GRAVELY 915162 – ZT XL 48 (01) PDF Document

Before attempting to operate your GRAVELY 915162 – ZT XL 48, you should:

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 the manual.

4. Review recommended lubrication, maintenance, and adjustments.

5. Review the Limited Warranty Policy.

6. Fill out a product registration card and return it, or register online.

When operating your GRAVELY 915162 – ZT XL 48, always follow these safety rules:

General Operation:

• Only trained adults may operate the unit.

• Read, understand, and follow all safety practices in the Owner/Operator Manual.

• Inspect the unit before each use for damaged parts, correctly operating safety interlocks, and deterioration of grass catchers.

• Keep the area of operation clear of all toys, debris, children, people, and pets.

• Operate only in good visibility and light.

• Wear adequate safety gear, sturdy shoes, safety glasses with side shields, and hearing protection.

• Avoid loose clothing or jewelry.

• Start and operate the unit only when seated in the operator’s position.

• Keep hands and feet away from all rotating parts and pinch points.

• NEVER direct discharge towards persons or property.

• ALWAYS disengage the attachment, stop the engine, remove the key, and engage the parking brake before leaving the operator’s position.

• Do not operate if the safety interlock system is damaged or disabled.

• Slow down before turning.

Slope Operation:

• Mow up and down slopes, not across them.

• Use slow speed on any slope. Keep all movements slow and gradual.

• Avoid starting, stopping, or turning on a slope.

• Do not operate on slopes over 15°.

• If you cannot back up a slope or feel uneasy on it, do not mow it.

• Do not park on slopes unless necessary, and if so, always chock the wheels and set the parking brake.

Fuel Safety:

• Handle fuel with care; it is highly flammable.

• Use an approved gasoline container.

• NO smoking, NO sparks, NO flames near the fuel.

• NEVER fill the fuel tank when the engine is running or hot.

• NEVER fill or drain the fuel tank indoors.

• Replace the fuel cap securely and clean up spilled fuel.

Maintenance Safety:

• Fumes from engine exhaust can cause injury or death. Do not run the engine in an enclosed area.

• Stop and inspect equipment if you strike an object.

• Mower blades are sharp. Wrap the blade(s) or wear gloves when servicing them.

• Keep all hardware properly tightened.

• NEVER store the machine with fuel in the tank inside a building where there is an open flame.

• Clean grass and debris from the unit to help prevent fires.

WARNING: Safety interlock failure and improper operation of the unit can result in death or serious injury. Check the system before each use to make sure it is functioning properly. If the GRAVELY 915162 – ZT XL 48 does not perform as stated in the tests below, contact your dealer for repairs.

* Test with engine running.

+ Operator lifts off seat.

Starting the Engine:

NOTICE: Disengage the PTO, engage the parking brake, and place the steering levers in neutral prior to starting the engine.

1. If the engine is cold, push the choke control away from the operator position to start. If the engine is warm or hot, do not use the choke.

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

IMPORTANT: DO NOT operate the starter for more than 15 seconds per minute as damage can occur.

3. Turn the ignition key to the start position and release once the engine has started.

4. Pull the choke lever toward the operator position when the engine is warm. Wait until the engine is running smoothly before operation.

IMPORTANT: Let the engine warm up for several seconds to several minutes depending on the outside temperature.

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.

IMPORTANT: Never engage the PTO if the mower is plugged with grass or other material.

3. Engage the PTO to start mower blades.

NOTICE: The parking brake must be disengaged prior to moving the steering levers from the neutral lockout position.

4. Release the parking brake.

5. Use the steering levers to move the unit.

6. Disengage the PTO to stop the mower blades.

• 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 grass length per cutting.

• Discharge clippings into areas already cut.

Ignition Switch: Has four positions: Stop (1), Headlight (2), Run (3), Start (4).

Throttle Lever: Fast (1) increases engine speed. Slow (2) decreases engine speed.

Choke Control: Used to start a cold engine. Push the lever away from the operator to start a cold engine, and pull it toward the operator once the engine runs smoothly.

Parking Brake: Engages and disengages the parking brake.

Power Take-Off (PTO) Switch: Engages and disengages the mower blades.

Steering Levers:

• Reverse: Pull both levers backward.

• Forward: Push both levers forward.

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

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

• Stop: Return both levers to neutral.

Mower Lift Pedal: Raises and lowers the mower deck. The Height of Cut Lever sets the cutting height.

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

1. To push the unit by hand, pull the bypass lever out and lock it in place, and then release the parking brake. The unit can now be pushed.

2. To drive the unit normally, push the bypass lever in.

WARNING: Operating the unit on slopes may lead to loss of steering control. When operating on slopes, be prepared to react to an emergency situation.

1. Return steering levers to the neutral position.

2. Immediately set the parking brake.

3. Turn off the PTO and engine.

To adjust the seat, lift the adjustment lever and slide the seat forward or backward to the desired position. Release the lever to lock the seat in place.

Always use gasoline that meets the following guidelines for your GRAVELY 915162 – ZT XL 48:

• Clean, fresh gasoline.

• A minimum of 87 octane/87 AKI (91 RON). High altitude use may require a different octane. Consult your engine manual.

• Gasoline with up to 10% ethanol (gasohol) or up to 10% MTBE (methyl tertiary butyl ether) is acceptable.

• The use of any gasoline exceeding 10% ethanol (E10) or 10% MTBE will void the product warranty.

• Never mix oil and gasoline.

IMPORTANT: Excessively oxygenated or reformulated fuels can damage the fuel system. If operating problems occur, use gasoline with a lower percentage of alcohol or ether.

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. See Specifications for fuel tank capacity.

IMPORTANT: DO NOT OVERFILL! Overfilling may cause permanent damage to evaporative emissions control system components. Filling to the recommended level ensures a vapor gap is required for fuel expansion.

6. Replace the fuel cap and tighten.

7. ALWAYS clean up spilled fuel.

CAUTION: Mower blades are sharp and can cut you. Wrap the blades or wear gloves, and use extra caution when servicing them.

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 mower blades on the mower deck with the mounting hardware in the correct order (Blade, Flat Washer, Bevel Washer, Bolt).

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

NOTICE: Adjust on a level surface, with the tires inflated to the correct air pressure.

Three measurements are required to level and adjust the deck pitch:

1. The distance from the mower blades to the ground:

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

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

2. The forward pitch of the mower blades:

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

3. The pitch of the mower blades from side-to-side:

• It should be within 1/4″ (6.35 mm) as measured on each side of the mower deck. This measurement must be taken when the mower blade ends are perpendicular to the frame of the unit.

To adjust, use the trunnions on the mower deck linkage. Adjust the trunnions first and then re-take all 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.

Cleaning Battery and Battery Cables:

1. Tip the seat forward.

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

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

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

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

6. Tip the seat back.

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

1. Adjust Steering Lever Height:

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

• Move the handlebar up or down until the mounting holes align with the preferred adjustment holes.

• Install mounting hardware and tighten.

2. Adjust Steering Lever Width:

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

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

3. Adjust Steering Lever Forward or Backward:

• Loosen, do not remove, the bolts securing the handlebar to the upper control arm.

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

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 the engine.

1. With the unit up to and 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 and slowly move the steering levers in forward and reverse five or six times.

6. Stop the engine, check the oil level, 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:

• IMPORTANT: NEVER clean the unit with high-pressure water or store it outdoors.

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

• Inspect the unit for signs of wear or damage. Ensure all fasteners are properly tightened.

Long Term Storage:

• Follow all instructions under 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.

• Add a quality fuel stabilizer to the fuel. Follow the recommended mix ratio on the stabilizer container.

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

• Safety interlock system is not engaged or is faulty: Check the safety interlock system.

• Fuel tanks empty: Fill the fuel tanks.

• Discharged battery: Charge the battery.

• Poor connection between battery and battery cables: Tighten and/or clean the battery and battery cables.

• Spark plug wire(s) loose or spark plug(s) faulty: Connect spark plug wire(s) or replace spark plug(s). Refer to the Engine Manual for instructions.

• Faulty electrical system or faulty engine: Contact your Gravely Dealer.

If the unit does not move, check these possible causes:

• The transmission bypass lever is engaged: Disengage the transmission bypass lever.

• Faulty hydrostatic belt: Replace the hydrostatic belt.

• Faulty transmission: Contact your Gravely Dealer.

Check the following potential issues:

• Operator presence switch not depressed: Depress the operator presence switch by sitting on the seat.

• Faulty operator presence switch: Contact your Gravely Dealer.

• Electric clutch connector is loose or disconnected: Connect the electric clutch connector.

• Faulty PTO belt: Replace the PTO belt.

• Faulty PTO switch, wires, connectors, or clutch: Contact your Gravely Dealer.

If your mower is not tracking straight, consider these solutions:

• Incorrect tire pressure: Check the tire pressure and adjust as needed.

• Steering levers need adjustment: Adjust the steering levers for forward and reverse speed.

• Hydrostatic transmission and/or linkage needs adjustment: Contact your Gravely Dealer.

Poor cutting quality can be caused by:

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

• Dull or faulty mower blades: Sharpen or replace the mower blades.