Gravely 992078 21HP-148Z User manual

Models
992077 19HP-144Z
992078 21HP-148Z
992079 23HP-152Z
992080 23HP-160Z
992081 25HP-152Z
992082 25HP-160Z
992310 19HP-144Z
992311 21HP-148Z
00265100 1/04
Printed in USA
Promaster 144Z / 148Z / 152Z / 160Z
Parts Manual

2
T
HE
M
ANUAL
Before you operate your unit, carefully and completely
read manuals supplied with the unit. The contents will
provide you with an understanding of safety instructions
and controls during normal operation and maintenance.
For your safety and the safety of others always read,
understand, and follow all DANGER, WARNING, and
CAUTION messages found in manuals and on safety
decals.
Hardware descriptions are given in decimals.
S
ERVICE AND
R
EPLACEMENT
P
ARTS
When ordering replacement parts or making service
inquiries, know the Model and Serial numbers of your unit
and engine.
Numbers are located on the product registration card in
the unit literature package. They are printed on a serial
number label, located on the frame of your unit.
• Record Unit Model and Serial numbers here:
• Record Engine Model and Serial numbers here:
UNAUTHORIZED REPLACEMENT PARTS
Use only Gravely replacement parts. The replacement of
any part on this vehicle with anything other than a
Gravely authorized replacement part may adversely
affect the performance, durability, or safety of this unit
and may void the warranty. Gravely disclaims liability for
any claims or damages, whether warranty, property
damage, personal injury or death arising out of the use of
unauthorized replacement parts.
Decimals to Fractions
.063 1/16 .563 9/16
.125 1/8 .625 5/8
.188 3/16 .688 11/16
.250 1/4 .750 3/4
.313 5/16 .813 13/16
.375 3/8 .875 7/8
.438 7/16 .938 15/16
.500 1/2 1.00 1
P
RODUCT
R
EGISTRATION
The Gravely dealer must register the product at the time
of purchase. Registering the product will help the
company process warranty claims or contact you with the
latest service information. All claims meeting
requirements during the limited warranty period will be
honored, whether or not the product registration card is
returned. Keep a proof of purchase if you do not register
your unit.
Customer Note: If Dealer does not register your product,
please fill out, sign and return the product registration
card to Gravely or go to www.gravely.com.
Y OUR S ATISFACTION I S I MPORTANT
Questions? Please follow these helpful steps:
1. Refer to the manuals supplied with your unit.
They will guide you through safe and proper
operation and maintenance.
They contain specifications on your unit.
If your questions are not answered in these manuals,
go to step number two.
2. Contact Your Dealer.
Our dealers will be happy to supply any service or
advice required to keep your unit operating at peak
efficiency.
A factory trained staff is available to support your
equipment needs. They stock genuine Gravely parts
and lubricants manufactured with the same precision
and skill as the original.
If your questions are not resolved by the support
staff, ask for the manager or owner.
When contacting your Dealer supply your model and
serial numbers.
TO SPEED PARTS ORDERING:
1. Know the model and serial numbers of your unit.
2. Know the part number required.
3. Know the quantity required.
4. Know the part description.

3
M
ODELS
Domestic
Model 992077
19HP Kawasaki with 44” Mower Deck
Serial No. 000101 and up
Model 992078
21HP Kawasaki with 48” Mower Deck
Serial No. 000101 and up
Model 992079
23HP Kawasaki with 52” Mower Deck
Serial No. 000101 and up
Model 992080
23HP Kawasaki with 60”Mower Deck
Serial No. 000101 and up
Model 992081
25HP Kohler with 52” Mower Deck
Serial No. 000101 and up
Model 992082
25HP Kohler with 60” Mower Deck
Serial No. 000101 and up
International
Model 992310
19HP Kawasaki with 44” Mower Deck
Serial No. 003000 and up
Model 992311
21HP Kawasaki with 48” Mower Deck
Serial No. 003000 and up
T
ABLE
O
F
C
ONTENTS
D
ECALS
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
M
AIN
F
RAME
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P
OWER
P
LANT
Engine and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel Tanks and Hoses . . . . . . . . . . . . . . . . . . . . . . . . 9
D
RIVE
T
RAIN
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Motors and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
H
YDRAULICS
Lift Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic Tank, Filter and Pump to Tank Circuit. . . . 14
Deck Lift and Motors to Pump Circuit. . . . . . . . . . . . 15
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 16
O
PERATOR
C
ONTROLS
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E
LECTRICAL
Continuity Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
M
OWER DECKS
Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Decks, Discharge Chute and Baffles . . . . . . . . . . . . 26
Belts, Spindles, Idlers, and Blades. . . . . . . . . . . . . . 28
Mounting Arms and Belt Guards . . . . . . . . . . . . . . . 27
Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
© Copyright 2004 Ariens Company

4
D
ECALS
Model 992077, 078, 079, 080, 081, 082, 310, 311
Item Part No. Qty. Description
1 05359400 1 Decal, Pinch Point
2 07756000 1 Decal, Danger Fan
3 07754100 2 Decal, Hot Surface
4 69229100 1 Set, Decal-Common Danger/Fuel
5 07731400 2 Decal, Mower Pan Head Danger
6 07742300 1 Decal, Warning
DANGER/PELIGRO
07731400D
WARNING/AVERTISSEMENT/ADVERTENCIA
Do not operate mower
unless guards are in
operating position or
bagger is attached.
Ne jamais utiliser
la tondeuse sans
protecteur sur le
canal d'ejection ou
sans le bac monte.
No operar segadora a
menos que las defensas
esten en posicion de
operacion o el
recogedor este fijo.
07742300B
• Risque de blessures - ne pas s’approcher des pièces en
mouvement.
• Evitar lesiones - Mantenerse alejado de las piezas giratorias.
• Avoid injury - Stay clear of rotating parts.
07735200C
DANGER / PELIGRO
05233900
RIGHT
TANK
LEFT
TANK
OFF
DANGER/PELIGRO
07731400D
05359400
077560
5
6
5
3
4
PD3540
4
4
2
1

5
D
ECALS
Model 992077, 078, 079, 080, 081, 082, 310, 311
Item Part No. Qty. Description
1 05359200 1 Decal, Service Instructions
2 07735300 1 Decal, Lift Lever
3 05358900 1 Decal, PM 152Z (079, 081)
05358700 1 Decal, PM 144Z (077)
05358800 1 Decal, PM 148Z (078)
05359000 1 Decal, PM 160Z (080, 082)
4 07757600 1 Decal, Instructional Steering
5 07734600 1 Decal, Belt Diagram
6 05234500 1 Decal, 52 (079, 081)
05359100 1 Decal, 44 (077)
05233300 1 Decal, 48 (078)
05232000 1 Decal, 60 (080, 082)
7 05304300 1 Decal, ZT Hood
8 05354700 1 Decal, Height of Cut
9 07757500 1 Decal, Parking Brake Lever
10 05358600 1 Decal, Control Panel
11 05225500 2 Decal, 15" Gravely Logo
12 05305100 1 Decal, American Flag
07735300B
07757600A
07757500A
05354700
4.5
3.5
2.5
1.5
5
4
3
2
1
05358600
5
11
4
9
PD3283
8
10
1
2
6
3
12
7

6
F
RAME
Model 992077, 078, 079, 080, 081, 082, 310, 311
Item Part No. Qty. Description
1 09281251 1 Intermediate Z Frame (077, 078, 079, 081)
09281351 1 Intermediate Z Frame (080, 082)
2 06530400 6 Nut, Spin Lock Flange .312-18
3 09267151 1 Hinge, Footboard Left Hand
4 06543100 1 Nut, Locking Top Flange .31-18
5 09292251 1 Bumper/Guard
6 07049900 2 Bolt, Serrated Flange Washer Head .38-16 x 1.00
7 07053300 2 Nut, Retainer .375-16 x .37
8 07412900 8 Screw, Tapping Hex Washer Head .38-16 x .50
9 05947500 1 Bolt, Hex .31-18 x 1.25 Grade 5
10 07533600 6 Bumper, Rubber
11 09283251 1 Seat Support
12 09282653 1 Footrest Panel
13 09267251 1 Hinge, Footboard Right Hand
14 06223900 4 Bolt, Round Head Square Neck .38-16 x .75 Grade 5
15 06542000 4 Nut, Locking Top Flange .38-16
16 09297253 1 Access Panel
17 07414100 2 Screw, Tapping .38-16 x 1.00 Hex Washer Head (310, 311)
PD3550
1
3
5
8
10
12
14
15 13
16
11
10
7
6
8
2
4
9
2
17

7
S
EAT
Model 992077, 078, 079, 080, 081, 082, 310, 311
Item Part No. Qty. Description
1 09214500 1 Seat
2 06543100 4 Nut, Locking Top Flange .31-18 (077, 078, 079, 080, 081, 082)
06543100 5 Nut, Locking Top Flange .31-18 (310, 311)
3 034738 2 Bushing, Flange .515 x .750 x .745 x 1.00
4 00164351 1 Seat Pivot Mount
5 09282700 1 Rod, Seat Frame Pivot
6 05717100 2 Ring, Retaining External .500 x .050
7 06432500 2 Washer, Thrust 1.14 x 1.50 x .20
8 044486 1 Cable, Hood
9 05946800 2 Bolt, Hex .25-20 x .75 Grade 5
10 06543500 2 Nut, Locking Top Flange .25-20
11 07531700 1 Knob, Wing .312-18 (077, 078, 079, 080, 081, 082)
PD3560
6 7
7 6
2
3
5
4
1
3
8 10
9
9
10
2
310, 311
2
077, 078, 079,
080, 081, 082
11

8
E
NGINE AND
C
LUTCH
Model 992077, 078, 079, 080, 081, 082, 310, 311
Item Part No. Qty. Description
1 08270000 1 Engine, Kohler, 25HP (081, 082)
08268800 1 Engine, Kawasaki 19HP (077, 310)
08268000 1 Engine, Kawasaki 21HP (078, 311)
08268900 1 Engine, Kawasaki 23HP (079, 080)
2 09294800 1 Muffler, Kohler (081, 082)
09281600 1 Muffler, Kawasaki (077, 078, 079, 080, 310, 311)
3 07218000 1 V-Belt HA 52 x .535 G48667
4 07414100 3 Screw, Tapping Hex Washer Head .38-16 x 1.00
5 05952400 1 Bolt, Hex .31-18 x 1.50 Grade 5
6 06543100 5 Nut, Locking Top Flange .31-18 (081, 082)
06543100 1 Nut, Locking Top Flang,e .31-18 (077, 078, 079, 080, 310, 311)
7 07327700 1 Pulley-V 4.00 x 1.125 with Key 1.42 Height
8 039160 1 Key, Square .25 x .625 x .25 SAE 8630 OR SAE 1035
9 09232700 1 Clutch, Electric
10 06445000 1 Washer, Flat Steel .515 x 1.625 x .25
11 06309300 1 Washer, Locking .44 x .109
12 05964600 1 Bolt, Hex .44-20 x 2.50 Grade 5
13 09282300 1 Weldment, Clutch Anchor
14 021134 31 in Gas Line, Bulk .25 ID
15 06939100 23 Hose, Clamp
16 06308600 4 Washer, Lock .31 x .078 Regular (Included with item 1)
17 06538600 4 Nut, Hex M8-1.25 (Included with item 1)
18 02749600 1 Nipple (081, 082)
19 07023500 1 Elbow .375-18 (081, 082)
20 00113800 1 Pipe Plug (081, 082)
21 09295751 1 Bracket, Oil Filter Mounting-Kohler (081, 082)
22 06212200 2 Bolt, Round Head Square Neck .31-18 x .62 (081, 082)
23 05946900 2 Bolt, Hex .31-18 x 1.00 Grade 5 (081, 082)
24 06435700 2 Washer, Flat Steel .38 x .875 x .083 (081, 082)
25 09258800 1 Filter Minder (081, 082)
26 07065800 1 Nipple, .125 NPT (081, 082)
27 09257500 AR Assembly, Air Cleaner
28 21537000 AR Filter, Outer Element
29 21539500 AR Fuel Filter, Kohler (081, 082)
21410800 AR Fuel Filter, Kawasaki (077, 078, 079, 080, 310, 311)
30 21397200 AR Oil Filter, Kohler (081, 082)
21535800 AR Oil Filter, Kawasaki (077, 078, 079, 080, 310, 311)
31 21525900 AR Spark Plug, Kohler (081, 082)
21536100 AR Spark Plug, Kawasaki (077, 078, 079, 080, 310, 311)
32 21536900 AR Filter, Inner Element
33 035329 1 Cock, Oil Drain (077, 078, 079, 310, 311)
34 035328 1 Adapter, Oil Drain (077, 078, 079, 310, 311)
35 021134 8 in Gas Line, Bulk .25" ID (077, 078, 079, 310, 311)
33
34
1
15
35
see
"Fuel Tanks"
A
1
3
4
5 6
7
8
9
10
11
12
13
14
15
28
29
30
31
32
16
17
2
PD0790
18
19
20
21
22
23
6
24
25
26
27
4
31
081, 082
077, 078, 079, 080, 310, 311

9
FUEL TANKS AND HOSES
Model 992077, 078, 079, 080, 081, 082, 310, 311
Item Part No. Qty. Description
1 09281500 1 Tank, Gas - Right Hand
2 05947000 8 Bolt, Hex .31-18 x .75 Grade 5
3 06308600 8 Washer, Locking .31 x .078
4 06435700 8 Washer, Flat Steel .38 x .875 x .083
5 021134 75 in Gas Line, Bulk .25" ID
6 06939100 4 Hose, Clamp
7 00191100 1 Tank, Left Hand Fuel (EYE-Q) 100 Series
8 09258200 1 Valve, Fuel
9 09239500 2 Cap, Gas
10 050246 AR Bushing
11 07064500 AR Fuel Tank Fitting
12 06918200 1 Clamp, Cushioned Steel (081, 082)
13 05948700 1 Bolt, Hex .38-16 x 1.00 Grade 5 (081, 082)
14 06542000 1 Nut, Locking Top Flange .38-16 (081, 082)
see
"Engine and
Clutch"
A
1
2 3
4
4
3
4
3
5
5
2
3
4
6
6
7
8
9
10
9
10 6
2
6
11
11
PD3660
12
13
14

10
TRANSMISSION
Model 992077, 078, 079, 080, 081, 082, 310, 311
Item Part No. Qty. Description
1 09285100 1 Hydrostat BDP with Auxiliary
2 050995 2 Key, Straight 5mm x 25mm x 5mm
3 051138 2 Sheave 4.0 x .199
4 416904 2 Washer, Flat Steel .281 x 1.00 x .063
5 06308400 2 Washer, Locking .25 x .062
6 05969800 2 Bolt, Hex M6 x 1.0 x 12
7 05947900 4 Bolt, Hex .25-20 x .50 Grade 5
8 05958000 4 Bolt, Hex .38-16 x 1.25 Grade 5
9 06444300 4 Washer, Flat Steel .39 x .75 x .125
10 06542000 7 Nut, Locking Top Flange .38-16
11 09285200 1 Pump
12 09219000 1 Assembly,Idler Arm Guard Drive (Includes 13 & 14)
13 09217051 1 Weldment, Idler Arm Ground Drive
14 05435800 2 Bearing, 1.00 x 1.12 x .75
15 09231100 1 Anchor, Idler Spring
16 08336000 1 Spring, Tension .120 x .845 x 6.50
17 06444300 1 Washer, Flat Steel .39 x.75 x.125
18 05965800 1 Bolt, Hex .50-13 x 3.50 Grade 5
19 07053100 1 Bearing, Pedestal Powdered Metal
20 06543600 1 Nut, Locking Top Flange .50-13
21 07327500 1 Idler, Flat 4.00 x 1.06
22 05962900 1 Bolt, Hex .38-16 x 2.25 Grade 5
23 09274900 1 Fan, Cooling
24 06442800 4 Washer, Flat Steel .656 x 1.31 x .095
25 09282900 2 Bracket, Return to Neutral/Damper
26 02513500 2 Spacer .344 x 1.00 x .375
27 05947500 2 Bolt, Hex .31-18 x 1.25 Grade 5
28 06543100 4 Nut, Locking Top Flange .31-18
29 05959400 1 Bolt, Hex .38-16 x .75 Grade 5
30 59203600 AR Kit, Pump Seal (BDP-10A)(One kit required for each pump)
31 03652200 2 Stud, Ball
PD3670
1
2 3
4
5
6
3
4 5
6
2
7
7
8 9
8
9
10
11
15
13
16
14
18
19
21
22
30
17
20
12
10
10
23
24
24
25
26
27
28 31
29
28
10