Ariens 915013 Lawn Mower User Manual

TABLE OF CONTENTS
Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-2
Section 7 - Drive Train . . . . . . . . . . . . . . . . . . . 7-22
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
7.1 Hydro Transmission Troubleshooting . . . . . . . .
7.2 Hydro-Gear Fluid recommendations . . . . . . . . .
7.3 Hydro-Gear Repair. . . . . . . . . . . . . . . . . . . . . . .
7.4 Replacement Of Parts . . . . . . . . . . . . . . . . . . . .
7.5 Oil Fill & Start-up Procedures . . . . . . . . . . . . . .
7.6 Hydro-Gear Transmission Removal. . . . . . . . . .
7.7 Hydro-Gear Transmission Installation . . . . . . . .
Section 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . . 2-3
7-22
7-24
7-24
7-26
7-27
.
7-28
7-28
Section 8 - Power Take Off . . . . . . . . . . . . . . . 8-29
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
8.1 PTO Jackshaft Removal . . . . . . . . . . . . . . . . . . 8-29
8.2 PTO Jackshaft Repair . . . . . . . . . . . . . . . . . . . . 8-29
8.3 PTO Jackshaft Installation . . . . . . . . . . . . . . . . . 8-29
Section 9 - Lift System. . . . . . . . . . . . . . . . . . . 9-30
9.1 Lift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.2 Lift System Removal . . . . . . . . . . . . . . . . . . . . . 9-30
Section 10 - Fuel System. . . . . . . . . . . . . . . . 10-31
10.1 Fuel System Troubleshooting . . . . . . . . . . . .
10.2 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Fuel System Contamination. . . . . . . . . . . . . .
10.4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Fuel Tank Removal . . . . . . . . . . . . . . . . . . . .
Section 3 - Specifications . . . . . . . . . . . . . . . . . 3-6
Section 4 - General Maintenance
& Adjustments . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.1 Controls And Features . . . . . . . . . . . . . . . . . . . . . 4-8
4.2 Check Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3 General Lubrication . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4 To Remove 48" Mower Deck . . . . . . . . . . . . . . . 4-10
4.5 To Install 48" Mower Deck . . . . . . . . . . . . . . . . . 4-10
4.6 To Remove 42" Mower Deck . . . . . . . . . . . . . . . 4-10
4.7 To Install 42" Mower Deck . . . . . . . . . . . . . . . . . 4-11
4.8 Mower Height Adjustment . . . . . . . . . . . . . . . . . 4-11
4.9 To Level Mower . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.10 Neutral Adjustment (Speed Control) . . . . . . . . 4-13
4.11 Adjusting The Unit To Track Straight . . . . . . . . 4-13
4.12 Anti-scalp Rollers (42" Deck) . . . . . . . . . . . . . . 4-14
4.13 Adjusting The Parking Brake . . . . . . . . . . . . . . 4-15
10-31
10-32
.
10-32
10-32
10-32
Section 11 - Electrical . . . . . . . . . . . . . . . . . . 11-33
11.1 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Electrical Measurements . . . . . . . . . . . . . . . .
11.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.5 Solenoid And Relays . . . . . . . . . . . . . . . . . . .
11.6 Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . .
11.7 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.8 Diodes And Rectifiers. . . . . . . . . . . . . . . . . . .
11.9 Electric Clutch . . . . . . . . . . . . . . . . . . . . . . . .
11.10 EZR Electrical . . . . . . . . . . . . . . . . . . . . . . .
11.11 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . .
11.12 Relays And Switches . . . . . . . . . . . . . . . . . .
Section 5 - Engine . . . . . . . . . . . . . . . . . . . . . . 5-16
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
11-33
11-33
11-34
11-37
11-38
11-39
11-39
11-39
11-39
11-39
11-43
11-44
Section 12 - Mower Attachment . . . . . . . . . . 12-45
12.1 42" Mower Spindle Removal . . . . . . . . . . . . .
12.2 48" Mower Spindle Removal . . . . . . . . . . . . .
12.3 42" Spindle Repair . . . . . . . . . . . . . . . . . . . . .
12.4 48" Spindle Repair . . . . . . . . . . . . . . . . . . . . .
Section 6 - Mower Deck. . . . . . . . . . . . . . . . . . 6-19
6.1 Clutch To Deck Drive Belt Replacement . . . . . . 6-19
6.2 Mower Deck Belt Replacement (48" Deck) . . . . 6-19
6.3 Mower Deck Belt Replacement (42" Deck) . . . . 6-20
6.4 Check Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
1
12-45
12-46
12-46
12-46
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 EZ Rider.
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 replacement parts. The replacement of
any part on this vehicle with anything other than a
Ariens authorized replacement part may adversely
affect the performance, durability, or safety of this unit
and may void the warranty. Ariens 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
Directional Reference
Ariens 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.
All reference to left, right, front, or rear are given from
the operator in the operator position and facing the
direction of forward travel.
1.6 TECHNICAL SERVICE
COMMUNICATIONS
Safety Messages
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.
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.
Serial Number
Figure 1
Ariens 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.
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 transaxles 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 both transaxles at the rear of unit.
2.8 CLEANING AND STORAGE
IMPORTANT: Never spray unit with water or store unit
outdoors to help prevent sealed bearing rust or
corrosion. 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.
• Your unit.
DO NOT leave unit unattended on a slope. ALWAYS
use wheel chocks when leaving 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
Model Number
Model
Engine
Manufacture
Fuel & Capacity - gal (L)
Idle RPM
Governed RPM
Crank Case Capacity (Oil Filter) - oz (L)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed Forward Max.
mph (kph)
Reverse Max. - mph (kph)
Transmission Lube
Drive Clutch
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear-Light psi (kN/m2)
Medium
Heavy
Lift System
Power Take Off
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius
Tire Size
Front
Rear
Diagnostic Lights
Attachments:
Mower Pan - in (cm)
Bagger 2 Bucket
Sno-Thro
Dozer Blade
Mulching Kit
Headlight Kit
Front Weight Kit
Rear Weight Kit
Tire Chain Kit
Bumper Kit
915304
EZR 1742
17.0 HP OHV
Briggs & Stratton
Unleaded 3.5 (13.3)
1800 RPM
3000 RPM
48 (1.66)
Paper Element
915305
EZR 2048
20.0 HP OHV
Briggs & Stratton
Unleaded 3.5 (13.3)
1800 RPM
3150 RPM
64 (1.9)
Paper Element
Foam Precleaner
9 Amp Unregulated
75 Micron
Foam Precleaner
9 Amp Unregulated
60 Micron
30W over 32oF (0oC)
5W30
below 32oF (0oC)
.030 Champion RC12YC
Hydro-Gear
0-5.2 (8.4)
30W over 32oF (0oC)
5W30
below 32oF (0oC)
.030 Champion RC12YC
Hydro-Gear
0-5.2 (8.4)
0-3.6 (5.8)
20W50
N/A
N/A
N/A
0-3.6 (5.8)
20W50
N/A
N/A
N/A
15-20 (103-138)
15-20 (103-138)
10-12 (83-103)
10-12 (83-103)
Spring Assist
Electric
12 Volt 255 C.C.A.
Optional (71501200)
High Back
Parking
Castor Wheels
0"
10-12 (83-103)
10-12 (83-103)
Spring Assist
Electric
12 Volt 255 C.C.A.
Optional (71501200)
High Back
Parking
Castor Wheels
0"
11.0x4.00-5
18x8.50-8
N/A
11.0x4.00-5
18x8.50-8
N/A
42 (106.7)
815008
N/A
815006
71501300
71501100
71500300
71500700
71501000
71501500
48 (122)
71501900
N/A
815006
N/A
71501100
71500300
71500700
71501000
71501500
3-6
Model Number
Model
Engine
Manufacture
Fuel & Capacity - gal (L)
Idle RPM
Governed RPM
Crank Case Capacity (Oil Filter) - oz (L)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed Forward Max. mph (kph)
Reverse Max. - mph (kph)
Transmission Lube
Drive Clutch
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear-Light psi (kN/m2)
Medium
Heavy
Lift System
Power Take Off
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius
Tire Size
Front
Rear
Diagnostic Lights
Attachments:
Mower Pan - in (cm)
Bagger 2 Bucket
Sno-Thro
Dozer Blade
Mulching Kit
Headlight Kit
Front Weight Kit
Rear Weight Kit
Tire Chain Kit
Bumper Kit
915013
EZR 1742
17.0 HP OHV
Briggs & Stratton
Unleaded 3.5 (13.3)
1800 RPM
3300 RPM
48 (1.4)
Paper Element
915014
EZR 2048
20.0 HP OHV
Briggs & Stratton
Unleaded 3.5 (13.3)
1800 RPM
3250 RPM
64 (1.9)
Paper Element
Foam Precleaner
9 Amp Unregulated
75 Micron
Foam Precleaner
9 Amp Unregulated
60 Micron
30W over 32oF (0oC)
30W over 32oF(0oC)
5W30 below 32oF (0oC)
.030 Champion RC12YC
Hydro-Gear
0 - 5.2 (0 - 8.4)
0 - 3.6 (0 - 5.8)
20 W 50
N/A
N/A
N/A
5W30 below 32oF (0oC)
.030 Champion RC12YC
Hydro-Gear
0 - 5.2 (0 - 8.4)
0 - 3.6 (0 - 5.8)
20 W 50
N/A
N/A
N/A
15-20 (103-138)
15-20 (103-138)
10-12 (83-103)
10-12 (83-103)
Spring Assist
Electric
12 Volt 255 C.C.A
Optional (715012)
High Back
Parking
Castor Wheels
0"
10-12 (83-103)
10-12 (83-103)
Spring Assist
Electric
12 Volt 290 C.C.A.
Optional (71500100)
High Back
Parking
Castor Wheels
0"
11.0x4.00-5
18x8.50-8
N/A
11.0x4.00-5
18x8.50-8
N/A
42 (106.7)
815008
815003
815006
71501300
71501100
71500300
71500700
71501000
71501500
48 (122)
71501900
815003
815006
N/A
71501100
71500300
71500700
71501000
71501500
3-7
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS
4.1 CONTROLS AND FEATURES
11
1
2
10
7
8
9
15
14
12
OE0680
13
3
6
5
4
OE0860
1.
2.
3.
4.
5.
6.
7.
8.
Steering Control Levers
Battery Compartment
Ignition Switch
Power Take Off (PTO)
Throttle Control (Throttle/Choke Control)
Choke Control (2048)
Parking Brake Lever
Attachment Lift Lever
9. Foot Rest
10. Fuel Level Indicator Window
11. Fuel Tank Cap
12. Discharge Chute
13. Anti-Scalp Rollers
14. Belt Cover
15. Locking Lever
Figure 2
4-8
4.2 CHECK FUEL LEVEL
The fuel level is shown through a window in the control
panel next to the parking brake.
WARNING: Fuel is highly flammable and its vapors are
explosive. Handle with care.
Front
NO smoking, NO sparks, NO flames.
Refer to Engine Manual for proper fuel.
Mower Drive Idler
To add fuel to the fuel tank:
1. ALWAYS place unit in open or well ventilated area.
2. Stop engine and allow to cool for two minutes.
3. Clean the fuel cap and the area around the fuel
cap to prevent dirt from entering the fuel tank.
Clutch Shaft Idler
Transaxle Idler
1
Back
2
O E0330
1. Fuel Cap
2. Fuel Level Window
Figure 3
OE0690
4. Remove the cap from the fuel tank.
5. Fill the fuel tank with the proper grade of fuel as
recommended by the engine manufacturer. Do not
spill any fuel.
6. Replace the cap on the fuel tank and tighten.
OE0700
Figure 4
CAUTION: Before performing any service or
adjustments:
7. ALWAYS clean up any spilled fuel before starting
the engine.
• Turn PTO switch "OFF".
4.3 GENERAL LUBRICATION
• Park mower on a hard, flat, level surface.
Refer to Figure 4 for the locations of the grease fittings
on the unit and the intervals at which to grease them.
• Place steering control levers in neutral
lock (fully outward) position.
All grease fittings should be greased at 25-hour
intervals. Clean and inspect parts and replace as
required.
• Set parking brake.
• Turn ignition switch "OFF" and remove
key.
1. Clean the fittings before attaching the grease gun.
• Wait for blades and all moving parts to
stop.
2. Thoroughly clean and dry all parts with a suitable
solvent.
3. Check all parts for wear and damage.
4. Replace all parts that are worn or damaged.
5. Use Sten Mix Hi-Temp Grease (a moly-lithium
grease) or equivalent. Add grease until it appears
at the ends of the bearing or ends of the shaft.
6. Every 25 hours apply motor oil to all pin
connections, pivots points and areas where sliding
occurs.
4-9
4.4 TO REMOVE 48" MOWER DECK
1. Turn off engine, engage parking brake and allow
hot parts to cool.
5
4
2. Place center deck lift handle in lowest (1) position.
2
3
6
1
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.
3. Engage attachment lift lock. Pull handle out and
rotate down 90o. Handle will spring into locked
position.
1. Front Pin
2. Front Lift Arm
3. Rear Hanger
4. Height Adjuster
5. Lift Lever Hook
6. Hair Pin
OE170
Figure 6
4.5 TO INSTALL 48" MOWER DECK
1. To center deck lift handle should be in the lowest
(1) position with the attachment lift lock engaged.
Disengaged
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.
Engaged
OE0730
O E0720
Figure 5
4. Disconnect mower belt idler spring from bolt under
frame.
2. Push mower under unit. Mower is easier to push in
from right side of the tractor.
5. Remove deck belt from mower pulley and electric
clutch.
3. Slide a washer down to tabbed end of front pin.
4. Align holes in front lift arms with slots at front of
frame and slide front pin through arms and frame.
6. Remove hair pins and washers holding height
adjusters to lift arm, and unhook height adjusters
from lift arm.
5. Secure front pin with washer and cotter pin.
6. Hook rear hanger into the holes in the bottom of
the frame on both sides.
7. Unhook the rear hangers from the holes in the
bottom of the frame.
7. Secure rear hangers with hair pins.
8. Remove cotter pin and washer from end of front
pin.
8. Hook the height adjusters onto the lift arm.
9. Slide front pin out to release front lift arms from
frame.
9. Secure height adjusters with washers and hair
pins.
10.Slide mower from under tractor. Mower is easier to
remove from the right side of the tractor.
10.Install deck belt onto mower pulley and electric
clutch.
11.Connect mower belt idler spring to bolt under
frame.
12.Disengage attachment lift lock.
4.6 TO REMOVE 42" MOWER DECK
1. Turn off engine, engage parking brake and allow
hot parts to cool.
2. Place center deck lift handle in lowest (1) position.
4 - 10
4.7 TO INSTALL 42" MOWER DECK
1. The center deck lift handle should be in the lowest
(1) position with the attachment lift lock engaged.
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.
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.
3. Engage attachment lift lock. Pull handle out and
rotate down 90o.
2. Push mower deck under tractor from right side of
unit.
3. Attach deck lift with washers and hair pins.
4. Attach rear deck link with clevis pins and hair pins.
5. Place drive belt around drive pulley, idler and
clutch pulley.
Disengaged
6. Place rod link in holding brackets at front of deck
and engage rod link locking brackets.
Engaged
OE0730
7. Tighten nut on end of rod link until it is snug.
O E0720
Figure 7
8. Disengage attachment lift lock.
4. Loosen nut on rod link at front of tractor. It is not
necessary to remove it entirely.
4.8 MOWER HEIGHT ADJUSTMENT
5. Release rod link locking brackets from rod link at
front of deck.
Cutting Height Settings Chart
6. Remove deck belt from drive pulley.
Setting
7. Remove hair pins and clevis pins from rear deck
link.
8. Remove hair pins and washers from deck lift.
9. Pivot right front wheel to allow deck to slide past.
10.Slide mower from under tractor. Mower is easier to
remove from the right side of the tractor.
1
2
4
3
Cut grass length
1
1-3/8" (35mm)
2
2" (51 mm)
3
2-3/4" (70 mm)
4
3-1/2" (89 mm)
5
4-3/8" (111 mm)
5
To Adjust 48" Deck:
6
3
4
1
8
1. Rod Link Lock
Brackets
2. Drive Pulley
3. Belt
4. Rear Deck Link Hair
Pin & Clevis Pin
7
2
5. Mower Frame
6. Idler
7. Adjuster Link Washer
& Hair PIn
8. Rod Link Nut
Figure 8
1. Adjusting Tab
2. Carriage Bolt Flange
Locknut
3. Height Adjuster
4. Height Adjuster Nut
OE0720
Figure 9
4 - 11
O t0770
1. To adjust mower height, place mower in the
number three (3) position.
2. Loosen height adjuster nuts.
3. Remove hair pins and washers holding height
adjusters to lift arm and unhook height adjusters
from lift arm.
4. Turn height adjusters equally clockwise to raise
mower, or equally counterclockwise to lower
mower. Adjust for a height of 2-3/4" from ground to
blade tip.
NOTE: Proper blade pitch is when the blade tip, measured from the bottom surface, is 1/8" to 1/4" lower at
front of mower deck than when same tip is at rear of
mower deck.
NOTE: To make measuring distance from blade to
ground easier, obtain a wood block about 1 inch square
by 5 inches long. Wrap the entire block with masking
tape. Hold block in vertical position with its lower tip on
ground. Push block against cutting edge of blade so as
to make a mark on tape. Pull the block away and with a
ruler measure the distance from lower block tip to
mark.
5
5. Hook height adjusters onto lift arm and check for
correct height. If not correct, continue to turn height
adjusters until height is correct.
6. Tighten height adjuster nuts.
2
1
3
4
(Shown from front)
7. Secure height adjusters with washers and hair
pins.
1. Mower Deck
2. Blade
3. Front Blade Height
To Adjust 42" Deck
4. Ground Level
5. Cutting Height
O T0860
1. Place mower in the number three (3) position.
Figure 10
2. Place anti-scalp rollers in highest position so they
do not touch the ground during adjustment.
To Adjust Side to Side Level (48" Deck)
3. Turn the nuts on the bottom of the adjusters
equally until the blade tips are 2-3/4" from the
ground.
NOTE: Proper blade pitch is when the blade tip, measured from the bottom surface, is 1/8" to 1/4" lower at
front of mower deck than when same tip is at rear of
mower deck.
1. Loosen height adjuster nuts.
2. Remove hair pins and washers holding height
adjusters to lift arm and unhook height adjusters
from lift arm.
4. Reset anti-scalp rollers to match desired
attachment position.
4.9 TO LEVEL MOWER
Adjust the mower while tractor is parked on level
ground or driveway. Make sure tires are properly
inflated (See Specifications). If tires are overinflated or
underinflated, you can not properly adjust your mower.
To Check Side to Side Level
3. On low side: Turn height adjuster nut clockwise on
low side of mower pan to raise low side. Raise low
side one half the measured difference in height
between the low side and the high side. On high
side: Turn height adjuster nut counterclockwise to
lower high side the other one half of the height
difference.
4. Hook height adjusters onto lift arm and check side
to side level. If not level, continue to turn height
adjusters until deck is level side to side.
5. Tighten height adjuster nuts.
6. Secure height adjusters with washers and hair
pins.
1. Position unit on a smooth, flat, level surface. Set
proper tire pressure.
2. Position blade(s) side to side; measure distance of
blade tips to floor at right and left side of mower
pan. Rotate blade(s) 180o and check again. The
measurement should be equal within 1/16 inch
side to side.
To Adjust Side to Side Level (42" Deck)
1. Place anti-scalp rollers in highest position so they
do not touch the ground during adjustment.
2. Put height adjustment lever in the number three (3)
position.
3. With a 1/2" open-end wrench, adjust the nuts on
the bottom of the adjuster link until each end of the
blade is 2-3/4" from the ground within 1/16".
4. Reset anti-scalp rollers to match desired
attachment position.
4 - 12
4.10 NEUTRAL ADJUSTMENT (SPEED
CONTROL)
1. Stop the engine. Remove the ignition key. Push the
PTO knob into the "OFF" position.
2
1
CAUTION: PREVENT personal injury!
ALWAYS MAKE CERTAIN that jack(s) or
blocks used are stable, strong and will
support the weight of the unit.
2. Place jack(s) under rear transaxles only. If jack(s)
are not available, place support blocks under both
transaxles at the rear of the unit to raise the rear
wheels off the ground.
3
1. Connecting Linkage
2. Lock Nut
3. Remove side shrouds.
3. Flange
Figure 11
4. Place a weight on the seat to close the seat switch.
Start the engine and run it at part throttle.
5. Remove the connecting linkage from the flange
bushing, Figure 12.
4.11 ADJUSTING THE UNIT TO TRACK
STRAIGHT
6. Rotate flange bushing until the wheel stops
rotating.
The primary reason the unit may not track straight is
incorrect or unbalanced tire air pressure.
1. First, check and adjust the tire pressure.
7. Lock the flange bushing in place by tightening the
lock nut.
2. With tire pressures equal and the rear of the unit
on jack stands, check the circumference of the tire.
If one tire is larger than the other, increase
pressure in the small tire and/or decrease pressure
in the larger tire.
8. Adjust the connecting rod length and reattach it to
the flange.
9. Loosen the lock nut and test by moving the
steering control levers.
10.Repeat procedure for the other side of the unit.
11.Reinstall side shrouds.
If the drive cannot be adjusted to neutral using the
above procedure, the link to the flange on the transaxle
can be adjusted.
1. With the rear of the unit jacked up and supported,
remove the connecting linkage at the flange
(Figure 11).
3. With both tires the same size, set the control
handles. The roller bearing on the speed control
arm must be in the neutral position on the neutral
detent strap.
4. Adjust upper control arm linkage until the control
handles will enter the neutral switch slot and
activate the neutral switches.
5. Tighten locking nuts on the control linkage.
2. Place a weight on the seat and start the engine.
Run it at part throttle.
3. Rotate the flange until the wheel stops turning and
tighten the lock nut.
4. Shut off the engine.
6. Disconnect linkage from the transmission, loosen
two cap screws in the speed control arm and
position pump weldment in the horizontal position
and tighten cap screws.
7. Start unit and by hand adjust the transmission
control cam until neutral is found.
5. Loosen the lock nut on the connecting linkage and
adjust the rod end to match the hole in the flange.
8. Tighten a transmission locking nut.
6. Reattach the connecting linkage and tighten the
lock nut to the rod end.
10.Set transmission linkage rod, then line up with hole
in control cam and install and tighten attachment
ball.
7. Loosen the flange lock nut and test.
9. Stop engine.
11.Loosen the transmission control locking nut.
12.Start unit and check tracking.
4 - 13
4.12 ANTI-SCALP ROLLERS (42" DECK)
Rollers are intended to prevent lawn scalping, not to
control cutting height.
1
For proper operation, adjust the anti-scalp rollers to the
same or higher than mower cutting height. For
example, when mowing at the number three (3) height
position, the anti-scalp rollers must be adjusted to their
number three (3) or higher position.
4
2
3
2
1. Eccentric
2. Locknuts and Bolts
5
3. Flange Bushing
4. Speed Control Arm
Figure 12
Figure 14
1. Remove side shrouds. Set aside.
2. Loosen bolts which attach the eccentric to the seat
support. Do not remove the bolts.
3. Rotate eccentric to adjust the travel of the speed
control arm. The thicker portion of the eccentric
shortens the distance the steering control lever will
travel forward. The thinner portion of the eccentric
lengthens the distance the steering control lever
will travel forward.
3
1
3
2
2
Shorter Travel
Longer Travel
1. Eccentric
2. Bolt
3. Speed Control Arm
Figure 13
1
23 4
5
O E0082
For final tracking adjustment:
1
4 32 1
OE0850
4. Adjust the rotation of the eccentrics on one or both
sides of the unit so that the steering control levers
align in the full forward position.
5. Tighten the eccentric’s bolts.
6. Reinstall the side shrouds.
4 - 14
O E0740
4.13 ADJUSTING THE PARKING BRAKE
The parking brake has no adjustments. If the brake is
not working properly inspect the linkage for wear and
replace as needed.
1
5
4
3
3
1. Brake Lever Pivot
2. Brake Lever
3. Flange Bushing
2
4. Brake Arm
5. Dump Valve
Figure 15
4 - 15
PE0380
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.
POSSIBLE CAUSES
(Refer to Key Below)
CORRECTIVE ACTION
Black Exhaust
Blue/White Exhaust
Difficult Starting
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
repair or replace
repair or replace
repair or replace
Erratic Running
Excessive Fuel Consumption
Excessive Crankcase Pressure
High Oil Pressure
Knocking
Loss of Power or System
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
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
Low Cranking Power
Low Oil Pressure
Misfiring
Overheating
Poor Compression
Starts and Stops
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
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:
IMPORTANT: To prevent severe damage to the
engine, proper cooling will need to be maintained.
1. Move the unit to level location.
2. Clean around the dipstick and filler tube to prevent
dirt from entering the engine.
1. Check the air intake screen on the engine each
day.
3. Remove the dipstick and wipe off the oil on the
dipstick.
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.
3. Check the engine cooling yearly.
5. When the dipstick is removed, note the oil level. Oil
should be between the full and add mark.
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 the hood from the units engine.
2. Remove the negative cable from the battery.
3. Remove the main drive belt from the engine
sheave by releasing the idler tension spring.
4. Remove the jackshaft drive belt from the engine
sheave by releasing the tension spring from the
right side of the transaxle sub frame.
5 - 17
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.
8. Remove the exhaust system from under the frame.
Disconnect at the exhaust port on the engine.
9. Remove the engine bolts.
10.Lift engine out of the unit and off the frame with a
hoist (engine).
11.Service, overhaul, or replace engine as required.
12.If replacing engine with a new engine, the following
items will have to be removed (if used) from old
engine. These items will not be included with a new
engine.
Engine sheave and key, mounting hardware, and
engine wiring harness.
5.10 ENGINE INSTALLATION
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, install
the exhaust system and then tighten the mounting
hardware.
4. Install the engine sheave, belts, springs, electrical
wiring, throttle, and choke controls.
5. Install the negative battery cable onto the battery.
6. Install the fuel line.
7. Fill engine with 30W above 32 oF (0oC) or 5W30
below 32oF (0oC).
8. Install the engine cover, then test operation and
function of the engine.
WARNING: AVOID EXHAUST FUMES! DO
NOT run engine in an enclosed area.
ALWAYS provide good ventilation and wait
until hazard has been removed.
9. 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.
5 - 18
SECTION 6 - MOWER DECK
6.2 MOWER DECK BELT REPLACEMENT
(48" DECK)
CAUTION: Before performing any service or
adjustments:
5
• Turn PTO switch "OFF".
4
• Park mower on a hard, flat, level surface.
• Place steering control levers in neutral
lock (fully outward) position.
2
1
• Set parking brake.
6
• Turn ignition switch "OFF" and remove
key.
3
• 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.
1. Clutch to
Deck Belt
2. Clutch Idler Arm
3. Drive Pulley
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.
4. Electric Clutch
5. Idler Spring
6. Mower Deck Belt
Figure 16
O T0830
1. Remove mower drive belt (see procedure above).
2. Detach mower deck from tractor. See to Remove
48" Mower Deck in Service and Adjustments.
WARNING: MOVING PARTS can cut or
amputate body parts. ALWAYS wait for
moving parts to stop before unit maintenance
or service.
3. Remove sheave covers.
4. Remove mower idler spring.
5. Remove mower deck belt.
6.1 CLUTCH TO DECK DRIVE BELT
REPLACEMENT
6. Install new mower deck belt onto mower sheaves
and idler.
7. Install mower idler spring.
CAUTION: Use PROPER SPRING TOOL
when releasing and installing springs. Stored
energy in springs can cause injury.
8. Reinstall sheave covers.
9. Reinstall mower deck to tractor. See To Install 48"
Mower Deck in Service and Adjustments.
1. Disconnect idler spring from the frame, Figure 16 .
IMPORTANT: This requires a spring hook. DO NOT
use a side cutter pliers. The belt can be easily removed
from the deck.
10.Reinstall mower drive belt.
2. Remove belt from electric clutch and drive pulley.
3. Install new belt onto drive pulley and electric
clutch, checking for belt clearance.
4. Connect idler spring to frame.
6 - 19
6.4 CHECK BLADES
6.3 MOWER DECK BELT REPLACEMENT
(42" DECK)
For best results mower blades must be kept sharp.
Replace bent, worn or damaged blades.
6
2
Blade Removal
8
5
CAUTION: Moving Parts and Sharp Blades
can cut or amputate body parts. Always use
sturdy gloves or padding to protect hands
when working with mower blades.
1
4
1. Shut off the engine and unit. Remove the ignition
key. Remove the ignition wire(s) from the spark
plug(s) to prevent accidental start-up.
7
3
2. Raise mower to highest position to allow access to
blades.
8
1.
2.
3.
4.
Clutch to Deck Belt
Clutch Idler Arm
Mower Deck Belt
Drive Pulley
5.
6.
7.
8.
Electric Clutch
Idler Spring
Idler Eye-bolt
Timing Mark
Figure 17
5
4
O E0820
1. Remove mower drive belt (see procedure above).
2. Detach mower deck from tractor. See To Remove
42" Mower Deck in Service and Adjustments.
1
3. Remove sheave covers.
4. Loosen belt idler pivot and slotted idler lock nut.
3
5. Install new belt. See installation decal for routing.
6. Tighten idler eye-bolt until spring is compressed to
7/8 inch. Tighten belt idler pivot and slotted idler
lock bolt.
2
1. Blade
2. Flat Washer
3. Lock Nut
7. Loosen mower idler eye-bolt.
4. Blade Tray
5. Retainer Hub
Figure 18
8. Remove mower deck belt.
9. Match marks on mower sheaves to marks on deck
to properly align blades. The blades are driven by a
timing belt and must be positioned 90o to each
other (Figure 17).
3. Remove the locknuts, flat washers, and blades
from the spindle shafts.
Blade Installation
1. Install the blades, flat washers, and locknuts in
reverse order of removal.
6 - 20
O E0510
1
2
1. Blade
2. Bolt or Pin
Figure 19
Figure 20
NOTE: The 42" deck uses a retainer hub and blade
tray with a rectangular hole. This feature helps ensure
the blades will be 90o to each other.
2. Tighten the lock nut(s) to a torque of 60 ft-lbs
(82 Nm).
3. Put the ignition wire(s) back on the spark plug(s).
IMPORTANT: When installing blades on the 42" Mower
Deck, the two blades must be 90o to each other.
O E0500
4. Slide blade onto an unthreaded portion of the steel
bolt or pin and hold the bolt or pin parallel with the
ground. If blade is balanced, it should remain in a
horizontal position. If either end of the blade moves
downward, sharpen the heavy end until the blade
is balanced.
Sharpening Mower Blades
NOTE: We do not recommend sharpening blades, but
if you do, be sure the blade is balanced.
An unbalanced blade will cause excessive vibration
and eventual damage to mower and engine.
1. The blade can be sharpened with a file or on a
grinding wheel. Do not attempt to sharpen while on
the mower.
2. Sharpen both ends of blade at original angle,
removing equal amounts of material from each end
to maintain proper blade balance. DO NOT grind
around corner at tips of blade. If cutting edge of
blade cannot be sharpened in a straight line to
within 1/8 inch of the end, replace blade with
Ariens replacement blade only.
3. To check blade balance, use a steel bolt or pin.
6 - 21
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
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
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
38
18
19
20
21
Inspect by-pass valve
Inspect charge pressure
Inspect inlet filter
Inspect charge relief valve
39
40
41
42
Inspect for loosely mounted
components
Steering column loose or binding
Pressure relief valve sticking open
Pressure relief sticking closed
Broken relief valve spring
7
8
9
10
11
12
13
14
15
16
7 - 22
Worn or stripped gear teeth
1
2
14
3
5
4
6
13
12
15
11
10
7
9
8
1.
2.
3.
4.
5.
Back Cover
Left Hand Brake Assembly
Brake Disc
Bevel Gear
Brake Shaft Kit
6. Bypass Actuator
7. Motor Shaft
8. Filter
9. Center Section Assembly
10.Cylinder Block Assembly
11.Input Shaft
12.Variable Swashplate
13.Cradle Bearing
14.Upper Housing Assembly
15.Control Arm
Figure 21 - Left Transaxle
PE0480
7 - 23
1
17
16
2
3
15
14
4
13
5
12
6
8
11
10
7
9
1.
2.
3.
4.
5.
6.
7.
8.
Back Cover
Brake Shaft Kit
Bevel Gear
Upper Housing Assembly
Bypass Actuator
Motor Shaft
Cylinder Block Assembly
Bypass Plate
9. Filter
10.Center Section Assembly
11.Cylinder Block Assembly
12.Input Shaft
13.Variable Swashplate
14.Cradle Bearing
15.Brake Disc
16.Right Hand Brake Arm Service
Assembly
17.Brake Disc
Figure 22 - Right Transaxle
PE0480
7.2 HYDRO-GEAR FLUID
RECOMMENDATIONS
Protect all exposed sealing surfaces and open cavities
from damage and foreign material.The outer surfaces
of the transaxle should be cleaned before beginning
any repairs.
The fluids used in Hydro-Gear transaxles have been
carefully selected, and only equivalent or better
products should be used.
Shaft Seals
7.3 HYDRO-GEAR REPAIR
Lip type seals are used on the pump input shaft, the
displacement control shaft and bypass actuator shaft of
the transaxle. These seals can be replaced without
major disassembly of the unit. Replacement of these
seals will require removal of the transaxle from the
machine frame.
Cleanliness is a primary means of assuring satisfactory
life of either new repaired units. Cleaning parts by
using solvent wash and air drying is usually adequate.
As with any precision equipment, all parts must be kept
free of foreign materials and chemicals.
To remove the input shaft seal carefully pull the seal
out of the housing bore with a "hook" type tool or a
slide hammer type puller. Care must be taken to avoid
damage to the housing bore or to the shaft sealing
surface.
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.
7 - 24
Lubricate the new seal prior to installation with a
petroleum jelly.
7. All components should remain in the upper
housing (positioned down).
Wrap the shaft spline with a thin plastic or cellophane
tape to prevent damage to the new seal lip during
installation.
8. Remove the brake gear from the brake shaft.
9. Remove the oil seals from the brakes shaft. Push
out the brake shaft to remove the support bearing.
NOTE: Prior to reassembly the lower and rear covers
must be thoroughly cleaned and old sealant must be
removed.
NOTE: The lip seals must not be re-used during reassembly.
Slide the seal over the shaft and press it into the
housing bore. Be careful not damage the seal. The
seal should seat against the retaining ring.
The displacement control shaft seal and bypass
actuator shaft seal may be replaced following similar
procedures.
10.Inspect the final drive gear teeth for excessive
wear or damage.
11.Inspect the brake gear internal splines for
excessive wear or damage. See Figure 24.
12.Inspect the brake cam for excessive wear and
damage.
Replace brake gear and cam as a complete kit if
excessive wear or damage is found, and inspect all
other mating parts.
13.Using a 9/16" socket (or box end) wrench, remove
the three assembly bolts retaining the center
section in the upper housing.
Figure 23
CAUTION: The pump and motor piston
springs may push the center section
assembly out of position while you remove
these bolts.
Internal Repair
1. Drain the oil by removing the breather assembly
and positioning the IHT so that the breather port is
down to allow the oil to drain thoroughly.
2. Position and secure the IHT with the upper housing
down to allow access to the ten housing assembly
cap screws.
3. Remove the eight rear housing assembly cap
screws.
4. Remove the ten bottom cover assembly screws.
5. Remove the torques head cap screw holding the
brake arm to the transaxle case.
6. Remove the bottom and rear covers from the
transaxle.
NOTE: The sealant will make the covers difficult to
remove.
Figure 24
14.Remove the center section assembly from the
housing. The pump block assembly should remain
in the upper housing on the input shaft, but may
stick to the center section. Check the check valve
plate bolt torque, but do not remove. Two styles of
check plates have been used, one has three bolts
while the other has four.The one with four bolts
should be torqued from 170 to 240 in-lbs.
(19.2-27.1 Nm) while the one with three bolts
should be torqued from 135 to 185 in-lbs
(15.2-20.9 Nm)
CAUTION: The aligning pins, motor shaft,
bypass plate, pump block and motor block
assemblies are NOT retained to the center
section or the upper housing and may
become separated from the assembly during
removal.
15.Remove the motor block assembly from the motor
shaft and inspect for unusual wear or damage. The
pistons should fit with very little side clearance in
the block bores, but must side freely.
NOTE: The correct bore diameter for the block is
0.6776 to 0.6784 and the pistons should be 0.6767 to
0.6770.
7 - 25
Figure 25
Figure 27
16.Remove the motor shaft, washers and bypass
plate from the center section and inspect for
unusual wear or damage.
19.Remove the slot guide from the displacement
control shaft.
Inspect the center section running surfaces for unusual
wear or damage.
20.Remove the bypass actuator from the housing.
21.Reposition the housing and remove the input shaft
lip seal from the housing bore. A hook type tool
may be used to pry the seal out. Care must be
taken to avoid damage to the housing bore, shaft
sealing surface or bearing. Once removed, the seal
is not reusable.
22.Remove the input shaft bearing ring.
23.Remove the pump input shaft assembly from the
housing.
24.Inspect the shaft and bearing for unusual wear or
damage.
25.Reposition the top housing and remove the
displacement control shaft and lip seal. Inspect the
housing for damage.
Figure 26
7.4 REPLACEMENT OF PARTS
17.Remove the pump block assembly, block thrust
washer and spring from the input shaft and inspect
for unusual wear or damage. The pistons should fit
with very little side clearance in the block bores,
but must slide freely.
NOTE: The correct bore diameter for the block is
0.6295 to 0.6303 and the pistons should be 0.6288 to
0.6291.
18.Remove the motor thrust bearing assembly
swashplate kit and cradle bearing from the housing
and inspect for unusual wear or damage.
All parts should be thoroughly cleaned in a suitable
solvent. All sealant material MUST be removed from
the housing prior to reassembly.
Inspect all parts for damage, nicks or unusual wear
patterns. Replace all parts having unusual, excessive
wear or discoloration.
Inspect the sealing surfaces, bearing surfaces, and
shaft splines. Polish the sealing areas on the shafts if
necessary. Replace any worn or damaged parts.
The running surfaces of the cylinder blocks MUST be
flat and free from scratches. If scratches or wear are
found on the running surface of the cylinder block or
center section, polish or replace the parts, When
polishing these surfaces, up to 0.0004" may be
removed. If this is not sufficient to obtain a flat surface
free of scratches, the part should be replaced.
Clean and lightly oil parts prior to assembly of the IHT.
Be sure to torque all threaded parts to the
recommended torque levels.
Replace all o-rings and shaft seals.
7 - 26
Apply the sealant to the lower and rear housing.
NOTE: Sealant must be of good quality, oil and heat
resistant.
CAUTION: Most parts have critical high
tolerance surfaces. Care must be exercised to
prevent damage to these surfaces during
assembly. Protect exposed surfaces, opening
and ports from damage or foreign material.
1. Install the displacement control shaft.
2. Install the pump input shaft assembly and retaining
ring into the housing.
3. Install the pump shaft lip seal.
16.Position the lower and rear covers onto housing
case onto the upper housing and secure with
assembly bolts. Torque the bolts from
135 to 165 in-lbs (15.2-18.6 Nm). The group of
bolts around the bottom and rear covers of the
housing have the same sequence number
because they are installed simultaneously at our
factory, the order in which you torque them should
not be important.
4. Reposition the upper housing and install the cradle
bearings.
After torquing all bolts, wipe off any excess sealant
from the seam of the housing.
5. Install the slot guide block onto the displacement
control shaft.
Reposition the transaxle assembly and check the
bypass actuator and axle shaft for freedom of
movement. The axle should not lock up but may be
tight, while the bypass actuator must rotate freely.
6. Install the swashplate assembly into the housing.
The slot on the swashplate must engage the slot
guide block on the displacement control shaft. Use
a tool such as a screwdriver to hold the guide block
in position while installing the swashplate.
7. Install the thrust washer and pump block spring
onto the pump shaft.
NOTE: To simplify the installation of the pump block,
wrap a rubber band snugly around the pistons. This is
intended to hold the pistons in their bores as the block
kit is handled during installation.
Torque the nut on the brake bolt from 120 to 185 in-lbs
(13.5-20.9 Nm)
17.Install a new lip seal on the displacement control
shaft & bypass actuator shaft.
18.Install the control arm and friction pack.
19.Install the bypass actuator arm and retaining ring.
Use care to avoid over extending the retaining ring.
8. With the swashplate in the neutral (0 angle),
lubricate the running surfaces and install the block
kit onto the pump input shaft. Make sure the
splines engage properly.
Prior to adding oil to the IHT it is recommended that
you test for leaks. This may be performed with a small
hand pump or by using compressed air and a regulator.
Do not allow more than 10 PSI to be applied or seal
damage may occur. To locate a leak, apply a soap
mixture around the housing seam and at all lip seals.
9. Install the aligning pins and the bypass actuator
into the housing.
7.5 OIL FILL & START-UP PROCEDURES
10.Install the bypass plate (small end first) into the
center section.
Fill the IHT with a 20W-50 engine oil. The correct
volume for fill should be 2 1/2 quarts (80 ounces).
11.Lubricate the running faces and install the motor
block kit onto the motor shaft.
It is recommended that the unit be purged prior to
installing into the tractor frame. The following is the
suggested purging procedures for repaired transaxle.
12.Position the washers and seal and install the
center section assembly onto the aligning pins and
pump input shaft.
13.Install the motor shaft into the center section.
14.Insert the two assembly bolts into the center
section and press center section down onto the
aligning pins and pump input shaft until sealed on
mounting bosses. While holding the center section
in position, torque the bolts evenly from 525 to 700
in-lbs (59.3-79 Nm).
15.Install the motor thrust bearing (with the thicker
race towards the pistons) by compressing the
piston springs and sliding the bearing assembly in
to place.
NOTE: The tool being showed is an example of what
you will need to compress the pistons and allow the
bearing to be installed.
1. Spin the input shaft in a clockwise direction at
1000-1500 RPM This may be performed in a drill
press (or equivalent).
2. Engage (actuate) the bypass.
3. Stroke the control lever forward for five seconds
and then reverse for five seconds. Do this three
times in each direction.
4. Return the control lever to neutral.
5. Disengage the bypass.
6. Stroke the control lever forward for five seconds
and then reverse for five seconds. Do this three
times in each direction.
NOTE: It may be necessary to repeat these steps in
the vehicle to fully purge the IHT.
7 - 27
Check the oil level after fully purging the unit of air. It
should be between 1.25" and 1.62" (3.175-4.11 cm)
from the top of the housing.
After installing the IHT, make sure all linkages and
actuators and functioning properly.
7.6 HYDRO-GEAR TRANSMISSION
REMOVAL
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.
Figure 28
3. Raise and block the unit frame on jack stands
behind of the transaxle in the frame.
Do not tighten any hardware until all the support
hardware is installed.
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 on the top of
the units frame by pulling the hair pin and releasing
the tension spring.
7. Tighten the shifting cam friction pack lock nut to
hold the transaxle neutral position.
8. Remove the cap screw, flat washer and locknut on
the shift rod and remove the shift rod ball joint from
the transaxle cam arm.
9. Do not remove or loosen the hardware on the
transaxle sub-frame at this point.
3. Install the two flat washers, compression spring
and hair pin on the rear of the brake rod which
return/release the brake arm.
4. Install the cap screw, flat washer and lock nut on
the shift rod ball joint securing it to the transaxle
shift cam.
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 wheel with the lug nuts removed
earlier.
10.Support the transaxles subframe with a floor jack
from the rear of the tractor.
11.Remove the rear anchor strap from the transaxle
subframe and the rear of the unit.
Transaxle Neutral Adjustment
12.Remove the two right and left front anchor bolts
holding the transaxle subframe to the tractor frame
and remove the two rear anchor bolts from the left
and right side holding the transaxle subframe to
the units frame and lower jack.
13.With the transaxle assembly removed from the
units frame, place the axle assembly on a flat work
surface.
1. Make sure that the rear of the unit is suspended
before the unit is started.
2. Make sure that the interlock system is operational
before proceeding.
3. Place a weight onto the seat to activate the seat to
activate the seat switch.
4. Unbolt tie rod from transaxle flange.
5. Start engine and observe wheel motion.
6. Turn transmission cam until wheel stops turning.
Tighten cam locking nut. Stop unit and connect
linkage.
7.7 HYDRO-GEAR TRANSMISSION
INSTALLATION
Before installing the transaxle assembly into the tractor
frame with the axle subassembly installed, the
following items will need to be done.
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.
2. When all the hardware is in place, tighten to the
appropriate torque according to the hardware
torque chart.
7. Adjust to proper length. Unlock cam locking nut
and start engine. Test for creep. Repeat if needed.
8. If neutral adjustment is needed refer to Neutral
Adjustment section.
7 - 28
SECTION 8 - POWER TAKE OFF
8.3 PTO JACKSHAFT INSTALLATION
8.1 PTO JACKSHAFT REMOVAL
1. Place the unit on a flat level surface, and lower the
mower pan.
2. Open the front panel by removing the two cap
screws in the lift handle cover plate. Remove the
two tap tites in the front panel and remove panel
exposing the battery and electrical system.
1. Prior to installing the jackshaft assembly into the
unit frame, check the condition of the clutch anchor
strap. Repair or replace if necessary.
2. Place the jackshaft drive belt into the jackshaft
sheave while reinstalling the PTO clutch jackshaft
assembly into the frame of the unit.
3. Remove the negative lead from the battery, and the
ignition coil lead from the spark plug(s) on the
engine.
3. Hold in place with four grade 5 cap screws
removed earlier. Torque to 25 ft-lbs (33.8 Nm)
4. Support the unit on jack stands. Remove the right
drive wheel.
4. Reattach the jackshaft idler tension spring to
transaxle subframe and plug the PTO wiring into
the clutch.
5. Remove the jackshaft idler tension spring from the
transaxle subframe.
5. Reinstall the right drive wheel. Remove the unit
from the jack stands.
6. Unplug the PTO clutch from the wire harness.
6. Install the PTO belt from the PTO clutch to the top
of the mower deck jackshaft.
7. Remove the PTO drive belt from the PTO clutch
and the top of the mower pan jackshaft.
8. Remove the four grade 5 cap screws on the top of
the frame holding the jackshaft assembly into the
frame.
7. Rotate the mower deck blades by hand. Check the
routing of the belt and function of the idlers.
8. Reattach the negative lead to the battery, and the
ignition coil lead to the spark plug(s) on the engine.
8.2 PTO JACKSHAFT REPAIR
1. Place the jackshaft assembly on a workbench.
Remove the grade 5 cap screw from the top of the
jackshaft assembly, and the grade 5 cap screw
from the bottom of the jackshaft assembly.
2. Remove the PTO clutch, the jackshaft sheave, and
pull the spindle shaft out of the bearings that are
pressed into the spindle housing.
3. Check spindle bearings for wear and replace as
needed.
4. Insert the spindle shaft into the spindle housing.
Hold in place with a flat washer, lock washer, and
grade 5 cap screw. Treat the cap screw with Loctite
#271 in reassembly.
5. Add key to spindle shaft and install the jackshaft
sheave.
6. Check electric PTO clutch for proper function and
operation prior to installation on the spindle shaft.
7. Install the grade 5 cap screw in the bottom of the
PTO clutch treated with Loctite #271 and torque tip
and bottom cap screws to 40 ft-lbs (54.2 Nm).
8 - 29
SECTION 9 - LIFT SYSTEM
9.1 LIFT SYSTEM
2. Place the lift handle in the highest cutting height
available.
Refer to Figure 29 for the lift system.
The mower pan lift system is a manual lift system
controlled by the operator.
9.2 LIFT SYSTEM REMOVAL
1. Remove the mower deck from the unit prior to lift
system removal.
3. Remove the plate, parking brake knob and front
panel to expose the lift system.
NOTE: The decklift handle must be in the highest position when the tension spring is released. This places
the spring in the relaxed state.
1
2
3
4
5
6
1.
2.
3.
4.
5.
6.
Tension Spring
Decklift Handle
Release
Detent Plate
Handle Bracket
Lift Lever
Figure 29
PE0450
4. Remove the tension spring.
5. Lower the decklift handle to reduce stress on the
release handle.
6. Remove springs on the release handle.
7. Inspect and replace worn parts as needed.
8. To remove lift weldment, remove two cap screws
holding bracket handle to lift weldment. Remove
cotter pins and two flat washers on each end of
weldment. Slide weldment to the left until it clears
the bushing. Lower and slide right to remove.
9. Assemble in reverse order.
9 - 30
SECTION 10 - FUEL SYSTEM
10.1 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
10 - 31
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
10.5 FUEL TANK REMOVAL
10.2 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.
10.3 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.
10.4 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.
1. Remove deck for easy access to gas tank bolts,
referring to Deck Removal.
2. Remove front plate and disconnect battery ground
wire.
3. Remove engine cover
4. Remove left side shroud, unhook two rear idler
springs.
5. Remove belt from engine sheave. Double idler
assembly may be removed for better access to
engine bolts.
6. Disconnect all engine wiring, throttle and/or choke
cable and gas line from engine. (Drain gasoline
back to gas tank.)
7. Remove engine bolts and remove engine. Remove
four gas tank bolts and remove gas tank.
Disconnect gas line and attach to new gas tank.
8. Install gas tank. Position as far back in the slots as
possible before completely tightening gas tank
bolts.
9. Reinstall engine, wiring, gas line, and throttle
cable.
10.Install double idler and belt. Hook up double idler
springs. Install left side shroud, engine cover, and
mower deck. Connect ground wire to battery and
install front access plate.
10 - 32
SECTION 11 - ELECTRICAL
11.1 TOOLS
11.2 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 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 replacement parts only. Engine parts, such as rectifiers or
alternator components should be secured through the
nearest engine service center.
Ariens 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.
11 - 33
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.
IMPORTANT: Disconnect the equipment battery when
making Ohmmeter test or damage to the Ohmmeter
may result.
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.
11.3 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.
Set-Up
The new battery is dry charged. The dealer or
customer must add electrolyte (sulfuric acid and
water).
1. Remove the battery from the unit.
2. Remove all the vent caps from the battery and set
the caps to one side.
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.
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!
11 - 34
Clean Battery
Corrosion and dirt on the battery and terminals can
cause the battery to "leak" power.
• Remove battery. (See Battery Removal and
Installation)
1
2
• Rinse the battery with plain water and dry.
• Clean terminals and battery cable ends with wire
brush until bright.
3
• Coat terminals with grease or petroleum jelly.
• Reinstall battery.
4
Battery Removal and Installation
1.
2.
3.
4.
Remove battery before service.
Negative (1) Terminal
Positive (+) Terminal
Battery Rod
Wing Nut
Figure 31
O E0151
2
1
5. Remove wing nut from the battery rod and remove
the rod.
3
6. Disconnect the negative (-) cable first.
4
7. Disconnect the positive cable (+) second.
8. Lift the battery out of the unit and place battery on
a bench or other well ventilated area where an acid
spill will not create damage.
1. Screws
2. Lift Lever Access
Panel
3. Parking Brake Knob
9. When service is finished, reinstall battery into unit
and connect positive (+) cable first, then negative
(-) cable and battery rod.
4. Front Panel
Figure 30
O E0710
10.Reinstall front panel, making sure tabs fit securely
into slots in frame. Secure with hardware.
11.Reinstall the lift lever access plate and the knob on
the parking brake lever.
To remove the battery from the unit:
1. Remove the two hex screws from the lift lever
access plate and remove the plate.
Inspection, Cleaning, Drying, and Maintenance
2. Remove the two self-tapping screws at the top of
the front panel.
3. Unscrew the knob from the parking brake lever.
4. Lift the front panel off the unit by lifting it up and out
of slots in frame, clearing the lift lever.
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.
11 - 35
Electrolyte Level
room temperature and the charging time can be
estimated. For example:
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.
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.
Charging
ALWAYS follow information provided on battery by
battery manufacturer. Contact battery manufacturer for
extensive instructions to charge battery.
Place unit on a level surface, shut off engine and open
battery compartment to gain access to battery.
Disconnect negative (-) cable first, then positive (+)
cable.
To charge battery:
OCV
Specific
Gravity
% of
Charge
Charging
Time
12.60
1.265
100%
---
12.4
1.225
75%
3 hours
12.20
1.180
50%
7 hours
12.00
1.130
25%
10 hours
11.80
1.100
0%
12 hours
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).
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.
IMPORTANT: Charging at higher rates will damage the
battery and cause excessive gassing and acid
spewing.
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).
Battery Charger
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.
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.
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
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).
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.
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.
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
11 - 36
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.
11.4 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.
11 - 37
Ignition Switch
NOTE: Refer to the wiring diagram of the unit involved
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 three positions: OFF, RUN, 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 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 A. These connections supply power to the rest of
the wiring harness. Connections G and M open to each
other.
START Position - Hold switch in START position while
testing. There should be continuity between contacts
S1 and S2. 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.
(03602300)
A
S2
S1
B
M
A
S2
G
OFF
S2
S1
B
M
G
RUN
S1
B
M
If a relay or solenoid fails to operate, the cause may be
either electrical or mechanical.
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 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.
Key Switch
A
cases a relay contact moves only a fraction of an inch
and the magnetic pull is small.
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.
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.
G
START
Figure 32
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.
11.5 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.
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
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.
11 - 38
11.6 LIGHTING CIRCUITS
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.
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).
Rectifiers
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.
If the fuse and lamps are good, check the circuit with
an AC/DC voltmeter.
11.7 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.
11.8 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.
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
a service center has access to the information and
parts required to test and repair or replace engine
components, including rectifiers and regulators.)
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.
11.9 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 dealers should be able to
test engines and engine components to pinpoint
troubles and narrow them down to properly advise the
engine serviceman.
11.10 EZR 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.
11 - 39
STEP 1
the starter solenoid and goes to ground through the
base of the starter solenoid.
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.
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.
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
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 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.
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.
.
Key Switch
B
Off
11.50-13.00 Volts
A
Run
Start
11.50-13.00 Volts
11.50-13.00 Volts
11.50-13.00 Volts
11.50-13.00 Volts
S-1
11.50-13.00 Volts
S-2
11.50-13.00 Volts
11.50-13.00 Volts
Contact resistance is 0.1-0.3 ohms when correct.
Seat Switch
Off
Pink
Run
Start
Connected to Ground through test switch
Black
Connected to Ground
Normally open contacts manually activated. contact
resistance is 0.1-0.3 ohms when correct.
11 - 40
PTO Switch
Off
Run
Start
Yellow/Red
11.50-13.00 Volts
11.50-13.00 Volts
Purple/white
Connected to PTO Clutch
Purple
11.50-13.00 Volts
11.50-13.00 Volts
Brown/Yellow
11.50-13.00 Volts
11.50-13.00 Volts
2 sets of contacts, one normally open, one normally closed. Contact resistance is 0.1-0.3 ohms when correct.
Left Hand Neutral Switch
Off
Run
Start
Brown/Yellow
11.50-13.00 Volts
11.50-13.00 Volts
White
11.50-13.00 Volts
11.50-13.00 Volts
Normally open contacts manually activated. Contact
Resistance is 0.1-0.3 ohms when correct.
Right Hand Neutral Switch
Off
Run
Start
White
11.50-13.00 Volts
11.50-13.00 Volts
Red/Violet
11.50-13.00 Volts
11.50-13.00 Volts
Normally open contacts manually activated. Contact
Resistance is 0.1-0.3 ohms when correct.
Seat/PTO Relay
Off
Run
Start
Purple
86
11.50-13.00 Volts
Pink
85
Connected to ground through seat switch
Yellow/Red
87
11.50-13.00 Volts
11.50-13.00 Volts
87A
Not Used
Not Used
30
11.50-13.00 Volts
11.50-13.00 Volts
Purple
11.50-13.00 Volts
Pins 85-86 coil resistance 87-100 ohms. pins 30-87 normally open. Pins 30-87A normally open. Contact resistance
is 0.1-0.3 ohms when correct.
Start Relay
Off
Yellow/Red
86
Black
85
Run
11.50-13.00 Volts
87A
Black
30
11.50-13.00 Volts
Connected to Ground
87
White/Black
Start
Not Used
Not Used
Connected to Ignition Module
Connected to Ground
Pins 85-86 coil resistance 87-100 ohms. pins 30-87 normally open. Pins 30-87A normally closed. Contact
resistance is 0.1-0.3 ohms when correct.
11 - 41
Solenoid
Off
Run
Small Brown
Start
11.50-13.00 Volts
Small Black
Connected to Ground
Large Red (Battery)
11.50-13.00 Volts
11.50-13.00 Volts
Large Red (Starter)
11.50-13.00 Volts
11.50-13.00 Volts
Normally open contacts (big terminals) coil resistance 3.0-5.0 ohms. Contact resistance is 0.1-0.3 ohms when
correct. Electrically activated.
PTO Clutch
Off
Run
Start
Purple/white
Black
Connected To Ground
Coil Resistance check clutch specifications.
Brake Switch
Off
Run
Start
Yellow/Red, Yellow/Red
11.50-13.00 Volts
11.50-13.00 Volts
Yellow/Red
11.50-13.00 Volts
11.50-13.00 Volts
Normally closed contacts mechanically activated. Contact resistance 0.1-0.3 ohms. Used on models 915013, 014,
015, 106, 306, 307.
11 - 42
11.11 WIRING DIAGRAMS
SEAT
SWITCH
SEAT / PTO RELAY
HEADLIGHTS
30
PINK
86
87a
BLACK
85
1
2
87
BLACK
BLACK
RED / YELLOW
BLACK
OPTIONAL
HOUR
METER
PTO
SWITCH
7
4
PTO
CLUTCH
1
3
PURPLE
PURPLE /
WHITE
1
OPTIONAL
BLACK
BRAKE
SWITCH
PURPLE
REGULATOR
2
RED / YELLOW
FUEL SOLENIOD
START
RELAY
ENGINE
1
30
2
BLACK
86
87a
87
BLACK
RED / YELLOW
WHITE / BLACK
STARTER
A
B
RED
B
RED
FUSE
30A
RIGHT HAND
NEUTRAL
SWITCH
M
BLACK
G
BLACK
BROWN
2
S1
RED / VIOLET
S2
STARTER
SOLENOID
2
1
A
BATTERY
LEFT HAND
NEUTRAL
SWITCH
85
RED / VIOLET
RED
BLACK
BLACK
WHITE
MAGNETO KILL
BROWN / YELLOW
9
1
KEY
SWITCH
BLACK
11 - 43
11.12 RELAYS AND SWITCHES
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
Relay
(03602300)
(03042800)
A
A
S2
A
S2
S1
B
87
S2
S1
B
86 87A
M
G
G
M
87
S1
B
85
30
OFF
RUN
PTO Switch
30
ENERGIZED
Neutral Switch
3
9
3
9
(01526100)
1
4
1
7
4
DISENGAGED
(down position)
1
7
2
STEERING LEVER
IN POSITION
(button up)
ENGAGED
(up position)
Seat Switch
Brake Switch
(03654200)
(03657100)
1
85
START
NOT ENERGIZED
(01545600)
86 87A
G
M
2
1
2
STEERING LEVER
OUT POSITION
(button down)
2
1
OPERATOR
OFF SEAT
1
2
DISENGAGED
(button down)
OPERATOR
ON SEAT
1
2
ENGAGED
(button up)
Solenoid
(03057700)
NOT ENERGIZED
ENERGIZED
PE 0520
11 - 44
SECTION 12 - MOWER ATTACHMENT
12.1 42" MOWER SPINDLE REMOVAL
2
1
3
4
4
5
5
6
7
8
1.
2.
3.
4.
6
7
8
Jackshaft
Compression Spring
Idler Pulley Assembly
Spindle Shaft
5.
6.
7.
8.
Drive Sprocket
Spindle Housing Assembly
Retainer Hub
Blade Tray
Figure 33
PE 0550
1. With the mower deck removed from the unit the
disassembly of the mower may be done.
5. Reduce belt tension on the belt by loosening the
nut for the idler pulley compression spring.
2. Remove the mower spindle covers.
6. Remove the spindle sheaves and shaft assemblies
3. Remove the mower deck blades hardware, mower
deck blades, blade trays retainer hub, spindle key
and bearing slinger.
7. Remove the mower spindle housings from the
mower deck stamping.
8. Assemble in reverse order.
4. Loosen belt idler pivot and slotted idler lock nut.
12 - 45
12.2 48" MOWER SPINDLE REMOVAL
1
2
3
4
6
5
7
8
7
8
1.
2.
3.
4.
Sheave
Ball Bearing
Sheave
Plastic Idler
5.
6.
7.
8.
Compression Spring
Ball Bearing
Retainer Hub
Blade Tray
Figure 34
12.3 42" SPINDLE REPAIR
With the mower deck removed from the unit, the
disassembly of the mower may be done.
The spindle should not be repaired. Replace it as an
assembly.
1. Remove the right and left side mower spindle
cover.
2. Remove the mower deck blades hardware, mower
deck blades, blade trays retainer hub, spindle key
and bearing slinger.
3. Remove the mower deck spindle drive belt form
the spindle sheaves.
4. Remove the spindle sheaves from the shaft
assemblies.
5. Remove the mower spindle housings from the
mower deck stamping.
6. Assemble in reverse order.
PE 0500
12.4 48" SPINDLE REPAIR
When the spindle housing has been removed from the
mower deck, the spindle shaft and bearings may be
removed from the housing.
1. Prior to removal of the bearing in the housing out in
a press.
2. If the housing has been damaged replace the
spindle shaft, bearings and housing.
3. Press new bearings into the spindle housing with a
press, make sure to insert the spindle shaft into the
housing before pressing the second bearing into
place.
12 - 46
Ariens Company
655 West Ryan Street
P.O. Box 157
Brillion, WI 54110-0157
920-756-2141
Fax 920-756-2407
www.ariens.com