Gravely ZT XL, ZT 1844 XL, ZT 2148 XL Manual

INTRODUCTION

THE MANUAL
Before operation of unit, carefully and completely read your manuals. The contents will provide you with an understanding of safety instructions and controls during normal operation and maintenance.
All reference to left, right, front, or rear are given from operator sitting in the operation position and facing the direction of forward travel.

SERVICE AND REPLACEMENT PARTS
When ordering publications, replacement parts, or making service inquiries, know the Model and Serial numbers of your unit and engine. Numbers are located on the product registration form in the literature package. They are printed on a serial number label, located on the frame of your unit.

PRODUCT REGISTRATION
The Gravely dealer must register the product at the time of purchase. Registering the product will help the company process warranty claims or contact you with the latest service information. All claims meeting requirements during the limited warranty period will be honored, whether or not the product registration card is returned. Keep a proof of purchase if you do not register your unit.
Customer Note: If the Dealer does not register your product, please fill out, sign and return the product registration card to Gravely or go to www.gravely.com on the internet.

UNAUTHORIZED REPLACEMENT PARTS
Use only Gravely replacement parts. The replacement of any part on this equipment with anything other than a Gravely authorized replacement part may adversely affect the performance, durability, and safety of this unit and may void the warranty. Gravely disclaims liability for any claims or damages, whether regarding warranty, property damage, personal injury or death arising out of the use of unauthorized replacement parts.
NOTE: To locate your nearest Gravely Dealer, call 1-920-756-4664 or go to www.gravely.com on the internet.

DEALER DELIVERY
Dealer should:

1. Test brakes after unit is assembled to be sure adjustment has not been disturbed in shipment (See Parking Brake Interlock System). Wheel brakes are properly adjusted at factory.
2. Check the safety interlock system to make sure that it is functioning properly. With operator on seat, unit must not start unless steering levers are in neutral (N) and Power Takeoff (PTO) is disengaged (Off). Engine must stop if operator leaves seat when steering levers are in any drive position or PTO is engaged (On). See Safety Interlock System.
3. Fill out Original Purchaser Registration Card and return the card to Gravely.
4. Explain Limited Warranty Policy.
5. Explain recommended lubrication and maintenance. Advise customer on adjustments. Instruct customer on controls and operation of unit. Discuss and emphasize the Safety Precautions. Give customer Owner/Operator, Parts, and Engine Manuals. Advise customer to thoroughly read and understand them.

Customer Note: Your Dealer has been provided complete set-up and preparation instructions which must be completed prior to you taking delivery of this unit. The dealer is required to review important information in this manual with you before or upon delivery of the unit or attachment.

SAFETY

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.
Slopes are a major factor related to loss-of-control and tip-over accidents. Operation on all slopes requires extra caution.
Tragic accidents can occur if the operator is not alert to the presence of children. Never assume that children will remain where you last saw them.
Gasoline is extremely flammable and the vapors are explosive, handle with care.
Disengage attachment, stop unit and engine, remove key, engage parking brake, and allow moving parts to stop before leaving operator's position.

SAFETY ALERT SYMBOL

These are safety alert symbols. They mean:

• ATTENTION!
• YOUR SAFETY IS INVOLVED!

When you see this symbol:

• BECOME ALERT!
• OBEY THE MESSAGE!

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

IMMINENTLY HAZARDOUS SITUATION! If not avoided, WILL RESULT in death or serious injury.

POTENTIALLY HAZARDOUS SITUATION! If not avoided, COULD RESULT in death or serious injury.

POTENTIALLY HAZARDOUS SITUATION! If not avoided, MAY RESULT in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTATIONS
NOTE: General reference information for proper operation and maintenance practices.

Specific procedures or information required to prevent damage to unit or attachment.

PRACTICES AND LAWS
Practice usual and customary safe working precautions, for the benefit of yourself and others. Understand and follow all safety messages. Be alert to unsafe conditions and the possibility of minor, moderate, or serious injury or death. Learn applicable rules and laws in your area, including those that may restrict the age of the operator.

REQUIRED OPERATOR TRAINING
Original purchaser of this unit was instructed by the seller on safe and proper operation. If unit is to be used by someone other than original purchaser (loaned, rented or sold), ALWAYS provide this manual and any needed safety training before operation.

SAFETY DECALS AND LOCATIONS
ALWAYS replace missing or damaged Safety Decals. Refer to Figure 2 for Safety Decal locations.

1. 
   TO AVOID SERIOUS INJURY OR DEATH

   	Read Owner/Operator Manual.
   	Keep children and others away from unit while operating.
   	Never direct discharge toward other people. Thrown objects can cause injury. Remove objects that could be thrown by the blade.
   	Look down and behind before and while backing.
   	Keep children out of work area and under watchful care of a responsible adult.
   	NEVER CARRY CHILDREN.
   	Go up and down slopes, not across. DO NOT operate on slopes over 17°.

   • If machine stops going uphill, stop blade and back down slowly.
   • Avoid sudden turns.
   • Keep safety devices (guards, shields, switches, etc.) in place and working.
   • Check interlock system per manual before use.
   • Understand location and function of all controls.
   • Never allow operation by untrained persons.
2. 
   ROTATING PARTS

   	Always keep feet and hands away from rotating parts.
   	Always stand clear of discharge area. Do not direct discharge toward other people.
   	Keep people away from unit while operating.
   	Shut off engine, remove key, read manual before you adjust or repair unit.
   	NO STEP! Always keep feet away from rotating parts.

3. 
   Do not operate mower unless guards are in operating position or bagger is attached.

   	Always stand clear of discharge area.
   	Do not operate mower unless bagger is attached or guards are in operating position.

4. HOT SURFACES!

   DO NOT touch parts which are hot from operation. ALWAYS allow parts to cool.

5. ROTATING PARTS

   AVOID INJURY. Stay clear of rotating parts.

6. AVOID INJURY. Stay clear of rotating parts.

SAFETY RULES

Read, understand, and follow all safety practices in Owner/Operator Manual before beginning assembly. Failure to follow instructions could result in personal injury and/or damage to unit.
ALWAYS remove key and/or wire from spark plug before assembly. Unintentional engine start up can cause death or serious injury.
Complete a walk around inspection of unit and work area to understand:

• Work area
• Your unit
• All safety decals

Determine which attachments are needed and can be used safely.
Inspect unit before each use for: missing or damaged decals and shields, correctly operating safety interlock system, and deterioration of grass catchers. Replace or repair as needed.
ALWAYS check overhead and side clearances carefully before operation. ALWAYS be aware of traffic when operating along streets or curbs.
Keep children and people away.
Keep children out of work area and under watchful care of a responsible adult.
Keep area of operation clear of all toys, pets, and debris. Thrown objects can cause injury.
Check for weak spots on docks, ramps or floors. Avoid uneven work areas and rough terrain. Stay alert for hidden hazards or traffic.
DO NOT operate near drop-offs, ditches, or embankments. Unit can suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.
Data indicates that operators, age 60 and above, are involved in a larger 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.
Read the entire Owner/Operator manual and other training material. If the operator or the mechanic cannot read the manual, it is the owner's responsibility to explain it to them. Only the user can prevent and is responsible for accidents or injuries occurring to themselves, other people or property.
Only trained adults may operate or service unit. Training includes actual operation.
Local regulations may restrict the age of the operator.
NEVER allow children to operate or play on or near unit. Be alert and shut off unit if children enter area.
NEVER operate unit after or during the use of medication, drugs or alcohol. Safe operation requires your complete and unimpaired attention at all times.
DO NOT wear loose clothing or jewelry and tie back hair that may get caught in rotating parts.
Wear adequate outer garments.
NEVER wear open sandals or canvas shoes during operation. Wear adequate safety gear, protective gloves and footwear.
Wear proper footwear to improve footing on slippery surfaces.
Always wear safety goggles or safety glasses with side shields when operating mower.
Moving parts can cut or amputate fingers or a hand. Wrap blade(s) or wear gloves to service. On multiblade mowers, rotation of one blade will cause all blades to rotate.
NEVER place your hands or any part of your body or clothing inside or near any moving part while unit is running.
ALWAYS keep hands and feet away from all rotating parts during operation. Rotating parts can cut off body parts.
ALWAYS keep body and hands away from pin holes or nozzles which eject hydraulic fluid under pressure.
DO NOT touch parts which are hot. Allow parts to cool.
ALWAYS keep hands and feet away from all pinch points.
Fumes from the engine exhaust can cause death or serious injury. DO NOT run engine in an enclosed area. Always provide good ventilation.
Read, understand, and follow all instructions in the manual and on the machine before starting. 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

Keep safety devices or guards in place and functioning properly. NEVER modify or remove safety devices.
Do not operate without either entire grass catcher or the discharge guard in place.
Stop engine before removing grass catcher or unclogging chute. Ensure Safety Interlock System is functioning properly. DO NOT operate unit if safety interlock is damaged or disabled.
Start and operate unit only when seated in operator's position. Steering control levers must be in neutral, PTO disengaged and parking brake set when starting engine.
Use care when approaching blind corners, shrubs, trees or other objects that may obscure vision.
Dust, smoke, fog, etc. can reduce vision and cause an accident. Mow only in daylight or good artificial light.
Avoid slippery surfaces. Always be sure of your footing.
DO NOT mow on wet grass. Reduced traction could cause sliding and effect the machine's stability.
Watch for traffic when operating near or crossing roadways.
Never carry passengers.
DO NOT try to stabilize the machine by putting your foot on the ground.
Never direct discharge towards persons or property that may be injured or damaged by thrown objects. Use extreme caution on gravel surfaces.
Always stand clear of the discharge area.
ALWAYS disengage PTO, stop unit and engine, remove key, engage parking brake and allow moving parts to stop before leaving operator's position.
Never engage PTO while raising attachment or when attachment is in raised position.
DO NOT operate at too fast a rate. DO NOT change engine governor settings or over-speed engine. Slow down before turning.
DO NOT operate in reverse unless absolutely necessary.
ALWAYS look down and behind before and while backing.
Stop and inspect equipment if you strike an object or if there is an unusual vibration. Repair, if necessary, before restarting. Never make adjustments or repairs with the engine running.
Mower blades are sharp and can cut you. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. NEVER weld or straighten mower blades.
Rotation of one blade may cause rotation of the other blades.
Take all possible precautions when leaving unit unattended. Shut off engine. Remove wire from spark plug and secure it away from spark plug.
ALWAYS remove key to prevent unauthorized use.
Know the weight of loads. Limit loads to those you can safely control and the unit can safely handle.
Disengage PTO when attachment is not in use. ALWAYS turn off power to attachment when travelling, crossing driveways, etc.
Mow up and down slopes, not across them.
DO NOT operate on slopes of more than 17 degrees.
Keep all movements on the slope slow and gradual. Do not make sudden changes in speed or direction.
Avoid starting or stopping on the slope. If tires lose traction, disengage the blades and proceed slowly straight down the slope.
If you cannot back up a slope or you feel uneasy on it, do not mow it.
DO NOT park on slopes unless necessary. When parking on slope always chock or block wheels. Always set parking brake.
Use a slow speed. Tires may lose traction on slopes even though the brakes are functioning properly.
Do not bypass transmission when on a slope.
Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.
Follow the manufacturer's recommendations for weight limits for towed equipment and towing on slopes.
NEVER allow children or others in or on towed equipment.
On slopes, the weight of the towed equipment may cause loss of control.
Travel slowly and allow extra distance to stop.
Use extra care when loading or unloading unit onto 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.
Keep unit free of debris. Clean up oil or fuel spills.
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 unless exhaust 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 by operator.
Fuel is highly flammable and its vapors are explosive. Handle with care. Use an approved fuel container.
NO smoking, NO sparks, NO flames. ALWAYS allow engine to cool before servicing.
NEVER fill fuel tank when engine is running or hot from operation.
NEVER fill or drain fuel tank indoors.
Replace fuel cap securely and clean up spilled fuel.
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.
When practical, remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer 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 fueling is complete. Do not use a nozzle lock-open device.
If fuel is spilled on clothing, change clothing immediately.
Avoid Electric Shock. Objects contacting both battery terminals at the same time may result in injury and unit damage. DO NOT reverse battery connections.
Reverse connections may result in sparks which can cause serious injury. Always connect positive (+) lead of charger to positive (+) terminal, and negative (-) lead to negative (-) terminal.
ALWAYS disconnect negative (-) cable FIRST and positive (+) cable SECOND. ALWAYS connect positive (+) cable FIRST, and negative (-) cable SECOND.
Explosive Gases from battery can cause death or serious injury. Poisonous battery fluid contains sulfuric acid and its contact with skin, eyes or clothing can cause severe chemical burns.
No flames, No sparks, No smoking near battery.
ALWAYS wear safety glasses and protective gear near battery. Use insulated tools.
DO NOT TIP battery beyond a 45° angle in any direction.
ALWAYS keep batteries out of reach of children.
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.
ALWAYS block wheels and know all jack stands are strong and secure and will hold weight of unit during maintenance. Release pressure slowly from components with stored energy.
NEVER attempt to make any adjustments to unit while engine is running (except where specifically recommended). Stop engine, remove key or spark plug wire and wait for all moving parts to stop before servicing or cleaning.
Check parking brake operation frequently. Adjust and service as required.
ALWAYS maintain unit in safe operating condition. Damaged or worn out muffler can cause fire or explosion.
Maintain or replace safety and instruction labels, as necessary.
NEVER store unit with fuel in fuel tank, inside a building where any ignition sources are present.
Shut off fuel and allow engine to cool completely before storing in closed area or covering unit.
Clean grass and debris from unit, especially from around muffler and engine, to help prevent fires.
For extended storage, shut off fuel and clean unit thoroughly. See engine manual for proper storage.
Lower cutting deck unless a positive mechanical lock is used.
Use only attachments or accessories designed for your unit.
Check all hardware at regular intervals, especially blade attachment bolts. Keep all hardware properly tightened.
Check attachment components frequently. If worn or damaged, replace with manufacturer's recommended parts.

ASSEMBLY

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

UNIT ASSEMBLY

Package Contents:
Unit, Mower Deck and Literature Pack

Preparation Checklist

Refer to the Owner/Operator manual as required.

1. Unpack Unit - Remove shrink wrap and packaging materials.
2. Remove Unit From Container - Open Bypass Valves (dump valves) (See Moving the Unit with the Engine Off).
   Push unit from container onto a level surface. Close the dump valves.
3. Tires - Check tire pressure (see Specifications).
4. Seat - Connect the seat cable to the frame with the hardware mounted on the frame. Put the seat in the operating position and secure with wing knob. See Seat Adjustments and Service Position.
5. Position Steering Levers - Rotate eccentric spacers to align handlebars. Tighten hardware securely. See Aligning the Steering Levers (Figure 11).
6. Battery - Remove battery from unit and charge (See Battery).
7. Check Engine Crankcase - Check and add oil if needed. See Engine Manual for specifications.
8. Fill Engine Fuel Tank - Add clean fuel to the fuel tank.
   
   Refer to Engine Manual for fuel type.
9. Hardware - Check for loose hardware.
10. Check Safety Interlock System - Check to see that the interlock system operates correctly (See Safety Interlock System).
    
    FAILURE OF INTERLOCK together with improper operation can result in severe personal injury.
11. Lubrication - Lubricate all fittings per maintenance label under seat and check hydrostat oil level (See Lubricate Unit).
12. Level Deck - Check unit to ensure deck level set at factory has been maintained (See Leveling the Mower Deck).
    
    Discharge chute must pivot freely. Always keep discharge chute down when mowing.
13. Check Function of all Controls - Ensure unit runs and performs properly.
    
    FAILURE OF CONTROLS could result in death or serious injury.

CONTROLS AND FEATURES

1. Fuel Tank
2. Steering Levers
3. Ignition Switch
4. Hour Meter
5. Throttle Lever
6. Choke Control
7. Power Take Off (PTO) Switch
8. Fuel Shut Off Valve
9. Mower Lift Pedal
10. Mower Deck with Chute Deflector
11. Mower Lift Lock
12. Seat Adjustment Lever
13. Parking Brake

OPERATION

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

CONTROLS AND FEATURES

See Figure 4 for Controls and Features locations.

Safety Interlock System

Safety interlock system failure and improper operation of unit can result in death or serious injury. Test this system each time the unit is operated. If this system does not function as described, do not operate until repairs are made.
Perform the following tests to ensure the safety interlock system is working properly. If the unit does not perform as stated, contact your Gravely dealer for repairs.
NOTE: When the parking brake is engaged, the steering levers are locked in neutral.

Parking Brake Interlock System

With the parking brake engaged, the steering levers must be locked in neutral.
With the parking brake disengaged, the engine must not start and Perform the following tests to ensure the safety interlock system the engine must shut off if the operator leaves the seat.

Steering Levers

The steering levers control speed and direction. In addition, they will stop the unit.

1. For reverse travel, pull both steering control levers backward.
2. For straight forward travel, push both steering control levers forward.
3. To turn left, pull the left back or push the right steering control lever forward or a combination of both.
4. To turn right, pull the right back or push the left steering control lever forward or a combination of both.

NOTE: The steering controls are mechanically locked in neutral whenever the parking brake is engaged.
NOTE: 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. To obtain minimum turning radius, slowly reverse inside wheel while moving outside wheel slowly forward.

	Ignition Switch Operate the ignition switch with the removable key. The switch has three positions: Off, On and Start. To start the engine, turn the key to Start, then release to On. To stop the engine, turn the key to Off.
	Choke Control Push the choke lever forward to start a cold engine. Pull the choke lever to the rear when the engine gets warm.
	Throttle Lever The throttle lever changes the engine speed. Move the throttle lever to Fast (1) to increase engine speed. Move the lever to Slow (2) to decrease engine speed.
	Power Take Off (PTO) Switch Power take off (PTO) switch engages and disengages the mower blades. Pull the power take off (PTO) switch to "On" position to engage mower blades. Push the power take off (PTO) switch to "Off" position to disengage mower blades. NOTE: The engine will not start unless the steering control levers are in the neutral position, the PTO switch is in the "Off" position and parking brake is set.

Mower Lift Pedal

Mower lift pedal raises and lowers mower deck for mowing or transport.

Transport:
Push mower lift pedal all the way forward until lift lock engages.
Cutting Height:
Put cutting height adjustment pin in desired hole. Push mower lift pedal forward and hold it while pushing down on the lift lock.
Slowly lower mower lift pedal until deck lift contacts cutting height adjustment pin.

	Fuel Shut-Off Valve Use this valve to control fuel flow from left or right fuel tank. Open the valve to operate the engine. Turn the valve to "Off" when storing or transporting the unit.
	Parking Brake Lever Pull lever up to engage parking brake. Push lever down to disengage parking brake.

Seat Adjustments

Make all seat adjustments with unit stationary, parking brake on and engine shut off.
To adjust seat forward or backward:

1. While seated, pull seat adjustment lever outward and slide seat into desired position.
2. Release lever and slide seat forward or back to lock seat into position.

Hour Meter

Records total number of hours the engine has been run.

Keep a record of Hour Meter readings for recommended Lubrication and Maintenance intervals.
NOTE: For accurate readings be sure Ignition Switch is OFF when unit is not in operation.

FILLING FUEL TANK

AVOID INJURY. Read and understand entire Safety section before proceeding.
Add fuel to Fuel Tank as needed. See your Engine Manual for correct type and grade of fuel.

To add fuel to the fuel tank:

1. Place unit in an open or well-ventilated open area.
2. Stop the engine and allow it to cool.
3. Clean the fuel cap and the area around the fuel cap to prevent dirt from entering the fuel tank. Remove the cap from the fuel tank.
4. Fill the fuel tank to within 1 in. (25 mm) below bottom of filler neck.
5. Replace fuel cap and tighten.
6. Clean up any spilled fuel.

PRE-START

Make sure all hardware is tight, all safety devices are in place and all adjustments are made correctly.

1. Check Safety Interlock System
   If this system does not function as described do not operate until repairs are made.
2. Check Air Cleaner
   Check air filter for dirt. Clean as required. Follow Engine Manual Maintenance Schedule.
3. Check Engine Fuel and Crankcase Oil
   Check and add fuel if required. Check that engine crankcase oil is full. Follow Engine Manual Maintenance Schedule.
4. Check Tire Pressure
5. Check Hydraulic Fluid Level
6. Adjust Seat
   Be sure all controls can be reached safely from operator's position.
7. Set Cutting Height
   Make sure the deck is set to the correct cutting height.

STOPPING IN AN EMERGENCY

The unit can be stopped immediately at any time by turning the ignition key to the "Off" position.

STARTING AND SHUT OFF

Read entire Owner/Operator Manual, Clutch Manual, and Engine Manual first. DO NOT attempt to start engine at this time.

To start the engine:

1. Make sure the steering levers are in neutral.
2. Put the PTO switch in the "Off" position.
3. Engage parking brake.
4. If the engine is cold, move the choke control to the "On" position. If the engine is warm or hot, do not use choke.
5. Move the throttle to 3/4 "Fast" position. See Engine Manual for detailed instructions.
6. Put the ignition key in the switch and turn it to the "Start" position.
7. As soon as the engine starts, release the key.
8. Move the choke control to the "Off" position from the "Choke" position. Wait until the engine is running smoothly before operation.

To stop the engine:

1. Bring the steering levers to neutral. Disengage the PTO and engage the parking brake.
2. Move the throttle lever to the "Slow" position.
3. Turn the ignition key to the "Off" position.

TO MOW WITH UNIT

Operate the unit only when seated in the operator's position.

1. Start the engine. Let the engine warm until it is running smoothly.
2. Release parking brake.
   
   Move the steering control levers slowly and keep the throttle control lever at slow speed until you learn how to operate the unit.
3. Bring the steering levers to neutral.
4. Slow the engine down to about 3/4 speed.
5. Turn ON the PTO switch to engage the mower.
   
   Never engage the PTO if the mower is plugged with grass or other material. This may cause damage to the electric clutch.
6. Move throttle control to fast.
7. Move the steering levers forward to obtain a slow ground speed.
8. To disengage the mower, move the PTO switch to the "Off" position.
9. When you know how to operate the unit, select a speed appropriate to your mowing conditions.

PARKING

To park the unit:

1. Bring the steering levers to neutral. Turn off PTO.
2. Move the throttle lever to the "Slow" position.
3. Engage the parking brake.
4. Lower the attachment.
5. Turn the ignition key to the "Off" position and remove the key.

MOVING THE UNIT WITH THE ENGINE OFF

Never tow unit.

1. Shut OFF engine.
2. Place seat in the service position (See Service Position).
3. Turn right and left bypass valve levers counter clockwise 1/2 turn (Figure 5).
   
   Do not bypass transmission when on a slope.
4. Disengage parking brake.
5. Push unit to desired location.
6. Engage parking brake.
7. Turn bypass valve levers clockwise 1/2 turn.

FOR BEST PERFORMANCE

Cut grass when it is dry.
Keep mower blades sharp.
Keep mower deck properly levelled.
Adjust anti-scalp rollers 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.
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.

MAINTENANCE SCHEDULE

AVOID INJURY. Read and understand entire Safety section before proceeding.
Proper maintenance can prolong the life of unit. The following charts show the recommended service schedule. 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.

Period	Service	Task
Each Use	Check Safety Interlock	Safety interlock system failure and improper operation of unit can result in death or serious injury. Test this system each time the unit is operated. If this system does not function as described, do not operate until repairs are made. See Safety Interlock System.
	Check Parking Brake Interlock System	See Parking Brake Interlock System.
	Check Hydraulic Fluid	Check hydraulic oil level mark on cap/dipstick. Add 15W50 synthetic oil as needed. Do not overfill. See Check Hydraulic Fluid Level.
	Check Tires	See Specifications for correct tire pressure.
	Follow Engine Manual Maintenance Schedule	Perform scheduled engine maintenance. Refer to engine manual for detailed instructions.
Every 25 Hours	Check Mower Blades	Check mower blades for wear. Sharpen or replace as needed. See Mower Blades.
Every 50 Hours	Lubricate Unit	Oil all pivot points and pin connections. Grease lube fittings. See Lubricate Unit.
	Check Brake Gap	Adjust gap if necessary. See Adjusting the Parking Brake
Every 100 Hours	Clean Battery	Keep battery and its terminals clean. See Clean Battery.
	Check Fasteners	Check mower blade mounting hardware and all other fasteners. Replace missing or damaged fasteners. Tighten all nuts and bolts to their correct torque value.
	Check Belts	Replace worn or deteriorated belts. See Remove PTO Belt and Replacing the Hydro Pump Belt.
Every 500 Hours	Change Hydraulic Fluid and Filter	Drain hydraulic fluid tank, replace hydraulic oil filter, refill system. See Hydraulic Fluid.

SERVICE AND ADJUSTMENTS

Gravely Dealers will provide any service which may be required to keep your unit operating at peak efficiency. Should engine service be required, it can be obtained from a Gravely Dealer or the engine manufacturer's authorized service center.

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

HOT SURFACES may result in injury. DO NOT touch engine or drive parts which are hot from operation. Allow parts to cool before servicing.

SERVICE POSITION

1. Place unit on a flat level surface. ALWAYS stop engine. Ensure unit is secure and will not tip over. Strap and clamp onto lift if used.
2. Place steering levers in neutral and engage parking brake.
3. Remove wing knob.
4. Tip seat forward (Figure 6)
   
   Be sure footing is secure to accomodate weight shift of seat when rotating it into service position.
5. When service is complete, lower seat and secure with wing knob or hex nut.

HYDRAULIC FLUID

HYDRAULIC FLUID can result in severe burns. Fluid in hydraulic system can penetrate skin and result in serious injury or death.
Be sure to stop the engine before doing any work on hydraulic parts.
Keep body and hands away from pin holes or nozzles which expel hydraulic fluid when under pressure. Use paper or cardboard, not hands, to search for leaks.
Ensure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before applying pressure to system.
FOREIGN FLUID INJECTED INTO BODY can result in gangrene. Fluid must be surgically removed within a few hours by a doctor familiar with this form of injury.

Check Hydraulic Fluid Level

1. Start the unit and run it to operating temperature (about 10 minutes).
2. Cycle the control levers forward and backward two or three times.
3. For units equipped with a hydraulic deck lift, raise and lower the deck completely two or three times.
4. Shut OFF engine. Engage parking brake. Remove the ignition key.
5. Put seat in service position. See Service Position.
6. Remove any dirt that may be around the cap/dipstick on the hydraulic reservoir.
7. Remove cap/dipstick.
8. Check hydraulic oil level mark on cap/dipstick.
9. Add 15W50 synthetic oil as needed. Do not overfill.

Change Hydraulic Fluid and Filter

Change the hydraulic oil filter and hydraulic oil every 500 hours. Use Mobil 15W50 synthetic oil for best component life.

1. Clean around dipstick cap and dipstick. Remove dipstick.
2. Place container under oil filter to catch oil.
3. Remove oil filter.
4. Allow tank to drain.
5. Lubricate rubber gasket on new oil filter with clean hydraulic oil.
6. Spin new oil filter onto filter housing until it makes contact. Tighten oil filter another 1/2 turn.
7. Add new oil to the oil tank. It will take about 2.5 quarts (2.4 L). Use Mobil 15W50 synthetic oil for best pump and wheel motor life.
8. Properly dispose of waste oil.

MOWER BLADES

Remove

Use sturdy gloves or padding to protect hands when working with mower blades.

1. Turn the engine off. Remove the ignition key. Remove the ignition wire from the spark plugs.
2. Remove the bolts, lock washer, flat washers, and blades from the spindle shafts.

Replace

1. Put the blades, flat washers, lock washers, and the bolts back on the spindle shafts.
2. Tighten the bolts to a torque of 115-125 lbf-ft (156-169.5 N•m).
3. Replace the ignition wire on the spark plugs.

Sharpen the Mower Blades

DO NOT sharpen mower blades while on unit. An unbalanced mower blade will cause excessive vibration and eventual damage to unit. Check mower blade balance before reinstalling blades.
NEVER weld or straighten bent blades.

1. Remove mower blade from unit.
   Discard mower blade if:
   • More than 1/2 in. (1.27 cm) of metal is removed.
   • Air lifts become eroded.
   • Blade is bent or broken.
2. Sharpen mower blade by removing an equal amount of material from each end of mower blade. DO NOT change angle of cutting edge or round the corner of the mower blade.
3. Check mower blade balance.
   Slide mower blade on an unthreaded bolt. A balanced blade should remain in a horizontal position. If either end of mower blade moves downward, sharpen the heavy end until blade is balanced.
4. Install mower blade(s) on unit.
5. Tighten the bolts to a torque of 115-125 lbf-ft (156-169.5 N•m).

BATTERY

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

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.
Unit comes equipped with a maintenance-free battery that requires no regular maintenance except cleaning the terminals.

Remove Battery

1. Shut OFF engine. Engage parking brake. Remove the ignition key.
2. Place seat in the service position (See Maintenance Schedule).
3. Disconnect cables from battery (negative, then positive) (Figure 8).
4. Remove hold down and remove battery.

Replace Battery

1. Replace battery and secure with battery hold down.
2. Reconnect cables to battery (positive, then negative). Position boot over positive terminal.
3. Return seat to operating position.

Clean Battery

Keep battery and its terminals clean. Inspect every 100 operating hours or monthly for best performance.

1. Remove battery from unit. See Remove Battery.
2. Clean terminals and battery cable ends with wire brush.
3. Coat terminals with dielectric grease or petroleum jelly.
4. Replace battery. See Replace Battery.

Charging the Battery

Battery Electrolyte First Aid
Follow First Aid directions for contact with battery fluid.

• External Contact: Flush with water.
• Eyes: Flush with water for at least 15 minutes and get medical attention immediately!
• Internal Contact: Drink large quantities of water. Follow with Milk of Magnesia, beaten egg or vegetable oil. Get medical attention immediately!

In case of internal contact, DO NOT induce vomiting!

DO NOT fast charge. Charging at a higher rate will damage or destroy battery. ONLY use an automatic charger designed for use with your battery.
ALWAYS follow information provided on battery by battery manufacturer. Contact battery manufacturer for extensive instructions to charge battery.

1. Remove battery from unit. See Remove Battery.
2. Place battery on bench or other well-ventilated place.
3. Connect positive (+) lead of charger to positive (+) terminal, and negative (–) lead to negative (–) terminal.
4. Charge battery according to charger and battery manufacturers' instructions.
5. Replace battery. See Replace Battery.

Jump-Starting
Gravely does not recommend jump-starting your unit. Jump-starting can damage engine and electrical system components. See your engine manual for more detailed information.

LUBRICATE UNIT

Apply oil at all pivot points and pin connections.

STEERING CONTROL NEUTRAL ADJUSTMENT

Eliminating Excessive Creeping of the Unit

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. If hydraulic system is cold, run unit for a minimum of five minutes, then shut OFF engine.
2. With the unit up to and facing a wall, jack up the unit so that both drive wheels are off the ground.
3. Remove the drive wheels from the unit.
4. Start the engine, run engine at full throttle, and release the parking brake.
5. Move the steering levers from Forward to Reverse several times to make sure controls are free. Then return steering levers to neutral position.
6. Check wheel(s) for movement.
   NOTE: The right and left hydraulic pumps are adjusted the same way.
7. If a wheel moves, adjust the return to neutral mechanism on the hydraulic pump:
   1. Loosen the set screw on the pump.
   2. Slowly move the stop bracket clockwise or counterclockwise until the wheel stops moving.
   3. Hold the stop bracket in position and tighten the set screw on the pump.
8. Move steering levers from Forward to Reverse several times and return steering levers to neutral position. Check wheel(s) for movement.
9. If wheel is still moving, repeat steps 7 and 8.
10. Shut OFF engine.
11. Replace drive wheels.

Aligning the Steering Levers

1. Shut OFF engine. Engage parking brake. Remove the ignition key.
2. Place seat in the service position (See Service Position).
3. Loosen brake interlock on the same side as steering lever to be adjusted.
4. Loosen tie rod jam nut and turn tie rod until steering levers are aligned.
5. Tighten jam nut on tie rod and tighten brake interlock.

ADJUSTING THE UNIT TO TRACK STRAIGHT

Prior to adjusting the tracking of the unit, shut OFF engine, engage parking brake, and remove the ignition key.
Check and adjust tire pressure. Increase pressure on side unit tracks to. DO NOT exceed maximum recommended tire pressure (See Specifications).
If tire pressure adjustment does not solve tracking problem, adjust the limiter bolts on the stop bracket (Figure 12). Front bolts adjust forward and rear bolts adjust reverse. Lengthen the limiter bolt (move closer to lever) on side which is too fast.

ADJUSTING THE HEIGHT OF THE STEERING LEVER HANDLES

The handles have three height positions.

1. Shut OFF engine. Engage parking brake. Remove the ignition key.
2. Remove the spacer, handle, and eccentric spacer from the steering lever.
   NOTE: Position the right and left handles at the same height position.
3. Install the spacer, handle, and eccentric spacer in the appropriate height position. Do not tighten the nut holding the eccentric spacer.
4. Turn the eccentric spacer until the right and left handles are the same height. Tighten nut.

ADJUSTING THE PARKING BRAKE

The parking brake might need adjustment over time and after new brake pads have been installed.
NOTE: Be sure to check parking brake on both sides of unit.

With parking brake engaged, spring length should measure 1-5/8 in. (1.14 cm) between jam nuts and trunnion. If the measurements are not within specifications, adjust the parking brake.

1. Engage parking brake.
2. Turn jam nuts until the spring measures 1-5/8 in. (4.14 cm).
3. Check to ensure the parking brake engages and disengages without binding by engaging and disengaging the parking brake several times.
4. Tighten jam nuts together.

NOTE: After installing new brake pads in calipers, they must be burnished by driving for a short distance (about 100 feet) with the brake on. To do this, bring parking brake lever part-way up while driving normally (in a straight line).

PTO BELT

MOVING PARTS can cut or amputate body parts. ALWAYS wait for moving parts to stop before performing maintenance or service.

DAMAGED OR WORN BELTS may result in injury and/or damage to unit. Check belts for excessive wear or cracks often.

PTO Belt Access

1. Properly stop and park unit (See Operation).
2. Lower the mower.
3. Place seat in most rearward position.
4. Remove belt covers.
5. Place foot board in open position.
   

Remove PTO Belt

Use care when releasing idler spring tension. Keep body parts well away from idlers when performing this operation.

1. Slowly release the tension on the PTO belt idler until all the tension is removed from the springs.
2. Remove PTO belt from deck.
3. Arrange new PTO belt on deck sheaves, and then slowly tension the idler springs.
4. Replace belt covers and return foot board to closed position.

REPLACING THE HYDRO PUMP BELT

1. Properly stop and park unit (See Operation).
2. Remove the PTO belt from the mower clutch sheave (See Remove PTO Belt).
   
   Use care when releasing idler spring tension. Keep body parts well away from idlers when performing this operation.
3. Slowly release the tension on the hydro pump belt idler until all the tension is removed from the springs.
4. Remove old hydro pump belt from right hand hydrostat sheave first (Figure 17).
5. Install new hydro pump belt by positioning belt on sheaves. Put belt onto right hand hydrostat sheave last.
6. Replace long mower belt on mower clutch sheave. See Remove PTO Belt.

MOWER DECKS

Removing the Mower Deck

1. Remove PTO belt (See Remove PTO Belt).
   
   AVOID INJURY. Mower lift arms and mower lift pedal could cause severe injury if they are not locked before removing the mower deck. ALWAYS lock mower deck lift before removing the deck.
2. Lock the mower deck in the service position. Push the mower lift pedal forward between cutting height number 4 and number 5 to align the holes in the deck lift shaft and the deck lift cover. Insert the cutting height pin in the holes on the side of the deck lift cover so it passes all the way through the deck lift cover and shaft.
   
   The mower lift arms are not locked unless the cutting height adjustment pin passes all the way through both the deck lift cover and shaft.
   NOTE: Support the mower deck on blocks or jack stands before disconnecting link chains from mower lift arms to prevent the deck from falling.
3. Remove link chains from mower lift arms. Note hole location on mower lift arms for replacement.
4. Remove the mower mounting pins connecting the mower mounting arms to the deck.
5. Slide mower deck out from under unit.

Installing the Mower Deck

1. Slide mower deck under unit.
2. Connect mower mounting arms to deck with mower mounting pins.
3. Install link chains on the mower lift arms in the same holes they were removed from.
4. Install PTO mower belt (See Remove PTO Belt).
5. Level mower deck (See Leveling the Mower Deck).

Leveling the Mower Deck

These adjustments should be made on a level surface with the tires inflated to the correct air pressure.
Level the mower with the slots where 4 chains fasten to the mower mounting brackets.

1. Shut OFF engine. Engage parking brake. Remove the ignition key.
2. Raise mower deck to its highest position and place 4-7/8 in. (12.4 cm) tall blocks at each rear corner and 4-3/4 in. (12 cm) tall blocks at each front corner.
3. Lower deck onto the blocks.
4. Loosen the locknuts on the side where the chains are slack and slide the bolt down the slot until the chains are tight.
5. Tighten the locknuts.
6. Lift mower and remove blocks.
7. Measure height of deck at each side. Measurements must be within 1/16 in. (1.59 mm) of each other.
8. If measurements are out of range, fix by adjusting chains on low side of deck.
9. Once deck is level side to side, measure height of deck at middle of front and on both sides of rear. Front of deck should be 1/8 in. (3.18 mm) lower than rear.

STORAGE

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

SHORT TERM

NEVER spray unit with high-pressure water or store unit outdoors.
Inspect unit for visible signs of wear, breakage or damage.
Keep all nuts, bolts and screws properly tightened and know unit is in safe working condition.
Store unit in a cool, dry protected area.

LONG TERM

Clean unit thoroughly with mild soap and low pressure water and lubricate (See Lubricate Unit in Maintenance). Touch up all scratched painted surfaces.
Remove weight from wheels by putting blocks under frame or axle.
When storing unit for extended periods of time, remove all fuel from tank and carburetor (run dry). Refer to Engine Manual.
Clean and charge the battery. Charge battery every three to four weeks when storing unit.

To Take the Unit Out of Storage

1. Refer to the engine service manual to prepare the engine for service.
2. Put fresh, clean fuel in the fuel tank.
3. Begin the maintenance schedule.
4. Charge and install the battery.

ACCESSORIES

SERVICE PARTS

SPECIFICATIONS

GRAVELY
A Division of Ariens Company
655 West Ryan Street
P.O. Box 157
Brillion, WI 54110-0157
920-756-2141
Fax 920-756-2407
www.gravely.com