Poulan Pro 541ZX Operator's Manual
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Poulan Pro 541ZX Operator's Manual

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Operator Manual
541ZX / 966681901
Please read the operator's manual carefully and make sure you
understand the instructions before using the machine.
Gasoline containing up to 10% ethanol (E10) is acceptable for
use in this machine. The use of any gasoline exceeding 10%
ethanol (E10) will void the product warranty.
Form Number 115 650627 Rev A
2013-10-15

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Summary of Contents for Poulan Pro 541ZX

  • Page 1 Operator Manual 541ZX / 966681901 Please read the operator’s manual carefully and make sure you understand the instructions before using the machine. Gasoline containing up to 10% ethanol (E10) is acceptable for use in this machine. The use of any gasoline exceeding 10% ethanol (E10) will void the product warranty.
  • Page 2 When this product is worn out and no longer used, it WARNING! Failure to follow cautious operating should be returned to the reseller or other party for practices can result in serious injury to the operator recycling. or other persons. The owner must understand these instructions, and must allow only trained persons who understand these instructions to operate the mower.

  • Page 3: Table Of Contents

    CONTENTS INTRODUCTION ............... 4 Stopping the Engine ..........19 Driving and Transport on Public Roads ...... 4 Operating On Hills ............ 19 Towing ................. 4 Mowing Tips ............. 20 Operating ..............4 Moving Machine By Hand ........21 Good Service .............. 5 MAINTENANCE ...............

  • Page 4: Introduction

    INTRODUCTION Congratulations Operating Thank you for purchasing a Poulan Pro ride-on mower. This This machine is constructed only for mowing grass on lawns machine is built for superior efficiency to rapidly mow primarily and even ground without obstacles such as stones, tree large areas.

  • Page 5: Good Service

    INTRODUCTION Good Service Poulan Pro's products are sold only in specialized retail stores with complete service. This ensures that you as a customer receive only the best support and service. Before the product is delivered, the machine has, for example, been inspected and adjusted by your retailer.

  • Page 6: Symbols And Decals

    SYMBOLS AND DECALS These symbols are found on the machine and in the operator manual. Study them carefully so that you know what they mean. IMPORTANT INFORMATION Xxxx xxxxxx xxxxx xxxx WARNING! xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.

  • Page 7: Safety Instructions

    SAFETY Safety Instructions • Watch for traffic when operating near or crossing These instructions are for your safety. Read them carefully. roadways. • Use extra care when loading or unloading the WARNING! THIS CUTTING MACHINE IS CAPABLE machine into a trailer or OF AMPUTATING HANDS AND FEET AND THROWING truck.

  • Page 8: Slope Operation

    SAFETY Slope Operation Slopes are a major factor related to loss of control and tip- WARNING! CHILDREN CAN BE INJURED BY over accidents, which can result in severe injury or death. THIS EQUIPMENT. The American Academy of Pediatrics Operation on all slopes requires extra caution. If you cannot recommends that children be a minimum of 16 years of age back up the slope or if you feel uneasy on it, do not mow it.

  • Page 9: General Maintenance

    SAFETY • Never fill containers inside a vehicle or on a truck or trailer • Mower blades are sharp. Wrap the blade or wear gloves, bed with plastic liner. Always place containers on the and use extra caution when servicing them. ground away from the vehicle when filling.

  • Page 10: Transport

    • Regularly clean deck and underside of deck, avoid spraying engine and electrical components with water. A spark arrestor for the muffler is available through your authorized Poulan Pro dealer. Transport WARNING! WARNING! Use extreme caution when loading the machine into a truck Engine exhaust and certain vehicle components contain or trailer using ramps.

  • Page 11: Control Locations

    CONTROLS This operator’s manual describes the PoulanPRO Zero Turn Rider. The rider is fitted with a Briggs & Stratton, four-stroke overhead valve engine. 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.

  • Page 12: Motion Control Levers

    CONTROLS Motion Control Levers The machine’s speed and direction are continuously variable using the two steering controls. The steering controls can be moved forward or backward about a neutral position. Parking Brake Furthermore, there is a neutral position, which is locked if the steering controls are moved outward.

  • Page 13: Throttle Control

    CONTROLS Throttle Control Ignition Switch The throttle control regulates the engine speed and thereby The ignition switch is placed on the control panel and is used the rate of rotation of the blades, assuming the blade switch is to start and stop the engine. pulled out, see Engaging the Mower Deck.

  • Page 14: Fuse

    CONTROLS Fuse Cutting Height Lever The 20 amp primary fuse is located on the left hand side of the machine. It is accessed by tilting the seat forward. The fuse is IMPORTANT INFORMATION Always raise the deck to the a flat pin type used in automobiles. highest position for transport.

  • Page 15: Fuel Tank

    CONTROLS Fuel Tank IMPORTANT INFORMATION Experience indicates that alcohol blended fuels (called gasohol, ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the 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.

  • Page 16: Operation

    OPERATION Before Starting Read the Safety section and following pages, if you are unfamiliar with the machine. Read the sections on Safety and Controls before starting the machine. Training Perform the daily maintenance before starting (see Due to unique steering capabilities, zero turn mowers are far Maintenance Schedule in the Maintenance section).

  • Page 17: Starting The Engine

    OPERATION Starting the Engine Move the steering controls outward to the locked (outer) neutral position. 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 the locked (transport) position.

  • Page 18: Running

    OPERATION Press in and turn the ignition key to the start position. Push the release button on the cutting height lever and move lever to the pin, release the button. Move throttle control to full throttle. IMPORTANT INFORMATION Do not run the starter for Engage the mower deck by pulling up the blade switch.

  • Page 19: Stopping The Engine

    OPERATION Stopping the Engine When the machine is standing still, activate the parking brake by pushing the lever release button and pulling the Move the throttle to the minimum position (tortoise lever upward. symbol). Move the steering controls outward. If the engine has been worked hard, allow it to idle at least 60 seconds to attain a normal operating temperature Disengage the mower deck by pressing the blade switch before stopping.

  • Page 20: Mowing Tips

    OPERATION Mowing Tips Weak Battery • Observe and flag rocks and other fixed objects to avoid If the battery is too weak to start the engine, it should be collisions. recharged. (See Battery in the Maintenance section.) • Begin with a high cutting height and reduce it until the If jumper cables are used for emergency starting, follow this desired mowing result is attained.

  • Page 21: Moving Machine By Hand

    OPERATION Moving Machine By Hand When pushing or pulling the mower, engage the EZT bypass WARNING! Bypass linkages are located close to linkages. The EZT bypass linkages are located on the rear of the muffler. To prevent burns, the engine should be shut off the frame, below the rear engine guard.

  • Page 22: Maintenance

    MAINTENANCE Maintenance Schedule The following is a list of maintenance procedures that must be recommended to maintain your machine in the best possible performed on the machine. For those points not described in condition and to ensure safe operation. this manual, visit an authorized service workshop. An annual Read Maintenance in the Safety section.
  • Page 23 MAINTENANCE At least Maintenance interval Daily once in hours each MAINTENANCE Before After year ■ Check/adjust throttle cable ● ● Check the condition of belts, belt pulleys ■ ■ Change the engine oil ■ ■ Replace the engine oil filter ■...

  • Page 24: Battery

    MAINTENANCE Battery STANDARD STATE APPROXIMATE BATTERY CHARGING TIME* TO FULL CHARGE AT 80 F / 27 Your mower is equipped with a maintenance free battery and BATTERY Maximum Rate at: does not need servicing. However, periodic charging of the CHARGE battery with an automotive type battery charger will extend its 50 Amps 30 Amps...

  • Page 25: Safety System

    Perform a standstill test and check that there is sufficient braking action. The engine can only be started when: To adjust the parking brake, contact the Poulan Pro service The mower deck is disengaged. workshop.

  • Page 26: Caster Wheels

    MAINTENANCE Caster Wheels V-belts Check every 100 hours of operation. Check for severe Check every 200 hours. Check that wheels rotate freely. cracking and large nicks. If wheels do not rotate freely take the unit to your dealer for service. NOTE: The belt will show some small cracks in normal operation.

  • Page 27: Adjusting The Mower Deck

    MAINTENANCE Turn either blade to align with the deck front-to-rear. If the Adjusting the Mower Deck front blade tip does not measure " to ½" higher in the Leveling deck rear, follow the front adjustment instructions that follow. Adjust the deck while the mower is on a level surface. With a or adjustable wrench, turn the nuts on the front Make sure the tires are inflated to the correct pressure.

  • Page 28: Cutting Blades

    CAUTION! Use protective glasses when cleaning and washing. Hardware Check daily. Inspect the entire machine for loose or missing hardware. IMPORTANT INFORMATION Special blade bolt is heat treated. Replace with a Poulan Pro bolt if required. Do not use lower grade hardware than specified.

  • Page 29: Transmission

    Transmission The transmission is maintenance free with no need for level checks or oil changes. If a leak occurs, replace the unit or contact your Poulan Pro dealer.

  • Page 30: Trouble Shooting

    TROUBLE SHOOTING Problem / Cause Engine will not start Engine overheats Blade switch is engaged Clogged air intake or cooling fins Steering controls are not locked in the neutral position Engine overloaded Parking brake is not activated Poor ventilation around engine Battery is dead Defective engine speed regulator Contamination in the carburetor or fuel line...

  • Page 31: Winter Storage

    STORAGE Winter Storage To ready the machine for storage: Thoroughly clean the machine, especially under the The machine should be readied for storage at the end of the mower deck. Touch up damage to the paint and spray mowing season or if it will not be in use for more than 30 days. a thin layer of oil on the underside of the mower deck to Fuel allowed to stand for long periods of time (30 days or avoid corrosion.

  • Page 32: Schematic

    SCHEMATIC...

  • Page 33: Technical Data

    TECHNICAL DATA Engine Frame Manufacturer Briggs & Stratton Cutting Width 54" / 137cm Type Cutting Height 1.5 - 4" / 3.8 - 10.2 cm Power 22 HP Uncut Circle Lubrication Pressure with oil filter Number of Blades Fuel Min 87 octane unleaded (Max Blade Length 38 cm ethanol 10%, Max MTBE 15%)

  • Page 34: Torque Specifications

    TECHNICAL DATA Torque Specifications Engine crankshaft bolt 75 ft/lb (100 Nm) Standard ¼" fasteners 9 ft/lb (12 Nm) Deck pulley bolts 75 ft/lb (100 Nm) Standard " fasteners 18 ft/lb (25 Nm) Lug nuts 75 ft/lb (100 Nm) Standard " fasteners 33 ft/lb (44 Nm) Blade bolt 60 ft/lb (81 Nm)

  • Page 35: Conformity Certificates

    CONFORMITY CERTIFICATES USA requirements Labels are placed on the engine and/or in the engine compartment stating that the machine will fulfill the requirements. This is also applicable to special requirements for any of the states, (California emission rules etc.). Do not remove any of these labels.

  • Page 36: Service Journal

    SERVICE JOURNAL Action Date, mtr reading, stamp, sign Delivery Service Charge the battery Adjust the tire pressure of all wheels to 15 PSI (1 bar) Mount the steering controls in the normal position Connect the contact box to the cable for the seat’s safety switch Check that the right amount of oil is in the engine Adjust the position of the steering controls Fill with fuel and open the fuel shut off valve...
  • Page 37 SERVICE JOURNAL Action Date, mtr reading, stamp, sign Daily Service Clean debris from mower. Check engine oil level. Check the tire pressures. Check underside of deck. Inspect deck pulleys. Check/clean the engine’s cooling air intake. Check safety system. Check seat belt. Check fuel system for leaks.

  • Page 38: Hour Service

    SERVICE JOURNAL Action Date, mtr reading, stamp, sign 100-Hour Service Grease fittings (caster pivots and caster wheels) Inspect dampeners Inspect frame Inspect throttle and choke cables Inspect hardware Check the tire pressures Change the engine oil and filter Change air filter Inspect spark plug Inspect fuel filter Check engine RPM...
  • Page 39 SERVICE JOURNAL Action Date, mtr reading, stamp, sign 300-Hour Service Grease fittings (caster pivots and caster wheels) Inspect dampeners Inspect frame Inspect throttle and choke cables Inspect hardware Check the tire pressures Change the engine oil and filter Change air filter Inspect spark plug Inspect fuel filter Check engine RPM...
  • Page 40 SERVICE JOURNAL Action Date, mtr reading, stamp, sign At least once each year Clean the engine’s cooling air intake. Replace the air cleaner’s pre-filter (foam). Replace the air filter’s paper cartridge. Change the engine oil. Replace the engine oil filter. Check/adjust the cutting height.
  • Page 41 SERVICE JOURNAL Action Date, mtr reading, stamp, sign...
  • Page 42 SERVICE JOURNAL Action Date, mtr reading, stamp, sign...

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