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Great Dane Chariot / Chariot LX GDRZ48-17KAE Operator'S Manual Download Page 4

Table of Contents

TABLE OF CONTENTS

All information, illustrations and 

specifications 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© 2002

Deere & Co.

John Deere Worldwide Commercial and 

Consumer Equipment Division

All rights reserved

Previous Editions

COPYRIGHT© 

OMTCU17095 J2 - English

Table of Contents

Safety .....................................................................................................................................................................................1

Operating .............................................................................................................................................................................10

Replacement Parts ...............................................................................................................................................................22

Service Intervals...................................................................................................................................................................23

Service Lubrication...............................................................................................................................................................24

Service Engine .....................................................................................................................................................................26

Service Transmission............................................................................................................................................................31

Service Steering & Brakes....................................................................................................................................................37

Service Mower......................................................................................................................................................................41

Service Electrical..................................................................................................................................................................51

Service Miscellaneous..........................................................................................................................................................57

Troubleshooting ....................................................................................................................................................................59

Storage .................................................................................................................................................................................64

Assembly ..............................................................................................................................................................................65

Specifications .......................................................................................................................................................................68

Index .....................................................................................................................................................................................70

Service Record GD ..............................................................................................................................................................71

Summary of Contents for Chariot / Chariot LX GDRZ48-17KAE

Page 1: ...reproductive harm California Proposition 65 Warning OMTCU17095 J2 TCU17095 H2 Chariot Chariot LX GDRZ48 17KAE GDRZ48 19KAE GDRZ52 23KAE GDRZ52 25KAE GDRZ52 25KHE GDRZ61 25KAE GDRZ61 25KHE GDRZ61 25KA...

Page 2: ...cing questions The machine shown in this manual may differ slightly from your machine but will be similar enough to help you understand our instructions RIGHT HAND and LEFT HAND sides are determined b...

Page 3: ...and record the information in the spaces provided DATE OF PURCHASE _________________________________________ DEALER NAME _________________________________________ DEALER PHONE _______________________...

Page 4: ...Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT OMTCU17095 J2 English Table of Contents Safety 1 Operating 10 Replacement Parts 22 Service In...

Page 5: ...most serious hazards The operator s manual also explains any potential safety hazards whenever necessary in special safety messages that are identified with the word CAUTION and the safety alert symb...

Page 6: ...yes and face from battery Do not charge or use booster cables or adjust post connections without proper instruction and training Contains sulfuric acid Avoid contact with the skin eyes or clothing In...

Page 7: ...ources Board CARB The emissions warranty applies only to those engines marketed by Great Dane that have been certified by the EPA and or CARB and used in the United States and Canada in off road mobil...

Page 8: ...ed can increase the hazard of personal injury Do not operate mower without discharge chute or entire grass catcher in place Never operate with the discharge deflector raised removed or altered unless...

Page 9: ...d trim or remove those obstacles Study mowing area Set up a safe mowing pattern Do not mow where traction or stability is doubtful Test drive area with mower lowered but not running Slow down when you...

Page 10: ...eep away from drop offs ditches and embankments Slow down before you make a sharp turn or operate on a slope Transport machine with decks lowered to improve stability Drive machine very slowly and avo...

Page 11: ...hardware tight Keep hands feet clothing jewelry and long hair away from any moving parts to prevent them from getting caught Lower attachments to the ground before servicing machine Disengage all powe...

Page 12: ...injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Prevent Fires Re...

Page 13: ...make sure it is plastic and has no screen or filter Static electric discharge can ignite gasoline vapors in an ungrounded fuel container Remove the fuel container from the bed of a vehicle or the trun...

Page 14: ...Inspect front caster spindles wheels Operator Station Controls MX15290 A Motion Control Levers B Park Brake Lever C Seat Adjustment Lever D Hourmeter E Ignition Key Switch F PTO Knob G Choke Carburet...

Page 15: ...at this test three times with the motion control levers in the following positions Right side motion control lever inward Left side motion control lever inward Both motion control levers inward 1 Move...

Page 16: ...nt to back push and hold the seat adjustment lever A away from the seat 3 Slide forward or backward to desired position 4 Release lever Seat Height Adjustment Chariot LX only 1 Sit on the operator sea...

Page 17: ...utting height NOTE The rear anti scalp wheels are located under the rear of the mower deck MX15281 3 Adjust anti scalp wheel A to one of two positions B Remove screw C nut and washer Adjust wheel up o...

Page 18: ...tion standard levers or neutral lock position optional over the lap levers MIF To turn ignition off turn key to the STOP position A To turn ignition on turn key to the run position B To start engine t...

Page 19: ...will need service See the service interval chart in the engine manufacturer s owners manual supplied with your machine to determine when the engine will need service Using the Choke Carbureted Engines...

Page 20: ...utral Position Optional Over the Lap Levers MX15293 Picture Note Motion control levers A shown in the neutral position Machine speed motion and direction can be controlled when the engine is running o...

Page 21: ...X13116 Push right control lever farther forward than the left control lever Gentle Right Turn MX13117 Push left control lever farther forward than the right control lever Sharp Left Turn MX13118 Push...

Page 22: ...seconds Repeat the procedure if necessary 8 Release key to run position C when engine starts 9 With engine started Push choke knob to off position Move throttle lever to full throttle position Unlock...

Page 23: ...down to disengage 4 Move throttle lever to 1 4 throttle position and run for 30 seconds then move throttle to slow position MIF 5 Turn key switch to STOP position A 6 Remove key cCAUTION Avoid injury...

Page 24: ...om machine Mowing Tips Mow grass with throttle lever in the full throttle position Cut grass when it is dry Keep mower deck and discharge chute clean Mow with sharp blades Properly level mower deck fo...

Page 25: ...engine and remove key Always wait for mower blades to stop turning before leaving operator seat Avoid Damage to Plastic and Painted Surfaces Do not wipe plastic parts unless rinsed first Insect repel...

Page 26: ...roduct Identification section of this manual Part Numbers Part numbers are subject to change without notice Part numbers may be different outside the U S A Item Part Number Battery AM124356 Fuel Tank...

Page 27: ...rovided with your machine for the complete procedure Grease caster wheel spindle bearings two places Grease mower deck thrust arms two places Remove debris from the underside of the mower deck Check d...

Page 28: ...MX15286 Chariot LX only Grease caster wheel bearings A Grease caster wheel spindle bearings B MX15289 Grease HOC shafts C two points on each side of the machine MX15319 Grease mower deck thrust arms...

Page 29: ...t tension arm J NOTE Use spray lubricant to lubricate the following items MX15335 Picture Note 48 52 and 61 inch mower decks MX15331 Picture Note 72 inch mower deck Lubricate mower deck idler pulleys...

Page 30: ...e FULL mark on dipstick If oil level is above the FULL mark drain to proper level 7 Install and tighten dipstick Changing Engine Oil and Filter 1 Run engine to warm oil 2 Park machine safely See Parki...

Page 31: ...ection See the engine manufacturer s owner s manual provided with your machine for the complete procedure Cleaning Engine Air Intake Screen and Fan Keep air intake screens and engine cooling fins clea...

Page 32: ...ct fuel hose A from the outlet side of fuel filter B and drain gasoline into a properly marked container 5 Remove fuel filter from inlet fuel hose C Discard filter 6 Connect a new fuel filter to hoses...

Page 33: ...service These codes can be accessed only by an authorized Kohler EFI servicing dealer When troubleshooting a problem with the Kohler EFI system basic engine operating problems must be eliminated befor...

Page 34: ...ly If the MIL indicates a problem with the EFI system first disconnect the Electronic Control Unit ECU connector and test for continuity between the component connector terminals and the corresponding...

Page 35: ...r cap from reservoir MX15294 4 Remove cap A from oil reservoir tank filler neck MX15312 5 Turn hydraulic oil filter B counterclockwise to remove 6 Allow hydraulic oil to drain into a drain pan with at...

Page 36: ...ave 3 Using a 1 2 in drive breaker bar and extension insert end of extension in 1 2 in drive square opening A in tension arm and carefully move tension arm B counter clockwise to release belt tension...

Page 37: ...g slot backward or forward to stop machine creep If machine creeps forward slide dampener to the rear of the adjusting slot Tighten nut If machine creeps backward slide dampener to the front of the ad...

Page 38: ...the direction the machine moves Maximum Speed Drift Adjustment 1 Park machine safely See Parking Safely in the Safety section 2 Tilt operator seat forward and support the seat frame NOTE If the machin...

Page 39: ...Transmission 35 SERVICE TRANSMISSION Hydraulic System Hose Routing MX15332 A Hydraulic Reservoir B Oil Filter C Right Hydraulic Pump D Right Wheel Motor E Left Wheel Motor F Left Hydraulic Pump A B F...

Page 40: ...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 Motor K Le...

Page 41: ...ariot 1 Park machine safely See Parking Safely in the Safety section 2 Raise and securely support the front of the mower deck MX15324 3 Remove locknut A capscrew B two trash guards C and wheel and tir...

Page 42: ...Spindle Bearing NOTE Adjustment required only if the front caster wheel shimmies during travel 1 Park machine safely See Parking Safely in the Safety section MX15286 2 Remove dust cover A from top of...

Page 43: ...Motion Control Levers Standard Center Steer Levers Check Alignment 1 Park machine safely See Parking Safely in the Safety section 2 The control lever gap is pre set at the factory If the gap requires...

Page 44: ...on of motion control levers MX15353 Loosen capscrews C Slide both levers forward or rearward to desired position on control arm until levers are aligned Tighten capscrews Adjusting Park Brake 1 Park m...

Page 45: ...t Shields 1 Park machine safely See Parking Safely in the Safety section 2 Lower mower deck to the lowest cutting height position NOTE Two retaining knobs are used on each cover on the 72 inch mower d...

Page 46: ...to the ground The difference between both measurements should be no greater than 3 mm 1 8 in 5 If side to side level is not within specifications an adjustment is necessary Adjusting Level Side to Si...

Page 47: ...heck clearance A from the top of the thrust arms B to the bottom of the thrust arm stop rod C The clearance should be 3 mm 1 8 in Adjust Thrust Arm to Stop Rod Clearance Transport Position MX13148 1 L...

Page 48: ...t of the machine Turn hex nut C clockwise to increase deck lift spring tension and reduce the effort to raise and lower the mower deck Turn hex nut C counterclockwise to decrease deck lift spring tens...

Page 49: ...st cutting height and lower the deck 3 Raise foot platform MX15327 4 Check the spindle drive belt A tension The belt should deflect a maximum of 13 mm 1 2 in when a force of 4 5 kg 10 lb is applied to...

Page 50: ...Deck Drive Belt 72 Inch Mower Deck 1 Park machine safely See Parking Safely in the Safety section 2 Remove mower deck drive belt covers MX15328 3 Release engine to deck drive belt tension by turning t...

Page 51: ...n or weld them Checking Mower Blades 1 Park machine safely See Parking Safely in the Safety Section 2 Raise the mower deck to the transport position also the 12 7 cm 5 in cutting height position 3 Rai...

Page 52: ...lades before installing Balancing Blades 1 Clean blade M61524 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 Gr...

Page 53: ...ulley B and nut A Tighten nut to 61 N m 50 lb ft 12 Install mower blade blade washers and blade bolt assembly Tighten nut to 81 N m 60 lb ft See Checking and Replacing Mower Blades Replacing Mower Spi...

Page 54: ...ousing M 10 Install the upper bearing N and retaining ring I 11 Install upper pulleys Right and Left Spindles A Install pulley D spacer C and nut B Tighten nut to 81 N m 60 lb ft Center Spindle E Inst...

Page 55: ...A and C over battery terminals Cleaning Battery and Terminals 1 Disconnect and remove battery 2 Wash battery with a solution of four tablespoons of baking soda to one gallon of water Be careful not to...

Page 56: ...p fuse is located behind the seat area MX15336 1 Remove defective fuse A from socket 2 Check metal clip in fuse window and discard fuse if clip is broken 3 Install new fuse in socket Replacing Fuses F...

Page 57: ...it 1 Remove defective fuse from socket 2 Check metal clip in fuse window and discard fuse if clip is broken 3 Install new fuse into socket Burnishing the PTO Clutch NOTE The clutch will only require b...

Page 58: ...Service Electrical 54 SERVICE ELECTRICAL Wiring Schematic Carbureted Engines MX15338...

Page 59: ...Service Electrical 55 SERVICE ELECTRICAL Wiring Schematic 26 HP Fuel Injected Engine MX15345...

Page 60: ...Service Electrical 56 SERVICE ELECTRICAL Wiring Schematic 28 HP Fuel Injected Engine MX15356...

Page 61: ...oid 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...

Page 62: ...es Cleaning Follow automotive practices to care for your machine s painted metal surfaces Use a high quality automotive wax regularly to maintain the factory look of your machine s painted surfaces Re...

Page 63: ...ugged fuel filter EFI Engines Only Air in fuel line Plugged air intake filter Spark plug wire is loose or disconnected Spark plug not gapped correctly Blown 20 amp fuse main power circuit Carbureted E...

Page 64: ...EFI electrical system and connections If problem continues have system serviced by an authorized Kohler EFI servicing dealer Engine Overheats Clean cooling fins Low oil level Do not operate at slow i...

Page 65: ...roblem continues have system serviced by an authorized Kohler EFI servicing dealer If Check Starter Will Not Work Dead battery Blown 20 amp fuse main power circuit Blown fusible link charging circuit...

Page 66: ...el valves open Traction drive belt damaged or worn Hydrostatic pump and or wheel motor problems See your Great Dane servicing dealer Machine Creeps With Engine Running and Motion Control Levers in a N...

Page 67: ...loose Blades are bent or worn Sharpen and balance blades Remove belt shields and check for debris on sheaves Check sheaves for proper alignment or damage See your Great Dane servicing dealer Mower Bl...

Page 68: ...hicle is not to be used for longer than 60 days 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 Remove spark plugs...

Page 69: ...ark on dipstick If oil level is above the FULL mark drain to proper level 10 Install and tighten dipstick Check Tire Pressure 1 Check tires for damage 2 Check tire pressure with an accurate gauge 3 Ch...

Page 70: ...s on the hinge stops NOTE The seat mounting hardware is attached to the seat plate with tie straps 3 Install seat B to the seat frame using four 5 16 18 locknuts and heavy flat washers C Tighten lockn...

Page 71: ...switch to on position mower clutch should engage Run blades for several minutes 7 Move PTO clutch switch to off position and shut the engine off 8 Check all belts for proper tension 9 Start the engine...

Page 72: ...LX With Mower Deck and Without Fuel 25 hp Kawasaki Engine 61 in Deck 501 kg 1104 lb 25 hp Kohler Engine 61 in Deck 501 kg 1104 lb 26 hp Kohler Engine 61 in Deck 501 kg 1104 lb 27 hp Kohler Engine 61...

Page 73: ...er Deck Mower Type Mulch Bag or Side Discharge Cutting Blades 3 Blade Bolt Torque 81 N m 60 lb ft Cutting Width 1 55 m 61 in Cutting Height approximate 25 to 127 mm 1 to 5 in Height Adjustment Increme...

Page 74: ...ce 38 Front Caster Wheels Remove and Install 37 Front Caster Wheels Service Bearings Chariot 37 Front Caster Wheels Service Bearings Chariot LX 37 Fuel Filter Replacing Fuel Injected Engines 28 Fuel F...

Page 75: ...pecifications 72 Inch Mower Deck 69 Spindle Bearings Replace 72 Inch Mower Deck 49 Spindle Bearings Replace 48 52 and 61 In Decks 48 Spindle Drive Belt Check and Adjust Tension 45 47 Spindle Drive Bel...

Page 76: ...Service Record GD 72 SERVICE RECORD GD Service Record GD Record Service Dates Engine Oil and Filter Change Lubricate Machine Air Cleaner Element Clean Replace...

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