Gravely Promaster 260Z Service Manual
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Gravely Promaster 260Z Service Manual

Gravely Promaster 260Z Service Manual

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See also: Owner's/operator's Manual
Promaster 260Z, 272Z

Service Manual

992036, 037, 038, 039, 309
992073, 074, 075, 076, 318, 319
8/04
Printed in USA

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Table of Contents

Troubleshooting

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Questions and answers

Greg Dayton
April 21, 2025

Ingine turns over but does not start after all safety procedures are followed

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1 comments:
Mr. Anderson
May 11, 2025

If the Gravely Promaster 260Z engine turns over but does not start after following all safety procedures, possible causes include:

1. PTO not disengaged – The engine will not start if the PTO is engaged.
2. Parking brake not engaged – The engine requires the parking brake to be set before starting.
3. Seat interlock issue – If the operator is not seated or the seat switch is faulty, the engine may not start or may shut off.
4. Hood raised (for models 992318 and 319) – The engine will not start or run with the hood raised.
5. Faulty safety interlock system – The system must function correctly; failure can prevent engine start.

Testing the interlock system and checking for proper operation is recommended if these conditions are met and the engine still does not start.

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Summary of Contents for Gravely Promaster 260Z

  • Page 1: Service Manual

    Promaster 260Z, 272Z Service Manual 992036, 037, 038, 039, 309 992073, 074, 075, 076, 318, 319 8/04 Printed in USA...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Introduction ......5 Cooling System......28 The Manual .
  • Page 3 Tyyppi: – Typ: – Tipo: rotacyjna kosiarka trawnikowa – Tractor Cortador de Relva – Trade Name: – Appellation commerciale : – Handelsbezeichnung: – Handelsnaam: – Firmanavn: Nome Gravely commerciale: – Nombre comercial: – Handelsnavn: – Handelsbeteckning: – Kauppanimi: Nazwa handlowa: – Nome da Marca: Model: –...
  • Page 4 Notified Body – Organisme notifié – Zertifizierungsstelle – SNCH Aangemelde instantie – Bemyndiget organ – Organismo notificato – 11, Route de Luxembourg Organismo notificado – Teknisk kontrollorgan – Anmält organ – L-5230 Sandweiler Ilmoitettu laitos – Organ zaświadczający – Organismo – Certificador Philip J.

  • Page 5: Introduction

    PREPARATION PRODUCT REGISTRATION Before starting any removal of parts, proper The Gravely dealer must register the product at the preparation is very important for efficient work. A clean time of purchase. Registering the product will help the work area at the start of each job will allow you to company process warranty claims or contact you with perform service repairs easily and quickly.

  • Page 6: Safety

    SAFETY NOTATIONS WARNING: This cutting machine is capable of NOTE: General reference information for proper opera- amputating hands and feet and throwing tion and maintenance practices. objects. Failure to observe the safety IMPORTANT: Specific procedures or information instructions in the manuals and on decals could required to prevent damage to unit or attachment.
  • Page 7 • 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.

  • Page 8: Safety Rules

    DANGER / PELIGRO • Avoid injury - Stay clear of rotating parts. DANGER / PELIGRO • Risque de blessures - ne pas s’approcher des pièces en mouvement. • Evitar lesiones - Mantenerse alejado de las piezas giratorias. WARNING/AVERTISSEMENT/ADVERTENCIA Do not operate mower Ne jamais utiliser No operar segadora a unless guards are in...
  • Page 9 Local regulations may restrict the age of the operator. Start and operate unit only when seated in operator’s position. Steering control levers must be in neutral, NEVER allow children to operate or play on or near PTO disengaged and parking brake set when starting unit.
  • Page 10 DO NOT operate on slopes of more than 17 degrees. Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers Use of a Rollover Protection System (ROPS) is on the ground away from your vehicle before filling. recommended for slope operation.
  • Page 11 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. For models 992318 and 319, engine must not start or run with hood raised.

  • Page 12: Specifications

    SPECIFICATIONS Model Number 992036 992037 992038 992039 992309 Model 260Z 27 HP 272Z 27 HP 272Z 31 HP 260Z 31 HP 260Z 31 HP Kawasaki Kawasaki Daihatsu Daihatsu Daihatsu 60 Inch Deck 72 Inch Deck 60 Inch Deck 72 Inch Deck 60 Inch Deck Engine Engine Manufacturer...
  • Page 13 u be 99 0 3 99 0 99 0 5 99 0 6 99 3 8 99 3 9 Model 260Z 27 HP 272Z 27 HP 260Z 27 HP 272Z 31 HP 260Z 27 HP 260Z 31 HP Kawasaki Kawasaki Daihatsu Daihatsu Daihatsu...

  • Page 14: Controls And Features

    CONTROLS AND FEATURES 24, 25 13, 17 12 OF 3223 1. Hood 16.Foot Board Latch 2. Fuel Tanks 17.Cylinder Stop Storage Post 3. Eye-Q™ 18.Headlights 4. Steering Levers 19.PTO (Power Take-Off) Switch 5. Mower Lift Lever 20.Ignition Switch 6. Seat Adjustment Lever 21.Oil Pressure Light 7.

  • Page 15: General Maintenance & Adjustments

    GENERAL MAINTENANCE & ADJUSTMENTS 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 WARNING: AVOID INJURY. Read and temperatures, dusty conditions, or airborne debris).

  • Page 16: Service And Adjustments

    See Hydraulic Oil System on page 25. Filter Hours 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.

  • Page 17: Transporting Unit

    1. Place hood in the full service position (see Service 2. Set parking brake. Positions on page 16). 3. Turn ignition key to Off (1) position. 2. Turn right and left bypass valve levers counter Diesel Models (992038, 039, 309, 992075, 076, clockwise 1/2 turn (Figure 5).

  • Page 18: Cleaning And Storage

    CLEANING AND STORAGE FILLING FUEL TANK WARNING: AVOID SHARP EDGES which EXPLOSIVE VAPORS and FLAMMABLE can cut. Movement of parts can cut off fingers FUEL can result in serious injury or death. or a hand. Wrap blades, wear gloves, and use Handle fuel with care.

  • Page 19: General Lubrication

    GENERAL LUBRICATION NOTE: Unit comes equipped with a maintenance-free battery that requires no regular maintenance except IMPORTANT: Wipe each fitting clean before and after cleaning the terminals. lubrication. Battery Removal and Installation Lube fitting locations are: front axle pivot (1) (Figure 8) Apply Sten Mix Hi-Temp Grease or equivalent to the Remove lube fittings.

  • Page 20: Basic Engine Maintenance

    Charging the Battery 2. Each day before operating, check the air cleaner element. Dirt can decrease the flow of air to the WARNING: FROZEN BATTERIES CAN engine. EXPLODE and result in death or serious 3. Each day before operating, check the air cooling injury.

  • Page 21: Pto Belt Removal

    PTO BELT REMOVAL 4. Place 1/2-inch driver and ratchet extension into square hole in PTO belt idler (Figure 10). Removal (Figures 10, 11 and 12) 5. While pulling PTO belt idler towards rear of unit, remove PTO mower belt from PTO belt idler. 6.

  • Page 22: Tires

    2. Place a 1/2-inch ratchet driver into square hole in Removal (Figure 14) idler pulley. CAUTION: Mower blades are sharp and can cut you. Wrap mower blades or wear gloves, and use extra caution when servicing. 1. Block mower blades to prevent rotation. 1.

  • Page 23: Steering Control Neutral Adjustment

    STEERING CONTROL NEUTRAL DO NOT Sharpen To This Pattern ADJUSTMENT Sharpen To This Pattern DISCARD if more than 1/2 in. (1.27 cm) OF 3310 1. Air Lift Erosion Area 2. Cutting Edge Figure 15 2. Sharpen mower blade by removing an equal amount of material from each end of mower blade.

  • Page 24: Adjusting Unit To Track Straight

    Eliminating Excessive Creeping of Unit recommended tire pressure. See Specifications on (Figure 16) page 12 for correct tire pressure. If tire pressure adjustment does not solve tracking WARNING: This adjustment requires problem, adjust limiter bolts on stop bracket (Figure operating engine and opening the hood (on 17).

  • Page 25: Parking Brake Adjustment

    PARKING BRAKE ADJUSTMENT MOWER DECK REMOVAL DANGER: MOVING PARTS can cut or 1/16 to 1/8 in. 1-1/2 in. amputate body parts. ALWAYS wait for (1.5 to 3.1 mm) (3.81 cm) moving parts to stop before performing maintenance or service. Removal (Figure 20) NOTE: Only remove PTO belt from electric clutch.
  • Page 26 LEVELING THE MOWER DECK These adjustments should be made on a level surface with the tires inflated to the correct air pressure. Level the mower with the slots where the four chains fasten to the mower mounting brackets (Figure 21). 1.

  • Page 27: Engine

    ENGINE ENGINE TROUBLESHOOTING The following troubleshooting chart is to be used to The troubleshooting key is generic and can be used for isolate engine problems and give possible causes and several types of engines. Use only those possible corrective action responses. causes and corrective actions that apply to the unit.

  • Page 28: Removing The Engine

    Radiator Fan Belt Removal bracket. Refer to Engine Manual for detailed instructions or see 9. Install transmission belt (see Transmission Belt your Gravely dealer for replacement. Removal on page 21). NOTE: Refer to Engine Manual for the correct type of Checking Coolant Level coolant.
  • Page 29 OF 3306 1. Radiator Cap 4. Radiator 2. Drain Plug 5. Radiator Filler Neck OF 3307 3. Coolant Reservoir 6. Bottom of Filler 1. Radiator cap 4. Coolant Reservoir Figure 24 2. Radiator 5. Radiator Filler Neck 7. Place suitable container under drain plug. 3.

  • Page 30: Drive Train

    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.

  • Page 31: Hydraulic Drive Flow Test

    HYDRAULIC DRIVE FLOW TEST REPLACING THE HYDRAULIC PUMP Use this procedure for trouble shooting the drive The two hydraulic pumps are located inside the chassis system if the unit becomes sluggish or loss of drive in front of the engine. The pumps are maintenance free becomes apparent.

  • Page 32: Replace Wheel Motor

    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. OK 0630 Figure 28 PD2231 HYDRAULIC DECK LIFT PRESSURE TEST 1.
  • Page 33 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. Lift Valve Figure 29...

  • Page 34: Hydraulic Diagram

    HYDRAULIC DIAGRAM Models 992073, 074, 075, 076, 318, 319 PD0630...
  • Page 35 Models 992036, 037, 039, 309 Lift Cylinder Lift Valve Deck Lower Return Inlet Deck Lift Left Pump Right Forward Pump High Pressure Right Left Wheel Forward Wheel Upper Upper Motor High Motor Reverse Pressure High Pressure Reverse High Pressure Lower Lower Filter PRESSURE...

  • Page 36: Mower Deck

    MOWER DECK Mower Spindles This unit utilizes a maintenance free extended life spindle. No routine maintenance is required. In the Highest Roller event of bearing failure or a bent shaft the spindle Position should be replaced. Lowest Roller To Remove the Spindle Position 1.

  • Page 37: Front Suspension

    FRONT SUSPENSION SUSPENSION The front suspension consists of a weldment that is a square tube (Figure 31). 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.

  • Page 38: Electrical

    They provide excellent service for the colors). money as long as they are used with care. Gravely Company recommends that all work be done in a professional manner. The use of the tubing to cover Digital Meters joints and the soldering of connections contribute to a Digital Meters do not have a movement and are there- professional looking job.

  • Page 39: Switches

    Voltage Measurement switches on speed selector and clutch levers may be out of adjustment and not activating.) There are two basic rules to be remembered when using a voltmeter. A voltmeter measures the voltage IMPORTANT: When checking switches, remove them difference between the test leads and the voltmeter is from their respective circuit by disconnecting the wires always connected across the circuit under test.

  • Page 40: Solenoid And Relays

    SOLENOID AND RELAYS If the voltage is correct, turn off the power and check continuity of the coil with an ohmmeter. If the coil is Solenoid and relays are both magnetically operated open, the solenoid is defective and must be replaced. devices.
  • Page 41 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.

  • Page 42: Wiring Diagrams

    WIRING DIAGRAMS Models 992036, 037 HEADLIGHTS AUXILIARY TEMPERATURE POWER START BLACK GAUGE OUTLET RELAY PRESSURE LIGHT FUSE LIGHT SWITCH 7.5A BLACK BLACK SEAT SWITCH PURPLE SWITCH HOUR CLUTCH METER PURPLE/ WHITE CHARGE BLACK LAMP ENGINE YELLOW / RED START RELAY BLACK FUEL STARTER...
  • Page 43 Model 992038, 039, 309 WATER HEADLIGHTS TEMP WATER PRESSURE OIL PRESSURE AUXULIARY HOUR METER GAUGE TEMP LIGHT SWITCH POWER (ENGINE) SENDER SUPPLY (ENGINE) ORANGE BLACK BLACK BLUE / WHITE BLACK BLACK BLACK FUSE BLACK 7.5A PURPLE LIGHT SWITCH PINK SEAT / PTO PREHEAT RELAY TIMER...
  • Page 44 Model 992073, 074...
  • Page 45 Models 992075, 076, 318, 319...

  • Page 46: Troubleshooting

    4. Discharged battery. 4. Charge battery (see Charging the Battery on page 20). 5. Faulty starter. 5. See your Gravely Dealer. Engine cranks but does not start. 1. Fuel tank empty. 1. Fill fuel tank (see Filling Fuel Tank on page 18).
  • Page 47 PTO switch. electrical system to the clutch for damage or wear. 4. Faulty PTO switch. 4. See your Gravely Dealer. Unit does not drive. 1. Parking brake engaged. 1. Disengage parking brake. 2. Transmission bypass levers 2.

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Promaster 272z

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