Surfer. Parts Manual. Models Surfer GSRKA1934S ENGLISH A 10/09 Printed in USA

Transcription

1 Surfer Parts Manual Models 9960 Surfer GSRKA193S ENGLISH A 10/09 Printed in USA

2 THE MANUAL Before you operate your unit, carefully and completely read manuals supplied with the unit. The contents will provide you with an understanding of safety instructions and controls during normal operation and maintenance. For your safety and the safety of others always read, understand, and follow all DANGER, WARNING, and CAUTION messages found in manuals and on safety decals. Hardware descriptions are given in decimals. Decimals to Fractions.063 1/ / /8.65 5/ / / /.50 3/.313 5/ / /8.85 /8.38 / / / SERVICE AND REPLACEMENT PARTS When ordering replacement parts or making service inquiries, know the Model and Serial numbers of your unit and engine. Numbers are located on the product registration card in the unit literature package. They are printed on a serial number label, located on the frame of your unit. Record Unit Model and Serial numbers here: PRODUCT REGISTRATION The Great Dane dealer must register the product at the time of purchase. Registering the product will help the company process warranty claims or contact you with the latest service information. All claims meeting requirements during the limited warranty period will be honored, whether or not the product registration card is returned. Keep a proof of purchase if you do not register your unit. Customer Note: If Dealer does not register your product, please fill out, sign and return the product registration card to Great Dane or go to YOUR SATISFACTION IS IMPORTANT Questions? Please follow these helpful steps: 1. Refer to the manuals supplied with your unit. They will guide you through safe and proper operation and maintenance. They contain specifications on your unit. If your questions are not answered in these manuals, go to step number two.. Contact your Dealer. Our dealers will be happy to supply any service or advice required to keep your unit operating at peak efficiency. A factory trained staff is available to support your equipment needs. They stock genuine Great Dane parts and lubricants manufactured with the same precision and skill as the original. If your questions are not resolved by the support staff, ask for the manager or owner. When contacting your Dealer supply your model and serial numbers. Record Engine Model and Serial numbers here: UNAUTHORIZED REPLACEMENT PARTS Use only Great Dane replacement parts. The replacement of any part on this vehicle with anything other than a Great Dane authorized replacement part may adversely affect the performance, durability, or safety of this unit and may void the warranty. Great Dane disclaims liability for any claims or damages, whether warranty, property damage, personal injury or death arising out of the use of unauthorized replacement parts. TO SPEED PARTS ORDERING: 1. Know the model and serial numbers of your unit.. Know the part number required. 3. Know the quantity required.. Know the part description.

3 MODELS GSRKA193S 19HP Kawasaki with 3-Inch Mower Deck Serial No and up TABLE OF CONTENTS MAIN FRAME Main Frame Assembly Foot Plate and Console Components POWER PLANT Fuel, Hydraulic and Handle Assembly Engine, Hydraulic and Main Frame Assembly HYDRAULICS Pump Components Hydraulic Schematic MOWER DECK Deck Assembly Wheel and Strut Assembly Spindle Assembly ELECTRICAL Wiring Harness Wiring Schematic DECALS Decals Copyright 009

4 MAIN FRAME ASSEMBLY PD ,

5 MAIN FRAME ASSEMBLY ITEM PART NO QTY DESCRIPTION 1 D Pad, Battery Insulator M683 Clamp, Hose (Red) # 3 TCU165 1 Hose, 1/" Id Low Perm Fuel 50 03H183 Cap Screw, 5/16" x 6" Bolt,.50 x 1.06 x Sld 5 Y Cable, Battery Starter - 8" Battery, 1V-U1-CCA 0 min Pin, Clevis Spg 3/8" Yoke Spec Y Tank, Fuel 10 AA Weldment, Reservior Guard 11 AA Cable, Battery - 5" Ground Console Battery Bracket, w/decal Bolt,.5-0 x.50 Hex 5 Y Shield, LH Pump Shield, RH Pump Shield, RH Motor Shield, LH Motor Assembly, Tire/Wheel 18/6.5 x 8 Slvr Shield, Engine 0 AA0119 Rod, Control 5/16 x.5 Y RH Cast Weight Machined LH Cast Weight Machined Clevis,.38- Adjustment Bolt, Hex.5-0 x.5 Grade Bolt, Hex x.5 Grade Bolt, x 3.00 Hex 5 Y Bolt, x 1.00 Fgh 8 Y Bolt, Hex x 1.5 Grade Nut,.50-0 Lug C 30 AA Washer,.313 Med Sprg Lock Y 31 AA Bolt,.5-0 x.65 Wsh Y Bolt, Round Head Square Neck.38-16x1.00 G Nut, Hex Nut, Flange Nut, Locking-Flange Nut, Locking-Nylon Nut, Spin Lock-Flange Nut, Locking-Nylon AA Washer,.313 Medium Spring Lock Y Trim, Rubber Edge " 1 N/A 1 Power Unit 19 Narrow 3

6 FOOT PLATE AND CONSOLE COMPONENTS

7 FOOT PLATE AND CONSOLE COMPONENTS ITEM PART NO QTY DESCRIPTION Plate, Platform Tab LH Bumper, Miner GBR Plate, Platform Tab Left Hand Anchor, Operator Presence Control Platform Bolt, Hex.5-0 x.5 Grade Washer, Flat-Steel.38 x.85 x Bolt, x 1.00 Round Head Square Neck G Bolt, x 1.00 Round Head Square Neck Grade Nut, Locking-Nylon Nut, Locking-Nylon Nut, Locking-Nylon D18 1 Cable, Choke 1 D00 Screw, 8-3 x.50 Pan PHL Y 15 M6331 Nut, 8-3 Elastic Stop 16 TCA Cable, Throttle Switch, PTO Engagement 18 1H86 1 Nut, Hex Switch, Key - 3 Position Meter, Hour Digital Top, Console w/decals 5

8 FUEL, HYDRAULIC AND HANDLE ASSEMBLY

9 FUEL, HYDRAULIC AND HANDLE ASSEMBLY ITEM PART NO QTY DESCRIPTION 1 D1308 Swivel Adjuster D Lever, Lock Y 3 D Base, Lock Lever Y Grommet, Rubber.88ID x 1.38OD x.1 5 D Grip, PVC.50 x 1.00 x D00 3 Screw, 8-3 x.50 Y D08 Fitting, 90 9/16 MOR x 3/8 HOSE 8 TCA Weldment, Reservior Hydraulic 9 GDA Filter, Oil 10 M Nut, 8-3 Elastic Stop 11 TCA151 1 Cap, Filler Oil Relay, Iso Mini Elec Cable Tie,.15 x Pin, Hair.091 x Solenoid, 1 V Starter Cable, 1" Starter Pad, Thigh Link, Brake Assembly, Control Panel w/decals (switches sold seperately) Handle, Support Bushing, Brake Pivot Y Weldment, Thigh Pad Bracket Switch, NO-NO-NC Grey Plunger Brake Lever, Offset Weldment, Console 3 w/decals RH Control Lever w/grip LH Control Lever w/grip 8 AA Harness, Wiring Weldment, Pin and Lock 30 3H60 1 Pin, Spring 5/3 x Bolt, Hex.5-0 x.5 Grade Bolt,.5-0 x 1.00 Hex 5 Y Bolt, Hex x 1.00 Grade 5 3 AA Nut,.5-0 Standard Hex Grade 5 Y 35 AA Washer,.50 Med Spring Lock Washer,.35 Reg Flat Bolt, Round Head Square Neck x 1.00 G Bolt, Round Head Square Neck x 1.5 G Nut, Locking-Nylon Nut, Locking-Nylon.38-16

10 8 ENGINE, HYDRAULIC AND MAIN FRAME ASSEMBLY

11 ENGINE, HYDRAULIC AND MAIN FRAME ASSEMBLY ITEM PART NO QTY DESCRIPTION 1 DT533 1 Hose, 3/8 SAE30r Fuel & Oil D1160 Washer,.50 Wide Heavy Flat Y 3 D113 Bolt, M6 x 1.00 x 10 Hex 8.8 Y D15 1 Bolt, /16-0 x 3.00 Hex 5 Y 5 D Switch (N.0.) 6 D Spacer,.68 x 1.38 x.35 Y D1806 Key, M5 x M5 x M30 RD 8 D Spring, Ext.900 x.135x.50 Y 9 D Pulley, V-belt.00x.39 w/bearing 10 D Clamp, Hose - 1/" Pinch 11 D Spring, Com 1.x.16x.50 Y 1 GDA Weldment, Pivot Idler Mount 13 M86863 Fitting, Tun 3/8 Hose Motor, Wheel HGM-1p-1 15 TCA15316 Assembly, Pump Pulley w/set Screw 16 TCA160 1 Fitting, Oil Drain 1 11H3 Pin, Cot.15 x.00 EXTP Y Tie Wrap, Black Bushing, Machine.50 x 1.5 x Bearing, Flange.50 x x.50 x Pulley, V-belt.8pd x Clutch Assembly, Ogura Plate, Clutch Dog Engine, Kawasaki 19hp FH580V Assembly, Hyd Pump Assembly, Hyd Pump Cover, Operator Presence Control Washer, Spring Y Assy, Rear Wheel Hub Belt, HA 68. EL AMD OHR Weldment, RH Brake Arm Weldment, LH Brake Shaft Hose, Hyd 1/ x 6 1/ Ezflex Weldment, Frame 3 w/decals Weldment, Idler Pivot Assy, Foot Plate Abrasion Sleeve Adapter,.5 FESW x 3/MJICX Adapter, Hydraulic Steel /8 "O" To Adapter, 8MJ-10MB90 1 M158 Shim,.00 x.8 x Ring, Retaining-External.50 x Grease Zerk,.5-8 Straight.69 LG Bolt, Hex x.5 Grade Bolt, Hex x 1.50 Grade Bolt, Hex x 1.5 Grade 5 D Key, Woodruff.185 x.5 9

12 ENGINE, HYDRAULIC AND MAIN FRAME ASSEMBLY ITEM PART NO QTY DESCRIPTION Bolt, 3/8-16 x 1.00 Hex Bolt, 3/8-16 x 1.5 Hex Bolt, 3/8-16 x.50 Hex Bolt, 3/8-16 x 3.5 Hex Bolt, /16-1 x.50 Hex Nut-Hex Washer,.35 Medium Spring Lock Y Washer-Flat-Steel.38 x 1.00 x Bolt, Round Head Square Neck.38-16x1.00 G Bolt, Round Head Square Neck.38-16x1.00 G Bolt, Round Head Square Neck.38-16x1.5 G Nut, Jam Grade Nut-Locking-Nylon 10- with Insert Nut-Jam Nut-Locking-Nylon Pin-Roll.156 x Screw, Machine 10- x.65 Panhead Nut-Locking-Nylon D Key,.50 x.50 x.995 TPR 10

13 PUMP COMPONENTS PD11 ITEM PART NO QTY DESCRIPTION Alignaball, 5/16 RH/Thread D08 Fitting, 90 9/16MOR x 3/8 Hose 3 D Fitting TCA Pump, Hydraulic TCA Pump, Hydraulic Switch, Plunger Diametral Pitch -N.O. -N.C Bolt, Hex 5/16-18 x 1.00 Grade Nut, Locking, Nylon 10- w/insert Nut, Locking, Nylon Screw, Machine 10- x.6 P/HD NS D19003 Pump Seal Kit 11

14 HYDRAULIC SCHEMATIC Item Description 1 Left Hydrostatic Pump Assembly Pump Block 3 Charge Pump System Change Check Shock Valve (Reverse) 5 Manual Bypass 6 Left Wheel Motor Cooling Orifice 8 System Change Check Shock Valve (Forward) 9 Charge Relief Valve 10 Right Hydrostatic Pump Assembly 11 Right Wheel Motor 1 Inlet Filter 13 Hydraulic Reservoir PD115 1

15 NOTES 13

16 1 DECK ASSEMBLY

17 DECK ASSEMBLY ITEM PART NO QTY DESCRIPTION Washer,.5 x x.10 D Pulley, Flat 5.0 x.38 w/bearing 3 D Washer, Blade D1806 Bearing, Flg 1.00 x 1.5 x Pulley, Spline Spindle Offset Pulley, V-belt 5. x.990 w/spl D019 Washer,.0 x.00 x.055 Fend Y 8 D J-bolt, 3/8-16 x.00 Y 9 GDA Pivot, Retainer Weld 10 GDU Blade, Lo-Lift 11 GDU Blade, 18" 1 H10 1 Nut-1/" Flange 13 H Retainer Spring, Chute Guard 15 M11935 Knob, Locking 16 N189 1 Spring, Tension 1 TCA Discharge Chute, 8" Deck 18 TCU18 1 Wheel, Gage Assembly, Spindle Housing Belt, HB 80.3 El AMD OHR Weldment, Idler Arm Weldment, 3" Deck w/decals 3 N/A Assembly, Front Wheel Caster (see page 16 for parts) Shield, Deck 3 w/decals Weldment, Idler Pivot Snap Ring, 1.00 x.0 Ext Grease Zerk, 1/-8 Straight.69 LG Bolt, Hex.38-16x Bolt, 3/8-16 x.5 Hex 5 Y Nut, Hex Grade 5 Y Bolt, x 1 Grade 5 Round Head Square Neck Bolt, 1/-0 x.50 Round Head Square Neck 5 Y Nut, Flange Nut, Low Crown Locking Acorn Washer,.06 x.813 x.065 Flat Y Nut, 3/-16 Flange Grade 8 Y Bolt, 5/8-11 x.00 Hex 8 Y Nut, Locking-Nylon Trim 1/ Bolt, 5/16-18 x.50 Hex 5 Y Bracket, Chute Support 15

18 WHEEL AND STRUT ASSEMBLY PD111 ITEM PART NO QTY DESCRIPTION 1 D Bushing, 1.03 x 1.50 x.19 D1806 Bearing, Flange 1.00 x 1.5 x Pin, Lock.38 x C-Spacer, 1.00 x 1. x Tube, 1.00 x.50 x Weldment, Caster Mount Bracket Weldment, Front Wheel Fork Wheel, Front 11 x x Bolt, x 6.00 Round Head Square Neck 10 AA Locknut, Crown Grease Zerk,.5-8 Straight.69 LG 16

19 SPINDLE ASSEMBLY PD113 ITEM PART NO QTY DESCRIPTION Spindle Assembly (Includes, 3,, 5, 15) Bearing, 6305LLC Casting, Spindle w/studs Spacer, 1.50 x x Shaft, Spindle Bolt, x 1.5 Round Head Square Neck Locknut,.5-16 Crown Y 8 N/A 1 Pulley, Cutter Housing - Refer to Deck Assembly on page Spacer, Spindle Top-Pulley Bolt, 5/8-11 x.00 Hex Nut, Standard Hex Grade 5 1 D Washer,.630 x 1.50 x.50 Flat 13 GDU Blade, x.80 Lift 1 GDU Blade, x.80 Lift Zerk, Grease S/O 1

20 WIRING HARNESS 1 PD106 ITEM PART NO QTY DESCRIPTION 1 AA Harness, Wiring 18

21 WIRING SCHEMATIC PD11 19

22 DECALS ITEM PART NO QTY DESCRIPTION 1 M Decal, Warning, Hot Surface TCU Decal, Directional Control 3 TCU Decal, Danger - Avoid Tipover AA Decal, Belt Path Decal, Warning 6 GDU105 1 Decal, Great Dane Decal, Danger - Thrown Objects Decal, Patent 9 GDU1056 Decal, Paw Print

23 DECALS WARNING Shield Missing. DO NOT Operate ITEM PART NO QTY DESCRIPTION Decal, Mower Pan Danger Decal, Warning 3 TCU Decal, Park Brake D Decal, Throttle 5 TCU180 1 Decal, General Caution 6 TCU Decal, PTO/Ignition D Decal, Surfer D183 1 Decal, Caution - Fire Hazard 9 M1155 Decal, Warning, Hot Surface Decal, Decal, Surfer Decal, Warning - Shield 13 GDU1056 Decal, Paw Print 3

24 Great Dane An Ariens Company 655 West Ryan Street Brillion, WI Fax