Related Manuals for Gravely Pro 100
Summary of Contents for Gravely Pro 100
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Page 1: Service Manual
Pro 100/150/200 Service Manual Models 988001-007, 059, 060, 062, 063, 069-072, 074, 075, 077-082, 085, 087, 088, 309 08484000 06/00 Printed in USA... -
Page 2: Table Of Contents
TABLE OF CONTENTS Section 1 - Introduction ....1-3 Section 6 - Steering And Controls ..6-20 1.1 The Manual. -
Page 3: Section 1 - Introduction
Operation and may void the warranty. Gravely disclaims liability for any claims or damages, whether warranty, property Before operation of the unit, carefully and completely damage, personal injury, or death arising out of the use read manuals supplied with the unit. -
Page 4: Section 2 - Safety
SECTION 2 - SAFETY 2.1 SAFETY ALERTS 2.6 PREPARATION Look for these symbols to point out Before starting any removal of parts, proper important safety precautions. They preparation is very important for efficient work. A clean mean: work area at the start of each job will allow you to perform service repairs easily and quickly. - Page 5 Keep area of operation clear of all toys, pets, and and engine. Remove key and wait for all moving parts debris. Objects can cause vehicle instability and injury. to stop. Remove wire from spark plug. Inspect unit and make any necessary repairs before restart. Check for weak spots on dock, ramps or floors.
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Page 6: Clean Unit
If leak ALWAYS clean unit before extended storage. See occurs, have it repaired by your Gravely Dealer. Engine Manual for proper storage. Spark Arrester This product is equipped with an internal combustion engine. -
Page 7: Section 3 - Specifications
SECTION 3 - SPECIFICATIONS Model Type Pro 100 Pro 100 Pro 150 Model Number 988001 988002 988059 Manufacture Briggs & Stratton Kawasaki Kawasaki Horsepower 12 HP 12.5 HP 14 HP Engine Spec. No. 281702-902512 FB 460V AS20 FC 420V-ES 15... - Page 8 Model Type Pro 150 Pro 150 Pro 150 Model Number 988074 988075 988077 Manufacture Kohler Kawasaki Kawasaki Horsepower 12.5 HP 12.5 HP 14 HP Engine Spec. No. PS-1283 FB 460V-DS20 GS01 FC 420V-ES 15 Fuel Unleaded Unleaded Unleaded Fuel Tank Cap. 4.5 gal.
- Page 9 Model Type Pro 150 Pro 150 Pro 200 Model Number 988091 988309 988003 Manufacture Kawasaki Kawasaki Kawasaki Horsepower 12.5 HP 10.9 HP 12.5 HP Engine Spec. No. FB 460V DS20 GS01 FC 420V ES15 FB 460V AS20 Fuel Unleaded Unleaded Unleaded Fuel Tank Cap.
- Page 10 Model Type Pro 200 Pro 200 Pro 200 Model Number 988007 988062 988063 Manufacture Kohler Kawasaki Briggs & Stratton Horsepower 18 HP 14 HP 16 HP Engine Spec. No. PS - 58516 FC 420V AS15 303777 - 0138 Fuel Unleaded Unleaded Unleaded Fuel Tank Cap.
- Page 11 Model Type Pro 200 Pro 200 Pro 200 Model Number 988081 988082 988085 Manufacture Briggs & Stratton Kohler Robin Horsepower 16 HP 18 HP 18 HP Engine Spec. No. 303777-0138 CV 18S PS-61527 EH 63 V Fuel Unleaded Unleaded Unleaded Fuel Tank Cap.
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Page 12: Section 4 - General Maintenance & Adjustments
1. Shift Lever 2. Steering Lever Latch 3. Steering Lever 4. Throttle-Choke Lever 5. Ignition Switch 6. PTO Lever 7. Operator Presence Controls Figure 2 - Pro 100 Pro 150 OG1131 OG0741 1. Shift Lever 6. PTO Lever 2. Steering Lever Latches 7. - Page 13 Pro 200 1. Shift Lever 8. Transmission Shifter Rod 2. Steering Lever Latch 9. PTO Switch (electric start models) 3. Steering Lever 10. Hour Meter (electric start models) 4. Throttle-Choke Lever 11. Choke Control (electric start models) 5. Ignition Switch 6.
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Page 14: General Lubrication
6. Clutch Actuating Strap 12. Wheel Clutch Arm 4. Wheel Clutch Arm 8. Traction Belt (Pro 200 7. Traction Belt Weldment Weldment shown - Pro 100 has 5. Brake Rod one belt) Figure 6 - Pro 200 9. Drive Wheel Figure 5 OG0751... -
Page 15: Adjusting The Levers
4 above. WARNING: Improper adjustment of steering levers can cause a loss of steering control. 1. Transmission 3. Shift Plate (Pro 150 Shifting Lever only) 2. Shift Arm 4. Transmission Figure 7 - Pro 100 and Pro 150 4 - 15... -
Page 16: Adjusting The Pto Clutch
Pro 200 3. Loosen the jam nut at the ball joint on the gear shift lever. To adjust the shift lever linkage, it may be necessary to adjust two different rods: (1) the transmission shifter 4. Rotate the clutch actuating rod until the clutch arm rod and (2) the clutch actuating rod. -
Page 17: Adjusting The Roller Chain
5. Mower Belt 6. Mower Clutch Sheave 1. Jam Nuts 5. Mower Belt 2. Spring 6. Mower Clutch Sheave Figure 10 - Pro 100 3. PTO Clutch Activating 7. Clutch Arm 8. Clutch Rod 4. PTO Clutch Actuating 9. PTO Idler Pulley 10.PTO Clutch Belt... -
Page 18: Section 5 - Engine
SECTION 5 - ENGINE 5.1 ENGINE TROUBLESHOOTING The troubleshooting key is generic and can be used for several types of engines. Use only those possible The following troubleshooting chart is to be used to causes and corrective actions that apply to the isolate engine problems and give possible causes and unit. -
Page 19: Checking Engine Oil
5.2 CHECKING ENGINE OIL Check the engine oil BEFORE EACH USE OR TWICE DAILY ON COMMERCIAL USE. 5.3 CHANGING OIL FILTER Some engines are equipped with an oil filter. Replace the oil filter every other oil change, in accordance with the Oil Change Intervals. -
Page 20: Section 6 - Steering And Controls
SECTION 6 - STEERING AND CONTROLS 6.1 STEERING CONTROLS 6.2 OPERATOR PRESENCE CONTROL The right and left hand controls should be checked The presence control linkage opens a switch when the each time the unit is used. Any parts or pivot points that hand grips are squeezed by the operator. -
Page 21: Section 7 - Drive Train
"OFF" position. Put the shift lever in neutral. 2. Loosen belt finger plate and remove mower belt from engine sheave (Figures 18 and 19). 1. Shift Arm 3. Transmission 2. Shift Plate (Pro 150 only) Figure 16 - Pro 100 and Pro 150 7 - 21... -
Page 22: Traction Clutch
2. Remove the mower belt from the mower clutch ing break-in. sheave, Figure 20. 8. Put the mower belt (and PTO belt on the Pro 100) 3. Remove the PTO clutch belt from clutch hub (recoil back on engine sheave. Tighten the belt finger model only). -
Page 23: Replacing The Traction Belts
Always compress or extend springs slowly. 6. Remove cotter pin and clevis pin holding the clutch rod to the clutch actuating straps (Pro 200), Wheel clutch arm weldment (Pro 100 and 150). See Figure 6. 7 - 23... -
Page 24: Replacing The Pto Clutch Belt
7.7 REPLACING THE PTO CLUTCH BELT of the ignition key-from the belt’s surface and tighten the bolt holding the belt guide. See Pro 100 And Pro 200 (All Models Except 988085) Figure 22 for the correct position of the belt guide. .06" Clearance .12"... -
Page 25: Electric Clutch
To remove wheels: 1. Jack unit to lift wheels off the ground. 2. Remove axle nut and washer. 3. Remove belts from pulleys. NOTE: The Pro 100 has one belt. 4. Loosen bolts from inside of brake drum. 7 - 25... -
Page 26: Section 8 - Fuel System
SECTION 8 - FUEL SYSTEM 8.1 FUEL SYSTEM TROUBLESHOOTING The troubleshooting key is generic and can be used for several types of transmissions. Use only those The following troubleshooting chart is to be used to possible causes and corrective actions that apply to the isolate fuel system problems and give possible causes unit. -
Page 27: Section 9 - 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 Digital Meters in a professional manner. The use of the tubing to cover joints and the soldering of connections contribute Digital Meters do not have a movement and are there- to a professional looking job. -
Page 28: Battery
Voltage Measurement WARNING: EXPLOSIVE GASES can result There are two basic rules to be remembered when in serious injury or death. ALWAYS keep open using a voltmeter. A voltmeter measures the voltage flames, sparks, or smoking materials away difference between the test leads and the voltmeter is from battery. - Page 29 Clean Battery 3. Remove caps and fill each cell to level indicated with electrolyte at 1.230 specific gravity and 80 Corrosion and dirt on the battery and terminals can cause the battery to "leak" power. 4. Let battery stand for one half hour. •...
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Page 30: Switches
IMPORTANT: Charging at higher rates will damage the 9. Operate unit as normal to charge battery. battery and cause excessive gassing and acid Storage spewing. The battery is a perishable item and it should be stored Battery Charger properly to obtain a long, useful life. Batteries not in Under normal conditions the engine alternator will keep use will self discharge. -
Page 31: Solenoid And Relays
G and M. These connections ground the engine magneto and stop the engine in the OFF position. The starter solenoid in the Gravely equipment is a sealed unit used to actuate the starter motor on the RUN Position - Should be continuity between contacts engines. -
Page 32: Lighting Circuits
RECTIFIER. A service information and parts available to properly diode is one type of rectifier. service the engine. Gravely dealers should be able to To check a diode, isolate if from the circuit by test engines and engine components to pinpoint disconnecting one end. -
Page 33: Interlock Switch
9.11 INTERLOCK SWITCH 1. Remove the subject interlock switch from the unit. 2. Set a VOM switch in the ohm (Rx1) position. 3. Connect the meter leads to the switch pins 4. No circuit (infinity) should be indicated. 5. Push in on the interlock switch plunger. A circuit (zero ohms) should be indicated. - Page 34 Pro 200 Walk-Behind Kohler Engine Ignition Switch Start Red (B) 12.00 12.00 12.00 Brown (S) 12.00 Pink (A) 12.00 12.00 Red/White (M) Connected to kill (magneto) circuit to ground Left and Right Presence Switch Start Brown 12.00 White (When activated) 12.00 to ground NOTES: NORMALLY OPEN SWITCHES.
- Page 35 Transmission Interlock Switch Start Brown 12.00 12.00 Brown/White 12.00 12.00 NOTES: NORMALLY CLOSED SWITCH. 0.1 TO 0.3 OHMS RESISTANCE WHEN CORRECT. PTO Interlock Switch Start Brown/White 12.00 12.00 Brown 12.00 12.00 NOTES: NORMALLY CLOSED SWITCH. 0.1 TO 0.3 OHMS RESISTANCE WHEN CORRECT. Briggs/Stratton Engine Make sure that all switches are in their proper position, power from the engine to the battery.
- Page 36 Left and Right Presence Switch Start Brown 12.00 12.00 White (When activated) 12.00 12.00 NOTES: NORMALLY OPEN SWITCHES. MANUALLY ACTIVATED. CONTACT RESISTANCE IS 0.1 - 0.3 OHMS RESISTANCE. Hourmeter Start Pink 12.00 12.00 White 12.00 to ground 12.00 to ground Solenoid Start Red (battery input lead)
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Page 37: Continuity Diagrams
9.14 CONTINUITY DIAGRAMS Recoil Start Models The diagrams below show the various states of connection for electrical components. The solid lines on switches show continuity. NOTE: All switches are viewed from the rear. Bale Switch Key Switch (09251900) (02456500) (button up) (button down) HAND HAND... -
Page 38: Key Switch
Electric Start Models The diagrams below show the various states of connection for electrical components. The solid lines on switches show continuity. NOTE: All switches are viewed from the rear. Relay Key Switch (03042800) (036023) START NOT ENERGIZED ENERGIZED Bale Switch PTO Switch (09251900) (01545600) - Page 39 Pro 100 and Pro 150 with Handlebar Switch The diagrams below show the various states of connection for electrical components. The solid lines on switches show continuity. NOTE: All switches are viewed from the rear. K e y S w i t c h...
- Page 40 Pro 100 and Pro 150 with Bale Switch The diagrams below show the various states of connection for electrical components. The solid lines on switches show continuity. NOTE: All switches are viewed from the rear. Bale Switch Key Switch (09251900)
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Page 41: Wiring Diagram
9.15 WIRING DIAGRAM Models 988089, 310 I N T E R L O C K M O D U L E RIGHT HANDLE BAR SWITCH W H I T E / B L A C K LEFT HANDLE BAR SWITCH Y E L L O W / R E D SWITCH ENGINE... - Page 42 Pro 200, Briggs & Stratton 16 HP 9 - 42...
- Page 43 Pro 200, Kohler Engine 9 - 43...
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Page 44: Electrical System
9.16 ELECTRICAL SYSTEM Model 988085, 087, 088, 091, 309 1. Key Switch Assembly 4. Neutral Start Switch 2. Single Pole N.O. with Cover 5. Neutral Start Switch (N.C.) 3. Electrical Interlock Module 9 - 44... - Page 45 All Models Except 988085, 087, 088, 091, 309 1. Switch 3. Interlock Module 2. Ignition Switch 4. Neutral Start Switch 9 - 45...
- Page 46 Gravely A division of Ariens Company 655 West Ryan Street P.O. Box 157 Brillion, WI 54110-0157 920-756-2141 Fax 920-756-2407 www.gravely.com...