TABLE OF CONTENTS Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-2 Section 7 - Drive Train . . . . . . . . . . . . . . . . . . . 7-22 1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2 Service And Replacement Parts . . . . . . . . . . . . . 1-2 1.3 Product Registration. . . . . . . . . . . . . . . . . . . . . . . 1-2 1.4 Unauthorized Replacement Parts . . . . . . . . . . . . 1-2 1.5 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.
SECTION 1 - INTRODUCTION 1.1 THE MANUAL 1.3 PRODUCT REGISTRATION The purpose of this manual is to provide complete instructions for service, maintenance, disassembly, repair, and installation of the mechanical components for the 915 EZ Rider. A warranty registration card must be filled out, signed, and returned at time of purchase. This card activates the warranty. Claims meeting requirements during limited warranty period will be honored.
SECTION 2 - SAFETY 2.1 SAFETY ALERTS rented or sold, ALWAYS provide the Operator’s Manual and any needed safety training before operation. Look for these symbols to point out important safety precautions. They mean: 2.6 PREPARATION Before starting any removal of parts, proper preparation is very important for efficient work. A clean work area at the start of each job will allow you to perform service repairs easily and quickly.
Avoid uneven and rough terrain. DO NOT operate near drop offs, ditches, or embankments. Unit can suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in. 2. If a preservative fluid was used in fuel tank, drain and discard. Fill fuel tank with fresh new fuel. 2.9 SAFETY RULES If tires lose traction, turn off power take off and proceed slowly straight down slope. Avoid wet surfaces.
Storage Avoid Sharp Edges. Sharp edges can cut. Moving parts can cut or amputate fingers or a hand. Wear gloves to service unit when handling sharp edges. DO NOT store unit inside a building with fuel in the fuel tank where any ignition sources are present. Allow unit to cool completely. ALWAYS keep hands away from any pinch points. ALWAYS keep hands and feet away from all moving parts during operation. Moving parts can cut off body parts. ALWAYS clean unit before extended storage.
SECTION 3 - SPECIFICATIONS Model Number Model Engine Manufacture Fuel & Capacity - gal (L) Idle RPM Governed RPM Crank Case Capacity (Oil Filter) - oz (L) Air Cleaner Charging Capacity Fuel Filter Engine Oil Spark Plug Gap Transmission Speed Forward Max. mph (kph) Reverse Max.
Model Number Model Engine Manufacture Fuel & Capacity - gal (L) Idle RPM Governed RPM Crank Case Capacity (Oil Filter) - oz (L) Air Cleaner Charging Capacity Fuel Filter Engine Oil Spark Plug Gap Transmission Speed Forward Max. mph (kph) Reverse Max.
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 11 1 2 10 7 8 9 15 14 12 OE0680 13 3 6 5 4 OE0860 1. 2. 3. 4. 5. 6. 7. 8. Steering Control Levers Battery Compartment Ignition Switch Power Take Off (PTO) Throttle Control (Throttle/Choke Control) Choke Control (2048) Parking Brake Lever Attachment Lift Lever 9. Foot Rest 10. Fuel Level Indicator Window 11. Fuel Tank Cap 12. Discharge Chute 13. Anti-Scalp Rollers 14. Belt Cover 15.
4.2 CHECK FUEL LEVEL The fuel level is shown through a window in the control panel next to the parking brake. WARNING: Fuel is highly flammable and its vapors are explosive. Handle with care. Front NO smoking, NO sparks, NO flames. Refer to Engine Manual for proper fuel. Mower Drive Idler To add fuel to the fuel tank: 1. ALWAYS place unit in open or well ventilated area. 2. Stop engine and allow to cool for two minutes. 3.
4.4 TO REMOVE 48" MOWER DECK 1. Turn off engine, engage parking brake and allow hot parts to cool. 5 4 2. Place center deck lift handle in lowest (1) position. 2 3 6 1 WARNING: AVOID injury from stored energy in lift assist spring. DO NOT unlock attachment lift lever with mower deck removed. ALWAYS engage Attachment Lift Lever Lock when removing mower deck. 3. Engage attachment lift lock. Pull handle out and rotate down 90o. Handle will spring into locked position. 1. Front Pin 2. Front Lift Arm 3.
4.7 TO INSTALL 42" MOWER DECK 1. The center deck lift handle should be in the lowest (1) position with the attachment lift lock engaged. WARNING: AVOID injury from stored energy in lift assist spring. DO NOT unlock attachment lift lever with mower deck removed. ALWAYS engage Attachment Lift Lever Lock when removing mower deck. WARNING: AVOID injury from stored energy in lift assist spring. DO NOT unlock attachment lift lever with mower deck removed.
1. To adjust mower height, place mower in the number three (3) position. 2. Loosen height adjuster nuts. 3. Remove hair pins and washers holding height adjusters to lift arm and unhook height adjusters from lift arm. 4. Turn height adjusters equally clockwise to raise mower, or equally counterclockwise to lower mower. Adjust for a height of 2-3/4" from ground to blade tip.
4.10 NEUTRAL ADJUSTMENT (SPEED CONTROL) 1. Stop the engine. Remove the ignition key. Push the PTO knob into the "OFF" position. 2 1 CAUTION: PREVENT personal injury! ALWAYS MAKE CERTAIN that jack(s) or blocks used are stable, strong and will support the weight of the unit. 2. Place jack(s) under rear transaxles only. If jack(s) are not available, place support blocks under both transaxles at the rear of the unit to raise the rear wheels off the ground. 3 1. Connecting Linkage 2. Lock Nut 3.
4.12 ANTI-SCALP ROLLERS (42" DECK) Rollers are intended to prevent lawn scalping, not to control cutting height. 1 For proper operation, adjust the anti-scalp rollers to the same or higher than mower cutting height. For example, when mowing at the number three (3) height position, the anti-scalp rollers must be adjusted to their number three (3) or higher position. 4 2 3 2 1. Eccentric 2. Locknuts and Bolts 5 3. Flange Bushing 4. Speed Control Arm Figure 12 Figure 14 1. Remove side shrouds.
4.13 ADJUSTING THE PARKING BRAKE The parking brake has no adjustments. If the brake is not working properly inspect the linkage for wear and replace as needed. 1 5 4 3 3 1. Brake Lever Pivot 2. Brake Lever 3. Flange Bushing 2 4. Brake Arm 5.
SECTION 5 - ENGINE 5.1 ENGINE TROUBLESHOOTING The following troubleshooting chart is to be used to isolate engine problems and give possible causes and corrective action responses. TROUBLE The troubleshooting key is generic and can be used for several types of engines. Use only those possible causes and corrective actions that apply to the unit.
5.2 CHECKING ENGINE OIL 13.Check for leakage at the drain plug and oil filter if used. Tighten the fittings as necessary if leakage occurs. Check the engine oil daily prior to use. IMPORTANT: Never operate the engine with the oil below the low mark on the dipstick. 14.Release the parking brake. 15.Return the unit into service. See the engine manual for oil specifications and oil filter service instructions. 5.
5. Remove the throttle and choke control from the engine. 6. Remove the electrical wiring from the engine (charge lead, starter cable, fuel solenoid lead, and magneto kill wire). 7. Remove fuel line from engine first. Drain fuel from line back into fuel tank. 8. Remove the exhaust system from under the frame. Disconnect at the exhaust port on the engine. 9. Remove the engine bolts. 10.Lift engine out of the unit and off the frame with a hoist (engine). 11.Service, overhaul, or replace engine as required.
SECTION 6 - MOWER DECK 6.2 MOWER DECK BELT REPLACEMENT (48" DECK) CAUTION: Before performing any service or adjustments: 5 • Turn PTO switch "OFF". 4 • Park mower on a hard, flat, level surface. • Place steering control levers in neutral lock (fully outward) position. 2 1 • Set parking brake. 6 • Turn ignition switch "OFF" and remove key. 3 • Wait for blades and all moving parts to stop. • Disconnect spark plug wire(s) from spark plug(s) and place wire(s) away from plug. 1. Clutch to Deck Belt 2.
6.4 CHECK BLADES 6.3 MOWER DECK BELT REPLACEMENT (42" DECK) For best results mower blades must be kept sharp. Replace bent, worn or damaged blades. 6 2 Blade Removal 8 5 CAUTION: Moving Parts and Sharp Blades can cut or amputate body parts. Always use sturdy gloves or padding to protect hands when working with mower blades. 1 4 1. Shut off the engine and unit. Remove the ignition key. Remove the ignition wire(s) from the spark plug(s) to prevent accidental start-up. 7 3 2.
1 2 1. Blade 2. Bolt or Pin Figure 19 Figure 20 NOTE: The 42" deck uses a retainer hub and blade tray with a rectangular hole. This feature helps ensure the blades will be 90o to each other. 2. Tighten the lock nut(s) to a torque of 60 ft-lbs (82 Nm). 3. Put the ignition wire(s) back on the spark plug(s). IMPORTANT: When installing blades on the 42" Mower Deck, the two blades must be 90o to each other. O E0500 4.
SECTION 7 - DRIVE TRAIN 7.1 HYDRO TRANSMISSION TROUBLESHOOTING The following troubleshooting chart is to be used to isolate hydro transmission problems and give possible causes and corrective action responses.
1 2 14 3 5 4 6 13 12 15 11 10 7 9 8 1. 2. 3. 4. 5. Back Cover Left Hand Brake Assembly Brake Disc Bevel Gear Brake Shaft Kit 6. Bypass Actuator 7. Motor Shaft 8. Filter 9. Center Section Assembly 10.Cylinder Block Assembly 11.Input Shaft 12.Variable Swashplate 13.Cradle Bearing 14.Upper Housing Assembly 15.
1 17 16 2 3 15 14 4 13 5 12 6 8 11 10 7 9 1. 2. 3. 4. 5. 6. 7. 8. Back Cover Brake Shaft Kit Bevel Gear Upper Housing Assembly Bypass Actuator Motor Shaft Cylinder Block Assembly Bypass Plate 9. Filter 10.Center Section Assembly 11.Cylinder Block Assembly 12.Input Shaft 13.Variable Swashplate 14.Cradle Bearing 15.Brake Disc 16.Right Hand Brake Arm Service Assembly 17.Brake Disc Figure 22 - Right Transaxle PE0480 7.
Lubricate the new seal prior to installation with a petroleum jelly. 7. All components should remain in the upper housing (positioned down). Wrap the shaft spline with a thin plastic or cellophane tape to prevent damage to the new seal lip during installation. 8. Remove the brake gear from the brake shaft. 9. Remove the oil seals from the brakes shaft. Push out the brake shaft to remove the support bearing.
Figure 25 Figure 27 16.Remove the motor shaft, washers and bypass plate from the center section and inspect for unusual wear or damage. 19.Remove the slot guide from the displacement control shaft. Inspect the center section running surfaces for unusual wear or damage. 20.Remove the bypass actuator from the housing. 21.Reposition the housing and remove the input shaft lip seal from the housing bore. A hook type tool may be used to pry the seal out.
Apply the sealant to the lower and rear housing. NOTE: Sealant must be of good quality, oil and heat resistant. CAUTION: Most parts have critical high tolerance surfaces. Care must be exercised to prevent damage to these surfaces during assembly. Protect exposed surfaces, opening and ports from damage or foreign material. 1. Install the displacement control shaft. 2. Install the pump input shaft assembly and retaining ring into the housing. 3. Install the pump shaft lip seal. 16.
Check the oil level after fully purging the unit of air. It should be between 1.25" and 1.62" (3.175-4.11 cm) from the top of the housing. After installing the IHT, make sure all linkages and actuators and functioning properly. 7.6 HYDRO-GEAR TRANSMISSION REMOVAL 1. Place the unit on a flat surface and remove the negative lead from the battery and the spark plug lead from the spark plug. 2. Remove key and spark plug wire. Figure 28 3.
SECTION 8 - POWER TAKE OFF 8.3 PTO JACKSHAFT INSTALLATION 8.1 PTO JACKSHAFT REMOVAL 1. Place the unit on a flat level surface, and lower the mower pan. 2. Open the front panel by removing the two cap screws in the lift handle cover plate. Remove the two tap tites in the front panel and remove panel exposing the battery and electrical system. 1. Prior to installing the jackshaft assembly into the unit frame, check the condition of the clutch anchor strap. Repair or replace if necessary. 2.
SECTION 9 - LIFT SYSTEM 9.1 LIFT SYSTEM 2. Place the lift handle in the highest cutting height available. Refer to Figure 29 for the lift system. The mower pan lift system is a manual lift system controlled by the operator. 9.2 LIFT SYSTEM REMOVAL 1. Remove the mower deck from the unit prior to lift system removal. 3. Remove the plate, parking brake knob and front panel to expose the lift system. NOTE: The decklift handle must be in the highest position when the tension spring is released.
SECTION 10 - FUEL SYSTEM 10.
10.5 FUEL TANK REMOVAL 10.2 FUEL PUMP The impulse style fuel pump is the most commonly used fuel pump. Impulse fuel pumps may either be mounted externally onto the carburetor fuel inlet or remotely mounted. These pumps are connected in the fuel line between the fuel supply and the carburetor or directly to the fuel inlet. Impulse fuel pumps are operated by crankcase impulses created by the up and down movement of the piston.
SECTION 11 - ELECTRICAL 11.1 TOOLS 11.2 ELECTRICAL MEASUREMENTS There are some specialized tools and test equipment that are needed for electrical repair work. A brief description of these follows. Long or needle nose pliers - used to connect or bend wires and connectors in close quarters. Diagonal cutters - used to cut wires or trim connections. Wire stripper/crimping tool - available separately or as a combination tool.
Voltage Measurement WARNING: EXPLOSIVE GASES can result in serious injury or death. ALWAYS keep open flames, sparks, or smoking materials away from battery. There are two basic rules to be remembered when using a voltmeter. A voltmeter measures the voltage difference between the test leads and the voltmeter is always connected across the circuit under test. POISONOUS BATTERY FLUID contains sulfuric acid and its contact with skin, eyes or clothing can cause severe chemical burns.
Clean Battery Corrosion and dirt on the battery and terminals can cause the battery to "leak" power. • Remove battery. (See Battery Removal and Installation) 1 2 • Rinse the battery with plain water and dry. • Clean terminals and battery cable ends with wire brush until bright. 3 • Coat terminals with grease or petroleum jelly. • Reinstall battery. 4 Battery Removal and Installation 1. 2. 3. 4. Remove battery before service.
Electrolyte Level room temperature and the charging time can be estimated. For example: Every 25 hours of operation, check electrolyte level of each cell by removing caps one at a time. The electrolyte level should be at level indicated. Use distilled water to fill each cell if needed. Install and tighten each cap after checking. IMPORTANT: When distilled water is added to battery during freezing weather, battery must be charged to mix water with electrolyte, or water will remain at top and freeze.
11.4 SWITCHES To jump start the battery: 1. Ensure battery is not frozen. If the fluid is frozen, remove battery from unit and allow to thaw before charging. Switches either open a circuit to stop current flow or close and allow current to flow through. 2. Connect the positive (+) jumper cable to the positive (+) terminal of the discharged battery. 3. Connect the other end of the same jumper cable to the positive (+) terminal of the booster battery. 4.
Ignition Switch NOTE: Refer to the wiring diagram of the unit involved to determine switch functions and test using the methods described. The ignition switch incorporates a number of functions, although not all functions are used on all equipment. The switch has three positions: OFF, RUN, and a momentary contact START position. Use an ohmmeter to check the continuity of the switch in each position. OFF Position - Should be continuity between contacts G and M.
11.6 LIGHTING CIRCUITS IMPORTANT: Diodes are marked to indicate polarity (a band on one end, an arrow on the side, or they fit on a holder only one way. Lighting circuits are simple circuits and easiest to trouble shoot in most equipment. They consist of the lights connected in parallel; a normally open switch, a protective fuse and a source of power (battery or engine alternator).
STEP 1 the starter solenoid and goes to ground through the base of the starter solenoid. Check out the battery. Using a hydrometer on all the battery cells to see if one or more is bad. Also use a voltmeter to check for proper voltage. Replace the battery if necessary and/or charge to proper level. Refer to Battery. PTO clutch check out: Remove the wiring harness PTO clutch leads from the clutch. With a multimeter check the clutch coil for resistance to see if the coil is good.
PTO Switch Off Run Start Yellow/Red 11.50-13.00 Volts 11.50-13.00 Volts Purple/white Connected to PTO Clutch Purple 11.50-13.00 Volts 11.50-13.00 Volts Brown/Yellow 11.50-13.00 Volts 11.50-13.00 Volts 2 sets of contacts, one normally open, one normally closed. Contact resistance is 0.1-0.3 ohms when correct. Left Hand Neutral Switch Off Run Start Brown/Yellow 11.50-13.00 Volts 11.50-13.00 Volts White 11.50-13.00 Volts 11.50-13.00 Volts Normally open contacts manually activated.
Solenoid Off Run Small Brown Start 11.50-13.00 Volts Small Black Connected to Ground Large Red (Battery) 11.50-13.00 Volts 11.50-13.00 Volts Large Red (Starter) 11.50-13.00 Volts 11.50-13.00 Volts Normally open contacts (big terminals) coil resistance 3.0-5.0 ohms. Contact resistance is 0.1-0.3 ohms when correct. Electrically activated. PTO Clutch Off Run Start Purple/white Black Connected To Ground Coil Resistance check clutch specifications.
11.
11.12 RELAYS AND SWITCHES The diagrams below show the various states of connection for electrical components. The solid lines on switches show continuity. NOTE: All switches are viewed from the rear.
SECTION 12 - MOWER ATTACHMENT 12.1 42" MOWER SPINDLE REMOVAL 2 1 3 4 4 5 5 6 7 8 1. 2. 3. 4. 6 7 8 Jackshaft Compression Spring Idler Pulley Assembly Spindle Shaft 5. 6. 7. 8. Drive Sprocket Spindle Housing Assembly Retainer Hub Blade Tray Figure 33 PE 0550 1. With the mower deck removed from the unit the disassembly of the mower may be done. 5. Reduce belt tension on the belt by loosening the nut for the idler pulley compression spring. 2. Remove the mower spindle covers. 6.
12.2 48" MOWER SPINDLE REMOVAL 1 2 3 4 6 5 7 8 7 8 1. 2. 3. 4. Sheave Ball Bearing Sheave Plastic Idler 5. 6. 7. 8. Compression Spring Ball Bearing Retainer Hub Blade Tray Figure 34 12.3 42" SPINDLE REPAIR With the mower deck removed from the unit, the disassembly of the mower may be done. The spindle should not be repaired. Replace it as an assembly. 1. Remove the right and left side mower spindle cover. 2.
Ariens Company 655 West Ryan Street P.O. Box 157 Brillion, WI 54110-0157 920-756-2141 Fax 920-756-2407 www.ariens.