Poulan 96042000900 Owner’s Manual

IMPORTANT MANUAL Do Not Throw Away

OPERATOR'S MANUAL

MODEL:

Read this Manual and follow all Warnings and
Safety Instructions. Failureto do so can result
in serious injury.

PK20H42YT

LAWN TRACTOR

ALWAYS WEAR EYE PROTECTION DURING OPERATION
Visit our website: www.poulan-pro.com

WARNING:

402956 Rev.1 03.t6.06 TR/VB

Printed in U.S.A.

Safe Operation Practices for Ride-On Mowers

SAFETY RULES &

DANGER: THIS CUTTINGMACHINEISCAPABLEOFAMPUTATINGHANDSAND FEETANDTHROWINGOBJECTS. FAILURE

TO OBSERVETHE FOLLOWINGSAFETYINSTRUCTIONSCOULDRESULTINSERIOUS INJURYOR DEATH.

WARNING: In order to prevent ac-

cidental starting when setting up,

transporting, adjusting or making re-

pairs, always disconnect spark plug

wire and place wire where it cannot

contact spark plug.

limb WARNING: Do not coast down a hill |

&

in neutral, you may lose control of the
tractor.

WARNING: Tow only the attachments
that are recommended by and com-

ply with specifications of the manu-
facturer of your tractor. Use common

sense when towing. Operate only at
the lowest possible speed when on a
slope. Too heavy of a load, while on

a slope, is dangerous. Tires can lose

traction with the ground and causeyou

to lose control of your tractor.

WARNING

Engine exhaust, some of its constituents, and cer-
tain vehicle components contain or emit chemicals

known tothe State of California to cause cancer and
birth defects or other reproductive harm.

WARNING

Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known

to the State of California to cause cancer and birth
defects or other reproductive harm. Wash hands

after handling.

I. GENERAL OPERATION

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

Do not put hands or feet near rotating parts or under
the machine. Keep clear of the discharge opening at

all times.
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 blades.
Be sure the area is clear of bystanders before operat-

ing. Stop machine if anyone enters the area.
Never carry passengers.
Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while back-

ing.
Never direct discharged material toward anyone. Avoid

discharging material against a wall or obstruction. Ma-
terial may ricochet back toward the operator. Stop the

blades when crossing gravel surfaces.

I

I

2

Donot operate machine without the entire grass catcher,

discharge guard, or other safety devices in place and
working.

Slow down before turning.

Never leave a running machine unattended. Always

turn off blades, set parking brake, stop engine, and
remove keys before dismounting.

Disengage blades when not mowing. Shut off engine

and wait for all parts to come to a complete stop before
cleaning the machine, removing the grass catcher, or

unclogging the discharge guard.
Operate machine 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 road-
ways.

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

Always wear eye protection when operating ma-
chine.

Data indicates that operators, age 60 years and above,
are involved in a large percentage of riding mower-re-
lated injuries. These operators should evaluate their

ability to operate the riding mower safely enough to
protect themselves and others from serious injury.

Follow the manufacturer's recommendation for wheel
weights or counterweights.

Keep machine free of grass, leaves or other debris
build-up which can touch hot exhaust / engine parts
and burn. Do not allow the mower deck to plow leaves

or other debris which can cause build-up to occur.
Clean any oil or fuel spillage before operating or
storing the machine. Allow machine to cool before
storage.

II. SLOPE OPERATION

Slopes are a major factor related to loss of control and
tip-over accidents, which can result in severe injury or

death. Operation on all slopes requires extra caution. If
you cannot back up the slope or if you feel uneasy on it,

do not mow it.

Mow up and down slopes, not across.
Watch for holes, ruts, bumps, rocks, or other hidden
objects. Uneven terrain could overturn the machine.

Tall grass can hide obstacles.
Choose a low ground speed so that you will not have
to stop or shift while on the slope.

Do not mow on wet grass. Tires may lose traction.
Always keep the machine in gear when going down

slopes. Do not shift to neutral and coast downhill.
Avoid starting, stopping, or turning on a slope. If the

tires lose traction, disengage the blades and proceed
slowly straight down the slope.

Keep all movement on the slopes slow and gradual.

Do not make sudden changes in speed or direction,
which could cause the machine to roll over.

Use extra care while operating machine with grass
catchers or other attachments; they can affect the

stability of the machine. Do no use on steep slopes.

Do not try to stabilize the machine by putting your foot
on the ground.

Do not mow near drop-offs, ditches, or embankments.
The machine could suddenly roll over ifa wheel isover
the edge or if the edge caves in.

Safe Operation Practices for Ride-On Mowers

SAFETY RULES

II1. CHILDREN

Tragic accidents can occur if the operator is not alert to
the presence of children. Children are often attracted to

the machine and the mowing activity. Never assume that
children will remain where you last saw them.

Keep children out of the mowing area and inthe watchful

care of a responsible adult other than the operator.

Be alert and turn machine off if a child enters the

area.

Before and while backing, look behind and down for

small children.

Never carry children, even with the blades shut off. They
may fall off and be seriously injured or interfere with

safe machine operation. Children who have been given

rides in the past may suddenly appear in the mowing

area for another ride and be run over or backed over

by the machine.
Never allow children to operate the machine.
Use extra care when approaching blindcorners, shrubs,

trees, or other objects that may block your view of a
child.

IV. TOWING

Tow only with a machine that has a hitch designed for
towing. Do not attach towed equipment except at the

hitch point.
Follow the manufacturer's recommendation for weight
limits for towed equipment and towing on slopes.

Never allow children or others in or on towed equip-
ment.

On slopes, the weight of the towed equipment may

cause loss of traction and loss of control.
Travel slowly and allow extra distance to stop.

V. SERVICE

SAFE HANDLING OF GASOLINE

Toavoid personal injury or property damage, use extreme
care in handling gasoline. Gasoline isextremely flammable

and the vapors are explosive.

Extinguish all cigarettes, cigars, pipes, and other

sources of ignition.

Use only approved gasoline container.
Never remove gas cap or add fuel with the engine run-

ning. Allow engine to cool before refueling.
Never fuel the machine indoors.

Never store the machine or fuel container where there
isan open flame, spark, or pilot light such as on a water

heater or other appliances.
Never fill containers inside a vehicle or on a truck or

trailer bed with plastic liner. Always place containers
on the ground away from your vehicle when filling.

Remove gas-powered equipmentfrom thetruck ortrailer

and refuel it on the ground. Ifthis is not possible, then

refuel such equipment with a portable container, rather

than from a gasoline dispenser nozzle.

Keep the nozzle in contact with the rim of the fuel tank

or container opening at alltimes untilfueling iscomplete.

Do not use a nozzle lock-open device.
If fuel is spilled on clothing, change clothing immedi-

ately.

Never overfill fuel tank. Replace gas cap and tighten

securely.

GENERAL SERVICE

Never operate machine in a closed area.
Keep all nuts and bolts tight to be sure the equipment
is in safe working 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 and remove any fuel-

soaked debris. Allow machine to cool before storing.
If you strike a foreign object, stop and inspect the

machine. Repair, if necessary, before restarting.
Never make any adjustments orrepairs with the engine

running.
Check grass catcher components and the discharge

guard frequently and replace with manufacturer's rec-
ommended parts, when necessary.
Mower blades are sharp. Wrap the blade or wear

gloves, and use extra caution when servicing them.
Check brake operation frequently. Adjust and service
as required.
Maintain or replace safety and instruction labels, as
necessary.

®@@@@

Be sure the area is clear of bystanders before operat-
ing. Stop machine if anyone enters the area.

Never carry passengers.
Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while back-

ing.
Never carry children, even with the blades shut off. They

may fall off and be seriously injured or interfere with
safe machine operation. Children who have been given

rides in the past may suddenly appear in the mowing
area for another ride and be run over or backed over

by the machine.
Keep children out of the mowing area and inthe watchful

care of a responsible adult other than the operator.
Be alert and turn machine off if a child enters the

area.
Before and while backing, look behind and down for

small children.
Mow up and down slopes (15° Max), not across.

Choose a low ground speed so that you will not have
to stop or shift while on the slope.

Avoid starting, stopping, or turning on a slope. If the

tires lose traction, disengage the blades and proceed
slowly straight down the slope.

If machine stops while going uphill, disengage blades,
shift into reverse and back down slowly.

Do not turn on slopes unless necessary, and then, turn
slowly and gradually downhill, if possible.

PRODUCT SPECIFICATIONS

Gasoline Capacity 2.50 Gallons
and type: Unleaded Regular

Oil Type (API-SG-SL): SAE 10W30 (above 32°F)

SAE 5W-30 (below 32°F)

Oil Capacity: W/Filter: 4.0 Pints

W/O Filter: 3.35 Pints

Spark Plug: Champion RC12YC
(Gap: .040")

Ground Speed (MPH): Forward: 0 - 5.5

Reverse: 0 - 2.4

Charging System: 15 AMPS @ 3600 RPM
Battery: AMP/HR: 35

MIN.CCA: 280
Case Size: U1R

Blade BoltTorque: 45-55FT.LBS.

CONGRATULATIONS on your purchase of a new tractor.
Ithas been designed, engineered and manufactured to give

you the best possible dependability and performance.

Should you experience any problem you cannot easily rem-
edy, please contact your nearest authorized servicecenter/
department We have competent, well-trained technicians

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".

CUSTOMER RESPONSIBILITIES

Read and observe the safety rules.
Follow a regular schedule in maintaining, caring for

and using your tractor.

Follow the instructions under "Maintenance" and "Stor-

age" sections of this owner's manual.

WARNING: This tractor is equipped with an internal com-

bustion engine and should not be used on or near any
unimproved forest-covered, brush-covered orgrass-covered

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.

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.
A spark arrester for the muffler is available through your

nearest authorized service center/department (See REPAIR
PARTS section of this manual).

TABLE OF CONTENTS

SAFETY RULES ............................................................ 2

PRODUCT SPECIFICATIONS ....................................... 4

CUSTOM ER RESPONSIBILITIES ................................. 4

ASSEMBLY .................................................................... 5

OPERATION .................................................................. 7

MAINTENANCE SCHEDULE ...................................... 14

MAINTENANCE .......................................................... 14

SERVICE AND ADJUSTMENTS ................................. 18

STORAGE .................................................................... 24

TROUBLESHOOTING ................................................. 25

WARRANTY ................................................................. 27

4

UNASSEMBLED PARTS

Key

(1) Oil Drain Tube

(2) Keys

ASSEMBLY

Your new tractor has been assembled at the factory with the exception of those parts left unassembled for shipping

puposes.

Slope Sheet

When right or left hand ismentioned inthis manual, itmeans
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.

Cut along dashed lines on all four panels of carton.
Remove end panels and lay side panels flat.

Check for any additional loose parts or cartons and
remove.

ADJUST SEAT (See Fig. 2)

Sit in seat.
Lift up adjustment lever (A) and slide seat until a com-

fortable position is reached which allows you to press

clutch/brake pedal all the way down.
Release lever to lock seat in position.

CHECK BATTERY (See Fig. 1)

Lift seat pan to raised position.
If this battery is put into service after month and year

indicated on label (label located between terminals)

charge battery for minimum of one hour at 6-10 amps.

(See "BATTERY" in the Maintenance section of this
manual for charging instructions).

DISCARD TERMINAL KEPS,,NUT HEX BOLT
PROTECTIVE CAPS _ "X_

TERMINAL I

POSITIVE (RED)

CABLE

i

(BLACK) CABLE

FIG. 1

FIG. 2

NOTE: You may now roll or drive your tractor off the skid.
Follow the appropriate instruction below to remove the

tractor from the skid.

,_WARNING: Before starting, read, understand and follow
all instructions in the Operation section of this manual. Be

sure tractor is in a well-ventilated area. Be sure the area in
front of tractor is clear of other people and objects.

TO ROLL TRACTOR OFF SKID (See Op-
eration section for location and function of

controls)

1. Raise attachment lift lever to its highest position.

2. Release parking brake by depressing brake pedal.

3. Place freewheel control in disengaged position to dis-
engage transmission (See "TO TRANSPORT" in the
Operation section of this manual).

ASSEMBLY

4. Roll tractor forward off skid.

5. Remove banding holding thedeflector shield up against
tractor.

TO DRIVE TRACTOR OFF SKID (See Op-
eration section for location and function of

controls)

1. Be sure all the above assembly steps have been com-
pleted.

2. Check engine oil level and fill fuel tank with gasoline.

3. Place freewheel control in "transmission engaged"
position (see "TO TRANSPORT" in Operation section
of this manual).

4. Sit on seat in operating position, depress brake pedal
and set the parking brake.

5. Raise attachment lift lever to its highest position.

6. Remove key from bag and start the engine (see "TO
START ENGINE" in the Operation section of this man-

ual). After engine has started, move throttle control to
idle (slow) position.

7. Release parking brake.

8. Slowly depress forward drive pedal and drive tractor
off skid.

9. Apply brake to stop tractor and set parking brake.

10. Turn ignition key to "STOP" position.
Continue with the instructions that follow.

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 on tires.

CHECK DECK LEVELNESS

For best cutting results, mower housing should be properly
leveled. See "TO LEVEL MOWER HOUSING" inthe Service

and Adjustments section of this manual.

CHECK FOR PROPER POSITION OF ALL
BELTS

See the figures that are shown for replacing motion and

mower blade drive belts in the Service and Adjustments
section of this manual. Verify that the belts are routed
correctly.

,/CHECKLIST

BEFORE YOU OPERATE YOUR NEW TRACTOR, WE

WISH TOASSURE THATYOURECEIVE THE BES TPER-

FORMANCEAND SATISFACTION FROM THIS QUALITY
PROD UCT.

PLEASE REVIEW THE FOLLOWING CHECKLIST.

,/ All assembly instructions have been completed.
,/ No remaining loose parts in carton.

,/ Battery is properly prepared and charged.
,/ 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

"transmission engaged" position (see "TO TRANS-

PORT" in the Operation section of this manual).

WHILE LEARNING HOWTO USEYOURTRACTOR, PAY
EXTRA ATTENTION TO THE FOLLOWING IMPORTANT

ITEMS:
,/ Engine oil is at proper level.

,/ Fuel tank is filled with fresh, clean, regular unleaded

gasoline.

,/ Become familiar with all controls, their location and

function. Operate them before you start the engine.

,/ Be sure brake system is in safe operating condition.
,/ Be sure Operator Presence System and Reverse Op-

eration System (ROS) are working properly (See the
Operation and Maintenance sections in this manual).

,/ It is important to purge the transmission before oper-

ating your tractor for the first time. Follow proper start-
ing and transmission purging instructions (See "TO

START ENGINE" and "PURGE TRANSMISSION" in
the Operation section of this manual).

CHECK BRAKE SYSTEM

After you learn how to operate your tractor, check to see that
the brake is operating properly. See "TO CHECK BRAKE"

in the Service and Adjustments section of this manual.

6

OPERATION

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

H

REVERSE NEUTRAL HIGH SLOW

L I\l

LOW CHOKE FAST

G

ENGINE OFF REVERSE ENGINE ON PARKING BRAKE MOWER HEIGHT

LIGHTS ON FUEL BATTERY REVERSE FORWARD CRUISE CONTROL

OPERATION

SYSTEM (ROS)

ENGINE START

m

ATTACHMENT ATTACHMENT

CLUTCH DISENGAGED CLUTCH ENGAGED

FREE WHEEL

(Automatic Models only)

DANGER, KEEP HANDS

AND FEET AWAY

&
&

&

DANGER indicates a hazard which, if not avoided,

will result in death or serious injury.

WARNING indicates a hazard which, if not avoided,
could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided,
might result in minor or moderate injury.

KEEP AREA CLEAR SLOPE HAZARDS

(SEE SAFETY RULES SECTION)

IGNITION SWITCH

MOWER LIFT

CLUTCH/BRAKE

PEDAL

Failure to follow instructions

could result in serious injury or
death. The safety alert symbol

is used to identify safety inform-
ation about hazards which can

result in death, serious injury
and/or property damage.

CAUTION when used without the alert symbol,
indicates a situation that could result in damage
to the tractor and/or engine.

HOT SURFACES indicates a hazard which,
if not avoided, could result in death, serious injury

and/or property damage.

FIRE indicates a hazard which, if not avoided,

could result in death, serious injury and/or
property damage.

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 applicable safety standards of the American National Standards Institute.

(A) ATTACHMENT LIFT LEVER- Used to raise and lower
the mower or other attachments mounted to your tractor.

(B) CLUTCH/BRAKE PEDAL- Usedfor braking the tractor
and starting the engine.

(C) PARKING BRAKE - Locks clutch/brake pedal into the

brake position.

(D)THROTTLE/CHOKE CONTROL- Used for starting and
controlling engine speed.

(E) ATTACHMENT CLUTCH LEVER - Used to engage
the mower blades, or other attachments mounted to your

tractor.

(F) IGNITION SWITCH - Used for starting and stopping
the engine.

03102

FIG. 3

(G) REVERSE OPERATION SYSTEM (ROS) "ON" PO-
SITION -Allows operation of mower or other powered

attachment while in reverse.
(H) LIGHT SWITCH - Turns the headlights on and off.

(J) CRUISE CONTROL LEVER - Used to set forward
movement of tractor at desired speed without holding the
forward drive pedal.

(K) FORWARD DRIVE PEDAL - Used for forward move-
ment of tractor.

(L) REVERSE DRIVE PEDAL- Used for reverse move-
ment of tractor.

8

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 standard safety glasses or a wide
vision safety mask worn over spectacles.

HOW TO USE YOUR TRACTOR

TO SET PARKING BRAKE(See Fig. 4)

Your tractor is equipped with an operator presence sens-
ing 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 brake pedal (B) all the way down and hold.
Pull parking brake lever (C) up and hold, release pres-

sure from brake pedal (B), then release parking brake

lever. Pedal should remain in brake position. Make

sure parking brake will hold tractor secure.

FIG. 4

STOPPING

MOWER BLADES -

To stop mower blades, move attachment clutch lever to
disengaged position (r_).

Turn ignition key (F) to "STOP" position and remove
key.Always remove key when leaving tractor to prevent

unauthorized use.
Never use choke to stop engine.

IMPORTANT: Leaving the ignition switch in any position

other than "STOP" will cause the battery to discharge and
go dead.

NOTE: Under certain conditions when tractor is standing
idle with the engine running, hot engine exhaust gases may

cause "browning" of grass. Toeliminate this possibility, al-
ways stop engine when stopping tractor on grass areas.

pletely, as described above, before

I& CAUTION: Always stop tractor com- I

leaving the operator's position.

FIG. 5

(I'll) Attachment (_) Disengaged

Clutch Position
Engage Position

GROUND DRIVE-

To stop ground drive, depress brake pedal all the way
down.

ENGINE -

Move throttle control (D) between half and full speed
(fast) position.

NOTE: Failure to move throttle control between half and
full speed (fast) position, before stopping, may cause en-

gine to "backfire".

FIG. 6

TO USE THROTTLE CONTROL - D (See Fig. 6)

Always operate engine at full speed (fast).

Operating engine at less than full speed (fast) reduces
engines operating efficiency.

Full speed (fast) offers the best bagging and mower
performance,

TO MOVE FORWARD AND BACKWARD

(See Fig. 7)

The direction and speed of movement is controlled by the
forward and reverse drive pedals.

Start tractor and release parking brake.
Slowly depress forward (K) or reverse (L) drive pedal to

begin movement. Ground speed increases the further
down the pedal is depressed.

TO USE CRUISE CONTROL -J (See Fig. 7)

The cruise control feature can be used for forward travel
only.