Promaster 250Z, 260Z, 272Z Service Manual 992018, 020, 023, 027, 029, 030 992032, 033, 034, 035 09254300A 8/04 Printed in USA
TABLE OF CONTENTS Mower Blades . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Adjusting Control Levers. . . . . . . . . . . . . . . . . . 22 Adjusting the Parking Brake . . . . . . . . . . . . . . . 22 Adjusting Unit To Track Straight . . . . . . . . . . . . 22 Leveling the Mower Deck . . . . . . . . . . . . . . . . .23 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Service and Replacement Parts . . . .
EC DECLARATION OF CONFORMITY ISSUED BY THE MANUFACTURER – DÉCLARATION DE CONFORMITÉ CE ÉMISE PAR LE FABRICANT – EU655 West Ryan Street ÜBEREINSTIMMUNGSERKLÄRUNG DES HERSTELLERS – VERKLARING VAN P.O.
Notified Body – Organisme notifié – Zertifizierungsstelle – Aangemelde instantie – Bemyndiget organ – Organismo notificato – Organismo notificado – Teknisk kontrollorgan – Anmält organ – Ilmoitettu laitos – Organ zaświadczający – Organismo – Certificador Philip J.
INTRODUCTION THE MANUAL honored, whether or not the product registration card is returned. Keep a proof of purchase if you do not register your unit. The purpose of this manual is to provide complete instructions for service, maintenance, disassembly, repair, and installation of the mechanical components for the Promaster 250Z, 260Z, and 272Z. Customer Note: If the dealer does not register your product, please fill out, sign, and return the product registration card to Gravely.
SAFETY WARNING: This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the safety instructions in the manuals and on decals could result in serious injury or death. WARNING: Slopes are a major factor related to loss-of-control and tip-over accidents. Operation on all slopes requires extra caution. NOTATIONS NOTE: General reference information for proper operation and maintenance practices.
• If machine stops going uphill, stop blade and back down slowly. • Avoid sudden turns. • Keep safety devices (guards, shields, switches, etc.) in place and working. • Check interlock system per manual before use. • Understand location and function of all controls. • Never allow operation by untrained persons. 2. DANGER! Always keep feet and hands away from rotating parts. OL 3030 Always stand clear of discharge area. Do not direct discharge toward other people.
07735200C DANGER / PELIGRO • Avoid injury - Stay clear of rotating parts. • Risque de blessures - ne pas s’approcher des pièces en mouvement. • Evitar lesiones - Mantenerse alejado de las piezas giratorias. DANGER/PELIGRO WARNING/AVERTISSEMENT/ADVERTENCIA Do not operate mower unless guards are in operating position or bagger is attached. 07742300B Ne jamais utiliser la tondeuse sans protecteur sur le canal d'ejection ou sans le bac monte.
Start and operate unit only when seated in operator’s position. Steering control levers must be in neutral, PTO disengaged and parking brake set when starting engine. Local regulations may restrict the age of the operator. NEVER allow children to operate or play on or near unit. Be alert and shut off unit if children enter area. NEVER operate unit after or during the use of medication, drugs or alcohol. Safe operation requires your complete and unimpaired attention at all times.
Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling. DO NOT operate on slopes of more than 17 degrees. Use of a Rollover Protection System (ROPS) is recommended for slope operation. When practical, remove gas-powered equipment from the truck or trailer and refuel it on the ground.
Shut off fuel and allow engine to cool completely before storing in closed area or covering unit. Test Steering PTO Levers Clean grass and debris from unit, especially from around muffler and engine, to help prevent fires. Parking Engine Brake STARTING INTERLOCK For extended storage, shut off fuel and clean unit thoroughly. See engine manual for proper storage. 1 Neutral Off Engaged Start Lower cutting deck unless a positive mechanical lock is used.
SPECIFICATIONS Model Number Model 992018 992023 992027 PM260Z 25 HP Kohler with 50 Inch Deck PM250Z 20 HP Briggs & Stratton with 50 Inch Deck PM260Z 25 HP Kohler with 72 Inch Deck Length - in (cm) 87 (221) Height - in (cm) 50 (127) Width - in (cm) Weight Actual - lbs (kg) 90 (229) 63 (160) 1100 (499) 85 (216) 1080 (490) Battery 12 volt Brakes Hydro/Dynamic Disk - Parking Turning Radius Tire Size Front 1259 (572) 0 15 x 6 - 6 15 x 6 - 6 15 x 6 - 6 Rear 23 x 10.5 - 12 23 x 8.
Model Number Model 992020 992029 992030 992032 992033 992034 992035 260Z 25 HP Kohler w/60" deck 260Z 25 HP Kawasaki w/60" deck 272Z 25 HP Kawasaki w/72" deck 272Z 26 HP EFI Kohler w/72" deck 260Z 26 HP Kawasaki w/50" deck 250Z 23 HP Kawasaki w/50" deck 250Z 23 HP Kawasaki w/50" dek Length - in (cm) 80 (203) 84 (213.
CONTROLS AND FEATURES 8 19 9 10 11 8 13 3 14 7 15 16 20 17 2 6 5 18 4 12 22 21 OF 1722 1 23 1. Mower Deck with Chute Deflector 12.Ignition Switch 2. Fuel Shut off Valve 13.Power Take Off (PTO) Switch 3. Parking Brake 14.Steering Levers 4. Battery 15.Mower Lift Lever 5. Hour Meter 16.Seat Adjustment Lever 6. Oil Pressure Indicator 7. Engine Frame and Hood 17.Seat Suspension Adjustment Knob (not on model 992034) 8. Fuel Tanks and Caps 18.Height of Cut Indicator 9.
GENERAL MAINTENANCE & ADJUSTMENTS MAINTENANCE SCHEDULE Proper maintenance can prolong the life of unit. The following chart shows the recommended service schedule. More frequent service may be required due to working conditions (Heavy loads, high ambient temperatures, dusty conditions, or airborne debris). WARNING: AVOID INJURY. Read and understand the entire Safety section before proceeding. Interval See the maintenance instructions in Engine Manual for additional information.
SERVICE AND ADJUSTMENTS Gravely Dealers will provide any service which may be required to keep your unit operating at peak efficiency. Should engine service be required, it can be obtained from a Gravely Dealer or engine manufacturer’s authorized service center. 7 4 5 1 8 2 3 WARNING: AVOID INJURY. Read and understand the entire Safety section before proceeding. 9 6 CAUTION: HOT SURFACES may result in injury. DO NOT touch engine or drive parts which are hot from operation.
5. Engage parking brake. IMPORTANT: Never spray unit with water or store unit outdoors. Water can seep into sealed bearings and reduce component life. Bearings are sealed against dirt and debris only. 6. Levers must be returned to their original position in order to operate the unit (Figure 5). TRANSPORTING UNIT A unit that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover trouble sources.
FILLING FUEL TANK Apply oil at all pivot points and pin connections. EXPLOSIVE VAPORS and FLAMMABLE FUEL can result in serious injury or death. Handle fuel with care. ALWAYS use an approved fuel container. 1 No Smoking! 2 No Lighted Materials! No Open Flame! 1 Allow engine to cool. Use caution with fuel. Fuel is very flammable. Keep fuel in a clean and tight container. Keep fuel away from fire or heat. Never put fuel in the fuel tank while the engine is running or hot.
• Eyes: Flush with water for at least 15 minutes and get medical attention immediately! Battery Removal and Installation Remove • Internal Contact: Drink large quantities of water. Follow with Milk of Magnesia, beaten egg or vegetable oil. Get medical attention immediately! 1. Place hood in full service position (see Service Positions on page 16). 2. Disconnect negative (-) cable first, then positive (+) cable (Figure 8). • In case of internal contact, DO NOT induce vomiting! 3.
BELTS WARNING: MOVING PARTS can cut or amputate body parts. ALWAYS wait for moving parts to stop before performing maintenance or service. 3 1 2 3 CAUTION: DAMAGED OR WORN BELTS may result in injury and/or damage to the unit. Check belts for excessive wear or cracks often. 72" Belt Layout 4 2 50" and 60" Belt Layout Belt Access 1 1. Properly stop and park unit (refer to Owner’s Manual). 4 5 2. Lower the mower. OF 1641 3. Place seat in most rearward position. 1. Long Mower Belt 4. Idlers 4.
5 1 3. Sharpen the beveled edges of the blades in a straight line. Do not change the angle of the beveled edge. If more than 0.5 inches (12.7 mm) are removed from the width of a blade, discard the blade. Make sure the sharpened blades are balanced. Balance must be held within 1.3 inch ounces. 6 2 3 4. Put the blades, the flat washers, lock washers, and the bolts back on the spindle shafts. 5. Tighten the bolts to a torque of 70 ft. lbs (95 Nm). Put the ignition wires back on the spark plugs.
ADJUSTING THE PARKING BRAKE 4. Have someone depress center of seat to activate seat switch. 1. The parking brake may be adjusted through the use of the jam nuts on the brake rod which push against the compression spring which pushes on the caliper arm. See Figure 14. 5. Start the engine and run at about half throttle or faster. Release parking brake. 6. Move the control levers from Forward to Reverse several times to make sure controls are free and check neutral adjustment.
LEVELING THE MOWER DECK 14.Tighten rear hex nut on each rod that was loosened in step 11. 1 Right Side View 1 1 1 1 These adjustments should be made on a level surface with the tires inflated to the correct air pressure. The mower is leveled from side to side with the slots where 4 chains fasten to the mower mounting brackets. The mower is leveled from front to rear by adjusting the rod running down each side of the frame (Figure 16). 1. Raise mower deck and insert 3" (7.6 cm) tall blocks to support deck.
ENGINE ENGINE TROUBLESHOOTING The following troubleshooting chart is to be used to isolate engine problems and give possible causes and corrective action responses. TROUBLE Black Exhaust Blue/White Exhaust Difficult Starting Erratic Running Excessive Fuel Consumption High Oil Pressure Knocking Loss of Power or System Low Cranking Power Low Oil Pressure Misfiring Overheating Poor Compression Starts and Stops The troubleshooting key is generic and can be used for several types of engines.
REMOVING THE ENGINE To Replace the Clutch 1. Place the mower in the full service position. 1. Remove the belt by relaxing the idler pulley. 2. Disconnect the battery cables, negative first. 2. Remove the center bolt. 3. Disconnect ignition wires using the connectors. CAUTION: DO NOT ALLOW the engine crankshaft to rotate. Damage to the engine may occur. 4. Remove the belts from the pulley and clutch. 5. Unscrew the bolt from the center of the output shaft and remove clutch.
DRIVE TRAIN 4. Turn the filter by hand, an additional 1/2 to 3/4 turn. 5. Fill the hydraulic oil reservoir to the top mark on the dipstick. It will take about 5 quarts. Use Mobil 15W50 synthetic oil. Start the engine and run for 1 to 2 minutes. WARNING: Hydraulic Fluid can result in severe burns. Fluid in hydraulic system can penetrate skin and result in serious injury or death. 6. After shutting off the engine, check the fluid level.
18.Lower the cover and start the engine. Run the engine for 1 - 2 minutes. After shutting off the engine, check the hydraulic fluid level. The dipstick should read between the high and low markings. replaced. If the flow drop is less than 1 GPM you will need to replace the wheel motor. REPLACING THE HYDRAULIC PUMP The two hydraulic pumps are located inside the chassis in front of the engine. The pumps are maintenance free and should be replaced in the event of a failure. See Figure 18.
2. Clean hose fittings, mark hoses for position and disconnect from valve. 13.Place the brake caliper into position and insert bolts from the inside of the frame outward. Use lock washer and nut and tighten. 14.Position wheel on hub and insert lug nuts finger tight. CAUTION: Some hydraulic fluid will leak out of the hoses. Clean up any spills. 15.Tighten lug nuts using the pattern shown in Figure 20. 3. Loosen mounting bolts and remove valve. 16.Lower the unit to the ground and start the engine.
HYDRAULIC DIAGRAM 992018, 023, 027 Lift Cylinder Lift Valve Deck Lower B Return Inlet A Deck Lift Left Pump A B Left Wheel Motor Upper B A Lower B Forward High Pressure A Right Pump Forward High Pressure Upper Reverse High Pressure Reverse High Pressure Right Wheel Motor A B Lower Oil Filter PRESSURE RETURN SUCTION Oil Tank PD1772 29
Models 992020, 029, 030, 032, 033, 034, 035 PD1774 30
MOWER DECK Mower Spindles This unit utilizes a maintenance free extended life spindle. No routine maintenance is required. In the event of bearing failure or a bent shaft the spindle should be replaced. To Remove the Spindle 1. Place the unit in service position. Turn key off and remove the spark plug wire from contact with spark plug. 2. Remove cutting blade by unscrewing bolt. CAUTION: Use sturdy gloves or padding to protect hands when working with mower blades 3. Remove belt from pulley. 4.
FRONT SUSPENSION SUSPENSION The front suspension consists of a weldment that is a square tube (Figure 22). A pivot pin holds the axle to the chassis. Two caster wheels are attached. The front axle is maintenance free except for one grease fitting at the chassis for the pivot pin. This fitting is greased as needed with Sten Mix Hi-Temp grease or equivalent. 3 4 1 4 2 1. Pivot Pin 3. Dust Cap 2. Spindle 4. Bearing Figure 22 To Replace the Caster Wheel 1.
ELECTRICAL TOOLS ELECTRICAL MEASUREMENTS 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 connections. Wire stripper/crimping tool - available separately or as a combination tool. Used to strip insulation from wires of various sizes, crimp terminals and connector or wires.
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. WARNING: EXPLOSIVE GASES can result in serious injury or death. ALWAYS keep open flames, sparks, or smoking materials away from battery. POISONOUS BATTERY FLUID contains sulfuric acid and its contact with skin, eyes, or clothing can cause severe chemical burns.
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). Check the alternator voltage regulator output (if used) at every period maintenance inspection.
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. the wiring harness. Connections G and M open to each other. START Position - Hold switch in START position while testing. There should be continuity between contacts S1 and S2. These connections apply power to close the solenoid contacts and operate the starter motor.
To check a diode, isolate it 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.
WIRING DIAGRAMS Models 992018, 020, 027 PD2110 PD3230 38
Model 992029, 030, 034, 035 PD3242 39
Model 992023 SEAT SWITCH SEAT / PTO RELAY PINK 87a CAB POWER SUPPLY 87 85 86 1 2 30 BLACK 2 HOUR METER PTO SWITCH RED / YELLOW 1 BLACK 7 4 1 2 1 3 PURPLE PTO CLUTCH PURPLE / WHITE 9 BLACK SWITCH OIL PRESSURE BLUE / WHITE FUEL SOLENIOD RED / YELLOW START RELAY ENGINE REGULATOR BROWN / YELLOW OIL LIGHT BLACK PURPLE BLACK MAGNETO KILL 87 86 87a WHITE / BLACK 85 RED / YELLOW 30 STARTER A B RED RED 1 B FUSE 30A A BRAKE SWITCH M BATTERY BLACK BLACK COIL 2 COI
Models 992032, 033 41
TROUBLESHOOTING TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION 1. PTO engaged. 1. Disengage PTO. 2. Parking brake disengaged. 2. Engage parking brake. 3. Loose or corroded battery cables. 3. Clean and tighten battery cables (see Servicing the Battery on page 18). 4. Discharged battery. 4. Charge battery (see Charging the Battery on page 19). 5. Faulty starter. 5. See your Gravely Dealer. 1. Fuel tank empty. 1. Fill fuel tank (see Filling Fuel Tank on page 18). 2. Faulty spark plug. 2.
TROUBLESHOOTING PROBLEM Unit does not drive. PROBABLE CAUSE CORRECTION 1. Parking brake engaged. 1. Disengage parking brake. 2. Transmission bypass levers open. 2. Close transmission bypass levers (see Moving Unit Manually on page 16). 3. Hydraulic oil level low. 3. Add hydraulic oil (see Checking Hydraulic Oil Level on page 26). 4. Faulty hydraulic drive system. 4. See your Gravely dealer.
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.
