Poulan 960 42 00-35 manual

OPERA TOR'S MANU AL MODEL: PB19546L T L A WN TRACTOR AL W A YS WEAR EYE PROTECTION DURING OPERA TION Visit our website: www .poulan-pro.com WARNING: Read this Man u al and follow all Warnings and Safety Instructions. F ail ure to do so can re sult in serious in ju ry . IMPORT ANT MANU AL Do Not Throw Away 411229 Rev . 6 04.28.08 SBW/TH Printed[...]

2 I. GENERAL OPERA TION • 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. • Only allow responsible adults, who are familiar with the in struc tions, to operate the machine. • [...]

3 • Be sure the area is clear of bystanders before operat- ing. Stop machine if anyone enters the area. • Never carry passengers. • Do not mow in reverse unless absolutely necessary . Al ways look down and behind before and while back- ing. • Never carry children, even with the blades shut off. They may fall off and be seriously injured or [...]

4 T ABLE OF CONTENTS SAFETY RULES ......................................................... 2-3 PRODUCT SPECIFICA TIONS ....................................... 4 CUSTOMER RESPONSIBILITIES ................................. 4 ASSEMBL Y ................................................................. 6-8 OPERA TION ...................................[...]

5 CONTENTS OF HARDW ARE P ACK (2) Keys Slope Sheet Key (1) Oil Drain Tube Steering Wheel Steering Extension Shaft Steering Wheel Adapter Steering Boot Steering Extension Shaft (2) Keys Slope Sheet Key (1) Oil Drain Tube 3TEERING 7HEEL Steering Extension Shaft Steering Wheel Adapter Steering Boot Steering Extension Shaft Seat Seat W asher W asher (1[...]

6 AS SEMBL Y TOOLS REQUIRED FOR AS SEMBL Y A socket wrench set will make assembly easier . Stan dard wrench sizes are listed. (1) 1/2" wrench Utility knife (2) 3/4" wrench Tire pres sure gauge Pliers When right or left hand is mentioned in this man ual, it means when you are in the operating po si tion (seated be hind the steer ing wheel)[...]

7 AS SEMBL Y NOTE: Y ou may now roll or drive your tractor off the skid. Follow the ap pro pri ate instruction below to remove the tractor from the skid. WARNING: Before start ing, read, un der stand and fol low all in struc tions in the Op er a tion section of this man u al. Be sure tractor is in a well-ventilated area. Be sure the area in front o[...]

8 AS SEMBL Y CHECK TIRE PRESSURE 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 on tires. CHECK DECK LEVELNESS For best cutting results, mower housing should be properly leveled. See “TO LEVEL MOWER HOUSING” [...]

9 OPERA TION These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their mean- ing. DANGER, KEEP HANDS AND FEET AWAY FREE WHEEL (Automatic Models only) OVER TEMP LIGHT KEEP AREA CLEAR SLOPE HAZARDS 15 15 (SEE SAFETY RULES SECTION) BATTERY REVERSE FORWARD FAST SLOW ENGINE ON ENGINE OFF OIL PRESSURE[...]

10 OPERA TION KNOW YOUR TRACTOR READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERA TING YOUR TRACTOR Compare the illustrations with your tractor to familiarize yourself with the locations of various controls and ad just ments. Save this manual for future reference. A TT ACHMENT CLUTCH LEVER - Used to engage the mower blades, or other attac[...]

11 NOTE: Under certain conditions when tractor is standing idle with the engine running, hot engine exhaust gases may cause “brown ing” of grass. T o eliminate this possibility , al- ways stop engine when stopping tractor on grass areas. OPERA TION The operation of any tractor can result in foreign objects thrown into the eyes, which can result[...]

12 OPERA TION REVERSE OPERA TION SYSTEM (ROS) Y our tractor is equipped with a Reverse Operation System (ROS). Any attempt by the operator to travel in the reverse direction with the attachment clutch engaged will shut off the engine unless ignition key is placed in the ROS "ON" position. WARNING: Backing up with the attachment clutch en-[...]

13 OPERA TION TO ST ART ENGINE (See Fig. 7) When starting the engine for the first time or if the engine has run out of fuel, it will take extra cranking time to move fuel from the tank to the engine. • Sit on seat in operating position, depress clutch/brake pedal and set parking brake. • Place gear shift lever in neutral (N) position. • Move[...]

14 MOWING TIPS • Mower should be properly leveled for best mowing per - for mance. See "TO LEVEL MOWER HOUSING" in the Service and Adjustments section of this manual. • The left hand side of mower should be used for trim- ming. • Drive so that clippings are discharged onto the area that has been cut. Have the cut area to the right o[...]

15 MAINTENANCE LUBRICA TION CHART d SPINDLE ZERK d FRONT WHEEL BEARING ZERK c SAE 30 OR 10W30 MOTOR OIL d GENERAL PURPOSE GREASE e REFER TO MAINTENANCE “ENGINE” SECTION IMPORT ANT : DO NOT OIL OR GREASE THE PIVOT POINTS WHICH HA VE SPECIAL NYL ON BEARINGS. VISCOUS LU BRI CANTS WILL A TTRACT DUST AND DIRT THA T WILL SHORT EN THE LIFE OF THE SELF[...]

16 MAINTENANCE TO SHARPEN BL ADE (See Fig. 11) NOTE: We do not recommend sharpening blade - but if you do, be sure the blade is balanced. Care should be taken to keep the blade balanced. An un- bal anced blade will cause excessive vibration and even tual dam age to mower and engine. • The blade can be sharpened with a file or on a grind- ing whee[...]

17 FIG. 11 BA TTERY Y our tractor has a battery charging system which is suf fi cient for normal use. However , periodic charging of the battery with an automotive charger will 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 orig[...]

18 MAINTENANCE CLEANING • Clean engine, battery , seat, finish, etc. of all foreign matter . • Keep finished surfaces and wheels free of all gasoline, oil, etc. • Protect painted surfaces with automotive type wax. We do not recommend using a garden hose or pressure washer to clean your tractor unless the engine and trans- mission are covered [...]

19 SERVICE AND ADJUSTMENTS WARNING: TO A VOID SE RI OUS IN JU RY , BEFORE PERFORMING ANY SERVICE OR ADJUST - MENTS: • Depress clutch/brake pedal fully and set parking brake. • Place gearshift lever in neutral (N) position. • Place attachment clutch in “DISENGAGED” position. • T urn ignition key to “STOP” and remove key . • Make su[...]

20 D C G E F M L K R Q A P G B • A TT ACH REAR LIF T LINKS (C) - Lift rear corner of mower and position slot in link assembly over pin (D) on rear mower bracket and secure with washer and retainer spring. • Hook end of clutch cable spring (Q) into hole in idler arm (R). • Push clutch cable housing guide (P) into bracket, slide collar (L) onto[...]

21 SERVICE AND ADJUSTMENTS TO LEVEL MOWER Make sure tires are properly inflated to the PSI shown on tires. If tires are over or under inflated, it may affect the appearance of your lawn and lead you to think the mower is not adjusted properly . VISUAL SIDE- TO -SIDE ADJUSTMENT (See Fig .20) • With all tires properly inflated and if your lawn appe[...]

22 SERVICE AND ADJUSTMENTS TO REPL ACE MOTION BEL T DRIVE (See Fig. 25) P ark the tractor on level surface. En gage parking brake. For as sis tance, there is a belt installation guide decal on bottom side of left footrest. BEL T REMOVAL - • Remove mower (See “TO RE MOVE MOWER” in this section of manual). NOTE: Observe entire motion drive belt[...]

23 ADJUSTMENT BOL T NEUTRAL L OCK GA TE GEARSHIFT LEVER FIG. 26 SERVICE AND ADJUSTMENTS TO ADJUST STEERING WHEEL ALIGN- MENT If steering wheel crossbars are not horizontal (left to right) when wheels are positioned straight forward, remove steer - ing wheel and reassemble per instructions in the Assembly section of this manual. FRONT WHEEL TOE-IN/C[...]

24 REPL ACING BA TTERY ( See Figs. 29 and 30 ) WARNING: Do not short battery ter mi nals by allowing a wrench or any other object to contact both terminals at the same time. Before connect- ing battery , remove metal bracelets, wristwatch bands, rings, etc. Positive terminal must be connected first to prevent sparking from ac ci - den tal grounding[...]

25 STORAGE 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 trac tor with gas o line in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any en clo sure. TRACTOR Remove mower from t[...]

26 TROUBLESHOOTING POINTS Will not start 1. Out of fuel. 1. Fill fuel tank. 2. Engine not “CHOKED” properly . 2. See “TO ST ART ENGINE” in Operation section. 3. Engine flooded. 3. Wait several minutes before attempting to start. 4. Bad spark plug. 4. Replace spark plug. 5. Dirty air filter . 5. Clean/replace air filter . 6. Dirty fuel filte[...]

27 TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine dies when 1. Reverse operation system 1. T urn ignition key to tractor is shifted (ROS) is not "ON" while ROS "ON" position. into reverse mower or other attachment See Operation section. is engaged. Engine continues to run 1. Faulty operator -safety presence control syste[...]

28 REP AIR P ARTS TRACTOR - - MODEL NUMBER PB19546L T (96042003500), PRODUCT NO . 960 42 00-35 NOTE: All component dimensions given in U.S. inches 1 inch = 25.4 mm KEY P ART NO . NO . DESCRIPTION 6 2 1 5,8 4,10 3,9 11 7 WHEELS AND TIRES KEY P ART NO . NO . DESCRIPTION KEY P ART NO . NO . DESCRIPTION 3 16 9 1 59192 Cap V alve Tire 2 65139 Stem V alv[...]

29 BATTERY FUSE AMMETER (OPTIONAL) RED RED RED RED WHITE BLACK BLUE BLACK BLACK BLACK/WHITE BLACK BLACK BLUE BLUE BROWN BLACK BLACK GRAY GRAY BLACK SOLENOID M A STARTER CLUTCH / BRAKE (PEDAL UP) SEAT SWITCH (NOT OCCUPIED) IGNITION UNIT HOUR METER FUEL LINE FUEL SHUT-OFF SOLENOID HEADLIGHTS S M B G A1 A2 L REVERSE SWITCH SPARK PLUGS GAP (2 PLUGS ON [...]

30 REP AIR P ARTS TRACTOR - - MODEL NUMBER PB19546L T (96042003500), PRODUCT NO . 960 42 00-35 ELECTRICAL 30 33 34 22 79 21 41 42 26 43 27 40 71 16 87 25 T02S 90 28 55 With 12V Outlet Option 59 103 With Service Minder Option 46 46 94 92 29 93 2[...]

31 REP AIR P ARTS TRACTOR - - MODEL NUMBER PB19546L T (96042003500), PRODUCT NO . 960 42 00-35 ELECTRICAL KEY P ART NO . NO . DESCRIPTION 1 163465 Battery 2 74760412 Bolt Hex Hd 1/4-20 unc x 3/4 8 193228 Box Battery 16 176138 Switch Interlock 21 183759 Harness Socket Light 22 4152J Bulb, Light # 1156 25 401662 Cable Battery 6 Ga. Red 14.5 26 175158[...]

32 37 181 181 194 194 36 36 236 183 152 159 2 159 230 230 180 162 196 68 222 159 chassis-te x_52-elite sv pro_r1 197 138 182 176 175 5 177 130 151 14 18 208 207 15 25 186 176 176 176 150 137 219 194 219 235 REP AIR P ARTS TRACTOR - - MODEL NUMBER PB19546L T (96042003500), PRODUCT NO . 960 42 00-35 CHASSIS[...]

33 2 194263 Drawbar 5 197783X428 Dash 14 183393X428 Hood 15 183834X599 Lens Grille LH 18 183828 Grille 25 183835X599 Lens Grille RH 36 17060512 Screw 5/16-18 x 3/4 37 193218X428 Fender 68 17490508 Screw Thdrol 5/16-18 x 1/2 130 191611 Screw 10 x 3/4 Single Lead-Hex 137 184921 Bumper Hood 138 193224X428 Cupholder 150 184322 Duct Heat Hood 151 407807[...]

34 70 74 56 185 186 189 49 187 50 51 190 52 51 29   165 166 64 188 172 172 2 17 26 195 125 125 125 161 35 175 192 158 134 192 157 141 140 139 176  174 1 22 15  184 167 160 42 DRIVETEX?PEERLESS?FENDER? 159 159 166 2 183 37 205 33 155 61      ª 202 225 116 162 REP AI[...]

35 KEY P ART NO . NO . DESCRIPTION 1 - - - - - - T ransaxle, P eerless 206-565 (See T ransaxle Breakdown) 2 123583X Key Square 15 19131316 Washer 13/32 x 13/16 x 16 Ga. 17 197297 Spring, Brake 22 197660 Rod Shift 23 409154x421 Knob 26 197455 Spring Brake RTN 29 197267 Rod, Brake 33 12000001 Ring E 35 197722 Rod, Brake, P ark 37 121749X W asher 25/3[...]

36 21 20 OPTIONAL EQUIPMENT Spark Arrester 29 18 15 37 28 engine-bs-1cyl-tex_4 12 42 85 9 90 84 45 1 81 82 69 2 79 97 96 REP AIR P ARTS TRACTOR - - MODEL NUMBER PB19546L T (96042003500), PRODUCT NO . 960 42 00-35 ENGINE 1 - - - - - - Engine B&S Model No. 31P677 2 137352 Muffler 9 194319 Keeper Belt Engine 12 405140 Pulley Engine 15 407545 T ank[...]

37 6 55 5 13 13 53 8 9 9 8 8 7 7 62 4 35 16 71 19 63 63 57 60 59 58 28 13 22 64 50 50 70 65 68 69 67 54 67 66 54 65 15 15 14 14 21 26 1 20 45 33 72 61 55 2 6 steering-tex_7-lt 1 186093X428 Wheel, Steering 2 184706 Axle Asm., F ront 4 403087 Spindle Asm., LH 5 403088 Spindle Asm., RH 6 6266H Bearing, Race Thrust Harden 7 121748X W asher 25/32 x 1-5/[...]

38 2 6 1 40 10 37 37 21 21 3 41 7 8 7 8 seat-tex_7-vgt 44 43 1 197514 Seat 2 180166 Bracket Pivot F ender 3 140675 Strap, Asm F ender 6 73800600 Nut, Lock w/Ins. 3/8-16 unc 7 124181X Spring, Seat Cprsn 8 171877 Bolt 5/16-18 unc x 3/4 w/Sems 10 196977 Pan, Seat 21 171852 Bolt, Shoulder 5/16-18 37 73800500 Nut, Lock 5/16-18 unc 40 197661 Handle Slide[...]

39 7 3 87 10 88 2 89 90 87 98 97 97 lift-tex_5 91 89 87 100 2 195223 Shaft Asm., Lift 3 195231 Lever Asm., Lift RH 7 196492X421 Grip, Lever 10 196314 Spring T orsion 87 194209 Pin Cotter 7/16 Bow Tie Lock 88 195303 Spring Lift Assist 89 19191912 Washer Clear Zinc 90 194208 Pin Cotter 5/16 Bow Tie Lock 91 195181 Link Lift Susp Mower Rear 97 17060612[...]

40 REP AIR P ARTS TRACTOR - - MODEL NUMBER PB19546L T (96042003500), PRODUCT NO . 960 42 00-35 MOWER DECK 30 42 43 60 38 63 46 147 55 64 30 32 31 33 56 34 56 57 59 240 188 1 69 69 69 199 40 145 46_man-T e x_lt_5 15 14 13 11 8 21 25 26 27 198 29 21 21 23 24 144 36 40 57 19 19 6 6 116 118 119 117 119 116 118 68 195 122 123 195 189 189 188 21 69 69 69[...]

41 1 405050x421 Mower Housing 6 195186 Arm Suspension 7 191611 Screw 10 x 3/4 Single Hex 8 193003 Bolt/Washer asm 7/16-20 unf 11 405380 Blade, 46" Hi-Lift (For bagging or discharge) 13 192872 Shaft Assembly , Mandrel 14 187281 Housing, Mandrel 15 110485X Bearing, Ball, Mandrel 19 196539 Bolt, Shoulder 21 73680500 Nut, Crownlock 5/16-18 unc 23 [...]

42 15 DEGREES MAX. FOLD ALONG DOTTED LINE THIS IS A 15 DEGREE SLOPE ONLY RIDE UP AND DOWN HILL, NOT ACROSS HILL SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION 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 preven[...]

43 LIMITED W ARRANTY The Manufacturer warrants to the original consumer purchaser that this product as manufactured is free from defects in materi- als and work man ship. 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 re[...]

44 T E C U M S E H ¨ Issued January 1980 Revised January 1991 T E C U M S E H ¨ SER VICE POLICY W ARRANTY LIMITED WARRANTIES FOR NEW PEERLESS GEAR POWER TRAIN COMPONENTS A. Products Warranted Peerless Gear and Machine Division of T ecumseh Products Company (“T ecumseh”), subject to the limitations contained below , will,at its option, repair [...]