Operator Manual
ZM3816 BF / 966582001
Please read the operator’s manual carefully and make sure you
understand the instructions before using the machine.
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Contents
IntRoDUCtIon................................................................ 5
Running..................................................................... 28
operating.on.Hills...................................................... 29
Mowing.tips............................................................... 30
stopping.the.engine.................................................. 31
Manual.transport....................................................... 32
MAIntenAnCe............................................................... 33
Maintenance.schedule.............................................. 33
Battery....................................................................... 35
safety.system............................................................ 36
tire.Pressures........................................................... 36
Parking.Brake............................................................ 37
V-belts........................................................................ 37
Deck.Belt................................................................... 37
eZt.Belt..................................................................... 38
Cutting.Blades........................................................... 38
Blade.replacement........................................... 38
General........................................................................ 5
Driving.and.transport.on.Public.Roads....................... 5
towing......................................................................... 5
operating..................................................................... 5
Good.service............................................................... 6
Manufacturing.number...................................... 6
sYMBoLs.AnD.DeCALs.................................................. 7
sAFetY............................................................................. 9
safety.Instructions....................................................... 9
Personal.safety.equipment....................................... 11
slope.operation......................................................... 11
safe.Handling.of.Gasoline......................................... 13
General.Maintenance................................................ 14
transport................................................................... 16
towing....................................................................... 16
spark.Arrestor............................................................ 16
ContRoLs..................................................................... 17
Control.Locations....................................................... 17
steering.Control.Levers............................................. 18
Parking.Brake............................................................ 19
throttle.Control.......................................................... 19
Ignition.switch............................................................ 19
Choke.Control............................................................ 20
Refueling.................................................................... 20
Fuel.shut.off.Valve.................................................... 21
Mower.Deck.Lifting.Lever.......................................... 21
tracking..................................................................... 21
Blade.Control.Lever................................................... 22
Manual.transport....................................................... 22
oPeRAtIon.................................................................... 23
training...................................................................... 23
steering..................................................................... 23
Before.starting........................................................... 24
starting.the.engine.................................................... 24
Jumper.cables................................................. 27
Adjusting.the.Mower.Deck......................................... 39
Leveling.Deck.................................................. 39
Caster.Wheels........................................................... 40
Cleaning..................................................................... 40
Hardware................................................................... 40
LUBRICAtIon................................................................. 41
Front.Wheel.Mount.................................................... 42
Front.Wheel.Bearings................................................ 42
engine.Lubrication..................................................... 42
steering.Control.shafts.............................................. 42
tRoUBLesHootInG..................................................... 43
Winter.storage........................................................... 45
stoRAGe........................................................................ 45
service....................................................................... 45
sCHeMAtICs.................................................................. 46
teCHnICAL.DAtA........................................................... 47
torque.specifications................................................ 47
ConFoRMItY.CeRtIFICAtes...................................... 50
seRVICe.JoURnAL........................................................ 51
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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.
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IntRoDUCtIon
Congratulations
Towing
Thank you for purchasing a McCulloch ride-on
mower. This machine is built for superior efficiency
to rapidly mow primarily large areas. A control panel
easily accessible to the operator and a hydrostatic
transmission regulated by steering controls both
contribute to the machine’s performance.
This manual is a valuable document. Read the
contents carefully before using or servicing the
machine. The following of instructions (use, service,
maintenance, etc.) by all who operate this machine
is important for the safety of the operator and others.
It can also considerably increase the life span of the
machine and increase its resale value.
If 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.
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.
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.
The machine must only be operated, maintained,
and repaired by persons familiar with the
Continuous dedication to improve our products require
that specifications and design are subject to change
without notice.
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.
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.
5
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IntRoDUCtIon
Good Service
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:
McCulloch’s products are sold only in specialized
retail stores with complete service. This ensures that
you as a customer receive only the best support and
service. Before the product is delivered, the machine
has, for example, been inspected and adjusted by
This Operator’s Manual belongs to the machine with
the manufacturing number:
Engine
Transmission
Manufacturing Number
The machine’s manufacturing number can be found
on the printed plate affixed to the left in the engine
compartment. Stated on the plate, from the top are:
•
•
•
The machine’s type designation (I.D.).
The manufacturer’s type number (Model).
The machine’s serial number (Serial no.)
Please have the type designation and serial number
available when ordering spare parts.
The engine’s manufacturing number is stamped on
one of the valve covers.
The plate states:
•
•
•
The engine’s model.
The engine’s type.
Code
Please have these available when ordering spare
parts.
The wheel motors and hydrostatic pumps have a
barcode decal affixed at the rear.
6
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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.
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.
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.
R N
Reverse
Neutral
Fast
Slow
Choke
Fuel
Warning!
Parking Brake
CE conformity
marking. Only for
European market
Warning! Rotating blades,
keep away from the
discharge deck
Do not touch parts
Battery acid is corrosive, explosive and flammable
Do not stand here
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
Use protective glasses
Use protective gloves
7
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sYMBoLs.AnD.DeCALs
Read
Operator’s
Manual
Shut off engine and
remove key before
performing any
Keep a safe
distance from
the machine
Use on slopes
no greater
than 10°
No passengers
maintenance or repair work
Whole body
exposure to
thrown objects
Severing of fingers
and toes
Do not open or
remove safety
shields while
Careful backing up,
watch for other
people
Careful going
forward, watch for
other people
engine is running
Moving sharp blades under cover
8
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sAFetY
Safety Instructions
These instructions are for your safety. Read them carefully.
WARNING!
WARNING!
This symbol means that important
safety instructions need to be
emphasized. It concerns your safety.
THIS CUTTING MACHINE IS CAPABLE
OF AMPUTATING HANDS AND FEET
AND THROWING OBJECTS. FAILURE
TO OBSERVE THE FOLLOWING
SAFETY INSTRUCTIONS COULD
RESULT IN SERIOUS INJURY OR
DEATH.
General Operation
•
Read, understand, and follow all instructions on
the machine and in the manual before starting.
•
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.
8011-512
Read the operator’s manual before starting the machine
•
•
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.
8011-513
•
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.
Clear the area of objects before mowing
9
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sAFetY
•
•
•
•
•
•
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.
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.
8011-520
Never take passengers
•
•
Follow the manufacturer’s recommendation for
wheel weights or counterweights.
Anyone who operates this machine must first read
and understand this Operation Manual. Local laws
may regulate the age of the user.
Keep machine free of grass, leaves or other
debris buildup which can touch hot exhaust or
engine parts and burn. Do not allow the mower
deck to plow leaves or other debris which can
cause buildup to occur. Clean any oil or fuel
spillage before operating or storing the machine.
WARNING!
Engine exhaust and certain vehicle
components contain or emit
•
chemicals considered to cause
cancer, birth defects, or other
reproductive system damage. The
engine exhaust contains carbon
monoxide, which is an odorless,
colorless, poisonous gas. Do not use
the machine in enclosed spaces.
•
Allow machine to cool before storage.
10
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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.
8011-670a
Personal protective equipment
•
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.
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.
6003-004
Mow up and down, not side to side
WARNING!
•
•
Do not drive up or down hills with
slopes greater than 10 degrees. Do
not drive across any slopes.
•
11
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sAFetY
Children
Tragic accidents can occur if the operator is not
alert to the presence of children. Children are often
attracted to the machine and the mowing activity.
Never assume that children will remain out of the path
of danger.
•
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.
8011-518
Keep children away from work area
•
•
Never allow children to operate the machine.
Use extra care when approaching blind corners,
shrubs, trees, or other objects that may block the
view of a child.
8011-517
Never allow children to operate the machine
12
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sAFetY
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.
Safe Handling of Gasoline
To avoid personal injury or property damage, use
extreme care in handling gasoline. Gasoline is
extremely flammable and the vapors are explosive.
•
Extinguish all cigarettes, cigars, pipes, and other
sources of ignition.
•
•
Use only approved gasoline container.
Never remove gas cap or add fuel with the engine
running. Allow engine to cool at least two (2)
minutes 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.
8011-516
•
•
Before beginning to refuel, minimize the risk of
static electricity by touching a metal surface.
Never fill containers inside a vehicle or on a truck
or trailer bed with plastic liner. Always place
containers on the ground away from the vehicle
when filling.
Never fill the fuel tank indoors
WARNING!
•
•
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.
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 at least two (2) minutes before
refueling.
•
•
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.
13
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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 the machine strikes a foreign object, stop and
inspect the machine. Repair, if necessary, before
restarting.
•
•
Never make any adjustments or repairs with the
engine running.
Check grass catcher components and the
discharge guard frequently and replace with
manufacturer’s recommended parts, when
necessary.
8011-515
Never drive the machine in an enclosed space
WARNING!
•
Mower blades are sharp. Wrap the blade or wear
gloves, and use extra caution when servicing
them.
Use protective glasses for
maintenance work.
•
•
•
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.
WARNING!
•
•
Do not change the settings of governors and
avoid running the engine with overly high engine
speeds. If the engine runs too fast, there is risk for
damaging the machine components.
Be very careful when handling battery acid. Acid
on skin can cause serious corrosive burns. If
battery acid is spilled on skin, rinse immediately
with water.
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.
•
•
Acid in the eyes can cause blindness, contact a
doctor immediately.
Be careful when servicing the battery. Explosive
gases form in the battery. Never perform
maintenance on the battery when smoking or near
open flames or sparks.
•
•
The battery can explode and cause serious injury
or damage.
Ensure that the equipment is in good condition
and that all nuts and bolts, especially those
fastening the blade attachments, are properly
tightened and torqued.
14
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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.
•
•
Use protective goggles.
Ensure that the fuel filler cap is mounted tightly
and no flammable substances are stored in an
open vessel.
WARNING!
Avoid electrical sparking and its
consequences by the following
routines:
6003-009
Do not smoke when performing maintenance on the battery.
The battery can explode and cause serious injury/damage.
•
•
•
•
Never work with the starter circuit if there is spilled
fuel.
Disconnect the negative cable from the battery
first and reconnect it last.
Do not make a bridge short circuit across the
starter relay to run the starter.
Never use the machine indoors or in spaces
lacking proper ventilation. The exhaust fumes
contain carbon monoxide, an odorless,
poisonous, and lethal gas.
•
Stop to inspect the equipment if the machine runs
over or into anything. If necessary, make repairs
before starting.
•
•
Never make adjustments with the engine running.
The machine is tested and approved only with the
equipment originally provided or recommended
by the manufacturer. Only use approved repair
parts for the machine.
8009-728
Risk of sparking
•
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.
8011-514
Regularly clean deck
15
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sAFetY
Transport
WARNING!
•
The machine is heavy and can cause serious
crushing injuries. Be extra cautious when it is
Escaping hydraulic oil under
loaded on or unloaded from a vehicle or trailer.
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.
•
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.
IMPORTANT INFORMATION
•
•
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.
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..
WARNING!
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.
This mower is equipped with an
internal combustion engine and
should not be used on or near any
unimproved forested, bush covered
or grassy lands unless the engine's
system is equipped with a spark
arrestor meeting applicable local or
state laws (if any).
Spark Arrestor
A spark arrestor for the muffler is available through
your authorized McCulloch dealer.
16
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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 belt-driven
hydraulic pumps. Using the left and right steering
controls, the flow is regulated and thereby the
direction and speed.
Control Locations
1
2
3
4
8077-001
5
6
7
8
9
1. Cutting height handle
2. Park brake
6. Blade control lever
7. Fuel tank cap
3. Choke/throttle control
4. Ignition switch
8. Fuel shut off valve
9. Bypass linkage
5. Motion control levers
17
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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.
In order, for example, to turn right while moving
forward, move the right control towards the neutral
position. The rotation of the right wheel is reduced and
the machine turns to the right.
8050-003
Steering controls
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.
WARNING!
The machine can turn very rapidly if
one steering control is moved much
further forward than the other.
If the steering controls are in uneven positions when
standing still or do not fit in the slots for moving the
controls outward, they can be adjusted.
8050-004
1. Forward
2. Neutral
3. Neutral slot, Neutral lock
4. Reverse
Motion control lever, right side
18
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ContRoLs
Parking Brake
The parking brake is found on the right side of the
machine. Pull the lever backward to activate the brake
and forward to release it.
IMPORTANT INFORMATION
The machine must stand absolutely still when
applying the parking brake. Always set the
parking brake before dismounting. Release
the parking brake before moving the mower.
8050-005
Parking brake not activated
Throttle Control
The throttle control regulates the engine speed and
thereby the rate of rotation of the blades.
In order to increase or decrease the engine speed,
the control is moved forward or back respectively.
Avoid idling the engine for long periods, as there is a
risk of fouling the spark plugs.
USE FULL THROTTLE WHEN MOWING, for best
mower performance and battery charging.
8050-006
Throttle control
Ignition Switch
The ignition key is placed on the control panel and is
used to start and stop the engine.
IMPORTANT INFORMATION
Do not run the starter for more than five
seconds each time. If the engine does not
start, wait about 10 seconds before retrying.
8050-006
Ignition switch
19
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ContRoLs
Choke Control
The choke control is used for cold starts in order to
provide the engine with a richer fuel mixture.
For cold starts the throttle knob should be pushed
forward all of the way.
WARNING!
Gasoline is highly flammable. Observe
caution and fill the tank outdoors (see
the safety instruction).
8050-007
Choke control
Refueling
Read the safety instructions before refueling. The
machine has one fuel tank, just behind the seat. The
tank volume is 3 gallons (11.4 liters).
Make sure the fuel cap is properly tightened and the
cap gasket is not damaged.
The engine will run on a minimum of 85-octane
unleaded gasoline (no oil mix). Environmentally
adapted alkylate gasoline can be used. See also
Technical Data concerning ethanol fuel. Methanol fuel
is not allowed. Do not use E85 alcohol based fuel.
Damage to engine and components may occur.
IMPORTANT INFORMATION
8050-012
Fuel tank
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.
WARNING!
The engine and the exhaust system,
become very hot during operation.
Risk for burns if touched.
Allow engine and exhaust system to
cool at least two (2) minutes before
refueling
WARNING!
Fill to bottom of filler neck. Do not
overfill. Wipe off any spilled oil or fuel.
Do not store, spill or use gasoline near
an open flame.
20
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ContRoLs
Fuel Shut Off Valve
The fuel shut off valve is located in the fuel line under
the seat. Tilt seat forward for access. The fuel valve is
ON when the valve is parallel to the fuel line. Rotate
the valve ¼ turn clockwise to turn fuel OFF.
IMPORTANT INFORMATION
In order to obtain an even cutting height, it is
important that the air pressure is 15 psi in all
tires.
8050-010
Fuel shut off valve in the OPEN position.
Mower Deck Lifting Lever
The lifting lever is used to place the mower deck in
the transport position or one of the 6 different cutting
height positions.
The cutting height is set by placing a lever in the
notch for the desired cutting height.
The lifting lever can also be used to temporarily adjust
the cutting height, such as when passing a minor
bump in the lawn.
IMPORTANT INFORMATION
Always use the high position (F) to transport.
8058-085
The mower deck’s lifting lever
Tracking
If the mower is not tracking straight, check the
air pressure in both rear tires. Recommended air
pressure is 15 psi. (1 bar) Tracking must be checked
on a flat and level concrete or blacktop surface.
If the unit still does not track straight contact your
McCulloch workshop for adjustments.
21
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ContRoLs
Blade Control Lever
To engage the mower blades, slowly lift the lever up
and into the the lock notch.
WARNING!
No adjustments or maintenance to be
carried out unless:
•
•
•
the engine stopped
8058-074
the ignition key removed
the parking brake activated
Mower deck blade control lever in the disengaged position
Manual Transport
When pushing or pulling the mower, be sure to
engage the EZT Hydrogear bypass linkages. The EZT
bypass linkages are located on the rear of the frame,
below the rear engine guard.
•
•
Raise the deck into the highest cutting position.
Pull the EZT bypass linkages out and into the
slots. Release linkages to hold in the bypass
position.
•
•
Release park brake.
To reengage the EZT’s to drive, reverse the above
procedure.
8050-018
Set bypass linkages into slots on both sides
22
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oPeRAtIon
Read the Safety section and following pages, if you
are unfamiliar with the machine.
Steering
To move forward and backward
Training
The direction and speed of the mower’s movements
is 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.
Zero turn mowers are far more maneuverable than
typical riding mowers due to their unique steering
capabilities.
We suggest that this section be reviewed in its entirety
prior to attempting to move the mower under its own
power. Additionally, we suggest when first operating
the mower, use a reduced throttle speed and reduced
ground speed by NOT moving control levers to the
furthest forward or reverse positions during initial
operation, or until operator becomes comfortable
with controls. We also suggest first time users, or new
users to Zero Turn mowers to become familiar with
the mower’s movement on a hard surface, such as
concrete or blacktop PRIOR to attempting to operate
on turf. Until operator becomes comfortable with
mower controls and zero turning capability, they may
damage turf due to overly aggressive maneuvers.
First time users should push mower (see Manual
Transport in the Operation section) to an open, flat
area, without other people or vehicles/obstacles
nearby. In order to move unit under its own power,
the operator must be in the seat, start engine (see
Before Starting in Operation section), adjust engine
speed to idle, disengage parking brake, do not
engage blades at this time, rotate control levers
inward. As long as the control levers have not been
moved forward or backwards, mower will not move.
Slowly move both control levers forward slightly. This
will allow mower to start moving forward in a straight
line. Pull back on control levers to the neutral position
and mower should stop moving. Pull back slightly on
control levers, this will allow mower to start moving
backwards. Push forward on control levers to the
neutral position and mower should stop moving.
To turn to the right
IMPORTANT INFORMATION
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.
When control levers are in the reverse position
they return to neutral when released. This may
cause the mower to suddenly stop.
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.
23
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oPeRAtIon
Before Starting
•
Read the sections Safety Instructions and
Controls before starting the machine.
•
Perform the daily maintenance before starting
(see Maintenance Schedule in the Maintenance
section).
•
•
Check that there is sufficient fuel in the fuel tank.
Adjust the seat to the desired position.
The following conditions must be fulfilled before the
engine can be started:
•
•
The driver must be seated on the seat.
The blade control lever for engaging the mower
blades must be down in the lower position.
•
•
The parking brake must be on.
Both steering controls must be in the locked
(outer) neutral position.
8050-020
Start conditions
Starting the Engine
1. Sit on the seat.
2. Raise the mower deck by pulling the lifting lever
upward to the transport position (F).
3. Activate the parking brake.
8058-085
Raise the mower deck
Disengage the mower blades by lowering the blade
control lever out of the lock notch and into the down
position.
8058-074
Set the blade control lever to the down position
24
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oPeRAtIon
Move the steering controls outward to the locked
(outer) neutral position.
8050-028
Place controls in neutral position
Move the throttle to the middle position.
8050-008
Set the throttle
If the engine is cold, the choke control should be
pushed forward to its extent.
8050-007
Choke control
25
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oPeRAtIon
Open the fuel valve.
8050-010
Open the fuel valve
Press in and turn the ignition key to the start position
8050-135
Turn to START position
When the engine starts, immediately release the
ignition key back to the run position.
IMPORTANT INFORMATION
Do not run the starter for more than 5 seconds
each time. If the engine does not start, wait
approximately 10 seconds before retrying.
8050-136
Release ignition to the RUN position
26
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oPeRAtIon
Slowly slide the choke control back to the middle
position when the engine has started.
Set the desired engine speed with the throttle. Allow
the engine to run at a moderate speed, “half throttle”
for 3-5 minutes before loading it to heavily. USE FULL
THROTTLE WHEN MOWING (no choke).
WARNING!
Engine exhaust and certain vehicle
components contain or emit chemicals
considered to cause cancer, birth
defects, or other reproductive system
damage. The engine exhaust contains
carbon monoxide, which is a odorless,
colorless, poisonous gas. Do not use
the machine in enclosed spaces.
8050-007
Use full throttle when mowing
IMPORTANT INFORMATION
Your mower is equipped with a 12-volt
negative grounded system. The other vehicle
must also be a 12-volt negative grounded
system. Do not use your mower to start other
vehicles.
WARNING!
Lead-acid batteries generate
explosive gases. Keep sparks,
flame and smoking materials away
from batteries. Always wear eye
protection when around batteries.
If your battery is too weak to start the engine, it should
be recharged. (See Battery in the Maintenance
section.)
If jumper cables are used for emergency starting,
follow this procedure:
Jumper cables
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
1. Remove BLACK cable first from chassis and then
from the fully charged battery.
2. Remove RED cable last from both batteries.
8011-642
Jumper cable connection
27
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oPeRAtIon
Running
1. Release the parking brake by moving the lever
downward.
NOTE: The mower is equipped with an operator
presence system. When the engine is running,
any attempt by the operator to leave the seat
without first setting the parking brake will shut off
the engine.
2. Move the steering controls to the neutral position
(N).
8050-005
8058-085
8058-075
Parking brake not activated
3. Select the cutting height by placing the lever into
the desired notch.
WARNING!
Ensure that no one is near mower when
engaging blade control lever.
Mower deck’s lifting lever
4. Engage the mower blade by sliding the lever
upwards and into the lock notch.
5. Move throttle control to full throttle.
6. The machine’s speed and direction are
continuously variable using the two steering
controls. When both controls are in the neutral
position, the machine stands still.
By moving both controls an equal amount forward
or backward, the machine moves in a straight line
forward or backward respectively.
In order, for example, to turn right while moving
forward, move the right control towards the neutral
position. The rotation of the right wheel is reduced
and the machine turns to the right.
Turning on the spot (zero turn) can be achieved
by moving one control backward (behind the
neutral position) and carefully moving the other
steering control forward from its neutral position.
Mower blade control lever locked into blade engagement
28
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oPeRAtIon
Operating on Hills
Read the Safety Instructions Driving on Slopes in the
Safety Instructions.
WARNING!
Do not drive up or down hills with
slopes greater than 10 degrees. Do not
drive across slopes.
•
The slowest speed possible should be used
before starting up or down hills.
•
•
Avoid stopping or changing speed on hills.
If stopping is absolutely necessary, pull drive
levers into the neutral position and push to the
outside of the unit and engage the parking brake.
8050-020
Start conditions
•
•
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.
IMPORTANT INFORMATION
When in reverse, control levers return to
neutral when released. This may cause the
mower to suddenly stop.
29
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oPeRAtIon
Mowing Tips
WARNING!
•
Observe and flag rocks and other fixed objects to
avoid collisions.
Clear the lawn of stones and other
objects that can be thrown out by the
blades.
•
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.
8011-603
Mowing pattern
•
•
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.
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.
•
•
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.
30
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oPeRAtIon
Stopping the Engine
Allow the engine to idle a minute in order to attain
normal operating temperature before stopping it, if
it has been worked hard. Avoid idling the engine for
longer periods, as there is a risk of the spark plugs
fouling.
•
Disengage the mower deck by sliding the blade
control lever out of the lock notch and down into
the lower position.
8058-074
Disengage the mower blades
•
•
•
Raise the mower deck by pulling the lifting lever
upward to the transport position.
When the machine is standing still, activate the
parking brake by pulling the lever backward.
Move the throttle to the minimum position (tortoise
symbol). Turn the ignition key to the stop position.
Never use choke to stop the engine.
•
•
Move the steering controls outward.
Remove key. Always remove key when leaving the
mower to prevent unauthorized use.
IMPORTANT INFORMATION
8058-085
Leaving the ignition switch in any other
position than “OFF” will cause the battery to
be discharged.
Raise the mower deck with the lifting lever
31
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oPeRAtIon
Manual Transport
When pushing or pulling the mower, be sure to
engage the EZT Hydrogear bypass linkages. The EZT
bypass linkages are located on the rear of the frame,
below the rear engine guard.
•
•
Raise the deck into the highest cutting position.
Pull the EZT bypass linkages out and into the
slots. Release linkages to hold in the bypass
position.
•
•
Release park brake.
To reengage the EZT’s to drive, reverse the above
procedure.
8050-018
Set bypass linkages into slots on both sides
32
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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
Weekly At Maintenance interval in
least
once
each
year
hours
Maintenance
Before
After
25
50
100 300
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
Sharpen/replace mower blades
Clean the engine’s cooling air intake 2)
Clean the air cleaner’s pre-filter 2) (foam)
Clean the air cleaner’s filter cartridge 2) (paper filter)
Check/adjust the parking brake
■
■
■
♦
■
♦
1)
First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace
every 50 hours.
In dusty conditions, cleaning and replacement are required more often.
For daily use, the machine should be lubricated twice weekly.
Performed by authorized service workshop.
2)
3)
4)
● = Described in this manual
♦ = Not described in this manual
■ = See engine manufacturers’ Owners Manual
33
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MAIntenAnCe
Daily
Weekly At Maintenance interval in
least
once
each
year
hours
Maintenance
Before
After
25
50
100 300
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
Check the caster wheels (every 200 hours)
Check/adjust the mower deck
●
♦
♦
●
●
♦
♦
●
Check the engine valve clearance 4)
Perform the 300-hour service 4)
Lubricate according to Lubrication Schedule 3,4)
●
●
●
1)
First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace
every 50 hours.
In dusty conditions, cleaning and replacement are required more often.
For daily use, the machine should be lubricated twice weekly.
Performed by authorized service workshop.
2)
3)
4)
● = Described in this manual
♦ = Not described in this manual
■ = See engine manufacturers’ Owners 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.
34
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MAIntenAnCe
Battery
Your mower is equipped with a maintenance free
battery that does not need servicing. However,
periodic charging of the battery with an automotive
type battery charger will extend its life.
Always use protective glasses when
handling the battery.
•
•
•
Keep battery and terminals clean.
Keep battery bolts tight.
Recharge at 6-10 amperes for 1 hour
STANDARD
BATTERY
STATE
OF
APPROXIMATE BATTERY CHARGING TIME*
TO FULL CHARGE AT 80OF / 27OC
To clean battery and terminals
Corrosion and dirt on the battery and terminals can
cause the battery to “leak” power.
1. Open the terminal access doors.
2. Remove the red terminal guard.
3. Disconnect BLACK battery cable first, then the
RED battery cable and remove the battery from
the machine.
Maximum Rate at:
CHARGE
50 Amps
30 Amps
20 Amps
10 Amps
12.6V
12.4V
12.2V
12.0V
11.8V
100%
75%
50%
25%
0%
- FULL CHARGE -
20 min.
45 min.
65 min.
85 min.
35 min.
75 min.
48 min.
95 min.
90 min.
180 min.
280 min.
370 min.
115 min.
150 min.
145 min.
195 min.
*Charging time depends on battery capacity,
condition, age, temperature and efficiency of charger
4. Rinse the battery with plain water and dry.
5. Clean terminals and battery cable ends with wire
brush until shiny.
6. Coat terminals with grease or petroleum jelly
7. Reinstall battery.
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.
IMPORTANT INFORMATION
Do not attempt to open or remove caps or
covers. Adding or checking level of electrolyte
is not necessary.
Positive terminal must be connected
first to prevent sparks from accidental
grounding.
Always use two wrenches for the terminal
screws.
Replacing battery
1. Lift seat and rotate forward.
2. Remove the terminal guard.
3. Using two ½" wrenches disconnect BLACK battery
cable then RED battery cable.
4. Unscrew the knob and remove 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.
8. First connect RED battery cable to positive (+)
battery terminal with hex bolt and hex nut.
9. Connect BLACK grounding cable to negative (-)
battery terminal with remaining hex bolt and hex
nut.
10. Fit the terminal guard.
11. Lower seat.
8050-109
Battery cleaning and installation
35
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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 driver is sitting in the driver’s seat.
4. The parking brake is on.
Make daily inspections to ensure that the safety
system works by attempting to start the engine
when one of the conditions is not met. Change the
conditions and try again.
8050-020
Start conditions
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.
IMPORTANT INFORMATION
In order to be able to drive, the driver must
sit in the seat and release the parking brake
before the steering controls can be moved into
the neutral position, otherwise the engine will
stop.
Tire Pressures
All tires should be at 15 psi / 103 kPa / 1 bar.
8011-564
Tire pressures
36
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MAIntenAnCe
Parking Brake
Visually check that no damage is found on the lever,
links, or switch belonging to the parking brake.
Perform a standstill test and check that there is
sufficient braking action.
To adjust the parking brake, contact the McCulloch
service workshop.
WARNING!
Faulty adjustment can result in reduced
braking ability and can cause an
accident.
8050-005
Check for proper operation of parking brake
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
To replace deck belt
Deck belt removal.
1. Park on a level surface. Apply park brake.
2. Lower the deck to the lowest cutting position.
3. Disengage the clutch by sliding the blade control
lever downwards.
8058-074
Disengage clutch to replace deck belt
4. Carefully lift the belt away from belt keepers and
off deck pulleys and remove from deck.
5. Replace belt (refer to the belt routing decal on the
deck) and re-engage clutch.
8050-013
Check deck belt for excessive wear
37
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MAIntenAnCe
EZT Belt
To replace EZT belt
Park the mower on a level surface. Engage the park
brake.
WARNING!
EZT belt removal
NOTE: Be careful not to damage the fan blades on
the EZT as this can affect cooling or damage the EZT.
The engine and the exhaust system,
become very hot during operation. Risk
for burns if touched. Allow engine and
exhaust system to cool at least two (2)
minutes.
1. Remove the deck belt (see To Replace Deck Belt
in this section of the manual).
2. Create slack in the belt by pushing the spring
loaded idler arm inward. Rotate arm to release
belt tension.
3. The belt should now be able to be removed from
the engine pulley and EZT pulleys.
Belt installation
1. Wrap the EZT belt around the EZT pulleys.
2. Route the belt around the inside of the idler pulley.
3. Wrap the belt around the engine pulley.
Cutting Blades
In order to attain the best mowing effect, it is important
that the blades are well sharpened and not damaged.
WARNING!
Bent or cracked blades or blades with large nicks
should be replaced.
Damaged blades should be replaced when hitting
obstacles that result in a breakdown. Let the service
workshop decide whether the blade can be repaired/
ground or must be replaced.
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.
Balance the blades after sharpening.
Check the blade mounts.
Blade replacement
1. Remove blade bolt by turning counterclockwise.
2. Install new or resharpened blade with stamped
“GRASS SIDE” facing towards ground/grass
(down) or “THIS SIDE UP” facing deck and cutter
housing.
1
2
3. Install and tighten blade bolt securely.
4. Torque blade bolt to 45-55 ft/lbs (60-75 Nm).
3
IMPORTANT INFORMATION
Special blade bolt is heat treated.
8052-007
Replace with a McCulloch bolt if required.
1. Blade
Do not use lower grade hardware than
specified.
2. Cutter housing
3. Blade bolt (special)
Blade attachment
38
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MAIntenAnCe
Adjusting the Mower Deck
WARNING!
Before performing any service or adjustment checklist:
1. Engage the parking brake.
2. Place the Blade switch in the disengaged position.
3. Turn ignition switch to “OFF” position and remove the key.
4. Make sure the blades and all moving parts have completely stopped.
5. Disconnect the spark plug wire from all spark plugs and place the wire where it cannot
come in contact with the plug.
WARNING!
Blades are sharp. Protect your hands
with gloves and/or wrap blades with a
heavy cloth when handling.
Check the tire pressure before adjustment of the
mower deck. See Checking Tire Pressure in
Maintenance. Faulty mower deck adjustments will
cause an uneven mowing result.
Leveling Deck
1. Position the mower on a level, preferably
concrete, surface.
2. Check the pressure in all four tires. See Technical
Data section.
3. Rotate blade to align side to side.
4. Turn front adjuster nut(s) to level deck side to
side.
8050-015
Side to side adjuster nut
IMPORTANT INFORMATION
This procedure will place the mower in a base
measurement position. Additional adjustment
may be required to achieve desired cut for the
type of grass or conditions involved.
39
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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 (1) and caster bolt (2).
1
2
2. Pull the wheel out of the fork and take care of the
sleeve (3).
3. Reinstall in reverse order. Tighten caster bolt.
3
IMPORTANT INFORMATION
8050-001
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.
Caster wheels
Only use O.E.M. specified tires.
Cleaning
Regular cleaning and washing, especially under the
mower deck, will increase the machine’s life-span.
Make it a habit to clean the machine directly after use
(after it is cooled), before the debris sticks.
Use compressed air to clean the top side of mower
deck. For cleaning the underside of the deck, use the
cleanout port.
Attach the quick connect (from the accessory packet)
to any garden hose. After mowing, snap the hose to
the cleanout port and turn on water.
Restart the mower and engage the blades to use the
spinning action to wash away debris. Make sure the
hose is away from the mower blades.
Avoid spraying water on the engine and electrical
components.
8058-084
Clean regularly
Use protective glasses when
cleaning and washing.
Hardware
Check daily. Inspect the entire machine for loose or
missing hardware.
40
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LUBRICAtIon
CHOKE
FAST
SLOW
8077-002
12/12.every.year
1/52.every.Week
1/365.every.day
Lubricate.with.grease.gun
oil.change
Lubricate.with.oil.can
Level.check
Filter.change
General
Remove the ignition key to prevent unintentional
movements during lubrication.
When lubricating with an oil can, it must be filled with
engine oil.
When lubricating with grease, unless otherwise stated,
use a high grade molybdenum disulphide grease.
For daily use, the machine should be lubricated twice
weekly.
Wipe away excess grease after lubrication.
It is important to avoid getting lubricant on the belts
or the drive surfaces on the belt pulleys. Should this
happen, attempt to clean them with spirits. If the belt
continues to slip after cleaning, it must be replaced.
Gasoline or other petroleum products must not be
used to clean belts.
41
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LUBRICAtIon
Front Wheel Mount
Lubricate with a grease gun, one zerk for each wheel
mount, until the grease is forced out.
Use only good quality bearing grease.
Grease from well-known brand names (petrochemical
companies, etc.) usually maintains a good quality.
Front Wheel Bearings
Lubricate with a grease gun, one zerk for each set of
wheel bearings, until the grease is forced out.
Use only good quality bearing grease.
IMPORTANT INFORMATION
Use minimal lubrication and remove excess
lubricant so that is does not come into contact
with belts or belt pulley drive surfaces.
8050-009
Lubricating the wheel bearings
Engine Lubrication
Refer to the engine manufacturer's manual for
maintenance and service instructions.
Steering Control Shafts
Tip the driver’s seat.
Lubricate with a grease gun, one zerk for each
steering control shaft, until the grease is forced out.
Use only good quality molybdenum disulphide
grease.
Grease from well-known brand names (petrochemical
companies, etc.) usually maintains a good quality.
8058-076
Lubricating the steering control shafts
42
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tRoUBLesHootInG
Problem
Cause
The engine will not start.
•
•
Blade lever is engaged.
Steering controls are not locked in neutral
position.
•
•
•
•
•
Driver is not sitting in driver’s seat.
Parking brake is not activated.
Battery is dead.
Contamination in carburetor or fuel line.
Fuel supply is closed or tap for fuel tank is in
wrong position.
•
Clogged fuel filter or fuel line.
The starter does not turn the engine over.
•
•
Dead battery.
Poor contacts on the battery terminal cable
connections.
•
•
•
Fuse blown.
Ignition system faulty.
Fault in the starter safety circuit. See Checking the
Safety System in the Maintenance section.
The engine runs rough.
•
•
•
•
Faulty carburetor.
Choke control used with warm engine.
Defective valves.
Defective piston, cylinder, piston ring, or
cylinder head seal.
•
•
•
•
•
•
•
•
•
•
•
•
•
Cylinder head bolts are loose.
Clogged fuel filter or jet.
Clogged ventilation valve on fuel cap.
Fuel tank nearly empty.
Fouled spark plug.
Spark plug is loose.
Defective ignition cable.
Defective spark plug electrode.
Defective spark plug connection.
Rich fuel mixture or fuel-air mixture.
Wrong fuel type.
Water in fuel.
Clogged air filter.
43
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tRoUBLesHootInG
Problem
Cause
The engine seems weak.
•
•
•
Clogged air filter.
Fouled spark plugs.
Carburetor incorrectly adjusted.
The engine overheats.
•
•
•
•
•
•
•
Clogged air intake or cooling fins.
Engine overloaded.
Poor ventilation around engine.
Defective engine speed regulator.
Soot in the combustion chamber.
Too little or no oil in the engine.
Fouled spark plug.
Battery not charging.
•
Poor contact with battery terminal cable
connectors.
The machine moves slowly, unevenly, or not at all.
•
Parking brake on.
•
•
Hydraulic pump bypass linkage engaged.
Drive belt for the transmission gears slack or has
come off.
•
•
Defective hydraulic system.
Air in hydraulic system.
Mower deck not engaging.
•
•
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 the
cable contact.
Fuse has blown.
Uneven mowing results.
•
Different air pressure in the tires on left and right
sides.
•
•
•
•
•
•
Bent blades.
Suspension for the mower deck is uneven.
Blades are dull.
Driving speed too high.
Grass is too long.
Grass collected under the mower deck.
The machine vibrates.
•
Blades are loose.
•
•
Blades are incorrectly balanced.
Engine is loose.
44
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stoRAGe
Winter Storage
To ready the machine for storage, follow these steps:
At the end of the mowing season, the machine should
be readied for storage (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.
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.
Fuel stabilizers are an acceptable option as regards
to the sticky residues that can occur during storage.
3. Change the engine oil; dispose of properly.
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
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.
WARNING!
6. Lubricate all grease zerks, joints, and axles.
Never store an engine with fuel in the
tank indoors or in poorly ventilated
spaces where fuel vapor can come in
contact with open flames, sparks, or a
pilot light such as in a boiler, hot water
tank, clothes drier, etc. Handle the
fuel with care. It is very flammable and
can cause serious personal injury and
property damage. Drain the fuel into
an approved container outdoors and
far away from open flame. Never use
gasoline for cleaning. Use a degreaser
and warm water instead.
7. Remove the battery. Clean, charge, and store the
battery in a cool place, but protect it from direct
cold.
8. Store the machine in a clean, dry place and cover
it for extra protection.
Service
When ordering spare parts, please specify the
purchase year, model, type, and serial number.
Always use genuine McCulloch spare parts.
An annual checkup at an authorized service workshop
is a good way to ensure that the machine performs its
best the following season.
45
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WIRInG.DIAGRAM
8053-002
46
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teCHnICAL.DAtA
Torque Specifications
Engine crankshaft bolt
Deck pulley bolts
Lug nuts
Blade bolt
Standard ¼" fasteners
50 ft/lb (67 Nm)
Standard 5/16" fasteners
Standard 3/8" fasteners
Standard 7/16" fasteners
Standard ½” fasteners
18 ft/lb (25 Nm)
33 ft/lb (44 Nm)
52 ft/lb (70 Nm)
80 ft/lb (110 Nm)
150 ft/lb (203 Nm)
75 ft/lb (100 Nm)
90 ft/lb (122 Nm)
9 ft/lb (12 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
SAE Grade 5
SAE Grade 8
Flangelock Screw
w/Flangelock Nut
Grade
ft./lbs
¼
5/16
3/8
ft./lbs
Nm
12
ft./lbs
Nm
18
ft./lbs
Nm
9
13
28
18
24
38
24
40
33
54
31
42
46
62
7/16
50
68
75
108
156
224
305
502
801
1912
½
75
102
150
203
339
513
1060
115
165
225
370
591
1410
9/16
5/8
110
150
250
378
782
¾
7/8
11/8
** Grade 5 - Minimum commercial quality (lower quality not recommended)
Metric Standard Hardware
Grade 8.8
ft./lbs
Grade 10.9
Grade 12.9
Grade
ft./lbs
M4
Nm
2
ft./lbs
2.2
Nm
3
ft./lbs
2.7
Nm
3.6
7
1.5
3
M5
4
4.5
6
5.2
M6
5.2
7
7.5
10
8.2
11
M7
8.2
11
12
16
15
20
M8
13.5
24
18
18.8
35.2
62.2
100
147
202
275
390
498
474
25
21.8
43.5
75
29
M10
M12
M14
M16
M18
M20
M22
M24
M27
32
47
58
43.5
70.5
108
142
195
276
353
530
58
83
100
159
235
323
440
628
794
1205
94
133
196
269
366
520
664
996
119
176
242
330
471
596
904
144
190
260
368
470
707
47
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teCHnICAL.DAtA
ZM3816 BF / 966582001
Engine
Manufacturer
Type
Briggs & Stratton(1
ELS
Power
16 hp (2
Fuel
Min 86 octane unleaded (Max ethanol 5%, Max MTBE 15%)
Fuel tank capacity
Cooling
3 gallons / 11.3 liters
Air cooled
Air filter
Standard
Alternator
12V / 16A
Starter
Electric 12V
Transmission
Transmission
Speed and direction controls
Speed forward
Speed reverse
Brakes
EZT Hydro Gear
Dual levers, foam gripped
5.8 mph / 9.3 km/h
3.3 mph / 5.3 km/h
Mechanical parking brake
11 x 3.7, 4 ply
Front caster tires, smooth tread
Rear tires, turf pneumatic
Tire pressure
18 x 7.5-8
15 PSI / 103 kPa / 1 bar
(1
Refer to the engine manufacturer’s Owner’s manual for
engine specifications.
(2
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.
48
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teCHnICAL.DAtA
ZM3816 BF / 966582001
Equipment
Cutting width
38"
Cutting height
1½" - 4” / 2.5 cm - 10.6 cm
2
Number of blades
Blade length
19.33" / 49 cm
Standard
Sprung seat
Blade engagement
Deck construction
Productivity
Electric clutch
Stamped
Output
2.23 acres/hr / 9025 m2/hr
Overall dimensions
Weight
550 lbs / 250 kg
75" / 191 cm
40" / 102 cm
43¾" / 112 cm
40" / 102 cm
55" / 140cm
Base machine length
Base machine width
Base machine height
Overall width, chute up
Overall width, chute down
49
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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.
CE requirements
If required, the vibration data corresponding to
Directive 2002/44/EC is given in the Technical Data
Section.
The Declaration of Conformity is included in the
literature packet.
50
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seRVICe.JoURnAL
Action
Date, mtr reading, stamp, sign
Delivery Service
1. Charge battery.
2. Adjust tire pressure of all wheels according to Technical Data.
3. Mount the steering controls in the normal position.
4. Connect the contact box to the cable for the seat’s
safety switch.
5. Check that the right amount of oil is in the engine.
6. Adjust the position of the steering controls.
7. Fill with fuel and open the fuel shut off valve.
8. Start the engine.
9. Check that there is drive to both wheels.
10. Check the mower deck adjustment.
11. 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.
12. Check the idle speed
13. Check the engine high idle speed
14. Inform the customer about:
Delivery service has been carried out.
No remaining notes.
The need and advantages of following the service schedule.
Certified:
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.
15. Fill in the sales papers
51
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seRVICe.JoURnAL
Action
Date, mtr reading, stamp, sign
After the First 10 Hours
1. Change engine oil.
25-Hour Service
1. Check the fuel pump’s air filter.
2. Check the hydraulic system’s oil level.
3. Check the tire pressures.
4. Lubricate the belt adjuster, mower deck.
5. Lubricate the belt adjuster, hydraulic pumps.
6. Check/clean the engine’s cooling air intake.
7. Clean air filter dust cap.
52
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seRVICe.JoURnAL
Action
Date, mtr reading, stamp, sign
50-Hour Service
1. Perform the 25-hour service.
2. Clean/replace the air cleaner’s filter cartridge (paper filter)
(shorter intervals for dusty operating conditions).
3. Change engine oil.
4. Lubricate according to lubrication chart.
5. Check/adjust the parking brake.
100-Hour Service
1. Perform the 25-hour service.
2. Perform the 50-hour service.
3. Change the engine oil filter.
4. Clean/replace the spark plugs.
5. Replace the fuel filter.
6. Clean the cooling fins on the engine and transmission.
7. Check V-belts.
8. Check/tighten caster wheel axle bolts (every 200 hours).
9. Change the air filter’s paper cartridge.
53
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seRVICe.JoURnAL
Action
Date, mtr reading, stamp, sign
300-Hour Service
1. Perform the 25-hour service.
2. Perform the 50-hour service.
3. Perform the 100-hour service.
4. Check/adjust the mower deck.
5. Clean the combustion chamber and grind the valve seats.
6. Check the engine valve clearance.
7. Replace the air cleaner’s prefilter (foam).
At Least Once Each Year
1. Clean the engine’s cooling air intake (25 hours).
2. Replace the air cleaner’s pre-filter (foam) (300 hours).
3. Replace the air filter’s paper cartridge.
4. Change the engine oil (50 hours).
5. Replace the engine oil filter (100 hours).
6. Check/adjust the cutting height.
7. Check/adjust the parking brake (50 hours).
8. Clean/change the spark plugs (100 hours).
9. Change the fuel filter (100 hours).
10. Clean the cooling fins (100 hours).
11. Check the engine valve clearance.
54
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P/N 115 359527R1
03/05/10
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