PoulanPRO 460ZX 966550201, 540ZX 966550301 ride-on mower Operator Manual
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Operator Manual
460ZX / 966550201
540ZX / 966550301
Please read the operator’s manual carefully and make sure you understand the instructions before using the machine.
To implement improvements, specifications and designs can be altered without prior notification.
Note that no legal demands can be placed based on the information contained in these instructions.
Use only original parts for repairs. The use of other parts voids the warranty.
Do not modify or install non-standard equipment to the unit without consent from the manufacturer.
Modifications to the unit may cause unsafe operations or damage the unit.
When this product is worn out and no longer used, it should be returned to the reseller or other party for recycling.
©2010 HTC. All rights reserved.
Beatrice, NE. Printed in U.S.A.
TABLE OF CONTENTS
INTRODUCTION ........................................................5
Driving and Transport on Public Roads ................5
Towing ...................................................................5
Operating ..............................................................5
Good Service.........................................................6
SYMBOLS AND DECALS ..........................................7
SAFETY ......................................................................9
Safety Instructions .................................................9
Personal Safety Equipment .................................11
Slope Operation ..................................................11
Safe Handling of Gasoline...................................13
General Maintenance ..........................................14
Transport .............................................................16
Towing .................................................................16
Spark Arrestor .....................................................16
CONTROLS .............................................................17
Control Locations ................................................17
Motion Control Levers .........................................18
Seat Adjustment Lever ........................................19
Bypass Linkage ...................................................19
Fuel Tank .............................................................20
Ignition Switch .....................................................21
Choke Control ......................................................21
Throttle Control ....................................................21
Blade Switch........................................................22
Parking Brake ......................................................22
Cutting Height Adjuster .......................................22
Fuses ...................................................................23
Fuel Shut Off Valve ..............................................23
OPERATION ............................................................24
Training ................................................................24
Steering ...............................................................24
Before Starting.....................................................25
Starting the Engine ..............................................25
Weak Battery .......................................................28
Jumper Cables ..............................................28
Running ...............................................................29
Operating On Hills ...............................................30
Mowing Tips ........................................................31
Stopping the Engine ............................................32
Manual Transport .................................................33
MAINTENANCE .......................................................34
Maintenance Schedule........................................34
Battery .................................................................36
Safety System ......................................................37
Tire Pressures ......................................................37
Parking Brake ......................................................38
Deck Belt .............................................................38
Pump Belt ............................................................39
Cutting Blades .....................................................40
Blade replacement ........................................40
Anti-scalp Rollers ................................................40
Adjusting the Mower Deck ..................................41
Deck Leveling ...............................................41
Caster Wheels .....................................................42
Hardware .............................................................42
Cleaning ..............................................................42
LUBRICATION .........................................................43
Wheel and Deck Zerks ........................................44
Front Wheel Mount ........................................44
Front Wheel Bearings ....................................44
Deck Spindles ...............................................44
TROUBLE SHOOTING ............................................45
Winter Storage .....................................................47
Service ................................................................47
SCHEMATIC ............................................................48
TECHNICAL DATA ...................................................49
Torque Specifications ..........................................49
CONFORMITY CERTIFICATES ................................52
SERVICE JOURNAL ................................................53
WARNING!
Failure to follow cautious operating practices can result in serious injury to the operator or other persons. The owner must understand these instructions, and must allow only trained persons who understand these instructions to operate the mower.
Each person operating the mower must be of sound mind and body and must not be under the influence of any mind altering substance.
WARNING!
Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the 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 State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
INTRODUCTION
Congratulations
Thank you for purchasing a PoulanPRO ride-on mower. This machine is built for superior efficiency to rapidly mow primarily large areas. A control panel easily accessible to the operator and a hydrostatic transmission regulated by steering controls both contribute to the machine’s performance.
This manual is a valuable document. Read the contents carefully before using or servicing the machine. The following of instructions (use, service, maintenance, etc.) by all who operate this machine is important for the safety of the operator and others.
It can also considerably increase the life span of the machine and increase its resale value.
If you sell your machine, be sure to give the operator’s manual to the new owner.
The final chapter of this operator’s manual provides a
Service Journal. Ensure that service and repair work are documented. A well-kept service journal reduces service costs for the maintenance and affects the machine’s resale value. Please contact your dealer for more information. Take the operator’s manual along when the machine is taken to your dealer for service.
General
In this operator’s manual, left and right, backward and forward are used in relation to the machine’s normal driving direction.
Continuous dedication to improve our products require that specifications and design are subject to change without notice.
Driving and Transport on Public Roads
Check applicable road traffic regulations before transporting on public roads. If the machine is transported, you must always use approved fastening equipment and ensure that the machine is well anchored. DO NOT operate this machine on public roadways.
Towing
If machine is equipped with a tow hitch, use extreme caution when towing. Never allow children or others in or on the towed equipment. Make wide turns to avoid jack-knifing. Travel slowly and allow extra distance to stop.
Do not tow on sloped ground. The weight of the towed equipment may cause loss of traction and loss of control.
Follow the manufacturer's recommendation for weight limits for towed equipment. Do not tow near ditches, canals, and other hazards.
Operating
This machine is constructed only for mowing grass on lawns and even ground without obstacles such as stones, tree stumps, etc. The machine can also be used for other tasks when equipped with special accessories provided by the manufacturer. Operating instructions for the accessories are provided with delivery. All other types of uses are incorrect. The manufacturer’s directions concerning operation, maintenance, and repairs must be carefully followed.
Lawn mowers and all power equipment, can be potentially dangerous if used improperly. Safety requires good judgement, careful use in accordance with these instructions and common sense.
The machine must only be operated, maintained, and repaired by persons familiar with the machine’s special characteristics and who are also knowledgeable about the safety instructions. Use only approved repair parts to maintain this machine.
Accident prevention regulations, other general safety regulations, occupational safety rules, and traffic regulations must be followed without fail.
Unauthorized modifications to the design of the machine may absolve the manufacturer from liability for any resulting personal injury or property damage.
5
INTRODUCTION
Good Service
PoulanPRO's products are sold only in specialized retail stores with complete service. This ensures that you as a customer receive only the best support and service. Before the product is delivered, the machine has, for example, been inspected and adjusted by your retailer. See the certificate in the Service Journal in this operator’s manual.
When you need spare parts or support in service questions, warranty issues, etc., please consult the following professional:
This Operator’s Manual belongs to the machine with the manufacturing number:
Manufacturing Number
The machine’s manufacturing number can be found on the printed plate affixed to the right in the engine compartment. Stated on the plate, from the top are:
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•
The machine’s type designation (I.D.).
The manufacturer’s type number (Model).
• The machine’s serial number (Serial no.)
Please have the type designation and serial number available when ordering spare parts.
The engine’s manufacturing number is stamped on one of the valve covers.
The plate states:
• The engine’s model.
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The engine’s type.
Code
Please have these available when ordering spare parts.
Engine Transmission
6
SymBOLS AND DECALS
These symbols are found on the machine and in the operator’s manual.
Study them carefully so that you know what they mean.
WARNING!
Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.
Used in this publication to notify the reader of a risk of personal injury or death, particularly if the reader should neglect to follow instructions given in the manual.
IMPORTANT INFORMATION
Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.
Used in this publication to notify the reader of a risk of material damage, particularly if the reader should neglect to follow instructions given in the manual.
Used also when there is a potential for misuse or misassembly.
R N
Reverse Neutral Fast Slow Choke Fuel
Warning! Parking Brake CE conformity marking. Only for
European market
Warning! Rotating blades, keep away from the discharge deck
Do not touch parts
Battery acid is corrosive, explosive and flammable Do not stand here
Noise emissions to the surroundings in accordance with the European Union’s directive. The machine’s emission is stated in the chapter TECHNICAL DATA and on the decals.
Only machines for European market
Use protective glasses Use protective gloves
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SymBOLS AND DECALS
Read
Operator’s
Manual
Shut off engine and remove key before performing any maintenance or repair work
Keep a safe distance from the machine
Use on slopes no greater than 10°
No passengers
Whole body exposure to thrown objects
Severing of fingers and toes
Do not open or remove safety shields while engine is running
Careful backing up, watch for other people
Careful going forward, watch for other people
Moving sharp blades under cover
SAFETy
Safety Instructions
These instructions are for your safety. Read them carefully.
WARNING!
This symbol means that important safety instructions need to be emphasized. It concerns your safety.
IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING
OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS
INJURY OR DEATH.
General Operation
• Read, understand, and follow all instructions on the machine and in the manual before starting.
• Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.
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Only allow responsible adults, who are familiar with the instructions, to operate the machine.
Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blades.
Be sure the area is clear of bystanders before operating. Stop machine if anyone enters the area.
Never carry passengers. The machine is only intended for use by one person.
Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing.
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Never direct discharged material toward anyone.
Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blades when crossing gravel surfaces.
Do not operate machine without the entire grass catcher, discharge guard, or other safety devices in place and working
Slow down before turning.
Never leave a running machine unattended.
Always turn off blades, set parking brake, stop engine, and remove keys before dismounting.
Disengage blades when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard.
Operate machine only in daylight or good artificial light.
Do not operate the machine while under the influence of alcohol or drugs.
8011-512
Read the operator’s manual before starting the machine
Clear the area of objects before mowing
8011-513
9
SAFETy
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Watch for traffic when operating near or crossing roadways.
Use extra care when loading or unloading the machine into a trailer or truck.
Always wear eye protection when operating machine.
Data indicates that operators age 60 years and above are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.
Follow the manufacturer’s recommendation for wheel weights or counterweights.
Anyone who operates this machine must first read and understand this Operation Manual. Local laws may regulate the age of the user.
Keep machine free of grass, leaves or other debris buildup which can touch the hot exhaust or engine parts and burn. Do not allow the mower deck to plow leaves or other debris, causing buildup to occur.
Clean any oil or fuel spillage before operating or storing the machine.
Allow machine to cool before storage.
Never take passengers
8011-520
WARNING!
Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer, birth defects, or other reproductive system damage. The engine exhaust contains carbon monoxide, which is an odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces.
10
SAFETy
Personal Safety Equipment
WARNING!
When using the machine, approved personal protective equipment (shown in illustrations) shall be used. Personal protective equipment cannot eliminate the risk of injury but it will reduce the degree of injury if an accident does happen. Ask your retailer for help in choosing the right equipment.
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Make sure that you have first aid equipment close at hand when using the machine.
Never use the machine when barefoot.
Always wear protective shoes or boots, preferably with steel toe caps.
Always wear approved protective glasses or a full visor when assembling or driving.
Always wear gloves when handling the blades.
Never wear loose clothing that can get caught in moving parts.
Use ear protectors to avoid damage to hearing.
Slope Operation
Slopes are a major factor related to loss of control and tip-over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution.
If you cannot back up the slope or if you feel uneasy on it, do not mow it.
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Mow up and down slopes (10 degrees maximum), not across.
Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.
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Choose a low ground speed so that you will not have to stop while on the slope.
Do not mow on wet grass. Tires may lose traction.
Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly straight down the slope.
Keep movement on the slopes slow and gradual.
Do not make sudden changes in speed or direction, which could cause machine to roll over.
Use extra care while operating machine with grass catchers or other attachments; they can affect the stability of the machine.
Do not use on steep slopes.
Do not try to stabilize the machine by putting a foot on the ground.
Do not mow near drop-offs, ditches, or embankments. The machine could suddenly roll over if a wheel is over the edge or if the edge caves in.
Personal protective equipment
Mow up and down, not side to side
8011-670a
6003-004
WARNING!
Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across any slopes.
11
SAFETy
Children
Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity.
Never assume that children will remain out of the path of danger.
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Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator.
Be alert and turn machine off if a child enters the area.
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Before and while backing, look behind and down for small children.
Never carry children, even with the blades shut off. They may fall off and be seriously injured or interfere with safe machine operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.
Never allow children to operate the machine.
Use extra care when approaching blind corners, shrubs, trees, or other objects that may block the view of a child.
Keep children away from work area
8011-518
Never allow children to operate the machine
8011-517
12
SAFETy
WARNING!
The engine must not be started when the driver’s floor plate or any protective plate for the mower deck’s drive belt is removed.
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Safe Handling of Gasoline
To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.
• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.
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Use only approved gasoline container.
Never remove gas cap or add fuel with the engine running. Allow engine to cool at least two (2) minutes before refueling.
Never fuel the machine indoors.
Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or other appliance.
Before beginning to refuel, minimize the risk of static electricity by touching a metal surface.
Never fill containers inside a vehicle or on a truck or trailer bed with plastic liner. Always place containers on the ground away from the vehicle when filling.
Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.
Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
If fuel is spilled on clothing, change clothing immediately.
Never overfill fuel tank. Replace gas cap and tighten securely.
Do not start the engine near spilled fuel.
Never use gasoline as a cleaning agent.
If leaks arise in fuel system, engine must not be started until problem has been resolved.
Check the fuel level before each use and leave space for the fuel to expand, as the heat from the engine and the sun may otherwise cause the fuel to expand and overflow.
Never fill the fuel tank indoors
8011-516
WARNING!
The engine and the exhaust system become very hot during operation.
There is risk for burns if touched.
Allow engine and exhaust system to cool at least two (2) minutes before refueling.
13
SAFETy
General Maintenance
• Never operate machine in a closed area.
• Keep all nuts and bolts tight to be sure the equipment is in safe working condition.
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Never tamper with safety devices. Check their proper operation regularly.
Keep machine free of grass, leaves, or other debris buildup. Clean oil or fuel spillage and remove any fuel-soaked debris. Allow machine to cool before storing.
If the machine strikes a foreign object, stop and inspect the machine. Repair, if necessary, before restarting.
Never make any adjustments or repairs with the engine running.
Check grass catcher components and the discharge guard frequently and replace with manufacturer’s recommended parts, when necessary.
Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them.
Check brake operation frequently. Adjust and service as required.
Maintain or replace safety and instruction labels, as necessary.
Do not modify safety equipment. Check regularly to be sure it works properly. The machine must not be driven with defective or unmounted protective plates, protective cowlings, safety switches, or other protective devices.
Do not change the settings of governors and avoid running the engine with overly high engine speeds. If the engine runs too fast, there is risk for damaging the machine components.
Be very careful when handling battery acid. Acid on skin can cause serious corrosive burns. If battery acid is spilled on skin, rinse immediately with water.
Acid in the eyes can cause blindness, contact a doctor immediately.
Be careful when servicing the battery. Explosive gases form in the battery. Never perform maintenance on the battery when smoking or near open flames or sparks.
The battery can explode and cause serious injury or damage.
Ensure that the equipment is in good condition and that all nuts and bolts, especially those fastening the blade attachments, are properly tightened and torqued.
14
Never drive the machine in an enclosed space
WARNING!
Use protective glasses for maintenance work.
8011-515
WARNING!
The battery contains lead and lead compounds, chemicals that are considered to cause cancer, birth defects, and other reproductive system damage. Wash your hands after handling the battery.
SAFETy
Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, fire or eye injury. Sparking in this circuit can not occur after the chassis cable
(normally negative, black) is removed from the battery.
• Use protective goggles.
• Ensure that the fuel filler cap is mounted tightly and no flammable substances are stored in an open vessel.
WARNING!
Avoid electrical sparking and its consequences by the following routines:
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Never work with the starter circuit if there is spilled fuel.
Disconnect the negative cable from the battery first and reconnect it last.
Do not make a bridge short circuit across the starter relay to run the starter.
6003-009
Do not smoke when performing maintenance on the battery.
The battery can explode and cause serious injury/damage.
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Never use the machine indoors or in spaces lacking proper ventilation. The exhaust fumes contain carbon monoxide, an odorless, poisonous, and lethal gas.
Stop to inspect the equipment if the machine runs over or into anything. If necessary, make repairs before starting.
Never make adjustments with the engine running.
The machine is tested and approved only with the equipment originally provided or recommended by the manufacturer. Only use approved repair parts for the machine.
The blades are sharp and can cause cuts and gashes. Wrap the blades or use protective gloves when handling them.
Check the parking brake’s functionality regularly.
Adjust and service as necessary.
The mulch blades should only be used in familiar areas when higher quality mowing is desired.
Reduce the risk of fire by removing grass, leaves, and other debris that may have accumulated on the machine.
Allow the machine to cool before putting it in storage.
Regularly clean deck and underside of deck, avoid spraying engine and electrical components with water.
Risk of sparking
Regularly clean deck
8009-728
8011-514
15
SAFETy
Transport
• The machine is heavy and can cause serious crushing injuries. Be extra cautious when it is loaded on or unloaded from a vehicle or trailer.
• Use an approved trailer to transport the machine.
Activate the parking brake, turn off the fuel supply, and fasten the machine with approved fastening devices, such as bands, chains, or straps, when transporting.
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Do not operate this machine on public roadways.
Check and abide by local traffic regulations before transporting the machine on any road.
Do not tow this machine: it may cause damage to the drive system.
Load the unit onto truck or trailer by driving up ramps of suitable strength using a slow speed. Do not lift! The machine is not intended to be lifted by hand.
Towing
If machine is equipped with a tow hitch, use extreme caution when towing. Never allow children or others in or on towed equipment..
Make wide turns to avoid jack-knifing. Travel slowly and allow extra distance to stop. Do not tow on sloped ground. The weight of the towed equipment may cause loss of traction and loss of control.
Follow the manufacturer’s recommendation for weight limits for towed equipment. Do not tow near ditches, canals, and other hazards.
Spark Arrestor
A spark arrestor for the muffler is available through your authorized PoulanPRO dealer.
WARNING!
Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin, causing serious injury. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.
IMPORTANT INFORMATION
The parking brake is not sufficient to lock the machine in place during transport. Ensure that the machine is well fastened to the transport vehicle. Always reverse the machine onto the transport vehicle to avoid tipping it over.
WARNING!
This mower is equipped with an internal combustion engine and should not be used on or near any unimproved forested, bush covered or grassy lands unless the engine's system is equipped with a spark arrestor meeting applicable local or state laws (if any).
16
CONTROLS
This operator’s manual describes the PoulanPRO Zero
Turn Rider. The rider is fitted with a Briggs & Stratton, four-stroke overhead valve engine.
Transmission from the engine is made via two beltdriven hydraulic pumps. Using the left and right steering controls, the flow is regulated and thereby the direction and speed.
Control Locations
10 11
1
9
8 7 6
1.
2.
3.
4.
5.
6.
Motion Control Levers
Seat Adjustment Lever
Lift Lever
Hour Meter
Throttle
Blade Switch
5 4
7.
8.
Ignition Switch
Choke Control
9. Bypass Linkage
10. Fuel Tank
11. Parking Brake
3 2
17
CONTROLS
Motion Control Levers
The machine’s speed and direction are continuously variable using the two steering controls. The steering controls can be moved forward or backward about a neutral position. Furthermore, there is a neutral position, which is locked if the steering controls are moved outward.
When both controls are in the neutral position (N), the machine stands still.
By moving both controls an equal amount forward or backward, the machine moves in a straight line forward or backward respectively.
In order, for example, to turn right while moving forward, move the right control towards the neutral position. The rotation of the right wheel is reduced and the machine turns to the right.
Zero turn can be achieved by moving one control backward (behind the neutral position) and carefully moving the other steering control forward from its neutral position. The rotation direction when zero turning is determined by which steering control is moved backward behind the neutral position.
If the left steering control is pulled backward, the machine turns to the left. Use extra care when using this maneuver.
If the steering controls are in uneven positions when standing still or do not fit in the slots for moving the controls outward, they can be adjusted
Steering controls
8050-833
WARNING!
The machine can turn very rapidly if one steering control is moved much further forward than the other.
2.
3.
4.
1. Forward
Neutral
Neutral slot, Neutral lock
Reverse
Motion control lever pattern (right side)
8050-846
18
CONTROLS
Seat Adjustment Lever
The seat can be adjusted lengthways. Release levers are located at the lower front right, or on the right side—depending on model. When making adjustments, sit on the seat. Slide the lever and maneuver seat to appropriate placement and release lever.
IMPORTANT INFORMATION
Before pushing or towing tractor, transmission must be unlocked and park brake released.
The tractor should never be pulled at more than 2 miles per hour (3.2 km/h) or for distances over ¼ mile (.402 km). Trailer the unit for distances over ¼ mile.
Bypass Linkage
Unlocking Transmission
When pushing or pulling the mower, engage the EZT
(Integrated Zeroturn Transaxle) bypass linkages. The
EZT bypass linkages are located on the rear of the frame, below the rear engine guard.
1. Raise the deck into the highest cutting position.
2.
3.
Pull the EZT bypass linkages up and out of the keyhole slots. Release the levers with the head outside the frame and held in the bypass position.
To reengage the EZT’s to drive, reverse the above procedure.
Seat adjustment
Bypass linkage, EZT engaged
8050-852
8058-032
Bypass linkage, EZT locked in the bypass position
8058-033
19
CONTROLS
Fuel Tank
The machine has one fuel tank, just behind the seat.
The tank capacity is 4 gallons (15.1 liters).
The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used. See also
Technical Data concerning ethanol fuel. Methanol fuel is not allowed.
When operating below 32°F (0°C) use fresh, clean winter grade gasoline to help insure good cold weather starting.
WARNING!
Gasoline is highly flammable. Observe caution and fill the tank outdoors. (See
Safety)
Fuel tank
8058-833
WARNING!
Fill to the bottom of the filler neck. Do not overfill. Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame.
WARNING!
The engine and the exhaust system, become very hot during operation.
Risk for burns if touched.
Allow engine and exhaust system to cool at least two (2) minutes before refueling.
IMPORTANT INFORMATION
Experience indicates that alcohol blended fuels (called gasohol, ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of
30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel the next season. See Storage Instructions for additional information. Never use engine or carburetor cleaners in the fuel tank or permanent damage may occur.
20
CONTROLS
Ignition Switch
The ignition key is placed on the driver’s panel and is used to start and stop the engine.
IMPORTANT INFORMATION
Do not run the starter for more than five seconds each time. If the engine does not start, wait about 10 seconds before retrying.
Choke Control
The choke is used for cold starts to provide the engine with a richer fuel mixture. Pull the choke control knob up. On models without a separate choke, push the throttle control all the way forward to the choke position.
Ignition Switch
Choke control
Throttle Control
The throttle control regulates the engine speed and thereby the rate of rotation of the blades, assuming the blade switch is pulled out, see Engaging the
Mower Deck.
In order to increase or decrease the engine speed, the control is moved.
Avoid idling the engine for long periods, as there is a risk of fouling the spark plug.
USE FULL THROTTLE WHEN MOWING, for best
Throttle control
8058-113
8058-113
8058-113
21
CONTROLS mower performance and battery charging.
Blade Switch
In order to engage the mower deck, pull the knob out; the mower blades are disengaged when the knob is
IMPORTANT INFORMATION
The machine must stand absolutely still when applying the parking brake. Always set the parking brake before dismounting. Release the parking brake before moving the mower.
depressed.
Parking Brake
The parking brake is found on the left of the machine.
Push the release button and pull the lever backward to activate the brake—push forward to release it.
The park brake is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion. The engine will stop if the park brake is engaged while the control levers are in
IMPORTANT INFORMATION
In order to obtain an even cutting height it is important that the air pressure in all four tires is the same 15 psi (1 bar).
Blade switch
Released parking brake
the drive position.
Cutting Height Adjuster
To set the desired deck cutting height, press the release button and move the lever forward to the correct cutting height on the cutting plate. The cutting height range is from 1½" (38mm) to 4" (102mm) in ½"
(13mm) increments. The heights are measured from the ground up to the blade tip with the engine not running.
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IMPORTANT INFORMATION
Always use the high position to transport.
Cut height lift lever
8058-113
8058-080-1
8058-019
CONTROLS
Fuses
Fuses are located on the left hand side of the machine. They are accessed by tilting the seat forward. They are flat pin fuses of the same type used in automobiles.
There are two fuses with ratings and functions:
20 Amp Primary fuse
7.5 Amp Mower deck coupling
Fuel Shut Off Valve
The fuel shut off valve is located at the left rear of the seat. The valve is off when the handle tab is turned perpendicular to the fuel line.
Fuses
8011-420
Fuel shut off valve in the CLOSED position
8011-419
23
OpERATION
Read the Safety section and following pages, if you are unfamiliar with the machine.
Training
Zero turn mowers are far more maneuverable than typical riding mowers due to their unique steering capabilities.
We suggest that this section be reviewed in its entirety prior to attempting to move the mower under its own power. Additionally, we suggest when first operating the mower, use a reduced throttle speed and reduced ground speed by NOT moving control levers to the furthest forward or reverse positions during initial operation, or until operator becomes comfortable with controls. We also suggest first time users, or new users to Zero Turn mowers to become familiar with the mower’s movement on a hard surface, such as concrete or blacktop PRIOR to attempting to operate on turf. Until operator becomes comfortable with mower controls and zero turning capability, they may damage turf due to overly aggressive maneuvers.
IMPORTANT INFORMATION
When control levers are in the reverse position they return to neutral when released. This may cause the mower to suddenly stop.
inward. As long as the control levers have not been moved forward or backwards, mower will not move.
Slowly move both control levers forward slightly. This will allow mower to start moving forward in a straight line. Pull back on control levers to the neutral position and mower should stop moving. Pull back slightly on control levers, this will allow mower to start moving backwards. Push forward on control levers to the neutral position and mower should stop moving.
To turn to the right
While moving in a forward direction, pull the right lever back towards the neutral position while maintaining the position of the left lever, this will slow the rotation of the right wheel and cause the machine to turn in that direction.
To turn to the left
While moving in a forward direction pull the left lever back towards the neutral position while maintaining the position of the right lever, this will slow the rotation of the left wheel and cause the machine to turn in that direction.
To zero turn
While moving in a forward direction, first pull both control levers back until the mower stops or slows dramatically. Then by alternating one lever slightly to the forward position and the other in the reverse position, achieve a zeroturn in the direction of the forward lever.
Steering
To move forward and backward
The direction and speed of the mower’s movements is effected by the movement of the control lever(s) on each side of mower. The left control lever controls the left wheel. The right control lever controls the right wheel.
First time users should push mower (see Manual
Transport in the Operation section) to an open, flat area, without other people or vehicles/obstacles nearby. In order to move unit under its own power, the operator must be in the seat, start engine (see
Before Starting in Operation section), adjust engine speed to idle, disengage parking brake, do not engage blades at this time, rotate control levers
24
OpERATION
Before Starting
• Read the sections Safety Instructions and
Controls before starting the machine.
• Perform the daily maintenance before starting (see Maintenance Schedule in the
Maintenance section).
•
•
Check that there is sufficient fuel in the fuel tank.
Adjust the seat to the desired position.
The following conditions must be fulfilled before the engine can be started:
• The blade switch for engaging the mower blades must be depressed.
•
•
The parking brake must be on.
Both steering controls must be in the locked
(outer) neutral position.
Starting the Engine
• Sit on the seat.
•
•
Raise the mower deck by pushing the release button on the top of the lifting lever. Pull the lifting lever backward to the locked (transport) position.
Activate the parking brake by pushing the release button in and pulling the lever fully upwards.
Cut height lift lever
Disengage the mower blades by depressing the blade switch.
Released parking brake
8058-019
8058-080-1
Blade switch
8058-113
25
OpERATION
Move the steering controls outward to the locked
(outer) neutral position.
Move the throttle to the middle position.
Place controls in neutral position
8058-077
8058-113
If the engine is cold, pull the choke control knob up.
NOTE: On models without a separate choke control, push throttle control all the way forward to the choke position.
Set the throttle
Set the choke control
8058-113
26
OpERATION
Press in and turn the ignition key to the start position.
When the engine starts, immediately release the ignition key back to the run position.
IMPORTANT INFORMATION
Do not run the starter for more than 5 seconds each time. If the engine does not start, wait approximately 10 seconds before retrying.
Set the desired engine speed with the throttle. Allow the engine to run at a moderate speed, “half throttle”, for 3-5 minutes before loading it too heavily.
USE FULL THROTTLE WHEN MOWING.
Return to run position
WARNING!
Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer, birth defects or other reproductive system damage. The engine exhaust contains carbon monoxide, which is a odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces.
Set the engine speed
8050-781
8058-113
27
OpERATION
Weak Battery
WARNING!
Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries.
If your battery is too weak to start the engine, it should be recharged. (See Battery in the Maintenance section.)
If “jumper cables” are used for emergency starting, follow this procedure:
IMPORTANT INFORMATION
Your mower is equipped with a 12-volt negative grounded system. The other vehicle must also be a 12-volt negative grounded system. Do not use your mower to start other vehicles.
Jumper cable connection
Jumper Cables
1. Connect each end of the RED cable to the
POSITIVE (+) terminal on each battery, taking care not to short against chassis.
2.
3.
Connect one end of the BLACK cable to the
NEGATIVE (-) terminal of the fully charged battery.
Connect the other end of the BLACK cable to a good CHASSIS GROUND on the mower with the discharged battery, away from the fuel tank and battery.
To remove cables, reverse order
1. Remove BLACK cable first from chassis and then from the fully charged battery.
2. Remove RED cable last from both batteries.
28
8011-642
OpERATION
Running
1.
2.
Release the parking brake by moving the lever downward.
Your mower is equipped with an operator presence system. When the engine is running, any attempt by the operator to leave the seat without first setting the parking brake will shut off the engine.
Move the steering controls to the neutral position (N).
IMPORTANT INFORMATION
The mower deck’s anti-scalp rollers should be evenly adjusted.
3. Set retaining pin into selected cutting height and secure the opposite side with a cotter hairpin.
Released parking brake
WARNING!
Ensure that no one is near mower when engaging blade switch. Make sure the work area is free from objects that could be thrown by the rotating blades.
4.
5.
6.
Push the release button on the cutting height lever and move lever to the pin, release the button.
Set the cutting height with the cutting height adjustment lever.
Engage the mower deck by pulling out the blade switch.
Secure selected cutting height
8058-080-1
8058-024
Mower deck lifting lever
8058-019
29
OpERATION
7. Move throttle control to full throttle (not choke).
The machine’s speed and direction are continuously variable using the two steering controls. When both controls are in the neutral position, the machine stands still.
By moving both controls an equal amount forward or backward, the machine moves in a straight line forward or backward respectively.
In order, for example, to turn right while moving forward, move the right control towards the neutral position. The rotation of the right wheel is reduced and the machine turns to the right.
Turning on the spot can be achieved by moving one control backward (behind the neutral position) and carefully moving the other steering control forward from its neutral position.
IMPORTANT INFORMATION
Control levers return to neutral when released.
This may cause the mower to suddenly stop.
Set blade engagement and throttle control
8058-113
Operating On Hills
Read the Safety Instructions Driving on Slopes in the
Safety section.
WARNING!
Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across slopes.
•
•
•
•
•
•
The slowest speed possible should be used before starting up or down hills.
Avoid stopping or changing speed on hills.
If stopping is absolutely necessary, pull drive levers into the neutral position and push to the outside of the unit and engage the parking brake.
To restart movement, release the parking brake.
Pull the control levers back to the center of the mower and press forward to regain forward motion.
Make all turns slowly.
8058-077
Place controls in neutral position and engage the parking brake.
30
OpERATION
Mowing Tips
• Observe and flag rocks and other fixed objects to avoid collisions.
• Begin with a high cutting height and reduce it until the desired mowing result is attained.
The average lawn should be cut to
2½" (64 mm) during the cool season and over 3" (76 mm) during the hot months. For healthier and better looking lawns, mow often after moderate growth.
For best cutting performance, grass over 6"
(15 cm) in height should be mowed twice.
Make the first cut relatively high; the second to the desired height.
•
•
•
•
•
•
The mowing result will be best with a high engine speed (the blades rotate rapidly) and low speed (the rider moves slowly). If the grass is not too long and dense, the driving speed can be increased without negatively affecting the mowing result.
The finest lawns are obtained by mowing often. The lawn becomes more even and the grass clippings more evenly distributed over the mown area. The total time taken is not increased as a higher operating speed can be used without poor mowing results.
Avoid mowing wet lawns. The mowing result is poorer because the wheels sink into the soft lawn, clumps build, and the grass clippings fasten under the cowling.
Hose the mower deck underside with water after each use. When cleaning, the mower deck shall be raised into the transport position. Make sure the mower is cooled and the engine is off.
Use compressed air to clean top surface of the deck. Avoid flooding water on top surface, engine and electrical components.
When the mulching kit is used, it is important that the mowing interval is frequent.
Mowing pattern
WARNING!
Clear the lawn of stones and other objects that can be thrown out by the blades.
WARNING!
Never drive the rider on terrain that slopes more than 10 degrees. Mow slopes up and down, never side to side. Avoid sudden directional changes.
8050-819
31
OpERATION
Stopping the Engine
Allow the engine to idle a minute in order to attain normal operating temperature before stopping it, if it has been worked hard. Avoid idling the engine for longer periods, as there is a risk of the spark plugs fouling.
1. Disengage the mower deck by depressing the blade switch.
2. Raise the mower deck by depressing the button and pulling backward to the transport position.
Disengage the mower deck
8011-668
3.
4.
5.
6.
When the machine is standing still, activate the parking brake by pulling the lever upward.
Move the throttle to the minimum position (tortoise symbol). Turn the ignition key to the stop position.
Move the steering controls outward.
Remove key. Always remove key when leaving the mower to prevent unauthorized use.
Mower deck lifting lever
32
IMPORTANT INFORMATION
Leaving the ignition switch in any other position than “OFF” will cause the battery to be discharged.
Released parking brake
8058-019
8058-080
OpERATION
Manual Transport
When pushing or pulling the mower, engage the EZT
(Integrated Zeroturn Transaxle) bypass linkages. The
EZT bypass linkages are located on the rear of the frame, below the rear engine guard.
1. Raise the deck into the highest cutting position.
2.
3.
Pull the EZT bypass linkages up and out of the keyhole slots. Release the levers with the head outside the frame and held in the bypass position.
To reengage the EZT’s to drive, reverse the above procedure.
Bypass linkage, EZT engaged
8058-032
Bypass linkage, EZT locked in the bypass position
8058-033
33
mAINTENANCE
Maintenance Schedule
The following is a list of maintenance procedures that must be performed on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by an authorized service workshop is recommended to maintain your machine in the best possible condition and to ensure safe operation.
Read Maintenance in the Safety section.
MAINTENANCE
Check the parking brake
Check the engine’s oil level (every refueling)
Check the safety system
Check for fuel and oil leakages
Check/clean the engine’s cooling air intake
Check the mower deck
Check for loose hardware (screws, nuts)
Clean under the mower deck
Start the engine and blades, listen for unusual sounds
Check for damage
Thoroughly clean around the engine
Clean around belts, belt pulleys
Check the tire pressures
Check battery connections
Sharpen
3)
/ Replace mower blades
Clean the engine’s cooling air intake
2)
Clean the air cleaner’s pre-filter
2)
(foam)
Clean the air cleaner’s filter cartridge
2)
(paper filter)
Check/adjust the parking brake
Inspect muffler/spark arrestor
Daily
Before After
●
♦
●
■
♦
♦
♦
♦
●
●
●
■
●
At least once each year
Maintenance interval in hours
10
●
●
♦
●
100
●
●
♦
●
300
●
●
♦
●
■
●
♦
■
■
●
●
♦
●
●
■
●
♦
■
■
●
●
♦
●
♦
♦
■
●
♦
1)
First change after 8-10 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
2)
In dusty conditions, cleaning and replacement are required more often.
3)
Performed by authorized service workshop.
●
= Described in this manual
♦
= Not described in this manual
■
= Refer to the engine manufacturer's manual
●
♦
●
●
■
♦
●
♦
♦
34
mAINTENANCE
Daily At least once each year
Maintenance interval in hours
MAINTENANCE
Check/adjust throttle cable
Check the condition of belts, belt pulleys
Change the engine oil
1)
Replace the engine oil filter
Clean/replace the spark plugs
Replace the fuel filter
Replace air filter
2)
(paper filter)
Check the caster wheels (every 200 hours)
Replace the air cleaner’s pre-filter
2)
(foam)
Dismantle and inspect starter
3)
(every 500 hours)
Check/adjust the mower deck
Check the engine valve clearance
3)
Perform the 300-hour service
3)
Before After
●
■
●
■
■
■
●
■
10
■
■
100
■
●
♦
♦
1)
First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
2)
In dusty conditions, cleaning and replacement are required more often.
3)
Performed by authorized service workshop.
●
= Described in this manual
♦
= Not described in this manual
■
= Refer to the engine manufacturer's manual
♦
♦
♦
●
300
■
●
■
●
•
•
•
•
•
WARNING!
Before performing any service or adjustment checklist:
Engage the parking brake.
Place the Blade-switch in the disengaged position.
Turn the ignition switch to “OFF” position and remove the key.
Make sure the blades and all moving parts have completely stopped.
Disconnect the spark plug wire from all spark plugs and place the wire where it cannot come in contact with the plug.
35
mAINTENANCE
•
•
•
Battery
Your mower is equipped with a maintenance free battery and does not need servicing. However, periodic charging of the battery with an automotive type battery charger will extend its life.
Keep battery and terminals clean.
Keep battery bolts tight.
See chart for charging times.
Always use protective glasses when handling the battery.
12.6V
12.4V
12.2V
12.0V
11.8V
STANDARD
BATTERY
STATE
OF
APPROXIMATE BATTERY CHARGING TIME*
TO FULL CHARGE AT 80
O
F / 27
O
C
Maximum Rate at:
50 Amps 30 Amps 20 Amps 10 Amps
CHARGE
100%
75%
50%
25%
- FULL CHARGE -
20 min.
45 min.
65 min.
35 min.
75 min.
115 min.
48 min.
95 min.
145 min.
0% 85 min.
150 min.
195 min.
*Charging time depends on battery capacity, condition, age, temperature and efficiency of charger
90 min.
180 min.
280 min.
370 min.
IMPORTANT INFORMATION
Do not attempt to open or remove caps or covers. Adding or checking level of electrolyte is not necessary.
Always use two wrenches for the terminal screws.
Cleaning battery and terminals
Corrosion and dirt on the battery and terminals can cause the battery to “leak” power.
1. Lift seat and rotate forward.
2. Disconnect BLACK battery cable first, then the RED battery cable and remove the battery from the machine.
3.
4.
5.
6.
Rinse the battery with plain water and dry.
Clean terminals and battery cable ends with wire brush until shiny.
Coat terminals with grease or petroleum jelly
Reinstall battery.
Replacing battery
1. Lift seat and rotate forward.
2.
3.
4.
5.
6.
Using two ½" wrenches disconnect BLACK battery cable then RED battery cable.
Position deck to lowest setting.
From underside of frame, remove the nuts that secure the battery hold-down.
Carefully remove the battery from the mower.
Install new battery with terminals in the same position as the old battery.
7.
8.
9.
Reinstall battery hold-down and secure with nuts removed in Step 5.
First connect RED battery cable to positive (+) battery terminal with hex bolt and hex nut.
Connect BLACK grounding cable to negative
(-) battery terminal with remaining bolt and nut
10. Tighten securely.
11. Lower seat
WARNING!
Do not short battery terminals by allowing a wrench or any other object to contact both terminals at the same time. Before connecting battery, remove metal bracelets, wristwatch bands, rings, etc.
Positive terminal must be connected first to prevent sparks from accidental grounding.
Remove battery hold-down to replace battery
8050-109
36
mAINTENANCE
Safety System
The machine is equipped with a safety system that prevents starting or driving under the following conditions.
The engine can only be started when:
• The mower deck is disengaged.
• The steering controls are in the outer, locked neutral position.
•
•
The driver is sitting in the driver’s seat.
The parking brake is on.
Make daily inspections to ensure that the safety system works by attempting to start the engine when one of the conditions is not met. Change the conditions and try again.
If the machine starts when one of these conditions is not met, turn the machine off and repair the safety system before using the machine again.
Make sure the engine stops when the parking brake is not engaged and the operator leaves the seated position.
Check that the engine stops if the mower blades are engaged and the driver temporarily moves off the drivers seat.
Steering controls locked in neutral
Tire Pressures
All four tires should have a pressure of 15 psi / 103 kPa /1 bar.
8058-078
Check tire pressure
8058-079
37
mAINTENANCE
Parking Brake
WARNING!
The machine must be standing absolutely still when the park brake is engaged.
Visually check that no damage is found on the lever, linages, or switch belonging to the parking brake.
Perform a stand still test and check that there is a braking action.
To adjust the parking brake, contact the PoulanPRO service workshop.
WARNING!
Faulty adjustment can cause an accident.
Released parking brake
Deck Belt
Check every 100 hours of operation. Check for severe cracking and large nicks.
NOTE: The belt will show some small cracks in normal operation.
The belts are not adjustable. Replace belts if they begin to slip from wear.
Deck Belt Removal
1. Park on a level surface. Apply parking brake.
2.
3.
4.
5.
Lower the deck into the lowest cutting position.
Remove bolts from belt shields and remove shields.
Remove any dirt or grass that may have accumulated around the cutter housings and entire deck surface.
Carefully roll the belt over the top of the cutter housing pulleys and off the mower.
Belt Shields
Removing deck belt
8058-080-1
8058-115
38
mAINTENANCE
2.
3.
4.
Deck Belt Installation
NOTE: For ease in installing the deck belt, refer to the routing decal on the top of the deck.
1. Wrap the deck belt around the electric clutch pulley that is located on the engine shaft.
Route the belt forward and up onto the deck.
Place belt around spring loaded idler pulley.
Wrap the belt around the stationary idler pulley and around the mandrel housings.
5.
6.
7.
Push inward on the idler arm and carefully route belt over stationary idler pulley. Once belt is properly routed, slowly release idler arm to tension belt.
Double check belt routing to make sure it
matches the decal affixed to the deck, and the belt does not have any twist. Correct as needed.
Replace belt shields on both mandrel housings and secure with fasteners.
2
1. Clutch pulley
2. Deck belt
Belt routing, 54" deck belt
Pump Belt
Replacing EZT (E-Series Zeroturn Transaxle) belt
Park the mower on a level surface. Engage the parking brake.
EZT Belt Removal
NOTE: To maintain efficient cooling and not damage the EZTs, be careful of the fan blades when servicing the belt.
• Remove the deck belt (see
Deck Belt Removal in this section of the manual).
•
•
Create slack in the belt by removing the spring on the pump idler arm.
The belt should now be able to be removed from the engine pulley and EZT pulleys.
•
•
•
EZT Belt Installation
• Wrap the EZT belt around the EZT pulleys
• Route the belt around the inside of the idler pulley.
•
Wrap the belt around the engine pulley.
Reattach the spring on the pump idler arm.
Install clutch onto engine shaft (pulley side down), making sure key is installed. Align the clutch anti-rotation tab into slot on clutch.
Secure clutch, install wire.
Reinstall the deck belt onto the electric clutch
(see Deck Belt Removal in this section of the manual).
1
8011-764
39
mAINTENANCE
Cutting Blades
To attain the best mowing effect, it is important that the blades are well sharpened and not damaged.
Bent or cracked blades or blades with large nicks should be replaced.
IMPORTANT INFORMATION
The sharpening of blades should be carried out by an authorized service workshop.
Damaged blades should be replaced after hitting obstacles that result in a breakdown. A service workshop should decide whether the blade can be repaired/ground or must be replaced. Balance the blades after sharpening and check the blade mounts.
Blade replacement
1. Remove blade bolt by turning counter clockwise.
2.
3.
4.
Install new or resharpened blade with stamped
“GRASS SIDE” facing towards ground/grass
(down) or “THIS SIDE UP” facing deck and cutter housing.
Install and tighten blade bolt securely.
Torque blade bolt to 90 ft/lbs (122 Nm).
WARNING!
Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.
IMPORTANT INFORMATION
Special blade bolt is heat treated.
Replace with a PoulanPRO bolt if required.
Do not use lower grade hardware than specified.
3
1
IMPORTANT INFORMATION
The anti-scalp rollers must not be used for gauge wheels or the roller and deck may be damaged.
2
Anti-scalp Rollers
Anti-scalp rollers are properly adjusted when they are just slightly off of the ground when the deck is at the desired cutting height in the operating position. Antiscalp rollers then keep the deck in the proper position to help prevent scalping in most terrain conditions.
IMPORTANT INFORMATION
Adjust anti-scalp rollers with the mower on a flat level surface.
The anti-scalp rollers can be set in three positions:
• Upper position 1½ to 2½" (38 to 64 mm) grass
•
•
Middle position 2½" to 4" (64 to 102 mm) grass
Lower position 4" to 6" (102 to 128 mm) grass.
The rollers should be approximately ¼" (6.5 mm) from ground. Do not adjust the rollers to support the deck.
40
1. Blade
2. Blade bolt (special)
3. Cutter housing
Blade attachment
Anti-scalp rollers
8058-082
8050-830
mAINTENANCE
Adjusting the Mower Deck
Deck Leveling
Adjust the deck while the mower is on a level surface. Make sure the tires are inflated to the correct pressure. See Transmission under Technical Data.
If tires are under or over inflated, the deck cannot be properly adjusted.
The deck should be adjusted slightly higher in the rear.
NOTE: To insure accuracy of leveling procedure, mower deck drive belt must be installed prior to leveling deck.
1. Wear heavy gloves. Turn each outer blade tip to align with the deck or in a side-to-side manner.
2. Measure from the floor surface up to the bottom of the blade tip on the discharge side of the mower deck. Retain this measurement.
3. Move to the opposite side, check that measurement is the same. If adjustment is required—with a ¾" or adjustable wrench, turn the lift link adjustment nuts on either side counter clockwise to lower or clockwise to raise. Adjust until both side-to-side measurements are equal.
Lift link adjustment nut
4.
5.
Turn any blade to align with the deck in frontto-rear manner. If the rear blade tip does not measure
1
/
8
" to ½" higher, follow the front adjustment instructions that follow.
With a
5
/
8
or adjustable wrench, turn the nuts on the front suspension linkage. Clockwise raises the front of the mower, counter clockwise will lower the front. Adjust nuts until rear of mower deck is positioned level to
1
/
8
" higher in the rear than the side-to-side measurement.
NOTE: This will place the mower deck in a base measurement position. Additional adjustment may be required to achieve desired cut for the type of grass or conditions being mowed.
Deck front adjustment nuts
8058-030
8058-031
41
mAINTENANCE
Caster Wheels
Check every 200 hours. Check that wheels rotate freely. If wheels do not rotate freely take the unit to your dealer for service.
Foam filled tires or solid tires will void the warranty.
IMPORTANT INFORMATION
DO NOT add any type of tire liner or foam fill material to the tires. Excessive loads created by foam filled tires will cause premature failures.
Only use O.E.M. specified tires.
Removal and installation of caster wheel
Remove nut and caster bolt.
Pull the wheel out of the yoke and take care of the spacers.
Install in reverse order. Tighten caster bolt.
Hardware
Check daily. Inspect the entire machine for loose or missing hardware.
Cleaning
Regular cleaning and washing, especially under the mower deck, will increase the machine’s life-span.
Make it a habit to clean the machine directly after use
(after it is cooled), before the dirt sticks.
Do not spray water on the top of the mower deck. Use compressed air to clean the top side of mower deck.
Regularly clean deck and underside of the deck with normal water pressure. Do not use a high pressure washer or steam cleaner. Avoid spraying engine and electrical components with water
Do not rinse hot surfaces with cold water. Let unit cool before washing.
1. Caster yoke
2. Caster bolt
3. Long spacer
4. Small spacers
Caster wheels
2
4
IMPORTANT INFORMATION
Use protective glasses when cleaning and washing.
1
3
8058-083
42
Lubrication Schedule
LUBRICATION
8058-019
12/12 Every year
1/52 Every Week
1/365 Every day
Lubricate with grease gun
Oil change
Filter change
Lubricate with oil can
Level check
General
For engine lubrication, see the engine manufacturer's
Owners Manual.
Remove the ignition key to prevent unintentional movements during lubrication.
When lubricating with an oil can, it must be filled with engine oil.
When lubricating with grease, unless otherwise stated, use a high grade molybdenum disulphide grease.
For daily use, the machine should be lubricated twice weekly.
Wipe away excess grease after lubrication.
It is important to avoid getting lubricant on the belts or the drive surfaces on the belt pulleys. Should this happen, attempt to clean them with spirits. If the belt continues to slip after cleaning, it must be replaced.
Gasoline or other petroleum products must not be used to clean belts.
43
LUBRICATION
Wheel and Deck Zerks
Use only good quality bearing grease.
Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality.
Front Wheel Mount
Lubricate with a grease gun until the grease is forced out.
Front Wheel Bearings
Lubricate 3-4 strokes with a grease gun on each set of wheel bearings.
Lubricating the front wheels
Deck Spindles
Lower the cutting deck completely.
If a grease gun without rubber hose is used, the foot plate must be removed.
Lubricate with a grease gun, 2-3 strokes per spindle.
IMPORTANT INFORMATION
Use minimal lubrication and remove excess lubricant so that is does not come into contact with belts or belt pulley drive surfaces.
Deck spindle
8050-009
8058-116
44
Problem
Engine will not start
Engine runs rough
Engine seems weak
Machine vibrates
TROUBLE SHOOTING
Starter does not turn the engine over
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Cause
• Blade switch is engaged.
• Steering controls are not locked in the neutral position
Parking brake is not activated
Battery is dead
Contamination in the carburetor or fuel line.
Fuel supply is closed or the shutoff valve for the fuel tank is in the wrong position
Clogged fuel filter or fuel line
Ignition system faulty
Battery is dead
Poor contact of the battery terminal cable connections
Blown fuse
Fault in the starter safety circuit. See
Safety System in the
Maintenance section
Faulty carburetor
Choke control is pulled out with a warm engine
Clogged fuel filter or jet
Clogged ventilation valve on the fuel cap
Fuel tank nearly empty
Fouled spark plugs
Rich fuel mixture or fuel-air mixture.
Wrong fuel type
Water in fuel
Clogged air filter
Clogged air filter
Fouled spark plugs
Carburetor incorrectly adjusted
Air trapped in hydraulic system
Blades are loose
Blades are incorrectly balanced
Engine is loose
45
46
TROUBLE SHOOTING
Problem
Engine overheats
Battery not charging
The machine moves slowly, unevenly, or not at all
Mower deck not engaging
Transaxle leaks oil
Uneven mowing results
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Cause
• Clogged air intake or cooling fins
• Engine overloaded
Poor ventilation around engine
Defective engine speed regulator
Too little or no oil in the engine
Contamination in the carburetor or fuel line.
Fouled spark plugs
Poor contact of the battery terminal cable connections
Charging lead is disconnected
Parking brake on
Bypass valve on pump open
Drive belt for the transmission slack or has come off
Air trapped in hydraulic system
Drive belt for the mower deck has come loose
Contact for the electromagnetic coupling has loosened
Blade switch is faulty or has come loose from cable contact
Blown fuse
Damaged seals, housing, or gaskets
Air trapped in hydraulic system
Different air pressure in tires on the left and right sides.
Bent blades
Suspending for the mower deck is uneven
Blades are dull
Driving speed too high
Grass is too long
Grass collected under the mower deck
STORAGE
Winter Storage
At the end of the mowing season, the machine should be readied for storage (or if it will not be in use for longer than 30 days). Fuel allowed to stand for long periods of time (30 days or more) can leave sticky residues that can plug the carburetor and disrupt engine function.
Fuel stabilizers are an acceptable option as regards to the sticky residues that can occur during storage.
Add stabilizer to the fuel in the tank or in the storage container. Always use the mixing ratios specified by the manufacturer of the stabilizer. Run the engine for at least 10 minutes after adding the stabilizer so that it reaches the carburetor. Do not empty the fuel tank and the carburetor if you have added stabilizer
WARNING!
Never store an engine with fuel in the tank indoors or in poorly ventilated spaces where fuel vapor can come in contact with open flames, sparks, or a pilot light such as in a boiler, hot water tank, clothes drier, etc. Handle the fuel with care.
It is very flammable and can cause serious personal injury and property damage. Drain the fuel into an approved container outdoors and far away from open flame. Never use gasoline for cleaning. Use a degreaser and warm water instead.
To ready the machine for storage, follow these steps:
1. Thoroughly clean the machine, especially under the mower deck. Touch up damage to the paint and spray a thin layer of oil on the underside of the mower deck to avoid corrosion.
2.
3.
Inspect the machine for worn or damaged parts and tighten any nuts or screws that may have become loose.
Change the engine oil; dispose of properly.
4.
5.
6.
7.
8.
Empty the fuel tanks or add a fuel stabilizer. Start the engine and allow it to run until the carburetor is drained of fuel or the stabilizer has reached the carburetor.
Remove the spark plug and pour about a tablespoon of engine oil into the cylinder. Turn over the engine so that the oil is evenly distributed and then refit the spark plug.
Lubricate all grease zerks, joints, and axles.
Remove the battery. Clean, charge, and store the battery in a cool place, but protect it from direct cold.
Store the machine in a clean, dry place and cover it for extra protection.
Service
When ordering spare parts, please specify the purchase year, model, type, and serial number.
Always use genuine PoulanPRO spare parts.
An annual check-up at an authorized service workshop is a good way to ensure that your machine performs its best the following season.
47
48
SCHEmATIC
TECHNICAL DATA
M12
M14
M16
M18
M20
M22
M24
M27 ft./lbs
M4
M5
M6
M7
M8
M10
Torque Specifications
Hex Head Cap Screws
Grade
9
/
16
5
/
8
¾
7
/
8
1
1
/
8 ft./lbs
¼
5
/
16
3
/
8
7
/
16
½
The torque values shown should be used as a general guideline when specific torque values are not given.
U.S. Standard Hardware
SAE Grade 5 SAE Grade 8 Flangelock Screw w/Flangelock Nut ft./lbs Nm
110
150
250
378
782 ft./lbs
9
18
31
50
75
150
203
339
513
1060
Nm
12
24
42
68
102 ft./lbs
13
28
46
75
115
165
225
370
591
1410
224
305
502
801
1912
Nm
18
38
62
108
156
24
40
33
54
** Grade 5 - Minimum commercial quality (lower quality not recommended)
Metric Standard Hardware
Grade Grade 8.8
Grade 10.9
Grade 12.9
195
276
353
530
43.5
70.5
108
142 ft./lbs
1.5
3
5.2
8.2
13.5
24
260
368
470
707
58
94
144
190
Nm
2
4
7
11
18
32
275
390
498
474
62.2
100
147
202 ft./lbs
2.2
4.5
7.5
12
18.8
35.2
366
520
664
996
83
133
196
269
Nm
3
6
10
16
25
47
330
471
596
904
75
119
176
242 ft./lbs
2.7
5.2
8.2
15
21.8
43.5
100
159
235
323
440
628
794
1205
Nm
3.6
7
11
20
29
58
49
TECHNICAL DATA
460ZX / 966550201 540ZX / 966550301
Engine
Manufacturer
Type
Power
Lubrication
Oil capacity excluding filter
Oil capacity including filter
Engine oil, Synthetic
Engine oil, Mineral Class
Fuel
Fuel tank capacity
Spark plugs/gap
Cooling
Air filter
Alternator
Starter
Transmission
Type
Speed and direction controls
Speed forward
Speed reverse
Brakes
Front caster tires, smooth tread
Rear tires, turf pneumatic
Tire pressure, front and rear
Briggs & Stratton
ELS
19.5 hp*
Pressure with oil filter
1.78 qt (1.68 liters)
2 qt (1.89 liters)
SAE 10W30, 10W40, 5W20
5W30 API, SF-SG
Min 87 octane, unleaded (Max methanol 10%, max MTBE 15%)
4 gallons (15.1 liters)
Champion RC12YC
.030" / 0.75 mm
Air cooling
Standard
12V 16A
Electric 12V
Dual Hydro-Gear EZT
Dual levers, foam gripped
0-6 mph / 0-9.7 km/h
0-3.5 mph / 0-5.6 km/h
Mechanical parking brake
11 x 4-5, 4 ply
18 x 8.5-8
15 PSI / 103 kPa / 1 bar
Briggs & Stratton
Professional
24 hp*
Pressure with oil filter
1.78 qt (1.68 liters)
2 qt (1.89 liters)
SAE 10W30, 10W40, 5W20
5W30 API, SF-SG
Min 87 octane, unleaded (Max methanol 10%, max MTBE 15%)
4 gallons (15.1 liters)
Champion RC12YC
.030" / 0.75 mm
Air cooling
Standard
12V 16A
Electric 12V
Dual Hydro-Gear EZT
Dual levers, foam gripped
0-9.5 mph / 0-15.3 km/h
0-5 mph / 0-8 km/h
Mechanical parking brake
11 x 4-5, 4 ply
18 x 9.5-8
15 PSI / 103 kPa / 1 bar
*The power rating of the engines indicated is the average net power output (at specified rpm) of a typical production engine for the engine model measured to SAE standard J1349/ISO1585. Mass production engines may differ from this value. Actual power output for the engine installed in the final machine will depend on the operating speed, environmental conditions and other variables.
50
Equipment
Cutting width
Cutting height
Uncut circle
Number of blades
Blade length
Nose rollers
Sprung seat
Hinged armrests
Blade engagement
Deck construction
Productivity
Output
Overall dimensions
Weight
Base machine length
Base machine width
Base machine height
Overall width, chute up
Overall width, chute down
TECHNICAL DATA
460ZX / 966550201
46"
1.5" - 4" / 2.5 cm - 10.6 cm
0
2
22¾ / 58 cm
No
Standard
No
Electric clutch
Stamped
540ZX / 966550301
54"
1.5" - 4" / 2.5 cm - 10.6 cm
0
3
18¼ / 46.4 cm
No
Standard
No
Electric clutch
Stamped
2.37 acres/hr / 9591 m
2
/hr
525 lbs / 238 kg
75" / 191 cm
40" 102 cm
41¾" / 106 cm
48" / 122 cm
56" / 142 cm
2.78 acres/hr / 11250 m
2
/hr
538 lbs / 244 kg
75" / 191 cm
40" 102 cm
41¾" / 106 cm
57" / 145 cm
67½" / 174 cm
51
CONFORmITy CERTIFICATES
USA requirements
Labels are placed on the engine and/or in the engine compartment stating that the machine will fulfill the requirements. This is also applicable to special requirements for any of the states, (California emission rules etc.). Do not remove any of these labels.
Certificates can also be supplied with the machine at delivery or written in the Engine manual. Take care of them as they are valuable documents.
CE requirements
If required, vibration data corresponding to Directive
2002/44/EC is given in the Technical Data Section.
The Declaration of Conformity is included in the literature packet.
52
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
Delivery Service
1.
Charge the battery.
2.
Adjust the tire pressure of all wheels to 15 PSI (1 bar).
3.
4.
5.
6.
Mount the steering controls in the normal position.
Connect the contact box to the cable for the seat’s safety switch.
Check that the right amount of oil is in the engine.
Adjust the position of the steering controls.
7.
8.
Fill with fuel and open the fuel shut off valve.
Start the engine.
9.
Check that there is drive to both wheels.
10. Check the mower deck adjustment.
11. Check:
Safety switch for the parking brake.
Safety switch for the mower deck.
Safety switch in the seat.
Safety switch in the steering controls.
Parking brake functionality.
Driving forward.
Driving backward.
12.
13.
14.
Engaging the blades.
Check engine high idle speed
Inform the customer about:
Need and advantages of following the service schedule.
Need and advantages of leaving the machine for service.
Effects of service and maintaining a service journal on the machine’s resale value.
Application areas for mulching.
Fill in the sales papers, etc.
Delivery service has been carried out.
No remaining notes.
Certified:
53
54
SERVICE JOURNAL
Action
Daily Service
1. Clean debris from mower.
2. Check engine oil level.
3. Check the tire pressures.
4. Check underside of deck.
5. Inspect deck pulleys.
6. Check/clean the engine’s cooling air intake.
7. Check safety system.
8. Check seat belt.
9. Check fuel system for leaks.
10. Inspect safety guards and shields.
11. Check brake adjustment.
Date, mtr reading, stamp, sign
After 10 hours
1. Change the engine oil.
2. Change the oil filter.
3. Check hydraulic oil level.
4. Inspect hydraulic hoses.
5. Inspect hydraulic belt.
6. Inspect hydraulic filter.
7. Check neutral position.
8. Check safety system.
9. Check seat belt.
10. Check fuel system for leaks.
11. Inspect safety guards and shields.
12. Check brake adjustment.
SERVICE JOURNAL
Action
100-Hour Service
1. Grease fittings (caster pivots and caster wheels)
2. Inspect dampeners
3. Inspect frame
4. Inspect throttle and choke cables
5. Inspect hardware
6. Check the tire pressures
7. Change the engine oil and filter
8. Change air filter
9. Inspect spark plug
10. Inspect fuel filter
11. Check engine RPM
12. Clean underside of deck
13. Check blade pitch
14. Grease blade spindles
15. Inspect spindle bearings
16. Inspect deck belt and blades
17. Inspect idler arm bearings
18. Inspect deck idler pulleys
19. Check hydraulic oil level
20. Inspect hydraulic filter
21. Inspect hydraulic drive belt
22. Inspect hydraulic hoses
23. Check neutral position
24. Inspect battery connections
25. Check safety system
26. Check seat belt
27. Check fuel system for leaks
28. Inspect safety guards and shields
29. Check brake adjustment
Date, mtr reading, stamp, sign
55
56
SERVICE JOURNAL
Action
300-Hour Service
1. Grease fittings (caster pivots and caster wheels)
2. Inspect dampeners
3. Inspect frame
4. Inspect throttle and choke cables
5. Inspect hardware
6. Check the tire pressures
7. Change the engine oil and filter
8. Change air filter
9. Inspect spark plug
10. Inspect fuel filter
11. Check engine RPM
12. Clean underside of deck
13. Check blade pitch
14. Grease blade spindles
15. Inspect spindle bearings
16. Inspect deck belt and blades
17. Inspect idler arm bearings
18. Inspect deck idler pulleys
19. Check brake adjustment
20. Inspect safety guards and shields
21. Replace hydraulic drive belt
22. Inspect hydraulic hoses
23. Check neutral position
24. Inspect battery connections
25. Load test battery
26. Clean electrical connections
27. Inspect the clutch
28. Check safety system
29. Check seat belt
30. Check fuel system for leaks
Date, mtr reading, stamp, sign
SERVICE JOURNAL
Action
At least once each year
1. Clean the engine’s cooling air intake.
2. Replace the air cleaner’s pre-filter (foam).
3. Replace the air filter’s paper cartridge.
4. Change the engine oil.
5. Replace the engine oil filter.
6. Check/adjust the cutting height.
7. Check/adjust the parking brake.
8. Clean/Change the spark plugs.
9. Replace the fuel filter.
10. Check the engine valve clearance.
Date, mtr reading, stamp, sign
57
58
Action
SERVICE JOURNAL
Date, mtr reading, stamp, sign
P/N 115 348227R1 02/16/10
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