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Summary of Contents for Gravely 985103
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Page 1: Service Manual
Professional 2-Wheel Tractor Service Manual Models 985103,104, 105, 107 - 115, 117 08483800 08/00 Printed in USA... -
Page 2: Table Of Contents
Section 1 - Introduction ....1-3 1.1 The Manual......1-3 1.2 Service And Replacement Parts . -
Page 3: Section 1 - Introduction
Gravely authorized replacement part may adversely affect the performance, durability, or safety of this unit and may void the warranty. Gravely disclaims liability for any claims or damages, whether warranty, property damage, personal injury, or death arising out of the use of unauthorized replacement parts. -
Page 4: Preparation
It is important to understand that this manual and any other Gravely instruction manuals do not cover every possible danger. It is impossible for Gravely to know of all possible dangers in operating and servicing the tractor and attachments. -
Page 5: Preparation
Learn the location and function of all controls. Learn how to use the controls to stop the wheels and attachment quickly in an emergency. Understand and follow each danger, warning, caution and instruction decal installed on this product. Never permit children to operate the Two-Wheel Tractor. -
Page 6: Section 3 - Specifications
2nd - 2.4 mph (3.9 kph) -Type Internal Slip Clutch -Drive -Output Speeds Construction SECTION 3 - SPECIFICATIONS 985103 985104 8HP Gear Drive Optional, individual, 7" (17.8 cm) x 1.75" (4.4 cm) drum type Manual, optional power steering kit available Zero (with steering kit) Zero Zero 4"... - Page 7 Model Number Description 12HP Gear Drive Brakes Steering Turning Radius Minimum Uncut Circle Optional Tire Sizes -Stud Tread -Trac Tread -Turf-Chief 18" x 6.5" x 8", 4 ply -Turf-Saver 18" x 8.5" x 8", 4 ply -Semi-Pneumatic 16" x 5" x 3", 4 ply Tire Pressure Battery 12 volt, BCI group...
- Page 8 Model Number Description Brakes Steering Turning Radius Minimum Uncut Circle Optional Tire Sizes -Stud Tread -Trac Tread -Turf-Chief -Turf-Saver -Semi-Pneumatic Tire Pressure 18 psi (124 Kn/m2) Battery 12V BCI Group Engine -Type -Horsepower -Number of Cylinders -Displacement -Fuel See Engine Manual -Fuel Capacity 2.0 gals.
- Page 9 Model Number Description 13.5 HP Gear Drive Brakes 7 x 1.75" Drum Type Steering Manual, optional power steering kit available Turning Radius Zero (with steering kit) Minimum Uncut Circle Optional Tire Sizes -Stud Tread -Trac Tread -Turf-Chief -Turf-Saver -Semi-Pneumatic Tire Pressure See Tire Sidewall Battery 12V BCI Group...
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Page 10: Section 4 - General Maintenance & Adjustments
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 1. Direction Control Lever 2. Steering Brake Handlebar (Optional) 3. Gear Shift Lever (Hi/Low Gear) 4. Operator Presence Control 5. Choke Control Knob (Models with Briggs & Stratton Engines) 6. -
Page 11: General Lubrication
Control Linkage Lubrication Every 25 hours of operation put a drop of engine oil on the pivots of the throttle lever, the direction control lever, the gear shift lever, the PTO control, and range shift handle. NOTE: There are no grease fittings on the tractor. Transmission Capacity: 5 U.S. -
Page 12: Hi/Low Gear Clutch Adjustment
1. Jam Nuts 7. Adjusting 2. Fwd-Rev Control Rod 3. Control Extension Rod 8. Fwd-Rev Lever 4. Fwd-Rev Neutral Spring 9. Adjustment Bracket 5. Large Spring 10. Cam Lever Arm 6. Brake Rod Assembly Figure 3 • To adjust the forward clutch, put the direction control in the forward position. -
Page 13: Pto Brake Adjustment
1. Adjusting Nuts 2. Jam Nuts 3. Adjustment Bracket 4.7 PTO BRAKE ADJUSTMENT • Adjust the PTO brake after every 100 hours of operation. WARNING: Stop the engine before adjusting the PTO brake. • Remove the attachment and lower the rear of the tractor to the ground. -
Page 14: Slip Clutch Adjustment
4.8 SLIP CLUTCH ADJUSTMENT • Adjust the slip clutch after every 100 hours of operation. WARNING: Stop the engine before adjusting the slip clutch. • Remove the attachment and lower the rear of the tractor to the ground. Carefully clean the front of the transmission. -
Page 15: Section 5 - Engine
5.1 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 Excessive Crankcase Pressure High Oil Pressure Knocking Loss of Power or System Low Cranking Power... -
Page 16: Checking Engine Oil
5.2 CHECKING ENGINE OIL Check the engine oil daily prior to use. IMPORTANT: Never operate the engine with the oil below the low mark on the dipstick. See the engine manual for oil specifications and oil filter service instructions. To check oil level: 1. -
Page 17: Engine Removal And Installation
5.5 ENGINE REMOVAL AND INSTALLATION 1. Remove ground cable from battery. 2. Drain Transmission oil. 3. Turn off fuel at fuel tank. Remove fuel line from fuel pump. 4. Remove the choke cable from carburetor. 5. Remove the throttle cable from the linkage. 6. -
Page 18: Section 6 - Steering & Controls
SECTION 6 - STEERING & CONTROLS 6.1 HANDLEBAR ASSEMBLY CAUTION: Before performing any service or adjustments: • Turn PTO switch "OFF". • Park mower on a hard, flat, level surface. • Place steering control levers in neutral lock (fully outward) position. •... -
Page 19: Steering Brakes (Optional)
1. Hi-Lo Control Handle 2. Hand Lever Pivot Assembly Figure 12 6.2 STEERING BRAKES (OPTIONAL) The steering brake is designed to stop one wheel from rotating. The opposite wheel continues to drive forward and the unit pivots on the stopped wheel. Connect the adjustment bracket to the cam lever arm with a clevis pin. - Page 20 1. Right Hand Brake Rod 2. Left Hand Brake Rod 3. Brake Fasten the instruction plate and the brake handle brackets to the rear hitch with the 1/2-13 x 2.00 bolts and 1/2" lock nuts. Right Side Installation: 1. Raise and block the right side of the tractor. 2.
- Page 21 11.Put a film of grease on the axle splines. Slide the wheel hub on the axle followed by a flat washer and lock nut. Tighten the nut to a torque of 80 ft.-lb. (108 Nm). Tighten the set screw. 12.Mount the tire assembly to the wheel hub. Left Side Installation: 1.
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Page 22: Power Take Off Control
6.4 POWER TAKE OFF CONTROL 1. Tie Rod 5. Lock Nut 2. Ball Joint 6. PTO Bellcrank 3. Jam Nut 4. Flat Washer Figure 15 Figure 16 1. Thread jam nut onto PTO shaft (supplied). Thread ball joint (supplied) onto PTO shaft until overall length of shaft and ball joint is 17.00 inches, Figure 16. -
Page 23: Section 7 - Drive Train
7.1 TRANSMISSION TROUBLE ANALYSIS The following troubleshooting chart is to be used to isolate hydro transmission problems and give possible causes and corrective action responses. TROUBLE Axles Will Not Turn Difficult Starting Erratic Running Jerky When Starting Jumps Out of Gear Knocking Loss of Power or System Noisy... -
Page 24: Clutch Adjustment
Before assuming that internal transmission problems exist, check all external linkage. Inspect the shifting linkage beginning with the control lever and work towards the transmission. Check for binding. Look for broken or missing cotter pins and sheared keys. 7.2 CLUTCH ADJUSTMENT Clutch adjustment is necessary anytime clutch slippage occurs. -
Page 25: Differential
To avoid damage to the rear pin plate bushing, it is not recommended that planetary system be further disassembled unless definite problems exist. If an unreasonable amount of play is noticed in the system: 1. Inspect orbit gear pins and bushings for wear. 2. - Page 26 10.Remove the differential assembly from the tractor. 11.Using wire cutters, remove wire securing bolts on each side of worm gear. Secure differential assembly upright in vise. (4 Speed Swiftamatic only). 1. Race Bearing 10.Differential Bevel Gear 2. Cone Bearing 11.Pinned Bevel Gear 3.
- Page 27 Figure 25 18.Install the pinned gear and differential gear on the pinned housing and install it on the worm gear. Use new drilled bolts (4 Speed Swiftamatic); clean bolts and apply a stud locking preparation to the bolt threads. Torque bolts to 17-20 ft-lbs (23 - 27 Nm) 19.Turn worm gear over and install the clutch housing, with differential gear, shifting gear and shims on the worm gear.
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Page 28: Power Take Off (Pto)
4-Speed Right Hand Axle 1. Stationary Pivot 6. Seal 2. O-Ring 7. Shifting Clutch 3. Shifting Yoke 8. Stationary Clutch 4. Clutch Sliding Pin 9. 2-Speed Axle Housing 5. Straight Axle Figure 28 23.Place equal amount of shims and a shellacked gasket on each axle housing. -
Page 29: Section 8 - Fuel System
8.1 FUEL SYSTEM TROUBLESHOOTING The following troubleshooting chart is to be used to isolate fuel system problems and give possible causes are corrective action responses TROUBLE Hard Starting Fuel Leak at Carburetor Engine Floods Will not idle Rich idle Idles with Needle Closed Hunts Erratic Idle Idles Fast Lean Will Not Accelerate... -
Page 30: Fuel Pump
8.2 FUEL PUMP The impulse style fuel pump is the most commonly used fuel pump. Impulse fuel pumps may either be mounted externally onto the carburetor fuel inlet or remotely mounted. These pumps are connected in the fuel line between the fuel supply and the carburetor or directly to the fuel inlet. -
Page 31: Section 9 - 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 32: Safety Interlock System
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 33 7. Replace the vent caps. It is not necessary to tighten more than finger tight. 8. Wash off the battery to remove electrolyte which may have spilled. Battery Electrolyte First Aid External contact: Flush with water. Eyes: Flush with water for at least 15 minutes and get medical attention immediately! Internal contact: Drink large quantities of water.
- Page 34 Specific Gravity Check The specific gravity should be checked with a hydrometer. NOTE: The specific gravity should be checked in each cell and should be the same for all cells. A variation in a cell reading could be an indication of a problem. Sub- tract .004 from 1.265 for each 10 or add .004 to 1.265 for each 10 A special temperature compensated hydrometer is...
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Page 35: Switches
gravity. Before reinstalling the battery in the spring, it should always be fully recharged. 9.5 SWITCHES Switches either open a circuit to stop current flow or close and allow current to flow through. A normally open (N.O.) switch prevents current flow until the switch is actuated, completing the circuit and allowing current to flow through it. -
Page 36: Fuses
There are also a number of mechanical problems that may cause the problem. The starter solenoid in the Gravely equipment is a sealed unit used to actuate the starter motor on the engines. These solenoids may have three or four connections. -
Page 37: Wiring Diagram
9.9 WIRING DIAGRAM Briggs & Stratton Engine and Kohler Engine 1. Steering Brake Harness 2. Handlebar Wiring Harness 3. Switch 7. Hourmeter 4. Solenoid 8. Ignition Switch 5. Wiring Harness 9. Fuse 6. Relay 10.Interlock Open Switch 9 -37 Robin Engine... -
Page 38: Continuity Diagram
9.10 CONTINUITY DIAGRAM 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 (03602300) Handlebar Switch (08828300) HAND ON HANDLE PTO Switch (08571800) ENAGED DISENGAGED... -
Page 39: Hp Electric Start - Kohler
9.11 12 HP ELECTRIC START - KOHLER 9 -39... -
Page 40: Hp Manual Start - Kohler
9.12 8 HP MANUAL START - KOHLER 9 -40... -
Page 41: Hp Electric Start - Kohler
9.13 8 HP ELECTRIC START - KOHLER 9 -41... -
Page 42: Hp Electric Start - Briggs
9.14 16 HP ELECTRIC START - BRIGGS 9 -42... -
Page 43: Robin Engines
9.15 ROBIN ENGINES 9 -43... - 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...
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