Ariens 915502 manual

915 ZOOM EZT & IZT 00459900 7/05 Printed in USA Service Manual Models 915 055, 057, 059, 06 5, 067, 501, 502[...]

1 Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-2 1.1 The Ma nual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2 Service And Replacem ent Part s . . . . . . . . . . . . . 1-2 1.3 Product Registratio n . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.4 Unauthori zed Replace ment Parts . . . . . . . . . . . . 1-[...]

1 - 2 1.1 THE MANUAL The pu rpose of thi s manual is to provide complete instru ctions for service, m aintenanc e, disasse mbly , repair , and in stallation of the mech anical c omponents for the 915 ZT . Dealer trained service p ersonnel s hould us e this manual a s a suppl ement to and reminde r of the train ing session s conduc ted by the c ompa[...]

2 - 3 2.1 SAFETY ALERT S Look f or these sy mbols to poi nt out important sa fety pre cautions. T hey mean: Attentio n! Personal Saf ety Is I nvolved! Become Alert! Obey The Message! The s afety alert symbol is used in dec als and with this manual. Understand th e safety mes sage. It con tains impor tant information abo ut personal s afety on or ne[...]

2 - 4 • Unders tand locatio n and func tion of all controls . • Never allow operat ion by un trained per sons. • Diseng age PTO, stop unit an d engine, se t parking brak e and re mov e k ey be fore m aking any inspecti ons, repairs , etc. 6. Hot Surfac es! DO NOT touch parts which are hot from operation. AL W A YS allo w p ar ts t o cool . 7.[...]

2 - 5 DO NOT t ry to stabil ize the m achine by p utting yo ur foot on th e ground. Know the weight of loa ds. Limit l oads to those yo u can safely control an d the unit can safel y handle . AL WA YS k eep protect ive structures , guards an d panels in good repair , in pla ce and se curely fastened . Do not ope rate with out either en tire grass c[...]

2 - 6 of char ger to posi tive ( +) terminal, and negati ve (-) lead to negati ve (-) te rminal. AL WA YS d isconnect negative (-) cable FIRS T and positi ve (+) cable S ECOND. AL WA YS connect pos itive (+) cable FIRST , and neg ativ e (-) cabl e SECOND. A frozen battery can explode and result in deat h or serious injury . DO NO T charge or jump s[...]

3 - 7 SECTION 3 - SPECI F ICATI ONS Model Number 915065 91550 2 915067 915055 915501 915 057 915059 Model 1540 1540 1 740 1944 1844 21 48 2352 Engine Ty p e Single Cylinder Ko hler Tw i n Cylind er Kawasa ki Singl e Cylinde r Kohle r Tw i n Cylinde r Kohle r Tw i n Cylinde r Kawasa ki T wi n Cylinder Kohler Engi ne Po wer – HP (kW) at Govern ed R[...]

4 - 8 4.1 CONTROLS AND FEATURES Figure 2 SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENT S 1. Ig niti on Sw itch 2. PTO Switc h 3. Throt tle Lev er 4. Seat 5. Steeri ng Lev ers 6. Parking Brak e 7. Fuel T ank 8. Headl ights (915067, 0 55, 057, 0 59, 501) 9. Axle Lo ck (91506 7, 055, 05 7, 059, 501 ) 10.Mo wer L ift Peda l 11 . M o w e r D e c k 12[...]

4 - 9 4.2 MOVING UNIT MANUALLY Diseng age (2) tra nsmission by pass leve rs to drive unit and en gage (1) tran smission by pass levers to push unit manuall y (Figure 3). Figure 3 4.3 FILLING FUEL T ANKS NO smoking, NO s park s, NO flames . Refer to Engine M anual for proper fuel . T o add fuel to the f uel tank: 1. AL WA Y S place uni t in open o r[...]

4 - 10 4.5 AXLE LOCKS (915067, 055, 057, 059, 501) (Figure 5) NOTE: The unit comes shi pped with th e front axle in the loc kout position. If a p ivoting front a xle is need ed: Remov e axle lo ck hardware from locko ut position and install axle lock hardwar e in pivot ing posi tion on both sides of fr ont axle. NOTE: T o lock front axle , install [...]

4 - 11 4.7 LEVELING AND ADJUST ING PITCH OF MOWER DECK Adjust on a level surface, with th e tires inf lated to the correc t air pres sure. Level Mower Deck 1. Install a djustm ent pin in the f ourth adjus tment ho le (Fig ure 7). Figure 7 2. Rotate the right and le ft mower blades until the ends of both mower blades ar e facing rea rward (Fig ure 8[...]

4 - 12 See F igure 9 for anti-scalp l ocations on models 915067, 0 55, 057, 05 9, 501. See Figure 10 for anti- scalp locatio ns on mode l 9150 65 and 502. There ar e two positi ons: • Highes t Position : Use to disa ble anti-s calp featu re. • Lowest P osition: Us e for all cutti ng posit ions. In the lo west posi tion the an ti-scalp rollers w[...]

4 - 13 T o adj ust the neutr al settin g for no wh eel rotation Model IZ T 915055, 057, 059, 06 7, 501: 1. Use a hex wrench to loos en the locki ng bolt (Fig ure 12). 2. With th e engine r unning an d the drive wheels off the gro und rotate the linkage in either di rection. The c orrect link age posit ion is when t he wheel i s not bein g driven ( [...]

4 - 14 • Move lev ers to neutral positio n. • Loosen mou nting hardwa re. • Position steerin g levers. • T i ghten moun ting hard ware. 3. Adjus t height of steeri ng levers. T here is a low and a high p osition for steering lev ers. • Remove mounti ng hardwar e and place steeri ng leve rs in the lo w or high pos ition. • T i ghten moun[...]

5 - 15 5.1 ENGINE T ROUBLESHOOTING The fol lowing trou bleshoot ing char t is to be used to isola te engine p roblems an d give po ssible causes and correc tive act ion responses . The troubles hooting ke y is generic and can be used for sever al types of e ngines. Us e only thos e possibl e causes and correctiv e actions th at apply t o the unit. [...]

5 - 16 5.2 CHECKING ENGINE OIL Check the engine oil dail y prior to use. IMPORT ANT : Never op erate the engine with th e oil below th e low mark on the dipstic k. See the Engine Ma nual for oil specif ications and oil filter service instruc tions. T o chec k oil le vel: 1. Move th e unit to l evel loc ation. 2. Clean a round t he dipstick an d fil[...]

5 - 17 7. Remove fuel line fr om engine first. Drain fu el from line ba ck into fuel tank. 8. Remove the electri c clutch an d the anti-r otation bol t. 9. Remove the engi ne bolts. 10.Lift engi ne out of the unit and off the fra me with a hoi st (eng ine) . 1 1. S ervice, o verhaul, or rep lace engi ne as requ ired. 12.If repl acing engine with a [...]

5 - 18 Figure 1 6 1 2 3 3 4 5 PE0760 2. 3. 1. Rear of Unit 5. 915055, 057 , 059 915065, 06 7 5. 915501, 5 02 915501, 5 02 915501, 5 02 3. 4. 1. Oil Drai n T ube 2. Oil Drai n V alve 3. I dler Pulley s 4. El ect ric Cl utc h 5. Muf fl er[...]

6 - 19 6.1 REPLACING PTO BELT Remove (Figure 17 ) 1. Lo wer mowe r deck to the g roun d. 2. R emove be lt covers from mo wer dec k. 3. Hook a p uller into idler ho le and pull i dler arm towards outside of unit until tensio n is remov ed from P TO be lt. Figure 1 7 4. R emove PT O bel t fr om lef t mo w er de ck pul ley . 5. Slowly release i dler a[...]

6 - 20 Do not c hange angl e of cuttin g edge or r ound the corner at the end of mower blade . 2. Sharp en mower blad e by removin g an equal amount o f materia l from each end of the m ower blade. 3. Check mower bla de balance b y sliding mower blade o n an unthr eaded bol t. If blade i s balanced, it should remain i n a horizo ntal position . If [...]

7 - 21 7.1 HYDRO T RANSM ISSION T ROUBLESHOOTING The fol lowing trou bleshoot ing char t is to be used to isola te hydro transmiss ion prob lems an d give po ssible cause s and corr ective action res ponses. The troubles hooting ke y is generic and can be used for sever al types of transm issions. Use on ly those possib le causes and cor rective ac[...]

7 - 22 Figure 2 0 Figure 2 1 7.2 HYDRO-GEAR FLUID RECOMMENDATIONS The flui ds used in Hydro-Gear transaxles have been careful ly selected, and only equivale nt or bett er products s hould be used. T ypi cally , an engi ne oil with a minimum rati ng of 55 sus at 210 o F and an A PI class ification of SH/CD is recomm ended. A 20W-50 eng ine oil ha s [...]

7 - 23 7.4 REPLACING HYDROST ATIC BELT Remove (Figure 22 ) Figure 2 2 1. Remove PT O belt (s ee Replacin g PT O Belt ). 2. Disconnec t electric cl utch connec tor . 3. Remove c lutch stop. 4. Disconnec t idler spring . 5. Remove hyd rost at ic bel t from hydr ost atic transm ission pulleys, p ulley , elec tric clu tch, and idler . Inst all ( Figure[...]

8 - 24 8.1 LIF T SYSTEM Refer to Figure 25 for the lift system. The mo wer pan lift system i s a manua l lift system contro ll ed by the opera tor . Mower Lif t Pedal Raises and lowers mower deck , Figure 23 Figure 2 3 NOTE: The adju stment pi n is used to set the he ight of the mower deck. See Specifi cations for cutting hei ght dimens ions. Figur[...]

9 - 25 9.1 STEERING CONTROLS Serial numbers 10,000 and above: Refer to Figure 26 thr u Figure 27 for S t eering. The s teering con trols shou ld remain i n the neutr al positi on unless m oved by the operator . When i n the neutral position th e brake rod will lo ck the transm issions to pr event move ment. When th e handleba rs are mov ed the li n[...]

9 - 26 Figure 27 Serial numbers below 10,000: Refer to Figure 28 and Figure 30 for S teering. The s teering con trols will swing ou tward when in neutral . In the out ward positi on, each hand lebar wil l contact a s witch. The switches m ust be engaged to start the e ngine. When th e handleba rs are moved inward a nd forward the lin k will shift t[...]

9 - 27 Figure 28 1. T ransax le Link 2. Rod Pivo t 3. S teeri ng Switch 4. Dampen er 5. Handleb ar 6. Roll Pin 1 2 4 5 6 3 3 1 2 Model EZ T 915065 and 502 with S erial Numbers Be low 10,000 PE01 70[...]

9 - 28 Figure 29 PE0172 1. Rod T ransaxle 2. Switch 3. Jam Nu ts 4. Nyloc Jam Nut 5. Handleb ar 6. Dampen er 7. Roll Pin Model IZT 915055, 0 57, 059, 067 , 501 with Se rial Number s Below 10,000 1 2 3 7 5 1 3 4 2 6[...]

9 - 29 9.2 ADJUSTING S TEERING LEVER HEIGHT FOR SERIAL NUMBERS ABOVE 10,000 ONLY (Figure 30) Figure 3 0 NOTE: Perform steps 1 and 2 for both ste ering leve rs. 1. Remove mou nti ng hardwar e and move handle bar up or d own until t he steering levers are at the approp riate heigh t. 2. Install mo unting hardwa re. NOTE: Align ha ndlebars by adjusti [...]

10 - 30 10.1 FUEL SYSTEM T ROUBLESHOOTING The fol lowing trou bleshoot ing char t is to be used to isola te fuel system pr oblems and give poss ible cau ses are c orrec tive a ction respon ses The troubles hooting ke y is generic and can be used for sever al types of transm issions. Use on ly those possib le causes and cor rective action s that app[...]

10 - 31 10.2 FUEL PUMP The im pulse sty le fuel pump i s the most commonly used fu el pump. Im pulse fuel p umps may either be mounted externally onto the c arburetor fue l inlet or remote ly mounte d. These pum ps are connected in the fuel li ne between t he fuel su pply and the carbureto r or directly to the fue l inlet. Impuls e fuel pum ps are [...]

11 - 32 1 1.1 T OOLS There ar e some s pecialize d tools an d test equ ipment that are n eeded for electrical repair work. A brief descr iption of thes e follows . Long or need le nose pliers - used to connect or bend wires a nd connector s in close q uarters. Diagonal cutters - used to cut wires or trim conne c- tions. Wire stripper/c rimping tool[...]

11 - 33 V olt age Measurement There ar e two bas ic rules to be remembe red when using a voltmete r . A v oltmeter mea sures the v oltage difference between the test leads a nd the vol tmeter is always connected a cross the c ircuit unde r test. Current Measurement The two rules t o remember when meas uring cu rrent with an a mmeter are; an ammeter[...]

11 - 34 IMPORT ANT : AL WA YS follow in formation provid ed on battery an d battery c harger . Contact battery and batt ery cha rger manufa ctur ers for det ailed instr ucti ons. 1. Remove battery fro m unit (see Battery Rem oval and I nstallation ). 2. Place battery in a well-vent ilated area. 3. Conne ct posit ive (+) lea d of char ger to posi ti[...]

11 - 35 1 1.5 SOLENOID AND RELAYS Soleno id and re lays are both magnetic ally opera ted devices . Both devic es operate on the princ iple that passing a curr ent of electrici ty through a co il of wire will create a magnetic fie ld stron g enough to at tract a piec e of iron or steel. E ach dev ice uses this principl e in a sligh tly different man[...]

11 - 36 current to a direct cu rrent is cal led a RECTIFIER. A diode i s one typ e of rect ifier . T o che ck a diode, isolate if fr om the c ircuit by disco nnecting one end. With a multite ster set on the lowes t ohms scale se tting , meas ure th e res ist ance in one dir ection, re verse the te st leads , and meas ure in the ot her directio n. R[...]

11 - 37 For mode ls with ser ial numb ers above 10,000 when the igni tion switch is in th e run positi on and wit h the steeri ng switc h in the neutr al (engage d), posi tion power is suppli ed to ter minal 86 o f the start relay and to termin al 30 of the PTO relay . Engagi ng the seat sw itch starts the hour me ter and energ izes the start relay[...]

11 - 38 2 sets of c ontacts, one normal ly open, one normall y closed. Contact resi stance is 0.1-0. 3 ohms whe n correct. Normal ly open con tacts manually activ ated. Contact Resis tance is 0.1-0.3 oh ms when c orrect. Pins 85-86 coi l resistance 87-100 ohms. pins 30-8 7 norma lly open . Pins 30- 87A nor mally ope n. Contact resistance is 0.1-0. [...]

11 - 39 Normal ly open con tacts (big termin als) coil r esistance 3.0 -5.0 ohms. Co ntact resistance is 0.1-0.3 o hms when correc t. Electrica lly activ ated. Coil Re sist ance che ck clut ch spec ificat ions. St arter Solenoid Relay Off Run St art Brown/Y ellow 86 1 1.50-13 .00 V olt s Small Blac k 85 Conn ected to Grou nd Large Red (Battery) 30 [...]

11 - 40 1 1.1 1 ELECTRICAL SYSTEM Figure 33 To E n g i n e T o Engine 1. Relay 2. Clutch Switch 3. Hour Meter 4. Key Switch 5. Switch NO 6. Switch, D ouble Pole NO/NO 1 2 3 4 5 6 Model 915 055, 057, 05 9, 065, 067, 501, 502 f or Serial Numb ers above 1 0,000[...]

11 - 41 1 1.12 WIRING DIAGRAMS Model 9 15055, 057, 059, 065, 0 67, 501, 502 for Seri al Numbers Abov e 10,000[...]

11 - 42 1 1.13 CON TIN UITY DIAGRAM PTO Switch 87 Key Switch Relay Seat Switch Parking Brake Switch Neutral Switch Solenoid Not Energized Energized Button Out Button In Operator Off Seat Button Out Button In Operator On Seat Disengaged (down position) Disengaged (down position) Not Energized Energized Off Run / Light Run Start The diagrams below sh[...]

11 - 43 1 1.14 ELECTRICAL FOR SERIAL NUMBERS ABOVE 5,0 00 AND BELOW 9,999 Safety Int erlock System W ARNING: Sa fety Interlo ck failure an d improp er operati on of unit can res ult in de ath or seri ous injur y . Check system b efore each u se to mak e sure it i s functio ning pro perly . Perform the following tests to ensure th e safety interl oc[...]

11 - 44 Diode c heck out: Dio des are ch ecked wi th an ohm meter s et on the d iode check , and shou ld only pass voltage in one dire ction. If i t passes vol tage in both direct ions or not at all the diode is bad a nd needs to be replaced . . Contact res istance is 0. 1-0.3 ohm s when co rrect. Normal ly open con tacts manu ally activ ated. cont[...]

11 - 45 Pins 8 5-86 co il resistance 8 7-100 ohm s. pins 30-87 norma lly open . Pins 30- 87A normall y closed. Contact resi stance is 0. 1-0.3 ohm s when co rrect. Normal ly open con tacts (big termin als) coil r esistance 3.0 -5.0 ohms. Co ntact resistance is 0.1-0.3 o hms when correc t. Electrica lly activ ated. Coil Re sist ance che ck clut ch s[...]

11 - 46 1 1.15 ELECTRICAL SYSTEM Figure 34 1. Relay 2. Clutch Switch 3. Key Switch 4. Switch NO 5. Neutral Sw itch 6. Interlock Switch 2 3 5 4 1 6 Model 91 5055, 057, 059, 065, 067, 501, 5 02 for Seria l Numbers Between 5,0 00 and 9,9 99[...]

11 - 47 1 1.16 WIRING DIAGRAMS Model 9150 55, 057, 0 59, 065, 06 7, 501, 50 2 for Ser ial Numbers Between 5,000 and 9,999[...]

11 - 48 1 1.17 CON TIN UITY DIAGRAM PTO Switch 87 Key Switch Relay Seat Switch Parking Brake Switch Neutral Switch Solenoid Not Energized Energized Button Out Button In Operator Off Seat Button Out Button In Operator On Seat Disengaged (down position) Disengaged (down position) Not Energized Energized Off Run / Light Run Start The diagrams below sh[...]

11 - 49 1 1.18 ELECTRICAL FOR SERIAL NUMBERS BE LOW 5,000 Safety Int erlock System W ARNING: Sa fety Interlo ck failure an d improp er operati on of unit can res ult in de ath or seri ous injur y . Check system b efore each u se to mak e sure it i s functio ning pro perly . Perform the following tests to ensure th e safety interl ock sys tem is wor[...]

11 - 50 . Contact res istance is 0. 1-0.3 ohm s when co rrect. Normal ly open con tacts manu ally activ ated. contact res istance is 0.1-0 .3 ohms when c orrect. 2 sets of c ontacts, one normal ly open, one normall y closed. Contact resi stance is 0.1-0. 3 ohms whe n correct. Normal ly open con tacts manually activ ated. Contact R esistance is 0.1-[...]

11 - 51 Pins 8 5-86 co il resistance 8 7-100 ohm s. pins 30-87 norma lly open . Pins 30- 87A normall y closed. Contact resi stance is 0. 1-0.3 ohm s when co rrect. Normal ly open con tacts (big termin als) coil r esistance 3.0 -5.0 ohms. Co ntact resistance is 0.1-0.3 o hms when correc t. Electrica lly activ ated. Coil Re sist ance che ck clut ch s[...]

11 - 52 1 1.19 ELECTRICAL SYSTEM Figure 35 Model 915055, 0 57, 059, 06 5, 067, 50 1, 502 f or Se rial Number s Below 5,000 1. Relay 2. Clutch Switch 3. Key Switch 4. Switch NO 5. Switch Doub le Pole N.O ./N.O. 2 3 5 4 1 5[...]

11 - 53 1 1.20 WIRING DIAGRAMS Model 91505 5, 057 , 059 , 065, 067, 501, 502 for Serial Number s Below 5,000[...]

11 - 54 1 1.21 CON TIN UITY DIAGRAM PTO Switch 87 Key Switch Relay Seat Switch Parking Brake Switch Neutral Switch Solenoid Not Energized Energized Button Out Button In Operator Off Seat Button Out Button In Operator On Seat Disengaged (down position) Disengaged (down position) Not Energized Energized Off Run / Light Run Start The diagrams below sh[...]

12 - 55 12.1 MOWE R S PINDLE REMOVAL Figure 3 6 The s pindles ar e assembli es that are r eplaced whe n worn. T o r emove th e spindle as semblies : 1. With th e mower deck removed from the unit th e disasse mbly of the m ower may be performed. 2. Remov e the mow e r spi nd le co ver s . 3. Remove the mowe r deck bla des . 4. Reduce belt tension on[...]

12 - 56 TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION Engine w ill not c rank/ sta rt 1. Safety interlock system is not engaged or is fa ulty . 2. Fuel tanks empty . 3. Fuel sh ut- off valve cl os ed. 4. Disch arged batter y . 5. Poor co nnec tion betwe en battery a nd battery c ables. 6. S park plug wire (s) loose or spark plug (s) f aul ty . [...]

12 - 57 Unit mo ves wi th engine of f and parkin g brake engage d 1. The parkin g brake needs adjust ment . 2. Fault y parking br ake. 1. Contact your A riens Deal er . 2. Contact your A riens Deal er . Hou r mete r co ntin ues to run wh en engine is not runnin g 1. Ignitio n key is in th e run posi tion with eng ine turne d off. 1. T urn ign ition[...]

12 - 58 SERVICE P ARTS BE SURE TO AL W A YS USE GENUINE ARIENS P ARTS TO KEEP YOUR UNIT RUNNING LIKE NEW P ART NO. QTY DESCRIPTION 03498400 1 40-inch Mo w er Blade (915065, 067 ) 00272800 1 44-inch Mo w er Blade (915502) 01593900 1 44-inch Mo w er Blade (915055) 00272900 1 44-inch Mo w er Blade (915501) 04919100 1 48-inch Mo w er Blade (915057) 049[...]

Ari ens Compan y 655 W est Ry an S treet P. O . B o x 1 5 7 Brillion, WI 541 10- 0157 920-756-2 141 Fax 920-7 56-240 7 www .a riens.com[...]