GRAVELY 915164 – ZT XL 54 (01) PDF Document

Before you operate your GRAVELY 915164 – ZT XL 54, it is your responsibility to perform the following checks to ensure safety and proper function:

1. Make sure all assembly has been properly completed.

2. Understand all Safety Precautions provided in the manuals.

3. Review the 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. Fill out the product registration card.

After unboxing your GRAVELY 915164 – ZT XL 54, follow these steps to prepare it for operation. You will need an adjustable wrench, a 9/16″ wrench, and petroleum jelly or dielectric grease.

Unpack Unit

1. Remove the unit and all other components from the shipping container.

2. Engage the transmission bypass levers (see “Moving Unit Manually” instructions).

3. Push the unit from the container onto a level surface.

4. Disengage the transmission bypass levers.

Connect Battery

Follow the instructions for battery installation, which involves connecting the negative (-) cable first, then the positive (+) cable.

Place Steering Levers in Operating Position

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

2. Adjust the seat as needed.

3. Remove the 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 the steering levers for height, width, and forward/backward position if necessary, then tighten the hardware.

Place Discharge Chute in Operating Position

1. The discharge chute is shipped in a transport position. Remove and discard the nuts holding it in this 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 of your GRAVELY 915164 – ZT XL 54, perform the following checks:

Check Tire Pressure: Ensure tires are inflated to the correct pressure as listed in the specifications. Do not overinflate. The front tire pressure should be 46 psi (317 kPa) and the rear tire pressure should be 10 psi (69 kPa).

Check Engine Oil Level: Refer to the separate Engine Manual for instructions.

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

Fill Fuel Tank: Fill the fuel tank with the correct type of gasoline. DO NOT OVERFILL.

Adjust Seat: Ensure the seat is adjusted to a comfortable operating position.

Check Safety Interlock System: Test the safety interlock system to ensure it is functioning properly.

Check Function of All Controls: Verify that all controls operate correctly before you begin mowing.

Perform the following tests to ensure the safety interlock system is working properly. If the unit does not perform as stated, contact your dealer for repairs. An operator must be in the seat for tests marked with a ‘+’.

*Test with engine running.

+Test requires operator to lift off the seat.

Understanding the controls is key to operating your GRAVELY 915164 – ZT XL 54 safely and effectively.

Ignition Switch: A key-operated switch with four positions: Stop, Headlight (if equipped), Run, and Start.

PTO (Power Take-Off) Switch: A push/pull switch that engages and disengages the mower blades.

Throttle Lever: Controls engine speed. Move it forward toward the rabbit icon for fast speed and backward toward the turtle icon for slow speed.

Choke Control: Used to start a cold engine. Push the lever away from you to engage the choke; pull it back toward you to disengage once the engine is running smoothly.

Parking Brake: Engages and disengages the parking brake. It must be engaged to start the engine and disengaged to drive the unit.

Steering Levers: Control the direction and speed of the mower. Push both forward to move forward, pull both back to reverse. To turn left, push the right lever forward more than the left, or pull the left lever back. Reverse this for a right turn. Returning both levers to the neutral position stops the mower.

Mower Lift Pedal: A foot-operated pedal that raises and lowers the mower deck. Use the Height of Cut Lever to set the desired cutting height.

Hour Meter: Displays total engine run time, job time (timer), and service interval reminders for engine oil, hydraulic oil, and air filter.

Starting the Engine

1. Ensure you are seated, the PTO is disengaged, the parking brake is engaged, and the steering levers are in the neutral position.

2. If the engine is cold, push the choke control fully forward (away from you).

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

4. Turn the ignition key to the START position. Release the key as soon as the engine starts. Do not operate the starter for more than 15 seconds per minute.

5. Once the engine starts and warms up, slowly pull the choke lever back toward you.

Stopping the Engine

1. Bring the unit to a complete stop by returning the steering levers to neutral.

2. Disengage the PTO to stop the mower blades.

3. Set the throttle lever to the slow position.

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

5. Set the parking brake.

Follow these tips for the best performance from your GRAVELY 915164 – ZT XL 54:

Mowing Operation Steps:

1. Start the engine and set the throttle lever to fast.

2. Engage the PTO to start the mower blades. Never engage the PTO if the mower deck is plugged with grass.

3. Release the parking brake.

4. Use the steering levers to move and steer the unit.

5. Disengage the PTO to stop the mower blades when finished.

Performance Tips:

• 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 you have already cut.

Note: Also follow the scheduled engine maintenance as detailed in the separate Engine Manual.

Always wear gloves and use extra caution as mower blades are sharp.

Remove

1. Lower the deck to its lowest position. For easier access, you can raise the deck access plate.

2. Block the mower blades with a piece of wood to prevent rotation.

3. Remove the mounting hardware (5/8″ hex bolt, bevel washer, flat washer) and the mower blade from the spindle.

Install

1. Install the new mower blade, flat washer, bevel washer, and 5/8″ hex bolt onto the mower deck spindle.

2. Block the blade to prevent rotation and torque the 5/8″ hex bolt to 80 – 120 lbf-ft (108 – 163 N·m).

Perform adjustments on a level surface with the tires inflated to the correct pressure. You will need to check three measurements:

1. Side-to-Side Pitch:

• Position the mower blades so they are perpendicular (at a right angle) to the frame of the unit.

• Measure the distance from the outside tip of each blade to the ground.

• The measurement should be within 1/4″ (6.35 mm) on each side.

2. Blade Height from Ground:

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

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

3. Forward Pitch:

• Position the blades so the ends are facing forward and backward.

• Measure the distance from the front tip and rear tip of the blade to the ground.

• The front of the deck should be 0″ – 1/4″ (0 – 6.35 mm) lower than the rear.

To make adjustments, you will need to adjust the deck link trunnions. Adjust the trunnions first, then re-take all three measurements until they are within the specified tolerances.

Battery Removal

1. Tip the seat forward for access.

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

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

4. Remove the battery bracket.

5. Remove the old battery.

Battery Installation

1. Install the replacement battery into the battery channel.

2. Rotate and align the battery bracket lengthwise to the battery and reinstall it with the taptite fastener.

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

4. Connect the positive (+) cable FIRST, then connect the negative (-) cable.

5. Tip the seat back into position.

Cleaning Battery and Cables

1. Disconnect the cables (negative first).

2. Clean the cable ends and battery terminals with a wire brush.

3. Rinse with a weak baking soda solution.

4. Apply petroleum jelly or dielectric grease and reconnect cables (positive first).

This procedure is necessary after changing the hydraulic fluid or if the system has air in it, which can cause erratic operation. This adjustment requires operating the engine, so use extreme care.

1. With the unit facing a wall for safety, jack up the rear of the unit so both drive wheels are off the ground and well supported.

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

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

4. Stop the engine. Put the transaxle bypass levers back in the drive (pull) position.

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

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

7. Repeat steps 2 through 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.

• Do not clean the unit with high-pressure water.

• Inspect 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.

• Touch up any scratched or chipped paint surfaces.

• Prepare the fuel system for storage: Gasoline left in the system will deteriorate. Add a quality fuel stabilizer to the fuel tank according to the manufacturer’s instructions. Run the engine for a minute to ensure the treated fuel circulates through the carburetor.

If your engine will not crank or start, check the following probable causes and corrections:

If your unit does not travel in a straight line, check the following:

1. Incorrect tire pressure: Check and adjust the tire pressure to the recommended specifications.

2. Steering levers need adjustment: The side the unit turns toward indicates that the wheel on that side is turning slower. You will need to perform a forward and reverse speed adjustment on the steering lever linkage. This involves adjusting the travel adjustment bolts on the lower control arm to either increase or decrease steering lever travel until the unit tracks straight.

3. Hydrostatic transmission and/or linkage needs adjustment: If the above steps do not resolve the issue, contact your Gravely Dealer.

If you are experiencing poor cutting quality, check these two common causes:

1. Mower deck not level or mower pitch is incorrect: The mower deck must be properly leveled from side-to-side and have the correct front-to-back pitch. Refer to the instructions for leveling and adjusting the pitch of the mower deck.

2. Dull or faulty mower blades: Sharp blades are essential for a clean cut. Sharpen the mower blades or replace them if they are worn or damaged.

Always use genuine Gravely parts to keep your unit running like new. Here is a list of common service parts for the model 915164:

You can add these optional accessories to your GRAVELY 915164 – ZT XL 54. See your authorized dealer for more information.