Country Clipper CHARGER 1055 User manual

PRODUCT MANUAL
Model Numbers & Serial Numbers
Manuals
Country Clipper Safety Instructions and Operation
Country Clipper Repair Parts
Kawasaki Engine Owner Manual
ROPS Safety Information
Warranty
Country Clipper Warranty
Kawasaki Engine Warranty
Hydro-Gear Warranty
Battery Warranty
Additional Information
Country Clipper Product Specifications
Notes/Service Records
P-13459 (11/19)
®
SERIAL # RANGE: 19244001 -

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): ____________________________________________
P-13459

TM
Safety Instructions & Operation
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.
SERIAL RANGE: 19244001 - ________
P-13459

TABLE OF CONTENTS
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 LOCATIONS JOYSTICK MODELS...........................................................................................6
OPERATION JOYSTICK MODELS...............................................................................................................7
CONTROL LOCATIONS TWINSTICK MODELS........................................................................................8
OPERATION TWINSTICK MODELS............................................................................................................8
OPERATION FREE WHEEL...........................................................................................................................9
MOWING RECOMMENDATIONS...............................................................................................................10
MAINTENANCE......................................................................................................................... 11
MAINTENANCE SCHEDULE........................................................................................................................11
MAINTENANCE INSTRUCTIONS................................................................................................................12
JOYSTICK ADJUSTMENT ............................................................................................................................13
TWINSTICK ADJUSTMENT .........................................................................................................................15
HYDROSTATIC TRANSMISSION................................................................................................................16
SEAT HOLD DOWN LATCH.........................................................................................................................16
PROCEDURE FOR RAISING AND LOWERING THE DECK FOR SERVICING.................................17
SECURING THE DECK PROP.......................................................................................................................19
LEVELING THE DECK ..................................................................................................................................20
ADJUSTING THE LATCH PLATE................................................................................................................21
TROUBLE SHOOTING CHECK LIST ..................................................................................... 22
BELT ROUTINGS....................................................................................................................... 24
WIRING SCHEMATIC FOR KAWASAKI JOYSTICK (E-6415)............................................ 25
WIRING SCHEMATIC FOR KAWASAKI TWINSTICK (E-6416)......................................... 26
WIRING SCHEMATIC FOR KOHLER JOYSTICK (E-6415) ................................................ 27
WIRING SCHEMATIC FOR KOHLER TWINSTICK (E-6416) ............................................. 28
HYDRAULIC SCHEMATIC:..................................................................................................... 29
NOTES / SERVICE RECORDS:................................................................................................ 30
NOTES / SERVICE RECORDS:................................................................................................ 31
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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.
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
ENSURE THE SAFETY OF EVERYONE.
PLEASE BE CAREFUL!
SAFETY INSTRUCTIONS AND
RECOMMENDATIONS
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).
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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.KNOW THE AREA YOU ARE TO
MOW. Watch for hidden danger such
as rocks, roots, sticks, holes, bumps,
and drop-offs, etc. Before mowing, pick
up all debris in area to be mowed.
Sharp and hard objects can be propelled
at a high speed and can act like
shrapnel. Walk through tall grass
BEFORE MOWING to make sure there
are no hidden dangers. Mow higher
than desired in tall grass to expose any
hidden objects and/or obstacles, clean
the area, and then mow to the desired
height.
12. NEVER REFUEL A MOWER
INDOORS. Allow the engine time to
cool before refueling. Unseen vapors
may be ignited by a spark. Always clean
up spilled gasoline. Never run the
engine indoors in a garage or any other
closed building. Allow engine to cool
before storing in any enclosure. The
engine exhaust and gasoline fumes are
dangerous.
13. DISENGAGE BLADES BEFORE
DRIVING ACROSS WALKS or
projecting objects.
14.NEVER REMOVE THE FUEL CAP or
add gasoline to a running or hot engine
that has not been allowed to cool for
several minutes after running. Always
make sure the gas cap is in place.
15.NEVER CARRY PASSENGERS.
16. DO NOT SMOKE AROUND THE
MOWER or the gasoline storage
container. Gasoline fumes can easily
ignite.
17.KEEP GASOLINE IN A WELL-
VENTILATED AREA away from your
living quarters and in tightly-capped
safety cans. Never store mower with
gasoline in the tank inside a building
where fumes may reach open flame or
spark.
18. DISENGAGE BLADES, STOP ENGINE
AND REMOVE IGNITION KEY before
any servicing. Be sure all moving parts
and all sounds have stopped. Let
engine cool and disconnect the spark
plugs so the engine cannot start by
accident. A SLIGHT ROTATION OF
THE BLADES COULD START THE
ENGINE.
19. KEEP ALL NUTS, BOLTS, AND
SCREWS TIGHT to be sure equipment
is in safe working condition, especially
blade mounting bolts.
20.MOWER SHOULD BE STOPPED AND
INSPECTED FOR DAMAGE after
striking a foreign object and the damage
should be repaired before restarting and
operating the equipment. Stop
immediately and check for damage or
loose parts if mower should start
vibrating.
21 KEEP SAFETY DEVICES AND
GUARDS IN PLACE. If any of the
safety switches become inoperable,
have them repaired immediately.
22 FOR PROPER USE OF ROLL OVER
PROTECTION SYSTEM (R.O.P.S.)
reference the R.O.P.S. manufactures
instruction. (If equipped)
23. DO NOT STEP OR STAND ON THE
MOWER HOUSING. Step or stand only
on the foot deck.
24. WATCH OUT FOR TRAFFIC near
roadways and when crossing roads.
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25. DO NOT USE MOWER WHEN GRASS
IS WET OR SLIPPERY.
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.
28. 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.
29. WEAR PERSONAL PROTECTIVE
EQUIPMENT. Eye, ear, feet and head
protection is recommended.
30. ONLY USE COUNTRY CLIPPER
APPROVED ACCESSORIES.
31. DO NOT CHANGE THE ENGINE
GOVERNOR SETTING or over speed
the engine.
32. BEWARE OF MOWER DISCHARGE
DIRECTION and do not point it at
anyone.
33. DO NOT OPERATE THE MOWER
UNDER THE INFLUENCE OF
ALCOHOL OR DRUGS.
34. USE CARE WHEN LOADING OR
UNLOADING MACHINE INTO A
TRAILER OR TRUCK.
35. USE CARE WHEN APPROACHING
BLIND CORNERS, shrubs, trees, or
other objects that may obscure vision.
36. CLEAN ALL GRASS AND DEBRIS
FROM MACHINE TO PREVENT
FIRES. Remove spilled oil or gasoline.
37. KEEP HANDS AND FEET AWAY
FROM MOVING PARTS. If possible do
not make adjustments with the engine
running.
38. NEVER MOW WHEN OTHER PEOPLE
OR PETS ARE IN THE AREA.
39. CAREFULLY RELEASE PRESSURE
FROM COMPONENTS WITH STORED
ENERGY.
40. 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).
41. USE JACK STANDS TO SUPPORT
COMPONENTS when required.
42. KEEP BODY AND HANDS AWAY
FROM PIN HOLES OR LEAKS IN
HIGH PRESSURE HYDRAULIC LINES.
Always use paper or cardboard to
search for leaks, NEVER use hands.
Make sure all hydraulic connections are
tight and that hydraulic lines are in good
condition before starting the engine.
SAFETY INTERLOCK SYSTEM
Your Country Clipper Zero Turn Radius Mower
is equipped with switches interlocked for your
safety.
ON JOYSTICK MODELS GROUND DRIVE
NEUTRAL IS WHEN THE JOYSTICK (CONTROL
LEVER) IS IN THE “DOWN” POSITION.
ON TWINSTICK MODELS GROUND DRIVE
NEUTRAL IS WHEN BOTH CONTROL LEVERS
ARE IN THE “OUT” POSITION.
1. The mower blades must be disengaged and
the Control Lever(s) must be in the neutral
position before the engine will start.
2. The engine will stop if the mower blade
clutch is engaged when the operator leaves
the driver’s seat.
3. The engine will stop if the Control Lever(s)
are not in the neutral position when the
operator leaves the driver’s seat.
4. The engine will stop if the brake is “SET”
and the Control Lever(s) are not in the
neutral position.
5. The engine will stop if the brake is “SET”
and the mower blade clutch is engaged.
DO NOT OPERATE MOWER IF SAFETY
SWITCHES AND GUARDS ARE NOT
OPERATING PROPERLY
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START UP AND OPERATION
CHECKLIST BEFORE OPERATION
1. Make sure fuel tank is full. Use regular
unleaded gasoline (see engine owner’s
manual for more details).
WARNING
HANDLE GASOLINE WITH CARE -- IT IS
HIGHLY FLAMMABLE. DO NOT SMOKE.
ENGINE SHOULD BE OFF AND COOL. USE
APPROVED GAS CONTAINER. NEVER FILL
TANK INDOORS. WIPE UP ANY SPILLS.
REPLACE CAP TIGHTLY.
2. Make sure dirt and foreign matter is kept out
of gas tank. Use a clean funnel and gas
can.
3. Do not mix oil with gasoline.
4. Do not use white, high test or premium
gasoline. Do not use de-icers, carburetor
cleaners, or other such additives.
5. Check the crankcase oil level. Make sure
the engine is off. The mower should be
parked on a level area. Do not overfill. (See
your engine manual for more detailed
instruction.)
6. Check battery fluid level.
7. Inspect V-belts.
8. Check tire pressure:
9. Make sure underside of mower deck is free
of grass.
10. Make sure mower blades are sharp and
secured tightly.
11. Clean the air intake screen on the engine if
necessary.
12. Perform any other maintenance as it
becomes necessary. (See the
“Maintenance” section of this manual.)
13. If equipped with R.O.P.S. (Roll Over
Protection System) reference manufactures
instructions.
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.
CONTROL LOCATIONS
JOYSTICK MODELS
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.
Throttle
Choke
Joystick
Control Lever
Ignition Key
Blade Clutch
Switch
Parking
Brake Lever
Cut Height
Adjust.
Cut Height
Foot
Cut Height
Stop Pin
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OPERATION
JOYSTICK MODELS
1. MOVE JOYSTICK CONTROL LEVER to
neutral “DOWN” position.
2. SET PARKING BRAKE. Pull up to set.
3. DISENGAGE MOWER BLADE CLUTCH by
moving clutch switch to “OFF” position.
4. PULL ENGINE CHOKE CONTROL to full
position for cold starts (Not applicable on
Fuel Injected models).
5. SET ENGINE THROTTLE TO 1/2
THROTTLE.
6. TURN IGNITION KEY to “START” position
and release to “RUN” as soon as engine
starts. NOTE: Prolonged cranking will
damage starter motor and shorten the
battery life
7. ADJUST ENGINE THROTTLE for desired
engine smoothness and speed. However,
use full throttle while mowing.
8. RELEASE PARKING BRAKE. Push brake
lever down to release.
IMPORTANT:
Until the operator is familiar with the
Country Clipper Zero Turn Radius
Mower, he/she should follow these
recommendations: 1) Disengage the
mower blades. 2) Go very slowly until
thoroughly familiar with the machine. 3)
Keep away from fences, buildings, and
other obstructions. 4) Move the Joystick
Control Lever smoothly and slowly. 5)
Practice until operation is smooth and
efficient.
9. TO DRIVE:
A. Move the Joystick Control Lever to the
“UP” position.
B. Move the Joystick Control Lever
forward to move forward. Increasing
forward movement of the Joystick
Control Lever will increase the speed
of travel.
C. To reverse the direction, pull the
Joystick Control Lever slightly back.
D. To turn, move the Joystick Control
Lever toward the direction you want to
turn.
E. To turn on a zero radius axis, go
slowly and move the Joystick Control
Lever to the side you wish to turn and
slightly to the rear at the same time.
CAUTION
FOR SMOOTH, SAFE OPERATION, MOVE
THE JOYSTICK CONTROL LEVER IN A
GENTLE, SLOW MOTION. NEVER PULL OR
PUSH THE JOYSTICK CONTROL LEVER
RAPIDLY, ESPECIALLY ON GRADES.
10. BRAKING: To brake mower, gently move
the Joystick Control Lever in the direction
opposite to travel. Note: If the parking brake
is engaged with the Joystick Control Lever in
the “UP” position the engine will stop.
11. CUTTING HEIGHT ADJUSTMENT: While
holding the Cut Height Adjustment Lever
with enough hand pressure to freely move
the Cut Height Pin, rotate the Cut Height
Stop Pin so the key on the pin aligns with the
key slot, then pull it out and move the Cut
Height Adjustment Lever to the desired cut
height. Reinsert the Cut Height Stop Pin.
12. ENGAGE MOWER BLADE CLUTCH: Set
engine throttle to 1/2–3/4 throttle, engage
the Blade Clutch Switch to the “ON” position,
set throttle to full. Note:The engine will not
start with the blade clutch switch in the “ON”
position. Engine will stop if the clutch switch
is “ON” and the Operator is not in the seat.
CAUTION
AVOID HILLS AND SLOPES. USE EXTREME
CAUTION WHEN MOWING UP OR DOWN
SLOPES. NEVER MOW ACROSS THE FACE
OF A SLOPE. IF A SLOPE MUST BE
ASCENDED, BACK UP THE SLOPE; DRIVE
FORWARD WHEN DESCENDING.
13. TO STOP:
A. Move Joystick Control Lever to neutral
position and then to the “DOWN”
position.
B. Disengage the mower blade clutch by
moving the clutch to the “OFF”
position.
C. Set the parking brake.
D. Turn ignition key to “OFF” position.
E. Remove the key and wait for all
movement and sound to cease before
dismounting.
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Right Hand Steering
Control Lever
Blade Clutch Switch
Choke
Throttle
Ignition Key
CONTROL LOCATIONS
TWINSTICK MODELS
WARNING
AVOID INHALING EXHAUST FUMES --
CARBON MONOXIDE GAS IS COLORLESS
AND ODORLESS, AND CAN CAUSE
UNCONSCIOUSNESS, AND IS POTENTIALLY
LETHAL. DO NOT RUN LAWN MOWER IN
GARAGE OR OTHER CONFINED AREA.
OPERATION
TWINSTICK MODELS
1. MOVE STEERING CONTROL LEVERS to
neutral “OUT” position.
2. SET PARKING BRAKE. Pull up to set.
3. DISENGAGE MOWER BLADE CLUTCH by
moving clutch switch to “OFF” position.
4. PULL ENGINE CHOKE CONTROL to full
position for cold starts.
5. SET ENGINE THROTTLE TO 1/2
THROTTLE.
6. TURN IGNITION KEY to “START” position
and release to “RUN” as soon as engine
starts. NOTE: Prolonged cranking will
damage starter motor and shorten the
battery life.
7. ADJUST ENGINE THROTTLE for desired
engine smoothness and speed. However,
use full throttle while mowing.
8. RELEASE PARKING BRAKE. Push brake
lever down to release.
IMPORTANT:
Until the operator is familiar with the
Country Clipper Zero Turn Radius
Mower, he/she should follow these
recommendations: 1) Disengage the
mower blades. 2) Go very slowly until
thoroughly familiar with the machine.
3) Keep away from fences, buildings,
and other obstructions. 4) Move the
Steering Control Lever smoothly and
slowly. 5) Practice until operation is
smooth and efficient.
9. TO DRIVE:
A. Move the Steering Control Levers to the
“IN” position.
B. Move the Steering Control Levers
forward to move forward. Increasing
forward movement of the Steering
Control Levers will increase the speed of
travel.
Cut Height
Adjustment Lever
Cut Height
Stop Pin
Cut Height Foot
Assist Lever
Left Hand
Steering
Control Lever
Parking Brake
Lever
Country Clipper Safety & Operation
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9
C. To reverse the direction, pull the
Steering Control Levers slightly back.
D. To turn, move one Steering Control
Lever slightly ahead of the other.
E. To turn on a zero radius axis, go slowly
and move one Steering Control Lever
forward and one Steering Control Lever
rearward. (For a right hand turn the left
hand Steering Control Lever will be
ahead of the right hand Steering Control.
For a left hand turn the right hand
Steering control will be ahead of the left
hand Steering Control.)
CAUTION
FOR SMOOTH, SAFE OPERATION, MOVE
THE STEERING CONTROL LEVER(S) IN A
GENTLE, SLOW MOTION. NEVER PULL OR
PUSH THE STEERING CONTROL LEVER(S)
RAPIDLY, ESPECIALLY ON GRADES.
10. BRAKING: To brake mower, gently move
the Steering Control Levers in the direction
opposite to travel. NOTE: If the parking
brake is engaged with the Steering Control
Lever(s) in the “IN” position the engine will
stop.
11. CUTTING HEIGHT ADJUSTMENT: While
holding the Cut Height Adjustment Lever
with enough hand pressure to freely move
the Cut Height Pin, rotate the Cut Height
Stop Pin so the key on the pin aligns with the
key slot, then pull it out and move the Cut
Height Adjustment Lever to the desired cut
height. Reinsert the Cut Height Stop Pin.
12. ENGAGE MOWER BLADE CLUTCH: Set
engine throttle to 1/2–3/4 throttle, engage
the Blade Clutch Switch to the “ON” position,
set throttle to full. Note: The engine will not
start with the blade clutch switch in the “ON”
position. Engine will stop if the clutch switch
is “ON” and the Operator is not in the seat.
CAUTION
AVOID HILLS AND SLOPES. USE EXTREME
CAUTION WHEN MOWING UP OR DOWN
SLOPES. NEVER MOW ACROSS THE FACE
OF A SLOPE. IF A SLOPE MUST BE
ASCENDED, BACK UP THE SLOPE; DRIVE
FORWARD WHEN DESCENDING.
13. TO STOP:
A. Move Steering Control Levers to neutral
position and then to the “OUT” position.
B. Disengage the mower blade clutch by
moving the clutch to the “OFF” position.
C. Set the parking brake.
D. Turn ignition key to “OFF” position.
E. Remove the key and wait for all
movement and sounds to cease before
dismounting.
CAUTION
WHEN LEAVING THE MOWER
UNATTENDED, ALWAYS REMOVE THE KEY
AND SET THE PARKING BRAKE, EVEN IF
JUST FOR A FEW MOMENTS. HELP
PROTECT CHILDREN AND OTHER
UNAUTHORIZED PERSONS FROM
ACCIDENTS.
OPERATION
FREE WHEEL
1. TO FREE WHEEL:
A. Unlock Transmission: Unscrew the
bypass valve between ½ -1 full turn
counterclockwise. NOTE: Both sides
must be done in order to free wheel.
B. To re-engage the transmissions screw
the bypass valve clockwise until tight
(DO NOT OVER TIGHTEN). NOTE:
Both sides must be done in order to lock
the wheels.
NOTE: The tractor should never be pulled at
more than 2 miles per hour or for any
appreciable distance.
Hydrostatic
Transmission
Bypass Valve
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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.).
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MAINTENANCE
CAUTION
BEFORE PERFORMING ANY MAINTENANCE, TURN OFF ENGINE
REMOVE KEY AND DISCONNECT SPARK PLUGS. USE EXTREME CARE WHEN WORKING ON
MACHINERY. DO NOT WEAR WATCHES OR JEWELRY. DO NOT WEAR LOOSE FITTING
CLOTHES, AND OBSERVE ALL COMMON SAFETY PRACTICES WITH TOOLS.
MAINTENANCE SCHEDULE
Maintenance Service Interval
Maintenance Procedure
Before Each Use or Daily

Check Engine Oil Level.
Check Mower Blades.
Check Operator Presence Control System.
Check for Loose Hardware.
Clean Engine Cooling System.
Remove Debris From Engine.
Remove Debris Build-Up Hydrostatic Transmission & Cooler
After Each Use or Daily

Clean Grass Build-Up from Deck Cutting Chamber.
After First 5 Hours

Change Engine Oil.
Check Wheel Lug Nuts. (75 ft/lbs or 102 Nm)
After First 75 Hours

Change Hydrostatic Transmission Oil & Filter (see pg. 16)
Every 10 Hours

Check Tire Pressure. (12-15 Psi / 83-103 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.)

Check Wheel Lug Nuts. (75 ft/lbs or 102 Nm)
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
Every 400 Hours

Change Hydrostatic Transmission Oil & Filter (see pg. 16)
Every 500 Hours
Or Annually 
Grease Front Caster Pivots
Replace Air Filter Element
Check Spark Plugs

Service Battery
Replace Safety decals when illegible. Write factory for free replacement.
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MAINTENANCE INSTRUCTIONS
1. ENGINE:
For complete maintenance and
operating information for your engine,
please refer to your engine operating
and maintenance instructions furnished
by the engine manufacturer and
included in your Country Clipper Zero
Turn Radius Mower information packet.
NOTE: Air intake screen must be kept
clean. If plugged, engine may be
seriously damaged by overheating.
2. BATTERY:
CAUTION
BATTERY ELECTROLYTE IS A POISONOUS
AND CORROSIVE SULFURIC ACID
SOLUTION. AVOID SPILLING ON SKIN,
EYES, AND CLOTHING.
Keep the electrolyte level above the
plates in each cell by adding distilled
water as it becomes necessary. Add
water just before operating the mower to
mix the water with the solution. Be
careful not to overfill the battery -- the
electrolyte solution is corrosive and can
cause damage to surrounding metal
parts if it should spill. When taking the
battery out of the mower for servicing,
make sure to connect the cables to the
battery exactly as they were prior to
removal. Always disconnect the ground
( -) wire first and always reconnect the
ground ( -) wire last.
Keep the battery clean. Remove the
corrosion around the battery terminals
by applying a solution of one part baking
soda to four parts water. Coat all
exposed terminal surfaces with a light
layer of grease or petroleum jelly to
prevent corrosion.
NOTE: At temperatures below 32 degrees F (0
degrees C) the full charge state must be
maintained to prevent cell electrolyte
from freezing and causing permanent
battery damage.
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:
Lug nuts should be torqued to 75 ft/lbs
and checked regularly for tightness.
4. MOWER BLADES:
Check sharpness of mower blades after
every 10 hours of operation. To sharpen
blades proceed as follows:
CAUTION
STOP ENGINE, REMOVE IGNITION KEY AND
SPARK PLUGS FOR SAFETY.
A. Remove bolt and blade washer
mounting blade on shaft. Remove
blade.
B. Blades should be discarded when worn
excessively.
C. Sharpen blades with a hand file, electric
grinder or blade sharpener. Wear
gloves and eye protection when
sharpening. Grind blade at original 25
degree bevel.
D. Check balance of blade by positioning
the blade on a nail or blade balance
pedestal. Grind the blade on the end
that is heavier until both sides balance.
E. Install blade, blade washer and bolt.
Make sure to torque bolt to 100 ft-lbs.
Model
Front tires
Rear tires
All
Models
12-15 psi
83-103 kPa
12-15 psi
83-103 kPa
New Blade
25 degrees
When notch
starts, discard
blade
DANGEROUS!
DO NOT USE
BLADE IN THIS
CONDITION
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Brake
Adjustment
Link
Brake
Arm
Lock Nut
Shoulder
Bolt
5. V-BELTS:
All belts should be checked every 50
hours. Replace any belts found to be in
poor condition. All belts are equipped
with spring loaded belt tighteners and do
not require tightening adjustments.
6. LUBRICATION:
A. Engine: Follow engine manufacturer’s
recommendation.
B. Front Caster Pivots: Lubricate fittings
with several pumps of multi-purpose
grease from a grease gun.(See pg. 18)
7. PARKING BRAKE ADJUSTMENTS:
A. Move Parking Brake Lever to the “OFF”
position.
B. Firmly hold the Brake Arm forward and
line up the Shoulder bolt with nearest
hole in the Brake Adjustment Link and
tighten the Shoulder Bolt and Lock Nut.
Repeat for other side. The Park Brake
Handle should require around 45lbs to
pull it on. If the Handle force is to high
move the Shoulder bolt(s) to the next
lighter setting. If too light, move to next
heavier setting.
JOYSTICK ADJUSTMENT
1. SETTING TRACKING AND FORWARD
SPEED:
A. The initial setting is done with the engine
TURNED OFF.
B. Remove both fender skirts.
C. Start by setting the RH transmission
speed. Disconnect the linkage that is
connected to the left side transmission
at the upper end.
D. On the outside (long) linkage that goes
from the joystick to the right side
transmission, Loosen the jam nuts on
both ends of the coupling nut. One of
these is a left-hand thread. Rotate the
coupling nut a couple turns to lengthen
it.
IMPORTANT:
Use two wrenches (one on the nut and
one on the coupling nut or rod end
housing) when loosening or tightening
jam nuts to prevent damaging the rod
end ball joints!
Left Side Transmission
Upper end bolt
Left side
transmission
Linkage
Jam
Nut
Rod
End
Lower
End
Bolt
Damper
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E. Lift the joystick control handle out of the
neutral position and hold it firmly in the
full forward position. Now, by hand,
rotate the coupling nut shortening the
linkage until resistance is felt from the
transmission control bottoming out in the
transmission. Rotate the coupling nut
back and forth a couple times to confirm,
and mark this position.
F. Now rotate the coupling nut exactly one
full turn longer and retighten the jam
nuts. When retightening make sure that
the ball joints on both top and bottom
are well centered so that they do not
bind up when moving the joystick handle
to the extremes of its travel.
NOTE: This full turn longer is required to
prevent internal damage to the
transmission.
G. Now set the LH transmission speed.
Reconnect the linkage to the left side
transmission. (see left side transmission
illustration on previous page).
H. Loosen the jam nuts on both ends of the
left side transmission linkage. One of
these is a left-hand thread. Now rotate
the linkage rod a couple turns to
lengthen it.
I. Hold the joystick control handle firmly in
the full forward position. Rotate the left
side transmission linkage rod to shorten
the linkage until resistance is felt from
the transmission control bottoming out in
the transmission. Rotate the rod back
and forth a couple times to be sure, and
mark this position.
J. Now rotate the linkage rod exactly one
full turn longerand retighten the jam
nuts. Make sure that the ball joints on
both top and bottom are centered.
NOTE: This full turn longer is required to
prevent internal damage to the
transmission.
K. Test drive the mower to check for
tracking at full speed. If needed, slow
the fast side by lengthening the control
rod connected to the faster
transmission. Use small adjustments of
about ¼ turn. Replace the fender skirts
when done.
2. SETTING NEUTRAL:
If, with the joystick handle in the DOWN
or start position and the engine running
the mower moves or travels, it is
necessary to adjust neutral. Raise the
drive wheels off the ground, secure the
mower on blocks or jack stands and
proceed as follows:
A. Remove the fender skirt on the joystick
side. Loosen the two nuts on the bottom
of the joystick neutral plate just enough
so that the plate can move freely.
Right Side Transmission
Inside
Linkage
Jam Nut
Coupling Nut
Outside
Linkage
Neutral
Plate
Neutral Plate
Nuts
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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. JOYSTICK CONTROL LEVER
SENSITIVITY ADJUSTMENT:
To change the sideways turning
response, adjust as follows:
A. Remove the right hand fender skirt
exposing the Joystick Control Lever
assembly.
B. Remove the cross bolt, nut, & spacers.
C. For quicker reacting steering place the
long, silver colored spacers toward the
inside of the rod end ball joints and the
shorter, gold colored spacers on the
outside of the ball joints. For slower
reacting steering place the short, gold
colored spacers on the inside and the
longer, silver colored spacers on the
outside. All 4 spacers must be used
when reassembling.
TWINSTICK ADJUSTMENT
1. TWINSTICK CONTROL LEVER
NEUTRAL ADJUSTMENT:
A. Loosen the bolts holding the Neutral
Plate.
B. Pull back the control lever until the wheel
spin is zero.
C. Tilt the Control lever outward, using the
lever, position and tighten the bolts
holding the Neutral Plates.
2. TWINSTICK CONTROL LEVER
FORWARD TRACKING:
In a large open area, actuate the
Twinstick Control levers into the full
forward position. If the mower veers in
either direction left or right some
adjustment is necessary. If the mower
veers to the right, then the left
transmission needs to be slowed down.
If the mower veers to the left then the
right transmission needs to be slowed
down.
A. Stop the machine and shut off the
engine.
B. Slightly loosen the nuts around the
turnbuckle on the faster side. Lengthen
the lower linkage rod by ¼ turn
increments, retighten and retest, until
the mower tracks straight.
C. Once the tracking is to the operators
liking, completely tighten the nuts on the
turnbuckle. Recheck and adjust the
Neutral Plate if required.
D. Reinstall the fender skirts and tighten all
bolts.
3. TO ADJUST “IN” OR OPERATING
POSITION OF THE TWINSTICK
STEERING CONTROL LEVERS:
If the Control levers are too close in the
center or the Control Levers Drag on the
Neutral Plate, adjust as follows:
Long silver
spacer
Short gold
spacer
Neutral
Plate
Long silver
spacer
Cross Bolt
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A. Tilt the Control Lever outward, loosen
the lock nut and adjust the bolt until
the gap between the handles is correct
or the Control lever does not rub on
the Neutral Plate.
B. Tighten the lock nut after the
adjustment is made.
HYDROSTATIC TRANSMISSION
Check oil level in Hydraulic Oil Reservoir
after every 25 hours of use. Oil level
should be checked when oil is COLD. If
necessary add 20W-50 motor oil to the
reservoir. DO NOT OVERFILL.
Thoroughly clean the Hydraulic Oil
Reservoir Cap and the surrounding area
PRIOR to removal of the cap. Take
caution to keep all foreign matter out of
the Hydraulic Oil Reservoir.
NOTE: NEVER WASH ACROSS VENTED CAP
WITH WATER OR STEAM.
It is essential that the unit exterior be
free from debris prior to doing any fluid
maintenance.
1. HYDROSTATIC TRANSMISSIONS FLUID
CHANGE:
SAE 20W-50 engine oil has been
selected for use by the factory and is
recommended for normal operating
temperatures.
A. Set the park brake.
B. Remove the oil filter.
C. After all the oil is drained out, replace the
filter (use part # H-2026 when ordering
from Country Clipper).Wipe off the filter
base surface, apply a film of new oil to
the gasket of the new filter and hand
tighten ¾ to one full turn after the filter
gasket contacts the filter base surface.
D. Refill the transmission with the
recommended oil through the Hydraulic
Oil Reservoir. continue filling until the
“Full Cold” line is reached on the
reservoir.
E. Recheck oil level after running.
SEAT HOLD DOWN LATCH
To release the seat hold down latch, pull
the latch handle to the right.
Seat
Latch
Lock Nut
Adjustment
Bolt
Vented
Hydraulic Oil Reservoir
Hydraulic
Oil Filter
Fluid
Level
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PROCEDURE FOR RAISING AND
LOWERING THE DECK FOR
SERVICING
1. RAISING THE DECK TO THE SERVICING
POSITION:
A. Remove cut height adjustment pin and
completely lower the cut height
adjustment lever. Re-insert the cut
height adjustment pin immediately
above Cut Height Adjustment Lever
(this will lock the cut height adjustment
lever into the lowest position).
B. Carefully rotate the Deck Belt Tension.
Latch to release tension on the Deck
Belt. Remove the engine to deck Drive
belt from the clutch on the engine. Flip
up the Front Step (if so equipped).
C. On the right side of the mower, lift and
hold up on the hook keeper. Lift up on
the release handle to disconnect the
back of the deck. The latch plate
should catch and hold the release
handle rod in place. (To adjust the latch
plate, see page 21.)
D. Position the front caster wheels so they
are away from the deck (such as the
tractor would be traveling in reverse).
E. Lift the nose of the deck until the deck
is standing near vertical (lifting can be
made easier if someone stands on the
rear bumper of the tractor.
F. Release the deck prop from its stowed
position and place the free end against
the deck lift casting as shown on page
19. Make sure the point of the prop
falls within the center clearance area.
IMPORTANT NOTE:
TO SECURE THE DECK, MAKE SURE
THAT THE DECK IS LIFTED FAR
ENOUGH TO ALLOW THE DECK
PROP TO ENGAGE THE DECK LIFT
CASTING.
2. RETURNING THE DECK TO THE
OPERATING POSITION:
A. Place the deck prop back in the stowed
position.
B. Push the bottom (back) of the deck
towards the rear of the tractor. Lower
the deck until it rests on the ground.
C. Lift up on the latch plate to release the
release handle rod. Push down on the
release handle until deck hooks lock into
place.
D. Install the engine to deck belt onto the
clutch on the engine.
E. Ensure that the engine to deck drive belt
is installed onto all of the pulleys and
idlers in the drive train. Carefully rotate
the Deck Belt Tension Latch to re-
tension the Deck Belt.
F. Lower the foot deck down into the
operation position. On units so
equipped, lower the front step.
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MOWER SHOWN IN
OPERATING POSITION.
MOWER SHOWN IN
SERVICING POSITION.
Front Caster Wheels
positioned out of the way.
Front Caster Pivot
Grease Zerk
Deck Hook
Flip Front
Step Up
Foot
Deck
Cut Height
Adjustment
Cut Height Adjustment Lever
Hook
Keeper
Latch Plate
Release
Handle
Release
Handle
Engine to Deck Belt
Removed from
Clutch
Deck raised to
service
Deck Prop
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