Country Clipper Trek Hydro ZT1400KA User manual

P-11548 (9/2001)
Safety Instructions & Operators Manual
Congratulations for buying a Country Clipper product. Your Country Clipper
Hydrostatic Drive Walk-behind 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 4-6. Following these instructions will help you continue
to enjoy the trouble-free performance expected of the Country Clipper product.
Copyright, Shivvers Mfg., 2004

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TABLE OF CONTENTS
SAFETY....................................................................................................................................4
ACCIDENT PATTERNS TO AVOID................................................................................................4
SAFETY INSTRUCTIONS AND RECOMMENDATIONS................................................................4
SAFETY INTERLOCK SYSTEM......................................................................................................6
START UP AND OPERATION.................................................................................................7
CHECKLIST BEFORE OPERATION...............................................................................................7
CONTROL LOCATIONS .................................................................................................................7
OPERATION....................................................................................................................................8
MOWING RECOMMENDATIONS .................................................................................................10
SPECIFICATIONS..................................................................................................................11
MAINTENANCE......................................................................................................................12
MAINTENANCE SCHEDULE........................................................................................................12
MAINTENANCE INSTRUCTIONS.................................................................................................13
TROUBLE SHOOTING CHECKLIST .....................................................................................17
BELT ROUTINGS...................................................................................................................19
WIRING SCHEMATICS..........................................................................................................20
HYDRAULIC SCHEMATIC.....................................................................................................21
NOTES / SERVICE RECORDS..............................................................................................21
Copyright, Shivvers Mfg., 2004

4
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
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 mower is
driven in reverse. The accident victims
are most often young children whom,
unseen by the operator of the mower,
were in the area being mowed.
AT COUNTRY CLIPPER, WE SHARE YOUR
DESIRE TO PROTECT YOURSELF, YOUR
FAMILY, YOUR FRIENDS AND YOUR
NEIGHBORS FROM ACCIDENTAL INJURY.
OBSERVING AND ENFORCING THE
FOLLOWING GUIDELINES WILL HELP TO
INSURE THE SAFETY OF EVERYONE.
PLEASE BE CAREFUL
SAFETY INSTRUCTIONS AND
RECOMMENDATIONS
1. PEOPLE WHO OPERATE, SERVICE, OR
ARE OTHERWISE ASSOCIATED with the
Country Clipper Hydrostatic Drive Walk-
behind Mower should be trained in its proper
use and warned of its dangers. Before
operating, adjusting, or servicing the Country
Clipper Hydrostatic Drive Walk-behind Mower
they should read and understand this entire
manual and the engine owner’s manual. If
the operator(s) or mechanic(s) can not read
English it is the owner’s responsibility to
explain this material to them. The owner/user
can prevent and is responsible for accidents
or injuries occurring to themselves, other
people or property.
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 across slopes. NEVER
mow up and down the face of a slope.
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 Hydrostatic Drive Walk-behind 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.
Copyright, Shivvers Mfg., 2004

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7. DO NOT MOVE SHIFT HANDLE(S) OR
TWIN TRACK GROUND SPEED LEVER(S)
from forward position to reverse position
rapidly. The speed and/or direction of travel
is instantly affected by movement of these
controls.
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
position.
10. WEAR STURDY, ROUGH-SOLED WORK
SHOES AND CLOSE-FITTING SLACKS
AND SHIRTS. Never operate mower in bare
feet, sandals or sneakers. Loose fitting
clothing, jewelry or long hair can become
entangled in moving parts.
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 MOW WHEN OTHER PEOPLE OR
PETS ARE IN THE AREA.
14. 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.
15. 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.
16. DO NOT SMOKE AROUND THE MOWER or
the gasoline storage container. Gasoline
fumes can easily Ignite.
17. DO NOT STEP OR STAND ON THE
MOWER HOUSING.
18. WATCH OUT FOR TRAFFIC near roadways
and when crossing roads. Slow down when
near roadways and sidewalks.
19. 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. Use approved container to store
gasoline.
20. DISENGAGE BLADES, STOP ENGINE AND
REMOVE IGNITION KEY before any
servicing, including emptying a grass
collection system or unclogging the discharge
chute. 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.
21. KEEP ALL NUTS, BOLTS, AND SCREWS
TIGHT to be sure equipment is in safe
working condition, especially blade mounting
bolts. Keep all parts in working order.
22. 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.
23. DISENGAGE BLADES BEFORE DRIVING
ACROSS WALKS, DRIVEWAYS or
projecting objects.
24. KEEP SAFETY DEVICES AND GUARDS IN
PLACE. If any of the safety switches or
devices become inoperable, have them
repaired immediately.
25. NEVER OPERATE WITHOUT GRASS
DEFLECTOR or entire grass collection
system in place and in proper working order.
26. DO NOT USE MOWER WHEN GRASS IS
WET AND SLIPPERY. Reduced footing
could cause slipping.
27. WALK, NEVER RUN BEHIND MOWER. Be
sure of your footing at all times.
28. MOW ONLY DURING DAYLIGHT.
29. THIS MACHINE IS NOT MEANT FOR
HIGHWAY OR STREET USE. It is not a
Copyright, Shivvers Mfg., 2004

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recreational vehicle and it should not be
operated as such.
30. ALWAYS DISENGAGE THE MOWER
BLADE CLUTCH when transporting.
31. 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.
32. NEVER PERFORM MAINTENANCE ON
HYDRAULIC LINES OR FITTINGS WHILE
ENGINE IS RUNNING.
33. 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.
34. WEAR PERSONAL PROTECTIVE
EQUIPMENT. Eye, ear, feet and head
protection is recommended.
35. ONLY USE COUNTRY CLIPPER
APPROVED ACCESSORIES.
36. NEVER RAISE DECK WITH BLADES
RUNNING.
37. DO NOT CHANGE THE ENGINE
GOVERNOR SETTING or over speed the
engine.
38. BEWARE OF MOWER DISCHARGE
DIRECTION and do not point it at anyone.
39. DO NOT OPERATE THE MOWER UNDER
THE INFLUENCE OF ALCOHOL OR
DRUGS.
40. USE CARE WHEN LOADING OR
UNLOADING MACHINE INTO A TRAILER
OR TRUCK.
41. USE CARE WHEN APPROACHING BLIND
CORNERS, shrubs, trees, or other objects
that may obscure vision.
42. CLEAN ALL GRASS AND DEBRIS FROM
MACHINE TO PREVENT FIRES. Remove
spilled oil or gasoline.
43. CAREFULLY RELEASE PRESSURE FROM
COMPONENTS WITH STORED ENERGY.
44. 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).
45. KEEP HANDS AND FEET AWAY FROM
MOVING PARTS. If possible do not make
adjustments with the engine running.
46. USE JACKSTANDS TO SUPPORT
COMPONENTS when required.
SAFETY INTERLOCK SYSTEM
Your Country Clipper Hydrostatic Drive
Walk-behind Mower is equipped with switches
interlocked for your safety.
1. The PTO must be disengaged before the
engine will start.
2. The Twin Track Ground Speed Levers must
be in Neutral before the engine will start.
3. The Key switch Must be “ON” before the
engine will start.
4. The engine will stop if the Operator releases
the Operator Presence Bail when the Twin
Track Ground Speed Levers are out of
neutral.
5. The engine will stop if the Operator releases
the Operator Presence Bail when the PTO is
engaged.
DO NOT OPERATE THE COUNTRY CLIPPER
HYDROSTATIC DRIVE WALK-BEHIND MOWER
IF SAFETY SWITCHES AND GUARDS ARE
NOT OPERATING PROPERLY
Copyright, Shivvers Mfg., 2004

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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)
Make sure dirt and foreign matter is kept out
of fuel tank. Use clean funnel and gas can.
Do not mix oil with fuel.
Do not use white, high test or premium
gasoline. Do not use de-icers, carburetor
cleaners, or other such additives.
2. 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.)
3. Check the hydrostatic transmission oil level.
(See “Maintenance” section of this manual.)
4. Inspect V-belts.
5. Check tire pressure. Set all tires to 16 psi
6. Make sure underside of mower deck is free of
grass.
7. Make sure mower blades are sharp and
secured tightly.
8. Clean the air intake screen on the engine if
necessary.
9. 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
1. OPERATOR PRESENCE BAIL
Located above the handle bar/grip
assemblies. When held down against the
handle grips, the Operator Presence Bail
senses that the operator is in the normal
operator’s position. If the operator releases
the Operator Presence Bail while either the
Twin Track Ground Speed Levers are out of
neutral or the PTO switch is engaged the
engine will stop running.
DANGER
HANDLE GASOLINE WITH CARE – IT IS
HIGHLY FLAMMABLE. DO NOT SMOKE.
ENGINE SHOULD BE OFF AND COOL.
USE APPROVED GASOLINE CONTAINER.
NEVER FILL FUEL TANK INDOORS. WIPE
UP ANY SPILLS. REPLACE CAP TIGHTLY.
2. TWIN TRACK GROUND SPEED LEVER(S)
Located in the center of the Control Console.
The right hand and/or left hand Twin Track
Ground Speed Lever sets the maximum
forward ground speed for the right hand
and/or left hand Hydrostatic Transmission.
3. PTO SWITCH
Located on the upper left hand corner of the
control console. When pulled “UP” into the
engage position, starts the electric clutch for
the mower blades.
4. FUEL SHUT-OFF VALVE
Located on the bottom of the fuel tank.
Opening the Fuel Shut-off Valve turns fuel
supply to engine on.
5. SHIFT HANDLE(S)
Located just below each handle grip.
Squeezing the left hand and/or right hand
Shift Handle causes the left hand and/or right
hand Hydrostatic Transmission to slow down,
stop or travel into reverse, depending on how
far the respective Shift Handle is squeezed.
The Shift Handles will have no effect on
forward travel of the machine if the Twin
Track Ground Speed Lever(s) are in neutral
or if the Neutral Latches are in the “lock”
position.
Squeezing the Shift Handles beyond neutral
(closer to the handle grips) will shift the
hydrostatic transmissions into the reverse
direction.
Copyright, Shivvers Mfg., 2004

6. NEUTRAL LATCHES
Located above the Shift Handles and on the
inside of the handle bars. While squeezing
the Shift Handles and holding the Hydrostatic
Transmissions in neutral, rotation of the top
“thumb grip” portion of Neutral Latches
towards the rear of the machine will lock the
Shift Handles into neutral. To release Neutral
Latches squeeze the Shift Handles until they
“fall” off of the locked position. `
WARNING
AVOID INHALING EXHAUST FUMES.
CARBON MONOXIDE GAS IS COLORLESS,
ODORLESS, CAN CAUSE
UNCONSCIOUSNESS, AND IS
POTENTIALLY LETHAL. DO NOT RUN
ENGINE IN GARAGE OR OTHER
CONFINED AREA
7. KEY SWITCH
Located towards the right side of the Control
Console. When in the “ON” position allows
the engine to run. When in the “OFF” position
shuts the engine off. Removing the Key can
prevent unauthorized operation.
8
8. THROTTLE/CHOKE CONTROL
Located on the upper right hand corner of the
Control Console. Moving Throttle/Choke
Control “forward” increases engine speed.
Maximum engine speed is obtained when the
Throttle/Choke Control stops in the forward
“detent” position. Moving Throttle/Choke
Control beyond the “detent” position to “full”
forward closes the choke on the engine.
9. COLD START RELEASE CHAIN
Located behind the right hand drive tire, on
the frame. Pulling the Cold Start Release
Chain out away from the frame and then “UP”,
latching it into the “key-holed” slot on the
frame removes belt tension from the
Hydrostatic Transmissions, thus easing force
required to start engine.
10. DRIVE WHEEL BYPASS VALVES
Located on the top corners of the left hand
and right hand Hydrostatic Transmissions.
Turning the Drive Wheel Bypass Valves ½
turn counterclockwise will open them, thus
allowing the machine to be moved by hand
without the engine running. To resume
normal operation close these valves. DO
NOT OVER-TIGHTEN.
OPERATION
1. TO START: Open Fuel Shut-off Valve (if
previously closed)
2. Move Twin Track Ground Speed Levers into
“Neutral”.
3. Switch PTO to “OFF” position.
4. Lock Shift Handles into “Neutral” with the
Neutral Latches.
5. Turn Key Switch to “RUN”
6. Move Engine Throttle/Choke Control to full
choke position for cold starts. For warm starts
place Throttle/Choke Control to ½ position.
7. Pull Recoil Rope to start Engine. Adjust
Throttle/Choke Control to desired Engine
RPM
NOTE: For cold weather starting (or when engine
has not been started for a long period of time) pull
the Cold Start Release Chain out and up. Hook
the Cold Start Release Chain into the “key-holed”
slot on the side of the frame. After starting the
engine the Cold Start Release Chain must be
SLOWLY returned to it’s original position of
operation.
NEUTRAL LATCH
Shown “locked” in neutral
p
osition
“THUMB GRIP”
HANDLE
GRIP
SHIFT HANDLE
Copyright, Shivvers Mfg., 2004

9
IMPORTANT: Until the operator is familiar with
the Country Clipper Zero Turning Radius Walk-
behind 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 Shift Handle(s) and
Twin Track Ground Speed Lever(s) smoothly and
slowly. Practice until operation is smooth and
efficient.
8. TO DRIVE: Hold the Operator Presence Bail
down against the handle bar.
Set desired forward ground speed with the
Twin Track Ground Speed Levers.
Note: The left hand Twin Track Ground
Speed Lever will set the ground speed for the
left hand drive wheel and the right hand Twin
Track Ground Speed lever will set the ground
speed for the right hand drive wheel.
While slowly squeezing both Shift Handles
release both Neutral Latches.
Note: Shift Handles should only be squeezed
far enough to release Neutral Latches, over
squeezing will cause drive wheels to be
shifted into reverse.
To travel straight forward slowly release both
Shift Handles.
To stop squeeze both Shift Handles back to
neutral. Squeezing past neutral will cause
machine to travel into reverse.
Squeeze the right hand Shift Handle to turn
right. Squeeze the left hand Shift Handle to
turn left.
To adjust forward tracking re-adjust the
ground speed with the Twin Track Ground
Speed Levers. Either slow down the side that
is tracking fast or speed up the side that is
tracking slow.
To travel in reverse squeeze both Shift
Handles past neutral and into reverse.
To make a zero radius axis turn, gently
squeeze either the right hand or left hand
Shift Handle past neutral and into reverse,
while regulating the opposite Shift Handle at a
similar forward speed.
For smooth operation avoid quick, jerky
movement of the Shift Handles. Squeeze the
Shift handles with deliberate intent and
purpose.
CAUTION
FOR SMOOTH, SAFE OPERATION, MOVE
THE SHIFT HANDLE(S) AND TWIN TRACK
GROUND SPEED CONTROL(S) IN A
GENTLE, SLOW MOTION. NEVER MOVE
THESE CONTROLS RAPIDLY,
ESPECIALLY ON GRADES
CAUTION
AVOID HILLS AND SLOPES. USE
EXTREME CAUTION WHEN MOWING
ACROSS SLOPES. NEVER MOW UP AND
DOWN SLOPES.
9. BLADE ENGAGEMENT: Pull up on the PTO
Switch to engage blade(s). Pushing down on
the PTO Switch will disengage the blade(s).
Note: The engine will stop if the operator
releases the Operator Presence Bail while the
PTO is engaged.
DANGER
THE ROTATING BLADE(S) UNDER THE
MOWER DECK ARE DANGEROUS.
CONTACT WITH BLADE(S) CAN CAUSE
SERIOUS INJURY OR DEATH. DO NOT
PUT FEET OR HANDS UNDER THE
MOWER DECK WHILE THE BLADE(S) ARE
ENGAGED.
IMPORTANT: On power units equipped with
Kawasaki 15 h.p. engines, NEVER engage blades
when engine RPM is less than half throttle. Doing
so may cause premature clutch failure and void
clutch warranty.
Copyright, Shivvers Mfg., 2004

10. TO STOP: Squeeze both Shift Handles into
neutral and lock into place with the neutral
latches.
Move the Twin Track Ground Speed Levers
into neutral.
Release the Operator’s Presence Bail
Turn the Key Switch to “OFF” and remove the
Key.
11. TO FREE WHEEL MACHINE: Unscrew
bypass valves on both hydrostatic
transmissions ½ turn counterclockwise. To
reset, turn bypass valves clockwise. DO NOT
OVERTIGHTEN.
12. TO CHANGE DECK CUTTING HEIGHT:
While lifting the deck, remove the Deck
Hanger Hairpin from the Deck Hanger Rod.
Re-insert Deck Hanger Hairpin into desired
hole on Deck Hanger Rod. NOTE: To obtain
a level cut, all four Deck Hanger Hairpins
must be installed in the same cutting height
hole on each of the Deck Hanger Rods.
CAUTION
FAILURE TO SECURELY AND
COMPLETELY LOCK BOTH SHIFT
HANDLES WITH THE NEUTRAL LATCHES
COULD CAUSE MACHINE TO
UNEXPECTEDLY LURCH FORWARD
CAUSING INJURY OR PROPERTY
DAMAGE
MOWING RECOMMENDATIONS
1. Keep mower blade(s) sharp.
2. Make sure mower deck and discharge chute
are clean.
3. When mowing tall grass, make two passes,
mowing off ½ of the desired cut height on the
first pass, and then the desired cut height on
the second pass. Check for hidden dangers
first.
4. Go slowly for trimming
5. When cutting grass always run the Engine at
FULL throttle. This “Engine” speed allows the
mower blades to operate at optimum cutting
speed. Control “GROUND” speed with the
Shift Handle(s) and/or Twin Track Ground
Speed Lever(s).
6. Vary ground speed to suit conditions. (i.e. Go
slower in tall thick grass, on slopes, wet
conditions, etc.)
CAUTION
WHEN LEAVING THE MOWER
UNATTENDED, ALWAYS REMOVE THE
KEY. EVEN IF LEAVING FOR JUST A FEW
MOMENTS. HELP PROTECT CHILDREN
AND UNAUTHORIZED PERSONNEL FROM
ACCIDENTS.
DANGER
NEVER CLEAN THE DISCHARGE CHUTE
OR MOWER DECK WHILE THE ENGINE IS
RUNNING. TURN OFF ENGINE AND WAIT
FOR ALL MOVEMENT TO STOP PRIOR TO
CLEANING.
Drive Wheel
Bypass Valve
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Copyright, Shivvers Mfg., 2004

11
SPECIFICATIONS
POWER UNIT
Model ZT1400KA ZT1500KA
Engine (see engine Owner’s Manual for
complete specifications) 14 h.p. Kawasaki
(single cylinder) 15 h.p. Kawasaki (twin cylinder)
Hydrostatic Pumps Hydrogear BDP-10A
Wheel Motors Parker-Ross
Turning Radius Zero-Turn
Ground Speed: Forward
Reverse 7 MPH (infinitely variable) 3-1/2 MPH (infinitely variable)
Electric Clutch Warner Mag-Stop
Length (Power Unit ONLY) 44”
Height 43-1/2”
Width (outside rear drive tires) 35-3/4”
Weight approx. (including deck frame) 390# 383#
Fuel capacity 6 Gallons
Belt, Engine to Hydrostatic
Transmissions P/N D-3671
Hydrostatic Transmission Oil Filter P/N H-2026
Tires
Rear Drive
Front Caster
16 x 6.50-8 (4 ply)
9 x 3.50-4 (4 ply)
DECK
Model 36W 48W
Cutting Width 36” 48”
Overall Width (w/ chute) 46” 58”
Overall Length (w/ Power Unit) 79” 75”
Blades Length 18-3/8” 17”
Blade Tip Speed 18,500 – 18,950 fpm
Blade Width x Thickness 2 ½” x.204”
Blade Quantity 2 3
Belt, Engine to Deck P/N D-3684 P/N D-3606
Cutting Height 1-½” to 4-½” (½” increments) 1-½” to 4-½” (½” increments)
Weight approx. (less deck frame) 160# 185#
Material Thickness 10 ga.
Reinforcement Thickness 7 ga.
Spindle Bearings 25 mm
NOTE: Power unit should be matched to deck to insure sufficient power is available for intended usage.
NOTE: All specifications subject to change without prior notice
Copyright, Shivvers Mfg., 2004

12
MAINTENANCE
CAUTION
BEFORE PERFORMING ANY MAINTENANCE, TURN OFF ENGINE, REMOVE KEY AND DISCONNECT
SPARK PLUG(S). 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 Safety Interlocks System ------------------------------------------------------------- before each use
Check for loose hardware --------------------------------------------------------------------- before each use
Grease front caster pivots --------------------------------------------------------------------- before each use
Check crankcase oil level --------------------------------------------------------------------- before each use
Clean grass from Hydrostatic transmission cooling fins--------------------------------- before each use
Check for loose or damaged hydraulic lines and fittings ------------------------------- before each use
Check air intake screen --------------------------------------------------------------------------- after each use
Clean grass from under deck -------------------------------------------------------------------- after each use
Check tire pressure ------------------------------------------------------------------------------- every 10 hours
Sharpen mower blades -------------------------------------------------------------------------- every 10 hours
Check Hydrostatic Transmission fluid -------------------------------------------------------- every 25 hours
Check drive belts ---------------------------------------------------------------------------------- every 50 hours
(20 hours break-in)
Grease deck spindle bearings ---------------------------------------------------------------- every 100 hours
Change Hydrostatic transmission oil and oil filter --------------------------------------- every 500 hours
(100 hours break-in)
Clean air filter pre-cleaner element ------------------------------------------- see engine owner’s manual
Service/Replace Air Cleaner Filter Element -------------------------------- see engine owner’s manual
Change engine crankcase oil -------------------------------------------------- see engine owner’s manual
Change engine oil filter ---------------------------------------------------------- see engine owner’s manual
Check/Replace spark plugs ----------------------------------------------------- see engine owner’s manual
Clean engine air cooling system ----------------------------------------------- see engine owner’s manual
Change/Clean fuel filter ------------------------------------------------------------------------------- as required
--------------------------------------------------------------------------------------------------------------------------------
Replace decals when illegible. Write factory for free replacement.
Copyright, Shivvers Mfg., 2004

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 Hydrostatic Drive Walk-behind Mower
information packet.
13
NOTE: Air intake screen must be kept
clean. If plugged, engine may be
seriously damaged by over heating.
2. TIRES:
Correct tire pressure is essential for
efficient operation of the mower. Check
tire pressure as requested in the
maintenance schedule. Inflate tires to 16
psi.
Lug nuts should be checked regularly for
tightness.
3. MOWER BLADES:
Check sharpness of mower blades after
every 10 hours of operation. To sharpen
blades proceed as follows:
A. Remove bolt, lockwasher, and cup
washer mounting blade on shaft.
Remove blade.
NOTE: Servicing the underside of the deck can
be simplified by raising the deck into the
servicing position. See Page 16 on how-
to raise deck into servicing position.
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, cup washer, lockwasher,
and bolt. Make sure to tighten bolt to 60
ft.lbs.
4. 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.
NOTE: See page 19 for belt routings.
5. LUBRICATION:
A. Engine: Follow engine manufacturer’s
recommendations.
B. Deck Spindles: Lubricate with 3 “shots”
only, every 100 hours.
C. Hydrostatic Transmission and filter:
Check the oil level in hydrostatic
transmission oil reservoir after every 25
hours of usage. The proper oil level
should register within the sight window of
the oil reservoir cover.
When adding oil be very careful to
keep the reservoir clean. Clean the Oil
Reservoir Cap and the surrounding area
prior to removing the Oil Reservoir Cap.
Replenish oil supply as required with
20W-50 Motor Oil. DO NOT OVERFILL.
(continued next page)
CAUTION
BEFORE SERVICING BLADE(S). STOP
ENGINE, REMOVE KEY, AND
DISCONNECT SPARK PLUG(S) FOR
SAFETY
When notch starts,
DISCARD blade
DANGEROUS
DO NOT USE
BLADE IN THIS
CONDITION
New Blade
Copyright, Shivvers Mfg., 2004

Change the oil in the reservoir and
Hydrostatic Transmission Filter after the
first 100 hours of operation, and then
every 500 hours after that. Remove the
filter and be sure that all oil has drained
from the reservoir. Replace with new filter
(P/N H-2026) and 20W-50 Motor Oil.
14
6. NEUTRAL ADJUSTMENTS:
A. Raise rear drive tires high enough to clear
the ground and securely support.
B. Start engine and run at full throttle.
C. NEUTRAL AT THE SHIFT HANDLES
i) Shift the Twin Track Ground Speed
Levers approximately into the middle
speed position.
NOTE: Operator Presence Bail must
be held down when shifting the Twin
Track Ground Speed Levers out of
neutral.
ii) Verify that the reverse spring is
collapsed to approximately 1-1/16”.
Adjust collapsed length of reverse
spring using the spring collapse jam
nut. Repeat for other side
NOTE: This can be done prior to
starting the engine.
iii) Squeeze the Shift Handles until
increased pressure is felt.. If the rear
drive tire is moving adjustment is
required. Loosen the lower jam nut
from the reverse link rod assembly. If
the rear drive tire is “creeping”
forward lengthen the reverse link rod
assembly by moving the top jam nut
and the spring collapse jam nut equal
amounts. If rear drive tire “creeps”
into reverse shorten the reverse link
rod assembly. Re-tighten lower jam
nut when length adjustments are
completed. Verify collapsed length of
reverse spring. Repeat for other side.
D. NEUTRAL AT THE TWIN TRACK
GROUND SPEED LEVERS
i) Move the Twin Track Ground Speed
Levers into neutral position. If rear
drive tire is “creeping” forward shorten
the forward link rod assembly by
loosening and repositioning the jam
nuts . Lengthen the forward link rod
assembly if the rear drive tire “creeps”
into reverse. Repeat for other side.
NOTE: If this adjustment cannot be
maintained, verify that spring located
on the pivot point of the Twin Track
Ground Speed Levers is collapsed to
approximately 11/16”.
WARNING
PORTIONS OF HYDRAULIC SYSTEM CAN
OPERATE UNDER HIGH PRESSURE.
HYDRAULIC FLUID ESCAPING UNDER
PRESSURE MAY HAVE SUFFICIENT FORCE
TO PENETRATE SKIN AND CAUSE SERIOUS
INJURY. HYDRAULIC FLUID INJECTED INTO
THE SKIN MUST BE SURGICALLY REMOVED
WITHIN A FEW HOURS BY A DOCTOR
FAMILIAR WITH THIS FORM OF INJURY OR
GANGRENE MAY RESULT. (see Hydraulic
Schematic on page 20)
Shift Handle Link
Speed Control
Link
Spring Collapse
Jam Nut
Reverse Spring
Top Jam Nut
Lower Jam Nut
Reverse Link
Forward Spring
Forward Link Control Arm
Standard Spring Hole
Medium Duty Spring Hole Heavy Duty Spring Hole
Copyright, Shivvers Mfg., 2004

E. NEUTRAL AT NEUTRAL LATCHES
i) Shift the Twin Track Ground Speed
Levers into the middle speed position.
ii) Squeeze the Shift Handle into neutral
(as previously adjusted). Rotate the
“Thumb Grip” portion of the neutral
latch rearward and release the Shift
Handle, locking the Shift Handle into
the neutral position. If the rear drive
tire “creeps” forward shorten the Shift
Handle Link Rod Assembly. If the
rear drive tires “creeps” into reverse
lengthen the Shift Handle Link Rod
Assembly.
NOTE: The Shift Handle Link Rod
must be disconnected from the Shift
Handle in order to change the length.
7. FORWARD TRACKING ADJUSTMENT:
A. If forward travel of the machine veers left
or right on level ground when the Twin
Track Ground Speed Levers are set at the
same forward position lengthen or
shorten Speed Control Link Rod.
Lengthening the Speed Control Link Rod
will increase forward ground speed and
shortening the Speed Control Link Rod
will decrease forward ground speed.
NOTE: It may be necessary to re-adjust
neutral following this adjustment.
15
8. HYDROSTATIC TRANSMISSION CONTROL
ARM TENSION SETTINGS:
A. For heavy or medium duty drive
conditions (i.e. when pulling a sulky unit,
or carrying a grass collection system),
added spring force might be required on
the Control Arm of the Hydrostatic
Transmissions to prevent the hydraulic
drive system from slowing down while
pulling the extra load.
B. To increase spring force, remove the
Forward Spring from the mounting bolt.
Remove the mounting bolt on the Control
Arm and place it into one of the lower
holes. Re-connect the Forward Spring to
the Control Arm.
NOTE: The middle hole on the Control
Arm is for “medium duty” service and the
bottom hole on the Control Arm is for
“heavy duty” service.
9. LEVELING THE MOWER DECK:
A. Move machine onto hard level surface
(i.e. concrete or blacktop).
B. Set tire pressure on all four tires.
C. Place all four Deck Hanger Hairpins so
that deck is in highest cutting height.
D. With all blades tips rotated to point
straight forward measure from the ground
to the front blade tips. If blade tips
measure more than 3/16” different loosen
the jam nuts on the Deck Hanger Rods.
Adjust length of the appropriate Deck
Hanger Rods until blade tips are within
3/16” of each other. The rear blade tips
should be approximately 1/8” farther from
the ground than the front blade tips. The
deck should hang firmly on all four Deck
Hanger Rods. Tighten the jam nuts on all
four Deck Hanger Rods once desired
side-to-side level and front-to-back rake is
obtained.
Deck Hanger
Hairpin
Deck Hanger
Rod
Jam Nut
Copyright, Shivvers Mfg., 2004

10. RAISING THE DECK TO SERVICE
POSITION:
A. Change deck cutting height to be at the
mid-position OR lower.
B. Position the front caster wheel to point
away from the deck (such as the mower
would be travelling in reverse).
C. Remove Belt Cover and push back the
Ball on the idler bar releasing tension on
belt. Remove the engine to deck belt from
spindles.
D. Remove Rear Deck Hanger Hairpin.
Remove Lynch pin from Rear Deck
Hanger Clevis pin. Remove Rear Deck
Hanger Clevis pin. Re-Install rear Deck
Hanger Hairpin. Repeat for other side.
E. Push down on handle bars until deck fully
rotates up to the service position.
11. LOWERING THE DECK TO OPERATION
POSITION:
A. Push down on Handle bars raising the
deck off of the ground. Push the machine
forward while lowering the deck back to
the ground.
B. Remove Rear Deck Hanger Hairpins.
Re-install Rear Deck Hanger Clevis pins
and Lynch pins. Re-Install Rear Deck
Hanger Hairpin.
C. Re-install the Engine to Deck Belt back
onto the Spindle pulleys (see page 19 for
proper belt routing).
16
D. Re-install the Belt Cover.
E. Re-position Deck Hanger Hairpins on the
Deck Hanger Rods to desired cutting
height.
CAUTION
DECK MUST BE LIFTED FAR ENOUGH TO GO
“OVER-CENTER”, THUS PREVENTING IT FROM
FALLING ON THE OPERATOR WHILE SERVICE
WORK IS BEING PERFORMED.
Deck Shown Raised into the SERVICE Position
Deck Hanger Rod set in “Mid-cut” height OR
lower
{
all four Deck Han
g
ers
}
Front Caster Wheel
Away from Deck
Lynch Pin/
Clevis Pin
Engine to Deck Belt
Removed From spindles Rear Deck Hanger Clevis
Pin Assemblies “UNHOOK”,
(both sides)
Copyright, Shivvers Mfg., 2004

17
TROUBLE SHOOTING CHECKLIST
1. ENGINE WON’T START:
Key Switch is “OFF” --------------------------------------------------------------- turn key switch “ON”
Mower blades engaged ---------------------------------------------------------------- disengage PTO
Drive not in neutral --------- move Twin Track Ground Speed Levers into “Neutral” position
Fuel shut-off Valve Closed -------------------------------------------------- open fuel shut-off valve
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
2. HARD TO START ENGINE:
Fuel line clogged ------------------------------------------------ clean fuel line and check fuel filter
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
3. 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
Maladjusted carburetor ----------------------------------------------------------- readjust carburetor*
4. ENGINE KNOCKS:
Low oil level --------------------------------------------------------------------------- check and add oil
fuel octane too low ------------------------------------------------------------- drain and replace with
higher octane gasoline
Over heated engine ---------------------------------------------- shut off engine and allow to cool
5. ENGINE SOMETIMES SKIPS AT HIGHER SPEEDS:
Carburetor maladjusted ----------------------------------------------------------- readjust carburetor
Faulty spark plugs -------------------------------------------------------------------- check spark plug
condition and reset gap*
Operator’s Presence Bail is being released ---------------------- slow down on rough terrain
6. ENGINE OVER HEATED:
Copyright, Shivvers Mfg., 2004

18
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
Running engine too slow -------------------------------------------------------- run engine faster
(NOTE: Always mow at full throttle setting.)
7. ENGINE IDLES POORLY:
Carburetor maladjustment ---------------------------------------------------- readjust carburetor
Improper spark plug gap ------------------------------------------------ check and re-gap plug*
8. ENGINE BACKFIRES:
Carburetor maladjustment -------------------------------------------------- readjust carburetor*
9. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD:
Drive belt broken or slipping -------------------------------------------------- replace drive belt
Hydrostatic Transmission shift arm disconnected --------------------------------- reconnect
Hydrostatic Transmission oil low ---------------------------------------------------------- add oil
Transmission in free wheel position ------------------- tighten bypass valves (see pg. 10)
Hydrostatic Transmission oil filter plugged -------------------------------------- replace filter
Loose Hydrostatic Transmission Oil------------ Tighten or replace Transmission oil filter
Bad Hydrostatic Transmission or Wheel Motor ------------------------------- consult dealer
10. MOWER LOSES POWER OR TRANSMISSIONS OVER HEATS:
Hydrostatic transmission oil too low or too high -------------------------------------- add oil
OR drain oil as needed
Hydrostatic Transmission damage ---------------------------------------------- consult dealer
Hydrostatic Transmission blowing oil out cap --------------------------- overfilled or water
contaminated
11. ENGINE STALLS WHEN BLADES ARE ENGAGED:
Operator Presence Bail Released --------------------Hold Operator Presence Bail down
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
12. DECK CUT UNLEVEL:
Low air pressure in tire ----------------------------------------------------- adjust tire pressure
Deck Mounting Hair Pins not in same holes ------------ move Hairpins into same holes
Deck Hanging Pins out of adjustment ----------------------------------- adjust hanging pins
Bent Blade(s) --------------------------------------------------------------------- replace blade(s)
• See engine manual for engine adjustments.
Copyright, Shivvers Mfg., 2004

BELT ROUTINGS
48” ENGINE TO DECK BELT
CLUTCH
Belt P/N D-3606
36” ENGINE TO DECK BELT HYDROSTATIC TRANSMISSION
CLUTCH
Belt P/N
D-3684
VIEWED FROM GROUND LOOKING UP
MOTOR
LEFT HAND
HYDROSTATIC
TRANSMISSION TRANSMISSION
HYDROSTATIC
RIGHT HAND
FRONT
Belt P/N
D-3671
19
Copyright, Shivvers Mfg., 2004

WIRING SCHEMATICS
14 HP KAWASAKI (ZT1400KA)
15 HP KAWASAKI (ZT1500KA)
20
NEUTRAL
RIGHT-HAND
BLUE #11
BLACK #7
OPERATOR
(N.C.)
PRESENCE LEFT-HAND
NEUTRAL
(N.C.) (N.C.)
BLUE #13
(OPTIONAL)
HOUR METER
BLUE #12
BLACK #9
RED #8 RED #17
(BOTH CIRCUITS N.O.)
CLUTCH SWITCH
N.C. = NORMALLY CLOSED
N.O. = NORMALLY OPEN
NOTE: ALL PLUGS VIEWED FROM WIRE END
("G" AND "M")
KEY SWITCH
BLUE #16
CLUTCH
BLACK #3 RED #4
BLUE #10
GROUND
BLACK #1
BLACK #5 BLACK #2
(NOT USED)
BLACK #3
BLUE #16
(OPTIONAL)
HOUR METER
(BOTH CIRCUITS N.O.)
CLUTCH SWITCH
BLUE #13
(N.C.)
LEFT-HAND
NEUTRAL
(N.C.)
PRESENCE
OPERATOR
RED #8
BLUE #12
BLACK #9
(N.C.)
NEUTRAL
RIGHT-HAND
RED #17 BLACK #7
BLUE #11
N.O. = NORMALLY OPEN
NOTE: ALL PLUGS VIEWED FROM WIRE END
N.C. = NORMALLY CLOSED
CLUTCH
BLACK #1
("G" AND "M")
KEY SWITCH
BLUE #10
ENGINE PLUG
RED #4
BLACK #6
BLACK #5
REGULATOR PLUG
BLACK #2 GROUND
Copyright, Shivvers Mfg., 2004

21
HYDRAULIC SCHEMATIC
NOTES / SERVICE RECORDS
CASE DRAIN
CHARGE PUMP INLET
HIGH PRESSURE
LEFT-HAND
WHEEL MOTOR
RIGHT-HAND
HYDROSTATIC
TRANSMISSION
LEFT-HAND
HYDROSTATIC
TRANSMISSION
OIL
FILTER
OIL TANK
HIGH PRESSURE - FORWARD
HIGH PRESSURE - REVERSE
HIGH PRESSURE - FORWARD
HIGH PRESSURE - REVERSE
RIGHT-HAND
WHEEL MOTOR
DATE SERVICE WORK COMPLETED
Copyright, Shivvers Mfg., 2004