Gravely 991104, 991079, 991097, 991081, 991102 User Manual

...
0 (0)

Pro-Turn 100

Zero-Turn Mowers

Parts Manual

Models

991079 – Pro-Turn 148

(SN 021000 +)

991080 – Pro-Turn 152

(SN 021000 +)

991081 – Pro-Turn 160

(SN 021000 +)

991095 – Pro-Turn 148

(SN 021000 +)

991096 – Pro-Turn 152

(SN 021000 +)

991097 – Pro-Turn 160

(SN 021000 +)

991102 – Pro-Turn 148 CARB

(SN 021000 +)

991103 – Pro-Turn 152 CARB

(SN 021000 +)

991104 – Pro-Turn 160 CARB

(SN 021000 +)

 

 

The use of any gasoline exceeding 10% ethanol (E10) or 10% MTBE will void the product warranty.

 

E10

L’utilisation d’une essence contenant plus de 10% d’éthanol (E10) ou de 10% de MTBE annulent la

 

garantie.

 

 

 

El uso de cualquier otro tipo de gasolina con un porcentaje superior al 10% de etanol (E10) o al 10% de

 

 

MTBE invalidará la garantía del producto.

 

 

 

 

 

 

 

ENGLISH

04562100A 1/13

 

 

Printed in USA

THE MANUAL

Before you operate your 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.

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.

Hardware descriptions are given in decimals.

Decimals to Fractions

.063

1/16

 

.563

9/16

 

 

 

 

 

.125

1/8

 

.625

5/8

 

 

 

 

 

.188

3/16

 

.688

11/16

 

 

 

 

 

.250

1/4

 

.750

3/4

 

 

 

 

 

.313

5/16

 

.813

13/16

 

 

 

 

 

.375

3/8

 

.875

7/8

 

 

 

 

 

.438

7/16

 

.938

15/16

 

 

 

 

 

.500

1/2

 

1.00

1

 

 

 

 

 

SERVICE AND REPLACEMENT PARTS

When ordering replacement parts or making service inquiries, know the Model and Serial numbers of your unit and engine.

Numbers are located on the product registration card in the unit literature package. They are printed on a serial number label, located on the frame of your unit.

• Record Unit Model and Serial numbers here:

PRODUCT REGISTRATION

The Gravely dealer must register the product at the time of purchase. Registering the product will help the company process warranty claims or contact you with the latest service information. All claims meeting requirements during the limited warranty period will be honored, whether or not the product registration card is returned. Keep a proof of purchase if you do not register your unit.

Customer Note: If Dealer does not register your product, please fill out, sign and return the product registration card to Gravely or go to www.gravely.com.

YOUR SATISFACTION IS IMPORTANT

Questions? Please follow these helpful steps:

1.Refer to the manuals supplied with your unit.

They will guide you through safe and proper operation and maintenance.

They contain specifications on your unit.

If your questions are not answered in these manuals, go to step number two.

2.Contact Your Dealer.

Our dealers will be happy to supply any service or advice required to keep your unit operating at peak efficiency.

A factory trained staff is available to support your equipment needs. They stock genuine Gravely parts and lubricants manufactured with the same precision and skill as the original.

If your questions are not resolved by the support staff, ask for the manager or owner.

When contacting your Dealer supply your model and serial numbers.

• Record Engine Model and Serial numbers here:

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.

TO SPEED PARTS ORDERING:

1.Know the model and serial numbers of your unit.

2.Know the part number required.

3.Know the quantity required.

4.Know the part description.

2

MODELS

Domestic

Model 991079 (Pro-Turn 148)

Kawasaki with 48” Mower Deck Serial No. 021000 and up

Model 991080 (Pro-Turn 152)

Kawasaki with 52” Mower Deck Serial No. 021000 and up

Model 991081 (Pro-Turn 160)

Kawasaki with 60” Mower Deck Serial No. 021000 and up

Model 991095 (Pro-Turn 148)

Kohler EFI with 48” Mower Deck Serial No. 021000 and up

Model 991096 (Pro-Turn 152)

Kohler EFI with 52” Mower Deck Serial No. 021000 and up

Model 991097 (Pro-Turn 160)

Kohler EFI with 60” Mower Deck Serial No. 021000 and up

Model 991102 (Pro-Turn 148 CARB)

Kawasaki with 48” Mower Deck Serial No. 021000 and up

Model 991103 (Pro-Turn 152 CARB)

Kawasaki with 52” Mower Deck Serial No. 021000 and up

Model 991104 (Pro-Turn 160 CARB)

Kawasaki with 60” Mower Deck Serial No. 021000 and up

TABLE OF CONTENTS

DECALS

Decals – Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Decals – Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MAIN FRAME

Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Tire Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

POWER UNIT

Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Hydraulic Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Transmission – Right Hand . . . . . . . . . . . . . . . . . . . .24

Transmission – Left Hand . . . . . . . . . . . . . . . . . . . . .28

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

ELECTRICAL

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Continuity Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .38

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

MOWER DECKS

Mechanical Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . .40

Belts, Spindles, Idlers & Blades, 48” & 52” Decks . . .42

Belts, Spindles, Idlers & Blades, 60” Deck . . . . . . . . .44

Deck & Mounting Arms . . . . . . . . . . . . . . . . . . . . . . .46

Anti-Scalp Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Discharge Chute & Belt Covers . . . . . . . . . . . . . . . . .50

Discharge Chute Storage. . . . . . . . . . . . . . . . . . . . . .53

ROPS

ROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

3

© Copyright 2013 Ariens Company

DECALS – SAFETY

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104

8

6

07800401

7

07700005A

4

P

07800403

5

3

 

 

07757500A

2

 

 

 

 

9

 

 

 

KEEP HANDS and FEET AWAY

 

 

 

1

 

 

 

02988100

 

 

 

PE105_G_safety_decals

Item

Part No.

Qty.

Description

1

07800402

1

Decal, Safety Deck Guarding

2

07800340

2

Decal, Safety Mower Deck

3

07757500

1

Decal, Parking Brake Lever

4

07756000

2

Decal, Danger Fan

5

07754100

2

Decal, Hot Surface

6

07800401

1

Decal, Safety Guarding

7

07800403

1

Decal, Main Safety Commercial

8

07700005

1

Decal, Maintenance Instructions

9

02988100

1

Decal, Danger

4

10

 

DECALS – STYLE

 

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104

 

5

 

2

11

1

 

4

05239700

03271900

9

3

9

8

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

08000605

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

Part No.

Qty.

Description

1

03271900

2

Decal, Transmission Disconnect

2

07800221

1

Decal, Seat Release

3

03891000

1

Decal, 48 (991079, 095, 102)

 

07800026

1

Decal, 52 (991080, 096, 103)

4

03818400

1

Decal, 60 (991081, 097, 104)

07757600

1

Decal, Instructional-Steering

5

08000526

1

Decal, Gravely Heritage, Large

6

03875000

1

Decal, Belt Routing (991079, 080, 095, 096, 102, 103)

7

08000605

1

Decal, Belt Routing (991081, 097, 104)

04014000

1

Decal, Pro-Turn 148 (991079, 095, 102)

 

04014100

1

Decal, Pro-Turn 152 (991080, 096, 103)

8

04014200

1

Decal, Pro-Turn 160 (991081, 097, 104)

03955200

1

Decal, Height of Cut

9

05366200

2

Decal, X-Factor Deck

10

04039400

1

Decal, Control Panel (991079, 080, 081, 102, 103, 104)

11

04422600

1

Decal, Control Panel (991095, 096, 097)

05239700

1

Decal, Fuel Valve

5

FRAME

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104 (SN 020000 – 021999)

6

7

 

5

8

5

5

4

5

3

2

3

9

11

 

5

 

6

 

 

 

 

 

 

8

10

 

 

6

 

5

 

 

 

 

1

12

 

 

 

PE001_G_frame

6

FRAME

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104 (SN 020000 – 021999)

Item

Part No.

Qty

Description

1

04243851

1

Foot Plate

2

04243953

1

Kick Plate

3

07412900

4

Screw, Tapping .38-16 x .50 Hex Washer Head Thread Rolling

4

03948151

1

Muffler Heat Shield

5

07415400

8

Screw, Tapping .38-16 x .75 Hex Washer Head

6

07400034

4

Screw, Tapping .25-20 x .50 Hex Washer Head

7

03995253

1

Pro-Turn 100 Bumper

8

03995751

2

Bumper Plate

9

04243253

1

Pro-Turn 100 60" Main Frame Weldment (991081, 097, 104)

 

04243153

1

Pro-Turn 100 48" – 52" Main Frame Weldment (991079, 080, 095, 096, 102, 103)

10

04053651

1

PTO Belt Finger Weldment

11

07533600

2

Bumper, Rubber

12

06530400

2

Nut, Spin Lock Flange .312-18

7

Gravely 991104, 991079, 991097, 991081, 991102 User Manual

FRAME

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104 (SN 022000 +)

6

7

 

5

 

 

 

 

8

 

 

 

 

 

 

15

16

 

 

 

 

 

 

 

15

 

14

 

 

 

 

 

 

 

 

5

5

 

17

18

 

 

 

 

 

 

 

3

 

 

 

 

 

4

 

 

 

 

 

 

2

5

 

 

 

17

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

15

 

 

 

 

 

15

 

 

 

 

 

 

9

 

16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

 

 

 

17

 

 

 

 

 

 

13

18

 

 

 

 

 

 

17

 

5

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

 

 

 

10

 

 

 

6

 

 

 

5

 

 

 

 

 

 

 

 

 

 

1

12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PE001_G_frame

8

FRAME

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104 (SN 022000 +)

Item

Part No.

Qty

Description

1

04243851

1

Foot Plate

2

04243953

1

Kick Plate

3

07412900

4

Screw, Tapping .38-16 x .50 Hex Washer Head Thread Rolling

4

03948151

1

Muffler Heat Shield

5

07415400

8

Screw, Tapping .38-16 x .75 Hex Washer Head

6

07400034

4

Screw, Tapping .25-20 x .50 Hex Washer Head

7

03995253

1

Pro-Turn 100 Bumper

8

03995751

2

Bumper Plate

9

04517353

1

Pro-Turn 100 60" Main Frame Weldment (991081, 097, 104)

 

04517253

1

Pro-Turn 100 48" – 52" Main Frame Weldment (991079, 080, 095, 096, 102, 103)

10

04053651

1

PTO Belt Finger Weldment

11

07533600

2

Bumper, Rubber

12

06530400

2

Nut, Spin Lock Flange .312-18

13

04517453

1

Bracket, Tank Mount Left Hand

14

04517553

1

Bracket, Tank Mount Right Hand

15

06212000

4

Bolt, Round Head Square Neck .38-16 x 1.00 Grade 5

16

06215700

2

Bolt, Round Head Square Neck .31-18 x .75 Grade 5

17

06545500

4

Nut, Nyloc Flange .38-16

18

06545400

2

Nut, Nyloc Flange .31-18

9

SEAT ASSEMBLY

 

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104

 

22

 

19

 

 

 

 

 

 

18

 

 

 

20

 

 

 

3

 

 

 

24

 

17

 

 

 

23

 

 

 

 

 

21

 

6

 

 

 

 

 

5

 

8

 

 

 

9

 

 

12

7

7

1

8

 

 

 

 

 

10

 

5

2

 

 

 

13

11

 

7

 

 

4

 

 

 

14

 

 

 

2 15

1

16

PE070_G_100i_seat

10

 

 

 

SEAT ASSEMBLY

 

 

 

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104

Item

Part No.

Qty

Description

1

05717100

2

Ring, Retaining External .500 x .050

2

06425300

2

Washer, Flat Steel .531 x 1.00 x .063

3

04052900

1

Seat, Suspension – with Belt, Light Gray

4

03837800

1

Shaft, 100I Seat Pivot

5

05500901

2

Bushing, Flange .516 x .750 x .625 x .937

6

03933251

1

Seat Plate Weldment

7

06545400

4

Nut, Locking Top Flange .31-18

8

05947000

2

Bolt, Hex .31-18 x .75

9

03918551

1

Pro-Turn 100 Left Hand Top Seat Latch Mount

10

03917951

1

Pro-Turn 100 Right Hand Top Seat Latch Mount

11

08321100

1

Spring, Tension .043 x .44 x 3.31

12

03917751

1

Pro-Turn 100 Seat Latch Weldment

13

06706900

1

Pin, Center .09 x .75 Extended Prong Square Cut

14

06436200

1

Washer, Flat Steel .406 x .812 x .065

15

03930451

1

Pro-Turn 100 Seat Latch Mount Weldment Right Hand

16

03930551

1

Pro-Turn 100 Seat Latch Mount Weldment Left Hand

17

59210400

AR

Kit, Armrest Assembly Right Hand

18

59210500

AR

Kit, Armrest Assembly Left Hand

19

59208800

AR

Kit, Back Cushion, Light Grey

20

59208900

AR

Kit, Seat Cushion, Light Grey

21

59208000

AR

Kit, Seat Knobs

22

59208100

AR

Kit, Seat Back

23

59207900

AR

Kit, Seat Slides

24

59207800

AR

Kit, Seat Spring and Saddle

11

BRAKE ASSEMBLY

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104

 

 

 

3

15

 

 

17

2

 

 

 

 

 

 

14

 

 

 

9

11

 

 

 

 

 

 

 

 

13

 

 

16

 

 

 

5

 

 

 

 

 

10

 

5

 

 

 

 

 

 

 

16

 

 

 

 

15

 

 

 

18

12

 

 

1

8

4

2

3

5

7 6

PE002_G_brakes

12

 

 

 

BRAKE ASSEMBLY

 

 

 

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104

Item

Part No.

Qty

Description

1

05946900

3

Bolt, Hex .31-18 x 1.00

2

05503900

2

Bushing, Flange .750 x 1.000 x .625 x 1.250

3

05714600

2

Ring, Retaining External .689 x .077

4

01522000

1

Bushing, Flanged

5

06545400

7

Nut, Nyloc Flange .31-18

6

05717100

1

Ring, Retaining External .500 x .050

7

03795900

1

Weldment, Parking Brake Arm

8

03826900

1

Grip, Parking Brake

9

07517300

1

Cable Tie

10

06608400

1

Key, Woodruff .13 x .63 HRD #5

11

06900318

2

Cable, Brake Actuating

12

01305900

1

Bushing, Flange .325 x .499 x .26 x .88

13

03780900

1

Plate, Neutral Interlock

14

06514900

1

Nut, Push .312

15

06216100

4

Bolt, Round Head Square Neck .31-18 x 1.00

16

03861451

2

Neutral Lock Latch

17

03878700

1

Weldment, 100I Neutral Lock

18

03251100

1

Weldment, Park Brake Arm

13

TIRE ASSEMBLY

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104

11

10

 

 

 

14

 

 

 

 

 

13

 

 

 

 

 

12

 

14

 

 

 

8

 

13

 

 

 

 

12

 

 

 

9

 

 

 

 

 

8

 

 

 

 

 

 

 

 

 

 

9

 

 

 

9

 

4

 

 

 

8

 

 

 

10

 

7

 

 

 

 

6

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

5

 

 

11

 

9

 

1

 

 

 

 

 

 

 

8

3

 

 

 

 

7

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

5

 

2

15

 

 

4

 

1

 

 

 

 

 

 

2

PE060_G_tires

14

 

 

 

TIRE ASSEMBLY

 

 

 

Model 991079, 080, 081, 095, 096, 097, 102, 103, 104

Item

Part No.

Qty

Description

1

07100903

2

Tire/Wheel Assembly, 13 x 6.50-6

 

07100914

AR

Tire, 13 x 6.50-6 Smooth

2

00675300

4

Spacer, Front Wheel

3

06500010

2

Nut, Nyloc Flange .50-13

4

05961200

2

Bolt, Hex .50-13 x 9.00

5

03924453

2

Fork

6

03760300

2

Spacer 1.258 x 1.75 x .550

7

05600432

2

Seal, Oil 1.75 x 2.332 x .312

8

05404700

4

Bearing, Cone 1.25 x .66

9

05404600

4

Bearing, Cup 2.328 x .465

10

07100810

2

Tire/Wheel Assembly, 23 x 10.50-12

 

07100210

AR

Tire, 23 x 10.00-12

11

06517600

10

Nut, Wheel .50-20 13/16 Across Flats, Automotive Type

12

06439800

2

Washer, Flat Steel .812 x 2.00 x .148

13

06536900

2

Nut, Jam Center Lock .75-16

14

03925900

2

Cap, Dust

15

05435700

AR

Bearing, 25 mm ID x 52 mm OD x 15 mm

15

FUEL TANKS

Model 991079, 080, 081, 095, 096, 097

 

 

 

1

 

14

 

23 (from Valve)

 

 

 

4

 

 

 

17

 

 

 

19

2

 

 

 

 

 

 

3

 

 

 

4

 

 

6

18

 

6

16

 

 

5

 

 

7

 

 

 

 

8

 

9

22 (to Right Hand Tank)

1

 

14

 

 

8

 

 

15

 

 

 

 

 

2

20

15

 

7

 

 

 

 

 

 

 

 

 

 

20

23 (to Left Hand Tank)

 

 

11

 

 

 

10

 

 

 

 

 

 

 

 

11

21 (to Engine)

 

 

 

 

 

 

 

13

 

 

6

 

 

 

 

 

 

12

 

G_fueltanks_serial_2500_up

16

 

 

 

FUEL TANKS

 

 

 

Model 991079, 080, 081, 095, 096, 097

Item

Part No.

Qty

Description

1

04558000

2

Cap, Fuel Vent-in Autolock

2

04082700

2

Grommet, Remote Vent Nitrile

3

03900300

2

Assembly, Medium Tank Fuel Pick-up

4

03278800

9

Clamp, Fuel Line

5

04340700

1

Tank, Left Hand Medium Gravely Fuel

6

07000018

8

Bolt, SEMS .31-18 x .62

7

07412900

2

Screw, Tapping Hex Washer Head Thread Rolling .38-16 x .50

8

06916000

2

J-Clamp

9

07517300

3

Cable Tie

10

04039151

1

PT100 Control Panel, Black

11

06900417

2

Cable, PT100 Throttle Control

12

04340600

1

Tank, RH Medium Gravely Fuel

13

06536000

4

Nut, Locking, Nylon 10-24 w/Insert

14

04068910

2

Valve, Combination

15

06116700

4

Screw, Machine Hex Washer Head 10-24 x .50

16

09258200

1

Valve, Fuel

17

04097700

2

Clamp, Hose, Spring .188

18

04306900

1

Tee, 1/4HS Run x 3/16HS Branch

19

06909400

1

J-Clamp

20

06100211

2

Screw, Machine HWH Stainless 10-24 x .38

2103278100 40” Hose, .25 Low-Perm Bulk Gas

2203278100 18” Hose, .25 Low-Perm Bulk Gas

2303278100 40” Hose, .25 Low-Perm Bulk Gas

17

Loading...
+ 39 hidden pages