Repair Parts Manual COUNTRY ZERO TURN MOWER

Transcription

1 Repair Parts Manual COUNTRY ZERO TURN MOWER Congratulations for buying a Country Clipper product. Your Country Clipper Zero Turn 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 on pages 3-5. Following these instructions will help you continue to enjoy the trouble-free performance expected of the Country Clipper product.

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3 SECTION - COUNTRY CLIPPER EDGE-40 & EDGE XLT-455 ZERO TURN RADIUS MOWER TABLE OF CONTENTS MOWER DECKS AND RELATED S. 48" DECK ASSEMBLY. 5" DECK ASSEMBLY 3. 60" DECK ASSEMBLY 4. DECK SPINDLE ASSEMBLY 5. DOUBLE IDLER & RELATED S (48" DECK) 6. DOUBLE IDLER & RELATED S (5" DECK) 7. DOUBLE IDLER & RELATED S (60" DECK) 8. STATIONARY IDLERS & RELATED S 9. LIFT HANDLE ASSEMBLY & RELATED S 0. LIFT ASSEMBLY & RELATED S. TRANSMISSION IDLERS & RELATED S SECTION - TRACTOR FRAME AND RELATED S. CASTER WHEEL ASSEMBLY 3. FRAME SIDES & RELATED S - EDGE 4. FRAME SIDES & RELATED S - EDGE XLT 5. FENDER ASSEMBLY 6. SEAT, FOOT DECK ASSEMBLY & RELATED S 7. FRONT STEP ASSEMBLY- EDGE XLT SECTION 3 - TRACTOR DRIVE AND RELATED S 8. FUEL TANKASSEMBLY 9. JOYSTICK STEERING CONTROL & RELATED S 0. JOYSTICK ASSEMBLY (CON'T). JOYSTICK STEERING CONTROL & RELATED S (CON'n. TWINSTICK STEERING CONTROL & RELATED S 3. PARKING BRAKE ASSEMBLY & RELATED S 4. MOTOR & TRANSMISSION ASS'Y & RELATED S-.SHP KAWASAKI 5. MOTOR & TRANSMISSION ASS'Y & RELATED S-4HP KAWASAKI 6. MOTOR & TRANSMISSION ASS'Y & RELATED S-6HP KOHLER 7. E-645 WIRE HARNESS ASS'Y & RELATED S (JOYSTICK) 8. E-646 WIRE HARNESS ASS'Y & RELATED S (TWINSTICK) 9. E-647 WIRE HARNESS ADAPTER & RELATED S- KAWASAKI 30. E-6436 WIRE HARNESS ADAPTER & RELATED S - KOHLER Country Clipper Division Shivvers Manufacturing Inc. 63 W. English St. Corydon, IA Ph Fax

4 48" DECK ASSEMBLY l660ak-00a~ REF NO. NO P 5 BUSHING 69-4W Baffle Wll:tt. 48" W Hanger Weldment P CHUTE HINGE W CASTING,HANGER,WIDE BASE A PULLEY COVER w/decals P GRIP, STANDUP A 48 LIGHT DECK w/decals B0W SPLITTER BAFFLE P OUTLET STIFFENER D-3775-W BELT, B-58 F /4" Flat Washer 3 F /6" Flat Washer 4 F /6-8 x " Capscrew 5 F-09-0 /4" LockWasher 6 F-5 9 /" WASHER, CUSTOM 7 F /6-8 x 3/4" CARRIAGE BOLT 8 F /8-6 x -/4" Carraige Bolt 9 F-83 Carriage Bolt, /4 X 3/4" 0 F-898 / x -3/4" Clevis Pin F-935 CARRIAGE BOLT, /4 X -/" F /4 x 5/8 Self Tapping Capscrew 3 F Nut, 5/6-8 Nyloc, Flanged 4 F /6-8 x " CARRIAGE BOLT, 5 F-0 FHCS, 5/6-8x0.75, YZ, GR5 REF NO. NO.. 6 F-3 NUT, /4-0 NYLOC, FLANGED 7 F-48 3 FHCS, 5/6-8 x.00, YZ, GR5 8 F-5 7 Nut,3/8-6 Nyloc, Flanged 9 F-6 6 FHCS, 3/8-6 x 6", VZ, GR5 30 F-6 FHCS, /4-0 x 3/4", GRS, YZ 3 F-575 SPRING, COMP.656 X.05 X.97 3 H Roller, 3-3/4 DIA. x 4-3/6L 33 H-39 4 /" Rue Ring 34 H-40 /" x 4-/" Clevis Pin 35 H-78 /" x 5-/" Clevis Pin 36 H-73 Chute, Discharge, Small 643-A Chute, Assembly 37 P-0935 Decal, WARNING 38 P-094 DECAL "DANGER ROTATING BLADES" 39 P-43 DECAL, HOIST POINT 40 P-93 DECAL, JAZEE DECK BELT ROUTING 4 P-950 DECAL, DECK SIZE, 48 4 P-496 DECAL, MISSING CHUTE 43 P-706 WARNING DECAL, DISCHARGE CHUTE A DECK PROP ASS'Y, EDGE XL T 65-5A DECK PROP ASS'Y, EDGE 45 3 SPINDLE ASS'Y (SEE pg.4) 46 DOUBLE IDLER ASS'Y (SEE pg.5) 47 REAR IDLER ASS'Y (SEE pg.7) 48 FRONT IDLER ASS'Y (SEE pg. 7)

5 5" DECK ASSEMBLY l660al-00a~ REF NO. NO P 5 BUSHING W Hanger Weldment P OUTLET STIFFENER, SMALL A PULLEY COVER w/decals A 5 LIGHT DECK w/decals BOW SPLITTER BAFFLE 7 D-394 BELT, DANDO" B-80" 8 F /6" Flat Washer 9 F-5 6 /"WASHER,CUSTOM 0 F-546 5/8-8 X 3/4" Capscrew F-83 Carriage Bolt, /4 X 3/4" F Nut, 5/8-8 Nyloc, Flanged 3 F-9 5 FHCS, /4-0 x 0.75, YZ, LOCK PATCH, GR5 4 F-0 FHCS, 5/6-8 x 0.75, YZ, GR5 5 F-3 NUT, /4-0 NYLOC, FLANGED 6 F-48 3 FHCS, 5/6-8 x.00, YZ, GR5 7 F-5 Nut,3/8-6 Nyloc, Flanged 8 F-57 CARRIAGE BOLT, /4 X -/4" 9 F-6 6 FHCS, 3/8-6x6", YZ, GR5 REF NO. NO.. 0 F-575 SPRING, COMP.656 X.05 X.97 H Roller, 3-3/4 DIA. x 4-3/6L H-39 4 /" Rue Ring 3 H-40 /" x 4-/" Clevis Pin A Chute, Discharge, Small 5 P-0935 Decal, WARNING 6 P-094 DECAL "DANGER ROTATING BLADES" 7 P-43 DECAL, HOIST POINT 8 P-93 DECAL, JAZEE DECK BELT ROUTING 9 P-95 DECAL, DECK SIZE, 5 30 P-496 DECAL, MISSING CHUTE 3 P-706 WARNING DECAL, DISCHARGE CHUTE A DECK PROP ASS'Y, EDGE XL T 6~5A DECK PROP ASS'Y, EDGE 43 SPINDLE ASS'Y (SEE pg.4) 44 DOUBLE IDLER ASS'Y (SEE pg.5) 45 REAR IDLER ASS'Y (SEE pg.7) 46 FRONT IDLERASS'Y (SEE pg.7)

6 60" DECK ASSEMBLY ~ AI A~ " REF NO. NO P 3 BUSHING W Hanger Weldment W 60" DUST BAFFLE WELDMENT P BUSHING P OUTLET STIFFENER, SMALL P PULLEY COVER w/decals P GRIP, STANDUP A 60 LIGHT DECK w/decals W SPLITTER BAFFLE 0 D-394 BELT, BANDO" B-80" F /6" Flat Washer F /6-8 x 7/8" Capscrew 3 F-5 6 /" WASHER, CUSTOM 4 F-546 5/6-8 x 3/4" Capscrew 5 F-83 Carriage Bolt, /4 X 3/4" 6 F-889 / x -5/8" Clevis Pin 7 F-935 CARRIAGE BOLT, /4 X -/" 8 F Nut, 5/6-8 Nyloc, Flanged 9 F /6-8 x " CARRIAGE BOLT, 0 F-9 4 FHCS, /4-0 x 0.75, YZ, LOCK PATCH, GR5 F-5 FHCS, 3/8-6 x.5, YZ, GR5 F-3 NUT, /4-0 NYLOC, FLANGED 3 F-48 3 FHCS, 5/6-8 x.00, YZ, GR5 4 F-5 0 Nut,3/8-6 Nyloc, Flanged 3 REF NO. NO.. 5 F-60 FHCS, 3/8-6 x 4 /", YZ, GR5 6 F-6 4 FHCS, 3/8-6 x 6", YZ, GR5 7 F-575 SPRING, COMP.656 X.05 X.97 8 H Roller, 3-3/4 DIA. x 4-3/6L 9 H-39 4 /" Rue Ring 30 H-40 /" x 4-/" Clevis Pin 3 H-78 /" x 5-/" Clevis Pin 3 H-73 Chute, Discharge, Small 33 H-77 Roller, 3-3/4 DIA. x 3 /4"L 34 P-0935 Decal, WARNING 35 P-094 DECAL "DANGER ROTATING BLADES" 36 P-43 DECAL, HOIST POINT 37 P-95 DECAL, DECK SIZE, P-496 DECAL, MISSING CHUTE 39 P-706 WARNING DECAL, DISCHARGE CHUTE 40 P-837 DECAL, DECK BELT ROUTING A DECK PROP ASS'Y, EDGE XL T 65-5A DECK PROP ASS'Y, EDGE 4 SPINDLE ASS'Y (SEE pg.4) 43 DOUBLE IDLER ASS'Y (SEE pg.5) 44 REAR IDLERASS'Y (SEE pg.7) 45 FRONT IDLER ASS'Y (SEE pg.7)

7 TORQUE TO 00-0 LB-FT PULLEY NOT INCLUDED * IN ASSEMBLY - DECK SPINDLE ASSEMBLY 69FN-00A (APPLY THIN LAYER OF CHEVRON RYKOTAC GREASE TO THE TOP SURFACES OF THE BEARING AND HOUSING PRIOR TO INSTALLING #3 (BEARING CAP). BLADE NOT INCLUDED IN ASSEMBLY 8 NEW MOWERS ARE SHIPPED WITH 3 to 4 oz OF CHEVRON SRI NLGI GREASE INSIDE EACH SPINDLE HOUSING. 9 ~ 0 TORQUE TO 00 LB-FT REF REF NO. NO.. NO. NO. F-078 3/4-6 TOP LOCK NUT 4 F P * 48" DECK PULLEY 5 H-707 * P * 5" DECK PULLEY 6 H-88 * P * 60" DECK PULLEY H P CAP, BEARING H H-639 O'RING, RUBBER OPTIONAL BLADES 5 D-3867 BEARING, #606 H P SHAFT, SPINDLE H P HOUSING, SPINDLE H P BLADE DRIVER H P BLADE WASHER H F-073 5/8- X.5 HHCS GR. 8 H P 4 SPINDLE SPACER, WASHER F /8-4 X.5 CAP SCREW 3 F LOCK WASHER /8-4 LOCK NUT GREASE PACKET BLADE, HIGH LIFT, 7" CUT 48" BLADE, HIGH LIFT, 8 3/8" CUT 5" BLADE, HIGH LIFT, " CUT 60" BLADE, LOW LIFT, 7" CUT 48" BLADE, LOW LIFT, 8 3/8" CUT, 5" BLADE, LOW LIFT, " CUT, 60" BLADE, GATOR, 7" CUT 48" BLADE, GATOR, 8 3/8" CUT 5" BLADE, GATOR, " CUT 60"

8 9 8 DOUBLE IDLER DRIVE BELT IDLER & RELATED S 48" DECK REF NO. NO. TY. 60-0P 4 WASHER, BEARING CAP P Belt Tightner Arm P EXTENSION FOR SPRING P BELT KEEPER, B BELT P MOUNTING PIN A IDLER ARM ASSEMBLY P HANDLE, BELT TENSIONER P SPACER, BELT GUARD P BELT GUARD 0 D-393 PULLEY, V-IDLER, 4.59 OD, AB, NTN D-394 PULLEY,FLATIDLER,NTN,DBLINSERT F /8-6 Stover Nut 3 F /-3 Stover Nut 4 F /8" Flat Washer 5 F /8" LOCKWASHER 6 F-68 3/8-6 x-/4" Capscrew REF NO. NO. 7 F F F F-5 F-56 F F-8 4 F F F F-0 8 F-4 9 F-5 30 H H-69 3 D TY. 3 3/8-6 x " Capscrew /" LOCKWASHER /-3 Hex Jam Nut 9 /" WASHER, CUSTOM /-3 x-/" Capscrew /4" x /" DRIVE SCREW /-3 X -/4" CARRIAGE BOLT 3 /-3 THIN NYLOC NUT 3/8-6 x " Carraige Bolt 5 Nut, 5/6-8 Nyloc, Flanged WASHER.406D X.5OD X 7GA TH FHCS, 3/8-6 x 0.75, YZ, GR5 7 Nut,3/8-6 Nyloc, Flanged BALL, -/4" SPRING,5 X -/,TAPERED ENDS FLANGED BUSHING

9 DOUBLE IDLER DRIVE BELT IDLER & RELATED S 5" DECK (X, OF #5) 30~ 5/ / 4 30 REF NO. NO. 60-0P P P SP A P P P P P P D D F F F F-68 8 F-464, 3/8" Spacer BELT KEEPER MOUNTING PIN IDLER ARM ASSEMBLY LINK, BELT TENSION SPRING EXTENSION HANDLE, BELT TENSIONER SHACKLE SPACER, BELT GUARD BELT GUARD PULLEY, V-IDLER, 4.59 OD, AB, NTN PULLEY, FLAT IDLER, NTN, DBL INSERT 3/8-6 Stover Nut 3/8" Flat Washer 3/8" LOCKWASHER 3/8-6 x-l/4" capscrew /" LOCKWASHER 6 REF NO. NO. 9 F F-5 F-733 F-8 3 F F F F-0 7 F-4 8 F-5 9 F-4 30 F-5 3 F-5 3 F H H D ex am u 6 /" WASHER, CUSTOM /4" x /" DRIVE SCREW /-3 X -/4" CARRIAGE BOLT /-3 THIN NYLOC NUT 3/8-6 x " carraige Bolt WASHER, 3/8 FENDER WASHER.406ID X.5OD X 7GA THK FHCS, 3/8-6 x 0.75, VZ, GRS FHCS, 3/8-6 x.5, VZ, GRS FHCS, 3/8-6 x ", VZ, GRS Nut,3/8-6 Nyloc, Flanged Nut,/-3 Nyloc, Flanged FHCS, /-3 xl-3/4", VZ, GRS BALL, -/4" SPRING,5 X -/,TAPERED ENDS FLANGED BUSHING

10 DOUBLE IDLER DRIVE BELT IDLER & RELATED ~ 60" DECK (X, OF #7) 6 DECK~ REF NO. NO. 60-0P P P P P P A P P P P D-393 TY. 4 WASHER, BEARING CAP Belt Tightner Arm 3/8" Spacer EXTENSION FOR SPRING BELT KEEPER, B BELT MOUNTING PIN IDLER ARM ASS EMBLY HANDLE, BELT TENSIONER SHACKLE SPACER, BELT GUARD BELT GUARD PULLEY, V-IDLER, 4.59 OD, AB, NTN REF NO. 3 D-394 PULLEY, FLAT IDLER, NTN, DBL INSERT 3 4 F /8-6 Stover Nut 33 5 F /8" Flat Washer 34 6 F /8" LOCKWASHER 35 7 F-68 3/8-6 x-/4" Capscrew 36 8 F-394 3/8-6 x " Capscrew 37 9 F-464 /" LOCKWASHER NO. TY. F-489 /-3 Hex Jam Nut F-5 6 /" WASHER, CUSTOM F-733 /4" x /" DRIVE SCREW F-8 /-3 X -/4" CARRIAGE BOLT F-966 /-3 THIN NYLOC NUT F-976 3/8-6 x " Carraige Bolt F Nut, 5/6-8 Nyloc, Flanged F-083 WASHER, 3/8 FENDER F-0 WASHER.406ID X.5OD X 7GA THK F-4 FHCS, 3/8-6 x 0.75, YZ, GR5 F-5 FHCS, 3/8-6x.5, YZ, GR5 F-4 FHCS, 3/8-6 x ", YZ, GR5 F-5 0 Nut,3/8-6 Nyloc, Flanged F-5 Nut, /-3 Nyloc, Flanged F-54 FHCS, /-3 x-3/4", YZ, GRS H-405 BALL, -/4" H-69 SPRING,5 X -/,TAPERED ENDS D-3730 FLANGED BUSHING

11 RIGHT REAR STATIONARY IDLER ASSEMBLY FRONT STATIONARY IDLER ASSEMBLY REF NO. NO. 60-0P 660-P P 4 D D F WASHER, BEARING CAP BELT KEEPER SPACER, IDLER MOUNT PULLEY, FLAT IDLER, 6 PULLEY, FLAT IDLER, 5 " LOCKWASHER 8 REF NO. NO. 7 F F-5 9 F F-079 F-06 F-5. /-3 Hex Jam Nut 6 /" WASHER, CUSTOM /-3 THIN NYLOC NUT CARRIAGE BOLT /-3 X 3-3/4 /-3 X 3-/ CARRIAGE BOLT Nut -3 N loc Flan eel

12 LIFT HANDLE ASSEMBLY & RELATED S REF NO. NO P LIFT HANDLE, LOWER 659-0W FRAME WELDMENT, LH. 3 F-6 3/8-6 X " CAPSCREW P HANDLE LINK P HANDLE PIVOT BRACKET P TOP PEG LATCH PLATE P LIFY HANDLE, UPPER 8 H-60 SPRING, /" OD. X 8" 9 F-46 NUT, /-0 JAM 0 F-67 CARRIAGE BOLT, 3/8-6 X /4" P SPRING ANCHOR PLATE F-5 NUT, /-3, NYLOC FLANGED 3 F-5 /-3 X /4" GR. 5 4 F-439 /-3 X 3" GR. 5 REF NO. NO P HANDLE PIVOT PIN 6 F NUT, 3/8-6 LOCKNUT (STOVER) 7 F-889 CLEVIS PIN, / X 5/8" 8 F-5 /" FLAT WASHER 9 H-39 RUE RING, /" 0 H-34 VINYL GRIP, 3/8 X /" H-460 SPRING EXTENSION CABLE F-8 FHCS /-3 X " GR. 5 3 F-5 5 NUT, 3/8-6, NYLOC FLANGED 4 F-47 FHCS 3/8-6 X - /", YZ GR SEE PAGE 9 9

13 LIFT ASSEMBLY & RELATED S ~ 6----::: 659-7A RELEASE HANDLE ASSEMBLY # # # # P DRAG BAR TAB A RELEASE HANDLE ASSEMBLY P 4 DRAG LINK BAR P DECK HOOK P LIFT BAR W RELEASE HANDLE WELDMENT P LIFT SLEEVE, FRONT P HOOK KEEPER P LIFT SLEEVE. REAR 3 H-547 SPRING, TORSION 6 F-879 5/6-8 X /4" GR.5 4 F NUT, 3/8-6, STOVER 7 F-5 5/6-8 STOVER NUT 5 F WASHER, FLAT, 3/8" P DECK LIFT PEDAL 6 F-87 PIN, GROOVED, /4X.so. HARDENED P 4 HANGER PIN 7 F-073 CAPSCREW, 3/8-6 X, GR. 5 0 F-85 CLEVIS PIN, / X /4" 8 H-40 TREAD PAD F NUT. /" JAM 9 F /" STOVER NUT F /-3 X 3 /, " THREAD P LATCH PLATE 3 F-5 8 WASHER, / NARROW P PLATE, CATCH 4 H-39 8 RUE RING, /" 3 F-58 NUT, /4" STOVER 5 H-40 CLEVIS PIN, / X 4 /" 33 F-83 CARRIAGE BOLT, /4-0 X 3/4" 6 F CLEVIS PIN, / X 3/4" 34 F-88 /-3 x 3-/" CAPSCREW 7 F /6-4 x " HHCS 35 F /6-4 JAM NUT P ADJUSTABLE HANGER END 0

14 TRANSMISSION IDLERS & RELATED S 8 8-(X) OF IDLER ARM ASSEMBLY # # # P Mounting Pin W WLDT, MOTOR MOUNT A SPRING ANCHOR ASS'Y A S/A, IDLER ARM P SPACER,3/8Xl-/4, P CLUTCH STOP 7 D-39 4" Idler Pulley /" Bore 8 D Flanged Bushing 5/8" Bore 9 F /8-6 Stover Nut 0 F /8-6 x -/" Capscrew # # F /8-6 Jam Nut F-5 5 / WASHER, CUSTOM 3 F Nut, 5/6-8 Nyloc, Flanged 4 F-0 8 FHCS, 5/6-8 x 0.75, Y, GRS 5 F-5 3 Nut,3/8-6 Nyloc, Flanged 6 F-5 6 Nut,/-3 Nyloc, Flanged 7 F-54 FHCS, /-3 xl-3/4", VZ, GRS 8 F-80 FHCS, 3/8-6 x 3", Y, GRS 9 H-69 SPRING,5 X -/,TAPERED ENDS 0 P-98 DECAL, HYDRO BELT ROUTING

15 CASTER WHEEL ASSEMBLY ---5 NOTCH TO REAR OF MOWER NUT TO INSIDE 9 - i@._ (r OF MOWER -~ j:@'(/)_ 4 / 5 7 VALVE STEM TO OUTSIDE OF MOWER 6 5 / ~(@-- 4 # # W 659-8A 659-8A 6-36P P P 5 D P D F-9 9 F F CASTER YOKE WELDMENT FRONT WHEEL ASS'Y (LH) FRONT WHEEL ASS'Y (RH) BEARING SPACER BEARING CAP, RED BEARING SHIELD BEARING, 5/8 ID X -3/8 OD DECAL, PSI 3" TIRE W/RIM /-3 X 8" GR. 5 BOLT /-3 LOCK NUT 3 6" X " ROLL PIN # # D BEARING, SPD SF-6-3 F /6" FLAT WASHER F /6" LOCK WASHER F-863 5/6"-8 X " W/NYLOC PATCH W FRONT AXLE (EDGE) W FRONT AXLE (EDGE XLT) H-056 GREASE ZERK P STOP TAB F /4" X 5/8" SELF TAPPING SCREW F-855 3/6" X " ROLL PIN

16 FRAME SIDE & RELATED S FOR EDGE 4 \ ~ 7 \ 7 # # 659-0W FRAME SIDE RH W FRAME SIDE LH W AXLE MOUNTING WELDMENT W MOTOR MOUNT WELDMENT P SIDE PANEL RH P SIDE PANEL LH. 7 F-386 /-3 x -/4" CAPSCREW BOW WLDT, ENGINE GUARD 9 F-6 FHCS, 3/8-6 x " GR P 4 DRAG BAR TAB D-3730 BUSHING, 5/8 BORE F-5 4 NUT, 3/8-6, NYLOC FLANGED P BAR, BUMPER BRACE 4 F-7 6 FHCS, /-3 X -/4" GR.5 5 F-5 NUT, /-3 NYLOC FLANGED 6 F-4 FHCS, 3/8-6 X " GR.5 7 F-8 3 FHCS, /-3 X ", GR.5 8 F-46 NUT, /-3 JAM 3

17 FRAME SIDE & RELATED S FOR EDGE XLT # # 659-0W FRAME SIDE RH W FRAME SIDE LH W AXLE MOUNTING WELDMENT W MOTOR MOUNT WELDMENT P SIDE PANEL RH. (JS) P SIDE PANEL RH. (TS) P SIDE PANEL RH. (JS) 700-0P SIDE PANEL LH. (TS) F-386 /-3 x -/4" CAPSCREW 700-0BOW WLDT, ENGINE GUARD F-6 FHCS, 3/8-6 x " GR P 4 DRAG BAR TAB D-3730 BUSHING, 5/8 BORE (JS ONLY) F-5 4 NUT, 3/8-6, NYLOC, FLANGED # # P BAR, BUMPER BRACE 4 F-7 6 FHCS, /-3 X -/4" GR.5 5 F-5 NUT, /- 3, NYLOC FLANGED 6 F-4 FHCS, 3/8-6 X " GR.5 7 F-8 3 FHCS, /-3 X ", GR.5 8 H-8 SEAL, SHAFT,.75,.375, D-385 BRG, TAPPERED, SET W FRONT AXLE WLDT. D-386 BRG, TAPARED, SET P " WASHER 3 F-78 3/6 X " COTTER PIN 4 F-74-4 SLOTTED NUT 5 H-94 GREASE CAP 6 F-46 NUT, /-3, JAM 4

18 FENDER ASSEMBLY / TWINSTICK FENDER ASSY REF REF NO. NO.. NO. NO A FENDER CAP w/decal, EDGE/XLT, RH (JS) 5 F- 8 FHCS, 5/6-8x" GR.5 w/patch 65-48A FENDER CAP w/decal. EDGE XLT, RH (TS) 6 F-0 5 FHCS, 5/6-8 X 3/4" GR.5 P-95 DECAL, CONTROL PANEL A FRONT PANEL w/decal, EDGE XLT A FENDER CAP w/decal, EDGE/XLT, LH (JS) A FRONT PANEL w/decal, EDGE 65-49A FENDER CAP w/decal, EDGE XLT, LH (TS) 8 F /6-8 ''u''-nut 4 P-38 DECAL, PARK BRAKE 9 F /4-0 "U"-NUT A FENDER SKIRT w/decal, EDGE/XLT, RH 0 H-8 CUP HOLDER A FENDER SKIRT w/decal, EDGE/XLT, LH P-039 DECAL, "CUT HEIGHT" 7 P-985 DECAL, NEW CC, SM, BLK P BRACKET, FENDER A LATCH PLATE RH W/DECAL 3 P-557 DECAL, "CAUTION" P LATCH PLATE LH. 4 P-370 DECAL, WARNING SEE PAGE 3 & 4 5 H-66 U CHANNEL TRIM SEE PAGE 3 & P NEUTRAL PLATE F-9 8 FHCS, /4-0x3/4", GR.5 w/patch 7 P-3000 DECAL, "USA" 3 F-5 5 5/6-8 LOCK NUT 8 P-984 DECAL, NEW CC, LG, BLK A LOCK PIN, DECK HEIGHT, ASSY 9 P-94 DECAL, EDGE EDGE ONLY 5

19 SEAT, FOOTDECK & RELATED S SEAT "#9" - (EDGE XLT) u :_, MOWER SIDE PLATE 5 REF NO. NO P PLATE, SEAT (EDGE) P PLATE, SEAT (EDGE XLT) P PLT, REAR SEAT FILLER P PLATE, ARM REST, RH P PLATE, ARM REST, LH, w/handle P PLATE. ARM REST, LH (TS) 5 H-753 PAD, ARM REST P FOOT DECK, EDGE A FOOT DECK w/decals, EDGE XLT 7 H-39 /" RUE RING P LIFT BAR g H-449 SEAT (EDGE) H-604 SEAT (EDGE XLT) P-34 SERIAL TAG P-473 SERIAL TAG LAMINATION DECAL 3 H-760 TRACK KIT 4 F-486 3/8-6 JAM NUT 5 F-0 8 FHCS, 5/6-8x3/4" GR5 6 F /6" FLAT WASHER 7 H-764 HANDLE, JOYSTICK W BRAKE HANDLE 9 F /6-8 x " CAPSCREW P SPACER, SEAT PAN F-4 FHCS 5 6-8x" GR5 6 REF NO NO A 4 T-HANDLE ASSEMBLY (EDGE) F /8-6 NYLOC NUT, FLANGED {EDGE XLT) F-34 6 HFCS /4-0x5/8" SELF TAPPING F /4-0x3/4" CAPSCREW F /4" FLAT WASHER F-5 /" WASHER F-09-0 /4" LOCK WASHER H-90 3 SPRING, ASSIST F-5 9 5/6-8 STOVER NUT P-05 DECAL, TRANSMISSION OIL P BATTERY HOLD DOWN H-460 CABLE F /4-0 STOVER NUT F-858 /4-0 "U" NUT H-96 HANDLE, GRIP P- 974 DECAL, EDGE XLT H-80 CAP PLUG, PLASTIC (EDGE XLT) H-46 3 RUBBER BUMPER H-636 SPRING F-8 FHCS, /4-0x-/4" GR5 E-6374 SEAT SWITCH F-785 SCREW, 4 X 3/ 4" E-649 PLUNGER, SEAT SWITCH

20 FRONT STEP ASSEMBLY (EDGE XLT ONLY) REF NO NO P FRONT STEP F-4 FHCS, 3/8-6 X 4" GR.5 F /8-6 LOCK NUT 659-4P BRACKET, STEP MOUNT, RH 659-4P BRACKET, STEP MOUNT, LH H-46 RUBBER BUMPER BUTTON F-4 FHCS, 3/8-6 X 3/ 4 ff GR.5 7

21 FUEL TANK & RELATED S # # P STRAP, FUEL TANK SEE PAGE &3 3 H-74 FUEL TANK ASSEMBLY, SMALL 4 P-9 CARB/EPA LABEL 5 F-0 FHCS, 5/6-8x3/4", GR5 6 F-5 5/6-8 Stover Nut 7 H ft Fuel Line 8 H-687 / 0.0. Hose Spring Clomp 9 H ft VENT LINE 0 H-698 HOSE CLAMP,.406 OD H-74 PICK UP TUBE H-74 GROMMET, PICK UP TUBE 3 H-678 REMOTE VENT 4 H-679 REMOTE VENT GROMMET 5 H-743 GAS CAP 8

22 JOYSTICK STEERING CONTROL AND RELATED S 7 REF NO g NO.. 65-A JOYSTICK ASSEMBLY F-03 BUTTON SHCS, / 4-0x " 65-9P PIN, PIVOT, JS, LONG F-5 /" WASHER 65-6P SPACER, JOYSTICK PANEL F-5 3 5/6-8 STOVER NUT F /4-0 LOCK NUT F-00-0 /4-0 x 3-/" CAPSCREW 65-6P BUSHING,.375 ROD END, SHORT 9 REF NO. NO P LINKAGE, INNER, JOYSTICK 65-07P BUSHING,.375 ROD END 65-00P TUBE, PIVOT, JOYSTICK P OUTER, LINKAGE, JOYSTICK 4 F-0 3 FHCS, 5/6-8 x 3/ 4" GR5 5 H-99 BOOT 6 H-765 NUT, JOYSTICK 7 H-764 HANDLE, JOYSTICK

23 JOYSTICK ASSEMBLY 65-A 9 / TORQUE TO: 0 FT-LBS - YOKE, SWIVEL ASSEMBLY J65-9AI A ROD ASSEMBLY, SHORT H-947 GASKET. FOAM, JOYSTICK P HOUSING, JOYSTICK P PIN, PIVOT, JOYSTICK 5 F-03 BUTTON SHCS, /4-0 x ", CZ W NEUTERAL PLATE, WLDT 7 E-6474 SWITCH, SNAP MOUNT P MOUNT, SWITCH 9 F /4-0 LOCK NUT P TUBE, GUIDE, CONTROL ROD P YOKE, SWIVEL, JOYSTICK H-705 RING, DETENT,.75 EXT. 3 F-37 NUT, #-4, NYLOCK P SPACER, CAM DETENT 5 F H P P 9 F-36 0 F-35 F-93 F D P 5 D F-5 7 H F /6 x " SPIRAL PIN SPRING, DETENT, JOYSTICK TAB, CAM DETENT TUBE-SPACER, DETENT CAM WASHER, FLAT, # PLAIN SCR, PANHD, PHLPS, #-4x-3/4" /-3 x " CAPSCREW /" FLAT WASHER THRUST BEARING PIVOT, JOYSTICK ( OF 65-8A) BUSHING, FLANGED ( OF 65-8A) /" WASHER, CUSTOM SPRING, BELLEVILLE,.50x x.073 /-3 STOVER NUT 0

24 JOYSTICK STEERING CONTROL & RELATED S (CON'T) # # F-4 FHCS, 3 8-6x GR P STAND-OFF, LINKAGE MOUNT 3 F-3 NUT, /4-0 NYLOC, FLANGED P OUTER LINKAGE, JS 5 F /6" FLAT WASHER P INNER LINKAGE, JS P STUD, LINKAGE MOUNT P ROD, SHIFT CROSS 9 F /8" LOCKWASHER P SWIVEL ARM H-757 LINKAGE, JS D-3730 BUSHING 3 F-5 5/6-6 STOVER NUT P DAMPER BOLT, 5/6-8 x 3/4 5 F-60 4 E-RING FOR /4" SHAFT 6 H-467 DUAL ACTION DAMPER 7 F-06 SHCS -4 X - 4 ZINC

25 TWINSTICK STEERING CONTROL & RELATED S (RIGHTHAND SHOWN, LEFTHAND OPPOSITE) _ MOWER SIDE PANEL 3 TRANSMISS ION / REF NO. NO P H W 4 F F-9 6 H P P 9 F- 5 0 F P F-93 3 F P 5 F- 8 LINK ROD ASS EMBLY GR IP, 5", CLOSED END DUAL LEVER CONTROL NUT, 5/6-8, NYLOC FLANGED FHCS, 5/6-8 X /" w/patch ADAPTER, ROD END, LONG TUBE SPACER LOWER SHIFT BLOCK WASHER /-3 NUT, FLANGE LOCK WASHER, NYLON / ID x /8" HHCS, /-3 X ", YZ GR5 NUT, 3/8-6, NYLOC FLANGED SHI FTING YOKE FHCS, /4-0 X - /4", YZ GR5 REF NO NO.. F /8-6 JAM NUT F /4" LOCK WASHER F- 60 E- RING FOR /4" SHAFT F-307 3/8-6 X /4" CAPSCREW D FLANGED BUSHING 5/8" BORE F /6-8 x 3 /" CAPSCR EW E SWITCH, SNAP MOUNT 647-4P MOUNTING BRACKET (RH) P MOUNTING BRACKET (LH) F-3 NUT, /4-0, NYLOC FLANGED F- 045 SPACER F / 4" FLAT WASHER P DAMPER BOLT, /4-0 H-843 DUAL ACTION DAMPNER, 750N P DAMPER BOLT, 5/6-8 X 3/4"

26 I PARKING BRAKE ASSEMBLY & RELATED S / 7 SEE PAGE 3 FOR SEAT HINGE S LEFT SIDE PANEL 6 0 # # F-546 F-5 3 F F F P 7 F-3 8 H W 0 F-748 H-635 F P 4 H /6-8 X 3/4" H.H.C.S. 5/6" STOVER LOCK NUT 5/6-8 X -/" H.H.C.S. 5/6-8 X " H.H.C.S " COTTER PIN LINK, PARK BRAKE NUT, /4-0, FLANGED NYLOC BRAKE LINK BAR, BENT BRAKE ROD WELDMENT /4" NYLOC LOCK NUT EXTENSION SPRING 3/4 X 4" / 4" FLAT WASHER LOWER BRAKE LINK COMPRESSION SPRING 3

27 MOTOR & TRANSMISSION ASS'Y & RELATED S FOR.5HP KAWASAKI TORQUE TO~ FT -LBS / 4 3 I # # M-5393 E D H E F-3 ENGINE, KAW.5HP, FR65 CLUTCH-BRAKE, 5ft/Ib V-BELT, KEVLAR CORD, A-65 OIL DRAIN VALVE OIL PRESSURE SWITCH 7/6-0x-/" CAPSCREW, KEY, /4 SQ. X -/4" # TWIN GR P 8 F-4 FHCS, 5/6-8 X 3/4" BOLT GR P FREE WHEEL ANCHOR 36 0 H-87 CHOKE CABLE 37 H-60 THROTTLE CABLE 38 P DECAL, "CLEAN" 39 3 F-8 SETSCREW, /4" X /4" P REAR HYDRO BRACE P MOTOR PULLEY 4 6 D TRANSAXLE, RH, ZT D TRANSAXLE, LH, ZT F /4" FLAT WASHER 45 9 H-759 MUFFLER, KAWASAKI P FREEWHEEL CHAIN W/SPRING W MOTOR MOUNT 50 H-539 FAN BLADE REPLACEMENT 5 3 P-384 DECAL, TIRE PRESSURE, PSI 5 4 F-007 3/8-6 X -/" HEX BOLT 53 5 F /-3 STOVER NUT 54 6 F /6" FLAT WASHER 55 7 F-5 8 5/6-8 LOCK NUT P CLUTCH STOP 4 # F /4-0 X 5/8" GR. 5 F-58 4 /4-0 LOCK NUTS D-3353 TIRE, 0x0-0, TURF (48" DECK) D-3787 TIRE, 0x-0, TURF (5" DECK) F LUG NUT, / X P BRACE, TRANSMISSION P HYDRO MOUNT BRACE F-7 4 FHCS, /-3 X - / 4" GR5 F-45 5/6-8 X 6" BOLT GR8 F-0 FHCS, /-3 X -/4" GR P HYDRO BRACE F /6-8 X 3" BOLT P FAN SHROUD F /8" FLAT WASHER F /8-6 LOCK NUT F-80 5/6-8 x -/4" CAPSCREW F-49 5/6-3/8 RUE RING H-76 HOSE, /" x 9" F /8-6 x -/4" CAPSCREW F /8" LOCK WASHER H-57 VENT TUBE ADAPTER H-76 VENT TUBE ADAPTER P WHEEL BACKING PLATE H-567 TRANSAXLE OIL FILTER H HOSE CLAMP H-549 HOSE 5" LONG D-379 SMALL HYDRO TANK

28 MOTOR & TRANSMISSION ASS'Y & RELATED S FOR 4HP KAWASAKI 8 TORQUE TO~ FT-LBS / 4 3 I 3 I # # M-5394 ENGINE, KAW 4HP, FR730 TWIN E-647 CLUTCH-BRAKE, 75ft/Ib 3 D-389 V-BELT, KEVLAR CORD, A-65 4 H-590 OIL DRAIN VALVE 5 E-6307 OIL PRESSURE SWITCH 6 F-3 7/6-0x-/" CAPSCREW, GR P KEY, /4 SQ. X -/4" # F-0 4 FHCS, 5/6-8 X 3/4" BOLT GR P FREE WHEEL ANCHOR 37 0 H-87 CHOKE CABLE 38 H-60 THROTTLE CABLE 39 P DECAL, "CLEAN" 40 3 F-8 SETSCREW, /4" X /4" P REAR HYDRO BRACE P MOTOR PULLEY 43 6 D TRANSAXLE, RH, ZT D TRANSAXLE, LH, ZT F / 4" FLAT WASHER 48 9 H-750 MUFFLER, KAWASAKI P FREEWHEEL CHAIN W/SPRING W MOTOR MOUNT 5 H-539 FAN BLADE REPLACEMENT 5 3 P-384 DECAL, TIRE PRESSURE, PSI 53 4 F-007 3/8-6 X -/" HEX BOLT 54 5 F /-3 STOVER NUT 55 6 F /6" FLAT WASHER 56 7 F-5 8 5/6-8 LOCK NUT P CLUTCH STOP 5 # F /4-0 X 5/8" GR. 5 F-58 4 /4-0 LOCK NUTS D-3787 TIRE, 0x-0, TURF F LUG NUT, / X P BRACE, TRANSMISSION P HYDRO MOUNT BRACE F-7 4 FHCS, /-3 X -/4" GR5 F-45 5/6-8 X 6" BOLT GR8 H-76 HOSE, /" x 9" P HYDRO BRACE F /6-8 X 3" BOLT P FAN SHROUD F /8" FLAT WASHER F /8-6 LOCK NUT F-80 5/6-8 x -/4" CAPSCREW F-49 5/6-3/8 RUE RING P WHEEL BACKING PLATE F /8-6 x -/4" CAPSCREW F /8" LOCK WASHER D-379 SMALL HYDRO TANK H-76 VENT TUBE ADAPTER H-57 VENT TUBE ADAPTER H-567 TRANSAXLE OIL FILTER H HOSE CLAMP H-549 HOSE 5" LONG 6-43P SPACER F-043 SPACER, ENGINE PULLEY

29 MOTOR & TRANSMISSION ASS'Y & RELATED S FOR 3HP & 6HP KOHLER 8-57 TORQUE T; FT -LBS / I 3 I # # M-5403 ENGINE, KOHLER, 3HP KT730 M-5399 ENGINE, KOHLER, 6HP KT745 E-637 CLUTCH-BRAKE, 5ft/b (3HP) E-647 CLUTCH-BRAKE, 75ft/b (6HP) 3 D-389 V-BELT, KEVLAR CORD, A-65 4 H-589 OIL DRAIN VALVE 5 F-043 SPACER 6 F-3 7/6-0x-/" CAPSCREW, GR P KEY, /4 SQ. X -/4" 8 F-0 4 FHCS, 5/6-8 X 3/4" BOLT GR P FREE WHEEL ANCHOR 0 H-404 CHOKE CABLE H-60 THROTTLE CABLE P DECAL, "CLEAN" 3 F-8 SETSCREW, /4" X /4" P REAR HYDRO BRACE P MOTOR PULLEY (3HP) P MOTOR PULLEY (6HP) 6 D TRANSAXLE, RH, ZT D TRANSAXLE, LH, ZT F / 4" FLAT WASHER 9 H-75 MUFFLER, KOH TWIN, LOW MOUNT P FREEWHEEL CHAIN W/SPRING W MOTOR MOUNT H-539 FAN BLADE REPLACEMENT 3 P-384 DECAL, TIRE PRESSURE, PSI 4 F-007 3/8-6 X -/" HEX BOLT 5 F /-3 STOVER NUT 6 F /6" FLAT WASHER 7 F LOCK NUT 6 # # P CLUTCH STOP F /4-0 X 5/8" GR. 5 F-58 4 /4-0 LOCK NUTS D-3787 TIRE, 0x -0, TURF F LUG NUT, / X P BRACE, TRANSMISSION P HYDRO MOUNT BRACE F-7 4 FHCS, /-3 X -/4" GR5 F-45 5/6-8 X 6" BOLT GR8 H-76 HOSE, /" x 9" P HYDRO BRACE F /6-8 X 3" BOLT P FAN SHROUD F /8" FLAT WASHER F /8-6 LOCK NUT F-80 5/6-8 x -/4" CAPSCREW F-49 5/6-3/8 RUE RING P WHEEL BACKING PLATE F FFCS, 3/8-6X-/", THRO FORM F /8" LOCK WASHER D-379 SMALL HYDRO TANK H-76 VENT TUBE ADAPTER H-57 VENT TUBE ADAPTER H-567 TRANSAXLE OIL FILTER H HOSE CLAMP H-549 HOSE 5" LONG F /6" LOCK WASHER F /6-8 X " CAPSCREW 6-43P SPACER

30 E-645 WIRE HARNESS & RELATED S (JOYSTICK) / ~-0 TO SEAT SWITCH BLUE #4--fi BLUE #A Seat SW Sw BLK. JOYSTICK ~- ij--5 Clutch TO STARTER 3~~ FRAME/ b ij RED-----n BLK.~ () RED Ignition YELLOW () BLUE-A-RED () RED ~BLK. YEL. # # E-67 E E E E F F E E F-858 F-09-0 E F F F P BATTERY HOUR METER SOLENOID START SWITCH CLUTCH SWITCH /4-0 NUT /4-0 X 5/8" CAPSCREW KEY, SET BRAKE SWITCH /4-0 U-NUT /4" LOCK WASHER FUSE, #ATC-30 /4-0 x 3/4" CAPSCREW /4-0 STOVER NUT /4" FLAT WASHER BATTERY HOLD DOWN WIRE HARNESS 7 E E-647 WIRE HARNESS ADAPTER (KAWASAKI) E-6436 WIRE HARNESS ADAPTER (KOHLER) 9 E-648 CABLE, BATTERY TO SOLENOID 0 E-649 CABLE, SOLENOID TO ENGINE E-6474 JOYSTICK SWITCH -NOT SHOWN- E-6374 SEAT SWITCH 7

31 E-646 WIRE HARNESS & RELATED S (TWINS TICK) BU<. YEL RED Left Nuetral Safety J 0 SEAT SWITCH BLUE #4~UJE f'la Seat Safety Conn \ () BLUE.. RED YEL. 0 STARTER 3 Starter Switch () BLUE_LED ~LI(. () RED RED ---0 BU<.~ Clutch Connector ~ Batt Ground # # E-67 BATTERY E-5878 HOUR METER E-6054 SOLENOID E-5873 START SWITCH E-6403 CLUTCH SWITCH E-646 WIRE HARNESS P BATTERY HOLD DOWN E-6445 KEY, SET F-858 /4-0 U-NUT F-09-0 / 4" LOCK WASHER E-607 FUSE, #ATC-30 F /4-0 x 3/4" CAPSCREW F-58 /4-0 STOVER NUT F /4" FLAT WASHER E-647 WIRE HARNESS ADAPTER (KAWASAKI) E-6436 WIRE HARNESS ADAPTER (KOHLER) E-648 CABLE, BATTERY TO SOLENOID E-649 CABLE, SOLENOID TO ENGINE F-0-0 /4-0 NUT F-05-0 /4-0 x 5/8" CAPSCREW -NOT SHOWN- E-6374 SEAT SWITCH 8

32 WIRE HARNESS ADAPTER & RELATED S FOR.5HP & 4HP KAWASAKI TO OIL PRESSURE SWITCH TO BATTERY ENGINE STARTER 3 # # F- 58 /4-0 STOVER NUT F-05-0 /4-0 x 5/8" CAPSCREW 3 E-6054 SOLENOID 4 E-645 WIRE HARNESS (JOYSTICK) E-646 WIRE HARNESS (TWINSTICK) 5 F-0-0 /4-0 NUT 6 E-648 CABLE, BATTERY TO SOLENOID 7 E-649 CABLE, SOLENOID TO ENGINE 8 E-647 KAWASAKI HARNESS ADAPTER 9

33 WIRE HARNESS ADAPTER & RELATED S FOR KOHLER TO ENGINE TO BATTERY + TO ENGINE STARTER 3 # # F- 58 NUT, FLANGED, /4-0, W/NYLOC, GR5 F-6 FHCS, /4-0 x 3/4", YZ, GRS 3 E-6054 SOLENOID 4 E-645 WIRE HARNESS (JOYSTICK) E-646 WIRE HARNESS (TWINSTICK) 5 F-0-0 /4-0 NUT 6 E-648 CABLE, BATTERY TO SOLENOID 7 E-649 CABLE, SOLENOID TO ENGINE 8 E-6436 KOHLER HARNESS ADAPTER 30

34 NOTES / SERVICE RECORDS: DATE SERVICE WORK COMPLETED

35

36 Repair Parts Manual Country Clipper Division Shivvers Manufacturing Inc. 63 W. English St. Corydon, IA Ph Fax