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Summary of Contents for McCulloch 966564101
- Page 1 Operator Manual ZM4619 / 966564101 Please read the operator’s manual carefully and make sure you understand the instructions before using the machine.
- Page 2 To implement improvements, specifications and designs can be altered without prior notification. Note that no legal demands can be placed based on the information contained in these instructions. Use only original parts for repairs. The use of other parts voids the warranty. Do not modify or install non-standard equipment to the unit without consent from the manufacturer. Modifications to the unit may cause unsafe operations or damage the unit. When this product is worn out and no longer used, it should be returned to the reseller or other party for recycling. ©2010 HTC. All rights reserved. Beatrice, NE. Printed in U.S.A.
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Page 3: Table Of Contents
INTRODUCTION ...5 Driving and Transport on Public Roads ...5 Towing ...5 Operating ...5 Good Service...6 SYMBOLS AND DECALS ...7 SAFETY ...9 Safety Instructions ...9 Personal Safety Equipment ...11 Slope Operation ...11 Safe Handling of Gasoline...13 General Maintenance ...14 Transport ...16 Towing ...16 Spark Arrestor ...16 CONTROLS ...17... - Page 4 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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Page 5: Introduction
Congratulations Thank you for purchasing a McCulloch ride-on mower. This machine is built for superior efficiency to rapidly mow primarily large areas. A control panel easily accessible to the operator and a hydrostatic transmission regulated by steering controls both contribute to the machine’s performance. -
Page 6: Good Service
Good Service McCulloch's products are sold only in specialized retail stores with complete service. This ensures that you as a customer receive only the best support and service. Before the product is delivered, the machine has, for example, been inspected and adjusted by This Operator’s Manual belongs to the machine with... -
Page 7: Symbols And Decals
These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. WARNING! Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. Used in this publication to notify the reader of a risk of personal injury or death, particularly if the reader should neglect to follow instructions given in the manual. - Page 8 Read Shut off engine and Operator’s remove key before Manual performing any maintenance or repair work Whole body Severing of fingers exposure to and toes thrown objects Moving sharp blades under cover SymBOLS AND DECALS Keep a safe distance from the machine Do not open or remove safety...
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Page 9: Safety
Safety Instructions These instructions are for your safety. Read them carefully. WARNING! This symbol means that important safety instructions need to be emphasized. It concerns your safety. IMPORTANT: 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 •... - Page 10 • 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.
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Page 11: Personal Safety Equipment
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. •... - Page 12 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.
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Page 13: Safe Handling Of Gasoline
WARNING! The engine must not be started when the driver’s floor plate or any protective plate for the mower deck’s drive belt is removed. 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. •... -
Page 14: General Maintenance
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. - Page 15 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. •...
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Page 16: Transport
Follow the manufacturer’s recommendation for weight limits for towed equipment. Do not tow near ditches, canals, and other hazards. Spark Arrestor A spark arrestor for the muffler is available through your authorized McCulloch dealer. SAFETy WARNING! Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin, causing serious injury. If injured by escaping... -
Page 17: Controls
This operator’s manual describes the McCulloch Zero Turn Rider. The rider is fitted with a Briggs & Stratton, four-stroke overhead valve engine. Control Locations Motion Control Levers Seat Adjustment Lever Lift Lever Hour Meter Throttle/choke CONTROLS Transmission from the engine is made via two belt- driven hydraulic pumps. -
Page 18: Motion Control Levers
Motion 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. -
Page 19: Seat Adjustment Lever
Seat Adjustment Lever The seat can be adjusted lengthways. Release levers are located at the lower front right, or on the right side—depending on model. When making adjustments, sit on the seat. Slide the lever and maneuver seat to appropriate placement and release lever. -
Page 20: Fuel Tank
Fuel Tank The machine has one fuel tank, just behind the seat. The tank capacity is 4 gallons (15.1 liters). 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. -
Page 21: Ignition Switch
Ignition Switch The ignition key is placed on the driver’s 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. Choke Control The choke is used for cold starts to provide the engine with a richer fuel mixture. Move the throttle control all the way forward to the choke position. -
Page 22: Blade Switch
Blade Switch In order to engage the mower deck, pull the knob out; the mower blades are disengaged when the knob is depressed. 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. Parking Brake The parking brake is found on the left of the machine. Push the release button and pull the lever backward to activate the brake—push forward to release it. -
Page 23: Fuses
Fuses Fuses are located on the left hand side of the machine. They are accessed by tilting the seat forward. They are flat pin fuses of the same type used in automobiles. There are two fuses with ratings and functions: 20 Amp Primary fuse 7.5 Amp Mower deck coupling Fuel Shut Off Valve... -
Page 24: Operation
Read the Safety section and following pages, if you are unfamiliar with the machine. Training 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. -
Page 25: Before Starting
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: •... - Page 26 Move the steering controls outward to the locked (outer) neutral position. Move the throttle to the middle position. If the engine is cold, pull the choke control knob up. NOTE: On models without a separate choke control, push throttle control all the way forward to the choke position.
- Page 27 Press in and turn the ignition key to the 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. 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 too heavily.
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Page 28: Weak Battery
Weak Battery WARNING! Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. 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: IMPORTANT INFORMATION Your mower is equipped with a 12-volt negative grounded system. The other vehicle must also be a 12-volt negative grounded... -
Page 29: Running
Running Release the parking brake by moving the lever downward. Your 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. -
Page 30: Operating On Hills
Move throttle control to full throttle (not choke). 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. -
Page 31: Mowing Tips
Mowing Tips • Observe and flag rocks and other fixed objects to avoid collisions. • Begin with a high cutting height and reduce it until the desired mowing result is attained. The average lawn should be cut to 2½" (64 mm) during the cool season and over 3"... -
Page 32: Stopping The Engine
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. -
Page 33: Manual Transport
Manual Transport When pushing or pulling the mower, engage the EZT (Integrated Zeroturn Transaxle) 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 up and out of the keyhole slots. -
Page 34: Maintenance
Maintenance Schedule The following is a list of maintenance procedures that must be performed on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by MAINTENANCE Check the parking brake Check the engine’s oil level (every refueling) Check the safety system Check for fuel and oil leakages... - Page 35 MAINTENANCE Check/adjust throttle cable Check the condition of belts, belt pulleys Change the engine oil Replace the engine oil filter Clean/replace the spark plugs Replace the fuel filter Replace air filter (paper filter) Check the caster wheels (every 200 hours) Replace the air cleaner’s pre-filter Dismantle and inspect starter Check/adjust the mower deck...
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Page 36: Battery
Battery Your mower is equipped with a maintenance free battery and does not need servicing. However, periodic charging of the battery with an automotive type battery charger will extend its life. • Keep battery and terminals clean. • Keep battery bolts tight. •... -
Page 37: Safety System
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: • The mower deck is disengaged. • The steering controls are in the outer, locked neutral position. -
Page 38: Parking Brake
Visually check that no damage is found on the lever, linages, or switch belonging to the parking brake. Perform a stand still test and check that there is a braking action. To adjust the parking brake, contact the McCulloch service workshop. WARNING! Faulty adjustment can cause an accident. -
Page 39: Pump Belt
Deck Belt Installation NOTE: For ease in installing the deck belt, refer to the routing decal on the top of the deck. Wrap the deck belt around the electric clutch pulley that is located on the engine shaft. Route the belt forward and up onto the deck. Place belt around spring loaded idler pulley. -
Page 40: Cutting Blades
The rollers should be approximately ¼" (6.5 mm) from ground. Do not adjust the rollers to support the deck. mAINTENANCE WARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling. IMPORTANT INFORMATION Special blade bolt is heat treated. Replace with a McCulloch bolt if required. Do not use lower grade hardware than specified. Blade Blade bolt (special) Cutter housing Blade attachment Anti-scalp rollers 8058-027... -
Page 41: Adjusting The Mower Deck
Adjusting the Mower Deck Deck Leveling Adjust the deck while the mower is on a level surface. Make sure the tires are inflated to the correct pressure. See Transmission under Technical Data. If tires are under or over inflated, the deck cannot be properly adjusted. The deck should be adjusted slightly higher in the rear. -
Page 42: Caster Wheels
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. IMPORTANT INFORMATION DO NOT add any type of tire liner or foam fill material to the tires. Excessive loads created by foam filled tires will cause premature failures. Only use O.E.M. specified tires. Removal and installation of caster wheel Remove nut and caster bolt. -
Page 43: Lubrication
Lubrication Schedule 12/12 Every year 1/52 Every Week 1/365 Every day General For engine lubrication, see the engine manufacturer's Owners Manual. Remove the ignition key to prevent unintentional movements during lubrication. When lubricating with an oil can, it must be filled with engine oil. -
Page 44: Wheel And Deck Zerks
Wheel and Deck Zerks Use only good quality bearing grease. Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality. Front Wheel Mount Lubricate with a grease gun until the grease is forced out. Front Wheel Bearings Lubricate 3-4 strokes with a grease gun on each set of wheel bearings. -
Page 45: Trouble Shooting
Problem Engine will not start Starter does not turn the engine over Engine runs rough Engine seems weak Machine vibrates TROUBLE SHOOTING Cause • Blade switch is engaged. • Steering controls are not locked in the neutral position • Parking brake is not activated •... - Page 46 Problem Engine overheats Battery not charging The machine moves slowly, unevenly, or not at all Mower deck not engaging Transaxle leaks oil Uneven mowing results TROUBLE SHOOTING Cause • Clogged air intake or cooling fins • Engine overloaded • Poor ventilation around engine •...
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Page 47: Winter Storage
Service When ordering spare parts, please specify the purchase year, model, type, and serial number. Always use genuine McCulloch spare parts. An annual check-up at an authorized service workshop is a good way to ensure that your machine performs its best the following season. -
Page 48: Schematic
SCHEmATIC... -
Page 49: Technical Data
The torque values shown should be used as a general guideline when specific torque values are not given. Grade SAE Grade 5 ft./lbs ft./lbs ¼ ½ ¾ ** Grade 5 - Minimum commercial quality (lower quality not recommended) Grade Grade 8.8 ft./lbs ft./lbs 13.5... - Page 50 Speed reverse Brakes Front caster tires, smooth tread Rear tires, turf pneumatic Tire pressure, front and rear TECHNICAL DATA ZM4619 / 966564101 Briggs & Stratton Professional 19.5 hp Pressure with oil filter Min 87 octane, unleaded (Max methanol 10%, max MTBE 15%) 4 gallons (15.1 liters)
- Page 51 Weight Base machine length Base machine width Base machine height Overall width, chute up Overall width, chute down TECHNICAL DATA ZM4619 / 966564101 46" 1.5" - 4" / 2.5 cm - 10.6 cm 22¾ / 58 cm Standard Electric clutch Stamped 2.37 acres/hr / 9591 m 525 lbs / 238 kg 75"...
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Page 52: Conformity Certificates
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. -
Page 53: Service Journal
Action Delivery Service Charge the battery. Adjust the tire pressure of all wheels to 15 PSI (1 bar). Mount the steering controls in the normal position. Connect the contact box to the cable for the seat’s safety switch. Check that the right amount of oil is in the engine. Adjust the position of the steering controls. -
Page 54: Daily Service
Action Daily Service 1. Clean debris from mower. 2. Check engine oil level. 3. Check the tire pressures. 4. Check underside of deck. 5. Inspect deck pulleys. 6. Check/clean the engine’s cooling air intake. 7. Check safety system. 8. Check seat belt. 9. - Page 55 Action 100-Hour Service 1. Grease fittings (caster pivots and caster wheels) 2. Inspect dampeners 3. Inspect frame 4. Inspect throttle and choke cables 5. Inspect hardware 6. Check the tire pressures 7. Change the engine oil and filter 8. Change air filter 9.
- Page 56 Action 300-Hour Service 1. Grease fittings (caster pivots and caster wheels) 2. Inspect dampeners 3. Inspect frame 4. Inspect throttle and choke cables 5. Inspect hardware 6. Check the tire pressures 7. Change the engine oil and filter 8. Change air filter 9.
- Page 57 SERVICE JOURNAL Action Date, mtr reading, stamp, sign At least once each year 1. Clean the engine’s cooling air intake. 2. Replace the air cleaner’s pre-filter (foam). 3. Replace the air filter’s paper cartridge. 4. Change the engine oil. 5. Replace the engine oil filter. 6. Check/adjust the cutting height. 7.
- Page 58 SERVICE JOURNAL Action Date, mtr reading, stamp, sign...
- Page 60 P/N 115 349428R1 03/08/10...
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