Instruction/ maintenance manual of the product POULANPRO 460ZX / 966550201 Poulan Pro
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Operator Manual 460ZX / 966550201 540ZX / 966550301 Please read the operator’ s manual car efully and mak e sur e you understand the instructions befor e using the machine.
©2010 HTC. All rights reserved. Beatrice, NE. Printed in U.S.A. T o implement improvements, specications and designs can be altered without prior notication. Note that no legal demands can be placed based on the information contained in these instructions.
INTRODUCTION ........................................................5 Driving and T ransport on Public Roads ................ 5 T owing ...................................................................5 Operating ...................................
W ARNING! 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 .
INTRODUCTION 5 Congratulations Thank you for purchasing a PoulanPRO ride-on mower . This machine is built for superior efciency to rapidly mow primarily large areas. A contr ol panel easily accessible to the operator and a hydrostatic transmission regulated by steering contr ols both contribute to the machine’s perfor mance.
INTRODUCTION 6 Good Service PoulanPRO's products ar e sold only in specialized retail stor es with complete service. This ensures that you as a customer receive only the best support and service.
R N SymBOLS AND DECALS 7 These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. 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.
Read Shut off engine and Keep a safe Use on slopes No passengers Operator’s remove key befor e distance from no greater Manual perfor ming any the machine than 10° maintenance or repair work Whole .
SAFETy 9 Safety Instructions These instructions are for your safety . Read them carefully . IMPORT ANT : THIS CUTTING MACHINE IS CAP ABLE OF AMPUT A TING HANDS AND FEET AND THROWING OBJECTS. F AILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESUL T IN SERIOUS INJUR Y OR DEA TH.
SAFETy 10 8011-520 Ne ver tak e passengers W atch for trafc when operating near or crossing • roadways. Use extra care when loading or unloading the • machine into a trailer or truck.
SAFETy 11 Personal Safety Equipment 8011-670a P ersonal protective equipment 6003-004 Mow up and do wn, not side to side Make sure that you have rst aid equipment close • at hand when using the machine. Never use the machine when barefoot. • Always wear protective shoes or boots, pr eferably • with steel toe caps.
SAFETy 12 8011-517 Ne ver allo w children to operate the machine 8011-518 K eep children awa y from work area Children T ragic accidents can occur if the operator is not alert to the presence of children. Childr en are often attracted to the machine and the mowing activity .
SAFETy 13 Safe Handling of Gasoline T o avoid personal injur y or pr operty damage, use extreme car e in handling gasoline. Gasoline is extremely ammable and the vapors ar e explosive. Extinguish all cigarettes, cigars, pipes, and other • sources of ignition.
SAFETy 14 8011-515 Ne ver driv e the machine in an enclosed space General Maintenance 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.
SAFETy 15 Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, re or eye injury . Sparking in this circuit can not occur after the chassis cable (normally negative, black) is removed from the battery .
SAFETy 16 IMPORT ANT INFORMA TION The parking brake is not sufcient to lock the machine in place during transport. Ensure that the machine is well fastened to the transport vehicle. Always reverse the machine onto the transport vehicle to avoid tipping it over .
CONTROLS 17 This operator’s manual describes the PoulanPRO Zero T urn Rider . The rider is tted with a Briggs & Stratton, four -stroke overhead valve engine. Motion Control Levers 1. Seat Adjustment Lever 2. Lift Lever 3. Hour Meter 4. Throttle 5.
W ARNING! The machine can turn very rapidly if one steering control is moved much further forward than the other . CONTROLS 18 Motion Control Levers The machine’s speed and direction ar e continuously variable using the two steering controls. The steering controls can be moved forwar d or backward about a neutral position.
CONTROLS 19 Seat Adjustment Lever The seat can be adjusted lengthways. Release levers are located at the lower fr ont 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 r elease lever .
CONTROLS 20 Fuel T ank The machine has one fuel tank, just behind the seat. The tank capacity is 4 gallons (15.1 liters). The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used.
CONTROLS 21 Ignition Switch The ignition key is placed on the driver’s panel and is used to start and stop the engine. IMPORT ANT INFORMA TION Do not run the starter for more than ve seconds each time. If the engine does not start, wait about 10 seconds before retrying.
CONTROLS 22 mower perfor mance and battery charging. Blade Switch In order to engage the mower deck, pull the knob out; the mower blades are disengaged when the knob is 8058-019 Cut height lift le ver.
CONTROLS 23 Fuses Fuses are located on the left hand side of the machine. They are accessed by tilting the seat forward. They ar e at pin fuses of the same type used in automobiles. There ar e two fuses with ratings and functions: 20 Amp Primary fuse 7.
OpERA TION 24 Read the Safety section and following pages, if you are unfamiliar with the machine. T raining Zero turn mowers are far mor e maneuverable than typical riding mowers due to their unique steering capabilities. We suggest that this section be r eviewed in its entirety prior to attempting to move the mower under its own power .
OpERA TION 25 8058-113 Blade s witch 8058-019 Cut height lift le ver 8058-080-1 Released parking brake Before Starting Read the sections Safety Instructions and • Controls befor e star ting the machine. Perfor m the daily maintenance before • starting (see Maintenance Schedule in the Maintenance section).
OpERA TION 26 8058-113 Set the throttle 8058-077 Place controls in neutral position 8058-113 Set the choke control Move the steering controls outwar d to the locked (outer) neutral position. Move the throttle to the middle position. If the engine is cold, pull the choke control knob up.
OpERA TION 27 W ARNING! Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer , birth defects or other reproductive system damage. The engine exhaust contains carbon monoxide, which is a odorless, colorless, poisonous gas.
OpERA TION 28 W ARNING! Lead-acid batteries generate explosive gases. Keep sparks, ame and smoking materials away from batteries. Always wear eye protection when around batteries. Weak Battery If your battery is too weak to star t the engine, it should be recharged.
OpERA TION 29 Running Release the parking brake by moving the lever 1. downward. Y our mower is equipped with an operator presence system. When the engine is running, any attempt by the operator to leave the seat without rst setting the parking brake will shut off the engine.
OpERA TION 30 Move throttle contr ol to full throttle (not choke). 7. The machine’s speed and direction ar e continuously variable using the two steering controls.
OpERA TION 31 Mowing Tips Observe and ag rocks and other xed • objects to avoid collisions. Begin with a high cutting height and reduce it • until the desired mowing r esult 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.
OpERA TION 32 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. A void idling the engine for longer periods, as there is a risk of the spark plugs fouling.
OpERA TION 33 8058-032 Bypass linkage, EZT engaged 8058-033 Bypass linkage, EZT loc ked in the b ypass position Manual T ransport When pushing or pulling the mower , engage the EZT (Integrated Zeroturn T ransaxle) bypass linkages. The EZT bypass linkages are located on the r ear of the frame, below the rear engine guar d.
mAINTENANCE 34 1) First change after 8-10 hours. When operating with a heavy load or at high ambient temperatures, r eplace every 50 hours. 2) In dusty conditions, cleaning and replacement ar e requir ed more often. 3) Performed by authorized service workshop.
mAINTENANCE 35 1) First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, r eplace every 50 hours. 2) In dusty conditions, cleaning and replacement ar e requir ed more often. 3) Performed by authorized service workshop.
mAINTENANCE 36 Battery Y our 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 ter minals clean. • Keep battery bolts tight.
Tire Pressures All four tires should have a pr essure of 15 psi / 103 kPa /1 bar . mAINTENANCE 37 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.
mAINTENANCE 38 W ARNING! The machine must be standing absolutely still when the park brake is engaged. Visually check that no damage is found on the lever , linages, or switch belonging to the parking brake. Perfor m a stand still test and check that there is a braking action.
2 1 mAINTENANCE 39 Pump Belt Replacing EZT (E-Series Zeroturn T ransaxle) belt Park the mower on a level surface. Engage the parking brake. EZT Belt Removal NOTE: T o maintain efcient cooling and not damage the EZT s, be careful of the fan blades when servicing the belt.
2 1 3 mAINTENANCE 40 IMPORT ANT INFORMA TION Special blade bolt is heat treated. Replace with a PoulanPRO bolt if required. Do not use lower grade hardware than specied.
mAINTENANCE 41 Adjusting the Mower Deck Deck Leveling Adjust the deck while the mower is on a level surface. Make sure the tires ar e inated to the correct pressur e. See T ransmission under T echnical Data . If tires ar e under or over inated, the deck cannot be properly adjusted.
1 2 3 4 mAINTENANCE 42 IMPORT ANT INFORMA TION DO NOT add any type of tire liner or foam ll material to the tires. Excessive loads created by foam lled tires will cause premature failures. Only use O.E.M. specied tires. 8058-083 1. Caster yoke 2.
LUBRICA TION 43 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 lled with engine oil. When lubricating with gr ease, unless otherwise stated, use a high grade molybdenum disulphide grease.
LUBRICA TION 44 8050-009 Lubricating the front wheels IMPORT ANT INFORMA TION Use minimal lubrication and remove excess lubricant so that is does not come into contact with belts or belt pulley drive surfaces. Wheel and Deck Zerks Use only good quality bearing grease.
TROUBLE SHOOTING 45 Problem Cause Engine will not start Blade switch is engaged. • Steering controls ar e not locked in the neutral position • Parking brake is not activated • Battery is dead • Contamination in the carburetor or fuel line.
TROUBLE SHOOTING 46 Problem Cause Engine overheats Clogged air intake or cooling ns • Engine overloaded • Poor ventilation around engine • Defective engine speed regulator • T oo little or no oil in the engine • Contamination in the carburetor or fuel line.
ST ORAGE 47 Winter Storage At the end of the mowing season, the machine should be readied for storage (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 carbur etor and disrupt engine function.
SCHEmA TIC 48.
TECHNICAL DA T A 49 T orque Specications Hex Head Cap Screws The torque values shown should be used as a general guideline when specic tor que values are not given. U.S. Standard Hardware Grade SAE Grade 5 SAE Grade 8 Flangelock Screw w/Flangelock Nut ft.
TECHNICAL DA T A 50 *The power rating of the engines indicated is the average net power output (at specied rpm) of a typical production engine for the engine model measured to SAE standar d J1349/ISO1585. Mass production engines may dif fer from this value.
TECHNICAL DA T A 51 460ZX / 966550201 540ZX / 966550301 Equipment Cutting width 46" 54" Cutting height 1.5" - 4" / 2.5 cm - 10.6 cm 1.5" - 4" / 2.5 cm - 10.6 cm Uncut circle 0 0 Number of blades 2 3 Blade length 22¾ / 58 cm 18¼ / 46.
CONFORmITy CERTIFICA TES 52 USA requirements Labels are placed on the engine and/or in the engine compartment stating that the machine will fulll the requir ements. This is also applicable to special requir ements for any of the states, (Califor nia emission rules etc.
SER VICE JOURNAL 53 Action Date, mtr reading, stamp, sign Delivery Service 1. Charge the battery . 2. Adjust the tire pr essure of all wheels to 15 PSI (1 bar). 3. Mount the steering controls in the normal position. 4. Connect the contact box to the cable for the seat’s safety switch.
SER VICE JOURNAL 54 Action Date, mtr reading, stamp, sign After 10 hours 1. Change the engine oil. 2. Change the oil lter . 3. Check hydraulic oil level. 4. Inspect hydraulic hoses. 5. Inspect hydraulic belt. 6. Inspect hydraulic lter . 7. Check neutral position.
SER VICE JOURNAL 55 Action Date, mtr reading, stamp, sign 100-Hour Service 1. Grease ttings (caster pivots and caster wheels) 2. Inspect dampeners 3. Inspect frame 4. Inspect throttle and choke cables 5. Inspect hardwar e 6. Check the tire pr essures 7.
SER VICE JOURNAL 56 Action Date, mtr reading, stamp, sign 300-Hour Service 1. Grease ttings (caster pivots and caster wheels) 2. Inspect dampeners 3. Inspect frame 4. Inspect throttle and choke cables 5. Inspect hardwar e 6. Check the tire pr essures 7.
SER VICE JOURNAL 57 Action Date, mtr reading, stamp, sign At least once each year 1. Clean the engine’s cooling air intake. 2. Replace the air cleaner’s pre-lter (foam). 3. Replace the air lter’s paper cartridge. 4. Change the engine oil. 5.
SER VICE JOURNAL 58 Action Date, mtr reading, stamp, sign.
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P/N 115 348227R1 02/16/10.
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