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Operator Manual
ZM3016 BF / 966676301
Please read the operator's manual carefully and make sure you
understand the instructions before using the machine.
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.
Form Number 115 456827 Rev A
2011-10-20
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Table of Contents
Related Manuals for McCulloch ZM3016 BF
Summary of Contents for McCulloch ZM3016 BF
- Page 1 Operator Manual ZM3016 BF / 966676301 Please read the operator’s manual carefully and make sure you understand the instructions before using the machine. 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.
- Page 2 In order 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. ©2011 All rights reserved. Orangeburg, SC Printed in U.S.A.
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Page 3: Table Of Contents
CONTENTS INTRODUCTION..............5 Running..............28 General................ 5 Operating.on.Hills............29 Driving.and.Transport.on.Public.Roads....... 5 Mowing.Tips............... 30 Towing................. 5 Stopping.the.Engine..........31 Operating..............5 Moving.Machine.By.Hand.......... 32 Good.Service............... 6 MAINTENANCE............... 33 Manufacturing.Number........6 Maintenance.Schedule..........33 SYMBOLS.AND.DECALS..........7 Battery............... 35 SAFETY................ - 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
INTRODUCTION Congratulations Towing Thank you for purchasing a McCulloch ride-on If machine is equipped with a tow hitch, use extreme mower. This machine is built for superior efficiency caution when towing. Never allow children or others in to rapidly mow primarily large areas. A control panel or on towed equipment. -
Page 6: Good.service
INTRODUCTION Good Service your retailer. See the certificate in the Service Journal McCulloch’s products are sold only in specialized in this operator’s manual. retail stores with complete service. This ensures that you as a customer receive only the best support and When you need spare parts or support in service service. -
Page 7: Symbols.and.decals
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 Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. Used in this publication to notify the reader of a risk Used in this publication to notify the reader of a risk of material damage, particularly if the reader should of personal injury or death, particularly if the reader... - Page 8 SYMBOLS.AND.DECALS Shut off engine and remove key before Read Keep a safe Use on slopes performing any Operator’s distance from no greater maintenance or Manual repair work the machine than 10° No passengers Whole body Severing of fingers Do not open or Careful backing up, Careful going exposure to...
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Page 9: Safety
SAFETY Safety Instructions These instructions are for your safety. Read them carefully. WARNING! WARNING! This symbol means that important THIS CUTTING MACHINE IS CAPABLE safety instructions need to be OF AMPUTATING HANDS AND FEET emphasized. It concerns your safety. 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. •... - Page 10 SAFETY • 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. • Operate machine only in daylight or good artificial light.
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Page 11: Personal.safety.equipment
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. 8011-670a Personal protective equipment • Always wear protective shoes or boots, preferably with steel toe caps. - Page 12 SAFETY • 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.
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Page 13: Safe.handling.of.gasoline
SAFETY 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. 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. •... -
Page 14: General.maintenance
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. - Page 15 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. WARNING! Avoid electrical sparking and its consequences by the following...
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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 an WARNING! authorized McCulloch dealer. 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). -
Page 17: Controls
CONTROLS This operator’s manual describes the McCulloch Zero hydraulic pumps. Using the left and right steering Turn Rider. The rider is fitted with a Briggs & Stratton controls, the flow is regulated and thereby the four-stroke overhead valve engine. direction and speed. -
Page 18: Steering.control.levers
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. There is also 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. -
Page 19: Parking.brake
CONTROLS Parking Brake 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. The parking brake is found on the right side of the machine. Pull the lever backward to activate the brake and push forward to release it. 8050-005 Parking brake not activated Throttle Control The throttle control regulates the engine speed and thereby the rate of rotation of the blades. -
Page 20: Choke.control
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 should be pushed forward to the choke position. WARNING! Gasoline is highly flammable. Observe caution and fill the tank outdoors (see 8050-006 the safety instruction). Choke control Fuel Tank Read the safety instructions before refueling. -
Page 21: Fuel.shut.off.valve
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. -
Page 22: Blade.control.lever
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 Mower deck blade control lever in the disengaged position • the parking brake activated Bypass Linkage Transaxle bypass linkages must be engaged when pushing or pulling the mower. -
Page 23: Operation
OPERATION To turn to the right Read the Safety section and following pages, if you are unfamiliar with the machine. While moving in a forward direction, pull the right lever back towards the neutral position while maintaining Training the position of the left lever, this will slow the rotation Due to unique steering capabilities, zero turn mowers of the right wheel and cause the machine to turn in are far more maneuverable than typical riding... -
Page 24: Before.starting
OPERATION Before Starting 1. Read the sections Safety Instructions and Controls before starting the machine. 2. Perform the daily maintenance before starting (see Maintenance Schedule in the Maintenance section). 3. Check that there is sufficient fuel in the fuel tank. 4. Adjust the seat to the desired position. The following conditions must be fulfilled before the engine can be started: •... - Page 25 OPERATION 4. Move the steering controls outward to the locked (outer) neutral position. 8050-028 Place controls in neutral position 5. Move the throttle to the middle position. 8050-008 Set the throttle 6. If the engine is cold, the choke control should be pushed forward to the choke position.
- Page 26 OPERATION 7. Open the fuel valve. 8050-010 Open the fuel valve 8. Press in and turn the ignition key to the start position 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, an odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces. 8050-135 Turn to START position 9. When the engine starts, immediately release the ignition key back to the run position.
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Page 27: Weak.battery
OPERATION 10. Slowly pull back on the choke control when the engine has started. 11. Set the engine speed with the throttle. Allow the engine to run at a moderate speed, approximately mid throttle, for 3-5 minutes before loading it too heavily. -
Page 28: Running
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. -
Page 29: Operating.on.hills
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 8050-020... -
Page 30: Mowing.tips
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 • Begin with a high cutting height and reduce it until blades. the desired mowing result is attained. The average lawn should be cut to 2½"... -
Page 31: Stopping.the.engine
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. -
Page 32: Moving.machine.by.hand
OPERATION Moving Machine By Hand 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. 1. Raise the deck into the highest cutting position. 2. -
Page 33: Maintenance
MAINTENANCE Maintenance Schedule The following is a list of maintenance procedures that an authorized service workshop is recommended to must be performed on the machine. For those points maintain your machine in the best possible condition not described in this manual, visit an authorized and to ensure safe operation. - Page 34 MAINTENANCE At least Maintenance interval Daily once in hours Maintenance each Before After year ● 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 ●...
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Page 35: Battery
MAINTENANCE Battery Your mower is equipped with a maintenance free Always use protective glasses when battery that does not need servicing. However, handling the battery. periodic charging of the battery with an automotive type battery charger will extend its life. • Keep battery and terminals clean. •... -
Page 36: Safety.system
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. -
Page 37: 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. -
Page 38: Ezt.belt
3. Seat the blade's opening firmly onto the cutter housing. 4. Tighten blade bolt securely. 5. Torque blade bolt to 45-55 ft/lbs (60-75 Nm). IMPORTANT INFORMATION Special blade bolt is heat treated. 8058-129 Replace with a McCulloch bolt if required. 1. Blade Do not use lower grade hardware than 2. Cutter housing specified. 3. Blade bolt (special) Blade attachment... -
Page 39: Adjusting.the.mower.deck
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. -
Page 40: Caster.wheels
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 and caster bolt. 2. -
Page 41: Lubrication
LUBRICATION 8050-924 12/12.Every.year Lubricate.with.grease.gun Filter.change. 1/52.Every.Week Oil.change Level.check 1/365.Every.day General Remove the ignition key to prevent unintentional Wipe away excess grease after lubrication. movements during lubrication. It is important to avoid getting lubricant on the belts When lubricating with an oil can, it must be filled with or the drive surfaces on the belt pulleys. -
Page 42: Front.wheel.mount
Lubricate with a grease gun, 2-3 strokes per spindle. Transmission The transmission is maintenance free with no need for level checks or oil changes. If a leak occurs, replace the unit or contact your McCulloch dealer. 8050-027 Lubricating the deck spindle after removing the foot plate Steering Control Shafts Tip the driver’s seat. -
Page 43: Troubleshooting
TROUBLESHOOTING Problem Cause Engine will not start • Blade switch is engaged. • Steering controls are not locked in the neutral position • Parking brake is not activated • Battery is dead • Contamination in the carburetor or fuel line. •... - Page 44 TROUBLESHOOTING Problem Cause Engine overheats • Clogged air intake or cooling fins • Engine overloaded • Poor ventilation around engine • Defective engine speed regulator • Too little or no oil in the engine • Contamination in the carburetor or fuel line. •...
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Page 45: Storage
When ordering spare parts, please specify the property damage. Drain the fuel into an purchase year, model, type, and serial number. approved container outdoors and store Always use genuine McCulloch spare parts. far away from open flame. Never use An annual checkup at an authorized service workshop gasoline for cleaning. Use a degreaser is a good way to ensure that the machine performs its and warm water instead. -
Page 46: Schematics
SCHEMATIC... -
Page 47: Technical.data
TECHNICAL.DATA Torque Specifications Engine crankshaft bolt 50 ft/lb (67 Nm) Standard ¼" fasteners 9 ft/lb (12 Nm) Deck pulley bolts 150 ft/lb (203 Nm) Standard " fasteners 18 ft/lb (25 Nm) Lug nuts 75 ft/lb (100 Nm) Standard " fasteners 33 ft/lb (44 Nm) Blade bolt 90 ft/lb (122 Nm) Standard... - Page 48 TECHNICAL.DATA The power rating of the engines Engine indicated is the average net power Manufacturer Briggs & Stratton output (at specified rpm) of a typical production engine for the engine model Type Intek measured to SAE standard J1349/ Power 16.5 hp (1,2 ISO1585.
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Page 49: 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 50 SERVICE.JOURNAL Date,.mtr.reading,.stamp,.sign 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.
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Page 51: Service.journal
SERVICE.JOURNAL Date,.mtr.reading,.stamp,.sign Action After 5-10 Hours Change the engine oil Action Date,.mtr.reading,.stamp,.sign 25-Hour Service Check the fuel pump’s air filter Sharpen/Replace mower blades if required Check the tire pressures Check battery cables Lubricate according to lubrication chart Check/clean the engine’s cooling air intake Clean the air cleaner’s pre-filter (foam) - Page 52 SERVICE.JOURNAL Date,.mtr.reading,.stamp,.sign Action 50-Hour Service Perform the 25-hour service Clean/replace the air cleaner’s filter cartridge (paper filter (shorter intervals for dusty operating conditions) Change engine oil Lubricate according to lubrication chart Check/adjust the parking brake Date,.mtr.reading,.stamp,.sign Action 100-Hour Service Perform the 25-hour service Perform the 50-hour service Change the engine oil filter Clean/replace the spark plugs...
- Page 53 SERVICE.JOURNAL Date,.mtr.reading,.stamp,.sign Action 300-Hour Service Perform the 25-hour service Perform the 50-hour service Perform the 100-hour service Check/adjust the mower deck Clean the combustion chamber and grind the valve seats Check the engine valve clearance Replace the air cleaner’s pre-filter (foam) Action Date,.mtr.reading,.stamp,.sign At Least Once Each Year...
- Page 54 SERVICE.JOURNAL Date,.mtr.reading,.stamp,.sign Action...
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