Poulan 96042000700 Owner’s Manual

IMPORTANT MANUAL Do Not Throw Away

OPERATOR'S MANUAL

MODEL:

Read this Manual and follow all Warnings and

Safety Instructions. Failure todo so can result
in serious injury.

PBGT26H54

LAWN TRACTOR

ALWAYS WEAR EYE PROTECTION DURING OPERATION
Visit our website: www.poulan-pro.com

WARNING:

402464 Rev. 2 03.t6.06 TR/VB

Printedin U.S.A.

Safe Operation Practices for Ride-On Mowers

SAFETY RULES &

DANGER: THIS CUTTINGMACHINEISCAPABLEOFAMPUTATINGHANDSAND FEETAND THROWINGOBJECTS. FAILURE

TO OBSERVETHEFOLLOWINGSAFETYINSTRUCTIONSCOULDRESULTIN SERIOUSINJURYOR DEATH.

WARNING: In order to prevent ac-

cidental starting when setting up,

transporting, adjusting or making re-

pairs, always disconnect spark plug

wire and place wire where it cannot

contact spark plug.

limb WARNING: Do not coast down a hill |

&

in neutral, you may lose control of the
tractor.

WARNING: Tow only the attachments
that are recommended by and com-

ply with specifications of the manu-
facturer of your tractor. Use common

sense when towing. Operate only at
the lowest possible speed when on a
slope. Too heavy of a load, while on

a slope, is dangerous. Tires can lose

traction with the ground and causeyou

to lose control of your tractor.

WARNING

Engine exhaust, some of its constituents, and cer-
tain vehicle components contain or emit chemicals

known tothe State of California to cause cancer and
birth defects or other reproductive harm.

WARNING

Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known

to the State of California to cause cancer and birth
defects or other reproductive harm. Wash hands

after handling.

I. GENERAL OPERATION

Read, understand, and follow all instructions on the
machine and in the manual before starting.

Do not put hands or feet near rotating parts or under
the machine. Keep clear of the discharge opening at

all times.
Only allow responsible adults, who are familiar with the

instructions, to operate the machine.
Clear the area of objects such as rocks, toys, wire, etc.,
which could be picked up and thrown by the blades.
Be sure the area is clear of bystanders before operat-

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.
Never direct discharged material toward anyone. Avoid

discharging material against a wall or obstruction. Ma-
terial may ricochet back toward the operator. Stop the

blades when crossing gravel surfaces.

I

I

2

Donotoperate machine without the entire grasscatcher,

discharge guard, or other safety devices in place and
working.

Slow down before turning.

Never leave a running machine unattended. Always

turn off blades, set parking brake, stop engine, and
remove keys before dismounting.

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 road-
ways.

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

Always wear eye protection when operating ma-
chine.

Data indicates that operators, age 60 years and above,
are involved in a large percentage of riding mower-re-
lated injuries. These operators should evaluate their

ability to operate the riding mower safely enough to
protect themselves and others from serious injury.

Follow the manufacturer's recommendation for wheel
weights or counterweights.

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
tip-over accidents, which can result in severe injury or

death. Operation on all slopes requires extra caution. If
you cannot back up the slope or if you feel uneasy on it,

do not mow it.

Mow up and down slopes, not across.
Watch for holes, ruts, bumps, rocks, or other hidden
objects. Uneven terrain could overturn the machine.

Tall grass can hide obstacles.
Choose a low ground speed so that you will not have
to stop or shift while on the slope.

Do not mow on wet grass. Tires may lose traction.
Always keep the machine in gear when going down

slopes. Do not shift to neutral and coast downhill.
Avoid starting, stopping, or turning on a slope. If the

tires lose traction, disengage the blades and proceed
slowly straight down the slope.

Keep all movement on the slopes slow and gradual.

Do not make sudden changes in speed or direction,
which could cause the machine to roll over.

Use extra care while operating machine with grass
catchers or other attachments; they can affect the

stability of the machine. Do no use on steep slopes.

Do not try to stabilize the machine by putting your foot
on the ground.

Do not mow near drop-offs, ditches, or embankments.
The machine could suddenly roll over ifa wheel is over
the edge or if the edge caves in.

Safe Operation Practices for Ride-On Mowers

SAFETY RULES

II1. CHILDREN

Tragic accidents can occur if the operator is not alert to
the presence of children. Children are often attracted to

the machine and the mowing activity. Never assume that
children will remain where you last saw them.

Keep childrenoutof the mowing area and inthe watchful

care of a responsible adult other than the operator.

Be alert and turn machine off if a child enters the

area.

Before and while backing, look behind and down for

small children.

Never carry children, even with the blades shut off. They
may fall off and be seriously injured or interfere with

safe machine operation. Children who have been given

rides in the past may suddenly appear in the mowing

area for another ride and be run over or backed over

by the machine.
Never allow children to operate the machine.
Use extracare when approaching blindcorners, shrubs,

trees, or other objects that may block your view of a
child.

IV. TOWING

Tow only with a machine that has a hitch designed for
towing. Do not attach towed equipment except at the

hitch point.
Follow the manufacturer's recommendation for weight
limits for towed equipment and towing on slopes.

Never allow children or others in or on towed equip-
ment.

On slopes, the weight of the towed equipment may

cause loss of traction and loss of control.
Travel slowly and allow extra distance to stop.

V. SERVICE

SAFE HANDLING OF GASOLINE

Toavoid personal injury or property damage, use extreme
care in handling gasoline. Gasoline isextremely flammable

and the vapors are explosive.

Extinguish all cigarettes, cigars, pipes, and other

sources of ignition.

Use only approved gasoline container.
Never remove gas cap or add fuel with the engine run-

ning. Allow engine to cool before refueling.
Never fuel the machine indoors.

Never store the machine or fuel container where there
isan open flame, spark, or pilot light such as on awater

heater or other appliances.
Never fill containers inside a vehicle or on a truck or

trailer bed with plastic liner. Always place containers
on the ground away from your vehicle when filling.

Remove gas-powered equipmentfrom the truck ortrailer

and refuel it on the ground. If this is not possible, then

refuel such equipment with a portable container, rather

than from a gasoline dispenser nozzle.

Keep the nozzle in contact with the rim of the fuel tank

or container opening at alltimes untilfueling iscomplete.

Do not use a nozzle lock-open device.
If fuel is spilled on clothing, change clothing immedi-

ately.

Never overfill fuel tank. Replace gas cap and tighten

securely.

GENERAL SERVICE

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
build-up. Clean oil or fuel spillage and remove any fuel-

soaked debris. Allow machine to cool before storing.
If you strike a foreign object, stop and inspect the

machine. Repair, if necessary, before restarting.
Never make any adjustments or repairs with the engine

running.
Check grass catcher components and the discharge

guard frequently and replace with manufacturer's rec-
ommended parts, when necessary.
Mower blades are sharp. Wrap the blade or wear

gloves, and use extra caution when servicing them.
Check brake operation frequently. Adjust and service
as required.
Maintain or replace safety and instruction labels, as
necessary.

®@@@@

Be sure the area is clear of bystanders before operat-
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.
Never carry children, even with the blades shut off. They

may fall off and be seriously injured or interfere with
safe machine operation. Children who have been given

rides in the past may suddenly appear in the mowing
area for another ride and be run over or backed over

by the machine.
Keep childrenout ofthe mowing area and inthe watchful

care of a responsible adult other than the operator.
Be alert and turn machine off if a child enters the

area.
Before and while backing, look behind and down for

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

Choose a low ground speed so that you will not have
to stop or shift while on the slope.

Avoid starting, stopping, or turning on a slope. If the

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 turn on slopes unless necessary, and then, turn
slowly and gradually downhill, if possible.

PRODUCT SPECIFICATIONS

Gasoline Capacity 4 Gallons
and type: Unleaded Regular

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

SAE 5W-30 (below 32°F)

Oil Capacity: W/Filter: 4.0 Pints

W/O Filter: 3.75 Pints

Spark Plug: Champion QC12YC
(Gap: .040")

Ground Speed (MPH): Forward: 0 - 5.8

Reverse: 0 - 2.1

Charging System: 16 AMPS @ 3600 RPM
Battery: AMP/HR: 35

MIN. CCA: 280
Case Size: U1R

Blade Bolt Torque: 45-55FT. LBS.

CONGRATULATIONS on your purchase of a new tractor.
Ithas been designed, engineered andmanufactured to give

you the best possible dependability and performance.

Should you experience any problem you cannot easily rem-
edy, please contact your nearest authorized servicecenter/
department We have competent, well-trained technicians

and the proper tools to service or repair this tractor.

Please read and retain this manual. The instructions will
enable you to assemble and maintain your tractor properly.

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" sections of this owner's manual.

WARNING: This tractor is equipped with an internal com-

bustion engine and should not be used on or near any
unimproved forest-covered, brush-covered orgrass-covered

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.

In the state of California the above is required by law
(Section 4442 of the California Public Resources Code).
Other states may have similar laws. Federal laws apply on

federal lands.
A spark arrester for the muffler is available through your

nearest authorized service center/department (See REPAIR
PARTS section of this manual).

TABLE OF CONTENTS

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

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

CUSTOM ER RESPONSIBILITIES ................................. 4

ASSEMBLY ................................................................. 6-9

OPERATION ........................................................... 10-16

MAINTENANCE SCHEDULE ...................................... 17

MAINTENANCE ..................................................... 17-20

SERVICE AND ADJUSTMENTS ............................ 21-25

STORAGE .................................................................... 26

TROUBLESHOOTING ............................................ 27-28

WARRANTY ................................................................. 30

4

UNASSEMBLED PARTS

(5) Large Retainer

Springs- 7/16

(2) Smaller Retainer

Springs - 5/16

ar

Mower

(1) 3/40.D. Washers

©

(5) 1-3/16 O.D. Washers

Mower Front Wheel

(t) Wheel

(1) 1-1/40.D. Washer

(t) Locknut

(1) Shoulder Bolt 3/8-16

Slope Sheet

(1) Oil Drain Tube
For Future Use

Keys

(2) Rear Lift Link

Assemblies

(2) Keys

ASSEMBLY

Your new tractor has been assembled at the factory with exception of those parts left unassembled for shipping pur-

poses.

TOOLS REQUIRED FOR ASSEMBLY

A socket wrench set will make assembly easier. Standard
wrench sizes are listed.

(t) 3/4" wrench (t) Utility knife

(t) 9/16" wrench (t) Pliers

(1) Tire Pressure Gauge
When right or left hand is mentioned in this manual, it

means from your point of view, when you are in the operat-

ing position (seated behind the steering wheel).

TO REMOVE TRACTOR FROM

CARTON

UNPACK CARTON

Remove all accessible loose parts and parts cartons
from carton.

Cut along dashed lines on all four panels of carton.
Remove end panels and lay side panels flat.

Remove mower and packing materials.
Check for any additional loose parts or cartons and

remove.

CHECK BATTERY (See Fig. 1)

Lift hood to raised position.

NOTE: Ifthis battery isput into service after month and year

indicated on label (L) (label is located between terminals)
charge battery for minimum of one hour at 6-10 amps.

(See "BATTERY" in Maintenance section of this manual
for charging instructions).

NOTE: You may now roll or drive your tractor off the skid.
Follow the appropriate instruction below to remove the

tractor from the skid.

_WARNING: Before starting, read, understand and follow

all instructions in the Operation section of this manual. Be
sure tractor is in awell-ventilated area. Besure the area in

front of tractor is clear of other people and objects.

TO ROLL TRACTOR OFF SKID (See Op-

eration section for location and function of
controls)

Raise attachment lift lever to its highest position.
Release parking brake by depressing brake pedal.

Place freewheel control in disengaged position to dis-
engage transmission (See "TO TRANSPORT" in the
Operation section of this manual).

Roll tractor forward off skid.

FIG. 2

FIG. 1

ADJUST SEAT (See Fig. 2)

Sit in seat.
Lift up adjustment lever (A) and slide seat until a com-

fortable position is reached which allows you to press
clutch/brake pedal all the way down.

Release lever to lock seat in position.

TO DRIVE TRACTOR OFF SKID (See Op-
eration section for location and function of

controls)

Be sure all the above assembly steps have been com-
pleted.

Check engine oil level and fill fuel tank with gasoline.

Place freewheel control in "transmission engaged"
position (see "TO TRANSPORT" in Operation section

of this manual).
Sit on seat in operating position, depress brake pedal

and set the parking brake.

Raise attachment lift lever to its highest position.

Remove key from bag and start the engine (see "TO
START" in the Operation section of this manual). After
engine has started, move throttle control to idle (slow)
position.

Release parking brake.
Slowly depress forward drive pedal and drive tractor

off skid.
Apply brake to stop tractor and set parking brake.
Turn ignition key to "STOP" position.

Continue with the instructions that follow.

6

ASSEMBLY

ASSEMBLE FRONT WHEEL TO
MOWER (See Fig. 3)

Using shoulder bolt, washer and Iocknut from parts
bag, assemble front wheel to mower asshown. Tighten

securely.

FIG. 5

FIG. 3

INSTALL MOWER AND DRIVE BELT

(See Figs. 4-12)

See MOWER AND DRIVE BELT ASSEMBLY Supplement
Sheet for additional guidance on this assembly.

Be sure tractor is on level surface and engage parking
brake.

Lower attachment lift lever to it's lowest position.

Turn steering wheel to the left as far as it will go and

position mower on right side of tractor with deflector

shield to the right.

NOTE: Be sure mower side suspension arms (A) are point-
ing forward before sliding mower under tractor.

Slide mower under tractor until it is centered under
tractor.

FIRST INSTALL ANTI-SWAY BAR (S).

- From right side of mower, insert anti-sway bar into
hole in transmission bracket (T).

FIG. 6

- Pivot bar towards you and insert other end of bar
into hole in rear mower bracket (D). Move mower as

needed to insert bar.

- Secure with washer and retainer spring as shown
using small 5/16 retainer spring.

FIG. 4

Remove plastic tie securing belt, bring belt forward

and check belt for proper routing in all mower pulley
grooves.

FIG. 7

ASSEMBLY

ATTACH MOWER SIDE SUSPENSION ARMS (A)TO
CHASSIS - Position hole inarm over pin (B) on outside

of tractor chassis and secure with washer and retainer
spring.
Repeat on opposite side of tractor.

FIG. 8

ATTACH REAR LIFT LINKS (C) - Insert rod end of lift

link assembly into hole in tractor lift shaft suspension
arm (L) and pivot link down to mower. Lift rear corner

of mower and position slot in link assembly over pin on
rear mower bracket (D) and secure with washer and
retainer spring.

Repeat on opposite side of tractor.

Turn steering wheel to position wheels straight for-
ward.

ATTACH FRONT LINK (E) - Work from left side of
tractor. Insert rod end of link assembly through front
hole in tractor front suspension bracket (F) and secure
with7/16 retainer spring (G) through hole in link located

behind the bracket.

Insert other end of link (E) into hole in front mower
bracket (H) and secure with washer and 5/16 retainer
spring (J).

FIG. 10

Disengage belt tension rod (K) from locking bracket
(L).

Install belt onto engine clutch pulley (M).

IMPORTANT" Check belt for proper routing in all mower
pulley grooves.

FIG. 9

02937

FIG. 11

8

ASSEMBLY

FIG. 12

Engage belt tension rod (K) on locking bracket (L).

CAUTION: Belt tension rod is spring
loaded. Have a tight grip on rod and en-

gage slowly.

Raise attachment lift lever to highest position.
If necessary, adjust gauge wheels before operating

mower as shown in the Operation section of this
manual.

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 on tires.

CHECK DECK LEVELNESS

For best cutting results, mower housing should be properly
leveled. See"TO LEVEL MOWER HOUSIN G"in the Service

and Adjustments section of this manual.

CHECK FOR PROPER POSITION OF ALL

BELTS

See the figures that are shown for replacing motion and
mower blade drive belts in the Service and Adjustments
section of this manual. Verify that the belts are routed
correctly.

,/CHECKLIST

BEFORE YOU OPERATE YOUR NEW TRACTOR, WE

WISH TOASSURE THATYOU RECEIVE THE BEST PER-

FORMANCE AND SATISFAC TION FROM THIS QUALITY
PRODUCT.

PLEASE REVIEW THE FOLLOWING CHECKLIST.

,/ All assembly instructions have been completed.
,/ No remaining loose parts in carton.

,/ Battery is properly prepared and charged.
,/ Seat is adjusted comfortably and tightened securely.
,/ All tires are properly inflated. (For shipping purposes,

the tires were overinflated at the factory).

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

front-to-rear for best cutting results. (Tires must be

properly inflated for leveling).

,/ Check mower and drive belts. Besure 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.

,/ Before driving tractor, be sure freewheel control is in

"transmission engaged" position (see "TO TRANS-
PORT" in the Operation section of this manual).

WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY

EXTRA ATTENTION TO THE FOLLOWING IMPORTANT
ITEMS:

,/ Engine oil is at proper level.
,/ Fuel tank is filled with fresh, clean, regular unleaded

gasoline.

,/ 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.
,/ Be sure Operator Presence System and Reverse Op-

eration System (ROS) are working properly (See the
Operation and Maintenance sections in this manual).

,/ It is important to purge the transmission before oper-

ating your tractor for the first time. Follow proper start-
ing and transmission purging instructions (See "TO
START ENGINE" and "PURGE TRANSMISSION" in

the Operation section of this manual).

CHECK BRAKE SYSTEM

After you learn how tooperate your tractor, check to see that
the brake is operating properly. See "TO CHECK BRAKE"
in the Service and Adjustments section of this manual.

OPERATION

These symbols may appear on your tractor or in literature supplied with the product, Learn and understand their mean-

ing.

H

REVERSE NEUTRAL HIGH SLOW

L I',,I

LOW CHOKE FAST

G

ENGINE OFF REVERSE ENGINE ON PARKING BRAKE MOWER HEIGHT

LIGHTS ON FUEL BATTERY REVERSE FORWARD CRUISE CONTROL

OPERATION

SYSTEM (ROS)

ENGINE START

m

ATTACHMENT

CLUTCH DISENGAGED

FREE WHEEL

(Automatic Models only)

ATTACHMENT

CLUTCH ENGAGED

DANGER, KEEP HANDS

AND FEET AWAY

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.

KEEP AREA CLEAR SLOPE HAZARDS

(SEE SAFETY RULES SECTION)

IGNITION SWITCH

MOWER LIFT

CLUTCH/BRAKE

PEDAL

&

Failure to follow instructions

could result in serious injury or
death. The safety alert symbol

is used to identify safety inform-
ation 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.

10