Gravely Promaster 400 - Default Chapter; Table of Contents

2
Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-3
1.1 The Manual. . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Service And Replacement Parts. . . . . . . . . 1-3
1.3 Product Registration . . . . . . . . . . . . . . . . . . 1-3
1.4 Unauthorized Replacement Parts. . . . . . . . 1-3
1.5 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Technical Service Communications . . . . . . 1-3
Section 2 - Safety. . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Signal Words. . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Notations. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Practices And Laws . . . . . . . . . . . . . . . . . . 2-4
2.5 Required Operator Training . . . . . . . . . . . . 2-4
2.6 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.7 Service Position . . . . . . . . . . . . . . . . . . . . . 2-4
2.8 Cleaning And Storage. . . . . . . . . . . . . . . . . 2-4
2.9 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.10 Clean Unit. . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Section 3 - Specifications . . . . . . . . . . . . . . . . . 3-8
Section 4 - General Maintenance
& Adjustments . . . . . . . . . . . . . . . . . . . . . . 4-11
4.1 Controls And Features . . . . . . . . . . . . . . . 4-11
4.2 Filling The Fuel Tank. . . . . . . . . . . . . . . . . 4-12
4.3 General Lubrication . . . . . . . . . . . . . . . . . 4-12
4.4 Transmission Neutral . . . . . . . . . . . . . . . . 4-13
4.5 Tires And Wheels . . . . . . . . . . . . . . . . . . . 4-13
4.6 Adjust Direction Control Pedal . . . . . . . . . 4-14
4.7 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.8 PTO Clutch Adjustment . . . . . . . . . . . . . . 4-15
Section 5 - Engine . . . . . . . . . . . . . . . . . . . . . . 5-17
5.1 Engine Troubleshooting . . . . . . . . . . . . . . 5-17
5.2 Checking The Engine Oil . . . . . . . . . . . . . 5-18
5.3 Changing The Engine Oil . . . . . . . . . . . . . 5-18
5.4 Engine Cooling System . . . . . . . . . . . . . . 5-18
5.5 Engine Removal . . . . . . . . . . . . . . . . . . . . 5-19
5.6 Engine Installation . . . . . . . . . . . . . . . . . . 5-20
Section 6 - Drive Train . . . . . . . . . . . . . . . . . . . 6-21
6.1 Hydraulic Schematic. . . . . . . . . . . . . . . . . 6-21
6.2 Priming The Transmission . . . . . . . . . . . . 6-22
6.3 Transmission Cooling System . . . . . . . . . 6-22
6.4 Transmission Oil Filter . . . . . . . . . . . . . . . 6-22
6.5 Flywheel And Pto Drive Shaft Removal . . 6-22
6.6 Transmission Troubleshooting . . . . . . . . . 6-23
6.7 Transmission Implement Pressure Check 6-24
6.8 Sunstrand Transmission Removal . . . . . . 6-24
6.9 Sunstrand Transmission Minor Repairs . . 6-25
6.10 Sunstrand Transmission Major Repair . . 6-26
6.11 Sunstrand Transmission Installation . . . . 6-29
6.12 Transaxle Troubleshooting . . . . . . . . . . . 6-30
6.13 Transaxle Removal. . . . . . . . . . . . . . . . . 6-31
6.14 Transaxle Repair. . . . . . . . . . . . . . . . . . . 6-32
6.15 Transaxle Installation . . . . . . . . . . . . . . . 6-35
6.16 PTO Gearbox Removal. . . . . . . . . . . . . . 6-35
6.17 PTO Gearbox Repair . . . . . . . . . . . . . . . 6-36
6.18 PTO Gearbox Installation . . . . . . . . . . . . 6-36
Section 7 - Steering & Controls . . . . . . . . . . . 7-37
7.1 Power Steering Schematic . . . . . . . . . . . . 7-37
7.2 Power Steering System Troubleshooting . 7-37
7.3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . 7-38
7.4 Steering Box Removal . . . . . . . . . . . . . . . 7-39
7.5 Steering Box Installation . . . . . . . . . . . . . . 7-39
7.6 Steering Cylinder Removal . . . . . . . . . . . . 7-39
7.7 Steering Cylinder Installation . . . . . . . . . . 7-39
7.8 Tie Rod Adjustment. . . . . . . . . . . . . . . . . . 7-39
Section 8 - Lift System. . . . . . . . . . . . . . . . . . . 8-40
8.1 Lift System Schematic . . . . . . . . . . . . . . . 8-40
8.2 Hydraulic Lift System Troubleshooting . . . 8-41
8.3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . 8-41
8.4 Hydraulic Lift Valve Removal . . . . . . . . . . 8-42
8.5 Hydraulic Lift Valve Installation . . . . . . . . . 8-42
8.6 Hydraulic Valve Adjustment . . . . . . . . . . . 8-43
8.7 Hydraulic Lift Cylinder Removal . . . . . . . . 8-43
8.8 Hydraulic Lift Cylinder Installation. . . . . . . 8-43
Section 9 - Fuel System. . . . . . . . . . . . . . . . . . 9-44
9.1 Fuel Injector Pump . . . . . . . . . . . . . . . . . . 9-44
9.2 Fuel System Priming. . . . . . . . . . . . . . . . . 9-44
9.3 Fuel System Contamination . . . . . . . . . . . 9-44
9.4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
Section 10 - Electrical . . . . . . . . . . . . . . . . . . 10-45
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
10.2 Electrical Measurements. . . . . . . . . . . . 10-45
10.3 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
10.4 Switches . . . . . . . . . . . . . . . . . . . . . . . . 10-48
10.5 Solenoid And Relays. . . . . . . . . . . . . . . 10-48
10.6 Lighting Circuits . . . . . . . . . . . . . . . . . . 10-49
10.7 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
10.8 Diodes And Rectifiers . . . . . . . . . . . . . . 10-49
10.9 Engine Electrical Component Check Out10-50
10.10 Continuity DiagramS. . . . . . . . . . . . . . 10-52
10.11 Wiring Diagrams . . . . . . . . . . . . . . . . . 10-53
Section 11 - Four Wheel Drive Assist. . . . . . 11-56
11.1 Four Wheel Assist Hydraulic Schematic 11-56
11.2 Four Wheel Assist Wiring Schematic . . 11-57
11.3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . 11-57
11.4 Manifold Removal . . . . . . . . . . . . . . . . . 11-58
11.5 Manifold Installation . . . . . . . . . . . . . . . 11-58
11.6 Wheel Motor Removal. . . . . . . . . . . . . . 11-58
11.7 Wheel Motor Installation . . . . . . . . . . . . 11-58
11.8 F/W/A On, Off, Reverse Switch. . . . . . . 11-58
11.9 Reverse Safety Switch . . . . . . . . . . . . . 11-58
Section 12 - Mower Deck. . . . . . . . . . . . . . . . 12-59
12.1 Service And Replacement Parts. . . . . . 12-59
12.2 Specifications . . . . . . . . . . . . . . . . . . . . 12-59
12.3 Installation And Removal . . . . . . . . . . . 12-60
12.4 Lubrication And Maintenance . . . . . . . . 12-60
12.5 Height Of Cut Adjustment . . . . . . . . . . . 12-60
12.6 Cleaning And Storage. . . . . . . . . . . . . . 12-61
12.7 Spindle Repair (greasable) . . . . . . . . . . 12-62
TABLE OF CONTENTS