IMPORTANT MANUAL OWNER'S MANUAL MODEL: Do Not Throw Away WARNING: Read this Owner's Manual and follow all Warnings and Safety Instructions. Failure to do so can result in serious injury. DPR22H48STA LAWN TRACTOR Always Wear Eye Protection During Operation 177167 Rev. 2 07.12.01 RH 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 THROWING 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 instructions, to operate the machine.
SAFETY RULES Safe Operation Practices for Ride-On Mowers • • • • • • • • • • • • • • 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. Always 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.
PRODUCT SPECIFICATIONS CUSTOMER RESPONSIBILITIES • • Read and observe the safety rules. Follow a regular schedule in maintaining, caring for and using your tractor. Follow the instructions under “Customer Responsibilities” and “Storage” sections of this owner’s manual. GASOLINE CAPACITY AND TYPE: 3.5 GALLONS 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: (GAP: .
UNASSEMBLED PARTS Gauge Wheels Steering Wheel (4) Shoulder Bolts (4) Wheels (4) Adjusting Bars Steering Sleeve Steering Sleeve Extension (4) Clevis Pins (4) Washers 3/8 x 3/4 x 14 Ga. Steering Wheel Adapter Steering Wheel Insert (4) Retainer Springs (double loop) Seat (4) Locknuts 3/8-16 Nose Roller (1) Washer 17/32 x 1-3/16 x 12 Gauge (2) Locknuts 5/16-18 (1) Knob (2) Washers 17/32 x 7/8 x 16 Ga.
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 STEERING WHEEL INSERT LOCK NUT A socket wrench set will make assembly easier. Standard wrench sizes are listed.
ASSEMBLY INSTALL SEAT (See Fig. 3) TO ROLL TRACTOR OFF SKID (See Operation section, page 12, for location and function of controls) Adjust seat before tightening adjustment knob. • Remove adjustment knob and flat 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.
ASSEMBLY TO ATTACH NOSE ROLLER (See Fig. 5) ASSEMBLE GAUGE WHEELS TO MOWER DECK (See Fig. 4) • Position brackets, 17/32 x 7/8 x 16 gauge washers, and nose roller between deck mounting brackets as shown. Be sure to position brackets on correct side, as shown. • Install hex bolts and lock nuts as shown. Tighten hardware securely. NOTE: Be sure bracket tabs are positioned in tab holes in deck brackets. The gauge wheels are designed to keep the mower deck in proper position when operating mower.
ASSEMBLY NOTE: To assist in locating hole in flanged pin, the hole in pin is inline with notch on head of pin. If necessary, move mower side-to-side to give space between plate and mower brackets. IMPORTANT: Check belt for proper routing in all mower pulley grooves. Engage belt tension rod by pushing rod into locking bracket. • Engage belt tension rod by pushing rod into locking bracket. INSTALL MOWER AND DRIVE BELT (See Figs.
ASSEMBLY 3CHECKLIST CHECK TIRE PRESSURE BEFORE YOU OPERATE AND ENJOY YOUR NEW TRACTOR, WE WISH TO ASSURE THAT YOU RECEIVE THE BEST PERFORMANCE AND SATISFACTION FROM THIS QUALITY PRODUCT. PLEASE REVIEW THE FOLLOWING CHECKLIST: 3 All assembly instructions have been completed. 3 No remaining loose parts in carton. 3 Battery is properly prepared and charged. (Minimum 1 hour at 6 amps). 3 Seat is adjusted comfortably and tightened securely. 3 All tires are properly inflated.
OPERATION These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning.
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.
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 spectacles or standard safety glasses. HOW TO USE YOUR TRACTOR CAUTION: Always stop tractor completely, as described above, before leaving the operator's position; to empty grass catcher, etc.
OPERATION TO ADJUST GAUGE WHEELS (See Fig. 9) TO OPERATE ON HILLS Gauge wheels are properly adjusted when they are slightly off the ground when mower is at the desired cutting height in operating position. Gauge wheels then keep the deck in proper position to help prevent scalping in most terrain conditions. NOTE:Adjust gauge wheels with tractor on a flat level surface. • Adjust mower to desired cutting height (See “TO ADJUST MOWER CUTTING HEIGHT” in the Operation section of this manual).
OPERATION TO START ENGINE (See Fig. 7) BEFORE STARTING THE ENGINE 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 engaged position. • Sit on seat in operating position, depress brake pedal and set parking brake. • Move attachment clutch to “DISENGAGED” position.
OPERATION MOWING TIPS PURGE TRANSMISSION • CAUTION: Never engage or disengage freewheel lever while the engine is running. • • To ensure proper operation and performance, it is recommended 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 developed during shipping of your tractor.
CUSTOMER RESPONSIBILITIES MAINTENANCE SCHEDULE FILL IN DATES AS YOU COMPLETE REGULAR SERVICE E GE RS S RS RS US OU SON ORA UR OU HOU H CH O T H A A 0 H S SE 25 50 10 E EE Y 8 R RY ERY ERY ERY FOR OR E E F SERVICE EV EV EV EV EV BE BE DATES Check Brake Operation Check Tire Pressure T R A C T 0 R Check Operator Presence and Interlock Systems Check for Loose Fasteners 7 Sharpen/Replace Mower Blades 4 Lubrication Chart Check Battery Level 6 Clean Battery and Terminals Check Transaxle Cooling Adjust B
CUSTOMER RESPONSIBILITIES TRACTOR IMPORTANT: TO ENSURE PROPER ASSEMBLY, CENTER HOLE IN BLADE MUST ALIGN WITH STAR ON MANDREL ASSEMBLY. Always observe safety rules when performing any maintenance. • BRAKE OPERATION Install and tighten blade bolt securely (45-55 Ft. Lbs. torque). IMPORTANT: SPECIAL BLADE BOLT HEAT TREATED. If tractor requires more than six (6) feet stopping distance at high speed in highest gear, then brake must be adjusted.
CUSTOMER RESPONSIBILITIES V-BELTS OIL DRAIN VALVE 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. CLOSED AND LOCKED POSITION TRANSAXLE COOLING The transmission fan and cooling fins 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.
CUSTOMER RESPONSIBILITIES TO SERVICE PRE-CLEANER • 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. TO SERVICE CARTRIDGE • Clean cartridge by tapping gently on flat surface. If very dirty or damaged, replace cartridge. • Reinstall precleaner cartridge, cover and secure with knobs. IN-LINE FUEL FILTER (See Fig.
SERVICE AND ADJUSTMENTS CAUTION: BEFORE PERFORMING ANY SERVICE OR ADJUSTMENTS: • Depress brake pedal fully and set parking brake. • Place attachment clutch in “DISENGAGED” position. • Turn ignition key “OFF” and remove key. • Make sure the blades and all moving parts have completely stopped. • Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. TRACTOR TO LEVEL MOWER HOUSING TO REMOVE MOWER (See Fig.
SERVICE AND ADJUSTMENTS BOTH FRONT LINKS MUST BE EQUAL IN LENGTH SUSPENSION ARM LIFT LINK ADJUSTMENT NUT FIG. 21 NUT “C” NUT “D” FRONT-TO-BACK ADJUSTMENT (See Figs. 22 and 23) 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-TO-SIDE.
SERVICE AND ADJUSTMENTS BELT TENSION ROD (DISENGAGED POSITION) RH SUSPENSION ARM IDLER PULLEY L.H. MANDREL RH MANDREL COVER SECONDARY IDLER ARM SPRING SECONDARY SPRING ARM CENTER MANDREL ELECTRIC CLUTCH PULLEY IDLER PULLEY IDLER PULLEY SPRING ARM R.H. MANDREL COVER FIG. 25 PRIMARY IDLER ARM TO ADJUST BRAKE (See Fig. 26) R.H. MANDREL Your tractor is equipped with an adjustable brake system which is mounted on the side of the transaxle.
SERVICE AND ADJUSTMENTS TO REPLACE MOTION DRIVE BELT (See Fig. 27) TO ADJUST TOE-IN (See Figs. 28 and 29) • Loosen jam nuts at adjustment sleeves on tie rod. • Adjust tie rod until dimension “A” is 1/8" to 1/4" less than dimension “B”. • Tighten jam nuts securely. 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.
SERVICE AND ADJUSTMENTS TO START ENGINE WITH A WEAK BATTERY (See Fig. 31) • • CAUTION: Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. • • If your battery is too weak to start the engine, it should be recharged. (See "BATTERY" in the CUSTOMER RESPONSIBILITIES section of this manual).
SERVICE AND ADJUSTMENTS ENGINE STOP TO ADJUST THROTTLE CONTROL CABLE (See Fig. 34) 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 to fast position. • Check that swivel is against stop. If it is not, loosen cable clamp screw and pull cable back until swivel is against stop.
STORAGE ENGINE 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. 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.
TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Will not start 1. 2. 3. 4. 5. 6. 7. Out of fuel. Engine not “CHOKED” properly. Engine flooded. Bad spark plug. Dirty air filter. Dirty fuel filter. Water in fuel. 1. 2. 3. 4. 5. 6. 7. 8. 9. Loose or damaged wiring. Carburetor out of adjustment. 8. 9. 10. Hard to start Engine valves out of adjustment. 10. Fill fuel tank. See “TO START ENGINE” in Operation section. Wait several minutes before attempting to start. Replace spark plug.
TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine continues to run when operator leaves seat with attachment clutch engaged 1. Faulty operator-safety presence control system. 1. Check wiring, switches and connections. If not corrected, contact an authorized service center/ department. Poor cut - uneven 1. 2. 3. 4. 5. Worn, bent or loose blade. Mower deck not level. Buildup of grass, leaves, and trash under mower. Bent blade mandrel.
SERVICE NOTES 30
TRACTOR - MODEL NUMBER DPR22H48STA SCHEMATIC RED BLACK BATTERY SOLENOID RED RED A AMMETER (OPTIONAL) STARTER WHITE WHITE A1 ELECTRIC CLUTCH BLACK CLUTCH / BRAKE (PEDAL UP) F A2 RED H B RED IGNITION SWITCH BLACK G BLACK M G L BLACK WHITE C S M FUSE RED B RED BLACK E A ORANGE 85 86 BLACK SEAT SWITCH (NOT OCCUPIED) D 30 87 PTO (DISENGAGED) 87A GREEN GREEN HOUR METER BLUE OPERATOR PRESENCE RELAY #1 BLACK (OPTIONAL) FUEL LINE BLACK BLUE FUEL SHUT-OFF SOLENOID SPAR
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA ELECTRICAL 22 21 79 42 24 41 43 40 26 27 27 81 25 16 33 30 52 50 D.C .
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA ELECTRICAL KEY NO. PART NO. DESCRIPTION 1 2 8 10 11 12 16 21 22 24 25 26 27 28 29 30 33 40 41 42 43 45 50 52 55 79 81 163465 74760412 7603J 145211 150109 145769 153664 166184 4152J 8860R 146148 175158 73510400 145491 160784 175566 140401 178450 17720408 131563 175141 122822X 174653 141940 17490508 163996 109748X Battery Bolt Hex Hd 1/4-20 UNC X 3/4 Tray, Battery Bolt, BTR FRT 1/4-20 x 7.
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA CHASSIS AND ENCLOSURES 17 29 166 60 159 161 166 60 30 28 166 31 156 157 9 3 54 58 209 155 213 54 214 158 166 209 20 11 59 64 209 209 209 144 3 60 3 142 3 1 26 25 26 143 154 209 166 13 142 3 145 37 3 2 37 3 14 74 38 206 3 38 34 14 209
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA CHASSIS AND ENCLOSURES KEY NO. PART NO.
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA DRIVE 57 51 243 212 89 116 63 66 221 90 219 19 59 221 215 61 224 19 214 96 221 96 222 19 225 220 217 19 61 233 223 223 35 42 39 151 51 49 47 221 120 34 36 36 35 37 239 238 6 33 231 239 53 28 26 95 55 22 29 77 25 27 19 24 26 26 15 52 32 77 1 241 48 20 27 19 52 16 38 62 226 150 40 51 237 52 30 244 202 50 17 65 42 6 228 216 223 226 227 218 241232 242 235 32 41 229 21 234 240 9 223 51 236 56 74
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA DRIVE KEY NO. 1 9 15 16 17 19 20 21 22 24 25 26 27 28 29 30 32 33 34 35 36 37 38 39 40 41 42 47 48 49 50 51 52 53 55 56 57 59 61 62 63 65 66 74 75 PART NO. ------ KEY NO. 76 77 78 89 90 95 96 116 120 150 151 202 212 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 DESCRIPTION Transaxle (See Breakdown) Hydro gear Model 323-0510 174367 Clutch Elec 74490544 Bolt Hex Flghd 5/16-18 Gr.
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA STEERING ASSEMBLY 38 12 72 1 73 41 42 37 37 36 88 91 43 71 29 67 67 68 46 67 8 29 13 6 65 17 46 2 8 6 87 5 87 3 32 68 82 29 5 11 4 43 40 43 33 29 15 10 34 35 38 6 8
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA STEERING ASSEMBLY KEY NO. PART NO.
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA ENGINE 8 102 3 1 14 38 13 10 25 81 26 6 17 17 5 16 32 62 72 34 31 33 37 39 45 33 23 29 4 OPTIONAL EQUIPMENT Spark Arrester KEY NO. PART NO. 1 3 164067 -------- 4 5 6 8 10 13 14 16 17 23 25 26 149723 159955 160589 171877 162797 165391 148456 11050600 17490624 169837 164068 73920600 DESCRIPTION Control Throttle Engine, Briggs Model 407777 (Order parts from engine mfg.
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA SEAT ASSEMBLY 1 8 8 9 14 9 7 7 10 5 6 22 21 2 24 5 16 25 15 11 4 13 17 3 12 KEY NO. PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 171684 140551 71110616 19131610 145006 73800600 124181X 17000616 19131614 174894 166369 121246X Seat 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 Nut Hex w/Ins. 3/8-16 Unc Spring Seat Cprsn 2 250 Blk Zi Screw 3/8-16 x 1 Washer 13/32 x 1 x 14 Ga.
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA DECALS 2 16 11 12 4 4 3 10 2 9 1 8 20 6 5 14 7 13 KEY NO. PART NO. DESCRIPTION KEY NO.
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA MOWER LIFT 29 28 27 25 24 23 7 8 41 5 49 37 38 30 40 1 36 13 50 4 13 3 26 6 2 6 5 4 11 13 12 51 49 52 31 13 51 32 13 32 53 20 49 18 54 16 17 15 13 54 KEY NO. 1 2 3 4 5 6 7 8 11 12 13 16 17 18 20 23 24 25 26 PART NO.
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA MOWER DECK 46 45 49 36 49 33 130 32 33 42 112 46 37 36 52 31 99 30 43 36 49 121 42 126 49 39 98 97 114 30 45 30 32 42 50 47 115 21 97 122 31 50 110 5 57 21 90 116 117 56 91 180 93 113 94 93 180 100 118 119 90 108 55 92 54 72 92 3 1 24 25 21 107 26 17 29 28 16 6 27 5 109 15 18 19 14 20 13 18 48 11 8 44 95
REPAIR PARTS TRACTOR - MODEL NUMBER DPR22H48STA MOWER DECK KEY NO. PART NO.
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 replace, 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.
15 MAX. SIGHT AND HOLD THIS LEVEL WITH SKY LINE OR TREE. CUT OUT ON D THIS OTT IS A ED L 15 S INES LOP E Operate your Tractor up and down the face of slopes (not greater than 15 ), never across the face. Make turns gradually to prevent tipping or loss of control. Exercise extreme caution when changing direction on slopes.
PARTS AND SERVICE Your POULAN PRO product has been expertly engineered and carefully manufactured to rigid quality standards. As with all mechanical products, some adjustments or part replacement may be necessary during the life of your unit. FOR SERVICE OR REPLACEMENT PARTS: 1. Consult your dealer/place of purchase. 2. Consult the yellow pages of your phone directory for the name of the nearest service dealer (under saws for Chain Saws or under lawn mowers for Trimmers, Brushcutters, and Blowers). 3.