Gravely Promaster 300 Service Manual
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Gravely Promaster 300 Service Manual

Gravely Promaster 300 Service Manual

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Summary of Contents for Gravely Promaster 300

  • Page 2: Table Of Contents

    Section 7 - Steering & Controls ... 7-16 12.11 Promaster 300 Electrical ... 12-43 7.1 Directional Control Cable ... . . 7-16 12.12 Interlock Switch.

  • Page 3: Section 1 - Introduction

    Operation and may void the warranty. Gravely disclaims liability for any claims or damages, whether warranty, property Before operation of the unit, carefully and completely damage, personal injury, or death arising out of the use read manuals supplied with the unit.

  • Page 4: Section 2 - Safety

    SECTION 2 - SAFETY 2.1 SAFETY ALERTS 2.6 PREPARATION Look for these symbols to point out Before starting any removal of parts, proper important safety precautions. They preparation is very important for efficient work. A clean mean: work area at the start of each job will allow you to perform service repairs easily and quickly.

  • Page 5: Safety Rules

    If leak drop offs, ditches, or embankments. Unit can suddenly occurs, have it repaired by your Gravely Dealer. turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.
  • Page 6 Protect eyes, face, and head from objects that may be Keep nuts and bolts tight and keep equipment in safe thrown from unit. Wear appropriate hearing protection. operating conditions. Avoid Sharp Edges. Sharp edges can cut. Moving Before maintenance, adjustments, or service (except parts can cut or amputate fingers or a hand.

  • Page 7: Section 3 - Specifications

    SECTION 3 - SPECIFICATIONS Model 990014 990015 990017 PM300 PM300 PM300 Engine Manufacturer Kohler Kohler Briggs & Stratton Model Number CV20S CV25 381777 Cycle Horsepower Steering Yoke Steering Yoke Steering Yoke Steering Turning Radius Zero Turn Zero Turn Zero Turn Front Tire Size 18 x 8.50 - 8, 4 ply 18 x 8.50 - 8, 4 ply...

  • Page 8: Section 4 - General Maintenance & Adjustments

    SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 1. Handlebar 7. Hour Meter 2. Choke Control 8. Ignition Switch 3. Mower Lift Lever 9. Parking Brake Lever 4. PTO Switch 10. Low Oil Pressure Warning Light 5. Direction Control Pedal 11.

  • Page 9: Filling The Fuel Tank

    50 hours of operation and every 500 hours thereafter. NOTE: Use only a replacement filter purchased from Gravely. Do not use an engine oil filter for the specified CAUTION: Read this manual and the Owner/ transmission filter.

  • Page 10: Adjustment Of Direction Control Pedal

    6. Loosen the jam nut and turn adjusting bolt clockwise for reverse creep or counterclockwise for forward creep until the free drive wheel stops. 7. Retighten the jam nut. 8. Tighten the two 5/16-18 retaining bolts to 14 ft-lbs (19 Nm) to secure the position of the neutral stop weldment.

  • Page 11: Section 5 - Engine

    SECTION 5 - ENGINE 5.1 ENGINE TROUBLESHOOTING The troubleshooting key is generic and can be used for several types of engines. Use only those possible The following troubleshooting chart is to be used to causes and corrective actions that apply to the isolate engine problems and give possible causes and unit.

  • Page 12: Engine Removal

    5.2 ENGINE REMOVAL 1. Disconnect the negative battery cables from battery. 2. Disconnect the fuel line at the gas tank. Drain any fuel from line. 3. Disconnect the throttle and choke cables. 4. Disconnect the battery and lead at starter, battery - lead and white ground lead at engine ground point, oil sensor and 2 lead engine connector.

  • Page 13: Section 6 - Mower Deck

    SECTION 6 - MOWER DECK 6.1 INSTALLING MOWER 1. Park unit on level surface, engage parking brake, shut off engine, and remove ignition key. 2. Move mower into position in front of unit. 3. Attach mower to unit with mounting hardware as shown below.

  • Page 14: Adjust Height Of Cut (50" Mower)

    3. Raise the mower by pulling up on the mower lift lever until the two mower locking pins can be removed. 4. Adjust mower to the desired height and reinsert the mower locking pins. Be sure to lock them behind the pin locking tabs.

  • Page 15: Spindle Replacement

    DO NOT grind around corner at top of blade. If cutting edge of blade cannot be sharpened to a square corner to within 1/8" of its end, replace blade with Gravely replacement blade only. Blades are available through your Gravely Dealer.

  • Page 16: Section 7 - Steering & Controls

    SECTION 7 - STEERING & CONTROLS 7.1 DIRECTIONAL CONTROL CABLE 4. Slide the cable out through the two brackets and remove from frame. 5. Inspect and replace any worn or damaged parts. 6. Reassemble in the reverse order. Turn the cable rod ends to the position marked prior to removal.

  • Page 17: Steering Shaft Removal

    3. Install the new cable in reverse order. See 3. Remove the cable. Figure 14. Adjust the cable tension by tightening 4. Install new cable. Reassemble in reverse order. the outside jam nuts on the cable, tighten inside NOTE: Be sure that when the brake lever is pulled jam nuts.

  • Page 18: Brake Pivot And Brake Arm

    7.7 BRAKE PIVOT AND BRAKE ARM 1. Disconnect the brake cable at the brake arm weldment. 2. Remove the two hex bolts attaching the brake pivot to the frame. Remove pivot and arm assembly. Separate the two by removing the E-ring. 3.

  • Page 19: Section 8 - Hydraulic System

    NOTE: Place lift lever into float position prior to working 4. Reconnect supply line if drained. on hydraulic system. Some lines may have pressure on 5. Replace filter with a new "Gravely" filter to insure them. proper oil filtering. 3. After any hydraulic hose maintenance, change oil 6.
  • Page 20 1. Drive Coupler 3. Hydraulic Pump 2. Hydraulic Tank 4. Housing Figure 17 PF1643 8 - 20...

  • Page 21: Hydraulic Tank

    8.3 HYDRAULIC TANK 3. Remove the two Allen bolts and lift the pump from the pump housing. 1. Place an open-top container that will hold at least NOTE: Pump is not repairable. 4 quarts of oil under the unit behind the right tire. 4.

  • Page 22: Hydraulic Valve Pressure Adjustment

    NOTE: On the earlier models of the Promaster 300, the 4. Start the engine and run at full throttle. Have lift position was "forward", hold position "center" and another person hold the hydraulic lift control in the float position "back".

  • Page 23: Section 9 - Drive Train

    SECTION 9 - DRIVE TRAIN 9.1 TRANSMISSION REMOVAL 4. Raise and block the drive wheels off the floor. 5. Remove the drive wheels. 6. Disconnect the wiring harness from the neutral start interlock switch(s). 7. Place an open-top container under the transmission and remove the two lower hydraulic hoses and the upper return hose.

  • Page 24: Eaton 851 Transmission

    9.2 EATON 851 TRANSMISSION The following tools are required for disassembly and reassembly of the transaxle. The following repair information applies to the Eaton • 3/8 in. Socket or End Wrench. 851 series hydrostatic transaxles. • 1 in. Socket or End Wrench •...

  • Page 25: Axle Housing Disassembly

    9.3 AXLE HOUSING DISASSEMBLY 6. Remove the axle from the axle housing by using a small press or by tapping the splined end of the 1. With the transaxle secure, use a 3/8 inch socket or axle shaft with a plastic head hammer. This will end wrench to remove the flange screws from one dislodge the seal and bearing from the axle (A-side or B-side) axle housing assembly.

  • Page 26: Motor Rotor Disassembly

    the friction pad assembly, reaction plate and backup 9.4 MOTOR ROTOR DISASSEMBLY plate. When the brake is applied, the rotating reaction IMPORTANT: Be extremely careful when removing the plate is squeezed between the stationary friction pad motor rotor assembly. The ball pistons are spring and the backup plate.

  • Page 27: Pump And Motor Rotor Inspection

    Turn the cover assembly back over and using a 19.Carefully remove the pump rotor assembly from No. 5 or 7 internal retaining ring pliers, remove the the housing, making sure the ball pistons are not input shaft retaining ring. dislodged from their bores. 9.

  • Page 28: Transaxle Reassembly

    7. To inspect the charge pump assembly, use a 5/32 11.Remove the O-ring from the dump valve nut. hex key to remove the cap screws from the charge 12.After removing the dump valve nut, remove the pump plate (see Figure 30). dump valve bracket and spring from the housing by sliding them over and lifting upward.

  • Page 29: Transaxle With Charge Pump

    9.8 TRANSAXLE WITH CHARGE PUMP 6. Aligning the rotation arrow with the input rotation, install the pump plate over the generator. 7. Install the four cap screws in the pump plate finger tight. 8. The bottom side of the pump rotor assembly incorporates five drive pins.

  • Page 30: Cover Reassembly

    15.Install the charge pressure relief valve spring in its bore. 16.Install the drive in the pump rotor assembly. 17.Install the cover gasket on the housing assembly. 9.9 COVER REASSEMBLY Figure 35 7. After engaging the control shaft and pivot dowel in the cover assembly, carefully rotate the input shaft Figure 34 to engage the pump rotor drive.

  • Page 31: Axle Housing Reassembly

    9.10 AXLE HOUSING REASSEMBLY of the ring gear with the notches in the housing assembly. (One axle housing or two, use the same 12.Rotate the secondary carrier assembly planet procedure for each). gears to align with the ring gear teeth. 13.When they are all in alignment, the ring gear will fall into place.

  • Page 32: Fluid Recommendations

    19.Install the primary sun gear (first) into the primary planetary assembly. Figure 39 20.Lubricate and install the backup plate in the axle housing assembly. Install by aligning the ears with Figure 40 the notches in the axle housing. 21.Aligning the splines, install the reaction plate on the primary sun gear (friction material must be 27.Reposition the transaxle and install the gasket and toward backup plate).

  • Page 33: Front Wheel

    5. Remove the transmission idler spring. Remove the 2. Use a screw driver to pry off the dust cap. Remove transmission belt, first from the idler pulley and the axle nut and slide wheel assembly off the then from the double groove engine sheave. washer and the outer bearing can be removed.
  • Page 34 4. Remove hub (remove key and spacer if needed). 5. Remove the cotter key and loosen the castle nut a couple of turns. Use a gear puller to brake the hub loose. Remove castle nut and washer, slide hub off (remove key if needed).

  • Page 35: Section 10 - Fuel System

    SECTION 10 - FUEL SYSTEM 10.1 FUEL SYSTEM TROUBLESHOOTING The troubleshooting key is generic and can be used for several types of transmissions. Use only those The following troubleshooting chart is to be used to possible causes and corrective actions that apply to the isolate fuel system problems and give possible causes unit.

  • Page 36: Section 11 - Power Take-Off (Pto)

    SECTION 11 - POWER TAKE-OFF (PTO) 3. Remove the idler spring, PTO belt, and the electric clutch (Figure 44). CAUTION: Before performing any service or 4. Install the electric clutch and torque the bolt to adjustments: 50 ft-lbs (67.8 Nm). 1.

  • Page 37: Section 12 - Electrical

    Digital meters do not have a movement and are there- colors). fore more rugged. The reading shows up directly on a Gravely Company recommends that all work be done display window of some type. Since they read direct, in a professional manner. The use of the tubing to...

  • Page 38: Battery

    Voltage Measurement WARNING: EXPLOSIVE GASES can result There are two basic rules to be remembered when in serious injury or death. ALWAYS keep open using a voltmeter. A voltmeter measures the voltage flames, sparks, or smoking materials away difference between the test leads and the voltmeter is from battery.
  • Page 39 Clean Battery IMPORTANT: When distilled water is added to battery during freezing weather, battery must be charged to Corrosion and dirt on the battery and terminals can mix water with electrolyte, or water will remain at top cause the battery to "leak" power. and freeze.

  • Page 40: Switches

    2. Connect the positive (+) jumper cable to the Specific % of Charging positive (+) terminal of the discharged battery. Gravity Charge Time 3. Connect the other end of the same jumper cable to 12.4 1.225 3 hours the positive (+) terminal of the booster battery. 4.

  • Page 41: Solenoid And Relays

    RUN Position - Should be continuity between contacts The starter solenoid in the Gravely equipment is a B and A. These connections supply power to the rest of sealed unit used to actuate the starter motor on the the wiring harness.

  • Page 42: Lighting Circuits

    To check the solenoid, disconnect the cables to the 12.8 DIODES AND RECTIFIERS starter motor, turn the ignition switch to the start Diodes are solid state, semiconductor devices. They position, and listen for the solenoid to snap inside contain no moving parts and conduct current better in contacts closed.

  • Page 43: Checking The Pto Clutch

    Engine servicing and repair should be referred to local engine manufactures service centers that have the service information and parts available to properly service the engine. Gravely dealers should be able to test engines and engine components to pinpoint troubles and narrow them down to properly advise the engine serviceman.

  • Page 44: Interlock Switch

    5. Turn the key to position 3. Sequentially touch pins 12.14 TIME DELAY MODULE R, I, and S with the free lead. A circuit (zero ohms) 1. Inspect and clean all wire connections. should be indicated. Touch the free lead to the 2.

  • Page 45: Continuity Diagrams

    12.16 CONTINUITY DIAGRAMS Models 990014, 990015, 990017 The diagrams below show the various states of connection for electrical components. The solid lines on switches show continuity. NOTE: All switches are viewed from the rear. Key Switch Relay (03602300) (046216) START NOT ENERGIZED ENERGIZED Seat Switch...
  • Page 46 Promaster 300 - Kohler Engine Key Switch Start Red (B) 12.00 Vdc 12.00 Vdc 12.00 Vdc Purple (A) 12.00 Vdc 12.00 Vdc Red / Violet (S2) 12.00 Vdc 12.00 Vdc Brown (S1) 12.00 Vdc Contact resistance is 0.1 - 0.3 ohms when correct.
  • Page 47 Promaster 300 - Kohler Engine Brake Switch Start Yellow / Red 12.00 Vdc Yellow / Red 12.00 Vdc Switch Fwd / Rev Neutral Start Brown / Yellow 12.00 Vdc Brown / Yellow 12.00 Vdc Normally closed contacts, manually activated. Contact resistance is 0.1 - 0.3 ohms when correct.

  • Page 48: Wiring Diagrams

    12.17 WIRING DIAGRAMS Models 990014, 990015 TIME DELAY MODULE S E A T / P T O R E L A Y G R E E N / W H I T E 86 85 SEAT SWITCH P I N K SWITCH CLUTCH PURPLE /...
  • Page 49 Model 990017 TIME DELAY MODULE S E A T / P T O R E L A Y G R E E N / W H I T E 86 85 SEAT SWITCH P I N K SWITCH CLUTCH PURPLE / WHITE HOURMETER P U R P L E...
  • Page 50 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.com...

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