Operator Manual 461ZX / 966681801 541ZX / 966681901 Please read the operator’s manual carefully and make sure you understand the instructions before using the machine. Gasoline containing up to 10% ethanol (E10) is acceptable for use in this machine. The use of any gasoline exceeding 10% ethanol (E10) will void the product warranty.
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.
TABLE OF CONTENTS INTRODUCTION.................................................................. 5 Driving and Transport on Public Roads.......................... 5 Towing............................................................................. 5 Operating........................................................................ 5 Good Service.................................................................. 6 Manufacturing Number................................................... 6 SYMBOLS AND DECALS....
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.
INTRODUCTION Congratulations Towing 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.
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.
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. IMPORTANT INFORMATION 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. Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.
SYMBOLS AND DECALS Read Operator’s Manual Whole body exposure to thrown objects Shut off engine and remove key before performing any maintenance or repair work Severing of fingers and toes Keep a safe distance from the machine Do not open or remove safety shields while engine is running Use on slopes no greater than 10° No passengers Careful backing up, watch for other people Careful going forward, watch for other people Battery acid is corrosive, explosive and flammable Moving sharp blades unde
SAFETY Safety Instructions These instructions are for your safety. Read them carefully. WARNING! WARNING! 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. This symbol means that important safety instructions need to be emphasized. It concerns your safety. General Operation • Read, understand, and follow all instructions on the machine and in the manual before starting.
SAFETY • • • • • • • • • • • • • 10 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. Watch for traffic when operating near or crossing roadways. Use extra care when loading or unloading the machine into a trailer or truck.
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. • • • • • • • Make sure that you have first aid equipment close at hand when using the machine. Never use the machine when barefoot.
SAFETY • • • 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. WARNING! CHILDREN CAN BE INJURED BY THIS EQUIPMENT. The American Academy of Pediatrics recommends that children be a minimum of 16 years of age before operating a riding lawn mower.
SAFETY Safe Handling of Gasoline 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 before refueling. 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. • Use only approved gasoline container.
SAFETY General Maintenance • • • • • • • • • • • • • • • • • 14 Never operate machine in a closed area. Keep all nuts and bolts tight to be sure the equipment is in safe working condition. 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.
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. WARNING! Avoid electrical sparking and its consequences by the following routines: • • • • • • • • • • • • • • • Use protective goggles.
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. Do not operate this machine on public roadways.
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 2 3 4 1 4 5 6 1. 2. 3. 4. 5. 6. 7 8 9 Motion Control Levers Parking brake Fuel shut off valve Bypass Linkages Fuel tank Blade switch 11 10 7. 8. 9.
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.
CONTROLS 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 the drive position. IMPORTANT INFORMATION The machine must stand absolutely still when applying the parking brake.
CONTROLS Ignition Switch The ignition switch is placed on the control panel and is used to start and stop the engine. 8058-113 Ignition Switch 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. 8058-113 Choke control Hour Meter The hour meter displays the total operating time.
CONTROLS Fuel Tank The machine has one fuel tank, just behind the seat. The tank capacity is 4 gallons (13.2 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.
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 IMPORTANT INFORMATION Always use the high position to transport.
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. 8050-852 Seat adjustment Bypass Linkages The levers are located on each side of the rear of the unit below the rear engine plate. The bypass linkage is used when manually pushing or pulling the unit.
OPERATION Read the Safety section and following pages, if you are unfamiliar with the machine. Training Due to unique steering capabilities, zero turn mowers are far more maneuverable than typical riding mowers. This section should be reviewed in its entirety prior to attempting to move the mower under its own power. When first operating the mower or until becoming comfortable with controls, use a reduced throttle speed and reduced ground speed.
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.
OPERATION 5. Move the steering controls outward to the locked (outer) neutral position. 8058-190 Place controls in neutral position 6. Move the throttle to the middle position. 8058-113 Set the throttle 7. 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.
OPERATION 8. Press in and turn the ignition key to the start 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. 0000-000 Turn to the start position 9. When the engine starts, immediately release the ignition key back to the run position.
OPERATION Weak Battery If your battery is too weak to start the engine, it should be recharged. (See Battery in the Maintenance section.) WARNING! Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. Jumper Cable Use 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.
OPERATION Running 1. 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. 2. Move the steering controls to the neutral position (N). 8058-191 Parking brake released 3. Set retaining pin into selected cutting height and secure the opposite side with a cotter hairpin.
OPERATION 5. Engage the mower deck by pulling out the blade switch. 6. 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.
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.
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. Push the blade switch down to disengage the mower blades. 8011-668 Disengage the mower deck 2. Raise the mower deck by pressing the release button on the lever and pulling the lever fully backward to the transport position. 3.
OPERATION Moving Machine By Hand 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. 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. 3. To reengage the EZT’s to drive, reverse the above procedure.
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 Daily MAINTENANCE Before After At least once each year Maintenance interval in hours 10 100 300 ■ ● 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
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. STANDARD BATTERY STATE APPROXIMATE BATTERY CHARGING TIME* TO FULL CHARGE AT 80OF / 27OC OF CHARGE Maximum Rate at: 50 Amps 30 Amps 20 Amps 10 Amps 12.6V 100% - FULL CHARGE - 12.4V 75% 20 min.
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.
MAINTENANCE IMPORTANT INFORMATION To avoid deck damage, the anti-scalp rollers must not be adjusted to support the deck. 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.
MAINTENANCE 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. Lower the deck into the lowest cutting position. 3. Remove bolts from belt shields and remove shields. 4.
MAINTENANCE Cutting Blades To attain the best mowing effect, it is important that blades are well sharpened and not damaged. Replace blades that have been bent or cracked when hitting obstacles. Let the service workshop decide whether a blade with large nicks can be repaired/ground or must be replaced. Balance the blades after sharpening. Check the blade mounts. WARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.
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.
MAINTENANCE Tire Pressures All four tires should have a pressure of 15 psi / 103 kPa /1 bar. 8058-079 Check tire pressure Cleaning Regular cleaning, 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 debris 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 the underside of the deck with normal water pressure.
LUBRICATION Lubrication Schedule 8058-174 12/12 Every year Lubricate with grease gun Lubricate with oil can 1/52 Every Week Oil change Level check 1/365 Every day Filter change 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.
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 around the grease cap. Front Wheel Bearings Lubricate 3-4 strokes with a grease gun on each set of wheel bearings. 8050-009 Lubricating the front wheels Deck Spindles Lower the cutting deck completely.
TROUBLE SHOOTING Problem Cause Engine will not start • 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.
TROUBLE SHOOTING Problem Cause Engine overheats • 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.
STORAGE Winter Storage The machine should be readied for storage at the end of the mowing season 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.
SCHEMATIC 48
TECHNICAL DATA Torque Specifications Engine crankshaft bolt Deck pulley bolts Lug nuts Blade bolt 50 ft/lb (67 Nm) 150 ft/lb (203 Nm) 75 ft/lb (100 Nm) 90 ft/lb (122 Nm) Standard ¼" fasteners Standard 5/16" fasteners Standard 3/8" fasteners Standard 7/16" fasteners Standard ½" fasteners 9 ft/lb (12 Nm) 18 ft/lb (25 Nm) 33 ft/lb (44 Nm) 52 ft/lb (70 Nm) 80 ft/lb (110 Nm) Hex Head Cap Screws The torque values shown should be used as a general guideline when specific torque values are not given. U.S.
TECHNICAL DATA 461ZX / 966681801 541ZX / 966681901 Briggs & Stratton 1) Briggs & Stratton 1) Professional Professional 19.5 hp 2) 22 hp 2) Pressure with oil filter Pressure with oil filter Min 87 octane, unleaded (Max methanol 10%, max MTBE 15%) Min 87 octane, unleaded (Max methanol 10%, max MTBE 15%) 3½ gallons (13.2 liters) 3½ gallons (13.
TECHNICAL DATA 461ZX / 966681801 541ZX / 966681901 Cutting width 46" 54" Cutting height 1½" - 4" / 2.5 cm - 10.6 cm 1½" - 4" / 2.5 cm - 10.6 cm Uncut circle 0 0 Number of blades 2 3 Blade length 22¾ / 58 cm 18¼ / 46.4 cm Nose rollers No No Sprung seat Standard Standard No No Blade engagement Electric clutch Electric clutch Deck construction Stamped Stamped 2.37 acres/hr / 9591 m2/hr 2.
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.
SERVICE JOURNAL Action Date, mtr reading, stamp, sign Delivery Service Charge the battery. Adjust the tire pressure of all wheels to 15 PSI (1 bar). 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. Fill with fuel and open the fuel shut off valve. Start the engine. Check that there is drive to both wheels. Check the mower deck adjustment.
SERVICE JOURNAL Action Daily Service Clean debris from mower. Check engine oil level. Check the tire pressures. Check underside of deck. Inspect deck pulleys. Check/clean the engine’s cooling air intake. Check safety system. Check seat belt. Check fuel system for leaks. Inspect safety guards and shields. Check brake adjustment. After 10 hours Change the engine oil. Change the oil filter. Check hydraulic oil level. Inspect hydraulic hoses. Inspect hydraulic belt. Inspect hydraulic filter.
SERVICE JOURNAL Action Date, mtr reading, stamp, sign 100-Hour Service Grease fittings (caster pivots and caster wheels) Inspect dampeners Inspect frame Inspect throttle and choke cables Inspect hardware Check the tire pressures Change the engine oil and filter Change air filter Inspect spark plug Inspect fuel filter Check engine RPM Clean underside of deck Check blade pitch Grease blade spindles Inspect spindle bearings Inspect deck belt and blades Inspect idler arm bearings Inspect deck idler pulleys Ch
SERVICE JOURNAL Action 300-Hour Service Grease fittings (caster pivots and caster wheels) Inspect dampeners Inspect frame Inspect throttle and choke cables Inspect hardware Check the tire pressures Change the engine oil and filter Change air filter Inspect spark plug Inspect fuel filter Check engine RPM Clean underside of deck Check blade pitch Grease blade spindles Inspect spindle bearings Inspect deck belt and blades Inspect idler arm bearings Inspect deck idler pulleys Check brake adjustment Inspect saf
SERVICE JOURNAL Action Date, mtr reading, stamp, sign At least once each year Clean the engine’s cooling air intake. Replace the air cleaner’s pre-filter (foam). Replace the air filter’s paper cartridge. Change the engine oil. Replace the engine oil filter. Check/adjust the cutting height. Check/adjust the parking brake. Clean/Change the spark plugs. Replace the fuel filter. Check the engine valve clearance.
SERVICE JOURNAL Action 58 Date, mtr reading, stamp, sign