TABLE OF CONTENTS Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Service and Replacement Parts . . . . . . . . 1.3 Product Registration . . . . . . . . . . . . . . . . . 1.4 Unauthorized Replacement Parts . . . . . . . 1.5 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Technical Service Communications . . . . . . 1.7 Preparation . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - INTRODUCTION 1.1 THE MANUAL 1.3 PRODUCT REGISTRATION The purpose of this manual is to provide complete instructions for service, maintenance, disassembly, repair, and installation of the mechanical components for the Promaster 260Z and 250Z. 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.
To reduce the incidence of misplaced tools or parts, place removed components with all attaching hardware 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. SECTION 2 - SAFETY 2.1 SAFETY ALERTS 2.5 REQUIRED OPERATOR TRAINING Look for these symbols to point out important safety precautions.
Operation • Only trained adults may operate unit. Understand: • Training includes actual operation. • How to operate all controls • Clearly understand instructions. • The functions of all controls • Be alert! Conditions can change. • How to STOP in an Emergency • Speed ranges Do not operate any of the control levers or power takeoff unless both feet are resting on the platform. DO NOT travel at too fast a rate. DO NOT change engine governor settings or over-speed engine.
Storage DO NOT store unit inside a building with fuel in the fuel tank where any ignition sources are present. Allow unit to cool completely. ALWAYS clean unit before extended storage. See Engine Manual for proper storage. Battery Avoid Electric Shock. DO NOT reverse battery connections. Explosive Gases! Poisonous battery fluid contains sulfuric acid and its contact with skin, eyes, or clothing can cause severe burns. No flames. No sparks. No smoking near battery.
SECTION 3 - SPECIFICATIONS Model Number 992020 and 022 992018 992021 992023 992024 Model PM260Z 25 HP Kohler with 60" deck PM260Z 25 HP Kohler with 50" deck PM260Z 22 HP Robin with 50" deck PM250Z 20HP Briggs & Stratton with 50" deck PM260Z 22 HP Robin with 60" deck 221 (87) 229 (90)* Length - cm (in) 229 (90)* Height - cm (in) 127 (50) Width - cm (in) 185 (73) Weight Actual - kg (lbs) 510 (1125) 160 (63) 499 (1100) 185 (73) 500 (1103) 490 (1080) Battery 12 volt Brakes Hydro/Dy
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 18 8 11 9 10 12 13 7 14 19 15 16 6 5 17 4 3 2 20 1 OF1722 Figure 2 1. Mower Deck with Chute Deflector 2. Fuel Shut Off Valve 3. Parking Brake 4. Battery 5. Hour Meter 6. Oil Pressure Indicator 7. Engine Frame and Hood (260Z) 8. Fuel Tanks and Caps 9. Choke Control 10. Throttle Control 11. Ignition Switch 12. Power Take Off (PTO) Switch 13. Steering Levers 14. Mower Lift Lever 15. Seat Adjustment Lever 16.
Daily Service Position: Place engine hood prop rod into service slot. Assure rod is engaged in slot properly. 4.2 SERVICE POSITION - 260Z 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. Full Service Position: Slowly release frame after seat contacts foot board. Use care and be sure of your footing. Do not step on mower deck. 5. When service is complete, lower hood and secure with latches.
When taking unit out of extended storage: 4.7 FASTENERS 1. Check for any damage or loose parts. Repair, replace, or tighten hardware before operation, especially blade attachment bolts. Each day before operating, check mower blade mounting hardware and all other fasteners. Replace fasteners that are missing or damaged. Tighten all nuts and bolts to their correct torque value. 2. If a preservative fluid was used in fuel tank, drain and discard. Fill fuel tank with fresh new fuel. 4.
4.9 BASIC ENGINE MAINTENANCE Replacing Mower Belts See your engine manual and Section 5 of this manual for detailed information on the operation and maintenance of your engine. NOTE: Long belt must be removed to remove short belt. 1. Roll long belt off left blade spindle and remove from deck. 1. Each day before operating, check the level of the oil in the engine. Never operate the engine when the oil level is below the add mark. 2. Roll short belt off right blade spindle and remove from deck.
4.12 MOWER BLADES 3 NOTE: If mower is used under sandy soil conditions, replace blades when air lifts become eroded through at ends (Figure 9). 2 1 2 4 1 3 5 4 1. 2. 3. 4. 50" and 60" Belt Layout 1. 2. 3. 4. 5. Long Mower Belt Short Mower Belt Springs Idlers Mower Clutch Sheave Figure 9 OF1640 CAUTION: Use sturdy gloves or padding to protect hands when working with mower blades. 6 5 1 1. Turn the engine off. Remove the ignition key. Remove the ignition wires from the spark plugs. 2.
4.13 STEERING CONTROL NEUTRAL ADJUSTMENT on the pump. The screw may be turned in or out to bring the unit into neutral. 8. If major adjustment is needed, it is best to remove the front ball joint from the bottom of the control levers and turn the stop screw in or out until neutral is found. If the unit has excessive creep when the control levers are in neutral, adjust as follows: (Figure 10) 9.
4.16 ADJUSTING THE UNIT TO TRACK STRAIGHT 4.15 ADJUSTING THE PARKING BRAKE 1. The Parking Brake may be adjusted through the use of the jam nuts on the brake rod which push against the compression spring which pushes on the caliper arm. See Figure 11. Check and adjust tire pressure. Increase pressure on side unit tracks toward. DO NOT exceed maximum recommended tire pressure (refer to Specifications). 2.
4.17 LEVELING THE MOWER DECK These adjustments should be made on a level surface with the tires inflated to the correct air pressure. Right Side View The mower is leveled from side to side with the slots where 4 chains fasten to the mower mounting brackets. The mower is leveled from front to rear by adjusting the rod running down each side of the frame (Figure 13). 9 2 1 3 7 8 1. Raise mower deck and insert 3” (7.6 cm) tall blocks to support deck. 2. Lower deck onto blocks so chains are slack. 3.
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 Black Exhaust Blue/White Exhaust Difficult Starting Erratic Running Excessive Fuel Consumption High Oil Pressure Knocking Loss of Power or System Low Cranking Power Low Oil Pressure Misfiring Overheating Poor Compression Starts and Stops The troubleshooting key is generic and can be used for several types of engines.
5.2 REMOVING THE ENGINE 1. Place the mower in the full service position. 3 2. Disconnect the battery cables, negative first. 3. Disconnect ignition wires using the connectors. 4. Remove the belts from the pulley and clutch. 5. Unscrew the bolt from the center of the output shaft and remove clutch. Refer to "Replacing the Clutch". 1 6. Remove the square key and the pulley. 7. Unclamp and remove the fuel line. Plug the fuel line and wipe up any spills. 8.
SECTION 6 - DRIVE TRAIN 15W50 synthetic oil. Start the engine and run for 1 - 2 minutes. WARNING: Hydraulic Fluid can result in severe burns. Fluid in hydraulic system can penetrate skin and result in serious injury or death. 6. After shutting off the engine, check the fluid level. The dipstick should read the fluid level between the high and low markings. 7. Properly dispose of waste oil. Be sure to stop the engine before doing any work on hydraulic parts.
To Replace a Hydraulic Pump 6.4 REPLACING THE HYDRAULIC PUMP The two hydraulic pumps are located inside the chassis in front of the engine. The pumps are maintenance free and should be replaced in the event of a failure. See Figure 15. 1. Lift cover to full service position. 2. Remove the cross channel. 3. Clean hoses and fittings and mark for location. 4. Disconnect hoses from pump. CAUTION: Some fluid will leak out. Clean up any spills. 1 5. Loosen belt from pulley. 6.
6.5 REPLACE WHEEL MOTOR Each drive wheel is mounted to a hydraulic drive motor. The drive motors are maintenance free. In the event of a failure, the drive motors should be replaced. 1 2 2 1 1. Hub 2. Hydraulic motor Figure 16 To Replace a Drive Motor 15.Tight lug nuts using the pattern shown in Figure 17. 1. Loosen the wheel lugs 1/4 turn. 16.Lower the unit to the ground and start the engine. Drive forward twenty feet and stop the engine. Check the hydraulic fluid level.
6.
SECTION 7 - MOWER DECK 7.1 MOWER DECK Mower Spindles This unit utilizes a maintenance free extended life spindle. No routine maintenance is required. In the event of bearing failure or a bent shaft the spindle should be replaced. To Remove the Spindle 1. Place the unit in service position. Turn key off and remove the spark plug wire from contact with the spark plug. 2. Remove cutting blade by unscrewing bolt. CAUTION: Use sturdy gloves or padding to protect hands when working with mower blades. 3.
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 WARNING: EXPLOSIVE GASES can result in serious injury or death. ALWAYS keep open flames, sparks, or smoking materials away from battery. 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. POISONOUS BATTERY FLUID contains sulfuric acid and its contact with skin, eyes or clothing can cause severe chemical burns.
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. 8. Connect positive (+) lead of charger to positive (+) terminal, and negative (-) lead to negative (-) terminal. 9. 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.
IMPORTANT: Charging at higher rates will damage the battery and cause excessive gassing and acid spewing. 9.4 SWITCHES Jump Starting 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.
Ignition Switch 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. NOTE: Refer to the wiring diagram of the unit involved to determine switch functions and test using the methods described. The ignition switch incorporates a number of functions, although not all functions are used on all equipment.
functioning) or the device is open and is therefore defective. Use an ohmmeter to check for continuity. 9.7 DIODES AND RECTIFIERS Diodes are solid state, semiconductor devices. They contain no moving parts and conduct current better in one direction than the other. They are electrical "check valves" and permit current flow in one direction, but not in the other. Diodes allow current to flow through one circuit without "backing up" into another.
9.
Model 992305 SEAT / PTO RELAY SEAT SWITCH PINK 87 87a 85 86 1 2 30 CAB POWER SUPPLY BLACK 2 RED / YELLOW 1 BLACK PTO SWITCH 7 HOUR METER 4 1 2 1 3 PURPLE PTO CLUTCH PURPLE / WHITE 9 BLACK BLACK OIL PRESSURE BROWN / YELLOW OIL LIGHT BLUE / WHITE FUEL SOLENIOD START RELAY RED / YELLOW 3 ENGINE REGULATOR PURPLE 1 BLACK MAGNETO KILL 2 87 86 87a WHITE / BLACK 85 30 STARTER SOLENOID BLUE 4 CE RELAY BLACK HOOD SWITCH 30 BLACK DECK LID SWITCH 1 LIGHT BLUE RED 2 8
Model 992023 SEAT SWITCH SEAT / PTO RELAY PINK 87a 87 85 86 1 2 30 CAB POWER SUPPLY BLACK 2 RED / YELLOW 1 BLACK PTO SWITCH 7 HOUR METER 4 1 2 1 3 PURPLE PTO CLUTCH PURPLE / WHITE 9 BLACK BLACK SWITCH OIL PRESSURE BLUE / WHITE FUEL SOLENIOD RED / YELLOW START RELAY ENGINE REGULATOR BROWN / YELLOW OIL LIGHT PURPLE BLACK MAGNETO KILL 87 86 87a WHITE / BLACK 85 30 RED / YELLOW STARTER BLACK A B RED RED 1 B FUSE 30A A BRAKE SWITCH M BATTERY BLACK BLACK 1 2
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.
