Great Dane GDWG17KAE User manual

cWARNING:The Engine Exhaust
from this product contains chemicals known
to the State of California to cause cancer,
birth defects or other reproductive harm.
California Proposition 65 Warning
OMGD10004 B2
D02-107
GD10004
B2
Gateway
GDWG17KAE, GDWG22KHE
OPERATOR’S MANUAL
North American Version
Litho in U.S.A.

Introduction
INTRODUCTION
Introduction
Using Your Operator’s Manual
This manual is an important part of your machine and
should remain with the machine when you sell it.
An engine manufacturer’s owner’s manual has been
provided with your machine. This will provide maintenance
and troubleshooting information for the engine installed in
your machine.
Reading your operator’s manual will help you and others
avoid personal injury or damage to the machine.
Information given in this manual will provide the operator
with the safest and most effective use of the machine.
Sections in your operator’s manual are placed in a specific
order to help you understand all the safety messages and
learn the controls so you can operate this machine safely.
You can also use this manual to answer any specific
operating or servicing 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 by
facing in the direction the machine will travel when going
forward. When you see a broken line (------), the item
referred to is hidden from view.
Special Messages
Your manual contains special messages to bring attention
to potential safety concerns, 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 the
manual that may help the operator in the operation or
service of the machine.
Record Identification Numbers
Gateway
GDWG17KAE Serial No. (414000 - 414999)
GDWG22KHE Serial No. (416000 - 416999)
If you need to contact an Authorized Service Center for
information on servicing, always provide the product model
and serial numbers.
You will need to locate the model and serial numbers for
the machine and for the engine of your machine and record
the information in the spaces provided.
DATE OF PURCHASE:
_________________________________________
DEALER NAME:
_________________________________________
DEALER PHONE:
_________________________________________
MX9259
MODEL NUMBER (A):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
SERIAL NUMBER (POWER UNIT) (B):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ENGINE SERIAL NUMBER (B):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ENGINE SPECIFICATION NUMBER (C):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
cCAUTION: Avoid injury! This symbol and text
highlight potential hazards or death to the
operator or bystanders that may occur if the
hazards or procedures are ignored.
IMPORTANT: Avoid damage! This text is used to tell
the operator of actions or conditions that might
result in damage to the machine.
A
B
C

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© 2001
OMGD10004 B2 - English
Table of Contents
Safety .....................................................................................................................................................................................1
Operating................................................................................................................................................................................6
Replacement Parts ...............................................................................................................................................................10
Service Intervals...................................................................................................................................................................11
Service Lubrication...............................................................................................................................................................12
Service Engine .....................................................................................................................................................................13
Service Transmission............................................................................................................................................................15
Service Mower......................................................................................................................................................................18
Service Electrical..................................................................................................................................................................21
Service Miscellaneous..........................................................................................................................................................24
Troubleshooting ....................................................................................................................................................................26
Storage.................................................................................................................................................................................29
Assembly ..............................................................................................................................................................................30
Specifications .......................................................................................................................................................................32
Index.....................................................................................................................................................................................33
Service Record GD ..............................................................................................................................................................34

Safety - 1
SAFETY
Safety
Understanding The Machine Safety Labels
MIF
The machine safety labels shown in this section are placed
in important areas on your machine to draw attention to
potential safety hazards.
On your machine safety labels, the words DANGER,
WARNING and CAUTION are used with this safety-alert
symbol. DANGER identifies the 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 symbol.
DANGER/POISON
MX9292 MX9258
•Shield eyes explosive gases can cause blindness or
injury.
•No sparks, flames, smoking.
•Sulfuric acid can cause blindness or severe burns.
•Flush eyes immediately with water get medical help fast.
•Keep out of the reach of children.
•Do not tip.
•Keep vent caps tight and level.
CAUTION
MX9295 MX9258
•This product is designed for professional and
commercial users.
•Operation training is required.
•Carefully read safety instructions.
•Know function of controls before operating.
•Practice with cutter blades off until confident.
•Clear mowing area of all debris.
•Keep all guards, covers and shields in place while
working.
•Do not disable or bypass any safety device.
•Always wear safety goggles while operating.
•Always park machine on level surface.
•Avoid contact with cutter blades; They may be rotating.
•Keep children and others clear from area.
•Set ground speed control to safe speed.
•Slowly and smoothly move speed control levers to start
and stop machine.
•Reduce speed and avoid sharp turns.
•Be careful on slopes; do not mow where stability or
traction is in doubt.
•To obtain additional operator manual and safety
instructions, contact Great Dane dealer or write Great
Dane Power Equipment, 4700 New Middle Rd.,
Jeffersonville, IN 47130, USA.

Safety - 2
SAFETY
DANGER
MX9293 MX9258
•Keep hands and feet away.
CAUTION
MX9294 MX9258
•Do not operate mower without chute deflector, mulching
plate or complete grass catcher assembly in position.
•Do not remove grass catcher, mulching plate or raise
the chute deflector until engine and blade(s) have stopped.
Emission Control System Certification Label
(Small Off-Road Gas Engines)
NOTE: Tampering with emission controls and
components by unauthorized personnel may result in
severe fines or penalties. Emission controls and
components can only be adjusted by EPA and/or
CARB authorized service centers. Contact your Great
Dane Equipment Retailer concerning emission
controls and component questions.
The presence of an emissions label signifies that the
engine has been certified with the United States
Environmental Protection Agency (EPA) and/or California
Air Resources 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 mobile equipment.
Emission Compliance Period (Small Off-Road
Gas Engines)
If your engine has the emission compliance category listed
on the emission control system certification or air index
label, this indicates the number of operating hours for
which the engine has been certified to meet EPA and/or
CARB emission requirements. The following table provides
the engine compliance period in hours associated with the
category found on the certification label.
Operating Safely
•Do not allow operation or service of the machine by
children or untrained adults.
•Read the operator’s manual and study the safety and
operation sections before operating the machine.
•Operate the machine in an open, unobstructed area
under the direction of an experienced operator.
•Learn the use of all controls.
•Operator experience is required to learn the moving,
stopping, turning and other operating characteristics of the
machine.
•Inspect machine before you operate. Be sure hardware
is tight. Repair or replace damaged, badly worn or missing
parts. Be sure guards and shields are in good condition
and fastened in place. Make any necessary adjustments
before you operate.
•Do not operate mower without discharge chute or entire
grass catcher in place.
•Check before each use that operator presence controls
are functioning correctly. Test safety systems. Do not
operate unless they are functioning correctly.
•Do not change the engine governor setting or
overspeed the engine.
•Check brake action before you operate. Adjust or
service brakes as necessary.
•Stop machine if anyone enters the area.
•Never raise mower decks when blades are running.
Agency Category Hours
EPA C 250
EPA B 500
EPA A 1000
CARB Moderate 125
CARB Intermediate 250
CARB Extended 500

Safety - 3
SAFETY
•If you hit an object, stop and inspect the machine. Make
repairs before you operate. Keep machine and
attachments properly maintained and in good working
order.
•Do not leave machine unattended when it is running.
•Only operate during daylight or with good artificial light.
•Slow down and be careful of traffic when operating near
or crossing roadways. Stop blades before crossing roads
or sidewalks. Use care when approaching blind corners,
shrubs, trees or other objects that may obstruct vision.
•Be aware of the mower discharge direction and make
sure that no one is in the path of the discharge direction.
•Use only accessories and attachments approved by the
manufacturer of the machine.
•Wear close fitting clothing and safety equipment
appropriate for the job.
•Always wear safety goggles or safety glasses with side
shields when operating the mower.
•Wear a suitable protective device such as earplugs.
Loud noise can cause impairment or loss of hearing.
•Do not wear radio or music headphones. Safe service
and operation requires your full attention.
Checking Mowing Area
•Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform the
job.
•Clear mowing area of objects that might be thrown.
Keep people and pets out of mowing area.
•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 travel over rough ground.
Parking Safely
1. Stop machine on a level surface, not on a slope.
2. Disengage PTO.
3. Lower attachments to the ground.
4. Lock park brake.
5. Stop engine.
6. Remove key.
7. Wait for engine and all moving parts to stop before you
leave the operator’s station.
Rotating Blades are Dangerous
HELP PREVENT SERIOUS OR FATAL ACCIDENTS:
MIF
•Rotating blades can cut off arms and legs.
•Keep hands, feet and clothing away from mower deck
when engine is running.
•Be alert at all times; drive forward carefully. People,
especially children, can move quickly into the mowing area
before you know it.
•Before backing up, shut off PTO and look down and
behind the machine carefully, especially for children.
•Do not mow in reverse.
•Shut off blades when you are not mowing.
•Do not operate machine if you are under the influence of
drugs or alcohol.
•Park machine safely before inspecting or unplugging
mower or bagger.
PROTECT CHILDREN:
•Never assume that children will remain where you last
saw them. Children are attracted to mowing activity; stay
alert to the presence of children.
•Keep children indoors when you are mowing. Turn the
machine off if a child enters the mowing area.
•Use extra care when you come to blind corners, shrubs,
trees or other objects that may block your vision.
•Do not let a child or an untrained person operate the
machine.
•Do not carry or let children ride on any attachment or
machine even with the blades off. Do not tow children in a
cart or trailer.
Avoid Tipping
•Slopes are a major factor related to loss-of-control and
tip-over accidents, which can result in severe injury or
death.

Safety - 4
SAFETY
•Drive across a hill - not up and down. If necessary, turn
slowly and in the downhill direction. Do not shift to neutral
and coast downhill.
•Avoid starting and stopping on a slope. If machine
stops, disengage mower blades and back down slowly.
•Do not drive where machine could slip or tip.
•Stay alert for holes and other hidden hazards in the
terrain.
•Keep away from drop-offs, ditches, and embankments.
•Slow down before you make a sharp turn or operate on
a slope.
•Mowing when grass is wet can cause reduced traction
and sliding.
Keep Riders Off
•Only allow the operator on the machine. Keep riders off.
•Riders on the machine or attachment may be struck by
foreign objects or thrown off the machine causing serious
injury.
•Riders obstruct the operator’s view resulting in the
machine being operated in an unsafe manner.
Checking Wheel Bolts
•A serious accident could occur causing serious injury if
wheel bolts are not tight.
•Check wheel bolt tightness often during the first 100
hours of operation.
•Wheel hardware must be tightened to specified torque
using the proper procedure anytime it is loosened.
Practice Safe Maintenance
•Only qualified, trained adults should service this
machine.
•Understand service procedures before doing work.
Keep area clean and dry.
•Never lubricate, service or adjust machine while it is
moving. Keep safety devices in place and in working
condition. Keep 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 power and stop the engine. Lock
park brake and remove the key. Let machine cool.
•Disconnect battery or remove spark plug wire before
making any repairs.
•Before servicing machine, carefully release pressure
from components with stored energy such as hydraulic
components.
•Keep all nuts and bolts tightened, especially blade
attachment bolts.
•Securely support any machine elements that must be
raised for service work. Lock service latches before
working on machine with raised attachments.
•Never run engine unless park brake is locked.
•Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Replace all worn or damaged safety and instruction decals.
•To prevent fires, remove any buildup of grease, oil or
debris from the machine, especially the engine
compartment.
•Charge batteries in an open, well-ventilated area, away
from sparks. Unplug battery charger before connecting or
disconnecting from the battery. Wear protective clothing
and use insulated tools.
•Do not modify machine or safety devices. Unauthorized
modifications may impair its function and safety.
•Do not wear radio or music headphones while servicing
the machine. Safe service requires your full attention.
Avoid High Pressure Fluids
•Hydraulic hoses and lines can fail due to physical
damage, kinks, age, and exposure. Check hoses and lines
regularly. Replace damaged hoses and lines.
•Hydraulic fluid connections can loosen due to physical
damage and vibration. Check connections regularly.
Tighten loose connections.
•Escaping fluid under pressure can penetrate the skin
causing serious injury. Avoid the hazard by relieving
pressure before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
•Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
•If an accident occurs, see a doctor immediately. Any
fluid 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
•Never remove fuel cap or add fuel with engine running
or hot. Allow engine to cool for several minutes.

Safety - 5
SAFETY
•Never store equipment with fuel in the tank inside a
building where fumes may reach an open flame or spark.
•Allow engine to cool before storing in any enclosure.
•To reduce fire hazard, keep engine free of grass, leaves
or excessive grease.
Tire Safety
Explosive separation of a tire and rim parts can cause
serious injury or death:
•Do not attempt to mount a tire without the proper
equipment and experience to perform the job.
•Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
•When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and not
in front of or over the tire assembly.
•Check tires for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.
Handling Fuel Safely
Fuel and fuel vapors are highly flammable and
explosive:
•Do not refuel machine while you smoke, when machine
is near an open flame or sparks, or when engine is running.
Stop engine and allow to cool before filling.
•Never remove the fuel cap or add fuel with the engine
running.
•Never fill fuel tank or drain fuel from a machine in an
enclosed area. Fill fuel tank outdoors.
•Prevent fires. Clean up spilled fuel immediately.
•Do not store machine with fuel in tank in a building
where fumes may reach an open flame or spark.
•Prevent fire and explosion caused by static electric
discharge. Use only non-metal, portable fuel containers
approved by the Underwriter’s Laboratory (U.L.) or the
American Society for Testing & Materials (ASTM). If using
a funnel, make sure it is plastic and has no screen or filter.
MIF
•Static electric discharge can ignite gasoline vapors in an
ungrounded fuel container. Remove the fuel container from
the bed of a vehicle or the trunk of a car and place on the
ground away from the vehicle before filling. Keep nozzle in
contact with container opening while filling.
•When practical, remove equipment from trailers or truck
beds and refuel them on the ground. If this is not possible,
use a portable, plastic fuel container to refuel equipment on
a truck bed or trailer.
•For gasoline engines, do not use gas with methanol.
Methanol is harmful to your health and to the environment.

Operating - 6
OPERATING
Operating
Daily Operating Checklist
❏Test safety systems.
❏Check tire pressure.
❏Check fuel level.
❏Check engine oil level.
❏Check transmission oil level.
❏Remove grass and debris from machine.
❏Clean air intake screen.
❏Check area below machine for leaks.
Console Controls
MX9254
A - Speed Control Lever
B - Tracking Adjustment Knob
C - Operator Presence Control Lever
D - Neutral Lock Lever
E - Handle Bar Grip
F - Steering/Reverse Control Grip Lever
G - Throttle Lever
H - Choke Control (may be incorporated into
throttle on some models)
I - PTO/Clutch Switch
J - Key Switch
Miscellaneous Controls
MX9255
A - Park Brake Lever
B - Hydraulic Pump Free-Wheel Levers
C - Fuel Shutoff Valve
Testing Safety Systems
Use the following checkout procedure to check for normal
operation of machine.
If there is a malfunction during one of these procedures, do
not operate machine. See your Great Dane dealer for
service.
Perform these tests in a clear open area. Keep bystanders
away.
A
B
C
D
E
F
E
F
C
D
GHI
J
cCAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
Move the vehicle to an outside area before
running the engine.
Do not run an engine in an enclosed area
without adequate ventilation.
•Connect a pipe extension to the engine
exhaust pipe to direct the exhaust fumes out of
the area.
•Allow fresh outside air into the work area to
clear the exhaust fumes out.
A
C
B

Operating - 7
OPERATING
Testing Operator Presence Safety Interlock
System
1. Lock park brake.
2. Engage neutral lock levers.
3. Move speed control lever to neutral position.
4. Move PTO/clutch switch to off position.
5. Do not depress operator presence levers.
6. Manual Start Engines Only: Turn key switch to run
position. Pull recoil starter.
7. Electric Start Engines Only: Turn key switch to start
position.
Result: The engine will crank but must not start (electric
start engines) or must not start (manual start engines).
Testing Park Brake
Stop the machine on a maximum 17°slope. Stop the
engine and lock the park brake.
Result: Park brake must hold the machine stationary. If the
machine moves more than 61 cm [24 in.] in one hour,
brakes need to be adjusted. See your Great Dane dealer.
Using the Park Brake
1. To lock brake, pull lever back firmly until it locks into
place.
2. To unlock, push lever to full forward position.
Starting the Engine
1. Open the fuel shut-off valve.
2. Lock park brake.
3. Engage neutral lock levers.
4. Move speed control lever to neutral position.
5. Move PTO/clutch switch to off position.
6. Move throttle lever to half-speed position and set choke
(separate choke control models). Move throttle lever into
choke position on models with choke incorporated into
throttle lever.
7. Manual Start Engines Only: Turn key switch to run
position. Pull recoil starter until the engine starts.
8. Electric Start Engines Only: Turn key switch to start
position for no more than five seconds. Release key to the
run position when engine starts.
•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.
9. Let the engine run at half-speed position for several
minutes to warm up before operating the machine. Reduce
choke setting as the engine warms up.
cCAUTION: Avoid injury! Children or bystanders
may attempt to move or operate an unattended
machine.
Always lock the park brake and remove the
key before leaving the machine unattended.
cCAUTION: Avoid injury! Engine exhaust fumes
contain carbon monoxide and can cause
serious illness or death.
Move the vehicle to an outside area before
running the engine.
Do not run an engine in an enclosed area
without adequate ventilation.
•Connect a pipe extension to the engine
exhaust pipe to direct the exhaust fumes out of
the area.
•Allow fresh outside air into the work area to
clear the exhaust fumes out.
IMPORTANT: Avoid damage! Starter may be
damaged if starter is operated for more than 20
seconds at a time:
•Wait two minutes before trying again if the engine
does not start.
IMPORTANT: Avoid damage! Unnecessary engine
idling may cause engine damage. Excessive idling
can cause engine overheating, carbon build-up and
poor performance.