Page 4 - SAFETY LABELS; Safety Labels
SAFETY LABELS SAFETY LABELS - 2 S/N DATE OF PURCHASE: _________________________________________ DEALER NAME: _________________________________________ DEALER PHONE: _________________________________________ PRODUCT IDENTIFICATION NUMBER: Model Number _________________________________________ Serial ...
Page 6 - SAFETY; Emission Compliance Period; Safety; Operator Training Required
SAFETY SAFETY - 4 CAUTION (H) Be safe! To avoid a fire hazard remove all leaves, grass and debris from engine, hydro pumps and motors, pulleys, belts, hoses, engine deck and cutter deck. DANGER/POISON (I) • Shield Eyes: Explosive gases can cause blindness or injury. • NO • Sparks • Flames • Smoking •...
Page 7 - Operating Safely
SAFETY SAFETY - 5 the job. Only use accessories and attachments ap- proved by the manufacturer. Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair, loose cloth- ing or jewelry may get tangled in moving parts. Inspect the area where the equipment is to be u...
Page 8 - Parking Safely; ROTATING BLADES ARE DANGEROUS!
SAFETY SAFETY - 6 Parking Safely Stop machine on a level surface, not on a slope. Disengage mower blades. Lock the park brake. Stop the engine. Remove the key. Wait for engine and all moving parts to stop before you leave the operator’s station. Close fuel shut-off valve, if your machine is equipped...
Page 9 - Keep Riders Off
SAFETY SAFETY - 7 Choose a low ground speed so you will not have to stop or shift while on a slope. Do not mow or operate machine on wet grass. Tires may lose traction. • • • Tires may lose traction on slopes even though the brakes are functioning properly. Avoid starting, stopping or turning on a s...
Page 10 - Prevent Fires; To avoid personal injury or property damage, use; Handling Waste Product and Chemicals
SAFETY SAFETY - 8 ommended parts, when necessary. Grass catcher com- ponents are subject to wear, damage, and deterioration which could expose moving parts or allow objects to be thrown. Keep all nuts and bolts tight, especially blade attach- ment bolts, to be sure the equipment is in safe working c...
Page 11 - OPERATING; Operating
OPERATING OPERATING - 9 Operating Daily Operating Checklist Make sure all necessary guards and shields are safely and securely attached. Check for loose, missing, or damaged parts. Remove mower deck belt shields. Clean grass and debris from belt area. Remove grass and debris from machine and mower d...
Page 12 - Mounting and Dismounting Machine Safely; ting height, stop engine and lock the park; Caster Mounting
OPERATING OPERATING - 10 A-Free-Wheeling Valves Mounting and Dismounting Machine Safely A Step on operator’s platform (A) at the rear of machine to mount the machine. Park machine safely. (See Parking Safely in the SAFETY section.) Step off operator’s platform to dismount machine. Keep operator’s pl...
Page 13 - NOTE: Adjust caster wheel spacers to keep; Setting Cutting Height; NOTE: Before setting cut height, ensure the; Caster to deck mounting position; Caster to deck mounting - Upper Positon
OPERATING OPERATING - 11 IMPORTANT: Do not allow washer (G) to set on caster yoke. It must be on top of height-of-cut spacer bushings (H). NOTE: Adjust caster wheel spacers to keep mower deck tilted slightly down at the front. Adjust caster wheel spacers (F) to compensate front HOC accordingly. Sett...
Page 14 - HOLE LOCATIONS
OPERATING OPERATING - 12 ������������� ������������ HOLE LOCATIONS To adjust the rear height of cut, use the chart above and match the hole locations on the chart up to the hole loca- tions on the picture. To adjust the front height of cut, use the chart above and in- sert the number of C-spacers to...
Page 15 - Testing the Park Brake; Locking Park Brake; Using the PTO
OPERATING OPERATING - 13 Clear area of bystanders, especially children. Pick up objects which may be thrown by the attachment. Pull PTO switch up to engage. Step completely off operator’s platform. Result: The engine must stop. Testing the Park Brake Stop machine on a 17° slope (30% grade) facing do...
Page 16 - Using the Hourmeter; Using the Motion Control Levers
OPERATING OPERATING - 14 Using the Hourmeter NOTE: The machine is equipped with an electric start. The hourmeter will continue to run with the key switch in the run position. A Hourmeter (A) shows number of hours the machine has been operated. Use hourmeter and SERVICE INTERVAL section to determine ...
Page 18 - Starting Engine
OPERATING OPERATING - 16 • Push left motion control lever forward and pull right motion control lever rearward at the same time. Starting Engine CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death. Move the machine to an outside area before runn...
Page 19 - Stopping the Engine; valve open, the machine will have unrestricted; Transporting Machine on a Trailer
OPERATING OPERATING - 17 NOTE: In cold weather or with a new machine, allow engine to reach operating temperature before engaging PTO to prevent engine from stalling. Pull PTO knob (B) up to engage mower deck. Move throttle lever to the fast position (C). NOTE: The travel speed and turn rate will va...
Page 20 - SERVICE INTERVALS; Mowing Travel Speeds
SERVICE INTERVALS SERVICE INTERVALS- 18 • Use a travel speed that fits the conditions: • Mow tall or wet grass twice. Cut grass at half desired height – then cut at desired height. • Travel slow when mowing tall, thick or wet grass. • Avoid damaging grass by slipping or skidding machine drive wheels....
Page 21 - SERVICE ENGINE; Service Lubrication; Grease; Lubricating Pump Idler Pivot
SERVICE ENGINE SERVICE ENGINE- 19 Service Lubrication Grease IMPORTANT: Avoid Damage! The recommended grease is effective within an average air temperature range of -29 to 135 degrees C (-20 to 275 degrees F). IMPORTANT: Avoid Damage! Use only NLGI No. 2 lithium based grease. • If operating outside ...
Page 22 - Service Engine
SERVICE ENGINE SERVICE ENGINE- 20 Service Engine Avoid Fumes CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause seri- ous illness or death. Move the machine to an outside area before running the engine. Do not run an engine in an enclosed area with- out adequate ventil...
Page 23 - Cleaning Engine Air Intake Screen and Fan
SERVICE ENGINE SERVICE ENGINE- 21 IMPORTANT: Avoid Damage! Change the oil more often if the machine is used in extreme conditions: Extremely dusty conditions. Frequent slow or low-speed operation. Frequent short trips. Clean area around dipstick cap and filter. Start engine and run until it reaches n...
Page 24 - SERVICE TRANSMISSION; Checking Spark Plug
SERVICE TRANSMISSION SERVICE TRANSMISSION- 22 • Do not wash paper element. • Do not attempt to clean paper element by tapping against another object. • Do not use pressurized air to clean element. • Replace element only if it is very dirty, damaged or the seal is cracked. NOTE: It may be necessary t...
Page 25 - Service Transmission; Changing Hydraulic Oil and Filter
SERVICE TRANSMISSION SERVICE TRANSMISSION- 23 Service Transmission Hydraulic Oil Use only 5W-50 or 15W-50 all synthetic oil. Checking Hydraulic Oil Level IMPORTANT: Avoid Damage! Check oil level in reser- voir tank when oil is cold. Do not overfill oil reservoir tank. Oil will expand during oper- ati...
Page 26 - Cleaning Hydraulic Oil Pump Cooling Fins; Checking Traction Drive Belt:
SERVICE TRANSMISSION SERVICE TRANSMISSION- 24 IMPORTANT: Avoid Damage! Do not add oil beyond FULL mark. Oil capacity after draining may be less than dry fill capacity. Check oil level before filling complete- ly. NOTE: Dry fill capacity for hydraulic system is 3.1L (3.3 qt.) . Fill oil reservoir with a...
Page 27 - Installing Traction Drive Belt:; Checking and Adjusting Motion Control Linkages; Checking Motion Control Linkages:
SERVICE TRANSMISSION SERVICE TRANSMISSION- 25 A B Remove two cap screws (A). Remove rear shield (B). CAUTION: Avoid injury! Tensioning spring is under high tension. Wear gloves and safety glasses, and use a spring puller to install and remove spring. 4 ⅝” - 5” C D E F G Picture Note: Traction drive ...
Page 28 - Adjusting Motion Control Return to Neutral (RTN)
SERVICE TRANSMISSION SERVICE TRANSMISSION- 26 A C B Rotate speed control bar (A) to full forward position. With engine off, move motion control levers (B) until they contact the speed control bar (A). A slight deflec- tion should be seen in the linkage rod (C). NOTE: Check machine tracking after maki...
Page 29 - SERVICE STEERING AND BRAKES; SERVICE STEERING AND BRAKES- 27; Adjusting Forward and Reverse Speeds; Adjusting Forward Speed:; Adjusting Reverse Speed:; Adjust Neutral Switch
SERVICE STEERING AND BRAKES SERVICE STEERING AND BRAKES- 27 Checking Transmission Tracking: Check and adjust motion control linkages. See Check- ing and Adjusting Motion Control Linkages in the SER- VICE TRANSMISSION section. Start engine and run until it reaches normal operating temperature. Move m...
Page 30 - SERVICE MOWER; Service Steering & Brakes; Adjusting Park Brake; Service Mower; CAUTION: Avoid injury! Help prevent serious
SERVICE MOWER SERVICE MOWER - 28 Picture Note: Engine removed for picture clarity. Park machine safely. (See Parking Safely in the SAFETY section.) Loosen nuts (A). Adjust neutral switch (B). If neutral switch sensitivity needs to be increased, adjust switch (B) down in slots. If neutral switch sens...
Page 31 - Adjusting Drive Belt Tension; Replacing Mower Deck Drive Belt; A B; Installing Mower Deck Drive Belt:; BELT ROUTING
SERVICE MOWER SERVICE MOWER - 29 Lift shield (B) and pull forward to disengage from under tabs (C) on the frame. Remove mower deck shield (B). CAUTION: Avoid injury! Help prevent serious personal injury. Do not operate the mower with- out the belt shields installed. Adjusting Drive Belt Tension Park...
Page 32 - Checking for Bent Mower Blades
SERVICE MOWER SERVICE MOWER - 30 C A B Connect idler tension spring and adjust tension. The length (C) of the tension spring should measure 17.5 to 18.1 cm (6 7/8 in. to 7 1/8 in.) from inside of hook to inside of hook. Install both mower deck belt shields. Install mower deck shield. Adjust mower de...
Page 33 - SERVICE ELECTRICAL; SERVICE ELECTRICAL - 31; Sharpening Blades; CAUTION: Avoid injury! Mower blades are; Balancing Blades
SERVICE ELECTRICAL SERVICE ELECTRICAL - 31 blade (C). 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 towards the ...
Page 34 - Removing and Installing Battery; H F
SERVICE ELECTRICAL SERVICE ELECTRICAL - 32 CAUTION: Avoid injury! Battery electrolyte contains sulfuric acid. It is poisonous and can cause serious burns: Wear eye protection and gloves. Keep skin protected. If electrolyte is swallowed, get medical attention immediately. If electrolyte is splashed i...
Page 35 - SERVICE MISCELLANEOUS; Using Booster Battery
SERVICE MISCELLANEOUS SERVICE MISCELLANEOUS - 33 cover (C). Connect negative (-) battery cable (B) and install cover (A). Cleaning Battery and Terminals Park machine safely. (See Parking Safely in the SAFETY section.) Disconnect and remove battery. Wash battery with solution of four tablespoons of b...
Page 36 - SERVICE MISCELLANEOUS - 34; Adjusting Operator Presence Switch; A B C; Service Miscellaneous; Using Proper Fuel; Filling Fuel Tank; CAUTION: Avoid injury! Fuel vapors are
SERVICE MISCELLANEOUS SERVICE MISCELLANEOUS - 34 of fuse holder is securely fastened to fuse socket. Adjusting Operator Presence Switch � Remove the OPC plate covering the operator presence switch by removing the two 3/8-16n1.25 carriage bolts securing it in place. Carefully cut the wire tie securin...
Page 37 - Removing and Installing Rear Drive Wheels
SERVICE MISCELLANEOUS SERVICE MISCELLANEOUS - 35 Important: Avoid damage! Dirt and water in fuel can cause engine damage: Clean dirt and debris from the fuel tank opening. Use clean, fresh, stabilized fuel. Fill the fuel tank at the end of each day’s operation to keep condensation out of the fuel ta...
Page 38 - Checking Tire Pressure
SERVICE MISCELLANEOUS SERVICE MISCELLANEOUS - 36 Tighten wheel nuts in numbered sequence shown for safe wheel installation. Tighten alternately until recom- mended torque value is reached. Checking Tire Pressure 2. CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when th...
Page 39 - TROUBLESHOOTING; Cleaning and Repairing Plastic Surfaces
TROUBLESHOOTING TROUBLESHOOTING - 37 Remove locknut (A), cap screw (B), and wheel assem- bly (C). Remove seals (D) and bearings (E) from wheel. Clean and inspect bearings (E). Replace as needed. Repack bearings with clean grease. Install bearings (E) and wheel spacer (F) (if removed), and new seals ...
Page 40 - STORAGE; Electrical System
STORAGE STORAGE - 38 Engine Will Not Start Or Is Hard To Start • Park brake lever not in the proper position. • OPC switch not depressed. Stand on platform or adjust switch. • Check that motion control levers are in neutral and neutral switches are correctly adjusted. • PTO engaged.• Stale or improp...
Page 41 - Machine
STORAGE STORAGE - 39 • Neutral switches faulty or not adjusted properly. See your authorized dealer. • Key switch or starter faulty. See your • authorized dealer. • PTO engaged.• Motion control levers and park brake lever not in proper position. Battery Will Not Charge • Loose or corroded connection...
Page 42 - ASSEMBLY; Storage
ASSEMBLY ASSEMBLY - 40 • Remove belt shields and clean debris from sheaves. • Check sheaves for proper alignment or damage. See authorized dealer. Mower Blades Do Not Engage • Deck drive belt slipping or broken. • Deck belt tension spring not installed or broken. • PTO switch faulty.• Fuse blown.• L...
Page 43 - SPECIFICATIONS; IMPORTANT: Avoid Damage! Prolonged exposure to; Removing Machine From Storage; Check Engine Oil Level
SPECIFICATIONS SPECIFICATIONS - 41 NOTE: The stored battery should be recharged every 90 days. Charge the battery. IMPORTANT: Avoid Damage! Prolonged exposure to sunlight could damage the hood surface. Store ma- chine inside or use a cover if stored outside. Store the vehicle in a dry, protected pla...
Page 44 - GETTING QUALITY SERVICE; GETTING QUALITY SERVICE - 42
GETTING QUALITY SERVICE GETTING QUALITY SERVICE - 42 If oil is level is below ADD mark, fill to proper level. If oil level is above the FULL mark, drain to proper level. Insert dipstick. Tighten cap. Connect Battery CAUTION: Avoid injury! Prevent Battery Explosions: • Keep sparks, lighted matches, an...
Page 45 - GETTING QUALITY SERVICE - 43; Great Dane Quality Continues with Quality Service; Item
GETTING QUALITY SERVICE GETTING QUALITY SERVICE - 43 Great Dane Quality Continues with Quality Service Great Dane provides a process to handle your questions or problems, should they arise, to ensure that product quality continues with your authorized Great Dane dealer’s parts and service support. F...
Page 46 - WIRING DIAGRAM
WIRING DIAGRAM Wiring Diagram - 44 GY R R TN GN Y W Y W LT/GN LT/GN LT/GN LT/GN LT/BU GY GRAY TN TAN PK PINK LT/BU LIGHT BLUE LT/GN LIGHT GREEN GN GREEN BU BLUE V VIOLET Y YELLOW OR ORANGE R RED BN BROWN BK BLACK W WHITE W ENGINE KILL GY LT/GN TN GY PTO SWITCH STARTER SOLINOID BK 87 BU 30 BK/OR Y VO...
Page 47 - HYDRAULIC SCHEMATIC; Hydraulic Schematic - 45
Page 48 - NOTES
Page 49 - MAIN FRAME ASSEMBLY
MAIN FRAME ASSEMBLY Frame Assembly - 46 963019 10 964016 6 964003 4 960022 6 960601 6 TCU21265 1 M68342 2 201005 1 960001 2 963001 2 964040 4 201019 1 201355 1 960044 2 967115 10 201150 2 960526 8 Battery 1 964040 4 201012 1 963019 10 D28159 1 03H1832 2 968087 4 967115 10 201356 1 201095 1 201204 1 ...
Page 51 - HYDRAULIC AND HANDLE ASSEMBLY
HYDRAULIC AND HANDLE ASSEMBLY Hydraulc and Handle Assembly - 48 960001 7 960600 6 201358 1 201359 1 200116 4 D13028 2 121080 3 963020 4 200654 1 TCA15195 1 960001 7 968087 6 960702 4 D13309 1 34H60 1 TCA15122 1 964048 3 180640 1 960002 2 201354 1 960000 2 121080 3 201022 1 D18079 1 960001 7 200690 1...
Page 53 - ENGINE, HYDRAULIC AND MAINFRAME ASSEMBLY
ENGINE, HYDRAULIC AND MAINFRAME ASSEMBLY Engine, Hydraulic And Mainframe Assembly - 50 D14252 1 960602 1 D18056 1 200665 1 200318 1 967115 6 960052 1 964001 1 403490 1 150052 1 191179 2 D18071 1 201143 1 191179 2 D18314 1 960049 1 968087 12 968087 12 960702 3 968087 12 963033 2 960502 1 111910 4 200...
Page 55 - FOOT PLATE/CONSOLE COMPONENTS; FOOT PLATE COMPONENTS
FOOT PLATE/CONSOLE COMPONENTS Foot Plate/Console Components - 52 FOOT PLATE COMPONENTS CONSOLE COMPONENTS 960001 4 200619 1 200767 1 963074 2 201136 1 200655 2 967115 2 960701 2 200693 1 968087 4 963019 4 964048 4 TCU16481 TCU14840 D18021 180620 1 200607 1 136574 1 192296 1 D18427 1 D24020 2 TCA1505...
Page 57 - DECK ASSEMBLY
DECK ASSEMBLY Deck Assembly - 54 201174 2 967348 2 GDU10231 1 D18055 6 200262 2 960046 16 964016 17 TCA16387 1 M132768 1 H141123 1 201178 1 968087 4 D18076 2 968087 4 964016 17 D23058 1 D18084 1 D13024 2 960502 12 N242189 1 201145 1 960051 1 D18032 1 964501 1 964022 1 D24019 2 959995 1 424390 1 D180...
Page 59 - WHEEL AND STRUT ASSEMBLY/PUMP COMPONENTS; PUMP COMPONENTS
WHEEL AND STRUT ASSEMBLY/PUMP COMPONENTS Wheel and Strut Assembly/Pump Components - 56 PUMP COMPONENTS 2 2 1 6 3 4 8 5 7 9 WHEEL AND STRUT ASSEMBLY 161397 1 D13008 1 D18076 2 201172 1 D18076 2 164145 4 201173 1 963011 1 200778 1 964000 1 191049 1 959995 1
Page 61 - SPINDLE ASSEMBLY
SPINDLE ASSEMBLY Spindle Assembly - 58 14 7 8 9 2 4 3 1 6 11 2 5 12 13 10
Page 63 - DECAL LOCATIONS
DECAL LOCATIONS Decal Locations - 60 18 7 17 8 17 19 2 16 3 6 3 4 1 14 5 11 9 10 S/N 12 13 15 3 20
