Poulan 192666 User Manual

MODEL NO. PO15538D

15.5 HP 38 Inch
Lawn Tractor

For Parts and Service, contact our authorized distributor: call 1-800-849-1297

For Technical Assistance: call 1-800-829-5886

192666 4.26.04 MH

PRINTED IN U.S.A.

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROW ING OBJECTS. FAILURE

TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

I. GENERAL 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
in struc tions, to operate the machine.

• Clear the area of objects such as rocks, toys, wire, etc.,
which could be picked up and thrown by the blade.

• Be sure the area is clear of other people before mow­ ing. Stop machine if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while back­ ing.

• Be aware of the mower discharge direction and do not
point it at anyone. Do not operate the mower without
either the entire grass catcher or the guard in place.

• Slow down before turning.

• Never leave a running machine unattended. Always
turn off blades, set parking brake, stop engine, and
remove keys before dismounting.

• Turn off blades when not mowing.

• Stop engine before removing grass catcher or un­ clog ging chute.

• Mow only in daylight or good artifi cial light.

• Do not operate the machine while under the infl uence
of alcohol or drugs.

• Watch for traffi c when operating near or crossing road­ ways.

• Use extra care when loading or unloading the machine
into a trailer or truck.

• Data indicates that operators, age 60 years and above,
are involved in a large percentage of riding mower-re­lated injuries. These operators should evaluate their
ability to operate the riding mower safely enough to
protect them selves and others from serious injury.

• Keep machine free of grass , leaves or other debris
build-up which can touch hot exhaust / engine parts
and burn. Do not allow the mower deck to plow leaves
or other debris which can cause build-up to occur.
Clean any oil or fuel spillage before operating or
storing the machine. Allow machine to cool before
storage.

II. SLOPE OPERATION

Slopes are a major factor related to loss-of-control and
tipover accidents, which can result in severe injury or death.
All slopes require extra caution. If you cannot back up the
slope or if you feel uneasy on it, do not mow it.

DO:

• Mow up and down slopes, not across.

• Remove obstacles such as rocks, tree limbs, etc.

• Watch for holes, ruts, or bumps. Uneven terrain could
overturn the machine.

• Use slow speed. Choose a low gear so that you will
not have to stop or shift while on the slope.

• Follow the manufacturer’s recommendations for wheel
weights or counterweights to improve stability.

• Use extra care with grass catchers or other at tach ments.
These can change the stability of the machine.

• Keep all movement on the slopes
Do not make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires lose trac­tion, disengage the blades and proceed slowly
down the slope.

Tall grass can hide obstacles.

slow

and

gradual

straight

DO NOT:

•

Do not

turn slowly and gradually downhill, if possible.

•

Do not

The mower could suddenly turn over if a wheel is over
the edge of a cliff or ditch, or if an edge caves in.

•

Do not

cause sliding.

•

Do not

on the ground.

•

Do not

turn on slopes unless necessary, and then,

mow near drop-offs, ditches, or embankments.

mow on wet grass. Reduced traction could

try to stabilize the machine by putting your foot

use grass catcher on steep slopes.

III. CHILDREN

Tragic accidents can occur if the operator is not alert to
the presence of children. Children are often attracted to
the ma chine and the mowing activity.
children will remain where you last saw them.

• Keep children out of the mowing area and under the
watchful care of another responsible adult.

• Be alert and turn machine off if children enter the
area.

• Before and when backing, look behind and
small children.

• Never carry children. They may fall off and be seriously
injured or interfere with safe machine operation.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.

Never

IV. SERVICE

• Use extra care in handling gasoline and other fuels.
They are fl ammable and vapors are explosive.

- Use only an approved container.

- Never remove gas cap or add fuel with the engine

running. Allow engine to cool before refueling. Do
not smoke.

- Never refuel the machine indoors.

- Never store the machine or fuel container inside where

there is an open fl ame, such as a water heater.

• Never run a machine inside a closed area.

• Keep nuts and bolts, especially blade attachment bolts,
tight and keep equipment in good condition.

• Never tamper with safety devices. Check their proper
op er a tion regularly.

• Keep machine free of grass, leaves, or other debris
build-up. Clean oil or fuel spillage. Allow machine to
cool before storing.

• Stop and inspect the equipment if you strike an object.
Repair, if necessary, before restarting.

• Never make adjustments or repairs with the engine
run ning.

• Grass catcher components are subject to wear, dam­ age, and deterioration, which could expose moving
parts or allow objects to be thrown. Frequently check
com po nents and replace with manufacturer's rec om ­mend ed parts, when nec es sary.

• Mower blades are sharp and can cut. Wrap the blade(s)

.

or wear gloves, and use extra caution when servicing
them.

• Check brake operation frequently. Adjust and service
as required.

2

assume that

down

for

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

• 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. Al ways
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.

• Keep children out of the mowing area and under the watchful
care of another responsible adult.

• Be alert and turn machine off if children enter the area.

• Before and when backing, look behind and down for small
children.

• Mow up and down slopes (15° Max), not across.

• Remove obstacles such as rocks, tree limbs, etc.

• Watch for holes, ruts, or bumps. Uneven terrain could overtur n
the machine. Tall grass can hide obstacles.

• Use slow speed. Choose a low gear so that you will not have
to stop or shift while on the slope.

• Avoid starting or stopping on a slope. If tires lose traction,
disengage the blades and proceed slowly straight down the
slope.

• If machine stops while going uphill, disengage blades, shift
into reverse and back down slowly.

• Do not tur n on slopes unless necessary, and then, turn slowly
and gradually downhill, if possible.

WAR NI NG : In order to prevent ac-
ci den tal starting when setting up,
trans port ing, ad just ing or making
repairs, al ways dis con nect spark
plug wire and place wire where it
can not contact spark plug.

WARNING: Do not coast down a hill
in neutral, you may lose control of
the tractor.

WARNING: Tow only the attach­ments that are rec om mend ed by
and comply with spec i fi ca tions of
the man u fac tur er of your tractor.
Use common sense when towing.
Operate only at the low est possible
speed when on a slope. Too heavy
of a load, while on a slope, is dan­ ger ous. Tires can lose trac tion with
the ground and cause you to lose
control of your tractor.

WARNING

Engine exhaust, some of its con stit u ents, and cer­ tain vehicle com po nents contain or emit chem i cals
known to the State of Cal i for nia to cause can cer and
birth de fects or oth er re pro duc tive harm.

WARNING

Battery posts, terminals and related ac ces so ries
contain lead and lead compounds, chem i cals known
to the State of Cal i for nia to cause can cer and birth
defects or oth er re pro duc tive harm. Wash hands
after handling.

3

PRODUCT SPECIFICATIONS

Gasoline Capacity 1.25 Gallons
and type: Unleaded Regular

Oil Type (API-SG-SL): SAE 30 (above 32°F)
SAE 5W-30 (below 32°F)

Oil Capacity: 3.0 Pints

Spark Plug: Champion RC12YC
(Gap: .030")

Ground Speed (MPH): Forward:
1st 1.1
2nd 2.2
3rd 3.4
4th 4.3
5th 5.5
Reverse: 1.7

Tire Pressure: Front: 14 PSI
Rear: 12 PSI

Charging System: 3 Amps Battery
5 Amps Headlights

Battery: AMP/HR: 28
MIN. CCA: 230
Case Size: U1R

Blade Bolt Torque: 27-35 FT. LBS.

CONGRATULATIONS on your purchase of a new tractor.
It has been designed, engineered and manu fac tured to give
you the best possible dependability and performance.

Should you experience any problem you cannot easily rem­edy, please contact your nearest authorized service center/
department. We have com pe tent, well-trained tech ni cians
and the proper tools to ser vice or repair this tractor.

Please read and retain this manual. The instructions will
enable you to assemble and maintain your tractor prop erly.
Always observe the “SAFETY RULES”.

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Follow a regular schedule in maintaining, caring for
and using your tractor.

• Follow the instructions under “Maintenance” and
“Stor age” sec tions of this own er’s manual.

WAR NI NG : This tractor is equipped with an internal com­ bus tion engine and should not be used on or near any
un im proved forest-covered, brush-covered or grass-cov ered
land unless the engine’s exhaust system is equipped with
a spark arrester meeting applicable local or state laws (if
any). If a spark arrester is used, it should be maintained
in effective working order by the operator.

A spark arrester for the muffl er is available through your
nearest authorized service center/depar tment (See RE PA I R
PARTS section of this manual).

TABLE OF CONTENTS

SAFETY RULES ......................................................... 2-3

PRODUCT SPECIFICATIONS ....................................... 4

CUSTOMER RESPONSIBILITIES................................. 4

ASSEMBLY................................................................. 6-8

OPERATION ............................................................. 9-13

MAINTENANCE SCHEDULE ...................................... 14

MAINTENANCE ..................................................... 14-17

SERVICE AND AD JUST MENTS ............................ 18-22

STORAGE .................................................................... 23

TROU BLE SHOOT ING ............................................24-25

REPAIR PARTS ...................................................... 28-41

WARRANTY................................................................. 42

4

UNASSEMBLED PARTS

Steering Wheel

Insert

Steering Wheel

Seat

(1) Washer

17/32 x 1-3/16 x 12 Gauge

(1) Lock

Washer 1/2

Steering

Boot

Steering Wheel

Adapter

(1) Large Flat Washer

Steering

Extension

Shaft

(1) Bolt

(1) Oil Drain Tube
For Future Use

Keys

(2) Keys

Slope Sheet

(1) Locknut 1/2-20

(1) Hex Bolt 1/4-28 x 1-1/4

(1) Locknut 1/4-28

5

ASSEMBLY

02

599

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. Stan dard
wrench sizes are listed.

(2) 1/2" wrenches Pliers

(1) 9/16" wrench Tire pressure gauge

Utility knife

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).

TO REMOVE TRACTOR FROM
CARTON

UNPACK CARTON

• Remove all accessible loose parts and parts cartons
from carton.

• Cut along dotted lines on all four panels of carton.
Remove end panels and lay side panels fl at.

• Check for any additional loose parts or cartons and
remove.

BEFORE REMOVING TRACTOR FROM
SKID

STEERING
WHEEL

ADAPT ER

1/4 LOCK NUT

INSERT

1/2 HEX NUT

LARGE FLAT
WAS HER

STEERING
BOOT

TABS

EXTENSION SHAFT

1/4 HEX BOLT

ATTACH STEERING WHEEL (See Fig. 1)

ASSEMBLE EXTENSION SHAFT AND BOOT

• Slide extension shaft onto lower steering shaft. Align
mount ing holes in extension and lower shafts and install
1/4 hex bolt and lock nut. Tighten securely.

IMPORTANT: TIGHTEN BOLT AND NUT SECURELY TO 10-12
FT. LBS TORQUE.

• Place tabs of steering boot over tab slots in dash and
push down to secure.

INSTALL STEERING WHEEL

• Position front wheels of the tractor so they are pointing
straight forward.

• Remove steering wheel adapter from steering wheel
and slide adapter onto steer ing shaft ex ten sion.

• Position steering wheel so cross bars are hor i zon tal
(left to right) and slide inside boot and onto adapt er.

• Assemble large fl at washer, 1/2 hex nut and tighten
se cure ly.

• Snap steering wheel insert into center of steer ing
wheel.

• Remove protective materials from tractor hood and
grill.

IMPORTANT: CHECK FOR AND RE MOVE ANY STA PLES
IN SKID THAT MAY PUNC TURE TIRES WHERE TRACTOR
IS TO ROLL OFF SKID.

LOWER
STEERING
SHAFT

TAB
SLOTS

FIG. 1

HOW TO SET UP YOUR TRACTOR

INSTALL SEAT (See Fig. 2)

Adjust seat before tightening adjustment bolt.

• Remove adjustment bolt, lock washer and fl at washer
se cur ing seat to cardboard packing and set aside for
as sem bly 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.

• Push down on seat to engage shoulder bolt in slot and
pull seat towards rear of tractor.

• Pivot seat and pan forward and assemble adjust­ment bolt, lockwasher and fl at washer loosely. Do not
tighten

• Lower seat into operating position and sit on seat.

• Slide seat until a comfortable position is reached
which allows you to press clutch/brake pedal all the
way down.

• Get off seat without moving its adjusted position.

• Raise seat and tighten adjustment bolt securely.

6

ASSEMBLY

SEAT

SEAT PAN

SHOULDER
BOLT

FLAT WASHER

LOCK WASHER

02465

ADJUSTMENT
BOLT

FIG. 2

CHECK BATTERY (See Fig. 3)

• Lift seat pan to raised position.

• If this battery is put into service after month and year
indicated on label (label located between terminals)
charge battery for minimum of one hour at 6-10 amps.
(See “BATTERY” in the Maintenance sec tion of this
manual for charg ing instructions).

SEAT PAN

LABEL

NOTE: You may now roll or drive your tractor off the skid.

Follow the appropriate instruction below to remove the
tractor from the skid.

TO ROLL TRACTOR OFF SKID (See
Op er a tion section for location and function
of con trols)

• Press lift lever plunger and raise attachment lift lever
to its highest po si tion.

• Release parking brake by depressing clutch/brake
ped al.

• Place gearshift lever in neutral (N) po si tion.

• Roll tractor forward off skid.

• Remove banding holding defl ector shield up against
trac tor.

TO DRIVE TRACTOR OFF SKID (See Op­ er a tion section for location and func tion of
con trols)

WARNING: Before starting, read, un der stand and follow

all in struc tions in the Operation section of this manual. Be
sure tractor is in a well-ventilated area. Be sure the area in
front of tractor is clear of other people and objects.

• Be sure all the above assembly steps have been com­pleted.

• Check engine oil level and fi ll fuel tank with gasoline.

• Sit on seat in operating position, depress clutch/brake
pedal and set the parking brake.

• Place gear shift lever in neutral (N) position.

• Press lift lever plunger and raise attachment lift lever
to its highest position.

• Start the engine. After engine has star ted, move throttle
control to idle position.

• Depress clutch/brake pedal into full "BRAKE" position
and hold. Move gearshift lever to 1st gear.

• Slowly release clutch/brake pedal and slowly drive
tractor off skid.

• Apply brake to stop tractor, set parking brake and place
gearshift lever in neutral position.

• Turn ignition key to "OFF" position.

Continue with the instructions that follow.

02602

FIG. 3

7

ASSEMBLY

CHECK TIRE PRESSURE

The tires on your tractor were overinfl ated at the factory
for shipping purposes. Correct tire pressure is important
for best cutting performance.

• Reduce tire pressure to PSI shown in “PRODUCT
SPEC I FI CA TIONS” section of this manual.

CHECK DECK LEVELNESS

For best cutting results, mower housing should be properly
leveled. See “TO LEVEL MOWER HOUSING” in the Service
and Adjustments section of this manual.

CHECK FOR PROPER POSITION OF ALL
BELTS

See the fi gures that are shown for replacing motion and
mower blade drive belts in the Service and Adjustments
sec tion of this manual. Verify that the belts are routed
correctly.

CHECK BRAKE SYSTEM

After you learn how to operate your tractor, check to see that
the brake is properly adjusted. See “TO ADJUST BRAKE”
in the Service and Adjustments section of this manual.

✓

CHE CKLIST

BEFORE YOU OPERATE AND ENJOY YOUR NEW TRAC­ TOR, WE WISH TO ASSURE THAT YOU RE CEIVE THE
BEST PER FORM ANCE AND SATISFACTION FROM THIS
QUAL ITY PRODUCT.

PLEASE REVIEW THE FOLLOWING CHECKLIST:

✓ All assembly instructions have been completed.
✓ No remaining loose parts in carton.
✓ Battery is properly prepared and charged. (Minimum

1 hour at 6 amps).

✓ Seat is adjusted comfortably and tightened securely.
✓ All tires are properly infl ated. (For shipping purposes,

the tires were overinfl ated at the factory).

✓ Be sure mower deck is properly leveled side-to-side/

front-to-rear for best cutting results. (Tires must be
properly infl ated for leveling).

✓ Check mower and drive belts. Be sure they are routed

properly around pulleys and inside all belt keepers.

✓ Check wiring. See that all connections are still secure

and wires are properly clamped.

WHILE LEARNING HOW TO USE YOUR TRAC TOR, PAY
EXTRA ATTENTION TO THE FOLLOWING IM POR TA N T
ITEMS:

✓ Engine oil is at proper level.
✓ Fuel tank is fi lled with fresh, clean, regular unleaded

gas o line.

✓ Become familiar with all controls - their location and

function. Operate them before you start the engine.

✓ Be sure brake system is in safe operating condition.

8

OPERATION

These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning.

REVERSE

ENGINE OFF

OVER TEMP

LIGHT

ATTACHMENT

CLUTCH ENGAGED

(Automatic Models only)

LIGHTS ON

FREE WHEEL

NEUTRAL

FUEL

ATTACHMENT

CLUTCH DISENGAGED

HIGH

ENGINE ON

OIL PRESSURE

LOW

ENGINE START

BATTERY

DANGER, KEEP HANDS

AND FEET AWAY

CHOKE

PARKING BRAKE

REVERSE

DANGER indicates a hazard which, if not avoided,
will result in death or serious injury.

WARNING indicates a hazard which, if not avoided,
could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided,
might result in minor or moderate injury.

FAST

P

FORWARD

KEEP AREA CLEAR

SLOW

PARKING BRAKE

LOCKED

MOWER HEIGHT

15

SLOPE HAZARDS

(SEE SAFETY RULES SECTION)

IGNITION

PARKING BRAKE

UNLOCKED

MOWER LIFT

15

Failure to follow instructions
could result in serious injury or
death. The safety alert symbol
is used to identify safety inform­ation about hazards which can
result in death, serious injury
and/or property damage.

CAUTION when used without the alert symbol,
indicates a situation that could result in damage

to the tractor and/or engine.

HOT SURFACES indicates a hazard which,
if not avoided, could result in death, serious injury
and/or property damage.

FIRE indicates a hazard which, if not avoided,
could result in death, serious injury and/or
property damage.

9