Gravely Promaster 100 User Manual

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 Cleaning And Storage. . . . . . . . . . . . . . . . . 2-4
2.8 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.9 Clean Unit. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Section 3 - Specifications . . . . . . . . . . . . . . . . . 3-7
Section 4 - General Maintenance
& Adjustments . . . . . . . . . . . . . . . . . . . . . . 4-15
4.1 Controls And Features . . . . . . . . . . . . . . . 4-15
4.2 Filling The Fuel Tank. . . . . . . . . . . . . . . . . 4-16
4.3 General Lubrication- . . . . . . . . . . . . . . . . . 4-17
4.5 Tensioning The Hydro Pump Belt . . . . . . . 4-17
4.6 Steering Control Neutral Adjustment . . . . 4-18
4.7 T-Bar Control Lever Alignment . . . . . . . . . 4-18
4.8 Check The Tires . . . . . . . . . . . . . . . . . . . . 4-18
4.9 Adjusting The Unit To Track Straight . . . . 4-18
4.10 Leveling The Mower Deck . . . . . . . . . . . 4-19
4.11 Adjusting Mower Belt . . . . . . . . . . . . . . . 4-20
Section 5 - Engine . . . . . . . . . . . . . . . . . . . . . . 5-21
5.1 Engine Troubleshooting . . . . . . . . . . . . . . 5-21
5.2 Checking Engine Oil . . . . . . . . . . . . . . . . . 5-22
5.3 Changing Oil Filter . . . . . . . . . . . . . . . . . . 5-22
5.4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.5 Check Spark Plug. . . . . . . . . . . . . . . . . . . 5-22
5.6 Engine Removal And Installation . . . . . . . 5-22
Section 6 - Cooling System Kawasaki Engines6-23
Section 7 - Mower Deck. . . . . . . . . . . . . . . . . . 7-24
7.1 Replacing Mower Belt. . . . . . . . . . . . . . . . 7-24
7.2 Mower Blade. . . . . . . . . . . . . . . . . . . . . . . 7-24
7.3 Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.4 50" Mower, Promaster 100 & 160. . . . . . . 7-25
7.5 50" And 60" Mower, Promaster 200 . . . . . 7-26
Section 8 - Mower Lift System . . . . . . . . . . . . .8-29
8.1 Mower Frame . . . . . . . . . . . . . . . . . . . . . . 8-29
8.2 Check Caster Wheels For Wear. . . . . . . . 8-29
8.3 To Replace Wheel Axle. . . . . . . . . . . . . . . 8-29
8.4 Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.5 Hydraulic System . . . . . . . . . . . . . . . . . . . .8-29
Section 9 - Steering And Direction Contols. . .9-32
9.1 Steering And Direction Controls . . . . . . . . .9-32
Section 10 - Drive Train . . . . . . . . . . . . . . . . . .10-33
10.1 Transmission Troubleshooting . . . . . . . .10-33
10.2 Replacing The Hydro Pump Belt. . . . . . .10-34
10.3 PTO Clutch Removal . . . . . . . . . . . . . . .10-34
10.4 PTO Bearing Removal And Installation. .10-34
10.5 PTO Clutch Installation . . . . . . . . . . . . . .10-34
10.7 Wheel and Hub Removal . . . . . . . . . . . .10-35
10.8 Wheel Installation . . . . . . . . . . . . . . . . . .10-35
Section 11 - Fuel System. . . . . . . . . . . . . . . . .11-36
11.1 Fuel System Troubleshooting . . . . . . . . .11-36
11.2 Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . .11-36
11.3 Fuel System Contamination . . . . . . . . . .11-36
Section 12 - Hydraulic System . . . . . . . . . . . .12-37
12.1 Run-in Procedure . . . . . . . . . . . . . . . . . .12-37
12.2 Hydraulic Flow . . . . . . . . . . . . . . . . . . . .12-37
12.3 Filter Change . . . . . . . . . . . . . . . . . . . . .12-37
12.4 Hydraulic Hoses . . . . . . . . . . . . . . . . . . .12-37
12.5 Hydraulic Tank Removal & Installation 12-37
12.6 Hydraulic Cooler Removal & Installation.12-37
12.7 Hydraulic Pump Removal . . . . . . . . . . . .12-41
12.8 Overhaul Seal Kit Instructions. . . . . . . . .12-42
12.9 O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . .12-43
12.10 Shaft Seals . . . . . . . . . . . . . . . . . . . . . .12-43
12.11 Hydraulic Motor Removal &
Replacement. . . . . . . . . . . . . . . . . . . . .12-43
Section 13 - Electrical . . . . . . . . . . . . . . . . . . .13-44
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-44
13.2 Electrical Measurements. . . . . . . . . . . . .13-44
13.3 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . .13-45
13.4 Charging . . . . . . . . . . . . . . . . . . . . . . . . 13-47
13.5 Switches . . . . . . . . . . . . . . . . . . . . . . . . .13-48
13.6 Solenoid And Relays. . . . . . . . . . . . . . . .13-48
13.7 Lighting Circuits . . . . . . . . . . . . . . . . . . .13-49
13.8 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . .13-49
13.9 Diodes And Rectifiers . . . . . . . . . . . . . . .13-49
13.10 Electric Clutch. . . . . . . . . . . . . . . . . . . .13-50
13.11 Checking the PTO Clutch . . . . . . . . . . .13-50
13.12 Continuity Diagrams . . . . . . . . . . . . . . .13-51
13.13 991000 Electrical . . . . . . . . . . . . . . . . .13-52
13.14 992000 Electrical . . . . . . . . . . . . . . . . .13-73
TABLE OF CONTENTS

Gravely Promaster 100 Specifications

General

Brand	Gravely
Model	Promaster 100
Category	Lawn Mower
Language	English