Gravely Promaster 260Z Service Manual
Gravely zero-turn riding mower service manual
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Also See for Promaster 260Z:
- Service manual (47 pages) ,
- Owner's/operator's manual (32 pages) ,
- Owner's and operator's manual (28 pages)
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Summary of Contents for Gravely Promaster 260Z
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Page 1: Service Manual
Promaster 250Z, 260Z, 272Z Service Manual 992018, 020, 023, 027, 029, 030 992032, 033, 034, 035 09254300A 8/04 Printed in USA... -
Page 2: Table Of Contents
Introduction ......5 The Manual ......5 Service and Replacement Parts . - Page 3 ARIENS COMPANY, que: Type: – Type : – Typ: – Riding Rotary Lawn Mower – Tondeuse à gazon autoportée rotative – Aufsitz-Sichelmäher – Rijdende Type: – Type: – Tipo: – roterende grasmaaier – Havetraktor med roterende knive – Trattorino con unità di taglio rotativa – Tractor Tipo: –...
- Page 4 Notified Body – Organisme notifié – Zertifizierungsstelle – Aangemelde instantie – Bemyndiget organ – Organismo notificato – Organismo notificado – Teknisk kontrollorgan – Anmält organ – Ilmoitettu laitos – Organ zaświadczający – Organismo – Certificador Philip J. Smucker: Quality and Conformance Manager (Keeper of Technical File) – Responsable de la qualité...
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Page 5: Introduction
Figure 1 PRODUCT REGISTRATION The Gravely dealer must register the product at the time of purchase. Registering the product will help the company process warranty claims or contact you with the latest service information. All claims meeting... -
Page 6: Safety
WARNING: This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the safety instructions in the manuals and on decals could result in serious injury or death. WARNING: Slopes are a major factor related to loss-of-control and tip-over accidents. - Page 7 • If machine stops going uphill, stop blade and back down slowly. • 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. •...
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Page 8: Safety Rules
DANGER / PELIGRO • Avoid injury - Stay clear of rotating parts. • 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 unless guards are in la tondeuse sans operating position or... - Page 9 Local regulations may restrict the age of the operator. NEVER allow children to operate or play on or near unit. Be alert and shut off unit if children enter area. NEVER operate unit after or during the use of medication, drugs or alcohol. Safe operation requires your complete and unimpaired attention at all times.
- Page 10 DO NOT operate on slopes of more than 17 degrees. Use of a Rollover Protection System (ROPS) is recommended for slope operation. Always wear a seat belt when operating unit using a Rollover Protection System (ROPS). Keep all movements on the slope slow and gradual. Do not make sudden changes in speed or direction.
- 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.
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Page 12: Specifications
Model Number Model Length - in (cm) Height - in (cm) Width - in (cm) Weight Actual - lbs (kg) Battery Brakes Turning Radius Tire Size Front Rear Engine - Manufacturer Model Number Cycle Engine Power- HP (KW/min Starting System Fuel Tank Capacity Fuel Idle RPM... - Page 13 Model Number 992020 Model 260Z 25 HP Kohler w/60" deck Length - in (cm) Height - in (cm) Width - in (cm) Weight Actual - lbs (kg) 1125 (510) Battery Brakes Turning Radius Tire Size Front Rear Engine - Manufacturer...
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Page 14: Controls And Features
CONTROLS AND FEATURES 9 10 11 1. Mower Deck with Chute Deflector 2. Fuel Shut off Valve 3. Parking Brake 4. Battery 5. Hour Meter 6. Oil Pressure Indicator 7. Engine Frame and Hood 8. Fuel Tanks and Caps 9. Choke Control (not on EFI* models) 10.Malfunction Indicator Light 11.Throttle Lever 12.Ignition Switch... -
Page 15: General Maintenance & Adjustments
GENERAL MAINTENANCE & ADJUSTMENTS MAINTENANCE SCHEDULE WARNING: AVOID INJURY. Read and understand the entire Safety section before proceeding. Interval Task Check Safety Interlock Check Parking Brake Interlock System Check Parking Brake Each Use Check Hydraulic Oil Level Check Tires Clean Unit Follow Engine Manual Maintenance Schedule Check Cooling System... -
Page 16: Service And Adjustments
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
5. Engage parking brake. 6. Levers must be returned to their original position in order to operate the unit (Figure 5). TRANSPORTING UNIT ALWAYS shut off engine, set parking brake, and remove key when transporting unit on a truck or trailer. Tie unit down securely. -
Page 18: Filling Fuel Tank
FILLING FUEL TANK EXPLOSIVE VAPORS and FLAMMABLE FUEL can result in serious injury or death. Handle fuel with care. ALWAYS use an approved fuel container. No Smoking! No Lighted Materials! No Open Flame! Allow engine to cool. Use caution with fuel. Fuel is very flammable. Keep fuel in a clean and tight container. -
Page 19: Basic Engine Maintenance
Battery Removal and Installation Remove 1. Place hood in full service position (see Service Positions on page 16). 2. Disconnect negative (-) cable first, then positive (+) cable (Figure 8). 3. Remove battery hold-down bracket and battery from unit. Install 1. -
Page 20: Belts
BELTS WARNING: MOVING PARTS can cut or amputate body parts. ALWAYS wait for moving parts to stop before performing maintenance or service. CAUTION: DAMAGED OR WORN BELTS may result in injury and/or damage to the unit. Check belts for excessive wear or cracks often. -
Page 21: Tires
1. Hydro Belt 5. Right Hand 2. Spring 6. Left Hand Hydrostat 3. Idler 4. Engine Sheave Figure 11 TIRES Before each use, make a visual check of tires.The correct air pressure is 12-15 psi (83-103 kn/m rear tires, and 20-25 psi (138-172 kn/m tires. -
Page 22: Adjusting Control Levers
4. Have someone depress center of seat to activate seat switch. 5. Start the engine and run at about half throttle or faster. Release parking brake. 6. Move the control levers from Forward to Reverse several times to make sure controls are free and check neutral adjustment. -
Page 23: Leveling The Mower Deck
LEVELING THE MOWER DECK These adjustments should be made on a level surface with the tires inflated to the correct air pressure. The mower is leveled from side to side with the slots where 4 chains fasten to the mower mounting brackets. The mower is leveled from front to rear by adjusting the rod running down each side of the frame (Figure 16). -
Page 24: Engine
ENGINE TROUBLESHOOTING The following troubleshooting chart is to be used to isolate engine problems and give possible causes and corrective action responses. TROUBLE Black Exhaust Blue/White Exhaust Difficult Starting Erratic Running Excessive Fuel Consumption High Oil Pressure Knocking Loss of Power or System Low Cranking Power Low Oil Pressure Misfiring... -
Page 25: Removing The Engine
REMOVING THE ENGINE 1. Place the mower in the full service position. 2. Disconnect the battery cables, negative first. 3. Disconnect ignition wires using the connectors. 4. Remove the belts from the pulley and clutch. 5. Unscrew the bolt from the center of the output shaft and remove clutch. -
Page 26: 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 27: Replacing The Hydraulic Pump
replaced. If the flow drop is less than 1 GPM you will need to replace the wheel motor. REPLACING THE HYDRAULIC PUMP The two hydraulic pumps are located inside the chassis in front of the engine. The pumps are maintenance free and should be replaced in the event of a failure. -
Page 28: Hydraulic Deck Lift Pressure Test
13.Place the brake caliper into position and insert bolts from the inside of the frame outward. Use lock washer and nut and tighten. 14.Position wheel on hub and insert lug nuts finger tight. 15.Tighten lug nuts using the pattern shown in Figure 16.Lower the unit to the ground and start the engine. -
Page 29: Hydraulic Diagram
HYDRAULIC DIAGRAM 992018, 023, 027 Lift Valve Return Inlet Left Forward Upper Wheel High Motor Pressure Reverse High Pressure Lower Filter Tank Deck Lower Deck Lift Left Pump Lift Cylinder Forward High Pressure Right Pump Reverse High Pressure PRESSURE RETURN SUCTION Right Wheel... - Page 30 Models 992020, 029, 030, 032, 033, 034, 035 PD1774...
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Page 31: Mower Deck
Mower Spindles This unit utilizes a maintenance free extended life spindle. No routine maintenance is required. In the event of bearing failure or a bent shaft the spindle should be replaced. To Remove the Spindle 1. Place the unit in service position. Turn key off and remove the spark plug wire from contact with spark plug. -
Page 32: Front Suspension
The front suspension consists of a weldment that is a square tube (Figure 22). 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. This fitting is greased as needed with Sten Mix Hi-Temp grease or equivalent. -
Page 33: Electrical
(for use on joints and connections), and an assortment of automotive type wire (in several colors). Gravely Company recommends that all work be done in a professional manner. The use of the tubing to cover joints and the soldering of connections contribute to a professional looking job. -
Page 34: 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 35: Switches
Check the alternator voltage regulator output (if used) at every period maintenance inspection. Over charging is a common cause of battery failure. Battery Charger Under normal conditions, the engine alternator will have no problem keeping battery charged. When unit has set for an extended period of time without operation and the battery has been completely discharged, a battery charger will be required for recharging. -
Page 36: Solenoid And Relays
the wiring harness. Connections G and M open to each other. START Position - Hold switch in START position while testing. There should be continuity between contacts S1 and S2. These connections apply power to close the solenoid contacts and operate the starter motor. In addition to the above test, place the switch in the run position and check between each contact and ground (metal case) to be sure no terminals are grounded. - Page 37 To check a diode, isolate it from the circuit by disconnecting one end. With a multitester set on the lowest ohms scale setting, measure the resistance in one direction, reverse the test leads, and measure in the other direction. Readings should be high in one direction and low in the other.
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Page 38: Wiring Diagrams
WIRING DIAGRAMS Models 992018, 020, 027 PD2110 PD3230... - Page 39 Model 992029, 030, 034, 035 PD3242...
- Page 40 Model 992023 HOUR METER BLACK OIL PRESSURE SWITCH FUEL SOLENIOD ENGINE REGULATOR MAGNETO KILL STARTER BLACK BATTERY BLACK COIL 2 COIL 1 STARTER SOLENOID BLACK SEAT / PTO RELAY POWER SUPPLY BLACK PURPLE LIGHT BLUE / WHITE WHITE / BLACK FUSE BLACK BROWN...
- Page 41 Models 992032, 033...
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Page 42: Troubleshooting
(see Servicing the Battery on page 18). 4. Charge battery (see Charging the Battery on page 19). 5. See your Gravely Dealer. 1. Fill fuel tank (see Filling Fuel Tank on page 18). 2. Replace spark plug. Refer to Engine Manual. - Page 43 3. Hydraulic oil level low. 4. Faulty hydraulic drive system. CORRECTION 1. Disengage parking brake. 2. Close transmission bypass levers (see Moving Unit Manually on page 16). 3. Add hydraulic oil (see Checking Hydraulic Oil Level on page 26). 4. See your Gravely dealer.
- Page 44 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...