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Poulan Pro PR20H42STD User manual

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IMPORTANT MANUAL Do Not Throw Away
OWNER'S MANUAL
MODEL:
PR20H42STD
LAWN TRACTOR
WARNING:
Read this Owner's Manual and follow
all Warnings and Safety Instructions.
Failure to do so can result in serious
injury.
ALWAYS WEAR EYE PROTECTION DURING OPERATION
180002 6.27.01 RD
Printed in U.S.A.
SAFETY RULES
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. GENERAL OPERATION
•Read, understand, and follow all instructionsinthemanual
and on the machine before starting.
• Only allow responsible adults, who are familiar with the
instructions, to operate the machine.
• Clear the area of objects such as rocks, toys, wire, etc.,
which could be picked up and thrown by the blade.
• Be sure the area isclear of other people before mowing.
Stop machine if anyone enters the area.
• Never carry passengers.
• Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while backing.
• Beaware ofthe mower discharge direction anddo notpoint
itat anyone. Do notoperate the mower without either the
entire grass catcher or the guard in place.
• Stow down before turning.
• Never leave a running machine unattended. Always turn
off blades, set parking brake, stop engine, and remove
keys before dismounting.
• Turn off blades when not mowing.
• Stop engine before removing grass catcher or unclogging
chute.
• Mow only indaylight or good artificial light.
• Do not operate the machine while under the influence of
alcohol or drugs.
• Watch for traffic when operating near or crossing road-
ways.
• Use extra carewhen loading or unloading themachine into
a trailer or truck.
• Dataindicatesthat operators, age 60years and above, are
involved in a large percentage of riding mower-related
injuries. These operators should evaluate their ability to
operate the riding mower safely enough to protect them-
selves and others from serious injury.
• Keep machine free ofgrass, leaves or other debris build-
up which can touch hot exhaust /engine parts and bum.
Do not allow the mower deck to plow leaves
or other debris which can cause build-up to occur. Clean
any oil or fuel spillage before operating or storing the
machine. Allow machine to cool before
storage.
I1.SLOPE OPERATION
Slopes are a major factor related to loss-of-controland tipover
accidents,which can result in severe injuryor death. All slopes
requireextracaution, tf youcannotback upthe slopeor ifyoufeel
uneasyon it, do notmow 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 the machine. Tallgrass can hide obstacles.
• Use slow speed. Choose a low gear so that you will not
have to stop or shift while on the slope.
• Follow the manufacturer's recommendations for wheel
weights or counterweights to improve stability.
• Use extra care with grass catchers or other attachments.
These can change the stability of the machine.
• Keep all movement on the slopes slowand gradual Do
not make sudden changes in speed or direction.
• Avoid starting or stopping on aslope. Iftires losetraction,
disengage the blades and proceed slowly straight down
the slope.
DO NOT:
•Do not turn on slopes unless necessary, and then, turn
slowly and gradually downhill, if possible.
•Do not mow near drop-offs, ditches, or embankments.
The mower could suddenly turn over ifa wheel isover the
edge of a cliff or ditch, or if an edge caves in.
•Do notmow on wet grass. Reduced traction could cause
sliding.
•Do not try tostabilize the machine by putting your foot on
the ground.
•Do not use grass catcher on steep slopes.
III. CHILDREN
Tragic accidents can occur if the operator is not alert to the
presence of children. Children are often attracted to the
machine and the mowing activity. Neverassumethatchildren
will remain where you last saw them.
• Keep children out of the mowing area and under the
watchful care of another responsible adult.
• Be alert and turn machine off ifchildren enter the area.
• Before and when backing, look behind and downforsmall
children.
• Never carry children. They may fall off and be seriously
injured or interfere with safe machine operation.
• Never allow children to operate the machine.
• Use extra care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
IV. SERVICE
•Use extracareinhandling gasoline and otherfuels. They
are flammable and vapors are explosive.
- Use only an approved container.
- Never remove gas cap or add fuel with the engine
running. Allow engine to cool before refueling. Do not
smoke.
- Never refuel the machine indoors.
- Never store the machine or fuel container insidewhere
there is an open flame, such as a water heater.
• Never run a machine inside a closed area.
• Keep nuts and bolts, especially blade attachment bolts,
tight and keep equipment in good condition.
• Never tamper with safety devices. Check their proper
operation regularly.
• Keep machine free ofgrass, leaves, or other debris build-
up. Clean oil orfuel spillage. Allow machine tocool before
storing.
• Stop and inspect the equipment if you strike an object.
Repair, ifnecessary, before restarting.
• Never make adjustments or repairs with the engine
running.
• Grass catcher components are subject towear, damage,
and deterioration, which could expose moving parts or
allowobjects tobe thrown. Frequently check components
and replace with manufacturer's recommended parts,
when necessary.
• Mower blades are sharp and can cut. Wrapthe blade(s)
or wear gloves, and use extra caution when servicing
them.
• Check brake operation frequently. Adjust and service
as required.
2
SAFETY RULES
Safe Operation Practices for Ride-On Mowers
Be sure the area is clear of other people before mowing.
Stop machine if anyone enters the area.
Never carry passengers or children even with the blades
off.
Do not mow in reverse unless absolutely necessary. Al-
ways look down and behind before and while backing.
Never carry children. They may fall off and be seriously
injured or interfere with safe machine operation.
Keep children out of the mowing area and under the
watchful care of another responsible adult.
Be alert and turn machine off if children enter the area.
Before and when backing, look behind and down for small
children.
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
overturn the machine. Tall grass can hide obstacles.
Use slow speed. Choose a low gear sothat you will not 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 straight down
the slope.
If machine stops while going uphill, disengage blades, shift
into reverse and back down slowly.
Do not turn on slopes unless necessary, and then, turn
slowly and gradually downhill, if possible.
&
&
Look for this symbol to point out im-
portant safety precautions. It means
CAUTION!!! BECOMEALERT!!! YOUR
SAFETY IS INVOLVED.
CAUTION: In order to prevent acciden-
tal starting when setting up, transport-
ing, adjusting or making repairs, al-
ways disconnect spark plug wire and
placewire where itcannot contact spark
plug.
CAUTION: Do not coast down a hill in
neutral, you may lose control of the
tractor.
CAUTION: Tow only the attachments
that are recommended by and comply
with specifications ofthe manufacturer
of your tractor. Use common sense
when towing. Operate only at the low-
est 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.
WARNING
Engine exhaust, some of its constituents, and cer-
tain 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 of California to cause cancer and birth
defects or other reproductive harm. Wash hands
after handling.
3
PRODUCT SPECIFICATIONS
GASOLINE CAPACITY 2.0 GALLONS
AND TYPE: UNLEADED REGULAR
OILTYPE (API-SF-SJ): SAE 30 (above 32°F)
SAE 5W-30 (below 32°F)
OIL CAPACITY: W/FILTER 4.0 PINTS
W/OFILTER 3.75 PINTS
SPARK PLUG: CHAMPION RC12YC
GAP: .040")
GROUND SPEED (MPH): Forward: 0-5.5
Reverse 0-2.4
TIRE PRESSURE: FRONT: 14PSI
REAR: 10PSI
CHARGING SYSTEM: 16 AMPS @ 3600 RPM
BATTERY: AMP/HR: 30
MIN.CCA: 240
CASE SIZE: U1R
BLADEBOLTTORQUE: 27-35 FT. LBS.
CONGRATULATIONS onyourpurchaseof anewtractor. It
has been designed, engineered and manufactured to give
you the best 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 proper tools to service or repair this tractor.
Please read and retain this manual. The instructionswill
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 inmaintaining, caring for and
using your tractor.
• Follow the instructions under the "Customer Responsi-
bilities" and "Storage" sections of this owner's manual.
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 is equipped
with a spark arrester meeting applicable local or state laws
(if any). If a spark arrester is used, it should be maintained
in effective working order by the operator.
A spark arrester for the muffler is available through your
nearest authorized service center/department (See REPAIR
PARTS section of this manual).
Inthe state ofCalifornia the above is required by law (Section
4442 ofthe California Public Resources Code). Other states
may have similar laws. Federal laws apply on federal lands.
TABLE OF CONTENTS
SAFETY RULES ........................................................ 2-3
PRODUCT SPECIFICATIONS ....................................... 4
CUSTOMER RESPONSIBILITIES ...................... 4, 16-19
ASSEMBLY ................................................................ 6-8
OPERATION ............................................................. 9-15
MAINTENANCE SCHEDULE ....................................... 16
SERVICE AND ADJUSTMENTS ............................. 20-25
STORAGE ................................................................... 26
TROUBLESHOOTING ............................................. 27-28
REPAIR PARTS -TRACTOR .................................. 30-45
WARRANTY ................................................................ 46
4
UNASSEMBLED PARTS
Steering Wheel
Steering
Wheel Insert
Sleeve
Steering
I Extension
Shaft
(1) Hex Bolt
3/8-16 x 1
Steering Adapter
(1) Large Flat
Washer f__-.
/\\\\\\
(1) Lock
washer 3/8
(1) Locknut
5/16-18
(1) Hex Bolt 5/16-18 x 1-1/4
Seat
(1) Washer @
17/32 x 1-3/16 x 12 Gauge
(1) Knob
For Future Use
Slope Sheet
(2) Keys
5
ASSEMBLY
You rnew tractor has been assembled at the factory with exception of those parts left unassembled for shipping purposes. To
ensure safe and proper operation of your 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
Asocket wrench set will make assembly easier. Standard
wrench sizes are listed.
Utility knife Pliers
(1) 9/16" wrenches Tire pressure gauge
(2) 1/2" wrenches
When right or left hand is mentioned inthis manual, it means
when you are in the operating position (seated behind the
steering wheel).
TO REMOVE TRACTOR FROM CAR-
TON
UNPACK CARTON
•Remove all accessible loose parts and parts cartons
from carton.
• Cut, from top to bottom, along lines on all four corners
of carton, and lay panels flat.
• Check for any additional loose parts or cartons and
remove.
BEFORE REMOVING TRACTOR FROM
SKID
ATTACH STEERING WHEEL (See Fig. 1)
ASSEMBLE EXTENSION SHAFT AND BOOT
• Slide extension shaft onto lower steering shaft. Align
mounting holes in extension and lower shafts and install
5/16 hex bolt and Iocknut. Tighten securely.
IMPORTANT: TIGHTEN BOLT AND NUTS SECURELY TO
18-22 FT. LBS TORQUE.
• Place tabs of steering boot over tab slots in dash and
push down to secure.
INSTALL STEERING WHEEL
• Position front wheels of the tractor so they are pointing
straightforward.
• Remove steering wheel adapter from steering wheel and
slide adapter onto steering shaft extension.
• Position steering wheel so cross bars are horizontal (left
to right) and slide inside boot and onto adapter.
• Assemble large flat washer, 3/8 lock washer, 3/8 hex
bolt and tighten securely.
• Snap steering wheetinsert into center of steering wheel.
• Remove protective materials from tractor hood and grill.
IMPORTANT: CHECK FOR AND REMOVE ANY STAPLES
IN SKID THAT MAY PUNCTURE TIRES WHERE TRACTOR
IS TO ROLL OFF SKID.
INSERT
.-----3/8 HEX BOLT
_.-------3/8 LOCK WASHER
LARGE FLAT
WASHER
STEERING
WHEEL
EXTENSION SHAFT
5/16 HEX BOLT
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.
• If this 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 "BATTERY" in CUSTOMER RESPONSIBILITIES
section of this manual for charging instructions).
6
ASSEMBLY
SEAT
BOX
LABEL
FIG. 2
INSTALL SEAT (See Fig. 3)
Adjust seat before tightening adjustment knob.
• Remove adjustment knob and flat washer securing seat
to cardboard packing and set aside for assembly of seat
to tractor.
• Pivot seat upward and remove from the cardboard
packing. Remove the cardboard packing and discard.
• Place seat on seat pan so head of shoulder bolt is
positioned over large slotted hole in pan.
• Push down on seat to engage shoulder bolt in slot and
pull seat towards rear of tractor.
• Pivot seat and pan forward and assemble adjustment
knob and flat washer loosely. Do not tighten.
• Lower seat into operating position and sit on seat.
• Slide seat until a comfortable position is reached which
allows you topress clutch/brake pedal all the way down.
• Get off seat without moving itsadjusted position.
• Raise seat and tighten adjustment knob securely.
;EAT
SHOULDER
BOLT
FLAT
ADJUSTMENT
KNOB
FIG. 3
NOTE: You may now roll or drive your tractor off the skid.
Follow the appropriate instruction below to remove the
tractor from the skid.
TO ROLL TRACTOR OFF SKID (See Opera-
tion section, page 10, for location and func-
tion of controls)
• Press lift lever plunger and raise attachment lift lever to
its highest position.
• Release parking brake bydepressing clutch/brake pedal.
• Place freewheel control in freewheeling position to
disengage transmission (See "TO TRANSPORT" in the
Operation section of this manual).
• Roll tractor forward off skid.
• Remove banding holding deflector shield up against
tractor.
TO DRIVE TRACTOR OFF SKID (See Opera-
tion section, page 10, for location and func-
tion of controls)
_kWARNING: Before starting, read, understand and follow
all instructionsin the Operation section of this manual. Be
sure tractor is in a well-ventilated area. Be sure the area in
front of tractor is clear of other people and objects.
• Be sure all the above assembly steps have been
completed.
• Check engine oil level and fill fuel tank with gasoline.
• Place freewheel control in "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 lift lever plunger and raise attachment lift lever to
its highest position.
• Start 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 position.
• 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
YOUR MOWER 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 of this manual).
7
ASSEMBLY
TO INSTALL MULCHER PLATE (See Fig. 4)
NOTE: If you installed the mulching blades you will need
to install the mulcher plate.
• 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 intohole on back of mower deck.
CAUTION: Do not remove deflector I
shield from mower. Raise and hold shield I
when attaching mulcher plate and allow
it to rest on plate while in operation.
DEFLECTOR
SHIELD MULCHER
LATCH
HOOKS
FIG. 4
TO CONVERT TO BAGGING OR DISCHARG-
ING
NOTE: The mulcher blades wilt discharge and bag grass,
but for best bagging and discharging install the high
performance blades.
• Remove mulcher plate and mulcher blades and install
high performance blades, (see BLADE REMOVAL in the
CUSTOMER RESPONSABILITYsection ofthis manual).
• Store mulcher blades and mulcher plate in asafe place.
Your mower is now ready for discharging or installation
of optional grass catcher accessory.
CHECK TIRE PRESSURE
The tires on your tractor were 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
For best cutting results, mower housing should be properly
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 BRAKE SYSTEM
After you learn how tooperate your tractor, check to see that
the brake is properly adjusted. See "TO ADJUST BRAKE"
in the Service and Adjustments section of this manual.
/CHECKLIST
BEFORE YOUOPERA TEAND ENJOY YOUR NEW TRAC-
TOR, WE WISH TO ASSURE THAT YOU RECEIVE THE
BEST PERFORMANCEAND SA TISFACTION FROM THIS
QUALITYPRODUCT.
PLEASE REVIEW THE FOLLOWING CHECKLIST:
,/ All assembly instructions have been completed.
,/ No remaining loose parts in carton.
,/ Battery is properly prepared and charged. (Minimum 1
hour at 6 amps).
,/ Seat is adjusted comfortably and tightened securely.
,/ All tires are properly inflated. (For shipping purposes,
the tires were overinflated at the factory).
,/ Be sure mower deck is properly leveled side-to-side/
front-to-rear 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.
,/ Before driving tractor, be sure freewheel control is in
drive position.
WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY
EXTRA ATTENTION TO THE FOLLOWING IMPORTANT
ITEMS:
,/ Engine oil isat 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 isimporfant topurge the transmission before operating
your tractor 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 your tractor or in literature supplied with the product. Learn and understand their meaning.
MA
BATTERY CAUTION OR REVERSE FORWARD FAST SLOW
WARNING
ENGINE ON ENGINE OFF OIL PRESSURE A
LIGHTS ON OVER TEMP _r
!
LIGHT
FUEL CHOKE MOWER HEIGHT PARKING BRAKE UNLOCKED
LOCKED MOWER LIFT
r 'l R N
ATTACHMENT REVERSE
CLUTCH ENGAGED
H L c®> I
IGNITION ATTACHMENT
CLUTCH DISENGAGED
NEUTRAL HIGH LOW PARKING BRAKE
KEEP AREA CLEAR SLOPE HAZARDS
(SEE SAFETY RULES SECTION)
DANGER, KEEP HANDS AND FEET AWAY
9
FREE WHEEL
(Automatic Models only)
OPERATION
KNOW YOUR TRACTOR
READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR
Compare the illustrations with you rtractor to familiarize you rself with the locations of various controls and adjustments. Save
this manual for future reference.
IGNITION
ATTACHMENT SWITCH SWITCH
AMMETER CLUTCH LEVER POSITION
THROTTLE
CLUTCH/BRAKE
PEDAL
O
LIFT LEVER
PLUNGER
ATTACHMENT
LIFT LEVER
MOWER DECK
HEIGHT ADJUSTMENT
POSITIONS
FREE WHEEL
CONTROL
PARKING
BRAKE
_MOTION
CONTROL
LEVER
FIG. 5
Our tractors conform to the safety standards of the American National Standards Institute.
ATTACHMENT CLUTCH LEVER: Used to engage the
mower blades, orotherattachments mounted toyourtractor.
LIGHT SWITCH: Turns the headlights on and off.
AMMETER -Indicates charging (+) or discharging (-) of
battery.
CHOKE CONTROL - Used when starting a cold engine.
THROTTLE CONTROL: Usedfor controllingengine speed.
CLUTCH/BRAKE PEDAL: Used for dectutching and brak-
ing the tractor and starting the engine.
PARKING BRAKE: Locks clutch/brake pedal into the brake
position.
MOTION CONTROL LEVER: Selects the speed and
direction of tractor.
ATTACHMENT LIFT LEVER: Used to raise, lower, and
adjust themower deck orotherattach merits mounted toyour
tractor.
LIFT LEVER PLUNGER: Used to release attachment lift
lever when changing its position.
IGNITION SWITCH: Used for starting and stopping the
engine.
FREEWHEEL CONTROL: Disengages transmission for
pushing or slowly towing the tractor with the engine off.
10