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

11
1 - - - - - - Engine B&S Model No. 31P677
2 137352 Muffler
9 194319 Keeper Belt Engine
12 405140 Pulley Engine
15 407545 Tank Fuel 1.50
18 197725 Cap Asm
20 176636X421 Control Throttle/Choke
21 416358 Screw #10 x 0.750
28 401137 Fuel Line
29 137180 Spark Arrester Kit
37 123487X Clamp Hose
42 10040700 Washer Lock 7/16
45 73510400 Nut Keps Hex 1/4-20 unc
69 165291 Gasket
79 192334 Screw Socket Hd 5/16-18 x .75
81 148456 Tube Drain Oil Easy
82 181654 Plug Drain Oil
84 17060620 Screw 3/8-16 x 1-1/4
85 173937 Bolt Hex 7/16-20 x 4 x Gr. 5-1.5
90 17000616 Screw 3/8-16 x 1.0
96 19091416 Washer 9/32 x 7/8 x 16 Ga.
97 17670412 Screw 1/4-20 x 3/4
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
ENGINE
KEY PART
NO. NO. DESCRIPTION
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm
Engine Power Rating Information
The gross power rating for individual gas engine models is labeled in accordance with SAE (Society of Automotive
Engineers) code J11940 (Small Engine Power & Torque Rating Procedure), and rating performance has been ob-
tained and corrected in accordance with SAE J1995 (Revision 2002-5). Actual gross engine power will be low-
er and is affected by, among other things, ambient operating conditions and engine-to-engine variability. Given both
the wide array of products on which engines are placed and the variety of environmental issues applicable to op-
erating the equipment, the gas engine will not develop the rated gross power when used in a given piece of power
equipment (actual “on-site” or net horsepower). This difference is due to a variety of factors including, but not lim-
ited to, accessories (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.), application limitations, am-
bient operating conditions (temperature, humidity, altitude), and engine-to-engine variability. Due to manufactur-
ing and capacity limitations, Briggs & Stratton may substitute an engine of higher rated power for this Series engine.

12
42
43
60
63
46
147
55
64
32
31
33
56
34
56
57
59
240
188
1
69
69
69
199
40
145
46_man-Tex_lt_4
15
14
13
11
8
144
36
40
57
19
19
6
6
68 195
122
123
195
189
188
21
69
21
25
26
27
29
23
24
198
21
21
69
21
30
38
200
47
113
129
3
46
2
46
208
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
MOWER DECK
117 119
116
118 117
116
118 119
70
7
7
37
67
152

13
1 405050x421 Mower Housing
2 405507 Cover Mandrel LH
3 405506 Cover Mandrel RH
5 4939M Retainer Spring
6 195186 Arm Suspension
7416358 Screw #10 x 0.750
8 193003 Bolt/Washer asm 7/16-20 unf
11 405380 Blade, 46" Hi-Lift
(For bagging or discharge)
13 192872 Shaft Assembly, Mandrel
14 187281 Housing, Mandrel
15 110485X Bearing, Ball, Mandrel
19 196539 Bolt, Shoulder
21 73680500 Nut, Crownlock 5/16-18 unc
23 192557 Bracket, Deflector
24 105304X Cap, Sleeve
25 197026 Spring, Torsion, Deflector
26 110452X Nut, Push
27 405357 Shield, Deflector
29 131491 Rod, Hinge
30 173984 Screw Thdrol Rolling Wsh Hd
31 187690 Washer, Spacer
32 197473 Pulley, Mandrel
33 400234 Nut, Toplock, Flanged
34 72110612 Bolt Carr Sh. 3/8-16 x 1-1/2 Gr. 5
36 197379 Pulley, Idler, Flat
37 19131316 Washer 13/32 x 13/16 x 16 Ga.
38 199189 Keeper Belt LH Mandrel
40 73900600 Nut, Lock Flg. 3/8-16 unc
42 198410 Spring Torsion Brake
43 197256 Spring Torsion Retainer
46 137729 Screw Thd Roll 1/4-20 x 5/8
47 197250 Bracket Clutch Cable
55 197249 Arm, Idler
56 199092 Spacer, Retainer
57 17000616 Screw Hexwsh Thd 3/8-16 x 1
59 141043 Guard, Tuv Idler (94)
60 199471 Arm Brake Mower
63 199478 Arm Brake Mower
64 405139 Linkage Brake
67 198398X421 Handle, Clutch Cable
68 405143 V-Belt
69 72140505 Bolt Rdhd Sqnk 5/16-18 x 5/8
70 198332 Clutch Asm. Manual
113 17000510 Screw 5/16-18
116 4898H Bolt SHLD
117 188606 Wheel Gage
118 73930600 Nut Centerlock 3/8-16 unc
119 19121414 Washer 3/8 x 7/8 x 14 Ga.
122 197258 Keeper Belt Eng. LH
123 197259 Keeper Belt Eng. RH
129 19131312 Washer 13/32 x 13/16 x 12 Ga.
144 199204 Keeper Belt
145 193197 Pulley Idler
147 401872 Spring Return
152 408714 Cable Clutch Manual w/Spr.
188 195161 Stud Fastener
189 73900500 Nut Lock Hex Flange
195 17000612 Screw Hexwsh Thdr 3/8-16 x 3/4
198 403149 Baffle Center Front
199 403150 Baffle Front RH
200 413524 Washer 13/32 x 1/2 x 11 Ga.
208 17670608 Screw 3/8-16 x 1/2
240 74520636 Bolt Fin Hex 3/8-16 x 2-1/4 Gr. 5
- - 192870 Mandrel Assembly (Includes hous-
ing, shaft assembly, and bear-
ing only - pulley/nut/washer and
blade bolt/washers not included)
- - 411232 Replacement Mower, Complete
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
MOWER DECK
KEY PART
NO. NO. DESCRIPTION KEY PART NO. NO. DESCRIPTION
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm

14
6
55
5
13
13
53 8
9
9
8
8
7
7
62
4
35
59
58
50
50
70
65
68
69
67
54
67
66
54
65
15
15
14
14
61
55
2
6
STEERINGTEX?,%'.$?
16

28
13 22
64
21
26
1
20
45
33
72
 
 
 
 
1 186093X428 Wheel, Steering
2 184706 Axle Asm., Front
4 403087 Spindle Asm., LH
5 403088 Spindle Asm., RH
6 6266H Bearing, Race Thrust Harden
7 121748X Washer 25/32 x 1-5/8 x 16 Ga.
8 12000029 Ring, Klip #T5304-75
9 121232X Cap, Spindle
13 121749X Washer 25/32 x 1-1/4 x 16 Ga.
14 10040600 Washer Lock 3/8
15 73540600 Nut, Crown Lock 3/8-24 unf
16 408220 Shaft Steering
19 194729 Plate Steering
20 198375X428 Boot, Steering
21 186737 Adapter, Wheel Steering
22 194845 Bushing, Strg. Blk
26 186095X428 Insert, Wheel Steering
28 17000612 Screw 3/8-16 x 3/4
33 10040500 Washer Lock 5/16
35 194732 Gear, Sector Plate
45 19113812 Washer 11/32 x 2-3/8 x 12 Ga.
50 73900600 Nut Lock Flg 3/8-16 unc
53 188967 WasherHardened.793x1.637x.060
54 74760636 Bolt Hex HS 3/8-16 unc x 2-1/4
55 414736 Spacer Brace Axle
57 407465 Bracket Upstop
58 194747 Bolt Shoulder Sector Pivot CFM
59 194748 Washer Thrust Sector Steering
60 73971000 Nut Flange Lock 5/8-11
61 194740 Draglink LH
62 194741 Draglink, RH
63 17000512 Screw 5/16-18 x 3/4
64 199849 Retainer Clip Spring Steering
65 194734 Brace Axle Front
66 71020748 Bolt Hex Fghd 7/16-14 x 3 Serr
67 194737 Bushing PM Front Axle
68 73900700 Nut Lock Flange 7/16-14 Gr. 5
69 199162 Washer 1.5 x .505 x .118
70 196197 Bracket Deck Susp. Front
71 196075 Shaft Ext. Steering
72 74780572 Bolt 5/16-18 x 4.5 Gr. 5
78 57079 Washer Thrust
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
STEERING
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm
KEY PART
NO. NO. DESCRIPTION KEY PART NO. NO. DESCRIPTION

15
2
6
1
40
10
37
37
21
21
3
41
7
8
7
8
seat-tex_7-vgt
44
43
1 197514 Seat
2 180166 Bracket Pivot Fender
3 140675 Strap, Asm Fender
6 73800600 Nut, Lock W/Ins. 3/8-16 unc
7 124181X Spring, Seat Cprsn
8 171877 Bolt 5/16-18 unc x 3/4 w/Sems
10 196977 Pan, Seat
21 171852 Bolt, Shoulder 5/16-18
37 73800500 Nut, Lock 5/16-18 unc
40 197661 Handle Slide
41 198200 Spring Latch
43 74760612 Bolt 3/8-16 unc x 3/4
44 19133812 Washer 13/32 x 2 3/8 x 12 Ga.
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
SEAT
KEY PART
NO. NO. DESCRIPTION KEY PART NO. NO. DESCRIPTION
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm

16
7
3
87
10
88
100
2
97
97
91
89
90
87
98
lift-tex_6
91
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
MOWER LIFT

17
2 195223 Shaft Asm., Lift
3 195231 Lever Asm., Lift RH
7 196492X421 Grip, Lever
10 196314 Spring Torsion
87 194209 Pin Cotter 7/16 Bow Tie Lock
88 410710 Spring Lift Assist
89 19191912 Washer Clear Zinc
90 194208 Pin Cotter 5/16 Bow Tie Lock
91 195181 Link Lift Susp Mower Rear
97 17000612 Screw 3/8-16 x .75 Smgml Tap/R.Z
98 195270 Link Lift Susp. Front Mower
100 73930600 Nut Centerlock 3/8 -16 unc
KEY PART
NO. NO. DESCRIPTION
NOTE: All component dimensions given in U.S. inches
1 inch = 25.4 mm
REPAIR PARTS
TRACTOR - - MODEL NUMBER PB19546LT (96042003502), PRODUCT NO. 960 42 00-35
MOWER LIFT