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TABLE OF CONTENTS
Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-3
Section 5 - Engine. . . . . . . . . . . . . . . . . . . . . . 5-16
5.1 Engine Troubleshooting . . . . . . . . . . . . . . 5-16
5.2 Removing the Engine. . . . . . . . . . . . . . . . 5-17
5.3 Installing The Engine . . . . . . . . . . . . . . . . 5-17
5.4 Electric Clutch . . . . . . . . . . . . . . . . . . . . . 5-17
1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Service and Replacement Parts . . . . . . . . 1-3
1.3 Product Registration . . . . . . . . . . . . . . . . . 1-3
1.4 Unauthorized Replacement Parts . . . . . . . 1-3
1.5 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Technical Service Communications. . . . . . 1-3
1.7 Preparation . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Section 6 - Drive Train . . . . . . . . . . . . . . . . . . 6-18
6.1 Checking The Hydraulic Fluid Level. . . . . 6-18
6.2 Changing Hydraulic Fluid And Filter . . . . 6-18
6.3 Hydraulic Drive Flow Test. . . . . . . . . . . . . 6-18
6.4 Replacing The Hydraulic Pump . . . . . . . . 6-19
6.5 Replace Wheel Motor . . . . . . . . . . . . . . . 6-20
6.6 Hydraulic Deck Lift Pressure Test . . . . . . 6-21
6.7 Replace Lift Valve . . . . . . . . . . . . . . . . . . 6-21
6.8 Hydraulic Diagram . . . . . . . . . . . . . . . . . . 6-22
Section 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Signal Words . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Practices and Laws . . . . . . . . . . . . . . . . . . 2-4
2.5 Required Operator Training . . . . . . . . . . . . 2-4
2.6 Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . 2-4
Section 7 - Mower Deck . . . . . . . . . . . . . . . . . 7-23
7.1 Mower Deck . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.2 Anti-Scalp Rollers . . . . . . . . . . . . . . . . . . 7-23
Section 3 - Specifications . . . . . . . . . . . . . . . . 3-7
Section 4 - General Maintenance
& Adjustments . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.1 Controls and Features . . . . . . . . . . . . . . . . 4-8
4.2 Service Position - 260Z . . . . . . . . . . . . . . . 4-9
4.3 Service Position - 250Z . . . . . . . . . . . . . . . 4-9
4.4 Moving the Unit-Engine Not Running. . . . . 4-9
4.5 Cleaning and Storage . . . . . . . . . . . . . . . . 4-9
4.6 Filling The Fuel Tank . . . . . . . . . . . . . . . . 4-10
4.7 Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.8 General Lubrication . . . . . . . . . . . . . . . . . 4-10
4.9 Basic Engine Maintenance . . . . . . . . . . . 4-11
4.10 Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.11 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.12 Mower Blades . . . . . . . . . . . . . . . . . . . . 4-12
4.13 Steering Control Neutral Adjustment . . . 4-13
4.14 Adjusting Control Levers . . . . . . . . . . . . 4-13
4.15 Adjusting The Parking Brake . . . . . . . . . 4-14
4.16 Adjusting The Unit To Track Straight . . . 4-14
4.17 Leveling The Mower Deck . . . . . . . . . . . 4-15
Section 8 - Front Suspension . . . . . . . . . . . . 8-24
Section 9 - Electrical. . . . . . . . . . . . . . . . . . . . 9-25
9.1 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.2 Electrical Measurements . . . . . . . . . . . . . 9-25
9.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.4 Switches. . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.5 Solenoid and Relays . . . . . . . . . . . . . . . . 9-29
9.6 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.7 Diodes and Rectifiers. . . . . . . . . . . . . . . . 9-30
9.8 Wiring Diagrams . . . . . . . . . . . . . . . . . . . 9-31
2
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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 Promaster 260Z and 250Z.
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.
Dealer trained service personnel should use this
manual as a supplement to and reminder of the training
sessions conducted by the company.
1.4 UNAUTHORIZED REPLACEMENT
PARTS
Use only Gravely replacement parts. The replacement
of any part on this vehicle with anything other than a
Gravely authorized replacement part may adversely
affect the performance, durability, or safety of this unit
and may void the warranty. Gravely disclaims liability
for any claims or damages, whether warranty, property
damage, personal injury, or death arising out of the use
of unauthorized replacement parts.
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.
1.5 DISCLAIMER
Gravely 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.
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.
1.6 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:
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.
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
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.
1.7 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.
Figure 1
1 - 3
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To reduce the incidence of misplaced tools or parts,
place removed components with all attaching hardware
in the disassembly order on a clean work surface.
Organization is a key part of proper reassembly.
Tools, instruments, and parts needed for the job should
be gathered before work is started. Interrupting a job to
locate tools or parts is a needless delay.
SECTION 2 - SAFETY
2.1 SAFETY ALERTS
2.5 REQUIRED OPERATOR TRAINING
Look for these symbols to point out
important safety precautions. They
mean:
Original purchaser of this unit was instructed by the
seller on safe and proper operation. If unit is to be used
by someone other than original purchaser; loaned,
rented or sold, ALWAYS provide the Operator’s Manual
and any needed safety training before operation.
Attention!
Personal Safety Is Involved!
Become Alert!
2.6 SAFETY RULES
Walk Around Inspection
Obey The Message!
Complete a walk around inspection of unit and work
area to understand:
2.2 SIGNAL WORDS
The safety alert symbol is used in decals on the unit
and with proper operation procedures in this manual.
They alert you to the existence and relative degree of
hazards.
• Work area.
• Your unit.
• All safety decals.
Understand the safety message. It contains important
information about personal safety on or near the unit.
Work Area
ALWAYS check overhead and side clearances carefully
before operation. ALWAYS be aware of traffic when
operating along streets or curbs.
DANGER: IMMINENTLY HAZARDOUS
SITUATION! If not avoided, WILL RESULT in
death or serious injury.
ALWAYS keep hands and feet within the limits of the
unit.
Keep children, people, and animals away. Keep
children out of work area and under watchful care of a
responsible adult.
WARNING: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, COULD RESULT
in death or serious injury.
Keep area of operation clear of all toys, pets, and
debris. Objects can cause vehicle instability and 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.
Check for weak spots on dock, ramps or floors. Avoid
uneven work areas and rough terrain. Stay alert for
hidden hazards.
DO NOT run engine in an enclosed area. Always
provide good ventilation.
2.3 NOTATIONS
NOTE: General reference information for proper oper-
ation and maintenance practices.
Unit
ALWAYS keep protective structures, guards, and
panels in good condition, in place and securely
fastened. NEVER modify or remove safety devices.
IMPORTANT: Specific procedures or information
required to prevent damage to unit or attachment.
Check Safety Interlock System for proper operation
daily (see Operation section). Do not operate unless
system operates properly.
2.4 PRACTICES AND LAWS
Practice usual and customary safe working
precautions, for the benefit of yourself and others.
Understand and follow all safety messages. Be alert to
unsafe conditions and the possibility of minor,
moderate, or serious injury or death. Learn applicable
rules and laws in your area.
2 - 4
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• Only trained adults may operate unit.
• Training includes actual operation.
• Clearly understand instructions.
• Be alert! Conditions can change.
Operation
Understand:
• How to operate all controls
• The functions of all controls
• How to STOP in an Emergency
• Speed ranges
NEVER operate unit after or during the use of
medication, drugs or alcohol. Safe operation requires
your complete and unimpaired attention at all times.
Do not operate any of the control levers or power take-
off unless both feet are resting on the platform.
NEVER allow anyone to operate the unit when their
alertness or coordination is impaired.
DO NOT travel at too fast a rate. DO NOT change
engine governor settings or over-speed engine.
DO NOT operate unit without wearing adequate outer
garments. Wear adequate safety gear and protective
gloves. Wear proper footwear to improve footing on
slippery surfaces.
Always back up slowly. Always look down and behind
before and while backing.
Never leave a running unit unattended. ALWAYS shut
off power take off, lower throttle setting, and stop
engine before leaving unit. ALWAYS remove key to
prevent unauthorized use.
Protect eyes, face, and head from objects that may be
thrown from unit. Wear appropriate hearing protection.
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.
Never carry passengers on any part of unit.
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.
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.
If tires lose traction, turn off power take off and proceed
slowly straight down slope. Avoid wet surfaces.
DO NOT touch unit parts which might be hot from
operation. Allow parts to cool before attempting to
maintain, adjust, or service.
Avoid parking on a slope. If necessary, use wheel
chocks.
Controls
DO NOT leave unit unattended on a slope. ALWAYS
use wheel chocks when leaving unit.
Come to a complete stop before reversing.
ALWAYS operate unit in good visibility and light.
Never jerk the control levers. Always use a steady even
action to achieve smooth control.
Fuel is highly flammable and its vapors can explode.
Use ONLY approved fuel containers.
NO Smoking!
Always be aware of obstructions that may cause injury
to operator or damage to the unit.
NO Sparks!
NO Flames!
Maintenance
ALWAYS maintain unit in safe operating condition.
Damaged or worn out muffler can cause fire or
explosion.
Allow engine to cool before servicing.
NEVER fill fuel tank when engine is running, hot, or
unit is indoors.
Check the conditions of the unit at the end of each day
and repair any damage or defects.
Abnormal Vibrations are a warning of trouble. Striking a
foreign object can damage unit. Immediately stop unit
and engine. Remove key and wait for all moving parts
to stop. Remove wire from spark plug. Inspect unit and
make any necessary repairs before restart.
ALWAYS block wheels and know all jack stands are
strong and secure and will hold weight of unit during
maintenance.
Keep nuts and bolts tight and keep equipment in safe
operating conditions.
Hazardous Slopes
DO NOT operate on steep slopes. Avoid operating on
slopes. When you must operate on a slope, travel up
and down the slope. Never operate across a slope.
Never operate on a slope greater than 10 degrees.
Before maintenance, adjustments, or service (except
where specifically recommended), shut off engine.
Allow hot parts to cool.
Keep unit free of dirt, stones, and other debris. Clean
up oil or fuel spills.
Child Safety
NEVER allow children to operate or play on or near
unit. Be alert and shut off unit if children enter area.
Personal Safety
Read and obey all warning, caution, and instructions
on the unit and in provided manuals.
2 - 5
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Storage
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 clean unit before extended storage. See
Engine Manual for proper storage.
Battery
Avoid Electric Shock. DO NOT reverse battery
connections.
Explosive Gases! Poisonous battery fluid contains
sulfuric acid and its contact with skin, eyes, or clothing
can cause severe burns.
No flames. No sparks. No smoking near battery.
Always wear safety glasses and protective gear near
battery.
DO NOT TIP battery beyond a 45o angle in any
direction.
ALWAYS KEEP BATTERIES OUT OF REACH of
children.
Transport
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 with attachment in raised position.
Lower attachment when unit is parked or stored unless
a positive mechanical lock is used.
Attachments and Accessories
Use only attachments or accessories designed for your
unit.
2 - 6
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SECTION 3 - SPECIFICATIONS
Model Number
Model
992020 and 022
992018
992021
992023
992024
PM260Z 25 HP
Kohler with
60" deck
PM260Z 25 HP
Kohler with
50" deck
PM260Z 22 HP
Robin with
50" deck
PM250Z 20HP
Briggs &
Stratton with
50" deck
PM260Z 22 HP
Robin with
60" deck
Length - cm (in)
229 (90)*
221 (87)
229 (90)*
Height - cm (in)
Width - cm (in)
Weight Actual - kg (lbs)
Battery
127 (50)
160 (63)
500 (1103)
12 volt
185 (73)
185 (73)
510 (1125)
499 (1100)
490 (1080)
511 (1128)
Brakes
Hydro/Dynamic Disk - Parking
0
Turning Radius
Tire Size Front
Rear
15 x 6 - 6
15 x 6 - 6
15 x 6 - 6
23 x 10.5 - 12
23 x 10.5 - 12
23 x 8.5 - 12
Engine - manufacturer
Model Number
Cycle
Kohler
Kohler
Robin
EH65V
4
Briggs & Stratton
35177
Robin
CV25S
CV25S
EH65V
Engine Power -
25 HP
25 HP
22 HP
20 HP
22 HP
-1
-1
-1
-1
-1
-1
HP (KW/min
)
(18.4 KW/min
)
(18.4 KW/min
)
(16.2 KW/min
Electric
)
(14.7 KW/min
)
(16.2 KW/min
)
Starting System
Fuel Tank Capacity
Fuel
9 gals. US (34 liters)
See Engine Manual
1800
Idle RPM
Governed RPM
Air Cleaner
3600
Large Capacity Dual Element
Air Cooled
Cooling Capacity
Engine Oil Type
Spark Plug Gap
Transmission
See Engine Manual
See Engine Manual
Hydrostatic Drive
9 MPH
Speed - Forward Max.
Reverse Max.
4.5 MPH
Transmission Lube
Drive Clutch
Mobil 1 15W-50 Synthetic
Hydrostatic
Tire Pressure Front
Rear
20-25 psi
12-15 psi
Lift System
Hydraulic
Power Take Off
Mower Deck
Electric PTO Clutch/Brake
High Performance
127 (50)
Cutting Width - cm (in)
Cutting Height - cm (in)
Cut Increments - cm (in)
152 (60)
152 (60)
2.5 - 12.7 (1 - 5)
Infinite between 2.5 - 12.7 (1 - 5)
3 - 7
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SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS
4.1 CONTROLS AND FEATURES
18
8
11
12
10
9
13
7
14
19
15
16
6
5
17
4
3
2
20
1
OF1722
Figure 2
1. Mower Deck with Chute Deflector
2. Fuel Shut Off Valve
3. Parking Brake
11. Ignition Switch
12. Power Take Off (PTO) Switch
13. Steering Levers
4. Battery
14. Mower Lift Lever
5. Hour Meter
15. Seat Adjustment Lever
6. Oil Pressure Indicator
7. Engine Frame and Hood (260Z)
8. Fuel Tanks and Caps
9. Choke Control
16. Seat Suspension Adjustment Knob (260Z)
17. Height of Cut Indicator
18. Hydraulic Oil Reservoir
19. Engine Hood Latch (260Z)
20. Foot Board Latch
10. Throttle Control
* Serial No. 010000 and up are 221 (87)
4 - 8
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Daily Service Position: Place engine hood prop rod
into service slot. Assure rod is engaged in slot properly.
4.2 SERVICE POSITION - 260Z
WARNING: ALWAYS block wheels and know
that jack stands or blocks used are stable,
strong, or secure and will hold the weight of
the unit during maintenance.
Full Service Position: Slowly release frame after seat
contacts foot board. Use care and be sure of your
footing. Do not step on mower deck.
5. When service is complete, lower hood and secure
with latches.
To ensure the unit is positioned in the proper service
position:
4.3 SERVICE POSITION - 250Z
1. Place unit on a flat level surface. ALWAYS stop
engine. Assure unit is secure and will not tip over.
Strap and clamp onto lift if used.
Firmly grasp seat frame handle and lift past vertical.
Lay inverted seat on foot rest. When service is
complete, return seat to upright position.
2. Place steering levers in neutral position and set
parking brake.
4.4 MOVING THE UNIT-ENGINE NOT
RUNNING
3. Unhook hood latches.
To move the unit without the engine running, rotate the
bypass valve levers located on the pumps toward the
center of the tractor approximately 1/2 turn using a
wrench. Levers must be returned to their original
position in order to operate the unit (Figure 4).
4. Firmly grasp engine frame and cover. Lift to
desired service position (Figure 3).
7
8
2
1
4
5
1
2
9
3
10
1. Left Bypass Valve Lever
2. Right Bypass Valve Lever
Figure 4
OF1730
11
6
4.5 CLEANING AND STORAGE
1. Steering Levers
2. Parking Brake
3. Footboard
4. Engine Hood & Frame
5. Engine Hood Prop Rod
6. Service Slot
7. Daily Service Position
8. Full Service Position
9. Engine
10. No Step Decal
11. Battery
WARNING: AVOID SHARP EDGES which
can cut. Movement of parts can cut off fingers
or a hand. Wrap blades, wear gloves, and use
extreme caution when servicing.
IMPORTANT: Never spray unit with water or store unit
outdoors to help prevent sealed bearing rust or
corrosion. Water can seep into sealed bearings and
reduce component life. Bearings are sealed against dirt
and debris only.
Figure 3
OF1811
CAUTION: WHEN OPENING ENGINE
COVER, USE CARE TO PROPERLY
ENGAGE PROP INTO SLOT. Be sure footing
is secure to accommodate weight shift of
hood when rotating to full service position.
A unit that is excessively dirty should be cleaned before
work starts. Cleaning will occasionally uncover trouble
sources. Dirt and abrasive dust reduce the efficient
work life of parts and can lead to costly replacement.
4 - 9
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When taking unit out of extended storage:
4.7 FASTENERS
1. Check for any damage or loose parts. Repair,
replace, or tighten hardware before operation,
especially blade attachment bolts.
Each day before operating, check mower blade
mounting hardware and all other fasteners. Replace
fasteners that are missing or damaged. Tighten all nuts
and bolts to their correct torque value.
2. If a preservative fluid was used in fuel tank, drain
and discard. Fill fuel tank with fresh new fuel.
4.8 GENERAL LUBRICATION
IMPORTANT: Wipe each fitting clean before and after
4.6 FILLING THE FUEL TANK
lubrication.
EXPLOSIVE VAPORS and FLAMMABLE
FUEL can result in serious injury or death.
Handle fuel with care. ALWAYS use an
approved fuel container.
Lube fitting locations are:
-each deck push arm (2)
-Hydro Idler (1)
No Smoking!
-front axle pivot (1)
No Lighted Materials!
No Open Flame!
Allow engine to cool.
Apply Sten Mix Hi-Temp Grease or equivalent to the
lube fittings. Order P/N: 00036700- ten pack of 14 oz.
cartridges.
When using Sten Mix Hi-Temp Grease for the first time,
all components should be thoroughly cleaned prior to
lubricating.
Use caution with fuel. Fuel is very flammable.
Keep fuel in a clean and tight container. Keep
fuel away from fire or heat. Never put fuel in
the fuel tank while the engine is running or
hot. Clean up any spilled fuel before starting
the engine.
Apply oil at all pivot points and pin connections.
4
1
Add fuel to the tank as needed. See your Engine
Manual for correct type and grade of fuel.
2
3
To add fuel to the fuel tank:
1. Refuel the unit only in a well ventilated, open area.
2. Stop the engine.
3. Clean the fuel cap and the area around the fuel
cap to prevent dirt from entering the fuel tank.
Remove the cap from the fuel tank.
4. Fill the fuel tank. Be careful not to spill the fuel. Do
not overfill, allow for fuel expansion. Stop filling
when fuel is about 1” below the bottom of the neck.
2
3
REF
LUBRICATION
QTY
DESCRIPTION-
LOCATION
REF
5. Install the cap on the fuel tank and tighten.
INTERVAL
6. Clean up any spilled fuel before starting the
engine.
1
2
3
4
GREASE
GREASE
GREASE
GREASE
2
1
2
1
CASTER PIVOT
AXLE PIVOT
50 Hrs.
400 Hrs
50 Hrs
50 Hrs
1
2
3
4
PUSH ARM PIVOT
PUSH ARM PIVOT
WARNING: POTENTIAL HAZARDOUS! Fuel
is extremely flammable and highly explosive.
Personal injury and property damage may
result if not handled properly.
OIL
ALL PIVOT POINTS,
PIN CONNECTIONS
50 Hrs
Figure 5
OF1791
• Fill the fuel tank outdoors in an open area.
Do not fill when the engine is hot. Wipe up
any fuel spills.
• Never fill the fuel tank completely full.
Empty space in tank allows fuel to
expand.
Description
Use
Interval
Grease fittings
Sten Mix Hi-Temp
grease or equivalent
50 hrs. running
time
• Never smoke when handling fuel. Stay
away from open flames. Fuel fumes can
be ignited by sparks.
Hydraulic
system
Mobil 15W50
synthetic oil
500 hrs running
time
4 - 10
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Replacing Mower Belts
4.9 BASIC ENGINE MAINTENANCE
NOTE: Long belt must be removed to remove short
belt.
See your engine manual and Section 5 of this manual
for detailed information on the operation and
maintenance of your engine.
1. Roll long belt off left blade spindle and remove from
deck.
1. Each day before operating, check the level of the
oil in the engine. Never operate the engine when
the oil level is below the add mark.
2. Roll short belt off right blade spindle and remove
from deck. Idler pivot bolt must be loosened slightly
to gain clearance to remove belt from under idler
pulley (Figure 7).
2. Each day before operating, check the air cleaner
element. Dirt can decrease the flow of air to the
engine.
CAUTION: Use care when releasing idler
spring tension. Keep body parts well away
from idlers when performing this operation.
3. Each day before operating, check the air cooling
system on the engine. Debris can decrease the
flow of air cooling the engine.
4. Follow the maintenance instructions in your engine
manual concerning oil and filter changes.
3. Arrange new mower belt(s) on deck (short belt
first). Retighten short belt idler pivot bolt. Install
belts on sheaves. Roll belts onto blade sheave last.
4.10 BELTS
4. Replace belt covers and return foot board to closed
position.
WARNING: MOVING PARTS can cut or
amputate body parts. ALWAYS wait for
moving parts to stop before performing
maintenance or service.
Replacing the Hydro Pump Belt
1. Properly stop and park unit (refer to unit Owner’s
Manual).
2. Remove the mower belt from the mower clutch
CAUTION: DAMAGED OR WORN BELTS
may result in injury and/or damage to the unit.
Check belts for excessive wear or cracks
often.
sheave. See Replacing Mower Belts.
3. Remove old hydro pump belt by rolling belt off right
hand hydrostat sheave first (Figure 8).
4. Install new pump belt by positioning belt on
sheaves. Roll belt onto right hand hydrostat sheave
last.
Belt Access
1. Properly stop and park unit (refer to Owner’s
Manual).
5. Put the mower belt back on mower clutch sheave.
See Replacing Mower Belts.
2. Lower the mower.
3. Place seat in most rearward position.
4. Remove belt covers.
5. Place foot board in open position (Figure 6).
6. Secure raised footboard with latch.
1
5
2
4
3
1. Footboard in open
position
3. Support Frame
4. Pivot
2. Footboard in closed
position
5. Latch
Figure 6
OF1802
4 - 11
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4.12 MOWER BLADES
NOTE: If mower is used under sandy soil conditions,
replace blades when air lifts become eroded through at
ends (Figure 9).
3
2
1
2
4
3
1
5
4
1. Cutting Blade
2. Square Corner
3. Air Lift Erosion
4. Air Lift
50" and 60" Belt Layout
1. Long Mower Belt
2. Short Mower Belt
3. Springs
Figure 9
OT0791
4. Idlers
5. Mower Clutch Sheave
Sharpen The Mower Blades
OF1640
Figure 7
CAUTION: Use sturdy gloves or padding to
protect hands when working with mower
blades.
6
5
1
1. Turn the engine off. Remove the ignition key.
Remove the ignition wires from the spark plugs.
2. Remove the bolts, lock washer, the flat washers,
and the blades from the spindle shafts.
2
3
3. Sharpen the beveled edges of the blades in a
straight line at a 25 degree angle. Do not change
the angle of the beveled edge. If more than 0.5
inches (12.7mm) are removed from the width of a
blade, discard the blade. Make sure the sharpened
blades are balanced. Balance must be held within
1.3 inch ounces.
4
4. Put the blades, the flat washers, lock washers, and
the bolts back on the spindle shafts.
1. Hydro Belt
2. Spring
3. Idler
5. Right Hand Hydrostat
6. Left Hand Hydrostat
5. Tighten the bolts to a torque of 70 ft. lbs.
4. Engine Sheave
6. Put the ignition wires back on the spark plugs.
Figure 8
OF1631
4.11 TIRES
Before each use, make a visual check of tires. The
correct air pressure is 12-15 psi (83-103 kn/m2) for the
rear tires, and 20-25 psi (138-172 kn/m2) for the front
tires.
4 - 12
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on the pump. The screw may be turned in or out to
bring the unit into neutral.
4.13 STEERING CONTROL NEUTRAL
ADJUSTMENT
8. If major adjustment is needed, it is best to remove
the front ball joint from the bottom of the control
levers and turn the stop screw in or out until neutral
is found.
If the unit has excessive creep when the control levers
are in neutral, adjust as follows: (Figure 10)
9. Then, with the adjustable arms of the parking
brake interlock positioned so the clamping bolt is in
the middle of the slot, adjust the ball joint on or off
the control link rod so that their mounting bolts fit
into the slot at the end of the adjustable interlock.
2
1
2
10.Reinstall the front ball joint(s).
NOTE: When properly adjusted, the parking brake
interlock will move upward when the parking brake is
set and hold the steering control levers in neutral. The
parking brake starting interlock switch will not be
depressed unless the steering control levers are in
neutral. The interlock holds the levers in neutral until
the parking brake is released.
4
3
11.Move the control levers, from forward to reverse
several times to make sure it is adjusted to neutral.
Readjust if necessary.
5
4
6
3
12.Stop the engine.
7
1. Stop Bolts
5. Parking Brake Interlock
Adjustable Arms
6. Clamping Bolt and Slot
7. Mounting Bolt
4.14 ADJUSTING CONTROL LEVERS
To be done after neutral has been set. (Figure 10).
2. Pump Levers
3. Front Ball Joints
4. Control Levers
1. If desired the steering control levers can be set to
match (be in line) when in neutral.
Figure 10
OF1820
2. Remove front ball joint from bottom of steering
control lever on side which is going to be adjusted.
Screw ball joint on or off link rod to hydrostat so
that control levers align. Replace rod end on lower
part of steering control lever.
WARNING: This adjustment requires
operation of the engine and opening of hood.
Use extreme care to avoid contact with
moving parts and hot surfaces. Be sure rear
of unit is well supported and secure before
starting engine.
3. If needed, adjust parking brake interlock so that
interlock is able to move up when both steering
control levers are in neutral. To do this, loosen the
clamping bolt on the adjustable member of the
interlock and slide it in either direction until the
interlock moves up and latches the ball joint
mounting bolts.
1. If hydraulic system is cold, run unit for a minimum
of five minutes, then shut off unit.
2. Make sure both control levers are in neutral. Raise
hood (260Z).
3. With the unit up to and facing a wall, jack the unit
up so that both drive wheels are off the ground.
4. Have someone depress center of seat to activate
seat switch.
5. Start the engine and run at about half throttle or
faster. Release parking brake.
6. Move the control levers from Forward to Reverse
several times to make sure controls are free and
check Neutral adjustment. If binding is found,
correct it.
7. Minor adjustments may be made by simply
adjusting the stop screw which contacts the lever
4 - 13
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4.15 ADJUSTING THE PARKING BRAKE
4.16 ADJUSTING THE UNIT TO TRACK
STRAIGHT
Check and adjust tire pressure. Increase pressure on
side unit tracks toward. DO NOT exceed maximum
recommended tire pressure (refer to Specifications).
1. The Parking Brake may be adjusted through the
use of the jam nuts on the brake rod which push
against the compression spring which pushes on
the caliper arm. See Figure 11.
2. Turn the nuts further on the rod (clockwise) to
tighten the brake and further off the rod
(counterclockwise) to loosen the brake.
If tire pressure adjustment does not solve tracking
problem, the limiter bolts at base of handles can be
adjusted. See Figure 12. Front bolts are for forward and
rear bolts are for reverse. Lengthen bolts (move closer
to lever) on side which is too fast.
3. Ensure when the brake is applied, the caliper arms
do not contact the return nuts on the rods in front of
the caliper arms. If they do, back them off slightly.
4. When installing new pads in the calipers, they must
be burnished by driving for a short distance (about
200 feet) with the brake on. To do this, bring the
parking brake lever part way up, while driving
normally (in a straight line). This quickly breaks-in
the pads for maximum effectiveness.
2
1
1
Front
1. Limiter Bolt
2. Lever
1
2
1
Figure 12
1. Jam Nuts
2. Compression Spring
OF1732
Figure 11
4 - 14
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4.17 LEVELING THE MOWER DECK
These adjustments should be made on a level surface
with the tires inflated to the correct air pressure.
Right Side View
1
2
The mower is leveled from side to side with the slots
where 4 chains fasten to the mower mounting brackets.
The mower is leveled from front to rear by adjusting the
rod running down each side of the frame (Figure 13).
9
3
7
8
1. Raise mower deck and insert 3” (7.6 cm) tall blocks
to support deck.
2. Lower deck onto blocks so chains are slack.
3. Measure from bottom of mower blade end to
ground.
5
5
4
4
6
6
4. Set hydraulic lift cylinder so cut of height reads the
same as blade height measurement.
5. Loosen the locknuts on the side where the chains
are slack and slide the bolt down the slot until the
chain is tight.
6. Tighten bolt and nuts in mower mounting brackets.
7. Lift mower and remove blocks.
Front of Unit
1. Rod
6. Mower Mounting
Brackets
2. Rear Hex Nut
3. Front Hex Nut
4. Chains
8. Measure height of deck at each side.
Measurements must be within 1/16” (1.5mm) of
each other.
7. Front Mower Lift Pivot
8. Rear Mower Lift Pivot
9. Hydraulic Cylinder
5. Lock Nuts and Slots
9. If measurements are out of range, fix by adjusting
chains on low side of deck.
Figure 13
10.Once deck is level side to side, measure height of
deck at middle of front and on both sides of rear.
Front of deck should be 1/8” (3mm) lower than rear.
OF1920
11.To adjust, loosen rear hex nut of the front mower lift
pivot on each rod.
12.Turn the front hex nut on each rod until mower is
1/8” (3mm) lower in front.
NOTE: If mower cannot be leveled, it may be neces-
sary to loosen the rear nut of the rear mower lift pivot to
get more threads at the front of rod for adjustment.
After loosening rear nut and adjusting level, tighten
front nut on rear mower lift pivot.
13.Tighten rear hex nut on each rod that was
loosened in step 11.
4 - 15
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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
Black Exhaust
POSSIBLE CAUSES
(Refer to Key Below)
CORRECTIVE ACTION
1, 20, 22, 25, 29, 31, 32, 33
4, 20, 25, 31, 33, 34
repair or replace
Blue/White Exhaust
Difficult Starting
Erratic Running
repair or replace
1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33
1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62
1, 20, 22, 23, 25, 39, 31, 32, 33
4, 41
repair or replace
repair or replace
Excessive Fuel Consumption
High Oil Pressure
Knocking
repair or replace
repair or replace
22, 26, 29, 31, 33, 36, 46, 59
1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33
2, 3, 4, 11
repair or replace
Loss of Power or System
Low Cranking Power
Low Oil Pressure
Misfiring
repair or replace
repair or replace
4, 36, 37, 39
repair or replace
10, 20, 25, 26, 28, 29, 32
1, 19, 25,
repair or replace
Overheating
repair or replace
Poor Compression
Starts and Stops
25, 28, 29, 31, 32, 33, 34,59,
1, 6, 10, 62
repair or replace
repair or replace
see electrical systems
see engine service manual
repair or replace
Vibration
20, 23, 25, 26, 29, 33, 45, 49
2, 11, 45
Will Not Crank
Will Not Start
charge battery or replace
repair or replace
1, 10, 62
see electrical systems
see engine service manual
TROUBLESHOOTING KEY
1
Restriction in air cleaner
Bad electrical connection
Faulty starter motor
Incorrect grade of lubricating oil 25
Low cranking speed
Fuel tank empty
22
23
24
Incorrect grade of fuel
Sticking throttle/restricted movement 44
Exhaust pipe restriction
Leaking cylinder head gasket
Overheating
43
Faulty suction pipe
Choked oil filter
2
3
4
5
6
7
45
46
47
48
49
Bad solenoid switch
Incorrect piston height
Damaged fan
Faulty engine mounting
Incorrectly aligned flywheel and/or
flywheel housing
26
27
28
Cold running
Incorrect tappet adjustment
Controls not in correct
operation position
8
9
Blocked fuel feed line
Faulty fuel lift pump
Choked fuel filter
Battery capacity low
Air in fuel system
Faulty fuel injection pump
Faulty fuel injectors or incorrect 35
type
29
30
31
32
33
34
Sticking valves
50
51
52
53
Faulty thermostat
Restriction in water jacket
Loose fan belt
Incorrect high pressure pipes
Worn cylinder bores
Pitted valves and seats
Broken, worn or sticking piston ring(s) 54
Worn valve stems and guides
Restriction in air cleaner
10
11
12
13
14
Choked radiator
Faulty water pump
Choked breather pipe
Damaged valve stem oil deflector (if
fitted)
55
56
15
Incorrect use of cold start
equipment
Faulty cold start equipment
Broken fuel injection pump
drive
36
Worn or damaged bearings
Insufficient oil in sump
57
58
Coolant level too low
16
17
37
38
Blocked sump strainer
Broken valve spring
Bad/defective oil temperature switch 59
18
19
Incorrect fuel pump timing
Incorrect valve timing
39
40
Oil pump worn
Pressure relief valve sticking open
60
61
Exhaust or vacuum pipe leak
Bad or defective water temperature
switch
20
21
Poor compression
Blocked fuel tank vent
41
42
Pressure relief valve sticking closed 62
Broken relief valve spring
Bad spark plug(s)
5 - 16
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5.2 REMOVING THE ENGINE
1. Place the mower in the full service position.
2. Disconnect the battery cables, negative first.
3. Disconnect ignition wires using the connectors.
4. Remove the belts from the pulley and clutch.
3
5. Unscrew the bolt from the center of the output shaft
and remove clutch. Refer to "Replacing the
Clutch".
1
6. Remove the square key and the pulley.
7. Unclamp and remove the fuel line. Plug the fuel
line and wipe up any spills.
8. Remove the engine mounting bolts and lift engine
out the top.
2
5.3 INSTALLING THE ENGINE
1. Position the new engine in the chassis, insert
mounting bolts and tighten.
1. Electric Clutch
2. Pulley
3. Anchor Bracket
2. Install pulley and then the clutch on the output
shaft.
NOTE: Check condition of square key and replace if
Figure 14
needed.
3. Place belts on pulley and clutch. Check for proper
routing of belts.
To Replace the Clutch
1. Remove the belt by relaxing the idler pulley.
4. Connect fuel line and ignition wires.
5. Connect battery, positive first.
2. Remove the center bolt.
6. Check oil level and add as needed.
CAUTION: DO NOT ALLOW the engine
crankshaft to rotate. Damage to the engine
may occur.
5.4 ELECTRIC CLUTCH
The motor output shaft has two pulley mechanisms.
The top pulley is direct drive and powers the hydraulic
system. The lower pulley is engaged by an electric
clutch and supplies power to the mower blades. See
Figure 14.
3. Disconnect electrical wires.
4. Remove nut from the anchor bracket.
5. Pull clutch from shaft.
6. Position new clutch on the shaft by aligning the
square key on the shaft with the keyway of the
clutch.
The clutch has no repairable parts.
If clutch does not operate, before replacing clutch:
1. Check the deck for debris that may be blocking
blades.
7. Clutch should be rotated to position the anchor
bracket with the slot in the stationary shell. Replace
nut and tighten.
2. Check PTO switch and wire harness for proper
operation.
8. Replace bolt and washers. Torque to
55 foot pounds.
5 - 17
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SECTION 6 - DRIVE TRAIN
15W50 synthetic oil. Start the engine and run for
1 - 2 minutes.
WARNING: Hydraulic Fluid can result in
severe burns. Fluid in hydraulic system can
penetrate skin and result in serious injury or
death.
6. After shutting off the engine, check the fluid level.
The dipstick should read the fluid level between the
high and low markings.
7. Properly dispose of waste oil.
Be sure to stop the engine before doing any
work on hydraulic parts.
Keep body and hands away from pin holes or
nozzles which expel hydraulic fluid when
under pressure. Use paper or cardboard, not
hands, to search for leaks.
Insure all hydraulic fluid connections are tight
and all hydraulic hoses and lines are in good
condition before applying pressure to system.
6.3 HYDRAULIC DRIVE FLOW TEST
Use this procedure for trouble shooting the drive
system if the unit becomes sluggish or loss of drive
becomes apparent. This test is to be performed one
side at a time.
1. Block and jack the unit up so that both drive wheels
are off the ground.
2. Place hood into the full service position.
3. Verify that the by-pass valves are closed and there
is no binding in the steering control linkage. If
binding occurs, you will need to correct the
problem before proceeding to the next steps.
WARNING: FOREIGN FLUID INJECTED
INTO BODY can result in gangrene. Fluid
must be surgically removed within a few hours
by a doctor familiar with this form of injury.
4. Make sure hydraulic fluid level is correct.
5. Clean hydraulic hoses at the wheel motor.
6.1 CHECKING THE HYDRAULIC FLUID
LEVEL
A check of the hydraulic fluid level should be made
daily.
6. Disconnect the hydraulic hoses at the wheel motor,
note the proper orientation of hoses.
7. Install a bi-directional flow gauge.
8. Have someone depress center of seat to activate
seat switch.
NOTE: The oil level should be centered between the
two marks on the dipstick.
9. Start the engine and run at about 3/4 throttle or
faster. Release parking brake.
To Check: First, remove any dirt that may be around
the cap on the tank. Remove the dipstick and check the
oil level. If required, add Mobil 15W50 synthetic oil
through the dipstick tube. Do not overfill.
10.Stroke the appropriate control lever full stroke
forward and hold.
11.Set the hydraulic system pressure to 200-400 PSI
by using the restriction valve. Note the GPM (gallon
per minute) flow on the meter. While keeping the
pump in full stroke, increase the hydraulic system
pressure to 1000-1200 PSI by using the restriction
valve. Note the GPM flow on the meter. Do not
keep hydraulic system under pressure for an
extended period of time to prevent damaging the
hydraulic system by inducing too much heat to the
system.
6.2 CHANGING HYDRAULIC FLUID AND
FILTER
The hydraulic fluid and filter should be changed every
500 hours of operation. To drain the hydraulic oil
reservoir, remove the filter and catch the hydraulic oil in
a pan.
The filter for the hydraulic system is located under the
chassis behind the left rear wheel. It is accessed from
the rear of the unit.
12.Open the restriction valve and move the control
lever back to neutral. Idle unit down for a few
seconds and shut off engine.
To Replace the Filter
1. Unscrew the filter and dispose of properly. Allow
tank to drain into container.
13.The acceptable flow drop would be less than 1
GPM difference between the low and high pressure
settings. If flow drop is greater than 1 GPM, the
hydro-pump will need to be repaired or replaced. If
the flow drop is less than 1 GPM you will need to
replace the wheel motor.
2. Place a film of oil on the new filter’s gasket.
3. Screw the filter on until it makes contact with the
sealing surface of the filter head.
4. Turn the filter by hand, an additional 1/2 to 3/4 turn.
5. Fill the hydraulic oil reservoir to the top mark on the
dipstick. It will take about 5 quarts. Use Mobil
6 - 18
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To Replace a Hydraulic Pump
1. Lift cover to full service position.
2. Remove the cross channel.
6.4 REPLACING THE HYDRAULIC PUMP
The two hydraulic pumps are located inside the chassis
in front of the engine. The pumps are maintenance free
and should be replaced in the event of a failure. See
Figure 15.
3. Clean hoses and fittings and mark for location.
4. Disconnect hoses from pump.
CAUTION: Some fluid will leak out. Clean up
any spills.
1
5. Loosen belt from pulley.
6. Remove bolt and washers from end of shaft.
2
7. Loosen pulley lock bolt and slide pulley from shaft.
Remove and inspect square key. Replace key if
damaged.
8. Remove back bolt on pump and loosen front bolt.
9. Remove pump.
10.Insert the new pump into position with the front bolt
in the mounting flange slot.
11.Insert rear bolt and tighten both bolts.
12.Attach hydraulic hoses to correct ports and tighten.
13.Position square key in shaft keyway and slide
pulley into position.
14.Screw the bolt, washer and lock washer into the
end of the shaft. Tighten securely.
15.Tighten pulley lock bolt.
16.Place belt on pulley.
1. Hydrostat BDP Pump
2. Variable-Displace Pump
17.Replace cross channel.
18.Lower the cover and start the engine. Run the
engine for 1 - 2 minutes. After shutting off the
engine, check the hydraulic fluid level. The dipstick
should read between the high and low markings.
Figure 15
6 - 19
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6.5 REPLACE WHEEL MOTOR
Each drive wheel is mounted to a hydraulic drive motor.
The drive motors are maintenance free. In the event of
a failure, the drive motors should be replaced.
1
2
2
1
1. Hub
2. Hydraulic motor
Figure 16
15.Tight lug nuts using the pattern shown in
Figure 17.
To Replace a Drive Motor
1. Loosen the wheel lugs 1/4 turn.
16.Lower the unit to the ground and start the engine.
Drive forward twenty feet and stop the engine.
Check the hydraulic fluid level. The dipstick should
read between the high and low markings.
2. Jack the drive wheels off the ground and securely
support the unit.
3. Remove the wheel.
4. Remove the brake caliper assembly by removing
the two bolts.
1
5. Unscrew the axle bolt at the center of the hub and
remove the hub. The hub is a taper fit on the axle.
Use a wheel puller to assist in removal.
4
3
6. Mark the hydraulic lines and remove.
CAUTION: Some fluid will leak out. Clean up
any spills.
2
5
7. Unscrew the two bottom bolts and pull the
hydraulic motor out.
Figure 17
OK0630
8. Remove the four bolt sleeves.
9. Insert the sleeves into the four bolt holes in the new
hydraulic motor.
10.Slide the motor into place and secure with two
bottom bolts. Apply Loctite to bolts.
11.Reattach hydraulic lines to proper ports and
tighten.
12.Clean the axle and the inside of the hub. Place hub
over axle and lightly tap into position. Screw the
axle nut onto the axle and tighten to 300-400 ft. lbs.
13.Place the brake caliper into position and insert
bolts from the inside of the frame outward. Use lock
washer and nut and tighten.
14.Position wheel on hub and insert lug nuts finger
tight.
6 - 20
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6.8 HYDRAULIC DIAGRAM
Lift
Cylinder
Lift
Valve
Deck Lower
Deck Lift
B
Return
A
Left Pump
A
B
Forward
High
Pressure
Inlet
A
Right Pump
B
Right
Wheel
Motor
Left
Wheel
Motor
Forward
High
Pressure
Upper
Upper
Reverse
B
A
High
Pressure
Reverse
High Pressure
B
A
Lower
Lower
Oil
Filter
PRESSURE
RETURN
SUCTION
Oil
Tank
6 - 22
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SECTION 7 - MOWER DECK
7.1 MOWER DECK
Mower Spindles
This unit utilizes a maintenance free extended life
spindle. No routine maintenance is required. In the
event of bearing failure or a bent shaft the spindle
should be replaced.
To Remove the Spindle
1. Place the unit in service position. Turn key off and
remove the spark plug wire from contact with the
spark plug.
2. Remove cutting blade by unscrewing bolt.
CAUTION: Use sturdy gloves or padding to
protect hands when working with mower
blades.
3. Remove belt from pulley (see Replacing Mover
Belts).
4. Remove pulley by unscrewing bolt. Lift pulley off
the shaft and check placement and condition of
key.
5. Unbolt spindle from deck.
To Install Spindle
6. Bolt new spindle to mower deck.
7. Place square key in position and slide pulley down
the shaft. Tighten bolt and washer.
8. Replace belts.
9. Install blade using flat washer, lock washer and
bolt. Torque to 70 ft. lbs.
7.2 ANTI-SCALP ROLLERS
All of the anti-scalp rollers are maintenance free. If any
roller, shaft, or weldment shows excessive wear it
should be replaced.
The caster-type rollers are replaced by removing the
top pin and dropping the weldment with roller out the
bottom. Note the position of spacers and bushings for
installation.
The rollers are replaced by removing the shaft. Note
the position of spacers for installation.
7 - 23
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SECTION 9 - ELECTRICAL
9.1 TOOLS
9.2 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 connec-
tions.
Wire stripper/crimping tool - available separately or
as a combination tool. Used to strip insulation from
wires of various sizes, crimp terminals and connector
or wires.
Soldering gun or soldering iron - used to solder all
splices and connections to terminals, connector, etc. A
soldering gun is faster and more convenient that wait-
ing for a soldering iron to heat.
Multimeter - analog or digital, to measure voltage,
amperage and ohms.
Tachometer - used to measure engine speed.
Required to properly test alternator and charging cir-
cuits where output is dependent upon engine speed.
Heat gun - used to shrink insulated tubing in place.
Used to replace electrical tape or insulated sleeving. To
use, place a piece of shrink tubing over a wire joint,
heat with the heat gun, until it shrinks slightly around
the joint.
Supplies - electrical tape, rosin core solder (never use
acid or acid core solder on electrical joints), an assort-
ment of various size terminals, connectors, insulated or
heat shrink tubing (for use on joints and connections),
and an assortment of automotive type wire (in several
colors).
Ariens Company recommends that all work be done in
a professional manner. The use of the tubing to cover
joints and the soldering of connections contribute to a
professional looking job. In addition to a pleasing
appearance, repairs made in this manner are more
likely to withstand vibration. (The weakest points in an
electrical system are the joints where wires are
attached.)
Replace all defective components with Ariens replace-
ment parts only. Engine parts, such as rectifiers or
alternator components should be secured through the
nearest engine service center.
Ariens Company does not recommend attempting to
repair electrical components. Most do not lend them-
selves to repair and you would have more money
invested in "time of repair" than the part would cost and
the results may not be as good.
In many electrical circuits, there is some visible effect
which indicates that the circuit is functioning properly. A
switch is turned "ON" and a lamp lights. A key is
turned, a starter motor runs and cranks the engine.
If the lamp does not light, or the starter motor does not
run, some means of measuring voltage, current flow,
resistance and continuity is needed, (continuity means
there is a complete electrical path through the circuit or
component.)
To know exactly what conditions exist in an electrical
circuit requires AC and DC Voltmeter, AC and DC
Ammeter, and an Ohmmeter.
Multimeter
A single combination meter that does all of these things
is available. Such a meter is called a Multimeter or Volt-
Ohm-multitester (VOM). Meters of this kind are avail-
able in many forms and all change functions and
ranges with switches, or by plugging test leads into dif-
ferent jacks. Multimeters are available in two basic
types, Analog and Digital.
Analog Meters
Analog Meters have a needle that moves across a
scale to give a reading. The longer the scale, the easier
it is to read and more accurate the reading will be. A
jeweled movement is used in this type of meter is more
likely to be damaged through rough handling (except
for overloaded Protected Meters) or by measuring high
values that exceed the range set on the meter than a
digital meter. They provide excellent service for the
money as long as they are used with care.
Digital Meters
Digital Meters do not have a movement and are there-
fore more rugged. The reading shows up directly on a
display window of some type. Since they read direct, no
skill in reading the scale is required, nor is it necessary
to set the range. The meter switches the ranges auto-
matically. One has only to select the function DC Volts,
AC Ampere, Ohms, etc.,) connect the test leads, and
the reading is shown on the display. Because of the
internal circuitry and the lack of a movement, these
meters are not likely to be damaged by overloads.
In the discussions that follow, either type of meter may
be used. Test procedures are the same. It is best to
learn proper procedures, even though some meters
may be more forgiving of mistakes. Where differences
in use may occur, they will be covered in the discus-
sion.
9 - 25
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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 sul-
furic acid and its contact with skin, eyes or
clothing can cause severe chemical burns.
ALWAYS wear safety glasses and protective
gear near battery.
DO NOT TIP any battery beyond 45 degree
angle in any direction.
ALWAYS KEEP BATTERIES OUT OF REACH
of children.
Current Measurement
The two rules to remember when measuring current
with an ammeter are; an ammeter measures the cur-
rent that flows through the meter, and to measure cur-
rent an ammeter must be connected into the circuit.
The latter rule means that the circuit must be opened,
and the ammeter wired into it. Because this procedure
is usually difficult, an ammeter is seldom used for trou-
bleshooting.
WARNING: REVERSE CONNECTIONS may
result in sparks which may result in injury.
ALWAYS connect/disconnect cables in proper
order.
Resistance Measurement
An Ohmmeter is used to make resistance measure-
ments and to check continuity through wires and elec-
trical components.
There is one rule to keep in mind when using an ohm-
meter. The ohmmeter has a self contained battery and
requires no electrical power. Using the ohmmeter on a
circuit that has power applied may result in damage to
the meter.
Battery Electrolyte First Aid
-External contact: Flush with water.
-Eyes: Flush with water for at least 15 minutes and get
medical attention immediately!
IMPORTANT: Disconnect the equipment battery when
making Ohmmeter test or damage to the Ohmmeter
may result.
-Internal contact: Drink large quantities of water. Follow
with Milk of Magnesia, beaten egg or vegetable oil. Get
medical attention immediately!
IMPORTANT: An ohmmeter reads the resistance of
whatever component is connected between the test
leads. It can be used to check wires, coils, light bulbs,
or any item that conducts current.
IMPORTANT: In case of internal contact, DO NOT
induce vomiting!
Inspection, Cleaning, Drying, and Maintenance
Inspect the top of battery, terminals, cables, terminal
posts, and case for any accumulation of dirt, corrosion
cracks or loose or broken parts. Keep battery and its
terminals clean. Inspect monthly to maintain best
performance. Replace battery if damaged.
9.3 BATTERY
When charging battery, remove it from unit first. Keep
batteries out of reach of children. ALWAYS follow
information provided on battery by battery
Remove hold down and bolt and lift battery out. Clean
or service battery away from unit. Remove corrosion
from battery terminals and cable connections with wire
brush, then wash with a weak baking soda solution.
manufacturer. Lead acid batteries generate explosive
gases. Severe chemical burns can result from improper
handling of battery electrolyte. Wear safety glasses
and proper protective gear when handling batteries to
prevent electrolyte from coming in contact with eyes,
skin or clothing.
Scrub the exterior of the battery and cable terminals
with a nonmetallic brush which has been dipped into a
mixture of baking soda and water.
WARNING: ELECTRIC SHOCK may result in
injury and/or damage to unit.
After cleaning, apply a thin coat of grease or petroleum
jelly to terminals and cable ends to retard corrosion.
Reinstall battery.
DO NOT allow tools or other objects to come
into contact with both terminal at the same
time. ALWAYS remove Negative (-) Cable first
to reduce risk of sparks when removing bat-
tery. ALWAYS connect Positive (+) Cable first,
then connect Negative (-) Cable when install-
ing battery.
Check the alternator voltage regulator output (if used)
at every periodic maintenance inspection. Over
charging is a common cause of battery failure.
Electrolyte Level
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.
9 - 26
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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.
8. Connect positive (+) lead of charger to positive (+)
terminal, and negative (-) lead to negative (-)
terminal.
9. Charge the battery at two and a half amps for ten
hours or until all cells are gassing freely and the
specific gravity is constant over three 30 minute
intervals.
Battery Charger
Under normal conditions, the engine alternator will
have no problem keeping battery charged. When unit
has set for an extended period of time without
operation and the battery has been completely
discharged, a battery charger will be required for
recharging.
10.Immediately after charging, check the electrolyte
level. If low, add distilled water to bring cell up to
required level.
11.Replace caps finger tight, wash off and dry battery.
Before using a charger, an attempt can be made to
recharge the battery using the engine alternator by
jump starting the unit and allowing the engine to run.
12.Reinstall battery into unit and connect positive (+)
cable first, then negative (-) cable.
Specific Gravity Check
Charging A New Battery
The specific gravity should be checked with a
hydrometer.
WARNING: FROZEN BATTERIES CAN
EXPLODE and result in death or serious
injury.
DO NOT charge a frozen battery. Let the
battery thaw out before putting on a charger.
NOTE: The specific gravity should be checked in each
cell and should be the same for all cells. A variation in a
cell reading could be an indication of a problem. Sub-
tract .004 from 1.265 for each 10oF below 80oF or add
.004 to 1.265 for each 10oF above 80oF.
A special temperature compensated hydrometer is
used to read the battery’s state of charge.
IMPORTANT: DO NOT fast charge. Charging at a
higher rate will damage or destroy battery.
The reading on the hydrometer gauge should be above
1.225. If the reading falls below 1.225 specific gravity
there will be an insufficient charge.
ALWAYS follow information provided on battery by
battery manufacturer. Contact battery manufacturer for
extensive instructions to charge battery.
ALWAYS charge the battery until the specific gravity of
1.265 is reached over 3 successive readings. Check
monthly to ensure charge is maintained. The
approximate state of charge can be determined by the
cell specific gravity of the rested open circuit voltage at
room temperature and the charging time can be
estimated. For example:
3
1
2
OCV
Specific
Gravity
% of
Charge
Charging
Time
1. Positive terminal
2. Negative terminal
3. Battery
12.60
12.4
1.265
1.225
1.180
1.130
1.100
100%
75%
50%
25%
0%
---
3 hours
7 hours
10 hours
12 hours
Figure 20
OF1670
12.20
12.00
11.80
1. Put unit into service position to gain access to
battery.
2. Disconnect negative (-) cable first, then positive (+)
cable.
3. Remove hold down and remove battery.
If using an automatic tapering 12 volt charger, choosing
a good quality 5 to 10 amps 15VDC minimum output
charger and charge for 3 to 12 hours according to the
battery state of charge (see table above) or until the
specific gravity in each cell reaches 1.255 - 1.265
specific gravity at 80 degrees F.
4. Place battery on bench or other well ventilated
place where electrolyte spill will not create
damage.
5. Remove caps and fill each cell to level indicated
with electrolyte at 1.230 ± specific gravity and 80
degrees F (27 degrees C).
If using a constant current charger, charge at 1 to 2
amperes for the time given on the table above or until
full specific gravity is reached.
6. Let battery stand for one half hour.
7. Check electrolyte level and add more if necessary.
9 - 27
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IMPORTANT: Charging at higher rates will damage the
battery and cause excessive gassing and acid
spewing.
9.4 SWITCHES
Switches either open a circuit to stop current flow or
close and allow current to flow through.
Jump Starting
A normally open (N.O.) switch prevents current flow
until the switch is actuated, completing the circuit and
allowing current to flow through it. An example is a light
switch - the lights are off until the switch is actuated
and the lights go on.
The unit used for jump starting should have a 12 volt
battery with at least 500 cold cranking amperes, and a
negatively grounded system.
1. Ensure battery is not frozen. If the fluid is frozen,
remove battery from unit and allow to thaw before
charging.
A normally closed (N.C.) switch allows current to flow
until the switch is actuated, breaking the circuit and
stopping current flow through it. An example is an
ignition switch that grounds the magneto when in the
off position (completing the circuit) but opens the circuit
when in the ON position allowing the engine to operate.
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.
Switches are selected with regard to Current rating
(contacts must be of sufficient size to carry the required
current), Voltage rating (switches insulated for specific
voltages), Case or housing (switches that are exposed
to moisture and must be sealed to prevent moisture
from entering), and Actuating type (push, pull, rotary,
momentary contact, or micro switches).
4. Connect one end of the second jumper cable to the
negative (-) terminal of the booster battery.
5. Make the final jumper cable connection to the
engine block or the furthest ground point away from
the discharged battery.
WARNING: Make sure cables are clear of any
moving engine parts before starting engine.
NOTE: Check that the connections to the switches are
secure and that a switch is being activated properly
before performing electrical test on switches. (Safety
switches on speed selector and clutch levers may be
out of adjustment and not activating.)
6. Start engine (refer to Owner’s Manual). If engine
will not start after several tries, unit or battery may
need service.
IMPORTANT: When checking switches, remove them
from their respective circuit by disconnecting the wires
from the switch at the connector(s). Damage could
result to the meter or machine components if switches
are left in.
7. After engine starts, leave cables connected for one
to two minutes.
8. Disconnect cables in reverse order.
9. Operate unit as normal to charge battery.
Normally Open Switch
Storage
To test a normally open switch (key, headlight, safety, or
seat) connect the ohmmeter across the switch
terminals. Meter should indicate open circuit (infinite
resistance). Activate the switch. The ohmmeter should
read up scale to zero resistance (Close Circuit). This
indicates the switch is operating properly. Also check
from each terminal to the switch case (if case is metal).
reading should show infinite resistance indicating no
short to ground.
The battery is a perishable item and it should be stored
properly to obtain a long, useful life. Batteries not in
use will self discharge.
If the battery will not be used for more than three
months, it should be removed and stored in a cool, dry
place.
Any collection of dirt, grease, or electrolyte should be
removed from the top of the battery.
The battery must be recharged monthly or when the
cell specific gravity reads less than 1.255 specific
gravity. Before reinstalling the battery in the spring, it
should always be fully recharged.
Variation from test results described indicates a
defective switch.
Normally Closed Switch
To test a normally closed switch connect the ohmmeter
across the switch terminals. Meter should indicate a
closed circuit (zero resistance). Activate the switch and
the meter should move to open circuit (infinite
resistance). Check from each terminal to ground
(switch case). Meter should show open circuit (infinite
resistance).
Variation from test results described indicates a
defective switch.
9 - 28
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To check electrically, connect a voltmeter across the
coil of the device and activate the circuit that operates
the relay or solenoid. If the meter indicates no voltage
is applied, the cause is in the control circuit.
Ignition Switch
NOTE: Refer to the wiring diagram of the unit involved
to determine switch functions and test using the meth-
ods described.
If the meter indicates proper voltage across the coil but
the device does not function, remove the power,
disconnect the wiring and check the continuity of the
coil with an ohmmeter. The meter should indicate
resistance, in the order of 3 to 5 ohms, if the coil is
intact. A high resistance indicates an open coil and a
defective device.
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. These connections ground the engine
magneto and stop the engine in the OFF position.
There are also a number of mechanical problems that
may cause the problem.
RUN Position - Should be continuity between contacts
B and A. These connections supply power to the rest of
the wiring harness. Connections G and M open to each
other.
The starter solenoid in the Ariens equipment is a
sealed unit used to actuate the starter motor on the
engines. These solenoids may have three or four
connections. The two large connections carry high
current to operate the starter motor. The small
connections are connected to the coil and carry the
control current.
START Position - Hold switch in START position while
testing. There should be continuity between contacts
S1 and S2. These connections apply power to close
the solenoid contacts and operate the starter motor.
To check the solenoid, disconnect the cables to the
starter motor, turn the ignition switch to the start
position, and listen for the solenoid to snap inside
contacts closed.
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
If no snap is heard, check across the coils with a
voltmeter. The voltage should read 12 volts with the
ignition switch in the start position. If no voltage
appears, the defect is in the start circuit.
continuity between contacts other that those described.
9.5 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.
If the voltage is correct, turn off the power and check
continuity of the coil with an ohmmeter. If the coil is
open, the solenoid is defective and must be replaced.
If the coil has the proper voltage applied, and the
continuity check indicates the coil is intact, the solenoid
plunger is stuck or the contacts are welded shut and
the solenoid must be replaced.
Relay - A basic relay consists of a coil of wire wound
around a soft iron (magnetic) core. When current is
passed through the coil, the core is magnetized and
pulls down on a magnetic lever. The lever in turn is
attached to several switch contacts which open or close
other electrical circuits. In this fashion, a small current
can control one or more larger electrical currents and
actuate several other devices. In most cases a relay
contact moves only a fraction of an inch and the
magnetic pull is small.
If the solenoid snaps shut, but the start does not
operate, check across the large contacts with an
ohmmeter. If there is no continuity when the solenoid
snaps shut, the contacts are defective and the solenoid
must be replaced.
9.6 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. They contain a
metal link designed to melt when a certain current
value is exceeded thus opening or disconnecting the
wiring. Once a fuse blows or melts it must be discarded
and replaced with a new fuse of the same value.
Solenoid - A basic solenoid consists of a coil of wire
wound around a hollow tube. A magnetic core slides
inside the tube. When current is passed through the
coil, the core is pulled into the solenoid with
considerable force. With proper design, a solenoid can
exert considerable force over a distance of several
inched. A solenoid can therefore, pull a lever, close a
heavy contact, or perform other jobs that require a
straight line pull.
Since the function of the fuse is to protect the circuit,
NEVER attempt to defect the protective device by
bridging or replacing with a device of a higher current
rating.
If a relay or solenoid fails to operate, the cause may be
either electrical or mechanical.
Electrical testing of these devices is simple. Since the
device either conducts current (and is therefore
9 - 29
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functioning) or the device is open and is therefore
defective. Use an ohmmeter to check for continuity.
9.7 DIODES AND RECTIFIERS
Diodes are solid state, semiconductor devices. They
contain no moving parts and conduct current better in
one direction than the other. They are electrical "check
valves" and permit current flow in one direction, but not
in the other.
Diodes allow current to flow through one circuit without
"backing up" into another. In engine alternator circuits,
a diode is used to convert current which flows back and
forth (AC) in a circuit to current which flows only in one
direction (DC). A device which converts alternating
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.) If the readings
are the same in both directions, the diode is defective
and must be replaced.
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.
Rectifiers
A battery is charged through the use of an alternator
located in or on the engine. A charging circuit contains
a rectifier because alternators produce alternating
current (AC) and batteries require direct current (DC)
for charging.
The rectifier may be built into the engine or it may be an
external part. It may also contain a regulator to prevent
overcharging the battery. (Servicing of rectifiers built
into the engine should be done by an approved engine
manufacturer’s service center. Such a service center
has access to the information and parts required to test
and repair or replace engine components, including
rectifiers and regulators.)
Units that contain both a rectifier and regulator are
tested in a working circuit to make sure the regulator
portion of the device is operating.
9 - 30
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9.8 WIRING DIAGRAMS
Models 992018, 020, 021, 022, 024
SEAT
SWITCH
SEAT / PTO RELAY
PINK
85
87a
87 86
1
2
30
CAB
BLACK
POWER
SUPPLY
2
1
W
PTO
SWITCH
BLACK
Y
O
PTO
CLUTCH
RE
7
PURPLE /
WHITE
HOUR
METER
4
3
1
2
1
9
PURPLE
BLACK
BLACK
OIL
LIGHT
W
Y
O
OIL PRESSURE
FUEL SOLENIOD
REGULATOR
BLUE / WHITE
RED /YELLOW
PURPLE
WN
O
BR
START
RELAY
3
1
2
ENGINE
4
BLACK
86
85
87a
87
MAGNETO KILL
WHITE / BLACK
30
STARTER
SOLENOID
W
RED
Y
O
BLACK
RE
A
B
RED
1
A
B
BRAKE
SWITCH
FUSE
30A
2
M
BATTERY
BLACK
V
T
BLACK
G
RE
S1
BROWN
RED / VIOLET
S2
KEY
SWITCH
9 - 31
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Model 992305
SEAT / PTO RELAY
SEAT
SWITCH
PINK
87a
87
85
86
1
2
30
CAB
BLACK
POWER
SUPPLY
2
1
W
PTO
SWITCH
BLACK
Y
O
PTO
CLUTCH
RE
7
PURPLE /
WHITE
HOUR
METER
4
3
1
2
1
9
PURPLE
BLACK
BLACK
OIL
LIGHT
W
Y
O
OIL PRESSURE
FUEL SOLENIOD
REGULATOR
BLUE / WHITE
RED /YELLOW
PURPLE
WN
O
BR
START
RELAY
3
1
2
ENGINE
BLACK
87a
87
86
85
MAGNETO KILL
WHITE / BLACK
BLUE
30
STARTER
SOLENOID
4
CE
RELAY
LIGHT BLUE
W
BLACK
2
1
Y
O
87a
87
86
85
HOOD
SWITCH
RE
30
BLACK
DECK
LID
SWITCH
L
B
2
1
PURPLE
A
B
RED
RED
1
A
B
BRAKE
SWITCH
FUSE
30A
2
M
BLACK
V
T
BATTERY
G
RE
BLACK
S1
BROWN
RED / VIOLET
S2
KEY
SWITCH
9 - 32
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Model 992023
SEAT
SWITCH
SEAT / PTO RELAY
PINK
85
87a
87 86
1
2
30
CAB
BLACK
POWER
SUPPLY
2
1
W
PTO
SWITCH
BLACK
Y
PTO
CLUTCH
RED
7
PURPLE /
WHITE
HOUR
METER
4
3
1
2
1
9
PURPLE
BLACK
BLACK
OIL
LIGHT
W
Y
OIL PRESSURE
FUEL SOLENIOD
REGULATOR
BLUE / WHITE
RED /YELLOW
PURPLE
WN
O
SWITCH
BR
START
RELAY
ENGINE
BLACK
86
85
87a
87
MAGNETO KILL
WHITE / BLACK
30
STARTER
W
Y
BLACK
RED
A
B
RED
RED
1
A
B
BRAKE
SWITCH
FUSE
30A
RED
2
M
BATTERY
BLACK
V
T
BLACK
G
RED
S1
BROWN
1
2
RED / VIOLET
STARTER
SOLENOID
S2
BLACK
KEY
SWITCH
9 - 33
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GRAVELY
A Division of Ariens Company
655 West Ryan Street
P.O. Box 157
Brillion, WI 54110-0157
920-756-2141
Fax 920-756-2407
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