Challenger Operators Manual P-13155

Challenger Operators Manual P-13155
Safety Instructions & Operators Manual
TM
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.
P-13155
TABLE OF CONTENTS
MODEL NUMBER’S & SERIAL NUMBER’S ........................................................................... 2 SAFETY ......................................................................................................................................... 3 ACCIDENT PATTERNS TO AVOID...............................................................................................................3 SAFETY INSTRUCTIONS AND RECOMMENDATIONS ...........................................................................3 SAFETY INTERLOCK SYSTEM .....................................................................................................................5 START UP AND OPERATION .................................................................................................... 6 CHECKLIST BEFORE OPERATION .............................................................................................................6 CONTROL LOCATION JOYSTICK MODELS ............................................................................................6 OPERATION JOYSTICK MODELS ..............................................................................................................7 OPERATION FREE WHEEL ..........................................................................................................................8 MOWING RECOMMENDATIONS .................................................................................................................9 MAINTENANCE ......................................................................................................................... 10 MAINTENANCE SCHEDULE........................................................................................................................10 MAINTENANCE INSTRUCTIONS ...............................................................................................................11 JOYSTICK ADJUSTMENT ............................................................................................................................12 HYDROSTATIC TRANSMISSIONS .............................................................................................................14 PROCEDURE FOR RAISING AND LOWERING THE DECK FOR SERVICING ................................15 SECURING THE DECK PROP ......................................................................................................................18 LEVELING THE DECK ..................................................................................................................................19 ADJUSTING THE LATCH PLATE ...............................................................................................................20 TROUBLE SHOOTING CHECK LIST...................................................................................... 21 BELT ROUTINGS ....................................................................................................................... 23 WIRING SCHEMATIC FOR KAWASAKI JOYSTICK (E-6415) ............................................ 24 WIRING SCHEMATIC FOR BRIGGS JOYSTICK (E-6415) .................................................. 25 WIRING SCHEMATIC FOR KOHLER JOYSTICK (E-6415) ................................................. 26 NOTES / SERVICE RECORDS: ................................................................................................ 27 NOTES / SERVICE RECORDS: ................................................................................................ 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
ACCIDENT PATTERNS TO AVOID
I.
SAFETY INSTRUCTIONS AND
RECOMMENDATIONS
CONTACT WITH THE ROTATING
BLADE -- This accident usually
happens when the operator is clearing
the discharge chute of grass, (especially
when the grass is wet), or when the
operator adjusts the machine without
turning it off and waiting for the blades
to completely stop.
II.
III.
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.
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.
PLEASE BE CAREFUL!
3
1.
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.
2.
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.
3.
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.
4.
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.
5.
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.
6.
KNOW HOW TO STOP QUICKLY.
Know the location and operation of
every control, especially how to brake
and how to disengage the mower
blades.
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).
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.
8.
DO NOT ALLOW CHILDREN TO
OPERATE MOWER. Do not allow
others who have not had instruction to
operate mower.
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 WELLVENTILATED 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.
9.
10.
11.
12.
13.
ALWAYS TURN ENGINE OFF AND
REMOVE KEY before leaving the
mower to prevent children and
inexperienced operators from starting
the engine. Never leave the mower
unattended with engine running. Always
wait for all moving parts and all sounds
to stop before leaving operator’s seat.
WEAR STURDY, ROUGH-SOLED
WORK SHOES AND CLOSE-FITTING
SLACKS AND SHIRTS. Never operate
mower in bare feet, sandals or
sneakers.
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.
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.
DISENGAGE BLADES BEFORE
DRIVING ACROSS WALKS or
projecting objects.
4
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.
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.
SAFETY INTERLOCK SYSTEM
29.
Your Country Clipper Zero Turn Radius Mower
is equipped with switches interlocked for your
safety.
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.
ON JOYSTICK MODELS GROUND DRIVE
NEUTRAL IS WHEN THE JOYSTICK (CONTROL
LEVER) IS IN THE “DOWN” POSITION.
1.
The mower blades must be disengaged
and the Control Lever(s) must be in the
neutral position before the engine will
start.
DO NOT OPERATE THE MOWER
UNDER THE INFLUENCE OF
ALCOHOL OR DRUGS.
2.
The engine will stop if the mower blade
clutch is engaged when the operator
leaves the driver’s seat.
33.
USE CARE WHEN LOADING OR
UNLOADING MACHINE INTO A
TRAILER OR TRUCK.
3.
The engine will stop if the Control
Lever(s) are not in the neutral position
when the operator leaves the driver’s
seat.
34.
USE CARE WHEN APPROACHING
BLIND CORNERS, shrubs, trees, or
other objects that may obscure vision.
4.
The engine will stop if the brake is
“SET” and the Control Lever(s) are not
in the neutral position.
35.
CLEAN ALL GRASS AND DEBRIS
FROM MACHINE TO PREVENT
FIRES. Remove spilled oil or gasoline.
5.
The engine will stop if the brake is
“SET” and the mower blade clutch is
engaged.
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.
DO NOT OPERATE MOWER IF SAFETY
SWITCHES AND GUARDS ARE NOT
OPERATING PROPERLY
5
START UP AND OPERATION
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.
CHECKLIST BEFORE OPERATION
1. Make sure fuel tank is full. Use regular
unleaded gasoline (see engine owner’s
manual for more details).
CONTROL LOCATION
JOYSTICK MODELS
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.
Throttle
Choke
Joystick Control Lever
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.)
Ignition Key
Blade Clutch Switch
Parking Brake Lever
Cut Height
Adjust.
Lever
6. Check battery fluid level.
7. Inspect V-belts.
8. Check tire pressure:
9. Make sure underside of mower deck is free
of grass.
Cut Height
Stop Pin
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.)
Cut Height Foot
Assist Lever
6
9. TO DRIVE:
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.
A.
OPERATION
C.
B.
JOYSTICK MODELS
D.
1. MOVE JOYSTICK CONTROL LEVER to
neutral “DOWN” position.
E.
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.
Move the Joystick Control Lever to the
“UP” position.
Move the Joystick Control Lever
forward to move forward. Increasing
forward movement of the Joystick
Control Lever will increase the speed
of travel.
To reverse the direction, pull the
Joystick Control Lever slightly back.
To turn, move the Joystick Control
Lever toward the direction you want to
turn.
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
5. SET ENGINE THROTTLE TO 1/2
THROTTLE.
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.
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
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.
7. ADJUST ENGINE THROTTLE for desired
engine smoothness and speed. However,
use full throttle while mowing.
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.
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.
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.
7
Retaining Slot
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.
B.
C.
D.
E.
Move Joystick Control Lever to neutral
position and then to the “DOWN”
position.
Disengage the mower blade clutch by
moving the clutch to the “OFF”
position.
Set the parking brake.
Turn ignition key to “OFF” position.
Remove the key and wait for all
movement and sound to cease before
dismounting.
Transmission
Release Chain
NOTE: The tractor should never be pulled at
more than 2 miles per hour or for any
appreciable distance.
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: Pull the
Transmission Release Chain out away
from the Hydrostatic Drive Axle and then
over into the retaining slot (each side
must individually be pulled out and over
into the retaining slot).
B. To re-engage the transmissions push
the Transmission Release Chain out of
the retaining slot.
Transmission Release Chains are
located on the rear side of the
Hydrostatic Drive Axles and below the
Engine Mounting Plate.
8
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.).
9
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







After Each Use or Daily
 Clean Grass Build-Up from Deck Cutting Chamber.
After First 5 Hours
 Change Engine Oil.
After First 100 Hours
 Check Wheel Lug Nuts. (75 ft/lbs or 102 Nm)
 Change Hydraulic Filter.
Every 10 Hrs
 Check Tire Pressure. (12 Psi / 83 kPa)
 Check Battery Fluid
 Sharpen Mower Blades
Every 25 Hours
 Service Air Cleaner. (Increase Frequency Under Severe
Conditions. See Engine Owner’s Manual for additional
information.)
Every 50 hours
 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)
Every 400 Hours
 Change Hydrostatic Transmission Oil & Filter
Every 500 Hours
Or Annually




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
Grease Front Caster Pivots
Replace Air Filter Element
Check Spark Plugs
Service Battery
Replace Safety decals when illegible. Write factory for free replacement.
10
MAINTENANCE INSTRUCTIONS
3. TIRES:
1. ENGINE:
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:
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.
Model
All
Models
NOTE: Air intake screen must be kept
clean. If plugged, engine may be
seriously damaged by overheating.
Front tires
12 psi
Rear tires
12 psi
Lug nuts should be torqued to 75 ft/lbs
and checked regularly for tightness.
4. MOWER BLADES:
2. BATTERY:
Check sharpness of mower blades after
every 10 hours of operation. To
sharpen blades proceed as follows:
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.
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
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.
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.
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.
E. Install blade, blade washer and bolt.
Make sure to torque bolt to 100 ft-lbs.
11
JOYSTICK ADJUSTMENT
5. V-BELTS:
1. SETTING TRACKING AND FORWARD
SPEED:
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.
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.
6. LUBRICATION:
A. Engine: Follow engine manufacturer’s
recommendation.
Upper end bolt
B. Front Caster Pivots: Lubricate fittings
with several pumps of multi-purpose
grease from a grease gun.(See pg. 19)
Left side
transmission
Linkage
7. PARKING BRAKE ADJUSTMENT FOR
CHALLENGER (SR500) MOWERS:
A. Move Parking Brake Lever to the “OFF”
position.
B. Adjust the top Adjustment Nut down or
up so that the Brake Rod Arm is fully
extended downward.
C. Move Parking Brake Lever to the “ON”
position.
D. Adjust the Bottom Adjustment Nut so
that the compression spring is
compressed to 5/8”.
Jam Nut
Rod end
(Repeat for other side).
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.
Top Brake
Adjustment Nuts
Brake Linkage
Assembly
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!
Bottom Brake
Adjustment
Nut
Brake Rod Arm
12
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.
Outside
Linkage
Inside
Linkage
Jam Nut
Coupling Nut
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.
Right Side Transmission
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.
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.
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).
13
Neutral
Plate
Cross Bolt
Long silver
spacer
Long silver
spacer
Short gold
spacer
Neutral Plate
Nuts
Short gold
spacer
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.
HYDROSTATIC TRANSMISSIONS
Before each use, check to be sure that
the cooling surfaces of the hydrostatic
transmissions are clean. Excessive
accumulation of oil, dirt, or trash may
cause the transmissions to overheat.
NOTE: NEVER WASH ACROSS VENTED
CAP WITH WATER OR STEAM.
JOYSTICK CONTROL LEVER
SENSITIVITY ADJUSTMENT:
Vented Cap
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.
Fluid Level
It is essential that the unit exterior be
free of debris prior to doing any fluid
maintenance.
1. HYDROSTATIC TRANSMISSION FLUID
CHANGE (CHALLENGER):
SAE 20W-50 engine oil has been
selected for use by factory and is
recommended for normal operating
temperatures. Each transmission holds
a maximum of 74 oz of oil.
14
maintenance or oil has been added to
the system.
Top Plug
IMPORTANT:
Side Plug
Failure to purge system properly may
cause one or all of these symptoms:
1) noisy operation. 2) Lack of power or
drive after short term operation. 3) High
operation temperature and excessive
expansion of oil.
1. PURGING PROCEDURE
Oil Hydrostatic Transmission
NOTE: Before starting procedure make sure the
transmission is at the proper oil level. If
it is not, fill to specifications.
A. Set the park brake.
The following procedures should be
performed with the vehicle drive wheels
off the ground then repeated under
normal operating conditions.
B. Open the by-pass valve.
C. Remove the oil filter.
D. Remove the top plug on the right side
transmission (reinstall at 110-150 in-lbs)
A. With the transmission unlocked (see
page 10 for details) and engine running,
slowly move the directional control in
both forward and reverse directions 5 to
6 times. As air is purged from the unit,
the oil level will drop.
E. Remove the side plug on the left side
transmission (reinstall at 180-240 in-lbs)
F. After all the oil is drained out, replace
the filter (use part # H-2567 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.
B. With the transmission locked and the
engine running, slowly move the
directional control in both forward and
reverse directions (5 to 6 times). Check
the oil level, and add oil as required
after stopping engine.
G. Refill the transmission with the
recommended oil through the expansion
tank. When the oil level in the
transmission reached the top or side
plug port reinstall the plug and continue
filling until the “Full Cold” line is reached
on the expansion tank. Each
transmission will take approximately 2
quarts of oil.
C. It may be necessary to repeat Steps A &
B until all air is completely purged from
the system. When the transaxle moves
forward and reverse at a normal speed
purging is complete.
PROCEDURE FOR RAISING AND
LOWERING THE DECK FOR
SERVICING
1. RAISING THE DECK:
NOTE: Due to the effect air has on efficiency in
hydrostatic drive, it is critical that it be
purged from the system.
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
These purge procedures should be
performed any time a hydrostatic
system has been opened for
15
(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).
2.
LOWERING THE DECK:
A. Place the deck prop back in the stowed
position.
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 22.)
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. Position the front caster wheels so they
are away from the deck (such as the
tractor would be traveling in reverse).
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 retension the Deck Belt.
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. Lower the foot deck down into the
operation position. On units so
equipped, lower the front step.
F. Release the deck prop from its stowed
position and place the free end against
the deck lift casting as shown on page
20. 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.
16
MOWER SHOWN IN
OPERATING POSITION.
Cut Height Adjustment Lever
Cut Height
Adjustment
Foot Deck
Flip Front
Step Up
Front Caster Pivot
Grease Zerk
Latch Plate
Front Caster Wheels
positioned out of the way.
MOWER SHOWN IN
SERVICING POSITION.
Hook
Keeper
Deck Hook
Deck raised to
service position
Engine to Deck Belt
Removed from Clutch
Deck Prop
17
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.
18
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
within 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
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.
6" Scale
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. This 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.
6. Confirm that the deck is hanging firmly on ALL four deck hanger bolts. Readjust any loose Deck Hanger
Bolts accordingly.
7. 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.
19
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
UP
(RELEASE)
LATCH
PLATE
DOWN
(LOCK)
RELEASE
HANDLE ROD
HOOK
KEEPER
RELEASE
HANDLE
DECK
HOOK
LATCH PLATE
ADJUSTMENT
20
TROUBLE SHOOTING CHECK LIST
1.
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
2.
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
3.
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
4.
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
5.
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.
21
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.
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.)
8.
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.
22
BELT ROUTINGS
Hydrostatic Transmission Drive Belt
(Viewed from ground looking up)
Right Hand Hydrostatic
Transmission Pulley
Left Hand Hydrostatic
Transmission Pulley
Belt
P/N D-3905
Motor Pulley
60” DECK BELT
P/N: D-3776-W
52” DECK BELT
P/N: D-3872
Clutch
Clutch
"V" IDLER
"V" IDLER
23
FroM \tire Side
Fr oM \./lr~ Sid~
Fusel
30 AMP
12Gn
Green / \./ hlte 19 F1.1el Cu-tof f
Red 19
EnginE" Plug, Char ge-
F'use
~ R~d
lOG~
19
Yol-tog~
Regulo.tor
Yellow 4 To Stnr"t solonojd Red
Green 25A
Green 25A- To DILPre-ssure Switch
To Engine O!L Press1.1re Sw itch
Blue 13
Blk 13 Mo.gneto Ground
Engine Plug Mng Ground
YEL 4
YEL I
Joy
S'\lck
In drive
B l u e 2 * 6Reo 8
Blue 1
Elk 10
Re~ 9
2B
Ko. wo.so.k1 Engine
Blc;e 2
YEL 2
El k 11
.J oystjck
RH
Fuse!
~e
YEL
'•• •
E- 629 7 key
:S wl"tch
2
lk 11
24
E-6054
Sol enolcl
Elk 40
Elk 17 12Go
?OSITION
l.
2
~FF
RUN
3 . START
To S-tortj Clutch not engnged e..
:S t eering Levers in Neu"trul
Engine Kil l: If Steoer ing levers in drive
2.. bro.ke Is on or
:s~o.. t
~,<n- ot=cup!~d
If Clu-tch Is on and
sea.. t
is not occup ied
Engine Block
Ground
Deck Clu tch
Cjrcui-t
So.fe -ty Clrcuit
Power C!rc1.1lt
GroV!nd C!rc::~o<lt
Hr M-tr Clrcul "t
Sto.r-t
Yellow
~
Reel
Blo.c:+<
Green
WIRING SCHEMATIC FOR KAWASAKI JOYSTICK (E-6415)
PLUS (E-6417) ADAPTER
E- 6417 Kohler To Ko.wo.so.kl
Engine Ado.pte r
Ho.rness Connect o r
H~rn~~s Conn~~tor
fus€1
3 0 AMP
12G~
Engine
Fuse
Briggs Engine
Frol""' 'W ire- Side
Red 19
Cho.rge
P~ug,
lOGo
Green 25 A
To Engine OIL Pres:s:ure Switch
Bl<.<e 13
Engine Plug Mo.g Ground
YEL 4
YEL
YEL
Blue
I
c~6Recl
Blue 1
Joy
Stick
In drive
8
Blk 10
Red 9 E-b297
Switchkey
tusel
-----------------·~-~--·~
e 2B
~
Bl
YEL
2
Ko.wo.so.ki Engine
Blu e
. Elk 11
Joystick
RH
YEL 2
Blk 11
25
Blk 10
Elk 3
E~6 054
Soleno id
Seo.t Switch
Un-occ~..<pi~d
Elk 40
Solder
Joint
To Si:o.ri::
POSITION
1.
OFF
CIRCUIT "MAK["
G + M
2. RUN
B + L
3 . START
B + L + S
Ground
Clutch not engo.ged &
Steering Levers: In Neutro.l
Engine Kill1 If S -teer ing lFver s in drive
& bro.ke Is on or
seo. t un-accupi e-ol
If Clutch is un and
seo.t Is: not; occupied
Blk 17 12G o
Engine Block
Red
( irc:i.-iii:
Sof ety :Circuli:
Stod
Power
Llrcult
Yl;"llo w
~
~
Groul'ld L ircui-t
Blnck
Hr Mtr Circuit
Green
A~~pter
WIRING SCHEMATIC FOR BRIGGS JOYSTICK (E-6415)
PLUS (E-6436) ADAPTER
E~6436
FroM \1/Jre Side
ru5 e l
\/ire Side
30 AMP
12Go
Kohler Englne
Connector FroM
Viol€' t-To volto.ge regulator
Red 19
Engin e Plug, Churge
FUSE
Re<i-C ~rb u retor
l OGo
Solenol<i
~ Red-To Fuel Solenoid Reel
- Blue -To Stur te r Coil
Gr<'<'n 25A
Green- To OiLPressure
To EnginE" OIL Pressure Swi-tch
Blue 13
\/ h lte-M~g
Englne Plug Ma g Ground
Y~l. J
Reel
Blue 2 6
~
8
Elk 10
kE' y
S WItc
YEL ~e 2B
Bluel3
Fuse!
Joy
S-tick
Reel 8
In d rive
Blue- To Kohler Plug Shu- -ter Coil
Blue 2
YEL 2
Elk 11
Joyst ick
RH
26
~
lk 1l
F use-2
Blk 10
Blk 3
Blue 26
914G~
Red
C
YEL 3
NC
YEL
I~
E- 6297
Switch
Blk 40
Bruke on
Blue 14
RPri
s
l6G~
Elk 17
Engine El ock
POSITION
I CIRCUIT
G + M
1. OFF
2. RUN
I
3. S TARTI
If Clu-tch is o n and
Sto rt Circuit
Snfety Circuit
Power Circui-t
Ground Circui-t
s eo. t
Hr
& klro.ke Is on or
seat un-occupied
B + L
B + L +
Clutch n o t e n gaged &
S teerlng Leve r s in Ne utral
Engine KiUt If Ste e r ing le-YE'rS in drive
GroL.-lnd
To Sto.rt:
"MAKE"
s
ls no t
occ upled
Mtr Circuit
Yellow
Bl ue
~
~
Green
12G~
WIRING SCHEMATIC FOR KOHLER JOYSTICK (E-6415)
Harn e£s Co nnecto r
Frorr~ 'Wire Side
Swii:c~
Ground \/hl t e
NOTES / SERVICE RECORDS:
DATE
SERVICE WORK COMPLETED
27
NOTES / SERVICE RECORDS:
DATE
SERVICE WORK COMPLETED
28
Safety Instructions & Operators Manual
TM
Country Clipper Division
Shivvers Manufacturing Inc.
613 W. English St.
Corydon, IA 50060-0467
Ph. 641-872-2544
Fax. 641-872-1593
P-13155
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