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 |
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
Model 992077, 078, 079, 080, 081, 082, 310, 311
1
12
11
2
10
|
|
|
07735300B |
3 |
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4 |
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9 |
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5 |
07757600A |
|
4.5 |
||
|
4
07757500A
|
3.5 |
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3 |
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2.5 |
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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
Model 992077, 078, 079, 080, 081, 082, 310, 311
4 |
8 |
|
10 |
11 |
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5 |
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6 |
||
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9 |
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2 |
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7 |
8
10
1
14
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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
Model 992077, 078, 079, 080, 081, 082, 310, 311
|
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27 |
|
1 |
32 |
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25 |
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28 |
1 |
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see |
26 |
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3 |
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"Fuel Tanks" |
29 |
|
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|
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A |
15 |
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31 |
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31 |
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35 |
||
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14 |
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23 |
33 |
||
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30 |
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16 19 |
5 |
6 |
24 |
21 |
15 |
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34 |
||||||
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2 |
17 |
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4 |
7 |
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18 |
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|
9 |
077, 078, 079, 080, 310, 311 |
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6 |
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4 13 |
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20 |
8 |
|
10 |
22 |
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081, 082 |
|
|
11 |
|
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12 |
|
PD0790 |
|
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||
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) |
|
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|
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||
|
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 |
|
|
|
|
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|
15 |
06939100 |
23 |
Hose, Clamp |
|
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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) |
|
|
|
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|
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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) |
|
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|
27 |
09257500 |
AR |
Assembly, Air Cleaner |
|
|
|
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|
28 |
21537000 |
AR |
Filter, Outer Element |
|
|
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|
|
|
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) |
|
|
|
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|
|
|
21535800 |
AR |
Oil Filter, Kawasaki (077, 078, 079, 080, 310, 311) |
|
|
||||
31 |
21525900 |
AR |
Spark Plug, Kohler (081, 082) |
|
|
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|
|
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
Model 992077, 078, 079, 080, 081, 082, 310, 311
2 4
3
3
4
9
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4 |
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3 |
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1 |
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2 |
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11 |
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13 |
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5 |
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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
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TRANSMISSION |
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||
Model 992077, 078, 079, 080, 081, 082, 310, 311 |
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8 |
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23 |
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8 |
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9 |
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11 |
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10 |
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9 |
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28 |
31 |
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1 |
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25 |
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30 |
27 |
26 |
28 |
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20 |
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17 |
22 |
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10 |
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21 |
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14 |
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3 |
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12 |
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13 |
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2 |
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24 |
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10 |
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15 |
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19 |
16 |
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4 |
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18 |
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10 |
2 |
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7 |
5 |
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3 |
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29 |
6 |
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24 |
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4 |
5 |
7 |
PD3670 |
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6 |
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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