GRAVELY 915188 – ZT XL 54 (01) PDF Document

For your GRAVELY 915188 – ZT XL 54, 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.

The use of any gasoline exceeding 10% ethanol (E10) or 10% MTBE will void the product warranty. Do not use E15, E20, or E85 gasoline. Never mix oil and gasoline.

Before attempting to operate your GRAVELY 915188 – ZT XL 54, 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.

Follow these steps for initial setup and pre-operation checks:

1. Place Unit in Operating Position:

• Push steering levers aside and tip the seat up.

• Adjust the seat as needed.

• 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 and tighten the hardware.

• Adjust steering levers if necessary.

2. Place Discharge Chute in Operating Position:

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

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

3. Check Tire Pressure:

• Check the tire pressure and inflate to the recommended pressure. See the Specifications section for correct values.

4. Check Engine Oil Level:

• Refer to the Engine Manual for instructions on checking the oil level.

5. Level Mower Deck:

• Ensure the mower deck is level and the pitch is adjusted correctly.

6. Fill Fuel Tank:

• Fill the fuel tank with the appropriate gasoline. DO NOT OVERFILL.

7. Adjust Seat:

• Adjust the seat to a comfortable operating position.

8. Check Safety Interlock System:

• Perform the safety interlock system test to ensure it is functioning properly before each use.

9. Check Function of All Controls:

• Familiarize yourself with and check the function of all controls as described in the Operation section of the manual.

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. A warning is issued that safety interlock failure and improper operation of the unit can result in death or serious injury. Check the system before each use.

* Test with engine running.

+ Operator lifts off seat.

Ignition Switch: Operates with a removable key and has four positions: Stop (1), Headlight (2), Run (3), Start (4).

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

Throttle Lever: Controls engine speed. Move forward for Fast, backward for Slow.

Choke Control: Used to start a cold engine. Push the lever away from the operator to engage the choke.

Parking Brake: Engages and disengages the parking brake.

Steering Levers: Control the movement of the mower.

• 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 levers to the neutral position.

Mower Lift Pedal: Raises and lowers the mower deck.

Height of Cut Lever: Sets the cutting height of the mower deck.

Hour Meter: Measures and displays engine run time, job time, and service intervals.

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 to start. Do not use the choke if the engine is warm or hot.

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

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

5. When the engine is warm, pull the choke lever toward the operator position. Wait until the engine is running smoothly before operation.

Stopping the Engine:

1. Stop the unit’s movement.

2. Disengage the PTO.

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.

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 their neutral lockout position.

5. Use the steering levers to move the unit.

6. Disengage the PTO to stop the mower blades.

In an emergency, especially on a slope where you may lose steering control:

1. Return steering levers to the neutral position.

2. Immediately set the parking brake.

3. Turn off the PTO and the engine.

To push the unit by hand, you must disengage the transmission bypass levers.

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

2. Pull each bypass lever out and lock it in place (position 2 in the manual diagram).

3. Release the parking brake.

4. You can now push the unit by hand.

To return to normal driving operation, push the bypass levers back in (position 1).

• 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.

For engine maintenance, refer to the separate Engine Manual for detailed instructions and 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 blade from the mower deck.

Install:

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

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

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

1. Adjust Steering Lever Height:

• Remove the 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 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).

The travel of the steering levers may need adjustment if the unit turns to the right or left when both levers are pushed fully forward or pulled fully back. The side the unit turns toward indicates the wheel on that side is turning slower than the other wheel.

1. Determine which way the unit turns.

2. Adjust the speed by loosening the jam nut on the appropriate adjustment bolt located on the lower control arm.

• Turning the adjustment bolt clockwise will decrease steering lever travel (slow down the wheel).

• Turning the adjustment bolt counter-clockwise will increase steering lever travel (speed up the wheel).

The forward travel adjustment bolt adjusts the rear travel of the lever, and the rear travel adjustment bolt adjusts the forward travel of the lever.

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 yet on the left mower deck pulley).

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 the hydraulic fluid and filter after the first 75 hours of operation and then every 400 hours. Use 15W-50 synthetic motor oil (Gravely p/n 00057100) or equivalent.

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 steps 1–7 for the other transaxle.

9. Add hydraulic fluid to the expansion tank until it reaches the cold fill line.

10. Purge the hydraulic system.

This adjustment requires operating the engine. Use extreme care.

1. With the unit facing a wall, jack up the unit so that 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 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 again and slowly move the steering levers 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 for wear or damage and ensure 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.

• Follow the engine storage procedures in the Engine Manual.

• Touch up all scratched or chipped paint surfaces.

• Prepare the fuel system for storage by adding a quality fuel stabilizer. Run the engine for a minute to ensure the treated gasoline has replaced the untreated gasoline in the carburetor, then stop the engine.

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

1. Safety interlock system: Ensure it is properly engaged (parking brake on, PTO off, steering levers in neutral). Check the system for faults.

2. Fuel: Check if the fuel tank is empty. If so, fill it.

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

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

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

6. Electrical System: If the above steps do not work, there may be a fault in the electrical system. Contact your Gravely Dealer.

7. Engine Fault: If the engine is faulty, contact your Gravely Dealer.

If the engine runs rough, check these possible causes:

• Choke engaged: Disengage the choke.

• Air filter plugged: Clean or replace the air filter cartridge.

• Faulty engine: If the problem persists, contact your Gravely Dealer.

If the unit does not move with the engine running when using the steering levers, check the following:

• Transmission bypass lever: Ensure the bypass lever is disengaged (pushed in for driving).

• Hydrostatic belt: The belt may be faulty. Replace it if necessary.

• Faulty transmission: If the belt is fine, there may be an issue with the transmission. Contact your Gravely Dealer.

If the PTO or mower blades do not engage or shut off unexpectedly, check these items:

• Operator presence switch: Ensure you are properly seated to depress the operator presence switch.

• Faulty operator presence switch: If you are seated correctly and the problem persists, the switch may be faulty. Contact your Gravely Dealer.

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

• Faulty PTO belt: The PTO belt may be worn or broken. Replace it.

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

If the engine overheats, take the following actions:

• Check engine oil level: If the oil level is low, add engine oil according to the Engine Manual.

• Check cooling system: The cooling system fins may be plugged with debris. Clean the cooling system.

• Faulty engine: If the oil level is correct and the cooling system is clean, there may be a fault with the engine. Contact your Gravely Dealer.

If the unit does not travel in a straight line, consider these causes:

• Incorrect tire pressure: Check and correct the tire pressure on all tires.

• Steering lever adjustment: The steering levers may need adjustment. Perform the Forward and Reverse Speed Adjustment procedure.

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

Poor cutting quality can be caused by:

• Incorrect mower deck level/pitch: Level and adjust the pitch of the mower deck.

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