Gravely 988001 Service Manual Download Page 6

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Service Position

Place unit on flat, level surface. ALWAYS stop engine 
and disengage clutches. Assure unit is secure and will 
not tip over. Strap and clamp onto lift, if used.

To ensure the unit is positioned in the proper service 
position:

1. Place jack stands under rear transaxles only.

2. If jacks are not available, place support blocks 

under both transaxles at the rear of unit.

Maintenance

ALWAYS maintain unit in safe operating condition. 
Damaged or worn out muffler can cause fire or 
explosion.

Check the conditions of the unit at the end of each day 
and repair any damage or defects.

ALWAYS block wheels and know all jack stands are 
strong and secure and will hold weight of unit during 
maintenance.

Keep nuts and bolts tight and keep equipment in safe 
operating conditions.

Before maintenance, adjustments, or service (except 
where specifically recommended), shut off engine.

Allow hot parts to cool.

Keep unit free of dirt, stones, and other debris. Clean 
up oil or fuel spills.

Storage

DO NOT store unit inside a building with fuel in the fuel 
tank where any ignition sources are present. Allow unit 
to cool completely.

ALWAYS clean unit before extended storage. See 
Engine Manual for proper storage.

Spark Arrester

This product is equipped with an internal combustion 
engine. DO NOT use on or near any unimproved, 
forest covered or brush covered land unless the 
exhaust system is equipped with a spark arrester 

meeting applicable local, state or federal laws. A spark 
arrester, if used, must be maintained in effective 
working order by the operator.

Battery

Avoid Electric Shock. DO NOT reverse battery 
connections.

Explosive Gases! Poisonous battery fluid contains 
sulfuric acid and its contact with skin, eyes, or clothing 
can cause severe burns.

No flames. No sparks. No smoking near battery.

Always wear safety glasses and protective gear near 
battery.

DO NOT TIP battery beyond a 45

o

 angle in any 

direction.

ALWAYS KEEP BATTERIES OUT OF REACH of 
children.

Transport

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 with attachment in raised position.

Lower attachment when unit is parked or stored unless 
a positive mechanical lock is used.

Attachments and Accessories

Use only attachments or accessories designed for your 
unit.

2.9  CLEAN UNIT

Brush grass, dirt and debris off of unit with a soft brush. 
Clean packed grass out from under mower deck. Apply 
paint or oil to exposed, bare metal surfaces to prevent 
rust. 

Inspect unit for visible signs of wear, breakage, or 
damage. Order any parts required and make 
necessary repairs to avoid delays when beginning use 
again.

Clean seat regularly, using a non-solvent cleaner. 
Extreme temperatures can damage seat when left 
unprotected against weather. If seat should tear, apply 
vinyl repair tape to protect damaged area.

Transaxle cooling fins must be kept clean to prevent 
damage from overheating. Use a cloth or brush to 
remove grass, chaff and debris.

Unless there are indications of leakage, transaxle does 
not have to be checked for proper oil level. If leak 
occurs, have it repaired by your Gravely Dealer.

WARNING: ALWAYS block wheels and know 
that jack stands or blocks used are stable, 
strong, or secure and will hold the weight of 
the unit during maintenance.

WARNING: ROTATING PARTS can amputate 
body parts. Keep hands and feet away. Loose 
clothing, long hair or scarves can get caught 
in rotating parts and cause death or serious 
injury.

CAUTION: Remove enough fuel so that no 
spills will occur.

Summary of Contents for 988001

Page 1: ...Pro 100 150 200 08484000 06 00 Printed in USA Service Manual Models 988001 007 059 060 062 063 069 072 074 075 077 082 085 087 088 309...

Page 2: ...g Engine Oil 5 19 5 3 Changing Oil Filter 5 19 5 4 Air Cleaner 5 19 5 5 Check Spark Plug 5 19 5 6 Engine Removal 5 19 5 7 Engine Installation 5 19 Section 6 Steering And Controls 6 20 6 1 Steering Con...

Page 3: ...1 4 UNAUTHORIZED REPLACEMENT PARTS Use only Gravely replacement parts The replacement of any part on this vehicle with anything other than a Gravely authorized replacement part may adversely affect th...

Page 4: ...ssembly order on a clean work surface Organization is a key part of proper reassembly Tools instruments and parts needed for the job should be gathered before work is started Interrupting a job to loc...

Page 5: ...n engine is running hot or unit is indoors Abnormal Vibrations are a warning of trouble Striking a foreign object can damage unit Immediately stop unit and engine Remove key and wait for all moving pa...

Page 6: ...contact with skin eyes or clothing can cause severe burns No flames No sparks No smoking near battery Always wear safety glasses and protective gear near battery DO NOT TIP battery beyond a 45o angle...

Page 7: ...Drive Belt Matched Set 07225800 07225800 07225800 Traction Drive Belt 049270 049270 04927 PTO Belt 041963 041963 N A Model Type Pro 150 Pro150 Pro 150 Model Number 988060 988069 988070 Manufacture Kaw...

Page 8: ...t Matched Set 07225800 07225800 07225800 Traction Drive Belt 049270 049270 049270 PTO Belt N A N A N A Model Type Pro 150 Pro 150 Pro 150 Model Number 988078 988079 988088 Manufacture Kohler Kohler Ka...

Page 9: ...Belt Matched Set 0 024 0 028 07225800 049029 Traction Drive Belt 07225800 049270 052776 PTO Belt N A N A 07225000 Model Type Pro 200 Pro 200 Pro 200 Model Number 988004 988005 988006 Manufacture Kohl...

Page 10: ...29 049029 Traction Drive Belt 052776 052776 052776 PTO Belt 07225000 07225000 07225000 Battery 041358 041358 041358 Model Type Pro 200 Pro 200 Pro 200 Model Number 988071 988072 988080 Manufacture Koh...

Page 11: ...h 8 7 kph 5 4 mph 8 7 kph Reverse Max 1 8 mph 2 9 kph 1 8 mph 2 9 kph 1 8 mph 2 9 kph Transmission Lube Sealed Sealed Sealed Spark Plug Champion Champion NGK Type RC 14 YC RC 12 YC Part 21526900 Spark...

Page 12: ...oke Lever 5 Ignition Switch 6 PTO Lever 7 Operator Presence Controls Pro 100 Figure 3 Pro 150 1 Shift Lever 2 Steering Lever Latches 3 Steering Levers 4 Throttle Choke Lever 5 Ignition Switch 6 PTO Le...

Page 13: ...ke Lever 5 Ignition Switch 6 PTO Lever recoil start models 7 Operator Presence Control 8 Transmission Shifter Rod 9 PTO Switch electric start models 10 Hour Meter electric start models 11 Choke Contro...

Page 14: ...ent air loss 4 6 THE STEERING LEVERS The steering levers are used to steer the unit Pull up on the left hand lever to turn to the left Pull up on the right lever to turn to the right Holding both leve...

Page 15: ...justing the steering levers 1 Repeat steps 3 and 4 above 2 Check to see if the gap between the steering lever and handlebar is 2 1 2 to 3 inches If not readjust per step 4 above 4 9 ADJUSTING THE SHIF...

Page 16: ...he jam nuts To adjust the clutch actuating rod 1 Stop the engine 2 Put the gear shift lever in the neutral position 3 Loosen the jam nut at the ball joint on the gear shift lever 4 Rotate the clutch a...

Page 17: ...the nut to secure the idler sprocket 1 Jam Nuts 2 Spring 3 PTO Clutch Actuating Arm 4 PTO Clutch Actuating Rod 5 Mower Belt 6 Mower Clutch Sheave Figure 10 Pro 100 1 PTO Idler Pulley 2 Spring 3 Jam N...

Page 18: ...2 Incorrect grade of 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 sol...

Page 19: ...moving spark plugs clean the area around base of plugs to keep dirt and debris out of the engine 2 Remove plugs and check condition Replace plugs if worn or reuse is questionable NOTE Do not clean the...

Page 20: ...ence control linkage opens a switch when the hand grips are squeezed by the operator The electrical switch is normally open and will shut off the engine when the hand grips are released SECTION 6 STEE...

Page 21: ...r selector in gear and turn the input shaft The output shaft will turn It may be easier to remove the drive chain when performing this test If the output shaft does not turn replace the transmission 7...

Page 22: ...e mower belt from the mower clutch sheave Figure 20 3 Remove the PTO clutch belt from clutch hub recoil model only 4 Remove the PTO clutch stop bracket electric model only 5 Loosen the 5 16 18 bolt ho...

Page 23: ...ve of the jackshaft pulley then off the jackshaft pulley and remove over the drive wheel 10 Install the new traction belts one at a time by reversing steps 8 and 9 above Be sure the first belt is seat...

Page 24: ...the transmission belt guide at the correct angle and approximately 06 inches the thickness of the ignition key from the belt s surface and tighten the bolt holding the belt guide See Figure 22 for th...

Page 25: ...e before placing clutch on shaft 7 9 WHEEL REMOVAL To remove wheels 1 Jack unit to lift wheels off the ground 2 Remove axle nut and washer 3 Remove belts from pulleys NOTE The Pro 100 has one belt 4 L...

Page 26: ...uel tank is made of composite material for long life without breaking down from the additive used in today s blended fuels SECTION 8 FUEL SYSTEM TROUBLE POSSIBLE CAUSES Refer to Key Below CORRECTIVE A...

Page 27: ...e part would cost and the results may not be as good 9 2 ELECTRICAL MEASUREMENTS In many electrical circuits there is some visible effect which indicates that the circuit is functioning properly A swi...

Page 28: ...it 2 Remove all the vent caps from the battery and set the caps to one side 3 Take the electrolyte which should be 1 265 specific gravity at 80o F and fill each cell so that the electrolyte is level w...

Page 29: ...st then positive cable To charge battery 1 Loosen strap and remove battery from unit 2 Place battery on bench or other well ventilated place where electrolyte spill will not create damage 3 Remove cap...

Page 30: ...arged 9 4 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 completi...

Page 31: ...trol 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 co...

Page 32: ...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 pola...

Page 33: ...be indicated 7 Replace the switch if it fails the above test 9 12 FUSE HOLDER 1 Use a VOM with the switch set in the ohm Rx1 position 2 Make a visual check of the fuse to determine that it is not burn...

Page 34: ...Brown S 12 00 Pink A 12 00 12 00 Red White M Connected to kill magneto circuit to ground Left and Right Presence Switch Off Run Start Brown 12 00 White When activated 12 00 to ground Hourmeter Off Ru...

Page 35: ...power from the engine to the battery Terminal L supplies power to the fuel shut off solenoid for starting Terminal G is connected to the kill circuit of the engine for an additional ground kill connec...

Page 36: ...OHMS RESISTANCE WHEN CORRECT Left and Right Presence Switch Off Run Start Brown 12 00 12 00 White When activated 12 00 12 00 Hourmeter Off Run Start Pink 12 00 12 00 White 12 00 to ground 12 00 to gro...

Page 37: ...ion Neutral Switch 034640 1 2 NEUTRAL button down 1 2 RUN button up PTO Switch 020916 1 2 1 2 HAND ON HANDLE Bale Switch 09251900 HAND OFF HANDLE 1 2 1 2 Key Switch 02456500 The diagrams below show th...

Page 38: ...GED down position 3 9 4 7 1 ENGAGED up position PTO Switch 01545600 HAND ON HANDLE Bale Switch 09251900 HAND OFF HANDLE 1 2 1 2 l 1 2 DISENGAGED button out 1 2 ENAGED button in Transmission Neutral Sw...

Page 39: ...utton in Transmission Neutral Switch 034640 1 2 NEUTRAL button down 1 2 RUN button up PTO Switch 020916 Handlebar Switch 08828300 1 2 HAND ON HANDLE 1 2 HAND OFF HANDLE 1 2 1 2 The diagrams below show...

Page 40: ...ral Switch 034640 1 2 NEUTRAL button down 1 2 RUN button up PTO Switch 020916 1 2 1 2 HAND ON HANDLE Bale Switch 09251900 HAND OFF HANDLE 1 2 1 2 Key Switch 02456500 The diagrams below show the variou...

Page 41: ...R E D V I O L E T 1 2 1 2 RIGHT HANDLE BAR SWITCH 1 2 LEFT HANDLE BAR SWITCH M A B C D E F BLACK BLACK ENGINE W H I T E B L A C K Y E L L O W R E D PG0500 B R O W N Y E L L O W R E D Y E L L O W KEY...

Page 42: ...9 42 Pro 200 Briggs Stratton 16 HP...

Page 43: ...9 43 Pro 200 Kohler Engine...

Page 44: ...9 44 9 16 ELECTRICAL SYSTEM Model 988085 087 088 091 309 1 2 3 4 5 1 Key Switch Assembly 2 Single Pole N O with Cover 3 Electrical Interlock Module 4 Neutral Start Switch 5 Neutral Start Switch N C...

Page 45: ...9 45 All Models Except 988085 087 088 091 309 1 2 3 4 4 1 Switch 2 Ignition Switch 3 Interlock Module 4 Neutral Start Switch...

Page 46: ...Gravely 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...

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