Gravely pro-turn 460 diesel 992236 Operator'S Manual Download Page 1

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Operator’s Manual

Manuel du I’utilisateur

Pro-Turn

400 Diesel

04887100

•

9/15

Printed in USA

ENGLISH

FRANÇAIS

™

Models

992236 – Pro-Turn 460 Diesel

(SN 050,000 +)

992240 – Pro-Turn 472 Diesel

(SN 050,000 +)

Summary of Contents for pro-turn 460 diesel 992236

Page 1: ...Operator s Manual Manuel du I utilisateur Pro Turn 400 Diesel 04887100 9 15 Printed in USA ENGLISH FRANÇAIS Models 992236 Pro Turn 460 Diesel SN 050 000 992240 Pro Turn 472 Diesel SN 050 000 ...

Page 2: ...covered by a separate manual specific to the engine This manual is included in the literature package that shipped with the unit Refer to this manual for engine service recommendations If the engine manual is not available contact the engine manufacturer for a replacement manual SERVICE AND REPLACEMENT PARTS When ordering publications replacement parts or making service inquiries know the model an...

Page 3: ...tion Card and return the card to Gravely 4 Explain Limited Warranty Policy 5 Explain recommended lubrication and maintenance Advise customer on adjustments Instruct customer on controls and operation of unit Discuss and emphasize the Safety Precautions Give customer this Owner Operator and the engine manual Advise customer to thoroughly read and understand them Customer Note Your Dealer has been p...

Page 4: ...fer to Figure 2 for safety decal locations SAFETY 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 Slopes are a major factor related to loss of control and tip over accidents Operation on all slopes requires extra caution Tragic accidents can occu...

Page 5: ...00611A 07800401 P 07800403 KEEP HANDS and FEET AWAY 02 98 81 00 Figure 2 1 2 5 3 6 7 4 8 9 1 DANGER DANGER Read and understand the operator s manual before operating unit 1 1 Amputation Hazard To avoid amputation hazard do not put hands near rotating blades To avoid amputation hazard do not put hands near moving belts Keep hands away from all rotating or moving parts Keep all guards and shields in...

Page 6: ...es over 15 DO NOT operate on slopes over 15 1 4 Service Hazard Before servicing unit do the following Read owners manual before servicing or making adjustments to unit Set parking brake Remove key and disconnect spark plug before servicing or making adjustments to unit 1 5 Bystander Hazard DO NOT operate the unit in the presence of bystanders Do not carry passengers Look behind when operating the ...

Page 7: ...r shielded areas Shut off engine remove key and read manual before servicing or making adjustments to unit Keep children and others away from unit while unit is in operation Keep feet and hands away from all rotating or moving parts DO NOT step or stand in this area 4 DANGER Discharge Hazard NEVER operate unit without discharge chute in operating position Thrown objects can cause injury or damage ...

Page 8: ... certification Replace a damaged roll bar do NOT attempt to repair or modify Any alteration of the roll bar must be approved by the manufacturer DO NOT exceed the machine weight rating of the roll bar 8 CAUTION No smoking Fill fuel tank to bottom of neck MAXIMUM MAX FILL Never fill fuel tank when engine is running hot or unit is indoors Never overfill fuel tank Replace fuel cap securely and clean ...

Page 9: ...dals or canvas shoes during operation Wear adequate safety gear protective gloves and footwear Wear proper footwear to improve footing on slippery surfaces Always wear eye and ear protection when operating machine Before Operating Keep all nuts and bolts tight to be sure the equipment is in safe working condition Maintain the machine to be in compliance with the maintenance schedule Clean grass an...

Page 10: ... off engine and wait for all parts to come to a complete stop before cleaning the machine removing the grass catcher or unclogging the discharge guard Know the weight of loads Limit loads to those you can safely control and the unit can safely handle Operating Conditions Always check overhead and side clearances carefully before operation Watch for traffic when operating near or crossing roadways ...

Page 11: ...y an approved container with an appropriately sized dispensing spout NO smoking NO sparks NO flames Remove equipment from the trailer and refuel it on the ground If this is not possible then refuel such equipment with a portable container rather than from a fuel dispenser nozzle Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fueling is complete...

Page 12: ...nit during maintenance Release any pneumatic or hydraulic pressure from components slowly 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 Lower cutting deck unless a positive mechanical lock is used Allow engine to cool before serv...

Page 13: ...ge 21 IMPORTANT Refer to engine manual for fuel type 14 Inspect Hardware Check for loose hardware 15 Check Safety Interlock System Check to see that the interlock system operates correctly See Safety Interlock System on page 16 16 Lubrication Lubricate all fittings per maintenance label under seat and check hydraulic oil level See Maintenance Schedule on page 24 17 Remove the knob retaining the di...

Page 14: ...unit to ensure deck level set at factory has been maintained See Leveling the Mower Deck on page 42 4 Check Function of all Controls Ensure unit runs and performs properly Figure 4 Reinstall hairpin and clevis here Shipping position for hairpin and clevis Figure 5 1 Recliner Pin 2 Bearing 3 Seat Adjustment Dial 4 Washer 5 Bowed Washer 6 Flat Washer 7 3 8 16 x 1 1 2 Hex Bolt 1 2 4 3 5 6 7 WARNING F...

Page 15: ...t Lock Lever 15 Seat Adjustment Lever 16 Seat Height Pressure Adjustment Knob 17 Parking Brake Lever 18 Transaxle Bypass Valve 19 Oil Pressure Light 20 Engine Overheat Light 21 Height of Cut HOC Index Wheel 22 Engine Preheat Indicator 23 Roll Over Protection Structure ROPS 24 Radiator Filler and Cap 25 Anti Scalp Wheels 26 12V Auxiliary Power Port 27 Seatback Adjustment Dial CONTROLS AND FEATURES ...

Page 16: ...ck pins in the hinge plate and secure with the hair pins Raise Center Bar Figure 7 1 Remove the two hair pins and then remove the ROPS lock pins from the hinge plate 2 Raise the center bar into up position 3 Install the ROPS lock pins in the hinge plate and secure with the hair pins 4 Tighten anti rattle knobs until threads place tension on upper bar Do not overtighten NOTICE Return the center bar...

Page 17: ... Switch Operate the ignition switch with the removable key The switch has three positions Off 1 On 2 Start 3 To start the engine turn the key to Start then release to On To stop the engine turn the key to Off Engine Preheat Light Indicates when the engine preheater is energized Preheater energizes for approximately 5 seconds when the key switch is turned to the Run position Oil Pressure Light Indi...

Page 18: ...by bypassing the transaxles The bypass valves 1 are located on the transaxles near the rear tires See To Push The Unit on page 23 NOTICE Make sure both transaxles are set to neutral before pushing the unit IMPORTANT DO NOT tow the unit Transport the unit on an appropriate truck or trailer Power Take Off PTO Switch Power take off PTO switch engages and disengages the mower blades Pull the power tak...

Page 19: ...he Off position Height of Cut HOC Figure 8 1 Push mower lift pedal to release deck pressure from HOC index wheel 2 If locked move transport lock lever to unlocked position 3 Rotate HOC index wheel to the desired HOC setting Height setting is viewed in the center the window on the top of the HOC adjustment assembly 4 Release mower lift pedal Fuel Control Lever Controls fuel flow from the left or ri...

Page 20: ... too far from the isolator The correct adjustment for the seat retainer threaded washer is 3 6 mm 1 8 1 4 below the bottom of the isolator mount HOUR MAINTENANCE METER Hour Meter only Models Hour meter measures engine runtime and cannot be reset Maintenance Models Figure 11 When the key is in the on position the Timer mode displays Press the Mode button to toggle between different models Timer Mea...

Page 21: ...110 volt voltage inverter FILLING FUEL TANK To add fuel to the fuel tank 1 Move unit to an open well ventilated area 2 Stop engine and allow it to cool 3 Clean fuel cap and surrounding area to prevent dust dirt and debris from entering fuel tanks 4 Remove fuel caps IMPORTANT See Specifications on page 47 for correct type and grade of fuel and fuel tank capacity 5 Fill fuel tanks to the bottom of f...

Page 22: ...gage the parking brake 2 Move the throttle lever to the Slow position 3 Allow engine to idle before shutting off unless there is a safety problem that requires immediate shut down 4 Turn the ignition key to the Off position STOPPING IN AN EMERGENCY 1 Return steering levers to neutral position 2 Immediately set parking brake 3 Turn off PTO and engine TO MOW WITH UNIT Operate the unit only when seat...

Page 23: ...6 Engage parking brake 7 Turn the bypass valves a quarter turn counter clockwise to the run position FOR BEST PERFORMANCE Cut grass when it is dry Keep mower blades sharp Keep mower deck properly leveled Adjust anti scalp rollers to prevent scalping Adjust the idler spring length as needed See Figure 34 Do not set height of cut too low For very tall grass mow twice Do not travel too fast Mow with ...

Page 24: ... Specifications on page 47 for correct tire pressure CAUTION Avoid injury Explosive separation of tire and rim parts is possible when they are serviced incorrectly Do not attempt to mount a tire without the proper equipment and experience to perform the job Do not inflate the tires above the recommended pressure Do not stand in front or over the tire assembly when inflating Use a clip on chuck and...

Page 25: ...ins and inside the engine shrouds to remove grass chaff or dirt Check Fasteners Check mower blade mounting hardware and all other fasteners Replace missing or damaged fasteners Tighten all nuts and bolts to their correct torque value Check Belts Replace worn or deteriorated belts See Replacing Mower Belts on page 38 and Replacing the Hydro Pump Belt on page 39 Every 400 Hours Change Gearbox Oil Co...

Page 26: ...heel Bearings 1 Shut off unit wait for all moving parts to stop remove key and engage parking brake 2 Remove wheel from fork 3 Remove end caps from wheel hub 4 Apply grease through fitting until grease squeezes through the seal in the wheel hub 5 Wipe off excess grease 6 Reinstall end caps onto hub 7 Reinstall wheel into fork After tightening bolt tire should not have any side to side play Tighten...

Page 27: ...for detailed instructions CHANGE ENGINE OIL Figure 14 Change oil per engine manufacturer s recommendations Refer to Engine Manual for detailed instructions 1 Run engine just prior to changing oil Warm oil will flow more freely and carry away more contamination 2 Remove the oil drain hose from the storage clip and move it to the service position 3 Remove drain plug and drain engine oil NOTICE Use t...

Page 28: ...n Hose Service Position 2 3 1 4 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 Ensure all hyd...

Page 29: ... to 22 5 N m 16 7 lb ft 10 Remove the cap from the expansion tank 11 Fill the expansion tank with 15W 50 synthetic motor oil Gravely p n 00057100 or equivalent until oil level reaches the cold fill line on the tank 12 Reinstall the expansion tank cap and then purge the system See Purging the Hydraulic System on page 29 13 Repeat steps 2 12 for the other transaxle Purging the Hydraulic System NOTIC...

Page 30: ...ine and allow to cool 2 Place suitable container under unit to catch coolant 3 Open engine block drain valve and allow coolant to drain See Figure 18 4 Place suitable container under radiator drain valve to catch coolant 5 Remove radiator screen to gain access to radiator 6 Loosen radiator fill cap and open radiator drain valve See Figure 18 WARNING To avoid personal injury DO NOT remove radiator ...

Page 31: ...e Figure 17 8 Replace radiator screen Fuel Filter Figure 19 NOTICE Unit has two fuel filters One cartridge style which is attached to the engine and one in line style which is installed in the fuel line between the fuel valve and the fuel pump 1 Place suitable container under unit to catch fuel 2 Remove fuel filter and dispose of properly 3 Install replacement fuel filter MOWER BLADES Remove Figur...

Page 32: ...gure 22 4 Install mower blade s on unit 5 Torque bolts to 156 217 N m 115 160 lb ft IMPORTANT When sharpening blades be sure to grind the same amount on each side Unbalanced blades will cause excessive vibration and could cause the spindles to wear prematurely CAUTION DO NOT sharpen mower blades while on unit An unbalanced mower blade will cause excessive vibration and eventual damage to unit Chec...

Page 33: ...rate will damage or destroy battery ONLY use an automatic charger designed for use with your battery ALWAYS follow information provided on battery by battery manufacturer Contact battery manufacturer for extensive instructions to charge battery 1 Remove battery from unit See Remove Battery on page 33 2 Place battery on bench or other well ventilated place 3 Connect positive lead of charger to posi...

Page 34: ...he fuse box on the right side of the seat 1 Remove defective relay from socket 2 Install new relay into socket STEERING CONTROL NEUTRAL ADJUSTMENT Eliminating Excessive Creeping of the Unit Figure 25 1 If hydraulic system is cold run unit for a minimum of five minutes then shut off engine 2 With the unit up to and facing a wall lift the unit so that both drive wheels are off the ground 3 Remove th...

Page 35: ... the wheel stops moving then tighten the jam nuts on each ball joint 13 Reinstall drive wheels Adjusting Transaxle Neutral NOTICE If neutral cannot be set adjusting the steering linkages the neutral mechanism on the transaxle may need to be adjusted Follow steps 1 6 in Eliminating Excessive Creeping of the Unit on page 34 1 If a hub moves adjust the return to neutral mechanism on the hydraulic pum...

Page 36: ...nd angle adjustment bolt 3 Rotate the steering lever assembly to desired forward lever position 4 Tighten hardware IMPORTANT Ensure that both levers are aligned and do not make contact with each other Adjust Lever Height Figures 28 and 29 1 Shut off engine Remove the ignition key 2 Remove pivot bolt and angle adjustment bolt from steering lever assembly and remove steering lever assembly 3 Positio...

Page 37: ...1 1 Engage parking brake and set both transmission bypass valves to the neutral position See To Push The Unit on page 23 2 Push the unit forward If the unit easily rolls forward the transmission brakes are not fully engaging Adjust the brake actuator travel to set the brake Adjust the Parking Brake 1 Engage the parking brake 2 Loosen the jam nuts on the rear of the compression spring until there i...

Page 38: ...ower belt item 2 from right blade sheave and from deck Idler pivot bolt must be loosened slightly to gain clearance to remove belt from under idler pulley 6 Arrange new mower belt s on deck short belt first Retighten short mower belt idler pivot bolt Install belts on sheaves Put belts onto center sheave last NOTICE The PTO idler spring length range is 31 31 8 cm 12 1 4 12 1 2 measured at a 8 9 cm ...

Page 39: ...ning belt on sheaves Put belt onto right hand hydrostat sheave last 7 Replace clutch stop Tighten hardware to 27 45 N m 20 33 lb ft 8 Replace long mower belt on mower clutch sheave See Replacing Mower Belts on page 38 Figure 33 1 PTO Mower Belt 2 Mower Drive Belt 3 Springs 4 Mower Drive Belt Idler 5 PTO Mower Belt Idler 6 Mower Clutch Sheave 7 Center Sheave 8 Belt Guide Bolt 1 2 4 7 6 5 3 3 8 Figu...

Page 40: ...bracket NOTICE There are two anti scalp rollers on the outside of the mower deck and two anti scalp rollers on the inside of the mower deck Make sure all anti scalp rollers are set at the same height Deck Lift Pedal Adjustment Figure 37 To adjust the foot pedal 1 Remove the hex bolt securing the foot pedal to the lift arm 2 Move foot pedal to desired position 3 Install hex bolt and torque to 71 95...

Page 41: ...he trunnions on both sides Ensure that both assist springs are adjusted to the same dimension NOTICE Lift springs must be adjusted to the same tension on each side of the deck to prevent cut quality issues Removing the Mower Deck Figure 39 1 Remove PTO belt See Replacing Mower Belts on page 38 NOTICE Support the mower deck on blocks or jack stands before disconnecting links from mower lift arms to...

Page 42: ...e not raise the low side of the deck using the height adjusters on the deck lift brackets see Figure 41 5 After deck is level side to side check the deck front to back pitch 6 Turn the blades so the blade ends point front to back as shown in Figure 40 7 Measure the distance between the ground and the cutting edge of the middle blade at the front of the deck Front position in Figure 40 and between ...

Page 43: ... slide between armature and rotor with slight contact Maximum A 0 050 cm 0 020 feeler gauge should slide between armature and rotor with slight contact 3 Repeat for each inspection slot To adjust 1 If necessary loosen gap adjustment nuts until a 0 040 cm 0 016 feeler gauge fits between armature and rotor 2 Slide a 0 050 cm 0 020 feeler gauge between armature and rotor 3 Tighten gap adjustment nut ...

Page 44: ...fuel system for extended periods without a stabilizer will deteriorate resulting in sludge and sediment deposits forming in the system These deposits can damage the fuel injectors and the fuel hoses filter and tank Prevent deposits from forming in the fuel system during storage by adding a quality diesel fuel stabilizer to the fuel Follow the recommended mix ratio found on the diesel fuel stabiliz...

Page 45: ...he off position 1 Ignition ground wire disconnected 2 Ignition switch failure 1 Connect ground wire to clean metal surface 2 Replace ignition switch see your Gravely Dealer Water temperature gauge is reading above normal engine is overheating 1 Engine oil level low 2 Coolant level low 3 Radiator plugged with debris 4 Faulty radiator 1 Add engine oil Refer to Engine Manual 2 Add coolant see Checkin...

Page 46: ...60 79212400 Anti Scalp Wheel Kit 79214400 Electric Deck Lift Kit SERVICE PARTS Be sure to always use genuine Gravely parts to keep your unit running like new Part Number Qty Description 21536900 1 Air Filter Inner Safety Element 21537000 1 Air Filter Outer Primary Element 21500001 1 Engine Oil Filter 21526200 1 Fuel Filter Cartridge 21500003 1 Fuel Filter Pre pump In Line 21548300 2 Hydraulic Oil ...

Page 47: ... D Tank Capacity L gal 49 13 Transmission Type Hydrostatic Drive Transmission Oil Use 15W 50 synthetic motor oil Gravely p n 00057100 or equivalent Hydraulic Oil Filter Yes Size and Weight Length cm in 224 8 88 5 226 8 89 3 Width cm in With Discharge Chute Without Discharge Chute 190 5 75 160 0 63 221 0 87 190 5 75 Height cm in ROPS Extended ROPS Folded 178 8 70 4 132 6 52 2 Weight kg lbs 842 1856...

Page 48: ...clusions set forth herein Such repair or replacement will be free of charge labor and parts to the original purchaser except as noted below Special Extensions The chart below details special extensions to this warranty Warranty Code Product Group Warranty Period Consumer Use Warranty Period Commercial Use CA Pro Turn 100 200 Pro Master Compact Pro Pro Stance Pro Ride Pro Walk Mowers Pro Zoom etc 3...

Page 49: ...ey are noted in the Limitations section above lubricants spark plugs oil oil filters air filters fuel filters brake linings brake arms brake shoes skid shoes scraper blades shear bolts mower blades mower vanes brushes headlights light bulbs knives cutters Any misuse alteration improper assembly improper adjustment neglect or accident which requires repair is not covered by this warranty Use of gas...

Page 50: ...nt of any defective part Ariens Company shall not be liable for incidental special or consequential damages including lost profits Some states do not allow the exclusion of incidental or consequential damages so the above limitation or exclusion may not apply to you AUSTRALIAN CONSUMER LAW The following applies solely to warranties subject to Subsection 102 1 of the Australian Consumer Law Our goo...

Page 51: ...655 West Ryan Street Brillion WI 54110 gravelymower com gravely custhelp com ...

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