GRAVELY 915186 – ZT XL 48 (01) PDF Document

For your GRAVELY 915186 – ZT XL 48, the use of any gasoline exceeding 10% ethanol (E10) or 10% MTBE will void the product warranty.

Always use gasoline that meets the following guidelines:

• 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.

• Use of any gasoline other than those approved above will void the engine warranty. If the pumps are not marked for the content of alcohol or ethers, check ethanol and MTBE levels with the fuel supplier.

• Do not modify the fuel system to use different fuels.

• Never mix oil and gasoline.

NOTICE: Excessively oxygenated or reformulated fuels (fuels blended with alcohols or ethers) can damage the fuel system or cause performance problems. If any undesirable operating problems occur, use a gasoline with a lower percentage of alcohol or ether.

Before attempting to operate your GRAVELY 915186 – 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 this manual.

4. Review recommended lubrication, maintenance and adjustments.

5. Review Limited Warranty Policy.

6. Fill out a product registration card and return the card to the Gravely Company.

To assemble your GRAVELY 915186 – ZT XL 48, 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 in the installation instructions.

Place Unit in Operating Position:

1. Push steering levers aside and tip the seat up. (Note: The seat is shipped 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 steering levers as needed. If no adjustment is desired, tighten the hardware.

Place Discharge Chute in Operating Position:

WARNING: Do not operate the mower unless the discharge chute is in the 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 915186 – ZT XL 48, perform the following checks:

Check Tire Pressure: Ensure tires are inflated to the recommended pressure found in the Specifications section. CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when serviced incorrectly. Do not attempt to mount a tire without proper equipment, do not inflate above recommended pressure, do not weld or heat the wheel assembly, and stand to the side when inflating.

Check Engine Oil Level: Refer to the Engine Manual.

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 for comfortable operation.

Check Safety Interlock System: WARNING: Safety interlock failure can result in death or serious injury. Check the system before each use to ensure it is functioning properly.

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

To ensure the safety interlock system on your GRAVELY 915186 – ZT XL 48 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.

Here is how to operate the main controls on your GRAVELY 915186 – ZT XL 48:

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

Throttle Lever: Push forward for Fast (increases engine speed). Pull back for Slow (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: Push the lever down to engage. Lift the lever up to disengage.

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

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

• Stop: Return both steering levers to the neutral position.

Mower Lift Pedal: Press the foot pedal to raise the deck. Use the Height of Cut Lever to set the desired cutting height while the deck is raised.

The hour meter on your GRAVELY 915186 – ZT XL 48 measures and displays engine run time, time spent on jobs, and service intervals. Press and release the toggle button to shift between functions. The total engine run time cannot be cleared.

The hour meter has three functions:

1. Timer (TMR1): Measures 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 it’s time. Press and hold the toggle button to reset the clock after service is complete.

3. Service Interval Presets: The hour meter is preset for recommended service intervals:

• Hydraulic oil and filter: First 75 hours, then every 400 hours thereafter.

• Engine oil and filter: First 25 hours, then every 100 hours thereafter.

To add fuel to your GRAVELY 915186 – ZT XL 48:

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. Overfilling may cause damage to emissions control components. Filling to the recommended level ensures a vapor gap for fuel expansion.

6. Replace the fuel cap and tighten.

7. ALWAYS clean up spilled fuel.

Starting the Engine:

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

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

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

3. 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.

4. If the choke was used, pull the choke lever toward you when the engine is warm and running smoothly.

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.

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

To move your GRAVELY 915186 – ZT XL 48 by hand:

1. Pull the bypass lever out and lock it in place. This disengages the transmission.

2. Release the parking brake.

3. Push the unit by hand.

To return to normal operation, push the bypass lever in to drive the unit normally.

WARNING: Operating on slopes may lead to loss of steering control. Be prepared to react to an emergency situation.

In an emergency:

1. Return steering levers to the neutral position.

2. Immediately set the parking brake.

3. Turn off the PTO and engine.

To get the best performance from your GRAVELY 915186 – ZT XL 48 mower:

• 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.

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 and mower blades from the mower deck.

Install:

1. Install the mower blades on the mower deck with mounting hardware (Flat Washer, Bevel Washer, 5/8″ Hex Bolt).

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

To level and adjust the deck on your GRAVELY 915186 – ZT XL 48, perform the adjustments on a level surface with tires inflated to the correct pressure. There are three required measurements:

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 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:

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

Adjusting The Mower Deck:

Adjusting the trunnions will adjust the height and pitch of the mower blades. Adjust the trunnions first, then re-take all three measurements and repeat as needed until all 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.

Charging the Battery:

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 to the negative (-) terminal.

4. Charge the battery according to the battery and charger manufacturers’ instructions. DO NOT fast charge.

5. Install the battery back on the unit.

To adjust the steering levers on your GRAVELY 915186 – ZT XL 48, make adjustments to each lever equally in the following order:

1. Adjust Steering Lever Height:

• Remove mounting hardware attaching the handlebars to the upper control arm.

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

• Install and tighten the mounting hardware.

2. Adjust Steering Lever Width:

• Loosen the 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).

If your GRAVELY 915186 – ZT XL 48 turns when both levers are pushed fully forward or pulled fully back, the speed may need adjustment. The side the unit turns toward indicates the wheel on that side is turning slower.

1. Determine which way the unit turns.

2. Adjust speed by loosening the jam nut on the appropriate adjustment bolt (located at the base of the lower control arm) and:

• Turn the adjustment bolt clockwise to decrease steering lever travel (slow down that wheel).

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

Note: The forward travel adjustment bolt adjusts the rear travel of the steering lever. The rear travel adjustment bolt adjusts the forward travel of the steering lever.

Remove:

1. Lower the mower deck to the ground.

2. Remove the belt covers from the mower deck.

3. CAUTION: Use care when releasing idler spring tension. Hook a puller into the idler hole and pull the idler arm towards the outside of the unit until tension is removed from the PTO belt.

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

5. Slowly release the idler arm until tension is removed from the idler spring.

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 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.

Remove:

1. Remove the PTO belt.

2. Disconnect the electric clutch connector.

3. Remove the clutch stop.

4. Disconnect the idler spring. CAUTION: Use care when releasing idler spring tension.

5. Remove the old hydrostatic belt from the hydrostatic transmission pulleys, pulley, electric clutch, and idler.

Install:

1. Install the new hydrostatic belt on the idler, electric clutch, pulley, and hydrostatic transmission pulleys.

2. Connect the idler spring.

3. Install the clutch stop.

4. Connect the electric clutch connector.

5. Install the PTO belt.

Check Hydraulic Fluid Level:

Check the system with the unit cold and parked on a flat, level surface. The hydraulic fluid should be at the cold fill line of the expansion tank. Run the unit for about one minute and recheck the level.

Change Hydraulic Fluid and Filter:

NOTICE: 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.

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

3. Remove the oil drain plug 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 another 3/4 turn.

6. Install the filter guards. Tighten 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 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 the engine.

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 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 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:

Remove all dirt, grease, leaves, etc. Store in a clean, dry area. Inspect for wear or damage and ensure fasteners are tight. Do not clean with high-pressure water or store outdoors.

Long Term Storage:

Follow all instructions for Short Term Storage. Remove and fully charge the battery, storing it in a clean, dry area. Refer to the Engine Manual for proper engine storage procedures. Touch up any scratched or chipped paint surfaces.

Fuel System for Storage:

To prevent gum deposits from forming, add a quality fuel stabilizer to the fuel. Follow the mix ratio on the stabilizer container.

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

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

3. Turn the fuel valve on.

4. Re-start 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.