McCulloch ZM4619 BF Operator'S Manual Download Page 1

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ZM4619 BF / 966660501

Operator Manual

Form Number 115 476327 Rev A

2011-12-19

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.

Summary of Contents for ZM4619 BF

Page 1: ...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 u...

Page 2: ...nformation 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 fro...

Page 3: ...RATION 24 Training 24 Steering 24 Before Starting 25 Starting the Engine 26 Jumper Cables Use 29 Running 30 Operating On Hills 31 Mowing Tips 32 Stopping the Engine 33 Moving Machine By Hand 34 MAINTE...

Page 4: ...d 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...

Page 5: ...g equipment and ensure that the machine is well anchored DO NOT operate this machine on public roadways Towing If machine is equipped with a tow hitch use extreme caution when towing Never allow child...

Page 6: ...ator Manual belongs to the machine with the manufacturing number Engine Manufacturing Number The machine s manufacturing number can be found on the printed plate affixed to the engine compartment Stat...

Page 7: ...eglect to follow instructions given in the manual 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 t...

Page 8: ...or s Manual Shut off engine and remove key before performing any maintenance or repair work Keep a safe distance from the machine Use on slopes no greater than 10 No passengers Whole body exposure to...

Page 9: ...e 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...

Page 10: ...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 i...

Page 11: ...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 slo...

Page 12: ...sible 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...

Page 13: ...er appliance Before you begin refueling 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 Alway...

Page 14: ...ly 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 Do not change the settings...

Page 15: ...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 you run over or i...

Page 16: ...ler by driving up ramps of suitable strength using a slow speed Do not lift The machine is not intended to be lifted by hand When loading or unloading this machine do not exceed the maximum recommende...

Page 17: ...iven hydraulic pumps Using the left and right steering controls the flow is regulated and thereby the direction and speed 1 2 11 13 5 8 9 12 4 10 7 6 3 5 14 8058 177 1 Steering control levers 2 Parkin...

Page 18: ...ation of the right wheel is reduced and the machine turns to the right Zero turn can be achieved by moving one control backward behind the neutral position and carefully moving the other steering cont...

Page 19: ...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 chargi...

Page 20: ...nd 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...

Page 21: ...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 syst...

Page 22: ...asured from the ground up to the blade tip with the engine not running 8058 019 The mower deck s lifting lever IMPORTANT INFORMATION To obtain an even cutting height it is important that the air press...

Page 23: ...ur meter cannot be manually reset 8058 173 Hour meter Tracking Bolts If the mower is not tracking straight check the air pressure in both rear tires Recommended air pressure is 15 psi 103 kPa 1 bar fo...

Page 24: ...e see Before Starting in the Operation section Adjust the engine speed to idle disengage the parking brake but do not engage the blades at this time Rotate control levers inward As long as the control...

Page 25: ...esired position 8058 024 Secure selected cutting height 5 Set the deck cutting height by inserting the lift pin into the desired cut height Resecure the lift pin with the hairpin 8050 852 Lengthways a...

Page 26: ...Pull the lifting lever backward to the locked transport position 3 Activate the parking brake by pushing the release button in and pulling the lever fully upwards 4 Disengage the mower blades by pres...

Page 27: ...8 170 Set the throttle 8058 171 Set the choke control 5 Move the steering controls outward to the locked outer neutral position 6 Move the throttle to the middle position 7 If the engine is cold the c...

Page 28: ...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 ma...

Page 29: ...ND on the mower with the discharged battery away from the fuel tank and battery To remove cables reverse order 4 Remove BLACK cable first from chassis and then from the fully charged battery 5 Remove...

Page 30: ...eering controls inwards out of the neutral position N 3 Push the release button on the cutting height lever and move lever to the pin release the button 8058 191 Parking brake released 8058 019 Mower...

Page 31: ...ols in neutral position 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 steering controls...

Page 32: ...awn 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 Avoid...

Page 33: ...ck by pressing the release button on the lever and pulling the lever upward to the transport position 6 Turn the ignition key to the stop position 7 Remove key Always remove key when leaving the mower...

Page 34: ...chine into truck or trailer by driving slowly up the ramps DO NOT LIFT The machine is not intended to be lifted by hand 8058 032 Left side bypass linkage EZT engaged 8058 033 Left side bypass linkage...

Page 35: ...fter 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 mo...

Page 36: ...lt pulleys Change the engine oil 1 Replace the engine oil filter Clean replace the spark plugs Replace the fuel filter Replace paper air filter 2 Check the caster wheels every 200 hours Replace the ai...

Page 37: ...g time depends on battery capacity condition age temperature and efficiency of charger Cleaning battery and terminals Corrosion and dirt on the battery and terminals can cause the battery to lose powe...

Page 38: ...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 enga...

Page 39: ...they are just slightly off of the ground when the deck is at the desired cutting height in the operating position Anti scalp rollers then keep the deck in the proper position to help prevent scalping...

Page 40: ...e deck 8058 108 Belt routing Deck Belt Installation NOTE For ease in installing the deck belt refer to the routing decal on the top of the deck 1 Wrap the deck belt around the electric clutch pulley t...

Page 41: ...blade can be repaired ground or must be replaced Balance the blades after sharpening Check the blade mounts 8058 166 Check the blades Blade replacement 1 Remove blade bolt by turning counterclockwise...

Page 42: ...required with a or adjustable wrench turn the lift link adjustment nuts on either side counter clockwise to lower or clockwise to raise Adjust until both side to side measurements are equal 8058 030...

Page 43: ...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 Do not spray water on the top of the mower deck...

Page 44: ...d be lubricated twice weekly 12 12 Every year 1 52 Every Week 1 365 Every day Lubricate with grease gun Oil change Filter change Level check Wipe away excess grease after lubrication It is important t...

Page 45: ...058 068 Lubricating the front wheels 8058 136 Deck spindle IMPORTANT INFORMATION Use minimal lubrication and remove excess lubricant so that is does not come into contact with belts or belt pulley dri...

Page 46: ...r contact of the battery terminal cable connections Blown fuse Fault in the starter safety circuit See Safety System in the Maintenance Section Engine runs rough Faulty carburetor Choke control is pul...

Page 47: ...brake on Bypass valve on pump open Drive belt for the transmission slack or has come off Air trapped in hydraulic system Mower deck not engaging Drive belt for the mower deck has come loose Contact fo...

Page 48: ...ks 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 tablespoo...

Page 49: ...49 SCHEMATICS...

Page 50: ...d 9 12 13 18 5 16 18 24 28 38 24 33 3 8 31 42 46 62 40 54 7 16 50 68 75 108 75 102 115 156 9 16 110 150 165 224 5 8 150 203 225 305 250 339 370 502 7 8 378 513 591 801 11 8 782 1060 1410 1912 Grade 5...

Page 51: ...capacity 3 5 gallons 13 2 liters Cooling Air cooled Air filter Standard Alternator 12V Starter Electric Transmission Transmission Hydrostatic transaxles Speed and direction controls Dual levers foam g...

Page 52: ...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 b...

Page 53: ...adjustment q Check The safety switch for the parking brake q The safety switch for the mower deck q The safety switch in the seat q The safety switch in the steering controls q Parking brake functiona...

Page 54: ...tamp sign 25 Hour Service Check the fuel pump s air filter q Sharpen Replace mower blades if required q Check the tire pressures q Check battery with cables q Lubricate according to lubrication chart...

Page 55: ...ine oil filter q Clean replace the spark plugs q Replace the fuel filter q Check V belts q Check tighten caster wheel axle bolts every 200 hours q Change the air filter s paper cartridge q 50 Hour Ser...

Page 56: ...engine oil 50 hours q Replace the engine oil filter 100 hours q Check adjust the cutting height q Check adjust the parking brake 50 hours q Clean Change the spark plugs 100 hours q Change the fuel fil...

Page 57: ...SERVICE JOURNAL Action Date mtr reading stamp sign 57...

Page 58: ...SERVICE JOURNAL Action Date mtr reading stamp sign 58...

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