Great Dane Chariot / Chariot LX GDRZ48-17KAE Operator's Manual

Great Dane Chariot / Chariot LX GDRZ48-17KAE Operator's Manual

Chariot chariot / chariot lx operator's manual
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Chariot / Chariot LX
GDRZ48-17KAE, GDRZ48-19KAE, GDRZ52-23KAE, GDRZ52-25KAE, GDRZ52-25KHE,
GDRZ61-25KAE, GDRZ61-25KHE, GDRZ61-25KAE, GDRZ61-25KHE, GDRZ61-26KHE,
GDRZ61-27KHE, GDRZ61-28KHE, GDRZ72-27KHE, GDRZ72-28KHE
TCU17095
H2
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
OMTCU17095 J2
North American Version
Litho in U.S.A.

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Summary of Contents for Great Dane Chariot / Chariot LX GDRZ48-17KAE

  • Page 1 Chariot / Chariot LX GDRZ48-17KAE, GDRZ48-19KAE, GDRZ52-23KAE, GDRZ52-25KAE, GDRZ52-25KHE, GDRZ61-25KAE, GDRZ61-25KHE, GDRZ61-25KAE, GDRZ61-25KHE, GDRZ61-26KHE, GDRZ61-27KHE, GDRZ61-28KHE, GDRZ72-27KHE, GDRZ72-28KHE TCU17095 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.
  • Page 2 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.
  • Page 3: Product Identification

    Product Identification Record Identification Numbers Chariot GDRZ48-17KAE, GDRZ48-19KAE, GDRZ52-23KAE, GDRZ52-25KAE, GDRZ52-25KHE, GDRZ61-25-KAE, GDRZ61-25KHE Serial No. (010001 - ) Chariot LX GDRZ61-25KAE, GDRZ61-25KHE, GDRZ61-26KHE, GDRZ61-27KHE, GDRZ61-28KHE, GDRZ72-27KHE, GDRZ72-28KHE Serial No. (010001 - ) If you need to contact an Authorized Service Center for information on servicing, always provide the product model and serial numbers.
  • Page 4: Table Of Contents

    TABLE OF CONTENTS Table of Contents Safety ...1 Operating ...10 Replacement Parts ...22 Service Intervals...23 Service Lubrication...24 Service Engine ...26 Service Transmission...31 Service Steering & Brakes...37 Service Mower...41 Service Electrical...51 Service Miscellaneous...57 Troubleshooting ...59 Storage ...64 Assembly ...65 Specifications ...68 Index ...70 Service Record GD ...71 All information, illustrations and...
  • Page 5: Safety

    Safety Understanding The Machine Safety Labels 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.
  • Page 6 DANGER To avoid injury from rotating blades and thrown objects, stay clear of deck edge and keep others away. Do not mow without discharge chute or entire grass catcher in place. DANGER: EXPLOSIVE GASES / POISON: CAUSES SEVERE BURNS • Cigarettes, flames or sparks could cause battery to explode.
  • Page 7 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 M117554, MX15274 Canada in off-road mobile equipment.
  • Page 8 Operator Training Required • The owner of the machine is responsible for training the users and mechanics of the machine. • The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people, or property. • Do not allow operation or service of the machine by untrained adults.
  • Page 9 Using a Spark Arrestor The engine in this machine is not equipped with a spark arrestor muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on or near any forest-covered, brush-covered or grass- covered land unless the exhaust system is equipped with a spark arrestor meeting any applicable local or state laws.
  • Page 10 PROTECT CHILDREN: • Never assume that children will remain where you last saw them. Children are attracted to mowing activity, stay alert to the presence of children. • Keep children indoors when you are mowing. Turn the machine off if a child enters the mowing area. •...
  • Page 11 Wear Appropriate Clothing • Always wear safety goggles, or safety glasses with side shields, and a hard hat when operating the machine. • Wear close fitting clothing and safety equipment appropriate for the job. • While mowing, always wear substantial footwear and long trousers.
  • Page 12 • Charge batteries in an open, well-ventilated area, away from sparks. Unplug battery charger before connecting or disconnecting from the battery. Wear protective clothing and use insulated tools. • Do not modify machine or safety devices. Unauthorized modifications may impair its function and safety. Avoid High-Pressure Fluids •...
  • Page 13 • When inflating tires, 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. • Check tires for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
  • Page 14: Operating

    Operating Daily Operating Checklist Make sure all necessary guards and shields are safely and securely attached. Check for loose, missing, or damaged parts. Remove mower deck belt shields. Clean grass and debris from belt area. Remove grass and debris from machine and mower deck.
  • Page 15 The safety systems installed on your machine should be checked before each machine use. Be sure you have read the machine operator manual and are completely familiar with the operation of the machine before performing these safety system checks. Use the following checkout procedures to check for normal operation of machine.
  • Page 16 Mounting and Dismounting Machine Safely Do not step on the mower deck when mounting and dismounting the machine. Mount the machine from the front using the foot plate (A). Park machine safely (see Parking Safely in the Safety section) before dismounting. Keep the foot plate clean.
  • Page 17 2. Move the mower deck lift lever (A) to the transport position (D). 3. Position the HOC adjustment pin (C) in the proper hole for the desired height-of-cut. 4. Pull back and hold the mower deck lift lever (A) and release the transport position lock lever (B).
  • Page 18 • Raise and pull rearward park brake lever (A) to the lock park brake. Unlocking Park Brake: • Lower park brake lever (A) forward to unlock the park brake. OPERATING Using the Key Switch NOTE: Machine will only start if the following conditions exist: •...
  • Page 19 Using the Throttle Lever • Push throttle lever (A) all the way forward to the full- throttle detent position (B) when mowing. • Move throttle lever (A) to the 1/2-throttle position (C) when starting and warming the engine. • Pull throttle lever (A) rearward to the slow position (D) to idle engine.
  • Page 20 Neutral Detent Position - Standard “Center Steer” Levers NOTE: When the control levers are in the neutral detent position, the control lever rollers (A) located on each side of the control console will be seated in the notches in the console. •...
  • Page 21 Forward: • Push both motion control levers forward at the same time. Reverse: • Pull both control levers past center rearward at the same time. Gentle Left Turn: • Push right control lever farther forward than the left control lever. OPERATING Gentle Right Turn: MX13114...
  • Page 22 Starting the Engine 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. •...
  • Page 23 Engaging Mower CAUTION: Avoid injury! Clear mowing area of all bystanders when operating this machine. Thrown objects could cause serious injury or death. Keep hands and feet away from blades and discharge opening. Do not mow in reverse unless absolutely necessary.
  • Page 24 Using Hydraulic Pump Free-Wheel Valves CAUTION: Avoid injury! With the free-wheel valves open, the machine will have unrestricted motion. • The machine may free-wheel out of control if the free-wheel valves are opened with the machine on an incline. • Park the machine on a level surface before opening the free-wheel valves.
  • Page 25 Mowing Travel Speeds Use slow travel speed for: • Trimming. • Working in close quarters. • Mowing tall grass. Use faster travel speeds for: • Normal mowing on level ground. Dismounting to Inspect Mower CAUTION: Avoid injury! Help prevent serious injury.
  • Page 26: Replacement Parts

    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.
  • Page 27: 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, dust or other severe conditions. • Engine oil and spark plugs may lose efficiency if vehicle is operated constantly at slow or low engine speeds or with frequent short trips.
  • Page 28: Service Lubrication

    Service Lubrication Grease IMPORTANT: Avoid damage! If operating outside that temperature range, contact your servicing dealer for a special-use grease. Use a general all-purpose grease with an NLGI grade No. 2 rating. Wet or high-speed conditions may require use of a special- use grease.
  • Page 29 • 48-, 51- and 61-Inch Mower Deck: Grease mower deck drive belt tension arm (H). • 72-Inch Mower Deck: • Grease engine-to-deck drive belt tension arm (I). • Apply spray lubricant to the spindle drive belt tension arm (J). SERVICE LUBRICATION NOTE: Use spray lubricant to lubricate the following items: MX15288...
  • Page 30: Service Engine

    Warranty repairs must be performed by an authorized Great Dane servicing dealer. Avoid Fumes...
  • Page 31 3. Put container under drain tube. 4. Open drain valve (A) using a 10 mm socket, 1 ft extension, swivel and 3/8 in. drive ratchet. 5. Allow oil to drain into an oil drain pan. 6. After oil drains, close drain valve. 7.
  • Page 32 Checking Spark Plug 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. Check spark plugs at the intervals recommended in the Service Intervals section.
  • Page 33 CAUTION: Avoid injury! Fuel system under pressure. Wear personal eye protection when disconnecting fuel hoses to guard against spraying fuel. 4. Disconnect fuel hose (A) from the outlet side of fuel filter (B), and drain gasoline into a properly marked container. 5.
  • Page 34 Keep in mind that EFI-related problems are more often caused by the wiring harness or connections than by the EFI components. Even small amounts of corrosion or oxidation on the terminals can interfere with the milliampere currents used in system operation. Cleaning the connectors and grounds will solve problems in many cases.
  • Page 35: Service Transmission

    Service Transmission Hydraulic Oil Use only 5W-50 or 15W-50 all synthetic oil. Checking Hydraulic Oil Level IMPORTANT: Avoid damage! Check oil level in reservoir tank when oil is cold. Do not overfill oil reservoir tank. Oil will expand during operation and could overflow. 1.
  • Page 36 CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death. Move the machine 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.
  • Page 37 5. Install new drive belt. 6. Install mower deck drive belt as shown. Checking and Adjusting Motion Control Linkages CAUTION: Avoid injury! Do not attempt this adjustment unless you are a qualified and properly trained technician. Check Neutral Creep CAUTION: Avoid injury! Engine exhaust fumes can cause sickness or death: •...
  • Page 38 2. Sit on the seat, and start the engine. 3. Operate machine to bring the hydraulic oil to normal operating temperature. 4. Move the machine in a level, wide-open area, such as an empty parking lot. 5. Run the engine at full throttle. 6.
  • Page 39 SERVICE TRANSMISSION Hydraulic System Hose Routing MX15332 A - Hydraulic Reservoir B - Oil Filter C - Right Hydraulic Pump D - Right Wheel Motor E - Left Wheel Motor F - Left Hydraulic Pump Service Transmission - 35...
  • Page 40 Hydraulic System Schematic A - Control Input Shaft B - Pump Block C - Charge Pump D - Charge System Check Valve E - Right Hydraulic Pump F - Manual Bypass (Free-Wheel) Valve G - Right Wheel Motor SERVICE TRANSMISSION H - Cooling Orifice MX15333 I - Charge Relief Valve...
  • Page 41: Service Steering & Brakes

    Service Steering & Brakes Remove and Install Front Caster Wheels Removing 1. Park machine safely. (See Parking Safely in the Safety section.) 2. Lift front of machine with a safe lifting device. 3. Remove hex nut (A) and wheel bolt (B). 4.
  • Page 42 3. Remove locknut (A), capscrew (B) and wheel assembly (C). 4. Remove spacers (D), seals (E) and bearings and bearing races (F) from wheel. 5. Clean and inspect bearings (F) and pack with clean grease. Replace bearings with races as needed. 6.
  • Page 43 SERVICE STEERING & BRAKES 2. The control lever gap is pre-set at the factory. If the gap requires adjustment, see your authorized Great Dane servicing dealer. Height Adjustment Procedure The position of the control levers can be varied higher or lower by approximately 25 mm (1 in.) depending on the...
  • Page 44 NOTE: If the ends of the levers strike against each other while in the neutral position, move the levers to the neutral lock position and carefully bend them outward. Move them back to the neutral position and check for the recommended gap of 3-6 mm (1/8-1/4 in.). •...
  • Page 45: Service Mower

    Service Mower Removing and Installing Mower Deck Foot Plate CAUTION: Avoid injury! Help prevent serious personal injury. Do not operate the mower without the foot plate installed. Removing Foot Plate 1. Park machine safely. (See Parking Safely in the Safety section.) 2.
  • Page 46 Leveling Mower Deck CAUTION: Avoid injury! Rotating blades are dangerous. Before adjusting or servicing mower: • Disconnect spark plug wire(s) to prevent engine from starting accidently. • Always wear gloves when handling mower blades or working near blades. NOTE: Mower deck anti-scalp wheels should not contact the ground.
  • Page 47 Adjusting Level (Front-to-Rear) IMPORTANT: Avoid damage! Adjust the left and right deck lift assist rods equally. NOTE: Adjust side-to-side mower level before adjusting front-to-rear level. Chariot LX model is equipped with a deck lift assist rod on each side of machine. Adjust both sides of the mower deck equally.
  • Page 48 Adjusting Deck Lift Assist Spring Tension NOTE: Deck lift assist spring tension is adjusted at the factory. If the effort required to raise or lower the mower deck is not satisfactory, an adjustment may be necessary. Check Spring Tension 1. Park machine on a hard, level surface. 2.
  • Page 49 4. Check the engine-to-deck drive belt tension. The belt 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. When properly adjusted, there would be approximately a 2 mm (1/16 in.) gap between the spring coils.
  • Page 50 A - PTO Clutch Sheave B - Mower Deck Drive Belt C - Tension Idler Sheave D - Left Spindle Sheave E - Center Spindle Sheave F - Idler Sheave G - Right Spindle Sheave H - Idler Sheave 6. Install new mower deck drive belt (B) as shown. 7.
  • Page 51 Before performing any service function, wait for all moving parts to stop turning. IMPORTANT: Avoid damage! When replacing mower blades, always use genuine Great Dane Service Parts. NOTE: Only replace blades. Never straighten or weld them. MX15327 Checking Mower Blades 1.
  • Page 52 Replacing Mower Blades 1. Use two long-handled 15/16 in. wrenches to loosen nut (A). 2. Remove nut (A), blade bolt (B), three 1/4 in. washers (C) and blade (D). 3. Install replacement blade: • Blade wing must face toward top of mower deck. IMPORTANT: Avoid damage! When installing the blade: •...
  • Page 53 2. Remove mower blade. (See Checking and Replacing Mower Blades.) 3. Remove nut (A), pulley (B) and spacer (C). 4. Remove retaining ring (D), spindle shaft (E), lower bearing (F) and spacer (G) from spindle housing (H). Discard bearing. 5. Remove and discard upper bearing (I). 6.
  • Page 54 5. Remove retaining ring (I), spindle shaft (J), lower bearing (K) and spacer (L) from spindle housing (M). Discard bearing. 6. Remove and discard upper bearing (N). 7. Clean entire assembly. 8. Install a new lower bearing (K) and spacer (L) on the spindle shaft (J).
  • Page 55: Service Electrical

    Service Electrical 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. Removing and Installing the Battery CAUTION: Avoid injury! The battery produces a flammable and explosive gas.
  • Page 56 Using Booster Battery CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode: • Do not attempt to jump start a frozen battery. Warm to 16 degrees C (60 degrees F). • Do not smoke near battery. •...
  • Page 57 SERVICE ELECTRICAL MX15337 Chariot LX models equipped with Kohler EFI engines have three additional fuses: • One 10-amp fuse (A), used to protect the fuel pump circuit. • One 20-amp fuse (B), used to protect the main power circuit. • One 30-amp fuse (C), used to protect the charge circuit. 1.
  • Page 58 SERVICE ELECTRICAL Wiring Schematic - Carbureted Engines MX15338 Service Electrical - 54...
  • Page 59 SERVICE ELECTRICAL Wiring Schematic - 26 HP Fuel Injected Engine MX15345 Service Electrical - 55...
  • Page 60 SERVICE ELECTRICAL Wiring Schematic - 28 HP Fuel Injected Engine MX15356 Service Electrical - 56...
  • Page 61: Service Miscellaneous

    Service Miscellaneous Filling Fuel Tank Use regular grade 87 octane unleaded fuel. (For gasoline engines only.) CAUTION: Avoid injury! Fuel vapors are explosive and flammable: • Shut engine off before filling fuel tank. • Do not smoke while handling fuel. •...
  • Page 62 Remove and Install Rear Drive Wheels Removing: 1. Park machine safely. (See Parking Safely in the Safety section.) 2. Slightly loosen five wheel nuts (A). 3. Lift machine with a safe lifting device. 4. Remove wheel nuts. 5. Remove wheel and tire assembly (B). Installing Rear Drive Wheels/Tightening Hardware: 1.
  • Page 63: Troubleshooting

    If you are experiencing a problem that is not listed in this chart, see your Great Dane servicing dealer for service. When you have checked all the possible causes listed and you are still experiencing the problem, see your Great Dane servicing dealer. Engine...
  • Page 64 Spark plug not gapped correctly. Replace spark plug. Carbureted Engines Only: Choke adjusted incorrectly. See your Great Dane servicing dealer. EFI system problem - check EFI electrical system and connections. If problem continues, have system serviced by an authorized Kohler EFI servicing dealer.
  • Page 65 Loose or corroded starter cable connections. Neutral start switches faulty or not adjusted properly. See your Great Dane servicing dealer. Key switch or starter faulty. See your Great Dane servicing dealer. PTO engaged. Motion control levers and park brake lever not in proper position.
  • Page 66 Starter Turns Slowly Machine Excessive Machine Vibration Machine Will Not Move With Engine Running Machine Creeps With Engine Running and Motion Control Levers in a Neutral Position Park Brake Park Brake Not Working Correctly Steering Steering Not Working Machine Will Not Follow a Straight Path TROUBLESHOOTING Check Loose or corroded battery or ground connections.
  • Page 67 Machine Moves to the Left or Right With Engine Running and Transmission in Neutral Mower Deck Discharge Chute Plugged Mower Deck Vibrates Mower Blades Do Not Engage Mower Mows Unevenly TROUBLESHOOTING Check Pump linkage (neutral position) out of adjustment. Check Grass is wet - mow grass only when dry.
  • Page 68: Storage

    Storage Storing Safety CAUTION: Avoid injury! Fuel vapors are explosive and flammable. Engine exhaust 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. •...
  • Page 69: Assembly

    Assembly Bag of Parts Qty. Description Operator’s Manual PDR Check List Prepare for Assembly • Remove machine from the shipping crate: • Remove box containing operator seat. • Cut plastic tie straps fastening the front wheels to the shipping crate. •...
  • Page 70 Install Motion Control Levers 1. Remove hardware from control arms. NOTE: The control lever mounting brackets have six holes. The levers can be installed in the top four holes, or for a lower lever position, install the levers in the lower four holes.
  • Page 71 Initial Adjustments CAUTION: Avoid injury! Clear area of bystanders before performing this service procedure. 1. Check free-wheel valves on both pump assemblies to make sure that the valves are closed. Tighten valves to 108-163 N•m (80-120 lb-ft). 2. Raise the rear of the machine until the drive wheels are off the ground.
  • Page 72: Specifications

    Specifications Engine NOTE: See engine manufacturer’s owner’s manual provided with your machine for engine specifications. Battery Voltage ........12 volt CCA .
  • Page 73 SPECIFICATIONS Height Adjustment Increments ..13 mm (1/2 in.) 52-Inch Mower Deck Mower Type ... . .Mulch, Bag or Side Discharge Cutting Blades .
  • Page 74: Index

    Index Air Cleaner Elements, Checking and Cleaning ... 27 Assembly ... 65 Balancing Blades ... 48 Battery, Cleaning ... 51 Battery, Remove and Install ... 51 Battery, Specifications ... 68 Battery, Using Booster ... 52 Belt Shields, Removing and Installing Mower Deck ... 41 Blades, Balance ...
  • Page 75 Mower Deck, Troubleshooting ... 63 Mower, Dismounting to Inspect ... 21 Mower, Engaging ... 19 Mowing Tips ... 20 Mowing Travel Speeds ... 21 Neutral Start Switch, Test ... 11 Oil Level, Checking Engine ... 26 Oil and Filter, Changing Engine ... 26 Oil, Engine ...
  • Page 76: Service Record Gd

    Service Record GD Record Service Dates Engine Oil and Filter Change SERVICE RECORD GD Lubricate Air Cleaner Element Machine Clean/Replace Service Record GD - 72...

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