Gravely 985109 manual

Ser vice Man ual Models 985103,104, 105, 107 - 115, 117 Pr of essional 2-Wheel T ractor 08483800 08/00 Printed in USA[...]

2 Section 1 - Introduction . . . . . . . . . . . . . . . . . . . 1-3 1.1 The Manu al . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.2 Serv ice And Rep lacement Parts . . . . . . . . . 1-3 1.3 Produc t Registration . . . . . . . . . . . . . . . . . . 1-3 1.4 Unautho rized Repla cement Parts . . . . . . . . 1-3 1.5 Disclai mer . . . . . . . [...]

1 -3 1.1 THE MANUAL The purpos e of this ma nual is t o provide c omplete instruc tions for ser vice, mai ntenance, disassemb ly , repair , a nd instal lation of the mecha nical comp onents for the unit. Dealer trai ned servi ce personnel should u se this manual as a suppl ement to an d reminder of the train ing sessi ons condu cted by t he compan [...]

2 -4 1.7 PREP ARATION Before s tarting any removal o f parts, p roper preparatio n is very impo rtant for efficient work. A clean work area at the start o f each job will all ow you to perform s ervice repai rs easily and quick ly . T o reduce the inci dence of m isplace d tools o r parts, place remov ed compon ents with all at taching har dware in[...]

2 -5 Learn the locatio n and func tion of all controls. Learn ho w to use the controls to stop the whee ls and attach ment quic kly in an e mergenc y . Understa nd and follow each dang er , warnin g, caution and instr uction dec al insta lled on th is product. Never pe rmit chil dren to op erate the T wo-Wheel T ractor . Do not allow a dults to ope[...]

3 -6 SECTION 3 - SPECIFICATIONS Model Nu mber 985103 985104 985105 985107 Description 8HP Gear Drive 8HP Gear Drive 8HP Gear Drive 12 HP Gear Drive Brakes Optional, individual, 7" (17.8 cm) x 1.75" (4.4 cm) drum type Steering Manual, optional power steering kit available T urning Radi us Zero (with steering kit) Minimum Uncut Circle Zero [...]

3 -7 Model Nu mber 985108 985109 9851 10 9851 1 1 Description 12HP Gear Drive 16HP Gear Drive 8HP Gear Drive 8HP Gear Drive Brakes Optional, individual, 7" (17.8 cm) x 1.75 (4.4 cm) drum type Steering Manual, optional power steering kit available T urning Radi us Zero (with steering kit) Minimum Uncut Circle Zero Optional T ire Sizes -Stud T r[...]

3 -8 Model Nu mber 9851 12 9851 13 9851 14 9851 15 Description 12 HP Gear Drive 12 HP Gear Drive 16 HP Gear Drive 8.5 HP Gear Drive Brakes 7 x 1.75" Drum Type N/A Steering Manual, optional power steeri ng kit available T urning Radi us Zero (with steering kit) Minimum Uncut Circle Zero Optional T ire Sizes -Stud T read 4.00-8 4.00-8 4.00-8 4.0[...]

3 -9 Model Nu mber 9851 17 Description 13.5 HP Gear Drive Brakes 7 x 1.75" Drum T ype Steering Manual, optional power steering kit available T urning Radi us Zero (with steering kit) Minimum Uncut Circle Zero Optional T ire Sizes -Stud T read 4.00"-8" -T rac T read 4.00"-8" -T urf -Chie f 18" x 6.50"-8" -T ur[...]

4 -10 4.1 CONTROLS AND FEATURES 4.2 FILLING THE FUEL T ANK Add fu el to the fu el tank as needed. See your en gine manual fo r the correc t type and grade of fuel. Put the un it in an op en area. S top the en gine and l ock the brak e. Clean th e fuel cap an d the area around th e fuel cap to p revent dirt from entering the fuel tank. Remove th e c[...]

4 -1 1 4.3 GENERAL LUBRICATION Control Linkage Lubrication Every 2 5 hours of operati on put a drop o f engine oi l on the pivot s of the throttle le ver , the direct ion control leve r , the ge ar shift lev er , the PT O contro l, and ra nge shift handle. NOTE: There are n o grease fittings on t he tracto r . T ransmission Capacity: 5 U.S. Quarts [...]

4 -12 • T o adjust th e forward c lutch, pu t the directi on control in the for ward pos ition. Lo osen the c ontrol extension rod rear set of jam n uts on the fwd-rev control rod. Adjus t the forwa rd nut until the larg e spring coils a re .010" (.254mm) a part. Hold the forward nut and jam with the rea r nut. 4.5 HI/LOW GEAR CLUTCH ADJUSTM[...]

4 -13 4.7 PT O BRAKE ADJUSTMENT • Adjust t he PT O brake a fter every 100 hours o f operatio n. • Remove the attachme nt and lower t he rear of the tractor to the ground. Ca refully clea n the front of the trans mission. R emove the quick hitch stud s from the t ransmis sion and r emove the quick h itch cast ing and PTO brake assembly (Figure 5[...]

4 -14 4.8 SLIP CLUTCH ADJUSTMENT • Adjust t he slip clutc h after ever y 100 hou rs of operatio n. • Remove the attachme nt and lower t he rear of the tractor to the ground. Ca refully clea n the front of the trans mission. R emove the quick hitch stud s from the t ransmis sion and r emove the quick h itch PT O assemb ly and PTO brak e assemb l[...]

5 -15 5.1 ENGINE T ROUBLESHOOTING The followi ng troubles hooting c hart is to b e used to isolate engine probl ems and give pos sible causes and corr ectiv e act io n re sp onse s. The trouble shooting key is generic and can be us ed for sever al types of e ngines. Use only thos e possibl e causes and correcti ve actions th at apply t o the unit. [...]

5 -16 5.2 CHE CKING ENGI NE OIL Check the engine oi l daily prior to u se. IMPORT ANT : Never opera te the engi ne with the oil below the l ow mark on the dipstick . See th e engine m anual for oil spe cification s and oil filter s ervice i nstruct ions. T o check oil leve l: 1. Move the unit to lev el loca tion. 2. Clean arou nd the dipstick and f[...]

5 -17 5.5 ENGINE REMOVAL AND INSTALLATION 1. Remove gr ound cable from batte ry . 2. D rai n T ransmis sion oil . 3. T urn off fuel at fuel tank . Remove fu el line fro m fuel pump. 4. R emo ve the choke cabl e fr om ca rbur eto r . 5. Remove the throttle cable from the link age. 6. Separate wiring harne ss at co nnector 7. Remove c able from s tar[...]

6 -18 6.1 HANDLEBAR ASSEMBLY 1. On Swift amatic trac tors, disc onnect the c otter pin that holds the Swiftama tic control l ever to the shifter weldment. D isconnect the extens ion sprin g from the c ontrol lever and s lide the control lever rearward u ntil it stop s agains t the inst rument pan el. See F igu re 10 . 2. Positio n the handl ebar ri[...]

6 -19 6.2 STEERING BRAKES (OPTIONAL) The steering b rake is des igned to st op one wheel f rom rotating . The opposite wheel co ntinues to driv e forward and the uni t pivots on the stoppe d wheel. Connect th e adjustm ent bracke t to the cam lever arm with a cl evis pin. 1. Park th e tractor in a level area . Put the p arking brake handle in the &[...]

6 -20 Fasten the i nstructio n plate an d the brake h andle brackets to th e rear hitch with the 1/2-1 3 x 2.00 bolts and 1/2" l ock nuts. Right Side Instal la tion: 1. Raise and block the r ight side o f the trac tor . 2. Unbolt the tire assem bly from th e wheel hub and remove. 3. Remove the axle nut , flat wash er and spac er . Remo ve th e[...]

6 -21 1 1. Put a film of gr ease on th e axle spline s. Slide the wheel hub on the axl e followed by a flat was her and lock nut. Tighten the nut to a torq ue of 80 f t.-lb. (108 Nm). Tighten the set s crew . 12.Mount th e tire ass embly to t he wheel hu b. Left Side Instal lation: 1. Raise and block the l eft side of the tractor. 2. Unbolt the tir[...]

6 -22 6.4 POWER T AKE OFF CONTROL 1. Thread ja m nut onto PTO shaft (s upplied). Th read ball joi nt (suppli ed) onto PTO shaft unti l overall length of shaft an d ball jo int is 1 7.00 inch es, Figure 16 . 2. Install r od/ball joint as sembly onto tractor , Figure 15 . 3. Start unit and test operatio n of PT O. T est to ensure that all i nterlocks[...]

7 -23 7.1 T RANSMISSION T R OUBLE ANALYSIS The followi ng troubles hooting c hart is to b e used to isolate hydro tran smissi on problem s and g ive possi ble causes and correcti ve action r esponses . The trouble shooting key is generic and can be us ed for sever al types of transm issions. Use on ly those possible c auses and corr ective acti ons[...]

7 -24 Before ass uming tha t internal transm ission problems exist, c heck all e xternal linkage . Inspect the shifti ng linkage beginnin g with the con trol lever and work towards the transmis sion. Chec k for bindi ng. Look fo r broken or miss in g cotte r pin s and shear ed keys . 7.2 CLUTCH ADJUSTMENT Clutch ad justment is necess ary anytim e c[...]

7 -25 T o avoid da mage to the rear pin p late bush ing, it is not recomm ended that p lanetary s ystem be fur ther disass embled un less de finite pr oblems e xist. If an unre asonable amount of p lay is notice d in the syste m: 1. Inspect o rbit gear p ins and bus hings for w ear . 2. Inspect t he orbit gear carrier b ushing for wear . 3. Check f[...]

7 -26 10.Remove the differenti al assembl y from th e tractor . 1 1. Us ing wire cutters, r emove wir e securi ng bolts on each si de of worm gea r . Sec ure differential assembl y upright i n vise. ( 4 Speed Sw iftamatic only). 12.Remove bolts s ecuring cl utch housi ng to worm gear . Re move cl utch hous ing, gears, and sh ims. 13.T urn worm gear[...]

7 -27 18.Instal l the pinn ed gear and d ifferential ge ar on the pinned h ousing a nd insta ll it on th e worm gear . Use new drilled bo lts (4 Spe ed Swiftama tic); clean b olts and apply a stud l ocking pr eparation to the bolt threads. T orque bolts to 1 7-20 ft-lbs (23 - 27 Nm) 19.T u rn worm gear over and inst all the c lutch hou sing, with d[...]

7 -28 23.Plac e equal am ount of shims and a sh ellacked gasket o n each axle housing. Install L .H. axle housing and differen tial assem bly in trac tor . Se cure axle hou sing to trac tor . 24.Instal l R.H. axle housing on tractor , being sur e the shifting clutch fits on the sh ifting gea r . Sec ure axle housing to tractor . T orque bolts to 45[...]

8 -29 8.1 FUEL SY STEM T R OUBLESHOOTING The followi ng troubles hooting c hart is to b e used to isolate fu el system prob lems and gi ve possible c auses are corr ective a ction resp onses The trouble shooting key is generic and can be us ed for sever al types of transm issions. Use on ly those possible c auses and corr ective acti ons that apply[...]

8 -30 8.2 FUEL P UMP The impuls e style fuel pump is the mo st commo nly used fuel pump. Impu lse fuel pum ps may e ither be mounted ex ternally onto the ca rburetor f uel inlet or remotely mounted. These pumps a re conne cted in th e fuel line between the fuel supply and the c arburetor or directly to the fuel inlet. Impulse fuel pumps are opera t[...]

9 -31 9.1 T OOLS There are s ome spec ialized tools and te st equipm ent that are n eeded for electrical r epair wor k. A brief descripti on of these fo llows. Long or needle nose pliers - us ed to connect or bend wires a nd connectors in clos e quarters. Diagonal cutters - use d to cut wi res or trim conne ctions. Wire stripper/crimping tool - ava[...]

9 -32 V oltage Measurement There are two basic rul es to be rem embered when using a v oltmeter . A voltme ter measur es the volta ge difference betwee n the te st leads and the voltm eter is always con nected ac ross the circ uit under te st. Current Measurement The two rul es to remem ber when m easuring c urrent with an amm eter ar e; an ammet e[...]

9 -33 7. Replace t he vent caps . It is no t necessary to tighten mo re than fi nger tight. 8. W a sh off the battery to rem ove electrol yte which may hav e spille d. Battery Electrol yte First Aid External contact: Flus h with water . Eyes: Fl ush with water for at leas t 15 minutes and get medical attention immediately ! I nternal contact: Drin [...]

9 -34 Specific Gravi ty Check The specif ic gravity should b e checked wi th a hydrome ter . NOTE: The specif ic gravity s hould be ch ecked in each cell an d sho uld be the sam e for al l ce lls. A variation in a cell r eading co uld be an indicati on of a pr oblem. Su b- tract .004 from 1.26 5 for each 10 o F be low 80 o F (27 o C) or add .0 04 t[...]

9 -35 gravity . Befo re reinsta lling the battery in the spring, it should a lways be fully rechar ged. 9.5 SW ITCHES Switches either ope n a circuit to stop cur rent flow or close a nd allow cur rent to flow through. A normall y open (N.O .) switch prev ents curren t flow until the switch i s actuated, c ompletin g the circuit and allowing current[...]

9 -36 If a rel ay or sol enoid fails to o perate, t he cau se may be either e lectrical or mechanic al. T o ch eck elec tric ally , conn ect a v oltmeter acro ss the coil of t he device a nd activ ate the circui t that oper ates the r elay or so leno id. I f the met er indi cates no vo lt ag e is appli ed, the cause is i n the con trol ci rcuit. If[...]

9 -37 9.9 WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 1. Steering Brak e Harness 2. Handleba r Wiring Harness 3. Swi tch 4. Sole noid 5. Wiring Harnes s 6. R elay 7. Hourme ter 8. Ignition Switc h 9. Fuse 10.Interlo ck Open Switch Robin Eng ine Briggs & Stratt on Engine and Kohler Eng ine[...]

9 -38 9.10 CONTINUITY DIAGRAM OFF M G S2 B S1 A RU N M G S2 B S1 A ST ART M G S2 B S1 A Ke y Switch (03602300) DISENGA GED (button in) Handlebar Switch (08828300) 1 2 HAND ON HANDLE 1 2 HAND OFF HANDLE Relay (03042800) 87 87A 86 85 30 NO T ENERGIZED 87 87A 86 85 30 ENERGIZED PTO Switc h (08571800) ENA GED (button out) 1 2 1 2 FWD/REV Switch (085719[...]

9 -39 9.1 1 12 HP ELECTRIC START - KOHLER[...]

9 -40 9.12 8 HP MANUAL STAR T - KOH LER[...]

9 -41 9.13 8 HP ELECTRIC START - KOHLER[...]

9 -42 9.14 16 HP ELECTRIC START - BRIGGS[...]

9 -43 9.15 ROBIN ENGINES[...]

Gravely A divisi on of Ari ens Co mpany 655 W est Ryan Street P .O. Box 157 Bri llion , WI 54 1 1 0-015 7 920-756-2 141 Fax 920-7 56-2407 www .gravely .com[...]