Table of Contents
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Operator Manual
461ZX / 966681801
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 394327 Rev B
2011-09-15
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Table of Contents
Related Manuals for Poulan Pro PRO 61ZX / 966681801
Summary of Contents for Poulan Pro PRO 61ZX / 966681801
- Page 1 Operator Manual 461ZX / 966681801 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 To implement improvements, specifications and designs can be altered without prior notification. Note that no legal demands can be placed based on the 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ..............5 Starting the Engine ............25 Driving and Transport on Public Roads ......5 Weak Battery ..............28 Towing ................5 Running ................ 29 Operating ............... 5 Operating On Hills ............30 Good Service ..............6 Mowing Tips .............. - Page 4 WARNING! Failure to follow cautious operating practices can result in serious injury to the operator or other persons. The owner must understand these instructions, and must allow only trained persons who understand these instructions to operate the mower. Each person operating the mower must be of sound mind and body and must not be under the influence of any mind altering substance.
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Page 5: Introduction
INTRODUCTION Congratulations Towing Thank you for purchasing a PoulanPRO ride-on If machine is equipped with a tow hitch, use extreme mower. This machine is built for superior efficiency caution when towing. Never allow children or others in to rapidly mow primarily large areas. A control panel or on the towed equipment. -
Page 6: Good Service
INTRODUCTION Good Service PoulanPRO'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 7: Symbols And Decals
SYMBOLS AND DECALS These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. IMPORTANT INFORMATION WARNING! Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. xxxxxx xxxxxxxxx. - Page 8 SYMBOLS AND DECALS Shut off engine and remove key before performing any Keep a safe Read Operator’s maintenance or repair distance from the Use on slopes no Manual work machine greater than 10° No passengers Whole body Severing of fingers Do not open or Careful backing up, Careful going...
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Page 9: Safety
SAFETY Safety Instructions These instructions are for your safety. Read them carefully. WARNING! WARNING! THIS CUTTING MACHINE IS CAPABLE This symbol means that important OF AMPUTATING HANDS AND FEET safety instructions need to be AND THROWING OBJECTS. FAILURE emphasized. It concerns your safety. TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR... - Page 10 SAFETY • 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.
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Page 11: Personal Safety Equipment
SAFETY Personal Safety Equipment WARNING! When using the machine, approved personal protective equipment (shown in illustrations) shall be used. Personal protective equipment cannot eliminate the risk of injury but it will reduce the degree of injury if an accident does happen. - Page 12 SAFETY • Do not use on steep slopes. • Do not try to stabilize the machine by putting a foot on the ground. • Do not mow near drop-offs, ditches, or embankments. The machine could suddenly roll over if a wheel is over the edge or if the edge caves in.
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Page 13: Safe Handling Of Gasoline
SAFETY Safe Handling of Gasoline WARNING! The engine and the exhaust system become very hot during operation. There is risk for burns if touched. Allow engine and exhaust system to cool before refueling. To avoid personal injury or property damage, use extreme care in handling gasoline. -
Page 14: General Maintenance
SAFETY General Maintenance • 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 buildup. - Page 15 SAFETY Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, fire or eye injury. Sparking in this circuit can not occur after the chassis cable (normally negative, black) is removed from the battery. WARNING! Avoid electrical sparking and its consequences by the following...
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Page 16: Transport
SAFETY Transport WARNING! • The machine is heavy and can cause serious Use extreme caution when loading crushing injuries. Be extra cautious when it is the machine into a truck or trailer loaded on or unloaded from a vehicle or trailer. using ramps. -
Page 17: Controls
CONTROLS Transmission from the engine is made via two belt- This operator’s manual describes the PoulanPRO Zero driven hydraulic pumps. Using the left and right Turn Rider. The rider is fitted with a Briggs & Stratton, steering controls, the flow is regulated and thereby the four-stroke overhead valve engine. -
Page 18: 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. Furthermore, there is a neutral position, which is locked if the steering controls are moved outward. -
Page 19: Parking Brake
CONTROLS 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. -
Page 20: Ignition Switch
CONTROLS Ignition Switch The ignition switch is placed on the control panel and is used to start and stop the engine. 8058-113 Ignition Switch Choke Control The choke is used for cold starts to provide the engine with a richer fuel mixture. Pull the choke control knob up. -
Page 21: Fuel Tank
CONTROLS Fuel Tank The machine has one fuel tank, just behind the seat. The tank capacity is 4 gallons (13.2 liters). The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used. See also Technical Data concerning ethanol fuel. -
Page 22: Fuses
CONTROLS Fuses Fuses are located on the left hand side of the machine. They are accessed by tilting the seat forward. They are flat pin fuses of the same type used in automobiles. There are two fuses with ratings and functions: 20 Amp Primary fuse 7.5 Amp Mower deck coupling IMPORTANT INFORMATION... -
Page 23: Seat Adjustment Lever
CONTROLS Seat Adjustment Lever The seat can be adjusted lengthways. Release levers are located at the lower front right, or on the right side—depending on model. When making adjustments, sit on the seat. Slide the lever and maneuver seat to appropriate placement and release lever. -
Page 24: Operation
OPERATION Read the Safety section and following pages, if you the control levers have not been moved forward or are unfamiliar with the machine. backwards, the mower will not move. Slowly move both control levers forward slightly. This Training will allow mower to start moving forward in a straight Due to unique steering capabilities, zero turn mowers line. -
Page 25: Before Starting
OPERATION Before Starting • Read the sections Safety Instructions and Controls before starting the machine. • Perform the daily maintenance before starting (see Maintenance Schedule in the Maintenance section). • Check that there is sufficient fuel in the fuel tank. •... - Page 26 OPERATION 5. Move the steering controls outward to the locked (outer) neutral position. 8058-190 Place controls in neutral position 6. Move the throttle to the middle position. 8058-113 Set the throttle 7. If the engine is cold, pull the choke control knob up.
- Page 27 OPERATION 8. Press in and turn the ignition key to the start position. IMPORTANT INFORMATION Do not run the starter for more than 5 seconds each time. If the engine does not start, wait approximately 10 seconds before retrying. 0000-000 Turn to the start position 9.
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Page 28: Weak Battery
OPERATION Weak Battery If your battery is too weak to start the engine, it should be recharged. (See Battery in the Maintenance section.) WARNING! Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. -
Page 29: Running
OPERATION Running 1. Release the parking brake by moving the lever downward. Your mower is equipped with an operator presence system. When the engine is running, any attempt by the operator to leave the seat without first setting the parking brake will shut off the engine. -
Page 30: Operating On Hills
OPERATION 5. Engage the mower deck by pulling out the blade switch. 6. Move throttle control to full throttle (not choke). The machine’s speed and direction are continuously variable using the two steering controls. When both controls are in the neutral position, the machine stands still. -
Page 31: Mowing Tips
OPERATION Mowing Tips WARNING! • Observe and flag rocks and other fixed Clear the lawn of stones and other objects to avoid collisions. objects that can be thrown out by the • Begin with a high cutting height and reduce it blades. -
Page 32: Stopping The Engine
OPERATION Stopping the Engine Allow the engine to idle a minute in order to attain normal operating temperature before stopping it, if it has been worked hard. Avoid idling the engine for longer periods, as there is a risk of the spark plugs fouling. -
Page 33: Moving Machine By Hand
OPERATION Moving Machine By Hand When pushing or pulling the mower, engage the EZT (Integrated Zeroturn Transaxle) bypass linkages. The EZT bypass linkages are located on the rear of the frame, below the rear engine guard. 1. Raise the deck into the highest cutting position. -
Page 34: Maintenance
MAINTENANCE Maintenance Schedule The following is a list of maintenance procedures that an authorized service workshop is recommended to must be performed on the machine. For those points maintain your machine in the best possible condition not described in this manual, visit an authorized and to ensure safe operation. - Page 35 MAINTENANCE Daily Maintenance interval least in hours once 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 ■...
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Page 36: Battery
MAINTENANCE Battery Your mower is equipped with a maintenance free STANDARD STATE APPROXIMATE BATTERY CHARGING TIME* TO FULL CHARGE AT 80 F / 27 battery and does not need servicing. However, BATTERY periodic charging of the battery with an automotive Maximum Rate at: CHARGE type battery charger will extend its life. -
Page 37: Safety System
MAINTENANCE Safety System The machine is equipped with a safety system that prevents starting or driving under the following conditions. The engine can only be started when: • The mower deck is disengaged. • The steering controls are in the outer, locked neutral position. -
Page 38: Anti-Scalp Rollers
MAINTENANCE IMPORTANT INFORMATION To avoid deck damage, the anti-scalp rollers must not be adjusted to support the deck. Anti-scalp Rollers Anti-scalp rollers are properly adjusted when they are just slightly off of the ground when the deck is at the desired cutting height in the operating position. -
Page 39: Deck Belt
MAINTENANCE Deck Belt Check every 100 hours 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 1. -
Page 40: Cutting Blades
MAINTENANCE Cutting Blades WARNING! To attain the best mowing effect, it is important that blades are well sharpened and not damaged. Blades are sharp. Protect your hands with gloves and/or wrap blades with a Replace blades that have been bent or cracked when heavy cloth when handling. -
Page 41: Adjusting The Mower Deck
MAINTENANCE Adjusting the Mower Deck Deck Leveling Adjust the deck while the mower is on a level surface. Make sure the tires are inflated to the correct pressure. See Transmission under Technical Data. If tires are under or over inflated, the deck cannot be properly adjusted. -
Page 42: Tire Pressures
MAINTENANCE Tire Pressures All four tires should have a pressure of 15 psi / 103 kPa /1 bar. 8058-079 Check tire pressure Cleaning CAUTION Regular cleaning, especially under the mower deck, Use protective glasses when will increase the machine’s life-span. Make it a habit cleaning and washing. -
Page 43: Lubrication
LUBRICATION Lubrication Schedule 8058-174 12/12 Every year Lubricate with grease gun Lubricate with oil can 1/52 Every Week Oil change Level check 1/365 Every day Filter change General For engine lubrication, see the engine manufacturer's Wipe away excess grease after lubrication. Owners Manual. -
Page 44: Wheel And Deck Zerks
LUBRICATION Wheel and Deck Zerks Use only good quality bearing grease. 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 around the grease cap. Front Wheel Bearings Lubricate 3-4 strokes with a grease gun on each set of wheel bearings. -
Page 45: Trouble Shooting
TROUBLE SHOOTING Problem Cause Engine will not start • Blade switch is engaged. • Steering controls are not locked in the neutral position • Parking brake is not activated • Battery is dead • Contamination in the carburetor or fuel line. •... - Page 46 TROUBLE SHOOTING Problem Cause Engine overheats • Clogged air intake or cooling fins • Engine overloaded • Poor ventilation around engine • Defective engine speed regulator • Too little or no oil in the engine • Contamination in the carburetor or fuel line. •...
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Page 47: Winter Storage
STORAGE Winter Storage To ready the machine for storage, follow these steps: The machine should be readied for storage at the 1. Thoroughly clean the machine, especially under end of the mowing season or if it will not be in use for the mower deck. -
Page 48: Schematic
SCHEMATIC... -
Page 49: Technical Data
TECHNICAL DATA Torque Specifications Engine crankshaft bolt 50 ft/lb (67 Nm) Standard ¼" fasteners 9 ft/lb (12 Nm) Deck pulley bolts 150 ft/lb (203 Nm) Standard " fasteners 18 ft/lb (25 Nm) Lug nuts 75 ft/lb (100 Nm) Standard " fasteners 33 ft/lb (44 Nm) Blade bolt 90 ft/lb (122 Nm) - Page 50 TECHNICAL DATA 461ZX / 966681801 541ZX / 966681901 Engine Manufacturer Briggs & Stratton Briggs & Stratton Type Professional Professional Power 19.5 hp 22 hp Lubrication Pressure with oil filter Pressure with oil filter Min 87 octane, unleaded (Max Min 87 octane, unleaded (Max Fuel methanol 10%, max MTBE 15%) methanol 10%, max MTBE 15%)
- Page 51 TECHNICAL DATA 461ZX / 966681801 541ZX / 966681901 Equipment Cutting width 46" 54" Cutting height 1½" - 4" / 2.5 cm - 10.6 cm 1½" - 4" / 2.5 cm - 10.6 cm Uncut circle Number of blades Blade length 22¾...
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Page 52: 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. Certificates can also be supplied with the machine at delivery or written in the Engine manual. -
Page 53: 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. - Page 54 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.
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Page 55: 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 56 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 57 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 58 SERVICE JOURNAL Action Date, mtr reading, stamp, sign...