Great Dane Lawn Mower GDRZ25KAE User Manual

Chariot  
GDRZ25KAE, GDRZ25KHE, GDRZ26KHE  
GD10001  
B2  
OPERATOR’S MANUAL  
cWARNING: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  
North American Version  
Litho in U.S.A.  
D02-105  
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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  
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SAFETY  
Safety  
DANGER  
Understanding The Machine Safety Labels  
MIF  
The machine safety labels shown in this section are placed  
in important areas on your machine to draw attention to  
potential safety hazards.  
MX9293 MX9214  
Keep hands and feet away.  
On your machine safety labels, the words DANGER,  
WARNING, and CAUTION are used with this safety-alert  
symbol. DANGER identifies the most serious hazards.  
CAUTION  
The operators manual also explains any potential safety  
hazards whenever necessary in special safety messages  
that are identified with the word, CAUTION, and the safety-  
alert symbol.  
DANGER/POISON  
MX9294 MX9214  
Do not operate mower without chute deflector, mulching  
plate or complete grass catcher assembly in position.  
Do not remove grass catcher, mulching plate or raise  
MX9292 MX9204  
the chute deflector until engine and blade(s) have stopped.  
Shield eyes, explosive gases can cause blindness or  
injury.  
No sparks, flames, smoking.  
Sulfuric acid can cause blindness or severe burns.  
Flush eyes immediately with water, get medical help  
fast.  
Keep out of the reach of children.  
Do not tip.  
Keep vent caps tight and level.  
Safety - 1  
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SAFETY  
components can only be adjusted by EPA and/or  
CAUTION  
CARB authorized service centers. Contact your Great  
Dane Equipment Retailer concerning emission  
controls and component questions.  
The presence of an emissions label signifies that the  
engine has been certified with the United States  
Environmental Protection Agency (EPA) and/or California  
Air Resources Board (CARB).  
The emissions warranty applies only to those engines  
marketed by Great Dane that have been certified by the  
EPA and/or CARB; and used in the United States and  
Canada in off-road mobile equipment.  
Emission Compliance Period (Small Off-Road  
Gas Engines)  
MX9295 MX9214  
If your engine has the emission compliance category listed  
on the emission control system certification or air index  
label, this indicates the number of operating hours for  
which the engine has been certified to meet EPA and/or  
CARB emission requirements. The following table provides  
the engine compliance period in hours associated with the  
category found on the certification label.  
This product is designed for professional and  
commercial users.  
Operation training is required.  
Carefully read safety instructions.  
Know function of controls before operating.  
Practice with cutter blades off until confident.  
Clear mowing area of all debris.  
Agency  
EPA  
Category  
Hours  
250  
C
Keep all guards, covers and shields in place while  
working.  
EPA  
B
500  
Do not disable or bypass any safety device.  
EPA  
A
1000  
125  
Always wear safety goggles while operating.  
Always park machine on level surface.  
CARB  
CARB  
CARB  
Moderate  
Intermediate  
Extended  
250  
Avoid contact with cutter blades. They may be rotating.  
Keep children and others clear from area.  
Set ground speed control to safe speed.  
500  
Slowly and smoothly move speed control levers to start  
Operating Safely  
and stop machine.  
Inspect machine before you operate. Be sure hardware  
Reduce speed and avoid sharp turns.  
is tight. Repair or replace damaged, badly worn, or missing  
parts. Be sure guards and shields are in good condition  
and fastened in place. Make any necessary adjustments  
before you operate.  
Be careful on slopes, do not mow where stability or  
traction is in doubt.  
To obtain additional operator manual and safety  
instructions, contact your Great Dane dealer or write Great  
Dane Power Equipment, 4700 New Middle Rd.,  
Jeffersonville, IN 47130, USA.  
Do not operate mower without discharge chute or entire  
grass catcher in place.  
Check before each use that operator presence controls  
are functioning correctly. Test safety systems. Do not  
operate unless they are functioning correctly.  
Emission Control System Certification Label  
(Small Off-Road Gas Engines)  
Do not change the engine governor setting or  
overspeed the engine.  
NOTE: Tampering with emission controls and  
components by unauthorized personnel may result in  
severe fines or penalties. Emission controls and  
Check brake action before you operate. Adjust or  
service brakes as necessary.  
Safety - 2  
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SAFETY  
Stop machine if anyone enters the area.  
Rotating Blades are Dangerous  
Never raise mower decks when blades are running.  
HELP PREVENT SERIOUS OR FATAL ACCIDENTS:  
If you hit an object, stop and inspect the machine. Make  
repairs before you operate. Keep machine and  
attachments properly maintained and in good working  
order.  
Do not leave machine unattended when it is running.  
Only operate during daylight or with good artificial light.  
Slow down and be careful of traffic when operating near  
or crossing roadways. Stop blades before crossing roads  
or sidewalks. Use care when approaching blind corners,  
shrubs, trees, or other objects that may obscure vision.  
Be aware of the mower discharge direction and make  
sure that no one is in the path of the discharge direction.  
MIF  
Use only accessories and attachments approved by the  
Rotating blades can cut off arms and legs.  
Keep hands, feet and clothing away from mower deck  
manufacturer of the machine.  
Wear close fitting clothing and safety equipment  
when engine is running.  
appropriate for the job.  
Be alert at all times, drive forward carefully. People,  
Always wear safety goggles or safety glasses with side  
especially children can move quickly into the mowing area  
before you know it.  
shields when operating the mower.  
Wear a suitable protective device such as earplugs.  
Before backing up, shut off PTO and look down and  
Loud noise can cause impairment or loss of hearing.  
behind the machine carefully, especially for children.  
Do not wear radio or music headphones. Safe service  
Do not mow in reverse.  
and operation requires your full attention.  
Shut off blades when you are not mowing.  
Do not operate machine if you are under the influence of  
Checking Mowing Area  
drugs or alcohol.  
Park machine safely before inspecting or unplugging  
Evaluate the terrain to determine what accessories and  
mower or bagger.  
attachments are needed to properly and safely perform the  
job.  
PROTECT CHILDREN:  
Clear mowing area of objects that might be thrown.  
Never assume that children will remain where you last  
Keep people and pets out of mowing area.  
saw them. Children are attracted to mowing activity, stay  
alert to the presence of children.  
Study mowing area. Set up a safe mowing pattern. Do  
not mow where traction or stability is doubtful.  
Keep children indoors when you are mowing. Turn the  
Test drive area with mower lowered but not running.  
machine off if a child enters the mowing area.  
Slow down when you travel over rough ground.  
Use extra care when you come to blind corners, shrubs,  
trees, or other objects that may block your vision.  
Parking Safely  
Do not let children or an untrained person operate the  
machine.  
1. Stop machine on a level surface, not on a slope.  
2. Disengage PTO.  
Do not carry or let children ride on any attachment or  
machine even with the blades off. Do not tow children in a  
cart or trailer.  
3. Lower attachments to the ground.  
4. Lock park brake.  
5. Stop engine.  
Avoid Tipping  
6. Remove key.  
Slopes are a major factor related to loss-of-control and  
7. Wait for engine and all moving parts to stop before you  
leave the operators station.  
tip-over accidents, which can result in severe injury or  
death.  
Safety - 3  
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SAFETY  
Drive across a hill - not up and down. If necessary, turn  
flashing warning lights may need to be installed.  
slowly and in the downhill direction. Do not shift to neutral  
and coast downhill.  
Practice Safe Maintenance  
Avoid starting and stopping on a slope. If machine  
stops, disengage mower blades and back down slowly.  
Only qualified, trained adults should service this  
machine.  
Do not drive where machine could slip or tip.  
Understand service procedure before doing work. Keep  
Stay alert for holes and other hidden hazards in the  
area clean and dry.  
terrain.  
Never lubricate, service, or adjust machine while it is  
Keep away from drop-offs, ditches, and embankments.  
moving. Keep safety devices in place and in working  
condition. Keep hardware tight.  
Slow down before you make a sharp turn or operate on  
a slope. On gear models, choose a low gear so that shifting  
and stopping will not be necessary while on the slope.  
Keep hands, feet, clothing, jewelry, and long hair away  
from any moving parts, to prevent them from getting  
caught.  
Transport machine with decks lowered to improve  
stability.  
Lower attachments to the ground before servicing  
Drive machine very slowly and avoid quick stops when  
machine. Disengage all power and stop the engine. Lock  
park brake and remove the key. Let machine cool.  
attachment is removed.  
Mowing when grass is wet can cause reduced traction  
Disconnect battery or remove spark plug wire before  
and sliding.  
making any repairs.  
Before servicing machine, carefully release pressure  
from components with stored energy such as hydraulic  
components.  
Keep Riders Off  
Only allow the operator on the machine. Keep riders off.  
Keep all nuts and bolts tightened, especially blade  
Riders on the machine or attachment may be struck by  
attachment bolts.  
foreign objects or thrown off the machine causing serious  
injury.  
Securely support any machine elements that must be  
raised for service work. Lock service latches before  
working on machine with raised attachments.  
Riders obstruct the operators view resulting in the  
machine being operated in an unsafe manner.  
Never run engine unless park brake is locked.  
Keep all parts in good condition and properly installed.  
Checking Wheel Bolts  
Fix damage immediately. Replace worn or broken parts.  
Replace all worn or damaged safety and instruction decals.  
A serious accident could occur causing serious injury if  
wheel bolts are not tight.  
To prevent fires, remove any buildup of grease, oil, or  
debris from the machine, especially the engine  
compartment.  
Check wheel bolt tightness often during the first 100  
hours of operation.  
Charge batteries in an open, well-ventilated area, away  
Wheel hardware must be tightened to specified torque  
from sparks. Unplug battery charger before connecting or  
disconnecting from the battery. Wear protective clothing  
and use insulated tools.  
using the proper procedure anytime it is loosened.  
Driving Safely on Public Roads  
Do not modify machine or safety devices. Unauthorized  
modifications may impair its function and safety.  
Avoid personal injury or death resulting from a collision with  
another vehicle on public roads:  
Do not wear radio or music headphones while servicing  
the machine. Safe service requires your full attention.  
Use safety lights and devices. Slow moving machines  
when driven on public roads are hard to see, especially at  
night.  
Avoid High Pressure Fluids  
Use extra care when loading or unloading the machine  
Hydraulic hoses and lines can fail due to physical  
into a trailer or truck.  
damage, kinks, age, and exposure. Check hoses and lines  
regularly. Replace damaged hoses and lines.  
Whenever driving on public roads, use flashing warning  
lights and turn signals according to local regulations. Extra  
Hydraulic fluid connections can loosen due to physical  
Safety - 4  
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SAFETY  
damage and vibration. Check connections regularly.  
Tighten loose connections.  
running.  
Never fill fuel tank or drain fuel from a machine in an  
enclosed area. Fill fuel tank outdoors.  
Escaping fluid under pressure can penetrate the skin  
causing serious injury. Avoid the hazard by relieving  
pressure before disconnecting hydraulic or other lines.  
Tighten all connections before applying pressure.  
Prevent fires. Clean up spilled fuel immediately.  
Do not store machine with fuel in tank in a building  
where fumes may reach an open flame or spark.  
Search for leaks with a piece of cardboard. Protect  
Prevent fire and explosion caused by static electric  
hands and body from high pressure fluids.  
discharge. Use only non-metal, portable fuel containers  
approved by the Underwriters Laboratory (U.L.) or the  
American Society for Testing & Materials (ASTM). If using  
a funnel, make sure it is plastic and has no screen or filter.  
If an accident occurs, see a doctor immediately. Any  
fluid injected into the skin must be surgically removed  
within a few hours or gangrene may result. Doctors  
unfamiliar with this type of injury should reference a  
knowledgeable medical source.  
Prevent Fires  
Never remove fuel cap, or add fuel with engine running  
or hot. Allow engine to cool for several minutes.  
Never store equipment with fuel in the tank inside a  
building where fumes may reach an open flame or spark.  
Allow engine to cool before storing in any enclosure.  
To reduce fire hazard, keep engine free of grass,  
leaves, or excessive grease.  
Tire Safety  
MIF  
Static electric discharge can ignite gasoline vapors in an  
Explosive separation of a tire and rim parts can cause  
serious injury or death:  
ungrounded fuel container. 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. Keep nozzle in  
contact with container opening while filling.  
Do not attempt to mount a tire without the proper  
equipment and experience to perform the job.  
Always maintain the correct tire pressure. Do not inflate  
When practical, remove equipment from trailers or truck  
the tires above the recommended pressure. Never weld or  
heat a wheel and tire assembly. The heat can cause an  
increase in air pressure resulting in a tire explosion.  
Welding can structurally weaken or deform the wheel.  
beds and refuel them on the ground. If this is not possible,  
use a portable, plastic fuel container to refuel equipment on  
a truck bed or trailer.  
For gasoline engines, do not use gas with methanol.  
When inflating tires, use a clip-on chuck and extension  
Methanol is harmful to your health and to the environment.  
hose long enough to allow you to stand to one side and not  
in front of or over the tire assembly.  
Check tires for low pressure, cuts, bubbles, damaged  
rims or missing lug bolts and nuts.  
Handling Fuel Safely  
Fuel and fuel vapors are highly flammable and  
explosive:  
Do not refuel machine while you smoke, when machine  
is near an open flame or sparks, or when engine is running.  
Stop engine and allow to cool before filling.  
Never remove the fuel cap or add fuel with the engine  
Safety - 5  
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OPERATING  
Operating  
Console Controls  
Daily Operating Checklist  
Test safety systems.  
F
E
Check tire pressure.  
Check fuel level.  
Check engine oil level.  
Remove and clean engine air filter.  
Check transmission oil reservoir level.  
Remove grass and debris from machine.  
Clean engine cooling air intake screen and cooling fins.  
Inspect all belts for damage.  
B
A
D
Sharpen and balance mower blades.  
Check area below machine for any fuel or oil leaks.  
C
MX9205  
Operating Controls  
A - Throttle Lever  
B - Key Switch  
C - Choke Lever  
F
E
D - PTO/Clutch Switch  
E - Hourmeter  
F - Ammeter  
A
D
G
B
C
Testing Safety Systems  
c
CAUTION: Avoid injury! Engine exhaust fumes  
contain carbon monoxide and can cause  
serious illness or death.  
Move the vehicle to an outside area before  
running the engine.  
Do not run an engine in an enclosed area  
without adequate ventilation.  
MX9206  
Connect a pipe extension to the engine  
exhaust pipe to direct the exhaust fumes out of  
the area.  
A - Park Brake Lever  
B - Height-of-Cut (HOC) Adjustment Pin  
C - Mower Deck Lift/Lower Pedal  
D - Mower Deck Transport Position Lock Lever  
E - Fuel Shutoff Valve  
F - Steering Control Levers  
G - Console  
Allow fresh outside air into the work area to  
clear the exhaust fumes out.  
Use the following checkout procedure to check for normal  
operation of machine.  
If there is a malfunction during one of these procedures, do  
not operate machine. See your Great Dane dealer for  
service.  
Perform these tests in a clear open area. Keep bystanders  
away.  
Operating - 6  
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OPERATING  
2. Unlock park brake.  
Testing Park Brake Safety Switch  
3. Move PTO/clutch switch to on position (mower deck  
drive engaged).  
1. Operator must be seated in the seat (seat safety switch  
engaged).  
4. Turn key switch to start position.  
2. Move control levers to neutral position.  
3. Move PTO/clutch switch to off position.  
4. Unlock park brake.  
Result: The engine must not crank.  
Using the Park Brake  
5. Turn key switch to start position.  
Result: The engine must not crank.  
Move park brake lever to the raised (locked) position to  
lock the park brake. This will also engage the park brake  
safety switch.  
Testing Park Brake  
Stop the machine on a maximum 17° slope. Stop the  
engine and lock the park brake.  
Starting the Engine  
Result: Park brake must hold the machine stationary. If the  
machine moves more than 61 cm [24 in.] in one hour,  
brakes need to be adjusted. See your Great Dane dealer.  
c
CAUTION: Avoid injury! Engine exhaust fumes  
contain carbon monoxide and can cause  
serious illness or death.  
Move the vehicle to an outside area before  
running the engine.  
Testing Neutral Start Safety Switch  
1. Operator must be seated in the seat (seat safety switch  
engaged).  
Do not run an engine in an enclosed area  
without adequate ventilation.  
2. Move control levers to forward travel position.  
3. Move PTO/clutch switch to off position.  
4. Lock park brake.  
Connect a pipe extension to the engine  
exhaust pipe to direct the exhaust fumes out of  
the area.  
Allow fresh outside air into the work area to  
clear the exhaust fumes out.  
5. Turn key switch to start position.  
Result: The engine must not crank.  
1. Open the fuel shutoff valve.  
2. Operator must be seated in the seat (seat safety switch  
engaged).  
Testing Seat Safety Switch  
1. Operator must be seated in the seat (seat safety switch  
engaged).  
3. Lock park brake.  
4. Move control levers to neutral position.  
5. Move PTO/clutch switch to off position.  
6. Move throttle lever to half-speed position.  
7. Adjust choke as required.  
2. Move control levers to neutral position.  
3. Start the engine.  
c
CAUTION: Avoid injury! Before engaging  
mower, clear area of bystanders, especially  
children.  
IMPORTANT: Avoid damage! Starter may be  
damaged if starter is operated for more than 20  
seconds at a time:  
4. Move PTO/clutch switch to on position.  
5. Operator rises slightly off the seat.  
Result: The engine must stop.  
Wait 2 minutes before trying again if the engine  
does not start.  
8. Turn key switch to start position for no more than 5  
seconds. Release key to the run position when engine  
starts.  
Testing PTO/Clutch Safety Switch  
If the engine does not start, wait 10 seconds.  
1. Operator must be seated in the seat (seat safety switch  
engaged).  
Turn key to start position again for no more than 5  
Operating - 7  
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OPERATING  
seconds.  
neutral position.  
Repeat the procedure if necessary.  
To drive the machine in reverse: Pull both control levers  
back evenly.  
IMPORTANT: Avoid damage! Unnecessary engine  
idling may cause engine damage. Excessive idling  
can cause engine overheating, carbon build-up and  
poor performance.  
Stopping the Machine  
NOTE: If the operator leaves the seat without placing  
the PTO switch in the off position, the mower blades  
will stop as soon the operator leaves the seat.  
9. Let the engine run at half-speed position for several  
minutes to warm up before operating the machine. Reduce  
choke setting as the engine warms up.  
1. Move the PTO/clutch switch to the off position.  
2. Return both control levers to the neutral position.  
Operating the Machine  
c
CAUTION: Avoid injury! Children or bystanders  
may attempt to move or operate an unattended  
machine.  
c
CAUTION: Avoid injury! Learn the use of the  
control levers. Practice at half throttle until  
becoming proficient and comfortable with the  
operation of the machine.  
Always lock the park brake and remove the  
key before leaving the machine unattended.  
Do not move control levers from forward to  
reverse or reverse to forward position rapidly.  
Sudden direction changes could cause loss of  
control or damage the machine.  
3. Lock park brake.  
4. Move the throttle lever to the half-speed position, and let  
the engine run at low throttle for a few seconds.  
5. Turn the key switch to the stop position.  
6. Remove key.  
1. Adjust mower deck to desired cutting height.  
2. Start and warm up engine at half throttle.  
3. Move PTO/clutch switch to on position.  
4. Move throttle lever to wide open position.  
5. Unlock park brake.  
Adjusting Cutting Height  
Cutting height can be adjusted from approximately 25-152  
mm (1-6 in.). Each hole adjusts the height of cut (HOC) in  
13 mm (1/2 in.) increments.  
NOTE: The travel speed and turn rate will vary with the  
amount that the control levers are moved.  
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.  
A
C
MX9220  
B
6. Drive the machine:  
To drive the machine forward: Push both control levers  
MX9215  
forward smoothly and evenly.  
1. Push the mower deck lift/lower pedal (A) forward to  
raise and latch the deck in the transport position.  
To turn the machine: Pull the control lever back on the  
same side as the direction of the desired turn. Push the  
other lever forward.  
2. Position the HOC adjustment pin (B) in the proper hole  
for the desired height of cut.  
To stop the machine: Return both control levers to the  
Operating - 8  
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OPERATING  
3. Depress and hold the mower deck lift/lower pedal (A)  
and release the transport position lock lever (C).  
NOTE: The pumps are located under the machine,  
behind the mower deck.  
4. Release the mower deck lift/lower pedal (A) and allow  
the pedal to rest against the HOC pin.  
Using the Fuel Shutoff Valve  
A
MX9226  
A
Picture Note: Left pump shown.  
2. Turn free-wheeling valves (A) on both pumps one full  
turn counterclockwise (open position).  
3. Unlock park brake.  
MX9409  
4. Push machine to desired location. Due to internal  
hydraulic system resistance, the machine will move slowly.  
Move the fuel shutoff valve (A) to the on position for normal  
operation. Move the valve to the off position when the  
machine is not in use and during transport.  
5. Turn free-wheeling valves (A) on both pumps one full  
turn clockwise (closed position). Tighten the valves to 9-14  
Nm (80-120 lb-in.).  
Moving the Machine Manually  
6. Lock park brake.  
c
CAUTION: Avoid injury! With the free-wheeling  
valve open, the machine will have unrestricted  
motion.  
The machine may free-wheel out of control if  
the free-wheeling valve is opened with the  
machine on an incline.  
Park the machine on a level surface before  
opening the free-wheeling valve.  
IMPORTANT: Avoid damage! Transmission damage  
may occur if the machine is moved or towed  
incorrectly:  
Move unit by hand only.  
Do not use another vehicle to move unit.  
Do not tow unit.  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
Operating - 9  
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REPLACEMENT PARTS  
Replacement Parts  
Parts  
We recommend Great Dane quality parts available at your  
Great Dane dealer.  
Part numbers may change. Use part numbers listed below  
when you order. If a number changes, your dealer will have  
the latest number.  
When you order parts, your Great Dane dealer needs your  
machine model and serial numbers and engine serial  
number. These are the numbers that you recorded in the  
Product Identification section of this manual.  
Part Numbers  
Item  
Part Number  
D18169  
Battery  
Fuel Tank Cap  
D18097  
Oil Reservoir Cap  
Oil Filter (Hydraulic System)  
Traction (Hydro) Drive Belt  
Engine to Blade Belts:  
D18081  
D18094  
D28030  
1,32 m (52 in.) Deck  
1,55 m (61 in.) Deck  
D28032  
D28029  
Mower Deck Drive Belts:  
1,32 m (52 in.) Deck  
1,55 m (61 in.) Deck  
D28031  
D28028  
Mower Blades:  
53 cm (21 in.)  
45 cm (18 in.)  
D18036  
D18037  
(Part numbers are subject to change without notice. Part  
Numbers may be different outside the U.S.A.)  
Replacement Parts - 10  
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SERVICE INTERVALS  
Service Intervals  
Check wheel nut torque.  
Servicing Your Machine  
IMPORTANT: Avoid damage! Operating in extreme  
conditions may require more frequent service  
intervals:  
Every 160 Hours  
Clean and inspect spark plugs.  
Change engine oil filter.  
Engine components may become dirty or  
plugged when operating in extreme heat, dust or  
other severe conditions.  
Check transmission oil level.  
Lubricate mower deck idler pulley pivots (three places).  
Lubricate seat platform hinges (two places)  
Lubricate pump control arms (five places).  
Lubricate control lever pivot shafts (two places).  
Lubricate throttle cable.  
Engine oil and spark plugs may lose efficiency if  
vehicle is operated constantly at slow or low engine  
speeds or with frequent short trips.  
Please use the following timetables to perform routine  
maintenance on your machine.  
NOTE: The following initial break-in items must be  
performed and verified to validate the warranty (dealer  
service invoice accepted).  
Lubricate choke control cable.  
Every 500 Hours  
Change transmission oil and filter.  
Break-In (After First 8 Hours of Operation)  
Change engine oil and filter.  
Check drive belt tension.  
Annually  
Replace all spindle bearings (6).  
Check transmission neutral adjustment.  
Check wheel nut torque.  
Replace all mower deck idler pulleys (3).  
Remove caster wheel roller bearings, clean and lubricate.  
Replace drive belts. Run-in and adjust tension.  
Clean power unit.  
Break-In (After First 24 Hours of Operation)  
Check drive belt tension.  
Replace hydraulic oil filter.  
Check all bolts and nuts; tighten as needed.  
Remove battery. Clean battery and holder.  
Replace spark plugs.  
Break-In (After First 40 Hours of Operation)  
Change transmission oil and filter.  
Every 40 Hours  
Change engine oil.  
Grease HOC shafts (five places).  
Grease caster wheel pivot bearings (two places).  
Grease caster wheel bearings (two places).  
Grease mower deck thrust arms (two places).  
Grease mower deck spindle bearings (three places) if  
equipped.  
Remove debris from the underside of the mower deck.  
Check drive belt tension.  
Check tire pressure.  
Check battery electrolyte level.  
Clean engine air filter.  
Service Intervals - 11  
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SERVICE LUBRICATION  
Service Lubrication  
NOTE: Use spray lubricant to lubricate the following  
items:  
Grease  
IMPORTANT: Avoid damage! If operating outside  
that temperature range, contact your Servicing  
dealer for a special-use grease.  
A
B
Use a general all-purpose grease with an NLGI grade No.2  
rating.  
D
Wet or high speed conditions may require use of a special-  
use grease. Contact your Servicing dealer for information.  
C
Spray Lubricant  
Use a general-purpose petroleum-based spray lubricant.  
MX9252  
Lubricate mower deck idler pulleys (A-D).  
Lubrication Points  
D
E
D
E
C
B
C
E
B
A
D
B
E
A
MX9206  
Grease caster wheel bearings (A).  
A
Grease caster wheel pivot bearings (B).  
Grease HOC shafts (C).  
MX9408  
Lubricate hydraulic pump control arms (A).  
Lubricate control lever pivot shaft (B).  
Lubricate seat platform hinges (C).  
Lubricate throttle control cable (D).  
Lubricate choke control cable (E).  
Grease mower deck thrust arms (D), located at the rear  
of the mower deck.  
Grease mower deck spindle bearings (E) if equipped.  
Service Lubrication - 12  
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SERVICE ENGINE  
Service Engine  
overfill.  
Avoid Fumes  
6. Install and tighten dipstick.  
c
CAUTION: Avoid injury! Engine exhaust fumes  
contain carbon monoxide and can cause  
serious illness or death.  
Changing Engine Oil and Filter  
Move the vehicle to an outside area before  
running the engine.  
Do not run an engine in an enclosed area  
without adequate ventilation.  
A
Connect a pipe extension to the engine  
exhaust pipe to direct the exhaust fumes out of  
the area.  
Allow fresh outside air into the work area to  
clear the exhaust fumes out.  
MX9413  
Engine Oil  
NOTE: An oil drain tube is provided with your machine.  
Attach the tube to the oil drain fitting on your engine,  
and open the valve (A) to drain the used oil. Close the  
valve, and remove the drain tube from the fitting after  
the oil has been drained. Store the drain tube after use.  
Use oil viscosity based on the expected air temperature  
range during the period between oil changes.  
Use oil that meets the following specification:  
Change engine oil and filter at the intervals recommended  
in the Service Intervals section. See the engine  
manufacturers owners manual provided with your  
machine for the complete procedure.  
API Service Classification SG or higher  
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:  
Cleaning Air Intake Screen and Engine Fins  
IMPORTANT: Avoid damage! The engine is air-  
cooled and requires a large amount of air intake  
when running. Reduced air intake can cause  
overheating:  
Check oil level before operating.  
Check oil level when the engine is cold and not  
running.  
Keep level between the FULL and the ADD marks.  
Shut off engine before adding oil.  
Keep air intake screen and cooling fins clean.  
Keep covers and screens in place.  
Keep air intake screens and engine cooling fins clear of  
debris to ensure proper cooling. See the engine  
manufacturers owners manual provided with your  
machine for the complete procedure.  
NOTE: Check oil twice a day if you run engine over 4  
hours in a day.  
Make sure engine is cold when checking engine oil  
level.  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
Checking and Cleaning Air Filter Elements  
2. Clean area around dipstick to prevent debris from falling  
into crankcase.  
c
CAUTION: Avoid injury! Touching hot surfaces  
can burn skin. The engine and components will  
be hot if the engine has been running. Allow  
the engine to cool before servicing.  
3. Remove dipstick. Wipe with a clean cloth.  
4. Install and tighten dipstick.  
5. Remove dipstick and check oil level on dipstick. Oil must  
be between ADD and FULL marks. If oil is low, add oil to  
bring oil level no higher than FULL mark on dipstick. Do not  
Service Engine - 13  
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SERVICE ENGINE  
Replacing Fuel Filter  
IMPORTANT: Avoid damage! Dirt and debris can  
enter the engine through a damaged filter element:  
Do not wash paper element.  
c
CAUTION: Avoid injury! Fuel vapors are  
explosive and flammable:  
Do not attempt to clean paper element by tapping  
against another object.  
Do not smoke while handling fuel.  
Keep fuel away from flames or sparks.  
Shut off engine before servicing.  
Cool engine before servicing.  
Work in a well-ventilated area.  
Clean up spilled fuel immediately.  
Do not use pressurized air to clean element.  
Replace element only if it is very dirty, damaged  
or the seal is cracked.  
Check and clean air filter elements at the intervals  
recommended in the Service Intervals section. See the  
engine manufacturers owners manual provided with your  
machine for the complete procedure.  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
Checking Spark Plug  
2. Turn fuel shutoff valve to off position.  
3. Disconnect the fuel hose from the outlet side of the fuel  
filter, and drain gasoline into a properly marked container.  
c
CAUTION: Avoid injury! Touching hot surfaces  
can burn skin. The engine and components will  
be hot if the engine has been running. Allow  
the engine to cool before servicing.  
4. Remove the fuel filter from the inlet fuel hose. Discard  
filter.  
IMPORTANT: Avoid damage! When installing a new  
fuel filter, the filter arrow must be pointing in the  
direction of fuel flow.  
Check spark plugs at the intervals recommended in the  
Service Intervals section. See the engine manufacturers  
owners manual provided with your machine for the  
complete procedure.  
5. Connect a new fuel filter to hoses.  
6. Turn fuel shutoff valve to ON position.  
Adjusting Carburetor  
NOTE: Carburetor is calibrated by the engine  
manufacturer and is not adjustable.  
If engine is operated at altitudes above 1829 m (6,000  
ft), some carburetors may require a special high  
altitude main jet.  
If engine is hard to start or runs rough, see the  
troubleshooting section of the engine manufacturers  
owners manual provided with your machine.  
Possible engine surging will occur at high throttle with  
transmission in Nneutral and mower disengaged. This is  
a normal condition due to the emission control system.  
After performing the checks in the troubleshooting section  
and your engine is still not performing correctly, contact the  
local engine manufacturers authorized servicing dealer.  
Service Engine - 14  
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SERVICE TRANSMISSION  
Service Transmission  
Avoid Fumes  
c
CAUTION: Avoid injury! Engine exhaust fumes  
contain carbon monoxide and can cause  
serious illness or death.  
A
Move the vehicle to an outside area before  
running the engine.  
Do not run an engine in an enclosed area  
without adequate ventilation.  
Connect a pipe extension to the engine  
exhaust pipe to direct the exhaust fumes out of  
the area.  
MX9233  
4. Turn hydraulic filter (A) counterclockwise to remove, and  
drain oil into a properly marked container with a capacity of  
at least 7.5 L (2.0 gal).  
Allow fresh outside air into the work area to  
clear the exhaust fumes out.  
5. Apply a film of clean oil to gasket of new filter.  
6. Install filter. Turn filter clockwise until gasket makes  
contact with the mounting surface. 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.  
7. Fill reservoir with approximately 2.8 L (3 qt) (low-profile  
tank) or 3.8 L (4 qt) (high-profile tank) of oil.  
8. Install reservoir cap.  
Checking Transmission Oil Level  
9. Bleed air from hydraulic system.  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
Adjusting Transmission Neutral Position  
2. Remove the hydraulic reservoir cap. The oil level should  
be 76 mm (3 in.) from the top of the filler pipe. Add oil as  
needed.  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
Changing Transmission Oil and Filter  
c
CAUTION: Avoid injury! Machine must be  
safely supported on jackstands before  
removing or installing wheels. Do not use a  
hoist or floor jack to support the machine.  
IMPORTANT: Avoid damage! Contamination of  
hydraulic fluid could cause transmission damage or  
failure. Do not open oil reservoir cap unless  
absolutely necessary.  
2. Raise drive wheel off the ground and securely support  
the machine, and block caster wheels.  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
3. Start and run the engine until it reaches normal  
operating temperature.  
2. Allow engine and hydraulic reservoir to cool.  
4. Observe wheel movement as control levers are moved  
back and forth. The wheels should travel in the correct  
direction as the levers are moved.  
3. Clean area around the reservoir filler cap, and remove  
the filler cap from the reservoir.  
Service Transmission - 15  
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SERVICE TRANSMISSION  
A
B
A
MX9244  
5. Move control levers to neutral position. The wheels  
MX9216  
should stop rotating. If the wheels continue to rotate, adjust  
the neutral adjustment knob(s) (A), located on each side of  
the seat, until wheel(s) stop rotating.  
Picture Note: Drive belt routing as viewed from the  
top of machine.  
3. Disconnect tension spring (A) from the anchor pin.  
4. Remove drive belt (B).  
B
5. Install new drive belt (B).  
6. Connect tension spring (A) to anchor pin.  
7. Install mower deck drive belt.  
Bleeding Hydraulic System  
c
CAUTION: Avoid injury! Escaping fluid under  
pressure can penetrate the skin causing  
serious injury. Avoid the hazard by relieving  
pressure before disconnecting hydraulic or  
other lines. Tighten all connections before  
applying pressure. Search for leaks with a  
piece of cardboard. Protect hands and body  
from high pressure fluids.  
MX9250  
6. Adjust neutral switch activator bolt(s) (B) as needed.  
The switches should be engaged when the control levers  
are in the neutral position.  
7. Shut engine off.  
8. Lower the machine to the ground.  
Use caution when filling and draining hydraulic  
oil. During periods of machine operation, the  
hydraulic oil reservoir can get hot. Allow  
engine and oil reservoir to cool before  
servicing.  
Removing and Installing Traction Drive Belt  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
2. Remove mower deck drive belt.  
IMPORTANT: Avoid damage! Contamination of  
hydraulic fluid could cause transmission damage or  
failure. Do not open oil reservoir cap unless  
absolutely necessary.  
Severe or unusual conditions may require a more  
frequent service interval.  
NOTE: Whenever hydraulic components are removed  
from the system, hoses are disconnected, or the  
system has been drained, trapped air must be removed  
from the hydraulic system.  
Service Transmission - 16  
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SERVICE TRANSMISSION  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
2. Check hydraulic oil level. Adjust as necessary.  
c
CAUTION: Avoid injury! Machine must be  
safely supported on jackstands before  
removing or installing wheels. Do not use a  
hoist or floor jack to support the machine.  
3. Raise drive wheels off the ground and block caster  
wheels.  
NOTE: The pumps are located under the machine,  
behind the mower deck.  
A
MX9226  
Picture Note: Left pump shown.  
4. Open free-wheeling valves (A) one full turn  
counterclockwise and start engine.  
5. Slowly move the control levers in both forward and  
reverse directions five to six times. As the air is purged  
from the unit, the oil level will drop.  
6. Turn off engine and check oil level. Adjust as necessary.  
7. Close the free-wheeling valves and tighten to 9-14 Nm  
(80-120 lb-in.).  
8. Start engine and slowly move the control levers in both  
forward and reverse directions five to six times.  
9. Turn off engine and lower machine to ground. Check oil  
level and adjust as necessary. Mower should move in  
forward and reverse at normal speed, if not, repeat  
procedure.  
Service Transmission - 17  
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SERVICE MOWER  
Service Mower  
If no adjustment is required, proceed to Step 8.  
Adjusting Mower Level  
H
G
c
CAUTION: Avoid injury! Mower blades are  
sharp. Always wear gloves when handling  
mower blades or working near blades.  
I
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
2. Inflate drive (rear) tires to 69-83 kPa (10-12 psi), and  
caster (front) tires to 110-139 kPa (16-20 psi).  
J
3. Adjust cutting height to 50 mm (2 in.), and lower mower  
to cutting position.  
MX9221  
7. Loosen jam nuts (G) and (H) on the swivel adjuster rod.  
Turn the jam nuts as required to obtain the desired height  
of position D.  
B
D
8. Measure the distance from the top of the mower deck to  
the ground at positions C and D. The height at position C  
must be 3-6 mm (1/8-1/4 in.) higher than position D.  
If adjustment is required, proceed to Step 9.  
If no adjustment is required, proceed to Adjust  
C
A
Cutting Height.  
9. Loosen the nut (I), and slide cap screw (J) in the slot  
until the desired height at position C is obtained. Tighten  
the nut.  
MX9288  
4. Measure the distance from the top of the mower deck to  
the ground at positions A and B. The height at position A  
must be 3-6 mm (1/8-1/4 in.) higher than position B.  
Adjust Cutting Height  
1. Set the cutting height to 89 mm (3-1/2 in.), and lower  
mower to cutting position.  
If adjustment is required, proceed to Step 5.  
If no adjustment is required, proceed to Step 6.  
F
E
A
MIF  
MX9284  
2. Turn right blade (A) so that the blade tip is pointing out  
of the middle of the discharge chute.  
5. Loosen jam nuts (E) and (F) on the swivel adjuster rod.  
Turn the jam nuts as required to obtain the desired height  
of position A.  
3. Measure from outside blade tip to flat ground surface. If  
the blade height (A) is not 89 mm (3-1/2 in.), adjust the  
cutting height.  
6. Measure the distance from the top of the mower deck to  
the ground at positions B and D. The heights of position B  
and D should be equal, 3 mm (1/8 in.).  
If adjustment is required, proceed to Step 7.  
Service Mower - 18  
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SERVICE MOWER  
counterclockwise.  
Removing and Installing Mower Deck Drive  
Belts  
B
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
2. Raise foot platform.  
C
3. Remove mower deck drive belt covers.  
MX9285  
4. Loosen the jam nut (B) on the link rod assembly, and  
turn the sleeve (C) until the blade height is 89 mm (3-1/2  
in.). Tighten the jam nut.  
B
Checking and Adjusting Mower Deck Drive  
Belt Tension  
A
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
D
2. Adjust the mower deck for the lowest cutting height, and  
lower the deck.  
C
A
MX9217  
4. Release mower deck drive belt tension, by turning the  
tension adjuster nut (A) counterclockwise.  
5. Remove mower deck drive belt (B).  
C
6. Release spindle drive belt tension by turning tension  
adjustment nut (C) counterclockwise.  
7. Remove spindle drive belt (D).  
8. Install new spindle drive belt (D) and adjust drive belt  
tension.  
B
9. Install new mower deck drive belt (B) and adjust drive  
belt tension.  
D
10.Install mower deck drive belt covers.  
11.Lower foot platform.  
MX9217  
3. Check the mower deck drive (A) and spindle drive (B)  
belt tension. The belts should deflect a maximum of 13 mm  
(1/2 in.) when a force of 4.5 kg (10 lb) is applied to the  
center of the longest span.  
To Increase Belt Tension: Turn nut (C - mower  
deck drive belt) or (D - spindle drive belt) clockwise.  
To Decrease Belt Tension: Turn nut (C - mower  
deck drive belt) or (D - spindle drive belt)  
Service Mower - 19  
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SERVICE MOWER  
Checking for Bent Mower Blades  
A
c
CAUTION: Avoid injury! Mower blades are  
sharp. Always wear gloves when handling  
mower blades or working near blades.  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
C
B
2. Lower mower deck to mowing position.  
D
MX9231  
2. Remove nut (A), blade (B), blade washers (C), and bolt  
(D).  
A
3. Install blade (B), blade washers (C), bolt (D) and secure  
using nut (A). Tighten nut to 80 Nm (60 lb-ft).  
MIF  
Balancing Mower Blades  
3. Measure distance (A) between blade tip and flat ground  
surface.  
1. Clean blade.  
4. Turn blade 180°. Measure distance between the other  
blade tip and flat ground surface.  
5. Install a new blade if the difference between the two  
measurements is more than 3 mm (1/8 in.).  
Servicing Mower Blades  
c
CAUTION: Avoid injury! Mower blades are  
sharp. Always wear gloves when handling  
mower blades or working near blades.  
M61524  
2. Put blade on nail in a vise. Turn blade to horizontal  
position.  
Removing and Installing Mower Blades  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
3. Check balance. If blade is not balanced, heavy end of  
blade will drop.  
4. Grind bevel of heavy end. Do not change blade bevel.  
Sharpening Blades  
c
CAUTION: Avoid injury! Always wear safety  
eye protection when grinding.  
Sharpen blades with grinder, hand file, or electric blade  
sharpener.  
Service Mower - 20  
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SERVICE MOWER  
D
A
B
A
E
B
F
C
M61830  
Keep original bevel (A) when grinding.  
Blade should have 0.40 mm (1/64 in.) cutting edge (B)  
K
or less.  
Balance blades before installing.  
J
Replacing Mower Spindle Bearings  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
I
2. Remove mower deck drive and spindle drive belt.  
3. Remove mower blade.  
H
G
MX9222A  
4. Remove upper pulleys:  
Side Spindles: Remove nut (A), spacer (B) and  
pulley (C).  
Center Spindle: Remove nut (D), drive pulley (E)  
and spindle pulley (F).  
5. Remove spindle shaft (G), lower bearing (H) and spacer  
(I) from spindle housing (J). Discard bearing.  
6. Remove and discard upper bearing (K).  
7. Clean entire assembly.  
8. Install a new lower bearing (H) and spacer (I) on the  
spindle shaft (G).  
IMPORTANT: Avoid damage! The clearance between  
the lower bearing and the housing is only 0.05 mm  
(0.002 in.). Do not force bearing into housing.  
9. Install the spindle shaft (G), lower bearing (H) and  
spacer (I) into the spindle housing (J).  
10.Install the upper bearing (K).  
Service Mower - 21  
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SERVICE MOWER  
11.Install upper pulleys:  
Side Spindles: Install pulley (C), spacer (B) and nut  
(A). Tighten nut to 80 Nm (60 lb-ft).  
Center Spindle: Install spindle pulley (F), drive  
pulley (E) and nut (D). Tighten nut to 80 Nm (60 lb-ft).  
12.Install mower blade. Tighten nut to 80 Nm (60 lb-ft).  
Replacing Mower Deck Idler Pulleys  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
2. Remove the mower deck drive and spindle drive belts.  
A
B
D
C
MX9252  
3. Remove mower deck drive tension idler pulleys (A) and  
(B), mower deck drive fixed idler pulley (C) and spindle  
drive tension idler pulley (D).  
4. Install new idler pulleys.  
5. Install spindle drive and mower deck drive belts.  
6. Adjust belt tension.  
Service Mower - 22  
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SERVICE ELECTRICAL  
Service Electrical  
battery tray.  
3. Tighten the cap screws and nuts (E) to secure the  
battery in the battery tray. Do not overtighten.  
WARNING: Battery posts, terminals and related  
accessories contain lead and lead components, chemicals  
known to the State of California to cause cancer and  
reproductive harm. Wash hands after handling.  
4. Connect the positive (+) battery cable (D) first, then the  
negative (-) cable (B).  
5. Apply general purpose grease or silicone spray to the  
terminals to prevent corrosion.  
Removing and Installing the Battery  
6. Slide covers (A and C) over battery terminals.  
c
CAUTION: Avoid injury! The battery produces a  
flammable and explosive gas. The battery may  
explode:  
Checking Battery Electrolyte Level  
Do not smoke near battery.  
c
CAUTION: Avoid injury! Battery electrolyte  
contains sulfuric acid. It is poisonous and can  
cause serious burns:  
Wear eye protection and gloves.  
Do not allow direct metal contact across  
battery posts.  
Wear eye protection and gloves.  
Keep skin protected.  
Remove negative cable first when  
disconnecting.  
If electrolyte is swallowed, get medical  
Install negative cable last when connecting.  
attention immediately.  
If electrolyte is splashed into eyes, flush  
immediately with water for 15-30 minutes and  
get medical attention.  
Removing:  
1. Park the vehicle safely. (See Parking Safely in the  
safety section.)  
If electrolyte is splashed onto skin, flush  
immediately with water and get medical  
attention if necessary.  
C
A
NOTE: Add only distilled water to replace normal  
electrolyte loss.  
D
B
1. Park the vehicle safely. (See Parking Safely in the  
safety section.)  
F
2. Remove battery from vehicle and set it on a level  
surface.  
3. Remove battery cell caps. Make sure cap vents are not  
plugged.  
E
G
MX9209  
2. Slide black cover (A) away from the negative (-) battery  
terminal and disconnect the negative (-) battery cable (B).  
3. Slide red cover (C) away from the positive (+) battery  
terminal and disconnect the positive (+) battery cable (D).  
B
4. Loosen the cap screws and nuts (E) on both sides of the  
battery tray.  
A
C
5. Remove battery (F) and isolator pad (G).  
Installing:  
1. Place isolator pad (G) in the battery tray.  
MIF  
2. Install battery (F) in the battery tray, making sure that  
the isolator pad (G) is between the bottom and sides of the  
4. Check electrolyte level. Electrolyte (A) should be  
Service Electrical - 23  
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SERVICE ELECTRICAL  
approximately halfway between bottom of filler neck (B)  
and top of plates (C).  
IMPORTANT: Avoid damage! Do not overfill battery.  
Electrolyte can overflow when battery is charged  
and cause damage.  
5. Add only distilled water if necessary.  
6. Install battery cell caps.  
7. Install battery.  
A
B
MX9245  
Cleaning Battery and Terminals  
1. Remove defective fuse (A - electric start circuit) or (B -  
charging circuit) from socket.  
c
CAUTION: Avoid injury! The battery produces a  
flammable and explosive gas. The battery may  
explode:  
2. Check metal clip in fuse window and discard fuse if clip  
is broken.  
3. Install new fuse into socket.  
Do not smoke near battery.  
Wear eye protection and gloves.  
Check and Adjust PTO Clutch Air Gap  
Do not allow direct metal contact across  
battery posts.  
NOTE: If clutch is not equipped with adjusting nuts (B),  
no adjustment is required.  
Remove negative cable first when  
disconnecting.  
1. Park the vehicle safely. (See Parking Safely in the  
safety section.)  
Install negative cable last when connecting.  
1. Disconnect and remove battery.  
2. Wash battery with a solution of four tablespoons of  
baking soda to one gallon of water. Be careful not to get the  
soda solution into the battery cells.  
3. Rinse the battery with plain water and dry.  
B
4. Clean terminals and battery cable ends with wire brush  
until bright.  
B
A
5. Install battery.  
MX9290  
6. Attach cable clamps to battery posts.  
2. Check the air gap at the three openings (A) around the  
clutch, using a feeler gauge. The air gap should be within  
0.012-0.584 mm (0.005-0.023 in.). If the gap is not within  
specifications, adjust the air gap.  
7. Apply petroleum jelly or silicone spray to terminal to  
prevent corrosion.  
3. Adjust the air gap to 0.34 mm (0.12 in.), by tightening or  
loosening the three adjustment nuts (B).  
Replacing Fuses  
IMPORTANT: Avoid damage! When replacing fuses -  
use only 20-amp fuses or you may damage the  
circuit.  
Two 20-amp fuses to protect the electric start and charging  
circuit are located behind the seat area.  
Service Electrical - 24  
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SERVICE ELECTRICAL  
Kohler Wiring Schematic  
MX9299A  
Service Electrical - 25  
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SERVICE MISCELLANEOUS  
Service Miscellaneous  
Filling Fuel Tank  
A
Use regular grade 87 octane unleaded fuel.  
Add fuel stabilizer to fuel before using it in your machine to  
prevent engine damage due to stale fuel. Follow directions  
on stabilizer container.  
B
c
CAUTION: Avoid injury! Fuel vapors are  
explosive and flammable:  
C
Shut engine off before filling fuel tank.  
Do not smoke while handling fuel.  
Keep fuel away from flames or sparks.  
E
F
Fill fuel tank outdoors or in well-ventilated  
area.  
G
D
F
Clean up spilled fuel immediately.  
E
C
Use clean, approved non-metal container to  
MX9223  
prevent static electric discharge.  
3. Remove lock nut (A), bolt (B), two spacers (C) and  
wheel assembly (D).  
Use clean, approved plastic funnel without  
screen or filter to prevent static electric  
discharge.  
4. Remove seals (E), bearings (F) and spacer tube (G)  
from wheel.  
IMPORTANT: Avoid damage! Dirt and water in fuel  
can cause engine damage:  
5. Clean and inspect bearings (F) and pack with clean  
grease. Replace bearings as needed.  
Clean dirt and debris from the fuel tank opening.  
Use clean, fresh, stabilized fuel.  
6. Install spacer tube (G), bearings (F) and new seals (E).  
7. Install wheel assembly (D), two spacers (C), bolt (B) and  
lock nut (A).  
Fill the fuel tank at the end of each days  
operation to keep condensation out of the fuel tank.  
Use a non-metallic funnel with a plastic mesh  
Servicing Caster Pivot Bearings  
strainer when filling the fuel tank or container.  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
Checking Wheel Nuts  
2. Raise and securely support the front of the mower deck.  
Tighten rear wheel nuts in an alternating pattern to 68 Nm  
(50 lb-ft.).  
Servicing Caster Wheel Roller Bearings  
1. Park machine safely. (See Parking Safely in the Safety  
section.)  
2. Raise and securely support the front of the mower deck.  
Service Miscellaneous - 26  
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SERVICE MISCELLANEOUS  
A
B
C
J
F
L
G
I
H
E
D
MX9224  
3. Remove cap (A), cotter pin (B), castle nut (C), caster  
yoke and wheel assembly (D) and caster bushing (E).  
NOTE: It is not necessary to remove the bearing races  
(F) and (G), unless the bearings need to be replaced.  
4. Remove seal (H) and lower bearing (I).  
5. Remove upper bearing (J).  
6. Clean and inspect bearings (I) and (J); pack with clean  
grease. Replace bearings if needed.  
7. Install lower bearing (I) and a new seal (H).  
8. Install upper bearing (J).  
NOTE: Do not overtighten castle nut (C). Tighten castle  
nut only enough to remove excess play from bearings.  
Align crossdrill and nut to allow installation of the  
cotter pin (B). The caster wheel yoke assembly must be  
free to rotate.  
9. Install caster bushing (E) on yoke shaft, and install  
caster yoke and wheel assembly (D), castle nut (C), and  
cotter pin (B).  
10.Apply grease to lubrication fitting (L) until you can see  
grease at the top bearing (J). Install grease cap (A).  
Service Miscellaneous - 27  
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TROUBLESHOOTING  
Troubleshooting  
Using Troubleshooting Chart  
If you are experiencing a problem that is not listed in this  
chart, see your Great Dane dealer for service.  
When you have checked all the possible causes listed and  
you are still experiencing the problem, see your Great  
Dane dealer.  
Engine  
NOTE: This engine troubleshooting chart covers items  
that are unique to the machine operation. See the  
engine manufacturer’s owner’s manual provided with  
your machine for detailed engine troubleshooting  
procedures.  
If  
Check  
Poor Engine Performance  
Dirt in fuel system or fuel is old; obtain fresh fuel from another  
supplier before suspecting machine problems. Suppliers blend fuels  
differently and changing suppliers will generally solve any  
performance problems.  
Fuel blended with alcohol or ether may contribute to performance  
problems by causing gum and varnish deposits, especially if fuel is  
stored for several weeks or more. Obtain fresh fuel.  
Engine Will Not Start  
Park brake not locked.  
Control levers are not in neutral position.  
PTO/clutch switch is in on position.  
Fuel shutoff valve in off position.  
Spark plug wire(s) loose or disconnected.  
Improper fuel.  
Plugged fuel filter.  
Electrical problem. (See Electrical Troubleshooting section)  
Engine Will Not Idle  
Operator rising off the seat.  
Engine Stops Or Misses When Operating On  
Hillsides  
Fuel tank less than half full of fuel.  
Operator rising off of the seat.  
Engine Backfires  
Operator rising off of the seat.  
Troubleshooting - 28  
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TROUBLESHOOTING  
Electrical  
If  
Check  
Starter Does Not Work Or Will Not Turn Engine  
Park brake is not locked.  
PTO/clutch switch is in on position.  
Battery terminals are corroded.  
Battery not charged.  
20-amp fuse is blown.  
Battery Will Not Charge  
Dead cell in the battery.  
Battery cables and terminals are dirty.  
Low engine speed or excessive idling.  
Machine Operation  
If  
Check  
Machine Vibrates Too Much Or Rattles Excessively Attachment drive belts worn or damaged.  
Traction drive belt damaged or worn.  
Dirt on drive sheaves.  
Machine Will Not Move With Engine Running  
Park brake locked.  
Transmission hydraulic oil level low.  
Free-wheeling valves are open.  
Traction drive belt damaged or worn.  
Machine Will Not Follow a Straight Path  
Steering tracking out of adjustment.  
Machine Moves To The Left Or Right With Engine  
Running And Transmission In Neutral  
Pump linkage (neutral position) out of adjustment.  
Mower  
If  
Check  
Discharge Chute Plugged  
Travel speed too fast.  
Grass too long.  
Grass too wet.  
Engine rpm not at wide open throttle.  
Restricted air flow.  
Belt installed incorrectly.  
Patches Of Grass Uncut  
Travel speed too fast.  
Engine rpm not at wide open throttle.  
Mower deck needs cleaning.  
Troubleshooting - 29  
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TROUBLESHOOTING  
If  
Check  
Belt Slipping  
Debris in sheaves.  
Worn belt.  
Too Much Vibration  
Debris on mower deck or in sheaves.  
Damaged sheaves or sheaves out of alignment.  
Damaged drive belt.  
Blades out of balance.  
Blades Scalping Grass  
Cutting too low.  
Mower wheels not adjusted correctly.  
Turning speed too fast.  
Ridges in terrain.  
Rough or uneven terrain.  
Low tire pressure.  
Mower Loads Down Engine  
Uneven Cut  
Engine rpm too low.  
Travel speed too fast.  
Debris wrapped around mower spindles.  
Mower deck not leveled properly.  
Travel speed too fast.  
Blades dull.  
Mower wheels not adjusted correctly.  
Tire pressure unequal.  
Grass Tips Are Jagged And Turn Grayish Brown  
After Mowing  
Dull mower blades.  
Mower deck not leveled properly.  
Troubleshooting - 30  
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STORAGE  
Storage  
circulate through carburetor.  
Storing Safety  
Engine:  
Engine storage procedure should be used when vehicle is  
not to be used for longer than 60 days.  
c
CAUTION: Avoid injury! Fuel vapors are  
explosive and flammable. Engine exhaust  
fumes contain carbon monoxide and can cause  
serious illness or death:  
1. Change engine oil and filter while engine is warm.  
2. Service air filter if necessary.  
Run the engine only long enough to move  
the machine to or from storage.  
3. Clean debris from engine air intake screen.  
4. Remove spark plugs. Put 30 mL (1 oz.) of clean engine  
oil in cylinders.  
Do not store vehicle with fuel in the tank  
inside a building where fumes may reach an  
open flame or spark.  
5. Crank the engine five or six times to allow oil to be  
distributed.  
Allow the engine to cool before storing the  
machine in any enclosure.  
6. Install spark plugs.  
7. Clean the engine and engine compartment.  
8. Remove battery.  
Preparing Machine for Storage  
9. Clean the battery and battery posts. Check the  
electrolyte level.  
1. Repair any worn or damaged parts. Replace parts if  
necessary. Tighten loose hardware.  
10.Move fuel shut-off valve to off position.  
2. Repair scratched or chipped metal surfaces to prevent  
rust.  
11.Store the battery in a cool, dry place where it will not  
freeze.  
3. Clean under the deck and remove grass and debris  
from inside chute and bagger.  
NOTE: The stored battery should be recharged every  
90 days.  
4. Wash the machine and apply wax to metal and plastic  
surfaces.  
12.Charge the battery.  
5. Run machine for five minutes to dry belts and pulleys.  
13.Store the vehicle in a dry, protected place. If vehicle is  
stored outside, put a waterproof cover over it.  
6. Apply light coat of engine oil to pivot and wear points to  
prevent rust.  
Removing Machine From Storage  
Preparing Fuel and Engine for Storage  
1. Check tire pressure.  
2. Check engine oil level.  
Fuel:  
3. Check battery electrolyte level. Charge battery if  
necessary.  
If you have been using Stabilized Fuel, add stabilized fuel  
to tank until the tank is full.  
4. Install battery.  
NOTE: Filling the fuel tank reduces the amount of air in  
the fuel tank and helps reduce deterioration of fuel.  
5. Check spark plug gap. Install and tighten plugs to  
specified torque.  
If you are not using Stabilized Fuel:  
6. Lubricate all grease points.  
1. Park machine safely in a well-ventilated area.  
7. Turn fuel shut-off valve to on position.  
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.  
8. Run the engine 5 minutes without the mower or any  
attachments running to allow oil to be distributed  
throughout engine.  
2. Turn on engine and allow to run until it runs out of fuel.  
3. Turn key to off position.  
9. Be sure all shields and guards or deflectors are in place.  
4. Mix fresh fuel and fuel stabilizer in separate container.  
Follow stabilizer instructions for mixing.  
5. Fill fuel tank with stabilized fuel.  
6. Run engine for a few minutes to allow fuel mixture to  
Storage - 31  
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ASSEMBLY  
Assembly  
be 6 mm (1/4 in.) above plates (B), but NO HIGHER  
than 6 mm (1/4 in.) from the bottom of the filler neck (C).  
Install Seat and Control Lever Handles  
1. Install seat on platform and secure using nuts provided  
in small parts bag.  
5. Install the battery caps before charging the battery.  
2. Connect seat safety switch to wiring harness.  
IMPORTANT: Avoid damage! Wait 20 minutes before  
charging the battery to allow the plates to absorb”  
the acid, so they will take a charge well.  
3. Install handles on control levers and secure using  
sleeves, cap screws and nuts provided in small parts bag.  
Battery must be charged before operation. Adding  
acid without charging will result in battery damage.  
Activate and Charge Battery  
6. Charge the battery for a minimum of 30 minutes at 5-10  
amps. If your battery charger has a Deep Cycle or  
Maintenance Free setting, use this setting to charge the  
battery. Failure to charge the battery before use will reduce  
battery performance and life.  
c
CAUTION: Avoid injury! Battery electrolyte  
contains sulfuric acid. It is poisonous and can  
cause serious burns:  
Wear eye protection and gloves.  
Keep skin protected.  
7. Install the battery in the machine.  
Check Fluid Levels  
If electrolyte is swallowed, get medical  
attention immediately.  
IMPORTANT: Avoid damage! Check all fluid levels  
before attempting to start the machine. Machine  
should be parked on a hard, level surface with the  
key switch in the STOP position.  
If electrolyte is splashed into eyes, flush  
immediately with water for 15-30 minutes and  
get medical attention.  
If electrolyte is splashed onto skin, flush  
immediately with water and get medical  
attention if necessary.  
Check Engine Oil Level  
Oil level should be between the ADD and FULL marks on  
the dipstick. Add oil as necessary.  
1. Park the vehicle safely. (See Parking Safely in the  
Safety section.)  
Check Transmission Oil Level  
2. Remove battery from machine and set it on a level  
surface.  
Hydraulic oil level should be to the top of the FULL COLD  
mark on the reservoir dipstick. Add oil as necessary.  
3. Remove battery cell caps. Make sure cap vents are not  
plugged.  
If your mower has no dipstick, make sure that oil is 76 mm  
(3 in.) from the top of the filler pipe.  
Lubricate Machine  
Lubricate all moving parts before operating the machine,  
see Lubrication Points in Service Lubrication section.  
C
Check Safety System  
A
B
For a complete checkout procedure of the safety interlock  
system, see Testing the Safety Interlock System in the  
Operating section.  
MIF  
4. Fill the battery:  
Only use battery acid with a 1.265 specific gravity.  
Slowly add acid (A) to each cell. The solution should  
Assembly - 32  
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ASSEMBLY  
Check Tire Pressure  
c
CAUTION: Avoid injury! Engine exhaust fumes  
contain carbon monoxide and can cause  
serious illness or death.  
c
CAUTION: Avoid injury! Explosive separation  
of tire and rim parts is possible when they are  
serviced incorrectly:  
Move the vehicle to an outside area before  
running the engine.  
Do not inflate the tires above the  
recommended pressure.  
Do not run an engine in an enclosed area  
without adequate ventilation.  
Do not stand in front or over the tire  
assembly when inflating. Use a clip-on chuck  
and extension hose long enough to allow you  
to stand to one side.  
Connect a pipe extension to the engine  
exhaust pipe to direct the exhaust fumes out of  
the area.  
Allow fresh outside air into the work area to  
clear the exhaust fumes out.  
1. Check tires for damage.  
2. Check tire pressure with an accurate gauge.  
3. Start and run the engine until it reaches normal  
operating temperature.  
3. Check that tires have equal pressure; add or remove air,  
if necessary.  
4. Move control levers to the forward position and observe  
drive wheel rotation; the drive wheels should rotate in the  
correct direction.  
Tire Size  
Pressure  
Front: 13 x 5.0 - 6  
Rear: 23 x 9.5- 12  
110-139 kPa (16-20 psi)  
69-83 kPa (10-12 psi)  
5. Move the control levers to the reverse position and  
observe drive wheel rotation; the drive wheels should  
rotate in the correct direction.  
NOTE: Neutral position and transmission linkage  
adjustments will needed to be recheck after several  
hours of operation.  
Level Mower Deck  
Before operating the machine, level the mower deck.  
6. Release control levers; the levers should return to the  
neutral position and wheel rotation should stop. If the  
wheels do not stop, adjust the neutral adjustment knob on  
each side of the seat.  
Initial Adjustments  
7. Move PTO/clutch switch to on position; mower clutch  
should engage. Run blades for several minutes.  
c
CAUTION: Avoid injury! Clear area of  
bystanders before performing this service  
procedure.  
8. Move PTO/clutch switch to off position and shut the  
engine off.  
1. Check free-wheeling valves on both pump assemblies  
to make sure that the valves are closed.  
9. Check all belts for proper tension.  
10.Start the engine and test drive the machine in an open  
area. Drive the machine forward; if the machine drifts to the  
right or left, adjust the transmission control linkage.  
2. Raise the rear of the machine until the drive wheels are  
off the ground. Support the machine with jackstands.  
PTO Clutch Run-in Procedure  
1. Start and run the engine at half throttle.  
2. Engage and disengage the PTO clutch five times (ten  
seconds on, ten seconds off).  
3. Move throttle lever to 3/4 throttle.  
4. Engage and disengage the PTO clutch five times (ten  
seconds on, ten seconds off).  
Assembly - 33  
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SPECIFICATIONS  
Specifications  
Dimensions  
Engine  
Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . 1,27 m (50 in.)  
Overall Height . . . . . . . . . . . . . . . . . . . . . . . 1,11 m (44 in.)  
Overall Length (All Models) . . . . . . . . . . . . . 1,98 m (78 in.)  
Overall Width (with 52-Inch Mower Deck) . . 1,57 m (62 in.)  
Overall Width (with 61-Inch Mower Deck) . . 1,80 m (71 in.)  
NOTE: See engine manufacturers owners manual  
provided with your machine for engine specifications.  
Battery  
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt  
CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 amp @ 0°  
Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . .25 minutes  
BCI Group Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U1  
52-Inch Mower Deck  
Mower Type . . . . . . . . . . . . . . . . . . . . . . . . Side Discharge  
Cutting Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3  
Blade Bolt Torque . . . . . . . . . . . . . . . . . . .80 Nm (60 lb-ft)  
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . 1,32 m (52 in.)  
Cutting Height (approximate) . . . 25 to 152 mm (1 to 6-in.)  
Height Adjustment . . . . . . . . . . 13 mm (1/2 in.) increments  
Tires  
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 x 5.0 - 6  
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 x 9.50 - 12  
Inflation Front . . . . . . . . . . . . . . . . 110-139 kPa (16-20 psi)  
Inflation Rear . . . . . . . . . . . . . . . . . . 69-83 kPa (10-12 psi)  
Wheel Nut Torque. . . . . . . . . . . . . . . . . . . 68 Nm (50 lb-ft)  
61-Inch Mower Deck  
Mower Type . . . . . . . . . . . . . . . . . . . . . . . . Side Discharge  
Cutting Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3  
Blade Bolt Torque . . . . . . . . . . . . . . . . . . .80 Nm (60 lb-ft)  
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . 1,55 m (61 in.)  
Cutting Height (approximate) . . . . 25 to 152 mm (1 to 6 in.)  
Height Adjustment . . . . . . . . . . 13 mm (1/2 in.) increments  
Capacities  
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.2 L (8 gal)  
Hydraulic System  
Low-Profile Tank. . . . . . . . . . . . . . . . . . . . . . . 4.3 L (4.5 qt)  
High-Profile Tank . . . . . . . . . . . . . . . . . . . . . . 5.2 L (5.5 qt)  
(Specifications and design subject to change without  
notice.)  
Hydraulic Oil Reservoir  
Low-Profile Tank. . . . . . . . . . . . . . . . . . . . . . . . 2.8 L (3 qt)  
High-Profile Tank . . . . . . . . . . . . . . . . . . . . . . . 3.8 L (4 qt)  
Net Weight (With Mower Deck and Without  
Fuel)  
23-hp Kawasaki engine/52 in. deck . . . . . 510 kg (1125 lb)  
25-hp Kohler engine/52 in. deck. . . . . . . . 533 kg (1175 lb)  
23-hp Kawasaki engine/61 in. deck . . . . . 535 kg (1180 lb)  
25-hp Kawasaki engine/61 in. deck . . . . . 535 kg (1180 lb)  
25-hp Kohler engine/61 in. deck. . . . . . . . 535 kg (1181 lb)  
26-hp Kohler engine/61 in. deck. . . . . . . . 544 kg (1200 lb)  
Travel Speeds  
Forward. . . . . . . . . . . . . . . . . . . . . . . 0-16 km/h (0-10 mph)  
Reverse . . . . . . . . . . . . . . . . . . . . . . . . 0-8 km/h (0-5 mph)  
Specifications - 34  
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INDEX  
Index  
A
S
Air Cleaner Elements, Replacing ................................... 13  
Air Cleaner Elements, Servicing ..................................... 13  
Storage, Preparing Fuel and Engine for .........................31  
Storage, Preparing Machine for ......................................31  
Storage, Removing Machine from ..................................31  
B
Battery and Terminals, Cleaning .................................... 24  
Battery, Removing and Installing .................................... 23  
Belt, Replacing Mower Drive (Primary) .......................... 19  
C
T
Transmission Oil Level, Checking ...................................15  
D
E
Engine and Fuel Storage, Preparing .............................. 31  
F
G
L
M
Mower Drive (Primary) Belt, Replacing .......................... 19  
Mower Level (Side-to-Side), Adjusting ........................... 18  
O
Oil Level, Checking Transmission .................................. 15  
P
Index - 35  
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NOTES  
Notes  
Notes  
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SERVICE RECORD GD  
Service Record GD  
Record Service Dates  
Engine Oil and  
Filter Change  
Lubricate  
Machine  
Air Cleaner Element  
Clean/Replace  
Service Record GD - 37  
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