Poulan Pro 438495 Operator'S Manual Download

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TROUBLESHOOTING POINTS

PROBLEM

CAUSE

CORRECTION

Will not start

1. Out of fuel.

1. Fill fuel tank.

2. Engine not “CHOKED” properly.

2. See “TO START ENGINE” in Operation section.

3. Engine flooded.

3. Wait several minutes before attempting to start.

4. Bad spark plug.

4. Replace spark plug.

5. Dirty air filter.

5. Clean/replace air filter.

6. Dirty fuel filter.

6. Replace fuel filter.

7. Water in fuel.

7. Empty fuel tank and carburetor, refill tank with fresh

gasoline and replace fuel filter.

8. Loose or damaged wiring.

8. Check all wiring.

9. Carburetor out of adjustment.

9. See “To Adjust Carburetor” in Service Adjustments

section.

10. Engine valves out of adjustment.

10. Contact an authorized service center/department.

Hard to start

1. Dirty air filter.

1. Clean/replace air filter.

2. Bad spark plug.

2. Replace spark plug.

3. Weak or dead battery.

3. Recharge or replace battery.

4. Dirty fuel filter.

4. Replace fuel filter.

5. Stale or dirty fuel.

5. Empty fuel tank and refill tank with fresh, clean

gasoline.

6. Loose or damaged wiring.

6. Check all wiring.

7. Carburetor out of adjustment.

7. See “To Adjust Carburetor” in Service Adjustments

section.

8. Engine valves out of adjustment.

8. Contact an authorized service center/department.

Engine will not

turn over

1. Clutch/brake pedal not depressed.

1. Depress clutch/brake pedal.

2. Attachment clutch is engaged.

2. Disengage attachment clutch.

3. Weak or dead battery.

3. Recharge or replace battery.

4. Blown fuse.

4. Replace fuse.

5. Corroded battery terminals.

5. Clean battery terminals.

6. Loose or damaged wiring.

6. Check all wiring.

7. Faulty ignition switch.

7. Check/replace ignition switch.

8. Faulty solenoid or starter.

8. Check/replace solenoid or starter.

9. Faulty operator presence switch(es).

9. Contact an authorized service center/department.

Engine clicks but

will not start

1. Weak or dead battery.

1. Recharge or replace battery.

2. Corroded battery terminals.

2. Clean battery terminals.

3. Loose or damaged wiring.

3. Check all wiring.

4. Faulty solenoid or starter.

4. Check/replace solenoid or starter.

Loss of power

1. Cutting too much grass/too fast.

1. Raise cutting height/reduce speed.

2. Throttle in “CHOKE” position.

2. Adjust throttle control.

3. Build-up of grass, leaves and trash under

mower.

3. Clean underside of mower housing.

4. Dirty air filter.

4. Clean/replace air filter.

5. Low oil level/dirty oil.

5. Check oil level/change oil.

6. Faulty spark plug.

6. Clean and regap or change spark plug.

7. Dirty fuel filter.

7. Replace fuel filter.

8. Stale or dirty fuel.

8. Empty fuel tank and refill tank with fresh, clean

gasoline.

9. Water in fuel.

9. Empty fuel tank and carburetor, refill tank with fresh

gasoline and replace fuel filter.

10. Spark plug wire loose.

10. Connect and tighten spark plug wire.

11. Dirty engine air screen/fins.

11. Clean engine air screen/fins.

12. Dirty/clogged muffler.

12. Clean/replace muffler.

13. Loose or damaged wiring.

13. Check all wiring.

14. Carburetor out of adjustment.

14. See “To Adjust Carburetor” in Service Adjustments

15. Engine valves out of adjustment.

15. Contact an authorized service center/department.

Summary of Contents for 438495

Page 1: ...AR EYE PROTECTION DURING OPERATION Visit our website www poulan com WARNING Read this Manual and follow all Warnings and Safety Instructions Failure to do so can result in serious injury IMPORTANT MANUAL Do Not Throw Away 438495 09 17 10 TH Printed in U S A ...

Page 2: ...op 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 chute 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 nea...

Page 3: ...ch 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 equipment 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 To avoid personal injury ...

Page 4: ...yrem edy pleasecontactyournearestauthorizedservicecenter 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 i...

Page 5: ...eel 1 Washer 1 Knob Steering Wheel Insert Seat 1 Seat Steering Boot Steering Extension Shaft Steering Wheel Adapter Keys 2 Keys Slope Sheet 1 Oil Drain Tube For Future Use 1 Hex Bolt 5 16 18 x 4 1 5 16 Lock Washer 1 Large Flat Washer ...

Page 6: ...rench set will make assembly easier Standard wrench sizes are listed 1 5 16 wrench Utility knife 2 7 16 wrenches Tire pressure gauge 2 1 2 wrenches Pliers 1 9 16 wrench Whenrightorlefthandismentionedinthismanual itmeans when you are in the operating position seated behind the steering wheel TOREMOVETRACTORFROMCARTON UNPACK CARTON Remove all accessible loose parts and parts cartons from carton Cut ...

Page 7: ...tires CHECK DECK LEVELNESS For best cutting results mower housing should be prop erly leveled See TO LEVEL MOWER HOUSING 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 CHECK BRA...

Page 8: ...for best cutting results Tires must be properly inflated 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 TRACTOR PAY EXTRA ATTENTION TO THE FOLLOWING IMPORTANT ITEMS Engine oil is at proper level Fuel tank is fille...

Page 9: ...r 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 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 mod...

Page 10: ...ects the speed and direction of the tractor IGNITION SWITCH Used for starting and stopping the engine Our tractors conform to the safety standards of the American National Standards Institute Fig 4 PARKING BRAKE CLUTCH BRAKE PEDAL THROTTLE CHOKE CONTROL GEAR SHIFT LEVER ATTACHMENT LIFT LEVER LIFT LEVER PLUNGER IGNITION SWITCH ATTACHMENT CLUTCH LEVER ROS ON POSITION HEIGHT ADJUSTMENT INDICATOR LIGH...

Page 11: ...o backfire Turn ignition key to OFF position and remove key Always remove key when leaving tractor to prevent unauthorized use Never use choke to stop engine IMPORTANT LEAVING THE IGNITION SWITCH IN ANY POSITION OTHER THAN OFF WILL CAUSE THE BATTERY TO BE DISCHARGED DEAD ATTACHMENT CLUTCH LEVER ENGAGED POSITION IGNITION KEY DISENGAGED POSITION PARKING BRAKE ENGAGED POSITION GEAR SHIFT LEVER THROTT...

Page 12: ...RATION SYSTEM ROS Your tractor is equipped with a Reverse Operation System ROS Any attempt by the operator to travel in the reverse direction with the attachment clutch engaged will shut off the engine unless ignition key is placed in the ROS ON position WARNING Backing up with the attachment clutch en gaged while mowing is strongly discouraged Turning the ROS ON to allow reverse operation with th...

Page 13: ...ngine performance See TO ADJUST CARBURETOR in the Service and Adjustments section of this manual ADD GASOLINE Fill fuel tank to bottom of filler neck Do not overfill Use fresh clean regular unleaded gasoline with a minimum of 87 octane Use of leaded gasoline will increase carbon and lead oxide deposits and reduce valve life Do not mix oil with gasoline Purchase fuel in quantities that can be used ...

Page 14: ...riveways etc After one or two rounds mow in the opposite direction making left hand turns until finished See Fig 7 Fig 7 If grass is extremely tall it should be mowed twice to reduce load and possible fire hazard from dried clip pings Make first cut relatively high the second to the desired height Do not mow grass when it is wet Wet grass will plug mower and leave undesirable clumps Allow grass to...

Page 15: ...r Loose Fasteners Check Replace Mower Blades Check Transaxle Cooling Che Check Operator Presence ROS Systems ck V Belts Check Mower Levelness GENERAL RECOMMENDATIONS The warranty on this tractor does not cover items that have beensubjectedtooperatorabuseornegligence Toreceive full value from the warranty operator must maintain tractor as instructed in this manual Some adjustments will need to be m...

Page 16: ...the ignition switch in the ROS ON position and the attachment clutch engaged any attempt by the operator to shift into reverse should NOT shut off the engine BLADE CARE Forbestresultsmowerbladesmustbekeptsharp Replace bent or damaged blades CAUTION Useonlyareplacementbladeap proved by the manufacturer of your tractor Using a blade not approved by the manu facturer of your tractor is hazardous coul...

Page 17: ... oil into container After oil has drained completely reinstall oil drain plug Do not tighten more than 13 Ft Lb s Refill engine with oil through oil fill dipstick tube Pour slowly Do not overfill For approximate capacity see PRODUCTSPECIFICATIONS sectionofthismanual Use gauge on oil fill cap dipstick for checking level Be sure dipstick cap is tightened securely for accurate reading Keep oil at FUL...

Page 18: ... the useful life of your tractor Use compressed air or a leaf blower to remove grass leaves and trash from tractor and mower IN LINE FUEL FILTER See Fig 12 The fuel filter should be replaced once each season If fuel filter becomes clogged obstructing fuel flow to carburetor replacement is required With engine cool remove filter and plug fuel line sec tions Place new fuel filter in position in fuel...

Page 19: ...onnect front links from deck by removing retainer springs Raise lift lever to raise suspension arms Slide mower out from under tractor IMPORTANT IFANATTACHMENTOTHERTHANTHEMOWER DECK IS TO BE MOUNTED ON THE TRACTOR REMOVE THE FRONTLINKSANDHOOKTHECLUTCHSPRINGINTOSQUARE HOLE IN FRAME TO INSTALL MOWER See Fig 13 Raise attachment lift lever to its highest position Slide mower under tractor with deflect...

Page 20: ...al If tires are over or underinflated you will not properly adjust your mower SIDE TO SIDE ADJUSTMENT See Figs 14 and 15 Raise mower to its highest position At the midpoint of both sides of mower measure height from bottom edge of mower to ground Distance A on both sides of mower should be the same or within 1 4 of each other If adjustment is necessary make adjustment on one side of mower only To ...

Page 21: ...ve belt upwards from transaxle pulley by deflecting belt keep ers Remove belt from center span keeper and pull belt away from tractor BELT INSTALLATION Carefully work new belt down between transaxle belt keepers and onto the input pulley Slide belt into the center span keeper Pull belt toward front of tractor and roll around the top groove of engine pulley Install belt through stationary idler and...

Page 22: ...wear eye protection when around batteries If your battery is too weak to start the engine it should be recharged See BATTERY in the Maintenance section of this manual If jumper cables are used for emergency starting follow this procedure IMPORTANT YOURTRACTORISEQUIPPEDWITHA12VOLT SYSTEM THE OTHER VEHICLE MUST ALSO BE A 12 VOLT SYSTEM DONOTUSEYOURTRACTORBATTERYTOSTART OTHER VEHICLES TO ATTACH JUMPE...

Page 23: ... preset at the factory and ad justment should not be necessary If adjustment is neces sary see engne manual TO ADJUST CARBURETOR Your carburetor is not adjustable If your engine does not operate properly due to suspected carburetor problems take your tractor to an authorized service center for repair and or adjustment 02495 HOOD HEADLIGHT WIRE CONNECTOR 02602 02603 SEAT PAN NUT POSITIVE RED CABLE ...

Page 24: ...FUELSYSTEMPARTSSUCH AS CARBURETOR FUEL FILTER FUEL HOSE OR TANK DURING STORAGE ALSO EXPERIENCE INDICATES THAT ALCOHOL BLENDED FUELS CALLED GASOHOL OR USING ETHANOLORMETHANOL CANATTRACTMOISTUREWHICH LEADSTOSEPARATIONANDFORMATIONOFACIDSDURING STORAGE ACIDIC GAS CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN STORAGE Empty the fuel tank by starting the engine and let it run until the fuel lines and ...

Page 25: ...own fuse 4 Replace fuse 5 Corroded battery terminals 5 Clean battery terminals 6 Loose or damaged wiring 6 Check all wiring 7 Faulty ignition switch 7 Check replace ignition switch 8 Faulty solenoid or starter 8 Check replace solenoid or starter 9 Faulty operator presence switch es 9 Contact an authorized service center department Engine clicks but will not start 1 Weak or dead battery 1 Recharge ...

Page 26: ... Replace blade Tighten blade bolt 7 Buildup of grass leaves and trash under mower 7 Clean underside of mower housing 8 Mower drive belt worn 8 Replace mower drive belt 9 Blades improperly installed 9 Reinstall blades sharp edge down 10 Improper blades used 10 Replace with blades listed in parts manual 11 Cloggedmowerdeckventholesfrombuildup of grass leaves and trash around mandrels 11 Clean around...

Page 27: ...used for rental or commercial purposes is limited to 90 days from the date of origi nal purchase 5 This Warranty applies only to products which have been properly assembled adjusted operated and maintained in ac cordance with the instructions furnished This Warranty does not apply to any product which has been subjected to altera tion misuse abuse improper assembly or installation delivery damage ...

Page 28: ...28 SERVICE NOTES ...

Page 29: ... 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 Hold page before you so that its left edge is vertically parallel to a tree trunk or other upright structure 3 Sight across the fold in the direction of hill slope ...

Page 30: ... I D Number b Description of part For Technical Assistance call 1 800 829 5886 For a Parts Manual go to our website www poulan com support asp NOTE HOP provides parts and service through its authorized distributors and dealers therefore all requests for parts and service should be directed to your local dealer s The philosophy of HOP is to continually improve all of its products If the operating c...

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