Gravely 990100, 990101, 990102 User Manual
Rapid XZ
Shown with optional 60” deck.
Parts Manual
Models
990100 - 27hp
990101 - 25hp
990102 - 30hp
00615300D 9/09
Printed in USA
THE MANUAL
PRODUCT REGISTRATION
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:
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 lubrican ts m anufa ctured with the sam e preci sion
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 990100
Rapid XZ, 27hp Kohler
Horizontal
Serial No. 000100 and up
Model 990101
Rapid XZ, 25hp Kohler
Hozizontal
Serial No. 000100 and up
TABLE OF CONTENTS
DECALS
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAIN FRAME
Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER PLANT
Model 990102
Rapid XZ, 30hp Kohler
Horizontal
Serial No. 000100 and up
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Tanks and Hoses . . . . . . . . . . . . . . . . . . . . . . . 12
DRIVE TRAIN
Hydrostatic Pumps and Idlers . . . . . . . . . . . . . . . . . 14
Rear Axle and Weights . . . . . . . . . . . . . . . . . . . . . . 16
OPERATOR CONTROLS
Brake Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Steering Levers & Linkages . . . . . . . . . . . . . . . . . . . 20
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULICS
Weight Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic Tank, Filter, Pumps, & Hoses. . . . . . . . . . 26
Hydraulic Routing Diagram . . . . . . . . . . . . . . . . . . . 28
ELECTRICAL
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Continuity Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3
© Copyright 2009 Ariens Company
Model 990100, 101, 102
07757600C
05363100
07757500B
ON
OFF
UP
DOWN
ATTACHMENT
LIFT
WEIGHT
TRANSFER
UP
DOWN
05363000A
A
4
9
7
6
PD3283
5
1
2
8
3
DECALS
Item Part No. Qty . Description
1 05363100 1 Decal, Service Instructions Rapid XZ
2 07757600 1 Decal, Instructional Steering
3 05363300 2 Decal, Gravely Rapid XZ Hood
4 07757500 1 Decal, Parking Brake Lever
5 05363000 1 Decal, Control Panel Rapid XZ
6 05231800 1 Decal, Gravely Logo
7 05305100 1 Decal, American Flag
8 07735200 2 Decal, Danger
9 07754100 1 Decal, Hot Surface
4
FRAME
1
4
7
11
10
9
6
5
2
22
8
13
14
3
10
12
12
23
17
16
19
21
18
18
19
20
20
15
12
10
10
10
Model 990100, 101, 102
Item Part No. Qty. Description
1 00474551 1 Weldment, Frame
2 00601451 1 Plate, Kohler Engine Mounting
3 06223600 2 Bolt, Round Head Square Neck .38-16 x 1.00 Grade 5
4 00668151 1 Guard, Hose Fitting - Left Hand
5 00666451 1 Guard, Hose Fitting - Right Hand
6 00664951 1 Bracket, Left Hand Hood Mounting
7 00665051 1 Bracket, Right Hand Hood Mounting
8 09079500 2 Latch, Rubber
9 00589153 1 Weldment, Foot Plate
10 07415400 10 Screw, Tapping .38-16 x .75 Hex Washer Head
1 1 00653551 1 Guard, Pump Belt
12 06545500 11 Nut, .38-16 Nyloc Flange
13 06224100 3 Bolt, Round Head Square Neck .38-16 x 1.25 Grade 5
14 00390951 1 Weldment, Clutch Stop
15 03652200 2 Stud, Ball
16 06116700 4 Screw, Machine 10-24 x .50 Hex Washer Head
17 07412900 4 Screw, Tapping .38-16 x .50 Hex Washer Head Thread Rolling
18 06543600 2 Nut, Locking Top Flange .50-13
19 05527200 2 Bushing, Flange .515 x .746 x 1.290 x 1.000
20 05961000 2 Bolt, Hex .50-13 x 2.25 Grade 5
21 08329100 1 Spring, Compression .085 x .80 x 1.00 WLD36
22 06223800 4 Bolt, Round Head Square Neck .38-16 x 1.75 Grade 5
23 00606051 2 Strap, Engine Mounting Support
5
Model 990100, 101, 102
PD0780
6
7
2
3
5
4
1
8
9
4
5
8
8
7
10
11
12
13
14
15
16
17
20
18
19
SEAT
6
SEAT
Item Part No. Qty. Description
1 03947200 1 Seat, Suspension, Light Grey (Includes items 13 – 20)
2 00474151 1 Plate, Seat Pivot
3 00587700 1 Rod, Seat Pivot (Outfront)
4 05521100 2 Bushing, Flange .515 x .750 x .745 x 1.00 Nylon
5 05717100 2 Ring, Retaining External .500 x .050
6 05947000 1 Bolt, Hex .31-18 x .75 Grade 5
7 06446300 2 Washer, Flat Steel .344 x 1.125 x .135
8 06545400 6 Nut, Nyloc Flange .31-18
9 06900010 1 Cable, Seat Prop
10 06216100 1 Bolt, Round Head Square Neck .31-18 x 1.00 Grade 5
11 07533600 2 Bumper, Rubber
12 06530400 2 Nut, Spin Lock Flange .312-18
13 59210400 AR Kit, Right Hand Armrest Assembly
14 59210500 AR Kit, Left Hand Armrest Assembly
15 59208800 AR Kit, Back Cushion, Light Grey
16 59208900 AR Kit, Seat Cushion, Light Grey
17 59208000 AR Kit, Seat Knobs
18 59208100 AR Kit, Seat Back
19 59207900 AR Kit, Seat Slides
20 59207800 AR Kit, Seat Spring and Saddle
Model 990100, 101, 102
7
Model 990100, 101, 102
1
2
2
3
4
5
5
6
6
7
7
8
8
8
8
9
9
10
12
11
13
14
15
3
3
16
HOOD
Item Part No. Qty. Description
1 00497353 1 Hood, Outfront Rapid XZ
2 07412900 10 Screw, Tapping .38-16 x .50 Hex Washer Head Thread
3 07415400 5 Screw, Tapping .38-16 x .75 Hex Washer Head Thread
4 00667553 1 Support, Lateral Hood
5 06530400 2 Nut, Spin Lock Flange .312-18
6 07533600 2 Bumper, Rubber
7 05963700 2 Bolt, Hex .31-18 x 2.25 Grade 5
8 06446300 4 Washer, Flat Steel .344 x 1.125 x .135
9 00476300 2 Spacer
10 06529800 2 Nut, Locking-Center .31-18
11 00595653 1 Bracket, Hood Left Hand
12 00595753 1 Bracket, Hood Right Hand
13 00664151 1 Bracket, Hood Support #2
14 00664051 1 Bracket, Hood Support #1
15 00676851 1 Cover, Wire
16 07517300 1 Wire Tie (Clutch wire to wire cover)
8
NOTES
9
Model 990100, 101, 102
1
2
10
12
13
15
18
17
4
5
6
7
8
9
25
3
PD3790
22
21
19
20
11
16
12
19
8
24
23
23
26
28
27
27
31
30
29
34
33
32
35
36
37
14
38
39
43
42
41
40
ENGINE AND CLUTCH
10
ENGINE/CLUTCH
Item Part No. Qty. Description
1 08200132 1 Engine, 27hp Kohler (990100)
08200118 1 Engine, 25hp Kohler (990101)
08200145 1 Engine, 30hp Kohler (990102)
2 07200113 1 Belt, B 41.313 Matched Set
3 00667451 1 Bracket, PTO Idler Mounting
4 06225000 1 Bolt, Round Head Square Neck .50-13 x 3.50 Grade 5
5 07300041 1 Sheave, Poly-V
6 00697900 1 Clutch, Warner Double Groove
7 06224100 1 Bolt, Round Head Square Neck .38-16 x 1.25 Grade 5
8 06545500 2 Nut, .38-16 Nyloc Flange
9 06529600 1 Nut, Locking Center .38-16
10 06308800 3 Washer, Locking .38 x .094 Regular
1 1 05948700 3 Bolt, Hex .38-16 x 1.00 Grade 5
12 07327600 2 V-Idler, 4.00 x .38
13 06400018 1 Washer, .406 x 1.0 x .38THK
14 00652700 1 Assembly, Idler Pivot Assembly (includes items 15 and 19)
15 00652300 1 Weldment, PTO Idler Pivot Arm (OFM)
16 06435900 1 Washer, Flat Steel .438 x 1.00 x .083
17 05957800 1 Bolt, Hex .38-16 x 3.00 Grade 5
18 07000031 1 Bearing, Pedest a l
19 05435800 2 Bearing, 1.00 x 1.12 x .75
20 06430200 1 Washer, Flat Steel .531 x 1.250 x .100
21 06500010 1 Nut, .50-13 Nyloc Flange
22 07030000 1 Bolt, Eye .375-16 x 2.50
23 06529400 2 Nut, Hex .38-16
24 06437200 1 Washer, Flat Steel .344 x .688 x .065
25 06529800 1 Nut, Locking Center .31-18
26 09267300 1 Pin, Pivot
27 07531700 2 Knob, Wing
28 00865151 1 Shroud, Cooling
29 00866951 1 Bracket, Tank Shroud Left Hand
30 00867051 1 Bracket, Tank Shroud Right Hand
31 05957900 4 Bolt, Hex .38-16 x 1.50 Grade 5
32 06223600 2 Bolt, Round Head Square Neck .38-16 x 1.00 Grade 5
33 06545500 4 Nut, .38-16 Nyloc Flange
34 00682451 1 Mount, Hydraulic Tank
35 06545500 2 Nut, .38-16 Nyloc Flange
36 05962900 4 Bolt, Hex .38-16 x 2.25 Grade 5
37 06542000 4 Nut, Locking Top Flange .38-16
38 06916000 2 J-Clamp
39 06437300 2 Washer, Flat Steel .281 x .62 x .065
40 05900040 1 Bolt, Hex .44-20 x 2.25 Grade 5 EP80
41 06309300 1 Washer, Locking .44 x .109 Regular
42 06603400 1 Key
43 08321200 1 Spring, Tension .135X.69X5.75
Model 990100, 101, 102
11
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