Great Dane Surfer GSRKA1952S Operator's Manual
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Great Dane Surfer GSRKA1952S Operator's Manual

Great dane surfer operator's manual
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®
Great Dane Surfer
®
GSRKA1952S
GSRKW2352S
OPERATOR'S MANUAL
200772 REV. 12/18/2006
North American Version

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Summary of Contents for Great Dane Great Dane Surfer GSRKA1952S

  • Page 1 ® Great Dane Surfer ® GSRKA1952S GSRKW2352S OPERATOR’S MANUAL 200772 REV. 12/18/2006 North American Version...
  • Page 3 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.

  • Page 4: Safety Labels

    DATE OF PURCHASE: _________________________________________ DEALER NAME: _________________________________________ DEALER PHONE: _________________________________________ PRODUCT IDENTIFICATION NUMBER: Model Number _________________________________________ Serial Number _________________________________________ ENGINE MODEL, SPECIFICATION, AND SERIAL NUMBER: Model Number _________________________________________ Specification _________________________________________ Serial Number _________________________________________ Safety Labels 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.
  • Page 5 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.
  • Page 6 • Only operate in good light, keeping away from holes and hidden hazards. • Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator’s position. Use seat belts if provided. •...
  • Page 7 • Do not mow in reverse. • Shut off blades when you are not mowing. • • Park machine safely before leaving the operator station for any reason including emptying the catchers or unplugging the chute. Protect Children • Death or serious injury can occur when young children associate having fun with a lawn mowing machine simply because someone has given them a ride on a machine.
  • Page 8 • Wear a suitable protective device such as earplugs. Loud noise can cause impairment or loss of hearing. Maintenance and Storage • Never operate machine in a closed area where dangerous carbon monoxide fumes can collect. • Disengage drives, lower implement, lock parking brake, stop engine and remove key or disconnect spark plug (for gas engines).
  • Page 9 plastic liner. Always place containers on the ground away from your vehicle before fueling. • Remove fuel-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.
  • Page 10 Mounting and Dismounting Machine Safely 1. Step on operator’s platform (A) at the rear of machine to mount the machine. 2. Park machine safely. (See Parking Safely in the SAFETY section.) 3. Step off operator’s platform to dismount machine. 4. Keep operator’s platform and suspension springs clean and free of debris.
  • Page 11 Rear of Deck Rear Deck Nominal Height Hole Position HOLE LOCATIONS To adjust the rear height of cut, use the chart above and match the hole locations on the chart up to the hole locations on the picture. To adjust the front height of cut, use the chart above and insert the number of C-spacers to correspond to the number on the chart to achieve the height of cut you desire.
  • Page 12 4. Turn key switch to the start position. Result: The engine must not crank. Testing Neutral Switch (Run) 1. Lock park brake. 2. Push PTO switch down to disengage. 3. Start engine. 4. Push one motion control lever forward. 5. Repeat procedure using the other lever. 6.
  • Page 13 Using the Throttle • Push throttle lever (A) forward to the fast position (B) when mowing. • Move throttle lever (A) to the half fast position (C) when starting and warming the engine. • Pull throttle lever (A) backward to the slow position (D) to idle engine. Do not run engine at slow idle any longer than necessary for cooldown after mowing.
  • Page 14 • Push both motion control levers forward at the same time. Reverse: • Pull both motion control levers past center rearward at the same time. Gentle Left Turn: • Push right motion control lever further forward than the left motion control lever.
  • Page 15 Starting Engine 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.
  • Page 16 IMPORTANT: Avoid Damage! Transmission damage may occur if the machine is towed or moved incorrectly: • Move machine by hand only. • Do not use another vehicle to move machine. • Do not tow machine. NOTE: The pump free-wheel valves must be turned fully clockwise (closed) during normal machine operation.

  • Page 17: 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 may lose efficiency if vehicle is operated constantly at slow or low engine speeds or with frequent short trips.

  • Page 18: Service Engine

    • Lubricate one pump idler pivot grease fitting (A). Lubricating Mower Deck Spindles • Lubricate three mower deck spindle grease fittings (A). Lubricating Mower Deck Idler Pivot • Lubricate one deck idler pivot grease fitting (A). Service Engine Avoid Fumes CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.
  • Page 19 CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Be cautious and wear protective clothing when servicing or working near a hot engine and components. IMPORTANT: Avoid Damage! Change the oil more often if the machine is used in extreme conditions: Extremely dusty conditions.

  • Page 20: Service Transmission

    Checking Spark Plug 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. Check spark plugs at the intervals recommended in the Service Intervals section.
  • Page 21 3. Remove dipstick cap (A). Wipe dipstick clean. NOTE: NOTE: Do not tighten dipstick cap when checking oil level. 4. Insert dipstick into reservoir filler neck (B). Do not tighten cap. 5. Remove dipstick. Check oil level on dipstick. Oil level should be in crosshatch area between ADD and FULL marks.
  • Page 22 Checking and Replacing Pump Traction Drive Belt CAUTION: Avoid injury! Fingers or loose clothing can get caught in rotating parts. Stop engine and wait for all moving parts to stop before servicing. NOTE: The traction drive belt will not require a tension adjustment. Belt is self-adjusted using a spring tensioner.
  • Page 23 1. Install traction drive belt (E) on drive sheaves (G) as shown. Ensure that traction drive belt is positioned in front of anchor cap screw (F). 2. Insert 1/2 in. breaker bar into hole (C) and rotate idler pulley (D) forward for additional clearance to install traction drive belt.
  • Page 24 Checking and Adjusting Transmission Tracking 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.

  • Page 25: Service Steering & Brakes

    Service Steering & Brakes Adjusting Park Brake Testing Park Brake: 1. Inflate tires to correct pressures. 2. Stop machine on a maximum 17° slope. 3. Lock park brake. • A properly adjusted park brake must prevent the drive wheels from turning.

  • Page 26: Service Mower

    Replacing Mower Deck Drive Belt Removing Mower Deck Drive Belt: 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Lower mower deck to the lowest cutting height position. 3. Remove mower deck shield. 4. Remove both mower deck belt shields. CAUTION: Avoid injury! Tensioning spring is under high tension.
  • Page 27 Disconnect battery or remove spark plug wire before making repairs. 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).

  • Page 28: Service Electrical

    • Balance blades before installing. Balancing Blades CAUTION: Avoid injury! Mower blades are sharp. Always wear gloves when handling mower blades or working near blades. 1. Clean blade. 2. Put blade on nail in a vise. Turn blade to horizontal position. 3.
  • Page 29 3. Slide back red cover (C) and disconnect positive (+) battery cable (D). 4. Loosen nut on front long carriage bolt (E). 5. Remove rear long carriage bolt (F) and nut. 6. Lift and slide battery (G) out from back of battery tray (H). 7.

  • Page 30: Service Miscellaneous

    • Check metal clip in fuse window. Discard fuse if clip is broken. • Install new 20 Amp fuse in socket. • Install socket with fuse in cover. Ensure that plastic tab of fuse holder is securely fastened to fuse socket. Adjusting Operator Presence Switch 1.
  • Page 31 2. Lift machine with a safe lifting device centered under tire support frame (A) on the side where tire is being removed. 3. Remove wheel nuts (B). 4. Remove wheel. Installing: 1. Install wheel with valve stem (C) facing out. 2.

  • Page 32: Troubleshooting

    CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when they are serviced incorrectly: Do not attempt to mount a tire without the proper equipment and experience to perform the job. Do not inflate the tires above the recommended pressure. Do not weld or heat a wheel and tire assembly.
  • Page 33 Engine Check Poor Engine Performance Fuel: • Dirt in fuel system or fuel is old. Replace fuel with fresh stabilized fuel. Obtain fuel from another supplier before suspecting machine problems. Suppliers blend fuels differently and changing suppliers will generally solve any performance problems.
  • Page 34 Check Starter Will Not Work • Blown fuse. • OPC Switch faulty or not adjusted properly. • Park brake switch is faulty. • Loose or corroded battery connections. • Neutral switches faulty or not adjusted properly. See your authorized dealer. •...
  • Page 35 Mower Deck Check Discharge Chute Plugged • Grass is wet-mow grass only when dry. • Raise cutting height. • Mow with engine at full fast throttle. • Ground speed too fast for conditions. • Correct installation of deck drive belt. Mower Deck Vibrates •...
  • Page 36 1. Change engine oil and filter while engine is warm. 2. Service air filter if necessary. 3. Clean debris from engine air intake screen. 4. On gas engines: • Remove spark plugs. Put 30 mL (1 oz) of clean engine oil in cylinders. •...

  • Page 37: Specifications

    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.
  • Page 38 Great Dane dealer’s parts and service support. Follow the steps below to get answers to any questions you may have about your product. Refer to your attachment and machine operator manuals. Contact your authorized Great Dane dealer with unanswered questions. Part Numbers Item Mower Blades:...
  • Page 39 SERVICE MISCELLANEOUS Wiring Schematics Service Miscellaneous Service Miscellaneous - 37...
  • Page 40 Service Miscellaneous Left Hydrostatic Pump Assembly Pump Block Charge Pump System Charge Check Shock Valve (Reverse) Manual Bypass Left Wheel Motor Cooling Orifice System Charge Check Shock Valve (Forward) SERVICE MISCELLANEOUS Hydraulic Schematics Charge Relief Valve Right Hydrostatic Pump Assembly Right Wheel Motor Inlet Filter Hydraulic Reservoir...
  • Page 41 SERVICE MISCELLANEOUS Service Miscellaneous - 39...

  • Page 42: Main Frame Assembly

    MAIN FRAME ASSEMBLY Frame Assembly - 40...
  • Page 43 MAIN FRAME ASSEMBLY ITEM PART NO D24020 M63431 JD26 102770 200601 200672 200741 200658 200775 200737 200739 251907 960032 960044 960113 963019 964003 964016 967115 967192 D13029 Frame Assembly - 41 DESCRIPTION SCREW, 8-32X .50 PAN PHL Y NUT, 8-32 ELASTIC STOP NUT, 1/2-20 LUG Y RELAY, ISO MINI ELEC.
  • Page 44 FUEL, HYDRAULIC AND HANDLE ASSEMBLY Fuel, Hydraulc and Handle Assembly - 42...
  • Page 45 FUEL, HYDRAULIC AND HANDLE ASSEMBLY ITEM PART NO D13028 D13308 D13309 D18093 D24028 TCA15373 GDA10066 gda10137 M68342 tca15021 TCA15122 TCA15195 TCU21265 34H60 19M7865 111886 121080 200116 200603 200654 200762 313270 960001 960046 960500 960702 963019 963020 964048 968087 200763 Fuel, Hydraulc and Handle Assembly - 43 DESCRIPTION SWIVEL ADJUSTER BASE, LOCK LEVER Y...
  • Page 46 ENGINE, HYDRAULIC AND MAINFRAME ASSEMBLY 23 H.P. Engine, Hydraulic And Mainframe Assembly - 44 19 H.P.
  • Page 47 ENGINE, HYDRAULIC AND MAINFRAME ASSEMBLY ITEM PART NO D18379 D18394 M86863 TCA15874 TCA15078 TCA16240 11H237 200612 200616 231104 231046 231647 24M7158 960025 960026 960044 960046 963053 967034 967115 967155 968087 TCU19166 200709 191125 191365 181073 191601 200785 Engine, Hydraulic And Mainframe Assembly - 45 DESCRIPTION CLAMP, HOSE - 1/2"...
  • Page 48 CLUTCH, PUMP COMPONENTS AND FOOT PLATE ASSEMBLY Clutch, Pump Components and Foot Plate Assembly - 46...
  • Page 49 CLUTCH, PUMP COMPONENTS AND FOOT PLATE ASSEMBLY ITEM PART NO D14160 D14213 D14252 D18038 D18056 D18067 D18071 D18145 D18314 D38128 GDA10004 GDA10005 GDU10025 TCA15316 111910 150052 191179 200318 200665 200666 200769 200770 403490 959995 960022 960046 960052 960055 960078 960602 960702 963020 963033...

  • Page 50: Hydraulic Components

    HYDRAULIC COMPONENTS Hydraulic Components - 48...
  • Page 51 HYDRAULIC COMPONENTS ITEM PART NO. TCA15122 TCA15373 D18379 TCA15078 D14196 R26375 231647 231104 231046 GDA10137 GDA10066 313270 14M7517 19M7784 M86863 D24028 D18394 TY22552 GDA10065 — M78480 Hydraulic Components - 49 DESCRIPTION HYDRAULIC RESERVOIR W/DECALS HOSE CLAMP WHEEL MOTOR ELBOW FITTING, PUMP END O-RING 90°...

  • Page 52: Fuel Components

    FUELCOMPONENTS/WIRING HARNESS FUEL COMPONENTS WIRING HARNESS 200704 Wiring Harness Fuel Components - 50...
  • Page 53 FUEL COMPONENTS/WIRING HARNESS FUEL COMPONENTS ITEM WIRING HARNESS ITEM PART NO. DESCRIPTION TCA15021 FUEL TANK 181251 CAP, FUEL D18144 GROMMET TCA15048 FUEL PICKUP M68342 CLAMP M88753 HOSE, FUEL, 10 FT. 1/4 IN. SAE 30-R7 14M7400 AM116304 FILTER 03M7191 CAP SCREW 19M7865 CAP SCREW 200603...
  • Page 54 CONSOLE AND BATTERY ASSEMBLY Console and Battery Assembly - 52...
  • Page 55 CONSOLE AND BATTERY ASSEMBLY iTEM PART NO D18079 D28159 TCU16323 03H1832 111886 121080 180640 180842 181148 191832 200606 200787 200614 200615 200671 200690 200692 200705 181148 963020 960000 960001 960047 960600 963001 964040 964048 967115 967185 968087 200745 Console and Battery Assembly - 53 DESCRIPTION GRIP, PVC .250 X 1.00 X 3.63 STRIP, BATTERY INSULATOR...

  • Page 56: Console Components

    FOOT PLATE/CONSOLE COMPONENTS FOOT PLATE COMPONENTS CONSOLE COMPONENTS Foot Plate/Console Components - 54...
  • Page 57 FOOT PLATE/CONSOLE COMPONENTS FOOT PLATE COMPONENTS ITEM CONSOLE COMPONENTS ITEM PART NO D18021 D18427 D24020 M63431 TCA15051 TCU14840 TCU16481 136574 14H846 180620 192296 200743 PART NO DESCRIPTION 200618 PLATE, PLATFORM 200619 PLATE, PLATFORM TAB LH 200655 BUMPER, MINER GBR-6 200691 WEDGE, PLATFORM 200693 PLATE, PLATFORM TAB RH...

  • Page 58: Deck Assembly

    DECK ASSEMBLY 46 42 35 Deck Assembly - 56...
  • Page 59 DECK ASSEMBLY ITEM PART NO D13024 D13055 D18032 D18055 D18084 D23058 D24019 D28050 GDA10103 GDU10231 GDU10268 H122207 H141123 M119352 M132768 M137637 M131739 N242189 TCA15346 TCA16387 TCU14540 TCU18344 TCU18742 TCU18744 TCU18848 TCU18852 TCU51051 03H1658 03H1729 03H1809 03H1836 160169 200041 999538 200747 200749 200155 959995...

  • Page 60: Pump Components

    WHEEL AND STRUT ASSEMBLY/PUMP COMPONENTS WHEEL AND STRUT ASSEMBLY PUMP COMPONENTS Wheel and Strut Assembly/Pump Components - 58...
  • Page 61 WHEEL AND STRUT ASSEMBLY/PUMP COMPONENTS WHEEL AND STRUT ASSEMBLY ITEM PUMP COMPONENTS ITEM PART NO DESCRIPTION D13008 BUSHING, 1.03 X 1.50 X .179 Y D18076 BRG, FLG 1.00X1.25X1.00 161397 PIN, LNC .438 X 2.00 Y 164145 C-SPACER, 1.00 X 1.77 X .500 191049 TUBE, RD 1.00X.500X4.76 200729...

  • Page 62: Spindle Assembly

    SPINDLE ASSEMBLY Spindle Assembly - 60...
  • Page 63 SPINDLE ASSEMBLY ITEM PART NO 200262 200046 200042 200044 200262 200045 D13055 D13024 967347 960502 D18055 GDU10231 200047 Spindle Assembly - 61 DESCRIPTION Spindle Assembly - Includes items 2, 3, 4, 5, 6, 14 Ball Bearing Housing Spacer - 1.000 x 1.250 x 2.772 Shaft, Spindle Bolt, 3/8-16 x 1.25 Rib Nut, Pulley (Special)

  • Page 64: Decal Locations

    DECAL LOCATIONS Decal Locations - 62...
  • Page 65 1. D18197 2. D18372 7. M137637 WARNING Shield Missing. DO NOT Operate. 9. 160169 10. TCU16323 14. GDU10257 ���� � ���� �� � � � � ���� ��� ������� ������ ��������� ���� ��������� ������ ��� ������ ������������ 16. TCU16481 DECAL LOCATIONS 4.

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