Poulan 161608 User Manual

OWNER'S MANUAL

MODEL NO. HD145H42G

14.5 HP 42 Inch Lawn Tractor

• Assembly

• Operation

• Customer Responsibilities

• Service and Adjustments

• Storage

• Troubleshooting

• Repair Parts

For Parts and Service, contact our authorized distributor: call 1-800-849-1297

For Technical Assistance: call 1-800-829-5886

161608 08.01.97 KFSW 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 THROW ING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING

SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

I. GENERAL OPERATION

• Read, understand, and follow all instructions in the manual and on the machine before starting.

• Only allow responsible adults, who are familiar with the in struc tions, 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 is clear of other people before mow ing. 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 back ing.

• Be aware of the mower discharge direction and do not point it at 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 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 un clog ging chute.

• Mow only in daylight or good artiﬁ cial light.

• Do not operate the machine while under the inﬂ uence of alcohol or drugs.

• Watch for trafﬁ c when operating near or crossing roadways.

• Use extra care when loading or unloading the machine into a trailer or truck.

II. SLOPE OPERATION

Slopes are a major factor related to loss-of-control and tipover 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.

Tall 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 at tach ments. These can change the stability of the machine.

• Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction.

• 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 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 if a wheel is over the edge of a cliff or ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction could cause sliding.

• Do not try to stabilize 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. Never assume that children 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 if children enter the area.

• Before and when backing, look behind and down for small 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 extra care in handling gasoline and other fuels. They are ﬂ ammable 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 inside where there is an open

ﬂ ame, 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 op er a tion regularly.

• Keep machine free of grass, leaves, or other debris build-up. Clean oil or fuel spillage. Allow machine to cool 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, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer's rec om mend ed parts, when nec es sary.

• 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.

Look for this symbol to point out im por tant safety precautions. It means CAUTION!!! BE COME ALERT!!! YOUR SAFE TY IS IN VOLVED.

CAUTION: Always disconnect spark plug wire and place wire where it cannot contact spark plug in order to prevent ac ci den tal starting when setting up, trans port ing, adjusting or making re pairs.

WARNING

The engine exhaust from this prod uct con tains chem i cals known to the State of Cal i for nia to cause can cer, birth defects, or other re pro duc tive harm.

CONGRATULATIONS on your purchase of a new tractor. It has

been designed, engineered and manu fac tured 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 tech ni cians and the proper tools to service or repair this tractor.

Please read and retain this manual. The instructions will enable you to assemble and maintain your tractor prop erly. Always observe the “SAFETY RULES”.

MODEL

NUMBER HD145H42G SERIAL NUMBER ____________________________________ DATE OF PURCHASE __________________________ THE MODEL AND SERIAL NUMBERS WILL BE FOUND ON A PLATE

UNDER THE SEAT. YOU SHOULD RECORD BOTH SERIAL NUMBER AND DATE OF PUR-

CHASE AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Follow a regular schedule in maintaining, caring for and using your tractor.

• Follow the instructions under “Customer Re spon si bil i ties” and “Stor age” sec tions of this own er’s manual.

PRODUCT SPECIFICATIONS

HORSEPOWER: 14.5 GASOLINE CAPACITY 2 GALLONS AND TYPE: UNLEADED REGULAR OIL TYPE (API-SF/SG/SH): SAE 30 (above 32°F) SAE 5W-30 (below 32°F) OIL CAPACITY: W/FILTER: 3.5 PINTS

W/O FILTER: 3.0 PINTS SPARK PLUG: CHAMPION RJ19LM (GAP: .030") VALVE CLEARANCE: INTAKE: .005" – .007"

EXHAUST: .009" – .011" GROUND SPEED (MPH): FORWARD: 0.0 - 5.7

REVERSE: 0.0 - 2.7 TIRE PRESSURE: FRONT: 14 PSI

REAR: 12 PSI CHARGING SYSTEM: 3 AMPS BATTERY

5 AMPS HEADLIGHTS BATTERY: AMP/HR: 25

MIN. CCA: 190

CASE SIZE: U1R BLADE BOLT TORQUE: 30–35 FT. LBS.

WARNING: This tractor is equipped with an internal com bus tion engine and should not be used on or near any un im proved 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 mufﬂ er is available through your nearest au tho rized service center/department (See RE PAIR PARTS section of this manual).

In the state of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.

SAFETY RULES ............................................................ 3

PRODUCT SPECIFICATIONS....................................... 3

CUSTOMER RESPONSIBILITIES...................... 3, 15-19

WARRANTY................................................................. 50

ASSEMBLY ................................................................. 6-9

OPERATION ........................................................... 10-14

INDEX

Adjustments:

Brake............................................................ 22

Carburetor ...................................................25

Mower

Front-To-Back......................................... 21

Side-To-Side...........................................21

Throttle Control Cable.................................. 24

Air Filter, Engine....................................................18

Air Screen, Engine ................................................18

Assembly ............................................................ 6-9

Battery:

Charging........................................................7

Cleaning ......................................................17

Starting with Weak Battery ...........................23

Storage ........................................................26

Terminals.....................................................17

Belt:

Motion Drive

Removal/Replacement............................. 22

Mower Belt(s)

Removal/Replacement............................. 22

Blade:

Sharpening .................................................16

Replacement ...............................................16

Brake Adjustment..................................................22

Carburetor Adjustment..........................................25

Controls, Tractor...................................................11

Customer Responsibilities .............................. 15-19

Engine:

Air Filter...................................................18

Air Screen ................................................18

Cooling Fins ............................................18

Engine Oil ...........................................13,17

Fuel Filter................................................. 19

Spark Plug(s)...........................................19

Tractor:

Battery ..................................................... 17

Blade ....................................................... 16

Lubrication Chart .....................................15

Maintenance Schedule.............................15

Tire Care ..........................................7,16,23

Transaxle..................................................17

Cutting Height, Mower..........................................12

Electrical:

Interlocks and Relays ...................................24

Schematic ....................................................29

Wiring Diagram............................................ 30

Engine:

Air Filter.......................................................18

Air Screen ....................................................18

Cooling Fins ................................................18

Oil Change ..................................................17

Oil Level....................................................... 13

Oil Type...................................................13,17

Preparation ..................................................13

Starting ........................................................14

Storage ........................................................26

Filter:

Air Filter.......................................................18

Fuel.............................................................. 19

Fuel:

Type.............................................................13

Storage ........................................................26

Fuse......................................................................24

Hood Removal/Installation....................................24

Leveling Mower Deck............................................ 21

Lubrication:

Chart............................................................15

Engine.......................................................... 17

Maintenance Schedule..........................................15

Mower:

Adjustment, Front-to-Back...........................21

Adjustment, Side-to-Side ............................ 21

Blade Replacement....................................... 16

Blade Sharpening ........................................ 16

Cutting Height.............................................. 12

Installation ...................................................20

Operation ....................................................13

Removal.......................................................20

Mowing Tips.........................................................14

Mufﬂ er ..................................................................19

Spark Arrester ..........................................3,40

Oil:

Cold Weather Conditions........................13,17

Engine.......................................................... 17

Storage .......................................................26

Operation ........................................................ 11-14

Operating Mower .................................................13

MAINTENANCE SCHEDULE ...................................... 15

SERVICE AND AD JUST MENTS ............................ 20-25

STORAGE.................................................................... 26

TROU BLE SHOOT ING............................................27-28

REPAIR PARTS - TRACTOR .................................30-47

PARTS ORDERING/SERVICE ........................................

Options:

Spark Arrester ...........................................3,40

Parking Brake.................................................. 11-12

Parts Bag ................................................................5

Parts, Replacement/Repair .............................. 30-47

Product Speciﬁ cations. ...........................................3

Repair Parts .................................................... 30-47

Safety Rules ............................................................3

Seat......................................................................... 7

Service and Adjustments ................................ 20-25

Carburetor.................................................... 25

Fuse ............................................................24

Hood Removal/Installation...........................24

Motion Drive Belt

Removal/Replacement............................. 22

Mower Belt(s)

Removal/Replacement............................. 22

Mower Adjustment

Front-to-Back.......................................... 21

Side-to-Side ...........................................21

Mower Removal/Installation......................... 20

Tire Care ..............................................7,16,23

Slope Guide Sheet ................................................51

Spark Plug(s)........................................................19

Speciﬁ cations .........................................................2

Starting the Engine.......................................... 13-14

Steering Wheel................................................... 6,23

Stopping the Tractor..............................................12

Storage .................................................................26

Throttle Control Cable Adjustment........................24

Tires.............................................................. 7,16,23

Troubleshooting Chart .................................... 27-28

Transaxle......................................................... 30-47

Warranty..................................................................3

Wiring Diagram..................................................... 30

Wiring Schematic.................................................. 29

CONTENTS OF HARDWARE PACK

Parts Bag contents shown full size

(1) Hex Bolt

3/8-16 x 1

(1) Large Flat Washer

(1) Hex Bolt 5/16-18 x 1-1/4

(1) Lockwasher 3/8

(1) Locknut

5/16-18

Parts packed separately in carton

Seat

Steering

Sleeve

Steering Wheel

(1) Shoulder Bolt 5/16-18

(1) Washer 17/32 x 1-3/16 x 12 Gauge

(2) Hex Bolts 1/4-20 x 3/4

(2) Washers 9/32 x 5/8 x 16 Gauge

(1) Hex Bolt 1/2-13 x 1

(1) Lock Washer 1/2

(2) Hex Nuts 1/4-20

(2) Lock Washers 1/4

Manual

Parts Bag

Parts bag contents not shown full size

(2) Shoulder Bolts

(2) Washers 17/32 x 15/16 x 12 Gauge

Steering Wheel Insert

Slope Sheet

(2) Gauge Wheels

Steering Extension Shaft

(2) Center-

lock Nuts

(2) Washers 3/8 x 7/8 x 14 Gauge

Steering Wheel Adapter

(2) Keys

ASSEMBLY

Your new 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

A socket wrench set will make assembly easier. Stan dard wrench sizes are listed.

(1) 3/4" Socket w/drive rachet Utility knife (2) 7/16" wrenches Tire pressure gauge (2) 1/2" wrenches (1) 9/16" wrench When right or left hand is mentioned in this man ual, it means when you

are in the operating po si tion (seated be hind the steer ing wheel).

TO REMOVE TRACTOR FROM CAR TON

UNPACK CARTON

• Remove all accessible loose parts and parts cartons from carton (See page

5).

• Cut, from top to bottom, along lines on all four corners of carton, and lay panels ﬂ at.

• Check for any additional loose parts or cartons and remove.

BEFORE ROLLING TRACTOR OFF SKID

STEERING WHEEL

ADAPTER

5/16 LOCKNUT

INSERT

3/8 HEX BOLT

3/8 LOCK WASHER

LARGE FLAT WASHER

STEERING BOOT

EXTENSION SHAFT

5/16 HEX BOLT

ATTACH STEERING WHEEL (See Fig. 1)

ASSEMBLE EXTENSION SHAFT AND BOOT

• Slide extension shaft onto lower steering shaft. Align mount ing holes in extension and lower shafts and install 5/16 hex bolt and lock nut. Tighten securely.

IMPORTANT: TIGHTEN BOLT AND NUT 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 straight forward.

• Slide steering wheel adapter onto steer ing shaft ex ten sion.

• Position steering wheel so cross bars are hor i zon tal (left to right) and slide inside boot and onto adapter.

• Assemble large ﬂ at washer, 3/8 lock washer, 3/8 hex bolt and tighten se cure ly.

• Snap steering wheel insert into center of steer ing wheel.

• Remove protective materials from tractor hood and grill.

IMPORTANT: CHECK FOR AND RE MOVE ANY STA PLES IN SKID THAT MAY PUNC TURE TIRES WHERE TRACTOR IS TO ROLL OFF SKID.

LOWER STEERING SHAFT

FIG. 1

TO ROLL TRACTOR OFF SKID (See Op er a tion section for location and function of con trols)

• Press lift lever plunger and raise attachment lift lever to its highest po si tion.

• Release parking brake by depressing clutch/brake ped al.

• Place freewheel control in free wheel ing po si tion to dis en gage transmission (See “TO TRANSPORT” in the Operation section of this manual).

• Roll tractor backwards off skid.

• Remove banding holding discharge guard up against tractor.

ASSEMBLY

HOW TO SET UP YOUR TRACTOR

CONNECT BATTERY (See Figs. 2 and 3)

CAUTION: Do not short battery ter mi nals by allowing a wrench or any other object to contact both terminals at the same time. Before connecting battery, re move metal bracelets, wristwatch bands, rings, etc.

SEAT PAN

Positive terminal must be connected ﬁ rst to prevent sparking from ac ci den tal grounding.

• Remove cardboard packing from seat pan and lift seat pan to raised po si tion.

• Open battery box door.

• Remove terminal protective caps and discard.

• 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.

• First connect RED battery cable to pos i tive (+) terminal with hex bolt, ﬂ at wash er, lock washer and hex nut as shown. Tighten securely.

• Connect BLACK grounding cable to neg a tive (-) ter mi nal with remaining hex bolt, ﬂ at wash er, lock washer and hex nut. Tighten securely.

• Close battery box door.

Open battery box door for:

• Inspection for secure connections (to tighten hard ware).

• Inspection for corrosion.

• Testing battery.

• Jumping (if required).

• Periodic charging .

BATTERY BOX DOOR

FIG. 3

INSTALL SEAT (See Fig. 4)

Adjust seat before tightening adjustment bolt.

• Remove cardboard packing on seat pan.

• Place seat on seat pan and assemble shoul der bolt.

• Assemble adjustment bolt, lock washer and ﬂ at washer loosely. Do not tighten.

• Tighten shoulder bolt securely.

• 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 bolt securely.

DISCARD TERMINAL PRO TEC TIVE CAPS

POSITIVE (RED) CABLE

HEX NUT

NEGATIVE (BLACK) CABLE

FIG. 2

LOCK WASHER

FLAT WASHER

HEX BOLT

SEAT PAN

SHOULDER BOLT

ADJUSTMENT BOLT

SEAT

FLAT WASHER

LOCK WASHER

FIG. 4

ASSEMBLY

ASSEMBLE GAUGE WHEELS TO MOWER DECK (See Fig. 5)

The gauge wheels are designed to keep the mower deck in proper position when operating mower. Be sure they are properly adjusted to ensure

optimum mower performance.

• Assemble gauge wheels with tractor on a ﬂ at level surface.

• Adjust mower to desired cutting height (See “TO AD JUST MOWER CUT TING HEIGHT” in the Operation sec tion of this manual).

• With mower in desired height of cut po si tion, gauge wheels should be assembled so they are slightly off the ground. In stall gauge wheel in appropriate hole with shoulder bolt, 17/32 washer, 3/8 washer, and 3/8-16 lock nut and tight en se cure ly.

• Repeat for opposite side installing gauge wheel in same adjustment hole.

GAUGE WHEEL MOUNTING BRACKET

3/8-16 LOCKNUT

3/8 WASH ER

GAUGE WHEEL

17/32 WASH ER

SHOULDER BOLT

FIG. 5

CHECK TIRE PRESSURE

The tires on your tractor were overinﬂ ated at the factory for shipping purposes. Correct tire pressure is important for best cutting performance.

• Reduce tire pressure to PSI shown in “PRODUCT SPEC I FI CA TIONS” on page 3 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.

See the ﬁ gures that are shown for replacing motion and mower blade drive belts in the Service and Adjustments sec tion of this manual. Verify that the belts are routed correctly.

CHECK BRAKE SYSTEM

After you learn how to operate 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 YOU OPERATE AND ENJOY YOUR NEW TRAC TOR, WE WISH TO ASSURE THAT YOU RECEIVE THE BEST PERFORMANCE AND SATISFACTION FROM THIS QUALITY PRODUCT.

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 inﬂ ated. (For shipping purposes, the tires were over-

inﬂ ated at the factory).

✓ Be sure mower deck is properly leveled side-to-side/front-to-rear for best

cutting results. (Tires must be properly inﬂ ated 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 is at proper level. ✓ Fuel tank is ﬁ lled with fresh, clean, regular unleaded gas o line. ✓ 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 is important to purge the transmission before op er at ing your tractor for

the ﬁ rst time. Follow proper starting and transmission purging instructions (See “TO START EN GINE” and “PURGE TRANSMISSION” in the Op er a tion section of this manual).

CHECK FOR PROPER POSITION OF ALL BELTS

OPERATION

(Hy

These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning.

BATTERY CAUTION OR

WARNING

ENGINE ON ENGINE OFF OIL PRESSURE CLUTCH LIGHTS ON LIGHTS OFF

FUEL CHOKE MOWER HEIGHT DIFFERENTIAL

REVERSE FORWARD FAST SLOW

LOCK

PARKING BRAKE

LOCKED

UNLOCKED

REVERSE NEUTRAL HIGH LOW

MOWER LIFT

DANGER, KEEP HANDS AND FEET AWAY

ATTACHMENT

CLUTCH ENGAGED

PARKING BRAKE

IGNITIONATTACHMENT

CLUTCH DISENGAGED

HYDROSTATIC FREE WHEEL

dro Models onl

OPERATION

KNOW YOUR TRACTOR

READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR

Compare the illustrations with your tractor to familiarize yourself with the locations of various controls and ad just ments. Save this manual for future reference.

CLUTCH/ BRAKE PEDAL

THROTTLE/CHOKE CONTROL

ATTACHMENT CLUTCH LEVER

PARKING BRAKE

LIGHT SWITCH POSITION

IGNITION SWITCH

LIFT LEVER PLUNGER

ATTACHMENT LIFT LEVER

MOWER HEIGHT ADJUSTMENT POSTITIONS

MOTION CONTROL LEVER

FREEWHEEL CONTROL

Our tractors conform to the safety standards of the American National Standards Institute.

ATTACHMENT CLUTCH LEVER : Used to engage the mower blades, or other attachments mounted to your tractor.

LIGHT SWITCH: Turns the headlights on and off. THROTTLE/CHOKE CONTROL - Used for starting and control-

ling engine speed. CLUTCH/BRAKE PEDAL: Used for declutching and brak ing the

tractor and starting the engine. PARKING BRAKE: Locks clutch/brake pedal into the brake posi-

tion. MOTION CONTROL LEVER: Selects the speed and di rec tion

of tractor.

FIG. 6

ATTACHMENT LIFT LEVER - Used to raise and lower the mower

deck or other attachments mounted to your 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 tow ing the trac tor with the engine off.

OPERATION

The operation of any tractor can result in foreign objects thrown into the eyes, which can result in severe eye dam age. Always wear safety glass es or eye shields while operating your tractor or per form ing any adjustments or repairs. We rec om mend a wide vision safety mask over the spectacles or stan dard safety glasses.

HOW TO USE YOUR TRACTOR

TO SET PARKING BRAKE (See Fig. 7)

Your tractor is equipped with an operator presence sens ing switch. When engine is running, any attempt by the op er a tor to leave the seat without ﬁ rst setting the parking brake will shut off the engine.

• Depress clutch/brake pedal into full “BRAKE” position and hold.

• Place parking brake lever in “ENGAGED” position and re lease pressure from clutch/brake pedal. Pedal should re main in “BRAKE” position. Make sure parking brake will hold tractor secure.

ATTACHMENT CLUTCH LEVER

THROTTLE CONTROL

“BRAKE” PO SI TION

CLUTCH/BRAKE PEDAL “DRIVE” POSITION

STOPPING (See Fig. 7)

MOWER BLADES -

• Move attachment clutch lever to “DIS EN GAGED” po si tion.

GROUND DRIVE -

• Depress clutch/brake pedal into full “BRAKE” position.

• Move motion control lever to neutral (N) position.

IMPORTANT: THE MOTION CONTROL LEVER DOES NOT RETURN TO NEUTRAL (N) POSITION WHEN THE CLUTCH/BRAKE PEDAL IS DEPRESSED.

ENGINE -

• Move throttle control to slow position.

NOTE: Failure to move throttle control to slow position and allowing engine to idle before stopping may cause engine to “back ﬁ re”.

• Turn ignition key to “OFF” position and remove key. Always remove key when leaving tractor to prevent un author ized use.

• Never use choke to stop engine.

NOTE: Under certain conditions when tractor is standing idle with the engine running, hot en gine exhaust gases may cause “browning” of grass. To eliminate this possibility, always stop engine when stopping tractor on grass areas.

“ENGAGED” POSITION

“DIS EN G A G E D ” POSITION

PAR K ING BRAKE “EN GAGED” PO SI TION

GEARSHIFT LEVER

“DISENGAGED” POSITION

FIG. 7

CAUTION: Always stop tractor com plete ly, as described above, before leav ing the operator's position; to empty grass catcher, etc.

TO USE THROTTLE CONTROL (See Fig. 7)

Always operate engine at full throttle.

• Operating engine at less than full throttle reduces the battery charging rate.

• Full throttle of fers the best bagging and mower per for mance.

TO MOVE FORWARD AND BACKWARD (See Fig. 7)

The direction and speed of movement is controlled by the motion control lever.

• Start tractor with motion control lever in neutral (N) position.

• Release parking brake and clutch/brake pedal.

• Slowly move motion control lever to desired position.

TO ADJUST MOWER CUTTING HEIGHT (See Fig. 6)

The position of the attachment lift lever determines the cutting height.

• Grasp lift lever.

• Press plunger with thumb and move lever to desired po si tion.

The cutting height range is approximately 1-1/2 to 4". The heights are measured from the ground to the blade tip with the engine not running. These heights are approximate and may vary depending upon soil conditions, height of grass and types of grass being mowed.

• The average lawn should be cut to approximately 2-1/2 inches during the cool season and to over 3 inches during hot months. For healthier and better looking lawns, mow often and after moderate growth.

• For best cutting performance, grass over 6 inches in height should be mowed twice. Make the ﬁ rst cut relatively high; the second to desired height.

OPERATION

TO OPERATE MOWER (See Fig. 8)

Your tractor is equipped with an operator presence sensing switch. Any attempt by the operator to leave the seat with the engine running and the attachment clutch engaged will shut off the engine.

• Select desired height of cut.

• Lower mower with attachment lift control.

• Start mower blades by engaging attachment clutch control.

• TO STOP MOWER BLADES - disengage attachment clutch con trol.

CAUTION: Do not operate the mower without either the en tire grass catcher, on mowers so equipped, or the dis charge guard in place.

"ENGAGED"

AT TACH MENT CLUTCH LEVER "DISENGAGED" PO SI TION

POSITION

ATTACHMENT LIFT LEVER "HIGH" PO SI TION

"LOW" POSITION

TO OPERATE ON HILLS

CAUTION: Do not drive up or down hills with slopes greater than 15° and do not drive across any slope.

• Choose the slowest speed before starting up or down hills.

• Avoid stopping or changing speed on hills.

• If slowing is necessary, move throttle control lever to slower position.

• If stopping is absolutely necessary, push clutch/brake pedal quickly to brake position and engage parking brake.

• Move motion control lever to neutral (N) position.

IMPORTANT: THE MOTION CONTROL LEVER DOES NOT RETURN TO NEUTRAL (N) POSITION WHEN THE CLUTCH/BRAKE PED AL IS DEPRESSED.

• To restart movement, slowly release parking brake and clutch/brake pedal.

• Slowly move motion control lever to slowest setting.

• Make all turns slowly.

TO TRANSPORT (See Figs. 9 and 6 )

When pushing or towing your tractor, be sure to disengage transmission by placing freewheel control in free wheel ing po si tion. Free wheel control is located at the rear drawbar of tractor.

• Raise attachment lift to highest position with at tach ment lift control.

• Pull freewheel control knob out and hold in position by inserting retainer spring into forward hole of control rod.

• Do not push or tow tractor at more than two (2) MPH.

• To reengage transmission, reverse above procedure.

NOTE: To protect hood from damage when transporting your tractor on a truck or a trailer, be sure hood is closed and secured to tractor. Use an appropriate means of tying hood to tractor (rope, cord, etc.).

FIG. 8

FIG. 9

OPERATION

BEFORE STARTING THE ENGINE

CHECK ENGINE OIL LEVEL (See Fig. 12)

• The engine in your tractor has been shipped, from the factory, already ﬁ lled with sum mer weight oil.

• Check engine oil with tractor on level ground.

• Remove oil ﬁ ll cap/dipstick and wipe clean, reinsert the dipstick and screw cap tight, wait for a few seconds, remove and read oil level. If necessary, add oil until “FULL” mark on dipstick is reached. Do not overﬁ ll.

• For cold weather operation you should change oil for easier starting (See “OIL VISCOSITY CHART” in the Customer Responsibilities sec tion of this manual).

• To change engine oil, see the Customer Re spon si bil i ties section in this manual.

ADD GASOLINE

• Fill fuel tank. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. (Use of leaded gasoline will increase carbon and lead oxide deposits and reduce valve life). Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshness.

IMPORTANT: WHEN OP ER AT ING IN TEM PERA TURES BELOW 32°F(0°C), USE FRESH, CLEAN WINTER GRADE GAS O LINE TO HELP INSURE GOOD COLD WEATHER STARTING.

WARNING: Experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and for ma tion 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 stor age of 30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage In struc tions for additional information. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.

CAUTION: Fill to bottom of gas tank ﬁ ller neck. Do not over ﬁ ll. Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open ﬂ ame.

TO START ENGINE (See Fig. 7)

When starting the engine for the ﬁ rst time or if the engine has run out of fuel, it will take extra cranking time to move fuel from the tank to the engine.

• Be sure freewheel control is in the transmission en gaged position.

• Sit on seat in operating position, depress clutch/brake pedal and set parking brake.

• Place motion control lever in neutral (N) position.

• Move attachment clutch to “DISENGAGED” position.

• Move throttle control to choke position.

Note: Before starting, read the warm and cold starting procedures below.

• Insert key into ignition and turn key clockwise to “START” position and release key as soon as engine starts. Do not run starter continuously for more than ﬁ fteen sec onds per minute. If the engine does not start after several attempts, move throttle control to fast position, wait a few minutes and try again. If engine still does not start, move the throttle control back to the choke position and retry.

WARM WEATHER STARTING (50° F and above)

• When engine starts, move the throttle control to the fast position.

• The attachments and ground drive can now be used. If the engine does not accept the load, restart the engine and allow it to warm up for one minute using the choke as described above.

COLD WEATHER STARTING ( 50° F and below)

• When engine starts, allow engine to run with the throttle control in the choke position until the engine runs roughly, then move throttle control to fast position. This may require an engine warm-up period from several seconds to several minutes, depending on the tem per a ture.

HYDROSTATIC TRANSMISSION WARM UP

• Before driving the unit in cold weather, the trans mis sion should be warmed up as follows:

• Be sure the tractor is on level ground.

• Place the motion control lever in neutral. Re lease the parking brake and let the clutch/brake slowly re turn to operating position.

• Allow one minute for transmission to warm up. This can be done during the engine warm up period.

• The attachments can also be used during the engine warm-up period after the transmission has been warmed up.

NOTE: If at a high altitude (above 3000 feet) or in cold temperatures (below 32 F) the carburetor fuel mixture may need to be adjusted for best engine performance. See “TO ADJUST CARBURETOR” in the Service and Adjustments section of this manual.

OPERATION

PURGE TRANSMISSION

CAUTION: Never engage or disengage freewheel lever while the engine is run-

ning.

To ensure proper operation and performance, it is rec om mend ed that the transmission be purged before operating tractor for the ﬁ rst time. This procedure will remove any trapped air inside the transmission which may have de vel oped during shipping of your tractor.

IMPORTANT: SHOULD YOUR TRANSMISSION RE QUIRE REMOVAL FOR SERVICE OR REPLACEMENT, IT SHOULD BE PURGED AFTER REINSTALLATION BEFORE OPERATING THE TRACTOR.

• Place tractor safely on level surface with engine off and parking brake set.

• Disengage transmission by placing freewheel control in freewheeling position (See “TO TRANSPORT” in this sec tion of manual).

• Sitting in the tractor seat, start engine. After the engine is running, move throttle control to slow position. With motion control lever in neutral (N) po si tion, slowly disengage clutch/brake pedal.

• Move motion control lever to full forward position and hold for ﬁ ve (5) seconds. Move lever to full reverse position and hold for ﬁ ve (5) seconds. Repeat this procedure three (3) times.

NOTE: During this procedure there will be no movement of drive wheels. The air is being removed from hydraulic drive system.

• Move motion control lever to neutral (N) position. Shut- off engine and set parking brake.

• Engage transmission by placing freewheel control in driving position (See “TO TRANSPORT” in this sec tion of manual).

• Sitting in the tractor seat, start engine. After the engine is running, move throttle control to half (1/2) speed. With motion control lever in neutral (N) position, slowly disengage clutch/brake pedal.

• Slowly move motion control lever forward, after the tractor moves approximately ﬁ ve (5) feet, slowly move motion control lever to reverse position. After the tractor moves approximately ﬁ ve (5) feet return the motion control lever to the neutral (N) position. Repeat this procedure with the motion control lever three (3) times.

• Your tractor is now purged and now ready for normal op er a tion.

MOWING TIPS

• Tire chains cannot be used when the mower hous ing is attached to tractor.

• Mower should be properly leveled for best mowing per for mance. See “TO LEVEL MOWER HOUSING” in the Service and Adjustments section of this manual.

• The left hand side of mower should be used for trim ming.

• Drive so that clippings are discharged onto the area that has been cut. Have the cut area to the right of the tractor. This will result in a more even dis tri bu tion of clippings and more uniform cutting.

• When mowing large areas, start by turning to the right so that clippings will discharge away from shrubs, fences, drive ways, etc. After one or two rounds, mow in the opposite direction making left hand turns until ﬁ nished (See Fig.

10).

• If grass is extremely tall, it should be mowed twice to reduce load and possible ﬁ re hazard from dried clip pings. Make ﬁ rst cut relatively high; the second to the desired height.

• Do not mow grass when it is wet. Wet grass will plug mower and leave undesirable clumps. Allow grass to dry before mowing.

• Always operate engine at full throttle when mowing to assure better mowing performance and proper dis charge of ma te ri al. Regulate ground speed by se lect ing a low enough gear to give the mower cut ting performance as well as the quality of cut desired.

• When operating attachments, select a ground speed that will suit the terrain and give best performance of the at tach ment being used.

FIG. 10

CUSTOMER RESPONSIBILITIES

MAINTENANCE SCHEDULE

FILL IN DATES AS YOU COMPLETE REGULAR SERVICE

Check Brake Operation

Check Tire Pressure

Check for Loose Fasteners

Sharpen/Replace Mower Blades

Lubrication Chart

Check Battery Level/Recharge

Clean Battery and Terminals

0 R

Check Transaxle Cooling

Adjust Blade Belt(s) Tension

Adjust Motion Drive Belt(s) Tension

Check Engine Oil Level

Change Engine Oil

Clean Air Filter

Clean Air Screen

Inspect Muffler/Spark Arrester

Replace Oil Filter (If equipped)

Clean Engine Cooling Fins

Replace Spark Plug

Replace Air Filter Paper Cartridge

Replace Fuel Filter

1 - Change more often when operating under a heavy load or in high ambient temperatures. 2 - Service more often when operating in dirty or dusty conditions. 3 - If equipped with oil filter, change oil every 50 hours. 4 - Replace blades more often when mowing in sandy soil.

BEFORE EACH USE

✔ ✔

✔

✔✔ ✔

✔

✔ ✔

✔ ✔ ✔

✔

1 2,3

✔

SERVICE DATES

✔

5 - If equipped with adjustable system. 6 - Not required if equipped with maintenance-free battery. 7 - Tighten front axle pivot bolt to 35 ft.-lbs. maximum. Do not overtighten.

GENERAL RECOMMENDATIONS

The warranty on this tractor does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must main tain tractor as instructed in this manual.

Some adjustments will need to be made periodically to properly maintain your tractor.

All adjustments in the Service and Adjustments section of this manual should be checked at least once each season.

• Once a year you should replace the spark plug, clean or replace air ﬁ lter, and check blades and belts for wear. A new spark plug and clean air ﬁ lter assure proper air-fuel mixture and help your engine run better and last longer.

BEFORE EACH USE

• Check engine oil level.

• Check brake operation.

• Check tire pressure.

• Check for loose fasteners.

LUBRICATION CHART

SPINDLE ZERK

FRONT WHEEL BEARING ZERK

ATTACHMENT CLUTCH PIVOT(S)

SAE 30 OR 10W30 MOTOR OIL

GENERAL PURPOSE GREASE

REFER TO CUSTOMER RESPONSIBILITIES “ENGINE” SECTION

IMPORTANT: DO NOT OIL OR GREASE THE PIVOT POINTS WHICH HAVE SPECIAL

NYLON BEARINGS. VISCOUS LU BRI CANTS WILL ATTRACT DUST AND DIRT THAT WILL SHORT EN THE LIFE OF THE SELF-LU BRI CAT ING BEARINGS. IF YOU FEEL THEY MUST BE LU BRI CAT ED, USE ONLY A DRY, POW DERED GRAPHITE TYPE LU BRI CANT SPARINGLY.

SPINDLE ZERK

FRONT WHEEL BEARING ZERK

ENGINE

CUSTOMER RESPONSIBILITIES

TRACTOR

Always observe safety rules when performing any main te nance.

BRAKE OPERATION

If tractor requires more than six (6) feet stopping distance at high speed in highest gear, then brake must be adjusted. (See “TO ADJUST BRAKE” in the Service and Ad just ments section of this manual).

TIRES

• Maintain proper air pressure in all tires (See “PROD UCT SPECIFICATIONS” on page 3 of this man ual).

• Keep tires free of gasoline, oil, or insect control chemi cals which can harm rubber.

• Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage.

NOTE: To seal tire punctures and prevent ﬂ at tires due to slow leaks, tire sealant may be purchased from your local parts dealer. Tire sealant also prevents tire dry rot and corrosion.

BLADE CARE

For best results mower blades must be kept sharp. Re place bent or damaged blades.

BLADE REMOVAL (See Fig. 11)

• Raise mower to highest position to allow access to blades.

• Remove hex bolt, lock washer and ﬂ at washer securing blade.

• Install new or resharpened blade with trailing edge up towards deck as shown.

• Reassemble hex bolt, lock washer and ﬂ at washer in exact order as shown.

• Tighten bolt securely (30-35 Ft. Lbs. torque).

IMPORTANT: BLADE BOLT IS GRADE 8 HEAT TREATED.

NOTE: We do not recommend sharpening blade - but if you do, be sure the blade is balanced.

TO SHARPEN BLADE (See Fig. 12)

Care should be taken to keep the blade balanced. An unbalanced blade will cause excessive vibration and even tual damage to mower and engine.

• The blade can be sharpened with a ﬁ le or on a grinding wheel. Do not attempt to sharpen while on the mower.

• To check blade balance, you will need a 5/8" diameter steel bolt, pin, or a cone balancer. (When using a cone balancer, follow the instructions supplied with bal anc er).

• Slide blade on to an unthreaded portion of the steel bolt or pin and hold the

MANDREL

BLADE

FLAT WASHER

LOCK WASHER

ASSEMBLY

TRAILING EDGE

bolt or pin parallel with the ground. If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced.

NOTE: Do not use a nail for balancing blade. The lobes of the center hole may appear to be centered, but are not.

CENTER HOLE

5/8" BOLT OR PIN

BLADE

FIG. 12

BATTERY

Your tractor has a battery charging system which is suf ﬁ cient for normal use. However, periodic charging of the battery with an automotive charger will extend its life.

• Keep battery and terminals clean.

• Keep battery bolts tight.

• Keep small vent holes open.

• Recharge at 6-10 amperes for 1 hour.

TO CLEAN BATTERY AND TERMINALS Corrosion and dirt on the battery and terminals can cause the battery to

“leak” power.

• Open battery box door.

• Disconnect BLACK battery cable ﬁ rst then RED bat tery cable and remove battery from tractor.

• Rinse the battery with plain water and dry.

• Clean terminals and battery cable ends with wire brush until bright.

• Coat terminals with grease or petroleum jelly.

• Reinstall battery (See “CONNECT BATTERY” in the As sem bly sec tion of this manual).

HEX BOLT (GRADE 8)*

*A GRADE 8 HEAT TREATED BOLT CAN BE

IDENTIFIED BY SIX LINES ON THE BOLT HEAD.

FIG. 11

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