915 ZOOM EZT & IZT Service Manual Models 915055, 057, 059, 065, 067, 501, 502 00459900 7/05 Printed in USA
TABLE OF CONTENTS above 10,000 only . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29 Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-2 1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Service And Replacement Parts . . . . . . . . . . . . . 1.3 Product Registration. . . . . . . . . . . . . . . . . . . . . . . 1.4 Unauthorized Replacement Parts . . . . . . . . . . . . 1.5 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.
SECTION 1 - INTRODUCTION 1.1 THE MANUAL the warranty. Claims meeting requirements during limited warranty period will be honored. 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. 1.4 UNAUTHORIZED REPLACEMENT PARTS Dealer trained service personnel should use this manual as a supplement to and reminder of the training sessions conducted by the company.
SECTION 2 - SAFETY 2.2 NOTATIONS NOTE: General reference information for proper operation and maintenance practices. 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. IMPORTANT: Specific procedures or information required to prevent damage to unit or attachment. 2.
operate the riding mower safely enough to protect themselves and others from serious injury. • Understand location and function of all controls. • Never allow operation by untrained persons. Only trained adults may operate unit. Training includes being familiar with controls and actual operation. • Disengage PTO, stop unit and engine, set parking brake and remove key before making any inspections, repairs, etc. NEVER operate unit after or during the use of medications, drugs or alcohol. 6.
DO NOT transport machine while engine is running. 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.
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.
SECTION 3 - SPECIFICATIONS Model Number Model 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 Brakes Electrical Starter Battery PTO (Power TakeOff) Fuel Fuel Type Fuel Tank Capacity – gal. (L) Transmission Size and Weight Length – in. (cm) Width – in. (cm) Weight – lbs (kg) Height – in. (cm) Tires Front Tire Size – in. (cm) Rear Tire Size – in.
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 2 1 4 3 5 6 7 14 8 15 1. 2. 3. 4. 5. 6. 7. 8. 9 13 7 Ignition Switch PTO Switch Throttle Lever Seat Steering Levers Parking Brake Fuel Tank Headlights (915067, 055, 057, 059, 501) 12 11 OE0220 10 9. Axle Lock (915067, 055, 057, 059, 501) 10.Mower Lift Pedal 11.Mower Deck 12.Discharge chute 13.Fuel Shut-Off Valve 14.Choke Control (915055, 057, 059, 501, 502) 15.
4.2 MOVING UNIT MANUALLY 1 1 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). 1 2 1. Fuel Cap Models 915065 and 502 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. 2 6. Fill fuel tanks to 2-1/2 in. (6.
4.5 AXLE LOCKS 4.6 REMOVING MOWER DECK (915067, 055, 057, 059, 501) (Figure 5) Remove (Figure 6) NOTE: The unit comes shipped with the front axle in the lockout position. 1. Remove PTO belt from electric clutch (see Replacing PTO Belt). 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: Perform steps 2 and 3 for the right and left sides of unit. 2.
4.7 LEVELING AND ADJUSTING PITCH OF MOWER DECK • TO RAISE the mower deck, turn rear trunnion clockwise several turns. Adjust on a level surface, with the tires inflated to the correct air pressure. • TO LOWER the mower deck, turn rear trunnion counterclockwise several turns. Level Mower Deck 6. Install rear trunnion and rear lift link on mower deck and mower lift. 1. Install adjustment pin in the fourth adjustment hole (Figure 7). 7.
4.9 HYDROSTATIC TRANSMISSION NEUTRAL ADJUSTMENT 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. 1. Shut off engine and engage the parking brake. There are two positions: • Highest Position: Use to disable anti-scalp feature. CAUTION: PREVENT personal injury! ALWAYS MAKE CERTAIN that jack(s) or blocks used are stable, strong and will support the weight of the unit. • Lowest Position: Use for all cutting positions.
• The unit turns to the right or left when both steering levers are pulled back as far rearward as possible. 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).
• Move levers to neutral position. The drive units should be properly adjusted for neutral. • Loosen mounting hardware. Engage the parking brake handle. The brake rod should be positioned to lock the drive. The safety switch should be disengaged. • 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.
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 14.Release the parking brake. Check the engine oil daily prior to use. 15.Return the unit into service. IMPORTANT: Never operate the engine with the oil below the low mark on the dipstick. 5.4 CHECKING ENGINE COOLING IMPORTANT: To prevent severe damage to the engine, proper cooling will need to be maintained. See the Engine Manual for oil specifications and oil filter service instructions. 1. Check the air intake screen on the engine each day. To check oil level: 1.
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.
915055, 057, 059 5. 5 915501, 502 915501, 502 915065, 067 5. 1 1. 2. 2 Rear of Unit 915501, 502 3. 1. Oil Drain Tube 3 2. Oil Drain Valve 3 3. 3. Idler Pulleys 4. Electric Clutch 44. 5.
SECTION 6 - MOWER DECK 6.1 REPLACING PTO BELT 6.2 REPLACING MOWER BLADE Remove (Figure 17) Remove (Figure 18) 1. Lower mower deck to the ground. CAUTION: Mower blades are sharp and can cut you. Wrap the blades or wear gloves, and use extra caution when servicing them 2. Remove belt covers from mower deck. CAUTION: Use care when releasing idler spring tension. Keep body parts well away from idler when performing this operation. 1. Block mower blades to prevent rotation. 2.
Do not change angle of cutting edge or round the corner at the end of mower blade. 2. Sharpen mower blade by removing an equal amount of material from each end of the mower blade. 3. Check mower blade balance by sliding mower blade on an unthreaded bolt. If blade is balanced, it should remain in a horizontal position. If either end of mower blade moves downward, sharpen the heavy end until mower blade is balanced. 4. Install mower blade on unit (see Replacing Mower Blade).
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 HYDRO-GEAR FLUID RECOMMENDATIONS Model EZT 915065, 502 2 2 The fluids used in Hydro-Gear transaxles have been carefully selected, and only equivalent or better products should be used. 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. 1 2 2 7.3 HYDRO-GEAR TRANSMISSION REMOVAL 1.
7.4 REPLACING HYDROSTATIC BELT Remove (Figure 22) 2 1 3 4 8 2 7 5 6 1. Hydrostatic Belt 2. Hydrostatic Transmission Pulley 3. Electric Clutch Connector 4. 5. 6. 7. 8. Pulley Clutch Stop Electric Clutch Idler Idler Spring OE0320 Figure 22 1. Remove PTO belt (see Replacing PTO Belt). 2. Disconnect electric clutch connector. 3. Remove clutch stop. CAUTION: Use care when releasing idler spring tension. Keep body parts well away from idler when performing this operation. 4. Disconnect idler spring. 5.
SECTION 8 - LIFT SYSTEM 8.1 LIFT SYSTEM 2 Refer to Figure 25 for the lift system. The mower pan lift system is a manual lift system controlled by the operator. 1 3 Mower Lift Pedal Raises and lowers mower deck, Figure 23 2 3 1 2 2 1 1. Adjustment Pin 2. Mower Lift Pedal 3. Adjustment Hole 4 Figure 23 1 05304900 NOTE: The adjustment pin is used to set the height of the mower deck. See Specifications for cutting height dimensions.
SECTION 9 - STEERING 9.1 STEERING CONTROLS Serial numbers 10,000 and above: 1. Remove the link to the transmission. Refer to Figure 26 thru Figure 27 for Steering. 2. Remove the handlebar and control arm. The steering controls should remain in the neutral position unless moved by the operator. When in the neutral position the brake rod will lock the transmissions to prevent movement. 3. Unscrew the flange nut that holds the weldment onto the spacer and bearing. 4.
Model IZT 915055, 057, 059, 067, 501 with Serial Numbers Above 10,000 1 2 5 4 2 6 1 3 4 5 7 1. 2. 3. 4. 5. 6. 7. Link Brake Rod Eccentric Weldment Flange Nut Handle Bar Control Arm PE0840 Figure 27 Serial numbers below 10,000: Refer to Figure 28 and Figure 30 for Steering. The steering controls will swing outward when in neutral. In the outward position, each handlebar will contact a switch. The switches must be engaged to start the engine.
Model EZT 915065 and 502 with Serial Numbers Below 10,000 1 3 2 6 4 1 5 3 2 1. 2. 3. 4. 5. 6.
Model IZT 915055, 057, 059, 067, 501 with Serial Numbers Below 10,000 2 7 1 3 2 1 3 6 5 4 1. 2. 3. 4. 5. 6. 7.
9.2 ADJUSTING STEERING LEVER HEIGHT FOR SERIAL NUMBERS ABOVE 10,000 ONLY (Figure 30) 1 2 5 3 4 1. 2. 3. 4. 5. Handlebar Steering Lever Mounting Hardware Adjustment Holes Eccentric Spacer OE0046 Figure 30 NOTE: Perform steps 1 and 2 for both steering levers. 1. Remove mounting hardware and move handlebar up or down until the steering levers are at the appropriate height. 2. Install mounting hardware. NOTE: Align handlebars by adjusting eccentric spacer until the height of handlebars are the same.
SECTION 10 - FUEL SYSTEM 10.
10.2 FUEL PUMP 10.3 FUEL SYSTEM CONTAMINATION 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. Any time fuel contamination is found in the fuel system (dirt, water algae, etc.) replace the fuel, fuel filter and flush the fuel lines. Remove the carburetor bowl and clean.
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.
2. Connect positive (+) cable first, then negative (-) cable. Voltage Measurement 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. 3. Apply petroleum jelly or dielectric grease to battery cable ends and terminals. 4. Tip seat back.
IMPORTANT: ALWAYS follow information provided on battery and battery charger. Contact battery and battery charger manufacturers for detailed instructions. 1. Remove battery from unit (see Battery Removal and Installation). 2. Place battery in a well-ventilated area. 3. Connect positive (+) lead of charger to positive (+) terminal, and negative (-) lead of charger to negative (-) terminal. 4. Charge battery according to battery charger and battery manufacturers’ instructions. 5.
11.5 SOLENOID AND RELAYS Solenoid and relays are both magnetically operated devices. Both devices operate on the principle that passing a current of electricity through a coil of wire will create a magnetic field strong enough to attract a piece of iron or steel. Each device uses this principle in a slightly different manner. 11.6 LIGHTING CIRCUITS Solenoid - A basic solenoid consists of a coil of wire wound around a hollow tube. A magnetic core slides inside the tube.
current to a direct current is called a RECTIFIER. A diode is one type of rectifier. To check a diode, isolate if from the circuit by disconnecting one end. With a multitester set on the lowest ohms scale setting, measure the resistance in one direction, reverse the test leads, and measure in the other direction. Readings should be high in one direction and low in the other. (If the readings are low in both directions, the diode is shorted, and if the readings are high, the diode is open.
For models with serial numbers above 10,000 when the ignition switch is in the run position and with the steering switch in the neutral (engaged), position power is supplied to terminal 86 of the start relay and to terminal 30 of the PTO relay. Engaging the seat switch starts the hour meter and energizes the start relay. The start relay when energized provides a ground to the PTO relay. Now engaging the PTO switch will engage the PTO clutch.
PTO Switch Off Run Brown Start 11.50-13.00 Volts Purple 11.50-13.00 Volts 11.50-13.00 Volts Red/Green 11.50-13.00 Volts 11.50-13.00 Volts Brown/Yellow 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. Neutral Switch Off Run Brown/Yellow Start 11.50-13.00 Volts Red/Green 11.50-13.00 Volts 11.50-13.00 Volts Normally open contacts manually activated. Contact Resistance is 0.1-0.3 ohms when correct.
Starter Solenoid Relay Brown/Yellow 86 Small Black 85 Large Red (Battery) 30 Off Run Start 11.50-13.00 Volts Connected to Ground 11.50-13.00 Volts 11.50-13.00 Volts Brown/White 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 Purple/white Black Connected To Ground Coil Resistance check clutch specifications.
11.11 ELECTRICAL SYSTEM Model 915055, 057, 059, 065, 067, 501, 502 for Serial Numbers above 10,000 2 1 3 6 4 5 1. 2. 3. 4. 5. 6.
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11.13 CONTINUITY DIAGRAM For Serial Numbers Above 10,000 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.
11.14 ELECTRICAL FOR SERIAL NUMBERS ABOVE 5,000 AND BELOW 9,999 switches on the red/green lead. Terminal A also supplies battery voltage to the hour meter. For models with serial numbers between 5,000 and 9,999 with the key switch in the "run" position, the seat switch "on" and the parking brake "off" power is supplied to terminal 86 of the start relay. Terminal 86 will also have power if the key switch is in "run", the PTO switch is "off" and the steering arms are in the "neutral" position.
Diode check out: Diodes are checked with an ohm meter set on the diode check, and should only pass voltage in one direction. If it passes voltage in both directions or not at all the diode is bad and needs to be replaced. . Key Switch B Off 11.50-13.00 Volts A Run Start 11.50-13.00 Volts 11.50-13.00 Volts 11.50-13.00 Volts 11.50-13.00 Volts S 11.50-13.00 Volts L 11.50-13.00 Volts 11.50-13.00 Volts Contact resistance is 0.1-0.3 ohms when correct. Seat Switch Off Run Start Red/Yellow 11.
Start Relay Off Yellow/Red 86 Black 85 Black/White 87 White/Black 87A Black 30 Run Start 11.50-13.00 Volts 11.50-13.00 Volts(A) Connected to Ground 11.50-13.00 Volts Connected to Ignition Module Connected to Ground Pins 85-86 coil resistance 87-100 ohms. pins 30-87 normally open. Pins 30-87A normally closed. Contact resistance is 0.1-0.3 ohms when correct. Starter Solenoid Off Run Start Small Brown/White 11.50-13.00 Volts Small Black Connected to Ground Large Red (Battery) 11.
11.15 ELECTRICAL SYSTEM Model 915055, 057, 059, 065, 067, 501, 502 for Serial Numbers Between 5,000 and 9,999 2 5 1 3 6 4 1. 2. 3. 4. 5. 6.
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11.17 CONTINUITY DIAGRAM For Serial Numbers Between 5,000 and 9,999 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.
11.18 ELECTRICAL FOR SERIAL NUMBERS BELOW 5,000 Safety Interlock System For models with serial numbers below 5,000 with the key switch is in the "run" position, the seat switch "on" and the parking brake "off" power is supplied to terminal 86 of the start relay. 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.
. Key Switch B Off Run 11.50-13.00 Volts A Start 11.50-13.00 Volts 11.50-13.00 Volts 11.50-13.00 Volts 11.50-13.00 Volts S 11.50-13.00 Volts L 11.50-13.00 Volts 11.50-13.00 Volts Contact resistance is 0.1-0.3 ohms when correct. Seat Switch Off Run Start Red/Yellow 11.50-13.00 Volts 11.50-13.00 Volts Purple 11.50-13.00 Volts 11.50-13.00 Volts Normally open contacts manually activated. contact resistance is 0.1-0.3 ohms when correct. PTO Switch Off Run Start Brown 11.50-13.
Start Relay Off Run Start Yellow/Red 86 11.50-13.00 Volts 11.50-13.00 Volts Black 85 Connected to Ground Black/White 87 11.50-13.00 Volts White/Black 87A Black 30 Connected to Ignition Module Connected to Ground Pins 85-86 coil resistance 87-100 ohms. pins 30-87 normally open. Pins 30-87A normally closed. Contact resistance is 0.1-0.3 ohms when correct. Starter Solenoid Off Run Start Small Brown/White 11.50-13.00 Volts Small Black Connected to Ground Large Red (Battery) 11.
11.19 ELECTRICAL SYSTEM Model 915055, 057, 059, 065, 067, 501, 502 for Serial Numbers Below 5,000 2 5 1 3 5 4 1. 2. 3. 4. 5. Relay Clutch Switch Key Switch Switch NO Switch Double Pole N.O./N.O.
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11.21 CONTINUITY DIAGRAM Model 915055, 057, 059, 065, 067, 501, 5025 for Serial Numbers Below 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 MOWER SPINDLE REMOVAL 3 2 4 1 1. 2. 3. 4. Spindle Assembly Idler Arm Idler - Flanged Idler - Flat PE0550 Figure 36 The spindles are assemblies that are replaced when worn. To remove the spindle assemblies: 1. With the mower deck removed from the unit the disassembly of the mower may be performed. 2. Remove the mower spindle covers. 3. Remove the mower deck blades. 4. Reduce belt tension on the belt by removing the idler pulley spring. 5.
TROUBLESHOOTING PROBLEM Engine will not crank/ start Engine runs rough Unit does not move with engine running when using steering levers PROBABLE CAUSE CORRECTION 1. Safety interlock system is not engaged or is faulty. 1. Check safety interlock system (see Safety Interlock System). 2. Fuel tanks empty. 2. Fill fuel tanks (see fIlling Fuel Tanks) 3. Fuel shut-off valve closed. 3. Open fuel shut-off valve. 4. Discharged battery. 4. Charge battery (see Charging the Battery). 5.
TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION Unit moves with engine off and parking brake engaged 1. The parking brake needs adjustment. 1. Contact your Ariens Dealer. 2. Faulty parking brake. 2. Contact your Ariens Dealer. Hour meter continues to run when engine is not running 1. Ignition key is in the run position with engine turned off. 1. Turn ignition key to the off position. Unit does not travel in a straight line 1. Incorrect tire pressure. 1.
SERVICE PARTS ACCESSORIES BE SURE TO ALWAYS USE GENUINE ARIENS PARTS TO KEEP YOUR UNIT RUNNING LIKE NEW SEE YOUR AUTHORIZED ARIENS DEALER TO ADD THESE OPTIONAL ACCESSOREIS TO YOUR UNIT. PART NO. QTY DESCRIPTION 03498400 1 40-inch Mower Blade (915065, 067) 00272800 1 44-inch Mower Blade (915502) 01593900 1 44-inch Mower Blade (915055) 00272900 1 44-inch Mower Blade (915501) PART NO.
Ariens Company 655 West Ryan Street P.O. Box 157 Brillion, WI 54110-0157 920-756-2141 Fax 920-756-2407 www.ariens.
