Use only Gravely replacement parts. Replacing any part and facing the direction of forward travel. on this unit with anything other than a Gravely authorized replacement part may adversely affect this unit’s 1.3 MODEL AND SERIAL NUMBERS performance, durability, or safety and may void the warranty.
1.8 SERVICE POSITION WARNING: Do not bypass transmission when unit is on a slope. WARNING: Personal injury can occur if safety precautions are not followed before 3. Disengage parking brake. and after servicing. 4. Push unit to desired location. • Place unit on a flat surface. 5.
Emission controls and components can only be adjusted by EPA and/or CARB authorized service centers. Contact your Gravely Equipment Retailer concerning emission controls and component questions. 2 - 4...
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Decal Description 05363100 Service Instructions Rapid XZ 05363000 Control Panel Rapid XZ 07757600 Steering Instruction 07754100 Hot Surface 05231800 Gravely Logo 05363300 Gravely Rapid XZ Hood 07735200 Danger Decal 05305100 American Flag 07757500 Parking Brake Lever Figure 4 2 - 5...
2.8 SAFETY RULES NEVER wear open sandals or canvas shoes during operation. Wear adequate safety gear, protective gloves Read, understand, and follow all safety practices in and footwear. Owner/Operator Manual before beginning assembly. Wear proper footwear to improve footing on slippery Failure to follow instructions could result in personal surfaces.
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DO NOT mow on wet grass. Reduced traction could If you cannot back up a slope or you feel uneasy on it, do cause sliding and affect the machine’s stability. not mow it. Watch for traffic when operating near or crossing DO NOT park on slopes unless necessary.
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If fuel is spilled on clothing, change clothing immediately. NEVER attempt to make any adjustments to unit while engine is running (except where specifically Avoid Electric Shock. Objects contacting both battery recommended). Stop engine, remove key or spark plug terminals at the same time may result in injury and unit wires and wait for all moving parts to stop before damage.
SECTION 3 - SPECIFICATIONS Model Number 990100 990102 Model Rapid XZ Rapid XZ Engine Kohler Kohler Engine Model Number CH740S CH750S Engine Power – hp (kW) at Maximum RPM 27 (20.1) 30 (22.3) Governed RPM (May be different from maximum RPM) 3750 ±50 3750 ±50 Cooling...
SECTION 5 - MAINTENANCE Proper maintenance can prolong the life of the unit. The WARNING: Personal injury can occur if following chart shows the recommended service safety precautions are not followed before schedule. and after servicing. The intervals listed in this chart are for average operating •...
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Interval Task Action Every 50 Lubricate Rear Axle and Pivot Points Apply grease to rear axle grease zerk. See “Lubricating Unit” Hours on page 13. Grease drive shaft spline, drive shaft (zerk), and U- joint (zerk) Oil all pivot points and pin connections. Every 100 Clean Battery Keep battery and battery terminals clean.
5.2 LUBRICATING UNIT 5.4 CHECKING MOWER GEARBOX OIL Check the mower gearbox oil level once a year or every 200 hours of operation. Check the level by parking the unit on a flat, level surface. Remove the oil plug on the side of the gearbox (accessible through the service hole underneath the deck).
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Installation.” on page 14). jelly. Jump-Starting 4. Close hood (see “Service Position” on page 3). Gravely does not recommend jump-starting the engine. Cleaning the Battery Jump-starting can damage engine and electrical system See Figure 8. components. See Engine Manual for more detailed information.
SECTION 6 - ADJUSTMENTS 6.1 ADJUSTING UNIT TO TRACK STRAIGHT 2. Place unit in the service position (see “Service Position” on page 3). WARNING: Before adjusting tracking, 3. Loosen the three nuts holding the right steering lever shut off engine, engage parking brake, flange bushing to the unit frame.
3. Start the engine and release the parking brake. levers to neutral, the pump(s) need to be adjusted. Take the unit to your Gravely Dealer for service or repair. 4. Move the steering levers back and forth (from forward to reverse) several times to make sure 6.3 STEERING LEVER HEIGHT...
Adjusting the Parking Brake 6.5 PARKING BRAKE INTERLOCK ADJUSTMENT WARNING: ALWAYS block wheels. Be sure The parking brake interlock needs adjustment: all jack stands are strong and secure and will hold weight of unit during maintenance. • When engaging the parking brake does not lock the steering levers in neutral, NOTE: Steering levers must be in neutral to engage the •...
NOTE: Gravely dealers should be able to test engines The troubleshooting guide is generic and can be used for and engine components to pinpoint troubles and narrow several types of engines. Use only those possible causes and corrective actions that apply to the engine supplied.
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ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION Engine Cranks But Does Defective fuel pump Replace fuel pump (refer to Engine Manual) Not Start (cont.) Faulty engine Repair or replace engine (refer to Engine Manual) Engine Does Not Crank PTO engaged Disengage PTO Parking brake disengaged Engage parking brake Loose or corroded battery cables...
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ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION Knocking Incorrect grade of fuel Use fuel recommended in manufacturer’s manual Overheating Allow to cool; determine cause Sticking valves Repair per instructions in manufacturer’s manual Worn cylinder bores Repair per instructions in manufacturer’s manual Broken, worn, or sticking piston rings Repair per instructions in manufacturer’s manual Incorrect piston height...
ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION Starts and Stops Restriction in air cleaner Remove obstruction Fuel tank empty Fill tank Choked fuel filter Remove obstruction Bad spark plugs Replace spark plugs; see manufacturer’s manual for recommendations Vibration Poor compression Repair per instructions in manufacturer’s manual Sticking throttle/restricted movement Lubricate or replace Leaking cylinder head gasket...
7.3 CHANGING OIL FILTER 2. Apply oil and reinstall over the paper air filter element. Replace the oil filter (Figure 16) at least every other oil 3. Wipe out the air cleaner cover to remove any dirt change (every 200 hours of operation). See Engine build up in the cover.
Figure 45 for instructions. 4. Install the exhaust system. Connect to exhaust port on engine. d. Remove the throttle and the choke from the 5. If necessary, install the fuel tank. See "Fuel Tank" on engine. page 52 and Figure 46 for instructions. e.
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NOTE: For fuel tank, see Figure 46. NOTE: For transmission belt, see Figure 45. 1. Belt Tension Spring 2. Eye Bolt 3. Idler Sheaves 4. Engine 5. Cooling Shroud 6. Wing Nut (typical of 2) 7. Shroud Bracket 8. Engine Bolt (typical of 4) 9.
SECTION 8 - ATTACHMENTS c. Release lock collar. WARNING: MOVING PARTS can cut or 3. If necessary, start the engine and use the lift arm up/ amputate body parts. ALWAYS wait for down switch (Figure 18) to align the lift arms with the moving parts to stop before performing attachment’s mounting arms.
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NOTE: The lift pin is stored on the lift cylinder in the stor- IMPORTANT: Make sure the rear lock latches engage age hole under the seat. the attachment. 6. Properly connect all other lift and control linkages 8. Turn off the engine and set the parking brake. following directions in the attachment’s owner/ 9.
8.2 RAISING ATTACHMENT INTO SERVICE POSITION Service NOTE: Raising the mower deck attachment is shown in Position the illustrations in this section. Other attachments are similar. CAUTION: AVOID INJURY! Stand to side of unit when pivoting an attachment into the service position.
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Remove the lift lock pin from the deck lift arm and store it under the seat. Figure 25 To install the deck lift lock pin: 1. Raise the deck to its highest position. 2. Insert the pin into the holes in the deck lift arm Figure 27 bracket so the pin slides under the carrier frame.
8.3 PTO BELT REPLACEMENT Remove PTO Belt See Figure 28. WARNING: MOVING PARTS can cut or 1. Shut off engine. Engage parking brake. Remove the amputate body parts. ALWAYS wait for ignition key. moving parts to stop before performing 2. Place unit in the service position (see “Service maintenance or service.
8.4 MOWER ATTACHMENT Mower Deck Troubleshooting PROBLEM PROBABLE CAUSE CORRECTION Uneven unit tire pressure. Inflate tires to correct pressure. Mower not level. Level mower deck. See "Adjust Mower Deck Level and Pitch" on page 32 Damaged gauge wheel or axle. Repair or replace damaged components.
Cutting blades. Height • NEVER weld or straighten mower blades. Highest Gravely recommends that a professional sharpen mower Cutting blades. Height Discard mower blade if (Figure 30): • More than 1/2 in. (1.27 cm) of metal is removed.
Remove Mower Drive Belt Install Mower Blade Belt 1. Set the deck to its lowest cutting height. See Figure 33. 2. Stop engine, wait for all moving parts to stop and hot 1. Route the new belt around the spindle pulleys and parts to cool, set the parking brake and remove the idler.
Distances should be within 3/16 in. (4.7 mm). If they 11. Pitching the front of the blades lower than the rear are not, raise the low side of the deck using the provides a balance between cut quality and the power needed to cut grass.
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Height Adjusters Loosen jam nuts on the lift bracket bolts. DO NOT place blocks under reinforcement bar. Figure 36 8 - 34...
SECTION 9 - LIFT SYSTEM 9.1 PRINCIPLES OF OPERATION 5. Remove bolt and nut and disconnect cylinder rod end from lift arm assembly. The attachment lift system consists of the following major 6. Remove attachment (see "Attachment Installation" components: on page 25). •...
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1. Frame 2. 90° Hydraulic Fitting 3. Attachment (Deck) Lift Cylinder 4. Jam Nut 5. Rod End 6. Bushing 7. Retaining Ring 8. Flange Bushing 9. Spacer 10. Bolt w/Lock and Flat Washers 11. Left Lift Latch 12. Lift Arm 13.
9.3 REPLACE LIFT ARM 4. Install attachment. See “Attachment Installation” on page 25. Replace any worn parts with new ones. See Figure 38. 9.4 REPLACE PIVOT SHAFT Remove Lift Arm 1. Remove bolt and nut from end of hydraulic cylinder See Figure 38.
SECTION 10 - WEIGHT TRANSFER SYSTEM 10.1 PRINCIPLES OF OPERATION The unit is designed to operate with the weight transfer system turned on to prevent damage to the lift arms and The function of the weight transfer system is to transfer the frame.
6. Using weight transfer UP/DOWN switch, extend and retract cylinder several times to assure proper operation. 7. Install attachment. 8. Turn weight transfer switch ON for operation. 10.4 REPLACE LIFT ARM See "Replace Lift Arm" on page 40 for instructions. 10.5 REPLACE PIVOT SHAFT See "Replace Pivot Shaft"...
SECTION 11 - HYDRAULIC SYSTEM 11.1 BASIC HYDRAULICS Mobile 1 Extended Performance 15W50 Synthetic Oil (Gravely p/n 00057100) has been selected for use by the The basic goal of any hydraulic system is transmitting factory. force and/or motion using a confined liquid. The liquid Fluid volume for the system is 6.5 quarts (6.2 liters).
(1.4 liters). Use Mobil 1 Extended valve block. Performance 15W50 Synthetic Oil or equivalent for 7. Drain oil remaining in valve block into a suitable best component life (Gravely p/n 00057100). container. NOTE: The entire system takes 6.5 quarts (6.2 liters) of Install Valve Block oil, but only about 1.5 quarts (1.4 liters) gets replaced...
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Weight Deck Lift Transfer Cylinder Cylinder B2 Port A1 Port A2 Port B1 Port B1 Port A2 Port P Port Valve Block T Port Aux Pump Bottom T Port Aux Output Top P Port A Port B Port A Port B Port A Port B Port...
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1. Hydraulic Reservoir and Filter 2. Deck Lift Hydraulic Cylinder 3. Right Drive Motor 4. Left Drive Motor 5. Left Pump 6. Right Pump 7. Weight Transfer Cylinder 8. Valve Block PD0370 PD3690 Figure 44 11 - 44...
SECTION 12 - TRANSMISSION provide straight tracking. The distance a lever is pushed WARNING: HYDRAULIC FLUID can result forward or pulled back controls volume of oil provided to in severe burns. Fluid in hydraulic system the pump, which in turn controls the speed of the wheel can penetrate skin and result in serious connected to it.
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TRANSMISSION TROUBLESHOOTING Problem Possible Cause Corrective Action Does not drive/track Steering handles out of adjustment Adjust steering handles (see “Adjusting Unit to straight Track Straight." on page 15 for adjustment procedure) Vehicle tires improperly inflated Inflate tires to proper pressure (see “Specifications“on page 9 for recommended tire pressures) Control linkage bent or out of adjustment...
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TRANSMISSION TROUBLESHOOTING Problem Possible Cause Corrective Action Erratic Running Control linkage bent or out of adjustment Adjust, repair or replace linkage Hydraulic oil level low Fill to proper level (see "Checking Hydraulic Oil Level" on page 41) Contaminated hydraulic oil Change oil (see "Changing Hydraulic Oil and Filter"...
12.3 TRANSMISSION BELT REPLACEMENT 5. Remove transmission belt from flywheel pulley, idler and two hydrostatic pump pulleys. See Figure 45. Install Transmission Belts Remove Transmission Belts 1. Install the new transmission belt on two hydrostatic 1. Shut off engine. Engage parking brake. Remove the pump pulleys, crankshaft pulley and idler as shown in ignition key.
12.4 HYDROSTATIC PUMP REPLACEMENT 9. Block or secure pump to prevent it from dropping when bolts are removed. (Pump weighs about 15 The hydrostatic pumps provide power to the unit’s drive pounds.) wheel motors. 10. Unbolt pump from frame. Remove pump. NOTE: The following procedures apply to replacing the Install Pump left pump.
SECTION 13 - FUEL SYSTEM 13.1 FUEL SYSTEM TROUBLESHOOTING The possible causes are generic and can be used for several types of fuel systems. Use only those possible The following troubleshooting chart is to be used to causes and corrective actions that apply to the unit. isolate fuel system problems and give possible causes are corrective action responses FUEL SYSTEM TROUBLESHOOTING...
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FUEL SYSTEM TROUBLESHOOTING Problem Possible Cause Corrective Action Will Not Accelerate Plugged air filter Clean or replace air filter Air bleed restricted Remove obstruction Plugged tank or vent Remove obstruction Fuel pickup restricted Remove obstruction Damaged adjustment needle and seat Replace needle and seat Incorrect float height Adjust float...
13.4 FUEL SYSTEM CONTAMINATION WARNING: GASOLINE is extremely Any time fuel contamination is found in the fuel system flammable and its vapors can explode if (dirt, water algae, etc.) replace the fuel, fuel filter and ignited. flush the fuel lines. Remove the carburetor bowl and •...
13.7 FUEL TANK REPLACEMENT See Figure 47. Remove Fuel Tank 1. Shut off engine. Engage parking brake. Remove the ignition key. 2. Place unit in the service position (see “Service Position” on page 3). WARNING: FUEL VAPORS are explosive and flammable. Store fuel in proper containers.
SECTION 14 - ELECTRICAL SYSTEM 14.1 ELECTRICAL SYSTEM REPAIRS 14.3 ELECTRICAL MEASUREMENTS Gravely recommends that all work be done in a In many electrical circuits, some visible effect indicates professional manner. Using tubing to cover joints and that the circuit is functioning properly. A switch is turned soldering connections contribute to a professional “ON”...
Current Measurement Normally Open Switch The two rules to remember when measuring current with Examples of a normally open switch include, without an ammeter are (1) an ammeter measures the current limitation, a key, headlight, safety, or seat switch. To test that flows through the meter, and (2) an ammeter must a normally open switch, connect an ohmmeter across the be connected into the circuit to measure current.
The starter solenoid in Gravely equipment is a sealed unit used to actuate the starter motor on the engines. These solenoids may have three or four connections.
the starter motor. The small connections are connected Electrical testing of these devices is simple. The device to the coil and carry the control current. either conducts current (functioning) or the device is open (defective). Use an ohmmeter to check for To check the solenoid, disconnect the cables to the continuity.
If the unit does not perform a result, current flows through the coil. This magnetizes as stated contact your Gravely dealer for repairs. the coil and pulls the armature onto the rotor with sufficient force to hold the two pieces together, effectively connecting the output and the input shafts.
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position. If there is no battery voltage to terminal B, check should have a coil resistance of 3.28-4.08 ohms. If the battery connection and the fuse in the red lead. the coil is bad the resistance will be higher or lower. 2.
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Seat Switch Start Red/Yellow Connected to Ground through Start Relay Purple 11.50-13.00 Volts 11.50-13.00 Volts Normally open contacts manually activated. contact resistance is 0.1-0.3 ohms when correct. PTO Switch Start Brown 11.50-13.00 Volts Purple 11.50-13.00 Volts 11.50-13.00 Volts Red/Green 11.50-13.00 Volts 11.50-13.00 Volts Brown/Yellow 11.50-13.00 Volts...
Accessories Part No. Description 79205200 24 x 12-12 BAR Style Wheel Kit 79208500 Headlight Kit 89010000 Rapid XZ 60" Side Discharge Deck 89202800 Foldable ROPS Kit Service Parts Part No. Description 01554800 Battery 21539600 Air Filter Inner Element 21537000 Air Filter Outer Element 21539500 Fuel Filter 21397200...
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GRAVELY 655 West Ryan Street P.O. Box 157 Brillion, WI 54110-0157 920-756-2141 Fax 920-756-2407 www.gravely.com WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.