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Gravely 991001-008, Service Manual

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Gravely 991001-008 Service Manual Download Page 2

 2

Section 1 - Introduction  . . . . . . . . . . . . . . . . . .  1-3

1.1 The Manual. . . . . . . . . . . . . . . . . . . . . . . . .  1-3
1.2 Service And Replacement Parts. . . . . . . . .  1-3
1.3 Product Registration . . . . . . . . . . . . . . . . . .  1-3
1.4 Unauthorized Replacement Parts. . . . . . . .  1-3
1.5 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . .  1-3
1.6 Technical Service Communications  . . . . . .  1-3

Section 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.1 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . .  2-4
2.2 Signal Words. . . . . . . . . . . . . . . . . . . . . . . .  2-4
2.3 Notations. . . . . . . . . . . . . . . . . . . . . . . . . . .  2-4
2.4 Practices And Laws  . . . . . . . . . . . . . . . . . .  2-4
2.5 Required Operator Training  . . . . . . . . . . . .  2-4
2.6 Preparation . . . . . . . . . . . . . . . . . . . . . . . . .  2-4
2.7 Cleaning And Storage. . . . . . . . . . . . . . . . .  2-4
2.8 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . .  2-4
2.9 Clean Unit . . . . . . . . . . . . . . . . . . . . . . . . . .  2-6

Section 3 - Specifications . . . . . . . . . . . . . . . . .  3-7

Section 4 - General Maintenance

& Adjustments . . . . . . . . . . . . . . . . . . . . . .  4-15

4.1 Controls And Features . . . . . . . . . . . . . . .  4-15
4.2 Filling The Fuel Tank. . . . . . . . . . . . . . . . .  4-16
4.3 General Lubrication- . . . . . . . . . . . . . . . . .  4-17
4.5 Tensioning The Hydro Pump Belt . . . . . . .  4-17
4.6 Steering Control Neutral Adjustment  . . . .  4-18
4.7 T-Bar Control Lever Alignment . . . . . . . . .  4-18
4.8 Check The Tires . . . . . . . . . . . . . . . . . . . .  4-18
4.9 Adjusting The Unit To Track Straight  . . . .  4-18
4.10 Leveling The Mower Deck  . . . . . . . . . . .  4-19
4.11 Adjusting Mower Belt  . . . . . . . . . . . . . . .  4-20

Section 5 - Engine  . . . . . . . . . . . . . . . . . . . . . .  5-21

5.1 Engine Troubleshooting  . . . . . . . . . . . . . .  5-21
5.2 Checking Engine Oil . . . . . . . . . . . . . . . . .  5-22
5.3 Changing Oil Filter  . . . . . . . . . . . . . . . . . .  5-22
5.4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . .  5-22
5.5 Check Spark Plug . . . . . . . . . . . . . . . . . . .  5-22
5.6 Engine Removal And Installation . . . . . . .  5-22

Section 6 - Cooling System Kawasaki Engines6-23

Section 7 - Mower Deck . . . . . . . . . . . . . . . . . .  7-24

7.1 Replacing Mower Belt . . . . . . . . . . . . . . . .  7-24
7.2 Mower Blade . . . . . . . . . . . . . . . . . . . . . . .  7-24
7.3 Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-25
7.4 50" Mower, Promaster 100 & 160 . . . . . . .  7-25
7.5 50" And 60" Mower, Promaster 200 . . . . .  7-26

Section 8 - Mower Lift System  . . . . . . . . . . . . .8-29

8.1 Mower Frame . . . . . . . . . . . . . . . . . . . . . .  8-29
8.2 Check Caster Wheels For Wear . . . . . . . .  8-29
8.3 To Replace Wheel Axle. . . . . . . . . . . . . . .  8-29
8.4 Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . .  8-29
8.5 Hydraulic System  . . . . . . . . . . . . . . . . . . . . 8-29

Section 9 - Steering And Direction Contols. . .9-32

9.1 Steering And Direction Controls . . . . . . . . .9-32

Section 10 - Drive Train . . . . . . . . . . . . . . . . . .10-33

10.1 Transmission Troubleshooting  . . . . . . . .10-33
10.2 Replacing The Hydro Pump Belt. . . . . . .10-34
10.3 PTO Clutch Removal  . . . . . . . . . . . . . . .10-34
10.4 PTO Bearing Removal And Installation. .10-34
10.5 PTO Clutch Installation . . . . . . . . . . . . . .10-34
10.7 Wheel and Hub Removal  . . . . . . . . . . . .10-35
10.8 Wheel Installation . . . . . . . . . . . . . . . . . .10-35

Section 11 - Fuel System . . . . . . . . . . . . . . . . . 11-36

11.1 Fuel System Troubleshooting . . . . . . . . . 11-36
11.2 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 11-36
11.3 Fuel System Contamination  . . . . . . . . . . 11-36

Section 12 - Hydraulic System . . . . . . . . . . . .12-37

12.1 Run-in Procedure . . . . . . . . . . . . . . . . . .12-37
12.2 Hydraulic Flow  . . . . . . . . . . . . . . . . . . . .12-37
12.3 Filter Change  . . . . . . . . . . . . . . . . . . . . .12-37
12.4 Hydraulic Hoses . . . . . . . . . . . . . . . . . . .12-37
12.5 Hydraulic Tank Removal & Installation

12-37

12.6 Hydraulic Cooler Removal & Installation.12-37
12.7 Hydraulic Pump Removal . . . . . . . . . . . .12-41
12.8 Overhaul Seal Kit Instructions. . . . . . . . .12-42
12.9 O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . .12-43
12.10 Shaft Seals . . . . . . . . . . . . . . . . . . . . . .12-43
12.11 Hydraulic Motor Removal & 

Replacement . . . . . . . . . . . . . . . . . . . . .12-43

Section 13 - Electrical  . . . . . . . . . . . . . . . . . . .13-44

13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-44
13.2 Electrical Measurements. . . . . . . . . . . . .13-44
13.3 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . .13-45
13.4 Charging . . . . . . . . . . . . . . . . . . . . . . . .  13-47

13.5 Switches . . . . . . . . . . . . . . . . . . . . . . . . .13-48
13.6 Solenoid And Relays. . . . . . . . . . . . . . . .13-48
13.7 Lighting Circuits  . . . . . . . . . . . . . . . . . . .13-49
13.8 Fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . .13-49
13.9 Diodes And Rectifiers . . . . . . . . . . . . . . .13-49
13.10 Electric Clutch . . . . . . . . . . . . . . . . . . . .13-50
13.11 Checking the PTO Clutch . . . . . . . . . . .13-50

13.12 Continuity Diagrams . . . . . . . . . . . . . . .13-51

13.13 991000 Electrical  . . . . . . . . . . . . . . . . .13-52

13.14 992000 Electrical  . . . . . . . . . . . . . . . . .13-73

TABLE OF CONTENTS

Summary of Contents for 991001-008

Page 1: ...Promaster 100 160 200 08484400 08 00 Printed in USA Service Manual Models 991001 008 992006 016 992301 304 ...

Page 2: ...Section 8 Mower Lift System 8 29 8 1 Mower Frame 8 29 8 2 Check Caster Wheels For Wear 8 29 8 3 To Replace Wheel Axle 8 29 8 4 Linkage 8 29 8 5 Hydraulic System 8 29 Section 9 Steering And Direction Contols 9 32 9 1 Steering And Direction Controls 9 32 Section 10 Drive Train 10 33 10 1 Transmission Troubleshooting 10 33 10 2 Replacing The Hydro Pump Belt 10 34 10 3 PTO Clutch Removal 10 34 10 4 PT...

Page 3: ... 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 the performance durability or 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 th...

Page 4: ...splaced tools or parts place removed components with all attaching hardware in the disassembly 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 locate tools or parts is a needless delay A list of required special tools has been included in this manual 2 7 CLEA...

Page 5: ...oking NO Sparks NO Flames Allow engine to cool before servicing NEVER fill fuel tank when 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 parts to stop Remove wire from spark plug Inspect unit and make any necessary repairs before restart Hazardous Slo...

Page 6: ...near battery Always wear safety glasses and protective gear near battery DO NOT TIP battery beyond a 45o 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 positi...

Page 7: ...Turn True Zero Turn Tire Size Rear 18 x 8 5 8 4 PLY 18 x 8 5 8 4 PLY 18 x 8 5 8 4PLY Rear Tire Pressure 20 25 psi 138 172 kN m 20 25 psi 138 172 kN m 20 25 psi 138 172 kN m Tire Size Front 11 x 4 4 4 PLY 11 x 4 4 4 PLY 11 x 4 4 4 PLY Front Tire Pressure 12 15 psi 83 103 kN m 12 15 psi 83 103 kN m 12 15 psi 83 103 kN m Diagnostic Light Oil Pressure Oil Pressure Oil Pressure Transmission Hydrostatic...

Page 8: ...e Zero Turn Tire Size Rear 18 x 8 5 8 4PLY 18 x 8 5 8 4PLY 18 x 8 5 8 4PLY Rear Tire Pressure 20 25 psi 138 172 kN m 20 25 psi 138 172 kN m 20 25 psi 138 172 kN m Tire Size Front 11 x 4 4 4 PLY 11 x 4 4 4 PLY 11 x 4 4 4 PLY Front Tire Pressure 12 15 psi 83 103 kN m 12 15 psi 83 103 kN m 12 15 psi 83 103 kN m Diagnostic Light Oil Pressure Oil Pressure Oil Pressure Transmission Hydrostatic Hydrostat...

Page 9: ...Turning Radius True Zero Turn True Zero Turn Tire Size Rear 18 x 8 5 8 4PLY 18 x 8 5 8 4PLY Rear Tire Pressure 20 25 psi 138 172 kN m 20 25 psi 138 172 kN m Tire Size Front 11 x 4 4 4 PLY 11 x 4 4 4 PLY Front Tire Pressure 12 15 psi 83 103 kN m 12 15 psi 83 103 kN m Diagnostic Light Oil Pressure Oil Pressure Transmission Hydrostatic Hydrostatic Hydro Pump Hydro Gear Variable Pump Hydro Gear Variab...

Page 10: ...g Hydro Dynamic Disc Parking Steering Twin T Bar Levers Twin T Bar Levers Twin T Bar Levers Turning Radius True Zero Turn True Zero Turn True Zero Turn Front Tire Size 13 x 5 6 13 x 5 6 13 x 5 6 Pressure 20 25 psi 20 25 psi 20 25 psi Rear Tire Size 20 x 10 10 20 x 10 10 20 x 10 10 Pressure 12 15 psi 12 15 psi 12 15 psi Starting System Electric Electric Electric Max Forward Speed 7 mph 11 2 kph 7 m...

Page 11: ... Dynamic Disc Parking Hydro Dynamic Disc Parking Hydro Dynamic Disc Parking Steering Twin T Bar Levers Twin T Bar Levers Twin T Bar Levers Turning Radius True Zero Turn True Zero Turn True Zero Turn Front Tire Size 13 x 5 6 13 x 5 6 13 x 5 6 Pressure 20 25 psi 20 25 psi 20 25 psi Rear Tire Size 20 x 10 10 20 x 10 10 20 x 10 10 Pressure 12 15 psi 12 15 psi 12 15 psi Max Forward Speed 7 mph 11 2 kph...

Page 12: ...king Steering Twin T Bar Levers Twin T Bar Levers Twin T Bar Levers Turning Radius True Zero Turn True Zero Turn True Zero Turn Front Tire Size 13 x 5 6 13 x 5 6 13 x 5 6 Pressure 20 25 psi 20 25 psi 20 25 psi Rear Tire Size 20 x 10 10 20 x 10 10 20 x 10 10 Pressure 12 15 psi 12 15 psi 12 15 psi Starting System Electric Electric Electric Max Forward Speed 7 mph 11 2 kph 7 mph 11 2 kph 7 mph 11 2 k...

Page 13: ...Hydro Dynamic Disc Parking Steering Twin T Bar Levers Twin T Bar Levers Twin T Bar Levers Turning Radius True Zero Turn True Zero Turn True Zero Turn Front Tire Size 13 x 5 6 13 x 5 6 13 x 5 6 Pressure 20 25 psi 20 25 psi 20 25 psi Rear Tire Size 20 x 10 10 20 x 10 10 20 x 10 10 Pressure 12 15 psi 12 15 psi 12 15 psi Starting System Electric Electric Electric Max Forward Speed 7 mph 11 2 kph 7 mph...

Page 14: ...ynamic Disc Parking Hydro Dynamic Disc Parking Steering Twin T Bar Levers Twin T Bar Levers Twin T Bar Levers Turning Radius True Zero Turn True Zero Turn True Zero Turn Front Tire Size 13 x 5 6 13 x 5 6 13 x 5 6 Pressure 20 25 psi 20 25 psi 20 25 psi Rear Tire Size 20 x 10 10 20 x 10 10 20 x 10 10 Pressure 12 15 psi 12 15 psi 12 15 psi Starting System Electric Electric Electric Max Forward Speed ...

Page 15: ...ers 4 Ammeter 5 Choke 003 004 007 008 009 301 302 6 Ignition Keyswitch 7 Choke Throttle 005 006 010 011 Throttle 003 004 007 008 009 301 302 8 PTO Switch 9 Deck Height Indicator On Units With Hydraulic Assist 10 Parking Brake Lever On 200 Series 11 Mower Lift Switch 12 Fuel Shut Off 13 Oil Light Figure 2 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 16: ...D COMMERCIAL TURF CARE EQUIPMENT N N SAFETY FIRST MADE IN THE U S A SPECIAL TRAINING NECESSARY READ OWNER S MANUALS BEFORE OPERA TING OR SERVICING KEEP ALL GUARDS AND SHIELDS IN PLACE NEVER PERMIT CHILDREN TO OPERATE LOOK FOR PEOPLE AND HAZARDS BEFORE LEAVING THE OPERATOR POSITION PUT PTO CONTROL IN THE OFF POSITION REMOVE IGNITION KEY CAUTION CAUTION DO NOT PARK ON SLOPES UNLESS WHEELS ARE CHOCKE...

Page 17: ...t 50 hours They both should be changed every 500 hours thereafter Be sure to stop engine before servicing any hydraulic parts 4 5 TENSIONING THE HYDRO PUMP BELT 1 Loosen the two nuts on the end of the idler rod 2 Tighten the two nuts until the gap in the coils of the spring is approximately 010 inches 25 mm 3 Lock the two nuts on the end of the idler rod Figure 4 PF2070 1 2 3 4 5 WARNING HYDRAULIC...

Page 18: ...l lever Loosen the bolts just enough to rotate the control levers on their shaft with some resistance 3 Position the control levers in the desired location and tighten the 5 16 18 bolt on each one 4 Move the control levers forward and backward as far as they will travel to check for interference in the instrument panel slots If there is interference readjust the neutral position 4 8 CHECK THE TIRE...

Page 19: ...d 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 the 4 chains fasten to the mower mounting brackets See Figure 8 1 Level the mower with blocks of equal height such as pieces of 2 x 4 s 2 Attempt to raise the mower until the chains on one side are tight 3 Loosen the locknuts on the side of the mower deck whe...

Page 20: ...ne Remove the ignition key 3 Remove footboard from support frame On 60 mower only 4 Loosen the jam nut on the idler rod See Figure 9 5 Turn the adjusting nut on the idler rod until the gap between the coils of the spring is 010 to 015 25 mm to 38 mm 6 Hold the adjusting nut and lock the jam nut against it Figure 9 1 Long Mower Belt 2 Short Mower Belt 3 Idler Rods 4 Springs 5 Jam nuts 6 Adjusting N...

Page 21: ...ect 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 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 engi...

Page 22: ...if worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and dam age 5 6 ENGINE REMOVAL AND INSTALLATION 1 Remove the battery cover and disconnect battery cables Remove negative cable first Remove the battery 2 Turn off fuel at fuel tank shut off valve and disconnect the f...

Page 23: ...aN authorized Gravely or Kawasaki Dealer SECTION 6 COOLING SYSTEM KAWASAKI ENGINES WARNING Never remove radiator cap while engine is running or hot If you must remove radiator cap follow these steps to avoid personal injury that can be caused by escaping steam or engine coolant Before removing cap turn engine off and let it cool Even when engine is cool be careful when removing radiator cap When e...

Page 24: ...oard back on the support frame 7 2 MOWER BLADE Regularly check mower blades for wear and that lock washer is fully compressed by cap screw s requires 25 30 ft lbs 33 8 40 6 Nm of torque on cap screw When blade needs sharpening block blade to prevent rotation and remove cap screw s lock washer s and blade from shaft Sharpen both edges of blade at original angle 25o removing equal amounts of materia...

Page 25: ...uts at top of spindle Remove pulleys Inspect shaft and woodruff key for wear 5 Unbolt and remove housing from deck 6 Install spindle in reverse order Apply grease to fitting on spindle Spindle Repair The spindle must be removed from the mower deck to remove the shaft and bearings Figure 14 Check spindle shaft for excessive play to repair 1 Remove the grease seals 2 Remove bearings and spindle shaf...

Page 26: ...r assembly 3 Release the mower PTO belt tension by removing tension on the idler pulley rod Figure 14 Loosen the two jam nuts and back them off Remove the belt 4 Remove the bolts holding the chains to the mower 5 Remove the mower mounting pin s and move the mounting arm s up 6 Slide mower out NOTE It may be easier if the lift is raised Figure 14 1 Seal 2 Bearing Housing 3 Spindle Shaft 4 Seal 5 Id...

Page 27: ...es 4 Unscrew nuts at top of spindle Remove pulleys Inspect shaft and woodruff key for wear 5 Unbolt and remove housing from deck 6 Install spindle in reverse order Apply grease to fitting on spindle Figure 15 1 Mower Mounting Arm 2 Mower Mounting Pin PF2040 1 2 1 2 1 2 50 Deck 60 Deck Promaster 200 CAUTION Mower blades may be sharp Use gloves or heavy padding to grip the blades ...

Page 28: ...7 28 OF0031 OF0041 Figure 16 1 Seal 2 Bearing Housing 3 Spindle Shaft 4 Seal 1 2 3 4 1 2 3 4 50 Deck 60 Deck Promaster 200 ...

Page 29: ...otter pin at top of shaft 2 Drop caster out from the bottom 3 Clean shaft and grease 4 Replace washers and bushings and reassemble 5 Apply grease 8 3 TO REPLACE WHEEL AXLE 1 Remove nut from axle bolt and pull axle bolt out Inspect roller bearing Clean roller and replace if needed 2 Grease axle bolt roller and wheel hub 3 Reassemble axle Tighten locking nut to remove play but allow wheel to turn 8 ...

Page 30: ... pump first 2 Connect hydraulic hose s to cylinder 3 Connect battery negative terminal first 4 Cycle unit up and down a few times to bleed the system 5 Add Dextron II or Dextron III to the full line on the reservoir if servicing is needed Hydraulic Cylinder Removal 1 Clean hydraulic fittings prior to removing hydraulic hoses 2 Disconnect hydraulic hoses Note orientation of hydraulic hoses 3 Discon...

Page 31: ...ldment noting where it was previously connected 4 Connect hydraulic hoses 5 Service electric hydraulic pump reservoir PF0881 OF0100 Figure 18 1 Motor Assembly 2 Adapter Assembly 3 Tank Reservoir 4 Hydraulic Lift Cylinder 1 2 3 4 1 2 3 4 60 Mower 50 Mower ...

Page 32: ...arm 3 Remove the neutral adjustment weldment and inspect woodruff key 4 Inspect bearing and pivot points for wear and replace as needed 5 Assemble in reverse order SECTION 9 STEERING AND DIRECTION CONTOLS PF2000 1 2 3 4 5 Figure 19 1 Steering Adjusting Rod 2 Rod End 3 Tension Spring 4 Speed Control Arm 5 Neutral Adjustment Weldment ...

Page 33: ... improperly installed 3 Inspect charge check valves 24 Inspect charge pump 45 Forks rod assembly incorrectly installed 4 Incorrect grade of lubricating oil 25 Bad transmission pump 46 Shifting keys broken or damaged 5 Low cranking speed 26 Overheating 47 Shifting washer in backwards 6 Controls not in correct operation position 27 Cold running 48 Shifter Brake shaft keyways damaged 7 Belts are miss...

Page 34: ...k back of unit and remove mower deck With deck removed lower rear of machine to floor This will make it much easier to remove the PTO 3 Use caution and remove the 5 8 bolt holding the PTO clutch in place Figure 21 10 4 PTO BEARING REMOVAL AND INSTALLATION 1 Separate the 2 clutch halves Press the bearing out from the inside of sheave 2 Inspect and replace any worn or damaged parts 3 Turn sheave ups...

Page 35: ...shaft Remove the castle nut and washer Slide hub off 5 Inspect hub bore woodruff key and shaft for any wear or damage Replace as needed 10 8 WHEEL INSTALLATION NOTE Use steel wool or fine sandpaper to remove any rust or paint from the motor shaft or wheel bore taper 1 Mark end of shaft to indicate where cotter key hole if used is located 2 Install key and slide hub on shaft 3 Install the washer an...

Page 36: ...ssemble the fuel system and check for proper operation SECTION 11 FUEL SYSTEM TROUBLE POSSIBLE CAUSES Refer to Key Below CORRECTIVE ACTION Hard Starting 1 3 4 6 11 12 14 16 17 18 clean repair or replace Fuel Leak at Carburetor 5 7 17 repair or replace Engine Floods 5 15 17 repair or replace Will not idle 1 2 3 6 repair or replace Rich idle 1 6 14 repair or replace idles with Needle Closed 14 repai...

Page 37: ...one on the fitting This prevents twisting off the fitting 1 When working on hoses have a container large enough to hold at least 4 qts of oil Some hoses will drain one side of the hydraulic tank and or oil cooler 2 After any hydraulic hose maintenance refer to Filter Change and Run In Procedure sections 12 5 HYDRAULIC TANK REMOVAL INSTALLATION 1 Place an open top container that will hold at least ...

Page 38: ...12 38 Figure 23 LP Low Pressure HP High Pressure FFBW Fluid Both Ways ...

Page 39: ...12 39 Figure 24 1 Cylinder Block Kit 2 Check Valve Kit 3 Charge Relief Valve Kit 4 Gerotor Assembly 5 Bypass Valve Kit 1 2 3 4 5 2 ...

Page 40: ...12 40 Models 992013 014 015 016 PF2020 Figure 25 ...

Page 41: ...2 nuts and bolts that hold the flanged support bushing Slide the bushing out 5 Remove the pump control bracket 6 If right pump is to be removed disconnect PTO safety switch to prevent damage to wires 7 Pinch off filter to pump hose and cooler to pump hose at pump Be sure not to over pinch and damage hoses Remove hoses Hold over container and drain hoses Cap off hoses to prevent contamination 8 Rem...

Page 42: ...harge relief valve spring and ball 4 Inspect the gerotor assembly charge pump cover and end cap for abnormal wear damage or foreign material Disassembly Procedures for the End Cap 1 Using a 6 mm hex wrench remove the 4 screws which retain the end cap to the pump housing The internal springs should separate the end cap from the housing Remove the end cap from the housing 2 Remove the old gasket fro...

Page 43: ... hammer type puller may also be used to remove the seal Care must be taken so as not to damage the housing bore shaft sealing surface or bearing Once removed the seal is not reusable 3 Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary Lubricate the new seal with clean oil 4 Wrap the spline or key end of the shaft with thin plasti...

Page 44: ...he part would cost and the results may not be as good 13 2 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 flo...

Page 45: ...dren 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 Battery Electrolyte First Aid External contact Flush with...

Page 46: ...a mixture of baking soda and water After cleaning apply a thin coat of grease or petroleum jelly to terminals and cable ends to retard corrosion Reinstall battery Check the alternator voltage regulator output if used at every periodic maintenance inspection Over charging is a common cause of battery failure Electrolyte Level Every 25 hours of operation check electrolyte level of each cell by remov...

Page 47: ...it used for jump starting should have a 12 volt battery with at least 500 cold cranking amperes and a negatively grounded system To jump start the battery 1 Ensure battery is not frozen If the fluid is frozen remove battery from unit and allow to thaw before charging 2 Connect the positive jumper cable to the positive terminal of the discharged battery 3 Connect the other end of the same jumper ca...

Page 48: ...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 ...

Page 49: ...tive or blown fuse If the fuse is blown check for a short in the wiring and correct before replacing the fuse If the fuse and lamps are good check the circuit with an AC DC voltmeter 13 8 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 certai...

Page 50: ...ts Engine servicing and repair should be referred to local engine manufactures service centers that have the service information and parts available to properly service the engine Gravely dealers should be able to test engines and engine components to pinpoint troubles and narrow them down to properly advise the engine serviceman 13 11 CHECKING THE PTO CLUTCH Measure Clutch Coil Resistance 1 Turn ...

Page 51: ...Switch 03602300 Relay 03042800 Seat Switch 03654200 Switch Neutral Start N O 020916 Lift Pump Switch 03437900 PTO Switch 00522100 3 9 ENGAGED up position DISENGAGED down position The diagrams below show the various states of connection for electrical components The solid lines on switches show continuity NOTE All switches are viewed from the rear 4 1 7 3 9 4 1 7 1 2 DISENGAGED 1 2 ENGAGED D A E C ...

Page 52: ... supplies power to the PTO switch neutral switches and terminal S2 to crank the engine Power is also routed through the diode to activate start kill relay and provide power to the fuel solenoid to keep the engine running Step 3 With the key in the RUN position verify power has been transferred to terminal A Terminal A supplies power to the seat relay terminals 30 86 and to the seat switch From the...

Page 53: ...BROWN BLACK YELLOW KEY SWITCH PURPL 1 2 4 3 9 1 PTO CLUTCH START RELAY BROWN YELLOW BLACK 1 2 YELLOW RED VIOLET SEAT SWITCH 1 2 PINK BLACK PURPL KEYED MAGNETO KILL RED BLACK HOUR METER BLACK PURPLE WHITE 1 2 SEAT RELAY STARTER SOLENIOD 3 STUD OIL PRESSURE BLUE WHITE PURPLE OIL LIGHT 7 RIGHT HAND NEUTRAL LEFT HAND NEUTRAL 2 1 4 YELLOW RED FUEL 30A RED YELLOW ...

Page 54: ...13 54 Promaster 100 Kohler Command 50 Deck with Lift Models 991006 ...

Page 55: ...Contact resistance is 0 1 0 3 ohms when correct Ignition Switch Off Run Start Red B 12 00 Vdc 12 00 Vdc 12 00 Vdc Purple A 12 00 Vdc 12 00 Vdc Red Violet S2 12 00 Vdc 12 00 Vdc Brown S1 12 00 Vdc 12 00 Vdc Relay Seat Off Run Start Pink 85 12 00 Vdc 12 00 Vdc Purple 86 12 00 Vdc 12 00 Vdc Yellow Red 87 12 00 Vdc 12 00 Vdc Purple 30 12 00 Vdc 12 00 Vdc Open 87A Relay Start Kill Off Run Start Black 8...

Page 56: ...n contacts Manually activated Contact resistance is 0 1 0 3 ohms when correct Relay Deck Lift Off Run Start Black 85 To Ground Purple 12 00 Vdc 12 00 Vdc Red 12 00 Vdc 12 00 Vdc Red 12 00 Vdc 12 00 Vdc 12 00 Vdc Open 12 00 Vdc PTO Switch Off Run Start Yellow Red 12 00 Vdc 12 00 Vdc Brown Yellow 12 00 Vdc 12 00 Vdc Purple 12 00 Vdc 12 00 Vdc Purple White to clutch 12 volt when activated Right Neutr...

Page 57: ... ohms when correct Key switch must be in RUN position to provide power to deck lift pump Seat Switch Off Run Start Pink 12 00 Vdc 12 00 Vdc Black to ground To Ground Hourmeter Off Run Start Black To Ground White 12 00 Vdc 12 00 Vdc Lift Switch Deck Off Run Start Red 12 00 Vdc 12 00 Vdc Green 12 volt when activated Blue 12 volt when activated ...

Page 58: ...ee that power has been transferred to terminal A R and B on the backside of the key switch Terminal A supplies power to the hourmeter and oil PSI switch and light Terminal R brings in the charge power from the engine to the battery Terminal B supplies power to the relay pin 86 and to the seat switch on to the time delay for the module holding circuit Step 4 With the key in the START position power...

Page 59: ...13 59 Promaster 100 Kohler 16 18 HP ...

Page 60: ...h Off Run Start Red I 12 00 Vdc 12 00 Vdc 12 00 Vdc Light Blue A 12 00 Vdc 12 00 Vdc Dark Blue R 12 00 Vdc 12 00 Vdc Purple B 12 00 Vdc 12 00 Vdc Brown S 12 00 Vdc Hourmeter Off Run Start Black 12 00 Vdc 12 00 Vdc White To Ground Right Interlock Switch Off Run Start Brown 12 00 Vdc 12 00 Vdc Brown White 12 00 Vdc 12 00 Vdc Left Interlock Switch Off Run Start Brown 12 00 Vdc 12 00 Vdc Brown White 1...

Page 61: ...ted Contact resistance is 0 1 0 3 ohms when correct Time Delay Module Off Run Start Brown 12 00 Vdc 12 00 Vdc Yellow 12 00 Vdc 12 00 Vdc Green 12 00 Vdc 12 00 Vdc Solenoid Off Run Start Brown S1 12 00 Vdc Brown S2 12 00 Vdc 12 00 Vdc Red from battery 12 00 Vdc 12 00 Vdc 12 00 Vdc Red to starter 12 00 Vdc PTO Interlock Switch Off Run Start Brown 12 00 Vdc 12 00 Vdc Brown White 12 00 Vdc 12 00 Vdc S...

Page 62: ...heck the 25 amp fuse or connection at the start solenoid Step 3 With the key switch in the RUN position see that power has been transferred to terminals L and A Terminal A supplies power to the relay pin 86 and on to the seat switch to activate the holding circuit for the time delay and fuel shut off solenoid Terminal A supplies power to the hourmeter and oil PSI light and brings in charge power f...

Page 63: ...13 63 Promaster 100 Briggs Stratton ...

Page 64: ...ch Off Run Start Brown S 12 00 Vdc Red B 12 00 Vdc 12 00 Vdc 12 00 Vdc White M Connected to ground Yellow L 12 00 Vdc 12 00 Vdc White Red G Engine Magneto Oil PSI Light Off Run Start Orange 12 00 Vdc 12 00 Vdc Green 12 00 Vdc 12 00 Vdc Hourmeter Off Run Start Black 12 00 Vdc 12 00 Vdc White 12 00 to ground 12 00 to ground PTO Interlock Switch Off Run Start Brown 12 00 Vdc 12 00 Vdc Brown White 12 ...

Page 65: ...h Off Run Start Brown 12 00 Vdc 12 00 Vdc Brown White 12 00 Vdc 12 00 to ground Relay Off Run Start Red and Green 86 12 00 Vdc 12 00 Vdc Black 87A Connected to ground kill thru relay pin 30 Green 85 12 00 Vdc 12 00 to ground Green 30 Connected to ground Time Delay Module Off Run Start Brown 12 00 Vdc 12 00 Vdc Yellow 12 00 Vdc 12 00 Vdc Green 12 00 Vdc 12 00 Vdc Solenoid Off Run Start Red battery ...

Page 66: ...omaster 100 Briggs Stratton Normally open switches manually activated Contact resistance is 0 1 0 3 ohms when correct Seat Switch Off Run Start Green Green 12 00 Vdc 12 00 Vdc Yellow Yellow 12 00 Vdc 12 00 Vdc ...

Page 67: ...supplies power to the relay pin 86 and on to the seat switch to activate the holding circuit for the time delay and fuel shut off solenoid Terminal A supplies power to the hourmeter and oil PSI light and brings in charge power from the engine to the battery Terminal M grounds the key switch with the unit Terminal G provides an additional ground for the kill circuit of the engine Step 4 With the ke...

Page 68: ...13 68 Model 992010 011 Briggs Stratton ...

Page 69: ...CK RELAY DELAY MOD PURPLE S B I R A IGNITION SWITCH GRN LIGHT LIGHT COOLANT TEMP OIL PRES GRN GRD CHG BATT CHG COIL CHG COIL CHG COIL CHG COIL KILL OIL TEMP OIL PRES RED YEL RED RED BLUE BATTERY 87 87A 30 85 86 87 87A 30 85 86 LIFT PUMP LIFT SWITCH ENG CONN REG RECT BLK BLK FUSE ORG BRN ORG GRN WHT WHT WHT GRN BRN WHT RED GRN YEL BRN RED LIGHT BLUE BRN WHT AMP ...

Page 70: ...s when correct Ignition Switch Off Run Start Brown S 12 00 Vdc Black I 12 00 Vdc 12 00 Vdc 12 00 Vdc Purple B 12 00 Vdc 12 00 Vdc Blue R 12 00 Vdc 12 00 Vdc Green A 12 00 Vdc 12 00 Vdc Start Relay Off Run Start Brown 86 12 00 Vdc Red 30 12 00 Vdc 12 00 Vdc 12 00 Vdc Yellow 87 12 00 Vdc Orange Brown White 85 Connected to ground Time Delay Module Off Run Start Purple 86 12 00 Vdc 12 00 Vdc Red White...

Page 71: ...own Connected to ground Brown Connected to ground Ignition Switch Off Run Start Brown S 12 00 Vdc Black I 12 00 Vdc 12 00 Vdc 12 00 Vdc Purple B 12 00 Vdc 12 00 Vdc Blue R 12 00 Vdc 12 00 Vdc Green A 12 00 Vdc 12 00 Vdc Left Neutral Switch Off Run Start Brown Connected to ground Black Connected to ground Pump Lift Switch Off Run Start Black 12 00 Vdc 12 00 Vdc 12 00 Vdc White Connected to ground H...

Page 72: ...olding circuit for the time delay Ignition Switch Off Run Start Brown S 12 00 Vdc Black I 12 00 Vdc 12 00 Vdc 12 00 Vdc Purple B 12 00 Vdc 12 00 Vdc Blue R 12 00 Vdc 12 00 Vdc Green A 12 00 Vdc 12 00 Vdc Time Delay Off Run Start Orange 12 00 Vdc Green 12 00 Vdc 12 00 Vdc PTO Switch Off Run Start Orange 12 00 Vdc 12 00 Vdc Light Blue When selected to on position 12 00 Vdc White Clutch Connected to ...

Page 73: ... in the RUN position see that power has been transferred to terminals A R and B on the backside of the key switch Terminal A supplies power to hourmeter PTO switch and oil pressure sensor Terminal R brings in the charge power from the engine to the battery Terminal B brings in power to the interlock relay and on to the seat switch for the holding circuit for the time delay Step 4 With the key in t...

Page 74: ...RELAY DELAY MOD S B I R A IGNITION SWITCH LIGHT LIGHT COOLANT TEMP OIL PRES GRD CHG BATT CHG COIL CHG COIL CHG COIL CHG COIL KILL OIL TEMP OIL PRES Y 87 87A 30 85 86 87 87A 30 85 86 LIFT PUMP LIFT SWITCH ENG CONN REG RECT BATTER BLK WHT GRN LIGHT BLUE BRN BRN WHT ORG BRN WHT YEL GRN GRN ORG PURPLE BRN GRN GRN FUSE RED YEL RED WHT RED RED WHT BLUE RED YEL BLK ...

Page 75: ...13 75 Model 992015 016 Kohler 20 HP ...

Page 76: ...13 76 Model 992301 Kohler 20 and 25 HP ...

Page 77: ...rect Ignition Switch Off Run Start Brown S 12 00 Vdc Black I 12 00 Vdc 12 00 Vdc 12 00 Vdc Purple B 12 00 Vdc 12 00 Vdc Blue R 12 00 Vdc 12 00 Vdc Green A 12 00 Vdc 12 00 Vdc Start Relay Off Run Start Brown 86 12 00 Vdc Red 30 12 00 Vdc 12 00 Vdc 12 00 Vdc Yellow 87 12 00 Vdc Orange Brown White 85 Connected to ground Time Delay Module Off Run Start Purple 86 12 00 Vdc 12 00 Vdc Red White 87A Conne...

Page 78: ...un Start Brown Connected to ground Brown Connected to ground Left Neutral Switch Off Run Start Brown Connected to ground Black Connected to ground Pump Lift Switch Off Run Start Black 12 00 Vdc 12 00 Vdc 12 00 Vdc White Connected to ground Hourmeter Off Run Start Green 12 00 Vdc 12 00 Vdc PTO Switch Off Run Start Orange 12 00 Vdc 12 00 Vdc Light Blue When selected to on position 12 00 White clutch...

Page 79: ...hes manually activated Contact resistance is 0 1 0 3 ohms when correct Module cannot be tested Seat Switch Off Run Start Yellow 12 00 Vdc 12 00 Vdc Green Holding circuit for the time delay Time Delay Off Run Start Orange 12 00 Vdc Green 12 00 Vdc 12 00 Vdc ...

Page 80: ...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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