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Poulan Pro PO1538D manual

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Table of contents for the manual

  • Page 1

    D OWNER'S MANUAL MODEL NO. PO1538D 15 HP 38 Inch Lawn Tractor Assembly • Operation • Maintenance • Service and Adjustments • Storage • Troubleshooting • Repair Parts For Parts and Sewice, contact our authorized distributor: call 1-800o849-1297 For Technical Assistance: call 1-800-829-5886 Poutan 187570 3.5.03 MH PRINTED IN U.S.A.[...]

  • Page 2

    _ SAFETY RULES ASAFE OPERATION PRACTICES FOR RIDE-ON MOWERS,_ ,MPO ANT: TR,S cuTr,N'G- ACH,NE,S CAPABLE OF AMPUTATING HANDS AND FEET AND TF, VVING OBJECTS FA,LURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH. I. GENERAL OPERATION • Read, understand, and follow all instructions in the manual and on the [...]

  • Page 3

    SAFETY RULES &Safe Operation Practices for Ride-On Mowers Be sure the area is clear 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. Always look down and behind before and while backing. Never carry children. The[...]

  • Page 4

    PRODUCT SPECIFICATIONS GASOLINE CAPACITY 1.25 GALLONS AND TYPE: UNLEADED REGULAR OIL TYPE (API-SF-SJ): SAE 30 (above 32°F) SAE 5W-30 (below 32°F) OIL CAPACITY: W/Filter 3.5 Pints W/O Filter 3.0 Pints SPARK PLUG: CHAMPION RC12YC GAP: .030") GROUND SPEED (MPH): FORWARD: tst 1.1 2nd 2,2 3rd 3.4 4th 4.3 5th 5.5 REVERSE: 1.7 FIRE PRESSURE: FRONT:[...]

  • Page 5

    UNASSEMBLED PARTS Steering Wheel Steering Wheel Insert I i Steering Wheel Adapter Steering Extension Shaft (1) Large Flat Washer (1) Hex Bolt 1/4-28 x 1-1/4 Steering Boot (1) Locknut 1/2-20 ® (1) Locknut 1/4-28 Seat (1) Washer 17/32 x 1-3/16 x 12 Gauge (1) Lock Washer 1/2 (1) Bolt (1) Oil Drain Tube For Future Use Keys 2) Keys Slope Sheet 5[...]

  • Page 6

    ASSEMBLY Your new tractor has been assembled at the factory with exception of those parts left unassembted for shipping purposes. To ensure safe and proper operation of your tractor all parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to insure proper tightness. TOOLS REQUIRED FOR ASSEMBLY A socket wren[...]

  • Page 7

    ASSEMBLY HOW TO SET UP YOUR TRACTOR INSTALL SEAT (See Fig. 2) Adjust seat before tightening adjustment bolt. • Remove adjustment belt, lock washer and flat washer securing seat to cardboard packing and set aside for assembly of seat to tractor. • Pivot seat upward and remove from the cardboard pack- ing. Remove the cardboard packing and discard[...]

  • Page 8

    ASSEMBLY CHECKTIRE PRESSURE ,/CHECKLIST The tires on your tractor were overinflated at the factory for shipping purposes. Correct tire pressure is important for best cutting performance. • Reduce tire pressure to PSI shown in "PRODUCT SPECIFICATIONS" section of this manual. CHECK DECK LEVELNESS For best cutting results, mower housing sh[...]

  • Page 9

    OPERATION These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning. R N H L I'-,I REVERSE NEUTRAL HIGH LOW CHOKE FAST SLOW IGNITION ENGINE OFF LIGHTS ON ENGINE ON OVER TEMP FUEL OIL PRESSURE LIGHT AI'rACHMENT A'I-rACHMENT CLUTCH ENGAGED CLUTCH DISENGAGED FREE WHEEL (Autom[...]

  • Page 10

    OPERATION KNOWYOUR TRACTOR READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR Compare the illustrations with your tractor to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference. THROTTLE/CHOKE ,, f, LIGHT SWITCH ATTACHMENT IGNITION POSITION CLUTCH LEVER SWITCH [...]

  • Page 11

    OPERATION [_ The operation of any tractor can result in foreign objects thrown into the eyes, which | 1 can result in severe eye damage. Always wear safety glasses or eye shields while op- I erating your tractor or performing any adjustments or repairs. We recommend a w de vision safety mask over spectacles or standard safety glasses. HOWTO USE YOU[...]

  • Page 12

    OPERATION TO OPERATE MOWER (See Fig. 6) Your tractor is equipped with an operator presence sensing switch. Any attempt by the operator to leave the seat with the engine running and the attachment clutch engaged will shut off the engine. Select desired height of cut. • Start mower blades by engaging attachment clutch control. • TO STOP MOWER BLA[...]

  • Page 13

    OPERATION CAUTION: Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during stor- age. 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[...]

  • Page 14

    MAINTENANCE .A,NTENANCESC. OO.E F,LL,. OA S AS YOU COMPLETE REGULAR SERV,CE ERV,OE OATES Check Brake Operati°n _ _ Check Tire Pressure Check Operator Presence and T Interlock Systems Check for Loose Fasteners ll/s _ ! A Sharpen/Replace Mower Blades _4 3 Lubrication Chart If T Check Battery Level R Clean Battery and Terminals I/ Check Transaxle Coo[...]

  • Page 15

    MAINTENANCE TRACTOR Always observe safety rules when performing any main- tenance. BRAKE OPERATION If tractor requires more than six (6) feet stopping distance at high speed in highest gear, then brake must be adjusted. (See "TO ADJUST BRAKE" in the Service and Adjustments section of this manual). TIRES • Maintainpmperairpressureinaltti[...]

  • Page 16

    MAINTENANCE BATTERY Your tractor has a battery charging system which is sufficient for normal use. However, periodic charging of the battery with an automotive charger wilt extend its life. • Keep battery and terminals clean. Keep battery bolts tight. Keep small vent holes open. • Recharge at 6-10 amperes for 1 hour. NOTE: The original equipmen[...]

  • Page 17

    MAINTENANCE CLEAN AIR SCREEN Air screen must be kept free of dirt and chaff to prevent engine damage from overheating. Clean with a wire brush or compressed air to remove dirt and stubborn dried gum fibers. ENGINE COOLING FINS (See Fig. 12) Remove any dust, dirt or oil from engine cooling fins to prevent engine damage-from overheating. Remove screw[...]

  • Page 18

    MAINTENANCE MUFFLER Inspect and replace corroded muffler and spark arrester (if equipped) as it could create a fire hazard and/or dam- age. SPARK PLUGS Replace spark plugs at the beginning of each mowing season or after every 100 hours of operation, whichever occurs first. Spark plug type and gap setting are shown in "PRODUCT SPECIFICATIONS&qu[...]

  • Page 19

    SERVICE AND ADJUSTMENTS WARNING: TO AVOID SERIOUS INJURY, BEFORE PERFORMING ANY SERVICE OR ADJUST- MENTS: Depress clutcWbrake pedal fully and set parking brake. Place gearshift lever in neutral (N) position. Place attachment clutch in "DISENGAGED" position. Turn ignition key to "STOP" and remove key. Make sure the blades and all[...]

  • Page 20

    SERVICE AND ADJUSTMENTS TO LEVEL MOWER HOUSING Adjust the mower while tractor is parked on level ground or driveway, Make sure tires are properly inflated (See "PRODUCT SPECIFICATIONS" section of this manual). If tires are over or underinflated, you will not properly adjust your mower. SIDE-TO-SIDE ADJUSTMENT (See Figs. 16 and 17) Raise m[...]

  • Page 21

    SERVICE AND ADJUSTMENTS MANDREL ENGINE PULLEY PULLEY RETAINER SPRING IDLER PULLEYS MANDREL PULLEY FIG. 20 TO CHECK AND ADJUST BRAKE (See Fig. 21) Your tractor is equipped with an adjustable brake system which is mounted on the right side of the transaxle. If tractor requires more than five (5) feet to stop at highest speed in highest gear on a leve[...]

  • Page 22

    SERVICE AND ADJUSTMENTS TO REMOVE WHEEL FOR REPAIRS (See Fig. 23) Block up axle securely. Remove axle cover, retaining ring and washers to allow wheel removal (rear wheel contains a square key - Do not lose). • Repair tire and reassemble. On rear wheels only: align grooves in rear wheel hub and axle. Insert square key. • Replace washers and sna[...]

  • Page 23

    SERVICE AND ADJUSTMENTS ENGINE TO REPLACE HEADLIGHT BULB • Raise hood. Pull bulb holder out of the hole in the backside of the grill. • Replace bulb in holder and push bulb holder securely back into the hole in the backside of the grill. • Close hood. INTERLOCKS AND RELAYS Loose or damaged wiring may cause your tractor to run poorly, stop run[...]

  • Page 24

    STORAGE ENGINE Immediately prepare your tractor for storage at the end of the season or if the tractor will not be used for 30 days or more. WARNING: Never store the tractor with gasoline in the tank inside a building where fumes may reach an open flame orspark. Allow the engine to cool before storing in any enclosure. TRACTOR • Remove mower from[...]

  • Page 25

    TROUBLESHOOTING POINTS PROBLEM Will not start Hard to start Engine will not turn over Engine clicks but will not start Loss of power Excessive vibration CAUSE 1. Out of fuel. 2. Engine not'_3HOKED" properly. 3. Engine flooded. 4. Bad spark plug. 5. Dirty air filter. 6. Dirty fuel filter. 7. Water in fuel. 8. Loose or damaged wiring. 9. Ca[...]

  • Page 26

    TROUBLESHOOTING POINTS CAUSE PROBLEM Engine continues to run when operator leaves seat with attachment clutch engaged Poor cut - uneven Mower blades will not rotate Poor grass discharge Headlight(s) not working (if so equipped) Battery will not charge Engine "backfires" when turning engine "OFF" 1. Faulty operator-safety presenc[...]

  • Page 27

    SCHEMATIC TRACTOR -- MODEL NUMBER PO1538D RED BLACK AMMETER OPTIONAL) _ED FUSE WHITE )G A_( IGNITION SWITCH i t '© 0_,-- i I _LUTCH/ER_,K_E (PEDAL UP) BLACK BL_CK f MEI-ER '(OPTIONAL) BLACK ; -_6E-L ', L BLUE _ _ LINE' • I i SOLENOID STARTER BLACK WHITE SEAT SWITCH (NOT OCCUPIED) I I I t BLACK BLAC K (CLUTCH OFF) I CONNECTOR[...]

  • Page 28

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D ELECTRICAL t i I i I 42 i 41 22 i 26 27 / / I I 48 I 27 / I I I F /I I / I II I I I I I I 161 ...... / / / / / / / // 28[...]

  • Page 29

    REPAIR PARTS TRACTOR -- MODEL NUMBER PO1538D ELECTRICAL KEY PART NO. NO. DESCRIPTION 1 163465 Battery 2 74760412 Bolt Hex Hd 1/4-20unc X 3/4 8 176689 Box Battery 16 176138 Switch Interlock 21 175685 Harness Asm Light W/4152j 22 4152J Bulb Light #1156 24 4799J Cable Battery 6 Ga 11 "red 25 146147 Cable Battery 26 175158 Fuse 20 AMP 27 73510400 [...]

  • Page 30

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D CHASSIS 212 3O 29 J 26 31 2O8 26 25 '209 12 53 28 55 54 57 10 35 205 34 38 O5 208 chassis-pl.lt 34 3O[...]

  • Page 31

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D CHASSIS KEY PART NO. NO. DESCRIPTION 1 174620 2 176554 3 17060612 5 155272 6 174643X014 8 155138 9 168347X011 10 72140608 11 174996 12 145660 13 172105X010 15 74180512 16 73510500 17 159639x428 18 184921 24 74780616 25 19131312 26 73800600 28 179101 29 140273X599 30 169465X428 31 136619 33 179716X428 34[...]

  • Page 32

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D DRIVE 57 16 / I 52 30 250 I 113 51 77 6 32 250 25 15 / 26 26 5 18 35 36 37 120...-- "_ 34 29 i 26 27 drive-saddle_25 32[...]

  • Page 33

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D DRIVE KEY PART KEY PART NO. NO. DESCRIPTION NO. NO. 2 146682 3 123666X 4 12000028 5 121520X 6 17060512 7 162240 8 131679 10 76020416 11 105701X 12 19151216 13 74550412 14 10040400 15 74490544 16 73800500 18 74780616 19 73800600 21 106933X 22 130804 24 73350600 25 106888X 26 19131316 27 76020412 28 17576[...]

  • Page 34

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D STEERING J _39 L i 36 51 54 71 17 47 67 57 67 43 34[...]

  • Page 35

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D STEERING KEY PART NO. NO. DESCRIPTION 1 140044X428 2 175131 3 169840 4 169839 5 6266H 6 121748X 7 19272016 8 12000029 9 3366R 10 175121 11 10040600 12 73940800 13 136518 15 145212 17 180641 26 126847X 28 19131416 29 17060612 30 76020412 32 130465 36 155099 37 152927 38 140045X428 39 19183812 40 7810H 41[...]

  • Page 36

    REPAIR PARTS TRACTOR ENGINE 2_ -- MODEL NUMBER PO1538D 3 81 13 4 78, 31 40 33 29 OPTIONAL EQUIPMENT I Spark Arrester 14 23 I 78 KEY PART NO. NO. DESCRIPTION 1 2 3 170551 Control TtVch Flag 17720408 Screw HexThd Cut 1/4-20 x 1/2 ........ Engine, B&S 282H07 4 137352 13 165291 14 148456 16 11050600 23 169837 29 137180 31 184900 32 140527 (Order [...]

  • Page 37

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D SEAT KEY NO. 1 2 3 4 5 6 7 8 9 10 12 13 J I I I I I i -.----- 16 I 5 23 17 12 PART NO. 127426X 140551 71110616 19131610 145006 73800600 124181X 17000616 19131614 182493 121246X 121248X DESCRIPTION Seat Bracket Seat Pivot Bolt Hex 3/8 - 16 X 1 Washer 13/32 X 1 Xl0Ga. Clip Push-In Hinged Nut Lock Hex w/In[...]

  • Page 38

    REPAIR PARTS TRACTOR DECALS 8 7 12 - - MODEL NUMBER PO1538D 2 14 6 8 15 4 3 KEY PART NO. NO. DESCRIPTION 1 2 3 4 6 7 8 9 181251 187580 184768 170563 157140 158168 172200 158166 17 Decal, Clutch/Brake Eng/Fr Decal, Replacement Decal, Engine HP Decal Warning Decal, Fender Danger English Decal Ins Str Wh Decal, Fender 5 Sp. Decal Fender KEY PART NO.[...]

  • Page 39

    REPAIR PARTS MOWER LIFT TRACTOR - - MODEL NUMBER PO1538D 5 6 13 2 13 31 32 19 20 KEY PART NO. NO. 1 159460 2 159471 3 105767X 4 12000002 5 19211621 6 120183X 7 109413X 8 124526X 11 139865 12 139866 13 4939M 15 173288 16 73350800 17 175689 18 73800800 19 139868 20 163552 31 169865 32 73540600 DESCRIPTION Wire Asm InnedSprg w/plunger Shaft Asm Lift R[...]

  • Page 40

    REPAIR PARTS TRACTOR - - MODEL NUMBER PO1538D MOWER DECK 11 21 68 9 29 27 8 4O[...]

  • Page 41

    REPAIR PARTS TRACTOR -- MODEL NUMBER PO1538D MOWER DECK KEY PART KEY PART NO. NO. DESCRIPTION NO. NO. 1 170280 Mower Housing Assembly 67 106932X 2 72140506 Bolt Carriage 5/16-18 x 3/4 68 144200 3 138017 Bracket Asm Ft. Sway Bar 69 76020312 4 169970 Bracket Deck Sway Bar 38"/42" 86 7631J 5 4939M Retainer Spring 87 128772 6 178024 Bar Sway [...]

  • Page 42

    LIMITED WARRANTY The Manufacturer warrants to the original consumer purchaser that this product as manufactured is free from defects in materi- als and workmanship. For a period of two (2) years from date of purchase by the original consumer purchaser, we will repair or replace, at our option, without charge for parts or labor incurred in replacing[...]

  • Page 43

    SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION 4_ ONLY RIDE UP AND DOWN HILL, NOT ACROSS HILL 15 DEGREES MAX. WARNING: To avoid serious injury, operate your tractor up and down the face of slopes, never across the face. Do not mow slopes greater than 15 degrees. Make turns gradually to prevent tipping or loss of control. Exercise extreme ca[...]

  • Page 44

    Poulan[...]