INSTALLATION INSTRUCTIONS COUNTRY CLIPPER

Transcription

1 JACK ASSEMBLY INSTALLATION INSTRUCTIONS COUNTRY CLIPPER 614 W. English St. Corydon, IA P (4/2011)

2 TABLE OF CONTENTS JACK KIT PARTS LIST... PAGE 3 DRAG BAR REMOVAL AND INSTALLATION PAGE 4 JACK SHAFT INSTALLATION... PAGE 5 JACK BASE INSTALLATION... PAGE 6 JACK OPERATING INSTRUCTIONS... PAGE 7 BELT TIGHTENER INSTRUCTIONS PAGE 8 DECK LEVELING INSTRUCTIONS... PAGE 9 LATCH PLATE ADJUSTMENT... PAGE 10 2

3 JACK KIT PARTS LIST * USED TO MAKE DECK LATCH HORIZONTAL ON 42" & 48" DECKS Parts List ITEM PART NUMBER DESCRIPTION QTY 1 H-2434 BUNGEE CORD 12" BLACK A JACK SHAFT ASSEM P JACK BASE 1 4 F /2-13 Lock Nut 5 5 F /2-13 X 2-3/4" CARRIAGE BOLT P DRAG BAR, JACK 2 7 F /8" LOCKWASHER 2 8 F /8-16 x 7/8" Capscrew P SPACER 2 10 F /2-13 x 7-1/2" Capscrew 1 11 F /16-18 Lock Nut 1 12 F /16-18 x 1-1/2" Capscrew 1 13 F /2-13 X 5-1/2" Capscrew 1 14 F /2" WASHER, CUSTOM 5 15 F /2" LOCKWASHER

4 DRAG BAR REMOVAL AND INSTALLATION STEP 1. REMOVE CUT HEIGHT PIN AND LOWER DECK TO LOWEST POSITION. REINSERT PIN TO "PIN DOWN" DECK CUT HEIGHT ADJUSTER BAR. RELEASE THE QUICK RELEASE SYSTEM (QRS). STEP 2. REMOVE LEFT OUTSIDE DRAG BAR FROM THE DECK LIFT CASTINGS (FIG. 1). FOR "THE BOSS": REMOVE THE LEFT OUTSIDE LINK BAR WITH ROLLER AND THE DECK LATCH FLIP BAR. REAR DECK LIFT CASTING (LEFT SIDE) REMOVE BOTH SETS OF CLEVIS PINS, FLAT WASHERS AND HAIR PINS REMOVE DRAG BAR FIG. 1 STEP 3. REPLACE WITH (2) NEW DRAG BARS. ONE ON EACH SIDE OF THE DECK LIFT CASTINGS. FASTEN WITH (2) 1/2" CARRIAGE BOLTS, (3) FLAT WASHERS ON FRONT CASTING, (2) LOCK WASHERS AND NUTS. INSERT CARRIAGE BOLTS FROM INSIDE OUT (FIG. 2). TIGHTEN NUTS UNTIL THEY MAKE CONTACT WITH THE LOCK WASHERS, BUT NOT TIGHT ENOUGH TO FLATTEN THEM. HOLE TOWARDS REAR OF DECK INSERT FROM INSIDE OUT F-1813 CARRIAGE BOLT REAR DECK LIFT CASTING (LEFT SIDE) F-1464 LOCK WASHERS F LOCK NUTS (3) F-1521 FLAT WASHERS USED AS SPACERS FIG. 2 4

5 JACK SHAFT INSTALLATION STEP 4. INSERT JACK ASSEMBLY BETWEEN DRAG BARS AT THE HOLES CLOSEST TO THE REAR. FASTEN WITH 3/8-16 X 7/8 HHCS, 3/8 LOCK WASHER AND SPACER. FIG. 3. STEP 5. INSERT 5/16-18 X 1-1/2 HHCS ALL THE WAY THROUGH THE LEFT DRAG BAR AND FASTNEN WITH LOCK NUT. STEP 6. HOOK BUNGEE CORD THROUGH THE LAST HOLE IN THE LEFT DRAG BAR THEN CRIMP LOOP CLOSED. HOOK THE OTHER END OF THE BUNGEE CORD TO JACK WHEN NOT IN USE A JACK SHAFT ASSEMBLY H-2434 BUNGEE CORD REAR DECK LIFT CASTING (LEFT SIDE) HOOK THROUGH THIS HOLE THEN CRIMP LOOP CLOSE F /16-18 X 1-1/2 HHCS F /16 LOCK NUT F /8-16 X 7/8 HHCS F /8 LOCK WASHER P SPACER (BOTH SIDES) LEFT DRAG BAR FIG. 3 5

6 JACK BASE INSTALLATION STEP 7. INSERT JACK BASE ON TOP OF THE DECK SO THAT THE FRONT FITS ON THE OUTSIDE OF THE DECK HANGER BRACKET AND IN THE REAR, THE DRAG BAR IS POSITIONED BETWEEN THE DECK HANGER BRACKET AND JACK BASE. FIG. 4. STEP 8. INSERT 1/2-13 X 5-1/2 HHCS IN THE FRONT OF THE DECK AND THE 1/2-13 X 7-1/2 HHCS IN THE REAR. MAKE SURE THE BOLTS ARE INSERTED FROM INSIDE OUT AND PASS THROUGH THE BRACKET, BASE AND HANGER IN THE FRONT AND THE BRACKET, DRAG BAR, HANGER AND BASE IN THE REAR. STEP 9. TIGHTEN THE (2) 1/2 LOCK NUTS UNTIL THEY MAKE CONTACT WITH THE BASE, THEN BACK THEM OFF 1/4 TURN. F /2-13 X 7-1/2 HHCS EXISTING DRAG BAR F /2-13 X 5-1/2 HHCS P JACK BASE DECK HANGER DECK HANGER BRACKET F /2 LOCK NUT FIG. 4 6

7 JACK OPERATING INSTRUCTIONS 1. WITH THE MOWER ENGINE OFF. REMOVE THE CUT HEIGHT ADJUSTMENT PIN AND LOWER THE DECK TO THE LOWEST POSITION. "PIN DOWN" THE DECK LIFT HANDLE BY REINSERTING THE ADJUSTMENT PIN IN THE HOLE DIRECTLY ABOVE THE HANDLE. 2. LOOSEN THE BELT TIGHTENER HANDLE AND REMOVE THE BELT FROM THE ENGINE PULLEY. UNHOOK THE REAR OF THE DECK BY LIFTING THE QRS HANDLE. 3. ROTATE THE FRONT WHEELS SO THEY POINT FORWARDS - SIMMULATING BACKING UP. 4. RELEASE THE BUNGEE CORD FROM THE END OF THE JACK. ROTATE THE JACK HANDLE INTO "CRANKING" POSITION AND PULL THE JACK UP UNTIL THE BOTTOM TELESCOPING SHAFT LOCKS INTO PLACE. PULL THE TOP OF THE JACK UP UNTIL THE TOP LOCKS INTO PLACE. (JACK SHOULD BE TO THE OUTSIDE OF THE DECK LIFT HANDLE). CRANK THE JACK CLOCKWISE 8-10 TURNS TO ALLOW THE JACK TO PIVOT AROUND THE DECK LIFT HANDLE AND UNTIL THE BALL END OF THE JACK ENTERS THE ROUND HOLE IN THE JACK BASE. (FIG. 5) CONTINUE TURNING UNTIL THE LEFT REAR WHEEL IS APPROXIMATELY 8" OFF THE GROUND. 5. LIFT UP ON THE FRONT AXLE OR APPLY PRESSURE TO THE RAISE LEFT REAR WHEEL TO RAISE THE FRONT END OF THE MOWER. CONTINUE TURNING THE HANDLE UNTIL THE DECK IS IN POSITION TO WORK ON. DO NOT OVER TURN CRANK! DAMAGE MAY OCCUR. 6. TO LOWER THE DECK, REVERSE THE PREVIOUS STEPS. NOTE: THERE IS A 5-10 CYCLE BREAK-IN PERIOD FOR THE ACME THREAD. THE FIRST FEW USES OF THE JACK MAY REQUIRE A HIGHER CRANKING FORCE. IT'S RECOMMENDED TO SPRAY A LIGHT COATING OF WHITE LITHIUM GREASE ON THE ACME THREADS ONCE OR TWICE PER SEASON. DO NOT USE OIL. IF THE JACK DOESN'T STAY LOCKED IN THE TELESCOPED POSITION, THERE ARE TWO (2) DETENTS SCREWS THAT CAN BE ADJUSTED USING A FLAT-HEAD SCREW- DRIVER. TURN CLOCKWISE TO ADD TENSION; COUNTER-CLOCKWISE TO LOOSEN. DETENT SCREW DETENT SCREW EXTENDED JACK ROUND HOLE IN JACK BASE FIG. 5 7

8 BELT TIGHTENER INSTRUCTIONS ON SOME OF COUNTRY CLIPPER OLDER MODEL 42" AND 48" DECKS, THE BELT TIGHTENER WAS INSTALLED IN A VERTICAL POSITION (STANDING UP). DUE TO CLEARANCE ISSUES WITH THE JACK, IT WILL BE NECESSARY TO LAY THE BELT TIGHTENER DOWN. FAILURE TO DO SO WILL RESULT IN EQUIPMENT DAMAGE. IF YOUR BELT TIGHTENER IS IN THE FLAT POSITION, NO OTHER ACTION IS REQUIRED. DISASSEMBLING THE BELT TIGHTENER: KEEP DISCARD DISCARD DISCARD F /2-13 X 1-1/2 HHCS KEEP DISCARD REASSEMBLING THE BELT TIGHTENER: F /2-13 LOCK NUT KEEP FIG. 6 F /2-13 LOCK NUT NEW FROM PARTS BAG ROTATE TO FLAT POSITION F /2 WASHERS NEW FROM PARTS BAG F /2-13 LOCK NUT REUSED DRILL DECK THRU HOLE 15/32 FOR 1/2 BOLT F /2-13 X 1-1/2 HHCS REUSED FIG. 7 8

9 DECK LEVELING INSTRUCTIONS * THE BELOW STEPS ARE ONLY NECESSARY IF YOUR DECK ISN'T LEVEL 1. SET THE TIRE PRESSURE ON ALL FOUR TIRES TO 12 PSI. 2. MOVE THE MOWER TO A HARD LEVEL SURFACE. 3. POSITION THE CUTTING BLADES SO THAT THEY RUN PARRALLEL WITH THE MOWER FRAME (FRONT TO BACK). 4. ON THE RIGHT FRONT DECK HANGER, RUN THE 1/2" JAM NUT TO THE TOP OF THE THREADS OF THE DECK HANGER BOLT. (FIG. 8) 5. SET THE DECK LEVELING ARM IN THE TOP-MOST CUTTING POSITION. ON THE FAR RIGHT BLADE, MEASURE THE DISTANCE FROM THE FLOOR TO THE FRONT OF THE BLADE TIP. ADJUST THE FRONT LEFT DECK HANGER SO THAT THE DISTANCE FROM THE FLOOR TO THE FRONT OF THE FAR LEFT BLADE IS WITHIN 1/8" OF THE MEASUREMENT FOR THE FAR RIGHT BLADE. ADJUST THE REAR DECK HANGERS SO THAT THE RAKE IS APPROXIMATELY 1/4" - 1/2" ON EACH SIDE. 6. MAKE SURE THE DECK IS NOT RESTING ON THE FLOOR AT ANY TIME DURING THE LEVELING PROCEDURE. IF THE DECK IS RESTING ON THE FLOOR, IT WILL NEED TO BE RAISED TO A SETTING THAT ALLOWS IT TO HANG FREELY. PERFORM THE SAME METHOD ABOVE. 7. LOCK THE JAM NUTS ON THE DECK HANGERS. FAILURE TO LOCK THE JAM NUTS WILL RESULT IN AN UNLEVEL DECK OR LOST DECK HANGER PARTS. DECK HANGER BOLT 1/2 JAM NUT FIG. 8 9

10 LATCH PLATE ADJUSTMENT 1. MAKE SURE THE DECK IS LEVEL AND PINNED DOWN BEFORE ADJUSTING THE LATCH PLATE. 2. LIFT UP ON THE HOOK KEEPER WHILE PULLING UP ON THE RELEASE HANDLE. THIS WILL DISCONNECT THE REAR OF THE DECK. 3. LOOSEN THE NUTS ON THE CATCH PLATE OF THE LATCH PLATE USING A 7/16 WRENCH. PULL UP ON THE RELEASE HANDLE AS FAR AS IT WILL ALLOW. SLIDE THE CATCH PLATE BACK OR FORWARD TO WHERE THE LATCH PLATE WILL CATCH THE RELEASE HANDLE ROD AT ITS HIGHEST LOCATION. THIGHTEN THE NUTS. 4. LIFT UP ON THE LATCH PLATE AND PUSH DOWN ON THE RELEASE HANDLE TO LOCK DECK HOOKS BACK IN PLACE. 5. DOUBLE CHECK THE LATCH PLATE ADJUSTMENT BY RELEASING THE DECK HANGERS AND PULLING UP ON THE RELEASE HANDLE. IF THE LATCH PLATE CATCHES THE RELEASE HANDLE ROD, NO FURTHER ADJUSTMENT IS NEEDED. IF IT DOES NOT, REPEAT STEPS 3-5. LATCH PLATE CATCH PLATE HOOK KEEPER DECK HOOK FIG. 9 RELEASE HANDLE 10