Ariens Sierra 1640H Service manual
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Sierra
®
Service Manual
Models 936014-026, 936305-313
03675400 04/00
Printed in USA
Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-2
1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Service and Replacement Parts . . . . . . . . 1-3
1.3 Product Registration . . . . . . . . . . . . . . . . . 1-3
1.4 Unauthorized Replacement Parts . . . . . . . 1-3
1.5 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Technical Service Communications . . . . . . 1-3
1.7 Preparation . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Signal Words . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Practices and Laws . . . . . . . . . . . . . . . . . . 2-4
2.5 Required Operator Training . . . . . . . . . . . . 2-4
2.6 Safety Precautions. . . . . . . . . . . . . . . . . . . 2-4
Section 3 - Specifications . . . . . . . . . . . . . . . . 3-7
Section 4 - General Maintenance
& Adjustments . . . . . . . . . . . . . . . . . . . . . . 4-15
4.1 Controls and Features . . . . . . . . . . . . . . . 4-15
4.2 Filling The Fuel Tank . . . . . . . . . . . . . . . . 4-16
4.3 General Lubrication . . . . . . . . . . . . . . . . . 4-16
4.4 Checking Fasteners . . . . . . . . . . . . . . . . . 4-16
4.5 Checking Engine Oil . . . . . . . . . . . . . . . . 4-16
4.6 Changing Oil . . . . . . . . . . . . . . . . . . . . . . 4-17
4.7 Checking Engine Cooling. . . . . . . . . . . . . 4-17
4.8 Cleaning The Air Cleaner . . . . . . . . . . . . 4-17
4.9 Changing The Air Cleaner Element . . . . . 4-17
4.10 Checking The Tires . . . . . . . . . . . . . . . . 4-17
4.11 Checking The Transmission Fluid (Hydro)4-18
4.12 Priming The Transmission (Hydro). . . . . 4-18
4.13 Checking The PTO Clutch . . . . . . . . . . . 4-18
4.14 Adjustment Of Transmission Neutral
(Hydro) . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.15 Adjustment Of Transaxle Neutral (Gear) 4-19
4.16 Adjustment Of Directional Control Pedal 4-20
4.17 Adjusting The Brake (Hydro) . . . . . . . . . 4-20
4.18 Adjusting The Brake (Gear) . . . . . . . . . . 4-20
4.19 Adjusting The Seat . . . . . . . . . . . . . . . . 4-21
4.20 Mower Deck Belt Adjustment . . . . . . . . . 4-21
4.21 Mower Belt Replacement. . . . . . . . . . . . 4-21
4.22 Mower Spindle Lubrication/
Jackshaft Lubrication . . . . . . . . . . . . . . 4-21
4.23 Transaxle Belt Replacement . . . . . . . . . 4-22
4.24 Steering . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Section 5 - Engine . . . . . . . . . . . . . . . . . . . . . . 5-23
5.1 Engine Troubleshooting . . . . . . . . . . . . . . 5-23
5.2 Engine Removal. . . . . . . . . . . . . . . . . . . . 5-24
5.3 Engine Installation . . . . . . . . . . . . . . . . . . 5-24
Section 6 - Hydro Drive Train . . . . . . . . . . . . . 6-25
6.1 Hydro Transmission Troubleshooting . . . . 6-25
6.2 Fluids/Greases. . . . . . . . . . . . . . . . . . . . . 6-26
6.3 Hydro Transmission Removal . . . . . . . . . 6-26
6.4 Hydro Transmission Repair (Minor) . . . . . 6-27
6.5 Hydro Transmission Repair (Major) . . . . . 6-28
2
6.6 Hydro Transmission Installation . . . . . . . . 6-33
Section 7 - Gear Drive Train . . . . . . . . . . . . . . 7-34
7.1 Gear Transmission Troubleshooting . . . . . 7-34
7.2 Gear Transaxle Removal (Peerless) . . . . 7-35
7.3 Transaxle Teardown . . . . . . . . . . . . . . . . . 7-35
7.4 Transaxle Installation . . . . . . . . . . . . . . . . 7-36
Section 8 - Steering. . . . . . . . . . . . . . . . . . . . . 8-37
8.1 Steering Unit Removal . . . . . . . . . . . . . . . 8-37
8.2 Steering Unit Assembly . . . . . . . . . . . . . . 8-37
8.3 Tie Rod Adjustment . . . . . . . . . . . . . . . . . 8-37
Section 9 - Lift System . . . . . . . . . . . . . . . . . .9-38
9.1 Lift System Over View . . . . . . . . . . . . . . . 9-38
9.2 Lift System Removal . . . . . . . . . . . . . . . . 9-38
9.3 Lift System Installation . . . . . . . . . . . . . . . 9-38
Section 10 - Fuel System . . . . . . . . . . . . . . . . 9-39
10.1 Fuel System Troubleshooting. . . . . . . . 10-39
10.2 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . 10-40
10.3 Fuel System Contamination. . . . . . . . . 10-40
10.4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . 10-40
Section 11 - Electrical . . . . . . . . . . . . . . . . . . 11-41
11.1 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41
11.2 Electrical Measurements . . . . . . . . . . . 11-41
11.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . 11-42
11.4 Switches. . . . . . . . . . . . . . . . . . . . . . . . 11-43
11.5 Solenoid And Relays . . . . . . . . . . . . . . 11-44
11.6 Lighting Circuits . . . . . . . . . . . . . . . . . . 11-45
11.7 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45
11.8 Diodes And Rectifiers . . . . . . . . . . . . . 11-46
11.9 Electric Clutch . . . . . . . . . . . . . . . . . . . 11-46
11.10 Electrical . . . . . . . . . . . . . . . . . . . . . . 11-46
11.11 Switch Continuity . . . . . . . . . . . . . . . . 11-48
11.12 Wiring Diagrams . . . . . . . . . . . . . . . . 11-52
Section 12 - Mower . . . . . . . . . . . . . . . . . . . . 12-62
12.1 40" And 48" Mower Removal . . . . . . . . 12-62
12.2 40" And 48" Mower Installation . . . . . . 12-62
12.3 40" Mower Spindle Removal . . . . . . . . 12-62
12.4 40" Spindle Repair . . . . . . . . . . . . . . . . 12-62
12.5 Spindle Installation. . . . . . . . . . . . . . . . 12-63
12.6 40" Jackshaft Removal And Repair . . . 12-63
12.7 40" Jackshaft Installation . . . . . . . . . . . 12-63
Section 13 - Sno-Thro Attachment . . . . . . . 13-64
13.1 Installation . . . . . . . . . . . . . . . . . . . . . . 13-64
13.2 Shear Bolt Replacement . . . . . . . . . . . 13-64
13.3 Mule Drive Belt. . . . . . . . . . . . . . . . . . . 13-64
13.4 Power Take Off (PTO) Belt . . . . . . . . . . 13-64
13.5 Auger/Impeller Drive Belt . . . . . . . . . . . 13-64
13.6 Oil And Grease Locations . . . . . . . . . . 13-64
13.7 Scraper Blade . . . . . . . . . . . . . . . . . . . 13-65
13.8 Runners . . . . . . . . . . . . . . . . . . . . . . . . 13-65
13.9 Discharge Chute Cable . . . . . . . . . . . . 13-65
13.10 Auger/Impeller, Gear Case Removal . 13-65
13.11 Gear Case . . . . . . . . . . . . . . . . . . . . . 13-65
SECTION 1 - INTRODUCTION
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 unit.
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.
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.
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.
Directional Reference
All reference to left, right, front, or rear are given from the operator in the operator position and facing the direction of forward travel.
1.2 SERVICE AND REPLACEMENT PARTS
When ordering publications, replacement parts, or making service inquiries, know the Model and Serial numbers of your unit and engine.
Numbers are located on the product registration form in the unit literature package. They are printed on a serial number label, located on the frame of your unit.
Serial Number
1.3 PRODUCT REGISTRATION
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.
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.
1.5 DISCLAIMER
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.
1.6 TECHNICAL SERVICE
COMMUNICATIONS
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.
Figure 1
1 - 3
1.7 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.
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.
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.
SECTION 2 - SAFETY
2.1 SAFETY ALERTS
Look for these symbols to point out important safety precautions. They mean:
Attention!
Personal Safety Is Involved!
Become Alert!
Obey The Message!
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.
Understand the safety message. It contains important information about personal safety on or near the unit.
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 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
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 the Operator’s Manual and any needed safety training before operation.
2.6 SAFETY PRECAUTIONS
Safe Operation Practices for Ride-On Mowers
This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death. Your complete and unimparied attention is required at all times.
General Operation
Read, understand, and follow all instructions in this owners manual, the engine manual and on the machine before starting.
Only allow responsible adults, who are familiar with the instructions, to operate the machine.
Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade.
Be sure the area is clear of other people and pets before mowing. Stop machine if anyone enters the area.
Never carry passengers.
Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while backing.
Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.
Slow down before turning to prevent tipping or loss of control.
Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove keys to prevent unauthorized use before dismounting.
Turn off blades when not mowing.
2 - 4
Disengage mower clutch, stop engine, remove key and wait for moving parts to stop before leaving operators position for any reason such as removing grass catcher or unclogging chute.
Mow only in daylight or good artificial light.
Do not operate the machine while under the influence of medication, alcohol or drugs.
Watch for traffic when operating near or crossing roadways or drives.
Use extra care when loading or unloading the machine into a trailer to truck.
Use only attachments or accessories designed for your unit. See your Ariens Dealer.
Wear sturdy foorwear. Do not operate riding mower barefoot or when wearing open sandals or canvas shoes. Do not wear loose clothing that may get caught in rotating parts of unit. Wear safety glasses with side shields when operating mower.
Slope Operation
Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.
Do
Mow up and down slopes, not across.
Remove obstacles such as rocks, free limbs, etc.
Watch for holes, ruts, or bumps. Uneven terrain could overturn the machine. Tall grass can hide obstacles.
Use slow speed. Choose a low gear so that you will not have to stop or shift while on the slope.
Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability.
Use extra care with grass catchers or other attachments. These can change the stability of the machine. Use only approved hitch points.
Limit loads to those you can safely control.
Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction.
Avoid starting or stopping on a slope. If tires lose traction, disengage mower clutch and proceed slowly straight down the slope. If you must stop when going up the slope and can not safely back down: for gear drive models, depress clutch/brake pedal, disengage mower clutch, place travel speed selector in first gear
(low speed) and slowly release the clutch/brake pedal.
For hydro models depress clutch/brake pedal only if necessary, disengage mower clutch, slowly release clutch brake pedal and slowly engage the forward pedal.
Do Not
Do not turn on slopes unless necessary, and then, turn slowly and gradually, downhill, if possible.
Do not mow near drop-offs, ditches, or embankments.
The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.
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.
Do not use grass catcher on steep slopes.
Children
Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.
Keep children out of the mowing area and under the watchful care of another responsible adult.
Be alert and turn machine off if children enter the area.
Before and when backing, look behind and down for small children.
Never carry children, even when attachments are off.
They may fall off and be seriously injured or interfere with safe machine operation.
Never allow children to operate the machine.
Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
Service
Do not change engine governor setting or over speed the engine.
Replace damaged or worn out mufler immediately.
Continued use could result in fire or explosion.
Use extra care in handling gasoline and other fuels.
They are flammable and vapors are explosive.
Use only an approved container.
Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. Do not smoke. Wipe off any spilled gasoline and allow vapors to dissipate before starting engine.
Replace fuel tank cap and container cap securely.
Never refuel the machine indoors.
Never store the machine or fuel container inside where there is an open flame, such as in a water heater.
Never run a machine inside a closed area. Exhaust fumes contain carbon monoxide an odorless and deadly gas.
Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition.
Never tamper with safety devices. Check their proper operation regularly.
2 - 5
Keep machine free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage. Allow machine to cool before storing.
Stop and inspect the equipment if you strike an object.
Repair any damage before restarting.
Never make adjustments or repairs with the engine running or when engine and exhaust parts are hot from operation.
Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace, with manufacturer’s recommended parts when necessary.
Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them.
Check brake operation frequently. Adjust and service as required.
Refer to Storage Section of this owners manual if unit is to be stored for extended period.
2 - 6
SECTION 3 - SPECIFICATIONS
Model No.
Description Name
Length, in. (m)
Height, in. (m)
Width, in. (m)
Wheel Base, in. (m)
Actual Weight, lbs. (kg)
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius, in. (cm)
Tire Size
Front
Rear
Diagnostic Lights
Engine
Manufacture
Fuel and Capacity, gal. (L)
Idle R.P.M.
Governed R.P.M.
Crank Case Capacity, oz. (L)
(Oil Filter)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed - Forward Max.
- Reverse Max
Transmission Lube
Drive Clutch
Axle Capacity
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear - Light & Medium
- Heavy (SnoThro)
Lift System
Power Take Off - Front
Mower Pan, in. (cm)
Bagger 3 Bucket/1 Bag
Sno-Thro
Dozer Blade
936014
Sierra 1340G
66.50 (1.68)
41.25 (1.05)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
Medium
Disc.
Gear
26 (66)
15x6.00-6
20x8.80-8
No
OHV 13 HP
Tecumseh
Unleaded, 3 (11.4)
2100
3250
32 (.95)
(No)
Paper Element
Foam Precleaner
3/5 AMP Unregulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RN-4C
Peerless 206-517
6 Speed
0.8 - 5.5 MPH
1.9 MPH
Grease
Belt Clutched
150 ft lb (110 Nm)
130 lb (58.9 kg)
450 lb (204 kg)
10 PSI/10 PSI
14 PSI/10PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
3 - 7
936015
Sierra 1440G
66.50 (1.68)
41.25 (1.05)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
Medium
Disc.
Gear
26 (66)
15x6.00-6
20x8.80-8
No
OHV 14 HP
Briggs
Unleaded, 3 (11.4)
1800
3250
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
3/5 AMP Unregulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Peerless 206-517
6 Speed
0.8 - 5.5 MPH
1.9 MPH
Grease
Belt Clutched
150 ft lb (110 Nm)
130 lb (58.9 kg)
450 lb (204 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936016
Sierra 1340H
66.50 (1.68)
41.25 (1.05)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
Medium
Disc.
Gear
26 (66)
15x6.00-6
20x8.80-8
Yes
OHV 13 HP
Tecumseh
Unleaded, 3 (11.4)
2100
3250
32 (.95)
(No)
Paper Element
Foam Precleaner
3/5 AMP Unregulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RN-4C
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
Model No.
Description Name
Length, in. (m)
Height, in. (m)
Width, in. (m)
Wheel Base, in. (m)
Actual Weight, lbs. (kg)
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius, in. (cm)
Tire Size
Front
Rear
Diagnostic Lights
Engine
Manufacture
Fuel and Capacity, gal. (L)
Idle R.P.M.
Governed R.P.M.
Crank Case Capacity, oz. (L)
(Oil Filter)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed - Forward Max.
- Reverse Max
Transmission Lube
Drive Clutch
Axle Capacity
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear - Light & Medium
- Heavy (SnoThro)
Lift System
Power Take Off - Front
Mower Pan, in. (cm)
Bagger 3 Bucket/1 Bag
Sno-Thro
Dozer Blade
936017
Sierra 1440H
66.50 (1.68)
41.25 (1.05)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
Medium-High
Disc.
Gear
20/26 (51/66)
15x6.00-6
20x8.00-8
Yes
OHV 14 HP
Briggs
Unleaded, 3 (11.4)
1800
3250
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
3/5 AMP Unregulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 OIl
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936018
Sierra 1540H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
20/26 (51/66)
15x6.00-6
20x8.00-8
Yes
OHV 15 HP
Kohler
Unleaded, 3 (11.4)
1800
3250
64 (1.9)
(Yes)
Paper Element
Foam Precleaner
15 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
10W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936019
Sierra 1640H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
20/26 (51/66)
15x6.00-6
20x8.00-8
Yes
OHV 16 HP
Briggs
Unleaded, 3 (11.4)
2100
3250 Max
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RN-4C
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
3 - 8
Model No.
Description Name
Length, in. (m)
Height, in. (m)
Width, in. (m)
Wheel Base, in. (m)
Actual Weight, lbs. (kg)
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius, in. (cm)
Tire Size
Front
Rear
Diagnostic Lights
Engine
Manufacture
Fuel and Capacity, gal. (L)
Idle R.P.M.
Governed R.P.M.
Crank Case Capacity, oz. (L)
(Oil Filter)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed - Forward Max.
- Reverse Max
Transmission Lube
Drive Clutch
Axle Capacity
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear - Light & Medium
- Heavy (SnoThro)
Lift System
Power Take Off - Front
Mower Pan, in. (cm)
Bagger 3 Bucket/1 Bag
Sno-Thro
Dozer Blade
936020
Sierra 1640H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
20/26 (51/66)
15x6.00-6
20x8.00-8
Yes
OHV 16 HP
Tecumseh
Unleaded, 3 (11.4)
1800
3250
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 OIl
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936021
Sierra 1648H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
518 (234)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
20 (51)
15x6.00-6
20x8.00-8
Yes
OHV 16 HP
Briggs
Unleaded 3 (11.4)
1800
3400
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 30 o
F (-1 o
C)
10W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
48 (122)
836010
834034
936022
Sierra 1340G
66.50 (1.68)
41.50 (1.06)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
Medium
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
No
OHV 13 HP
Tecumseh
Unleaded 3 (11.4)
2100
3250 Max
32 (.95)
(No)
Paper Element
Foam Precleaner
315 AMP Unregulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RN-4C
Peerless 206-517
0.8 - 5.5 MPH
1.9 MPH
Grease
Belt Clutched
150 ft lb (110 Nm)
130 lb (58.9 kg)
450 lb (204 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
3 - 9
Model No.
Description Name
Length, in. (m)
Height, in. (m)
Width, in. (m)
Wheel Base, in. (m)
Actual Weight, lbs. (kg)
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius, in. (cm)
Tire Size
Front
Rear
Diagnostic Lights
Engine
Manufacture
Fuel and Capacity, gal. (L)
Idle R.P.M.
Governed R.P.M.
Crank Case Capacity, oz. (L)
(Oil Filter)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed - Forward Max.
- Reverse Max
Transmission Lube
Drive Clutch
Axle Capacity
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear - Light & Medium
- Heavy (SnoThro)
Lift System
Power Take Off - Front
Mower Pan, in. (cm)
Bagger 3 Bucket/1 Bag
Sno-Thro
Dozer Blade
936023
Sierra 1540H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
26 (66)
15x6.00-6
20x8.50-8
Yes
OHV 15 HP
Briggs & Stratton
Unleaded, 3 (11.4)
1800
3250
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
10W30 Above 40 o
F (4 o
C)
.030 Champion RN-46
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 OIl
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936024
Sierra 1548H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
518 (234)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
Yes
OHV 15 HP
Kohler
Unleaded, 3 (11.4)
1800
3250
64 (1.9)
(Yes)
Paper Element
Foam Precleaner
15 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 30 o
F (-1 o
C)
10W30 Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
48 (122)
836010
834034
936025
Sierra 1640H
66.50 (1.68)
41.50 (1.06)
52.00 (1.32)
46.00 (1.17)
518 (234)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
Yes
OHV 13 HP
Briggs & Stratton
Unleaded, 3 (11.4)
1800
3400
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Unregulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 30 o
F (-1 o
C)
30W Above 30 o
F (-1 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
6 Speed
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
48 (122)
N/A
836010
834034
3 - 10
Model No.
Description Name
Length, in. (m)
Height, in. (m)
Width, in. (m)
Wheel Base, in. (m)
Actual Weight, lbs. (kg)
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius, in. (cm)
Tire Size
Front
Rear
Diagnostic Lights
Engine
Manufacture
Fuel and Capacity, gal. (L)
Idle R.P.M.
Governed R.P.M.
Crank Case Capacity, oz. (L)
(Oil Filter)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed - Forward Max.
- Reverse Max
Transmission Lube
Drive Clutch
Axle Capacity
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear - Light & Medium
- Heavy (SnoThro)
Lift System
Power Take Off - Front
Mower Pan, in. (cm)
Bagger 3 Bucket/1 Bag
Sno-Thro
Dozer Blade
936026
Sierra 1540H
66.50 (1.68)
42.50 (1.08)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
Yes
OHV 15 HP
Kohler
Unleaded, 3 (11.4)
1800
3250 Max
64 (1.9)
(Yes)
Paper Element
Foam Precleaner
15 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 30 o
F (-1 o
C)
10W30 Above 30 o
F (-1 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936305
Sierra 1640G
66.50 (1.68)
42.50 (1.08)
52.00 (1.32)
46.00 (1.17)
400 (181)
12 Volt 290 CCA
Optional (736008)
Medium
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
No
OHV 14 HP
Briggs
Unleaded, 3 (11.4)
1800
3050 Max
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Peerless 206-517
6 Speed
0.7-4.8 MPH
1.6 MPH
Grease
Belt Clutched
150 ft lb (110 Nm)
130 lb (58.9 kg)
450 lb (204 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
49 (124) Optional 836301
836008/836007
836010
834034
936306
Sierra 1640H
66.50 (1.68)
41.25 (1.05)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
Medium
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
Yes
OHV 14.0 HP
Briggs
Unleaded, 3 (11.4)
1800
2900 Max
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
3/5 AMP Unregulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 312-0750
0-5.0 MPH
0-2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
30 (76.2)
836008/836007
836010
834034
3 - 11
Model No.
Description Name
Length, in. (m)
Height, in. (m)
Width, in. (m)
Wheel Base, in. (m)
Actual Weight, lbs. (kg)
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius, in. (cm)
Tire Size
Front
Rear
Diagnostic Lights
Engine
Manufacture
Fuel and Capacity, gal. (L)
Idle R.P.M.
Governed R.P.M.
Crank Case Capacity, oz. (L)
(Oil Filter)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed - Forward Max.
- Reverse Max
Transmission Lube
Drive Clutch
Axle Capacity
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear - Light & Medium
- Heavy (SnoThro)
Lift System
Power Take Off - Front
Mower Pan, in. (cm)
Bagger 3 Bucket/1 Bag
Sno-Thro
Dozer Blade
936307
Sierra 1640H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
20/26 (51/66)
15x6.00-6
20x8.00-8
Yes
1.6 HO V-Twin
Briggs & Stratton
Unleaded, 3 (11.4)
1800
3000
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30w Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 312-0750
0.0 - 5.0 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936308
Sierra 1640G
66.50 (1.68)
41.25 (1.05)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
Medium
Disc.
Gear
20/26 (51/66)
15x6.00-6
20x8.00-8
Yes
14.0 HP OHV
Briggs & Stratton
Unleaded, 3 (11.4)
1800
3250 Max
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
3/5 AMP Unregulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Peerless 206-517
6 Speed
0.8-5.5 MPH
1.9 MPH
Grease
Belt Clutched
150 ft lb (110 Nm)
130 lb (58.9 kg)
450 lb (204 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936309
Sierra 1648H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
518 (234)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
20 (51)
15x6.00-6
20x8.00-8
Yes
OHV 16 HP
Tecumseh
Unleaded, 3 (11.4)
1800
3400
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
0.0-5.5 MPH
0.0-2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
48 (122)
836010
834034
3 - 12
Model No.
Description Name
Length, in. (m)
Height, in. (m)
Width, in. (m)
Wheel Base, in. (m)
Actual Weight, lbs. (kg)
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius, in. (cm)
Tire Size
Front
Rear
Diagnostic Lights
Engine
Manufacture
Fuel and Capacity, gal. (L)
Idle R.P.M.
Governed R.P.M.
Crank Case Capacity, oz. (L)
(Oil Filter)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed - Forward Max.
- Reverse Max
Transmission Lube
Drive Clutch
Axle Capacity
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear - Light & Medium
- Heavy (SnoThro)
Lift System
Power Take Off - Front
Mower Pan, in. (cm)
Bagger 3 Bucket/1 Bag
Sno-Thro
Dozer Blade
936310
Sierra 1648H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
Yes
OHV 15 HP
Briggs & Stratton
Unleaded, 3 (11.4)
1800
3250
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30w Above 40 o
F (4 o
C)
.030 Champion RN-4C
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936311
Sierra 1640H
66.50 (1.68)
41.25 (1.05)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
Yes
OHV 16.0 HP
Briggs & Stratton
Unleaded, 3 (11.4)
1800
3250 Max
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
6 Speed
0.0-5.5 MPH
0.0-2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
936312
Sierra 1540G
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
480 (217)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
No
OHV 15 HP
Briggs & Stratton
Unleaded, 3 (11.4)
1800
3050
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W40 Below 40 o
F (4 o
C)
30W Above 40 o
F (4 o
C)
.030 Champion RN-4C
Peerless 206-517
6 Speed
0.8-5.5 MPH
1.9 MPH
Grease
Belt Clutched
150 ft lb (110 Nm)
130 lb (58.9 kg)
450 lb (204 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
40 (101)
836008/836007
836010
834034
3 - 13
Model No.
Description Name
Length, in. (m)
Height, in. (m)
Width, in. (m)
Wheel Base, in. (m)
Actual Weight, lbs. (kg)
Battery
Hour Meter
Seat
Brakes
Steering
Turning Radius, in. (cm)
Tire Size
Front
Rear
Diagnostic Lights
Engine
Manufacture
Fuel and Capacity, gal. (L)
Idle R.P.M.
Governed R.P.M.
Crank Case Capacity, oz. (L)
(Oil Filter)
Air Cleaner
Charging Capacity
Fuel Filter
Engine Oil
Spark Plug Gap
Transmission
Speed - Forward Max.
- Reverse Max
Transmission Lube
Drive Clutch
Axle Capacity
Allowable Added Weight
Rear Axle Maximum Load
Tire Pressure With Loads
Front/Rear - Light & Medium
- Heavy (SnoThro)
Lift System
Power Take Off - Front
Mower Pan, in. (cm)
Bagger 3 Bucket/1 Bag
Sno-Thro
Dozer Blade
936313
Sierra 1648H
66.50 (1.68)
42.00 (1.07)
52.00 (1.32)
46.00 (1.17)
518 (234)
12 Volt 290 CCA
Optional (736008)
High
Disc.
Gear
26 (66)
15x6.00-6
20x8.00-8
Yes
OHV 16 HP
Briggs & Stratton
Unleaded, 3 (11.4)
1800
3050
56 (1.7)
(Yes)
Paper Element
Foam Precleaner
16 AMP Regulated
120 Micron
2 1/2 GPA Capacity
5W30 Below 30 o
F (-1 o
C)
30w Above 30 o
F (-1 o
C)
.030 Champion RC12YC
Hydrogear 325-0750
0.0 - 5.5 MPH
0.0 - 2.5 MPH
20W50 Oil
Belt Clutched
175 ft lb (129 Nm)
130 lb (58.9 kg)
568 lb (257 kg)
10 PSI/10 PSI
14 PSI/10 PSI
Manual
Electric
48 (122)
N/A
836010
834034
3 - 14
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS
4.1 CONTROLS AND FEATURES
3
1
6
077180
14
13
12
11
21
1. Fuel Tank Fill
2. Clutch/Brake Pedal
3. Attachment Lift Lever
4. Throttle/Choke Lever
5. Head Light Switch
6. Travel Speed Selector (Gear only)
7. Ignition/Key Switch
8. PTO Switch
9. Headlights
10.Parking Brake control
11.Fuel Level Indicator
12.Seat Position or Adjustment
13.Transmission Disconnect Control
(Hydro Only)
14.Expansion Hose with Vent (Hydro Only)
15.Mower Height Indicator
16.Choke Control (16 HP B&S Twin Only)
17.Cruise Control Switch (Hydro Only)
18.Indicator Lights (Hydro Only)
19.Forward Pedal (Hydro Only)
20.Reverse Pedal (Hydro Only)
21.Anti-Scalp Roller
9
PT0640
16
2
Figure 2
4
15
18
10
OT0200
5
17
8
7
19
20
OT0121
4 - 15
4.2 FILLING THE FUEL TANK
WARNING: Use caution with fuel. Fuel is very flammable. Keep fuel in a clean and tight container. Keep fuel away from fire and heat.
Never put fuel in the fuel tank while the engine is running or hot. Clean up any spilled fuel before starting the engine.
Add fuel to the fuel tank as needed. See your engine manual for the correct type and grade of fuel to be used.
1. Put the unit in an open and well ventilated area prior to refueling.
2. Stop the engine and set the parking brake.
Figure 4
OT0572
Figure 3
936-2
3. Raise the seat and clean the fuel cap and in the area around the fuel cap. Remove the cap from the fuel tank.
4. Fill the fuel tank with the proper grade of fuel recommended by the engine manufacturer. Be careful not to spill any fuel.
5. Install fuel cap on the fuel tank and tighten.
6. Clean up any spilled fuel before starting engine.
4.3 GENERAL LUBRICATION
All grease fittings should be greased at 25-hour intervals. Clean the fittings before attaching the grease gun.
Use a moly-lithium grease. Add grease until it appears at the ends of the bearing or ends of the shaft.
See Figure 3 for the locations of the grease fittings on your machine.
Every 25 hours apply motor oil to all pin connections, pivots points and areas where sliding occurs.
4.4 CHECKING FASTENERS
Each day before operating the unit, check all nuts, bolts and other fasteners. Replace fasteners that are missing or damaged.
Tighten all nuts and bolts that are loose.
4.5 CHECKING ENGINE OIL
Check the engine oil daily prior to use. Never operate the engine with the oil below the low mark on the dipstick.
See your 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.
Figure 5
936-3
3. Remove the dipstick and wipe off the oil.
4 - 16
4. Put the dipstick back into the engine, tighten in place, and remove again.
5. When the dipstick is removed, note the oil level and add oil accordingly. Do not over fill.
4.6 CHANGING OIL
WARNING: Engine muffler and other parts will be hot if unit has been running.
Engine oil should be changed after the first 5 hours of operation and every 25 hours there after.
1. Move the unit to a level and well ventilated area and set the parking brake.
2. If the engine is cold, let the unit run for 5 minutes.
3. When the engine is warm, stop the engine and raise the hood. Clean the area around the dipstick and drain plug.
Figure 7
936-5
Check the air intake screen on the engine each day.
Remove any grass, dirt, or debris that may have accumulated on it. The air intake screen must be kept clean.
4.8 CLEANING THE AIR CLEANER
Check the air cleaner element every day. Clean the air cleaner precleaner every 25 hours. Wash the precleaner with soap and water. Dry the precleaner, apply oil and reinstall over the paper air filter element.
Figure 6
936-4
4. Put an open container that will hold 1 gallon of oil under the drain plug. Remove the drain plug.
5. Allow the engine oil to drain completely. Clean and reinstall the oil drain plug.
6. Remove the oil filter. 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. Start and run the engine.
7. Stop the engine and recheck the oil level and add as necessary. Check for leakage at the drain plug and oil filter. Tighten the fittings as necessary if leakage occurs.
8. Lower the hood and latch in place, release the parking brake and return the unit to service.
4.7 CHECKING ENGINE COOLING
IMPORTANT: To prevent severe damage to the engine, proper cooling will need to be maintained.
Check the engine cooling yearly. Clean more often in dirty conditions. Remove the engine blower housing and clean the outer surface of the engine. Do not run the engine with the blower housing removed.
4 - 17
Figure 8
936-6
Wipe out the air cleaner cover to remove any dirt build up in the cover. Reinstall the cover over the air cleaner prior to operating the engine. See your engine manual for instructions.
4.9 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.
4.10 CHECKING THE TIRES
Before each use, make a visual check of the tires. For correct air pressure see Section 3 for specifications.
4.11 CHECKING THE TRANSMISSION
FLUID (HYDRO)
The transaxle is filled and tested at the factory and should not require fluid when the unit is put into service. Inspect the transaxle for leaks or damage to the housing. If leakage is observed, do not operate until the leakage is repaired.
Check the oil level and fill to the correct level if needed.
Figure 10
936-8
3. Start engine and run at low idle.
4. Stroke the travel control pedal forward for five seconds and then reverse for five seconds. Do this three times in each direction.
Figure 9
936-7
The oil should be between 1.25 and 1.60" from the top of the housing in the 310-0750 axle. It may be checked by removing the expansion hose. Typically, an API classification CG/CD engine oil is used with a viscosity range equivalent to 20W50.
4.12 PRIMING THE TRANSMISSION
(HYDRO)
The following is suggested for the priming of new or repaired transaxles to assure proper operating performance.
1. Locate the unit on a flat level surface to limit the chance of the unit rolling while performing the following procedures.
2. Actuate the bypass (freewheel control).
Figure 11
936-9
5. Return the travel control to neutral.
6. Disengage the bypass and drive the unit forward and then reverse. Do this three times each way for a distance of approximately five feet.
7. Some units may require repeating the previous six steps to achieve proper operating performance.
4.13 CHECKING THE PTO CLUTCH
Measure Clutch Coil Resistance:
1. Turn engine and power take off (PTO) switch off.
2. Disconnect clutch wire connections.
3. Set meter to check ohms.
4. Connect meter leads in clutch connector.
4 - 18
2
3
1
Figure 12
936-8
5. If meter reads below 6.00 ohms or above 8.00 ohms, then the clutch has failed and needs to be replaced.
6. If meter reads between 6.00 to 8.00 ohms, proceed to measure clutch current draw.
Measure Clutch Current Draw
1. Turn engine off.
2. Remove 30 amp fuse.
3. Set meter to check amps (10 amp scale).
4. Connect one meter lead to the fuse holder.
5. Connect the other meter lead to the second wire in the fuse connector.
6. Turn the ignition switch to run, sit on the seat and turn the PTO switch to on.
7. If the meter reads below 3.5 amps, the problem would be in the electrical system leading to the clutch (battery, relay, switch wiring).
If after completing the tests:
• The resistance falls between 6.00 and 8.00 ohms.
• The amp draw is 3.50 or above.
The electric clutch is within factory specifications and is not the source of the problem.
1. Neutral Adjustment Bolt
2. Spring-Forward
3. Spring-Reverse
Figure 13
4. Turn the adjustment bolt counterclockwise until the wheels turn in the other direction.
5. Center the adjustment bolt between these two points.
4.15 ADJUSTMENT OF TRANSAXLE
NEUTRAL (GEAR)
OT0041
1. Raise and block the rear of the unit so that the rear wheels are of the ground.
2. Remove the left rear wheel.
3. Remove the spring loaded ball joint from the transaxle shift arm.
1
4.14 ADJUSTMENT OF TRANSMISSION
NEUTRAL (HYDRO)
1. Raise and block the rear of the unit so that the rear wheels are off the ground.
2. With the operator in the seat, start the unit and allow the transmission to warm up prior to adjustment.
3. With the parking brake released, turn the adjustment bolt clockwise until the rear wheels turn in one direction.
2
3
1. Speed Selector
2. Ball Joint (2)
3. Link
Figure 14
OT0030
4. Place the operator shift lever in neutral.
5. Move the transaxle shift arm to neutral, the OK To
Start light will come on in the dash if the parking brake is set and the ignition switch is in the run position.
4 - 19
6. Adjust the ball joint to align with ball on the transaxle shift arm. Attach the ball joint to the ball on the shift arm.
4.16 ADJUSTMENT OF DIRECTIONAL
CONTROL PEDAL
Remove the clevis pin holding the shift rod to the control pedal cross shaft. Push the forward pedal down and mark the pedal arm. Depress the rear directional control pedal and mark the pedal arm.
Place the pedal arm in the center of the forward and reverse marks and adjust the clevis to allow the clevis pin to be installed. Hold in place with the hardware removed earlier.
Figure 16
936-12
If the clearance is not correct, make the necessary adjustment with the brake lever tension nut.
The brake arm compression spring in the front of the brake arm should be compressed to 0.75" with the parking brake set.
6
2
Figure 15
936-11
3
5
1
4.17 ADJUSTING THE BRAKE (HYDRO)
The brake was set at the factory for a specific running clearance. To check for proper setting, place a feeler gage between two of the disks (the brake will need to be released). There should be 0.015" to 0.025" clearance.
4
1. Disc Brake
2. Castellated Nut w/Cotter Pin
3. Compression Spring- .78" OD x 1 " long
4. Feeler Gage
5. Washer
6. Nylon Lock Nut
Figure 17
OT0840
4.18 ADJUSTING THE BRAKE (GEAR)
The brake was set at the factory for a specific running clearance.
Raise and support the rear of the unit with the wheels off the ground.
Tighten the brake adjustment nut and then back off the nut until the rear wheel drag is eliminated.
4 - 20
tension spring is 4.5" or shorter the belt is worn and will need to be replaced.
4
3
1
2
1. Disc
Brake
2. Adjustment Nut
3. Compression Spring .78" x 1" long
Figure 18
OT0830
With the parking brake set, the rear compression spring on the brake arm should be compressed to
0.75" long.
Adjust the rear lock nut on the brake control rod until
0.75" is obtained.
4.19 ADJUSTING THE SEAT
The seat is mounted on adjustable rails and may be adjusted by moving the lever at the front center of the seat.
Figure 20 936-15
4.21 MOWER BELT REPLACEMENT
Disconnect the main idler spring from the unit frame and remove the PTO drive belt from the PTO clutch and the top of the mower deck jackshaft assembly.
936-16 Figure 21
Figure 19
936-14
Move the lever to the center of the seat and slide seat to the desired position. Release the lever. The seat will latch into place.
4.20 MOWER DECK BELT ADJUSTMENT
The mower deck belt adjustment is controlled by a tension spring hooked to the mower deck belt idler.
If the tension spring is 4.5" or longer the belt is in good condition and will not need to be replaced. If the
Remove the mower deck belt tension idler spring from the anchor post.
Remove the left hand spindle sheave cover. Remove the mower deck belt from the spindles and the jackshaft.
Replace the new belt in the reverse order.
4.22 MOWER SPINDLE LUBRICATION/
JACKSHAFT LUBRICATION
The mower deck spindles and jackshaft assemblies use sealed prelubricated bearings.
No lubrication is needed through the life of machine.
Oil idler arm pivot point every 50 Hrs. Grease may be added to fill the cavity.
4 - 21
4.23 TRANSAXLE BELT REPLACEMENT
1. Disconnect the main idler spring from the unit frame and remove the PTO drive belt from the PTO clutch and the top of the mower deck jackshaft assembly.
1
2
3
2
1
Figure 22 936-17
2. Remove the wire harness from the PTO clutch.
3. Remove the cap screw, holding the step in the center of the PTO clutch and remove the strap from the clutch.
4. Loosen the hardware securing the belt finger to the main drive belt idler.
5. Depress clutch/brake pedal and remove the main drive belt from the idler, engine and transmission pulleys.
6. Install new main drive belt in reverse order and secure belt finger hardware with 1/16" to 1/8" clearance between belt fingers and belt.
4.24 STEERING
If looseness is noticed in the steering system, check hardware for tightness and wear points for excessive wear. Replace as needed.
Proper front wheel toe-in is necessary to assure proper steering and to reduce tire wear. Proper toe-in is when front of wheels are 1/16-1/8 in (.016-.032 mm) closer together than rear of wheels (measured at horizontal centerline of rim flange).
If unit wanders or excessive tire wear develops, toe-in should be checked. To correct toe-in, loosen jam nuts at tie rods ends, turn tie rod clockwise to decrease or counterclockwise to increase toe-in. Tighten jam nuts.
1. Tie Rod End
2. Jam Nut
3. Tie Rod
Figure 23
PT0092
4 - 22
SECTION 5 - ENGINE
5.1 ENGINE TROUBLESHOOTING
The following trouble shooting chart is to be used to isolate engine problems and give possible causes and corrective action responses.
The trouble shooting key is generic and can be used for several types of engines. Use only those possible causes and corrective actions that apply to the unit.
Black Exhaust
Blue/White Exhaust
Difficult Starting
Erratic Running
Excessive Fuel Consumption
Excessive Crankcase Pressure
High Oil Pressure
Knocking
Loss of Power or System
Low Cranking Power
Low Oil Pressure
Misfiring
Overheating
Poor Compression
Starts and Stops
Vibration
TROUBLE
Will Not Crank
Will Not Start
1
2
Restriction in air cleaner
Bad electrical connection
5
6
3
4
7
Faulty starter motor
Incorrect grade of lubricating oil
Low cranking speed
Fuel tank empty
8
9
Controls not in correct operation position
Blocked fuel feed line
Faulty fuel lift pump
10 Choked fuel filter
11 Battery capacity low
12 Air in fuel system
13 Faulty fuel injection pump
14 Faulty fuel injectors or incorrect type
15 Incorrect use of cold start equipment
16 Faulty cold start equipment
17 Broken fuel injection pump drive
18 Incorrect fuel pump timing
19 Incorrect valve timing
20 Poor compression
21 Blocked fuel tank vent
POSSIBLE CAUSES
(Refer to Key Below)
1, 20, 22, 25, 29, 31, 32, 33
4, 20, 25, 31, 33, 34
1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33
1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62
1, 20, 22, 23, 25, 29, 31, 32, 33
25, 31, 33, 34, 45, 55
4, 41
22, 26, 29, 31, 33, 36, 46, 59
1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33
2, 3, 4, 11
4, 36, 37, 39
10, 20, 25, 26, 28, 29, 32
1, 19, 25
25, 28, 29, 31, 32, 33, 34, 59
1, 6, 10, 62
CORRECTIVE ACTION
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 repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace see electrical systems see engine service manual repair or replace charge battery or replace repair or replace see electrical systems see engine service manual
34
35
36
29
30
31
32
33
37
38
39
40
41
42
22
23
24
25
26
27
28
TROUBLESHOOTING KEY
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
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
Over full air cleaner
Worn or damaged bearings
Insufficient oil in sump 58
Bad/defective oil temperature switch 59
Oil pump worn
Pressure relief valve sticking open
60
61
Pressure relief valve sticking closed 62
Broken relief valve spring
55
56
57
50
51
52
53
54
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
Blocked sump strainer
Broken valve spring
Exhaust or vacuum pipe leak
Bad or defective water temperature switch
Bad spark plug(s)
5 - 23
5.2 ENGINE REMOVAL
1. Open and remove the hood from the unit.
2. Remove the negative cable from the battery.
3. Remove the attachment from the unit.
4. Remove the PTO clutch from the bottom of the engine sheave. Remove the main drive belt from the engine sheave by setting the parking brake.
5. Remove the throttle and choke control from the engine.
6. Remove the electrical wiring from the engine
(charge lead, oil pressure lead, fuel solenoid lead, and magneto kill wire).
7. Remove the exhaust system from under the frame.
Separate the muffler from the exhaust pipe that is bolted to the engine.
8. Remove the engine bolts and lift the engine with a hoist to remove it from the frame.
5.3 ENGINE INSTALLATION
1. Check the engine base and unit frame for damage before installing the engine.
2. Place the throttle, choke control, and electrical wire out of the way prior to placing the engine onto the unit frame.
3. Once the engine is bolted onto the frame install the exhaust system and then tighten the mounting hardware.
4. Install the engine sheave and belts. Connect PTO clutch, electrical wiring, throttle and choke controls.
5. Prior to installing the attachment check for proper belt alignment and clutch function.
6. Install the negative battery cable onto the battery.
7. Reinstall the attachment onto the unit.
8. Install and close the unit hood and test operation and function of the engine.
Figure 24
9336-18
Figure 25
936-19
5 - 24
SECTION 6 - HYDRO DRIVE TRAIN
6.1 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
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
POSSIBLE CAUSES
(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, 55
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
1, 4, 7, 12, 18, 28, 26
1, 7, 8, 18, 28, 37, 38, 46, 48
CORRECTIVE ACTION repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace
1
2
3
Inspect control linkage
Inspect acceleration valves
Inspect charge check valves
TROUBLESHOOTING KEY
22 Inspect hoses and lines for wear
23 Inspect implement relief valve
24 Inspect charge pump
6
7
4
5
Incorrect grade of lubricating oil
Low cranking speed
25 Bad transmission pump
26 Overheating
Controls not in correct operation position 27 Cold running
Belts are missing, to tight, loose or glazed 28 Bad transmission motor
8
9
Overload of vehicle
Replacement parts damaged
10 Replacement parts improperly installed
11 Improperly torqued attaching screws
29
30
31
32
Check system pressure
Shift rod grooves worn
Reverse chain broken
Damaged cooling fan
12
13
14
15
Air in hydraulic system
Broken shifter stop
Inspect charge check valves
Inspect acceleration valves
16 Check oil level-gear box sump or reservoir
17 Inspect heat exchanger
33 Inspect auxiliary relief valve
34 Inspect cooling fan
35 Inspect transmission cooling fins
36 Worn or damaged bearings
37 Metallic pieces or foreign objects in unit
18
19
20
21
Inspect by-pass valve
Inspect charge pressure
Inspect inlet filter
Inspect charge relief valve
38 Inspect for loosely mounted components
39 Steering column loose or binding
40 Pressure relief valve sticking open
41 Pressure relief valve sticking closed
42 Broken relief valve spring
43 Burrs on gearing
44 Gears improperly installed
45 Forks & rod assembly incorrectly installed
46 Shifting keys broken or damaged
47 Shifting washer in backwards
48 Shifter/Brake shaft keyways damaged
49 Unit clutch not disengaging
50 Shifter stop assembled backwards
51 Improper fit of case to cover
52 Dowel pins not installed
53 Differential bevel gears broken
54 Spring in shifter weak or broken
55 Worn or stripped gear teeth
6 - 25
6.2 FLUIDS/GREASES
The fluids used in Hydro-gear transaxles have been carefully selected. If substitutions are made, use equivalent products.
Typically, an engine oil with a minimum rating of 55 sus at 210 o
F (99 o
C) and an API classification of SH/CD is recommended. A 20W-50 engine oil has been selected for use by the factory.
The grease used in the manufacture of Hydro-Gear products is a STEMS Premium grease and should be substituted with equivalent products only if it is not readily available in your area.
NOTE: This grease is not compatible with all grease types.
6.3 HYDRO 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. Raise the mower pan lift arm and remove the four nuts holding the plastic insert onto the left side of the rear deck and remove the plastic insert.
3. Raise the seat and remove the wire harness from the seat switch, and remove the four carriage bolts holding the rear deck to the unit frame and remove the fuel cap from the fuel tank.
4. Lower the seat and rotate the seat deck forward and over the mower deck lift arm and off the unit frame.
5. Replace the fuel cap on the fuel tank and remove the fuel tank from the unit by releasing the fuel line from the fuel pickup tube in the tank.
6. Raise and block the unit frame on jack stands forward of the transaxle in the frame.
7. Remove the unit tail board by removing the upper two carriage bolts and the lower self tapping screws.
8. Move the tail board to the rear and up to release the transaxle dump valve link and transaxle oil expansion hose.
Figure 26
936-8
9. Remove the rear wheels by removing the hub cap, snap ring, hub cap ring, rear wheel, axle key, two flat washers and spacers.
10.Set the parking brake and remove the main drive belt from the input sheave on top of the transaxle.
11.Release the parking brake.
12.Remove the lock nut on the end of the brake rod, along with the flat washers and spring.
13.Remove the cotter pin and washer on the shift rod and remove the shift rod from the transaxle cam arm. Do not remove or loosen the hardware on the transaxle sub-frame at this point.
14.Release the upper and lower tension springs on the left rear of the transaxle sub-frame.
15.Support the transaxle with a floor jack from the rear of the unit.
16.Remove the two right front anchor bolts holding the transaxle subframe to the unit frame and remove the left front bolts holding the transaxle subframe to the unit frame.
17.Remove the two rear bolts on both sides of the unit frame holding the transaxle subframe to the unit frame.
6 - 26
major disassembly of the unit. Replacement of these seals will require removal of the transaxle from the machine frame.
1. 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.
Figure 27
18.Move the transaxle assembly to the rear and out of the unit frame.
19.With the transaxle assembly removed from the unit frame, place the axle assembly on a flat work surface.
6.4 HYDRO TRANSMISSION REPAIR
(MINOR)
Minor repairs may be performed, following the procedures in this section.
Cleanliness is a primary means of assuring satisfactory life of either new or 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.
Figure 29 936-35
2. Lubricate the new seal prior to installation with a petroleum jelly.
3. Wrap the shaft spline with a thin plastic or cellophane tape to prevent damage to the new seal lip during installation.
4. 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.
Figure 28
936-35
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.
Shaft Seals
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
6 - 27
6.5 HYDRO TRANSMISSION REPAIR
(MAJOR)
1. Drain the oil by removing the breather assembly and positioning the transmission so the breather port is down to allow the oil to drain thoroughly.
CAUTION: The axle/differential assembly may stick as the lower housing is being lifted off of the upper housing.
Figure 30 936-37
2. Position and secure the transmission with the upper housing down to allow access to the twenty housing assembly cap screws.
3. Using the appropriate tool, remove the twenty assembly screws.
4. Loosen the nut and the brake arm mounting bolt.
Figure 32 936-22
7. Inspect the lower housing for damage. Inspect the axle journal bearing pockets for excessive wear.
Inspect the brake rotor/stator pocket for excessive wear.
NOTE: Prior to reassembly the housing mating surfaces must be thoroughly cleaned and old sealant must be removed.
8. Lift the axle/differential assembly out of the upper housing.
NOTE: It will be necessary to remove any burrs or rust from the axle ends prior to the removal of the two bronze bearings or damage to the bearings will occur.
9. Remove the two bronze journal bearings, four lip seals and flat washers from the axle ends.
NOTE: The lip seals must not be re-used during reassembly.
10.Inspect the bronze bearings for excessive wear.
The bearings should be 0.7535" to 0.7561" I.D.
11.Inspect the axle ends for damage or excessive wear. The axle ends should be 0.7486" to 0.7496".
936-38
Figure 31
5. Separate the two housing halves by applying pressure with two large straight blade screw drivers. Use caution to prevent damage to the mating sealing surfaces as you separate the two halves.
NOTE: The sealant will make two halves difficult to separate.
6. All components should remain in the upper housing half (positioned down) as the bottom is lifted off.
6 - 28
936-23
Figure 33
12.Inspect the differential bevel gears by rotating the axle ends.
13.Inspect the final drive gear teeth for excessive wear or damage.
14.Check the differential assembly screw for proper torque. The correct torque should be 12-14 ft. lbs.
(.75-.9 Nm).
15.Inspect the journal bearings inside the differential housing for excessive wear by feeling the shafts for an unreasonable amount of play.
16.If excessive wear or damage has been found, the complete assembly must be replaced.
17.Remove the brake rotors and stators by sliding one at a time off the ends of the splined motor shaft.
18.Inspect each side of both rotors for excessive wear or damage.
19.Inspect the rotors internal splines for excessive wear or damage.
20.Inspect the stators for excessive wear and damage.
21.Replace rotors and stators as a complete kit if excessive wear or damage is found, and inspect all other mating parts.
22.Remove the oil filter. After inspecting the filter for unusual particles that it may have trapped, dispose of it properly and replace it with a new oil filter during reassembly.
23.Using a 9/16" socket (or box end) wrench, remove the three assembly bolts retaining the center section in the upper housing.
CAUTION: The pump and motor piston springs may push the center section assembly out of position while you remove these bolts.
936-29
Figure 34
24.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. Inspect 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 170-240 in. lbs.
(10.5-14.7 Nm) while the one with three bolts should be torqued from 135-185 in. lbs.
(8-11.5 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.
Figure 35
936-30
25.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 slide freely.
6 - 29
NOTE: The correct bore diameter for the block is
0.6776" to 0.6784" and the pistons should be 0.6767" to 0.6770".
26.Remove the motor shaft, washers and bypass plate from the center section and inspect for unusual wear or damage.
27.Inspect the center section running surfaces for unusual wear or damage.
28.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".
29.Remove the two internal hex head cap screws retaining the jackshaft to the housing with a 5mm hex wrench and remove the jackshaft/pinion gear assembly from the housing.
30.Inspect the jackshaft running surface for excessive wear or damage. The jackshaft should be 0.4986" to 0.4996".
31.Inspect the pinion gear bore for excessive wear or damage. The bore should be 0.5014" to 0.5024".
32.Inspect the pinion gear teeth for excessive wear or damage.
33.If excessive wear or damage was found, the complete assembly should be replaced.
taken to avoid damage to the housing bore, shaft sealing surface or bearing. Once removed, the seal is not reusable.
38.Remove the input shaft bearing ring.
39.Remove the pump input shaft assembly from the housing.
40.Inspect the shaft and bearing for unusual wear or damage.
41.Reposition the top housing and remove the displacement control shaft and lip seal.
42.Inspect the housing for damage.
Replacement of Parts
All parts should be thoroughly cleaned in a suitable solvent. All sealant material MUST be removed from the housing halves prior to reassembly.
1. Inspect all parts for damage, nicks or unusual wear patterns. Replace all parts having unusual, excessive wear or discoloration.
2. Inspect the sealing surfaces, bearing surfaces, and shaft splines. Polish the sealing areas on the shafts if necessary. Replace any worn or
damaged parts.
NOTE: 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.
3. Clean and lightly oil parts prior to assembly of the transmission.
4. Be sure to torque all threaded parts to the recommended torque levels.
5. Replace all o-rings and shaft seals.
CAUTION: Most parts have critical high tolerance surfaces. Care must be exercised to prevent damage to these surfaces during assembly. Protect exposed surfaces, openings and parts from damage or foreign material.
936-31
Figure 36
34.Remove the motor thrust bearing assembly, swashplate kit and cradle bearing from the housing and inspect for unusual wear or damage.
35.Remove the slot guide from the displacement control shaft.
36.Remove the bypass actuator from the housing.
37.Reposition the housing and remove the input shaft tip seal from the housing bore. A hook type tool may be used to pry the seal out. Care must be
6 - 30
6. Install the displacement control shaft.
7. Install the pump input shaft assembly and retaining ring into the housing.
8. Install the pump shaft lip seal.
9. Reposition the upper housing and install the cradle bearings.
10.Install the slot guide block onto the displacement control shaft.
936-32
Figure 37
11.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.
12.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. Be certain to remove the rubber band.
13.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.
14.Install the pinion gear and washers onto the jackshaft. Install the jackshaft assembly into the housing and torque the bolts from 12-170 in. lbs.
(7.4-10.5 Nm).
15.Install the aligning pins and the bypass actuator into the housing.
16.Install the washers and lip seal onto the motor shaft.
17.Install the motor shaft into the center section.
18.Install the bypass plate (small end first) into the center section.
19.Lubricate the running faces and install the motor block kit onto the motor shaft.
20.Position the washers and seal and install the center section assembly onto the aligning pins and pump input shaft.
936-33
Figure 38
21.Insert the three 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 525-700 in. lbs. (32-43 Nm).
22.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 shown is an example of what you will need to compress the pistons and allow the bearing to be installed.
23.Fill the axle pockets of the upper housing with
Rykon Premium grease (inside of bearing locations).
NOTE: This grease is not compatible with all grease types.
24.Do not overfill, and wipe off any excess grease or sealant will not cure properly.
936-21
Figure 39
25.Install the washers and seals onto the differential axle assembly and align them for installation.
6 - 31
26.Install the differential axle assembly into the housing.
27.Install a new filter onto the center section check valve plate.
28.Install the rotors and stators. Install a stator, then a rotor (hub to inside), then a stator, then a rotor (hub to inside), then two stators.
29.Install the brake bolt (with nut) into the upper housing.
30.Apply the sealant to the lower housing.
NOTE: Sealant must be of good quality, oil and heat resistant.
Figure 40
936-24
Position the lower housing onto the upper housing and secure with assembly bolts. Torque the bolts from
135-165 in. lbs. (8-10 Nm).
NOTE: The bolts around the front of the housing are installed simultaneously at our factory. The order in which you torque them is not important.
31.After torquing all bolts, wipe off any excess sealant from the seam of the housing.
32.Reposition the transaxle assembly and check the bypass actuator and axle shafts for freedom of movement. The axle should not lock up but may be tight, while the bypass actuator must rotate freely.
33.Torque the nut on the brake bolt from 120-185 in. lbs. (7-11 Nm).
34.Install a new lip seal on the displacement control shaft and bypass actuator shaft.
35.Install the brake pins and brake arm.
36.Adjust the brake clearance as described in the brake adjustment section.
37.Install the control arm and friction pack.
38.Install the bypass actuator arm and retaining ring.
Use care to avoid over extending the retaining ring.
39.Prior to adding oil to the transmission 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
6 - 32 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. Do not submerge unit or the brake will be damaged.
Oil Fill & Start-Up Procedures
Fill the transmission with a 20W-50 engine oil. The correct volume for fill should be 2-1/2 quarts (2.4 L).
It is recommended that the unit be purged prior to installing into the unit frame. The following is the suggested purging procedures for repaired transaxle.
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 transmission.
7. Check the oil level after fully purging the unit of air.
It should be between 1.25-1.62" (3.1-4.1 cm) from the top of the housing.
8. After installing the transmission, make sure all linkages and actuators are functioning properly.
6.6 HYDRO TRANSMISSION
INSTALLATION
Before installing the transaxle assembly into the unit frame with the axle subassembly installed the following items will need to be completed.
1
2
4
3
5
6
1. Disc Brake
2. Castellated Nut w/Cotter Pin
3. Compression Spring- .78" OD x 1 " long
4. Feeler Gage
5. Washer
6. Nylon Lock Nut
Figure 41
OT0840
Make sure the brake rod has two flat washers and a heavy coil spring installed on it before inserting the transaxle into the unit frame.
1. Guide the shift rod into the shift arm and the brake rod into the brake arm as the transaxle is inserted into the frame from the rear of the unit.
2. Start the two rear 3/8" self tapping bolts into the rear of the transaxle sub frame to support the axle assembly while installing the rest of the hardware.
Do not tighten any hardware until all the support hardware is installed.
3. When all the hardware is in place, tighten to an appropriate torque.
4. Reinstall the tension spring to the shift linkage on the top and bottom of the right axle.
5. Install the two flat washers, compression spring, and lock nut on the rear of the brake rod which operates the brake arm.
6. Install the flat washer and cotter pin on the shift rod.
7. Set the parking brake and install the main drive belt on the transaxle input sheave and check the belt routing on the idler arm and engine pulley, release the parking brake.
6 - 33
8. Check the belt fingers and belt alignment.
9. Reinstall the rear tail board on the unit installing the dump valve rod and transaxle oil expansion hose.
Reuse the hardware removed earlier, two carriage bolts and two self tapping cap screws.
10.Reinstall the fuel tank and attach the fuel line, route the seat switch wires over the fuel tank.
11.With the mower deck lift arm in the up position reinstall the rear deck onto the unit frame and over the fuel tank.
12.Route the seat switch wires through the rear deck and attach to the seat switch.
13.Install the fuel cap onto the fuel tank, attach the rear deck to the unit frame.
14.Before installing the left rear wheel install the two flat washers and spacers, install the rear wheel with key in the key way.
15.Replace the hub cap retainer and snap ring and place the hub cap over hub cap retainer.
16.Leave the right wheel off the transaxle for neutral adjustment.
Transaxle Neutral Adjustment
Make sure that the rear of the unit is suspended before the unit is started, set the parking brake and start the engine.
Make sure that the interlock system is operational before proceeding.
1. Place a weight onto the seat to activate the seat switch, and release the parking brake.
2. Turn in the cap screw on the bottom of the transaxle subframe that will pivot the top of the shift arm to the rear.
3. The axle should drive to the rear.
4. Turn the cap screw out on the axle subframe which will allow the shift arm to pivot forward and the axle should rotate forward.
5. Center the cap screw between these two points and the transaxle should be in hydraulic neutral.
6. Reinstall the right rear wheel identical to the left rear wheel.
SECTION 7 - GEAR DRIVE TRAIN
7.1 GEAR 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
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
POSSIBLE CAUSES
(Refer to Key Below)
7, 8, 10, 13, 30, 31, 36, 38, 44, 45, 56, 53, 55
1, 5, 6, 38, 45
1, 7, 8, 10, 13, 26, 30, 36, 44, 45, 46, 47, 48, 53
6, 7, 8, 30, 31, 36, 38, 44, 46, 48, 53, 54, 55
1, 8, 13, 30, 36, 44, 45, 46, 54
4, 8, 13, 30, 36, 37, 44, 46, 53, 55
7, 8, 11
4, 8, 11, 36, 37, 38, 43, 55
26, 36, 51
4, 8, 32, 34, 36, 43
1, 6, 36, 43, 48, 55
N/A
1
1, 6, 7, 8, 11, 36, 37, 44, 46, 48, 53, 55
1, 8, 13, 30, 36, 44, 45, 47, 50, 51, 54
30, 44
CORRECTIVE ACTION repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace repair or replace
8
9
10
11
12
13
14
15
16
4
5
6
1
2
3
7
17
18
19
20
21
Inspect control linkage
Inspect acceleration valves
Inspect charge check valves
22
23
24
Incorrect grade of lubricating oil
Low cranking speed
Controls not in correct operation position
25
26
27
Belts are missing, to tight, loose or glazed
Overload of vehicle
Replacement parts damaged
28
29
30
31 Replacement parts improperly installed
Improperly torqued attaching screws 32
Air in hydraulic system 33
Broken shifter stop
Inspect charge check valves inspect acceleration valves
Check oil level-gear box sump or reservoir
Inspect heat exchanger
34
35
36
37
38
Inspect by-pass valve
Inspect charge pressure
Inspect inlet filter
Inspect charge relief valve
39
40
41
42
TROUBLESHOOTING KEY
Inspect hoses and lines for wear
Inspect implement relief valve
Inspect charge pump
Bad transmission pump
Overheating
Cold running
Bad transmission motor
Check system pressure
Shift rod grooves worn
Reverse chain broken
50
51
52
Damaged cooling fan
Inspect auxiliary relief valve
Inspect cooling fan
Inspect transmission cooling fins
Worn or damaged bearings
Metallic pieces or foreign objects in unit
53
54
55
Inspect for loosely mounted components
Steering column loose or binding
Pressure relief valve sticking open
Pressure relief valve sticking closed
Broken relief valve spring
43
44
45
46
47
48
49
Burns on gearing
Gears improperly installed
Forks & rod assembly incorrectly installed
Shifting keys broken or damaged
Shifting washer in backwards
Shifter/Brake shaft keyways damaged
Unit clutch not disengaging
Shifter stop assembled backwards
Improper fit of case to cover
Dowel pins not installed
Differential bevel gears broken
Spring in shifter weak or broken
Worn or stripped gear teeth
7 - 34
7.2 GEAR TRANSAXLE REMOVAL
(PEERLESS)
1. Place the unit on a flat surface and remove the negative lead from the battery and remove the spark plug lead from the spark plug.
2. Raise and support the rear of the unit. Remove the rear wheel with associate hardware.
3. Remove the rear tailboard from the unit. Engage the parking brake and remove the main drive belt from the input sheave on top of the transaxle.
4. Release the parking brake and remove the brake rod from the transaxle brake arm.
5. Remove the shift link ball joint from the shift arm.
6. Support the transaxle and remove the mounting hardware and lower the transaxle out of the frame.
7.3 TRANSAXLE TEARDOWN
This unit contains an aluminum tag showing the model number.
The following steps will need to be taken prior to disassembly.
1. Clean the outside surface of the transaxle.
2. Position the shift lever in the neutral position.
3. Remove the set screw, spring and index ball.
4. Remove the neutral start switch.
5. Remove the hex head screws that hold the cover to the case.
6. Push the shift lever rod while pulling cover off of the case. The shifting lever may temporarily remain in the case. Lift off cover.
7. Remove the two brake bracket screws and remove the brake assembly.
8. Remove the oil from the unit prior to removing the gear shaft assemblies.
9. Remove the top bearing block on the bull gear of the differential. Remove the bull gear, bevel pinion gears with center shaft and the axles.
There are 3 shaft assemblies in this transaxle: the output shaft, the countershaft, and the shifter/brake shaft assembly. Remove these assemblies as complete as possible from the case.
As these assemblies are taken apart, lay the parts out in a systematic order. This will help to make reassembly easier and inspection of all parts possible.
Clean each part as the parts are laid out.
The input shaft can also be removed and inspected or serviced. Remove the snap ring on the bevel gear and pull the shaft through the case. The square cut "O" ring must be replaced if the shaft is removed.
Tecumseh tool part No. 670251, is used for removal and installation of needle bearings for the input shaft.
The needle bearing on the inboard side is installed
.135-.150" below flush.
Reassembly
1. Apply grease between the bearings in the cover and install the input shaft, bevel gear and snap ring.
2. Oil both keyways and slide keys and collar on the shifter/brake shaft.
NOTE: Assemble the countershaft and the shifter/ brake shaft. Match them together and place into the housing as a single unit.
Figure 42
7 - 35
Figure 43
3. Push the shifting keys through the reverse sprocket and push the neutral collar over the end of the keys and pull the neutral collar and reverse gear up against the shoulder of the shifter/brake shaft.
4. Insert the countershaft into the smaller reverse gear. Insert a thin thrust washer next to the gear and then install the larger bevel towards the reverse gear. Place another thin thrust washer on the back side of the bevel gear.
NOTE: As all the gears are placed back into the assembly, each should be oiled prior to assembly.
5. Build the gears on the counter shaft and shifter/ brake shaft alternately, meshing each gear with it’s mating gear on the other shaft. The first gear on the shifter/brake would be the largest of the shifting gears. Place this gear next to the neutral collar with the flat side of the gear next to the collar.
6. Then place a shifting washer onto the shifter/brake shaft with the rounded edge towards the shifting keys. Continue this procedure until all the gears on both shafts have been added.
NOTE: It is not only important that the gears match up diameter-wise, but must match up according to thickness.
7. Add the spacer to countershaft on the other side of the reverse gear. Then place a thrust washer on each end of the counter shaft and insert the bronze bushings.
8. Place the large washer on the end of the shifter/ brake shaft, the bronze bushing and the "O" ring.
9. Place the spur gear onto the splines on the other end of the shifter/brake shaft. The thin washer and bushing conclude the assembly of these 2 shafts.
10.Place the output gear on the stepped end of the output pinion. The shaft in the output pinion is permanently pressed. Place the thrust washers on each end and then the bronze bushings.
7.4 TRANSAXLE INSTALLATION
1. With the transaxle support plates mounted on the axle, place the axle assembly into the unit frame.
2. Place the brake rod into the brake arm assembly prior to mounting the axle.
3. Install all the axle mounting hardware and tighten.
4. Set the parking brake and install the main drive belt onto the axle sheave.
5. Release the parking brake and check the belt finger locations and belt routing.
6. Install the link ball joint onto the shift arm.
7. Attach the neutral switch wiring plug onto the neutral switch, check for OK to start light.
8. Attach the rear tailboard onto the rear of the unit.
9. Check for proper operation and place the unit on the ground and test the unit.
7 - 36
SECTION 8 - STEERING
8.1 STEERING UNIT REMOVAL
1. Open and remove the hood from the unit. Remove the battery by first removing the negative battery cable and then the positive battery cable. Release the battery hold down strap and remove the battery.
2. Remove the indicator lights from the dash, remove the wiring plugs from all the switches and hour meter if installed.
3. Remove the steering wheel and steering column cone from the top of the dash assembly. Remove the knob from the throttle control, and remove the throttle control from the dash support. Remove the screws that hold the side panels to the dash support.
4. Remove the remaining screws around the base of the dash assembly from the unit frame and lift the dash assembly off the unit.
5. Remove the upper dash support and steering shaft bearing.
8.2 STEERING UNIT ASSEMBLY
1. Reassemble the steering pinion support and shim for correct back lash.
Figure 45
Figure 44
936-20
6. Remove the electrical components from the right side of the top dash support and remove the upper dash support from the unit.
7. Remove the steering rod arm from the left side of the unit. Remove the two snap rings from the ends of the shaft and rack assembly.
8. Remove the flange bushings from the side of the lower dash support and move the steering gear assembly to the left and rotate out of the right side of the dash support.
9. Disassemble the pinion gear support bracket and check for wear on the rack or pinion gear. Replace the parts as needed.
2. Insert the steering assembly through the lower dash support and add the flange bushings and snap rings to hold the unit in place.
3. Rotate the steering shaft up and install the upper dash support with the steering shaft bearing.
4. Reinstall the electrical components on the right side of the upper dash support. Install the dash assembly and secure to the unit frame with the screws removed earlier.
5. Secure the side panels to the dash assembly and reattach the wiring and indicating lights if used.
6. Reattach the steering wheel and the steering column cone to the top of the dash assembly.
8.3 TIE ROD ADJUSTMENT
1. With the pinion gear in the center of the rack assembly the steering rod arm should be on the end of the rack shaft in the vertically down position.
2. The front wheels should be toed in 1/8 of an inch in the front of the wheel compared to the rear of the front wheels. Adjust tie rod and ball joints to hold this dimension.
3. With the front wheels pointed straight forward attach the tie rod from the top of the left front wheel to the steering arm in the vertically down position. this will give you the maximum steering rotation right and left.
8 - 37
SECTION 9 - LIFT SYSTEM
9.1 LIFT SYSTEM OVER VIEW
The lift system on the unit uses a spring assisted system to take the weight of the attachment away from the operator.
9.2 LIFT SYSTEM REMOVAL
1. With the mower attachment removed from the unit the lift handle should be left in the up position.
2. Remove the cotter pins on the mower lift link.
3. Remove the left center lift bracket support. Support the lift assembly and remove the left bracket.
Remove the spring assembly from the unit.
4. Removal of the upper lift assembly handle on the rear deck of the unit will need to be removed.
5. Move the fuel tank forward to allow access to the mounting hardware.
6. Remove the plastic handle covering on the lift handle.
7. Release and remove the detent lever tension spring.
8. Remove the pivot pin from the lift linkage and remove detent lever from the linkage.
9. Remove the external ring from the ends of the lift lever pivot and remove the washers and bushings.
10.Remove the carriage bolts and nuts holding the pivot rod to the rear deck supports.
9.3 LIFT SYSTEM INSTALLATION
1. Insert the cross shaft and coil assembly into the support bracket still in the unit and mount the left with the hardware removed with it.
2. Insert the fuel line and wire harness into the J clamp and bend closed.
3. Insert the lift rod into the lift arm cross shaft and secure with washers and cotter pin.
4. Reassemble the upper lift assembly into the rear deck support and secure with the hardware removed earlier.
5. Install the bushings and washers onto the rod ends and secure with the external retaining rings.
6. Install the pivot pin into the lift linkage and attach the detent lever tension spring.
7. Reinstall the plastic handle covering over the metal lift handle subframe.
8. Attach the mower lift link and secure with the cotter pin.
9. Check function and operation prior to installing the mower attachment.
3
1. Lift Handle
2. Lift Link
3. Tension Spring
4. Spring Assembly
Figure 46
4
1
2
PT0111
9 - 38
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 and corrective action responses. The troubleshooting
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 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)
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, 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
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
3
4
1
2
5
6
Plugged air filter
Leaky carburetor gasket
Throttle or choke shaft worn
Choke not functioning properly
Plug atmospheric vent
Air bleed restricted
TROUBLESHOOTING KEY
7
8
Damaged or leaky "O" rings
Damaged diaphragm
9 Stuck or dirty ball check
10 Diaphragm upside down
11 Plugged tank or vent
12 Fuel pick-up restricted
13
14
15
16
Idler port restricted
Damage adjustment needle and seat
Incorrect float height
Main nozzle restricted
17 Dirty, stuck needle and seat
18 Fuel inlet plugged
10 - 39
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.
Figure 47
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 with out breaking down from the additive used in today’s blended fuels.
10 - 40
SECTION 11 - ELECTRICAL
11.1 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 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 on wires.
Soldering gun or soldering iron - used to solder all splices and connections to terminals, connectors, etc.
A soldering gun is faster and more convenient than 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.
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, and it shrinks tightly around the joint to insulate it.
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 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 at the joints where wires are attached. Vibration causes wires to flex at these points and eventually to break).
Replace all defective components with Ariens Factory replacement parts only. Engine parts, such as rectifiers or alternator components should be secured through the nearest engine service center.
Ariens 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.
11.2 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 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 - 41
Voltage Measurement
A voltmeter measures the voltage difference between the test leads and the voltmeter is always connected across the circuit under test.
Current Measurement
The 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.
Resistance Measurement
An ohmmeter is used to make resistance measurements and to check continuity through wires and electrical components.
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
Set-Up:
The 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 80 o
F (27 o
C), 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.
11 - 42
Maintenance:
Do an occasional visual inspection. See to it that the battery remains clean, both the case and the terminals.
This visual inspection should be done once a month.
Check the level of the electrolyte. It may be necessary to add distilled water. This should be checked before each usage.
Another important check is the specific gravity. The specific gravity should be checked with the hydrometer.
The reading on the gauge should be above 1.225. If the reading is allowed to fall below 1.225 specific gravity you will have an insufficient charge. If this happens charge the battery until specific gravity of
1.265 is reached over 3 successive readings. This check should be done monthly.
The state of charge can be determined approximately by the cell specific gravity or the rested open circuit voltage at room temperature and the charging time can be estimated. For example:
OCV
12.60
12.40
12.20
12.00
11.80
Specific
Gravity
1.265
1.225
1.180
1.130
1.100
% of
Charge
100%
75%
50%
25%
0%
Charging
Time
---
3 hours
7 hours
10 hours
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 o
F (27 o
C).
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.
WARNING: When charging battery, remove it from the unit and make certain that you connect the positive (+) lead of the charger to the positive (+) terminal and the negative (-) lead to the negative (-) terminal. Reverse connections can cause sparks and potential unsafe conditions.
Storage:
During the off season it is important to have the battery in the same good condition or it will not deliver power when needed.
1. Make sure the battery is fully charged and the electrolyte is to the proper level.
2. Make sure the battery is clean (both the case and terminals.)
3. After cleaning the terminals, spread petroleum jelly on the terminals to prevent loss of charge and prevent corrosion.
4. Leave the cables disconnected.
5. It would be best to leave the battery in a cool, dry area during the off season. This will slow down the loss of charge during non-use periods.
6. Check your battery monthly during the off season and if the battery has a low specific gravity apply a charge to it. 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 and plates will sulfate permanently if not recharged. 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.
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 10
(27 o
C) or add .004 to 1.265 for each 10 o
F (12 o
C) above 80 o
F (27 o
C) .
o
F (12 o
C) below 80 o
F
11.4 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 electrically, remove them from their respective circuit by disconnecting the wires from the switch at the connector(s) before testing or damage could result to the meter or machine components.
When an ohmmeter or multimeter set on the ohms scale, check the switch for three things: continuity between contacts of a normally open switch that closes when the switch is activated; that contacts of a normally closed switch open when the switch is activated; and that there are no shorts between contacts or between contact and ground (switch case) that should not be there.
Variation from test results described indicates a defective switch.
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 (high 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 high resistance indicating no short to ground.
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
11 - 43
the meter should move to open circuit (high resistance). Check from each terminal to ground
(switch case). Meter should show open circuit (high resistance).
Ignition Switch
NOTE: Refer to the wiring diagram of the unit involved to determine switch functions and test using the methods described.
Key Switch
(03602300)
B
A
S2
S1
M G
OFF
B
A
S2
S1
M G
RUN
Figure 48
B
A
S2
S1
M G
START
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.
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
(03042800)
87
86 87A 85
87
86 87A 85
30 30
NOT ENERGIZED
Figure 49
ENERGIZED
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 inches. A solenoid can therefore, pull a lever, close a heavy contact, or perform other jobs that require a straight line pull.
If a relay or solenoid fails to operate, the cause may be either electrical or mechanical.
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.
11 - 44
Figure 50
The starter solenoid in the Ariens equipment is a sealed unit used to actuate the starter motor on the engines. This solenoid may have three or four connections.The two large connections carry high current to operate the starter motor. The small connections are connected to the coil and carry the control current.
To check the solenoid, disconnect the cables to the starter motor, turn the ignition switch to the start position, and listen for the solenoid to snap inside contacts closed.
If no snap is heard, check across the coils with a voltmeter. The voltage should read 12 volts with the ignition switch in the start position. If no voltage appears, the defect is in the start circuit.
If the voltage is correct, turn off the power and check continuity of the coil with an ohmmeter. If the coil is open, the solenoid is defective and must be replaced.
If the coil has the proper voltage applied, and the continuity check indicates the coil is intact, the solenoid plunger is stuck or the contacts are welded shut and the solenoid must be replaced.
If the solenoid snaps shut, but the 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.
11.6 LIGHTING CIRCUITS
Lighting circuits are simple circuits and easiest to trouble shoot in most equipment. They consist of the lights connected in parallel, a normally open switch, a protective fuse and a source of power (battery or engine alternator).
If only one light is out, check the connector, then check the bulb for continuity (high resistance indicates a defective or burned out bulb).
If all the lights are out, check the fuse for continuity
(high resistance indicates a defective or blown fuse). 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.
Replace defective devices only with factory replacements parts.
Figure 51
11 - 45
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. 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 a rectifier.
To check a diode, isolate if from the circuit by disconnecting one end. With a multitester set on the lowest ohms scale setting, measure the resistance in one direction, reverse the test leads, and measure in the other direction. Readings should be high in one direction and low in the other. (If the readings are low in both directions, the diode is shorted, and if the readings are high, the diode is open.) If the readings are the same in both directions, the diode is defective and must be replaced.
IMPORTANT: Diodes are marked to indicate polarity (a band on one end, an arrow on the side, or they fit on a holder only one way.
Rectifiers
A battery is charged through the use of an alternator located in or on the engine. A charging circuit contains a rectifier because alternators produce alternating current (AC) and batteries require direct current (DC) for charging.
The rectifier may be built into the engine or it may be an external part. It may also contain a regulator to prevent overcharging the battery. (Servicing of rectifiers built into the engine should be done by an approved engine manufacturer’s service center. Such 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 on the dash panel. The clutch is also designed so that a brake is applied to the output shaft when the clutch is disengaged (off).
Figure 52
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 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 manufacturers 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 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. (D) the parking brake pedal pushed. (E) cruise control in the off position. If no power to start the engine, start the following check list:
Step 1: Check out the battery. Use 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.
11 - 46
Step 2: Use a voltmeter to make sure you have power to terminal (B) on the back side of the ignition switch in the off position. If you don’t have power to terminal (B) check the battery connections and the fuse in the red lead.
Step 3: With the ignition switch in the "run" position, check to see if power has been transferred from terminal (B) to terminal (A). Terminal (A) on the ignition switch supplies power to the back of the PTO switch on the purple lead and on to the brake switch on the brown/yellow lead out of the brake switch on the red/ violet lead to the start light and to terminal (S2) on the ignition switch and to terminal 86 on solenoid #2.
Terminal (A) also supplies power to terminal 30 and terminal 86 on solenoid #1 and to the hour meter, and the voltage sensor and sensor light. When the operator is in the seat, power will transfer from terminal 30 to terminal 67 and on to the front PTO switch, and on to terminal 86 on the solenoid #2 in the yellow/red lead and on to the cruise control switch. Power is supplied to the fuel shut off solenoid from terminal 86 on solenoid #2.
Step 4: With the ignition switch in the start position, power is transferred from terminal (S2) to (S1).
Terminal solenoid and goes to ground through the base of the starter solenoid.
Clutch check out: Remove the clutch lead to the wiring harness and check the clutch with a VOM for field resistance to see if the coil is good (3.0 - 3.9). If bad, the resistance will be high or not at all.
Ignition switch check out: Voltage check out in the
"off" position, check for voltage at terminal B. Voltage should not be present on terminals A, S1, S2.
With the ignition switch in the "run" position, check for voltage at terminals B, A, S2. It should not be present on terminal S1.
With the ignition switch in the "start" position, check for voltage at terminals B, A, S2, S1.
PTO switch check out: The PTO switch is a push/pull switch with straight across 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 contact.
Diode check out: Diodes are checked with an Ohm meter set on diode check, and should pass voltage in only one direction. If a diode passes voltage in both directions or not at all the diode is defective and will need to be replaced.
11 - 47
11.11 SWITCH CONTINUITY
Key Switch
(03602300)
B
A
S2
S1
M G
OFF
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.
Seat Switch
(03654200)
B
A
S2
S1
M G
RUN
B
A
S2
S1
M G
START
1 2
OPERATOR
OFF SEAT
1 2
OPERATOR
ON SEAT
Light Switch
(03656800)
OFF ON
Clutch / Brake Switch
(03657100)
1 2
ENGAGED
(button in)
1 2
DISENGAGED
(button out)
PTO Switch
(53603800)
1 2
3 4
DISENGAGED
Cruise Control Switch
(03656900)
1 2
3 4
ENGAGED
1 4
5
6
OFF
1 4
5
6
CRUISE ON
1 4
5
6
SET
Relay
(03042800)
87
86 87A 85
30
NOT ENERGIZED
87
86 87A 85
30
ENERGIZED
Transmission Neutral Switch
(08803700)
1 2 1 2
DISENGAGED
(button out)
ENAGED
(button in)
Safety Switch
(03657100)
1 2
ENGAGED
(button out)
1 2
DISENGAGED
(button in)
11 - 48
Key Switch Off
11:50-13:00 B
A
S-1
S-2
Contact Resistance Is 0.1-0.3 Ohms When Correct.
Run
11.50-13.00 Vdc
11.50-13.00 Vdc
11.50-13.00 Vdc
Start
11.50-13.00 Vdc
11.50-13.00 Vdc
11.50-13.00 Vdc
11.50-13.00 Vdc
Seat Switch Off Run
11.50-13.00 Vdc
Connected To Ground
Start
11.50-13.00 Vdc Pink
Black
Normally Open Contacts Manually Activated. Contact Resistance Is 0.1-0.3 Ohms When Correct.
Yellow/red (2)
Purple/white (2)
Purple
Brown/yellow
PTO Switch Off Run
11.50-13.00 Vdc
Start
11.50-13.00 Vdc
Connected To PTO Clutch And Light
11.50-13.00 Vdc 11.50-13.00 Vdc
11.50-13.00 Vdc 11.50-13.00 Vdc
2 Sets Of Contacts, One Normally Open, One Normally Closed. Contact Resistance Is 0.1-0.3 Ohms When
Correct
Brown/yellow
Red/violet (3)
Brake Switch Off Run
11.50-13.00 Vdc
11.50-13.00 Vdc
Start
11.50-13.00 Vdc
11.50-13.00 Vdc
Normally Open Contacts Manually Activated. Contact Resistance Is 0.1-0.3 Ohms When Correct.
Relay #1
Pink
85
Purple
Yellow/red
87a
Purple (3)
86
87
30
Off Run
11.50-13.00 Vdc
11.50-13.00 Vdc
11.50-13.00 Vdc
Not Used
Start
11.50-13.00 Vdc
11.50-13.00 Vdc
11.50-13.00 Vdc
Not Used
11.50-13.00 Vdc 11.50-13.00 Vdc
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 When Correct.
11 - 49
Relay #2
Black
Yellow/red
87
White/black
Black
85
86
87a
30
Off Run
11.50-13.00 Vdc
Connected To Ground
Not Used
Connected To Ignition Module
Connected To Ground
Start
11.50-13.00 Vdc
Not Used
Pins 85-86 Coil Resistance 87-100 Ohms. Pins 30-87 Normally Open Pins 30-87a Normally Closed Contact
Resistance Is O.1-0.3 Ohms When Correct.
Orange
Orange
Light Switch - Off Position Off Run
11.50-13.00 Vdc
Start
11.50-13.00 Vdc
Normally Open Contacts Manually Activated. Contact Resistance Is 0.1-0.3 Ohms When Correct.
Headlight Off Run
11.50-13.00 Volt W/switch On
Start
Orange
Black
Solenoid
Small Brown
Small Black
Large Red (Battery)
Large Red (Starter)
Off Run
Connector To Ground
11.50-13.00 Vdc 11.50-13.00 Vdc
Start
11.50-13.00 Vdc
11.50-13.00 Vdc
11.50-13.00 Vdc
Normally Open Contacts (Big Terminals) Coil Resistance 3.0-5.0 Ohms. Contact Resistance Is 0.1-0.3 Ohms
When Correct. Electrically Activated.
Purple/white (2)
Black
PTO Clutch Off Run
Connected To Ground
Coil Resistance 6.0-8.0 Ohms Reference Page 10.
Start
11 - 50
Cruise Switch Off Run
11.50-13.00
Connector To Ground
Start
11.50-13.00
Yellow/red
Black
Green/white
Yellow
Normally Open Contacts, Manually Activated. Contact Resistance Is 0.1-0.3 Ohms When Correct.
Cruise Relay
Yellow
Black
Yellow
Yellow
85
86
87
87a
30
Off Run Start
Pins 85-85 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.
Cruise Magnet Off Run
Yellow
Black Connected To Ground
Cruise Control Resistance Is 23.3-26.8 Ohms When Correct.
Start
Cruise Safety Switch
Green/white
Blue
Off Run Start
Normally Open Contacts, Manually Activated. Contact Resistance Is 0.1-0.3 Ohms When Correct.
11 - 51
11.12 WIRING DIAGRAMS
Models 936305, 308
1
13
RED
14
BLACK
ORANGE
ORANGE
YELLOW / RED
RED
ENGINE
WHITE / BLACK
4
+ RED
5
STARTER
15
11
2
HOUR
METER
BLACK
PURPLE
7.5A
3
PURPLE
87a
30
87
86
85
SEAT RELAY
YELLOW / RED
17
PINK
SEAT SWITCH 16
BLACK
7.5A
RED
3
B
A
M
G
BLACK
BROWN
S1
PURPLE
BLACK
87a
30
87
86
85
START
RELAY
17
BLACK
YELLOW / RED
18
YELLOW / RED
START
DIODE
RED / VIOLET
S2
KEY
SWITCH 7
10
BRAKE
SWITCH
BLACK
8
RED / VIOLET
NEUTRAL
SWITCH
9
PTO
SWITCH
6
PTO CLUTCH
12
BLACK
11 - 52
Model 936018
1
BLACK
13
PURPLE
VOLT
MODULE
BLACK
PURPLE
WHITE / RED
LOW BATTERY
LIGHT
10
PURPLE
OIL PRESSURE
LIGHT
9
19
14
PURPLE
WHITE / BLACK
+
4
RED
ENGINE
STARTER
BLACK
5
15
RED
RED
11
HOUR
METER
BLACK
2
7.5A
3
87a
30
87
86
85
PINK
20
BLUE / WHITE
YELLOW / RED
SEAT SWITCH
16
AGE SENSOR
30A
RED
3
B
A
M
BLACK
87a
30
87
86
85
PURPLE
20
BLACK G
BLACK
BROWN S1
YELLOW / RED
YELLOW / RED
2
1
RED / VIOLET
S2
KEY
SWITCH
7
10
BRAKE SWITCH
BLACK
START LIGHT 9
PTO LIGHT
PTO
SWITCH
PURPLE / WHITE
6
9
PURPLE / WHITE
BLACK
OFF
17
ON
8
21
12
BLACK
MOM
85
86
87
30
87a
YELLOW
CRUISE SWITCH
BLUE
BLACK
8
BLACK BROWN / YELLOW
CRUISE
MAGNET
20
18
BLACK
11 - 53
Model 936019
1
15 PURPLE
BLACK
PURPLE
WHITE / RED
LOW BATTERY
LIGHT
10
VOLT
MODULE
21
HOUR
METER
BLACK
BLACK
PURPLE
16
RED
YELLOW / RED
RED
WHITE / BLACK
+
4
RED
ENGINE
STARTER
BLACK
5
17
13
2
7.5A
3
87a
30
87
86
85
PURPLE
YELLOW / RED
7
PINK
SEAT SWITCH
18
AGE SENSOR
30A
RED
3
B
A
M
G
BLACK
87a
30
87
86
85
7
BLACK
YELLOW / RED
11
YELLOW / RED
BLACK
BROWN S1
RED / VIOLET
S2
KEY
SWITCH
8
12
BRAKE SWITCH
BLACK
START LIGHT
PTO
SWITCH
PTO LIGHT
PURPLE / WHITE
6
10
14
10
PURPLE / WHITE
BLACK
OFF
CRUISE
SWITCH
11
19
ON
9
BLACK
85
86
87
30
87a
MOM
YELLOW
SAFETY SWITCH
BLUE
BLACK
9
CRUISE
MAGNET
BLACK BROWN / YELLOW
7
BLACK
20
11 - 54
Model 936020
1
BLACK
PURPLE
HOUR
METER
15
PURPLE
VOLT
MODULE
BLACK
PURPLE
WHITE / RED
LOW BATTERY
LIGHT
10
PURPLE
OIL PRESSURE
LIGHT
10
BLACK
BLUE / WHITE
21
2
7.5A
3
YELLOW / RED
RED
30A
RED
3
WHITE / BLACK
+
4
RED
ENGINE
STARTER
BLACK
5
17
B
G
BLACK
BROWN S1
S2
A
M
RED
KEY
SWITCH
8
BLACK
87a
30
87
86
85
PURPLE
PINK
7 YELLOW / RED
SEAT SWITCH
18
AGE SENSOR
87a
30
87
86
85
7
BLACK
YELLOW / RED
11
YELLOW / RED
RED / VIOLET
12
BRAKE SWITCH
BLACK
START LIGHT 10
PTO
SWITCH
PTO LIGHT
PURPLE / WHITE
6
10
14
PURPLE / WHITE
BLACK
OFF
CRUISE
SWITCH
11
19
ON
9
BLACK
MOM
85
86
87
30
87a
YELLOW
SAFETY SWITCH
BLUE
7
16
13
9
BLACK
CRUISE
MAGNET
BLACK BROWN / YELLOW
BLACK
20
11 - 55
Models 936021, 307, 309
1
BLACK
PURPLE
HOUR
METER
13
VOLT
MODULE
PURPLE
BLACK
PURPLE
WHITE / RED
LOW BATTERY
LIGHT
9
PURPLE
OIL PRESSURE LIGHT
19
9
BLACK
BLUE / WHITE
2
7.5A
3 20
YELLOW / RED
87a
30 87
86
85
PURPLE
PINK
SEAT SWITCH
16
AGE SENSOR
YELLOW / RED
RED
30A
RED
3
WHITE / BLACK
+
4
RED
ENGINE
STARTER
BLACK
5
17
B
G
BLACK
BROWN S1
RED
A
M
S2
KEY
SWITCH
7
BLACK
87a 30
87
86
85
20
BLACK
YELLOW / RED
21
YELLOW / RED
RED / VIOLET
10
BRAKE SWITCH
BLACK
START LIGHT 9
PTO
SWITCH
PTO LIGHT
PURPLE / WHITE
6
9
PURPLE / WHITE
BLACK
OFF
CRUISE
SWITCH
21
19
ON
8
12
BLACK
MOM
85
86
87
30
87a
YELLOW
SAFETY SWITCH
BLUE
20
18
14
11
8
BLACK
CRUISE
MAGNET
BLACK BROWN / YELLOW
BLACK
11 - 56
Model 936022
1
15
RED
16
BLACK
ORANGE
ORANGE
RED
ENGINE
WHITE / BLACK
4
+ RED
5
STARTER
17
13
2
HOUR
METER
BLACK
PURPLE
7.5A
3
PURPLE
87a
30
87
86
85
SEAT RELAY
YELLOW / RED
7
PINK
SEAT SWITCH 18
BLACK
7.5A
RED
3
B
A
M
G
BLACK
BROWN
S1
PURPLE
BLACK
87a
30
87
86
85
7
YELLOW / RED
BLACK
START
RELAY
YELLOW / RED
START
DIODE
11
RED / VIOLET
S2
KEY
SWITCH 8
12
BRAKE
SWITCH
BLACK
9
NEUTRAL
SWITCH
RED / VIOLET
10
PTO
SWITCH
6
PTO CLUTCH
14
BLACK
11 - 57
Models 936023, 310
1
13 PURPLE
BLACK
PURPLE
WHITE / RED
LOW BATTERY
LIGHT
9
VOLT
MODULE
19
HOUR
METER
BLACK
BLACK
ORANGE
22
ORANGE
YELLOW / RED
RED
WHITE / BLACK
+
4
RED
ENGINE
STARTER
BLACK
5
15
14
RED
11
2
7.5A
3
87a
30
87
86
85
YELLOW / RED
20
PINK
SEAT SWITCH
16
AGE SENSOR
PURPLE
10 A
RED
3
B
A
M
G
BLACK
BROWN S1
BLACK
87a
30
87
86
85
20
BLACK
YELLOW / RED
21
YELLOW / RED
RED / VIOLET
S2
KEY
SWITCH
7
10
BRAKE SWITCH
BLACK
START LIGHT
PTO
SWITCH
PTO LIGHT
PURPLE / WHITE
6
9
9
PURPLE / WHITE
BLACK
OFF
CRUISE
SWITCH
21
17
ON
8
12
BLACK
85
86
87
30
87a
MOM
YELLOW
SAFETY SWITCH
BLUE
8
BLACK
CRUISE
MAGNET
20
BLACK
BLACK BROWN / YELLOW
18
11 - 58
Models 936024, 026
1
BLACK
13
PURPLE
VOLT
MODULE
BLACK
PURPLE
WHITE / RED
LOW BATTERY
LIGHT
10
PURPLE
OIL PRESSURE
LIGHT
9
19
HOUR
METER
BLACK
PURPLE
WHITE / BLACK
+
4
RED
-
ENGINE
STARTER
BLACK
5
15
14
RED
RED
11
2
7.5A
3
87a
30
87
86
85
PINK
20
BLUE / WHITE
YELLOW / RED
SEAT SWITCH
16
AGE SENSOR
30A
RED
3
B
A
M
BLACK
87a
30
87
86
85
PURPLE
20
BLACK
G
YELLOW / RED
2
1
BLACK
BROWN S1
YELLOW / RED
RED / VIOLET
S2
KEY
SWITCH
7
10
BRAKE SWITCH
BLACK
START LIGHT 9
PTO
SWITCH
PTO LIGHT
PURPLE / WHITE
6
9
PURPLE / WHITE
BLACK
OFF
17
ON
8
21
12
BLACK
MOM
85
86
87
30
87a
YELLOW
CRUISE SWITCH
BLUE
BLACK
8
BLACK BROWN / YELLOW
CRUISE
MAGNET
20
18
BLACK
11 - 59
Models 936025, 027, 311, 313
1
BLACK
PURPLE
HOUR
METER
13
VOLT
MODULE
PURPLE
BLACK
PURPLE
WHITE / RED
LOW BATTERY
LIGHT
9
PURPLE
OIL PRESSURE LIGHT
19
9
BLACK
BLUE / WHITE
2
7.5A
3
20
YELLOW / RED
87a
30
87
86
85
PURPLE
PINK
SEAT SWITCH
16
AGE SENSOR
YELLOW / RED
RED
30A
RED
3
B
A
M
WHITE / BLACK
+
4
RED
ENGINE
STARTER
BLACK
5
17
G
BLACK
BROWN S1
RED
S2
KEY
SWITCH
7
BLACK
87a
30
87
86
85
20
BLACK
YELLOW / RED
21
YELLOW / RED
RED / VIOLET
10
BRAKE SWITCH
BLACK
START LIGHT 9
PTO
SWITCH
PTO LIGHT
PURPLE / WHITE
6
9
PURPLE / WHITE
BLACK
OFF
CRUISE
SWITCH
21
19
ON
8
12
BLACK
MOM
85
86
87
30
87a
YELLOW
SAFETY SWITCH
BLUE
20
18
14
11
8
BLACK
CRUISE
MAGNET
BLACK BROWN / YELLOW
BLACK
11 - 60
Model 936312
1
13
RED
14
BLACK
ORANGE
ENGINE
19
ORANGE
YELLOW / RED
RED
WHITE / BLACK
4
+ RED
5
STARTER
15
11
2
HOUR
METER
BLACK
PURPLE
7.5A
3
PURPLE
87a
30
87
86 85
SEAT RELAY
YELLOW / RED
17
PINK
SEAT SWITCH 16
BLACK
10 A
RED
3
B
A
M
G
BLACK
BROWN
S1
PURPLE
BLACK
87a
30
87
86
85
START
RELAY
17
BLACK
YELLOW / RED
18
YELLOW / RED
START
DIODE
RED / VIOLET
S2
KEY
SWITCH 7
10
BRAKE
SWITCH
BLACK
8
NEUTRAL
SWITCH
RED / VIOLET
9
PTO
SWITCH
6
PTO CLUTCH
12
BLACK
11 - 61
SECTION 12 - MOWER
12.1 40" AND 48" MOWER REMOVAL
1. Remove the key from the ignition switch and the negative cable from the battery prior to removing the mower assembly.
2. Release the mower PTO belt tension by releasing the idler spring on the left side of the unit behind the front wheel. Lower the mower assembly and remove the hair pins and washers from the lift links.
3. Remove the two hair pins from the rear support control arms on the mower support linkage.
4. Slide the mower pan assembly forward to release the front hanger rod from the retainer hooks under the front axle.
5. Remove the mower deck drive belt from the PTO clutch and the top of the jackshaft assembly.
6. Raise the front of the unit to provide clearance for the mower assembly and remove the mower from under the unit.
12.2 40" AND 48" MOWER INSTALLATION
1. Raise the front of the unit and position the mower deck under the unit and hook the mower front support rod in the support hooks under the front axle.
2. Lower the front of the unit, insert the rear support control arms into the rear support brackets, and secure with hair pins removed earlier.
3. Lower the mower lift mechanism and attach the mower lift links and secure with washers and hair pins removed earlier.
4. Attach the mower drive belt to the top of the mower jackshaft assembly and route the belt inside of the belt finger on the PTO idler, and on to the PTO clutch.
5. Using a spring puller reattach the PTO idle tension spring to the unit frame behind the left front tire, check location and routing of the PTO belt before engaging the PTO clutch with engine running.
6. Reattach the battery negative cable to the battery and insert the ignition key into the ignition switch.
12.3 40" MOWER SPINDLE REMOVAL
1. With the mower deck removed from the unit the disassembly of the mower may be done.
2. Remove the left side mower spindle cover.
3. Remove the mower deck blades hardware, mower deck blades, blade trays retainer hub, spindle key and bearing slinger.
4. Remove the mower deck spindle drive belt from the spindle sheaves.
5. Remove the mower deck right side support arms to provide clearance to remove the right spindle.
6. Remove the spindle sheaves and shaft assemblies
7. Remove the mower spindle housings from the mower deck stamping.
48" Mower Spindle Removal
With the mower deck removed from the unit, the disassembly of the mower may be done.
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.
12.4 40" SPINDLE REPAIR
When the spindle housing has been removed from the mower deck the bearings may be removed from the housing.
1. Prior to removal of the bearings check for bearing damage and remove if necessary.
2. Attach a bearing puller to the bearing in the housing and remove the spindle bearings.
3. If the housing has been damaged replace the bearings and housings.
4. Press new bearings into the spindle housing with a press, make sure to insert the spacer tube into the housing before pressing the second bearing into place.
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 - 62
12.5 SPINDLE INSTALLATION
1. Place the spindle housings into the mower deck stamping and attach with new hardware.
2. Insert spindle shaft and sheave assemblies into the spindle housings with spacer washer under sheaves.
3. Reattach the right side mower support arms to the mower deck stamping.
4. Reattach the mower deck spindle drive belt.
5. Reinstall the bearing slinger, spindle key, retainer hub, blade trays, and mower deck blades with hardware removed earlier.
6. Check mower deck blades for clearance inside of the mower deck stamping and mounting flatness.
12.6 40" JACKSHAFT REMOVAL AND
REPAIR
1. Remove the mower deck idler tension spring from the spring anchor.
2. Remove the mower deck drive belt from the jackshaft assembly.
3. Remove the hardware holding the jackshaft assembly to the mower deck stamping, remove the assembly.
4. Remove the nylock nut on the top of the spindle assembly and remove the double pulley assembly.
5. Check the bearings, and spindle shaft for wear and replace the damage parts.
6. Bearings need to be removed with a bearing puller and replaced with a bearing driver in a press.
NOTE: The bearings should have a light press fit to the bore of the pulley assembly, to tight of a press fit will preload the bearing and cause premature bearing failure.
7. Check idler arm pivot bushings for wear and movement, check the idler for run out and interferences.
8. Reassemble the double pulley assembly with the bearing spacer tube inside the assembly.
9. Place the double pulley assembly onto the spindle shaft and hold in place with a flat washer and nylock lock nut.
12.7 40" JACKSHAFT INSTALLATION
1. Place the jackshaft assembly on the mower deck stamping and attach with new hardware and torque according to the torque table.
2. Reinstall the mower spindle drive belt onto the jackshaft assembly and attach the mower deck idler tension spring to the spring anchor.
3. Rotate the mower jackshaft assembly and check routing of the belt and idler clearance to the mower deck stamping.
12 - 63
SECTION 13 - SNO-THRO ATTACHMENT
13.1 INSTALLATION
1. With the housing and push frame assembly positioned on a flat level surface, roll unit into position over push frame with the front of the unit over the pivot support.
2. Lift pivot support into position on the front of the unit frame and install upper mounting latch pin into the unit frame.
3. Raise the rear of the push frame and secure to the unit with the latch pin on each side of the frame.
4. With the PTO in the off position and connect the
PTO drive belt from the PTO clutch to the top drive spindle on the push frame.
5. Manual lift the front of the auger/impeller housing and block it 3 to 4 inches from the floor. Insert gas cylinder onto the anchor arm and
6. Connect the lift link on the housing to the lift bell crank, install a washer and secure with a hair pin.
7. Connect the lift arm to the lift bell crank and secure with a clevis pin.
8. Secure the chute crank support to the right side of the unit frame with capscrews and lock nuts.
9. Attach the lift arm to the lift lever with clevis pin and hair pin.
10.Remove the blocking from under the snow head, attachment may now be raised or lowered with the attachment lift lever on the blower push frame.
11.Secure the discharge chute crank to the spool with a hair pin.
13.2 SHEAR BOLT REPLACEMENT
WARNING: Stop engine, lower attachment, remove key, and wait for moving parts to stop before leaving operators position and attempting to maintain or inspect auger.
Occasionally an object may enter auger/impeller housing and jam auger, breaking shear bolts which secure auger to shaft. This allows auger to turn freely on shaft preventing damage to gear drive.
IMPORTANT: Use only Ariens Shear Bolts for replacement. Use of any other type of shear bolt may result in sever damage to unit.
To replace shear bolt, slide auger outward against rollpin and align hole in shaft with hole in auger (holes in shaft for roll pins and shear bolts line up). Drive shear bolt through hole; (if shear bolt was broken this will drive remaining part from shaft and secure with nut).
13.3 MULE DRIVE BELT
1. Remove belt guard hardware and guard from housing. Release tension on flat idler and remove belt from "V" and flat idler on push frame.
2. Remove lower mounting rod and stabilizer strap from pivot support (to free mule drive belt from double idler).
3. Remove belt from drive spindle pulley and housing double pulley. Replace mule drive belt in reverse order; be sure belt seats properly in housing pulley, idlers, over lower mounting pin, around bottom groove in drive spindle pulley, and around two idlers on idler bracket- (flat idler rides against back of "V" groove and "V" groove idler against front).
Mule Drive Belt Adjustment
Mule drive belt idler spring is to extend 4 inches inside hook to inside hook. To increase tension, position pivot pin (on idler assembly at bottom rear of housing) to next lower hole in mounting bracket.
13.4 POWER TAKE OFF (PTO) BELT
Release tension on the push frame idlers and remove mule drive belt from drive spindle pulley.
Remove PTO belt fro PTO and drive spindle pulley.
Replace PTO belt in reverse order and adjust accordingly.
13.5 AUGER/IMPELLER DRIVE BELT
Remove belt guard hardware and guard from housing.
Release tension on flat idler and remove mule drive belt from "V" and flat idler on push frame, and double pulley on auger/impeller housing.
Pull spring loaded idler away from drive belt, remove belt from large lower pulley and top double pulley.
13.6 OIL AND GREASE LOCATIONS
CAUTION: DO NOT touch Sno-Thro drive parts which are hot from operation. Allow such parts to cool before servicing unit.
IMPORTANT: Wipe each fitting clean before and after lubrication.
NOTE: Use Ariens Multi-Purpose Grease (Part Number 000150) or good grade of general purpose grease at zerk fittings and oil at lubrication points.
Sno-Thro should be lubricated at beginning of season and every 25 operating hours. Refer to illustration for grease and oiling points.
13 - 64
13.7 SCRAPER BLADE
IMPORTANT: If scraper blade wears too far auger/ impeller housing may be damaged.
Scraper blade is adjustable to compensate for wear.
To adjust scraper blade, raise and block Sno-Thro securely. With runners adjusted to their full position, loosen lock nuts retaining scraper blade, reposition it down, (Flush with runners) and tighten lock nuts.
13.8 RUNNERS
CAUTION: Adjust auger/impeller housing height to provide clearance over gravel or crushed rock surfaces to avoid throwing these objects.
Runners should be adjusted as conditions require.
Raising or lowering runners controls distance scraper blade is held above surface to be cleared.
When operating unit on gravel surface, lower runners so that the housing will not pick up gravel. On concrete, black-topped, or packed snow surfaces raise runners so that the scraper blade scrapes clean. To reduce tendency of housing to ride up over heavy, wet, or hardpacked snow, remove runners and install in their narrow edge down position.
To adjust runners, place unit on a flat level surface and insert a spacer under center of scraper blade that will provide desired clearance. loosen runner hardware, raise or lower runners to surface unit is resting upon, and tighten hardware.
NOTE: Uneven rear tire pressure or runner adjustment will result in uneven clearing.
13.9 DISCHARGE CHUTE CABLE
To adjust discharge chute cable, loosen clamp, rotate discharge chute in desired direction (to stop), and reposition cable. Tighten clamp and replace guard.
13.10 AUGER/IMPELLER, GEAR CASE
REMOVAL
1. Remove taptite, washer, cap screw, washer, and lock washer securing belt guard to housing and remove belt guard.
2. Remove belt from pulley.
3. Remove set screws securing pulley to worm shaft and remove pulley and woodruff key.
4. Remove three nuts securing flange bearing to housing and remove bearing.
5. Remove cap screw, lock washer, washer, and flange bushing from ends of auger shaft. Remove rib neck bolts and flange whiz lock nuts securing bearing supports to housing and remove supports.
6. Pull auger/impeller and gear case from housing.
7. Remove two way lock nuts and shear bolts securing augers to auger shaft and remove augers.
8. Drive roll pins securing impeller to worm shaft and remove impeller.
13.11 GEAR CASE
1. Remove four bolts from bearing flange.
2. Remove flange and gasket.
NOTE: At this point bronze gear cannot be removed.
3. Using bearing adjustment wrench remove adjustment plug.
4. While holding input shaft in one hand and using a mallet, strike case until bearing cone pops out of the case.
5. Bronze gear can then be removed from case.
6. After bronze gear is removed, input shaft can be removed.
NOTE: It is not necessary to remove the end cap from case.
7. To remove worm gear and bearings, simply remove bolt and washer from end of shaft.
8. Check all parts for wear or damage and replace as necessary.
9. Assembly is done by inserting bronze and worm gear at same time.
10.Using adjustment wrench, tighten down on adjustment plug until input shaft is snug.
11.Replace side cover using a sealant on threads of two bottom bolts.
Gear Case Lubrication
Fill gear case with Ariens Special L-2 Gear Lubricant
(Part No. 000080) until lever reaches bottom of threads in filler hole.
Check auger gear case lubricant level every 25 hours of operation.
To check, place unit in a warm location over night to allow lubricant to flow to level. Remove filler plug.
Lubricant must be at least up to bottom of filler hole with unit resting on a level surface (extra lubricant will not damage gear case).
13 - 65
Ariens Company
655 West Ryan Street
P.O. Box 157
Brillion, WI 54110-0157
920-756-2141
Fax 920-756-2407 www.ariens.com

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