McCulloch ZM4619 Operator`s manual

Operator Manual
ZM4619 BF / 966660501
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 476327 Rev A
2011-12-19
When this product is worn out and no longer used, it
should be returned to the reseller or other party for
recycling.
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.
©2011. All rights reserved.
Orangeburg, SC. Printed in U.S.A.
CONTENTS
INTRODUCTION................................................................ 5
Driving and Transport on Public Roads....................... 5
Towing.......................................................................... 5
Operating..................................................................... 5
Good Service............................................................... 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
Towing........................................................................ 16
Spark Arrestor............................................................ 16
Transport.................................................................... 16
CONTROLS...................................................................... 17
Control Locations....................................................... 17
Steering Control Levers............................................. 18
Parking Brake............................................................ 19
Throttle Control.......................................................... 19
Blade Switch.............................................................. 19
Ignition Switch........................................................... 20
Choke Control............................................................ 20
Fuses......................................................................... 20
Fuel Tank.................................................................... 21
Fuel Shut Off Valve.................................................... 22
Cutting Height Adjuster............................................. 22
Bypass Linkages....................................................... 22
Seat Adjustment Lever.............................................. 23
Hour Meter................................................................. 23
Tracking Bolts............................................................ 23
OPERATION..................................................................... 24
Training...................................................................... 24
Steering..................................................................... 24
Before Starting........................................................... 25
Starting the Engine.................................................... 26
Jumper Cables Use............................................. 29
Running..................................................................... 30
Operating On Hills..................................................... 31
Mowing Tips.............................................................. 32
Stopping the Engine.................................................. 33
Moving Machine By Hand......................................... 34
MAINTENANCE................................................................ 35
Maintenance Schedule.............................................. 35
Battery....................................................................... 37
Safety System............................................................ 38
Parking Brake............................................................ 38
Tire Pressures............................................................ 39
Anti-scalp Rollers....................................................... 39
V-belts........................................................................ 40
Deck Belt Removal.............................................. 40
Cutting Blades........................................................... 41
Blade replacement.............................................. 41
Adjusting the Mower Deck........................................ 42
Leveling deck...................................................... 42
Caster Wheels........................................................... 43
Cleaning.................................................................... 43
Hardware................................................................... 43
LUBRICATION.................................................................. 44
Lubrication Schedule................................................. 44
Wheel and Deck Zerks.............................................. 45
Front Wheel Mount............................................... 45
Front Wheel Bearings.......................................... 45
Deck Spindles...................................................... 45
Transmission.............................................................. 45
TROUBLESHOOTING...................................................... 46
STORAGE........................................................................ 48
Winter Storage........................................................... 48
Service....................................................................... 48
SCHEMATICS................................................................... 49
TECHNICAL DATA........................................................... 50
Torque Specifications................................................ 50
Accessories............................................................... 50
CONFORMITY CERTIFICATES......................................... 52
SERVICE JOURNAL......................................................... 53
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) 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 the 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
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:
This Operator 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 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
Engine
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
Warning!
Fast
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
Australia and
New Zealand only
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
Do not open or
remove safety
shields while
engine is running
Use on slopes no
greater than 10°
No passengers
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!
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.
This symbol means that important
safety instructions need to be
emphasized. It concerns your safety.
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.
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.
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 the hot exhaust or
engine parts and burn.
Do not allow the mower deck to plow leaves or
other debris, causing 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 a 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.
WARNING!
Do not drive up or down hills with
slopes greater than 10 degrees. And
do not drive across any slopes.
6003-004
Mow up and down, not side to side
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. Keep children out of the
mowing area and in the watchful care
of a responsible adult other than the
operator.
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 where you last
saw them.
• Keep children out of the mowing area and in the
watchful care of a responsible adult other than the
operator.
• 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 your
view of a child.
8011-519
Be extra cautious when driving on slopes
8011-517
Never allow children to operate the machine
8011-518
Keep children away from work area
12
SAFETY
Safe Handling of Gasoline
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.
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 containers.
• 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 you begin refueling, 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 must not be started
when the driver’s floor plate or any
protective plate for the mower deck’s
drive belt is removed.
13
SAFETY
General Maintenance
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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 you strike 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 you run the engine too fast, you risk
damaging the machine components.
Be very careful when handling battery acid. Acid
on skin can cause serious corrosive burns. If you
spill battery acid on your 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.
Make sure 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:
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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 chassis 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 you run 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
0000-000
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.
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.
Spark Arrestor
A spark arrestor for the muffler is available through
any authorized McCulloch dealer.
16
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!
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.
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
arrester meeting applicable local or
state laws (if any). If a spark arrester
is used, it should be maintained
in effective working order by the
operator.
CONTROLS
This operator’s manual describes the McCulloch
Zero Turn Rider. The rider is fitted with a four-stroke
overhead valve engine.
Transmission from the engine is made via a belt-
driven hydraulic pumps. Using the left and right
steering controls, the flow is regulated and thereby the
direction and speed.
Control Locations
3
2
4
5
1
5
8058-177
6
7
8
9
10
11
12
13
14
1. Steering control levers
8. Seat adjustment lever
2. Parking brake
9. Blade switch
3. Tracking adjustment
10. Ignition switch
4. Fuel shut off valve
11. Throttle
5. Bypass Linkages
12. Choke control
6. Fuel tank
13. Hour meter
7. Fuses
14. Deck lift
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. Furthermore, there is 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.
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.
8058-022
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
8011-79122
CONTROLS
Parking Brake
IMPORTANT INFORMATION
The machine must be not be moving when
engaging 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 left of the machine.
Push the release button and pull the lever backward
to activate the brake—push forward to release it.
8058-191
Parking brake released
Throttle Control
The throttle control regulates the engine speed and
the rate of rotation of the blades, assuming the blade
switch is pulled out,
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.
8058-173
Throttle control
Blade Switch
To engage the mower deck, pull the blade switch
knob out. The mower blades are disengaged when
the knob is pressed down fully.
8058-173
Blade switch
19
CONTROLS
Ignition Switch
The ignition switch is placed on the control panel and
is used to start and stop the engine.
On models equipped with headlights, turn the key
clockwise to ACCESSORY for headlight use.
8052-001
Ignition switch
Choke Control
The choke control is used for cold starts to provide
the engine with a richer fuel mixture.
For cold starts throttle/choke control should be
pushed fully forward forward to the choke position.
8058-173
Choke control
Fuses
Fuses are located on the left hand side of the
machine. They are accessed by tilting the seat
forward. They are flat pin fuses of the same type used
in automobiles.
There are two fuses with ratings and functions:
20 Amp Primary fuse
7.5 Amp Mower deck coupling
8011-420
Fuses
20
CONTROLS
Fuel Tank
Read the safety instructions before refueling. The
machine has one fuel tank, just behind the console.
The tank capacity is 3.5 gallons (13.25 liters).
Regularly check the gas cap gasket for damage and
keep the cap properly tightened.
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.
WARNING!
Gasoline is highly flammable. Observe
caution and fill the tank outdoors (see
the safety instruction).
8058-021
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.
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.
When operating in temperatures below 32° F. (0° C.),
use fresh, clean winter grade gasoline to insure good
cold weather starting.
21
CONTROLS
Fuel Shut Off Valve
The fuel shut off valve is located at the left rear of the
seat. The valve is off when the handle tab is turned
perpendicular to the fuel line.
IMPORTANT INFORMATION
Always raise the deck to the highest position
for transport.
8011-419
Fuel shut off valve in the CLOSED position
Cutting Height Adjuster
To set the desired deck cutting height, press the
release button and move the lever forward to the
preset height pin and release the button. See Before
Starting in the Operation section to change the
cutting height. The cutting height range is from 1½"
(38mm) to 4" (102mm) in ½" (13mm) increments. The
heights are measured from the ground up to the blade
tip with the engine not running.
IMPORTANT INFORMATION
To obtain an even cutting height, it is
important that the air pressure in all tires is 15
psi / 103 kPa / 1 bar.
8058-019
The mower deck’s lifting lever
Bypass Linkages
The levers are located on each side of the rear of the
unit below the rear engine plate. The bypass linkage
is used when manually pushing or pulling the unit.
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.
8058-0147
Left side bypass linkage
22
CONTROLS
Seat Adjustment Lever
The seat can be adjusted lengthways. When making
adjustments, the lever under the right side of the
seat is pulled up, after which the seat can be moved
backward or forward.
IMPORTANT INFORMATION
Seat should not be adjusted while unit is in
motion.
8050-852
Lengthways adjustment
Hour Meter
The hour meter displays the total operating time.
It will flash CHG OIL (Change Oil) at 50 hour intervals.
The flash duration is one hour before and one hour
after the interval. The CHG OIL icon will come on
and shut off automatically. The hour meter cannot be
manually reset.
8058-173
Hour meter
Tracking Bolts
If the mower is not tracking straight, check the
air pressure in both rear tires. Recommended air
pressure is 15 psi (103 kPa / 1 bar) for all tires.
Tracking must be checked on a flat and level concrete
or blacktop surface.
Rotating the tracking bolts allow fine tuning
adjustments so the machine tracks straight with the
steering control levers in the full forward position.
Rotate the bolts counter clockwise (as viewed from
the operation position) to increase the speed on the
left lever. Rotate clockwise to decrease speed.
8058-191
Tracking knob
23
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.
24
IMPORTANT INFORMATION
When control levers are in the reverse position
they return to neutral when released. This may
cause the mower to suddenly stop.
OPERATION
Before Starting
1. Read the sections on Safety 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.
8050-852
Lengthways adjustment
5. Set the deck cutting height by inserting the lift pin
into the desired cut height. Resecure the lift pin
with the hairpin.
8058-024
Secure selected cutting height
The following conditions must be fulfilled before the
engine can be started:
• The blade switch must be pressed downward into
the disengaged position.
• The parking brake must be up into the activated
position.
• Both steering controls must be in the locked
(outer) neutral position.
25
OPERATION
Starting the Engine
1. Sit on the seat.
2. Raise the mower deck by pushing the release
button on the top of the lifting lever. Pull the lifting
lever backward to the locked (transport) position.
8058-019
Mower deck lifting lever
3. Activate the parking brake by pushing the release
button in and pulling the lever fully upwards.
8058-191
Pull parking brake upwards to activate.
4. Disengage the mower blades by pressing the
blade switch downwards.
8058-173
Blade switch
26
OPERATION
5. Move the steering controls outward to the locked
(outer) neutral position.
8058-186
Place controls in neutral position
6. Move the throttle to the middle position.
8058-170
Set the throttle
7. If the engine is cold, the choke control should be
pushed forward to the choke position.
8058-171
Set the choke control
27
OPERATION
8. Press in and turn the ignition key to the start
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.
8050-780
Turn to the start position
9. When the engine starts, immediately release the
ignition key back to the run position. Push the
choke control in gradually when the engine has
started.
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.
8050-781
Return to run position
10. 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).
8058-149
Set the engine speed
28
OPERATION
Weak Battery
WARNING!
Lead-acid batteries generate
explosive gases. Keep sparks, flame
and smoking materials away from
batteries. Always wear eye protection
when around batteries.
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.
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.
8011-642
Jumper cable connection
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.
29
OPERATION
Running
1. Release the parking brake by pushing the top
release button in and 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).
8058-191
Parking brake released
3. Push the release button on the cutting height lever
and move lever to the pin, release the button.
WARNING!
Make sure that no one is near mower
when engaging blade switch.
Make sure the work area is free from
objects that could be thrown by the
rotating blades.
8058-019
Mower deck lifting lever
4. Move throttle control to full throttle.
5. Engage the mower deck by pulling out the blade
switch.
8058-172
Set blade engagement and throttle control
30
OPERATION
Operating On Hills
Read the Safety Instructions Driving on Slopes in the
Safety section.
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 steering
controls into the neutral position and push to the
outside of the unit. Engage the parking brake.
8058-186
Place controls in neutral position
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.
8058-191
Parking brake released
31
OPERATION
Mowing Tips
•
•
•
•
•
•
•
•
32
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
1. Move the throttle to the minimum position (tortoise
symbol).
2. Move the steering controls outward.
3. Disengage the mower deck by pressing the blade
switch down.
8058-173
Disengage the mower deck and move throttle to minimum
4. Raise the mower deck by pressing the release
button on the lever and pulling the lever upward to
the transport position.
5. When the machine is standing still, activate the
parking brake by pushing the lever release button
and pulling the lever upward.
If the engine has been worked hard, allow it to idle
at least 60 seconds to attain a normal operating
temperature before stopping. To prevent fouling
the spark plugs, avoid idling the engine for longer
periods.
8058-019
Raise the mower deck
6. Turn the ignition key to the stop position.
7. Remove 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.
33
OPERATION
Moving Machine By Hand
When pushing or pulling the mower, engage the
EZT 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. Engage the parking brake.
3. Pull the EZT bypass linkages up and out of
the keyhole slots. Release the levers with the
head outside the frame and held in the bypass
position.
4. To reengage the EZT’s to drive, reverse the
above procedure.
Load the machine into truck or trailer by driving slowly
up the ramps. DO NOT LIFT! The machine is not
intended to be lifted by hand.
8058-032
Left side bypass linkage, EZT engaged
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!
Make no adjustments without:
•
the engine stopped,
•
the ignition key removed,
•
the parking brake activated
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.
34
8058-033
Left side bypass linkage, EZT locked in the bypass position
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
Check the parking brake
Check the engine’s oil level (every refueling)
Check the safety system
Check for fuel and oil leakages
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
Before
●
■
●
♦
After
At
least
once
each
year
■
●
●
●
♦
♦
♦
♦
Check the tire pressures
Check battery connections
Sharpen3)/ Replace mower blades
Clean the engine’s cooling air intake 2)
Clean the air cleaner foam pre-filter 2)
Clean the air cleaner paper filter cartridge 2)
Check/adjust the parking brake
Inspect muffler/spark arrester
1)
■
■
■
♦
♦
Maintenance interval
in hours
25
50
100
300
●
●
●
■
■
♦
♦
First change after 8-10 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
conditions, cleaning and replacement are required more often. 3) Performed by authorized service workshop.
2)
In dusty
● = Described in this manual
♦ = Not described in this manual
■ = Refer to the engine manufacturer's manual
35
MAINTENANCE
Daily
MAINTENANCE
Before
After
At least
once
each
year
Maintenance
interval
in hours
25
50
100
■
●
Check/adjust throttle cable
Check the condition of belts, belt pulleys
Change the engine oil
1)
Replace the engine oil filter
Clean/replace the spark plugs
Replace the fuel filter
Replace paper air filter 2)
Check the caster wheels (every 200 hours)
Replace the air cleaner foam pre-filter 2)
Check/adjust the mower deck
Check the engine valve clearance 3)
Perform the 300-hour service 3)
1)
●
■
■
■
●
■
●
■
●
♦
♦
■
First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
conditions, cleaning and replacement are required more often. 3) Performed by authorized service workshop.
■
■
●
■
●
●
♦
♦
2)
● = Described in this manual
♦ = Not described in this manual
■ = Refer to the engine manufacturer's manual
WARNING!
Before performing any service or adjustment checklist:
•
•
•
•
•
36
300
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.
In dusty
MAINTENANCE
Battery
Your mower is equipped with a maintenance free
battery and 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.
STANDARD
STATE
BATTERY
OF
CHARGE
APPROXIMATE BATTERY CHARGING TIME*
TO FULL CHARGE AT 80OF / 27OC
Maximum Rate at:
50 Amps
30 Amps
20 Amps
10 Amps
12.6V
100%
- FULL CHARGE -
12.4V
75%
20 min.
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
CAUTION!
Always wear eye protection when
around batteries.
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.
Replacing battery
1. Lift seat and rotate forward.
2. Using two ½" wrenches disconnect BLACK
battery cable then RED battery cable.
3. Position deck to lowest setting.
4. Front underside of frame, remove the nuts that
secure the battery hold-down.
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 hold-down and secure with
nuts removed in Step 4.
8. Reconnect RED battery cable to positive (+)
battery terminal with bolt and hex nut.
9. Connect BLACK grounding cable to negative
(-) battery terminal with remaining hex bolt and
hex nut
10. Replace terminal boot cover.
11. Lower seat.
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.
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.
8050-109
Remove battery hold-down to replace battery
37
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.
3. 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.
8058-026
Steering controls locked in neutral
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.
IMPORTANT INFORMATION
The machine must be absolutely standing still
when applying the parking brake.
WARNING!
Faulty adjustment will result in
reduced braking ability and can cause
an accident.
38
8058-191
Parking brake
MAINTENANCE
Tire Pressures
All tires should be at 15 psi / 103 kPa / 1 bar.
8011-564
Check tire pressures
Anti-scalp Rollers
IMPORTANT INFORMATION
Adjust anti-scalp rollers with the mower on a
flat level surface.
Anti-scalp rollers are properly adjusted when they are
just slightly off of the ground when the deck is at the
desired cutting height in the operating position. Antiscalp rollers then keep the deck in the proper position
to help prevent scalping in most terrain conditions.
Anti-scalp rollers can be set in four positions. The
rollers should be approximately ¼" (6.5 mm) from
ground. Do not adjust the rollers to support the deck.
8058-135
Anti-scalp rollers
IMPORTANT INFORMATION
To avoid deck damage, the anti-scalp rollers
must not be adjusted to support the deck.
39
MAINTENANCE
V-belts
1
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 Removal
1. Park on a level surface. Apply parking brake.
2. Lower the deck into the lowest cutting position.
3. Remove bolts from belt shields and remove
shields.
4. Remove any dirt or grass that may have
accumulated around the cutter housings and
entire deck surface.
5. Loosen the nut securing the belt guide. Note the
position of the belt guide for reinstallation.
6. Push inward on the idler arm to release the
tension on the belt.
7. Carefully slip the belt over the top of the cutter
housing pulleys and remove belt from the deck.
Deck Belt Installation
NOTE: For ease in installing the deck belt, refer to
the routing decal on the top of the deck.
1. Wrap the deck belt around the electric clutch
pulley that is located on the engine shaft.
2. Route the belt forward and up onto the deck.
3. Place belt around spring loaded idler pulley.
4. Wrap the belt around the stationary idler pulley
and around the mandrel housings.
5. Push inward on the idler arm and carefully route
belt over stationary idler pulley. Once the belt is
properly routed, slowly release the idler arm to
tension belt.
6. Double check belt routing to make sure it
matches the decal affixed to the deck, and the
belt does not have any twist. Correct if needed.
7. Tighten the belt guide and replace belt shields on
both mandrel housings and secure with fasteners.
NOTE: The belt guide should be perpendicular to
the belt when installation is complete.
40
2
3
1. Belt shields
2. Belt guide
3. Idler arm
Removing the deck belt
1
8058-107
8058-108
Belt routing
MAINTENANCE
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 by
hitting obstacles.
Let the service workshop decide whether the blade
can be repaired/ground or must be replaced. Balance
the blades after sharpening.
Check the blade mounts.
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.
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 spindle
housing.
3. Seat the blade opening firmly onto the spindle
housing.
4. Tighten blade bolt securely.
5. Torque blade bolt to 45-55 ft/lbs (60-75 Nm).
8058-166
Check the blades
3
1
2
IMPORTANT INFORMATION
Special blade bolt is heat treated.
Replace with a McCulloch bolt if required.
Do not use lower grade hardware than
specified.
1. Blade
2. Blade bolt (special)
3. Spindle housing
Blade attachment
8058-129
41
MAINTENANCE
Adjusting the Mower Deck
Leveling deck
Adjust the deck while the mower is on a level
surface. Make sure the tires are inflated to the correct
pressure. See Technical Data / Transmission. If
tires are under or over inflated, the deck cannot be
properly adjusted. Raise the deck to the highest
(transport) position.
The deck should be adjusted slightly higher in the
rear.
NOTE: To insure accuracy of leveling procedure,
mower deck drive belt must be installed prior to
leveling deck.
1. Wear heavy gloves. Turn each blade tip to align
side to side.
2. Measure from the floor surface up to the bottom of
the blade tip on the discharge side of the mower
deck. Record this measurement.
3. Move to the opposite side, check that the
measurement is the same. If adjustment is
required—with a ¾" or adjustable wrench, turn
the lift link adjustment nuts on either side counter
clockwise to lower or clockwise to raise. Adjust
until both side-to-side measurements are equal.
80158-166
Set blades to begin alignment
8058-030
4. Turn either blade to align with the deck front-torear. If the front blade tip does not measure 1/8" to
½" higher in the rear, follow the front adjustment
instructions that follow.
5. With a 5/8 or adjustable wrench, turn the nuts on
the front suspension linkage. Clockwise raises the
front of the mower, counterclockwise will lower
the front. Adjust nuts until rear of mower deck is
positioned level to 1/8" higher in the rear than the
side-to-side measurement.
NOTE: 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.
Lift link adjustment nut
8058-031
Deck front adjustment nuts
42
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 yoke and take care of the
spacers.
3. Install 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.
8011-619-4
Caster wheels
Only use O.E.M. specified tires.
Cleaning
IMPORTANT INFORMATION
Regular cleaning, 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.
Do not spray water on the top of the mower deck. Use
compressed air to clean the top side of mower deck.
Regularly clean the underside of the deck with normal
water pressure. Do not use a high pressure washer or
steam cleaner. Avoid spraying engine and electrical
components with water.
For models fitted with a 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 supply.
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.
Do not rinse hot surfaces with cold water. Let unit cool
before washing.
Hardware
Check daily. Inspect the entire machine for loose or
missing hardware.
Use protective glasses when
cleaning and washing.
8058-084
Clean regularly
43
LUBRICATION
Lubrication Schedule
8058-174
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.
44
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.
LUBRICATION
Wheel and Deck Zerks
Use only good quality bearing grease.
Grease from well-known brand names (petrochemical
companies, etc.) usually maintains a good quality.
Front Wheel Mount
Lubricate 3-4 strokes with a grease gun on each set of
wheel bearings.
Front Wheel Bearings
Lubricate 3-4 strokes with a grease gun on each set of
wheel bearings.
8058-068
Lubricating the front wheels
IMPORTANT INFORMATION
Use minimal lubrication and remove excess
lubricant so that is does not come into contact
with belts or belt pulley drive surfaces.
Deck Spindles
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.
8058-136
Deck 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.
45
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
•
Air trapped in hydraulic system
•
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
46
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.
•
Bent blades
•
Suspending for the mower deck is uneven
•
Blades are dull
•
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
47
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 dryer, 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.
48
To ready the machine for storage:
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 check-up at an authorized service
workshop is a good way to ensure that your machine
performs its best the following season.
SCHEMATICS
49
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
¼
9
12
13
18
/16
18
24
28
5
ft./lbs
Nm
38
24
33
40
54
/8
31
42
46
62
7
/16
50
68
75
108
½
75
102
115
156
9
/16
110
150
165
224
/8
150
203
225
305
¾
250
339
370
502
/8
378
513
591
801
11/8
782
1060
1410
1912
3
5
7
** Grade 5 - Minimum commercial quality (lower quality not recommended)
Metric Standard Hardware
Shank Size (Diameter in inches, fine or coarse thread)
Grade
Grade 8.8
Grade 12.9
ft./lbs
Nm
ft./lbs
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
Accessories
Collection system
50
Grade 10.9
Size
TECHNICAL DATA
ZM4619 / 966660501
Engine
Manufacturer
Type
Power
Lubrication
Fuel
Fuel tank capacity
Briggs & Stratton
Professional
19 hp1,2)
Pressure with oil filter
Min 87 octane unleaded (Max
ethanol 10%, Max MTBE 15%)
Air cooled
Air filter
Standard
Starter
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)
Refer to the engine manufacturer's
owner manual for engine specifications.
3.5 gallons / 13.2 liters
Cooling
Alternator
1)
12V
Electric
Transmission
Transmission
Speed and direction controls
Hydrostatic transaxles
Dual levers, foam gripped
Speed forward
0-6.5 mph / 0-10.5 km/h
Speed reverse
0-3.5 mph / 0-5.6 km/h
Brakes
Front caster tires, smooth tread
Rear tires, turf pneumatic
Tire pressure
Mechanical parking brake
4.1-5
18 x 8.5-8
15 PSI / 103 kPa / 1 bar
Frame
Cutting Width
46" / 117cm
Cutting Height
1.5 - 4" / 3.8 - 10.2 cm
Uncut Circle
0
Number of Blades
2
Blade Length
Anti-scalp Rollers
15" / 38 cm
3
Sprung Seat
Standard
Hour Meter
Standard
Blade Engagement
Electromagnetic Clutch
Deck Construction
Stamped
Productivity
2.4 acres/h / 9712 m2/h
Dimensions
Weight
525 lbs / 238 kg
Base Machine Length
75" / 191cm
Base Machine Height
40" 102cm
Base Machine Width
41.5" / 106 cm
Overall Width, Chute Up
48" / 122 cm
Overall Width, Chute Down
56" / 142 cm
51
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.
52
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
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.
q
q
q
q
Delivery service has
been carried out
No remaining notes
Certified:
53
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
After the First 10 Hours
Change 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 with cables
Lubricate according to lubrication chart
Check/clean the engine’s cooling air intake
Clean the air cleaner foam pre-filter
54
q
q
q
q
q
q
q
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
50-Hour Service
Perform the 25-hour service
Clean/replace the air cleaner paper filter cartridge
(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
q
q
q
q
q
q
q
q
55
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 foam pre-filter
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 foam pre-filter (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
56
q
q
q
q
q
q
q
q
q
q
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
57
SERVICE JOURNAL
Action
58
Date, mtr reading, stamp, sign