Country Clipper Zero Turn Radius Mower Safety Instructions & Operator's Manual
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Safety Instructions & Operators Manual
®
Zero Turn Radius Mower
Congratulations for buying a Country Clipper product. Your Country Clipper Zero Turning Radius
Riding Mower was designed and built to provide long and trouble free service. Keep in mind that it, like any other mechanical device, can be potentially dangerous if used improperly, and hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the equipment. Study this manual and pay special attention to the important Safety Precautions on pages 3-6. Following these instructions will help you continue to enjoy the trouble-free performance expected of the Country Clipper product.
P-11834 (5/04)
TABLE OF CONTENTS
PROCEDURE FOR RAISING AND LOWERING THE DECK FOR SERVICING ................................19
2
SAFETY
ACCIDENT PATTERNS TO AVOID
I. CONTACT WITH THE ROTATING
BLADE -- This accident usually happens when the operator is clearing the discharge chute of grass, (especially when the grass is wet), or when the operator adjusts the machine without turning it off and waiting for the blades to completely stop.
II.
PROPELLED OBJECTS -- Sticks, rocks, wires, and other objects can be propelled out through the discharge chute or from under the mower housing.
Bystanders are particularly vulnerable.
III.
GRASS CATCHER OR GUARD -- The mower shall not be operated without either the entire grass catcher or guard in place.
1.
2.
3.
SAFETY INSTRUCTIONS AND
RECOMMENDATIONS
PEOPLE WHO OPERATE, SERVICE,
OR ARE OTHERWISE ASSOCIATED
with the Country Clipper Zero Turning
Radius Mower should be trained in its proper use and warned of its dangers.
Before operating, adjusting, or servicing the Country Clipper Zero Turning
Radius Mower they should read and understand this entire manual and the engine owner’s manual.
AVOID CONTACT WITH MOVING
PARTS. Keep hands and feet from under mowing deck and away from blades at all times. Turn engine (motor) off if you must unclog the chute.
AVOID HILLS AND SLOPES. Use extreme caution when mowing up or down slopes. NEVER mow across the face of a slope. If a slope must be ascended, back up the slope; drive forward when descending. Reduce speed and use caution to start, stop and maneuver. To prevent loss of control on a slope avoid sharp turns, sudden changes in direction, and sudden stops and starts. riding mowers are used on steep slopes, embankments or hills. The operator in these cases can come in contact with the blades or sustain injuries during a fall.
V. MOWER RUNNING OVER THE VICTIM
-- This usually happens when a riding mower is driven in reverse. The accident victims are most often young children whom, unseen by the operator of the mower, were in the area being mowed.
AT COUNTRY CLIPPER, WE SHARE YOUR
DESIRE TO PROTECT YOURSELF, YOUR
FAMILY, YOUR FRIENDS AND YOUR
NEIGHBORS FROM ACCIDENTAL INJURY.
OBSERVING AND ENFORCING THE
FOLLOWING GUIDELINES WILL HELP TO
INSURE THE SAFETY OF EVERYONE.
PLEASE BE CAREFUL!
4.
5.
6.
DISENGAGE POWER TO MOWER
BEFORE BACKING UP. Do not mow in reverse unless ABSOLUTELY necessary and then only after turning around and observing the entire area behind the mower. Go slowly. Most
“running over victim” accidents occur in reverse.
BEGINNING OPERATORS SHOULD
LEARN HOW TO STEER the Country
Clipper Zero Turning Radius Mower before attempting to mow. Start with slow engine speed and drive without the blades engaged in an open area until comfortable with the machine.
KNOW HOW TO STOP QUICKLY.
Know the location and operation of every control, especially how to brake and how to disengage the mower blades.
3
7.
DO NOT MOVE CONTROL LEVER(S) from forward position to reverse position rapidly. The speed and/or direction of travel is affected instantly by movement of the Control Lever(s).
8. DO NOT ALLOW CHILDREN TO
OPERATE MOWER. Do not allow others who have not had instruction to operate mower.
9. ALWAYS TURN ENGINE OFF AND
REMOVE KEY before leaving the mower to prevent children and inexperienced operators from starting the engine. Never leave the mower unattended with engine running. Always wait for all moving parts and all sounds to stop before leaving operator’s seat.
10. WEAR STURDY, ROUGH-SOLED
WORK SHOES AND CLOSE-FITTING
SLACKS AND SHIRTS. Never operate mower in bare feet, sandals or sneakers.
11. KNOW THE AREA YOU ARE TO
MOW. Watch for hidden danger such as rocks, roots, sticks, holes, bumps, and drop-offs, etc. Before mowing, pick up all debris in area to be mowed.
Sharp and hard objects can be propelled at a high speed and can act like shrapnel. Walk through tall grass
BEFORE MOWING to make sure there are no hidden dangers. Mow higher than desired in tall grass to expose any hidden objects and/or obstacles, clean the area, and then mow to the desired height.
12. NEVER REFUEL A MOWER
INDOORS. Allow the engine time to cool before refueling. Unseen vapors may be ignited by a spark. Always clean up spilled gasoline. Never run the engine indoors in a garage or any other closed building. Allow engine to cool before storing in any enclosure. The engine exhaust and gasoline fumes are dangerous.
13. DISENGAGE BLADES BEFORE
DRIVING ACROSS WALKS or projecting objects.
14.
NEVER REMOVE THE FUEL CAP or add gasoline to a running or hot engine that has not been allowed to cool for
4 several minutes after running. Always make sure the gas cap is in place.
15.
NEVER CARRY PASSENGERS.
16. DO NOT SMOKE AROUND THE
MOWER or the gasoline storage container. Gasoline fumes can easily ignite.
17. KEEP GASOLINE IN A WELL-
VENTILATED AREA away from your living quarters and in tightly-capped safety cans. Never store mower with gasoline in the tank inside a building where fumes may reach open flame or spark.
18. DISENGAGE BLADES, STOP ENGINE
AND REMOVE IGNITION KEY before any servicing. Be sure all moving parts and all sounds have stopped. Let engine cool and disconnect the spark plugs so the engine cannot start by accident. A SLIGHT ROTATION OF
THE BLADES COULD START THE
ENGINE.
19. KEEP ALL NUTS, BOLTS, AND
SCREWS TIGHT to be sure equipment is in safe working condition, especially blade mounting bolts.
20. VEHICLE SHOULD BE STOPPED
AND INSPECTED FOR DAMAGE after striking a foreign object and the damage should be repaired before restarting and operating the equipment. Stop immediately and check for damage or loose parts if mower should start vibrating.
21 KEEP SAFETY DEVICES AND
GUARDS IN PLACE. If any of the safety switches become inoperable, have them repaired immediately.
22. DO NOT STEP OR STAND ON THE
MOWER HOUSING. Step or stand only on the foot deck.
23.
WATCH OUT FOR TRAFFIC near roadways and when crossing roads.
24. DO NOT USE MOWER WHEN GRASS
IS WET OR SLIPPERY.
25.
MOW ONLY DURING DAYLIGHT.
26. THIS MACHINE IS NOT MEANT FOR
HIGHWAY OR STREET USE. It is not a recreational vehicle and it should not be operated as such.
27. ALWAYS DISENGAGE THE MOWER
BLADE CLUTCH when transporting.
28. KEEP ALL SAFETY LABELS IN
LEGIBLE CONDITION. Remove grease, dirt, grass, etc. that may cover safety labels. Replace any safety label that is missing or damaged.
29. WEAR PERSONAL PROTECTIVE
EQUIPMENT. Eye, ear, feet and head protection is recommended.
30. ONLY USE COUNTRY CLIPPER
APPROVED ACCESSORIES.
31. DO NOT CHANGE THE ENGINE
GOVERNOR SETTING or over speed the engine.
32. BEWARE OF MOWER DISCHARGE
DIRECTION and do not point it at anyone.
33. DO NOT OPERATE THE MOWER
UNDER THE INFLUENCE OF
ALCOHOL OR DRUGS.
34. USE CARE WHEN LOADIING OR
UNLOADING MACHINE INTO A
TRAILER OR TRUCK.
35. USE CARE WHEN APPROACHING
BLIND CORNERS, shrubs, trees, or other objects that may obscure vision.
36. CLEAN ALL GRASS AND DEBRIS
FROM MACHINE TO PREVENT
FIRES. Remove spilled oil or gasoline.
37. KEEP HANDS AND FEET AWAY
FROM MOVING PARTS. If possible do not make adjustments with the engine running.
38. NEVER MOW WHEN OTHER PEOPLE
OR PETS ARE IN THE AREA.
39. CAREFULLY RELEASE PRESSURE
FROM COMPONENTS WITH STORED
ENERGY.
5
40. USE CARE WHEN REPLACING
BLADES. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blade(s). Never straighten or weld blade(s).
41. USE JACKSTANDS TO SUPPORT
COMPONENTS when required.
42. KEEP BODY AND HANDS AWAY
FROM PIN HOLES OR LEAKS IN
HIGH PRESSURE HYDRAULIC LINES.
Always use paper or cardboard to search for leaks, NEVER use hands.
Make sure all hydraulic connections are tight and that hydraulic lines are in good condition before starting the engine.
SAFETY INTERLOCK SYSTEM
Your Country Clipper Zero Turning Radius
Mower is equipped with switches interlocked for your safety.
ON JOYSTICK MODELS GROUND DRIVE
NEUTRAL IS WHEN THE JOYSTICK (CONTROL
LEVER) IS IN THE “DOWN” POSITION.
ON TWINSTICK MODELS GROUND DRIVE
NEUTRAL IS WHEN BOTH CONTROL LEVERS
ARE IN THE “OUT” POSITION.
1. The mower blades must be disengaged before engine will start.
2. The Control Lever(s) must be in the neutral position before the engine will start.
3. The engine will stop if the mower blade clutch is engaged when the operator leaves the driver’s seat.
4. The engine will stop if the Control
Lever(s) are not in the neutral position when the operator leaves the driver’s seat.
5. The engine will stop if the brake is
“SET” and the Control Lever(s) are not in the neutral position.
6. The engine will stop if the brake is “SET” and the mower blade clutch is engaged.
DO NOT OPERATE MOWER IF SAFETY
SWITCHES AND GUARDS ARE NOT
OPERATING PROPERLY
START UP AND OPERATION
1.
CHECKLIST BEFORE OPERATION
Make sure fuel tank is full. Use regular unleaded gasoline (see engine owner’s manual for more details).
8.
6.
7.
3.
4.
WARNING
HANDLE GASOLINE WITH CARE -- IT IS
HIGHLY FLAMMABLE. DO NOT SMOKE.
ENGINE SHOULD BE OFF AND COOL. USE
APPROVED GAS CONTAINER. NEVER FILL
TANK INDOORS. WIPE UP ANY SPILLS.
REPLACE CAP TIGHTLY.
2. Make sure dirt and foreign matter is kept out of gas tank. Use a clean funnel and gas can.
Do not mix oil with gasoline.
Do not use white, high test or premium gasoline. Do not use de-icers, carburetor cleaners, or other such additives.
5. Check the crankcase oil level. Make sure the engine is off. The mower should be parked on a level area. Do not overfill. (See your engine manual for more detailed instruction.)
Check battery fluid level.
Inspect V-belts.
Check tire pressure:
Model
All
Front tires
12 psi
Rear tires
12 psi
9.
Models
Make sure underside of mower deck is free of grass.
10.
Make sure mower blades are sharp and secured tightly.
11.
Clean the air intake screen on the engine if necessary.
6
12.
Perform any other maintenance as it becomes necessary. (See the
“Maintenance” section of this manual.)
IMPORTANT: Before cutting grass, clutch must be broken-in as follows: With engine at full RPM engage deck until blades come to full speed and then disengage until blades come to a complete stop.
Repeat 10 times to “break-in” the clutch properly.
CONTROL LOCATIONS
JOYSTICK MODELS
Throttle
Choke
Joystick Control
Lever
Ignition Key
Cut Height Foot
Assist Lever
Cut Height Stop
Pin
Blade Clutch Switch
Cut Height
Adjustment Lever
Parking Brake Lever
WARNING
AVOID INHALING EXHAUST FUMES --
CARBON MONOXIDE GAS IS COLORLESS
AND ODORLESS, AND CAN CAUSE
UNCONSCIOUSNESS, AND IS POTENTIALLY
LETHAL. DO NOT RUN LAWN MOWER IN
GARAGE OR OTHER CONFINED AREA.
OPERATION
JOYSTICK MODELS
1.
2.
3.
4.
5.
6.
MOVE JOYSTICK CONTROL LEVER
TO neutral “DOWN” position.
SET PARKING BRAKE. Pull up to set.
DISENGAGE MOWER BLADE
CLUTCH by moving clutch switch to
“OFF” position.
PULL ENGINE CHOKE CONTROL to full position for cold starts.
SET ENGINE THROTTLE TO 1/2
THROTTLE.
TURN IGNITION KEY to “START” position and release to “RUN” as soon as engine starts. NOTE: Prolonged cranking will damage starter motor and shorten the battery life
7.
ADJUST ENGINE THROTTLE AND
CHOKE for desired engine smoothness and speed. NOTE: When mowing, always run engine at full throttle.
8.
RELEASE PARKING BRAKE. Push brake lever down to release.
IMPORTANT: Until the operator is familiar with the Country Clipper Zero Turning
Radius Mower, he/she should follow these recommendations: Disengage the mower blades. Go very slowly until thoroughly familiar with the machine.
Keep away from fences, buildings, and other obstructions. Move the Joystick
Control Lever smoothly and slowly.
Practice until operation is smooth and efficient.
9.
TO DRIVE:
A. Move the Joystick Control Lever to the
“UP” position.
B. Move the Joystick Control Lever forward to move forward. Increasing forward movement of the Joystick
Control Lever will increase the speed of travel.
7
C. To reverse the direction, pull the
Joystick Control Lever slightly back.
D. To turn, move the Joystick Control
Lever toward the direction you want to turn..
E. To turn on a zero radius axis, go slowly and move the Joystick Control
Lever to the side you wish to turn and slightly to the rear at the same time.
CAUTION
FOR SMOOTH, SAFE OPERATION, MOVE
THE JOYSTICK CONTROL LEVER IN A
GENTLE, SLOW MOTION. NEVER PULL OR
PUSH THE JOYSTICK CONTROL LEVER
RAPIDLY, ESPECIALLY ON GRADES.
10.
BRAKING: To brake mower, gently move the Joystick Control Lever in the direction opposite to travel. If the parking brake is engaged with the
Joystick Control Lever in the “UP” position the engine will stop.
11.
CUTTING HEIGHT ADJUSTMENT:
With the Cut Height Adjustment Lever latched into the top cut height latch.
Insert Cut Height Stop Pin to desired cutting height. Pull Cut Height
Adjustment Lever rearward and then to the left to clear top cut height latch.
Lower Cut Height Adjustment Lever until it rests on Cut Height Stop Pin. NOTE:
Pushing on the Cut Height Foot Assist
Lever will make the Cut Height
Adjustment Lever easier to operate.
12.
ENGAGE MOWER BLADE CLUTCH:
Set the Blade Clutch Switch to the “ON” position. The engine will not start if the blade clutch is engaged. If the operator is not in the seat, the engine will stop if the clutch is engaged.
CAUTION
AVOID HILL AND SLOPES. USE EXTREME
CAUTION WHEN MOWING UP OR DOWN
SLOPES. NEVER MOW ACROSS THE FACE
OF A SLOPE. IF A SLOPE MUST BE
ASCENDED, BACK UP THE SLOPE; DRIVE
FORWARD WHEN DESCENDING.
13.
TO STOP:
A. Move Joystick Control Lever to neutral position and then to the “DOWN” position.
B. Disengage the mower blade clutch by moving the clutch to the “OFF” position.
C. Set the parking brake.
D. Slow engine speed with throttle to slowest position.
E. Turn ignition key to “OFF” position.
F. Remove the key and wait for all movement and all sound to cease before dismounting.
Throttle
CONTROL LOCATIONS
TWINSTICK MODELS
Choke
Right Hand Steering
Control Lever
Ignition Key
Blade Clutch Switch
Cut Height
Adjustment Lever
Cut Height Foot
Assist Lever
Left Hand Steering
Control Lever
8
Cut Height Stop
Pin
Parking Brake
Lever
WARNING
AVOID INHALING EXHAUST FUMES --
CARBON MONOXIDE GAS IS COLORLESS
AND ODORLESS, AND CAN CAUSE
UNCONSCIOUSNESS, AND IS POTENTIALLY
LETHAL. DO NOT RUN LAWN MOWER IN
GARAGE OR OTHER CONFINED AREA.
OPERATION
TWINSTICK MODELS
1. MOVE STEERING CONTROL LEVERS TO neutral “OUT” position.
2. SET PARKING BRAKE. Pull up to set.
3. DISENGAGE MOWER BLADE CLUTCH by moving clutch switch to “OFF” position.
4. PULL ENGINE CHOKE CONTROL to full position for cold starts.
5. SET ENGINE THROTTLE TO 1/2
THROTTLE.
6. TURN IGNITION KEY to “START” position and release to “RUN” as soon as engine starts. NOTE: Prolonged cranking will damage starter motor and shorten the battery life.
7. ADJUST ENGINE THROTTLE AND
CHOKE for desired engine smoothness and speed. NOTE: When mowing, always run engine at full throttle.
8. RELEASE PARKING BRAKE. Push brake lever down to release.
IMPORTANT: Until the operator is familiar with the Zero Turning Radius Mower, he/she should follow these recommendations.
Disengage the mower blades. Go very slowly until thoroughly familiar with the machine. Keep away from fences, buildings, and other obstructions. Move the Steering Control Levers smoothly and slowly. Practice until operation is smooth and efficient.
9. TO DRIVE:
A. Move the Steering Control Levers to the
“IN” position.
B. Move the Steering Control Levers forward to move forward. Increasing forward movement of the Steering
Control Levers will increase the speed of travel.
C. To reverse the direction, pull the
Steering Control Levers slightly back.
D. To turn, move one Steering Control
Lever slightly ahead of the other.
E. To turn on a zero radius axis, go slowly and move one Steering Control Lever forward and one Steering Control Lever rearward. (For a right hand turn the left hand Steering Control Lever will be ahead of the right hand Steering
Control. For a left hand turn the right hand Steering control will be ahead of the left hand Steering Control.)
CAUTION
FOR SMOOTH, SAFE OPERATION, MOVE
THE STEERING CONTROL LEVER(S) IN A
GENTLE, SLOW MOTION. NEVER PULL OR
PUSH THE STEERING CONTROL LEVER(S)
RAPIDLY, ESPECIALLY ON GRADES.
10. BRAKING: To brake mower, gently move the Steering Control Levers in the direction opposite to travel. If the parking brake is engaged with the Steering Control Lever(s) in the “IN” position the engine will stop.
11. CUTTING HEIGHT ADJUSTMENT: With the
Cut Height Adjustment Lever latched into the top cut height latch. Insert Cut
Height Stop Pin to desired cutting height. Pull Cut Height Adjustment
Lever rearward and then to the left to clear top cut height latch. Lower Cut
Height Adjustment Lever until it rests on
Cut Height Stop Pin. NOTE: Pushing
9 on the Cut Height Foot Assist Lever will make the Cut Height Adjustment Lever easier to operate.
12. ENGAGE MOWER BLADE CLUTCH: Set the Blade Clutch Switch to the “ON” position. The engine will not start if the blade clutch is engaged. If the operator is not in the seat, the engine will stop if the clutch is engaged.
CAUTION
AVOID HILL AND SLOPES. USE EXTREME
CAUTION WHEN MOWING UP OR DOWN
SLOPES. NEVER MOW ACROSS THE FACE
OF A SLOPE. IF A SLOPE MUST BE
ASCENDED, BACK UP THE SLOPE; DRIVE
FORWARD WHEN DESCENDING.
13. TO STOP:
A. Move Steering Control Levers to neutral position and then to the “OUT” position.
B. Disengage the mower blade clutch by moving the clutch to the “OFF” position.
C. Set the parking brake.
D. Slow engine speed with throttle to slowest position.
E. Turn ignition key to “OFF” position.
F. Remove the key and wait for all movement and all sound to cease before dismounting.
CAUTION
WHEN LEAVING THE MOWER
UNATTENDED, ALWAYS REMOVE THE KEY
AND SET THE PARKING BRAKE, EVEN IF
JUST FOR A FEW MOMENTS. HELP
PROTECT CHILDREN AND OTHER
UNAUTHORIZED PERSONS FROM
ACCIDENTS.
14. TO FREE WHEEL MACHINE: UNLOCK
TRANSMISSION: Unscrew both bypass valves between ½ to 1 full turn counterclockwise. To reset, turn valves clockwise. DO NOT OVERTIGHTEN.
Hydrostatic Transmission
Bypass Valve
(one on each hydrostatic transmission)
NOTE: The tractor should never be pulled at more than 2 miles per hour or for any appreciable distance.
1.
2.
MOWING RECOMMENDATIONS
Keep mower blades sharp.
Make sure deck and discharge are clean.
4.
5.
3.
CAUTION
POWER MUST BE OFF TO CLEAN
DISCHARGE CHUTE. TURN ENGINE OFF
AND WAIT FOR ALL MOVING PARTS TO
STOP.
When mowing tall grass, make two passes, mowing off 1/2 of the desired cut on the first pass, and then the desired height the second pass. Check for hidden dangers first.
Go slowly for trimming.
Always cut grass with the engine at full throttle speed. This “ENGINE” speed allows the cutting blades to operate at optimum cutting speed. Control
“GROUND” speed with the Control
Lever(s).
6. Vary ground speed to suit conditions
(i.e. go slower in tall thick grass, on hills, wet conditions, etc.).
10
MAINTENANCE
CAUTION
BEFORE PERFORMING ANY MAINTENANCE, TURN OFF ENGINE
REMOVE KEY AND DISCONNECT SPARK PLUGS. USE EXTREME CARE WHEN WORKING ON
MACHINERY. DO NOT WEAR WATCHES OR JEWELRY. DO NOT WEAR LOOSE FITTING
CLOTHES, AND OBSERVE ALL COMMON SAFETY PRACTICES WITH TOOLS.
MAINTENANCE SCHEDULE
SERVICE
WHEN
Check crankcase oil level --------------------------------------------------------------------- before each use
Clean grass from Hydrostatic Transmission fins and oil cooler ---------------------- before each use
Check air intake screen --------------------------------------------------------------------------- after each use
Clean grass under deck -------------------------------------------------------------------------- after each use
Check tire pressure ------------------------------------------------------------------------------- every 10 hours
Check battery fluid -------------------------------------------------------------------------------- every 10 hours
Sharpen mower blades -------------------------------------------------------------------------- every 10 hours
Clean air filter pre-cleaner element ----------------------------------------------------------- every 25 hours
Check Hydrostatic Transmission oil level --------------------------------------------------- every 25 hours
Check drive belts ---------------------------------------------------------------------------------- every 50 hours
(20 hours break-in)
Service Air Cleaner Filter Element ---------------------------------------------------------- every 100 hours
Change engine crankcase oil ------------------------------------------------------------------------- 100 hours
oil filter -------------------------------------------------------------------------- 200 hours
Replace air filter element --------------------------------------------------------------- annually or 500 hours
Check spark plugs ------------------------------------------------------------------------ annually or 500 hours
Service battery ---------------------------------------------------------------------------- annually or 500 hours
--------------------------------------------------------------------------------------------------------------------------------
Replace decals when illegible. Write factory for free replacement.
11
MAINTENANCE INSTRUCTIONS
1. ENGINE:
For complete maintenance and operating information for your engine, please refer to your engine operating and maintenance instructions furnished by the engine manufacturer and included in your Country Clipper Zero
Turning Radius Mower information packet.
NOTE: Air intake screen must be kept clean. If plugged, engine may be seriously damaged by over heating.
2. BATTERY:
CAUTION
BATTERY ELECTROLYTE IS A POISONOUS
AND CORROSIVE SULFURIC ACID
SOLUTION. AVOID SPILLING ON SKIN,
EYES, AND CLOTHING.
Keep the electrolyte level above the plates in each cell by adding distilled water as it becomes necessary. Add water just before operating the mower to mix the water with the solution. Be careful not to overfill the battery -- the electrolyte solution is corrosive and can cause damage to surrounding metal parts if it should spill. When taking the battery out of the mower for servicing, make sure to connect the cables to the battery exactly as they were prior to removal. Always disconnect the ground
( - ) wire first and always reconnect the ground ( - ) wire last.
Keep the battery clean. Remove the corrosion around the battery terminals by applying a solution of one part baking soda to four parts water. Coat all exposed terminal surfaces with a light layer of grease or petroleum jelly to
3. prevent corrosion.
NOTE: At temperatures below 32 degrees F (0 degrees C) the full charge state must be maintained to prevent cell electrolyte from freezing and causing permanent battery damage.
TIRES:
12
Correct tire pressure is essential for efficient operation of the mower. Check tire pressure as requested in the maintenance schedule. Inflate tires to the pressures listed below:
Model
All
Models
Front tires
12 psi
Rear tires
12 psi
Lug nuts should be torqued to 75 ft/lbs and checked regularly for tightness.
4. MOWER BLADES:
Check sharpness of mower blades after every 10 hours of operation. To sharpen blades proceed as follows:
CAUTION
STOP ENGINE, REMOVE IGNITION KEY AND
SPARK PLUGS FOR SAFETY.
A. Remove bolt, lockwasher, and cup washer mounting blade on shaft.
Remove blade.
B. Blades should be discarded when worn excessively.
DANGEROUS!
DO NOT USE
BLADE IN THIS
CONDITION
New Blade
25 degrees
When notch starts, discard blade
C. Sharpen blades with a hand file, electric grinder or blade sharpener. Wear gloves and eye protection when sharpening. Grind blade at original 25 degree bevel.
D. Check balance of blade by positioning the blade on a nail or blade balance pedestal. Grind the blade on the end that is heavier until both sides balance.
E. Install blade, cup washer, lockwasher, and bolt. Make sure to tighten bolt to 60 ft.lbs.
5.
V-BELTS:
All belts should be checked every 50 hours. Replace any belts found to be in poor condition. All belts are equipped with spring loaded belt tighteners and do not require tightening adjustments.
6.
LUBRICATION:
A. Engine: Follow engine manufacturer’s recommendation.
B. Deck Spindles: Lubricate with 3 “shots” only, every 100 hours.
C. Hydrostatic Transmissions: Check oil level in Hydraulic Oil Reservoir after every 25 hours of use. Oil level should be checked when oil is COLD. If necessary add 20W-50 motor oil to the reservoir. DO NOT OVERFILL.
Thoroughly clean the Hydraulic Oil
Reservoir Cap and the surrounding area
PRIOR to removal of the cap. Take caution to keep all foreign matter out of the Hydraulic Oil Reservoir.
Change the oil in the Hydraulic Oil
Reservoir after the first 100 hours of use, and then every 500 hours after that. To change oil, remove the
Hydraulic Oil Filter and allow all of the oil to drain from the Hydraulic Oil
Reservoir. Replace with a new
Hydraulic Oil Filter (P/N H-2026) and
20W-50 Motor Oil.
Hydraulic Oil Reservoir
7. PARKING BRAKE ADJUSTMENT:
A. Move Parking Brake Lever to the “OFF” position.
B. With moderate pressure manually actuate the Lower Brake Arm up and forward. Tighten the Brake Adjustment
Nut to have approximately ½” of “freeplay” between the Brake Adjustment Nut and Brake Anchor Mount.
C. Repeat for the other side
Brake Anchor Mount
½” Clearance
(approx.)
Lower Brake Arm
Brake Adjustment Nut
Hydraulic Oil Filter
13
8. JOYSTICK CONTROL LEVER
NEUTRAL ADJUSTMENT:
With the engine running, if the machine travels in either direction when the
Joystick Control Lever is in the neutral
“DOWN” position, stop the engine, elevate the rear wheels clear of the ground and adjust as follows:
A. Remove the right hand fender skirt exposing the Joystick Control Lever
Assembly.
B. Start the engine.
C. Run engine at fast idle with Joystick
Control Lever in the “DOWN” position.
D. Loosen the locknuts tightened against the rod end ball joints on the Upper
Linkage Rod Assembly that corresponds to the wheel that is turning.
Note: One of these is a left hand nut and will have to be turned backwards.
E. Adjust the Neutral Position by turning the rod in the Upper Linkage Rod
Assembly until the wheel stops turning.
F. Retighten the locknuts on Upper
Linkage Rod Assembly and check to make sure the drive wheel is still not turning.
H.
G. Repeat steps B through F for other side.
Shut off engine before removing from blocks. Replace fender skirt.
Cross Bolt
9. JOYSTICK CONTROL LEVER
SENSITIVITY ADJUSTMENT
To change the sideways turning response adjust as follows:
A. Remove the right hand fender skirt exposing the Joystick Control Lever assembly.
B. Remove the cross bolt, nut, and spacers
C. Reassemble the spacers as desired.
(2) spacers between the rod end ball joints and the joystick pivot shaft will quicken the side to side response, (1) spacer slows the response.
NOTE: It is important that there is at least one spacer on each side of the rod end ball joints to prevent damage. Also the small diameter of the spacer must point towards the rod end ball joint.
Spacers (3) per side
Joystick
Pivot Shaft
Lock Nut
Left hand Upper
Linkage Rod
Assembly
Right hand Upper
Linkage Rod
Assembly
Lock Nut
14
10. JOYSTICK CONTROL LEVER DETENT
ADJUSTMENT:
If the Joystick Control Lever does not lock in the “UP” position, turn the detent adjustment screw clockwise until a desirable locking action is obtained. If the Joystick Control Lever is hard to slide up and down, turn the detent adjustment screw counter-clockwise until a desirable sliding action is obtained.
Joystick
Assembly
Lock Nut
Upper Linkage
Rod Assembly
Lock Nut
Detent
Adjustment
8. TWINSTICK CONTROL LEVER
NEUTRAL ADJUSTMENT:
A. Remove the fender skirts from each side of the machine.
B. Block up the unit so that the Drive
Wheels are off the ground.
C. Start the engine and run at a fast idle with the Steering control levers in the
“out” position.
D. Loosen the locknuts tightened against the rod end ball joints in the Upper
Linkage Assembly. (Note: One of these is a left hand nut and will have to be turned backwards.)
E. Adjust the Neutral Position by turning the rod in the upper linkage until the wheel stops turning.
F. Retighten the nuts on the Upper Linkage
Assembly and check to see that the drive wheel is still not turning.
G. Repeat steps B-F for the other side.
H. Shut off engine before removing the blocks.
(see Illustration at top of next column)
9. To Adjust “IN” Position of the Twinstick
Steering Control Levers:
A.
Remove the Front Bolts, Nuts and
Washers which hold the Fender Cap in place.
B.
C.
D.
Pull the boot from the hole in the fender cap, exposing the cast iron lever.
Using a 5/32” Allen Wrench, turn the setscrew to adjust the stop.
Replace the Boot into the hole in the
Fender Cap.
E. Replace the Front Bolts, Nuts, and
Washers.
(see Illustration on next page)
15
10. To Align Twinstick Control Lever
Handles Forward / Reverse:
A. Sit on the seat and push the control levers full forward and full backward. If the ends do not match the handles maybe adjusted as follows:
B. Locate Setscrew stops in the Steering
Control Lever Base which stop the lever in each direction. (Note: The one at the rear is the stop for FWD and the one in the front is the stop for REV.)
C. Adjust setscrew stops so that handles line-up together when shifted full forward and full reverse.
Access Hole to
Control Lever
“Forward” Stop
Control Lever “IN” position Stop
In a large open area, actuate the Control lever(s) into the full forward position. If the mower veers in either direction left or right some adjustment is necessary. If the mower veers to the right, then the right hydrostat needs to be sped up. If the mower veers to the left, then the left hydrostat needs to be sped up.
A.
B.
Stop the machine and shut off the engine.
Slightly loosen the bolt at the lower end of the upper linkage assembly on the side that is slower. Using a 1/8” hex wrench turn the setscrew ¼ turn in. It may take several test drives to get the mower to track straight forward.
C.
Once the tracking is to the operators liking, completely tighten the bolt on the control linkage assembly that was loosened earlier.
D. Recheck to make sure neutral adjust has not been effected. Readjust neutral if necessary.
Setscrew to adjust forward tracking
Upper Linkage Assembly
Control Lever
“Reverse” Stop
Note: To prevent damage to Control Linkages the Control Lever must always hit on the
Stop Screws. Never adjust Stops out so that the Control Lever “bottoms” out onother parts of the linkage.
11. TO MAKE JOYSTICK MORE
RESPONSIVE:
Remove dampener from front dampener mounting stud, reattach to back dampener mounting stud. Move dampeners on both sides.
See picture to right:
12. ADJUSTING FOR STRAIGHT
FORWARD TRACKING (Joystick and
Twinstick):
16
Loosen Nut
12. JOYSTICK CONTROL LEVER SHIFTING
FORCE ADJUSTMENT:
To change the amount of force required to shift the joystick control lever adjust as follows:
A. Heavier Force to Shift Joystick
Control Lever: Remove e-ring clip from dampener mounting stud. Position dampener onto the heavy dampener mounting stud (top). Re-install the e-ring clip.
B. Lighter Force to Shift Joystick
Control Lever: Remove e-ring clip from dampener mounting stud. Position dampener onto the light dampener mounting stud (bottom). Re-install the e-
Heavy Dampener mounting stud
Light Dampener mounting stud
E-ring
Dampener
ring clip.
17
BELT ROUTINGS
Hydrostatic Transmission Drive Belt
(viewed from ground looking up)
Release tension from Hydrostat
Drive Belt
Right Hand Hydrostatic
Transmission Pulley
Insert Small punch or
Screwdriver into this hole to
“Lock” Idler Arm in the release position when changing Hydrostat Drive Belt
Left Hand Hydrostatic
Transmission Pulley
Hydrostat Drive Belt
P/N D-3769
Motor Pulley
Idler Arm
48” Deck Belt
P/N D-3727
52” Deck Belt
P/N D-3733
60” Deck Belt
P/N D-3764
Deck Drive Belt
Clutch
18
PROCEDURE FOR RAISING AND
LOWERING THE DECK FOR
SERVICING
1. RAISING THE DECK:
A. Remove cut height adjustment pin and completely lower the cut height adjustment lever. Re-insert the cut height adjustment pin into the 3-1/2” cut height position (this will lock the cut height adjustment lever into the lowest position).
B. Release Tension from the Engine to
Deck Drive Belt by carefully rotating the
Deck Belt Tension Latch. Remove the
Engine to Deck Drive Belt from the clutch on the engine.
C. Lift the rear corner of the deck and disconnect the rear deck mounting latch. Repeat for the other side.
D. Position the front caster wheels so they are away from the deck (such as the tractor would be traveling in reverse).
E. Lift the nose of the deck until the deck is standing vertical (lifting can be made easier if someone stands on the rear bumper of the tractor). IMPORTANT
NOTE: MAKE SURE THAT THE
DECK IS LIFTED FAR ENOUGH TO
GO COMPLETELY “OVER-CENTER”.
This will prevent the deck from falling down when servicing the underside of the mower deck.
2. LOWERING THE DECK:
A. Push the bottom (back) of the deck towards the rear of the tractor. Lower the deck until it rests on the ground.
B. Lift the rear corner of the deck and reconnect the rear deck mounting latch.
Repeat for the other side.
C.
Re-install the Engine to Deck Drive belt onto ALL of the pulleys, including the clutch. Insure that the Engine to
Deck Drive Belt is properly routed onto all of the pulleys and idlers in
the drive train.
D.
Carefully rotate the Deck Belt Tension
Latch to re-tension the Engine to Deck
Drive Belt.
Cut Height Adjustment
Lever
Cut Height Adjustment
Pin
Foot Deck
Center Deck Spindle
MOWER SHOWN IN OPERATION
POSITION.
Deck Belt Tension
Latch
Front Caster
Wheels positioned
out of the way.
Rear Deck Mounting
Latch
19
MOWER SHOWN IN SERVICING
POSITION.
Deck Raised
“OVER –CENTER”
Engine to Deck Belt removed from Center spindle & Clutch
LEVELING THE DECK:
1. Set the tire pressure on all four tires
2. Move the tractor to a hard, level surface (i.e. concrete or blacktop). Place 2 x 4 board under each corner of the deck shell. Just inside of the anti-scalping wheels in front and under both rear corners.
Lower the deck down onto the boards. The deck must rest on the boards, NOT the anti-scalping wheels. Adjust the deck hangers longer or shorter until the deck “just” comes off of the boards.
Remove the boards and verify that the deck is hanging on all four deck hangers; re-adjust if necessary. To set the proper “rake” of the deck shorten both rear deck leveling screws 1-1/2 to
2 turns. Lock the jam nuts on the deck hangers. (NOTE: the two rear deck hangers will be easier to adjust if the fender skirts are removed).
Rear Deck
Hanger, one each side
Pin deck lift in this hole when leveling a charger deck.
Two turns of the hanger bolts = 5/32”.
The blades should be 1/8” to 1/4” lower in front for a clean cut.
Two 2 x 4 boards
(stacked on top of each other).
Place just inside of anti-scalping wheels on each side
Front Deck
Hanger, one each side
20
2 x 4 board (on
Edge), One each front corner, just inside of antiscalping wheels
TROUBLE SHOOTING CHECK LIST
1. ENGINE WON’T TURN OVER:
Mower ------------------------------------------------- disengage blades
Drive not in neutral ------------------------ move Control Lever(s) to neutral position
Ignition ------------------------------------------------------------------ consult dealer
2. ENGINE WILL TURN OVER BUT WON’T START:
clean or replace fuel filters
Over or under choked --------------------------------------------------------- adjust choke
Spark plug not firing ------------------------------------------------------ check spark plug
condition and reset gap*
Ignition ------------------------------------------------------------------ consult dealer
3. HARD TO START ENGINE:
Fuel line clogged ----------------------------------- clean fuel line and check fuel filter
Spark plug wire loose or grounded ---------------------------- check spark plug wires
Spark plug(s) faulty or improperly gapped -------------------------- check spark plug
4.
Dirty or maladjusted carburetor ------------------------------------- readjust carburetor*
consult dealer for carburetor service
ENGINE STARTS BUT CUTS OUT:
Water in gasoline ---------------- drain old gasoline and replace with new gasoline bowl line
Vent in fuel cap plugged --------------------------------------------------------- check vent
Engine dies when Control Lever(s) is move from “neutral” ----- parking brake set
Low oil level --------------------------------------------------------------- check and add oil
Ignition ------------------------------------------------------------- consult dealer
Fuel octane too low ------------------------------------------------- drain and replace with gasoline
Over heated engine ---------------------------------- shut off engine and allow to cool
* See engine manual for engine adjustments.
21
6. ENGINE SOMETIMES SKIPS AT HIGHER SPEEDS:
8.
7.
Bouncing off seat safety switch -------------------------- slow down on rough terrain
ENGINE OVER HEATED:
Air intake screen or fins clogged ------------------------ clean intake screen and fins
Fuel mixture too lean ------------------------------------------------- readjust carburetor*
Oil level too low or too high ------------------------------------------------ adjust oil level
Running engine too slow ------------------------------------------------ run engine faster
(NOTE: Always mow at full throttle setting.)
ENGINE IDLES POORLY:
Improper spark plug gap ---------------------------------------- check and re-gap plug*
10. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD:
Transmission locks in free wheel position --------- put in lock position (see pg. 10)
Drive belt broken or slipping ------------------------------------------- replace drive belt
Transmission ---------------------------------------------------------- consult dealer
11. MOWER LOSES POWER OR TRANSMISSIONS OVER HEATS:
12. ENGINE STALLS WHEN BLADES ARE ENGAGED:
Operator not on seat -------------------------------------------------------------- sit on seat
Bad blade spindle bearing -------------------------------------------------- consult dealer
Deck drive belt not properly routed ------------------------------------------------ reroute
Blades blocked by foreign material ----------------------------------- clean under deck
• See engine manual for engine adjustments.
22
Black wires = Ground
Red wires = Power
Blue wires = Kill Circuit
Yellow wires = Start Circuit
Green wires = Signal Circuit
KOHLER
ENGINE PLUG #2
CHARGE
FUEL
SOLENOID
MAGNETO
OIL PRESSURE
SWITCH
WIRING SCHEMATIC
BRAKE SWITCH
N.C.
COM
TWIN LEVER STEER ONLY
OPTIONAL
KOHLER
ENGINE PLUG #1
CHARGE
MAGNETO
FUEL
SOLENOID
OPTIONAL
PTO SWITCH
COM.
(CIRCUIT "C")
N.O.
(CIRCUIT "C")
N.C.
(CIRCUIT "C")
COM. (CIRCUIT "A")
N.O. (CIRCUIT "A")
OPTIONAL
23
IGNITION SWITCH
S
M
L
B
G
START SWITCH
POSITION CIRCUIT MAKE
OFF G+M
ON
START
B+L
B+L+S
HYDRAULIC SCHEMATIC:
OIL COOLER
OIL TANK
CASE DRAIN
CHARGE PUMP INLET
HIGH PRESSURE
LEFT-HAND
HYDROSTATIC
TRANSMISSION
HIGH PRESSURE
- REVERSE
RIGHT-HAND
HYDROSTATIC
TRANSMISSION
HIGH PRESSURE - REVERSE
DATE
LEFT-HAND
WHEEL MOTOR
RIGHT-HAND
WHEEL MOTOR
NOTES / SERVICE RECORDS:
SERVICE WORK COMPLETED
24
Safety Instructions & Operators Manual
®
WARNING
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects, or other reproductive harm.
Country Clipper Division
Shivvers Manufacturing Inc.
613 W. English St.
Corydon, IA 50060-0467
Ph. 641-872-2544
Fax. 641-872-1593
25
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