GRAVELY 915160 – ZT XL 42 (01) PDF Document

Before attempting to operate your GRAVELY 915160 – ZT XL 42, please complete the following steps:

1. Make sure all assembly has been properly completed.

2. Understand all Safety Precautions provided in the manuals.

3. Review control functions and operation of the unit. Do not operate the unit unless all controls function as described in this manual.

4. Review recommended lubrication, maintenance and adjustments.

5. Review Limited Warranty Policy.

6. Fill out a product registration card and return it.

Follow these steps for initial assembly:

Unpack Unit:

Remove the unit and all other components from the shipping container. Engage the transmission bypass lever to push the unit from the container onto a level surface, then disengage the bypass lever.

Connect Battery:

Follow the instructions for Battery Removal and Installation, performing steps 4 and 5 of the installation section.

Place Unit in Operating Position (Steering Levers):

1. Push steering levers aside and tip the seat up.

2. Adjust the seat as needed.

3. Remove hardware from the top hole of the steering lever. Slide the steering lever back to align the slot with the hole at the top of the steering pivot arm.

4. Adjust steering levers as needed and then tighten hardware.

Place Discharge Chute in Operating Position:

1. Remove and discard the nuts holding the discharge chute in the transport position.

2. Remove the plastic knobs from the chute hardware and use them to mount the chute to the deck in the operating position.

Before each use, perform the following checks:

Check Engine Oil Level: Refer to the Engine Manual.

Level Mower Deck: Ensure the mower deck is level and the pitch is adjusted correctly.

Fill Fuel Tank: Fill the fuel tank, but do not overfill.

Adjust Seat: Adjust the seat to a comfortable operating position.

Check Tire Pressure: Ensure tires are inflated to the recommended pressure. See Specifications for correct pressure.

Check Safety Interlock System: Verify the system is functioning properly before each use.

Check Function of All Controls: Ensure all controls operate as described in the manual.

To ensure the safety interlock system is working properly, perform the following tests. If the unit does not perform as stated, contact your dealer for repairs.

* Test with engine running.

+ Operator lifts off seat.

Ignition Switch: Has four positions: Stop (1), Headlight (2), Run (3), Start (4). Use the key to operate.

Throttle Lever: Push towards the rabbit icon for Fast speed, and towards the turtle icon for Slow speed.

Choke Control: Push the lever away from the operator position to start a cold engine. Pull the lever toward the operator position after the engine starts to run smoothly. Do not choke a warm engine.

Parking Brake: Push the lever down to engage (2) and pull up to disengage (1).

Power Take-Off (PTO) Switch: Pull the switch up to engage (2) the mower blades and push down to disengage (1).

Steering Levers:

• Reverse: Pull both levers backward.

• Forward: Push both levers forward.

• Left: Pull the left lever back or push the right lever forward.

• Right: Pull the right lever back or push the left lever forward.

• Stop: Return both levers to the neutral position.

Mower Lift Pedal: Press the mower lift pedal and place the height of cut lever to the desired adjustment notch to raise and lower the deck.

1. Place the unit in an open, well-ventilated area.

2. Stop the engine and allow it to cool.

3. Clean the fuel cap and surrounding area to prevent debris from entering the tank.

4. Remove the fuel cap.

5. Fill the fuel tank to the bottom of the filler neck. DO NOT OVERFILL. This allows for a vapor gap required for fuel expansion.

6. Replace the fuel cap and tighten it.

7. Always clean up spilled fuel.

IMPORTANT: ALWAYS use gasoline that meets the following guidelines:

• Clean, fresh gasoline.

• A minimum of 87 octane/87 AKI (91 RON).

• Gasoline with up to 10% ethanol (E10) or up to 10% MTBE is acceptable. The use of any gasoline exceeding these percentages will void the product warranty.

• Never mix oil and gasoline.

Starting the Engine:

1. Disengage the PTO, engage the parking brake, and place the steering levers in neutral.

2. If the engine is cold, push the choke control away from the operator. If warm, do not use the choke.

3. Move the throttle to the 1/3 Fast position.

4. Turn the ignition key to the start position and release once the engine has started. Do not operate the starter for more than 15 seconds per minute.

5. If the choke was used, pull the choke lever toward the operator position once the engine is running smoothly.

Stopping the Engine:

1. Stop the unit.

2. Disengage PTO.

3. Set the throttle lever to slow.

4. Turn the ignition switch to the off position and remove the key.

5. Set the parking brake.

1. Start the engine.

2. Set the throttle lever to fast.

3. Engage the PTO to start the mower blades. Never engage the PTO if the mower is plugged with grass or other material.

4. Release the parking brake. The parking brake must be disengaged before moving the steering levers from the neutral lockout position.

5. Use the steering levers to move the unit.

6. Disengage the PTO to stop the mower blades.

To push the unit by hand, pull the bypass lever out and lock it in place (2), and then release the parking brake.

To drive the unit normally, push the bypass lever in (1).

WARNING: DO NOT disengage or bypass transmission and coast downhill.

In an emergency situation, especially on slopes where loss of steering control may occur, follow these steps:

1. Return steering levers to the neutral position.

2. Immediately set the parking brake.

3. Turn off the PTO and engine.

• Cut grass when it is dry.

• Keep mower blades sharp.

• Keep the mower deck properly leveled.

• Adjust anti-scalp rollers to prevent scalping.

• Do not set the height of cut too low. For very tall grass, mow twice.

• Do not travel too fast.

• Mow with the engine set at full throttle.

• When mulching, only remove 1/3 of the grass length per cutting.

• Discharge clippings into areas already cut.

Remove:

1. Block the mower blades to prevent rotation.

2. Remove the mounting hardware (5/8″ Hex Bolt, Bevel Washer, Flat Washer) and mower blades from the mower deck.

Install:

1. Install the new mower blades on the mower deck with the mounting hardware in the correct order: Mower Blade, Bevel Washer, Flat Washer, 5/8″ Hex Bolt.

2. Torque the 5/8″ hex bolt to 80 – 120 lbf-ft (108 – 163 N•m).

Adjust the deck on a level surface with tires inflated to the correct pressure. Three measurements are required:

1. The Distance From The Mower Blades To The Ground:

• In the lowest cutting position, the distance should be 1-1/2″ ± 1/4″ (3.8 cm ± 0.64 cm).

• In the highest cutting position, the distance should be 4-1/2″ ± 1/4″ (11.4 cm ± 0.64 cm).

2. The Forward Pitch Of The Mower Blades:

• The blades should be pitched forward 0″ – 1/4″ (6.35 mm). This measurement must be taken when the mower blade ends are facing forward.

3. The Pitch Of The Mower Blades From Side-To-Side:

• The height difference from side to side should be within 1/4″ (6.35 mm). This measurement must be taken when the mower blade ends are perpendicular to the frame of the unit.

To make adjustments, adjust the trunnions and re-take the three measurements until they are within the specified tolerances.

Battery Removal:

1. Tip the seat forward.

2. Disconnect the negative (-) cable first, then the positive (+) cable.

3. Loosen and remove the taptite fastener from the battery bracket.

4. Remove the battery bracket.

5. Remove and properly dispose of the old battery.

Battery Installation:

1. Remove the taptite fastener located by the battery decal.

2. Install the replacement battery into the battery channel.

3. Rotate and align the battery bracket lengthwise to the battery, ensuring the tab corner is flush with the battery.

4. Reinstall the taptite fastener and tighten.

5. Apply petroleum jelly or dielectric grease to the battery cable ends and terminals.

6. Connect the positive (+) cable first, then the negative (-) cable.

7. Tip the seat back into position.

Cleaning Battery and Cables:

1. Disconnect the cables (negative first).

2. Clean the battery cable ends and terminals with a wire brush and rinse with a weak baking soda solution.

3. Apply petroleum jelly or dielectric grease.

4. Reconnect the cables (positive first).

WARNING: FROZEN BATTERIES CAN EXPLODE. DO NOT charge a frozen battery. Let the battery thaw before charging.

1. Remove the battery from the unit.

2. Place the battery in a well-ventilated area.

3. Connect the positive (+) lead of the charger to the positive (+) terminal, and the negative (-) lead of the charger to the negative (-) terminal.

4. Charge the battery according to the battery charger and battery manufacturers’ instructions. IMPORTANT: DO NOT fast charge. Charging at a higher rate will damage or destroy the battery.

5. Install the battery back on the unit.

Make adjustments to each steering lever equally. It is recommended to make adjustments in the following order:

1. Adjust Steering Lever Height:

1. Remove the mounting hardware that attaches the handlebars to the upper control arm.

2. Move the handlebar up or down until the mounting holes are aligned with the preferred adjustment holes.

3. Install mounting hardware and tighten.

2. Adjust Steering Lever Width:

1. Loosen the hardware at the base of the lower control arm.

2. Rotate the eccentric spacer to move the levers away from or closer to the operator’s position.

3. Adjust Steering Lever Forward or Backward:

1. Loosen (do not remove) the bolts securing the handlebar to the upper control arm.

2. Slide the steering lever forward or backward to the desired position and tighten the bolts (tighten the upper bolt first).

Forward and Reverse Speed Adjustment:

If the unit does not track in a straight line, the speed may need adjustment. The side the unit turns toward indicates the wheel on that side is turning slower. To adjust, loosen the jam nut and turn the adjustment bolt:

• Turn the adjustment bolt clockwise to decrease steering lever travel (slowing the wheel).

• Turn the adjustment bolt counter-clockwise to increase steering lever travel (speeding up the wheel).

Remove:

1. Lower the mower deck to the ground.

2. Remove the belt covers from the mower deck.

3. Hook a puller into the idler hole and pull the idler arm towards the outside of the unit to release tension from the PTO belt.

4. Remove the PTO belt from the left mower deck pulley.

5. Slowly release the idler arm.

6. Remove the PTO belt from the mower deck and electric clutch.

Install:

1. Install the new PTO belt on the electric clutch and mower deck (but not on the left mower deck pulley yet).

2. Hook a puller into the idler hole and pull the idler arm towards the outside of the unit until the PTO belt can be routed around the left mower deck pulley.

3. Slowly release the idler arm until the idler pulley rests firmly against the PTO belt.

4. Install the belt covers on the mower deck.

Change hydraulic fluid and filter after the first 75 hours of operation and then every 400 hours. Use 15W-50 synthetic motor oil.

1. Place a container under the oil filter to catch oil.

2. Remove the filter guard and oil filter from the transaxle.

3. Remove the oil drain plug or fitting from the inlet port and allow the transaxle to drain completely.

4. Clean the filter mounting surface and lubricate the rubber gasket on the new oil filter with clean hydraulic oil.

5. Spin the new oil filter onto the filter housing until it makes contact, then tighten it another 3/4 turn.

6. Install the filter guards and tighten the mounting screws to 5.38 lbf-ft (7.3 N•m).

7. Fill with 15W-50 synthetic motor oil until oil appears at the bottom of the drain plug (about 2 quarts per transaxle). Install the drain plug and tighten it to 14.97 lbf-ft (20.3 N•m).

8. Repeat for the other transaxle.

9. Add hydraulic fluid to the expansion tank and purge the system.

WARNING: This adjustment requires operating the engine. Use extreme care to avoid contact with moving parts and hot surfaces. Be sure the rear of the unit is well supported and secure before starting.

1. With the unit facing a wall, jack up the unit so that both drive wheels are off the ground.

2. Disengage the parking brake and put the transaxle bypass levers in the neutral position.

3. Start the engine and slowly move the steering levers in forward and reverse five or six times.

4. Stop the engine and put the transaxle bypass levers in the drive position.

5. Start the engine again and slowly move the steering levers in forward and reverse five or six times.

6. Stop the engine, check the oil level in the expansion tank, and add oil as needed.

7. Repeat steps 2 – 6 until the transaxles operate smoothly in forward and reverse at normal speeds without excessive noise.

Short Term Storage:

• Remove all dirt, grease, leaves, etc. Store in a clean, dry area.

• Inspect the unit for wear or damage and ensure all fasteners are tight.

Long Term Storage:

• Follow all instructions for Short Term Storage.

• Remove and fully charge the battery. Store it in a clean, dry area.

• Refer to the Engine Manual for proper engine storage procedures.

• Touch up all scratched or chipped paint surfaces.

Fuel System for Long Term Storage:

To prevent gum deposits from forming, add a quality fuel stabilizer to the fuel.

1. Turn the fuel valve off while the engine is running and allow it to run until it stops.

2. Add fuel stabilizer according to the manufacturer’s instructions.

3. Turn the fuel valve on.

4. Restart the engine.

5. Run the engine outdoors for 1 minute to ensure treated gasoline has replaced untreated gasoline in the carburetor.

6. Slow the engine to an idle speed.

7. Stop the engine.

If your engine will not crank or start, check the following:

• Safety interlock system: Check that the system is properly engaged (see Safety Interlock System test).

• Fuel tanks: Ensure the fuel tanks are not empty.

• Battery: The battery may be discharged. Charge the battery.

• Battery connections: Check for a poor connection between the battery and battery cables. Tighten and/or clean them.

• Spark plugs: The spark plug wire(s) may be loose or the plug(s) may be faulty. Connect the wires or replace the plugs per the Engine Manual.

• Electrical system/Engine fault: If the above steps do not work, there may be a faulty electrical system or engine. Contact your Gravely Dealer.

If the engine runs rough, try these solutions:

• Choke: The choke may be engaged. Disengage the choke.

• Air filter: The air filter cartridge may be plugged. Clean or replace it per the Engine Manual.

• Engine fault: If the problem persists, there may be an engine fault. Contact your Gravely Dealer.

If the unit does not move with the engine running, check the following:

• Transmission bypass lever: The lever may be engaged. Disengage the transmission bypass lever.

• Hydrostatic belt: The belt may be faulty. It may need to be replaced.

• Transmission: The transmission may be faulty. Contact your Gravely Dealer.

Check these possible causes:

• Operator presence switch: The switch is not depressed. Depress it by sitting on the seat.

• Faulty operator presence switch: The switch itself may be faulty. Contact your Gravely Dealer.

• Electric clutch connector: It may be loose or disconnected. Connect it.

• Faulty PTO belt: The belt may be worn or broken and needs replacement.

• Faulty PTO components: The PTO switch, wires, connectors, or clutch may be faulty. Contact your Gravely Dealer.

If the engine overheats, investigate these causes:

• Engine oil level: The oil level may be low. Add engine oil per the Engine Manual.

• Cooling system: The cooling system may be plugged. Clean it per the Engine Manual.

• Faulty engine: If the issue continues, contact your Gravely Dealer.

If your mower is not traveling straight, check these points:

• Tire pressure: Check for incorrect tire pressure and adjust as needed.

• Steering levers: The levers may need adjustment. See the “Forward and Reverse Speed Adjustment” instructions.

• Transmission/linkage: The hydrostatic transmission and/or linkage may need adjustment. Contact your Gravely Dealer.

For poor cutting quality, consider the following:

• Mower deck level/pitch: The mower deck may not be level or the pitch is incorrect. Level and adjust the pitch of the mower deck.

• Mower blades: The blades may be dull or faulty. Sharpen or replace the mower blades.