Ariens 915501 Service manual

Zoom
Service Manual
Ariens Models 915035, 037, 039, 041, 313, 501
Gravely Models 915034, 036, 038, 040
00173200 09/03
Printed in USA
TABLE OF CONTENTS
Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-2
6.3 Sharpening Mower Blade. . . . . . . . . . . . . . . . . . 6-20
1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Service And Replacement Parts . . . . . . . . . . . . . 1-2
1.3 Product Registration. . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Unauthorized Replacement Parts . . . . . . . . . . . . 1-2
1.5 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Technical Service Communications . . . . . . . . . . . 1-2
Section 7 - Drive Train . . . . . . . . . . . . . . . . . . . 7-21
7.1 Hydro Transmission Troubleshooting . . . . . . . .
7.2 Hydrostatic Belt Replacement . . . . . . . . . . . . . .
7.3 Hydro-Gear Fluid Recommendations . . . . . . . .
7.4 Hydro-gear Transmission Removal . . . . . . . . . .
7.5 Hydro-Gear Transmission Installation . . . . . . . .
7.6 Electric Clutch Adjustment . . . . . . . . . . . . . . . . .
Section 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Practices And Laws . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Required Operator Training . . . . . . . . . . . . . . . . . 2-3
2.6 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.7 Service Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.8 Cleaning And Storage . . . . . . . . . . . . . . . . . . . . . 2-3
2.9 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
7-21
7-22
7-22
7-22
7-23
7-23
Section 8 - Lift System. . . . . . . . . . . . . . . . . . . 8-25
8.1 Lift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Section 9 - Fuel System. . . . . . . . . . . . . . . . . . 9-26
9.1 Fuel System Troubleshooting . . . . . . . . . . . . . .
9.2 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Fuel System Contamination. . . . . . . . . . . . . . . .
9.4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-26
9-27.
9-27
9-27
Section 10 - Electrical . . . . . . . . . . . . . . . . . . 10-28
10.1 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Electrical Measurements . . . . . . . . . . . . . . . .
10.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Solenoid And Relays . . . . . . . . . . . . . . . . . . .
10.6 Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . .
10.7 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8 Diodes And Rectifiers . . . . . . . . . . . . . . . . . .
10.9 Electric Clutch . . . . . . . . . . . . . . . . . . . . . . . .
10.10 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.11 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . .
10.12 Continuity Diagram . . . . . . . . . . . . . . . . . . .
10.13 Electrical System . . . . . . . . . . . . . . . . . . . . .
Section 3 - Specifications . . . . . . . . . . . . . . . . . 3-6
Section 4 - General Maintenance
& Adjustments . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.1 Controls And Features . . . . . . . . . . . . . . . . . . . . . 4-8
4.2 Fuel Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . 4-9
4.4 Remove Mower Deck . . . . . . . . . . . . . . . . . . . . . 4-12
4.5 Level and Adjust Pitch Of Mower Deck . . . . . . . 4-12
4.6 Hydrostatic Transmission Neutral Adjustment . . 4-13
4.7 Adjusting Unit to Track Straight . . . . . . . . . . . . . 4-13
4.8 Steering Lever Adjustments . . . . . . . . . . . . . . . . 4-14
4.9 Adjusting the Parking Brake . . . . . . . . . . . . . . . . 4-15
10-28
10-28
10-29
10-32
10-33
10-33
10-34
10-34
10-34
10-34
10-36
10-40
10-41
Section 5 - Engine . . . . . . . . . . . . . . . . . . . . . . 5-16
Section 11 - Mower Attachment . . . . . . . . . . 11-42
5.1 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . 5-16
5.2 Checking Engine Oil. . . . . . . . . . . . . . . . . . . . . . 5-17
5.3 Changing Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.4 Checking Engine Cooling . . . . . . . . . . . . . . . . . . 5-17
5.5 Cleaning The Air Cleaner . . . . . . . . . . . . . . . . . . 5-17
5.6 Changing The Air Cleaner Element . . . . . . . . . . 5-17
5.7 Inspect Muffler/Spark Arrester . . . . . . . . . . . . . . 5-17
5.8 Replace Spark Plugs . . . . . . . . . . . . . . . . . . . . . 5-17
5.9 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.10 Engine Installation . . . . . . . . . . . . . . . . . . . . . . 5-18
11.1 Mower Spindle Removal . . . . . . . . . . . . . . . . 11-42
Section 6 - Mower Deck. . . . . . . . . . . . . . . . . . 6-19
6.1 Clutch To Deck Drive Belt Replacement . . . . . . 6-19
6.2 Check Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
1
SECTION 1 - INTRODUCTION
1.1 THE MANUAL
1.3 PRODUCT REGISTRATION
The purpose of this manual is to provide complete
instructions for service, maintenance, disassembly,
repair, and installation of the mechanical components
for the 915 Zoom.
A warranty registration card must be filled out, signed,
and returned at time of purchase. This card activates
the warranty. Claims meeting requirements during
limited warranty period will be honored.
Dealer trained service personnel should use this
manual as a supplement to and reminder of the training
sessions conducted by the company.
1.4 UNAUTHORIZED REPLACEMENT
PARTS
Use only Ariens/Gravely replacement parts. The
replacement of any part on this vehicle with anything
other than a Ariens/Gravely authorized replacement
part may adversely affect the performance, durability,
or safety of this unit and may void the warranty. Ariens/
Gravely disclaims liability for any claims or damages,
whether warranty, property damage, personal injury, or
death arising out of the use of unauthorized
replacement parts.
Read all information for servicing a part or system
before repair work is started to avoid needless
disassembly.
Operation
Before operation of the unit, carefully and completely
read manuals supplied with the unit. The contents will
provide you with an understanding of safety
instructions and controls during normal operation and
maintenance.
1.5 DISCLAIMER
Safety Messages
Ariens/Gravely reserves the right to discontinue, make
changes to, and add improvements upon its products
at any time without public notice or obligation. The
descriptions and specifications contained in this
manual were in effect at printing. Equipment described
within this manual may be optional. Some illustrations
may not be applicable to your unit.
For your safety and the safety of others always read,
understand, and follow all DANGER, WARNING, and
CAUTION messages found in manuals and on safety
decals.
Directional Reference
All reference to left, right, front, or rear are given from
the operator in the operator position and facing the
direction of forward travel.
1.2 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 unit literature package. They are printed on a serial
number label, located on the frame of your unit.
Engine Serial Number
1.6 TECHNICAL SERVICE
COMMUNICATIONS
Ariens/Gravely Technical Service communicates
information to the field using Service Letters, Service
Bulletins, Product Notices, and Campaigns. Each
communication signifies a type of information and
priority. The dealer is responsible to carry out the
directive provided in the communication. The types of
communication are:
Service Letter - General technical information for the
dealer. Technical information on how to service the
product and product improvements.
Service Bulletin - Notification to update products to
resolve certain issues or a notification of a policy
change.
Product Notices - Notification of limited product
located in a certain region. This is a limited distribution
to only those who received the product involved.
Campaigns - Notification of a safety related issue. All
products must be updated and are tracked by the
factory until all units are corrected.
Unit Serial Number
Figure 1
1-2
SECTION 2 - SAFETY
2.1 SAFETY ALERTS
rented or sold, ALWAYS provide the Operator’s Manual
and any needed safety training before operation.
Look for these symbols to point out
important safety precautions. They
mean:
2.6 PREPARATION
Before starting any removal of parts, proper
preparation is very important for efficient work. A clean
work area at the start of each job will allow you to
perform service repairs easily and quickly.
Attention!
Personal Safety Is Involved!
Become Alert!
Obey The Message!
To reduce the incidence of misplaced tools or parts,
place removed components with all attaching hardware
in the disassembly order on a clean work surface.
Organization is a key part of proper reassembly.
2.2 SIGNAL WORDS
The safety alert symbol is used in decals on the unit
and with proper operation procedures in this manual.
They alert you to the existence and relative degree of
hazards.
Tools, instruments, and parts needed for the job should
be gathered before work is started. Interrupting a job to
locate tools or parts is a needless delay. A list of
required special tools has been included in this
manual.
Understand the safety message. It contains important
information about personal safety on or near the unit.
CAUTION: Remove enough fuel so that no
spillage will occur. Remove battery to prevent
spillage of electrolyte.
DANGER: IMMINENTLY HAZARDOUS
SITUATION! If not avoided, WILL RESULT in
death or serious injury.
2.7 SERVICE POSITION
WARNING: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, COULD RESULT
in death or serious injury.
WARNING: Always block wheels and know
that jack stands or blocks used are stable,
strong, or secure and will hold the weight of
the unit during maintenance.
CAUTION: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, MAY RESULT in
minor or moderate injury. It may also be used
to alert against unsafe practices.
To ensure the unit is positioned in the proper service
position:
1. Place jack stands under rear transaxle only.
2.3 NOTATIONS
NOTE: General reference information for proper operation and maintenance practices.
IMPORTANT: Specific procedures or information
required to prevent damage to unit or attachment.
2.4 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.
2.5 REQUIRED OPERATOR TRAINING
2. If jacks are not available, place support blocks
under transaxle at the rear of unit.
2.8 CLEANING AND STORAGE
IMPORTANT: To help prevent sealed bearing rust or
corrosion never spray unit with water or store unit
outdoors. Water can seep into sealed bearings and
reduce component life. Bearings are sealed against dirt
and debris only.
A unit that is excessively dirty should be cleaned
before work starts. Cleaning will occasionally uncover
trouble sources. Dirt and abrasive dust reduce the
efficient work life of parts and can lead to costly
replacement.
When taking unit out of extended storage:
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,
2-3
1. Check for any damage or loose parts. Repair
replace, or tighten hardware before operation.
Avoid uneven and rough terrain. 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.
2. If a preservative fluid was used in fuel tank, drain
and discard. Fill fuel tank with fresh new fuel.
2.9 SAFETY RULES
If tires lose traction, turn off power take off and proceed
slowly straight down slope. Avoid wet surfaces.
Walk Around Inspection
Complete a walk around inspection of unit and work
area to understand:
Avoid parking on a slope. If necessary, use wheel
chocks.
• Work area.
DO NOT leave unit unattended on a slope. ALWAYS
use wheel chocks when leaving unit.
• Your unit.
• All safety decals.
ALWAYS operate unit in good visibility and light.
Work Area
ALWAYS check overhead and side clearances
carefully before operation. ALWAYS be aware of traffic
when operating along streets or curbs.
ALWAYS keep hands and feet within the limits of the
unit.
Keep children, people, and animals 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. Objects can cause vehicle instability and injury.
Check for weak spots on dock, ramps or floors. Avoid
uneven work areas and rough terrain. Stay alert for
hidden hazards.
Fuel is highly flammable and its vapors can explode.
Use ONLY approved fuel containers.
NO Smoking!
NO Sparks!
NO Flames!
Allow engine to cool before servicing.
NEVER fill fuel tank when engine is running, hot, or unit
is indoors.
Abnormal Vibrations are a warning of trouble. Striking a
foreign object can damage unit. Immediately stop unit
and engine. Remove key and wait for all moving parts
to stop. Remove wire from spark plug. Inspect unit and
make any necessary repairs before restart.
Hazardous Slopes
DO NOT operate on steep slopes. Avoid operating on
slopes. When you must operate on a slope, travel up
and down the slope. Never operate across a slope.
Never operate on a slope greater than 10 degrees.
DO NOT run engine in an enclosed area. Always
provide good ventilation.
Unit
ALWAYS keep protective structures, guards, and
panels in good condition, in place and securely
fastened. NEVER modify or remove safety devices.
Child Safety
NEVER allow children to operate or play on or near
unit. Be alert and shut off unit if children enter area.
Check Safety Interlock System for proper operation
daily (see Operation section). Do not operate unless
system operates properly.
Personal Safety
Read and obey all warning, caution, and instructions
on the unit and in provided manuals.
Operation
• Only trained adults may operate unit.
Understand:
• Training includes actual operation.
• How to operate all controls
• Clearly understand instructions.
• The functions of all controls
• Be alert! Conditions can change.
• How to STOP in an Emergency
• Speed ranges
Do not operate any of the control levers or power takeoff unless both feet are resting on the platform.
DO NOT travel at too fast a rate. DO NOT change
engine governor settings or over-speed engine.
Always back up slowly. Always look down and behind
before and while backing.
Never leave a running unit unattended. ALWAYS shut
off power take off, lower throttle setting, and stop
engine before leaving unit. ALWAYS remove key to
prevent unauthorized use.
NEVER operate unit after or during the use of
medication, drugs or alcohol. Safe operation requires
your complete and unimpaired attention at all times.
NEVER allow anyone to operate the unit when their
alertness or coordination is impaired.
DO NOT operate unit without wearing adequate outer
garments. Wear adequate safety gear and protective
gloves. Wear proper footwear to improve footing on
slippery surfaces.
Protect eyes, face, and head from objects that may be
thrown from unit. Wear appropriate hearing protection.
Never carry passengers on any part of unit.
2-4
Storage
Avoid Sharp Edges. Sharp edges can cut. Moving
parts can cut or amputate fingers or a hand. Wear
gloves to service unit when handling sharp edges.
DO NOT store unit inside a building with fuel in the fuel
tank where any ignition sources are present. Allow unit
to cool completely.
ALWAYS keep hands away from any pinch points.
ALWAYS keep hands and feet away from all moving
parts during operation. Moving parts can cut off body
parts.
ALWAYS clean unit before extended storage. See
Engine Manual for proper storage.
Battery
DO NOT touch unit parts which might be hot from
operation. Allow parts to cool before attempting to
maintain, adjust, or service.
Avoid Electric Shock. DO NOT reverse battery
connections.
Explosive Gases! Poisonous battery fluid contains
sulfuric acid and its contact with skin, eyes, or clothing
can cause severe burns.
Controls
Come to a complete stop before reversing.
No flames. No sparks. No smoking near battery.
Never jerk the control levers. Always use a steady
even action to achieve smooth control.
Always be aware of obstructions that may cause injury
to operator or damage to the unit.
Maintenance
Always wear safety glasses and protective gear near
battery.
DO NOT TIP battery beyond a 45o angle in any
direction.
ALWAYS maintain unit in safe operating condition.
Damaged or worn out muffler can cause fire or
explosion.
ALWAYS KEEP BATTERIES OUT OF REACH of
children.
Check the conditions of the unit at the end of each day
and repair any damage or defects.
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.
ALWAYS block wheels and know all jack stands are
strong and secure and will hold weight of unit during
maintenance.
Transport
DO NOT transport with attachment in raised position.
Keep nuts and bolts tight and keep equipment in safe
operating conditions.
Lower attachment when unit is parked or stored unless
a positive mechanical lock is used.
Before maintenance, adjustments, or service (except
where specifically recommended), shut off engine.
Attachments and Accessories
Allow hot parts to cool.
Keep unit free of dirt, stones, and other debris. Clean
up oil or fuel spills.
Use only attachments or accessories designed for your
unit.
2-5
SECTION 3 - SPECIFICATIONS
Ariens Models
Model Number
Description
Engine
915035
915037
1640
1844
Single Cylinder
Engine Power - HP (kW) @ governed
RPM
Max Governed RPM
Fuel Tank Capacity - gal. (L)
Starter
Transmission
Speed: Forward Max. - mph (km/h)
915039
2048
Briggs & Stratton
16 (11.9)
18 (13.4)
915041
915501
915313
2252
1844
2252
Twin Cylinder Briggs & Stratton
20 (14.9)
22 (16.4)
18 (12.8)
22 (13.5)
2900
3100
44 (112)
52 (132)
3400
8 (30.28)
Electric
Hydrostatic
6.5 (10.5)
Reverse Max. - mph (km/h)
PTO
Battery
Brakes
Cutting Height - in. (cm)
Cutting Width - in. (cm)
Tire Pressure: Front - psi (kPa)
40 (102)
46 (317)
Rear - psi (kPa)
Tire Size: Front - in. (cm)
10 (69)
11 x 4
44 (112)
3 (3.2)
Electric Clutch/Brake
12 Volt Maintenance Free
Internal Transmission
1-1/2 - 4-1/2 (3.81 - 11.4)
48 (122)
52 (132)
46 (317)
12 (83)
11 x 4 (27.9 x 10.2)
(27.9 x
10.2)
Rear - in. (cm)
18 x 8.5
18 x 9.5 (45.7 x 24.1)
(45.7 x
21.6)
Turning Radius
Weight - lbs (kg)
Height - in. (cm)
Length - in. (cm)
Width - in. (cm)
Max. Towing Capacity - lbs (kg)
Max. Tongue Weight - lbs (kg)
CE Sound and Vibration
Oper. Ear Sound Pressure (Lpa) in dBA
660 (299)
Zero
714 (324)
740 (336)
41 (104)
76 (193)
46.5 (118)
300 (136)
30 (13.6)
687 (312)
687 (312)
740 (336)
NA
86
91
NA
.76
2.6
Y axis
.59
1.1
Z axis
At Operator Feet: X axis
NA
1.10
.34
1.8
.34
Y axis
.42
.42
Z axis
At Operator Seat: X axis
NA
1.19
.35
1.2
.35
Y axis
.37
.37
Z axis
.87
.87
44 (112)
(m/sec2)
Vibration Measure
At Operator Hands: X axis
3-6
Gravely Models
Model Number
Description
Engine
Engine Power - HP (kW) @ governed
RPM
Max Governed RPM
Fuel Tank Capacity - gal. (L)
Starter
Transmission
Speed: Forward Max. - mph (km/h)
915034
915036
ZT1640
ZT1844
Single Cylinder
915038
915040
ZT2048
ZT2252
Twin Cylinder Briggs & Stratton
Briggs & Stratton
16 (11.9)
18 (13.4)
20 (14.9)
22 (16.4)
3400
8 (30.28)
Electric
Hydrostatic
6.5 (10.5)
Reverse Max. - mph (km/h)
PTO
Battery
Brakes
Cutting Height - in. (cm)
Cutting Width - in. (cm)
Tire Pressure: Front - psi (kPa)
40 (102)
46 (317)
Rear - psi (kPa)
Tire Size: Front - in. (cm)
10 (69)
11 x 4
3 (3.2)
Electric Clutch/Brake
12 Volt Maintenance Free
Internal Transmission
1-1/2 - 4-1/2 (3.81 - 11.4)
44 (112)
48 (122)
46 (317)
52 (132)
12 (83)
11 x 4 (27.9 x 10.2)
(27.9 x 10.2)
18 x 8.5
Rear - in. (cm)
Turning Radius
Weight - lbs (kg)
Height - in. (cm)
Length - in. (cm)
Width - in. (cm)
Max. Towing Capacity - lbs (kg)
Max. Tongue Weight - lbs (kg)
(45.7 x 21.6)
18 x 9.5 (45.7 x 24.1)
Zero
687 (312)
714 (324)
41 (104)
76 (193)
46.5 (118)
300 (136)
30 (13.6)
660 (299)
44 (112)
3-7
740 (336)
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS
4.1 CONTROLS AND FEATURES
1
2
3
4
5
13
6
7
8
6
9
12
10
11
1.
2.
3.
4.
5.
6.
7.
8.
Ignition Switch
PTO Switch
Throttle Lever
Choke Control (915038, 039, 040, 041, 313, 501)
Seat
Steering Lever
Parking Brake
Fuel Tank
9. Axle Lock
10. Mower Lift Pedal
11. Mower Deck
12. Discharge Chute
13. Fuel Shut-Off Valve
Figure 2
4-8
4.2 FUEL LEVEL
Safety Interlock System
WARNING: Safety interlock failure and
improper operation of unit can result in death
or serious injury. Check system before each
use to make sure it is functioning properly.
Fuel Shut-Off Valve
3
1
OFF
LEFT
TANK
RIGHT
TANK
Perform the following tests to ensure the
safety interlock system is working properly. If
the unit does not perform as stated contact
your Ariens/Gravely dealer for repairs.
2
OF1881
Figure 3
Use this valve to control fuel flow from left (1) or right
(2) fuel tank (Figure 3).
Test
Steering
PTO
Lever
1
Neutral
Parking
Engine
Open the valve to operate the engine. Turn the valve to
"Off" (3) when storing or transporting the unit.
Brake
Off
Engaged
Starts
Off
Engaged
Doesn’t
WARNING: Fuel is highly flammable and its
vapors are explosive. Handle with care. NO
smoking, NO sparks, NO flames.
Lockout
Position
2
Forward
To add fuel to the fuel tank:
1. ALWAYS place unit in open or well ventilated area.
Start
3
Neutral
On
Engaged
Lockout
2. Stop engine and allow to cool for two minutes.
Doesn’t
Start
3. Clean fuel caps and surrounding area to prevent
dust, dirt, and debris from entering fuel tanks.
Position
4
Out of
4. Remove fuel caps.
Off
Disengaged
Neutral
Lockout
Position
Doesn’t
Start
5*+
Reverse
Off
Disengaged
Shuts Off
6*+
Neutral
Lockout
Position
On
Engaged
Shuts Off
7*+
Out of
Neutral
Lockout
Position
Off
Disengaged
Shuts Off
IMPORTANT: See Engine Manual for correct type and
grade of fuel.
5. Fill fuel tanks to 1/2 in. (1.3 cm) below bottom of
filter neck. See Specifications for capacity of fuel
tanks.
6. Replace fuel caps.
7. ALWAYS clean up any spilled fuel before starting
the engine.
4.3 MAINTENANCE SCHEDULE
CAUTION: Before performing any service or
adjustments:
* Test with engine running.
• Turn PTO switch "OFF".
+ Operator lifts off seat.
• Park mower on a hard, flat, level surface.
• Place steering control levers in neutral
lock (fully outward) position.
• Set parking brake.
• Turn ignition switch "OFF" and remove
key.
• Wait for blades and all moving parts to
stop.
WARNING: AVOID INJURY. Read and
understand the entire Safety section before
proceeding.
4-9
IMPORTANT: Proper maintenance can prolong the life
of unit. The following chart shows the recommended
service schedule. Refer to the maintenance
instructions in the Engine Manual for additional
information.
1
7
NOTE: To access the cooling system, fuel filter, oil
drain petcock, and oil fill/dipstick, the seat must be
tipped forward.
2
NOTE: To access the air filter, open the hood.
6
3
NOTE: Use Figure 4 to locate items called out in the
maintenance schedule.
4
5
1. Cooling System
4. Oil Filter
2. Air filter (precleaner
and cartridge)
5. Spark Plug
3. Fuel Filter
7. Oil Fill/Dipstick
6. Oil Drain Petcock
Figure 4
Interval
Each Use
Task
Action
Check Safety Interlock
System
WARNING: 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.
Check Parking Brake
Engage parking brake and engage transmission bypass
lever. Push unit. If unit rolls, contact your Ariens/Gravely
Dealer.
Clean Unit
Clean engine battery, seat, mower deck, etc. of all dirt and
debris. Do not use solvents, hard cleaners, or abrasives.
NOTE: Protect painted surfaces with automotive type wax.
Check Tires
See Specifications for correct tire pressure.
Check Mower Blades
Check for worn or damaged mower blades.
Check Engine Oil
Use oil fill/dipstick to check engine oil level. Add engine oil if
needed, refer to Engine Manual for detailed instructions.
Check Battery
Keep battery and battery terminals clean.
Lubricate Unit
Apply grease to the two
front wheel zerks.
Zerk
25 Hours or Every Season
OE0046
Clean Air Filter Precleaner1
Clean air filter precleaner. Refer to Engine Manual for
detailed instructions.
4 - 10
Interval
Task
Action
Change Engine OIl2
Drain engine oil by opening oil drain petcock. Refer to
Engine Manual for detailed instructions.
Check Fasteners
Check mower blade mounting hardware and all other
fasteners. Replace fasteners that are missing or damaged.
Tighten all nuts and bolts to the correct torque value.
Inspect Muffler and Spark
Arrestor
Replace muffler and (if equipped) spark arrestor if corroded.
Contact your Ariens/Gravely Dealer.
Clean Air Filter Cartridge1
Clean air filter cartridge. Refer to Engine Manual for detailed
instructions.
Change Oil Filter
Clean oil filter. Refer to Engine Manual for detailed
instructions.
Replace Spark Plug
Replace spark plug. Refer to Engine Manual for detailed
instructions.
Replace Fuel Filter
Replace fuel filter. Refer to Engine Manual for detailed
instructions.
Clean Cooling System1
Clean cooling system. Refer to Engine Manual for detailed
instructions.
Check All Belts
Replace worn or deteriorated belts.
• Check hydrostatic belt (see Hydrostatic Belt
Replacement).
• Check PTO belt (see PTO Belt Replacement).
Clean/Replace Spark Plugs
Clean/replace spark plugs. Refer to Engine Manual for
detailed instructions.
Clean/Replace Fuel Filter
Clean/replace fuel filter. Refer to Engine Manual for detailed
instructions.
50 Hours or Every Season
100 Hours or Every
Season
Yearly
1
Service more often when operating under heavy loads, high temperatures, or dusty conditions. Replace air filter precleaner
and cartridge if very dirty.
2
Change after first 5 to 8 hours of use. Change every 25 hours when operating under heavy loads or in high temperatures.
4 - 11
4.4 REMOVE MOWER DECK
1
Remove (Figure 5)
2
3
1. Remove PTO belt from electric clutch.
NOTE: Perform step 2 and 3 for the right and left side
of unit.
2. Remove guide arm from front mount bracket.
3. Remove rear lift link, rear trunnion, front lift link,
and front trunnion from mower deck and mower lift.
4. Slide mower deck out from under unit.
Install (Figure 5)
1. Slide mower deck under unit.
NOTE: Perform step 2 and 3 for the right and left side
of unit.
1. Adjustment Pin
2. Mower LIft Pedal
2. Install rear lift link, rear trunnion, front lift link, and
front trunnion on mower deck and mower lift.
Figure 6
3. Install guide arm on front mount bracket.
NOTE: The rear blade cutting height should be 2-7/8 to
3 in. (7.3 to 7.6 cm) from rear edge of mower blades to
the ground on both blades.
4. Install PTO belt.
3
2
4
5
2
3. Fourth Adjustment
Hole
6
IMPORTANT: The distance from rear edge of mower
blades to the ground MUST NOT exceed 3 in. (7.6 cm)
(Figure 7).
1
Mower Deck Shown From The Side
2
1
3
6
5
1. Mower Deck
9
8
7
1. Mower Deck
6. Front Mount Bracket
2. Mower Lift
7. Front Trunnion
3. PTO Belt
8. Rear Lift Link
4. Guide Arm
9. Rear Trunnion
4
2. Mower Blade(s)
4. Front Blade Cutting
Height
3. Front of Mower Deck
5. Ground
6. Rear Blade Cutting
Height
Figure 7
OA0010
3. Measure from rear edge of mower blades to the
ground.
5. Front Lift Link
Figure 5
4. Perform steps 5 through 7 if the measurement is
too high or too low on either side of mower deck.
4.5 LEVEL AND ADJUST PITCH OF
MOWER DECK
5. Remove rear lift link and rear trunnion from mower
deck and mower lift.
Adjust on a level surface, with the tires inflated to the
correct air pressure.
• TO RAISE the mower deck, turn rear trunnion
clockwise several turns.
Level Mower Deck
• TO LOWER the mower deck, turn rear trunnion
counterclockwise several turns.
1. Install adjustment pin in the fourth adjustment hole
(Figure 6).
2. Rotate the right and left mower blades until the
ends of both mower blades are facing rearward
(Figure 7).
6. Install rear trunnion and rear lift link on mower deck
and mower lift.
7. Check that the mower deck is level:
a. Rotate right and left mower blades to face sideto-side.
4 - 12
b. Measure outer edge of mower blades to ground.
Measurement must be within 1/4 inch (6.35 mm).
• If mower deck is not level, repeat steps 5 and 6.
• If mower deck is level, record the distance from
rear edge of mower blades to the ground and then
adjust pitch of mower deck.
Adjust Pitch of Mower Deck
To adjust the neutral setting for no wheel rotation:
4. Use a hex wrench to loosen the locking bolt (Figure
8) until the linkage can be rotated by hand.
5. With the engine running and the drive wheels off
the ground, rotate the linkage in either direction.
The correct linkage position is obtained when the
wheel is not being driven (under power).
6. Hold the linkage in place and tighten the locking
bolt.
IMPORTANT: The mower blade end used to level the
mower deck must be used to adjust the pitch of the
mower deck.
7. Shut off engine and reconnect steering rods.
1. Rotate the right and left mower blades 180 degrees
until the end of the mower blade that was used to
level the mower deck is facing forward (Figure 7).
8. Check parking brake linkage for proper movement.
1
NOTE: The front blade cutting height should be 1/16 1/4 in. (1.59 - 6.35 mm) lower than the rear blade cutting height (Figure 7).
4
3
2. Measure from front edge of right and left mower
blades to the ground.
3. Subtract front blade cutting height measurement
from rear blade cutting height measurement
(Figure 7).
4. Perform steps 5 though 7 if the front blade cutting
height is too high or too low on either side on either
side of mower deck.
2
5. Remove front lift link and front trunnion from mower
deck and mower lift (Figure 5).
1. Locking Bolt
2. Reverse Arm
• TO RAISE the mower deck, turn front trunnion
clockwise several turns.
3. Forward Arm
4. Return Spring
Figure 8
• TO LOWER the mower deck, turn front trunnion
counterclockwise several turns.
6. Install front trunnion and front lift link on mower
deck and mower lift.
4.7 ADJUSTING UNIT TO TRACK
STRAIGHT
7. Check mower deck pitch.
Tires must be inflated to specifications, drive units
should be adjusted for neutral.
• If mower deck pitch is not correct, repeat steps 2
through 6.
NOTE: Before making the following adjustments;
check the dampener on each of the steering handles. It
is possible that the fixed position of the dampener is
limiting the travel of the steering arm. To adjust the
dampener arm; loosen the dampener anchor nut to
allow movement. Tighten when done.
• If mower deck pitch is correct, the adjustment is
complete.
4.6 HYDROSTATIC TRANSMISSION
NEUTRAL ADJUSTMENT
1. Shut off engine.
1. Start engine and warm up hydraulics.
2. Position rear wheels off the ground. Be careful to
secure the unit to the lift or position the unit to face
a wall for safety. Disconnect the rods from the
handlebars to the linkage.
2. Operate the unit and position it with adequate
running space.
3. Engage seat switch and start the engine.
Disengage the parking brake. The drive wheels
should not be rotating. If the wheels are not driven
to rotate, proceed to Steering Control Neutral
Adjustment.
3. Push both handles to full forward. The unit should
travel in a straight line. If the unit steers to one
side, adjustment is needed. Make note of which
way the unit is turning. Adjustment will be made to
the drive unit on the opposite side off the direction
of the turn. This is the faster wheel.
4. Loosen the jam nuts on the transaxle rod.
5. Screw the nyloc jam nut further down one or two
turns (depending on the amount of turning that
needs correction).
4 - 13
6. Move top jam nuts down to tighten on the nyloc
jam nut. Tighten the jam nuts against each other.
7. Return to step one and repeat until the unit tracks
straight.
2
1
3
6
2
1
3
5
4
1. Rod Transaxle
2. Switch
3. Jam Nuts
4. Nyloc Jam Nut
5. Handlebar
6. Dampener
Figure 9
4.8 STEERING LEVER ADJUSTMENTS
Adjusting Steering Levers to Match (Figure 10)
NOTE: Each steering lever can be positioned further
forward or further backward.
1. Loosen mounting hardware.
2. Position steering levers to match.
3. Tighten mounting hardware.
Adjusting Height of Steering Levers (Figure
10)
There is a low and a high position for steering levers.
Remove mounting hardware and place steering levers
in the low or high position.Tighten mounting hardware.
4 - 14
1
4
2
3
1
2
High
Position
Low Position
2
1
1. Steering Lever
2. Mounting Hardware
1. Nyloc Adjusting Nut
2. Parking Brake Rod
Figure 10
4.9 ADJUSTING THE PARKING BRAKE
3. Handle
4. Safety Switch
PE0831
When properly adjusted the parking brake will lock the
linkage on both drives and activate the safety switch
(Figure 11).
The drive units should be properly adjusted for neutral.
Engage the parking brake handle. The brake rod
should be positioned to lock the drive. The safety
switch should be disengaged.
To adjust the linkage:
Move the adjusting nut clockwise/counterclockwise as
needed to properly position the brake shaft.
NOTE: The safety switch can be loosened for minor
adjustments.
4 - 15
Figure 11
SECTION 5 - ENGINE
5.1 ENGINE TROUBLESHOOTING
The following troubleshooting chart is to be used to
isolate engine problems and give possible causes and
corrective action responses.
TROUBLE
The troubleshooting key is generic and can be used for
several types of engines. Use only those possible
causes and corrective actions that apply to the
unit.
Black Exhaust
Blue/White Exhaust
Difficult Starting
Erratic Running
Excessive Fuel Consumption
Excessive Crankcase Pressure
High Oil Pressure
Knocking
Loss of Power or System
Low Cranking Power
Low Oil Pressure
Misfiring
Overheating
Poor Compression
Starts and Stops
POSSIBLE CAUSES
(Refer to Key Below)
1, 20, 22, 25, 29, 31, 32, 33
4, 20, 25, 31, 33, 34
1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33
1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62
1, 20, 22, 23, 25, 29, 31, 32, 33
25, 31, 33, 34, 45, 55
4, 41
22, 26, 29, 31, 33, 36, 46, 59
1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33
2, 3, 4, 11
4, 36, 37, 39
10, 20, 25, 26, 28, 29, 32
1, 19, 25,
25, 28, 29, 31, 32, 33, 34,59,
1, 6, 10, 62
Vibration
Will Not Crank
Will Not Start
20, 23, 25, 26, 29, 33, 45, 49
2, 11, 45
1, 10, 62
CORRECTIVE ACTION
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
see electrical systems
see engine service manual
repair or replace
charge battery or replace
repair or replace
see electrical systems
see engine service manual
TROUBLESHOOTING KEY
1
2
3
4
5
6
7
22
23
24
25
26
27
28
Incorrect grade of fuel
Sticking throttle/restricted movement
Exhaust pipe restriction
Leaking cylinder head gasket
Overheating
Cold running
Incorrect tappet adjustment
43
44
45
46
47
48
49
29
30
31
32
33
34
35
Sticking valves
Incorrect high pressure pipes
Worn cylinder bores
Pitted valves and seats
Broken, worn or sticking piston ring(s)
Worn valve stems and guides
Restriction in air cleaner
50
51
52
53
54
55
56
36
Worn or damaged bearings
57
Faulty suction pipe
Choked oil filter
Bad solenoid switch
Incorrect piston height
Damaged fan
Faulty engine mounting
Incorrectly aligned flywheel and/or
flywheel housing
Faulty thermostat
Restriction in water jacket
Loose fan belt
Choked radiator
Faulty water pump
Choked breather pipe
Damaged valve stem oil deflector (if
fitted)
Coolant level too low
37
38
Insufficient oil in sump
Bad/defective oil temperature switch
58
59
Blocked sump strainer
Broken valve spring
18
19
Restriction in air cleaner
Bad electrical connection
Faulty starter motor
Incorrect grade of lubricating oil
Low cranking speed
Fuel tank empty
Controls not in correct
operation position
Blocked fuel feed line
Faulty fuel lift pump
Choked fuel filter
Battery capacity low
Air in fuel system
Faulty fuel injection pump
Faulty fuel injectors or incorrect
type
Incorrect use of cold start
equipment
Faulty cold start equipment
Broken fuel injection pump
drive
Incorrect fuel pump timing
Incorrect valve timing
39
40
Oil pump worn
Pressure relief valve sticking open
60
61
20
21
Poor compression
Blocked fuel tank vent
41
42
Pressure relief valve sticking closed
Broken relief valve spring
62
Exhaust or vacuum pipe leak
Bad or defective water temperature
switch
Bad spark plug(s)
8
9
10
11
12
13
14
15
16
17
5 - 16
5.2 CHECKING ENGINE OIL
13.Check for leakage at the drain plug and oil filter if
used. Tighten the fittings as necessary if leakage
occurs.
Check the engine oil daily prior to use.
IMPORTANT: Never operate the engine with the oil
below the low mark on the dipstick.
14.Release the parking brake.
15.Return the unit into service.
See the engine manual for oil specifications and oil
filter service instructions.
5.4 CHECKING ENGINE COOLING
To check oil level:
1. Move the unit to level location.
2. Clean around the dipstick and filler tube to prevent
dirt from entering the engine.
3. Remove the dipstick and wipe off the oil on the
dipstick.
IMPORTANT: To prevent severe damage to the
engine, proper cooling will need to be maintained.
1. Check the air intake screen on the engine each
day.
2. The air intake screen must be kept clean. Remove
any grass, dirt, or debris that may have
accumulated.
4. Put the dipstick back into the engine and tighten
the place and remove again.
5. When the dipstick is removed, note the oil level. Oil
should be between the full and add mark.
3. Check the engine cooling yearly.
5.5 CLEANING THE AIR CLEANER
6. Replace dipstick.
1. Check the air cleaner element every day.
7. If required, add 5W30 below 40o or 30W above
40o. Do not overfill.
2. Clean the air cleaner precleaner every 25 hours.
See your engine manual for instructions.
8. Clean up any spillage that may have occurred.
3. Apply oil and reinstall over the paper air filter
element.
5.3 CHANGING OIL
WARNING: Do NOT touch parts which are
hot. Allow parts to cool before servicing.
Engine muffler and other parts will be hot if unit has
been running.
1. Engine oil should be changed after the first five
hours of operation and every 25 hours there after.
2. Move the unit to a level and well ventilated area
and set the parking brake.
4. Wipe out the air cleaner cover to remove any dirt
build up in the cover.
5. Reinstall the cover over the air cleaner prior to
operating the engine. See your Engine Manual.
5.6 CHANGING THE AIR CLEANER
ELEMENT
Replace the air cleaner element when clogged or every
100 hours. Do not attempt to clean. See your Engine
Manual for instructions.
3. If the engine is cold, let the unit run for five
minutes.
5.7 INSPECT MUFFLER/SPARK
ARRESTER
4. When the engine is warm, stop the engine.
5. Clean the area around the dipstick and (drain
hose).
Inspect muffler and (if equipped) spark arrester.
Replace muffler if corroded, as it could create a fire
hazard and/or damage.
6. Put an open container that will hold one gallon of
oil under the drain hose.
5.8 REPLACE SPARK PLUGS
7. Open the drain valve.
8. Allow the engine oil to drain completely into the
one gallon container. Remove container and
contents for future recycling as required.
9. Close the oil drain valve.
10.If used; remove the oil filter.
11.Clean the oil filter port and install a new oil filter
according to the instructions on the oil filter. Fill
with new oil to the "full" mark on the dipstick.
12.Start and run the engine for one minute. Stop the
engine and recheck the oil level and add as
necessary.
Spark plug type and gap setting are shown in
Specifications. See Engine Manual for detailed
instructions.
5.9 ENGINE REMOVAL
1. Remove deck.
2. Remove the hood from the units engine.
3. Remove the negative cable from the battery.
4. Remove the main drive belt from the engine
sheave by releasing the idler tension spring.
5 - 17
5.10 ENGINE INSTALLATION
5. Remove the throttle and choke control from the
engine.
6. Remove the electrical wiring from the engine
(charge lead, starter cable, fuel solenoid lead, and
magneto kill wire).
7. Remove fuel line from engine first. Drain fuel from
line back into fuel tank.
1. Check the engine base and unit frame for damage
before installing the engine.
2. Place the throttle and choke controls, fuel line, and
electrical wires out of the way prior to installing the
engine.
3. Once the engine is bolted onto the frame, tighten
the mounting hardware.
8. Disengage the idler spring and remove the drive
belt.
4. Install the engine sheave, belts, springs, electrical
wiring, throttle, and choke controls.
9. Remove the electric clutch and the anti-rotation
bolt.
10.Remove the engine bolts.
5. Place the drive belt in position and replace the
tension spring.
11.Lift engine out of the unit and off the frame with a
hoist (engine).
6. Install the negative battery cable onto the battery.
12.Service, overhaul, or replace engine as required.
8. Fill engine with 30W above 32oF (0oC) or 5W30
below 32oF (0oC).
7. Install the fuel line.
13.If replacing engine with a new engine, the following
items will have to be removed (if used) from the old
engine. These items will not be included with a new
engine.
9. Install the engine cover, then test operation and
function of the engine.
Engine sheave and key, mounting hardware, and
engine wiring harness.
WARNING: AVOID EXHAUST FUMES! DO
NOT run engine in an enclosed area.
ALWAYS provide good ventilation and wait
until hazard has been removed.
10.Check the fluid levels as follows:
a) Start the engine and allow it to reach to
operating temperature. DO NOT operate engine
for more than two minutes.
b) Shut the engine off, wait for engine to cool, and
be sure the engine oil level is between the full and
add marks on the dipstick. If it is below the ad
mark, add recommended oil. DO NOT overfill.
1
3
MACHINE
BACK
2
4
1. Oil Drain Tube
2. Idler Pulleys
3. Spring
4. Drive Belt
PE0760
Figure 12
5 - 18
SECTION 6 - MOWER DECK
2
CAUTION: Before performing any service or
adjustments:
3
4
6
5
1
• Turn PTO switch "OFF".
• Park mower on a hard, flat, level surface.
• Place steering control levers in neutral
lock (fully outward) position.
• Set parking brake.
• Turn ignition switch "OFF" and remove
key.
• Wait for blades and all moving parts to
stop.
• Disconnect spark plug wire(s) from spark
plug(s) and place wire(s) away from plug.
7
1.
2.
3.
4.
5. Idler Pulley
6. Idler Arm
7. Belt Cover
Idler Spring
Electric Clutch
PTO Belt
Idler Hole
Figure 13
WARNING: AVOID injury from stored energy
in lift assist spring. DO NOT unlock
attachment lift lever with mower deck
removed. ALWAYS engage attachment lift
lever lock when removing mower deck.
OE0080
6.2 CHECK BLADES
For best results mower blades must be kept sharp.
Replace bent, worn or damaged blades.
Removal (Figure 14)
CAUTION: Use care when releasing idler
spring tension. Keep body parts well away
from idler when performing this operation.
WARNING: MOVING PARTS can cut or
amputate body parts. ALWAYS wait for
moving parts to stop before unit maintenance
or service.
1. Block mower blades to prevent rotation.
6.1 CLUTCH TO DECK DRIVE BELT
REPLACEMENT
Remove (Figure 13)
1. Lower mower deck to the ground.
2. Remove belt covers from mower deck.
CAUTION: Use care when releasing idler
spring tension. Keep body parts well away
from idler when performing this operation.
2. Remove mounting hardware and mower blades
from mower deck.
Install (Figure 14)
1. Install mower blades on mower deck with mounting
hardware.
2. Torque 5/8" hex bolt to 80 to 120 lb-ft (108 to 163
Nm).
3. Hook a puller into idler hole and pull idler arm
towards outside of unit until tension is removed
from PTO belt.
4. Remove PTO belt from left mower deck pulley.
Install
Install in reverse order.
6 - 19
2
1
DO NOT Sharpen to this Pattern
4
Sharpen to this Pattern
3
1. Flat Washer
2. Bevel Washer
DISCARD if
more than
1/2 in.
(1.27 cm)
3. 5/8" Hex Bolt
4. Mower Blade
Figure 14
OE0039
1
6.3 SHARPENING MOWER BLADE
1. Air Lift Erosion Area
2. Cutting Edge
CAUTION: DO NOT sharpen mower blade
while on unit. An unbalanced mower blade will
cause excessive vibration and eventual
damage to unit. Check mower blade balance
prior to reinstalling mower blades. NEVER
weld or straighten mower blades.
Figure15
1. Remove mower blade from unit.
Ariens recommends having mower blades sharpened
by a professional. Contact your Ariens/Gravely dealer.
Discard mower blade if (Figure 15):
• more than 1/2 in. (1.27 cm) of metal is removed.
• the air lift erosion area is eroded.
• the mower blade is bent or broken.
Do not change angle of cutting edge or round the
corner at the end of mower blade.
2. Sharpen mower blade by removing an equal
amount of material from each end of mower blade.
3. Check mower blade balance by sliding mower
blade on an unthreaded bolt. If blade is balanced, it
should remain in a horizontal position. If either end
of mower blade moves downward, sharpen the
heavy end until mower blade is balanced.
4. Install mower blade on unit.
6 - 20
2
SECTION 7 - DRIVE TRAIN
7.1 HYDRO TRANSMISSION TROUBLESHOOTING
The following troubleshooting chart is to be used to
isolate hydro transmission problems and give possible
causes and corrective action responses.
TROUBLE
Axles Will Not Turn
Difficult Starting
Erratic Running
Jerky When Starting
Jumps Out of Gear
Knocking
Loss of Power or System
Noisy
Oil Leakage
Operates Hot
Operates in One Direction Only
Pump Failure
Speed Loss Under Load
Speed Loss Under Load
Will Not Drive
Will Not Shift
The troubleshooting key is generic and can be used for
several types of transmissions. Use only those
possible causes and corrective actions that apply to the
unit.
POSSIBLE CAUSES
CORRECTIVE ACTION
(Refer to Key Below)
1, 7, 8, 12, 16, 18, 28, 32, 38, 42, 46
1, 6, 7, 8, 12, 16, 25, 26, 28, 38, 42, 46
1, 4, 6, 7, 8, 12, 18, 25, 26, 28, 42, 46, 55
1, 4, 7, 8, 12, 18, 28, 38, 46
N/A
4, 8, 12, 18, 28, 37, 42
4, 12, 18, 28, 37, 42, 46
4, 12, 18, 26, 28, 32, 37, 42
4, 22, 51, 16
4, 16, 28, 32, 35, 42
1, 8, 12, 30, 46
4, 12, 37
1, 6, 11, 28, 37, 46, 51
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
1, 4, 7, 12, 18, 28, 26
1, 7, 8, 18, 28, 37, 38, 46, 48
repair or replace
repair or replace
TROUBLESHOOTING KEY
1
2
3
4
5
6
17
Inspect control linkage
Inspect acceleration valves
Inspect charge check valves
Incorrect grade of lubricating oil
Low cranking speed
Controls not in correct operation
position
Belts are missing, to tight, loose or
glazed
Overload of vehicle
Replacement parts damaged
Replacement parts improperly
installed
Improperly torqued attaching screws
Air in hydraulic system
Broken shifter stop
Inspect charge check valves
Inspect acceleration valves
Check oil level-gear box sump or
reservoir
Inspect heat exchanger
18
19
20
21
Inspect by-pass valve
Inspect charge pressure
Inspect inlet filter
Inspect charge relief valve
7
8
9
10
11
12
13
14
15
16
22
23
24
25
26
27
Inspect hoses and lines for wear
Inspect implement relief valve
Inspect charge pump
Bad transmission pump
Overheating
Cold running
43
44
47
48
49
50
Burrs on gearing
Gears improperly installed
Shifting washer in backwards
Shifter/Brake shaft keyways damaged
Unit clutch not disengaging
Shifter stop assembled backwards
28
Bad transmission motor
51
Improper fit of case to cover
29
30
31
Check system pressure
Shift rod grooves worn
Reverse chain broken
52
53
54
Dowel pins not installed
Differential bevel gears broken
Spring in shifter weak or broken
32
33
34
35
36
37
Damaged cooling fan
55
Inspect auxiliary relief valve
Inspect cooling fan
Inspect transmission cooling fins
Worn or damaged bearings
Metallic pieces or foreign objects in unit
38
Inspect for loosely mounted
components
Steering column loose or binding
Pressure relief valve sticking open
Pressure relief sticking closed
Broken relief valve spring
39
40
41
42
7 - 21
Worn or stripped gear teeth
7.2 HYDROSTATIC BELT REPLACEMENT
Remove (Figure 16)
7.3 HYDRO-GEAR FLUID
RECOMMENDATIONS
The fluids used in Hydro-Gear transaxles have been
carefully selected, and only equivalent or better
products should be used.
1
9
Typically, an engine oil with a minimum rating of 55 sus
at 210oF and an API classification of SH/CD is
recommended. A 20W-50 engine oil has been selected
for use by the factory.
2
8
3
4
7.4 HYDRO-GEAR TRANSMISSION
REMOVAL
2
5
6
7
1. Place the unit on a flat surface and remove the
negative lead from the battery and the spark plug
lead from the spark plug.
2. Remove key and spark plug wire.
3. Raise and block the unit frame on jack stands
behind of the transaxle in the frame.
1. Hydrostatic Belt
5. Bracket
2. Hydrostatic
Transmission Pulley
6. Electric Clutch
3. Electric Clutch
Connector
8. Idler Spring
4. Pulley
7. Idler
9. Anchor Bolt
Figure16
4. Remove the rear wheels by removing the lug nuts
holding the wheels to the axle hub.
5. Release the transmission belt tension spring and
remove the transmission belt from the input sheave
on top of the transaxles.
6. Release the parking brake control rod by pulling
the hair pin and releasing the tension spring at
locking gear.
2. Disconnect electric clutch connector.
7. Remove the single locknut on the shift rod and
remove the shift rod from the transaxle arm. Do not
move the two jam nuts.
3. Remove bracket.
8. Take knob off of dump valve arm.
1. Remove PTO belt.
CAUTION: Use care when releasing idler
spring tension. Keep body parts well away
from idler when performing this operation.
4. Disconnect idler spring from anchor bolt.
5. Remove hydrostatic belt from hydrostatic
transmission pulleys, pulley, electric clutch, and
idler.
Install (Figure 16)
9. Do not remove or loosen the hardware on the
transaxle subframe at this point.
10.Support the transaxles subframe with a floor jack
from the rear of the tractor.
11.Remove the right and left anchor bolts holding the
transaxle subframe to the tractor frame and lower
jack.
12.With the transaxle assembly removed from the
units frame, place the axle assembly on a flat work
surface.
1. Install hydrostatic belt on idler, electric clutch,
pulley, and hydrostatic transmission pulleys.
2. Connect idler spring to anchor bolt.
3. Install bracket.
4. Connect electric clutch connector.
5. Install PTO belt.
7 - 22
7.6 ELECTRIC CLUTCH ADJUSTMENT
WARNING: The mower blades MUST STOP
in 5 seconds or less when the PTO is
disengaged. Adjust or replace electric clutch
as required.
3
Test Mower Blade Stopping Time (Figure 18)
1
2
2
1
4
1. Transaxle, Right Hand
3. Dump Rod
2. Transaxle, Left Hand
4. Axle Brace
1. Electric Clutch
2. PTO Belt
Figure 18
OE0080
To determine if the PTO stops the mower blades within
5 seconds or less, measure the amount of time from
when the PTO is shut off to when the PTO belt stops
rotating.
Figure17
7.5 HYDRO-GEAR TRANSMISSION
INSTALLATION
1. Lower mower deck to the lowest position.
Install the transaxle assembly into the tractor frame
with the axle subassembly installed.
2. Start engine and set throttle lever to FAST.
3. Engage PTO to start mower blades.
1. Make sure the brake rod has two flat washers and
a heavy coil spring installed on it before inserting
the transaxle into the tractor frame.
4. Shut off PTO and simultaneously start measuring
the amount of time it takes for the PTO belt to stop
rotating.
2. Lift transaxle assembly up into the frame.
• If the PTO belt stops rotating in 5 seconds or less,
the electric clutch does not need to be adjusted.
Do not tighten any hardware until all the support
hardware is installed.
3. When all the hardware is in place, tighten.
4. With the two flat washers, compression spring and
hair pin on the rear of the brake rod, put rod
through transaxle linkage and tighten bottom nut
up the rod.
• If the PTO belt does not stop in 5 seconds or less,
adjust the electric clutch.
5. Install the transmission drive belt on the transaxle
input sheave and check the belt routing on the idler
arm and engine pulley and install idler arm tension
spring.
6. Install the dump valve rod and attach the ball knob.
7. Install the rear wheels with the lug nuts removed
earlier.
8. Check for neutral adjustment and parking brake
engagement.
7 - 23
Adjust Electric Clutch (Figure 19)
Test Electric Clutch
1. Start unit, engage and disengage PTO two or three
times.
2
1
2. Stop engine, set parking brake, remove ignition
key, and wait for all hot parts to cool.
3. Recheck air gap between armature and rotor.
Adjust air gap if needed.
4. Retest mower blade stopping time:
3
6
4
5
1. Armature
2. Inspection Slot
3. Gap Adjustment Nut
3
• If mower blades stop in 5 seconds or less, the
electric clutch is functioning correctly.
• If mower blades DO NOT stop in 5 seconds or
less, the electric clutch MUST be replaced. Contact
your Ariens/Gravely dealer.
4. Air Gap
5. Electric Clutch
6. Rotor
Figure 19
OE0070
NOTE: Ariens/Gravely recommends having the electric
clutch adjusted by a professional. Contact your Ariens/
Gravely dealer.
If the electric clutch fails to engage or disengage
properly, begins to make an abnormal noise, or if the
mower blade stopping time is too high, check the air
gap at the three inspection slots.
Inspect air gap:
1. Stop engine, set parking brake, remove ignition
key, and wait for all hot parts to cool.
2. Measure air gap between armature and rotor.
• Minimum: A 0.005 in. feeler gauge should slide
between armature and rotor with slight contact.
• Maximum: A 0.023 in. feeler gauge should slide
between armature and rotor with slight contact.
Adjust air gap:
NOTE: Adjust air gap as evenly as possible.
1. Loosen gap adjustment nut closest to inspection
slot.
2. Slide a 0.012 in. feeler gauge between armature
and rotor.
3. Tighten gap adjustment nut until there is a slight
contact on feeler gauge.
4. Repeat steps 1 through 3 for each inspection slot.
Be certain to adjust all three locations.
7 - 24
SECTION 8 - LIFT SYSTEM
8.1 LIFT SYSTEM
Refer to Figure 20.
The mower pan lift system is a manual lift system
controlled by the operator.
3
1
3
2
1. Foot Pedal Lift
2. Lift Assembly
3. Linkage
Figure 20
PE0910
Lower deck onto blocks to remove weight from lift
system.
Check snap rings, bushings, and cotter pins for wear.
Replace worn and defective parts as needed.
8 - 25
SECTION 9 - FUEL SYSTEM
9.1 FUEL SYSTEM TROUBLESHOOTING
The following troubleshooting chart is to be used to
isolate fuel system problems and give possible causes
are corrective action responses
TROUBLE
Hard Starting
Fuel Leak at Carburetor
Engine Floods
Will not idle
Rich idle
idles with Needle Closed
Hunts Erratic Idle
Idles Fast Lean
Will Not Accelerate
Over Rich Acceleration
Hesitates
Will Not Run at High Speed
Low Power
Hunts at High Speed
Runs With Needle Closed
Engine Overspeeds
The troubleshooting key is generic and can be used for
several types of transmissions. Use only those
possible causes and corrective actions that apply to the
unit.
POSSIBLE CAUSES
(Refer to Key Below)
1, 3, 4, 6, 11, 12, 14, 16, 17, 18
5, 7, 17
5, 15, 17
1, 2, 3, 6
1, 6, 14
14
2, 3, 6, 7, 12, 13, 14, 15, 18
2, 3, 7
1, 6, 11, 12, 14, 15, 16
1, 15
2, 6, 11, 12, 16
1, 11, 12, 14, 16
1, 3, 11, 14, 15, 16, 17, 18
3, 6, 7, 12, 14, 15, 16, 18
14
2, 3, 7, 14
TROUBLESHOOTING KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Plugged Air Filter
Leaky Carburetor Gasket
Throttle or Choke Shaft Worn
Choke Not Functioning
Properly
Plugged Atmospheric Vent
Air Bleed Restricted
Damaged or Leaky "O" Rings
Damaged Diaphragm
Stuck or Dirty Ball Check
Diaphragm Upside Down
Plugged Tank or Vent
Fuel Pick-up Restricted
Idler Port Restricted
Damaged Adjustment Needle
and Seat
Incorrect Float Height
Main Nozzle Restricted
Dirty, Stuck Needle and Seat
Fuel Inlet Plugged
9 - 26
CORRECTIVE ACTION
clean, repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
9.2 FUEL PUMP
The impulse style fuel pump is the most commonly
used fuel pump. Impulse fuel pumps may either be
mounted externally onto the carburetor fuel inlet or
remotely mounted. These pumps are connected in the
fuel line between the fuel supply and the carburetor or
directly to the fuel inlet.
Impulse fuel pumps are operated by crankcase
impulses created by the up and down movement of the
piston. A hose called a pulse line connects the fuel
pump diaphragm chamber and transmits the impulses
to the pump diaphragm. The impulses actuate the
diaphragm and the flap valves to lift the fuel from the
fuel tank to the carburetor.
1
915038, 039, 040, 041, 313
915034, 035, 036, 037
2
9.3 FUEL SYSTEM CONTAMINATION
Any time fuel contamination is found in the fuel system
(dirt, water algae, etc.) replace the fuel, fuel filter and
flush the fuel lines. Remove the carburetor bowl and
clean. Replace all items that cannot be cleaned.
Reassemble the fuel system and check for proper
operation.
9.4 FUEL TANK
The fuel tank is made of composite material for long life
without breaking down from the additive used in
today’s blended fuels.
To Remove (Figure 21)
1. Shut off fuel.
2. Remove control panel.
3. Disconnect fuel line.
4. Loosen top bolts.
5. Remove bottom bolts.
To Install
The fuel tanks are installed in reverse order.
9 - 27
1. Fuel Valve
2. Control Panel
Figure 21
PE0820
SECTION 10 - ELECTRICAL
10.1 TOOLS
10.2 ELECTRICAL MEASUREMENTS
There are some specialized tools and test equipment
that are needed for electrical repair work. A brief
description of these follows.
Long or needle nose pliers - used to connect or bend
wires and connectors in close quarters.
Diagonal cutters - used to cut wires or trim connections.
Wire stripper/crimping tool - available separately or
as a combination tool. Used to strip insulation from
wires of various sizes, crimp terminals and connector
or wires.
Soldering gun or soldering iron - used to solder all
splices and connections to terminals, connector, etc. A
soldering gun is faster and more convenient that waiting for a soldering iron to heat.
Multimeter - analog or digital, to measure voltage,
amperage and ohms.
Tachometer - used to measure engine speed.
Required to properly test alternator and charging circuits where output is dependent upon engine speed.
Heat gun - used to shrink insulated tubing in place.
Used to replace electrical tape or insulated sleeving. To
use, place a piece of shrink tubing over a wire joint,
heat with the heat gun, until it shrinks slightly around
the joint.
Supplies - electrical tape, rosin core solder (never use
acid or acid core solder on electrical joints), an assortment of various size terminals, connectors, insulated or
heat shrink tubing (for use on joints and connections),
and an assortment of automotive type wire (in several
colors).
Ariens/Gravely Company recommends that all work be
done in a professional manner. The use of the tubing to
cover joints and the soldering of connections contribute
to a professional looking job. In addition to a pleasing
appearance, repairs made in this manner are more
likely to withstand vibration. (The weakest points in an
electrical system are the joints where wires are
attached.)
Replace all defective components with Ariens/Gravely
replacement parts only. Engine parts, such as rectifiers
or alternator components should be secured through
the nearest engine service center.
Ariens/Gravely Company does not recommend
attempting to repair electrical components. Most do not
lend themselves to repair and you would have more
money invested in "time of repair" than the part would
cost and the results may not be as good.
In many electrical circuits, there is some visible effect
which indicates that the circuit is functioning properly. A
switch is turned "ON" and a lamp lights. A key is
turned, a starter motor runs and cranks the engine.
If the lamp does not light, or the starter motor does not
run, some means of measuring voltage, current flow,
resistance and continuity is needed, (continuity means
there is a complete electrical path through the circuit or
component.)
To know exactly what conditions exist in an electrical
circuit requires AC and DC Voltmeter, AC and DC
Ammeter, and an Ohmmeter.
Multimeter
A single combination meter that does all of these things
is available. Such a meter is called a Multimeter or VoltOhm-multitester (VOM). Meters of this kind are available in many forms and all change functions and
ranges with switches, or by plugging test leads into different jacks. Multimeters are available in two basic
types, Analog and Digital.
Analog Meters
Analog Meters have a needle that moves across a
scale to give a reading. The longer the scale, the easier
it is to read and more accurate the reading will be. A
jeweled movement is used in this type of meter is more
likely to be damaged through rough handling (except
for overloaded Protected Meters) or by measuring high
values that exceed the range set on the meter than a
digital meter. They provide excellent service for the
money as long as they are used with care.
Digital Meters
Digital Meters do not have a movement and are therefore more rugged. The reading shows up directly on a
display window of some type. Since they read direct,
no skill in reading the scale is required, nor is it necessary to set the range. The meter switches the ranges
automatically. One has only to select the function DC
Volts, AC Ampere, Ohms, etc.,) connect the test leads,
and the reading is shown on the display. Because of
the internal circuitry and the lack of a movement, these
meters are not likely to be damaged by overloads.
In the discussions that follow, either type of meter may
be used. Test procedures are the same. It is best to
learn proper procedures, even though some meters
may be more forgiving of mistakes. Where differences
in use may occur, they will be covered in the discussion.
10 - 28
Voltage Measurement
WARNING: EXPLOSIVE GASES can result
in serious injury or death. ALWAYS keep open
flames, sparks, or smoking materials away
from battery.
There are two basic rules to be remembered when
using a voltmeter. A voltmeter measures the voltage
difference between the test leads and the voltmeter is
always connected across the circuit under test.
POISONOUS BATTERY FLUID contains sulfuric acid and its contact with skin, eyes or
clothing can cause severe chemical burns.
ALWAYS wear safety glasses and protective
gear near battery.
DO NOT TIP any battery beyond 45 degree
angle in any direction.
ALWAYS KEEP BATTERIES OUT OF
REACH of children.
Current Measurement
The two rules to remember when measuring current
with an ammeter are; an ammeter measures the current that flows through the meter, and to measure current an ammeter must be connected into the circuit.
The latter rule means that the circuit must be opened,
and the ammeter wired into it. Because this procedure
is usually difficult, an ammeter is seldom used for troubleshooting.
WARNING: REVERSE CONNECTIONS may
result in sparks which may result in injury.
ALWAYS connect/disconnect cables in proper
order.
Resistance Measurement
An Ohmmeter is used to make resistance measurements and to check continuity through wires and electrical components.
There is one rule to keep in mind when using an ohmmeter. The ohmmeter has a self contained battery and
requires no electrical power. Using the ohmmeter on a
circuit that has power applied may result in damage to
the meter.
Set-Up
The new battery is dry charged. The dealer or
customer must add electrolyte (sulfuric acid and
water).
IMPORTANT: Disconnect the equipment battery when
making Ohmmeter test or damage to the Ohmmeter
may result.
1. Remove the battery from the unit.
IMPORTANT: An ohmmeter reads the resistance of
whatever component is connected between the test
leads. It can be used to check wires, coils, light bulbs,
or any item that conducts current.
3. Take the electrolyte which should be 1.265 specific
gravity at 80oF, and fill each cell so that the
electrolyte is level with the bottom of the fill ring.
10.3 BATTERY
When charging battery, remove it from unit first. Keep
batteries out of reach of children. ALWAYS follow
information provided on battery by battery
manufacturer. Lead acid batteries generate explosive
gases. Severe chemical burns can result from
improper handling of battery electrolyte. Wear safety
glasses and proper protective gear when handling
batteries to prevent electrolyte from coming in contact
with eyes, skin or clothing.
WARNING: ELECTRIC SHOCK may result in
injury and/or damage to unit.
DO NOT allow tools or other objects to come
into contact with both terminal at the same
time. ALWAYS remove Negative (-) Cable first
to reduce risk of sparks when removing battery. ALWAYS connect Positive (+) Cable first,
then connect Negative (-) Cable when installing battery.
2. Remove all the vent caps from the battery and set
the caps to one side.
4. The battery should stand for 1/2 hour. Now check
electrolyte level in each cell again. If necessary
add more electrolyte to bring the level up to the
bottom of the ring.
5. Charge until all cells are gassing freely, and the
specific gravity is constant over three successive
readings taken at 30 minute intervals.
6. Immediately after charging check level of
electrolyte. If the level is low add distilled water to
bring it up to the required level.
7. Replace the vent caps. It is not necessary to
tighten more than finger tight.
8. Wash off the battery to remove electrolyte which
may have spilled.
Battery Electrolyte First Aid
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!
IMPORTANT: In case of internal contact, DO NOT
induce vomiting!
10 - 29
NOTE: Unit comes equipped with a maintenance-free
battery that requires no regular maintenance except
cleaning the terminals.
1
WARNING: 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.
2
Clean Battery
Corrosion and dirt on the battery and terminals can
cause the battery to "leak" power.
3
6
4
• Remove battery. (See Battery Removal and
Installation)
• Rinse the battery with plain water and dry.
7
• Clean terminals and battery cable ends with wire
brush until bright.
• Coat terminals with grease or petroleum jelly.
1. Clamping Knob or
Nut
2. Seat
3. Positive (+) Cable
4. Positive (+) Terminal
• Reinstall battery.
Battery Removal and Installation
Remove battery before service (Figure 22).
Remove
2. Disconnect negative (-) cable first, then positive (+)
cable.
3. Remove battery hold-down bracket and battery
from unit.
Install
1. Install battery on the unit with battery hold-down
bracket.
2. Connect positive (+) cable first, than negative (-)
cable.
3. Apply petroleum jelly or dielectric grease to battery
cable ends and terminals.
5. Battery
6. Negative (-) Cable
7. Negative (-) Terminal
Figure 22
1. Remove clamping knob or nut and tip seat forward.
4. Tip seat back and secure to unit with clamping
knob or nut.
5
OE0120
Inspection, Cleaning, Drying, and Maintenance
Inspect the top of battery, terminals, cables, terminal
posts, and case for any accumulation of dirt, corrosion
cracks or loose or broken parts. Keep battery and its
terminals clean. Inspect monthly to maintain best
performance. Replace battery if damaged.
Remove hold down and bolt and lift battery out. Clean
or service battery away from unit. Remove corrosion
from battery terminals and cable connections with wire
brush, then wash with a weak baking soda solution.
Scrub the exterior of the battery and cable terminals
with a nonmetallic brush which has been dipped into a
mixture of baking soda and water.
After cleaning, apply a thin coat of grease or petroleum
jelly to terminals and cable ends to retard corrosion.
Reinstall battery.
Check the alternator voltage regulator output (if used)
at every periodic maintenance inspection. Over
charging is a common cause of battery failure.
Electrolyte Level
Every 25 hours of operation, check electrolyte level of
each cell by removing caps one at a time. The
electrolyte level should be at level indicated. Use
distilled water to fill each cell if needed. Install and
tighten each cap after checking.
10 - 30
room temperature and the charging time can be
estimated. For example:
IMPORTANT: When distilled water is added to battery
during freezing weather, battery must be charged to
mix water with electrolyte, or water will remain at top
and freeze.
OCV
Specific
Gravity
% of
Charge
Charging
Time
ALWAYS follow information provided on battery by
battery manufacturer. Contact battery manufacturer for
extensive instructions to charge battery.
12.60
1.265
100%
---
12.4
1.225
75%
3 hours
Place unit on a level surface, shut off engine and open
battery compartment to gain access to battery.
12.20
1.180
50%
7 hours
12.00
1.130
25%
10 hours
11.80
1.100
0%
12 hours
Charging
Disconnect negative (-) cable first, then positive (+)
cable.
To charge battery:
If using an automatic tapering 12 volt charger, choosing
a good quality 5 to 10 amps 15VDC minimum output
charger and charge for 3 to 12 hours according to the
battery state of charge (see table above) or until the
specific gravity in each cell reaches 1.255 - 1.265
specific gravity at 80oF (27oC).
1. Loosen strap and remove battery from unit.
2. Place battery on bench or other well ventilated
place where electrolyte spill will not create
damage.
3. Remove caps and fill each cell to level indicated
with electrolyte at 1.230 specific gravity and 80oF
(27oC).
If using a constant current charger, charge at 1 to 2
amperes for the time given on the table above or until
full specific gravity is reached.
4. Let battery stand for one half hour.
5. Check electrolyte level and add more if necessary.
6. Connect positive (+) lead of charger to positive (+)
terminal, and negative (-) lead to negative (-)
terminal.
7. Charge the battery at two and a half amps for ten
hours or until all cells are gassing freely and the
specific gravity is constant over three 30 minute
intervals.
IMPORTANT: Charging at higher rates will damage the
battery and cause excessive gassing and acid
spewing.
Battery Charger
Under normal conditions the engine alternator will keep
the battery charged. When unit has set for an extended
period of time without operation and the battery has
been completely discharged, a battery charger will be
required for recharging.
Specific Gravity Check
The specific gravity should be checked with a
hydrometer.
NOTE: The specific gravity should be checked in each
cell and should be the same for all cells. A variation in a
cell reading could be an indication of a problem. Subtract .004 from 1.265 for each 10oF below 80oF (27oC)
or add .004 to 1.265 for each 10oF above 80oF (27oC).
A special temperature compensated hydrometer is
used to read the battery’s state of charge.
The reading on the hydrometer gauge should be above
1.225. If the reading falls below 1.225 specific gravity
there will be an insufficient charge.
Before using a charger, an attempt can be made to
recharge the battery using the engine alternator by
jump starting the unit and allowing the engine to run.
Jump Starting
Jump starting, battery charging, or replacement is
required when the starter motor will not crank the
engine.
The unit used for jump starting should have a 12 volt
battery with at least 500 cold cranking amperes, and a
negatively grounded system.
ALWAYS charge the battery until the specific gravity of
1.265 is reached over 3 successive readings. Check
monthly to ensure charge is maintained. The
approximate state of charge can be determined by the
cell specific gravity of the rested open circuit voltage at
10 - 31
WARNING: FROZEN BATTERIES CAN
EXPLODE and result in death or serious
injury. DO NOT charge a frozen battery. Let
the battery thaw out before putting on a
charger.
UNIT MOVEMENT can result in death or
serious injury. NEVER jump start unit directly
to the starter or starter solenoid. Unit can
move forward or backward and injure the
person jump starting unit.
10.4 SWITCHES
To jump start the battery:
1. Ensure battery is not frozen. If the fluid is frozen,
remove battery from unit and allow to thaw before
charging.
Switches either open a circuit to stop current flow or
close and allow current to flow through.
2. Connect the positive (+) jumper cable to the
positive (+) terminal of the discharged battery.
3. Connect the other end of the same jumper cable to
the positive (+) terminal of the booster battery.
4. Connect one end of the second jumper cable to the
negative (-) terminal of the booster battery.
5. Make the final jumper cable connection to the
engine block or the furthest ground point away
from the discharged battery.
WARNING: Make sure cables are clear of any
moving engine parts before starting engine.
6. Start engine (refer to Owner’s Manual). If engine
will not start after several tries, unit or battery may
need service.
7. After engine starts, leave cables connected for one
to two minutes.
8. Disconnect cables in reverse order.
9. Operate unit as normal to charge battery.
Storage
The battery is a perishable item and it should be stored
properly to obtain a long, useful life. Batteries not in
use will self discharge.
If the battery will not be used for more than three
months, it should be removed and stored in a cool, dry
place.
Any collection of dirt, grease, or electrolyte should be
removed from the top of the battery.
The battery must be recharged monthly or when the
cell specific gravity reads less than 1.255 specific
gravity. Before reinstalling the battery in the spring, it
should always be fully recharged.
A normally open (N.O.) switch prevents current flow
until the switch is actuated, completing the circuit and
allowing current to flow through it. An example is a light
switch - the lights are off until the switch is actuated
and the lights go on.
A normally closed (N.C.) switch allows current to flow
until the switch is actuated, breaking the circuit and
stopping current flow through it. An example is an
ignition switch that grounds the magneto when in the
off position (completing the circuit) but opens the circuit
when in the ON position allowing the engine to operate.
Switches are selected with regard to Current rating
(contacts must be of sufficient size to carry the required
current), Voltage rating (switches insulated for specific
voltages), Case or housing (switches that are exposed
to moisture and must be sealed to prevent moisture
from entering), and Actuating type (push, pull, rotary,
momentary contact, or micro switches).
NOTE: Check that the connections to the switches are
secure and that a switch is being activated properly
before performing electrical test on switches. (Safety
switches on speed selector and clutch levers may be
out of adjustment and not activating.)
IMPORTANT: When checking switches, remove them
from their respective circuit by disconnecting the wires
from the switch at the connector(s). Damage could
result to the meter or machine components if switches
are left in.
Normally Open Switch
To test a normally open switch (key, headlight, safety,
or seat) connect the ohmmeter across the switch
terminals. Meter should indicate open circuit (infinite
resistance). Activate the switch. The ohmmeter should
read up scale to zero resistance (Close Circuit). This
indicates the switch is operating properly. Also check
from each terminal to the switch case (if case is metal).
Reading should show infinite resistance indicating no
short to ground.
Variation from test results described indicates a
defective switch.
Normally Closed Switch
To test a normally closed switch connect the ohmmeter
across the switch terminals. Meter should indicate a
closed circuit (zero resistance). Activate the switch and
the meter should move to open circuit (infinite
resistance). Check from each terminal to ground
(switch case). Meter should show open circuit (infinite
resistance).
Variation from test results described indicates a
defective switch.
10 - 32
Ignition Switch
NOTE: Refer to the wiring diagram of the unit (Continuity Diagram) to determine switch functions and test
using the methods described.
The ignition switch incorporates a number of functions,
although not all functions are used on all equipment.
The switch has four positions: OFF, RUN, RUN/LIGHT
and a momentary contact START position. Use an
ohmmeter to check the continuity of the switch in each
position.
OFF Position - Should be continuity between contacts
G, L and M. These connections ground the engine
magneto and stop the engine in the OFF position.
RUN Position - Should be continuity between contacts
B and L. These connections supply power to the rest of
the wiring harness. Connections G and M open to each
other. RUN/LIGHT in addition to B and L, A and Y
should have continuity
START Position - Hold switch in START position while
testing. There should be continuity between contacts B,
L and S. These connections apply power to close the
solenoid contacts and operate the starter motor.
In addition to the above test, place the switch in the run
position and check between each contact and ground
(metal case) to be sure no terminals are grounded. If
the switch is operating properly, there will be no
continuity between contacts other that those described.
10.5 SOLENOID AND RELAYS
Solenoid and relays are both magnetically operated
devices. Both devices operate on the principle that
passing a current of electricity through a coil of wire will
create a magnetic field strong enough to attract a piece
of iron or steel. Each device uses this principle in a
slightly different manner.
To check electrically, connect a voltmeter across the
coil of the device and activate the circuit that operates
the relay or solenoid. If the meter indicates no voltage
is applied, the cause is in the control circuit.
If the meter indicates proper voltage across the coil but
the device does not function, remove the power,
disconnect the wiring and check the continuity of the
coil with an ohmmeter. The meter should indicate
resistance, in the order of 3 to 5 ohms, if the coil is
intact. A high resistance indicates an open coil and a
defective device.
There are also a number of mechanical problems that
may cause the problem.
The starter solenoid in the Ariens/Gravely equipment is
a sealed unit used to actuate the starter motor on the
engines. These solenoids may have three or four
connections. The two large connections carry high
current to operate the starter motor. The small
connections are connected to the coil and carry the
control current.
To check the solenoid, disconnect the cables to the
starter motor, turn the ignition switch to the start
position, and listen for the solenoid to snap inside
contacts closed.
If no snap is heard, check across the coils with a
voltmeter. The voltage should read 12 volts with the
ignition switch in the start position. If no voltage
appears, the defect is in the start circuit.
If the voltage is correct, turn off the power and check
continuity of the coil with an ohmmeter. If the coil is
open, the solenoid is defective and must be replaced.
If the coil has the proper voltage applied, and the
continuity check indicates the coil is intact, the solenoid
plunger is stuck or the contacts are welded shut and
the solenoid must be replaced.
If the solenoid snaps shut, but the starter does not
operate, check across the large contacts with an
ohmmeter. If there is no continuity when the solenoid
snaps shut, the contacts are defective and the solenoid
must be replaced.
Relay - A basic relay consists of a coil of wire wound
around a soft iron (magnetic) core. When current is
passed through the coil, the core is magnetized and
pulls down on a magnetic lever. The lever in turn is
attached to several switch contacts which open or
close other electrical circuits. In this fashion, a small
current can control one or more larger electrical
currents and actuate several other devices. In most
cases a relay contact moves only a fraction of an inch
and the magnetic pull is small.
10.6 LIGHTING CIRCUITS
Solenoid - A basic solenoid consists of a coil of wire
wound around a hollow tube. A magnetic core slides
inside the tube. When current is passed through the
coil, the core is pulled into the solenoid with
considerable force. With proper design, a solenoid can
exert considerable force over a distance of several
inches. A solenoid can therefore, pull a lever, close a
heavy contact, or perform other jobs that require a
straight line pull.
If a relay or solenoid fails to operate, the cause may be
either electrical or mechanical.
Lighting circuits are simple circuits and easiest to
trouble shoot in most equipment. They consist of the
lights connected in parallel; a normally open switch, a
protective fuse and a source of power (battery or
engine alternator).
If only one light is out, check the connector, then check
the bulb for continuity (high resistance indicates a
defective or burned out bulb).
If all the lights are out, check the fuse for continuity
(high resistance indicates a defective or blown fuse).
Refer to Fuses. If the fuse is blown, check for a short in
the wiring and correct before replacing the fuse.
10 - 33
a service center has access to the information and
parts required to test and repair or replace engine
components, including rectifiers and regulators.)
If the fuse and lamps are good, check the circuit with
an AC/DC voltmeter.
10.7 FUSES
Fuses are connected in electrical circuits to protect the
circuits from damage due to overload or short circuits.
Fuses are a "weak link" in the circuit. They contain a
metal link designed to melt when a certain current
value is exceeded thus opening or disconnecting the
wiring. Once a fuse blows or melts it must be discarded
and replaced with a new fuse of the same value.
Since the function of the fuse is to protect the circuit,
NEVER attempt to defect the protective device by
bridging or replacing with a device of a higher current
rating.
Electrical testing of these devices is simple. Since the
device either conducts current (and is therefore
functioning) or the device is open and is therefore
defective. Use an ohmmeter to check for continuity.
10.8 DIODES AND RECTIFIERS
Diodes are solid state, semiconductor devices. They
contain no moving parts and conduct current better in
one direction than the other.
Diodes allow current to flow through one circuit without
"backing up" into another. In engine alternator circuits,
a diode is used to convert current which flows back and
forth (AC) in a circuit to current which flows only in one
direction (DC). A device which converts alternating
current to a direct current is called a RECTIFIER. A
diode is one type of rectifier.
To check a diode, isolate if from the circuit by
disconnecting one end. With a multitester set on the
lowest ohms scale setting, measure the resistance in
one direction, reverse the test leads, and measure in
the other direction. Readings should be high in one
direction and low in the other. (If the readings are low in
both directions, the diode is shorted, and if the
readings are high, the diode is open.) If the readings
are the same in both directions, the diode is defective
and must be replaced.
IMPORTANT: Diodes are marked to indicate polarity (a
band on one end, an arrow on the side, or they fit on a
holder only one way.
Rectifiers
A battery is charged through the use of an alternator
located in or on the engine. A charging circuit contains
a rectifier because alternators produce alternating
current (AC) and batteries require direct current (DC)
for charging.
The rectifier may be built into the engine or it may be
an external part. It may also contain a regulator to
prevent overcharging the battery. (Servicing of
rectifiers built into the engine should be done by an
approved engine manufacturer’s service center. Such
Units that contain both a rectifier and regulator are
tested in a working circuit to make sure the regulator
portion of the device is operating.
10.9 ELECTRIC CLUTCH
The electric clutch is used to turn on and off the
attachment used on the unit by use of a switch. The
clutch is also designed so that a brake is applied to the
output shaft when the clutch is disengaged (off).
The field coil is mounted to a bearing support and does
not rotate. The rotor is attached to the power output
shaft and rotates around the field assembly. The
armature is attached to the output pulley. The armature
assembly is held close to the rotor by the brake
assembly. The clutch is engaged by applying current to
the coil connection. This results in a current flowing
through the coil, magnetizing the coil pulling the
armature onto the rotor with sufficient force to hold the
two pieces together, effectively connecting the output
and the input shafts together. Pulling the armature
against the rotor pulls it away from the brake, releasing
the brake.
Engine Electrical Components
Engine servicing and repair should be referred to local
engine manufactures service centers that have the
service information and parts available to properly
service the engine. Ariens/Gravely dealers should be
able to test engines and engine components to pinpoint
troubles and narrow them down to properly advise the
engine serviceman.
10.10 ELECTRICAL
Initial check out: Make sure that all switches are in their
proper position for starting: (A) PTO off. (B) transaxle in
neutral position. (C) operator on the seat. If no battery
voltage to start the engine. Start the checklist.
STEP 1
Check out the battery. Using a hydrometer on all the
battery cells to see if one or more is bad. Also use a
voltmeter to check for proper voltage. Replace the
battery if necessary and/or charge to proper level.
Refer to Battery.
STEP 2
Use a voltmeter to make sure you have battery voltage
to terminal (B) on the back side of the ignition switch in
the off position. If you don’t have battery voltage to
terminal (B) check the battery connection and the fuse
in the red lead.
STEP 3
With the ignition switch in the "run" position, check to
see if the battery voltage is being transferred from
10 - 34
terminal (B) to terminal (A). Terminal (A) on the ignition
switch supplies battery voltage to the back of the PTO
switch on the purple lead and on to the neutral
switches on the red/violet lead to terminal S2 on the
ignition switch and to terminal 85 on solenoid #2.
Terminal (A) also supplies battery voltage to terminal
30 and 85 on solenoid #1 and on to the hour meter.
When the operator is in the seat, battery voltage will
transfer from terminal 30 to terminal 87 and on to the
front terminal of the PTO switch and on to terminal 85
on solenoid #2 in the yellow/red lead. Battery voltage is
supplied to the fuel shut off solenoid from terminal 85
on solenoid #2.
STEP 4
With ignition switch in the start position, battery voltage
is transferred from terminal S2 to S1. Terminal S1
Transfers battery voltage to the one small terminal on
the starter solenoid and goes to ground through the
base of the starter solenoid.
PTO clutch check out: Remove the wiring harness PTO
clutch leads from the clutch. With a multimeter check
the clutch coil for resistance to see if the coil is good.
The clutch used on models 915014, 016, 306 should
have a coil resistance of (1.98-3.98) ohms. If the coil is
bad the resistance will be higher or not at all.
Ignition switch check out: Battery voltage check in the
"off" position, check for voltage at terminal "B". It
should not be present on terminals A, S1, S2.
With the ignition switch in the "run" position, check for
battery voltage at terminal B, A, S2. It should not be
present at terminal S1.
With the ignition switch in the "start" position, check for
battery voltage at terminals B, A, S2, S1.
PTO switch check out: The PTO switch is a push/pull
switch with normal open and closed contacts. Power
transfer should be checked with a voltmeter. The
switch contacts should be checked with an ohm meter
with the wire harness plug removed. The light switch is
similar to the PTO switch with only one set of contacts.
Diode check out: Diodes are checked with an ohm
meter set on the diode check, and should only pass
voltage in one direction. If it passes voltage in both
directions or not at all the diode is bad and needs to be
replaced.
The clutch used on models 915013, 015, 307 should
have a coil resistance of (5.87-7.87) ohms. If the coil is
bad the resistance will be higher or not at all.
.
Normally open contacts manually activated. contact
resistance is 0.1-0.3 ohms when correct.
10 - 35
10.11 WIRING DIAGRAMS
Off
RED / GREEN
PTO
SWITCH
7
PURPLE /
WHITE A
1
PURPLE
PTO
CLUTCH
B
4
SEAT
SWITCH
BLACK
1
2
RED /
YELLOW
+
BROWN
-
9
3
BROWN
HOUR
METER
1
5
5
4
4
3
3
1
1
2
2
6
6
FUEL
SOLENIOD
PARKING
BRAKE
SWITCH
2
YELLOW /
RED
START
RELAY
REGULATOR
ENGINE
MAGNETO
KILL
BLACK
WHITE /
BLACK
87 86
87a
85
30
BLACK /WHITE
STARTER
PURPLE
G
B
BLACK
B
1
4
2
B
BROWN /
YELLOW
M
G
BATTERY
Y
LT. BLUE
3
1
4
2
BLACK
A
RED
A
B
RED
FUSE
B
RIGHT
STEERING
CONTROL
SWITCH
YELLOW / RED
WHITE
RED
L
BROWN /
YELLOW 3
LEFT
STEERING
CONTROL
SWITCH
S
KEY
SWITCH
COIL 1
STARTER
SOLENOID
BROWN / WHITE
BROWN / WHITE
BLACK
HEADLIGHT
LIGHT
FUSE
LT. A
BLUE
B LT.
10 - 36
BLUE
BLACK
LT.
BLUE
BLACK
COIL 2
GROUND A
PATH FUSE B
BLACK
Operator Off Seat, Start, PTO Off
RED / GREEN
PTO
SWITCH
7
PURPLE /
WHITE A
1
PURPLE
PTO
CLUTCH
B
4
SEAT
SWITCH
BLACK
1
2
RED /
YELLOW
+
BROWN
-
9
3
BROWN
HOUR
METER
1
5
5
4
4
3
3
1
1
2
2
6
6
FUEL
SOLENIOD
PARKING
BRAKE
SWITCH
2
YELLOW /
RED
START
RELAY
REGULATOR
ENGINE
MAGNETO
KILL
BLACK
WHITE /
BLACK
87 86
87a
85
30
BLACK /WHITE
STARTER
PURPLE
G
B
BLACK
B
1
4
2
B
BROWN /
YELLOW
M
G
BATTERY
Y
LT. BLUE
3
1
4
2
BLACK
A
RED
A
B
RED
FUSE
B
RIGHT
STEERING
CONTROL
SWITCH
YELLOW / RED
WHITE
RED
L
BROWN /
YELLOW 3
LEFT
STEERING
CONTROL
SWITCH
S
KEY
SWITCH
COIL 1
STARTER
SOLENOID
BROWN / WHITE
BROWN / WHITE
BLACK
HEADLIGHT
LIGHT
FUSE
LT. A
BLUE
B LT.
10 - 37
BLUE
BLACK
LT.
BLUE
BLACK
COIL 2
GROUND A
PATH FUSE B
BLACK
Operator Off Seat, Run, PTO Off
RED / GREEN
PTO
SWITCH
7
PURPLE /
WHITE A
1
PURPLE
PTO
CLUTCH
B
4
SEAT
SWITCH
BLACK
1
2
RED /
YELLOW
+
BROWN
-
9
3
BROWN
HOUR
METER
1
5
5
4
4
3
3
1
1
2
2
6
6
FUEL
SOLENIOD
PARKING
BRAKE
SWITCH
2
YELLOW /
RED
START
RELAY
REGULATOR
ENGINE
MAGNETO
KILL
BLACK
WHITE /
BLACK
87 86
87a
85
30
BLACK /WHITE
STARTER
PURPLE
G
B
BLACK
B
1
4
2
B
BROWN /
YELLOW
M
G
BATTERY
Y
LT. BLUE
3
1
4
2
BLACK
A
RED
A
B
RED
FUSE
B
RIGHT
STEERING
CONTROL
SWITCH
YELLOW / RED
WHITE
RED
L
BROWN /
YELLOW 3
LEFT
STEERING
CONTROL
SWITCH
S
KEY
SWITCH
COIL 1
STARTER
SOLENOID
BROWN / WHITE
BROWN / WHITE
BLACK
HEADLIGHT
LIGHT
FUSE
LT. A
BLUE
10 - 38
B LT.
BLUE
BLACK
LT.
BLUE
BLACK
COIL 2
GROUND A
PATH FUSE B
BLACK
Operator On Seat, Run, PTO On, Driving
RED / GREEN
PTO
SWITCH
7
PURPLE /
WHITE A
1
PURPLE
PTO
CLUTCH
B
4
SEAT
SWITCH
BLACK
1
2
RED /
YELLOW
+
BROWN
-
9
3
BROWN
HOUR
METER
1
5
5
4
4
3
3
1
1
2
2
6
6
FUEL
SOLENIOD
PARKING
BRAKE
SWITCH
2
YELLOW /
RED
START
RELAY
REGULATOR
ENGINE
MAGNETO
KILL
BLACK
WHITE /
BLACK
87 86
87a
85
30
BLACK /WHITE
STARTER
PURPLE
G
B
BLACK
B
1
4
2
B
BROWN /
YELLOW
M
G
BATTERY
Y
LT. BLUE
3
1
4
2
BLACK
A
RED
A
B
RED
FUSE
B
RIGHT
STEERING
CONTROL
SWITCH
YELLOW / RED
WHITE
RED
L
BROWN /
YELLOW 3
LEFT
STEERING
CONTROL
SWITCH
S
KEY
SWITCH
COIL 1
STARTER
SOLENOID
BROWN / WHITE
BROWN / WHITE
BLACK
HEADLIGHT
LIGHT
FUSE
LT. A
BLUE
10 - 39
B LT.
BLUE
BLACK
LT.
BLUE
BLACK
COIL 2
GROUND A
PATH FUSE B
BLACK
10.12 CONTINUITY DIAGRAM
The diagrams below show the various states of connection for electrical components.
The solid lines on switches show continuity.
NOTE: All switches are viewed from the rear.
Key Switch
B
M
L
S
B
M
L
S
Y
B
Y
G
Y
G
G
A
OFF
M
L
S
Y
G
A
B
M
L
S
A
A
START
RUN
RUN / LIGHT
Relay
PTO Switch
3
9
3
9
87
87
86 87A
85
86 87A
30
4
1
7
4
DISENGAGED
(down position)
1
2
30
7
ENGAGED
(up position)
NOT ENERGIZED
1
1
2
2
BUTTON UP
OPERATOR
OFF SEAT
1
2
BUTTON DOWN
OPERATOR
ON SEAT
Solenoid
NOT ENERGIZED
ENERGIZED
Brake Switch
Seat Switch
1
85
Neutral Switch
ENERGIZED
3
4
1
2
BUTTON OUT
10 - 40
PE0520
3
4
1
2
BUTTON IN
10.13 ELECTRICAL SYSTEM
1
3
2
4
7
5
6
8
9
To Starter
1. Clutch Switch
6. Switch N.O.
2. Relay
7. Interlock Switch N.C.
3. Double Pole Switch N.O./N.O.
8. Diode
4. 25 Amp Fuse
9. Solenoid
5. 10 Amp Fuse
10 - 41
SECTION 11 - MOWER ATTACHMENT
11.1 MOWER SPINDLE REMOVAL
1
2
3
4
1.
2.
3.
4.
Spindle Cover
Idler Arm
Spindle Assembly
Hub
Figure 23
1. Remove the mower deck from the unit for
disassembly of the mower.
6. Remove the mower spindle housings from the
mower deck stamping.
2. Remove the mower spindle covers.
7. Assemble in reverse order.
3. Remove the mower deck blades, retainer hub,
spindle key and bearing slinger.
Spindle Repair
Spindles should be replaced as a unit.
4. Reduce belt tension on the belt by releasing the
idler pulley compression spring.
5. Remove the spindle sheaves and shaft assemblies
11 - 42
PE0550
Ariens Company
655 West Ryan Street
P.O. Box 157
Brillion, WI 54110-0157
920-756-2141
Fax 920-756-2407
www.ariens.com