Zoom Service Manual Ariens Models 915035, 037, 039, 041, 313, 501 Gravely Models 915034, 036, 038, 040 00173200 09/03 Printed in USA
TABLE OF CONTENTS Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-2 6.3 Sharpening Mower Blade. . . . . . . . . . . . . . . . . . 6-20 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 Zoom. 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 Ariens Models Model Number Description Engine 915035 915037 1640 1844 Single Cylinder Engine Power - HP (kW) @ governed RPM Max Governed RPM Fuel Tank Capacity - gal. (L) Starter Transmission Speed: Forward Max. - mph (km/h) 915039 2048 Briggs & Stratton 16 (11.9) 18 (13.4) 915041 915501 915313 2252 1844 2252 Twin Cylinder Briggs & Stratton 20 (14.9) 22 (16.4) 18 (12.8) 22 (13.5) 2900 3100 44 (112) 52 (132) 3400 8 (30.28) Electric Hydrostatic 6.5 (10.5) Reverse Max.
Gravely Models Model Number Description Engine Engine Power - HP (kW) @ governed RPM Max Governed RPM Fuel Tank Capacity - gal. (L) Starter Transmission Speed: Forward Max. - mph (km/h) 915034 915036 ZT1640 ZT1844 Single Cylinder 915038 915040 ZT2048 ZT2252 Twin Cylinder Briggs & Stratton Briggs & Stratton 16 (11.9) 18 (13.4) 20 (14.9) 22 (16.4) 3400 8 (30.28) Electric Hydrostatic 6.5 (10.5) Reverse Max. - mph (km/h) PTO Battery Brakes Cutting Height - in. (cm) Cutting Width - in.
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 1 2 3 4 5 13 6 7 8 6 9 12 10 11 1. 2. 3. 4. 5. 6. 7. 8. Ignition Switch PTO Switch Throttle Lever Choke Control (915038, 039, 040, 041, 313, 501) Seat Steering Lever Parking Brake Fuel Tank 9. Axle Lock 10. Mower Lift Pedal 11. Mower Deck 12. Discharge Chute 13.
4.2 FUEL LEVEL Safety Interlock System WARNING: Safety interlock failure and improper operation of unit can result in death or serious injury. Check system before each use to make sure it is functioning properly. Fuel Shut-Off Valve 3 1 OFF LEFT TANK RIGHT TANK Perform the following tests to ensure the safety interlock system is working properly. If the unit does not perform as stated contact your Ariens/Gravely dealer for repairs.
IMPORTANT: Proper maintenance can prolong the life of unit. The following chart shows the recommended service schedule. Refer to the maintenance instructions in the Engine Manual for additional information. 1 7 NOTE: To access the cooling system, fuel filter, oil drain petcock, and oil fill/dipstick, the seat must be tipped forward. 2 NOTE: To access the air filter, open the hood. 6 3 NOTE: Use Figure 4 to locate items called out in the maintenance schedule. 4 5 1. Cooling System 4. Oil Filter 2.
Interval Task Action Change Engine OIl2 Drain engine oil by opening oil drain petcock. Refer to Engine Manual for detailed instructions. Check Fasteners Check mower blade mounting hardware and all other fasteners. Replace fasteners that are missing or damaged. Tighten all nuts and bolts to the correct torque value. Inspect Muffler and Spark Arrestor Replace muffler and (if equipped) spark arrestor if corroded. Contact your Ariens/Gravely Dealer.
4.4 REMOVE MOWER DECK 1 Remove (Figure 5) 2 3 1. Remove PTO belt from electric clutch. NOTE: Perform step 2 and 3 for the right and left side 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 5) 1. Slide mower deck under unit. NOTE: Perform step 2 and 3 for the right and left side of unit. 1. Adjustment Pin 2. Mower LIft Pedal 2.
b. 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. Adjust Pitch of Mower Deck To adjust the neutral setting for no wheel rotation: 4. Use a hex wrench to loosen the locking bolt (Figure 8) until the linkage can be rotated by hand. 5.
6. Move top jam nuts down to tighten on the nyloc jam nut. Tighten the jam nuts against each other. 7. Return to step one and repeat until the unit tracks straight. 2 1 3 6 2 1 3 5 4 1. Rod Transaxle 2. Switch 3. Jam Nuts 4. Nyloc Jam Nut 5. Handlebar 6. Dampener Figure 9 4.8 STEERING LEVER ADJUSTMENTS Adjusting Steering Levers to Match (Figure 10) NOTE: Each steering lever can be positioned further forward or further backward. 1. Loosen mounting hardware. 2. Position steering levers to match. 3.
1 4 2 3 1 2 High Position Low Position 2 1 1. Steering Lever 2. Mounting Hardware 1. Nyloc Adjusting Nut 2. Parking Brake Rod Figure 10 4.9 ADJUSTING THE PARKING BRAKE 3. Handle 4. Safety Switch PE0831 When properly adjusted the parking brake will lock the linkage on both drives and activate the safety switch (Figure 11). The drive units should be properly adjusted for neutral. Engage the parking brake handle. The brake rod should be positioned to lock the drive.
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. 5.4 CHECKING ENGINE COOLING To check oil level: 1. Move the unit to level location. 2.
5.10 ENGINE INSTALLATION 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. 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.
SECTION 6 - MOWER DECK 2 CAUTION: Before performing any service or adjustments: 3 4 6 5 1 • Turn PTO switch "OFF". • Park mower on a hard, flat, level surface. • Place steering control levers in neutral lock (fully outward) position. • Set parking brake. • Turn ignition switch "OFF" and remove key. • 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. 7 1. 2. 3. 4. 5. Idler Pulley 6. Idler Arm 7.
2 1 DO NOT Sharpen to this Pattern 4 Sharpen to this Pattern 3 1. Flat Washer 2. Bevel Washer DISCARD if more than 1/2 in. (1.27 cm) 3. 5/8" Hex Bolt 4. Mower Blade Figure 14 OE0039 1 6.3 SHARPENING MOWER BLADE 1. Air Lift Erosion Area 2. Cutting Edge CAUTION: DO NOT sharpen mower blade while on unit. An unbalanced mower blade will cause excessive vibration and eventual damage to unit. Check mower blade balance prior to reinstalling mower blades. NEVER weld or straighten mower blades.
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.
7.2 HYDROSTATIC BELT REPLACEMENT Remove (Figure 16) 7.3 HYDRO-GEAR FLUID RECOMMENDATIONS The fluids used in Hydro-Gear transaxles have been carefully selected, and only equivalent or better products should be used. 1 9 Typically, an engine oil with a minimum rating of 55 sus at 210oF and an API classification of SH/CD is recommended. A 20W-50 engine oil has been selected for use by the factory. 2 8 3 4 7.4 HYDRO-GEAR TRANSMISSION REMOVAL 2 5 6 7 1.
7.6 ELECTRIC CLUTCH ADJUSTMENT WARNING: The mower blades MUST STOP in 5 seconds or less when the PTO is disengaged. Adjust or replace electric clutch as required. 3 Test Mower Blade Stopping Time (Figure 18) 1 2 2 1 4 1. Transaxle, Right Hand 3. Dump Rod 2. Transaxle, Left Hand 4. Axle Brace 1. Electric Clutch 2.
Adjust Electric Clutch (Figure 19) Test Electric Clutch 1. Start unit, engage and disengage PTO two or three times. 2 1 2. Stop engine, set parking brake, remove ignition key, and wait for all hot parts to cool. 3. Recheck air gap between armature and rotor. Adjust air gap if needed. 4. Retest mower blade stopping time: 3 6 4 5 1. Armature 2. Inspection Slot 3. Gap Adjustment Nut 3 • If mower blades stop in 5 seconds or less, the electric clutch is functioning correctly.
SECTION 8 - LIFT SYSTEM 8.1 LIFT SYSTEM Refer to Figure 20. The mower pan lift system is a manual lift system controlled by the operator. 3 1 3 2 1. Foot Pedal Lift 2. Lift Assembly 3. Linkage Figure 20 PE0910 Lower deck onto blocks to remove weight from lift system. Check snap rings, bushings, and cotter pins for wear. Replace worn and defective parts as needed.
SECTION 9 - FUEL SYSTEM 9.
9.2 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 10 - ELECTRICAL 10.1 TOOLS 10.2 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.
NOTE: Unit comes equipped with a maintenance-free battery that requires no regular maintenance except cleaning the terminals. 1 WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 2 Clean Battery Corrosion and dirt on the battery and terminals can cause the battery to "leak" power. 3 6 4 • Remove battery.
room temperature and the charging time can be estimated. For example: 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. OCV Specific Gravity % of Charge Charging Time ALWAYS follow information provided on battery by battery manufacturer. Contact battery manufacturer for extensive instructions to charge battery. 12.60 1.265 100% --- 12.4 1.
10.4 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 (Continuity Diagram) 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 four positions: OFF, RUN, RUN/LIGHT 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, L and M.
a service center has access to the information and parts required to test and repair or replace engine components, including rectifiers and regulators.) If the fuse and lamps are good, check the circuit with an AC/DC voltmeter. 10.7 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.
terminal (B) to terminal (A). Terminal (A) on the ignition switch supplies battery voltage to the back of the PTO switch on the purple lead and on to the neutral switches on the red/violet lead to terminal S2 on the ignition switch and to terminal 85 on solenoid #2. Terminal (A) also supplies battery voltage to terminal 30 and 85 on solenoid #1 and on to the hour meter.
10.11 WIRING DIAGRAMS Off RED / GREEN PTO SWITCH 7 PURPLE / WHITE A 1 PURPLE PTO CLUTCH B 4 SEAT SWITCH BLACK 1 2 RED / YELLOW + BROWN - 9 3 BROWN HOUR METER 1 5 5 4 4 3 3 1 1 2 2 6 6 FUEL SOLENIOD PARKING BRAKE SWITCH 2 YELLOW / RED START RELAY REGULATOR ENGINE MAGNETO KILL BLACK WHITE / BLACK 87 86 87a 85 30 BLACK /WHITE STARTER PURPLE G B BLACK B 1 4 2 B BROWN / YELLOW M G BATTERY Y LT.
Operator Off Seat, Start, PTO Off RED / GREEN PTO SWITCH 7 PURPLE / WHITE A 1 PURPLE PTO CLUTCH B 4 SEAT SWITCH BLACK 1 2 RED / YELLOW + BROWN - 9 3 BROWN HOUR METER 1 5 5 4 4 3 3 1 1 2 2 6 6 FUEL SOLENIOD PARKING BRAKE SWITCH 2 YELLOW / RED START RELAY REGULATOR ENGINE MAGNETO KILL BLACK WHITE / BLACK 87 86 87a 85 30 BLACK /WHITE STARTER PURPLE G B BLACK B 1 4 2 B BROWN / YELLOW M G BATTERY Y LT.
Operator Off Seat, Run, PTO Off RED / GREEN PTO SWITCH 7 PURPLE / WHITE A 1 PURPLE PTO CLUTCH B 4 SEAT SWITCH BLACK 1 2 RED / YELLOW + BROWN - 9 3 BROWN HOUR METER 1 5 5 4 4 3 3 1 1 2 2 6 6 FUEL SOLENIOD PARKING BRAKE SWITCH 2 YELLOW / RED START RELAY REGULATOR ENGINE MAGNETO KILL BLACK WHITE / BLACK 87 86 87a 85 30 BLACK /WHITE STARTER PURPLE G B BLACK B 1 4 2 B BROWN / YELLOW M G BATTERY Y LT.
Operator On Seat, Run, PTO On, Driving RED / GREEN PTO SWITCH 7 PURPLE / WHITE A 1 PURPLE PTO CLUTCH B 4 SEAT SWITCH BLACK 1 2 RED / YELLOW + BROWN - 9 3 BROWN HOUR METER 1 5 5 4 4 3 3 1 1 2 2 6 6 FUEL SOLENIOD PARKING BRAKE SWITCH 2 YELLOW / RED START RELAY REGULATOR ENGINE MAGNETO KILL BLACK WHITE / BLACK 87 86 87a 85 30 BLACK /WHITE STARTER PURPLE G B BLACK B 1 4 2 B BROWN / YELLOW M G BATTERY Y LT.
10.12 CONTINUITY DIAGRAM 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.
10.13 ELECTRICAL SYSTEM 1 3 2 4 7 5 6 8 9 To Starter 1. Clutch Switch 6. Switch N.O. 2. Relay 7. Interlock Switch N.C. 3. Double Pole Switch N.O./N.O. 8. Diode 4. 25 Amp Fuse 9. Solenoid 5.
SECTION 11 - MOWER ATTACHMENT 11.1 MOWER SPINDLE REMOVAL 1 2 3 4 1. 2. 3. 4. Spindle Cover Idler Arm Spindle Assembly Hub Figure 23 1. Remove the mower deck from the unit for disassembly of the mower. 6. Remove the mower spindle housings from the mower deck stamping. 2. Remove the mower spindle covers. 7. Assemble in reverse order. 3. Remove the mower deck blades, retainer hub, spindle key and bearing slinger. Spindle Repair Spindles should be replaced as a unit. 4.
Ariens Company 655 West Ryan Street P.O. Box 157 Brillion, WI 54110-0157 920-756-2141 Fax 920-756-2407 www.ariens.
