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1. 4 12 4 7 Adjusting The Pto Clutch 4 14 4 8 Adjusting The Steering 4 14 4 9 Adjusting Front Wheels 4 15 4 10 Front Wheel Bearings 4 15 4 11 Adjusting The Range Selector 4 15 4 12 Hydraulic 4 15 4 13 Check 4 16 Section 5 5 17 5 1 Engine Troubleshooting 5 17 5 2 Checking Engine 5 18 5 3 Sentry 5 18 5 4 Changing 5 18 5 5 Changing Oil Filter 5 18 5 6 Air 5 18 5 7 Check Spark 5 19 5 8 Engine 5 19 5 9 Adaptor Plate 5 19 5 10 Engine Installation 5 19 Section 6 Steering amp Controls 6 20 Section 7 Lift 7 21 TA Manual 7 21 7 2 Electric Hydraulic 7 21 7 3 Electric Hydraulic Pump Switch 7 22 7 4 Hydraulic 7 22 7 5 Hydraulic Cylinder 7 22 Section 8 Drive 8 23 8 1 Transmission Troubleshooting 8 23 8 2 Checking The Transmission Oil 8 23 8 3 Transmission 8 24 8 4 Tr
2. SECTION 9 FUEL SYSTEM 9 1 FUEL SYSTEM TROUBLESHOOTING The following troubleshooting chart is to be used to isolate fuel system problems and give possible causes are corrective action responses The troubleshooting key is generic and can be used for several types of transmissions Use only those possible causes and corrective actions that apply to the unit TROUBLE Hard Starting POSSIBLE CAUSES Refer to Key Below 1 3 4 6 11 12 14 16 17 18 CORRECTIVE ACTION clean repair or replace Fuel Leak at Carburetor 5 7 17 repair or replace Engine Floods 5 15 17 repair or replace Will not idle 1 2 3 6 repair or replace Rich idle 1 6 14 repair replace idles with Needle Closed 14 repair or replace Hunts Erratic Idle 2 3 6 7 12 13 14 15 18 repair or replace Idles Fast Lean 22321 repair replace Will Not Accelerate 1 6 11 12 14 15 16 repair or replace Over Rich Acceleration 1 15 repair or replace Hesitates 2 6 11 12 16 repair or replace Will Not Run at High Speed 1 11 12 14 16 repair or replace Low Power 1 3 11 14 15 16 17 18 repair or replace Hunts at High Speed 3 6 7 12 14 15 16 18 repair or replace Runs With Needle Closed 14 repair or replace Engine Overspeeds 2 3 7 14 repair or replace TROUBLESHOOTING KEY 1 Plugged Air Filter 2 Leaky Carburetor Gasket 3 Throttle or Choke Shaft Wo
3. a Put the male universal shaft on the PTO shaft Rotate the U joint to 90 and rotate against the unit frame right side b Use a 15 16 wrench to remove the lock nut on the end of the shaft c Pull shaft forward out of the transmission case d Drive out seal and remove bearing bearing races and remove if worn or damaged Use a bearing puller to remove the races f Use the snap ring clamp and snap ring pliers to remove the snap ring 1 2 Sleeve Bushing 3 PTO Spur Gear Figure 17 10 Shaft 161 12 Inspect all parts for wear and damage 13 Replace all worn or damaged parts 8 6 ASSEMBLY OF 10 SHAFT PTO SHAFT 1 If bearings to be replaced secure a complete new bearing set as the parts are matched 2 Put snap ring in the groove and press races from either side using a driver 3 Put cone in front race and press seal into position 4 Put cone spacer bearing cone spacer and gear in position and slide shaft into place 5 Put a hardened washer 33845 next to the gear and secure assembly with new lock nut Use the U joint assembly to hold the shaft 8 7 DISASSEMBLY OF 9 SHAFT ASSEMBLY PTO CLUTCH CAUTION PTO spring is under high pressure Use extreme caution when disassembling 1 Use a bearing puller with long legs in a push puller to compress the spring 2 Compress spring until the clutch cup clears the retaini
4. red middle and blue bottom Install switch into dash reconnect the battery negative terminal first and check operational function of the switch 7 4 HYDRAULIC HOSE Removal CAUTION When hydraulic pump is operated hydraulic fluid is under high pressure To avoid injury disconnect battery negative terminal first prior to working on hoses Clean hydraulic fittings prior to removing hoses Disconnect hydraulic hose s from cylinder end first Disconnect hydraulic hose s from pump end Replace hoses as needed Installation 1 Connect hydraulic hose s to pump first 2 Connect hydraulic hose s to cylinder 3 4 Cycle unit up and down a few times to bleed the Connect battery negative terminal first system Add Dextron or Dextron III to the full line on the reservoir if servicing is needed 7 5 HYDRAULIC CYLINDER Removal CAUTION When hydraulic pump is operated hydraulic fluid is under high pressure To avoid injury disconnect battery negative terminal first prior to working on hoses 6 Clean hydraulic fittings prior to removing the hydraulic hoses Disconnect hydraulic hoses Note orientation of hydraulic hoses Disconnect cylinder from mower lift weldment Note which hole the cylinder is connected to Remove the left side retaining ring from the hydraulic cylinder shaft Support hydraulic cylinder and slide hydraulic
5. INTERLOCK SWITCH BROWN 6 3 6 9 BROWN 4 SOLENOID FWD REV SWITCH INTERLOCK SWITCH RED 1 STARTER MOTOR BROWN IGNITION SWITCH AMMETER LIGHT IMPLEMENT ant LIFT SWITCH fuse HORA BLUE WHITE GREEN WHITE LIGHT LIGHT SWITCH BLACK WHITE GREEN HOURMETER 2 BLACK PINK P Te PURPLE tE DARK WHITE WHITE BLUE Se HEADLIGHTS S ORANGE GREEN _ GREEN YELLOW 870 we RELAY or SEAT 124 30 SWITCH BLACK LT BLU BLK GREEN YELLOW L MODULE YELLOW CONNECTOR IGNITION REGULATOR PURPLE I white 0320 10 42 Model 987071 S N 000101 and Model 987072 S N 000101 000214 TIME DELAY MODULE RELAY ee HEAD LIGHTS M 87 dee 5d GREEN WHITE 5 PINK 1 2 SEAT SWITCH HOUR METER 5 8 8 OIL PRE LIG gt OIL PRESSURE 4 4 BLUE WHITE FUEL YELLOW RED 3 3 RELAY REGULATOR RED 14 ool e 000 MAGNETO KILL 2 2 WHITE BLACK 5 850 5 5 a STARTER FUSE 30 RED A B RED os SOLENOID RED 5 8
6. On 20 5 HP units loosen the jam nuts on the tie rods and rotate the tire rod tube so that the front centerline of the tire is 1 8 to 1 2 closer than the rear centerline and so that the tie rods are the same length Tighten the jam nuts 4 10 FRONT WHEEL BEARINGS 70 gt 1 2 Cone Bearing 3 Cup Bearing Figure 10 64020 CAUTION To prolong bearing life repack the bearings with grease once a year Removal 1 Jack up the front of the unit 2 Remove the caps 3 Remove the nut washer spacer bearing and wheel assembly for each spindle 4 Use apiece of clean bar stock and a hammer to tap out the inside bearing and seal Inspection and Repair 1 Thoroughly clean the wheel hub and other parts 2 Replace any part which is worn or damaged 3 bearing is replaced also replace the bearing cup Use a bearing puller to remove the bearing cups Installation 1 If removed install new bearing cups with a driver Pack the bearings with wheel bearing grease 2 Lay the inside bearing in the cup and press a new seal in place 3 Puta film of grease on the lip of the seal 4 Clean the spindles 5 Slide a spacer on the spindle followed by the wheel assembly 6 Fill the wheel hub cavity with grease Put the outside bearing in the cup followed with a spacer flatwasher and a nut 7 Tighten the nuts back off until the wheel turns freely Replace the caps with the driver 4 11 A
7. clean the area around the oil fill cap or dipstick before removing it 3 Remove the dipstick wipe oil off Reinsert the dipstick and push it all the way down into the tube 4 Remove the dipstick and check the oil level The oil level should be up to but not over the F mark on the dipstick 5 If the level is low add oil of the proper type up to the F mark on the dipstick Always check the level with the dipstick before adding more oil NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick 5 3 OIL SENTRY Some engines are equipped with an optional Oil Sentry oil pressure switch If the oil pressure decreases below an acceptable level the Oil Sentry will either shut off the engine or activate a warning signal depending on the application NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to the F mark on the dipstick This includes engines equipped with Oil Sen try 5 4 CHANGING OIL For a new engine change oil after the first 5 hours of operation Thereafter change oil as shown in the Oil Change Intervals table Oil Change Intervals Oil Type Engine Type Interval Temperature ABOVE 32 F 0 C With Filter 50 Hours SAE 30 Without Filter 25 Hours With Filter 25 Hours Multiviscosity Without Filte
8. lube fittings Order P N 00036800 Three pack of 3 oz cartridges 00036700 ten pack of 14 oz cartridges Add grease until it appears at the ends of the bearings The locations of the seven fittings are On the direction control pedal On the front axle at each king pin On the front axle Figure 2 On the steering mechanism Figure 3 Every 25 hours apply motor oil to all pin connections pivot points and areas where sliding occurs in the clutch transmission PTO and lift control systems Every 25 hours of operation put a drop of engine oil on the pivots of the throttle lever the direction control lever the gear shift lever the PTO control and range shift handle Figure 2 PJ0370 3 1 Grease Fittings for 3 Adjusting Bolt Steering Arms 4 Lock Nut 2 Grease Fittings for Steering Columns 5 Adjusting Nut Figure 3 puns70 4 5 ADJUSTING THE BRAKES Brake service is required if the brake does not stop and hold the tractor effectively the brake should be effective enough to cause the rear wheels to slide if applied suddenly on a concrete or asphalt surface CAUTION Replace the brake band when the lining is as thin as the ignition key Replace the brake drum if it is visibly worn or rough 1 2 Left Hand Brake Rod Figure 4 To adjust the brake 1 Stop the unit on a
9. Front 16x6 5 8 16x6 5 8 16x7 5 8 Rear 23 x 8 5 12 23 x 8 5 12 23 x 10 5 12 16 16 18 Manufacturer Kohler Kohler Kohler Width of Cut 40 102 cm 50 127 cm or 60 152 cm w optional mowers Fuel and Capacity gal L Unleaded 5 3 20 Unleaded 5 3 20 Unleaded 5 3 20 Idle RPM 1600 1600 1600 Governed RPM No Load 3300 3300 3300 Crank Case Capacity oz L 1 75 qt 1 66 L w Filter 1 5 qt 1 42 L w o Filter Oil Filter Yes Air Cleaner Dual element Dual element Dual element Charging Capacity 15 amp 15 amp 15 amp Fuel Filter Yes Yes Yes Engine Oil See Engine Manual See Engine Manual See Engine Manual Spark Plug Gap 0 025 0 025 0 025 Speed Forward Lo Range mph kph 0 1 7 0 2 7 0 1 7 0 2 7 0 1 7 0 2 7 Hi Range mph kph 0 8 5 0 13 7 0 8 5 0 13 7 0 8 5 0 13 7 Speed Reverse Lo Range mph kph 0 3 8 0 6 1 0 3 8 0 6 1 0 3 8 0 6 1 Hi Range mph kph 0 3 8 0 6 1 0 3 8 0 6 1 0 3 8 0 6 1 Drive Clutch Individual forward reverse friction Transmission Lube API Service API Service API Service SC10W 30 Motor Oil SC10W 30 Motor Oil SC10W 30 Motor Oil Transaxle Capacity 6 qt 5 7 L 6 qt 5 7 L 6 qt 5 7 L Tire Pressure Front 14 PSI 18 PSI 14 PSI 18 PSI 14 PSI 18 PSI Rear 14 PSI 16 PSI 14 PSI 16 PSI 14 PSI 16 PSI Lift System Manual 60 Only 60 Only 60 O
10. Incorrectly aligned flywheel and or position flywheel housing 8 Blocked fuel feed line 29 Sticking valves 50 Faulty thermostat 9 Faulty fuel lift pump 30 Incorrect high pressure pipes 51 Restriction in water jacket 10 Choked fuel filter 31 Worn cylinder bores 52 Loose fan belt 11 Battery capacity low 32 Pitted valves and seats 53 Choked radiator 12 Air in fuel system 33 Broken worn or sticking piston ring s 54 Faulty water pump 13 Faulty fuel injection pump 34 Worn valve stems and guides 55 Choked breather pipe 14 Faulty fuel injectors or incorrect 35 Restriction in air cleaner 56 Damaged valve stem oil deflector if type fitted 15 Incorrect use of cold start 36 Worn or damaged bearings 57 Coolant level too low equipment 16 Faulty cold start equipment 37 Insufficient oil in sump 58 Blocked sump strainer 17 Broken fuel injection pump drive 38 Bad defective oil temperature switch 59 Broken valve spring 18 Incorrect fuel pump timing 39 Oil pump worn 60 Exhaust or vacuum pipe leak 19 Incorrect valve timing 40 Pressure relief valve sticking open 61 Bad or defective water temperature switch 20 Poor compression 41 Pressure relief valve sticking closed 62 Bad spark plug s 5 17 5 2 CHECKING ENGINE OIL Check the engine oil BEFORE EACH USE OR TWICE DAILY ON COMMERCIAL USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 To keep dirt grass clippings etc out of the engine
11. The ohmmeter should read up scale to zero resistance Close Circuit This indicates the switch is operating properly Also check from each terminal to the switch case if case is metal 10 35 Reading should show infinite resistance indicating short to ground Variation from test results described indicates a defective switch Normally Closed Switch To test a normally closed switch connect the ohmmeter across the switch terminals Meter should indicate a closed circuit zero resistance Activate the switch and the meter should move to open circuit infinite resistance Check from each terminal to ground switch case Meter should show open circuit infinite resistance Variation from test results described indicates a defective switch Ignition Switch NOTE Refer to the wiring diagram of the unit involved to determine switch functions and test using the meth ods described The ignition switch incorporates a number of functions although not all functions are used on all equipment The switch has three positions OFF RUN momentary contact START position Use an ohmmeter to check the continuity of the switch in each position OFF Position Should be continuity between contacts G and M These connections ground the engine magneto and stop the engine in the OFF position RUN Position Should be continuity between contacts B and A These connections supply power to the rest of the wiring harness Con
12. an Ohmmeter Multimeter single combination meter that does all of these things is available Such a meter is called a Multimeter or Volt Ohm multitester VOM Meters of this kind are avail able in many forms and all change functions and ranges with switches or by plugging test leads into dif ferent jacks Multimeters are available in two basic types Analog and Digital Analog Meters Analog Meters have a needle that moves across a scale to give a reading The longer the scale the easier it is to read and more accurate the reading will be A jeweled movement is used in this type of meter is more likely to be damaged through rough handling except for overloaded Protected Meters or by measuring high values that exceed the range set on the meter than a digital meter They provide excellent service for the money as long as they are used with care Digital Meters Digital Meters do not have a movement and are there fore more rugged The reading shows up directly on a display window of some type Since they read direct no skill in reading the scale is required nor is it neces sary to set the range The meter switches the ranges automatically One has only to select the function DC Volts AC Ampere Ohms etc connect the test leads and the reading is shown on the display Because of the internal circuitry and the lack of a movement these meters are not likely to be damaged by overloads In the discussions that follow eit
13. and repair should be referred to local engine manufacturer s service centers that have the service information and parts available to properly service the engine Gravely dealers should be able to test engines and engine components to pinpoint troubles and narrow them down to properly advise the engine serviceman 10 37 10 9 ELECTRICAL SYSTEM Models 987066 072 2 5 gt gt gt 6 ac N gt 9285 SOS Now lt 2 PJ0022 10 38 10 10 CONTINUITY DIAGRAMS Models 987066 067 068 069 The diagrams below show the various states of connection for electrical components The solid lines on switches show continuity NOTE All switches are viewed from the rear Key Switch Relay 0115200 03042800 NOT ENERGIZED ENERGIZED Seat Switch PTO amp FWD REV Interlock Switch 03654200 02913100 lt OPERATOR BUTTON UP BUTTON DOWN OFF SEAT ON SEAT Light Switch Lift Pump Switch 08973300 03437900 Solenoid 03492300 NOT ENERGIZED ENERGIZED 10 39 Models
14. clamp onto lift if used To ensure the unit is positioned in the proper service position 1 Place jack stands under rear transaxles only 2 If jacks are not available place support blocks under both transaxles at the rear of unit CAUTION Remove enough fuel so that no A spills will occur Maintenance ALWAYS maintain unit in safe operating condition Damaged or worn out muffler can cause fire or explosion Check the conditions of the unit at the end of each day and repair any damage or defects ALWAYS block wheels and know all jack stands are strong and secure and will hold weight of unit during maintenance Keep nuts and bolts tight and keep equipment in safe operating conditions Before maintenance adjustments or service except where specifically recommended shut off engine Allow hot parts to cool Keep unit free of dirt stones and other debris Clean up oil or fuel spills Storage DO NOT store unit inside a building with fuel in the fuel tank where any ignition sources are present Allow unit to cool completely ALWAYS clean unit before extended storage See Engine Manual for proper storage Spark Arrester This product is equipped with an internal combustion engine DO NOT use on or near any unimproved forest covered or brush covered land unless the exhaust system is equipped with a spark arrester meeting applicable local state or federal laws A spark arrester if used must be maintained
15. cylinder shaft out on the right side far enough to clear cylinder Remove cylinder from tractor Installation NOTE Hydraulic ports for fittings need to be facing up 1 2 3 Slide cylinder shaft through hydraulic cylinder and out through left side of unit frame Install left side retaining ring on cylinder shaft Reconnect hydraulic cylinder to mower lift weldment noting where it was previously connected Connect hydraulic hoses SECTION 8 DRIVE TRAIN 8 1 TRANSMISSION TROUBLESHOOTING The following troubleshooting chart is to be used to isolate transmission problems and give possible causes and corrective action responses Problem Possible Cause 1 Unit will not move Axle key sheared Clutch lining worn linkage broken Shifting fork dowel pin sheared in slide rod Broken axle Crankshaft key sheared Differential failure check to see if brake drum turns 2 Unit will move only in reverse Adjustment of range linkage Hi lo range in neutral Forward clutch lining worn or linkage broken 3 Unit will move only in forward Reverse clutch lining worn or linkage broken 4 Attachment does not operate PTO linkage out of adjustment PTO clutch lining worn out Crankshaft key sheared 5 Attachment will not stop PTO clutch stuck PTO linkage out of adjustment 6 Difficult or impossible to shift Control linkage Hi Low Range Roll pin in shifter arm sheared Broken shifter fork Burred h
16. left side adjusting bolt clockwise with your fingers until it is tight Then back the nut off one fourth turn 4 Tighten the lock nut against the adjusting nut being careful not to move the adjusting nut 5 Turn the steering wheel to the left as far as it will go 6 Repeat the above two steps for the right side adjusting nut 7 Check for tightness or backlash in the steering gear through the full range of the steering wheel rotation There should be no noticeable tightness or backlash in the rack and pinion mesh If there is repeat above steps as required Upon completion of the steering gear adjustment recheck the steering wheel free play If the free play is still excessive look for loose steering arms on the king pins loose or worn ball joints or other signs of wear Tighten or replace as required 4 9 ADJUSTING FRONT WHEELS Adjust the front wheel toe in as follows 1 Rotate the steering wheel until the two steering arm weldments are parallel to the frame side Figure 9 2 On 13 5 HP and 16 HP engine units loosen the jam nuts on the tie rods and disconnect the outside ball joint Position the front tires by hand so that the distance between the front centerline of the tire is 1 8 to 1 2 less than the distance between the rear centerline Adjust the tie rods so that the ball joint can be connected to the tie rod arm without moving the tire and so that the tie rods are the same length Tighten the jam nuts 3
17. level surface 2 Stop the engine and block the wheels so the unit cannot roll 3 Loosen the jam nut and remove the clevis pin at the brake band NOTE Do not adjust the brake rod on the left hand side which attaches to the brake pedal This rod is for adjusting the direction control pedal only 4 Turn the clevis clockwise to tighten or counterclockwise as needed 5 To check the adjustment reconnect the clevis and brake band with the pin 6 Push the direction control pedal all the way forward 1 Brake Band Assembly 2 Brake Drum Figure 5 7 Push the brake pedal by hand while watching the motion of the brake band The brake is correctly adjusted when the band becomes tight on the drum as the direction control pedal moves to neutral If the band is tight before the pedal moves to neutral the brake is too tight If too tight or too loose repeat steps 4 5 6 and 7 until the correct adjustment is obtained 8 Install the cotter pin in the clevis pin and tighten the jam nut 9 Check the effectiveness of the brake while operating the unit 4 6 ADJUSTING THE FORWARD AND REVERSE CLUTCHES The forward and reverse clutches must be checked every 100 hours If the lining has worn to a thickness of less than 0 150 inch 3 8 mm replace the lining The forward clutch is on the right side of the transmission and the reverse clutch is on the left side of the transmission NOTE Damage will occur if the unit
18. lift lever on the shaft and drive the bushings into the frame 3 Put the snap ring on the key in the shaft 4 Reassemble the lift lever 1 Disconnect black ground wire at frame 2 Remove switch from dash leave the three leads connected to switch 3 Clean hydraulic fittings and mark hoses to insure proper routing when pump is installed 4 Disconnect hydraulic hoses from pump CAUTION Support electric hydraulic lift pump when removing mounting bolts Remove the two mounting bolts and lift pump out of unit Drain hydraulic fluid through reservoir cap The pump is not repairable If it is not functioning properly replace it Installation 2 6 Install pump with the two mounting bolts Reconnect hydraulic hoses Refer to Figure 13 for proper routing Install switch into dash with green terminal to the top and blue terminal to the bottom Reconnect black ground wire to frame Remove cap and service hydraulic reservoir with Dextron II or Dextron III to full line Install cap Reconnect battery negative terminal first 7 3 ELECTRIC HYDRAULIC PUMP SWITCH Removal CAUTION Disconnect negative battery terminal first 12 Remove switch from dash disconnect the three leads Installation 1 The switch can only be installed one way Check orientation of switch for proper load hookup Connect the three leads to the switch green top
19. reading could be an indication of a problem Sub tract 004 from 1 265 for each 10 F below 80 F 27 C or add 004 to 1 265 for each 10 F above 80 F 27 C A special temperature compensated hydrometer is used to read the battery s state of charge The reading on the hydrometer gauge should be above 1 225 the reading falls below 1 225 specific gravity there will be an insufficient charge ALWAYS charge the battery until the specific gravity of 1 265 is reached over 3 successive readings Check monthly to ensure charge is maintained The approximate state of charge can be determined by the cell specific gravity of the rested open circuit voltage at room temperature and the charging time can be estimated For example Specific of Charging Gravity Charge Time 12 60 1 265 100 12 4 1 225 75 3 hours 12 20 1 180 50 7 hours 12 00 1 130 25 10 hours 11 80 1 100 0 12 hours If using an automatic tapering 12 volt charger choosing a good quality 5 to 10 amps 15VDC minimum output charger and charge for 3 to 12 hours according to the battery state of charge see table above or until the specific gravity in each cell reaches 1 255 1 265 specific gravity at 80 F 27 C If using a constant current charger charge at 1 to 2 amperes for the time given on the table above or until full specific gravity is reached 10 34 IMPORTANT Charging at higher rates will damage the
20. 2 SECTION 1 INTRODUCTION 1 1 THE MANUAL The purpose of this manual is to provide complete instructions for service maintenance disassembly repair and installation of the mechanical components for the unit Dealer trained service personnel should use this manual as a supplement to and reminder of the training sessions conducted by the company Read all information for servicing a part or system before repair work is started to avoid needless disassembly Operation Before operation of the unit carefully and completely read manuals supplied with the unit The contents will provide you with an understanding of safety instructions and controls during normal operation and maintenance Safety Messages For your safety and the safety of others always read understand and follow all DANGER WARNING and CAUTION messages found in manuals and on safety decals Directional Reference All reference to left right front or rear are given from the operator in the operator position and facing the direction of forward travel 1 2 SERVICE AND REPLACEMENT PARTS When ordering publications replacement parts or making service inquiries know the Model and Serial numbers of your unit and engine Numbers are located on the product registration form in the unit literature package They are printed a serial number label located on the right instrument panel brace under the hood 1 3 PRODUCT REGISTRATION A warranty regist
21. 3 20 Idle RPM 1600 Governed RPM Hi Low 3300 Crank Case Capacity oz L 1 64 qt 1 55 Oil Filter Yes Air Cleaner Dual element Charging Capacity 15 amp Fuel Filter Yes Engine Oil See Engine Manual Spark Plug Gap 0 030 Speed Forward Lo Range mph kph 0 1 7 0 2 7 Hi Range mph kph 0 8 5 0 13 7 Speed Reverse Lo Range mph kph 0 3 8 0 6 1 Hi Range mph kph 0 3 8 0 6 1 Drive Clutch Individual forward reverse friction Transmission Lube API Service SC10W 30 Motor Oil Transaxle Capacity 6 qt 5 7 L Tire Pressure Front 14 PSI 18 PSI Rear 14 PSI 16 PSI Lift System Manual 64 Only Hydraulic 65 Only Hydraulics Type N A Capacity qt L N A Power Take Off Internal twin clutch cups Center standard front optional SECTION 4 GENERAL MAINTENANCE amp ADJUSTMENTS 4 1 CONTROLS AND FEATURES Ammeter Throttle Control Choke Control Direction Control Pedal Gear Selector Range Selector PTO Control Warning Light Oil Pressure Figure 1 Hourmeter side of panel Attachment Lift Switch Ignition Switch Brake Pedal Brake Lock Lever Release Button Manual Lift Lever Lift Range Control PJ0340 PJ0350 4 2 FILLING THE FUEL TANK WARNING Use caution with fuel Fuel is very flammable Keep fuel in a clean and tight conta
22. 8 Idler Shaft 4 Shaft 8 9 PTO Drive Assy Final Drive Pinion Shaft 10 Shaft 7 10 PTO CLutch Shaft 9 Figure 15 0060 Remove the cover bolts 2 Place aclean cloth or box under the transmission to catch any parts that might fall out 3 Clean paint and debris off the exposed part of 1 6 and 8 shafts Tap the cover with a soft hammer and pry off with two screwdrivers or pry bars Tap 1 6 and 8 shafts and the PTO yoke shaft as the cover is worked off 1 Ball 2 Plug 3 Spring Figure 16 8 5 GEAR AND SHAFT REMOVAL 1 Remove idler gear assembly and races from 2 shaft assembly Remove 7 shaft assembly Remove 5 shaft assembly Remove 4 shaft assembly Remove the hi lo detent spring and ball A magnet can be used to lift the ball out of the case Figure 17 6 Remove 1 shaft assembly along with hi lo shift fork 7 Remove 3 shaft assembly 8 Remove 6 shaft assembly 9 Remove 8 shaft assembly 10 Remove 2 shaft Slide races towards reverse drive to clear 9 shaft 11 Removal of 9 shaft assembly PTO clutch a Remove engine b Disconnect PTO lever c Remove E ring PTO lever and key d Pull yoke shaft out and remove PTO yoke Note orientation of yoke e Remove front PTO cap f Remove retaining ring on rear clutch cup g Slide assembly forward Swing rear outward and pull out of case 12 Removal of 10 shaft assembly PTO shaft
23. 987071 072 The diagrams below show the various states of connection for electrical components The solid lines on switches show continuity NOTE All switches are viewed from the rear Key Switch Relay 03602300 03042800 NOT ENERGIZED ENERGIZED Seat Switch PTO amp FWD REV Interlock Switch 03654200 02913100 lt OPERATOR OPERATOR BUTTON UP BUTTON DOWN OFF SEAT ON SEAT Light Switch Lift Pump Switch 08973300 03437900 Solenoid 03492300 NOT ENERGIZED ENERGIZED Model 987070 10 40 PJ0440 Model 987070 Key Switch 000 Seat Switch PTO amp FWD REV Interlock Switch 0400 01100 Light Switch Lift Pump Switch 000 0400 Solenoid 0400 PJ0451 10 41 10 11 WIRING DIAGRAMS Models 987066 067 069 PTO
24. CHECK TIRES NOTE Keep tires properly inflated at all times For proper tire inflation when working under various condi tions refer to chart below Use a low pressure tire gauge for accurate pressure readings Loading Light amp Medium Heavy Sno Thro Front 10 psi 14 psi Back 10 psi Check tire pressure at least once a month Over inflation may cause operator discomfort and excessive tire tracks on lawns or soft surfaces Under inflation causes short tire life NOTE After checking and or inflating replace and tighten valve caps to prevent air loss 5 5 1 ENGINE TROUBLESHOOTING The following troubleshooting chart is to be used to isolate engine problems and give possible causes and corrective action responses unit The troubleshooting key is generic and can be used for several types of engines Use only those possible causes and corrective actions that apply to the TROUBLE Black Exhaust POSSIBLE CAUSES Refer to Key Below 1 20 22 25 29 31 32 33 CORRECTIVE ACTION repair or replace Blue White Exhaust 4 20 25 31 33 34 repair or replace Difficult Starting 1 5 7 8 9 10 20 21 22 29 31 32 33 repair or replace Erratic Running 1 7 8 9 10 20 21 23 26 29 33 59 62 repair or replace Excessive Fuel Consumption 1 20 22 23 25 29 31 32 33 repair or replace Excessive Crankc
25. DJUSTING THE RANGE SELECTOR Move the Hi Lo shift lever as far as it will go in both directions Measure the distance between the lever and the end of the slot This distance would not be less than 5 16 inch 7 9 mm Adjust the clevis so that the clearance between the Hi Lo shift lever and the control cover plate slot is equal for both positions of the lever 4 12 HYDRAULIC LIFT WARNING Keep body and hands away from pin holes or nozzles which eject hydraulic fluid under pressure Use paper or cardboard and not hands to search for leaks Be sure to stop the engine and put the attachment in the down position before doing any work on hydraulic parts WARNING Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury Foreign fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result Check the hydraulic fluid level when the hydraulic lift will not raise the attachment or leaks are observed check the hydraulic fluid level 1 Clean the area around the reservoir and cap 2 Remove the cap 3 The correct hydraulic fluid level is one inch from the top of the reservoir Add Dextron ATF to maintain this level 4 13
26. GRAVELY Professional G Series Service Manual Models 987066 072 08483900 05 00 Printed USA TABLE CONTENTS Section 1 Introduction 1 3 1 1 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 1 3 1 6 Technical Service Communications 1 3 1 7 1 3 Section 2 2 4 2 1 Safety lt 2 4 2 2 Signal 5 2 4 2 3 2 4 2 4 Practices And Laws 2 4 2 5 Required Operator Training 2 4 2 6 2 4 2 7 Service Position 2 4 2 8 Cleaning And Storage 2 4 2 9 Safety lt 2 5 Section 3 Specifications 3 7 Section 4 General Maintenance 8 4 10 4 1 Controls And Features 4 10 4 2 Filling Fuel 4 11 4 3 Clean Air Intake Cooling Areas 4 11 4 4 General Lubrication 4 11 4 5 Adjusting The Brakes 4 11 4 6 Adjusting The Forward And Reverse
27. LWAYS use wheel chocks when leaving unit ALWAYS operate unit in good visibility and light Fuel is highly flammable and its vapors can explode Use ONLY approved fuel containers NO Smoking NO Sparks NO Flames Allow engine to cool before servicing NEVER fill fuel tank when engine is running hot or unit is indoors Abnormal Vibrations are a warning of trouble Striking a foreign object can damage unit Immediately stop unit and engine Remove key and wait for all moving parts to stop Remove wire from spark plug Inspect unit and make any necessary repairs before restart Hazardous Slopes DO NOT operate on steep slopes Avoid operating on slopes When you must operate on a slope travel up and down the slope Never operate across a slope Never operate on a slope greater than 10 degrees Child Safety NEVER allow children to operate or play on or near unit Be alert and shut off unit if children enter area Personal Safety Read and obey all warning caution and instructions on the unit and in provided manuals Only trained adults may operate unit e Training includes actual operation Clearly understand instructions Be alert Conditions can change NEVER operate unit after or during the use of medication drugs or alcohol Safe operation requires your complete and unimpaired attention at all times 2 5 NEVER allow anyone to operate the unit when their alertness or coordination is impaired DO NO
28. T operate unit without wearing adequate outer garments Wear adequate safety gear and protective gloves Wear proper footwear to improve footing on slippery surfaces Protect eyes face and head from objects that may be thrown from unit Wear appropriate hearing protection Avoid Sharp Edges Sharp edges can cut Moving parts can cut or amputate fingers or a hand Wear gloves to service unit when handling sharp edges ALWAYS keep hands away from any pinch points ALWAYS keep hands and feet away from all moving parts during operation Moving parts can cut off body parts DO NOT touch unit parts which might be hot from operation Allow parts to cool before attempting to maintain adjust or service Controls Come to a complete stop before reversing Never jerk the control levers Always use a steady even action to achieve smooth control Always be aware of obstructions that may cause injury to operator or damage to the unit Service Position WARNING ALWAYS block wheels and know that jack stands or blocks used are stable strong or secure and will hold the weight of the unit during maintenance WARNING ROTATING PARTS can amputate A body parts Keep hands and feet away Loose clothing long hair or scarves can get caught in rotating parts and cause death or serious injury Place unit on flat level surface ALWAYS stop engine and disengage clutches Assure unit is secure and will not tip over Strap and
29. a l 2 BROWN O SOLENOID LIFT PUMP FUSE 40 AMP HYDRAULIC SWITCH LIFT PUMP A B BLUE WHITE O GREEN WHITE BROWN YELLOW LIFT PUMP SWITGH PTO FWD REV SWITCH SWITCH BLUE O O RED YELLOW 1 2 1 BLACK 0431 10 43 Model 987072 S N 000215 and up HEAD LIGHTS RELAY TIME DELAY MODULE gt 87 4 30 0000 08560 GREEN WHITE PINK 1 2 HOUR METER SEAT SWITCH ENGINE 8 OIL PRE LIG OIL PRESSURE FUEL YELLOW RED 3 3 RELAY REGULATOR RED 1 1 30 0000 MAGNETO KILL WHITE BLACK 87 2 2 O49 O8 850 8 5 BLACK 2 STARTER AMMETER FUSE 30 RED A 5 RED RED T 9 O 5 5 4 2 gt z 7 2 BROWN 5 STARTER SOLENOID LIFT PUMP KEY FUSE 40 AMP HYDRAULIC SWITCH LIFT PUMP A B BLUE WHITE GREEN WHITE BROWN YELLOW LIFT PUMP FWD REV SWITCH SWITCH BLUE RED YELLOW L 1 2 10 44 PJ0432 Model 987070 3 5 Aeja
30. ansmission Disassembly 8 25 8 5 Gear And Shaft Removal 8 25 8 6 Assembly of 10 Shaft PTO Shaft 8 26 8 7 Disassembly of 9 Shaft Assembly PTO 8 26 8 8 Assembly of 9 Shaft PTO Clutch 8 26 8 9 Disassembly of 8 Shaft Differential Axle 8 26 8 10 Assembly of 8 Differential Axle 8 27 8 11 Inspection amp Repair 1 and 2 Shaft 8 27 8 12 Gear and Shaft Installation 8 28 8 13 Transmission Assembly 8 29 8 14 Forward Reverse Clutch Bearing 8 30 8 15 Forward Reverse Clutch Seal Replacement 8 30 Section 9 Fuel 9 31 9 1 Fuel System Troubleshooting 9 31 9 2 Fuel PUMP 2 9 31 9 3 Fuel System Contamination 9 31 9 4 Fuel Tank 9 31 Section 10 Electrical 10 32 TOONS 10 32 10 2 Electrical Measurements 10 32 10 3 Battery Wade tee tad 10 33 10 4 Switches 10 35 10 5 Solenoid 10 36 10 6 Lighting Circuits 10 37 10 7 tay 10 37 10 8 Diodes And Rectifiers 10 37 Engine Electrical Components 10 37 10 9 Electrical System 10 38 10 10 Continuity Diagrams 10 39 10 11 Wiring Diagrams 10 4
31. ase Pressure 25 31 33 34 45 55 High Oil Pressure 4 41 repair or replace Knocking 22 26 29 31 33 36 46 59 repair or replace Loss of Power or System 1 8 10 20 21 22 23 25 26 31 32 33 repair or replace Low Cranking Power 2 3 4 11 repair or replace Low Oil Pressure 4 36 37 39 repair or replace Misfiring 10 20 25 26 28 29 32 repair or replace Overheating 1 19 25 repair replace Poor Compression 25 28 29 31 32 33 34 59 repair or replace Starts and Stops 1 6 10 62 repair or replace see electrical systems see engine service manual 21 Blocked fuel tank vent 42 Broken relief valve spring Vibration 20 23 25 26 29 33 45 49 repair or replace Will Not Crank 2 11 45 charge battery replace Will Not Start 1 10 62 repair replace see electrical systems see engine service manual TROUBLESHOOTING KEY 1 Restriction in air cleaner 22 Incorrect grade of fuel 43 Faulty suction pipe 2 Bad electrical connection 23 Sticking throttle restricted movement 44 Choked oil filter 3 Faulty starter motor 24 Exhaust pipe restriction 45 Bad solenoid switch 4 Incorrect grade of lubricating oil 25 Leaking cylinder head gasket 46 Incorrect piston height 5 Low cranking speed 26 Overheating 47 Damaged fan 6 Fuel tank empty 27 Cold running 48 Faulty engine mounting 7 Controls not in correct operation 28 Incorrect tappet adjustment 49
32. ay be convenient to disconnect the brake linkage to position the jack stands 6 Remove the right tire assembly Loosen the 3 4 lock nut Use gear puller to loosen hub Remove lock nut washer hub and key Repeat on left side if the differential 8 shaft assembly is to be removed 7 Disconnect the Fwd Rev neutral switch 8 Remove forward and reverse clutch springs 9 Disconnect the Fwd Rev shifter rod from the Fwd Rev clutch roll arm Disconnect the neutral detent strap and neutral detent spring 10 Remove the left and right side lower forward reverse mounting plate bolts 11 Swing both plates up and out of the way 12 Disconnect ground wires from transmission 13 Clean the right axle and remove the axle bearing retainer 14 the forward clutch assembly Remove the spring flat washer and retaining ring from the forward clutch 1 shaft assembly Repeat on the other side if the reverse shaft 2 shaft assembly is to be removed 15 Remove the brake band and brake drum 16 Remove the E ring on the PTO yoke shaft Remove all visible paint and debris from PTO yoke shaft 17 Put the gear shift lever in the Neutral position the PTO control in the On position and the Hi Lo lever in the Lo position 8 24 8 4 TRANSMISSION DISASSEMBLY Forward Clutch Shaft 1 Reverse Clutch Shaft 2 Shaft 6 3rd amp 4th Gear Shaft 3 7 1st amp 2nd Gear Shaft 5 Differential Assy
33. battery and cause excessive gassing and acid spewing Battery Charger Under normal conditions the engine alternator will keep the battery charged When unit has set for an extended period of time without operation and the battery has been completely discharged a battery charger will be required for recharging Before using a charger an attempt can be made to recharge the battery using the engine alternator by jump starting the unit and allowing the engine to run Jump Starting Jump starting battery charging or replacement is required when the starter motor will not crank the engine The unit used for jump starting should have a 12 volt battery with at least 500 cold cranking amperes and a negatively grounded system EXPLODE and result in death or serious injury DO NOT charge a frozen battery Let the battery thaw out before putting ona charger UNIT MOVEMENT can result in death or serious injury NEVER jump start unit directly to the starter or starter solenoid Unit can move forward or backward and injure the person jump starting unit WARNING FROZEN BATTERIES CAN To jump start the battery 1 Ensure battery is not frozen If the fluid is frozen remove battery from unit and allow to thaw before charging 2 Connect the positive jumper cable to the positive terminal of the discharged battery 3 Connect the other end of the same jumper cable to the positive terminal of the booster batter
34. ch job will allow you to perform service repairs easily and quickly To reduce the incidence of misplaced tools or parts place removed components with all attaching hardware in the disassembly order on a clean work surface Organization is a key part of proper reassembly Tools instruments and parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a needless delay A list of required special tools has been included in this manual CAUTION Remove enough fuel so that no spillage will occur Remove battery to prevent spillage of electrolyte 2 7 SERVICE POSITION WARNING Always block wheels and know that jack stands or blocks used are stable strong or secure and will hold the weight of the unit during maintenance To ensure the unit is positioned in the proper service position 1 Place jack stands under rear transaxles only 2 If jacks are not available place support blocks under both transaxles at the rear of unit 2 8 CLEANING AND STORAGE IMPORTANT Never spray unit with water or store unit outdoors A unit that is excessively dirty should be cleaned before work starts Cleaning will occasionally uncover trouble sources Dirt and abrasive dust reduce the efficient work life of parts and can lead to costly replacement Brush grass dirt and debris off of unit with a soft brush Clean packed grass out from under mower deck Apply pain
35. e ignition switch to the start position and listen for the solenoid to snap inside contacts closed If no snap is heard check across the coils with a voltmeter The voltage should read 12 volts with the ignition switch in the start position If no voltage appears the defect is in the start circuit If the voltage is correct turn off the power and check continuity of the coil with an ohmmeter If the coil is open the solenoid is defective and must be replaced If the coil has the proper voltage applied and the continuity check indicates the coil is intact the solenoid plunger is stuck or the contacts are welded shut and the solenoid must be replaced If the solenoid snaps shut but the start does not operate check across the large contacts with an ohmmeter If there is no continuity when the solenoid snaps shut the contacts are defective and the solenoid must be replaced 10 36 10 6 LIGHTING CIRCUITS Lighting circuits are simple circuits and easiest to trouble shoot in most equipment They consist of the lights connected in parallel a normally open switch a protective fuse and a source of power battery or engine alternator If only one light is out check the connector then check the bulb for continuity high resistance indicates a defective or burned out bulb If all the lights are out check the fuse for continuity high resistance indicates a defective or blown fuse If the fuse is blown check for a short in
36. er thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Air dry 4 Saturate precleaner in clean fresh engine oil and squeeze out excess oil 5 Reinstall precleaner over paper element Service Paper Element Every 100 hours of operation more often under extremely dusty or dirty conditions check the paper element Replace the element as necessary 1 Remove the precleaner if so equipped from the paper element 2 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 3 With the air cleaner disassembled check the base plate Make sure it is secured and not bent or damaged Also check the element cover seals and breather tube for damage or improper fit Replace all damaged components NOTE Operating the engine with damaged or loose components could allow unfiltered air into the engine causing premature wear and failure 4 Reinstall the paper element 5 If so equipped install the precleaner washed and oiled over paper element 6 Reinstall element cover seals air cleaner cover and wing nuts Tighten wing nuts 1 2 to 1 full turn after nuts contact cover Do not overtighten 5 7 CHECK SPARK PLUG Every 100 hours or operation remove the spark plugs check condition and reset gaps or replace with new plu
37. from the circuit by disconnecting one end With a multitester set on the lowest ohms scale setting measure the resistance in one direction reverse the test leads and measure in the other direction Readings should be high in one direction and low in the other If the readings are low in both directions the diode is shorted and if the readings are high the diode is open If the readings are the same in both directions the diode is defective and must be replaced IMPORTANT Diodes are marked to indicate polarity a band one end an arrow on the side or they fit ona holder only one way Rectifiers A battery is charged through the use of an alternator located in or on the engine A charging circuit contains a rectifier because alternators produce alternating current AC and batteries require direct current DC for charging The rectifier may be built into the engine or it may be an external part It may also contain a regulator to prevent overcharging the battery Servicing of rectifiers built into the engine should be done by an approved engine manufacturer s service center Such a service center has access to the information and parts required to test and repair or replace engine components including rectifiers and regulators Units that contain both a rectifier and regulator are tested in a working circuit to make sure the regulator portion of the device is operating Engine Electrical Components Engine servicing
38. g 5 I N3399 O O 1 1895 98 N3399 58 028 L g vig send 5 HOLIMS _ 551215 queg 3 lt m youms vel a n 5 1467 ainssald HO N3349 J LIHMW N3 399 417 5 Old W E O Maneg gt 9 2 0310 10 45 GRAVELY Gravely A division of Ariens Company 655 West Ryan Street P O Box 157 Brillion WI 54110 0157 920 756 2141 Fax 920 756 2407 www gravely com
39. ged replace seal Put a film of grease on a new gasket and put it in place on the engine 7 Slide the adaptor plate in place with the assistance of a soft hammer 8 Start all four bolts and then tighten 9 Replace the bearing set key and gear 5 10 ENGINE INSTALLATION 1 Coat the engine pilot with gasket eliminator making sure the surface is clean and free of oil 2 Set the engine on a jack Adjust the jack so the crankshaft is on the centerline of the hole in the transmission 3 Slide the engine into the transmission Rotate the forward clutch to mesh the bevel gears 4 Install the four bolts and tighten 5 Reverse the disassembly process for engine connections and replacement of rear deck and hood ar WO 5 19 SECTION 6 STEERING amp CONTROLS The steering wheel operates through a rack to pivot worn The upper and lower bushing sleeves should be two weldments Each front king pin is controlled replaced when shaft play becomes excessive separately through a tie rod from the weldment NOTE The larger units will have a different design tie The king pins should be checked for looseness rod and tie rod ends the adjustment procedure is the Replace the lower thrust bearing if it becomes rusted or same See section on Adjustments 13 5 and 16 HP Units 20 5 HP Units Figure 11 SECTION 7 SYSTEM 7 1 MANUAL LIFT 5 Reassemble the locator casting and mount to the frame 6 Put
40. gs as necessary 1 Before removing spark plugs clean the area around base of plugs to keep dirt and debris out of the engine 2 Remove plugs and check condition Replace plugs when worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and dam age 5 8 ENGINE REMOVAL 1 Disconnect battery cables Remove negative cable first Turn off fuel at fuel tank Remove the rear deck Disconnect the choke and throttle cables Disconnect the engine harness plug oil sensor switch and starter cable Disconnect the fuel line at the engine 7 Remove rear hitch assembly 4 bolts 2 at each bearing retainer 8 Place a jack under the engine to provide support during removal 9 Remove the four bolts holding the engine to the frame 10 Slide the engine rearward out of the transmission Take care to keep the gear and bearing set on the crankshaft 5 9 ADAPTOR PLATE Removal and Installation 1 Remove the gear key and bearing set 2 Remove the four bolts which mount the adaptor plate to the pilot 3 Use a soft hammer to remove the adapter plate to the pilot 4 Inspect the adaptor plate bearing set and gear for damage and wear 5 Replace any worn or damaged parts 6 Remove all residue off the adaptor gasket from the engine and adaptor plate Check oil seal for damage If dama
41. h the lights are off until the switch is actuated and the lights go on A normally closed N C switch allows current to flow until the switch is actuated breaking the circuit and stopping current flow through it An example is an ignition switch that grounds the magneto when in the off position completing the circuit but opens the circuit when in the ON position allowing the engine to operate Switches are selected with regard to Current rating contacts must be of sufficient size to carry the required current Voltage rating switches insulated for specific voltages Case or housing switches that are exposed to moisture and must be sealed to prevent moisture from entering and Actuating type push pull rotary momentary contact or micro switches NOTE Check that the connections to the switches are secure and that a switch is being activated properly before performing electrical test on switches Safety switches on speed selector and clutch levers may be out of adjustment and not activating IMPORTANT When checking switches remove them from their respective circuit by disconnecting the wires from the switch at the connector s Damage could result to the meter or machine components if switches are left in Normally Open Switch To test a normally open switch key headlight safety or seat connect the ohmmeter across the switch terminals Meter should indicate open circuit infinite resistance Activate the switch
42. her type of meter may be used Test procedures are the same It is best to learn proper procedures even though some meters may be more forgiving of mistakes Where differences in use may occur they will be covered in the discus sion 10 32 Voltage Measurement There are two basic rules to be remembered when using a voltmeter A voltmeter measures the voltage difference between the test leads and the voltmeter is always connected across the circuit under test Current Measurement The two rules to remember when measuring current with an ammeter are an ammeter measures the cur rent that flows through the meter and to measure cur rent an ammeter must be connected into the circuit The latter rule means that the circuit must be opened and the ammeter wired into it Because this procedure is usually difficult an ammeter is seldom used for trou bleshooting Resistance Measurement An ohmmeter is used to make resistance measure ments and to check continuity through wires and elec trical components There is one rule to keep in mind when using an ohm meter The ohmmeter has a self contained battery and requires no electrical power Using the ohmmeter circuit that has power applied may result in damage to the meter IMPORTANT Disconnect the equipment battery when making Ohmmeter test or damage to the Ohmmeter may result IMPORTANT An ohmmeter reads the resistance of whatever component is connected between the tes
43. i lo shifting gear 7 Gear shift lever will 1 3 1 3 or 4 2 gears not in neutral position or 4 2 position Gears not aligned rock tractor or momentarily engaged clutch 6 shaft bent 8 6 shaft turns but not wheels Shafts 1 thru 6 are likely okay Problem is probably in 7 final pinion or 8 differential Possible broken axle 8 2 CHECKING THE TRANSMISSION OIL To check the transmission oil level 1 Remove the fill tube cap Add oil until it reaches the 1 Move the unit to a level area Stop the engine and bottom of the check plug hole lock the brake 2 Reinstall and tighten the fill tube cap and check 2 Raise the rear fender Clean the check plug and plug remove it 3 The oil level is correct when oil is at the bottom of the hole 4 Ifthe level is correct reinstall and tighten the plug If the level is low add oil To add oil 1 Tube 2 Check Plug Figure 14 8 3 TRANSMISSION REMOVAL NOTE It is not necessary to remove the engine unless the PTO clutch assembly 9 Shaft is to be removed The engine was removed for the total tear down of the transmission 1 Remove rear deck 2 Disconnect the battery ground cable 3 Drain transmission fluid 4 Turn off fuel at fuel tank and disconnect fuel line at engine 5 Jack unit to lift rear wheels Do not use engine as a jack point Block front wheels Position jack stands at the rear of the frame It m
44. in effective working order by the operator Battery Avoid Electric Shock DO NOT reverse battery connections Explosive Gases Poisonous battery fluid contains sulfuric acid and its contact with skin eyes or clothing can cause severe burns No flames No sparks No smoking near battery Always wear safety glasses and protective gear near battery DO NOT TIP battery beyond a 45 angle in any direction ALWAYS KEEP BATTERIES OUT OF REACH of children Transport Use extra care when loading or unloading unit onto trailer or truck Secure unit chassis to transport vehicle NEVER secure from rods or linkages that could be damaged DO NOT transport with attachment in raised position Lower attachment when unit is parked or stored unless a positive mechanical lock is used Attachments and Accessories Use only attachments or accessories designed for your unit 2 6 SECTION 3 SPECIFICATIONS Model Number 987066 987067 987068 Description 16 HP Kohler Manual amp 16 HP Kohler Manual amp 18 HP Kohler amp Hydraulic Hydraulic Lift Hydraulic Lift Lift Battery 12 Volt 12 Volt 12 Volt Hour Meter Standard Standard Standard Brakes External Band Brake on External Band Brake on External Band Brake on Transmission Transmission Transmission Steering Rack amp Pinion Rack amp Pinion Rack amp Pinion w Heavy Tie Rods Turning Radius in cm 26 5 67 3 26 5 67 3 26 5 67 3 Tire Size
45. iner Keep fuel away from fire and heat Never put fuel in the fuel tank while the engine is running or hot Clean up any spilled fuel before starting the engine Add fuel to the fuel tank as needed See your engine manual for the correct type and grade of fuel to be used Put the unit in an open and well ventilated area prior to refueling Stop the engine and set the parking brake Clean the fuel cap and in the area around the fuel cap Remove the cap from the fuel tank Fill the fuel tank with the proper grade of fuel recommended by the engine manufacturer Be careful not to spill any fuel Install fuel cap on the fuel tank and tighten 4 3 CLEAN AIR INTAKE COOLING AREAS To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times Every 50 hours of operation more often under extremely dusty dirty conditions remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled NOTE Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating 4 4 GENERAL LUBRICATION There are seven grease fittings to be greased at 25 hour intervals IMPORTANT Wipe each fitting clean before and after lubrication Apply Sten Mix Hi Temp Grease or equivalent to the
46. is operated with a lining thickness of less than 0 150 inch 3 8 mm Inspect and adjust the clutches as follows 1 Stop the engine and place the direction control pedal in the neutral position 2 Raise the rear fender 3 Measure the clearance in the slot The correct clearance is 0 030 inch 0 76 mm to 0 060 inch 1 5 mm for the forward clutch and 0 010 inch 0 25 mm to 0 030 inch 0 76 mm for the reverse clutch 1 Clutch Lining 2 Clutch Ring 3 Clutch Disc Figure 6 1 Reverse Clutch Spring 2 Forward Reverse Slide Rod 3 Forward Reverse Clutch Spring Figure 7 4 Adjust the bolts which go through the flange on the place with the jam nut Loosen the jam nut which axle bearing retainer so that the forward reverse holds the slide rod bushing in place Adjust the clutch springs are straight up and down when the bushing on the slide rod until the clearance is clutches have zero clearance Lock the bolt in correct Lock the bushing in place with the jam nut 5 Lubricate the clutch once each season Remove the clutch and apply a film of high quality lithium base grease to the splined clutch shaft While the clutch is off check the lining wear If the lining has worn near the rivet heads replace the lining Readjust the clutch as described above 4 7 ADJUSTING THE PTO CLUTCH The PTO clutch should be adjusted whenever there is less than 0 5 inches of free travel in the clutch leve
47. ment of automotive type wire in several colors Gravely Company recommends that all work be done in a professional manner The use of the tubing to cover joints and the soldering of connections contribute to a professional looking job In addition to a pleasing appearance repairs made in this manner are more likely to withstand vibration The weakest points in an electrical system are the joints where wires are attached Replace all defective components with Gravely replacement parts only Engine parts such as rectifiers or alternator components should be secured through the nearest engine service center Gravely Company does not recommend attempting to repair electrical components Most do not lend them selves to repair and you would have more money invested in time of repair than the part would cost and the results may not be as good 10 2 ELECTRICAL MEASUREMENTS In many electrical circuits there is some visible effect which indicates that the circuit is functioning properly A switch is turned ON and a lamp lights A key is turned a starter motor runs and cranks the engine If the lamp does not light or the starter motor does not run some means of measuring voltage current flow resistance and continuity is needed continuity means there is a complete electrical path through the circuit or component To know exactly what conditions exist in an electrical circuit requires AC and DC Voltmeter AC and DC Ammeter and
48. n proper order WARNING REVERSE CONNECTIONS may Set Up The new battery is dry charged The dealer or customer must add electrolyte sulfuric acid and water 1 Remove the battery from the unit 2 Remove all the vent caps from the battery and set the caps to one side 3 Take the electrolyte which should be 1 265 specific gravity at 80 F and fill each cell so that the electrolyte is level with the bottom of the fill ring 4 The battery should stand for 1 2 hour Now check electrolyte level in each cell again If necessary add more electrolyte to bring the level up to the bottom of the ring 5 Charge until all cells are gassing freely and the specific gravity is constant over three successive readings taken at 30 minute intervals 6 Immediately after charging check level of electrolyte If the level is low add distilled water to bring it up to the required level 7 Replace the vent caps It is not necessary to tighten more than finger tight 8 Wash off the battery to remove electrolyte which may have spilled Battery Electrolyte First Aid External contact Flush with water Eyes Flush with water for at least 15 minutes and get medical attention immediately Internal contact Drink large quantities of water Follow with Milk of Magnesia beaten egg or vegetable oil Get medical attention immediately IMPORTANT In case of internal contact DO NOT induce vomiting 10 33 Clean Battery Corrosi
49. nections G and M open to each other START Position Hold switch in START position while testing There should be continuity between contacts 1 and S2 These connections apply power to close the solenoid contacts and operate the starter motor In addition to the above test place the switch in the run position and check between each contact and ground metal case to be sure no terminals are grounded If the switch is operating properly there will be no continuity between contacts other that those described 10 5 SOLENOID AND RELAYS Solenoid and relays are both magnetically operated devices Both devices operate on the principle that passing a current of electricity through a coil of wire will create a magnetic field strong enough to attract a piece of iron or steel Each device uses this principle a slightly different manner Relay A basic relay consists of a coil of wire wound around a soft iron magnetic core When current is passed through the coil the core is magnetized and pulls down on a magnetic lever The lever in turn is attached to several switch contacts which open or close other electrical circuits In this fashion a small current can control one or more larger electrical currents and actuate several other devices In most cases a relay contact moves only a fraction of an inch and the magnetic pull is small Solenoid A basic solenoid consists of a coil of wire wound around a hollow tube A magnetic core
50. ng ring Remove the retaining ring Remove the rear clutch cup and key Remove the cone gear front clutch cup and key Release the spring slide remaining parts off the shaft while noting their position 7 Inspect all parts for damage and wear 8 Replace all parts damaged worn The retaining rings should be replaced 1 Thrust Washer 2 N Thrust Bearing Figure 18 9 Shaft PJ0150 8 8 ASSEMBLY OF 9 SHAFT PTO CLUTCH Reverse the disassembly procedure Be sure the retaining ring is in place before releasing the spring pressure Use plenty of 30 W engine oil on clutch parts Failure to do so will cause the PTO clutch to stick in the On position 8 9 DISASSEMBLY OF 8 SHAFT DIFFERENTIAL AXLE 1 Remove the four bolts holding the assembly 2 Use soft hammer to loosen the assembly and pull apart 3 Remove the axle retaining rings 4 Remove bearings from the end cap with a soft hammer 1 Bevel Pin 2 Drive Block 3 Final Drive Gear Figure 19 8 Shaft 8 10 ASSEMBLY 8 DIFFERENTIAL AXLE Reverse the disassembly procedure Use nut retaining compound on the four bolts and tighten to a torque of 25 ft lbs 33 8 Nm 1 N Thrust Bearing 2 Spur Gear Figure 20 1 Shaft Left 1 N Thrust Bearing Figure 21 2 Shaft 8 11 INSPECTION amp REPAIR 1 AND 2 SHAFT Inspect all parts for
51. nly Hydraulic 61 Only 61 Only 61 Only Hydraulics Type ATF Dextron ATF Dextron II ATF Dextron Capacity qt L 1 0 9 1 0 9 1 0 9 Power Take Off Internal twin clutch cups Center standard front optional Model Number 987069 987070 987071 Description 20 HP Kohler amp Hydraulic 16 HP Briggs amp Stratton 13 5 HP Robin Manual Lift Hydraulic Lift Battery 12 Volt 12 Volt 12 Volt Hour Meter Standard Standard Standard Brakes External Band Brake on External Band Brake on External Band Brake on Transmission Transmission Transmission Steering Rack amp Pinion Rack amp Pinion Rack amp Pinion w Heavy Tie Rods Turning Radius in cm 26 5 67 3 26 5 67 3 26 5 67 3 Tire Size Front 16x7 5 8 16x6 5 8 16x6 5 8 Rear 23 x 10 5 12 23 8 5 12 23 8 5 12 20 16 13 5 Manufacturer Kohler Briggs amp Stratton Robin Width of Cut in cm 40 102 cm 50 127 cm or 60 152 cm w optional mowers Fuel and Capacity gal L Unleaded 5 3 20 Unleaded 5 3 20 Unleaded 5 3 20 Idle RPM 1600 1600 1600 Governed RPM Hi Low 3300 3300 3300 Crank Case Capacity 1 75 qts 1 66 L w o Filter 3 5 pints 1 66 L w Filter 1 27 qts 1 2 L 3 pints 1 42 L w o Filter Oil Filter Yes Yes Air Cleaner Dual element Dual element Dual element Charging Capacity 15 amp 16 amp 12 5 amp Fuel Filte
52. on and dirt on the battery and terminals can cause the battery to leak power Remove battery See Battery Removal and Installation Rinse the battery with plain water and dry Clean terminals and battery cable ends with wire brush until bright e Coat terminals with grease or petroleum jelly Reinstall battery Inspection Cleaning Drying and Maintenance Inspect the top of battery terminals cables terminal posts and case for any accumulation of dirt corrosion cracks or loose or broken parts Keep battery and its terminals clean Inspect monthly to maintain best performance Replace battery if damaged Remove hold down and bolt and lift battery out Clean or service battery away from unit Remove corrosion from battery terminals and cable connections with wire brush then wash with a weak baking soda solution Scrub the exterior of the battery and cable terminals with a nonmetallic brush which has been dipped into a mixture of baking soda and water After cleaning apply a thin coat of grease or petroleum jelly to terminals and cable ends to retard corrosion Reinstall battery Check the alternator voltage regulator output if used at every periodic maintenance inspection Over charging is common cause of battery failure Electrolyte Level Every 25 hours of operation check electrolyte level of each cell by removing caps one at a time The electrolyte level should be at level indicated Use di
53. own from the additive used in today s blended fuels 9 31 SECTION 10 ELECTRICAL 10 1 TOOLS There are some specialized tools and test equipment that are needed for electrical repair work A brief description of these follows Long or needle nose pliers used to connect or bend wires and connectors in close quarters Diagonal cutters used to cut wires or trim connec tions Wire stripper crimping tool available separately or as combination tool Used to strip insulation from wires of various sizes crimp terminals and connector or wires Soldering gun or soldering iron used to solder all splices and connections to terminals connector etc A soldering gun is faster and more convenient that wait ing for a soldering iron to heat Multimeter analog or digital to measure voltage amperage and ohms Tachometer used to measure engine speed Required to properly test alternator and charging cir cuits where output is dependent upon engine speed Heat gun used to shrink insulated tubing in place Used to replace electrical tape or insulated sleeving To use place a piece of shrink tubing over a wire joint heat with the heat gun until it shrinks slightly around the joint Supplies electrical tape rosin core solder never use acid or acid core solder on electrical joints an assort ment of various size terminals connectors insulated or heat shrink tubing for use on joints and connections and an assort
54. place by tapping with a soft hammer 2 Start all of the cover bolts then tighten the cover bolts Install the two engine mounting bolts Tighten all four if engine wasn t removed 3 Install the E ring on the PTO yoke shaft 4 Install the brake drum and brake band 5 Put a seal protector coated with oil on the axle in the axle bearing retainer assembly Coat a new gasket with grease and stick it to the axle bearing retainer Slide the assembly in place on the axle and install the four bolts Remove the seal protector Repeat on the other side if removed Put the snap rings on 1 and 2 shafts and coat the splines with grease Put the flat washer spring and clutch assembly s in place Reconnect the ground wires to the transmission Swing the forward reverse mounting plates back down into place Install bolts and tighten Retighten front mounting bolts Reconnect the direction control lever neutral detent spring and detent stop 10 Install forward reverse neutral switch 11 Reconnect the forward reverse neutral switch 12 Coat the axle s with grease put the key s in place and put the wheel hub s on the axle s Install washer and lock nut 13 To adjust the clutch see section on Clutch Adjustment 14 1 the engine was removed see section on Engine Installation 15 If the engine was not removed a Replace the rear hitch arm b Mount the tire assembly s Remove jack stand
55. r when it is in the On position See Figure 8 to see where this free travel is measured The free travel should be between 0 5 inch 12 7 mm and 1 0 inch 25 4 mm CLEARANCE Figure 8 2 0400 1 Stop the engine and lock the brake 2 Loosen the bolts holding the switch bracket and push the bracket down 3 Raise the rear fender 4 Push the PTO lever to On 5 Disconnect the PTO control from the transmission lever 6 Turn the control rod to change the free travel Each turn will change it by about 0 25 inch Turn clockwise to increase and counterclockwise to decrease the free travel 7 Reconnect the control rod to the transmission lever Check for correct free travel Repeat steps 4 through 6 as necessary 8 Put the PTO control in the Off position 9 Move the switch bracket up until the switch closes makes a circuit Tighten the switch bracket hardware CAUTION Make sure the PTO control assembly does not rest on the switch body 4 8 ADJUSTING THE STEERING Adjustment of the steering gear is usually needed whenever there is more than 2 inches of free play in the steering wheel To adjust the steering gear 1 Loosen the lock nuts on both adjusting bolts 1 Adjusting Bolt 2 Adjusting Nut 3 Lock Nut 4 Steering Arm Weldments Figure 9 2 Turn the steering wheel to the right as far as it will go 3 Turn the adjusting nut on the
56. r 25 Hours Temperature BELOW 32 F 0 C With Filter 50 Hours Multiviscosity Without Filter 25 Hours NOTE 25 hours for continuous and or heavy duty operation Change the oil while the engine is still warm The oil will flow freely and carry away more impurities Make sure the engine is level when filling checking or changing the oil Change the oil as follows 1 Remove the oil drain plug and oil fill cap Tilt the engine slightly towards the oil drain to obtain better drainage 2 Reinstall the drain plug Make sure it is tightened securely 3 Fill with new oil of the proper type to the F mark on the dipstick Always check the level on the dipstick before adding more oil 4 Reinstall the oil fill cap Make sure it is tightened securely 5 5 CHANGING OIL FILTER Some engines are equipped with an oil filter Replace the oil filter every other oil change in accordance with the Oil Change Intervals table See engine manufacturers manual for proper type Replace as follows 1 Drain the oil from the engine crankcase 2 Allow the oil filter to drain 3 Remove the old filter and wipe the filter adapter gasket surface 4 Place a new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads 5 Puta drop of oil on your fingertip and wipe it on the
57. r Yes Yes Yes Engine Oil See Engine Manual Spark Plug Gap 0 025 0 030 0 030 Speed Forward Lo Range mph kph 0 1 7 0 2 7 0 1 7 0 2 7 0 1 7 0 2 7 Hi Range mph kph 0 8 5 0 13 7 0 8 5 0 13 7 0 8 5 0 13 7 Speed Reverse Lo Range mph kph 0 3 8 0 6 1 0 3 8 0 6 1 0 3 8 0 6 1 Hi Range mph kph 0 3 8 0 6 1 0 3 8 0 6 1 0 3 8 0 6 1 Drive Clutch Individual forward reverse friction Transmission Lube API Service API Service API Service SC10W 30 Motor Oil SC10W 30 Motor Oil SC10W 30 Motor Oil Transaxle Capacity 6 qt 5 7 L 6 qt 5 7 L 6 qt 5 7 L Tire Pressure Front 14 PSI 18 PSI 14 PSI 18 PSI 14 PSI 18 PSI Rear 14 PSI 16 PSI 14 PSI 16 PSI 14 51 16 PSI Lift System Manual 64 Only 64 Only Hydraulic Yes 65 Only 65 Only Hydraulics Type ATF Dextron II ATF Dextron N A Capacity qt L 1 0 9 1 0 9 N A Power Take Off Internal twin clutch cups Center standard front optional Model Number 987072 Description 20 5 HP Robin Manual LIft Battery 12 Volt Hour Meter Standard Brakes External Band Brake on Transmission Steering Rack amp Pinion Turning Radius in cm 26 5 67 3 Tire Size Front 16x7 5 8 Rear 23 x 8 5 12 Engine 20 5 HP Manufacturer Robin Width of Cut in cm 40 102 cm 50 127 cm or 60 152 cm w optional mowers Fuel and Capacity gal L Unleaded 5
58. ration card must be filled out signed and returned at time of purchase This card activates the warranty Claims meeting requirements during limited warranty period will be honored 1 4 UNAUTHORIZED REPLACEMENT PARTS Use only Gravely replacement parts The replacement of any part on this vehicle with anything other than a Gravely authorized replacement part may adversely affect the performance durability or safety of this unit and may void the warranty Gravely disclaims liability for any claims or damages whether warranty property damage personal injury or death arising out of the use of unauthorized replacement parts 1 5 DISCLAIMER Gravely reserves the right to discontinue make changes to and add improvements upon its products at any time without public notice or obligation The descriptions and specifications contained in this manual were in effect at printing Equipment described within this manual may be optional Some illustrations may not be applicable to your unit 1 6 TECHNICAL SERVICE COMMUNICATIONS Gravely Technical Service communicates information to the field using Service Letters Service Bulletins Product Notices and Campaigns Each communication signifies a type of information and priority The dealer is responsible to carry out the directive provided in the communication The types of communication are Service Letter General technical information for the dealer Technical information on how to se
59. rn 4 Choke Not Functioning Properly 5 Plugged Atmospheric Vent 6 Air Bleed Restricted 7 Damaged or Leaky O Rings 8 Damaged Diaphragm 9 Stuck or Dirty Ball Check 10 Diaphragm Upside Down 11 Plugged Tank or Vent 12 Fuel Pick up Restricted 13 Idler Port Restricted 14 Damaged Adjustment Needle and Seat 15 Incorrect Float Height 16 Main Nozzle Restricted 17 Dirty Stuck Needle and Seat 18 Fuel Inlet Plugged 9 2 FUEL PUMP The impulse style fuel pump is the most commonly used fuel pump Impulse fuel pumps may either be mounted externally onto the carburetor fuel inlet or remotely mounted These pumps are connected in the fuel line between the fuel supply and the carburetor or directly to the fuel inlet Impulse fuel pumps are operated by crankcase impulses created by the up and down movement of the piston A hose called a pulse line connects the fuel pump diaphragm chamber and transmits the impulses to the pump diaphragm The impulses actuate the diaphragm and the flap valves to lift the fuel from the fuel tank to the carburetor 9 3 FUEL SYSTEM CONTAMINATION Any time fuel contamination is found in the fuel system dirt water algae etc replace the fuel fuel filter and flush the fuel lines Remove the carburetor bowl and clean Replace all items that cannot be cleaned Reassemble the fuel system and check for proper operation 9 4 FUEL TANK The fuel tank is made of composite material for long life without breaking d
60. rough terrain Stay alert for hidden hazards DO NOT run engine in an enclosed area Always provide good ventilation Unit ALWAYS keep protective structures guards and panels in good condition in place and securely fastened NEVER modify or remove safety devices Check Safety Interlock System for proper operation daily see Operation section Do not operate unless system operates properly Operation Understand How to operate all controls The functions of all controls How to STOP an Emergency Speed ranges Do not operate any of the control levers or power take off unless both feet are resting on the platform DO NOT travel at too fast a rate DO NOT change engine governor settings or over speed engine Always back up slowly Always look down and behind before and while backing Never leave a running unit unattended ALWAYS shut off power take off lower throttle setting and stop engine before leaving unit ALWAYS remove key to prevent unauthorized use Never carry passengers on any part of unit Avoid uneven and rough terrain DO NOT operate near drop offs ditches or embankments Unit can suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in If tires lose traction turn off power take off and proceed slowly straight down slope Avoid wet surfaces Avoid parking on a slope If necessary use wheel chocks DO NOT leave unit unattended on a slope A
61. rubber gasket Allow a minute or two for the oil to be absorbed by the filter material then install in on the engine Turn the oil filter clockwise until rubber gasket contacts the filter adapter then tighten filter an additional 1 2 turn 6 Reinstall drain plug Make sure it is tight 7 Fill the crankcase with new oil of the proper type to the F mark on the dipstick Add an additional 1 2 pint of oil for the filter capacity 8 Test run the engine to check for leaks Stop the engine allow a minute for the oil to drain down and recheck the level on the dipstick Make sure oil level is up to but not over the F mark on the dipstick 5 6 AIR CLEANER This engine is equipped with a replaceable high density paper air cleaner element Some engines are also equipped with an oiled foam precleaner which surrounds the paper element Check the air cleaner daily or before starting the engine Check for buildup of dirt and debris around the air cleaner system Keep this area clean Also check 5 18 for loose or damaged components Replace all bent or damaged air cleaner components Service Precleaner If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions 1 Remove wing nuts air cleaner cover element cover seals and element cover 2 Remove the precleaner from paper element Wash the precleaner in warm water with detergent 3 Rinse the preclean
62. rvice the product and product improvements Service Bulletin Notification to update products to resolve certain issues or a notification of a policy change Product Notices Notification of limited product located in a certain region This is a limited distribution to only those who received the product involved Campaigns Notification of a safety related issue All products must be updated and are tracked by the factory until all units are corrected 1 7 PREPARATION Before starting any removal of parts proper preparation is very important for efficient work A clean work area at the start of each job will allow you to perform service repairs easily and quickly To reduce the incidence of misplaced tools or parts place removed components with all attaching hardware in the disassembly order on a clean work surface Organization is a key part of proper reassembly Tools instruments and parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a needless delay 1 3 2 2 1 SAFETY ALERTS Look these symbols to point out important safety precautions They mean Attention Personal Safety Is Involved Become Alert Obey The Message 2 2 SIGNAL WORDS The safety alert symbol is used in decals on the unit and with proper operation procedures in this manual They alert you to the existence and relative degree of ha
63. s d Reconnect engine cables wiring harness oil sensor switch and fuel line e Put new fluid in transmission 8 14 FORWARD REVERSE CLUTCH BEARING 1 Remove the trunnion bearing disc assembly from the transmission Use a flange puller with three bolts positioned to fit the trunnion lip to press the trunnion off the bearing Turn the assembly over and remove the snap ring older style clutch Readjust the position of the three bolts to fit the bearing Press the bearing off the disc assembly Inspect all parts Replace any worn or damaged parts Press the bearing on the disc assembly Turn the assembly over and press the trunnion on the bearing 1 Clutch Ring Assembly 3 Fwd Rev Clutch 2 Ball Bearing Trunnion Figure 29 8 15 FORWARD REVERSE CLUTCH SEAL REPLACEMENT Small Seal 1 2 3 Remove the trunnion bearing and disc assembly Carefully remove the old seal with a small punch Put a film of grease on the lip of the new seal and slide it on the thimble Coat outer area of seal with Loctite Put the thimble over the shaft and seat the seal with a driver Large Seal 1 The inside clutch hub must removed to install this seal Follow the procedure for removal of the clutch shaft in the transmission disassembly 2 Remove the old seal Install the new seal with a driver Coat outer area of seal with Loctite Assemble transmission
64. slides inside the tube When current is passed through the coil the core is pulled into the solenoid with considerable force With proper design a solenoid can exert considerable force over a distance of several inches A solenoid can therefore pull a lever close a heavy contact or perform other jobs that require a straight line pull If a relay or solenoid fails to operate the cause may be either electrical or mechanical To check electrically connect a voltmeter across the coil of the device and activate the circuit that operates the relay or solenoid If the meter indicates no voltage is applied the cause is in the control circuit If the meter indicates proper voltage across the coil but the device does not function remove the power disconnect the wiring and check the continuity of the coil with an ohmmeter The meter should indicate resistance in the order of 3 to 5 ohms if the coil is intact A high resistance indicates an open coil and a defective device There are also a number of mechanical problems that may cause the problem The starter solenoid in the Gravely equipment is a sealed unit used to actuate the starter motor on the engines These solenoids may have three or four connections The two large connections carry high current to operate the starter motor The small connections are connected to the coil and carry the control current To check the solenoid disconnect the cables to the starter motor turn th
65. soft hammer until the shaft is in place b Install the square retaining ring c Slide the front PTO cap coated with gasket eliminator in place and secure with two bolts d At the rear rotate the bearing snap ring gap to the top position e Put O rings and a key in the PTO yoke shaft Coat the O rings with grease f Slide the PTO yoke in position over the key and into the case Note orientation of yoke heavy side to rear g Install woodruff key PTO lever flat side inward and E ring h Connect PTO lever to the PTO rod with a washer and cotter pin 5 Install the shaft assemblies in the following order a 6 shaft Install interlock pin detent balls detent spring and shift forks if removed If removed replace the shifter weldments and associated parts first b 8 shaft differential c 1 shaft with 2 speed shift rail detent ball detent spring and plug Reconnect 2 speed linkage d 3 shaft e 2 shaft Put the bearing and bearing race near the end of the shaft so as to clear the PTO assembly f 4 shaft g 5 shaft h 7 shaft 8 13 TRANSMISSION ASSEMBLY 1 Clutch Seal 2 Seal Figure 27 Transmission Cover Assembly 7 6 4 1 4 2 Compression Spring 5 Compression Spring 3 Clutch Seal Figure 28 Transmission Case Assembly 1 Coat the case and cover with gasket eliminator and place new gasket on the case Slide the cover in
66. stilled water to fill each cell if needed Install and tighten each cap after checking IMPORTANT When distilled water is added to battery during freezing weather battery must be charged to mix water with electrolyte or water will remain at top and freeze Charging ALWAYS follow information provided on battery by battery manufacturer Contact battery manufacturer for extensive instructions to charge battery Place unit on a level surface shut off engine and open battery compartment to gain access to battery Disconnect negative cable first then positive cable To charge battery 1 Loosen strap and remove battery from unit 2 Place battery on bench or other well ventilated place where electrolyte spill will not create damage 3 Remove caps and fill each cell to level indicated with electrolyte at 1 230 specific gravity and 80 F 27 C 4 Let battery stand for one half hour 5 Check electrolyte level and add more if necessary 6 Connect positive lead of charger to positive terminal and negative lead to negative terminal 7 Charge the battery at two and a half amps for ten hours or until all cells are gassing freely and the specific gravity is constant over three 30 minute intervals Specific Gravity Check The specific gravity should be checked with a hydrometer NOTE The specific gravity should be checked in each cell and should be the same for all cells A variation in a cell
67. t leads It can be used to check wires coils light bulbs or any item that conducts current 10 3 BATTERY When charging battery remove it from unit first Keep batteries out of reach of children ALWAYS follow information provided on battery by battery manufacturer Lead acid batteries generate explosive gases Severe chemical burns can result from improper handling of battery electrolyte Wear safety glasses and proper protective gear when handling batteries to prevent electrolyte from coming in contact with eyes skin or clothing WARNING ELECTRIC SHOCK may result in A injury and or damage to unit DO NOT allow tools or other objects to come into contact with both terminal at the same time ALWAYS remove Negative Cable first to reduce risk of sparks when removing bat tery ALWAYS connect Positive Cable first then connect Negative Cable when install ing battery WARNING EXPLOSIVE GASES can result A in serious injury or death ALWAYS keep open flames sparks or smoking materials away from battery POISONOUS BATTERY FLUID contains sul furic acid and its contact with skin eyes or clothing can cause severe chemical burns ALWAYS wear safety glasses and protective gear near battery DO NOT TIP any battery beyond 45 degree angle in any direction ALWAYS KEEP BATTERIES OUT OF REACH of children result in sparks which may result in injury ALWAYS cables i
68. t or oil to exposed bare metal surfaces to prevent rust Inspect unit for visible signs of wear breakage or damage Order any parts required and make necessary repairs to avoid delays when beginning use again 054 Transaxle cooling fins must clean to prevent damage from overheating Use a cloth or brush to remove grass chaff and debris Unless there are indications of leakage transaxle does not have to be checked for proper oil level If leak occurs have it repaired by your Gravely Dealer When taking unit out of extended storage 1 Check for any damage or loose parts Repair replace or tighten hardware before operation 2 preservative fluid was used in fuel tank drain and discard Fill fuel tank with fresh new fuel 2 9 SAFETY RULES Walk Around Inspection Complete a walk around inspection of unit and work area to understand Work area Your unit All safety decals Work Area ALWAYS check overhead and side clearances carefully before operation ALWAYS be aware of traffic when operating along streets or curbs ALWAYS keep hands and feet within the limits of the unit Keep children people and animals away Keep children out of work area and under watchful care of a responsible adult Keep area of operation clear of all toys pets and debris Objects can cause vehicle instability and injury Check for weak spots on dock ramps or floors Avoid uneven work areas and
69. the lift lever assembly on the shaft so as to align with the key Use a soft hammer to drive in place while holding down on the push rod 7 Install the set screw and tighten the jam nut 7 2 ELECTRIC HYDRAULIC PUMP 1 Lift Lever Shaft 3 Lever Pawl 2 Lift Lever Assembly 4 Locator Casting Figure 12 0230 Disassembly 1 Remove the set screw in the lift lever assembly 2 Apply liquid wrench to the shaft through the hole where the is positioned 3 Loosen the two bolts holding the locator casting and remove 4 Disassemble the lift lever assembly by removing the grip and rotate the push rod counterclockwise to disengage the pawl 1 Motor A bl 5 Fluid Flows both 5 Remove the key and the snap ring from the shaft 2 he y Ways High Pressure 6 Using a punch and hammer drive the pivot 3 Hydraulic Cylinder 1000 psi bushing outward from the frame 4 Fluid Flows Both 7 Slide the lift lever shaft weldment to the left Lift up Ways High Pressure 400 on the right end and pull from the frame 8 Inspect and replace all worn or damaged parts Figure 18 64000 Assembly 1 Slide the left end of the lift lever shaft weldment CAUTION Disconnect negative battery into the frame hole and move to the left Lower the terminal first right end and slide into the right hole 2 Slide new pivot bushings on the shaft and start in Removal the holes Slide the
70. the wiring and correct before replacing the fuse If the fuse and lamps are good check the circuit with an AC DC voltmeter 10 7 FUSES Fuses are connected in electrical circuits to protect the circuits from damage due to overload or short circuits Fuses are a weak link in the circuit They contain a metal link designed to melt when a certain current value is exceeded thus opening or disconnecting the wiring Once a fuse blows or melts it must be discarded and replaced with a new fuse of the same value Since the function of the fuse is to protect the circuit NEVER attempt to defect the protective device by bridging or replacing with a device of a higher current rating Electrical testing of these devices is simple Since the device either conducts current and is therefore functioning or the device is open and is therefore defective Use an ohmmeter to check for continuity 10 8 DIODES AND RECTIFIERS Diodes are solid state semiconductor devices They contain no moving parts and conduct current better in one direction than the other Diodes allow current to flow through one circuit without backing up into another In engine alternator circuits a diode is used to convert current which flows back and forth AC in a circuit to current which flows only in one direction DC A device which converts alternating current to a direct current is called a RECTIFIER A diode is one type of rectifier To check a diode isolate if
71. wear and damage Replace any worn or damaged parts If a bearing or thrust race is damaged replace the bearing and both thrust races 1 16 Teeth 10 DP Gear 2 20 Teeth 10 DP Gear Figure 22 3 Shaft 1 20 10 2 30 10 Figure 23 4 Shaft 0090 1 30 10 2 26 10 3 20 10 Figure 24 5 Shaft 0110 1 1st amp 3rd 3 30 Teeth 10 DP Shifter Sliding Gear 2 2nd amp 4th Shifter 4 36 Teeth 10 DP Sliding Gear Figure 25 6 Shaft 1 30 8 Figure 26 7 Shaft 0130 8 12 GEAR AND SHAFT INSTALLATION 1 Put the key in the hub of the gear bearing assembly which goes on the right end of the 1 shaft Put grease on the hub and slide the gear bearing assembly into the clutch hub forward clutch in the cover 2 Put the key in the hub of the reverse gear and bearing assembly which goes on the left end of 2 shaft Put grease on the bug and slide the reverse gear and bearing assembly into the clutch hub reverse 3 Position the controls PTO to On Hi Lo to Lo Gear to Neutral Fwd Rev to Neutral 4 Installation of 9 shaft assembly PTO clutch a Put the front of the assembly through the front hole of the case Move rearward into the bearing Tap the bearing with a
72. y 4 Connect one end of the second jumper cable to the negative terminal of the booster battery 5 Make the final jumper cable connection to the engine block or the furthest ground point away from the discharged battery WARNING Make sure cables are clear of any moving engine parts before starting engine 6 Start engine refer to Owner s Manual If engine will not start after several tries unit or battery may need service 7 After engine starts leave cables connected for one to two minutes 8 Disconnect cables in reverse order 9 Operate unit as normal to charge battery Storage The battery is a perishable item and it should be stored properly to obtain a long useful life Batteries not in use will self discharge If the battery will not be used for more than three months it should be removed and stored in a cool dry place Any collection of dirt grease or electrolyte should be removed from the top of the battery The battery must be recharged monthly or when the cell specific gravity reads less than 1 255 specific gravity Before reinstalling the battery in the spring it should always be fully recharged 10 4 SWITCHES Switches either open a circuit to stop current flow or close and allow current to flow through A normally open N O switch prevents current flow until the switch is actuated completing the circuit and allowing current to flow through it An example is a light switc
73. zards Understand the safety message It contains important information about personal safety on or near the unit DANGER IMMINENTLY HAZARDOUS SITUATION If not avoided WILL RESULT in death or serious injury WARNING POTENTIALLY HAZARDOUS SITUATION If not avoided COULD RESULT in death or serious injury A CAUTION POTENTIALLY HAZARDOUS SITUATION If not avoided MAY RESULT in minor or moderate injury It may also be used to alert against unsafe practices 2 3 NOTATIONS NOTE General reference information for proper oper ation and maintenance practices IMPORTANT Specific procedures or information required to prevent damage to unit or attachment 2 4 PRACTICES AND LAWS Practice usual and customary safe working precautions for the benefit of yourself and others Understand and follow all safety messages Be alert to unsafe conditions and the possibility of minor moderate or serious injury or death Learn applicable rules and laws in your area 2 5 REQUIRED OPERATOR TRAINING Original purchaser of this unit was instructed by the seller on safe and proper operation If unit is to be used by someone other than original purchaser loaned rented or sold ALWAYS provide the Operator s Manual and any needed safety training before operation 2 6 PREPARATION Before starting any removal of parts proper preparation is very important for efficient work A clean work area at the start of ea

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