Poulan 163022 User Manual

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Page 1

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OWNER'S MANUAL

MODEL NO. HD145H42H

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

HLE

COPY

Poulan

163022 11.13.97 RD

PRINTED IN U.S.A.

Page 2

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.

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 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 is clear 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. 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 unclogging

chute.

Mow only in daylight 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 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 ordeath. All slopes require extra

caution. If you cannot back up the

slope or if you feel uneasy on it, do pot 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. Ta// 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 stow 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 aiert 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 cari^ 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

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 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 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, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer's recommended parts, when nec

essary.

• 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 portant safety precautions. It means CAUTION!!! BECOME ALERT!!! YOUR

SAFETY IS INVOLVED. CAUTION: Always disconnect spark plug

wire and place wire where it cannot contact spark plug in order to prevent accidental

starting when setting up, transporting, adjusting or making repairs.

A WARNING ^

The engine exhaust from this product con

tains chemicals known to the State of Califor nia to cause cancer, birth defects, or other reproductive harm.

Page 3

CONGRATULATIONS on your purchase of a 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 tech

nicians 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 properly. Always observe the “SAFETY RULES”.

MODEL NUMBER

HD145H42H SERIAL NUMBER DATE OF PURCHASE. THE MODELANDSERIALNUMBERSWILL BE FOUND

ON A PLATE UNDER THE SEAT. YOU SHOULD RECORD BOTH SERIAL NUMBER AND

DATE OF PURCHASE AND KEEP IN A SAFE PLACÉ FOR FUTURE REFERENCE. .

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Followa regular schedule in maintaining, caring forand using your tractor.

• Follow the instructions under “Customer Responsibili

ties” and “Storage” sections of this owner’s manual.

PRODUCT SPECIFICATIONS

HORSEPOWER: 14.5 GASOLINE CAPACITY

AND TYPE: OIL TYPE (API-SF/SG/SH): SAE 30 (above 32°F)

OIL CAPACITY: SPARK PLUG:

(GAP: .030“)

VALVE CLEARANCE:

GROUND SPEED (MPH): FORWARD: 4.7

TIRE PRESSURE:

CHARGING SYSTEM: 3 AMPS BATTERY

BATTERY:

BLADE BOLT TORQUE:

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, 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 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.

2 GALLONS UNLEADED REGULAR

SAE 5W-30 (below 32°F)

3.0 PINTS

CHAMPION RJ19LM

INTAKE: .005" - .007“ EXHAUST: .009"-.011"

REVERSE: 2.2 FRONT: 14PSI

REAR: 12 PSI

5 AMPS HEADLIGHTS AMP/HR: 25

MIN. CCA: 190 CASE SIZE; U1R

27-35 FT. LBS.

Page 4

TABLE OF CONTENTS

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

PRODUCT SPECIFICATIONS CUSTOMER RESPONSIBILITIES

................................................ 3

........

.......................

3. 15-19

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

ASSEMBLY OPERATION

..........

.................................................................

.......................................................................

6-9

10-14

INDEX

Adjustments;

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

Carburetor Mower

Throttle Control Cable Air Filter, Engine Air Screen, Engine Assembly

......................................

Front-To-Back Side-To-Side

.................................................

............................

...............................

.....................

......................................

...................................

Battery:

Charging

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

Starting with Weak Battery

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

Terminals Belt:

Motion Drive

Mower Belt(s)

Biade:

Sharpening

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

Brake Adjustment

.............................................

..........................................

Rem ovat/Replacem ent Removal/Replacement

......................................

....................................22

Carburetor Adjustment Controls, Tractor Customer Responsibilities

Engine:

Air Filter........................................

Air Screen Cooling Fins

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

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

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

T ractor:

Battery

..........................................

Blade

............................................

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

Maintenance Schedule Tire Care Transaxle

Cutting Height, Mower

............................

.....................................

................

.....................................

.................................

................

...............................

......................................

.............................

Electrical:

Interlocks and Relays Schematic

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

.........................................

......................

.............

...............

15-19

7,16,23

21 21

24 18 18

6-9

23 17

22 22

18 18 18

17 12

24 29

Engine:

Air Filter

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

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

Oil Change.....................................

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

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

Preparation Starting Storage

Filter:

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

Fuel

Fuel:

Type Storage

Fuse..........................................................

Hood Removal/lnstallation

Leveling Mower Deck Lubrication:

Chart

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

Maintenance Schedule

Mower:

Adjustment, Front-to-Back

Adjustment, Side-to-Side

Blade Replacement Blade Sharpening

Cutting Height

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

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

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

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

Muffler.......................................................19

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

Oil:

Cold Weather Conditions

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

Storage

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

Operating Mower

.........................................

.............................................

...........................................

...........

..................................................

.........................

.................................................

.............................................

MAINTENANCE SCHEDULE....................................

SERVICE AND ADJUSTMENTS

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

TROUBLESHOOTING

REPAIR PARTS - TRACTOR

PARTS ORDERING/SERVICE...................BACK COVER

......................................

.....................................

i....

.......... 26

.....................

............................

...........................

............

...............

.........................

............................

..................................

..........

.....................................

:i9

21 21

13,17

13 14

16 12

............................

..........................................

.................................

Options:

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

20-25

27-28

30-47

Parking Brake Parts Bag

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

Product Specifications

...................................

.............................................

.............................

11-12

Repair Parts

....................................

30-47

Safety Rules Seat

...........................................................

Service and Adjustments .................

Carburetor

Tire Care

Slope Guide Sheet

Spark Plug(s) Specifications Starting the Engine Steering Wheel Stopping the Tractor

Storage....

Throttle Control Cable Adjustment Tires

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

T ransaxle............................................30-47

Warranty Wiring Diagram Wiring Schematic

...............................................

Fuse Hood Removal/1 nstallation Motion Drive Belt

Mower Belt(s)

Mower Adjustment

Mower Removal/lnstallation

....................

................................................

Removal/Replacement Removal/Replacement

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

Side-to-Side

...................................

..................................

...........................................

............................................

............................

.....................................

...............................................

1..................25

...........

..............

...............................

...........

...............................

..................................................

.....................................................

........................................

....................................

20-25

24 22 22

7,16,23

13-14

6,23

........

7,16,23

Page 5

CONTENTS OF HARDWARE PACK

Parts Bag contents shown full size

(1) Hex Bolt

3/8-16 X 1

(1) Large Flat Washer '' ' ^ (1) Lockwasher 3/8

(1) Locknut

5/16-18

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

Parts packed separately in carton

Seat

Steering

Sleeve

Steering Wheel

(1) Shoulder Bolt 5/16-18 (1) Hex Bolt 1/2-13 x 1

(1) Lock Washer 1/2

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

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

(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

i ^ I Ipgg^

Wheel

(2) Gauge Wheels

Steering Extension Shaft

(2) Center-

lock Nuts

(2) Washers 3/8

X 7/8 X 14 Gauge

—1 —,3—

Steering Wheel

Adapter

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

(2) Keys

Slope Sheet

Page 6

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. Standard wrench sizes are listed.

(1) 3/4“ Socket w/drive rächet

(2) 7/16" wrenches (2) 1/2" wrenches (1) 9/16" wrench

When right or left hand is mentioned in this manual, it

means when you are in the operating position (seated behind the steering wheel).

TO REMOVE TRACTOR FROM CARTON

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 flat.

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

Utility knife Tire pressure gauge

BEFORE ROLLING TRACTOR OFF 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 locknut. 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 steering shaft exten sion.

• 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 wheel insert 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.

TO ROLL TRACTOR OFF SKID (See Opera tion section for location and function of con trols)

• Press lift lever plunger and raise attachment lift (ever to its highest position.

• Release parking brake by depressing clutch/brake pedal.

• Place freewheel control in freewheeling position to disengage transmission (See “TO TRANSPORT in the Operation section of this manual).

• Roll tractor backwards off skid.

• Remove banding holding discharge guard up against tractor.

Page 7

ASSEMBLY

HOW TO SET UP YOUR TRACTOR

CONNECT BATTERY (See Figs. 2 and 3)

CAUTION: Do not short battery termi nals by allowing a wrench or any other

object to contact both terminals at the same time. Before connecting battery, remove metal bracelets, wristwatch bands, rings, etc.

Positive terminal must be connected first to prevent sparking from acciden tal grounding.

• Remove cardboard packing from seat pan and lift seat pan to raised position,

• 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-tO amps.

• First connect RED battery cable to positive (+) terminal with hex bolt, flat washer, lock washer and hex nut as shown. Tighten securely.

• Connect BLACK grounding cable to negative (-) termi nal with remaining hex bolt, flat washer, 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 .

DISCARD TERMINAL PROTECTIVE CAPS

BATTERY BOX DOOR

RG.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 shoulder bolt.Tighten shoulder bolt securely.

• Assemble adjustment bolt, lock washer 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 bolt securely.

POSITIVE (RED) CABLE

LOCK WASHER

FLAT WASHER

NEGATIVE

(BLACK) CABLE

FIG. 2

FIG. 4

Page 8

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 flat level surface.

• Adjust mower to desired cutting height (See ‘TO AD

JUST MOWER CUTTING HEIGHT in the Operation section of this manual).

• With mower in desired height of cut position, gauge wheels should be assembled so they are slightly off the ground. Install gauge wheel in appropriate hole with shoulder bolt, 17/32 washer, 3/8 washer, and 3/8-16

' locknut and tighten securely.

• Repeat for opposite side installing gauge wheel in

same adjustment hole.

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” 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.

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 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

TRACTOR, WE WISH TOASSURE THAT YOU RECEIVE THE BEST PERFORMANCE AND SA TISFACTION 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 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.

WHILELEARNING HOWTO USE YOUR TRACTOR, PA Y

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 is important to purge the transmission before operat-

Op-

eration section of this manual).

Page 9

OPERATION

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

Q A

BATTERY

CAUTION OR REVERSE

WARNING

STOP

ENGINE ON ENGINE OFF OIL PRESSURE CLUTCH LIGHTS ON OVER TEMP

FUEL

l\l mif ^

CHOKE MOWER HEIGHT DIFFERENTIAL PARKING BRAKE UNLOCKED

FORWARD FAST SLOW

a| ©1

LIGHT

LOCK LOCKED

R N H L (®)|I

ÎL

REVERSE NEUTRAL HIGH

MOWER LIFT

DANGER, KEEP HANDS AND FEET AWAY

ATTACHMENT

CLUTCH ENGAGED

LOW

ATTACHMENT

CLUTCH DISENGAGED

PARKING BRAKE

IGNITION

....

4-is

HYDROSTATIC FREE WHEEL

(Hydro Models only)

Page 10

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 adjustments. Save this manual for future reference.

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

controlling engine speed. CLUTCH/BRAKE PEDAL: Used for declutching and

braking 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 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 towing the tractor with the engine off.

Page 11

OPERATION

The operation of any tractor can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your tractor or performing any adjustments or repairs. We recommend a wide vision safety mask over the spectacles or standard safety glasses.

HOW TO USE YOUR TRACTOR

TO SET PARKING BRAKE (See Fig. 7)

Your tractor is equipped with an operator presence sensing switch. When engine is running, any attempt by the operator to leave the seat without first 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

release pressure from clutch/brake pedal. Pedal should remain in “BRAKE” position. Make sure parking brake

will hold tractor secure.

STOPPING (See Fig. 7J

MOWER BLADES -

• Move attachment clutch lever to “DISENGAGED” po sition.

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 “backfire”.

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

• Never use choke to stop engine.

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

CAUTION: Always stop tractor com pletely, as describe 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 offers the best bagging and mower perfor 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 position.

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 first cut relatively high; the second to desired height.

Page 12

OPERATION

TO OPERATE MOWER (See Fig. 8)

Yourtractor 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 control.

CAUTION: Do not operate the mower

without either the entire grass catcher, on mowers so equipped, or the dis

charge guard in place.

TO OPERATE ON HILLS

CAUTION: Do not drive up or down

• 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 PEDAL 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.

hills with slopes greater than 15° and do not drive across any slope.

TO TRANSPORT (See Figs. 9 and 6 )

When pushing or towing your tractor, be sure to disengage transmission by placing freewheel control in freewheeling position. Free wheel control is located at the rear drawbar of tractor.

• Raise attachment lift to highest position with attach 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. 9

Page 13

OPERATION

BEFORE STARTING THE ENGINE

CHECK ENGINE OIL LEVEL (See Fig. 12)

• The engine in your tractor has been shipped, from the factory, already filled with summer weight oil.

• Check engine oil with tractor on level ground.

• Remove oil fill 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 overfill.

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

• To change engine oil, see the Customer Responsibili 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 OPERATING IN TEMPERATURES

BELOW 32°F(0“C), USE FRESH. CLEAN WINTER GRADE GASOLINE 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 formation of acids during storage. Acidic gas can darnage 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 Instruc 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 filler neck. Do not overfill. Wipe off any

spilled oil or fuel. Do not store, spill or use gasoline near an open flame.

TO START ENGINE (See Fig. 7)

When starting the engine for the first 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 fifteen 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 engineto 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 perature.

HYDROSTATIC TRANSMISSION WARM UP

• Before driving the unit in cold weather, the transmis

sion should be warmed up as follows:

• Be sure the tractor is on level ground.

• Place the motion control lever in neutral. Release the parking brake and let the clutch/brake slowly return 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 afterthetransmission 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.

Page 14

OPERATION

PURGE TRANSMISSION

CAUTION: Never engage or disengage

freewheel lever while the engine is run

To ensure proper operation and performance, it is recom

mended that the transmission be purged before operating tractor for the first time. This procedure will remove any

trapped air inside the transmission which may have devel

oped during shipping of your tractor.

IMPORTANT: SHOULD YOURTRANSMISSION REQUIRE

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 section of manual).

• Sitting in the tractor seat, start engine. Afterthe engine is running, move throttle control to slow position. With motion control lever in neutral (N) position, slowly

disengage clutch/brake pedal.

• Move motion control lever to full forward position and hold for five (5) seconds. Move lever to full reverse position and hold for five (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 section of manual).

• Sitting in the tractor seat, start engine. Afterthe 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 five (5) feet, slowly move motion control lever to reverse position. After the tractor moves approximately five (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 operation.

ning.

MOWING TIPS

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

• Mower should be properly leveled for best mowing performance. 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 distribution 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, driveways, etc. After one or two rounds, mow in the opposite direction making left hand turns until finished (See Fig. 10).

• If grass is extremely tall, it should be mowed twice to

reduce load and possible fire hazard from dried clip pings. Make first 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 material. Regulate ground speed by select

ing a low enough gear to give the mower cutting 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 attachment being used.

Page 15

CUSTOMER RESPONSIBILITIES

MAINTENANCE SCHEDULE

FILL IN DATES AS YOU COMPLETE REGULAR SERVICE

Check Brake Operation Check Tire Pressure Check for Loose Fasteners Shatpen/Replace Mower Blades Lubrication Chart Check Battery Level/Recharge Clean Battery and Terminals 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 - Sen/ice more often when operating in dirty or dusty conditions. 3 - If equipped with oil fiiter, change oii every 50 hours. 4 - Replace blades more often when mowing in sandy soil.

✓ ✓

§/ t/

✓

✓ 4

✓ ✓ l/e

✓ ✓

✓

1^2,3

✓ 2 ✓ 2

✓

SERVICE DATES

✓ 7

✓ 5 ✓ s

i^.2

✓

§/"2

✓

✓ 2

✓

5 - If equipped with adjustable system., 6 - Not required if equipped with maintenance-free battery. 7 - Tighten front axle pivot bolt to 35 fL-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 maintain 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 filter, and check blades and belts for

wear. A new spark plug and clean air filter 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

0SAE 30 OR 10W30 MOTOR OIL ©GENERAL PURPOSE GREASE

©REFER TO CUSTOMER RESPONSIBILITIES “ENGINE” SECTION

IMPORTANT: DO NOT OIL OR GREASE THE PIVOT POINTS

VVHICH HAVE SPECIAL NYLON BEARINGS. VISCOUS LUBRI CANTS WILL ATTRACT DUST AND DIRT THAT WILL SHORTEN THE LIFE OF THE SELF-LUBRICATING BEARINGS. IF YOU FEEL THEY MUST BE LUBRICATED, USE ONLY A DRY, POW DERED GRAPHITE TYPE LUBRICANT SPARINGLY.

Page 16

CUSTOMER RESPONSIBILITIES

TRACTOR

Always observe safety rules when performing any mainte 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 Adjust ments section of this manual).

TIRES

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

• 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 flat 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.

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 file 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

ancer).

• Slide blade onto an unthreaded portion of the steel bolt

or pin and hold the 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.

BLADE REMOVAL (See Fig. 11)

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

• Remove hex bolt, lock washer and flat washer securing

blade.

» Install new or resharpened blade with trailing edge up

towards deck as shown.

• Reassemble hex bolt, lock washer and flat washer in

exact order as shown.

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

IMPORTANT: BLADE BOLT IS GRADE 8 HEATTREATED.

NOTE: We do not recommend sharpening blade - but if you

do, be sure the blade is balanced.

BATTERY

Your tractor has a battery charging system which is suffi 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 first 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 petroleurti jelly.

• Reinstall battety (See “CONNECT BATTERY" in the Assembly section of this manual).

Page 17

CUSTOMER RESPONSIBILITIES

V-BELTS

Check V-belts for deterioration and wear after 100 hours of operation and replace if necessary. The belts are not

adjustable. Replace belts if they begin to slip from wear.

TRANSAXLE COOLING

The fan and cooling fins of transmission should be kept clean to assure proper cooling.

Do not attempt to clean fan or transmission while engine is running or while the transmission is hot.

• Inspect cooling fan to be sure fan blades are intact and clean.

• Inspect cooling fins for dirt, grass clippings and other materials. To prevent damage to seals, do not use compressed air or high pressure sprayer to clean cooling fins.

TRANSAXLE PUMP FLUID

The transaxle was sealed at the factory and fluid mainte

nance is not required for the life of the transaxle. Should the transaxle ever leak or require servicing, contact your near est authorized service center/department.

ENGINE

LUBRICATION

Only use high quality detergent oil rated with API service classification SF, SG, or SH. Select the oil’s SAE viscosity grade according to your expected operating temperature.

TO CHANGE ENGINE OIL (See Fig. 13)

Determine temperature range expected before oil change.

All oil must meet API service classification SF, SG or SH.

• Be sure tractor is on level surface.

• Oil will drain more freely when warm.

• Catch oil in a suitable container.

• Remove oil fill cap/dipstick. Be careful not to allow dirt to enter the engine when changing oil.

• Remove drain plug.

• After oil has drained completely, replace oil drain plug and tighten securely.

• Refill engine with oil through oil fill dipstick tube. Pour slowly. Do not overfill. For approximate capacity see "PRODUCT SPECIFICATIONS" on page 3 of this manual.

• Use gauge on oil fill cap/dipstickforchecking level. Be sure dipstick cap is tightened securely for accurate

..........................;“Fr -

reading. Keep oil at “FULL” line on dipstick.

..........................

NOTE: Although multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, these multi-viscosity oils

will result in increased oil consumption when used above

32°F. Check your engine oil level more frequently to avoid possible engine damage from running low on oil.

Change the oil after every 50 hours of operation or at least

once a year if the tractor is not used for 50 hours in one year. Check the crankcase oil level before starting the engine

and after each eight (8) hours of operation. Tighten oil fill cap/dipstick securely each time you check the oil level.

Page 18

CUSTOMER RESPONSIBILITIES

AIR FILTER (See Fig. 14A)

Your engine will not run properly using a dirty air filter.

Clean the foam pre-cleaner after every 25 hours of opera

tion or every season. Service paper cartridge every 100

hours of operation or every season, whichever occurs first.

Service air cleaner more often under dusty conditions.

• Remove knob(s) and cover. TO SERVICE PRE-CLEANER

• Slide foam pre-cleaner off cartridge.

• Wash it in liquid detergent and water.

• Squeeze it dry in a clean cloth.

• Saturate it in engine oil. Wrap it in clean, absorbent cloth and squeeze to remove excess oil.

• If very dirty or damaged, replace pre-cleaner.

• Reinstall pre-cleaner over cartridge.

• Reinstall cover and secure with knob(s).

TO SERVICE CARTRIDGE

• Remove cartridge nut.

• Carefully remove cartridge to prevent debris from en tering carburetor. Clean base carefully to prevent

debris from entering carburetor.

• Clean cartridge by tapping gently on fiat surface. If very dirty or damaged, replace cartridge.

• Reinstall cartridge, nut, precleaner, cover and secure with knob(s).

IMPORTANT: PETROLEUM SOLVENTS, SUCH AS

KEROSENE, ARE NOT TO BE USED TO CLEAN THE CARTRIDGE. THEY MAY CAUSE DETERIORATION OF

THE CARTRIDGE. DO NOT OIL CARTRIDGE. DO NOT

USE PRESSURIZED AIR TO CLEAN OR DRY CARTRIDGE.

ENGINE OIL FILTER (See Fig. 14B)

Replace the engine oil filter every season or every other oil change if the tractor is used more than 100 hours in one year.

• Unscrew old fiiter by turning counterclockwise. Use a suitable container to catch oil.

• Apply a thin coating of new engine oil to rubber gasket on replacement oil filter.

• Install replacement oil filter by turning clockwise until

rubber gasket contacts mounting surface, then tighten

filter an additional 1/2 to 3/4 turn.

• Fill crankcase with new oil (See “TO CHANGE EN GINE OIL” in this section of this manual). For approxi mate capacity see “PRODUCT SPECIFICATIONS” on page 3 of this manual.

• Start engine and check for oil leaks. Correct any leaks before placing engine into full operation.

ENGINE COOLING FINS (See Fig. 15)

Remove any dust, dirt or oil from engine cooling fins to prevent engine damage from overheating.

• Remove screws from blower housing and lift housing and dipstick tube assembly off engine.

• Cover oil fill opening to prevent entry of dirt.

• Use compressed air or stiff bristle brush to thoroughly clean engine cooling fins.

CLEAN AIR SCREEN (See Fig. 14A)

Air screen must be kept free of dirt and chaff to prevent engine damage from overheating. Clean with a wire brush or compressed air to remove dirt and stubborn dried gum fibers.

FIG. 15

Page 19

CUSTOMER RESPONSIBILITIES

MUFFLER

Inspect and replace corroded muffler and spark arrester (if

equipped) as it could create a fire hazard arld/or damage.

SPARK PLUGS

Replace spark plugs at the beginning of each mowing season or after every 100 hours of operation, whichever occurs first. Spark plug type and gap setting are shown in “PRODUCT SPECIFICATIONS” on page 2 of this manual.

IN-LINE FUEL FILTER (See Fig. 16)

The fuel filter should be replaced once each season. If fuel filter becomes clogged, obstructing fuel flow to carburetor,

replacement is required.

• With engine cool, remove filter and plug fuel line sections.

» Place new fuel filter in position in fuel line with arrow

pointing towards carburetor.

» Be sure there are no fuel line leaks and clamps are

properly positioned.

• Immediately wipe up any spilled gasoline.

CLEANING

• Clean engine, battery, seat, finish, etc. of all foreign matter.

• Keep finished surfaces and wheels free of all gasoline, oil, etc.

• Protect painted surfaces with automotive type wax.

We do not recommend using a garden hose to clean your tractor unless the electrical system, muffler, air filter and

carburetor are covered to keep water out. Water in engine

can result in a shortened engine life.

Page 20

SERVICE AND ADJUSTMENTS

CAUTION: BEFORE PERFORMINC3 ANY SERVICE OR ADJUSTMENTS:

• Depress clufch/brake pedal fully and set parking brake.

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

TRACTOR TO REMOVE MOWER (See Fig. 17)

Mower will be easier to remove from the right side of tractor.

• Place attachment clutch in “DISENGAGED” position.

• Move attachment lift leverforward to lower mowerto its lowest position.

• Roll belt off engine pulley.

• Disconnect clutch rod from dutch lever by removing retainer spring.

• Disconnect anti-sway bar from chassis bracket by removing retainer spring.

• Disconnect suspension arms from rear deck brackets

by removing retainer springs.

• Disconnect front links from deck by removing retainer springs.

• Raise lift lever to raise suspension arms. Slide mower out from under tractor.

IMPORTANT; IF AN ATTACHMENT OTHER THAN THE

MOWER IS TO BE MOUNTED TO THE TRACTOR, THE R.H. AND LH. SUSPENSION ARMS MUST BE REMOVED FROM TRACTOR.

TO INSTALL MOWER (See Fig. 17)

• Raise attachment lift lever to its highest position.

• Slide mower u nder tractor with discharge guard to right side of tractor.

• Lower lift lever to its lowest position.

• Install mower in reverse order of removal instructions.

• Place attachment clutch in “DISENGAGED” position.

• Turn ignition key “OFF” and remove key.

• Make sure the blades and ail moving parts have completely stopped.

• Disconnect spark plug wire from spark plug and place wire where it cannot come in contact

with plug.

RETAINER SPRINGS

(BOTH SIDES)

RETAINER SPRINGS

(BOTH SIDES)

FIG. 17

Page 21

SERVICE AND ADJUSTMENTS

TO LEVEL POWER HOUSING

Adjust the mower while tractor is parked on level ground or driveway. Make sure tires are properly inflated (See “PRODUCT SPECIFICATIONS” on page 2 of this manual).

If tires are over or underinflated, you will not properly adjust

your mower. SIDE-TO-SIDE ADJUSTMENT (See Figs. 18 and 19)

• Raise mower to its highest position.

• At the midpoint of both sides of mower, measure height from bottom edge of mowerto ground. Distance “A” on both sides of mower should be the same or within 1/4" of each other.

• If adjustment is necessary, make adjustment on one side of mower only.

• To raise one side of mower, tighten lift link adjustment

nut on that side.

• To lower one side of mower, loosen lift link adjustment

nut on that side.

NOTE: Three full turns of adjustment nut will change mower height about 1/8“.

• Recheck measurements after adjusting.

FRONT-TO-BACK ADJUSTMENT (See Figs. 20 and 21)

IMPORTANT: DECK MUST BE LEVEL SIDE-TO-SIDE. IF

THE FOLLOWING FRONT-TO-BACK ADJUSTMENT IS NECESSARY, BE SURE TO ADJUST BOTH FRONT LINKS EQUALLY SO MOWER WILL STAY LEVEL SIDE-TOSIDE.

To obtain the best cutting results, the mower housing should be adjusted so that the front is approximately 1 /8" to 1/2“ lower than the rear when the mower is in its highest position.

Check adjustment on right side of tractor. Measure dis tance “D” directly in front and behind the mandrel at bottom edge of mower housing as shown.

• Before making any necessary adjustments, check that both front links are equal in length. Both links should be approximately 10-3/8".

• If links are not equal in length, adjust one link to same length as other link.

• To lower front of mower loosen nut “E” on both front links an equal number of turns.

• When distance “D” is 1/8“ to 1/2“ lower at front than rear, tighten nuts “P against trunnion on both front links.

• To raise front of mower, loosen nut “P from trunnion on both front links. Tighten nut “E” on both front links an equal number of turns.

• When distance “D” is 1/8" to 1/2" lower at front than rear, tighten nut “P against trunnion on both front links.

• Recheck side-to-side adjustment.

Page 22

SERVICE AND ADJUSTMENTS

TO REPLACE MOWER BLADE DRIVE BELT

(See Fig. 22)

The mower blade drive belt may be replaced without tools.

Park the tractor on level surface. Engage parking brake. BELT REMOVAL -

• Remove mower from tractor (See ‘TO REMOVE MOWER” in this section of this manual).

• Work belt off both mandrel pulleys and idler pulleys.

• Pull belt away from mower.

BELT INSTALLATION -

• Install new belt in reverse order of removal.

• Make sure belt is in all pulley grooves and inside all belt guides.

• Install mower in reverse order of removal instructions.

TO ADJUST BRAKE (See Fig. 23)

Your tractor is equipped with an adjustable brake system which is mounted on the side of the transaxle.

If tractor requires more than six (6) feet stopping distance

at high speed in highest gear, then brake must be adjusted.

• Depress clutch/brake pedal and engage parking brake.

• Measure distance between brake operating arm and nut “A” on brake rod.

• If distance is other than 1-3/4", loosen jam nut and turn nut “A” until distance becomes 1-3/4". Retighten jam nut against nut “A”.

• Road test tractorfor proper stopping distance as stated

above. Readjust if necessary. If stopping distance is still greater than six (6) feet in highest gear, further

maintenance is necessary. Contact your nearest au

thorized sen/ice center/department.

WITH PARKING BRAKE “ENGAGED”

DO NOT TOUCH THIS NUT. IF FURTHER BRAKE ADJUSTMENT IS NECESSARY CONTACT YOUR NEAREST AUTHORIZED SERVICE CENTER/DEPARTMENT

FIG. 23

TO REPLACE MOTION DRIVE BELT (See Fig. 24)

Park the tractor on level surface. Engage parking brake. For assistance, there is a belt installation guide decal on bottom side of left footrest.

• Remove mower (See ‘TO REMOVE MOWER” in this section of this manual.)

• Remove upper belt keeper.

• Remove belt from stationary idler and clutching idler.

• Pull belt slack toward rear of tractor. Carefully remove belt upwards from transmission input pulley and over cooling fan blades.

• Pull belt toward front of tractor and remove downward from around engine pulley.

• Install new belt by reversing above procedure.

IMPORTANT: MAKE SURE UPPER BELT KEEPER IS

POSITIONED PROPERLY BETWEEN LOCATOR TAB.

FIG. 24

Page 23

SERVICE AND ADJUSTMENTS

TO ADJUST STEERING WHEEL ALIGNMENT

If steering wheel crossbars are not horizontal (left to right)

when wheels are positioned straightforward, remove steer

ing wheel and reassemble per instructions in the Assembly

section of this manual.

FRONT WHEEL TOE-IN/CAMBER

The front wheel toe-in and camber are not adjustable on your tractor. If damage has occurred to affect the front wheel toe-in or camber, contact your nearest authorized

service center/departmeht.

TO REMOVE WHEEL FOR REPAIRS (See Fig. 25)

• Block up axle securely.

• Remove axle cover, retaining ring and washers to allow wheel removal (rear wheel contains a square key - Do not lose).

• Repair tire and reassemble.

• On rear wheels only: align grooves in rear wheel hub and axle. Insert square key.

• Replace washers and snap retaining ring securely in axle groove.

• Replace axle cover.

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

WASHERS

RETAINING RING

AXLE COVER

SQUARE KEY (REAR WHEEL ONLY)

FIG. 25

Page 24

SERVICE AND ADJUSTMENTS

TO START ENGINE WITH A WEAK BATTERY

(See Fig. 26)

CAUTION: Lead-acid batteries gener ate explosive gases. Keep sparks, flame and smoking materials away from bat

If your battery is too weak to start the engine, it should be recharged. If "jumper cables” are used for emergency starting, follow this procedure:

IMPORTANT; YOUR TRACTOR IS EQUIPPED WITH A 12

VOLT NEGATIVE GROUNDED SYSTEM. THE OTHER VEHICLE MUST ALSO BE A 12 VOLT NEGATIVE GROUNDED SYSTEM. DO NOT USE YOUR TRACTOR BATTERY TO START OTHER VEHICLES,

TO ATTACH JUMPER CABLES -

• Connect each end of the RED cable to the POSITIVE

(+) terminal of each battery, taking care not to short against chassis.

• Connect one end of the BLACK cable to the NEGA

TIVE (-) terminal of fully charged battery.

• Connect the other end of the BLACK cable to good

CHASSIS GROUND, away from fuel tank and battery.

TO REMOVE CABLES, REVERSE ORDER -

• BLACK cable first from chassis and then from the fully

charged battery.

• RED cable last from both batteries.

teries. Always wear eye protection when around batteries.

TO REPLACE HEADLIGHT BULB

• Raise hood.

• Puli bulb holder out of the hole in the backside of the grill.

• Replace bulb in holder and push bulb holder securely back into the hole in the backside of the grill.

• Close hood.

INTERLOCKS AND RELAYS

Loose or damaged wiring may cause your tractor to run poorly, stop running, or prevent it from starting.

• Check wiring. See electrical wiring diagram in the Repair Parts section of this manual.

TO REPLACE FUSE

Replace with 30 amp automotive-type plug-in fuse. The fuse holder is located behind the dash.

TO REMOVE HOOD AND GRILL ASSEMBLY (See Fig. 27)

• Raise hood.

• Unsnap headlight wire connector.

• Stand in front of tractor. Grasp hood at sides, tilt toward engine and lift off of tractor.

• To replace, reverse above procedure.

POSITIVE TERMINAL NEGATIVE TERMINAL

CHASSIS-

POSITIVE TERMINAL

FIG. 26

NEGATIVE TERMINAL

■ CABLES

CHARGED BATTERY

Page 25

SERVICE AND ADJUSTMENTS

ENGINE

TO ADJUST THROTTLE CONTROL CABLE (See Fig. XX)

The throttle control has been preset at the factory and adjustment should not be necessary. Check adjustment as described below before loosening cable. If adjustment is necessary, proceed as follows;

• With engine not running* move throttle control lever from slow to choke position. Slowly move lever from choke to fast position.

• Check that holes “A” in governor control lever and hole

in governor plate line-up. If holes “A” are not aligned, loosen clamp screw and move throttle cable until holes are aligned. Tighten clamp screw securely.

PRELIMINARY SETTING -

• Air cleaner assembly must be assembled to the carbu retor when making carburetor adjustments.

• Be sure the throttle control cable is adjusted properly (see above).

FINAL SETTING -

• Start engine and allow to warm for five minutes. Make final adjustments with engine running and shift/motion controi lever in neutrai (N) position.

• Move throttle control lever to slow position. With finger, rotate and hold throttle lever against idle speed screw. Turn idle speed screw to attain 1750 RPM.

• While still holding throttle lever against idle speed screw, turn idle mixture valve full travel clockwise then counterclockwise until engine runs rough. Turn valve to a point midway between those two positions. Re

lease throttle lever.

ACCELERATION TEST -

• Move throttle control lever from slow to fast position. If engine hesitates or dies, turn idie mixture vaive out

(counterclockwise) 1 /8 turn. Repeat test and continue to adjust, if necessary, until engine accelerates smoothly.

High speed stop is factory adjusted. Do not adjust damage may result.

IMPORTANT: NEVER TAMPER WITH THE ENGINE

GOVERNOR, WHICH IS FACTORY SET FOR PROPER ENGINE SPEED. OVERSPEEDING THE ENGINE ABOVE THE FACTORY HIGH SPEED SETTING CAN BE DANGEROUS. IF YOU THINK THE ENGINE-GOVERNED HIGH SPEED NEEDS ADJUSTING, CONTACT YOUR NEAREST AUTHORIZED SERVICE CENTER/ DEPARTMENT, WHICH HAS PROPER EQUIPMENT AND EXPERIENCE TO MAKE ANY NECESSARY

ADJUSTMENTS.

TO ADJUST CARBURETOR (See Fig. 2B)

NOTE: The carburetor on this engine is low emission. It is equipped with an idle fuel adjusting needle with a limiter cap, which allows some adjustment within the limits al

lowed by the cap. Do not attempt to remove the lirhiter cap. The limiter cap cannot be removed without breaking the adjusting needle.

The carburetor has been preset at the factory and adjust

ment should not be necessary. However, minor adjust ment may be required to compensate fordifferences in fuel, temperature, altitude or load. If the carburetor does need adjustment, proceed as follows:

In general, turning idle mixture valve in (clockwise) de

creases the supply of fuel to the engine giving a leaner fuel/

air mixture. Turning the idle mixture valve out (counter clockwise) increases the supply of fuel to the engine giving

a richer fuel/air mixture.

IMPORTANT: DAMAGE TO THE NEEDLE VALVE AND

THE SEAT IN CARBURETOR MAY RESULT IF SCREW IS TURNED IN TOO TIGHT.

Page 26

STORAGE

Immediately prepare your tractor for storage at the end of the season or if the tractor will not be used for 30 days or more.

CAUTION: Never store the tractor with gasoline in the tank inside a building where fumes may reach an open fiame

or spark. Allow the engine to cool before storing in any enciosure.

TRACTOR

Remove mower from tractor for winter storage. When

mower is to be stored for a period of time, clean it thor

oughly, remove all dirt, grease, leaves, etc. Store In a

clean, dry area.

• Clean entire tractor (See “CLEANING” in the Customer Responsibilities section of this manual).

• Inspect and replace belts, if necessary (See belt re placement instructions in the Service and Adjustments section of this manual).

• Lubricate as shown in the Customer Responsibilities section of this manual.

• Be sure that all nuts, bolts and screws are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary.

• Touch up all rusted or chipped paint surfaces; sand lightly before painting.

BATTERY

• Fully charge the battery for storage.

• After a period of time in storage, battery may require recharging.

• To help prevent corrosion and power leakage during long periods of storage, battery cables should be disconnected and battery cleaned thoroughly (see ‘TO CLEAN BATTERY AND TERMINALS” in. the Cu$-;

tomer Responsibilities section of this manual).

• After cleaning,'leave cables disconnected and place

cables where they cannot come in contact with battery terminals.

• Be sure battery drain tube is securely attached.

• If battery Is removed from tractor for storage, do not store battery directly on concrete or damp surfaces.

ENGINE

FUEL SYSTEM

IMPORTANT: IT IS IMPORTANT TO PREVENT GUM DEPOSITS FROM FORMING IN ESSENTIAL FUEL SYSTEM PARTS SUCH AS CARBURETOR, FUEL FILTER, FUEL HOSE, OR TANK DURING STORAGE. ALSO, EXPERIENCE INDICATES THAT ALCOHOL BLENDED FUELS (CALLED GASOHOL OR USING ETHANOL OR

METHANOL) CAN ATTRACT MOISTURE WHICH LEADS TO SEPARATION AND FORMATION OF ACIDS DURING STORAGE. ACIDIC GAS CAN DAMAGE THE FUEL SYSTEM OF AN ENGINE WHILE IN STORAGE.

« Drain the fuel tank.

• Start the engine and let it run until the fuel lines and carburetor are empty.

• Never use engine or carburetor cleaner products in the fuel tank of permanent damage may occur.

• Use fresh fuel next season.

NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during stor age. Add stabilizer to gasoline in fuel tank or storage container. Always follow the mix ratio found on stabilizer container. Run engine at least 10 minutes after adding stabiIizer to allow the stabiIizer to reach the carburetor. Do not drain the gas tank and carburetor if using fuel stabilizer.

ENGINE OIL

Drain oil (with engine warm) and replace with clean engine oil. (See “ENGINE” in the Customer Responsibilities section of this manual).

CYLINDERS

Remove spark plug(s). Pour one ounce of oil through spark plug hole(s) into

cylinder(s). Turnjgnitiqn key to “START position for a few seconds

to distribute oil. Replace with new spark plug(s).

OTHER

Do not store gasoline from one season to another. Replace your gasoline can if your can starts to rust.

Rust and/or dirt in your gasoline will cause problems. If possible, store your tractor indoors and cover it to

give protection from dust and dirt. Cover your tractor with a suitable protective coverthat

does not retain moisture. Do not use plastic. Plastic cannot breathe which allows condensation to form and will cause your tractor to rust.

IMPORTANT: NEVER COVER TRACTOR WHILE ENGINE

AND EXHAUST AREAS ARE STILL WARM.

Page 27

TROUBLESHOOTING POINTS

PROBLEM CAUSE CORRECTION

Will not start 1. Otrt of fuel. 1. Fill fuel tank.

Hard to start 1. Dirty air filter.

Engine will not turn over 1. Clutch/brake pedal not depressed.

2. Engine not “CHOKED" property. 2.

Engine flooded.

4. Bad spark plug.

5. Dirty air filter.

6. Dirty fuel filter.

Water in fuel. Loose or damaged wiring. 8. Check all wiring.

8. Carburetor out of adjustment.

9. Engine valves out of adjustment. 10. Contact an authorized service center/department.

10.

Bad spark plug.

3. Weak or dead battery. 3.

4. Dirty fuel filter.

5. Stale or dirty fuel.

6. Loose or damaged wiring.

Carburetor out of adjustment.

8. Engine valves out o1 adjustment.

2. Attachment Clutch is engaged. Weak or dead battery. 3.

3. Blown fuse.

.4.

5. Corroded battery terminals.

6. Loose or damaged wiring.

7. Faulty ignition switch.

8. Faulty solenoid or starter.

9. Faulty operator presence switch(es).

See “TO START ENGINE” in Operation section.

Wait several minutes before attempting to start.

Replace spark plug.

5. Clean/replace air filter.

Replace fuel filter.

Drain fuel tank and carburetor, refill tank with fresh gasoline and replace fuel filter.

See "To Adjust Carburetor” in Service Adjustments section.

1. Clean/replace air filter.

2. Replace spark plug. Recharge or replace battery.

4. Replace fuel filter.

5. Drain fuel tank and refill with fresh gasoline.

6. Check all wiring.

See “To Adjust Carburetor” in Service Adjustments

\ section.

8. Contact an authorized service center/department.

1. Depress clutch/brake pedal. Disengage attachment clutch.

2. Recharge or replace battery.

Replace fuse.

Clean battery terminals.

6. Check all wiring. Check/replace ignition switch.

8. Check/replace solenoid or starter.

Contact an authorized service center/department.

Engine clicks but will not 1. Weak or dead battery. start

Loss of power 1. Cutting too much grass/loo fast. 1. Set in “Higher Cut” position/reduce speed.

Excessive vibration 1,

Corroded battery terminals.

3. Loose or damaged wiring.

4. Faulty solenoid or starter.

2. Throttle in “CHOKE” position.

Build-up of grass, leaves and trash under mower.

Dirty air filter.

Low oil level/dirty oil.

6. Faulty spark plug.

7. Dirty fuel filter. 7. Replace fuel filter;

8. Stale or dirty fuel. 8. Drain fuel tank and refill with fresh gasoline.

9. Water in fuel. 9. Drain fuel tank and carburetor, refill tank with fresh

10. Spark plug wire loose. 10. Connect and tighten spark plug wire;

11.

Dirty engine air screen/fins.

12. Dirty/clogged muffler. 12.

13. Loose or damaged wiring. 13. Check all wiring.

14.

Carburetor out of adjustment.

15.

Engine valves out of adjustment.

Worn, bent or loose blade.

Bent blade mandrel.

Loose/damaged part(s).

1. Recharge or replace battery.

2. Clean battery terminals.

3. Check all wiring.

Check/replace solenoid or starter.

Adjust throttle control.

3. Clean underside of mower housing. Clean/replace air filter.

Check oil level/change oil.

Clean and regap or change spark plug.

gasoline and replace fuel filter.

Clean engine air screen/fins.

11. Clean/replace muffler.

14.

See To Adjust Carburetor” in Service Adjustments section.

15. Contact an authorized service center/department.

Replace blade. Tighten blade bolt.

Replace blade mandrel.

Tighten loose part(s). Replace damaged parts.

Page 28

TROUBLESHOOTING POINTS

PROBLEM

Engine continues to run when operator leaves seat with attachment clutch

engaged

Poor cut - uneven

Mower blades will not rotate

Poor grass discharge

CAUSE

1. Faulty operator-safety presence control system.

1. Worn, bent or loose blade.

2. Mower deck not level.

3. Buildup of grass, leaves, and trash under mower.

4. Bent blade mandrel.

5. Clogged mower deck vent holes from buildup of

grass, leaves, and trash around mandrels.

1. Obstnjction In clutch mechanism.

2. Wom/damaged mower drive belt.

3. Frozen idler pulley.

4. Frozen blade mandrel.

1. Engine speed too slow.

2. Travel speed too fast.

3. Wet grass.

4. Mower deck not level.

5. Low/uneven tire air pressure.

6. Worn, bent or loose blade.

7. Buildup of grass, leaves and trash under mower.

8. Mower drive belt worn.

9. Blades improperly installed,

to. improper blades used.

11. Clogged mower deck vent holes from buildup of grass, leaves, and trash around mandrels.

CORRECTION

1. Check wiring, switches and connections. If not corrected, contact an authorized service center/ department.

1. Replace blade. Tighten blade bolt.

2. Level mower deck.

3. Clean underside of mower housing.

4. Replace blade mandrel.

5. Clean around mandrels to open vent holes.

1. Remove obstruction.

2. Replace mower drive belt.

3. Replace idler pulley.

4. Replace blade mandrel.

1. Place throttle control in “FAST position.

2. Shift to slower speed.

3. Allow grass to dry before mowing.

4. Level mower deck.

5. Check tires for proper air pressure.

6. Replace/sharpen blade. Tighten blade bolt.

7. Clean underside of mower housing. 8; Replace mower drive belt.

9. Reinstall blades sharp edge down.

10. Replace with blades listed in this manual.

11. Clean around mandrels to open vent holes.

Headlight(s) not working

(if so equipped]

1. Switch Is “OFF”.

2. Buib(s) burned out.

3. Faulty light switch.

4. Loose or damaged wiring.

5. Blown fuse.

Battery will not charge

1. Bad battery cell(s).

2. Poor cable connections.

3. Faulty regulator (if so equipped).

4. Faulty alternator.

Loss of drive 1. Freewheel control in “disengaged" position.

2. Motion drive belt worn, damaged, or broken.

3. Air trapped in transmission during shipment or servicing.

Engine “backfires” when turning engine

1. Engine throttle control not set at “SLOW”

position for 30 seconds before stopping engine.

“OFF”

1. Turn switch “ON”.

2. Replace bulb(s).

3. Check/rèplace light switch.

4. Check wiring and connections.

5. Replace fuse.

1. Replace battery.

2. Check/clean all connections.

3. Replace regulator.

4. Replace alternator.

1. Place freewheel control in "engaged” position.

2. Replace motion drive belt.

3. Purge transmission.

1. Move throttle control to “SLOW” position and allow to Idle for 30 seconds before stopping engine.

Page 29

SCHEMATIC

TRACTOR - - MODEL NUMBER HD145H42H

BLACK

IGNITION SWITCH

POSITION

OFF

RUN/LIGHT

RUN

START

CIRCUIT “MAKE”

G + M + L NONE

B + L+S

B + L B + L

A + Y NONE NONE

NOTE

YOUR TRACTOR IS EQUIPPED WITH A SPECIAL ALTERNATOR SYSTEM. THE LIGHTS ARE NOT CONNECTED TO THE BATTERY. BUT HAVE THEIR

L0-J

OWN ELECTRICAL SOURCE. BECAUSE OF THIS, THE

HEADLIGHTS

BRIGHTNESS OF THE LIGHTS

WILL CHANGE WITH ENGINE

SPEED. AT IDLE THE LIGHTS WILL DIM. AS THE ENGINE IS SPEEDED UP, THE LIGHTS WILL BECOME THEIR BRIGHTEST,

NON-REMOVABLE

CONNECTIONS

WIRING INSULATED CLIPS

NOTE: IF WIRING INSULATED CLIPS WERE REMOVED FOR SERVICING OF UNIT, THEY SHOULD BE REPLACED TO PROPERLY SECURE YOUR WIRING.

BUCK I

REMOVABLE

Page 30

REPAIR PARTS

ELECTRICAL

TRACTOR - - MODEL NUMBER HD145H42H

Page 31

REPAIR PARTS

ELECTRICAL

TRACTOR - - MODEL NUMBER HD145H42H

KEY PART NO. NO. DESCRIPTION

1 144925 Battery 12 Volt 25 Amp

74760412

2 3 19091016 Washer 9/32 X 5/8 X 16 Ga

10040400

4 6 73220400 Nut Fin Hex 1/4-20 Unc

156417

153664

10090400

73350400 Nut Jam Hex 1/4-20 Unc

136850

21 22 4152J

4799J

146147'

108824X

4207J

121305X

140301 Switch Ign 4 Pos W/L P/L

30 31 12421IX

141226

122147X

33 40 156442 41

71110408 42 131563 Cover Terminal Red 43 145673 Solenoid 44 73640400 48 140844 52 141940 Protection Loop

140422 Harness Eng B&S 14 OHV Dual

Bolt Hex Hd 1/4-20unc X 3/4

Washer Lock Hvy Helical 1/4

Case Battery Mech Hinge Switch Interlock Push-In

Washer Lock 1/4 Harness Socket Light

Bulb, Light # 1156 Cable Starter 6ga 11" Bed

Cable Battery 6 Ga Red w/16 wire

Fuse 30 Amp Auto Green Cable Ground 6ga 12"black Switch Plunger Nc Gray

Nut Ignition Cover Sw Key Key Ign Molded Generic Harness Ign Bolt Fin Hex 1/4-20uncx 1/2

Nut Keps BIk Fin Hex 1/4-20 Unc x 1/2

Adapter Ammeter Rectangular

NOTE: All component dimensions given in U.S. inches

1 inch = 25.4 mm

Page 32

REPAIR PARTS

TRACTOR - - MODEL NUMBER HD145H42H

CHASSIS AND ENCLOSURES

Page 33

REPAIR PARTS

TRACTOR - - ^ODEL NUMBER HD145H42H

CHASSIS AND ENCLOSURES

KEY

NO.

10 11 155927 Panel Asm. Dash Lh 12 13 14 17490608 15 16 17 159639X428

18 126938X 20 156437 Plate Mtg Battery/Fuel Tank 23 124028X 24 74780616 Bolt Fin Hex 3/8-16 Unc x 1 Gr. 5 25 19131312 26 73800600 28 157373 Grill Private Lable BIk 29 140273 30 157583X428 Fender Asm LT w/Shift MS-428 31 136619 Bracket Fender 33 34 105475X428 Footrest Pnt. Rh Ms-428 35 72110606 Bolt RdHd Sht. Sqnk. 3/8-16x 3/4 37 38 139886 Bracket Asm. Pvt. Lh Mwr. Rear 39 139887 Bracket Asm. Pvt. Rh Mwr. Rear

52 19091416 Washer 9/32 x 7/8 x 16 Ga. 53 144697 Bracket Grille LH 54 161464

55 57 74780412

58 150127 Air Duct Private Label

140 145

NOTE: All component dimensions given in U.S. inches

PART NO.

1 160393 Chassis WIdmt. 2 140356 3 17490612 Screw Thdrol. 3/8-16 x 3/4Ty-Tt 4 19131216 5 155272 6 155923 Saddle Fender Shift Flat 8 155138

161937X011 Dash Private Label

72140608 Bolt RdHd Sqnk. 3/8-16 Line x 1 145660

155934X010 74180512 Screw Mach Trhd 5/16-18 Unc x 3/4

73510500 Nut Keps 5/16-18 Unc

105476X428

17490508

73800400 Nut Lock Hex W/lns. 1 /4-20

144696

158418

156524 Rod Pivot Chassis/Hood

5479J

1 inch = 25.4 mm

DESCRIPTION

Drawbar Stretch 94 Washer 13/32 x 3/4 x 16 Ga.

Bumper Hood/Dash Clip Retainer Slide-On

Clip Tinnerman Grile P/L Panel Dash Rh Screw Thdrol. 3/8-16 x 1/2 Ty-Tt

Hood Pnt Steel Private Label Bumper Hood

Bushing Snap Nyl. BIk Fuel Line Washer 13/32 x 13/16 x 12 Ga.

Nut Lock Hex w/lnsert 3/8-16 UNC Lens Grille Private label

Footrest Pnt. Lh Ms-428

Screw Thdrol. 5/16-18 x 1/2 Tyt

Screw hex Wshd 8-18 x 7/8 Bracket, Grille RH Bolt Fin Hex 1/4-20 x .75

Bracket Suspension Front Plug Btn BIk

Page 34

REPAIR PARTS

DRIVE

TRACTOR - ~ MODEL NUMBER HD145H42H

ri'

^ I

¡I ^ 0’ 6^

Si-"

Page 35

REPAiR PARTS

DRIVE

TRACTOR - " MODEL NUMBER HD145H42H

KEY NO.

10 76020416 15 74490544 Bolt Hex FLGHD 5/16-18 Gr. 5 73 141418

16 73800500 Nut, Lock Hex w/lns 5/16-18 UNC 18 19 73800600 Nut, Lock Hex w/Wsh 3/8-16 UNC 76 21 106933X 22 145627 24 25 106888X 26 27 76020412 28 145204 29 30 130807 32 74760512 34 35 120183X 36 37 1572H Pin, Roll 38 123674X 39 74760644 40 4470J Spacer, Split 41 154777 42 19131312 47 127783 48 49 123205X 50 74760624 51

52 73680500 53 10571 OX

55 105709X

56 74760620 57 161850 59 61 17490612 62 63 64 71170764

PART

NO.

140607 Transaxle (See Breakdown) Hydro 65

142431

144698

141003

74780616 Bolt Hex 3/8-16 UNC x 1 Gr.5

73350600 Nut 81

19131316

71673

155071 19211616 Washer 93

154407

73680600 Nut

140312 8883R

161399

DESCRIPTION NO.

Gr Model 0310-0500 Spring, Return, Brake Pulley, Transmission Rod, Shift Pin, Cotter 1/8x1

Knob Rd. 1/2-13 Piste. Thds. BIk. Rod, Brake

Spring, Rod, Brake

Washer 13/32 x 13/16 x 16 Ga.

Pin, Cotter 1/8 X 3/4 Rod, Parking Brake 86 157480 Cap, Parking Brake 87 Bracket, Transmission Bolt Hex 5/16-18 UNC x 3/4 Shaft, Foot Pedal 91 Bearing, Nylon 92

Pulley, idler. Flat 95 Bolt 96 4479H

Keeper, Beit

Washer 13/32 x 13/16 x 12 Ga.

Pulley, idler, V-Belt Beilcrank Clutch Grnd Drv Stv Retainer, Belt 105

Bolt 106 Nut Crownlock 5/16-18 109 145098

Link, Clutch 116 Spring, Return, Clutch Bolt, Hex 3/8-16 UNC x 1-1/4 148 159103 V-Belt, Drive 149 122052X Keeper, Belt, Center 150 Screwj Thdrol 3/8-16 x 3/4 Type TT Cover, Pedal Pulley, Engine Bolt Hex 7/16x4 Gr.5

KEY PART

NO.

10040700 Washer 66 161488 69

142432 70

134683

141417 Strap, Torque, Lh

19132012 Washer 13/32 x 1-1/4 x 12 Ga.

74 121199X

75 121749X

12000001

77 123583X 78 121748X

161081

82 123782X 83 19171216 Washer 17/32 x 3/4 x 16 Ga. 84

141423

19212016 Washer 21/32 x 1-1/4 x 16 Ga.

12000008 Ring, Clip

88 89 151147

74780536

74780524 Bolt Hex 5/16-18 UNC x 1-1/2

142564

140462

144643

144201

73510600 Nut Keps 3/8-16 UNC

19111216

100

73940800

103 104

141421

71070516

74780520

: 108

17541026

72110610

144 19111016 Washer 11/32 x 5/8 x 16 Ga.

150935

19133210

151

NOTE: All component dimensions give in U.S. inches,

inch =

DESCRIPTION

Keeper, Belt Engine Hydro Screw

Guide, Belt, Mower Drive RH

Strap, Torque, Rh Spacer, Split Washer 25/32 x 1-1/4 x 16 Ga. Ring, E

Key, Square Washer 25/32 x 1-5/8 x 16 Ga. Asm, Shaft

Spring, Torsion

Rod, Tie

Bushing, Steering Rod

Console, Shift

Bolt Hex 5/16-18x2-1/4 Line Fuel

Fanr Control Asm Bypass Hydro

Spring, Retainer 1"

Keeper, Belt Rh Washer 11/32 x 3/4 x 16 Ga.

Nut Hex Jam Toplock 1/2-20 UNF Arm, Control Pump 500 Hydro

Bolt, Head Hex 5/16x18x1

Bolt H 5/16-18 UNC X 1-1/4 Screw Hex Wh Hd #10-24 x 1 -5/8 Adaptor Fan Hydro Lt Hyd Alum Bolt Carriage 3/8-16x1.25

Spacer Spacer Retainer Pm Mower Bushing Nylon Collered Washer 13/32 x2 x 10 Ga.

25.4 mm.

Page 36

REPAIR PARTS

STEERING ASSEMBLY

-L.

37-

TRACTOR - - MODEL NUMBER HD145H42H

-38

-11

-39

-41

-42

-37

--36

Page 37

REPAIR PARTS

STEERING ASSEMBLY

TRACTOR -^MODEL NUMBER HD14SH42H

KEY

NO.

10 156438 Link Drag Extended Stamped 11 10040600 Washer Lock Hvy Hid Spr 3/8 13 154779 Bearing /\xle 15 73901000 Nut Lock Flange 5/8-11 Unc 17

18 57079 Washer Thrust 515x 750x 033

19 124035X 20 126684X 22 71200410 23 25 154406 26 126847X Bushing Link Drag BIk LR 27 28 29 17490612 Screw Thdrol 3/8-16x3/4 Ty-tt 30 76020412 Pin Cotter 1/8 X 3/4 Cad 32 130465 Rod Tie Wire Form 19 75 Mech 36 155099 Bushing Steering 37 152927 38 140045 Cap Wheel Steer Ayp 39

40 41 100711L Adapter Wheel Strg 42 145054 43 121749X 44 46 47 51 73800500 Nut Lock Hex W/lns. 5/16-18 Unc P 54 62 156594 Kit Steering Assembly Service 63 65 154780 Spacer Axle 66 154404 Bearing Arm Pittman 67 68 154429 Brace /kxle

NOTE: All component dimensions given in U.S. inches

PART NO.

140044 Wheel Steering Ayp/kelch BIk

2 154427

3 156483 4

157473 Spindle Asm RH

6266H 6 121748X Washer 25/32 X 1-5/8 X 16 Ga 7

19272016

8 12000029 Ring Klip #15304-75

3366R Bearing Col Strg BIk

156546' Shaft Asm Strg

127501 Shaft Asm Pittman

136874

19131416

19133808

781 OH

153720 Extension Steering 121232X Cap Spindle FrTop BIk 6855M Fitting Grease

74780520 Bolt Fin Hex 5/16-18 Unc P 74780616

74781044

1 inch = 25.4 mm

DESCRIPTION

Axle Asm Fr Spindle Asm LH

Bearing Race Thrust Harden Washer 27/32 X 1-1/4 X 16 Ga

Support Shaft Washer Shim 1/4 X 5/8 X 062 Screw Hex Socket 1/4-20 x 5/8

Bracket Steering Gear Sector 22 Teeth

Washer 13/32 X 7/8 X 16 Ga

Screw Washer 13/32 x 2-3/8 x 8 Ga

Nut Lock Center 3/8-24 Unf Boot Dash P/L Steering

Washer 25/32 X 1 1/4 X 16 Ga

Bolt Fin Hex 3/8-16unc x 1 Gr. 5

Bolt Fin Hex 5/8r11 Unc x 2-3/4

37'

Page 38

REPAIR PARTS

SEAT ASSEMBLY

TRACTOR - - MODEL NUMBER HD145H42H

KEY PART NO. NO.

1 140116 2 140551 3 74760616 4 19131610 5

145006

73800600

124181X

17490616

19131614

155925 121246X

12 13 121248X

72050412

DESCRIPTION

Seat 2300/1316 BIk/bIk AYPPL Bracket Pivot Seat 8 720 Bolt Fin Hex 3/8-16 Unc x 1 Washer Flat 13/32 x 1 x 10 Ga Clip Push In Hinged Nut Crownlock 3/8-16 Unc Spring Seat Cprsn 2 250 Bik 2i Screw Thdrol 3/8-16 X 1 Ty-tt Washer 13/32X 1 X 14 Ga Pan Seat Bracket Mounting Switch Bushing Snap BIk Nyl 50 Id Bolt Rdhd Sht Nk 1/4-20x1-1/2

KEY NO.

15 134300

16 121250X

17 123976X 18 124238X 21 153236

22 73680500

23 74780814 24 19171912

25 127018X

26 10040800

NOTE: All component dimensions given in U.S. inches

PART NO.

1 inch = 25.4 mm

DESCRIPTION

Spacer Split 28x 96 Yel Zinc Spring Cprsn 1 27 Bik Pnt

Nut Lock 1/4 Lge Fig Gr 5 Zinc Cap Spring Seat Bolt Shoulder 5/16-18 Unc BIkz Nut Crown Lock 5/16-18 Bolt Fin Hex 1/2-13 X 7/8 Gr 5 Washer 17/32 X 1-3/16 X 12 Ga Bolt Shoulder 5/16-18X62 Washer Lock Hvy Hid Spr 1/2

Page 39

REPAIR PARTS

DECALS

TRACTOR - " MODEL NUMBER' HD145H42H

KEY

NO.

11 16 17 18

PART NO.

158181

158168

158037

158038

158167

7 158166

157141

141897

160396 158169 145005

158176

WHEELS AND

DESCRIPTION Decal Saddle Inst. Oper Eng/Sp P/L

Decal Steering Wheel Insert Decal Hood RH Decal Hood LH Decal Fender Sd Lawn

Decal Fender Logo

Decal Caution Fender Eng/Sp Decal Clutch/brake Eng/Sp Decal V-Belt Sch Decal Mulch Bag Poulan Decal Btry Dngr/Psn P/L Sym Decal Seat Acc

KEY NO.

Available accessories not included with tractor:

KEY PART NO. NO.

10 7152J 11 104757X

-- 144334

PART NO.

158172 138311 142341 163022 163023

LBD48 LSB42

LC05 C42 LA018 MK420

1 59192 2 65139 3 106222X 4 59904

5 106732X427 6 278H 7 9040H 8 106108X427 9 106268X

DESCRIPTION Decal Repicment Engine

Decal Handle Lft Height Adjust Decak Drawbar Cntrl Mvt Hyd LT Manual Owner's English Manual Owner's Spanish

42" Snow Blade 42" Snow Blower Wheel Weights Grass Catcher

Tire Chains

Mulch Kit w/Blades

DESCRIPTION

Cap Valve Tire Stem Valve Tire FTs 15X60-6 Service Tube Front (Service Item Only)

Rim Asm 6" front White Service

Fitting Grease (Front Wheel Only)

Bearing Flange (Front Wheel Only)

Rim Asm 8" rear White Service Tire R Ts 18 X 9.5-8 C Service Tube Rear (Service Item Only)

Cap Axle BIk 1 50 X 1 00

Sealant, Tire (10 oz. Tube)

NOTE: All component dimensions given in U.S. inches

1 inch = 25.4 mm

Page 40

REPAIR PARTS

ENGINE

TRACTOR -- MODEL NUMBER HD145H42H

Page 41

REPAIR PARTS

ENGINE

TRACTOR — MODEL NUMBER HD145H42H

KEY

NO.

13 272293 14 13280324 15 13200300 16 11050600 23 29 137180 Kit Spark Arrestor (Flat Scrn) 31 161911 Tank Fuel Front

32 33 35 37 137040 38 Oil Drain Plug (Order From Engine

40 124028X 44 46 62 10040500 Washer Lock Hvy Hid Spr 5/16 72 78 17490620 Screw Thdrol 3/8-16x1-1/4 TYTT 81 128861 Nut Flange 1/4-20 Starter Nut

NOTE: All component dimensions given in U.S. inches

PART NO. DESCRIPTION

140310

17720410 Screw Hex Thd Cut 1/4-20x5/8 T

..........

3 4 137352

159880 Shield Browning/Debris Guard

140527 Cap Asm Fuel 123487X Clamp Hose 17490512

17490412 19091416

71070512

1 inch = 25.4 mm

Control Th/ch LH Flag 23.5 Engine B&S 287707

Muffler Exhaust LT B&S 14HP 1C OHV Gasket Eng 1 313 Id Tin Plated Nipple Pipe 3/8 Npt X 3" Elbow Std 90 Degree 3/8-18 Npt

Washer Lock Ext Tooth 3/8

Screw Thdrol 5/16-18 x 3/4 TYT Line Fuel 20"

Manufacturer) Bushing Snap Nyl BIk Fuel Line Screw Thdrol 1/4-20 x 3/4

Washer 9/32 x 7/8 x 16 Ga

Screw Hex Hd Cap 5/16-18 x 3/4

Page 42

noe'-

v\0''*®

tlü'

Page 43

REPAIR PARTS

LIFT

TRACTOR " " MODEL NUMBER HD145H42H

KEY

NO.

4 12000002 E-ring Truarc #5133-62

11 139865 Link Lift LH 12 13 4939M Retainer Spring 15 16 17 18

19 20 3146R Retainer Spring 31 32

NOTE; All component dimensions given in U.S. inches

PART NO. DESCRIPTION

159460 2 159471 Shaft Asm Lft 3 105767X

5 19211621 6 120183X Bearing Nylon 7

109413X 8 124526X

139866 Link Lift RH

127218 Link Front 73350800 Nut Jam Hex 1/2-13 Unc 130171 73800800 Nut Lock W/wsh 1/2-13unc 139868

140302 73540600 Nut Crownlock 3/8-24

1 inch = 25.4 mm

Wire Asm Inner W/Plunger Pin Groove WasherPltd 21/32 X 1 X21 Ga Grip Handle Bicycle

Button Plunger Black

Trunnion BIk Zinc Arm Suspension Rear Bearing Pvt. Lift Spherical

Page 44

REPAIR PARTS

MOWER DECK

TRACTOR ~ - MODEL NUMBER HD145H42H

Page 45

REPAIR PARTS

MOWERDECK

TRACTOR - - MODEL NUMBER HD145H42H

KEY PART NO.

10 11 138498 12 13 14 128774 15 16 17 18

19 20 21 22 23 131267 24 25 123713X 26 27 28 29 30 31 32 33 137266 34 35 36

37 40 41 43 44

45 46 48 49 5051131340

NO. DESCRIPTION NO. NO.

144393 2 72140506 Bolt Rdhd Sqnk 5/16-18unc X3/4 53 3

138017 4

138440 5

4939M 6

130832 Arm Suspension Rear 8

850857 9

10030600 Washer Lock Hvy 3/8

140296 Washer Hard Blade Mower Vented 68

129895

137645 Shaft Asm W/lower Bearing 73 127847

110485X

140329 Stripper Mower Vented 76

72110610 Bolt Rdhd Sqnk 3/8-16 X 1-1/4 77

72140505 Bolt Rdhd Sqnk 5/16-18 X 5/8 78

132827 Bolt Shoulder

136888

73680500

134753 Stiffener Bracket 42" deck 82 142028

105304X

110452X Nut Push Phos & Oil 92 73800600 Nut Lock Hex w/lns 3/8-16 Unc

130968

19111016

131491

157772

129963 Washer Spacer Mower Vented

153535

72110614

133835

131494 19131316 73680600 133551 Rod Pivot W/nibs 140083 Rod Clutch Secondary W/nibs 140088 4497H 137729 133944 155066

69180

Mower Housing Bracket Asm Fr Sway Bar 38/42 54

Bracket Asm Deck 42" sway Bar 55 Retainer Spring

Bolt 3/8-24 X 1 1/4 59

Blade High Perf 42" Bearing Bail

Housing Mandrel Vented Bearing Ball Mandrel

Baffle Vortex 42 80 153701 NutCrownlock 5/16-18 UNC

Bracket Deflector Mower 42" Cap Sleeve 80x 112 BIk Mower Spring Torsion Deflector 2 52

Shield Deflector Mower 42" BIk

Washer 11/32 X 5/8 X 16 Ga

Rod Hinge 42" 6 75 Wig 113 Screw Thdrol Washer Head 114

Pulley Mandrel 42" 116 4898H Nut 9/16 Top Lock FIng

Bolt Rdhd 3/8-16uncx1-3/4 Gr5

Fastner Christmas Tree 119

Pulley Idler Flat 3 060 Washer 13/32 x 13/16 x 16 Ga Nut Crownlock 3/8-16 UNC

Guard Mandrel LH Black Spring Retainer 1" Zinc/cad Screw Hex Thd Cut

Washer Hardened Smaller

Roller Asm Cam Follower 42" dec

Bolt Shidr 10-24 Zinc Gr 5 42" Nut Lock #10-24 Unc

KEY PART

DESCRIPTION

52 139888

131845X900 133943 Washer Hardened

155046 Arm Idler 42“ mower LT/YT 56 122052X 58

140086 Spring Torsion Brakes 42"

141043 67

162132

144200

71 142427 Rod Clutch Primary 38/42

131870 74

121748X

75 12000029 Ring Klip #t5304-75

128903

127845

160570 79

127498

73350600

83 120958X 84 156084

72140618

155197 Bracket Gauge Wheel Lh

111

155198 Bracket Gauge Wheel Rh

112

17490512

73510500 Nut Keps 5/16-18 Unc 72110504

115 117 105455X Wheel Gauge BIk

73930600 Nut Center!ock 3/8-16 Unc

118

19121414

-^120

19171512

121

143723 Bracket Extruded Gauge Wheel 128 153390 132 19132203

141 6266h Washer Thrust .75 x 1.230

- -

130794

144783 Deck Serv (Std. Deck - Order

NOTE: All component dimensions given in U.S. inches

1 inch = 25.4 mm

Bolt Shoulder 5/16-18 Unc BIkz

Arm Asm Pad Brake

Spacer Retainer Pm Mower Guard TUV Idler

Knob Rd 7/16-14 V-Belt Mower

Spring Return Arm Clutch Secondary Washer 25/32 X 1-5/8 X 16 Ga

Bolt Shoulder 3/8-16 Unc 1 44 Keeper Spring 4 000 Lever Asm Clutch Primary P/L Bushing 747 Od X 794 Lg Brass Spring Clutch Mower

Nut Hex Jam 3/8-16 Unc Trunnion Adj Washer Sintered

Keeper Belt Idler

Bolt Rdhd Sqnk 3/8-16x2-1/4

Screw Thdrol 5/16-18x3/4

Bolt Carr 5/16-Uncx1/2

Bolt Shoulder

Washer 3/8 x 7/8 x 14 Gauge Washer 17/32 X 15/16 X12 Gauge

Washer Felt Washer 13/32 x 1-3/8 x 3 Ga.

Mandrel Asm Service (Includes Key Nos. 8-10,12-15, 31 and 33)

seperately gauge wheel components 111-121.)

Page 46

REPAIR PARTS

TRACTOR - - MODEL NUMBER HD145H42H

TRANSAXLE HYDRO GEAR - MODEL NUMBER 310-0500

Page 47

REPAIR PARTS

TRACTOR — MODEL MUWBER HD145H42H

TRANSAXLE HYDRO GEAR - MODEL NUMBER 310-0500

KEY PART NO. NO.

1 142986

142987

142932

142928

142933

142934

6 7 142935 8 150771 9 142937

142938

142939

142940

15 17

142941 150772

150773

19 23 142944 24 142945

142946

25 26 150774 27 142948

142949

142950

150787

30 34 142951

142952

142953

142954

142955

150777

DESCRIPTION

Housing, Lower Assembly, Upper Housing

Seal, Lip

Ring, Wire Retaining Ring, Retaining Bearing, Shaft Ball Bearing, Cradle Bearing, Thrust 30 x 52 x 13

Swashplate, Variable

Block, Cylinder Assembly

Arm, Trunnion

Seal, Lip Guide, Slot Shaft, Motor Bearing, Thrust 42 x 68 x 16 Block, Cylinder Assembly Seal, Lip 10 X 25 X 7 Actuator, Bypass Center Section Assembly Kit Seal, Lip 26 X 42 X 8 Ririg, Retaining

Washer 26 x 35 x 1

Nut, Jam Oil Filter Element

Arm, Bypass

Ring, Retaining

Arm, Actuating

Pin, Actuating Bolt 5/16-24 X 1-3/4

KEY PART

NO.

150778

142958

41 43 142884 44 142990

52 142991

53 142961

142963

56 58 142964

59 142965

62 142966 63 142967 64 142920

142969

144610

92 142977 93 142978 98 142993

142976

142917

113

142918

114

142980

119

144607

134

144608

135 139 150775

150776

140

NOTE: All component dimensions given in U.S. inches

1 inch = 25.4 mm

DESCRIPTION

Locknut, Hex 5/16-24 UNJC Brake Rotor/Stator Kit Washer 7/16 x 7/8 x .060 Differential Assembly Washer 3/4 x 1.5 x .13 Seal .75 X 1.25 x .250 Shaft, Input Bolt 1/4-20x1.38 Pin .5 OD x .43 ID X .750 Arm, Control Puck, Dampener Set Screw Spring Stud 5/16-24 Spring, Block Washer, Block Thrust Sleeve Bearing Seal, Wiper

Cap, Vent Assembly Fitting, 0-Ring Assembly

Spacer

Nut, Castle 5/16-24 Pin, Cotter

Spring, Compression

Nut, Hex 5/16-24

Page 48

SERVICE NOTES

Page 49

SERVICE NOTES

Page 50

LIMITED WARRANTY

The Manufacturer warrants to the original consumer purchaser that this product as manufactured is free from defects in

materials and workmanship. For a period of two (2) years from date of purchase by the original consumer purchaser, we will repair or repiace, at our option, without charge for parts or labor incurred in replacing parts, any part which we find to be defective due to materials or workmanship. This Warranty is subject to the following limitations and exclusions.

1. This warranty does not apply to the engine, other than AYR manufactured transaxle/transmission components, battery (except as noted below) or components parts thereof. Please refer to the applicable manufacturer's warranty on these items.

2. Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the purchaser. Transportation charges for any parts submitted for replacement under this warranty must be paid by the purchaser unless such return is requested by American Yard Products.

3. Battery Warranty: On products equipped with a Battery, we will replace, without charge to you, any battery which we find to be defective in manufacture, during the first ninety (90) days of ownership. After ninety (90) days, we will exchange the Battery, charging you' 1/12 of the price of a new Battery for each full month from the date of the original sale. Battery must be maintained in accordance with the instructions furnished.

4. The Warranty period for any products used for rental or commercial purposes is limited to 90 days from the date of original purchase.

5. This Warranty applies only to products which have been properly assembled, adjusted, operated, and maintained in accordance with the instructions furnished. This Warranty does not apply to any product which has been subjected to alteration, misuse, abuse, improper assembly or installation, delivery damage, or to normal wear of the product.

6. Exclusions: Excluded from this Warranty are belts, blades, blade adapters, normal wear, normal adjustments, standard

hardware and normal maintenance.

7. In the event you have a claim under this Warranty, you must return the product to an authorized service dealer. Should you have any unanswered questions concerning this Warranty, please contact;

American Yard Products In Canada contact: Service Department American Yard Products

P.O. Box1687 1580 Trinity Drive, Units 5-8

Orangeburg, SC 29116 USA Mississauga, Ontario

L5T 1L6

giving the model number, serial number and date of purchase of your product and the name and address of the authorized dealer from whom it was purchased.

THIS WARRANTY DOES NOT APPLY TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND ANY IMPLIED WARRAN TIES ARE LIMITED TO THE SAME TIME PERIODS STATED HEREIN FOR OUR EXPRESSED WARRANTIES. Some areas

do not allow the limitation of consequential damages or limitations of how long an implied Warranty may last, so the above limitations or exclusions may not apply to you. This Warranty gives you specific legal rights, and you may have other rights which vary from locale to locale.

This is a limited Warranty within the meaning of that term as defined in the Magnuson-Moss Act of 1975.

Page 51

SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION

ONLY RIDE UP AND DOWN HILL,

SIGHTING GUIDE

NOT ACROSS HILL

'®”st5-p|°i:'A/es

Operate your Tractor up and down the face of slopes (not greater than 15°), never across the face. Make turns gradu

ally to prevent tipping or loss of control. Exercise extreme caution when changing direction on slopes.

Page 52

Poulan

Poulan 163022 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual