Great Dane GDB10028, GDB10029, GDB10027, GDB10025, GDB10026, GDB10030, Scamper HG GDB10025 User Manual [en, es]

1.74 Mb
Loading...

Scamper HG

GDB10025, GDB10026, GDB10027, GDB10028, GDB10029, GDB10030

GD10003

B3

OPERATOR’S MANUAL

c WARNING: The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

California Proposition 65 Warning

OMGD10003 B3

North American Version

Litho in U.S.A.

INTRODUCTION

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.

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 instructions.

RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the machine will travel when going forward. When you see a broken line (------), the item referred to is hidden from view.

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.

cCAUTION: 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.

Record Identification Numbers

Scamper HG

GDB10025 (15 hp, Recoil, 36-Inch Deck) Serial No. (TCHR15W010001-

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:

_________________________________________

B

A

MX18836

MODEL NUMBER (A):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

SERIAL NUMBER (POWER UNIT) (A):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ENGINE SERIAL NUMBER (B):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ENGINE SPECIFICATION NUMBER (B):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

Introduction

 

TABLE OF CONTENTS

Safety .....................................................................................................................................................................................

1

Operating................................................................................................................................................................................

7

Replacement Parts ...............................................................................................................................................................

11

Service Intervals...................................................................................................................................................................

12

Service Lubrication...............................................................................................................................................................

13

Service Engine .....................................................................................................................................................................

14

Service Transmission............................................................................................................................................................

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 notice.

COPYRIGHT© 2003

Deere & Co.

John Deere Worldwide Commercial and

Consumer Equipment Division

All rights reserved

Previous Editions

COPYRIGHT© 2002

OMGD10003 B3 - English

Table of Contents

SAFETY

Understanding The Machine Safety Labels

CAUTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

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.

Keep vent caps tight and level.

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.

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.

Safety - 1

SAFETY

DANGER

MX9293 MX9261

Keep hands and feet away.

CAUTION

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 EPA and/or CARB authorized service centers. Contact your Great Dane Equipment Retailer concerning emission controls and component questions.

The presence of an emissions label signifies that the engine has been certified with the United States Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB).

The emissions warranty applies only to those engines marketed by Great Dane that have been certified by the EPA and/or CARB; and used in the United States and Canada in off-road mobile equipment.

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

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 maintained and in good working order.

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.

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.

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:

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 Riders 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.

Checking Wheel Bolts

A serious accident could occur causing serious injury if wheel bolts are not tight.

Check wheel bolt tightness often during the first 100 hours of operation.

Wheel hardware must be tightened to specified torque using the proper procedure anytime it is loosened.

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.

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. Wear 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 - 4

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

The seller of the chemical products used with your machine is responsible for providing the MSDS for that product.

Static electric discharge can ignite gasoline vapors in an ungrounded fuel container. Remove 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.

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

 

 

 

 

 

 

H

C

 

 

 

 

 

I

 

 

 

 

 

 

C

 

D

G

B

A

D

 

F

E

 

 

 

E

F

 

 

 

 

 

 

MX9263

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

Miscellaneous Controls

A

B A

MX18837 MX9264

A- Transmission Drive/Bypass/Park Brake Selector

B- Fuel Shutoff Valve

Testing Safety Systems

cCAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the vehicle to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

Allow fresh outside air into the work area to clear the exhaust fumes out.

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.

Result: Engine must shut off immediately.

Using the Transmission Drive/Bypass/Park

Brake Selector

cCAUTION: Avoid 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

D C

B

MX18837

1. To engage park brake function, move transmission

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

cCAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the vehicle to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

Allow fresh outside air into the work area to clear the exhaust fumes out.

1.Open the fuel shutoff valve.

2.Move transmission drive/bypass/park brake selector into park position.

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 switch 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

cCAUTION: 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.

C A B A C

D D

MX9263

7. Place palms on operator’s presence controls (C) and fingers on steering/reverse control levers (D). With thumbs,

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.

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 - 9

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 cut height range is set by the way 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).

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.

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

cCAUTION: 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.

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

D38163

• 1.22m (48 in.) Deck

D38131

• 1.32m (52 in.) Deck

D38162

 

 

Mower Deck Drive Belts:

 

1.32m (48 in.)

D18007

1.55m (52 in.)

D38163

 

 

Mower Blades:

 

• 48-Inch Mower Deck: 42cm

D18086

(16.5 in.) Blade

 

• 36 and 52-Inch Mower

D18037

Decks: 45cm (18 in.) Blade

 

 

 

 

(Part numbers are subject to change without notice. Part numbers may be different outside the U.S.A.)

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 spindle bearings (three places).

Lubricate spindle drive belt tension arms.

Lubricate front caster wheels.

Lubricate front caster wheel spindles.

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.

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.

Service Intervals - 12

SERVICE LUBRICATION

Service Lubrication

Grease

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

I

 

H

 

 

J

 

 

 

F

D

C

 

B

 

 

A

D

A

B

 

 

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).

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).

Service Lubrication - 13

SERVICE ENGINE

Service Engine

Avoid Fumes

cCAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the vehicle to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

Allow fresh outside air into the work area to clear the exhaust fumes out.

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.

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.

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.

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.

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 - 14

SERVICE ENGINE

Checking and Cleaning Air Filter Elements

cCAUTION: 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 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.

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

cCAUTION: 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

your dealer.

Replacing Fuel Filter

cCAUTION: 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.

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

cCAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the vehicle to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

Allow fresh outside air into the work area to clear the exhaust fumes out.

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

cCAUTION: 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.

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

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 control rod.

9.Install control rod, swivel and retaining clip in drive arm.

NOTE: If additional adjustment is needed, see your Great Dane dealer.

Removing and Installing Drive Belt

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

2.Remove mower deck belt guard.

Service Transmission - 16

SERVICE TRANSMISSION

B

A

MX9291

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.

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.

To Decrease Belt Tension: 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.

A

MX9291

Picture Note: Drive belt routing as viewed from the top of machine.

3. Remove pump drive belt (A) as previously described.

C

E

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

cCAUTION: 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

cCAUTION: 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).

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

cCAUTION: Avoid injury! Mower blades are dangerous!

Always wear gloves while working on blades.

Always wear safety eye protection when grinding.

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

cCAUTION: 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.

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.)

A

B

C

D

I

H

G

F

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

E

B

F

C

G

D

H

 

 

I

 

N

 

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.

6.Remove and discard upper bearing (N).

7.Clean entire assembly.

8.Install a new lower bearing (K) and spacer (L) on the spindle shaft (J).

IMPORTANT: Avoid damage! The clearance between the lower bearing and the housing is only 0.05 mm (0.002 in.). Do not force bearing into housing.

9. Install the spindle shaft (J), lower bearing (K) and spacer

(L) into the spindle housing (M).

10.Install the upper bearing (N) and retaining ring (I).

11.Install upper pulleys:

Right and Left Spindles (A): Install pulley (D), spacer (C) and nut (B). Tighten nut to 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.)

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.

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

cCAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode:

Do not smoke near battery.

Wear eye protection and gloves.

Do not allow direct metal contact across battery posts.

Remove negative cable first when disconnecting.

Install negative cable last when connecting.

Removing:

1.Park the vehicle safely. (See Parking 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.

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.

Cleaning Battery and Terminals

cCAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode:

Do not smoke near battery.

Wear eye protection and gloves.

Do not allow direct metal contact across battery posts.

Remove negative cable first when disconnecting.

Install negative cable last when connecting.

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

MIF TS204

Service Electrical - 22

SERVICE ELECTRICAL

cCAUTION: Avoid injury! The battery 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

SERVICE ELECTRICAL

Wiring Schematics

MX9418a

Picture Note: Kawasaki Manual Start Shown Above

MX18838

Picture Note: Kawasaki Electric Start Shown Above

Service Electrical - 24

+ 61 hidden pages