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Great Dane C5 Chariot GCBR2652S, Operator'S Manual, Page: 32 / 88

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Great Dane C5 Chariot GCBR2652S Operator'S Manual Download Page 32

Service Transmission - 30

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

Summary of Contents for C5 Chariot GCBR2652S

Page 1: ...200964 06 17 2007 TCU20866 C5 Chariot GCBR2652S GCBR2661S GCKA1948S GCKA1952S GCBV2348S GCBV2361S GCKH2348S GCKH2352S GCKH2361S OPERATOR S MANUAL...

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Page 3: ...cerns machine damage as well as helpful operating and servicing information Please read all the information carefully to avoid injury and machine damage NOTE General information is given throughout th...

Page 4: ...__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ROPS SERIAL NUMBER D Safety Labels Understanding The Machine Safety Labels The machine safety lab...

Page 5: ...flames or sparks could cause battery to explode Always shield eyes and face from battery Do not charge or use booster cables or adjust post connections without proper instruction and training Contain...

Page 6: ...e away Maintain all safety devices Before leaving machine Stop engine Set park brake Remove key WARNING AVOID CRUSHING Keep Rollover Protective Structure fully extended Do not jump if machine tips Use...

Page 7: ...te clothing including hard hat safety glasses and hearing protection Long hair loose clothing or jewelry may get tangled in moving parts Inspect the area where the equipment is to be used and remove a...

Page 8: ...orized dealer An installed spark arrestor must be maintained in good working order by the operator Checking Mowing Area Clear mowing area of objects that might be thrown Keep people and pets out of mo...

Page 9: ...slope If the tires lose traction disengage the blades and proceed slowly straight down the slope Keep all movement on slopes slow and gradual Do not make sudden changes in speed or direction which co...

Page 10: ...ety lights and devices Slow moving machines when driven on public roads are hard to see especially at night Whenever driving on public roads use flashing warning lights and turn signals according to l...

Page 11: ...bolts tight especially blade attachment bolts to be sure the equipment is in safe working condition Check brake operation frequently Adjust and service as required On multi bladed machines take care...

Page 12: ...r caps securely after use For gasoline engines do not use gas with methanol Methanol is harmful to your health and to the environment Handling Waste Product and Chemicals Waste products such as used o...

Page 13: ...ne from the front using the foot plate A Park machine safely See Parking Safely in the SAFETY section before dismounting Keep the foot plate clean Raising and Lowering Operator Seat Raising the Seat 1...

Page 14: ...To release seat belt press red button C until buckle comes out of latch Raising and Lowering ROPS Raising ROPS 1 Park machine safely See Parking Safely in the SAFETY section 2 Remove spring pin A from...

Page 15: ...f cut 4 Pull back and hold the mower deck lift lever A and release the transport position lock lever B 5 Allow the mower deck lift lever A to rest against the HOC adjustment pin C Adjusting Mower Deck...

Page 16: ...he lap levers 2 Lock the park brake 3 Pull PTO knob up to engage 4 Turn key switch to the start position Result The engine must not crank Testing Park Brake Switch 1 Sit on the operator seat with the...

Page 17: ...brake Result Park brake must hold the machine stationary Machine should move no more that 61 cm 24 in in one hour If machine moves more than that brakes need to be adjusted See Adjusting Park Brake in...

Page 18: ...PTO knob B down Using the Throttle Lever Push throttle lever A all the way forward to the full throttle detent position B when mowing Move throttle lever A to the 1 2 throttle position C when startin...

Page 19: ...on Motion control levers must be in the neutral lock position the PTO switch disengaged and the park brake locked to start the engine Forward and reverse movement of the motion control levers is preve...

Page 20: ...both motion control levers forward or rearward until the machine comes to a stop NOTE The motion control linkages are adjustable If adjustment is required see Checking and Adjusting Motion Control Li...

Page 21: ...position B If the engine does not start wait 10 seconds Turn key to start position again for no more than 5 seconds Repeat the procedure if necessary 8 Release key to run position C when engine starts...

Page 22: ...es Both front and rear straps must be directed down and outward from machine Mowing Tips Mow grass with throttle lever in the full fast position Cut grass when it is dry Keep mower deck and discharge...

Page 23: ...de of the mower deck Every 50 Hours or Weekly Whichever Comes First Change engine oil and filter See the engine manufacturer s owner s manual provided with your machine for the complete procedure Grea...

Page 24: ...spindle bearings B 3 Grease HOC shafts C two points on each side of the machine 4 Grease mower deck thrust arms D located at the rear of the mower deck 5 Apply grease to three spindle bearings IMPORTA...

Page 25: ...performed by any non road engine repair establishment or individual Warranty repairs must be performed by an authorized servicing dealer Avoid Fumes Engine Oil Use oil viscosity based on the expected...

Page 26: ...s Check for leaks around filter and drain valve 15 Stop engine 16 Check oil level Remove dipstick Wipe with a clean cloth Install dipstick and allow the cap to rest on the end of the tube Do not tight...

Page 27: ...hoses Picture Note Kawasaki engine shown 4 Locate fuel hose A coming from fuel tank disconnect it from the inlet side of fuel filter B and drain gasoline into a properly marked container 5 Remove fuel...

Page 28: ...gasket makes contact with mounting surface Tighten 1 2 to 3 4 turn after gasket contact NOTE Reservoir capacity is approximately 1 9 L 2 0 qt Total system capacity is approximately 3 5 L 3 75 qt 9 Fi...

Page 29: ...ll mower deck drive belt as shown Checking and Adjusting Motion Control Linkages CAUTION Avoid injury Engine exhaust fumes contain carbon monoxide and can cause serious illness or death Move the machi...

Page 30: ...E and rotate the swivel 8 Rotate swivel D to adjust To stop forward creep rotate each swivel D counterclockwise one rotation To stop rearward creep rotate each swivel D clockwise one rotation 9 Connec...

Page 31: ...s 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 b Adjust the screw A or B one turn clockwise c Tighten the jam n...

Page 32: ...Service Transmission 30 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...

Page 33: ...ol 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 J Left Wheel M...

Page 34: ...6 Install spacer tube F press bearings E into wheel and tire assembly 7 Install wheel and tire assembly D two trash guards C cap screw B and locknut A Adjusting Front Caster Spindle Bearing NOTE Adjus...

Page 35: ...w seal H 9 Install seal assembly H 10 Carefully install caster yoke and wheel assembly D NOTE Do not overtighten castle nut C Tighten castle nut only enough to install the cotter pin B The caster whee...

Page 36: ...ion and check for the recommended gap of 3 6 mm 1 8 1 4 in If positions of the control levers are unequal an adjustment is necessary Alignment Procedure 1 Adjust position of motion control levers Loos...

Page 37: ...chine safely See Parking Safely in the SAFETY section 2 Inflate tires to the correct pressure 3 Raise the mower deck lift lever to transport position 4 Inspect mower blades for Blade sharpness Blade d...

Page 38: ...ade discharge side in the straight forward front to rear position 3 Measure from right front blade tip to the ground 4 Turn blade 180 and measure from right rear blade tip to the ground The height C o...

Page 39: ...actory an adjustment may be necessary Check Spring Tension 1 Park machine safely See Parking Safely in the SAFETY section 2 Raise the mower deck lift lever to the transport position 3 Measure distance...

Page 40: ...sion by turning the tension adjuster nut A counterclockwise 5 Remove mower deck drive belt B A PTO Clutch Sheave B Mower Deck Drive Belt C Tension Idler Sheave D Left Spindle Sheave E Center Spindle S...

Page 41: ...Sharpen blades with grinder hand file or electric blade sharpener Keep original bevel A when grinding Blade should have 0 40 mm 1 64 in cutting edge B or less Balance blades before installing Balancin...

Page 42: ...wn to the State of California to cause cancer and reproductive harm Wash hands after handling Service the Battery Safely Removing and Installing the Battery Removing 1 Park machine safely See Parking...

Page 43: ...chine for several minutes 6 Carefully disconnect the booster cables in the exact reverse order negative cable first and then the positive cable Replacing Fuse One 20 amp fuse is located behind the sea...

Page 44: ...Service Electrical 42 SERVICE ELECTRICAL Wiring Schematic...

Page 45: ...tion 2 Allow engine to cool 3 Remove any trash from area around fuel tank cap 4 Remove fuel tank cap slowly to allow any pressure built up in tank to escape 5 Fill fuel tank only to bottom of filler n...

Page 46: ...tal or primer showing 1 Clean area to be repaired with rubbing alcohol or mineral spirits 2 Use paint stick with factory matched colors available from your authorized dealer to fill scratches Follow d...

Page 47: ...erate at slow idle Operate at full throttle setting Cooling air intake screen is dirty Plugged air intake filter Operating at too fast ground speed for conditions Engine Lacks Power Plugged air intake...

Page 48: ...Improper tire Inflation Hydrostatic transmission oil low Traction drive belt slipping Traction drive belt damaged or worn If Check Machine Will Not Follow a Straight Path Steering tracking out of adj...

Page 49: ...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 times to allow oil to be distributed 5 Clean the engine...

Page 50: ...down rod and disengage hooked end B from bumper 3 Remove all bumper mounting bolts and retaining hardware except for the lower left cap screw C at each side of the machine Discard any assembly washer...

Page 51: ...the machine with jackstands 3 Start and run the engine until it reaches normal operating temperature 4 Move control levers to the forward position and observe drive wheel rotation the drive wheels sh...

Page 52: ...tor Manual for this machine contact your dealer Parts catalogs and operator manuals are also available online at GreatDaneMowers com Parts We recommend Great Dane quality parts available at your Great...

Page 53: ...Getting Quality Service 51 GETTING QUALITY SERVICE...

Page 54: ...ENGINE AND RELATED COMPONENTS B S 23 HP VANGUARD 52 ENGINE AND RELATED COMPONENTS B S 23 HP VANGUARD...

Page 55: ...ER FLAT 8 IS07093 10 ZN 17 180908 HEAD FILTER 1 18 191800 CLAMP 6 17 5MM PINCH 19 200316 WLDT BRACKET CLUTCH 1 20 200352 BUMPER REAR KH BV 1 21 200376 BRACKET EXHAUST SUPPORT 1 22 200377 SHIELD EXHAUS...

Page 56: ...ENGINE AND RELATED COMPONENTS B S 26 HP ELS 54 ENGINE AND RELATED COMPONENTS B S 26 HP ELS...

Page 57: ...8 8 Y 24 960022 BOLT 2 5 16 18 X 750 HEX 5 Y 25 960026 BOLT 4 5 16 18 X 1 75 HEX 5 Y 26 135139 BOLT 2 1 2 X 1 06 X 3 8 16 SLD 5 Y 27 14M7396 LOCKNUT 1 FLANGE ISO7043 M8X1 25 28 14M7397 LOCKNUT 3 FLANG...

Page 58: ...ENGINE AND RELATED COMPONENTS Kawasaki Kai Kohler 56 7 RKOHU QJLQH 7 DZDVDNL DL QJLQH ENGINE AND RELATED COMPONENTS KAWASAKI KAI KOHLER...

Page 59: ...CUSTOM SCREW HEX FL JDS121 M10 8 26 960603 WASHER 1 438 MED SPRG LOCK Y 27 03M7184 BOLT 1 M8X1 25X20 CRG 8 8 Y 28 960078 BOLT 1 7 16 14 X 750 HEX 5 Y 29 111910 CABLE TIE 2 15 X 8 50 30 135139 BOLT 2...

Page 60: ...HOSE 1 3 R56101 CLIP 2 4 GDA10012 FUEL TANK 1 5 D18144 BUSHING 1 6 GDU10026 FUEL PICKUP 1 INCLUDES M145626 7 M63277 LOCK NUT 2 7 925 MM 5 16 8 E53830 CLAMP 2 9 D14081 LOCK NUT 2 7 925 MM 5 16 10 N102...

Page 61: ...n Qty Remarks 1 TCU14989 TUBE 2 2 M131171 GRIP 2 3 GDU10047 STRAP 2 4 19M8320 SCREW 4 M10 X 45 5 14M7518 FLANGE NUT 4 M10 6 03M7195 BOLT 2 M10 X 45 7 M85516 LOCK NUT 2 M10 8 TCU13271 ARM 2 9 GDU10275...

Page 62: ...ELECTRICAL AND RELATED COMPONENTS 60 ELECTRICAL AND RELATED COMPONENTS...

Page 63: ...CH 1 OGURA Kai Kohler 23 D14288 SCREW 4 24 M63431 LOCK NUT 4 25 H122207 FLANGE NUT 2 26 AM101006 DIODE 5 1000V 3AMP 27 TCU17832 DIODE 1 400V 6AMP 28 D38018 WIRING HARNESS 1 FULL SUSPENSION SEAT ONLY 2...

Page 64: ...CONSOLE AND CONTROL ASSEMBLY 62 CONSOLE AND CONTROL ASSEMBLY...

Page 65: ...MM 17 03M7195 BOLT 2 M10 X 45 18 M85516 LOCK NUT 2 19 19H1936 CAP SCREW 2 3 8 X 3 4 20 GX10707 EXTENSION SPRING 2 21 D14236 SCREW 2 22 14H778 NUT 4 190 23 TCA13253 PIVOT 1 24 03M7184 BOLT 2 M8 X 20 25...

Page 66: ...HYDROSTATIC DRIVE SYSTEM COMPONENTS 64 HYDROSTATIC DRIVE SYSTEM COMPONENTS...

Page 67: ...HARGE INLET MAKE FROM TY22503 8 D18379 CLAMP 12 9 D14197 FITTING 4 10 M86863 TEE FITTING 2 11 D28026 HOSE 2 HIGH PRESSURE SHORT 12 GDA10089 HYDRAULIC HOSE 2 HIGH PRESSURE LONG 13 D24026 FITTING 4 14 M...

Page 68: ...TRACTION DRIVE AND BRAKES 66 TRACTION DRIVE AND BRAKES...

Page 69: ...50 27 H137328 LOCK NUT 5 28 19M8008 CAP SCREW 2 M8 X 25 29 14M7151 NUT 2 M8 30 960526 NUT 10 1 2 20 LUG 31 GDA10000 TIRE AND WHEEL ASSEMBLY 2 23 X 9 5 X 12 32 GDU10096 SUPPORT 1 33 03M7199 BOLT 4 M12...

Page 70: ...HYDRAULIC SCHEMATIC 68 HYDRAULIC SCHEMATIC...

Page 71: ...X 1 X 0 134 3 TCU17356 PAD 1 CUT TO LENGTH 4 200324 SEAT PLATE YELLOW 1 5 135139 BOLT 1 1 2 X 1 06 X 3 8 16 6 K40003 LOCK NUT 1 7 03M7184 BOLT 1 M8 X 20 8 E83830 CLAMP 3 9 14M7396 LOCK NUT 1 M8 10 M6...

Page 72: ...FRAME ASSEMBLY 70 FRAME ASSEMBLY...

Page 73: ...0222 PLATE 1 5 03M7199 BOLT 4 M12 X 35 6 H137329 LOCK NUT 8 7 03M7197 BOLT 4 M12 X 25 8 JD7844 LUBRICATION FITTING 2 9 200329 PLATFORM 2 10 135139 LOCK NUT 2 11 964022 LOCK NUT 2 12 GDU10165 FENDER 1...

Page 74: ...FRONT CASTER ASSEMBLY 72 FRONT CASTER ASSEMBLY FRONT CASTER ASSEMBLY...

Page 75: ...TCA13769 TIRE AND WHEEL ASSEMBLY 1 13 CASTER 6 19M7978 CAP SCREW 1 7 14M7276 NUT 1 M16 8 TCU13454 SPACER 1 9 E14625 SEAL 1 10 JD8933 BEARING CONE 2 11 145553 BEARING CUP 2 12 24H1801 WASHER 1 13 11M70...

Page 76: ...ROPS 74 ROPS NOTES Ref No Part No Description Qty Remarks 1 200550 ROPS 1...

Page 77: ...Notes 75 NOTES...

Page 78: ...SPINDLE ASSEMBLY 76 SPINDLE ASSEMBLY...

Page 79: ...1 Includes items 7 10 14 6 200045 Bolt 3 3 8 16 7 967333 Nut Pulley Special 3 8 D18209 Pulley Cutter Housing 48 Deck 3 D18084 Pulley Cutter Housing 52 Deck 3 D18211 Pulley Cutter Housing 61 Deck 3 9...

Page 80: ...DECK LIFT ASSEMBLY 78 DECK LIFT ASSEMBLY...

Page 81: ...LEVER 1 16 TCU17371 TORSION SPRING 1 17 03M7204 BOLT 3 M12 X 60 18 TCU15816 SPACER 2 19 200355 HOC PIN 1 20 D25107 ROD 1 21 D23049 SWIVEL 1 22 14H1039 NUT 2 5 8 23 24H1111 WASHER 3 17 32 X 1 1 16 X 09...

Page 82: ...48 CUTTING DECK 80 48 CUTTING DECK...

Page 83: ...GDA10084 ARM 1 RH 20 GDA10085 ARM 1 LH 21 D18076 BUSHING 4 22 JD7844 LUBRICATION FITTING 3 23 19H3280 SCREW 2 1 4 X 1 24 964024 LOCK NUT 2 25 TCA13292 PIN FASTENER 2 26 03M7185 BOLT 2 M8 X 25 27 14M73...

Page 84: ...52 61 CUTTING DECK 82 52 61 CUTTING DECK...

Page 85: ...52 DECK 1 19 GDU10228 BELT V 1 20 GDU10232 BLADE 20 940 LO LIFT 61 3 GDU10231 BLADE 18 00 LO LIFT 52 3 21 GDU10262 DECAL BELT PATH 48 52 61 1 22 GDU10269 DECAL 61 1 23 H122207 NUT 1 4 FLANGE PREVAILIN...

Page 86: ...LABELS 84 LABELS...

Page 87: ...DU10269 LABEL 1 13 TCU20575 LABEL 4 ROPS CERTIFICTATION 14 TCU51051 LABEL 1 DANGER ROTATING BELTS 15 M17554 LABEL 2 WARNING HOT SURFACES 16 M127610 LABEL 1 IGNITION 17 M131739 LABEL 2 DANGER BLADE CON...

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