Gravely 250Z manual

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2 Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-3 1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . 1 -3 1.2 Ser v ice and R eplacement Par ts . . . . . . . . 1-3 1.3 Product Registration . . . . . . . . . . . . . . . . . 1-3 1.4 Unauthor ized Re placement Par ts . . . . . . . 1- 3 1.5 Disc laimer . . . . . . . . . . .[...]

1 - 3 1.1 THE MANUAL The pur p ose of this m anual is to provide complete instr ucti ons f or ser vice, main tenance, disa ssembly , repair , and install ation of the mechani cal com ponents for the Promaster 260Z and 25 0Z. Dealer trained se rv ice per sonnel sh ould us e this manual as a supple ment to and reminder of the training session s condu[...]

2 - 4 T o reduce the in cidence of misplac ed tools or par ts, place removed components with al l attaching hardware in the d isassembly order on a clean work sur f ace. Organ ization is a ke y par t of pr oper reass embly . T oo ls, instr uments, an d par ts nee ded f or the job should be gather ed bef ore work is star ted. In terrup ting a job to[...]

2 - 5 Ope ratio n Understan d: • How to operate all con trols • The func tio ns of all cont r ols • How to ST OP in an E mergency • Speed ran ges Do not ope rate any of the control l e v ers or power tak e - off unle ss both feet are res ting on the platf or m. DO NOT trav el at too fast a rate. DO NO T c hange engine gov ern or settings or[...]

2 - 6 Storage DO NO T store unit inside a buildi ng with fuel in the fue l tank wher e any ignition s ources are pres ent. All o w unit to cool complete ly . AL W A YS cl ean unit be f ore e xtended s torage. See Engine Manual f or proper storage. Battery A v oid Elec tric S hoc k. DO NO T re v erse batter y connec tions. Explo sive Gases! P oisono[...]

3 - 7 SECTION 3 - SPECIFICATIONS Model N umber 992020 and 02 2 992018 992021 992023 992024 Model PM260Z 25 HP K ohler with 60" d eck PM260Z 25 HP K ohler with 50" d eck PM260Z 22 HP Robin with 50" d eck PM250Z 2 0HP Briggs & Stratton with 50" dec k PM260Z 22 HP Robin with 60" dec k Length - cm (in) 229 (90)* 221 (87) 22[...]

4 - 8 4.1 CONTROLS AND FEA TURES SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1. Mow er Dec k w ith Chute D eflector 2. Fuel Shut Off V alve 3. P arking Br ak e 4. Battery 5. Hour Me ter 6. Oil Pres sure Indicato r 7. Engine F rame and Hood (26 0Z) 8. Fuel T anks and Ca ps 9. Chok e Contro l 1[...]

4 - 9 4.2 SERVICE P OSITIO N - 26 0Z T o ensure the unit is position ed in the pro per ser vice positi on: 1. Place unit on a f lat lev el surface. AL W A YS stop engine. Assur e unit is s ecure and will not tip over . Strap and clamp onto lift if used. 2. Place steer ing lev ers in neutral positi on and se t par king brake. 3. Unhook hood latc hes[...]

4 - 10 When ta king uni t out of extended storage: 1. Check f or any damag e or loose par ts. Repair , replace, or tighten hardware bef ore operati on, espec ially blade attachme nt bolt s. 2. If a pre ser v ative fluid was used in fuel tan k, drain and disc ard. Fill fuel ta nk with fresh n e w fuel. 4.6 FILLING THE FUEL T ANK Add fuel to the tank[...]

4 - 11 4.9 BASIC ENGINE MAINTENANCE See your engin e manual and S ection 5 of this manual for detailed informa tion o n the operation a nd mainten ance of your engi ne. 1. Each d a y bef ore operating, check the lev el of the oil in the engine. Nev er operate the en gine when the oil le v el is below the add m ark. 2. Each d a y bef ore operating, [...]

4 - 12 4.11 TIRES Before each use, ma k e a visua l check of tires. The correc t air pressu re is 12 -15 psi (83- 103 kn/m2) f or the rear tir es, and 20-25 ps i (138-17 2 kn/m2) for the front tires. 4.12 MOWER BLADES NO TE: If mow er is use d under san dy soil co nditions, replace blades when air l ifts becom e eroded through at ends (Figur e 9) .[...]

4 - 13 4.13 STEER IN G CONTROL NEUTRAL ADJUSTMENT If the unit has e xcessive creep w hen the control lev ers are in neutral, adj ust as follows: (Figur e 10) 1. If hydraulic sy stem is co ld, r un unit for a mini mum of five minutes, then shut off unit. 2. M ake sure both contr ol lev ers are in neutral. Ra ise hood (2 60Z). 3. W ith the un it up t[...]

4 - 14 4.15 A DJUSTING THE P ARKING BRAKE 1. The P arking Br ak e ma y be adjus ted thr ough t he use of t he jam nuts o n the brake rod which pu sh agains t the comp ression spr ing which pushes on the cal iper ar m. Se e Figure 11. 2. T ur n the nuts fur th er on the ro d (clockwise) to tighten the brake and fur th er off the ro d (coun terclockw[...]

4 - 15 4.17 LE VELING THE MO WER DEC K These ad justments should be made on a le v el sur f ace with the tires infla ted to the correc t air pressure. The mower is lev eled from s ide to si de with the slots where 4 c hains f asten to the mower mounting b r ackets. The mower is le veled from front to rear by adjust ing the rod r unnin g down each s[...]

5 - 16 5.1 ENGINE T ROUB LESHOOTING The follo wing troubleshooti ng char t is to be u sed to isola te engine pro b lems an d give possible causes and correcti v e actio n respon se s . The troubleshootin g ke y is gener ic and c an be use d f or se ver al type s of en gines. Use onl y those possible causes and correcti v e actio ns that apply to th[...]

5 - 17 5.2 REMOVING THE ENGINE 1. Plac e the m ow er in the f ull s ervice pos i tio n. 2. Di sconnect t he batter y cables, negative first. 3. Di sconnect i gnition w ires using th e connec tors. 4. Re mov e the belts fr om the pulley and clu tch. 5. Un screw the bolt f rom the cente r of the outp ut shaft and rem ov e clutch. Refer to "Repl [...]

6 - 18 6.1 CHECKING THE HYDRAULIC FLUID LEVEL A check of the hydraulic fluid lev el should be m ade dai ly . NO TE: The oil lev el should b e centered b etween the two mar ks on th e dipstick. To C h e c k : Fi rst, remove any dir t that m a y be aroun d the cap on the tank. Remove the dipstick and check the oil lev el. If re quired, a dd Mobil 15W[...]

6 - 19 6.4 REPLACING THE HYDRAULIC PUMP The two hydraulic pumps a re located i nside th e chassis in fron t of the engine. The pum ps are m aintenance fr ee and sho uld be re placed in th e e v ent of a f ailure. See Figure 15. T o R eplace a Hydraulic Pump 1. Li ft cov er to full ser vice po sition. 2. Rem ov e the cros s channel. 3. Cle an hoses [...]

6 - 20 6.5 RE PLACE W HEEL MOT OR Each dr ive wheel is mounted to a hydraulic dri v e motor . The dr iv e motors ar e maintenanc e free. In the e vent of a failure, the drive motors should b e replaced . T o Replace a Drive Motor 1. L oosen the wheel lugs 1/4 tur n. 2. Jack the dr ive wheels off the ground and s ecurely suppor t the un it. 3. Re mo[...]

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6 - 22 6.8 HYDRAULIC DIAGRAM A A B B A A B B A B Lift Cylinder Oil Filter Left Wheel Motor Upper Lower Right Wheel Motor Upper Lower PRESSURE RETURN SUCTION Right Pump Left Pump Oil T ank Deck Lo wer Deck Lift Lift V alve Re verse High Pressure F orward High Pressure Re verse High Pressure F orward High Pressure Return Inlet[...]

7 - 23 7.1 MOWER DEC K Mower Spin dles This uni t utilizes a ma intenanc e free extended life spindl e. No routine mai ntenance is required. In the ev ent of bear ing failure or a bent shaft the s pindle shoul d be r eplac ed. T o Remo ve the Spindle 1. Plac e the u nit in service pos iti on. T urn k ey off an d remove the spar k plug wire from con[...]

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9 - 25 9.1 T OOLS There are some spe cialized tools an d test equipment that are needed for electri cal repai r work. A brief descr iption of these follows. Long or needle nose pliers - used to connect or ben d wires and conne ctors in c lose qu ar ter s. Diagonal cutters - used to cut wires or tri m connec- tions. Wire stripper/crimping tool - ava[...]

9 - 26 V oltage Measurement There are two basic rul es to be rem embered when using a v oltm eter . A voltmeter mea sures th e v olta ge difference between th e test lea ds and the voltmeter i s alwa ys co nnected ac ross the circuit un der test . Current Measurement The two r ules to rem ember wh en measur ing cu rrent with an a mmeter are; an amm[...]

9 - 27 IMPORT AN T : When distil led water is add ed to batter y dur ing freez ing weather , batter y must be charged to mix water with ele ctrolyte, or w a ter will rem ain at top and fre eze . Battery Charger Under n orma l condit ions, the engi ne alter nator will hav e no problem keeping batte r y charg ed. When un it has se t f or an extended [...]

9 - 28 IMPORT AN T : Ch arging at hi gher rates wil l damage the batter y and cause excessive gassin g and aci d spe wing. J ump Starting The unit u sed f or jump star ting sho uld hav e a 12 volt batter y with at le ast 500 cold cranking am peres, and a negatively grounde d system. 1. E nsure batter y i s not frozen. If the fl uid is frozen, remov[...]

9 - 29 Ignition Switc h NO TE: Ref er to the wir ing diagram of the unit inv olv ed to deter m ine switch functions and test u sing the meth - ods de scribed. The ignit ion s witch inco rp orates a number of fun ctions, althoug h not all f unctions ar e used on all equipme nt. The switch has th ree positio ns: OFF , R UN, and a momentar y con tact [...]

9 - 30 functio ning) or th e de vice i s open and is therefore defectiv e. Use an ohmm eter to check for continuity . 9.7 DIODES AND RECTIFIERS Diodes are solid state, semicondu ctor devices. They contai n no moving par ts and c onduct cur rent better in one dir ection than t he other . The y are electr ical "che c k valv es" and per m it[...]

9 - 31 9.8 WIRING DIAGRAMS Models 992018, 020, 021, 022, 024 87a 30 85 86 87 30 85 86 87 WHITE / BLACK ENGINE BLACK BRO WN KEY SWITCH 1 2 BRO WN / YELLOW BLACK RED / VIOLET SEA T SWITCH 12 PINK BLACK PURPLE MA GNETO KILL RED BLACK HOUR METER BLACK PURPLE / WHITE SEA T / PT O RELA Y 3 OIL PRESSURE BLUE / WHITE BRAKE SWITCH 2 1 4 FUSE 30A PTO CLUTCH [...]

9 - 32 Model 992305 87a 30 85 86 87 30 85 86 87 WHITE / BLACK ENGINE BLACK BRO WN KEY SWITCH 1 2 BRO WN / YELLOW BLACK RED / VIOLET SEA T SWITCH 12 PINK BLACK PURPLE MA GNETO KILL RED BLACK HOUR METER BLACK PURPLE / WHITE SEA T / PT O RELA Y 3 OIL PRESSURE BLUE / WHITE BRAKE SWITCH 2 1 4 FUSE 30A PTO CLUTCH 12 PTO SWITCH 4 3 9 1 7 ST AR T RELA Y RE[...]

9 - 33 Model 992023 87a 30 85 86 87 30 85 86 87 WHITE / BLACK ENGINE BRO WN KEY SWITCH 1 2 BRO WN / YELLOW BLACK RED / VIOLET SEA T SWITCH 12 PINK BLACK PURPLE MA GNETO KILL RED BLACK HOUR METER BLACK PURPLE / WHITE SEA T / PT O RELA Y OIL PRESSURE BLUE / WHITE BRAKE SWITCH FUSE 30A PTO CLUTCH 12 PTO SWITCH 4 3 9 1 7 ST AR T RELA Y REGULA T OR FUEL[...]

GRA VEL Y A Division of Ariens Company 655 West Ryan Str eet P .O. Box 157 Brillion, WI 54110-0157 920-756-2141 Fax 920-756-2407 www .gravely .com[...]