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Poulan Pro PRGT25H48A User manual

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IMPORTANT MANUAL Do Not Throw Away
Poulan _q
OWNER'S MANUAL
MODEL:
PRGT25H48A
LAWN TRACTOR
_bWARNING:
Read the 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
181515 Rev. 2 06.17.02 RH
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 followatlinstructions inthe manual
and on the machine beforestarting.
•Only allow responsible adults, who are familiar with the
instructions,tooperate the machine.
Clear the area of objectssuch as rocks, toys, wire, etc.,
whichcould be pickedup and thrown by the blade.
•Be sure the area isclear of otherpeople before mowing.
Stop machine ifanyone entersthe area.
Never carry passengers.
• Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while backing.
• Be aware ofthe mowerdischargedirection and do notpoint
itat anyone. Do not operate the mower without either the
entire grass catcher or the guard in place.
• Slow down before turning.
• Never leave a running machine unattended. Always tum
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 in daylight or good artificial light.
• Do not operate the machine while under the influence of
alcohol ordrugs.
•Watch for traffic when operating near or crossing road-
ways.
• Use extra care when loading or unloading the machine into
a trailer or truck.
• Dataindicates that 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 dding 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.
II. SLOPE OPERATION
Slopes are a major factor related to loss-of-control and tipever
accidents, which can result in severe injury or death. All slopes
require extra caution. If you cannot back up the 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 the machine. Tafl grass 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.
• Avoidstartingorstoppingonaslope. Iftireslosetraction,
disengage the blades and proceed slowly straight down
the slope.
DO NOT:
•Do not turnon slopes unlessnecessary, and then, turn
slowlyand graduallydownhill,ifpossible.
•Do not mow near drop-offs,ditches, or embankments.
The mowercould suddenlytum overifa wheel isoverthe
edge ofa cliffor ditch,or ifan edge caves in.
•Do notmow on wetgrass. Reduced traction could cause
sliding.
•Donottrytostabilizethemachinebyputtingyourfooton
theground.
•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.
• Beforeandwhenbacking, lookbehindanddownforsmall
children.
•Never carry children. They may fall off and be seriously
injured or interferewith safe machine operation.
• Never allow children to operate the machine.
•Use extracare when approachingblind corners, shrubs,
trees, or other objects that may obscure vision.
IV. SERVICE
•Useextracareinhandlinggasolineand other fuels. They
are flammable and vaporsare explosive.
-Useonlyan appreved container.
-Never remove gas cap or add fuel with the engine
running. Allowengineto coolbeforerefueling. Do not
smoke.
- Never refuel the rnachine indoors.
- Never store the machine or fuelcontainer inside where
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 machinefree ofgrass,leaves, orotherdebdsbuild-
up.Clean oilorfuelspillage.Allowmachinetocoolbefore
stonng.
•Stop and inspectthe equipment ifyou strike an object.
Repair, ifnecessary,before restarting.
•Never make adjustments or repairs with the engine
running.
•Grasscatchercomponentsare subjecttowear, damage,
and deterioration,which could expose moving parts or
allowobjectstobethrown.Frequentlycheckcomponents
and replace with manufacturer's recommended parts,
when necessary.
• Mower blades are sharp and can cut. Wrap the 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 isclear 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. Always
look down and behind before and while backing.
Never carry children. They may fall off and be seriously
injured or interfere wrlh 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, nits. or bumps. Uneven terrain could over-
turn the machine. Tall grass can hide obstacles.
• Use slow speed. Choose a low gear so that you will not have
to stop or shift wh_leon 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 whulegoing uphill,disengage blades, shift
into reverse and back down slowly.
•Do not tum on slopes unless necessary, and then, turn slowly
and gradually downhdl, 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
place wire 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 of the 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 },our 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 5.0 GALLONS
AND TYPE: UNLEADED REGULAR
OILTYPE (API-SF-SJ): SAE 30 (above 32°F)
SAE 5W-30 (below 32°F)
OILCAPACITY: W/FILTER: 4.0 PINTS
W/OFILTER: 3.75 PINTS
SPARK PLUG: CHAMPION RC12YC
GAP: .040")
GROUND SPEED (MPH): FORWARD: 0- 5.8
REVERSE: 0-2.1
TIRE PRESSURE: FRONT: 14 PSI
REAR: 10 PSI
CHARGING SYSTEM: 16 AMPS @ 3600 RPM
BATTERY: AMP/HR: 35
MIN. CCA: 280
CASESIZE: U1R
BLADE BOLT TORQUE: 45-55 FT. LBS.
CUSTOMER RESPONSIBILITIES
Read and observe the safety rules.
•Followa regularschedule inmaintaining, cadng for and
using your tractor.
•Follow the instructionsunder"Customer Responsibili-
ties"and "Storage" sectionsofthis owner's manual.
WARNING: This tractor is equipped with an internal
combustion 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, itshould be maintained
in effective working order by the operator.
A spark arrester for the muffler is available through your
nearest authorized service centre/department (See RE-
PAIR PARTS section of this manual).
CONGRATULATIONS on your purchase ofa new tractor. 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/
department We have competent, well-trained technicians and the proper toolsto service or repairthis tractor.
Please read and retainthis manual. The instructionswillenable you toassemble and maintainyourtractorproperly. Always
observe the "SAFETY RULES".
TABLE OF CONTENTS
SAFETY RULES ........................................................ 2-3
PRODUCT SPECIFICATIONS ....................................... 4
CUSTOMER RESPONSIBILITIES ...................... 4, 16-19
ASSEMBLY ................................................................ 6-9
OPERATION ......_..................................................... 10-15
MAINTENANCE SCHEDULE ....................................... 16
SERVICE AND ADJUSTMENTS ............................. 20-26
STORAGE ................................................................... 27
TROUBLESHOOTING ............................................. 2829
REPAIR PARTS -TRACTOR .................................. 32-46
WARRANTY ................................................................ 50
4
UNASSEMBLED PARTS
Steering Wheel
Steering Steering
Wheel Adapter Wheel Insert
Steering Sleeve
Steering Sleeve
Extension
Seat
(1) Washer
17/32 x 1-3/16 x 12 Gauge
(1) Knob
Mower
(5) Retainer Springs _
(double loop)
_(2) Retainer Springs (single loop)
(2)Flanged
_Pins
(1)Front Plat_
Assembly %5
Gauge Wheel
f" (4) Adjusting Bar
o
o
o
o
o
,.,(4) Washers
/e x 3/4 x 14Ca.
(4) Locknut 3/8-16
®
(4) Wheels
(4) Clevis Pins
(4) Shoulder Bolt
Nose Roller
(2) Locknuts Retainer
5/16-18 Spring
For Future Use
Keys
(2) Keys
Slope Sheet
5
ASSEMBLY
Your newtractor has been assembled at the factory withexception ofthose parts leftunassembled forshipping 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
A socket wrench set willmake assembly easier. Standard
wrench sizes are listed.
(1) Pliers (1) Tire pressure gauge
(2) 9/16" wrench (1) Utility knife
(1) 1/2" wrench (1) 3/4" socket w/drive ratchet
When right or left hand is mentioned in this 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 corners
of carton, and lay panels flat.
• Remove mower and packing materials.
• Check for any additional loose parts or cartons and
remove.
BEFORE REMOVING TRACTOR FROM
SKID
STEERING
_WHEEL
_....,.,.. INSERT
_- HEX BOLT
:_LOCK WASHER
I(_ LARGE FLAT
ASHER
STEERING _ \ _" _-_J_ // STEERING
WHEEL \."_-_ J L _,,-"_JJ WHEEL
STEERING _ADAPTOR
SLEEVE _TABS
EXTENTION
ALL-_- --_-,
STEERING ,- -_-: -- - t\\_
SHAFT """-"',.,.--- '|,,_-_-'---__ "_,,
STEERING ,,/',,
SLEEVE _ _,_' ',_." /
ATrACH STEERING WHEEL (See Fig. 1)
•Remove hexbolt,lockwasher and largeflatwasher frem
steering shaft.
•Position frontwheels of the tractorso they are pointing
straightforward.
•Slide the steering sleeve over the steedng shaft.
•Align tabs and press steering sleeve extension into
bottom ofsteering wheel.
•Positionsteering wheel so crossbars are horizontal(left
to right) and slide ontosteering wheel adapter.
•Secure steering wheel to steering shaft with hex bolt,
lock washer and large flat washer previously removed.
Tighten securely.
•Snap steeringwheelinsert int°center°t steering wheel"
• Remove protectivematerials fromtractor hoodand grill.
IMPORTANT: CHECK FOR AND REMOVE ANY STAPLES
IN SKID THAT MAY PUNCTURE TIRES WHERE TRACTOR
IS TO ROLL OFF SKID,
FIG. 1
HOW TO SET UP YOUR TRACTOR
CHECK BATTERY (See Fig. 2)
•Lift hood to raised position.
•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" inCUSTOMER RESPONSIBILITIES
section of this manual forcharging instructions).
-' LABEL
i
.?
FIG. 2
6
ASSEMBLY
INSTALL SEAT (See Fig. 3)
Adjust seat before tightening adjustment knob.
Remove adjustment knob and flat washer securing seat
tocardboard 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 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
SEAT PAN
FLAT WASHER
AOJUST.ENT/!
KNOB
SHOULDER
BOLT
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 for location and function of con-
trols)
• Press liftlever plunger and raise attachment lift leverto
its highest position.
• Release parking brake by depressing 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.
TO DRIVE TRACTOR OFF SKID (See Opera-
tion section for location and function of con-
trols)
WARNING: Before startin_h read, understand and
follow all instructionsintheOperation sectionofthismanual.
Besure tractor isin awell-ventilated area. Be sure thearea
in front of tractor isclear ofother 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"posi-
tion.
Sit on seat in operating position, depress brake pedal
and set the parking brake•
• 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 leverforward and slowly
drive tractor off skid.
• Apply brake to stop tractor and set parking brake.
• Turn ignition key to "OFF" position.
Continue with the instructions that follow.
ASSEMBLE GAUGE WHEELS TO MOWER
DECK (See Fig. 4)
The gauge wheels are designed to keep the mower deck in
proper position when operating mower. Be sure they are
properly adjusted to ensu re optimum mower performance.
• Slide gauge wheel bar down into bracket channel, Be
sure that gauge wheel bar aligning holes are on top.
Assemble gauge wheels as shown using shoulder bolts,
3/8 washers and 3/8-16 center Iocknuts and tighten
securely.
• For ease of mower to tractor assembly, raise gauge
wheels to highest position and retain with clevis pins and
spring retainers.
• Adjust gauge wheels before operating mower. See"TO
ADJUST GAUGE WH EELS" inthe Operation section of
this manual.
RETAINER
SPI_
PIN
SHOULDER
BOLT ADJUSTING
BAR
GAUGE,
WHEEL 3/8WASHER 3/8-16 CENTER
LOQKNUT
FIG. 4
7
ASSEMBLY
TO ATTACH NOSE ROLLER (See Fig. 5)
1. Assemble brackets "A"and "B" to the inside of mower
mounting brackets as shown. Tighten securely.
NOTE: Be sure bracket tabs are positionedintab holes in
mower brackets.
2. Positionnoseroller between bracketsand installrodand
retainer spring.
Hex Bolt
Lock
Nut Rod
Tab
Hole
"B"
Bracket
"A"
Bracket
Retainer Spring
Nose Roller
FIG. 5
INSTALL MOWER AND DRIVE BELT (See
Figs. 6 and 7)
Be sure tractor ison level surface and mower suspension
armsare raised withattachment liftcontrol.Engage parking
brake.
•Cut and remove ties securing anti-sway bar and belts.
Swing anti-sway bar to leftside ofmower deck.
•Slide mower under tractor with deflectorshield to right
side of tractor.
IMPORTANT: Check belt for proper routing in all mower
pulley grooves.
•Ifequipped, turnheight adjustment knobcounterclock-
wise until it stops. LOCK BRACKET
BELT TENSION ROD
(DISENGAGED POSITION)
CHASSIS _- _'_"
5"
BRACKET
GAUGE
WHEEL
•Lower mower linkage withattachment lift control.
• Be sure belt tension rod isin disengaged position.
•Install belt into electric clutch pulley groove.
•Place the suspension arms on outward pointing deck
pins. Retain with double loop retainer spring with loops
upas shown.
Installfront plate assembly totractor suspension brack-
etsand retainwithsingle loopretainersprings as shown.
•Position front plate assembly between front mower
brackets. Raise deck and plate assembly toalign holes
and insert flanged pins. Secure pins with double loop
retainer springs between theplate assembly and mower
brackets.
NOTE: To assist in locating hole in flanged pin, the hole in
pin is inline with notch on head of pin.If necessary, move
mower side-to-side to give space between plate and mower
brackets.
IMPORTANT: Check belt for proper routing in all mower
pulleygrooves. Engage belt tension rodby pushing rod into
lockingbracket.
•Engage belt tension rod by pushing rod into locking
bracket.
I & CAUTION: Belt tension rod is spring [
loaded. Have a tight grip on rodand
engage slowly.
°. Connect anti-sway bar to chassis bracket under left
footrest and retain with double loop retainer spring.
If equipped, turn height adjustment knob clockwise to
remove slack from mower suspension.
• Raise deck to highest position.
• Adjust gauge wheels before operating mower as shown
in the Operation section of this manual.
FRONT
SUSPENSION ELECTRIC
BRACKETS CLUTCH PULLEY
FRONT
MOWER LOOP
BRACKET IRETAINER SPRING
PIN
FRONT pLATE
ASSEMBLY
SINGLE
RETAINER
SPRINGS
DOUBLE LOOP
RETAINER
SPRING
USE PLIERS FOR
RETAINER
KJ/ LOOP UP
ANTI-SWA'_
BAR
SUSPENSION ARMS
DOUBLE LOOP
RETAINER SPRING
(OUTWARD POINTING
DECK PINS)
FIG. 6
8
DEFLECTOR
SHIELD
ASSEMBLY
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 MOWER LEVELNESS
For best cutting results, mower 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, mower
drive, and mower blade drive belts in the Service and
Adjustments section of this manual. Verify that the belts are
routed correctly.
,/CHECKL IS T
BEFORE YOUOPERA TEAND ENJOY YOUR NEW TRAC-
TOR, WE WISH TO ASSURE THAT YOU RECEIVE THE
BEST PERFORMANCEAND SA TISFAC TION FROM THIS
QUALITY PRODUC T_
PLEASE REVIEW THE FOLLOWING CHECKLIST"
,/ All assembly instructions have been completed.
,/ No remaining loose parts in carton.
,/ Batteryis 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 ovednflated 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 A TTENTION 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.
,/" Itisimportant topurgethe transmission before operating
your tractor for the first time. Follow proper starting and
transmission purging instructions (See "TO START
ENGINE" and "PURGETRANSMISSION" in Operation
section of this manual).
9
OPERATION
These symbols may appear on your tractor or in literature suppled withthe product. Learn and understand their meaning.
f:l A ,=
BATTERY CAUTION OR REVERSE FORWARD FAST SLOW
WARNING
ENG,NEONENG,NEOFFO,LPRESSOREL,GHTSONOVI,_=P I
FUEL CHOKE MOWER HEIGHT PARKING BRAKE UNLOCKED MOWER LIFT
LOCKED
R
ATFACHMENT REVERSE
CLUTCH ENGAGED
N H L (®>SI
NEUTRAL HIGH LOW
IGNITION ATTACHMENT
CLUTCH DISENGAGED
PARKING BRAKE
KEEP AREA CLEAR SLOPE HAZARDS
(SEE SAFETYRULES SECTION)
DANGER, KEEP HANDS AND FEET AWAY
10
FREE WHEEL
(AutomaticModels only)