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Gravely 250Z Lawn Mower User Manual

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1. 3 Disengage parking brake 4 Push unit to desired location 5 Engage parking brake 6 Levers must be returned to their original position in order to operate the unit Figure 5 TRANSPORTING UNIT ALWAYS shut off engine set parking brake and remove key when transporting unit on a truck or trailer Tie unit down securely Do not tie down by linkages guards cables or other parts that may be damaged STARTING AND SHUTTING OFF THE ENGINE NOTE DO NOT operate starter more than 15 seconds per minute as overheating and damage can occur If engine will not start see Troubleshooting on page 42 or refer to Engine Manual NOTE PTO must be disengaged and parking brake engaged prior to starting engine To start 1 Insert ignition key Figure 6 2 Move throttle control lever to middle position NOTE If engine is cold move choke control to the on position Once engine has started and is warmed up move choke control to the off position If engine is warm do not use choke 3 Turn ignition key to Start 3 position If engine does not start in five seconds release ignition key wait and then repeat Once engine has started ignition key will return to the Run 2 position Figure 6 To shut off 1 Disengage PTO 2 Set parking brake 3 Turn ignition key to Off 1 position CLEANING AND STORAGE WARNING AVOID SHARP EDGES which can cut Movement of parts can cut off fingers or a hand Wrap
2. DO NOT allow tools or other objects to come into contact with both terminals at the same time ALWAYS remove Negative cable first to reduce risk of sparks when removing battery ALWAYS connect Positive 4 cable first then connect Negative cable when installing battery After cleaning apply a thin coat of grease or petroleum jelly to terminals and cable ends to retard corrosion 34 WARNING EXPLOSIVE GASES can result in serious injury or death ALWAYS keep open flames sparks or smoking materials away from battery POISONOUS BATTERY FLUID contains sulfuric acid and its contact with skin eyes or clothing can cause severe chemical burns ALWAYS wear safety glasses and protective gear near battery DO NOT TIP any battery beyond 45 degree angle in any direction ALWAYS KEEP BATTERIES OUT OF REACH of children WARNING REVERSE CONNECTIONS may result in sparks which may result in injury ALWAYS connect disconnect cables in proper order WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Battery Electrolyte First Aid External contact Flush with water Eyes Flush with water for at least 15 minutes and get medical attention immediately Internal contact Drink large quantities of water Follow with Milk of Mag
3. Lydtrykk ved f rerens Lpa inn Ljudeffekt vid forarens ron Lpa i dB Kuljettajan korvaan kohdistuva nenpaine dBA Robocze ci nienie akustyczne na uchu Lpa decybelach Oper Press o do Som no Ouvido Lpa em dBA 90 90 Vibration Measure m sec at Operator Mesure des vibrations m s au niveau de l op rateur Vibration m s an des Bedieners Gemeten trilling bij m sec Vibrationsm linger m s ved brugerens Vibrazioni percepite dall operatore m sec Medida de vibraci n m seg en el operador Vibrasjonsm ling m s ved f rerens Vibrationsm tt m s vid f rarens m s kuljettajan Pomiar wibracji m sec operatora Medida Vibrac o m seg no Operador Hands Mains H nde De handen van de gebruiker Haender Mani Manos Hender K siss Rece M os X 3 2 2 5 M 0 5 2 5 Z 209 2 5 Feet Pieds F e De voeten van de gebruiker F dder Piedi Pies Fetter F tter Jaloissa Stopy P s X 0 2 0 5 Y 0 2 0 5 7 os 0 7 Seat Si ge Sitz De bestuurdersplaats Saede Sedile Asiento Sete Sate Istuimella Siedzenie Assento X 0 3 0 5 id 0 3 0 5 7 o5 0 6 INTRODUCTION THE MANUAL The purpose of this manual is to provide complete instructions for service maintenance disassembly repair and ins
4. 11 Move the control levers from forward to reverse several times to make sure it is adjusted to neutral Readjust if necessary 12 Stop the engine ADJUSTING CONTROL LEVERS To be done after neutral has been set Figure 13 1 If desired the steering control levers can be set to match be in line when in neutral Remove front ball joint from bottom of steering control lever on side which is going to be adjusted Screw ball joint on or off link rod to hydrostat so that control levers align Replace rod end on lower part of steering control lever If needed adjust parking brake interlock so that interlock is able to move up when both steering control levers are in neutral To do this loosen the clamping bolt on the adjustable member of the interlock and slide it in either direction until the interlock moves up and latches the ball joint mounting bolts Tighten the clamping bolt 22 ADJUSTING THE PARKING BRAKE 1 The parking brake may be adjusted through the use of the jam nuts on the brake rod which push against the compression spring which pushes on the caliper arm See Figure 14 Turn the nuts further on the rod clockwise to tighten the brake and further off the rod counterclockwise to loosen the brake Ensure when the brake is applied the caliper arms do not contact the return nuts on the rods in front of the caliper arms If they do back them off slightly When installing new pads in the ca
5. Screw the axle nut onto the axle and tighten to 300 400 ft Ibs 406 542 Nm 13 the brake caliper into position and insert bolts from the inside of the frame outward Use lock washer and nut and tighten 14 Position wheel on hub and insert lug nuts finger tight 15 Tighten lug nuts using the pattern shown in Figure 20 16 Lower the unit to the ground and start the engine Drive forward twenty feet and stop the engine Check the hydraulic fluid level The dipstick should read between the high and low markings OK 0630 Figure 20 HYDRAULIC DECK LIFT PRESSURE TEST Use this test for trouble shooting the hydraulic lift system if the lift becomes sluggish or loss of lift occurs 1 Place unit into the service position 2 Clean and disconnect the hydraulic hose at the lower side of hydraulic lift valve Figure 21 and install a 1500 psi minimum hydraulic pressure gauge using a tee fitting 3 Have someone depress center of seat to activate seat switch 4 Start the engine and run at about 3 4 throttle or faster 5 Move the deck lift lever to the raise position and hold Relief pressure should be 650 psi minimum from the Hydro Gear auxiliary pump 6 If the mower deck height creeps down during operation the hydraulic valve cylinder or hydraulic hose is faulty You will need to check the condition of the hoses and verify that there are no hydraulic leaks and the fittings are tight 7 Remove the valve R
6. To test a normally closed switch connect the ohmmeter across the switch terminals Meter should indicate a closed circuit zero resistance Activate the switch and the meter should move to open circuit infinite resistance Check from each terminal to ground switch case Meter should show open circuit infinite resistance Variation from test results described indicates a defective switch Ignition Switch NOTE Refer to the wiring diagram of the unit involved to determine switch functions and test using the meth ods described The ignition switch incorporates a number of functions although not all functions are used on all equipment The switch has three positions OFF RUN and a momentary contact START position Use an ohmmeter to check the continuity of the switch in each position OFF Position Should be continuity between contacts G and M These connections ground the engine magneto and stop the engine in the OFF position RUN Position Should be continuity between contacts B and A These connections supply power to the rest of the wiring harness Connections G and M open to each other START Position Hold switch in START position while testing There should be continuity between contacts 51 and S2 These connections apply power to close the solenoid contacts and operate the starter motor In addition to the above test place the switch in the run position and check between each contact and ground metal case
7. Faulty engine Fill fuel tank see Filling Fuel Tank on page 18 Replace spark plug Refer to Engine Manual Clean or replace air cleaner Refer to Engine Manual Clean or replace fuel filter Refer to Engine Manual Refer to Engine Manual or see your Gravely Dealer Battery light does not light up when starting engine 1 Discharged battery Charge battery see Charging the Battery on page 19 Oil pressure light is on 1 Oil pressure is low Refer to Engine Manual Fuel Water separator light is on 1 Fuel water separator filter dirty or damaged Clean or replace fuel water separator filter Refer to Engine Manual Engine is overheating 1 Engine oil level is low 2 Cooling fins screen on engine plugged with debris Add engine oil Refer to Engine Manual Clean engine and surrounding area Engine continues to run when ignition key is in the off position 1 Ignition ground wire disconnected 2 Ignition switch failure Connect ground wire to clean metal surface Replace ignition switch see your Gravely Dealer PTO or mower blades do not engage or shuts off 1 Operator presence switch not depressed 2 Eye Q alarm setting is turned on 3 The Eye Q circuitry senses an overload to the PTO clutch and is shutting off the PTO switch 4 Faulty PTO switch Depress operator presence switch
8. Original purchaser of this unit was instructed by the seller on safe and proper operation If unit is to be used by someone other than original purchaser loaned rented or sold ALWAYS provide this manual and any needed safety training before operation SAFETY DECALS AND LOCATIONS ALWAYS replace missing or damaged safety decals See Figure 2 for safety decal locations 1 DANGER TO AVOID SERIOUS INJURY OR DEATH Read Operator s Manual OL 1801 0 OL 4370 Keep children and others away from unit while operating Never direct discharge toward other 09 people Thrown objects can cause injury V Me M OL 0910 Look down and behind before and while backing Never carry children Go up and down slopes not across DO EN NOT operate on slopes over 17 OL 4450 If machine stops going uphill stop blade and back down slowly Avoid sudden turns Keep safety devices guards shields switches etc in place and working Check interlock system per manual before use Understand location and function of all controls Never allow operation by untrained persons 2 DANGER Always keep feet and hands away from BEN rotating parts OL 3030 Always stand clear of discharge area Do 23 not direct discharge toward other people X OL 0910 Keep people away from unit while operating O
9. care Use an approved fuel container NO smoking NO sparks NO flames ALWAYS allow engine to cool before servicing NEVER fill fuel tank when engine is running or hot from operation NEVER fill or drain fuel tank indoors Replace fuel cap securely and clean up spilled fuel 10 Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling When practical remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than from a gasoline dispenser nozzle Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device If fuel is spilled on clothing change clothing immediately Avoid Electric Shock Objects contacting both battery terminals at the same time may result in injury and unit damage DO NOT reverse battery connections Reversed connections may result in sparks which can cause serious injury Always connect positive cable FIRST and negative cable SECOND Explosive Gases from battery can cause death or serious injury Poisonous battery fluid contains sulfuric acid and its contact with skin eyes or clothing can cause severe chemical burns No flames No sparks No smoking near battery ALWA
10. engine service center Gravely Company does not recommend attempting to repair electrical components Most do not lend them selves to repair and you would have more money invested in time of repair than the part would cost and the results may not be as good 33 ELECTRICAL MEASUREMENTS In many electrical circuits there is some visible effect which indicates that the circuit is functioning properly A switch is turned ON and a lamp lights A key is turned a starter motor runs and cranks the engine If the lamp does not light or the starter motor does not run some means of measuring voltage current flow resistance and continuity is needed continuity means there is a complete electrical path through the circuit or component To know exactly what conditions exist in an electrical circuit requires AC and DC Voltmeter AC and DC Ammeter and an Ohmmeter Multimeter A single combination meter that does all of these things is available Such a meter is called a Multimeter or Volt Ohm multitester VOM Meters of this kind are avail able in many forms and all change functions and ranges with switches or by plugging test leads into dif ferent jacks Multimeters are available in two basic types Analog and Digital Analog Meters Analog Meters have a needle that moves across a scale to give a reading The longer the scale the easier it is to read and more accurate the reading will be A jeweled movement used in this type
11. i samsvar med Overensstammer med T ytt seuraavat vaatimukset Jest zgodny z De acordo com 98 37 EC 89 336 EEC 2000 14 EC Conformity Assessment Annex VI Annexe VI de l valuation de conformit Konformit tsbewertung Anhang VI Bijlage VI voor beoordeling van overeenstemming Vurdering af overensstemmelse Anneks VI Annesso VI della valutazione di conformit Anexo VI de la evaluaci n de la conformidad Samsvarsvurdering etter vedlegg VI Bed mning av verensst mmelse Bilaga VI Vaatimustenmukaisuuden arviointi liite VI Dodatek VI Ocena zgodno ci Anexo VI da Avalia o de Conformidade Representative Measured Sound Power Level Lwa Niveau de puissance acoustique repr sentatif mesur Repr sentativer gemessener Ger uschpegel Lwa Representatief gemeten geluidsniveau Lwa Repr sentativt m lt st jeffektniveau Lwa Livello di potenza sonora rappresentativo rilevato Lwa Nivel de potencia ac stica representativo medido Lwa Representativt malt lydeffektniva Lwa Representativ uppm tt ljudniv Lwa Tyypillinen mitattu nitehotaso Lwa Zmierzony reprezentatywny poziom mocy akustycznej Lwa N vel de Pot ncia de Som Medido Representativo Lwa Guaranteed Sound Power Level Lwa Niveau de puissance acoustique garanti Lwa Garantierter Ger uschpegel Lwa Gegarandeerd geluidsniveau Lwa G
12. into the end of the shaft Tighten securely 15 Tighten pulley lock bolt 16 Place belt on pulley 17 Replace cross channel 27 18 Lower the cover and start the engine Run the engine for 1 2 minutes After shutting off the engine check the hydraulic fluid level The dipstick should read between the high and low markings REPLACE WHEEL MOTOR Each drive wheel is mounted to a hydraulic drive motor The drive motors are maintenance free In the event of a failure the drive motors should be replaced 2 Hydraulic motor Figure 19 To Replace a Drive Motor 1 Loosen the wheel lugs 1 4 turn Figure 19 2 Jack the drive wheels off the ground and securely support the unit Remove the wheel Remove the brake caliper assembly by removing the two bolts Unscrew the axle bolt at the center of the hub and remove the hub The hub is a taper fit on the axle Use a wheel puller to assist in removal Mark the hydraulic lines and remove CAUTION Some fluid will leak out Clean up any spills Unscrew the two bottom bolts and pull the hydraulic motor out Remove the four bolt sleeves Insert the sleeves into the four bolt holes in the new hydraulic motor 10 Slide the motor into place and secure with two bottom bolts Apply Loctite to bolts 11 Reattach hydraulic lines to proper ports and tighten 12 Clean the axle and the inside of the hub Place hub over axle and lightly tap into position
13. o wiadczamy ze N s abaixo assinados certificamos em nome da ARIENS COMPANY que Type Type Typ Type Type Tipo Tipo Type Typ Tyyppi Typ Tipo Riding Rotary Lawn Mower Tondeuse gazon autoport e rotative Aufsitz Sichelm her Rijdende roterende grasmaaier Havetraktor med roterende knive Trattorino con unit di taglio rotativa Tractor cortac sped giratorio Plentraktor med rotorklipper Rotorakgrasklippare Ajoleikkuri Samobiezna rotacyjna kosiarka trawnikowa Tractor Cortador de Relva Trade Name Appellation commerciale Handelsbezeichnung Handelsnaam Firmanavn Nome Gravely commerciale Nombre comercial Handelsnavn Handelsbeteckning Kauppanimi Nazwa handlowa Nome da Marca Model Mod le Modell Model Model Modello Modelo Modell Modell Malli Model Modelo 992318 992319 Cutting Width cm Largeur de coupe cm Schnittbreite cm Maaibreedte cm Klippebredde cm 152 152 Larghezza di taglio cm Ancho de corte cm Klippebredde cm Klippbredd cm Leikkuuleveys cm ciecia cm Largura de corte cm Conforms to Est conforme Mit den Anforderungen der folgenden Richtlinien bereinstimmt Voldoet aan Eri overensstemmelse med E conforme a Cumple con Er
14. operate in reverse unless absolutely necessary ALWAYS look down and behind before and while backing Stop and inspect equipment if you strike an object or if there is an unusual vibration Repair if necessary before restarting Never make adjustments or repairs with the engine running Mower blades are sharp and can cut you Wrap the blade s or wear gloves and use extra caution when servicing them NEVER weld or straighten mower blades Rotation of one blade may cause rotation of the other blades Take all possible precautions when leaving unit unattended Shut off engine Remove wire from spark plug and secure it away from spark plug ALWAYS remove key to prevent unauthorized use Know the weight of loads Limit loads to those you can safely control and the unit can safely handle Disengage PTO when attachment is not in use ALWAYS turn off power to attachment when traveling crossing driveways etc Mow up and down slopes not across them DO operate on slopes of more than 17 degrees Use of a Rollover Protection System ROPS is recommended for slope operation Always wear a seat belt when operating unit using a Rollover Protection System ROPS Keep all movements on the slope slow and gradual Do not make sudden changes in speed or direction Avoid starting or stopping on the slope If tires lose traction disengage the blades and proceed slowly straight down the slope If you cannot back up a slope or you fee
15. position allowing the engine to operate 35 Switches are selected with regard to Current rating contacts must be of sufficient size to carry the required current Voltage rating switches insulated for specific voltages Case or housing switches that are exposed to moisture and must be sealed to prevent moisture from entering and Actuating type push pull rotary momentary contact or micro switches NOTE Check that the connections to the switches are secure and that a switch is being activated properly before performing electrical test on switches Safety switches on speed selector and clutch levers may be out of adjustment and not activating IMPORTANT When checking switches remove them from their respective circuit by disconnecting the wires from the switch at the connector s Damage could result to the meter or machine components if switches are left in Normally Open Switch To test a normally open switch key headlight safety or seat connect the ohmmeter across the switch terminals Meter should indicate open circuit infinite resistance Activate the switch The ohmmeter should read up scale to zero resistance Close Circuit This indicates the switch is operating properly Also check from each terminal to the switch case if case is metal reading should show infinite resistance indicating no short to ground Variation from test results described indicates a defective switch Normally Closed Switch
16. r kvalitet och produkt6verensstammelse Innehavare av tekniska data Laadusta ja vaatimustenmukaisuudesta vastaava johtaja Teknisen tiedoston haltija Kierownik do spraw jako ci i zgodno ci Przechowujacy Dokumentacje Techniczna Gestor de Qualidade e Conformidade Zelador de Arquivos T cnicos Signature Signature Unterschrift Handtekening Underskrift Firma Firma Signatur Namnteckning Allekirjoitus Podpis Assinatura 11 24 2003 Date Date Datum Datum Dato Data Fecha Dato Datum P iv ys Data Data CE Sound and Vibration Bruits et vibrations vibraci n CE CE lyd og vibrasjon CE CE CE Gerausch und Vibrationswerte CE ljudniv och vibrationer CE melu ja t rin Geluid en trilling CE stoj og vibration CE D wi ku i Wibracji Som e Vibra o CE Livello sonoro e vibrazioni CE Sonido y Ref EN836 2001 Model Mod le Modell Model Model Modello Modelo Modell Modell Malli Model 992318 992319 Modelo Oper Ear Sound Pressure Lpa in dBa Pression acoustique aux oreilles de l op rateur Lpa en dBA Ger uschpegel am Ohr des Bedieners Lpa in dBa Geluidsdruk bij het oor van de gebruiker Lpa in dBA Strojtryk ved brugerens ere Lpa m lt i Pressione sonora all orecchio dell operatore Lpa in Presi n de sonido en el o do Lpa in dBA
17. the battery Servicing of rectifiers built into the engine should be done by an approved engine manufacturer s service center Such a service center has access to the information and parts required to test and repair or replace engine components including rectifiers and regulators Units that contain both a rectifier and regulator are tested in a working circuit to make sure the regulator portion of the device is operating 37 WIRING DIAGRAMS Models 992018 020 027 TO lo PD2110 PD3230 38 Model 992029 030 034 035 SEAT SEAT PTO RELAY SWITCH 0000 87 as 00 POWER am E SUPPLY BLACK 2 a SWITCH 55 on ud 5 CLUTCH HOUR gt 4 PURPLE Hos 5 WHITE PURPLE 5 OIL BLACK OIL PRESSURE C BLACK BLUE WHITE d p A FUEL SOLENIOD RED YELLOW ni z ENGINE 9 REGULATOR PURPLE gt BLACK MAGNETO KILL WHITE BLACK El STARTER JL LL LL LL LL CI SOLENOID E CE LIGHT BLUE SZ RELAY BLACK eee E srt BRAKE i SWITCH DECR 5 1 27 BLACK Nu El PURPLE 1 x Q gt a D O x hs BATTERY O O O Go DI RED VIOLET O 62 PD3242 39 Model
18. 5 Mower Clutch Sheave 1 Long Mower Belt 2 Short Mower Belt 3 Springs Figure 10 CAUTION Use care when releasing idler spring tension Keep body parts well away from idlers when performing this operation 3 Arrange new mower belt s on deck short belt first Retighten short belt idler pivot bolt Install belts on sheaves Roll belts onto blade sheave last 4 Replace belt covers and return foot board to closed position Replacing the Hydro Pump Belt 1 Properly stop and park unit refer to unit Owner s Manual 2 Remove the mower belt from the mower clutch sheave See replacing Mower Belts 3 Remove old hydro pump belt by rolling belt off right hand hydrostat sheave first Figure 11 4 Install new pump belt by positioning belt on sheaves Roll belt onto right hand hydrostat sheave last 5 Put the mower belt back on mower clutch sheave See Replacing Mower Belts 1631 Spring ldler Engine Sheave 5 Right Hand Hydrostat 6 Left Hand Hydrostat Figure 11 TIRES Before each use make a visual check of tires The correct air pressure is 12 15 psi 83 103 kn m for the rear tires and 20 25 psi 138 172 kn m for the front tires MOWER BLADES NOTE If mower is used under sandy soil conditions replace mower blades when air lifts become eroded through at ends Figure 12 3 Air Lift Erosion 4 Air Lift 1 Cutting Blade 2 Square C
19. 992023 CAB POWER SUPPLY 2 HOUR BLACK METER BLACK OIL PRESSURE BLUE WHITE SWITCH FUEL SOLENIOD RED YELLOW LL ENGINE REGULATOR PURPLE MAGNETO KILL WHITE BLACK STARTER STARTER SOLENOID KEY E SWITCH BLACK 40 SEAT PTO RELAY SEAT SWITCH PINK S 1 2 BLACK PTO z SWITCH 5 gt CLUTCH 4 PURPLE WHITE 1 O PURPLE O 5 d Pe E BLACK z o S START RELAY 0000 BLACK Q 87a 87 86 85 O 3 5 2 7 od a 1 O BRAKE SWITCH Q 2 E 4 a 3 RED VIOLET PD3251 Models 992032 033 9 9 9 99 655555 ms XY O OQ P 41 TROUBLESHOOTING TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION Engine does not crank 1 PTO engaged 2 Parking brake disengaged 3 Loose or corroded battery cables 4 Discharged battery 5 Faulty starter Disengage PTO Engage parking brake Clean and tighten battery cables see Servicing the Battery on page 18 Charge battery see Charging the Battery on page 19 See your Gravely Dealer Engine cranks but does not start 1 Fuel tank empty 2 Faulty spark plug 3 Air cleaner is plugged or dirty 4 Fuel filter is dirty 5
20. E FLOW TEST Use this procedure for trouble shooting the drive system if the unit becomes sluggish or loss of drive becomes apparent This test is to be performed one side at a time 1 Block and jack the unit up so that both drive wheels are off the ground 2 Place hood into the full service position 3 Verify that the bypass valves are closed and there is no binding in the steering control linkage If binding occurs you will need to correct that problem before proceeding to the next steps 4 Make sure hydraulic fluid level is correct 5 Clean hydraulic hoses at the wheel motor 6 Disconnect the hydraulic hoses at the wheel motor note the proper orientation of hoses 7 Install a bi directional flow gauge 8 Have someone depress center of seat to activate seat switch 9 Start the engine and run at about 3 4 throttle or faster Release parking brake 10 Stroke the appropriate control lever full stroke forward and hold 11 Set the hydraulic system pressure to 200 400 PSI by using the restriction valve Note the GPM gallon per minute flow on the meter While keeping the pump in full stroke increase the hydraulic system pressure to 1000 1200 PSI by using the restriction valve Note the GPM flow on the meter Do not keep hydraulic system under pressure for an extended period of time to prevent damaging the hydraulic system by inducing too much heat to the system 12 the restriction valve and move the con
21. EPLACE LIFT VALVE The lift valve is located inside the chassis on the left side See Figure 21 1 Place hood in full service position 28 2 Clean hose fittings mark hoses for position and disconnect from valve CAUTION Some hydraulic fluid will leak out of the hoses Clean up any spills Loosen mounting bolts and remove valve Mount new valve and tighten bolts Connect hoses to proper ports The hydraulic system is self bleeding Check hydraulic fluid level after running the engine The dipstick should read between the high and low markings ook Cc Lift Valve Figure 21 HYDRAULIC DIAGRAM 992018 023 027 Lift Cylinder Lift Valve Deck Lower p Return Inlet Deck Lift Left Pump Forward High Pressure Left Right Wheel Upper Forward Wheel Motor High Reverse Motor Pressure High Pressure Reverse High Pressure PRESSURE mmm RETURN SUCTION PD1772 29 Models 992020 029 030 032 033 034 035 Wheel Motor Lift Cylinder Deck Lower MM Deck Lift Left Pump Right Pump Ex Forward Upper High B Pressure Soen Ge Pressure ci d A Reverse High Pressure Lower
22. GRAVELY Promaster 250Z 260Z 2722 Service Manual 029 030 H 027 992018 020 023 992032 033 035 034 09254300 8 04 Printed in USA TABLE OF CONTENTS Introduction 5 The Manual 5 Service and Replacement Parts 5 Product Registration 5 Unauthorized Replacement Parts 5 Disclaimer 5 Technical Service Communications 5 5 Safety 6 Safety Alert Symbol 6 Signal 6 5 6 Practices and Laws 6 Required Operator Training 6 Safety Decals And Locations 6 Safety 8 Specifications 12 Controls and Features 14 General Maintenance amp Adjustments 15 Maintenance 15 Service and Adjustments 16 Service Positions 16 Moving Unit Manually 16 Transporting Unit 17 Starting and Shutting Off the Engine 17 Cleaning and 17 Filling Fuel Tank 18 Easteners Lee seis da themed ehh 18 General Lubric
23. L 4370 Shut off engine remove key and read manual before you adjust or repair unit ex OL 4010 NO STEP Always keep feet away from rotating parts OL 4420 3 WARNING Always stand clear of discharge area Do not operate mower unless guards are in ec operating position bagger is attached OL 3320 4 HOT SURFACES DO NOT touch parts which are hot from operation ALWAYS allow parts to cool AVOID INJURY Stay clear of rotating fan OL 4740 DANGER PELIGRO Avoid injury Stay clear of rotating parts isque de blessures ne pas s approcher des pi ces en mouvement ll aS cx Do not operate mower Ne jamais utiliser No operar segadora unless guards are in tondeuse sans menos que las defensas f xv operating position or protecteursurle esten en posicion de CIC bagger is attached canal d ejection ou operacion o el sans le bac monte recogedor este tijo Evitar lesiones Mantenerse alejado de las piezas giratorias DANGER PELIGRO Read the operator s manual If machine stops going uphill stop blade and Keep children and others away from unit while Ier down slowly operating Avoid sudden turns Never direct discharge toward other people e Keep safety devices guards shields switches Thrown objects can cause injury ete in place and workin Look down and behind b
24. Motor KT gt PRESSURE mmm RETURN SUCTION 30 Forward High Pressure Right Upper Wheel MOWER DECK Mower Spindles This unit utilizes a maintenance free extended life spindle No routine maintenance is required In the event of bearing failure or a bent shaft the spindle should be replaced To Remove the Spindle 1 Place the unit in service position Turn key off and remove the spark plug wire from contact with spark plug 2 Remove cutting blade by unscrewing bolt CAUTION Use sturdy gloves or padding to protect hands when working with mower blades 3 Remove belt from pulley 4 Remove pulley by unscrewing bolt Lift pulley off the shaft and check placement and condition of key 5 Unbolt spindle from deck To Install Spindle 1 Bolt new spindle to mower deck 2 Place square key in position and slide pulley down the shaft Tighten bolt and washer 3 Replace belts 4 Install blade using flat washer lock washer and bolt Torque to 70 ft 105 95 Nm ANTI SCALP ROLLERS All of the anti scalp rollers are maintenance free If any roller shaft or weldment shows excessive wear it should be replaced The caster type rollers are replaced by removing the top pin and dropping the weldment with roller out the bottom Note the position of spacers and bushings for installation The rollers are replaced by removing the shaft Not
25. PORTANT DO NOT fast charge Charging at a higher rate will damage or destroy battery ALWAYS follow information provided on battery by battery manufacturer Contact battery manufacturer for extensive instructions to charge battery 1 Put unit into service position to gain access to battery 2 Disconnect Negative cable first then Positive 4 cable 3 Remove hold down and remove battery 4 Place battery on bench or other well ventilated place where electrolyte spill will not create damage 5 Connect Positive lead of charger to Positive terminal Connect Negative lead to Negative terminal 6 Charge battery at two and half amps for ten hours or until all cells are gassing freely 7 Reinstall battery into unit and connect Positive cable first then Negative cable SWITCHES Switches either open a circuit to stop current flow or close and allow current to flow through A normally open N O switch prevents current flow until the switch is actuated completing the circuit and allowing current to flow through it An example is a light switch the lights are off until the switch is actuated and the lights go on A normally closed N C switch allows current to flow until the switch is actuated breaking the circuit and stopping current flow through it An example is an ignition switch that grounds the magneto when in the off position completing the circuit but opens the circuit when in the ON
26. YS wear safety glasses and protective gear near battery Use insulated tools DO NOT TIP battery beyond a 45 angle in any direction ALWAYS keep batteries out of reach of children Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling ALWAYS block wheels and know all jack stands are strong and secure and will hold weight of unit during maintenance Release pressure slowly from components with stored energy NEVER attempt to make any adjustments to unit while engine is running except where specifically recommended Stop engine remove key or spark plug wire and wait for all moving parts to stop before servicing or cleaning Check parking brake operation frequently Adjust and service as required ALWAYS maintain unit in safe operating condition Damaged or worn out muffler can cause fire or explosion Maintain or replace safety and instruction labels as necessary NEVER store unit with fuel in fuel tank inside a building where any ignition sources are present Shut off fuel and allow engine to cool completely before storing in closed area or covering unit Clean grass and debris from unit especially from around muffler and engine to help prevent fires For extended storage shut off fuel and clean unit thoroughly See engine manual for proper storage Lower cutting deck unless a po
27. aranteret st jeffektniveau Lwa Livello di potenza sonora garantito Lwa Nivel de potencia ac stica garantizado Lwa Garantert lydeffektniva Lwa Garanterad uppm tt ljudniv Lwa Taattu nitehotaso Lwa Gwarantowany reprezentatywny poziom mocy akustycznej Lwa N vel de Pot ncia de Som Garantido Lwa 992318 104 dBA 992319 104 dBA 992318 105 dBA 992319 105 dBA Notified Body Organisme Zertifizierungsstelle SNCH Aangemelde instantie Bemyndiget organ Organismo notificato 11 Route de Luxembourg Organismo notificado Teknisk kontrollorgan Anm lt organ L 5230 Sandweiler Ilmoitettu laitos Organ za wiadczajacy Organismo Certificador Philip J Smucker Quality and Conformance Manager Keeper of Technical File NU Responsable de la qualit et de la conformit des produits D positaire de la fiche technique Manager Qualit tssicherung und Konformitat Archivar der technischen Akte Kwaliteits en Ariens Company normalisatiemanager Beheerder van technische bestand Cheffor Brillion WI 54110 0157 USA kvalitet og overensstemmelse Indehaver af tekniske data Responsabile della qualit e della conformit del prodotto Depositario del file tecnico Gerente de calidad y conformidad Depositario del archivo t cnico Kvalitet og samsvarsansvarlig innehaver av teknisk fil Chef f
28. atic Tire Pressure Front 20 25 psi Rear 12 15 psi Lift system Hydraulic Power Take Off Electric PTO Clutch Brake Cutting Width in cm 60 152 72 183 60 152 50 127 Cutting Height in cm 1 5 2 5 12 7 Cutting Increments in cm Infinite between 1 5 2 5 12 7 13 CONTROLS AND FEATURES N PER MS SU LL Mower Deck with Chute Deflector 12 Ignition Switch Fuel Shut off Valve 13 Power Take Off PTO Switch Parking Brake 14 Steering Levers Battery 15 Mower Lift Lever Hour Meter 16 Seat Adjustment Lever Oil Pressure Indicator 17 Seat Suspension Adjustment Knob not on Engine Frame and Hood model 992034 Fuel Tanks and Caps 18 Height of Cut Indicator 9 Choke Control not on EFI models 19 Hydraulic Oil Reservoir 10 Malfunction Indicator Light 20 Engine Hood Latch 11 Throttle Lever 21 Cylinder Stop Storage Post 22 Cylinder Stops 1 2 3 4 5 6 7 8 Electronic Fuel Injection Figure 3 14 GENERAL MAINTENANCE amp ADJUSTMENTS MAINTENANCE SCHEDULE Proper maintenance can prolong the life of unit The following chart shows the recommended service schedule More frequent service may be required due WARNING AVOID INJURY Read and to working conditions Heavy loads high ambient understand the entire Safety section before temperatures dusty conditions or airborne debris proceeding See the maintenance in
29. ation 18 Servicing the Battery 18 Basic Engine Maintenance 19 Belts EE EX EE DE 20 Mower 21 Adjusting Control Levers 22 Adjusting the Parking Brake 22 Adjusting Unit To Track Straight 22 Leveling the Mower Deck 23 Engine 1 2 2 22 Das te ed de 24 Engine Troubleshooting 24 Removing the Engine 25 Installing the Engine 25 Electric Cehe ied he eed Ps 25 Drive leo ie IRI RA 26 Checking the Hydraulic Fluid Level 26 Changing Hydraulic Fluid and Filter 26 Hydraulic Drive 26 Replacing the Hydraulic Pump 27 Replace Wheel 27 Hydraulic Deck Lift Pressure Test 28 Replace Lift 28 Hydraulic Diagram 29 Mower Deck 31 Anti Scalp 31 Front Suspension 32 Electrical v Le et aci ei 33 LEAD es ce SE 33 Electrical Measurements 33 ii IUe Peek Ae 34 Solenoid and 36 FUSES C 36 Diodes and Rectifiers 36 Wiring 38 Troubleshooti
30. ator leaves seat SPECIFICATIONS Model Number 992018 992023 992027 Model PM260Z 25 HP Kohler 2502 20 HP Briggs 8 2602 25 HP Kohler with with 50 Inch Deck Stratton with 50 Inch 72 Inch Deck Deck Length in cm 87 221 90 229 Height in cm 50 127 Width in cm 63 160 85 216 Weight Actual Ibs kg 1100 499 1080 490 1259 572 Battery 12 volt Brakes Hydro Dynamic Disk Parking Turning Radius 0 Tire Size Front 15x6 6 15x6 6 15x6 6 Rear 23 x 10 5 12 23 8 5 12 12 1 5 12 Engine Manufacturer Kohler Briggs amp Stratton Kohler Model Number CV25S 351777 CV25S Cycle 4 Engine Power 25 HP 20 HP 25 HP HP KW min 1 18 6 KW min 14 7 KW min 1 18 6 KW min 1 Starting System Electric Fuel Tank Capacity 9 gals US 34 liters Fuel See Engine Manual Idle RPM 1800 Governed RPM 3600 Air Cleaner Large Capacity Dual ELement Cooling Capacity Air Cooled Engine Oil Type See Engine Manual Spark Plug Gap See Engine Manual Transmission Hydrostatic Drive Speed Forward Max Reverse Max 9 MPH 4 5 MPH Transmission Lube Mobil 1 15W 50 Synthetic Drive Clutch Hydrostatic Tire Pressure Front 20 25 psi Rear 12 15 psi Lift system Hydraulic Power Take Off Electric PTO Clutch Brake Cutting Width in cm 50 127 72 183 Cutting Height
31. blades wear gloves and use extreme caution when servicing 17 IMPORTANT Never spray unit with water or store unit outdoors Water can seep into sealed bearings and reduce component life Bearings are sealed against dirt and debris only A unit that is excessively dirty should be cleaned before work starts Cleaning will occasionally uncover trouble sources Dirt and abrasive dust reduce the efficient work life of parts and can lead to costly replacement WARNING AVOID INJURY Read and understand the entire Safety section before proceeding Short Term NEVER spray unit with high pressure water or store unit outdoors Inspect unit for visible signs of wear breakage or damage Keep all nuts bolts and screws properly tightened and know unit is in safe working condition Store unit in a cool dry protected area Long Term Clean unit thoroughly and lubricate Touch up all scratched painted surfaces Remove weight from wheels by putting blocks under frame or axle When storing unit for extended periods of time remove all fuel from tank and carburetor run dry Refer to Engine Manual Clean and charge battery Charge battery every three to four weeks when storing unit When taking unit out of extended storage 1 Check for any damage or loose parts Repair replace or tighten hardware before operation especially blade attachment bolts 2 preservative fluid was used in fuel tank drai
32. by sitting on seat Turn off the alarm that deactivates the PTO on a regular schedule See the Owner s Manual Check the mower deck for clogging or debris Check the electrical system to the clutch for damage or wear See your Gravely Dealer 42 TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION Unit does not drive Parking brake engaged Transmission bypass levers open Hydraulic oil level low Faulty hydraulic drive system 1 2 Disengage parking brake Close transmission bypass levers see Moving Unit Manually on page 16 Add hydraulic oil see Checking Hydraulic Oil Level on page 26 See your Gravely dealer 43 om GRAVELY E BRAVE LY A Division of Ariens Company 655 West Ryan Street P O Box 157 Brillion WI 54110 0157 920 756 2141 Fax 920 756 2407 www gravely com WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
33. can be used for isolate engine problems and give possible causes and several types of engines Use only those possible corrective action responses causes and corrective actions that apply to the unit TROUBLE POSSIBLE CAUSES CORRECTIVE ACTION Refer to Key Below Black Exhaust 1 20 22 25 29 31 32 33 repair or replace Blue White Exhaust 4 20 25 31 33 34 repair or replace Difficult Starting 1 5 7 8 9 10 20 21 22 29 31 32 33 repair or replace Erratic Running 1 7 8 9 10 20 21 23 26 29 33 59 62 repair or replace Excessive Fuel Consumption 1 20 22 23 25 39 31 32 33 repair or replace High Oil Pressure 4 41 repair or replace Knocking 22 26 29 31 33 36 46 59 repair or replace Loss of Power or System 1 8 10 20 21 22 23 25 26 31 32 33 repair or replace Low Cranking Power 2 3 4 11 repair or replace Low Oil Pressure 4 36 37 39 repair or replace Misfiring 10 20 25 26 28 29 32 repair or replace Overheating 1 19 25 repair or replace Poor Compression 25 28 29 31 32 33 34 59 repair or replace Starts and Stops 1 6 10 62 repair or replace see electrical systems see engine service manual Vibration 20 23 25 26 29 33 45 49 repair or replace Will Not Crank 2 11 45 charge battery or replace Will Not Start 1 10 62 repair replace See electrical systems see engine service manual TROUBLESHOOTING KEY 1 Restriction in air cleaner 22 Incorrect grade of
34. case of internal contact DO NOT induce vomiting IMPORTANT DO NOT fast charge Charging at a higher rate will damage or destroy battery ALWAYS follow information provided on battery and battery charger Contact battery manufacturer and battery charger manufacturer for detailed instructions 1 Remove battery from unit see Battery Removal and Installation on page 19 Place battery on bench or other well ventilated area 3 Connect positive lead of charger to positive terminal and negative lead to negative terminal Charge battery according to the instructions from battery charger manufacturer and battery manufacturer Storage The battery is a perishable item and it should be stored properly to obtain a long useful life Batteries not in use will self discharge If the battery will not be used for more than three months it should be removed and stored in a cool dry place Any collection of dirt grease or electrolyte should be removed from the top of the battery The battery must be recharged monthly Before reinstalling the battery in the spring it should always be fully recharged BASIC ENGINE MAINTENANCE See your engine manual and Engine Chapter of this manual for detailed information on the operation and maintenance of your engine 1 Each day before operating check the level of the oil in the engine Never operate the engine when the oil level is below the add mark Each day befo
35. doctor familiar with this form of injury CHECKING THE HYDRAULIC FLUID LEVEL A check of the hydraulic fluid level should be made daily NOTE The oil level should be centered between the two marks on the dipstick To Check First remove any dirt that may be around the cap on the tank Remove the dipstick and check the oil level If required add Mobil 15W50 synthetic oil through the dipstick tube Do not overfill CHANGING HYDRAULIC FLUID AND FILTER The hydraulic fluid and filter should be changed every 500 hours of operation To drain the hydraulic oil reservoir remove the filter and catch the hydraulic oil in a pan The filter for the hydraulic system is located under the chassis behind the left rear wheel It is accessed from the rear of the unit To Replace the Filter 1 Unscrew the filter and dispose of properly Allow tank to drain into container 2 Place a film of oil on the new filter s gasket 3 Screw the filter on until it makes contact with the sealing surface of the filter head 4 Turn the filter by hand an additional 1 2 to 3 4 turn 5 Fill the hydraulic oil reservoir to the top mark on the dipstick It will take about 5 quarts Use Mobil 15W50 synthetic oil Start the engine and run for 1 to 2 minutes 6 After shutting off the engine check the fluid level The dipstick should read the fluid level between the high and low markings 7 Properly dispose of waste oil HYDRAULIC DRIV
36. dult Keep area of operation clear of all toys and debris Thrown objects can cause injury Check for weak spots on docks ramps or floors Avoid uneven work areas and rough terrain Stay alert for hidden hazards or traffic DO NOT operate near drop offs ditches or embankments Unit can suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in Data indicates that operators age 60 and above are involved in a larger percentage of riding mower related injuries These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury Read the entire Owner Operator manual and other training material If the operator or the mechanic cannot read the manual it is the owner s responsibility to explain it to them Only the user can prevent and is responsible for accidents or injuries occurring to themselves other people or property Only trained adults may operate unit Training includes actual operation Local regulations may restrict the age of the operator NEVER allow children to operate or play on or near unit Be alert and shut off unit if children enter area NEVER operate unit after or during the use of medication drugs or alcohol Safe operation requires your complete and unimpaired attention at all times DO NOT wear loose clothing or jewelry and tie back hair that may get caught in rotating parts Wear adequate out
37. e the cause may be either electrical or mechanical To check electrically connect a voltmeter across the coil of the device and activate the circuit that operates the relay or solenoid If the meter indicates no voltage is applied the cause is in the control circuit If the meter indicates proper voltage across the coil but the device does not function remove the power disconnect the wiring and check the continuity of the coil with an ohmmeter The meter should indicate resistance in the order of 3 to 5 ohms if the coil is intact A high resistance indicates an open coil and a defective device There are also a number of mechanical problems that may cause the problem The starter solenoid in the Ariens equipment is a sealed unit used to actuate the starter motor on the engines These solenoids may have three or four 36 connections The two large connections carry high current to operate the starter motor The small connections are connected to the coil and carry the control current To check the solenoid disconnect the cables to the starter motor turn the ignition switch to the start position and listen for the solenoid to snap inside contacts closed If no snap is heard check across the coils with a voltmeter The voltage should read 12 volts with the ignition switch in the start position If no voltage appears the defect is in the start circuit If the voltage is correct turn off the power and check continuity of
38. e the position of spacers for installation 31 FRONT SUSPENSION The front suspension consists of a weldment that is a square tube Figure 22 A pivot pin holds the axle to the chassis Two caster wheels are attached The front axle is maintenance free except for one grease fitting atthe chassis for the pivot pin This fitting is greased as needed with Sten Mix Hi Temp grease or equivalent 1 Pivot Pin 3 Dust Cap 2 Spindle 4 Bearing Figure 22 To Replace the Caster Wheel 1 Support the axle to keep the wheel off the ground 2 Remove dust cap and spindle nut at top of spindle 3 Lift axle to allow caster spindle to drop out of sleeve check washers bearings and spacers for position 4 Place washers bearings and spacers onto the new caster spindle 5 Insert spindle into the axle sleeve 6 Place washer and nut onto the spindle and tighten Fork should pivot freely with no end play 7 Replace dust cap 32 ELECTRICAL TOOLS There are some specialized tools and test equipment that are needed for electrical repair work A brief description of these follows Long or needle nose pliers used to connect or bend wires and connectors in close quarters Diagonal cutters used to cut wires or trim connec tions Wire stripper crimping tool available separately or as a combination tool Used to strip insulation from wires of various sizes crimp terminals and connector or wires Soldering gun or solde
39. efore and while backing Check interlock system per manual before use Never carry children Understand location and function of all controls Go up and down slopes not across Never allow operation by untrained parsons POUR EVITER LES BLESSURES GRAVES PARA EVITAR DANOS SERIOS O LA OU LA MORT MUERTE Lire le manuel d utilisation Leer el manual del operador loigner les enfants et tout autre personne Mantenga la unidad alejada de los ni os y otras pendant le fonctionnement de la machine personas cuando est en funcionamiento Ne jamais d charger directement en direction Nunca dirija la descarga hacia otras personas de quelqu un Des particules projet es que los objetos lanzados pueden provocar peuvent provoquer des blessures Regardez derri re et sur les c t s lorsque vous reculez Ne transportez jamais d enfant Nunca monten ni os Tondez toujours de haut en bas et Suba y baje pendientes no transversalmente inversement jamais le long des pentes Si la maquina se detiene subiendo cuesta Si la machine s arr te en montee Debrayez desactive la cuchilla y baje lentamente Evite viradas subitas Mantenga artefactos de seguridad defensas lesiones Antes y durante retroceso mirar hacia abajo detras Maintenez toujours en place tous les protectores interruptores et en su lugar y elements de s curit protecteurs trabajando interrupteurs et Ve
40. ent 6 Loosen the locknuts on the side where the chains are slack and slide the bolt down the slot until the chain is tight 7 Tighten bolt and nuts in mower mounting brackets 8 Lift mower and remove blocks 9 Measure height of deck at each side Measurements must be within 1 16 1 5 mm of each other 10 If measurements are out of range fix by adjusting chains on low side of deck 11 Once deck is level side to side measure height of deck at middle of front and on both sides of rear Front of deck should be 1 8 3 mm lower than rear 12 To adjust loosen rear hex nut of the front mower lift pivot on each rod 13 Turn the front hex nut on each rod until mower is 1 8 8 mm lower in front NOTE If mower cannot be leveled it may be neces sary to loosen the rear nut of the rear mower lift pivot to get more threads at the front of rod for adjustment After loosening rear nut and adjusting level tighten front nut on rear mower lift pivot 23 14 Tighten rear hex nut on each rod that was loosened in step 11 Front of Unit PF 1920 Front Mower Lift Pivot Rear Mower Lift Pivot Hydraulic Cylinder Rod Rear Hex Nut Front Hex Nut Chains Lock Nuts and Slots Mower Mounting Brackets Figure 16 ENGINE TROUBLESHOOTING The following troubleshooting chart is to be used to The troubleshooting key is generic and
41. er garments NEVER wear open sandals or canvas shoes during operation Wear adequate safety gear protective gloves and footwear Wear proper footwear to improve footing on slippery surfaces Always wear safety goggles or safety glasses with side shields when operating mower Moving parts can cut or amputate fingers or a hand Wrap blade s or wear gloves to service On multiblade mowers rotation of one blade will cause all blades to rotate NEVER place your hands or any part of your body or clothing inside or near any moving part while unit is running ALWAYS keep hands and feet away from all rotating parts during operation Rotating parts can cut off body parts ALWAYS keep body and hands away from pin holes or nozzles which eject hydraulic fluid under pressure DO NOT touch parts which are hot Allow parts to cool ALWAYS keep hands and feet away from all pinch points Fumes from the engine exhaust can cause death or serious injury DO NOT run engine in an enclosed area Always provide good ventilation Read understand and follow all instructions in the manual and on the machine before starting Understand How to operate all controls The functions of all controls How to STOP in an Emergency Braking and steering characteristics Turning radius and clearances Keep safety devices or guards in place and functioning properly NEVER modify or remove safety devices Do not operate without either entire gras
42. fuel 43 Faulty suction pipe 2 Bad electrical connection 23 Sticking throttle restricted movement 44 Choked oil filter 3 Faulty starter motor 24 Exhaust pipe restriction 45 Bad solenoid switch 4 Incorrect grade of lubricating oil 25 Leaking cylinder head gasket 46 Incorrect piston height 5 Low cranking speed 26 Overheating 47 Damaged fan 6 Fuel tank empty 27 Cold running 48 Faulty engine mounting 7 Controls not in correct operation 28 Incorrect tappet adjustment 49 Incorrectly aligned flywheel and or position flywheel housing 8 Blocked fuel feed line 29 Sticking valves 50 Faulty thermostat 9 Faulty fuel lift pump 30 Incorrect high pressure pipes 51 Restriction in water jacket 10 Choked fuel filter 31 Worn cylinder bores 52 Loose fan belt 11 Battery capacity low 32 Pitted valves and seats 53 Choked radiator 12 Air in fuel system 33 Broken worn or sticking piston ring s 54 Faulty water pump 13 Faulty fuel injection pump 34 Worn valve stems and guides 55 Choked breather pipe 14 Faulty fuel injectors or incorrect type 35 Restriction in air cleaner 56 Damaged valve stem oil deflector if fitted 15 Incorrect use of cold start equipment 36 Worn or damaged bearings 57 Coolant level too low 16 Faulty cold start equipment 37 Insufficient oil in sump 58 Blocked sump strainer 17 Broken fuel injection pump drive 38 Bad defective oil temperature switch 59 Broken valve spring 18 Incorrect fuel pump timing 39 Oil pump worn 60 Exhaust or vacuum pipe leak 19 Incorrect val
43. in cm 1 5 2 5 12 7 Cutting Increments in cm Infinite between 1 5 2 5 12 7 12 Model Number 992020 992029 992030 992032 992033 992034 992035 Model 2602 25 2602 25 2722 25 272226 2602 26 2502 23 2502 23 Kohler Kawasaki Kawasaki EFI Kohler Kawasaki Kawasaki Kawasaki w 60 deck w 60 deck w 72 deck w 72 deck w 50 deck w 50 deck w 50 dek Length in cm 80 203 84 213 4 80 203 Height in cm 50 127 Width in cm 73 185 85 216 73 185 63 160 Weight Actual lbs kg 1125 510 1259 572 1125 510 1100 499 Battery 12 volt Brakes Hydro Dynamic Disk Parking Turning Radius 0 Tire Size Front 15 x 6 6 Rear 23 x 10 5 12 Engine Manufacturer Kohler Kawasaki Kohler Kawasaki Model Number CV25S FH721V CV26S FH601V FH680V Cycle 4 Engine Power HP kw 25 18 6 26 19 3 19 14 1 23 17 2 Governed RPM Governed RPM 3600 Idle RPM 1800 Starting System Electric Fuel Tank Capacity 9 gals US 34 liters Fuel See Engine Manual Air Cleaner Large Capacity Dual ELement Cooling Capacity Air Cooled Engine Oil Type See Engine Manual Spark Plug Gap See Engine Manual Transmission Hydrostatic Drive Speed Forward Max 9 MPH Reverse Max 4 5 MPH Transmission Lube Mobil 1 15W 50 Synthetic Drive Clutch Hydrost
44. l surface ALWAYS shut off engine set parking brake and remove ignition key Ensure unit is secure and will not tip over When a lift is used strap and clamp unit to the lift 1 Place steering levers in neutral position and set parking brake 2 Unhook hood latches Firmly grasp hood frame handle and lift to the desired service position Figure 4 CAUTION When opening hood use care to properly engage hood prop rod into service slot Be sure footing is secure to accommodate weight shift of hood when rotating to full service position Daily Service Position Place hood prop rod into service slot Ensure prop rod is engaged in service slot properly Full Service Position Slowly release hood after seat contacts foot board Use care and be sure of your footing Do not step on mower deck 3 When service is complete lower hood and secure with hood latches 16 OF 1811 6 Service Slot 7 Full Service Position 8 Engine 9 No Step Decal 10 Battery Steering Levers Parking Brake Footboard Engine Hood amp Frame Engine Hood Prop Rod Figure 4 MOVING UNIT MANUALLY OF 1730 2 Left Bypass Valve Lever 1 Right Bypass Valve Lever Figure 5 IMPORTANT Never tow unit 1 Place hood in the full service position see Service Positions on page 16 2 Rotate the bypass valve dump levers located on the pumps using a wrench WARNING Do not bypass transmission when on a slope
45. l uneasy on it do not mow it DO NOT park on slopes unless necessary When parking on slope always chock or block wheels Always parking brake Use a slow speed Tires may lose traction on slopes even though the brakes are functioning properly DO NOT bypass transmission when on a slope Tow only with a machine that has a hitch designed for towing Do not attach towed equipment except at the hitch point Follow the manufacturer s recommendations for weight limits for towed equipment and towing on slopes NEVER allow children or others in or on towed equipment On slopes the weight of the towed equipment may cause loss of control Travel slowly and allow extra distance to stop Use extra care when loading or unloading unit onto trailer or truck Secure unit chassis to transport vehicle NEVER secure from rods or linkages that could be damaged DO NOT transport machine while engine is running ALWAYS turn off power to attachment and shut off fuel when transporting unit Keep unit free of debris Clean up oil or fuel spills This product is equipped with an internal combustion type engine DO NOT use unit on or near any unimproved forest covered or brush covered land unless exhaust system is equipped with a spark arrester meeting applicable local state or federal laws A spark arrester if it is used must be maintained in effective working order by operator Fuel is highly flammable and its vapors are explosive Handle with
46. lipers they must be burnished by driving for a short distance about 200 feet with the brake To do this bring the parking brake lever part way up while driving normally in a straight line This quickly breaks in the pads for maximum effectiveness 1 Jam Nuts PF 1732 Figure 14 ADJUSTING UNIT TO TRACK STRAIGHT Check and adjust tire pressure Increase pressure on side unit tracks to DO NOT exceed maximum recommended tire pressure refer to Specifications If tire pressure adjustment does not solve tracking problem the limiter bolts at base of handles can be adjusted See Figure 15 Front bolts are for forward and rear bolts are for reverse Lengthen bolts move closer to lever on side which is too fast 1 Limiter Bolt 2 Lever Figure 15 LEVELING THE MOWER These adjustments should be made on a level surface with the tires inflated to the correct air pressure The mower is leveled from side to side with the slots where 4 chains fasten to the mower mounting brackets The mower is leveled from front to rear by adjusting the rod running down each side of the frame Figure 16 1 Raise mower deck and insert 3 7 6 cm tall blocks to support deck 2 Lower deck onto blocks so chains are slack 3 Measure from bottom of mower blade end to ground 4 Shut off engine Engage parking brake Remove the ignition key 5 Set hydraulic lift cylinder so cut of height reads the same as blade height measurem
47. n and discard Fill fuel tank with fresh new fuel FILLING FUEL TANK EXPLOSIVE VAPORS and FLAMMABLE FUEL can result in serious injury or death Handle fuel with care ALWAYS use an approved fuel container No Smoking No Lighted Materials No Open Flame Allow engine to cool Use caution with fuel Fuel is very flammable Keep fuel in a clean and tight container Keep fuel away from fire or heat Never put fuel in the fuel tank while the engine is running or hot Clean up any spilled fuel before starting the engine Add fuel to the tank as needed IMPORTANT Refer to Engine Manual for correct type and grade of fuel See Specifications for fuel tank capacity To add fuel to the fuel tank 1 Refuel the unit only in a well ventilated open area 2 Stop the engine 3 Clean the fuel cap and the area around the fuel cap to prevent dirt from entering the fuel tank Remove the cap from the fuel tank 4 Fill the fuel tank Be careful not to spill the fuel Do not overfill allow for fuel expansion Stop filling when fuel is about 1 below the bottom of the neck 5 Install the cap on the fuel tank and tighten 6 Clean up any spilled fuel before starting the engine FASTENERS Each day before operating check mower blade mounting hardware and all other fasteners Replace fasteners that are missing or damaged Tighten all nuts and bolts to their correct torque value GENERAL LUBRICATION IMPORTANT Wipe each fit
48. nections and apply grease to front axle grease zerk see Hours Pivot Points General Lubrication on page 18 Clean Battery Keep battery and battery terminals clean see Cleaning the Battery on page 19 Check Fasteners Check mower blade mounting hardware and all other fasteners Replace missing Every or damaged fasteners Tighten all nuts and bolts to their correct torque value 100 Check Belts Replace worn or deteriorated belts Hours Check mower drive belt see Replacing Mower Belts on page20 for mower drive belt location Check PTO belt see PTO Belt Removal on page 20 for PTO belt location Check radiator fan belt refer to Engine Manual Every Front Axle Caster Repack front axle caster pivots see General Lubrication on page 18 400 Pivots Hours Every Change Hydraulic Oil and See Hydraulic Oil System on page 26 500 Filter Hours 15 SERVICE AND ADJUSTMENTS Gravely Dealers will provide any service which may be required to keep your unit operating at peak efficiency Should engine service be required it can be obtained from a Gravely Dealer or engine manufacturer s authorized service center WARNING AVOID INJURY Read and understand the entire Safety section before proceeding CAUTION HOT SURFACES may result in injury DO NOT touch engine or drive parts which are hot from operation Allow parts to cool before servicing SERVICE POSITIONS IMPORTANT Place unit on a flat leve
49. nesia beaten egg or vegetable oil Get medical attention immediately IMPORTANT In case of internal contact DO NOT induce vomiting Inspection Cleaning Drying and Maintenance Inspect the top of the battery terminals cables terminal posts and case for any accumulation of dirt corrosion cracks or loose or broken parts Keep battery and its terminals clean Inspect monthly to maintain best performance Replace battery if damaged Remove hold down and bolt and lift battery out Clean or service battery away from unit Remove corrosion from battery terminals and cable connections with wire brush then wash with a weak baking soda solution Scrub the exterior of the battery and cable terminals with a nonmetallic brush which has been dipped into a mixture of baking soda and water Reinstall battery Check the alternator voltage regulator output if used at every period maintenance inspection Over charging is a common cause of battery failure Battery Charger Under normal conditions the engine alternator will have no problem keeping battery charged When unit has set for an extended period of time without operation and the battery has been completely discharged a battery charger will be required for recharging Charging a New Battery WARNING FROZEN BATTERIES CAN EXPLODE and result in death or serious injury DO NOT charge a frozen battery Let the battery thaw out before putting on a charger IM
50. ng 42 GRAVELY dd Ariens Company 655 West Ryan Street P O Box 157 EC DECLARATION OF CONFORMITY ISSUED BY THE MANUFACTURER DECLARATION DE CONFORMITE CE EMISE PAR LE FABRICANT EU UBEREINSTIMMUNGSERKLARUNG DES HERSTELLERS VERKLARING VAN OVEREENSTEMMING VOOR DE EU AFGEGEVEN DOOR DE FABRIKANT EF Brillion Wisconsin 54110 0157 USA Telephone 920 756 2141 Facsimile 920 756 2407 OVERENSSTEMMELSESERKL ERING UDSTEDT AF FABRIKANTEN DICHIARAZIONE DI CONFORMIT CE RILASCIATA DAL PRODUTTORE DECLARACI N DE CONFORMIDAD CE EMITIDA POR EL FABRICANTE EF SAMSVARSERKL ERING FRA PRODUSENTEN EG DEKLARATIONEN OM OVERENSSTAMMELSE UTFARDAD AV TILLVERKAREN VALMISTAJAN ANTAMA EY VAATIMUSTENMUKAISUUSVAKUUTUS DEKLARACJA ZGODNOSCI Z PRZEPISAMI EC WYDANA PRZEZ PRODUCENTA DECLARAGAO DE CONFORMIDADE CE EMITIDA PELO FABRICANTE We the undersigned ARIENS COMPANY certify that Nous soussign s ARIENS COMPANY certifions que Der Unterzeichnete ARIENS COMPANY bescheinigt dass Wij de ondergetekenden ARIENS COMPANY verklaren dat Undertegnede ARIENS COMPANY attesterer at La sottoscritta societ ARIENS COMPANY certifica che Nosotros los abajo firmantes ARIENS COMPANY certificamos que Undertegnede ARIENS COMPANY bekrefter at Undertecknad ARIENS COMPANY intygar att Allekirjoittanut ARIENS COMPANY vakuuttaa ett My ni ej podpisani ARIENS COMPANY
51. ng the terminals Battery Removal and Installation Remove 1 Place hood in full service position see Service Positions on page 16 Disconnect negative cable first then positive cable Figure 8 Remove battery hold down bracket and battery from unit Install 1 Install battery on unit with battery hold down bracket Connect positive cable first then negative cable Coat terminals with dielectric grease or petroleum jelly 4 Close hood Cleaning the Battery 1 Disconnect negative cable first then positive cable Clean battery cable ends and terminals with wire brush Rinse with a weak baking soda solution Connect positive cable first then negative cable Coat terminals with dielectric grease or petroleum jelly OF 3227 1 4 Positive Terminal 5 Positive Cable 2 Negative Terminal 3 Negative Cable Figure 8 Charging the Battery WARNING FROZEN BATTERIES CAN EXPLODE and result in death or serious injury DO NOT charge a frozen battery Let battery thaw before charging Follow First Aid directions for contact with battery fluid External Contact Flush with water 19 Eyes Flush with water for at least 15 minutes and get medical attention immediately nternal Contact Drink large quantities of water Follow with Milk of Magnesia beaten egg or vegetable oil Get medical attention immediately In
52. of meter is more likely to be damaged through rough handling except for overloaded Protected Meters or by measuring high values that exceed the range set on the meter than a digital meter They provide excellent service for the money as long as they are used with care Digital Meters Digital Meters do not have a movement and are there fore more rugged The reading shows up directly display window of some type Since they read direct no skill in reading the scale is required nor is it neces sary to set the range The meter switches the ranges automatically One has only to select the function DC Volts AC Ampere Ohms etc connect the test leads and the reading is shown on the display Because of the internal circuitry and the lack of a movement these meters are not likely to be damaged by overloads In the discussions that follow either type of meter may be used Test procedures are the same It is best to learn proper procedures even though some meters may be more forgiving of mistakes Where differences in use may occur they will be covered in the discus sion Voltage Measurement There are two basic rules to be remembered when using a voltmeter A voltmeter measures the voltage difference between the test leads and the voltmeter is always connected across the circuit under test Current Measurement The two rules to remember when measuring current with an ammeter are an ammeter measures the cur rent that flow
53. orner Figure 12 Sharpening Mower Blade CAUTION Use sturdy gloves or padding to protect hands when working with mower blades 1 Turn the engine off Remove the ignition key 2 Remove the bolts lock washer the flat washers and blades from the spindle shafts 3 4 5 Sharpen the beveled edges of the blades in a straight line Do not change the angle of the beveled edge If more than 0 5 inches 12 7 mm are removed from the width of a blade discard the blade Make sure the sharpened blades are balanced Balance must be held within 1 3 inch ounces Put the blades the flat washers lock washers and the bolts back on the spindle shafts Tighten the bolts to a torque of 70 ft los 95 Nm Put the ignition wires back on the spark plugs STEERING CONTROL NEUTRAL ADJUSTMENT If the unit has excessive creep when the control levers are in neutral adjust as follows Figure 13 1 OF 1820 Stop Bolts 2 Pump Levers 3 Front Ball Joints 4 Control Levers Parking Brake Interlock Clamping Bolt and Slot Mounting Bolt Figure 13 WARNING This adjustment requires operation of the engine and opening of hood Use extreme care to avoid contact with moving parts and hot surfaces Be sure rear of unit is well supported and secure before starting engine 1 2 3 If hydraulic system is cold run unit for a minimum of five minutes then shut off unit Make sure b
54. oth control levers are in neutral Raise hood With the unit up to and facing a wall jack the unit up so that both drive wheels are off the ground Have someone depress center of seat to activate Seat switch Start the engine and run at about half throttle or faster Release parking brake Move the control levers from Forward to Reverse several times to make sure controls are free and check neutral adjustment If binding is found correct it Minor adjustments may be made by simply adjusting the stop screw which contacts the lever on the pump The screw may be turned in or out to bring the unit into neutral If major adjustment is needed it is best to remove the front ball joint from the bottom of the control levers and turn the stop screw in or out until neutral is found Then with the adjustable arms of the parking brake interlock positioned so the clamping bolt is in the middle of the slot adjust the ball joint on or off the control link rod so that their mounting bolts fit into the slot at the end of the adjustable interlock 10 Reinstall the front ball joint s NOTE When properly adjusted the parking brake interlock will move upward when the parking brake is set and hold the steering control levers in neutral The parking brake starting interlock switch will not be depressed unless the steering control levers are in neutral The interlock holds the levers in neutral until the parking brake is released
55. r is responsible to carry out the directive provided in the communication The types of communication are Service Letter General technical information for the dealer Technical information on how to service the product and product improvements Service Bulletin Notification to update products to resolve certain issues or a notification of a policy change Product Notices Notification of limited product located in a certain region This is a limited distribution to only those who received the product involved Campaigns Notification of a safety related issue All products must be updated and are tracked by the factory until all units are corrected PREPARATION Before starting any removal of parts proper preparation is very important for efficient work A clean work area at the start of each job will allow you to perform service repairs easily and quickly WARNING This cutting machine is capable of amputating hands and feet and throwing objects Failure to observe the safety instructions in the manuals and on decals could result in serious injury or death WARNING Slopes are a major factor related to loss of control and tip over accidents Operation on all slopes requires extra caution WARNING Tragic accidents can occur if the operator is not alert to the presence of children Never assume that children will remain where you last saw them WARNING Gasoline is extremely flammable and the vapor
56. ranty 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 the dealer does not register your product please fill out sign and return the product registration card to Gravely UNAUTHORIZED REPLACEMENT PARTS Use only Gravely replacement parts The replacement of any part on this unit with anything other than a Gravely authorized replacement part may adversely affect the performance durability and safety of this unit and may void the warranty Gravely disclaims liability for any claims or damages whether warranty property damage personal injury or death arising out of the use of unauthorized replacement parts DISCLAIMER Gravely reserves the right to discontinue make changes to and add improvements upon its products at any time without public notice or obligations The descriptions and specifications contained in this manual were in effect at printing Equipment described within this manual may be optional Some illustrations may not be applicable to your unit TECHNICAL SERVICE COMMUNICATIONS Gravely Technical Service communicates information to the field using Service Letters Service Bulletins Product Notices and Campaigns Each communication signifies a type of information and priority The deale
57. re operating check the air cleaner element Dirt can decrease the flow of air to the engine Each day before operating check the air cooling system on the engine Debris can decrease the flow of air cooling the engine Follow the maintenance instructions in your engine manual concerning oil and filter changes BELTS WARNING MOVING PARTS can cut or amputate body parts ALWAYS wait for moving parts to stop before performing maintenance or service CAUTION DAMAGED OR WORN BELTS may result in injury and or damage to the unit Check belts for excessive wear or cracks often Belt Access 1 W rnm 1 Properly stop and park unit refer to Owner s Manual Lower the mower Place seat in most rearward position Remove belt covers Place foot board in open position Figure 9 Secure raised footboard with latch OF 1802 3 Support Frame 4 Pivot 5 Latch Footboard in open position 2 Footboard in closed position Figure 9 Replacing Mower Belts NOTE Long belt must be removed to remove short belt 1 Roll long belt off left blade spindle and remove from deck Roll short belt off right blade spindle and remove from deck Idler pivot bolt must be loosened slightly to gain clearance to remove belt from under idler pulley Figure 10 20 72 Belt Layout 50 and 60 Belt Layout OF 1641 4 Idlers
58. rical check valves and permit current flow in one direction but not in the other Diodes allow current to flow through one circuit without backing up into another In engine alternator circuits a diode is used to convert current which flows back and forth AC in a circuit to current which flows only in one direction DC A device which converts alternating current to a direct current is called a RECTIFIER A diode is one type of rectifier check a diode isolate it from the circuit by disconnecting one end With a multitester set on the lowest ohms scale setting measure the resistance in one direction reverse the test leads and measure in the other direction Readings should be high in one direction and low in the other If the readings are low in both directions the diode is shorted and if the readings are high the diode is open If the readings are the same in both directions the diode is defective and must be replaced IMPORTANT Diodes are marked to indicate polarity a band on one end an arrow on the side They fit on a holder only one way Rectifiers A battery is charged through the use of an alternator located in or on the engine A charging circuit contains a rectifier because alternators produce alternating current AC and batteries require direct current DC for charging The rectifier may be built into the engine or it may be an external part It may also contain a regulator to prevent overcharging
59. rifique en d manual el sistema de engranar Controler le bon fonctionnement du syst me antas de usar de s curit avant utilisation tel qu indiqu J Tenga conocimiento de funciones y dans le manuel d utilisation localizaciones de todos los controles Comprenez bien la fonction et la situation permitir que personal a necesaria chacun des leviers et boutons de commande formaci n use la m quina Ne jamais permettre l utilisation par des personnes n ayant pas requ la formation n cessaire Zeen Figure 2 Safety Decals SAFETY RULES Read understand and follow all safety practices in Owner Operator Manual before beginning assembly Failure to follow instructions could result in personal injury and or damage to unit ALWAYS remove key from ignition and wire from spark plug before assembly Unintentional engine start up can cause death or serious injury Complete a walk around inspection of unit and work area to understand Work area Your unit All safety decals Inspect unit before each use for missing or damaged decals and shields correctly operating safety interlock system and deterioration of grass catchers Replace or repair as needed ALWAYS check overhead and side clearances carefully before operation ALWAYS be aware of traffic when crossing or operating along streets or curbs Keep children and people away Keep children out of work area and under watchful care of a responsible a
60. ring iron used to solder all splices and connections to terminals connector etc A soldering gun is faster and more convenient that wait ing for a soldering iron to heat Multimeter analog or digital to measure voltage amperage and ohms Tachometer used to measure engine speed Required to properly test alternator and charging cir cuits where output is dependent upon engine speed Heat gun used to shrink insulated tubing in place Used to replace electrical tape or insulated sleeving To use place a piece of shrink tubing over a wire joint heat with the heat gun until it shrinks tightly around the joint Supplies electrical tape rosin core solder never use acid or acid core solder on electrical joints an assort ment of various size terminals connectors insulated or heat shrink tubing for use on joints and connections and an assortment of automotive type wire in several colors Gravely Company recommends that all work be done in a professional manner The use of the tubing to cover joints and the soldering of connections contribute to a professional looking job In addition to a pleasing appearance repairs made in this manner are more likely to withstand vibration The weakest points in an electrical system are the joints where wires are attached Replace all defective components with Gravely replacement parts only Engine parts such as rectifiers or alternator components should be secured through the nearest
61. s are explosive handle with care WARNING Disengage attachment stop unit and engine remove key engage parking brake and allow moving parts to stop before leaving operator s position SAFETY ALERT SYMBOL These are safety alert symbols They mean ATTENTION 2779 YOUR SAFETY IS INVOLVED A When you see this symbol BECOME ALERT OBEY THE MESSAGE OL3900 SIGNAL WORDS The safety alert symbols above and signal words below are used on decals and in this manual Read and understand all safety messages DANGER IMMINENTLY HAZARDOUS SITUATION If not avoided WILL RESULT in death or serious injury WARNING POTENTIALLY HAZARDOUS SITUATION If not avoided COULD RESULT in death or serious injury CAUTION POTENTIALLY HAZARDOUS SITUATION If not avoided MAY RESULT in minor or moderate injury It may also be used to alert against unsafe practices NOTATIONS NOTE General reference information for proper opera tion and maintenance practices IMPORTANT Specific procedures or information required to prevent damage to unit or attachment PRACTICES AND LAWS Practice usual and customary safe working precautions for the benefit of yourself and others Understand and follow all safety messages Be alert to unsafe conditions and the possibility of minor moderate or serious injury or death Learn applicable rules and laws in your area REQUIRED OPERATOR TRAINING
62. s catcher or the discharge guard in place Stop engine before removing grass catcher or unclogging chute Ensure Safety Interlock System is functioning properly DO NOT operate unit if safety interlock is damaged or disabled Start and operate unit only when seated in operator s position Steering control levers must be in neutral PTO disengaged and parking brake set when starting engine Use care when approaching blind corners shrubs trees or other objects that may obscure vision Dust smoke fog etc can reduce vision and cause an accident Mow only in daylight or good artificial light Avoid slippery surfaces Always be sure of your footing DO NOT mow on wet grass Reduced traction could cause sliding and effect the machine s stability Watch for traffic when operating near or crossing roadways Never carry passengers DO NOT try to stabilize the machine by putting your foot on the ground Never direct discharge towards persons or property that may be injured or damaged by thrown objects Use extreme caution on gravel surfaces Always stand clear of the discharge area ALWAYS disengage PTO stop unit and engine remove key engage parking brake and allow moving parts to stop before leaving operator s position Never engage PTO while raising attachment or when attachment is in raised position DO NOT operate at too fast a rate DO NOT change engine governor settings or over speed engine Slow down before turning DO NOT
63. s through the meter and to measure cur rent an ammeter must be connected into the circuit The latter rule means that the circuit must be opened and the ammeter wired into it Because this procedure is usually difficult an ammeter is seldom used for trou bleshooting Resistance Measurement An Ohmmeter is used to make resistance measure ments and to check continuity through wires and elec trical components There is one rule to keep in mind when using an ohm meter The ohmmeter has a self contained battery and requires no electrical power Using the ohmmeter on a circuit that has power applied may result in damage to the meter IMPORTANT Disconnect the equipment battery when making Ohmmeter test or damage to the Ohmmeter may result IMPORTANT An ohmmeter reads the resistance of whatever component is connected between the test leads It can be used to check wires coils light bulbs or any item that conducts current BATTERY When charging battery remove it from unit first Keep batteries out of reach of children ALWAYS follow information provided on battery by battery manufacturer Lead acid batteries generate explosive gases Severe chemical burns can result from improper handling of battery electrolyte Wear safety glasses and proper protective gear when handling batteries to prevent electrolyte from coming in contact with eyes skin or clothing WARNING ELECTRIC SHOCK may result in injury and or damage to unit
64. sitive mechanical lock is used Use only attachments or accessories designed for your unit Check all hardware at regular intervals especially blade attachment bolts Keep all hardware properly tightened Check attachment components frequently If worn or damaged replace with manufacturer s recommended parts Safety Interlock System WARNING Safety interlock system failure and improper operation of unit can result in death or serious injury Test this system each time unit is operated If this system does not function as described do not operate until repairs are made Perform the following tests to ensure safety interlock system is working properly If unit does not perform as stated contact your Gravely dealer for repairs NOTE For all models when parking brake is engaged steering levers are locked in neutral 11 Test Steering PTO Parking Engine Levers Brake STARTING INTERLOCK 1 Neutral Off Engaged Start 2 Neutral On Engaged Doesn t Start 3 Neutral Off Disengaged Doesn t Start OPERATING INTERLOCK ENGINE ON 4 Neutral On Engaged Shuts Off 5 Neutral Off Disengaged Shuts Off 6 Neutral Off Engaged On Operator lifts off seat Parking Brake Interlock System With parking brake engaged steering levers must be locked in neutral With parking brake disengaged engine must not start and engine must shut off if oper
65. structions in Engine Manual for additional information Interval Task Action Check Safety Interlock WARNING Safety interlock system failure and improper operation of unit can result in death or serious injury Test this system each time unit is operated If this system does not function as described do not operate until repairs are made see Safety Interlock System on page 11 Check Parking Brake See Parking Brake Interlock System on page 11 Interlock System Check Parking Brake Engage parking brake Push unit If unit rolls adjust parking brake see Parking Brake Adjustment on page 22 Each Use Check Hydraulic Oil Level See Checking Hydraulic Oil Level on page 26 Check Tires See Specifications on page 12 for correct tire pressure Clean Unit Clean engine battery seat mower deck etc of all dirt and debris Do not use solvents hard cleaners or abrasives NOTE Protect painted surfaces with automotive type wax Follow Engine Manual Perform scheduled engine maintenance Refer to Engine Manual for detailed Maintenance Schedule instructions Check Cooling System Check cooling system for dirt and debris Refer to Engine Manual for detailed instructions Every 25 Check Mower Blades Ensure mower blade hardware is tightened to 115 125 Ibf ft 156 169 Nm Hours Check mower blades for wear Sharpen or replace mower blades as needed see Sharpening Mower Blade on page 19 Every 50 Lubricate Front Axle and Oil all pivot points pin con
66. t pounds 74 5 Nm shaft NOTE Check condition of square key and replace if needed 3 Place belts on pulley and clutch Check for proper routing of belts 4 Connect fuel line and ignition wires 5 Connect battery positive first 6 Check oil level and add as needed ELECTRIC CLUTCH The motor output shaft has two pulley mechanisms The top pulley is direct drive and powers the hydraulic system The lower pulley is engaged by an electric clutch and supplies power to the mower blades See Figure 17 The clutch has no repairable parts If the clutch does not operate before replacing clutch 1 Check the deck for debris that may be blocking blades 2 Check PTO switch and wire harness for proper operation 1 Electric Clutch 2 Pulley 3 Anchor Bracket Figure 17 25 DRIVE TRAIN WARNING Hydraulic Fluid can result in severe burns Fluid in hydraulic system can penetrate skin and result in serious injury or death Be sure to stop the engine before doing any work on hydraulic parts Keep body and hands away from pin holes or nozzles which expel hydraulic fluid when under pressure Use paper or cardboard not hands to search for leaks Insure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before applying pressure to system WARNING FOREIGN FLUID INJECTED INTO BODY can result in gangrene Fluid must be surgically removed within a few hours by a
67. tallation of the mechanical components for the Promaster 250Z 2602 and 272Z Dealer trained service personnel should use this manual as a supplement to and reminder of the training sessions conducted by the company Read all information for servicing a part or system before repair work is started to avoid needless disassembly Operation Before operation of the 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 Safety Messages 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 Directional Reference All reference to left right front or rear are given from operator seated in operation position and facing the direction of forward travel SERVICE AND REPLACEMENT PARTS When ordering publications replacement parts or making service inquiries know the Model and Serial numbers of your unit and engine Numbers are located on the product registration form in the unit literature package They are printed on a serial number label located on the frame of your unit Serial Number Label OA0017 Figure 1 PRODUCT REGISTRATION The Gravely dealer must register the product at the time of purchase Registering the product will help the company process war
68. the coil with an ohmmeter If the coil is open the solenoid is defective and must be replaced If the coil has the proper voltage applied and the continuity check indicates the coil is intact the solenoid plunger is stuck or the contacts are welded shut and the solenoid must be replaced If the solenoid snaps shut but the start does not operate check across the large contacts with an ohmmeter If there is no continuity when the solenoid snaps shut the contacts are defective and the solenoid must be replaced FUSES Fuses are connected in electrical circuits to protect the circuits from damage due to overload or short circuits Fuses are a weak link in the circuit They contain a metal link designed to melt when a certain current value is exceeded thus opening or disconnecting the wiring Once a fuse blows or melts it must be discarded and replaced with a new fuse of the same value Since the function of the fuse is to protect the circuit NEVER attempt to defect the protective device by bridging or replacing with a device of a higher current rating Electrical testing of these devices is simple Since the device either conducts current and is therefore functioning or the device is open and is therefore defective Use an ohmmeter to check for continuity DIODES AND RECTIFIERS Diodes are solid state semiconductor devices They contain no moving parts and conduct current better in one direction than the other They are elect
69. ting clean before and after lubrication Lube fitting locations are front axle pivot 1 Figure 7 Apply Sten Mix Hi Temp Grease or equivalent to the lube fittings Order P N 00036700 Ten pack of 14 oz cartridges When using Sten Mix Grease for the first time all components should be thoroughly cleaned prior to lubricating Apply oil at all pivot points and pin connections OF 1792 Lubrication Location Interval Caster Pivot 400 hours Repack Grease Axle Pivot 50 hours Oil All Pivot Points Pin Connections 50 hours Figure 7 IMPORTANT Wipe front axle grease zerk and two front axle caster pivots clean before and after lubrication NOTE Use Stens Mix Hi Temp Grease or equivalent part number 00036700 Description Use Interval Grease fittings Sten Mix grease or equivalent 50 hrs running time Hydraulic system Mobil 15W50 500 hrs running synthetic oil time SERVICING THE BATTERY T WARNING AVOID INJURY Read and understand the entire Safety section before proceeding A WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling NOTE Unit comes equipped with a maintenance free battery that requires no regular maintenance except cleani
70. to be sure no terminals are grounded If the switch is operating properly there will be no continuity between contacts other that those described SOLENOID AND RELAYS Solenoid and relays are both magnetically operated devices Both devices operate on the principle that passing a current of electricity through a coil of wire will create a magnetic field strong enough to attract a piece of iron or steel Each device uses this principle in a slightly different manner Relay A basic relay consists of a coil of wire wound around a soft iron magnetic core When current is passed through the coil the core is magnetized and pulls down on a magnetic lever The lever in turn is attached to several switch contacts which open or close other electrical circuits In this fashion a small current can control one or more larger electrical currents and actuate several other devices In most cases a relay contact moves only a fraction of an inch and the magnetic pull is small Solenoid A basic solenoid consists of a coil of wire wound around a hollow tube A magnetic core slides inside the tube When current is passed through the coil the core is pulled into the solenoid with considerable force With proper design a solenoid can exert considerable force over a distance of several inched A solenoid can therefore pull a lever close a heavy contact or perform other jobs that require a straight line pull If a relay or solenoid fails to operat
71. trol lever back to neutral Idle unit down for a few seconds and shut off engine 13 The acceptable flow drop would be less than 1 GPM difference between the low and high pressure settings If flow drop is greater than 1 GPM the hydro pump will need to be repaired or replaced If the flow drop is less than 1 you will need to replace the wheel motor REPLACING THE HYDRAULIC PUMP The two hydraulic pumps are located inside the chassis in front of the engine The pumps are maintenance free and should be replaced in the event of a failure See Figure 18 1 Hydrostat BDP Pump 2 Variable Displace Pump Figure 18 To Replace a Hydraulic Pump 1 Lift cover to full service position 2 Remove the cross channel 3 Clean hoses and fittings and mark for location 4 Disconnect hoses from pump CAUTION Some fluid will leak out Clean up any spills 5 Remove belt from pulley 6 Remove bolt and washers from end of shaft 7 Loosen pulley lock bolt and slide pulley from shaft Remove and inspect square key Replace key if damaged 8 Remove back bolt on pump and loosen front bolt 9 Remove pump 10 Insert the new pump into position with the front bolt in the mounting flange slot 11 Insert rear bolt and tighten both bolts 12 Attach hydraulic hoses to correct ports and tighten 13 Position square key in shaft keyway and slide pulley into position 14 Screw the bolt washer and lock washer
72. ve timing 40 Pressure relief valve sticking open 61 Bad or defective water temperature Switch 20 Poor compression 41 Pressure relief valve sticking closed 62 Bad spark plug s 21 Blocked fuel tank vent 42 Broken relief valve spring 24 REMOVING THE ENGINE To Replace the Clutch 1 Place the mower in the full service position 1 Remove the belt by relaxing the idler pulley 2 Disconnect the battery cables negative first 2 Remove the center bolt 3 Disconnect ignition wires using the connectors CAUTION DO NOT ALLOW the engine 4 Remove the belts from the pulley and clutch crankshaft to rotate Damage to the engine 5 Unscrew the bolt from the center of the output shaft may occur and remove clutch Refer to Replacing the Clutch 3 Disconnect electrical wires 6 Remove the square key and the pulley 4 Remove nut from the anchor bracket 7 Unclamp and remove the fuel line Plug the fuel 5 Pull clutch from shaft line and wipe up any spills 6 Position new clutch on the shaft by aligning the 8 Remove the engine mounting bolts and lift engine square key on the shaft with the keyway of the out the top clutch 7 Clutch should be rotated to position the anchor INSTALLING THE ENGINE bracket with the slot in the stationary shell 1 Position the new engine in the chassis insert Replace nut and tighten mounting bolts and tighten 8 Replace bolt and washers Torque to 55 foot 2 Install pulley and then the clutch on the outpu

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