Country Clipper CHALLENGER D510, Product Manual, Page: 35 / 96

5.12
5.8.6 Plugs… Remove the top plug on the right side transaxle (Torque to 180 in-lbs) and remove the
side plug on the left side transaxle.
5.8.7 Install New Filter… After all the oil is drained out, replace the filters (use part H-2567 when
ordering from Country Clipper). Wipe off the filter base surface, apply a film of new oil to the
gasket of the new filter and hand tighten ¾ to one full turn after the filter gasket contacts the
filter base surface.
5.8.8 Fill Transaxle… Fill the transaxles with new 20W-50 motor oil through the expansion tank. When
the oil level in the transaxle reaches the top or side plug port reinstall the plug and continue filling
until the “Full Cold” line is reached on the expansion tank. Refilling both transaxles will take
approximately 4 quarts of oil.
5.8.9
Purge Procedure…
Trapped air must be removed from the hydrostatic drive system to achieve
optimum operation and longevity of the drive. Air creates inefficiency because its compression
and expansion rate are higher than that of the oil approved for use in hydrostatic drive system.
5.8.10 Drive Wheels Off Ground… Raise the rear drive wheels off the ground for the initial air purging.
5.8.11 Activate Bypass… Activate the Bypass to allow the drive tire to free wheel.
5.8.12 Start Engine… Start the engine and move throttle to ¾ to full throttle operation.
5.8.13 Activate Drive Lever(s)… Slowly operate the drive lever(s) in both forward and reverse directions
5 to 10 times.
5.8.14
Check Oil Level…
Check oil level; add oil as required after stopping the engine.
5.8.15 Repeat As Necessary… Repeat steps as necessary until all air is purged from the system.
5.8.16 De-Activate Bypass… De-Activate the Bypass to allow normal drive wheel operation.
5.8.17 Activate Drive Lever(s)… Slowly operate the drive lever(s) in both forward and reverse directions
5 to 10 times.
5.8.18 Check Oil Level… Check oil level; add oil as required after stopping the engine.
5.8.19 Drive Wheels on Ground… Lower the rear drive wheels to the ground.
5.8.20
Normal Operation…
Operate the mower for 30 to 60 minutes under normal driving conditions
and re-check the oil level. Add oil as required.
Note: Any servicing dealer attempting a warranty repair must have prior approval before conducting
maintenance of a Hydro-Gear product unless the servicing dealer is a current Authorized Hydro-Gear
Service Center.
Standard Operation Adjustments
5.9 Periodically adjustments may be required to maintain certain operating parameters or for operator
preference. The following section will provide details on how to make these adjustments.
Park Brake Adjustment
5.9.1 Disengage Park Brake… Push
the brake handle down to
disengage the Park Brake.
5.9.2 Adjustment Nut… Adjust the
top brake Adjustment Nut down
or up so that the Brake Rod Arm
is fully extended downward
5.9.3 Engage Park Brake… Pull the
brake handle up to engage the
Park Brake.
5.9.4 Adjust Compression Spring…
Adjust the Bottom Adjustment
Nut so that the compression
spring is compressed to 1/2”.
5.9.5 Adjust Both Linkages… Repeat
the adjustment on the other
side.
Top Brake
Adjustment Nuts
Brake Linkage
Assembly
Brake Rod Arm Bottom Brake
Adjustment
½”