Gravely 260Z Service Manual 09254300A

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Page Count: 44

Promaster 250Z, 260Z, 272Z

09254300A 8/04

Printed in USA

Service Manual

992018, 020, 023, 027, 029, 030

992032, 033, 034, 035

2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

The Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Service and Replacement Parts . . . . . . . . . . . . .5

Product Registration . . . . . . . . . . . . . . . . . . . . . .5

Unauthorized Replacement Parts. . . . . . . . . . . .5

Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Technical Service Communications . . . . . . . . . .5

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . 6

Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Notations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Practices and Laws. . . . . . . . . . . . . . . . . . . . . . .6

Required Operator Training . . . . . . . . . . . . . . . .6

Safety Decals And Locations . . . . . . . . . . . . . . . 6

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Controls and Features. . . . . . . . . . . . . . . . . . . . 14

General Maintenance & Adjustments. . . . . . . . 15

Maintenance Schedule . . . . . . . . . . . . . . . . . . .15

Service and Adjustments . . . . . . . . . . . . . . . . .16

Service Positions . . . . . . . . . . . . . . . . . . . . . . .16

Moving Unit Manually . . . . . . . . . . . . . . . . . . . .16

Transporting Unit . . . . . . . . . . . . . . . . . . . . . . .17

Starting and Shutting Off the Engine. . . . . . . . .17

Cleaning and Storage . . . . . . . . . . . . . . . . . . . .17

Filling Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . .18

Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

General Lubrication . . . . . . . . . . . . . . . . . . . . .18

Servicing the Battery. . . . . . . . . . . . . . . . . . . . .18

Basic Engine Maintenance . . . . . . . . . . . . . . . .19

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Mower Blades . . . . . . . . . . . . . . . . . . . . . . . . . .21

Adjusting Control Levers. . . . . . . . . . . . . . . . . .22

Adjusting the Parking Brake . . . . . . . . . . . . . . .22

Adjusting Unit To Track Straight . . . . . . . . . . . .22

Leveling the Mower Deck . . . . . . . . . . . . . . . . .23

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Engine Troubleshooting . . . . . . . . . . . . . . . . . .24

Removing the Engine . . . . . . . . . . . . . . . . . . . .25

Installing the Engine . . . . . . . . . . . . . . . . . . . . .25

Electric Clutch. . . . . . . . . . . . . . . . . . . . . . . . . .25

Drive Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Checking the Hydraulic Fluid Level. . . . . . . . . .26

Changing Hydraulic Fluid and Filter . . . . . . . . .26

Hydraulic Drive Flow Test . . . . . . . . . . . . . . . . .26

Replacing the Hydraulic Pump . . . . . . . . . . . . .27

Replace Wheel Motor . . . . . . . . . . . . . . . . . . . .27

Hydraulic Deck Lift Pressure Test . . . . . . . . . . .28

Replace Lift Valve . . . . . . . . . . . . . . . . . . . . . . .28

Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . .29

Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Anti-Scalp Rollers . . . . . . . . . . . . . . . . . . . . . . .31

Front Suspension. . . . . . . . . . . . . . . . . . . . . . . .32

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Electrical Measurements. . . . . . . . . . . . . . . . . .33

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Solenoid and Relays. . . . . . . . . . . . . . . . . . . . .36

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Diodes and Rectifiers . . . . . . . . . . . . . . . . . . . .36

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . .38

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .42

TABLE OF CONTENTS

3

Ariens Company

655 West Ryan Street

P.O. Box 157

Brillion, Wisconsin 54110-0157

USA

Telephone (920) 756-2141

Facsimile (920) 756-2407

EC DECLARATION OF CONFORMITY ISSUED BY THE MANUFACTURER –

DÉCLARATION DE CONFORMITÉ CE ÉMISE PAR LE FABRICANT – EU-

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 –

DEKLARACJA ZGODNO

Ś

CI Z PRZEPISAMI EC WYDANA PRZEZ PRODUCENTA –

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:

Type:

–

Type :

–

Typ:

–

Type:

–

Type:

–

Tipo:

–

Tipo:

–

Type:

–

Typ:

–

Tyyppi:

–

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 –

Trade Name:

–

Appellation commerciale :

–

Handelsbezeichnung:

–

Handelsnaam:

–

Firmanavn: Nome

commerciale:

–

Nombre comercial:

–

Handelsnavn:

–

Handelsbeteckning:

–

Kauppanimi: Nazwa handlowa:

–

Nome da Marca:

Gravely

Model:

–

Modèle :

–

Modell:

–

Model:

–

Model:

–

Modello:

–

Modelo:

–

Modell:

–

Modell:

–

Malli:

–

Model:

–

Modelo: 992318 992319

Cutting Width (cm):

–

Largeur de coupe (cm) :

–

Schnittbreite (cm):

–

Maaibreedte (cm):

–

Klippebredde (cm):

–

Larghezza di taglio (cm):

–

Ancho de corte (cm):

–

Klippebredde (cm)

–

: Klippbredd (cm):

–

Leikkuuleveys (cm):

–

Szerokość cięcia (cm):

–

Largura de corte (cm):

152 152

Conforms to:

–

Est conforme à :

–

Mit den Anforderungen der folgenden Richtlinien übereinstimmt:

–

Voldoet aan:

–

Er i

overensstemmelse med:

–

È conforme a:

–

Cumple con:

–

Er i samsvar med:

–

Överensstämmer med:

–

Täyttää seuraavat vaatimukset:

–

Jest zgodny z:

–

De acordo com:

98/37/EC, 89/336/EEC;

2000/14/EC Conformity Assessment Annex VI.

–

Annexe VI de l'évaluation de conformité.

–

Konformitätsbewertung, Anhang VI.

–

Bijlage VI voor beoordeling van overeenstemming.

–

Vurdering af overensstemmelse Anneks VI.

–

Annesso VI della valutazione di conformità.

–

Anexo VI de la evaluación de la conformidad.

–

Samsvarsvurdering etter vedlegg VI.

–

Bedömning av överensstämmelse Bilaga VI.

–

Vaatimustenmukaisuuden arviointi, liite VI.

–

Dodatek VI, Ocena zgodno

ś

ci.

–

Anexo VI da Avaliação de Conformidade.

Representative Measured Sound Power Level (Lwa)

–

Niveau de

puissance acoustique représentatif mesuré (Lwa)

–

Repräsentativer

gemessener Geräuschpegel (Lwa)

–

Representatief gemeten

geluidsniveau (Lwa)

–

Repræsentativt, målt støjeffektniveau (Lwa)

–

Livello di potenza sonora rappresentativo rilevato (Lwa)

–

Nivel de

potencia acústica representativo medido (Lwa)

–

Representativt

målt lydeffektnivå (Lwa)

–

Representativ uppmätt ljudnivå (Lwa)

–

Tyypillinen mitattu äänitehotaso (Lwa)

–

Zmierzony reprezentatywny

poziom mocy akustycznej (Lwa)

–

Nível de Potência de Som

Medido Representativo (Lwa)

Guaranteed Sound Power Level (Lwa) – Niveau de puissance

acoustique garanti (Lwa) – Garantierter Geräuschpegel (Lwa) –

Gegarandeerd geluidsniveau (Lwa) – Garanteret støjeffektniveau

(Lwa) – Livello di potenza sonora garantito (Lwa) – Nivel de potencia

acústica garantizado (Lwa) – Garantert lydeffektnivå (Lwa) –

Garanterad uppmätt ljudnivå (Lwa) – Taattu äänitehotaso (Lwa) –

Gwarantowany reprezentatywny poziom mocy akustycznej (Lwa) –

Nível de Potência de Som Garantido (Lwa) –

992318: 104 dBA992318: 105 dBA

992319: 104 dBA992319: 105 dBA

4

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)

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:

Quality and Conformance Manager (Keeper of Technical File)

–

Responsable de la qualité et de la conformité des produits

(Dépositaire de la fiche technique)

–

Manager Qualitätssicherung

und Konformität (Archivar der technischen Akte)

–

Kwaliteits- en

normalisatiemanager (Beheerder van technische bestand)

–

Chef for

kvalitet og overensstemmelse (Indehaver af tekniske data)

–

Responsabile della qualità e della conformità del prodotto

(Depositario del file tecnico)

–

Gerente de calidad y conformidad

(Depositario del archivo técnico)

–

Kvalitet- og samsvarsansvarlig

(innehaver av teknisk fil)

–

Chef för kvalitet och

produktöverensstämmelse (Innehavare av tekniska data)

–

Laadusta

ja vaatimustenmukaisuudesta vastaava johtaja (Teknisen tiedoston

haltija)

–

Kierownik do spraw jakości i zgodności

(Przechowujący Dokumentację Techniczną)

–

Gestor de Qualidade

e Conformidade (Zelador de Arquivos Técnicos)

Ariens Company

Brillion, WI 54110-0157 USA

Signature

–

Signature

–

Unterschrift

Handtekening

–

Underskrift

–

Firma Firma

–

Signatur

–

Namnteckning Allekirjoitus

–

Podpis

–

Assinatura

11/24/2003

Date

–

Date

–

Datum

Datum

–

Dato

–

Data

Fecha

–

Dato Datum

–

Päiväys Data

–

Data

Model:

–

Modèle :

–

Modell:

–

Model:

–

Model:

–

Modello:

–

Modelo:

–

Modell: Modell:

–

Malli:

–

Model:

–

Modelo: 992318 992319

Oper. Ear Sound Pressure (Lpa) in dBA – Pression acoustique aux oreilles de l’opérateur (Lpa) en dBA –

Geräuschpegel am Ohr des Bedieners (Lpa) in dBA – Geluidsdruk bij het oor van de gebruiker (Lpa) in dBA –

Strøjtryk ved brugerens øre (Lpa) målt i dBA – Pressione sonora all’orecchio dell’operatore (Lpa) in dBA – Presión

de sonido en el oído (Lpa) in dBA – Lydtrykk ved førerens øre (Lpa) inn dBA – Ljudeffekt vid förarens öron (Lpa) i

dBA – Kuljettajan korvaan kohdistuva äänenpaine (Lpa), dBA – Robocze ciśnienie akustyczne na uchu (Lpa) w

decybelachA – Oper. Pressão do Som no Ouvido (Lpa) em dBA 90 90

Vibration Measure (m/sec2) at Operator

–

Mesure des vibrations (m/s2) au niveau de l’opérateur

–

Vibration (m/

s2) an des Bedieners

–

Gemeten trilling bij (m/sec2)

–

Vibrationsmålinger (m/s2) ved brugerens

–

Vibrazioni

percepite dall’operatore (m/sec2)

–

Medida de vibración (m/seg2) en el operador

–

Vibrasjonsmåling (m/s2) ved

førerens

–

Vibrationsmått (m/s2) vid förarens

–

Tärinä (m/s2) kuljettajan

–

Pomiar wibracji (m/sec2) u operatora

–

Medida de Vibração (m/seg.2) no Operador

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

5

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.

Dealer trained service personnel should use this

manual as a supplement to and reminder of the training

sessions conducted by the company.

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.

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.

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.

Figure 1

PRODUCT REGISTRATION

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

honored, whether or not the product registration card is

returned. Keep a proof of purchase if you do not

register your unit.

Customer Note: If the dealer does not register your

product, please fill out, sign, and return the product

registration card to Gravely.

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.

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.

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 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.

Product Notices - Notification of limited product

located in a certain region. This is a limited distribution

to only those who received the product involved.

Campaigns - Notification of a safety related issue. All

products must be updated and are tracked by the

factory until all units are corrected.

PREPARATION

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.

INTRODUCTION

Serial Number

Label

OA0017

6

SAFETY ALERT SYMBOL

These are safety alert symbols. They

mean:

•ATTENTION!

•YOUR SAFETY IS INVOLVED!

When you see this symbol:

•BECOME ALERT!

•OBEY THE MESSAGE!

SIGNAL WORDS

The safety alert symbols above and signal words below

are used on decals and in this manual.

Read and understand all safety messages.

NOTATIONS

NOTE: General reference information for proper opera-

tion and maintenance practices.

IMPORTANT: Specific procedures or information

required to prevent damage to unit or attachment.

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.

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.

SAFETY DECALS AND LOCATIONS

ALWAYS replace missing or damaged safety decals.

See Figure 2 for safety decal locations.

1. DANGER! TO AVOID SERIOUS INJURY OR

DEATH

Read Operator’s Manual.

Keep children and others away from unit

while operating.

Never direct discharge toward other

people. Thrown objects can cause injury.

Look down and behind before and while

backing.

Never carry children.

Go up and down slopes, not across. DO

NOT operate on slopes over 17o.

SAFETY

WARNING: This cutting machine is capable of

amputating hands and feet and throwing

objects. Failure to observe the safety

instructions in the manuals and on decals could

result in serious injury or death.

WARNING: Slopes are a major factor related to

loss-of-control and tip-over accidents. Operation

on all slopes requires extra caution.

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.

WARNING: Disengage attachment, stop unit

and engine, remove key, engage parking brake,

and allow moving parts to stop before leaving

operator’s position.

DANGER: IMMINENTLY HAZARDOUS

SITUATION! If not avoided, WILL RESULT in

death or serious injury.

WARNING: POTENTIALLY HAZARDOUS

SITUATION! If not avoided, COULD RESULT in

death or serious injury.

CAUTION: POTENTIALLY HAZARDOUS

SITUATION! If not avoided, MAY RESULT in

minor or moderate injury. It may also be used to

alert against unsafe practices.

OL1253

OL3900 OL 1801

OL 4370

OL 0910

OL 4460

OL 4470

OL 4450

17°

MAX

7

• 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.

Always stand clear of discharge area. Do

not direct discharge toward other people.

Keep people away from unit while

operating.

Shut off engine, remove key, and read

manual before you adjust or repair unit.

NO STEP! Always keep feet away from

rotating parts.

3. WARNING!

Always stand clear of discharge area.

Do not operate mower unless guards are in

operating position or bagger is attached.

4. HOT SURFACES!

DO NOT touch parts which are hot from

operation. ALWAYS allow parts to cool.

5. DANGER!

AVOID INJURY. Stay clear of rotating parts.

AVOID INJURY. Stay clear of rotating fan.

OL 3030

OL 0910

OL 4370

OL 4010

OL 4420

OL 4430

OL 3320

OD 0061

OL 4730

OL 4740

8

Figure 2 - Safety Decals

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.

ALWAYS remove key from ignition and wire from spark

plug before assembly. Unintentional engine start up

can cause death or serious injury.

Complete a walk around inspection of unit and work

area to understand:

• 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.

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.

Keep children out of work area and under watchful care

of a responsible adult.

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.

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.

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.

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.

Only trained adults may operate unit. Training includes

actual operation.

• Risque de blessures - ne pas s’approcher des pièces en

mouvement.

• Evitar lesiones - Mantenerse alejado de las piezas giratorias.

• Avoid injury - Stay clear of rotating parts.

07735200C

DANGER / PELIGRO

DANGER/PELIGRO

WARNING/AVERTISSEMENT/ADVERTENCIA

Do not operate mower

unless guards are in

operating position or

bagger is attached.

Ne jamais utiliser

la tondeuse sans

protecteur sur le

canal d'ejection ou

sans le bac monte.

No operar segadora a

menos que las defensas

esten en posicion de

operacion o el

recogedor este fijo.

07742300B

DANGER/PELIGRO

• Read the operator's manual.

• Keep children and others away from unit while

operating.

• Never direct discharge toward other people.

Thrown objects can cause injury.

• Look down and behind before and while backing.

• Never carry children.

• Go up and down slopes, not across.

• 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.

• Leer el manual del operador.

• Mantenga la unidad alejada de los niños y otras

personas cuando esté en funcionamiento.

• Nunca dirija la descarga hacia otras personas,

ya que los objetos lanzados pueden provocar

lesiones.

• Antes y durante retroceso mirar hacia abajo y

detras.

• Nunca monten niños.

• Suba y baje pendientes, no transversalmente.

• Si la maquina se detiene subiendo cuesta,

desactive la cuchilla y baje lentamente.

• Evite viradas subitas.

• Mantenga artefactos de seguridad (defensas,

protectores, interruptores, etc.) en su lugar y

trabajando.

• Verifique en el manual el sistema de engranar

antes de usar.

• Tenga conocimiento de funciones y

localizaciones de todos los controles.

• No permitir que personal sin la necesaria

formación use la máquina.

TO AVOID SERIOUS INJURY OR DEATH

POUR EVITER LES BLESSURES GRAVES

OU LA MORT PARA EVITAR DAÑOS SERIOS O LA

MUERTE

• Lire le manuel d'utilisation.

• 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.

• Ne transportez jamais d'enfant.

• Tondez toujours de haut en bas et

inversement jamais le long des pentes.

• Si la machine s

'a

rrête en montee. Debrayez

la lame et redescendez doucement.

• Evitez les virages brusques.

• Maintenez toujours en place tous les

elements de sécurité (protecteurs,

interrupteurs, etc.).

• 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.

MAX

17

05359300

DANGER / PELIGRO

9

Local regulations may restrict the age of the operator.

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.

DO NOT wear loose clothing or jewelry and tie back

hair that may get caught in rotating parts.

Wear adequate outer garments.

NEVER wear open sandals or canvas shoes during

operation. Wear adequate safety gear, protective

gloves and footwear.

Wear proper footwear to improve footing on slippery

surfaces.

Always wear safety goggles or safety glasses with side

shields when operating mower.

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 place your hands or any part of your body or

clothing inside or near any moving part while unit is

running.

ALWAYS keep hands and feet away from all rotating

parts during operation. Rotating parts can cut off body

parts.

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.

ALWAYS keep hands and feet away from all pinch

points.

Fumes from the engine exhaust can cause death or

serious injury. DO NOT run engine in an enclosed

area. Always provide good ventilation.

Read, understand, and follow all instructions in the

manual and on the machine before starting.

Understand:

• How to operate all controls

• The functions of all controls

• How to STOP in an Emergency

• Braking and steering characteristics

• Turning radius and clearances

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.

Stop engine before removing grass catcher or

unclogging chute.

Ensure Safety Interlock System is functioning properly.

DO NOT operate unit if safety interlock is damaged or

disabled.

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.

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.

Avoid slippery surfaces. Always be sure of your footing.

DO NOT mow on wet grass. Reduced traction could

cause sliding and effect the machine’s stability.

Watch for traffic when operating near or crossing

roadways.

Never carry passengers.

DO NOT try to stabilize the machine by putting your

foot on the ground.

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.

ALWAYS disengage PTO, stop unit and engine,

remove key, engage parking brake and allow moving

parts to stop before leaving operator’s position.

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.

DO NOT operate in reverse unless absolutely

necessary.

ALWAYS look down and behind before and while

backing.

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.

Mower blades are sharp and can cut you. Wrap the

blade(s) or wear gloves, and use extra caution when

servicing them.

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.

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.

Disengage PTO when attachment is not in use.

ALWAYS turn off power to attachment when traveling,

crossing driveways, etc.

Mow up and down slopes, not across them.

10

DO NOT operate on slopes of more than 17 degrees.

Use of a Rollover Protection System (ROPS) is

recommended for slope operation.

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.

If you cannot back up a slope or you feel uneasy on it,

do not mow it.

DO NOT park on slopes unless necessary. When

parking on slope always chock or block wheels. Always

set parking brake.

Use a slow speed. Tires may lose traction on slopes

even though the brakes are functioning properly.

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.

Follow the manufacturer’s recommendations for weight

limits for towed equipment and towing on slopes.

NEVER allow children or others in or on towed

equipment.

On slopes, the weight of the towed equipment may

cause loss of control.

Travel slowly and allow extra distance to stop.

Use extra care when loading or unloading unit onto

trailer or truck.

Secure unit chassis to transport vehicle. NEVER

secure from rods or linkages that could be damaged.

DO NOT transport machine while engine is running.

ALWAYS turn off power to attachment and shut off fuel

when transporting unit.

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.

Fuel is highly flammable and its vapors are explosive.

Handle with care. Use an approved fuel container.

NO smoking, NO sparks, NO flames. ALWAYS allow

engine to cool before servicing.

NEVER fill fuel tank when engine is running or hot from

operation.

NEVER fill or drain fuel tank indoors.

Replace fuel cap securely and clean up spilled fuel.

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.

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.

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 fuel is spilled on clothing, change clothing

immediately.

Avoid Electric Shock. Objects contacting both battery

terminals at the same time may result in injury and unit

damage. DO NOT reverse battery connections.

Reversed connections may result in sparks which can

cause serious injury. Always connect positive (+) cable

FIRST, and negative (-) cable SECOND.

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.

No flames, No sparks, No smoking near battery.

ALWAYS wear safety glasses and protective gear near

battery. Use insulated tools.

DO NOT TIP battery beyond a 45o angle in any

direction.

ALWAYS keep batteries out of reach of children.

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.

ALWAYS block wheels and know all jack stands are

strong and secure and will hold weight of unit during

maintenance.

Release pressure slowly from components with stored

energy.

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.

ALWAYS maintain unit in safe operating condition.

Damaged or worn out muffler can cause fire or

explosion.

Maintain or replace safety and instruction labels, as

necessary.

NEVER store unit with fuel in fuel tank, inside a

building where any ignition sources are present.

11

Shut off fuel and allow engine to cool completely before

storing in closed area or covering unit.

Clean grass and debris from unit, especially from

around muffler and engine, to help prevent fires.

For extended storage, shut off fuel and clean unit

thoroughly. See engine manual for proper storage.

Lower cutting deck unless a positive mechanical lock is

used.

Use only attachments or accessories designed for your

unit.

Check all hardware at regular intervals, especially

blade attachment bolts. Keep all hardware properly

tightened.

Check attachment components frequently. If worn or

damaged, replace with manufacturer’s recommended

parts.

Safety Interlock System

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.

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.

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.

Test Steering

Levers

PTO Parking

Brake

Engine

STARTING INTERLOCK

1 Neutral Off Engaged Start

2 Neutral On Engaged Doesn’t

Start

3 Neutral Off Disengaged Doesn’t

Start

OPERATING INTERLOCK (ENGINE ON)

4* Neutral On Engaged Shuts Off

5* Neutral Off Disengaged Shuts Off

6* Neutral Off Engaged On

*Operator lifts off seat.

12

SPECIFICATIONS

Model Number 992018 992023 992027

Model 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) 87 (221) 90 (229)

Height - in (cm) 50 (127)

Width - in (cm) 63 (160) 85 (216)

Weight Actual - lbs (kg) 1100 (499) 1080 (490) 1259 (572)

Battery 12 volt

Brakes Hydro/Dynamic Disk - Parking

Turning Radius 0

Tire Size Front 15 x 6 - 6 15 x 6 - 6 15 x 6 - 6

Rear 23 x 10.5 - 12 23 x 8.5 - 12 12 x 1.5 - 12

Engine - Manufacturer Kohler Briggs & Stratton Kohler

Model Number CV25S 351777 CV25S

Cycle 4

Engine Power- 25 HP 20 HP 25 HP

HP (KW/min -1) (18.6 KW/min -1) (14.7 KW/min -1) 18.6 KW/min -1)

Starting System Electric

Fuel Tank Capacity 9 gals. US (34 liters)

Fuel See Engine Manual

Idle RPM 1800

Governed RPM 3600

Air Cleaner Large Capacity Dual ELement

Cooling Capacity Air Cooled

Engine Oil Type See Engine Manual

Spark Plug Gap See Engine Manual

Transmission Hydrostatic Drive

Speed - Forward Max. 9 MPH

Reverse Max. 4.5 MPH

Transmission Lube Mobil 1 15W - 50 Synthetic

Drive Clutch Hydrostatic

Tire Pressure Front 20-25 psi

Rear 12-15 psi

Lift system Hydraulic

Power Take Off Electric PTO Clutch/Brake

Cutting Width - in (cm) 50 (127) 72 (183)

Cutting Height - in (cm) 1 - 5 (2.5 - 12.7)

Cutting Increments - in (cm) Infinite between 1 - 5 (2.5 - 12.7)

13

Model Number 992020 992029 992030 992032 992033 992034 992035

Model 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

Kawasaki

w/50" deck

250Z 23 HP

Kawasaki

w/50" deck

250Z 23 HP

Kawasaki

w/50" dek

Length - in (cm) 80 (203) 84 (213.4) 80 (203)

Height - in (cm) 50 (127)

Width - in (cm) 73 (185) 85 (216) 73 (185) 63 (160)

Weight Actual - lbs (kg) 1125 (510) 1259 (572) 1125 (510) 1100 (499)

Battery 12 volt

Brakes Hydro/Dynamic Disk - Parking

Turning Radius 0

Tire Size Front 15 x 6 - 6

Rear 23 x 10.5 - 12

Engine - Manufacturer Kohler Kawasaki Kohler Kawasaki

Model Number CV25S FH721V CV26S FH601V FH680V

Cycle 4

Engine Power - HP (kw) @

Governed RPM

25 (18.6) 26 (19.3) 19 (14.1) 23 (17.2)

Governed RPM 3600

Idle RPM 1800

Starting System Electric

Fuel Tank Capacity 9 gals. US (34 liters)

Fuel See Engine Manual

Air Cleaner Large Capacity Dual ELement

Cooling Capacity Air Cooled

Engine Oil Type See Engine Manual

Spark Plug Gap See Engine Manual

Transmission Hydrostatic Drive

Speed - Forward Max. 9 MPH

Reverse Max. 4.5 MPH

Transmission Lube Mobil 1 15W - 50 Synthetic

Drive Clutch Hydrostatic

Tire Pressure Front 20-25 psi

Rear 12-15 psi

Lift system Hydraulic

Power Take Off Electric PTO Clutch/Brake

Cutting Width - in (cm) 60 (152) 72 (183) 60 (152) 50 (127)

Cutting Height - in (cm) 1 - 5 (2.5 - 12.7)

Cutting Increments - in (cm) Infinite between 1 - 5 (2.5 - 12.7)

14

Figure 3

CONTROLS AND FEATURES

1. Mower Deck with Chute Deflector

2. Fuel Shut off Valve

3. Parking Brake

4. Battery

5. Hour Meter

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

12.Ignition Switch

13.Power Take Off (PTO) Switch

14.Steering Levers

15.Mower Lift Lever

16.Seat Adjustment 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

OF 1722

123

18

2

17

16

15

14

19

4

22

21

20

6

5

7

3

*Electronic Fuel Injection

8910 11

12

13

8

15

MAINTENANCE SCHEDULE Proper maintenance can prolong the life of unit. The

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).

See the maintenance instructions in Engine Manual for

additional information.

GENERAL MAINTENANCE & ADJUSTMENTS

WARNING: AVOID INJURY. Read and

understand the entire Safety section before

proceeding.

Interval Task Action

Each Use

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

until repairs are made (see Safety Interlock System on page 11).

Check Parking Brake

Interlock System See Parking Brake Interlock System on page 11.

Check Parking Brake Engage parking brake. Push unit. If unit rolls adjust parking brake (see Parking

Brake Adjustment on page 22).

Check Hydraulic Oil Level See Checking Hydraulic Oil Level on page 26.

Check Tires See Specifications on page 12 for correct tire pressure.

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

Hours Check Mower Blades 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

Hours Lubricate Front Axle and

Pivot Points Oil all pivot points, pin connections and apply grease to front axle grease zerk (see

General Lubrication on page 18).

Every

100

Hours

Clean Battery Keep battery and battery terminals clean (see Cleaning the Battery on page 19).

Check Fasteners Check mower blade mounting hardware and all other fasteners. Replace missing

or damaged fasteners. Tighten all nuts and bolts to their correct torque value.

Check Belts Replace worn or deteriorated belts.

• Check mower drive belt (see Replacing Mower Belts on page20 for mower

drive belt location).

• Check PTO belt (see PTO Belt Removal on page 20 for PTO belt location).

• Check radiator fan belt (refer to Engine Manual).

Every

400

Hours

Grease Front Axle Caster

Pivots Repack front axle caster pivots (see General Lubrication on page 18).

Every

500

Hours

Change Hydraulic Oil and

Filter See Hydraulic Oil System on page 26.

16

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.

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.

1. Place steering levers in neutral position and set

parking brake.

2. Unhook hood latches. Firmly grasp hood frame

handle and lift to the desired service position

(Figure 4).

Daily Service Position: Place hood prop rod into

service slot. Ensure prop rod is engaged in service slot

properly.

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.

3. When service is complete, lower hood, and secure

with hood latches.

Figure 4

MOVING UNIT MANUALLY

Figure 5

IMPORTANT: Never tow unit.

1. Place hood in the full service position (see Service

Positions on page 16).

2. Rotate the bypass valve dump levers located on

the pumps using a wrench.

3. Disengage parking brake.

4. Push unit to desired location.

WARNING: AVOID INJURY. Read and

understand the entire Safety section before

proceeding.

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.

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.

WARNING: Do not bypass transmission when

on a slope.

1. Steering Levers

2. Parking Brake

3. Footboard

4. Engine Hood &

Frame

5. Engine Hood Prop

Rod

6. Service Slot

7. Full Service Position

8. Engine

9. No Step Decal

10.Battery

OF 1811

1

23

4

5

6

7

8

9

10

1. Right Bypass Valve

Lever 2. Left Bypass Valve

Lever

OF 1730

21

17

5. Engage parking brake.

6. Levers must be returned to their original position in

order to operate the unit (Figure 5).

TRANSPORTING UNIT

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.

NOTE: PTO must be disengaged and parking brake

engaged prior to starting engine.

To start:

1. Insert ignition key (Figure 6).

2. Move throttle control lever to middle position.

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.

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.

Figure 6

To shut off:

1. Disengage PTO.

2. Set parking brake.

3. Turn ignition key to Off (1) position.

CLEANING AND STORAGE

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.

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.

Short Term

NEVER spray unit with high-pressure water or store

unit outdoors.

Inspect unit for visible signs of wear, breakage or

damage.

Keep all nuts, bolts and screws properly tightened and

know unit is in safe working condition.

Store unit in a cool, dry protected area.

Long Term

Clean unit thoroughly and lubricate. Touch up all

scratched painted surfaces.

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.

Clean and charge battery. Charge battery every three

to four weeks when storing unit.

When taking unit out of extended storage:

1. Check for any damage or loose parts. Repair,

replace or tighten hardware before operation,

especially blade attachment bolts.

2. If a preservative fluid was used in fuel tank, drain

and discard. Fill fuel tank with fresh new fuel.

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.

START

RUN

OFF

1

2

3OF 1750

WARNING: AVOID INJURY. Read and

understand the entire Safety section before

proceeding.

18

FILLING FUEL TANK

Add fuel to the tank as needed.

IMPORTANT: Refer to Engine Manual for correct type

and grade of fuel. See Specifications for fuel tank

capacity.

To add fuel to the fuel tank:

1. Refuel the unit only in a well ventilated, open area.

2. Stop the engine.

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.

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.

5. Install the cap on the fuel tank and tighten.

6. Clean up any spilled fuel before starting the

engine.

FASTENERS

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.

GENERAL LUBRICATION

IMPORTANT: Wipe each fitting clean before and after

lubrication.

Lube fitting locations are: front axle pivot (1) (Figure 7)

Apply Sten Mix Hi-Temp Grease or equivalent to the

lube fittings. Order P/N: 00036700 - Ten pack of 14 oz.

cartridges.

When using Sten Mix Grease for the first time, all

components should be thoroughly cleaned prior to

lubricating.

Apply oil at all pivot points and pin connections.

Figure 7

IMPORTANT: Wipe front axle grease zerk and two

front axle caster pivots clean before and after

lubrication.

NOTE: Use Stens Mix Hi-Temp Grease or equivalent

(part number 00036700).

SERVICING THE BATTERY

NOTE: Unit comes equipped with a maintenance-free

battery that requires no regular maintenance except

cleaning the terminals.

EXPLOSIVE VAPORS and FLAMMABLE

FUEL can result in serious injury or death.

Handle fuel with care. ALWAYS use an

approved fuel container.

No Smoking!

No Lighted Materials!

No Open Flame!

Allow engine to cool.

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.

Description Use Interval

Grease fittings Sten Mix HI-Temp

grease or equivalent 50 hrs. running time

Hydraulic system Mobil 15W50

synthetic oil 500 hrs. running

time

WARNING: AVOID INJURY. Read and

understand the entire Safety section before

proceeding.

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.

1

2

1

Item Lubrication Item Location Interval

1 Repack 2 Caster Pivot 400 hours

2 Grease 1 Axle Pivot 50 hours

Oil All Pivot Points, Pin

Connections 50 hours

OF 1792

19

Battery Removal and Installation

Remove

1. Place hood in full service position (see Service

Positions on page 16).

2. Disconnect negative (-) cable first, then positive (+)

cable (Figure 8).

3. Remove battery hold-down bracket and battery

from unit.

Install

1. Install battery on unit with battery hold-down

bracket.

2. Connect positive (+) cable first, then negative (-)

cable.

3. Coat terminals with dielectric grease or petroleum

jelly.

4. Close hood.

Cleaning the Battery

1. Disconnect negative (-) cable first, then positive (+)

cable.

2. Clean battery cable ends and terminals with wire

brush. Rinse with a weak baking soda solution.

3. Connect positive (+) cable first, then negative (-)

cable.

4. Coat terminals with dielectric grease or petroleum

jelly.

Figure 8

Charging the Battery

Follow First Aid directions for contact with battery fluid.

•External Contact: Flush with water.

•Eyes: Flush with water for at least 15 minutes and

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!

• In case of internal contact, DO NOT induce

vomiting!

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.

1. Remove battery from unit (see Battery Removal

and Installation on page 19).

2. Place battery on bench or other well-ventilated

area.

3. Connect positive (+) lead of charger to positive (+)

terminal, and negative (-) lead to negative (-)

terminal.

4. Charge battery according to the instructions from

battery charger manufacturer and battery

manufacturer.

Storage

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.

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.

The battery must be recharged monthly. Before

reinstalling the battery in the spring, it should always be

fully recharged.

BASIC ENGINE MAINTENANCE

See your engine manual and Engine Chapter of this

manual for detailed information on the operation and

maintenance of your engine.

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. Each day before operating, check the air cleaner

element. Dirt can decrease the flow of air to the

engine.

3. Each day before operating, check the air cooling

system on the engine. Debris can decrease the

flow of air cooling the engine.

4. Follow the maintenance instructions in your engine

manual concerning oil and filter changes.

WARNING: FROZEN BATTERIES CAN

EXPLODE and result in death or serious

injury. DO NOT charge a frozen battery. Let

battery thaw before charging.

1. Battery

2. Negative (-) Terminal

3. Negative(-) Cable

4. Positive (+) Termina

l

5. Positive (+) Cable

2

3

1

54

OF 3227

20

BELTS

Belt Access

1. Properly stop and park unit (refer to Owner’s

Manual).

2. Lower the mower.

3. Place seat in most rearward position.

4. Remove belt covers.

5. Place foot board in open position (Figure 9).

6. Secure raised footboard with latch.

Figure 9

Replacing Mower Belts

NOTE: Long belt must be removed to remove short

belt.

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).

Figure 10

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.

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).

2. Remove the mower belt from the mower clutch

sheave. See replacing Mower Belts.

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.

5. Put the mower belt back on mower clutch sheave.

See Replacing Mower Belts.

WARNING: MOVING PARTS can cut or

amputate body parts. ALWAYS wait for

moving parts to stop before performing

maintenance or service.

CAUTION: DAMAGED OR WORN BELTS

may result in injury and/or damage to the unit.

Check belts for excessive wear or cracks

often.

1. Footboard in open

position

2. Footboard in closed

position

3. Support Frame

4. Pivot

5. Latch

1

52

3

4

OF 1802

CAUTION: Use care when releasing idler

spring tension. Keep body parts well away

from idlers when performing this operation.

72" Belt

Layout

50" and 60"

Belt Layout

1. Long Mower Belt

2. Short Mower Belt

3. Springs

4. Idlers

5. Mower Clutch

Sheave

OF 1641

1

2

3

4

1

2

5

3

4

21

Figure 11

TIRES

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.

MOWER BLADES

NOTE: If mower is used under sandy soil conditions,

replace mower blades when air lifts become eroded

through at ends (Figure 12).

Figure 12

Sharpening Mower Blade

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. 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.

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.

STEERING CONTROL NEUTRAL

ADJUSTMENT

If the unit has excessive creep when the control levers

are in neutral, adjust as follows: (Figure 13)

Figure 13

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.

3. With the unit up to and facing a wall, jack the unit

up so that both drive wheels are off the ground.

CAUTION: Use sturdy gloves or padding to

protect hands when working with mower

blades.

3

6

2

4

51

1. Hydro Belt

2. Spring

3. Idler

4. Engine Sheave

5. Right Hand

Hydrostat

6. Left Hand Hydrosta

t

OF 1631

4

2

3

1

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.

1. Stop Bolts

2. Pump Levers

3. Front Ball Joints

4. Control Levers

5. Parking Brake

Interlock

6. Clamping Bolt and

Slot

7. Mounting Bolt

OF 1820

1

2

2

4

3

5

3

7

6

4

22

4. Have someone depress center of seat to activate

seat switch.

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.

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.

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.

10.Reinstall the front ball joint(s)

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.

11.Move the control levers, from forward to reverse

several times to make sure it is adjusted to neutral.

Readjust if necessary.

12.Stop the engine.

ADJUSTING CONTROL LEVERS

To be done after neutral has been set. (Figure 13).

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.

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.

4. Tighten the clamping bolt.

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.

2. Turn the nuts further on the rod (clockwise) to

tighten the brake and further off the rod

(counterclockwise) to loosen the brake.

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.

Figure 14

ADJUSTING UNIT TO TRACK STRAIGHT

Check and adjust tire pressure. Increase pressure on

side unit tracks to. DO NOT exceed maximum

recommended tire pressure (refer to Specifications).

If tire pressure adjustment does not solve tracking

problem, the limiter bolts at base of handles can be

adjusted. See Figure 15. Front bolts are for forward

and rear bolts are for reverse. Lengthen bolts (move

closer to lever) on side which is too fast.

Figure 15

2

1

1

1. Jam Nuts

2. Compression Spring

PF 1732

12

1

Front

1. Limiter Bolt

2. Lever

23

LEVELING THE MOWER DECK

These adjustments should be made on a level surface

with the tires inflated to the correct air pressure.

The mower is leveled from side to side with the slots

where 4 chains fasten to the mower mounting brackets.

The mower is leveled from front to rear by adjusting the

rod running down each side of the frame (Figure 16).

1. Raise mower deck and insert 3" (7.6 cm) tall blocks

to support deck.

2. Lower deck onto blocks so chains are slack.

3. Measure from bottom of mower blade end to

ground.

4. Shut off engine. Engage parking brake. Remove

the ignition key.

5. Set hydraulic lift cylinder so cut of height reads the

same as blade height measurement.

6. Loosen the locknuts on the side where the chains

are slack and slide the bolt down the slot until the

chain is tight.

7. Tighten bolt and nuts in mower mounting brackets.

8. Lift mower and remove blocks.

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.

14.Tighten rear hex nut on each rod that was

loosened in step 11.

Figure 16

Right Side View

Front of Unit

1

1

1

1

1

1

1

1

1

11

1. Rod

2. Rear Hex Nut

3. Front Hex Nut

4. Chains

5. Lock Nuts and Slots

6. Mower Mounting

Brackets

7. Front Mower Lift

Pivot

8. Rear Mower Lift

Pivot

9. Hydraulic Cylinder

PF 1920

24

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.

ENGINE

TROUBLE POSSIBLE CAUSES

(Refer to Key Below)

CORRECTIVE ACTION

Black Exhaust 1, 20, 22, 25, 29, 31, 32, 33 repair or replace

Blue/White Exhaust 4, 20, 25, 31, 33, 34 repair or replace

Difficult Starting 1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33 repair or replace

Erratic Running 1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62 repair or replace

Excessive Fuel Consumption 1, 20, 22, 23, 25, 39, 31, 32, 33 repair or replace

High Oil Pressure 4, 41 repair or replace

Knocking 22, 26, 29, 31, 33, 36, 46, 59 repair or replace

Loss of Power or System 1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33 repair or replace

Low Cranking Power 2, 3, 4, 11 repair or replace

Low Oil Pressure 4, 36, 37, 39 repair or replace

Misfiring 10, 20, 25, 26, 28, 29, 32 repair or replace

Overheating 1, 19, 25, repair or replace

Poor Compression 25, 28, 29, 31, 32, 33, 34, 59, repair or replace

Starts and Stops 1, 6, 10, 62 repair or replace

see electrical systems

see engine service manual

Vibration 20, 23, 25, 26, 29, 33, 45, 49 repair or replace

Will Not Crank 2, 11, 45 charge battery or replace

Will Not Start 1, 10, 62 repair or replace

see electrical systems

see engine service manual

TROUBLESHOOTING KEY

1 Restriction in air cleaner 22 Incorrect grade of fuel 43 Faulty suction pipe

2 Bad electrical connection 23 Sticking throttle/restricted movement 44 Choked oil filter

3 Faulty starter motor 24 Exhaust pipe restriction 45 Bad solenoid switch

4 Incorrect grade of lubricating oil 25 Leaking cylinder head gasket 46 Incorrect piston height

5 Low cranking speed 26 Overheating 47 Damaged fan

6 Fuel tank empty 27 Cold running 48 Faulty engine mounting

7 Controls not in correct operation

position

28 Incorrect tappet adjustment 49 Incorrectly aligned flywheel and/or

flywheel housing

8 Blocked fuel feed line 29 Sticking valves 50 Faulty thermostat

9 Faulty fuel lift pump 30 Incorrect high pressure pipes 51 Restriction in water jacket

10 Choked fuel filter 31 Worn cylinder bores 52 Loose fan belt

11 Battery capacity low 32 Pitted valves and seats 53 Choked radiator

12 Air in fuel system 33 Broken, worn or sticking piston ring(s) 54 Faulty water pump

13 Faulty fuel injection pump 34 Worn valve stems and guides 55 Choked breather pipe

14 Faulty fuel injectors or incorrect type 35 Restriction in air cleaner 56 Damaged valve stem oil deflector (if

fitted)

15 Incorrect use of cold start equipment 36 Worn or damaged bearings 57 Coolant level too low

16 Faulty cold start equipment 37 Insufficient oil in sump 58 Blocked sump strainer

17 Broken fuel injection pump drive 38 Bad/defective oil temperature switch 59 Broken valve spring

18 Incorrect fuel pump timing 39 Oil pump worn 60 Exhaust or vacuum pipe leak

19 Incorrect valve timing 40 Pressure relief valve sticking open 61 Bad or defective water temperature

switch

20 Poor compression 41 Pressure relief valve sticking closed 62 Bad spark plug(s)

21 Blocked fuel tank vent 42 Broken relief valve spring

25

REMOVING THE ENGINE

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.

5. Unscrew the bolt from the center of the output shaft

and remove clutch. Refer to "Replacing the

Clutch".

6. Remove the square key and the pulley.

7. Unclamp and remove the fuel line. Plug the fuel

line and wipe up any spills.

8. Remove the engine mounting bolts and lift engine

out the top.

INSTALLING THE ENGINE

1. Position the new engine in the chassis, insert

mounting bolts and tighten.

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

Figure 17.

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.

Figure 17

To Replace the Clutch

1. Remove the belt by relaxing the idler pulley.

2. Remove the center bolt.

3. Disconnect electrical wires.

4. Remove nut from the anchor bracket.

5. Pull clutch from shaft.

6. Position new clutch on the shaft by aligning the

square key on the shaft with the keyway of the

clutch.

7. Clutch should be rotated to position the anchor

bracket with the slot in the stationary shell.

Replace nut and tighten.

8. Replace bolt and washers. Torque to 55 foot

pounds (74.5 Nm).

3

1

2

1. Electric Clutch

2. Pulley

3. Anchor Bracket

CAUTION: DO NOT ALLOW the engine

crankshaft to rotate. Damage to the engine

may occur.

26

CHECKING THE HYDRAULIC FLUID

LEVEL

A check of the hydraulic fluid level should be made

daily.

NOTE: The oil level should be centered between the

two marks on the dipstick.

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.

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.

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.

2. Place a film of oil on the new filter’s gasket.

3. Screw the filter on until it makes contact with the

sealing surface of the filter head.

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.

6. After shutting off the engine, check the fluid level.

The dipstick should read the fluid level between the

high and low markings.

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.

1. Block and jack the unit up so that both drive wheels

are off the ground.

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.

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.

7. Install a bi-directional flow gauge.

8. Have someone depress center of seat to activate

seat switch.

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.

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.

12.Open the restriction valve and move the control

lever back to neutral. Idle unit down for a few

seconds and shut off engine.

13.The acceptable flow drop would be less than 1

GPM difference between the low and high

pressure settings. If flow drop is greater than 1

GPM, the hydro-pump will need to be repaired or

DRIVE TRAIN

WARNING: Hydraulic Fluid can result in

severe burns. Fluid in hydraulic system can

penetrate skin and result in serious injury or

death.

Be sure to stop the engine before doing any

work on hydraulic parts.

Keep body and hands away from pin holes or

nozzles which expel hydraulic fluid when

under pressure. Use paper or cardboard, not

hands, to search for leaks.

Insure all hydraulic fluid connections are tight

and all hydraulic hoses and lines are in good

condition before applying pressure to system.

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.

27

replaced. If the flow drop is less than 1 GPM you

will need to replace the wheel motor.

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

Figure 18.

Figure 18

To Replace a Hydraulic Pump

1. Lift cover to full service position.

2. Remove the cross channel.

3. Clean hoses and fittings and mark for location.

4. Disconnect hoses from pump.

5. Remove belt from pulley.

6. Remove bolt and washers from end of shaft.

7. Loosen pulley lock bolt and slide pulley from shaft.

Remove and inspect square key. Replace key if

damaged.

8. Remove back bolt on pump and loosen front bolt.

9. Remove pump.

10.Insert the new pump into position with the front bolt

in the mounting flange slot.

11.Insert rear bolt and tighten both bolts.

12.Attach hydraulic hoses to correct ports and tighten.

13.Position square key in shaft keyway and slide

pulley into position.

14.Screw the bolt, washer and lock washer into the

end of the shaft. Tighten securely.

15.Tighten pulley lock bolt.

16.Place belt on pulley.

17.Replace cross channel.

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.

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.

Figure 19

To Replace a Drive Motor

1. Loosen the wheel lugs 1/4 turn. (Figure 19)

2. Jack the drive wheels off the ground and securely

support the unit.

3. Remove the wheel.

4. Remove the brake caliper assembly by removing

the two bolts.

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.

6. Mark the hydraulic lines and remove.

7. Unscrew the two bottom bolts and pull the

hydraulic motor out.

8. Remove the four bolt sleeves.

9. Insert the sleeves into the four bolt holes in the

new hydraulic motor.

10.Slide the motor into place and secure with two

bottom bolts. Apply Loctite to bolts.

11.Reattach hydraulic lines to proper ports and

tighten.

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)

CAUTION: Some fluid will leak out. Clean up

any spills.

1

2

1. Hydrostat BDP

Pump

2. Variable-

Displace Pump

CAUTION: Some fluid will leak out. Clean up

any spills.

1

2

1

2

1. Hub 2. Hydraulic motor

28

13.Place the brake caliper into position and insert

bolts from the inside of the frame outward. Use

lock washer and nut and tighten.

14.Position wheel on hub and insert lug nuts finger

tight.

15.Tighten lug nuts using the pattern shown in Figure

20.

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.

Figure 20

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

lower side of hydraulic lift valve (Figure 21) and

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

side. See Figure 21.

1. Place hood in full service position.

2. Clean hose fittings, mark hoses for position and

disconnect from valve.

3. Loosen mounting bolts and remove valve.

4. Mount new valve and tighten bolts.

5. Connect hoses to proper ports.

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.

Figure 21

1

3

2

4

5

OK 0630

CAUTION: Some hydraulic fluid will leak out

of the hoses. Clean up any spills.

Lift Valve

29

HYDRAULIC DIAGRAM

992018, 023, 027

A

A

B

B

A

A

B

B

A

B

Lift

Cylinder

Oil

Filter

Left

Wheel

Motor

Upper

Lower

Right

Wheel

Motor

Upper

Lower

PRESSURE

RETURN

SUCTION

Right Pump

Left Pump

Oil

Tank

Deck Lower

Deck Lift

Lift

Valve

Reverse

High Pressure

Forward

High

Pressure Reverse

High

Pressure

Forward

High

Pressure

Return

Inlet

PD1772

30

Models 992020, 029, 030, 032, 033, 034, 035

PD1774

31

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.

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.

MOWER DECK

CAUTION: Use sturdy gloves or padding to

protect hands when working with mower

blades

32

SUSPENSION

The front suspension consists of a weldment that is a

square tube (Figure 22). A pivot pin holds the axle to

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.

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.

FRONT SUSPENSION

3

4

4

2

1

1. Pivot Pin

2. Spindle

3. Dust Cap

4. Bearing

33

TOOLS

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.

ELECTRICAL MEASUREMENTS

In many electrical circuits, there is some visible effect

which indicates that the circuit is functioning properly. A

switch is turned "ON" and a lamp lights. A key is

turned, a starter motor runs and cranks the engine.

If the lamp does not light, or the starter motor does not

run, some means of measuring voltage, current 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.

ELECTRICAL

34

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.

Current Measurement

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.

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

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.

Battery Electrolyte First Aid

• External contact: Flush with water.

• Eyes: Flush with water for at least 15 minutes and

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.

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.

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.

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.

WARNING: EXPLOSIVE GASES can result in

serious injury or death. ALWAYS keep open

flames, sparks, or smoking materials away

from battery.

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.

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.

35

Check the alternator voltage regulator output (if used)

at every period maintenance inspection. Over charging

is a common cause of battery failure.

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.

Charging a New Battery

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.

3. Remove hold down and remove battery.

4. Place battery on bench or other well-ventilated

place where electrolyte spill will not create

damage.

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.

7. Reinstall battery into unit and connect Positive (+)

cable first, then Negative (-) cable.

SWITCHES

Switches either open a circuit to stop current flow or

close and allow current to flow through.

A normally open (N.O.) switch prevents current flow

until the switch is actuated, 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.

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.

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).

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.)

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.

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.

Variation from test results described indicates a

defective switch.

Normally Closed Switch

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).

Variation from test results described indicates a

defective switch.

Ignition Switch

NOTE: Refer to the wiring diagram of the unit involved

to determine switch functions and test using the meth-

ods described.

The ignition switch incorporates a number of functions,

although not all functions are used on all equipment.

The switch has three positions: OFF, RUN, and a

momentary contact START position. Use an ohmmeter

to check the continuity of the switch in each position.

OFF Position - Should be continuity between contacts

G and M. These connections ground the engine

magneto and stop the engine in the OFF position.

RUN Position - Should be continuity between contacts

B and A. These connections supply power to the rest of

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.

36

the wiring harness. Connections G and M open to each

other.

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.

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

continuity between contacts other that those described.

SOLENOID AND RELAYS

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

37

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.

38

WIRING DIAGRAMS

Models 992018, 020, 027

PD3230

PD2110

39

Model 992029, 030, 034, 035

PD3242

40

Model 992023

87a

30

85

86

87

30

85

86

87

WHITE / BLACK

ENGINE

BROWN

KEY

SWITCH

1

2

BROWN / YELLOW

BLACK

RED / VIOLET

SEAT

SWITCH

12

PINK

BLACK

PURPLE

MAGNETO KILL

RED

BLACK

HOUR

METER

BLAC

K

PURPLE /

WHITE

SEAT / PTO RELAY

OIL PRESSURE

BLUE / WHITE

BRAKE

SWITCH

FUSE

30A

PTO

CLUTCH

12

PTO

SWITCH

4

3

9

1

7

START

RELAY

REGULATOR

FUEL SOLENIOD

OIL

LIGHT

RED / YELLOW

PURPLE

BA

BLACK

STARTER

1

2

BLACK

CAB

POWER

SUPPLY

87a

BLACK

M

G

S2

B

S1

A

RED /

YELLOW

RED / YELLOW

RED / VIOLET

SWITCH

BLACK

BATTERY

RED

RED

RED

BLACK

STARTER

SOLENOID

COIL 2 COIL 1

PD3251

41

Models 992032, 033

42

TROUBLESHOOTING

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE CORRECTION

Engine does not crank. 1. PTO engaged.

2. Parking brake disengaged.

3. Loose or corroded battery

cables.

4. Discharged battery.

5. Faulty starter.

1. Disengage PTO.

2. Engage parking brake.

3. Clean and tighten battery cables

(see Servicing the Battery on

page 18).

4. Charge battery (see Charging

the Battery on page 19).

5. See your Gravely Dealer.

Engine cranks but does not start. 1. Fuel tank empty.

2. Faulty spark plug.

3. Air cleaner is plugged or dirty.

4. Fuel filter is dirty.

5. Faulty engine.

1. Fill fuel tank (see Filling Fuel

Tank on page 18).

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. Refer to Engine Manual or see

your Gravely Dealer.

Battery light does not light up

when starting engine. 1. Discharged battery. 1. Charge battery (see Charging

the Battery on page 19).

Oil pressure light is on. 1. Oil pressure is low. 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.

2. Cooling fins/screen on engine

plugged with debris.

1. Add engine oil. Refer to Engine

Manual.

2. Clean engine and surrounding

area.

Engine continues to run when

ignition key is in the off position. 1. Ignition ground wire

disconnected.

2. Ignition switch failure.

1. Connect ground wire to clean

metal surface.

2. Replace ignition switch (see your

Gravely Dealer).

PTO or mower blades do not

engage or shuts off. 1. Operator presence switch not

depressed.

2. Eye-Q alarm setting is turned

on.

3. The Eye-Q circuitry senses an

overload to the PTO clutch and

is shutting off the PTO switch.

4. Faulty PTO switch.

1. Depress operator presence

switch by sitting on seat.

2. Turn off the alarm that

deactivates the PTO on a regular

schedule. See the Owner’s

Manual.

3. Check the mower deck for

clogging or debris. Check the

electrical system to the clutch for

damage or wear.

4. See your Gravely Dealer.

43

Unit does not drive. 1. Parking brake engaged.

2. Transmission bypass levers

open.

3. Hydraulic oil level low.

4. Faulty hydraulic drive system.

1. Disengage parking brake.

2. Close transmission bypass

levers (see Moving Unit Manually

on page 16).

3. Add hydraulic oil (see Checking

Hydraulic Oil Level on page 26).

4. See your Gravely dealer.

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE CORRECTION

GRAVELY

A Division of Ariens Company

655 West Ryan Street

P.O. Box 1 57

Brillion, WI 54110-0157

920-756-2141

Fax 920-756-2407

www.gravely.com