Country Clipper 2204MT Assembly instructions

OWNERS MANUAL & SAFETY INSTRUCTIONS
for
TRACTOR MODELS 2204MT & 2504MT
DECK MODELS 5204M & 6004M
Mid-Mount Zero Turn Radius Mowers
Congratulations for buying a Commercial Clipper product. Your Commercial Clipper Zero Turning
Radius Riding Mower was designed and built to provide long and trouble free service. Keep in mind that
it, like any other mechanical device, can be potentially dangerous if used improperly, and hazard control
and accident prevention are dependent upon the awareness, concern, prudence, and proper training of
personnel involved in the operation, transport, maintenance, and storage of the equipment. Study this
manual and pay special attention to the important Safety Precautions. Following these instructions will
help you continue to enjoy the trouble-free performance expected of the Commercial Clipper product.
P-11456 (7/00)

TABLE OF CONTENTS
I. OWNER INFORMATION
Warranty Information ---------------------------------------------------- II
Specifications ------------------------------------------------------------ III
II. SAFETY
Accident Patterns --------------------------------------------------------- 1
Safety Instructions and Recommendation ------------------------- 1
Safety Interlock Systems ----------------------------------------------- 3
III. START UP AND OPERATION
Checklist Before Operation -------------------------------------------- 3
Control Locations --------------------------------------------------------- 4
Operation ------------------------------------------------------------------- 4
Mowing Recommendations ------------------------------------------- 6
VI. MAINTENANCE
Maintenance Schedule ------------------------------------------------ 6
Maintenance Instructions --------------------------------------------- 7
Leveling the Deck ------------------------------------------------------ 10
Raising and Lowering Deck for Servicing ----------------------- 11
Trouble Shooting Checklist ------------------------------------------ 13
Wiring Schematic ------------------------------------------------------- 15
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WARRANTY INFORMATION
SERIAL NUMBER__________________________________________________________
DATE PURCHASED________________________________________________________
Condition of Mower (New or Used)______________________________________________
Hour Meter Reading__________________________________________________________
SERVICE SCHEDULE
Service Performed and Date
___________________________________________________________________________
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P-11456
II

TRACTOR SPECIFICATIONS
w/ 52" DECK w/ 60" DECK
Length
All Models -------------------------------------------------- 81" 81"
Width
All Models ------------------------------------------------ 49" 49"
Height
All Models (To top of seat back)------------------- 43" 43"
Weight
All Models -------------------------------------------------- Approx. 680 lbs.
Fuel Tank
All Models ------------------------------------------------ Approx. 11 gallons
Hydrostats
All Models -------------------------------------------------- (2) Hydro-Gear
BDU-10L
Engine
------------------------------- 22 hp. , 23 hp. & 25 hp. twin Kohler Command
Engine to Hydrostat belt (Kevlar)
All Models ----------------------------------------------------(SPECIAL) A-112
Tires Front Rear
All Models 13-5.00 x 6- 23-9.50 x 12
DECK SPECIFICATIONS
ITEM 52" 60"
Cutting width 52" 60"
Cutting height --------1-1/2" to 5"--------
Blades (3)-18-3/8" (3)-21"
Overall width
including chute 61-1/2" 69 1/2"
Material thickness 10 GA. 10 GA.
Reinforcement plate 7 GA. 10 GA.
Spindle bearings 25mm 25mm
Weight 235 lbs. 236 lbs.
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SAFETY
ACCIDENT PATTERNS TO AVOID
I. CONTACT WITH THE ROTATING
BLADE -- This accident usually
happens when the operator is clearing
the discharge chute of grass, (especially
when the grass is wet), or when the
operator adjusts the machine without
turning it off and waiting for the blades
to completely stop.
II. PROPELLED OBJECTS -- Sticks,
rocks, wires, and other objects can be
propelled out through the discharge
chute or from under the mower housing.
Bystanders are particularly vulnerable.
III. GRASS CATCHER OR GUARD -- The
mower shall not be operated without
either the entire grass catcher or guard
in place.
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.
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!
SAFETY INSTRUCTIONS AND
RECOMMENDATIONS
1. PEOPLE WHO OPERATE, SERVICE,
OR ARE OTHERWISE ASSOCIATED
with the Zero Turning Radius Mower
should be trained in its proper use and
warned of its dangers. Before
operating, adjusting, or servicing the
Zero Turning 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 mowing 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 Zero
Turning Radius Mower before
attempting to mow. Start with slow
engine speed and drive without the
blades engaged in an open area until
comfortable with the machine.
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 STEERING CONTROL
LEVERS from forward position to
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reverse position rapidly. The speed
and/or direction of travel is affected
instantly by movement of the Steering
Control Levers.
8. DO NOT ALLOW CHILDREN TO
OPERATE MOWER. Do not allow
others who have not had instruction to
operate mower.
9. ALWAYS TURN ENGINE OFF AND
REMOVE KEY before leaving the
mower to prevent children and
inexperienced operators from starting
the engine. Never leave the mower
unattended with engine running. Always
wait for all moving parts and all sounds
to stop before leaving operator’s seat.
10. WEAR STURDY, ROUGH-SOLED
WORK SHOES AND CLOSE-FITTING
SLACKS AND SHIRTS. Never operate
mower in bare feet, sandals or
sneakers.
11. NEVER CARRY PASSENGERS.
12. 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.
13. 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.
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. DO NOT SMOKE AROUND THE
MOWER or the gasoline storage
container. Gasoline fumes can easily
ignite.
16. 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.
17. 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.
18. KEEP ALL NUTS, BOLTS, AND
SCREWS TIGHT to be sure equipment
is in safe working condition, especially
blade mounting bolts.
19. VEHICLE SHOULD BE STOPPED
AND INSPECTED FOR DAMAGE after
striking a foreign object and the damage
should be repaired before restarting and
operating the equipment. Stop
immediately and check for damage or
loose parts if mower should start
vibrating.
20. DISENGAGE BLADES BEFORE
DRIVING ACROSS WALKS or
projecting objects.
21 KEEP SAFETY DEVICES AND
GUARDS IN PLACE. If any of the
safety switches become inoperable,
have them repaired immediately.
22. DO NOT STEP OR STAND ON THE
MOWER HOUSING. Step or stand only
on the foot deck.
23. WATCH OUT FOR TRAFFIC near
roadways and when crossing roads.
24. DO NOT USE MOWER WHEN GRASS
IS WET OR SLIPPERY.
25. MOW ONLY DURING DAYLIGHT.
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26. THIS MACHINE IS NOT MEANT FOR
HIGHWAY OR STREET USE. It is not
a recreational vehicle and it should not
be operated as such.
27. ALWAYS DISENGAGE THE MOWER
BLADE CLUTCH when transporting.
SAFETY INTERLOCK SYSTEM
Your Zero Turning Radius Mower is equipped
with switches interlocked for your safety.
1. The mower blades must be disengaged
before engine will start.
2. The Steering Control Levers must be in
the neutral “OUT” position before the
engine will start.
3. The engine will stop if the mower blade
clutch is engaged when the operator
leaves the driver’s seat.
4. The engine will stop if the Steering
Control Levers are not in the neutral
“OUT” position when the operator
leaves the driver’s seat.
5. The engine will stop if the brake is
“SET” and the Steering Control Levers
are moved to the “IN” position.
6. The engine will stop if the brake is
“SET” and the mower blade clutch is
engaged.
DO NOT OPERATE MOWER IF SAFETY
SWITCHES 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 the hydrostatic transmission oil
level. (See “Maintenance” section of this
manual.)
7. Check battery fluid level.
8. Inspect V-belts.
9. Check tire pressure:
Model Front tires Rear tires
All
Models 12 psi 12 psi
10. Make sure underside of mower deck is
free of grass.
11. Make sure mower blades are sharp and
secured tightly.
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12. Clean the air intake screen on the
engine if necessary.
13. 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 seat clutch properly.
CONTROL LOCATIONS
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
1. MOVE STEERING CONTROL LEVERS TO
neutral “OUT” position.
2. SET PARKING BRAKE. Pull up to set.
3. DISENGAGE MOWER BLADE CLUTCH by
moving clutch switch to “OFF” position.
4. PULL ENGINE CHOKE CONTROL to full
position for cold starts.
5. SET ENGINE THROTTLE TO 1/2
THROTTLE.
6. TURN IGNITION KEY to “START” position
and release to “RUN” as soon as engine
starts. NOTE: Prolonged cranking will
damage starter motor and shorten the
battery life.
7. ADJUST ENGINE THROTTLE AND
CHOKE for desired engine smoothness and
speed.
Steering Control Levers NOTE: When mowing, always run engine
at full throttle.
Choke Cut Height
Adjustment
Lever
Blade Clutch
Switch
8. RELEASE PARKING BRAKE. Push brake
lever down to release.
IMPORTANT: Until the operator is familiar with
the Zero Turning Radius Mower, he/she
should follow these recommendations:
Disengage the mower blades. Go very
slowly until thoroughly familiar with the
machine. Keep away from fences,
buildings, and other obstructions. Move
the Steering Control Levers smoothly
and slowly. Practice until operation is
smooth and efficient.
Ignition
Key
Throttle
Parking Brake
Lever
Cut Height
Stop pin 10. TO DRIVE: Move the Steering Control
Levers to the “IN” position. Move the
Steering Control Levers forward to move
forward. Increasing forward movement
of the Steering Control Levers will
increase the speed of travel. To reverse
the direction, pull the Steering Control
Levers slightly back. To turn, move one
Steering Control Lever slightly ahead of
the other. 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
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FOR SMOOTH, SAFE OPERATION, MOVE
THE STEERING CONTROL LEVERS IN A
GENTLE, SLOW MOTION. NEVER PULL OR
PUSH THE STEERING CONTROL LEVERS
RAPIDLY, ESPECIALLY ON GRADES.
11. BRAKING: To brake mower, gently
move the Steering Control Levers in the
direction opposite to travel. If the
parking brake is engaged with the
Steering Control Levers in the “IN”
position the engine will stop.
12. 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 right to clear top cut height latch.
Lower Cut Height Adjustment Lever until
it rests on Cut Height Stop Pin.
13. ENGAGE MOWER BLADE CLUTCH:
Set the Blade Clutch Switch to the “ON”
position. The engine will not start if the
blade clutch is engaged. If the operator
is not in the seat, the engine will stop if
the clutch is engaged.
CAUTION
AVOID HILL AND SLOPES. USE EXTREME
CAUTION WHEN MOWING UP OR DOWN
SLOPES. NEVER MOW ACROSS THE FACE
OF A SLOPE. IF A SLOPE MUST BE
ASCENDED, BACK UP THE SLOPE; DRIVE
FORWARD WHEN DESCENDING.
14. TO STOP:
A. Move Steering Control Levers to
neutral position and then to the “OUT”
position.
B. Disengage the mower blade clutch by
moving the clutch to the “OFF” position.
C. Set the parking brake.
D. Slow engine speed with throttle to
slowest position.
E. Turn ignition key to “OFF” (left)
position.
F. Remove the key and wait for all
movement and all sound to cease
before dismounting.
CAUTION
WHEN LEAVING THE MOWER
UNATTENDED, ALWAYS REMOVE THE KEY
AND SET THE PARKING BRAKE, EVEN IF
JUST FOR A FEW MOMENTS. HELP
PROTECT CHILDREN AND OTHER
UNAUTHORIZED PERSONS FROM
ACCIDENTS.
15. TO FREE WHEEL MACHINE: UNLOCK
TRANSMISSION: The transmission release
levers are located on each side of the mower
behind the rear drive axles and below the
engine mounting plate. Lift the levers slightly,
push them forward and then down to release the
transmissions for free wheeling. To engage the
transmissions lift the levers slightly, pull them to
the rear and then down. NOTE: The tractor
should never be pulled at more than 2 miles per
hour or for any appreciable distance.
Transmission
Release Valve
Free Wheel
Leve
r
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MOWING RECOMMENDATIONS 3. When mowing tall grass, make two
passes, mowing off 1/2 of the desired
cut on the first pass, and then the
desired height the second pass. Check
1. Keep mower blades sharp.
for hidden dangers first.
2. Make sure deck and discharge are
clean.
4. Go slowly for trimming.
CAUTION 5. Always cut grass with the engine at full
throttle speed. This “ENGINE” speed
allows the cutting blades to operate at
optimum cutting speed. Control
“GROUND” speed with the Steering
Control Levers.
POWER MUST BE OFF TO CLEAN
DISCHARGE CHUTE. TURN ENGINE OFF
AND WAIT FOR ALL MOVING PARTS TO
STOP.
6. Vary ground speed to suit conditions
(i.e. go slower in tall thick grass, on hills,
wet conditions, etc.).
MAINTENANCE
Replace decals when illegible. Write factory for free replacement.
CAUTION
BEFORE PERFORMING ANY MAINTENANCE, TURN OFF ENGINE
REMOVE KEY AND DISCONNECT SPARK PLUGS. USE EXTREME CARE WHEN WORKING ON
MACHINERY. DO NOT WEAR WATCHES OR JEWELRY. DO NOT WEAR LOOSE FITTING
CLOTHES, AND OBSERVE ALL COMMON SAFETY PRACTICES WITH TOOLS.
MAINTENANCE SCHEDULE
SERVICE WHEN
Check crankcase oil level --------------------------------------------------------------------- before each use
Clean grass from Hydrostat fans and cooling fans -------------------------------------- before each use
Check air intake screen --------------------------------------------------------------------------- after each use
Clean grass under deck -------------------------------------------------------------------------- after each use
Check tire pressure ------------------------------------------------------------------------------- every 10 hours
Check battery fluid -------------------------------------------------------------------------------- every 10 hours
Sharpen mower blades -------------------------------------------------------------------------- every 10 hours
Clean air filter pre-cleaner element ----------------------------------------------------------- every 25 hours
Check Hydrostatic transmission fluid --------------------------------------------------------- every 25 hours
Check drive belts ---------------------------------------------------------------------------------- every 50 hours
(20 hours break-in)
Service Air Cleaner Filter Element ---------------------------------------------------------- every 100 hours
Change engine crankcase oil ------------------------------------------------------------------------- 100 hours
oil filter -------------------------------------------------------------------------- 200 hours
Change Hydrostat oil and oil filter ----------------------------------------------------------- every 500 hours
(100 hours break-in)
Replace air filter element --------------------------------------------------------------- annually or 500 hours
Check spark plugs ------------------------------------------------------------------------ annually or 500 hours
Service battery ---------------------------------------------------------------------------- annually or 500 hours
MAINTENANCE INSTRUCTIONS
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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
Mower information packet.
NOTE: Air intake screen must be kept
clean. If plugged, engine may be
seriously damaged by over heating.
2. BATTERY:
CAUTION
BATTERY ELECTROLYTE IS A POISONOUS
AND CORROSIVE SULFURIC ACID
SOLUTION. AVOID SPILLING ON SKIN,
EYES, AND CLOTHING.
Keep the electrolyte level above the
plates in each cell by adding distilled
water as it becomes necessary. Add
water just before operating the mower to
mix the water with the solution. Be
careful not to overfill the battery -- the
electrolyte solution is corrosive and can
cause damage to surrounding metal
parts if it should spill. When taking the
battery out of the mower for servicing,
make sure to connect the cables to the
battery exactly as they were prior to
removal. Always disconnect the ground
( - ) wire first and always reconnect the
ground ( - ) wire last.
Keep the battery clean. Remove the
corrosion around the battery terminals
by applying a solution of one part baking
soda to four parts water. Coat all
exposed terminal surfaces with a light
layer of grease or petroleum jelly to
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.
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 checked regularly
for tightness.
4. MOWER BLADES:
Check sharpness of mower blades after
every 10 hours of operation. To
sharpen blades proceed as follows:
CAUTION
STOP ENGINE, REMOVE IGNITION KEY AND
SPARK PLUGS FOR SAFETY.
A. Remove bolt, lockwasher, and cup
washer mounting blade on shaft.
Remove blade.
B. Blades should be discarded when
worn excessively.
DANGEROUS!
DO NOT USE
BLADE IN THIS
CONDITION
New Blade
25 degrees
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.
When notch
starts, discard
blade
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.
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E. Install blade, cup washer,
lockwasher, and bolt. Make sure to
tighten bolt to 60 ft.lbs.
5. V-BELTS:
There are 3 V-belts on your Country
Clipper Mower . They should be
checked every 50 hours. Replace any
belts found to be in poor condition. All
belts are equipped with spring loaded
belt tighteners and do not require
tightening adjustments.
6. LUBRICATION:
A. Engine: Follow engine
manufacturer’s recommendation.
B. Deck Spindles: Lubricate with 3
“shots” only, every 100 hours.
C. Hydrostatic Transmission & Filter:
Follow instructions listed below.
DIRT OR WATER IN OIL CAN RUIN
THE HYDROSTATIC TRANSMISSIONS
Check the oil level in hydrostatic
transmission oil reservoir after every 25
hours of usage. Clean the oil reservoir
cap and the area around it prior to
removal. Check the oil level on the
dipstick. The proper oil level should
register between the marked hole on the
dipstick and the end of the dipstick.
Replenish as needed with 20W-50
Motor Oil. DO NOT OVER FILL. When
checking the oil level, be very careful to
keep the reservoir clean
Change the oil in the reservoir and
hydrostatic transmission filter after the
first 100 hours of use, then every 500
hours after that. Remove the filter and
be sure all oil has drained from the
reservoir. Replace with new filter (P/N
7252) and 20W-50 Motor Oil.
7. PARKING BRAKE ADJUSTMENT:
A. With the brake handle in the
“RELEASE” position and the actuating
lever against the stop, remove the cotter
pin from the castle nut. Insert a 0.010
feeler gauge between the brake disc
and the brake puck. Tighten the castle
nut with the feeler gauge inserted until
the gauge fits snugly between the disc
and puck. The gap should not be so
tight that the feeler gauge cannot be
reinserted after removal. Back the
castle nut to the closest pin hole and
reinsert the cotter pin.
Hydrostat Transmission
Oil Filter (located
UNDERNEATH of Engine
Mounting Plate)
Oil Reservoir Cap
Dipstick
Fuel Cap
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Castle Nut
.010 between Bake Disk
and Brake Puck
Brake Linkage
Spring
Stop
Actuating
Lever

8. STEERING CONTROL ADJUSTMENTS
A. To Adjust Neutral:
a. Remove the fender skirts from each
side of the machine.
b. Block up the unit so that the Drive
Wheels are off the ground.
c. Start the engine and run at a fast idle
with the Steering control levers in the
“out” position.
d. Loosen the locknuts tightened against
the rod end ball joints in the Upper
Linkage Assembly. (Note: One of these
is a left hand nut and will have to be
turned backwards.)
e. Adjust the Neutral Position by turning
the rod in the upper linkage until the
wheel stops turning.
f. Retighten the nuts on the Upper
Linkage Assembly and check to see that
the drive wheel is still not turning.
g. Repeat steps 1-6 for the other side.
h. Shut off engine before removing the
blocks.
B. To Adjust “IN” Position of the Steering
Controls:
a. Remove the 2 Front Bolts,
Lockwashers, and Washers which hold
the Fender Cap.
b. Pull the boot from the hole in the
fender cap, exposing the cast iron lever.
c. Using a 5/32” Allen Wrench, turn the
setscrew to adjust the stop.
d. Replace the Boot into the hole in the
Fender Cap.
c. Replace the 2 Front Bolts,
Lockwashers, and Washers.
C. To Align Handles:
Sit on the seat and push the control
levers full forward and full backward. If
the ends do not match the handles
maybe adjusted as follows:
a. Locate Setscrew stops in the Steering
Control Lever Base which stop the lever
in each direction. (Note: The one at the
rear is the stop for FWD and the one in
the front is the stop for REV.)
b. Adjust setscrew stops so that handles
line-up together when shifted full forward
and full reverse.
D. Adjusting for Straight Forward
Tracking:
In a large open area, actuate the control
handles into the full forward position. If
the mower veers in either direction Left
for Right some adjustment is necessary.
a. If the mower veers to the right, then
the right hydrostat needs to be sped up.
If the mower veers to the left, then the
left hydrostat need to be sped up.
b. Stop the machine and shut off the
engine.
c. Slightly loosen the bolt at the lower
end of the upper linkage assembly on
the side that is slower. Using a 1/8”
allen wrench turn the setscrew 1/4 turn
in. It may take several test drives to get
the mower to track straight forward.
d. Once the tracking is to the operators
liking, completely tighten the bolt on the
control linkage assembly that was
loosened earlier.
e. Recheck to make sure neutral adjust
has not been effected, see procedure A.
INWARD
STOP
SETSCREW.
LOOSEN BOLT ON
LINKAGE
SETSCREW USED TO
ADJUST FORWARD
TRACKING
RH LOCKNUT
UPPER LINKAGE
A
SSEMBL
Y
TURN THIS ROD TO
A
DJUST NEUTRAL
ROD END
BALL JOINT
LH LOCKNUT
REVERSE
STOP
SETSCREW.
ACCESS HOLE
FORWARD STOP
SETSCREW.
STEERING CONTROL
LEVER
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9. HYDROSTATIC TRANSMISSIONS:
Before each use, check to be sure that
the cooling fins of the hydrostatic
transmissions are clean. Excessive
accumulation of oil, dirt, or trash may
cause the transmissions to overheat.
NEVER WASH ACROSS TOP OF
RESERVOIR with water or steam. Fill
reservoir as required per the
maintenance schedule listed in this
book.
10. HYDROSTAT DRIVE BELT
REPLACEMENT PROCEDURE:
(The hydrostatic drive is equipped with
an automatic, anti-backlash belt take-
up)
A. Remove the 3/8” bolt lockwasher,
heavy washer, and spring, from the rear
of the assembly.
B. Squeeze the clamp latch to release
the clamp, allowing the idler arm/pulley
to swing forward towards the front of the
mower. Remove old belt if required.
Replace with new belt.
C. With the belt in place on all
pullies reinsert the spring, heavy
washer, lockwasher, and 3/8” bolt.
Tighten 3/8” bolt fully.
11. LEVELING THE DECK:
A. Set the tire pressure on all four tires
B. Move the tractor to a hard, level
surface (i.e. Concrete or blacktop).
Place a 2 x 4 board under all four
corners of the deck shell, just inside
of the anti-scalping wheels. Lower
the deck down onto the boards.
The deck must rest on the boards,
NOT the anti-scalping wheels. .
Adjust the deck hangers longer or
shorter until the deck “just” comes
off of the boards. Remove the
boards and verify that the deck is
hanging on all four deck hangers,
re-adjust if necessary. Lock the jam
nuts on the deck hangers. (NOTE:
the two rear deck hangers will be
easier to adjust if the fender skirts
are removed).
Motor Pulley
Idler Pulley
3/8” bolt,
lockwasher, &
Heav
y
washe
r
Hydrostat drive
belt
Hydrostat
Drive Pulley
10 P-11456
Spring
Clamp
3/8” Pin and
Rue-Ring
Rear Deck
Hanger, one
each side
Front Deck
Hanger, One each
side
2 x 4 board, One
each corner, just
inside of anti-
scalping wheel
Clamp Latch
Clamp Tube

PROCEDURE FOR RAISING AND
LOWERING THE DECK FOR
SERVICING
12. RAISING THE DECK:
A. Remove cut height adjustment pin and
completely lower the cut height
adjustment lever. Re-insert the cut
height adjustment pin into the 3-1/2” cut
height position (this will lock the cut
height adjustment lever into the lowest
position).
B. Flip up the foot deck to allow access to
the engine to deck drive belt. Roll the
engine to deck drive belt off the center
spindle. Hook the engine to deck drive
belt onto the bolt protruding out of the
top of the foot deck support angle.
C. Lift the rear corner of the deck and
disconnect the rear deck mounting
latch. Repeat for the other side.
D. Position the front caster wheels so they
are away from the deck (such as the
tractor would be traveling in reverse).
E. Attach a hoist to the deck lift bolt. Lift
the nose of the deck until the deck is
standing vertical and the deck latch
engages.
IMPORTANT NOTE: MAKE SURE
THAT THE DECK IS LIFTED FAR
ENOUGH FOR THE DECK LATCH TO
FULLY ENGAGE THE LOCKING PIN
(located on the left side of the deck
mounting suspension). This will
prevent the deck from falling down
when servicing the underside of the
mower deck.
13. LOWERING THE DECK:
A. While lifting the nose of the deck disengage
the deck latch from the locking pin. Push
the bottom of the deck towards the rear of
the tractor while holding the deck latch so
that it clears the locking pin. Lower the deck
until it rest on the ground.
B. Lift the rear corner of the deck and re-
connect the rear deck mounting latch.
Repeat for the other side.
C. Roll the engine to deck drive belt back onto
the center spindle. Insure that the engine
to deck drive belt is installed onto all of the
pulleys and idlers in the drive train.
D. Lower the foot deck down into the operation
position.
MOWER SHOWN IN OPERATION
POSITION.
Cut Height Adjustment
Pin
Cut Height Adjustment
Leve
r
Locking Pin
Deck Latch
Foot Deck
Center Deck Spindle
Rear Deck Mounting
Latch Rear Corner
Front Caster
Wheels positioned
out of the way.
Deck Lift
Bolt
11 P-11456

MOWER SHOWN IN SERVICING
POSITION.
Engine to Deck Drive Belt
hooked to bolt. Deck Latch in locked
p
osition. Foot Deck in up position
Hoist
12 P-11456

TROUBLE SHOOTING CHECK LIST
1. ENGINE WON’T TURN OVER:
Mower blades engaged ------------------------------------------------- disengage blades
Drive not in neutral ---- move Steering Control Levers to neutral “OUT” 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 Steering Control Levers are moved “IN” ---- 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.
13 P-11456

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:
Drive belt broken or slipping ------------------------------------------- replace drive belt
Shift linkage cable disconnected ----------------------------------------------- reconnect
Transmission shift arm disconnected ----------------------------------------- reconnect
Transmission oil low ------------------------------------------------------------------- add oil
Transmission locks in free wheel position --------- put in lock position (see pg. 5)
Hydrostat oil filter plugged ---------------------------------------------------- replace filter
Bad transmission -------------------------------------------------------------- consult dealer
Gear mating transmission/gearbox disconnected --------------------- consult dealer
11. MOWER LOSES POWER OR TRANSMISSIONS OVER HEATS:
Hydrostat transmission oil too low or too high ---------------------------------- add oil
OR drain oil as needed
Transmission damage ------------------------------------------------------- consult dealer
Transmission blowing oil out cap ------------------------------------ overfilled or water
contaminated
12. 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
* See engine manual for engine adjustments.
14 P-11456

WIRING SCHEMATIC:
Black wires = Ground
Red wires = Power
Blue wires = Kill Circuit
Yellow wires = Start Circuit
Green wires = Signal Circuit
START SWITCH
POSITION CIRCUIT “MAKE
OFF G+M
ON B+L
START B+L+S
15 P-11456