This document is an Owner/Operator Manual for the Gravely ZT XL series of zero-turn mowers. The models covered are 915110 (2042 ZT XL), 915112 (2548 ZT XL), 915114 (2554 ZT XL), 915118 (1842 ZT XL), and 915120 (2448 ZT XL). The manual provides comprehensive information on the safe and proper operation, maintenance, and storage of these units.
The primary function of the Gravely ZT XL is lawn mowing, utilizing a zero-turn radius for enhanced maneuverability. This allows the operator to turn the unit within its own footprint, making it highly efficient for navigating around obstacles and reducing uncut areas. The unit is designed for both residential and commercial use, depending on the specific model and warranty terms.
Usage Features:
The ZT XL series features a user-friendly control layout. The ignition switch has four positions: Stop, Headlight, Run, and Start, operated with a removable key. A throttle lever allows the operator to control engine speed, with positions for Fast and Slow. For cold starts, a choke control is available (on specific models) to enrich the fuel mixture, which should be pushed in once the engine warms up.
Steering is managed by two independent steering levers. Pushing both levers forward moves the unit forward, while pulling both backward engages reverse. To turn, the operator manipulates the levers differentially: pulling one back while pushing the other forward, or adjusting the forward/backward position of each lever. The steering levers must be in the neutral position to start the engine. The manual emphasizes returning both steering levers to neutral to stop the unit.
A parking brake is included to secure the unit when stationary, engaging and disengaging with a lever. The Power Take-Off (PTO) switch engages and disengages the mower blades. The mower lift pedal is used to raise and lower the mower deck, and an adjustment pin sets the cutting height. The seat is adjustable, allowing the operator to slide it forward or backward for comfort and to increase leverage when lifting the mower deck.
The unit is equipped with a safety interlock system, which is crucial for preventing accidents. This system ensures that the engine only starts when the PTO is disengaged, the parking brake is engaged, and the steering levers are in neutral. It also shuts off the engine if the operator lifts off the seat while the PTO is engaged or if the steering levers are out of neutral with the PTO engaged. Regular checks of this system are mandatory before each use.
Fueling the unit involves cleaning the fuel caps and surrounding area, removing the caps, and filling the tanks to 2-1/2 inches (6.35 cm) below the bottom of the filler neck. The manual stresses using the correct type and grade of fuel as specified in the Engine Manual and replacing fuel caps securely.
In an emergency, the operator should bring the steering levers back to neutral, set the parking brake, and turn off the engine. For manual movement of the unit, transmission bypass levers can be disengaged to allow pushing.
Maintenance Features:
The manual outlines a detailed maintenance schedule to prolong the unit's life and ensure safe operation.
Each Use:
- Safety Interlock System: Must be checked before each operation to ensure it functions correctly.
- Parking Brake: Checked by engaging it and the transmission bypass lever, then attempting to push the unit. If it rolls, service is required.
- Clean Unit: The engine, battery, seat, and mower deck should be cleaned of dirt and debris. Solvents, hard cleaners, or abrasives should not be used.
- Tires: Tire pressure should be checked according to specifications. The manual provides warnings about explosive separation of tire and rim parts if serviced incorrectly, advising against mounting tires without proper equipment, over-inflating, welding/heating wheel assemblies, or standing in front of the tire during inflation.
- Mower Blades: Checked for wear or damage.
- Engine Maintenance: Scheduled maintenance as per the Engine Manual, including oil draining using the supplied petcock.
Hours or Every Season:
- Battery: Keep terminals clean.
- Lubricate Unit: Apply grease to the zerk on each front wheel.
Hours or Every Season:
- Fasteners: Check all mower blade mounting hardware and other fasteners, replacing missing or damaged ones and tightening to correct torque values.
Hours or Every Season:
- Belts: Replace worn or deteriorated belts. This includes checking and replacing the hydrostatic belt and PTO belt, with detailed instructions provided for removal and installation.
Additional Maintenance Procedures:
- Tipping Seat Forward: The seat can be tipped forward for full access to the engine.
- Opening and Closing Hood: The hood can be opened by pulling up on the back until it hits the stop, and closed by pushing down.
- Opening Deck Access Plate: This involves installing the adjustment pin, setting the parking brake, and raising the plate.
- Replacing Mower Blade: Detailed instructions are provided for removing and installing mower blades, emphasizing caution due to sharp edges and specifying torque values for the hex bolt.
- Levelling and Adjusting Pitch of Mower Deck: This critical adjustment ensures an even cut. It involves measuring the distance from the blades to the ground, the forward pitch, and the side-to-side pitch, then adjusting trunnions as needed.
- Servicing Battery: Includes cleaning battery and battery cables, removing and installing the battery, and charging instructions. Warnings are given regarding frozen batteries and proper jump-starting procedures (though jump-starting is not recommended by Gravely).
- Adjusting Steering Levers: Instructions for adjusting steering lever height and forward/reverse speed to ensure the unit tracks straight.
- Replacing PTO Belt: Step-by-step guide for removing and installing the PTO belt, with a caution about releasing idler spring tension.
- Replacing Hydrostatic Belt: Step-by-step guide for removing and installing the hydrostatic belt, also with a caution about releasing idler spring tension.
Storage:
- Short Term Storage: Involves cleaning the unit, removing dirt, grease, and leaves, and storing it in a clean, dry area. Inspection for wear or damage and ensuring fasteners are tightened are also recommended. High-pressure water should not be used for cleaning, and the unit should not be stored outdoors.
- Long Term Storage: Includes all short-term storage steps, plus removing and fully charging the battery, draining fuel from the fuel tank, referring to the Engine Manual for specific engine storage procedures, and touching up scratched or chipped paint surfaces.
The manual also includes a troubleshooting section to help operators diagnose and resolve common issues such as the engine not cranking/starting, running rough, the unit not moving, PTO/mower blades not engaging, engine overheating, hour meter continuing to run, unit not traveling straight, and unit creeping.
Overall, the manual emphasizes safety through numerous warnings and cautions, providing operators with the necessary knowledge to safely and effectively use and maintain their Gravely ZT XL zero-turn mower.
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