Safety First. Please remember to always use SAFE shop practices when performing all service procedures.

Transcription

1 Safety First Please remember to always use SAFE shop practices when performing all service procedures.

2 2006 Update Manual January 2006

3 Country Clipper 2006 Update Manual Index Joystick Kill Switch Oil Pressure Switch Boss Hydro Lines Double Idler Kit Linkage Service Kits Zeton Twinstick Zeton Joystick Charger Joystick Charger Twinstick JAZEE Joystick JAZEE Grasscatcher Upgrade

4 Joystick Kill Switch PROBLEM Joystick Kill Switch may not engage when the joystick is in the neutral position AFFECTING All Joystick Models built before SN# 24320

5 Remove Fender Skirt Disconnect Upper Linkages Remove joystick side panel. Disconnect the upper linkages from the joystick assembly. Note Number of Spacers & Location Remove Joystick Handle Be sure to note the number of spacers and their location when removing the linkage bolt. Remove the handle from the joystick. Joystick Kill Switch Page 1

6 Remove Joystick Yoke Disconnect the Kill Switch Wires 3 Remove the three bolts that secure the joystick yoke to the side panel and slide the joystick assembly down through the joystick boot. Disconnect the kill switch wires and note their location. The wire sequence is blue-yellow-black with the black wire connected to the terminal on the side of the kill switch. Note Joystick Radius Location Remove Radius Edge After removing the joystick assembly, note the location of the groove in the yoke. Remove at least 1/8 of the radius on both sides of the groove to allow the tang on the kill switch to make solid contact with the joystick shaft when the joystick is in neutral position. Joystick Kill Switch Page 2

7 Reattach Kill Switch Remove More Radius (if necessary) Reattach the kill switch to the joystick assembly and slide the joystick shaft all the way down the yoke to ensure that the shaft will engage the kill switch tang. Remove more of the radius if necessary. Reattach Kill Switch Wires Reattach Joystick Yoke Reattach the kill switch wires. The wire sequence is blue-yellow-black with the black wire connected to the terminal on the side of the kill switch. Replace the three bolts that secure the joystick yoke to the side panel and slide the joystick assembly up through the joystick boot. Joystick Kill Switch Page 3

8 Attach Joystick Handle Reattach Upper Linkages Attach the handle to the joystick. Reconnect the upper linkages to the joystick assembly. Attach Fender Skirt Attach joystick side panel. Joystick Kill Switch Page 4

9 Oil Pressure Switch PROBLEM The 26-HP Kawasaki Liquid Cooled Engines on 2005 Boss lawnmowers built prior to the serial numbers listed below have the wrong oil pressure switch KALJB SN KALJB SN KALTB SN KALTB SN24158

10 Service Bulletin# PRODUCTS AFFECTED: 26 HP Kawasaki Liquid Cooled Engines SUBJECT: Oil Pressure Switches It has come to our attention that all 26-hp Kawasaki Liquid Cooled Engines on 2005 Boss lawnmowers built prior to the serial numbers listed below have the wrong oil pressure switch. We specify Kawasaki engines with normally open pressure switches, but were shipped engines with normally closed switches. The oil pressure switch is used to ground the hour meter on the mower. A normally closed switch will cause the hour meter to work when the key switch is turned on, but quits working when the oil pressure builds up and opens the switch. To correct the problem, you must order a new oil pressure switch from your distributor, part number E-6307, and replace the one that came with the engine. All mowers built prior to the serial numbers below are affected: 2660KALJB SN KALTB SN KALJB SN KALTB SN If you need further information, please contact John Grimes, Service Manager, at (800) COUNTRY CLIPPER MOWERS CORYDON,IA yclipper.com

11 Hydro Lines Kit# 629CN-001A

12 Prepare Mower Remove Fender Skirts Remove the fender skirts. Raise the machine off the ground and remove the wheels. Be sure to use jack stands or secure the mower in some way so it can t fall. Remove Deck Lift Spring Remove Old Steel Lines Remove the deck lift spring. Remove the old steel lines. Hydro Lines Page 1

13 New Hydro Lines Kit - One Side Elbows - O-Ring The New Hydro Lines Kit Includes: H-2492 H-2491 H-2495 H-2496 Insert Elbows The new 90 degree fittings have o-rings to seal them. The o-ring must be lightly oiled before placing them in the pump. This allows them to seal without tearing the o-ring. Both Elbows In - Placement Remove the old straight fittings from the pump and replace them with the new 90 degree fittings. The short fitting goes in the outside hole and the long fitting goes in the inside hole, as shown. Torque these fittings at 35 ft lb. The outside fitting must be placed into the pump flat. The inside fitting must be tilted approximately 30 degrees to allow the hose to clear the outside fitting. Hydro Lines Page 2

14 Wheel Motors Install New Hose Remove the steel lines and leave the straight fittings in the wheel motor. They should be torqued at 35 ft lbs. NOTE: If over torqued, but NOT leaking, do not adjust them. The new long steel braided hose fastens to the front wheel motor fitting and to the inside pump fitting. Snug Fittings Install Other Line Snug fittings so it will stay in place. Be sure it clears all the obstacles and bolt heads. Place the short hose on the rear wheel motor fitting and the outside pump fitting. Tighten the fittings snugly. Hydro Lines Page 3

15 Clear Obstacles Correct Position When you get them in the correct position, they will look like the picture. Twist the lines to the point that the lines clear everything. Torque all the hose fittings to 28 ft lbs. Replace Deck Lift Spring Replace Fender Skirt & Wheel Replace the deck lift spring. Replace the fender skirts and tires and take mower down from jack stands. Hydro Lines Page 4

16 Double Idler Kit

17 Remove Pulley Covers Locate Bolts on Bottom of Deck Remove the pulley covers. Locate the idler pulley and spring anchor bots on the bottom of the deck. Locate Bolts on Bottom of Deck Remove Flexible Idler Locate the idler pulley and spring anchor bots on the bottom of the deck. Using an allen wrench and a half inch combination wrench, remove the flexible idler. Double Idler Kit Page 1

18 Remove Spring Anchor Bolt Remove Idler Assembly 3 Remove the spring anchor bolt. Remove the Idler Assembly. NOTE: On newer decks, remove the belt tensioner. Remove Stationary Idler Bolt Remove Idler Pulley & Spacers Remove the stationary idler bolt. Remove the idler pulley and spacers Double Idler Kit Page 2

19 Remove Spring Anchor Bolt & Belt Remove Front Idler Remove the spring anchor bolt. Remove the front Idler. Prepare New Hole Template Secure Template to Deck Place the template provided in the kit on the deck as shown. Secure the template to the deck with masking tape. Double Idler Kit Page 3

20 Hole Template Hole Placement Punch the X on the Diagram Mark the new holes with a hole punch. Punch the X on each hole. The template should set against the rear deck hangers as shown. Note the new hole placement. Remove Hole Template Drill 3 rd Hole Remove the template and lay it aside so you can reference it. The hole size is marked on each hole. Using the hole saw provided in the kit, drill the 1 1/8 hole for the base of the double idler. Double Idler Kit Page 4

21 Drill 1 st Hole Drill 2 nd & 4 th Hole Use a pilot drill to drill the holes. Drill hole #1. Drill the 2 nd and 4 th hole. Drill 5 th Hole Drill 6 th Hole Drill the 5 th hole for the belt tensioner handle. Drill the 6 th hole for the front stationery pulley. Double Idler Kit Page 5

22 Enlarge 2 nd, 3 rd, 4 th, 5 th & 6 th Hole Block Up Deck With the deck upside down, block the rear of the deck so that you can reach underneath the deck with your hand. Using the correct bit for each hole, enlarge each hole to the correct size. Attach Reinforcement Brackets Install Double Idler Base Two reinforcement brackets are provided in the kit. The large one fits the early model decks. The small one fits the later model decks. Choose the one that fits your deck and align it with the holes for the double idler. Place the double idler base on the deck as shown. Align the holes and place the bolts in front the top side down. The nuts will go on the bottom side of the deck. Double Idler Kit Page 6

23 Tighten Double Idler Base Bolts Double Idler Base - Top View Tighten the bolts. Turn the deck back over. The Double Idler Base should stick up through the deck as shown. Block Up Deck Double Idler Block up the rear of the deck so your arm can reach under the deck. The double idler comes in the kit assembled as shown above. Double Idler Kit Page 7

24 Install Pin on Bolt Install Double Idler on Deck Place the pin on the bolt. Attach Belt Tensioner Slide the double idler into the base as shown. Place a nut and washer on the bottom side and tighten the bolt. NOTE: When placing the double idler into deck, be sure to use your other hand to catch the pin. It will fall all the way through if not stopped. Put Idler Pulley Back On Attach Belt Tensioner. Put idler pulley back on. Double Idler Kit Page 8

25 Install Stationery Idler Bolt Install Stationery Idler on Deck Place the 1/2 x 3 1/2 bolt in the 1 st hole for the stationery idler pulley. Place the 1/2 spacer on the bolt. Put the pulley on the spacer, the 1/2 washer and bearing cover on the pulley and tighten the nut. Do the same with the pully in the 6th hole. Place Belt Guide & Belt on Pulley Tighten Belt Guide Nut Place the belt guides on the flat idler pulleys and leave them loose until you put the belt on. NOTE: Make sure guide is orientated so it does not touch the belt guide. After you have the belt on, adjust the belt guides and tighten them. Double Idler Kit Page 9

26 Attach Pulley Covers. Replace the pulley covers. Double Idler Kit Page 9

27 Linkage Service Kits Zeton Twinstick 629DB-001A Zeton Joystick 629DA-001A Charger Twinstick 629CX-001A Charger Joystick 629CW-001A JAZEE II Twinstick 629CZ-001A JAZEE/JAZEE II Joystick 629CY-001A

28 Linkage Service Kit Zeton Twinstick 629DB-001A

29 Zeton Twinstick Linkage Kit Jack Up Mower The Zeton Linkage Kit Includes: P P 4 - F H P 2 - F F P Raise the mower off floor. Place Mower on Jack Stands Remove Wheel Place jack stands under the frame for safety. Remove the wheel. Zeton Linkage Kit Page 1

30 Remove Fender Skirts Remove Lower Linkage Bolt 3 Remove the fender skirts. Locate the lower linkage and remove the bolt that holds the linkage to the linkage dish assembly. Remove Lower Linkage Remove E-Ring Remove the bolt that holds the lower linkage to the hydro pump shift lever. Remove the E-Ring from the steering dampener. Zeton Linkage Kit Page 2

31 Remove Dampener Remove Upper Linkage Bolt Pull the dampener from it pin. Remove the bolt holding the upper linkage to the linkage disk. Remove Linkage Disk Bolt Remove Linkage Disk Remove the bolt holding the linkage disk to its pin. Remove the linkage disk. Zeton Linkage Kit Page 3

32 Lower Linkages Place Shoulder Washer in Linkage Place shoulder washer in the ball joint on pump end of lower linkage. Place shoulder of washer to inside. Set the new lower linkage the same length as the old one and snug the lock nuts. NOTE: We are using a shoulder washer in order to use existing size hardware. NOTE: Length is measured from hole center to hole center. Attach Linkage to Mower Place Shoulder Washer Place the new shoulder washer (H-2465) in the ball joint on the front end of the new lower linkage. The shoulder should be placed toward the linkage disk. Bolt the new lower linkage to the hydro pump shift lever using the bolt and washer that held the old one. Tighten the bolt. Zeton Linkage Kit Page 4

33 New Linkage Bolt Place Bolt into Linkage Note the new allen head bolt. (F-1974) Place the bolt through the back side of the ball joint through the shoulder washer. Place Bolt into Disk Tighten Bolt Place the bolt through the linkage disk as shown. Place the nut on the bolt and tighten. Zeton Linkage Kit Page 5

34 Place Disk on Pin Put Disk Bolt in Place Place the linkage disk back on the mounting pin. Place the bolt back in the mounting mounting pin to hold the linkage disk in place. Tighten Plate Bolt Locate Upper Linkage Bolt Tighten the bolt. Pull handle back and locate the bolt in the upper linkage holding it to the pivot block. Zeton Linkage Kit Page 6

35 Remove Upper Linkage Bolt Upper Linkage Rods Lengthen the new heavy linkage to the same length as the old one. Snug the lock nuts down. Remove the upper linkage bolt. It is easier to get to the bolt by removing the fender cap, but can be done as shown. NOTE: Length is measured from hole center to hole center. Place Shoulder Washer Place Bolt in Linkage Place the shoulder washer in the upper ball joint. The shoulder should be toward the pivot block. Place the allen head bolt (F-1974) through the linkage. The nut is used as a lock nut after the bolt is screwed through the pivot block. Zeton Linkage Kit Page 7

36 Attach Linkage to Mower Linkage Disk Kit Parts Locate the threaded holt in pivot block and fasten the linkage rod to the pivot block. Tighten the bolt and place the lock nut on the back side of the pivot block and lock it down. In the parts packet, locate the 1/4 x 1 hex head cap screw, two 1/4 flat washers and the female dampener. Insert Bolt in Linkage Disk Place Second Washer Place the washer on the bolt and insert. Place the bolt through the slot on the linkage disk. Place the second 1/4 washer on the bolt as shown. Zeton Linkage Kit Page 8

37 Place Dampener Bolt Attach Upper Linkage to Disk Place the female dampener bolt in the lower ball joint as shown. Screw the 1/4 bolt into the female dampener bolt. Tighten Upper Linkage Bolt Attach Dampener Tighten the linkage bolt. Place the dampener onto the new dampener bolt. Zeton Linkage Kit Page 9

38 Replace E-Ring Place Steering Lever in Neutral Replace the E-Ring. Place the steering lever in neutral position and crank the engine. Adjust Neutral Tighten the Lock Nuts Adjust neutral until the wheel hub quits turning. Tighten the lock nuts on the upper linkage rods. Zeton Linkage Kit Page 10

39 Tighten Lock Nuts Attach Side Panel & Wheel Tighten the lock nuts on the lower linkage rods. Replace the side panel and replace the wheel. Torque the wheel to 75 ft. lbs. Test Drive Leftside Adjustment Drive the mower. If the linkage rods are the correct length, the machine will run straight. If it does not run straight, go the 2004 Update Manual and follow the directions in Section 7, Part 2 for twinsticks. LEFTSIDE ADJUSTMENT On a twinstick, both sides are adjusted in the same manner. Follow the directions again for the left side. Zeton Linkage Kit Page 11

40 Linkage Kit Zeton Joystick P-12131

41 1 Remove Wheels and Side Panels 2 Locate Linkage Rods Remove wheels and side panels from both sides. Locate the upper linkage rod and lower linkage rod on the right side. 3 Remove the Linkage Rods 4 Remove the Linkage Disk Remove the linkage rods from the linkage disk. Remove the linkage disk assembly. Zeton Joystick Linkage Kit Page 1

42 5 Remove the Upper Linkage Rod 6 Remove the Upper Linkages Remove the upper linkage rod from the swivel arm. Remove the upper linkage rod from the joystick. 7 Locate the Left Side Linkage Rod 8 Remove the Lower Linkage Rod Remove the lower linkage rod. Locate the lower linkage rod on the left hand side. Zeton Joystick Linkage Kit Page 2

43 9 10 Remove the Roll Pin Remove the Roll Pin Use a hammer and punch to tap out the roll pin. Remove the roll pin from the swivel arm. 11 Remove the Swivel Arm 12 Slide Shift Rod Out Slide the shift rod out of the tractor. Remove the swivel arm from the shift rod. Zeton Joystick Linkage Kit Page 3

44 13 14 New Shift Rod Insert New Shift Rod The new shift rod is an inch longer than the old one. It has the same part number. Replace the old shift rod with the new one provided in the kit. 15 New Shift Rod Holes 16 Pin the Swivel Arm Note the location of the three roll pin holes in the new shift rod. Use the middle one. The other two are for older mowers. Pin the swivel arm in the middle hole with a F-1503 (3/16 x 1 ) roll pin as shown. Zeton Joystick Linkage Kit Page 4

45 17 Replace Linkage Disk 18 Place Washer and Ring on Shaft Place the linkage disk assembly onto the end of the shaft. Place a P thrust washer on the shaft and place the spirol ring (F-1739) into the groove at the end of the shaft. 19 Adjust Linkage Rod Length 20 Place Bushings on Bolt Place two of the F-1989 ball joint bushings on the new F /4 20 X3 1/2 bolt with the small end toward the ball joint. Make both upper linkage rods exactly the same length as the old ones that were removed. Measure from hole center to hole center. Zeton Joystick Linkage Kit Page 5

46 21 Place Washer in Ball Joint 22 Place Upper Linkage Rod on Bolt Place the H-1465 shoulder washer into the upper ball joint of the upper linkage. Place the upper linkage rod on the bolt with the washer shoulder away from the the head of the bolt as shown. Place a ball joint bushing on the bolt with the small end toward the ball joint. 23 Place the Bolt through the Shaft 24 Place a Bushing on the Bolt Place the bolt through the pivot shaft on the joystick. Place a ball joint bushing on the bolt with the small end to the outside as shown. Zeton Joystick Linkage Kit Page 6

47 25 Place a Spacer on Upper Linkage 26 Place Upper Linkage on Bolt Place a shoulder washer in the second upper linkage. Place the upper linkage on the bolt with the spacer shoulder toward the pivot shaft. 27 Place Bushings on Bolt 28 Place Locknut on Bolt Place the two ball joint bushings on the bolt with the small end toward the ball joint. Place a F /4 locknut on the bolt. Zeton Joystick Linkage Kit Page 7

48 29 Tighten the Bolt 30 Place Bolt Through Linkage Rod Tighten the bolt. Place a 1/4 20 x 1 1/4 (F-1706) bolt through the lower end of the inside linkage rod. Place a H-2465 shoulder washer into the hole with the shoulder to the outside Place a Washer on the Bolt Slide the Bolt into the Slot Place a 1/4 flat washer on the bolt. Slide the bolt into the slot on the shift rod from the inside out. Zeton Joystick Linkage Kit Page 8

49 33 Place Washer on Bolt 34 Place Lock Nut on Bolt Place another 1/4 flat washer onto the bolt. Place a 1/4 locknut onto the bolt and tighten. Slide the bolt out against the allen screw in the end of the shift rod. 35 Place Washer in Lower Ball Joint 36 Place Washer on Bolt Place a shoulder washer in the lower ball joint of the outside linkage with the shoulder to the outside. Place a 1/4 flat washer on the bolt and slide it through the slot on the linkage disk assembly. Place a flat washer on the bolt. Zeton Joystick Linkage Kit Page 9

50 37 Place Locknut on Bolt 38 Remove the Lower Linkage Place the locknut on the bolt and tighten. But sure to pull the bolt out against the allen screw in the linkage disk. Remove the lower linkage rod on the right side. 39 Adjust Linkage Rod Length 40 Place Shoulder Washer Place a shoulder washer in the back ball joint so the shoulder will be against the shift lever on the transmission. Adjust the new lower linkage rod to the same length as the old one. Measure hole center to hole center. Zeton Joystick Linkage Kit Page 10

51 41 Fasten Linkage to Shift Lever 42 Tighten Fasten the linkage rod to the shift lever with the shoulder washer facing in. Tighten the bolt. 43 Place Shoulder Washer in Ball Joint 44 Place Bolt Through Linkage Disk Place a shoulder washer into the front ball joint with the shoulder facing forward. Place a 1/4 20 x 1 1/2 bolt through the ball joint on the back side of the linkage disk assembly throught the back top hole as shown. Place a locknut on the bolt and tighten. Zeton Joystick Linkage Kit Page 11

52 45 Tighten Lock Nuts 46 Locate Lower Linkage Tighten the jam nuts on the lower linkage. Locate the left side lower linkage rod. 47 Remove the Lower Linkage 48 Adjust Linkage Rod Length Adjust the new linkage rod to the same length as the old linkage rod. Measure from hole center to hole center. Remove the lower linkage rod. Zeton Joystick Linkage Kit Page 12

53 49 Place Washer in Ball Joint 50 Attach Lower Linkage Place the shoulder washer into the ball joint so that the shoulder will be against the shift lever. Attach the lower linkage to the shift lever and tighten. 51 Place Washer in Ball Joint 52 Place Bolt Through Linkage Place a shoulder washer in the ball joint so the shoulder will be against the back side of the shift rod tab. Insert a F /4 x 1 1/4 bolt inside the out through the linkage and the shift rod tab and place a locknut on it. Zeton Joystick Linkage Kit Page 13

54 53 Tighten 54 Tighten Jam Nuts Tighten the bolt. Tighten the jam nuts. 55 Adjust Neutral Adjust neutral as needed. Zeton Joystick Linkage Kit Page 14

55 Linkage Kit Charger Joystick P-12129

56 1 Remove Tire 2 Remove Side Panel Remove the wheel. Remove the fender skirt. 3 Remove E-ring 4 Remove E-ring Remove the e-ring from the top end of the dampener. Remove the e-ring that holds the dampener to the linkage. Charger Linkage Kit Page 1

57 5 Remove Dampener 6 Remove the Linkage Rod Remove the dampener. 7 Remove the Linkage Rod 8 Remove the right hand linkage from the swivel arm as shown. Adjust Linkage Rod Length Adjust the new 3/8 linkage rod to the same length as the old 1/4 linkage rod. Measure from hole center to hole center. Remove the linkage rod from the shift arm. Charger Linkage Kit Page 2

58 9 Tighten the Jam Nuts 10 Insert Shoulder Washer and Bolt Tighten the jam nuts on the new linkage rod. Place a shoulder washer into the upper ball joint so the shoulder will be against the swivel arm. Place a F /4 x 1 1/2 bolt throught the ball joint as shown and add a 1/4 flat washer. 11 Attach Linkage Rod to Swivel Arm 12 Place Bolt in Shift Lever Attach the linkage rod to the swivel arm with the linkage rod to the back side of the arm as shown. Place a 1/4 flat washer on the front side with a locknut. Push the linkage rod out against the allen screw in the slot and tighten. Place a 1/4 x 1 bolt (F ) through the shift lever slot with a 1/4 flat washer on each side of the shift lever. Place the new P dampener bolt through the lower ball joint and screw it on the bolt. Charger Linkage Kit Page 3

59 13 Tighten 14 Replace Dampener Tighten the bolt. Replace the dampener and e-rings. 15 Remove Bolt 16 Remove Short Linkage Remove the short linkage rod from the swivel arm. Remove the bolt that holds the linkage rods to the joystick. Charger Linkage Kit Page 4

60 17 Remove Linkage Rod 18 Adjust Length of Linkage Rod Adjust the new P linkage rod to the same length as the old one. Measure from hole center to hole center. Remove the long linkage rod from the shift lever. 19 Snug Jam Nuts 20 Adjust Length of Linkage Rod Snug the jam nuts. Adjust the new short linkage rod to the same length as the old one. Measure from hole center to hole center. Charger Linkage Kit Page 5

61 21 Place Washer in Ball Joint 22 Place Bushings on Bolt Place a shoulder washer into the upper ball joint Place two ball joint bushings on the new F /4 20 x 3 bolt with the small end away from the bolt head as shown. 23 Insert Bolt in Ball Joint 24 Place Bolt in Pivot Shaft Place the short linkage rod on the F-1765 bolt against the ball joint bushings. Place another ball joint bushing on the bolt with the small end toward the ball joint. Place the bolt inside out through the pivot shaft as shown. Charger Linkage Kit Page 6

62 25 Place Bushing on Bolt 26 Place Washer in Ball Joint Place another ball joint bushing on the bolt with the small end away from the pivot shaft. Place a shoulder washer in the upper ball joint on the new long linkage rod. The shoulder must be to the inside and the bend in the linkage rod will be out. 27 Place Linkage Rod on Bolt 28 Place Bushings on Bolt Place the linkage rod on the bolt as shown. Place two ball joint bushings on the bolt with the small ends toward the inside. Charger Linkage Kit Page 7

63 29 Place Locknut on Bolt 30 Place Washer in Ball Joint Place a locknut on the bolt and tighten. Place a shoulder washer in the lower ball joint of the short linkage with the shoulder facing out. 31 Place Bolt in Ball Joint 32 Place Washer on Bolt Insert a 1/4 20 x 1 1/4 bolt into the ball joint from the inside out. Place a 1/4 washer on the bolt. Charger Linkage Kit Page 8

64 33 Insert Bolt Through Swivel Arm 34 Place Washer on Bolt Slide the bolt through the slot in the swivel arm with the linkage rod behind the swivel arm as shown. Place a flat washer and locknut on the bolt. Slide the linkage rod against the allen screw and tighten. Place a 1/4 flat washer on a F /4 20 x 1 bolt. 35 Insert Bolt Through Shift Lever 36 Insert Dampener Bolt Place the bolt from the inside of the shift lever out through the slot on the right hand pump shift lever as shown. Place another 1/4 flat washer on the bolt. Place a P dampener bolt through the lower ball joint on the long linkage rod. Charger Linkage Kit Page 9

65 37 Tighten Dampener Bolt 38 Adjust Neutral Adjust neutral. Be sure to leave the linkage rods turned so they do not catch on anything. Screw the dampener bolt onto the bolt. Slide the bolt out against the allen screw and tighten. 39 Replace Dampener 40 Tighten Jam Nuts Replace the steering dampener on the right side. Replace e-rings on the dampener. Tighten the jam nuts on the right side. Charger Linkage Kit Page 10

66 Charger Twinstick Service Kit P-12170

67 Remove Side Panel & Wheel Remove E-Rings Remove the side panel and wheel. Remove the e-rings from the steering dampener. Remove Dampener Locate Bolt Remove the steering dampener. Locate the bolt that holds the linkage to the the twin stick pivot block and remove that bolt. Charger Twinstick Page 1

68 Remove Lower Linkage Bolt Adjust Linkage Rod 3 Remove the lower linkage bolt from the hydro shift lever. Adjust the new P linkage rod to the same length as the old linkage rod. Measure from hole center to hole center. Place Washer in Ball Joint Place Bolt in Washer Place a new D-2465 shoulder washer in the ball joint as shown. Place the new F-1974 socket head bolt through the upper ball joint on the linkage rod so that the shoulder of the washer will be against the pivot block. Charger Twinstick Page 2

69 Tighten Bolt Place Nut on Bolt Using a 1/8 allen wrench, screw the bolt into the pivot block and tighten. Place the F-1748 thin nyloc nut on the back side of the pivot block and tighten. This acts as a jam nut and prevents the bolt from backing out. Place Washer & Bolt in Shift Arm Place Washer on Bolt Place a 1/4 flat washer on a 1/4 20 x 1 bolt. Place it through the slot in the hydro shift arm as shown. Place a second washer on the bolt. Charger Twinstick Page 3

70 Place Dampener Bolt in Ball Joint Place Bolt in Dampener Bolt Place the new P dampener bolt through the lower ball joint. Screw the bolt into the dampener bolt. Hold Bolt Against Set Screw Replace Dampener Hold the bolt out against the setscrew in the hydro shift lever and tighten the bolt. Replace the dampener and e-rings. Charger Twinstick Page 4

71 Readjust Neutral Replace Wheel & Side Panel Readjust neutral as needed. Repeat Process on Other Side The left and right side are the same. Repeat the process on the other side. Charger Twinstick Page 5

72 Linkage Kit JAZEE Joystick P-12130

73 1 Remove Tire 2 Remove Side Panels Remove the wheels. Remove the fender skirts. 3 Locate Linkage Rods 4 Remove Linkage Rods Locate the lower linkage rods under the seat. Remove the lower linkagerods from the transmissions. JAZEE Linkage Kit Page 1

74 5 Remove Linkage Rods 6 Adjust Linkage Rod Length Adjust the new 3/8 linkage rod so it is the same length as the old linkage rod. Measure from hole center to hole center. Snug the jam nuts. 3 Note that the two ball joints are 90 degrees from each other. Remove the lower linkages from the hydro shift rods. 7 Place Washer in Ball Joint 8 Insert Bolt in Ball Joint Insert a shoulder washer into the upper ball joint. Insert a F /4 20 x 1 1/4 bolt with a 1/4 flat washer on it through the top ball joint. JAZEE Linkage Kit Page 2

75 9 Put Washer on Bolt 10 Slide Bolt in Swivel Arm Slide the bolt through the slot in the swivel arm. Place a 1/4 flat washer on the bolt. 11 Place Washer and Nut on Bolt 12 Remove the Right Linkage Rod Remove the right hand linkage rod and adjust the new linkage rod to the same length as the old one. Measure from hole center to hole center. Place a 1/4 flat washer on the bolt with a 1/4 locknut. Slide the bolt out to the allen screw and tighten. JAZEE Linkage Kit Page 3

76 13 Insert Washer in Ball Joint 14 Insert Bolt in Ball Joint Place a shoulder washer into the top ball joint on the right hand lower linkage. 15 Place Bolt in Swivel Arm 16 Insert a 1/4 20 x 1 1/4 bolt in the ball joint as shown. Place a 1/4 flat washer on the bolt. Add Washer & Bolt to Linkage Insert the bolt into the slot on the swivel arm. Place a 1/4 flat washer on the bolt with a lock nut. Slide the linkage out against the allen screw and tighten. JAZEE Linkage Kit Page 4

77 17 Place Washer in Ball Joint 18 Fasten Linkage Rods to Shift Arm Place a 5/16 spacer (H-2466) into the lower ball joint on both lower linkage rods. Use a 5/16 18 x 1 1/2 bolt to fasten the bottom of each linkage rod to the hydro shift lever. 19 Remove Upper Linkage Rods 20 Remove Upper Linkage Rods Remove the left upper linkage rod. Remove the right upper linkage rod. JAZEE Linkage Kit Page 5

78 21 Adjust Linkage Rod Length 22 Place Bushings on Bolt Adjust the new 3/8 linkage rods to the same length as the old linkage rods. Measure hole center to hole center. Place two H-1989 ball joint bushings onto the new F /4 20 x 3 1/2 bolt. Be sure the small ends are away from the bolt head as shown. 23 Place Washer in Ball Joint 24 Insert Bolt into Ball Joint Insert a shoulder washer into the the inside linkage rod ball joint. Insert the bolt through the ball joint. Put the shoulder toward the pivot shaft. Place another ball joint bushing on the bolt with the small end toward the ball joint. JAZEE Linkage Kit Page 6

79 25 Insert Bolt in Pivot Shaft 26 Place Washer in Ball Joint Place the bolt through the pivot shaft. Place a ball joint bushing on the bolt with the small end away from the pivot shaft. Place a shoulder washer in the outside linkage rod ball joint. 27 Place Linkage Rod on Bolt 28 Put Bushing and Nut on Bolt Place the linkage on the bolt with the shoulder washer toward the pivot shaft. Put two ball joint bushings on the bolt with the small end toward the ball joint. Place a locknut on the ball joint. JAZEE Linkage Kit Page 7

80 29 Tighten 30 Place Washer on Bolt Tighten the nut. Place a 1/4 flat washer on a F /4 20 x 1 1/2 bolt. 31 Place Bolt in Swivel Arm 32 Place Ball Joint on Bolt Place the bolt in the slot of the back swivel arm as shown. Place another 1/4 washer on the bolt. Place the ball joint on the bolt as shown and place a locknut on the bolt. JAZEE Linkage Kit Page 8

81 33 Slide the Linkage Rod Out 34 Tighten Slide the linkage rod out against the allen screw. Tighten the nut. 35 Place Washer on Bolt 36 Slide Bolt in Swivel Arm Place a 1/4 flat washer onto a 1/4 20 x 1 1/2 bolt. Slide the bolt into the slot on the front swivel arm. Place another 1/4 flat washer onto the bolt. JAZEE Linkage Kit Page 9

82 37 Place Washer in Ball Joint 38 Place Ball Joint on Bolt Place a shoulder washer into the lower ball joint on the outer or right hand linkage rod with the shoulder toward the swivel arm. Place the ball joint on the bolt. 39 Put Locknut on Bolt and Tighten 40 Adjust Neutral Adjust neutral Place a 1/4 locknut on the bolt, slide the ball joint out against the allen screw, and tighten the nut. JAZEE Linkage Kit Page 10

83 41 Tighten Jam Nuts 42 Place Spacer in Ball Joint Tighten the jam nuts. Place a new 5/16 spacer (H-2466) into the backside of the new bottom ball joint on the left hand lower linkage. Place F /16 18 x 1 1/2 bolt through the ball joint from front to back. 43 Slide Bolt Through Shift Lever 44 Place Washer and Locknut on Bolt Slide the bolt through the shift lever on the transmission. Place 5/16 flat washer and locknut on the bolt. JAZEE Linkage Kit Page 11

84 45 Tighten Tighten the nut. JAZEE Linkage Kit Page 12

85 JAZEE Grasscatcher Upgrade

86 Items Included in the Bagger Upgrade Kit The Bagger Upgrade Kit contains the following items: Old Bagger Notice that there is no blower unit on the front of the mower. 4 hose Lid Assembly Transition Blower Assembly Rear Deflector Debris Screen Blower Belt Front Bumper Weldment Hose Support Bracket Hardware Packet Remove Grass Hose Remove Old Bagger Transition Remove grass hose from old bagger transition and the lid assembly. Remove the old bagger transition. Bagger Upgrade Page 1

87 Remove Blower Blades Remove Lanyard 3 Remove blower blades and transition. Make arrangements for immediate return to Country Clipper. NOTE: Installation of high lift blades is recommended. Remove the lanyard from the frame and lid assembly. Remove Hinge Bolts Remove Grasscatcher Lid Remove the hinge bolts securing the lid assembly to the frame. Remove the old bagger lid assembly. Bagger Upgrade Page 2

88 Grasscatcher Unit Kit Install Grasscatcher Lid Assembly This part of the kit includes parts used to replace the bagger lid. Place the new lid assembly on the bagger frame. Install Hinge Bolts Install & Tighten Bagger Lanyard Install the hinge bolts. Attach the new lanyard to the bagger lid assembly. Bagger Upgrade Page 3

89 Attach Lanyard Extension Tighten Lanyard Extension Bolt Attach the lanyard extension to the lanyard. Tighten the bolt. NOTE: Be sure to leave it loose enough that it will swivel. Connect Lanyard Bolt Attach Lanyard Extension Attach the extension to the hole in the frame where the old lanyard was removed. Attach the extension to the bagger frame. Bagger Upgrade Page 4

90 Tighten Lanyard Extension Attach Transition Tighten the bolt. NOTE: Be sure to leave it loose enough that it will swivel. Attach the new transition. Use the same bolt holes that the old one used. Tighten Transition Bolts Deck Upgrade Tighten the bolts. This parts packet includes the parts to place the blower on the mower and the clamps for the hoses. Bagger Upgrade Page 5

91 Remove Scalper Bracket Bolt Remove Front Scalper Roller Remove the bolt in the front scalper bracket. Remove the front scalper roller. Replace Front Scalper Roller Tighten Front Scalper Roller Replace the front scalper roller with the one provided in the kit. Tighten the bolt in the front scalper roller. NOTE: It has been turned down to allow space for the blower bracket to fit. Bagger Upgrade Page 6

92 Remove Front Spindle Bolt Add Blower Drive Pulley Remove the nut on the front spindle. NOTE: Leave lock washer in place. Place the blower drive pulley on the spindle, screw it on and tighten it. NOTE: Put flat side of pulley down on lock washer. Locate Blower Adjustment Bolts Add Blower Pulley Belt The new blower has adjustment bolts on the bottom of the mounting bracket. Loosen the adjustment bolt shown in the second picture so the belt can be put on. Place the belt on the blower pulley and the two idlers. Remove pulley cover if necessary. Bagger Upgrade Page 7

93 Place Blower on Scalper Roller Place Belt on Drive Pulley Hold the belt on the pulleys and place the blower on the scalper roller spacer. The blower bracket will slide down beside the shortened roller and set on the spacer. Place the belt on the drive pulley. Place Clevis Pin in Bracket Tighten Blower Bolts and Belt Place the 6 clevis pin in the top hole of the scalper bracket and through the blower meeting bracket and pin it on. Tighten the belt by turning the belt tension screw. Tighten the bottom bolts to hold the blower in place. Bagger Upgrade Page 8

94 Attach Bumper Weldment Attach Grass Hose Using the 1/2 x 3 bolt, clamp the bumper weldment to the mower bumper. Tighten the bolts. Secure Tube With Lanyard Check the length of the 6 hose. It should be 62 long. If longer, cut to length. Place the hose on the lid assembly with the large clamp on the tube. Tighten the clamp. Attach the lower end to the transition. Final View - Secure Lanyard Place the cable around the lower end of the 6 tube. Place the hook on the bungee cord into both ends of the cable as shown. Hook the other end of the bungee into the hole in the front of the transtion as shown. Bagger Upgrade Page 9

95 Attach Hose Support Attach Hose to Blower Outlet Place tab on the top right hand bolt on the bumper. Bolt the hose support to the tab as shown above. Place a small clamp on the 4 hose and slide the hose on to the blower outlet tube. Clamp on Blower Tube Secure Transition End Tighten the clamp. Place the second clamp on the other end of the 4 hose and slide it onto the transition. Tighten the hose. Bagger Upgrade Page 10

96 Attach Rear Deflector Attach Debris Screen Attach the rear deflector by placing the flange inside the back of the lid assembly as shown. Bolt in in place with two 1/4 bolts and tighten. Place the debris screen against the bottom of the lid as shown. When placed properly, the back side will hook under the rear deflector as shown. Attach Debris Screen with Lanyard Final View A bungee cord is attached to the debris screen. Pull it to the top of the lid assembly. Find the hole that goes through the lid and the rear deflector. Hook the bungee cord in that hole. This will hold the debris screen in place. Bagger Upgrade Page 11