McCulloch 966676301 Operator`s manual

Operator Manual
ZM3016 BF / 966676301
Please read the operator’s manual carefully and make sure you
understand the instructions before using the machine.
Gasoline containing up to 10% ethanol (E10) is acceptable for
use in this machine. The use of any gasoline exceeding 10%
ethanol (E10) will void the product warranty.
Form Number 115 456827 Rev A
2011-10-20
In order to implement improvements, specifications and designs can be altered without
prior notification.
Note that no legal demands can be placed based on the information contained in these
instructions.
Use only original parts for repairs. The use of other parts voids the warranty.
Do not modify or install non-standard equipment to the unit without consent from the
manufacturer. Modifications to the unit may cause unsafe operations or damage the unit.
When this product is worn out and no longer used, it should
be returned to the reseller or other party for recycling.
©2011 All rights reserved.
Orangeburg, SC Printed in U.S.A.
CONTENTS
INTRODUCTION................................................................ 5
General........................................................................ 5
Driving and Transport on Public Roads....................... 5
Towing......................................................................... 5
Operating..................................................................... 5
Good Service............................................................... 6
Manufacturing Number...................................... 6
SYMBOLS AND DECALS.................................................. 7
SAFETY............................................................................. 9
Safety Instructions....................................................... 9
Personal Safety Equipment....................................... 11
Slope Operation......................................................... 11
Safe Handling of Gasoline......................................... 13
General Maintenance................................................ 14
Transport................................................................... 16
Towing....................................................................... 16
Spark Arrestor............................................................ 16
CONTROLS..................................................................... 17
Control Locations....................................................... 17
Steering Control Levers............................................. 18
Parking Brake............................................................ 19
Throttle Control.......................................................... 19
Ignition Switch............................................................ 19
Choke Control............................................................ 20
Fuel Tank................................................................... 20
Fuel Shut Off Valve.................................................... 21
Mower Deck Lifting Lever.......................................... 21
Tracking..................................................................... 21
Blade Control Lever................................................... 22
Bypass Linkage......................................................... 22
OPERATION.................................................................... 23
Training...................................................................... 23
Steering..................................................................... 23
Before Starting........................................................... 24
Starting the Engine.................................................... 24
Weak Battery............................................................. 27
Jumper cables................................................. 27
Running..................................................................... 28
Operating on Hills...................................................... 29
Mowing Tips............................................................... 30
Stopping the Engine.................................................. 31
Moving Machine By Hand.......................................... 32
MAINTENANCE............................................................... 33
Maintenance Schedule.............................................. 33
Battery....................................................................... 35
Safety System............................................................ 36
Tire Pressures........................................................... 36
Parking Brake............................................................ 37
V-belts........................................................................ 37
Deck Belt .................................................................. 37
EZT Belt..................................................................... 38
Cutting Blades........................................................... 38
Blade Replacement......................................... 38
Adjusting the Mower Deck......................................... 39
Leveling Deck.................................................. 39
Caster Wheels........................................................... 40
Cleaning..................................................................... 40
Hardware................................................................... 40
LUBRICATION................................................................. 41
Front Wheel Mount.................................................... 42
Front Wheel Bearings................................................ 42
Deck Spindle.............................................................. 42
Transmission............................................................. 42
Steering Control Shafts.............................................. 42
Engine Lubrication..................................................... 42
TROUBLESHOOTING..................................................... 43
STORAGE........................................................................ 45
Winter Storage........................................................... 45
Service....................................................................... 45
SCHEMATICS.................................................................. 46
TECHNICAL DATA........................................................... 47
Torque Specifications................................................ 47
CONFORMITY CERTIFICATES...................................... 50
SERVICE JOURNAL........................................................ 51
WARNING!
Failure to follow cautious operating practices can result in serious injury to the
operator or other persons. The owner must understand these instructions, and must
allow only trained persons who understand these instructions to operate the mower.
Each person operating the mower must be of sound mind and body and must not be
under the influence of any mind altering substance.
WARNING!
Engine exhaust, some of its constituents, and certain vehicle components contain or
emit chemicals known to the State of California to cause cancer and birth defects or
other reproductive harm.
WARNING!
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
INTRODUCTION
Congratulations
Towing
Thank you for purchasing a McCulloch ride-on
mower. This machine is built for superior efficiency
to rapidly mow primarily large areas. A control panel
easily accessible to the operator and a hydrostatic
transmission regulated by steering controls both
contribute to the machine’s performance.
This manual is a valuable document. Read the
contents carefully before using or servicing the
machine. The following of instructions (use, service,
maintenance, etc.) by all who operate this machine
is important for the safety of the operator and others.
It can also considerably increase the life span of the
machine and increase its resale value.
If you sell your machine, be sure to give the operator’s
manual to the new owner.
The final chapter of this operator’s manual provides a
Service Journal. Ensure that service and repair work
are documented. A well-kept service journal reduces
service costs for the maintenance and affects the
machine’s resale value. Please contact your dealer for
more information. Take the operator’s manual along
when the machine is taken to your dealer for service.
If machine is equipped with a tow hitch, use extreme
caution when towing. Never allow children or others in
or on towed equipment.
Make wide turns to avoid jack-knifing. Travel slowly
and allow extra distance to stop. Do not tow on sloped
ground. The weight of the towed equipment may
cause loss of traction and loss of control.
Follow the manufacturer’s recommendation for weight
limits for towed equipment. Do not tow near ditches,
canals, and other hazards.
General
In this operator’s manual, left and right, backward and
forward are used in relation to the machine’s normal
driving direction.
Continuous dedication to improve our products
require that specifications and design are subject to
change without notice.
Driving and Transport on Public Roads
Check applicable road traffic regulations before
transporting on public roads. If the machine is
transported, you must always use approved fastening
equipment and ensure that the machine is well
anchored. DO NOT operate this machine on public
roadways.
Operating
This machine is constructed only for mowing grass
on lawns and even ground without obstacles such
as stones, tree stumps, etc. The machine can also
be used for other tasks when equipped with special
accessories provided by the manufacturer. Operating
instructions for the accessories are provided with
delivery. All other types of uses are incorrect. The
manufacturer’s directions concerning operation,
maintenance, and repairs must be carefully followed.
Lawn mowers and all power equipment, can be
potentially dangerous if used improperly. Safety
requires good judgement, careful use in accordance
with these instructions and common sense.
The machine must only be operated, maintained,
and repaired by persons familiar with the
machine’s special characteristics and who are also
knowledgeable about the safety instructions. Use only
approved repair parts to maintain this machine.
Accident prevention regulations, other general safety
regulations, occupational safety rules, and traffic
regulations must be followed without fail.
Unauthorized modifications to the design of the
machine may absolve the manufacturer from liability
for any resulting personal injury or property damage.
5
INTRODUCTION
Good Service
McCulloch’s products are sold only in specialized
retail stores with complete service. This ensures that
you as a customer receive only the best support and
service. Before the product is delivered, the machine
has, for example, been inspected and adjusted by
This Operator’s Manual belongs to the machine with
the manufacturing number:
Manufacturing Number
The machine’s manufacturing number can be found
on the printed plate affixed to the left in the engine
compartment. Stated on the plate, from the top are:
• The machine’s type designation (I.D.).
• The manufacturer’s type number (Model).
• The machine’s serial number (Serial no.)
Please have the type designation and serial number
available when ordering spare parts.
The engine’s manufacturing number is stamped on
one of the valve covers.
The plate states:
• The engine’s model.
• The engine’s type.
• Code
Please have these available when ordering spare
parts.
The wheel motors and hydrostatic pumps have a
barcode decal affixed at the rear.
6
your retailer. See the certificate in the Service Journal
in this operator’s manual.
When you need spare parts or support in service
questions, warranty issues, etc., please consult
the following professional:
Engine
Transmission
SYMBOLS AND DECALS
These symbols are found on the machine and in the
operator’s manual.
Study them carefully so that you know what they
mean.
IMPORTANT INFORMATION
WARNING!
Xxxx xxxxxx xxxxx xxxx xxxxxxxxx
xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx
xxxxxx.
Used in this publication to notify the reader of a risk
of personal injury or death, particularly if the reader
should neglect to follow instructions given in the
manual.
Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx
xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.
Used in this publication to notify the reader of a risk
of material damage, particularly if the reader should
neglect to follow instructions given in the manual.
Used also when there is a potential for misuse or
misassembly.
R N
Reverse
Neutral
Fast
Warning!
Parking Brake
Slow
CE conformity
marking. Only for
European market
Choke
Fuel
Do not stand here,
Use protective glasses
Noise emissions to the surroundings
in accordance with the European
Union’s directive. The machine’s
emission is stated in the chapter
TECHNICAL DATA and on the
decals.
Only machines for European market
Electromagnetic
Compatibility (EMC)
Compliance
Use protective gloves
7
SYMBOLS AND DECALS
Read
Operator’s
Manual
Whole body
exposure to
thrown objects
Shut off engine and
remove key before
performing any
maintenance or
repair work
Severing of fingers
and toes
Keep a safe
distance from
the machine
Use on slopes
no greater
than 10°
No passengers
Do not open or
remove safety
shields while
engine is running
Careful backing up,
watch for other
people
Careful going
forward, watch for
other people
Battery acid is corrosive, explosive and flammable
Moving sharp blades under cover
Warning! Rotating blades,
keep away from the
discharge deck
Do not touch parts
8
SAFETY
Safety Instructions
These instructions are for your safety. Read them
carefully.
WARNING!
THIS CUTTING MACHINE IS CAPABLE
OF AMPUTATING HANDS AND FEET
AND THROWING OBJECTS. FAILURE
TO OBSERVE THE FOLLOWING
SAFETY INSTRUCTIONS COULD
RESULT IN SERIOUS INJURY OR
DEATH.
General Operation
• Read, understand, and follow all instructions on
the machine and in the manual before starting.
• It is recommended that someone be aware that
you are mowing and can provide help in case of
injury or accident.
• Do not put hands or feet near rotating parts or
under the machine. Keep clear of the discharge
opening at all times.
• Only allow responsible adults, who are familiar
with the instructions, to operate the machine.
• Clear the area of objects such as rocks, toys, wire,
etc., which could be picked up and thrown by the
blades.
• Be sure the area is clear of bystanders before
operating. Stop machine if anyone enters the
area.
• Never carry passengers. The machine is only
intended for use by one person.
• Do not mow in reverse unless absolutely
necessary. Always look down and behind before
and while backing.
• Never direct discharged material toward anyone.
Avoid discharging material against a wall or
obstruction. Material may ricochet back toward
the operator. Stop the blades when crossing
gravel surfaces.
• Do not operate machine without the entire grass
catcher, discharge guard, or other safety devices
in place and working
• Slow down before turning.
• Never leave a running machine unattended.
Always turn off blades, set parking brake, stop
engine, and remove keys before dismounting.
WARNING!
This symbol means that important
safety instructions need to be
emphasized. It concerns your safety.
8011-512
Read the operator’s manual before starting the machine
8011-513
Clear the area of objects before mowing
9
SAFETY
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•
10
Disengage blades when not mowing. Shut
off engine and wait for all parts to come to a
complete stop before cleaning the machine,
removing the grass catcher, or unclogging the
discharge guard.
Operate machine only in daylight or good artificial
light.
Do not operate the machine while under the
influence of alcohol or drugs.
Watch for traffic when operating near or crossing
roadways.
Use extra care when loading or unloading the
machine into a trailer or truck.
Always wear eye protection when operating
machine.
Wear proper Personal Protective Equipment
(PPE) while operating this machine, including (at
a minimum) sturdy footwear, eye protection, and
hearing protection. Do not mow in shorts and/or
footwear with open toes. See the next section.
Data indicates that operators age 60 years and
above are involved in a large percentage of riding
mower-related injuries. These operators should
evaluate their ability to operate the riding mower
safely enough to protect themselves and others
from serious injury.
Follow the manufacturer’s recommendation for
wheel weights or counterweights.
Anyone who operates this machine must first read
and understand this Operation Manual. Local laws
may regulate the age of the user.
Keep machine free of grass, leaves or other
debris buildup which can touch hot exhaust or
engine parts and burn. Do not allow the mower
deck to plow leaves or other debris which can
cause buildup to occur. Clean any oil or fuel
spillage before operating or storing the machine.
Allow machine to cool before storage.
8011-520
Never take passengers
WARNING!
Engine exhaust and certain vehicle
components contain or emit chemicals
considered to cause cancer, birth
defects, or other reproductive system
damage. The engine exhaust contains
carbon monoxide, which is an
odorless, colorless, poisonous gas.
Do not use the machine in enclosed
spaces.
SAFETY
Personal Safety Equipment
WARNING!
When using the machine, approved
personal protective equipment (shown
in illustrations) shall be used. Personal
protective equipment cannot eliminate
the risk of injury but it will reduce the
degree of injury if an accident does
happen. Ask your retailer for help in
choosing the right equipment.
•
•
•
•
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•
Make sure that you have first aid equipment close
at hand when using the machine.
Never use the machine when barefoot.
Always wear protective shoes or boots, preferably
with steel toe caps.
Always wear approved protective glasses or a full
visor when assembling or driving.
Always wear gloves when handling the blades.
Never wear loose clothing that can get caught in
moving parts.
Use ear protectors to avoid damage to hearing.
8011-670a
Personal protective equipment
Slope Operation
Slopes are a major factor related to loss of control and
tip-over accidents, which can result in severe injury or
death. Operation on all slopes requires extra caution.
If you cannot back up the slope or if you feel uneasy
on it, do not mow it.
• Mow up and down slopes (10 degrees maximum),
not across.
• Watch for holes, ruts, bumps, rocks, or other
hidden objects. Uneven terrain could overturn the
machine. Tall grass can hide obstacles.
• Choose a low ground speed so that you will not
have to stop while on the slope.
• Do not mow on wet grass. Tires may lose traction.
• Avoid starting, stopping, or turning on a slope. If
the tires lose traction, disengage the blades and
proceed slowly straight down the slope.
• Keep movement on the slopes slow and gradual.
Do not make sudden changes in speed or
direction, which could cause machine to roll over.
• Use extra care while operating machine with
grass catchers or other attachments; they can
affect the stability of the machine.
6003-004
Mow up and down, not side to side
WARNING!
Do not drive up or down hills with
slopes greater than 10 degrees. Do
not drive across any slopes.
11
SAFETY
•
•
•
Do not use on steep slopes.
Do not try to stabilize the machine by putting a
foot on the ground.
Do not mow near drop-offs, ditches, or
embankments. The machine could suddenly roll
over if a wheel is over the edge or if the edge
caves in.
WARNING!
CHILDREN CAN BE INJURED BY
THIS EQUIPMENT. The American
Academy of Pediatrics recommends
that children be a minimum of 16 years
of age before operating a riding lawn
mower.
Children
Tragic accidents can occur if the operator is not
alert to the presence of children. Children are often
attracted to the machine and the mowing activity.
Never assume that children will remain out of the path
of danger.
• Be alert and turn machine off if a child enters the
area.
• Before and while backing, look behind and down
for small children.
• Never carry children, even with the blades shut
off. They may fall off and be seriously injured or
interfere with safe machine operation. Children
who have been given rides in the past may
suddenly appear in the mowing area for another
ride and be run over or backed over by the
machine.
• Never allow children to operate the machine.
• Use extra care when approaching blind corners,
shrubs, trees, or other objects that may block the
view of a child.
8011-518
Keep children away from work area
8011-517
Never allow children to operate the machine
12
SAFETY
Safe Handling of Gasoline
WARNING!
The engine must not be started
when the driver’s floor plate or any
protective plate for the mower deck’s
drive belt is removed.
To avoid personal injury or property damage, use
extreme care in handling gasoline. Gasoline is
extremely flammable and the vapors are explosive.
• Extinguish all cigarettes, cigars, pipes, and other
sources of ignition.
• Use only approved gasoline container.
• Never remove gas cap or add fuel with the engine
running. Allow engine to cool before refueling.
• Never fuel the machine indoors.
• Never store the machine or fuel container where
there is an open flame, spark, or pilot light such
as on a water heater or other appliance.
• Before beginning to refuel, minimize the risk of
static electricity by touching a metal surface.
• Never fill containers inside a vehicle or on a truck
or trailer bed with plastic liner. Always place
containers on the ground away from the vehicle
when filling.
• Remove gas-powered equipment from the truck
or trailer and refuel it on the ground. If this is not
possible, refuel such equipment with a portable
container, rather than from a gasoline dispenser
nozzle.
• Keep the nozzle in contact with the rim of the fuel
tank or container opening at all times until fueling
is complete. Do not use a nozzle lock-open
device.
• If fuel is spilled on clothing, change clothing
immediately.
• Never overfill fuel tank. Replace gas cap and
tighten securely.
• Do not start the engine near spilled fuel.
• Never use gasoline as a cleaning agent.
• If leaks arise in fuel system, engine must not be
started until problem has been resolved.
• Check the fuel level before each use and leave
space for the fuel to expand, as the heat from the
engine and the sun may otherwise cause the fuel
to expand and overflow.
8011-516
Never fill the fuel tank indoors
WARNING!
The engine and the exhaust system
become very hot during operation.
There is risk for burns if touched.
Allow engine and exhaust system to
cool before refueling.
13
SAFETY
General Maintenance
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•
•
•
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•
•
•
•
•
•
•
14
Never operate machine in a closed area.
Keep all nuts and bolts tight to be sure the
equipment is in safe working condition.
Never tamper with safety devices. Check their
proper operation regularly.
Keep machine free of grass, leaves, or other
debris buildup. Clean oil or fuel spillage and
remove any fuel-soaked debris. Allow machine to
cool before storing.
If the machine strikes a foreign object, stop and
inspect the machine. Repair, if necessary, before
restarting.
Never make any adjustments or repairs with the
engine running.
Check grass catcher components and the
discharge guard frequently and replace with
manufacturer’s recommended parts, when
necessary.
Mower blades are sharp. Wrap the blade or wear
gloves, and use extra caution when servicing
them.
Check brake operation frequently. Adjust and
service as required.
Maintain or replace safety and instruction labels,
as necessary.
Do not modify safety equipment. Check regularly
to be sure it works properly. The machine must not
be driven with defective or unmounted protective
plates, protective cowlings, safety switches, or
other protective devices.
Do not change the settings of governors and
avoid running the engine with overly high engine
speeds. If the engine runs too fast, there is risk for
damaging the machine components.
Be very careful when handling battery acid. Acid
on skin can cause serious corrosive burns. If
battery acid is spilled on skin, rinse immediately
with water.
Acid in the eyes can cause blindness, contact a
doctor immediately.
Be careful when servicing the battery. Explosive
gases form in the battery. Never perform
maintenance on the battery when smoking or near
open flames or sparks.
The battery can explode and cause serious injury
or damage.
Ensure that the equipment is in good condition
and that all nuts and bolts, especially those
fastening the blade attachments, are properly
tightened and torqued.
8011-515
Never drive the machine in an enclosed space
CAUTION
Use protective glasses for
maintenance work.
WARNING!
The battery contains lead and lead
compounds, chemicals that are
considered to cause cancer, birth
defects, and other reproductive system
damage. Wash your hands after
handling the battery.
SAFETY
Sparking can occur when working with the battery
and the heavy cables of the starter circuit. This can
cause battery explosion, fire or eye injury. Sparking
in this circuit can not occur after the chassis cable
(normally negative, black) is removed from the battery.
WARNING!
Avoid electrical sparking and its
consequences by the following
routines:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Use protective goggles.
Ensure that the fuel filler cap is mounted tightly
and no flammable substances are stored in an
open vessel.
Never work with the starter circuit if there is spilled
fuel.
Disconnect the negative cable from the battery
first and reconnect it last.
Do not make a bridge short circuit across the
starter relay to run the starter.
Never use the machine indoors or in spaces
lacking proper ventilation. The exhaust fumes
contain carbon monoxide, an odorless,
poisonous, and lethal gas.
Stop to inspect the equipment if the machine runs
over or into anything. If necessary, make repairs
before starting.
Never make adjustments with the engine running.
The machine is tested and approved only with the
equipment originally provided or recommended
by the manufacturer. Only use approved repair
parts for the machine.
The blades are sharp and can cause cuts and
gashes. Wrap the blades or use protective gloves
when handling them.
Check the parking brake’s functionality regularly.
Adjust and service as necessary.
The mulch blades should only be used in familiar
areas when higher quality mowing is desired.
Reduce the risk of fire by removing grass, leaves,
and other debris that may have accumulated on
the machine.
Allow the machine to cool before putting it in
storage.
Regularly clean deck and underside of deck,
avoid spraying engine and electrical components
with water.
6003-009
Do not smoke when performing maintenance on the battery.
The battery can explode and cause serious injury/damage.
8009-728
Risk of sparking
8011-514
Regularly clean deck
15
SAFETY
Transport
•
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•
•
•
•
The machine is heavy and can cause serious
crushing injuries. Be extra cautious when it is
loaded on or unloaded from a vehicle or trailer.
Use an approved trailer to transport the machine.
Activate the parking brake, turn off the fuel supply,
and fasten the machine with approved fastening
devices, such as bands, chains, or straps, when
transporting.
Do not operate this machine on public roadways.
Check and abide by local traffic regulations
before transporting the machine on any road.
Do not tow this machine: it may cause damage to
the drive system.
Load the unit onto truck or trailer by driving up
ramps of suitable strength using a slow speed. Do
not lift! The machine is not intended to be lifted by
hand.
When loading or unloading this machine, do not
exceed the maximum recommended operation
angle of 10O.
WARNING!
Use extreme caution when loading the
machine into a truck or trailer using
ramps. There is the possibility of
serious injury or death if the machine
falls off the ramps.
IMPORTANT INFORMATION
The parking brake is not sufficient to lock the
machine in place during transport. Ensure that
the machine is well fastened to the transport
vehicle. Always reverse the machine onto the
transport vehicle to avoid tipping it over.
WARNING!
Towing
If machine is equipped with a tow hitch, use extreme
caution when towing. Never allow children or others in
or on towed equipment.
Make wide turns to avoid jack-knifing. Travel slowly
and allow extra distance to stop. Do not tow on sloped
ground. The weight of the towed equipment may
cause loss of traction and loss of control.
Follow the manufacturer’s recommendation for weight
limits for towed equipment. Do not tow near ditches,
canals, and other hazards.
Escaping hydraulic oil under
pressure can have sufficient force
to penetrate the skin, causing
serious injury. If injured by escaping
fluid, see a doctor at once. Serious
infection or reaction can develop
if proper medical treatment is not
administered immediately.
Spark Arrestor
A spark arrestor for the muffler is available through an
authorized McCulloch dealer.
16
WARNING!
This mower is equipped with an
internal combustion engine and
should not be used on or near any
unimproved forested, bush covered
or grassy lands unless the engine's
system is equipped with a spark
arrestor meeting applicable local or
state laws (if any).
CONTROLS
This operator’s manual describes the McCulloch Zero
Turn Rider. The rider is fitted with a Briggs & Stratton
four-stroke overhead valve engine.
Transmission from the engine is made via belt-driven
hydraulic pumps. Using the left and right steering
controls, the flow is regulated and thereby the
direction and speed.
Control Locations
1
2
3
4
8058-111
5
1.
2.
3.
4.
5.
6
Cutting height handle
Park brake
Choke/throttle control
Ignition switch
Blade control lever
7
6.
7.
8.
9.
8
9
Motion control levers
Fuel tank
Fuel shut off valve
Bypass linkage
17
CONTROLS
Steering Control Levers
The machine’s speed and direction are continuously
variable using the two steering controls. The steering
controls can be moved forward or backward about a
neutral position. There is also a neutral position, which
is locked if the steering controls are moved outward.
When both controls are in the neutral position (N), the
machine stands still.
By moving both controls an equal amount forward
or backward, the machine moves in a straight line
forward or backward respectively.
In order, for example, to turn right while moving
forward, move the right control towards the neutral
position. The rotation of the right wheel is reduced and
the machine turns to the right.
Zero turn can be achieved by moving one control
backward (behind the neutral position) and carefully
moving the other steering control forward from its
neutral position. The rotation direction when zero
turning is determined by which steering control is
moved backward behind the neutral position. If the left
steering control is pulled backward, the machine turns
to the left. Use extra care when using this maneuver.
If the steering controls are in uneven positions when
standing still or do not fit in the slots for moving the
controls outward, they can be adjusted.
8050-003
Steering controls
WARNING!
The machine can turn very rapidly if
one steering control is moved much
further forward than the other.
1. Forward
2. Neutral
3. Neutral slot, Neutral lock
4. Reverse
Motion control lever, right side
18
8050-004
CONTROLS
Parking Brake
IMPORTANT INFORMATION
The machine must stand absolutely still when
applying the parking brake. Always set the
parking brake before dismounting. Release
the parking brake before moving the mower.
The parking brake is found on the right side of the
machine. Pull the lever backward to activate the brake
and push forward to release it.
8050-005
Parking brake not activated
Throttle Control
The throttle control regulates the engine speed and
thereby the rate of rotation of the blades.
In order to increase or decrease the engine speed,
the control is moved forward or back respectively.
Avoid idling the engine for long periods, as there is a
risk of fouling the spark plugs.
USE FULL THROTTLE WHEN MOWING, for best
mower performance and battery charging.
8050-006
Throttle control
Ignition Switch
The ignition switch is placed on the control panel and
is used to start and stop the engine.
IMPORTANT INFORMATION
Do not run the starter for more than five
seconds each time. If the engine does not
start, wait about 10 seconds before retrying.
8050-006
Ignition switch
19
CONTROLS
Choke Control
The choke control is used for cold starts in order to
provide the engine with a richer fuel mixture.
For cold starts the throttle should be pushed forward
to the choke position.
WARNING!
Gasoline is highly flammable. Observe
caution and fill the tank outdoors (see
the safety instruction).
8050-006
Choke control
Fuel Tank
Read the safety instructions before refueling. The
machine has one fuel tank, just behind the seat. The
tank volume is 3 gallons (11.4 liters).
Make sure the fuel cap is properly tightened and the
cap gasket is not damaged.
The engine will run on a minimum of 85-octane
unleaded gasoline (no oil mix). Environmentally
adapted alkylate gasoline can be used. See also
Technical Data concerning ethanol fuel. Methanol
fuel is not allowed. Do not use E85 alcohol based fuel.
Damage to engine and components may occur.
IMPORTANT INFORMATION
Experience indicates that alcohol blended
fuels (called gasohol, ethanol or methanol)
can attract moisture which leads to separation
and formation of acids during storage. Acidic
gas can damage the fuel system of an engine
while in storage. To avoid engine problems,
the fuel system should be emptied before
storage of 30 days or longer. Drain the gas
tank, start the engine and let it run until the
fuel lines and carburetor are empty. Use fresh
fuel the next season. See Storage Instructions
for additional information. Never use engine
or carburetor cleaners in the fuel tank or
permanent damage may occur.
8050-012
Fuel tank
WARNING!
The engine and the exhaust system,
become very hot during operation.
Risk for burns if touched.
Allow engine and exhaust system to
cool before refueling.
WARNING!
Fill to bottom of filler neck. Do not
overfill. Wipe off any spilled oil or fuel.
Do not store, spill or use gasoline near
an open flame.
20
CONTROLS
Fuel Shut Off Valve
The fuel shut off valve is located in the fuel line under
the seat. Tilt seat forward for access. The fuel valve is
ON when the valve is parallel to the fuel line. Rotate
the valve ¼ turn clockwise to turn fuel OFF.
IMPORTANT INFORMATION
In order to obtain an even cutting height, it is
important that the air pressure is 15 psi in all
tires.
8050-010
Fuel shut off valve in the OPEN position.
Mower Deck Lifting Lever
The lifting lever is used to place the mower deck in
the transport position or one of the 6 different cutting
height positions.
The cutting height is set by placing a lever in the
notch for the desired cutting height.
The lifting lever can also be used to temporarily adjust
the cutting height, such as when passing a minor
bump in the lawn.
IMPORTANT INFORMATION
Always use the high position (F) to transport.
8058-085
The mower deck’s lifting lever
Tracking
If the mower is not tracking straight, check the
air pressure in both rear tires. Recommended air
pressure is 15 psi. (1 bar) Tracking must be checked
on a flat and level concrete or blacktop surface.
If the unit still does not track straight contact your
McCulloch workshop for adjustments.
21
CONTROLS
Blade Control Lever
To engage the mower blades, slowly lift the lever up
and into the the lock notch.
WARNING!
No adjustments or maintenance to be
carried out unless:
•
the engine stopped
•
the ignition key removed
•
the parking brake activated
8058-074
Mower deck blade control lever in the disengaged position
Bypass Linkage
Transaxle bypass linkages must be engaged when
pushing or pulling the mower. The release levers are
located on each side of the rear of the unit below the
rear engine plate. See Moving Machine By Hand in
the Operation section.
WARNING!
Bypass linkages are located close
to the muffler. To prevent burns, the
engine should be shut off and allowed
to cool before the bypass linkage
levers are handled.
8050-018
Set bypass linkages into slots on both sides
22
OPERATION
Read the Safety section and following pages, if you
are unfamiliar with the machine.
Training
Due to unique steering capabilities, zero turn mowers
are far more maneuverable than typical riding
mowers.
This section should be reviewed in its entirety prior to
attempting to move the mower under its own power.
When first operating the mower or until becoming
comfortable with controls, use a reduced throttle
speed and reduced ground speed. DO NOT move
control levers to the furthest forward or reverse
positions during initial operation.
First time users should become familiar with the
mower’s movement on a hard surface, such as
concrete or blacktop PRIOR to attempting to operate
on turf. Until the operator becomes comfortable with
the mower controls and zero turning capability, overly
aggressive maneuvers may damage turf.
To turn to the right
While moving in a forward direction, pull the right lever
back towards the neutral position while maintaining
the position of the left lever, this will slow the rotation
of the right wheel and cause the machine to turn in
that direction.
To turn to the left
While moving in a forward direction pull the left lever
back towards the neutral position while maintaining
the position of the right lever, this will slow the rotation
of the left wheel and cause the machine to turn in that
direction.
To zero turn
While moving in a forward direction, first pull both
control levers back until the mower stops or slows
dramatically.
Then by alternating one lever slightly to the forward
position and the other in the reverse position,
complete the turn.
Steering
To move forward and backward
The direction and speed of the mower’s movements
are effected by the movement of the control lever(s)
on each side of mower. The left control lever controls
the left wheel. The right control lever controls the right
wheel.
First time users should push the mower (see Moving
Machine By Hand in the Operation section) to an
open, flat area without other people, vehicles or
obstacles nearby. To move the unit under its own
power, the operator must sit in the seat and start
the engine (see Before Starting in the Operation
section). Adjust the engine speed to idle, disengage
the parking brake but do not engage the blades at
this time. Rotate control levers inward. As long as
the control levers have not been moved forward or
backwards, the mower will not move.
Slowly move both control levers forward slightly. This
will allow mower to start moving forward in a straight
line. Pull the control levers back to the neutral position
and the mower should stop moving.
Pull back slightly on control levers, allowing the mower
to move backwards. Push the control levers forward to
the neutral position and mower should stop moving.
IMPORTANT INFORMATION
When control levers are in the reverse position
they return to neutral when released. This may
cause the mower to suddenly stop.
23
OPERATION
Before Starting
1. Read the sections Safety Instructions and
Controls before starting the machine.
2. Perform the daily maintenance before starting
(see Maintenance Schedule in the Maintenance
section).
3. Check that there is sufficient fuel in the fuel tank.
4. Adjust the seat to the desired position.
The following conditions must be fulfilled before the
engine can be started:
• The driver must be seated on the seat.
• The blade control lever for engaging the mower
blades must be down in the lower position.
• The parking brake must be on.
• Both steering controls must be in the locked
(outer) neutral position.
8050-020
Start conditions
Starting the Engine
1. Raise the mower deck by pulling the lifting lever
upward to the transport position (F).
2. Activate the parking brake.
8058-085
Raise the mower deck
3. Disengage the mower blades by lowering the
blade control lever out of the lock notch and into
the down position.
8058-074
Set the blade control lever to the down position
24
OPERATION
4. Move the steering controls outward to the locked
(outer) neutral position.
8050-028
Place controls in neutral position
5. Move the throttle to the middle position.
8050-008
Set the throttle
6. If the engine is cold, the choke control should be
pushed forward to the choke position.
8050-007
Choke control
25
OPERATION
7. Open the fuel valve.
8050-010
Open the fuel valve
8. Press in and turn the ignition key to the start
position
WARNING!
Engine exhaust and certain vehicle
components contain or emit chemicals
considered to cause cancer, birth
defects or other reproductive system
damage. The engine exhaust contains
carbon monoxide, an odorless,
colorless, poisonous gas. Do not use
the machine in enclosed spaces.
8050-135
Turn to START position
9. When the engine starts, immediately release the
ignition key back to the run position.
IMPORTANT INFORMATION
Do not run the starter for more than 5 seconds
each time. If the engine does not start, wait
approximately 10 seconds before retrying.
8050-136
Release ignition to the RUN position
26
OPERATION
10. Slowly pull back on the choke control when the
engine has started.
11. Set the engine speed with the throttle. Allow the
engine to run at a moderate speed, approximately
mid throttle, for 3-5 minutes before loading it too
heavily. USE FULL THROTTLE WHEN MOWING
(no choke).
WARNING!
Engine exhaust and certain vehicle
components contain or emit chemicals
considered to cause cancer, birth
defects, or other reproductive system
damage. The engine exhaust contains
carbon monoxide, which is a odorless,
colorless, poisonous gas. Do not use
the machine in enclosed spaces.
Weak Battery
8050-007
Use full throttle when mowing
IMPORTANT INFORMATION
Your mower is equipped with a 12-volt
negative grounded system. The other vehicle
must also be a 12-volt negative grounded
system. Do not use your mower to start other
vehicles.
WARNING!
Lead-acid batteries generate
explosive gases. Keep sparks,
flame and smoking materials away
from batteries. Always wear eye
protection when around batteries.
If the battery is too weak to start the engine, it should
be recharged. (See Battery in the Maintenance
section.)
Jumper Cables Use
1. Connect each end of the RED cable to the
POSITIVE (+) terminal on each battery, taking
care not to short against chassis.
2. Connect one end of the BLACK cable to the
NEGATIVE (-) terminal of the fully charged battery.
3. Connect the other end of the BLACK cable to a
good CHASSIS GROUND on the mower with the
discharged battery, away from the fuel tank and
battery.
To remove cables, reverse order
4. Remove BLACK cable first from chassis and then
from the fully charged battery.
5. Remove RED cable last from both batteries.
8011-642
Jumper cable connection
27
OPERATION
Running
1. Release the parking brake by moving the lever
downward.
NOTE: The mower is equipped with an operator
presence system. When the engine is running,
any attempt by the operator to leave the seat
without first setting the parking brake will shut off
the engine.
2. Move the steering controls inwards, out of the
neutral position (N).
8050-005
Parking brake not activated
3. Select the cutting height by placing the lever into
the desired notch.
WARNING!
Make sure that no one is near mower
when engaging the blade.
Make sure the work area is free from
objects that could be thrown by the
rotating blades.
8058-085
4. Move throttle control to full throttle.
5. Engage the mower blade by sliding the lever
upwards and into the lock notch.
6. The machine’s speed and direction are
continuously variable using the two steering
controls. When both controls are in the neutral
position, the machine stands still.
By moving both controls an equal amount forward
or backward, the machine moves in a straight line
forward or backward respectively.
In order, for example, to turn right while moving
forward, move the right control towards the neutral
position. The rotation of the right wheel is reduced
and the machine turns to the right.
Turning on the spot (zero turn) can be achieved
by moving one control backward (behind the
neutral position) and carefully moving the other
steering control forward from its neutral position.
Mower deck’s lifting lever
8058-075
Mower blade control lever locked into blade engagement
28
OPERATION
Operating on Hills
Read the Safety Instructions Driving on Slopes in the
Safety Instructions.
WARNING!
Do not drive up or down hills with
slopes greater than 10 degrees. Do not
drive across slopes.
•
•
•
•
•
•
The slowest speed possible should be used
before starting up or down hills.
Avoid stopping or changing speed on hills.
If stopping is absolutely necessary, pull drive
levers into the neutral position and push to the
outside of the unit and engage the parking brake.
To restart movement, release the parking brake.
Pull the control levers back to the center of the
mower and press forward to regain forward
motion.
Make all turns slowly.
8050-020
Start conditions
IMPORTANT INFORMATION
When in reverse, control levers return to
neutral when released. This may cause the
mower to suddenly stop.
29
OPERATION
Mowing Tips
•
•
•
•
•
•
•
•
30
Observe and flag rocks and other fixed objects to
avoid collisions.
Begin with a high cutting height and reduce it until
the desired mowing result is attained.
The average lawn should be cut to
2½" (64 mm) during the cool season and over 3"
(76 mm) during the hot months. For healthier and
better looking lawns, mow often after moderate
growth.
For best cutting performance, grass over 6" (15
cm) in height should be mowed twice. Make the
first cut relatively high, the second to the desired
height.
The mowing result will be best with a high engine
speed (the blades rotate rapidly) and low speed
(the rider moves slowly). If the grass is not
too long and dense, the driving speed can be
increased without negatively affecting the mowing
result.
The finest lawns are obtained by mowing often.
The lawn becomes more even and the grass
clippings more evenly distributed over the mown
area. The total time taken is not increased as a
higher operating speed can be used without poor
mowing results.
Avoid mowing wet lawns. The mowing result is
poorer because the wheels sink into the soft lawn,
clumps build, and the grass clippings fasten
under the cowling.
Hose the mower deck underside with water after
each use. When cleaning, the mower deck shall
be raised into the transport position. Make sure
the mower is cooled and the engine is off.
Use compressed air to clean top surface of the
deck. Avoid flooding water on top surface, engine
and electrical components.
When the mulching kit is used, it is important that
the mowing interval is frequent.
WARNING!
Clear the lawn of stones and other
objects that can be thrown out by the
blades.
8011-603
Mowing pattern
WARNING!
Never drive the rider on terrain that
slopes more than 10 degrees. Mow
slopes up and down, never side to side.
Avoid sudden directional changes.
OPERATION
Stopping the Engine
Allow the engine to idle a minute in order to attain
normal operating temperature before stopping it, if
it has been worked hard. Avoid idling the engine for
longer periods, as there is a risk of the spark plugs
fouling.
1. Disengage the mower deck by sliding the blade
control lever out of the lock notch and down into
the lower position.
8058-074
Disengage the mower blades
2. Raise the mower deck by pulling the lifting lever
upward to the transport position.
3. When the machine is standing still, activate the
parking brake by pulling the lever backward.
4. Move the throttle to the minimum position (tortoise
symbol). Turn the ignition key to the stop position.
Never use choke to stop the engine.
5. Move the steering controls outward.
6. Remove the key. Always remove key when leaving
the mower to prevent unauthorized use.
IMPORTANT INFORMATION
Leaving the ignition switch in any other
position than OFF will cause the battery to be
discharged.
8058-085
Raise the mower deck with the lifting lever
31
OPERATION
Moving Machine By Hand
When pushing or pulling the mower, be sure to
engage the EZT Hydrogear bypass linkages. The EZT
bypass linkages are located on the rear of the frame,
below the rear engine guard.
1. Raise the deck into the highest cutting position.
2. Pull the EZT bypass linkages out and into the
slots. Release linkages to hold in the bypass
position.
3. Release park brake.
4. To reengage the EZT’s to drive, reverse the above
procedure.
WARNING!
Bypass linkages are located close
to the muffler. To prevent burns, the
engine should be shut off and allowed
to cool before the bypass linkage
levers are handled.
WARNING!
Use extreme caution when loading the
machine into a truck or trailer using
ramps. There is the possibility of
serious injury or death if the machine
falls off the ramps.
WARNING!
Make no adjustments without:
•
•
•
32
the engine stopped,
the ignition key removed,
the parking brake activated
8050-018
Set bypass linkages into slots on both sides
MAINTENANCE
Maintenance Schedule
The following is a list of maintenance procedures that
must be performed on the machine. For those points
not described in this manual, visit an authorized
service workshop. An annual service carried out by
an authorized service workshop is recommended to
maintain your machine in the best possible condition
and to ensure safe operation.
Read Maintenance in the Safety section.
Daily
Maintenance
Before
Check the parking brake
●
Check the engine’s oil level (every refueling)
■
Check the safety system
●
♦
Check for fuel and oil leakages
After
Check/clean the engine’s cooling air intake
■
Check the mower deck
●
●
●
♦
♦
♦
♦
Check for loose hardware (screws, nuts)
Clean under the mower deck
Start the engine and blades, listen for unusual sounds
Check for damage
Thoroughly clean around the engine
Clean around belts, belt pulleys
At least
once
each
year
Maintenance interval
in hours
25
50
100
300
●
●
●
Check the tire pressures
Check battery
Sharpen/replace mower blades
Clean the engine’s cooling air intake 2)
■
■
Clean the air cleaner’s pre-filter
■
■
2)
(foam)
Clean the air cleaner’s filter cartridge 2) (paper filter)
■
■
Check/adjust the parking brake
♦
♦
First change after 5-8 hours. When operating with a heavy load or at high
ambient temperatures, replace every 50 hours.
2)
In dusty conditions, cleaning and replacement are required more often.
3)
For daily use, the machine should be lubricated twice weekly.
4)
Performed by authorized service workshop.
● = Described in this manual
♦ = Not described in this manual
■ = See engine manufacturers’ Owners Manual
1)
33
MAINTENANCE
Maintenance
Daily
Before
After
At least
once
each
year
Maintenance interval
in hours
25
50
●
Change the engine oil
■
1)
■
Replace the engine oil filter
■
■
Clean/replace the spark plugs
■
■
●
Check the caster wheels (every 200 hours)
Check/adjust the mower deck
Check the engine valve clearance 4)
Perform the 300-hour service 4)
Lubricate according to Lubrication Schedule 3,4)
●
♦
♦
●
●
●
●
First change after 5-8 hours. When operating with a heavy load or at high
ambient temperatures, replace every 50 hours.
2)
In dusty conditions, cleaning and replacement are required more often.
3)
For daily use, the machine should be lubricated twice weekly.
4)
Performed by authorized service workshop.
● = Described in this manual
♦ = Not described in this manual
■ = See engine manufacturers’ Owners Manual
1)
WARNING!
Before performing any service or adjustment checklist:
• Engage the parking brake.
• Place the Blade-switch in the disengaged position.
• Turn the ignition switch to OFF position and remove the key.
• Make sure the blades and all moving parts have completely stopped.
• Disconnect the spark plug wire from all spark plugs and place the wire where it cannot
come in contact with the plug.
34
300
●
●
Check/adjust throttle cable
Check the condition of belts, belt pulleys
100
●
♦
♦
●
MAINTENANCE
Battery
Your mower is equipped with a maintenance free
battery that does not need servicing. However,
periodic charging of the battery with an automotive
type battery charger will extend its life.
• Keep battery and terminals clean.
• Keep battery bolts tight.
• See chart for charging times.
Cleaning battery and terminals
Corrosion and dirt on the battery and terminals can
cause the battery to lose power.
1. Open the terminal access doors.
2. Disconnect BLACK battery cable first, then the
RED battery cable and remove the battery from
the machine.
3. Rinse the battery with plain water and dry.
4. Clean terminals and battery cable ends with wire
brush until shiny.
5. Coat terminals with grease or petroleum jelly
6. Reinstall battery.
IMPORTANT INFORMATION
Do not attempt to open or remove caps or
covers. Adding or checking level of electrolyte
is not necessary.
Always use two wrenches for the terminal
screws.
Replacing battery
1. Lift seat and rotate forward.
2. Open terminal access doors
3. Using two ½" wrenches disconnect BLACK battery
cable then RED battery cable.
4. Using a 7/16 wrench, remove the bolts on either
side of the terminal guard and lift off guard.
5. Carefully remove the battery from the mower.
6. Install new battery with terminals in the same
position as the old battery.
7. Reinstall battery terminal guard.
8. First connect RED battery cable to positive (+)
battery terminal with hex bolt and hex nut.
9. Connect BLACK grounding cable to negative (-)
battery terminal with remaining hex bolt and hex
nut.
10.Close access doors.
11.Lower seat.
Always use protective glasses when
handling the battery.
STANDARD
STATE
BATTERY
APPROXIMATE BATTERY CHARGING TIME*
TO FULL CHARGE AT 80OF / 27OC
OF
CHARGE
Maximum Rate at:
50 Amps
30 Amps
20 Amps
10 Amps
12.6V
100%
12.4V
75%
20 min.
- FULL CHARGE 35 min.
48 min.
90 min.
12.2V
50%
45 min.
75 min.
95 min.
180 min.
12.0V
25%
65 min.
115 min.
145 min.
280 min.
11.8V
0%
85 min.
150 min.
195 min.
370 min.
*Charging time depends on battery capacity,
condition, age, temperature and efficiency of charger
WARNING!
Do not short battery terminals by
allowing a wrench or any other object
to contact both terminals at the same
time. Before connecting battery, remove
metal bracelets, wristwatch bands,
rings, etc.
Positive terminal must be connected
first to prevent sparks from accidental
grounding.
2
1
2
1. Terminal guard
2. Access doors
Battery cleaning and installation
CZ-22
35
MAINTENANCE
Safety System
The machine is equipped with a safety system that
prevents starting or driving under the following
conditions.
The engine can only be started when:
1. The mower deck is disengaged.
2. The steering controls are in the outer, locked
neutral position.
4. The parking brake is on.
Make daily inspections to ensure that the safety
system works by attempting to start the engine
when one of the conditions is not met. Change the
conditions and try again.
If the machine starts when one of these conditions
is not met, turn the machine off and repair the safety
system before using the machine again.
Make sure the engine stops when the park brake
is not engaged and the operator leaves the seated
position.
Check that the engine stops if the mower blades are
engaged and the driver temporarily moves off the
drivers seat.
8050-020
Start conditions
IMPORTANT INFORMATION
In order to be able to drive, the driver must
sit in the seat and release the parking brake
before the steering controls can be moved into
the neutral position, otherwise the engine will
stop.
Tire Pressures
All tires should be at 15 psi / 103 kPa / 1 bar.
8011-564
Tire pressures
36
MAINTENANCE
Parking Brake
Visually check that no damage is found on the lever,
links, or switch belonging to the parking brake.
Perform a standstill test and check that there is
sufficient braking action.
To adjust the parking brake, contact the McCulloch
service workshop.
WARNING!
Faulty adjustment can result in reduced
braking ability and can cause an
accident.
8050-005
V-belts
Check for proper operation of parking brake
Check every 100 hours of operation. Check for severe
cracking and large nicks.
NOTE: The belt will show some small cracks in normal
operation.
The belts are not adjustable. Replace belts if they
begin to slip from wear.
Deck Belt
Deck Belt Replacement
Deck belt removal.
1. Park on a level surface. Apply park brake.
2. Lower the deck to the lowest cutting position.
3. Disengage the clutch by sliding the blade control
lever downwards.
8058-074
Disengage clutch to replace deck belt
4. Carefully lift the belt away from belt keepers and
off deck pulleys and remove from deck.
5. Replace belt (refer to the belt routing decal on the
deck) and re-engage clutch.
8050-013
Check deck belt for excessive wear
37
MAINTENANCE
EZT Belt
To replace EZT belt
Park the mower on a level surface. Engage the park
brake.
WARNING!
EZT belt removal
NOTE: Be careful not to damage the fan blades on
the EZT as this can affect cooling or damage the EZT.
1. Remove the deck belt (see Deck Belt
Replacement in this section of the manual).
2. Create slack in the belt by pushing the spring
loaded idler arm inward. Rotate arm to release
belt tension.
3. The belt should now be able to be removed from
the engine pulley and EZT pulleys.
The engine and the exhaust system,
become very hot during operation. Risk
for burns if touched. Allow engine and
exhaust system to cool.
Belt installation
1. Wrap the EZT belt around the EZT pulleys.
2. Route the belt around the inside of the idler pulley.
3. Wrap the belt around the engine pulley.
Cutting Blades
To attain the best mowing effect, it is important that
blades are well sharpened and not damaged.
Replace blades that have been bent or cracked when
hitting obstacles.
Let the service workshop decide whether a blade
with large nicks can be repaired/ground or must be
replaced. Balance the blades after sharpening.
Check the blade mounts.
Blade Replacement
1. Remove blade bolt by turning counterclockwise.
2. Install new or resharpened blade with stamped
GRASS SIDE facing towards ground/grass
(down) or THIS SIDE UP facing deck and cutter
housing.
3. Seat the blade's opening firmly onto the cutter
housing.
4. Tighten blade bolt securely.
5. Torque blade bolt to 45-55 ft/lbs (60-75 Nm).
WARNING!
Blades are sharp. Protect your hands
with gloves and/or wrap blades with a
heavy cloth when handling.
The sharpening of blades should be
carried out by an authorized service
workshop.
1
2
3
IMPORTANT INFORMATION
Special blade bolt is heat treated.
Replace with a McCulloch bolt if required.
Do not use lower grade hardware than
specified.
38
1. Blade
2. Cutter housing
3. Blade bolt (special)
Blade attachment
8058-129
MAINTENANCE
Adjusting the Mower Deck
WARNING!
Before performing any service or adjustment checklist:
1. Engage the parking brake.
2. Place the Blade switch in the disengaged position.
3. Turn ignition switch to OFF position and remove the key.
4. Make sure the blades and all moving parts have completely stopped.
5. Disconnect the spark plug wire from all spark plugs and place the wire where it cannot
come in contact with the plug.
WARNING!
Blades are sharp. Protect your hands
with gloves and/or wrap blades with a
heavy cloth when handling.
Check the tire pressure before adjustment of the
mower deck. See Checking Tire Pressure in
Maintenance. Faulty mower deck adjustments will
cause an uneven mowing result.
Leveling Deck
1. Position the mower on a level, preferably
concrete, surface.
2. Check the pressure in all four tires. See Technical
Data section.
3. Rotate blade to align side to side.
4. Turn front adjuster nut(s) to level deck side to
side.
8050-227
Side to side blade alignment
IMPORTANT INFORMATION
This will place the mower deck in a standard
measurement position. Depending on the
type of grass being mowed or environmental
conditions, additional adjustments may be
required to achieve the desired cut.
8050-015
Side to side adjuster nut
39
MAINTENANCE
Caster Wheels
Check every 200 hours. Check that wheels rotate
freely. If wheels do not rotate freely take the unit to
your dealer for service.
Foam filled tires or solid tires will void the warranty.
Removal and installation of caster wheel
1. Remove nut and caster bolt.
2. Pull the wheel out of the fork and take care of the
sleeve.
3. Reinstall in reverse order. Tighten caster bolt.
IMPORTANT INFORMATION
DO NOT add any type of tire liner or foam fill
material to the tires. Excessive loads created
by foam filled tires will cause premature
failures.
8050-908
Caster wheels
Only use O.E.M. specified tires.
Cleaning
Regular cleaning and washing, especially under the
mower deck, will increase the machine’s life-span.
Make it a habit to clean the machine directly after use
(after it is cooled), before the debris sticks.
Use compressed air to clean the top side of mower
deck. For cleaning the underside of the deck, use the
cleanout port.
Attach the quick connect (from the accessory packet)
to any garden hose. After mowing, snap the hose to
the cleanout port and turn on water.
Restart the mower and engage the blades to use the
spinning action to wash away debris. Make sure the
hose is away from the mower blades.
Avoid spraying water on the engine and electrical
components.
Use protective glasses when
cleaning and washing.
Hardware
Check daily. Inspect the entire machine for loose or
missing hardware.
40
8058-084
Clean regularly
LUBRICATION
8050-924
12/12 Every year
Lubricate with grease gun
1/52 Every Week
Oil change
Filter change
Level check
1/365 Every day
General
Remove the ignition key to prevent unintentional
movements during lubrication.
When lubricating with an oil can, it must be filled with
engine oil.
When lubricating with grease, unless otherwise stated,
use a high grade molybdenum disulphide grease.
For daily use, the machine should be lubricated twice
weekly.
Wipe away excess grease after lubrication.
It is important to avoid getting lubricant on the belts
or the drive surfaces on the belt pulleys. Should this
happen, attempt to clean them with spirits. If the belt
continues to slip after cleaning, it must be replaced.
Gasoline or other petroleum products must not be
used to clean belts.
41
LUBRICATION
Wheel and Deck Zerks
Front Wheel Mount
Use only good quality bearing grease.
Grease from well-known brand names (petrochemical
companies, etc.) usually maintains a good quality.
Lubricate with a grease gun, one zerk for each wheel
mount, until the grease is forced out.
Front Wheel Bearings
Lubricate 3-4 strokes with a grease gun on each set of
wheel bearings.
IMPORTANT INFORMATION
Use minimal lubrication and remove excess
lubricant so that is does not come into contact
with belts or belt pulley drive surfaces.
8050-009
Lubricating the wheel bearings
Deck Spindle
Lower the cutting deck completely.
If a grease gun without rubber hose is used, the foot
plate must be removed.
Lubricate with a grease gun, 2-3 strokes per spindle.
Transmission
The transmission is maintenance free with no need for
level checks or oil changes. If a leak occurs, replace
the unit or contact your McCulloch dealer.
8050-027
Lubricating the deck spindle after removing the foot plate
Steering Control Shafts
Tip the driver’s seat.
Lubricate with a grease gun, 2-3 strokes for each
steering control shaft.
Engine Lubrication
Refer to the engine manufacturer's manual for
maintenance and service instructions.
8058-076
Lubricating the steering control shafts
42
TROUBLESHOOTING
Problem
Cause
Engine will not start
•
Blade switch is engaged.
•
Steering controls are not locked in the neutral position
•
Parking brake is not activated
•
Battery is dead
•
Contamination in the carburetor or fuel line.
•
Fuel supply is closed or the shutoff valve for the fuel tank is in
the wrong position
•
Clogged fuel filter or fuel line
•
Ignition system faulty
•
Battery is dead
•
Poor contact of the battery terminal cable connections
•
Blown fuse
•
Fault in the starter safety circuit. See Safety System in the
Maintenance Section
•
Faulty carburetor
•
Choke control is pulled out with a warm engine
•
Clogged fuel filter or jet
•
Clogged ventilation valve on the fuel cap
•
Fuel tank nearly empty
•
Fouled spark plugs
•
Rich fuel mixture or fuel-air mixture.
•
Wrong fuel type
•
Water in fuel
•
Clogged air filter
•
Clogged air filter
•
Fouled spark plugs
•
Carburetor incorrectly adjusted
•
Blades are loose
•
Blades are incorrectly balanced
•
Engine is loose
Starter does not turn the engine over
Engine runs rough
Engine seems weak
Machine vibrates
43
TROUBLESHOOTING
Problem
Cause
Engine overheats
•
Clogged air intake or cooling fins
•
Engine overloaded
•
Poor ventilation around engine
•
Defective engine speed regulator
•
Too little or no oil in the engine
•
Contamination in the carburetor or fuel line.
•
Fouled spark plugs
•
Poor contact of the battery terminal cable connections
•
Charging lead is disconnected
•
Parking brake on
•
Bypass valve on pump open
•
Drive belt for the transmission slack or has come off
•
Air trapped in hydraulic system
•
Drive belt for the mower deck has come loose
•
Contact for the electromagnetic coupling has loosened
•
Blade switch is faulty or has come loose from cable
contact
•
Blown fuse
•
Damaged seals, housing, or gaskets
•
Air trapped in hydraulic system
•
Different air pressure in tires on the left and right sides.
•
Suspending for the mower deck is uneven
•
Blades are dull or bent
•
Driving speed too high
•
Grass is too long
•
Grass collected under the mower deck
Battery not charging
The machine moves slowly, unevenly, or not at all
Mower deck not engaging
Transaxle leaks oil
Uneven mowing results
44
STORAGE
Winter Storage
The machine should be readied for storage at the
end of the mowing season, or if it will not be in use for
longer than 30 days. Fuel allowed to stand for long
periods of time (30 days or more) can leave sticky
residues that can plug the carburetor and disrupt
engine function.
Fuel stabilizers are an acceptable option as regards
to the sticky residues that can occur during storage.
Add stabilizer to the fuel in the tank or in the storage
container. Always use the mixing ratios specified by
the manufacturer of the stabilizer. Run the engine for
at least 10 minutes after adding the stabilizer so that
it reaches the carburetor. Do not empty the fuel tank
and the carburetor if you have added stabilizer.
WARNING!
Never store an engine with fuel in the
tank indoors or in poorly ventilated
spaces where fuel vapor can come in
contact with open flames, sparks, or a
pilot light such as in a boiler, hot water
tank, clothes drier, etc. Handle the
fuel with care. It is very flammable and
can cause serious personal injury and
property damage. Drain the fuel into an
approved container outdoors and store
far away from open flame. Never use
gasoline for cleaning. Use a degreaser
and warm water instead.
To ready the machine for storage, follow these steps:
1. Thoroughly clean the machine, especially under
the mower deck. Touch up damage to the paint
and spray a thin layer of oil on the underside of
the mower deck to avoid corrosion.
2. Inspect the machine for worn or damaged parts
and tighten any nuts or screws that may have
become loose.
3. Change the engine oil; dispose of properly.
4. Empty the fuel tanks or add a fuel stabilizer. Start
the engine and allow it to run until the carburetor
is drained of fuel or the stabilizer has reached the
carburetor.
5. Remove the spark plug and pour about a
tablespoon of engine oil into the cylinder. Turn
over the engine so that the oil is evenly distributed
and then refit the spark plug.
6. Lubricate all grease zerks, joints, and axles.
7. Remove the battery. Clean, charge, and store the
battery in a cool place, but protect it from direct
cold.
8. Store the machine in a clean, dry place and cover
it for extra protection.
Service
When ordering spare parts, please specify the
purchase year, model, type, and serial number.
Always use genuine McCulloch spare parts.
An annual checkup at an authorized service workshop
is a good way to ensure that the machine performs its
best the following season.
45
SCHEMATIC
46
TECHNICAL DATA
Torque Specifications
Engine crankshaft bolt Deck pulley bolts Lug nuts Blade bolt 50 ft/lb (67 Nm)
150 ft/lb (203 Nm)
75 ft/lb (100 Nm)
90 ft/lb (122 Nm)
Standard ¼" fasteners Standard 5/16" fasteners Standard 3/8" fasteners Standard 7/16" fasteners Standard ½" fasteners 9 ft/lb (12 Nm)
18 ft/lb (25 Nm)
33 ft/lb (44 Nm)
52 ft/lb (70 Nm)
80 ft/lb (110 Nm)
Hex Head Cap Screws
The torque values shown should be used as a general guideline when specific torque values are not given.
U.S. Standard Hardware
Shank Size (Diameter in inches, fine or coarse thread)
Grade
SAE Grade 5
SAE Grade 8
Flangelock Screw
w/Flangelock Nut
Size
ft./lbs
Nm
ft./lbs
Nm
ft./lbs
Nm
¼
9
12
13
18
/16
18
24
28
38
24
33
/8
31
42
46
62
40
54
/16
50
68
75
108
½
75
102
115
156
/16
110
150
165
224
/8
150
203
225
305
¾
250
339
370
502
/8
378
513
591
801
1 /8
782
1060
1410
1912
5
3
7
9
5
7
1
** Grade 5 - Minimum commercial quality (lower quality not recommended)
Metric Standard Hardware
Shank Size (Diameter in millimeters, fine or coarse thread)
Grade
Grade 8.8
Size
ft./lbs
Grade 10.9
Nm
ft./lbs
Grade 12.9
Nm
ft./lbs
Nm
M4
1.5
2
2.2
3
2.7
3.6
M5
3
4
4.5
6
5.2
7
M6
5.2
7
7.5
10
8.2
11
M7
8.2
11
12
16
15
20
M8
13.5
18
18.8
25
21.8
29
M10
24
32
35.2
47
43.5
58
M12
43.5
58
62.2
83
75
100
M14
70.5
94
100
133
119
159
M16
108
144
147
196
176
235
M18
142
190
202
269
242
323
M20
195
260
275
366
330
440
M22
276
368
390
520
471
628
M24
353
470
498
664
596
794
M27
530
707
474
996
904
1205
47
TECHNICAL DATA
(1
Engine
Manufacturer
Type
Power
Lubrication
Fuel
Fuel tank capacity
Briggs & Stratton
Intek
16.5 hp (1,2
Pressure with oil filter
Min 86 octane unleaded (Maxethanol 5%, Max MTBE 15%)
3 gallons / 11.3 liters
Cooling
Air cooled
Air filter
Standard
Alternator
12V / 16A
Starter
Electric 12V
Transmission
Transmission
Speed and direction controls
EZT Hydro Gear
Dual levers, foam gripped
Speed forward
7 mph / 11.3 km/h
Speed reverse
3.3 mph / 5.3 km/h
Brakes
Front caster tires, smooth tread
Rear tires, turf pneumatic
Tire pressure
Mechanical parking brake
11 x 4-5 4 ply
18 x 6.5-8
15 PSI / 103 kPa / 1 bar
Equipment
Cutting width
30"
Cutting height
1½" - 4" / 2.5 cm - 10.6 cm
Number of blades
1
Blade length
29½" / 75 cm
Sprung seat
Standard
Hinged armrests
No
Blade engagement
Manual
Deck construction
Stamped
Productivity
Output
1.6 acres/hr / 6475 m2/hr
Overall dimensions
Weight
Base machine length
66½" / 169 cm
Base machine width
39¼" 99.7 cm
Base machine height
33½" / 85 cm
Overall width, chute up
35½" / 90 cm
Overall width, chute down
48
395 lbs / 179 kg
37" / 94cm
The power rating of the engines
indicated is the average net power
output (at specified rpm) of a typical
production engine for the engine model
measured to SAE standard J1349/
ISO1585. Mass production engines
may differ from this value. Actual
power output for the engine installed
in the final machine will depend on
the operating speed, environmental
conditions and other variables.
(2
For engine specifications, refer to the
engine manufacturer's Owner Manual.
CONFORMITY CERTIFICATES
USA Requirements
Labels are placed on the engine and/or in the engine
compartment stating that the machine will fulfill the
requirements. This is also applicable to special
requirements for any of the states, (California emission
rules etc.). Do not remove any of these labels.
Certificates can also be supplied with the machine at
delivery or written in the Engine manual. Take care of
them as they are valuable documents.
49
SERVICE JOURNAL
Date, mtr reading, stamp, sign
Action
Delivery Service
Charge the battery.
Adjust the tire pressure of all wheels to 15 PSI (1 bar).
Mount the steering controls in the normal position.
Connect the contact box to the cable for the seat’s safety switch.
Check that the right amount of oil is in the engine.
Adjust the position of the steering controls.
Fill with fuel and open the fuel shut off valve.
Start the engine.
Check that there is drive to both wheels.
Check the mower deck adjustment.
q
q
q
q
q
q
q
q
q
q
Check:
The safety switch for the parking brake.
The safety switch for the mower deck.
The safety switch in the seat.
The safety switch in the steering controls.
Parking brake functionality.
Driving forward.
Driving backward.
Engaging the blades.
Check the idle speed
Check the engine high idle speed
q
q
q
q
q
q
q
q
q
q
Inform the customer about:
The need and advantages of following the service schedule.
The need and advantages of leaving the machine for service every 300
hours.
The effects of service and maintaining a service journal on the
machine’s resale value.
Application areas for Mulching.
Fill in the sales papers, etc.
50
q
q
q
q
Delivery service has
been carried out.
No remaining notes.
Certified:
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
After 5-10 Hours
Change the engine oil
Action
q
Date, mtr reading, stamp, sign
25-Hour Service
Check the fuel pump’s air filter
Sharpen/Replace mower blades if required
Check the tire pressures
Check battery cables
Lubricate according to lubrication chart
Check/clean the engine’s cooling air intake
Clean the air cleaner’s pre-filter (foam)
q
q
q
q
q
q
q
51
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
50-Hour Service
Perform the 25-hour service
Clean/replace the air cleaner’s filter cartridge (paper filter
(shorter intervals for dusty operating conditions)
Change engine oil
Lubricate according to lubrication chart
Check/adjust the parking brake
Action
q
q
q
q
q
Date, mtr reading, stamp, sign
100-Hour Service
Perform the 25-hour service
Perform the 50-hour service
Change the engine oil filter
Clean/replace the spark plugs
Replace the fuel filter
Check V-belts
Check tighten caster wheel axle bolts (every 200 hours)
Change the air filter’s paper cartridge
52
q
q
q
q
q
q
q
q
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
300-Hour Service
Perform the 25-hour service
Perform the 50-hour service
Perform the 100-hour service
Check/adjust the mower deck
Clean the combustion chamber and grind the valve seats
Check the engine valve clearance
Replace the air cleaner’s pre-filter (foam)
Action
q
q
q
q
q
q
q
Date, mtr reading, stamp, sign
At Least Once Each Year
Clean the engine’s cooling air intake (25 hours)
Replace the air cleaner’s pre-filter (foam) (300 hours)
Replace the air filter’s paper cartridge
Change the engine oil (50 hours)
Replace the engine oil filter (100 hours)
Check/adjust the cutting height
Check/adjust the parking brake (50 hours)
Clean/Change the spark plugs (100 hours)
Change the fuel filter (100 hours)
Check the engine valve clearance
q
q
q
q
q
q
q
q
q
q
53
SERVICE JOURNAL
Action
54
Date, mtr reading, stamp, sign