GRAVELY 915184 – ZT XL 42 (01) PDF Document

Before you attempt to operate your GRAVELY 915184 – 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 the manual.

4. Review recommended lubrication, maintenance, and adjustments.

5. Review the Limited Warranty Policy.

6. Fill out and return the product registration card.

To assemble your GRAVELY 915184 – ZT XL 42, follow these steps:

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 transmission bypass lever.

Connect Battery: See the “Battery Removal and Installation” section and perform steps 4 and 5 of the installation instructions.

Place Unit in Operating Position:

1. Push the steering levers aside and tip the seat up. The seat is shipped positioned as far back as possible.

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 the steering levers as needed. If no adjustment is desired, tighten the hardware.

Place Discharge Chute in Operating Position:

1. Remove and discard the nuts holding the discharge chute in its 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 of your GRAVELY 915184 – ZT XL 42, perform the following checks:

Check Tire Pressure: Ensure tires are inflated to the recommended pressure as listed in the Specifications section. Do not inflate above the recommended pressure.

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

Level Mower Deck: See “LEVELING AND ADJUSTING PITCH OF MOWER DECK” instructions.

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

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

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

Check Function of All Controls: Ensure all controls are working as described in the Operation section.

Perform the following tests to ensure the safety interlock system is working properly on your GRAVELY 915184 – ZT XL 42. 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), and Start (4).

Throttle Lever: Fast (rabbit icon) increases engine speed. Slow (turtle icon) decreases engine speed.

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

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

Power Take-Off (PTO) Switch: Pull the switch up to engage (2) mower blades. Push the switch down to disengage (1) 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, or a combination of both.

Right Turn: Pull the right lever back or push the left lever forward, or a combination of both.

Stop: Return both steering levers to the neutral position.

Mower Lift Pedal: Raises and lowers the mower deck. Press the pedal to lift the deck and adjust the height of cut lever.

The hour meter on your GRAVELY 915184 – ZT XL 42 has three main functions:

1. Timer (TMR1): Measures the time spent on individual jobs. Press and hold the toggle button to reset the timer to zero.

2. Service Alert: Displays maintenance interval reminders for changing engine oil (CHG OIL), changing hydraulic oil and filter (CHG HYD OIL), and servicing the air filter (SRV AIRFILTER). The alert starts counting down two hours before maintenance is due and flashes NOW when the time is reached. Press and hold the toggle button to reset the clock after service is performed.

3. Service Interval Presets: The hour meter is preset for recommended service intervals. For hydraulic oil and filter, it is the first 75 hours, then every 400 hours thereafter. For engine oil and filter, it is the first 25 hours, then every 100 hours thereafter.

To adjust the seat, lift the adjustment lever located under the front of the seat 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 915184 – ZT XL 42:

• Clean, fresh gasoline.

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

• 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.

IMPORTANT: Excessively oxygenated or reformulated fuels can damage the fuel system. If you experience starting or performance problems, switch to a different fuel provider or brand.

Starting the Engine:

1. Ensure 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 away from the operator position. Do not use the choke if the engine is warm.

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

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

5. When the engine is warm and running smoothly, pull the choke lever back toward the operator position.

Stopping the Engine:

1. Stop the unit’s movement.

2. Disengage the 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. IMPORTANT: 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 their neutral lockout position.

5. Use the steering levers to move the unit.

6. When finished, disengage the PTO to stop the mower blades.

To move the unit without starting the engine, you must disengage the transmission.

1. Locate the bypass levers at the rear of the unit.

2. Pull each bypass lever out and lock it in place.

3. Release the parking brake.

4. You can now push the unit by hand.

5. To drive the unit normally again, push the bypass levers back in.

Refer to your Engine Manual for detailed engine maintenance schedules.

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, hex bolt).

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

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

1. Distance from Mower Blades to Ground:

• In the lowest cutting position, the blade tip should be 1-1/2″ ± 1/4″ from the ground.

• In the highest cutting position, the blade tip should be 4-1/2″ ± 1/4″ from the ground.

2. Forward Pitch of Mower Blades:

• With the blade tips facing forward, the front tip should be 0″ – 1/4″ lower than the rear tip.

3. Side-to-Side Pitch of Mower Blades:

• With the blades perpendicular to the frame of the unit, the measurement from each blade tip to the ground should be within 1/4″ of each other.

Adjustment: To make adjustments, use the trunnions on the deck linkage. Adjust the trunnions first, then re-take all three measurements until they are within the specified tolerances.

Remove:

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.

Install:

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.

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 to 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 bolts. Tighten the upper bolt first.

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.

This adjustment requires operating the engine. Use extreme care.

1. With the unit facing a wall, jack up the rear of the unit so both drive wheels are off the ground and secure it.

2. Disengage the parking brake and put the transaxle bypass levers in the neutral (roll) 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 in the drive 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, 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.

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

• Safety interlock system: Ensure it is properly engaged. Check the system as described in the manual.

• Fuel tanks: Make sure they are not empty.

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

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

• Spark plugs: Check for loose spark plug wire(s) or faulty plug(s). Connect or replace as needed.

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

If your unit does not travel in a straight line, consider these possible causes and corrections:

• Incorrect tire pressure: Check that the tires are inflated to the pressure specified in the manual.

• Steering lever adjustment: The steering levers may need adjustment. Refer to the “Forward and Reverse Speed Adjustment” section.

• Hydrostatic transmission/linkage: The transmission or linkage may need adjustment. Contact your Gravely Dealer.

If you are having issues with the PTO or mower blades, check the following:

• Operator presence switch: Ensure you are properly depressing the switch by sitting on the seat.

• Electric clutch connector: Check if it is loose or disconnected. Reconnect it if necessary.

• PTO belt: The belt may be faulty. Replace it if needed.

• Faulty components: If the issue persists, there may be a faulty operator presence switch, PTO switch, wires, connectors, or clutch. Contact your Gravely Dealer.

If you are experiencing poor cutting quality, try the following:

• Check mower deck level/pitch: Ensure the mower deck is level and the pitch is correct. Adjust as necessary following the instructions in the manual.

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