Poulan Pro 460ZX, Operator'S Manual

Page 1: ...Operator Manual 460ZX 966550201 540ZX 966550301 Please read the operator s manual carefully and make sure you understand the instructions before using the machine ...

Page 2: ... information contained in these instructions Use only original parts for repairs The use of other parts voids the warranty Do not modify or install non standard equipment to the unit without consent from the manufacturer Modifications to the unit may cause unsafe operations or damage the unit When this product is worn out and no longer used it should be returned to the reseller or other party for ...

Page 3: ...OPERATION 24 Training 24 Steering 24 Before Starting 25 Starting the Engine 25 Weak Battery 28 Jumper Cables 28 Running 29 Operating On Hills 30 Mowing Tips 31 Stopping the Engine 32 Manual Transport 33 MAINTENANCE 34 Maintenance Schedule 34 Battery 36 Safety System 37 Tire Pressures 37 Parking Brake 38 Deck Belt 38 Pump Belt 39 Cutting Blades 40 Blade replacement 40 Anti scalp Rollers 40 Adjustin...

Page 4: ...nd mind and body and must not be under the influence of any mind altering substance WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the 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 ...

Page 5: ...ning equipment and ensure that the machine is well anchored DO NOT operate this machine on public roadways Towing If machine is equipped with a tow hitch use extreme caution when towing Never allow children or others in or on the towed equipment Make wide turns to avoid jack knifing Travel slowly and allow extra distance to stop Do not tow on sloped ground The weight of the towed equipment may cau...

Page 6: ... s type designation I D The manufacturer s type number Model The machine s serial number Serial no Please have the type designation and serial number available when ordering spare parts The engine s manufacturing number is stamped on one of the valve covers The plate states The engine s model The engine s type Code Please have these available when ordering spare parts your retailer See the certifi...

Page 7: ...es Do not touch parts marking Only for keep away from the European market discharge deck Battery acid is corrosive explosive and flammable Do not stand here Noise emissions to the surroundings in accordance with the European Union s directive The machine s emission is stated in the chapter TECHNICAL DATA and on the decals Only machines for European market Use protective glasses Use protective glov...

Page 8: ...erforming any the machine than 10 maintenance or repair work Whole body Severing of fingers Do not open or Careful backing up Careful going exposure to and toes remove safety watch for other forward watch for thrown objects shields while people other people engine is running Moving sharp blades under cover symbols and decals 8 ...

Page 9: ... unless absolutely necessary Always look down and behind before and while backing Never direct discharged material toward anyone Avoid discharging material against a wall or obstruction Material may ricochet back toward the operator Stop the blades when crossing gravel surfaces Do not operate machine without the entire grass catcher discharge guard or other safety devices in place and working Slow...

Page 10: ...hts or counterweights Anyone who operates this machine must first read and understand this Operation Manual Local laws may regulate the age of the user Keep machine free of grass leaves or other debris buildup which can touch the hot exhaust or engine parts and burn Do not allow the mower deck to plow leaves or other debris causing buildup to occur Clean any oil or fuel spillage before operating o...

Page 11: ...obstacles Choose a low ground speed so that you will not have to stop while on the slope Do not mow on wet grass Tires may lose traction Avoid starting stopping or turning on a slope If the tires lose traction disengage the blades and proceed slowly straight down the slope Keep movement on the slopes slow and gradual Do not make sudden changes in speed or direction which could cause machine to rol...

Page 12: ...esponsible 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...

Page 13: ...ground If this is not possible 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 all times until fueling is complete Do not use a nozzle lock open device If fuel is spilled on clothing change clothing immediately Never overfill fuel tank Replace gas cap and tighten securely D...

Page 14: ...egularly to be sure it works properly The machine must not be driven with defective or unmounted protective plates protective cowlings safety switches or other protective devices Do not change the settings of governors and avoid running the engine with overly high engine speeds If the engine runs too fast there is risk for damaging the machine components Be very careful when handling battery acid ...

Page 15: ...ary make repairs before starting Never make adjustments with the engine running The machine is tested and approved only with the equipment originally provided or recommended by the manufacturer Only use approved repair parts for the machine The blades are sharp and can cause cuts and gashes Wrap the blades or use protective gloves when handling them Check the parking brake s functionality regularl...

Page 16: ... Check and abide by local traffic regulations before transporting the machine on any road Do not tow this machine it may cause damage to the drive system Load the unit onto truck or trailer by driving up ramps of suitable strength using a slow speed Do not lift The machine is not intended to be lifted by hand Towing If machine is equipped with a tow hitch use extreme caution when towing Never allo...

Page 17: ... 1 Seat Adjustment Lever 2 Lift Lever 3 Hour Meter 4 Throttle 5 Blade Switch 6 Ignition Switch 7 Choke Control 8 Bypass Linkage 9 Fuel Tank 10 Parking Brake 11 Transmission from the engine is made via two belt driven hydraulic pumps Using the left and right steering controls the flow is regulated and thereby the direction and speed Control Locations 9 10 11 2 6 3 5 4 7 1 8 ...

Page 18: ...right while moving forward move the right control towards the neutral position The rotation of the right wheel is reduced and the machine turns to the right Zero turn can be achieved by moving one control backward behind the neutral position and carefully moving the other steering control forward from its neutral position The rotation direction when zero turning is determined by which steering con...

Page 19: ...cated on the rear of the frame below the rear engine guard Raise the deck into the highest cutting 1 position Pull the EZT bypass linkages up and out of 2 the keyhole slots Release the levers with the head outside the frame and held in the bypass position To reengage the EZT s to drive reverse the 3 above procedure 8058 032 Bypass linkage EZT engaged 8058 033 Bypass linkage EZT locked in the bypas...

Page 20: ...he 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 gas tank start the engine and let it run until the fuel lines and carburetor are empty Use fresh fuel the next season See Storage Instructions for additional information Never use engine or carburetor cleaners in the fuel tank or permanent damage may...

Page 21: ...choke control knob up On models without a separate choke push the throttle control all the way forward to the choke position Throttle Control The throttle control regulates the engine speed and thereby the rate of rotation of the blades assuming the blade switch is pulled out see Engaging the Mower Deck In order to increase or decrease the engine speed the control is moved Avoid idling the engine ...

Page 22: ...ismounting Release the parking brake before moving the mower depressed Parking Brake The parking brake is found on the left of the machine Push the release button and pull the lever backward to activate the brake push forward to release it The park brake is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion The engine will stop if the par...

Page 23: ...ame type used in automobiles There are two fuses with ratings and functions 20 Amp Primary fuse 7 5 Amp Mower deck coupling Fuel Shut Off Valve The fuel shut off valve is located at the left rear of the seat The valve is off when the handle tab is turned perpendicular to the fuel line 8011 419 Fuel shut off valve in the CLOSED position 8011 420 Fuses ...

Page 24: ...r must be in the seat start engine see Before Starting in Operation section adjust engine speed to idle disengage parking brake do not engage blades at this time rotate control levers IMPORTANT INFORMATION When control levers are in the reverse position they return to neutral when released This may cause the mower to suddenly stop inward As long as the control levers have not been moved forward or...

Page 25: ...ition The following conditions must be fulfilled before the engine can be started The blade switch for engaging the mower blades must be depressed The parking brake must be on Both steering controls must be in the locked outer neutral position Starting the Engine Sit on the seat Raise the mower deck by pushing the release button on the top of the lifting lever Pull the lifting lever backward to th...

Page 26: ... the choke control Move the steering controls outward to the locked outer neutral position Move the throttle to the middle position If the engine is cold pull the choke control knob up NOTE On models without a separate choke control push throttle control all the way forward to the choke position ...

Page 27: ...ION Do not run the starter for more than 5 seconds each time If the engine does not start wait approximately 10 seconds before retrying 8050 781 Return to run position 8058 113 Set the engine speed Press in and turn the ignition key to the start position When the engine starts immediately release the ignition key back to the run position Set the desired engine speed with the throttle Allow the eng...

Page 28: ...taking care not to short against chassis Connect one end of the BLACK cable to the 2 NEGATIVE terminal of the fully charged battery Connect the other end of the BLACK cable 3 to a good CHASSIS GROUND on the mower with the discharged battery away from the fuel tank and battery To remove cables reverse order Remove BLACK cable first from chassis and 1 then from the fully charged battery Remove RED c...

Page 29: ...enly adjusted 8058 080 1 Released parking brake WARNING Ensure that no one is near mower when engaging blade switch Make sure the work area is free from objects that could be thrown by the rotating blades Set retaining pin into selected cutting height and 3 secure the opposite side with a cotter hairpin Push the release button on the cutting height lever 4 and move lever to the pin release the but...

Page 30: ... forward from its neutral position IMPORTANT INFORMATION Control levers return to neutral when released This may cause the mower to suddenly stop Operating On Hills Read the Safety Instructions Driving on Slopes in the Safety section The slowest speed possible should be used before starting up or down hills Avoid stopping or changing speed on hills If stopping is absolutely necessary pull drive le...

Page 31: ...lawn becomes more even and the grass clippings more evenly distributed over the mown area The total time taken is not increased as a higher operating speed can be used without poor mowing results Avoid mowing wet lawns The mowing result is poorer because the wheels sink into the soft lawn clumps build and the grass clippings fasten under the cowling Hose the mower deck underside with water after e...

Page 32: ...er position than OFF will cause the battery to be discharged 8011 668 Disengage the mower deck Raise the mower deck by depressing the button 2 and pulling backward to the transport position 8058 080 Released parking brake 8058 019 Mower deck lifting lever When the machine is standing still activate the 3 parking brake by pulling the lever upward Move the throttle to the minimum position tortoise 4...

Page 33: ...d Zeroturn Transaxle bypass linkages The EZT bypass linkages are located on the rear of the frame below the rear engine guard Raise the deck into the highest cutting 1 position Pull the EZT bypass linkages up and out of 2 the keyhole slots Release the levers with the head outside the frame and held in the bypass position To reengage the EZT s to drive reverse the 3 above procedure ...

Page 34: ...re screws nuts Clean under the mower deck Start the engine and blades listen for unusual sounds Check for damage Thoroughly clean around the engine Clean around belts belt pulleys Check the tire pressures Check battery connections Sharpen3 Replace mower blades Clean the engine s cooling air intake 2 Clean the air cleaner s pre filter 2 foam Clean the air cleaner s filter cartridge 2 paper filter C...

Page 35: ...move the key Make sure the blades and all moving parts have completely stopped Disconnect the spark plug wire from all spark plugs and place the wire where it cannot come in contact with the plug MAINTENANCE Daily At least once each year Maintenance interval in hours Before After 10 100 300 Check adjust throttle cable Check the condition of belts belt pulleys Change the engine oil 1 Replace the en...

Page 36: ...ery with plain water and dry 3 Clean terminals and battery cable ends with 4 wire brush until shiny Coat terminals with grease or petroleum jelly 5 Reinstall battery 6 Replacing battery Lift seat and rotate forward 1 Using two wrenches disconnect BLACK 2 battery cable then RED battery cable Position deck to lowest setting 3 From underside of frame remove the nuts that 4 secure the battery hold dow...

Page 37: ...n Make daily inspections to ensure that the safety system works by attempting to start the engine when one of the conditions is not met Change the conditions and try again If the machine starts when one of these conditions is not met turn the machine off and repair the safety system before using the machine again Make sure the engine stops when the parking brake is not engaged and the operator lea...

Page 38: ...urs of operation Check for severe cracking and large nicks NOTE The belt will show some small cracks in normal operation The belts are not adjustable Replace belts if they begin to slip from wear Deck Belt Removal Park on a level surface Apply parking brake 1 Lower the deck into the lowest cutting position 2 Remove bolts from belt shields and remove 3 shields Remove any dirt or grass that may have...

Page 39: ...ch anti rotation tab into slot on clutch Secure clutch install wire Reinstall the deck belt onto the electric clutch see Deck Belt Removal in this section of the manual 8011 764 1 Clutch pulley 2 Deck belt Belt routing 54 deck belt Deck Belt Installation NOTE For ease in installing the deck belt refer to the routing decal on the top of the deck Wrap the deck belt around the electric clutch 1 pulle...

Page 40: ...replacement Remove blade bolt by turning counter clockwise 1 Install new or resharpened blade with stamped 2 GRASS SIDE facing towards ground grass down or THIS SIDE UP facing deck and cutter housing Install and tighten blade bolt securely 3 Torque blade bolt to 90 ft lbs 122 Nm 4 Anti scalp Rollers Anti scalp rollers are properly adjusted when they are just slightly off of the ground when the dec...

Page 41: ...ement is the same If adjustment is required with a or adjustable wrench turn the lift link adjustment nuts on either side counter clockwise to lower or clockwise to raise Adjust until both side to side measurements are equal 8058 030 Lift link adjustment nut 8058 031 Deck front adjustment nuts Turn any blade to align with the deck in front 4 to rear manner If the rear blade tip does not measure 1 ...

Page 42: ... yoke and take care of the spacers Install in reverse order Tighten caster bolt Hardware Check daily Inspect the entire machine for loose or missing hardware Cleaning Regular cleaning and washing especially under the mower deck will increase the machine s life span Make it a habit to clean the machine directly after use after it is cooled before the dirt sticks Do not spray water on the top of the...

Page 43: ...y use the machine should be lubricated twice weekly 12 12 Every year 1 52 Every Week 1 365 Every day Lubricate with grease gun Oil change Filter change Lubricate with oil can Level check 8058 019 Wipe away excess grease after lubrication It is important to avoid getting lubricant on the belts or the drive surfaces on the belt pulleys Should this happen attempt to clean them with spirits If the bel...

Page 44: ...se Grease from well known brand names petrochemical companies etc usually maintains a good quality Front Wheel Mount Lubricate with a grease gun until the grease is forced out Front Wheel Bearings Lubricate 3 4 strokes with a grease gun on each set of wheel bearings 8058 116 Deck spindle Deck Spindles Lower the cutting deck completely If a grease gun without rubber hose is used the foot plate must...

Page 45: ...oor contact of the battery terminal cable connections Blown fuse Fault in the starter safety circuit See Safety System in the Maintenance section Engine runs rough Faulty carburetor Choke control is pulled out with a warm engine Clogged fuel filter or jet Clogged ventilation valve on the fuel cap Fuel tank nearly empty Fouled spark plugs Rich fuel mixture or fuel air mixture Wrong fuel type Water ...

Page 46: ...g brake on Bypass valve on pump open Drive belt for the transmission slack or has come off Air trapped in hydraulic system Mower deck not engaging Drive belt for the mower deck has come loose Contact for the electromagnetic coupling has loosened Blade switch is faulty or has come loose from cable contact Blown fuse Transaxle leaks oil Damaged seals housing or gaskets Air trapped in hydraulic syste...

Page 47: ...the fuel tanks or add a fuel stabilizer Start 4 the engine and allow it to run until the carburetor is drained of fuel or the stabilizer has reached the carburetor Remove the spark plug and pour about a 5 tablespoon of engine oil into the cylinder Turn over the engine so that the oil is evenly distributed and then refit the spark plug Lubricate all grease zerks joints and axles 6 Remove the batter...

Page 48: ...SCHEMATIC 48 ...

Page 49: ... 203 225 305 250 339 370 502 7 8 378 513 591 801 11 8 782 1060 1410 1912 Grade 5 Minimum commercial quality lower quality not recommended Metric Standard Hardware Grade Grade 8 8 Grade 10 9 Grade 12 9 ft lbs ft lbs Nm ft lbs Nm ft lbs Nm Shank Size Diameter in millimeters fine or coarse thread M4 1 5 2 2 2 3 2 7 3 6 M5 3 4 4 5 6 5 2 7 M6 5 2 7 7 5 10 8 2 11 M7 8 2 11 12 16 15 20 M8 13 5 18 18 8 25...

Page 50: ...Engine oil Mineral Class SAE 10W30 10W40 5W20 5W30 API SF SG SAE 10W30 10W40 5W20 5W30 API SF SG Fuel Min 87 octane unleaded Max methanol 10 max MTBE 15 Min 87 octane unleaded Max methanol 10 max MTBE 15 Fuel tank capacity 4 gallons 15 1 liters 4 gallons 15 1 liters Spark plugs gap Champion RC12YC 030 0 75 mm Champion RC12YC 030 0 75 mm Cooling Air cooling Air cooling Air filter Standard Standard ...

Page 51: ... Standard Hinged armrests No No Blade engagement Electric clutch Electric clutch Deck construction Stamped Stamped Productivity Output 2 37 acres hr 9591 m2 hr 2 78 acres hr 11250 m2 hr Overall dimensions Weight 525 lbs 238 kg 538 lbs 244 kg Base machine length 75 191 cm 75 191 cm Base machine width 40 102 cm 40 102 cm Base machine height 41 106 cm 41 106 cm Overall width chute up 48 122 cm 57 145...

Page 52: ...or any of the states California emission rules etc Do not remove any of these labels Certificates can also be supplied with the machine at delivery or written in the Engine manual Take care of them as they are valuable documents CE requirements If required vibration data corresponding to Directive 2002 44 EC is given in the Technical Data Section The Declaration of Conformity is included in the li...

Page 53: ... drive to both wheels 10 Check the mower deck adjustment 11 Check Safety switch for the parking brake Safety switch for the mower deck Safety switch in the seat Safety switch in the steering controls Parking brake functionality Driving forward Driving backward Engaging the blades 12 Check engine high idle speed 13 Inform the customer about Need and advantages of following the service schedule Need...

Page 54: ...Check safety system 9 Check seat belt 10 Check fuel system for leaks 11 Inspect safety guards and shields 12 Check brake adjustment Daily Service 1 Clean debris from mower 2 Check engine oil level 3 Check the tire pressures 4 Check underside of deck 5 Inspect deck pulleys 6 Check clean the engine s cooling air intake 7 Check safety system 8 Check seat belt 9 Check fuel system for leaks 10 Inspect ...

Page 55: ...l filter 11 Check engine RPM 12 Clean underside of deck 13 Check blade pitch 14 Grease blade spindles 15 Inspect spindle bearings 16 Inspect deck belt and blades 17 Inspect idler arm bearings 18 Inspect deck idler pulleys 19 Check hydraulic oil level 20 Inspect hydraulic filter 21 Inspect hydraulic drive belt 22 Inspect hydraulic hoses 23 Check neutral position 24 Inspect battery connections 25 Ch...

Page 56: ...11 Check engine RPM 12 Clean underside of deck 13 Check blade pitch 14 Grease blade spindles 15 Inspect spindle bearings 16 Inspect deck belt and blades 17 Inspect idler arm bearings 18 Inspect deck idler pulleys 19 Check brake adjustment 20 Inspect safety guards and shields 21 Replace hydraulic drive belt 22 Inspect hydraulic hoses 23 Check neutral position 24 Inspect battery connections 25 Load ...

Page 57: ...r intake 2 Replace the air cleaner s pre filter foam 3 Replace the air filter s paper cartridge 4 Change the engine oil 5 Replace the engine oil filter 6 Check adjust the cutting height 7 Check adjust the parking brake 8 Clean Change the spark plugs 9 Replace the fuel filter 10 Check the engine valve clearance ...

Page 58: ...SERVICE JOURNAL 58 Action Date mtr reading stamp sign ...

Page 59: ......

Page 60: ...P N 115 348227R1 02 16 10 ...