Gravely Promaster 200 User Manual

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

Gravely Promaster 200 Specifications

General

Brand	Gravely
Model	Promaster 200
Category	Lawn Mower
Language	English

Summary

Safety Information and Precautions

Safety Alerts and Signal Words

Defines DANGER, WARNING, CAUTION and alert symbols.

Required Operator Training

Emphasizes the need for proper training for all operators.

General Safety Rules

Covers inspections, work area, and safe operation practices.

Personal Safety Guidelines

Guidelines for operator awareness, protective gear, and avoiding hazards.

Battery Safety Precautions

Precautions for handling and working near the battery.

Equipment Specifications

Model Specifications (991001-991003)

Detailed specifications for Promaster 100 models 991001, 991002, and 991003.

Model Specifications (991004-991006)

Detailed specifications for Promaster 100 models 991004, 991005, and 991006.

Model Specifications (991007-991008)

Detailed specifications for Promaster 100 models 991007 and 991008.

Model Specifications (992006-992008)

Detailed specifications for Promaster 200 models 992006, 992007, and 992008.

Model Specifications (992009-992011)

Model Specifications (992012-992014)

Model Specifications (992015-992301)

Model Specifications (992302-992304)

General Maintenance and Adjustments

Filling the Fuel Tank Safely

Hydraulic Fluid Level Check

Tensioning the Hydro Pump Belt

Steering Control Neutral Adjustment

Leveling the Mower Deck

Adjusting Mower Belt Tension

Engine Service and Troubleshooting

Engine Troubleshooting Chart

A chart listing common engine troubles, causes, and corrective actions.

Engine Oil and Filter Maintenance

Engine Removal and Installation

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

Cooling System for Kawasaki Engines

Radiator Cap Safety Warnings

Important safety warnings for removing the radiator cap.

Mower Deck Service

Replacing Mower Belt

Mower Blade Maintenance

Guidelines for checking, sharpening, and replacing mower blades.

Mower Removal and Spindle Repair

Mower Removal (50" & 60" Mower)

Mower Spindle Removal

Mower Lift System

Hydraulic Pump Removal and Hoses

Steps for removing the hydraulic pump and managing hoses.

Hydraulic Cylinder Removal

Hydraulic Cylinder Installation

Steering and Direction Controls

Steering Component Servicing

Drive Train Systems

Transmission Troubleshooting Chart

Chart for diagnosing and correcting transmission problems.

Hydro Pump Belt Replacement

PTO Clutch Servicing

Fuel System Operations

Fuel System Troubleshooting

Chart for diagnosing and correcting fuel system problems.

Fuel Pump and Contamination

Hydraulic System Service

Hydraulic System Maintenance Procedures

Covers run-in, filter change, and hose handling.

Hydraulic Tank and Cooler Servicing

Hydraulic Pump Removal

Step-by-step guide for removing the hydraulic pump.

Overhaul Seal Kit Instructions

Hydraulic Pump Disassembly

Hydraulic Motor Removal & Replacement

Steps for removing and replacing the hydraulic motor.

Electrical System Diagnosis

Electrical Measurement Basics

Voltage, Current, and Resistance Measurement

Battery Safety and Handling

Warnings and first aid for battery handling.

Battery Setup and Cleaning

Specific Gravity Check

Battery Charging and Jump Starting

Procedures for charging the battery and jump starting.

Switch Types and Ignition Switch Testing

Solenoids and Relays

Testing Solenoids, Relays, Fuses, Diodes

Electric Clutch Operation and Testing

Description of electric clutch and procedures for testing.

PTO Clutch Checking

Procedure to measure PTO clutch resistance and current draw.

Electrical System Checkout (Models 991000)

Installation checkout steps for 991000 series electrical system.

Switch and Relay Test Values (Models 991005, 006)

Seat Switch, Hourmeter, Lift Switch Test Values (Models 991005, 006)

Electrical System Checkout (Model 99100 Kohler)

Installation checkout steps for 99100 Kohler electrical system.

Switch and Relay Test Values (Model 99100 Kohler)

Electrical System Checkout (Model 99100 Briggs/Stratton)

Installation checkout steps for 99100 Briggs/Stratton electrical system.

Switch and Light Test Values (Model 99100 Briggs/Stratton)

Switch, Relay, Time Delay, Solenoid Test Values (Model 99100 Briggs/Stratton)

Seat Switch Test Values (Model 99100 Briggs/Stratton)

Electrical System Checkout (Model 99200 Briggs/Stratton)

Installation checkout steps for 99200 Briggs/Stratton electrical system.

Switch and Relay Test Values (Models 992010, 011)

Switch, Hourmeter, Oil Light Test Values (Models 992010, 011)

Seat Switch and Time Delay Test Values (Models 992010, 011)

Electrical System Checkout (Model 992000)

Installation checkout steps for 992000 electrical system.

Switch and Relay Test Values (Models 992013-301)

Neutral Switches, Pump Lift, Hourmeter Test Values (Models 992013-301)

Oil Light Test Values (Models 992013-301)

Seat Switch and Time Delay Test Values (Models 992013-301)