Promaster 250Z, 260Z, 272Z
Service Manual
992018, 020, 023, 027, 029, 030
992032, 033, 034, 035
09254300A 8/04
Printed in USA
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Ariens Company
EC DECLARATION OF CONFORMITY ISSUED BY THE MANUFACTURER –
DÉCLARATION DE CONFORMITÉ CE ÉMISE PAR LE FABRICANT – EU-
655 West Ryan Street
P.O. Box 157
ÜBEREINSTIMMUNGSERKLÄRUNG DES HERSTELLERS – VERKLARING VAN
OVEREENSTEMMING VOOR DE EU, AFGEGEVEN DOOR DE FABRIKANT – EF
OVERENSSTEMMELSESERKLÆRING UDSTEDT AF FABRIKANTEN – DICHIARAZIONE
DI CONFORMITÀ CE RILASCIATA DAL PRODUTTORE – DECLARACIÓN DE
CONFORMIDAD CE EMITIDA POR EL FABRICANTE – EF-SAMSVARSERKLÆRING FRA
PRODUSENTEN – EG-DEKLARATIONEN OM ÖVERENSSTÄMMELSE UTFÄRDAD AV
TILLVERKAREN – VALMISTAJAN ANTAMA EY-VAATIMUSTENMUKAISUUSVAKUUTUS –
Brillion, Wisconsin 54110-0157
USA
Telephone (920) 756-2141
Facsimile (920) 756-2407
DEKLARACJA ZGODNO
DECLARAÇÃO DE CONFORMIDADE CE EMITIDA PELO FABRICANTE
We the undersigned, ARIENS COMPANY, certify that: Nous, soussignés ARIENS COMPANY, certifions que : Der Unterzeichnete,
ARIENS COMPANY, bescheinigt, dass: Wij, de ondergetekenden, ARIENS COMPANY, verklaren dat: Undertegnede, ARIENS
COMPANY, attesterer, at: La sottoscritta società 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, että: My, niżej podpisani, ARIENS COMPANY, oświadczamy, że: Nós, abaixo
assinados, certificamos em nome da ARIENS COMPANY, que:
ŚCI Z PRZEPISAMI EC WYDANA PRZEZ PRODUCENTA –
–
–
–
–
–
–
–
–
–
–
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Type:
Type:
Tipo:
–
–
–
Type :
Type:
Type:
–
Typ:
Tipo:
–
–
Riding Rotary Lawn Mower – Tondeuse à gazon autoportée rotative – Aufsitz-Sichelmäher – Rijdende
–
–
–
roterende grasmaaier – Havetraktor med roterende knive – Trattorino con unità di taglio rotativa – Tractor
cortacésped giratorio – Plentraktor med rotorklipper – Rotoråkgräsklippare – Ajoleikkuri – Samobieżna
rotacyjna kosiarka trawnikowa – Tractor Cortador de Relva –
Typ:
Tipo:
–
Tyyppi:
–
Typ:
Trade Name:
commerciale:
–
–
Appellation commerciale :
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Handelsbezeichnung:
–
Handelsnaam:
–
Firmanavn: Nome
Gravely
Nombre comercial: Handelsnavn:
–
–
Handelsbeteckning:
–
Kauppanimi: Nazwa handlowa:
–
Nome da Marca:
Model: Modèle :
Cutting Width (cm):
Larghezza di taglio (cm):
Szerokość cięcia (cm):
–
–
Modell:
Largeur de coupe (cm) :
Ancho de corte (cm):
Largura de corte (cm):
–
Model:
–
Model:
–
Modello:
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Modelo:
–
–
Modell:
Maaibreedte (cm):
: Klippbredd (cm):
–
Modell:
–
Malli:
Klippebredde (cm):
Leikkuuleveys (cm):
–
Model:
–
Modelo:
992318
992319
152
–
–
Schnittbreite (cm):
–
–
152
–
–
Klippebredde (cm)
–
–
–
–
Conforms to:
overensstemmelse med:
Jest zgodny z: De acordo com:
–
Est conforme à :
–
Mit den Anforderungen der folgenden Richtlinien übereinstimmt:
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Voldoet aan:
–
Er i
–
È conforme a:
–
Cumple con: Er i samsvar med: Överensstämmer med:
–
–
–
Täyttää seuraavat vaatimukset:
–
–
98/37/EC, 89/336/EEC;
2000/14/EC Conformity Assessment Annex VI.
Annexe VI de l'évaluation de conformité. Konformitätsbewertung, Anhang VI.
Vurdering af overensstemmelse Anneks VI. Annesso VI della valutazione di conformità.
Samsvarsvurdering etter vedlegg VI. Bedömning av överensstämmelse Bilaga VI. Vaatimustenmukaisuuden arviointi, liite VI.
Dodatek VI, Ocena zgodno ci. Anexo VI da Avaliação de Conformidade.
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Bijlage VI voor beoordeling van overeenstemming.
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Anexo VI de la evaluación de la conformidad.
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ś
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Representative Measured Sound Power Level (L
)
–
Niveau de
Guaranteed Sound Power Level (L ) – Niveau de puissance
wa
wa
puissance acoustique représentatif mesuré (L
)
–
Repräsentativer acoustique garanti (L ) – Garantierter Geräuschpegel (L ) –
wa
wa
wa
gemessener Geräuschpegel (L
)
–
Representatief gemeten
Gegarandeerd geluidsniveau (L ) – Garanteret støjeffektniveau
wa
wa
geluidsniveau (L
)
–
Repræsentativt, målt støjeffektniveau (L
)
–
(L ) – Livello di potenza sonora garantito (L ) – Nivel de potencia
wa wa
wa
wa
Livello di potenza sonora rappresentativo rilevato (L
)
–
Nivel de
Representativt
Representativ uppmätt ljudnivå (L
acústica garantizado (L ) – Garantert lydeffektnivå (L ) –
Garanterad uppmätt ljudnivå (L ) – Taattu äänitehotaso (L ) –
wa wa
Gwarantowany reprezentatywny poziom mocy akustycznej (L ) –
wa
wa wa
potencia acústica representativo medido (L
)
–
wa
målt lydeffektnivå (L
)
–
)
–
wa
wa
wa
Tyypillinen mitattu äänitehotaso (L
)
–
Zmierzony reprezentatywny Nível de Potência de Som Garantido (L ) –
wa
wa
poziom mocy akustycznej (L
)
–
Nível de Potência de Som
wa
Medido Representativo (L
)
wa
992318: 104 dB
992319: 104 dB
992318: 105 dB
992319: 105 dB
A
A
A
A
3
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Notified Body – Organisme notifié – Zertifizierungsstelle –
Aangemelde instantie – Bemyndiget organ – Organismo notificato –
Organismo notificado – Teknisk kontrollorgan – Anmält organ –
Ilmoitettu laitos – Organ zaświadczający – Organismo –
Certificador
SNCH
11, Route de Luxembourg
L-5230 Sandweiler
Philip J. Smucker:
11/24/2003
Date Date
Dato
Dato Datum
Data
Quality and Conformance Manager (Keeper of Technical File)
Responsable de la qualité et de la conformité des produits
(Dépositaire de la fiche technique)
und Konformität (Archivar der technischen Akte)
normalisatiemanager (Beheerder van technische bestand)
–
–
–
Datum
Data
Datum
Fecha
Päiväys Data
–
–
–
–
Manager Qualitätssicherung
Ariens Company
–
Kwaliteits- en
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–
–
Chef for Brillion, WI 54110-0157 USA
kvalitet og overensstemmelse (Indehaver af tekniske data)
Responsabile della qualità e della conformità del prodotto
–
Signature
Handtekening
Signatur Namnteckning Allekirjoitus
Podpis Assinatura
–
Signature
–
Unterschrift
(Depositario del file tecnico)
(Depositario del archivo técnico)
(innehaver av teknisk fil) Chef för kvalitet och
produktöverensstämmelse (Innehavare av tekniska data)
ja vaatimustenmukaisuudesta vastaava johtaja (Teknisen tiedoston
haltija) Kierownik do spraw jakości i zgodności
(Przechowujący Dokumentację Techniczną) Gestor de Qualidade
–
Gerente de calidad y conformidad
–
Underskrift
–
Firma Firma
–
Kvalitet- og samsvarsansvarlig
–
–
–
–
–
–
Laadusta
–
–
e Conformidade (Zelador de Arquivos Técnicos)
CE Sound and Vibration – Bruits et vibrations
CE – CE Geräusch- und Vibrationswerte – CE
Geluid en trilling – CE støj og vibration –
Livello sonoro e vibrazioni CE – Sonido y
vibración CE – CE-lyd og -vibrasjon – CE
ljudnivå och vibrationer – CE, melu ja tärinä –
CE Dźwięku i Wibracji – Som e Vibração CE –
(Ref. EN836-2001)
Model:
–
Modèle :
–
Modell:
–
Model:
–
Model:
–
Modello:
–
Modelo:
–
Modell: Modell:
–
Malli:
–
Model:
–
992318
992319
Modelo:
Oper. Ear Sound Pressure (L ) in dB – Pression acoustique aux oreilles de l’opérateur (L ) en dB –
pa
A
pa
A
Geräuschpegel am Ohr des Bedieners (L ) in dB – Geluidsdruk bij het oor van de gebruiker (L ) in dB –
pa
A
pa
A
Strøjtryk ved brugerens øre (L ) målt i dB – Pressione sonora all’orecchio dell’operatore (L ) in dB – Presión
pa
A
pa
A
de sonido en el oído (L ) in dB – Lydtrykk ved førerens øre (L ) inn dB – Ljudeffekt vid förarens öron (L ) i
pa
A
pa
A
pa
dB – Kuljettajan korvaan kohdistuva äänenpaine (L ), dB – Robocze ciśnienie akustyczne na uchu (L ) w
A
pa
A
pa
decybelach – Oper. Pressão do Som no Ouvido (L ) em dB
90
90
A
pa
A
2
2
Vibration Measure (m/sec ) at Operator
–
Mesure des vibrations (m/s ) au niveau de l’opérateur
–
Vibration (m/
2
2
2
s ) an des Bedieners
–
Gemeten trilling bij (m/sec )
percepite dall’operatore (m/sec )
Vibrationsmått (m/s ) vid förarens
Medida de Vibração (m/seg. ) no Operador
–
Vibrationsmålinger (m/s ) ved brugerens
Medida de vibración (m/seg ) en el operador
–
Vibrazioni
2
2
2
–
–
Vibrasjonsmåling (m/s ) ved
2
2
2
førerens
–
–
Tärinä (m/s ) kuljettajan
–
Pomiar wibracji (m/sec ) u operatora
–
2
Hands – Mains – Hände – De handen van de gebruiker – Hænder – Mani – Manos – Hender – Händer – Käsissä
– Ręce – Mãos
X
Y
Z
3.2
0.5
0.9
< 2.5
< 2.5
< 2.5
Feet – Pieds – Füße – De voeten van de gebruiker – Fødder – Piedi – Pies – Føtter – Fötter – Jaloissa – Stopy
– Pés
X
Y
Z
0.2
0.2
0.8
0.5
0.5
0.7
Seat – Siège – Sitz – De bestuurdersplaats – Sæde – Sedile – Asiento – Sete – Säte – Istuimella – Siedzenie –
Assento
X
Y
Z
0.3
0.3
0.5
0.5
0.5
0.6
4
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INTRODUCTION
honored, whether or not the product registration card is
returned. Keep a proof of purchase if you do not
register your unit.
THE MANUAL
The purpose of this manual is to provide complete
instructions for service, maintenance, disassembly,
repair, and installation of the mechanical components
for the Promaster 250Z, 260Z, and 272Z.
Customer Note: If the dealer does not register your
product, please fill out, sign, and return the product
registration card to Gravely.
Dealer trained service personnel should use this
manual as a supplement to and reminder of the training
sessions conducted by the company.
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.
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.
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.
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.
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 dealer is responsible to carry out the
directive provided in the communication. The types of
communication are:
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.
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.
Serial Number
Label
Product Notices - Notification of limited product
located in a certain region. This is a limited distribution
to only those who received the product involved.
OA0017
Campaigns - Notification of a safety related issue. All
products must be updated and are tracked by the
factory until all units are corrected.
Figure 1
PRODUCT REGISTRATION
PREPARATION
The Gravely dealer must register the product at the
time of purchase. Registering the product will help the
company process warranty claims or contact you with
the latest service information. All claims meeting
requirements during the limited warranty period will be
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.
5
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SAFETY
NOTATIONS
NOTE: General reference information for proper opera-
tion and maintenance practices.
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.
IMPORTANT: Specific procedures or information
required to prevent damage to unit or attachment.
WARNING: Slopes are a major factor related to
loss-of-control and tip-over accidents. Operation
on all slopes requires extra caution.
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.
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 vapors are explosive, handle with care.
REQUIRED OPERATOR TRAINING
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.
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:
SAFETY DECALS AND LOCATIONS
ALWAYS replace missing or damaged safety decals.
See Figure 2 for safety decal locations.
•ATTENTION!
1. DANGER! TO AVOID SERIOUS INJURY OR
DEATH
OL1253
•YOUR SAFETY IS INVOLVED!
When you see this symbol:
•BECOME ALERT!
•OBEY THE MESSAGE!
OL3900
Read Operator’s Manual.
OL 1801
Keep children and others away from unit
while operating.
SIGNAL WORDS
The safety alert symbols above and signal words below
are used on decals and in this manual.
OL 4370
Never direct discharge toward other
people. Thrown objects can cause injury.
Read and understand all safety messages.
OL 0910
DANGER: IMMINENTLY HAZARDOUS
SITUATION! If not avoided, WILL RESULT in
death or serious injury.
Look down and behind before and while
backing.
OL 4460
WARNING: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, COULD RESULT in
death or serious injury.
Never carry children.
OL 4470
CAUTION: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, MAY RESULT in
minor or moderate injury. It may also be used to
alert against unsafe practices.
Go up and down slopes, not across. DO
NOT operate on slopes over 17o.
MAX
17°
OL 4450
6
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• 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
rotating parts.
OL 3030
Always stand clear of discharge area. Do
not direct discharge toward other people.
OL 0910
Keep people away from unit while
operating.
OL 4370
Shut off engine, remove key, and read
manual before you adjust or repair unit.
OL 4010
NO STEP! Always keep feet away from
rotating parts.
OL 4420
3. WARNING!
Always stand clear of discharge area.
OL 4430
Do not operate mower unless guards are in
operating position or bagger is attached.
OL 3320
4. HOT SURFACES!
DO NOT touch parts which are hot from
operation. ALWAYS allow parts to cool.
OD 0061
5. DANGER!
AVOID INJURY. Stay clear of rotating parts.
OL 4730
AVOID INJURY. Stay clear of rotating fan.
OL 4740
7
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DANGER / PELIGRO
• Avoid injury - Stay clear of rotating parts.
• Risque de blessures - ne pas s’approcher des pièces en
mouvement.
DANGER/PELIGRO
• Evitar lesiones - Mantenerse alejado de las piezas giratorias.
WARNING/AVERTISSEMENT/ADVERTENCIA
Do not operate mower Ne jamais utiliser No operar segadora
a
unless guards are in
operating position or protecteur sur le
bagger is attached. canal d'ejection ou operacion
sans le bac monte. recogedor este fijo.
la tondeuse sans
menos que las defensas
esten en posicion de
el
o
07742300B
DANGER / PELIGRO
17
MAX
TO AVOID SERIOUS INJURY OR DEATH
•
•
Read the operator's manual.
•
If machine stops going uphill, stop blade and
back down slowly.
Keep children and others away from unit while
operating.
•
•
Avoid sudden turns.
DANGER/PELIGRO
•
Never direct discharge toward other people.
Thrown objects can cause injury.
Look down and behind before and while backing.
Never carry children.
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.
•
•
•
•
•
•
Go up and down slopes, not across.
POUR EVITER LES BLESSURES GRAVES
OU LA MORT
PARA EVITAR DAÑOS SERIOS
MUERTE
O
LA
•
•
Lire le manuel d'utilisation.
•
Leer el manual del operador.
Mantenga la unidad alejada de los niños
personas cuando esté en funcionamiento.
Éloigner les enfants et tout autre personne
pendant le fonctionnement de la machine.
Ne jamais décharger directement en direction
de quelqu’un. Des particules projetées
peuvent provoquer des blessures.
Regardez derrière et sur les côtés lorsque
vous reculez.
•
y
otras
•
•
Nunca dirija la descarga hacia otras personas,
ya que los objetos lanzados pueden provocar
lesiones.
•
•
Antes
detras.
Nunca monten niños.
Suba baje pendientes, no transversalmente.
Si la maquina se detiene subiendo cuesta,
desactive la cuchilla baje lentamente.
Evite viradas subitas.
y
durante retroceso mirar hacia abajo
y
•
•
Ne transportez jamais d'enfant.
•
•
•
Tondez toujours de haut en bas et
inversement jamais le long des pentes.
y
•
Si la machine s'arrête en montee. Debrayez
y
la lame et redescendez doucement.
Evitez les virages brusques.
•
•
•
•
Mantenga artefactos de seguridad (defensas,
Maintenez toujours en place tous les
elements de sécurité (protecteurs,
interrupteurs, etc.).
protectores, interruptores, etc.) en su lugar
trabajando.
y
•
•
•
Verifique en el manual el sistema de engranar
antes de usar.
•
Controler le bon fonctionnement du système
de sécurité avant utilisation tel qu'indiqué
dans le manuel d'utilisation.
Comprenez bien la fonction et la situation de
chacun des leviers et boutons de commande.
Ne jamais permettre l'utilisation par des
personnes n'ayant pas reçu la formation
nécessaire.
Tenga conocimiento de funciones
y
localizaciones de todos los controles.
No permitir que personal sin la necesaria
formación use la máquina.
•
•
05359300
Figure 2 - Safety Decals
Keep children out of work area and under watchful care
of a responsible adult.
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.
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.
ALWAYS remove key from ignition and wire from spark
plug before assembly. Unintentional engine start up
can cause death or serious injury.
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.
Complete a walk around inspection of unit and work
area to understand:
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.
• 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.
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.
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.
Only trained adults may operate unit. Training includes
actual operation.
8
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Local regulations may restrict the age of the operator.
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.
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.
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.
DO NOT wear loose clothing or jewelry and tie back
hair that may get caught in rotating parts.
Avoid slippery surfaces. Always be sure of your footing.
Wear adequate outer garments.
DO NOT mow on wet grass. Reduced traction could
cause sliding and effect the machine’s stability.
NEVER wear open sandals or canvas shoes during
operation. Wear adequate safety gear, protective
gloves and footwear.
Watch for traffic when operating near or crossing
roadways.
Wear proper footwear to improve footing on slippery
surfaces.
Never carry passengers.
Always wear safety goggles or safety glasses with side
shields when operating mower.
DO NOT try to stabilize the machine by putting your
foot on the ground.
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 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.
NEVER place your hands or any part of your body or
clothing inside or near any moving part while unit is
running.
ALWAYS disengage PTO, stop unit and engine,
remove key, engage parking brake and allow moving
parts to stop before leaving operator’s position.
ALWAYS keep hands and feet away from all rotating
parts during operation. Rotating parts can cut off body
parts.
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.
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.
DO NOT operate in reverse unless absolutely
necessary.
ALWAYS keep hands and feet away from all pinch
points.
ALWAYS look down and behind before and while
backing.
Fumes from the engine exhaust can cause death or
serious injury. DO NOT run engine in an enclosed
area. Always provide good ventilation.
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.
Read, understand, and follow all instructions in the
manual and on the machine before starting.
Understand:
Mower blades are sharp and can cut you. Wrap the
blade(s) or wear gloves, and use extra caution when
servicing them.
• How to operate all controls
• The functions of all controls
• How to STOP in an Emergency
• Braking and steering characteristics
• Turning radius and clearances
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.
Keep safety devices or guards in place and functioning
properly. NEVER modify or remove safety devices.
Do not operate without either entire grass catcher
or the discharge guard in place.
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.
Stop engine before removing grass catcher or
unclogging chute.
Disengage PTO when attachment is not in use.
ALWAYS turn off power to attachment when traveling,
crossing driveways, etc.
Ensure Safety Interlock System is functioning properly.
DO NOT operate unit if safety interlock is damaged or
disabled.
Mow up and down slopes, not across them.
9
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DO NOT operate on slopes of more than 17 degrees.
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.
Use of a Rollover Protection System (ROPS) is
recommended for slope operation.
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.
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.
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 you cannot back up a slope or you feel uneasy on it,
do not mow it.
If fuel is spilled on clothing, change clothing
immediately.
DO NOT park on slopes unless necessary. When
parking on slope always chock or block wheels. Always
set parking brake.
Avoid Electric Shock. Objects contacting both battery
terminals at the same time may result in injury and unit
damage. DO NOT reverse battery connections.
Use a slow speed. Tires may lose traction on slopes
even though the brakes are functioning properly.
Reversed connections may result in sparks which can
cause serious injury. Always connect positive (+) cable
FIRST, and negative (-) cable SECOND.
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.
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.
Follow the manufacturer’s recommendations for weight
limits for towed equipment and towing on slopes.
No flames, No sparks, No smoking near battery.
NEVER allow children or others in or on towed
equipment.
ALWAYS wear safety glasses and protective gear near
battery. Use insulated tools.
On slopes, the weight of the towed equipment may
cause loss of control.
DO NOT TIP battery beyond a 45o angle in any
direction.
Travel slowly and allow extra distance to stop.
ALWAYS keep batteries out of reach of children.
Use extra care when loading or unloading unit onto
trailer or truck.
Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known to
the State of California to cause cancer and
Secure unit chassis to transport vehicle. NEVER
secure from rods or linkages that could be damaged.
reproductive harm. Wash hands after handling.
DO NOT transport machine while engine is running.
ALWAYS block wheels and know all jack stands are
strong and secure and will hold weight of unit during
maintenance.
ALWAYS turn off power to attachment and shut off fuel
when transporting unit.
Release pressure slowly from components with stored
energy.
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.
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.
Fuel is highly flammable and its vapors are explosive.
Handle with care. Use an approved fuel container.
ALWAYS maintain unit in safe operating condition.
Damaged or worn out muffler can cause fire or
explosion.
NO smoking, NO sparks, NO flames. ALWAYS allow
engine to cool before servicing.
Maintain or replace safety and instruction labels, as
necessary.
NEVER fill fuel tank when engine is running or hot from
operation.
NEVER store unit with fuel in fuel tank, inside a
building where any ignition sources are present.
NEVER fill or drain fuel tank indoors.
Replace fuel cap securely and clean up spilled fuel.
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Shut off fuel and allow engine to cool completely before
storing in closed area or covering unit.
Test
Steering
Levers
PTO
Parking
Brake
Engine
Clean grass and debris from unit, especially from
around muffler and engine, to help prevent fires.
STARTING INTERLOCK
For extended storage, shut off fuel and clean unit
thoroughly. See engine manual for proper storage.
1
2
Neutral
Neutral
Off
On
Engaged
Engaged
Start
Doesn’t
Start
Lower cutting deck unless a positive mechanical lock is
used.
3
Neutral
Off
Disengaged
Doesn’t
Start
Use only attachments or accessories designed for your
unit.
Check all hardware at regular intervals, especially
blade attachment bolts. Keep all hardware properly
tightened.
OPERATING INTERLOCK (ENGINE ON)
4*
5*
6*
Neutral
Neutral
Neutral
On
Off
Off
Engaged
Disengaged
Engaged
Shuts Off
Shuts Off
On
Check attachment components frequently. If worn or
damaged, replace with manufacturer’s recommended
parts.
*Operator lifts off seat.
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.
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 operator leaves seat.
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.
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SPECIFICATIONS
Model Number
Model
992018
992023
992027
PM260Z 25 HP Kohler
with 50 Inch Deck
PM250Z 20 HP Briggs &
Stratton with 50 Inch
Deck
PM260Z 25 HP Kohler with
72 Inch Deck
Length - in (cm)
Height - in (cm)
Width - in (cm)
Weight Actual - lbs (kg)
Battery
87 (221)
90 (229)
50 (127)
63 (160)
85 (216)
1100 (499)
1080 (490)
12 volt
1259 (572)
Brakes
Hydro/Dynamic Disk - Parking
Turning Radius
Tire Size Front
Rear
0
15 x 6 - 6
23 x 8.5 - 12
Briggs & Stratton
351777
15 x 6 - 6
23 x 10.5 - 12
Kohler
15 x 6 - 6
12 x 1.5 - 12
Kohler
Engine - Manufacturer
Model Number
Cycle
CV25S
CV25S
4
Engine Power-
25 HP
20 HP
25 HP
-1
-1
-1
-1
HP (KW/min
)
(18.6 KW/min
)
(14.7 KW/min
Electric
)
18.6 KW/min
)
Starting System
Fuel Tank Capacity
Fuel
9 gals. US (34 liters)
See Engine Manual
1800
Idle RPM
Governed RPM
Air Cleaner
3600
Large Capacity Dual ELement
Air Cooled
Cooling Capacity
Engine Oil Type
Spark Plug Gap
Transmission
See Engine Manual
See Engine Manual
Hydrostatic Drive
9 MPH
Speed - Forward Max.
Reverse Max.
4.5 MPH
Transmission Lube
Drive Clutch
Mobil 1 15W - 50 Synthetic
Hydrostatic
Tire Pressure Front
Rear
20-25 psi
12-15 psi
Lift system
Hydraulic
Power Take Off
Cutting Width - in (cm)
Cutting Height - in (cm)
Cutting Increments - in (cm)
Electric PTO Clutch/Brake
50 (127)
72 (183)
1 - 5 (2.5 - 12.7)
Infinite between 1 - 5 (2.5 - 12.7)
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Model Number
Model
992020
992029
992030
992032
992033
992034
992035
260Z 25 HP
Kohler
w/60" deck
260Z 25 HP
Kawasaki
w/60" deck
272Z 25 HP
Kawasaki
w/72" deck
272Z 26 HP
EFI Kohler
w/72" deck
260Z 26 HP 250Z 23 HP 250Z 23 HP
Kawasaki
w/50" deck
Kawasaki
w/50" deck
Kawasaki
w/50" dek
Length - in (cm)
Height - in (cm)
Width - in (cm)
Weight Actual - lbs (kg)
Battery
80 (203)
84 (213.4)
50 (127)
85 (216)
1259 (572)
12 volt
80 (203)
73 (185)
73 (185)
63 (160)
1100 (499)
1125 (510)
1125 (510)
Brakes
Hydro/Dynamic Disk - Parking
Turning Radius
Tire Size Front
Rear
0
15 x 6 - 6
23 x 10.5 - 12
Kohler
Engine - Manufacturer
Model Number
Cycle
Kohler
CV25S
Kawasaki
FH721V
Kawasaki
CV26S
FH601V
FH680V
4
Engine Power - HP (kw) @
Governed RPM
25 (18.6)
26 (19.3)
19 (14.1)
23 (17.2)
Governed RPM
Idle RPM
3600
1800
Starting System
Fuel Tank Capacity
Fuel
Electric
9 gals. US (34 liters)
See Engine Manual
Large Capacity Dual ELement
Air Cooled
Air Cleaner
Cooling Capacity
Engine Oil Type
Spark Plug Gap
Transmission
See Engine Manual
See Engine Manual
Hydrostatic Drive
9 MPH
Speed - Forward Max.
Reverse Max.
4.5 MPH
Transmission Lube
Drive Clutch
Mobil 1 15W - 50 Synthetic
Hydrostatic
Tire Pressure Front
Rear
20-25 psi
12-15 psi
Lift system
Hydraulic
Power Take Off
Cutting Width - in (cm)
Cutting Height - in (cm)
Cutting Increments - in (cm)
Electric PTO Clutch/Brake
60 (152)
72 (183)
1 - 5 (2.5 - 12.7)
Infinite between 1 - 5 (2.5 - 12.7)
60 (152)
50 (127)
13
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CONTROLS AND FEATURES
8
19
13
3
10
9
11
8
14
7
15
16
20
17
2
6
5
18
4
12
22
21
OF 1722
1
23
1. Mower Deck with Chute Deflector
2. Fuel Shut off Valve
3. Parking Brake
12.Ignition Switch
13.Power Take Off (PTO) Switch
14.Steering Levers
4. Battery
15.Mower Lift Lever
5. Hour Meter
16.Seat Adjustment Lever
6. Oil Pressure Indicator
7. Engine Frame and Hood
8. Fuel Tanks and Caps
9. Choke Control (not on EFI* models)
10.Malfunction Indicator Light
11.Throttle Lever
17.Seat Suspension Adjustment Knob (not on
model 992034)
18.Height of Cut Indicator
19.Hydraulic Oil Reservoir
20.Engine Hood Latch
21.Cylinder Stop Storage Post
22.Cylinder Stops
*Electronic Fuel Injection
Figure 3
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GENERAL MAINTENANCE & ADJUSTMENTS
Proper maintenance can prolong the life of unit. The
MAINTENANCE SCHEDULE
following chart shows the recommended service
schedule. More frequent service may be required due
to working conditions (Heavy loads, high ambient
temperatures, dusty conditions, or airborne debris).
WARNING: AVOID INJURY. Read and
understand the entire Safety section before
proceeding.
See the maintenance instructions 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
Check Parking Brake
Interlock System
Check Parking Brake
Engage parking brake. Push unit. If unit rolls adjust parking brake (see Parking
Each Use
Check Hydraulic Oil Level
Check Tires
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
Maintenance Schedule
Perform scheduled engine maintenance. Refer to Engine Manual for detailed
instructions.
Check Cooling System
Check cooling system for dirt and debris. Refer to Engine Manual for detailed
instructions.
Every 25 Check Mower Blades
Hours
Ensure mower blade hardware is tightened to 115 – 125 lbf-ft. (156 – 169 Nm).
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 connections and apply grease to front axle grease zerk (see
Hours
Pivot Points
Clean Battery
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.
Every
100
Check Belts
Replace worn or deteriorated belts.
drive belt location).
Hours
• Check radiator fan belt (refer to Engine Manual).
Every
400
Grease Front Axle Caster
Pivots
Hours
Every
500
Hours
Change Hydraulic Oil and
Filter
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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.
7
4
5
1
8
2
3
WARNING: AVOID INJURY. Read and
understand the entire Safety section before
proceeding.
9
6
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.
OF 1811
10
1. Steering Levers
2. Parking Brake
3. Footboard
6. Service Slot
7. Full Service Position
8. Engine
4. Engine Hood &
Frame
9. No Step Decal
10.Battery
SERVICE POSITIONS
IMPORTANT: Place unit on a flat level 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.
5. Engine Hood Prop
Rod
Figure 4
MOVING UNIT MANUALLY
1. Place steering levers in neutral position and set
parking brake.
1
2. Unhook hood latches. Firmly grasp hood frame
handle and lift to the desired service position
2
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.
OF 1730
Daily Service Position: Place hood prop rod into
service slot. Ensure prop rod is engaged in service slot
properly.
1. Right Bypass Valve
Lever
2. Left Bypass Valve
Lever
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.
Figure 5
IMPORTANT: Never tow unit.
1. Place hood in the full service position (see Service
3. When service is complete, lower hood, and secure
with hood latches.
2. Rotate the bypass valve dump levers located on
the pumps using a wrench.
WARNING: Do not bypass transmission when
on a slope.
3. Disengage parking brake.
4. Push unit to desired location.
16
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5. Engage parking brake.
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.
6. Levers must be returned to their original position in
TRANSPORTING UNIT
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.
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.
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.
NOTE: PTO must be disengaged and parking brake
engaged prior to starting engine.
Inspect unit for visible signs of wear, breakage or
damage.
To start:
2. Move throttle control lever to middle position.
Keep all nuts, bolts and screws properly tightened and
know unit is in safe working condition.
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.
Store unit in a cool, dry protected area.
Long Term
Clean unit thoroughly and lubricate. Touch up all
scratched painted surfaces.
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.
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.
OFF
Clean and charge battery. Charge battery every three
to four weeks when storing unit.
1
RUN
When taking unit out of extended storage:
START
2
1. Check for any damage or loose parts. Repair,
replace or tighten hardware before operation,
especially blade attachment bolts.
OF 1750
3
2. If a preservative fluid was used in fuel tank, drain
and discard. Fill fuel tank with fresh new fuel.
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 blades, wear gloves, and use
extreme caution when servicing.
17
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Apply oil at all pivot points and pin connections.
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.
1
2
No Smoking!
No Lighted Materials!
No Open Flame!
Allow engine to cool.
1
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.
OF 1792
Item
Lubrication
Repack
Grease
Oil
Item
Location
Caster Pivot
Axle Pivot
Interval
400 hours
50 hours
50 hours
1
2
2
1
Add fuel to the tank as needed.
All Pivot Points, Pin
Connections
IMPORTANT: Refer to Engine Manual for correct type
and grade of fuel. See Specifications for fuel tank
capacity.
Figure 7
IMPORTANT: Wipe front axle grease zerk and two
front axle caster pivots clean before and after
lubrication.
To add fuel to the fuel tank:
1. Refuel the unit only in a well ventilated, open area.
2. Stop the engine.
NOTE: Use Stens Mix Hi-Temp Grease or equivalent
(part number 00036700).
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.
Description
Grease fittings
Use
Interval
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.
Sten Mix HI-Temp
50 hrs. running time
grease or equivalent
Hydraulic system
Mobil 15W50
synthetic oil
500 hrs. running
time
5. Install the cap on the fuel tank and tighten.
6. Clean up any spilled fuel before starting the
engine.
SERVICING THE BATTERY
FASTENERS
WARNING: AVOID INJURY. Read and
understand the entire Safety section before
proceeding.
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.
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.
GENERAL LUBRICATION
IMPORTANT: Wipe each fitting clean before and after
lubrication.
Apply Sten Mix Hi-Temp Grease or equivalent to the
lube fittings. Order P/N: 00036700 - Ten pack of 14 oz.
cartridges.
NOTE: Unit comes equipped with a maintenance-free
battery that requires no regular maintenance except
cleaning the terminals.
When using Sten Mix Grease for the first time, all
components should be thoroughly cleaned prior to
lubricating.
18
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• Eyes: Flush with water for at least 15 minutes and
Battery Removal and Installation
Remove
1. Place hood in full service position (see Service
get medical attention immediately!
• Internal Contact: Drink large quantities of water.
Follow with Milk of Magnesia, beaten egg or
vegetable oil. Get medical attention immediately!
2. Disconnect negative (-) cable first, then positive (+)
• In case of internal contact, DO NOT induce
vomiting!
3. Remove battery hold-down bracket and battery
from unit.
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.
Install
1. Install battery on unit with battery hold-down
bracket.
1. Remove battery from unit (see Battery Removal
2. Connect positive (+) cable first, then negative (-)
cable.
2. Place battery on bench or other well-ventilated
area.
3. Coat terminals with dielectric grease or petroleum
jelly.
3. Connect positive (+) lead of charger to positive (+)
terminal, and negative (-) lead to negative (-)
terminal.
4. Close hood.
Cleaning the Battery
1. Disconnect negative (-) cable first, then positive (+)
cable.
4. Charge battery according to the instructions from
battery charger manufacturer and battery
manufacturer.
2. Clean battery cable ends and terminals with wire
brush. Rinse with a weak baking soda solution.
Storage
3. Connect positive (+) cable first, then negative (-)
cable.
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.
4. Coat terminals with dielectric grease or petroleum
jelly.
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.
2
The battery must be recharged monthly. Before
reinstalling the battery in the spring, it should always be
fully recharged.
3
1
BASIC ENGINE MAINTENANCE
5
4
See your engine manual and Engine Chapter of this
manual for detailed information on the operation and
maintenance of your engine.
OF 3227
1. Battery
4. Positive (+) Terminal
5. Positive (+) Cable
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.
2. Negative (-) Terminal
3. Negative(-) Cable
2. Each day before operating, check the air cleaner
element. Dirt can decrease the flow of air to the
engine.
Figure 8
Charging the Battery
WARNING: FROZEN BATTERIES CAN
3. Each day before operating, check the air cooling
system on the engine. Debris can decrease the
flow of air cooling the engine.
EXPLODE and result in death or serious
injury. DO NOT charge a frozen battery. Let
battery thaw before charging.
4. Follow the maintenance instructions in your engine
manual concerning oil and filter changes.
Follow First Aid directions for contact with battery fluid.
• External Contact: Flush with water.
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BELTS
3
WARNING: MOVING PARTS can cut or
1
amputate body parts. ALWAYS wait for
moving parts to stop before performing
maintenance or service.
2
72" Belt
Layout
3
4
CAUTION: DAMAGED OR WORN BELTS
may result in injury and/or damage to the unit.
Check belts for excessive wear or cracks
often.
2
50" and 60"
Belt Layout
Belt Access
1. Properly stop and park unit (refer to Owner’s
Manual).
1
4
5
OF 1641
2. Lower the mower.
1. Long Mower Belt
2. Short Mower Belt
3. Springs
4. Idlers
3. Place seat in most rearward position.
4. Remove belt covers.
5. Mower Clutch
Sheave
6. Secure raised footboard with latch.
Figure 10
CAUTION: Use care when releasing idler
spring tension. Keep body parts well away
from idlers when performing this operation.
1
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.
2
5
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).
4
OF 1802
3
1. Footboard in open
position
3. Support Frame
2. Remove the mower belt from the mower clutch
sheave. See replacing Mower Belts.
4. Pivot
5. Latch
2. Footboard in closed
position
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.
Figure 9
Replacing Mower Belts
NOTE: Long belt must be removed to remove short
belt.
5. Put the mower belt back on mower clutch sheave.
See Replacing Mower Belts.
1. Roll long belt off left blade spindle and remove
from deck.
2. 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
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3. 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.
5
1
6
2
3
4. Put the blades, the flat washers, lock washers, and
the bolts back on the spindle shafts.
5. Tighten the bolts to a torque of 70 ft. lbs (95 Nm).
Put the ignition wires back on the spark plugs.
4
STEERING CONTROL NEUTRAL
ADJUSTMENT
If the unit has excessive creep when the control levers
are in neutral, adjust as follows: (Figure 13)
OF 1631
1. Hydro Belt
2. Spring
5. Right Hand
Hydrostat
6. Left Hand Hydrostat
3. Idler
4. Engine Sheave
2
Figure 11
1
TIRES
2
Before each use, make a visual check of tires.The
correct air pressure is 12-15 psi (83-103 kn/m2) for the
rear tires, and 20-25 psi (138-172 kn/m2) for the front
tires.
4
3
MOWER BLADES
NOTE: If mower is used under sandy soil conditions,
replace mower blades when air lifts become eroded
5
6
3
2
4
OF 1820
1
7
1. Stop Bolts
5. Parking Brake
Interlock
3
2. Pump Levers
3. Front Ball Joints
4. Control Levers
6. Clamping Bolt and
Slot
7. Mounting Bolt
4
Figure 13
1. Cutting Blade
2. Square Corner
3. Air Lift Erosion
4. Air Lift
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.
Figure 12
Sharpening Mower Blade
CAUTION: Use sturdy gloves or padding to
protect hands when working with mower
blades.
1. If hydraulic system is cold, run unit for a minimum
of five minutes, then shut off unit.
2. Make sure both control levers are in neutral. Raise
hood.
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. With the unit up to and facing a wall, jack the unit
up so that both drive wheels are off the ground.
21
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4. Have someone depress center of seat to activate
seat switch.
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.
5. Start the engine and run at about half throttle or
faster. Release parking brake.
6. 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.
2. Turn the nuts further on the rod (clockwise) to
tighten the brake and further off the rod
(counterclockwise) to loosen the brake.
7. 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.
3. 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.
4. When installing new pads in the calipers, 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.
8. 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.
9. 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.
1
2
1
1. Jam Nuts
10.Reinstall the front ball joint(s)
2. Compression Spring
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.
PF 1732
11.Move the control levers, from forward to reverse
several times to make sure it is adjusted to neutral.
Readjust if necessary.
Figure 14
ADJUSTING UNIT TO TRACK STRAIGHT
12.Stop the engine.
Check and adjust tire pressure. Increase pressure on
side unit tracks to. DO NOT exceed maximum
recommended tire pressure (refer to Specifications).
ADJUSTING CONTROL LEVERS
If tire pressure adjustment does not solve tracking
problem, the limiter bolts at base of handles can be
and rear bolts are for reverse. Lengthen bolts (move
closer to lever) on side which is too fast.
1. If desired the steering control levers can be set to
match (be in line) when in neutral.
2. 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.
1. Limiter Bolt
1
2. Lever
2
3. 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.
Front
1
4. Tighten the clamping bolt.
Figure 15
22
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14.Tighten rear hex nut on each rod that was
loosened in step 11.
LEVELING THE MOWER DECK
These adjustments should be made on a level surface
with the tires inflated to the correct air pressure.
1
Right Side View
1
1
1
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
1
1
1. Raise mower deck and insert 3" (7.6 cm) tall blocks
to support deck.
1
1
1
1
1
2. Lower deck onto blocks so chains are slack.
3. Measure from bottom of mower blade end to
ground.
Front of Unit
PF 1920
1. Rod
7. Front Mower Lift
Pivot
4. Shut off engine. Engage parking brake. Remove
the ignition key.
2. Rear Hex Nut
3. Front Hex Nut
4. Chains
8. Rear Mower Lift
Pivot
5. Set hydraulic lift cylinder so cut of height reads the
same as blade height measurement.
9. Hydraulic Cylinder
6. Loosen the locknuts on the side where the chains
are slack and slide the bolt down the slot until the
chain is tight.
5. Lock Nuts and Slots
6. Mower Mounting
Brackets
7. Tighten bolt and nuts in mower mounting brackets.
8. Lift mower and remove blocks.
Figure 16
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" (3 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
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ENGINE
ENGINE TROUBLESHOOTING
The following troubleshooting chart is to be used to
isolate engine problems and give possible causes and
corrective action responses.
The troubleshooting key is generic and can be used for
several types of engines. Use only those possible
causes and corrective actions that apply to the
unit.
TROUBLE
POSSIBLE CAUSES
(Refer to Key Below)
1, 20, 22, 25, 29, 31, 32, 33
CORRECTIVE ACTION
Black Exhaust
repair or replace
Blue/White Exhaust
Difficult Starting
Erratic Running
4, 20, 25, 31, 33, 34
repair or replace
1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33
1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62
1, 20, 22, 23, 25, 39, 31, 32, 33
4, 41
repair or replace
repair or replace
Excessive Fuel Consumption
High Oil Pressure
Knocking
repair or replace
repair or replace
22, 26, 29, 31, 33, 36, 46, 59
1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33
2, 3, 4, 11
repair or replace
Loss of Power or System
Low Cranking Power
Low Oil Pressure
Misfiring
repair or replace
repair or replace
4, 36, 37, 39
repair or replace
10, 20, 25, 26, 28, 29, 32
1, 19, 25,
repair or replace
Overheating
repair or replace
Poor Compression
Starts and Stops
25, 28, 29, 31, 32, 33, 34, 59,
1, 6, 10, 62
repair or replace
repair or replace
see electrical systems
see engine service manual
repair or replace
Vibration
20, 23, 25, 26, 29, 33, 45, 49
2, 11, 45
Will Not Crank
Will Not Start
charge battery or replace
repair or replace
1, 10, 62
see electrical systems
see engine service manual
TROUBLESHOOTING KEY
1
Restriction in air cleaner
Bad electrical connection
Faulty starter motor
Incorrect grade of lubricating oil
Low cranking speed
Fuel tank empty
22
23
24
25
26
27
28
Incorrect grade of fuel
Sticking throttle/restricted movement 44
Exhaust pipe restriction
Leaking cylinder head gasket
Overheating
43
Faulty suction pipe
Choked oil filter
2
3
4
5
6
7
45
46
47
48
49
Bad solenoid switch
Incorrect piston height
Damaged fan
Faulty engine mounting
Incorrectly aligned flywheel and/or
flywheel housing
Cold running
Incorrect tappet adjustment
Controls not in correct operation
position
8
9
Blocked fuel feed line
Faulty fuel lift pump
Choked fuel filter
Battery capacity low
Air in fuel system
29
30
31
32
33
34
Sticking valves
50
51
52
53
Faulty thermostat
Restriction in water jacket
Loose fan belt
Choked radiator
Faulty water pump
Choked breather pipe
Damaged valve stem oil deflector (if
fitted)
Incorrect high pressure pipes
Worn cylinder bores
Pitted valves and seats
Broken, worn or sticking piston ring(s) 54
Worn valve stems and guides
Restriction in air cleaner
10
11
12
13
14
Faulty fuel injection pump
Faulty fuel injectors or incorrect type 35
55
56
15
16
17
18
19
Incorrect use of cold start equipment 36
Worn or damaged bearings
Insufficient oil in sump
Bad/defective oil temperature switch 59
Oil pump worn
Pressure relief valve sticking open
57
58
Coolant level too low
Blocked sump strainer
Broken valve spring
Exhaust or vacuum pipe leak
Bad or defective water temperature
switch
Faulty cold start equipment
Broken fuel injection pump drive
Incorrect fuel pump timing
Incorrect valve timing
37
38
39
40
60
61
20
21
Poor compression
Blocked fuel tank vent
41
42
Pressure relief valve sticking closed 62
Broken relief valve spring
Bad spark plug(s)
24
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To Replace the Clutch
REMOVING THE ENGINE
1. Remove the belt by relaxing the idler pulley.
2. Remove the center bolt.
1. Place the mower in the full service position.
2. Disconnect the battery cables, negative first.
3. Disconnect ignition wires using the connectors.
4. Remove the belts from the pulley and clutch.
CAUTION: DO NOT ALLOW the engine
crankshaft to rotate. Damage to the engine
may occur.
5. Unscrew the bolt from the center of the output shaft
and remove clutch. Refer to "Replacing the
Clutch".
3. Disconnect electrical wires.
4. Remove nut from the anchor bracket.
5. Pull clutch from shaft.
6. Remove the square key and the pulley.
7. Unclamp and remove the fuel line. Plug the fuel
line and wipe up any spills.
6. Position new clutch on the shaft by aligning the
square key on the shaft with the keyway of the
clutch.
8. Remove the engine mounting bolts and lift engine
out the top.
7. Clutch should be rotated to position the anchor
bracket with the slot in the stationary shell.
Replace nut and tighten.
INSTALLING THE ENGINE
1. Position the new engine in the chassis, insert
mounting bolts and tighten.
8. Replace bolt and washers. Torque to 55 foot
pounds (74.5 Nm).
2. Install pulley and then the clutch on the output
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
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.
3
1. Electric Clutch
2. Pulley
3. Anchor Bracket
1
2
Figure 17
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DRIVE TRAIN
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.
WARNING: Hydraulic Fluid can result in
severe burns. Fluid in hydraulic system can
penetrate skin and result in serious injury or
death.
6. After shutting off the engine, check the fluid level.
The dipstick should read the fluid level between the
high and low markings.
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.
7. Properly dispose of waste oil.
HYDRAULIC DRIVE 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.
Insure all hydraulic fluid connections are tight
and all hydraulic hoses and lines are in good
condition before applying pressure to system.
1. Block and jack the unit up so that both drive wheels
are off the ground.
WARNING: FOREIGN FLUID INJECTED
INTO BODY can result in gangrene. Fluid
must be surgically removed within a few hours
by a doctor familiar with this form of injury.
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.
CHECKING THE HYDRAULIC FLUID
LEVEL
A check of the hydraulic fluid level should be made
daily.
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.
NOTE: The oil level should be centered between the
two marks on the dipstick.
7. Install a bi-directional flow gauge.
8. Have someone depress center of seat to activate
seat switch.
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.
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.
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.
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.
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.
12.Open the restriction valve and move the control
lever back to neutral. Idle unit down for a few
seconds and shut off engine.
2. Place a film of oil on the new filter’s gasket.
13.The acceptable flow drop would be less than 1
GPM difference between the low and high
3. Screw the filter on until it makes contact with the
sealing surface of the filter head.
pressure settings. If flow drop is greater than 1
GPM, the hydro-pump will need to be repaired or
26
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replaced. If the flow drop is less than 1 GPM you
will need to replace the wheel motor.
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.
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
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.
1
2
1. Hydrostat BDP
Pump
2
2. Variable-
1
1
2
Displace Pump
1. Hub
2. Hydraulic motor
Figure 19
To Replace a Drive Motor
Figure 18
To Replace a Hydraulic Pump
1. Lift cover to full service position.
2. Remove the cross channel.
2. Jack the drive wheels off the ground and securely
support the unit.
3. Clean hoses and fittings and mark for location.
4. Disconnect hoses from pump.
3. Remove the wheel.
4. Remove the brake caliper assembly by removing
the two bolts.
CAUTION: Some fluid will leak out. Clean up
any spills.
5. 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.
5. Remove belt from pulley.
6. Remove bolt and washers from end of shaft.
6. Mark the hydraulic lines and remove.
7. Loosen pulley lock bolt and slide pulley from shaft.
Remove and inspect square key. Replace key if
damaged.
CAUTION: Some fluid will leak out. Clean up
any spills.
8. Remove back bolt on pump and loosen front bolt.
9. Remove pump.
7. Unscrew the two bottom bolts and pull the
hydraulic motor out.
10.Insert the new pump into position with the front bolt
in the mounting flange slot.
8. Remove the four bolt sleeves.
11.Insert rear bolt and tighten both bolts.
9. Insert the sleeves into the four bolt holes in the
new hydraulic motor.
12.Attach hydraulic hoses to correct ports and tighten.
13.Position square key in shaft keyway and slide
pulley into position.
10.Slide the motor into place and secure with two
bottom bolts. Apply Loctite to bolts.
14.Screw the bolt, washer and lock washer into the
end of the shaft. Tighten securely.
11.Reattach hydraulic lines to proper ports and
tighten.
15.Tighten pulley lock bolt.
16.Place belt on pulley.
17.Replace cross channel.
12.Clean the axle and the inside of the hub. Place hub
over axle and lightly tap into position. Screw the
axle nut onto the axle and tighten to 300-400 ft. lbs.
(406-542 Nm)
27
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13.Place the brake caliper into position and insert
bolts from the inside of the frame outward. Use
lock washer and nut and tighten.
2. Clean hose fittings, mark hoses for position and
disconnect from valve.
14.Position wheel on hub and insert lug nuts finger
tight.
CAUTION: Some hydraulic fluid will leak out
of the hoses. Clean up any spills.
15.Tighten lug nuts using the pattern shown in Figure
20.
3. Loosen mounting bolts and remove valve.
4. Mount new valve and tighten bolts.
5. Connect hoses to proper ports.
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.
6. The hydraulic system is self-bleeding. Check
hydraulic fluid level after running the engine. The
dipstick should read between the high and low
markings.
1
4
3
2
5
OK 0630
Figure 20
Lift Valve
Figure 21
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
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.
REPLACE LIFT VALVE
The lift valve is located inside the chassis on the left
1. Place hood in full service position.
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HYDRAULIC DIAGRAM
992018, 023, 027
Lift
Cylinder
Lift
Valve
Deck Lower
Deck Lift
B
Return
A
Inlet
Left Pump
A
B
Forward
High
Pressure
A
Right Pump
B
Right
Wheel
Motor
Left
Wheel
Motor
Forward
High
Pressure
Upper
Upper
Reverse
B
A
High
Pressure
Reverse
High Pressure
B
A
Lower
Lower
Oil
Filter
PRESSURE
RETURN
SUCTION
Oil
Tank
PD1772
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Models 992020, 029, 030, 032, 033, 034, 035
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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. lbs. (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. Note
the position of spacers for installation.
31
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FRONT SUSPENSION
SUSPENSION
The front suspension consists of a weldment that is a
the chassis. Two caster wheels are attached. The front
axle is maintenance free except for one grease fitting
at the chassis for the pivot pin. This fitting is greased as
needed with Sten Mix Hi-Temp grease or equivalent.
3
4
1
4
2
1. Pivot Pin
2. Spindle
3. Dust Cap
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
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ELECTRICAL
TOOLS
ELECTRICAL MEASUREMENTS
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 soldering 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 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.
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 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 on a
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.
33
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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.
WARNING: EXPLOSIVE GASES can result in
serious injury or death. ALWAYS keep open
flames, sparks, or smoking materials away
from battery.
Current Measurement
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.
The two rules to remember when measuring current
with an ammeter are; an ammeter measures the cur-
rent that flows 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.
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.
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 Electrolyte First Aid
• External contact: Flush with water.
BATTERY
• Eyes: Flush with water for at least 15 minutes and
get medical attention immediately!
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.
• Internal contact: Drink large quantities of water.
Follow with Milk of Magnesia, 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.
WARNING: ELECTRIC SHOCK may result in
injury and/or damage to unit.
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 (+) cable
first, then connect Negative (-) cable when
installing battery.
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.
After cleaning, apply a thin coat of grease or petroleum
jelly to terminals and cable ends to retard corrosion.
Reinstall battery.
34
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Check the alternator voltage regulator output (if used)
at every period maintenance inspection. Over charging
is a common cause of battery failure.
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).
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.
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.)
Charging a New Battery
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.
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.
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.
IMPORTANT: 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
(+) cable.
Variation from test results described indicates a
defective switch.
3. Remove hold down and remove battery.
Normally Closed Switch
4. Place battery on bench or other well-ventilated
place where electrolyte spill will not create
damage.
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).
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.
Variation from test results described indicates a
defective switch.
7. Reinstall battery into unit and connect Positive (+)
cable first, then Negative (-) cable.
Ignition Switch
NOTE: Refer to the wiring diagram of the unit involved
to determine switch functions and test using the meth-
ods described.
SWITCHES
Switches either open a circuit to stop current flow or
close and allow current to flow through.
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.
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.
OFF Position - Should be continuity between contacts
G and M. These connections ground the engine
magneto and stop the engine in the OFF position.
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 position allowing the engine to operate.
RUN Position - Should be continuity between contacts
B and A. These connections supply power to the rest of
35
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the wiring harness. Connections G and M open to each
other.
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.
START Position - Hold switch in START position while
testing. There should be continuity between contacts
S1 and S2. These connections apply power to close
the solenoid contacts and operate the starter motor.
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.
In addition to the above test, place the switch in the run
position and check between each contact and ground
(metal case) to be sure no terminals are grounded. If
the switch is operating properly, there will be no
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.
continuity between contacts other that those described.
SOLENOID AND RELAYS
If the voltage is correct, turn off the power and check
continuity of the coil with an ohmmeter. If the coil is
open, the solenoid is defective and must be replaced.
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.
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.
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.
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.
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.
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.
If a relay or solenoid fails to operate, 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.
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 electrical "check
valves" and permit current flow in one direction, but not
in the other.
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.
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.
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
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To 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 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.
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Model 992029, 030, 034, 035
PD3242
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Model 992023
SEAT
SWITCH
SEAT / PTO RELAY
PINK
85
87a
87 86
1
2
CAB
POWER
SUPPLY
30
BLACK
2
PTO
SWITCH
1
W
/
PTO
CLUTCH
D
LO
E
L
7
R
E
PURPLE /
WHITE
BLACK
HOUR
METER
Y
4
3
1
2
1
9
PURPLE
OIL
LIGHT
W
BLACK
LO
L
YE
OIL PRESSURE
FUEL SOLENIOD
REGULATOR
/
BLUE / WHITE
RED / YELLOW
PURPLE
BLACK
N
OW
R
SWITCH
B
START
RELAY
ENGINE
BLACK
86
85
87a
87
MAGNETO KILL
WHITE / BLACK
30
STARTER
OW
L
YE
/
D
E
R
A
B
BLACK
RED
RED
1
A
B
BRAKE
SWITCH
FUSE
30A
RED
2
M
BATTERY
T
LE
BLACK
IO
V
BLACK
/
G
D
RE
S1
COIL 2
COIL 1
BROWN
RED / VIOLET
STARTER
SOLENOID
S2
KEY
SWITCH
BLACK
PD3251
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Models 992032, 033
41
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TROUBLESHOOTING
TROUBLESHOOTING
PROBABLE CAUSE
PROBLEM
CORRECTION
1. Disengage PTO.
Engine does not crank.
1. PTO engaged.
2. Parking brake disengaged.
2. Engage parking brake.
3. Loose or corroded battery
cables.
3. Clean and tighten battery cables
(see Servicing the Battery on
4. Discharged battery.
4. Charge battery (see Charging
5. Faulty starter.
5. See your Gravely Dealer.
Engine cranks but does not start.
1. Fuel tank empty.
1. Fill fuel tank (see Filling Fuel
2. Faulty spark plug.
3. Air cleaner is plugged or dirty.
4. Fuel filter is dirty.
2. Replace spark plug. Refer to
Engine Manual.
3. Clean or replace air cleaner.
Refer to Engine Manual.
4. Clean or replace fuel filter. Refer
to Engine Manual
5. Faulty engine.
5. Refer to Engine Manual or see
your Gravely Dealer.
Battery light does not light up
when starting engine.
1. Discharged battery.
1. Oil pressure is low.
1. Charge battery (see Charging
Oil pressure light is on.
1. Refer to Engine Manual.
Fuel/Water separator light is on.
1. Fuel/water separator filter dirty
or damaged.
1. Clean or replace fuel/water
separator filter. Refer to Engine
Manual
Engine is overheating
1. Engine oil level is low.
1. Add engine oil. Refer to Engine
Manual.
2. Cooling fins/screen on engine
plugged with debris.
2. Clean engine and surrounding
area.
Engine continues to run when
ignition key is in the off position.
1. Ignition ground wire
disconnected.
1. Connect ground wire to clean
metal surface.
2. Ignition switch failure.
2. Replace ignition switch (see your
Gravely Dealer).
PTO or mower blades do not
engage or shuts off.
1. Operator presence switch not
depressed.
1. Depress operator presence
switch by sitting on seat.
2. Eye-Q alarm setting is turned
on.
2. Turn off the alarm that
deactivates the PTO on a regular
schedule. See the Owner’s
Manual.
3. The Eye-Q circuitry senses an
overload to the PTO clutch and
is shutting off the PTO switch.
3. Check the mower deck for
clogging or debris. Check the
electrical system to the clutch for
damage or wear.
4. Faulty PTO switch.
4. See your Gravely Dealer.
42
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TROUBLESHOOTING
PROBABLE CAUSE
PROBLEM
Unit does not drive.
CORRECTION
1. Parking brake engaged.
1. Disengage parking brake.
2. Transmission bypass levers
open.
2. Close transmission bypass
levers (see Moving Unit Manually
3. Hydraulic oil level low.
3. Add hydraulic oil (see Checking
4. Faulty hydraulic drive system.
4. See your Gravely dealer.
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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
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