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.
SECTION 2 - SAFETY 2.1 SAFETY ALERTS rented or sold, ALWAYS provide the Operator’s Manual and any needed safety training before operation. Look for these symbols to point out important safety precautions. They 2.6 PREPARATION mean: Before starting any removal of parts, proper Attention! preparation is very important for efficient work.
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ALWAYS keep hands and feet within the limits of the Allow engine to cool before servicing. unit. NEVER fill fuel tank when engine is running, hot, or unit is indoors. Keep children, people, and animals away. Keep children out of work area and under watchful care of a Abnormal Vibrations are a warning of trouble.
If leak This product is equipped with an internal combustion occurs, have it repaired by your Gravely Dealer. engine. DO NOT use on or near any unimproved, forest covered or brush covered land unless the...
SECTION 3 - SPECIFICATIONS Model Number 991001 991002 991003 Description Promaster 100 Promaster 100 Promaster 100 Engine 16 HP 2-cyl Air Cooled 18 HP 2-cyl Air Cooled 16 HP 2-cyl Air Cooled Engine Manufacturer Kohler Kohler Briggs & Stratton Model Number...
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Model Number 991004 991005 991006 Description Promaster 100 Promaster 100 Promaster 100 Engine 18 HP 2-cyl Air Cooled 18 Hp 2 cyl Air Cooled 18 HP 2 cyl Air Cooled Engine Manufacturer Kohler Kohler Kohler Model Number MV18S-PS-58550 MV18S-PS-61541 MV18S-PS-61541...
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Model Number 991007 991008 Description Promaster 100 Promaster 160 Engine 18 Hp 2 cyl Air Cooled 18 HP 2 cyl Air Cooled Engine Manufacturer Kohler Kohler Model Number CV18S-PS-61541 CV18S-PS-61541 Fuel and Capacity - gals (L) Unleaded Unleaded 3.5 (13.2) 3.5 (13.2)
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Model Number 992006 992007 992008 Description PM200 PM200 PM200 Engine 18 HP 4 cycle 25 HP 4 cycle 20 HP 4 cycle Engine Manufacturer Kawasaki Kohler Kohler Model Number FD590V Cv25S CV20S Fuel and Capacity - gals (L) Unleaded Unleaded Unleaded 7 (26.5) 7 (26.5)
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Model Number 992009 992010 992011 Description PM200 PM200 PM200 Engine 20 HP 4 cycle 20 HP 4 cycle 20 HP 4 cycle Engine Manufacturer Kohler Kawasaki Kawasaki Model Number CV20S FD590V FD590V Starting System Electric Electric Electric Fuel and Capacity - gals (L) Unleaded Unleaded Unleaded...
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Model Number 992012 992013 992014 Description PM200 PM200 PM200 Engine 22 HP 4 cycle 20 HP 4 cycle 25 HP 4 cycle Engine Manufacturer Kohler Kohler Kohler Model Number CV22S CV205 CV25S Fuel Tank Capacity Unleaded Unleaded Unleaded 7 (26.5) 7 (26.5) 7 (26.5) Idle RPM...
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Model Number 992016 992015 992301 Description PM200 PM200 PM200 EXPORT Engine Manufacturer Kawasaki Kawasaki Kohler Model Number FD590V FD590V CV205 Cycle Horsepower 12.7 FW @ 2750 MIN-1 Fuel Tank Capacity - gals (L) Unleaded Unleaded Unleaded 7 (26.5) 7 (26.5) 7 (26.5) Idle RPM 1800 RPM...
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Model Number 992302 992303 992304 Description PM200 Export PM200 Export PM200 Export Engine Manufacturer Kohler Kawasaki Kawasaki Model Number CV205 FD590V FD590V Cycle Horsepower 12.7 FW @ 2750 MIN-1 12.7 FW @ 2750 MIN-1 12.7 FW @ 2750 MIN-1 Fuel Tank Capacity - gals (L) Unleaded Unleaded Unleaded...
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 1. Fuel Tank 8. PTO Switch 2. Hydraulic Oil Tank 9. Deck Height Indicator (On Units With 3. Steering T-Bar Control Levers Hydraulic Assist) 4. Ammeter 10. Parking Brake Lever ( On 200 Series) 5.
991 Series ENGINE WILL NOT CONFORMS TO ANSI START UNLESS B71.4 SAFETY STANDARD COMMERCIAL TURF THE PTO CONTROL IS IN THE OFF POSITION CARE EQUIPMENT. THE T -BAR CONROL LEVERS ARE IN THE NEUTRAL POSITION CAUTION CAUTION SAFETY FIRST DO NOT PARK ON SPECIAL TRAINING NECESSARY.
4.3 GENERAL LUBRICATION Be sure to stop engine before servicing any hydraulic parts. Apply a small amount of oil to the pivot points as required for smooth and proper operation. WARNING: HYDRAULIC FLUID UNDER Apply high quality lithium base grease to the lube PRESSURE can penetrate skin and cause fittings in each of the pump arm bushings and the front severe burns that can result in death or...
STEERING CONTROL NEUTRAL 4.7 T-BAR CONTROL LEVER ALIGNMENT ADJUSTMENT Refer to Figure 7. If the unit has excessive creep when the twin T-bar control levers are in neutral, adjust as follows. See Figure 5 WARNING: This adjustment requires operation of the engine and removal of guards.
Figure 8 - Promaster 200 PF3030 wheel. 2. Adjust the neutral closer to reverse on the right Promaster 100 and 160 wheel. 1. Raise the mower by pulling up on handle until two 3. Reduce the air pressure slightly in the right tire.
4.11 ADJUSTING MOWER BELT 1. Long Mower Belt 5. Jam nuts 2. Short Mower Belt 6. Adjusting Nuts 3. Idler Rods 7. Spindle Sheaves 4. Springs 8. Idlers Figure 9 P G0341 Check the mower belt after the first 8 hours of operation for proper tension.
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.
5.2 CHECKING ENGINE OIL Check the engine oil BEFORE EACH USE OR TWICE DAILY ON COMMERCIAL USE as follows. 5.3 CHANGING OIL FILTER Some engines are equipped with an oil filter. Replace the oil filter every other oil change. See engine manufacturers manual for proper intervals and oil type.
CAUTION: Change any damaged or worn first stop. parts to new ones obtained from a Gravely Step back while pressure releases. Dealer or an authorized Kawasaki Dealer. When you are sure that all pressure has been released, use the cloth to press the cap down, 6.4 COOLANT CHANGE...
.010" to .015" (.25 mm to .38 mm). When 1/8 of an inch of its end, replace blade. Use Gravely the belt is tight, hold the adjusting nut and lock the replacement blade only.
Figure 12 2. Remove bearings and spindle shaft. PF0800 NOTE: Bearing and bearing race must be replaced as 7.4 50" MOWER, PROMASTER 100 & 160 a set. 3. Press out the bearing race. Mower Removal 4. Insert and press in the new races. Check to see 1.
Promaster 100, 160 1. Seal 2. Bearing Housing 3. Spindle Shaft 4. Seal 5. Idler Pulley Rod Figure 14 PF0710 7.5 50" AND 60" MOWER, PROMASTER 200 Mower Removal 1. Lower the mower until the supporting chains are slack. The deck may need to be on blocks.
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Promaster 200 50" Deck 60" Deck PF2040 1. Mower Mounting Arm 2. Mower Mounting Pin Figure 15 Mower Spindle Removal 1. With the mower deck removed from the unit the spindle can be removed. 2. Loosen the idler arms and remove belts from spindle sheaves.
SECTION 8 - MOWER LIFT SYSTEM Standard on Promaster 160 and 200 The mower lift system consists of the mower frame with caster wheels, the hydraulic pump and reservoir, and the hydraulic lift cylinder with linkage. 8.1 MOWER FRAME To remove mower frame, Figure 17: 60"...
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(Electric/Hydraulic Pump) 3. Connect the three leads to the switch—green - top, red - middle, and blue - bottom. CAUTION: Remove attachment from tractor 4. Install switch into dash. Reconnect the battery, or disconnect attachment at mower lift arm negative terminal first and check operation of prior to working on lift system.
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3. Reconnect hydraulic cylinder to mower lift 4. Connect hydraulic hoses. weldment, noting where it was previously 5. Service electric/hydraulic pump reservoir. connected. 50" Mower 60" Mower OF0100 1. Motor Assembly 3. Tank Reservoir PF0881 2. Adapter Assembly 4. Hydraulic Lift Cylinder Figure 18 8 - 31...
SECTION 9 - STEERING AND DIRECTION CONTOLS 9.1 STEERING AND DIRECTION CONTROLS 1. Remove the tension spring, Figure 19. 2. Unbolt the steering rod end from the speed control arm. 3. Remove the neutral adjustment weldment and inspect woodruff key 4.
SECTION 10 - DRIVE TRAIN 10.1 TRANSMISSION 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 hydro transmission problems and give possible unit.
10.2 REPLACING THE HYDRO PUMP BELT 3. Use caution and remove the 5/8" bolt holding the PTO clutch in place, Figure 21. 1. Stop the engine. Remove the ignition key. Put the PTO switch in the "off" position. Put the speed CAUTION: The two part PTO clutch and drive control lever in the neutral position.
10.6 IDLER PULLEY 10.8 WHEEL INSTALLATION To remove the idler pulley: 1. Loosen the two jam nuts on the idler rod enough to Models 991007, 008 remove the belt. 2. Loosen and remove the hex bolt that holds the idler arm.
SECTION 11 - FUEL SYSTEM 11.1 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.
2. Loosen the rear hydraulic hose by using an 11/16" wrench along with a 5/8" wrench on the oil cooler 3. Replace filter with a new Gravely filter to insure fitting to prevent damage from twisting the cooler proper oil filtering.
Models 991007, 008 PF0762 Figure 26 12.7 HYDRAULIC PUMP REMOVAL 5. Remove the pump control bracket. 6. If right pump is to be removed disconnect PTO Left or Right Side safety switch to prevent damage to wires. 1. Loosen the tension on the hydro pump drive belt. 7.
12.8 OVERHAUL SEAL KIT INSTRUCTIONS Disassembly Procedures for the End Cap 1. Using a 6 mm hex wrench, remove the 4 screws Use seal kit P/N 58800300 to overhaul pump. which retain the end cap to the pump housing. The The procedure below is for the disassembly and internal springs should separate the end cap from replacement of the BDP-10L variable pump end cap...
7. Install the charge relief valve ball and spring. The 2. Carefully pull the seal out of the housing bore. A charge relief ball goes into the end cap charge hole hook-type tool may be used to grasp the seal and pocket first and the spring is installed between the pull it out.
Digital Meters do not have a movement and are there- colors). fore more rugged. The reading shows up directly on a Gravely Company recommends that all work be done display window of some type. Since they read direct, in a professional manner. The use of the tubing to...
Voltage Measurement 13.3 BATTERY There are two basic rules to be remembered when WARNING: ELECTRIC SHOCK may result in using a voltmeter. A voltmeter measures the voltage injury and/or damage to unit. difference between the test leads and the voltmeter is always connected across the circuit under test.
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Set-Up Check the alternator voltage regulator output (if used) at every periodic maintenance inspection. Over The new battery is dry charged. The dealer or charging is a common cause of battery failure. customer must add electrolyte (sulfuric acid and water). Electrolyte Level 1.
If using a constant current charger, charge at 1 to 2 The unit used for jump starting should have a 12 volt amperes for the time given on the table above or until battery with at least 500 cold cranking amperes, and a full specific gravity is reached.
13.5 SWITCHES Ignition Switch NOTE: Refer to the wiring diagram of the unit involved Switches either open a circuit to stop current flow or to determine switch functions and test using the meth- close and allow current to flow through. ods described.
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.
3. Select meter to check amps (10 amp scale). service the engine. Gravely dealers should be able to 4. Place meter leads into fuse holder. test engines and engine components to pinpoint 5.
13.12 CONTINUITY DIAGRAMS Models 991005, 006, 007, 008 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. Seat Switch Key Switch (03602300) (03654200) OPERATOR OPERATOR...
13.13 991000 ELECTRICAL Models 991005, 006 Promaster 100 Kohler Command Installation checkout: Make sure that all switches are in their proper position: PTO switch off, Neutral switches activated. (T-levers centered). Step 1: Check out the battery. Use a hydrometer on all the battery cells to see if one or more is bad.
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Promaster 100 Kohler Command - 40" Deck, Model 991005 PURPL HOUR METER BLACK SEAT SEAT RELAY SWITCH PINK BLACK YELLOW / RED OIL LIGHT PURPLE SWITCH PURPLE / YELLOW / WHITE BLACK WHITE / BLACK START RELAY BLACK ENGINE RED / VIOLET...
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Promaster 100 Kohler Command - 50" Deck with Lift, Models 991005, 006 Ignition Switch Start Red (B) 12.00 Vdc 12.00 Vdc 12.00 Vdc Purple (A) 12.00 Vdc 12.00 Vdc Red/Violet (S2) 12.00 Vdc 12.00 Vdc Brown (S1) 12.00 Vdc 12.00 Vdc Contact resistance is 0.1-0.3 ohms when correct.
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Promaster 100 Kohler Command - 50" Deck with Lift, Models 991005, 006 Relay - Deck Lift Start Black (85) To Ground Purple 12.00 Vdc 12.00 Vdc 12.00 Vdc 12.00 Vdc 12.00 Vdc 12.00 Vdc 12.00 Vdc Open 12.00 Vdc Pins 85-86 coil resistance is 87-100 ohms.
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Promaster 100 Kohler Command - 50" Deck with Lift, Models 991005, 006 Seat Switch Start Pink 12.00 Vdc 12.00 Vdc Black (to ground) To Ground Normally open contacts. Manually activated. Contact resistance is 0.1-0.3 ohms when correct. Hourmeter Start Black...
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Promaster 100 Kohler 16-18 HP Installation checkout: Make sure that all switches are in their proper position: PTO switch off, Neutral switches activated. (T-levers centered). Step 1: Check out the battery. Use a hydrometer on all the battery cells to see if one or more is bad. Also use a voltmeter to check for proper voltage.
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Promaster 100 Kohler 16 -18 HP Ignition Switch Start Red (I) 12.00 Vdc 12.00 Vdc 12.00 Vdc Light Blue (A) 12.00 Vdc 12.00 Vdc Dark Blue (R) 12.00 Vdc 12.00 Vdc Purple (B) 12.00 Vdc 12.00 Vdc Brown (S) 12.00 Vdc Contact resistance is 0.1-0.3 ohms when correct.
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Promaster 100 Kohler 16 -18 HP Time Delay Module Start Brown 12.00 Vdc 12.00 Vdc Yellow 12.00 Vdc 12.00 Vdc Green 12.00 Vdc 12.00 Vdc Solenoid Start Brown (S1) 12.00 Vdc Brown (S2) 12.00 Vdc 12.00 Vdc Red (from battery) 12.00 Vdc...
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Promaster 100 Briggs/Stratton -16 HP Installation checkout: Make sure that all switches are in their proper position: PTO switch off, Neutral switches activated. (T-levers centered). Step 1: Check out the battery. Use a hydrometer on all the battery cells to see if one or more is bad. Also use a voltmeter to check for proper voltage.
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Promaster 100 - Briggs & Stratton Ignition Switch Start Brown (S) 12.00 Vdc Red (B) 12.00 Vdc 12.00 Vdc 12.00 Vdc White (M) Connected to ground Yellow (L) 12.00 Vdc 12.00 Vdc White/Red (G) Engine Magneto Normally open, manually activated.
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Promaster 100 - Briggs & Stratton Left Interlock Switch Start Brown 12.00 Vdc 12.00 Vdc Brown/White 12.00 Vdc 12.00 to ground Normally open switches, manually activated. Contact resistance is 0.1-0.3 ohms when correct. Relay Start Red and Green (86) 12.00 Vdc 12.00 Vdc...
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Promaster 200 Briggs/Stratton -16 HP Installation checkout: Make sure that all switches are in their proper position: PTO switch off, Neutral switches activated. (T-levers centered). Step 1: Check out the battery. Use a hydrometer on all the battery cells to see if one or more is bad. Also use a voltmeter to check for proper voltage.
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Model 992010, 011 Kawasaki 18 HP ELECTRIC CLUTCH LIGHT LIFT LIFT BLUE PUMP SWITCH L. NEUT. R. NEUT. HOUR METER BRN/WHT SWITCH BRN/WHT BATTERY START SEAT RELAY INTERLOCK SWITCH RELAY SOLENOID TEMP STARTER MOTOR DELAY FUSE REG-RECT COIL PURPLE IGNITION SWITCH BATT COIL...
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Model 992010, 011 Kawasaki 18 HP, Briggs & Stratton Ignition Switch Start Brown (S) 12.00 Vdc Black (I) 12.00 Vdc 12.00 Vdc 12.00 Vdc Purple (B) 12.00 Vdc 12.00 Vdc Blue (R) 12.00 Vdc 12.00 Vdc Green (A) 12.00 Vdc 12.00 Vdc Contact resistance is 0.1-0.3 ohms when correct.
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Model 992010, 011 Kawasaki 18 HP, Briggs & Stratton Right Neutral Switch Start Brown Connected to ground Brown Connected to ground Ignition Switch Start Brown (S) 12.00 Vdc Black (I) 12.00 Vdc 12.00 Vdc 12.00 Vdc Purple (B) 12.00 Vdc 12.00 Vdc Blue (R) 12.00 Vdc...
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Model 992010, 011 Kawasaki 18 HP, Briggs & Stratton Seat Switch Start Yellow 12.00 Vdc 12.00 Vdc Green Holding circuit for the time delay Ignition Switch Start Brown (S) 12.00 Vdc Black (I) 12.00 Vdc 12.00 Vdc 12.00 Vdc Purple (B) 12.00 Vdc 12.00 Vdc Blue (R)
13.14 992000 ELECTRICAL Promaster 200 Kohler Installation checkout: Make sure that all switches are in their proper position: PTO switch off, Neutral switches activated. (T-levers centered). Step 1: Check out the battery. Use a hydrometer on all the battery cells to see if one or more is bad. Also use a voltmeter to check for proper voltage.
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Model 992013, 014 Kawasaki 20 HP ELECTRIC CLUTCH LIGHT LIFT LIFT BLUE PUMP SWITCH L. NEUT. HOUR METER R. NEUT. BRN/WHT SWITCH BRN WHT BATTER START SEAT RELAY INTERLOCK SWITCH RELAY SOLENOID TEMP STARTER MOTOR DELAY FUSE REG-RECT COIL PURPLE IGNITION SWITCH BATT...
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Model 992301 Kohler 20 and 25 HP 13 - 76...
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Models 992013, 014, 015, 016, 301 Ignition Switch Start Brown (S) 12.00 Vdc Black (I) 12.00 Vdc 12.00 Vdc 12.00 Vdc Purple (B) 12.00 Vdc 12.00 Vdc Blue (R) 12.00 Vdc 12.00 Vdc Green (A) 12.00 Vdc 12.00 Vdc Contact resistance is 0.1-0.3 ohms when correct. Start Relay Start Brown (86)
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Models 992013, 014, 015, 016, 301 Right Neutral Switch Start Brown Connected to ground Brown Connected to ground Normally open switches. Contact resistance is 0.1-0.3 ohms when correct. Left Neutral Switch Start Brown Connected to ground Black Connected to ground Normally open switches.
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Models 992013, 014, 015, 016, 301 Seat Switch Start Yellow 12.00 Vdc 12.00 Vdc Green Holding circuit for the time delay Normally open switches, manually activated. Contact resistance is 0.1-0.3 ohms when correct. Time Delay Start Orange 12.00 Vdc Green 12.00 Vdc 12.00 Vdc Module cannot be tested.
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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...