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Poulan Pro PC1538D manual

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Table of contents for the manual

  • Page 1

    i OWNER'S MANUAL MODEL NO. PC1538D 15 HP 38 Inch Lawn Tractor Assembly • Operation • Maintenance • Service and Adjustments • Storage • Troubleshooting • Repair Parts For Parts and Service, contact our authorized distributor: call 1-800-849-1297 For Technical Assistance: call 1-800-829-5886 | Poulan 187581 3.5.03 MH PRINTED IN U.S.A[...]

  • Page 2

    SAFETY RULES _i SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS ,_ IMPORTANT: THIS CUTTING"I_ACHINE IS CAPABLE OF AMPUTATING HANDSAND FEET AND T!_=_/VlNG OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULTIN SERIOUS INJURY OR DEATH. I. GENERAL OPERATION Read, understand, and follow all instructions in the manual and on the m[...]

  • Page 3

    SAFETY RULES Asafe Operation Practices for Ride-On Mowers A 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 [...]

  • 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): TIRE PRESSURE: CHARGING SYSTEM: BA'FrERY: FORWARD: 1st 1.1 2nd 2.2 3rd 3,4 4t[...]

  • Page 5

    UNASSEMBLED PARTS Steering Wheel Steering Wheel Insert 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 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 wren[...]

  • Page 7

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

  • Page 8

    ASSEMBLY 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 in "PRODUCT SPECIFICATIONS" section of this manual. CHECK DECK LEVELNESS For best cutting results, mower housing should be pro[...]

  • 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 Ikl REVERSE NEUTRAL HIGH LOW CHOKE FAST SLOW IGNITION ENGINE OFF LIGHTS ON ENGINE ON ENGINE START PARKING BRAKE PARKING BRAKE PARKING BRAKE LOCKED UNLOCKED Ol , = I OVER TEMP FUEL OIL PRESSURE BA'I-I'E[...]

  • Page 10

    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 IGNmON UGHT SWITCH CLUTCH LEVER SWITCH POSITION THROTTL_CHOKE CONTROL_ [...]

  • Page 11

    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 op- erating your tractor or performing any adjustments or repairs. We recommend a wide vision safety mask over spectacles or standard safety glasses. HOW TO USE YOUR TRACTO[...]

  • 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 gasehol 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 M..NTEN.NCE SC.EOULE FILL IN DATES _ AS YOU COMPLETE REGULAR SERVICE _.,_ _'_'-_J"__-7_'_- _ -J_O'_-- ..... _" £'_"J_'r_£-_"_--4_/_=t_" S E R V IC E DATES Check Brake Operation _1_ Check Tire Pressure Check Operator Presence and T Interlock Systems Check for Loose Fasteners V_s V&[...]

  • 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 • Maintain proper air press[...]

  • 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 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 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 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 al[...]

  • Page 20

    SERVICE AND ADJUSTMENTS TO LEVEL MOWER HOUSING rear, tighten nuts "F" against trunnion on both front links. Adjust the mower while tractor is parked on level ground or driveway. Make sure tiros are properly inflated (See "PRODUCT SPECIFICATIONS" section of this manual). If tires are over or underinflated, you will not properly a[...]

  • Page 21

    SERVICE AND ADJUSTMENTS R...SUSPEHS,O. ARM MANDREL ENGINE PULLEY PULLEY SPRING IDLER 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 le[...]

  • Page 22

    SERVICE AND ADJUSTMENTS Position the gear shift lever in the neutral (N) posi- tion. Tighten adjustment bolt securely. NOTE: If additional clearance is needed to get to adjustment bolt, move mower deck height to the lowest position. _.._GEARSHIFTLEVER ADJUSTMENT BOLT NEUTRAL LOCK GATE FIG. 23 TO ADJUST STEERING WHEEL ALIGN- MENT If steering wheel c[...]

  • Page 23

    SERVICE AND ADJUSTMENTS Lift seat pan to raised position. Disconnect BLACK batterycable firstthen 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 termin[...]

  • 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. AIIowthe engine to cool before storing in any enclosure. TRACTOR Remove mower from trac[...]

  • 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"CHOKED" 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. Car[...]

  • Page 26

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

  • Page 27

    SCHEMATIC TRACTOR - - MODEL NUMBER PC1538D RED BATFERY BLACK /7 ) I RED _ -_ )G AI( IGNITION SWITCH .Eo FUSE ° I I I WHI33E i O , (_11 -- i I L ....... J CLUTCH / BRAKE (PEDAL UP) BLACK BLACK _f' METER SOLENOID STARTER BLACK WHITE SEAT SWITCH , ....... i (NQT OCCUPIED) ) _ ATrMENTCLUTCH _ -- __ BLACK (CLUTCH OFF) j GROUNDING CONNECTOR IGNITIO[...]

  • Page 28

    REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538D ELECTRICAL 41 27 [ 25 22 26 ¢. / I I I I I I I I I I I I I I It I I I I I ,16 I I 16_ i / t I I t t 29 I 28 I / / ,% ¢ / /I / / / / 28[...]

  • Page 29

    REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538D 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 PC1538D CHASSIS 208 30 207 26 33 IO 25 5 53 51 52 29 12 28 208 206 35 34 26 chassis-pl.lt_stlt_50 30[...]

  • Page 31

    REPAIR PARTS TRACTOR -- MODEL NUMBER PC1538D CHASSIS KEY PART NO. NO. DESCRIPTION 1 174619 2 176554 3 17060612 5 155272 9 168336X010 10 72140608 11 174996 12 145660 13 172105X010 14 17490608 17 159639x428 18 184921 24 74780616 25 19131312 26 73800600 28 179101 29 140273X599 30 169468X428 31 136619 33 179716X428 34 179717X428 35 72110606 37 17490508[...]

  • Page 32

    REPAIR PARTS TRACTOR -- MODEL NUMBER PC1538D DRIVE 77 37 116 150 48 26 27 drive-fender.stlt_22 32[...]

  • Page 33

    REPAIR PARTS TRACTOR -- MODEL NUMBER PC1538D DRIVE KEY PART KEY PART NO. NO, DESCRIPTION NO. NO. 2 146682 3 123666X 4 12000028 5 121520X 6 17060512 8 165619 10 76020416 11 105701X 13 74550412 14 1OO404O0 15 74490544 16 73680500 18 74780616 19 73800600 21 106933X 22 130804 24 73350600 25 106888X 26 19131316 27 76020412 28 175765 29 71673 30 174973 3[...]

  • Page 34

    REPAIR PARTS TRACTOR -- MODEL NUMBER PC1538D STEERING _39 ¢ / I 36 17 68 67 67 67 34[...]

  • Page 35

    REPAIR PARTS TRACTOR -- MODEL NUMBER PC1538D 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 - - MODEL NUMBER PC1538D ENGINE 2 3 81 13 4 KEY NO. 1 2 3 4 13 14 16 23 29 31 32 31 40 78 '33 33 29 OPTIONAL EQUIPMENT Spark Arrester PART NO. 170551 17720408 137352 165291 148456 11050600 169837 137180 184900 140527 23 DESCRIPTION Control Th/ch Flag Screw Hex Thd Cut 1/4-20 x 1/2 Engine, B&S 282H07 (Order parts from[...]

  • Page 37

    REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538D SEAT KEY NO. 1 2 3 4 5 6 7 8 9 10 12 13 PART NO. 127426X 140551 71110616 19131610 145006 73800600 124181X 17000616 19131614 182493 121246X 121248X KEY PART DESCRIPTION NO. NO. DESCRIPTION Seat Bracket Seat Pivot Bolt Hex 3/8 - 16 X 1 Washer 13/32 X 1 X10Ga. Clip Push-In Hinged Nut Lock Hex w/Ins 3/8 - 1[...]

  • Page 38

    REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538D DECALS 9 7 12 1 14 6 8 15 3 17 KEY PART KEY PART NO. NO. DESCRIPTION NO. NO. 1 187580 Decal, NPR Replace 3 184768 Decal, Engine HP 4 170563 Decal, Warning 6 157140 Decal, Fender Danger English 7 158168 Decal, Ins StrWh 8 172200 Decal, Fender 5 Sp. 9 158166 Decal, Fender 12 181552 Decal, Hood RH 14 181[...]

  • Page 39

    REPAIR PARTS TRACTOR -- MODEL NUMBER PC1538D 13 11 , 12 I 19 I MOWER LIFT 5 2 13 13 13_ 32 2O 2O 15 KEY PART NO. NO. DESCRIPTION 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 Wire Asm Inner/Sprg w/plu[...]

  • Page 40

    REPAIR PARTS TRACTOR - - MODEL NUMBER PC1538D MOWER DECK 68 3 S 'J" J 6 4 - 9 16 J 13_ 4O 2 29 27 S _..,.._,- 10[...]

  • Page 41

    REPAIR PARTS TRACTOR -- MODEL NUMBER PC1538D MOWER DECK KEY PART NO. NO. 1 170280 2 72140506 3 138017 4 169970 5 4939M 6 178024 8 850857 9 10030600 10 140296 11 134148 13 139774 138497 137645 14 128774 15 110485X 16 174493 19 132827 21 73680500 23 137607 24 105304X 25 123713X 26 110452X 27 106736X428 28 19111016 29 106735X 30 173984 31 129963 32 15[...]

  • 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 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 cauti[...]

  • Page 44

    Poulan[...]