Country Clipper Challenger D520 Product Manual
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Country Clipper Challenger D520 Product Manual

Country Clipper Challenger D520 Product Manual

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SERIAL RANGE: 24266001 - ________
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
Hydro-Gear Warranty
Battery Warranty
Additional Information
Country Clipper Product Specifications
Notes/Service Records
P-13706 (Rev B)

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  • Page 1 SERIAL RANGE: 24266001 - ________ 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 Hydro-Gear Warranty Battery Warranty Additional Information Country Clipper Product Specifications...

  • Page 2: Mower Information

    CHALLENGER Service Parts & Information 52” Blade  High Lift            High Lift Fusion  Gator  Low Lift  1  H‐2883 H‐2884  H‐2666  H‐2660  60” Blade  High Lift            High Lift Fusion  Gator  Low Lift    H‐2885 H‐2886  H‐2667  H‐2661    52” Deck Belt   D‐3951  60” Deck Belt   D‐3776‐W    Transaxle Drive Belt  D‐3769    Transaxle  Hydro‐Gear ZT‐3400  Transaxle Hydraulic Oil  20W‐50 | API SL  4 Quarts  Transaxle Oil Volume  (2 quarts per Transaxle) ...

  • Page 3: Safety Instructions And Operation

            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   ...

  • Page 5: Section 1... Basic Information

    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.  Country Clipper factory fills the engine with 10W‐30 conventional engine oil (API Service Class SL or  Higher). Consult engine owner’s manual for specific oil recommendations.  Typically, 2 quarts of oil are required per engine oil change with filter. Consult engine owner’s manual for  specific oil recommendations and capacity.  Country Clipper uses 20W‐50 conventional engine oil to fill the hydraulic transmission drive. (API Service  Class SL or Higher)  Country Clipper recommends NLGI #2 grease for grease points.  Warranty Registration The Warranty Registration must be completed within 30 days from date of purchase to validate the warranty. As  the new equipment owner, you are expected to confirm that the form is completed and documentation  forwarded to Country Clipper Mfg. at the time of delivery. Warranty registration should be completed by the  selling dealership either by submitting through the online registration site or mailing the registration card to  Country Clipper.  The warranty is nontransferable.  Model/Serial Number Your model & serial number can be located on the frame rail just above the grass discharge side of the deck.   These numbers will be needed when ordering service replacement parts.    Model & Serial Number Tag     Parts/Service Genuine Country Clipper replacement parts must be used on your mower for warranty consideration.  Replacement parts are available through your Country Clipper Dealer.  Remember to provide the following  information from your mower when ordering service parts:  1. Correct Serial Number  2. Correct Model Number  3. Correct Part Number  Warranty repair and service must be performed through your Country Clipper Dealer. Visit  www.countryclipper.com to locate your nearest dealer. ...
  • 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.  Before operating, adjusting, or servicing your Country Clipper mower read, understand and follow all  instructions in this manual including the engine owner’s manual.  Keep hands and feet away from rotating parts or under the machine. Keep clear of the deck discharge  area and/or blades while in operation. Turn the engine off before servicing these areas.  Disengage blades when not mowing. Shut off the engine and wait for all rotating parts to stop prior to  cleaning, inspecting, servicing, removing grass catcher, and/or unclogging the discharge chute.  Always remain seated during operation of the mower. If equipped with Roll Over Protection Structure  (ROPS) and in the upright position, always buckle yourself in the seat.  Mower must be operated by responsible adults with the proper instruction and training on safe  operation.  Clear area to be mowed of debris that could be propelled by the blades such as rocks, wire, toys, sticks,  etc.  Maintain a safe distance from people and pets prior to and during operation of the mower.  Disengage  blades and shut the engine off if anyone enters the area.  Never allow passengers.  Do not mow in reverse unless absolutely necessary. Always look down and behind before and during  backing up.  2.10 Never direct mower discharge toward people or animals. Avoid directing discharge material toward walls  or obstructions as material may ricochet back toward the operator. Disengage blades when crossing  gravel surfaces.  2.11 Never operate the machine without the discharge chute, grass catcher, or other safety devices in place  and functioning properly. Periodically check for signs of wear or deterioration and replace as needed.  2.12 Slow down during turns.  2.13 Know the location and operation of all controls; especially brake operation and how to disengage the  mower blades.  2.14 Speed and/or direction of travel is affected instantly by movement of drive control lever(s). Avoid rapid  change of direction and stroke of the drive control lever(s). ...

  • Page 7: Slope Operation

    Slope Operation Operation on slopes, hills, and/or embankments is a key factor that can cause loss of control or tip over accidents  that can result in severe injury or death. Operation on all slopes requires extra caution. Country Clipper  recommends the operator survey the slope and terrain conditions prior to operating on or near a slope.  Prudent  discretion and judgement should be exercised to ensure safe operation. Country Clipper mowers are designed to  maximize stability but as with all machines there are limitations. Grass, soil, and weather conditions along with  the slope and terrain impact the maximum slope that can be mowed. A slope should be evaluated prior to each  mowing to determine if conditions have changed that would lead to un‐safe operation.  Never operate on a slope  greater than 15 degrees.  2.24 Back‐up and drive down slopes, not across the face of a slope.  2.25 Avoid holes, ruts, bumps, rocks, or other hidden hazards. Uneven terrain could result in loss of control or  overturn of the machine.  2.26 Avoid mowing on wet grass; the drive tires could lose traction.  2.27 Reduce speed and use gradual movements to start, stop and maneuver the mower.  2.28 To prevent loss of control on a slope avoid sharp turns, sudden changes in direction, and sudden stops  and starts. If tires loose traction, disengage the blades and proceed slowly straight down the slope.  2.29 If equipped with a grass catcher or other attachment use extra care; they can affect the stability. Avoid  using on steep slopes.  2.30 Do not try to stabilize the machine by putting your foot or hand on the ground.  2.31 Do not mow or drive near drop‐offs, ditches, or embankments; sudden roll‐over could occur if a wheel  goes over the edge.  2.32 Avoid mowing slopes that have rocks, water, cliffs, and roadways at the bottom.    Children Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to  the machine and the mowing activity. Never assume that children will remain where you last saw them.   2.33 Keep children out of the operating area and under the watchful care of a responsible adult other than the  operator.  2.34 Do not carry children, even with the blade(s) shut off. Children could fall off and be seriously injured or ...

  • 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; additional weight may cause loss of traction and control. 2.48 Do not attempt a zero‐turn with a towed implement. Service (Safe Handling of Gasoline) Use extreme caution when handling gasoline to avoid personal injury and/or property damage. Gasoline is very  flammable and gasoline vapors are explosive.        2.49 Gasoline vapors ignite easily; extinguish all ignition sources prior to handling. (i.e. cigarettes, cigars, pipes,  open flames, spark sources, etc.)  2.50 Only use approved gasoline containers. 2.51 Never remove gas cap or add fuel with the engine running. 2.52 Allow engine to cool before refueling. 2.53 Never refuel inside a building or other confined space such as an enclosed trailer. 2.54 Do not store machine or fuel container near open flames or source of ignition; water heaters, furnace,  space heater, etc.  2.55 Remove gas powered equipment from the truck or trailer and refuel equipment on the ground.  If not  possible, use a portable container rather than gasoline pump nozzle.  2.56 Never fill gasoline containers inside a vehicle or on a truck or trailer bed with a plastic liner. Place  container(s) on the ground away from vehicle before filling.  2.57 Keep fuel nozzle in contact with the rim of the fuel tank at all times until re‐fueling is complete. ...

  • Page 9: Safety Interlock System

    2.74 Never allow untrained personnel to service machine. Understand service procedures before doing work.  2.75 Keep debris and grass off the mower to prevent premature parts failures or fires.    Safety Interlock System Your Country Clipper mower is equipped with a safety interlock system. This system is integrated into the  operator controls and seat to prevent serious injury or death to the operator, bystanders, or property damage.  Proper operation of this system is critical and should be checked frequently.  Note: operator must be seated  properly on the mower during the test and the engine should be previously warmed up to operating  temperature.  Joystick Models… Neutral Lock is when the Joystick Drive Control Lever is in the “Down” position.  Twin Stick Models… Neutral Lock is when both Twin Stick Drive Control Levers are in the “Out” position.  2.76 The Deck Engagement Switch must be disengaged before the engine will start.  2.77 The Drive Control Lever(s) must be in the Neutral Lock position before the engine will start.  2.78 The engine will stop if the Deck Engagement Switch is engaged when the operator leaves the driver’s seat.  2.79 The engine will stop if the Drive Control Lever(s) are not in the Neutral Lock position when the operator  leaves the driver’s seat.  2.80 The engine will stop if the Park Brake is engaged and the Drive Control Lever(s) are not in the Neutral Lock  position.  2.81 The engine will stop if the Park Brake is engaged and the Deck Engagement Switch is engaged.  Do not operate mower if any of these tests fail to produce the results indicated. Contact your Country Clipper  dealer to troubleshoot and resolve the issue.    Roll Over Protection Structure (ROPS) This mower is equipped with a factory certified Roll Over Protection Structure (ROPS). The rules listed below must  be adhered to. When used correctly, the ROPS can dramatically decrease fatality rate in the instance of a roll‐over.  2.82 Periodically ensure the bolts that attach the ROPS to the mower are securely fastened. ...

  • Page 10: Safety Decals

    Danger …Denotes immediate hazards that WILL result in severe injury or death. Warning …Denotes a hazard or unsafe practice which COULD result in severe personal injury or death.   Caution …Denotes a hazard or unsafe practice which COULD result in minor or moderate personal injury.  ...
  • Page 11 P-13593… ROPS Safety – If ROPS must be lowered for operation, DO NOT wear seat belt and drive with caution. P-13751… CAUTION – Safety Decal Replace Safety Decals when missing or illegible. Contact your Country Clipper Dealer or Country Clipper for free replacement.

  • Page 12: Control Descriptions

    Section 3… Controls Your Country Clipper mower has a variety of controls and switches that are used to operate and adjust key  operational parameters of the mower.  Make sure you become familiar and proficient in the use of these controls.  A proficient understanding of the function of these controls will assure the operator’s confidence and safety  during operation and servicing the mower.        3.7  3.6  3.5  3.4  3.1  3.3  3.2  Ignition Switch  Hour Meter  Blade Engagement Switch  Joystick Drive Control Lever   Throttle Control Lever  Twin Stick Drive Control Lever  Choke Push‐Pull Control         3.10      3.11      3.12      3.13  3.9      3.8  3.15   ...

  • Page 13: Control Decals

    connected to the key switch; turn the key counterclockwise to the “Run + Accessory” position to power  the accessory.  Turn switch to “Off” position to shutoff engine and any 12‐volt accessory connected to  the key switch.  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.  Throttle Control Lever: Connected to the engine throttle control by a cable. Move the throttle lever  generally forward to increase engine rpm and rearward to decrease engine rpm.   Choke Push‐Pull Control: Connected to the engine choke control by a cable. Pull the choke knob up to  assist starting a cold engine.  Push knob down after engine has started.    Hour Meter:  The hour meter records accumulative time while the engine is running.  Joystick Drive Control Lever: Connected to the drive transaxles to translate the control lever movement  to forward, reverse, and turning motion of the mower.  Twin Stick Drive Control Levers: Connected to the respective drive transaxle for each side to translate  the control lever movement to forward, reverse, and turning motion of the mower.  Park Brake Lever: When the lever is pulled up the brake is applied on both transaxles.  Push down to  release.  Cut Height Selector Plate & Pin: Used to set the cut height of the deck.  3.10 Transport Release Latch: Used to engage or bypass the deck transport position.  3.11 Cut Height Foot Pedal: Used to raise and lower the cutting deck.    3.12 Seat Suspension Adjustment: Used to adjust the seat suspension per the operator comfort.  3.13 Seat Slide Lever: Used to adjust the seat fore or aft for comfort.  3.14 Graduated Sight Gauge: Visually Indicates the fuel fill level.  3.15 Seat Recline Lever: Used to adjust seat back recline level.  Control Decals               P-13437… Transport Latch – Lock position will P- 11382…...
  • Page 14                     P-13477… Deck Height Position – Used as a relative reference of the cutting blade height above the ground surface. P-13481… Throttle Control Position, Idle RPM to Full Throttle      ...

  • Page 15: Section 4... Start Up & Operation

    Section 4… Start Up & Operation Warning Never allow untrained people or children to operate the mower. Do not operate the mower with faulty, missing or maladjusted components. 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 16: Starting The Engine

    Neutral Lock position while the engine is running and the Parking Brake is released, immediately turn the ignition switch to “OFF” and set the Parking Brake. The Drive Control Neutral Lock position and /or the Transmission Linkages require adjustment as outlined in the Maintenance section or by contacting your Country Clipper Dealer.

  • Page 17: Stopping The Engine

    If mower cutting blades continue to rotate longer than 7 seconds, adjustment is required. Contact your Country Clipper Dealer for proper adjustment. Roll Over Protection Structure (ROPS) Proper use of the ROPS along with the seat belt is effective in reducing injuries in the event of an overturn ...
  • Page 18 4.3.1 The two‐post ROPS can be folded down by removing the Cotter Pins and pulling out the T‐Handle  Clevis Pins.  This should only be done to operate the mower under low hanging tree limbs or other  obstructions. Additionally, this may be required when loading the mower in an enclosed trailer.  NOTE: Minimize the chance of injury or death from a rollover incident by:  Warning Substitution of mounting hardware, seat belt, etc., with components not equal or superior to the original certified components will void the certification and will reduce or eliminate protection for the operator in the event of a roll-over. Warning Use of the ROPS in the “folded”...

  • Page 19: Mower Driving Operation

    OR DEATH. Important Until the operator is familiar with their Country Clipper Zero Turning Radius Mower, they should follow these recommendations: Disengage the mower blades. Go very slowly (throttle engine rpm down to ½ throttle or less) until thoroughly familiar with the machine. Keep away from fences, buildings, and other obstructions.
  • Page 20 Switch, shut off the Blade Engagement Switch, place the Drive Control Lever(s) in the Neutral Lock position, set the Parking Brake, and remove the key. Inspect the mower and contact your Country Clipper dealer to resolve the issue before continuing the operation.

  • Page 21: Deck Cut Height Adjustment

    Deck Cut Height Adjustment The Deck Cut Height adjustment is adjustable in ¼ inch increments from 1 ½ to 5 inches to achieve your  desired cut height. The Transport Latch is a two‐position latch; in the Lock position the deck will lock in  the transport position when raised with the Cut Height Foot Pedal, in the Un‐Lock position the deck will  not lock in the transport position when raised to the transport position by the Cut Height Foot Pedal.   4.5.1 Transport Latch in Lock Position…With the deck locked in the transport position insert the Cut  Height Pin to the desired height. Press the Cut Height Foot Pedal to lift the deck then lift the  Transport Latch straight up and slowly allow the deck to lower until the weight of the deck is  supported by the Cut Height Pin. Release the Transport Latch back to the Lock position. The next  time the deck is raised to the transport position it will lock in place.  4.5.2 Transport Latch in Un‐Lock Position… In the un‐lock position, the deck won’t latch in the  transport position.  To change the cut height, press the Cut Height Foot Pedal to lift the deck.  While holding the deck up insert the Cut Height Pin to the desired height. Slowly allow the deck to  lower until the weight of the deck is supported by the Cut Height Pin.    Transport Latch Transport Latch (Locked Position) (Unlocked Position) Cut Height Pin Cut Height Cut Height Cut Height Pin Foot Pedal Foot Pedal...
  • Page 22 Section 4, Figure 1...
  • Page 23 Section 4, Figure 2...

  • Page 24: 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 25: Transmission Free Wheel Release

    4.7.4 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.)  4.7.5 Normal Mowing… It is recommended to cut off only 1/3 of the grass blade to maintain a healthy  lawn. When mowing an area for the first time it is recommended to cut the turf slightly higher to  avoid scalping uneven terrain and to avoid unseen obstacles in the lawn. If the grass is taller than  6 inches it may require mowing twice to get the desired quality of cut.  4.7.6 Turf Growth Rate… Turf grows at different rates during the seasonal growing period. Turf usually  experiences the greatest growth rate from early Spring to the start of Summer. During this period  the grass may require more frequent mowing to maintain the desired appearance. As you move  into Mid‐Summer, less frequent mowing may be required. If regular mowing intervals cannot be  maintained; mow at a higher cut height and then come back a couple days later and mow at the  desired cut height.  4.7.7 Alternate Cutting Direction… Always alternate the mowing pattern to keep grass blades growing  straight and to disperse grass clippings evenly throughout the lawn.  4.7.8 Keep Blades Sharp… Dull blades and improperly sharpened blades can cause cut quality issues.   See Mower Blade Service for information and details on the proper maintenance of blades.  Warning Never work with blades while engine is running and/or blade engagement switch is in the “on” position. Mower blades are sharp. Wear gloves or wrap the blade before handling and servicing them.

  • Page 26: Mower Transportation

    Mower Transportation When transporting the mower from one location to another via a transport vehicle, follow the proceeding  guidelines.  4.9.1 Raise Deck and Latch in Transport… Depress the cut height foot pedal to raise the deck into  transport position and secure the transport latch into the lock position.  Warning Caution should be exercised when loading and unloading a mower on a trailer or transport vehicle. Depending on the trailer or transport vehicle; the ramp slope could cause loss of control or tip over. Use full width ramps for loading and unloading a machine for transport. 4.9.2 Load on Transport Vehicle… Throttle the engine back to approximately ½ throttle and proceed up ...
  • Page 27 4.12.1 Max Pulling Weight… The recommended maximum pulling capacity is 200 lbs.  4.12.2 Max Tongue Weight… The recommended maximum tongue weight is 35 lbs.  Warning Use extreme caution when towing on slopes; additional weight may cause loss of traction and control. Minimize travel speed to assist in maintaining control of towed implement. Warning Do not attempt a zero-turn with a towed implement.  ...

  • Page 28: Section 5... Maintenance

    Use of the appropriate Personnel Protective Equipment (PPE) is required. Important This listed maintenance schedule is a general minimum guideline. If mower isn’t functioning as intended, perform necessary maintenance or repairs. Contact a Country Clipper Dealer as necessary. Maintenance Schedule  ...

  • Page 29: Maintenance Introduction

    Danger GASOLINE IS EXTREMELY FLAMMABLE AND ITS VAPORS CAN EXPLODE IF IGNITED. STORE GASOLINE ONLY IN APPROVED CONTAINERS, IN WELL VENTILATED, UNOCCUPIED BUILDINGS, AND AWAY FROM SPARKS OR FLAMES. SPILLED FUEL COULD IGNITE IF IT COMES IN CONTACT WITH HOT PARTS OR SPARKS FROM IGNITION. Caution When performing maintenance or service operations that require raising the mower off the ground or removing the tires, DO NOT rely entirely on a hydraulic or mechanical Jack to...

  • Page 30: Engine Maintenance

    Warning Electrical shock can cause injury. Do not touch wires while engine is running. Warning Wear the appropriate Personal Protective Equipment (PPE) when servicing the mower. It is required that the servicing personnel wear protective eyewear, hearing protection, hand protection and foot protection. Engine Maintenance Check Engine Oil daily or after every 4 hours of use. Refer to the manufacture’s engine manual for the ...

  • Page 31: Grease Points

    Other Maintenance    5.1.9 Air Filter… Check the engine air filter before each use.  Examine for dirt and debris build‐up on the  filter.  Replace as required.  Follow the engine manufacture’s recommendations.   5.1.10 Remove Air Filter… Remove air cleaner cover and filter element from mower.   5.1.11 Install Filter… Install a new filter and reinstall the air cleaner cover.  Check to make sure the air  cleaner cover sealed and is secure.  5.1.12 Check Air Cleaner Assembly… Check all fittings and clamps periodically for tightness and inspect  hoses for holes or cracks.  Make sure there is no path for dirt ingestion into the engine.   5.1.13 IMPORTANT… Do not operate engine without the air filter in place. Do not clean the filter  element, replace with a new filter only. Improper cleaning of used air filter elements can get dust  on the inside of the filter causing dirt ingestion and engine failure.  5.1.14 Fuel Filter… Refer to engine owner’s manual for schedule and procedure for replacing.  5.1.15 Spark Plugs…  Refer to engine owner’s manual for schedule and procedure for replacing.  5.1.16 Engine Cleaning… Proper engine cooling is essential. To prevent overheating, clean screens,  cooling fins, and other external surfaces of engine.  See engine owner’s manual for specific  requirements.     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.  There is a zerk located on each caster wheel.   Re‐lubrication should be at a rate of 10 pumps  of NLGI #2 grease every 50hrs or annually.   ...

  • Page 32: Tires

      5.2.3 Caster Brake… Disassemble, clean and apply a   liberal film of grease between O‐ring and top   bearing.  Reassemble and set locknut until   desired rotational force is obtained.    Locknut     Drive   Washer CASTER BRAKE ADJUSMENT     If caster does not remain stationary when lifting   the   D eck up to service position… Tighten Locknut.    DO  NOT OVER TIGHTEN.   Caster If caster has excess rotational drag during normal   operation… Loosen Locknut.    DO NOT COMPLETELY DISENGAGE LOCKNUT.  O-ring  If proper rotational force of caster cannot be  obtained with slight adjustments of the Locknut,  Bearing disassemble, cleaning and re‐greasing of the caster   brake O‐ring is required.        Note:     Tighten Locknut so it takes 40 – 60 IN/LBS to rotate the caster.  Loosen or tighten locknut until this is achieved.    After 5 hours of service, inspect and adjust as necessary.  After 100 hours or annually, clean and re‐grease. ...

  • Page 33: Belts

    If this occurs while operating the mower, place the Drive Control Lever(s) in Neutral Lock position, set the Park Brake, and turn the engine off. Inspect machine for cause and contact your Country Clipper dealer to remedy the issue before continuing Electrical System Your Country Clipper mower is a 12‐volt, negative ground system. ...

  • Page 34: Deck Service

    Deck Service Your Country Clipper mower has been designed with a Stand‐Up  Deck feature to allow you access to the underside of your deck for  cleaning and routine maintenance. There are two different  procedures to stand up the deck depending on how your mower is  equipped; Manual Lift or Powered Lift. All 52” & 60” decks models  come standard with the Manual Lift option. The Powered Lift option  can be installed on the 52” & 60” deck models as an optional  accessory.    Manual Deck Lift Procedure (Service Position)    5.6.1 Step 1. Position The Mower… Standing up the deck must be done on a hard level surface. When  positioning the mower on the hard surface, back up the mower so the Front Caster Tires swing  away from the deck. Turn the engine off, and remove the key.  5.6.2 Step 2. Transport Latch… Move Transport Latch forward to the lock position and push the Cut  Height Foot Pedal forward and lock the deck in the transport position.      Transport Latch   (Unlocked Position)                   5.6.3 Step 3. Lower Deck to Ground Surface… Remove the Cut Height Pin from the Cut Height Selector  plate. Push the Cut Height Foot Pedal Forward and move the Transport Latch to the unlock  position. Lower the deck so it is resting on the ground surface.  5.6.4 Step 4. Lock Deck in Lowest Position… Step off the mower platform. Push the Cut Height Foot ...
  • Page 35                                     Cut Height   Foot Pedal               Clutch   Drive Pulley         Front Step Deck Belt Tension Lever  ...
  • Page 36 Warning Do not attempt to flip deck without releasing deck belt from clutch pulley on the engine or from the center spindle assembly pulley!   Warning     Manually lifting the deck can be very strenuous. Use proper lifting techniques, lift with hips and  ...

  • Page 37: Mower Blade Service

    Manual Deck Lowering (Mowing Position)  5.6.8 Step 1. Lower Deck… While holding the lift handle, push the rear of the deck rearward towards  the drive tires, lower deck until it rests on the ground surface.  5.6.9 Step 2. Un‐Lock Deck from Lowest Position… Push the Cut Height Foot Pedal to the most  rearward position and remove the Cut Height Pin in the Cut Height Selector plate. (Note: This  takes a fair amount of effort; a ½ inch breaker bar can be used in the Cut Height Foot Pedal to  reduce the effort required.)  Warning The Cut Height Foot Pedal is a Stored Energy Device when being locked down to stand up the deck and during the unlock process. Use extreme caution when performing this procedure. Keep bystanders clear of the area.
  • Page 38 5.7.2 Blade Removal… Remove the 5/8‐inch blade bolt and washer using a 15/16‐inch wrench.  The  blade spindle can be held from turning by using 1 ½ inch wrench on the blade driver above the  blade or by blocking the blade rotation with a block of wood.  5.7.3 Blade Sharpening… The blades can be sharpened with a grinder or touched up with a file. Note  the angle of the cutting edge and try to maintain when sharpening.      5.7.4 Blade Balance… Check the blade balance after sharpening. There are a variety of blade balancing  techniques and commercial blade balancing tools available through a majority of hardware supply  stores. If the blade is out of balance, true it up before re‐installing.   5.7.5 Blade Straightness… Lay the blade on a flat surface and check to make sure both cutting edges  are in the same cutting plane. Replace blade if warped or distorted.        5.7.6 Twisted Blade… Also check the blade for twisting when placed on the flat surface. Replace blade if  twisted or distorted.      5.11...

  • Page 39: Hydraulic Drive Service

      5.7.7 Blade Wear… Blades should be discarded if excessive wear, cracks, and/or distortion are present.    5.7.8 Re‐Install Blades… Install blade, washer, and bolt to spindle assembly. Torque blade bolt to 100  ft‐lbs. (136 Nm).  DANGER FAILURE TO CORRECTLY TORQUE THE BLADE BOLT MAY RESULT IN THE LOSS OF THE BLADE WHICH CAN CAUSE SERIOUS INJURY OR DEATH.   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… Check oil level by removing the top port plug (see figure below). The oil level should be  at the bottom of each transaxle’s top port opening. If oil is required, remove the fill port plug and  add oil until the oil level just reaches the top port. Then install top port plug and fill port plug into ...
  • Page 40 Caution On level ground the mower should track straight when the Joystick Drive Control Lever is shifted straight forward. If the mower veers left or right, make proper adjustments as outlined or contact a Country Clipper dealer for assistance. 5.13...

  • Page 41: Standard Operation Adjustments

    Standard Operation Adjustments Periodically adjustments may be required to maintain certain operating parameters or for operator  preference. The following section will provide details on how to make these adjustments.    27/32” Parking Brake Adjustment  Compression Spring   5.9.1 Disengage Parking Brake… Push the Parking  Brake Lever down to disengage the Parking  Brake.  5.9.2 Adjustment Nut… Adjust the Adjustment Nut  until the Compression Spring contacts both  the Adjustment Nut and the Brake Stud.  5.9.3 Engage Parking Brake… Pull the Parking  Brake Lever up to engage the Parking Brake.  5.9.4 Compression Spring… The Compression  Spring should be compressed to  Adjustment Parking Brake approximately 27/32”.  Brake Stud Link Rod 5.9.5 Adjust Both Linkages… Repeat the  adjustment on the other side.    Joystick Forward Tracking & Speed Adjustment  (Always confirm tire pressure setting before making adjustment)    5.9.6 Locate Mower on Hard Level Surface… ...
  • Page 42 nut until the transaxle control plate just contacts the end of the adjustment slot.  (This may  require the help of a second person).   5.9.11 Set the Right‐Side Transaxle Linkage Length… Rotate the coupling nut exactly one full turn to  lengthen the right‐side linkage, retighten the jam nuts.  When retightening, make sure that the  ball joints on both top and bottom are aligned so that they do not bind up when moving the  Joystick Drive Control Lever to the extremes of its travel.  5.9.12 Shorten Left Side Transaxle Linkage… Hold the  Joystick Drive Control Lever firmly in the full  Left Side Transaxle Linkage speed forward position, shorten the linkage to  the left side transaxle by rotating the coupling  Left Side Transaxle Jam Nut nut until the transaxle control plate just  contacts the end of the adjustment slot (this  Coupling Nut may require the help of a second person).  5.9.13 Set the Left Side Transaxle Linkage Length…  Jam Nut 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.  Transaxle Adjustment Slot Control Plate 5.9.14 Test Drive Mower… Operate mower at full ...
  • Page 43 5.9.22 Lower Drive Wheels to The Ground… Lower drive wheels to the ground surface and reinstall  Fender Skirt.    Right Side Transaxle Twin Stick Neutral Lock Adjustment  Jam Nut 5.9.23 Set Neutral Lock Position… If the mower  moves or travels with the engine running  Coupling Nut and the Twin Stick Drive Control Levers in  the Neutral Lock Position; the Neutral  Jam Nut Lock position needs adjusted. Each Twin  Stick Drive Control Lever is linked directly  to a Transaxle Control Plate via an  Adjustment Slot adjustable length ball joint rod‐end  linkage.   5.9.24 Drive Wheels Off Ground … Shut the  Transaxle engine off and raise the rear drive wheels  Control Plate off the ground, secure mower on blocks  or jack stands.  5.9.25 Loosen The Coupling Nut… Determine the side that needs adjustment. Locate the Coupling Nut  on the linkage. Use two wrenches and loosen the Jam Nuts; spin Jam Nuts back a couple of turns.    (Note: bottom Jam Nut has left‐hand threads.)  5.9.26 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 ...
  • Page 44 Twin Stick Handle Adjustments  5.9.32 Twin Stick Handle Height Adjustment… The length or height of the handles has two available  positions. Mount the handles in the upper set of holes or the  lower set of holes for maximum operator comfort.  5.9.33 Twin Stick Fore & Aft Adjustment… Adjust the handles fore  and aft position before tightening the handle mounting bolts.   The fore/aft position of the handles should be set such that  they are aligned with each other while in the neutral position.  5.9.34 Twin Stick Handle Gap Adjustment… Adjust the gap between  the handles by turning in or out the Gap Adjustment Screw on  Handle the handle base.  There should be about one inch gap between  Mounting the ends of the operator handles when they are “in” (driving  Holes position).  Make the height of the handles the same, or in line  with each other.  This may require adjusting both sides.      Fore/Aft Adjustment Slot Gap Adjustment Screw 5.17...
  • Page 45 Deck Leveling Adjustment  (Note: The deck has been factory leveled. If leveling is required follow this procedure.)  5.9.35 Locate Mower on Hard Level Surface… Locate mower on a hard level surface, engage Park Brake  and shut the engine off.  5.9.36 Confirm Tire Pressure… Set the tire pressure on each of the four tires to 12psi (83kPa). (Make  sure all four tires are equal).  5.9.37 Set Cut Height To 3 Inches… Set the deck cutting height to 3 inches and rotate the two outside  blades by hand until one end of each outside blade points forward (toward the front of tractor).   3.000” 5.9.38 Ground to Blade Tip Measurement… Measure from the ground to the front blade tip on each  outside blade of the deck.  These measurements should be approximately 3 inches and within 1/8  inch of each other.  (Note: To simplify this measuring, an optional Blade Measuring Tool, part number 629‐374A is  available from your local Country Clipper Dealer).  (Important: Do not attempt to set the deck cut height higher or lower than specified. This could  cause failure of the deck drive system.)  5.9.39 Front Deck Height of Cut Adjustment… If adjustment is needed; turn the Height of Cut Adjusting  Bolt clock‐wise to raise the deck, turn the Height of Cut Adjusting Bolt counter clock‐wise to lower  the deck so the blade height is approximately 3 inches. Make sure the left and right‐side  measurements are within 1/8 inch from one side to the other.  5.18...
  • Page 46 5.9.40 Rear Blade Tip Measurement (Deck Rake) … Measure the rear blade tip height from the ground  on both sides of the deck. 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.  5.9.41 Rear Deck Height of Cut Adjustment… If adjustment is needed; turn the Height of Cut Adjusting  Bolt clockwise to raise the deck, turn the Height of Cut Adjusting Bolt counter clockwise to lower  the deck. Make sure the left and right‐side measure approximately within 1/8 inch from one side  to the other.  5.9.42 Recheck Deck Blade Tip Measurements… Recheck all measurements. Make adjustments as  required.  (NOTE: Deck should be hanging equally on all 4 Deck Hangers when properly adjusted.)  5.9.43 Set Deck to Desired Cut Height… Set deck to the desired operation cut height position.    Deck Lift Assist Spring  5.9.44 Deck Lift Assist Spring… The Deck Lift Assist Spring is used to reduce the effort required to raise  and/or lower the deck.  Changing the length of the spring stretch will have a direct effect on this  effort. Reducing the gap between the Spring Anchor Tab and Deck Lift Assist Spring will decrease  the effort required to lift the deck. Increasing the gap will increase the effort.  (Note: Reducing the gap between the Spring Anchor Tab and Deck Lift Assist Spring beyond the  Factory Settings can cause cut quality issues. The deck can float up, especially when operating  over rough ground.)  5.9.45 Factory Settings… Country Clipper recommends the following measurements between the Spring  Anchor Tab and the Spring:  48” & 52” Deck = 1 inch  60” Deck = 0.5 inches  5.9.46 Adjust Spring Length… Turn the bolt clockwise to reduce the gap; counter clockwise to increase  the gap.          Deck Lift Assist Spring Measure Spring...

  • Page 47: Section 6... Troubleshooting

    Engine Will Not Turn Over Replace fuse and/or investigate cause and Blown fuse correct Stater Solenoid Consult Country Clipper Dealer Ignition Switch Consult Country Clipper Dealer Engine Starter Consult Country Clipper Dealer Other Consult Engine Owner Manual or C.C. Dealer...
  • Page 48 Replace with correct OEM belt Excessive Belt Wear Incorrect belt tension Consult Country Clipper Dealer or Breakage Incorrect belt alignment Consult Country Clipper Dealer Other Consult Country Clipper Dealer Important Consult your Country Clipper Dealer for assistance in troubleshooting and/or repairing problems.
  • Page 49 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. Stringers commonly occur by operator error or maintenance poor blade maintenance.

  • Page 50: Section 7... Belt Routing

    Section 7… Belt Routing 52” & 60” Deck Belt Routing Hydro Belt Routing (Viewed from ground looking up) Right Hand Hydrostatic Left Hand Hydrostatic Transmission Pulley Transmission Pulley Motor Pulley...

  • Page 51: Section 8... Maintenance Record

    Section 8… Maintenance Record Date Hours Service Performed...

  • Page 52: Repair Parts

    Repair Parts SERIAL RANGE: 24266001 - ________ P-13706 (Rev B)
  • Page 53 SEAT BASE & ISOLATORS SEAT, ARM RESTS, & RELATED PARTS ENGINE 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 54 52" MOWER DECK CHALLENGER (D520) SERIAL RANGE: 24266001 - ________ FIXED IDLER ASS'Y, FRONT BELT TENSION (SEE PG 7) LEVER DOUBLE IDLER ASS'Y (SEE PG 6) (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 55 60" MOWER DECK CHALLENGER (D520) SERIAL RANGE: 24266001 - ________ SPINDLE ASS'Y (SEE PG 4) BELT TENSION FIXED IDLER LEVER DOUBLE IDLER ASS'Y ASS'Y, FRONT (SEE PG 6) (SEE PG 5) (SEE PG 7) FIXED IDLER ASS'Y, REAR (SEE PG 7) CHUTE ASS'Y (SEE PG 3) ITEM #...
  • Page 56 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 57: Deck Spindle Assembly

    CHALLENGER DECK SPINDLE ASSEMBLY (D520) {D-4020} TORQUE TO 75 FT/LBS SERIAL RANGE: 24266001 - ________ 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 58 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 59: Belt Tension Lever

    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 60 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 61 CHALLENGER DECK LIFT ASSEMBLY (D520) & RELATED PARTS SERIAL RANGE: 242666001 - ________ 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 62: Deck Lift Assembly

    CHALLENGER DECK LIFT ASSEMBLY (D520) & RELATED PARTS (CON'T) SERIAL RANGE: 24266001 - ________ 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 63 CHALLENGER CUT HEIGHT ASSEMBLY (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ 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 64 CHALLENGER PIVOTING FRONT AXLE (D520) & FLOOR PAN SERIAL RANGE: 24266001 - ________ 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 65 CHALLENGER TIRES & FRONT STEP (D520) SERIAL RANGE: 24266001 - ________ 4 0 -6 0 IN/L BS TO ROTATE TIGHTEN ITEM # 1 8 UNTIL IT TAKES 4 0 -6 0 IN/L BS TO ROTATE THE TIRE ASSEM BL Y APPL Y 1 -2 DROPS OF GREEN L OCTITE 6 8 0 TO M AL E THREADS...
  • Page 66 CHALLENGER FRONT PANEL (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ PARTS M ARKED "*" ARE INCL UDED IN ITEM # 6 BRAKE HANDLE ASS'Y (SEE DETAIL) BRAKE HANDLE ASS'Y ITEM # PART # DESCRIPTION 714-503P BRAKE HANDLE, OFFSET 714-512P BRAKE LINK 714-532P...

  • Page 67: Front Panel Assy

    CHALLENGER FRONT PANEL ASS'Y (D520) & RELATED PARTS (CON'T) SERIAL RANGE: 24266001 - ________ ROUTE COMMON JOYSTICK ASS'Y WIRE HARNESS E-6822 (SEE PG 19) UNDER FLANGE AND SECURE WITH E-5842 TWIN LEVER ASS'Y (SEE PG 22) FUEL TANK ASS'Y (SEE PG 18) FRONT PANEL ASS'Y (SEE PG 13) BRAKE HANDLE ASS'Y...
  • Page 68 CHALLENGER BATTERY BOX & (D520) ROPS POSTS SERIAL RANGE: 24266001 - ________ ITEM # PART # DESCRIPTION 721-142P MOUNT PLATE - ROPS 721-143P BATTERY BOX 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-2152...

  • Page 69: Rops Assembly

    CHALLENGER ROPS ASSEMBLY (D520) SERIAL RANGE: 24266001 - ________ PART OF ITEM #3 ROPS POST W/ DECAL PART OF ITEM #1 PART OF ITEM #1 PART OF ITEM #1 ITEM # PART # DESCRIPTION 720-162A WLDT, FRAME W/ DECALS 724-107P HINGE PLATE, ROPS 721-157A TUBE, POST - ROPS, W/ DECAL...

  • Page 70: Brake Handle Assembly

    CHALLENGER BRAKE ASSEMBLY (D520) SERIAL RANGE: 24266001 - ________ BRAKE HANDLE ASSEMBLY (SEE PG 13) ITEM # PART # DESCRIPTION 714-473P BRACKET, DECK FLIP & BRAKE ROD HANGER, LH 714-501P BRACKET, DECK FLIP & BRAKE ROD HANGER, RH 714-511W WLDT, BRAKE ROD 714-512P BRAKE LINK F-1009-01...
  • Page 71 CHALLENGER BRAKE ASSEMBLY (D520) (CON'T) SERIAL RANGE: 24266001 - ________ 27/32" WITH THE BRAKES SET, SPRING SHOUL D COL L APSE TO 2 7 /3 2 " BETWEEN NUT & BRAKE STUD ITEM # PART # DESCRIPTION 714-511W WLDT, BRAKE ROD 714-522P BRAKE STUD F-1009-01...
  • Page 72 CHALLENGER FUEL TANK ASSEMBLY & (D520) BATTERY HOLD DOWN SERIAL RANGE: 24266001 - ________ KAWASAKI - 23" IF A TANK IS REQUIRED, IT CAN ONLY BE PURCHASED AS A COMPLETE ASSEMBLY KAWASAKI - 52" H-3081 (PARTS MARKED "* " ARE INCLUDED IN ASS'Y) (BATTERY NOT SHOWN) ITEM #...

  • Page 73: Joystick Control & Related Parts

    CHALLENGER JOYSTICK CONTROL (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ PART OF # 7 RH SIDE PANEL INSERT LINKAGE THRU SLOT IN SIDE PANEL & FRAME WELDMENT ITEM # PART # DESCRIPTION 625-100P TUBE, PIVOT, JOYSTICK 625-107P BUSHING, .375 ROD END 625-116P BUSHING, .375 ROD END, SHORT 714-544P...

  • Page 74: Joystick Assembly

    CHALLENGER JOYSTICK ASSEMBLY (D520) {720-161A} SERIAL RANGE: 24266001 - ________ PART OF # 8 PART OF # 8 SEE DETAIL YOKE, SWIVEL, ASS'Y (714-594A) ITEM # PART # DESCRIPTION 625-096P YOKE, SWIVEL, JOYSTICK 625-099P TUBE, GUIDE, CONTROL ROD 714-593P TAB, CAM DETENT 625-106P PIN, PIVOT, JS 625-124P...

  • Page 75: Joystick Assembly Mounting & Related Parts

    CHALLENGER JOYSTICK ASSEMBLY MOUNTING (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ JOYSTICK ASS'Y (SEE PG 20) FRONT PANEL ASS'Y (SEE PG 13) TRANSMISSION (SEE PG 27) ITEM # PART # DESCRIPTION 625-100P TUBE, PIVOT, JOYSTICK 625-116P BUSHING, .375 ROD END, SHORT 638-028P DAMPER BOLT 5/16-18 X 3/4"...
  • Page 76 CHALLENGER TWIN LEVER CONTROL (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ RIGHT HAND SHOWN LEFT HAND OPPOSITE RH SIDE PANEL TRANSMISSION INSERT THRU (SEE PG 27) SLOT IN SIDE PANEL & FRAME WELDMENT ITEM # PART # DESCRIPTION 625-100P TUBE, PIVOT, JOYSTICK 625-116P...
  • Page 77 CHALLENGER TWIN LEVER ASSEMBLY (D520) {721-149A - RIGHT SIDE} SERIAL RANGE: 24266001 - ________ {721-150A - LEFT SIDE} RIGHT HAND SHOWN LEFT HAND OPPOSITE ITEM # PART # DESCRIPTION 714-074P PIN, PIVOT, TWIN LEVER 721-006P SPRING GUIDE, TS 721-088W WLDT, TWIN STICK PIVOT, R 721-089W WLDT, TWIN STICK PIVOT, L 721-090W...

  • Page 78: Control Panel Assembly

    CONTROL PANEL ASSEMBLY CHALLENGER (D520) 714-533A (KAW) SERIAL RANGE: 24266001 - ________ PART OF #1 PART OF #1 ITEM # PART # DESCRIPTION 714-599A CONTROL PANEL W/ DECALS E-5878 HOUR METER E-6369 RETAINER CLIP E-6403 PTO SWITCH E-6717 IGNITION SWITCH, 4 POSITION E-6718 KEY ASSEMBLY F-1022-26...

  • Page 79: Fender Assembly & Related Parts

    FENDER ASSEMBLY CHALLENGER (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ REM OVE KNOCKOUTS ON PL ASTIC FENDERS FOR TWIN L EVER M ODEL S ONL Y! (BOTH FENDERS) CONTROL PANEL (SEE PG 2 5 ) ITEM # PART # DESCRIPTION H-3251 FENDER, LH...
  • Page 80 CHALLENGER TRANSMISSION ASSEMBLY (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ (LOOKING AT BOTTOM) USE CENTER HOLE IDLER ARM ASS'Y (720-156A) TEETH TO INSIDE (ITEM #1) ITEM # QTY PART # DESCRIPTION ITEM # QTY PART # DESCRIPTION 714-454P TAB, DUMP VALVE, COMMON F-1664 HHCS, 1/2-13 X 2-1/4", YZ, GR5 714-521P...
  • Page 81 CHALLENGER TRANSMISSION ASSEMBLY, (D520) DAMPERS & RELATED PARTS SERIAL RANGE: 24266001 - ________ (LOOKING AT BOTTOM) 10 4 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 721-122P BRACKET, DAMPER OFFSET, RH F-1011-02 NUT, HEX 5/16-18...
  • Page 82 CHALLENGER SEAT BASE (D520) & ISOLATORS SERIAL RANGE: 24266001 - ________ ITEM # PART # DESCRIPTION 721-135P PAN, SEAT MOUNT F-1009-03 WASHER, FLAT, 3/8, YZ F-2336 HHCS, 3/8-16 X 2-1/4”, GR5 F-1179 NUT, HEX PAL, 3/8-24, HEX LOCK F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ F-2102 WASHER .406ID X 2.25OD X 7GA THK F-2120...
  • Page 83 CHALLENGER SEAT, ARM RESTS, (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ JOYSTICK MODELS ONLY ITEM # PART # DESCRIPTION 720-138P BRACKET, PIVOTING ARM REST (TWINSTICK) 720-138P BRACKET, PIVOTING ARM REST (JOYSTICK) 721-139P ARM REST, BASE MOUNT, LH (HINGED) 721-140P ARM REST, BASE MOUNT, RH (HINGED) 721-141P...
  • Page 84 CHALLENGER ENGINE (D520) SERIAL RANGE: 24266001 - ________ GROUND KAWASAKI 23.5 HP - FX730 (USE THROTTLE CABLE H-2610 & CHOKE CABLE H-2287) ITEM # PART # DESCRIPTION 621-113P SQUARE KEY 1/4 X 1/4 X 1-1/4 D-3974 MOTOR, PULLEY, 4.51 W/ 1-1/8'' SHAFT F-1228 SET SCREW, SOCKET, 1/4-20 X 1/4", W/NYLOC F-2243...
  • Page 85 CHALLENGER ENGINE & CLUTCH MOUNTING (D520) & RELATED PARTS SERIAL RANGE: 24266001 - ________ (L OOKING AT BOTTOM ) TORQUE SPEC = 55-60 FT/LBS ORIENT CLUTCH SO THE WIRE CONNECTOR IS TOWARDS THE DISCHARGE SIDE OF MOWER SECURE CLUTCH PIGTAIL TO CLUTCH STOP TO PREVENT CONTACT WITH HYDRO BELT ITEM #9 - TORQUE SPEC: 30-32 FT/LBS...

  • Page 86: Wire Harness & Related Parts

    WIRE HARNESS & RELATED PARTS ACCESSORY HR METER BATTERY (-) BATTERY (+) SOLENIOD IGN SW CLUTCH REGULATOR (KAWASAKI) KAWASAKI OIL PRESSURE ENGINE SWITCH (KOHLER) SOLENIOD ENGINE GND ENGINE (KAWASAKI) SEAT SW (E-6491) STARTER SOLENIOD SW (E-6054) BRAKE SW (E-6692) LH NEUTRAL SW JOYSTICK SW (IF EQUIPPED) (E-6692)
  • Page 88 COUNTRY CLIPPER LIMITED WARRANTY  Models: Challenger  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  Clipper dealer to be defective in material, workmanship, or both, and operated and maintained as shown  by Country Clipper's instructions and manuals for a period of 4 years or 600 hours (whichever occurs  first) of Residential use* from the date of original purchase.  The first three years will include parts and  labor.  The fourth year will be parts only.    *Residential use is defined as use of the equipment on property the same as your primary residence or  farmstead.  If the equipment is used on more than one property, this is considered Commercial use, and  the Commercial Warranty will apply. If usage exceeds industry norms for Residential mowing, validation  of usage maybe required to retain the Consumer Limited Warranty.  Commercial Limited Warranty  When used for Commercial, business, production agriculture, horticultural or non‐profit institutional  use, the Limited Warranty term is 4 years or 600 hours (whichever occurs first) from date of purchase.   The first three years will provide allowance for parts and labor.  The fourth year will be parts only.  Mowers used for Rental purposes are not Warranted.  The Warranty applies to Country Clipper Challenger and subsequent revisions to these models sold in  the United States and Canada until said warranty is revised.  Warranty Exceptions   Normal service parts are Warranted for 90 days from the original purchase date for defects in  materials or workmanship (Belts, Tires, Deck Rollers, Mower Blades, Deck Chute, and  Plastic/Cloth Seat Components).   Batteries have a 6 month Warranty by the battery manufacturer.   Related accessories are Warranted for 1 year from their original date of purchase.   The engine Warranty is covered by the engine manufacture and is not Warranted by Country  Clipper.  The engine manufacturer’s Warranty statement is included in the literature packet.   The transmission Warranty is covered by the transmission manufacture and is not Warranted by  Country Clipper.  The transmission manufacturer’s Warranty statement is included in the  literature packet.  Page 1 of 3  P‐13486  REV B ...
  • Page 89 Items and Conditions Not Covered by this Warranty  Items and conditions not covered include:   Pickup and delivery charges to and from authorized Country Clipper dealer.   Repair or replacement caused by accident, misuse, neglectful or improper maintenance,  improper repairs performed or parts installed, use of After Market parts, unauthorized alteration  or modification, and/or normal wear and deterioration for turf equipment.   Routine maintenance services, adjustments, cleaning and / or expendables (i.e. mower blades,  lubricants, fuel, fuel filters, spark plugs, oil, oil filters, and air filters)     Damaged incurred due to a natural disaster or exposure to the elements.   Repairs required due to use of incompatible parts, accessories, or supplies used on the  equipment other than recommended in the operator’s manual or other instructional guides  provided by Country Clipper.   Replacement Parts  Replacement parts for Residential and Commercial use mowers that have exceeded the Warranty period  are Warranted for 90 days from the date of replacement against defects in material and workmanship.  A  proof of purchase, of the replacement part, is required at the time the claim is submitted.  Labor on  replacement parts is not Warranted.  Replacement parts on mowers used for Rental operation are not  Warranted.  There are no other express Warranties for this product in effect during this time period.  An authorized Country Clipper dealer must perform all Warranty work using Country Clipper approved  parts.  Obtaining Warranty Service  A completed Warranty registration must be submitted within 10 days of the date of purchase.  If the  dealer does not register the product, the customer is responsible to complete the product registration  card in the literature package and return it to Country Clipper.  The servicing dealer will require a proof  of purchase if the product has not been registered.   Page 2 of 3  P‐13486  REV B ...
  • Page 90 Customer Responsibility   The owner is responsible for delivery of the mower to the Country Clipper approved servicing  dealer, within the Warranty period, and its return after Warranty work is completed.    The owner is responsible for maintaining and adjusting the equipment as outlined in the owner’s  manual.   Prompt notification to an Authorized Country Clipper Dealer or Country Clipper representative of  the need for warranty repair.   Having the warranty work performed by an authorized Country Clipper Dealer.    Contacting the desired Country Clipper servicing dealer to arrange the service through their  shop.    Contact the desired Country Clipper servicing dealer to arrange the service through their shop.  Use our  dealer locator at www.countryclipper.com or U.S. and Canada customers can call 800‐344‐8237 to locate  their nearest dealer.  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.  All implied Warranties, including those of merchantability and fitness for a particular purpose are, unless  specifically required by the law of the jurisdiction, hereby excluded.  Where implied Warranties are  required by law, including those of merchantability and fitness for a particular purpose, they are, where  allowed by the law of the State, limited to the above stated term of this Warranty.  Liability for  consequential damages, under any and all Warranties, both express and implied are hereby excluded  unless specifically required by the statutory law of the jurisdiction.  No claim of breach of Warranty shall  be cause for cancellation or rescission of the contract of sale of Country Clipper equipment. This  Warranty applies to the original purchaser only and is non‐transferable.  This Warranty gives you specific legal rights, and you may also have other rights, which vary from region  to region.   To obtain the nearest servicing dealer:    Dealer locator:  www.countryclipper.com  Mail:  Country Clipper a Division of  Email:    service@countryclipper.com ...
  • Page 91 , 2021 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 Clipper dealer to be defective in material, workmanship, or both, and operated and maintained as shown by Country Clipper's instructions and manuals for a period of 2 years from the date of original purchase.
  • Page 92 A completed product registration must be submitted at the time of purchase. If the dealer does not register the product, the customer is responsible to complete the product registration card in the literature package and return it to Country Clipper. The servicing dealer will require a proof of purchase if the product has not been registered.
  • Page 93 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 94: Four-Cycle Engine

    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 97: All Models

    All Models Warranty Policies and Procedures BLN-50225_P18 Revision March, 2019...

  • Page 98: Limited Warranty

    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 99 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 100: Warranty Claims Procedure

    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 101 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 102: Specifications

    SPECIFICATIONS CHALLENGER – Joystick Steering 23552KAJ- 23560KAJ- MODEL D520 / D520W D520 / D520W Engine 23.5 H.P. Kawasaki FX730 (726cc) Hydrostatic Hydro-Gear ZT-3400 Transmissions Steering Control Single Joystick Fuel Capacity 7 Gallons Tires, Rear 22 x 11-10 Tires, Front 13 x 6.5-6 Turning Radius Zero-Turn Ground Speed...
  • Page 103 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-13706 (Rev B)

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