Gravely Atlas JSV EFI 2016 Service Manual
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Gravely Atlas JSV EFI 2016 Service Manual

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Table of Contents

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2016 Atlas JSV EFI
Service Manual
Models 996200, 996201 (SN 160101 +)
21901443A

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Summary of Contents for Gravely Atlas JSV EFI 2016

  • Page 1 2016 Atlas JSV EFI Service Manual Models 996200, 996201 (SN 160101 +) 21901443A...
  • Page 3 Service Manual is available in electronic format at www.gravely.com. This Service Manual is designed primarily for use by trained Gravely JSV dealers and technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
  • Page 4 SAFETY WARNINGS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
  • Page 5 TRADEMARKS GRAVELY ACKNOWLEDGES THE FOLLOWING PRODUCT(S) MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Torx, Registered Trademark of Textron Some Gravely factory publications can be downloaded from www.gravely.com or purchased by contacting the nearest Gravely dealer.
  • Page 7 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: CVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8:...

  • Page 9: Table Of Contents

    ................1.20 DECIMAL EQUIVALENTS 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 10: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 11: Vehicle And Engine Serial Number Locations

    ENGINE SERIAL NUMBER - The engine model and serial number can be found on a decal applied to the top of the engine near the coolant inlet. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 12: Vehicle Information

    Cylinder Holding & Camshaft Timing Valve Spring Compressor Adapter 21900598 Plate 21900599 21900591 Flywheel Holding Tool Flywheel Puller Crankshaft Removal / Installation 21900603 21900614 Tool Kit 21900604 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 13 Fuel Pump Service Tool Digital Wrench® Diagnostic Kit 21900612 21900602 21900617 Digital Wrench® Software Digital Wrench® USB-Serial Adapter Digital Wrench® SmartLink Module 21900607 Cable 21900606 21900590 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 14 Drive Clutch Spider Removal and Universal Clutch Compressor Installation Tool 21900605 21900609 CHAPTER 6 — TRANSMISSION Drive Clutch Puller Clutch Center Distance Tool Snorkel Tool 21900611 21900594 21900593 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 15 CV Boot Clamp Pliers 21900610 21900596 CHAPTER 8 — BODY / STEERING / SUSPENSION Ball Joint Tool 21900592 CHAPTER 10 — ELECTRICAL Connector Test Kit 21900601 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 16: Specifications

    1900 lb / 862 kg cargo and accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 17: 2016 Atlas Jsv3000 Efi Specifications

    Circuit Breaker Feet) 10 Amp: Brake Lights:, Drive, Fuel Pump Fuses 20 Amp: Accessory, ECM, *Not in Fuse/Relay Box Lights 30 Amp: EPS (OPT)* 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 18: 2016 Atlas Jsv6000 Efi Overview

    2100 lb / 953 kg cargo and accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.10 © Copyright Ariens Company...
  • Page 19 Circuit Breaker Feet) 10 Amp: Brake Lights:, Drive, Fuel Pump Fuses 20 Amp: Accessory, ECM, *Not in Fuse/Relay Box Lights 30 Amp: EPS (OPT)* 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.11 © Copyright Ariens Company...

  • Page 20: Misc. Specifications And Charts

    60 lb-ft (81 Nm) Wheels) Rear Engine Coupler 55 lb-ft (75 Nm) Fastener (In Sequence) Front Engine Mount 40 lb-ft (54 Nm) Fasteners 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.12 © Copyright Ariens Company...
  • Page 21 Drive Clutch Cover Bolts 9 lb-ft (12 Nm) Driven Clutch Retaining 9–12 lb-ft (12–16 Nm) Ring Bolts Driven Clutch Torx 47 lb-in (5.3 Nm) Screws 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.13 © Copyright Ariens Company...
  • Page 22 Rear Brake Junction 35 lb-in (4 Nm) Block Screws Rear Axle Nut 110 lb-ft (149 Nm) Rear Caliper Mounting 48 lb-ft (65 Nm) Bolts 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.14 © Copyright Ariens Company...
  • Page 23 48 lb-ft (65 Nm) Bolts Rear Brake Disc 28 lb-ft (38 Nm) Mounting Bolts Rear Wheel Hub Castle 110 lb-ft (149 Nm) Nuts 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.15 © Copyright Ariens Company...

  • Page 24: Conversion Table

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.16 © Copyright Ariens Company...

  • Page 25: Standard Bolt Torque Specification

    70 (97) 7/16-14 35 (48) 55 (76) 80 (110) 7/16-20 50 (69) 75 (104) 110 (152) 1/2-13 55 (76) 90 (124) 120 (166) 1/2-20 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.17 © Copyright Ariens Company...

  • Page 26: Metric Bolt Torque Specification

    151 (205) 177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.18 © Copyright Ariens Company...

  • Page 27: Sae Tap / Drill Sizes

    1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.19 © Copyright Ariens Company...

  • Page 28: Decimal Equivalents

    16 mm = 0.6299″ 41/64 0.6406″ 21/32 0.6563″ 17 mm = 0.6693″ 0.6719″ 43/64 11/16 0.6875″ 45/64 0.7031″ 18 mm = 0.7087″ 23/32 0.7188″ 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 1.20 © Copyright Ariens Company...
  • Page 29 ................2.27 COOLING SYSTEM HOSES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 30 ............... . .2.37 BRAKE PAD / DISC INSPECTION 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 31: General Information - Maintenance

    Rear Wheel Hub Castle 110 lb-ft (149 Nm) Nuts Tie Rod Jam Nut 14 lb-ft (19 Nm) Shock Mounting Bolts 40 lb-ft (54 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 32: Service Specifications - Maintenance

    50 / 50 Extended Life Antifreeze 5 Qt (4.7 L) Fuel 87 Octane (minimum) 10 Gal (37.8 L) Brake / Clutch Fluid DOT 4 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 33: Periodic Maintenance Chart

    Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death. Have an authorized Gravely dealer perform these services. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 34: Pre-Ride - 50 Hour Maintenance Interval

    Front / Rear Suspension 500 (800) Lubricate (if applicable) 50 H ■ Inspect for free movement; replace pedal assembly if 500 (800) Throttle Pedal 50 H needed 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 35: 50 - 500 Hour Maintenance Interval

    500 H 36 M ▶ Coolant Replace coolant 60 M Inspect periodically; adjust when parts ■ Toe Adjustment are replaced Headlight Aim Adjust as needed 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 36: Maintenance Quick Reference

    Engine Coolant coolant every five years coolant reservoir bottle. Antifreeze * More often under severe use, such as operated in water or under severe loads. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 37 100 hours or every 12 months, Transmission threads Fluid whichever comes first * More often under severe use, such as operated in water or under severe loads. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 38: Grease Lubrication Points

    All Season Grease Grease the fitting thoroughly washing or Propshaft Yoke (3 pumps maximum) submerging the vehicle JSV3000 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.10 © Copyright Ariens Company...
  • Page 39 MAINTENANCE JSV6000 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.11 © Copyright Ariens Company...

  • Page 40: Service Products And Lubricants

    Additives / Sealants / Thread Locking Agents / Misc. Loctite® Threadlock 242 (10 mL) 00065100 Ethanol Treatment (4 oz) 04730300 DOT 4 Brake Fluid (12 oz) 21900587 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.12 © Copyright Ariens Company...

  • Page 41: General Vehicle Inspection And Maintenance

    • Drive Shaft Boots - Inspect inner and outer boots for tears or damage on both front and rear drive shafts • Check all suspension components for wear or damage 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.13 © Copyright Ariens Company...

  • Page 42: Shift Cable Inspection / Adjustment

    7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.14 © Copyright Ariens Company...

  • Page 43: Fuel System And Air Intake Maintenance

    Never drain the fuel when the engine is hot.Severe pump must be replaced as an assembly. Refer to “Fuel burns may result. Pump Replacement”, page 4.14 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.15 © Copyright Ariens Company...

  • Page 44: Fuel Lines

    Test”, page 4.25 procedure if experiencing a lack of throttle response. 3. Be sure fuel lines are routed and retained properly. NOTE Make sure lines are not kinked or pinched. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.16 © Copyright Ariens Company...

  • Page 45: Engine Intake Pre-Filter Screen Service

    1. Tilt the rear cargo box to access the airbox. 2. Release the airbox cover latches and remove the back cover (A) to access the air filter element. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.17 © Copyright Ariens Company...

  • Page 46: Engine Air Intake Exploded View

    HOSE, AIRBOX SUPPLY BOOT, THROTTLE BODY SCREW CLAMP, HOSE INTAKE, FENDER REAR BOLT DUCT, INTAKE AIR ASM, AIR INTAKE CLAMP, HOSE SPRING ASM, AIRBOX 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.18 © Copyright Ariens Company...

  • Page 47: Engine Maintenance

    6. Reinstall the dipstick and screw it into place. NOTE The dipstick must be screwed completely in to ensure accurate measurement. 7. Remove the dipstick and check the oil level. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.19 © Copyright Ariens Company...

  • Page 48: Engine Oil And Filter Change

    14. Start the engine and allow it to idle for 30 seconds. 15. Stop the engine and inspect for oil leaks. Wait at least 15 seconds before removing the dipstick. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.20 © Copyright Ariens Company...

  • Page 49: Engine Crankcase Breather Hose Inspection

    21. Dispose of used oil and filter properly. dislodge and leak. Cylinder Leakage Service Limit: If leakage exceeds service limit, inspect the engine for the cause. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.21 © Copyright Ariens Company...

  • Page 50: Valve Clearance Inspection

    10. Inspect the valve cover gasket and replace if necessary. 11. Install valve cover and the bolts. Torque bolts to specification. TORQUE Valve Cover Bolts: 7 lb-ft (10 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.22 © Copyright Ariens Company...

  • Page 51: Exhaust - Spark Arrestor

    A synthetic brush may melt if components are warm. If necessary, blow debris from screen with compressed air. 4. Inspect the screen for wear and damage. Replace if needed. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.23 © Copyright Ariens Company...

  • Page 52: Transmission And Front Gearcase Maintenance

    5. Remove the fill plug. 6. Place a drain pan under the transmission drain plug. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.24 © Copyright Ariens Company...

  • Page 53: Front Gearcase Lubrication

    6. Remove the fill plug. 7. Place a drain pan under the front gearcase drain plug. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.25 © Copyright Ariens Company...

  • Page 54: Cooling System Maintenance

    • Straight water or antifreeze may cause the system to freeze, corrode, or overheat. FLUID CAPACITY Recommended Anti-Freeze/Coolant: Premium Pre-Mixed Extended Life Antifreeze 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.26 © Copyright Ariens Company...

  • Page 55: Cooling System Hoses

    Make sure radiator fins are clean to prevent not over-tighten hose clamps at radiator, or radiator overheating. fitting may distort. TORQUE Radiator Hose Clamp: 3 lb-ft (4 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.27 © Copyright Ariens Company...

  • Page 56: Radiator Inspection / Cleaning

    MAX level. 9. Refer to “Cooling System Bleeding Procedure”, page 3.17. FLUID CAPACITY Recommended Anti-Freeze/Coolant: Premium Pre-Mixed Extended Life Antifreeze 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.28 © Copyright Ariens Company...

  • Page 57: Cvt / Final Drive / Wheel And Tire Maintenance

    CVT system and has not been operated for a period of time, be sure to check the CVT system components for water damage. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.29 © Copyright Ariens Company...

  • Page 58: Drive Shaft Boot Inspection

    75 lb-ft (102 Nm) Castle Nuts Rear Wheel Hub 110 lb-ft (149 Nm) Castle Nuts NOTE Do not lubricate the stud or the lug nut. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.30 © Copyright Ariens Company...

  • Page 59: Wheel Removal

    TIRE INSPECTION • Improper tire inflation may affect vehicle maneuverability. • When replacing a tire always use original equipment size and type. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.31 © Copyright Ariens Company...

  • Page 60: Electrical And Ignition System Maintenance

    5. Install and tighten the black (negative) cable last. 6. Verify the cables are properly routed and reinstall the storage container and passenger seat. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.32 © Copyright Ariens Company...

  • Page 61: Chassis / Engine Electrical Ground

    10. Install spark plug high tension lead. Ensure lead is water and dry with compressed air. pushed down all the way so it engages onto the spark plug. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.33 © Copyright Ariens Company...

  • Page 62: Steering Maintenance

    1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.34 © Copyright Ariens Company...

  • Page 63: Wheel Toe Adjustment

    • After alignment is complete, torque jam nuts to (A) - (B) = 1/8" to 3/16" (3.2 to 4.8 mm) specification. TORQUE Tie Rod Jam Nut: 14 lb-ft (19 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.35 © Copyright Ariens Company...

  • Page 64: Suspension Maintenance

    40 lb-ft (54 Nm) requirements. Use a commercially available spanner wrench to adjust pre-load as necessary to avoid bottoming of the shocks. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.36 © Copyright Ariens Company...

  • Page 65: Brake System Maintenance

    6. The disc (s) should be replaced if thickness is less than the specified service limit (Refer to “Service Specifications - Brake System”, page 9.4 for specifications). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.37 © Copyright Ariens Company...
  • Page 66 MAINTENANCE NOTES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 2.38 © Copyright Ariens Company...
  • Page 67 ..............3.39 CYLINDER HEAD DISASSEMBLY 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 68 ................3.78 FINAL CRANKCASE ASSEMBLY 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 69 ..................3.83 COOLING SYSTEM 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 70: General Information - Engine

    • Oil Pressure Regulator • Oil Pump Pickup Assembly ALL of the top-end engine components can be serviced while the engine is mounted in the chassis. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 71: Torque Specifications - Engine

    Bolts) Oil Pump Cover Bolt 8 lb-ft (11 Nm) Bearing Retainer 8 lb-ft (11 Nm) Fastener Crankcase Bolts (In 22 lb-ft (30 Nm) Sequence) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 72: Service Specifications - Engine

    Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 73 Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter Balance Bearing Journal O.D. (Standard) 1.1798 - 1.1802″ (29.969 - 29.979 mm) Shaft 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 74: Engine Detail - Torque Values / Sequences / Assembly Notes

    ENGINE / COOLING SYSTEM ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 75: Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve

    ENGINE / COOLING SYSTEM CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 76: Cylinder / Oil Filter / Oil Pump / Breather

    ENGINE / COOLING SYSTEM CYLINDER / OIL FILTER / OIL PUMP / BREATHER 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.10 © Copyright Ariens Company...

  • Page 77: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

    ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.11 © Copyright Ariens Company...

  • Page 78: Spark Plug / Starter / Throttle Body / Valve Cover

    ENGINE / COOLING SYSTEM SPARK PLUG / STARTER / THROTTLE BODY / VALVE COVER 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.12 © Copyright Ariens Company...

  • Page 79: Piston / Crankshaft / Balance Shaft

    ENGINE / COOLING SYSTEM PISTON / CRANKSHAFT / BALANCE SHAFT 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.13 © Copyright Ariens Company...

  • Page 80: Engine Cooling System Service

    7. Lower Radiator Hose 2. Fan Shroud 5. Radiator Drain Plug 8. Bypass Hose 3. Cooling Fan 6. Upper Radiator Hose 9. Water Pump Hose 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.14 © Copyright Ariens Company...

  • Page 81: Cooling System Specifications

    (commercially available). pre-mixed, ready to use. 3. The radiator cap relief pressure is 13 psi. Replace cap if it does not meet this specification. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.15 © Copyright Ariens Company...

  • Page 82: Radiator Fan Removal

    9. Lift up on the flexible portion of the hood liner to access the upper radiator hose and remove the hose from the radiator. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.16 © Copyright Ariens Company...

  • Page 83: Thermostat Replacement

    2. Remove the pressure cap to relieve any system pressure. Refer to “Radiator Cap Pressure Test”, page 3.15 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.17 © Copyright Ariens Company...

  • Page 84: Water Pump Cover And Impeller Service (Stator Cover Remains On Engine)

    2. Disconnect the (-) negative battery cable. 3. Remove all debris and thoroughly clean water pump area and right-hand side of engine block. 4. Open the hood. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.18 © Copyright Ariens Company...

  • Page 85: Water Pump Mechanical Seal / Oil Seal Replacement

    4. Open the hood. 5. Remove the pressure cap from the filler neck. 6. Completely drain cooling system and engine as outlined in this chapter. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.19 © Copyright Ariens Company...
  • Page 86 NOT place fingers between cover and crankcase at any time during the removal process or injury could result. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.20 © Copyright Ariens Company...
  • Page 87 19. Extract the mechanical seal (Item 8) and the oil seal engine damage may result. (Item 9) from the stator cover. 23. Clean and de-grease the water pump drive shaft (H). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.21 © Copyright Ariens Company...
  • Page 88 21900595 is supporting the assembly. 26. Lubricate the new water pump oil seal with clean engine oil. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.22 © Copyright Ariens Company...
  • Page 89 33. If needed, install a commercially available stator cover removal handles tool to the water cover bolt holes to aid in stator cover installation. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.23 © Copyright Ariens Company...
  • Page 90 38. Install a new water pump cover gasket. TORQUE Stator Cover and Water Pump Cover: 9 lb-ft (12 Nm) (Apply Loctite® 204™ to bolt threads) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.24 © Copyright Ariens Company...
  • Page 91 48. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter. 49. Check for leaks. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.25 © Copyright Ariens Company...

  • Page 92: Engine Service

    Inspect CPS O-ring and replace if before attempting to perform any work. needed. 2. Thoroughly clean the engine and chassis. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.26 © Copyright Ariens Company...
  • Page 93 28. Place engine onto a commercially available engine 23. Remove the (8) bolts (N) securing the coupler stand for service. brackets to the engine and transmission. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.27 © Copyright Ariens Company...

  • Page 94: Engine Installation

    TORQUE properly position the clutch center distance. Front Engine Mount Fasteners: 40 lb-ft (54 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.28 © Copyright Ariens Company...
  • Page 95 17. Instal the starter motor onto the engine. 18. Install the starter motor and battery cables as outlined in Chapter 10. TORQUE Starter Motor Fastener: 7 lb-ft (10 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.29 © Copyright Ariens Company...
  • Page 96 Chapter 5. 29. Install the left-hand rear wheel and torque wheel nuts to specification. TORQUE Wheel Nuts (Steel): 60 lb-ft (81 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.30 © Copyright Ariens Company...

  • Page 97: Engine Mounting And Torque Values

    ENGINE / COOLING SYSTEM ENGINE MOUNTING AND TORQUE VALUES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.31 © Copyright Ariens Company...

  • Page 98: Engine Break-In Period

    6. Upon assembly, torque the crankcase gallery plug to specification. TORQUE Oil Gallery Plug: 11 lb-ft (15 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.32 © Copyright Ariens Company...

  • Page 99: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.33 © Copyright Ariens Company...

  • Page 100: Setting Tdc (Top-Dead-Center)

    This cam shaft sprockets to ensure the engine is at TDC will set TDC of the compression stroke. of the compression stroke. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.34 © Copyright Ariens Company...

  • Page 101: Engine Disassembly / Inspection - Top End

    Replace the sealing washer (F) upon reassembly. 5. Replace isolators (B) and valve cover seal (C) if oil leaks are evident. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.35 © Copyright Ariens Company...

  • Page 102: Camshaft Sprocket Inspection

    6. Mark the intake (I) and exhaust (J) camshafts to ensure proper assembly. NOTE Replace intake camshaft sprocket bolt if loosened or removed. TORQUE Intake Camshaft Sprocket Bolt: 33 lb-ft (45 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.36 © Copyright Ariens Company...

  • Page 103: Camshaft Inspection

    MEASUREMENT Camshaft Lobe Height: Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm) Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.37 © Copyright Ariens Company...

  • Page 104: Cam Chain And Guide Service

    5. Upon installation, torque all fasteners to specification and reassemble engine and vehicle as outlined in this chapter. TORQUE Cam Chain Guide Fasteners: 9 lb-ft (12 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.38 © Copyright Ariens Company...

  • Page 105: Cylinder Head Disassembly

    (21900599). CYLINDER HEAD DISASSEMBLY WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.39 © Copyright Ariens Company...

  • Page 106: Cylinder Head Inspection

    7. Repeat the previous steps to remove the remaining valves. 8. Clean the combustion chamber and head gasket surface. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.40 © Copyright Ariens Company...

  • Page 107: Valve Inspection

    The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent NOTE or damaged. The valve guides cannot be replaced. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.41 © Copyright Ariens Company...

  • Page 108: Combustion Chamber Cleaning

    2. Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage. Pay close attention to the areas around spark plug and valve seats. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.42 © Copyright Ariens Company...
  • Page 109 * If the seat is too narrow, widen using the 45° cutter a few times. and re-check contact point on the valve face and seat width after each cut. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.43 © Copyright Ariens Company...

  • Page 110: Cylinder Removal

    Exhaust Seat Cutter Diameter: 1.364 in. (34.65 mm) 8. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.44 © Copyright Ariens Company...

  • Page 111: Cylinder Inspection

    4. Repeat procedure for second ring. 5. Remove oil control ring top rail first, then bottom rail. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.45 © Copyright Ariens Company...

  • Page 112: Piston-To-Cylinder Clearance

    3.8957 - 3.8968″ (98.953 - 98.980 mm) MEASUREMENT Piston Pin O.D.: Std.: 0.8659 - 0.8661″ (21.995 - 22.0 mm) Service Limit: 0.8651″ (21.975 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.46 © Copyright Ariens Company...

  • Page 113: Piston Ring Installed Gap

    Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm) Service Limit: 0.0042" (0.108 mm) Second Ring: Std.: 0.0007 - 0.0029" (.020 - 0.076 mm) Service Limit: 0.0035" (0.89 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.47 © Copyright Ariens Company...

  • Page 114: Honing To Oversize

    NOTE Do not allow cylinder to heat up during honing. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.48 © Copyright Ariens Company...

  • Page 115: Camshaft Installation / Timing

    7. Carefully install the camshaft carrier onto the camshafts. 5. Wrap the cam chain around the exhaust cam sprocket and hold the exhaust cam in its current position. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.49 © Copyright Ariens Company...
  • Page 116 12. Remove the Cylinder Holding & Camshaft Timing Plate (21900591) from the end of the camshafts. 13. If needed, install the camshaft carrier and bolts. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.50 © Copyright Ariens Company...
  • Page 117 8 lb-ft (11 Nm) 17. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 15. Insure the new sealing washer (G) is in place. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.51 © Copyright Ariens Company...

  • Page 118: Camshaft Timing - Quick Reference

    ENGINE / COOLING SYSTEM CAMSHAFT TIMING - QUICK REFERENCE 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.52 © Copyright Ariens Company...

  • Page 119: Valve Cover Installation

    5. Install the (3) valve cover shoulder bolts (C) and isolators (D) using a T40 driver. 6. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 9 lb-ft (12 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.53 © Copyright Ariens Company...

  • Page 120: Engine Assembly - Top End

    2. Install lower rail with end gap positioned as shown in illustration 1. 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.54 © Copyright Ariens Company...

  • Page 121: Piston / Connecting Rod Assembly

    5. Verify all ring end gaps are correctly located on piston. Place cam chain and guides in alignment with chain room. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.55 © Copyright Ariens Company...

  • Page 122: Cylinder Head Assembly

    1. Apply engine oil to valve guides and seats. 2. Lubricate the valve stems with clean engine oil. NOTE Valve springs to be installed with the paint mark facing 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.56 © Copyright Ariens Company...

  • Page 123: Valve Sealing Test

    The valve seats should hold fluid with no valve keepers are seated correctly. seepage. 3. Repeat for exhaust valves by pouring fluid into each exhaust port (C). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.57 © Copyright Ariens Company...

  • Page 124: Cylinder Head Installation

    Step 1: 21 lb-ft (28 Nm) Step 2: 26 lb-ft (35 Nm) Step 3: Additional 135° Step 4 (M6 bolts): 8 lb-ft (11 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.58 © Copyright Ariens Company...

  • Page 125: Valve Clearance Check / Adjustment

    The camshaft lobes should face out. TORQUE Camshaft Carrier Bolts: 8 lb-ft (11 Nm) 5. Carefully install the camshaft carrier onto the camshafts. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.59 © Copyright Ariens Company...
  • Page 126 20. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.60 © Copyright Ariens Company...
  • Page 127 ENGINE / COOLING SYSTEM 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.61 © Copyright Ariens Company...

  • Page 128: Intake Valve Lash - Tappet Selection Matrix

    0.926-0.950 520 522 525 528 530 532 535 538 540 542 545 0.951-0.975 522 525 528 530 532 535 538 540 542 545 0.976-1.000 525 528 530 532 535 538 540 542 545 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.62 © Copyright Ariens Company...

  • Page 129: Exhaust Valve Lash - Tappet Selection Matrix

    0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545 0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.63...

  • Page 130: Engine Disassembly / Inspection - Lower End

    Inspect shaft and shaft bearing surfaces in case and stator housing for wear. 8. Tighten center bolt of tool 21900614 and remove flywheel. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.64 © Copyright Ariens Company...

  • Page 131: Starter One-Way Clutch Removal / Inspection

    8. Remove clutch and inspect both sides of drive rollers (B) and roller contact surface (C) inside hub for wear, damage, or uneven surface. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.65 © Copyright Ariens Company...

  • Page 132: Stator Removal

    4. Remove the 2 bolts that secure the stator wire routing bracket (4) to the stator cover. 5. Remove the stator (E) from the stator cover. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.66 © Copyright Ariens Company...

  • Page 133: Oil Pump Removal

    NOTE The larger oil pump sprocket mounts to the balance shaft extension, the smaller oil pump sprocket mounts to the oil pump shaft. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.67 © Copyright Ariens Company...
  • Page 134 There is a spacer in between the inner oil pump geroter and the oil pump cover. 8. Remove the oil pump geroter that is in the engine case (if needed). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.68 © Copyright Ariens Company...

  • Page 135: Oil Pump Assembly

    Oil Capacity: 2 Qt (1.9 L) Oil Type:: Synthetic 4–Cycle Oil Pressure (Minimum): 10 PSI @ 1200 RPM 40 PSI @ 7000 RPM 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.69 © Copyright Ariens Company...

  • Page 136: Crankcase Separation

    3. Remove and discard the (15) flange bolts from magneto side crankcase evenly in a criss-cross pattern. 2. Pull upward on the balance shaft and remove it from the crankcase. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.70 © Copyright Ariens Company...

  • Page 137: Crankshaft Removal

    4. With the help of an assistant holding the crankshaft, slowly tighten the screw “C” until the crankcase is completely separated from the crankshaft. 5. Remove all special tools from the crankcase. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.71 © Copyright Ariens Company...

  • Page 138: Crankshaft Inspection

    3. Remove the retaining ring. MEASUREMENT Small End I.D. Std: 0.8665 - 0.8670″ (22.010 - 22.023 mm) Service Limit: 0.08682″ (22.053 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.72 © Copyright Ariens Company...
  • Page 139 13. Install the bearing retainer and torque the fastener to specification. TORQUE Bearing Retainer Fastener: 8 lb-ft (11 Nm) Apply Loctite® 272™ 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.73 © Copyright Ariens Company...

  • Page 140: Mag Side Crankcase Bearing Service

    Loctite® 641 (Yellow), or Loctite® 603 (Green) if unavailable, to the bearings. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.74 © Copyright Ariens Company...

  • Page 141: Oil Pressure Regulator (Bypass) Valve Inspection

    4. Thoroughly clean the valve. 5. Replace the o-ring and lubricate with clean engine oil. 6. Press the oil pressure valve into the crankcase until fully seated. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.75 © Copyright Ariens Company...

  • Page 142: Engine Assembly - Lower End

    PTO end of the crankshaft with numbers facing OUT. Be sure seal lip does not fold back when moving over the crankshaft flange. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.76 © Copyright Ariens Company...

  • Page 143: Balance Shaft Installation / Timing

    BALANCE SHAFT INSTALLATION / TIMING 1. Position balance shaft in the crankcase. 2. Rotate crankshaft to align the timing marks (A) as shown below. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.77 © Copyright Ariens Company...

  • Page 144: Final Crankcase Assembly

    10. Place engine onto a commercially available engine stand for top end engine assembly as outlined in this chapter. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.78 © Copyright Ariens Company...

  • Page 145: Starter One-Way Clutch Installation

    MAG side crankshaft. DO NOT apply engine oil to the crankshaft taper. TORQUE One Way Clutch Retaining Bolts: 9 lb-ft (12 Nm) Apply Loctite® 272™ 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.79 © Copyright Ariens Company...
  • Page 146 Fully install the flywheel until seated on the crankshaft taper. 8. Install the flywheel washer. 9. Hold flywheel with commercially available strap wrench. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.80 © Copyright Ariens Company...

  • Page 147: Stator / Stator Cover Installation

    TORQUE Stator Mounting Bolts: 9 lb-ft (12 Nm) Apply Loctite® 242™ TORQUE Stator Wire Retainer: 6 lb-ft (9 Nm) Apply Loctite® 242™ 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.81 © Copyright Ariens Company...

  • Page 148: Troubleshooting - Engine / Cooling System

    • Cylinder, piston, ring, or valve wear or damage (check compression) • CVT not operating properly • Restricted exhaust muffler • Cam worn excessively Piston Failure - Scoring • Lack of lubrication 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.82 © Copyright Ariens Company...
  • Page 149 • Thermostat stuck open Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.83 © Copyright Ariens Company...
  • Page 150 ENGINE / COOLING SYSTEM NOTES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 3.84 © Copyright Ariens Company...
  • Page 151 ................4.25 OPERATION OVERVIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 152 ..........4.39 ENGINE CONTROLLER REPROGRAMMING (REFLASH) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 153: General Information - Fuel System

    SPECIAL TOOLS - FUEL SYSTEM TOOL DESCRIPTION PART NUMBER Fuel Pressure Gauge Kit 21900612 Fuel Pump Service Tool 21900602 Digital Wrench® 21900617 Diagnostic Kit 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 154 Digital Wrench® - Download Website For the most recent information on Digital Wrench® software and update downloads please visit the dealer extranet. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 155: Torque Specifications - Fuel System

    7 lb-ft (10 Nm) ECT Sensor 17 lb-ft (23 Nm) Throttle Pedal Bracket 18 lb-ft (24 Nm) Nuts Fuel Rail Mounting 7 lb-ft (10 Nm) Screws 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 156: Electronic Fuel Injection

    5. Temperature Manifold Absolute Pressure Sensor (T-MAP) - Located in the rubber intake boot between the throttle body and the cylinder head. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 157 - Located between the throttle body and engine intake. 10. Ignition Coil - Located under the driver’s seat next to the battery. 11. Spark Plug Wire 12. Spark Plug 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 158: Fuel System Operation Overview

    During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 159: Fuel Tank Service

    Tank Vent / Rollover Valve Fuel Fill Hose Fuel Sender Nut Fuel Inlet Fuel Pump / Regulator Fuel Cap Fuel Level Float Arm Gasket Preliminary Fuel Filter 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 160: Fuel Line Removal / Installation

    6. Be sure fuel line is routed and retained properly. 5. Remove the fuel tank vent line (B) from the tank fitting. 6. Disconnect the fuel pump electrical harness (C). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.10 © Copyright Ariens Company...

  • Page 161: Fuel Tank Installation

    8. Install storage bins and driver and passenger seat bases. 9. Slide the fuel tank toward front of vehicle and remove the tank from vehicle. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.11 © Copyright Ariens Company...

  • Page 162: Fuel Pump Service

    7.0 volts, the ECU will fail to operate 1. Remove the fuel pump assembly from the fuel tank. the system. Refer to “Fuel Pump Replacement”, page 4.14 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.12 © Copyright Ariens Company...
  • Page 163 Turn on the key switch and listen for the pump to activate. NOTE If the pump starts, repeat steps 3, 4 and 5 to verify correct pressure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.13 © Copyright Ariens Company...

  • Page 164: Fuel Pump Replacement

    PFA nut. Discard the PFA nut. NOTE Apply downward force on the fuel pump flange while removing the fuel pump nut. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.14 © Copyright Ariens Company...
  • Page 165 16. Gently push down on fuel pump flange ensuring flange is centered. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.15 © Copyright Ariens Company...
  • Page 166 Be sure to engage the retainers on each fuel line until each snaps into place. Pull on fuel lines lightly to confirm connection. 22. Connect the fuel pump electrical harness. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.16 © Copyright Ariens Company...

  • Page 167: Electronic Control Unit (Ecu)

    To prevent engine over-speed and possible failure, maximum engine RPM is controlled by the interface between the ECU and Electronic Throttle Control (ETC). Engine Max Operating RPM: 7750 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.17 © Copyright Ariens Company...

  • Page 168: Ecu Replacement

    Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Screws: 24 lb-in (2.7 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.18 © Copyright Ariens Company...

  • Page 169: Electronic Throttle Control (Etc)

    ETC Housing Retaining Bolts: the ETC is faulty, the entire ETC assembly must be 7 lb-ft (10 Nm) replaced. Intake Boot Clamp: 3 lb-ft (4 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.19 © Copyright Ariens Company...

  • Page 170: Crankshaft Position Sensor (Cps)

    CPS and flywheel encoder ring for damage. Refer to “CPS Replacement”, page 4.21 procedure. 4. If the resistance is incorrect, follow the “CPS Replacement”, page 4.21 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.20 © Copyright Ariens Company...

  • Page 171: Cps Replacement

    6. Torque CPS retaining bolt to specification. TORQUE CPS Retaining Bolt: 9 lb-ft (12 Nm) 7. Route CPS wire lead through wire clip and reconnect CPS harness connector. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.21 © Copyright Ariens Company...

  • Page 172: Temp / Manifold Absolute Pressure Sensor (T-Map)

    7 lb-ft (10 Nm) NOTE This sensor should only be tested using the Digital Wrench® Diagnostic Software (dealer only). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.22 © Copyright Ariens Company...

  • Page 173: Engine Coolant Temperature Sensor (Ect)

    Refer to “Coolant Temperature Sensor”, page 10.28 for additional ECT sensor information. Gravely dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.23 © Copyright Ariens Company...

  • Page 174: Ect Sensor Replacement

    8. Reconnect the fuel line to the fuel rail. 9. Add the required amount of coolant and bleed the system. Refer to “Cooling System Bleeding Procedure”, page 3.17. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.24 © Copyright Ariens Company...

  • Page 175: Pedal Position Sensor (Pps)

    • Reverse – 32% The Pedal Position Sensor is calibrated to the throttle pedal. If the PPS is faulty, the throttle pedal assembly must be replaced. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.25 © Copyright Ariens Company...

  • Page 176: Fuel Injector Service

    Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.26 © Copyright Ariens Company...

  • Page 177: Fuel Injector Test

    14. Install the fuel rail mounting screws and torque to specification. TORQUE Fuel Rail Mounting Screws: 7 lb-ft (10 Nm) 15. Reinstall the fuel line to the fuel rail. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.27 © Copyright Ariens Company...
  • Page 178 18. Turn the key to the on position and wait for fuel pump to prime the fuel system. 19. Start the engine briefly and inspect the fuel rail and injectors for fuel leaks. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.28 © Copyright Ariens Company...

  • Page 179: Fuel System Diagnostics

    MODE button or turn the ignition key OFF once the codes are recorded. 2. Press and hold the MODE button to enter the diagnostics code menu. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.29 © Copyright Ariens Company...
  • Page 180 Driver Circuit Grounded P1265 Driver Circuit Open / Grounded P1691 Rear Differential Output Driver Circuit Short to B+ P1692 Driver Circuit Grounded P1693 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.30 © Copyright Ariens Company...
  • Page 181 Accelerator Position / Brake Condition Exists 520275 P150A Position Interaction Throttle Position Sensor Neither Position Sensor Passed 520276 P150B (1 or 2 Indeterminable) Test 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.31 © Copyright Ariens Company...
  • Page 182 Condition Exists 520308 P1533 Difference Exceeds Limit ECU Fault - ICO Condition Exists 520309 P1534 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.32 © Copyright Ariens Company...

  • Page 183: Fuel System Troubleshooting

    • Poor fuel quality (old fuel) • Spark plug(s) fouled • Fouled spark plug • Spark plug wires loose or worn • Injector failure • Faulty electrical connection 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.33 © Copyright Ariens Company...

  • Page 184: Digital Wrench Operation

    Diagnostic procedures are added to subsequent versions of Digital Wrench® as they become available. Check your release version often and upgrade when available to be sure you are using the most current software available. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.34...

  • Page 185: Digital Wrench® Communication Errors

    Wrench®. 3. If a newer update is available, it should be downloaded before using Digital Wrench®. NOTE Always operate with the latest update. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.35 © Copyright Ariens Company...

  • Page 186: Digital Wrench Updates

    6. To download the software you must visit the Ariens 3. Toggle the Auto-Updates button to the ON position. and Gravely dealer extranet then click the JSV icon. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.36 © Copyright Ariens Company...
  • Page 187 Digital Wrench® start-up screen should match the update you just downloaded. NOTE Versions and updates are subject to change. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.37 © Copyright Ariens Company...

  • Page 188: Digital Wrench® Feature Map

    FUEL SYSTEM DIGITAL WRENCH® FEATURE MAP 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.38 © Copyright Ariens Company...

  • Page 189: Engine Controller Reprogramming (Reflash)

    F11. The information in the on-line help is the most current and complete information available. This should be your first step until you are familiar with the process. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.39 © Copyright Ariens Company...
  • Page 190 Digital Wrench®. Enter the VIN along with the customer’s name and address. When completed, click the Authorize button once to proceed. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.40 © Copyright Ariens Company...
  • Page 191 PC during the process. 14. Once reprogramming procedure complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.41 © Copyright Ariens Company...
  • Page 192 FUEL SYSTEM NOTES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 4.42 © Copyright Ariens Company...
  • Page 193 ................5.24 TROUBLESHOOTING 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 194: General Information - Cvt System

    Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 195: Torque Specifications - Cvt System

    Drive Clutch Button to Tower 000-.005” Clearance Drive Clutch Shaft Diameter 1.374” (34.89 mm) 1.372” (34.86 mm) Vespel® Thrust Washer Thickness 0.030” (0.76 mm) 0.025” (0.64 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 196: Cvt System Overview

    CVT area. This is especially critical on units system is similar to a power governor. Rather than vary subjected to frequent water forging. throttle position, as a conventional governor does, the 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 197: Overheating / Diagnosis

    MPH. Use High gear when basic operational ground speeds are more than 7 MPH. NOTE Using High gear for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of drive belt burning. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 198: Cvt System Service

    SEAL, OUTER BRACKET, SCREEN BELT SEAL, COVER INTAKE, FENDER REAR CLAMP, NARROW DUCT, CLUTCH INTAKE INNER CLUTCH COVER CLAMP, BAND HOSE, CLUTCH AIR INLET 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 199: Cvt Disassembly

    4. Install the Drive Clutch Holding Tool (21900613) on the drive clutch. 8. Remove the inner clutch cover from the vehicle. Drive Clutch Holding Tool 21900613 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 200: Cvt Assembly

    7. Clean the splines inside the driven clutch and on the CVT Duct Hose Clamps: 3 lb-ft (4 Nm) transmission input shaft. Apply a light film of grease to the splines on the shaft. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 201: Drive Belt Service

    2. Remove the fasteners (B) retaining the outer clutch cover. 3. Remove the outer clutch cover from the vehicle. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 202: Belt Inspection

    4 lb-ft (6 Nm) 3. Install the airbox to the frame and torque the mounting bolts to specification. TORQUE Airbox Mounting Screws: 8 lb-ft (11 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.10 © Copyright Ariens Company...

  • Page 203: Drive Clutch Service

    CVT SYSTEM DRIVE CLUTCH SERVICE DRIVE CLUTCH EXPLODED VIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.11 © Copyright Ariens Company...

  • Page 204: Clutch Disassembly

    Cover Bushing Inspection: Replace the cover bushing if more brass than Teflon® is visible on the bushing. Refer to “Bushing Service”, page 5.17 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.12 © Copyright Ariens Company...

  • Page 205: Drive Clutch Spring Inspection

    Refer to “Roller, Pin, and Thrust Washer Inspection”, page 5.15 procedure. TORQUE Shift Weight Fasteners (Nuts): 50 lb-in (5.6 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.13 © Copyright Ariens Company...

  • Page 206: Button To Tower Clearance Inspection

    To maintain proper clutch balance and belt-to-sheave worn, damaged or cracked. clearance, be sure to reinstall the original quantity and thickness of washers/spacers beneath the spider during assembly. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.14 © Copyright Ariens Company...

  • Page 207: Roller, Pin, And Thrust Washer Inspection

    Roller Pin Tool to replace rollers and pins. Take care not to damage roller bushing or bearing surface of the new pin during installation. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.15 © Copyright Ariens Company...
  • Page 208 Replace the drive clutch assembly if shaft is worn or damaged. MEASUREMENT Shaft Diameter: Standard: 1.374” (34.89 mm) Service Limit: 1.372” (34.86 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.16 © Copyright Ariens Company...

  • Page 209: Moveable Sheave Bushing Inspection

    4. Install puller adapter (Item 10 from kit). 5. Install main adapter (Item D) onto puller. 6. With towers pointing toward the vise, slide sheave onto puller rod. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.17 © Copyright Ariens Company...
  • Page 210 19. Remove nut from puller rod and set aside. and clutch cover off rod. 20. Remove sheave from puller. 21. Remove installation tool. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.18 © Copyright Ariens Company...

  • Page 211: Clutch Assembly

    9. Torque cover bolts evenly to specification. TORQUE Drive Clutch Cover Bolts: 9 lb-ft (12 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.19 © Copyright Ariens Company...

  • Page 212: Driven Clutch Service

    CVT SYSTEM DRIVEN CLUTCH SERVICE EXPLODED VIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.20 © Copyright Ariens Company...

  • Page 213: Clutch Disassembly / Inspection

    3. Place the driven clutch into the Universal Clutch Compressor 21900605. Spin the compressor tool handle down to apply downward pressure on the spring cup (C). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.21 © Copyright Ariens Company...

  • Page 214: Clutch Assembly

    5. Install driven clutch assembly and drive belt. input shaft. 12. Lube splines with a light film of grease. Do not lubricate the bearings! 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.22 © Copyright Ariens Company...
  • Page 215 CVT SYSTEM 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.23 © Copyright Ariens Company...

  • Page 216: Troubleshooting

    Belt burnt, thin -Dragging brake -Inspect brake system. spots -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.24 © Copyright Ariens Company...
  • Page 217 -Replace belt. Refer to belt burnt troubleshooting Engagement -Thin spots on belt, worn belt and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.25 © Copyright Ariens Company...
  • Page 218 CVT SYSTEM NOTES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 5.26 © Copyright Ariens Company...
  • Page 219 ..................6.33 EXPLODED VIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 220: General Information - Transmission

    10-14 lb-ft (14-19 Nm) Plug Bellcrank Nut 12–18 lb-ft (16–24 Nm) SERVICE SPECIFICATIONS - TRANSMISSION FLUID CAPACITY Recommended Transmission Lubricant:Synthetic Transmission Fluid (Quart)Capacity: 41 oz. (1200 ml) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 221: Shift Lever Service

    5. Remove the retaining ring (J) and slide the shift lever (D) off the mounting bracket and out from the frame. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 222: Shift Cable Service

    7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 223: Transmission Removal

    ETC (B), fuel injectors (C), rear differential relay and solenoid (D). Remove the (5) plastic tie straps (E) retaining the harness to the intake plenum. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 224 Place a spacer or support between the vehicle frame and engine to hold the engine up in position while removing the transmission to engine mounting bolts. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 225 Have an assistant help guide the transmission in and out of the vehicle while using a hoist to prevent personal injury or damage to vehicle components. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 226: Transmission Installation

    NOTE DO NOT torque fastener at this time. 4. Align the front transmission mounting holes with the transmission joint bracket mounting holes. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 227 12. Torque the rear transmission mount bolt (B) to specification. TORQUE Rear Transmission Mount Bolt: 40 lb-ft (54 Nm) 13. Remove the lifting straps and overhead or portable hoist. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 228 Reconnect the fuel line to the fuel rail. NOTE Be sure to tug on the fuel line after installing it to make sure it is secured. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.10 © Copyright Ariens Company...
  • Page 229 Synthetic Transmission Fluid. Refer “Transmission Lubrication”, page 2.24. FLUID CAPACITY Recommended Transmission Lubricant: Synthetic Transmission Fluid Capacity: 41 oz (1200 mL) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.11 © Copyright Ariens Company...

  • Page 230: Transmission Mounting Torque Values

    TRANSMISSION TRANSMISSION MOUNTING TORQUE VALUES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.12 © Copyright Ariens Company...

  • Page 231: Transmission Service

    This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.13 © Copyright Ariens Company...

  • Page 232: Transmission Disassembly

    8. Remove the spacer (J). 4. Remove E-clip (C) that retains spring washer (D), flat washer (D) and gear switch (E). Remove the switch. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.14 © Copyright Ariens Company...
  • Page 233 13. Remove the shift shaft rail (Q) and shift forks from the transmission housing as an assembly. CAUTION Do not pry on case sealing surfaces.Use only the designated pry points on the transmission. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.15 © Copyright Ariens Company...
  • Page 234 If disassembly is required, refer to “Gear Cluster Disassembly”, page 6.17. 17. Slide engagement dog (X) off of shift fork guides. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.16 © Copyright Ariens Company...

  • Page 235: Gear Cluster Disassembly

    CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.17 © Copyright Ariens Company...

  • Page 236: Snorkel Shaft Removal / Disassembly

    5. Use an arbor press to remove the snorkel tube from the snorkel shaft. 6. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.18 © Copyright Ariens Company...

  • Page 237: Planetary Differential Disassembly

    8. Remove the retaining ring to remove the remaining washer, bearing and gear from the snorkel shaft. 2. Remove the (6) screws retaining the differential cover and remove the cover. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.19 © Copyright Ariens Company...

  • Page 238: Planetary Differential Bushing Replacement

    Bushing replacement can be performed on all necessary differential components. If bushing replacement is required, proceed to Planetary Differential Bushing Replacement”. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.20 © Copyright Ariens Company...
  • Page 239 7. Press the new bushing into the planet gear until it is flush on each end. Repeat this procedure for the remaining planet gears. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.21 © Copyright Ariens Company...

  • Page 240: Planetary Differential Assembly

    5. Install screws hand tight. Place assembly in soft jaw bottoms out. vise and torque to specification. TORQUE Differential Cover Screws: 18–22 lb-ft (24–30 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.22 © Copyright Ariens Company...

  • Page 241: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.23 © Copyright Ariens Company...

  • Page 242: Snorkel Gear Backlash Procedure

    Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.24 © Copyright Ariens Company...
  • Page 243 If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.25 © Copyright Ariens Company...
  • Page 244 15. Once the backlash is set, apply Loctite ® 242 to the threads and install the locking screw to secure the snorkel tube. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.26 © Copyright Ariens Company...

  • Page 245: Transmission Assembly

    Torque specification. TORQUE Shift Fork Screws: 17 lb-ft (23 Nm) 4. Slide engagement dog (U) onto retaining pins of shift fork. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.27 © Copyright Ariens Company...
  • Page 246 Be sure the shift forks are engaged into the engagement dogs. NOTE Shift fork pins should be offset towards the input shaft as shown above. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.28 © Copyright Ariens Company...
  • Page 247 (.070" or 1.8 mm from outer face of bore). 12. Apply a continuous bead of Gearcase Sealant to the left hand transmission mating surface. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.29 © Copyright Ariens Company...
  • Page 248 23. Install the sector cover and align the transmission case dowel with the alignment hole. Install and torque the bolts to specification. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.30 © Copyright Ariens Company...
  • Page 249 Install the nut and torque to specification. 26. Refer to “Transmission Installation”, page 6.8 to complete the repair. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.31 © Copyright Ariens Company...

  • Page 250: Troubleshooting

    If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.32 © Copyright Ariens Company...

  • Page 251: Transmission Exploded View

    TRANSMISSION TRANSMISSION EXPLODED VIEW EXPLODED VIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.33 © Copyright Ariens Company...
  • Page 252 Bearing, Ball Dog, Engagement 102. Ring Gear, 53T Bearing, Ball Shift Dog, Park 104. Screw, M8 x 1.25 x 25 Bearing, Ball Gear, 46T 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 6.34 © Copyright Ariens Company...
  • Page 253 ..............7.29 DRIVE SHAFT CUTAWAY VIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 254: General Information - Final Drive

    Rear Caliper Mounting 48 lb-ft (65 Nm) Bolts SERVICE SPECIFICATIONS - FINAL DRIVE SERVICE PART DESCRIPTION SPECIFICATION Front Gearcase Coil 21.6 - 26.4 Ω Resistance 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 255: Front Bearing Carrier Service

    The bearing should rotate quietly and smoothly with no detectable up and down movement and minimal movement sideways between the inner and outer races. Visually inspect for moisture, dirt or corrosion. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 256: Bearing Replacement

    4. Inspect bearing carrier housing for scratches, wear or damage. Replace front bearing carrier if damaged. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 257: Bearing Carrier Installation

    10. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around the end of the shaft. Install the center cap and/or rubber dust cap. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 258: Front Drive Shaft Service

    FRONT DRIVE SHAFT INSTALLATION 1. Install new spring ring on the end of the drive shaft. Apply an anti-seize compound to splines. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 259: Front Propshaft Service

    5. Reverse this procedure to reinstall the front propshaft. Use a NEW roll pin upon installation. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 260 5. Install front skid plate. 6. Install front section of the propshaft. 7. Install the front gearcase. Refer to “Front Gearcase Installation”, page 7.21 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 261: Propshaft U-Joint Service

    Press Set, place a receiving cup adapter (2) with a larger ID than the U-joint cap OD on one end. 5. Tighten clamp with hand tools to force U-joint cups out of yoke. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 262: Propshaft U-Joint Assembly

    6. Tighten clamp to install caps simultaneously into yoke bores. 7. Push U-joint side to side during clamping to seat into caps properly. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.10 © Copyright Ariens Company...
  • Page 263 10. Place larger adapter (7) with ID larger than yoke bore on side with retaining ring. 11. Tighten clamp until other cap is below retaining ring groove. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.11 © Copyright Ariens Company...

  • Page 264: Front Gearcase Service

    Cover Screws, M6 (T30 Torx) Grommet Cover Plate Assembly Fill Plug Gearcase Housing Drain Plug, Magnetic Clutch Housing (Ring Gear) Retaining Ring, External Roll Cage 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.12 © Copyright Ariens Company...

  • Page 265: All Wheel Drive Operation

    The front drive will remain engaged until the torque requirement goes away (i. e. rear wheels regain traction). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.13 © Copyright Ariens Company...

  • Page 266: Awd Diagnosis

    9. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.14 © Copyright Ariens Company...

  • Page 267: Front Gearcase Removal

    8. Remove the grease zerk fitting from the left front lower control arm. 9. Remove the front gearcase from the left-hand side between the upper and lower control arms. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.15 © Copyright Ariens Company...

  • Page 268: Front Gearcase Disassembly / Inspection

    Nylon spacer is non-serviceable and should not be removed. 4. Remove and inspect the armature plate . Refer to “AWD Diagnosis”, page 7.14 detailed inspection process. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.16 © Copyright Ariens Company...
  • Page 269 9. Inspect the pinion gear for chipped, broken or missing teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.17 © Copyright Ariens Company...
  • Page 270 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.18 © Copyright Ariens Company...

  • Page 271: Front Gearcase Assembly

    4. Install the RH output hub into the gearcase housing. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.19 © Copyright Ariens Company...
  • Page 272 11. Install a new O-ring on the cover plate assembly. NOTE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.20 © Copyright Ariens Company...

  • Page 273: Front Gearcase Installation

    7. Install the drive shafts into the front gearcase. Refer to “Front Gearcase Installation”, page 7.21 procedure. TORQUE Front Gearcase Cover Plate Screws: 7–11 lb-ft (10–15 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.21 © Copyright Ariens Company...
  • Page 274 9. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.22 © Copyright Ariens Company...

  • Page 275: Rear Drive Shaft Service

    3. Insert the drive shaft into the bearing carrier and tilt the carrier up. 4. Install the Rear Axle Brace. Refer to “Rear Axle Brace Installation”, page 8.40 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.23 © Copyright Ariens Company...

  • Page 276: Drive Shaft Service

    OUTER CV JOINT / BOOT REPLACEMENT 1. Use a side cutters to cut and discard the boot clamps. NOTE Tap on inner race only! 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.24 © Copyright Ariens Company...
  • Page 277 8. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.25 © Copyright Ariens Company...

  • Page 278: Inner Plunging Joint / Boot Replacement

    Before you remove your instrument, be sure the small end of the boot is in its correct location on the shaft. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.26 © Copyright Ariens Company...
  • Page 279 9. Visually inspect joint for damage. Replace if needed. 10. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.27 © Copyright Ariens Company...
  • Page 280 19. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.28 © Copyright Ariens Company...

  • Page 281: Drive Shaft Cutaway View

    FINAL DRIVE DRIVE SHAFT CUTAWAY VIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.29 © Copyright Ariens Company...
  • Page 282 FINAL DRIVE NOTES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 7.30 © Copyright Ariens Company...
  • Page 283 ............. . .8.32 BALL JOINT SERVICE PREPARATION 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 284 .................8.42 SPRING REPLACEMENT 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 285: General Information - Body / Steering / Suspension

    New ball joint bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. Detail View 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 286: Torque Specifications - Body / Steering / Suspension

    Rear Axle Nut 110 lb-ft (149 Nm) application. Rear Caliper Mounting 48 lb-ft (65 Nm) Bolts 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 287: Cab Frame

    FRAME, CAB FRONT RH SCREW RIVET HIP BOLSTER NUT, FLANGE BOLT HIP BOLSTER, RH SCREW WASHER HIP BOLSTER, LH NUT, NYLOK BOLT PLATE, WINDSHIELD MOUNT SCREW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 288 HANDLE, GRAB FRAME, CAB FRONT BOLT RIVET FRAME, CAB SIDE LH FRAME, CAB MIDDLE FRAME, CAB SIDE RH HEADREST BOLT SCREW PLATE, WINDSHIELD MOUNT 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 289: Chassis Assembly Views

    SUPPORT, FLOOR LH ROCKER, LH WASHER SUPPORT, FLOOR RH ROCKER, RH CLIP, U SPEED NUT PLATE, WINDSHIELD MT SCREW GROMMET BOLT BRACKET, WINDSHIELD SCREW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 290 BODY / STEERING / SUSPENSION Main Frame / Frame Supports - JSV6000 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 291: Body Components Assembly Views

    SEAL, GLOVEBOX UPPER LH GROMMET GROMMET, SHIFT LEVER DASH, STORAGE HOLDER, CUP SCREW CLIP PANEL, DASH CONTROLS RIVET SCREW DASH, PANEL LOWER DASH, PANEL UPPER 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 292: Hood / Front Fenders / Front Fascia

    GRILL, FRONT UPPER FENDER, FRONT RH RIVET GRILL, UPPER TRIM FLARE, FENDER FRONT LINER, HOOD SCREW FLARE, FENDER FRONT SCREW GROMMET LATCH HOOD SCREW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.10 © Copyright Ariens Company...

  • Page 293: Floor / Rear Fenders / Skid Plate / Storage - Jsv3000

    FLOOR SCREW ASM, FENDER REAR PANEL, CLOSEOFF UPPER LH LOWER FLOOR, FRONT ASM, FENDER REAR UPPER RH GROMMET FENDER, REAR W/ ROCKER LH 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.11 © Copyright Ariens Company...
  • Page 294 SHAFT FLOOR FENDER, FRONT W/ FLOOR, FRONT FENDER, REAR ROCKER RH UPPER LH SCREW GROMMET FENDER, REAR UPPER RH FLOOR RIVET PANEL, CLOSEOFF 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.12 © Copyright Ariens Company...
  • Page 295 FLOOR, PANEL REAR FLOOR, REAR RIVET ASM, FENDER REAR PANEL, CLOSEOFF REAR UPPER LH SCREW ASM, FENDER REAR PANEL, CLOSEOFF UPPER RH LOWER 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.13 © Copyright Ariens Company...

  • Page 296: Seat Mounting / Seat Belts - Jsv3000

    ASM, SEAT BELT CAP, BOLT HEAD ASM, SEAT BACK BUCKLE, SEAT BELT BRACKET, SEAT HINGE GROMMET WASHER CLAMP, WIRE/TUBE PIN, SEAT LATCH SCREW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.14 © Copyright Ariens Company...
  • Page 297 BRACKET, SEAT HINGE DBL BUCKLE, SEAT BELT DRVR ASM, SEAT BACK PSNGR BUCKLE, SEAT BELT PSNGR BRACKET, SEAT HINGE COVER, SEAT BELT MNT 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.15 © Copyright Ariens Company...

  • Page 298: Rear Cargo Box Service

    BODY / STEERING / SUSPENSION REAR CARGO BOX SERVICE TAILGATE / CARGO BOX PANELS ASSEMBLY VIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.16 © Copyright Ariens Company...
  • Page 299 ROD, LATCH LH SCREW CAP, TAILGATE LATCH ROD, LATCH RH PIN, TAILGATE LATCH SHIELD, HEAT EXHAUST WASHER BUSHING, TAILGATE SHIELD, HEAT EXHAUST LATCH REAR 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.17 © Copyright Ariens Company...

  • Page 300: Cargo Box Removal

    6. Lift the cargo box from the frame. Two people or an appropriate overhead hoist may be needed to remove the box from the frame. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.18 © Copyright Ariens Company...

  • Page 301: Body Component Removal

    5. Carefully pull the front fascia down to remove it from the vehicle. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.19 © Copyright Ariens Company...

  • Page 302: Front Fenders Removal

    3. Pop the shifter cap off and remove the screw and pull up on the shifter grip to remove it. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.20 © Copyright Ariens Company...

  • Page 303: Rocker Panel Removal - Jsv3000

    Low or High gear to ease removal. 8. Carefully pull the lower dash panel towards the seat and up to remove it. Dash Storage Panel 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.21 © Copyright Ariens Company...

  • Page 304: Rocker Panel Removal - Jsv6000

    8. Installation is reverse of removal. Front Rocker Panel Removal 1. Remove rear rocker panel. Refer to “Rear Rocker Panel Removal” procedure. 2. Remove front seat base. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.22 © Copyright Ariens Company...

  • Page 305: Main Floor Removal

    5. Remove the (3) plastic tie straps retaining the pedal position sensor harness to the front floor. 6. If equipped, remove the fasteners retaining the EPS unit to the lower steering shaft. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.23 © Copyright Ariens Company...

  • Page 306: Rear Floor Removal - Jsv6000

    8. Remove the wire harness grommet (D) Fig. 1 to separate the fuse box, ECU and diagnostic connector wire harness from the storage box. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.24 © Copyright Ariens Company...
  • Page 307 10. Remove (14) T-40 Torx fasteners (F) Fig. 3 from the main floor panel. 11. Lift the floor panel out of the vehicle. 12. Installation is the reverse order of removal. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.25 © Copyright Ariens Company...

  • Page 308: Steering Assembly Service

    BOLT SHAFT, STEERING, UPPER / SCREW LOWER ASM, GEAR BOX, STEERING BOLT BUSHING, STEERING CAP, STEERING WHEEL PIN, COTTER ASM, SHOCK, OIL LOCKING 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.26 © Copyright Ariens Company...

  • Page 309: Steering Wheel Removal (Non-Eps)

    5. Refer to steps 11-13 of the “Steering Shaft Bearing Replacement”, page 8.28 procedure for installation. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.27 © Copyright Ariens Company...

  • Page 310: Steering Shaft Bearing Replacement

    13. Wipe the pivot tube clean of any excess Loctite ®. 14. Install steering wheel cap and field test steering operation. PART DESCRIPTION STEERING WHEEL HUB INSERT BUSHING SHAFT, UPPER TILT ASSEMBLY 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.28 © Copyright Ariens Company...

  • Page 311: Assembly View

    FITTING, ZERK CARRIER, BEARING SCREW JOINT, BALL RING, RETAINING INT WASHER RING, RETAINER EXT BEARING, BALL SEALED SCREW SHAFT, PIVOT SHIELD, CV NUT, FLANGE 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.29 © Copyright Ariens Company...

  • Page 312: Front Lower A-Arm Removal

    60 lb-ft (81 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.30 © Copyright Ariens Company...

  • Page 313: Front Upper A-Arm Removal

    4. Install wheel and torque wheel nuts to specification. TORQUE Wheel Nuts (Steel): 60 lb-ft (81 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.31 © Copyright Ariens Company...

  • Page 314: Ball Joint Service

    (21900592) on the upper ball joint. To service the lower ball joint: 6. Remove and discard the lower ball joint pinch bolt. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.32 © Copyright Ariens Company...

  • Page 315: Ball Joint Installation

    A-arm to engage the Installation Adapter and Spacer. 5. Tighten the Press Asm. screw and fully install the ball joint into the arm. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.33 © Copyright Ariens Company...
  • Page 316 Front Shock Mounting Bolts: 40 lb-ft (54 Nm) Front Caliper Mounting Bolts: 30 lb-ft (41 Nm) Wheel Nuts (Steel): 60 lb-ft (81 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.34 © Copyright Ariens Company...

  • Page 317: Rear Suspension Link And Axle Brace

    BODY / STEERING / SUSPENSION REAR SUSPENSION LINK AND AXLE BRACE EXPLODED VIEW 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.35 © Copyright Ariens Company...

  • Page 318: Rear Upper Suspension Link Removal

    Upon repair completion, test vehicle at low speeds 4. Remove the upper suspension link out the back of before putting into service. the machine. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.36 © Copyright Ariens Company...

  • Page 319: Rear Lower Suspension Link Removal

    4. Install wheel and torque wheel nuts to specification. TORQUE Wheel Nuts (Steel): 60 lb-ft (81 Nm) WARNING Upon repair completion, test vehicle at low speeds before putting into service. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.37 © Copyright Ariens Company...

  • Page 320: Rear Axle Brace Removal

    6. Remove the two T-25 Torx head screws retaining the brake junction block to the rear axle brace. 7. Remove the brake line from the four retainer clips 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.38 © Copyright Ariens Company...

  • Page 321: Rear Axle Bearing Replacement

    Do not allow the Loctite ® compound to get in the bearing. 7. Wipe the housing clean of any excess compound and install the snap ring. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.39 © Copyright Ariens Company...

  • Page 322: Rear Axle Brace Installation

    6. Install the hub/disc assembly, two washers, and new axle nut. Torque nut to specification. TORQUE Rear Axle Nut: 110 lb-ft (149 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.40 © Copyright Ariens Company...

  • Page 323: Shock / Spring Service

    BODY / STEERING / SUSPENSION SHOCK / SPRING SERVICE SHOCKS ASSEMBLY VIEW Front Shock Rear Shock 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.41 © Copyright Ariens Company...

  • Page 324: Shock Removal / Installation

    5. Turn adjustment cam to set preload distance noted in Step 1. 6. Reinstall shock onto vehicle and torque new fasteners to specification. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 8.42 © Copyright Ariens Company...
  • Page 325 REAR BRAKE DISC SERVICE ............... . .9.27 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual...
  • Page 326 ................... .9.29 BRAKES LOCK 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 327: General Information - Brake System

    The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves further outward and becomes self adjusting. Fluid 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 328: Torque Specifications - Brake System

    0.010" (0.254 mm) Rear Caliper Piston Bore I.D. 1.505" (38.23 mm) 1.507" (38.28 mm) Rear Caliper Piston O.D. 1.500" (38.10 mm) 1.498" (38.05 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 329: Brake System Service

    BRAKE FLUID LINE, FRONT LH BRAKE FLUID LINE, REAR RH CALIPER, FRONT RH CALIPER, REAR LH BRAKE FLUID LINE, FRONT RH BRAKE FLUID LINE, REAR LH 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 330: Brake Bleeding / Fluid Change

    Caliper Bleed Screws: 47 lb-in (5.3 Nm) 14. Repeat Steps 9 - 13 for the remaining brake calipers. 15. Install master cylinder reservoir cover. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...
  • Page 331 Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2" (1.3 cm). 17. Check brake system for fluid leaks. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 332: Master Cylinder Service

    4. Follow the “Brake Bleeding / Fluid Change” procedure. 5. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 333: Foot Brake Pedal Service

    2. Remove the retaining clip and clevis pin from the master cylinder to free it from the brake pedal. 3. Slide the brake pedal and bushings off the pedal mount bracket. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual © Copyright Ariens Company...

  • Page 334: Front Brake Pad Service

    6. Remove the inner pad from the bracket and caliper. NOTE When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.10 © Copyright Ariens Company...

  • Page 335: Pad Inspection

    If brake pads are contaminated with grease, oil, or TORQUE liquid soaked do not use the pads. Use only new, clean pads. Wheel Nuts (Steel): 60 lb-ft (81 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.11 © Copyright Ariens Company...

  • Page 336: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.12 © Copyright Ariens Company...

  • Page 337: Front Caliper Service

    PART DESCRIPTION Asm, Brake Pad Piston, Brake Asm, Caliper Mount Ring Caliper, Brake Bolt Boot, Pin Seal Bleeder Screw Boot, Pin Bushing Cap, Plug 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.13 © Copyright Ariens Company...

  • Page 338: Caliper Removal

    5. Loosen brake pad adjustment set screw (B) to allow brake pad removal after the caliper is removed. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.14 © Copyright Ariens Company...

  • Page 339: Caliper Inspection

    Replace if damaged or worn beyond service limit. MEASUREMENT Front Caliper Piston Bore I.D.: Standard: 1.373" (34.87 mm) Service Limit: 1.375" (34.93 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.15 © Copyright Ariens Company...

  • Page 340: Caliper Assembly

    Front Caliper Mounting Bolts: Piston should slide in and out of bore smoothly, with light resistance. 30 lb-ft (41 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.16 © Copyright Ariens Company...
  • Page 341 If the brake drags, re-check assembly and installation. NOTE If new brake pads are installed, brake burnishing is recommended. Refer to “Brake Burnishing Procedure”, page 9.12. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.17 © Copyright Ariens Company...

  • Page 342: Front Brake Disc Service

    Service Limit: 0.170" (4.32 mm) MEASUREMENT MEASUREMENT Brake Disc Runout: Brake Disc Thickness Variance Service Limit: 0.010" (0.254 mm) Service Limit: 0.002” (0.051 mm) difference between measurements 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.18 © Copyright Ariens Company...

  • Page 343: Disc Replacement

    Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. TORQUE Front Brake Disc Mounting Bolts: 18 lb-ft (24 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.19 © Copyright Ariens Company...

  • Page 344: Rear Brake Pad Service

    Remove excess fluid from reservoir as required. Rear Brake Pad Thickness Standard: 0.298 ± .007" (7.56 ± .178 mm) Service Limit: 0.150" (3.8 mm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.20 © Copyright Ariens Company...

  • Page 345: Pad Installation

    4. Slowly pump brake pedal until pressure has been built up. Maintain at least 1/2" (12.7 mm) of brake fluid in reservoir to prevent air from entering master cylinder. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.21 © Copyright Ariens Company...

  • Page 346: Rear Caliper Service

    Seal, Caliper - Inner Screw Seal, Caliper - Outer Kit, Brake Pad CALIPER REMOVAL 1. Elevate and safely support the rear of the vehicle. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.22 © Copyright Ariens Company...

  • Page 347: Caliper Disassembly

    5. After fluid has drained into the container, remove the two caliper mounting bolts and brake caliper. 6. Clean the brake disc, caliper body and caliper pistons with brake cleaner or alcohol. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.23 © Copyright Ariens Company...

  • Page 348: Caliper Inspection

    2. Coat piston with clean DOT 4 Brake Fluid. Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.24 © Copyright Ariens Company...

  • Page 349: Caliper Installation

    If the brake drags, re-check assembly and installation. NOTE If new brake pads are installed, brake burnishing is recommended. Refer to “Brake Burnishing Procedure”, page 9.21. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.25 © Copyright Ariens Company...
  • Page 350 BRAKE SYSTEM 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.26 © Copyright Ariens Company...

  • Page 351: Rear Brake Disc Service

    Service Limit 0.170" (4.32 mm) MEASUREMENT MEASUREMENT Brake Disc Thickness Variance: Brake Disc Runout Service Limit: 0.002” (0.051 mm) Service Limit: 0.010" (0.254 mm) difference between measurements 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.27 © Copyright Ariens Company...
  • Page 352 Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. TORQUE Rear Brake Disc Mounting Bolts: 28 lb-ft (38 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.28 © Copyright Ariens Company...
  • Page 353 • Caliper pistons sticking • Improper assembly of brake system components PEDAL VIBRATION • Disc damaged • Disc worn (runout or thickness variance exceeds service limit) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.29 © Copyright Ariens Company...
  • Page 354 BRAKE SYSTEM NOTES 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 9.30 © Copyright Ariens Company...
  • Page 355 ............. . 10.28 COOLANT TEMPERATURE SENSOR 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.1...
  • Page 356 ............10.44 STARTING SYSTEM TESTING FLOW CHART 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.2...

  • Page 357: General Information - Electrical System

    Disconnect it from the wiring harness or power • ECU* supply. • Speed Key Accessory (if installed) NOTE *Components are located under rear passenger seat base on CREW models. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.3 © Copyright Ariens Company...

  • Page 358: Special Tools - Electrical

    47 VAC ± 25% RPM) Stator Leg Voltage (5000 79 VAC ± 25% RPM) Starter Solenoid Terminal 2.5 Ω ± 20% Resistance (77 °F) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.4 © Copyright Ariens Company...

  • Page 359: Switches / Controls

    9.6 if replacing the brake switch, as the brake bleeding procedure will need to be performed. NOTE Pins 7 and 8 provide power and ground to light the switch lamp. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.5 © Copyright Ariens Company...

  • Page 360: Ignition Key Switch

    1 and 2; 4 and 5. NOTE Pins 7 and 8 provide power and ground to light the switch lamp. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.6 © Copyright Ariens Company...

  • Page 361: Transmission (Gear Position) Switch

    Do not pull on the wiring. 2. Test transmission switch for continuity in each gear position and compare to the specifications below. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.7 © Copyright Ariens Company...

  • Page 362: Vehicle Speed Sensor Service

    4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.8 © Copyright Ariens Company...

  • Page 363: Rear Diff Solenoid Service

    CAUTION Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.9 © Copyright Ariens Company...

  • Page 364: Instrument Cluster Service

    Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.10...

  • Page 365: Rider Information Display

    10. Unit Lock - N/A on this model. 11. Hour Meter - Illuminates when the display (2) is showing hours. 12. Low Oil Pressure Indicator - N/A on this model. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.11 © Copyright Ariens Company...

  • Page 366: Information Display Area

    2. To reset to 0, push and hold the MODE button until the distance display changes to 0. Engine hours are logged anytime the engine is running. Total hours can not be reset. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.12 © Copyright Ariens Company...
  • Page 367 7. Toggle the MODE button until the odometer is displayed. 15. Press and hold the MODE button to save the setting and advance to the next display option. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.13 © Copyright Ariens Company...

  • Page 368: Diagnostic Mode

    • The third number (located bottom right) can be 1 to 2 digits in length. This number equates to the fault mode (FMI). 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.14 © Copyright Ariens Company...

  • Page 369: Instrument Cluster Pinouts

    2. Press and hold the MODE button to enter the diagnostics code menu. Constant Power (Vdc) Ground High Beam Input Fuel Level Sensor 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.15 © Copyright Ariens Company...
  • Page 370 5. To exit the diagnostic mode, press and hold the MODE button or turn the ignition key OFF once the codes are recorded. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.16 © Copyright Ariens Company...
  • Page 371 Driver Circuit Grounded P1265 Driver Circuit Open / Grounded P1691 Rear Differential Output Driver Circuit Short to B+ P1692 Driver Circuit Grounded P1693 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.17 © Copyright Ariens Company...
  • Page 372 Accelerator Position / Brake Condition Exists 520275 P150A Position Interaction Throttle Position Sensor Neither Position Sensor Passed 520276 P150B (1 or 2 Indeterminable) Test 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.18 © Copyright Ariens Company...
  • Page 373 Condition Exists 520308 P1533 Difference Exceeds Limit ECU Fault - ICO Condition Exists 520309 P1534 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.19 © Copyright Ariens Company...

  • Page 374: Instrument Cluster Removal

    The instrument cluster bezel is a snap-on assembly and is a serviceable part. 2. Disconnect the wire harness connector from the back side of the instrument cluster. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.20 © Copyright Ariens Company...

  • Page 375: Instrument Cluster Installation

    4. Connect the wire harness to the instrument cluster. 5. Install the upper dash panel and push rivets. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.21 © Copyright Ariens Company...

  • Page 376: All Wheel Drive Coil Service

    80% of all electrical issues are caused by bad/failed connections and grounds. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.22 © Copyright Ariens Company...

  • Page 377: Headlight Service

    Make sure the tab on the bulb locates properly in the housing. 6. Install the harness onto the new headlight bulb and install the hood. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.23 © Copyright Ariens Company...

  • Page 378: Headlight Housing Removal

    7. Test the headlight after installation to verify proper operation. 8. Adjust headlights to proper height. Refer to “Headlight Adjustment”, page 10.23 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.24 © Copyright Ariens Company...

  • Page 379: Tail Light / Brake Light Service

    3. Install the new LED lamp assembly by reversing this procedure. 4. Test the tail light / brake light after installation to verify proper function. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.25 © Copyright Ariens Company...

  • Page 380: Fuel Sender Service

    6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly. Refer to “Fuel Pump Replacement”, page 4.14 procedure. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.26 © Copyright Ariens Company...

  • Page 381: Cooling System Service

    ELECTRICAL COOLING SYSTEM SERVICE COOLING SYSTEM BREAK-OUT DIAGRAM 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.27 © Copyright Ariens Company...

  • Page 382: Fan Control Circuit Operation / Testing

    4. If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.28 © Copyright Ariens Company...

  • Page 383: Ignition Coil Service

    Ignition Coil Retaining Bolt: 75 lb-in (8.5 Nm) 7. Connect the harness connection to the ignition coil and then connect the (-) negative battery cable. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.29 © Copyright Ariens Company...

  • Page 384: Fuse Box: Fuses / Relays / Circuit Break Service

    EFI system, and drive system. A separate 20-amp circuit breaker, located near the fuse/relay box, protects the fan motor circuit. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.30...

  • Page 385: Fuse Box Detail View

    Brown / White 12 Vdc power input from key Orange switch to enable relay. Provides 12 Vdc power for lights, White drive and accessory circuits. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.31 © Copyright Ariens Company...
  • Page 386 Orange switch to enable relay. Provides 12 Vdc power for EPS Orange operation. REAR DIFF SOLENOID RELAY provides power to the following system: 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.32 © Copyright Ariens Company...

  • Page 387: Charging System Service

    8. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.33 © Copyright Ariens Company...

  • Page 388: Charging System Stator (Alternator) Tests

    79 VAC ± 25% 2. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.34 © Copyright Ariens Company...

  • Page 389: Stator (Alternator) Replacement

    3. If replacing the regulator / rectifier (A), remove the (2) retaining screws (B) and disconnect the wire harness (C). Remove the regulator (A) and heat sink plate (D) from the vehicle. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.35 © Copyright Ariens Company...
  • Page 390 212° F or 100° C. If it turns off, verify the cooling fins are clean, free from debris and that adequate airflow is present. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.36 © Copyright Ariens Company...

  • Page 391: Charging System Testing Flow Chart

    Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched: 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.37...

  • Page 392: Battery Service

    Refer to “OCV - Open Circuit Voltage Test”, page 10.39 procedure. 5. Charge the battery as recommended. Refer to “Battery Charging Procedure”, page 10.40. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.38 © Copyright Ariens Company...

  • Page 393: Battery Terminal Block

    The following are two tests which can easily be made on a sealed Maintenance Free battery to determine its condition: OCV Test and a Load Test. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.39 © Copyright Ariens Company...

  • Page 394: Battery Charging Procedure

    Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.40 © Copyright Ariens Company...

  • Page 395: Starter System Service

    Voltage should not exceed .1 DC volts per connection NOTE The negative (-) battery cable is mounted to the engine using the upper starter mounting bolt / stud. 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.41 © Copyright Ariens Company...

  • Page 396: Starter Motor Installation

    • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. TORQUE Starter Motor Fasteners: 7 lb-ft (10 Nm) 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.42 © Copyright Ariens Company...
  • Page 397 ELECTRICAL 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.43 © Copyright Ariens Company...

  • Page 398: Starting System Testing Flow Chart

    ELECTRICAL STARTING SYSTEM TESTING FLOW CHART 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual 10.44 © Copyright Ariens Company...
  • Page 399 Cab Frame Inspection.............9.24 Assembly View ............8.5 Installation ............9.25 Camshaft Removal...............9.22 Chain and Guide Service .........3.38 Brake Disc, Front Decompression Mechanism ........3.37 Inspection.............9.18 Inspection.............3.37 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual IX.1 © Copyright Ariens Company...
  • Page 400 Spring Inspection ...........5.13 Drive Shaft Boot Inspection .........2.30 Maintenance / Inspection .......... 5.4 Overheating Diagnostics ........... 5.5 Driven Clutch Service Notes ............5.2 Assembly .............5.22 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual IX.2 © Copyright Ariens Company...
  • Page 401 Oil Pump Removal..........3.67 Service Notes ............7.2 Piston / Rod Assembly ..........3.55 Service Specifications ..........7.2 Piston / Rod Inspection ..........3.46 Special Tools ............7.2 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual IX.3 © Copyright Ariens Company...
  • Page 402 Service Specifications ..........4.5 Maintenance Quick Reference Chart ......2.8–2.9 Special Tools ............4.3 Master Cylinder Torque Specifications ..........4.5 Installation ............. 9.8 Troubleshooting .............4.33 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual IX.4 © Copyright Ariens Company...
  • Page 403 Relay Operation ............10.31 Starter Motor Rocker Panel Installation ............10.42 Removal...............8.21 Removal............. 10.41 Removal - CREW ...........8.22 Starter Solenoid Bench Test............10.42 Operation ............10.42 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual IX.5 © Copyright Ariens Company...
  • Page 404 Thermostat Replacement ..........3.17 Clearance / Adjustment ...........3.59 Throttle Pedal Inspection ..........2.16 Exhaust Valve Lash - Tappet Selection Matrix....3.63 Tie Rod End Inspection..........2.34 Inspection.............3.41 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual IX.6 © Copyright Ariens Company...
  • Page 405 Voltage Drop Test ............ 10.41 Water Pump Mechanical Seal / Oil Seal Replacement .....3.19 Removal / Installation ..........3.18 Wheel Alignment ............2.34 Wheel, Installation .............2.31 Wheel, Removal............2.31 21901443 R02 - 2016 Gravely Atlas JSV3000 / JSV6000 EFI Service Manual IX.7 © Copyright Ariens Company...

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