Professional 2-Wheel Tractor Service Manual Models 985103,104, 105, 107 - 115, 117 08483800 08/00 Printed in USA
TABLE OF CONTENTS Section 1 - Introduction . . . . . . . . . . . . . . . . . . . 1-3 1.1 The Manual. . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Section 6 - Steering & Controls . . . . . . . . . . . 6-18 6.1 Handlebar Assembly. . . . . . . . . . . . . . . . . 6-18 1.2 Service And Replacement Parts . . . . . . . . . 1-3 6.2 Steering Brakes (Optional) . . . . . . . . . . . . 6-19 1.3 Product Registration . . . . . . . . . . . . . . . . . . 1-3 6.3 Adjusting Brakes . . . . . . . . . . . . . . . .
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.
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. in the disassembly order on a clean work surface. Organization is a key part of proper reassembly. 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.
Learn the location and function of all controls. Learn how to use the controls to stop the wheels and attachment quickly in an emergency. Understand and follow each danger, warning, caution and instruction decal installed on this product. 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.
SECTION 3 - SPECIFICATIONS Model Number Description 985103 8HP Gear Drive Brakes 985104 985105 985107 8HP Gear Drive 8HP Gear Drive 12 HP Gear Drive Optional, individual, 7" (17.8 cm) x 1.75" (4.
Model Number Description 985108 12HP Gear Drive Brakes 985109 985110 985111 16HP Gear Drive 8HP Gear Drive 8HP Gear Drive Optional, individual, 7" (17.8 cm) x 1.75 (4.4 cm) drum type Steering Manual, optional power steering kit available Turning Radius Zero (with steering kit) Minimum Uncut Circle Zero Optional Tire Sizes -Stud Tread 4" x 8", 4 ply 4" x 8", 4 ply 4" x 8", 4 ply -Trac Tread 4" x 8", 4 ply 4" x 8", 4 ply 4" x 8", 4 ply 4" x 8", 4 ply -Turf-Chief 18" x 6.
Model Number Description 985112 985113 985114 985115 12 HP 12 HP 16 HP 8.5 HP Gear Drive Gear Drive Gear Drive Gear Drive 7 x 1.75" Drum Type N/A Brakes Steering Manual, optional power steering kit available Turning Radius Zero (with steering kit) Minimum Uncut Circle Zero Optional Tire Sizes -Stud Tread 4.00-8 4.00-8 4.00-8 -Trac Tread 4.00-8 4.00-8 4.00-8 4.00-8 -Turf-Chief 18" x 6.50"-8" 18" x 6.50"-8" 18" x 6.50"-8" 18" x 6.50"-8" -Turf-Saver 18" x 8.50"-8" 18" x 8.
Model Number 985117 Description 13.5 HP Gear Drive Brakes 7 x 1.75" Drum Type Steering Manual, optional power steering kit available Turning Radius Zero (with steering kit) Minimum Uncut Circle Zero Optional Tire Sizes -Stud Tread 4.00"-8" -Trac Tread 4.00"-8" -Turf-Chief 18" x 6.50"-8" -Turf-Saver 18" x 8.50"-8" -Semi-Pneumatic Tire Pressure Battery Engine -Type -Horsepower -Number of Cylinders -Displacement 16" x 5" x 3" See Tire Sidewall 12V BCI Group Robin EH410-0226T 13.
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 1 2 4 7 10 3 15 9 12 13 6 4 5 11 14 8 4 OH0160 1. 2. 3. 4. 5. Direction Control Lever Steering Brake Handlebar (Optional) Gear Shift Lever (Hi/Low Gear) Operator Presence Control Choke Control Knob (Models with Briggs & Stratton Engines) 6. PTO Control 7. Ignition Switch 8. Kick Stand 9. Throttle Control 10. Hour meter 11. Brake Handle Cross Bar 12. Range Shift Handle (Two Speed Axle) 13.
4.3 GENERAL LUBRICATION Control Linkage Lubrication CAUTION: Before performing any service or adjustments: 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. NOTE: There are no grease fittings on the tractor. • Turn PTO switch "OFF". • Park mower on a hard, flat, level surface. • Place steering control levers in neutral lock (fully outward) position.
4.6 STEERING BRAKE ADJUSTMENT (APPLICABLE MODELS) 2 6 1. 2. 3. 4. 1 7 7 1 7 4 5 7 1 8 3 • 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).
2 3 1 7 1 2 1 9 1 2 5 6 8 2 4 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 4.7 PTO BRAKE ADJUSTMENT • Adjust the PTO brake after every 100 hours of operation. WARNING: Stop the engine before adjusting the PTO brake. OH0191 NOTE: Do not tighten the bolts in a circular sequence, by tightening the bolt next to one which was just tightened.
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). NOTE: The attachment gasket must be replaced if damaged.
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. TROUBLE 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.
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. See the engine manual for oil specifications and oil filter service instructions. To check oil level: 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. 4. Put the dipstick back into the engine, and remove again. 5.
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.
SECTION 6 - STEERING & CONTROLS 6.1 HANDLEBAR ASSEMBLY CAUTION: Before performing any service or adjustments: • Turn PTO switch "OFF". • Park mower on a hard, flat, level surface. • Place steering control levers in neutral lock (fully outward) position. engine and out between the left side of the frame and the PTO control. Rotate the handlebar into the mounting position. 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.
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. 1. Hi-Lo Control Handle Assembly 2. Hand Lever Pivot Figure 12 4.
1 2 3 4 8 5 6 4 7 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 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. 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.
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. 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. 3. Remove the axle nut, flat washer and spacer. Remove the wheel hub set screw. 4. Use a puller and remove the wheel hub. 5.
6.4 POWER TAKE OFF CONTROL 6.5 RANGE SHIFT CONTROL (TWO SPEED AXLE) 1 5 2 1 4 3 1 6 3 3 2 4 1. 2. 3. 4. Tie Rod Ball Joint Jam Nut Flat Washer 5. Lock Nut 6. PTO Bellcrank Weldment 5 Figure 15 9 PH0051 4 8 1. 2. 3. 4. 5. Shifter Cam Shifter Rod Compression Spring Spring Washer Shifter Crank 7 6. Shift Lever Block 7. Mower Height Adjuster Bracket Shim 8. Shifter Link 9. Compression Spring Figure 17 Figure 16 1. Thread jam nut onto PTO shaft (supplied).
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.
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 avoid damage to the rear pin plate bushing, it is not recommended that planetary system be further disassembled unless definite problems exist. If an unreasonable amount of play is noticed in the system: 1. Inspect orbit gear pins and bushings for wear. 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.
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 2 3 4 1 2 3 9 4 13 14 11 5 8 12 11 16 7 19 11 10 17 18 6 1. 2. 3. 4. 5. 6. 7. 8. Race Bearing Cone Bearing Clutch Housing Clutch Worm Gear Shim Clutch Worm Gear Shim Spider Bevel Gear Flange Bushing Differential Shifting Bevel Gear Needle Thrust Bearing 7 20 1. 2. 3. 4. 5.
Figure 26 2-Speed Right Hand Axle 1 Figure 25 2 3 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) 4 5 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. 6 7 20.
4-Speed Right Hand Axle 20 19 17 18 16 1 2 9 15 3 4 4 14 5 8 6 11 Stationary Pivot O-Ring Shifting Yoke Clutch Sliding Pin Straight Axle 6. 7. 8. 9. Seal Shifting Clutch Stationary Clutch 2-Speed Axle Housing Figure 28 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.
SECTION 8 - FUEL SYSTEM 8.
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.
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.
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. glasses and proper protective gear when handling batteries to prevent electrolyte from coming in contact with eyes, skin or clothing. WARNING: ELECTRIC SHOCK may result in injury and/or damage to unit.
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.
Specific Gravity Check Jump Starting The specific gravity should be checked with a hydrometer. 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. Subtract .004 from 1.265 for each 10 oF below 80oF (27oC) or add .004 to 1.265 for each 10oF above 80oF (27oC). Jump starting, battery charging, or replacement is required when the starter motor will not crank the engine.
gravity. Before reinstalling the battery in the spring, it should always be fully recharged. Variation from test results described indicates a defective switch. 9.5 SWITCHES Ignition Switch 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.
If a relay or solenoid fails to operate, the cause may be either electrical or mechanical. 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. 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.
9.9 WIRING DIAGRAM 1 4 3 5 2 7 8 6 10 9 Robin Engine Briggs & Stratton Engine and Kohler Engine 1. Steering Brake Harness 2. Handlebar Wiring Harness 3. 4. 5. 6. Switch Solenoid Wiring Harness Relay 9 -37 7. Hourmeter 8. Ignition Switch 9. Fuse 10.
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.
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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.
