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Chariot GDRZ25KAE, GDRZ25KHE, GDRZ26KHE

GD10001 B2

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

OMGD10001 B2 D02-105
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.

GDRZ26KHE Serial No. (459000 - 460999) 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. DATE OF PURCHASE: _________________________________________ DEALER NAME: _________________________________________ DEALER PHONE: _________________________________________

B

Special Messages
Your manual contains special messages to bring attention to potential safety concerns, machine damage as well as helpful operating and servicing information. Please read all the information carefully to avoid injury and machine damage.

C

A

MX9204

MODEL NUMBER (A): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ SERIAL NUMBER (POWER UNIT) (B): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ENGINE SERIAL NUMBER (B): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ENGINE SPECIFICATION NUMBER (C): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

c CAUTION:potential hazards orsymbol to the Avoid injury! This and text highlight death
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
Chariot GDRZ25KAE Serial No. (455000 - 455999) GDRZ25KHE Serial No. (457000 - 458999)

Introduction

TABLE OF CONTENTS
Table of Contents

Safety .....................................................................................................................................................................................1 Operating................................................................................................................................................................................6 Replacement Parts ...............................................................................................................................................................10 Service Intervals...................................................................................................................................................................11 Service Lubrication...............................................................................................................................................................12 Service Engine .....................................................................................................................................................................13 Service Transmission............................................................................................................................................................15 Service Mower......................................................................................................................................................................18 Service Electrical..................................................................................................................................................................23 Service Miscellaneous..........................................................................................................................................................26 Troubleshooting ....................................................................................................................................................................28 Storage .................................................................................................................................................................................31 Assembly ..............................................................................................................................................................................32 Specifications .......................................................................................................................................................................34 Index .....................................................................................................................................................................................35 Service Record GD ..............................................................................................................................................................36

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© 2002 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© 2001 OMGD10001 B2 - English

Table of Contents

SAFETY
Safety

Understanding The Machine Safety Labels

DANGER

MIF

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. • Keep hands and feet away.

MX9293 MX9214

CAUTION

DANGER/POISON

MX9294 MX9214

• Do not operate mower without chute deflector, mulching plate or complete grass catcher assembly in position.
MX9292 MX9204

• Shield eyes, explosive gases can cause blindness or injury. • • No sparks, flames, smoking. Sulfuric acid can cause blindness or severe burns.

• Do not remove grass catcher, mulching plate or raise the chute deflector until engine and blade(s) have stopped.

• 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.

Safety - 1

Avoid contact with cutter blades. Set ground speed control to safe speed. The following table provides the engine compliance period in hours associated with the category found on the certification label. contact your Great Dane dealer or write Great Dane Power Equipment. Carefully read safety instructions. Be sure guards and shields are in good condition and fastened in place. covers and shields in place while working. • • • • • • Do not disable or bypass any safety device. or missing parts. They may be rotating. IN 47130. • Check before each use that operator presence controls are functioning correctly. Make any necessary adjustments before you operate. Operating Safely • Inspect machine before you operate. Emission Compliance Period (Small Off-Road Gas Engines) MX9295 MX9214 • This product is designed for professional and commercial users. 4700 New Middle Rd. badly worn. Practice with cutter blades off until confident. • Check brake action before you operate. Repair or replace damaged. Know function of controls before operating. Be sure hardware is tight. Keep children and others clear from area. Contact your Great Dane Equipment Retailer concerning emission controls and component questions. Jeffersonville. • Slowly and smoothly move speed control levers to start and stop machine.2 . • Be careful on slopes. this indicates the number of operating hours for which the engine has been certified to meet EPA and/or CARB emission requirements. Adjust or service brakes as necessary. and used in the United States and Canada in off-road mobile equipment. Test safety systems. Do not operate unless they are functioning correctly. The emissions warranty applies only to those engines marketed by Great Dane that have been certified by the EPA and/or CARB. • Do not change the engine governor setting or overspeed the engine. Always wear safety goggles while operating.. • Do not operate mower without discharge chute or entire grass catcher in place. do not mow where stability or traction is in doubt. USA. Always park machine on level surface. • To obtain additional operator manual and safety instructions. • • • • • Operation training is required. Clear mowing area of all debris. Agency EPA EPA EPA CARB CARB CARB Category C B A Moderate Intermediate Extended Hours 250 500 1000 125 250 500 • Keep all guards. If your engine has the emission compliance category listed on the emission control system certification or air index label. 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. • Reduce speed and avoid sharp turns. Emission controls and Safety . 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).SAFETY CAUTION components can only be adjusted by EPA and/or CARB authorized service centers.

MIF • Keep hands. • • Do not mow in reverse. Remove key. Parking Safely 1.SAFETY • • Stop machine if anyone enters the area. Keep people and pets out of mowing area. Lock park brake. 5. • Clear mowing area of objects that might be thrown. Stop blades before crossing roads or sidewalks. • Test drive area with mower lowered but not running. trees. Wait for engine and all moving parts to stop before you leave the operator’s station. stay alert to the presence of children. • Do not wear radio or music headphones. especially children can move quickly into the mowing area before you know it. Stop machine on a level surface. Do not mow where traction or stability is doubtful. • Wear a suitable protective device such as earplugs. • Do not carry or let children ride on any attachment or machine even with the blades off. especially for children. not on a slope. • Wear close fitting clothing and safety equipment appropriate for the job. Safety .3 . 6. Rotating Blades are Dangerous HELP PREVENT SERIOUS OR FATAL ACCIDENTS: • If you hit an object. • Always wear safety goggles or safety glasses with side shields when operating the mower. or other objects that may obscure vision. Safe service and operation requires your full attention. drive forward carefully. Avoid Tipping • Slopes are a major factor related to loss-of-control and tip-over accidents. • Keep children indoors when you are mowing. Use care when approaching blind corners. Disengage PTO. 7. Make repairs before you operate. trees. 3. Stop engine. Never raise mower decks when blades are running. Loud noise can cause impairment or loss of hearing. • Slow down and be careful of traffic when operating near or crossing roadways. Slow down when you travel over rough ground. • Study mowing area. Children are attracted to mowing activity. • Use only accessories and attachments approved by the manufacturer of the machine. shrubs. Keep machine and attachments properly maintained and in good working order. Set up a safe mowing pattern. which can result in severe injury or death. Only operate during daylight or with good artificial light. • Before backing up. • • Do not leave machine unattended when it is running. • Be aware of the mower discharge direction and make sure that no one is in the path of the discharge direction. Do not tow children in a cart or trailer. 4. shut off PTO and look down and behind the machine carefully. feet and clothing away from mower deck when engine is running. or other objects that may block your vision. stop and inspect the machine. 2. • Do not operate machine if you are under the influence of drugs or alcohol. shrubs. • Do not let children or an untrained person operate the machine. Turn the machine off if a child enters the mowing area. • Use extra care when you come to blind corners. People. Lower attachments to the ground. • Rotating blades can cut off arms and legs. Shut off blades when you are not mowing. PROTECT CHILDREN: • Never assume that children will remain where you last saw them. • Park machine safely before inspecting or unplugging mower or bagger. • Be alert at all times. Checking Mowing Area • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job.

If necessary.SAFETY • Drive across a hill . Wear protective clothing and use insulated tools. • Keep away from drop-offs. especially at night. • Whenever driving on public roads. use flashing warning lights and turn signals according to local regulations. • Use extra care when loading or unloading the machine into a trailer or truck. Keep hardware tight. Unauthorized modifications may impair its function and safety. Keep safety devices in place and in working condition. Let machine cool. carefully release pressure from components with stored energy such as hydraulic components. Keep area clean and dry. If machine stops. • Never lubricate. • Check wheel bolt tightness often during the first 100 hours of operation. or debris from the machine. remove any buildup of grease. • Keep all parts in good condition and properly installed. oil.4 . • Riders obstruct the operator’s view resulting in the machine being operated in an unsafe manner. to prevent them from getting caught. • Charge batteries in an open. Lock service latches before working on machine with raised attachments. or adjust machine while it is moving. • Securely support any machine elements that must be raised for service work.not up and down. • Mowing when grass is wet can cause reduced traction and sliding. • Lower attachments to the ground before servicing machine. flashing warning lights may need to be installed. • Do not drive where machine could slip or tip. Practice Safe Maintenance • Only qualified. Check hoses and lines regularly. • Keep all nuts and bolts tightened. especially blade attachment bolts. • Riders on the machine or attachment may be struck by foreign objects or thrown off the machine causing serious injury. Keep Riders Off • Only allow the operator on the machine. and embankments. jewelry. • Understand service procedure before doing work. • Keep hands. well-ventilated area. • Drive machine very slowly and avoid quick stops when attachment is removed. Lock park brake and remove the key. Safe service requires your full attention. turn slowly and in the downhill direction. Unplug battery charger before connecting or disconnecting from the battery. trained adults should service this machine. away from sparks. • To prevent fires. choose a low gear so that shifting and stopping will not be necessary while on the slope. and long hair away from any moving parts. Extra Avoid High Pressure Fluids • Hydraulic hoses and lines can fail due to physical damage. disengage mower blades and back down slowly. • Before servicing machine. feet. and exposure. Replace damaged hoses and lines. On gear models. ditches. • Transport machine with decks lowered to improve stability. • Wheel hardware must be tightened to specified torque using the proper procedure anytime it is loosened. Disengage all power and stop the engine. • Slow down before you make a sharp turn or operate on a slope. • Disconnect battery or remove spark plug wire before making any repairs. Keep riders off. Replace worn or broken parts. clothing. Driving Safely on Public Roads Avoid personal injury or death resulting from a collision with another vehicle on public roads: • Use safety lights and devices. • Stay alert for holes and other hidden hazards in the terrain. • Never run engine unless park brake is locked. • Hydraulic fluid connections can loosen due to physical Safety . • Do not modify machine or safety devices. • Do not wear radio or music headphones while servicing the machine. Do not shift to neutral and coast downhill. Replace all worn or damaged safety and instruction decals. • Avoid starting and stopping on a slope. age. kinks. Checking Wheel Bolts • A serious accident could occur causing serious injury if wheel bolts are not tight. Slow moving machines when driven on public roads are hard to see. especially the engine compartment. service. Fix damage immediately.

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. leaves.L. Welding can structurally weaken or deform the wheel. 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. MIF • Static electric discharge can ignite gasoline vapors in an ungrounded fuel container. running. • Do not store machine with fuel in tank in a building where fumes may reach an open flame or spark. or add fuel with engine running or hot. Keep nozzle in contact with container opening while filling. Prevent Fires • Never remove fuel cap. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. make sure it is plastic and has no screen or filter. Allow engine to cool for several minutes. • Never remove the fuel cap or add fuel with the engine Safety . Handling Fuel Safely Fuel and fuel vapors are highly flammable and explosive: • Do not refuel machine while you smoke. If this is not possible. • If an accident occurs. • When inflating tires. cuts. • Always maintain the correct tire pressure. Protect hands and body from high pressure fluids. • Never fill fuel tank or drain fuel from a machine in an enclosed area. • To reduce fire hazard. Clean up spilled fuel immediately. bubbles. plastic fuel container to refuel equipment on a truck bed or trailer. Stop engine and allow to cool before filling. • Search for leaks with a piece of cardboard. Remove the fuel container from the bed of a vehicle or the trunk of a car and place on the ground away from the vehicle before filling. remove equipment from trailers or truck beds and refuel them on the ground. Never weld or heat a wheel and tire assembly. or when engine is running. when machine is near an open flame or sparks. Fill fuel tank outdoors. Methanol is harmful to your health and to the environment. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. use a portable. • Never store equipment with fuel in the tank inside a building where fumes may reach an open flame or spark. Tighten all connections before applying pressure. do not use gas with methanol. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source.SAFETY damage and vibration. • Prevent fires. • Prevent fire and explosion caused by static electric discharge. see a doctor immediately. • Check tires for low pressure. The heat can cause an increase in air pressure resulting in a tire explosion. Check connections regularly. Do not inflate the tires above the recommended pressure.5 . • Escaping fluid under pressure can penetrate the skin causing serious injury. keep engine free of grass. or excessive grease. • When practical.) or the American Society for Testing & Materials (ASTM). Use only non-metal. • For gasoline engines. If using a funnel. • Allow engine to cool before storing in any enclosure. Tighten loose connections. portable fuel containers approved by the Underwriter’s Laboratory (U. damaged rims or missing lug bolts and nuts.

Mower Deck Lift/Lower Pedal . See your Great Dane dealer for service. • Allow fresh outside air into the work area to clear the exhaust fumes out. ❏ Check fuel level. Do not run an engine in an enclosed area without adequate ventilation.Mower Deck Transport Position Lock Lever . ❏ Check tire pressure. Keep bystanders away.Hourmeter . Perform these tests in a clear open area.Fuel Shutoff Valve . MX9206 A B C D E F G . Move the vehicle to an outside area before running the engine. ❏ Inspect all belts for damage. Operating Controls F A D B C G E B A D C MX9205 A B C D E F .6 . ❏ Remove grass and debris from machine. Use the following checkout procedure to check for normal operation of machine.OPERATING Operating Daily Operating Checklist Console Controls E F ❏ Test safety systems.Steering Control Levers .Console • Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.Height-of-Cut (HOC) Adjustment Pin .Key Switch . Operating .Ammeter Testing Safety Systems c CAUTION: Avoidmonoxide and can causefumes injury! Engine exhaust contain carbon serious illness or death. ❏ Check engine oil level. do not operate machine. ❏ Check transmission oil reservoir level. ❏ Check area below machine for any fuel or oil leaks. ❏ Remove and clean engine air filter. If there is a malfunction during one of these procedures. ❏ Sharpen and balance mower blades.Choke Lever .PTO/Clutch Switch . ❏ Clean engine cooling air intake screen and cooling fins.Throttle Lever .Park Brake Lever .

5. Turn key switch to start position. 3. 5. Move PTO/clutch switch to off position. Move PTO/clutch switch to on position (mower deck drive engaged). Result: Park brake must hold the machine stationary. Operator must be seated in the seat (seat safety switch engaged). 4. Do not run an engine in an enclosed area without adequate ventilation. Open the fuel shutoff valve. especially children. Move the vehicle to an outside area before running the engine. Move control levers to neutral position. Move PTO/clutch switch to off position. 4. Operator must be seated in the seat (seat safety switch engaged). See your Great Dane dealer. Lock park brake. wait 10 seconds. • • If the engine does not start.] in one hour. Operating . Turn key switch to start position for no more than 5 seconds. c CAUTION: Avoid injury! Before engaging mower. 4. 2. 2. Using the Park Brake Move park brake lever to the raised (locked) position to lock the park brake. If the machine moves more than 61 cm [24 in. Operator rises slightly off the seat.OPERATING Testing Park Brake Safety Switch 1. Testing Park Brake Stop the machine on a maximum 17° slope. Move control levers to neutral position. Turn key to start position again for no more than 5 Testing Neutral Start Safety Switch 1. Release key to the run position when engine starts. 5. 3. This will also engage the park brake safety switch. 3. 8. 3. Testing Seat Safety Switch 1.7 . 4. Operator must be seated in the seat (seat safety switch engaged). Unlock park brake. brakes need to be adjusted. 6. 3. Starting the Engine c CAUTION: Avoidmonoxide and can causefumes injury! Engine exhaust contain carbon serious illness or death. 1. • Allow fresh outside air into the work area to clear the exhaust fumes out. Operator must be seated in the seat (seat safety switch engaged). • Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area. Lock park brake. Move control levers to forward travel position. Unlock park brake. Adjust choke as required. 7. 2. Move throttle lever to half-speed position. IMPORTANT: Avoid damage! Starter may be damaged if starter is operated for more than 20 seconds at a time: • Wait 2 minutes before trying again if the engine does not start. clear area of bystanders. Start the engine. Operator must be seated in the seat (seat safety switch engaged). Result: The engine must stop. Result: The engine must not crank. 2. Result: The engine must not crank. Move control levers to neutral position. Move PTO/clutch switch to off position. Stop the engine and lock the park brake. Move PTO/clutch switch to on position. 5. Turn key switch to start position. Result: The engine must not crank. Testing PTO/Clutch Safety Switch 1. 4. Turn key switch to start position. 2.

Reduce choke setting as the engine warms up. Drive the machine: To drive the machine forward: Push both control levers forward smoothly and evenly. Let the engine run at half-speed position for several minutes to warm up before operating the machine. 2. Operating the Machine c CAUTION: Avoid injury! at halfthe use of the Learn control levers.). 9. Return both control levers to the neutral position. 4. 1. 5. Unlock park brake.OPERATING seconds. 4. IMPORTANT: Avoid damage! Unnecessary engine idling may cause engine damage. Do not move control levers from forward to reverse or reverse to forward position rapidly. 3. 1. 2.8 B MX9215 1. the mower blades will stop as soon the operator leaves the seat. Sudden direction changes could cause loss of control or damage the machine. A C MX9220 6. Start and warm up engine at half throttle. c CAUTION: Avoidmove or Childrenan unattended injury! or bystanders may attempt to operate machine. Excessive idling can cause engine overheating. NOTE: The travel speed and turn rate will vary with the amount that the control levers are moved. Always lock the park brake and remove the key before leaving the machine unattended. Push the other lever forward. Lock park brake. Adjust mower deck to desired cutting height. 2. Turn the key switch to the stop position. Move the PTO/clutch switch to the off position.) increments. To drive the machine in reverse: Pull both control levers back evenly. carbon build-up and poor performance. 6. Each hole adjusts the height of cut (HOC) in 13 mm (1/2 in. Remove key. Move the throttle lever to the half-speed position. Practice throttle until becoming proficient and comfortable with the operation of the machine. 3. and let the engine run at low throttle for a few seconds. The deck can also be raised and locked in a transport position to provide maximum ground clearance when moving the machine from one area to another. Position the HOC adjustment pin (B) in the proper hole for the desired height of cut. 5. To stop the machine: Return both control levers to the Operating . Push the mower deck lift/lower pedal (A) forward to raise and latch the deck in the transport position. Move PTO/clutch switch to on position. Move throttle lever to wide open position. Adjusting Cutting Height Cutting height can be adjusted from approximately 25-152 mm (1-6 in. To turn the machine: Pull the control lever back on the same side as the direction of the desired turn. neutral position. • Repeat the procedure if necessary. Stopping the Machine NOTE: If the operator leaves the seat without placing the PTO switch in the off position. .

). 4. the will unrestricted motion. behind the mower deck. • Park the machine on a level surface before opening the free-wheeling valve. • The machine may free-wheel out of control if the free-wheeling valve is opened with the machine on an incline. 6. Release the mower deck lift/lower pedal (A) and allow the pedal to rest against the HOC pin.9 . Park machine safely. Push machine to desired location. Depress and hold the mower deck lift/lower pedal (A) and release the transport position lock lever (C). 1. Unlock park brake. (See Parking Safely in the Safety section. Do not use another vehicle to move unit. Turn free-wheeling valves (A) on both pumps one full turn counterclockwise (open position). 4. the machine will move slowly. 2. IMPORTANT: Avoid damage! Transmission damage may occur if the machine is moved or towed incorrectly: • • • Move unit by hand only. Move the valve to the off position when the machine is not in use and during transport. Tighten the valves to 9-14 N•m (80-120 lb-in. NOTE: The pumps are located under the machine.OPERATING 3. 5.) Operating . Using the Fuel Shutoff Valve A MX9226 A Picture Note: Left pump shown. Move the fuel shutoff valve (A) to the on position for normal operation. Turn free-wheeling valves (A) on both pumps one full turn clockwise (closed position). MX9409 3. Lock park brake. Moving the Machine Manually c CAUTION: AvoidmachineWithhavefree-wheeling injury! the valve open. Due to internal hydraulic system resistance. Do not tow unit.

your Great Dane dealer needs your machine model and serial numbers and engine serial number.) Deck D28031 D28028 Mower Blades: • • 53 cm (21 in.A.) 45 cm (18 in.55 m (61 in. Part numbers may change.) Deck 1. Part Numbers may be different outside the U. your dealer will have the latest number.10 .32 m (52 in. When you order parts.REPLACEMENT PARTS Replacement Parts Parts We recommend Great Dane quality parts available at your Great Dane dealer. These are the numbers that you recorded in the Product Identification section of this manual.) Replacement Parts .32 m (52 in. Use part numbers listed below when you order.) Deck D28032 D28029 Part Number D18169 D18097 D18081 D18094 D28030 Mower Deck Drive Belts: • • 1.) D18036 D18037 (Part numbers are subject to change without notice. If a number changes. Part Numbers Item Battery Fuel Tank Cap Oil Reservoir Cap Oil Filter (Hydraulic System) Traction (Hydro) Drive Belt Engine to Blade Belts: • • 1.) Deck 1.S.55 m (61 in.

Clean power unit. NOTE: The following initial break-in items must be performed and verified to validate the warranty (dealer service invoice accepted). Lubricate seat platform hinges (two places) Lubricate pump control arms (five places). Check wheel nut torque.11 . Lubricate mower deck idler pulley pivots (three places). Break-In (After First 40 Hours of Operation) Change transmission oil and filter. Annually Replace all spindle bearings (6). Check drive belt tension. Remove battery. Clean engine air filter. Change transmission oil and filter. Lubricate control lever pivot shafts (two places). Break-In (After First 24 Hours of Operation) Check drive belt tension. Check battery electrolyte level. Grease HOC shafts (five places). Grease caster wheel pivot bearings (two places). Grease mower deck thrust arms (two places). tighten as needed. Check transmission oil level. Please use the following timetables to perform routine maintenance on your machine. Check tire pressure. Every 40 Hours Change engine oil. Replace hydraulic oil filter. clean and lubricate. Check transmission neutral adjustment. Grease caster wheel bearings (two places). Remove caster wheel roller bearings. Grease mower deck spindle bearings (three places) if equipped. Lubricate throttle cable. • Engine oil and spark plugs may lose efficiency if vehicle is operated constantly at slow or low engine speeds or with frequent short trips. Clean battery and holder. Service Intervals . Every 500 Hours Break-In (After First 8 Hours of Operation) Change engine oil and filter. Remove debris from the underside of the mower deck. Change engine oil filter. Every 160 Hours Clean and inspect spark plugs. Check all bolts and nuts. Check drive belt tension. dust or other severe conditions.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. Replace drive belts. Lubricate choke control cable. Replace all mower deck idler pulleys (3). Check wheel nut torque. Replace spark plugs. Run-in and adjust tension.

Lubricate seat platform hinges (C). NOTE: Use spray lubricant to lubricate the following items: A B D C Spray Lubricant Use a general-purpose petroleum-based spray lubricant. • • • • • A MX9408 Lubricate hydraulic pump control arms (A). Grease HOC shafts (C). Lubricate control lever pivot shaft (B). Use a general all-purpose grease with an NLGI grade No. Service Lubrication .2 rating. Lubricate choke control cable (E). Wet or high speed conditions may require use of a specialuse grease.12 . MX9252 Lubrication Points D E D B C E A E A MX9206 B B D C E • • • Grease caster wheel bearings (A). • Lubricate mower deck idler pulleys (A-D). • Grease mower deck thrust arms (D).SERVICE LUBRICATION Service Lubrication Grease IMPORTANT: Avoid damage! If operating outside that temperature range. contact your Servicing dealer for a special-use grease. Grease caster wheel pivot bearings (B). Contact your Servicing dealer for information. • Grease mower deck spindle bearings (E) if equipped. Lubricate throttle control cable (D). located at the rear of the mower deck.

Attach the tube to the oil drain fitting on your engine. Remove dipstick. Oil must be between ADD and FULL marks. Move the vehicle to an outside area before running the engine. Cleaning Air Intake Screen and Engine Fins IMPORTANT: Avoid damage! The engine is aircooled and requires a large amount of air intake when running. Install and tighten dipstick. Make sure engine is cold when checking engine oil level. See the engine manufacturer’s owner’s manual provided with your machine for the complete procedure. Wipe with a clean cloth. Allow the engine to cool before servicing. 6. c CAUTION: Avoidmonoxide and can causefumes injury! Engine exhaust contain carbon serious illness or death. Changing Engine Oil and Filter A MX9413 Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. 4. • Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area. Do not run an engine in an enclosed area without adequate ventilation. NOTE: Check oil twice a day if you run engine over 4 hours in a day. Checking and Cleaning Air Filter Elements c CAUTION:skin. Do not Keep air intake screens and engine cooling fins clear of debris to ensure proper cooling. • Allow fresh outside air into the work area to clear the exhaust fumes out. Store the drain tube after use. Close the valve. Use oil that meets the following specification: • API Service Classification SG or higher NOTE: An oil drain tube is provided with your machine. Park machine safely.13 . Clean area around dipstick to prevent debris from falling into crankcase. • • Keep level between the FULL and the ADD marks. (See Parking Safely in the Safety section.) 2. and open the valve (A) to drain the used oil. The engine and components will Avoid injury! Touching hot surfaces can burn be hot if the engine has been running. 1. 5. See the engine manufacturer’s owner’s manual provided with your machine for the complete procedure.SERVICE ENGINE Service Engine Avoid Fumes overfill. 3. • Check oil level when the engine is cold and not running. Keep covers and screens in place. 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. and remove the drain tube from the fitting after the oil has been drained. add oil to bring oil level no higher than FULL mark on dipstick. Install and tighten dipstick. Shut off engine before adding oil. Remove dipstick and check oil level on dipstick. Change engine oil and filter at the intervals recommended in the Service Intervals section. If oil is low. Reduced air intake can cause overheating: • • Keep air intake screen and cooling fins clean. Service Engine .

the filter arrow must be pointing in the direction of fuel flow. 3. See the engine manufacturer’s owner’s manual provided with your machine for the complete procedure. The engine and components will Avoid injury! Touching hot surfaces can burn be hot if the engine has been running.000 ft). some carburetors may require a special high altitude main jet. • Keep fuel away from flames or sparks. If engine is hard to start or runs rough. Turn fuel shutoff valve to off position. Park machine safely. 5.14 . Replacing Fuel Filter c CAUTION: and flammable: vapors are Avoid injury! Fuel explosive • Do not smoke while handling fuel. Connect a new fuel filter to hoses. After performing the checks in the troubleshooting section and your engine is still not performing correctly. Service Engine . 1. Remove the fuel filter from the inlet fuel hose. (See Parking Safely in the Safety section. and drain gasoline into a properly marked container. IMPORTANT: Avoid damage! When installing a new fuel filter. See the engine manufacturer’s owner’s manual provided with your machine for the complete procedure. • Cool engine before servicing. see the troubleshooting section of the engine manufacturer’s owner’s manual provided with your machine. This is a normal condition due to the emission control system. 6. Check spark plugs at the intervals recommended in the Service Intervals section. • Do not attempt to clean paper element by tapping against another object. • Work in a well-ventilated area. Turn fuel shutoff valve to ON position. 4. Discard filter.) 2. contact the local engine manufacturer’s authorized servicing dealer. damaged or the seal is cracked. Possible engine surging will occur at high throttle with transmission in “N” neutral and mower disengaged. • Replace element only if it is very dirty.SERVICE ENGINE IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element: • Do not wash paper element. • Clean up spilled fuel immediately. Check and clean air filter elements at the intervals recommended in the Service Intervals section. If engine is operated at altitudes above 1829 m (6. • Do not use pressurized air to clean element. • Shut off engine before servicing. Adjusting Carburetor NOTE: Carburetor is calibrated by the engine manufacturer and is not adjustable. Checking Spark Plug c CAUTION:skin. Disconnect the fuel hose from the outlet side of the fuel filter. Allow the engine to cool before servicing.

0 gal). Service Transmission .) Changing Transmission Oil and Filter IMPORTANT: Avoid damage! Contamination of hydraulic fluid could cause transmission damage or failure. Start and run the engine until it reaches normal operating temperature. and block caster wheels. Raise drive wheel off the ground and securely support the machine. Park machine safely. Add oil as needed. (See Parking Safely in the Safety section. Move the vehicle to an outside area before running the engine.15 . Install reservoir cap. Turn filter clockwise until gasket makes contact with the mounting surface. 7.SERVICE TRANSMISSION Service Transmission Avoid Fumes c CAUTION: Avoidmonoxide and can causefumes injury! Engine exhaust contain carbon serious illness or death. 6. Do not open oil reservoir cap unless absolutely necessary. Apply a film of clean oil to gasket of new filter. 8. Turn hydraulic filter (A) counterclockwise to remove. Tighten 1/2 to 3/4 turn after contact. Transmission Oil Use only Quaker State® 5W-50 or Mobil-1® 15W-50 all synthetic oil. c CAUTION: Avoid injury! Machinebefore be must safely supported on jackstands removing or installing wheels. 3. Observe wheel movement as control levers are moved back and forth.8 L (3 qt) (low-profile tank) or 3. The wheels should travel in the correct direction as the levers are moved. Park machine safely. Remove the hydraulic reservoir cap. Checking Transmission Oil Level 1.5 L (2. • Allow fresh outside air into the work area to clear the exhaust fumes out. and remove the filler cap from the reservoir.) 2. • Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area. (See Parking Safely in the Safety section. Park machine safely. 1.) 2.) from the top of the filler pipe. Adjusting Transmission Neutral Position 1. 4. Allow engine and hydraulic reservoir to cool. 9. Fill reservoir with approximately 2. Bleed air from hydraulic system. and drain oil into a properly marked container with a capacity of at least 7. 2.8 L (4 qt) (high-profile tank) of oil. 5. MX9233 A 4. Clean area around the reservoir filler cap. 3. Install filter. The oil level should be 76 mm (3 in. (See Parking Safely in the Safety section. Do not use a hoist or floor jack to support the machine. Do not run an engine in an enclosed area without adequate ventilation.

until wheel(s) stop rotating. Bleeding Hydraulic System MX9250 c CAUTION:can penetrate Escapingcausing Avoid injury! fluid under pressure the skin serious injury. the hydraulic oil reservoir can get hot. Disconnect tension spring (A) from the anchor pin. If the wheels continue to rotate. 4. Use caution when filling and draining hydraulic oil. Service Transmission .SERVICE TRANSMISSION A B A MX9244 5. Park machine safely. 6. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Allow engine and oil reservoir to cool before servicing. Connect tension spring (A) to anchor pin. 7.16 . B 5. (See Parking Safely in the Safety section. Shut engine off. Removing and Installing Traction Drive Belt 1.) 2. Install mower deck drive belt. located on each side of the seat. Adjust neutral switch activator bolt(s) (B) as needed. Remove drive belt (B). Protect hands and body from high pressure fluids. Severe or unusual conditions may require a more frequent service interval. The wheels should stop rotating. Search for leaks with a piece of cardboard. Install new drive belt (B). Do not open oil reservoir cap unless absolutely necessary. 8. 3. 7. IMPORTANT: Avoid damage! Contamination of hydraulic fluid could cause transmission damage or failure. During periods of machine operation. NOTE: Whenever hydraulic components are removed from the system. or the system has been drained. MX9216 Picture Note: Drive belt routing as viewed from the top of machine. Move control levers to neutral position. Remove mower deck drive belt. Tighten all connections before applying pressure. Lower the machine to the ground. trapped air must be removed from the hydraulic system. 6. adjust the neutral adjustment knob(s) (A). The switches should be engaged when the control levers are in the neutral position. hoses are disconnected.

Close the free-wheeling valves and tighten to 9-14 N•m (80-120 lb-in. (See Parking Safely in the Safety section.SERVICE TRANSMISSION 1. the oil level will drop. Adjust as necessary. A MX9226 Picture Note: Left pump shown. 4.) 2.17 . Do not use a hoist or floor jack to support the machine. Park machine safely. Raise drive wheels off the ground and block caster wheels. Service Transmission . Check oil level and adjust as necessary. 3. Mower should move in forward and reverse at normal speed. NOTE: The pumps are located under the machine. 8.). Open free-wheeling valves (A) one full turn counterclockwise and start engine. Adjust as necessary. repeat procedure. c CAUTION: Avoid injury! Machinebefore be must safely supported on jackstands removing or installing wheels. 5. 7. 9. 6. Turn off engine and check oil level. As the air is purged from the unit. Slowly move the control levers in both forward and reverse directions five to six times. if not. behind the mower deck. Turn off engine and lower machine to ground. Check hydraulic oil level. Start engine and slowly move the control levers in both forward and reverse directions five to six times.

and slide cap screw (J) in the slot until the desired height at position C is obtained. Measure the distance from the top of the mower deck to the ground at positions B and D. 9. adjust the cutting height. • If no adjustment is required. Loosen jam nuts (G) and (H) on the swivel adjuster rod. Measure the distance from the top of the mower deck to the ground at positions A and B. Always wear gloves when handling mower blades or working near blades. 3. proceed to Step 7. Adjust Cutting Height 1. 6. Tighten the nut. 2. 1.). and caster (front) tires to 110-139 kPa (16-20 psi). and lower mower to cutting position. (See Parking Safely in the Safety section. Adjust cutting height to 50 mm (2 in. 3. Service Mower . Turn the jam nuts as required to obtain the desired height of position A. proceed to Step 8. The height at position A must be 3-6 mm (1/8-1/4 in. proceed to Step 5. Measure the distance from the top of the mower deck to the ground at positions C and D. Loosen jam nuts (E) and (F) on the swivel adjuster rod.). proceed to Step 6. Measure from outside blade tip to flat ground surface. Set the cutting height to 89 mm (3-1/2 in. • If adjustment is required. • If adjustment is required. Loosen the nut (I). Turn right blade (A) so that the blade tip is pointing out of the middle of the discharge chute. If the blade height (A) is not 89 mm (3-1/2 in. Inflate drive (rear) tires to 69-83 kPa (10-12 psi). proceed to Step 9. Park machine safely. E F A MIF MX9284 5.18 . The height at position C must be 3-6 mm (1/8-1/4 in.) higher than position D. If no adjustment is required. • • If adjustment is required.) 2.) higher than position B.).SERVICE MOWER Service Mower Adjusting Mower Level • If no adjustment is required. G H I J MX9221 B D 7.). Turn the jam nuts as required to obtain the desired height of position D. MX9288 C A 4. ±3 mm (1/8 in. c CAUTION: Avoid injury! Mower blades are sharp. 8. proceed to Adjust Cutting Height. The heights of position B and D should be equal. and lower mower to cutting position.

Raise foot platform.spindle drive belt) clockwise. Adjust the mower deck for the lowest cutting height. Loosen the jam nut (B) on the link rod assembly. Remove mower deck drive belt (B).mower deck drive belt) or (D . The belts should deflect a maximum of 13 mm (1/2 in. Park machine safely. Release mower deck drive belt tension.spindle drive belt) Service Mower . 11.5 kg (10 lb) is applied to the center of the longest span. MX9285 4. Remove mower deck drive belt covers. • To Decrease Belt Tension: Turn nut (C . D A C A MX9217 4. B Checking and Adjusting Mower Deck Drive Belt Tension 1.SERVICE MOWER counterclockwise. 6. • To Increase Belt Tension: Turn nut (C .mower deck drive belt) or (D . and lower the deck. Tighten the jam nut. B D MX9217 9. 3. Park machine safely. 3. Release spindle drive belt tension by turning tension adjustment nut (C) counterclockwise. 10. (See Parking Safely in the Safety section. C 5.) 2. (See Parking Safely in the Safety section.). 7.) when a force of 4.Lower foot platform. B Removing and Installing Mower Deck Drive Belts 1.Install mower deck drive belt covers. 8.19 . Install new mower deck drive belt (B) and adjust drive belt tension.) C 2. Install new spindle drive belt (D) and adjust drive belt tension. and turn the sleeve (C) until the blade height is 89 mm (3-1/2 in. by turning the tension adjuster nut (A) counterclockwise. Remove spindle drive belt (D). Check the mower deck drive (A) and spindle drive (B) belt tension.

(See Parking Safely in the Safety section. 5. Tighten nut to 80 N•m (60 lb-ft). 4. MIF Balancing Mower Blades 1. Measure distance between the other blade tip and flat ground surface. or electric blade sharpener. Turn blade to horizontal position. Remove nut (A). bolt (D) and secure using nut (A).SERVICE MOWER Checking for Bent Mower Blades A c CAUTION: Avoid injury! Mower blades are sharp. (See Parking Safely in the Safety section. blade (B). hand file. Grind bevel of heavy end. blade washers (C). Removing and Installing Mower Blades 1. Service Mower . Measure distance (A) between blade tip and flat ground surface. and bolt (D).20 . Servicing Mower Blades c CAUTION: Avoid injury! Mower blades are sharp. 3. Turn blade 180°. Park machine safely. Lower mower deck to mowing position. Clean blade. 3.). 1. Park machine safely. Install a new blade if the difference between the two measurements is more than 3 mm (1/8 in. Always wear gloves when handling mower blades or working near blades. heavy end of blade will drop. blade washers (C). • Sharpen blades with grinder. 3.) M61524 2. 4. Do not change blade bevel.) 2. Sharpening Blades c CAUTION: Avoid injury! Always wear safety eye protection when grinding. Always wear gloves when handling mower blades or working near blades. If blade is not balanced. Check balance. C B D MX9231 A 2. Put blade on nail in a vise. Install blade (B).

) 2. 6.21 .05 mm (0. lower bearing (H) and spacer (I) from spindle housing (J).Install the upper bearing (K). J Replacing Mower Spindle Bearings 1. Do not force bearing into housing. 8. Remove upper pulleys: • Side Spindles: Remove nut (A). lower bearing (H) and spacer (I) into the spindle housing (J). Remove spindle shaft (G). Install a new lower bearing (H) and spacer (I) on the spindle shaft (G). spacer (B) and pulley (C). 9. Install the spindle shaft (G). Park machine safely. • Center Spindle: Remove nut (D). (See Parking Safely in the Safety section. 10. IMPORTANT: Avoid damage! The clearance between the lower bearing and the housing is only 0.) cutting edge (B) or less. K • Blade should have 0. 3. Remove and discard upper bearing (K). Remove mower deck drive and spindle drive belt.SERVICE MOWER A A B F B D E C M61830 • Keep original bevel (A) when grinding.002 in. Discard bearing.40 mm (1/64 in.). drive pulley (E) and spindle pulley (F). Service Mower . Remove mower blade. 7. H I G MX9222A 4. 5. Clean entire assembly. • Balance blades before installing.

SERVICE MOWER 11. Tighten nut to 80 N•m (60 lb-ft). Install spindle drive and mower deck drive belts. spacer (B) and nut (A). Adjust belt tension. drive pulley (E) and nut (D). Replacing Mower Deck Idler Pulleys 1. Tighten nut to 80 N•m (60 lb-ft). Remove the mower deck drive and spindle drive belts. 6.Install upper pulleys: • Side Spindles: Install pulley (C). 4. Service Mower . mower deck drive fixed idler pulley (C) and spindle drive tension idler pulley (D).Install mower blade. • Center Spindle: Install spindle pulley (F).) 2.22 . Tighten nut to 80 N•m (60 lb-ft). 12. 5. Remove mower deck drive tension idler pulleys (A) and (B). Install new idler pulleys. A B D C MX9252 3. Park machine safely. (See Parking Safely in the Safety section.

Removing: 1. • If electrolyte is splashed onto skin. Slide black cover (A) away from the negative (-) battery terminal and disconnect the negative (-) battery cable (B). WARNING: Battery posts. Apply general purpose grease or silicone spray to the terminals to prevent corrosion. • Remove negative cable first when disconnecting. Remove battery cell caps. Slide covers (A and C) over battery terminals. Install battery (F) in the battery tray. • Wear eye protection and gloves.) C A D Checking Battery Electrolyte Level c CAUTION:sulfuricinjury!ItBattery electrolyte can Avoid contains acid. 5. Make sure cap vents are not plugged. terminals and related accessories contain lead and lead components. NOTE: Add only distilled water to replace normal electrolyte loss. chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. (See Parking Safely in the safety section. Park the vehicle safely.) 2. 3. 5. 6. 4. The battery maya injury! The battery produces flammable and explode: • Do not smoke near battery. • Keep skin protected. • Install negative cable last when connecting. Place isolator pad (G) in the battery tray. • If electrolyte is swallowed. • Do not allow direct metal contact across battery posts. (See Parking Safely in the safety section. Remove battery from vehicle and set it on a level surface. is poisonous and cause serious burns: • Wear eye protection and gloves. Slide red cover (C) away from the positive (+) battery terminal and disconnect the positive (+) battery cable (D). C B A Installing: 1. F B 1. Loosen the cap screws and nuts (E) on both sides of the battery tray. Check electrolyte level. 2. Remove battery (F) and isolator pad (G). 2. Do not overtighten. making sure that the isolator pad (G) is between the bottom and sides of the MIF 4.23 . Removing and Installing the Battery c CAUTION: Avoidexplosive gas. 4. E G MX9209 3. flush immediately with water and get medical attention if necessary. Tighten the cap screws and nuts (E) to secure the battery in the battery tray. • If electrolyte is splashed into eyes. 3. Park the vehicle safely. Connect the positive (+) battery cable (D) first. then the negative (-) cable (B). Electrolyte (A) should be Service Electrical .SERVICE ELECTRICAL Service Electrical battery tray. flush immediately with water for 15-30 minutes and get medical attention. get medical attention immediately.

Install battery cell caps. 7.SERVICE ELECTRICAL approximately halfway between bottom of filler neck (B) and top of plates (C). Replacing Fuses IMPORTANT: Avoid damage! When replacing fuses use only 20-amp fuses or you may damage the circuit. 3. 6. (See Parking Safely in the safety section.023 in. 7. Check the air gap at the three openings (A) around the clutch.) B A B MX9290 2. 4. Add only distilled water if necessary. Service Electrical . Check metal clip in fuse window and discard fuse if clip is broken. B A Cleaning Battery and Terminals MX9245 c CAUTION: Avoidexplosive gas. Attach cable clamps to battery posts. • Do not allow direct metal contact across battery posts.electric start circuit) or (B charging circuit) from socket. • Wear eye protection and gloves.584 mm (0. 1. Disconnect and remove battery.005-0. Adjust the air gap to 0.). If the gap is not within specifications. Install battery. no adjustment is required. Be careful not to get the soda solution into the battery cells. Install battery. • Install negative cable last when connecting.24 . adjust the air gap.12 in. 5. 3.012-0. • Remove negative cable first when disconnecting. 5. Remove defective fuse (A . by tightening or loosening the three adjustment nuts (B). 2. Clean terminals and battery cable ends with wire brush until bright. 1. Install new fuse into socket. Rinse the battery with plain water and dry. 3.34 mm (0. Wash battery with a solution of four tablespoons of baking soda to one gallon of water. IMPORTANT: Avoid damage! Do not overfill battery. Check and Adjust PTO Clutch Air Gap NOTE: If clutch is not equipped with adjusting nuts (B). 1.). Electrolyte can overflow when battery is charged and cause damage. Two 20-amp fuses to protect the electric start and charging circuit are located behind the seat area. Park the vehicle safely. The air gap should be within 0. 2. Apply petroleum jelly or silicone spray to terminal to prevent corrosion. 6. The battery maya injury! The battery produces flammable and explode: • Do not smoke near battery. using a feeler gauge.

SERVICE ELECTRICAL Kohler Wiring Schematic MX9299A Service Electrical .25 .

5. Remove seals (E). Servicing Caster Pivot Bearings 1. 4. Clean and inspect bearings (F) and pack with clean grease. 6.SERVICE MISCELLANEOUS Service Miscellaneous Filling Fuel Tank Use regular grade 87 octane unleaded fuel. Service Miscellaneous . approved non-metal container to prevent static electric discharge. • Use clean. • Fill fuel tank outdoors or in well-ventilated area. stabilized fuel. bearings (F) and new seals (E). • Keep fuel away from flames or sparks. • Do not smoke while handling fuel.). approved plastic funnel without screen or filter to prevent static electric discharge. Install spacer tube (G). (See Parking Safely in the Safety section. Servicing Caster Wheel Roller Bearings 1. two spacers (C) and wheel assembly (D). bolt (B).) 2. B C E F G F E C D MX9223 3. • Use a non-metallic funnel with a plastic mesh strainer when filling the fuel tank or container. two spacers (C).) 2. (See Parking Safely in the Safety section. Replace bearings as needed. Follow directions on stabilizer container. Install wheel assembly (D). bearings (F) and spacer tube (G) from wheel. IMPORTANT: Avoid damage! Dirt and water in fuel can cause engine damage: • • Clean dirt and debris from the fuel tank opening. • Clean up spilled fuel immediately. fresh. Raise and securely support the front of the mower deck. Add fuel stabilizer to fuel before using it in your machine to prevent engine damage due to stale fuel. Park machine safely. 7.26 . • Use clean. Use clean. Checking Wheel Nuts Tighten rear wheel nuts in an alternating pattern to 68 N•m (50 lb-ft. • Fill the fuel tank at the end of each day’s operation to keep condensation out of the fuel tank. Park machine safely. bolt (B) and lock nut (A). Remove lock nut (A). Raise and securely support the front of the mower deck. A c CAUTION: and flammable: vapors are Avoid injury! Fuel explosive • Shut engine off before filling fuel tank.

Install upper bearing (J).27 . Tighten castle nut only enough to remove excess play from bearings. The caster wheel yoke assembly must be free to rotate. Remove upper bearing (J). and install caster yoke and wheel assembly (D). unless the bearings need to be replaced. NOTE: Do not overtighten castle nut (C).SERVICE MISCELLANEOUS A B C J F L G I H E D MX9224 3. castle nut (C). Remove cap (A). 5.Apply grease to lubrication fitting (L) until you can see grease at the top bearing (J). 7. 4. pack with clean grease. NOTE: It is not necessary to remove the bearing races (F) and (G). Remove seal (H) and lower bearing (I). Install grease cap (A). 6. Service Miscellaneous . castle nut (C). Install caster bushing (E) on yoke shaft. Align crossdrill and nut to allow installation of the cotter pin (B). Replace bearings if needed. 10. 8. 9. cotter pin (B). Install lower bearing (I) and a new seal (H). caster yoke and wheel assembly (D) and caster bushing (E). and cotter pin (B). Clean and inspect bearings (I) and (J).

Fuel tank less than half full of fuel. obtain fresh fuel from another supplier before suspecting machine problems. Plugged fuel filter. Operator rising off of the seat.28 . Spark plug wire(s) loose or disconnected. PTO/clutch switch is in on position. Improper fuel. see your Great Dane dealer. If Poor Engine Performance Check Dirt in fuel system or fuel is old. Engine NOTE: This engine troubleshooting chart covers items that are unique to the machine operation. Troubleshooting . Engine Will Not Start Park brake not locked. Obtain fresh fuel.TROUBLESHOOTING Troubleshooting Using Troubleshooting Chart If you are experiencing a problem that is not listed in this chart. Control levers are not in neutral position. Electrical problem. see your Great Dane dealer for service. Fuel blended with alcohol or ether may contribute to performance problems by causing gum and varnish deposits. See the engine manufacturer’s owner’s manual provided with your machine for detailed engine troubleshooting procedures. Fuel shutoff valve in off position. Suppliers blend fuels differently and changing suppliers will generally solve any performance problems. Operator rising off of the seat. especially if fuel is stored for several weeks or more. When you have checked all the possible causes listed and you are still experiencing the problem. (See Electrical Troubleshooting section) Engine Will Not Idle Engine Stops Or Misses When Operating On Hillsides Engine Backfires Operator rising off the seat.

Pump linkage (neutral position) out of adjustment. Low engine speed or excessive idling.TROUBLESHOOTING Electrical If Starter Does Not Work Or Will Not Turn Engine Check Park brake is not locked. Battery Will Not Charge Dead cell in the battery. Engine rpm not at wide open throttle. Battery not charged. Battery terminals are corroded. PTO/clutch switch is in on position. Patches Of Grass Uncut Travel speed too fast. Machine Operation If Check Machine Vibrates Too Much Or Rattles Excessively Attachment drive belts worn or damaged. Grass too long. Dirt on drive sheaves. Transmission hydraulic oil level low. Grass too wet. Traction drive belt damaged or worn. Engine rpm not at wide open throttle. Mower deck needs cleaning. 20-amp fuse is blown. Restricted air flow. Mower If Discharge Chute Plugged Check Travel speed too fast. Troubleshooting .29 . Free-wheeling valves are open. Machine Will Not Move With Engine Running Park brake locked. Machine Will Not Follow a Straight Path Machine Moves To The Left Or Right With Engine Running And Transmission In Neutral Steering tracking out of adjustment. Belt installed incorrectly. Battery cables and terminals are dirty. Traction drive belt damaged or worn.

Grass Tips Are Jagged And Turn Grayish Brown After Mowing Dull mower blades. Debris wrapped around mower spindles. Blades Scalping Grass Cutting too low. Uneven Cut Mower deck not leveled properly. Tire pressure unequal. Ridges in terrain. Mower deck not leveled properly. Damaged sheaves or sheaves out of alignment. Damaged drive belt. Turning speed too fast. Troubleshooting . Mower wheels not adjusted correctly. Mower wheels not adjusted correctly. Blades out of balance. Blades dull.TROUBLESHOOTING If Belt Slipping Check Debris in sheaves. Low tire pressure. Too Much Vibration Debris on mower deck or in sheaves.30 . Mower Loads Down Engine Engine rpm too low. Travel speed too fast. Worn belt. Rough or uneven terrain. Travel speed too fast.

1. . 9. 3. Remove spark plugs. 5. Check spark plug gap. Run machine for five minutes to dry belts and pulleys. 9. Clean under the deck and remove grass and debris from inside chute and bagger. NOTE: The stored battery should be recharged every 90 days. If you are not using “Stabilized Fuel”: 1. Repair scratched or chipped metal surfaces to prevent rust. Follow stabilizer instructions for mixing. 3. 10. Run the engine 5 minutes without the mower or any attachments running to allow oil to be distributed throughout engine.Charge the battery. Run engine for a few minutes to allow fuel mixture to Storage . Put 30 mL (1 oz. 2.STORAGE Storage Storing Safety circulate through carburetor. 4. Park machine safely in a well-ventilated area. 2.Store the battery in a cool. 7. 6. protected place. Check the electrolyte level. 8. • Allow the engine to cool before storing the machine in any enclosure. c CAUTION: and flammable. Engine: Engine storage procedure should be used when vehicle is not to be used for longer than 60 days. 6. 2. 4. 7. Apply light coat of engine oil to pivot and wear points to prevent rust. 4. Crank the engine five or six times to allow oil to be distributed. 11. If vehicle is stored outside. Remove battery. 2. Clean debris from engine air intake screen. Wash the machine and apply wax to metal and plastic surfaces. 13. • Do not store vehicle with fuel in the tank inside a building where fumes may reach an open flame or spark.31 1. Engine exhaust Avoid injury! Fuel vapors are explosive fumes contain carbon monoxide and can cause serious illness or death: • Run the engine only long enough to move the machine to or from storage. Clean the battery and battery posts.Store the vehicle in a dry. Check battery electrolyte level. Turn fuel shut-off valve to on position. Change engine oil and filter while engine is warm. 12. Removing Machine From Storage Preparing Fuel and Engine for Storage Fuel: If you have been using “Stabilized Fuel”. Fill fuel tank with stabilized fuel. add stabilized fuel to tank until the tank is full. 3. 6. dry place where it will not freeze. Check tire pressure. 5. Install and tighten plugs to specified torque. 6. 4. Check engine oil level. Install battery. Turn key to off position. 3. 5. Charge battery if necessary. put a waterproof cover over it. Lubricate all grease points. Turn on engine and allow to run until it runs out of fuel. NOTE: Try to anticipate the last time the machine will be used for the season so very little fuel is left in the fuel tank. Clean the engine and engine compartment. Install spark plugs. Service air filter if necessary.) of clean engine oil in cylinders. Repair any worn or damaged parts. 8. Be sure all shields and guards or deflectors are in place. Tighten loose hardware. 5.Move fuel shut-off valve to off position. NOTE: Filling the fuel tank reduces the amount of air in the fuel tank and helps reduce deterioration of fuel. Replace parts if necessary. Preparing Machine for Storage 1. Mix fresh fuel and fuel stabilizer in separate container.

) from the bottom of the filler neck (C). Remove battery cell caps. Make sure cap vents are not plugged. level surface with the key switch in the STOP position. • Keep skin protected. see Testing the Safety Interlock System in the Operating section.) above plates (B). If your mower has no dipstick. Slowly add acid (A) to each cell. C Check Safety System A B For a complete checkout procedure of the safety interlock system. so they will take a charge well. is poisonous and cause serious burns: • Wear eye protection and gloves. MIF 4. see Lubrication Points in Service Lubrication section. • If electrolyte is splashed into eyes.) from the top of the filler pipe. but NO HIGHER than 6 mm (1/4 in. Activate and Charge Battery c CAUTION:sulfuricinjury!ItBattery electrolyte can Avoid contains acid.ASSEMBLY Assembly Install Seat and Control Lever Handles 1. Battery must be charged before operation.265 specific gravity. • If electrolyte is swallowed. cap screws and nuts provided in small parts bag. 1. Install the battery caps before charging the battery. Add oil as necessary. Connect seat safety switch to wiring harness.) 2. 5. If your battery charger has a Deep Cycle or Maintenance Free setting. Install the battery in the machine. Machine should be parked on a hard. The solution should Assembly .32 . be 6 mm (1/4 in. Remove battery from machine and set it on a level surface. Charge the battery for a minimum of 30 minutes at 5-10 amps. Check Transmission Oil Level Hydraulic oil level should be to the top of the FULL COLD mark on the reservoir dipstick. flush immediately with water for 15-30 minutes and get medical attention. Add oil as necessary. make sure that oil is 76 mm (3 in. 6. get medical attention immediately. 3. Park the vehicle safely. IMPORTANT: Avoid damage! Wait 20 minutes before charging the battery to allow the plates to “absorb” the acid. • If electrolyte is splashed onto skin. 3. Failure to charge the battery before use will reduce battery performance and life. 7. Adding acid without charging will result in battery damage. use this setting to charge the battery. (See Parking Safely in the Safety section. 2. Check Fluid Levels IMPORTANT: Avoid damage! Check all fluid levels before attempting to start the machine. Fill the battery: • • Only use battery acid with a 1. Install seat on platform and secure using nuts provided in small parts bag. Lubricate Machine Lubricate all moving parts before operating the machine. Check Engine Oil Level Oil level should be between the ADD and FULL marks on the dipstick. flush immediately with water and get medical attention if necessary. Install handles on control levers and secure using sleeves.

2.5. Tire Size Front: 13 x 5. mower clutch should engage. if the machine drifts to the right or left. 6. Move the control levers to the reverse position and observe drive wheel rotation. adjust the transmission control linkage. 3. Support the machine with jackstands. 7. PTO Clutch Run-in Procedure 1. • Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area. level the mower deck. Check free-wheeling valves on both pump assemblies to make sure that the valves are closed. 3. 3. Move control levers to the forward position and observe drive wheel rotation. adjust the neutral adjustment knob on each side of the seat. the drive wheels should rotate in the correct direction. 1. Check tires for damage. Assembly . 4.6 Rear: 23 x 9. 2. the levers should return to the neutral position and wheel rotation should stop. Move throttle lever to 3/4 throttle. 9.0 . the drive wheels should rotate in the correct direction. Check all belts for proper tension. If the wheels do not stop. add or remove air. Run blades for several minutes. Check that tires have equal pressure. Initial Adjustments c CAUTION: Avoid injury! Clear area of bystanders before performing this service procedure. Raise the rear of the machine until the drive wheels are off the ground. • Allow fresh outside air into the work area to clear the exhaust fumes out. 8. 1. Engage and disengage the PTO clutch five times (ten seconds on. Drive the machine forward. if necessary. 5. ten seconds off). Move the vehicle to an outside area before running the engine. NOTE: Neutral position and transmission linkage adjustments will needed to be recheck after several hours of operation. Release control levers.12 Pressure 110-139 kPa (16-20 psi) 69-83 kPa (10-12 psi) c CAUTION: Avoidmonoxide and can causefumes injury! Engine exhaust contain carbon serious illness or death. 10. Move PTO/clutch switch to on position. Engage and disengage the PTO clutch five times (ten seconds on. Move PTO/clutch switch to off position and shut the engine off. Start and run the engine until it reaches normal operating temperature. 4.Start the engine and test drive the machine in an open area. Start and run the engine at half throttle. 2.ASSEMBLY Check Tire Pressure c CAUTION: Avoid injury!possible when they are Explosive separation of tire and rim parts is serviced incorrectly: • Do not inflate the tires above the recommended pressure. Do not run an engine in an enclosed area without adequate ventilation. Check tire pressure with an accurate gauge. ten seconds off). • Do not stand in front or over the tire assembly when inflating. Level Mower Deck Before operating the machine. Use a clip-on chuck and extension hose long enough to allow you to stand to one side.33 .

SPECIFICATIONS Specifications Engine NOTE: See engine manufacturer’s owner’s manual provided with your machine for engine specifications. . . . . . . . . . . . .) Overall Height . . . . . . . .50 . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2 in. .57 m (62 in. . . . .32 m (52 in. . . 535 kg (1180 lb) 25-hp Kohler engine/61 in. . . .12 Inflation Front . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 qt) High-Profile Tank . . . . . . . . . . U1 52-Inch Mower Deck Mower Type . . . . . . . . . . . . . . . . . . . . . . . 535 kg (1181 lb) 26-hp Kohler engine/61 in. . . . . . . . . . . . . . . . 1. . . . . . . . . . . 535 kg (1180 lb) 25-hp Kawasaki engine/61 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 152 mm (1 to 6-in. . . . . . deck . . . . . . . .80 N•m (60 lb-ft) Cutting Width . . . . . 12 volt CCA . . . . . . . . . . . . . . . . .98 m (78 in. . . . . . . . .5 qt) Hydraulic Oil Reservoir Low-Profile Tank . . . . . . . . . . . . . . . . .8 L (3 qt) High-Profile Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-83 kPa (10-12 psi) Wheel Nut Torque. . . . . . . . 1. . . 4. . . . . . . . . . . . . . . . .11 m (44 in. . .) Overall Width (with 61-Inch Mower Deck) . . . . . . . . . . . . . . .2 L (8 gal) Hydraulic System Low-Profile Tank . . . . . . . deck .) Cutting Height (approximate) . deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . deck . 1. . . . . . . . . . . . . . . .) Overall Width (with 52-Inch Mower Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . deck . . . . . . . . . . . . . Dimensions Wheel Base . . 0-16 km/h (0-10 mph) Reverse . . . . . . deck . 30. . .55 m (61 in. . . . . Side Discharge Cutting Blades . . . . . . . . . 13 mm (1/2 in. . . 5. . . 2. . . .27 m (50 in.3 Blade Bolt Torque . 533 kg (1175 lb) 23-hp Kawasaki engine/61 in. . . . . . 1. . . . . . . . . . . . . .0 .6 Rear . . .80 m (71 in. . . . . . . . . .25 minutes BCI Group Size. . . . 1. . . . . . . .) Height Adjustment .) Capacities Fuel Tank . .34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Discharge Cutting Blades . . . . 23 x 9. 25 to 152 mm (1 to 6 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Blade Bolt Torque . .80 N•m (60 lb-ft) Cutting Width . . . . . . . . . . .3 L (4. . . .) Cutting Height (approximate) . . . . . . 3. . . . . . .) Overall Length (All Models) .) increments (Specifications and design subject to change without notice. 510 kg (1125 lb) 25-hp Kohler engine/52 in. . . . . . . . . . . 13 x 5. 68 N•m (50 lb-ft) 61-Inch Mower Deck Mower Type . . . . . . 1. . .2 L (5. . . . . . . 0-8 km/h (0-5 mph) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) increments Tires Front . .) Height Adjustment . . . . . . . . . . . . .) Battery Voltage . . . . . . . . . . . . . . . . . . . . 235 amp @ 0° Reserve Capacity . . . . . . . . . . . . . . . 544 kg (1200 lb) Travel Speeds Forward.8 L (4 qt) Net Weight (With Mower Deck and Without Fuel) 23-hp Kawasaki engine/52 in. . . . . . . . . . . . . . . . . . . . 110-139 kPa (16-20 psi) Inflation Rear . .

............................... Testing ....... Replacement .................................. 13 T Testing Safety Systems ....................................... Removing and Installing ......... 31 Fuel Tank............................................................................................................................................................ Starting .......................................................................... Troubleshooting .. 20 Mower Drive (Primary) Belt................................................14 Specifications .................. 14 Chart......................... 20 Blades.... 10 Index ...................................................................... 13 S Safety Systems............................................33 Transmission Oil ....... Servicing .......5 Service Interval Chart ................................................................................................... Preparing ...............31 Storing Safety ..........31 Storage.................... Changing Transmission ..........31 B Battery and Terminals....... Using ..15 D Daily Operating Checklist .. Changing Engine .........14 A Air Cleaner Elements................................... 13 Air Cleaner Elements................ Checking Spark .. Adjusting .... Replacing Mower Drive (Primary) ...... Checking .............................................................. Checking .................. Check ............................................. 12 L Leveling Mower Side-to-Side ................ Preparing Machine for ....................... Replacement ........... 7 C Carburetor......................... Checking Mower . Replacing ......................................................................................................................................................15 Transmission Oil................ 11 Cleaning Air Intake Screen ..... 23 Belt... 19 Mower Level (Side-to-Side).6 Tire Pressure.................................... Changing Engine . 5 Fuel Storage .........................6 Safety.....................31 Storage. 26 G Grease ............... Removing Machine from ................ 19 Blades................... 15 Fuel Safety ......................... Adjusting .........................36 Spark Plug................ Checking ................... 13 Oil.................................. 6 P Park Brake............................... 15 Operating Checklist........................ Changing .............. Servicing Mower .........15 Transmission Oil Level......35 ............... 15 Oil............................................................................................................. Tire .........10 Plug................................................... 18 M Mower Blades.............. 20 Brake..... Cleaning .. Servicing ............................. Replacing ........... Checking . Using Park .. 24 Battery............................................ 28 F Filter........................................ Transmission ........ Service Interval .......................................................................... 13 Engine and Fuel Storage................................................................................................ Daily ....................11 Service Record ....... 31 Engine..................................................................INDEX Index Parts..... 7 Part Numbers.................... 20 Mower Blades........ 13 Oil Level.................................................. Filling ......................................................................................................................................................34 Storage. 18 O Oil Level....... 13 Filter.............................. Checking Engine .................................................... 6 E Engine Oil Level.................. Checking Transmission ....... Preparing Fuel and Engine for .................................. 7 Engine............

NOTES Notes Notes .

37 .SERVICE RECORD GD Service Record GD Record Service Dates Engine Oil and Filter Change Lubricate Machine Air Cleaner Element Clean/Replace Service Record GD .