McCulloch ZM3816 BF manual

ZM3816 BF / 966582001 Operator Manual Please read the operator’s manual carefully and make sure you understand the instructions before using the machine.[...]

©2010 HTC. All rights reserved. Beatrice, NE. Printed in U.S.A. In order to implement improvements, specications and designs can be altered without prior notication. 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[...]

     [...]

W ARNING! 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 in[...]

 5 Congratulations Thank you for purchasing a McCulloch ride-on mower . This machine is built for superior efciency to rapidly mow primarily large areas. A contr ol panel easily accessible to the operator and a hydrostatic transmission regulated by steering contr ols both contribute to the machine’s perfor m[...]

 6 Good Service McCulloch’s products ar e sold only in specialized retail stor es with complete service. This ensures that you as a customer receive only the best support and service. Before the pr oduct is delivered, the machine has, for example, been inspected and adjusted by your retailer . See the certic[...]

  7 R N These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. IMPORT ANT INFORMA TION Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. Reverse Neutral Fast Slow Choke Fuel W arning! Parking Brake CE[...]

  8 Read Shut off engine and Keep a safe Use on slopes No passengers Operator’s remove key befor e distance fr om no greater Manual perfor ming any the machine than 10° maintenance or repair work Whole body Severing of ngers Do not open or Careful backing up, Careful going exposure to and [...]

 9 W ARNING! This symbol means that important safety instructions need to be emphasized. It concerns your safety . Safety Instructions These instructions are for your safety . Read them car efully . General Operation Read, understand, and follow all instructions on • the machine and in the manual before starting. Do not put hand[...]

 10 Operate machine only in daylight or good articial • light. Do not operate the machine while under the • inuence of alcohol or drugs. W atch for trafc 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 opera[...]

 11 Personal Safety Equipment Make sure that you have rst aid equipment close • at hand when using the machine. Never use the machine when barefoot. • Always wear protective shoes or boots, pr eferably • with steel toe caps. Always wear approved pr otective glasses or a full • visor when assembling or driving. Always we[...]

 12 8011-517 Ne ver allo w children to operate the machine 8011-518 K eep children awa y from work area Children T ragic accidents can occur if the operator is not alert to the presence of children. Childr en are often attracted to the machine and the mowing activity . Ne v er assume that children will r emain out of the path of d[...]

 13 8011-516 Ne ver fill the fuel tank indoors Safe Handling of Gasoline T o avoid personal injury or property damage, use extreme car e in handling gasoline. Gasoline is extremely ammable and the vapors ar e explosive. Extinguish all cigarettes, cigars, pipes, and other • sources of ignition. Use only approved gasoline cont[...]

 14 8011-515 Ne ver driv e the machine in an enclosed space 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 r egularly . Keep machine free of grass, leaves, or [...]

 15 Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, re 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 ller c[...]

 16 IMPORT ANT INFORMA TION The parking brake is not sufcient 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 . W ARNING! Escaping hydraulic oil under pressure can have sufcient for[...]

 17 CHOKE FAST SLOW This operator’s manual describes the McCulloch Zero T urn Rider . The rider is tted with a four -stroke overhead valve engine. T ransmission from the engine is made via belt-driven hydraulic pumps. Using the left and right steering controls, the ow is r egulated and thereby the direction and speed[...]

 18 8050-003 Steering controls Steering Control Levers The machine’s speed and direction ar e continuously variable using the two steering controls. The steering controls can be moved forwar d or backward about a neutral position. Further more, ther e is a neutral position, which is locked if the steering controls ar e mov[...]

 19 Throttle Control The throttle contr ol regulates the engine speed and thereby the rate of r otation of the blades. In order to incr ease or decrease the engine speed, the control is moved forwar d or back respectively . Avoid idling the engine for long periods, as ther e is a risk of fouling the spark plugs. USE FULL THR[...]

 20 Choke Control The choke control is used for cold starts in order to provide the engine with a richer fuel mixtur e. For cold starts the throttle knob should be pushed forward all of the way . Refueling Read the safety instructions before r efueling. The machine has one fuel tank, just behind the seat. The tank volume is [...]

 21 Fuel Shut Off V alve 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 tur n fuel OFF . 8050-010 Fuel shut off valv e in the OPEN position. 8058-085 The mower dec k’ s [...]

 22 Manual T ransport When pushing or pulling the mower , be sure to engage the EZT Hydrogear bypass linkages. The EZT bypass linkages are located on the r ear of the frame, below the rear engine guar d. Raise the deck into the highest cutting position. • Pull the EZT bypass linkages out and into the • slots. Release lin[...]

  23 Read the Saf ety section and following pages, if you are unfamiliar with the machine. T raining Zero turn mowers are far mor e maneuverable than typical riding mowers due to their unique steering capabilities. We suggest that this section be reviewed in its entir ety prior to attempting to move the mower under its ow[...]

  24 Before Starting Read the sections Safety Instructions and • Controls befor e star ting the machine. Perfor m the daily maintenance before starting • (see Maintenance Schedule in the Maintenance section). Check that there is sufcient fuel in the fuel tank. • Adjust the seat to the desired position. • The fo[...]

  25 Move the steering controls outwar d to the locked (outer) neutral position. Move the throttle to the middle position. If the engine is cold, the choke control should be pushed forward to its extent. 8050-008 Set the throttle 8050-028 Place controls in neutral position 8050-007 Choke control[...]

  26 8050-135 T urn to ST AR T position 8050-136 Release ignition to the R UN position 8050-010 Open the fuel valv e Open the fuel valve. 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. IMPORT ANT INFORMA TION Do not run the st[...]

  27 Slowly slide the choke control back to the middle position when the engine has started. Set the desired engine speed with the thr ottle. 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). W ARNING! Engine exhaust an[...]

  28 Running Release the parking brake by moving the lever 1. 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 rst setting the parking brake will shut off the engine. Move the steering controls to the neutral positi[...]

  29 W ARNING! Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across slopes. Operating on Hills Read the Safety Instructions Driving on Slopes in the Saf ety Instructions . The slowest speed possible should be used • before starting up or down hills. Avoid stopping or changing speed on h[...]

  30 Mowing Tips Observe and ag rocks and other xed objects to • avoid collisions. Begin with a high cutting height and reduce it until • the desired mowing r esult 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 healthie[...]

  31 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. A void 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 l[...]

  32 Manual T ransport When pushing or pulling the mower , be sure to engage the EZT Hydrogear bypass linkages. The EZT bypass linkages are located on the r ear of the frame, below the rear engine guar d. Raise the deck into the highest cutting position. • Pull the EZT bypass linkages out and into the • slots. Release[...]

 33 Maintenance Schedule The following is a list of maintenance procedur es that must be perfor med on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by Check the parking brake ● Check the engine’s oil level (every refueling) ■ Ch[...]

 34 1) First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, r eplace every 50 hours. 2) In dusty conditions, cleaning and replacement ar e requir ed more often. 3) For daily use, the machine should be lubricated twice weekly . 4) Perfor med by authorized service workshop. ?[...]

 35 Battery Y our 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. Keep battery and ter minals clean. • Keep battery bolts tight. • Recharge at 6-10 amperes for 1 hour • T o c[...]

 36 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 ar e in the outer , locked neutral position. 3. The driver is sitting in the driver’s seat.[...]

 37 Parking Brake Visually check that no damage is found on the lever , links, or switch belonging to the parking brake. Perfor m a standstill test and check that there is sufcient braking action. T o adjust the parking brake, contact the McCulloch service workshop. W ARNING! Faulty adjustment can result in reduc[...]

 38 3 2 1 W ARNING! 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. EZT Belt T o replace EZT belt Park the mower on a level surface. Engage the park brake. EZT belt removal NOTE: Be careful not to damage[...]

 39 Adjusting the Mower Deck Check the tire pr essure before adjustment of the mower deck. See Checking Tire Pressure in Maintenance . Faulty mower deck adjustments will cause an uneven mowing result. Leveling Deck Position the mower on a level, preferably 1. concrete, surface. Check the pressur e in all four tires.[...]

 40 1 2 3 Caster Wheels Check every 200 hours. Check that wheels rotate freely . If wheels do not rotate fr eely take the unit to your dealer for service. Foam lled tires or solid tir es will void the warranty . Removal and installation of caster wheel Remove nut (1) and caster bolt (2). 1. Pull the wheel out of [...]

  41 CHOKE FAST SLOW General Remove the ignition key to prevent unintentional movements during lubrication. When lubricating with an oil can, it must be lled with engine oil. When lubricating with grease, unless otherwise stated, use a high grade molybdenum disulphide grease. For daily use, the machine should be [...]

  42 Front Wheel Mount Lubricate with a grease gun, one zerk for each wheel mount, until the grease is for ced out. Use only good quality bearing grease. Grease fr om well-known brand names (petrochemical companies, etc.) usually maintains a good quality . Front Wheel Bearings Lubricate with a grease gun, one zerk f[...]

 43 Problem Cause The engine will not start. Blade lever is engaged. • Steering controls ar e 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[...]

 44 Problem Cause The engine seems weak. Clogged air lter . • Fouled spark plugs. • Carburetor incorr ectly adjusted. • The engine overheats. Clogged air intake or cooling ns. • Engine overloaded. • Poor ventilation around engine. • Defective engine speed regulator . • Soot in the com[...]

  45 Winter Storage 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 carbur etor and disrupt engine function. Fuel stabilizers are an accep[...]

46  8053-002[...]

    47 HEX HEAD CAP SCREWS The torque values shown should be used as a general guideline when specic tor que values are not given. U.S. Standard Hardware Grade SAE Grade 5 SAE Grade 8 Flangelock Screw w/Flangelock Nut Shank Size (Diameter in inches, ne or coarse thread) ft./lbs ft./lbs Nm ft./lbs Nm f[...]

    48 (1 Refer to the engine manufacturer’s Owner’s manual for engine specications. (2 The power rating of the engines indicated is the average net power output (at specied rpm) of a typical production engine for the engine model measur ed to SAE standard J1349/ISO1585. Mass pr oduction engines m[...]

    49 ZM3816 BF / 966582001 Equipment Cutting width 38" Cutting height 1½" - 4” / 2.5 cm - 10.6 cm Number of blades 2 Blade length 19.33" / 49 cm Sprung seat Standard Blade engagement Electric clutch Deck construction Stamped Productivity Output 2.23 acres/hr / 9025 m 2 /hr Overall dimens[...]

50    USA requirements Labels are placed on the engine and/or in the engine compartment stating that the machine will fulll the requir ements. This is also applicable to special requir ements for any of the states, (Califor nia emission rules etc.). Do not remove any of these l[...]

51   Action Date, mtr reading, stamp, sign Delivery Service 1. Charge battery . 2. Adjust tire pr essure of all wheels according to T echnical 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 amoun[...]

52   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 lter . 2. Check the hydraulic system’s oil level. 3. Check the tire pr essures. 4. Lubricate the belt adjuster , mower deck. 5. Lubricate the belt adjuster , hydra[...]

53   Action Date, mtr reading, stamp, sign 50-Hour Service 1. Perfor m the 25-hour service. 2. Clean/replace the air cleaner’s lter cartridge (paper lter) (shorter intervals for dusty operating conditions). 3. Change engine oil. 4. Lubricate according to lubrication chart. 5. Check/adjust the par[...]

54   Action Date, mtr reading, stamp, sign At Least Once Each Y ear 1. Clean the engine’s cooling air intake (25 hours). 2. Replace the air cleaner’s pre-lter (foam) (300 hours). 3. Replace the air lter’s paper cartridge. 4. Change the engine oil (50 hours). 5. Replace the engine oil lter [...]

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P/N 115 359527R1 03/05/10[...]