Poulan Pro PB19546LT/96042003502 Owner's manual

REPAIR PART'S MANUAL
MODEL: 96042003502
PB19546LT
LAWN TRACTOR
ALWAYS WEAR EYE PROTECTION DURING OPERATION
Visit our website: www.poulan-pro.com
WARNING:
Read this Manual and follow all Warnings
and Safety Instructions. Failure to do so can
result in serious injury.
IMPORTANT MANUAL Do Not Throw Away
03076
419057 01.08.08 SR Printed in U.S.A.

2
M
FUSE
STARTER
SOLENOID
BATTERY
CLUTCH/BRAKE
(PEDAL UP)
REVERSE SWITCH
(NOT IN REVERSE)
SEAT SWITCH
(NOT OCCUPIED)
SHORTING
CONNECTOR
CHASSIS
HARNESS
IGNITION
UNIT
HOUR
METER
CHASSIS HARNESS
CONNECTOR
(MATING SIDE)
DASH HARNESS
CONNECTOR
(MATING SIDE)
FUEL
LINE
FUEL SHUT-OFF
SOLENOID
(IF SO EQUIPPED)
JUNCTION
CONNECTOR
SM
B
GL
2
3
1
6
A2
A1
M
63
52
41
6
5
4
3
2
1
SPARK
PLUGS GAP
(2 PLUGS ON
TWIN CYL. ENGINES)
(OPTIONAL)
NON-REMOVABLE
CONNECTIONS
REMOVABLE
CONNECTIONS
WIRING INSULATED CLIPS
NOTE: IF WIRING INSULATED
CLIPS WERE REMOVED FOR
SERVICING OF UNIT, THEY
SHOULD BE RE-INSTALLED TO
PROPERLY SECURE YOUR
WIRING.
SCH11
IGNITION SWITCH
CIRCUITPOSITION
OFF
B+A1
RUN/OVERRIDE
B+S+A1START
M+G+A1
B+A1RUN
“MAKE”
L+A2
ATTACHMENT CLUTCH
(CLUTCH OFF)
BLACK
BLACK /WHITE
BLUE
BLUE BLACK
BLACKBLACK
BLACK
BLACK
BLACK
BLACK
BLACK
DER
RED
WHITE
WHITE
GRAY
GRAY
BLACK
BLACK
POWER OUTLET
(OPTIONAL)
12V
BLACK
A
AMMETER
(OPTIONAL)
RED
BLACK
BROWN
HEADLIGHTS
LIGHT SWITCH
ORANGE
LIGHTING SYSTEM OUTPUT
5 AMP AC @ 3600 RPM
ALTERNATOR
14 VOLTS AC MIN. @ 3600 RPM (LIGHTS OFF)
DIODE
28 VOLTS AC MIN. @ 3600 RPM
(CHARGING SYSTEM DISCONNECTED)
CHARGING SYSTEM OUTPUT
3 AMP DC @ 3600 RPM
NOTE
YOUR TRACTOR IS
EQUIPPED WITH A SPECIAL
ALTERNATOR SYSTEM.
THE LIGHTS ARE NOT
CONNECTED TO THE
BATTERY, BUT HAVE THEIR
OWN ELECTRICAL SOURCE.
BECAUSE OF THIS, THE
BRIGHTNESS OF THE LIGHTS
WILL CHANGE WITH ENGINE
SPEED. AT IDLE THE LIGHTS
WILL DIM. AS THE ENGINE IS
SPEEDED UP, THE LIGHTS
WILL BECOME THEIR
BRIGHTEST.
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
SCHEMATIC

3
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm
KEY PART
NO. NO. DESCRIPTION
6
2
1
5,8
4,10
3,9
11
7
WHEELS AND TIRES
KEY PART
NO. NO. DESCRIPTION KEY PART
NO. NO. DESCRIPTION
3
16
9
1 59192 Cap Valve Tire
2 65139 Stem Valve
3 106222X Tire F T 15 x 6 0 - 6 Service
4 59904 Tube Front (Service Item Only)
5 106732X421 Rim Asm 6" front Service
6 278H Fitting Grease (Front Wheel Only)
7 9040H Bearing Flange (Front Wheel nly)
8 106108X421 Rim Asm 8" Rear Service
9 106268X Tire R T 18 x 9.5-8C Service
10 7152J Tube Rear (Service Item Only)
11 104757X421 Cap Axle Blk 1 50 x 1 00
- - 144334 Sealant, Tire (10 oz. Tube)
20
14
2
2 408834 Decal Eng. H.P.
3 186164 Decal Hood LH
4 408794 Decal Side Panel Logo
5 411174 Decal Lwr Dash
6 170563 Decal Warning, Keep Hand Away
7 413417 Decal Replacement Parts
8 411658 Decal Fender Warn S/F
9 172740 Decal Fender Logo
11 172743 Decal Ins Strg Whl
12 408948 Decal Fend SD RH
13 408949 Decal Fend SD LH
14 160396 Decal V-Belt Schematic
16 186163 Decal Hood RH
20 145005 Decal Bat Dan/Psn
- - 193226X428 Pad Footrest LH
- - 193227X428 Pad Footrest RH
- - 413437 Manual Operator's (Eng/French)
- - 419057 Manual Parts (Eng/French)
7
11 44
6
5 5
12 13
8

4
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
ELECTRICAL
30
33
34
22
79 21
41
42
26
43
27
40
71
16
87
25
T02S
90
28
55
With 12V Outlet Option
59
103
With Service Minder Option
4646
94
92
29
93
2

5
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
ELECTRICAL
KEY PART
NO. NO. DESCRIPTION
1 163465 Battery
2 74760412 Bolt Hex Hd 1/4-20 unc x 3/4
8 193228 Box Battery
16 176138 Switch Interlock
21 183759 Harness Socket Light
22 4152J Bulb, Light # 1156
25 401662 Cable Battery 6 Ga. Red 14.5
26 175158 Fuse
27 73510400 Nut Keps Hex 1/4-20 unc
28 198885 Cable Ground 18" Rear Battery Blk 6 Ga.
29 401545 Switch Seat
30 193350 Switch Ign
33 411935 Key/Chain
34 110712X Switch Light/Reset
40 401098 Harness Ign
41 17720408 Screw 1/4-20 unc x 1/2
42 131563 Cover Terminal Red
43 192507 Solenoid
55 17060512 Screw 5/16-18 x 3/4
71 400449 Harness Ign. Chass.
79 175242 Socket Asm. Bulb
87 197802 Switch Interlock Clutch
90 400725 Cover Terminal
92 196615 Harness Pigtail Reverse Switch
93 192540 Screw Plastic 10-14 x 2.0
94 191834 Modual Reverse ROS
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm

6
37
181
181
194
194
36
236
236
183
152
159
180
162
196
287
138
182
176
175
177
130
151
2
159
159
58
189
189
189
228
194
228
137
137
14
18
208
207
15
25
186
176
5
176
176
235
235
150
68
217
Chassis-tex_elite-sv-pro_11_r1
230
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
CHASSIS

7
2412282 Drawbar Lower
5 197783X428 Dash
14 183393X428 Hood
15 183834X599 Lens Grille LH
18 183828 Grille
25 183835X599 Lens Grille RH
36 17060512 Screw 5/16-18 x 3/4
37 414872X428 Fender
58 412280 Drawbar Upper
68 17490508 Screw Thdrol 5/16-18 x 1/2
130 416358 Screw #10 x 0.750
137 184921 Bumper Hood
138 193224X428 Cupholder
150 184322 Duct Heat Hood
151 407807 Bracket Pivot
152 194329 Shield Browning/Debris
159 17000612 Screw Hexwsh Thdrol 3/8-16 x 3/4
162 142432 Screw Hex Wsh Hi-Lo 1/4 x 1/2
175 193243 Crossmember
176 400776 Screw 10-24 x 5/8 Wshd Qdrx
177 195228 Bushing Steering
180 194260 Chassis
181 193102X428 Bushing Mtg. Fender Crgo.
182 193057 Dash Lower
183 74780520 Bolt Fin Hex 5/16-18 x 1-1/4
186 183829X428 Insert Grille
189 17000512 Screw 5/16-18 x 3/4
194 73900500 Nut Lock Hex Flange 5/16-18
196 410584 Console Asm. Deck Lift
207 183833 Bezel Grille RH
208 183832 Bezel Grille LH
217 409167 Rod Pivot Hood
228 195161 Stud Fastener
230 170165 Bolt Shoulder 5/16-18
235 406129 Spacer Fender
236 73930500 Nut center Lock 5/16-18
287 17600406 Screw 1/4-20 x 3/8
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
CHASSIS
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm
KEY PART
NO. NO. DESCRIPTION

8
56
185
171
186
189 49
187
50
51
190
52
51
51
231
170
29
232
233 165166
64
188
172
172
17
195
125
125
125
161
35
175
192
134
192
157
141
140
139
23
178
174
176
22
15
15
203
184
167
160
160
42
159
159
166
155
61
202
116
193
2
73 26
158
1
drive-tex_D6800_Fender_7_r1
237
205 33
1
221
70
74
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
DRIVE

9
KEY PART
NO. NO. DESCRIPTION
1- - - - - - Transaxle, D6800
(Contact Transaxle Manufacture )
2 123583X Key Square
15 19131316 Washer 13/32 x 13/16 x 16 Ga.
17 197297 Spring, Brake
22 197660 Rod Shift
23 409154x421 Knob
26 197455 Spring Brake RTN
29 197267 Rod, Brake
33 12000001 Ring E
35 197722 Rod, Brake, Park
37 121749X Washer 25/32 x 1-1/4 x 16 Ga.
42 8883R Cover, Foot Pedal
49 72110614 Bolt
50 194327 Pulley Idler Flat
51 73900600 Lock Nut 3/8-16
52 194326 Idler V-Groove
56 411245 V-Belt, Drive
61 123666X Pulley Transaxle
64 196200 Shaft Asm. Pedal Brake Control
70 193225X428 Console
73 74490544 Bolt 5/16-18 Gr. 5
74 142432 Screw 1/4 x 1/2
116 73900500 Nut Lock Hex Flange 5/16-18
125 17000512 Screw 5/16-18 x 3/4
134 402430 Arm Shift
139 74550412 Bolt 1/4-20 unf Gr. 8 w/Patch
140 10040400 Washer Lock Hvy Helical 1/4
141 19091210 Washer 9/32 x 3/4 x 10 Ga.
155 12000028 Ring Retainer
157 105701X Washer Plate Shf
158 194352 Keeper T/A
159 76020412 Pin Cotter 1/8 x 3/4
160 169484 Retainer Clip
161 195403 Spring, Return, Clutch
165 196212 Busing Shaft Brake Hand Control
166 197290 Nut Push .625
167 405257 Latch Brake Parking
170 413430 Keeper Belt Centerspan
171 72110622 Bolt
172 197657 Strap Torque LH
174 197289 Nut Push
175 198981 Shaft Asm Shift
176 196214 Arm Clevis Rod Shift
178 197456 Spring Shift
184 198403X505 Handle Parking Brake
185 72110620 Bolt
186 194321 Spacer Retainer
187 19133210 Washer
188 194323 Link Clutch Ground Drive
189 194317 Bellcrank Ground Drive
190 194318 Keeper Bellcrank Ground Drive
192 150360 Nut Lock Center 1/4-28
193 17060512 Screw 5/16-18 x 3/4
195 197332 Bracket Brake Rod
202 199589 Link Shift
203 19111116 Washer 11/32 x 11/16 x 16 Ga.
205 121748X Washer 25/32 x 1-5/8 x 16 Ga.
221 403187 Retainer Spring Clip Handle
231 407287 Idler V- Groove
232 74780716 Bolt 7/16-14 x 1 Gr. 5
233 405296 Washer Serrated
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
DRIVE
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm
KEY PART
NO. NO. DESCRIPTION

10
21
20
OPTIONAL EQUIPMENT
Spark Arrester
29
18
15
37
28
engine-bs-1cyl-tex_4
12
42
85
9
90
84
45
1
81
82
69 2
79
97
96
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
ENGINE