Country Clipper BOSS XL 9015 Product Manual
  1. Manuals
  2. Brands
  3. Country Clipper Manuals
  4. Lawn Mower
  5. BOSS XL 9015
  6. Product manual
Country Clipper BOSS XL 9015 Product Manual

Country Clipper BOSS XL 9015 Product Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
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-13730 (Rev B)

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BOSS XL 9015 and is the answer not in the manual?

Questions and answers

Related Manuals for Country Clipper BOSS XL 9015

Summary of Contents for Country Clipper BOSS XL 9015

  • 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

    BOSS XL Service Parts & Information 60” Blade  High Lift Fusion  High Lift  Gator  Low Lift  1  H‐2886 H‐2885  H‐2667  H‐2661  72” Blade  High Lift Fusion  High Lift  Gator  Low Lift    H‐2887 H‐2656  H‐2877  H‐2662    60” Deck Belt   D‐3796  72” Deck Belt   D‐3797    Engine to Deck Belt   (60” Deck)  D‐4075  (72” Deck)  D‐3902  Transaxle Drive Belt  D‐3900    Transaxle  Hydro‐Gear ZT‐5400  Transaxle Filter (Kit) ...

  • 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.  The following information and instructions provided in the manual can help you  attain years of performance from your Country Clipper.  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 trim side of the deck.  These numbers will be needed when ordering service replacement parts.      Parts/Service Genuine Country Clipper replacement parts must be used on your mower for warranty consideration.  Replacement parts are available through your 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.    1.1 ...
  • 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-13480… 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 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  3.2  3.1  3.4  3.4  3.5  3.3  Ignition Switch  Electronic Fuel Gage / Hour Meter  Blade Engagement Switch  Joystick Drive Control Lever   Throttle Control Lever  Twin Stick Drive Control Lever  Choke Push‐Pull Control or EFI Engine Mil  Light Diagnostic (If Equipped with EFI)                       3.10  3.11  3.9  3.8    Parking Brake Lever  3.10 Transport Latch ...

  • Page 13: Control Descriptions

      3.14  3.12  3.13    3.12 Seat Suspension Adjustment   3.14 Lumbar Support Selector   3.13 Seat Slide Lever                                                 3.15  3.16           ...

  • Page 14: Control Decals

    EFI Engine Mil Light Diagnostic: The Mil light is used on fuel injected engines only.  During normal  operation the light will turn on when the ignition switch is turned to the “Run” position prior to starting  the engine. Then after the engine is started the light shuts off.  If the Mil light does not come on when  the ignition switch is turned to the “Run” position or if it illuminates while the engine is running, a fault is  currently happening and dealer service is required.  Electronic Fuel Gage / Hour Meter:  Indicates the fuel fill level and 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 Lumbar Support Selector: Used to adjust the seat back for comfort.  3.15 Seat Recline Knob: Used to adjust seat back recline level.  3.16 Arm Rest Adjustment: Used to adjust the arm rest up or down per operator comfort.  Control Decals           P-13437… Transport Latch – Lock position will P- 11382…...
  • Page 15           P-13481… Throttle Control Position, Idle RPM to P-13477… Deck Height Position – Used as a Full Throttle relative reference of the cutting blade height above the ground surface.   P-13482… Malfunction Indicator Lamp, used on equipment equipped with Electronic  ...

  • Page 16: Section 4... Start Up & Operation

    Section 4… Start Up & Operation Warning Never allow untrained people or children to operate or service 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 17: 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 18: 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 19 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 20: Mower Driving Operation

    OR DEATH. Important Until the operator is familiar with their Country Clipper Mower, they should follow these recommendations: Disengage the mower blades. Go slow (throttle engine rpm down to ½ throttle or less) until thoroughly familiar with the mower. Keep away from fences, buildings, and other obstructions.
  • Page 21 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 22: 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.       ...
  • Page 23 Section 4, Figure 1...
  • Page 24 Section 4, Figure 2...

  • Page 25: 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 MOWER WITHOUT THE DISCHARGE CHUTE OR GRASS CATCHER, ALL SAFETY DEVICES, GUARDS AND SHIELDS IN PLACE AND IN WORKING ORDER.

  • Page 26: 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 27: 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 28 4.12.2 Max Tongue Weight… The recommended maximum tongue weight is 50 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. 4.13...

  • Page 29: 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 30: 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 31: 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 32: Grease Points

    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. The mower is  equipped with a safety air filter. The main filter is installed over the safety filter.  The safety filter  does not need replaced unless it gets contaminated with dirt or moisture.    5.1.10 Remove Air Filter… Remove dust cap and filter from the canister. Inspect safety filter.  5.1.11 Install Filter… Install a new main filter into the canister and re‐install the dust cap.  Check to make  sure the dust cap 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 are  required 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 33 5.2.2 Deck Lift Jack… (If Equipped, Boss XL 72” Deck  Standard Equipment) Locate the grease zerk on  the jack cross shaft.  Re‐lubrication should be  at a rate of 5 pumps of NLGI #2 grease every 50  hours or annually.                  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 ...

  • Page 34: Tires

    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 35: Deck Service

    5.5.3 Electrical Fuse… Country Clipper uses two 30 Amp  Fuses to protect the electrical system. The fuses are  located behind the seat on the right‐hand inner  fender panel.  The fuses protect the electric system  from a direct short to ground.        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 60” decks models come standard with the Manual Lift  option. The 72” deck models come standard with the  Powered Lift option. The Powered Lift option can be installed  on the 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.                         ...
  • Page 36 Warning Never attempt to stand the deck up without the Cut Height Foot Pedal all the way rearward and locked in place with the Cut Height Pin. When properly done, the Rear Deck Hooks will be released from the deck hangers.  ...
  • Page 37 5.6.7 Step 7. Stand Up Deck… Use the deck lift handle located in the center of the front edge of the  deck to lift the nose of the deck up. Lift until the deck is fully upright and is “Over‐Center” so it  locks in place. Set the Parking Brake.                         Warning Check stability before servicing underside of the deck. Make sure Park Brake is on and the key is out of the Ignition Switch. 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 ...
  • Page 38 5.6.16 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.                          5.6.17 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.  5.6.18 Step 4. Lock Deck in Lowest Position… Step off the mower platform. Push the Cut Height Foot  Pedal to the most rearward position and re‐insert the Cut Height Pin in the Cut Height Selector  plate so the Foot Pedal is locked down. (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.
  • Page 39                         Warning Do not attempt to flip deck without releasing deck belt from clutch pulley on the engine or from the center spindle assembly pulley! Failure to do so could cause permanent damage to the Deck Belt Drive! Danger TO AVOID SERIOUS INJURY OR DEATH, KEEP HANDS, FEET, AND BODY PARTS AWAY FROM...
  • Page 40 5.6.23 Step 9. Fit Assembled Tool to Pinion Gear… Fit the 5/8 Inch Socket onto the Pinion Gear Hex  Head.                     18V Minimum    No Impact or Hammer Drill   5.6.24  Step 10. Raise Deck to Service Position… Rest the drill on the Anti‐Rotation Stop; securely grip  the drill and slowly start turning the Pinion Gear clockwise. Continue operating the drill until the  jack stops rising. The Powered Deck Lift Jack will stop rising when the cycle is complete. Set the  Parking Brake.                        Warning Operating the Powered Jack Tool with the Rear Deck Hooks connected or the Deck Belt connected will cause permanent damage to the Deck Suspension System.

  • Page 41: Mower Blade Service

    5.6.26 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.)  5.6.27 Step 3. Transport Latch… Place Transport Latch in the lock position. Raise the deck up to the  transport position and let it lock into place. Make sure both Rear Deck Hangers re‐connect to the  Deck Hanger Clevis Pins.  5.6.28 Step 4. Reconnect Deck Drive Belt…   Re‐install the Engine to Deck belt. Unhook the belt from the bolt and re‐install on the center  spindle pulley Make sur the belt is properly installed on the Electric Clutch Pulley and routed  properly on the belt tensioner idlers. Check to make sure the belt routing is not impeded by the  frame, transaxles, or other mower components. Re‐install Foot Plate. Slowly rotate Deck Belt  Tension Lever and re‐apply spring tension to the belt.  5.6.29 Step 5. Lower Foot Step…  Pivot the Front Step back down for use.  5.6.30 Step 6. Cut Height Pin… Re‐insert the Cut Height Pin to the desired cut height.  5.6.31 Step 7. Lower Deck to Cut Height… Lower deck to desired cut height and position Transport Latch  to the desired position.  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. Dull blades also require  more power to operate.    5.7.1 Damaged Blade… Any blade which is bent, cracked or broken must be replaced.  Warning Make sure the Ignition and Blade Engagement Switches are off, Drive Lever(s) in neutral lock, Brake on, and Negative battery cable disconnected prior to servicing.
  • Page 42 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.        5.14...

  • Page 43: 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… Inspect the oil level by locating the expansion tank for each transaxle behind the  operator seat under the fender.  There is a sight slot on the inner panel of the fender. The oil level  should be visible in the slot. If required, add 20W‐50 motor oil until the oil level can be seen in the  slot. Never fill the expansion above the sight slot. The expansion tank’s primary purpose is to  allow heated oil to expand. If the tank is over filled, there is a potential during operation the oil ...

  • Page 44: Standard Operation Adjustments

    5.8.5 Drain Oil… Place an oil drain pan (12 inch or more in diameter and 8 qt. capacity is optimal)  beneath the oil filter. Remove the oil filter cover from the transaxle to drain the oil. Remove the  O‐ring from the cover and discard the O‐ring.    5.8.6 Remove Filter… After the oil has drained from the transaxle, remove the oil filter from the  transaxle housing.  5.8.7 Install New Filter… Install a new filter and a new O‐ring onto the filter cover and install the filter  cover. Torque cover to 480‐580 in‐lbs. (54‐65 Nm).  5.8.8 Fill Transaxle… Fill the transaxle with new 20W‐50 motor oil through the expansion tank until the  fluid level can be seen in the sight slot. There is a vent plug at the top of the transaxle that can be  opened to improve the new oil fill rate but it is not a requirement.  5.8.9 Purge Procedure… Trapped air must be removed from the hydrostatic drive system to achieve  optimum operation and longevity of the drive. Air creates inefficiency because its compression  and expansion rate is higher than that of the oil approved for use in hydrostatic drive system.  5.8.10 Drive Wheels Off Ground… Raise the rear drive wheels off the ground and secure the mower on  blocks or Jack Stands for the initial air purging.  5.8.11 Activate Bypass… Activate the Bypass to allow the drive tire to free wheel.  5.8.12 Start Engine… Start the engine and move throttle to ¾ to full throttle operation.  5.8.13 Activate Drive Lever(s)… Slowly operate the drive lever(s) in both forward and reverse directions  5 to 10 times.  5.8.14 Check Oil Level… Check oil level; add oil as required after stopping the engine.  5.8.15 Repeat As Necessary… Repeat steps as necessary until all air is purged from the system.  5.8.16 De‐Activate Bypass… De‐Activate the Bypass to allow normal drive wheel operation.  5.8.17 Drive Wheels on Ground… Lower the rear drive wheels to the ground.  5.8.18 Normal Operation… Operate the mower for 30 to 60 minutes under normal driving conditions  and re‐check the oil level. Add oil as required.  Note: Any servicing dealer attempting a warranty repair must have prior approval before conducting ...
  • Page 45 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.     Joystick Forward Tracking & Speed Adjustment ‐ (Always confirm tire pressure setting before making adjustment) ...
  • Page 46 5.9.11 Set The Outer Linkage Length… Rotate the Coupling Nut  exactly one full turn to lengthen the Outer 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 – side to  side.    5.9.12 Set Left Transmission Linkage… Reconnect the linkage  to the left side transmission by reinserting the bolt back  into the Swivel Arm.  5.9.13 Loosen Jam Nuts on Left Linkage… Loosen the Jam Nuts  on both ends of the Left Transmission Linkage.  (One of  these is a left‐hand thread.)  Note: Use two wrenches (one on the nut and one on the Coupling Nut or rod end housing) when  loosening or tightening Jam Nuts to prevent damaging the rod end ball joints!  5.9.14 Lengthen Left Transmission Linkage… Rotate the linkage rod a couple turns to lengthen it.  5.9.15 Joystick Full Forward… Lift the Joystick Drive Control Lever out of the neutral position and hold it  firmly in the full forward position.  5.9.16 Shorten Left Linkage… Rotate the left side transmission linkage rod to shorten the linkage until  resistance is felt from the transmission control bottoming out in the transmission.  Rotate the  linkage back and forth a couple times to confirm, and mark this position.  5.9.17 Set The Left Transmission Linkage… 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.  5.9.18 Reinstall Rear Drive Tire… Reinstall rear drive tires.  Properly torque all lug nuts to 75 FT/LBS.  5.9.19 Test Drive Mower… Operate mower at full forward travel; if mower drives straight no further  adjustment is required, if the mower veers to the left, the right‐hand transmission needs to be  slowed down, if the mower veers to the right, the left‐hand transmission needs to be slowed  down.  5.9.20 Adjust Full Forward Tracking… Determine which transmission needs to be slowed down to obtain  straight forward travel.  With the engine shut off, make small ¼ turn adjustments to lengthen the ...
  • Page 47 On level ground the mower should track straight when the Twin Stick Drive Control Levers are   shifted straight forward. If the mower veers left or right, make proper adjustments as outlined   or contact a Country Clipper dealer for assistance.     Twin Stick Neutral Lock Adjustment ...
  • Page 48 5.9.34 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: the bottom Jam Nut has left‐hand threads.)  5.9.35 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 hub stops turning. Turn off the engine and  retighten the jam nuts.  5.9.36 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. Drive wheels should be stationary. Repeat process if  necessary.  5.9.37 Reinstall Rear Drive Tire… Reinstall rear drive tires.  Properly torque all lug nuts to 75 FT/LBS.  5.9.38 Lower Drive Wheels to The Ground… Lower drive wheels to the ground surface and recheck  Neutral Lock Position.    Twin Stick Forward Tracking Adjustment  5.9.39 Forward Tracking… In an open area, actuate the Twin Stick  Drive Control Levers into the full forward position at ¾ to  full engine throttle. If the mower veers either left or right,  some adjustment is required. If mower is veering to the  right, then the left transmission needs to be slowed down  or vice versa.  5.9.40 Position Mower… Stop the mower, engage Park Brake, and  shut the engine off.  5.9.41 Adjust Tracking… On the transmission that needs  adjustment; turn the Tracking Adjustment Screw in until it  contacts the stop, then turn screw at ½ turn (slowing  speed) increments, until the mower tracks straight. ...
  • Page 49 Deck Leveling Adjustment  (Note: The deck has been factory leveled. If leveling is required follow this procedure.)  5.9.45 Locate Mower on Hard Level Surface… Locate mower on a hard level surface, engage Park Brake  and shut the engine off.  5.9.46 Confirm Tire Pressure… Set the tire pressure on each of the four tires to 12psi (83kPa). (Make  sure all four tires are equal).  5.9.47 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).  5.9.48 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 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.)  5.9.49 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.  5.9.50 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.      5.21...
  • Page 50 5.9.51 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.  5.9.52 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.)  5.9.53 Set Deck to Desired Cut Height… Set deck to the desired operation cut height position.  Deck Lift Assist Spring  5.9.54 Deck Lift Assist Spring… The Deck Lift Assist Springs are 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.)  5.9.55 Factory Settings… Country Clipper recommends the following measurements between the Spring  Anchor Tab and the Spring:  52” Deck = 1 1/8 inches  60” Deck = 1 inch  72” Deck = 3/4 inch    5.9.56 Adjust Spring Length… Turn  the bolt clockwise to reduce  the gap; counter clockwise to  increase the gap.  5.9.57 Adjust Both Springs… The  Left and Right Deck Lift Assist  Springs must be adjusted  equally.        5.22...

  • Page 51: 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 52 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 53 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 54: Belt Routing

    Section 7… Belt Routing 60” Deck Belt Routing 72” Deck Belt Routing...
  • Page 55 Hydro Belt Routing (Viewed from ground looking up) Right Hand Hydrostatic Left Hand Hydrostatic Transmission Pulley Transmission Pulley Motor Pulley...

  • Page 56: Section 8... Maintenance Record

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

  • Page 57: Repair Parts

    Repair Parts SERIAL RANGE: 24266001 - ________ P-13730 (Rev B)
  • Page 58 HYDRO IDLER DOUBLE IDLER TIRES BATTERY ENGINES ENGINE & CLUTCH MOUNTING & RELATED PARTS WIRE HARNESS & RELATED PARTS (CARBURETED) WIRE HARNESS SCHEMATIC (CARBURETED) Country Clipper Division, Shivvers Manufacturing Inc. 613 W English St. Corydon, IA 50060-0467 Ph. 641-872-2544 Fax. 641-872-1593...
  • Page 59 BOSS XL 60" DECK ASSEMBLY (9015) {730B-002A} SERIAL RANGE: 24266001 - ________ DECK IDL ER ASS' Y (SEE PG 5 ) SPINDL E ASS' Y (SEE PG 4 ) TIGHTEN TOP NUT (ITEM # 2 4 ) TO ACHIEVE 2 -1 /2 " SPACING BETWEEN DECK AND PUL L EY COVER CHUTE ASS' Y (SEE PG 3 )
  • Page 60 BOSS XL 72" DECK ASSEMBLY (9015) {730A-002A} SERIAL RANGE: 24266001 - ________ DECK IDL ER TIGHTEN TOP NUT (ITEM # 2 1 ) ASS' Y TO ACHIEVE 1 -1 /2 " SPACING (SEE PG 5 ) BETWEEN DECK AND PUL L EY COVER SPINDL E ASS' Y (SEE PG 4 ) CHUTE ASS' Y...
  • Page 61 BOSS XL DISCHARGE CHUTE ASSEMBLY (9005) & RELATED PARTS SERIAL RANGE: 21286001 - ________ PART OF ITEM # 2 7 2 " DECK Item # Part # Description 643-110P CHUTE HINGE 643-135A OUTLET STIFFENER W/DECALS, SMALL F-1009-02 WASHER, FLAT F-1015-15 HHCS, 5/16-18 X 1", YZ, GR5 F-1671 BOLT, CARRIAGE, 5/16-18 X 3/4", YZ, GR5...

  • Page 62: Deck Spindle Assembly

    BOSS XL DECK SPINDLE ASSEMBLY (9005) {629JY-001A} SERIAL RANGE: 21286001 - ________ TORQUE TO 1 7 0 -1 9 0 FT/L BS PARTS M ARKED ' *' ARE PART OF FOR USE WITH FOR USE WITH COM PL ETE CENTER SPINDL E OUTER SPINDL ES ASSEM BL Y DECK...
  • Page 63 BOSS XL DECK IDLER (9005) SERIAL RANGE: 21286001 - ________ DECK DECK Item # Part # Description 620-201P WASHER, BEARING CAP 621-103P MOUNTING PIN 643-078W SINGLE IDLER ARM LONG WLDT 668-045P SPACER, SPRING MTG D-3730 BUSHING, DU 5/8 DIA X 1/2 LG D-3904 PULLEY, FLAT IDLER, 5"...
  • Page 64 BOSS XL DECK LIFT ASSEMBLY (9005) & RELATED PARTS SERIAL RANGE: 21286001 - ________ 6 0 " DECK -USE BACK HOL E 7 2 " DECK -USE FRONT HOL E REAR DECK HANGER (SEE PG 1 OR 2 ) Item # Part # Description 724-021W...
  • Page 65 BOSS XL DECK LIFT ASSEMBLY (9005) & RELATED PARTS (CON'T) SERIAL RANGE: 21286001 - ________ 7 2 0 -0 9 9 A (ITEM # 3 ) INSTAL L ITEM # 1 2 IN OUTER M OST GROOVES FUL L Y TIGHTEN ITEM # 1 6 THEN BACK OFF 1 /2 TO 1 TURN 7 2 0 -1 0 0 A...
  • Page 66 BOSS XL CUT HEIGHT ASSEMBLY (9005) & RELATED PARTS SERIAL RANGE: 212868001 - ________ CUT HEIGHT SUB-ASSEM BL Y (SEE DETAIL ) INSIDE VIEW OF CUT HEIGHT SUB-ASSEM BL Y, SHOWING DECAL S INCL UDES ITEM S 2 3 & 2 4 WITH DECK CONNECTED TIGHTEN UNTIL GAP HOOK SPRING WITH OPENING...

  • Page 67: Jack Assembly

    BOSS XL JACK ASSEMBLY (9015) SERIAL RANGE: 24275001 - ________ STANDARD EQUIPM ENT ON 7 2 " M ODEL S ONL Y APPL Y 1 -2 DROPS OF BL UE L OCTITE 2 4 2 OR EQUIVAL ENT TO FEM AL E THREADS APPL Y 1 -2 DROPS OF BL UE L OCTITE 2 4 2 OR EQUIVAL ENT TO...

  • Page 68: Pivoting Front Axle

    BOSS XL PIVOTING FRONT AXLE (9015) SERIAL RANGE: 24275001 - ________ TORQUE TO 2 5 0 FT/L BS 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 724-170W WLDT, FRONT AXLE...
  • Page 69 BOSS XL FRONT STEP & FOOT PAN (9015) SERIAL RANGE: 24275001 - ________ PARTS M ARKED ' *' STANDARD ON 7 2 " DECK M ODEL S ONL Y Item # Part # Description 629-958P JACK - DRILL ANTI ROTATION STOP 629-983P ANTI ROTATION PIVOT STOP 663-134P...

  • Page 70: Front Panel

    BOSS XL FRONT PANEL (9015) SERIAL RANGE: 24266001 - ________ INCLUDES ITEMS 5, 7, 8, 9, 10 & 11 Item # Part # Description 730-028A FRONT PANEL W/ DECALS F-2063 NUT, 5/16-18, NYLOC, FLANGED, YZ F-2119 FHCS, 1/4-20 X 3/4", YZ, GR5, LOCK PATCH F-2120 FHCS, 5/16-18 X 3/4", YZ, GR5 H-1626...
  • Page 71 RIGHT HAND FENDER BOSS XL (9015) & RELATED PARTS SERIAL RANGE: 24266001 - ________ PARTS M ARKED " * " ARE PART OF ITEM # 1 SEAT M OUNT FRONT PANEL (SEE PG 1 8 ) PART OF ITEM # 1 1 (SEE PG 1 2 ) Item # Part #...
  • Page 72 BOSS XL LEFT HAND FENDER (9005) & RELATED PARTS SERIAL RANGE: 21286001 - ________ PART OF ITEM # 1 BATTERY BOX (SEE PG 3 2 ) FRONT PANEL (SEE PG 1 2 ) SIDE M OUNT CHANNEL PART OF ITEM # 1 1 (SEE PG 2 2 ) Item # Part #...

  • Page 73: Engine Guard

    BOSS XL ENGINE GUARD (9015) SERIAL RANGE: 24266001 - ________ DO NOT OVERTIGHTEN FASTENERS Item # Part # Description 724-160P ENGINE GUARD 724-140W WLDT, MUFFLER GUARD W/ HITCH 724-166W WLDT, ENGINE WRAP F-2126 FHCS, 3/8-16 X 2”, YZ, GR5 F-2141 FHCS, 3/8-16 X 1", YZ, GR5 F-2142 FHCS, 3/8-16 X 4", YZ, GR5...

  • Page 74: Rops Assembly

    BOSS XL ROPS ASSEMBLY (9015) SERIAL RANGE: 24266001 - ________ PART OF ITEM #10 PART OF ITEM #1 PART OF ITEM #1 PART OF ITEM #1 Item # Part # Description 730-029A WLDT, FRAME W/ DECALS 724-107P HINGE PLATE, ROPS F-1521 WASHER, 1/2"...
  • Page 75 BOSS XL SEAT & RELATED PARTS (9005) SERIAL RANGE: 21286001 - ________ PART OF ITEM # 1 4 J OYSTICK M ODEL S ONL Y Item # Part # Description 724-075P SECURITY GRIP MOUNT 724-105P ARM REST MOUNT 724-116P SEAT PAN 724-124W WLDT, ARM REST MOUNT 724-125W...
  • Page 76 BOSS XL SEAT BASE (9005) SERIAL RANGE: 21286001 - ________ INSTAL L AFTER BOL T IS SECURED Item # Part # Description 660-038P SPACER, 3/8" WIDE 724-043P SEAT MOUNT ANGLE, LH 724-109P SEAT MOUNT ANGLE, RH 724-153P STIFFENER, FENDER CAP F-1009-02 WASHER, FLAT F-1009-03...

  • Page 77: Fuel Tank Assembly

    BOSS XL FUEL TANK ASSEMBLY (9010) SERIAL RANGE: 22290001 - ________ KAWASAKI - 48" KAWASAKI 58" IF A TANK IS REQUIRED, IT CAN ONLY BE PURCHASED AS A COMPLETE ASSEMBLY {H-3224} (PARTS MARKED '* ' ARE INCLUDED IN ASS'Y) Item # Part # Description E-6820...

  • Page 78: Joystick Control & Related Parts

    BOSS XL JOYSTICK CONTROL (9015) & RELATED PARTS SERIAL RANGE: 24275001 - ________ PART OF ITEM # 1 0 SIDE M OUNT (SEE PG 2 2 ) SWIVEL ARM (SEE PG 2 2 ) TRANSM ISSION (SEE PG 2 7 ) Item # Qty Part # Description...

  • Page 79: Joystick Assembly

    BOSS XL JOYSTICK ASSEMBLY (9015) {720-161A} SERIAL RANGE: 24275001 - ________ TORQUE TO 1 0 FT/L BS PART OF # 7 PART OF # 7 DETAIL YOKE, SWIVEL, ASS'Y (714-594A) Item # Qty Part # Description Item # Qty Part # Description 625-096P YOKE, SWIVEL, JOYSTICK F-1005-05 NUT, 1/2-13, CENTERLOCK, YZ, GR5...

  • Page 80: Joystick Assembly Mounting & Related Parts

    BOSS XL JOYSTICK ASSEMBLY MOUNTING (9005) & RELATED PARTS SERIAL RANGE: 21286001 - ________ FRAM E J OYSTICK CONTROL (SEE PG 2 0 ) TRANSM ISSION (SEE PG 2 7 ) Item # Qty Part # Description Item # Qty Part # Description 638-028P DAMPER BOLT 5/16-18 X 3/4"...
  • Page 81 BOSS XL TWIN LEVER CONTROL (9005) & RELATED PARTS SERIAL RANGE: 21286001 - ________ (RIGHT SIDE SHOWN) INSTAL L AFTER BOL TS ARE SECURED FRAM E TRANSM ISSION (SEE PG 2 7 ) Item # Qty Part # Description Item # Qty Part # Description 638-028P DAMPER BOLT 5/16-18 X 3/4"...
  • Page 82 BOSS XL TWIN LEVER ASSEMBLY (9015) SERIAL RANGE: 24275001 - ________ {714-136A - RIGHT SIDE} {714-137A - LEFT SIDE} 10 13 (RIGHT SIDE SHOWN) SIDE M OUNT (SEE PG 2 3 ) Item # Part # Description 714-074P PIN, PIVOT, TWIN LEVER 721-006P SPRING GUIDE, TS 721-090W...

  • Page 83: Control Panel

    CONTROL PANEL BOSS XL (9005) SERIAL RANGE: 21286001 - ________ CARBURETED ENGINES ONL Y EFI ENGINES ONL Y FENDER CAP (SEE PG 1 3 ) CARBURETED ENGINES ONL Y EFI ENGINES ONL Y Item # Part # Description E-6403 PTO SWITCH E-6717 IGNITION SWITCH, 4-POSITION W/ PLASTIC KEYWAY E-6718...

  • Page 84: Brake Assembly

    BOSS XL BRAKE ASSEMBLY (9015) SERIAL RANGE: 24275001 - ________ TIGHTEN FIRST (BEFORE ITEM S # 1 0 & # 1 1 ) Item # Part # Description 714-522P BRAKE STUD 724-034W WLDT, BRAKE ROD 724-040P BRAKE HANDLE MOUNT PLATE 724-054W WLDT, BRAKE HANDLE E-6474...
  • Page 85 TRANSMISSION BOSS XL (9015) & RELATED PARTS SERIAL RANGE: 24266001 - ________ (RIGHT SIDE SHOWN) FENDER CAP (SEE PG 1 3 - RH, PG 1 4 - L H) HYDRO BEL T ROUTING ENGINE PUL L EY HYDRO IDL ER L H TRANSM ISSION RH TRANSM ISSION Item #...
  • Page 86 BOSS XL HYDRO MOUNT (9005) SERIAL RANGE: 21286001 - ________ DOUBL E IDL ER ASS' Y (SEE PG 3 0 ) Item # Part # Description 724-015P HYDRO MOUNT PLATE 724-016P HYDRO MOUNT BRACE 724-046P DOUBLE IDLER TENSION ARM 724-048P DOUBLE IDLER MOUNTING BRACKET F-1125 NUT, HEX 5/16-18, CENTERLOCKING...
  • Page 87 BOSS XL HYDRO IDLER (9005 ) SERIAL RANGE: 21286001 - ________ (LOOKING AT BOTTOM) AFTER PRESSING IN BUSHINGS (ITEM # 5 ), ENSURE PIN (ITEM # 2 ) ROTATES FREEL Y Item # Part # Description 620-201P WASHER, BEARING CAP 709-077P MOUNTING PIN 709-123P...
  • Page 88 BOSS XL DOUBLE IDLER ASSEMBLY (9005) SERIAL RANGE: 20258001 - ________ AFTER PRESSING IN BUSHINGS (ITEM # 7 ), ENSURE PIN (ITEM # 4 ) ROTATES FREEL Y ASSEM BL E BOL T BEFORE FL AT PORTION ASSEM BL ING PUL L EYS &...
  • Page 89 BOSS XL TIRES & RELATED PARTS (9015) SERIAL RANGE: 24275001 - ________ 4 0 -6 0 IN/L BS TO ROTATE TIGHTEN ITEM # 1 4 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 90: Battery Box

    BOSS XL BATTERY BOX (9005) SERIAL RANGE: 21286001 - ________ Item # Part # Description 724-147P BACK PLATE, BATTERY BOX 724-148P BATTERY BOX ----- 12 VOLT BATTERY YSP 40, 350 CCA F-2124 FHCS, 3/8-16 X 3/4", YZ, GR5 F-2132 NUT, 1/4-20 NYLOC, FLANGED, YZ F-2151 NUT, 3/8-16 NYLOC, FLANGED, YZ F-2162...
  • Page 91 BOSS XL ENGINES (9015) SERIAL RANGE: 24266001 - ________ GROUND ENGINE STARTER KAWASAKI 31 HP - FX921V 35 HP - FX1000V (USE THROTTL E CABL E H-3 1 6 4 & CHOKE CABL E H-3 1 6 6 ) Item # Qty Part # Description 1 724-154P KEY STOCK, 1/4 X 1/4 X 2-1/2...
  • Page 92 BOSS XL ENGINE & CLUTCH MOUNTING (9005) SERIAL RANGE: 21286001 - ________ (L OOKING AT BOTTOM ) TORQUE TO 5 5 -6 0 FT/L BS ITEM # 1 0 TORQUE SPECS KAWASAKI = 3 0 -3 2 FT/L BS ROUTE CL UTCH PIGTAIL &...
  • Page 97 COUNTRY CLIPPER LIMITED WARRANTY  Models: Boss XL  Effective 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 5 years or 1200 hours (whichever occurs  first) of Residential use* from the date of original purchase.  The first three years will include parts and  labor.  The fourth and fifth 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 5 years or 1200 hours (whichever occurs first) from date of purchase.   The first three years will provide allowance for parts and labor.  The fourth and fifth year will be parts  only. Mowers used for Rental purposes are not Warranted.  The Warranty applies to Country Clipper Boss XL and subsequent revisions to these models sold in the  United States and Canada until said warranty is revised.  Warranty Exceptions2217   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‐13488  REV B ...
  • Page 98 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‐13488  REV B ...
  • Page 99 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 100 , 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 101 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 102 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 103: 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 106: All Models

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

  • Page 107: 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 108 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 109: 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 110: Open Circuit Voltage

    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 111: Specifications

    SPECIFICATIONS BOSS XL - Joystick Steering 3560KAJ-9015 / 9015W 3572KAJ-9015 / 9015W MODEL 3160KAJ-9015 / 9015W 31 H.P. Kawasaki 35 H.P. Kawasaki FX1000V (999cc) Engine FX921V (999cc) Hydro-Gear ZT-5400 Hydrostatic Transmission Steering Control Single Joystick Fuel Capacity 10.25 Gallons Tires, Rear 26 x12-12 26 x14-12 Tires, Front...
  • Page 112 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-13730 (Rev B)

This manual is also suitable for:

Boss xl 9015wBoss xl 9005

Table of Contents