Poulan PD22H42STB User Manual

IMPORTANT MANUAL Do Not Throw Away

02478

OWNER'S MANUAL

WARNING:

MODEL:

Read this Owner's Man u al and follow all
Warnings and Safety Instructions. Fail ure
to do so can re sult in serious in ju ry.

PD22H42STB

LAWN TRACTOR

ALWAYS WEAR EYE PROTECTION DURING OPERATION

191897 03.15.04 RD

Printed in U.S.A.

SAFETY RULES

SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS

IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROW ING OBJECTS. FAILURE

TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

I. GENERAL OPERATION

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

• Only allow responsible adults, who are familiar with the
in struc tions, to operate the machine.

• Clear the area of objects such as rocks, toys, wire, etc.,
which could be picked up and thrown by the blade.

• Be sure the area is clear of other people before mow­ ing. Stop machine if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while back­ ing.

• Be aware of the mower discharge direction and do not
point it at anyone. Do not operate the mower without
either the entire grass catcher or the guard in place.

• Slow down before turning.

• Never leave a running machine unattended. Always
turn off blades, set parking brake, stop engine, and
remove keys before dismounting.

• Turn off blades when not mowing.

• Stop engine before removing grass catcher or un­ clog ging chute.

• Mow only in daylight or good artifi cial light.

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

• Watch for traffi c when operating near or crossing road­ ways.

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

• Data indicates that operators, age 60 years and above,
are involved in a large percentage of riding mower-re­lated injuries. These operators should evaluate their
ability to operate the riding mower safely enough to
protect them selves and others from serious injury.

• Keep machine free 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 tipover
accidents, which can result in severe injury or death. All slopes
require extra caution. If you cannot back up the slope or if you
feel uneasy on it, do not mow it.

DO:

• Mow up and down slopes, not across.

• Remove obstacles such as rocks, tree limbs, etc.

• Watch for holes, ruts, or bumps. Uneven terrain could
overturn the machine.

• Use slow speed. Choose a low gear so that you will
not have to stop or shift while on the slope.

• Follow the manufacturer’s recommendations for wheel
weights or counterweights to improve stability.

• Use extra care with grass catchers or other at tach ments.
These can change the stability of the machine.

• Keep all movement on the slopes
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
down the slope.

Tall grass can hide obstacles.

slow

and

gradual

straight

DO NOT:

•

Do not

turn slowly and gradually downhill, if possible.

•

Do not

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

cause sliding.

•

Do not

on the ground.

•

Do not

turn on slopes unless necessary, and then,

mow near drop-offs, ditches, or embankments.

mow on wet grass. Reduced traction could

try to stabilize the machine by putting your foot

use grass catcher on steep slopes.

III. CHILDREN

Tragic accidents can occur if the operator is not alert to
the presence of children. Children are often attracted to
the ma chine and the mowing activity.
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
small children.

• Never carry children. They may fall off and be seriously
injured or interfere with safe machine operation.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.

Never

IV. SERVICE

• Use extra care in handling gasoline and other fuels.
They are fl ammable and vapors are explosive.

- Use only an approved container.

- Never remove gas cap or add fuel with the engine

running. Allow engine to cool before refueling. Do
not smoke.

- Never refuel the machine indoors.

- Never store the machine or fuel container inside where

there is an open fl ame, such as a water heater.

• Never run a machine inside a closed area.

• Keep nuts and bolts, especially blade attachment bolts,
tight and keep equipment in good condition.

• Never tamper with safety devices. Check their proper
op er a tion regularly.

• Keep machine free of grass, leaves, or other debris
build-up. Clean oil or fuel spillage. Allow machine to
cool before storing.

• Stop and inspect the equipment if you strike an object.
Repair, if necessary, before restarting.

• Never make adjustments or repairs with the engine
run ning.

• Grass catcher components are subject to wear, dam­ age, and deterioration, which could expose moving
parts or allow objects to be thrown. Frequently check
com po nents and replace with manufacturer's rec om ­mend ed parts, when nec es sary.

• Mower blades are sharp and can cut. Wrap the blade(s)

.

or wear gloves, and use extra caution when servicing
them.

• Check brake operation frequently. Adjust and service
as required.

2

assume that

down

for

SAFETY RULES

SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS

IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROW ING OBJECTS. FAILURE

TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

• Be sure the area is clear of other people before mowing. Stop
machine if anyone enters the area.

• Never carry passengers or children even with the blades
off.

• Do not mow in reverse unless absolutely necessary. Al ways
look down and behind before and while backing.

• Never carry children. They may fall off and be seriously injured
or interfere with safe machine operation.

• Keep children out of the mowing area and under the watchful
care of another responsible adult.

• Be alert and turn machine off if children enter the area.

• Before and when backing, look behind and down for small
children.

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

• Remove obstacles such as rocks, tree limbs, etc.

• Watch for holes, ruts, or bumps. Uneven terrain could overturn
the machine. Tall grass can hide obstacles.

• Use slow speed. Choose a low gear so that you will not have
to stop or shift while on the slope.

• Avoid starting or stopping on a slope. If tires lose traction,
disengage the blades and proceed slowly straight down the
slope.

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

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

Engine exhaust, some of its con stit u ents, and cer­ tain vehicle com po nents contain or emit chem i cals
known to the State of Cal i for nia to cause can cer and
birth de fects or oth er re pro duc tive harm.

WARNING: In order to prevent ac­ ci den tal starting when setting up,
trans port ing, ad just ing or making re­pairs, al ways dis con nect spark plug
wire and place wire where it can not
contact spark plug.

WARNING: Do not coast down a hill
in neutral, you may lose control of the
tractor.

WARNING: Tow only the attachments
that are rec om mend ed by and com­ply with spec i fi ca tions of the man u ­fac tur er of your tractor. Use common
sense when towing. Operate only at
the low est possible speed when on a
slope. Too heavy of a load, while on
a slope, is dan ger ous. Tires can lose
trac tion with the ground and cause you
to lose control of your tractor.

WARNING

WARNING

Battery posts, terminals and related ac ces so ries
contain lead and lead compounds, chem i cals known
to the State of Cal i for nia to cause can cer and birth
defects or oth er re pro duc tive harm. Wash hands
after handling.

3

PRODUCT SPECIFICATIONS

GASOLINE CAPACITY 4.0 GALLONS
AND TYPE: UNLEADED REGULAR

OIL TYPE (API-SF-SJ): SAE 30 (above 32°F)

SAE 5W-30 (below 32°F)

OIL CAPACITY: W/FILTER 4.0 PINTS
W/O FILTER 3.75 PINTS

SPARK PLUG: CHAM PI ON QC12YC
(GAP: .040")

GROUND SPEED (MPH): Forward: 0-5.5
Reverse 0-2.4

TIRE PRESSURE: FRONT: 14 PSI
REAR: 10 PSI

CHARGING SYSTEM: 3 AMPS BATTERY
5 AMPS HEADLIGHTS

BATTERY: AMP/HR: 35
MIN. CCA: 280
CASE SIZE: U1R

BLADE BOLT TORQUE: 27–35 FT. LBS.

CONGRATULATIONS on your purchase of a new tractor.
It has been designed, engineered and manu fac tured to give
you the best possible dependability and performance.

Should you experience any problem you cannot easily rem­edy, please contact your nearest authorized service center/
department. We have competent, well-trained tech ni cians
and the proper tools to service or repair this tractor.

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

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” sec tions of this own er’s manual.

WARNING: This tractor is equipped with an internal com­ bus tion engine and should not be used on or near any
un im proved forest-covered, brush-covered or grass-cov ered
land unless the engine’s exhaust system is equipped with
a spark arrester meeting applicable local or state laws (if
any). If a spark arrester is used, it should be maintained
in effective working order by the operator.

A spark arrester for the muffl er is available through your
nearest authorized service center/depar tment (See RE PA I R
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.

TABLE OF CONTENTS

SAFETY RULES ......................................................... 2-3

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

CUSTOMER RESPONSIBILITIES................................. 4

ASSEMBLY.................................................................6-8

OPERATION .............................................................9-15

MAINTENANCE SCHEDULE ...................................... 16

MAINTENANCE ..................................................... 16-19

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

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

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

REPAIR PARTS - TRACTOR .................................. 30-45

WARRANTY................................................................. 46

4

UNASSEMBLED PARTS

Steering Wheel

Steering
Sleeve

Steering

Wheel Insert

Steering
Extension
Shaft

Seat

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

(1) Knob

Gauge Wheels

(4) Wheels

(4) Clevis Pins

(1) Large Flat
Washer

Steering Adapter

(1) Locknut 1/2-20

(4) Adjusting Bar

(4) Retainer Springs
(double loop)

(1) Oil Drain Tube

(4) Washers

3/8 x 3/4 x 14 Ga.

(4) Shoulder Bolt

(4) Locknut 3/8-16

Slope Sheet

(1) Hex Bolt 1/4-28 x 1-1/4

(1) Locknut 1/4-28

(2) Keys

5

02601

ASSEMBLY

02746

Your new tractor has been assembled at the factory with exception of those parts left unassembled for shipping purposes.
To ensure safe and proper operation of your tractor all parts and hardware you assemble must be tightened securely. Use
the correct tools as necessary to insure proper tightness.

TOOLS REQUIRED FOR ASSEMBLY

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

Utility knife Pliers
(1) 3/4" wrenches Tire pressure gauge
(2) 7/16" wrenches Utility knife
When right or left hand is mentioned in this man ual, it means

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

TO REMOVE TRACTOR FROM CAR­ TON

UNPACK CARTON

• Remove all accessible loose parts and parts cartons
from carton .

• Cut along dotted lines on all four panels of carton.
Remove end panels and lay side panels fl at.

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

BEFORE REMOVING TRACTOR FROM
SKID

ATTACH STEERING WHEEL (See Fig. 1)

ASSEMBLE EXTENSION SHAFT AND BOOT

• Slide extension shaft onto lower steering shaft. Align
mount ing holes in extension and lower shafts and install
1/4 hex bolt and lock nut. Tighten securely.

IMPORTANT: TIGHTEN BOLT AND NUT SECURELY TO 10-12
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.

• Remove steering wheel adapter from steering wheel and
slide adapter onto steer ing shaft ex ten sion.

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

• Assemble large fl at washer, 1/2 hex nut and tighten se­ cure ly.

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

• Remove protective materials from tractor hood and grill.

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

INSERT

1/2 HEX NUT

LARGE FLAT
WASHER

STEERING
WHEEL

ADAPTER

EXTENSION SHAFT

1/4 LOCKNUT

LOWER
STEERING
SHAFT

STEERING
BOOT

TABS

1/4 HEX BOLT

TAB
SLOTS

FIG. 1

HOW TO SET UP YOUR TRACTOR

CHECK BATTERY (See Fig. 2)

• Lift hood to raised position.

• If this battery is put into service after month and year
indicated on label (label located between terminals)
charge battery for minimum of one hour at 6-10 amps.
(See "BATTERY" in the Maintenance section of this
manual for charg ing in struc tions).

TERMINAL TERMINAL

LABEL

6

FIG. 2

ASSEMBLY

INSTALL SEAT (See Fig. 3)

Adjust seat before tightening adjustment knob.

• Remove adjustment knob and fl at washer securing
seat to cardboard packing and set aside for assembly
of seat to tractor.

• Pivot seat upward and remove from the cardboard pack­ing. Remove the cardboard packing and discard.

• Place seat on seat pan so head of shoulder bolt is
positioned over large slotted hole in pan.

• Push down on seat to engage shoulder bolt in slot and
pull seat towards rear of tractor.

• Pivot seat and pan forward and assemble adjustment
knob and fl at 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 ad just ed position.

• Raise seat and tighten adjustment knob securely.

SEAT

SEAT PAN

SHOULDER
BOLT

FLAT WASHER

ADJUSTMENT
KNOB

FIG. 3

NOTE: You may now roll or drive your tractor off the skid.

Follow the ap pro pri ate instruction below to remove the
tractor from the skid

.

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

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

• Release parking brake by de press ing clutch/brake
ped al.

• Place freewheel control in "trans mis sion dis en gaged
position" (See “TO TRANS PORT” in the Op er a tion
section of this manual).

• Roll tractor forward off skid.

• Remove banding holding the defl ector shield up against
tractor.

TO DRIVE TRAC TOR OFF SKID (See Op­ er a tion section for location and function of
con trols)

WARNING: Before start ing, read, un der stand and fol low

all in struc tions in the Op er a tion section of this man u al. Be
sure tractor is in a well-ventilated area. Be sure the area in
front of tractor is clear of other peo ple and objects.

• Be sure all the above assembly steps have been com­pleted.

• Check engine oil level and fi ll fuel tank with gasoline.

• Place freewheel control in "trans mis sion en gaged"
po si tion (see "TO TRANSPORT" in Op er a tion section
of this manual).

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

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

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

• Start the engine. After engine has started, move throttle
control to idle position.

• Release parking brake.

• Slowly move the mo tion control lever for ward and slowly
drive tractor off skid.

• Apply brake to stop trac tor, set park ing brake and place
motion con trol lever in neutral po si tion.

• Turn ignition key to "STOP" position.

Continue with the in struc tions that follow.

ASSEMBLE GAUGE WHEELS TO MOWER
DECK (See Fig. 4A)

The gauge wheels are de signed to keep the mower deck
in proper position when operating mower. Be sure they
are properly adjusted to ensure optimum mower perfor-

mance.

• Slide gauge wheel bar down into bracket channel, Be
sure that gauge wheel bar aligning holes are on top.
As sem ble gauge wheels as shown using shoulder bolts,
3/8 washers and 3/8-16 center locknuts and tighten
securely.

• Adjust gauge wheels before operating mower. See “TO
ADJUST GAUGE WHEELS” in the Operation sec tion
of this manual.

RETAINER
SPRING

PIN

SHOULDER
BOLT

GAUGE
WHEEL

7

AD JUST ING
BAR

3/8 WASH ER

3/8-16 CENTER
LOCKNUT

FIG. 4A

ASSEMBLY

INSTALL MULCHER PLATE (See Figs. 4B)

• Install two latch hooks to mulcher plate using screw,
washer, lock washer, and weld nut as shown.

NOTE: Pre-assemble weld nut to latch hook by in sert ing
weld nut from the top with hook pointing down.

• Tighten hardware securely.

• Raise and hold defl ector shield in up right po si tion.

• Place front of mulcher plate over front of mower deck
open ing and slide into place, as shown.

• Hook front latch into hole on front of mower deck.

• Hook rear latch into hole on back of mower deck.

CAUTION: Do not remove defl ector
shield from mower.

DEFLECTOR
SHIELD

MULCHER
PLATE

LATCH
HOOKS

FIG. 4B

TO CONVERT TO BAGGING OR
DISCHARGING

Simply remove mulcher plate and store in a safe place.
Your mower is now ready for discharging or installation of
optional grass catcher accessory.

NOTE: It is not necessary to change blades. The mulcher
blades are designed for discharging and bagging also.

CHECK TIRE PRESSURE

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

• Reduce tire pressure to PSI shown in “PRODUCT
SPEC I FI CA TIONS” section of this manual.

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.

✓

CHE CKLIST

BEFORE YOU OPERATE AND ENJOY YOUR NEW TRAC­ TOR, WE WISH TO ASSURE THAT YOU RECEIVE THE
BEST PERFORMANCE AND SATISFACTION FROM THIS
QUALITY PRODUCT.

PLEASE REVIEW THE FOLLOWING CHECKLIST:

✓ All assembly instructions have been completed.
✓ No remaining loose parts in carton.
✓ Battery is properly prepared and charged. (Minimum

1 hour at 6 amps).

✓ Seat is adjusted comfortably and tightened securely.
✓ All tires are properly infl ated. (For shipping purposes,

the tires were overinfl ated at the factory).

✓ Be sure mower deck is properly leveled side-to-side/

front-to-rear for best cutting results. (Tires must be
properly infl ated for leveling).

✓ Check mower and drive belts. Be sure they are routed

properly around pulleys and inside all belt keepers.

✓ Check wiring. See that all connections are still secure

and wires are properly clamped.

✓ Before driving tractor, be sure freewheel control is in

drive position.

WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY
EXTRA ATTENTION TO THE FOLLOWING IMPORTANT
ITEMS:

✓ Engine oil is at proper level.
✓ Fuel tank is fi lled with fresh, clean, regular unleaded

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 op er -

at ing your tractor for the fi rst time. Follow proper start­ing and transmission purging instructions (See “TO
START ENGINE” and “PURGE TRANSMISSION” in
the Op er a tion section of this manual).

CHECK DECK LEVELNESS

For best cutting results, mower housing should be properly
leveled. See “TO LEVEL MOWER HOUSING” in the Service
and Adjustments section of this manual.

CHECK FOR PROPER POSITION OF ALL
BELTS

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

8

OPERATION

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

REVERSE

ENGINE OFF

OVER TEMP

LIGHT

ATTACHMENT

CLUTCH ENGAGED

(Automatic Models only)

LIGHTS ON

FREE WHEEL

NEUTRAL

FUEL

ATTACHMENT

CLUTCH DISENGAGED

HIGH

ENGINE ON

OIL PRESSURE

LOW

ENGINE START

BATTERY

DANGER, KEEP HANDS

AND FEET AWAY

CHOKE

PARKING BRAKE

REVERSE

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.

FAST

P

FORWARD

KEEP AREA CLEAR

SLOW

PARKING BRAKE

LOCKED

MOWER HEIGHT

15

SLOPE HAZARDS

(SEE SAFETY RULES SECTION)

IGNITION

PARKING BRAKE

UNLOCKED

MOWER LIFT

15

Failure to follow instructions
could result in serious injury or
death. The safety alert symbol
is used to identify safety inform­ation 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.

9

OPERATION

KNOW YOUR TRACTOR

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

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

THROTTLE
CONTROL

CLUTCH/BRAKE
PEDAL

HEIGHT
ADJUSTMENT
KNOB

FREE WHEEL
CONTROL

CHOKE
CONTROL

AMMETER

AT TAC H MENT
CLUTCH LEVER

IGNITION
SWITCH

LIGHT
SWITCH
POSITION

LIFT LEVER
PLUNGER

ATTACHMENT
LIFT LEVER

PARKING
BRAKE

MOTION
CONTROL
LEVER

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 POSITION - Turns the headlights on and
off.

AMMETER - Indicates charging (+) or discharging (-) of
battery.

CHOKE CONTROL - Used when starting a cold engine.

THROTTLE CONTROL - Used for controlling engine

speed.

CLUTCH/BRAKE PEDAL - Used for declutching and brak­ ing the tractor and starting the engine.

PARKING BRAKE - Locks clutch/brake pedal into the
brake position.

FIG. 5

FREEWHEEL CONTROL - Disengages transmission for

pushing or slowly towing the tractor with the engine off.
MOTION CONTROL LEVER - Selects the speed and

di rec tion of tractor.
ATTACHMENT LIFT LEVER - Used to raise, lower, and

adjust 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.

HEIGHT ADJUSTMENT KNOB - Used to adjust the mow er
cutting height.

10