2005DEC09 Countax Garden Tractors - Safety Instructions CERTIFICATE OF CONFORMITY Training I, the undersigned Adam Bennett of Countax Limited, Great Haseley, Oxford, ENGLAND certify that the lawnmowers: Model: C Series C300M C30H C300H C400H C600H C800H C600-4WD C800-4WD 9.32 9.69 9.69 10.44 11.93 13.42 11.93 13.42 Engine operating speed 2800rpm 3000rpm 3000rpm 3000rpm 3000rpm 3000rpm 3000rpm 3000rpm Engine manufacturer Briggs & Stratton Honda Honda Honda Honda Honda Honda Honda Engine type Petrol Petrol Petrol Petrol Petrol Petrol Petrol Petrol Mass in kg 241 241 241 243 244 261 264 Max drawbar pull (kg) at coupling hook 400 400 400 400 400 400 Max sound power level 98db(A) 99db(A) 99db(A) 100db(A) 100db(A) Max rear axle weight (kg) 250 250 250 250 Vibration (m/s/s) Hands 2.76 2.76 2.76 Vibration (m/s/s) Seat 0.76 0.76 Type of cutting device Cutterbar 92cm Power (kW) Std width of cutting device TABLE OF CONTENTS Safety Instructions Page 1 Operating Instructions Page 2 Controls Page 3-6 Powered Grass Collector (PGC) Page 7 Using Your Countax Tractor Page 8-9 281 Routine Maintenance Page 10-12 400 400 Trouble Shooting: 100db(A) 100db(A) 100db(A) 250 250 250 250 2.76 2.76 2.76 2.76 2.76 0.76 0.76 0.76 0.76 0.76 0.76 Cutterbar Cutterbar Cutterbar Cutterbar Cutterbar Cutterbar Cutterbar 92cm 92cm 97cm 107cm 122cm 107cm 122cm Cutting Page 13 Cutter Levelling Page 14-15 Grass Collecting Page 16 Tyres & Wheels Page 17 Starting & Running Page 18 Electrics Page 19 Supplementary Instructions Model: A Series Power (kW) A25/50HE 14.91 14.91 18.63 C Series Specifications Page 21 A Series Specifications Page 22 Personal Service Records Page 23 3000rpm 3000rpm 3000rpm Honda Honda Kawasaki Engine type Petrol Petrol Petrol Mass in kg 290 290 295 Max drawbar pull (kg) at coupling hook 400 400 400 Max sound power level 104db(A) 104db(A) 104db(A) Max rear axle weight (kg) 250 250 250 Vibration (m/s/s) Hands 2.76 2.76 2.76 Vibration (m/s/s) Seat 0.53 0.53 0.53 Type of cutting device Cutterbar Cutterbar Cutterbar 127cm 127cm 127cm Std width of cutting device Page 20 A20/50HE Engine manufacturer Engine operating speed for Manual Tractors A20/50H Conforms to the specification of Directive 84/538/EEC (as adapted to the technical progress by Directive 88/180/ EEC and Directive 89/392/EEC (amended by 91/368/EEC, 93/44/EEC and 93/31/EEC) and Directive 89/336/EEC and amended by 91/263/EEC, 92/31/EEC) and 2000/14/EC. Standards used: BS5107, EN292, ISO3767, ISO3864 Tested at Oxford, England. 1. Read the instructions carefully. Be familiar with controls and the use of equipment. 2. Never allow children or people unfamiliar with these instructions to operate the mower. 3. Never mow while people, especially children or pets, are nearby. 4. The operator or user is responsible for accidents or hazards occurring to other people or their property. 5. Do not carry passengers. 6. All drivers should seek to obtain professional and practical instruction. In addition the following should be noted: • The need for care and concentration when working with this machine. • Control of a tractor sliding on a slope; control will not be regained by applying the brake. • The main reasons for loss of control are: i. Insufficient wheel grip ii. Driving too fast iii. Operating on steep slopes (max 15º) iv. Incorrect load distribution Preparation 1. Check that the machine complies with all applicable regulations, including those in force when used on the public highway. 2. When mowing, always wear substantial footwear and long trousers. Do not operate when barefoot or with sandals. 3. Thoroughly inspect the area where the tractor is to be used and remove all stones, sticks, wires and bones or any other foreign objects. 4. WARNING – petrol is highly flammable: • Store fuel in containers specifically designed for this purpose. • Refuel outdoors only and do not smoke while refuelling. • Add fuel before starting the engine. Never remove the cap from the fuel tank or add petrol while the engine is running or when engine is hot. • If petrol is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until petrol vapours have dissipated. • Replace the fuel cap securely. 5. Replace faulty silencers. I declare on behalf of Countax Limited that these machines conform to EC Essential Health and Safety requirements. Signed: 6. Before using, always inspect to see that the blades, bolts and cutter assembly are not worn or damaged. 7. Check the condition of the tyres and ensure that they are inflated to the correct pressures (refer to page 14). This is particularly important if the machine is to be taken on the public highway. A. Bennett (Technical Director) 01/01/2002 8. Check that the mower is in good working order, paying special attention to brakes and steering. 9. Check that all linkages, connections and pivot nuts are secure and that the wheel nuts are tightened correctly. Page 1 Countax Garden Tractors - Personal Service Record Countax Garden Tractors - Operating Instructions Safety 1. Read the instructions carefully. Be familiar with controls and the use of equipment. 2. Do not operate the engine in a confined space where dangerous fumes can collect. 3. Mow only in daylight or in very good artificial light. 4. Before starting the engine, disengage blade and attach ment drives and shift into neutral. 5. Take care on slopes - maximum 15º for 2WD and 25º on 4WD models. On no account should slopes steeper than 25º be driven on. 6. Remember, there is no such thing as a ‘safe slope’. Travel on grass slopes requires particular care to guard against overturning: • Do not stop or start suddenly when going up or downhill. • Engage drive slowly. Always keep the machine in drive when travelling up or down a slope. • Machine speed should be kept low on slopes and in tight turns. • Stay alert for humps and hollows and other hidden hazards. • Avoid mowing across the face of a slope. 7. Watch out for traffic when crossing or working near road ways. 8. Stop the blades rotating before crossing roadways. 9. When using the machine, never direct discharge or mate rial towards bystanders or allow anyone near the machine while in operation. 10. Never operate the mower with defective guards, shields or without protective safety devices in place and in good working order. 11.Do not change governor settings to increase the revs of the engine. Operating an engine at excessive speed increases the risk of injury. 12. Before leaving the operators position: • Disengage the drive to the cutter blades and attach ments, then lower the attachments. • Apply the Parking Brake (change into neutral first – on manual tractor). • Stop the engine and remove the ignition key. 13. Always disengage drive to attachments, stop the engine and disconnect the spark plug lead or remove the ignition key before: • Cleaning blockages. • Checking, cleaning or working on the mower. • Refuelling. • Removing the Grass Collector. Also: • After striking a foreign object inspect the mower for damage and make any repairs before restarting the tractor. • If the machine starts to vibrate abnormally, check immediately and call your dealer if necessary. 14. Disengage drive to attachments when transporting or not in use. 15. Reduce the throttle setting during engine run-out. 16. Never work on the mower when the engine is running. Always: • Use good common sense at all times and to ensure this tractor is safe and serviceable fit only original manufacturers supplied spares. • Inspect the area to be cut, note the position of any stumps, manhole covers, bumps or depressions and avoid them to prevent damaging the blades. • Ensure the fuel tank is full before you start the machine. We recommend the use of STANDARD UNLEADED fuel. • Disconnect both battery terminals before attempting any work in the engine compartment. Never • Leave the tractor unattended and running. • Put hands near moving blades, belts or the Power Take-Off pulley while they are rotating. Powered Grass Collector (PGC) PGC Tipping Lever* Cutting Height Adjustment Lever* PGC Connection Lever Model Date of Purchase Date of Registration Name of Dealer Serial Number 1st First Service (12 months) 4th Fourth Service (48 months) DEALER STAMP OR NAME & ADDRESS Service Date: Hours: DEALER STAMP OR NAME & ADDRESS Service Date: Dealer’s Signature: Dealer’s Signature: 2nd Second Service (24 months) 5th DEALER STAMP OR NAME & ADDRESS Service Date: Power Take-Off (PTO) Engage Lever PGC Lift Lever* Use this page as a personal record of the service history of your Countax garden tractor. Ask your dealer to stamp the appropriate box at the same time as your Service Record Card. Hours: Hours: Fifth Service (60 months) DEALER STAMP OR NAME & ADDRESS Service Date: Hours: Dealer’s Signature: Dealer’s Signature: 3rd Third Service (36 months) 6th Sixth Service (72 months) Tractor Drive Pedals DEALER STAMP OR NAME & ADDRESS Service Date: PGC Net Cutter Deck Collector Height Adjustment Lever Page 2 Anti-scalp Wheel * Where fitted Dealer’s Signature: Hours: DEALER STAMP OR NAME & ADDRESS Service Date: Dealer’s Signature: Page 23 Hours: Countax Garden Tractors – A Series Specification Countax Garden Tractors – Operating Instructions, Controls Seat Adjustment (Figure 1) Weight A20/50H PGC Capacity Turning Radius The seat on your Countax tractor is adjustable forward and backward to suit the operator. Simply lift the seat latch at the front of the seat and slide the seat forward or backward as appropriate. Always ensure the seat is latched back into position before driving off. A20/50H 290 kg 300 litres 99cm A20/50HE 290 kg A20/50HE PGC Capacity Forward Speeds A25/50HE 290 kg 390 litres 0-7 mph A20/50HE PGC 68 kg A25/50HE PGC Capacity Tyre Pressures Ignition (Figure 2 & 11) A25/50HE PGC 68 kg 390 litres Front: 0.8-1.1 KGF/cm (12-16 psi) Fuel Tank Capacity Transmission Rear: 0.43-0.7 KGF/cm (6-10 psi) 7 litres (1.5 gallons) Tuff Torq K62 Hydrostatic The “key start” controls both the ignition and the starter. The engine cannot be started without the park brake being on; the “P” light (Figure 11 - C) indicates the brake is engaged. Insert the key and turn to the first position, then turn further to activate the starter. Release when the engine starts. To stop the engine, turn the key to the left (having first switched off both the cutter and Power Take-off). To prevent unauthorised use, always remove the key after use. THE IGNITION MUST ALWAYS BE TURNED OFF BEFORE THE TRACTOR CAN BE RE-STARTED. A20/50H PGC 59 kg A20/50H: 2.72m; A20/50HE and A25/50HE: 2.87m 1m Figure 1 1.84m Choke (Figure 3) 1.19m An independent choke is fitted to some models. This choke should be used in conjunction with a fast throttle setting when starting the engine from cold. It should be cancelled as soon as possible. Do not use the choke when starting a warm engine. Figure 2 Figure 3 Engine Speed Control (Figure 4) The lever is pushed up for FAST( ) and down for SLOW ( ). On some models the choke control is above the fast setting, a cold engine is started on the Choke setting, a warm one on the FAST setting. The Choke setting should be cancelled as soon as possible. The engine should be operated on the FAST setting at all times. Model Engine Displacement Power Torque Bore Stroke A20/50H Honda Twin Cylinder OHV 90º V-Twin 14.91kW 614cc 14.91kW 20hp 44.1NM 77mm 66mm A20/50HE Honda Twin Cylinder OHV 90º V-Twin 14.91kW 614cc 14.91kW 20hp 44.1NM 77mm 66mm A25/50HE Kawasaki Twin Cylinder V-Twin 18.64kW 614cc 18.64kW 25hp 44.1NM 77mm 66mm RPM Meter (Figure 5) Hour Meter (Figure 5) M / MIN Your tractor is fitted with an hour meter to assist you in adhering to the recommended service intervals. The hour meter only operates whilst the engine is actually running. We recommend that your garden tractor is serviced after 50 hours of use or yearly, whichever comes first. Service intervals are preset into the PCB memory and will flash up ‘S’ on the park brake display before the service is due. This will be reset by your dealer. Note: 50 hours of mowing at 5 mph equates to 250 miles of grass cutting ! Page 22 Figure 4 The RPM monitor on the electronic display indicates the engine speed. This feature should be used when the cutter deck is engaged and in conjunction with the forward speed. To ensure complete cutting and collection the engine speed should not be allowed to fall below 2600rpm, the display will flash should this happen. If, when in use, the display does flash and the engine speed drops below 2600rpm, there are two options: a) Reduce forward speed b) Raise the cutting height. Page 3 Figure 5 Countax Garden Tractors – Operating Instructions, Controls Drive Controls - Hydrostatic (Figure 6) Figure 6 The forward speed of the tractor is controlled by footpedal ‘A’. Reversing is controlled by footpedal ‘B’. Moving Off / Reversing (Figure 6 & 7) Pedal A To move off, ensure your feet are off pedals ‘A’ and ‘B’ and then release the parking brake by pushing the hand lever ‘C’ (figure 7, page 4) to the forward position. Now gently depress pedal ‘A’ and you will move off. The further you depress pedal ‘A’ the faster you will go. Its function is similar to that of a car accelerator except that it controls the hydrostatic transmission and does not affect the speed of the engine. To reverse simply depress pedal ‘B’ and the tractor will begin to reverse. As with the forward pedal, the speed of reversing is increased as the pedal is pushed further. Countax Garden Tractors – C Series Specification Weight 7 litres (1.5 gallons) 2WD 63.5cm 4WD 77cm PGC Capacity Forward Speeds 300 litres 0-6 mph Transmission Tyre Pressures Tuff Torq K46 Hydrostatic or Peerless MST 206/536A Transaxle or Front: 0.8-1.1 KGF/cm (12-16 psi) Rear: 0.7-1.1 KGF/cm (10-12 psi) Fuel Tank Capacity C300-Mulcher C600-Mulcher C300M C300H C30H C400H C600H C800H C600-4WD C800-4WD PGC 241 kg 244 kg 241 kg 241 kg 241 kg 243 kg 244 kg 261 kg 264 kg 281 kg 59 kg Transmission 4WD Tuff Torq K57 & HFWD Turning Radius Pedal B 2.72m (2WD) 2.85m (4WD) 0.93m Stopping 1.75m (2WD) 1.88m (4WD) To stop the tractor simply release either pedal ‘A’ or ‘B’ and the natural braking of the hydrostatic system will bring the tractor to a stand still. For smooth braking release either pedal gradually, for an emergency stop remove foot rapidly. 1.12m Parking (Figure 6 & 7) Remove your foot from pedals ‘A’ and ‘B’ (as you would stop normally) and then simply pull the parking brake lever ‘C’ to the upright position - a “P” will be indicated on the dashboard display (Page 5 Figure 11 (C)). When you turn off the engine, the natural braking of the hydrostatic system will add to the effect of the brake. It’s like leaving your car in gear. Lever C Figure 7 Neutral Valve (Figure 8) The natural braking of hydrostatic transmission means that it is not possible to easily push or freewheel the tractor. To disengage, first make certain that the machine is on a flat even surface. Release the parking brake by moving the handbrake lever forward ‘C’. Locate the C Series Neutral Valve, situated alongside the rear right wheel or the A Series, alongside the rear left wheel. Disengage by pulling out the lever. You will now be able to push the tractor at a speed not exceeding 2 mph. Make sure you disengage the Neutral Valve by pushing the lever back BEFORE starting your tractor. C Series Position A Series Position Figure 8 Differential Lock - A Series (Figure 9) The A Series is fitted with a differential lock for maximum traction on slopes and slippery ground. The differential lock should only be used in situations where one wheel is slipping and the other is not. In a situation when one wheel starts to slip and extra traction is required simply depress pedal ‘D’ (Figure 9) and the differential will lock both wheels to drive at the same speed. Immediately the differential lock is not required release the engage pedal ‘D’ and as soon as the wheels are rotating at the same speed and not under load (i.e. on a slope) the lock will automatically release. Pedal D Figure 9 Important - DO NOT ATTEMPT TO STEER THE TRACTOR OUT OF A STRAIGHT LINE WHILST THE DIFF LOCK IS ENGAGED. Page 4 Model Engine Displacement Power Torque Bore Stroke C300 Mulcher Honda Twin Cylinder OHC 90º V-Twin 9.69kW 530cc 9.69kW 13hp 35.9NM 77mm 57mm C600 Mulcher Honda Twin Cylinder OHC 90º V-Twin 11.93kW 530cc 11.93kW 16hp 36.5NM 77mm 57mm C300M Briggs & Stratton Single Cylinder INTEK 9.32kW 465cc 9.32kW 12.5hp 24.5NM 87.3mm 66mm C30H Honda Single Cylinder OHV 9.69kW ???cc 9.69kW 13hp ???NM ??mm ??mm C300H Honda Twin Cylinder OHC 90º V-Twin 9.69kW 530cc 9.69kW 13hp 35.9NM 77mm 57mm C400H Honda Twin Cylinder OHC 90º V-Twin 10.44kW 530cc 10.44kW 14hp 35.9NM 77mm 57mm C600H Honda Twin Cylinder OHC 90º V-Twin 11.93kW 530cc 11.93kW 16hp 36.5NM 77mm 57mm C800H Honda Twin Cylinder OHC 90º V-Twin 13.42kW 614cc 13.42kW 18hp 44.1NM 77mm 66mm C600-4WD Honda Twin Cylinder OHC 90º V-Twin 11.93kW 530cc 11.93kW 16hp 36.5NM 77mm 57mm C600-4WD Honda Twin Cylinder OHC 90º V-Twin 13.42kW 614cc 13.42kW 18hp 44.1NM 77mm 66mm Page 21 Countax Garden Tractors - Supplementary Manual Tractor Instructions Drive Controls - Manual Gears (Figure 53 & 54) Figure 53 If your tractor is fitted with a manual transmission, the six forward speeds and reverse are controlled manually via a control lever to the right of the driver. A pedal to the right of the console controls the brake and clutch. Moving Off/Reversing (Figure 53 & 54) The tractor can be driven off in any of the forward gears, with each number representing a speed that the tractor can travel at (e.g. 1=SLOW, 6=FAST). Depress and hold the Brake/Clutch pedal (Figure 53), move the Gear Select Lever to the required gear (Figure 54) then SLOWLY release the pedal to engage drive to the wheels of your tractor. The machine MUST ALWAYS be at a standstill before you change the lever settings to a different speed. Cutter On/Off Switch (Figure 10 & 11) The cutter switch controls the electromagnetic blade clutch. To switch the cutter on, push the switch and then release it, this will engage the cutter deck. To indicate that the Cutter Deck is engaged, the Cutter Deck Indicator will flash (Figure 11 - A). To stop the Cutter Deck, push the switch again. Although the Cutter Deck is automatically switched off when the engine is stopped or when the operator gets off the seat, it is not good practice to rely on these features, the Cutter Deck should always be switched OFF as soon as you have finished cutting and certainly BEFORE stopping the engine or getting off the tractor. The Cutter will only work whilst the operator is sat on the seat. Should your tractor be fitted with 4WD it will have ESA. This is set to an angle of 25 degrees at the factory. If this angle is exceeded then the display will flash 250 and a warning siren will sound. For smooth braking depress the Brake/Clutch pedal gradually, for an emergency stop depress foot rapidly. Parking (Figure 53 & 55) To park, depress the Brake/Clutch pedal, then push and hold down the Parking Brake. Release the footpedal, the Park Brake should then be locked in position. To release the Park Brake simply depress the Brake/Clutch footpedal and the Park Brake will spring off. Figure 54 The exceptional traction of 4WD will allow you to cut in very slippery conditions, and it also allows the tractor to ascend very steep slopes. If the slope alarm sounds DO NOT attempt to cut or drive at a greater angle than the one you are on. As all terrains and conditions vary, great care should be maintained when operating the tractor. DO NOT take the tractor into an area where it could become unstable. B C A Figure 11 On no account should slopes steeper than 250 be driven on. Figure 55 Cutting Height Lever - Manual Lift Tractors (Figure 12) To engage the PTO, push the lever down and to the left and release lever upwards. The PTO lever is pushed down and to the right into its locator to disengage. Always have this lever in the ‘disengaged’ position when it is not in use. DO NOT PUT HANDS NEAR MOVING PULLEYS AND BELTS. Parking Brake Figure 11d The Cutter Height Lever is located at the right hand side on the rear body. The height is simply adjusted by pushing DOWN for a lower cut or pulling UP for a higher cut. There are 10 possible cutting heights, which are represented by numbers with 1 being LOW. We recommend that positions 3 or 4 are used for mowing lawns and 8 or 9 for very long grass and paddocks. When mowing in wet conditions it is advisable to select a slightly higher cutting position than would normally be used. Electric Lifts (where fitted) - (Figure 13 & 11A) Figure 12 DIAL-A-HEIGHT The cutting height is adjusted by turning the rotary switch anti-clockwise to lower the deck and clockwise to raise the deck. The height indicator on the electronic display (Figure 11 - A) shows the deck position (0-lowest to 9-highest). To get the best from this refinement use it to continuously adjust cutting height to suit ground and grass conditions. Do not make downward adjustments on the move until you are familiar with the height control, this will avoid “scalping” the lawn. Figure 56 Page 20 Figure 10 Electronic Slope Alert (ESA) (Figure 11d) Stopping (Figure 53) Power Take-Off (PTO) Manual Tractors (Figure 56) Countax Garden Tractors - Operating Instructions, Controls Page 5 Figure 13 Countax Garden Tractors - Operating Instructions, Controls Electric Lifts (where fitted) - (Figure 14 & 15) Countax Garden Tractors- Troubleshooting (Electrical) NET EMPTY Emptying the Powered Grass Collector is achieved by pressing a switch (Figure 15) on the dashboard UP to open, DOWN to close. Figure 14 Using the lever (figure 16) raise or lower the Powered Grass Collector to either the Transport position or the Collecting position. Power Take-Off - C Series (Figure 17A) 10 10 AMP LIGHTS 10 AMP FUEL SOLENOID / PTO WIRE / HE LOOM RELAY IF THE ELECTRIC SWEEPER LIFT FAILS TO OPERATE CHECK: 4 Fuse 7 on the Fuse Holder (green 30amp fuse) has not blown (Figure 52C) Figure 52A SPARE C Series Fuse Box 10 10 10 10 20 20 If “C” Appears in the Park Brake Window for more than 2 minutes. 20 AMP CHARGE This indicates that the battery is not charging. CHECK: 4 The main charge fuse has not blown (Figure 52A,B,C) 20 AMP IGNITION Transport Position Figure 16 Power Take-Off - A Series (Figure 17B) To engage the PTO, push the lever down and to the left and release lever upwards. The PTO lever is pushed down and to the right into its locator to disengage. Always have this lever in the ‘disengaged’ position when it is not in use. DO NOT PUT HANDS NEAR MOVING PULLEYS AND BELTS. SPARE IF THIS IS NOT THE CASE CONTACT YOUR TRACTOR DEALER. To engage the PTO drive, the PTO lever is lifted up and out of its locator and then moved to the left and released to find its own height. To disengage the PTO pull the lever up and to the right. Always have this lever in the ‘disengaged’ position when it is not in use. DO NOT PUT HANDS NEAR MOVING PULLEYS AND BELTS. Using the lever (figure 16) raise or lower the Powered Grass Collector. SPARE 10 AMP CLUTCH Figure 15 Collecting Position 10 20 AMP CHARGE 20 AMP IGNITION IF THIS IS NOT THE CASE CONTACT YOUR TRACTOR DEALER. Manual PGC Lift Lever (Figure 16) 10 CHECK: 4 Fuse 6 on the Fuse Holder (red 10amp fuse) has not blown (Figure 52B). 4 That nothing is caught between the deck and the chassis. 20 AUXILIARY LIFT Raising the Auxiliary (Grass Collector) Lift is achieved by pressing a switch (Figure 14) on the dashboard - UP to raise, DOWN to lower. 20 If the Electric Deck Lift on Your Tractor Fails to Operate: 10 AMP CLUTCH IF THIS IS NOT THE CASE CONTACT YOUR TRACTOR DEALER Figure 17B SPARE 10 AMP LIGHTS Figure 52B Figure 17A SPARE 10 AMP Deck Lift 10 AMP FUEL SOLENOID / PTO WIRE / HE LOOM RELAY Models with Dial-a-height Pressing the rocker switch turns ON the headlights. Turn the headlights OFF by pressing the rocker switch again. The headlights will not operate without the ignition switch turned on. 30 10 10 10 10 Lights (Figure 18) 20 20 Figure 51 20 AMP CHARGE 20 AMP IGNITION 10 AMP CLUTCH Figure 52C 10 AMP LIGHTS 10 AMP FUEL SOLENOID / PTO WIRE / HE LOOM RELAY C Series Fuse Box Location Figure 18 Page 6 Page 19 SPARE 30 AMP SWEEPER LIFT 10 AMP DECK LIFT Models with Dial-a-height and PGC electric lift Countax Garden Tractors - Troubleshooting (Starting & Running) Engine Fails to Turn Over: CHECK: 4 That the brake is depressed or the parking brake is on and that you are sitting on the seat. 4 That the battery terminals are connected (Page 10). 4 That fuse 2 (yellow 20amp ignition fuse) has not blown or been dislodged. 4 That the battery is charged. Figure 49 If The Engine Misfires, Loses Power or Stalls in Use: CHECK: 4 That you have not run out of fuel. 4 That the Air Filter Pre-cleaner is not blocked (see Engine – Air and Cooling). 4 That the cooling air intakes are not blocked. 4 If the ignition lights have gone off – check yellow 20amp fuse, fuse 2 on the fuse holder. 4 That fuse 5 (red, 10amp) has not blown or been dislodged. IF THIS IS NOT THE CASE CONTACT YOUR TRACTOR DEALER. Position X Fit the Net as shown in Figure 21 with the net rod in position ‘X’. To remove the net, release the net rod and secure in the removal position ‘Y’. When removing the net, we suggest you employ the assistance of another person. 1. Partially open the PGC net (100mm (4”)). Disconnect opening rod by pulling back on sprung locking tube and uncoupling from pin. Repeat other side. 2. Undo net locking clip (both sides), unhook levers from locating pins. 3. With one person standing each side of the collector net, slide the net off the locating arms. 4. Reverse operation for fitting. If the Engine Turns Over and Does Not Start: IF THIS IS NOT THE CASE CONTACT YOUR TRACTOR DEALER. Fitting the Net - C Series & A20/50H (Figure 19) Fitting the Net - A20/50HE (Figure 20) IF THIS IS NOT THE CASE CONTACT YOUR TRACTOR DEALER. CHECK: 4 That the fuel tank is full and the Petrol Tap is turned ON (if fitted). 4 That the Spark Plug Lead is connected. 4 That the outlet in the fuel tank is not blocked. 4 That the Spark Plug is clean and set to the correct gap (see engine manufacturer’s handbook for relevant spark plug data). 4 That the Fuel Filter is not blocked (see Engine – Air and Cooling). 4 That fuse 5 (red, 10amp) has not blown or been dislodged. Countax Garden Tractors - Operating Instructions, Powered Grass Collector Net Rod Position Y Figure 19 Locating Lever Locking Clip Net Rod PGC Connection (Figure 21) Figure 50 To connect the Powered Grass Collector (PGC) to the tractor, ensure that both are on an even surface with the locking levers on the collector facing the Lift Arms on the tractor. Lift the seat and the PTO flap so that both are resting in the upright position. Move the Collector manually to the tractor; lower the lift arms using the lift lever. Locate the collector channels with the Lift Arms and push until it stops at its limit. Securing Pin Installing the Drive Belt (Figure 22) Place the drive belt over the PTO pulley of the Powered Grass Collector, and then feed it underneath the PTO flap. The lower half is pulled left and under the Belt Hook then fed around the PTO pulley. Be sure that this is installed the right way round otherwise the brush will work in reverse and collection will be poor. Lock the Locating Lever over the Lift Arm Lugs (this also tightens the PTO Drive Belt). Rotate the Locking Clips over the Locating Lugs to securely lock the Powered Collector in place. To disconnect, reverse this procedure. ALWAYS CHECK BELT TENSION IS 19mm DEFLECTION AT 2KGs PRESSURE. REFER TO PAGE 12 FOR ADJUSTMENT INSTRUCTIONS. A20/50HE NET ASSEMBLY Figure 20 Lift Arm Lugs Collector Channels Locking Lever If the Cutter Deck Fails to Operate: Locking Clips CHECK: 4 That fuse 3 on the Fuse Holder (red 10amp Clutch fuse) has not blown (page 19) 4 Whether you have got off the seat – the safety switch will disengage the cutter. 4 The battery has lost charge and will no longer hold the clutch in operation. Figure 21 IF THIS IS NOT THE CASE CONTACT YOUR TRACTOR DEALER. Figure 22 Low Fuel Warning (Figure 50) Belt Hook When the petrol gets low on your tractor a warning will appear on the dash next to the fuel picture to tell you to fill up again as the tractor is about to run out of petrol. Page 18 Page 7 Countax Garden Tractors - Using your Countax tractor Connecting Net Empty Socket - A20/50HE (Figure 23) Countax Garden Tractors - Troubleshooting (Tyres & Wheels) Persistent Flat Tyres Figure 23 Connect Net Empty Plug to socket as shown in Figure 23. This plug MUST BE FITTED before attempting to use your Powered Grass Collector. Adjusting the Sweeper Height (Figure 24) Using the sweeper Height Lever select the position appropriate to the conditions and the height of cut. TO GET THE BEST SWEEPING PERFORMANCE AND TO PRESERVE THE BRUSHES SELECT THE HIGHEST SETTING THAT WORKS - start high and adjust down until the brushes start to collect (normally the middle adjustment hole). Do not set the brushes too low - this will lead to scarifying and a very untidy finish as well as shortening brush life. The rim of the wheel has been damaged causing the seal on the tube-less tyre to be broken. There are two solutions: 4 If the damage is not severe, treat with Countax Tyre Sealant (Pt No. 52903501). 4 If the damage is significant it is necessary to order a new wheel from your dealer. If you have Hawthorn, Blackthorn or Wild Rose in your garden – this will puncture any tyre. It makes sense to check any area you intend to cut or drive over and to remove any branches. THE LONG-TERM SOLUTION IS TO TREAT ALL FOUR TYRES WITH COUNTAX TYRE SEALANT – FOLLOW THE INSTRUCTIONS ON THE BOTTLE. IF YOUR TYRES SPIN OR LOSE GRIP CHECK: 4 That all tyres are inflated to there correct pressures (see page 21). 4 Are you going too fast for the conditions? To Tip Cuttings - C Series & A20/50H (Figure 25) When the collector is full, raise the collector to the transport position. Drive to your tipping area, reverse to the grass pile, and select neutral if the tractor is manual. Then extend the tipping lever and pull it towards the seating position. This pivots the collector and so empties the collector. Once the grass is off-loaded return the collector to the upright position and put the tipping lever in its original position. To Tip Cuttings - A20/50HE (Figure 14 & 15) You can check the contents of the PGC through the clear cover. When it is full, raise the Collector to the transport position (Page 6, Figure 14). Drive to your tipping area, reverse to the pile, then depress then PGC Net Empty Switch (Page 6, Figure 15). Figure 46 This is an inevitable problem faced by around 5% of Countax users. Like all garden machinery, the most common cause of punctures are THORNS! Blackthorn, Hawthorn and Rose are usually at the bottom of the problem and will puncture any tyre not fitted with very expensive guards. There are less expensive ways to overcome this problem and it is advisable to check and avoid these possible causes: Removal of Front Wheel (Figure 46) Figure 24 Standard Grass Collection When cutting the grass and collecting follow these simple steps: 1 Always run the engine at maximum speed. 2. Lower the sweeper to the working postion. RememberTO GET THE BEST SWEEPING PERFORMANCE AND TO PRESERVE THE BRUSHES SELECT THE HIGHEST SETTING THAT WORKS. 3. Engage the sweeper drive. 4. Engage the cutter deck drive. 5. Lower the deck to the desired height of cut. 6. Drive forward at a speed that does not cause the engine speed to drop. REMEMBER if the RPM display flashes below 2600rpm, there are two options: a) Reduce forward speed b) Raise the cutting height. Sometimes when cutting long grass or a paddock, it may be better to cut the grass and disperse the clippings directly to the ground. Alternatively remove collector net, fit the deflector accessory and spread the cut grass prior to final collection. 4 4 Apply Parking Brake. Place chocks under the wheels that are to remain on the ground. 4 Remove the plastic hubcap. 4 Use a 19mm socket/spanner to loosen the wheel nut whilst on the ground – DO NOT REMOVE. 4 Place a jack under the front axle at the jacking point Figure 46 (on the side appropriate to the wheel that is to be removed). Jack the tractor up until the wheel to be removed is well clear of the ground. 4 Remove the wheel nut and washer and keep safe. 4 Taking care not to dislodge the tractor from the jack, pull the wheel off. When the tyre is repaired, replace the wheel preferably using a new M12 Nyloc nut (Part No. 04822400). Tighten to a torque setting of 5.25Kg.m (38lb/ft). Check to ensure wheel turns freely. Figure 47 Figure 48 Figure 25 Removal of Rear Wheel (Figure 47 & 48) 4 4 4 4 4 4 Page 8 Under the Chassis Apply Parking Brake. Place chocks under the wheels that are to remain on the ground. Loosen the the four wheel nuts. Place a jack under the jacking point shown in Figure 47 (on the side appropriate to the wheel that is to be removed). Jack the tractor up until the wheel to be removed is well clear of the ground. Remove the wheel nuts using a 19mm spanner/socket. Once removed, keep safe and remove the wheel. When replacing the wheel re-tighten the nuts to 5.25kg.m (38lb/ft). Page 17 Countax Garden Tractors - Troubleshooting (Grass Collecting) Countax Garden Tractors - Mulch Mowing Grass Collection Mulch Mowing If your Collector appears to be not picking up satisfactorily, check the following: 4 The PTO lever is engaged. 4 That the PTO pulley beneath the seat is turning – if not, call your dealer. 4 That the Collector Belt is not reversed (if it is correct, the brush revolves against the forward direction of the tractor (Figure 45). 4 That the Brush Height Adjustment Lever is not set too high or too low. 4 That there is not a build up of congealed grass on the leading edge of the Brush Guard. 4 That the Brush is not clogged. 4 That the Collector Belt is not slipping, if it is then adjust the tension or replace the worn or damaged belt. See Page 11. 4 That the Collector net is not clogged. If so, wash or brush with a stiff hand brush. 4 That the Brush is not damaged. Mulching can save time, avoids creating piles of rotting cuttings and feeds your lawn. When Mulch mowing it is necessary to observe certain rules: If you are still experiencing difficulties with collection please contact your dealer. 1. 2. 3. 4. 5. Figure 45 6. 7. to 8. Figure 26A Reduce the height of the grass by no more than 1/3rd its height in each pass. If the grass has grown long make several passes to achieve the cut height you require. Run the engine at maximum speed. Mow often, particularly in spring and early summer. Short clippings of 25mm (1”) or less decompose more quickly. If an unsightly residue of cuttings is being left – increase the cutting height. Drive forward at a speed that does not cause the engine speed to drop. REMEMBER if the RPM display flashes below 2600rpm, there are two options: a) Reduce forward speed b) Raise the cutting height. Vary the mowing pattern from cut to cut. Always keep the underside of the cutting deck clean ensure good grass flow. Always check that the blades are sharp and in good condition – never attempt to sharpen or replace them yourself. New Countax blades are not expensive; it is good practice to ask your dealer to change them. Figure 26B High Grass Mulch Deck - (Figure 26B) The real alternative when cutting long or paddock grass is the “high grass mulch” deck. When using the high grass mulch deck please ensure the following: 1. 2. 3. Page 16 When cutting very tall grass set the deck at the higher settings 7-9. Drive forward at a speed that does not cause the engine speed to drop. REMEMBER if the RPM display flashes below 2600rpm, there are two options: a) Reduce forward speed b) Raise the cutting height. Regularly check the cutter deck drive belt tension in accordance with the instructions (page 11). Page 9 Figure 27 Countax Garden Tractors - Routine Maintenance Countax Garden Tractors - Troubleshooting (Cutter Levelling) Levelling Side to Side Engine Maintenance Please refer to the engine manufacturer’s handbook enclosed with this manual. Battery Maintenance (Figure 28) The battery fitted to your tractor is a low maintenance sealed unit. Should your battery require charging for any reason please note that sealed lead acid batteries require a special 2 stage charging unit. Any battery charged on a standard battery charger will fail prematurely. Your dealer will be able to supply a battery charger specifically designed for the battery fitted to your tractor. The battery charger part number is 449563000. If your tractor does not start, refer to the troubleshooting section in this manual. Cutter Deck Maintenance Figure 28 The battery in your Countax garden tractor is very similar to that found in your car. To remove, simply undo the NEGATIVE terminal connection, followed by the positive. REMOVAL OF CUTTER DECK (Figures 29, 30, 31 & 32) The Cutter Deck can be quickly removed for servicing or cleaning, or to give greater clearance when driving or towing over uneven ground. Figure 29 Follow this sequence: 1. Lower the cutting deck to its lowest position (see Controls - Page 5). 2. De-tension the Cutter Drive Belt with the lever under the left running board (Figure 29). 3. Remove the 3 securing pins from the front of the deck (Figure 30 - A, B & C) by undoing the Rue Clips (Figures 31 & 32) and removing them. 4. Remove the 2 securing pins from the back of the deck (Figure 30 - D and E). 5. Slip the cutter drive belt off the Engine Pulley. 6. Slide the deck out. 7. If you are going to use the tractor without the deck, remove the Securing Bar (Figure 30 - F). 8. Remove the fifth wheel - G (A Series tractors only). De-Tensioned Tensioned Front of tractor D C Tractors up to serial No. 41130 This adjustment is best done with the deck in a position three up from its lowest cut – check the level both sides and levelling is then achieved by adjusting the left side ( as you are sat on the Tractor) of the deck at 2 points. REAR ADJUSTMENT (Figure 42 or 43) 1. Find the Deck Level Disc (Figure 42 or 43) near the back (near side) wheel. This has a concentric slot in which the Deck Levelling Rod is located. 2. Using a 13mm spanner, loosen the M8 Nyloc nut (A) securing this stud just enough to permit some movement. 3. Now lift or depress the Deck depending on the adjustment you wish to achieve. This will move the stud up or down the disc – the higher up and nearer the centre of the disc the higher the deck. 4. Check with your ruler or tape and having levelled the Deck at the rear, re-tighten the Nyloc nut. FRONT ADJUSTMENT (Figure 44) 1. Having levelled the rear of the Deck, check if the front is level. If not, find the Deck Adjustment Plate (Figure 44) which is forward of the Cutter Deck near the front (left) wheel. 2. Before making adjustments, loosen the two sets of nuts and bolts (A & B). 3. Using a 13mm spanner, loosen (upper) locknut (C). 4. Now adjust the height by using a ratchet or spanner to turn the Nyloc nut (D) clockwise (up) to raise the Deck or anti-clockwise (down) to lower it. 5. When level is achieved, tighten lock nut (C), re-tighten nuts and bolts A & B. 6. Raise and lower the cutter deck and then re-check level. A B Figure 42 A20/50HE tractor A B Figure 43 A C D B Figure 44 Manual Deck Lift DECK LEVEL SYSTEM FOR ‘C’ SERIES F C Series & A20/50H tractor Tractors from serial No. 41201 Side to Side Level This adjustment is best done with the deck in a position three up from its lowest cut – check the level both sides and levelling is then achieved by adjusting the left side ( as you are sat on the Tractor) of the deck at 2 points. To Clean The Cutter Deck Rear Adjustment Remove the deck as instructed, stand it on its side and hose off accumulated cuttings. DO NOT SPRAY WATER DIRECTLY ONTO BEARING HOUSINGS. To prevent a drop in performance it may be necessary to routinely check for this grass build up, particularly at the beginning of the season when the grass is lush and wet. It is best to regularly check and clean the Cutter Deck as often as possible, this can be done by either removing the Deck or raising the tractor safely on a ramp. Locate the top lock nut ( A ) and loosen this off using a 17mm Spanner. Now wind the adjuster nut (B) either up or down using a 19mm Spanner to alter the height of the deck on the left hand side to match that on the right hand side. Use the marks on the plate as a guide as to how much to raise or lower the deck. When the deck is level at the rear tighten the lock nut securely E B G Figure 30 Unsecured Secured A A B Dial Height Deck Lift Front Adjustment A Locate the top lock nut ( A ) and loosen this off using a 17mm Spanner. Now wind the adjuster nut (B) either up or down using a 19mm Spanner to alter the height of the deck on the left hand side to match that on the right hand side. Use the marks on the plate as a guide as to how much to raise or lower the deck. When the deck is level at the front tighten the lock nut securely. Raise and then lower the cutter deck and then re-check the level. If it is still incorrect re adjust as required B A Front Adjustment NOTE: 38, 44 and 50” Mulch decks must be set 10mm higher at the front than the back Figure 31 Page 10 Figure 32 Page 15 B Countax Garden Tractors - Troubleshooting (Cutter Levelling) The Cutter Deck should be set so that it is parallel to the surface it is cutting with a maximum variation from side to side or front to back of 3mm. Engine to Cutter Drive Belt Tension Levelling Front to Back You need two people for this operation – one to lift the Deck while the other removes or relocates the adjuster Trunnion. 1. Ensure that the Anti-Scalp Wheels are all set to the same height – if not, rectify (Figure 40). 2. Lower the Cutter Deck to a position one above the lowest setting – check levels with a ruler or tape. 3. Now locate the Front to Back Adjustment Rod to the right rear offside wheel, you will find the Trunnion (Figure 41) that links the rod to the Deck Hanger Bracket. Both the Trunnion and the Rod are threaded and adjustment is achieved by rotating the Trunnion to ‘in-effect’ lengthen the Rod. 4. To free the Trunnion, use a 17mm spanner or socket to remove the M10 Nyloc nut and washer and push it free. 5. Rotate the Trunnion to advance it up the Rod to lift the back of the Deck. Rotate it the other way to lift the front. Adjustment is rapid, so try one or two turns first and relocate the Trunnion and secure – then check the effect. Repeat and re-check if necessary. Countax Garden Tractors - Routine Maintenance Figure 40 For best results, set the Anti-Scalp Wheels in the middle adjustment holes. If you are experiencing scalping, this can be minimised by setting the wheels in the lowest adjustment holes. Front to Back Adjustment Rod The correct tension of the Cutter Drive Belt is critical. If incorrectly set it can lead to engine damage and invalidate warranty. To check the tension put the deck in a middle cutting height position. (Position 5 on the electric lift display). 1. Select a midway position on the belt, using a spring balance; apply a 2Kg (4-5lbs) pull (Figure 33). 2. Using a ruler or tape, measure the deflection achieved which must be 13mm (1/2”). If more, the belt tension must be increased, if less – decreased. To correct the tension, follow this procedure: 1. Release the tension on the belt by pulling the Belt Tension Lever (page 10, Figure 29) forward. 2. Taking care not to burn yourself on a hot exhaust, locate the Trunnion at the end of the Belt Tension Rod – lift the bonnet and look to the front (nearside) close to the exhaust (see Figure 34). 3. Remove the Spring Clip and washer holding the Trunnion in place on the Deck Tension Cradle (Figure 35) and release the Trunnion so it can be turned. 4. Both the Trunnion and the Belt Tension Rod are threaded. The belt tension is increased by turning the Trunnion towards the end of the Rod and reduced by winding in the reverse direction. 5. Having made the adjustment, re-locate and secure the Trunnion, re-tension the Belt with the Belt Tension Lever – then re-check the Belt tension. Transmission Drive Belt Figure 33 Figure 34 Belt Tension Rod The transmission drive belt is self-tensioning. When the hand brake is released and the drive belt engaged, the belt will retain its tension correctly. When the drive is disengaged using the hand brake the park brake engages. This setting is adjustable but should be carried out by your dealer, anyone not familiar with this setting may cause serious damage to the transmission. Trunnion Trunnion Transmission Oil Tank (Figure 36) Deck Hanger Bracket Figure 41 This is located in the Tractor rear body and should be approximately half full when the machine is cold. This level will rise when the engine is warm as the oil expands. It should return to the half way point once the machine has cooled down. The oil should not need to be topped up in normal use. If a noticeable drop in the level occurs then your dealer should be contacted. Figure 35 Transmission Oil Tank Figure 36 Page 14 Page 11 Countax Garden Tractors - Routine Maintenance PTO Main Drive Belt Countax Garden Tractors - Troubleshooting (Cutting) Figure 37 The PTO drive belt is self-tensioning when the drive is engaged. If this belt does require any adjustment it should be carried out by your dealer; anyone not familiar with this setting may cause serious damage or even injury when using a machine with badly adjusted belts. Accessory Drive Belt Installation (Figure 38, 39) The information contained on this, and the following pages is given on the understanding that Countax accepts no responsibility for work carried out by a customer or for any damage thus caused, whether or not the service instructions have been misunderstood. To be sure that your warranty terms are not breached, service work should only be carried out by your dealer. Cutter Fails to Start or Cuts Out when Switched On 1. 2. Lift the PTO Guard. Place the drive belt over the PTO pulley of the Powered Grass Collector. 3. The lower half of the belt is pulled left and through the belt hook. 4. Feed the belt around the PTO pulley clockwise. 5. Lock the Locating Lever over the Lift Arm Lugs. 6. Check Belt Tension- (19mm deflection 2kgs pressure). 7. Rotate the locking clips over the Locating Lugs. If the belt Tension is incorrect, movement of the sweeper Locking Levers on the threaded rod can adjust it. Ensure the lock nuts are suitably tightened after adjustment. Belt tension should be set in the working position. Check: 4 Are you on the tractor? – Unless you sit on the seat, the safety switch cuts out the Cutter Deck. 4 That either the Cutter Switch or the Safety Switch on the seat is not faulty – if so, call your dealer. 4 Is the battery low? – The Clutch Engage Switch will only operate if the battery is well charged. Uneven Cutting Check: 4 That all tyres are inflated to their correct pressures. C Series: A Series: Figure 38 4 4 4 4 (FRONT: 0.8 – 1.1KGF/cm (12 – 16PSI) (BACK: 0.7 – 1.1KGF/cm (10 – 12PSI) The Cutter seems to Lose Power and the Belt Slips and Overheats Check: 4 That the Tensioner Rod is correctly applied (Page 10, Figure 29) 4 That the Cutter Belt Tension is correct (see page 11). 4 That the Cutter Deck is not clogged with wet cuttings. 4 That the Cutter Drive belt is not worn. We do not recommend that customers attempt to change cutting blades themselves, remember that it is never worthwhile to have blades re-ground. It is cheaper and better to replace blades – re-grinding is likely to affect the hardening of the blade and its balance. The Cutter Deck should be set so that it is parallel to the surface it is cutting with a maximum variation from side to side, or front to back of 3mm. Check this by placing the tractor on a hard level surface and measuring the clearance heights front to back and side to side with a steel ruler or tape, with the Cutter set one adjustment up from its lowest position. If the Cutter Deck seems to require levelling, first check these other possible causes: (FRONT: 0.8 – 1.1KGF/cm (12 – 16PSI) (BACK: 0.43 – 0.7KGF/cm (6 – 10PSI) 4 That the front axle is pivoting freely. The deck suspension brackets are moving freely and not locking up. That the deck is level from side to side and back to front (see Cutter Deck Levelling). That one or more of the cutter blades are not worn or damaged – if this is the case, it is necessary to call your tractor dealer. 4 4 4 Uneven Cut (Cuts Shorter One Side than the Other) mm Figure 39 Check: 4 That the tyres are all inflated to the correct pressures (see above). 4 That the front axle is pivoting freely. 4 That the deck suspension brackets are moving freely and not hitching up. 4 That the side deck level adjustment is correct (page 15). Cut is Uneven or Untidy in One or More Sectors Check: 4 That the Cutter Deck is levelled correctly front to back (page 14). 4 That one or more of the blades are not worn or damaged – if so, call your dealer. Page 12 Page 13 Are the tyres correctly inflated? – If not, rectify using the figures opposite as a reference. Are the Cutter Deck Hanger brackets (Figure 41) moving freely or are they hitching up. To check this, lift the Cutter Deck to its highest position and lift and rock it, watching to ensure that the brackets move freely – if not, clean and lubricate. Is the front axle pivoting freely? – If not, it may require lubrication or adjustment. Is there any impact damage that has bent or distorted the Deck or Suspension Brackets (a matter for your dealer)?