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Great Dane GDWG17KAE Operator's Manual

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Gateway
GDWG17KAE, GDWG22KHE
GD10004
B2
OPERATOR'S MANUAL
c WARNING:
The Engine Exhaust
from this product contains chemicals known
to the State of California to cause cancer,
birth defects or other reproductive harm.
California Proposition 65 Warning
OMGD10004 B2
D02-107
North American Version
Litho in U.S.A.

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  • Page 1 Gateway GDWG17KAE, GDWG22KHE GD10004 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 OMGD10004 B2 D02-107 North American Version...
  • Page 2 __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ service of the machine. Record Identification Numbers Gateway GDWG17KAE Serial No. (414000 - 414999) GDWG22KHE Serial No. (416000 - 416999) Introduction...

  • Page 3: Table Of Contents

    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..................................21 Service Miscellaneous................................24 Troubleshooting ..................................26 Storage ....................................29 Assembly ....................................30 Specifications ..................................32 Index .....................................33 Service Record GD ................................34 All information, illustrations and specifications in this manual are based on the latest information at the time of...

  • Page 4: Safety

    • Keep out of the reach of children. • To obtain additional operator manual and safety instructions, contact Great Dane dealer or write Great • Do not tip. Dane Power Equipment, 4700 New Middle Rd., • Keep vent caps tight and level.
  • Page 5 The emissions warranty applies only to those engines service brakes as necessary. marketed by Great Dane that have been certified by the • Stop machine if anyone enters the area. EPA and/or CARB and used in the United States and Canada in off-road mobile equipment.
  • Page 6 SAFETY • If you hit an object, stop and inspect the machine. Make Rotating Blades are Dangerous repairs before you operate. Keep machine and attachments properly maintained and in good working HELP PREVENT SERIOUS OR FATAL ACCIDENTS: order. • Do not leave machine unattended when it is running. •...
  • Page 7 SAFETY • Drive across a hill - not up and down. If necessary, turn making any repairs. slowly and in the downhill direction. Do not shift to neutral • Before servicing machine, carefully release pressure and coast downhill. from components with stored energy such as hydraulic •...
  • Page 8 SAFETY • 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.

  • Page 9: Operating

    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.
  • Page 10 5. Move PTO/clutch switch to off position. machine moves more than 61 cm [24 in.] in one hour, brakes need to be adjusted. See your Great Dane dealer. 6. Move throttle lever to half-speed position and set choke (separate choke control models). Move throttle lever into...
  • Page 11 OPERATING Stopping the Engine on the same side as the direction of the desired turn. To stop the machine: Return both speed control lever to 1. Move the throttle lever to the half-speed position, and let the neutral position. the engine run at low throttle for a few seconds. To drive the machine in reverse: Squeeze both steering 2.
  • Page 12 OPERATING Moving the Machine Manually 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.

  • Page 13: Replacement Parts

    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 14: Service Intervals

    SERVICE INTERVALS Every 160 hours Service Intervals Servicing Your Machine Clean and inspect spark plugs. IMPORTANT: Avoid damage! Operating in extreme Replace engine oil filter. conditions may require more frequent service intervals: Check transmission oil level. • Engine components may become dirty or Lubricate mower deck idler pulleys (three places).

  • Page 15: Service Lubrication

    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 16: Service Engine

    SERVICE ENGINE overfill. Service Engine Avoid Fumes 6. Install and tighten dipstick. CAUTION: Avoid injury! Engine exhaust fumes Changing Engine Oil and Filter contain carbon monoxide and can cause serious illness or death. Move the vehicle to an outside area before running the engine.
  • Page 17 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. CAUTION: Avoid injury! Fuel vapors are explosive and flammable: • Do not attempt to clean paper element by tapping against another object.

  • Page 18: Service Transmission

    SERVICE TRANSMISSION Service Transmission Avoid Fumes IMPORTANT: Avoid damage! Contamination of oil could cause transmission damage or failure. Do not open oil reservoir cap unless absolutely necessary. CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause 1. Park machine safely. (See Parking Safely in the Safety serious illness or death.
  • Page 19 SERVICE TRANSMISSION Removing and Installing Drive Belt 1. Park machine safely. (See Parking Safely in the Safety section.) 2. Remove mower deck belt guards. MX9260 5. If machine does not drive in a straight line, adjust tracking adjustment knob (A) to compensate. NOTE: If further adjustment is required, proceed to Adjusting Transmission Neutral Position, then adjust MX9241...
  • Page 20 SERVICE TRANSMISSION from the system, hoses are disconnected, or the system has been drained, trapped air must be removed from the hydraulic system. 1. Park machine safely. (See Parking Safely in the Safety section.) 2. Check hydraulic oil level. Adjust as necessary. CAUTION: Avoid injury! Machine must be safely supported on jackstands before removing or installing wheels.

  • Page 21: Service Mower

    SERVICE MOWER 5. Release spindle drive belt tension by turning the Service Mower Adjusting Belt Tension tensioner adjuster nut (C). 1. Park machine safely. (See Parking Safely in the Safety 6. Remove spindle drive belt (D). section.) 7. Install the new spindle drive belt (D) and adjust the drive belt tension.
  • Page 22 SERVICE MOWER M61830 • Keep original bevel (A) when grinding. • Blade should have 0.40 mm (1/64 in.) cutting edge (B) or less. MX9231 • Balance blades before installing. 2. Remove nut (A), blade (B), blade washers (C) and bolt (D).
  • Page 23 SERVICE MOWER 11.Install upper pulleys: • Side Spindles: Install pulley (C), spacer (B) and nut (A). Tighten nut to 80 N•m (60 lb-ft). • Center Spindle: Install spindle pulley (F), drive pulley (E) and nut (D). Tighten nut to 80 N•m (60 lb-ft). 12.Install mower blade.

  • Page 24: Service Electrical

    SERVICE ELECTRICAL the isolator pad (G) is between the bottom and sides of the Service Electrical battery tray. WARNING: Battery posts, terminals and related 3. Tighten the cap screws and nuts (E) to secure the accessories contain lead and lead components, chemicals battery in the battery tray.
  • Page 25 SERVICE ELECTRICAL 6. Attach cable clamps to battery posts. 7. Apply petroleum jelly or silicone spray to terminal to prevent corrosion. Replacing Fuses IMPORTANT: Avoid damage! When replacing fuses - use only 20-amp fuses or you may damage the circuit. The machine is equipped with two 20-amp fuses (electric start units) and one 20-amp fuse (manual start units) to protect the electric start and/or charging circuit.
  • Page 26 SERVICE ELECTRICAL Wiring Schematic MX9403A Picture Note: Kawasaki Electric Start MX9404A Picture Note: Kawasaki Manual Start Service Electrical - 23...

  • Page 27: Service Miscellaneous

    SERVICE MISCELLANEOUS Service Miscellaneous Filling Fuel Tank 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. CAUTION: Avoid injury! Fuel vapors are explosive and flammable: •...
  • Page 28 SERVICE MISCELLANEOUS yoke and wheel assembly (C). 4. Remove and discard upper (D) and lower (E) bushings. 5. Install new bushings (D and E). 6. Install caster yoke and wheel assembly (C), spacer bushings (B) and lynch pin (A). 7. Apply grease to lubrication fitting (F). Checking Wheel Bolts Tighten rear wheel nuts in an alternating pattern to 68 N•m (50 lb-ft).

  • Page 29: 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.
  • Page 30 TROUBLESHOOTING Check Battery Will Not Charge Dead cell in the battery. Battery cables and terminals are dirty. Low engine speed or excessive idling. Machine Operation Check Machine Vibrates Too Much Or Rattles Excessively Attachment drive belts worn or damaged. Traction drive belt damaged or worn. Dirt on drive sheaves.
  • Page 31 TROUBLESHOOTING Check 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 Engine rpm too low. Travel speed too fast. Debris wrapped around mower spindles. Uneven Cut Mower deck not leveled properly.

  • Page 32: Storage

    STORAGE circulate through carburetor. Storage Storing Safety Engine: Engine storage procedure should be used when vehicle is CAUTION: Avoid injury! Fuel vapors are not to be used for longer than 60 days. explosive and flammable. Engine exhaust fumes contain carbon monoxide and can cause 1.

  • Page 33: Assembly

    ASSEMBLY Maintenance Free setting, use this setting to charge the Assembly Activate and Charge Battery battery. Failure to charge the battery before use will reduce battery performance and life. CAUTION: Avoid injury! Battery electrolyte 7. Install the battery in the machine. contains sulfuric acid.
  • Page 34 ASSEMBLY Initial Adjustments CAUTION: Avoid injury! Clear area of bystanders before performing this service procedure. 1. Raise the rear of the machine until the drive wheels are off the ground. Support the machine with jackstands. 2. Start and run the engine until it reaches normal operating temperature.

  • Page 35: Specifications

    SPECIFICATIONS (Specifications and design subject to change without Specifications Engine notice.) NOTE: See engine manufacturer’s owner’s manual provided with your machine for engine specifications. Battery Voltage ........12 volt CCA .

  • Page 36: Index

    INDEX Index Safety Systems, Testing ...........6 Safety, Tire ................5 Air Cleaner Elements, Replacing ........13 Service Interval Chart .............11 Air Cleaner Elements, Servicing ........13 Service Record ...............34 Spark Plug, Checking .............14 Specifications ..............32 Battery and Terminals, Cleaning ........22 Storage, Preparing Fuel and Engine for ......29 Battery, Removing and Installing ........
  • Page 37 NOTES Notes Notes...
  • Page 38 NOTES Notes Notes...
  • Page 39 NOTES Notes Notes...

  • Page 40: Service Record Gd

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

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Gdwg22khe

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