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  9. Poulan Pro PC1538A User manual

Poulan Pro PC1538A User manual

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OWNER'S MANUAL
MODELNO.PC1538A
15HP38Inch
LawnTractor
• Assembly
•Operation
Customer Responsibilities
• Service and Adjustments
• Storage
• Troubleshooting
• Repair Parts
ForPartsand Service,contactourauthodzeddistributor,call 1-800-849-1297
ForTechnlcsiAssistance:call1-800-829-5886
|
181223 01.25.02 RH
PRINTED IN U.S.A.
SAFETY RULES
AS'F OP"A"ONPRAC C S O.R,O -ONMOW.S&
IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THR'OWING OBJECTS.
FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
I. GENERAL OPERATION
Read,understand,and followall instructionsinthemanual
and on the machine beforestarting.
•Only allow responsibleadults, who are familiar with the
instructions,tooperate the machine.
•Clear the area ofobjectssuch es rocks,toys,wire, etc.,
whichcouldbe picked up and thrown bythe blade.
•Be sure thearea isclear ofotherpeople before mow=ng.
Stop machineifanyone enters the area.
•Never carry psssengers.
•Do not mow in reverse unless absolutely necessery.
Always lookdown and behindbefore and whilebacking.
• Be awareofthernowerdischargedirectionanddo notpeint
itat anyone. Do notoperate the mower withouteitherthe
entiregrass catcher or the guard in place.
•Slowdownbefore turning.
•Never leavea runningmachineunattended. Always tum
offblades, set parkingbrake, stop engine, and remove
keys before dismounting.
•Turn offbladeswhen notmowing.
•Stopenginebefore removinggrasscatcherorunclnggjng
chute.
•Mow onlyindaylightor good artificiallight.
•Do notoperate the machine whileunder the influenceof
alcoholordrugs.
•Watch for trafficwhen operating near or crossingroad-
ways.
•Useextracerewhen loadingorunloedingthe machineinto
a trailerortruck.
•Dataindicatesthat operators,age 60 yearsandabove, are
involvedin a large percentage of ridingmower-related
injuries.These operators shouldevaluate their abilityto
operate the ridingmower safelyenough toprotectthem-
selves and othersfrom seriousinjury.
•Keep rnachinefree ofgrass, leaves orotherdebrtsbuild-
up whichcantouchhot exhaust/ engine parts and bum.
Do not allow the mower deck to plow leaves
orotherdebriswhichcan cause build-uptooccur. Clean
any oil or fuel spillage before operating or storing the
machine. Allow machine to cool before
storage.
II. SLOPE OPERATION
SIo_. are a majorfactorrslatedto loss-of-controland tipever
accidents,whichcanresultin severeinjuryor death. All slopes
requireextracaution.Ifyoucannotbackuptheslopeorif youfeel
ucaasyon it,do notmowit.
DO:
•Mow upand downslopes, not across.
•Remove obstaclessuch as rocks,tree limbs, etc.
•Watch for holes, ruts, or bumps. Uneven terrain could
overtum the machine. Tallgrass can hide Gbstacles.
•Use slow speed. Choose a lowgear so thatyou will not
have tostop or shiftwhile on the slope.
•Followthe manufacturer's recommendations for wheel
weightsor counterweightsto improve stability.
•Use extracare withgrass catchers or otherattachments.
These can change the stabilityof the machine.
•Keepallmovementontheslopesslowandgradual. DO
not make suddenchanges in speed ordirection.
2
•Avoidstartingorstoppingon aslope. Iftireslosetraction,
disengage the blades and proceed slowlystraightdown
the slope.
DO NOT:
•Do not rum on slopes unlessnecessary, and then, rum
slowty and graduallydownhill, ifpe_ible.
•Do not mow near drop-offs, ditches, or embankments.
The mower couldsuddenlyrumover ifa wheel isOverthe
edge of a cliffor ditch,or ifan edge caves in.
•Do not mowonwet grass. Reducedtraction couldcause
sliding.
•Do not trytostabilizethe machinebyputtingyourfoot on
theground.
•Do not usegrass catcher on steep slopes.
III. CHILDREN
Tragic accidentscan occur if the operator isnot alert tothe
presence of children. Children are often attracted to the
machine andthemowing activity.Neverassumethatchildren
willremain where you lestsaw them.
•Keep children out of the mowing area and under the
watchfulcare ofanother responsibleadult.
•Be alert and turn machine offit childrenenter the area.
•Beforeandwhen becking,lookbehind and downforsmall
children.
•Never carry children. They may falloffand beseriously
injured orinterfere with safe machineoperation.
•Never allow childrento operatethe machine.
• Use extracare when approachingblindcomers, shrubs,
trees, or other objectsthat may obscure vision.
IV. SERVICE
•Useextracera inhandlinggaselineand otherfuels. They
are flammable and vaporsare explosive.
-Use only an appreved container.
-Never remove gas cap or add fuel with the engine
running. Allowengine tocoolbeforerefueling. Do not
smoke.
-Never refuelthereachine indoors.
-Never storethe machineorfuelcontainerinsidewhere
there is an open flame, suchas a water heater.
•Never run a machine insidea closedarea.
•Keep nuts and bolts,especially blade attachment belts,
tightand keep equipment ingoodcondition.
•Never tamper with safety devices. Check their proper
operationregularly.
•Keep rnachinefree ofgrass,leaves, orotherdebrisbuild-
up. Clean oilorfuelspillage. Allowmachine tocoolbefore
storing.
•Stop and inspect the equipment if you strikean object.
Repair, if necessary, before restarting.
•Never make adjustments or repairs with the engine
running.
•Grasscatchercoreponents are subjecttowear, damage,
and deterioration,which could expose moving parts or
allowobjectstobethrown. Frequentlycheckcomponents
and replace with manufacturer's recommended parts,
when necessa_.
•Mower blades are sharpand can cut. Wraptheblade(s)
or wear gloves, and use extra caution when servicing
them.
•Check brake operation frequently. Adjust and service
as required.
SAFETY RULES
_lb Safe Operation Practices for Ride-On Mowers
• Be sure the area is dear of other people before mowing.
Stop machine if anyone enters the area.
• Never carry passengers or children even with the blades
off.
•Do not mow in reverse unless absolutely necessary. Al-
ways look down and behind before and while backing.
•Never carry children. They may fall off and be seriously
injured or interfere with safe machine operation.
•Keep children out of the mowing area and under the
watchful care of another responsible adult.
•Be alert and turn machine off if children enter the area.
• Before and when backing, look behind and down for small
children.
Mow up and down slopes (15 ° Max), not across.
Remove obstacles such as rocks, tree limbs, etc.
Watch for holes, ruts, or bumps. Uneven terrain could
overturn the machine. Tall grass can hide obstacles.
•Use slew speed. Choose a low gear so that you willnot have
to stop or shift while on the slope.
• Avoid starting or stopping on a slope. If tires lose traction,
disengage the blades and proceed slowly straight down
the slope.
•If machine stops while going uphill, disengage blades, shift
into reverse and back down slowly.
•Do not turn on slopes unless necessary, and then, turn
slowly and gradually downhill, if possible.
Look for this symbol to point out im-
portant safety precautions. It means
CAUTION!II BECOMEALERTIII YOUR
SAFETY IS INVOLVED.
&CAUTION: In order to prevent acciden-
tal starting when setting up,_ransport-
ing, adjusting or making repairs, al-
ways disconnect spark plug wire and
place wire where Itcannot contact spark
plug.
CAUTION: Do not coast down ahill in
neutral, you may lose control of the
tractor.
&CAUTION: Tow only the attachments
that are recommended by and comply
with specifications ofthe manufacturer
of your tractor. Use common sense
when towing. Operate only at the low-
est possible speed when on a slope.
Too heavy of a load, while on a slope,
is dangerous. TIres can lose tract,on
with the ground and cause you to lose
control of your tractor.
WARNING
Engine exhaust, some of its constituents, and cer-
tain vehicle components contain or emit chemicals
known tothe State of California to cause cancer and
birth defects or other reproductive harm.
WARNING
Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known
to the Stats of California to cause cancer and birth
defects or other reproductive harm. Wash hands
aflerhandllng. I
3
PRODUCT SPECIFICATIONS
GASOLINE CAPACITY 1.25GALLONS
ANDTYPE: UNLEADED REGULAR
OILTYPE (API-SF-SJ): SAE30 (above 32°F)
SAE 5W-30 (below32°F)
OILCAPACITY: 3 PINTS
SPARKPLUG: CHAMPION RC12YC
GAP: .030")
GROUND SPEED (MPH): FORWARD:
1st 1.1
2nd 2.2
3rd 3.3
4th 4.4
5th 4.9
REVERSE: 1.4
TIRE PRESSURE: FRONT: 14 PSI
REAR: 12 PSI
CHARGING SYSTEM: 3 AMPS BA'I-I'ERY
5 AMPS HEADUGHTS
BATTERY: AMP/HR: 28
MIN. CCA: 230
CASE SIZE: U1R
BLADEBOLTTORQUE: 27-35 FT.LBS.
CONGRATULATIONS on yourpumhaseof a newtractor. It
has been designed, engineered and manufactured to give
you the best possibledependability and performance.
Should you experience any problem you cannot easily
remedy, please contact your nearest authorized service
center/department. We have competent, well-trained tech-
n=c_ansand the propertools to service or repair thistractor.
Please read and retain this manual. The instructionswill
enable you toassemble and maintain yourtractor properly.
Always observe the "SAFETY RULES'.
CUSTOMER RESPONSIBILITIES
•Read and observe the safety rules.
•Followa regularschedule inmaintaining, caring for and
using your tractor.
•Follow the instructionsunder =Customer Responsibili-
ties" and =Storage"sections of thisowner's manual.
WARNING: This tractor is equipped with an intemal com-
bustion engine and should not be used on or near any
unimproved forest-covered, brush-covered or grass-cov-
ered land unless the engine's exhaust system isequipped
with a spark arrester meeting applicable local orstate laws
(ifany). If a spark arrester is used, itshould be maintained
ineffective workingorder by the operator.
Aspark arrester for the muffler is available through your
nearest authorized service center/department (See RE-
PAIR PARTS section of this manual).
TABLE OF CONTENTS
SAFETY RULES ........................................................ 2-3
PRODUCT SPEClRCATIONS ....................................... 4
CUSTOMER RESPONSIBILITIES ...................... 4, 14-18
ASSEMBLY ................................................................ 6-8
OPERATION ............................................................. 9-13
MAINTENANCE SCHEDULE ....................................... 14
SERVICE AND ADJUSTMENTS ............................. 19-23
STORAGE ................................................................... 24
TROUBLESHOOTING ............................................. 25-26
REPAIR PARTS ...................................................... 28-43
WARRANTY ............................................................ 45.46
4
UNASSEMBLED PARTS
I
Steering Wheel
F,=,=======,,,==I_
i
Steering Wheel
Insert
i I I i
Steering Wheel
Adapter
O
Steering
Extension
Shaft
(1) Large Flat Washer
tiliiil-iit-I-I-I-il-I-I-I-il
5/16-18 x 1-1/4
Steering
Boot
(1) Hex Bolt
3/8-16 x 1
(1) Lockwasher 3/8
@
(1) Locknut
5/16-18
Seat
(1) Washer
17/32 x1-3/16 x12 Gauge
(1) Lock
Washer 1/2
(1) Bolt
Keys
2) Keys
Slope Sheet
5
ASSEMBLY
Your new tractor hasbeen assembled at thefactory with exception ofthose parts leftunassembledfor shipping purposes. To
ensure safe and proper operation of yourtractor all parts and hardware you assemble mustbe tightened securely. Use the
correct tools as necessary to insure proper tightness.
TOOLS REQUIRED FOR ASSEMBLY
A socket wrench set willmake assembly easier. Standard
wrench sizes are listed.
(2) 1/2" wrenches Pliers
(1) 9/16" wrench Tire pressuregauge
Utility knife
When rightor lefthandismentioned inthis manual, itmeans
when you are in the operating position (seated behind the
steedng wheel).
TO REMOVE TRACTOR FROM CARTON
UNPACK CARTON
•Remove all accessible loose parts and parts cartons
from carton.
•Cut, from top to bottom, along lines on all four comers
of carton, and lay panels flat.
•Check for any additional loose parts or cartons and
remove.
BEFORE REMOVING TRACTOR FROM
SKID
ATI'ACH STEERING WHEEL (See Fig. 1)
ASSEMBLE EXTENSION SHAFT AND BOOT
• Slide extension shaft onto lower steedng shaft. Align mount-
ing holes in extension and lower shafts and install
5/16 hex bolt and Iocknut. Tighten securely,
IMPORTANT: TIGHTEN BOLT AND NUT SECURELY TO
18-22 FT. LBS TORQUE.
•Place tabs of steering boot over tab slots in dash and push
down to secure.
INSTALL STEERING WHEEL
•Position front wheels of the tractor so they are pointing
straight forward.
Remove steering wheel adapter from steedng wheel and
slide adapter onto steedng shaft extension.
Position steedn_ wheel so cross bars are horizontal (left to
right) and slide unside boot and onto adapter.
•Assemble large flat washer, 3/8 lock washer, 3/8 hax boitand
tighten securely.
•Snap steering wheel insert into center of steedng wheel
Remove protective materials from tractor hood and grill.
IMPORTANT: CHECK FOR AND REMOVE ANY STAPLES
IN SKID THAT MAY PUNCTURE TIRES WHERE TRACTOR
IS TO ROLL OFF SKID.
_OC INSERT
K WASHER
(_._ LARGE FLAT
WASHER
WHEEL
STEERING
BOOT
ADAPTER EXTENSION
5/16 HEX
RG. 1
6
ASSEMBLY
HOW TO SET UP YOUR TRACTOR
CHECK BA'B'ERY (See Fig. 2)
•Lift seat pan to raised position.
•If this battery is put into service alter month and year
indicated on label (label located between terminals)
charge battery foeminimum of one hourat 6-10 amps.
(See "BATTERY" inCustomer Responsibilities,s_'tJon
of this manual for charging inst--).
SEAT PAN
LABEL
FIG. 2
INSTALL SEAT (See Fig. 3)
Adjust seat before tightening adjus_nent boll
• Remove adjustment bait. lock washer and fiat washer
securing seat to cardboard pac_ and set aside for
assembly of seat to tractor.
•Pivot seat upward and remove from the cardboard
packing. Remove the cardboard packing and discard.
•Place seat on seat pan so head of shoulder bolt is
positioned over large slotted holein pan.
•Push down on seat to engage shoulder boltin,slotand
pull seat towards rear oftram'tot.
•Pivot seat and pan forward and assemble adjustment
bolt, Iockwasher and flatwasher loosely.Do nottighten
•Lower seat intooperating position and s_ton seat.
•Slide seat untila comfortable position isreached which
allowsyou topressclutctVbrakepedalall theway down.
•Get off seat without moving its adjusted position.
•Raise seat and tighten adjustment bolt securely.
SHOULDER
BOLT
FLAT WASHER
LOCK WASHERs,
ADJUSTMENT
BOLT
FIG. 3
NOTE: YOUmay now rollor drive your tractor offthe skid.
Follow the appropriate instruction below to remove the
tractor from the skid.
7
ASSEMBLY
/CHECKLIST
TO ROLLTRACTOR OFF SKID (See Operation
section, page 10, for location and function of
controls)
•Press lift lever plunger and raise attachment liftlever to
its highest position.
•Release parkingbrakebydepressingdutch[orake pedal.
•Place gearshift lever in neutral (N) position.
•Roll tractorforward offskid.
•Remove banding holding deflector shield up against
tractor.
TO DRIVE TRACTOR OFF SKID (See Opera-
tion section, page 10, for location and func-
tion of controls)
,AWARNING: Before starting, read, understand and follow
all instructions inthe Operation section of this manual. Be
sure tractor isina well-ventilated area. Be sure the area in
front of tractoris clear of other people and objects.
•Be sure all the above assembly steps have been
completed.
• Check engine oillevel and fill fuel tank with gasoline.
• Sit on seat in operating position, depress clutch/brake
pedal and set the parking brake.
•Place gear shift lever in neutral (N) position.
•Press liftlever plunger and raise attachment liftlever to
its highest position.
•Start theengine.After engine hasstarted, move throttle
controlto idle position.
•Depress clutch/brake pedal into full "BRAKE" position
and hold. Move gearshift lever to 1st gear.
•Slowly release clutch/brake pedal and slowly ddve
tractor offskid.
• Apply brake to stop tractor, set parking brake and place
gearshift lever in neutral position.
• Turn ignition key to "OFF" position.
Continue with the instructions that follow.
CHECK _RE PRESSURE
The tires on yourtractorwere ovednflated at the factory for
shipping purposes. Correct tire pressure is important for
best cuttingperformance.
•Reduce tire pressure to PSI shown in =PRODUCT
SPECIFICATIONS" section of this manual.
CHECK DECK LEVELNESS
For bestcutting results, mower housing shouldbe properly
leveled. See "1"OLEVEL MOWER HOUSING" inthe Service
and Adjustments section of this manual.
CHECK FOR PROPER POSITION OF ALL
BELTS
See the figures that are shown for replacing motion and
mower blade drive belts in the Service and Adjustments
section of this manual. Verify that the belts are routed
correctly.
CHECK BRAKE SYSTEM
Alter youlearnhow tooperateyourtractor,check tosee that
the brake ispropedy adjusted. See "TO ADJUST BRAKE"
In the Service and Adjustments section ofthis manual.
BEFORE YOUOPERA TEAND ENJO YYOUR NEW TRAC-
TOR, WE WISH TO ASSURE THAT YOU RECEIVE THE
BEST PERFORMANCE AND SATISFACTION FROM THIS
QUALITY PRODUCT.
PLEASE REVIEW THE FOLLOWING CHECKLIST:
,/ Allassembly instructionshave been completed.
,/ No remaining loose parts in carton.
•/Battery isproperly prepared and charged. (Minimum 1
hour at 6 amps).
J Seat is adjusted comfortably and tightened securely.
,/ All tires are properly inflated. (For shipping purposes,
the tires were ovednflated at the factory).
•/ Be sure mower deck is propedy leveled side-to-side/
front-to-rear for best cutting results. (Tires must be
properly inflated for leveling).
,/ Check mower and ddve belts. Be sure they are routed
propedy around pulleys and inside all belt keepers.
,/ Check widng. See that all connections are stillsecure
and wires are propedy clamped.
WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY
EXTRA ATTENTION TO THE FOLLOWING IMPORTANT
ITEMS:
,/ Engine oil is at proper level.
/Fuel tank is filled with fresh, clean, regular unleaded
gasoline.
/Become familiar with all controls - their location and
function. Operate them before you start the engine.
,/ Be sure brake system is in safe operating condition.
8
OPERATION
These symbols may appear on yourtractor or in literature supplied with the product. Learn and understand their meaning.
BAI-rERY CAUTION OR REVERSE FORWARD FAST SLOW
WARNING
ENGINE ON ENGINE OFF OIL PRESSURE LIGHTS ON OVER TEMP '_
LIGHT t
FUEL CHOKE MOWER HEIGHT PARKING BRAKE UNLOCKED MOWER LIFT
LOCKED
R N H L
ATTACHMENT REVERSE
CLUTCH ENGAGED
IGNITION A'I'rACHMENT
CLUTCH DISENGAGED
NEUTRAL HIGH LOW PARKING BRAKE
KEEP AREA CLEAR SLOPE HAZARDS
(SEE SAFETY RULES SECTION)
DANGER, KEEP HANDS AND FEET AWAY
9
FREE WHEEL
(Automatic Models ordy)
OPERATION
KNOW YOUR TRACTOR
READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR
Compare the illustrationswithyour tractor to familiarize yourself with the locations of various controls and adjustments. Save
this manual for future reference.
THRO'FrLEJ
CHOKE
AI-rACHMENT IGNITION
CLUTCH SWITCH
LEVER
LIGHT SWITCH
POSITION
ATTACHMENT
UFTLEVER
CLUTCH/
BRAKE
PEDAL o,MOWER DECK
> HEIGHT ADJUSTMENT
PosmoNs
PARKING
BRAKE
GEARSHIFT
LEVER
RG. 4
Our tractorsconform tothe safety standards of the Amedcan National Standards Institute.
ATTACHMENT CLUTCH LEVER: Used to engage the
mower blades,orotherattachmentsmounted toyourtractor.
UGHT SWITCH PosmoN: Tums the headlights on and
off.
THROTTLE/CHOKE CONTROL: Used for starting and
controllingengine speed.
CLUTCH/BRAKE PEDAL: Used for dectutching and brak-
ingthe tractor and starting the engine.
PARKING BRAKE: Locksclutch/brake pedal intothe brake
position.
GEARSHIFT LEVER: Selects the speed and direction of
tractor.
ATTACHMENT LIFT LEVER: Used to raise, lower, and
adjustthe mowerdeckerother attachments mountedtoyour
tractor.
LIFT LEVER PLUNGER: Used to release attachment lift
lever when changing itsposition.
IGNmON SWITCH: Used for starting and stopping the
engine.
10