Country Clipper 2204MT Assembly instructions

OWNERS MANUAL & SAFETY INSTRUCTIONS

for

TRACTOR MODELS 2204MT & 2504MT

DECK MODELS 5204M & 6004M

Mid-Mount Zero Turn Radius Mowers

Congratulations for buying a Commercial Clipper product. Your Commercial Clipper Zero Turning

Radius Riding Mower was designed and built to provide long and trouble free service. Keep in mind that

it, like any other mechanical device, can be potentially dangerous if used improperly, and hazard control

and accident prevention are dependent upon the awareness, concern, prudence, and proper training of

personnel involved in the operation, transport, maintenance, and storage of the equipment. Study this

manual and pay special attention to the important Safety Precautions. Following these instructions will

help you continue to enjoy the trouble-free performance expected of the Commercial Clipper product.

P-11456 (7/00)

TABLE OF CONTENTS

I. OWNER INFORMATION

Warranty Information ---------------------------------------------------- II

Specifications ------------------------------------------------------------ III

II. SAFETY

Accident Patterns --------------------------------------------------------- 1

Safety Instructions and Recommendation ------------------------- 1

Safety Interlock Systems ----------------------------------------------- 3

III. START UP AND OPERATION

Checklist Before Operation -------------------------------------------- 3

Control Locations --------------------------------------------------------- 4

Operation ------------------------------------------------------------------- 4

Mowing Recommendations ------------------------------------------- 6

VI. MAINTENANCE

Maintenance Schedule ------------------------------------------------ 6

Maintenance Instructions --------------------------------------------- 7

Leveling the Deck ------------------------------------------------------ 10

Raising and Lowering Deck for Servicing ----------------------- 11

Trouble Shooting Checklist ------------------------------------------ 13

Wiring Schematic ------------------------------------------------------- 15

I P-11456

WARRANTY INFORMATION

SERIAL NUMBER__________________________________________________________

DATE PURCHASED________________________________________________________

Condition of Mower (New or Used)______________________________________________

Hour Meter Reading__________________________________________________________

SERVICE SCHEDULE

Service Performed and Date

___________________________________________________________________________

_____________________

P-11456

TRACTOR SPECIFICATIONS

w/ 52" DECK w/ 60" DECK

Length

All Models -------------------------------------------------- 81" 81"

Width

All Models ------------------------------------------------ 49" 49"

Height

All Models (To top of seat back)------------------- 43" 43"

Weight

All Models -------------------------------------------------- Approx. 680 lbs.

Fuel Tank

All Models ------------------------------------------------ Approx. 11 gallons

Hydrostats

All Models -------------------------------------------------- (2) Hydro-Gear

BDU-10L

Engine

------------------------------- 22 hp. , 23 hp. & 25 hp. twin Kohler Command

Engine to Hydrostat belt (Kevlar)

All Models ----------------------------------------------------(SPECIAL) A-112

Tires Front Rear

All Models 13-5.00 x 6- 23-9.50 x 12

DECK SPECIFICATIONS

ITEM 52" 60"

Cutting width 52" 60"

Cutting height --------1-1/2" to 5"--------

Blades (3)-18-3/8" (3)-21"

Overall width

including chute 61-1/2" 69 1/2"

Material thickness 10 GA. 10 GA.

Reinforcement plate 7 GA. 10 GA.

Spindle bearings 25mm 25mm

Weight 235 lbs. 236 lbs.

III P-11456

SAFETY

ACCIDENT PATTERNS TO AVOID

I. CONTACT WITH THE ROTATING

BLADE -- This accident usually

happens when the operator is clearing

the discharge chute of grass, (especially

when the grass is wet), or when the

operator adjusts the machine without

turning it off and waiting for the blades

to completely stop.

II. PROPELLED OBJECTS -- Sticks,

rocks, wires, and other objects can be

propelled out through the discharge

chute or from under the mower housing.

Bystanders are particularly vulnerable.

III. GRASS CATCHER OR GUARD -- The

mower shall not be operated without

either the entire grass catcher or guard

in place.

IV. OVERTURNING -- This happens when

riding mowers are used on steep

slopes, embankments or hills. The

operator in these cases can come in

contact with the blades or sustain

injuries during a fall.

V. MOWER RUNNING OVER THE VICTIM

-- This usually happens when a riding

mower is driven in reverse. The

accident victims are most often young

children whom, unseen by the operator

of the mower, were in the area being

mowed.

WE SHARE YOUR DESIRE TO PROTECT

YOURSELF, YOUR FAMILY, YOUR FRIENDS

AND YOUR NEIGHBORS FROM ACCIDENTAL

INJURY. OBSERVING AND ENFORCING THE

FOLLOWING GUIDELINES WILL HELP TO

INSURE THE SAFETY OF EVERYONE.

PLEASE BE CAREFUL!

SAFETY INSTRUCTIONS AND

RECOMMENDATIONS

1. PEOPLE WHO OPERATE, SERVICE,

OR ARE OTHERWISE ASSOCIATED

with the Zero Turning Radius Mower

should be trained in its proper use and

warned of its dangers. Before

operating, adjusting, or servicing the

Zero Turning Radius Mower they should

read and understand this entire manual

and the engine owner’s manual.

2. AVOID CONTACT WITH MOVING

PARTS. Keep hands and feet from

under mowing deck and away from

blades at all times. Turn engine (motor)

off if you must unclog the chute.

3. AVOID HILLS AND SLOPES. Use

extreme caution when mowing up or

down slopes. NEVER mow across the

face of a slope. If a slope must be

ascended, back up the slope; drive

forward when descending. Reduce

speed and use caution to start, stop and

maneuver. To prevent loss of control on

a slope avoid sharp turns, sudden

changes in direction, and sudden stops

and starts.

4. DISENGAGE POWER TO MOWER

BEFORE BACKING UP. Do not mow

in reverse unless ABSOLUTELY

necessary and then only after turning

around and observing the entire area

behind the mower. Go slowly. Most

“running over victim” accidents occur in

reverse.

5. BEGINNING OPERATORS SHOULD

LEARN HOW TO STEER the Zero

Turning Radius Mower before

attempting to mow. Start with slow

engine speed and drive without the

blades engaged in an open area until

comfortable with the machine.

6. KNOW HOW TO STOP QUICKLY.

Know the location and operation of

every control, especially how to brake

and how to disengage the mower

blades.

7. DO NOT MOVE STEERING CONTROL

LEVERS from forward position to

1 P-11456

reverse position rapidly. The speed

and/or direction of travel is affected

instantly by movement of the Steering

Control Levers.

8. DO NOT ALLOW CHILDREN TO

OPERATE MOWER. Do not allow

others who have not had instruction to

operate mower.

9. ALWAYS TURN ENGINE OFF AND

REMOVE KEY before leaving the

mower to prevent children and

inexperienced operators from starting

the engine. Never leave the mower

unattended with engine running. Always

wait for all moving parts and all sounds

to stop before leaving operator’s seat.

10. WEAR STURDY, ROUGH-SOLED

WORK SHOES AND CLOSE-FITTING

SLACKS AND SHIRTS. Never operate

mower in bare feet, sandals or

sneakers.

11. NEVER CARRY PASSENGERS.

12. KNOW THE AREA YOU ARE TO

MOW. Watch for hidden danger such

as rocks, roots, sticks, holes, bumps,

and drop-offs, etc. Before mowing, pick

up all debris in area to be mowed.

Sharp and hard objects can be

propelled at a high speed and can act

like shrapnel. Walk through tall grass

BEFORE MOWING to make sure there

are no hidden dangers. Mow higher

than desired in tall grass to expose any

hidden objects and/or obstacles, clean

the area, and then mow to the desired

height.

13. NEVER REFUEL A MOWER

INDOORS. Allow the engine time to

cool before refueling. Unseen vapors

may be ignited by a spark. Always

clean up spilled gasoline. Never run the

engine indoors in a garage or any other

closed building. Allow engine to cool

before storing in any enclosure. The

engine exhaust and gasoline fumes are

dangerous.

14. NEVER REMOVE THE FUEL CAP or

add gasoline to a running or hot engine

that has not been allowed to cool for

several minutes after running. Always

make sure the gas cap is in place.

15. DO NOT SMOKE AROUND THE

MOWER or the gasoline storage

container. Gasoline fumes can easily

ignite.

16. KEEP GASOLINE IN A WELL-

VENTILATED AREA away from your

living quarters and in tightly-capped

safety cans. Never store mower with

gasoline in the tank inside a building

where fumes may reach open flame or

spark.

17. DISENGAGE BLADES, STOP ENGINE

AND REMOVE IGNITION KEY before

any servicing. Be sure all moving parts

and all sounds have stopped. Let

engine cool and disconnect the spark

plugs so the engine cannot start by

accident. A SLIGHT ROTATION OF

THE BLADES COULD START THE

ENGINE.

18. KEEP ALL NUTS, BOLTS, AND

SCREWS TIGHT to be sure equipment

is in safe working condition, especially

blade mounting bolts.

19. VEHICLE SHOULD BE STOPPED

AND INSPECTED FOR DAMAGE after

striking a foreign object and the damage

should be repaired before restarting and

operating the equipment. Stop

immediately and check for damage or

loose parts if mower should start

vibrating.

20. DISENGAGE BLADES BEFORE

DRIVING ACROSS WALKS or

projecting objects.

21 KEEP SAFETY DEVICES AND

GUARDS IN PLACE. If any of the

safety switches become inoperable,

have them repaired immediately.

22. DO NOT STEP OR STAND ON THE

MOWER HOUSING. Step or stand only

on the foot deck.

23. WATCH OUT FOR TRAFFIC near

roadways and when crossing roads.

24. DO NOT USE MOWER WHEN GRASS

IS WET OR SLIPPERY.

25. MOW ONLY DURING DAYLIGHT.

2 P-11456

26. THIS MACHINE IS NOT MEANT FOR

HIGHWAY OR STREET USE. It is not

a recreational vehicle and it should not

be operated as such.

27. ALWAYS DISENGAGE THE MOWER

BLADE CLUTCH when transporting.

SAFETY INTERLOCK SYSTEM

Your Zero Turning Radius Mower is equipped

with switches interlocked for your safety.

1. The mower blades must be disengaged

before engine will start.

2. The Steering Control Levers must be in

the neutral “OUT” position before the

engine will start.

3. The engine will stop if the mower blade

clutch is engaged when the operator

leaves the driver’s seat.

4. The engine will stop if the Steering

Control Levers are not in the neutral

“OUT” position when the operator

leaves the driver’s seat.

5. The engine will stop if the brake is

“SET” and the Steering Control Levers

are moved to the “IN” position.

6. The engine will stop if the brake is

“SET” and the mower blade clutch is

engaged.

DO NOT OPERATE MOWER IF SAFETY

SWITCHES ARE NOT OPERATING

PROPERLY

START UP AND OPERATION

CHECKLIST BEFORE OPERATION

1. Make sure fuel tank is full. Use regular

unleaded gasoline (see engine owner’s

manual for more details).

WARNING

HANDLE GASOLINE WITH CARE -- IT IS

HIGHLY FLAMMABLE. DO NOT SMOKE.

ENGINE SHOULD BE OFF AND COOL. USE

APPROVED GAS CONTAINER. NEVER FILL

TANK INDOORS. WIPE UP ANY SPILLS.

REPLACE CAP TIGHTLY.

2. Make sure dirt and foreign matter is kept

out of gas tank. Use a clean funnel and

gas can.

3. Do not mix oil with gasoline.

4. Do not use white, high test or premium

gasoline. Do not use de-icers,

carburetor cleaners, or other such

additives.

5. Check the crankcase oil level. Make

sure the engine is off. The mower

should be parked on a level area. Do

not overfill. (See your engine manual for

more detailed instruction.)

6. Check the hydrostatic transmission oil

level. (See “Maintenance” section of this

manual.)

7. Check battery fluid level.

8. Inspect V-belts.

9. Check tire pressure:

Model Front tires Rear tires

All

Models 12 psi 12 psi

10. Make sure underside of mower deck is

free of grass.

11. Make sure mower blades are sharp and

secured tightly.

3 P-11456

12. Clean the air intake screen on the

engine if necessary.

13. Perform any other maintenance as it

becomes necessary. (See the

“Maintenance” section of this manual.)

IMPORTANT: Before cutting grass, clutch must

be broken-in as follows: With engine at

full RPM engage deck until blades come

to full speed and then disengage until

blades come to a complete stop.

Repeat 10 times to seat clutch properly.

CONTROL LOCATIONS

WARNING

AVOID INHALING EXHAUST FUMES --

CARBON MONOXIDE GAS IS COLORLESS

AND ODORLESS, AND CAN CAUSE

UNCONSCIOUSNESS, AND IS POTENTIALLY

LETHAL. DO NOT RUN LAWN MOWER IN

GARAGE OR OTHER CONFINED AREA.

OPERATION

1. MOVE STEERING CONTROL LEVERS TO

neutral “OUT” position.

2. SET PARKING BRAKE. Pull up to set.

3. DISENGAGE MOWER BLADE CLUTCH by

moving clutch switch to “OFF” position.

4. PULL ENGINE CHOKE CONTROL to full

position for cold starts.

5. SET ENGINE THROTTLE TO 1/2

THROTTLE.

6. TURN IGNITION KEY to “START” position

and release to “RUN” as soon as engine

starts. NOTE: Prolonged cranking will

damage starter motor and shorten the

battery life.

7. ADJUST ENGINE THROTTLE AND

CHOKE for desired engine smoothness and

speed.

Steering Control Levers NOTE: When mowing, always run engine

at full throttle.

Choke Cut Height

Adjustment

Lever

Blade Clutch

Switch

8. RELEASE PARKING BRAKE. Push brake

lever down to release.

IMPORTANT: Until the operator is familiar with

the Zero Turning Radius Mower, he/she

should follow these recommendations:

Disengage the mower blades. Go very

slowly until thoroughly familiar with the

machine. Keep away from fences,

buildings, and other obstructions. Move

the Steering Control Levers smoothly

and slowly. Practice until operation is

smooth and efficient.

Ignition

Key

Throttle

Parking Brake

Lever

Cut Height

Stop pin 10. TO DRIVE: Move the Steering Control

Levers to the “IN” position. Move the

Steering Control Levers forward to move

forward. Increasing forward movement

of the Steering Control Levers will

increase the speed of travel. To reverse

the direction, pull the Steering Control

Levers slightly back. To turn, move one

Steering Control Lever slightly ahead of

the other. To turn on a zero radius axis,

go slowly and move one Steering

Control Lever forward and one Steering

Control lever rearward. (For a right

hand turn the left hand Steering Control

lever will be ahead of the right hand

Steering Control. For a left hand turn

the right hand Steering control will be

ahead of the left hand Steering Control.)

CAUTION

4 P-11456

FOR SMOOTH, SAFE OPERATION, MOVE

THE STEERING CONTROL LEVERS IN A

GENTLE, SLOW MOTION. NEVER PULL OR

PUSH THE STEERING CONTROL LEVERS

RAPIDLY, ESPECIALLY ON GRADES.

11. BRAKING: To brake mower, gently

move the Steering Control Levers in the

direction opposite to travel. If the

parking brake is engaged with the

Steering Control Levers in the “IN”

position the engine will stop.

12. CUTTING HEIGHT ADJUSTMENT:

With the Cut Height Adjustment Lever

latched into the top cut height latch.

Insert Cut Height Stop Pin to desired

cutting height. Pull Cut Height

Adjustment Lever rearward and then to

the right to clear top cut height latch.

Lower Cut Height Adjustment Lever until

it rests on Cut Height Stop Pin.

13. ENGAGE MOWER BLADE CLUTCH:

Set the Blade Clutch Switch to the “ON”

position. The engine will not start if the

blade clutch is engaged. If the operator

is not in the seat, the engine will stop if

the clutch is engaged.

CAUTION

AVOID HILL AND SLOPES. USE EXTREME

CAUTION WHEN MOWING UP OR DOWN

SLOPES. NEVER MOW ACROSS THE FACE

OF A SLOPE. IF A SLOPE MUST BE

ASCENDED, BACK UP THE SLOPE; DRIVE

FORWARD WHEN DESCENDING.

14. TO STOP:

A. Move Steering Control Levers to

neutral position and then to the “OUT”

position.

B. Disengage the mower blade clutch by

moving the clutch to the “OFF” position.

C. Set the parking brake.

D. Slow engine speed with throttle to

slowest position.

E. Turn ignition key to “OFF” (left)

position.

F. Remove the key and wait for all

movement and all sound to cease

before dismounting.

CAUTION

WHEN LEAVING THE MOWER

UNATTENDED, ALWAYS REMOVE THE KEY

AND SET THE PARKING BRAKE, EVEN IF

JUST FOR A FEW MOMENTS. HELP

PROTECT CHILDREN AND OTHER

UNAUTHORIZED PERSONS FROM

ACCIDENTS.

15. TO FREE WHEEL MACHINE: UNLOCK

TRANSMISSION: The transmission release

levers are located on each side of the mower

behind the rear drive axles and below the

engine mounting plate. Lift the levers slightly,

push them forward and then down to release the

transmissions for free wheeling. To engage the

transmissions lift the levers slightly, pull them to

the rear and then down. NOTE: The tractor

should never be pulled at more than 2 miles per

hour or for any appreciable distance.

Transmission

Release Valve

Free Wheel

Leve

5 P-11456

MOWING RECOMMENDATIONS 3. When mowing tall grass, make two

passes, mowing off 1/2 of the desired

cut on the first pass, and then the

desired height the second pass. Check

1. Keep mower blades sharp.

for hidden dangers first.

2. Make sure deck and discharge are

clean.

4. Go slowly for trimming.

CAUTION 5. Always cut grass with the engine at full

throttle speed. This “ENGINE” speed

allows the cutting blades to operate at

optimum cutting speed. Control

“GROUND” speed with the Steering

Control Levers.

POWER MUST BE OFF TO CLEAN

DISCHARGE CHUTE. TURN ENGINE OFF

AND WAIT FOR ALL MOVING PARTS TO

STOP.

6. Vary ground speed to suit conditions

(i.e. go slower in tall thick grass, on hills,

wet conditions, etc.).

MAINTENANCE

Replace decals when illegible. Write factory for free replacement.

CAUTION

BEFORE PERFORMING ANY MAINTENANCE, TURN OFF ENGINE

REMOVE KEY AND DISCONNECT SPARK PLUGS. USE EXTREME CARE WHEN WORKING ON

MACHINERY. DO NOT WEAR WATCHES OR JEWELRY. DO NOT WEAR LOOSE FITTING

CLOTHES, AND OBSERVE ALL COMMON SAFETY PRACTICES WITH TOOLS.

MAINTENANCE SCHEDULE

SERVICE WHEN

Check crankcase oil level --------------------------------------------------------------------- before each use

Clean grass from Hydrostat fans and cooling fans -------------------------------------- before each use

Check air intake screen --------------------------------------------------------------------------- after each use

Clean grass under deck -------------------------------------------------------------------------- after each use

Check tire pressure ------------------------------------------------------------------------------- every 10 hours

Check battery fluid -------------------------------------------------------------------------------- every 10 hours

Sharpen mower blades -------------------------------------------------------------------------- every 10 hours

Clean air filter pre-cleaner element ----------------------------------------------------------- every 25 hours

Check Hydrostatic transmission fluid --------------------------------------------------------- every 25 hours

Check drive belts ---------------------------------------------------------------------------------- every 50 hours

(20 hours break-in)

Service Air Cleaner Filter Element ---------------------------------------------------------- every 100 hours

Change engine crankcase oil ------------------------------------------------------------------------- 100 hours

oil filter -------------------------------------------------------------------------- 200 hours

Change Hydrostat oil and oil filter ----------------------------------------------------------- every 500 hours

(100 hours break-in)

Replace air filter element --------------------------------------------------------------- annually or 500 hours

Check spark plugs ------------------------------------------------------------------------ annually or 500 hours

Service battery ---------------------------------------------------------------------------- annually or 500 hours

MAINTENANCE INSTRUCTIONS

6 P-11456

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