McCulloch Lawn Mower 966582001 User Guide

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.  
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P/N 115 359527R1  
03/05/10  
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