Country Clipper CHALLENGER D510 Product Manual
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Country Clipper CHALLENGER D510 Product Manual

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SERIAL RANGE: 21286001 - ________
PRODUCT MANUAL
Common Service Parts & Mower Information
Manuals
Country Clipper Safety Instructions and Operation
Country Clipper Repair Parts
Warranty
Country Clipper Warranty
Kawasaki Engine Warranty
Kohler Engine Warranty
Hydro-Gear Warranty
Battery Warranty
Additional Information
Country Clipper Product Specifications
Notes/Service Records
P-13540 (Rev B 11/21)

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Summary of Contents for Country Clipper CHALLENGER D510

  • Page 1 SERIAL RANGE: 21286001 - ________ PRODUCT MANUAL Common Service Parts & Mower Information Manuals Country Clipper Safety Instructions and Operation Country Clipper Repair Parts Warranty Country Clipper Warranty Kawasaki Engine Warranty Kohler Engine Warranty Hydro-Gear Warranty Battery Warranty Additional Information...
  • Page 2 Common Service Parts & Information 48” Blade High Lift w/o Fusion Low Lift Gator H-2882 H-2659 H-2665 52” Blade High Lift w/o Fusion High Lift Low Lift Gator H-2883 Fusion H-2884 H-2660 H-2666 60” Blade High Lift w/o Fusion High Lift Low Lift Gator H-2885...
  • Page 3 Safety Instructions and Operation...

  • Page 4: Table Of Contents

    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) .....................

  • Page 5: Warranty Registration

    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.
  • Page 6 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.

  • Page 7: 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.

  • Page 8: Towing

    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;...

  • Page 9: Safety Interlock System

    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.

  • Page 10: Safety Decals

    The following illustrations depict the various safety decals used on the equipment with a brief explanation for those requiring one. Safety Decals P-12706… WARNING – Deck Discharge Opening Safety. P-12496… DANGER – Discharge Chute or Grass Catcher has been removed. P-11370…...

  • Page 11: Controls

    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.

  • Page 12: Control Descriptions

    Control Descriptions Ignition Switch: A three position switch: “Off”, “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. Turn switch to “Off” position to shutoff engine. 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.

  • Page 13: Control Decals

    Control Decals P-13188… Startup & Operation Instructions. P-13482… Throttle Control Position, Idle Rpm to Full Throttle P-13437… Transport Latch – Lock position will P-13421… Deck Height Position – Used as a permit the deck to lock in transport relative reference of the cutting blade when raised to that position.

  • Page 14: Pre-Operation Checklist

    Section 4… Start Up & Operation Warning 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 impact the mower operation. Danger ENGINE SHOULD BE OFF AND COOL BEFORE REFUELING.

  • Page 15: Starting The Engine

    “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.

  • Page 16: Mower Driving Operation

    Mower Driving Operation Country Clipper offers two types of steering options; Joystick Drive Control and Twin Stick Drive Control. Both options will be explained below. Danger NEVER MAKE SUDDEN STOPS OR REVERSE IN DIRECTION, ESPECIALLY WHEN OPERATING ON A SLOPE. SPEED AND/OR DIRECTION OF TRAVEL ARE AFFECTED INSTANTLY BY MOVEMENT OF DRIVE CONTROL LEVER(S).

  • Page 17: Deck Cut Height Adjustment

    In case of steering control loss during operation of the mower; place the Steering Control Lever(s) in the neutral lock position, set the Park Brake, shut off the Blade Engagement Switch, and shut off the Ignition Switch. Inspect the machine and contact your Country Clipper dealer to resolve the issue before continuing operation.
  • Page 18 Section 4, Figure 1...
  • Page 19 Section 4, Figure 2...

  • Page 20: Blade Engagement

    Blade Engagement Danger KEEP HANDS AND FEET AWAY FROM ROTATING PARTS OR UNDER THE MACHINE. KEEP CLEAR OF THE DECK DISCHARGE AREA AND/OR BLADES WHILE OPERATING. DISENGAGE BLADES AND SHUT THE ENGINE OFF IF ANYONE ENTERS THE AREA. Danger NEVER OPERATE THE MACHINE WITHOUT THE DISCHARGE CHUTE, GRASS CATCHER, OR OTHER SAFETY DEVICES IN PLACE AND FUNCTIONING PROPERLY.

  • Page 21: Transmission Free Wheel Release

    4.6.4 Travel Speed… Vary ground speed of mower to suite the turf conditions and terrain during the year. (i.e. slowdown in tall thick grass, on slopes, wet conditions, rough terrain etc.) 4.6.5 Normal Mowing… It is recommended to cut off only 1/3 of the grass blade to maintain a healthy lawn.

  • Page 22: Mower Transportation

    4.9.3 4.9.4 Inspect Mower… Inspect mower for any loose, worn, or damaged components. Tighten, replace, or repair as required. Contact your Country Clipper dealer for parts, assistance, or to schedule a service appointment. 4.9.5 Service Mower… Thoroughly lubricate and service per maintenance schedule, Section 5.

  • Page 23: Preseason Mower Prep

    Preseason Mower Prep 4.10 When preparing the mower for a new season, reinstall the battery and perform the Pre-Operation Checklist at the beginning of this section or contact your Country Clipper Dealer to schedule a pre-season service appointment. Mower Towing 4.11...

  • Page 24: Maintenance

    • See engine owner’s manual for specific manufacture recommendations for service requirements and frequency. (Increase Service Frequency under sever operating conditions.) Contact your Country Clipper Dealer for service assistance or to schedule maintenance with the dealer. Danger SHUT OFF THE ENGINE AND WAIT FOR ALL ROTATING PARTS TO STOP. ROTATING PARTS CAN CAUSE SEVERE INJURY OR DEATH.

  • Page 25: Maintenance Introduction

    Routine removal of this build up is crucial for optimal mower performance. Some repairs will require assistance from a trained service mechanic and should not be attempted by unskilled personnel. Contact your Authorized Country Clipper Dealer when assistance is needed or to schedule maintenance at the dealership. Engine Maintenance Check Engine Oil daily or after every 4 hours of use.
  • Page 26 Engine Oil Filter Engine Oil Drain Oil Drain Valve Close Drain & Install Filter… After the oil has drained, turn the drain valve clockwise to close the 5.1.5 valve. Install a new oil filter. 5.1.6 Clean Up… Clean up any spills or drips and remove the used oil container. 5.1.7 Refill Engine Crankcase…...

  • Page 27: Grease Points

    Grease Points Country Clipper has designed your mower to minimize the required grease points. Some components utilize sealed bearings, others utilize self-lubricating bushings. However, there are a few locations that require to be greased. These are shown below. 5.2.1 Caster Wheels… The grease zerk for the front caster wheel is located on the tire rim hub.

  • Page 28: Tires

    Front Caster Tires…………….……………………… 10 to 16 PSI / 69 to 110 kPa (Recommended 12 PSI / 83 kPa) Rear Drive Tire Lug Nuts… Country Clipper recommends that the lug nut torque be checked 5.3.2 within the first 5 hrs of initial operation, thereafter every 50 hours. Repeat inspection process following the removal of tires for replacement or repair.

  • Page 29: Deck Service

    5.5.3 Electrical Fuse… Country Clipper uses two 30 Amp Fuses to protect the electrical system. The fuses are located under the seat between the seat springs. The fuses protect the electric system from a direct short to ground. Electrical System...
  • Page 30 Warning Never attempt to stand the deck up without the Cut Height Foot Pedal all the way rearward and Cut Height Pin locked in place with the . When properly done, the Rear Deck Hooks will be released from the deck hangers. Deck Belt Tension Front Step Lever...
  • Page 31 Warning Manually lifting the deck can be very strenuous. Use proper lifting techniques, lift with hips and knees (not your back). Adding a counter balance at the rear of the mower can reduce the effort. Keep bystanders clear of the area. Danger TO AVOID SERIOUS INJURY OR DEATH, KEEP HANDS, FEET, AND BODY PARTS AWAY FROM LIFT MECHANISM, DECK, AND REAR OF TRACTOR DURING LIFT TO AND FROM SERVICING...

  • Page 32: Mower Blade Service

    Mower Blade Service Mower blade sharpness should be checked daily or prior to each usage. A sharp blade in good condition is essential in obtaining an efficient quality of cut. A dull worn blade will tear the grass instead of cutting the grass, potentially leaving a brown ragged top on the grass within a few hours.
  • Page 33 5.7.6 Twisted Blade… Also check the blade for twisting when placed on the flat surface. Replace blade if twisted or distorted. 5.7.7 Blade Wear… Blades should be discarded if excessive wear, cracks, and/or distortion are present. Re-Install Blades… Install blade and bolt to spindle assembly. Torque blade bolt to 100 ft-lbs (136 5.7.8 Nm).

  • Page 34: Hydraulic Drive Service

    Hydraulic Drive Service Regular external maintenance of the Hydraulic Transaxle drives will ensure proper cooling of the hydraulic system. Maintenance should include the following: 5.8.1 Oil Level… Inspect the oil level by locating the expansion tank behind the operator seat. The oil level should be at the “Full Cold”...

  • Page 35: Standard Operation Adjustments

    Install New Filter… After all the oil is drained out, replace the filters (use part H-2567 when ordering from Country Clipper). Wipe off the filter base surface, apply a film of new oil to the gasket of the new filter and hand tighten ¾ to one full turn after the filter gasket contacts the filter base surface.
  • Page 36 Joystick Forward Tracking & Speed Adjustment (Always confirm tire pressure setting before making adjustment) 5.9.6 Locate Mower on Hard Level Surface… Locate mower on a hard level surface, engage Park Brake and shut the engine off. 5.9.7 Remove Right Side Fender… Remove Right Side Fender to access the Right Side transaxle linkage coupling nut.
  • Page 37 5.9.13 Set the Left Side Transaxle Linkage Length… Rotate the linkage exactly one full turn longer and retighten the jam nuts. Use two wrenches and make sure the ball joints on each end are aligned so that they do not bind up when moving the joystick lever to the extremes of its travel. 5.9.14 Test Drive Mower…...
  • Page 38 5.9.27 Adjust Coupling Nut… Start the engine and maintain the Twin Stick Levers in the Neutral Lock position. Rotate the Coupling Nut until the drive wheel stops turning. Turn off the engine and retighten the jam nuts. 5.9.28 Recheck Neutral Lock Position… Check to make sure Neutral Lock is adjusted as desired by positioning the Twin Stick Drive Control Levers in drive and operating forward and reverse and then reposition into the Neutral Lock position.
  • Page 39 The rear blade tip height should be equal or greater than the front blade tip height. Country Clipper recommends that the rear blade tip measure 1/8 to 1/4 inch higher than the front blade tip measurement.
  • Page 40 Factory Settings can cause cut quality issues. The deck can float up, especially when operating over rough ground.) 5.9.46 Factory Settings… Country Clipper recommends the following measurements between the Spring Anchor Tab and the Spring: 48” & 52” Deck = 1 inch 60”...
  • Page 41 Section 6… Troubleshooting Problem Cause Remedy Mower blade engagement switch is in “On” position Press switch down to “Off” position Joystick… press control lever down to “Neutral Lock ” position Drive lever(s) not in “Neutral” position Twinstick… move drive levers out to “Neutral Lock”...
  • Page 42 Problem Cause Remedy Steering linkage out of adjustment Re-adjust drive linkage Drive belt slipping or pulley damage Repair or replace drive belt or pulley Mower Operates in Bypass valves not closed completely Close Bypass valves One Direction Only or Air trapped in hydraulic system Purge transaxles Jerky When Starting Transaxle faulty...
  • Page 43 Common Cut Quality Problems Problem: Streaking Problem: Stringers Streaking is when thin strips of uncut grass are left after mowing. Stringers are sparse patches of uncut grass left behind in the Streaking commonly occurs by operator error or poor blade lawn surface.

  • Page 44: Belt Routing

    Section 7… Belt Routing XLT - Challenger 48”, 52” & 60” Deck Belt Routing Hydro Belt Routing (Viewed from ground looking up) Left Hand Hydrostatic Right Hand Hydrostatic Transmission Pulley Transmission Pulley Motor Pulley...
  • Page 45 Section 8… Maintenance Record Date Hours Service Performed...
  • Page 46 Repair Parts SERIAL RANGE: 21286001 - ________ P-13540 (Rev B 11/21)
  • Page 47 SEAT BASE & RELATED PARTS SEAT BASE & RELATED PARTS (CON’T) ENGINES ENGINE & CLUTCH MOUNTING & RELATED PARTS WIRE HARNESS & RELATED PARTS WIRE HARNESS SCHEMATIC Country Clipper Division, Shivvers Manufacturing Inc. 613 W English St. Corydon, IA 50060-0467 Ph. 641-872-2544 Fax. 641-872-1593...
  • Page 48 CHALLENGER 52" MOWER DECK (D510) {722E-002A} SERIAL RANGE: 21286001 - ________ BELT TENSION FIXED IDLER LEVER ASS'Y, FRONT (SEE PG 6) (SEE PG 7) DOUBLE IDLER ASS'Y (SEE PG 5) SPINDLE ASS'Y (SEE PG 4) FIXED IDLER ASS'Y, REAR (SEE PG 7) CHUTE ASS'Y (SEE PG 3) ITEM #...
  • Page 49 CHALLENGER 60" MOWER DECK (D510) {722D-002A} SERIAL RANGE: 21286001 - ________ SPINDLE ASS'Y (SEE PG 4) BELT TENSION LEVER FIXED IDLER DOUBLE IDLER ASS'Y (SEE PG 6) ASS'Y, FRONT (SEE PG 5) (SEE PG 7) FIXED IDLER ASS'Y, REAR (SEE PG 7) CHUTE ASS'Y (SEE PG 3) ITEM #...
  • Page 50 CHALLENGER DISCHARGE CHUTE ASS'Y (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ PART OF ITEM # 2 ITEM # PART # DESCRIPTION 643-110P CHUTE HINGE 643-135A OUTLET STIFFENER W/ DECALS, SMALL F-1009-02 WASHER, FLAT F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ F-2066 BOLT, CARRIAGE, 5/16-18 X 1", YZ, GR5 F-2148...
  • Page 51 CHALLENGER DECK SPINDLE ASSEMBLY (D510) {D-4020} TORQUE TO 75 FT/LBS SERIAL RANGE: 21286001 - ________ PARTS MARKED "* " ARE PART OF COMPLETE ASSEMBLY BLADE PART NUMBERS 52" DECK H-2883 HIGH LIFT W/O FUSION (STANDARD) H-2884 HIGH LIFT W/ FUSION H-2660 LOW LIFT H-2666 GATOR 60"...
  • Page 52 CHALLENGER DOUBLE IDLER (D510) DRIVE BELT IDLER SERIAL RANGE: 21286001 - ________ BELT TENSION LEVER (SEE PG 6) DECK ITEM # PART # DESCRIPTION 620-201P WASHER, BEARING CAP 660-039P MOUNT, DOUBLE IDLER 660-081P EXTENSION, SPRING 660-107P BELT KEEPER, A BELT 668-021P SPACER, BELT GUARD 714-183P...
  • Page 53 CHALLENGER BELT TENSION LEVER (D510) SERIAL RANGE: 21286001 - ________ ORIENTATION FOR 52" DECK ITEM # PART # DESCRIPTION 722-040P BELT TIGHTENER ARM, 52" DECK 722-044P BELT TIGHTENER ARM, 60" DECK 660-038P SPACER, 3/8" WIDE 660-184P HANDLE, BELT TENSIONER 661-015P SHACKLE F-1005-03 NUT, 3/8-16, CENTERLOCK, YZ, GR5...
  • Page 54 CHALLENGER FIXED IDLER ASSEMBLIES (D510) SERIAL RANGE: 21286001 - ________ REAR FRONT DECK DECK DECK ITEM # PART # DESCRIPTION 620-201P WASHER, BEARING CAP 660-112P BELT KEEPER, 52" DECK 660-114P BELT KEEPER, 60" DECK 660-206P SPINDLE SPACER D-3903 PULLEY, FLAT IDLER, 6" (NTN) D-3904 PULLEY, FLAT IDLER, 5"...
  • Page 55 CHALLENGER DECK LIFT ASSEMBLY (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ ONL Y PARTIAL L Y TIGHTEN UNTIL COM PL ETE ASS' Y IS INSTAL L ED (PAGES 9 -1 1 ) ITEM # PART # DESCRIPTION 720-010P CLAMP EXTENSION 720-079W WLDT, DECK LIFT, REAR...
  • Page 56 CHALLENGER DECK LIFT ASSEMBLY (D510) & RELATED PARTS (CON'T) SERIAL RANGE: 21286001 - ________ TIGHTEN BOL T AND FIRST NUT TO WEL DM ENT, THEN INSTAL L SPRING, WASHER, AND SECOND NUT (DO NOT OVERTIGHTEN) FUL L Y TIGHTEN THEN BACK OFF 1 /2 TO 1 TURN 720-099A...
  • Page 57 CHALLENGER CUT HEIGHT ASSEMBLY (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ CUT HEIGHT SUB-ASSEM BL Y (SEE DETAIL ) INSIDE VIEW OF CUT HEIGHT SUB-ASSEM BL Y, SHOWING DECAL S INCL UDES ITEM S 1 9 & 2 0 HOOK SPRING (WITH HOOK ON TOP) IN TOP HOL E - 5 2 "...
  • Page 58 CHALLENGER PIVOTING FRONT AXLE (D510) SERIAL RANGE: 21286001 - ________ & FLOOR PAN TORQUE TO 2 5 0 FT/L BS GREASE GREASE TORQUE TO 2 5 FT/L BS M AX ENSURE AXL E M OVES FREEL Y ITEM # PART # DESCRIPTION 606-303P WASHER, 10GA GALVANIZED...
  • Page 59 CHALLENGER TIRES & FRONT STEP (D510) SERIAL RANGE: 21286001 - ________ TORQUE TO 7 5 FT/L BS TORQUE TO 7 5 FT/L BS (APPL Y COAT OF GREASE) PARTS M ARKED "*" ARE INCL UDED IN ITEM # 9 FIL L CAVITY WITH GREASE ITEM # PART #...
  • Page 60 CHALLENGER FRONT PANEL (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ TWIN LEVER MODELS ONLY PART OF ITEM # 2 3 PARTS M ARKED "*" ARE INCL UDED IN ITEM # 4 TWIN LEVER MODELS ONLY BRAKE HANDLE ASSEMBLY (SEE DETAIL) BRAKE HANDLE ASS'Y ITEM #...
  • Page 61 CHALLENGER FRONT PANEL ASS'Y (D510) & RELATED PARTS (CON'T) SERIAL RANGE: 21286001 - ________ ROUTE COMMON WIRE HARNESS E-6778 TWIN LEVER ASS'Y UNDER FLANGE AND SECURE (SEE PG 21) WITH E-5842 JOYSTICK ASS'Y (SEE PG 18) FUEL TANK ASS'Y (SEE PG 17) FRONT PANEL ASS'Y (SEE PG 13) BRAKE HANDLE ASS'Y...
  • Page 62 CHALLENGER BATTERY BOX (D510) SERIAL RANGE: 21286001 - ________ SPADES MUST BE DOWN ITEM # PART # DESCRIPTION 721-030P BOX, BATTERY 721-031P CLAMP, BATTERY E-6054 SOLENOID 12VOLT E-6659 BATTERY, YPS 35 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ F-2120 FHCS, 5/16-18 X 3/4", YZ, GR5 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ F-2162...
  • Page 63 CHALLENGER BRAKE ASSEMBLY (D510) SERIAL RANGE: 21286001 - ________ BRAKE HANDL E ASSEM BL Y (SEE PG 1 3 ) ITEM # PART # DESCRIPTION 659-159P BRAKE LINK E-6692 PLUNGER SWITCH, RAIL MOUNT F-1009-01 FLAT WASHER, 1/4", YZ F-1492 RUE RING, 5/16 F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ F-2122...
  • Page 64 CHALLENGER FUEL TANK ASSEMBLY (D510) SERIAL RANGE: 21286001 - ________ KOHLER - 24" KAWASAKI - 32" KOHLER - 44" KAWASAKI - 46" IF A TANK IS REQUIRED, IT CAN ONLY BE PURCHASED AS A COMPLETE ASSEMBLY H-3081 (PARTS MARKED "* " ARE INCLUDED IN ASS'Y) ITEM # PART #...
  • Page 65 CHALLENGER JOYSTICK CONTROL (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ PART OF # 6 INSERT L INKAGE THRU INSTAL L AFTER BOL TS SL OT IN FRONT PANEL (ITEM # 1 7 ) ARE SECURED TO PANEL ITEM # PART # DESCRIPTION 625-100P...
  • Page 66 CHALLENGER JOYSTICK ASSEMBLY (D510) {714-455A} SERIAL RANGE: 21286001 - ________ PART OF # 8 PART OF # 8 SEE DETAIL APPL Y SM AL L AM OUNT OF GREASE (ITEM # 2 9 ) TO 2 FACES ON BOTTOM YOKE, SWIVEL, ASS'Y (625-169A) ITEM # PART #...
  • Page 67 CHALLENGER JOYSTICK ASSEMBLY MOUNTING (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ J OYSTICK ASS' Y (SEE PG 1 9 ) FRONT PANEL ASS' Y (SEE PG 1 3 ) TRANSM ISSION (SEE PG 2 5 ) ITEM # PART # DESCRIPTION 625-100P...
  • Page 68 CHALLENGER TWIN LEVER CONTROL (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ FRONT PANEL ASS' Y (SEE PG 1 3 ) BRAKE ASS' Y INSTAL L AFTER BOL T (ITEM # 1 0 ) (SEE PG 1 6 ) IS SECURED TO PANEL TRANSM ISSION (SEE PG 2 5 )
  • Page 69 CHALLENGER TWIN LEVER ASSEMBLY (D510) {721-086A - RIGHT SIDE} SERIAL RANGE: 21286001 - ________ {721-087A - LEFT SIDE} (RIGHT HAND SHOWN, LEFT HAND OPPOSITE) ITEM # PART # DESCRIPTION 714-074P PIN, PIVOT, TWIN LEVER 714-266P HOUSING, TWIN LEVER, R 714-269P HOUSING, TWIN LEVER, L 721-006P SPRING GUIDE, TS...
  • Page 70 CHALLENGER CONTROL PANEL (D510) SERIAL RANGE: 21286001 - ________ 714-118A - KAWASAKI 721-120A - KOHLER PART OF # 1 ITEM # PART # DESCRIPTION 721-125A CONTROL PANEL W/ DECAL E-6717 IGNITION SWITCH, 4 POSITION E-5878 HOUR METER E-6403 PTO SWITCH E-6718 KEY ASSEMBLY F-1022-26...
  • Page 71 CHALLENGER FENDER ASSEMBLY (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ PART OF #1 REMOVE KNOCKOUTS ON PLASTIC FENDERS FOR TWIN LEVER MODELS (BOTH FENDERS) CONTROL PANEL FOR JOYSTICK MODELS (SEE PG 23) (RIGHT HAND FENDER ONLY) PART OF #1 PART OF #2 PART OF # 2 BATTERY BOX...
  • Page 72 CHALLENGER TRANSMISSION ASSEMBLY (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ (L OOKING AT BOTTOM ) USE BOTTOM SL OT, TEETH TO INSIDE (ITEM # 3 ) IDL ER ARM ASS' Y (7 1 4 -2 5 6 A) ITEM # QTY PART # DESCRIPTION ITEM # QTY PART # DESCRIPTION...
  • Page 73 CHALLENGER TRANSMISSION ASSEMBLY (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ (L OOKING AT BOTTOM ) DAM PER CONNECTION DAM PER CONNECTION TO TRANSM ISSION TO FRAM E ITEM # QTY PART # DESCRIPTION 638-028P DAMPER BOLT: 5/16-18 X 3/4 721-121P BRACKET, DAMPER OFFSET, LH 721-121P BRACKET, DAMPER OFFSET, RH F-1011-02 NUT, HEX 5/16-18...
  • Page 74 CHALLENGER TRANSMISSION ASSEMBLY (D510) & RELATED PARTS CON'T SERIAL RANGE: 21286001 - ________ ROUTE HOSE THROUGH MOTOR MOUNT ITEM # PART # DESCRIPTION 721-029P PLT, TANK MOUNT F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ F-2162 FHCS, 1/4-20 X 3/4", YZ, GR5 H-2517 VENT TUBE ADAPTER H-2567...
  • Page 75 CHALLENGER SEAT BASE (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ SECURE SPRING EXTENSION CABL E (ITEM # 8 ) ITEM # PART # DESCRIPTION 721-013P PLT, SEAT MOUNT, LOW F-1009-03 WASHER, FLAT, 3/8, YZ F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ F-2129 FHCS, 5/16-18 X 1-1/2", YZ, GR5 F-2141...
  • Page 76 CHALLENGER SEAT BASE (D510) & RELATED SERIAL RANGE: 21286001 - ________ PARTS (CON'T) JOYSTICK MODELS ONLY ITEM # PART # DESCRIPTION 720-017P MOUNT PLATE, ARM REST, R 720-018P MOUNT PLT, ARM REST, L 720-071P PLT, ARM REST, LH, JS 721-061P PLATE, SPACER F-1015-15 HHCS, 5/16-18 X 1", YZ, GR5...
  • Page 77 CHALLENGER ENGINES (D510) SERIAL RANGE: 21286001 - ________ KOHLER KAWASAKI 24 HP FS730 25 HP ZT740 GROUND GROUND KAWASAKI INSTAL L ED KOHL ER INSTAL L ED APPL Y L IGHT COAT APPL Y L IGHT COAT OF NEVERSIEZE OF NEVERSIEZE (USE THROTTL E CABL E H-2 6 1 0 (USE THROTTL E CABL E H-2 6 1 1 &...
  • Page 78 CHALLENGER ENGINE & CLUTCH MOUNTING (D510) & RELATED PARTS SERIAL RANGE: 21286001 - ________ (L OOKING AT BOTTOM ) TORQUE SPEC = 5 5 -6 0 FT/L BS ORIENT CL UTCH SO THE WIRE CONNECTOR IS TOWARDS THE DISCHARGE SIDE OF M OWER SECURE CL UTCH PIGTAIL TO CL UTCH STOP TO PREVENT CONTACT WITH HYDRO BEL T...
  • Page 81 Effective: Units Retailed after October 1, 2020 Consumer Limited Warranty Country Clipper, a Division of Shivvers Mfg., Inc. will Warrant on the terms and conditions herein, that we will repair, adjust, or replace parts found by examination by the factory or by an authorized Country...
  • Page 82 Country Clipper. The servicing dealer will require a proof of purchase if the product has not been registered.
  • Page 83 General Conditions Country Clipper may change the design of its products from time to time. Nothing contained in this Warranty shall be construed as obligating Country Clipper to incorporate said design changes into previously manufactured products, nor shall said changes be construed as an admission that previous designs were defective.
  • Page 84 KAWASAKI LIMITED WARRANTY FOUR-CYCLE ENGINE Kawasaki Motors Corp., U.S.A., P.O. Box 888285, Grand Rapids, MI 49588-8285 (hereinafter “Kawasaki”) warrants to the initial purchaser of each new Kawasaki four-cycle engine purchased in any of the following regions: North, Central or South America, Caribbean, Australia, New Zealand, and all territories of the United States of America (collectively, the "Purchase Area") that it will repair or replace, free of charge, any engine parts found to be defective, under normal use and proper maintenance, for a period of thirty-six (36) months, subject to the following conditions, exclusions, obligations and limitations.
  • Page 85 EMISSION CONTROL SYSTEM WARRANTY STATEMENT the State of California’s emissions regulations. Part I: United States and Canada Your Warranty Rights and Obligations engine at no cost to you including diagnosis, parts, and labor. Your emission control system may include such parts as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included may be hoses, connec Warranty Coverage whose failure would increase the emissions of any regulated pollutant.
  • Page 86 General Emissions Warranty Coverage free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to the part as described in Kawasaki’s applica saki warranty station. any such part fails during the warranty period, the part will be repaired or replaced by Kawasaki at no charge to the owner provided the repair or replacement is performed at a warranty station.
  • Page 87 LIMITED WARRANTY, CONFIDANT Kohler Co. warrants to the original retail consumer that each new engine will be free from manufacturing defects in materials or workmanship for the applicable coverage period as set forth below, beginning on date of purchase; provided the engine is operated and maintained in accordance with Kohler Co.’s instructions and manuals. Type of use Residential 3 Years...
  • Page 88 B) CALIFORNIA AND FEDERAL EXHAUST AND EVAPORATIVE EMISSIONS CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board, US Environmental Protection Agency (“US EPA”) and Kohler Co. are pleased to explain the exhaust and evaporative emissions control systems warranty on your 2018-2020 Small Off-Road Engine (“SORE”) and engine powered equipment as applicable.
  • Page 89 PARTS COVERED BY WARRANTY Listed below are the parts (if equipped) covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. •...
  • Page 90 All Models Warranty Policies and Procedures BLN-50225_P18 Revision March, 2019...
  • Page 91 Hydro-Gear Warranty Policies and Procedures ® Limited Warranty BLN-50225_P18 March, 2019 Hydro-Gear Limited Partnership (hereinafter referred to as "Hydro-Gear") warrants to the original equipment manufacturer (OEM), authorized distributor, or authorized servicing dealer purchasing a Hydro-Gear product or replacement parts (such purchaser is hereinafter referred to as "Buyer") that the product or replacement parts will be free from defects in material and workmanship at the time of shipment from Hydro-Gear, and will conform to such drawings and specifica- tions as are applicable to the product or replacement parts under Hydro-Gear's sales agreement with Buyer.
  • Page 92 All Models Hydro-Gear Warranty Policies and Procedures ® Warranty Periods BLN-50225_P18 March, 2019 Note: Proof of purchase must be available if requested to assist in determining commencement of the warranty period. If proof of purchase is not available, the Hydro-Gear Serial Number will determine the commencement of the warranty period.
  • Page 93 Warranty Claims Procedure A. Claims submitted to Hydro-Gear will require a Hydro-Gear, OEM, Outdoor Power Equipment Institute (OPEI) or equivalent claim form from the servicing dealer. Dealer claims must provide all pertinent information typical on OPEI claim forms, i.e.., owner's name, servicing dealer, Hydro-Gear Serial Numbers, symptoms, repair date, and type of use, etc.
  • Page 94 Battery Warranty Terms The OE Interstate Battery will be covered under a free replacement warranty for 6 months. This warranty period will begin the date the lawnmower is purchased by the end user. Battery Warranty Process If you have a lawnmower that won’t start, please complete these steps before calling for a warranty replacement. Completion of these steps before calling will expedite the warranty process.
  • Page 95 SPECIFICATIONS CHALLENGER – Joystick Steering MODEL 2552KOJ-D510 2560KOJ-D510 2452KAJ-D510 2460KAJ-D510 Engine 25 H.P. Kohler ZT740 (747cc) 24 H.P. Kawasaki FS730 (726cc) Hydrostatic Hydrogear ZT-3400 w/RTN Spring Transmissions Steering Control Single Joystick Fuel Capacity 7 Gallons Tires, Rear 22x11-10 Tires, Front 13X6.5-6 Turning Radius Zero-Turn...
  • Page 96 PRODUCT MANUAL Country Clipper Division Shivvers Manufacturing, Inc. 613 W. English St. Corydon, IA 50060-0467 Ph. 641-872-2544 Fax. 641-872-1593 P-13540 (Rev B 11/21)

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