screw

M6 x 1.0 x 20

M6 x 1.0

M10 x 1.5 x 25

Lock Nut

Cap Screw

Switch, Neutral

Cap Screw

5/16-18 x 1

Bushing

Jam Nut

5/16-24

19M7372

14M7360

D14081

Cap Screw

M5 x 0.8 x 16

M5 x 0.8

5/16-18

Nut

Lock Nut

TCU19201

TCU19202

TCU18929

TCU18931

TCU18932

TCU18930

TCU19203

TCU19204

TCU19209

TCU19205

TCU19206

TCU19207

TCU19208

24H1305

Arm, Control RTN

Arm, Return

Arm, RH Inner RTN

Arm, LH Inner RTN

Arm, LH Outer RTN

Arm, RH Outer RTN

Spacer

28*

29*

30*

31*

32*

33*

34*

35*

Spring

Screw

Washer

5/16 x 1 patch lock

Washer, Nylon

Lock Nut

5/16-24

Spacer

Washer

.406 x .812 x .065 Flat

* Included with new Hydrostatic Pump.

NOTES

Drive Controls and Linkage - 47

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PARK BRAKE

MX20211

Park Brake - 48

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PARK BRAKE

Ref. No.

Part No.

D18038

Description

Qty.

Remarks

Switch

19M7373

14M7360

K40003

19H1801

TCU12713

GDU10037

AM105809

TCU20956

D12352

Cap Screw

Nut

Lock Nut

Cap Screw

Spacer

M5 x 0.8 x 20

M5 x 0.8

3/8"-16"

3/8"-16 x 2"

Bushing

Swivel

Rod

Lever

Nut

Spring Pin

Roll Pin

Arm

Shaft

Bushing

Grip

14H846

J16931

34H268

3/8"

TCA15174

TCA15070

24H1413

D18079

24H1341

19M3804

14M7518

24H1305

M94087

0.891" x 1.375" x 0.048"

Washer

Cap Screw

Flange Lock Nut

Washer

Spacer Plate

Turn Buckle

17/32" x 15/16" x 0.060"

M10 x 1.5 x 40

M10 x 1.5

TCU20955

NOTES

Park Brake - 49

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HYDROSTATIC PUMP DRIVE AND PTO

Hydrostatic Pump Drive and PTO - 50

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HYDROSTATIC PUMP DRIVE AND PTO

Ref. No.

Part No.

GDU10025

TCA15316

D28091

GDA10017

GDA10006

D18314

GDA10004

D18403

GDA10005

D18071

D14213

E63526

403490

19H3031

14M7400

03M7191

D24022

D14252

D14208

22H907

D14160

D18067

19M7810

24H1305

03M7191

JD7842

K40003

D44003

D18145

D18056

200665

200666

960078

960022

967115

Description

Qty.

Remarks

V-Belt

Pulley, RH Pump

Pulley, Engine Drive

PTO Clutch

Bracket

Set screws included

All Units Except KAI

Idler

Idler Post

Bushing

Idler Arm

Spring, Idler

Cap Screw

Flange Nut

M10 x 1.5

Ring

Cap Screw

3/8" x 2-1/2"

Lock Nut

M10 x 1.5

Carriage Bolt

Cap Screw, PTO Clutch

Washer, Split Lock

Set Screw

M10 x 1.5 x 25

7/16" x 2.5" Kohler

7/16" x 3" Kawasaki

Washer

Key, Special

Cap Screw, Spring Anchor

Washer

Carriage Bolt

Grease Fitting

Lock Nut

M5 x 28

M10 x 1.5 x 80

M10 x 1.5 x 25

Washer

Key, Special

Spacer, PTO Clutch

PTO Clutch

Clutch Dog Plate

Bolt, Hex

7/16"-14 x .750

5/16"-18 x .750

5/16"-18

Bolt, Hex

Locknut

NOTES

Hydrostatic Pump Drive and PTO - 51

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HYDROSTATIC COMPONENTS

MX20223

Hydrostatic Components - 52

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HYDROSTATIC COMPONENTS

Ref. No.

Part No.

TCA15122

Description

Qty.

Remarks

Cap

TCA15373

D18379

TCA15078

D14196

Hydraulic Reservoir

Hose Clamp

Wheel Motor

Elbow Fitting, Pump End

Pump, LH

Pump, RH

Nut

Carriage Bolt, Pump Mounting

Oil Filter

Elbow Fitting

Lock Nut, Reservoir Mounting

Cap Screw, Reservoir Mounting

Tee Fitting

Includes decals

Includes O-ring

TCA14966

TCA14965

14M7518

03M7192

GDA10137

GDA10066

313270

14M7517

19M7784

M86863

D24028

D18394

TY22552

GDA10065

R26375

231647

231104

231046

D18206

200950

24M7158

11H237

TCU19166

M78480

D14280

Includes items 25-35 on page 5

M10 x 1.5

M10 x 1.5 x 30

—

M10 x 1.5

M10 x 1.5 x 20

Fitting

Hose, High Pressure

Hose, Return

Adapter

25 ft bulk (cut to length)

O-Ring

Included with fitting

Includes O-ring

90° Fitting, Upper

Straight Adapter, Lower

90° Fitting, Lower

Key

Hub

Washer

Cotter Pin

Castle Nut

Tie Straps

Bolt

Not shown

3/8-16 x 1

NOTES

Hydrostatic Components - 53

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HYDRAULIC SCHEMATIC

A - Left Hydrostatic Pump Assembly

B - Pump Block

C - Charge Pump

D - System Charge Check Shock Valve (Reverse)

E - Manual Bypass

F - Left Wheel Motor

G - Cooling Orifice

H - System Charge Check Shock Valve (Forward)

I - Charge Relief Valve

J - Right Hydrostatic Pump Assembly

K - Right Wheel Motor

MX20151

L - Inlet Filter

M - Hydraulic Reservoir

Hydraulic Schematic - 54

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PLATFORM COMPONENTS

ꢀꢁ

ꢀꢀ

ꢁ

ꢀꢄ

ꢀꢆ

ꢀꢃ

ꢀꢆ

ꢂ

ꢇ

ꢄ

ꢆꢆ

ꢈ

ꢆꢇ

ꢆꢀ

ꢀ

ꢀꢂ

ꢅ

ꢆꢉ

ꢀꢈ ꢆꢇ

ꢀꢇ

ꢀꢅ

ꢀꢉ

ꢆꢃ

ꢆꢇ

ꢃ

ꢆ

Ref. No.

Part No.

D18038

Description

Park Brake Switch

Qty.

Remarks

D38128

200299

200618

200619

200655

200691

200693

200767

200770

200935

960001

963074

960046

960055

960502

960701

963019

963033

964013

964048

967115

967340

968087

Com. Spring 1.22x.162x2.5

Platform Weldment

Platform Plate

Platform Tab LH Plate

Miner GBR-6 Bumper

Platform Wedge

Platform Tab Plate

OPC Anchor

Spring Washer

OPC Cover

Bolt

1/4-20 x .750 Hex Gr. 5

5/16-18 x 1.00

3/8-16 x 1.00 Hex Gr. 5

3/8-16 x 3.25 Hex Gr. 5

3/8-16 Hex Gr. 5

3/8 Reg. Flat

3/8-16 x 1.00

3/8-16 x 3/4

10-24 Nylock

1/4-20 Nyloc

Carriage Bolt

Bolt

Nut

Washer

Carriage Bolt

Locknut

Screw

Locknut

5/16-18 Nyloc

10-24 x .625 PAN PHL MAC

3/8-16 Nyloc

Platform Components - 55

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FUEL TANK AND LINES

MX20229

Fuel Tank and Lines - 56

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FUEL TANK AND LINES

Ref. No.

Part No.

TCA15021

181251

D18144

Description

Qty.

Remarks

Fuel Tank

Cap, Fuel

Grommet

No Lanyard

TCA15048

M68342

Fuel Pickup

Clamp

M88753

Hose, Fuel, 1/4 in. SAE 30-R7

Nut

Filter

Cap Screw

Bracket

10 Ft. Hose

14M7400

AM116304

03M7191

19M7865

TCU18489

NOTES

Fuel Tank and Lines - 57

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KOHLER ENGINE AND RELATED COMPONENTS

KOHLER Engine and Related Components - 58

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KOHLER ENGINE AND RELATED COMPONENTS

Ref. No.

Part No.

D28121

Description

Qty.

Remarks

Muffler

Gasket

TCA15389

X6PMTX-S

03M7188

19M8317

14M7396

14M7298

D18427

D18359

D24020

M63431

14H846

12M7032

Oil Drain Hose

Oil Drain Plug

Carriage Bolt, Engine Mounting

Cap Screw, Engine Mounting

Flange Lock Nut, Engine Mounting

Flange Nut, Muffler

Cable, Choke

M8 x 1.25 x 40

M8 x 1.25

Cable, Throttle

Bolt, Throttle Cable

Lock Nut, Throttle Cable

Nut, Choke Cable

0.164" x 1/2"

0.164"

3/8"

Washer

* NOTE: See authorized KOHLER servicing engine dealer for engines and engine related service items. Always

reference the engine model number when ordering parts.

NOTES

KOHLER Engine and Related Components - 59

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KAWASAKI ENGINE AND RELATED COMPONENTS

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KAWASAKI ENGINE AND RELATED COMPONENTS

Ref. No.

Part No.

TCA15321

191601

Description

Qty.

Remarks

Muffler

Gasket Kit,

Includes Items 2, 8, & 17

TCA16240

TCU19288

03M7188

19M8317

14M7396

12M7065

D18427

Oil Drain Fitting

Shield, Muffler

Carriage Bolt, Engine Mounting

Cap Screw, Engine Mounting

Flange Lock Nut, Engine Mounting

Lock Washer

M8 x 1.25 x 40

M8 x 1.25

5/16"

Cable, Choke

TCA15051

D24020

M63431

Cable, Throttle

Bolt, Throttle Cable

Lock Nut, Throttle Cable

Nut, Choke Cable

Bracket, Muffler Support Rh

Bracket, Muffler Support Lh

Washer, Helical Spring Lock

Nut

Screw, Hex, Iso4017

Screw, Hex, Fl

Screw, Flanged Metric

Shield, Heat

0.164" x 1/2"

0.164"

3/8"

14H846

TCU15761

TCU15762

12H303

14M7273

19M7139

19M7865

19M8040

191365

M8 x 1.25 x 20

M8 x 1.25 x 16

M6 x 60 (HS, Head Marked 10.9)

M146170

14M7298

Spacer

Nut

M8 x 1.25 Flange

* NOTE: See authorized Kawsaki servicing engine dealer for engines and engine related service items. Always

reference the engine model number when ordering parts.

NOTES

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KOHLER LOGIC SCHEMATIC

MX20146

NOTES

KOHLER Logic Schematic - 62

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KAWASAKI LOGIC SCHEMATIC

ꢍ ꢀ ꢈ J D < ( / / 2 :

ꢍ ꢀ ꢈ J D % / $ & . ꢋ :

% / 8 ( ꢍ ꢀ ꢈ J D ꢎ

% / 8 ( ꢍ ꢀ ꢈ J D

% / $ & . ꢍ ꢀ ꢈ J D

Kawasaki Logic Schematic - 63

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BATTERY, ELECTRICAL HARNESS AND COMPONENTS

Battery, Electrical Harness and Components - 64

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BATTERY, ELECTRICAL HARNESS AND COMPONENTS

Ref. No.

Part No.

TCA15061

200204

Description

Wiring Harness

Cap Screw

Nut

Qty.

Remarks

Main Kohler

Main Kawasaki

M5 x 0.8 x 16

M5 x 0.8

19M7372

14M7360

AM123716

57M7120

24H1283

AM129887

TCU13098

TCA15075

M110159

TCU17401

AM118802

M72685

D28159

200085

D18318

191227

14M7396

03M7184

H110730

03H1832

14M7396

N/A

Relay

Fuse

Washer

20A

Hour Meter

Clip

Key Switch

Nut

Ignition Key

Switch, PTO

Spacer

Isolator Pad

Battery Box

Cable, Positive

Cable, Negative

Flange Nut

Carriage Bolt

Flange Nut

Cap Screw

Nut

Dry Charged Battery

Adapter Assy, Kawasaki

Solenoid Mounting Plate

Start Solenoid

Starter Cable

Fusible Link

Capscrew, 1/4 x .75

Locknut, 1/4" Whiz

Battery

M8 x 1.25

M8 x 1.25 x 20

5/16"

5/16" x 6"

200074

200069

180640

180842

200924

960001

964040

12"

—

M78480

Tie Strap

Not shown

NOTES

Battery, Electrical Harness and Components - 65

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CASTER WHEELS AND REAR WHEELS

MX20207

Caster Wheels and Rear Wheels - 66

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CASTER WHEELS AND REAR WHEELS

Ref. No.

Part No.

TCU17863

Description

Spacer, Caster Bushing

Seal

Qty.

Remarks

E14625

D38035

D28051

11M7083

A12188

M135582

JD7844

D25004

D33007

D28097

D24008

D38009

TCA15086

19M7785

14M7518

D38065

TCA15147

TCA15148

JD26

Bearing Assembly, Caster Wheel

Bearing Assembly, Caster Yoke

Cotter Pin

Castle Nut

Cap, Bearing

Grease Fitting

Yoke

Spacer, Caster Wheel

Cap Screw

Nut

Caster Wheel and Tire Assembly

Caster Arm

Cap Screw

Nut

Seal

Wheel and Tire Assembly, Rear

Lug Nut, Rear Wheel

Cup and cone

1"-14

3/4"-16 x 8"

3/4"-16

Includes items 3 and 17

M10 x 1.5 x 25

M10 x 1.5

48" deck, 20 x 8-8 tire

52" & 61" deck, 20 x 10-8 tire

Not shown

—

NOTES

Caster Wheels and Rear Wheels - 67

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MOWER DECK LIFT LINKAGE

MX20232

Mower Deck Lift Linkage - 68

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MOWER DECK LIFT LINKAGE

Ref. No.

Part No.

D18225

E63526

GDA10010

GDA10009

P46402

24H1413

R27434

Description

Qty.

Remarks

Grip

Nut

M10 Nut

Lift Arm, LH Rear

Lift Arm, RH Rear

Snap Ring

Washer

Snap Ring

Nut

N10215

3/8"

150749

19M8162

GDU10048

Chain, Deck Lift

Cap Screw

U-Bolt

M10 x 1.5 x 40

3/4"

14H1058

TCU15817

200075

GDA10008

GDA10007

E63526

TCA14877

TCA14876

TCA14879

TCA14878

TCA14881

TCA14880

M83541

JD8744

19H3280

D24008

TCA13292

03M7185

14M7396

M137523

TCU15892

H143731

M88183

Nut

Rod, Deck Lift

Swivel

Lift Arm, LH Front

Lift Arm, RH Front

Nut

Thrust Arm, LH, 48" Deck

Thrust Arm, RH, 48" Deck

Thrust Arm, LH, 52" Deck

Thrust Arm, RH, 52" Deck

Thrust Arm, LH, 61" Deck

Thrust Arm, RH, 61" Deck

Bushing

Grease Zerk

Bolt

Nut

Pivot Pin, Thrust Arm

Bolt

Nut

Pin, Clevis

Bushing

M10 x 1.5

3/4-16 x 3 HHCS

3/4-16 PTHN

1/4-20 x 1 CHCS

1/4-20

Nut, Push

Ring, Locking

NOTES

Mower Deck Lift Linkage - 69

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MOWER DECK

MX20240

Mower Deck - 70

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MOWER DECK

Ref. No.

Part No.

TCA15385

Description

Mower Deck, 48" S/O

Mower Deck, 52" S/O

Mower Deck, 61" S/O

Bushing

Qty.

Remarks

TCA15386

TCA15387

TCU14540

TCU18344

TCU18847

TCU18848

TCU18849

TCU18744

200082

Support Strap

Belt, Engine-to-Blades, 48" Deck

Belt, Engine-to-Blades, 52" Deck

Belt, Engine-to-Blades, 61" Deck

Roller, Anti-Scalp

Belt Cover, LH

Belt Cover, RH

Knob, Belt Cover

Pivot, Anti-Scalp Roller

Bolt

48" and 52" deck

61" deck

48" and 52" deck

61" deck

TCU18413

200084

48" deck

52" deck

61" deck

TCU18411

TCU18413

M119352

GDA10103

03H1729

H122207

TCA15346

D18032

03H1658

24H1305

K40003

03H1836

AM128170

AM128243

M132768

H141123

03H1809

D23058

1/4-20 x 1 CHCS

1/4-20 PTFHN

Nut

Arm, Idler Engine-to-Blade

Pulley, Flat Tension Idler

Bolt

3/8-16 x 2-1/4 CHCS

3/8 SAE

3/8-16 PTHN

3/8-16 x 4.00 CHCS

48" deck

52" and 61" deck

Washer

Nut

Bolt

Discharge Chute

Spring, Torsional Discharge Chute

Clip, Retainer

Bolt

J-Hook

3/8-16 x 3-3/4 CHCS

N242189

14H1090

N10215

Spring, Deck Belt Tension

Nut

3/8-16 Nyloc

3/8-16 PTHN

Nut

D28050

Pulley, Flat Blade-to-Blade

Spacer, Blade-to-Blade Pulley

Bolt

TCU18742

03H1480

03H1853

3/8-16 x 1-1/4 CHCS

61" deck only, 1/2 x 4-1/2 x 13

CHCS

Bolt

E62934

JD7844

200095

Flange Lock Nut

Grease Zerk

Bracket, Chute Support

61" deck only, 1/2-13

48" Only

NOTES

Mower Deck - 71

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MOWER DECK SPINDLES

ꢀꢇ

ꢂ

ꢄ

ꢁ

ꢆ

ꢇ

ꢀꢀ

ꢀ

ꢃ

ꢈ

ꢆ

ꢅ

ꢀꢆ

ꢀꢃ

ꢀꢉ

Mower Deck Spindles - 72

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MOWER DECK SPINDLES

Ref. No.

Part No.

200262

200046

200042

200044

200196

200045

967333

D18209

D18084

D18211

D13024

967348

Description

Spindle Assembly

Ball Bearing

Qty.

Remarks

Includes items 2, 3, 4, 5, 6, 14

Housing

Spacer

1.000 x 1.250 x 2.772

Shaft, Spindle

Bolt

3/8-16 x 1.25 Rib

3/4-16 Flange

Nut, Pulley

Pulley, Cutter Housing, 48" Deck

Pulley, Cutter Housing, 52" Deck

Pulley, Cutter Housing, 61" Deck

Spacer, Pulley

Bolt, Blade

5/8-11 x 2 Grade 8

3/8-16 Std Hex Gr5

960502

Nut

D18055

GDU10230

GDU10231

GDU10232

959995

Spacer, Blade Bolt

16.5" Blade, 48" Deck

18.0" Blade, 52" Deck

21.0" Blade, 61" Deck

Zerk, Grease S/O

NOTES

Mower Deck Spindles - 73

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LABELS AND DECALS

Labels and Decals - 74

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LABELS AND DECALS

Ref. No.

Part No.

GDU10257

M137637

Description

Qty.

Remarks

Decal

"Great Dane"

Danger-Rotating Blades

No Step (61" only)

Warning-Avoid Tipover

Patent

Super Surfer Series II

Warning-Hot Surface

D28181

1841115907

TCU15909

TCU19020

M134406

TCU16323

TCU14840

TCU51051

M131739

D18372

M131748

GDU10267

GDU10268

GDU10269

TCU15910

TCU15911

TCU15912

D18021

Decal

Park Brake

General Caution

Danger-Rotating Belts

Danger-Blade Contact

Caution-Fire Hazard

Danger-Thrown Objects

48"

52"

61"

Directional Control

Cut Height, LH

Cut Height, RH

Throttle

Hydro Oil Reservoir

Warning-Hot Surface (Reservoir)

Warning-Hot Surface (Belt Cover)

PTO / Ignition

D18023

M117554

M134406

TCU16481

TCU18852

Belt Path

NOTES

Labels and Decals - 75

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