Gravely Lawn Mower 985103 User Manual

Professional 2-WheelTractor

Service Manual

Models 985103,104, 105, 107 - 115, 117

08483800 08/00

Printed in USA

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SECTION 1 - INTRODUCTION

1.1 THE MANUAL

1.4 UNAUTHORIZED REPLACEMENT

PARTS

The purpose of this manual is to provide complete

instructions for service, maintenance, disassembly,

repair, and installation of the mechanical components

for the unit.

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.

Dealer trained service personnel should use this

manual as a supplement to and reminder of the training

sessions conducted by the company.

Read all information for servicing a part or system

before repair work is started to avoid needless

disassembly.

1.5 DISCLAIMER

Operation

Gravely reserves the right to discontinue, make

changes to, and add improvements upon its products

at any time without public notice or obligation. The

descriptions and specifications contained in this

manual were in effect at printing. Equipment described

within this manual may be optional. Some illustrations

may not be applicable to your unit.

Before operation of the 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.

Safety Messages

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.

1.6 TECHNICAL SERVICE

COMMUNICATIONS

Gravely Technical Service communicates information

to the field using Service Letters, Service Bulletins,

Product Notices, and Campaigns. Each

Directional Reference

All reference to left, right, front, or rear are given from

the operator in the operator position and facing the

direction of forward travel.

communication signifies a type of information and

priority. The dealer is responsible to carry out the

directive provided in the communication. The types of

communication are:

1.2 SERVICE AND REPLACEMENT PARTS

Service Letter - General technical information for the

dealer. Technical information on how to service the

product and product improvements.

When ordering publications, replacement parts, or

making service inquiries, know the Model and Serial

numbers of your unit and engine.

Service Bulletin - Notification to update products to

resolve certain issues or a notification of a policy

change.

Numbers are located on the product registration form in

the unit literature package. They are printed on a serial

number label, located under the hood of your unit.

Product Notices - Notification of limited product

located in a certain region. This is a limited distribution

to only those who received the product involved.

1.3 PRODUCT REGISTRATION

A warranty registration card must be filled out, signed,

and returned at time of purchase. This card activates

the warranty. Claims meeting requirements during

limited warranty period will be honored.

Campaigns - Notification of a safety related issue. All

products must be updated and are tracked by the

factory until all units are corrected.

Specific Model and Serial Numbers are on a label

located on the frame of your Tractor and on a label

located on the product registration form. Record those

numbers below and transfer the label from the product

registration to place indicated below. Use these

numbers whenever parts or service is required.

1 -3

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in the disassembly order on a clean work surface.

Organization is a key part of proper reassembly.

1.7 PREPARATION

Before starting any removal of parts, proper

preparation is very important for efficient work. A clean

work area at the start of each job will allow you to

perform service repairs easily and quickly.

Tools, instruments, and parts needed for the job should

be gathered before work is started. Interrupting a job to

locate tools or parts is a needless delay.

To reduce the incidence of misplaced tools or parts,

place removed components with all attaching hardware

SECTION 2 - SAFETY

unsafe conditions and the possibility of minor,

moderate, or serious injury or death. Learn applicable

rules and laws in your area.

2.1 SAFETY ALERTS

Look for these symbols to point out

important safety precautions. They

mean:

2.5 MAINTENANCE AND STORAGE

Attention!

Keep the equipment in good condition. Maintain it as

directed in this manual. Check all hardware at regular

intervals.

Personal Safety Is Involved!

Become Alert!

Use only Gravely accessories, attachment and

replacement parts.

Obey The Message!

2.2 SIGNAL WORDS

Do not overspeed the engine. Do not override the

governor.

The safety alert symbol is used in decals on the unit

and with proper operation procedures in this manual.

They alert you to the existence and relative degree of

hazards.

Before making any repairs, adjustments inspections or

cleaning unit disengage the PTO, turn off and remove

the ignition key and wait for all motion to stop.

Understand the safety message. It contains important

information about personal safety on or near the unit.

To reduce fire hazard and overheating, keep

equipment free of grass, leaves, debris or excessive

lubricants.

DANGER: IMMINENTLY HAZARDOUS

SITUATION! If not avoided, WILL RESULT in

death or serious injury.

Worn out mufflers can result in fire or explosion and

should be replaced immediately.

Never store equipment with gasoline in tank inside a

building where fumes may reach an open flame or

spark. Allow engine to cool before storing in any

enclosure.

WARNING: POTENTIALLY HAZARDOUS

SITUATION! If not avoided, COULD RESULT

in death or serious injury.

2.6 SAFETY RULES

Improper use of this tractor can injure people and

damage the equipment. People using or servicing this

tractor must read and follow the instructions in this

manual.

CAUTION: POTENTIALLY HAZARDOUS

SITUATION! If not avoided, MAY RESULT in

minor or moderate injury. It may also be used

to alert against unsafe practices.

It is important to understand that this manual and any

other Gravely instruction manuals do not cover every

possible danger. It is impossible for Gravely to know of

all possible dangers in operating and servicing the

tractor and attachments.

2.3 NOTATIONS

NOTE: General reference information for proper oper-

ation and maintenance practices.

IMPORTANT: Specific procedures or information

required to prevent damage to unit or attachment.

The purchaser must give these instructions to the

people operating and maintaining this tractor. These

people must use eye and foot protection.

2.4 PRACTICES AND LAWS

2.7 TRAINING

Read this manual, the attachment manual and the

engine manual carefully before operating unit.

Practice usual and customary safe working

precautions, for the benefit of yourself and others.

Understand and follow all safety messages. Be alert to

2 -4

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Learn the location and function of all controls.

only if at least one of the operator presence switches is

depressed.

Learn how to use the controls to stop the wheels and

attachment quickly in an emergency.

Do not use the equipment in the dark without adequate

lighting.

Understand and follow each danger, warning, caution

and instruction decal installed on this product.

Keep away from moving parts. Stay clear of the

attachment whenever the engine is running.

Never permit children to operate the Two-Wheel

Tractor. Do not allow adults to operate it without proper

instruction. Safe operation of this equipment requires

your complete and unimpaired attention at all times. Do

not operate unit after or during the consumption of

drugs or alcohol.

Do not let people other than the operator near the

operating equipment. Never direct disengage the

attachment drive when moving the tractor to and from

work areas.

Use a slow speed and engage the shift lever slowly

when operating on slopes.

Keep all people and animals away from the operating

area.

Travel across slopes, not up and down. Use extreme

caution when changing direction on slopes. Do not

operate on steep slopes.

2.8 PREPARATION

Use caution with gasoline. Gasoline is very flammable

and its vapors are explosive. Keep it in a clean, tight

and approved (Red) container. Never put gasoline in

the fuel tank while the engine is running or hot. Clean

up spilled gasoline before starting engine. Do not fill

fuel tank indoors. Never allow smoking materials,

sparks or flame (match, pilot light, etc.) near mower or

fuel container. Replace fuel tank cap and fuel container

cap securely.

Look for and keep away from hazards, such as

dropoffs. Stay alert for holes, rocks and other hidden

hazards in the area of operation.

After hitting an object, disengage the PTO, turn off and

remove the ignition key and wait for all motion to stop.

Check for damage. Repair any damage before

restarting unit.

Look behind when operating in reverse. Look for

people and hazards.

Inspect area of operation and remove all material

which could be thrown by the attachment such as

stones, sticks, wires and other foreign objects.

Operate only from the operator’s position, just behind

the handlebars.

If there is a sudden change in the sound or vibration of

the equipment, disengage the PTO, turn off and

remove the ignition key, wait for all motion to stop and

check for damage. Repair any damage or failure before

restarting unit.

When hauling the equipment, connect the chassis to

the transporting vehicle. Never connect from control

levers, rods, or like items that could be damaged.

Replace all parts that become damaged or lost.

Wear hand, foot, head, ear and eye protection. Do not

wear loose clothing, which might get caught in rotating

parts of the unit.

Never run the engine indoors except to move it outside.

Exhaust fumes are dangerous.

Go slowly on slick surfaces. Always be sure of your

footing, keep a firm grip on the handlebars and walk,

never run.

Before making adjustments, cleaning, removing

obstructions or servicing the tractor or attachment

move the PTO to "OFF", turn the ignition switch to

"OFF", remove the ignition key and wait until all moving

parts completely stop.

Follow traffic laws when operating on or near a road.

Before leaving the operator’s position, put the PTO

lever in the "OFF" position, turn off and remove ignition

key. Move the shift control to first gear position.

WARNING: Always block wheels and know

that jack stands or blocks used are stable,

strong, or secure and will hold the weight of

the unit during maintenance.

Do not touch parts which might be hot from operation.

Before attempting to maintain, adjust or service allow

such parts to cool.

2.9 OPERATION

Be certain that all shields, guards, and interlock

switches are in the correct position and operating

properly.

Before starting the engine, put the PTO lever in the

"OFF" position and the gear shift lever in the neutral

"N" position.

Check the operation of the operator presence controls

before operating the tractor. With either the PTO or the

direction control lever engaged, the engine should run

2 -5

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SECTION 3 - SPECIFICATIONS

Model Number

985103

985104

985105

985107

Description

8HP Gear Drive

12 HP Gear Drive

Brakes

Optional, individual, 7" (17.8 cm) x 1.75" (4.4 cm) drum type

Manual, optional power steering kit available

Zero (with steering kit)

Steering

Turning Radius

Minimum Uncut Circle

Optional Tire Sizes

-Stud Tread

-Trac Tread

-Turf-Chief

Zero

4" x 8", 4 ply

18" x 6.5" x 8", 4 ply

18" x 8.5" x 8", 4 ply

16" x 5" x 3", 4 ply

18 psi

18" x 6.5" x 8", 4 ply

18" x 8.5" x 8", 4 ply

16" x 5" x 3", 4 ply

18 psi

18" x 6.5" x 8", 4 ply

18" x 8.5" x 8", 4 ply

16" x 5" x 3", 4 ply

18 psi

18" x 6.5" x 8", 4 ply

18" x 8.5" x 8", 4 ply

16" x 5" x 3", 4 ply

18 psi

-Turf-Saver

-Semi-Pneumatic

Tire Pressure

Battery

12 volt, BCI group

Kohler

12 volt, BCI group

Kohler

12 volt, BCI group

Kohler

12 volt, BCI group

Kohler

Engine

-Type

K181T

K181S

M12T (PS471525)

12HP at 3600 RPM

One

-Horsepower

-Number of Cylinders

-Displacement

-Fuel

8HP at 3600 RPM

One

8HP at 3600 RPM

One

8HP at 3600 RPM

One

18 cu. in. (305.4 cc)

29 cu. in. (476.5 cc)

Gasoline, 87 minimum

octane

Gasoline, 87 minimum

octane

Gasoline, 87 minimum

octane

Gasoline, 87 minimum

octane

-Fuel Capacity

-Cooling

1.25 gals. (4.7 L)

Air

1.25 gals. 4.7 L)

Air

1.25 gals. (4.7 L)

Air

2.0 gals. (4.7 L)

Air

-Air Filter

Dual Element with

PreCleaner

Dual Element with

PreCleaner

Dual Element with

PreCleaner

Dual Element with

PreCleaner

-Lubrication

-Oil Type

Splash System

See Engine Manual

2.5 pts. (1.2 L)

N/A

Splash System

See Engine Manual

2.5 pts. (1.2 L)

N/A

Splash System

See Engine Manual

2.5 pts. (1.2 L)

N/A

Splash System

See Engine Manual

2.5 pts. (1.2 L)

-Oil Capacity

-Oil Filter

Spin on oil filter

12 volt, 15 amp

-Charging System

Transmission

-Type

Recoil

12 volt, 15 amp

All gear planetary transmission with fully enclosed PTO and immersion clutch

SAE 30W API service class SF or higher

-Oil Type

-Oil Capacity

-Cooling

5 qts (4.7 L)

Air

5 qts (4.7 L)

Air

5 qts (4.7 L)

Air

5 qts (4.7 L)

Air

-Number of Speeds

Speeds (with 18" tires)

-Forward

2 forward/2 reverse

4 forward/4 reverse

1st - 2.0 mph (3.2 kph)

2nd - 2.5 mph (4.0 kph)

1st - 1.3 mph (2.1 kph)

1st - 1.4 mph (2.3 kph)

2nd - 1.8 mph (2.9 kph)

3rd - 2.7 mph (4.4 kph)

4th - 3.7 mph (6.0 kph)

2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.4 mph (5.5 kph)

-Reverse

1st - 1.9 mph (3.1 kph)

2nd - 2.4 mph (3.9 kph)

1st - 1.2 mph (2.0 kph

2nd - 1.6 mph (2.6 kph)

3rd - 2.4 mph (3.9 kph)

4th - 3.1 mph (5.0 kph)

1st - 1.3 mph (2.1 kph)

2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.3 mph (5.3 kph)

PTO

-Type

Internal Slip Clutch

-Drive

All gear shaft driven off high/low planetary

High - 1179 RPM, low - 888 RPM at 3300 engine RPM

Cast-iron transmission case with 7-gauge framing

-Output Speeds

Construction

3 -6

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Model Number

985108

985109

985110

985111

Description

12HP Gear Drive

16HP Gear Drive

8HP Gear Drive

Brakes

Optional, individual, 7" (17.8 cm) x 1.75 (4.4 cm) drum type

Manual, optional power steering kit available

Zero (with steering kit)

Steering

Turning Radius

Minimum Uncut Circle

Optional Tire Sizes

-Stud Tread

-Trac Tread

-Turf-Chief

Zero

4" x 8", 4 ply

18" x 6.5" x 8", 4 ply

18" x 8.5" x 8", 4 ply

16" x 5" x 3", 4 ply

18 psi

18" x 6.5" x 8", 4 ply

18" x 8.5" x 8", 4 ply

16" x 5" x 3", 4 ply

18 psi

18" x 6.5" x 8", 4 ply

18" x 8.5" x 8", 4 ply

16" x 5" x 3", 4 ply

18 psi

18" x 6.5" x 8", 4 ply

18" x 8.5" x 8", 4 ply

16" x 5" x 3", 4 ply

18 psi

-Turf-Saver

-Semi-Pneumatic

Tire Pressure

Battery

12 volt, BCI group

Kohler

12 volt, BCI group

Briggs & Stratton

303447

None

12 volt, BCI group

Kohler

Engine

Kohler

-Type

M12S (PS471529)

12HP at 3600 RPM

One

PS-301058

PS-30159

-Horsepower

-Number of Cylinders

-Displacement

-Fuel

16 HP at 3600 RPM

Two

8 HP at 3600 RPM

One

8 HP at 3600 RPM

One

29 cu. in. (477 cc)

29.3 cu. in. (480 cc)

18 cu. in. (305.4 cc)

See Engine Manual

18 cu. in. (305.4 cc)

See Engine Manual

Gasoline, 87 minimum

octane

Gasoline, 87 minimum

octane

-Fuel Capacity

-Cooling

2.0 gals. (7.5 L)

Air

1.5 gals. (5.7 L)

Air

1.25 gals. (4.7 L)

Air

1.25 gals. (4.7 L)

Air

-Air Filter

Dual Element with

PreCleaner

Dual Element with

PreCleaner

Dual Element with

PreCleaner

Dual Element with

PreCleaner

-Lubrication

Splash System

Full pressure pump with

oil filter

Splash System

-Oil Type

-Oil Capacity

-Oil Filter

See Engine Manual

2.5 pts. (1.2 L)

See Engine Manual

3.0 pts. (1.4 L)

See Engine Manual

2.5 pts. (1.2 L)

Spin on oil filter

Recoil

See Engine Manual

2.5 pts. (1.2 L)

Spin on oil filter

12 volt, 15 amp

Spin on oil filter

12 volt, 16 amp

Spin on oil filter

12 volt, 15 amp

-Charging System

Transmission

-Type

All gear planetary transmission with fully enclosed PTO and immersion clutch

SAE 30W API service class SF or higher

-Oil Type

-Oil Capacity

-Cooling

5 qts (4.7 L)

Air

5 qts (4.7 L)

Air

5 qts (4.7 L)

Air

5 qts (4.7 L)

Air

-Number of Speeds

Speeds

2 forward/2 reverse

4 forward/4 reverse

-Forward

1st - 1.4 mph (2.3 kph)

2nd - 1.8 mph (2.9 kph)

3rd - 2.7 mph (4.4 kph)

4th - 3.7 mph (6.0 kph)

1st - 1.4 mph (2.3 kph)

2nd - 1.8 mph (2.9 kph) 2nd - 1.8 mph (2.9 kph) 2nd - 1.8 mph (2.9 kph)

3rd - 2.7 mph (4.4 kph)

4th - 3.7 mph (6.0 kph)

1st - 1.4 mph (2.3 kph)

3rd - 2.7 mph (4.4 kph)

4th - 3.7 mph (6.0 kph) 4th - 3.7 mph (6.0 kph)

1st - 1.3 mph (2.1 kph) 1st - 1.3 mph (2.1 kph)

3rd - 2.7 mph (4.4 kph)

-Reverse

1st - 1.3 mph (2.1 kph)

2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.3 mph (5.3 kph)

1st - 1.3 mph (2.1 kph)

2nd - 1.7 mph (2.7 kph) 2nd - 1.7 mph (2.7 kph) 2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.3 mph (5.3 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.3 mph (5.3 kph) 4th - 3.3 mph (5.3 kph)

3rd - 2.6 mph (4.2 kph)

PTO

-Type

-Drive

Internal Slip Clutch

All gear shaft driven off All gear shaft driven off

high/low planetary high/low planetary

Internal Slip Clutch

All gear shaft driven off

high/low planetary

All gear shaft driven off

high/low planetary

Output Speeds

Construction

High - 1179 RPM, low - 888 RPM at 3300 engine RPM

Cast-iron transmission case with 7-gauge framing

3 -7

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Model Number

985112

985113

985114

985115

Description

12 HP

16 HP

8.5 HP

Gear Drive

N/A

Gear Drive

Brakes

7 x 1.75" Drum Type

Steering

Manual, optional power steering kit available

Turning Radius

Minimum Uncut Circle

Optional Tire Sizes

-Stud Tread

-Trac Tread

-Turf-Chief

Zero (with steering kit)

Zero

4.00-8

18" x 6.50"-8"

18" x 8.50"-8"

N/A

18" x 6.50"-8"

18" x 8.50"-8"

N/A

18" x 6.50"-8"

18" x 8.50"-8"

16" x 5" x 3"

See Tire Sidewall

12V BCI Group

Briggs & Stratton

303447

18" x 6.50"-8"

18" x 8.50"-8"

16" x 5" x 3"

See Tire Sidewall

12V BCI Group

Robin

-Turf-Saver

-Semi-Pneumatic

Tire Pressure

Battery

18 psi (124 Kn/m2)

12V BCI Group

Kohler

18 psi (124 Kn/m2)

12V BCI Group

Kohler

Engine

-Type

PS-471529

12 HP

PS-471529

12 HP

EH252-0225T

8.5 HP

-Horsepower

-Number of Cylinders

-Displacement

-Fuel

16 HP

One

Two

One

29.3 cu. in. (480 cc)

Auto Gasoline

1.5 gals. (5.7 L)

Air

15.31 cu. in. (251 cc)

Auto Gasoline

1.5 gals. (5.7 L)

Air

See Engine Manual

2.0 gals. (7.5 L)

Air

See Engine Manual

2.0 gals. (7.5 L)

Air

-Fuel Capacity

-Cooling

-Air Filter

Dual Element with

PreCleaner

Dual Element with

PreCleaner

Dual Element with

PreCleaner

Dual Element with

PreCleaner

-Lubrication

-Oil Type

Splash Type

See Engine Manual

2.5 pts. (1.2 L)

Splash Type

See Engine Manual

2.5 pts. (1.2 L)

Pump w/oil filter

See Engine Manual

3.0 pts. (1.4 L)

Splash Type

SAE 20#, 30# 10W-30

2.1 pts. (1.0 L)

-Oil Capacity

-Oil Filter

Spin on oil filter

12 volt, 15 amp

Spin on oil filter

12 volt, 15 amp

Spin on oil filter

12 volt, 16 amp

Spin on oil filter

-Charging System

Transmission

-Type

13 volt, 11.5 amp

All gear transmission w/fully enclosed PTO and immersion clutch

SAE 30W API service class SF or higher

-Oil Type

-Oil Capacity

-Cooling

5 qts. (4.7 L)

Air

5 qts. (4.7 L)

Air

5 qts. (4.7 L)

Air

5 qts. (4.7 L)

Air

-Number of Speeds

-Direction Control

Speeds (with 18" tires)

-Forward

4 forward/4 reverse

(with 14" tires)

1st - 1.4 mph (2.3 kph)

2nd - 1.8 mph (2.9 kph)

3rd - 2.7 mph (4.4 kph)

4th - 3.7 mph (6.0 kph)

1st - 1.3 mph (2.1 kph)

2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.4 mph (5.5 kph)

2nd - 1.8 mph (2.9 kph) 2nd - 1.8 mph (2.9 kph)

3rd - 2.7 mph (4.4 kph) 3rd - 2.7 mph (4.4 kph)

4th - 3.7 mph (6.0 kph) 4th - 3.7 mph (6.0 kph)

1st - 1.3 mph (2.1 kph) 1st - 1.3 mph (2.1 kph)

2nd - 1.7 mph (2.7 kph) 2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph) 3rd - 2.6 mph (4.2 kph)

4th - 3.3 mph (5.3 kph) 4th - 3.3 mph (5.3 kph)

-Reverse

1st - 1.3 mph (2.1 kph)

2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.3 mph (5.3 kph)

1st - 1.3 mph (2.1 kph)

2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.3 mph (5.3 kph)

PTO

-Type

-Drive

Internal Slip Clutch

All gear shaft driven off All gear shaft driven off

high/low planetary high/low planetary

Internal Slip Clutch

All gear shaft driven off

high/low planetary

All gear shaft driven off

high/low planetary

-Output Speeds

Construction

High - 1179 RPM, low - 888 RPM at 3300 engine RPM

Cast-iron transmission case with 7-gauge framing

3 -8

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Model Number

985117

Description

13.5 HP Gear Drive

7 x 1.75" Drum Type

Brakes

Steering

Manual, optional power

steering kit available

Turning Radius

Minimum Uncut Circle

Optional Tire Sizes

-Stud Tread

-Trac Tread

-Turf-Chief

Zero (with steering kit)

Zero

4.00"-8"

18" x 6.50"-8"

18" x 8.50"-8"

16" x 5" x 3"

See Tire Sidewall

12V BCI Group

Robin

-Turf-Saver

-Semi-Pneumatic

Tire Pressure

Battery

Engine

-Type

EH410-0226T

13.5 HP

-Horsepower

-Number of Cylinders

-Displacement

-Fuel

One

24.67 cu. in. (440 cc)

Auto gasoline

1.5 gal. (5.7 L)

Air

-Fuel Capacity

-Cooling

-Air Filter

Dual element

Splash Type

See Engine Manual

5 qts. (4.7 L)

Spin on filter

12 volt, 12.5 amp

-Lubrication

-Oil Type

-Oil Capacity

-Oil Filter

-Charging System

Transmission

-Type

Gear transmission

-Oil Type

SAE 30W API service

class SF or higher

-Oil Capacity

-Cooling

5 qts. (4.7 L)

Air

-Number of Speeds

-Direction Control

Speeds (with 18" tires)

-Forward

4 forward/4 reverse

1st - 1.4 mph (2.3 kph)

2nd - 1.8 mph (2.9 kph)

3rd - 2.7 mph (4.4 kph)

4th - 3.7 mph (6.0 kph)

-Reverse

1st - 1.3 mph (2.1 kph)

2nd - 1.7 mph (2.7 kph)

3rd - 2.6 mph (4.2 kph)

4th - 3.3 mph (5.3 kph)

PTO

-Type

-Drive

Internal Slip Clutch

All gear shaft driven off

high/low planetary

-Output Speeds

Construction

High - 1179 RPM,

Low - 888 RPM at 3300

engine RPM

Cast-iron transmission

case with 7-gauge

framing

3 -9

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SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS

4.1 CONTROLS AND FEATURES

OH0160

1. Direction Control Lever

8. Kick Stand

2. Steering Brake Handlebar (Optional)

3. Gear Shift Lever (Hi/Low Gear)

4. Operator Presence Control

9. Throttle Control

10. Hour meter

11. Brake Handle Cross Bar

5. Choke Control Knob (Models with Briggs & Stratton

12. Range Shift Handle (Two Speed Axle)

Engines)

6. PTO Control

7. Ignition Switch

13. Parking Brake Handle (Optional on 8.5 HP)

14. Instruction Plate

15. Choke Lever (Models with Robin Engines)

16. Choke Control Knob (Models with Briggs & Stratton

Figure 1

Add fuel to the fuel tank as needed. See your engine

manual for the correct type and grade of fuel.

4.2 FILLING THE FUEL TANK

WARNING: Use caution with fuel. Fuel is very

flammable. Keep fuel in a clean and tight

container. Keep fuel away from fire or heat.

Never put fuel in the fuel tank while the engine

is running or hot. Clean up any spilled fuel

before starting engine.

Put the unit in an open area. Stop the engine and lock

the brake. Clean the fuel cap and the area around the

fuel cap to prevent dirt from entering the fuel tank.

Remove the cap from the fuel tank. Fill the fuel tank.

Be careful not to spill the fuel. Install the cap on the fuel

tank and tighten. Clean up any spilled fuel before

starting the engine.

4 -10

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4.3 GENERAL LUBRICATION

Control Linkage Lubrication

CAUTION: Before performing any service or

Every 25 hours of operation put a drop of engine oil on

the pivots of the throttle lever, the direction control

lever, the gear shift lever, the PTO control, and range

shift handle.

adjustments:

• Turn PTO switch "OFF".

• Park mower on a hard, flat, level surface.

• Place steering control levers in neutral

lock (fully outward) position.

NOTE: There are no grease fittings on the tractor.

Transmission

• Set parking brake.

Capacity: 5 U.S. Quarts (4.7 liters)

Grade: SAE 30W API service class SF or higher

Viscosity: Summer: SAE 30W or SAE 10W-30

• Turn ignition switch "OFF" and remove

key.

• Wait for all moving parts to stop.

Winter: (32^oF or below) SAE 10W or

SAE 10W-30

4.4 FORWARD-REVERSE CLUTCH

ADJUSTMENT

• After 25 hours of operation, check the adjustment

of the forward-reverse clutch.

• After every 100 hours of operation, check the level

of the lubricant in the transmission. Never operate

the tractor when the transmission oil level is below

the "LOW’ mark on the dipstick.

WARNING: Stop the engine before adjusting

the forward-reverse clutch.

• Stop the engine and raise the hood. Make sure that

the tractor is level. Clean the dipstick tube and the

dipstick (Figure 2). Remove the dipstick, wipe it

with a clean cloth or towel and put it back in the

tube. Pull the dipstick out again and look at the oil.

• The reverse clutch is adjusted correctly when the

direction control lever stops 15 degrees past

vertical to the rear. The lever should return to

neutral position from reverse when adjusted

correctly.

• If the oil level is below the low mark on the dipstick,

clean the area around the filler plug and remove

the filler plug. Add new clean lubricant until the

dipstick indicates that the oil level is correct. See

specification. Install the filler plug and dipstick.

• To adjust the reverse clutch, loosen the control

extension rod jam nuts on the end of the fwd-rev

control rod. Adjust the rear nut so that the direction

control lever stops 15 degrees past vertical to the

rear. Hold the rear nut and jam with the forward nut

(Figure 3).

• The forward clutch is adjusted correctly when the

direction control lever is in the full forward position

and the large spring has a coil clearance of .010"

(.254 mm).

1. Oil Filler Plug

2. Dipstick

3. Dipstick Tube

OH0230

Figure 2

4 -11

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4.6 STEERING BRAKE ADJUSTMENT

(APPLICABLE MODELS)

• Park the unit in a level area. Put the parking brake

handle in the "OFF" (down) position. Loosen the

jam nuts on the right and left brake rod assemblies

(Figures 2 & 3). Turn the adjusting nuts until the

brake handle cross bar is parallel with the

instrument panel (Figure 1).

• Move the brake handlebar all the way to the right

and measure the distance from the right end edge

of the brake handle cross bar to the right side of

the instrument panel. Move the brake handlebar all

the way to the left and make the same

1. Jam Nuts

7. Adjusting

nuts

8. Fwd-Rev Lever

Assembly

9. Adjustment Bracket

10. Cam Lever Arm

measurement on the left.

2. Fwd-Rev Control Rod

3. Control Extension Rod

4. Fwd-Rev Neutral

Spring

5. Large Spring

6. Brake Rod Assembly

• Adjust the nuts until the difference between the two

measurements is 1/2" to 3/4" (13 to 19 mm). Turn

both adjusting nuts the same amount, clockwise to

increase the measurement difference or

counterclockwise to decrease the measurement

difference. Tighten the jam nuts.

OH0181

Figure 3

• Loosen the jam nuts below the compression spring

(Figure 4) on the right side of the tractor and adjust

until one has the desired tension for the right

brake. Tighten the jam nuts.

• To adjust the forward clutch, put the direction

control in the forward position. Loosen the control

extension rod rear set of jam nuts on the fwd-rev

control rod. Adjust the forward nut until the large

spring coils are .010" (.254mm) apart. Hold the

forward nut and jam with the rear nut.

IMPORTANT: Replace brake shoes before lining is

worn to rivet heads.

If correct braking action cannot be achieved after

performing the above procedures, do the following:

4.5 HI/LOW GEAR CLUTCH ADJUSTMENT

• After every 25 hours of operation, check the

adjustment of the gear clutch.

1. Loosen the 5/16-24 nut and bolt which fastens cam

lever arm to brake cam.

2. Remove cam lever arm from the brake cam. Rotate

the cam lever arm one spine to the rear and put

back on brake cam. Tighten nut and bolt.

WARNING: Stop the engine before adjusting

the gear clutch.

• The clutch is adjusted correctly when the gear shift

lever is in the "HIGH" or "LOW" position and the

spring coils are .010" (.254 mm) apart.

• To adjust the "HIGH" clutch, loosen and separate

the hi-low control rod jam nuts on the rear of the

control extension rod. Put the gear shift lever in the

"HIGH" position. Adjust the nut (front) near the

spring until the spring coils are .010" (.254 mm)

apart. Move the gear shift lever to the "NEUTRAL"

position. Hold the nut adjusted to the spring and

jam with the other (rear) nut (Figure 4).

• To adjust the "LOW" clutch, loosen and separate

the hi-lo control rod jam nuts on the end of the

control extension rod. Put the gear shift lever in the

"LOW" position. Adjust the nut (rear) near the

spring until the spring coils are 0.10" (.254 mm)

apart. Move the gear shift lever to the "NEUTRAL"

position. Hold the nut adjusted to the spring and

jam with the other (front) nut.

4 -12

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1. Adjusting Nuts

2. Jam Nuts

3. Adjustment Bracket

4. Pivot Plate

5. Brake Rod Assembly

6. Hi-Lo Control Rod

7. Large Spring

8. Hi-Lo Lever Assembly

9. Control Extension Rod

Figure 4

OH0191

NOTE: Do not tighten the bolts in a circular sequence,

by tightening the bolt next to one which was just tight-

ened. The bolts should be tightened in a cross

sequence, by tightening one bolt, then tightening the

bolt which is across from it on the plate. Continue

tightening the bolts in this sequence until all the bolts

are tightened.

4.7 PTO BRAKE ADJUSTMENT

• Adjust the PTO brake after every 100 hours of

operation.

WARNING: Stop the engine before adjusting

the PTO brake.

• Remove the attachment and lower the rear of the

tractor to the ground. Carefully clean the front of

the transmission. Remove the quick hitch studs

from the transmission and remove the quick hitch

casting and PTO brake assembly (Figure 5).

NOTE: The attachment gasket must be replaced if

damaged.

• Tighten all PTO brake bolts until the springs are

solid. Back all bolts up 1/2 turn (Figure 5).

1. Quick Hitch Adapter

2. Quick Hitch Stud

OH0200

Figure 6

• Make sure the trunnion block is on the shipper

shaft and held in place by the dog. The dog should

rest on the spiral teeth of the clutch dog plate.

Install the gasket.

1. PTO Brake Bolts

2. Springs

3. PTO Shaft

• Align the splines on the quick hitch shaft with those

in the dog. Slide the quick hitch casting and PTO

brake assembly back into the place on the front of

the transmission. Install the quick hitch studs and

tighten.

Figure 5

OH0210

4 -13

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• Remove the dog and trunnion block. Disconnect

the wiring harness from the PTO brake interlock

switch and remove the shifter parts. Slide the

shipper shaft assembly through the top of the

advance casting. Slide the clutch assembly and

pinion shaft out of the transmission. Remove the

retaining ring and slide the clutch assembly off of

the pinion shaft. Turn all of the jam nuts

4.8 SLIP CLUTCH ADJUSTMENT

• Adjust the slip clutch after every 100 hours of

operation.

WARNING: Stop the engine before adjusting

the slip clutch.

• Remove the attachment and lower the rear of the

tractor to the ground. Carefully clean the front of

the transmission. Remove the quick hitch studs

from the transmission and remove the quick hitch

PTO assembly and PTO brake assembly (Figures

5 & 6).

counterclockwise to loosen.

• Torque bolts in stages using the pattern shown in

Figure 8:

1. Tighten bolts down until the spring starts to

compress.

NOTE: The attachment gasket must be replaced if

2. Tighten bolts to 80-85 in-lbs (9-9.6 Nm).

damaged.

3. Tighten nuts to 165-170 in-lbs (18.6-19.2 Nm).

4. Finish tightening the nuts to 100-150 ft-lbs

(136-203 Nm).

Figure 8

OH0220

1. Back Plate

2. Brake Disc

3. Dog Plate Brake

4. Trunnion Block

5. Seal

6. Quick Hitch Shaft

7. Quick Hitch Casting

8. Dog

9. Friction Washer

10.Dog Plate

11.Drive Plate

12.Friction Washer

13.Back Plate

14.Pinion Shaft

15.Shipper Shaft

16.Shipper Shaft Gasket

17.Shipper Shaft Body

18.Shipper Shaft

19.Set Screw

NOTE: Do not tighten the bolts in a circular sequence,

that is, by tightening the bolt next to one which was just

tightened. The bolts should be tightened in a cross

sequence, that is, by tightening one bolt, then

tightening the bolt which is across from it on the plate.

Continue tightening the bolts in this sequence until all

the bolts are tightened. (Figure 8)

20.Roll Pin

• Slide the clutch assembly back onto the pinion

shaft, install the retaining ring and slide the pinion

shaft completely into the transmission. Install the

shipper shaft and other parts that were removed

previously. Make sure the trunnion block is on the

shipper shaft and held in place by the dog. The

dog should rest on the spiral teeth of the clutch dog

plate. Install the gasket. Align the splines on the

quick hitch shaft with those in the dog. Slide the

quick hitch casting and PTO brake assembly back

into place on the front of the transmission. Install

the quick hitch studs and tighten.

Figure 7

4 -14

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SECTION 5 - ENGINE

5.1 ENGINE TROUBLESHOOTING

The following troubleshooting chart is to be used to

isolate engine problems and give possible causes and

corrective action responses.

The troubleshooting key is generic and can be used for

several types of engines. Use only those possible

causes and corrective actions that apply to the unit.

TROUBLE

POSSIBLE CAUSES

(Refer to Key Below)

CORRECTIVE ACTION

Black Exhaust

1, 20, 22, 25, 29, 31, 32, 33

4, 20, 25, 31, 33, 34

repair or replace

Blue/White Exhaust

Difficult Starting

1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33

1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62

1, 20, 22, 23, 25, 29, 31, 32, 33

25, 31, 33, 34, 45, 55

Erratic Running

Excessive Fuel Consumption

Excessive Crankcase Pressure

High Oil Pressure

Knocking

4, 41

22, 26, 29, 31, 33, 36, 46, 59

1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33

2, 3, 4, 11

Loss of Power or System

Low Cranking Power

Low Oil Pressure

Misfiring

4, 36, 37, 39

10, 20, 25, 26, 28, 29, 32

1, 19, 25,

Overheating

Poor Compression

Starts and Stops

25, 28, 29, 31, 32, 33, 34,59,

1, 6, 10, 62

repair or replace

see electrical systems

see engine service manual

Vibration

20, 23, 25, 26, 29, 33, 45, 49

2, 11, 45

repair or replace

Will Not Crank

Will Not Start

charge battery or replace

1, 10, 62

repair or replace

see electrical systems

see engine service manual

TROUBLESHOOTING KEY

Restriction in air cleaner

Bad electrical connection

Faulty starter motor

Incorrect grade of lubricating oil

Low cranking speed

Fuel tank empty

Incorrect grade of fuel

Sticking throttle/restricted movement

Exhaust pipe restriction

Leaking cylinder head gasket

Overheating

Faulty suction pipe

Choked oil filter

Bad solenoid switch

Incorrect piston height

Damaged fan

Faulty engine mounting

Incorrectly aligned flywheel and/or

flywheel housing

Cold running

Incorrect tappet adjustment

Controls not in correct operation

position

Blocked fuel feed line

Faulty fuel lift pump

Choked fuel filter

Battery capacity low

Air in fuel system

Faulty fuel injection pump

Faulty fuel injectors or incorrect

type

Sticking valves

Incorrect high pressure pipes

Worn cylinder bores

Faulty thermostat

Restriction in water jacket

Loose fan belt

Pitted valves and seats

Choked radiator

Broken, worn or sticking piston ring(s)

Worn valve stems and guides

Restriction in air cleaner

Faulty water pump

Choked breather pipe

Damaged valve stem oil deflector (if

fitted)

Incorrect use of cold start

equipment

Worn or damaged bearings

Coolant level too low

Faulty cold start equipment

Broken fuel injection pump drive

Incorrect fuel pump timing

Incorrect valve timing

Insufficient oil in sump

Bad/defective oil temperature switch

Oil pump worn

Blocked sump strainer

Broken valve spring

Exhaust or vacuum pipe leak

Bad or defective water temperature

switch

Pressure relief valve sticking open

Poor compression

Blocked fuel tank vent

Pressure relief valve sticking closed

Broken relief valve spring

Bad spark plug(s)

5 -15

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13.Check for leakage at the drain plug and oil filter if

used. Tighten the fittings as necessary if leakage

occurs.

5.2 CHECKING ENGINE OIL

Check the engine oil daily prior to use.

IMPORTANT: Never operate the engine with the oil

below the low mark on the dipstick.

14.Release the parking brake.

15.Return the unit into service.

See the engine manual for oil specifications and oil

filter service instructions.

5.4 AIR CLEANER

To check oil level:

Dry type air cleaner elements should be replaced after

100 to 200 hours if engine is normally operated under

good clean air conditions. Service and replace element

more frequently under dusty or dirty conditions.

1. Move the unit to level location.

2. Clean around the dipstick and filler tube to prevent

dirt from entering the engine.

3. Remove the dipstick and wipe off the oil on the

depth stick.

To clean the element remove and tap lightly on a flat

surface to remove loose surface dirt. Replace element

if dirt does not drop off easily. Do not wash or dry

elements in any liquid or attempt to blow dirt off with air

hose as this will puncture the filter element.

4. Put the dipstick back into the engine, and remove

again.

5. When the dipstick is removed, note the oil level. Oil

should be between the full and add mark.

Carefully handle new element. Do not use if gasket

surfaces are bent or twisted. Check the following when

installing new element (Figure 9).

6. Replace dipstick.

7. If required, add 5W30 below 40^oor 30W above

1. Back plate must be securely tightened to

40^o. Do not overfill.

carburetor. Replace back plate if bent or cracked.

8. Clean up any spillage that may have occurred.

2. Gasket surfaces of element must be flat against

back plate and cover to seal effectively.

5.3 CHANGING OIL

3. Washer must be in place between cover and wing

nut to seal and prevent unfiltered air from entering

through hole in cover. If washer is not used, make

sure wing nut (special) properly seals area around

cover hole.

WARNING: Do NOT touch parts which are

hot. Allow parts to cool before servicing.

Engine muffler and other parts will be hot if unit has

been running.

4. Wing nut must be finger tight.

1. Engine oil should be changed after the first five

hours of operation and every 25 hours there after.

2. Move the unit to a level, well ventilated area and

set the parking brake.

3. If the engine is cold, let the unit run for five

minutes.

4. When the engine is warm, stop the engine.

5. Clean the area around the dipstick and drain.

6. Put an open container that will hold one gallon of

oil under the drain.

7. Open the drain.

8. Allow the engine oil to drain completely into the

one gallon container. Remove container and

contents for future recycling as required.

9. Close the oil drain.

10.If used; remove the oil filter.

11.Clean the oil filter port and install a new oil filter

according to the instructions on the oil filter. Fill

with new oil to the "full" mark on the dipstick.

Figure 9

12.Start and run the engine for one minute. Stop the

engine and recheck the oil level and add as

necessary.

5 -16

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5.5 ENGINE REMOVAL AND

INSTALLATION

1. Remove ground cable from battery.

2. Drain Transmission oil.

3. Turn off fuel at fuel tank. Remove fuel line from fuel

pump.

4. Remove the choke cable from carburetor.

5. Remove the throttle cable from the linkage.

6. Separate wiring harness at connector

7. Remove cable from starter motor.

8. Remove rear hitch from tractor.

9. Remove 2 lower bolts securing engine to the

chassis casting.

10.Remove the 2 upper bolts from the engine but

leave in place the casting to support the braces.

11.Remove engine from tractor.

Install engine in reverse order.

5.6 ENGINE MAINTENANCE

See the engine manual for maintenance instructions.

Check the air cleaner and engine oil daily. Check the

cooling system every 25 hours. Clean all of the grass

and other material from the cooling fins and intake

screen of the engine. If necessary, remove the engine

shrouds to clean the engine. See the engine manual

for the type of oil, oil change, etc. Never operate the

engine when the oil level is below the low mark on the

dipstick. See the engine manual for air cleaner

maintenance instructions.

5.7 ENGINE STORAGE

If engine is to be out of service for a considerable

length of time, the following steps are recommended:

1. Drain oil from crankcase while engine is still hot

and flush with clean, light oil. Refill crankcase.

2. Drain fuel tank and carburetor.

3. Clean exterior of engine.

4. Spread a light film of oil over any exposed surfaces

of engine subject to corrosion.

5. Pour tablespoon of oil into spark plug hole, crank

engine slowly by hand and replace spark plug.

6. Store in dry place.

5 -17

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SECTION 6 - STEERING & CONTROLS

engine and out between the left side of the frame

and the PTO control. Rotate the handlebar into the

mounting position.

6.1 HANDLEBAR ASSEMBLY

CAUTION: Before performing any service or

adjustments:

3. Retain the handlebar in position with four

3/8-16 x 1.25 Grade 8 bolts and lock nuts. The

Grade 8 bolt has six marks on the head. See

Figure 11.

• Turn PTO switch "OFF".

• Park mower on a hard, flat, level surface.

• Place steering control levers in neutral

lock (fully outward) position.

• Set parking brake.

• Turn ignition switch "OFF" and remove

key.

• Wait for blades and all moving parts to

stop.

• Disconnect spark plug wire(s) from spark

plug(s) and place wire(s) away from plug.

WARNING: MOVING PARTS can cut or

amputate body parts. ALWAYS wait for

moving parts to stop before unit maintenance

or service.

1. On Swiftamatic tractors, disconnect the cotter pin

that holds the Swiftamatic control lever to the

shifter weldment. Disconnect the extension spring

from the control lever and slide the control lever

rearward until it stops against the instrument panel.

See Figure 10.

1. Handlebar

2. Grade 8 Bolt

Figure 11

4. Reassemble the Swiftamatic control lever linkage

and connect the wiring harness.

5. Mount the Hi-Lo gear control handle assembly and

hand lever pivot to the left handle with a

1/2-13 x 3.50 bolt and 1/2-13 thin lock nut. See

Figure 12.

1. Control Lever

2. Frame

3. Handlebar

Figure 10

2. Position the handlebar right side up. Move the left

handle of the handlebar under the right side of the

frame and the wiring harness. Proceed across the

6 -18

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6.3 ADJUSTING BRAKES

After each use wash dirt from the brakes with water.

Each day before operating, check all nuts, bolts, and

other fasteners. Replace missing or damaged pieces.

Brake service is required if the brakes do not stop and

hold the unit effectively.

Adjust the brake linkage as follows:

1. Stop the unit on a level surface.

2. Stop the engine and block the wheels so the unit

cannot roll.

3. Remove wheels and brake drums.

4. Inspect brakes and drum.

1. Hi-Lo Control Handle

Assembly

2. Hand Lever Pivot

5. Loosen the jam nuts at the ends of right and left

brake rods or whichever side needs adjusting.

6. Turn bottom nuts a couple of turns clockwise to

shorten travel a bit.

Figure 12

7. Tighten all jam nuts.

6.2 STEERING BRAKES (OPTIONAL)

8. Carefully test the operation of the wheel brakes. If

necessary, repeat the above procedures to get the

correct brake action.

The steering brake is designed to stop one wheel from

rotating. The opposite wheel continues to drive forward

and the unit pivots on the stopped wheel.

IMPORTANT: Replace brake shoes before lining is

worn to rivet heads.

Connect the adjustment bracket to the cam lever arm

with a clevis pin.

If correct braking action cannot be achieved after

performing the above procedure, do the following:

1. Park the tractor in a level area. Put the parking

brake handle in the "OFF" (down) position. Loosen

the jam nuts on the right and left brake rod

assemblies. Turn the adjusting nuts until the brake

handle cross bar is parallel with the instrument

panel.

9. Loosen the 5/16-24 nut and bolt which fastens the

cam lever arm to brake cam.

10.Remove cam lever arm from the brake cam.

Rotate the cam lever arm one spine to the rear and

put back on brake cam. Tighten nut and bolt.

2. Move the brake handlebar all the way to the right

and measure the distance from the right end edge

of the brake handle cross bar to the right side of

the instrument panel. Move the brake handlebar all

the way to the left and make the same

measurement on the right.

3. Adjust the nuts until the difference between the two

measurements is 1/2" to 3/4" (13 to 19 mm). Turn

both adjusting nuts the same amount, clockwise to

increase the measurement difference or

counterclockwise to decrease the measurement

difference.

4. Tighten the jam nuts. Loosen the jam nuts below

the compression spring on the right side of the

tractor and adjust until one has the desired tension

for the right brake. Tighten the jam nuts.

6 -19

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1. Right Hand Brake Rod

2. Left Hand Brake Rod

3. Brake

4. Shoe Return Box Spring

5. Back Plate

6. Brake Cam

7. Shoe Return Spring

8. Cam Lever Arm

Figure 13

PH0220

Fasten the instruction plate and the brake handle

brackets to the rear hitch with the 1/2-13 x 2.00 bolts

and 1/2" lock nuts.

7. Slide the brake handle onto the rear of the right

hand brake rod assembly and insert the rod into

the slot of the brake handlebar weldment. Place

the carriage bolt through the brake handle, and put

two nylon washers on the bolt between the handle

and the handlebar weldment. Push the bolt through

the handlebar weldment and retain with another

nylon washer, rubber washer, steel washer, and

lock nut. Connect the adjustment bracket to the

cam lever arm with a clevis pin, two .406 x .812 x

.065 flat washers and a .09 x .75 cotter pin.

Right Side Installation:

1. Raise and block the right side of the tractor.

2. Unbolt the tire assembly from the wheel hub and

remove.

3. Remove the axle nut, flat washer and spacer.

Remove the wheel hub set screw.

4. Use a puller and remove the wheel hub.

8. Put both spacers on the axle.

5. Remove the four bolts that retain the end plate to

the axle housing.

NOTE: The short spacer is used with the wheel hub for

the 8.50 x 8 tire assembly.

NOTE: Do not remove the end plate.

9. Replace the set screw in the wheel hub with a

7/16-14 x 3/4 set screw.

6. Slide the brake assembly over the axle. Rotate

until the holes in the back plate align with the holes

in the end plate and axle housing (cam lever arm at

2 o’clock position). Retain with four 3/8-16 x 7/8"

bolts. If necessary, turn the bolt in the cam lever

arm to where the lock washer and nut face away

from the axle housing.

10.Mount the brake drum to the wheel hub with four

1/2-13 x 1-3/8" bolts and 1/2-13 lock nuts. Four

1/2-13 x 1-5/8" bolts are required when the wheel

hub for the 8.50 x 8 tire assembly is used.

NOTE: The valve stem is turned to the outside, and the

1/2-13 lock nuts should be on the outside.

6 -20

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11.Put a film of grease on the axle splines. Slide the

wheel hub on the axle followed by a flat washer

and lock nut. Tighten the nut to a torque of 80 ft.-lb.

(108 Nm). Tighten the set screw.

.065" flat washer and a .09" x .75" cotter pin at

each end.

10.Slide the rear of the left hand brake rod assembly

into the left end of the handlebar weldment from

the front. Connect the adjustment bracket to the

pivot plate with a .375" x .75" clevis pin, two .406" x

.812" x .065" flat washers, and a .09" x .75" cotter

pin.

12.Mount the tire assembly to the wheel hub.

Left Side Installation:

1. Raise and block the left side of the tractor.

2. Unbolt the tire assembly from the wheel hub and

remove.

11.Put both spacers on the axle.

NOTE: The short spacer only is used with the wheel

hub for the 8.50 x 8 tire assembly.

3. Remove the axle nut, flat washer and spacer.

Remove the wheel hub set screw.

12.Replace the set screw in the wheel hub with a

7/16-14 x 3/4" set screw.

4. Use a puller and remove the wheel hub.

5. Remove the four bolts that retain the end plate to

the axle housing.

13.Mount the brake drum to the wheel hub with four

1/2-13 x 1-3/8" bolts and 1/2-13 lock nuts. Four

1/2-13 x 1-5/8" bolts are required when the wheel

hub for the 8.50 x 8 tire assembly is used.

NOTE: Do not remove the end plate.

6. Slide the brake assembly over the axle. Rotate

until the holes in the end plate align with the holes

in the axle housing (cam lever arm at the 12 o’clock

position). Retain with four 3/8-16 x 7/8" bolts.

NOTE: The valve stem is turned to the outside, and the

1/2-13 lock nuts should be on the outside.

14.Put a film of grease on the axle splines. Slide the

wheel hub on the axle followed by a flat washer

and lock nut. Tighten the nut to a torque of 80 ft.-lb.

(108 Nm). Tighten the set screw

7. Remove the bolt which attaches the left handlebar

support to the advance casting. Install the pivot

stud in the same location. See Figure 14.

15.Mount the tire assembly to the wheel hub.

1. Pivot Stud

3. E-Ring

2. Flat Washer

4. Pivot Plate

Figure 14

8. Place the following on the pivot stud:

- E-Ring

- .656" x 1.312" x .095" Flat Washer

- Pivot Plate

- .656" x 1.312" x .095" Flat Washer

- E-Ring

9. Connect the brake link rod to the pivot plate and

the cam lever arm. Retain with a .406" x .812" x

6 -21

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6.4 POWER TAKE OFF CONTROL

6.5 RANGE SHIFT CONTROL (TWO SPEED

AXLE)

1. Tie Rod

5. Lock Nut

2. Ball Joint

3. Jam Nut

4. Flat Washer

6. PTO Bellcrank

Weldment

Figure 15

PH0051

1. Shifter Cam

2. Shifter Rod

3. Compression Spring

4. Spring Washer

5. Shifter Crank

6. Shift Lever Block

7. Mower Height Adjuster

Bracket Shim

8. Shifter Link

9. Compression Spring

Figure 17

PH0240

Figure 16

1. Thread jam nut onto PTO shaft (supplied). Thread

ball joint (supplied) onto PTO shaft until overall

length of shaft and ball joint is 17.00 inches,

Figure 16.

2. Install rod/ball joint assembly onto tractor,

Figure 15.

3. Start unit and test operation of PTO. Test to ensure

that all interlocks function as described in the

owner’s manual.

NOTE: Slight adjustment of the PTO rod length may be

necessary to achieve proper operation.

6 -22

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SECTION 7 - DRIVE TRAIN

7.1 TRANSMISSION TROUBLE ANALYSIS

The following troubleshooting chart is to be used to

isolate hydro transmission problems and give possible

causes and corrective action responses.

The troubleshooting key is generic and can be used for

several types of transmissions. Use only those

possible causes and corrective actions that apply to the

unit.

TROUBLE

Axles Will Not Turn

POSSIBLE CAUSES

(Refer to Key Below)

CORRECTIVE ACTION

1, 7, 8, 12, 16, 18, 28, 32, 38, 42, 46

1, 6, 7, 8, 12, 16, 25, 26, 28, 38, 42, 46

1, 4, 6, 7, 8, 12, 18, 25, 26, 28, 42, 46, 55

1, 4, 7, 8, 12, 18, 28, 38, 46

N/A

repair or replace

Difficult Starting

Erratic Running

Jerky When Starting

Jumps Out of Gear

Knocking

4, 8, 12, 18, 28, 37, 42

4, 12, 18, 28, 37, 42, 46

4, 12, 18, 26, 28, 32, 37, 42

4, 22, 51, 16

Loss of Power or System

Noisy

Oil Leakage

Operates Hot

4, 16, 28, 32, 35, 42

Operates in One Direction Only

Pump Failure

1, 8, 12, 30, 46

4, 12, 37

Speed Loss Under Load

1, 6, 11, 28, 37, 46, 51

Speed Loss Under Load

Will Not Drive

1, 4, 7, 12, 18, 28, 26

repair or replace

1, 7, 8, 18, 28, 37, 38, 46, 48

Will Not Shift

TROUBLESHOOTING KEY

Inspect control linkage

Inspect acceleration valves

Inspect charge check valves

Incorrect grade of lubricating oil

Low cranking speed

Inspect hoses and lines for wear

Inspect implement relief valve

Inspect charge pump

Bad transmission pump

Overheating

Burrs on gearing

Gears improperly installed

Forks & rod assembly incorrectly installed

Shifting keys broken or damaged

Shifting washer in backwards

Controls not in correct operation

position

Cold running

Shifter/Brake shaft keyways damaged

Belts are missing, to tight, loose or 28

glazed

Bad transmission motor

Unit clutch not disengaging

Overload of vehicle

Check system pressure

Shift rod grooves worn

Reverse chain broken

Shifter stop assembled backwards

Improper fit of case to cover

Dowel pins not installed

Replacement parts damaged

Replacement parts improperly

installed

Improperly torqued attaching

screws

Damaged cooling fan

Differential bevel gears broken

Air in hydraulic system

Broken shifter stop

Inspect charge check valves

Inspect acceleration valves

Check oil level-gear box sump or

reservoir

Inspect auxiliary relief valve

Inspect cooling fan

Inspect transmission cooling fins

Worn or damaged bearings

Metallic pieces or foreign objects in

unit

Spring in shifter weak or broken

Worn or stripped gear teeth

Inspect heat exchanger

Inspect for loosely mounted

components

Inspect by-pass valve

Inspect charge pressure

Inspect inlet filter

Steering column loose or binding

Pressure relief valve sticking open

Pressure relief sticking closed

Broken relief valve spring

Inspect charge relief valve

7 -23

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Before assuming that internal transmission problems

exist, check all external linkage. Inspect the shifting

linkage beginning with the control lever and work

towards the transmission. Check for binding. Look for

broken or missing cotter pins and sheared keys.

Timing Marks

7.2 CLUTCH ADJUSTMENT

Clutch adjustment is necessary anytime clutch

slippage occurs.

Clutch rods when engaged should just completely

compress the springs on the clutch actuating lever

when fully engaged.

To adjust, tighten the jam nuts until proper adjustment

is obtained.

If external adjustments do not correct problems,

internal examination may be necessary.

7.3 TRANSMISSION REMOVAL

1. Remove engine from tractor.

2. Remove battery.

Figure 18

When replacing this unit in the transmission it is

necessary to mesh the teeth on the actuating rod and

the clutch slide rods (Figure 19) to accept the

assembly.

3. Remove capscrews holding the handles, fuel tank,

and battery box assembly to the chassis, and lift

assembly off chassis.

4. Remove wheels and wheel hubs.

7.4 FORWARD-REVERSE CLUTCH &

PLANETARY SYSTEM

To gain access to the forward-reverse clutch and

planetary system, remove advance housing and rotate

actuating rod with the lever until entire planetary

system is released. All components of the forward-

reverse clutch assembly are now ready for inspection.

1. Examine all parts for excessive wear or play.

2. Pay particular attention to the orbit gears and the

orbit gear pins. If the bores of the gears are scored

or out-of-round, replace gears and pins.

3. Check internal gear teeth for wear.

1. Bearing Nut

9. Reverse Idler Spur

Gear

10.Front Pin Spacer

11.Friction Disk

4. If friction surface of clutch cup is worn or damaged,

replace cup.

2. Compression Spring

3. Front Pin Plate

4. Sun Pinion Spur Gear

5. Quill and Bushing

Assembly

6. Orbit Spur Gear

7. Forward-Reverse Orbit

Gear Steel Pin

5. Check the friction surfaces of the reverse cone and

internal gear for scoring. If surfaces are damaged,

replace parts to prevent rapid wear of a new clutch.

12.Reverse Gear Cone

13.Clutch Cup Assembly

14.Right hand Clutch Slide

Rod

15.Internal Spur

16.Gear Cup

When replacing the forward-reverse clutch unit, the

planetary gears must be timed.

Time planetary gears as follows:

8. Spacer

1. Place sun pinion in bore of front pin plate.

Figure 19

2. Secure pin-plate quill to the pin plate with three

quill-securing bolts.

7.5 FIRST -SECOND GEAR, CLUTCH AND

PLANETARY

To examine the first-second clutch and planetary,

remove engine and release unit by turning the

actuating shaft.

3. Place the orbit gear pins in orbit gears.

4. Mesh the three gears with sun pinion so that the

timing marks form an equal sided triangle. Timing

marks (Figure 19) are white paint marks on the

opposite side of gears.

7 -24

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To avoid damage to the rear pin plate bushing, it is not

recommended that planetary system be further

disassembled unless definite problems exist.

6. Carefully examine the shifting yoke, shifting clutch,

stationary clutch and clutch housing. Particular

attention should be given to see that the stationary

clutch is properly secured against rotation. Also

make sure the shifting clutch slides freely on the

shifting gear.

If an unreasonable amount of play is noticed in the

system:

1. Inspect orbit gear pins and bushings for wear.

2. Inspect the orbit gear carrier bushing for wear.

3. Check for worn or damaged gearing.

1. Stationary Pivot

2. Shifting Yoke

3. Clutch Sliding Pin

Figure 21

1. Ring Gear and Bushing

2. Planet Gear Carrier

3. Internal Orbit Gear

4. External Orbit Gear

7. If no discrepancies have been found at this point or

if the failure is obviously a part of the differential

assembly, remove the differential assembly.

8. Remove left hand wheel hub.

Figure 20

9. Remove left hand axle housing with axle.

7.6 DIFFERENTIAL

Before assuming internal Swiftamatic difficulties,

inspect the external linkage and parts for binding.

Carefully check the following:

1. Check linkage for binding, sheared spring pin,

loose nuts or debris build up.

2. Check to see that the shifter arm is not binding on

the stationary pivot.

3. Check to see that the clutch sliding pivot is free.

4. Check to see that the extension spring is in place.

5. Check stationary clutch bolt. Be sure it is not

sheared.

6. Raise tractor wheels. Turn one wheel by hand. The

other wheel should turn in the opposite direction.

Check for tightness and rough spots while turning.

7.7 DIFFERENTIAL REMOVAL

1. Drain oil from transmission.

1. Straight Axle

2. Axle Housing

3. End Plate

2. Raise tractor and remove wheels.

3. Remove right hand wheel hub.

Figure 22

4. Disconnect Swiftamatic shift linkage.

5. Remove right hand axle housing with axle.

7 -25

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10.Remove the differential assembly from the tractor.

11.Using wire cutters, remove wire securing bolts on

each side of worm gear. Secure differential

assembly upright in vise. (4 Speed Swiftamatic

only).

1. Axle Housing Shim

2. Axle Housing Gasket

3. Race Bearing

4. Cone Bearing

5. Clutch Worm Gear

Shim

8. Differential Housing

9. Differential Bevel Gear

10.4 Lead Worm Gear

11.Drive Block

12.Spider Bevel Gear

13.Spider Pinion Pin

14.Differential Locking

Housing

6. Roller Bearing Cup

7. Roller Bearing Cone

1. Race Bearing

2. Cone Bearing

3. Clutch Housing

4. Clutch Worm Gear

Shim

5. Clutch Worm Gear

Shim

10.Differential Bevel Gear

11.Pinned Bevel Gear

12.Splined Pinned Shifter

13.Roller Bearing Cup

14.Roller Bearing Cone

15.Pinned Housing

16.Thrust Washer

Figure 24 - 2-Speed

15.Disassemble the differential mechanism-carefully

checking the bore of the gears and the spider arms

for scoring. Check the backs of the shifting train

pinions.

6. Spider Bevel Gear

7. Flange Bushing

8. Differential Shifting

Bevel Gear

17.Worm 8 Start Gear

18.Spider Pin

16.Reassemble the differential mechanism using new

thrust needle bearings if any other parts were

replaced. On the two spider arms with snap ring

grooves at the end, assemble in this sequence:

spider gear, shifting train pinion, bearing, spacer

and snap ring. On the other two arms assemble in

this sequence: spider gear, race, bearing, spacer

and snap ring.

19.Dowel Pin

20.Dowel Pin

9. Needle Thrust Bearing

Figure 23 - 4-Speed

12.Remove bolts securing clutch housing to worm

gear. Remove clutch housing, gears, and shims.

13.Turn worm gear over and remove pinned housing

and gears.

17.Tilt the differential mechanism and install it in the

worm gear.

14.Tilt differential mechanism and remove from worm

gear. The mechanism does not ride on the inside

surface of the gear.

7 -26

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Figure 26

2-Speed Right Hand Axle

Figure 25

18.Install the pinned gear and differential gear on the

pinned housing and install it on the worm gear. Use

new drilled bolts (4 Speed Swiftamatic); clean bolts

and apply a stud locking preparation to the bolt

threads. Torque bolts to 17-20 ft-lbs (23 - 27 Nm)

19.Turn worm gear over and install the clutch housing,

with differential gear, shifting gear and shims on

the worm gear. Torque bolts to 20 ft-lbs (27 Nm).

Replace with new bolts.

20.Check end play of shifting gear .00 - .010

maximum. Remove clutch housing and adjust

shims as necessary. Torque bolts to 20 ft-lbs (27

Nm).

2-Speed Left Hand Axle

21.For the 4 Speed Swiftamatic, insert wire through

one bolt head, cross and insert through other, then

twist ends together securely. Trim twist to 1/2 inch

length. Repeat, securing other bolts on other side

of gear (Figure 27).

22.Install differential on L.H. axle in L.H. axle housing.

(Pinned housing side of differential assembly in

axle housing.) Be sure thrust pin is in place in the

differential assembly so it will be between the

axles.

1. Arm Shifter

2. Stationary Pivot

3. O-Ring

7. Seal

8. Sliding Differential

Locking Clutch

4. Shifting Yoke

5. Clutch Sliding Pin

6. Straight Differential

Locking Axle

9. Housing Axle

10.Straight Axle

Figure 27

7 -27

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4-Speed Right Hand Axle

1. Stationary Pivot

6. Seal

2. O-Ring

7. Shifting Clutch

8. Stationary Clutch

9. 2-Speed Axle Housing

3. Shifting Yoke

4. Clutch Sliding Pin

5. Straight Axle

Figure 28

1. Back Plate

2. Brake Disc

3. Dog Plate Brake

4. Trunnion Block

5. Seal

6. Quick Hitch Shaft

7. Quick Hitch Casting

8. Dog

9. Friction Washer

10.Dog Plate

11.Drive Plate

12.Friction Washer

13.Back Plate

14.PInion Shaft

15.Shipper Shaft

16.Shipper Shaft Gasket

17.Shipper Shaft Body

18.Shipper Shaft

19.Set Screw

23.Place equal amount of shims and a shellacked

gasket on each axle housing. Install L.H. axle

housing and differential assembly in tractor. Secure

axle housing to tractor.

24.Install R.H. axle housing on tractor, being sure the

shifting clutch fits on the shifting gear. Secure axle

housing to tractor. Torque bolts to 45 ft-lbs

(61 Nm).

20.Roll Pin

Figure 29

25.Remove the engine and high-low planetary or the

advance casting and the forward-reverse

planetary.

1. Check the dog block for wear.

2. Examine shifter shaft for wear.

26.Using a screwdriver or similar tool, check the

differential assembly for play. Running clearance

should be .008" - .012". Adjust by adding or

removing an equal amount of shims from each axle

housing.

3. For closer inspection of the shifter assembly,

remove the assembly by removing jam nut inside

of advance casting and then removing the shoulder

bolt.

27.Adjust axles for .008" - .012" end play. Add or

remove shims behind the bearing cap.

4. Inspect shifter body and its components for

damage.

5. Check for bearing failures.

7.8 POWER TAKE OFF (PTO)

If it becomes difficult to shift the power takeoff in and

out of gear, check external linkage for binding.

6. Examine pinion shaft for twisting.

7. Replace worn or damaged parts.

To examine the PTO, remove attachment boss plate on

the front of advance casting. At this point the dog gear

and shifting eccentrics are exposed (Figure 30).

Proceed as follows:

7 -28

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SECTION 8 - FUEL SYSTEM

The troubleshooting key is generic and can be used for

8.1 FUEL SYSTEM TROUBLESHOOTING

several types of transmissions. Use only those

possible causes and corrective actions that apply to the

unit.

The following troubleshooting chart is to be used to

isolate fuel system problems and give possible causes

are corrective action responses

TROUBLE

Hard Starting

POSSIBLE CAUSES

(Refer to Key Below)

CORRECTIVE ACTION

1, 3, 4, 6, 11, 12, 14, 16, 17, 18

clean, repair or replace

repair or replace

Fuel Leak at Carburetor

Engine Floods

5, 7, 17

5, 15, 17

Will not idle

1, 2, 3, 6

Rich idle

1, 6, 14

Idles with Needle Closed

Hunts Erratic Idle

Idles Fast Lean

2, 3, 6, 7, 12, 13, 14, 15, 18

2, 3, 7

Will Not Accelerate

Over Rich Acceleration

Hesitates

1, 6, 11, 12, 14, 15, 16

1, 15

2, 6, 11, 12, 16

1, 11, 12, 14, 16

1, 3, 11, 14, 15, 16, 17, 18

3, 6, 7, 12, 14, 15, 16, 18

Will Not Run at High Speed

Low Power

Hunts at High Speed

Runs With Needle Closed

Engine Overspeeds

2, 3, 7, 14

TROUBLESHOOTING KEY

Plugged Air Filter

Leaky Carburetor Gasket

Throttle or Choke Shaft Worn

Choke Not Functioning

Properly

Plugged Atmospheric Vent

Air Bleed Restricted

Damaged or Leaky "O" Rings

Damaged Diaphragm

Stuck or Dirty Ball Check

Diaphragm Upside Down

Plugged Tank or Vent

Fuel Pick-up Restricted

Idler Port Restricted

Damaged Adjustment Needle

and Seat

Incorrect Float Height

Main Nozzle Restricted

Dirty, Stuck Needle and Seat

Fuel Inlet Plugged

8 -29

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8.2 FUEL PUMP

8.3 FUEL SYSTEM CONTAMINATION

The impulse style fuel pump is the most commonly

used fuel pump. Impulse fuel pumps may either be

mounted externally onto the carburetor fuel inlet or

remotely mounted. These pumps are connected in the

fuel line between the fuel supply and the carburetor or

directly to the fuel inlet.

Any time fuel contamination is found in the fuel system

(dirt, water algae, etc.) replace the fuel, fuel filter and

flush the fuel lines. Remove the carburetor bowl and

clean. Replace all items that cannot be cleaned.

Reassemble the fuel system and check for proper

operation.

Impulse fuel pumps are operated by crankcase

impulses created by the up and down movement of the

piston. A hose called a pulse line connects the fuel

pump diaphragm chamber and transmits the impulses

to the pump diaphragm. The impulses actuate the

diaphragm and the flap valves to lift the fuel from the

fuel tank to the carburetor.

8.4 FUEL TANK

The fuel tank is made of composite material for long life

without breaking down from the additives used in

today’s blended fuels.

8 -30

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SECTION 9 - ELECTRICAL

9.1 TOOLS

9.2 ELECTRICAL MEASUREMENTS

There are some specialized tools and test equipment

that are needed for electrical repair work. A brief

description of these follows.

Long or needle nose pliers - used to connect or bend

wires and connectors in close quarters.

Diagonal cutters - used to cut wires or trim

connections.

Wire stripper/crimping tool - available separately or

as a combination tool. Used to strip insulation from

wires of various sizes, crimp terminals and connector

or wires.

Soldering gun or soldering iron - used to solder all

splices and connections to terminals, connector, etc. A

soldering gun is faster and more convenient that

waiting for a soldering iron to heat.

Multimeter - analog or digital, to measure voltage,

amperage and ohms.

Tachometer - used to measure engine speed.

Required to properly test alternator and charging

circuits where output is dependent upon engine speed.

Heat gun - used to shrink insulated tubing in place.

Used to replace electrical tape or insulated sleeving. To

use, place a piece of shrink tubing over a wire joint,

heat with the heat gun, until it shrinks slightly around

the joint.

Supplies - electrical tape, rosin core solder (never use

acid or acid core solder on electrical joints), an

assortment of various size terminals, connectors,

insulated or heat shrink tubing (for use on joints and

connections), and an assortment of automotive type

wire (in several colors).

Gravely Company recommends that all work be done

in a professional manner. The use of the tubing to

cover joints and the soldering of connections contribute

to a professional looking job. In addition to a pleasing

appearance, repairs made in this manner are more

likely to withstand vibration. (The weakest points in an

electrical system are the joints where wires are

attached.)

Replace all defective components with Gravely

replacement parts only. Engine parts, such as rectifiers

or alternator components should be secured through

the nearest engine service center.

Gravely Company does not recommend attempting to

repair electrical components. Most do not lend

themselves to repair and you would have more money

invested in "time of repair" than the part would cost and

the results may not be as good.

In many electrical circuits, there is some visible effect

which indicates that the circuit is functioning properly. A

switch is turned "ON" and a lamp lights. A key is

turned, a starter motor runs and cranks the engine.

If the lamp does not light, or the starter motor does not

run, some means of measuring voltage, current flow,

resistance and continuity is needed, (continuity means

there is a complete electrical path through the circuit or

component.)

To know exactly what conditions exist in an electrical

circuit requires AC and DC Voltmeter, AC and DC

Ammeter, and an Ohmmeter.

Multimeter

A single combination meter that does all of these things

is available. Such a meter is called a Multimeter or Volt-

Ohm-multitester (VOM). Meters of this kind are avail-

able in many forms and all change functions and

ranges with switches, or by plugging test leads into dif-

ferent jacks. Multimeters are available in two basic

types, Analog and Digital.

Analog Meters

Analog Meters have a needle that moves across a

scale to give a reading. The longer the scale, the easier

it is to read and more accurate the reading will be. A

jeweled movement is used in this type of meter is more

likely to be damaged through rough handling (except

for overloaded Protected Meters) or by measuring high

values that exceed the range set on the meter than a

digital meter. They provide excellent service for the

money as long as they are used with care.

Digital Meters

Digital Meters do not have a movement and are there-

fore more rugged. The reading shows up directly on a

display window of some type. Since they read direct,

no skill in reading the scale is required, nor is it neces-

sary to set the range. The meter switches the ranges

automatically. One has only to select the function DC

Volts, AC Ampere, Ohms, etc.,) connect the test leads,

and the reading is shown on the display. Because of

the internal circuitry and the lack of a movement, these

meters are not likely to be damaged by overloads.

In the discussions that follow, either type of meter may

be used. Test procedures are the same. It is best to

learn proper procedures, even though some meters

may be more forgiving of mistakes. Where differences

in use may occur, they will be covered in the discus-

sion.

9 -31

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glasses and proper protective gear when handling

batteries to prevent electrolyte from coming in contact

with eyes, skin or clothing.

Voltage Measurement

There are two basic rules to be remembered when

using a voltmeter. A voltmeter measures the voltage

difference between the test leads and the voltmeter is

always connected across the circuit under test.

WARNING: ELECTRIC SHOCK may result in

injury and/or damage to unit.

Current Measurement

DO NOT allow tools or other objects to come

into contact with both terminal at the same

time. ALWAYS remove Negative (-) Cable first

to reduce risk of sparks when removing bat-

tery. ALWAYS connect Positive (+) Cable first,

then connect Negative (-) Cable when install-

ing battery.

The two rules to remember when measuring current

with an ammeter are; an ammeter measures the cur-

rent that flows through the meter, and to measure cur-

rent an ammeter must be connected into the circuit.

The latter rule means that the circuit must be opened,

and the ammeter wired into it. Because this procedure

is usually difficult, an ammeter is seldom used for trou-

bleshooting.

WARNING: EXPLOSIVE GASES can result

in serious injury or death. ALWAYS keep open

flames, sparks, or smoking materials away

from battery.

Resistance Measurement

An ohmmeter is used to make resistance measure-

ments and to check continuity through wires and elec-

trical components.

There is one rule to keep in mind when using an ohm-

meter. The ohmmeter has a self contained battery and

requires no electrical power. Using the ohmmeter on a

circuit that has power applied may result in damage to

the meter.

POISONOUS BATTERY FLUID contains sul-

furic acid and its contact with skin, eyes or

clothing can cause severe chemical burns.

ALWAYS wear safety glasses and protective

gear near battery.

DO NOT TIP any battery beyond 45 degree

angle in any direction.

ALWAYS KEEP BATTERIES OUT OF

REACH of children.

IMPORTANT: Disconnect the equipment battery when

making Ohmmeter test or damage to the Ohmmeter

may result.

IMPORTANT: An ohmmeter reads the resistance of

whatever component is connected between the test

leads. It can be used to check wires, coils, light bulbs,

or any item that conducts current.

WARNING: REVERSE CONNECTIONS may

result in sparks which may result in injury.

ALWAYS connect/disconnect cables in proper

order.

9.3 SAFETY INTERLOCK SYSTEM

The tractor has an electrical interlock system. Several

switches need to be engaged for the engine to start

and run. The switches in the system are:

Set-Up

The new battery is dry charged. The dealer or

customer must add electrolyte (sulfuric acid and

water).

• PTO Interlock

• Forward/Reverse Interlock

1. Remove the battery from the unit.

• Left and Right presence on handlebars (only one

needs to be engaged)

2. Remove all the vent caps from the battery and set

the caps to one side.

• Steering Brake Presence (Optional) electrically has

the same function as the right hand presence

switch.

3. Take the electrolyte which should be 1.265 specific

gravity at 80^oF, and fill each cell so that the

electrolyte is level with the bottom of the fill ring.

The PTO, forward/reverse and one of the presence

switches must be closed for the engine to start. Once

the engine is running only one of the presence

switches needs to be closed.

4. The battery should stand for 1/2 hour. Now check

electrolyte level in each cell again. If necessary

add more electrolyte to bring the level up to the

bottom of the ring.

5. Charge until all cells are gassing freely, and the

specific gravity is constant over three successive

readings taken at 30 minute intervals.

9.4 BATTERY

When charging battery, remove it from unit first. Keep

batteries out of reach of children. ALWAYS follow

information provided on battery by battery

manufacturer. Lead acid batteries generate explosive

gases. Severe chemical burns can result from

improper handling of battery electrolyte. Wear safety

6. Immediately after charging check level of

electrolyte. If the level is low add distilled water to

bring it up to the required level.

9 -32

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7. Replace the vent caps. It is not necessary to

tighten more than finger tight.

Remove hold down and bolt and lift battery out. Clean

or service battery away from unit. Remove corrosion

from battery terminals and cable connections with wire

brush, then wash with a weak baking soda solution.

8. Wash off the battery to remove electrolyte which

may have spilled.

Scrub the exterior of the battery and cable terminals

with a nonmetallic brush which has been dipped into a

mixture of baking soda and water.

Battery Electrolyte First Aid

External contact: Flush with water.

Eyes: Flush with water for at least 15 minutes and get

medical attention immediately!

After cleaning, apply a thin coat of grease or petroleum

jelly to terminals and cable ends to retard corrosion.

Reinstall battery.

Internal contact: Drink large quantities of water.

Follow with Milk of Magnesia, beaten egg or vegetable

oil. Get medical attention immediately!

Check the alternator voltage regulator output (if used)

at every periodic maintenance inspection. Over

charging is a common cause of battery failure.

IMPORTANT: In case of internal contact, DO NOT

induce vomiting!

Electrolyte Level

Inspection, Cleaning, Drying, and Maintenance

Every 25 hours of operation, check electrolyte level of

each cell by removing caps one at a time. The

electrolyte level should be at level indicated. Use

distilled water to fill each cell if needed. Install and

tighten each cap after checking.

Inspect the top of battery, terminals, cables, terminal

posts, and case for any accumulation of dirt, corrosion

cracks or loose or broken parts. Keep battery and its

terminals clean. Inspect monthly to maintain best

performance. Replace battery if damaged.

IMPORTANT: When distilled water is added to battery

during freezing weather, battery must be charged to

mix water with electrolyte, or water will remain at top

and freeze.

Models with Briggs & Stratton Engines

and Kohler Engines

Charging

ALWAYS follow information provided on battery by

battery manufacturer. Contact battery manufacturer for

extensive instructions to charge battery.

Place unit on a level surface, shut off engine and open

battery compartment to gain access to battery.

Disconnect negative (-) cable first, then positive (+)

cable.

To charge battery:

1. Loosen strap and remove battery from unit.

2. Place battery on bench or other well ventilated

place where electrolyte spill will not create

damage.

Models with Robin Engines

3. Remove caps and fill each cell to level indicated

with electrolyte at 1.265 specific gravity at 80^oF

(27^oC).

4. Let battery stand for one half hour.

5. Check electrolyte level and add more if necessary.

6. Connect positive (+) lead of charger to positive (+)

terminal, and negative (-) lead to negative (-)

terminal.

1. Fuel Cap

2. Negative Battery Cable

3. Battery

7. Charge the battery at two and a half amps for ten

hours or until all cells are gassing freely and the

specific gravity is constant over three 30 minute

intervals.

4. Positive Battery Cable

Figure 30

9 -33

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Specific Gravity Check

Jump Starting

The specific gravity should be checked with a

hydrometer.

Jump starting, battery charging, or replacement is

required when the starter motor will not crank the

engine.

NOTE: The specific gravity should be checked in each

cell and should be the same for all cells. A variation in a

cell reading could be an indication of a problem. Sub-

tract .004 from 1.265 for each 10^oF below 80^oF (27^oC)

or add .004 to 1.265 for each 10^oF above 80^oF (27^oC).

The unit used for jump starting should have a 12 volt

battery with at least 500 cold cranking amperes, and a

negatively grounded system.

WARNING: FROZEN BATTERIES CAN

EXPLODE and result in death or serious

injury. DO NOT charge a frozen battery. Let

the battery thaw out before putting on a

charger.

UNIT MOVEMENT can result in death or

serious injury. NEVER jump start unit directly

to the starter or starter solenoid. Unit can

move forward or backward and injure the

person jump starting unit.

A special temperature compensated hydrometer is

used to read the battery’s state of charge.

The reading on the hydrometer gauge should be above

1.225. If the reading falls below 1.225 specific gravity

there will be an insufficient charge.

ALWAYS charge the battery until the specific gravity of

1.265 is reached over 3 successive readings. Check

monthly to ensure charge is maintained. The

approximate state of charge can be determined by the

cell specific gravity of the rested open circuit voltage at

room temperature and the charging time can be

estimated. For example:

To jump start the battery:

1. Ensure battery is not frozen. If the fluid is frozen,

remove battery from unit and allow to thaw before

charging.

OCV

Specific

Gravity

% of

Charge

Charging

Time

2. Connect the positive (+) jumper cable to the

positive (+) terminal of the discharged battery.

12.60

12.4

1.265

1.225

1.180

1.130

1.100

100%

75%

50%

25%

---

3. Connect the other end of the same jumper cable to

the positive (+) terminal of the booster battery.

3 hours

7 hours

10 hours

12 hours

12.20

12.00

11.80

4. Connect one end of the second jumper cable to the

negative (-) terminal of the booster battery.

5. Make the final jumper cable connection to the

engine block or the furthest ground point away

from the discharged battery.

If using an automatic tapering 12 volt charger, choosing

a good quality 5 to 10 amps 15VDC minimum output

charger and charge for 3 to 12 hours according to the

battery state of charge (see table above) or until the

specific gravity in each cell reaches 1.255 - 1.265

specific gravity at 80^oF (27^oC).

WARNING: Make sure cables are clear of any

moving engine parts before starting engine.

6. Start engine (refer to Owner’s Manual). If engine

will not start after several tries, unit or battery may

need service.

If using a constant current charger, charge at 1 to 2

amperes for the time given on the table above or until

full specific gravity is reached.

7. After engine starts, leave cables connected for one

to two minutes.

IMPORTANT: Charging at higher rates will damage the

battery and cause excessive gassing and acid

spewing.

8. Disconnect cables in reverse order.

9. Operate unit as normal to charge battery.

Storage

Battery Charger

The battery is a perishable item and it should be stored

properly to obtain a long, useful life. Batteries not in

use will self discharge.

Under normal conditions the engine alternator will keep

the battery charged. When unit has set for an extended

period of time without operation and the battery has

been completely discharged, a battery charger will be

required for recharging.

If the battery will not be used for more than three

months, it should be removed and stored in a cool, dry

place.

Before using a charger, an attempt can be made to

recharge the battery using the engine alternator by

jump starting the unit and allowing the engine to run.

Any collection of dirt, grease, or electrolyte should be

removed from the top of the battery.

The battery must be recharged monthly or when the

cell specific gravity reads less than 1.255 specific

9 -34

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gravity. Before reinstalling the battery in the spring, it

should always be fully recharged.

Variation from test results described indicates a

defective switch.

Ignition Switch

9.5 SWITCHES

NOTE: Refer to the wiring diagram of the unit involved

to determine switch functions and test using the

methods described.

Switches either open a circuit to stop current flow or

close and allow current to flow through.

A normally open (N.O.) switch prevents current flow

until the switch is actuated, completing the circuit and

allowing current to flow through it. An example is a light

switch - the lights are off until the switch is actuated

and the lights go on.

The ignition switch incorporates a number of functions,

although not all functions are used on all equipment.

The switch has three positions: OFF, RUN, and a

momentary contact START position. Use an ohmmeter

to check the continuity of the switch in each position.

A normally closed (N.C.) switch allows current to flow

until the switch is actuated, breaking the circuit and

stopping current flow through it. An example is an

ignition switch that grounds the magneto when in the

off position (completing the circuit) but opens the circuit

when in the ON position allowing the engine to operate.

OFF Position - Should be continuity between contacts

G and M. These connections ground the engine

magneto and stop the engine in the OFF position.

RUN Position - Should be continuity between contacts

B and A. These connections supply power to the rest of

the wiring harness. Connections G and M open to each

other.

Switches are selected with regard to Current rating

(contacts must be of sufficient size to carry the required

current), Voltage rating (switches insulated for specific

voltages), Case or housing (switches that are exposed

to moisture and must be sealed to prevent moisture

from entering), and Actuating type (push, pull, rotary,

momentary contact, or micro switches).

START Position - Hold switch in START position while

testing. There should be continuity between contacts

S1 and S2. These connections apply power to close

the solenoid contacts and operate the starter motor.

In addition to the above test, place the switch in the run

position and check between each contact and ground

(metal case) to be sure no terminals are grounded. If

the switch is operating properly, there will be no

continuity between contacts other than those

described.

NOTE: Check that the connections to the switches are

secure and that a switch is being activated properly

before performing electrical test on switches. (Safety

switches on speed selector and clutch levers may be

out of adjustment and not activating.)

IMPORTANT: When checking switches, remove them

from their respective circuit by disconnecting the wires

from the switch at the connector(s). Damage could

result to the meter or machine components if switches

are left in.

9.6 SOLENOID AND RELAYS

Solenoid and relays are both magnetically operated

devices. Both devices operate on the principle that

passing a current of electricity through a coil of wire will

create a magnetic field strong enough to attract a piece

of iron or steel. Each device uses this principle in a

slightly different manner.

Normally Open Switch

To test a normally open switch (key, headlight, safety,

or seat) connect the ohmmeter across the switch

terminals. Meter should indicate open circuit (infinite

resistance). Activate the switch. The ohmmeter should

read up scale to zero resistance (Close Circuit). This

indicates the switch is operating properly. Also check

from each terminal to the switch case (if case is metal).

Reading should show infinite resistance indicating no

short to ground.

Relay - A basic relay consists of a coil of wire wound

around a soft iron (magnetic) core. When current is

passed through the coil, the core is magnetized and

pulls down on a magnetic lever. The lever in turn is

attached to several switch contacts which open or

close other electrical circuits. In this fashion, a small

current can control one or more larger electrical

currents and actuate several other devices. In most

cases a relay contact moves only a fraction of an inch

and the magnetic pull is small.

Variation from test results described indicates a

defective switch.

Solenoid - A basic solenoid consists of a coil of wire

wound around a hollow tube. A magnetic core slides

inside the tube. When current is passed through the

coil, the core is pulled into the solenoid with

considerable force. With proper design, a solenoid can

exert considerable force over a distance of several

inches. A solenoid can therefore, pull a lever, close a

heavy contact, or perform other jobs that require a

straight line pull.

Normally Closed Switch

To test a normally closed switch connect the ohmmeter

across the switch terminals. Meter should indicate a

closed circuit (zero resistance). Activate the switch and

the meter should move to open circuit (infinite

resistance). Check from each terminal to ground

(switch case). Meter should show open circuit (infinite

resistance).

9 -35

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If a relay or solenoid fails to operate, the cause may be

either electrical or mechanical.

Electrical testing of these devices is simple. Since the

device either conducts current (and is therefore

functioning) or the device is open and is therefore

defective. Use an ohmmeter to check for continuity.

To check electrically, connect a voltmeter across the

coil of the device and activate the circuit that operates

the relay or solenoid. If the meter indicates no voltage

is applied, the cause is in the control circuit.

9.8 DIODES AND RECTIFIERS

Diodes are solid state, semiconductor devices. They

contain no moving parts and conduct current better in

one direction than the other.

If the meter indicates proper voltage across the coil but

the device does not function, remove the power,

disconnect the wiring and check the continuity of the

coil with an ohmmeter. The meter should indicate

resistance, in the order of 3 to 5 ohms, if the coil is

intact. A high resistance indicates an open coil and a

defective device.

Diodes allow current to flow through one circuit without

"backing up" into another. In engine alternator circuits,

a diode is used to convert current which flows back and

forth (AC) in a circuit to current which flows only in one

direction (DC). A device which converts alternating

current to a direct current is called a RECTIFIER. A

diode is one type of rectifier.

There are also a number of mechanical problems that

may cause the problem.

The starter solenoid in the Gravely equipment is a

sealed unit used to actuate the starter motor on the

engines. These solenoids may have three or four

connections. The two large connections carry high

current to operate the starter motor. The small

connections are connected to the coil and carry the

control current.

To check a diode, isolate if from the circuit by

disconnecting one end. With a multitester set on the

lowest ohms scale setting, measure the resistance in

one direction, reverse the test leads, and measure in

the other direction. Readings should be high in one

direction and low in the other. (If the readings are low in

both directions, the diode is shorted, and if the

readings are high, the diode is open.) If the readings

are the same in both directions, the diode is defective

and must be replaced.

To check the solenoid, disconnect the cables to the

starter motor, turn the ignition switch to the start

position, and listen for the solenoid to snap inside

contacts closed.

IMPORTANT: Diodes are marked to indicate polarity (a

band on one end, an arrow on the side, or they fit on a

holder only one way.

If no snap is heard, check across the coils with a

voltmeter. The voltage should read 12 volts with the

ignition switch in the start position. If no voltage

appears, the defect is in the start circuit.

Rectifiers

If the voltage is correct, turn off the power and check

continuity of the coil with an ohmmeter. If the coil is

open, the solenoid is defective and must be replaced.

A battery is charged through the use of an alternator

located in or on the engine. A charging circuit contains

a rectifier because alternators produce alternating

current (AC) and batteries require direct current (DC)

for charging.

If the coil has the proper voltage applied, and the

continuity check indicates the coil is intact, the solenoid

plunger is stuck or the contacts are welded shut and

the solenoid must be replaced.

The rectifier may be built into the engine or it may be

an external part. It may also contain a regulator to

prevent overcharging the battery. (Servicing of

rectifiers built into the engine should be done by an

approved engine manufacturer’s service center. Such a

service center has access to the information and parts

required to test and repair or replace engine

If the solenoid snaps shut, but the start does not

operate, check across the large contacts with an

ohmmeter. If there is no continuity when the solenoid

snaps shut, the contacts are defective and the solenoid

must be replaced.

components, including rectifiers and regulators.)

9.7 FUSES

Units that contain both a rectifier and regulator are

tested in a working circuit to make sure the regulator

portion of the device is operating.

Fuses are connected in electrical circuits to protect the

circuits from damage due to overload or short circuits.

Fuses are a "weak link" in the circuit. They contain a

metal link designed to melt when a certain current

value is exceeded thus opening or disconnecting the

wiring. Once a fuse blows or melts it must be discarded

and replaced with a new fuse of the same value.

Since the function of the fuse is to protect the circuit,

NEVER attempt to defect the protective device by

bridging or replacing with a device of a higher current

rating.

9 -36

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9.9 WIRING DIAGRAM

Robin Engine

Briggs & Stratton Engine

and Kohler Engine

1. Steering Brake

Harness

2. Handlebar Wiring

Harness

3. Switch

4. Solenoid

5. Wiring Harness

6. Relay

7. Hourmeter

8. Ignition Switch

9. Fuse

10.Interlock Open Switch

9 -37

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9.10 CONTINUITY DIAGRAM

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.

Relay

(03042800)

Key Switch

(03602300)

87A

OFF

RUN

START

NOT ENERGIZED

ENERGIZED

Handlebar Switch

(08828300)

Solenoid

(03492300)

HAND

OFF HANDLE

HAND

ON HANDLE

NOT ENERGIZED

ENERGIZED

PTO Switch

(08571800)

FWD/REV Switch

(08571900)

ENAGED

(button out)

NEUTRAL

(button out)

FORWARD OR REVERSE

(button in)

DISENGAGED

(button in)

PH0421

9 -38

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9.11 12 HP ELECTRIC START - KOHLER

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9.12 8 HP MANUAL START - KOHLER

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9.13 8 HP ELECTRIC START - KOHLER

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9.14 16 HP ELECTRIC START - BRIGGS

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9.15 ROBIN ENGINES

9 -43

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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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