Ariens 915502, 915057, 915067, 915059, 915501 User Manual

...

915 ZOOM EZT & IZT

Service Manual

Models 915055, 057, 059, 06 5, 067, 501, 502

00459900 7/05

Printed in USA

TABLE OF CONTENTS

Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-2

1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Service And Replacement Parts . . . . . . . . . . . . . 1-2

1.3 Product Registration. . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Unauthorized Replacement Parts . . . . . . . . . . . . 1-2

1.5 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Technical Service Communications . . . . . . . . . . . 1-2

Section 2 - Safety. . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.1 Safety Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Equipment Safety. . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Section 3 - Specifications . . . . . . . . . . . . . . . . . 3-7

Section 4 - General Maintenance

& Adjustments . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.1 Controls and Features . . . . . . . . . . . . . . . . . . . . . 4-8

4.2 Moving Unit Manually. . . . . . . . . . . . . . . . . . . . . . 4-9

4.3 Filling Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.4 General Lubrication . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.5 Axle Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.6 Removing Mower Deck . . . . . . . . . . . . . . . . . . . 4-10

4.7 Leveling and Adjusting Pitch of Mower Deck. . . 4-11

4.8 Adjusting Anti-Scalp Roller. . . . . . . . . . . . . . . . . 4-11

4.9 Hydrostatic Transmission Neutral Adjustment . . 4-12

4.10 Adjusting the Unit to Track Straight . . . . . . . . . 4-13

4.11 Adjusting the Parking Brake. . . . . . . . . . . . . . . 4-14

Section 5 - Engine . . . . . . . . . . . . . . . . . . . . . . 5-15

5.1 Engine Troubleshooting. . . . . . . . . . . . . . . . . . . 5-15

5.2 Checking Engine Oil. . . . . . . . . . . . . . . . . . . . . . 5-16

5.3 Changing Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.4 Checking Engine Cooling. . . . . . . . . . . . . . . . . . 5-16

5.5 Cleaning the Air Cleaner . . . . . . . . . . . . . . . . . . 5-16

5.6 Changing the Air Cleaner Element. . . . . . . . . . . 5-16

5.7 Inspect Muffler/spark Arrester . . . . . . . . . . . . . . 5-16

5.8 Replace Spark Plugs . . . . . . . . . . . . . . . . . . . . . 5-16

5.9 Engine Removal. . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.10 Engine Installation . . . . . . . . . . . . . . . . . . . . . . 5-17

Section 6 - Mower Deck. . . . . . . . . . . . . . . . . . 6-19

6.1 Replacing PTO Belt . . . . . . . . . . . . . . . . . . . . . . 6-19

6.2 Replacing Mower Blade. . . . . . . . . . . . . . . . . . . 6-19

6.3 Sharpening Mower Blade. . . . . . . . . . . . . . . . . . 6-19

Section 7 - Drive Train . . . . . . . . . . . . . . . . . . . 7-21

7.1 Hydro Transmission Troubleshooting. . . . . . . . . 7-21

7.2 Hydro-Gear Fluid Recommendations. . . . . . . . . 7-22

7.3 Hydro-Gear Transmission Removal. . . . . . . . . . 7-22

7.4 Replacing Hydrostatic Belt. . . . . . . . . . . . . . . . . 7-23

Section 8 - Lift System. . . . . . . . . . . . . . . . . . . 8-24

8.1 Lift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

8.2 Lift System Removal . . . . . . . . . . . . . . . . . . . . . 8-24

Section 9 - Steering . . . . . . . . . . . . . . . . . . . . . 9-25

9.1 Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . 9-25

9.2 Adjusting Steering Lever Height for Serial Numbers

above 10,000 only . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29

Section 10 - Fuel System. . . . . . . . . . . . . . . . 10-30

10.1 Fuel System Troubleshooting . . . . . . . . . . . . 10-30

10.2 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31.

10.3 Fuel System Contamination. . . . . . . . . . . . . . 10-31

10.4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31

10.5 Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . 10-31

Section 11 - Electrical . . . . . . . . . . . . . . . . . . 11-32

11.1 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32

11.2 Electrical Measurements . . . . . . . . . . . . . . . . 11-32

11.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33

11.4 Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34

11.5 Solenoid And Relays . . . . . . . . . . . . . . . . . . . 11-35

11.6 Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . . 11-35

11.7 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35

11.8 Diodes And Rectifiers. . . . . . . . . . . . . . . . . . . 11-35

11.9 Electric Clutch . . . . . . . . . . . . . . . . . . . . . . . . 11-36

11.10 Electrical - Serial numbers above 10,000 . . 11-36

11.11 Electrical System . . . . . . . . . . . . . . . . . . . . . 11-40

11.12 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . 11-41

11.13 Continuity Diagram. . . . . . . . . . . . . . . . . . . . 11-42

11.14 Electrical - Serial numbers above 5,000 and

below 9,999 . . . . . . . . . . . . . . . . . . . . . . . . . 11-43

11.15 Electrical System . . . . . . . . . . . . . . . . . . . . . 11-46

11.16 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . 11-47

11.17 Continuity Diagram. . . . . . . . . . . . . . . . . . . . 11-48

11.18 Electrical - Serial numbers below 5,000. . . . 11-49

11.19 Electrical System . . . . . . . . . . . . . . . . . . . . . 11-52

11.20 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . 11-53

11.21 Continuity Diagram. . . . . . . . . . . . . . . . . . . . 11-54

Section 12 - Mower Attachment . . . . . . . . . . 12-55

12.1 Mower Spindle Removal . . . . . . . . . . . . . . . . 12-55

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 915 ZT.

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.

1. Unit Serial Number Label

2. Engine Serial Number Label

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 issue 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 PRODUCT REGISTRATION

A warranty registration card must be filled out, signed, and returned at time of purchase. This card activates

1 - 2

SECTION 2 - SAFETY

WARNING: This cutting machine is capable

of amputating hands and feet and throwing objects. Failure to observe the safety instructions in the manuals and on decals could result in serious injury or death.

Slopes are a major factor related to loss-ofcontrol and tip-over accidents. Operation on all slopes requires extra caution.

Tragic accidents can occur if the operator is not alert to the presence of children. Never assume that children will remain where you last saw them.

Gasoline is extremely flammable and the vapors are explosive, handle with care.

Disengage attachment, stop unit and engine, remove key, engage parking brake, and allow moving parts to stop before leaving operator’s position.

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!

The safety alert symbol is used in decals and with this manual. 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 RESUL T 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.

2.2 NOTATIONS

NOTE: General reference information for proper oper-

ation and maintenance practices. IMPORTANT: Specific procedures or information

required to prevent damage to unit or attachment.

2.3 EQUIPMENT SAFETY

ALWAYS replace missing or damaged Safety Decals.

1. Caution!

• Maximum tongue weight: 30 lbs.

• Maximum trailer weight: 300 lbs.

• Do not use hitch with bagger attached.

• Do not use on steep hills or slopes.

• Do not park on hills when trailer is attached.

• Do not use with any ground engaging equipment.

2. Danger! Avoid injury - Stay clear of rotating parts.

3. Danger! Always keep feet and hands away from rotating

parts. Always stand clear of discharge area. Do not direct

discharge toward other people. Keep people away from unit while operating. Shut off engine, remove key, and read manual

before you adjust or repair unit. NO STEP! Always keep feet away from rotating

parts.

4. Warning! Always stand clear of discharge area. Do not operate mower unless bagger is attached

or guards are in operating position.

5. Danger! To Avoid Serious Injury or Death Read the operator’s manual. Keep children and others away from unit while

operating. Never direct discharge toward other people.

Thrown objects can cause injury. Look down and behind before and while backing. Never carry children. Go up and down slopes, not across.

DO NOT operate on slopes over 10

• If machine stops going uphill, stop blade and back down slowly.

• Avoid sudden turns.

• Keep safety devices (guards, shields switches, etc.) in place and working.

• Check interlock system per manual before use.

2 - 3

• Understand location and function of all controls.

• Never allow operation by untrained persons.

• Disengage PTO, stop unit and engine, set parking brake and remove key before making any inspections, repairs, etc.

6. Hot Surfaces! DO NOT touch parts which are hot from operation.

ALWAYS allow parts to cool.

7. Caution No smoking. Fill fuel tanks to 2-1/2 in. (6.35 cm) below bottom of

filler neck.

• Never fill fuel tank when engine is running, hot or unit is indoors. Never overfill fuel tank.

• Replace fuel cap securely and clean up spilled fuel.

2.4 SAFETY RULES

If unit is to be used by someone other than original purchaser; loaned, rented or sold, ALWAYS provide this manual and any needed safety training before operation. Only the user can prevent and is responsible for accidents or injuries occurring to themselves, other people or property. Read, understand, and follow all safety practices in Owner/Operator Manual before assembling, using or working on this mower. ALWAYS remove key from ignition and wire from spark plug before assembly, or working on this unit.

Inspect unit before each use for: missing or damaged decals and shields, correctly operating safety interlock system, and deterioration of grass catchers. Replace or repair as needed.

ALWAYS check overhead and side clearances carefully before operation. ALWAYS be aware of traffic when crossing or operating along streets or curbs. Keep children, people, and pets away. Be alert and shut off unit if anyone enters work area. Keep children under watchful care of a responsible adult.

NEVER allow children to operate or pl ay on or near unit.

Keep area of operation clear of all toys, and debris. Thrown objects can cause injury.

Stay alert for hidden hazards, holes and ruts. Avoid uneven or rough terrain. DO NOT operate near dropoffs, ditches, or embankmants. Unit can suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.

Dust, fog, etc. can reduce vision and cause an accident. Operate unit only when there is good visibility and light.

Data indicates that operators, age 60 and above, are involved in larger percentage of riding mower related injuries. These operators should evaluate their ability to

operate the riding mower safely enough to protect themselves and others from serious injury.

Only trained adults may operate unit. Training includes being familiar with controls and actual operation.

NEVER operate unit after or during the use of medications, drugs or alcohol.

NEVER allow anyone to operate this unit when their alertness or coordination is impaired.

Wear adequate safety gear, sturdy shoes and protective gloves.

DO NOT wear l oose clothing or jewelry and tie back hair that may get caught in rotating parts. Protect eyes, face and head from objects that may be thrown from unit. Wear appropriate hearing protection. Always wear safety goggle s or safety glasses wi th side shi elds when operating mower.

Avoid sharp edges. Sharp edges can cut. Moving parts can cut off fingers or a hand. ALWAYS keep hands and feet away from all rotating parts during operation. Rotating parts can cut off body parts.

ALWAYS keep hands away from all pinch points. Start and operate unit only when sealed in operator’s

position. Steering control levers must be in neutral, PTO disengaged and parking brake set when starting engine. ALWAYS keep body and hands away from pin holes or nozzles which eject hydraulic fluid under pressure.

DO NOT touch unit parts which might be hot from operation. Allow parts to cool before attempting to maintain, adjust or service.

NEVER place your hands or any part of your body or clothing inside or near any moving part while unit is running.

NEVER direct discharge towards persons or property. Thrown objects may ricochet back towards operator. ALWAYS stand clear of the discharge area.

ALWAYS disengage attachment, stop unit and engine, remove key, engine parking brake, and allow moving parts to stop before leaving operator’s position.

Use extreme caution on gravel surfaces. Disengage PTO when attachment is not in use and

when crossing gravel surfaces. DO NOT operate unit if safety interlock system is

damaged or disabled. Check safety interlock before each use.

ALWAYS remove key to prevent unauthorized use. DO NOT operate at too fast a rate. Slow down before

turning. Stop engine before removing grass catcher or

unclogging chute. SO NOT mow on wet grass. Reduced traction could

cause sliding.

2 - 4

DO NOT try to stabilize the machine by putting your foot on the ground.

Know the weight of loads. Limit loads to those you can safely control and the unit can safely handle.

ALWAYS keep protective structures, guards and panels in good repair, in place and securely fastened.

Do not operate without either entire grass catcher or the discharge guard in place.

DO NOT operate in reverse unless absolutely necessary. ALWAYS look down and behind before and while backing; especially for children.

Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability when using attachments.

NEVER carry passengers-es pec ia ll y ch ild r en- even with blades off.

Use extra care when approaching blind corners or objects that may obscure vision of hidden obstacles and children.

If you cannot back up a slope or you feel uneasy on it, do not mow it.

Mow up and down slopes, not across them. Use slow speed on any slope. Tires may lose traction

on slopes even though the brakes are functioning properly.

Keep all movements on the slope slow and gradual. DO NOT make sudden changes in spe ed or dire cti on.

Use extra care while operating machines with grass catcher or other attachments. They can affect stability of the machine.

Avoid starting, stopping, or turning on a slope. If tires lose traction, disengage the blades and proceed slowly straight down the slope.

DO NOT operate on slopes over 10

DO NOT park on slopes unless necessary. If unit is parked on a slope, AL WAYS chock or block wheels and set parking brake.

DO NOT disengage or bypass transmission and coast downhill.

Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.

Follow the manufacturer’s recommendations for weight limits for towed equipment and towing slopes.

NEVER allow children or others in or on towed equipment.

On slopes, the weight of the towed equipment may cause loss of traction and loss of control. Travel slowly and allow extra dista nce to stop. Use extra care when loading or unloading unit onto trailer or truck.

Secure unit chassis to transport vehicle. NEVER secure from rods or linkages that could be

damaged.

DO NOT transport machine while engine is running. ALWAYS turn off power to attachment and shut off fuel

when transporting unit. Keep unit free of grass clippings, leaves and other

debris. Clean up oil or fuel spills. This product is equipped with an internal combustion

type engine. DO NOT use unit on or near any unimproved, forest-covered or brush-covered land unless exhaust system is equipped with a spark arrester meeting applicable local, state or federal laws. A spark arrester, if it is used, must be maintained in effective working order by operator.

Fuel is highly flammable and its vapors are explosive. Handle with care. Use an approved fuel container.

NO smoking. NO sparks, NO flames. ALWAYS allow engine to cool before servicing. NEVER fill fuel tank when engine is running or hot from

operation. NEVER fill or drain fuel tank indoors. NEVER overfill fuel tank. Replace fuel cap securely and clean up spilled fuel. NEVER fill containers inside a vehicle or on a truck or

trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

When practical, remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle.

Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

If fuel is spilled on clothing, change clothing immediately.

Avoid Electric Shock. Objects contacting both battery terminals at the same time may result in injury and unit damage. DO NOT reverse battery connections.

Explosive Gases from battery can cause death or serious injury. Poisonous battery fluid contains sulfuric acid and its contact with skin, eyes or clothing can cause severe chemical burns.

NO flames, NO sparks, NO smoking near battery. ALWAYS wear safety glasses and protective gear near

battery. Use insulated tools. DO NOT TIP battery beyond a 45

angle in any

direction. ALWAYS keep batteries out of reach of children. Battery posts, terminals and related accessories

contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Reverse connections may result in sparks which can cause serious injury. Always connect positive (+) lead

2 - 5

of charger to positive (+) terminal, and negative (-) lead to negative (-) terminal.

ALWAYS disconnect negative (-) cable FIRST and positive (+) cable SECOND. ALWAYS connect positive (+) cable FIRST, and negative (-) cable SECOND.

A frozen battery can explode and result in death or serious injury. DO NOT charge or jump start a battery containing frozen fluid. Thaw the battery before putting on a charger or jump starting.

ALWAYS keep protective structures, guards, and panels in good repair, in place and securely fastened. NEVER modify or remove safety devices.

DO NOT change engine governor settings or overspeed engine.

Fumes from engine exhaust can cause injury or death. DO NOT run engine in an enclosed area. Always provide good ventilation.

ALWAYS maintain unit in safe operating condition. Damaged or worn out muffler can cause fire or explosion.

Stop and inspect equipment if you strike an object or if there is an unusual vibration. Repair, if necessary, before restarting. Never make adjustment s or repairs with the engine running.

Mower blades are sharp and can cut you. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. NEVER weld or straighten mower blades.

Rotation of one blade may cause rotation of the other blades.

Check brake operation frequently. Adjust and service as required.

Keep all hardware properly tightened. Stored energy in springs can cause injury. Maintain or replace safety and instruction labels, as

necessary. Never store the machine or fuel container inside a

building where there is an open flame, such as a water heater.

Shut off fuel (if provided) and allow engine to cool completely before storing in closed area or covering unit.

Clean grass and debris from unit, especially from around muffler and engine, to help prevent fires.

For extended storage, clean unit thoroughly. See Engine Manual for proper storage.

Use only attachments or accessories designed for your unit.

Check attachment components frequen tly. If worn or damaged, replace with manufacturer’s recommended parts.

2 - 6

SECTION 3 - SPECIFICATIONS

Model Number 915065 915502 915067 915055 915501 915057 915059 Model 1540 1540 1740 1944 1844 2148 2352 Engine

Type Engine Power –

HP (kW) at Governed RPM

Max Governed RPM

Speed

Forward Max. – m.p.h (km/h)

Reverse Max. – m.p.h (km/h)

Turning Radius Zero Brakes Internal Transmission Electrical

Starter Electric Battery 12 Volt Maintenance Free PTO (Power Take-

Off)

Fuel

Fuel Type Refer to Engine Manual Fuel Tank

Capacity – gal. (L)

Transmission Hydrostatic Drive Size and Weight

Length – in. (cm) 76 (193) Width – in. (cm) 55.5 (141) 59 (150) 63 (160) 66 (168) Weight – lbs (kg) 616 (279) 660 (299) 687 (312) 714 (324) 740 (336) Height – in. (cm) 40 (102) 43 (109)

Tires

Front Tire Size – in. (cm)

Rear Tire Size – in. (cm)

Front Tire Pressure – psi (kPa)

Rear Tire Pressure – psi (kPa)

Mower Deck

Cutting Height – in. (cm)

Cutting width – in. (cm)

Max. Towing Capacity – lbs (kg)

Max. Tongue Weight – lbs (kg)

Single

Cylinder

Kohler

15 (11.2) 15 (11.2) 16 (11.9) 19 (14.2) 18 (13.4) 21 (15.7) 23 (17.2)

3375 2700 3375 3250 2550 3250

6.0 (9.7) 6.5 (10.5)

18 x 8.5 (45.7 x 21.6) 18 x 9.5 (45.7 x 24.1)

Twin

Cylinder

Kawasaki

10 (69) 12 (83)

40 (102) 44 (112) 48 (122) 52 (132)

Single

Cylinder

Kohler

Electric Clutch/Brake

11 x 4 (27.9 x 10.2)

1-1/2 - 4-1/2 (3.81 - 11.4)

Twin

Cylinder

Kohler

3.0 (4.8)

8 (30.3)

46 (317)

300 (136)

30 (13.6)

Twin

Cylinder

Kawasaki

Twin Cylinder Kohler

3 - 7

SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS

4.1 CONTROLS AND FEATURES

1. Ignition Switch

2. PTO Switch

3. Throttle Lever

4. Seat

5. Steering Levers

6. Parking Brake

7. Fuel Tank

8. Headlights (915067, 055, 057, 059, 501)

9. Axle Lock (915067, 055, 057, 059, 501)

10.Mower Lift Pedal

11.M ower Deck

12.Discharge chute

13.Fuel Sh ut-Off Valve

14.Choke Control (915055, 057, 059, 501, 502)

15.Hour Meter (915067, 055, 057, 059, 501, and optional on 915065, 502)

OE0220

Figure 2

4 - 8

4.2 MOVING UNIT MANUALLY

WARNING: DO NOT disengage or bypass

transmission and coast downhill.

Disengage (2) transmission bypass levers to drive unit and engage (1) transmission bypass levers to push unit manually (Figure 3).

Models 915065

and 502

05305600

Models 915055,

057, 059, 067

and 501

05305200

1. Transmission Bypass Lever Engaged

2. Transmis si on By p as s Lev er D ise ng age d

OE0260

Figure 3

1. Fuel Cap

OE0180

Figure 4

4. Remove the cap from the fuel tank.

5. Fill the fuel tank with the proper grade of fuel as recommended by the engine manufacturer. Do not spill any fuel.

6. Fill fuel tanks to 2-1/2 in. (6.35 cm) below bottom of filler neck.

7. Replace the cap on the fuel tank and tighten.

8. ALWAYS clean up any spilled fuel before starting the engine.

4.4 GENERAL LUBRICATION

Each front caster has a grease fitting. All grease fittings should be greased at 25-hour

intervals. Clean and inspect parts and replace as required.

1. Clean the fittings before attaching the grease gun.

2. Use Stens Mix Hi-Temp grease (a moly-lithium grease) or equivalent. Add grease unti l it appe ar s at the ends of the bearing or ends of the shaft.

3. Check all parts for wear and damage.

4. Every 25 hours apply motor oil to all pin connections, pivots points and areas where sliding occurs.

4.3 FILLING FUEL TANKS

WARNING: Fuel is highly flammable and its

vapors are explosive. H andle with care.

NO smoking, NO sparks, NO flames. Refer to Engine Manual for proper fuel. To add fuel to the fuel tank:

1. ALWAYS place unit in open or well ventilated area.

2. Stop engine and allow to cool for two minutes.

3. Clean the fuel cap and the area around the fuel cap to prevent dirt from entering the fuel tank.

CAUTION: Before performing any service or adjustments:

• Turn PTO switch "OFF".

• Park mower on a hard, flat, level surface.

• Set parking brake.

• Turn ignition switch "OFF" and remove key.

• Wait for blades and all moving parts to stop.

4 - 9

4.5 AXLE LOCKS

4.6 REMOVING MOWER DECK

(915067, 055, 057, 059, 501) (Figure 5)

NOTE: The unit comes shipped with the front axle in

the lockout position. If a pivoting front axle is needed: Remove axle lock

hardware from lockout position and install axle lock hardware in pivoting position on both sides of front axle.

NOTE: To lock front axle, install axle lock hardware in the lockout position on both sides of the axle.

1. Front Axle

2. Pivoting Position

3. Lockout Position

4. Axle Lock Hardware

OE0240

Remove (Figure 6)

1. Remove PTO belt from electric clutch (see Replacing PTO Belt).

NOTE: Perform steps 2 and 3 for the right and left sides of unit.

2. Remove guide arm from front mount bracket.

3. Remove rear lift link, rear trunnion, front lift link, and front trunnion from mower deck and mower lift.

4. Slide mower deck out from under unit.

Install (Figure 6)

1. Slide mower deck under unit.

NOTE: Perform steps 2 and 3 for the right and left sides of unit.

2. Install rear lift link, rear trunnion, front lift link, and front trunnion on mower deck and mower lift.

3. Install guide arm on front mount bracket.

4. Install PTO belt on electric clutch (see Replacing PTO Belt)).

Figure 5

1. Mower Deck

2. Front Trunnion

3. Front Lift Link

4. Front Mount Bracket

5. Mower Lift

6. Guide Arm

7. PTO Belt

8. Rear Trunnion

9. Rear Li ft Link

OE0230

Figure 6

4 - 10

4.7 LEVELING AND ADJUSTING PITCH

OF MOWER DECK

Adjust on a level surface, with the tires inflated to the correct air pressure.

Level Mower Deck

1. Install adjustment pin in the fourth adjustment hole (Figure 7).

• TO RAISE the mower deck, turn rear trunnion clockwise several turns.

• TO LOWER the mower deck, turn rear trunnion counterclockwise several turns.

6. Install rear trunnion and rear lift link on mower deck and mower lift.

7. Check that the mower deck is level: Rotate right and left mower blades to face side-to-

side. Measure outer edge of mower blades to ground.

Measurement must be within 1/4 inch (6.35 mm).

• If mower deck is not level, repeat steps 5 and 6.

• If mower deck is level, record the distance from rear edge of mower blades to the ground and then adjust pitch of mower deck.

1. Adjustment Pin

2. Mower Lift Pedal

OE0060

Figure 7

2. Rotate the right and left mower blades until the ends of both mower blades are facing rearward (Figure 8).

NOTE: The rear blade cutting height should be 2-7/8 to 3 in. (7.3 to 7.6 cm) from rear edge of mower blades to the ground on both blades (Figure 8).

IMPORTANT: The distance from rear edge of mower blades to the ground MUST NOT exceed 3 in. (7.6 cm) (Figure 8).

Mower Deck Shown

From The Side

1. Mower Deck

2. Mower Blade

3. Front of Mower Deck

4. Front Blade Cutting Height

5. Ground

6. Rear Blade Cutting Height

OE0010

Figure 8

3. Measure from rear edge of mower blades to the ground.

4. Perform steps 5 through 7 if the measurement is too high to too low on either side of mower deck.

5. Remove rear lift link and rear trunnion from mower deck and mower lift.

Adjust Pitch of Mower Deck

IMPORTANT: The mower blade end used to level the

mower deck must be used to adjust the pitch of the mower deck.

1. Rotate the right and left mower blades 90 degrees until the end of the mower blade that was used to level the mower deck is facing forward (Figure 8).

NOTE: The front blade cutting height should be 1/16 1/4 inch (1.59 - 6.35 mm) lower than the rear blade cutting height.

2. Measure from front edge of right and left mower blades to the ground.

3. Subtract front blade cutting height measurement from rear blade cutting height measurement.

4. Perform steps 5 through 7 if the front blade cutting height is too high or too low on either side on either side of mower deck.

5. Remove front lift link and front trunnion from mower deck and mower lift (Figure 6).

• TO RAISE the mower deck, turn front trunnion clockwise several turns.

• TO LOWER the mower deck, turn front trunnion counterclockwise several turns.

6. Install front trunnion and front lift link on mower deck and mower lift.

7. Check mower deck pitch.

• If mower deck pitch is not correct, repeat steps 2 through 6.

• If mower deck pitch is correct, the adjustment is complete.

4.8 ADJUSTING ANTI-SCALP ROLLER

NOTE: The anti-scalp rollers are intended to prevent

lawn scalping, not to control cutting height. All antiscalp rollers should be set at the same height.

4 - 11

See Figure 9 for anti-scalp locations on models 915067, 055, 057, 059, 501. See Figure 10 for antiscalp locations on model 915065 and 502.

There are two positions:

• Highest Position: Use to disable anti-scalp feature.

• Lowest Position: Use for all cutting positions.

In the lowest position the anti-scalp rollers will touch the ground.

1. Anti-s calp Roller

2. Lowest Position

3. Highest Position

OE0038

Figure 9

4.9 HYDROSTATIC TRANSMISSION NEUTRAL ADJUSTMENT

1. Shut off engine and engage the parking brake.

CAUTION: PREVENT personal injury! ALWAYS MAKE CERTAIN that jack(s) or blocks used are stable, strong and will support the weight of the unit.

2. Position rear wheels off the ground. Be careful to secure the unit to the lift or position the unit to face a wall for safety. Disconnect the rods from the handlebars to the linkage.

3. Pull the pin that holds the locking arm to the brake rod then release the locking arm and disengage it from the gear.

4. Engage seat switch and start the engine.The drive wheels shou ld not be rot atin g. If t he whee ls are no t driven to rotate, proceed to Steering Control Neutral Adjustment.

To adjust the neutral setting for no wheel rotation Model EZT 915065 and 502:

5. Use a hex wrench to loosen the locking bolt (Figure

11) until the linkage can be rotated by hand.

6. With the engine running and the drive wheels off the ground, rotate the linkage in either direction. The correct linkage position is when the wheel is not being driven (under power).

7. Hold the linkage in place and tighten the locking bolt.

8. Shut off engine and reconnect steering rods.

9. Reconne ct p a rk ing brak e pi n. Che ck p a rki ng brak e linkage for proper movement.

1. Anti-scalp Roller

2. Lowest Position

3. Highest Position

Figure 10

OE0310

4 - 12

1. Locking Bolt

2. Steering R od

3. Pin

4. Locking Arm

Figure 11

To adjust the neutral setting for no wheel rotation Model IZT 915055, 057, 059, 067, 501:

1. Use a hex wrench to loosen the locking bolt (Figure

12).

2. With the engine running and the drive wheels off the ground rotate the linkage in either direction. The correct linkage position is when the wheel is not being driven (under power).

3. Hold the linkage in place and tighten the locking bolt.

4. Shut off engine.

5. To reconnect the steering rod it should be positioned through the hole in the trunnion. Two jam nuts are above and one nyloc nut is below the trunnion.

6. Without moving the transmission linkage turn the first jam nut towards the trunnion until it makes contact.

7. The nyloc nut is turned toward the trunnion until tight.

8. Move the second jam nut to contact the first jam nut and tighten together.

9. Reconnect parking brake pin.

• The unit turns to the right or left when both steering levers are pulled back as far rearward as possible.

NOTE: The side the unit turns toward indicates that the wheel on that side is turning slower than the other wheel. Either the wheel that is turning faster needs to slow down or the wheel that is turning slower needs to be sped up to allow the unit to travel in a straight line.

See steering section for illu strations.

1. Determine which way the unit turns.

2. Tip seat forward

NOTE: The forward travel adjustment bolt adjusts forward travel of the steering lever. The rear travel adjustment bolt adjusts the rearward travel of the steering lever.

3. Adjust speed by:

• Turning adjustment bolt clockwise to decrease steering lever travel.

• Turning adjustment bolt counterclockwise to increase steering lever travel.

1. Locking Bolt

2. Steering Rod

3. Jam Nut

4. Nyloc Nut

Figure 12

4.10 ADJUSTING THE UNIT TO TRACK STRAIGHT

Model EZT 915065, 502 with serial numbers above 10,000

(Figure 13) IMPORTANT: The unit should track within 2 feet

(0.61 m) of a straight line for 30 feet (9.14 m). The travel of the steering levers may need adjustment

if:

• The unit turns to the right or left when both steering levers are pushed as far forward as possible.

1. Forward Travel Adjustment Belt

2. Rear Travel Adjustm en t Belt

3. Steering Lev er

OE0330

Figure 13

Model EZT 915065, 502 with serial numbers below 10,000:

1. Determine which way the unit turns.

2. Move handlebars to neutral position. Handlebars should line-up with each other. To adjust handlebar position; loosen mounting bolts, realign and tighten bolts.

3. Locate the stop bolts for handlebar travel.

4. Make a length adjustment of the stop bolt to either shorten the stroke of the handlebar on the outside of the turn, or lengthen the stroke of the handlebar on the inside of the turn.

Model IZT 915055, 057, 059, 067, 501 with serial numbers below 10,000:

1. Determine which way the unit turns.

2. Adjust steering levers to match. Note each steering lever can be positioned further forward or further backward.

4 - 13

• Move levers to neutral position.

• Loosen mounting hardware.

• Position steering levers.

• Tighten mounting hardware.

3. Adjust height of steering levers. There is a low and a high position for steering levers.

• Remove mounting hardware and place steering levers in the low or high position.

• Tighten mounting hardware. The forward or backward full travel of the steering levers is controlled by the position of the dampener.

4. Locate the dampener. The mounting hole in the frame should be slotted.

5. Slide adjustment bolt to the back of the machine to speed the side up (inside of turn). Slide adjustment bolt forward to slow down this side of the machine (outside of turn).

6. Adjust as needed. The steering lever neutral position may need adjustment.

Model IZT 915055, 057, 059, 067, 501 with serial numbers above 10,000

IMPORTANT: The unit should track within 2 feet (0.61 m) of a straight line for 30 feet (9.14 m).

The travel of the steering levers may need adjustment if:

• The unit turns to the right or left when both steering levers are pushed as far forward as possible.

• The unit turns to the right or left when both steering levers are pulled back as far rearward as possible.

See steering section for illustrations.

1. Determine which way the unit turns.

2. Tip seat forward

NOTE: The forward travel adjustment bolt adjusts forward travel of the steering lever. The rear travel adjustment bolt adjusts the rearward travel of the steering lever.

3. Adjust speed by:

• Turning adjustment bolt clockwise to decrease steering lever travel.

4. Turning adjustment bolt counterclockwise to increase steering lever travel.

4.11 ADJUSTING THE PARKING BRAKE

When properly adjusted the parking brake will lock the linkage on both drives and activate the safety switch (Figure 14).

The drive units should be properly adjusted for neutral. Engage the parking brake handle. The brake rod

should be positioned to lock the drive. The safety switch should be disengaged.

To adjust the linkage: Move the adjusting nut (Figure 15) clockwise/

counterclockwise as needed to properly position the brake rod.

NOTE: The safety switch can be loosened for minor adjustments.

1. Clip

2. Locking Gear

3. Locking Arm

Figure 14

1. Nylon Adjusting Nut

2. Double Pole Switch

3. Brake Rod

PE0832

Figure 15

4 - 14

SECTION 5 - ENGINE

5.1 ENGINE TROUBLESHOOTING

The following troubleshooting chart is to be used to isolate engine problems and give possible causes and corrective action responses.

The troubleshooting key is generic and can be used for several types of engines. Use only those possible causes and corrective actions that apply to the unit.

TROUBLE POSSIBLE CAUSES

(Refer to Key Below)

Black Exhaust 1, 20, 22, 25, 29, 31, 32, 33 repair or replace Blue/White Exhaust 4, 20, 25, 31, 33, 34 repair or replace Difficult Starting 1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33 repair or replace Erratic Running 1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62 repair or replace Excessive Fuel Consumption 1, 20, 22, 23, 25, 29, 31, 32, 33 repair or replace Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55 repair or replace High Oil Pressure 4, 41 repair or replace Knocking 22, 26, 29, 31, 33, 36, 46, 59 repair or replace Loss of Power or System 1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33 repair or replace Low Cranking Power 2, 3, 4, 11 repair or replace Low Oil Pressure 4, 36, 37, 39 repair or replace Misfiring 10, 20, 25, 26, 28, 29, 32 repair or replace Overheating 1, 19, 25, repair or replace Poor Compression 25, 28, 29, 31, 32, 33, 34,59, repair or replace Starts and Stops 1, 6, 10, 62 repair or replace

Vibration 20, 23, 25, 26, 29, 33, 45, 49 repair or replace Will Not Crank 2, 11, 45 charge battery or replace Will Not Start 1, 10, 62 repair or replace

CORRECTIVE ACTION

see electrical systems see engine service manual

TROUBLESHOOTING KEY

1 Restriction in air cleaner 22 Incorrect grade of fuel 43 Faulty suction pipe 2 Bad electrical connection 23 Sticking throttle/restricted movement 44 Choked oil filter 3 Faulty starter motor 24 Exhaust pipe restriction 45 Bad solenoid switch 4 Incorrect grade of lubricating oil 25 Leaking cylinder head gasket 46 Incorrect piston height 5 Low cranking speed 26 Overheating 47 Damaged fan 6 Fuel tank empty 27 Cold running 48 Faulty engine mounting 7 Controls not in correct

operation position 8 Blocked fuel feed line 29 Sticking valves 50 Faulty thermostat 9 Faulty fuel lift pump 3 0 Incorrect high pressure pipes 51 Restriction in water jacket 10 Choked fuel filter 31 Worn cylinder bores 52 Loose fan belt 11 Battery capacity low 32 Pitted valves and seats 53 Choked radiator 12 Air in fuel system 33 Broken, worn or sticking piston ring(s) 54 Faulty water pump 13 Faulty fuel injection pump 34 Worn valve stems and guides 55 Choked breather pipe 14 Faulty fuel injectors or incorrect

type 15 Incorrect use of cold start

equipment 16 Faulty cold start equipment 37 Insufficient oil in sump 58 Blocked sump strainer 17 Broken fuel injection pump

drive 18 Incorrect fuel pump timing 39 Oil pump worn 60 Exhaust or vacuum pipe leak 19 Incorrect valve timing 40 Pressure relief valve sticking open 61 Bad or defective water temperature

20 Poor compression 41 Pressure relief valve sticking closed 62 Bad spark plug(s) 21 Blocked fuel tank vent 42 Broken relief valve spring

28 Incorrect tappet adjustment 49 Incorrectly aligned flywheel and/or

flywheel housing

35 Restriction in air cleaner 56 Damaged valve stem oil deflector (if

fitted)

36 Worn or damaged bearings 57 Coolant level too low

38 Bad/defective oil temperature switch 59 Broken valve spring

switch

5 - 15

5.2 CHECKING ENGINE OIL

Check the engine oil daily prior to use. IMPORTANT: Never operate the engine with the oil

below the low mark on the dipstick. See the Engine Manual for oil specifications and oil

filter service instructions. To check oil level:

1. Move the unit to level location.

2. Clean around the dipstick and filler tube to prevent dirt from entering the engine.

3. Remove the dipstick and wipe off the oil on the dipstick.

4. Put the dipstick back into the engine, tighten in place, and remove again.

5. When the dip stic k is re moved , note the oi l lev el. Oi l should be between the full and add mark.

6. Replace dipstick.

7. If required, add oil. Do not overfill.

8. Clean up any spillage that may have occurred.

5.3 CHANGING OIL

WARNING: Do NOT touch part s which are

hot. Allow parts to cool before servicing.

Engine muffler and other parts will be hot if unit has been running.

1. Engine oil should be changed after the first five hours of operation and every 25 hours there after.

2. Move the unit to a level and well ventilated area and set the parking brake.

3. If the engine is cold, let the unit run for five minutes.

4. When the engine is warm, stop the engine.

5. Clean the area around the dipstick and drain hose.

6. Put an open container that will hold one gallon of oil under the drain hose.

7. Open the drain valve.

8. Allow the engine oil to drain completely into the one gallon container. Remove container and contents for future recycling as required.

9. Close the oil drain valve.

10.If used, remove the oil filter.

11.Clean the oil filter port and install a new oil filter according to the instructions on the oil filter. Fill with new oil to the "full" mark on the dipstick.

12.Start and run the engine for one minute. Stop the engine and recheck the oil level and add as necessary.

13.Check for leakage at the drain plug and oil filter if used. Tighten the fittings as necessary if leakage occurs.

14.Release the parking brake.

15.Return the unit into service.

5.4 CHECKING ENGINE COOLING

IMPORTANT: To prevent severe damage to the

engine, proper cooling will need to be maintained.

1. Check the air intake screen on the engine each day.

2. The air intake screen must be kept clean. Remove any grass, dirt, or debris that may have accumulated.

3. Check the engine cooling yearly.

5.5 CLEANING THE AIR CLEANER

1. Check the air cleaner element every day.

2. Clean the air cleaner precleaner every 25 hours. See your Engine Manual for instructions.

3. Apply oil and reinstall over the paper air filter element.

4. Wipe out the air cleaner cover to remove any dirt build up in the cover.

5. Reinstall the cover over the air cleaner prior to operating the engine. See your Engine Manual.

5.6 CHANGING THE AIR CLEANER ELEMENT

Replace the air cleaner element when clogged or every 100 hours. Do not attempt to clean. See your Engine Manual for instructions.

5.7 INSPECT MUFFLER/SPARK ARRESTER

Inspect muffler and (if equipped) spark arrester. Replace muffler if corroded, as it could create a fire hazard and/or damage.

5.8 REPLACE SPARK PLUGS

Spark plug type and gap setting are shown in Specifications. See Engine Manual for detailed instructions.

5.9 ENGINE REMOVAL

1. Remove deck.

2. Remove the hood.

3. Remove the negative cable from the battery.

4. Remove the main drive belt from the engine sheave by releasing the idler tension spring.

5. Remove the throttle and choke control from the engine.

6. Remove the electrical wiring from the engine (charge lead, starter cable, fuel solenoid lead, and magneto kill wire).

5 - 16

7. Remove fuel line from engine first. Drain fuel from line back into fuel tank.

8. Remove the electric clutch and the anti-rotation bolt.

9. Remove the engine bolts.

10.Lift engine out of the unit and off the frame with a hoist (engine).

11.Service, overhaul, or replace engine as required.

12.If replacing engine with a new engine, the following items will have to be removed (if used) from the old engine. These items will not be included with a new engine:

• Engine sheave and key

• Mounting hardware

• Engine wiring harness.

5.10 ENGINE INSTALLATION

1. Check the engine base and unit frame for damage before installing the engine.

2. Place the throttle and choke controls, fuel line, and electrical wires out of the way prior to installing the engine.

3. Once the engine is bolted onto the frame, install the exhaust system and then tighten the mounting hardware.

4. Install the engine sheave, belts, springs, electrical wiring, throttle, and choke controls.

5. Install the negative battery cable onto the battery.

6. Install the fuel line.

7. Fill engine with 10-30 above 32°F (0°C) or 5W30 below 32°F (0°C).

8. Install the engine cover, then test operation and function of the engine.

WARNING: AVOID EXHAUST FUMES! DO NOT run engine in an enclosed area. ALWAYS provide good ventilation and wait until hazard has been removed.

9. Check the fluid levels as follows: a) Start the engine and allow it to reach to

operating temperature. DO NOT operate engine for more than two minutes.

b) Shut the engine off, wait for engine to cool, and

be sure the engine oil level is between the full and add marks on the dipstick. If it is below the add mark, add recommended oil. DO NOT overfill.

5 - 17

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