Great Dane GSRKW2352S manual

® 200772 REV . 12/18/2006 Great Dane Surfer ® GSRKA1952S GSRKW2352S OPERA T OR’S MANUAL North Am erican V ersi on[...]

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All information, illustrations and specificat ions in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT© 2006 Auburn Consolidated Industries, Inc. All right s reserved Previous Editions COPYRIGHT© 2002 W ARNING: The Engine Exhaust from this produ[...]

Safety Labels - 2 SAFETY LABELS DA TE OF PURCHASE: _________________________________________ DEALER NAME: _________________________________________ DEALER PHONE: _________________________________________ PRODUCT IDENTIFICA T ION NUMBER: Model Number _________________________________________ Serial Number _________________________________________ EN[...]

Safety - 3 SAFETY • Read operator ’s manual • Keep shields in place • Never carry riders • Keep people a safe distance away • Maintain all safety devices • Before leaving machine: • S top engine • Set park brake • Remove key CAUTION (I) Be safe! T o avoid a fire hazard re move all leaves, grass and debris from engine, hydro pump[...]

Safety - 4 SAFETY • 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. • Slow down and use extra care on hillsides. Be su re to travel in the recommended d[...]

Safety - 5 SAFETY • Do not mow in reverse. • Shut off blades when you are not mowing. • • Park machine safely before leavin g the operator station for any reason including emptying the catchers or unplugging the chute. Protect Chil dren c • Death or serious injury can occu r when young children associate having fun with a lawn mowing mach[...]

Safety - 6 SAFETY • Wear a suitable protective devic e 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[...]

Operating - 7 OPERATING plastic liner . Always place contai ners on the ground away from your vehicle before fueling. • Remove fuel-powered equipment from t he truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container , rather than fro m a fuel dispenser nozzle. • Keep the nozzle[...]

Operating - 8 OPERATING Mounting and Dismount ing Machine Safely c 1. S tep 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. S tep off operator ’s platform to dismount machine. 4. Keep operator ’s platform and suspension springs clean and free of d[...]

Operating - 9 OPERATING HOLE LOCA TIONS T o adju st 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. T o 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[...]

Operating - 10 OPERATING 4. T urn key switch to the start position. Result: The engine must not crank. T esting Neutral Switch (Run) 1. Lock park brake. 2. Push PT O switch down to disengage. 3. S tart engine. 4. Push one motion control lever forward. 5. Repeat procedure using the other lever . 6. Repeat procedure pushing each mot ion control lever[...]

Operating - 1 1 OPERATING Using the Throttle c MX12847 • Push throttle lever (A) forward to the fast position (B) when mo wing. • 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[...]

Operating - 12 OPERATING c • Push both motion control levers forward at the same time. Reverse: c • Pull both motion control levers past center rearward at the same time. Gentle Left T urn: c • Push right motion control lever further forward than the left motion control lever . Gentle Right T urn: c • Push left motion control lever further [...]

Operating - 13 OPERATING St arting Engine c 1. S tand on operator ’s platform. 2. Lock park brake. c 3. Put motion control levers (A) in the NEUTRAL position. 4. Push PT O switch knob (B) down to disengage PT O. 5. Move throttle lever (C) to set engine speed at the 1/2 to 3/4 fast position. 6. Position choke knob (D): • Cold engine: Pull kn ob [...]

Operating - 14 OPERATING NOTE: The pump free-wheel valves mu st be turned fully clockwise (closed) during normal mach ine operation. When the machine needs to be moved without st arting the engine, use the pump free-wheel valves: 1. Lock park brake. NOTE: The pumps (A) are located in the back of the mach ine, behind the rear shield (B). c 2. T urn [...]

Service Intervals - 15 SERVICE INTERVALS Service Intervals Servicing Y our Machine c Please use the following timetables to perform routine maintenance on your machine. Servicing Engine See engine manufacturer ’s owner’s manual provided with your machine for engine service informatio n. Break-In (After First 10 Hours) • Check air pressure in [...]

Service Engine - 16 SERVICE ENGINE • Lubricate one pump idler pivot grease fitting (A). Lubricating Mower Deck S pindles c • Lubricate three mower deck spindle grease fittings (A). Lubricating Mower Deck Idler Pivot c • Lubricate one deck idler pivot grease fitting (A). Service Engine A void Fumes c Engine Oil Use oil viscosity based on the e[...]

Service Engine - 17 SERVICE ENGINE c 1. Clean area around dipstick cap and filter . 2. S tart engine and run until it reaches normal opera ting temperature. 3. Park machine safely . (See Parking Safely in the SAFETY section.) c 4. Insert drain tube over oil drain fitting (A) 5. Put oil drain pan under drain tube. 6. Loosen drain plug. 7. Allow oil [...]

Service T ransmission - 18 SERVICE T RANSMISSION Checking Sp ark Plug c Check spark plugs at the intervals recommended in the Service Intervals section. See the engine manufactu rer ’ s owner ’s manual provided with your machine for the complete proce dure. Cleaning Engi ne O il Cooler - Kohl er Engines Keep engine oil cooler fins clear of debr[...]

Service T ransmission - 19 SERVICE T RANSMISSION 3. Remove dipstick cap (A). Wipe dipstick clean. NOTE: NOTE: Do not tig hten dipstick cap when ch ecking oil level. 4. Insert dipstick into reservoir fi ller 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 mark[...]

Service T ransmission - 20 SERVICE T RANSMISSION Checking and Re placing Pu mp T raction Drive Belt c NOTE: The traction drive belt will not require a ten sion adjustment. Belt is self-adjusted using a spring ten sioner . Checking T raction Drive Belt: 1. Park machine safely . (See Parking Safely in the SAFETY section.) c 2. Remove two cap screws ([...]

Service T ransmission - 21 SERVICE T RANSMISSION 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. 3. Install rear [...]

Service T ransmission - 22 SERVICE T RANSMISSION Checking and Adjusting T ransmission T racking c NOTE: Check and adjust transmissio n tracking on a hard, level surface. Checking T ransmission Tracking: 1. Check and adjust motion control linkages. See Checking and Adju sting Motion Control Linkages in the SERVICE TRANSMISSION section. 2. S tart eng[...]

Service S teering & Brakes - 23 SERVICE S TEERING & BRAKES Service Steering & Brakes Adjusting Park Brake T esting Park Brake: 1. Inflate tires to correct pressures. c 2. S top machine on a maximum 17° slope. 3. Lock park brake. • A properly adjusted park brake must prevent the drive wheels from turning. • If the drive wheels turn,[...]

Service Mower - 24 SERVICE MOWER Replacing Mower Deck Drive Be lt 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. c c 5. Release mower deck drive belt t ension by turnin[...]

Service Mower - 25 SERVICE MOWER c Picture Note: Mower deck with side discharge used for illustration. 3. Measure distance (A) between blade tip and flat ground surface. 4. Rotate blade 180° and measure distance between other blade tip and flat ground surface. 5. Install new blade if the difference between the two measurements is more than 3 mm (1[...]

Service Electrical - 26 SERVICE ELECTRICAL • Balance blades before installing. Balancing Blades c 1. Clean blade. c c 2. Put blade on nail in a vise. Turn blade to horizontal position. 3. Check balance. If blade is not balanced, heavy end of blade will drop. 4. Grind bevel of heavy end. Do not change blade bevel. Service Electrical WA R N I N G :[...]

Service Electrical - 27 SERVICE ELECTRICAL 3. Slide back red cover (C) and disc onnect positive (+) batte ry cable (D). c 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. Inspect isolator pad (I). Replace as needed. Installing: 1. Place [...]

Service Miscellaneou s - 28 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. Remove the OPC plate covering the ope[...]

Service Miscellaneou s - 29 SERVICE MISCELLANEOUS c 2. Lift machine with a safe lif ti ng device centered under tire support frame (A) on the side where tire is being removed. c 3. Remove wheel nuts (B). 4. Remove wheel. Installing: 1. Install wheel with valve stem (C) facing out. 2. Install and tighten wheel nuts alternately until recommended torq[...]

T roubleshooting - 30 T ROUBLESHOOTING 1.1. Check tires f or damage. 2. Check tire pressure with an accurate gauge. 3. Add air , if necessary: c Servicing Caster Wheel Roller Bearing s 1. Park machine safely . (See Parking Safely in the SAFETY section.) 2. Raise and securely support front of machine. c 3. Remove locknut (A), cap screw (B), and whee[...]

T roubleshooting - 31 T ROUBLESHOOTING Engine Electrical System If 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 pr[...]

T roubleshooting - 32 T ROUBLESHOOTING Machine Park Brake Ste e ri n g If Check S tarter Will Not Work • Blown fuse. • OPC Switch faulty or not adjusted properly . • Park brake switch is faulty . • Loose or corroded battery connections. • Neutral switches f aulty or not adjusted properly . See your a uthorized dealer . • Key switch or s[...]

S torage - 33 ST O R A G E Mower Deck Sto r ag e Storin g Saf ety c Preparing Machine for Storage 1. Repair any worn or damaged parts. Replace parts if necessary . T ighten loose hardware. 2. Repair scratched or chipped metal surfaces to prevent r ust. 3. Remove grass and debris from machin e. 4. Clean under the deck and remove grass a nd debris fr[...]

Assembly - 34 ASSEMBLY 1. Change engine oil and filter while engine is warm. 2. Service air filter if necessary . 3. Clean debris from engine air in take screen. 4. On gas engines: • Remove spark plugs. Put 30 mL (1 oz) of clean engine oil in cylinders. • Install spark plugs, but do not connect spark plug wires. • Crank the engine five or six[...]

S pecifications - 35 S PECIFICATIONS Connect Battery c c 1. Connect positive (red) cable to batte ry positive (+) ter minal. Install red terminal cover (A). 2. Connect negative (black) cable t o battery negative (-) terminal. Install black terminal cover (B). Check Machine Safety Systems Perform safety system check to make sure the electronic safet[...]

Getting Quality Service - 36 GETTING QUALITY SERVICE authorized 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 questio ns. Part Numbers (Part numb[...]

Service Miscellaneou s - 37 SERVICE MISCELLANEOUS Service Miscellaneo us Wiring Schematics c[...]

Service Miscellaneou s - 38 SERVICE MISCELLANEOUS Service Miscellaneous Hydraulic Schematics c Left Hydrost atic 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) Charge Relief V alve Right Hydrostatic Pump Assembly Right Wheel Moto[...]

Service Miscellaneou s - 39 SERVICE MISCELLANEOUS c[...]

MAIN FRAME ASSEMBL Y Frame Assembly - 40 18 15 1 1 21 9 15 13 20 21 5 3 8 22 6 16 17 19 14 10 1 4 2 7 19[...]

MAIN FRAME ASSEMBL Y Frame Assembly - 41 ITEM P ART NO QTY DESCRIPTION 1 D24020 3 SCREW , 8-32X .50 P AN PHL Y 2 M63431 3 NUT , 8-32 ELASTIC STOP 3 JD26 8 NUT , 1/2-20 LUG Y 4 102770 3 RELA Y , ISO MINI ELEC. 5 200601 2 ASSY , TIRE/WHL 18/8.5X8 YELLOW 6 200672 4 SP ACER, .625X.120X.400 Y 7 N/A 1 ASSEMBL Y , CONSOLE 8 N/A 1 POWER UNIT 9 200741 1 GUA[...]

FUEL, HYDRAULIC AND HANDLE ASSEMBL Y Fuel, Hydraulc and Handle Assembly - 42 23 29 12 14 31 18 21 17 1 20 23 4 25 16 28 2 3 26 30 1 1 22 7 8 6 5 24 27 13 9 30 15 19 10 15[...]

ITEM P ART NO QTY DESCRIPTION 1 D13028 2 SWIVEL ADJUSTER 2 D13308 1 BASE, LOCK LEVER Y 3 D13309 1 LEVER, LOCK Y 4 D18093 2 GRIP , CONTROL 5 D24028 1 FTG, 90 9/16 MOR X 3/8 HOSE 6 TCA15373 1 WLDT , RESERVIOR HYDRAULIC 7 GDA10066 1 ELBOW , FITTING 8 gda10137 1 FIL TER, OIL 9 M68342 2 CLAMP , HOSE (RED) # 10 tca15021 1 T ANK, FUEL ASSY 1 1 TCA15122 1 [...]

ENGINE, HYDRAULIC AND MAINFRAME ASSEMBL Y 2 2 13 14 15 21 1 1 3 1 12 20 5 16 4 26 7 23 17 18 23 22 10 25 8 9 24 23 6 19 27 19 H.P . 23 H.P . 28 29 30 31 32 Engine, Hydraulic And Mainframe Assembly - 44[...]

ITEM P ART NO QTY DESCRIPTION 1 D18379 12 CLAMP , HOSE - 1/2" PINCH 2 D18394 4 HOSE ASSEMBL Y 3 M86863 2 FTG, TUN 3/8 HOSE 4 TCA15874 2 HUB, REAR WHEEL 5 TCA15078 2 MOTOR, WHEEL HGM-12P-7172 6 TCA16240 1 FITTING, OIL DRAIN 7 1 1H237 2 PIN, COT .125 X 2.00 EXTP Y 8 200612 1 WLDT , BRAKE SHAFT 9 200616 1 WLDT , RH BRAKE ARM 10 N/A 1 ENGINE, KA W[...]

CLUTCH, PUMP COMPONENTS AND FOOT PLA TE ASSEMBL Y 39 21 22 15 34 39 29 23 38 4 36 27 8 18 6 14 37 1 2 19 5 31 3 39 7 39 24 16 17 12 17 1 1 33 25 32 28 9 30 20 15 35 10 39 6 26 26 13 Clutch, Pump Components and Foot Plate Assembly - 46[...]

ITEM P ART NO QTY DESCRIPTION 1 D14160 2 WASHER, .250 WIDE HEA VY FLA T Y 2 D14213 2 BOL T , M6 X 1.00 X 10 HEX 8.8 Y 3 D14252 1 BOL T , 7/16-20X3.00 HEX 5 Y 4 D18038 1 SWITCH 5 D18056 1 SP ACER, .468 X 1.38 X .375 Y 6 D18067 2 KEY , M5 X M5 X M30 RD 7 D18071 1 SPRING, EXT .900X.135X4.50 Y 8 D18145 1 KEY , .250 X .250 X .995 TPR 9 D18314 1 PULLEY ,[...]

HYDRAULIC COMPONENTS Hydraulic Components - 48[...]

HYDRAULIC COMPONENTS Hydraulic Components - 49 ITEM P ART NO. QTY DESCRIPTION 1 TCA15122 1 CAP 2 TCA15373 1 HYDRAULIC RESERVOIR W/DECALS 3 D18379 12 HOSE CLAMP 4 TCA15078 2 WHEEL MOTOR 5 D14196 4 ELBOW FITTING, PUMP END 6 R26375 8 O-RING 7 231647 2 90° FITTING, UPPER W/O-RING 8 231 104 2 STRAIGHT ADAPTER, LOWER W/O-RING 9 231046 2 90° FITTING, LO[...]

FUELCOMPONENTS/WIRING HARNESS Fuel Components - 50 FUEL COMPONENTS WIRING HARNESS 200704 Wiring Harness[...]

ITEM P ART NO. QTY DESCRIPTION 1 TCA15021 1 FUEL T ANK 2 181251 1 CAP , FUEL 3 D18144 1 GROMMET 4 TCA15048 1 FUEL PICKUP 5 M68342 5 CLAMP 6 M88753 AR HOSE, FUEL, 10 FT . 1/4 IN. SAE 30-R7 7 14M7400 4 NUT 8 AM1 16304 1 FIL TER 9 03M7191 4 CAP SCREW 10 19M7865 6 CAP SCREW 1 1 200603 1 BRACKET FUEL COMPONENTS/WIRING HARNESS Fuel Components - 51 FUEL C[...]

CONSOLE AND BA TTER Y ASSEMBL Y Console and Battery Assembly - 52 23 25 1 1 22 23 25 17 12 6 14 1 15 16 29 18 13 2 10 27 9 26 20 28 7 30 29 4 19 8 3 5 29 24 21 31 32[...]

CONSOLE AND BA TTER Y ASSEMBL Y Console and Battery Assembly - 53 iTEM P ART NO QTY DESCRIPTION 1 D18079 1 GRIP , PVC .250 X 1.00 X 3.63 2 D28159 1 STRIP , BA TTERY INSULA TOR 3 TCU16323 1 LABEL. P ARK BRAKE DIRECTION 4 03H1832 2 BOL T , 5/16-18 X 6.00 CRG 2 Y 5 1 1 1886 1 P-CLIP , .500 INSULA TED 6 121080 3 PIN, HAR .091 X 1.63 5/16-1/2 Y 7 180640[...]

FOOT PLA TE/CONSOLE COMPONENTS Foot Plate/Console Components - 54 FOOT PLA TE COMPONENTS CONSOLE COMPONENTS 10 4 7 6 1 1 5 12 9 8 3 1 2 13 3 2 1 1 1 4 5 6 12 7 10 9 8[...]

FOOT PLA TE COMPONENTS CONSOLE COMPONENTS ITEM P ART NO QTY DESCRIPTION 1 200618 1 PLA TE, PLA TFORM 2 200619 1 PLA TE, PLA TFORM T AB LH 3 200655 2 BUMPER, MINER GBR-6 4 200691 2 WEDGE, PLA TFORM 5 200693 1 PLA TE, PLA TFORM T AB RH 6 200767 1 ANCHOR, OPC 7 960001 4 BOL T , 1/4-20 X .750 HEX 5 Y 8 960023 2 BOL T , 5/16-18 X 1.00 HEX 5 Y 9 960701 2[...]

DECK ASSEMBL Y Deck Assembly - 56 14 7 2 5 1 25 43 44 3 43 8 23 22 5 18 43 28 21 38 21 19 33 4 10 45 15 20 13 35 46 42 35 41 31 30 39 42 36 37 34 24 29 9 12 40[...]

DECK ASSEMBL Y Deck Assembly - 57 ITEM P ART NO QTY DESCRIPTION 1 D13024 3 SP ACER, 1.500X1.000X.510 Y 2 D13055 3 NUT , 7/8-14 3 D18032 1 Pulley , Flat 5.0x.38 w/BRG 4 D18055 9 W ASHER, BLADE 5 D18084 3 PULLEY , SPLINE SPINDLE OFFSET 6 D23058 1 J-BOL T , 3/8-16 X 4.00 Y 7 D24019 2 W ASHER, .402X2.00X.055 FEND Y 8 D28050 1 PULLEY , FLA T 5.00X.375 W[...]

WHEEL AND STRUT ASSEMBL Y/PUMP COMPONENTS Wheel and Strut Assembly/Pump Components - 58 PUMP COMPONENTS 2 2 1 6 3 4 8 5 7 9 WHEEL AND STRUT ASSEMBL Y 1 1 1 6 7 8 5 4 3 2 4 9 10[...]

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 - 60 14 7 8 9 2 4 3 1 6 1 1 2 5 12 13 10[...]

SPINDLE ASSEMBL Y Spindle Assembly - 61 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 200262 1 Shaft, Spindle 6 200045 6 Bolt, 3/8-16 x 1.25 Rib 7 D13055 3 Nut, Pulley (Special) 8 N/A 3 Pulley , Cutter Housing - See [...]

DECAL LOCA TIONS Decal Locations - 62 19 15 19 1 2 10 3 8 17 1 1 17 7 1 S/N 12 6 13 18 4 5 9 14 7 3[...]

DECAL LOCA TIONS Decal Locations - 63 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 NOT Operate. 200037 MA Y BE COVERED BY ONE OR MORE OF THE FOLLOWING P A TENT[...]