Gravely Promaster 400 Service Manual
  1. Manuals
  2. Brands
  3. Gravely Manuals
  4. Lawn Mower
  5. Promaster 400
  6. Service manual
Gravely Promaster 400 Service Manual

Gravely Promaster 400 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Promaster 400 and is the answer not in the manual?

Questions and answers

Related Manuals for Gravely Promaster 400

Summary of Contents for Gravely Promaster 400

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Section 1 - Introduction ....1-3 Section 7 - Steering & Controls ... 7-37 1.1 The Manual.

  • Page 3: Section 1 - Introduction

    Operation 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: Safety Rules

    2.9 SAFETY RULES turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in. Walk Around Inspection If tires lose traction, turn off power take off and proceed Complete a walk around inspection of unit and work slowly straight down slope.
  • Page 6 ALWAYS keep hands and feet away from all moving Keep unit free of dirt, stones, and other debris. Clean parts during operation. Moving parts can cut off body up oil or fuel spills. parts. Storage DO NOT touch unit parts which might be hot from DO NOT store unit inside a building with fuel in the fuel operation.

  • Page 7: Clean Unit

    Use a cloth or brush to remove grass, chaff and debris. Unless there are indications of leakage, transaxle does not have to be checked for proper oil level. If leak occurs, have it repaired by your Gravely Dealer. 2 - 7...

  • Page 8: Section 3 - Specifications

    SECTION 3 - SPECIFICATIONS Model Number 989003, 989014 & 989049 989004, 989015, 989050 Description PM400 22HP PM400 30HP Diff Lock Engine - Manufacture Yanmar 3TNA72-NC Yanmar 3TN82E-NC - Cycles - Power 53.6 cu in (879 cc) 83.1 cu in (1362 cc) Battery 12 Volt, BCI Group 24F 12 Volt, BCI Group 24F...
  • Page 9 Model Number 989051 & 989300 989052 & 989301 Description PM400 31HP Diff Lock PM400 31HP Diff Lock & Four Wheel Drive Assist Engine - Manufacture Yanmar 3TNE82A Yanmar 3TNE82A - Cycles - Power 81.21 cu in (1330 cc) 81.21 cu in (1330 cc) Battery 12 Volt, BCI Group 24F 12 Volt, BCI Group 24F...
  • Page 10 Model Number 989057 989306 Description PM 460 PM 460 Engine - Manufacture Kubota Kubota - Cycles - Power 30 HP at 3000 RPM 30 HP at 3000 RPM Battery 12 Volt 12 Volt Brakes Drum 7" x 1.75" Drum 7" x 1.75" Steering Hydraulic Hydraulic...

  • Page 11: Section 4 - General Maintenance & Adjustments

    SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES RANGE 0 0 0 0 0 H O U 1/10 OF1961 1. Differential Lock Control 10. Light Switch (Optional) 2. Seat Adjustment Lever 11. Cruise Control Switch (optional) 3. Fuel Cap 12.

  • Page 12: Filling The Fuel Tank

    4.2 FILLING THE FUEL TANK WARNING: 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.

  • Page 13: Transmission Neutral

    2. Raise the seat plate. Wheel Alignment 3. Remove the check plug. Oil level should be at the Proper alignment of rear wheels is necessary to assure top of the check tube. proper steering and to reduce tire wear. Proper toe-in is when the front of the wheels are 1/16"...

  • Page 14: Adjust Direction Control Pedal

    4.6 ADJUST DIRECTION CONTROL PEDAL IMPORTANT: Correct adjustment of the direction control pedal is necessary to prevent severe damage to the hydrostatic transmission. 1. Pedal (Neutral Position) 2. Forward Stop Bolt Figure 7 OF1480 1. Direction Control 3. Direction Control Pedal Weldment 2.

  • Page 15: Brakes

    4.7 BRAKES After each use of unit, wash dirt from brakes with water. Each day before operation, inspect all parts and fasteners. Repair or replace any missing, worn or damaged brake or linkage parts. Tighten all nuts and bolts. Brake service is required if brakes do not stop and hold unit effectively.
  • Page 16 10 DEGREES BEFORE VERTICAL FOR ETREME OPERA TION VERTICAL FOR NORMAL OPERATION Figure 10 OF0840 1. Clutch Pac 4. Bushing 2. Bar Spring 5. Jam Nut 3. Clutch Trunnion 6. PTO Slide Rod Figure 11 OF0830 4 - 16...

  • Page 17: 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 18: Checking The Engine Oil

    5.2 CHECKING THE ENGINE OIL 5.4 ENGINE COOLING SYSTEM Check the engine oil level daily. Never operate the engine with oil level below the low mark on the dipstick. See your engine manual for oil specifications and oil filter service instructions. To check the oil level: 1.

  • Page 19: Engine Removal

    IMPORTANT: To prevent severe damage to engine, 5.5 ENGINE REMOVAL maintain proper coolant level. DANGER: Never remove radiator cap while engine is running hot. If you must remove radiator cap follow these steps to avoid personal injury that can be caused by escaping steam or engine coolant.

  • Page 20: Engine Installation

    10.Position a hoist over the engine and use a chain to hook to the engine installation brackets. See Figure 15. 11.Remove the engine mount bolts. 12.Use caution when lifting the engine out of the unit. Avoid contact with the radiator and solenoid. Make sure engine mounts do not catch hydraulic and fuel hoses during engine removal.

  • Page 21: Section 6 - Drive Train

    SECTION 6 - DRIVE TRAIN 6.1 HYDRAULIC SCHEMATIC Figure 16 6 - 21...

  • Page 22: Priming The Transmission

    6.2 PRIMING THE TRANSMISSION NOTE: Some oil may spill out of filter as it is rotated from vertical to horizontal position when installing it. IMPORTANT: The transmission must be primed after Keep container in place to catch spilled oil. changing the oil or oil filter to prevent internal 5.

  • Page 23: Transmission Troubleshooting

    2. Flywheel drive shaft installation: a. To remove PTO drive shaft, remove the four bolts connecting the drive shaft to the transmission a. Connect the flywheel adapter plate by installing and PTO gearbox. the eight bolts with loctite applied. 4. PTO drive shaft installation: b.

  • Page 24: Transmission Implement Pressure Check

    6.7 TRANSMISSION IMPLEMENT 6.8 SUNSTRAND TRANSMISSION PRESSURE CHECK REMOVAL NOTE: Make sure the hydraulic system is serviced 1. Disconnect and remove battery negative terminal properly prior to starting a pressure check. first, for access to the right side transmission mounting bolts and spacers. 1.

  • Page 25: Sunstrand Transmission Minor Repairs

    4. Loosen the PTO drive shaft at both ends, at front of 6.9 SUNSTRAND TRANSMISSION MINOR transmission. REPAIRS 5. Remove the front two screen bolts and carefully Charge Pump bend screen down far enough for access to the lower transmission mounting bolts and spacers. See Figure 21.

  • Page 26: Sunstrand Transmission Major Repair

    10.Place the O-ring into the housing assembly, then 6.10 SUNSTRAND TRANSMISSION slide the assembly into position over shaft. MAJOR REPAIR 11.Line up the location marks, then insert torque screws (5) and torque to spec. Replacement of Shaft and Trunnion Seals 1.
  • Page 27 9. Remove the two cap screws then remove the fixed swashplate from the counterbore in the housing. Visually inspect the wear surface for damage. 10.The pump shaft and motor shaft can be removed by pressing them out through the large cavity of the housing, Figure 29.
  • Page 28 27.Press the pump shaft (into the bearing already assembled in the housing. 28.Press the bearing into the housing. Then press the motor shaft into the bearing. 1. Bearing Figure 30 1. Pin 4. Control Shaft 16.Tilt the swashplate back to its full angle 2.

  • Page 29: Sunstrand Transmission Installation

    39.Insert the cap screws and torque to 25-30 ft-lbs (111-133 Nm). Check for proper internal assembly by slowly rotating the pump, motor and control shafts while tightening these screws. 40.Install charge pump. 6.11 SUNSTRAND TRANSMISSION INSTALLATION 1. Place a new O-ring seal on the transmission. Use a film of grease to hold the O-ring in place.

  • Page 30: Transaxle Troubleshooting

    6.12 TRANSAXLE TROUBLESHOOTING CAUSE REMEDY Unit Cannot Be Shifted (Or Difficult To Shift) Gears improperly installed Review positioning of gearing. Forks and rod assembly incorrectly installed Remove assembly. Recheck and correctly position parts. Axle Housing not installed or not tightened Seal retainers are not properly sealed.

  • Page 31: Transaxle Removal

    CAUSE REMEDY Shift lever bent and hitting unit frame Replace shift lever. Shift rod grooves worn Replace shift rods. Shift rod of improper length or grooving Check rod length. Replace with correct part. installed Constant mesh gears improperly installed on Reposition gears.

  • Page 32: Transaxle Repair

    4. Place a drain pan under the transaxle and remove the oil drain plug. After the transaxle is drained disconnect the hydraulic reservoir supply hose at the transaxle. 5. Jack the front of the unit up high enough to slide the transaxle out from under it and securely block unit.
  • Page 33 11.Install the back bendix plate with the four allen 11.Install the wheel assembly and tighten the lug bolts head bolts using loctite. to spec. 12.Install the key and hub. Place the belleville springs 12.Lower the unit and service with clean fresh oil. on axle, cups facing each other and install axle nut.
  • Page 34 a. Axle supports. 1. Check the roller bearings on the axles, remove any rust and clean. 2. Clean the axle supports and inspect. b. Case and cover. 1. Check for leaks or cracks. 2. Replace the oil seals. 3. Inspect and replace the needle bearings if needed.

  • Page 35: Transaxle Installation

    6.15 TRANSAXLE INSTALLATION 6.16 PTO GEARBOX REMOVAL 1. Use a jack and raise the transaxle into place. Install the four spacers and apply loctite to the four transaxle to frame mounting bolts and start them into the transaxle. 2. Apply loctite and start the four bolts into the transaxle at the transaxle plate.

  • Page 36: Pto Gearbox Repair

    6.17 PTO GEARBOX REPAIR 7. Remove the retaining ring from the PTO clutch hub at the PTO input gear and remove the PTO input 1. Remove the lower sight tube fitting and drain the gear. See Figure 49. oil. 2. Place the gearbox on two blocks of wood, output shaft up.

  • Page 37: Section 7 - Steering & Controls

    SECTION 7 - STEERING & CONTROLS 7.1 POWER STEERING SCHEMATIC Refer to Figure 51 for proper hydraulic hose routing. 1. Axle Pin Weldment 5. Steering Idler 2. Axle Weldment Weldment 3. RH Ball Socket 6. Kingpin Weldment 4. LH Ball Socket 7.

  • Page 38: Hydraulic Hoses

    7.3 HYDRAULIC HOSES wrenches, one on the hose and one on the fitting, to prevent damage by twisting off the fitting. NOTE: When loosening or tightening any hydraulic hoses, use the correct wrench. If hoses are to be dis- connected or reconnected at a fitting use two 1.

  • Page 39: Steering Box Removal

    1. When disconnecting hoses, have an open top 7.5 STEERING BOX INSTALLATION container to drain hydraulic oil into. 1. Slide the power steering unit into place and secure 2. Clean all fittings and hoses where maintenance is with the four nuts. Install the nylon bushing if to be performed, prior to removing hoses to avoid removed.

  • Page 40: Section 8 - Lift System

    SECTION 8 - LIFT SYSTEM 8.1 LIFT SYSTEM SCHEMATIC PORT B LIFT LIFT CYLINDER CYLINDER PORT A PORT C POWER STEERING PORT D UNIT PORT E PORT H PORT G PRESSURE HYDRULIC VALVE RETURN EXHAUST SUCTION PORT F TRANSAXLE TRANSMISSION RADIATOR STEERING CYLINDER...

  • Page 41: Hydraulic Lift System Troubleshooting

    8.2 HYDRAULIC LIFT SYSTEM TROUBLESHOOTING Problem Probable Cause Corrective Action Mower deck will not raise Hydraulic system low on fluid Add oil to hydraulic system Pinched or restricted hydraulic hose Repair or replace Air in system Bleed hydraulic system Hydraulic valve or valve linkage Repair or replace Transmission charge pressure too low Adjust...

  • Page 42: Hydraulic Lift Valve Removal

    8.4 HYDRAULIC LIFT VALVE REMOVAL Power Steering 1. Valve 2. Lift Cylinder Figure 54 4. Pay close attention to the lift control linkage at both CAUTION: Prior to working on the hydraulic ends for signs of wear. Repair or replace any worn valve, move the lift lever to the float position to or damaged parts.

  • Page 43: Hydraulic Valve Adjustment

    3. Connect the lift control linkage to the valve spool. 8.8 HYDRAULIC LIFT CYLINDER INSTALLATION 4. Refer to Servicing The Hydraulic System and Priming the Transmission if hydraulic system 1. Install the hydraulic cylinder with the ram towards bleeding is needed. the attachment with the two clevis pins and cotter 5.

  • Page 44: Section 9 - Fuel System

    2. Clamp off the fuel lines at the feed pump and fuel filter assembly and loosen the fuel line clamps. NOTE: The engines Gravely uses are self bleeding to the fuel pump. Once fuel reaches the fuel pump the 3. Remove the fuel line at the feed pump fitting and engine should be able to start by cranking the engine pull the hose down through the frame.

  • Page 45: Section 10 - 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 Digital Meters cover joints and the soldering of connections contribute Digital Meters do not have a movement and are there- to a professional looking job.

  • Page 46: Battery

    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;...
  • Page 47 Another important check is the specific gravity.The 3. After cleaning the terminals, spread petroleum jelly specific gravity should be checked with the hydrometer. on the terminals to prevent loss of charge and The reading on the gauge should be above 1.225. If prevent corrosion.

  • Page 48: Switches

    To jump start the battery: NOTE: Check that the connections to the switches are secure and that a switch is being activated properly 1. Ensure battery is not frozen. If the fluid is frozen, before performing electrical test on switches. (Safety remove battery from unit and allow to thaw before switches on speed selector and clutch levers may be charging.

  • Page 49: Lighting Circuits

    NEVER attempt to defect the protective device by may cause the problem. bridging or replacing with a device of a higher current The starter solenoid in the Gravely equipment is a rating. sealed unit used to actuate the starter motor on the Electrical testing of these devices is simple.

  • Page 50: Engine Electrical Component Check Out10-50

    3. Once continuity to ground is achieved, set the service the engine. Gravely dealers should be able to VOM to the "12" volts D.C. position. Turn the key to test engines and engine components to pinpoint the "Run"...
  • Page 51 3. If steps 2 and 3 check okay, the time delay is Fuel Shut Off Solenoid functioning properly. 1. If engine fails to start, verify, with the key switch in the start position, that power (12 volts) is present at Fuse Holder the white lead to the fuel solenoid.

  • Page 52: Continuity Diagrams

    10.10 CONTINUITY DIAGRAMS 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. Key Switch (09056700) GLOW PLUG START (COUNTERCLOCKWISE) Relay Seat Switch (03042800) (03490500) OPERATOR...

  • Page 53: Wiring Diagrams

    10.11 WIRING DIAGRAMS Promaster 400, 30-H 10 - 53...
  • Page 54 Promaster 400, 22-H 10 - 54...
  • Page 55 Model 989057, 306 CRUISE CAB POWER OIL PRESSURE PRESSURE HOUR METER HEAD LIGHT CONTROL SUPPLY SWITCH LIGHT (ENGINE) WATER TEMP WATER GAUGE TEMP SENDER BLACK BLACK BLACK (ENGINE) BLUE / WHITE BLACK ORANGE BLACK BLACK BLACK PURPLE LIGHT SWITCH SEAT SWITCH TIME DELAY MODULE (Optional)

  • Page 56: Section 11 - Four Wheel Drive Assist

    SECTION 11 - FOUR WHEEL DRIVE ASSIST 11.1 FOUR WHEEL ASSIST HYDRAULIC SCHEMATIC NOTE: This hydraulic schematic is from a belly-mount (frame brace) manifold. For an axle-mount manifold, the manifold would be inverted and the single solenoid would face to the right side. 11 - 56...

  • Page 57: Four Wheel Assist Wiring Schematic

    11.2 FOUR WHEEL ASSIST WIRING SCHEMATIC 11.3 HYDRAULIC HOSES 4. Fittings which use an O-ring seal do not use a hydraulic sealer for preventing leaks. Fittings NOTE: When loosening or tightening any hydraulic without an O-ring seal should use a hydraulic hoses, use the correct wrench.

  • Page 58: Manifold Removal

    11.4 MANIFOLD REMOVAL 3. Disconnect the two hydraulic hoses at the wheel motor and cap. 1. Disconnect the three wire leads at the manifold 4. Remove the two hydraulic adapters from the wheel solenoid. motor. 2. Disconnect the three hydraulic hoses at the 5.

  • Page 59: Section 12 - Mower Deck

    SECTION 12 - MOWER DECK 12.1 SERVICE AND REPLACEMENT PARTS When ordering replacement parts or making service inquiries, know the Model and Serial Number of your Serial Number attachment and unit. Numbers are located on the product registration card in the attachment literature package.

  • Page 60: Installation And Removal

    12.3 INSTALLATION AND REMOVAL To install the mower deck: 1. Drive the tractor unit up to the deck so that the mower arm ball sockets align with the deck mounting bracket holes. 2. Fasten each arm weldment to the bracket with the trunnion pin.

  • Page 61: Cleaning And Storage

    5. If the distances are not equal, loosen jam nuts on 3. Sharpen and balance the blades. the rod ends. NOTE: Gravely recommends having the mower blades 6. Turn the height adjustment weldments until sharpened by a professional. distance is the same at the front and rear of the 4.

  • Page 62: Spindle Repair (Greasable)

    NOTE: Do not use harsh or abrasive cleaners on any Spindle Installation painted surface. Do not allow gasoline or oil to remain 1. Install the spindle using the six mounting bolts and on the surface. torque to spec. 2. Inspect for damage, wear, and loose or missing 2.
  • Page 63 Figure 60 - 60" Gauge Wheels, Roller and Height Adjustments Figure 61 - 72" Gauge Wheels, Roller and Height Adjustments PF3250 12 - 63...
  • Page 64 Figure 62 - Mower Mounting PF3170 Figure 63 - Mower Gearbox 12 - 64...
  • Page 65 Figure 64 - Mower Drive PF3190 12 - 65...
  • Page 66 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...

This manual is also suitable for:

Promaster 460989003989004989014989015989049 ... Show all

Table of Contents

Save PDF