Poulan Pro 161608 Owner's Manual
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Poulan Pro 161608 Owner's Manual

Poulan Pro 161608 Owner's Manual

14.5 hp 42 inch lawn tractor
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OWNER'S MANUAL
MODEL NO. HD145H42G
14.5 HP 42 Inch
Lawn Tractor
•
Assembly
•
Operation
•
Customer Responsibilities
•
Service and Adjustments
•
Storage
•
For Parts and Service, contact our authorized distributor: call 1-800-849-1297
For Technical Assistance: call 1-800-829-5886
Troubleshooting
•
Repair Parts
161608 08.01.97 KFSW
PRINTED IN U.S.A.

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Summary of Contents for Poulan Pro 161608

  • Page 1 Lawn Tractor • Assembly • Operation • For Parts and Service, contact our authorized distributor: call 1-800-849-1297 Customer Responsibilities • Service and Adjustments • Storage • Troubleshooting • Repair Parts For Technical Assistance: call 1-800-829-5886 161608 08.01.97 KFSW 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 THROW ING 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.

  • Page 3: Product Specifications

    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.

  • Page 4: Table Of Contents

    SAFETY RULES ... 3 PRODUCT SPECIFICATIONS... 3 CUSTOMER RESPONSIBILITIES... 3, 15-19 WARRANTY... 50 ASSEMBLY... 6-9 OPERATION ... 10-14 INDEX Adjustments: Brake... 22 Carburetor ... 25 Mower Front-To-Back ... 21 Side-To-Side... 21 Throttle Control Cable... 24 Air Filter, Engine... 18 Air Screen, Engine ... 18 Assembly ...

  • Page 5: Contents Of Hardware Pack

    CONTENTS OF HARDWARE PACK Parts Bag contents shown full size (1) Large Flat Washer (1) Hex Bolt 5/16-18 x 1-1/4 (1) Shoulder Bolt 5/16-18 (1) Hex Bolt 1/2-13 x 1 (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 (2) Washers 9/32 x 5/8 x 16 Gauge...

  • Page 6: Tools Required For 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 opera- tion 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.

  • Page 7: Hex Bolt 5/16-18

    HOW TO SET UP YOUR TRACTOR CONNECT BATTERY (See Figs. 2 and 3) CAUTION: Do not short battery ter- mi nals by allowing a wrench or any other object to contact both terminals at the same time. ing battery, re move metal bracelets, wristwatch bands, rings, etc.

  • Page 8: Check Tire Pressure

    ASSEMBLE GAUGE WHEELS TO MOWER DECK (See Fig. 5) The gauge wheels are designed to keep the mower deck in proper posi- tion when operating mower. Be sure they are properly adjusted to ensure optimum mower performance. • Assemble gauge wheels with tractor on a fl at level surface. •...
  • Page 9 OPERATION These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning. BATTERY CAUTION OR REVERSE FORWARD FAST SLOW WARNING ENGINE ON ENGINE OFF OIL PRESSURE CLUTCH LIGHTS ON LIGHTS OFF FUEL CHOKE MOWER HEIGHT DIFFERENTIAL...
  • Page 10 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 refer- ence. ATTACHMENT CLUTCH LEVER THROTTLE/CHOKE...

  • Page 11: To Move Forward And Backward

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

  • Page 12: To Operate On Hills

    TO OPERATE MOWER (See Fig. 8) Your tractor is equipped with an operator presence sensing switch. Any attempt by the operator to leave the seat with the engine running and the attachment clutch engaged will shut off the engine. • Select desired height of cut.

  • Page 13: Before Starting The Engine

    BEFORE STARTING THE ENGINE CHECK ENGINE OIL LEVEL (See Fig. 12) • The engine in your tractor has been shipped, from the factory, already fi lled with sum mer weight oil. • Check engine oil with tractor on level ground. •...

  • Page 14: Mowing Tips

    PURGE TRANSMISSION CAUTION: Never engage or disengage freewheel lever while the engine is run- ning. To ensure proper operation and performance, it is rec om mend ed that the transmission be purged before operating tractor for the fi rst time. This procedure will remove any trapped air inside the transmission which may have de vel oped during shipping of your tractor.

  • Page 15: Warranty

    CUSTOMER RESPONSIBILITIES MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE Check Brake Operation Check Tire Pressure Check for Loose Fasteners Sharpen/Replace Mower Blades Lubrication Chart Check Battery Level/Recharge Clean Battery and Terminals Check Transaxle Cooling Adjust Blade Belt(s) Tension Adjust Motion Drive Belt(s) Tension Check Engine Oil Level Change Engine Oil...

  • Page 16: Lock Washers

    CUSTOMER RESPONSIBILITIES TRACTOR Always observe safety rules when performing any main te nance. BRAKE OPERATION If tractor requires more than six (6) feet stopping distance at high speed in highest gear, then brake must be adjusted. (See “TO ADJUST BRAKE” in the Service and Ad just ments section of this manual).

  • Page 17: Customer Responsibilities

    CUSTOMER RESPONSIBILITIES V-BELTS Check V-belts for deterioration and wear after 100 hours of operation and replace if necessary. The belts are not ad just able. Re place belts if they begin to slip from wear. TRANSAXLE COOLING The fan and cooling fi ns of transmission should be kept clean to assure proper cooling.

  • Page 18: Carburetor

    CUSTOMER RESPONSIBILITIES AIR FILTER (See Fig. 14A) Your engine will not run properly using a dirty air fi lter. Clean the foam pre-cleaner after every 25 hours of op er a tion or every season. Service paper cartridge every 100 hours of operation or every season, whichever occurs fi...

  • Page 19: Spark Plugs

    CUSTOMER RESPONSIBILITIES MUFFLER Inspect and replace corroded muffl er and spark arrester (if equipped) as it could create a fi re hazard and/or damage. SPARK PLUGS Replace spark plugs at the beginning of each mowing season or after every 100 hours of operation, whichever occurs fi rst. Spark plug type and gap setting are shown in “PROD UCT SPECIFICATIONS”...

  • Page 20: Service And Adjustments

    SERVICE AND ADJUSTMENTS CAUTION: BEFORE PERFORMING ANY SERVICE OR ADJUSTMENTS: • Depress clutch/brake pedal fully and set parking brake. • Place motion control lever in neutral (N) position. • Place attachment clutch in “DISENGAGED” position. • Turn ignition key “OFF” and remove key. •...

  • Page 21: Side-To-Side

    SERVICE AND ADJUSTMENTS TO LEVEL MOWER HOUSING Adjust the mower while tractor is parked on level ground or driveway. Make sure tires are properly infl ated (See “PROD UCT SPECIFICATIONS” on page 2 of this manual). If tires are over or underinfl ated, you will not properly adjust your mower.

  • Page 22: To Replace Mower Blade Drive Belt

    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 MOW ER” in this section of this manual).

  • Page 23: Washers

    SERVICE AND ADJUSTMENTS TO AD JUST STEER ING WHEEL ALIGN- MENT If steering wheel crossbars are not horizontal (left to right) when wheels are positioned straight forward, 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.

  • Page 24: Interlocks And Relays

    SERVICE AND ADJUSTMENTS TO START ENGINE WITH A WEAK BAT TERY (See Fig. 26) CAUTION: Lead-acid batteries gen er ate ex plo sive gases. Keep sparks, fl ame and smoking ma te ri als away from bat- ter ies. Always wear eye pro tec tion when around batteries.

  • Page 25: Throttle Control Cable

    SERVICE AND ADJUSTMENTS ENGINE TO AD JUST THROTTLE CON TROL CABLE (See Fig. 28) The throttle control has been preset at the factory and ad just ment should not be necessary. Check adjustment as described below before loosening cable. If adjustment is necessary, proceed as follows: •...

  • Page 26: Terminals

    TROUBLESHOOTING POINTS PROBLEM CAUSE Out of fuel. Will not start Engine not “CHOKED” properly. Engine fl ooded. Bad spark plug. Dirty air fi lter. Dirty fuel fi lter. Water in fuel. Loose or damaged wiring. Carburetor out of adjustment. Engine valves out of adjustment. Hard to start Dirty air fi...

  • Page 27: Troubleshooting Points

    TROUBLESHOOTING POINTS PROBLEM CAUSE Engine continues to run Faulty operator-safety presence control system. when operator leaves seat with attachment clutch engaged Poor cut - uneven Worn, bent or loose blade. Mower deck not level. Buildup of grass, leaves, and trash under mower. Bent blade mandrel.

  • Page 28: Schematic

    TRACTOR - - MODEL NUMBER HD145H42G SCHEMATIC AMMETER (OPTIONAL) WHITE IGNITION SWITCH BLUE IGNITION SWITCH POSITION CIRCUIT “MAKE” G + M + L NONE RUN/LIGHT B + L A + Y B + L NONE START B + L + S NONE BATTERY FUSE 30 AMP.

  • Page 29: Repair Parts

    REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G ELECTRICAL...
  • Page 30 TRACTOR - - MODEL NUMBER HD145H42G ELECTRICAL KEY PART NO. NO. NOTE: All component dimensions given in U.S. inches REPAIR PARTS DESCRIPTION 144925 Battery 12 Volt 25 Amp 74760412 Bolt Hex Hd 1/4-20unc X 3/4 19091016 Washer 9/32 X 5/8 X 16 Ga 10040400 Washer Lock Hvy Helical 1/4 73220400...
  • Page 31 REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G CHASSIS AND ENCLOSURES...

  • Page 32: Chassis And Enclosures

    REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G CHASSIS AND ENCLOSURES NOTE: All component dimensions given in U.S. inches PART DESCRIPTION 159530 Chassis Wldmt. 140356 Drawbar Stretch 94 17490612 Screw Thdrol. 3/8-16 x 3/4 Ty-Tt 19131216 Washer 13/32 x 3/4 x 16 Ga. 155272 Bumper Hood/Dash 155923...
  • Page 33 REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G DRIVE...

  • Page 34: Washers

    REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G DRIVE PART DESCRIPTION 140607 Transaxle (See Breakdown) Hydro Gr Model 0310-0500 142431 Spring, Return, Brake 144698 Pulley, Transmission 141003 Rod, Shift 76020416 Pin, Cotter 1/8 x 1 74490544 Bolt Hex FLGHD 5/16-18 Gr. 5 73800500 Nut, Lock Hex w/Ins 5/16-18 UNC 74780616...
  • Page 35 REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G STEERING ASSEMBLY steering_pl.lt_16...

  • Page 36: Steering Assembly

    TRACTOR - - MODEL NUMBER HD145H42G STEERING ASSEMBLY NOTE: All component dimensions given in U.S. inches REPAIR PARTS PART DESCRIPTION 140044 Wheel Steering Ayp/kelch Blk 154427 Axle Asm Fr 156483 Spindle Asm LH 157473 Spindle Asm RH 6266H Bearing Race Thrust Harden 121748X Washer 25/32 X 1-5/8 X 16 Ga 19272016...

  • Page 37: Seat Assembly

    TRACTOR - - MODEL NUMBER HD145H42G SEAT ASSEMBLY PART DESCRIPTION 140116 Seat 2300/1316 Blk/blk AYPPL 140551 Bracket Pivot Seat 8 720 74760616 Bolt Fin Hex 3/8-16 Unc x 1 19131610 Washer Flat 13/32 x 1 x 10 Ga 145006 Clip Push In Hinged 73800600 Nut Crownlock 3/8-16 Unc 124181X...

  • Page 38: Wheels And Tires

    158166 Decal Fender Logo 157141 Decal Cau tion Fender Eng/Sp 141897 Decal Clutch/brake Eng/Sp 160396 Decal V-Belt Sch 158169 Decal Mulch Bag Poulan 145005 Decal Btry Dngr/Psn P/L Sym 158176 Decal Seat Acc WHEELS AND TIRES 4,10 REPAIR PARTS PART...
  • Page 39 REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G ENGINE OPTIONAL EQUIPMENT Spark Arrester...
  • Page 40 REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G ENGINE PART DESCRIPTION 140310 Control Th/ch LH Flag 23.5 17720410 Screw Hex Thd Cut 1/4-20x5/8 T - - - - - - Engine B&S 287777 137352 Muffl er Exhaust LT B&S 14HP IC OHV 272293 Gasket Eng 1 313 Id Tin Plated 13280324...
  • Page 41 TRACTOR - - MODEL NUMBER HD145H42G LIFT REPAIR PARTS 17 18...
  • Page 42 TRACTOR - - MODEL NUMBER HD145H42G LIFT REPAIR PARTS PART DESCRIPTION 159460 Wire Asm Inner W/Plunger 159471 Shaft Asm Lft 105767X Pin Groove 12000002 E-ring Truarc #5133-62 19211621 Washer Pltd 21/32 X 1 X 21 Ga 120183X Bearing Nylon 109413X Grip Handle Bicycle 124526X Button Plunger Black...
  • Page 43 TRACTOR - - MODEL NUMBER HD145H42G MOWER DECK 81 82 REPAIR PARTS...

  • Page 44: Mower Deck

    TRACTOR - - MODEL NUMBER HD145H42G MOWER DECK PART DESCRIPTION 144393 Mower Housing 72140506 Bolt Rdhd Sqnk 5/16-18unc X3/4 138017 Bracket Asm Fr Sway Bar 38/42 138440 Bracket Asm Deck 42" sway Bar 4939M Retainer Spring 130832 Arm Suspension Rear 850857 Bolt 3/8-24 X 1 1/4 10030600...
  • Page 45 REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G TRANSAXLE HYDRO GEAR - MODEL NUMBER 310-0500...
  • Page 46 REPAIR PARTS TRACTOR - - MODEL NUMBER HD145H42G TRANSAXLE HYDRO GEAR - MODEL NUMBER 310-0500 KEY PART NO. NO. DESCRIPTION 142986 Housing, Lower 142987 Assembly, Upper Housing 142932 Seal, Lip 142928 Ring, Wire Retaining 142933 Ring, Retaining 142934 Bearing, Shaft Ball 142935 Bearing, Cradle 150771...
  • Page 47 SERVICE NOTES...
  • Page 48 SERVICE NOTES...

  • Page 49: Replacement

    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 replace, at our option, without charge for parts or labor incurred in replacing parts, any part which we fi...

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