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Gravely 989003, Service Manual

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Summary of Contents for 989003

Page 1: ......

Page 2: ...rbox Repair 6 36 6 18 PTO Gearbox Installation 6 36 Section 7 Steering Controls 7 37 7 1 Power Steering Schematic 7 37 7 2 Power Steering System Troubleshooting 7 37 7 3 Hydraulic Hoses 7 38 7 4 Steer...

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

Page 4: ...e 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 locate tools or parts is a needless del...

Page 5: ...lose traction turn off power take off and proceed slowly straight down slope Avoid wet surfaces Avoid parking on a slope If necessary use wheel chocks DO NOT leave unit unattended on a slope ALWAYS u...

Page 6: ...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 wi...

Page 7: ...PORTANT Never spray unit with water or store unit outdoors Clean seat regularly using a vinyl cleaner not solvent Extreme temperatures can damage seat when left unprotected against weather If seat sho...

Page 8: ...with Precleaner Donaldson Type Dry Paper Element with Precleaner Engine Oil Type API Service CD 20W50 Motor Oil API Service CD 20W50 Motor Oil Oil Filter Integral Replaceable Integral Replaceable Coo...

Page 9: ...Type API Service CD 20W50 Motor OIl API Service CD 20W50 Motor OIl Oil Filter Integral Replaceable Integral Replaceable Cooling Liquid Liquid Charging Capacity Automotive 40 Amp Alternator Automotive...

Page 10: ...n Type Dry Paper Engine Oil Type API Service CD API Service CD Charging Capacity Automotive 40 Amp Alternator Automotive 40 Amp Alternator Transmission Oil and Capacity qts L API Service CC 10W30 or 3...

Page 11: ...y 6 Temperature Gauge 7 Battery Warning Light 8 Throttle Control Lever 9 Oil Pressure Warning Light 10 Light Switch Optional 11 Cruise Control Switch optional 12 Hourmeter 13 Park Brake Lock Lever 14...

Page 12: ...sually observing the level in the vinyl hose which is fastened to the front of the gearbox cover The lubricant level is correct when it is approximately even with the center of the PTO output lower sh...

Page 13: ...f rear wheels is necessary to assure proper steering and to reduce tire wear Proper toe in is when the front of the wheels are 1 16 to 1 8 closer together than the rear of wheels measured at horizonta...

Page 14: ...ator Turn rod end counterclockwise to move pedal angle toward operator and clockwise to move pedal angle away from operator 3 Replace hardware holding rod end to direction control weldment 4 Adjust co...

Page 15: ...lever arm to brake cam 2 Remove cam lever arm from brake cam Rotate cam lever arm one spine to the rear and put it back on brake cam 3 Tighten nut and bolt 4 Repeat above steps if necessary 4 8 PTO CL...

Page 16: ...VERTICAL FOR NORMAL OPERATION 10 DEGREES BEFORE VERTICAL FOR ETREME OPERA TION Figure 10 OF0840 Figure 11 1 Clutch Pac 2 Bar Spring 3 Clutch Trunnion 4 Bushing 5 Jam Nut 6 PTO Slide Rod OF0830 1 2 3 4...

Page 17: ...ct 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 solenoid swi...

Page 18: ...e is warm stop it and raise the hood 3 Clean the areas around the dipstick and drain plug 4 Put an open top container that will hold five quarts under the drain plug 5 Remove the drain plug 6 Allow th...

Page 19: ...hose at the radiator NOTE Mark one of the two fuel hoses to ensure proper reinstallation 5 Close the fuel shut off valve at the fuel filter Clean the fuel hoses and fittings Disconnect the fuel hoses...

Page 20: ...d tighten 3 Install the flywheel adapter plate apply loctite to bolts and tighten Lubricate the transmission drive shaft 4 Refer to the appropriate wiring diagram in Electrical section to ensure corre...

Page 21: ...6 21 6 1 HYDRAULIC SCHEMATIC SECTION 6 DRIVE TRAIN Figure 16...

Page 22: ...level surface 2 Place a container under filter to catch oil spillage as filter is removed 3 Use an oil filter removal tool to unscrew filter Discard old filter 4 Fill new oil filter with fresh clean...

Page 23: ...nes and install U joint attach U joint to transmission with the two mounting bolts 3 PTO drive shaft removal a To remove PTO drive shaft remove the four bolts connecting the drive shaft to the transmi...

Page 24: ...r shim as opposed to two or more thin shims 4 Once the correct pressure has been established shut down the unit and remove the pressure gauge and install the pipe plug 6 8 SUNSTRAND TRANSMISSION REMOV...

Page 25: ...rom the transmission 2 Note the orientation of the charge pump housing to adjacent housing and mark to insure proper relocation 3 Clean the shaft extension to remove sharp edges burrs and abrasive res...

Page 26: ...TRANSMISSION MAJOR REPAIR NOTE Prior to major disassembly the charge pump must be removed 1 Place the transmission with the shafts in a vertical position Remove the cap screws from the center section...

Page 27: ...large cavity of the housing Figure 29 11 The motor shaft bearing is removed by pressing out toward the front of the housing Replace the bearing if necessary 12 Visually inspect the needle bearings an...

Page 28: ...ousing until flush to 1 64 below counterbore for lip seals 25 Install new pins through the swashplate and shafts Use two pins on the control shaft installing the first pin until the second pin can be...

Page 29: ...the pump motor and control shafts while tightening these screws 40 Install charge pump 6 11 SUNSTRAND TRANSMISSION INSTALLATION 1 Place a new O ring seal on the transmission Use a film of grease to h...

Page 30: ...ect fork flanges should be toward each other On 3 gear cluster small gear and medium gear chamfers go down toward big gear Improper fit of case to cover Recheck positioning of thrust washers A misplac...

Page 31: ...lled or not tightened Seal retainers are not properly sealed Tighten axle housing bolts Burrs on gears Remove gear and hone smooth Parts missing Install missing parts Broken shifter stop allowing unit...

Page 32: ...re 38 6 14 TRANSAXLE REPAIR Axle Bearing Replacement NOTE The axle bearings can be inspected and replaced without removing the transaxle from unit 1 Place a drain pan under the transaxle and remove th...

Page 33: ...stall the lift arm weldment 11 Install the wheel assembly and tighten the lug bolts to spec 12 Lower the unit and service with clean fresh oil 13 Prime the transmission Transaxle Repair Center Section...

Page 34: ...the shifter fork on both shifter forks 3 Inspect the shifter fork for straightness and wear e Differential 1 Check security of the parts 2 Check shifter collar for wear two speed 3 Check the ball bear...

Page 35: ...rods at the transaxle 9 Install the transmission Connect the hydraulic reservoir supply hose 10 Service the transmission and transaxle with clean fresh oil 6 16 PTO GEARBOX REMOVAL NOTE Position the...

Page 36: ...replace any worn or damaged parts 11 Inspect the two case halves and replace the oil seals prior to reassembling the PTO gearbox 12 Assemble the PTO gearbox reversing the disassembly procedure watchi...

Page 37: ...ng Arm Weldment 1 2 3 4 5 6 3 3 4 4 7 PF1144 Problem Probable Cause Corrective Action Rear wheels will not turn Hydraulic system low on fluid Air in system Pinched or restricted hydraulic hose Service...

Page 38: ...rect wrench If hoses are to be dis connected or reconnected at a fitting use two wrenches one on the hose and one on the fitting to prevent damage by twisting off the fitting Figure 51 1 Power Steerin...

Page 39: ...parts 7 5 STEERING BOX INSTALLATION 1 Slide the power steering unit into place and secure with the four nuts Install the nylon bushing if removed 2 Connect the five hydraulic hoses to the power steeri...

Page 40: ...T SYSTEM PRESSURE RETURN SUCTION IN OUT AUX LT RT TRANSAXLE STEERING CYLINDER TRANSMISSION LIFT CYLINDER HYDRULIC VALVE POWER STEERING UNIT IN EXHAUST OUT PORT A PORT C PORT E PORT D PORT B PORT F POR...

Page 41: ...ic diagram Figure 54 for proper hydraulic hose routing 4 Fittings which use an O ring seal do not use a hydraulic sealer for preventing leaks Fittings without an O ring seal should use a hydraulic sea...

Page 42: ...ds for signs of wear Repair or replace any worn or damaged parts 8 5 HYDRAULIC LIFT VALVE INSTALLATION 1 Install the hydraulic valve with the four mounting bolts 2 Connect the three hydraulic hoses to...

Page 43: ...e to increase the hydraulic pressure or counterclockwise to decrease the hydraulic pressure 5 Shutdown the unit once the recommended pressure is consistently maintained Hold the adjusting screw and ti...

Page 44: ...assembly and fuel filter assembly 2 Clamp off the fuel lines at the feed pump and fuel filter assembly and loosen the fuel line clamps 3 Remove the fuel line at the feed pump fitting and pull the hose...

Page 45: ...invested in time of repair than the part would cost and the results may not be as good 10 2 ELECTRICAL MEASUREMENTS In many electrical circuits there is some visible effect which indicates that the c...

Page 46: ...new battery is dry charged Electrolyte must be added sulfuric acid and water 1 Remove the battery from the unit 2 Remove all the vent caps from the battery and set the caps to one side 3 Take the ele...

Page 47: ...ttery in a cool dry area during the off season This will slow down the loss of charge during non use periods 6 Check your battery monthly during the off season and if the battery has a low specific gr...

Page 48: ...lector 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 connec...

Page 49: ...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 wit...

Page 50: ...one lead to the B pin 3 Turn the ignition key to the off position Sequentially touch pins R I A S and the case with the free meter lead No circuit infinity should be indicated 4 Turn the key to the St...

Page 51: ...A circuit zero Ohms should be indicated 4 Replace the switch if it fails the above test Fuel Shut Off Solenoid 1 If engine fails to start verify with the key switch in the start position that power 12...

Page 52: ...GIZED ST B I 50 ST B I 50 ST B I 50 GLOW PLUG COUNTERCLOCKWISE OFF ON 1 OPERATOR OFF SEAT 2 1 OPERATOR ON SEAT 2 Light Switch Optional 03656800 BLACK WHITE FUEL SOLENIOD 1 2 3 RED BLACK GRAY YELLOW RE...

Page 53: ...10 53 10 11 WIRING DIAGRAMS Promaster 400 30 H...

Page 54: ...10 54 Promaster 400 22 H...

Page 55: ...HITE ORANGE YELLOW BLACK OIL PRESSURE LIGHT ALTERNATOR BATTERY SOLENIOD STARTER FUEL SOLENIOD GLOW PLUG ENGINE KEY SWITCH GLOW PLUG RELAY HOUR METER HEAD LIGHT LIGHT SWITCH CRUISE CONTROL CAB POWER SU...

Page 56: ...ULIC SCHEMATIC NOTE This hydraulic schematic is from a belly mount frame brace manifold For an axle mount manifold the manifold would be inverted and the single solenoid would face to the right side S...

Page 57: ...ic oil into 2 Clean all fittings and hoses where maintenance is to be performed prior to removing hoses to avoid hydraulic system contamination Cap hoses fittings and hydraulic component ports 3 Repai...

Page 58: ...b loose on the axle Remove the castle nut the rest of the way and slide the hub off of the axle 3 Disconnect the two hydraulic hoses at the wheel motor and cap 4 Remove the two hydraulic adapters from...

Page 59: ...of Cut 60 152 4 cm 72 182 9 cm 72 182 9 cm Height of Cut 1 5 4 5 3 81 11 43 cm Deck Construction 10 gauge welded and bolted construction w 3 16 4 8 mm thick reinforcing support plate Blades Number 3...

Page 60: ...ly Sten Mix Hi Temp Grease or equivalent to the lube fittings Order P N 000368 Three Pack of 3 oz cartridges or P N 00036700 10 pack of 14 oz tubes If using Sten Mix Hi Temp Grease for the first time...

Page 61: ...elt Figure 59 5 Reinstall the tension spring 6 Replace belt covers and any other parts Blade Service Every 25 hours or operation or when the cut is visually poor check the blades for sharpness To shar...

Page 62: ...to press or seat bearing races This will cause damage to the spindle bearing 6 Press bearing races into spindle housing tapered under cut towards center of spindle housing Inspect that the races are s...

Page 63: ...12 63 Figure 60 60 Gauge Wheels Roller and Height Adjustments Figure 61 72 Gauge Wheels Roller and Height Adjustments PF3250...

Page 64: ...12 64 Figure 62 Mower Mounting PF3170 Figure 63 Mower Gearbox...

Page 65: ...12 65 Figure 64 Mower Drive PF3190...

Page 66: ...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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