Poulan Pro PR625Y22RKP User Manual

SELF-PROPELLED ROTARY

LAWN MOWER

WARNING: This lawn mower is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-covered or grass-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.

193733 Rev. 6 06.12.09 BY

Printed in U.S.A.

TABLE OF CONTENTS

Safety Rules	.................2-3	Maintenance .............	16-18	Storage.....................	25-26
Assembly ......................	4-7	Service and		Troubleshooting........	26-27
Operation....................	8-15	Adjustments..............	19-24

SAFETY RULES

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.

Look for this symbol to point out important safety precautions. It means CAUTION!!! BECOME ALERT!!! YOUR SAFETY IS INVOLVED.

WARNING: In order to prevent accidental starting when setting up, transporting, adjusting or making repairs, always disconnect spark plug wire and place wire where it cannot come in contact with plug.

WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

CAUTION: Muffler and other engine parts become extremely hot during operation and remain hot after engine has stopped. To avoid severe burns on

contact, stay away from these areas.

I. GENERAL OPERATION

•Read, understand, and follow all instructions on the machine and in the manual(s) before starting. Be thoroughly familiar with the controls and the proper use of the machine before starting.

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

•Only allow responsible individuals, who are familiar with the instructions, to operate the machine.

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

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

•Do not operate the mower when barefoot or wearing open sandals. Always wear substantial foot wear.

• Do not pull mower backwards unless absolutely necessary. Always look down and behind before and while moving backwards.

• Never direct discharged material toward anyone. Avoiddischargingmaterialagainst a wall or obstruction. Material may richochet back toward the operator. Stop the blade when crossing gravel surfaces.

• Do not operate the mower without proper guards, plates, grass catcher or other safety protective devices in place.

• See manufacturer’s instructions for proper operation and installation of accessories. Only use accessories approved by the manufacturer.

• Stop the blade(s) when crossing gravel drives, walks, or roads.

• Stop the engine (motor) whenever you leave the equipment, before cleaning the mower or unclogging the chute.

• Shut the engine (motor) off and wait until the blade comes to complete stop before removing grass catcher.

• Mow only in daylight / good artifi cial light.

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

• Never operate machine in wet grass. Always be sure of your footing: keep a firm hold on the handle; walk, never run.

• Disengage the self-propelled mechanism or drive clutch on mowers so equipped before starting the engine.

• If the equipment should start to vibrate abnormally, stop the engine (motor) and check immediately for the cause. Vibration is generally a warning of trouble.

• Always wear safety goggles or safety glasses with side shields when operating mower.

II. SLOPE OPERATION

Slopes are a major factor related to slip & fall accidents which can result in severe injury. All slopes require extra caution. If you feel uneasy on a slope, do not mow it.

	DO:
	• Mow across the face of slopes: never
	up and down. Exercise extreme caution
2	when changing direction on slopes.

TROUBLESHOOTING - See appropriate section in manual unless directed to an authorized Service Center.

PROBLEM		CAUSE	CORRECTION
Loss of power	1.	Rear of lawn mower	1.	Raise cutting height.
		housing or cutting blade
		dragging in heavy grass.
	2.	Cutting too much grass.	2.	Raise cutting height.
	3.	Dirty air filter.	3.	Clean/replace air filter.
	4.	Buildup of grass, leaves,	4.	Clean underside of mower
		and trash under mower.		housing.
	5.	Too much oil in engine.	5.	Check oil level.
	6.	Walking speed too fast.	6.	Cut at slower walking speed.
Poor cut –	1.	Worn, bent or loose blade.	1.	Replace blade. Tighten
uneven				blade bolt.
	2.	Wheel heights uneven.	2.	Set all wheels at same
				height.
	3.	Buildup of grass, leaves	3.	Clean underside of
		and trash under mower.		mower housing.
Excessive	1.	Worn, bent or loose blade.	1.	Replace blade. Tighten
vibration				blade bolt.
	2.	Bent engine crankshaft.	2.	Contact a qualified service
				center.
Starter rope	1.	Engine flywheel brake is on	1.	Depress control bar to
hard to pull		when control bar is released.		upper handle before
				pulling starter rope.
	2.	Bent engine crankshaft.	2.	Contact a qualified service
				center.
	3.	Blade adapter broken.	3.	Replace blade adapter.
	4.	Blade dragging in grass.	4.	Move lawn mower to cut
				grass or to hard surface.
Grass catcher	1.	Cutting height too low.	1.	Raise cutting height.
not filling	2.	Lift on blade worn off.	2.	Replace blade.
(If so equipped)	3.	Catcher not venting air.	3.	Clean grass catcher.
Hard to push	1.	Grass is too high or wheel	1.	Raise cutting height.
		height is too low.
	2.	Rear of lawn mower	2.	Raise rear of lawn mower
		housing or cutting blade		housing one (1) setting
		dragging in grass.		higher.
	3.	Grass catcher too full.	3.	Empty grass catcher.
	4.	Handle height position not	4.	Adjust handle height to suit.
		right for you.
Loss of drive	1.	Belt wear.	1.	Check/replace drive belt.
or slowing of	2.	Belt off of pulley.	2.	Check/reinstall drive belt.
drive speed	3.	Drive cable worn or broken.	3.	Replace drive cable.
	4.	“Loose” drive control system.	4. Adjust drive control.

27

ENGINE

FUEL SYSTEM

IMPORTANT: It is important to prevent gum deposits from forming in essential fuel system parts such as carburetor, fuel fi lter, fuel hose, or tank during storage. 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 or 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 storage. 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 stabilizer to allow the stabilizer 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 oil. (See “ENGINE” in the Maintenance section of this manual).

CYLINDER

•Remove spark plug.

•Pour one ounce (29 ml) of oil through spark plug hole into cylinder.

•Pull starter handle slowly to distribute oil.

•Replace with new spark plug.

BATTERY (IF EQUIPPED)

Disconnect the battery from the engine connector and charge battery 48 hours.

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 unit indoors and cover it to protect it from dust and dirt.

•Cover your unit with a suitable protective cover that does not retain moisture. Do not use plastic. Plastic cannot breathe, which allows condensation to form and will cause your unit to rust.

IMPORTANT: Never cover mower while engine and exhaust areas are still warm. CAUTION: Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame

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

TROUBLESHOOTING - See appropriate section in manual unless directed to an authorized Service Center.

PROBLEM		CAUSE	CORRECTION
Does not start	1.	Dirty air filter.	1.	Clean/replace air filter.
	2.	Out of fuel.	2.	Fill fuel tank.
	3.	Stale fuel.	3.	Drain fuel tank and refill tank
				with fresh, clean gasoline.
	4.	Water in fuel.	4.	Drain fuel tank and refill tank
				with fresh, clean gasoline.
	5.	Spark plug wire is	5.	Connect wire to plug.
		disconnected.
	6.	Bad spark plug.	6.	Replace spark plug.
	7.	Loose blade or broken	7.	Tighten blade bolt or
		blade adapter.		replace blade adapter.
	8.	Control bar in released	8.	Depress control bar to
		position.		handle.
	9.	Control bar defective.	9.	Replace control bar.
	10.Fuel valve lever (if so		10.Turn fuel valve lever
		equipped) in OFF position.		to the ON position.
	11. Weak battery (if equipped).		11. Charge battery.
	12.Disconnected battery		12.Connect battery to engine.
		connector (if equipped).
		26

•Remove obstacles (rocks, tree limbs, etc.)

•Watch for holes, ruts, or bumps. Tall grass can hide obstacles.

DO NOT:

•Do not trim near drop-offs, ditches or embankments. The operator could lose footing or balance.

•Do not trim excessively steep slopes.

•Do not mow on wet grass. Reduced footing could cause slipping.

III. CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

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

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

•Before and while walking backwards, look behind and down for small children.

•Never allow children to operate the mower.

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

IV. SAFE HANDLING OF GASOLINE

Use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

•Extinguish all cigarettes, cigars, pipes and other sources of ignition.

•Use only an approved container.

•Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling.

•Never refuel the machine indoors.

•Never store the machine or fuel container where there is an open flame, spark or pilot light such as a water heater or on other appliances.

•Never fill containers inside a vehicle, on a truck or trailer bed with a plastic liner. Always place containers on the ground

away from your vehicle before filling.

•Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this 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 all times until fueling is complete. Do not use a nozzle lock-open device.

•If fuel is spilled on clothing, change clothing immediately.

•Never overfi ll fuel tank. Replace gas cap and tighten securely.

V. GENERAL SERVICE

•Never run machine inside a closed area.

•Never make adjustments or repairs with the engine (motor) running. Disconnect the spark plug wire, and keep the wire away from the plug to prevent accidental starting.

•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.

•Keepmachinefreeofgrass,leaves,orother 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 attempt to make wheel height adjustments while the engine is running.

•Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects tobethrown.Frequentlycheckcomponents and replace with manufacturer’s recommended parts, when necessary.

•Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them.

•Do not change the engine governor setting or overspeed the engine.

•Maintain or replace safety and instruction labels, as necessary.

CONGRATULATIONS on your purchase of a new Lawn Mower. It has been designed, engineered and manufactured to give you the best possible dependability and performance. Should you experience any problems you cannot easily remedy, please contact your nearest authorized service center. They have competent, well trained technicians and the proper tools to service or repair this unit.

•Read the SAFETY RULES and this Operator's Manual in its entirety before you attempt to assemble or operate your new lawn mower to insure proper operation and to prevent injury to yourself and others. Save this manual for future reference.

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

•All parts such as nuts, washers, bolts, etc., necessary to complete the assembly have

been placed in the parts bag.

3

TO REMOVE MOWER FROM CARTON

•Remove all loose parts from carton.

•Remove lawn mower housing with care. Avoid touching blade under housing. Always wear gloves or other protection when working under or lifting mower.

THINGS TO KNOW BEFORE YOU ASSEMBLE OR OPERATE YOUR LAWN MOWER

Do I have a side or rear discharge lawn mower?

Look for the grass discharge opening on your mower. If the opening is on the right side of the mower housing, it is a side discharge mower. If the opening is at the back of the mower housing, it is a rear discharge mower. Only rear discharge lawn mowers have a grass catcher included with the mower. Approved grass catchers for side discharge mowers may be purchased from your nearest authorized dealer.

Do I have a mulching lawn mower?

Look for the grass discharge opening on your mower. Raise the discharge guard (rear door on rear discharge mowers). If the opening is closed off by a plate, then your lawn mower is mulcher ready. To convert to a discharging mower, see the Operation section of this manual.

What is the right and left side of the lawn mower?

When right hand (RH) or left hand (LH) is mentioned in this manual, it means when you are in the operating position (standing behind the handle).

What kind of engine is on my lawn mower?

When learning how to operate your new lawn mower, you will need to know what kind of engine powers the mower. A decal on the engine will indicate the manufacturer and type or brand name of the engine.

BRIGGS & STRATTON ENGINES

FRONT

	LEFT	RIGHT	TECUMSEH	HONDA
	HAND	HAND
			ENGINES	ENGINES
	SIDE	SIDE

®

BACK or REAR (Operating Position)

ASSEMBLY

CAUTION: Do not operate this lawn mower without the discharge guard or an entire approved grass catcher in place. These guards are for your protection and are required by the American National Standards Institute and Consumer Products Safety Commission.

CAUTION: Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.

HOW TO SET UP YOUR LAWN MOWER

UNFOLD HANDLE

IMPORTANT: Unfold handle carefully so as not to pinch or damage control cables.

2 POSITION / “ADJUSTABLE” HANDLES

•Raise handles until lower handle section locks into place in operating position.

4

STORAGE

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

CAUTION: Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame

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

LAWN MOWER

When lawn mower is to be stored for a period of time, clean it thoroughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area.

•Clean entire lawn mower (See “CLEANING” in the Maintenance section of this manual).

•Lubricate as shown in the Maintenance section of this manual.

•Be sure that all nuts, bolts, screws, and pins 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.

HANDLE

Your handle may be folded for storage as shown.

•Squeeze the bottom ends of lower handle towards each other until handle clears the handle brackets and swing handles forward over mower.

•Loosen upper handle mounting hardware enough to allow upper handle to be folded back.

IMPORTANT: When folding handles for storage or transportation, be sure to fold handles as shown or you may damage the control cables.

Operator	MOWING
presence	POSITION
control bar
FOLD	Upper
FORWARD
FOR	handle
STORAGE
	Handle
	knob
	Lower handle

2POSITION / “ADJUSTABLE” HANDLES When setting you handles up from the storage position, the lower handle will automatically lock into mowing position.

3POSITION HANDLES

When setting up your handle from the storage position, the lower handle will require manually locking into the mowing position.

3 POSITION “EZ”

Knob

Bolt

Handle adjustment bracket

SQUEEZE

TO FOLD

3 POSITION “QUICK”

Lower handle	Handle pin
	SQUEEZE

Handle adjustment bracket

25

MODELS WITH GEARCASE-MOUNTED BELT KEEPER AND NO DEBRIS SHIELD:

•Remove drive cover.

•Remove spring and belt keeper.

•Remove belt from gearcase pulley.

Gearcase pulley	Drive
	cover
	Spring
	Belt
	keeper
	Belt

•Turn lawn mower on its side. See engine manual for proper direction of turning over the engine.

•Remove blade and blade adapter.

•Remove belt from blade adapter.

•Position the blade adapter on the engine crankshaft. Be sure key in adapter and crankshaft keyway are aligned; and that the drive belt is inside the tabs of the belt retainer.

Blade adapter	Key	Crankshaft
		keyway
Lockwasher
Blade
Blade
bolt Hardened		Belt
washer	Trailing edge	retainer

•Route the other end of the new drive belt through hole in housing.

•Return mower to upright position.

•Install new belt on gearcase pulley.

•Reinstall belt keeper and spring.

•Reinstall drive cover.

NOTE: Always use factory approved belt to assure proper fit and long life.

•Turn lawn mower on its side with air filter and carburetor down.

•Reinstall blade and blade adapter.

ENGINE

CARBURETOR

The carburetor has been preset at the factory and adjustment should not be necessary. However, minor adjustment may be required to compensate for differences in fuel, temperature, altitude or load.

•The air filter must be assembled to the carburetor when running engine.

•Best carburetor adjustment is obtained when fuel tank is 1/4 full.

•In order for the engine to run, the opera-

tor presence control bar must be held in the operating position. Therefore, and assistant will be required to hold the control bar in the operating position when making final adjustment to the carburetor.

See the ADJUSTMENT section of your engine manual for further instructions.

ENGINE SPEED

The engine speed has been factory set. Do not attempt to increase engine speed as it may result in personal injury. If you believe the engine is running too fast

or too slow, take your lawn mower to an authorized engine service center for repair and adjustment.

THROTTLE CONTROL

If it becomes necessary to adjust or replace the throttle control, see the ADJUSTMENT section of your engine manual.

24

Operator presence control bar

LIFT

UP

LIFT

UP

MOWING	ALL HANDLES
POSITION	•	Raise upper handle section into place on
		lower handle, remove protective padding
		and tighten both handle knobs.
	•	Remove handle padding holding opera-
		tor presence control bar to upper handle.
Upper	•	Your lawn mower handle can be ad-
		justed for your mowing comfort. Refer to
handle		“ADJUST HANDLE” in the Service and
		Adjustments section of this manual.
	NOTE: For shipping purposes, the rear
Handle	wheels on your lawn mower may not be
knob	adjusted to the same position as the front
	wheels. Before operating mower adjust all

wheels to the same cutting height.

Lower handle

3 POSITION “EZ” HANDLES

•Raise lower handle section to operating position and align hole in handle with one of three height positioning holes.

•Insert handle bolt through handle and bracket and secure with knob.

•Repeat for opposite side of handle.

Knob

Bolt

INSTALL REAR WHEELS (HIGH WHEEL MOWERS ONLY)

Some high wheel models require washers which will be provided in a parts bag. If provided, install washers on the axle fi rst as shown.

•Install one (1) rear wheel on the axle of rear wheel adjuster.

•Install 3/8-16 locknut and tighten securely.

•Repeat procedure for other rear wheel.

Handle adjustment bracket

3 POSITION “QUICK” HANDLES

	Axle
	O-Ring
	Washer
Flanged	Wheel
locknut	assembly

•Raise lower handle section to operating position and squeeze the bottom ends of lower handle towards each other until the pin in handle can be inserted into one of the three height adjustment holes.

Handle pin SQUEEZE

Handle adjustment bracket

ASSEMBLE GRASS CATCHER (REAR DISCHARGE MOWERS ONLY) IMPORTANT: If your model lawn mower

is mulcher ready, the mulcher plate or plug must be removed before using mower as a bagger. To convert mower to bagging or discharging, see the Operation section in this manual.

Look at the different grass catcher illustrations that follow. Determine which type of grass catcher you have and follow the appropriate instructions.

5