| OWNER'S MANUAL MODEL NO. PC1538C 15 HP 38 Inch LawnTractor Assembly • Operation • Maintenance • Service and Adjustments • Storage • Troubleshooting • Repair Parts For Parts and Service, contact our authorized distdbutor: call 1-800-849-1297 For Technical Assistance: call 1-800-829-5886 Poulan 186888 2.5.03 RD PRINTED IN U.S.A.
SAFETY RULES _ SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS ,_ IMPORTANT: THIS CUTTING"RIACHINEIS CAPABLEOF AMPUTATING HANDS AND FEET AND TI_ING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONSCOULD RESULT IN SERIOUS INJURY OR DEATH. I. GENERAL • • • • • • • • • • • • • • DO NOT: OPERATION Read, understand, and follow all instructions in the manual and on the machine before starting. Only allow responsible adults, who are familiar with the instructions, to operate the machine.
SAFETY RULES '_Safe Operation Practices for Ride-On & 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. They may fall off and be seriously injured or interfere with safe machine operation.
PRODUCT SPECIFICATIONS GASOLINE CAPACITY AND TYPE: 1,25 GALLONS UNLEADED REGULAR OIL TYPE (API-SF-SJ): SAE 30 (above 32°F) SAE 5W-30 (below 32°F) 3 PINTS CHAMPION RC12YC OIL CAPACITY: SPARK PLUG: GAP: .030") GROUND SPEED (MPH): TIRE PRESSURE: CHARGING SYSTEM: BATTERY: BLADE BOLT TORQUE: CONGRATULATIONS on your purchase of a new tractor. It has been designed, engineered and manufactured to give you the best possible dependability and performance.
UNASSEMBLED Steering Wheel PARTS Seat @ (1) Washer 17/32 x 1-3/16 x 12 Gauge (1) Lock Washer 1/2 Steering Wheel Insert Steering Boot i i Steering Wheel Adapter Steering Extension Shaft (1) Bolt (1) Oil Drain Tube For Future Use Keys 1111 ,e,s Slope Sheet (1) Large Flat Washer (1) Locknut 1/2-20 @ (1) Hex Bolt 1/4-28 x 1-1/4 (1) Locknut 1/4-28 5
ASSEMBLY Your new tractor has been assembled at the factory with exception of those parts left unassembled 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 wrench set will make assembly easier. Standard wrench sizes are listed.
ASSEMBLY HOW TO SET UP YOUR TRACTOR INSTALL SEAT (See Fig. 2) SEAT PAN Adjust seat before tightening adjustment bolt. Remove adjustment bolt, lock washer and fiat washer securing seat to cardboard packing and set aside for assembly of seat to tractor. Pivot seat upward and remove from the cardboard packing. Remove the cardboard packing and discard. • Place seat on seat pan so head of shoulder bolt is positioned over large slotted hole in pan.
ASSEMBLY CHECKTIRE ,/CHECKLIST 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 in "PRODUCT SPECIFICATIONS" section of this manual.
OPERATION These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning.
OPERATION KNOW YOUR 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. ATTACHMENT CLUTCH LEVER LIGHT SWITCH POSITION IGNITION SWITCH THRO'I-rL_CHOKE ATTACHMENT LIFT LEVER CLUTCH/BRAKE PEDAL /_ MOWERDECK "HEIGHT ADJUSTMENT POSITIONS PARKING BRAKE GEARSHIFT LEVER FIG.
OPERATION The operation of any tractor can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your tractor or performing any adjustments or repairs. We recommend a wide vision safety mask over spectacles or standard safety glasses. HOWTO IMPORTANT: LEAVING THE IGNITION SWITCH IN ANY POSITION OTHER THAN "OFF" WILL CAUSE THE BATTERY TO BE DISCHARGED, (DEAD). USE YOUR TRACTOR TO SET PARKING BRAKE (See Fig.
OPERATION TO OPERATE TO TRANSPORT (See Fig. 6) MOWER Yourtractor isequipped 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. • I I I POSITION ATTACHMENT • When pushing or towing your tractor, be sure gearshift lever is in neutral (N) position.
OPERATION MOWING TIPS CAUTION: Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidicgas can damage the fuel system ofan 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 next season.
MAINTENANCE FILL tN DATES ASYOOCOMPLETE REGULAR SERVICE !'_4"_""£-q_'/_£'_F Check Check BrakePressure Operation Tire _ Check Operator Presence Interlock Systems Check for Loose Fasteners A Sharpen/Replace Lubrication Chart T Check Battery Level 1_4 R _1_ 1_5 Blades Clean Battery and Terminals li/ Check Transaxle v' Check V-Belts Check Engine Cooling Oil Level I_ E Change Engine Oil (without N Clean Air Filter 1_2 G Clean Air Screen 1_2 Clean Muffler/Spark I/1,
MAINTENANCE TRACTOR MANDREL ASSEMBLY TRAILING EDGE UP Always observe safety rules when performing any maintenance. CENTER HOLE 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 B RAKE" in the Service and Adjustments section of this manual). LOCK WASHER STAR TIRES • • Maintainproperairpressureinalltires(See"PRODUCT SPECIFICATIONS" section of this manual).
MAINTENANCE BATTERY NOTE: Although multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, these multi-viscosity oils will result in increased oil consumption when used above 32°F Check your engine oil level more frequently to avoid possible engine damage from running low on oil. Yourtractor has a battery charging system which issufficient for normal use. However, periodic charging of the battery with an automotive charger will extend its life. Keep battery and terminals clean.
MAINTENANCE CLEAN AIR SCREEN AIR 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. Your engine will not run properly using a dirty air filter, Replace pre-cleaner after every 25 hours of operation or every season. Service paper cartridge every t00 hours of operation or every season, whichever occurs first. ENGINE COOLING FINS (See Fig.
MAINTENANCE MUFFLER Inspect and replace corroded muffler and spark arrester (if equipped) as it could create a fire hazard and/or damage. SPARK CLAMP PLUGS FUE_ 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" section of this manual. cLAMP FILTER FIG. 14 IN-LINE FUEL FILTER (See Fig. 14) The fuel filter should be replaced once each season.
SERVICE AND ADJUSTMENTS WARNING: MENTS: • • TO AVOID SERIOUS INJURY, BEFORE ANY SERVICE OR ADJUST- Depress clutch/brake 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 moving parts have completely stopped. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.
SERVICE AND ADJUSTMENTS TO LEVEL MOWER rear, tighten nuts =F" against trunnion on both front links. 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 mower to its highest position.
SERVICE AND ADJUSTMENTS TO REPLACE (See Fig. 22) R.H, SUSPENSION ARM ,,,._ MANDREL PULLEY ;: ._ .:._ BELT BELT REMOVAL • Remove mower (See 'q'O REMOVE MOWER" in this section of manual). NOTE: Observe entire motion drive belt and position of all belt guides and keepers. • Remove belt from stationary idler and clutching idler. Remove belt downward from around engine pulley. • Pull belt slack toward rear of tractor. Remove belt upwards from transaxle pulley by deflecting belt keepers.
SERVICE AND ADJUSTMENTS Position the gear shift lever in the neutral (N) position. Tighten adjustment bolt securely. WASHERS RETAINING RING NOTE: If additionalclearanceis needed to get toadjustment bolt, move mower deck height to the lowest position. AXLE COVER__ SQUARE KEY(REAR-------___ WHEELONL_ GEARSHIFT LEVER FIG. 24 TO START ENGINE (See Fig. 25) WITH A WEAK BATTERY WARNING: Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries.
SERVICE AND ADJUSTMENTS Lift seat pan to raised position. Disconnect BLACK battery cable first then RED battery cable and carefully remove battery from tractor. Install new battery with terminals in same position as old battery. First connect RED battery cable to positive (+) terminal with hex bolt and keps nut as shown. Tighten securely. Slide terminal cover over terminal. _/OODHEADLIGHT \ Connect BLACK grounding cable to negative (-) terminal with remaining hex bolt and keps nut. Tighten securely.
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, FUEL SYSTEM IMPORTANT: IT IS IM PORTANTTO PREVENT GUM DEPOSITS FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH AS CARBURETOR, FUEL FILTER, FUEL HOSE, OR TANK DURING STORAGE. ALSO, EXPERIENCE INDICATES THAT ALCOHOL BLENDED FUELS (CALLED GASOHOL OR USING ETHANOL OR METHANOL) CAN A3q'RACT MOISTURE WHICH LEADSTO SEPARATION AND FORMATION OF ACIDS DU RING STORAGE.
TROUBLESHOOTING PROBLEM Will not start CAUSE CORRECTION 1. Out of fuel. 1. Fill fuel tank. 2. 3. 4. 5. 6. 7. Engine not =CHOKED" properly. Engine flooded. Bad spark plug. Dirty air filter. Dirty fuel filter. Water in fuel. 2. 3. 4. 5. 6. 7. See =TO START ENGINE" in Operation section. Wait several minutes before attempting to start. Replace spark plug. Clean/replace air filter. Replace fuel filter. Drain fuel tank and carburetor, refill tank with fresh 8. 9. Loose or damaged wiring.
TROUBLESHOOTING PROBLEM POINTS CAUSE 1. Check wiring, switches and connections. If not corrected, contact an authorized service center/ department. Worn, bent or loose blade. Mower deck not level. Buildup of grass, leaves, and trash under mower. Bent blade mandrel. 1. 2. Replace blade. Tighten blade bolt. Level mower deck. 3. 4. Clean underside of mower housing. Replace blade mandrel. 5. Clogged mower deck vent holes from buildup of grass, leaves, and trash around mandrels. 5.
TRACTOR SCHEMATIC - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 4k BATFERY I o+ FUSE AMMETER (OPTIONAL) STARTER BLACK WHITE ____ RED I '© I I ' O_;-i t_ G ..... J CLUTCH / BRAKE (PEDAL UP) A1 J SOLENOID I WHFFE IGNITION (NOT OCCUPIED) SEAT SWITCH 1 SWITCH i ........ ........
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 ELECTRICAL 22 21 I I I I Ii f / I I I I I I i t i [ I 26 I I 25 48 29 27 I I I I I I 28
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER ELECTRICAL KEY NO. PART NO.
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 CHASSIS 30 29 12 28 25 26 5 208 207 26 33 10 13 • _ .
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER CHASSIS KEY NO. PART NO.
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 DRIVE i 26 32 27
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 DRIVE KEY NO. 2 3 4 5 6 8 10 11 13 14 16 18 19 21 22 24 25 26 27 28 29 30 32 34 35 36 37 38 39 41 47 48 49 50 51 52 53 55 56 57 59 61 62 PART NO.
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 STEERING 68 67 67 47 67 65 43 I 3O 34 iIz'l _l II 6
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 STEERING KEY NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 15 17 26 28 29 30 32 36 37 38 39 40 41 42 43 44 46 47 51 54 65 67 68 71 82 85 88 91 NOTE: PART NO.
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 ENGINE 3 2_ 72 81 4 78 I 38 14 33 37 31 29 \ OPTIONAL 23 EQUIPMENT Spark Arrester 36
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER ENGINE KEY NO. PART NO.
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 SEAT 8 _,_ ! 12 KEY NO. PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 12 13 127426X 140551 71110616 19131610 145006 73800600 124181X 17000616 19131614 182493 121246X 121248X 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/Ins 3/8 - 16 Spring Seat Cprsn 2 250 BIk Zi Screw 3/8-16 x 1.
REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 DECALS 7 8 12 \ 1 14 6 8 15 9 3 17 KEY NO. 1 3 4 6 7 8 9 12 14 15 16 PART NO. 185413 184768 170563 157140 158168 172200 158166 181552 181553 145005 156369 WHEELS 2_ KEY NO. DESCRIPTION NPR Decal Replace Decal, Engine HP Decal Warning Decal, Fender Danger English Decal Ins Str Wh Decal, Fender 5 Sp. Decal Fender Decal, Hood RH Decal, Hood LH Decal, Caution, Battery Decal, Oper Inst. PART NO.
REPAIR PARTS TRACTOR MOWER - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 LIFT 7 5 3 6 11 13 19 2O 13 15 i_ 161718 20 32 \ 19 15 13_ 32 4O 20
REPAIR PARTS TRACTOR MOWER - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 LIFT KEY NO. PART NO.
REPAIR PARTS TRACTOR MOWER - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 DECK 68 28 26 \ 2 2 86 42
REPAIR PARTS TRACTOR MOWER KEY NO. - - MODEL NUMBER PC1538C, PRODUCT NUMBER 954 57 09-32 DECK PART NO.
SERVICE 44 NOTES
LIMITED WARRANTY The Manufacturer warrantsto the original consumer purchaser that this product as manufacturedis free from defects in materials 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 parts, any part which we find to be defective due to materials or workmanship. This Warranty is subject to the following limitations and exclusions. 1.
POLICY Issued January 1980 WARRANTY Revised January 1991 LIMITED NEW PEERLESS GEAR WARRANTIES FOR POWERTRAIN COMPONENTS A.
SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION ONLY RIDE UP AND DOWN HILL, NOT ACROSS HILL "M 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 caution when changing direction on slopes. 1. Fold this page along dotted line indicated above. 2.
Poulan
