Page 3 - Introduction; Product Identification; Record Identification Numbers
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© 2007 Auburn Consolidated Industries, Inc. All rights reserved Previous Editions COPYRIGHT© 200...
Page 4 - SAFETY LABELS; Safety Labels; Understanding The Machine Safety Labels
Safety Labels - 2 SAFETY LABELS ENGINE MODEL, SPECIFICATION, AND SERIAL NUMBER: Model Number _________________________________________ Specification _________________________________________ Serial Number _________________________________________ Safety Labels Understanding The Machine Safety Labels...
Page 5 - SAFETY; Emission Control System Certification Label; Safety; Operator Training Required
Safety - 3 SAFETY CAUTION: HELP AVOID INJURY (H) • Operator training required • Read operator’s manual • Keep shields in place • Never carry riders • Keep people a safe distance away • Maintain all safety devices • Before leaving machine: • Stop engine • Set park brake • Remove key CAUTION (I) Be sa...
Page 6 - Using a Spark Arrestor; Checking Mowing Area; Rotating Blades are Dangerous
Safety - 4 SAFETY • Only operate in good light, keeping away from holes and hidden hazards. • Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator’s position. Use seat belts if provided. • Slow down and use extra care on hillsides...
Page 8 - Maintenance and Storage; Prevent Fires; Tire Safety
Safety - 6 SAFETY • Wear close fitting clothing and safety equipment appropriate for the job. • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. • Wear a suitable protective device such as earplugs. Loud noise can c...
Page 9 - OPERATING; Handling Waste Product and Chemicals; Operating; Daily Operating Checklis; Avoid Damage to Plastic and Painted Surfaces
Operating - 7 OPERATING c • Prevent fire and explosion caused by static electric discharge. Static electric discharge can ignite fuel vapors in an ungrounded fuel container. • Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the gro...
Page 10 - Mower Deck Controls; Miscellaneous Controls; Raising and Lowering Thigh Pad
Operating - 8 OPERATING K-Choke L-Throttle Lever M-Park Brake Lever Mower Deck Controls c MX20093 A-Mower Deck Lift Levers B-Height-of-Cut (HOC) Pin Miscellaneous Controls c MX20094 A-Free-Wheeling Valves Mounting and Dismounting Machine Safely c MX20095 1. Step on operator’s platform (A) at the rea...
Page 11 - Leveling Mower Deck
Operating - 9 OPERATING 3. Stop engine and lock park brake. c MX20099 4. Remove retaining ring (A) from HOC pin (B). 5. Push down on deck lift lever (C). 6. Remove HOC pin. 7. Place HOC pin in desired height hole (D). 8. Release deck lift lever (C). 9. Install retaining ring (A) in HOC pin (B). 10. ...
Page 13 - Adjusting Mower Deck Anti-Scalp Wheels; Testing PTO Switch
Operating - 11 OPERATING Adjusting Overall Cutting Height NOTE: When adjusting U-bolts, maintain a minimum clearance of 3 mm (1/8 in.) between mower deck and stop pads. Adjust both sides of the mower deck equally. All lift chains must remain taut. c MX20099 1. Adjust four U-bolts (A) (two on each si...
Page 14 - Testing Operator Presence Switch; Testing the Park Brake
Operating - 12 OPERATING Testing Operator Presence Switch NOTE: Ensure OPC switch bracket is depressed when standing on operator’s station. 1. Stand on operator’s platform with motion control levers in the NEUTRAL position. 2. Start engine. 3. Unlock park brake. 4. Step completely off operator’s pla...
Page 15 - Using the Throttle; Using the Motion Control Levers
Operating - 13 OPERATING Using the Throttle c MX12847 • Push throttle lever (A) forward to the fast position (B) when mowing. • Move throttle lever (A) to the half fast position (C) when starting and warming the engine. • Pull throttle lever (A) backward to the slow position (D) to idle engine. Do n...
Page 17 - Starting Engine
Operating - 15 OPERATING Starting Engine c 1. Stand on operator’s platform. 2. Lock park brake. c MX20091 3. Put motion control levers (A) in the NEUTRAL position. 4. Push PTO switch knob (B) down to disengage PTO. 5. Move throttle lever (C) to set engine speed at the 1/2 to 3/4 fast position. 6. Po...
Page 18 - Using Pump Free-Wheel Valves
Operating - 16 OPERATING Using Pump Free-Wheel Valves c NOTE: The pump free-wheel valves must be turned fully clockwise (closed) during normal machine operation. When the machine needs to be moved without starting the engine, use the pump free-wheel valves: 1. Lock park brake. NOTE: The pumps (A) ar...
Page 19 - Service Intervals - 17; SERVICE INTERVALS; Service Intervals
Service Intervals - 17 SERVICE INTERVALS Service Intervals Servicing Your Machine c Please use the following timetables to perform routine maintenance on your machine. Servicing Engine See engine manufacturer’s owner’s manual provided with your machine for engine service information. Break-In (After...
Page 20 - SERVICE ENGINE
Service Engine - 18 SERVICE ENGINE Lubricating Deck Lift Pivot Points c MX20104 • Lubricate two front deck lift pivot grease fittings (A) and two rear deck lift pivot grease fittings (B). Lubricating Pump Idler Pivot c MX15095 • Lubricate one pump idler pivot grease fitting (A). Lubricating Mower De...
Page 21 - Checking Engine Oil Level; Changing Engine Oil and Filter
Service Engine - 19 SERVICE ENGINE Checking Engine Oil Level c NOTE: Check oil twice a day if you run engine over 4 hours in a day. Make sure engine is cool when checking engine oil level. 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Allow engine to cool. 3. Clean area arou...
Page 22 - Cleaning Engine Air Intake Screen and Fan; Checking Spark Plug
Service Engine - 20 SERVICE ENGINE 14. Insert dipstick. Tighten cap. 15. Start engine and run at slow throttle for approximately two minutes. Check for leaks around filter and drain valve. 16. Stop engine. 17. Check oil level: • Remove dipstick cap. Wipe dipstick clean. NOTE: Allow dipstick cap to r...
Page 23 - Service Transmission - 21; SERVICE TRANSMISSION; Service Transmission; Hydraulic Oil; Changing Hydraulic Oil and Filter
Service Transmission - 21 SERVICE TRANSMISSION c MX20149 3. Slide hose clamps (A) away from fuel filter (B). 4. Place drain pan under hoses to catch any fuel that may be left in the hoses. 5. Disconnect hoses from fuel filter (B). 6. Install new fuel filter (B). • Make sure fuel filter (B) is instal...
Page 24 - Service Transmission - 22; Cleaning Hydraulic Oil Pump Cooling Fins; Checking and Replacing Pump Traction Drive Belt; Removing Traction Drive Belt
Service Transmission - 22 SERVICE TRANSMISSION c NOTE: Dry fill capacity for hydraulic system is 3.1L (3.3 qt). 10. Fill oil reservoir with approximately 1.9L (2 qt) of oil. 11. Insert dipstick. Tighten cap. 12. Start engine. 13. Move throttle lever to 1/2 to 2/3 position. 14. Unlock park brake. c 1...
Page 25 - Service Transmission - 23; Installing Traction Drive Belt:; Checking and Adjusting Motion Control Linkages
Service Transmission - 23 SERVICE TRANSMISSION c MX20126 3. Remove four cap screws (A). 4. Remove rear shield (B). c c MX20167 Picture Note: Traction drive belt idler pulley bottom view. 5. Insert 1/2 in. breaker bar into hole (C) and rotate idler pulley (D) forward to ease tension on traction drive...
Page 26 - Service Transmission - 24; Checking and Adjusting Transmission Tracking; Adjusting Forward and Reverse Speeds
Service Transmission - 24 SERVICE TRANSMISSION Adjusting Motion Control Return to Neutral (RTN) Linkages: c 1. Stop engine. 2. Lock park brake. 3. Lift machine with a safe lifting device centered under rear tire support frame. 4. Start the machine with motion control levers in neutral. 5. Stand on t...
Page 27 - SERVICE STEERING & BRAKES; Adjust Neutral Switch; Service Steering & Brakes; Adjusting Park Brake
Service Steering & Brakes - 25 SERVICE STEERING & BRAKES c MX20115 Picture Note: Arrow shows direction of speed control bar (A) movement when decreasing forward speed. 2. Loosen lock lever (B) on speed control bar (A). • To decrease forward speed, pull speed control bar (A) toward the operat...
Page 28 - SERVICE MOWER; Service Mower; Removing and Installing Mower Deck Shield; Removing and Installing Mower Deck Drive Belt Shields; Adjusting Drive Belt Tension
Service Mower - 26 SERVICE MOWER Service Mower Removing and Installing Mower Deck Shield c Removing Mower Deck Shield: 1. Park machine safely. (See Parking Safely in the SAFETY section.) c MX20105 2. Remove two knobs (A). 3. Lift shield (B) and pull forward to disengage from under tabs (C) on the fr...
Page 29 - Checking for Bent Mower Blades
Service Mower - 27 SERVICE MOWER c MX20118 5. Release mower deck drive belt tension by turning adjuster nut (A) counterclockwise until two threads remain protruding through adjuster nut (A). 6. Disconnect idler spring (B) from idler arm (C) using a spring puller tool. c MX20120 7. Loosen idler pulle...
Page 30 - Checking and Replacing Mower Blades; Sharpening Blades
Service Mower - 28 SERVICE MOWER c MX20122 Picture Note: Mower deck with side discharge used for illustration. 3. Measure distance (A) between blade tip and flat ground surface. 4. Rotate blade 180° and measure distance between other blade tip and flat ground surface. 5. Install new blade if the dif...
Page 31 - Service Electrical - 29; SERVICE ELECTRICAL; Balancing Blades; Service Electrical; Service the Battery Safely
Service Electrical - 29 SERVICE ELECTRICAL • Keep original bevel (A) when grinding. • Blade should have 0.40 mm (1/64 in.) cutting edge (B) or less. • Balance blades before installing. Balancing Blades c 1. Clean blade. c c c c c c c c c 2. Put blade on nail in a vise. Turn blade to horizontal posit...
Page 32 - Service Electrical - 30; Removing and Installing Battery; Using Booster Battery
Service Electrical - 30 SERVICE ELECTRICAL Checking the Battery (Sealed Batteries) NOTE: Do not attempt to open, add fluid or service battery. Any attempt to do so will void warranty. • Keep battery and terminals clean. • Keep battery bolts tight. • Keep small vent holes open. c Recharge, if necessa...
Page 33 - Service Miscellaneous - 31; SERVICE MISCELLANEOUS; Replacing Fuse; Service Miscellaneous; Using Proper Fuel
Service Miscellaneous - 31 SERVICE MISCELLANEOUS c 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....
Page 34 - Service Miscellaneous - 32; Removing and Installing Rear Drive Wheels; Tightening Rear Drive Wheel Hardware
Service Miscellaneous - 32 SERVICE MISCELLANEOUS c Fill fuel tank at the end of each day’s operation to prevent condensation and freezing during cold weather. 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Allow engine to cool. 3. Remove any trash from area around fuel tank c...
Page 35 - Service Miscellaneous - 33; Checking Tire Pressure; Servicing Caster Wheel Roller Bearings; Cleaning and Repairing Plastic Surfaces
Service Miscellaneous - 33 SERVICE MISCELLANEOUS Checking Tire Pressure c 1. Check tires for damage. 2. Check tire pressure with an accurate gauge. 3. Add air, if necessary: c Servicing Caster Wheel Roller Bearings 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Raise and secu...
Page 36 - TROUBLESHOOTING; Cleaning and Repairing Metal Surfaces; Troubleshooting; Using Troubleshooting Chart
Troubleshooting - 34 TROUBLESHOOTING 2. Dry thoroughly to avoid water spots. Cleaning and Repairing Metal Surfaces Cleaning: Follow automotive practices to care for your vehicle painted metal surfaces. Use a high-quality automotive wax regularly to maintain the factory look of your vehicle’s painted...
Page 37 - Electrical System
Troubleshooting - 35 TROUBLESHOOTING Electrical System Machine Park Brake Steering Engine Lacks Power • Reduce load. • Plugged air intake system. • Plugged fuel filter. • Improper type of fuel. Drain tank and fill with correct fuel. • Clean cooling fins to help prevent overheating. • Replace spark p...
Page 38 - STORAGE; Mower Deck; Storage; Storing Safety
Storage - 36 STORAGE Mower Deck Storage Storing Safety c Preparing Machine for Storage 1. Repair any worn or damaged parts. Replace parts if necessary. Tighten loose hardware. 2. Repair scratched or chipped metal surfaces to prevent rust. 3. Remove grass and debris from machine. 4. Clean under the d...
Page 39 - ASSEMBLY; Removing Machine From Storage; Assembly; Check Hydraulic Oil Level; Check Engine Oil Level
Assembly - 37 ASSEMBLY 1. Change engine oil and filter while engine is warm. 2. Service air filter if necessary. 3. Clean debris from engine air intake screen. 4. On gas engines: • Remove spark plugs. Put 30 mL (1 oz) of clean engine oil in cylinders. • Install spark plugs, but do not connect spark ...
Page 40 - SPECIFICATIONS; Specifications
Specifications - 38 SPECIFICATIONS Connect Battery c c 1. Connect positive (red) cable to battery positive (+) terminal. Install red terminal cover (A). 2. Connect negative (black) cable to battery negative (-) terminal. Install black terminal cover (B). Check Mower Deck Level The mower deck is asse...
Page 41 - Getting Quality Service - 39; GETTING QUALITY SERVICE; Getting Quality Service; Service Literature
Getting Quality Service - 39 GETTING QUALITY SERVICE Getting Quality Service Service Literature If you would like to order a copy of the Parts Catalog or Operator Manual for this machine, contact your Great Dane Dealer. Parts catalogs and operator manuals are also available online at GreatDaneMowers...
Page 42 - Service Miscellaneous - 40
Service Miscellaneous - 40 SERVICE MISCELLANEOUS Service Miscellaneous Wiring Schematics c
Page 43 - Service Miscellaneous - 41; Kawasaki Wiring Schematics
Service Miscellaneous - 41 SERVICE MISCELLANEOUS Kawasaki Wiring Schematics Service Miscellaneous
Page 44 - Service Miscellaneous - 42; Hydraulic Schematics
Service Miscellaneous - 42 SERVICE MISCELLANEOUS Service Miscellaneous Hydraulic Schematics c Left Hydrostatic Pump Assembly Pump Block Charge Pump System Charge Check Shock Valve (Reverse) Manual Bypass Left Wheel Motor Cooling Orifice System Charge Check Shock Valve (Forward) Charge Relief Valve R...
Page 45 - Service Miscellaneous - 43
Page 46 - MAIN FRAME, TRACTION DECK, CONSOLE AND OPC PLATFORM
Main Frame, Traction Deck, Console and OPC Platform - 44 MAIN FRAME, TRACTION DECK, CONSOLE AND OPC PLATFORM 9 8 16 15 23 22 29 28 24 25 12 27 17 6 4 3 2 5 31 20 1 7 19 30 14 11 18 21 13 24 24 26 32
Page 47 - Description
Main Frame, Traction Deck, Console and OPC Platform - 45 MAIN FRAME, TRACTION DECK, CONSOLE AND OPC PLATFORM Ref. No. Part No. Description Qty. Remarks 1 TCA14936 Frame - 1 W/ 48"-52" Deck TCA14946 Frame - 1 W/ 61" Deck 2 D15356 Fender, Left 1 D15355 Fender, Right 1 3 200038 Weight 2 4 1...
Page 48 - Drive Controls and Linkage - 46; DRIVE CONTROLS AND LINKAGE
Drive Controls and Linkage - 46 DRIVE CONTROLS AND LINKAGE 10 1 14 16 17 15 8 20 2 20 6 5 11 10 12 13 3 35 26 32 31 33 27 23 18 22 30 34 32 24 29 33 19 25 7 21 28 9 4 36
Page 49 - NOTES
Drive Controls and Linkage - 47 DRIVE CONTROLS AND LINKAGE * Included with new Hydrostatic Pump. NOTES Ref. No. Part No. Description Qty. Remarks 1 D18069 Speed Limiter 1 2 200080 Steering Controller, RH 1 200081 Steering Controller, LH 1 3 D13029 Control Rod 2 4 14M7303 Flange Nut 2 M6 x 1.0 5 J169...
Page 50 - PARK BRAKE
Park Brake - 48 PARK BRAKE MX20211 1 3 4 23 6 19 17 18 5 7 12 2 20 14 13 16 15 16 15 22 10 11 21 8 11 9
Page 52 - Hydrostatic Pump Drive and PTO - 50; HYDROSTATIC PUMP DRIVE AND PTO
Hydrostatic Pump Drive and PTO - 50 HYDROSTATIC PUMP DRIVE AND PTO 15 15 21 25 24 14 20 11 7 8 9 8 27 13 26 23 10 26 22 12 18 17 6 20 4 11 19 2 3 28 29 1 19 21 5 16 19 31 17 18 29 33 32 28 3
Page 54 - Hydrostatic Components - 52; HYDROSTATIC COMPONENTS
Hydrostatic Components - 52 HYDROSTATIC COMPONENTS MX20223 13 1 2 11 12 14 3 15 3 18 18 3 15 3 10 4 29 19 3 3 18 21 20 23 22 20 16 3 5 20 20 9 8 7 16 5 17 3 3 16 17 20 5 20 6 21 23 22 20 24 26 28 25 27 4
Page 56 - Hydraulic Schematic - 54; HYDRAULIC SCHEMATIC
Hydraulic Schematic - 54 HYDRAULIC SCHEMATIC F I A D B E G K J C H L E M D I G B C H A - Left Hydrostatic Pump AssemblyB - Pump BlockC - Charge PumpD - System Charge Check Shock Valve (Reverse)E - Manual BypassF - Left Wheel MotorG - Cooling OrificeH - System Charge Check Shock Valve (Forward)I - Ch...
Page 57 - PLATFORM COMPONENTS
Platform Components - 55 PU PLATFORM COMPONENTS Ref. No. Part No. Description Qty. Remarks 1 D18038 Park Brake Switch 1 2 D38128 Com. Spring 1.22x.162x2.5 1 3 200299 Platform Weldment 1 4 200618 Platform Plate 1 5 200619 Platform Tab LH Plate 1 6 200655 Miner GBR-6 Bumper 2 7 200691 Platform Wedge 2...
Page 58 - Fuel Tank and Lines - 56; FUEL TANK AND LINES
Fuel Tank and Lines - 56 FUEL TANK AND LINES MX20229 7 7 10 10 1 9 3 6 5 5 8 5 6 5 4 2 11
Page 60 - KOHLER Engine and Related Components - 58; KOHLER ENGINE AND RELATED COMPONENTS
KOHLER Engine and Related Components - 58 KOHLER ENGINE AND RELATED COMPONENTS 9 11 10 12 13 7 5 6 6 6 4 3 8 1 2
Page 62 - KAWASAKI ENGINE AND RELATED COMPONENTS
KAWASAKI ENGINE AND RELATED COMPONENTS 9 12 13 7 5 6 6 6 3 11 10 20 22 18 2 2 19 14 21 1 18 4 17 16 17 8 15 23
Page 64 - KOHLER Logic Schematic - 62; KOHLER LOGIC SCHEMATIC
KOHLER Logic Schematic - 62 KOHLER LOGIC SCHEMATIC NOTES MX20146
Page 65 - Kawasaki Logic Schematic - 63; KAWASAKI LOGIC SCHEMATIC
Kawasaki Logic Schematic - 63 KAWASAKI LOGIC SCHEMATIC *'31*'$ %25()7 /%6 92/ 7$036 &&0$*67 23 &/87&+%5$.( : $51(531, (/(&75,&37 2&/87&+ &/87&+ 37 2 62/(12,' )8(/ 02'8/( ,*1,7,21 3/8* 63 $5. 3/8* 63 $5. 02'8/( ,*1,7,21 62/(12,' )8(/ *'317< &&$ %&...
Page 66 - Battery, Electrical Harness and Components - 64; BATTERY, ELECTRICAL HARNESS AND COMPONENTS
Battery, Electrical Harness and Components - 64 BATTERY, ELECTRICAL HARNESS AND COMPONENTS 11 10 13 9 12 7 8 4 3 2 4 3 2 5 1 16 17 19 19 18 14 23 15 21 20 6 24 25 26 27 28 29 31 30 22 32
Page 68 - Caster Wheels and Rear Wheels - 66; CASTER WHEELS AND REAR WHEELS
Caster Wheels and Rear Wheels - 66 CASTER WHEELS AND REAR WHEELS MX20207 15 3 2 4 14 8 4 7 10 16 1 3 10 12 9 11 18 5 13 17 17 6
Page 70 - Mower Deck Lift Linkage - 68; MOWER DECK LIFT LINKAGE
Mower Deck Lift Linkage - 68 MOWER DECK LIFT LINKAGE MX20232 8 5 7 12 14 14 6 6 23 13 12 5 7 12 7 7 10 16 2 9 15 4 5 4 1 22 24 18 19 21 20 17 18 3 16 10 8 9 7 5 2 12 25 26 27 28
Page 72 - MOWER DECK
Mower Deck - 70 MOWER DECK 17 1 29 5 6 8 30 18 32 20 8 9 5 11 7 24 25 22 2 31 2 23 14 12 16 15 13 16 28 3 27 21 26 4 10 MX20240 19
Page 74 - Mower Deck Spindles - 72; MOWER DECK SPINDLES
Page 76 - Labels and Decals - 74; LABELS AND DECALS
Labels and Decals - 74 LABELS AND DECALS 2 3 4 5 7 9 14 12 13 11 15 16 17 18 19 20 21 22 23 1 10 24 6
