McCulloch 96041018001 User Manual

OPERATOR’S MANUAL
MODEL NO. 96041018001
22 HP* 42 INCH
LAWN TRACTOR

• Assembly

• Operation

• Maintenance

• Service and Adjustments

• Storage

• Troubleshooting

For Parts and Service, contact our authorized distributor:

call 1-800-849-1297 For Technical Assistance: call 1-800-829-5886

*As rated by the engine manufacturer

Gasoline containing up to 10% ethanol (E10) is acceptable for use in this machine.

The use of any gasoline exceeding 10% ethanol (E10) will void the product warranty.

532 43 45-43 Rev. 2

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

DANGER: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROW ING OBJECTS. FAILURE
TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

WARNING: In order to prevent ac ci den tal
starting when setting up, trans port ing,
ad just ing or making repairs, al ways
dis con nect spark plug wire and place
wire where it can not contact spark plug.

WARNING: Do not coast down a hill in neu­tral, you may lose control of the tractor.

WARNING: Tow only the attachments
that are rec om mend ed by and comply
with spec i fi ca tions of the man u fac tur er
of your tractor. Use common sense
when towing. Operate only at the low est
possible speed when on a slope. Too
heavy of a load, while on a slope, is
dan ger ous. Tires can lose trac tion with
the ground and cause you to lose control
of your tractor.

• Do not operate the machine while under the influence
of alcohol or drugs.

• Watch for traffic when operating near or crossing
road ways.

• 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 mower­related injuries. These operators should evaluate their
ability to operate the riding mower safely enough to
protect them selves and others from serious injury.

• Follow the manufacturer's recommendation for wheel
weights or counterweights.

• Keep machine free of grass , leaves or other debris
build-up which can touch hot exhaust / engine parts
and burn. Do not allow the mower deck to plow leaves
or other debris which can cause build-up to occur.
Clean any oil or fuel spillage before operating or storing
the machine. Allow machine to cool before storage.

I. 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 in struc tions, to operate the machine.

• Clear the area of objects such as rocks, toys, wire, etc.,
which could be picked up and thrown by the blades.

• Be sure the area is clear of bystanders before
operating. Stop machine if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while
back ing.

• 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 chute, 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.

• 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 chute.

• Operate machine only in daylight or good artificial
light.

II. SLOPE OPERATION

Slopes are a major factor related to loss of control and
tip-over accidents, which can result in severe injury or
death. Operation on all slopes requires extra caution. If
you cannot back up the slope or if you feel uneasy on it,
do not mow it.

• Mow up and down slopes, 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 or shift while on the slope.

• Do not mow on wet grass. Tires may lose traction.

Always keep the machine in gear when going down

slopes. Do not shift to neutral and coast downhill.

• Avoid starting, stopping, or turning on a slope. If the
tires lose traction, disengage the blades and proceed
slowly straight down the slope.

• Keep all movement on the slopes slow and gradual.
Do not make sudden changes in speed or direction,
which could cause the machine to roll over.

• Use extra care while operating machine with grass
catchers or other at tach ments; they can affect the
stability of the machine. Do no use on steep slopes.

• Do not try to stabilize the machine by putting your 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.

2

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

III. CHILDREN

Tragic accidents can occur if the operator is not alert to
the presence of children. Children are often attracted to
the ma chine and the mowing activity. Never assume that
children will remain where you last saw them.

• Keep children out of the mowing area and in the watchful
care of a responsible adult other than the operator.

• Be alert and turn machine off if a child enters the
area.

• Before and while backing, look behind and down for
small children.

• Never carry children, even with the blades shut off. They
may fall off and be seriously injured or interfere with
safe machine operation. Children who have been given
rides in the past may suddenly appear in the mowing
area for another ride and be run over or backed over
by the machine.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs,
trees, or other objects that may block your view of a child.

IV. TOWING

• Tow only with a machine that has a hitch designed for
towing. Do not attach towed equipment except at the
hitch point.

• Follow the manufacturer's recommendation for weight
limits for towed equipment and towing on slopes.

• Never allow children or others in or on towed
equipment.

• On slopes, the weight of the towed equipment may
cause loss of traction and loss of control.

• Travel slowly and allow extra distance to stop.

V. SERVICE

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 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 appliances.

• Never fill containers inside a vehicle or on a truck or
trailer bed with plastic liner. Always place containers
on the ground away from your vehicle when filling.

• Remove gas-powered equipment from the truck or
trailer and refuel it on the ground. If this is not possible,
then refuel such equipment with a portable container,
rather than from a gasoline dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete.
Do not use a nozzle lock-open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace gas cap and tighten
securely.

GENERAL SERVICE

• 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
build-up. Clean oil or fuel spillage and remove any fuel­soaked debris. Allow machine to cool before storing.

• If you strike a foreign object, stop and inspect the
machine. Repair, if necessary, before restarting.

• Never make any adjustments or repairs with the engine
run ning.

• Check grass catcher components and the discharge
chute frequently and replace with manufacturer's rec­ommended parts, when necessary.

• Mower blades are sharp. Wrap the blade or wear
gloves, and use extra caution when servicing them.

• Check brake operation frequently. Adjust and service
as required.

• Maintain or replace safety and instruction labels, as
necessary.

• Be sure the area is clear of bystanders before operat­ing. Stop machine if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary.
Al ways look down and behind before and while backing.

• 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.

• 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.

• Mow up and down slopes (15° Max), not across.

• Choose a low ground speed so that you will not have
to stop or shift while on the slope.

• Avoid starting, stopping, or turning on a slope. If the
tires lose traction, disengage the blades and proceed
slowly straight down the slope.

• If machine stops while going uphill, disengage blades,
shift into reverse and back down slowly.

• Do not turn on slopes unless necessary, and then, turn
slowly and gradually downhill, if possible.

3

PRODUCT SPECIFICATIONS

Gasoline Capacity 1.50 Gallons
and Type: Unleaded Regular

Oil Type (API-SG-SL): SAE 30 (above 32°F)
SAE 5W-30 (below 32°F)

Oil Capacity: W/Filter: 56 oz.
W/O Filter: 48 oz.

Spark Plug: Champion RC12YC
(Gap: .030")

Ground Speed (MPH): Forward: 0 - 5.2
Reverse: 0 - 2.9

Charging System: 3 Amps Battery
5 Amps Headlights

Battery: AMP/HR: 28
Min. CCA: 230
Case Size: U1R

Blade Torque: 45-55 FT. LBS.

CONGRATULATIONS on your purchase of a new tractor.
It has been designed, engineered and manu fac tured to give
you the best possible dependability and performance.

Should you experience any problem you cannot easily
remedy, please contact your nearest authorized service
center/department. We have competent, well-trained tech ni­ cians and the proper tools to service or repair this tractor.

Please read and retain this manual. The instructions will
enable you to assemble and maintain your tractor prop erly.
Always observe the “SAFETY RULES”.

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Follow a regular schedule in maintaining, caring for
and using your tractor.

• Follow the instructions under “Maintenance” and “Stor­ age” sec tions of this manual.

WARNING: This tractor is equipped with an internal com­ bus tion engine and should not be used on or near any un­ im proved forest-covered, brush-covered or grass-cov ered
land unless the engine’s exhaust system is equipped with
a spark arrester meeting applicable local or state laws (if
any). If a spark arrester is used, it should be maintained
in effective working order by the operator.

A spark arrester for the muffler is available through your
nearest authorized service center/department.

TABLE OF CONTENTS

SAFETY RULES ......................................................... 2-3

PRODUCT SPECIFICATIONS ....................................... 4

CUSTOMER RESPONSIBILITIES ................................. 4

ASSEMBLY ................................................................. 6-7

OPERATION .............................................................8-13

MAINTENANCE SCHEDULE ...................................... 14

MAINTENANCE .....................................................14-17

SERVICE AND AD JUST MENTS ............................ 18-23

STORAGE .................................................................... 24

TROU BLE SHOOT ING ............................................ 25-26

WARRANTY ................................................................. 28

4

Steering

Wheel Insert

Steering Wheel

Adapter

UNASSEMBLED PARTS

Steering Wheel

(1) Large

Steering

Wheel

Steering Boot

Flat Washer

(1) Hex Bolt

Steering
Extension
Shaft

(1) Lock
Washer

(1) Seat

Key(s)

Seat

(1) Washer

(1) Bolt

Slope Sheet

(1) Oil Drain Tube
For Future Use

5

ASSEMBLY

Your new tractor has been assembled at the factory with exception of those parts left unassembled for shipping purposes.
To ensure safe and proper operation of your tractor all parts and hardware you assemble must be tightened securely. Use
the correct tools as necessary to ensure proper tightness.

TOOLS REQUIRED FOR ASSEMBLY

A socket wrench set will make assembly easier. Stan dard
wrench sizes are listed.

(1) 5/16" wrench Utility knife

(2) 7/16" wrenches Tire pressure gauge

(2) 1/2" wrenches Pliers

(1) 9/16" wrench

When right or left hand is mentioned in this man ual, it means
when you are in the operating po si tion (seated be hind the
steer ing wheel).

TO REMOVE TRACTOR FROM CARTON

UNPACK CARTON

• Remove all accessible loose parts and parts cartons
from carton .

• Cut along dotted lines on all four panels of carton.
Remove end panels and lay side panels flat.

• Check for any additional loose parts or cartons and
remove.

BEFORE REMOVING TRACTOR FROM
SKID

TO CHECK BATTERY (See Fig. 1)

• Lift seat to raised position.

NOTE: If this battery is put into service after month and
year indicated on label (label is located between terminals)
charge battery for minimum of one hour at 6-10 amps.
(See "BATTERY" in Maintenance section of this manual
for charging instructions).

• For battery and battery cable installation see "RE­PLACING BATTERY" in the "Service and Adjustments"
section in this manual.

LABEL

INSTALL STEERING WHEEL

• Position front wheels of the tractor so they are pointing
straight forward.

• Remove steering wheel adapter from steering wheel
and slide adapter onto steer ing shaft ex ten sion.

• Position steering wheel so cross bars are hor i zon tal
(left to right) and slide inside boot and onto adapt er.

• Assemble large flat washer, lock washer, bolt and
tighten se cure ly.

• Snap steering wheel insert into center of steer ing wheel.

• Remove protective materials from trac tor hood and grill.

IMPORTANT: CHECK FOR AND REMOVE ANY STAPLES IN
SKID THAT MAY PUNCTURE TIRES WHERE TRACTOR IS TO
ROLL OFF SKID.

INSERT

LOCK
WASHER

STEERING
BOOT

TAB

LOWER
STEERING
SHAFT

TAB
SLOT

BOLT

LARGE
FLAT
WASHER

STEERING
WHEEL

ADAPTER

EXTENSION SHAFT

Fig. 2

INSTALL SEAT (See Figs. 3 and 4)

• Remove bolt and flat washer se cur ing seat to cardboard
packing and set aside for as sem bly of seat to tractor.
Remove the cardboard packing and discard.

Fig. 1

ATTACH STEERING WHEEL (See Fig. 2)

ASSEMBLE EXTENSION SHAFT AND BOOT

• Slide extension shaft onto lower steering shaft.

• Place tabs of steering boot over tab slots in dash and
push down to secure.

SEAT
SWITCH

PAD

SLOT

SEAT
PAN

TAPE

WIRING HARNESS

6

Fig. 3

ASSEMBLY

• Connect switch to seat.

• Place seat on seat pan so all three (3) bottom pads
are positioned over large slotted holes in pan.

• Push down on seat to engage pads in slots and pull
seat towards rear of tractor.

• Raise seat and tighten bolt securely.

SLOT

PAD

FLAT
WASHER

SEAT PAN

BOLT

• Remove tape and discard.

• Lower seat into operating position and sit on seat.
Press clutch/brake pedal all the way down. If operating
position is not comfortable, adjust seat.

TAB

Fig. 4

ADJUSTMENT

TAPE

HANDLE

TO ADJUST SEAT (See Fig. 4)

Grasp adjustment handle and pull up, slide seat to desired
po si tion and release adjustment handle.

NOTE: You may now roll your tractor off the skid. Follow the
instructions below to remove the tractor from the skid.

WARNING: Before start ing, read, un der stand and fol low
all in struc tions in the Op er a tion section of this man u al. Be
sure tractor is in a well-ventilated area. Be sure the area in
front of tractor is clear of other peo ple and objects.

TO ROLL TRACTOR OFF SKID (See Op er a tion
section for location and function of con trols)

• Raise attachment lift lever to its highest po si tion.

• Release parking brake by de press ing clutch/brake ped al.

• Place freewheel control in "trans mis sion dis en gaged

position" (See “TO TRANS PORT” in the Op er a tion
section of this manual).

• Roll tractor forward off skid.

• Remove banding holding the deflector shield up against

tractor.

Continue with the instructions that follow.

CHECK TIRE PRESSURE

The tires on your tractor were overinflated at the factory
for shipping purposes. Correct tire pressure is important
for best cutting performance.

• Reduce tire pressure to PSI shown on sides of tires.

CHECK DECK LEVELNESS

For best cutting results, mower housing should be prop­erly leveled. See “TO LEVEL MOWER HOUSING” in the
Service and Adjustments section of this manual.

CHECK FOR PROPER POSITION OF BELTS

See the figures that are shown for replacing motion and
mower blade drive belts in the Service and Adjustments sec­ tion of this manual. Verify that the belts are routed correctly.

CHECK BRAKE SYSTEM

After you learn how to operate your tractor, check to see that
the brake is operating properly. See “TO CHECK BRAKE”
in the Service and Adjustments section of this manual.

✓CHECKLIST

BEFORE YOU OPERATE YOUR NEW TRAC TOR, WE
WISH TO ASSURE THAT YOU RECEIVE THE BEST
PERFORMANCE AND SATISFACTION FROM THIS
QUALITY PRODUCT.

PLEASE REVIEW THE FOLLOWING CHECKLIST:

✓ All assembly instructions have been com plet ed.
✓ No remaining loose parts in carton.
✓ Battery is properly prepared and charged.
✓ Seat is adjusted comfortably and tightened securely.
✓ All tires are properly inflated. (For shipping purposes,

the tires were overinflated at the factory).

✓ Be sure mower deck is properly leveled side-to-side/

front-to-rear for best cutting results. (Tires must be
properly inflated for leveling).

✓ Check mower and drive belts. Be sure they are routed

properly around pulleys and inside all belt keepers.

✓ Check wiring. See that all connections are still secure

and wires are properly clamped.

✓ Before driving tractor, be sure free wheel control is in

“transmission engaged” position (see “TO TRANS­ PORT” in the Operation section of this man u al).

WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY
EXTRA ATTENTION TO THE FOLLOWING IMPORTANT
ITEMS:

✓ Engine oil is at proper level.
✓ Fuel tank is filled with fresh, clean, regular unleaded

gasoline.

✓ Become familiar with all controls, their location and

function. Operate them before you start the engine.

✓ Be sure brake system is in safe operating condition.
✓ Be sure Operator Presence System and Reverse Op-

eration System (ROS) are working properly (See the
Operation and Maintenance sections in this manual).

✓ It is important to purge the transmission before op er at-

ing your tractor for the first time. Follow proper start­ing and transmission purging instructions (See “TO
START EN GINE” and “PURGE TRANSMISSION” in
the Op er a tion section of this manual).

7

DANGER, KEEP HANDS

AND FEET AWAY

FREE WHEEL

(Automatic Models only)

OVER TEMP

LIGHT

KEEP AREA CLEAR

SLOPE HAZARDS

15

15

(SEE SAFETY RULES SECTION)

BATTERY

REVERSE

FORWARD

FAST

SLOW

ENGINE ON

ENGINE OFF

OIL PRESSURE

FUEL

CHOKE

MOWER HEIGHT

PARKING BRAKE

LOCKED

PARKING BRAKE

UNLOCKED

REVERSE

NEUTRAL

HIGH

LOW

ATTACHMENT

CLUTCH ENGAGED

PARKING BRAKE

IGNITION SWITCH

ATTACHMENT

CLUTCH DISENGAGED

P

ENGINE START

MOWER LIFT

Failure to follow instructions
could result in serious injury or
death. The safety alert symbol
is used to identify safety inform­ation about hazards which can
result in death, serious injury
and/or property damage.

DANGER indicates a hazard which, if not avoided,
will result in death or serious injury.

WARNING indicates a hazard which, if not avoided,
could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided,
might result in minor or moderate injury.

CAUTION when used without the alert symbol,
indicates a situation that could result in damage
to the tractor and/or engine.

FIRE indicates a hazard which, if not avoided,
could result in death, serious injury and/or
property damage.

HOT SURFACES indicates a hazard which,
if not avoided, could result in death, serious injury
and/or property damage.

REVERSE

OPERATION

SYSTEM (ROS)

LIGHTS ON

OPERATION

These symbols may appear on your tractor or in literature supplied with the product. Learn and understand their meaning.

8

PARKING BRAKE

CLUTCH/BRAKE
PEDAL

THROTTLE/CHOKE
CONTROL

ATTACHMENT
LIFT LEVER

IGNITION
SWITCH

ATTACHMENT
CLUTCH LEVER

ROS "ON"
POSITION

LIGHT SWITCH

MOTION
CONTROL
LEVER

FREEWHEEL
CONTROL

OPERATION

KNOW YOUR TRACTOR

READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TRACTOR

Compare the illustrations with your tractor to familiarize yourself with the locations of various controls and ad just ments.
Save this manual for future reference.

ROS "ON"
POSITION

LIGHT SWITCH

THROTTLE/CHOKE
CONTROL

ATTACHMENT

CLUTCH/BRAKE
PEDAL

PARKING BRAKE

CLUTCH LEVER

IGNITION
SWITCH

ATTACHMENT
LIFT LEVER

FREEWHEEL
CONTROL

Our tractors conform to the applicable safety standards of the American National Standards Institute.

ATTACHMENT CLUTCH LEVER - Used to engage the
mower blades, or other attachments mounted to your tractor.

ATTACHMENT LIFT LEVER - Used to raise, lower, and adjust
the mower deck or other attachments mounted to your tractor.

CLUTCH/BRAKE PEDAL - Used for declutching and brak­ ing the tractor and starting the engine.

MOTION CONTROL LEVER - Selects the speed and
di rec tion of the tractor.

IGNITION SWITCH - Used for starting and stopping the
engine.

MOTION
CONTROL
LEVER

Fig. 5

LIGHT SWITCH - Turns the headlights on and off.

PARKING BRAKE - Locks clutch/brake pedal into the

brake position.

REVERSE OPERATION SYSTEM (ROS) “ON” POSI­TION - Allows operation of mower deck or other powered

attachment while in reverse.

THROTTLE/CHOKE CONTROL - Used for starting and
con trol ling engine speed.

FREEWHEEL CONTROL - Disengages transmission for
pushing or slowly tow ing the trac tor with the engine off.

9