Gravely 992311 21HP-148Z, 992081 25HP-152Z, 992078 21HP-148Z, 992080 23HP-160Z, 992077 19HP-144Z User Manual

...
4 (1)

Promaster 144Z / 148Z / 152Z / 160Z

Parts Manual

Models

992077 19HP-144Z

992078 21HP-148Z

992079 23HP-152Z

992080 23HP-160Z

992081 25HP-152Z

992082 25HP-160Z

992310 19HP-144Z

992311 21HP-148Z

00265100 1/04 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 992077

19HP Kawasaki with 44” Mower Deck Serial No. 000101 and up

Model 992078

21HP Kawasaki with 48” Mower Deck Serial No. 000101 and up

Model 992079

23HP Kawasaki with 52” Mower Deck Serial No. 000101 and up

Model 992080

23HP Kawasaki with 60”Mower Deck Serial No. 000101 and up

Model 992081

25HP Kohler with 52” Mower Deck Serial No. 000101 and up

Model 992082

25HP Kohler with 60” Mower Deck Serial No. 000101 and up

International

Model 992310

19HP Kawasaki with 44” Mower Deck Serial No. 003000 and up

Model 992311

21HP Kawasaki with 48” Mower Deck Serial No. 003000 and up

TABLE OF CONTENTS

DECALS

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

MAIN FRAME

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

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

POWER PLANT

Engine and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fuel Tanks and Hoses . . . . . . . . . . . . . . . . . . . . . . . . 9

DRIVE TRAIN

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Motors and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . 11

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

HYDRAULICS

Lift Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic Tank, Filter and Pump to Tank Circuit. . . . 14 Deck Lift and Motors to Pump Circuit. . . . . . . . . . . . 15 Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 16

OPERATOR CONTROLS

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ELECTRICAL

Continuity Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 21

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

MOWER DECKS

Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Decks, Discharge Chute and Baffles . . . . . . . . . . . . 26

Belts, Spindles, Idlers, and Blades. . . . . . . . . . . . . . 28

Mounting Arms and Belt Guards . . . . . . . . . . . . . . . 27

Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3

© Copyright 2004 Ariens Company

DECALS

Model 992077, 078, 079, 080, 081, 082, 310, 311

1

2

05359400

077560

3

OFF

4

LEFT

 

 

TANK

 

05233900

 

 

RIGHT

 

 

TANK

 

5

DANGER / PELIGRO

07731400D

WARNING/AVERTISSEMENT/ADVERTENCIA

Do not operate mower

Ne jamais utiliser

No operar segadora a

unless guards are in

la tondeuse sans

menos que las defensas

operating position or

protecteur sur le

esten en posicion de

bagger is attached.

canal d'ejection ou

operacion o el

07742300B

sans le bac monte.

recogedor este fijo.

4

DANGER / PELIGRO

• Avoid injury - Stay clear of rotating parts.

• Risque de blessures - ne pas s’approcher des pièces en mouvement.

07735200C

• Evitar lesiones - Mantenerse alejado de las piezas giratorias.

5

DANGER / PELIGRO

07731400D

4

6

PD3540

Item

Part No.

Qty.

Description

1

05359400

1

Decal, Pinch Point

2

07756000

1

Decal, Danger Fan

3

07754100

2

Decal, Hot Surface

4

69229100

1

Set, Decal-Common Danger/Fuel

5

07731400

2

Decal, Mower Pan Head Danger

6

07742300

1

Decal, Warning

4

Gravely 992311 21HP-148Z, 992081 25HP-152Z, 992078 21HP-148Z, 992080 23HP-160Z, 992077 19HP-144Z User Manual

DECALS

Model 992077, 078, 079, 080, 081, 082, 310, 311

1

12

11

2

10

 

 

 

07735300B

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

9

 

5

07757600A

4.5

 

4

07757500A

 

3.5

 

 

3

 

 

2.5

 

8

2

5

1.5

6

 

1

7

PD3283

Item

Part No.

Qty.

Description

1

05359200

1

Decal, Service Instructions

2

07735300

1

Decal, Lift Lever

3

05358900

1

Decal, PM 152Z (079, 081)

 

05358700

1

Decal, PM 144Z (077)

 

05358800

1

Decal, PM 148Z (078)

 

05359000

1

Decal, PM 160Z (080, 082)

4

07757600

1

Decal, Instructional Steering

5

07734600

1

Decal, Belt Diagram

6

05234500

1

Decal, 52

(079, 081)

 

05359100

1

Decal, 44

(077)

 

05233300

1

Decal, 48

(078)

 

05232000

1

Decal, 60

(080, 082)

7

05304300

1

Decal, ZT Hood

8

05354700

1

Decal, Height of Cut

9

07757500

1

Decal, Parking Brake Lever

10

05358600

1

Decal, Control Panel

11

05225500

2

Decal, 15" Gravely Logo

12

05305100

1

Decal, American Flag

5

FRAME

Model 992077, 078, 079, 080, 081, 082, 310, 311

4

8

10

11

5

6

 

 

9

2

 

 

7

8

10

1

14

 

 

 

15

13

Item

Part No.

Qty.

Description

 

1

09281251

1

Intermediate Z Frame (077, 078, 079, 081)

 

 

09281351

1

Intermediate Z Frame (080, 082)

 

2

06530400

6

Nut, Spin Lock Flange .312-18

 

3

09267151

1

Hinge, Footboard Left Hand

 

4

06543100

1

Nut, Locking Top Flange .31-18

 

5

09292251

1

Bumper/Guard

 

6

07049900

2

Bolt, Serrated Flange Washer Head .38-16 x 1.00

 

7

07053300

2

Nut, Retainer .375-16 x .37

 

8

07412900

8

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

 

9

05947500

1

Bolt, Hex .31-18 x 1.25 Grade 5

 

10

07533600

6

Bumper, Rubber

 

11

09283251

1

Seat Support

 

12

09282653

1

Footrest Panel

 

13

09267251

1

Hinge, Footboard Right Hand

 

14

06223900

4

Bolt, Round Head Square Neck .38-16 x .75 Grade 5

15

06542000

4

Nut, Locking Top Flange .38-16

 

16

09297253

1

Access Panel

 

17

07414100

2

Screw, Tapping .38-16 x 1.00 Hex Washer Head (310, 311)

16

2

3

17

12

PD3550

6

SEAT

Model 992077, 078, 079, 080, 081, 082, 310, 311

1

077, 078, 079,

9

080, 081, 082

11 2

8 10

3

9

310, 311

2

5

7

4

6

3

2

10

6 7

PD3560

Item

Part No.

Qty.

Description

1

09214500

1

Seat

2

06543100

4

Nut, Locking Top Flange .31-18 (077, 078, 079, 080, 081, 082)

 

06543100

5

Nut, Locking Top Flange .31-18 (310, 311)

3

034738

2

Bushing, Flange .515 x .750 x .745 x 1.00

4

00164351

1

Seat Pivot Mount

5

09282700

1

Rod, Seat Frame Pivot

6

05717100

2

Ring, Retaining External .500 x .050

7

06432500

2

Washer, Thrust 1.14 x 1.50 x .20

8

044486

1

Cable, Hood

9

05946800

2

Bolt, Hex .25-20 x .75 Grade 5

10

06543500

2

Nut, Locking Top Flange .25-20

11

07531700

1

Knob, Wing .312-18 (077, 078, 079, 080, 081, 082)

7

ENGINE AND CLUTCH

Model 992077, 078, 079, 080, 081, 082, 310, 311

 

 

 

27

 

1

32

 

 

 

 

 

 

25

 

 

 

28

1

 

 

 

 

 

 

 

 

 

see

26

 

 

 

3

 

 

 

"Fuel Tanks"

29

 

 

 

 

 

 

A

15

 

 

 

 

 

 

 

 

31

 

 

31

 

35

 

 

14

 

 

 

 

 

 

 

 

 

23

33

 

 

 

30

 

 

 

 

 

 

 

16 19

5

6

24

21

15

 

 

 

34

 

 

2

17

 

 

4

7

 

 

 

 

 

 

 

 

 

 

 

 

18

 

 

9

077, 078, 079, 080, 310, 311

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

4 13

 

 

 

 

 

 

 

20

8

 

10

22

 

 

 

 

 

081, 082

 

 

11

 

 

 

 

 

 

 

 

12

 

PD0790

 

 

 

 

 

 

 

 

Item

Part No.

Qty.

Description

 

 

 

 

 

 

1

08270000

1

Engine, Kohler, 25HP (081, 082)

 

 

 

 

 

 

08268800

1

Engine, Kawasaki 19HP (077, 310)

 

 

 

 

 

08268000

1

Engine, Kawasaki 21HP (078, 311)

 

 

 

 

 

08268900

1

Engine, Kawasaki 23HP (079, 080)

 

 

 

 

2

09294800

1

Muffler, Kohler (081, 082)

 

 

 

 

 

 

09281600

1

Muffler, Kawasaki (077, 078, 079, 080, 310, 311)

 

 

3

07218000

1

V-Belt HA 52 x .535 G48667

 

 

 

 

 

4

07414100

3

Screw, Tapping Hex Washer Head .38-16 x 1.00

 

 

5

05952400

1

Bolt, Hex .31-18 x 1.50 Grade 5

 

 

 

 

 

6

06543100

5

Nut, Locking Top Flange .31-18 (081, 082)

 

 

 

 

06543100

1

Nut, Locking Top Flang,e .31-18 (077, 078, 079, 080, 310, 311)

 

7

07327700

1

Pulley-V 4.00 x 1.125 with Key 1.42 Height

 

 

 

8

039160

1

Key, Square .25 x .625 x .25 SAE 8630 OR SAE 1035

 

 

9

09232700

1

Clutch, Electric

 

 

 

 

 

10

06445000

1

Washer, Flat Steel .515 x 1.625 x .25

 

 

 

 

11

06309300

1

Washer, Locking .44 x .109

 

 

 

 

 

12

05964600

1

Bolt, Hex .44-20 x 2.50 Grade 5

 

 

 

 

 

13

09282300

1

Weldment, Clutch Anchor

 

 

 

 

 

14

021134

31 in

Gas Line, Bulk .25 ID

 

 

 

 

 

15

06939100

23

Hose, Clamp

 

 

 

 

 

 

16

06308600

4

Washer, Lock .31 x .078 Regular (Included with item 1)

 

 

17

06538600

4

Nut, Hex M8-1.25 (Included with item 1)

 

 

 

18

02749600

1

Nipple (081, 082)

 

 

 

 

 

19

07023500

1

Elbow .375-18 (081, 082)

 

 

 

 

 

20

00113800

1

Pipe Plug (081, 082)

 

 

 

 

 

21

09295751

1

Bracket, Oil Filter Mounting-Kohler (081, 082)

 

 

 

22

06212200

2

Bolt, Round Head Square Neck .31-18 x .62 (081, 082)

 

 

23

05946900

2

Bolt, Hex .31-18 x 1.00 Grade 5 (081, 082)

 

 

 

24

06435700

2

Washer, Flat Steel .38 x .875 x .083 (081, 082)

 

 

 

25

09258800

1

Filter Minder (081, 082)

 

 

 

 

 

26

07065800

1

Nipple, .125 NPT (081, 082)

 

 

 

 

 

27

09257500

AR

Assembly, Air Cleaner

 

 

 

 

 

28

21537000

AR

Filter, Outer Element

 

 

 

 

 

29

21539500

AR

Fuel Filter, Kohler (081, 082)

 

 

 

 

 

 

21410800

AR

Fuel Filter, Kawasaki (077, 078, 079, 080, 310, 311)

 

 

30

21397200

AR

Oil Filter, Kohler (081, 082)

 

 

 

 

 

 

21535800

AR

Oil Filter, Kawasaki (077, 078, 079, 080, 310, 311)

 

 

31

21525900

AR

Spark Plug, Kohler (081, 082)

 

 

 

 

 

 

21536100

AR

Spark Plug, Kawasaki (077, 078, 079, 080, 310, 311)

 

 

32

21536900

AR

Filter, Inner Element

 

 

 

 

 

33

035329

1

Cock, Oil Drain (077, 078, 079, 310, 311)

 

 

 

34

035328

1

Adapter, Oil Drain (077, 078, 079, 310, 311)

 

 

 

35

021134

8 in

Gas Line, Bulk .25" ID (077, 078, 079, 310, 311)

 

 

8

FUEL TANKS AND HOSES

Model 992077, 078, 079, 080, 081, 082, 310, 311

2 4

3

3

4

9

 

 

 

4

 

 

 

3

 

1

 

2

 

 

 

 

 

 

11

 

 

 

13

 

 

 

5

 

 

10

6

Item

Part No.

Qty.

Description

1

09281500

1

Tank, Gas - Right Hand

2

05947000

8

Bolt, Hex .31-18 x .75 Grade 5

3

06308600

8

Washer, Locking .31 x .078

4

06435700

8

Washer, Flat Steel .38 x .875 x .083

5

021134

75 in

Gas Line, Bulk .25" ID

6

06939100

4

Hose, Clamp

7

00191100

1

Tank, Left Hand Fuel (EYE-Q) 100 Series

8

09258200

1

Valve, Fuel

9

09239500

2

Cap, Gas

10

050246

AR

Bushing

11

07064500

AR

Fuel Tank Fitting

12

06918200

1

Clamp, Cushioned Steel (081, 082)

13

05948700

1

Bolt, Hex .38-16 x 1.00 Grade 5 (081, 082)

14

06542000

1

Nut, Locking Top Flange .38-16 (081, 082)

7

9

6

10

11

5

4

3

2

see "Engine and Clutch"

A

6

14

6

12

8

PD3660

9

 

 

 

 

 

TRANSMISSION

 

Model 992077, 078, 079, 080, 081, 082, 310, 311

 

 

 

 

 

8

 

23

 

 

 

 

 

 

 

 

 

 

8

 

 

 

9

 

11

 

 

 

 

 

 

 

 

10

 

9

 

 

28

31

 

 

 

1

 

 

25

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30

27

26

28

 

 

 

 

 

 

 

 

 

 

 

 

 

20

 

 

 

 

 

 

 

 

17

22

 

 

 

10

 

 

 

21

 

 

 

 

 

 

14

 

 

 

 

3

 

12

 

13

 

 

2

 

 

 

 

 

 

 

24

 

 

 

 

10

 

 

15

 

 

 

19

16

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

18

 

10

2

 

7

5

 

 

 

 

3

 

29

6

 

 

 

 

 

24

 

 

 

 

 

 

 

 

4

5

7

PD3670

 

 

 

 

 

 

6

 

 

Item

Part No.

Qty. Description

 

 

 

 

 

1

09285100

1

Hydrostat BDP with Auxiliary

2

050995

2

Key, Straight 5mm x 25mm x 5mm

3

051138

2

Sheave 4.0 x .199

4

416904

2

Washer, Flat Steel .281 x 1.00 x .063

5

06308400

2

Washer, Locking .25 x .062

6

05969800

2

Bolt, Hex M6 x 1.0 x 12

7

05947900

4

Bolt, Hex .25-20 x .50 Grade 5

8

05958000

4

Bolt, Hex .38-16 x 1.25 Grade 5

9

06444300

4

Washer, Flat Steel .39 x .75 x .125

10

06542000

7

Nut, Locking Top Flange .38-16

11

09285200

1

Pump

12

09219000

1

Assembly,Idler Arm Guard Drive (Includes 13 & 14)

13

09217051

1

Weldment, Idler Arm Ground Drive

14

05435800

2

Bearing, 1.00 x 1.12 x .75

15

09231100

1

Anchor, Idler Spring

16

08336000

1

Spring, Tension .120 x .845 x 6.50

17

06444300

1

Washer, Flat Steel .39 x.75 x.125

18

05965800

1

Bolt, Hex .50-13 x 3.50 Grade 5

19

07053100

1

Bearing, Pedestal Powdered Metal

20

06543600

1

Nut, Locking Top Flange .50-13

21

07327500

1

Idler, Flat 4.00 x 1.06

22

05962900

1

Bolt, Hex .38-16 x 2.25 Grade 5

23

09274900

1

Fan, Cooling

24

06442800

4

Washer, Flat Steel .656 x 1.31 x .095

25

09282900

2

Bracket, Return to Neutral/Damper

26

02513500

2

Spacer .344 x 1.00 x .375

27

05947500

2

Bolt, Hex .31-18 x 1.25 Grade 5

28

06543100

4

Nut, Locking Top Flange .31-18

29

05959400

1

Bolt, Hex .38-16 x .75 Grade 5

30

59203600

AR

Kit, Pump Seal (BDP-10A)(One kit required for each pump)

31

03652200

2

Stud, Ball

10

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