Zoom/HVZ Service Manual Model 915085 - 2350 ENGLISH 00652100 2/07 Printed in USA
TABLE OF CONTENTS Section 1 - Introduction. . . . . . . . . . . . . . . . . . . 1-2 6.2 Sharpening Mower Blade. . . . . . . . . . . . . . . . . . 6-20 6.3 Replacing the PTO Belt . . . . . . . . . . . . . . . . . . . 6-21 1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2 Model and Serial Numbers. . . . . . . . . . . . . . . . . . 1-2 1.3 Product Registration. . . . . . . . . . . . . . . . . . . . . . . 1-2 1.4 Unauthorized Replacement Parts . . . . . . . . . . . . 1-2 1.
SECTION 1 - INTRODUCTION 1.1 THE MANUAL Before operation of unit, carefully and completely read your manuals. The contents will provide you will an understanding of safety instructions and controls during normal operation and maintenance. All reference to left, right, front, or rear are given from operator seated in operation position and facing the direction of forward travel. 1.
SECTION 2 - SAFETY 2.4 SAFETY RULES 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-of-control 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.
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. 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. Start and operate unit only when sealed in operator’s position.
NEVER fill fuel tank when engine is running or hot from operation. of charger to positive (+) terminal, and negative (-) lead to negative (-) terminal. NEVER fill or drain fuel tank indoors. ALWAYS disconnect negative (-) cable FIRST and positive (+) cable SECOND. ALWAYS connect positive (+) cable FIRST, and negative (-) cable SECOND. NEVER overfill fuel tank. Replace fuel cap securely and clean up spilled fuel. A frozen battery can explode and result in death or serious injury.
SECTION 3 - SPECIFICATIONS Model Number 915085 Model 2350 Engine Type Kohler Engine Power – hp (kW) at Maximum RPM 23 (17.1) Governed RPM (May be different from maximum RPM) 3350 Speed Forward Max. – m.p.h (km/h) 6.0 (9.6) Reverse Max. – m.p.h (km/h) 3 (4.8) Turning Radius Zero Brakes Internal Transmission Electrical Starter Electric Battery 12 Volt Maintenance Free PTO (Power Take-Off) Electric Clutch/Brake Fuel Fuel Type Refer to Engine Manual Fuel Tank Capacity – gal. (L) 3.
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES 3 2 4 5 6 8 1 11 10 9 7 1. Ignition Switch 7. Parking Brake 2. PTO Switch 8. Fuel Tank 3. Choke Lever 9. Mower Lift Pedal 4. Throttle Lever 10.Mower Deck 5. Seat 11.Discharge Chute OE0 6.
4.2 MOVING UNIT MANUALLY 3. Check all parts for wear and damage. WARNING: DO NOT disengage or bypass transmission and coast downhill 4. Every 25 hours apply motor oil to all pin connections, pivots points and areas where sliding occurs. Disengage (1) transmission bypass levers to drive unit and engage (2) transmission bypass levers to push unit manually (Figure 3). CAUTION: Before performing any service or adjustments: 1 • Turn PTO switch "OFF". • Park mower on a hard, flat, level surface.
4.6 LEVELING AND ADJUSTING PITCH OF MOWER DECK (Figure 6): NOTE: Adjust on a level surface, with the tires inflated to the correct air pressure (see Specifications). There are three measurements required to level and adjust the pitch of the mower deck. • Should be 0.0 in. (0.0 mm) to 1/4 in. (6.35 mm) pitched forward. NOTE: This measurement must be taken when the mower blades ends are facing forward. 1. The distance from the mower blades to the ground. Forward Pitch of Mower Blades 2.
4.7 HYDROSTATIC TRANSMISSION NEUTRAL ADJUSTMENT Adjusting The Mower Deck To Adjust Mower Blade Height And Pitch (Figure 8): If the mower blade height and pitch cannot be adjusted to the measurements indicates, it will be necessary to adjust the position of the mower deck. CAUTION: PREVENT personal injury! ALWAYS MAKE CERTAIN that jack(s) or blocks used are stable, strong and will support the weight of the unit.
until the wheel stops turning. The transmission is now in neutral (wheel is not under power). 5 10.Hold the linkage (5) in place and tighten the locking bolt (4). 11.Repeat for each side as necessary. 12.Shut off engine. 13.Reinstall the steering rod (2) and carefully reconnect wireform link (3), making sure transmission and handles stay in neutral position. Adjust trunnion or wireform link as necessary. 14.Reconnect parking brake links (7, Figure 12). 4.
Install bolts here for pivoting front axle Install bolts here for non-pivoting front axle DC7883.
4.10 ADJUSTING THE PARKING BRAKE 1 2 7 3 6 4 1. 2. 3. 4. 5. 6. 7. Brake Link Neutral Latch Switch Brake Adjustment Nut Brake Link Brake Lever Hair Pin 5 PE1261 Figure 12 When properly adjusted the parking brake will lock the linkage on both drives and activate the safety switch (Figure 13). The drive units should be properly adjusted for neutral. To adjust for neutral: 1. Engage the parking brake handle. The brake rod should be positioned to lock the drive. The safety switch should be disengaged.
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.
ENGINE TROUBLESHOOTING PROBLEM Erratic Running (cont.
ENGINE TROUBLESHOOTING PROBLEM Misfiring Overheating Poor Compression Starts and Stops Vibration Will Not Crank Will Not Start PROBABLE CAUSE CORRECTION Choked fuel filter Remove obstruction Poor compression Repair per instructions in manufacturer’s manual Leaking cylinder head gasket Replace per instructions in manufacturer’s manual Overheating Allow to cool; determine cause Incorrect tappet adjustment Adjust per instructions in manufacturer’s manual Sticking valves Repair per instructi
5.2 CHECKING ENGINE OIL Past Production Drain valve. Press in and rotate CCW to drain or CW to close Check the engine oil 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. 5.3 CHANGING OIL Current Production Drain plug WARNING: DO NOT touch parts which are hot. Allow parts to cool before servicing. Engine muffler and other parts will be hot if unit has been running.
5.9 ENGINE REMOVAL 5.10 ENGINE INSTALLATION See Figure 15 for this procedure. 1. Check the engine base and unit frame for damage before installing the engine. 1. Remove the battery cable from the negative battery terminal (12). 2. Remove the mower belt (4) from the electric clutch (5) by releasing the idler tension spring (6). 3. Remove the transmission drive belt (14) from the engine sheave by releasing the tension spring from the right side of the transmission idler arm. 2.
1. Engine 2. Engine Mounting Bolt (4 places) 3. Sheave 4. Drive Belt 5. Electric Clutch 6. Spring 7. Idler Arm 8. Idler Sheave 9. Muffler 10.Gas Line 11.Battery 12.Negative Terminal 13.Positive Terminal 14.Transmission Belt 15.Spring 16.
SECTION 6 - MOWER DECK 6.1 REPLACING MOWER BLADE 1. Remove mower blade from unit (see Replacing Mower Blade). Remove (Figure 16) Ariens recommends having mower blades sharpened by a professional. Contact your Ariens dealer. Discard mower blade if (Figure 17): CAUTION: Mower blades are sharp and can cut you. Wrap the blades or wear gloves, and use extra caution when servicing them. • More than 1/2 in. (1.27 cm) of metal is removed. • The air lift erosion area is eroded.
6.3 REPLACING THE PTO BELT 5. Slowly release idler arm (5) until tension is removed from idler spring (1). Remove (Figure 18) 1. Lower mower deck to the ground. Install 2. Remove belt covers (6) from mower deck NOTE: Do not install PTO belt on left mower deck pulley in step 1. 1. Install PTO belt (3) on electric clutch (2) and mower deck. CAUTION: Use care when releasing idler spring tension. Keep body parts well away from idler when performing this operation. 2.
SECTION 7 - DRIVE TRAIN 7.1 PRINCIPLES OF OPERATION The hydro transmission is a self contained unit designed for the transfer and control of power. It provides an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation. See the manufacturer’s manual for a hydraulic schematic. This transaxle uses a variable displacement pump with a maximum displacement of 10cc per revolution, and motor with a fixed displacement of 10cc per revolution.
TRANSMISSION TROUBLESHOOTING Problem Operates hot Leaks oil No or low power Axles Will Not Turn Erratic Running Jerky when starting Possible Cause Corrective Action Debris buildup around transaxle and cooling fins Clean off debris Cooling fan damaged Repair or replace cooling fan Oil level low Fill to proper level Contaminated oil Change oil Excessive loading Reduce loading Air trapped in hydraulic system Purge hydraulic system Damaged or worn hoses or lines Replace damaged hoses or lin
TRANSMISSION TROUBLESHOOTING Problem Knocking Possible Cause Corrective Action Control linkage bent or out of adjustment Repair or replace linkage Oil level low Fill to proper level Contaminated or incorrect oil Change oil Air trapped in hydraulic system Purge hydraulic system Bypass assembly sticking Repair or replace bypass Metallic pieces or foreign objects in unit Repair or replace transmission Loose parts Repair or replace loose parts 7.3 HYDRO-GEAR FLUID RECOMMENDATIONS 6.
7.7 HYDRO-GEAR TRANSMISSION REMOVAL 8. At the end of each steering link, remove the hairpin and pull the links away from the transmission. See Figure 19 for procedure. 9. Remove the dump valve rod (1) from the transmission. 1. Place the unit on a flat surface. Do not remove or loosen the hardware on the transaxle sub-frame at this point. Remove the negative lead from the battery and the spark plug lead from the spark plug. 10.Support the transaxles with a floor jack from the rear of the unit. 2.
7.8 REPLACING HYDROSTATIC BELT 3 5 Remove (Figure 20) 1. Remove PTO belt (see Replacing the PTO Belt). 2. Disconnect electric clutch connector from PTO. CAUTION: Use care when releasing idler spring tension. Keep body parts well away from idler when performing this operation. 2 3. Disconnect idler spring (4). 4. Remove hydrostatic belt (1) from hydrostatic transmission pulleys (2), pulley (5), electric clutch, and idler (3). 4 Install 1 1 4 1.
SECTION 8 - LIFT SYSTEM 8.1 LIFT SYSTEM The mower pan lift system is a manual lift system controlled by the operator. OE0090 Mower Lift Pedal Figure 22 Raises and lowers mower deck, Figure 21. Press mower lift pedal (1) and install adjustment pin (3) in the desired adjustment hole (2). 8.2 LIFT SYSTEM REMOVAL See Figure 23 Remove the mower deck from the unit before removing the lift system. 3 The lift system is held in place with retaining rings and a nyloc nut.
SECTION 9 - STEERING 9.2 ADJUSTING STEERING LEVERS 9.1 STEERING CONTROLS Adjusting Steering Lever Height (Figure 24) Refer to Figure 24 for Steering. 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 transmission to prevent movement. 5 1 2 When the handlebars are moved the link will shift the transmissions into forward or reverse. The steering mechanism can be taken apart for inspection and lubrication.
SECTION 10 - FUEL SYSTEM 10.1 FUEL SYSTEM TROUBLESHOOTING The following troubleshooting chart is to be used to isolate fuel system problems and give possible causes are corrective action responses The possible causes are generic and can be used for several types of fuel systems. Use only those possible causes and corrective actions that apply to the unit.
FUEL SYSTEM TROUBLESHOOTING Problem Will Not Accelerate Over Rich Acceleration Hesitates Will Not Run at High Speed Low Power Hunts at High Speed Runs With Needle Closed Engine Overspeeds Possible Cause Corrective Action Plugged air filter Clean or replace air filter Air bleed restricted Remove obstruction Plugged tank or vent Remove obstruction Fuel pickup restricted Remove obstruction Damaged adjustment needle and seat Replace needle and seat Incorrect float height Adjust float Main no
10.2 FUEL PUMP 10.4 FUEL TANK 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. The fuel tank is made of composite material for long life without breaking down from the additive used in today’s blended fuels.
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 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. Current Measurement 2. Connect positive (+) cable first, then negative (-) cable. 3. Apply petroleum jelly or dielectric grease to battery cable ends and terminals. 4. Tip seat back.
• In case of internal contact, DO NOT induce vomiting! Normally Open Switch IMPORTANT: DO NOT fast charge. Charging at a higher rate will damage or destroy battery. 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.
L and S. These connections apply power to close the solenoid contacts and operate the starter motor. In addition to the above test, place the switch in the run position and check between each contact and ground (metal case) to be sure no terminals are grounded. If the switch is operating properly, there will be no continuity between contacts other that those described. 11.5 SOLENOID AND RELAYS Solenoid and relays are both magnetically operated devices.
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).
11.10 ENGINE ELECTRICAL COMPONENTS STEP 3 Engine servicing and repair should be referred to local engine manufactures service centers that have the service information and parts available to properly service the engine. Ariens dealers should be able to test engines and engine components to pinpoint troubles and narrow them down to properly advise the engine serviceman. 11.11 ZOOM/HVZ ELECTRICAL See Figure 31 - Figure 36 for wiring and circuit diagrams.
Key Switch Off B 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 Connected to Ground through Start Relay 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.
Solenoid Off Run Brown/Yellow Start 11.50-13.00 Volts Small Black Connected to Ground Large Red (Battery) 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 Start Purple/white Black Connected To Ground Coil Resistance 3.28 - 4.08 ohms. Parking Brake Switch Off Run Start Red/Green 11.50-13.
11.
Activate Start Relay (On Seat) Circuit PE1290 PE1290 Figure 32 11 - 41
Activate Start Relay (Off Seat) Circuit PE1290 PE1290 Figure 33 11 - 42
Activate PTO CLutch and PTO Relay Circuit PE1290 PE1290 Figure 34 11 - 43
Cranking Circuit PE1290 PE1290 Figure 35 11 - 44
Engine Kill Circuit PE1290 PE1290 Figure 36 11 - 45
11.13 ELECTRICAL SYSTEM 1 2 3 4 5 6 1. Clutch Switch 2. Relay 3. Switch Double Pole N.O./N.O. 4. Key Switch 5. Switch N.O. 6.
11.
SECTION 12 - MOWER ATTACHMENT 12.1 MOWER SPINDLE REMOVAL 50" DECK 1 2 3 6 4 4 5 1. 2. 3. 4. 5. 6. Idler Idler Arm Spindle Sheave Spindle Assembly Mower Blade Spindle Cover PE0870 Figure 38 See Figure 38 for this procedure. The spindles (4) are assemblies that are replaced as a unit when worn. To remove the spindle assemblies: 4. Reduce belt tension on the belt by removing the idler pulley spring. 5. Remove the spindle sheaves (3) and square key. 1.
SECTION 13 - TROUBLESHOOTING TROUBLESHOOTING PROBLEM Engine will not crank/ start Engine runs rough Unit does not move with engine running when using steering levers PTO or mower blades do not engage or shuts off. 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 The Fuel Tank) 3. Fuel shut-off valve closed. 3. Open fuel shut-off valve. 4.
TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTION 1. Engine oil level low. 1. Add engine oil. Refer to Engine Manual for detailed instructions. 2. Cooling system plugged. 2. Clean cooling system. Refer to Engine Manual for detailed instructions. 3. Faulty engine. 3. Contact your Ariens Dealer. 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.
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 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.
