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Gravely Promaster 100 User Manual

Gravely Promaster 100
80 pages
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Promaster 100/160/200
08484400 08/00
Printed in USA
Service Manual
Models 991001-008, 992006-016, 992301-304

Table of Contents

Questions and Answers:

Gravely Promaster 100 Specifications

General IconGeneral
BrandGravely
ModelPromaster 100
CategoryLawn Mower
LanguageEnglish

Summary

SECTION 1 - INTRODUCTION

1.1 THE MANUAL

Overview of the service manual's purpose and usage guidelines.

1.2 SERVICE AND REPLACEMENT PARTS

How to order parts and make inquiries using unit numbers.

1.3 PRODUCT REGISTRATION

Information on warranty activation via registration card.

1.4 UNAUTHORIZED REPLACEMENT PARTS

Warning against using non-Gravely parts and warranty implications.

1.5 DISCLAIMER

Gravely's right to change products without notice.

1.6 TECHNICAL SERVICE COMMUNICATIONS

How Gravely communicates technical updates to dealers.

SECTION 2 - SAFETY

2.1 SAFETY ALERTS

Explains symbols for important safety precautions and warnings.

2.2 SIGNAL WORDS

Defines DANGER, WARNING, and CAUTION signal words for hazard levels.

2.3 NOTATIONS

Explains NOTE and IMPORTANT notations used in the manual.

2.4 PRACTICES AND LAWS

General safety precautions and awareness of local laws.

2.5 REQUIRED OPERATOR TRAINING

Emphasizes training for new operators and manual provision.

2.6 PREPARATION

Guidelines for preparing the work area and gathering tools before service.

2.7 CLEANING AND STORAGE

Proper procedures for cleaning and storing the unit.

2.8 SAFETY RULES

Walk-around inspection, work area safety, and general operating rules.

SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS

4.1 CONTROLS AND FEATURES

Identifies and describes key controls and features of the unit.

4.2 FILLING THE FUEL TANK

Step-by-step instructions for safely refueling the unit.

4.3 GENERAL LUBRICATION

Schedule and procedure for lubricating pivot points and fittings.

4.4 HYDRAULIC FLUID LEVEL

Procedure for checking and maintaining the hydraulic fluid level.

4.5 TENSIONING THE HYDRO PUMP BELT

Instructions for adjusting the tension of the hydro pump belt.

4.6 STEERING CONTROL NEUTRAL ADJUSTMENT

Procedure to correct steering creep by adjusting neutral position.

4.7 T-BAR CONTROL LEVER ALIGNMENT

Steps to align T-bar control levers for proper neutral positioning.

4.8 CHECK THE TIRES

Recommended tire pressure for front and rear tires.

4.9 ADJUSTING THE UNIT TO TRACK STRAIGHT

Methods for adjusting tire pressure and lever orientation.

4.10 LEVELING THE MOWER DECK

Steps for adjusting deck level front-to-rear and side-to-side.

4.11 ADJUSTING MOWER BELT

Procedure for setting the correct tension on the mower belts.

SECTION 5 - ENGINE

5.1 ENGINE TROUBLESHOOTING

Chart for diagnosing engine problems with causes and actions.

5.2 CHECKING ENGINE OIL

Daily procedure for checking engine oil level.

5.3 CHANGING OIL FILTER

Guidance on replacing the oil filter during maintenance.

5.4 AIR CLEANER

Information on the type and maintenance of the air cleaner element.

5.5 CHECK SPARK PLUG

Procedure for inspecting and replacing spark plugs.

5.6 ENGINE REMOVAL AND INSTALLATION

Step-by-step guide for removing and reinstalling the engine.

SECTION 6 - COOLING SYSTEM KAWASAKI ENGINES

6.1 RADIATOR HOSES

Inspection of radiator hoses for wear and damage.

6.2 RADIATOR AND RADIATOR CAP

Checking the radiator and cap for dirt, damage, and proper sealing.

6.3 COOLING FAN AND DRIVE BELT

Inspection of fan blades, belt condition, and tension.

6.4 COOLANT CHANGE

Recommendation for coolant replacement intervals by authorized dealers.

SECTION 7 - MOWER DECK

7.1 REPLACING MOWER BELT

Detailed procedure for replacing mower belts.

7.2 MOWER BLADE

Safety and procedure for checking, sharpening, and balancing mower blades.

7.3 ROLLERS

Procedure for disassembling, cleaning, and greasing mower deck rollers.

7.4 50" MOWER, PROMASTER 100 & 160

Specific instructions for mower removal and spindle service.

7.5 50" AND 60" MOWER, PROMASTER 200

Instructions for removing the mower deck assembly.

SECTION 8 - MOWER LIFT SYSTEM

8.1 MOWER FRAME

Procedure for removing the mower frame assembly.

8.2 CHECK CASTER WHEELS FOR WEAR

Steps to inspect and replace caster bushings.

8.3 TO REPLACE WHEEL AXLE

Instructions for removing and replacing wheel axles.

8.4 LINKAGE

Procedure for inspecting and replacing lift linkage bushings.

8.5 HYDRAULIC SYSTEM

General information about the mower lift hydraulic system components.

SECTION 9 - STEERING AND DIRECTION CONTOLS

9.1 STEERING AND DIRECTION CONTROLS

Procedure for adjusting steering rod and neutral weldment.

SECTION 10 - DRIVE TRAIN

10.1 TRANSMISSIONTROUBLESHOOTING

Chart for diagnosing hydro transmission issues.

10.2 REPLACING THE HYDRO PUMP BELT

Steps to replace the hydro pump drive belt.

10.3 PTO CLUTCH REMOVAL

Procedure for removing the PTO clutch assembly.

10.4 PTO BEARING REMOVAL AND INSTALLATION

Steps for servicing PTO clutch bearings.

10.5 PTO CLUTCH INSTALLATION

Reassembly procedure for the PTO clutch.

10.6 IDLER PULLEY

Instructions for removing and inspecting the idler pulley.

10.7 WHEEL AND HUB REMOVAL

Procedure for removing wheels and hubs.

10.8 WHEEL INSTALLATION

Steps for installing wheels and hubs correctly.

SECTION 11 - FUEL SYSTEM

11.1 FUEL SYSTEM TROUBLESHOOTING

Chart for diagnosing fuel system problems.

11.2 FUEL PUMP

Explanation of the impulse-style fuel pump operation.

11.3 FUEL SYSTEM CONTAMINATION

Procedure for addressing fuel system contamination.

SECTION 12 - HYDRAULIC SYSTEM

12.1 RUN-IN PROCEDURE

Steps for running the unit after hydraulic maintenance.

12.2 HYDRAULIC FLOW

Information on hydraulic pressure lines and checks.

12.3 FILTER CHANGE

Procedure for replacing the hydraulic system filter.

12.4 HYDRAULIC HOSES

Safety and procedure for disconnecting/connecting hydraulic hoses.

12.5 HYDRAULIC TANK REMOVAL & INSTALLATION

Steps for removing and reinstalling the hydraulic tank.

12.6 HYDRAULIC COOLER REMOVAL & INSTALLATION

Procedure for servicing the hydraulic oil cooler.

12.7 HYDRAULIC PUMP REMOVAL

Detailed steps for removing the hydraulic pump.

12.8 OVERHAUL SEAL KIT INSTRUCTIONS

Guide for using seal kits to overhaul the hydraulic pump.

12.9 O-RINGS

Procedure for replacing O-rings on check valve plugs and bypass valves.

12.10 SHAFT SEALS

Instructions for replacing lip-type shaft seals on pumps.

12.11 HYDRAULIC MOTOR REMOVAL & REPLACEMENT

Steps for removing and replacing hydraulic motors.

SECTION 13 - ELECTRICAL

13.1 TOOLS

Lists and describes specialized tools for electrical repair.

13.2 ELECTRICAL MEASUREMENTS

Explains basic electrical measurements and meter types.

13.3 BATTERY

Safety precautions and first aid for battery handling.

13.4 CHARGING

Procedure for charging the battery using the unit or a charger.

13.5 SWITCHES

Explains switch types and testing procedures for continuity.

13.6 SOLENOID AND RELAYS

Describes operation and function of solenoids and relays.

13.7 LIGHTING CIRCUITS

Basic troubleshooting for lighting system issues.

13.8 FUSES

Explanation of fuse function and replacement procedures.

13.9 DIODES AND RECTIFIERS

Describes function and testing of diodes and rectifiers.

13.10 ELECTRIC CLUTCH

Explanation and testing of the electric clutch operation.

13.11 CHECKING THE PTO CLUTCH

Procedure for checking PTO clutch coil resistance and current draw.

13.12 CONTINUITY DIAGRAMS

Visual representations of switch and relay connections.

13.13 991000 ELECTRICAL

Installation checkout and electrical checks for specific models.

13.14 992000 ELECTRICAL

Installation checkout and electrical checks for specific models.

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