Great Dane GSRKA1934S manual

201018 10/02/2007 Great Dane ® GSRKA1934S[...]

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W ARNING: The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer , birth de- fects or other reproductive harm. California Proposition 65 W arning All information, illustrations and specifications in this manual are based on the latest infor- mation at the time of publication. The right is reserved [...]

SAFETY LABELS SAFETY LABELS - 2 S/N DA TE OF PURCHASE: _________________________________________ DEALER NAME: _________________________________________ DEALER PHONE: _________________________________________ PRODUCT IDENTIFICA TION NUMBER: Model Number _________________________________________ Serial Number _________________________________________[...]

SAFETY LABELS SAFETY LABELS - 3 W ARNING (B) T o avoid injury from rotating belts, keep all shields and guards in place. DANGER (C) T o avoid injury from rotating blades, stay clear of deck edge. DANGER (D) T o avoid injury from rotating blades and thrown objects, stay clear of deck edge and keep others away . Do not mow without discharge chute or [...]

SAFETY SAFETY - 4 CAUTION (H) Be safe! T o avoid a fire hazard remove all leaves, grass and debris from engine, hydro pumps and motors, pulleys, belts, hoses, engine deck and cutter deck. DANGER/POISON (I) • Shield Eyes: Explosive gases can cause blindness or injury . • NO • Sparks • Flames • Smoking • Sulfuric acid can cause blindness[...]

SAFETY SAFETY - 5 the job. Only use accessories and attachments ap- proved by the manufacturer . Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair , loose cloth- ing or jewelry may get tangled in moving parts. Inspect the area where the equipment is to be used and remove all objects such as rocks, toys a[...]

SAFETY SAFETY - 6 Parking Safely Stop machine on a level surface, not on a slope. Disengage mower blades. Lock the park brake. Stop the engine. Remove the key . W ait for engine and all moving parts to stop before you leave the operator ’s station. Close fuel shut-off valve, if your machine is equipped. Disconnect the negative battery cable or re[...]

SAFETY SAFETY - 7 Choose a low ground speed so you will not have to stop or shift while on a slope. Do not mow or operate machine on wet grass. T ires may lose traction. • • • T ires may lose traction on slopes even though the brakes are functioning properly . Avoid starting, stopping or turning on a slope. If the tires lose traction, disenga[...]

SAFETY SAFETY - 8 ommended parts, when necessary . Grass catcher com- ponents are subject to wear , damage, and deterioration which could expose moving parts or allow objects to be thrown. Keep all nuts and bolts tight, especially blade attach- ment bolts, to be sure the equipment is in safe working condition. Check brake operation frequently . Adj[...]

OPERA TING OPERA TING - 9 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. Remove grass and debris from operator stati[...]

OPERA TING OPERA TING - 10 A-Free-Wheeling V alves Mounting and Dismounting Machine Safely A Step on operator ’s platform (A) at the rear of machine to mount the machine. Park machine safely . (See Parking Safely in the SAFETY section.) Step off operator’s platform to dismount machine. Keep operator ’s platform and suspension springs clean an[...]

OPERA TING OPERA TING - 1 1 IMPORT ANT : Do not allow washer (G) to set on caster yoke. It must be on top of height-of-cut spacer bushings (H). NOTE: Adjust caster wheel spacers to keep mower deck tilted slightly down at the front. Adjust caster wheel spacers (F) to compensate front HOC accordingly . Setting Cutting Height NOTE: Before setting cut [...]

OPERA TING OPERA TING - 12        HOLE LOCA TIONS T o adjust the rear height of cut, use the chart above and match the hole locations on the chart up to the hole loca- tions on the picture. T o adjust the front height of cut, use the chart above and in - sert the number of C[...]

OPERA TING OPERA TING - 13 Clear area of bystanders, especially children. Pick up objects which may be thrown by the attachment. Pull PTO switch up to engage. Step completely off operator’s platform. Result: The engine must stop. T esting the Park Brake Stop machine on a 17° slope (30% grade) facing down- hill. Stop the engine and lock the park [...]

OPERA TING OPERA TING - 14 Using the Hourmeter NOTE: The machine is equipped with an electric start. The hourmeter will continue to run with the key switch in the run position. A Hourmeter (A) shows number of hours the machine has been operated. Use hourmeter and SERVICE INTER V AL section to determine when machine needs service. Using the Motion C[...]

OPERA TING OPERA TING - 15 Forward: 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 T urn: • • • Push right motion control lever further forward than the left motion control lever Gentle Right T urn: • Push left motion control lever further[...]

OPERA TING OPERA TING - 16 • Push left motion control lever forward and pull right motion control lever rearward at the same time. 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 enc[...]

OPERA TING OPERA TING - 17 NOTE: In cold weather or with a new machine, allow engine to reach operating temperature before engaging PTO to prevent engine from stalling. Pull PTO knob (B) up to engage mower deck. Move throttle lever to the fast position (C). NOTE: The travel speed and turn rate will vary with the amount that the motion control lever[...]

SER VICE INTERV ALS SERVICE INTER V ALS- 18 • Use a travel speed that fits the conditions: • Mow tall or wet grass twice. Cut grass at half desired height – then cut at desired height. • T ravel slow when mowing tall, thick or wet grass. • Avoid damaging grass by slipping or skidding machine drive wheels. Practice smooth control lever mo[...]

SER VICE ENGINE SERVICE ENGINE- 19 Service Lubrication Grease IMPORT ANT : Avoid Damage! The recommended grease is effective within an average air temperature range of -29 to 135 degrees C (-20 to 275 degrees F). IMPORT ANT : Avoid Damage! Use only NLGI No. 2 lithium based grease. • If operating outside that temperature range, contact your servic[...]

SER VICE ENGINE SERVICE ENGINE- 20 Service Engine A void Fumes CAUTION: A void injury! Engine exhaust fumes contain carbon monoxide and can cause seri- ous illness or death. Move the machine to an outside area before running the engine. Do not run an engine in an enclosed area with- out adequate ventilation. • Connect a pipe extension to the engi[...]

SER VICE ENGINE SERVICE ENGINE- 21 IMPORT ANT : A void Damage! Change the oil more often if the machine is used in extreme conditions: Extremely dusty conditions. Frequent slow or low-speed operation. Frequent short trips. Clean area around dipstick cap and filter . Start engine and run until it reaches normal operating temperature. Park machine s[...]

SER VICE TRANSMISSION SERVICE TRANSMISSION- 22 • Do not wash paper element. • Do not attempt to clean paper element by tapping against another object. • Do not use pressurized air to clean element. • Replace element only if it is very dirty , damaged or the seal is cracked. NOTE: It may be necessary to check the air filter more frequently [...]

SER VICE TRANSMISSION SERVICE TRANSMISSION- 23 Service T ransmission Hydraulic Oil Use only 5W-50 or 15W -50 all synthetic oil. Checking Hydraulic Oil Level IMPORT ANT : A void Damage! Check oil level in reser- voir tank when oil is cold. Do not overfill oil reservoir tank. Oil will expand during oper - ation and could overflow . Park machine saf[...]

SER VICE TRANSMISSION SERVICE TRANSMISSION- 24 IMPORT ANT : A void Damage! Do not add oil beyond FULL mark. Oil capacity after draining may be less than dry fill capacity . Check oil level before filling complete- ly . NOTE: Dry fill capacity for hydraulic system is 3.1L (3.3 qt.) . Fill oil reservoir with approximately 1.9L (2 qt.) of oil. Inse[...]

SER VICE TRANSMISSION SERVICE TRANSMISSION- 25 A B Remove two cap screws (A). Remove rear shield (B). CAUTION: A void injury! T ensioning spring is under high tension. Wear gloves and safety glasses, and use a spring puller to install and remove spring. 4 ⅝” - 5” C D E F G Picture Note: T raction drive belt idler pulley bottom view . Insert 3[...]

SER VICE TRANSMISSION SERVICE TRANSMISSION- 26 A C B Rotate speed control bar (A) to full forward position. With engine off, move motion control levers (B) until they contact the speed control bar (A). A slight deflec- tion should be seen in the linkage rod (C). NOTE: Check machine tracking after making adjust- ments. Start the engine and run unti[...]

SER VICE STEERING AND BRAKES SERVICE STEERING AND BRAKES- 27 Checking T ransmission T racking: Check and adjust motion control linkages. See Check- ing and Adjusting Motion Control Linkages in the SER- VICE TRANSMISSION section. Start engine and run until it reaches normal operating temperature. Move machine to an open, level area for operation. A [...]

SER VICE MOWER SERVICE MOWER - 28 Picture Note: Engine removed for picture clarity . Park machine safely . (See Parking Safely in the SAFETY section.) Loosen nuts (A). Adjust neutral switch (B). If neutral switch sensitivity needs to be increased, adjust switch (B) down in slots. If neutral switch sensitivity needs to be decreased, adjust switch (B[...]

SER VICE MOWER SERVICE MOWER - 29 Lift shield (B) and pull forward to disengage from under tabs (C) on the frame. Remove mower deck shield (B). CAUTION: A void injury! Help prevent serious personal injury . Do not operate the mower with- out the belt shields installed. Adjusting Drive Belt T ension Park machine safely . Adjust mower deck to the 76 [...]

SER VICE MOWER SERVICE MOWER - 30 C A B Connect idler tension spring and adjust tension. The length (C) of the tension spring should measure 17.5 to 18.1 cm (6 7/8 in. to 7 1/8 in.) from inside of hook to inside of hook. Install both mower deck belt shields. Install mower deck shield. Adjust mower deck to desired cutting height. Checking for Bent M[...]

SER VICE ELECTRICAL SERVICE ELECTRICAL - 31 blade (C). Install replacement blade: Blade wing must face toward top of mower deck. IMPORT ANT : A void Damage! When installing the blade: Make sure the blade is properly seated on the spindle. Make sure the concave side of the large washer faces towards the blade. • • Install blade bolt (A), blade ([...]

SER VICE ELECTRICAL SERVICE ELECTRICAL - 32 CAUTION: A void injury! Battery electrolyte contains sulfuric acid. It is poisonous and can cause serious burns: Wear eye protection and gloves. Keep skin protected. If electrolyte is swallowed, get medical attention immediately . If electrolyte is splashed into eyes, flush immediately with water for 15-[...]

SER VICE MISCELLANEOUS SERVICE MISCELLANEOUS - 33 cover (C). Connect negative (-) battery cable (B) and install cover (A). Cleaning Battery and T erminals Park machine safely . (See Parking Safely in the SAFETY section.) Disconnect and remove battery . W ash battery with solution of four tablespoons of bak - ing soda to one gallon of water . Be car[...]

SER VICE MISCELLANEOUS SERVICE MISCELLANEOUS - 34 of fuse holder is securely fastened to fuse socket. Adjusting Operator Presence Switch � Remove the OPC plate covering the operator presence switch by removing the two 3/8-16n1.25 carriage bolts securing it in place. Carefully cut the wire tie securing the harness to the plate. A B C Loosen the tw[...]

SER VICE MISCELLANEOUS SERVICE MISCELLANEOUS - 35 Important: A void damage! Dirt and water in fuel can cause engine damage: Clean dirt and debris from the fuel tank opening. Use clean, fresh, stabilized fuel. Fill the fuel tank at the end of each day’ s operation to keep condensation out of the fuel tank. Use a non-metallic funnel with a plastic [...]

SER VICE MISCELLANEOUS SERVICE MISCELLANEOUS - 36 T ighten wheel nuts in numbered sequence shown for safe wheel installation. T ighten alternately until recom- mended torque value is reached. Checking Tire Pressure 2. CAUTION: A void injury! Explosive separation of tire and rim parts is possible when they are serviced incorrectly: Do not attempt to[...]

TROUBLESHOOTING TROUBLESHOOTING - 37 Remove locknut (A), cap screw (B), and wheel assem- bly (C). Remove seals (D) and bearings (E) from wheel. Clean and inspect bearings (E). Replace as needed. Repack bearings with clean grease. Install bearings (E) and wheel spacer (F) (if removed), and new seals (D). Install wheel assembly (C), cap screw (B) and[...]

ST ORAGE STORAGE - 38 Engine Will Not Start Or Is Hard T o Start • Park brake lever not in the proper position. • OPC switch not depressed. Stand on platform or adjust switch. • Check that motion control levers are in neutral and neutral switches are correctly adjusted. • PTO engaged. • Stale or improper fuel/fuel level. • Plugged fuel [...]

ST ORAGE STORAGE - 39 • Neutral switches faulty or not adjusted properly . See your authorized dealer . • Key switch or starter faulty . See your • authorized dealer . • PTO engaged. • Motion control levers and park brake lever not in proper position. Battery Will Not Charge • Loose or corroded connections. • Blown fuse or fusible lin[...]

ASSEMBL Y ASSEMBL Y - 40 • Remove belt shields and clean debris from sheaves. • Check sheaves for proper alignment or damage. See authorized dealer . Mower Blades Do Not Engage • Deck drive belt slipping or broken. • Deck belt tension spring not installed or broken. • PTO switch faulty . • Fuse blown. • Loose electrical connections. ?[...]

SPECIFICA TIONS SPECIFICA TIONS - 41 NOTE: The stored battery should be recharged every 90 days. Charge the battery . IMPORT ANT : A void Damage! Prolonged exposure to sunlight could damage the hood surface. Store ma- chine inside or use a cover if stored outside. Store the vehicle in a dry , protected place. If vehicle is stored outside, put a wat[...]

GETTING QUALITY SERVICE GETTING QUALITY SER VICE - 42 If oil is level is below ADD mark, fill to proper level. If oil level is above the FULL mark, drain to proper level. Insert dipstick. T ighten cap. Connect Battery CAUTION: Avoid injury! Prevent Battery Explosions: • Keep sparks, lighted matches, and open flame away from the top of battery .[...]

GETTING QUALITY SERVICE GETTING QUALITY SER VICE - 43 Great Dane Quality Continues with Quality Service Great Dane provides a process to handle your questions or problems, should they arise, to ensure that product quality continues with your authorized Great Dane dealer ’s parts and service support. Follow the steps below to get answers to any qu[...]

WIRING DIAGRAM Wiring Diagram - 44 GY R R TN GN Y W Y W LT/GN LT/GN LT/GN LT/GN LT/BU GY GRAY TN TAN PK PINK LT/BU LIGHT BLUE LT/GN LIGHT GREEN GN GREEN BU BLUE V VIOLET Y YELLOW OR ORANGE R RED BN BROWN BK BLACK W WHITE W ENGINE KILL GY LT/GN TN GY PTO SWITCH STARTER SOLINOID BK 87 BU 30 BK/OR Y VOLTAGE REGULATOR 86 85 BK V CLUTCH BN D D RIGHT SAF[...]

HYDRAULIC SCHEMA TIC Hydraulic Schematic - 45[...]

NOTES Notes - 46[...]

MAIN FRAME ASSEMBL Y Frame Assembly - 46 963019 10 964016 6 964003 4 960022 6 960601 6 TCU21265 1 M68342 2 201005 1 960001 2 963001 2 964040 4 201019 1 201355 1 960044 2 967115 10 201150 2 960526 8 Battery 1 964040 4 201012 1 963019 10 D28159 1 03H1832 2 968087 4 967115 10 201356 1 201095 1 201204 1 201094 1 960027 4 960031 4 201202 1 960601 6 9600[...]

MAIN FRAME ASSEMBL Y Frame Assembly - 47 PART NO QTY DESCRIPTION D28159 1 STRIP, BATTERY INSULATOR M68342 2 CLAMP, HOSE (RED) # TCU21265 1 HOSE, 1/4" ID LOW PERM FUEL 50 03H1832 2 BOLT, 5/16-18 X 6.00 CRG 2 Y 135139 4 BOLT, 1/2 X 1.06 X 3/8-16 SLD 5 Y 181148 1 CABLE, BATTERY STARTER - 48" BATTERY 1 BATTERY, 12V-U1-CCA270MIN 200658 1 PIN, [...]

HYDRAULIC AND HANDLE ASSEMBL Y Hydraulc and Handle Assembly - 48 960001 7 960600 6 201358 1 201359 1 200116 4 D13028 2 121080 3 963020 4 200654 1 TCA15195 1 960001 7 968087 6 960702 4 D13309 1 34H60 1 TCA15122 1 964048 3 180640 1 960002 2 201354 1 960000 2 121080 3 201022 1 D18079 1 960001 7 200690 1 200606 1 200671 1 200615 1 201354 1 963053 1 200[...]

HYDRAULIC AND HANDLE ASSEMBL Y Hydraulc and Handle Assembly - 49 P ART NO QTY DESCRIPTION D13028 2 SWIVEL ADJUSTER D13308 1 BASE, LOCK LEVER Y D13309 1 LEVER, LOCK Y D18023 1 DECAL, HYDRO OIL SPECS. D18079 1 GRIP , PVC .250 X 1.00 X 3.63 D18093 2 GRIP , CONTROL D24020 3 SCREW , 8-32X .50 P AN PHL Y D24028 1 FTG, 90 9/16 MOR X 3/8 HOSE GDA10066 1 EL[...]

ENGINE, HYDRAULIC AND MAINFRAME ASSEMBL Y Engine, Hydraulic And Mainframe Assembly - 50 D14252 1 960602 1 D18056 1 200665 1 200318 1 967115 6 960052 1 964001 1 403490 1 150052 1 191179 2 D18071 1 201143 1 191179 2 D18314 1 960049 1 968087 12 968087 12 960702 3 968087 12 963033 2 960502 1 111910 4 200769 1 231104 2 TCA15078 2 231647 2 960046 10 2009[...]

ENGINE, HYDRAULIC AND MAINFRAME ASSEMBL Y Engine, Hydraulic And Mainframe Assembly - 51 P ART NO QTY DESCRIPTION DT5332 1 HOSE, 3/8 SAE30R7 FUEL & OIL D14160 2 W ASHER, .250 WIDE HEA VY FLA T Y D14213 2 BOL T , M6 X 1.00 X 10 HEX 8.8 Y D14252 1 BOL T , 7/16-20X3.00 HEX 5 Y d18038 1 SWITCH (N.0.) D18056 1 SP ACER, .468 X 1.38 X .375 Y D18067 2 K[...]

FOOT PLA TE/CONSOLE COMPONENTS Foot Plate/Console Components - 52 FOOT PLA TE COMPONENTS CONSOLE COMPONENTS 960001 4 200619 1 200767 1 963074 2 201136 1 200655 2 967115 2 960701 2 200693 1 968087 4 963019 4 964048 4 TCU16481 TCU14840 D18021 180620 1 200607 1 136574 1 192296 1 D18427 1 D24020 2 TCA15051 1 M63431 2 200780 1 14H846 1 105684 1[...]

FOOT PLA TE COMPONENTS CONSOLE COMPONENTS FOOT PLA TE/CONSOLE COMPONENTS Foot Plate/Console Components - 53 P ART NO QTY DESCRIPTION 200619 1 PLA TE, PLA TFORM T AB LH 200655 2 BUMPER, MINER GBR-6 200693 1 PLA TE, PLA TFORM T AB 200767 1 ANCHOR, OPC 201 136 1 PLA TFORM 960001 4 BOL T , 1/4-20 X .750 HEX 5 Y 960701 2 W ASHER, .313 REG FLA T Y 963019[...]

DECK ASSEMBL Y Deck Assembly - 54 201174 2 967348 2 GDU10231 1 D18055 6 200262 2 960046 16 964016 17 TCA16387 1 M132768 1 H141123 1 201178 1 968087 4 D18076 2 968087 4 964016 17 D23058 1 D18084 1 D13024 2 960502 12 N242189 1 201145 1 960051 1 D18032 1 964501 1 964022 1 D24019 2 959995 1 424390 1 D18076 2 201357 1 M119352 2 967333 2 999538 .5 TCU187[...]

DECK ASSEMBL Y Deck Assembly - 55 P ART NO QTY DESCRIPTION D13024 2 SP ACER, 1.500X1.000X.510 Y D18032 1 PULLEY , FLA T 5.0X.38 W/BRG D18055 6 W ASHER, BLADE D18076 2 BRG, FLG 1.00X1.25X1.00 D18084 1 PULLEY , SPLINE SPINDLE OFFSET D18209 1 PULLEY , V -BEL T 5.27X.990 W/SPL D24019 2 W ASHER, .402X2.00X.055 FEND Y D23058 1 J-BOL T , 3/8-16 X 4.00 Y G[...]

WHEEL AND STRUT ASSEMBL Y/PUMP COMPONENTS Wheel and Strut Assembly/Pump Components - 56 PUMP COMPONENTS 2 2 1 6 3 4 8 5 7 9 WHEEL AND STRUT ASSEMBL Y 161397 1 D13008 1 D18076 2 201172 1 D18076 2 164145 4 201173 1 963011 1 200778 1 964000 1 191049 1 959995 1[...]

WHEEL AND STRUT ASSEMBL Y PUMP COMPONENTS ITEM P ART NO QTY DESCRIPTION 1 D14196 2 FTG, ADP JIC-ORB 6801-08-08 2 D24028 2 FTG, 90 9/16 MOR X 3/8 HOSE 3 D38157 1 ALIGNABALL, 5/16-24 RH THD 4 TCA14966 1 PUMP , RH HYDRO PG-1GRQ TCA14965 1 PUMP , LH HYDRO PG-1GRQ 5 191256 1 SWITCH, PLUNGER DP - N.O. - N.C. 6 960023 1 BOL T , 5/16-18 X 1.00 HEX 5 Y 7 96[...]

SPINDLE ASSEMBL Y Spindle Assembly - 58 14 7 8 9 2 4 3 1 6 1 1 2 5 12 13 10[...]

SPINDLE ASSEMBL Y Spindle Assembly - 59 ITEM P ART NO QTY DESCRIPTION 1 200262 1 Spindle Assembly - Includes items 2, 3, 4, 5, 6, 14 2 200046 2 Ball Bearing 3 200042 1 Housing 4 200044 1 Spacer - 1.000 x 1.250 x 2.772 5 200261 1 Shaft, Spindle 6 200045 6 Bolt, 3/8-16 x 1.25 Rib 7 967333 2 Nut, Pulley (Special) 8 N/A 2 Pulley , Cutter Housing - See [...]

DECAL LOCA TIONS Decal Locations - 60 18 7 17 8 17 19 2 16 3 6 3 4 1 14 5 1 1 9 10 S/N 12 13 15 3 20[...]

DECAL LOCA TIONS Decal Locations - 61 T o avoid injury from rotating belts, keep all shields and guards in place Para evitar ser lesionado por las correas en movimiento, mantener todos los escudos y protectores en su luga r . ADVERTENCIA WARNING W ARNING Shield Missing. DO NO T Operate. 200037 MA Y BE COVERED BY ONE OR MORE OF THE FOLLOWING P A TEN[...]