Husqvarna 966582301 Operator's Manual
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Operator Manual
Form Number 115 476327 Rev A 2011-12-19
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.
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
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.
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.
Towing
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.
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.
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.
IMPORTANT INFORMATION
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 Slow Choke Fuel
Warning!
Parking Brake CE conformity marking. Only for
European market
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
Shut off engine and remove key before performing any maintenance or repair work
Keep a safe distance from the machine
Use on slopes no greater than 10° No passengers
Whole body exposure to thrown objects
Severing of fingers and toes
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.
WARNING!
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
Clear the area of objects before mowing
8011-513
9
SAFETY
• 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.
Never take passengers
WARNING!
8011-520
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.
10
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.
• 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.
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.
Personal protective equipment
8011-670a
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.
Be extra cautious when driving on slopes
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.
Never allow children to operate the machine
8011-519
8011-517
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.
Never fill the fuel tank indoors
WARNING!
8011-516
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
• 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.
Never drive the machine in an enclosed space
CAUTION!
Use protective glasses for maintenance work.
8011-515
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.
14
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 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.
6003-009
Do not smoke when performing maintenance on the battery.
The battery can explode and cause serious injury/damage.
• 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.
Risk of sparking
Regularly clean deck
8009-728
0000-000
15
SAFETY
Transport
• 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 10 O .
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.
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.
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.
16
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 beltdriven 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
6
7 8 9 10 11
1. Steering control levers
2. Parking brake
3. Tracking adjustment
4. Fuel shut off valve
5. Bypass Linkages
6. Fuel tank
7. Fuses
12 13 14
8. Seat adjustment lever
9. Blade switch
10. Ignition switch
11. Throttle
12. Choke control
13. Hour meter
14. Deck lift
8058-177
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.
Steering controls
8058-022
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
8011-79122
18
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.
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.
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.
Blade switch
8058-191
8058-173
8058-173
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.
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.
Ignition switch
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
Choke control
Fuses
20
8052-001
8058-173
8011-420
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).
Fuel tank
8058-021
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.
When operating in temperatures below 32° F. (0° C.), use fresh, clean winter grade gasoline to insure good cold weather starting.
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.
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.
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.
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.
22
Left side bypass linkage
8011-419
8058-019
8058-0147
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.
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.
Lengthways adjustment
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.
Hour meter
Tracking knob
8050-852
8058-173
8058-191
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.
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.
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.
IMPORTANT INFORMATION
When control levers are in the reverse position they return to neutral when released. This may cause the mower to suddenly stop.
24
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.
5. Set the deck cutting height by inserting the lift pin into the desired cut height. Resecure the lift pin with the hairpin.
Lengthways adjustment
8050-852
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.
Secure selected cutting height
8058-024
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.
3. Activate the parking brake by pushing the release button in and pulling the lever fully upwards.
Mower deck lifting lever
8058-019
4. Disengage the mower blades by pressing the blade switch downwards.
Pull parking brake upwards to activate.
8058-191
8058-173
Blade switch
26
OPERATION
5. Move the steering controls outward to the locked
(outer) neutral position.
6. Move the throttle to the middle position.
Place controls in neutral position
8058-186
8058-170
7. If the engine is cold, the choke control should be pushed forward to the choke position.
Set the throttle
Set the choke control
8058-171
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.
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.
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).
8050-780
8050-781
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.
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.
Jumper cable connection
8011-642
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).
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.
Parking brake released
4. Move throttle control to full throttle.
5. Engage the mower deck by pulling out the blade switch.
Mower deck lifting lever
8058-191
8058-019
Set blade engagement and throttle control
8058-172
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.
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.
8058-186
8058-191
Parking brake released
31
OPERATION
Mowing Tips
• 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.
Mowing pattern
WARNING!
Clear the lawn of stones and other objects that can be thrown out by the blades.
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.
8011-603
32
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.
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.
8058-019
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.
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.
8058-032
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.
8058-033
Left side bypass linkage, EZT locked in the bypass position
34
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 At least once each year
Maintenance interval in hours
25 50 100 300 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
Check the tire pressures
Check battery connections
Sharpen 3) / 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
Before After
●
♦
●
■
♦
♦
♦
♦
●
●
■
●
●
■ ■
●
●
♦
♦
■ ■
■
♦
♦
1) First change after 8-10 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) Performed by authorized service workshop.
●
= Described in this manual
♦
= Not described in this manual
■
= Refer to the engine manufacturer's manual
35
MAINTENANCE
MAINTENANCE
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)
Daily
Before After
■
●
■
●
●
■
■
♦
♦
■
●
At least once each year
Maintenance interval in hours
25 50 100 300
■
●
■
■
■
●
■
●
●
♦
♦
1) 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) Performed by authorized service workshop.
●
= Described in this manual
♦
= Not described in this manual
■
= Refer to the engine manufacturer's manual
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.
36
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.
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.
STANDARD
BATTERY
12.6V
12.4V
12.2V
12.0V
11.8V
STATE
OF
CHARGE
100%
75%
50%
25%
0%
APPROXIMATE BATTERY CHARGING TIME*
TO FULL CHARGE AT 80 O F / 27 O C
Maximum Rate at:
50 Amps 30 Amps 20 Amps 10 Amps
- FULL CHARGE -
20 min.
45 min.
35 min.
75 min.
48 min.
95 min.
90 min.
180 min.
65 min.
85 min.
115 min.
150 min.
145 min.
195 min.
280 min.
370 min.
*Charging time depends on battery capacity, condition, age, temperature and efficiency of charger
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.
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.
Remove battery hold-down to replace battery
8050-109
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.
Steering controls locked in neutral
8058-026
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.
Parking brake
38
8058-191
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.
Anti-scalp rollers
IMPORTANT INFORMATION
To avoid deck damage, the anti-scalp rollers must not be adjusted to support the deck.
8058-135
39
MAINTENANCE
V-belts
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.
3
1
1. Belt shields
2. Belt guide
3. Idler arm
Removing the deck belt
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.
Belt routing
2
1
8058-107
8058-108
40
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.
Check the blades
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).
1
IMPORTANT INFORMATION
Special blade bolt is heat treated.
Replace with a McCulloch bolt if required.
Do not use lower grade hardware than specified.
2
1. Blade
2. Blade bolt (special)
3. Spindle housing
Blade attachment
3
8058-166
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.
Set blades to begin alignment
80158-166
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
Deck front adjustment nuts
42
8058-031
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.
Only use O.E.M. specified tires.
Caster wheels
8011-619-4
Cleaning
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.
Clean regularly
IMPORTANT INFORMATION
Use protective glasses when cleaning and washing.
8058-084
43
Lubrication Schedule
LUBRICATION
8058-174
12/12 Every year
1/52 Every Week
1/365 Every day
Lubricate with grease gun
Oil change
Filter change
Level check
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.
44
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.
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.
8058-068
8058-136
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.
Deck spindle
45
46
Problem
Engine will not start
Starter does not turn the engine over
Engine runs rough
Engine seems weak
Machine vibrates
TROUBLESHOOTING
Cause
• 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
TROUBLESHOOTING
Problem
Engine overheats
Battery not charging
Cause
• 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
The machine moves slowly, unevenly, or not at all • Parking brake on
• Bypass valve on pump open
• Drive belt for the transmission slack or has come off
• Air trapped in hydraulic system
Mower deck not engaging
Transaxle leaks oil
• 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
Uneven mowing results • 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
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.
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.
48
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.
Grade SAE Grade 5
U.S. Standard Hardware
SAE Grade 8 Flangelock Screw w/Flangelock Nut ft./lbs Nm Size ft./lbs Nm ft./lbs Nm
½
9 /16
5 /8
¾
7 /8
¼
5 /16
3 /8
7 /16
9
18
31
50
75
110
150
250
378
12
24
42
68
102
150
203
339
513
13
28
46
75
115
165
225
370
591
18
38
62
108
156
224
305
502
801
1 1 /8 782 1060 1410 1912
** Grade 5 - Minimum commercial quality (lower quality not recommended)
Grade
Size
M14
M16
M18
M20
M22
M24
M27
M4
M5
M6
M7
M8
M10
M12 ft./lbs
70.5
108
142
195
276
353
530
1.5
3
5.2
8.2
13.5
24
43.5
Grade 8.8
Metric Standard Hardware
Nm ft./lbs
Grade 10.9
Nm
94
144
190
260
368
470
707
7
11
18
32
58
2
4
100
147
202
275
390
498
474
2.2
4.5
7.5
12
18.8
35.2
62.2
133
196
269
366
520
664
996
10
16
25
47
83
3
6
24
40
33
54 ft./lbs
Grade 12.9
Nm
119
176
242
330
471
596
904
2.7
5.2
8.2
15
21.8
43.5
75
159
235
323
440
628
794
1205
3.6
7
11
20
29
58
100
Accessories
Collection system
50
Engine
Manufacturer
Type
Power
Lubrication
Fuel
Fuel tank capacity
Cooling
Air filter
Alternator
Starter
Transmission
Transmission
Speed and direction controls
Speed forward
Speed reverse
Brakes
Front caster tires, smooth tread
Rear tires, turf pneumatic
Tire pressure
Frame
Cutting Width
Cutting Height
Uncut Circle
Number of Blades
Blade Length
Anti-scalp Rollers
Sprung Seat
Hour Meter
Blade Engagement
Deck Construction
Productivity
Dimensions
Weight
Base Machine Length
Base Machine Height
Base Machine Width
Overall Width, Chute Up
Overall Width, Chute Down
TECHNICAL DATA
ZM4619 / 966660501
Briggs & Stratton
Professional
19 hp 1,2)
Pressure with oil filter
Min 87 octane unleaded (Max ethanol 10%, Max MTBE 15%)
3.5 gallons / 13.2 liters
Air cooled
Standard
12V
Electric
Hydrostatic transaxles
Dual levers, foam gripped
0-6.5 mph / 0-10.5 km/h
0-3.5 mph / 0-5.6 km/h
Mechanical parking brake
4.1-5
18 x 8.5-8
15 PSI / 103 kPa / 1 bar
46" / 117cm
1.5 - 4" / 3.8 - 10.2 cm
0
2
15" / 38 cm
3
Standard
Standard
Electromagnetic Clutch
Stamped
2.4 acres/h / 9712 m 2 /h
525 lbs / 238 kg
75" / 191cm
40" 102cm
41.5" / 106 cm
48" / 122 cm
56" / 142 cm
1) 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.
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
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
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: q q q q q q q q q q q q q q q q q q q q
53
After the First 10 Hours
Change engine oil q
Action
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
Date, mtr reading, stamp, sign q q q q q q q
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 q q q q q
Action
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
Date, mtr reading, stamp, sign q q q q q q q q
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
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 q q q q q q q
Date, mtr reading, stamp, sign q q q q q q q q q q
Action
SERVICE JOURNAL
Date, mtr reading, stamp, sign
57
58
Action
SERVICE JOURNAL
Date, mtr reading, stamp, sign
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