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 All information, illustrations and specifications in this manual are based on the latest information at the time of publication.
MODEL NUMBER (POWER UNIT) (A): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ SERIAL NUMBER (POWER UNIT) (A): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ENGINE MODEL NUMBER(B): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ENGINE SERIAL NUMBER (B):...
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DANGER Do not mow without discharge chute or entire grass catcher in place. 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.
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WARNING To avoid injury from rotating belts, keep all shields and guards in place. WARNING Hot surface CAUTION • Operator training required SAFETY LABELS • Read operator’s manual • Keep shields in place • Never carry riders • Keep people a safe distance away •...
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NOTE: Tampering with emission controls and components by unauthorized personnel may result in severe fines or penalties. Emission controls and components can only be adjusted by EPA and/or CARB authorized service centers. Contact your Great Dane Equipment Retailer concerning emission controls and component questions.
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• Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the machine while under the influence of alcohol or drugs. • Use care when loading or unloading the machine into or off of a trailer or truck.
Replace only with replacement parts approved by your Great Dane. • Layers of heavy clothing can interfere with proper positioning of the seat belt and can reduce the effectiveness of the seat belt.
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Keep Riders Off • Only allow the operator on the machine. Keep riders off. • Riders on the machine or attachment may be struck by foreign objects or thrown off the machine causing serious injury. • Riders obstruct the operator’s view resulting in the machine being operated in an unsafe manner.
• Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors. • Park machine on level ground. Never allow untrained personnel to service machine. Understand service procedure before doing work. • Use jack stands or lock service latches to support components when required.
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• Never remove the fuel tank cap or add fuel with the engine running. Allow engine to cool before refueling. • Never add fuel to or drain fuel from the machine indoors. Move machine outdoors and provide adequate ventilation. • Clean up spilled fuel immediately. If fuel is spilled on clothing, change clothing immediately.
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• Be careful not to spill fuel on machine. Fuel may damage surface. Wipe up spilled fuel immediately. • Prolonged exposure to sunlight will damage the hood surface. Operator Station Controls A- Motion Control Levers B- Park Brake Lever C- Seat Adjustment Lever D- Hourmeter E- Ignition Key Switch F - PTO Knob...
Adjusting Seat Front-to-Back Adjustment 1.Park machine safely. (See Parking Safely in the SAFETY section.) 2.Sit on the operator seat. CAUTION: Avoid injury! Never adjust seat while machine is moving. Stop machine before adjusting seat to prevent loss of machine control. 3.To adjust the seat front to back, push and hold the seat adjustment lever (A) away from the seat.
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4.Push ROPS into upright position. 5.Install drilled pin (B) into holes on left and right side of ROPS, and secure in place with spring pins (A). 6.Check the ROPS bolt torque if the ROPS is loose. Lowering ROPS CAUTION: Avoid injury! Use roll-over protection system (ROPS) in lowered position only when low clearance operation is necessary.
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NOTE: The rear anti-scalp wheels are located under the rear of the mower deck. 4.Adjust anti-scalp wheel (A) to one of two positions (B). • Remove screw (C), nut and washer. • Adjust wheel up or down so it is approximately 6-13 mm (1/4-1/2 in.) above mowing surface.
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Testing Seat Switch Procedure 1: 1.Sit on the operator seat with the motion control levers in the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers). 2.Unlock the park brake. 3.Push PTO knob down to disengage. 4.Turn key switch to the start position.
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Using the Key Switch NOTE: Machine will only start if the following conditions exist: • Park brake is locked. • PTO is disengaged. • Motion control levers are in the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers). STOP •...
Using the Choke Engage Choke: • Pull choke knob (A) out. Disengage Choke: • Push choke knob (A) in. Using the Motion Control Levers CAUTION: Avoid injury! Learn use of the motion control levers and practice at half throttle until becoming proficient and comfortable with the operation of the machine.
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Forward and Reverse Motion: CAUTION: Avoid injury! Children or bystanders can be injured or killed by moving machine and rotating blades. Before traveling forward or rearward:• •Carefully check area around machine. •Disengage mower before backing up. 1.Move throttle lever to the full-throttle position. 2.Unlock the park brake.
Sharp Left Turn: • Push right control lever forward and pull left control lever rearward at the same time. Sharp Right Turn: • Push left control lever forward and pull right control lever rearward at the same time. Starting the Engine CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.
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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. IMPORTANT: Avoid damage! To help prevent damage to PTO clutch: •...
• Mow tall or wet grass twice. Cut grass at half desired height – then cut at desired height. • Travel slow when mowing tall, thick or wet grass. • Avoid damaging grass by slipping or skidding machine drive wheels. Practice smooth control lever movements.
Service Lubrication Grease IMPORTANT: Avoid damage! The recommended grease is effective within an average air temperature range of -29 to 135 degrees C (-20 to 275 degrees F). 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.
6.Grease traction drive belt tension arm pivot (G). 7.Grease mower deck drive belt tension arm (H). NOTE: Use spray lubricant to lubricate the following items: 8.Lubricate mower deck idler pulleys (K-M). SERVICE ENGINE 9.Lubricate hydraulic pump control arms (N). 10.Lubricate control lever pivot shaft (O). 11.Lubricate seat platform hinges (P).
Checking Engine Oil Level CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components. IMPORTANT: Avoid damage! Failure to check the oil level regularly could lead to serious engine problems if oil level is low: •...
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Cleaning Engine Air Intake Screen and Fan CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.• •Clear work area of bystanders. •Wear eye protection when using compressed air for cleaning purposes. •Reduce compressed air pressure to 210 kPa (30 psi). IMPORTANT: Avoid damage! An obstructed air intake screen can cause engine damage due to overheating.
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.
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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.
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Check Neutral Creep 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.
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NOTE: If the machine travels to the left, adjust the right speed drift screw (A). If the machine travels to the right, adjust the left speed drift screw (B). 3.Adjust the appropriate speed drift screw (A or B) as follows: a.Loosen jam nut (C or D).
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SERVICE TRANSMISSION Hydraulic System Hose Routing A- Hydraulic Reservoir B- Oil Filter C- Right Hydraulic Pump D- Right Wheel Motor E- Left Wheel Motor F - Left Hydraulic Pump Service Transmission - 30...
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 H- Cooling Orifice I - Charge Relief Valve SERVICE STEERING &...
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Removing and Installing Front Caster Wheels Removing 1.Park machine safely. (See Parking Safely in the SAFETY section.) CAUTION: Avoid injury! The machine may fall or slip from an unsafe lifting device or supports, injuring anyone beneath it. • Remove key before raising machine. •...
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1.Park machine safely. (See Parking Safely in the SAFETY section.) 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 holes chosen for mounting...
• To mount in the high position, mount the levers to the top four holes in the mounting bracket. • To mount in the low position, mount the levers to the bottom four holes in the mounting bracket. Checking and Aligning Motion Control Levers - Optional Over the Lap Levers Check Alignment: 1.Park machine safely.
Removing Foot Plate 1.Park machine safely. (See Parking Safely in the SAFETY section.) 2.Raise foot plate (A) using hole (B). 3.Remove and retain hardware (C) securing foot plate (A) on both sides of machine. 4.Remove foot plate. Installing Foot Plate 1.Install foot plate (A) using hardware (C) saved earlier.
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Picture Note: Discharge chute raised for photo clarity. 3.Position right mower blade (A) (discharge side) in the side-to-side position. 4.Measure from outside blade tip to the ground. • The difference between both measurements should be no greater than 3 mm (1/8 in.). 5.If side-to-side level is not within specifications, an adjustment is necessary.
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Checking and Adjusting Cutting Height CAUTION: Avoid injury! Rotating blades are dangerous. Before adjusting or servicing mower: •Remove ignition key or disconnect battery negative (-) cable to prevent engine from starting accidently. •Always wear gloves when handling mower blades or working near blades.
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4.Loosen jam nut (A). 5.Check the mower deck drive belt (B) 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.
IMPORTANT: Avoid damage! When replacing mower blades, always use genuine Great Dane Service Parts. NOTE: Only replace blades. Never straighten or weld them. Checking Mower Blades 1.Park machine safely. (See Parking Safely in the Safety Section). 2.Raise the mower deck to the transport position (also the 12.7 cm [5 in.] cutting height position).
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.Clean entire assembly. 7.Install a new lower bearing (F) and spacer (G) on the spindle shaft (E). IMPORTANT: Avoid damage! The clearance between the lower bearing and the housing is only 0.05 mm (0.002 in.).
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Installing: 1.Install battery (H) using J-bolts (G), bracket (F), washers and nuts (E). 2.Connect the positive battery cable (D) first, then the negative cable (B). 3.Apply petroleum jelly or silicone spray to the terminals to prevent corrosion. 4.Slide covers (A and C) over battery terminals. Cleaning Battery and Terminals 1.Park machine safely.
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SERVICE ELECTRICAL Wiring Schematic Service Electrical - 42...
Service Miscellaneous Using Proper Fuel Use regular grade unleaded fuel with an octane rating of 87 octane or higher. Fuel blends containing up to 10% ethanol or up to 15% MTBE reformulated fuel are acceptable. Do not use fuel or additives containing methanol as engine damage can occur.
2.Slightly loosen five wheel nuts (A). CAUTION: Avoid injury! The machine can fall or slip from an unsafe lifting device or supports. •Use a safe lifting device rated for the load to be lifted. •Lower machine onto jack stands or other stable supports and block wheels before servicing.
Loose or corroded battery or ground connections. 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.
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Traction drive belt slipping. Hydraulic pump free-wheel valves open. Traction drive belt damaged or worn. Hydrostatic pump and/or wheel motor problems. See your Great Dane servicing dealer. Machine Creeps With Engine Needs shift control linkage adjustment. Running and Motion Control...
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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. •Do not store vehicle with fuel in the tank inside a building where fumes may reach an open flame or spark.
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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. •...
CAUTION: Avoid injury! Machine component is heavy. Use a safe lifting device or get an assistant to help lift and hold component into place for installation. NOTE: Using a tapered drift will aid in the alignment of mounting holes and ease installation of cap screws. 5.Lay ROPS on the ground, slide it up to the bumper and align the appropriate hole in the ROPS flange with the lower rear mounting holes in the machine frame and bumper.
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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 serial number and engine serial number. These are the numbers that you recorded in the Product Identification section of this manual.
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GETTING QUALITY SERVICE Getting Quality Service - 51...
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ENGINE AND RELATED COMPONENTS - B&S 23 HP VANGUARD ENGINE AND RELATED COMPONENTS - B&S 23 HP VANGUARD - 52...
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LABELS - 85 Remarks HYDRO OIL SPECS. THROTTLE CONSOLE NO STEP CHARIOT WARNING SLOPE PUPPY PAW GREAT DANE BLACK GREAT DANE WHITE MOTION CONTROL OTL KIT MOTION CONTROL CONSOLE BELT PATH 48", 52", 61" DECK ROPS CERTIFICTATION DANGER, ROTATING BELTS...