advertisement
Safety Instructions & Operators Manual
Congratulations for buying a Country Clipper product. Your Country Clipper Zero Turn 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 3-5. Following these instructions will help you continue to enjoy the trouble-free performance expected of the Country
Clipper product.
TM
P-13160
TABLE OF CONTENTS
PROCEDURE FOR RAISING AND LOWERING THE DECK FOR SERVICING ............................... 17
WIRING SCHEMATIC FOR KAWASAKI JOYSTICK (E-6415) ............................................. 25
WIRING SCHEMATIC FOR KAWASAKI TWINSTICK (E-6416) .......................................... 26
WIRING SCHEMATIC FOR KAWASAKI JOYSTICK (E-6415) ............................................. 27
WIRING SCHEMATIC FOR KAWASAKI TWINSTICK (E-6416) .......................................... 28
1
MODEL NUMBER’S & SERIAL NUMBER’S
Date of Purchase:
____________________________________________
Mower Model Number:
____________________________________________
Mower Serial Number:
Engine Spec Number:
____________________________________________
____________________________________________
Hydro Serial Number (RH):
____________________________________________
Hydro Serial Number (LH):
____________________________________________
2
SAFETY
I.
II.
ACCIDENT PATTERNS TO AVOID
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.
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.
IV.
OVERTURNING -- This happens when 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.
1.
2.
3.
4.
5.
6.
PLEASE BE CAREFUL!
SAFETY INSTRUCTIONS AND
RECOMMENDATIONS
PEOPLE WHO OPERATE, SERVICE,
OR ARE OTHERWISE ASSOCIATED
with the Country Clipper Zero Turn
Radius Mower should be trained in its proper use and warned of its dangers.
Before operating, adjusting, or servicing the Country Clipper Zero Turn 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 mower 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.
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 Turn 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 l eaving 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.
4
14.
NEVER REMOVE THE FUEL CAP or add gasoline to a running or hot engine that has not been allowed to cool for 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. MOWER 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. THIS MACHINE IS NOT MEANT FOR
HIGHWAY OR STREET USE. It is not a recreational vehicle and it should not be operated as such.
26. ALWAYS DISENGAGE THE MOWER
BLADE CLUTCH when transporting.
27. 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.
28. WEAR PERSONAL PROTECTIVE
EQUIPMENT. Eye, ear, feet and head protection is recommended.
29. ONLY USE COUNTRY CLIPPER
APPROVED ACCESSORIES.
30. DO NOT CHANGE THE ENGINE
GOVERNOR SETTING or over speed the engine.
31. BEWARE OF MOWER DISCHARGE
DIRECTION and do not point it at anyone.
32. DO NOT OPERATE THE MOWER
UNDER THE INFLUENCE OF
ALCOHOL OR DRUGS.
33. USE CARE WHEN LOADING OR
UNLOADING MACHINE INTO A
TRAILER OR TRUCK.
34. USE CARE WHEN APPROACHING
BLIND CORNERS, shrubs, trees, or other objects that may obscure vision.
35. CLEAN ALL GRASS AND DEBRIS
FROM MACHINE TO PREVENT FIRES.
Remove spilled oil or gasoline.
36. KEEP HANDS AND FEET AWAY
FROM MOVING PARTS. If possible do not make adjustments with the engine running.
37. NEVER MOW WHEN OTHER PEOPLE
OR PETS ARE IN THE AREA.
5
38. CAREFULLY RELEASE PRESSURE
FROM COMPONENTS WITH STORED
ENERGY.
39. 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).
40. USE JACK STANDS TO SUPPORT
COMPONENTS when required.
41. 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 Turn 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 and the Control Lever(s) must be in the neutral position before the engine will start.
2. The engine will stop if the mower blade clutch is engaged when the operator leaves the driver’s seat.
3. The engine will stop if the Control Lever(s) are not in the neutral position when the operator leaves the driver’s seat.
4. The engine will stop if the brake is
“SET” and the Control Lever(s) are not in the neutral position.
5. 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
CHECKLIST BEFORE OPERATION
1. Make sure fuel tank is full. Use regular unleaded gasoline (see engine owner’s manual for more details).
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.
3. Do not mix oil with gasoline.
4. 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.)
6. Check battery fluid level.
7. Inspect V-belts.
8. Check tire pressure:
9. 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.
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.
Parking Brake Lever
6
CONTROL LOCATIONS
JOYSTICK MODELS
Throttle
Ignition Key
Choke
Cut Height Foot
Assist Lever
Joystick
Control Lever
Blade Clutch
Switch
Cut Height
Adjust.
Lever
Cut Height
Stop Pin
WARNING
AVOID INHALING EXHAUST FUMES!
CARBON MONOXIDE GAS IS COLORLESS,
ODORLESS AND CAN CAUSE
UNCONSCIOUSNESS AND IS POTENTIALLY
LETHAL. DO NOT RUN LAWN MOWER IN
GARAGE OR OTHER CONFINED AREAS.
OPERATION
JOYSTICK MODELS
1. MOVE JOYSTICK CONTROL LEVER to neutral “DOWN” 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 (Not applicable on
Fuel Injected models).
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 for desired engine smoothness and speed. However, use full throttle while mowing.
8. RELEASE PARKING BRAKE. Push brake lever down to release.
IMPORTANT:
Until the operator is familiar with the
Country Clipper Zero Turn Radius
Mower, he/she should follow these recommendations: 1) Disengage the mower blades. 2) Go very slowly until thoroughly familiar with the machine.
3) Keep away from fences, buildings, and other obstructions. 4) Move the
Joystick Control Lever smoothly and slowly. 5) Practice until operation is smooth and efficient.
7
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.
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.
Note
: 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 (depress end button on pin to unlock) 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 engine throttle to 1/2
–3/4 throttle, engage the Blade Clutch Switch to the “ON” position, set throttle to full.
Note
: The engine will not start with the blade clutch switch in the “ON” position. Engine will stop if the clutch switch is “ON” and the Operator is not in the seat.
CAUTION
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.
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.
Turn ignition key to “OFF” position.
E. Remove the key and wait for all movement and sound to cease before dismounting.
CONTROL LOCATIONS
TWINSTICK MODELS
Choke
Right Hand Steering
Control Lever
Throttle
Ignition Key
Blade Clutch Switch
Parking Brake
Lever
Cut Height
Adjustment Lever
Left Hand Steering
Control Lever
Cut Height Foot
Assist 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.
Cut Height
Stop Pin
8
7. ADJUST ENGINE THROTTLE for desired engine smoothness and speed. However, use full throttle while mowing.
8. RELEASE PARKING BRAKE. Push brake lever down to release.
IMPORTANT:
Until the operator is familiar with the
Country Clipper Zero Turn Radius
Mower, he/she should follow these recommendations: 1) Disengage the mower blades. 2) Go very slowly until thoroughly familiar with the machine.
3) Keep away from fences, buildings, and other obstructions. 4) Move the
Steering Control Lever smoothly and slowly. 5) 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.
9
10. BRAKING: To brake mower, gently move the Steering Control Levers in the direction opposite to travel. NOTE: 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 on the Cut Height Foot Assist
Lever will make the Cut Height Adjustment
Lever easier to operate.
12. ENGAGE MOWER BLADE CLUTCH: Set engine throttle to 1/2
–3/4 throttle, engage the Blade Clutch Switch to the “ON” position, set throttle to full.
Note
: The engine will not start with the blade clutch switch in the “ON” position. Engine will stop if the clutch switch is “ON” and the Operator is not in the seat.
CAUTION
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.
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.
Turn ignition key to “OFF” position.
E. Remove the key and wait for all movement and sounds 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.
OPERATION
FREE WHEEL
1. TO FREE WHEEL:
A. Unlock Transmission: Unscrew the bypass valve between ½ -1 full turn counterclockwise. NOTE: Both sides must be done in order to free wheel.
B. To re-engage the transmissions screw the bypass valve clockwise until tight
(DO NOT OVER TIGHTEN). NOTE:
Both sides must be done in order to lock the wheels.
Hydrostatic
Transmission
Bypass Valve
NOTE: The tractor should never be pulled at more than 2 miles per hour or for any appreciable distance.
10
CAUTION
NEVER OPERATE MOWER WITHOUT
DISCHARGE CHUTE IN PLACE.
MOWING RECOMMENDATIONS
1. Keep mower blades sharp.
2. Make sure deck and discharge are clean.
CAUTION
TURN ENGINE OFF AND WAIT FOR ALL
MOVING PARTS TO STOP BEFORE
CLEANING DISCHARGE CHUTE.
3. When mowing tall grass, make two passes.
Mow off ½ of the desired cut on the first pass, and then the desired height the second pass. Check for hidden dangers.
4. Go slowly for trimming.
5. Always cut grass with the engine at full throttle speed.
NOTE: Operating the engine at full throttle assures that the cutting blades are operating 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.).
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
Maintenance Service Interval Maintenance Procedure
Before Each Use or Daily
Check Engine Oil Level.
Check Mower Blades.
Check Operator Presence Control System.
Check for Loose Hardware.
Clean Engine Cooling System.
Remove Debris From Engine.
Remove Debris Build-Up Hydrostatic Transmission & Cooler
After Each Use or Daily
After First 5 Hours
After First 100 Hours
Every 10 Hrs
Clean Grass Build-Up from Deck Cutting Chamber.
Change Engine Oil.
Check Wheel Lug Nuts. (75 ft/lbs or 102 Nm)
Change Hydraulic Filter.
Check Tire Pressure. (12 Psi / 83 kPa)
Check Battery Fluid
Sharpen Mower Blades
Every 25 Hours
Every 50 hours
Service Air Cleaner. (Increase Frequency Under Severe
Conditions. See Engine Owner’s Manual for additional information.)
Check Hydraulic Oil Level.
Check Drive Belt Condition.
Check Engine RPM (3500-3600 rpm)
Every 100 hours
Change Engine Oil & Filter. (Increase Frequency Under
Severe Conditions. See Engine Owner’s Manual for
Additional Information.)
Remove Engine Shrouds & Clean Cooling Fins.
Check Spark Plug
Check Wheel Lug Nuts. (75 ft/lbs or 102 Nm)
Change Hydrostatic Transmission Oil & Filter
Every 400 Hours
Every 500 Hours
Or Annually
Grease Front Caster Pivots
Replace Air Filter Element
Check Spark Plugs
Service Battery
Replace Safety 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
Turn Radius Mower information packet.
NOTE: Air intake screen must be kept clean. If plugged, engine may be seriously damaged by overheating.
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 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.
12
3. TIRES:
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 Front tires Rear tires
All
Models
12 psi 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 and blade 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, blade washer and bolt.
Make sure to torque bolt to 100 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. Front Caster Pivots: Lubricate fittings with several pumps of multi-purpose grease from a grease gun.(See pg. 19)
7. PARKING BRAKE ADJUSTMENT FOR
CHARGER (1035) MOWERS:
A.
Move Parking Brake Lever to the “OFF” position.
B. Firmly hold the Brake Arm forward and line up the Shoulder bolt with nearest hole in the Brake Adjustment Link and tighten the Shoulder Bolt and Lock Nut.
Repeat for other side. The Park Brake
Handle should require around 45lbs to pull it on. If the Handle force is to high move the Shoulder bolt(s) to the next lighter setting. If too light, move to next heavier setting.
Brake
Adjustment
Link
Brake
Arm
Lock Nut
Shoulder Bolt
JOYSTICK ADJUSTMENT
1. SETTING TRACKING AND FORWARD
SPEED:
A. The initial setting is done with the engine TURNED OFF.
B. Remove both fender skirts.
C. Start by setting the RH transmission speed. Disconnect the linkage that is connected to the left side transmission at the upper end.
Left side transmission
Linkage
Jam Nut
Upper end bolt
Rod end
Left Side Transmission
D. On the outside (long) linkage that goes from the joystick to the right side transmission, Loosen the jam nuts on both ends of the coupling nut. One of these is a left-hand thread. Rotate the coupling nut a couple turns to lengthen it.
IMPORTANT:
Use two wrenches (one on the nut and one on the coupling nut or rod end housing) when loosening or tightening jam nuts to prevent damaging the rod end ball joints!
13
Inside
Linkage
Right Side Transmission
Outside
Linkage
Coupling Nut
Jam Nut
E. Lift the joystick control handle out of the neutral position and hold it firmly in the full forward position. Now, by hand, rotate the coupling nut shortening the linkage until resistance is felt from the transmission control bottoming out in the transmission. Rotate the coupling nut back and forth a couple times to confirm, and mark this position.
F. Now rotate the coupling nut exactly one
full turn longer and retighten the jam nuts.
When retightening make sure that the ball joints on both top and bottom are well centered so that they do not bind up when moving the joystick handle to the extremes of its travel.
NOTE: This full turn longer is required to prevent internal damage to the transmission.
G. Now set the LH transmission speed.
Reconnect the linkage to the left side transmission. (see left side transmission illustration on previous page).
H. Loosen the jam nuts on both ends of the
left side transmission linkage. One of these is a left-hand thread. Now rotate the linkage rod a couple turns to lengthen it.
I.
Hold the joystick control handle firmly in the full forward position. Rotate the left side transmission linkage rod to shorten the linkage until resistance is felt from the transmission control bottoming out in the transmission. Rotate the rod back and forth a couple times to be sure, and mark this position.
J. Now rotate the linkage rod exactly one
full turn longer and retighten the jam nuts.
Make sure that the ball joints on both top and bottom are centered.
NOTE: This full turn longer is required to prevent internal damage to the transmission.
K. Test drive the mower to check for tracking at full speed. If needed, slow the fast side by lengthening the control rod connected to the faster transmission. Use small adjustments of about ¼ turn. Replace the fender skirts when done.
2. SETTING NEUTRAL:
If, with the joystick handle in the DOWN or start position and the engine running the mower moves or travels, it is necessary to adjust neutral. Raise the drive wheels off the ground, secure the mower on blocks or jack stands and proceed as follows:
A. Remove the fender skirt on the joystick side. Loosen the two nuts on the bottom of the joystick neutral plate just enough so that the plate can move freely.
14
Neutral
Plate
Cross Bolt
Long silver spacer
Long silver spacer
Short gold spacer
Neutral Plate
Nuts
B. Start the engine. With the joystick still down, position the handle so both wheels are stationary.
C. Tighten the two nuts on the bottom of the neutral plate, being careful not to shift it out of position.
D. Recheck neutral before placing the mower back on the ground. Then shut off the engine and remove the mower from the blocks. Replace the fender skirt.
3. 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, & spacers.
C. For quicker reacting steering place the long, silver colored spacers toward the inside of the rod end ball joints and the shorter, gold colored spacers on the outside of the ball joints. For slower reacting steering place the short, gold colored spacers on the inside and the longer, silver colored spacers on the outside. All 4 spacers must be used when reassembling.
Short gold spacer
TWINSTICK ADJUSTMENT
1. TWINSTICK CONTROL LEVER
NEUTRAL ADJUSTMENT:
A. Loosen the bolts holding the Neutral
Plate.
B. Pull back the control lever until the wheel spin is zero.
C. Tilt the Control lever outward, using the lever, position and tighten the bolts holding the Neutral Plates.
Neutral
Plate
15
2. TWINSTICK CONTROL LEVER
FORWARD TRACKING:
In a large open area, actuate the
Twinstick Control levers 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 left transmission needs to be slowed down.
If the mower veers to the left then the right transmission needs to be slowed down.
A. Stop the machine and shut off the engine.
B. Slightly loosen the nuts around the turnbuckle on the faster side. Lengthen the lower linkage rod by ¼ turn increments, retighten and retest, until the mower tracks straight.
C. Once the tracking is to the operators liking, completely tighten the nuts on the turnbuckle. Recheck and adjust the
Neutral Plate if required.
D. Reinstall the fender skirts and tighten all bolts.
3.
TO ADJUST “IN” OR OPERATING
POSITION OF THE TWINSTICK
STEERING CONTROL LEVERS:
If the Control levers are too close in the center or the Control Levers Drag on the Neutral Plate, adjust as follows:
A. Tilt the Control Lever outward, loosen the lock nut and adjust the bolt until the gap between the handles is correct or the Control lever does not rub on the Neutral Plate.
B. Tighten the lock nut after the adjustment is made.
Adjustment
Bolt
Lock Nut
HYDROSTATIC TRANSMISSION
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
16 surrounding area PRIOR to removal of the cap. Take caution to keep all foreign matter out of the Hydraulic Oil
Reservoir.
NOTE: NEVER WASH ACROSS VENTED
CAP WITH WATER OR STEAM.
It is essential that the unit exterior be free of debris prior to doing any fluid maintenance.
1. HYDROSTATIC TRANSMISSIONS FLUID
CHANGE:
SAE 20W-50 engine oil has been selected for use by factory and is recommended for normal operating temperatures.
Vented
Cap
Hydraulic Oil Reservoir
Fluid
Level
Hydraulic Oil Filter
A. Set the park brake.
B. Remove the oil filter.
C. After all the oil is drained out, replace the filter (use part # H-2026 when ordering from Country Clipper).Wipe off the filter base surface, apply a film of new oil to the gasket of the new filter and hand tighten ¾ to one full turn after the filter gasket contacts the filter base surface.
D. Refill the transmission with the recommended oil through the Hydraulic
Oil Reservoir. continue filling until the
“Full Cold” line is reached on the reservoir.
E. Recheck oil level after running.
SEAT HOLD DOWN LATCH
To release the seat hold down latch, pull the latch handle to the right.
Seat
Latch
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 immediately above Cut Height Adjustment Lever
(this will lock the cut height adjustment lever into the lowest position).
B. Carefully rotate the Deck Belt Tension.
Latch to release tension on the Deck
Belt. Remove the engine to deck Drive belt from the clutch on the engine. Flip up the Front Step (if so equipped).
C. On the right side of the mower, lift and hold up on the hook keeper. Lift up on the release handle to disconnect the back of the deck. The latch plate should catch and hold the release handle rod in place. (To adjust the latch plate, see page 21.)
17
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 near vertical (lifting can be made easier if someone stands on the rear bumper of the tractor.
F. Release the deck prop from its stowed position and place the free end against the deck lift casting as shown on page
19. Make sure the point of the prop falls within the center clearance area.
IMPORTANT NOTE:
TO SECURE THE DECK, MAKE SURE
THAT THE DECK IS LIFTED FAR
ENOUGH TO ALLOW THE DECK
PROP TO ENGAGE THE DECK LIFT
CASTING.
2. LOWERING THE DECK:
A. Place the deck prop back in the stowed position.
B. Push the bottom (back) of the deck towards the rear of the tractor. Lower the deck until it rests on the ground.
C. Lift up on the latch plate to release the release handle rod. Push down on the release handle until deck hooks lock into place.
D. Install the engine to deck belt onto the clutch on the engine.
E. Ensure that the engine to deck drive belt is installed onto all of the pulleys and idlers in the drive train. Carefully rotate the Deck Belt Tension Latch to re-tension the Deck Belt.
F. Lower the foot deck down into the operation position. On units so equipped, lower the front step.
Latch Plate
Hook
Keeper
MOWER SHOWN IN
SERVICING POSITION.
Deck raised to service position
Release
Handle
Deck Hook
Engine to Deck Belt
Removed from Clutch
MOWER SHOWN IN
OPERATING POSITION.
Cut Height Adjustment Lever
Cut Height
Adjustment
Foot
Deck
Flip Front
Step Up
Front Caster Pivot
Grease Zerk
Release
Handle
Front Caster Wheels positioned out of the way.
Deck Prop
18
SECURING THE DECK PROP
Deck Prop shown in the “Stowed” position. Deck Prop being placed against the Deck lift casting.
Deck Prop securely in place against Deck lift casting.
19
LEVELING THE DECK
NOTE: The Deck has been leveled at the Factory.
If leveling is needed, use the following procedures.
1. Move the tractor to a hard surface (i.e. concrete or blacktop).
2. Set the tire pressure on each of the four tires to 12 psi.
3. Set the deck cutting height to the highest position and rotate the two outside blades by hand until one end of each outside blade points forward (toward the front of tractor).
4. Measure from the ground to the front blade tip of each outside blade. These measurements should be w ithin 1/8” of each other. (NOTE: To simplify this measuring, an optional Blade Measuring tool, part
Number 629-
374A is available from your local “Country Clipper” Dealer).
Deck hanger bolt
Part # F-1936
1/2" Jam nut
Part # F-1489
6" Scale
Note: If you run out of threads, remount the deck mounting in this upper hole.
IF ATTEMPTING TO ADJUST DECK
HIGHER THAN DESIGN
SPECIFICATIONS, DECK DRIVE
FAILURE COULD OCCUR.
5. If adjustment is needed, loosen the jam nut(s) of the Deck Hanger Bolt(s) and adjust the Deck Hanger
Bolt(s) up or down accordingly. It may be necessary to adjust both the front and rear Deck Hanger Bolts for a given side.
6. Once the side to side cut height is within tolerance, measure from the ground to the blade tip at the rear of each outside blade. Thi s measurement should be between 1/8” and ¼” higher from the ground than the front of the blade from the ground on the corresponding side of the deck. Adjust rear and/or the front deck hangers accordingly to obtain the proper measurement Re-measure the side to side cutting height to confirm that they are still within 1/8” of each other At the front of the blade.
7. Confirm that the deck is hanging firmly on ALL four deck hanger bolts. Readjust any loose Deck Hanger
Bolts accordingly.
8. Once all of the above measurements are confirmed, tighten ALL jam nuts on the Deck Hanger Bolts.
Failure to tighten can result in an un-level cutting deck and/or lost Deck Hanger Components.
20
642-175P
ADJUSTING THE LATCH PLATE
1. Level the deck before proceeding to adjust the latch plate. (Follow instructions on previous page.) Pin the deck in the lowest position before proceeding to adjust the latch plate.
2. Lift up on the hook keeper, while pulling up on the release handle. This will disconnect the rear of the deck.
3. Loosen nuts on the adjustment of the latch plate using a 7/16 wrench. Pull up on the release handle as far as it will allow. Slide adjustment back or forward to where the latch plate will catch the release handle rod at its highest location. Tighten nuts back.
4. Lift up on latch plate and push down on the release handle to lock deck hooks in place.
5. Double check the latch plate adjustment by releasing the deck hangers and pulling up on the release handle. If the latch plate catches the release handle rod, no further adjustment needs to be made. If it does not, follow steps 3-5, as needed.
ADUSTMENT
NUTS
LATCH
PLATE
RELEASE
HANDLE ROD
HOOK
KEEPER
DECK
HOOK
UP
(RELEASE)
DOWN
(LOCK)
RELEASE
HANDLE
LATCH PLATE
ADJUSTMENT
21
4.
5.
3.
2.
1.
TROUBLE SHOOTING CHECK LIST
ENGINE WON’T TURN OVER:
Mower blades engaged ---------------------------------------------------------------- disengage blades
Drive not in neutral ---------------------------------------- move Control Lever(s) to neutral position
Blown fuse ---------------------------------------------------------------------------------------- replace fuse
Dead battery ------------------------------------------------------------------------------ charge or replace
Solenoid ---------------------------------------------------------------------------------------- consult dealer
Ignition switch --------------------------------------------------------------------------------- consult dealer
Starter ------------------------------------------------------------------------------------------- consult dealer
ENGINE WILL TURN OVER BUT WON’T START:
No gas ------------------------------------------------------------------------------------------------------ refuel
clean or replace fuel filters
Over or under choked ------------------------------------------------------------------------- adjust choke
Spark plug not firing ---------------------------------------------------------------------- check spark plug
condition and reset gap*
Carburetor maladjustment ----------------------------------------------- reset carburetor adjustment*
Ignition switch --------------------------------------------------------------------------------- consult dealer
HARD TO START ENGINE:
Fuel line clogged --------------------------------------------------- clean fuel line and check fuel filter
Faulty fuel pump ------------------------------------------------------------------------------ consult dealer
Spark plug wire loose or grounded ------------------------------------------- check spark plug wires
Spark plug(s) faulty or improperly gapped ------------------------------------------ check spark plug
condition and reset gap*
Electronic ignition defective ---------------------------------------------------------------- consult dealer
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
clean carburetor bowl
Clogged fuel line ---------------------------------------------------------------------------- check fuel filter
clean fuel line
Vent in fuel cap plugged ------------------------------------------------------------------------ check vent
Faulty fuel pump ------------------------------------------------------------------------------ consult dealer
Maladjusted carburetor -------------------------------------------------------------- readjust carburetor*
Engine dies when Control Lever(s) is move from “neutral” --------------------- parking brake set
release brake
ENGINE KNOCKS:
Low oil level ------------------------------------------------------------------------------- check and add oil
Ignition timing off ----------------------------------------------------------------------------- consult dealer
Fuel octane too low ---------------------------------------------------------------- drain and replace with
higher octane gasoline
Over heated engine -------------------------------------------------- shut off engine and allow to cool
* See engine manual for engine adjustments.
22
6. ENGINE SOMETIMES SKIPS AT HIGHER SPEEDS:
Incorrect Ignition Timing -------------------------------------------------------------------- consult dealer
Carburetor maladjusted --------------------------------------------------------------- readjust carburetor
Faulty spark plugs ------------------------------------------------------------------------ check spark plug
condition and reset gap*
Bouncing off seat safety switch ------------------------------------------ slow down on rough terrain
7.
8.
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
Improper ignition timing --------------------------------------------------------------------- consult dealer
Running engine too slow ---------------------------------------------------------------- run engine faster
(NOTE: Always mow at full throttle setting.)
ENGINE IDLES POORLY:
Carburetor maladjustment ------------------------------------------------------------ readjust carburetor
Improper spark plug gap -------------------------------------------------------- check and re-gap plug*
9. ENGINE BACKFIRES:
Carburetor maladjustment ---------------------------------------------------------- readjust carburetor*
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
Shift linkage disconnected ----------------------------------------------------------------------- reconnect
Transmission oil low ------------------------------------------------------------------------- consult dealer
Bad transmission ----------------------------------------------------------------------------- consult dealer
11. TRANSMISSION LOSES POWER OR TRANSMISSIONS OVER HEATS:
Transmission damage ----------------------------------------------------------------------- consult dealer
12. MOWER TRANSMISSION DOES NOT ENGAGE RIGHT AND/OR LEFT HAND:
Transmission Free Wheel engaged------------------------------------------ disengage Free Wheel
Loose or damage Control Linkage ------------------------------------------------------- consult dealer
Low Transmission oil ------------------------------------------------------------------------ consult dealer
13. ENGINE STALLS WHEN BLADES ARE ENGAGED:
Operator not on seat ------------------------------------------------------------------------------ sit on seat
Faulty interlock system ---------------------------------------------------------------------- consult dealer
Bad blade spindle bearing ----------------------------------------------------------------- consult dealer
Deck drive belt not properly routed ---------------------------------------------------------------- reroute
Blades blocked by foreign material -------------------------------------------------- clean under deck
14. DECK BLADES WILL NOT ENGAGE:
Blown fuse----------------------------------------------------------------------------------------- replace fuse
Faulty wiring ----------------------------------------------------------------------------------- consult dealer
Faulty electric clutch ------------------------------------------------------------------------- consult dealer
* See engine manual for engine adjustments.
23
BELT ROUTINGS
Hydrostatic Transmission Drive Belt
(Viewed from ground looking up)
Release tension from Hydrostat
Drive Belt
Right Hand Hydrostatic
Transmission Pulley
Idler
Pulley
Belt
P/N D-3524
Left Hand Hydrostatic
Transmission Pulley
Deck Drive Belt
Motor Pulley
52” DECK BELT
P/N: D-3872
60
” DECK BELT
P/N: D-3872
24
Clutch
"V" IDLER
WIRING SCHEMATIC FOR KAWASAKI JOYSTICK (E-6415)
PLUS (E-6417) ADAPTER
25
WIRING SCHEMATIC FOR KAWASAKI TWINSTICK (E-6416)
PLUS (E-6417) ADAPTER
26
WIRING SCHEMATIC FOR KOHLER JOYSTICK (E-6415)
PLUS (E-6547) ADAPTER
27
WIRING SCHEMATIC FOR KOHLER TWINSTICK (E-6416)
PLUS (E-6547) ADAPTER
28
CASE DRAIN
CHARGE PUMP INLET
HIGH PRESSURE
HYDRAULIC SCHEMATIC:
OIL COOLER
OIL TANK
LEFT-HAND
WHEEL MOTOR
LEFT-HAND
HYDROSTATIC
TRANSMISSION
HIGH PRESSURE
- REVERSE
29
RIGHT-HAND
WHEEL MOTOR
RIGHT-HAND
HYDROSTATIC
TRANSMISSION
DATE
NOTES / SERVICE RECORDS:
SERVICE WORK COMPLETED
30
DATE
NOTES / SERVICE RECORDS:
SERVICE WORK COMPLETED
31
DATE
NOTES / SERVICE RECORDS:
SERVICE WORK COMPLETED
32
Safety Instructions & Operators Manual
Country Clipper Division
Shivvers Manufacturing Inc.
613 W. English St.
Corydon, IA 50060-0467
Ph. 641-872-2544
Fax. 641-872-1593
P-13160
TM
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
Related manuals
advertisement
Table of contents
- 4 Accident Patterns to Avoid
- 4 Safety Instructions and Recommendations
- 6 Safety Interlock System
- 7 Checklist Before Operation
- 7 Control Locations - Joystick
- 8 Operation - Joystick
- 9 Control Locations - Twinstick
- 9 Operation - Twinstick
- 11 Operation - Free Wheel
- 11 Mowing Recommendations
- 12 Maintenance Schedule
- 13 Maintenance Instructions
- 14 Joystick Adjustment
- 16 Twinstick Adjustment
- 17 Hydrostatic Transmission
- 18 Seat Hold Down Latch
- 18 Procedure for Raising and Lowering the Deck for Servicing
- 20 Securing the Deck Prop
- 21 Leveling the Deck
- 22 Adjusting the Latch Plate