Country Clipper Boss XL 9000 User manual

SERIAL RANGE: 20258001 - ________
PRODUCT MANUAL
Common Service Parts & Mower Information
Manuals
Country Clipper Safety Instructions and Operation
Country Clipper Repair Parts
Kawasaki Engine Owners
Warranty
Country Clipper Warranty
Kawasaki Engine Warranty
Hydro-Gear Warranty
Battery Warranty
Additional Information
Country Clipper Product Specifications
Notes/Service Records
P-13495 (12/20)

Common Service Parts & Information
52”BladeHighLiftFusion
H‐28841
HighLift
H‐2883
Gator
H‐2666
LowLift
H‐2660
60”BladeHighLiftFusion
H‐28861
HighLift
H‐2885
Gator
H‐2667
LowLift
H‐2661
72”BladeHighLiftFusion
H‐28871
HighLift
H‐2656
Gator
H‐2877
LowLift
H‐2662
52”DeckBeltChargerD‐3658
60”DeckBeltChargerD‐3776‐W
60”DeckBeltBossXLD‐3796
72”DeckBeltBossXLD‐3797
EnginetoDeckBeltBossXLBossXL60”D‐4075BossXL72”D‐3902
TransaxleDriveBeltD‐3900
Transaxle(Charger)Hydro‐Gear4400(BossXL)Hydro‐Gear5400
TransaxleFilter(Charger)Hydro‐GearPN72537(BossXL)Hydro‐GearPN71943
TransaxleHydraulicOil20W‐50APISJorHigher
TransaxleOilVolume(Charger)~4.0Quarts(BossXL)~5.25Quarts
TirePressure
(Recommendation)Front12PSIRear12PSI
EngineKawasaki*
FX801V,FX921V,FX1000V
EngineOilFilterKawPN49065‐7010
EngineOilSAE10W‐30or40APISJorHigher
AirFilter
InnerOuter
KawPN
11013‐7039
KawPN
11013‐7038
SparkPlugFX801V=NGKBPR4ES
FX921V,FX1000V=NGKBPR5ES
EngineRPM3600
*Pleaseconsulttheengineowner’smanualforspecificmaintenanceproceduresandrequirements.
1Standardbladeshippedwithmower.
MowerInformation
DateofPurchase:

MowerModelNumber:

MowerSerialNumber:

EngineSpecNumber:

HydroSerialNumber(RH):

HydroSerialNumber(LH):


P-13495

Safety Instructions and Operation
P-13495

Table of Contents – Safety Instructions and Operation
BASIC INFORMATION .............................................................................................................................. 1.1
Warranty Registration................................................................................................................... 1.1
Model/Serial Number ................................................................................................................... 1.1
Parts/Service ................................................................................................................................. 1.1
MOWER SAFETY GUIDELINES.................................................................................................................. 2.1
Slope Operation ............................................................................................................................ 2.2
Children ......................................................................................................................................... 2.2
Hauling .......................................................................................................................................... 2.2
Towing........................................................................................................................................... 2.3
Service (Safe Handling of Gasoline) .............................................................................................. 2.3
General Service ............................................................................................................................. 2.3
Safety Interlock System................................................................................................................. 2.4
Roll Over Protection Structure (ROPS).......................................................................................... 2.4
Safety Alerts .................................................................................................................................. 2.4
Safety Decals ................................................................................................................................. 2.5
CONTROLS............................................................................................................................................... 3.1
Control Descriptions...................................................................................................................... 3.3
Control Decals ............................................................................................................................... 3.4
START UP & OPERATION ......................................................................................................................... 4.1
Pre-Operation Checklist ................................................................................................................ 4.1
Starting the Engine........................................................................................................................ 4.2
Stopping the Engine ...................................................................................................................... 4.2
Roll Over Protection Structure (ROPS).......................................................................................... 4.3
Mower Driving Operation ............................................................................................................. 4.5
Deck Height Adjustment ............................................................................................................... 4.6
Blade Engagement ........................................................................................................................ 4.9
Mowing Recommendations .......................................................................................................... 4.9
Transmission Free Wheel Release............................................................................................... 4.10
Mower Transportation................................................................................................................ 4.11
Mower Storage............................................................................................................................ 4.11
Preseason Mower Prep ............................................................................................................... 4.12
Mower Towing ............................................................................................................................ 4.12
MAINTENANCE........................................................................................................................................ 5.1
Maintenance Schedule.................................................................................................................. 5.1
Maintenance Introduction ............................................................................................................ 5.2
Engine Maintenance ..................................................................................................................... 5.2
Grease Points ................................................................................................................................ 5.4
Tires............................................................................................................................................... 5.5
Belts............................................................................................................................................... 5.5
Electrical System ........................................................................................................................... 5.5
Deck Service .................................................................................................................................. 5.6
Mower Blade Service .................................................................................................................. 5.12
Hydraulic Drive Service ............................................................................................................... 5.14
Standard Operation Adjustments ............................................................................................... 5.15
TROUBLESHOOTING................................................................................................................................ 6.1
BELT ROUTING ........................................................................................................................................ 7.1
MAINTENANCE RECORD ......................................................................................................................... 8.1
P-13495

1.1
Section 1… Basic Information
Thank you for purchasing a new Country Clipper mower. This manual will assist the operator in the proper
operation and maintenance of the mower. Following the information and instructions provided in the manual can
help you attain years of performance from your Country Clipper mower.
1.1 Country Clipper factory fills the engine with 10W-30 conventional engine oil (API Service Class SJ or
Higher). Consult engine owner’s manual for specific oil recommendations.
1.2 Typically 2 quarts of oil are required per engine oil change with filter. Consult engine owner’s manual for
specific oil recommendations and capacity.
1.3 Country Clipper uses 20W-50 conventional engine oil to fill the hydraulic transmission drive. (API Service
Class SJ or Higher)
1.4 Country Clipper recommends NLGI #2 grease for grease points.
Warranty Registration
The Warranty Registration must be completed within 30 days from date of purchase to validate the warranty. As
the new equipment owner, you are expected to confirm that the form is completed and documentation
forwarded to Country Clipper Mfg. at the time of delivery. Warranty registration should be completed by the
selling dealership either by submitting through the online registration site or mailing the registration card to
Country Clipper. The warranty is nontransferable.
Model/Serial Number
Your model & serial number can be located on the frame rail just above the grass discharge side of the deck.
These numbers will be needed when ordering service replacement parts.
Parts/Service
Genuine Country Clipper replacement parts must be used on your mower for warranty consideration.
Replacement parts are available through your authorized Country Clipper servicing dealer. Remember to provide
the following information from your mower when ordering service parts:
1. Correct Serial Number
2. Correct Model Number
3. Correct Part Number
Warranty repair and service must be performed through your authorized Country Clipper Dealer. Visit
www.countryclipper.com to locate your nearest dealer.
P-13495
Safety Instructions and Operation

2.1
Section 2… Mower Safety Guidelines
At Country Clipper, we share your desire to protect your family, friends, neighbors, and yourself from accidental
injury. Never allow untrained people to operate the mower. It’s the owner’s responsibility to receive proper
training in the operation of the mower and any other individuals authorized to use the machine. Observing and
enforcing the following guidelines will help to ensure the safety of everyone.
2.1 Before operating, adjusting, or servicing your Country Clipper mower read, understand and follow all
instructions in this manual including the engine owner’s manual.
2.2 Keep hands and feet away from rotating parts or under the machine. Keep clear of the deck discharge
area and/or blades while in operation. Turn the engine off before servicing these areas.
2.3 Disengage blades when not mowing. Shut off the engine and wait for all rotating parts to stop prior to
cleaning, inspecting, servicing, removing grass catcher, and/or unclogging the discharge chute.
2.4 Always remain seated during operation of the mower. If equipped with Roll Over Protection Structure
(ROPS) and in the upright position, always buckle yourself in the seat.
2.5 Mower must be operated by responsible adults with the proper instruction and training on safe
operation.
2.6 Clear area to be mowed of debris that could be propelled by the blades such as rocks, wire, toys, sticks,
etc.
2.7 Maintain a safe distance from people and pets prior to and during operation of the mower. Disengage
blades and shut the engine off if anyone enters the area.
2.8 Never allow passengers.
2.9 Do not mow in reverse unless absolutely necessary. Always look down and behind before and during
backing up.
2.10 Never direct mower discharge toward people or animals. Avoid directing discharge material toward walls
or obstructions as material may ricochet back toward the operator. Disengage blades when crossing
gravel surfaces.
2.11 Never operate the machine without the discharge chute, grass catcher, or other safety devices in place
and functioning properly. Periodically check for signs of wear or deterioration and replace as needed.
2.12 Slow down during turns.
2.13 Know the location and operation of all controls; especially brake operation and how to disengage the
mower blades.
2.14 Speed and/or direction of travel is affected instantly by movement of drive control lever(s). Avoid rapid
change of direction and stroke of the drive control lever(s).
2.15 Always disengage blades, place drive control lever(s) in neutral lock, engage parking brake, and remove
ignition key when leaving operators seat. Never leave a running machine unattended.
2.16 Always operate machine during daylight or with adequate working lights.
2.17 Do not operate the mower while under the influence of alcohol or drugs.
2.18 Watch for traffic when operating near or crossing roadways and sidewalks.
2.19 Wear appropriate eye protection when operating or servicing the machine.
2.20 Wear appropriate ear protection during operation of the mower.
2.21 Assure extra care is taken when loading and unloading the machine on a trailer or truck.
2.22 Stay alert of surroundings. Watch for rocks, stumps, mounds, depressions, low hanging limbs or other
objects that could be a potentially hazardous while mowing.
2.23 Prevent fires by keeping engine and exhaust areas clear of grass clippings and other debris. Do not park or
back mower over or immediately adjacent to flammable materials. Do not mow on or into piles of leaves.
This may cause the leaves to become lodged around the engine and muffler and catch fire.
P-13495
Safety Instructions and Operation

2.2
Slope Operation
Operation on slopes, hills, and/or embankments is a key factor that can cause loss of control or tip over accidents
that can result in severe injury or death. Operation on all slopes requires extra caution. Country Clipper
recommends the operator survey the slope and terrain conditions prior to operating on or near a slope. Prudent
discretion and judgement should be exercised to ensure safe operation. Country Clipper mowers are designed to
maximize stability but as with all machines there are limitations. Grass, soil, and weather conditions along with
the slope and terrain impact the maximum slope that can be mowed. A slope should be evaluated prior to each
mowing to determine if conditions have changed that would lead to un-safe operation. Never operate on a slope
greater than 15 degrees.
2.24 Back-up and drive down slopes, not across the face of a slope.
2.25 Avoid holes, ruts, bumps, rocks, or other hidden hazards. Uneven terrain could result in loss of control or
overturn of the machine.
2.26 Avoid mowing on wet grass; the drive tires could lose traction.
2.27 Reduce speed and use gradual movements to start, stop and maneuver the mower.
2.28 To prevent loss of control on a slope avoid sharp turns, sudden changes in direction, and sudden stops
and starts. If tires loose traction, disengage the blades and proceed slowly straight down the slope.
2.29 If equipped with a grass catcher or other attachment use extra care; they can affect the stability. Avoid
using on steep slopes.
2.30 Do not try to stabilize the machine by putting your foot or hand on the ground.
2.31 Do not mow or drive near drop-offs, ditches, or embankments; sudden roll-over could occur if a wheel
goes over the edge.
2.32 Avoid mowing slopes that have rocks, water, cliffs, and roadways at the bottom.
Children
Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to
the machine and the mowing activity. Never assume that children will remain where you last saw them.
2.33 Keep children out of the operating area and under the watchful care of a responsible adult other than the
operator.
2.34 Do not carry children, even with the blade(s) shut off. Children could fall off and be seriously injured or
interfere with safe machine operation. Children who have been given rides in the past could suddenly
appear in the mowing area for another ride and be run over or backed over by the machine.
2.35 Disengage blades and shut the engine off if a child enters the area.
2.36 Never allow children to operate the machine.
2.37 Never leave the running mower unattended, especially when children are present.
2.38 Always remove the ignition key when the mower is not in use.
2.39 Monitor the area for blind spots that may obstruct your view of a child (ie. corners, shrubs, trees,
ornaments, etc.)
Hauling
Caution should be exercised when loading and unloading a mower on a trailer or transport vehicle. Depending on
the trailer or transport vehicle; the ramp slope could cause loss of control or tip over.
2.40 Use full width ramps for loading and unloading a machine for transport.
2.41 Reduce speed and use gradual movements to start, stop and maneuver the mower up the trailer ramp.
2.42 Set the park brake and secure the mower with tie downs before transporting.
P-13495
Safety Instructions and Operation

2.3
Towing
2.43 Do not exceed recommendation for weight limits for towed equipment and towing on slopes.
2.44 Tow only with a machine designed with a hitch for towing.
2.45 Only use an approved hitch for the machine.
2.46 Keep children off the towed equipment.
2.47 Use extreme caution when towing on slopes; additional weight may cause loss of traction and control.
2.48 Do not attempt a zero-turn with a towed implement.
Service (Safe Handling of Gasoline)
Use extreme caution when handling gasoline to avoid personal injury and/or property damage. Gasoline is very
flammable and gasoline vapors are explosive.
2.49 Gasoline vapors ignite easily; extinguish all ignition sources prior to handling. (i.e. cigarettes, cigars, pipes,
open flames, spark sources, etc.)
2.50 Only use approved gasoline containers.
2.51 Never remove gas cap or add fuel with the engine running.
2.52 Allow engine to cool before refueling.
2.53 Never refuel inside a building or other confined space such as an enclosed trailer.
2.54 Do not store machine or fuel container near open flames or source of ignition; water heaters, furnace,
space heater, etc.
2.55 Remove gas powered equipment from the truck or trailer and refuel equipment on the ground. If not
possible, use a portable container rather than gasoline pump nozzle.
2.56 Never fill gasoline containers inside a vehicle or on a truck or trailer bed with a plastic liner. Place
container(s) on the ground away from vehicle before filling.
2.57 Keep fuel nozzle in contact with the rim of the fuel tank at all times until re-fueling is complete.
2.58 If fuel is spilled, do not attempt to start the engine and avoid creating any source of ignition until fuel
vapors have dissipated.
2.59 If fuel is spilled on clothing, change clothing immediately.
2.60 Only refuel on level ground to avoid over filling.
2.61 Never over fill fuel tank. Replace gas cap securely when re-fueling is complete.
General Service
2.62 Never operate engine in an enclosed space where dangerous carbon monoxide fumes can collect.
2.63 Do not touch hot surfaces on the machine.
2.64 Keep all nuts and bolts tight to assure the equipment is in safe working condition. Never operate a poorly
maintained machine.
2.65 Never interfere or tamper with intended function of a safety device. Check proper operation regularly.
2.66 Keep the entire machine free of grass, leaves, and other debris. Clean up any fuel or oil spillage on the
machine. Failure to do so, can affect the safety and operation of the machine. Additionally, it can increase
the danger of a fire due to contact with a hot surface on the machine.
2.67 Allow machine to cool before storing.
2.68 If you strike something with the mower, turn the mower blades off, engage park brake, shut the engine
off, and inspect the machine for damage. Repair if required prior to restarting and operating the machine.
2.69 Never make adjustments or repairs with the engine running.
2.70 Mower blades are sharp. Wrap the blade or wear gloves before servicing them.
2.71 Check operation of the park brake frequently. Adjust and service as needed.
2.72 Maintain or replace safety decals as required.
2.73 If equipped with a grass catcher, inspect components and the discharge guard frequently and replace with
manufacturer’s recommended parts, as required.
P-13495
Safety Instructions and Operation

2.4
2.74 Never allow untrained personnel to service machine. Understand service procedures before doing work.
2.75 Keep debris and grass off the mower to prevent premature parts failures or fires.
Safety Interlock System
Your Country Clipper mower is equipped with a safety interlock system. This system is integrated into the
operator controls and seat to prevent serious injury or death to the operator, bystanders, or property damage.
Proper operation of this system is critical and should be checked frequently. Note: operator must be seated
properly on the mower during the test and the engine should be previously warmed up to operating
temperature.
Joystick Models… Neutral Lock is when the Joystick Drive Control Lever is in the “Down” position.
Twin Stick Models… Neutral Lock is when both Twin Stick Drive Control Levers are in the “Out” position.
2.76 The Deck Engagement Switch must be disengaged before the engine will start.
2.77 The Drive Control Lever(s) must be in the Neutral Lock position before the engine will start.
2.78 The engine will stop if the Deck Engagement Switch is engaged when the operator leaves the driver’s seat.
2.79 The engine will stop if the Drive Control Lever(s) are not in the Neutral Lock position when the operator
leaves the driver’s seat.
2.80 The engine will stop if the Park Brake is engaged and the Drive Control Lever(s) are not in the Neutral Lock
position.
2.81 The engine will stop if the Park Brake is engaged and the Deck Engagement Switch is engaged.
Do not operate mower if any of these test fail to produce the results indicated. Contact your Country Clipper
dealer to troubleshoot and resolve the issue.
Roll Over Protection Structure (ROPS)
This mower is factory equipped with a Roll Over Protection Structure (ROPS). The rules listed below must be
adhered to. When used correctly, the ROPS will dramatically decrease fatality rate in the instance of a roll-over.
2.82 Periodically ensure the bolts that attach the ROPS to the machine are securely fastened.
2.83 Always operate the machine with the ROPS secured in the upright position.
2.84 If the surrounding environment ( i.e. low-lying tree limbs, signage, guide wires, etc.) makes it impossible
to mow with the ROPS upright, temporarily lower the ROPS at the hinge point, mow the obstructed area,
then immediately secure the ROPS upright.
2.85 Always wear the provided seat belt when ROPS is in the upright position. Failure to use the seat belt
severely hinders the safety benefits of the ROPS.
2.86 In the event of a roll-over, replace the ROPS before resuming use of the machine.
Safety Alerts
This safety alert symbol is used to call attention to a message intended to provide a
reasonable degree of Personal Safety for operators and servicing personnel. All operators
and mechanics should read this manual and be familiar with the safe operation and service
procedures before proceeding. Improper operation and/or maintenance can result in
personnel injury.
Additionally, “IMPORTANT” and “NOTE” may be used to call attention to special mechanical information and
noteworthy general information.
…Denotes immediate hazards that WILL result in severe injury or death.
Danger
P-13495
Safety Instructions and Operation

2.5
The following illustrations depict the various safety decals used on the equipment with a brief explanation for
those requiring one.
Safety Decals
P-11370… WARNING - Operating Safety.
P-12557… CAUTION – Fuel Handling Safety.
P-12706… WARNING – Deck Discharge Opening
Safety.
P-12496… DANGER – Discharge Chute or Grass
Catcher has been removed.
P-10941… DANGER – Rotating Blade Safety.
…Denotes a hazard or unsafe practice which COULD result in severe personal injury or death.
Warning
P-13495
Safety Instructions and Operation

2.6
P-13480... ROPS Safety – If ROPS must be
lowered for operation do not wear seat
belt and drive with extra care.
Replace Safety Decals when missing or illegible.
Contact your Country Clipper Dealer or Country Clipper for free replacement of Safety Decals.
P-13495
Safety Instructions and Operation


3.1
Section 3… Controls
YourCountryClippermowerhasavarietyofcontrolsandswitchesthatareusedtooperateandadjustkey
operationalparametersofthemower.Makesureyoubecomefamiliarandproficientintheuseofthesecontrols.
Aproficientunderstandingofthefunctionofthesecontrolswillassuretheoperator’sconfidenceandsafety
duringoperationandservicingthemower.

3.1 IgnitionSwitch
3.2 BladeEngagementSwitch
3.3 ThrottleControlLever
3.4 ChokePush‐PullControl(IfEquipped)
3.5 HourMeter

3.6 ElectronicFuelGage(IfEquipped)
3.7 FloatFuelGage(IfEquipped)
3.8 JoystickDriveControlLever(IfEquipped)
3.9 TwinStickDriveControlLever(IfEquipped)
3.10 EFIEngineMilLightDiagnostic(IfEquipped)



3.11 ParkingBrake
3.12 CutHeightPlatePin
3.13 TransportLatch
3.14 CutHeightFootPedal


P-13495
Safety Instructions and Operation


3.2


3.15 SeatSuspensionAdjustment(BossXL)
3.16 SeatSlideLever(BossXL)
3.17 LumbarSupportSelector(BossXL)



3.18 SeatReclineKnob(BossXL)

3.19 SeatSuspensionAdjustment(Charger)
3.20 SeatSlideLever(Charger)

P-13495
Safety Instructions and Operation


3.3


3.21 SeatReclineLever(Charger)3.22 ArmRestAdjustment(Charger&BossXL)
Control Descriptions
3.1 IgnitionSwitch:Afourpositionswitch:“Off”,“Run+Accessory”,“Run”,and“Start”.Withkeyinserted,
rotateclockwisetothe“Start”position,releasekeywhenenginestarts.Theswitchwillautomatically
returntothe“Run”position.Ifunitisequippedwitha12voltaccessory(i.e.LightKitorsimilar)
connectedtothekeyswitch;turnthekeycounterclockwisetothe“Run+Accessory”positiontopower
theaccessory.Turnswitchto“Off”positiontoshutoffengineandany12voltaccessoryconnectedto
thekeyswitch.
3.2 BladeEngagementSwitch:Thisisatwopositionswitch:pullswitchuptoengagethemowerblades,
pushswitchdowntodisengagethemowerblades.
3.3 ThrottleControlLever:Connectedtotheenginethrottlecontrolbyacable.Movethethrottlelever
generallyforwardtoincreaseenginerpmandrearwardtodecreaseenginerpm.
3.4 ChokePush‐PullControl:Connectedtotheenginechokecontrolbyacable.Pullthechokeknobupto
assiststartingacoldengine.Pushknobdownafterenginehasstarted.
3.5 HourMeter:Thehourmeterrecordsaccumulativetimewhiletheengineisrunning.
3.6 ElectronicFuelGage:Indicatesthefuelfilllevel.
3.7 FloatFuelGage:Indicatesthefuelfilllevel.
3.8 JoystickDriveControlLevers:Connectedtothedrivetransaxlestotranslatethecontrollevermovement
toforward,reverse,andturningmotionofthemower.
3.9 TwinStickDriveControlLever:Connectedtotherespectivedrivetransaxleforeachsidetotranslatethe
controllevermovementtoforward,reverse,andturningmotionofthemower.
3.10 EFIEngineMilLightDiagnostic:TheMillightisusedonfuelinjectedenginesonly.Duringnormal
operationthelightwillturnonwhentheignitionswitchisturnedtothe“Run”positionpriortostarting
theengine.Thenaftertheengineisstartedthelightshutsoff.IftheMillightilluminateswhilethe
engineisrunningafaultiscurrentlyhappening,anddealerserviceisrequired.
3.11 ParkBrake:Whentheleverispulledupthebrakeisappliedonbothtransaxles.
3.12 CutHeightSelectorPlate&Pin:Usedtosettheheightofcutofthedeck.
3.13 TransportReleaseLatch:Usedtobypassthedecktransportposition.
3.14 CutHeightFootPedal:Usedtoraiseandlowerthecuttingdeck.
3.15 SeatSuspensionAdjustment(BossXL):Usedtoadjusttheseatsuspensionpertheoperatorcomfort.
3.16 SeatSlideLever(BossXL):Usedtoadjusttheseatforeoraftforcomfort.
3.17 LumbarSupportSelector(BossXL):Usedtoadjusttheseatbackforcomfort.
P-13495
Safety Instructions and Operation


3.4
3.18 SeatReclineKnob(BossXL):Usedtoadjustseatbackreclinelevel.
3.19 SeatSuspensionAdjustment(Charger):Usedadjusttheseatsuspensionpertheoperatorcomfort.
3.20 SeatSlideLever(Charger)Usedtoadjusttheseatforeoraftforcomfort.
3.21 SeatReclineLever(Charger):Usedtoadjusttheseatbackreclinelevel.
3.22 ArmRestAdjustment(Charger&BossXL):Usedtoadjustthearmrestupordownperoperator
comfort.
Control Decals

P- 11382… Brake “ON” / “OFF” Position.


P-13188… Startup & Operation Instructions.
P-13437… Transport Latch – Lock position will
permit the deck to lock in transport
when raised to that position. Un-lock
position will not lock the deck in
transport when raised in transport.
P-13477… Deck Height Position – Used as a
relative reference of the cutting blade
height above the ground surface.
P-13495
Safety Instructions and Operation


3.5


P-13482… Throttle Control Position, Idle Rpm to
Full Throttle.


P-13481… Malfunction Indicator Lamp, Used on
equipment equipped with Electronic
Fuel Injection engine. Lamp will
illuminate if problems or faults detected
while engine is running. Service
required by a Kohler Authorized Dealer.

P-13495
Safety Instructions and Operation

4.1
Section 4… Start Up & Operation

PRE‐OPERATIONCHECKLIST
Fuel
Fillfueltanktoappropriatelevelwithfresh,cleanunleaded
fuel.ConsultEngineOwner’sManualforfuel
recommendations.
EngineOilLevelConsultEngineOwner’sManualforproperprocedure.
EngineAirFilterConsultEngineOwner’sManualforproperprocedure.
EngineClearanydebrisfromengine,checkforloosehardware,
and/orleaks.
HydraulicTransaxleDriveOilCheckoillevel.
MowerDeckCleandebris&grassasnecessaryfromtopandbottomofdeck.
BladesCheckconditionofblades.Makesurebladesaresecurely
fastened.Sharpenasrequired.
TiresCheckTirePressure(12Psior83kPa,Front&Rear).
BeltsCheckbeltsforwearandproperalignment.
GeneralCheckforloosehardware,missingcomponents,and/orleaks.
Safety
CheckOperatorPresenceControlSystem(SeeSection2Safety
InterlockSystem)andmissingordamagedsafetyshieldsor
guards.
ROPSROPSinthelockeduprightposition.HardwaresecuringROPS
andtheSeatBeltissecure.UseSeatBeltwheninuse.
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 AREAS.
Danger
Never allow untrained people to operate the mower. Do not operate machine with faulty
equipment. Clear area of debris and obstacles and stay alert to changing conditions that can
im
p
act the mower o
p
eration.
Warning
Wear the appropriate Personal Protective Equipment (PPE) when operating and/or servicing
the mower. It is required that the operator or servicing personnel wear protective eye wear,
hearing protection, hand protection and/or foot protection.
Warning
ENGINE SHOULD BE OFF AND COOL BEFORE REFUELING. USE APPROVED GAS CONTAINER.
NEVER FILL TANK INDOORS. NEVER OVER FILL THE FUEL TANK. CLEAN UP ANY SPILLS.
REPLACE CAP AND SECURE TIGHTLY.
Danger
TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE, USE EXTREME CARE IN HANDLING
FUEL. FUEL IS EXTREMELY FLAMMABLE AND THE VAPORS ARE EXPLOSIVE. KEEP FUEL
AWAY FROM IGNITION SOURCES.
Danger
P-13495
Safety Instructions and Operation

4.2
Starting The Engine
4.1 Themower’sSafetyInterlockSystemisdesignedtoprotecttheoperatorandbystandersfromaccidental
injuryduetounintentionalenginestartingand/ortheoperatorleavingtheoperatorzone.Theengine
starterwillnotengageuntiltheoperatorsatisfiesthefollowingconditions:
4.1.1 SteeringDriveControlLever(s)areintheneutrallockposition.
4.1.2 DeckBladeEngagementSwitchisinthe“Off”position(PushedDown).
4.1.3 NOTE:Theoperator’sseathasasafetyswitchintegratedintotheseatcushion.Theswitchis
activatedbytheweightoftheoperator.Shouldtheoperatorbecomeunseated,foranyreason,
whentheDriveControlLever(s)is/areinthedrivepositionand/ortheBladeEngagementSwitch
is“ON”theenginewillstop.
4.1.4 NOTE:Thefollowingstepsarethecorrectprocedureforstartingtheengine.Contactyour
CountryClipperDealerifdifficultyisencountered.
4.1.5 PriortostartingthemowerforthedayperformthePre‐OperationCheckList.
4.1.6 MakesureDriveControlLever(s)areintheNeutrallockpositionandtheDeckBlade
Engagementisinthe“Off”position(PushedDown).Onlystarttheenginefromthe
operator’sposition.Additionally,itisrecommendedtoapplytheParkBrakebefore
starting.
4.1.7 PullupontheengineChokeKnob,ifunitisequippedwithone,whenengineiscoldora
warmenginefailstostartwithin5secs.Avoidfloodingtheengineoncestartedby
pushingtheChokeKnobtotheoffposition.
4.1.8 PositionThrottleControlLevertomid‐range.
4.1.9 CarburetedEngine…InsertkeyintoIgnitionSwitch.Withkeyinserted,rotateclockwisetothe
“Start”position,releasekeywhenenginestarts.Theswitchwillautomaticallyreturntothe“Run”
position.Ifunitisequippedwitha12voltaccessory(i.e.LightKitorsimilar)connectedtothekey
switch;turnthekeycounterclockwisetothe“Run+Accessory”positiontopowertheaccessory.
4.1.10 PerformSafetyInterlockSystemcheck...(SeeSection2SafetyInterlockSystem)
4.1.11 Allowtheenginetoidleafewminutesbeforeadvancingtofullthrottleand/oractivatingthe
mowerbladeengagement.
Stopping The Engine
4.2 Thefollowingstepsarethecorrectprocedureforstoppingtheengine.
4.2.1 Movethedrivecontrollever(s)totheneutrallockposition.
4.2.2 Throttletheenginebackto½throttleandturn“Off”theDeckBladeEngagementswitch.
4.2.3 Movethethrottletoidleandallowtheenginetorunatidleforacoupleofminutestocooldown.
4.2.4 TurnIgnitionSwitchto“Off”positiontoshutoffengineandany12voltaccessoryconnectedto
thekeyswitch.SettheParkBrake.RemovekeyfromIgnitionSwitchbeforeleavingthemower.
Do not run the electric starter continuously for more than 5 seconds; otherwise the battery may
discharge quickly. If the engine does not start right away, wait 15 seconds and try again.
Important
THE SAFETY INTERLOCK SYSTEM MUST NOT BE DISCONNECTED OR BYPASSED.
UNEXPECTED OPERATION COULD OCCUR RESULTING IN PERSONAL INJURY OR DEATH.
Danger
When leaving the mower unattended, always remove the Ignition Key and set the Park Brake,
even if for just a few moments. This will discourage unauthorized personnel from operating the
mower.
Warning
P-13495
Safety Instructions and Operation

4.3
Roll Over Protection Structure (ROPS)
4.3 ProperuseoftheROPSalongwiththeseatbeltiseffectiveinreducinginjuriesintheeventofanoverturn
accident.OverturningtheunitwiththeROPSloweredorremovedcanresultinseriesinjuryordeath.
ROPS Hardware Torque Table
Metric Fasteners Class 8.8 lb-ft Inch Fasteners Grade 5 lb-ft
M10 29 7/16
–
14 37
M12 53 ½ - 13 57
M14 87 9/16
–
12 82
M16 135 5/8
–
11 110
M18 195 ¾ - 10 200
This Roll Over Protection Structure (ROPS) has been certified to industry or government
standards. Any damage or alteration to the ROPS, mounting hardware, or seat belt voids the
certification and will reduce or eliminate protection for the operator in the event of a roll-over.
The ROPS, mounting hardware, (proper torque – see table) and seat belt should be checked
after the first 100 hours and 500 hours thereafter for any evidence of damage, wear, or
cracking. In the event of damage or alteration the ROPS must be replaced prior to further
operation of the vehicle.
Warning
Substitution of mounting hardware, seat belt, etc., with components not equal or superior to
the original certified components will void the certification and will reduce or eliminate
protection for the operator in the event of a roll-over.
Warning
This vehicle is equipped with a certified Roll Over Protection Structure (ROPS). The seat belt
must be worn during vehicle operation. Failure to do so will reduce or eliminate protection for
the operator in the event of a roll-over.
Warning
All labels, caution decals, ROPS certification data, etc. must be kept intact and legible at all
times.
Warning
P-13495
Safety Instructions and Operation

4.4
4.3.1 Thetwo‐postROPScanbefoldeddownbyremovingtheCotterPinsandpullingouttheT‐Handle
ClevisPins.Thisshouldonlybedonetooperatethemowerunderlowhangingtreelimbsorother
obstructions.Additionally,thismayberequiredwhenloadingthemowerinanenclosedtrailer.
NOTE:Minimizethechanceofinjuryordeathfromarolloverincidentby:
4.3.2 KeepROPSinthelockeduprightpositionandweartheseatbelt.
4.3.3 AlwaysusetheROPSonslopesalongwiththeseatbelt.ReviewSection2SlopeOperationfor
instructionandwarnings.
4.3.4 OnlylowertheROPSwhenabsolutelynecessaryduetooverheadobstructions.
4.3.5 DonotwearseatbeltwhentheROPSisinthefoldedposition.
4.3.6 Inspecttheareapriortomowingforadequateoverheadclearance.
4.3.7 Inspectseatbeltonadailybasis,includingthemountinghardwaretotheseat.Replaceseatbeltif
worn,damagedordefective.Replaceifanyofthecomponentsindicatethesesigns:
4.3.8 Cutsorfraying.
4.3.9 Extremeorunusualwear.
4.3.10 WebbingweakeningduetoUVexposure.
4.3.11 Damagetothebuckle,latchplateorhardware.
4.3.12 Anyotherproblems.
4.3.13 Intheeventofaroll‐overorotherdamagetotheROPS,theROPSmustbereplacedto
retainthebestprotection.
4.3.14 InspecttheROPSafterthefirst100hoursofoperation.Aftertheinitialinspection,inspectthe
ROPSevery500hoursafterthat.
Use of the ROPS in the “folded” position should only be when absolutely necessary. Do not
use the seat belt if the ROPS is not in the up position.
Warning
Structural damage, alteration, or overturn can impair the protective capability of the ROPS. Do
not remove or alter the ROPS components. Do not attempt to weld or straighten the ROPS.
Failure to adhere to these instructions could result in severe injury or death.
Warning
ContactofanoverheadobstructionwiththeROPScancausethemowertotipbackwards.
Makesureade
q
uateoverheadclearanceisobtainedbeforeo
p
eratin
g
.
Important
P-13495
Safety Instructions and Operation