Great Dane GDB10028, GDB10025, GDB10027, GDB10030, GDB10029 User Manual
...
Scamper HG
GDB10025, GDB10026, GDB10027,
GDB10028, GDB10029, GDB10030
GD10003
B3
OPERATOR’S MANUAL
c WARNING: The Engine Exh aust
from this product contains chemicals known
to the State of California to cause cancer,
birth defects or other reproductive harm.
California Proposition 65 Warning
OMGD10003 B3
North American Version
Litho in U.S.A.
INTRODUCTION
Introduc tion
Using Your Operator’s Manual
This manual is an important part of your machine and
should remain with the machine when you sell it.
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.
Reading your operator’s manual will help you and others
avoid personal injury or damage to the machine.
Information given in this manual will provide the operator
with the safest and most effective use of the machine.
Sections in your operator’s manual are placed in a specific
order to help you understand all the safety messages and
learn the controls so you can operate this machine safely.
You can also use this manual to answer any specific
operating or servicing questions.
The machine shown in this manual may differ slightly from
your machine, but will be similar enough to help you
understand our instr uctions.
RIGHT-HAND and LEFT-HAND sides are determined by
facing in the direction the machine will travel when going
forw ard. When you see a broken line (------), the item
referred to is hidden from view.
GDB10026 (15 hp, Recoil, 48-Inch Deck) Serial No.
(TCHR15W010001-
GDB10027 (17 hp, Recoil, 48-Inch Deck) Serial No.
(TCHR17W010001-
GDB10028 (17 hp, Electric, 48-Inch Deck) Serial No.
(TCHE17W010001-
GDB10029 (17 hp, Recoil, 52-Inch Deck) Serial No.
(TCHR17W010001-
GDB10030 (17 hp, Electric, 52-Inch Deck) Serial No.
(TCHE17W010001-
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 below.
DATE OF PURCHASE:
_________________________________________
DEALER NAME:
_________________________________________
DEALER PHONE:
_________________________________________
Special Messages
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.
c 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 us ed t o 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.
Record Identification Numbers
Scamper HG
B
A
MX18836
MODEL NUMBER (A):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
SERIAL NUMBER (POWER UNIT) (A):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ENGINE SERIAL NUMBER (B):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ENGINE SPECIFICATION NUMBER (B):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
GDB10025 (15 hp, Recoil, 36-Inch Deck) Serial No.
(TCHR15W010001-
Introduction
TABLE OF CONTENTS
Table of Contents
Safety .....................................................................................................................................................................................1
Operating................................................................................................................................................................................7
Replacement Parts................................ .............................................. ...... ...........................................................................11
Service Intervals...................................................................................................................................................................12
Service Lubrication...............................................................................................................................................................13
Service Engine .....................................................................................................................................................................14
Service Tr ansmission............................................................................................................................................................16
Service Mower......................................................................................................................................................................18
Service Electrical..................................................................................................................................................................22
Service Miscellaneous..........................................................................................................................................................25
Troubleshooting ....................................................................................................................................................................27
Storage.................................................................................................................................................................................32
Assembly..............................................................................................................................................................................33
Specifications .......................................................................................................................................................................35
Index.....................................................................................................................................................................................36
Service Record GD ..............................................................................................................................................................37
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
John Deere Worldwide Commercial and
Consumer Equipment Division
notice.
COPYRIGHT© 2003
Deere & Co.
All rights reserved
Previous Editions
COPYRIGHT© 2002
OMGD10003 B3 - English
Table of Contents
SAFETY
Safety
Understanding The Machine Safety Labels
Safety-Alert Symbol
The machine safety labels shown in this section are placed
in important areas on your machine to draw attention to
potential safety hazards.
On your machine safety labels, the words DANGER,
WARNING, and CAUTION are used with this safety-alert
symbol. DANGER identifies the most serious hazards.
The operator’s manual also explains any potential safety
hazards whenever necessary in special safety messages
that are identified with the word, CAUTION, and the safetyalert symbol.
CAUTION
MX9295 M9261
• This product is designed for professional and
commercial users.
• Operation training is required.
• Carefully read safety instructions.
• Know function of controls before operating.
• Practice with cutter blades off until confident.
• Clear mowing area of all debris.
• Keep all guards, covers and shields in place while
working.
• Do not disable or bypass any safety device.
DANGER/POISON
MX9292 MX9261
• Shield eyes, explosive gases can cause blindness or
injury.
• No sparks, flames, smoking.
• Sulfuric acid can cause blindness or severe burns.
• Flush eyes immediately with water, get medical help
fast.
• Keep out of the reach of children.
• Do not tip.
• Always wear safety goggles while operating.
• Always park machine on level surface.
• Avoid contact with cutter blades. They may be rotating.
• Keep children and others clear from area.
• Set ground speed control to safe speed.
• Slowly and smoothly move speed control levers to start
and stop machine.
• Reduce speed and avoid sharp turns.
• Always hold on to safety bar while operating.
• Be careful on slopes, do not mow where stability or
traction is in doubt.
• To obtain additional operator manual and safety
instructions, contact Great Dane dealer or write to: Great
Dane Power Equipment, P.O. Box 33009, Raleigh, NC
27636-3009, USA.
• Keep vent caps tight and level.
Safety - 1
SAFETY
DANGER
• Keep hands and feet away.
CAUTION
MX9293 MX9261
Emission Compliance Period (Small Off-Road Gas Engines)
If your engine has the emission compliance category listed
on the emission control system certification or air index
label, this indicates the number of operating hours for which
the engine has been certified to meet EPA and/or CARB
emission requirements. The following table provides the
engine compliance period in hours associated with the
category found on the certification label.
Agency Category Hours
EPA C 250
EPA B 500
EPA A 1000
CARB Moderate 125
CARB Intermediate 250
CARB Extended 500
Operating Safely
MX9294 MX9261
• Do not operate mower without chute deflector, mulching
plate or complete grass catcher assembly in position.
• Do not remove grass catcher, mulching plate or raise the
chute deflector until engine and blade(s) have stopped.
Emission Control System Certification Label (Small Off-Road Gas Engines)
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 EP A and/or CARB
authorized service centers. Contact your Great Dane
Equipment Retailer concerning emission controls and
component questions.
The presence of an emissions label signifies that the
engine has been certified with the United States
Environmental Protection Agency (EPA) and/or California
Air Resources Board (CARB).
The emissions warranty applies only to those en gines
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.
• Do not allow operation or service of the machine by
children or untrained adults.
• Read the operator’s manual and study the safety and
operation sections before operating the machine.
• Operate the machine in an open, unobstructed area
under the direction of an experienced operator.
• Learn the use of all controls.
• Operator experience is required to learn the moving,
stopping, turning and other operating characteristics of the
machine.
• 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.
• Do not operate mower without discharge chute or entire
grass catcher in place.
• Check before each use that operator presence controls
are functioning correctly. Test safety systems. Do not
operate unless they are functioning correctly.
• Do not change the engine governor setting or overspeed
the engine.
• Check park brake function before operating. Adjust or
service park brake as necessary.
• Stop machine if anyone enters the area.
• Never raise mower decks when blades are running.
Safety - 2
SAFETY
• If you hit an object, stop and inspect the machine. Make
repairs before you operate. Keep machine and attachments
properly maintain ed and in goo d wor king or der.
• Do not leave machine unattended when it is running.
• Only operate during daylight or with good artificial light.
• Slow down and be careful of traffic when operating near
or crossing roadways. Stop blades before crossing roads or
sidewalks. Use care when approaching blind corners,
shrubs, trees, or other objects that may obscure vision.
• Be aware of the mower discharge direction and make
sure that no one is in the path of the discharge direction.
• Use only accessories and attachments approved by the
manufacturer of the machine.
• Wear close fitting clothing and safety equipment
appropriate for the job.
• Always wear safety goggles or safety glasses with side
shields and a hard hat when operating the mower.
• Wear a suitable protective device such as earplugs.
Loud noise can cause impairment or loss of hearing.
• Do not wear radio or music headphones. Safe service
and operation requires your full attention.
Slow down when you travel over rough ground.
Parking Safely
1. Stop machine on a level surface, not on a slope.
2. Disengage PTO.
3. Lock park brake.
4. Stop engine.
5. Remove key.
6. Wait for engine and all moving parts to stop before you
leave the operator’s station.
Rotating Blades are Dangerous
HELP PREVENT SERIOUS OR FATAL ACCIDENTS:
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 grasscovered 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.
A spark arrestor for your machine may be available from
your authorized dealer. An installed spark arrestor must be
maintained in good working order by the operator.
Checking Mowing Area
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform the
job.
• Clear mowing area of objects that might be thrown.
Keep people and pets out of mowing area.
• Low-hanging branches and similar obstacles can injure
the operator or interfere with mowing operation. Before
mowing, identify potential obstacles such as low-hanging
branches, and trim or remove those obstacles.
• 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.
MIF
• Rotating blades can cut off arms and legs.
• Keep hands, feet and clothing away from mower deck
when engine is running.
• Be alert at all times, drive forward carefully. People,
especially children can move quickly into the mowing area
before you know it.
• Before backing up, shut off PTO and look down and
behind the machine carefully, especially for children.
• Do not mow in reverse.
• Shut off blades when you are not mowing.
• Do not operate machine if you are under the influence of
drugs or alcohol.
• Park machine safely before inspecting or unplugging
mower or bagger.
PROTECT CHILDREN:
• Never assume that children will remain where you last
saw them. Children are attracted to mowing activity; stay
alert to the presence of children.
• Keep children indoors when you are mowing. Turn the
Safety - 3
SAFETY
machine off if a child enters the mowing area.
• Use extra care when you come to blind corners, shrubs,
trees, or other objects that may block your vision.
• Do not let children or an untrained person operate the
machine.
• Do not carry or let children ride on any attachment or
machine even with the blades off. Do not tow children in a
cart or trailer.
Avoid Tipping
• Slopes are a major factor related to loss-of-control and
tip-over accidents, which can result in severe injury or
death.
• Drive across a hill - not up and down. If necessary, turn
slowly and in the downhill direction. Do not shift to neutral
and coast downhill.
• Avoid starting and stopping on a slope. If machine
stops, disengage mower blades and back down slowly.
• Do not drive where machine could slip or tip.
• Stay alert for holes and other hidden hazards in the
terrain.
• Keep away from drop-offs, ditches, and embankments.
• Slow down before you make a sharp turn or operate on
a slope.
• Mowing when grass is wet can cause reduced traction
and sliding.
Keep Rider s Off
• 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.
• Riders obstruct the operator’s view resulting in the
machine being operated in an unsafe manner.
Practice Safe Maintenance
• Only qualified, trained adults should service this
machine.
• Understand service procedure before doing work. Keep
area clean and dry.
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
• Never lubricate, service, or adjust machine while it is
moving. Wait for all movement to stop on machine before
adjusting, cleaning or repairing.
• Keep safety devices in place and in working condition.
Keep hardware tight.
• On multi-bladed machines, be aware that rotating one
blade can cause other blades to rotate.
• Keep hands, feet, clothing, jewelry, and long hair away
from any moving parts, to prevent them from getting
caught.
• Disengage all power and stop the engine. Lock park
brake and remove the key. Let machine cool.
• Disconnect battery or remove spark plug wire (for
gasoline engines) before making any repairs.
• Before servicing machine, carefully release pressure
from any components with stored energy , such as hydraulic
components.
• Keep all nuts and bolts tightened, especially blade
attachment bolts.
• Securely support any machine elements that must be
raised for service work. Use jack stands or lock service
latches to support components when needed.
• Never run engine unless park brake is locked.
• Use care when checking blades. Wrap blades or wear
gloves and use caution when servicing them. Only replace
blades. Never straighten or weld them.
• Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Replace all worn or damaged safety and instruction decals.
Checking Whe el Bolts
• A serious accident could occur causing serious injury if
wheel bolts are not tight.
• Check wheel bolt tightness often during the first 100
hours of operation.
• Wheel hardware must be tightened to specified torque
using the proper procedure anytime it is loosened.
Safety - 4
• Grass catcher components are subject to wear,
damage, and deterioration which could expose moving
parts or allow objects to be thrown. Check components
frequently and replace with manufacturer’s recommended
parts when necessary.
• Charge batteries in an open, well-ventilated area, away
from sparks. Unplug battery charger before connecting or
disconnecting from the battery. W ear protective clothing
and use insulated tools.
• Do not modify machine or safety devices. Unauthorized
modifications may impair its function and safety.
• Check park brake function frequently. Adjust and service
SAFETY
as needed.
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.
• To reduce fire hazard, keep engine and engine
compartment free of grass, leaves, or excessive grease.
• Clean up oil or fuel spillage.
• Allow engine to cool before storing in any enclosure.
• Never remove fuel cap, or add fuel with engine running
or hot. Allow engine to cool for several minutes.
• Never store equipment with fuel in the tank inside a
building where fumes may reach an open flame or spark.
• Always shut off fuel when storing or transporting
machine.
Tire Safety
Explosive separation of a tire and rim parts can cause
serious injury or death:
• Do not attempt to mount a tire without the proper
equipment and experience to perform the job.
• Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
• When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and not
in front of or over the tire assembly.
• Check tires for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.
Handling Fuel Safely
Fuel and fuel vapors are highly flammable:
• Do not refuel machine while you smoke, when machine
is near an open flame or sparks, or when engine is running.
Stop engine and allow to cool before filling.
• Never remove the fuel cap or add fuel with the engine
running.
• Replace all fuel tanks and container caps securely.
• Never fill fuel tank or drain fuel from a machine in an
enclosed area. Fill fuel tank outdoors.
• Prevent fires. Clean up spilled fuel immediately . If fuel is
spilled on clothing, change clothing immediately. Do not
attempt to start the engine but move the machine away
from the area of spillage and avoid creating any source of
ignition until fuel vapors have dissipated.
• Do not store fuel in container or machine with fuel in
tank in a building where fumes may reach an open flame or
spark.
• Prevent fire and explosion caused by static electric
discharge. Use only non-metal, portable fuel containers
approved by the 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.
Safety - 5
SAFETY
• Static electric discharge can ignite gasoline vapors in an
ungrounded fuel container. Remov e the fuel container from
the bed of a machine or trailer or the trunk of a car and
place on the ground away from the machine before filling.
Keep nozzle in contact with container opening while filling.
Do not use a nozzle lock-open device.
The seller of the chemical products used with your machine
is responsible for providing the MSDS for that product.
• When practical, remove equipment from trailers or truck
beds and refuel them on the ground. If this is not possible,
use a portable, plastic fuel container to refuel equipment on
a truck bed or trailer.
• 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.
Safety - 6
OPERATING
Operating
Daily Operating Checklist
❏ Test safety systems.
❏ Check tire pressure.
❏ Check fuel level.
❏ Check engine oil level.
❏ Remove grass and debris from machine.
❏ Clean air intake screen.
❏ Check area below machine for leaks.
Console Controls
C
Miscellaneous Controls
A
H
I
C
B
A
A
B
G
D
FFE
A - Speed Control Lever
B - Tracking Adjustment Knob
C - Operator Presence Control Lever
D - Neutral Lock Lever
E - Handlebar Grip
F - Steering/Reverse Control Grip Lever
G - Throttle Lever/Choke Control (choke may be
individual control on some models)
H - PTO/Clutch Switch
I - Key Switch
D
E
MX9263
MX18837 MX9264
A - Transmission Drive/Bypass/Park Brake
Selector
B - Fuel Shutoff Valve
Testing Safety Systems
c CAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
Move the vehicle to an outside area before
running the engine.
Do not run an engine in an enclosed area
without adequate ventilation.
• Connect a pipe extension to the engine
exhaust pipe to direct the e xhaust f umes out of
the area.
• Allow fresh outside air into the work area to
clear the exhaust fumes out.
Use the following checkout procedure to check for normal
operation of machine.
If there is a malfunction during one of these procedures, do
not operate machine. See your Great Dane dealer for
service.
Operating - 7
OPERATING
Perform these tests in a clear open area. Keep bystanders
away.
Testing Transmission Drive/Bypass/Park Brake Selector - Park Function
Stop the machine on a maximum 17° slope. Stop the
engine and lock the park brake.
Result: Park brake must hold the machine stationary. If the
machine moves more than 61cm (24 in.) in one hour,
brakes need to be adjusted. See your Great Dane dealer.
Testing Operator Presence Safety Interlock System
1. Move transmission drive/bypass/park brake selector into
park brake position.
2. Move control levers to neutral position.
3. Move PTO/clutch switch to off position.
4. Start engine.
5. Move transmission drive/bypass/park brake selector into
drive position.
6. Do not depress operator presence levers.
7. Move speed control lever forward.
drive/bypass/park brake selector lever (A) back firmly until it
locks into park position (B).
2. To disengage park brake function, move control lever to
the right and then forward, locking into bypass (C) or drive
(D) position.
Starting the Engine
c CAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
Move the vehicle to an outside area before
running the engine.
Do not run an engine in an enclosed area
without adequate ventilation.
• Connect a pipe extension to the engine
exhaust pipe to direct the e xhaust f umes out of
the area.
• Allow fresh outside air into the work area to
clear the exhaust fumes out.
1. Open the fuel shutoff valve.
2. Move transmission drive/bypass/park brake selector into
park position.
Result: Engine must shut off immediately.
Using the Transmission Drive/Bypass/Park Brake Selector
c CAUTION: A v oid injury! Children or bystanders
may attempt to move or operate an unattended
machine.
Always lock the park brake and remove the key
before leaving the machine unattended.
A
C
D
B
MX18837
1. To engage park brake function, move transmission
3. Engage neutral lock levers.
4. Move speed control lever to neutral position.
5. Move PTO/clutch switch to off position.
6. Move throttle lever to half-speed position and set choke
(separate choke control models). Move throttle lever into
choke position on models with choke incorporated into
throttle lever.
7. Manual Start Engines Only: Turn key s witch to run
position. Pull recoil starter until the engine starts.
8. Electric Start Engines Only: Turn key switch to start
position for no more than five seconds. Release key to the
run position when engine starts.
• If the engine does not start, wait 10 seconds.
• Turn key to start position again for no more than 5
seconds.
• Repeat the procedure if necessary.
IMPORTANT: Avoid damage! Unnecessary engine
idling may cause engine damage. Excessive idling
can cause engine overheating, carbon build-up and
poor performance.
9. Let the engine run at half-speed position for several
minutes to warm up before operating the machine. Reduce
Operating - 8
OPERATING
choke setting as the engine warms up.
Stopping the Engine
1. Move the throttle lever to the half-speed position, and let
the engine run at low throttle for a few seconds.
2. Turn the key switch to the stop position.
3. Remove key.
4. Move transmission drive/bypass/park brake selector into
park position.
5. Close the fuel shutoff valve.
Operating the Machine
c CAUTION: Avoid injury! Learn the use of the
control levers. Practice at half throttle until
becoming proficient and comfortable with the
operation of the machine.
Do not move control levers from forward to
reverse or reverse to forward position rapidly.
Sudden direction changes could cause loss of
control or damage the machine.
1. Verify mower deck is adjusted to desired cut height.
2. Start and warm-up engine.
NOTE: The travel speed and turn rate will vary with the
amount that the control lever is moved.
3. Move transmission drive/bypass/park brake selector into
drive position.
4. Move throttle lever to wide open position.
5. Depress operator presence control levers and grasp
handlebar grips with both hands.
6. Move PTO/clutch switch to on position.
push the neutral lock levers (A) forward.
To drive the machine forward: Push speed control lever
(B) forward smoothly and evenly to desired forward speed.
To turn the machine: Squeeze steering control grip lever
(D) on the same side as the direction of the desired turn.
To stop the machine: Return speed control lever to the
neutral position and set thumb locks.
To drive the machine in reverse: Squeeze both steering/
reverse control grip levers (D) evenly.
Stopping the Machine
NOTE: For emergency stop of blades and unit drive,
release operate presence control levers.
1. Return steering/reverse control levers to the neutral
position and set thumb locks. Move speed control lever to
neutral position.
2. Move the PTO/clutch switch to the off position.
3. Move the throttle lever to the half-speed position, and let
the engine run at low throttle for a few seconds.
4. Turn the key switch to the stop position.
5. Move transmission drive/bypass/park brake selector into
park position.
6. Remove key.
Adjusting Cut Height
NOTE: The cut heights listed reflect the three blade
spacers being on the top side of blade. An additional
19mm (0.75 in.) of adjustment can be made in 6.3mm
(0.25 in.) increments by moving the spacers to the top
side of the spindle assembly.
Cutting height can be changed by adjusting the machine at
the traction deck and the front casters. The traction deck
allows for 51mm (2 in.) of height adjustment and the front
casters allow for up to 76mm (3 in.) of height adjustment.
C
A
D
7. Place palms on operator’s presence controls (C) and
fingers on steering/reverse control levers (D). With thumbs,
B
A
C
D
MX9263
Operating - 9
1. Check tire pressure. Inflate front caster wheels to 6983kPa (10-12 psi). Inflate rear tires to 172-207kPa (25-30
psi).
2. Place blocks at the rear of the mower deck, beyond the
outside edge of each tire.
OPERATING
A
MX9269
3. With a second person holding the handlebar grips firmly,
loosen and remove bolts (A) from both sides of machine.
4. With bolts removed from machine, tilt rear of machine up
or down by handlebar grips to accommodate height
desired.
NOTE: The c ut height r ange is set b y t he wa y the upper
traction deck is bolted to the mower deck.
• Bolting the upper traction deck holes to the lower
mower deck holes sets the cut height range at 89108mm (3.5-4.25 in.).
• Bolting the upper traction deck holes to the upper
mower deck holes sets the cut height range at 6483mm (2.5-3.25 in.).
• Bolting the lower traction deck holes to the upper
mower deck holes sets the cut height range at 3857mm (1.5-2.25 in.).
5. Insert bolts into desired holes and tighten to 81-109N•m
(60-80 lb-ft).
Using the Fuel Shutoff Valve
Move the fuel shutoff valve to the on position for normal
operation. Move the fuel shutoff valve to the off position
when the machine is not in use, transported or trailered.
Moving the Machine Manually
c CAUTION: Avoid injury! With the machine in
neutral, the machine will have unrestricted
motion.
• The machine may free-wheel out of control
when in neutral position and on an incline.
• Park the machine on a level surface before
moving machine into neutral position.
IMPORTANT: Avoid damage! Transmission damage
may occur if the machine is moved or towed
incorrectly:
• Move unit by hand only.
• Do not use another vehicle to move unit.
• Do not tow unit.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Move transmission drive/bypass/park brake selector into
neutral position.
3. Push machine to desired location. Due to internal
hydraulic system resistance, the machine will move slowly.
4. Move transmission drive/bypass/park brake selector into
park brake position.
B
MX9257
6. Front mower deck height can be adjusted by moving
shims (B). Each shim is equal to 13mm (0.5 in.) of
adjustment.
Operating - 10
REPLACEMENT PARTS
Replacement Parts
Parts
We recommend Great Dane quality parts available at your
Great Dane dealer.
Part numbers may change, use part numbers listed below
when you order. If a number changes, your dealer will have
the latest number.
When you order parts, your Great Dane dealer needs your
machine serial number and engine serial number. These
are the numbers that you recorded in the Product
Identification section of this manual.
Part Numbers
Item Part Number
Battery T425221
Fuel Tank Cap D18097
Traction (Hydro) Drive Belt D18388
Engine to Blade Belts:
• 92cm (36 in.) Deck
• 1.22m (48 in.) Deck
• 1.32m (52 in.) Deck
Mower Deck Drive Belts:
• 1.32m (48 in.)
• 1.55m (52 in.)
Mower Blades:
• 48-Inch Mower Deck: 42cm
(16.5 in.) Blade
• 36 and 52-Inch Mower
Decks: 45cm (18 in.) Blade
(Part numbers are subject to change without notice. Part
numbers may be different outside the U.S.A.)
D38163
D38131
D38162
D18007
D38163
D18086
D18037
Replacement Parts - 11
SERVICE INTERVALS
Service Intervals
Servicing Your Machine
IMPORTANT: Avoid damage! Operating in extreme
conditions may require more frequent service
intervals:
• Engine components may become dirty or
plugged when operating in extreme heat, dust or
other severe conditions.
• Engine oil and spark plugs may lose efficiency if
vehicle is operated constantly at slow or low engine
speeds or with frequent short trips.
Please use the following timetables to perform routine
maintenance on your machine.
NOTE: The following initial break-in items must be
performed and verified to validate the warranty (dealer
service invoice accepted).
Break-In (After First 8 Hours of Operation)
Change engine oil and filter.
Check drive belt tension.
Check mower deck drive belt tension (36-Inch Mower
Deck).
Check engine-to-deck drive belt tension (48 and 52-Inch
Mower Deck).
Check spindle drive belt tension (48 and 52-Inch Mower
Deck).
Check transmission neutral adjustment.
Check wheel nut torque.
Check and adjust (as needed) park brake.
Remove debris from the underside of the mower deck.
Every 25 Hours or Weekly (Whichever Comes First)
Grease caster wheel spindle bearings (two places).
Grease lower control arms (two places).
Remove debris from the underside of the mower deck.
Check drive belt tension.
Check tire pressure.
Clean engine air filter.
Check wheel nut torque.
Every 160 Hours or Monthly (Whichever Comes First)
Check transmission oil level.
Lubricate mower deck idler pulley pivots (three places).
Lubricate seat platform hinges (two places)
Lubricate pump control arms (five places).
Lubricate control lever pivot shafts (two places).
Lubricate throttle cable.
Lubricate choke control cable (Carbureted Engines Only).
Annually
Inspect all spindle bearings (6). Replace as needed.
Inspect all mower deck idler pulleys. Replace as needed.
Remove and inspect caster wheel roller bearings; clean
and pack with grease. Replace as needed.
Inspect drive belts. Replace as needed. Run-in and adjust
tension.
Clean power unit.
Check all bolts and nuts; tighten as needed.
Remove battery. Clean battery and holder (electric start).
Replace spark plugs.
Grease spindle bearings (three places).
Lubricate spindle drive belt tension arms.
Lubricate front caste r wheels.
Lubricate front caste r wheel spi ndl es.
Remove debris from the underside of the mower deck.
Every 50 Hours or Weekly (Whichever Comes First)
Change engine oil and filter. See the engine manufacturer’s
owner’s manual provided with your machine for the
complete procedure.
Service Intervals - 12
Service Lubrication
Grease
SERVICE LUBRICATION
IMPORTANT: Avoid damage! If operating outside
that temperature range, contact your Servicing
dealer for a special-use grease.
Use a general all-purpose grease with an NLGI grade No.2
rating.
Wet or high speed conditions may require use of a specialuse grease. Contact your Servicing dealer for information.
Spray Lubricant
Use a general-purpose petroleum-based spray lubricant.
Lubrication Points
H
H
J
I
F
D
E
MX15287
• Apply grease to three spindle bearings (E), until grease
is expelled from vent on spindle housings.
• Lubricate mower deck idler pulleys (F).
NOTE: Use spray lubricant to lubricate the following
items:
• Lubricate speed control lever pivot shaft (G).
• Lubricate throttle control cable (H).
• Lubricate choke control cable (I) if independent.
• Lubricate hydro pump lower control arms on both sides
(J).
C
AD
B
B
A
MX18835
• Grease caster wheel bearings (A).
• Grease caster wheel pivot bushings (B).
• Grease cutter housings (C) (two on 36-Inch mower
deck, three on 48 and 52-inch mower decks).
• Grease idler arm bushings ( D).
Service Lubrication - 13
SERVICE ENGINE
Service Engine
Avoid Fumes
c CAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
Move the vehicle to an outside area before
running the engine.
Do not run an engine in an enclosed area
without adequate ventilation.
• Connect a pipe extension to the engine
exhaust pipe to direct the exhaust f umes out of
the area.
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.
• If oil is low, add oil to bring oil level no higher than the
FULL mark on dipstick.
• If oil level is above the FULL mark, drain to proper
level.
7. Install and tighten dipstick.
• Allow fresh outside air into the work area to
clear the exhaust fumes out.
Engine Oil
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
Use oil that meets the following specification:
• See the engine manufacturer’s owner’s manual provided
with your machine for the correct specifications.
Checking Engine Oil Level
IMPORTANT: Avoid damage! Failure to check the oil
level regularly could lead to serious engine
problems if oil level is low:
• Check oil level before operating.
• Check oil level when the engine is cold and not
running.
• Keep level between the FULL and the ADD marks.
• Shut off engine before adding oil.
Changing Engine Oil and Filter
A
MX9414
NOTE: An oil drain tube is provided with this machine.
Attach the tube to the oil drain fitting on the engine,
and open valve (A) to drain the used oil. Close the
valve, and remove the drain tube from the fitting after
the oil has been drained. Store the drain tube after use.
Change engine oil and filter 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.
NOTE: Check oil twice a day if the engine runs over
four hours in a day.
Make sure engine is cold when checking engine oil
level.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Allow engine to cool.
3. Clean area around dipstick to prevent debris from falling
into crankcase.
4. Remove dipstick (A). Wipe with a clean cloth.
5. Install dipstick and allow the cap to rest on the end of the
tube. Do not tighten the cap.
Service Engine - 14
Cleaning Air Intake Screen and Engine Fins
IMPORTANT: Avoid damage! The engine is aircooled and requires a large amount of air intake
when running. Reduced air intake can cause
overheating:
• Keep air intake screen and cooling fins clean.
• Keep covers and screens in place.
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.
SERVICE ENGINE
Checking and Cleaning Air Filter Elements
c CAUTION: Avoid injury! Touching hot surfaces
can burn skin. The engine and components will
be hot if the engine has been running. Allow
the engine to cool before servicing.
IMPORTANT: Avoid damage! Dirt and debris can
enter the engine through a damaged filter element:
• Do not wash paper element.
• Do not attempt to clean paper element b y 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.
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.
Checking Spark Plugs
your dealer.
Replacing Fuel Filter
c CAUTION: Avoid injury! Fuel vapors are
explosive and flammable:
• Do not smoke while handling fuel.
• Keep fuel away from flames or sparks.
• Shut off engine before servicing.
• Cool engine before servicing.
• Work in a well-ventilated area.
• Clean up spilled fuel immediately.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Turn fuel shutoff valve to off position.
3. Disconnect the fuel hose from the outlet side of the fuel
filter, and drain gasoline into a properly marked container.
4. Remove the fuel filter from the inlet fuel hose. Discard
filter.
c CAUTION: Avoid injury! Touching hot surfaces
can burn skin. The engine and components will
be hot if the engine has been running. Allow
the engine to cool before servicing.
Check spark plugs at the intervals recommended in the
Service Intervals section. See the engine manufacturer’s
owner’s manual provided with your machine for the
complete procedure.
Adjusting Carburetor
NOTE: Carburetor is calibrated by the engine
manufacturer and is not adjustable.
If engine is operated at altitudes above 1829 m (6,000
ft), some carburetors may require a special high
altitude main jet.
If engine is hard to start or runs rough, see the
troubleshooting section of the engine manufacturer’s
owner’s manual provided with your machine.
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.
After performing the checks in the troubleshooting section
and your engine is still not performing correctly, contact
IMPORTANT: Avoid damage! When installing a new
fuel filter, the filter arrow must be pointing in the
direction of fuel flow.
5. Connect a new fuel filter to hoses.
6. Turn fuel shutoff valve to on position.
Service Engine - 15
SERVICE TRANSMISSION
Service Transmission
Avoid Fumes
c CAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
Move the vehicle to an outside area before
running the engine.
Do not run an engine in an enclosed area
without adequate ventilation.
• Connect a pipe extension to the engine
exhaust pipe to direct the exhaust f umes out of
the area.
• Allow fresh outside air into the work area to
clear the exhaust fumes out.
Transmission Oil
The Hydro-Gear transaxle units used in this machine are
designed to be maintenance free. If service is required,
contact a Great Dane dealer.
Adjusting Transmission Tracking
c CAUTION: Avoid injury! Clear area of all
bystanders before performing this service
procedure.
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Start and run the engine until it reaches normal
operating temperature.
3. Move machine to an open area for operation.
adjustment knob (A) to compensate.
Adjusting Transmission Neutral Position
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Raise drive wheels off the ground, securely support the
machine and block caster wheels.
3. Move speed control lever to neutral position.
4. Start and run the engine until it reaches normal
operating temperature.
5. Observe wheel movement. Wheels should not rotate.
A
MX9262
6. Determine which drive motor is in need of adjustment.
7. Remove retaining clip, control rod and swivel from drive
arm (A).
8. Adjust accordingly by turning swivel up or down con trol
rod.
9. Install control rod, swivel and retaining clip in drive arm.
NOTE: If additional adjustment is needed, see your
Great Dane dealer.
4. Drive machine forward by pushing speed control lever
forward slowly.
A
MX9263
5. If machine does not drive in a straight line, turn tracking
Service Transmission - 16
Removing and Installing Drive Belt
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Remove mower deck belt guard.
SERVICE TRANSMISSION
B
A
Picture Note: Drive belt routing as viewed from the
top of machine.
3. Disconnect tension spring (A) from anchor pin.
4. Remove drive belt (B).
5. Install new drive belt (B).
6. Connect tension spring (A) to anchor pin.
MX9291
7. Install mower deck belt guard.
Service Transmission - 17
SERVICE MOWER
Service Mower
Adjusting Belt Tension
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Remove belt covers.
3. Adjust to proper tension. The belt should deflect a
maximum of 13mm (0.5 in.) when a force of 4.5kg (10 lb) is
applied to the center of the longest span.
A
B
MX9238
4. To Increase Belt Tension: Turn nut (A - main mower
deck drive belt) or (B - spindle drive belt) clockwise.
A
MX9291
Picture Note: Drive belt routing as viewed from the
top of machine.
3. Remove pump drive belt (A) as previously described.
E
C
T o Decrease Belt Te nsion: Turn nut (A - main mower deck
drive belt) or (B - spindle drive belt) counterclockwise.
Removing and Installing Mower Deck Drive Belts
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Remove mower deck belt covers.
B
D
MX9238
4. Release mower deck drive belt tension by turning the
tension adjuster nut (B) counterclockwise.
5. Remove mower deck drive belt (C).
6. Release spindle drive belt tension by turning the
tensioner adjuster nut (D) counterclockwise.
7. Remove spindle drive belt (E).
8. Install the new spindle drive belt (E) and adjust the drive
belt tension.
9. Install new mower deck drive belt (C) and adjust the
drive belt tension.
10.Install pump drive belt (A).
11.Install mower deck drive belt covers.
Service Mower - 18
SERVICE MOWER
Checking for Bent Mower Blades
c CAUTION: Avoid injury! Mower blades are
sharp. Always wear gloves when handling
mower blades or working near blades.
1. Park machine safely. (See Parking Safely in the Safety
section.)
A
MIF
2. Measure distance (A) between blade tip and flat ground
surface.
3. Turn blade 180°. Measure distance between other blade
tip and flat ground surface.
4. Install new blade, if the difference between the two
measurements is more than 3mm (0.13 in.).
Replacing Mower Blades
2. Remove nut (A), blade bolt (B), three 1/4 in. washers (C)
and blade (D).
3. Install replacement blade:
• Blade wing must face toward top of mower deck.
IMPORTANT: Avoid damage! When installing the
blade:
• Make sure the blade is properly seated on the
spindle.
• Make sure the concave side of the large washer
faces toward the blade.
• Install blade bolt (B), blade (D), three 1/4 in. washers
(C) and nut (A) .
• Tighten blade nut to 81 N•m (60 lb-ft).
4. Lower machine.
5. Adjust mower deck to a desirable cutting height.
Sharpening Blades
c CAUTION: Avoid injury! Mower blades are
dangerous!
• Always wear gloves while working on
blades.
• Always wear safety eye protection when
grinding.
c CAUTION: Avoid injury! Mower blades are
sharp. Always wear gloves when handling
mower blades or working near blades.
A
C
D
B
MX15357
1. Use two long-handled 15/16 in. wrenches to loosen nut
(A).
• Sharpen blades with grinder, hand file or electric blade
sharpener.
A
B
MX8333
• Keep original bevel (A) when grinding.
• Blade should have 0.40 mm (1/64 in.) cutting edge (B)
or less.
• Balance blades before installing.
Service Mower - 19
SERVICE MOWER
Balancing Blades
c CAUTION: Avoid injury! Mower blades are
sharp. Always wear gloves when handling
mower blades or working near blades.
1. Clean blade.
M61524
2. Put blade on nail in a vise. Turn blade to horizontal
position.
A
B
C
D
I
H
G
F
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.
Replacing Mower Spindle Bearings - 36-Inch
Mower Deck
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Remove mower blade. (See Replacing Mower Blades.)
E
MX15354
3. Remove nut (A), pulley (B) and spacer (C).
4. Remove retaining ring (D), spindle shaft (E), lower
bearing (F) and spacer (G) from spindle housing (H).
Discard bearing.
5. Remove and discard upper bearing (I).
6. Clean entire assembly.
7. Install a new lower bearing (F) and spacer (G) on the
spindle shaft (E).
IMPORTANT: Avoid damage! The clearance between
the lower bearing and the housing is only 0.05 mm
(0.002 in.). Do not force bearing into housing.
8. Install the spindle shaft (E), lower bearing (F) and
spacer (G) into the spindle housing (H).
9. Install the upper bearing (I) and retaining ring (D).
10.Install spacer (C).
11.Install pulley (B) and nut (A). Tighten nut to 61 N•m (50
lb-ft).
12.Install mower blade, blade washers and blade bolt
assembly. Tighten nut to 81 N•m (60 lb-ft). (See Checking
and Replacing Mower Blades.)
Service Mower - 20
SERVICE MOWER
Replacing Mower Spindle Bearings - 48 and 52-Inch Mower Decks
1. Park machine safely. (See Parking Safely in the Safety
section.)
2. Remove engine-to-deck drive and spindle drive belts.
3. Remove mower blade. (See Replacing Mower Blades.)
A
B
C
D
I
N
E
F
G
H
7. Clean entire assembly.
8. Install a new lower bearing (K) and spacer (L) on the
spindle shaft (J).
IMPORTANT: Avoid damage! The clearance between
the lower bearing and the housing is only 0.05 mm
(0.002 in.). Do not force bearing into housing.
9. Install the spindle shaft (J), lower bearing (K) and spacer
(L) into the spindle housing (M).
10.Install the upper bearing (N) and retaining ring (I).
11.Install upper pulleys:
• Right and Left Spindles (A): Install pulley (D),
spacer (C) and nut (B). Tighten nut to 68 N•m (50 lb-ft).
• Center Spindle (E): Install spindle pulley (H), drive
pulley (G) and nut (F). Tighten nut to 68 N•m (50 lb-ft).
12.Install mower blade, blade washers and blade bolt
assembly. Tighten nut to 81 N•m (60 lb-ft). (See Checking
and Replacing Mower Blades.)
Replacing Mower Deck Idler Pulleys
1. Park machine safely. (See Parking Safely in the Safety
section.)
M
L
K
J
MX9222
4. Remove pulleys:
• Right and Left Spindles (A): Remove nut (B),
spacer (C) and pulley (D).
• Center Spindle (E): Remove nut (F), drive pulley (G)
and spindle pulley (H).
5. Remove retaining ring (I), spindle shaft (J), lower
bearing (K) and spacer (L) from spindle housing (M).
Discard bearing.
2. Remove the mower deck drive and spindle drive belts.
A
B
MX9267
3. Remove the mower deck drive tension idler pulley (A)
and the mower and spindle drive tension idler pulley (B).
4. Install new idler pulleys.
5. Install spindle drive and mower deck drive belts.
6. Adjust belt tension.
6. Remove and discard upper bearing (N).
Service Mower - 21
SERVICE ELECTRICAL
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.
Removing and Installing the Battery
c CAUTION: A v oid injury! The batt ery produces a
flammable and explosive gas. The battery may
explode:
• Do not smoke near battery.
• Wear eye protection and gloves.
• Do not allow direct metal contact across
battery posts.
• Remove negative cable first when
disconnecting.
• Install negative cable last when connecting.
Removing:
1. Park the vehicle safely . (See P arking Safely in the Safety
section.)
2. Slide black cover away from the negative (-) battery
terminal and disconnect the negative (-) battery cable.
3. Slide red cover away from the positive (+) battery
terminal and disconnect the positive (+) battery cable.
4. Loosen the cap screws and nuts on both sides of the
battery tray.
Cleaning Battery and Terminals
c CAUTION: A v oid injury! The batt ery produces a
flammable and explosive gas. The battery may
explode:
• Do not smoke near battery.
• Wear eye protection and gloves.
• Do not allow direct metal contact across
battery posts.
• Remove negative cable first when
disconnecting.
• Install negative cable last when connecting.
1. Disconnect and remove battery.
2. Wash battery with a solution of four tablespoons of
baking soda to one gallon of water. Be careful not to get the
soda solution into the battery cells.
3. Rinse the battery with plain water and dry.
4. Clean terminals and battery cable ends with wire brush
until bright.
5. Install battery.
6. Attach cable clamps to battery posts.
7. Apply petroleum jelly or silicone spray to terminal to
prevent corrosion.
Using Booster Battery
5. Remove battery and isolator pad.
Installing:
1. Place isolator pad in the battery tray .
2. Install battery in the battery tray, making sure that the
isolator pad is between the bottom and sides of the battery
tray.
3. Tighten the cap screws and nuts to secure the battery in
the battery tray. Do not overtighten.
4. Connect the positive (+) battery cable first, then the
negative (-) cable.
5. Apply general purpose grease or silicone spray to the
terminals to prevent corrosion.
6. Slide covers over battery terminals.
Service Electrical - 22
MIF TS204
SERVICE ELECTRICAL
c CAUTION: A v oid injury! The batt ery produces a
flammable and explosive gas. The battery may
explode:
• Do not attempt to jump start a frozen battery .
Warm to 16 degrees C (60 degrees F).
• Do not smoke near battery.
• Wear eye protection and gloves.
• Keep sparks and flames away.
• Do not connect the negative (-) booster
cable to the negative (-) terminal of the
discharged battery. Connect at a good ground
location away from the discharged battery.
• Do not cross jump the battery, damage to
electronic modules will result.
F
C
E
D
Replacing Fuses
IMPORTANT: Avoid damage! When replacing fuses use only 20-amp fuses or you may damage the
circuit.
The machine is equipped with two 20-amp fuses (electric
start units) and one 20-amp fuse (manual start units) to
protect the electric start and/or charging circuit. These
fuses are located under the control panel area.
1. Remove defective fuse from socket.
2. Check metal clip in fuse window and discard fuse if clip
is broken.
3. Install new fuse into socket.
B A
M71044
A - Booster Battery
B - Disabled Vehicle Battery
1. Connect positive booster cable to booster battery (A)
positive post (C).
2. Connect the other end of positive booster cable to the
disabled vehicle battery (B) positive post (D).
3. Connect negative booster cable to booster battery
negative post (E).
4. Connect the other end (F) of negative booster cable to a
unpainted metal part of the disabled machine’s engine,
away from battery.
5. Start the engine of the disabled machine and run
machine for several minutes.
6. Carefully disconnect the booster cables in the exact
reverse order: negative cable first and then the positive
cable.
Service Electrical - 23
Wiring Schematics
SERVICE ELECTRICAL
MX9418a
Picture Note: Kawasaki Manual Start Shown Above
MX18838
Picture Note: Kawasaki Electric Start Shown Above
Service Electrical - 24
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