Page 3 - Introduction; Special Messages; 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© 2006 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 DATE OF PURCHASE: _________________________________________ DEALER NAME: _________________________________________ DEALER PHONE: _________________________________________ PRODUCT IDENTIFICATION NUMBER: Model Number _________________________________________ Serial Numb...
Page 5 - SAFETY; Emission Control System Certification Label; Safety; Operator Training Required
Safety - 3 SAFETY • 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 safe! To avoid a fire hazard remove all leaves, grass and debr...
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 a suitable protective device such as earplugs. Loud noise can cause impairment or loss of hearing. Maintenance and Storage • Never operate machine in a closed area where dangerous carbon monoxide fumes can collect. • Disengage drives, lower implement, lock parking brake, sto...
Page 9 - OPERATING; Handling Waste Product and Chemicals; Operating; Daily Operating Checklis; Avoid Damage to Plastic and Painted Surfaces; Miscellaneous Controls
Operating - 7 OPERATING plastic liner. Always place containers on the ground away from your vehicle before fueling. • Remove fuel-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a...
Page 10 - Mounting and Dismounting Machine Safely; Raising and Lowering Thigh Pad; Setting Cutting Height
Operating - 8 OPERATING Mounting and Dismounting Machine Safely c 1. Step on operator’s platform (A) at the rear of machine to mount the machine. 2. Park machine safely. (See Parking Safely in the SAFETY section.) 3. Step off operator’s platform to dismount machine. 4. Keep operator’s platform and s...
Page 11 - HOLE LOCATIONS; Testing PTO Switch
Operating - 9 OPERATING 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 locations on the picture. To adjust the front height of cut, use the chart above and insert the number of C-spacers to correspond to the number on the...
Page 12 - Testing Operator Presence Switch; Testing the Park Brake
Operating - 10 OPERATING 4. Turn key switch to the start position. Result: The engine must not crank. Testing Neutral Switch (Run) 1. Lock park brake. 2. Push PTO switch down to disengage. 3. Start engine. 4. Push one motion control lever forward. 5. Repeat procedure using the other lever. 6. Repeat...
Page 13 - Using the Throttle; Using the Motion Control Levers
Operating - 11 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 15 - Starting Engine
Operating - 13 OPERATING Starting Engine c 1. Stand on operator’s platform. 2. Lock park brake. c 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. Position c...
Page 16 - Transporting Machine on a Trailer
Operating - 14 OPERATING 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) are located in the back of the ma...
Page 17 - Service Intervals - 15; SERVICE INTERVALS; Service Intervals
Service Intervals - 15 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 18 - SERVICE ENGINE; Lubricating Mower Deck Spindles; Checking Engine Oil Level; Changing Engine Oil and Filter
Service Engine - 16 SERVICE ENGINE • Lubricate one pump idler pivot grease fitting (A). Lubricating Mower Deck Spindles c • Lubricate three mower deck spindle grease fittings (A). Lubricating Mower Deck Idler Pivot c • Lubricate one deck idler pivot grease fitting (A). Service Engine Avoid Fumes c E...
Page 19 - Cleaning Engine Air Intake Screen and Fan
Service Engine - 17 SERVICE ENGINE c 1. Clean area around dipstick cap and filter. 2. Start engine and run until it reaches normal operating temperature. 3. Park machine safely. (See Parking Safely in the SAFETY section.) c 4. Insert drain tube over oil drain fitting (A) 5. Put oil drain pan under d...
Page 20 - Service Transmission - 18; SERVICE TRANSMISSION; Service Transmission
Service Transmission - 18 SERVICE TRANSMISSION Checking Spark Plug c 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. Cleaning Engine Oil Cooler - Kohler Engines Keep e...
Page 21 - Service Transmission - 19; Changing Hydraulic Oil and Filter
Service Transmission - 19 SERVICE TRANSMISSION 3. Remove dipstick cap (A). Wipe dipstick clean. NOTE: NOTE: Do not tighten dipstick cap when checking oil level. 4. Insert dipstick into reservoir filler neck (B). Do not tighten cap. 5. Remove dipstick. Check oil level on dipstick. Oil level should be...
Page 22 - Service Transmission - 20; Checking and Replacing Pump Traction Drive Belt; Removing Traction Drive Belt; Installing Traction Drive Belt:
Service Transmission - 20 SERVICE TRANSMISSION Checking and Replacing Pump Traction Drive Belt c NOTE: The traction drive belt will not require a tension adjustment. Belt is self-adjusted using a spring tensioner. Checking Traction Drive Belt: 1. Park machine safely. (See Parking Safely in the SAFET...
Page 23 - Service Transmission - 21; Checking and Adjusting Motion Control Linkages
Service Transmission - 21 SERVICE TRANSMISSION 1. Install traction drive belt (E) on drive sheaves (G) as shown. Ensure that traction drive belt is positioned in front of anchor cap screw (F). 2. Insert 1/2 in. breaker bar into hole (C) and rotate idler pulley (D) forward for additional clearance to...
Page 24 - Service Transmission - 22; Checking and Adjusting Transmission Tracking; Adjusting Forward and Reverse Speeds; Adjust Neutral Switch
Service Transmission - 22 SERVICE TRANSMISSION Checking and Adjusting Transmission Tracking c NOTE: Check and adjust transmission tracking on a hard, level surface. Checking Transmission Tracking: 1. Check and adjust motion control linkages. See Checking and Adjusting Motion Control Linkages in the ...
Page 25 - SERVICE STEERING & BRAKES; Service Steering & Brakes; Adjusting Park Brake; Service Mower; Removing and Installing Mower Deck Shield; Adjusting Drive Belt Tension
Service Steering & Brakes - 23 SERVICE STEERING & BRAKES Service Steering & Brakes Adjusting Park Brake Testing Park Brake: 1. Inflate tires to correct pressures. c 2. Stop machine on a maximum 17° slope. 3. Lock park brake. • A properly adjusted park brake must prevent the drive wheels ...
Page 26 - SERVICE MOWER; Replacing Mower Deck Drive Belt; Checking for Bent Mower Blades
Service Mower - 24 SERVICE MOWER Replacing Mower Deck Drive Belt Removing Mower Deck Drive Belt: 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Lower mower deck to the lowest cutting height position. 3. Remove mower deck shield. 4. Remove both mower deck belt shields. c c 5. ...
Page 27 - Checking and Replacing Mower Blades; Sharpening Blades
Service Mower - 25 SERVICE MOWER c Picture Note: Mower deck with side discharge used for illustration. 3. Measure distance (A) between blade tip and flat ground surface. 4. Rotate blade 180° and measure distance between other blade tip and flat ground surface. 5. Install new blade if the difference ...
Page 28 - Service Electrical - 26; SERVICE ELECTRICAL; Balancing Blades; Service Electrical; Service the Battery Safely
Service Electrical - 26 SERVICE ELECTRICAL • Balance blades before installing. Balancing Blades c 1. Clean blade. c c 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 chang...
Page 29 - Service Electrical - 27; Using Booster Battery; Replacing Fuse
Service Electrical - 27 SERVICE ELECTRICAL 3. Slide back red cover (C) and disconnect positive (+) battery cable (D). c 4. Loosen nut on front long carriage bolt (E). 5. Remove rear long carriage bolt (F) and nut. 6. Lift and slide battery (G) out from back of battery tray (H). 7. Inspect isolator p...
Page 30 - Service Miscellaneous - 28; SERVICE MISCELLANEOUS; Adjusting Operator Presence Switch; Service Miscellaneous; Using Proper Fuel
Service Miscellaneous - 28 SERVICE MISCELLANEOUS • Check metal clip in fuse window. Discard fuse if clip is broken. • Install new 20 Amp fuse in socket. • Install socket with fuse in cover. Ensure that plastic tab of fuse holder is securely fastened to fuse socket. Adjusting Operator Presence Switch...
Page 31 - Service Miscellaneous - 29; Removing and Installing Front Caster Wheels; Tightening Rear Drive Wheel Hardware
Service Miscellaneous - 29 SERVICE MISCELLANEOUS c 2. Lift machine with a safe lifting device centered under tire support frame (A) on the side where tire is being removed. c 3. Remove wheel nuts (B). 4. Remove wheel. Installing: 1. Install wheel with valve stem (C) facing out. 2. Install and tighte...
Page 32 - TROUBLESHOOTING; Servicing Caster Wheel Roller Bearings; Cleaning and Repairing Plastic Surfaces; Troubleshooting; Using Troubleshooting Chart
Troubleshooting - 30 TROUBLESHOOTING 1.1. 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 securely support front of machine. c 3....
Page 33 - Engine
Troubleshooting - 31 TROUBLESHOOTING Engine Electrical System If Check Poor Engine Performance Fuel: • Dirt in fuel system or fuel is old. Replace fuel with fresh stabilized fuel. Obtain fuel from another supplier before suspecting machine problems. Suppliers blend fuels differently and changing sup...
Page 34 - Machine
Troubleshooting - 32 TROUBLESHOOTING Machine Park Brake Steering If Check Starter Will Not Work • Blown fuse. • OPC Switch faulty or not adjusted properly. • Park brake switch is faulty. • Loose or corroded battery connections. • Neutral switches faulty or not adjusted properly. See your authorized ...
Page 35 - STORAGE; Mower Deck; Storage; Storing Safety
Storage - 33 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 36 - ASSEMBLY; Removing Machine From Storage; Assembly; Check Hydraulic Oil Level; Check Engine Oil Level
Assembly - 34 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 37 - SPECIFICATIONS; Specifications; Getting Quality Service
Specifications - 35 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 Machine Safety Systems Perform safety s...
Page 38 - Getting Quality Service - 36; GETTING QUALITY SERVICE; Part Numbers
Getting Quality Service - 36 GETTING QUALITY SERVICE authorized Great Dane dealer’s parts and service support. Follow the steps below to get answers to any questions you may have about your product. Refer to your attachment and machine operator manuals. Contact your authorized Great Dane dealer with...
Page 39 - Service Miscellaneous - 37
Service Miscellaneous - 37 SERVICE MISCELLANEOUS Service Miscellaneous Wiring Schematics c
Page 40 - Service Miscellaneous - 38; Hydraulic Schematics
Service Miscellaneous - 38 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 41 - Service Miscellaneous - 39
Page 42 - MAIN FRAME ASSEMBLY
MAIN FRAME ASSEMBLY Frame Assembly - 40 18 15 11 21 9 15 13 20 21 5 3 8 22 6 16 17 19 14 10 1 4 2 7 19
Page 43 - ITEM
MAIN FRAME ASSEMBLY Frame Assembly - 41 ITEM PART NO QTY DESCRIPTION 1 D24020 3 SCREW, 8-32X .50 PAN PHL Y 2 M63431 3 NUT, 8-32 ELASTIC STOP 3 JD26 8 NUT, 1/2-20 LUG Y 4 102770 3 RELAY, ISO MINI ELEC. 5 200601 2 ASSY, TIRE/WHL 18/8.5X8 YELLOW 6 200672 4 SPACER, .625X.120X.400 Y 7 N/A 1 ASSEMBLY, CON...
Page 44 - FUEL, HYDRAULIC AND HANDLE ASSEMBLY
FUEL, HYDRAULIC AND HANDLE ASSEMBLY Fuel, Hydraulc and Handle Assembly - 42 23 29 12 14 31 18 21 17 1 20 23 4 25 16 28 2 3 26 30 11 22 7 8 6 5 24 27 13 9 30 15 19 10 15
Page 46 - ENGINE, HYDRAULIC AND MAINFRAME ASSEMBLY; Engine, Hydraulic And Mainframe Assembly - 44
ENGINE, HYDRAULIC AND MAINFRAME ASSEMBLY 2 2 13 14 15 21 11 3 1 12 20 5 16 4 26 7 23 17 18 23 22 10 25 8 9 24 23 6 19 27 19 H.P. 23 H.P. 28 29 30 31 32 Engine, Hydraulic And Mainframe Assembly - 44
Page 48 - CLUTCH, PUMP COMPONENTS AND FOOT PLATE ASSEMBLY; Clutch, Pump Components and Foot Plate Assembly - 46
CLUTCH, PUMP COMPONENTS AND FOOT PLATE ASSEMBLY 39 21 22 15 34 39 29 23 38 4 36 27 8 18 6 14 37 1 2 19 5 31 3 39 7 39 24 16 17 12 17 11 33 25 32 28 9 30 20 15 35 10 39 6 26 26 13 Clutch, Pump Components and Foot Plate Assembly - 46
Page 50 - HYDRAULIC COMPONENTS; Hydraulic Components - 48
Page 52 - FUELCOMPONENTS/WIRING HARNESS; FUEL COMPONENTS
FUELCOMPONENTS/WIRING HARNESS Fuel Components - 50 FUEL COMPONENTS WIRING HARNESS 200704 Wiring Harness
Page 53 - FUEL COMPONENTS/WIRING HARNESS
ITEM PART NO. QTY DESCRIPTION 1 TCA15021 1 FUEL TANK 2 181251 1 CAP, FUEL 3 D18144 1 GROMMET 4 TCA15048 1 FUEL PICKUP 5 M68342 5 CLAMP 6 M88753 AR HOSE, FUEL, 10 FT. 1/4 IN. SAE 30-R7 7 14M7400 4 NUT 8 AM116304 1 FILTER 9 03M7191 4 CAP SCREW 10 19M7865 6 CAP SCREW 11 200603 1 BRACKET FUEL COMPONENTS...
Page 54 - CONSOLE AND BATTERY ASSEMBLY; Console and Battery Assembly - 52
CONSOLE AND BATTERY ASSEMBLY Console and Battery Assembly - 52 23 25 11 22 23 25 17 12 6 14 1 15 16 29 18 13 2 10 27 9 26 20 28 7 30 29 4 19 8 3 5 29 24 21 31 32
Page 56 - FOOT PLATE/CONSOLE COMPONENTS; FOOT PLATE COMPONENTS
FOOT PLATE/CONSOLE COMPONENTS Foot Plate/Console Components - 54 FOOT PLATE COMPONENTS CONSOLE COMPONENTS 10 4 7 6 11 5 12 9 8 3 1 2 13 3 2 1 11 4 5 6 12 7 10 9 8
Page 58 - DECK ASSEMBLY
DECK ASSEMBLY Deck Assembly - 56 14 7 2 5 1 25 43 44 3 43 8 23 22 5 18 43 28 21 38 21 19 33 4 10 45 15 20 13 35 46 42 35 41 31 30 39 42 36 37 34 24 29 9 12 40
Page 60 - WHEEL AND STRUT ASSEMBLY/PUMP COMPONENTS; Wheel and Strut Assembly/Pump Components - 58; PUMP COMPONENTS
WHEEL AND STRUT ASSEMBLY/PUMP COMPONENTS Wheel and Strut Assembly/Pump Components - 58 PUMP COMPONENTS 2 2 1 6 3 4 8 5 7 9 WHEEL AND STRUT ASSEMBLY 1 11 6 7 8 5 4 3 2 4 9 10
Page 62 - SPINDLE ASSEMBLY; Spindle Assembly - 60
SPINDLE ASSEMBLY Spindle Assembly - 60 14 7 8 9 2 4 3 1 6 11 2 5 12 13 10
Page 64 - DECAL LOCATIONS
DECAL LOCATIONS Decal Locations - 62 19 15 19 1 2 10 3 8 17 11 17 7 1 S/N 12 6 13 18 4 5 9 14 7 3
Page 65 - WARNING
DECAL LOCATIONS Decal Locations - 63 To avoid injury from rotating belts, keep all shields and guards in place Para evitar ser lesionado por las correas en movimiento, mantener todos los escudos y protectores en su lugar. ADVERTENCIA WARNING WARNING S h i e l d M i s s i n g . D O N O T O p e r a t ...
