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Poulan Pro PR20H42STA Operating manual

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IMPORTANT MANUAL Do Not Throw Away
TM
OWNER'S MANUAL
MODEL:
PR20H42STA
LAWN TRACTOR
WARNING: i
Read this Owner's Manual and follow i
all Warnings and Safety Instructions.
Failure to do so can result in serious
injury.
ALWAYS WEAR EYE PROTECTION DURING OPERATION
279860 PR20H42STA 173411 1.18.00 TR
Printed in U.S.A.
SAFETY RULES X't
4Mk Safe Operation Practices for Ride-On Mowers
IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS.
FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
I. GENERALOPERATION
• Read, understand, and follow all instructions in the
manual and on the machine before starting.
• Only allowresponsible adults,who arefamiliar withthe
instructions, to operate the machine.
• Clear the area of objects such as rocks, toys, wire,
etc., whichcould bepicked upand thrownbythe blade.
• Be sure thearea isclear ofotherpeople beforemowing.
Stop machine if anyone enters the area.
•Never carry passengers.
• Do not mow in reverse unless absolutely necessary.
Always lookdownand behindbeforeandwhilebacking.
•Be aware ofthe mower discharge direction and do not
point itat anyone. Do not operate the mower without
either the entire grass catcher or the guard in place.
•Slow down before turning.
•Never leave arunning machine unattended. Always
turn off blades, set parking brake, stop engine, and
remove keys before dismounting.
•Turn offblades when not mowing.
•Stop engine before removing grass catcher or unclog-
ging chute.
•Mow only in daylight or good artificial light.
• Do not operate the machine while underthe influence
of alcphol or drugs.
•Watch for traffic when operating near or crossing
roadways.
•Useextracarewhen loading or unloadingthemachine
into a trailer or truck.
•Data indicates thatoperators, age60 yearsand above,
are involved in alarge percentage of riding mower-
related injurias. These operatorsshouldevaluate their
ability to operate the riding mower safely enough to
protect themselves and others from serious injury.
II. SLOPE OPERATION
Slopes are a major factor related to loss-of-control and
tipover accidents, which can resultin sever injuryordeath.
AUslopes require extra caution, Ifyou cannot back upthe
slope or if you feel uneasy on it, do not mow it.
DO:
• Mow up and down slopes, not across.
• Remove obstacles such as rocks, tree limbs, etc.
•Watch for holes, ruts,or bumps. Uneven terrain could
overturn tbe machine. Ta// grass can hide obstacles.
•Use slow speed. Choose alow gear sothatyou willnot
have to stop or shiftwhile on the slope.
•Followthe manufacturer's recommendationsforwheel
weights or counterweights to improve stability.
•Use extra care with grass catchers or other attach-
ments. These can change thestabilityofthe machine.
•Keepallmovementontheslopesslowandgradual. Do
not make sudden changes in speed ordirection.
•Avoid starting or stopping on a slope. If tires lose
traction, disengage the blades and proceed slowly
straight down the slope.
DO NOT:
• Do not turn on slopesunlessnecessary, and then, turn
slowly and gradually downhill,ifpossible.
•Do not mow near drop-offs,ditches, or embankments.
The mower couldsuddenlytumoverif awheel isoverthe
edge of a cliff or ditch, or if an edge caves in.
•Donotmowonwetgrass.Reducedtractioncouldcause
sliding.
• Do not try to stabilizethe machine byputting your foot
on the ground.
•Do not use grass catcher on steep slopes.
nl, CHILDREN
Tragic accidents can occuriftheoperator is not alert tothe
presence of children. Children are often attracted to the
machine and the mowing activity. Never assume that
children will remain where you lastsaw them.
•Keep children out of the mowing area and under the
watchful care of another responsibleadult.
•Be alert and turn machine offifchildren enter the area.
•Before and when backing, look behind and down for
small children.
•Never carry children. They may falloffand be seriously
injured or interfere withsafe machine operation.
•Never allow childrentooperate the machine.
•Use extra care whenapproaching blindcorners, shrubs,
trees, or other objectsthat may obscure vision.
IV. SERVICE
•Use extra care in handling gasoline and other fuels.
They are flammable and vapors are explosive.
Use only anapproved container.
Never remove gas cap or add fuel with the engine
running. Allow engine to coolbefore refueling. Do
not smoke.
Never refuel themachine indoors,
Never store the machine or fuel container inside
where there isanopen flame, suchasa water heater.
•Never run a machine insidea closed area,
•Keep nuts and bolts,especially blade attachment bolts,
tight and keep equipmentin good condition.
•Never tamper withsafety devicas. Check their proper
operation regulady.
•Keep machine free of grass, leaves, or other debris
buUd-up. Clean oilorfuelspillage. Allowmachine tocool
before storing.
• Stop and inspect the equipment if you strike an object.
Repair, if necessary, before restarting.
• Never make adjustments or repairs with the engine
running.
•Grass catcher components are subject to wear, dam-
age, and deterioration,whichcouldexpose moving parts
orallow objectstobethrown. Frequently check compo-
nents and replace with manufacturer's recommended
parts, when necessery.
•Mowerbladesaresharpandcancut. Wrapthe blade(s)
or wear gloves, and use extra .caution when servicing
them.
•Check brake operation frequently. Adjust and service
as required.
2
A SAFETy RULES
Safe Operation Practices for Ride-On Mowers A
•Besurethe areais clear of other people before mowing.
Stop machine ifanyone enters the area.
•Never carrypassengers orchildren evenwiththeblades
off.
•Do not mow in reverse unless absolutely necessary.
Alwayslookdown and behind before and whilebacking.
•Never carry children. They may fall offand be seriously
injuredor interfere with safe machine operation.
•Keep children out of the mowing area and under the
watchfulcare ofanother responsible adult.
•Be alert and turnmachine off ifchildren enter the area.
•Before and when backing, look behind and down for
smallchildren.
•Mow up and down slopes (15 ° Max), not across.
• Remove obstacles such as rocks, tree limbs, etc.
•Watch for holes, ruts, or bumps. Uneven terrain could
overturnthe machine. Tall grass can hide obstacles.
•Useslow speed. Choose a low gear sothatyou willnot
have to stop or shift while on the slope.
•Avoid starting or stopping on a slope. If tires lose
traction, disengage the blades and proceed slowly
straightdown the slope.
•If machine stops while going uphill, disengage blades,
shiftinto reverse and back down slowly.
•Do notturn on slopes unless necessary, and then, turn
slowlyand gradually downhill, ifpossible.
Lookfor this symbolto point out important
safety precautions. It means CAUTION!t!
BECOME ALERT!!! YOUR SAFETY IS IN-
VOLVED,
CAUTION: Do not coast down a hill in
neutral, you may lose control of the trac-
tor.
ACAUTION: Tow only the attachments
that are recommended by and comply
with specifications of the manufacturer
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 cause you to lose control
of your tractor.
ACAUTION: In order to prevent acciden-
tal starting when setting up, transport-
ing, adjusting or making repairs, always
disconnect spark plug wire and place
wire where itcannot contact spark plug.
WARNING A
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproduc-
tive harm.
3
PRODUCT SPECIFICATIONS
GASOLINE CAPACITY 2.0 GALLONS
AND'tYPE: UNLEADED REGULAR
OILTYPE(API-SF/SG/SH): SAE 30 (above32°F)
SAE 5W-30 (below 32°F)
OIL CAPACITY: W/FILTER: 3.5 PINTS
W/OFILTER: 3.0 PINTS
SPARK PLUG: CHAMPION RC12YC
(GAP: .030=)
FALVE CLEARANCE: INTAKE: .003"- .005"
EXHAUST: .005"- .007"
GROUND SPEED (MPH): Forward: 0-5.5
Reverse 0-2.4
TIRE PRESSURE: FRONT: 14 PSI
REAR: 10 PSI
CHARGING SYSTEM: 3 AMPS Battery
5AMPS Battery
BA'N'ERY: AMP/HR: 25
MIN. CCA: 190
CASESIZE: U1R
BLADE BOLTTORQUE: 27---35FT. LBS.
CUSTOMER RESPONSIBILITIES
•Read and observe the safety rules.
•Followa regular schedule in maintaining, caring for and
usingyour tractor.
•Followthe instructionsunder the "Customer Responsi-
bilities"and "Storage' sections ofthis owner's manual.
CONGRATULATIONS on yourpurchase ofa new Tractor.
Ithas been designed, engineered and manufactured togive
you thebest possible dependability and performance.
Should you experience any problem you cannot easily
remedy, please contact your nearest authorized service
center. We have competent, well-trained technicians and
the propertools to service or repair this tractor.
Please read and retain this manual. The instructions will
enable you toassemble and maintain your tractor properly.
Always observe the "SAFETY RULES'.
WARNING: This tractor isequipped with an internal com-
bustion engine and should not be used on or near any
unimproved forest-covered, brush-covered or grass-cov-
ered land unless the engine's exhaust system isequipped
with a spark arrester meeting applicable local or state laws
(if any). If a spark arrester isused, itshould be maintained
in effective working order by the operator.
Inthestate ofCalifomiathe above isrequiredby law(Section
4442 oftheCalifornia PublicResources Code). Other states
may have similar laws. Federal laws applyon federal lands,
TABLE OF CONTENTS
SAFETY RULES ........................................................ 2-3
PRODUCT SPECIFICATIONS ....................................... 4
CUSTOMER RESPONSIBILITIES ...................... 4, 15-18
ASSEMBLY ................................................................ 6-8
OPERATION ............................................................. 5-14
MAINTENANCE SCHEDULE ....................................... 15
SERVICE AND ADJUSTMENTS ............................. 15-24
STORAGE ................................................................... 25
TROUBLESHOOTING ............................................. 26-27
REPAIR PARTS - TRACTOR .................................. 30-43
WARRANTY .........................................................,.,,. . . 46
4
UNASSEMBLED PARTS
Steering Wheel
Steering
Wheel Insert
Sleeve t
Steering Adapter
Steering
Extension
Shaft
(1) Hex Bolt
3/8-16 x 1
r
(1) Large Flat
(1) Lock
washer 3/8
_x 1-1/4
(1) Locknut
5/16-18
Seat
(1) Washer
17/32 x 1-3/16 x 12 Gauge
(1) Knob
(1) Shoulder
Bolt 5/16-18
Slope Sheet
(2) Keys
(2) Mulch
5
ASSEMBLY
Your new tractorhas been assembled atthe factory with exception ofthose partsleft unassembied for shippingpurposes. To
ensure safe and proper operation ofyour tractor all parts and hardware you assemble must be tightened securely. Use the
correct tools as necessary to insure proper tightness.
TOOLS REQUIRED FOR ASSEMBLY
A socketwrench set willmake assembly easier. Standard
wrench sizes are listed.
(1) 3/4" Socket w/ddve ratchet Utility knife
(1) 9/16" wrenches Tire pressure gauge
(2) 1/2" wrenches Phillips Screwdriver
When right or left hand ismentioned inthis manual, itmeans
when you are in the operating position (seated behind the
steedng wheel).
TO REMOVE TRACTOR FROM CARTON
UNPACK CARTON
•Remove all accessible loose parts and parts cartons
from carton.
•Cut, from top to bottom, along lines on all four comers
of carton, and lay panels flat.
•Check for any additional loose parts or cartons and
remove.
BEFORE REMOVING TRACTOR FROM
SKID
A'FrACH STEERING WHEEL (See Fig. 1)
ASSEMBLE EXTENSION SHAFT AND BOOT
•Slide extension shaft onto lower steering shaft. Align
mounting holes inextension andlower shafts and install
5/16 hex boltand Iocknut. Tighten securely.
•Place tabs of steering boot over tab slots in dash and
pushdown tosecure.
INSTALL STEERING WHEEL
•Positionfront wheels ofthe tractor sothey are pointing
straightforward.
•Remove steedngwheeladapter fromsteedng wheel an_
slideadapter onto steedng shaftextension.
•Positionsteeringwheel socrossbarsare horizontal (left
toright) and slide insideboot and onto adapter.
Assemble large flat washer, 3/8 lock washer, 3/8 hex
boltand tighten securely.
•Snap steedng wheel insert intocenter of steering wheel
•Remove protectivematerials from tractor hood and gdlL
IMPORTANT: CHECK FOR AND REMOVE ANY STAPLES
IN SKIDTHAT MAY PUNCTURE TIRES WHERE TRACTOR
IS TO ROLL OFF SKID.
INSERT
3/8 LOCK WASHER
LARGE FLAT
WASHER
STEERING
WHEEL
ADAPTER/
STEERING
BOOT
TABS
EXTENSION SHAFT
/
_5/16 HEX BOLT
5/16 LOCKNUT __;-'-
LOWER
SHAFT "_-_ "_ ' / _TAB
"_._- _ r_SLOTS
FIG. 1
HOW TO SET UP YOUR TRACTOR
CHECK BATTERY (See Fig. 2)
• Lift seat pan to raised position and open battery box
door.
•Ifthis battery is put into service after month and year
indicated on label (label located between terminals)
charge battery for minimum of one hour at 6-10 amps,
(See"BAI-rERY" inCUSTOMER RESPONSIBILITIES
sectionof this manual for charging instructions).
6
ASSEMBLY
SEAT
BATTERY
BOX
LABEL
FIG. 2
INSTALL SEAT (See Fig. 3)
Adjust seat before tightening adjustment knob.
• Remove adjustment knobandflatwasher securingseat
tocardboard packing and set asidefor assembly ofseat
to tractor.
•Pivot seat upward and remove from the cardboard
packing. Remove cardboard packing and discard.
•Place seat on seat pan and assemble shoulder bolt.
Tighten shoulder boltsecurely.
•Assemble adjustment knoband flatwasher loosely. Do
nottighten.
•Lower seat intooperating positionand siton seat.
•Slide seat until a comfortable positionis reached which
allowsyou to press clutch/brake pedal all the way down.
• Get off seat without moving its adjusted position.
• Raise seat and tighten adjustment knob securely.
SEAT FAN SEAT
SHOULDER
BOLT
ADJUSTMENT
FLAT WASHER
FIG. 3
NOTE: You may now rollor drive your tractor off the skid.
Follow the appropriate instruction below to remove the
tractor from the skid.
TO ROLL TRACTOR OFF SKID (See Operation
section, page 10, for location and function of
controls)
•Presslift lever plungerand raise attachment liftlever to
its highest position.
• Releaseparkingbrakebydepressingclutch/brakepodal.
• Place freewheel control in freewheeling position to
disengage transmission (See"TO TRANSPORF" in the
Operation section of this manual).
•Roll tractor forward off skid.
• Remove banding holding discharge guard up against
tractor.
TO DRIVE TRACTOR OFF SKID (See Opera-
tion section, page 10, for location and func-
tion of controls)
,AWARNING: Beforestarting,read, understand and follow
all instructionsin the Operation section of this manual. Be
sure tractor isin awell-ventilated area. Be sure the area in
front oftractor isclear ofother people and objects.
•Be sure all the above assembly steps have been
completed.
•Check engine oillevel and fillfuel tank with gasoline.
•Placefreewheel controlin "transmissiOn engaged" po-
sition.
• Sit on seat in operating position, depress clutch/brake
pedal and set the parking brake.
• Place motion control lever in neutral (N) position.
• Press liftlever plungerand raise attachment liftlever to
its highest position.
• Starf the engine. After engine has started, move throttle
control to idle position.
• Release parking brake,
•Slowly move the motion control lever forward and slowly
drive tractor off skid.
• Apply brake to stop tractor, set parking brake and place
motion control lever in neutral pos!tion.
•Turn ignition key to "OFF" position.
Continue with the instructions that follow.
IMPORTANT: FOR SHIPPING PURPOSES, THE
MULCHER PLATE WAS PREATTACHED TO YOUR
MOWER. THE MULCHER PLATE MUST ONLY BE USED
WITH THE MULCHING BLADES THAT CAME PACKED
SEPARATELY IN THE CARTON.
YOUR MOWER CAME FACTORY EQUIPPED WITH HIGH
PERFORMANCE BLADES, WHICH ARE THE BEST
BLADES FOR BAGGING AND DISCHARGING. TO USE
YOU RMOWER WITH THE HIGH PERFORMANCE BLADES
THE MULCHER PLATE MUST BE REMOVED FROM THE
MOWER (SEE FIG. 4).
TO SET UP YOUR MOWER FOR MULCHING
•Remove high performance blades and install mulcher
blades, (see BLADE REMOVAL in the CUSTOMER
RESPONSABILITY section ofthis manual).
7
ASSEMBLY
TO INSTALL MULCHER PLATE (See Fig. 4)
NOTE: Ifyouinstalledthemulchingbladesyouwillneedto install
the mulcherplate.
•Raise and hold deflector shield in upright position.
• Place front of mulcher plate over front of mower deck
opening and slide into place, as shown.
•Hook front latch into hole on front of mower deck.
•Hook rear latch into hole on back of mower deck.
I& CAUTION: Do not remove deflector shield
from mower. Raise and hold guard when
attaching mulcher plate and allow it to
rest on plate while in operation.
DEFLECTOR MULCHER
SHIELD PLATE
LATCH
HOOKS
FIG. 4
TO CONVERT TO BAGGING OR
DISCHARGING
NOTE: The mulcher blades willdischarge and baggrass, but
forbestbaggingand discharging installthe highperformance
blades.
•Remove mulcher plate and mulcher blades and install
highperformanceblades, (see BLAD EREMOVAL inthe
CUSTOMER RESPONSABIMTY sectionofthismanual).
•Store mulcher blades and mulcher plate in asafe piece.
Your mower isnow ready for discharging or installation
ofoptional grass catcher accessory.
CHECK TIRE PRESSURE
The tires on your tractorwere overinflated at the factory for
shipping purposes. Correct tire pressure is important for
best cutting performance.
•Reduce tire pressure to PSI shown in "PRODUCT
SPECIFICATIONS" section of this manual.
CHECK DECK LEVELNESS
Forbestcuffing results, mower housing should be propedy
leveled. See"TO LEVEL MOWER HOUSING" inthe 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 BRAKE SYSTEM
Afteryou learn how toope rate yourtractor,checktosee that
the brake isproperly adjusted. See "TO ADJUST BRAKE"
in the Service and Adjustments section ofthis manual.
,I CHECKLIST
BEFORE YOUOPERA TEAND ENJOY YOUR NEW TRAC-
TOR, WE WISH TO ASSURE THAT YOU RECEIVE THE
BEST PERFORMANCE AND SA TISFAC TION FROM THIS
QUALITYPRODUCT.
PLEASE REVIEW THE FOLLOWING CHECKLIST:
•/All assembly instructions have been completed,
,/ No remaining loose parts in carton.
,/ Batteryisproperlypreparedandcharged. (Minimum1
hour at 6 amps).
#" Seat isadjusted comfortably and tightened securely.
#Alltires are properly inflated. (For shippingpurposes,
the tires were ovednflated at the factory).
,/ Be sure mower deck is propedy 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
propedy around pulleys and inside all beltkeepers.
_" Check wiring. See that all connections are stillsecure
and wires are properly clamped.
#" Before driving tractor, be sure freewheel controlis in
drive position.
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.
It isimportant to purge the transmission before operating
your trector for the first time. Follow proper starting and
transmission purging instructions (See "TO START
ENGINE" and "PURGE TRANSMISSION" in the Opera-
tion section of this manual).
8
OPERATION
These symbols may appear on yourtractor or in literature supplied with the product. Learn and understand their meaning.
BA'I-IE RY CAUTION OR REVERSE FORWARD FAST SLOW
WARNING Oi
A
"41,
txl 0 @ =
FUEL CHOKE MOWER HEIGHT PARKING BRAKE UNLOCKED MOWER LIFT
LOCKED
t 't R N
ATTACHMENT REVERSE
CLUTCH ENGAGED NEUTRAL HIGH LOW PARKING BRAKE
KEEP AREA CLEAR SLOPE HAZARDS
ATFACHMENT
IGNITION CLUTCH DISENGAGED (SEE SAFETY RULES SECTION)
DANGER, KEEP HANDS AND FEET AWAY FREE WHEEL
(Automatic Models only)
9
OPERATION
KNOW YOUR TRACTOR
READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR
Compare the illustrationswith yourtractor tofamiliarize yourselfwiththe locationsof various controlsand adjustments. Save
thismanual for future reference.
IGNITION
ATTACHMENT SWITCH SWITCH
AMMETER CLUTCH LEVER POSITION
THROTTLE
CLUTCH/BRAKE
PEDAL
HEIGHT
ADJUSTMENT
KNOB, PARKING
BRAKE
LIFt'LEVER
PLUNGER
ATTACHMENT
LIFT LEVER
-MOTION
FREE WHEEL ii
CONTROL CONTROL
LEVER
FIG. 5
Our tractors conform to the safety standards ofthe American National Standards Institute.
A'FI'ACHMENT CLUTCH LEVER: Used to engage the
mowerblades, orotherattachments mounted toyour tractor.
LIGHT SWITCH: Turns the headlights on and off.
AMMETER - Indicates charging (+) or discharging (-) of
battery.
CHOKE CONTROL - Used when starting acoldengine.
THROTTLE CONTROL: Used forcontrollingengine speed.
CLUTCH/BRAKE PEDAL: Used for declutching and brak-
ing the tractor and starting the engine.
PARKING BRAKE: Locksclutch/brake pedal intothebrake
position.
FREEWHEEL CONTROL: Disengages transmission for
pushing or slowly towing the tractor with the engine off.
MOTION CONTROL LEVER: Selects the speed and
direction oftractor,
ATTACHMENT LIFT LEVER: Used to raise, lower, and
adjust themower deck orother attachments mountedtoyour
tractor.
LIFT LEVER PLUNGER: Used to release attachment lift
lever when changing itsposition.
IGNITION SWITCH: Used for starting and stopping the
engine.
HEIGHT ADJUSTMENT KNOB - Used toadjustthe mower
cuttingheight.
10