Gravely ZT HD 48, ZT HD 52, ZT HD 60, ZT HD 44 Manual

WELCOME

Every machine in the Gravely lineup is designed for long-lasting and unsurpassed performance. We are confident your machine will be part of your family for many years to come.

Have Questions or Need Assistance?
www.gravely.com
A parts manual for your unit is available for free download or purchase at www.gravely.com.

REGISTER YOUR PRODUCT!
It is extremely important to register your product at time of purchase. Product registration activates the warranty and establishes a communication link from the Ariens Company.
Locate the model and serial number decal on your unit and register those numbers online at www.gravely.com. See Figure 1 for decal location. Be aware that the original selling dealer may have already completed product registration on behalf of the original purchaser.

Record model number here.

MANUALS
Before operating or servicing the unit, carefully and completely read the manuals provided with the unit. They contain safety instructions and important information about unit controls. The engine on this unit is covered by a separate manual. Refer to the engine manual for engine service recommendations. Contact the engine manufacturer for a replacement manual if necessary.
Your dealer must review important information in this manual with you before or upon delivery of the unit. It is your responsibility to read and understand all safety precautions and instructions in the manuals. If you do not understand or have difficulty following the instructions, contact your Gravely dealer for assistance. To locate your nearest Gravely dealer, go to www.gravely.com.

Read these safety rules and follow them closely. Failure to follow these rules could lead to loss of control of unit, severe personal injury or death to you or bystanders, or result in damage to property or the machine.

PRACTICES & LAWS
Practice usual and customary safe working precautions. Learn applicable rules and laws in your area. Always follow the practices set forth in this manual.

EMISSION CONTROL SYSTEM
This equipment and/or its engine may include exhaust and evaporative emissions control system components required to meet U.S. Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB) regulations. Tampering with emission controls and components by unauthorized personnel may result in severe fines or penalties. Emission controls and components can only be adjusted by an Ariens Company dealer or an authorized engine manufacturer's service center. Contact your Ariens Company Equipment Retailer concerning emission controls and component questions.

REQUIRED OPERATOR TRAINING

Read and understand the Operator's Manual and decals on the unit. This information is for your safety and the proper use of your equipment.
Failure to follow these instructions and warnings may cause death or serious injury. If you have purchased this product from an Gravely dealer, the dealer can provide you with training. Familiarize yourself and any other operators with all controls and the safe use of the features of this unit. If you loan, rent or sell this product to others, provide them with all manuals.
If you have any questions, please call our customer support line at 920-756-4688 or contact us at www.gravely.com. Do not use this equipment if, after reading the Operator's Manual and the on-board decals, you have any questions about the safe use of this product.

AVOID INJURY.
This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the safety instructions in the manuals and on decals could result in serious injury or death.

SAFETY ALERT SYMBOL
This is the safety alert symbol. It means:

• ATTENTION!
• YOUR SAFETY IS INVOLVED!

When you see this symbol:

• BECOME ALERT!
• OBEY THE MESSAGE!

SIGNAL WORDS
The safety alert symbol above and signal words below are used on decals and in this manual. Read and understand all safety messages.

1. 
   Indicates an IMMINENTLY HAZARDOUS SITUATION! If not avoided, WILL RESULT in death or serious injury.
2. 
   Indicates a POTENTIALLY HAZARDOUS SITUATION! If not avoided, COULD RESULT in death or serious injury.
3. 
   Indicates a POTENTIALLY HAZARDOUS SITUATION! If not avoided, MAY RESULT in minor or moderate injury. It may also be used to alert against unsafe practices.
4. NOTICE: Indicates information or procedures that are considered important but not hazard related. If not avoided property damage could result.

SAFETY DECALS
The safety decals on your machine are visual reminders of the important safety information in this manual. All messages on your unit must be fully understood and carefully followed. Safety decals on the machine are explained below.

Safety Decal Locations
ALWAYS replace missing or damaged safety decals. Replacement decal part numbers are found in the parts manual for your machine and may be ordered from your dealer.
See Figure 2 for safety decal locations.

Safety Decal Descriptions

1. 
   Discharge Hazard - NEVER operate unit without discharge chute in operating position. Thrown objects can cause injury or damage.
   
   DO NOT operate mower unless all guards are in operating position or bagger is attached.
   

2. 
   Discharge Hazard - NEVER direct discharge toward people, pets or property. Thrown objects can cause injury or damage.
   
   Amputation Hazard - NEVER stick hands or feet under deck or shielded areas.
   
   Shut off engine, remove key, and read manual before servicing or making adjustments to unit.
   
   Keep children and others away from unit while unit is in operation.
   
   Keep feet and hands away from all rotating or moving parts.
   
   DO NOT step or stand in this area.
   

3. 
   Read and understand the operator's manual before operating unit.
   
   1. Amputation Hazard
      To avoid amputation hazard DO NOT put hands near rotating blades.
      
      To avoid amputation hazard DO NOT put hands near moving belts.
      
      Keep hands away from all rotating or moving parts.
      
      Keep all guards and shields in place.
      
   2. Discharge Hazard
      Discharge Hazard - NEVER direct discharge toward people, pets or property. Thrown objects can cause injury or damage.
      
      DO NOT operate mower unless all guards are in operating position or bagger is attached.
      
      Keep children and people away from unit during operation.
      
   3. Tipping Hazard
      Avoid tipping hazard.
      
      DO NOT operate on slopes over 15°.
      
      DO NOT operate on slopes over 15°.
      
   4. Service Hazard
      Before servicing unit do the following:
      Read owners manual before servicing or making adjustments to unit.
      
      Set parking brake.
      
      Remove key and disconnect spark plug before servicing or making adjustments to unit.
      
   5. Bystander Hazard
      DO NOT operate the unit in the presence of bystanders.
      
      DO NOT carry passengers.
      
      Look behind when operating the unit in reverse.
      
   6. Loss of Traction Hazard
      If loss of traction is experienced do the following:
      
      Disengage PTO.
      
      Proceed off slope slowly.
      
      DO NOT try to turn or speed up.
      

4. 
   ALWAYS keep hands and feet away from discharge chute.
   

5. HOT PARTS!
   DO NOT touch parts which are hot from operation. ALWAYS allow parts to cool.
   

6. ROTATING PARTS!
   AVOID INJURY. Stay clear of rotating parts.
   

SAFETY RULES
The following safety instructions are based on the B71.1 specifications of the American National Standards Institute and ISO 5395 in effect at the time of production.

Training
Read, understand, and follow all instructions on the machine and in the manual(s) before starting. Be sure the area is clear of bystanders and pets before operating. Stop machine if anyone enters the area. Improper use of power equipment can cause serious permanent injury or death to the operator or a bystander.
Understand:

• How to operate all controls
• The functions of all controls
• How to STOP in an emergency
• Braking and steering characteristics
• Turning radius and clearances If the operator or the mechanic cannot read the manual, it is the owner's responsibility to explain it to them. ALWAYS train any inexperienced operators and require them to read and understand all manuals and decals. Only allow responsible adults, who are familiar with the instructions, to operate this machine. Only the operator can prevent and is responsible for accidents or injuries occurring to themselves, other people or property.

Operator Age
DO NOT allow children under the age of 18 to operate any outdoor power equipment. Local regulations may restrict the age of the operator. Data indicates operators age 60 years and above are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

Operation
Be sure the area is clear of bystanders before operating. Stop machine if anyone enters the area.
NEVER operate machine in a closed or poorly-ventilated area.
ALWAYS maintain unit in safe operating condition. Damaged or worn out muffler can cause fire or explosion.
This product is equipped with an internal combustion type engine. DO NOT use unit on or near any unimproved, forest-covered or brush-covered land unlessexhaust system is equipped with a spark arrester meeting applicable local, state or federal laws. A spark arrester, if it is used, must be maintained in effective working order byoperator.
DO NOT operate machine while feeling tired, ill or under the influence of alcohol or other drugs.
DO NOT put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.
DO NOT touch parts which are hot. Allow parts to cool.
DO NOT operate machine without the entire grass catcher, discharge guard or other safety devices in place and working.
ALWAYS keep hands and feet away from all pinch points.
Avoid slippery surfaces. ALWAYS be sure of your footing.
NEVER carry passengers.
NEVER direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blade(s) when crossing gravel surfaces.
NEVER engage PTO when attachment, including mower blades, is not in use. ALWAYS turn off power to attachment when not in active use such as traveling or crossing driveways.
ALWAYS disengage PTO, stop unit and engine, remove key, engage parking brake and allow moving parts to stop before leavingoperator's position.
NEVER engage PTO while raising the attachment, including mower blades, or when attachment is in the raised position.
Keep safety devices or guards in place and functioning properly. NEVER modify or remove safety devices.
DO NOT mow in reverse unless absolutely necessary. ALWAYS look down and behind before and while backing.
Stop engine before removing grass catcher or unclogging chute.
Slow down before turning.
If you strike a foreign object, stop and inspect the machine. Repair, if necessary, before restarting.
NEVER leave a running machine unattended. ALWAYS turn off blade(s), set parking brake, stop engine and remove key before dismounting.
Disengage blade(s) when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard.
Know the weight of loads. Limit loads to those you can safely control and the unit can safely handle.

Slope Operation
Slopes are a major factor related to loss of control and tip-over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution. If you cannot back up the slope or if you feel uneasy on it, DO NOT mow it.
DO NOT operate on slopes of more than 15°.
Mow up and down slopes, not across.
ALWAYS keep the machine in gear when going down slopes. DO NOT shift to neutral and coast downhill.
Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.
DO NOT mow on moist or wet grass. Tires may lose traction causing a loss of control.
Use extra care while operating machine with grass catchers or other attachments; they can affect the stability of the machine. DO NOT use on steep slopes.
Keep all movements on the slope slow and gradual. DO NOT make sudden changes in speed or direction, which could cause the machine to roll over.
Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blade(s) and proceed slowly straight down the slope.
Operation on slopes may lead to loss of steering control. When operating on slopes be prepared to react to an emergency situation:

• Return steering levers to neutral position.
• Immediately set parking brake.
• Turn off PTO and engine.
  DO NOT try to stabilize the machine by putting your foot on the ground.

DO NOT park on slopes unless necessary. When parking on slope ALWAYS chock or block wheels. ALWAYS set parking brake.
Choose a low ground speed so you will not have to stop or shift while on a slope.
DO NOT mow near drop-offs, ditches, or embankments. The machine could suddenly roll over if a wheel goes over the edge or if the edge caves in.
DO NOT bypass transmission or allow transmission to free-wheel when on a slope.

Fuel
To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.
Ethanol blends must not exceed E10. Higher ethanol content may cause your machine to run hotter and damage your engine.
Replace fuel cap securely and clean up spilled fuel before starting engine.
Extinguish all cigarettes, cigars, pipes and other sources of ignition.
Use only an approved gasoline container.
NEVER store the machine or fuel container where there is an open flame, spark or pilot light such as on a water or space heater or other appliances.
NEVER fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. ALWAYS place containers on the ground away from your vehicle before filling.
NEVER fuel the machine indoors.
NEVER remove gas cap or add fuel with the engine running. Allow engine to cool before fueling.
Fuel is highly flammable and its vapors are explosive. Handle with care. Use only an approved gasoline container with an appropriately-sized dispensing spout.
NO smoking, NO sparks, NO flames.
Remove gas-powered equipment from the trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.
Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fueling is complete. DO NOT use a nozzle lock-open device.
NEVER overfill fuel tank. Replace gas cap and tighten securely.
If fuel is spilled on clothing, change clothing immediately.

Service
The use of non-genuine replacement parts or accessories could adversely affect machine operation and safety.
Do not change engine governor setting or overspeed the engine.
Maintain or replace safety and instruction labels as necessary.
Keep unit free of debris. Clean up oil or fuel spills.
ALWAYS block wheels and know all jack stands are strong and secure and will hold weight of unit during maintenance.
Release any pneumatic or hydraulic pressure from components slowly.
NEVER attempt to make any adjustments to unit while engine is running (except where specifically recommended). Stop engine, remove key and spark plug wire and wait for all moving parts to stop before servicing or cleaning.
Lower cutting deck unless a positive mechanical lock is used.
Allow engine to cool before servicing.
Moving parts can cut or amputate fingers or a hand. On multiblade mowers, rotation of one blade will cause all blades to rotate.
NEVER weld or straighten mower blades.
NEVER make adjustments or repairs with the engine running.
Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them.
ALWAYS keep body and hands away from pin holes or nozzles which eject hydraulic fluid under pressure.

Transporting Unit
Use extra care when loading or unloading the machine into a trailer or truck.
Secure unit chassis to transport vehicle. NEVER secure from rods or linkages that could be damaged.
DO NOT transport machine while engine is running.
ALWAYS turn off power to attachment and shut off fuel when transporting unit.

Storage
NEVER store unit with fuel in fuel tank inside a building where any ignition sources are present.
Keep machine free of grass, leaves or other debris build-up. Clean up oil or fuel spillage and remove any fuel-soaked debris. Allow machine to cool before storing.
For extended storage, close fuel shut off valve and clean unit thoroughly. See engine manual for proper storage.

ASSEMBLY

AVOID INJURY. Read and understand the Safety section before proceeding.

1. Remove wrap and packaging materials from unit.
2. Remove and discard cable ties.
3. Remove unit from shipping container. See Move Unit Manually.
4. Remove and retain front seat hardware. See Figure 3.
   

5. Align rear seat hardware with key slots in seat plate. See Figure 4.
   

6. Adjust seat to forward-most position. See Adjust Seat. See Figure 5.
7. Rotate seat forward.
8. Reinstall hardware removed in step step 4.
   

14. Remove and retain two eccentric spacers, two round head square neck bolts and two locking nuts securing steering levers to upper control arms.
15. Rotate steering levers to operating position and install eccentric spacer between steering lever plates using original hardware.
    
16. Adjust steering levers. SeeAdjust Steering Levers.
17. Check tire pressures and inflate to recommendation. SeeCheck Tire Pressure. See Specifications.
18. Make sure deck is level. SeeLevel and Pitch Mower Deck.
19. Ensure all hardware is tight.

1. Fuel Tank and Cap
2. Fuel Level Window
3. Oil Filter
4. Oil Drain
5. Engine Oil Dipstick
6. Air Filter
7. Ignition Key
8. Choke Control Knob (Models 991160, 991162, 991164, 991166)
9. Throttle Control Lever
10. Power Take-off (PTO) Knob
11. Hour Meter
12. Height-of-Cut Adjustment System
13. Transport Lock Release Lever

14. Deck Lift Pedal
15. Seat Adjustment Lever
16. Parking Brake Lever
17. Belt Cover (2)
18. Steering Lever (2)
19. Discharge Chute
20. Anti-Scalp Wheel (6)
21. Transaxle Bypass Lever (2)
22. Battery (Under Seat)
23. Fuse Box
24. Hydraulic Oil Expansion Tank (2)

AVOID INJURY. Read and understand the Safety section before proceeding.

See Figure 8 for all controls and features locations.

IGNITION KEY
See Figure 9.
Controls power to the engine. The key cannot be removed when in run position.

CHOKE CONTROL KNOB
Models 991160, 991162, 991164, 991166
See Figure 10. Controls airflow to the engine.

THROTTLE CONTROL LEVER
See Figure 11. Controls engine speed.

POWER-TAKE-OFF (PTO) KNOB
See Figure 12. Controls power to mower blades. The engine will not start with the PTO knob in the on position.

AVOID INJURY. Blades will not immediately stop after pushing PTO knob down to off position.

HOUR METER
Displays the amount of time spent on individual jobs, service alerts, and recommended service intervals.

HEIGHT-OF-CUT ADJUSTMENT SYSTEM
Sets the height of cut.

TRANSPORT LOCK RELEASE LEVER
See Figure 13. Releases deck from transport lock position.

DECK LIFT PEDAL
Raises mower deck to change height-of-cut setting.

SEAT ADJUSTMENT LEVER
Unlocks seat to allow operator to move seat forward or backward and then lock in desired position.

PARKING BRAKE LEVER
See Figure 14. Controls the parking brake. The engine will not start with brake in the off position.

SAFETY INTERLOCK SYSTEM
Monitors the interaction of various unit features for operator safety.

STEERING LEVERS
Control the direction and speed of unit. To stop unit, return both steering levers to neutral.

TRANSAXLE BYPASS LEVERS
Engage and disengage the transaxles so unit may be moved with the engine off.

ANTI-SCALP WHEELS
Help prevent the deck from contacting the ground and scalping the lawn when passing over a high spot.

OPERATION

AVOID INJURY.
Read and understand the Safety section before proceeding.

All references to left, right, front or rear are given from the perspective of operator in operator's position, facing the direction of forward travel.

EMERGENCY STOPPING

1. Move steering levers to neutral position.
2. Set parking brake.
3. Push PTO knob down to off position.
4. Turn ignition key to off position and remove key.

BEFORE OPERATING UNIT

Register your product! See Register Your Product!.

1. Check fuel level and add fuel if needed.
   
   Use fresh unleaded fuel with an octane rating of at least 87. DO NOT use E85 blended fuels; the engine is not E20 / E30 / E85 compatible. The maximum recommended ethanol content is 10%. Gravely recommends using a quality fuel stabilizer in all fuel. See Short-Term Storage.
2. Check engine oil level and add oil if needed. Refer to engine manual.
3. Check condition of air cleaner. Refer to engine manual.
4. Check function of the Safety Interlock
   System by performing the tests in Check Safety Interlock System. Contact your Gravely dealer for repair if any of the tests fail.
5. Set cutting height. See Figure 15.
   
   1. Push mower lift pedal forward until transport lock engages.
   2. Insert adjustment pin through desired setting in height-of-cut adjustment system.
   3. Push mower lift pedal slightly forward, release transport lock and slowly release pedal until it contacts adjustment pin and stops.

START THE ENGINE

1. Push PTO knob down to off position.
2. Move steering levers to neutral position.
3. Engage parking brake.
4. Models 991160, 991162, 991164, 991166 Only: If engine is cold, pull choke knob up to on position. If engine is warm or hot, turn choke off.
5. Set throttle to slow speed.
6. Insert ignition key and turn to start position. Release key when engine starts.
   NOTICE: Do not operate the starter for more than 10 seconds at a time. If the engine does not start, allow a 60-second cool down period between starting attempts.
7. Models 991160, 991162, 991164, 991166 Only: If choke is on, wait a few seconds after engine starts and then push choke knob down to off position.
   
   Make sure choke is completely off. Engine will not run smoothly using partial choke.

OPERATE UNIT

1. Release parking brake.
   
   AVOID INJURY.
   Move the steering levers slowly and keep the throttle at slow speed until you learn how to operate the unit.
2. Set throttle to slow speed.
3. Pull PTO knob up to on position.
   
   Never engage the PTO if the mower is plugged with grass or other material. This may cause damage to the electric clutch.
4. Move throttle control lever to fast.
5. Move steering levers to begin mowing.

Direction of Travel	Lever Position
Forward	Push both levers forward from neutral position.
Reverse	Pull both levers backward from neutral position.
Right Turn	Push left lever farther forward than the right lever.
Left Turn	Push right lever farther forward than the left lever.
Stop	Return both levers to neutral position.

Aggressive turning can scuff or damage lawns. Always keep both wheels rotating when making sharp turns. DO NOT make turns with inside wheel completely stopped. For minimum turning radius, slowly reverse inside wheel while moving outside wheel slowly forward.

For Best Mowing Results

• Cut grass when it is dry.
• Keep mower blades sharp.
• Keep mower deck properly leveled.
• Adjust anti-scalp wheels to prevent scalping.
• Do not set 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. Do not cut more than 2.5 cm (1") at any one time.
• Discharge clippings into areas already cut.
• Vary cutting pattern with each mowing.
• Do not allow grass or debris to collect inside of mower deck. Clean after each use. Stop the Engine

AVOID INJURY.
Wait for all moving parts to stop before leaving operator's position.

1. Place steering levers in neutral position and rotate outward.
2. Engage parking brake.
3. Push PTO knob down to off position.
4. Set throttle to slow speed.
5. Turn ignition key to off position and remove key.

MOVE UNIT MANUALLY
Bypass the transaxles to move the unit with the engine off.

There is one transaxle bypass lever on each side of unit. Ensure that both levers are fully in front or rear position.

1. Stop engine, remove key and wait for moving parts to stop and for hot parts to cool. SeeDo not allow grass or debris to collect inside of mower deck. Clean after each use. Stop the Engine.
2. Pull both transaxle bypass levers out into bypass position. See Figure 16.
   
3. Release parking brake and push unit to desired location.
4. Engage parking brake.
5. Return transaxle bypass levers to operating position. See Figure 17.
   

TRANSPORT UNIT

1. Push deck lift pedal completely forward to engage transport lock. Release pedal.
2. Move unit to transport vehicle.
3. Stop engine, engage parking brake, remove key from ignition.
4. Secure mower frame to transport vehicle.
   NOTICE: NEVER secure unit to vehicle from rods or linkages that could be damaged.

RELEASE TRANSPORT LOCK

1. Push deck lift pedal forward and lift transport lock release lever.
2. Slowly return mower lift pedal to resting position.

MAINTENANCE

AVOID INJURY.
Read and understand the Safety section before proceeding.
Proper maintenance can prolong the life of unit. The Maintenance Schedule shows the recommended service schedule.
Your Gravely dealer can provide service and adjustments to keep your unit operating at peak efficiency. Contact an authorized engine manufacturer's service center for engine service.
More frequent service may be required due to working conditions (heavy loads, high ambient temperatures, dusty conditions, or airborne debris).
See the maintenance instructions in the Engine Manual for additional information.

SERVICE POSITION
See Figure 18.

1. Park unit on a flat, level surface.
2. Stop engine, remove key and wait for moving parts to stop and for hot parts to cool.
3. Engage parking brake.
4. Chock wheels. Strap and clamp unit onto lift, if used.
5. Place steering levers in neutral position and rotate outward.
6. Rotate seat forward.

MAINTENANCE SCHEDULE

Service Performed	Each Use	Every 25 hours	Every 50 hours	Every 100 hours	Every 400 hours
Check Safety Interlock System
Check Hydraulic System
Check Parking Brake
Check Engine Oil *
Change Engine Oil *
Check Tire Pressure
Check Mower Blades
Check Battery
Clean Battery
Check Carbon Canister Filter
Check Air Filter *
Check Fasteners
Lubricate Unit
Clean Engine Cooling System*
Check Belts
Change Hydraulic Oil and Filter **

* Refer to engine manual for instructions.
**Change after first 75 hours of operation.

SERVICE PARTS
See your Gravely dealer to purchase service parts for your unit.

HOUR / MAINTENANCE METER
Hour Meter-only Models
Hour meter measures engine runtime and cannot be reset.

Maintenance Models
See Figure 19. When the key is in the on position, the Timer mode displays. Press the Mode button to toggle between different modes. Timer: Measures engine runtime until reset. To reset the timer, press the Mode button to select TMR1 mode and then hold Mode button for 3 seconds.

Turn ignition key to the off position when unit is not in use. Some meters may count hours when the key is in the on position, even if the engine is off. This results in inaccurate maintenance intervals.
Service Alerts: Counts down hours until service is needed and displays "Now" when service is due. Service time is measured for:

• Engine oil and filter changes (CHG OIL)
• Hydraulic oil and filter changes (CHG H OIL)
• Air filter service (SVC AIRFILTER) The service intervals preset into the hour meter are:
• Hydraulic oil and filter: First 75 hours and every 400 hours thereafter
• Engine oil and filter: First 25 hours and every 100 hours thereafter
• Air filter: Every 100 hours

NOTICE: The preset engine oil services intervals are normal recommended intervals. Specific engine manufacturer's recommendations may vary.
To clear a service message, press the mode button to select service alert mode and then hold the mode button for 3 seconds.

CHECK SAFETY INTERLOCK SYSTEM
Check function of the Safety Interlock System by performing the tests below. Contact your Gravely dealer for repair if any of the tests fail.

CHECK PARKING BRAKE

1. Park unit on a flat, level surface.
2. Position steering levers in neutral.
3. Engage parking brake.
4. Stop engine and wait for moving parts to stop and for hot parts to cool.
5. Bypass transaxles. SeeMove Unit Manually.
6. Push unit forward.

• If unit does not move forward, no adjustment is needed.
• If unit moves forward easily, adjust the brake lever.

CHECK ENGINE OIL
NOTICE: Engine oil level must be maintained at correct level or engine damage may occur. Refer to engine manual.

CHECK TIRE PRESSURE
See Specifications for recommended tire pressure.

AVOID INJURY.
Explosive separation of tire and rim parts is possible.

• DO NOT inflate tires above the recommended pressure.
• DO NOT inflate tires with a compressor; use a hand pump.
• DO NOT stand in front of tire assembly when inflating. Use a clip-on chuck and extension hose long enough to allow you to stand to one side.
• DO NOT mount a tire without proper equipment and experience.

CHECK FASTENERS
Check for loose or missing hardware.

LUBRICATE UNIT

1. Apply oil to all pivot points and pin connections.

Lubricate Seat
See Figure 20.

1. Place unit in service position. SeeService Position.
2. Apply grease to seat tracks through slots under seat plate.
   
3. Return seat to operating position and slide seat back and forth to spread grease along tracks.

CHECK MOWER BLADES
Check blades for wear. Replace or sharpen as needed.

AVOID INJURY. Use sturdy gloves or padding to protect hands when working with mower blades.
Rotation of one blade rotates the other blades.

Remove Blades

1. Stop engine, remove key and wait for moving parts to stop and for hot parts to cool.
2. Disconnect spark plug wires.
3. Remove hardware securing blades to spindles and remove blades. Retain all hardware for reinstallation. See Figure 21.
   

Sharpen Blades

DO NOT sharpen blades while attached to unit.

1. Remove blades. Discard blades if:
   • More than 1.3 cm (1/2") of metal is removed.
   • Air lifts are eroded.
   • Blades are bent or broken.
2. File or grind an equal amount of material from each cutting edge of the blade until sharp. DO NOT change angle of cutting edge or round the corner of the blade. See Figure 22.
   
   Unbalanced blades cause excessive vibration and eventual damage to unit. Balance blades before reinstalling on unit. NEVER weld or straighten blades.
   

3. Check blade balance by sliding blade on an unthreaded bolt. If blade does not remain horizontal, sharpen the heavy end until blade is balanced.

Install Blades
See Figure 21.

1. Reinstall blades and secure with original hardware. Torque to 156 N•m – 217 N•m (115 lb-ft – 160 lb-ft).

BATTERY SERVICE

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Remove Battery

1. Place unit in service position. See Service Position.
2. Disconnect the negative cable and then the positive cable from the battery.
   See Figure 23.
   

3. Loosen hex nut securing right hold-down bracket to frame.
4. Remove T bracket from lower slots in hold-down brackets.
5. Remove battery.

Clean Battery

1. Clean terminals and battery cable ends with a wire brush.
2. Coat terminals with dielectric grease or petroleum jelly.

Install Battery

DO NOT allow direct metal contact across battery posts.

1. Reinstall positive cable and then the negative cable.
2. Insert T bracket through lower slots in hold-down brackets.
3. Tighten hex nut securing right hold-down bracket to frame.
4. Return seat to operating position 5. See Figure 24.

Charge Battery
Check battery with a voltmeter. If battery is less than 11 volts, charge battery.
NOTICE: DO NOT fast charge. Charging at a higher rate damages or destroys the battery. ONLY use an automatic charger designed for use with your battery.
NOTICE: Always follow information provided on battery by battery manufacturer. Contact battery manufacturer for detailed information about charging.

1. Remove battery from unit. SeeRemove Battery.
2. Place battery on bench or other wellventilated area.
3. Connect positive lead of charger to positive battery terminal.
4. Connect negative lead of charger to negative battery terminal.
5. Charge battery following battery manufacturer's instructions.
6. Reinstall battery. SeeInstall Battery.

Jump Starting
Gravely does not recommend jump starting your unit. Jump-starting can damage engine and system components. Refer to engine manual for details.

CHECK MOWER BELTS
Check belts for wear and replace as needed.

CHECK HYDRAULIC SYSTEM
Check Hydraulic Oil Level

1. Place unit in service position. SeeService Position.
2. Check oil level in expansion tanks. Oil should reach the cold fill indicator mark. See Figure 24.
   
   Engine should be cold when checking initial oil level.
   
3. Operate engine for 1 minute and recheck oil levels.
4. Add hydraulic oil, if needed.
   1. Remove expansion tank caps.
   2. Fill expansion tanks with 15W-50 synthetic motor oil (Gravely p/n 00057100) or equivalent) until oil reaches the cold fill indicator mark. See Figure 24.
   3. Reinstall expansion tank caps.

Change Hydraulic Oil and Filter

1. Operate unit for a few minutes to warm hydraulic oil.
2. Stop engine, remove key and wait for all moving parts to stop and for hot parts to cool.
3. Position container under oil filter to catch used oil. See Figure 25.
4. Remove filter guard and oil filter from transaxle.
5. Remove the vent / fill plug from the fill port and allow transaxle to drain completely.
   
6. Wipe filter-mounting surface clean.
7. Lubricate rubber gasket on new oil filter with clean hydraulic oil.
8. Spin filter onto filter housing until it makes contact, and then turn filter 3/4 turn to tighten.
9. Reinstall filter guard and torque to 7.3 N•m (65 lb-in). DO NOT overtighten.
10. Add 15W-50 synthetic motor oil (Gravely p/n 00057100) or equivalent) until oil appears at the bottom of the fill port (1892.7 mL (64 fl. ounces) per transaxle).
11. Reinstall the vent / fill plug and torque to 20.3 N•m (180 lb-in).
12. Add hydraulic oil to expansion tank until oil reaches cold fill indicator mark.
13. Repeat steps 3 – 12 for other transaxle.
14. Purge hydraulic system. SeePurge Hydraulic System.

Purge Hydraulic System
Purge air from hydraulic system after draining oil or changing the filter.

AVOID INJURY. This adjustment requires operating the engine. Use extreme care to avoid contact with moving parts and hot surfaces. Be sure rear of unit is well supported and secure before starting engine.

1. Park unit facing a wall or chock wheels.
2. Release parking brake.
3. Support unit so drive wheels are off the ground.
4. Bypass transaxles. SeeMove Unit Manually.
5. Start the engine and slowly move steering levers forward and backward 5 or 6 times.
6. Stop engine.
7. Return transaxle bypass levers to operating position. SeeMove Unit Manually.
8. Start engine.
9. Slowly move steering levers forward and backward 5 or 6 times.
10. Stop engine, lower unit to ground and check oil level. Add oil if needed.
11. Repeat steps 1 – 10 until transaxles operate smoothly in forward and reverse at normal speed without excessive noise.

ADJUST SEAT
See Figure 26.

1. Pull seat adjustment lever up to unlock seat.
2. Move seat to desired position.
3. Release seat adjustment lever to lock seat in place.

6. Stop engine, remove key and wait for moving parts to stop and for hot parts to cool.
7. Engage parking brake.
8. Loosen mounting hardware, align levers and tighten hardware. See Figure 29.
   

Adjust Forward Position
The steering lever forward position may be adjusted for operator comfort.

1. Stop engine, remove key and wait for moving parts to stop and for hot parts to cool.
2. Loosen mounting hardware on steering lever assemblies.
3. Place steering levers in desired position:

• Gently push levers forward for greater distance from operator.
• Gently pull levers back for closer distance to operator.

4. Tighten hardware.

ADJUST UNIT TO DRIVE STRAIGHT
NOTICE: Reverse travel can only be adjusted by your Gravely dealer.

Adjust Tire Pressure

1. Place unit in service position. SeeService Position.
2. Check tire pressures. If needed, adjust to recommended pressures. SeeSpecifications.
3. Check tracking.

• If unit does not track straight, increase tire pressure to the drive wheel of the side it moves toward.
  
  DO NOT exceed maximum tire pressure listed on tire sidewall.
• If increasing tire pressure does not correct tracking, adjust the limiter bolts as directed below.

Adjust Limiter Bolts
See Figure 30.
Limiter bolts can be adjusted to increase or decrease drive wheel speeds. To adjust:

1. Loosen jam nut.
   • Turn limiter bolt counterclockwise to increase maximum drive wheel speed on that side.
   • Turn limiter bolt clockwise to reduce maximum drive wheel speed on that side.
2. Tighten jam nut.
   
3. Align steering levers. SeeAdjust Steering Levers.

ADJUST TRANSAXLES
Check For Excessive Creep

AVOID INJURY. This adjustment requires operating the engine. Use extreme care to avoid contact with moving parts and hot surfaces. Be sure rear of unit is well supported and secure before starting engine.

1. Operate unit for a minimum of 5 minutes to warm hydraulic system.
2. Stop engine and engage parking brake.
3. Chock front wheels and support unit so both drive wheels are off the ground.
4. Remove drive wheels.
5. Start engine, move throttle lever to fast position and release parking brake.
6. Move steering levers forward and backward 5 or 6 times and then return levers to neutral position.
7. Check hubs for rotation.
   • If there is only slight rotation, stop engine, reinstall wheels and lower unit to ground.
   • If there is excessive rotation, adjust neutral position as directed below.

Torque wheel lug nuts to 81.3 N•m – 122.0 N•m (60 lb-ft – 90 lb-ft).

Adjust Neutral Position
If wheel hub has excessive rotation after checking for excessive creep, adjust neutral position.

1. Loosen the return-to-neutral screw on the transaxle. See Figure 31.
   
2. Slowly turn transaxle control arm in the opposite direction of hub rotation until hub stops. See Figure 32.
   

3. Hold the transaxle control arm in position and tighten the return-to-neutral screw.
4. Start engine, move throttle lever to fast position and release parking brake.
5. Move steering levers forward and backward 5 or 6 times and then return levers to neutral position.

6. Check wheel hubs for rotation.
   • If there is only slight rotation, stop engine, reinstall wheels, return unit to operating position and advance to Adjust Parking Brake Lever.
   • If there is excessive rotation, repeat steps 1 – 6.

Torque wheel lug nuts to 81.3 N•m – 122.0 N•m (60 lb-ft – 90 lb-ft).

ELECTRICAL SERVICE
See Figure 33.

Replace Fuse
NOTICE: To avoid damaging the circuit, replace fuses with fuses of the same amperage rating. Determine the cause of electrical failure and repair before replacing failed electrical components.

1. Place unit in service position. SeeService Position.
2. Remove defective fuse.
3. Determine cause of fuse failure and repair condition.
4. Install new fuse.

Replace Relay
NOTICE: Relays are interchangeable. Use only quality replacement parts. See Service Parts.

1. Place unit in service position. See Service Position.
2. Remove defective relay.
3. Determine cause of relay failure and repair condition.
4. Install new relay.
   

4. Slowly remove spring hook from anchor bolt to release tension from belt idler.
5. Remove PTO belt.

Remove Mower Drive Belt

1. Remove PTO belt. See Remove PTO Belt.
   
   Use care when releasing idler spring tension. Keep body parts away from idlers when performing this operation. See Figure 36 and Figure 37.
   
2. Slowly remove spring hook from anchor bolt to release tension from belt idler.
3. Remove mower drive belt.

Install Mower Drive Belt
See Figure 38 and Figure 39.

1. Install mower drive belt around bottom groove of split pulley at deck center and around bottom groove of right spindle pulley.
2. Reinstall idler spring hook around anchor bolt to apply tension to belt.

Make sure belt has tension and is aligned in all pulleys.

Install PTO Belt

Mower drive belt MUST be installed before PTO belt.

1. Install PTO belt around clutch sheave at rear of unit. See Figure 40.
2. Install PTO belt around top groove of split pulley at deck center and around left spindle pulley.

3. Align belt with idler pulleys.
4. Reinstall idler spring hook around anchor bolt to apply tension to belt.
   
   
   Make sure belt has tension and is aligned in all pulleys. See Figure 41.
   

5. Reinstall belt covers and secure with original hardware.

REPLACE TRANSAXLE DRIVE BELT
Remove Transaxle Drive Belt

1. Place unit in service position. See Service Position.
2. Remove PTO belt from clutch. See Remove PTO Belt.
   
   Use care when releasing idler spring tension. Keep body parts away from idlers when performing this operation.

4. Remove hardware securing clutch stop bracket to frame and remove bracket.
   NOTICE: DO NOT cut cable tie.
   See Figure 43.
   

5. Remove transaxle drive belt from drive system in the following order:
   1. From right transaxle sheave.
   2. From left transaxle sheave.
   3. From clutch sheave.

Install Transaxle Drive Belt
See Figure 44.

1. Install transaxle drive belt to drive system in the following order:
   1. Around clutch sheave.
   2. Around left transaxle sheave.
   3. Around right transaxle sheave.
2. Align belt with idler pulley.
3. Reinstall idler spring hook onto anchor bolt. Make sure belt has tension and is aligned in all pulleys.
   
   
   Make sure belt has tension and is aligned in all pulleys. See Figure 45.
   

4. Reinstall clutch stop bracket and secure with original hardware. See Figure 46.
   

ADJUST ANTI-SCALP WHEELS
See Figure 48.
The anti-scalp wheels are set at the factory for typical mowing height, but can be adjusted for high or low cutting conditions. Make sure all wheels are set to the same height.

1. Place unit in service position. SeeService Position.
2. Remove hardware securing anti-scalp wheels to deck and remove wheels.

ADJUST PARKING BRAKE LEVER
See Figure 49.

1. Place unit in service position. SeeService Position.
2. Loosen jam nuts on cable adjustment barrel.
3. Adjust cable tension.
   • To increase lever response, loosen the upper jam nut and tighten the lower jam nut until both jam nuts are tight against cable bracket.
   • To decrease lever sensitivity, loosen the lower jam nut and tighten the upper jam nut until both jam nuts are tight against cable bracket.
4. Check parking brake and readjust if necessary. SeeCheck Parking Brake.

7. Remove hardware retaining deck lift links to deck lift brackets. See Figure 52.
   

8. Remove deck from under unit.

Install Deck

1. Position deck under unit. See Figure 53.
2. Reinstall drag links to frame with original hardware.
3. Secure deck lift links to deck lift brackets with original hardware.
   

4. Reinstall PTO belt. See Install PTO Belt.
5. Reconnect lift-assist springs to spring pegs.
6. Level the deck. See Level and Pitch Mower Deck.

LEVEL AND PITCH MOWER DECK

Make sure unit is on a flat, level surface and that tires are inflated to the recommended pressures.

Check Blade Level and Pitch

1. Raise deck to 3 1/2" (8.9 cm) cutting height.
2. Stop engine, remove key and wait for moving parts to stop and for hot parts to cool.
3. Engage parking brake. See Figure 54.
4. Position mower blades so ends point left to right across the width of the deck.
5. Measure the distance between the ground and the cutting edge of the left and right blades. If the measurements are not within 4.7 mm (3/16") of each other, level the deck. SeeLevel and Pitch Mower Deck.
   

6. Position mower blades so ends point front to back and measure the following:
   See Figure 55.
   
   • At the front of the deck, measure the distance between the ground and the cutting edge of the middle blade.
   • At the rear of the deck, measure the distance between the ground and the cutting edge of the left and the right blades.

Level Mower Deck
See Figure 56.

1. Lower the high side of deck:
   1. Loosen jam nuts against deck-leveling links.
   2. Turn adjustment bolts counterclockwise.
   3. Measure distance between the ground and cutting edges of left and right blades. Continue adjustment if necessary.
   4. Tighten jam nuts against deck-leveling links.
2. Raise the low side of deck:
   1. Loosen jam nuts against deck-leveling links.
   2. Turn adjustment bolts clockwise.
   3. Measure distance between the ground and cutting edges of left and right blades. Continue adjustment if necessary.
   4. Tighten jam nuts against deck-leveling links.

Adjust Blade Pitch

Side-to-side deck heights MUST remain level even after completing pitch adjustment.

Pitching the front of the blades lower than the rear provides a balance between cut quality and the power needed to cut grass. Certain cutting conditions require the deck rear to be pitched lower than the front. Positioning the deck this way requires more engine power but can provide better cut quality.

1. Increase forward pitch:
   1. Loosen jam nuts against all deck-leveling links.
   2. Turn front adjustment bolts counterclockwise to lower deck front.
   3. Turn rear adjustment bolts clockwise to raise deck rear.
   4. Check adjustment. SeeCheck Blade Level and Pitch.
   5. Tighten jam nuts against deck-leveling links.
2. Decrease forward pitch:
   1. Loosen jam nuts against all deck-leveling links.
   2. Turn front adjustment bolts clockwise to raise deck front.
   3. Turn rear adjustment bolts counterclockwise to lower deck rear.
   4. Check adjustment. SeeCheck Blade Level and Pitch.
   5. Tighten jam nuts against deck-leveling links.

STORAGE

SHORT-TERM STORAGE

NEVER wash unit with highpressure water or store outdoors.

1. Allow unit to cool and clean with mild soap and water.
2. Tighten all hardware to correct specifications.
3. Inspect unit for visible signs of wear or damage. Repair as needed.
4. Prepare fuel system for storage.
   NOTICE: Gravely recommends using a quality fuel stabilizer in all fuel. Gasoline left in the fuel system without a stabilizer, even for short periods of time, deteriorates and leaves gummy deposits in the system that may damage the carburetor and fuel hoses, filter and tank. For the best effectiveness, add stabilizer to all fuel containers whenever purchasing fuel. Add the stabilizer to the container before adding fuel.
   1. Add fuel stabilizer (seeService Parts) or equivalent according to manufacturer's instructions to the fuel tank and any fuel containers with remaining fuel.
   2. Run engine outdoors for at least 5 minutes to allow stabilizer to reach the carburetor.
5. Turn key to off position and remove from ignition.
6. Store unit in a cool, dry, protected area. DO NOT store unit outdoors.

LONG-TERM STORAGE

1. Perform short-term storage procedures.
2. Lubricate as directed inMaintenance Schedule.
3. Touch-up all scratched painted surfaces.
4. Remove and charge battery as directed inBattery Service. Store battery in a cool, dry, protected area.
5. Store unit in a cool, dry, protected area. DO NOT store unit outdoors.

START-OF-SEASON PREPARATION

1. Before adding fuel for the first time after long-term storage, add fresh, stabilizertreated fuel to fuel tank and any fuel containers with remaining fuel.
2. Charge and install the battery.

See your Gravely dealer for a complete list of compatible accessories and attachments for your unit.

Bagger Kits*

*Bagger kits are ordered in two parts. Complete baggers require Base Kit 89100800 plus the kit matching the deck size of the unit.

SPECIFICATIONS

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