Gravely Sport Zoom ZT1232, ZT1440 Riding Mower Service Manual

 Fa (GRAVELY)
Sport Zoom ZT1232/ ZT1440
Ariens 915031, 033
Gravely 915030, 032
Service Manual
e
01610600 8/03
Printed in USA
TABLE OF CONTENTS
Section6- FuelSystem .................
Section 1 - Introduction .................. 1-3
1.1 TheManual ........................ 1-3
1.2 Model and Serial Numbers ............ 1-3
1.3 Product Registration ................. 1-3
1.4 Unauthorized Replacement Parts ....... 1-3
1.5 Disclaimer ............e.0mereere. 1-3
Section2- Safety ....................... 2-4
2.1 Safety AlertSymbol.................. 2-4
2.2 Signal Words ................eserem. 2-4
2.3 Notations ...........—e———eseeereroen. 2-4
2.4 Practices and Laws .............e.—.—. 2-4
2.5 Réquired Operator Training ............ 2-4
26 SafetyRules. ....................... 2-4
Section 3 - Specifications ................ 3-7
Section 4 - General Maintenance
&Adjustments................. 4-8
41 Controlsand Features... ............. 4-8
4.2 Safety Interlock System. .............. 4-8
4.3 Filling FuelTank. .................... 4-9
4.4 Service Position. .................... 4-9
4.5 Cleaning and Storage ................ 4-9
4.6 Maintenance Schedule .............. 4-10
4.7 Remove and Install 32-inch Mower Deck. 4-11
4.8 Leveling 32-inch Mower Deck ......... 4-11
4.9 Remove and Install 40-inch Mower Deck. 4-12
4.10 Leveling the 40-inch Mower Deck . . ... 4-12
4.11 Adjust Level Of Mower Deck ......... 4-12
4.12 Mower Height Adjustment ........... 4-13
4.13 Antiscalp Roller Adjustment
(915032, 033). .................... 4-13
4.14 Mower Deck Pitch Adjustment. ....... 4-13
4.15 Hydrostatic Transmission Neutral
Adjustment. ................ LL 4-14
4.16 Adjusting Unit to Track Straight ....... 4-14
4.17 Adjust Parking Brake ............... 4-15
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
59 EngineRemoval. ................... 5-17
5.10 Engine Installation... ............... 5-18
6.1 Fuel System Troubleshooting. .........
6.2 FuelTank Removal. .................
6.3 Fuel System Contamination. ..........
6.4 Рие! ТапК.........................
бесНоп 7 - Опме Тта!п............. 5.5. ...
7.1 Hydro Transmission Troubleshooting . . . .
7.2 Hydro-Gear Fluid Recommendations ...
7.3 Hydrostatic Belt Replacement .........
7.4 Hydro-Gear Transmission Removal . . . ..
7.5 Hydro-Gear Transmission Installation . . .
Section 8 - MowerDeck .................
8.1 PTO Belt Replacement
(915030/915031)...................
8.2 Mower Belt Replacement
(915032/915033) ...................
8.3 Mower Blade Replacement ....... SR.
8.4 32-inch Mower Spindle Repair. ........
8.5 40-inch Mower Spindle Repair. ........
8.6 To Replace the Electric Clutch... ......
8.7 To Replace Clutch Spindle Bearings . . . .
88 LiftSystem........................
Section 9- Electrical....................
91 Tools. ........ oi erre.
9.2 Electrical Measurements. ............
93 Battery. ......... 4 eee 40
9.4 Servicing the Battery ................
9.5 Switches. ..............—.-sesrrerec.
9.6 Solenoid and Relays ................
9.7 Ризез.................... 55555...
9.8 Diodes and Rectifiers... .............
99 ElectricClutch .....................
9.10 Electrical ........................
9.11 Wiring Diagram ...................
9.12 Continuity Diagram ................
9.13 Electrical System.................
``
C
=
1.1 THE MANUAL
The purpose of this manual is to provide complete
instructions for service, maintenance, disassembly,
repair, and installation of the mechanical components
for the Sport Zoom.
Dealer trained service personnel should use this
manual as a supplement to and reminder of the training
sessions conducted by the company.
Read all information for servicing a part or system
before repair work is started to avoid needless
disassembly.
All reference to left, right, front, or rear are given from
operator seated in operation position and facing the
direction of forward travel.
1.2 MODEL AND SERIAL NUMBERS
When ordering replacement parts or making service
inquiries, know the Model and Serial numbers of your
unit and engine.
Numbers are located on the product registration form in
the unit literature package. They are printed on a serial
number label, located on the frame of your unit.
Engine Serial Number Label
Unit Serial Number Label
Figure 1 OA0017
* Record Unit Model and Serial numbers here.
* Record Engine Model and Serial numbers here.
SECTION 1 - INTRODUCTION
1.3 PRODUCT REGISTRATION
The Ariens/Gravely dealer must register the product at
the time of purchase. Registering the product will help
the company process warranty claims or contact you
with the latest service information. All claims meeting
requirements during the limited warranty period will be
honored, whether or not the product registration card is
returned. Keep a proof of purchase if you do not
register your unit.
Customer Note: If the dealer does not register your
product, please fill out, sign, and return the product
registration card to Ariens/Gravely.
1.4 UNAUTHORIZED REPLACEMENT
PARTS
Use only Ariens/Gravely replacement parts. The
replacement of any part on this unit with anything other
than Ariens/Gravely authorized replacement part may
adversely affect the performance, durability, and safety
of this unit and may void the warranty. Ariens/Gravely
disclaims liability for any claims or damages, whether
warranty, property damage, personal injury or death
arising out of the use of unauthorized replacement
parts.
1.5 DISCLAIMER
Ariens/Gravely reserves the right to discontinue,
change, and improve its products at any time without
notice or obligation to the purchaser.
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.
A WARNING À
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
SECTION 2- SAFETY
WARNING: This cutting machine is capable of
amputating hands and feet and throwing
objects. Failure to observe the safety
instructions in the manuals and on decals could
result in serious injury or death.
Slopes are a major factor related to loss-of-
control and tip-over accidents. Operation on all
slopes requires extra caution.
Tragic accidents can occur if the operator is not
, Alert to the presence of children. Never assume
“that children will remain where you last saw
them.
Gasoline is extremely flammable and the vapors
are explosive, handle with care.
Disengage attachment, stop unit and engine,
remove key, engage parking brake, and allow
moving parts to stop before leaving operators
position.
2.1 SAFETY ALERT SYMBOL
These are safety alert symbols. They
mean:
ATTENTION!
«YOUR SAFETY IS INVOLVED!
When you see this symbol:
BECOME ALERT!
«OBEY THE MESSAGE!
OL1253
OL3500
2.2 SIGNAL WORDS
The safety alert symbols above and signal words below
are used on decals and in this manual.
Read and understand all safety messages.
DANGER: IMMINENTLY HAZARDOUS
SITUATION! If not avoided, WILL RESULT in
death or serious injury.
WARNING: POTENTIALLY HAZARDOUS
SITUATION! if not avoided, COULD RESULT in
death or serious injury.
CAUTION: POTENTIALLY HAZARDOUS
SITUATION! if not avoided, MAY RESULT in
minor or moderate injury. It may also be used to
alert against unsafe practices.
2.3 NOTATIONS
NOTE: General reference information for proper opera-
tion 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, including those that may
restrict the age of the operator.
2.5 REQUIRED OPERATOR TRAINING
Original purchaser of this unit was instructed by the
seller on safe and proper operation. If unit is to be used
by someone other than original purchaser (loaned,
rented or sold), ALWAYS provide this manual and any
needed safety training before operation.
2.6 SAFETY RULES
If unit is to be used by someone other than original
purchaser; loaned, rented or sold, ALWAYS provide
this manual and any needed safety training before
operation.
Read, understand, and follow all safety practices in
Owner/Operator Manual before assembling, using or
working on this mower.
ALWAYS remove key from ignition and wire from spark
plug before assembly, or working on this unit.
Inspect unit before each use for: missing or damaged
decals and shields, correctly operating safety interlock
system, and deterioration of grass catchers. Replace or
repair as needed.
ALWAYS check overhead and side clearances carefully
before operation. ALWAYS be aware of traffic when
crossing or operating along streets or curbs.
Keep children, people, and pets away. Be alert and
shut off unit if anyone enters work area. Keep children
under watchful care of a responsible adult.
NEVER allow children to operate or play on or near
unit.
Keep area of operation clear of all toys, and debris.
Thrown objects can cause injury.
Stay alert for hidden hazards, holes, and ruts.
Avoid uneven or rough terrain. DO NOT operate near
drop offs, ditches, or embankments. Unit can suddenly
2-4
“>
turn over if a wheel is over the edge of a cliff or ditch, or
if an edge caves in.
Dust, fog, etc. can reduce vision and cause an
accident. Operate unit only when there is good visibility
and light.
Data indicates that operators, age 60 and above, are
involved in a larger percentage of riding mower related
injuries. These operators should evaluate their ability to
operate the riding mower safely enough to protect
themselves and others from serious injury.
Only trained adults may operate unit. Training includes
being familiar with controls and actual operation.
NEVER operate unit after or during the use of
medication, drugs or alcohol.
NEVER allow anyone to operate this unit when their
alertness or coordination is impaired.
Wear adequate safety gear, sturdy shoes, and
protective gloves.
DO NOT wear loose clothing or jewelry and tie back
hair that may get caught in rotating parts.
Protect eyes, face and head from objects that may be
thrown from unit. Wear appropriate hearing protection.
Always wear safety goggles or safety glasses with side
shields when operating mower.
Avoid sharp edges. Sharp edges can cut. Moving parts
can cut off fingers or a hand.
ALWAYS keep hands and feet away from all rotating
parts during operation. Rotating parts can cut off body
parts.
ALWAYS keep hands away from all pinch points.
DO NOT touch unit parts which might be hot from
operation. Allow parts to cool before attempting to
maintain, adjust or service.
NEVER place your hands or any part of your body or
clothing inside or near any moving part while unit is
running.
NEVER direct discharge towards persons or property.
Thrown objects may ricochet back towards operator.
ALWAYS stand clear of the discharge area.
ALWAYS disengage attachment, stop unit and engine,
- remove key, engage parking brake, and allow moving
parts to stop before leaving operator's position.
Use extreme caution on gravel surfaces.
Disengage PTO when attachment is not in use and
when crossing gravel surfaces.
DO NOT operate unit if safety interlock system is
damaged or disabled. Check safety interlock before
each use.
ALWAYS remove key to prevent unauthorized use.
DO NOT operate at too fast a rate. Slow down before
turning.
Stop engine before removing grass catcher or
unclogging chute.
DO NOT mow on wet grass. Reduced traction could
cause sliding.
DO NOT try to stabilize the machine by putting your
foot on the ground.
Know the weight of loads. Limit loads to those you can
safely control and the unit can safely handle.
ALWAYS keep protective structures, guards and panels
in good repair, in place and securely fastened.
Do not operate without either entire grass catcher or
the discharge guard in place.
DO NOT operate in reverse unless absolutely
necessary. ALWAYS look down and behind before and
while backing; especially for children.
Follow the manufacturer's recommendations for wheel
weights or counterweights to improve stability when
using attachments.
NEVER carry passengers-especially children—even
with blades off.
Use extra care when approaching blind corners or
objects that may obscure vision of hidden obstacles
and children.
If you cannot back up a slope or you feel uneasy on it,
do not mow it.
Mow up and down slopes, not across them.
Use slow speed on any slope. Tires may lose traction
on slopes even though the brakes are functioning
properly.
Keep all movements on the slope slow and graaual.
DO NOT make sudden changes in speed or direction.
Use extra care while operating machines with grass
catcher or other attachments. They can affect stability
of the machine.
Avoid starting, stopping, or turning on a slope. If tires
lose traction, disengage the blades and proceed slowly
straight down the slope.
DO NOT operate on slopes over 10°.
DO NOT park on slopes unless necessary. If unit is
parked on a slope, ALWAYS chock or block wheels and
set parking brake.
DO NOT disengage or bypass transmission and coast
downhill.
Tow only with a machine that has a hitch designed for
towing. Do not attach towed equipment except at the
hitch point.
Follow the manufacturer's recommendations for weight
limits for towed equipment and towing on slopes.
NEVER allow children or others in or on towed
equipment.
On slopes, the weight of the towed equipment may
cause loss of traction and loss of control.
Travel slowly and allow extra distance to stop.
Use extra care when loading or unloading unit onto
trailer or truck.
Secure unit chassis to transport vehicle. NEVER
secure from rods or linkages that could be damaged.
DO NOT transport machine while engine is running.
Keep unit free of grass clippings, leaves, and other
debris. Clean up oil or fuel spills.
This product is equipped with an internal combustion
type engine. DO NOT use unit on or near any
unimproved, forest-covered or brush covered land
unless exhaust system is equipped with a spark
arrester meeting applicable local, state or federal laws.
A spark arrester, if it is used, must be maintained in
effective working order by operator.
Fuel i$ highly flammable and its vapors are explosive.
Handle with care. Use an approved fuel container.
NO smoking, NO sparks, NO flames. ALWAYS aliow
engine to cool before servicing.
NEVER fill fuel tank when engine is running or hot from
operation.
NEVER fill or drain fuel tank indoors.
NEVER overfill fuel tank.
Replace fuel cap securely and clean up spilled fuel.
NEVER fill containers inside a vehicle or on a truck or
trailer bed with a plastic liner. Always place containers
on the ground away from your vehicle before filling.
When practical, remove gas-powered equipment from
the truck or trailer and refuel it on the ground. If this is
not possible, then refuel such equipment on a trailer
with a portable container, rather than from a gasoline
dispenser nozzle.
Keep the nozzle in contact with the rim of the fuel tank
or container opening at all times until fueling is
complete. Do not use a nozzle lock-open device.
If fuel is spilled on clothing, change clothing
immediately.
Avoid Electric Shock. Objects contacting both battery
terminals at the same time may result in injury and unit
damage. DO NOT reverse battery connections.
Explosive Gases from battery can cause death or
serious injury. Poisonous battery fluid contains sulfuric
acid and its contact with skin, eyes or clothing can
cause severe chemical burns.
NO flames, NO sparks, NO smoking near battery.
ALWAYS wear safety glasses and protective gear near
battery.
DO NOT TIP battery beyond a 45° angle in any
direction.
ALWAYS keep batteries out of reach of children.
Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known to
the State of California to cause cancer and
reproductive harm. Wash hands after handling.
Reverse connections may result in sparks which can
cause serious injury. Always connect positive (+) lead
of charger to positive (+) terminal, and negative (-) lead
to negative (-) terminal.
ALWAYS disconnect negative (-) cable FIRST and
positive (+) cable SECOND. ALWAYS connect positive
(+) cable FIRST, and negative (-) cable SECOND.
A frozen battery can explode and result in death or
serious injury. DO NOT charge or jump start a battery
containing frozen fluid. Thaw the battery before putting
on a charger or jump starting.
ALWAYS keep protective structures, guards, and
panels in good repair, in place and securely fastened.
NEVER modify or remove safety devices.
DO NOT change engine governor settings or over-
speed engine.
Fumes from engine exhaust can cause injury or death.
DO NOT run engine in an enclosed area. Always
provide good ventilation.
ALWAYS maintain unit in safe operating condition.
Damaged or worn out muffler can cause fire or
explosion.
Stop and inspect equipment if you strike an object or if
there is an unusual vibration. Repair, if necessary,
before restarting. Never make adjustments or repairs
with the engine running.
Mower blades are sharp and can cut you. Wrap the
blade(s) or wear gloves, and use extra caution when
servicing them. NEVER weld or straighten mower
blades.
Rotation of one blade may cause rotation of the other
blades.
Check brake operation frequently. Adjust and service
as required.
Keep all hardware properly tightened.
Stored energy in springs can cause injury.
Maintain or replace safety and instruction labels, as
necessary.
Never store the machine or fuel container inside a
building where there is an open flame, such as a water
heater.
Allow engine to cool completely before storing in
closed area or covering unit.
For extended storage, clean unit thoroughly. See
Engine Manual for proper storage.
Use only attachments or accessories designed for your
unit.
Check attachment components frequently. If worn or
damaged, replace with manufacturer's recommended
parts.
<
SECTION 3 - SPECIFICATIONS
Model Number 915030/915031 915032/915033
Description 211232 211440
Engine Manufacturer Briggs & Stratton |
Engine Power - hp (kW) @ governed RPM 12 (8.9) 14 (10.4)
Max Governed RPM 3150
Fuel Tank Capacity - gal (L) 1.6 (6)
Starter Electric
Transmission Hydrostatic
Speed:Forward - mph (km/h) 6.0 (9.7)
Reverse - mph (km/h) 2.5 (4)
Power Take-Off
Electric PTO Clutch/Brake
Battery
12 Volt Maintenance Free
Parking Brake
Cog
Cutting Height - in. (cm)
1.25 to 4 (3.18 to 10.2)
Cutting width - in. (cm) 32 (81) 40 (102)
Max Tire Pressure:
Front - psi (kPa) 50 (345)
Rear - psi (kPa) 12 (83)
Tire Size:Front - in. (cm)
Rear - in. (cm)
9 x 3.5 (23 x 8.9)
18 x 6.5 (45.7 x 16.5)
9x35(23x89) —
18 x 6.5 (45.7 x 16.5)
Turning Radius Zero
Weight — Ibs (kg) 500 (227) 515 (233)
Height — in. (cm) 38 (96.5)
Length — in. (cm) 63 (160)
Width — in. (cm) 36 (91) 50 (127)
Max. Towing Capacity - lbs (kg) 300 (1 36)
Max. Tongue Weight - Ibs (kg) 30 (13.6)
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS
4.1 CONTROLS AND FEATURES
DADD4Z
Figure 1
1. Seat 7. Parking Brake
2. Ignition Switch 8. Mower Deck
3. PTO Switch 9. Discharge Chute
4. Throttle Lever 10.Mower Lift Lever
5. Steering Lever 11.Fuel Level Indicator
6. Transmission Bypass Lever 12.Fuel Tank
4.2 SAFETY INTERLOCK SYSTEM NOTE: With the parking brake engaged, the steering
levers are locked in neutral.
WARNING: Safety interlock failure and Test ¡Steering |PTO [Parking Brake [Engine
improper operation of unit can result in death Lever
or serious injury. Check system before each 1 Neutral Off Engaged Starts
use to make sure it is functioning properly. > Neutral Off Disengaged Doesn't
Start
Perform the following tests to ensure safety interiock 3 Neutral On Engaged Doesn't
system is working property. Start
4*+ Neutral On Engaged Shuts Off
5*+ Neutral Off Disengaged Shuts Off
*Test with engine running.
+Operator lifts off seat.
4.3 FILLING FUEL TANK
0 EXPLOSIVE VAPORS and FLAMMABLE
FUEL can result in serious injury or death.
Handle fuel with care. ALWAYS use an
approved fuel container.
No Smoking!
No Lighted Materials!
No Open Flame!
Allow engine to cool.
Use caution with fuel. Fuel is very flammable.
Keep fuel in a clean and tight container. Keep
fuel away from fire or heat. Never put fuel in
the fuel tank while the engine is running or
hot. Clean up any spilled fuel before starting
the engine.
When taking unit out of extended storage:
1. Check for any damage or loose parts. Repair
replace, or tighten hardware before operation.
2. If a preservative fluid was used in fuel tank, drain
and discard. Fill fuel tank with fresh new fuel.
IMPORTANT: Proper maintenance can prolong life of
unit. The following chart shows recommended service
schedule. Refer to maintenance instructions in Engine
Manual for additional information.
NOTE: Use Figure 2 to locate items called out in main-
tenance schedule.
1. Clean fuel cap and surrounding area to prevent
dust, dirt, and debris from entering fuel tank.
2. Remove fuel cap.
IMPORTANT: See Engine Manual for correct type and
grade of fuel.
3. Fill fuel tank to 1/2 in. (1.3 cm) below bottom of
filler neck. See Specifications for fuel tank capacity.
4. Replace fuel cap.
4.4 SERVICE POSITION
CAUTION: Remove enough fuel so that no
spillage will occur. Remove battery to prevent
spillage of electrolyte.
1. Cooling System 5. Muffler
2. Fuel Filter 6. Qil Drain Plug
3. Air Filter 7. Oil Fill/Dipstick
4. Spark Plug
OE0045
Figure 2
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.
To ensure the unit is positioned in the proper service
position: |
1. Place jack stands under rear transaxles oniy.
2. If jacks are not available, place support blocks
under both transaxles at the rear of unit.
4.5 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.
4-9
4.6 MAINTENANCE SCHEDULE
| Each Use
System
Check Parking Brake
death or serious injury. Test this system each time unit is operated. If this
system does not function as described, do not operate until repairs are
made.
Engage parking brake and engage transmission bypass lever (see Moving Unit
Manually). Push unit. If unit rolls, contact your Ariens/Gravely dealer.
Clean Unit Clean engine, battery, seat, mower deck, etc. of all dirt and debris. Do not use
solvents, hard cleaners, or abrasives.
Protect painted surfaces with automotive type wax.
Check Tires See Specifications for correct tire pressure.
"= Check Mower Blade(s) Check for worn or damaged blade(s) (see Sharpening Mower Blade).
Check Engine Oil Use oil fill/dipstick (item 7) to check engine oil level. Add engine oil if needed, refer
to Engine Manual for detailed instructions.
25 Hours | Check Battery Keep battery and battery terminals clean (see Cleaning Battery and Battery
or Every Cables).
Season
Lubricate Unit
Clean Air Fitter!
Apply grease to two front wheel zerks.
Zerk
Clean air filter (item 3). Refer to Engine Manual for detailed instructions.
50 Hours
or Every
Season
Change Engine Oil?
Check Fasteners
Inspect Muffler and Spark
Arrestor
Drain engine oil by opening oil drain plug (item 6). Refer to Engine Manual for
detailed instructions.
Check mower blade mounting hardware and all other fasteners. Replace fasteners
that are missing or damaged. Tighten all nuts and bolts to correct torque value.
Replace muffler (item 5) and spark arrestor (if equipped) if corroded. Contact your
Ariens/Gravely Dealer.
100
Hours or
Every
Season
Replace Spark Plug
Replace Fuel Filter
Clean Cooling System‘
Check All Belts
Replace spark plug (item 4). Refer to Engine Manual for detailed instructions.
Replace fuel filter (item 2). Refer to Engine Manual for detailed instructions.
Clean cooling system (item 1). Refer to Engine Manual for detailed instructions.
Replace worn or deteriorated belts.
Check hydrostatic belt (see Hydrostatic Belt Replacement).
Check РТО belt (see P70 Belt Replacemen)).
Check mower belt (see Mower Belt Replacement (915032).
! Service more often when operating under heavy loads, high temperatures, or dusty conditions. Replace air filter
if very dirty.
2 Change after first 5 to 8 hours of use. Change every 25 hours when operating under heavy loads or in high
temperatures.
4.7 REMOVE AND INSTALL 32-INCH
MOWER DECK
Remove (Figure 3)
1. Remove PTO belt.
2. Disconnect electric clutch connector.
3. Disconnect guide arms from unit.
4.
Disconnect two rear links and front guide from
mower deck.
5. Slide mower deck out from under unit.
Install
1. Slide mower deck under unit.
Install front guide and rear links on mower deck.
Install guide arms on unit.
Connect electric clutch connector.
Install PTO belt.
о к N
LL
Disconne
Guide Arm Link Here
Here
Disconnect
Front Guide
Here
1. Guide Arm 4. Electric Clutch
2. Rear Link Connector
3. PTO Belt 5. Mower Deck
6. Front Guide
OE0032
Figure 3
2. Make certain the key is off and the spark plug wire
is removed. By hand rotate the measured blade to
the opposite side of the deck.
CAUTION: Use gloves or wrap a rag over the
sharp edges of the blade to prevent injury.
A
NOTE: Measure the distance of the same blade edge
on the new side (side opposite the discharge chute) of
the deck.
To Adjust the Level (Figure 5)
NOTE: Raise low side of mower deck half the mea-
sured distance between low and high side of mower
deck. Lower high side of mower deck half the mea-
sured distance between high and low side of mower
deck.
1. On low side: Turn trunnion nut clockwise several
turns.
2. On high side: Turn trunnion nut counterclockwise
several turns.
3. Check that mower deck is level.
Mower Deck Shown From The Front
2 3
N \
4 UL A
Ус OS
d Ty
3. Mower Blade
4. Cutting Height
5. Ground
Figure 4
1. Discharge Chute
Opening
2. Mower Deck
OA0009
4.8 LEVELING 32-INCH MOWER DECK
Adjust on a level surface, with tires inflated to correct
air pressure, and mower lift lever in the middie position.
Check the Level (Figure 4)
NOTE: Cutting height should be within 1/4 in. (6.3 mm)
on each side of mower deck.
1. With mower blade(s) (Figure 4) in line with
discharge chute, measure distance from bottom of
mower blade to the ground.
1. Rear Guide
2. Trunnion Nut
OEDOSS
Figure 5
4-11
4.9 REMOVE AND INSTALL 40-INCH
MOWER DECK
Remove with the engine off and the mower deck raised
up place support blocks under the frame of the mower
deck.
1. Lower the mower deck onto the support blocks
using the height adjustment lever. This will remove
tension on the linkage supporting the deck.
2. Unplug the electrical connector to the electric
clutch (Figure 6).
1. Deck Lift Rod
2. Trunnion
3. Bottom Clip
Figure 7
4.10 LEVELING THE 40-INCH MOWER
DECK
Adjust on a level surface with tires inflated to the
correct air pressure. The lift lever should be in the
1. Pin middie position.
2. Clip | NOTE: The cutting height should be within 1/4 inch (6.3
3. Electrical Connector mm) side to side on the same blade. Either blade may
be used. For convenience use the blade next to the dis- NS
charge chute. ЦИ
Figure 6
1. With the key removed and the spark plug wire off,
3. Release the idler tension spring. Remove the rotate the blade by hand until one edge is at the
mower belt from engine pulley. discharge opening.
4. At the front support, pull one clip and remove the CAUTION: Use gloves or wrap a rag over the
pin from the link. A sharp edges of the blade to prevent injury.
5. At the rear of the deck pull the bottom clip (Figure
7) and remove the washer before pulling out the 2 Measure the distance from the bottom of the blade
linkage. Repeat for the other support. to the ground.
6. Slide the deck out from under the mower. 3. Rotate the blade half of a turn. This will place the
opposite end of the blade at the discharge chute.
The measured end of the blade will be at the
center of the mower deck.
4. Measure the distance of the same blade edge to
the ground.
5. Adjust mower deck if needed.
4.11 ADJUST LEVEL OF MOWER DECK
NOTE: Raise low side of mower deck half the mea-
sured distance between low and high side of mower
deck. Lower high side of mower deck half the mea-
sured distance between high and low side of mower
deck. O
e
1. On low side: Remove bottom spring clip (Figure 7)
and rotate the link rod clockwise (shorten) several
turns. Reattach link rod to mower deck.
2. On the high side: Remove bottom spring clip and
rotate the link rod counterclockwise (lengthen)
several turns. Reattach link rod to mower deck.
3. Check level.
4.12 MOWER HEIGHT ADJUSTMENT
1. Place deck lift handle in middle position. If mower
deck needs adjustment both the front and rear rods
must be changed to maintain level (Figure 8).
2. Adjust the rear of the deck by pulling the pins on
the two trunnions and screwing the trunnion up or
down the link rod as needed.
3. The front is adjusted by removing the pin on the
rod pivot and screwing the pivot on the deck lift rod
as needed.
3. Pin
4. Mounting Hardware
1. Mower Deck
2. Antiscalp Roller
CE0040
NO Ye
7/ —
6
1. Rod Pivot 3. Link Rod
2. Deck Lift Rod 4. Trunnion
PAD331
Figure 8
4.13 ANTISCALP ROLLER ADJUSTMENT
(915032, 033)
IMPORTANT: Antiscalp rollers prevent lawn scalping.
DO NOT use antiscalp rollers to set cutting height.
Adjust all antiscalp rollers to same height.
NOTE: Adjust on a level surface, with tires inflated to
correct air pressure (see Specifications).
1. Select cutting height.
2. Adjust all antiscalp rollers to within 1/2 inch (1.27
cm) of ground (Figure 9).
Figure 9
4.14 MOWER DECK PITCH ADJUSTMENT
Adjust on a level surface, with tires inflated to correct
air pressure, and mower lift lever in the middle position.
NOTE: The front blade cutting height should be 1/16 -
3/8 in. (1.59 - 9.53 mm) lower than the rear blade cut-
ting height.
Check (Figure 10)
1. With the end of the mower blade(s) facing forward,
measure distance from bottom of mower blade(s)
to the ground at front of mower deck.
2. Turn mower blade(s) 180 degrees and measure
distance from bottom of mower blade(s) to the
ground at rear of mower deck.
3. Adjust mower deck if needed.
Mower Deck Shown From The Side
1 2
N \ 3
— IN Aa Y
em.
N /
x > 7
6 5 4
1. Mower Deck 4. Front Blade Cutting
2. Mower Blade(s) Height
3. Front of Mower Deck “5. Ground
6. Rear Blade Cutting
Figure 10
CAOOTO
Adjust (Figure 11)
NOTE: Perform steps 1 through 3 for 32-inch mower
decks. Go to step 4 for 40-inch mower decks.
4
” 1. Locking Bolt 3. Forward Arm
% 2. Reverse Arm 4. Return Spring
1. Trunnion
2, Front Guide Figure 12
Figure 11 OA0034
4.16 ADJUSTING UNIT TO TRACK
1. To raise front of mower deck: Turn trunnion STRAIGHT
clockwise several turns.
Tires must be inflated to specifications and drive units
2. To lower front of mower deck: Turn trunnion should be adjusted for neutral (Figure 13).
counterclockwise several turns. 1. Start engine and warm up hydraulics.
3. Check mower blade pitch. 2. Operate the unit and position it with adequate
e If mower blade pitch is not correct, go to step 4, running space.
e If mower blade pitch is correct, the adjustment is 3. Push both handles to full forward. The unit should
complete. travel in a straight line. If the unit steers to one side,
4. Check mower blade pitch. adjustment is needed. Make note of which way the
unit is turning. Adjustment will be made to the drive
5. Readjust as required.
ead) quire unit on the opposite side off the direction of the
4.15 HYDROSTATIC TRANSMISSION turn. This is the faster wheel.
NEUTRAL ADJUSTMENT 4. Remove the pin and pull the trunnion away from
the linkage.
1. Shut off engine.
2. Position rear wheels off the ground. Be careful to
secure the unit to the lift or position the unit to face
a wall for safety.
3. Engage seat switch and start the engine.
5. Screw the trunnion further onto the steering rod
one or two turns (depending on the amount of
turning that needs correction).
6. Put trunnion back into the linkage and insert pin.
Disengage the parking brake. The drive wheels 7. Return to step one and repeat until unit tracks
should not be rotating. If the wheels are not driven straight.
to rotate, proceed to Steering Control Neutral
Adjustment.
To adjust the neutral setting for no wheel rotation:
4. Use a hex wrench to loosen the locking bolt (Figure
12) until the linkage can be rotated by hand.
5, With the engine running and the drive wheeis off
the ground, rotate the linkage in either direction.
The correct linkage position is obtained when the
wheel is not being driven (under power).
6. Hold the linkage in place and tighten the locking
bolt.
7. Shut off engine and reconnect steering rod.
8. Check parking brake linkage for proper movement.
4-14
a
и
EE
x,
1. Pin 3. Steering Rod
2. Trunnion 4. Dump Rod
Figure 13 P-0060
1. Drive Lock
2. Safety Switch
Figure 14
4.17 ADJUST PARKING BRAKE
When properly adjusted the parking brake will lock the
linkage on both drives and activate the safety switch
(Figure 14).
The drive units should be properly adjusted for neutral.
Engage the parking brake handle. The brake shaft
should be positioned to lock the drive and activate the
safety switch.
To adjust the linkage:
Move the adjusting nut clockwise/counterclockwise as
needed to properly position the brake shaft (Figure 15).
NOTE: The safety switch can be loosened for minor
adjustments.
1. Parking Brake
Handle
2. Adjusting Nut
3. Arm Locking Rod
4. Pivot Adjusting Nut
5. Brake Shaft
РЕо1 21
Figure 15
SECTION 5 - ENGINE
5.1 ENGINE TROUBLESHOOTING
The following troubleshooting chart is to be used to The troubleshooting key is generic and can be used for
isolate engine problems and give possible causes and several types of engines. Use only those possible
corrective action responses. causes and corrective actions that apply to the
unit.
TROUBLE POSSIBLE CAUSES CORRECTIVE ACTION
(Refer to Key Below)
Black Exhaust 1, 20, 22, 25, 29, 31, 32, 33 repair or replace
Blue/White Exhaust 4, 20, 25, 31, 33, 34 repair or replace
Difficult Starting 1,5,7, 8,9, 10, 20, 21, 22, 29, 31, 32, 33 repair or replace
Erratic Running 1,7,8,9, 10, 20, 21, 23, 26, 29, 33, 59, 62 repair or replace
Excessive Fuel Consumption 1, 20, 22, 23, 25, 39, 31, 32, 33 repair or replace
High Oil Pressure 4, 41 repair or replace
Knocking 22, 26, 29, 31, 33, 36, 46, 59 repair or replace
Loss of Power or System 1,8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33 repair or replace
Low Cranking Power 2,3, 4, 11 repair or replace
Low Oil Pressure 4, 36, 37, 39 repair or replace
Misfiring 10, 20, 25, 26, 28, 29, 32 repair or replace
Overheating 1,19, 25, repair or replace
Poor Compression 25, 28, 29, 31, 32, 33, 34,59, repair or replace
Starts and Stops 1,6, 10, 62 repair or replace
see electrical systems
see engine service manual
Vibration 20, 23, 25, 26, 29, 33, 45, 49 repair or replace
Will Not Crank 2,11,45 charge battery or replace
Will Not Start 1, 10, 62 repair or replace
see electrical systems
see engine service manual
TROUBLESHOOTING KEY
| Restriction in air cleaner 22 Incorrect grade of fuel 43 Faulty suction pipe
2 Bad electrical connection 23 Sticking throttle/restricted movement 44 Choked oil filter
3 Faulty starter motor 24 Exhaust pipe restriction 45 Bad solenoid switch
4 Incorrect grade of lubricating oil 25 Leaking cylinder head gasket 46 Incorrect piston height
5 Low cranking speed 26 Overheating 47 Damaged fan
6 Fuel tank empty 27 Cold running 48 Faulty engine mounting
7 Controls not in correct 28 Incorrect tappet adjustment 49 Incorrectly aligned flywheel and/or
operation position flywheel housing
8 Blocked fuel feed line 29 Sticking valves 50 Faulty thermostat
9 Faulty fuel lift pump 30 Incorrect high pressure pipes 51 Restriction in water jacket
10 Choked fuel filter 31 Worn cylinder bores 52 Loose fan belt
11 Battery capacity low 32 Pitted valves and seats 53 Choked radiator
12 Air in fuel system 33 Broken, worn or sticking piston ring(s) 54 Faulty water pump
13 Faulty fuel injection pump 34 Worn valve stems and guides 55 Choked breather pipe
14 Faulty fuel injectors or incorrect 35 Restriction in air cleaner 56 Damaged valve stem oil deflector (if
type fitted)
15 Incorrect use of cold start 36 Worn or damaged bearings 57 Coolant level too low
equipment
16 Faulty cold start equipment 37 Insufficient oil in sump 58 Blocked sump strainer
17 Broken fuel injection pump 38 Bad/defective oil temperature switch 59 Broken vaive spring
drive
18 Incorrect fuel pump timing 39 Oil pump worn 60 Exhaust or vacuum pipe leak
19 Incorrect valve timing 40 Pressure relief valve sticking open 61 Bad or defective water temperature
switch
20 Poor compression 41 Pressure relief valve sticking closed 62 Bad spark plug(s)
21 Blocked fuel tank vent 42 Broken relief valve spring
5-16
5.2 CHECKING ENGINE OIL
Check the engine oil daily prior to use.
IMPORTANT: Never operate the engine with the oil
below the low mark on the dipstick.
See the engine manual for oil specifications and oil
filter service instructions.
To check oil level:
1. Move the unit to level location.
2. Clean around the dipstick and filter tube to prevent
dirt from entering the engine.
3. Remove the dipstick and wipe off the oil on the
dipstick.
4. Put the dipstick back into the engine and tighten
the place and remove again.
5. When the dipstick is removed, note the oil level. Oil
should be between the full and add mark.
6. Replace dipstick.
7. If required, add 5W30 below 40° or 30W above
40°. Do not overtill.
8. Clean up any spillage that may have occurred.
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.
3. if the engine is cold, let the unit run for five minutes.
>
When the engine is warm, stop the engine.
5. Clean the area around the dipstick and (drain
hose).
6. Put an open container that will hold one gallon of
oil under the drain hose.
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.
10.1f 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.
13.Check for leakage at the drain plug and oil filter if
used. Tighten the fittings as necessary if leakage
occurs.
14.Release the parking brake.
15.Return the unit into service.
5.4 CHECKING ENGINE COOLING
IMPORTANT: To prevent severe damage to the engine,
proper cooling will need to be maintained.
1. Check the air intake screen on the engine each
day.
2. The air intake screen must be kept clean. Remove
any grass, dirt, or debris that may have
accumulated.
3. Check the engine cooling yearly.
5.5 CLEANING THE AIR CLEANER
1. Check the air cleaner element every day.
2. Clean the air cleaner precleaner every 25 hours.
See your engine manual for instructions.
3. Apply oil and reinstall over the paper air filter
element.
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.
5.7 INSPECT MUFFLER/SPARK
ARRESTER
Inspect muffler and (if equipped) spark arrester.
Replace muffler if corroded, as it could create a fire
hazard and/or damage.
5.8 REPLACE SPARK PLUGS
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 throttle and choke control from the
engine.
5. Remove the electrical wiring from the engine
(charge lead, starter cable, fuel solenoid lead, and
magneto kill wire).
6. Remove fuel line from engine first. Drain fuel from
line back into fuel tank.
7. Remove the engine bolts.
5-17
8. Lift engine out of the unit and off the frame with a
hoist (engine).
9. Service, overhaul, or replace engine as required.
10.If replacing engine with a new engine, the following |
items will have to be removed (if used) from old CN
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, 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°F (0°C) or 5W30
below 32°F (0°C).
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. а
ALWAYS provide good ventilation and wait №,
until hazard has been removed. 7
1. 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
add mark, add recommended oil. DO NOT
overfill.
SECTION 6 - FUEL SYSTEM
6.1 FUEL SYSTEM TROUBLESHOOTING
The following troubleshooting chart is to be used to
isolate fuel system problems and give possible causes
are corrective action responses.
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.
TROUBLE
POSSIBLE CAUSES
(Refer to Key Below)
CORRECTIVE ACTION
Hard Starting
1, 3, 4,6, 11, 12, 14, 16, 17, 18
clean, repair or replace
Fuel Leak at Carburetor 5,7, 17 repair or replace
Engine Floods 5, 15, 17 repair or replace
Will Not Idle 1,2,3,6 repair or replace
Rich idie 1, 6, 14 repair or replace
Idies With Needle Closed 14 repair or replace
Hunts Erratic idle 2,3, 6, 7, 12, 13, 14, 15, 16 repair or replace
Idies Fast Lean 2,3,7
repair or replace
Will Not Accelerate
1,6, 11, 12, 14, 15, 16
repair or replace
Over Rich Acceleration
1,15
repair or replace
Hesitates
2, 6, 11, 12, 16
repair or replace
Will Not Run at High Speed
1, 11, 12, 14, 16
repair or replace
Low Power
1, 3, 11, 14, 15, 16, 17, 18
repair or replace
Hunts at High Speed
3, 6, 7, 12, 14, 15, 16, 18
repair or replace
Runs With Needle Closed
14
repair or replace
Engine Overspeeds
2,3,7,14
repair or replace
TROUBLESHOOTING KEY
Throttle or choke shaft worn
Choke not functioning properly
Damaged adjustment needle and seat
Dirty, stuck needle and seat
1 Plugged air filter
2 Leaky carburetor gasket
3
4
5 Plugged atmospheric vent
6 Air bleed restricted
7 Damaged or leaky O-rings
8 Damaged diaphragm
S Stuck or dirty ball check
10 Diaphragm upside down
11 Plugged tank or vent
12 Fuel pickup restricted
13 idler port restricted
14
15 Incorrect float height
16 Main nozzle restricted
17
18 Fuel inlet plugged
6-19
6.2 FUEL TANK REMOVAL
1. Remove seat and disconnect wires.
2. Remove rear hood if applicable.
3. Remove battery cover (Figure 16).
oN
4. Loosen bolts to gas tank and remove top bracket. | ” J
WARNING: Gasoline is volatile. Keep away
from sparks and open flame. Gasoline fumes
will ignite.
5. Drain gas into a suitable container and dispose of it
properly.
6. Disconnect fuel hose.
7. Remove fuel tank.
o A \ N a
SN
1. Battery Cover 3. Gas Line
2. Top Bracket
PEOOBOP
Figure 16
6.3 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.
6.4 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.
0
| wa В
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. 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.
TROUBLE POSSIBLE CAUSES (Refer to Key Below)
Axles Will Not Turn 1,7,8,12, 16, 18, 28, 32, 38, 42, 46
Difficult Starting 1,6,7, 8, 12, 16, 25, 26, 28, 38, 42, 46
Erratie Running 1, 4, 6, 7, 8, 12, 18, 25, 26,28, 42, 46, 55
Jerky When Starting 1, 4, 7, 8, 12, 18, 28, 38, 46
Jumps Out of Gear N/A
Knocking 4, 8, 12, 18, 28, 37, 42
Loss of Power or System 4, 12, 18, 28, 37, 42, 46
Noisy 4, 12, 18, 26, 28, 32, 37, 42
Oil Leakage 4, 22, 51, 16
Operates Hot 4, 16, 28, 32, 35, 42
Operates in One Direction Onty 1, 8, 12, 30, 46
Pump Failure 4, 12, 37
Speed Loss Under Load 1, 6, 11, 28, 37, 46, 51
Speed Loss Under Load 1,4,7, 12, 18, 28, 26
Will Not Drive 1,7,8, 18, 28, 37, 38, 46, 48
Will Not Shift
TROUBLESHOOTING KEY
1 Inspect control linkage 22 Inspect hoses and lines for wear 43 Burrs on gearing
2 Inspect acceleration valves 23 Inspect implement relief vaive 44 Gears improperly installed
3 Inspect charge check valves 24 Inspect charge pump 47 Shifting washer in backwards
4 Incorrect grade of lubricating oil 25 Bad transmission pump 48 5Shifter/Brake shaft keyways damaged
5 Low cranking speed 26 Overheating 49 Unit clutch not disengaging
6 Controls not in correct operation 27 Cold running 50 Shifter stop assembled backwards
position
7 Belts are missing, too tight, loose 28 Bad transmission motor 51 Improper fit of case to cover
or glazed
8 Overload of vehicle 29 Check system pressure 52 Dowel pins not installed
9 Replacement parts damaged 30 Shift rod grooves worn 53 Differential bevel gears broken
10 replacement parts improperly 31 Reverse chain broken 54 Spring In shifter weak or broken
installe
11 Improperly torqued attaching 32 Damaged cooling fan 55 Worn or stripped gear teeth
screws
12 Air in hydraulic system 33 Inspect auxiliary relief vaive
13 Broken shifter stop 34 Inspect cooling fan
14 Inspect charge check valves 35 Inspect transmission cooling fins
15 Inspect acceleration valves 36 Worn or damaged bearings
16 Check oil level-gear box sump or 37 Metallic pieces or foreign objects in unit
reservoir
17 Inspect heat exchanger 38 Inspect for loosely mounted
components
18 Inspect bypass valve 39 Steering column loose or binding
19 Inspect charge pressure 40 Pressure relief valve sticking open
20 Inspect inlet filter 41 Pressure relief sticking closed
21 Inspect charge relief valve 42 Broken relief valve spring
7.2 HYDRO-GEAR FLUID
RECOMMENDATIONS
The fluids used in Hydro-Gear transaxles have been
carefully selected, and only equivalent or better
products should be used.
Typically, an engine oil with a minimum rating of 55 sus
at 210°F and an API classification of SH/CD is
recommended. A 20W-50 engine oil has been selected
for use by the factory.
7.3 HYDROSTATIC BELT REPLACEMENT
Remove (Figure 17)
1. Remove PTO belt.
CAUTION: Use care when releasing idler
spring tension. Keep body parts well away
from idler when performing this operation.
NOTE: It may be helpful to remove the weight attached
to the rear of the frame. This will allow easier access.
2. Disconnect idler spring.
3. Remove hydrostatic belt from engine sheave and
hydrostatic transmission pulleys.
Install (Figure 17)
1. Install hydrostatic belt on hydrostatic transmission
pulleys and engine sheave.
2. Connect idler spring.
3. Install PTO belt.
3.. Remove mower deck.
4. Raise and block the unit frame on jack stands
behind of the transaxle in the frame.
5. Remove clip (Figure 18) from parking brake locking
arm on both transmissions.
. Unscrew knob from dump valve linkage.
1. Clip
2. Locking Gear
3. Locking Arm
Figure 18
1. Hydrostatic 3. Engine Sheave
Transmission 4. Idler Spring
Pulleys 5. ldler Pulley
2. Hydrostatic Belt
Figure 17 ев
7.4 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.
NOTE: Rear weight may be removed for convenience.
7. Pull clips from bell crank rods and push rod away
from the bracket. (Figure 19).
8. Remove tires.
9. Support the transaxles subframe with a floor jack
from the rear of the tractor.
3. Bell Crank Rod
4. Subframe
1. Dump Valve Knob
2. Clip
PE0060
Figure 19
9
10.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.
11.With the transaxle assembly removed from the
units frame, place the axle assembly on a flat work
surface (Figure 20)
РЕ0060
Figure 20
7.5 HYDRO-GEAR TRANSMISSION
INSTALLATION
After removing the transmission subframe, the
transmissions are unbolted and replaced. Check new
transmission for linkage, breathers, and pulleys.
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.
Do not tighten any hardware until all the support
hardware is installed.
2. When all the hardware is in place, tighten to the
appropriate torque according to the hardware
torque chart.
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.
After transmission subframe assembly is reinstalled,
check for neutral adjustment and parking brake lock.
Transaxle Neutral Adjustment
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. 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 Neutra/
Adjustment section.
7-23
SECTION 8 - MOWER DECK
8.1 PTO BELT REPLACEMENT (915030/
915031)
Remove (Figure 21)
1. Lower mower deck to the ground.
8.2 MOWER BELT REPLACEMENT
(915032/915033)
1
CAUTION: Use care when releasing idler
spring tension. Keep body parts well away
from idler when performing this operation.
2. Disconnect idler spring.
3. Remove PTO belt from mower deck pulley and
engine sheave.
rte
1. Right Pulley 6. Cluich
2. idier 7. Front Bracket
3. Idler Spring 8. Clutch Bracket
4. Mower Belt 9. Mower Deck
5. Left Pulley E001
Figure 22
Remove (Figure 22) 3
1. Remove mower deck (see Aermove and Install 40
1. Engine Sheave 4. Idler Spring inch Mower Deck).
2. PTO Belt 5. Mower Deck Pulley CAUTION: Use care when releasing idler
3. Idler Pulley A spring tension. Keep body parts well away
Figure 21 Cs from idler when performing this operation.
Install 2. Remove idler spring.
1. Install PTO belt on engine sheave and mower deck 3. Remove front bracket and clutch bracket.
pulley.
2. Connect idler spring.
4. Remove mower belt.
8.3 MOWER BLADE REPLACEMENT
CAUTION: Mower blades are sharp and can
cut you. Wrap the blades or wear gloves, and
use extra caution when servicing them.
32-Inch Mower Decks (Figure 23)
Remove
1. Place mower lift lever in the highest position.
2. Block mower blade to prevent rotation.
3. Remove mower blade from clutch.
Install
1. Install mower blade on clutch.
2. Torque hex bolts to 45-55 Ibf-ft (61-75 Nem).
8-24
и —__B 4 } me Ba —— — tas
Ne
"oo,
5 — В
1. Clutch 4. Lock Washer
2. Mower Blade 5. Hex Bolt
3, Washer
= Figure 23 ore
40-inch Mower Deck (Figure 24)
NOTE: The 40-inch mower deck has two blades.
4, 3/4-in. Jam Nut
5, 3/4-in. Lock Washer
1. Spindle
2. Blade Tray
3. Mower Blade
Figure 24 ron
Remove
1. Place mower lift lever in the highest position.
2. Block mower blades to prevent rotation.
3. Remove mower blades and blade trays from
spindles.
Install
1. Install blade trays and mower blades on spindles.
2. Torque 3/4 in. jam nuts to 50-60 Ibf-ft (68-81 Nm).
8.4 32-INCH MOWER SPINDLE REPAIR
To repair the spindle bearings (Figure 25):
1. Remove mower deck from the unit.
2. Unscrew the bolt at the center of the top pulley.
3. Remove the pulley and key from the shaft. The
shaft with the clutch and blades should drop out of
the spindle housing.
4. Remove the bearing, spacer, and slinger from
inside the spindle housing.
The bearing should be replaced. DO NOT service.
Reinstall in reverse order.
1. Slinger 4. Electric Clutch
2. Steel Spacer 5. Debris Shield
3. Ball Bearing
PEOTSO
Figure 25
8.5 40-INCH MOWER SPINDLE REPAIR
To repair the blade spindles:
1. Remove the mower deck from the unit.
2. Remove spindle center.
3. Remove drive belt from spindle sheave by
removing idler arm spring. The belt can be taken
off the sheave.
4. Unscrew nut from center of blade. Remove blade.
The spindle and sheave should push upward. This will
give access to the spindle bearing, slinger, and spacer.
The bearing should be replaced. DO NOT service.
Install in reverse order.
8-25
1. Slinger 5. Spindle Sheave
2. Ball Bearing 6. Spacer
3. Spacer 7. Clutch Bracket
4. Clutch
Figure 26 ena
8.6 TO REPLACE THE ELECTRIC CLUTCH
1. Remove the mower deck from the unit (Figure 26).
2. Remove drive belt by removing idler arm spring.
3. Unbolt the clutch bracket and remove the
assembly.
4. Unscrew the bolt at the center of the clutch. The
clutch should pull off the spindle.
8.7 TO REPLACE CLUTCH SPINDLE
BEARINGS
1. Remove the mower deck from the unit (Figure 26).
2. Remove drive belt by removing idler arm spring.
The clutch has two bearings, one on each side of
the housing.
3. Unscrew the top bolt to remove the sheave and
key. The top bearing is accessible.
4. Unbolt housing from the mower deck to gain
access to the second bearing.
The bearings should be replaced. DO NOT service.
Assemble in reverse order.
8.8 LIFT SYSTEM
The deck lift system requires only general maintenance
(lubrication of moving parts). Any parts that break or
wear excessively should be replaced (Figure 27).
PAO331
Figure 27
ed fi
0
SECTION 9 - ELECTRICAL
9.1 TOOLS
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 connec-
tions.
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 wait-
ing 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 cir-
cuits 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 assort-
ment 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 replace-
ment 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 them-
selves 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.
9.2 ELECTRICAL MEASUREMENTS
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 Volt-
Ohm-multitester (VOM). Meters of this kind are avail-
able in many forms and all change functions and
ranges with switches, or by plugging test leads into dif-
ferent 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 there-
fore 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 neces-
sary 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 discus-
sion.
Voltage Measurement
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.
Current Measurement
The two rules to remember when measuring current
with an ammeter are; an ammeter measures the cur-
rent that flows through the meter, and to measure cur-
rent 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 trou-
bleshooting.
ResistanceMeasurement
An Ohmmeter is used to make resistance measure-
ments and to check continuity through wires and elec-
trical components.
There is one rule to keep in mind when using an ohm-
meter. 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.
9.3 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 bat-
tery. ALWAYS connect Positive (+) Cable first,
then connect Negative (-) Cable when install-
ing battery.
WARNING: EXPLOSIVE GASES can result
in serious injury or death. ALWAYS keep open
flames, sparks, or smoking materials away
from battery.
POISONOUS BATTERY FLUID contains sul-
furic 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.
0 WARNING: REVERSE CONNECTIONS may
result in sparks which may result in injury.
ALWAYS connect/disconnect cables in proper
order.
9.4 SERVICING THE BATTERY
NOTE: Unit comes equipped with a maintenance-free
battery that requires no regular maintenance except
cleaning terminals.
WARNING: Battery posts, terminals and
related accessories contain lead and lead
compounds, chemicals known to the STate of
California to cause cancer and reproductive
harm. Wash hands after handling.
To Remove the Battery
1. Remove seat.
2. Remove top bracket.
3. Disconnect connections to the battery terminals,
negative side first.
4. Pull battery out.
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 by removing seat
and the bracket over the battery.
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 80°F, and fill each cell so 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.
fe
cb
0
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 vent caps. lt 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!
-Intefnal 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!
Inspection, Cleaning, Drying, and Maintenance
Inspect the top of battery, terminals, cables, terminal
posts, and case for any accumulation of dirt, corrosion
cracks or loose or broken parts. Keep battery and its
terminals clean. Inspect monthly to maintain best
performance. Replace battery if damaged.
Remove hold down and bolt and lift battery out. Clean
or service battery away from unit. Remove corrosion
from battery terminals and cable connections with wire
brush, then wash with a weak baking soda solution.
Scrub the exterior of the battery and cable terminals
with a nonmetallic brush which has been dipped into a
mixture of baking soda and water.
After cleaning, apply a thin coat of grease or petroleum
jelly to terminals and cable ends to retard corrosion.
Reinstall battery.
Check the alternator voltage regulator output (if used)
at every periodic maintenance inspection. Over
charging is a common cause of battery failure.
Electrolyte Level
Every 25 hours of operation, check electrolyte level of
each cell by removing caps one at a time. The
electrolyte level should be at level indicated. Use
distilled water to fill each cell if needed. Install and
tighten each cap after checking.
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.
Battery Charger
Under normal conditions, the engine alternator will
have no problem keeping 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.
Charging A New Battery
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.
IMPORTANT: DO NOT fast charge. Charging at a
higher rate will damage or destroy battery.
ALWAYS follow information provided on battery by
battery manufacturer. Contact battery manufacturer for
extensive instructions to charge battery.
1. Positive terminal
2. Negative terminal
Figure 23
3. Battery
OF1670
1. Put unit into service position to gain access to
battery.
2. Disconnect negative (-) cable first, then positive (+)
cable.
3. Remove hold down and remove battery.
4. Place battery on bench or other well ventilated
place where electrolyte spill will not create
damage.
5. Remove caps and fill each cell to level indicated
with electrolyte at 1.230 + specific gravity and 80
degrees F (27 degrees C).
6. Let battery stand for one half hour.
7. Check electrolyte level and add more if necessary.
8. Connect positive (+) lead of charger to positive (+)
terminal, and negative (-) lead to negative (-)
terminal.
9. 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.
10.Immediately after charging, check the electrolyte
level. If low, add distilled water to bring cell up to
required level.
11.Replace caps finger tight, wash off and dry battery.
12.Reinstall battery into unit and connect positive (+)
cable first, then negative (-) cable.
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. Sub-
tract .004 from 1.265 for each 10°F below 80°F or add
.004 to 1.265 for each 10°F above 80°F.
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
room temperature and the charging time can be
estimated. For example:
OCV Specific % of Charging
Gravity Charge 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 80 degrees F.
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.
Jump Starting
The unit used for jump starting should have a 12 volt
battery with at least 500 cold cranking amperes, and a
negatively grounded system.
1. Ensure battery is not frozen. If the fluid is frozen,
remove battery from unit and allow to thaw before
charging.
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 Owners 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 cabies 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.
9-30
a E ETT ——
9.5 SWITCHES
Switches either open a circuit to stop current flow or
close and allow current to flow through.
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.
Ignition Switch
NOTE: Refer to the wiring diagram of the unit involved
to determine switch functions and test using the meth-
ods 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.
9.6 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
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
inched. A solenoid can therefore, pull a lever, close a
heavy contact, or perform other jobs that require a
straight line pull.
If a relay or solenoid fails to operate, the cause may be
either electrical or mechanical.
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.
To check the solenoid, disconnect the cables to the
starter motor, turn the ignition switch to the start
position, and listen for the solenoid to snap inside
contacts closed.
if no snap is heard, check across the coils with a
voltmeter. The voltage should read 12 volts with the
ignition switch in the start position. If no voltage
appears, the defect is in the start circuit.
If the voltage is correct, turn off the power and check
continuity of the coil with an onmmeter. 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 start 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.
9.7 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.
9.8 DIODES AND RECTIFIERS
Diodes are solid state, semiconductor devices. They
contain no moving parts and conduct current better in
one direction than the other. They are electrical "check
valves" and permit current flow in one direction, but not
in 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 it from the circuit by
disconnecting one end. With a multitester set on the
lowest ohms scale setting, measure the resistance in
one direction, reverse the test leads, and measure in
the other direction. Readings should be high in one
direction and low in the other. (If the readings are low in
both directions, the diode is shorted, and if the
readings are high, the diode is open.) If the readings
are the same in both directions, the diode is defective
and must be replaced.
IMPORTANT: Diodes are marked to indicate polarity (a
band on one end, an arrow on the side). They fit on a
holder only one way. | |
Rectifiers
A battery is charged through the use of an alternator
located in or on the engine. A charging circuit contains
a rectifier because alternators produce alternating
current (AC) and batteries require direct current (DC)
for charging.
The rectifier may be built into the engine or it may be an
external part. It may also contain a regulator to prevent
overcharging the battery. (Servicing of rectifiers built
into the engine should be done by an approved engine
manufacturer's service center. Such 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.
9.9 ELECTRIC CLUTCH
The electric clutch is used to turn on and off the
attachment used on the unit by the 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
9-32
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. |
9.10 ELECTRICAL
Initial check out: Make sure that all switches are in their
proper position for starting: (A) PTO off. (B) transaxle in
neutral position. (C) operator on the seat. If no battery
voltage start the engine. Start the checklist.
STEP 1
Check out the battery. Use a hydrometer on all the
battery cells to see it one or more is bad. Also use a
voltmeter to check for proper voltage. replace the
battery if necessary and/or charge to proper level.
Refer to Battery.
STEP 2
Use a voltmeter to make sure you have battery voltage
to terminal (B) on the back side of the ignition switch in
the off position. If you don't have battery voltage to
terminal (B) check the battery connection and the fuse
in the read 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 the 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 51
transfers battery voltage to the one small terminal on
the starter solenoid and goes to ground through the
base of the starter solenoid.
PTO clutch check out: Remove the wiring harness PTO
clutch leads from the clutch. With a multimeter check
the clutch coil for resistance to see if the coil is good.
The clutch used on models 222227
Ignition switch check out: battery voltage check in the
off position, check for voltage at terminal (B). It should
not be present on terminals (B), (A), S2, 51.
With the ignition switch in the run position, check for
battery voltage at terminal (B), (A), S2. It should not be
present at 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 directions. if it passes voltage in both
directions or not at all the diode is bad and needs to be
replaced.
rm A EEE
9.11 WIRING DIAGRAM
Models 915030, 031, 032, 033—START, OPERATOR OFF SEAT
/ N . | PTO
a TT CLUTCH
PURPLE ! , 1 я o AL B
' I 4 PURPLE!
6186 SEAT | 4 "to WHITE 000006
SWITCH \, PARKING 9 =
5 |5 BRAKE — PTO |
RED/ SWITCH
REGULATOR 1 RED SWITCH [<
DIODE 9
3 |3 а 2
MAGNETO KILL 219 WHITE / BLACK Fg © >
3 =
| 4|4 5 5
STARTER 3 e
| >
BLACK pe HEADLIGHT
START
RELAY
wl [2 HEADLIGHT
2 13 SWITCH _
, ^ 30 86 85
BLACK IN LT. BLUE i
87a 87 и
| А BLACK /WHITE E
=
POSITIVE © е
of PATH FUSE 8
=
9
o PARKING
> BRAKE
+ = | ® E” START SWITCH
+ =
= BATTERY A
= ©! o
bl =
BLACK
COIL 2 COIL 1 O,
BROWN > *
A x x RED / VIOLET
STARTER © y,
SOLENOID ROUND
KEY PATH FUSE
SWITCH
Da A à BLACK
FUSE =
25A BLACK
9-34
a ram
Models 915030, 031, 032, 033—PTO, OPERATOR ON SEAT
ME mini
A PTO
po 7 CLUTCH
PURPLE f \ 1 A B
| ar —— | 4 PURPLE/
616 SEAT \ ; 3 STO WHITE CO
SWITCH \, PARKING 9 —
BRA PTO
51° 1 RED/ SWITCH SWITCH
REGULATOR 114 YELLOW
ENGINE 2 1 2 PTO 3
DIODE a
MAGNETO KILL_| of > WHITE / BLACK A = :
o ©
| STARTER 414 = с
>
BLACK HEADLIGHT
START
La RELAY
tal
wl |B HEADLIGHT
3 13 SWITCH
m A
BLACK —rh LT. BLUE _
87a a
BLACK /WHITE =
>
POSITIVE © a
i PATH FUSE E
RED A В RED O To 5 1
= O
| us PARKING
i > BRAKE
Lo Om 25A ® START SWITCH
r A DIODE ,
BATTERY O
= ©! ©
= BLACK |
CoIL 2 8 COIL 1 BROWN \ Or,
7 ъ RED / VIOLET
STARTER ©
SOLENOID GROUND
KEY PATH FUSE
BLACK + SWITCH
FUSE =
25A BLACK
Models 915030, 031, 032, 033—RUN, OPERATOR OFF SEAT
a | PTO
men CLUTCH
PURPLE 1 Г ’ A B
ur CU OT4 PURPLE/
| —]
616 SEAT \ 3 WHITE
SWITCH vf PARKING O Tolo
PTO
>> 1 RED/ SWITCH SWITCH
REGULATOR YELLOW
ENGINE 111 : PTO Е
DIODE A
313 a =
pu
MAGNETO KILL |, | 5 WHITE /BLACK ЖК = :
о 5
STARTER 418 = ©
i >
BLACK HEADLIGHT
START
и RELAY
ш 2 HEADLIGHT
21 13 SWITCH ee
@ 1% 86 85
BLACK AN LT. BLUE -
87a 87 w
LAN A BLACK /WHITE =
=
POSITIVE o
a PATH FUSE e
x 8 =
RED A RED ©
| Ш PARKING
> BRAKE
Но © 25A ® == START SWITCH
= -
BATTERY O
= ©.
BLACK |
COIL 2 d COIL 1 BROWN \ @r,
A \ RED / VIOLET
STARTER = J
SOLENOID 62) GROUND
KEY PATH FUSE
à BLACK $ SWITCH + BLACK
FUSE —
25A BLACK
Models 915030, 031, 032, 033—OFF
,° PTO
po 7 CLUTCH
PURPLE | 1 o АО B
1
| — | 4 PURPLE/
6/6 SEAT \ 3 ST WHITE 600000
SWITCH NN PARKING 9 —
BRA PTO
ecuLaron ||, Lg, SWITCH SWITCH
R
111
ENGINE —¢-0 O———0 | On PTO =
DIODE +
313 a ul
pan
MAGNETO KILL 219 WHITE / BLACK rx = Е
| ë 5
| STARTER 414 3
[=
BLACK "HEADLIGHT
START
À RELAY
wl |B HEADLIGHT 0006)
21 12 SWITCH о
a” N 30 86 85
BLACK fx LT. BLUE —-
87a 87 wi
LAN N BLACK /WHITE =
=
POSITIVE а
2 PATH FUSE | © e
° A В © do 5 6
® À
| ui PARKING
| > BRAKE
о © ® = START SWITCH
+ Teno | A DIODE ,
BATTERY o
= © ‘о T
BLACK | ©
COIL 2 0 COIL 1 BROWN \ Dw 3
A > \ RED / VIOLET
| о y
STARTER © Î
SOLENOID GROUND
KEY PATH FUSE
BLACK é SWITCH BLACK A 8
FUSE =
25A BLACK
|
|
|
;
9-37
9.12 CONTINUITY DIAGRAM
Models 915030, 031, 032, 033
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
(01563700) (03042800)
^ 82 == I
Te
Mm a Jes 87A 85 | Е B7A ss ||
START 30 30 meee
NOT ENERGIZED ENERGIZED
PTO Switch Light Switch
(01545600) 9 а 9 (03656800)
TS TT»
4 1 7 4 4 7 OFF ON
DISENGAGED ENGAGED
(down position) - (up position)
Seat Switch Brake Neutral Switch
(02754100) (03657100)
] _
1 2 1 2
| | — 1 2 1 2
OPERATOR OPERATOR BUTTON UP BUTTON DOWN
OFF SEAT ON SEAT
Solenoid
(03679000)
NOT ENERGIZED ENERGIZED
9.13 ELECTRICAL SYSTEM
Models 915030, 031, 032, 033
To Starter |
1. Clutch Switch 6. Single Pole N.O. Switch
2. Diode 7. Solenoid
3. N.O. Switch 8. Light
4. 25 Amp Fuse 9. Key Switch
5. Relay PE0080