Page 1
MOW’N MACHINE
FZ22K
TM
MAN0999
(Rev. 11/7/2013)
Page 2
TO THE DEALER:
Assembly and proper installation of this product is the responsibility of the Woods
and safety rules. Make sure all items on the Dealer’s Pre-Delivery and Delivery Check Lists in the Operator’s Manual
are completed before releasing equipment to the owner.
The dealer must complete the online Product Registration form at the Woods Dealer Website which certifies that
all Dealer Check List items have been completed. Dealers can register all Woods product at
dealer.WoodsEquipment.com under Product Registration.
Failure to register the product does not diminish customer’s warranty rights.
TO THE OWNER:
Read this manual before operating your Woods equipment. The information presented will prepare you to do a better
and safer job. Keep this manual handy for ready reference. Require all operators to read this manual carefully and
become acquainted with all adjustment and operating procedures before attempting to operate. Replacement manuals
can be obtained from your dealer. To locate your nearest dealer, check the Dealer Locator at
www.WoodsEquipment.com, or in the United States and Canada call 1-800-319-6637.
The equipment you have purchased has been carefully engineered and manufactured to provide dependable and
satisfactory use. Like all mechanical products, it will require cleaning and upkeep. Lubricate the unit as specified.
Observe all safety information in this manual and safety decals on the equipment.
For service, your authorized Woods dealer has trained mechanics, genuine Woods service parts, and the necessary
tools and equipment to handle all your needs.
Use only genuine Woods service parts. Substitute parts will void the warranty and may not meet standards required for
safe and satisfactory operation. Record the model number and serial number of your equipment in the spaces
provided:
®
dealer. Read manual instructions
Model:
Serial Number:
Provide this information to your dealer to obtain correct repair parts.
Throughout this manual, the term
The terms
an exclamation mark) to indicate the degree of hazard for items of personal safety.
_______________________________
(see Safety Decal section for location) ____________________________________
CAUTION, WARNING,
NOTICE
and
is used to indicate that failure to observe can cause damage to equipment.
DANGER
Date of Purchase:
are used in conjunction with the Safety-Alert Symbol (a triangle with
_____________________
2 Introduction
Gen’l (Rev. 3/28/2012)
Page 3
TABLE OF CONTENTS
Si no lee Ingles, pida ayuda a
alguien que si lo lea para que le
traduzca las medidas de seguridad.
LEA EL INSTRUCTIVO!
!
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
DEALER CHECK LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
INDEX TO PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .44
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
REPLACEMENT PARTS WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACK COVER
WARNING
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
WARNING
This product contains chemicals,
including lead, known to the State of
California to cause cancer, and birth
defects or other reproductive harm.
Wash hands after handling.
MAN0999 (12/4/2012)
Introduction 3
Page 4
SPECIFICATIONS
WARNING
Engine: FZ22K . . . . . . . . . . . . . . . . . . . . . . . . .Kawasaki, 4-Cycle, Air Cooled
Horsepower: FZ22K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 HP
Fuel Type:. . . . . . . . . . . Gasoline (minimum 85 octane, unleaded recommended)
Standard Tire Size: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 x 10.50 - 12
Front (optional) . . . . . . . . . . . . . . . . . . . . . 23 x 8.50 - 12
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . .15 x 6.00 - 6 Rib
Recommended Air Pressure:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 psi
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum 18 psi
Fuel Tank Capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5 Gallons
Power Unit Dimensions: Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45"
Over all Length . . . . . . . . . . . . . . . . . . . . . . . . . . 80.75
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 lbs
Recommended Mowers: FZ22K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" ,54", 61"
"
GENERAL INFORMATION
■
Some illustrations in this manual show the
mower with safety shields removed to provide a
better view. The Mow’n Machine should never be
operated with any safety shielding removed.
The purpose of this manual is to assist you in operating
and maintaining your Mow’n Machine. Read it carefully.
It furnishes information and instructions that will help
you achieve years of dependable performance. These
instructions have been compiled from extensive field
experience and engineering data. Some information
may be general in nature due to unknown and varying
operating conditions. However, through experience
and these instructions, you should be able to develop
procedures suitable to your particular situation.
The illustrations and data used in this manual were current at the time of printing but, due to possible inline
production changes, your machine may vary slightly in
detail. We reserve the right to redesign and change the
machines as may be necessary without notification.
Throughout this manual, references are made to right
and left directions. These are determined by standing
behind the equipment, facing the direction of forward
travel.
4 Introduction
MAN0999 (12/4/2012)
Page 5
TRAINING
Safety is a primary concern in the design and
manufacture of our products. Unfortunately, our
efforts to provide safe equipment can be wiped
out by an operator’s single careless act.
In addition to the design and configuration of
equipment, hazard control and accident prevention are dependent upon the awareness, concern, judgement, and proper training of
personnel involved in the operation, transport,
maintenance, and storage of equipment.
It has been said, “The best safety device is an
informed, careful operator.” We ask you to be
that kind of operator.
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Safety instructions are important! Read all
attachment and power unit manuals; follow all
safety rules and safety decal information. (Replacement manuals and safety decals are available from
your dealer. To locate your nearest dealer, check
the Dealer Locator at www.WoodsEquipment.com,
or in the United States and Canada call 1-800-319-
6637.) Failure to follow instructions or safety rules
can result in serious injury or death.
Data indicates that those operators age 60 years
and above are involved in a large percentage of riding mower-related injuries. Those operators should
evaluate their ability to operate the riding mower
safely enough to protect themselves and others
from injury.
If you do not understand any part of this manual
and need assistance, see your dealer.
Know your controls and how to stop engine and
attachment quickly in an emergency.
Operators must be instructed in and be capable
of the safe operation of the equipment, its attachments, and all controls. Do not allow anyone to
operate this equipment without proper instructions.
equipment for eyes, hair, hands, hearing, and head;
and respirator or filter mask where appropriate
Make sure attachment is properly secured,
adjusted, and in good operating condition.
Make sure the driveline spring-activated locking
collar slides freely and is seated firmly in power
unit PTO groove. Make sure the set screws
securely attach driveline to the attachment gearbox
shaft.
The safety interlock system was installed for
your protection. Do not disconnect, disable, override, or execute any action that would cause this
system to malfunction. If malfunction occurs, stop
all operation and contact dealer for repair.
Remove accumulated debris from this equipment, power unit, and engine to avoid fire hazard.
Keep children out of the mowing area and under
the watchful care of a responsible adult other than
the operator.
Make sure all safety decals are installed.
Replace if damaged. (See Safety Decals section for
location.)
Make sure shields and guards are properly
installed and in good condition. Replace if damaged.
Be sure either the discharge chute, mulching
end cap, or complete vacuum attachment is
installed and in good condition. Replace if damaged.
When using weight transfer system, correct
counterweight must be used to maintain stability.
See counterweight chart in power unit manual or
contact dealer.
When equipped with ROPS, total vehicle weight
with all equipment, ballast, and operator must not
exceed 2,590 lbs.
Inspect and clear area of stones, branches, or
other hard objects that might be thrown, causing
injury or damage.
.
Never allow children or untrained persons to
operate equipment.
PREPARATION
Check that all hardware is properly installed.
Always tighten to torque chart specifications
unless instructed otherwise in this manual.
Always wear relatively tight and belted clothing
to avoid getting caught in moving parts. Wear
sturdy, rough-soled work shoes and protective
MM F-Series (Rev. 8/1/2008)
Do not mow on wet grass.
While fueling, extinguish all cigarettes, cigars,
pipes, and other sources of ignition.
Never fuel the machine indoors.
Never fill fuel containers inside a vehicle or a
truck or trailer bed with a plastic liner. Always
place container on the ground away from the vehicle before filling.
(Safety Rules continued on next page)
Safety 5
Page 6
(Safety Rules continued from previous page)
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Remove gas-powered equipment from the truck
or trailer and refuel on the ground. If this is not
possible, then refuel such equipment on a trailer
with a portable container, rather than from a
gasoline dispenser nozzle.
Keep the nozzle in contact with the rim of the
fuel tank 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 over-fill tank. Replace gas cap and tighten
securely.
Handle fuel carefully; it is highly flammable.
Always use an approved container. Never remove
fuel cap or add fuel while engine is running. Allow
engine to cool before refueling. Wipe up all spilled
fuel before starting engine.
TRANSPORTATION
Use extra care when loading or unloading the
machine onto a trailer or truck.
Do not operate or transport on steep slopes.
Do not operate or transport equipment while
under the influence of alcohol or drugs.
Transport power unit facing rearward when
equipped with a sunshade.
OPERATION
Keep bystanders away from equipment.
Keep children out of the mowing area and under
the watchful care of a responsible adult other than
the operator.
Make sure people and objects are clear of
attachment and discharge area before engaging
PTO.
Be alert and turn machine off if a child enters
the mowing area.
Before and while backing, look behind and
down for children.
Never direct discharge toward people, animals,
or property.
Do not operate or transport equipment while
under the influence of alcohol or drugs.
Operate only in daylight or good artificial light.
Keep hands, feet, hair, and clothing away from
equipment while engine is running. Stay clear of all
moving parts.
When improperly operated, power unit can roll
over or upset. Use of rollover protective structure
(ROPS) with seat belt securely fastened will reduce
the possibility of injury or death if rollover or upset
occurs.
Always use the seat belt when the foldable
ROPS is in the upright position. Do not use the
seat belt if the foldable ROPS is in the down position. The ROPS and seat belt must be used in all
conditions except when mowing on flat terrain
under branches or other obstructions. Return
ROPS to upright position and fasten seatbelt as
soon as possible.
Use care when operating with ROPS or sunshade around shrubs, trees or other objects that
can become entangled with power unit.
Use extreme care when approaching blind corners, shrubs, trees, or other objects that may block
your vision.
Always comply with all state and local lighting
and marking requirements.
Never allow riders on power unit or attachment.
Start engine from operator's seat after disengaging power unit PTO and placing steering levers
in neutral.
Look down and to the rear and make sure area
is clear before operating in reverse.
Do not mow in reverse unless absolutely necessary.
Slow down before turning.
Do not operate on slopes greater than 15
degrees (27% grade).
Mow up and down slopes, not across.
If the tires lose traction on a slope, disengage
the blade(s) and proceed slowly straight down the
slope.
Do not stop, start, or change directions suddenly on slopes.
Do not make sudden changes in speed or direction which could cause the machine to roll over.
Use extreme care and reduce ground speed on
slopes and rough terrain.
(Safety Rules continued on next page)
6 Safety
MM F-Series (Rev. 8/1/2008
Page 7
(Safety Rules continued from previous page)
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Installation of a grasscatcher assembly will
reduce the stability and maneuverability of the
Mow'n Machine when operating on sloping terrain.
Do not tow a trailer over 200 lbs. Do not tow a
trailer or add power unit ballast with a combined
weight over 200 lbs. Too much weight can cause
loss of traction or stability on a slope. It can also
reduce parking brake ability. Too much weight will
shorten the hydraulic system life. Never tow a
trailer with a grass collection system attached to
the power unit.
Watch for hidden hazards on the terrain during
operation.
Watch for traffic when operating near or crossing roadways.
Uneven terrain could overturn the machine.
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 goes over the edge or if the edge caves in.
Stop power unit and equipment immediately
upon striking an obstruction. Turn off engine,
remove key, inspect, and repair any damage before
resuming operation.
Do not drive or operate mower in tilt-up position. Power unit stability is not adequate and resulting loads can damage or cause failure of tilt-up
mechanism.
Never leave a running machine unattended.
Moving steering levers rapidly from forward to
reverse or reverse to forward could cause loss of
control.
Do not operate power unit with attachment
removed. Attachment is required for power unit
stability.
Before attempting to unplug vacuum hoses, disengage PTO, stop power unit, and remove key.
MAINTENANCE
Before dismounting power unit, follow these
steps: lower attachment to ground, shut off PTO,
set parking brake, shut off engine, position steering levers to neutral swing-out position, and
remove key.
Before attempting to unplug vacuum hoses, dis-
engage PTO, stop power unit, and remove key.
Before performing any service or maintenance,
lower attachment to ground, turn off power unit
engine, remove key, and disconnect battery ground
cable (negative -).
Before working underneath, read manual
instructions, securely block up, and check stability.
Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system
failure, or mechanical component failure.
Do not modify or alter or permit anyone else to
modify or alter the equipment or any of its components in any way.
Do not work on mower in tilt-up position unless
lock-up mechanism is in good condition. Replace if
damaged.
Always wear relatively tight and belted clothing
to avoid getting caught in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and head;
and respirator or filter mask where appropriate
Make sure attachment is properly secured,
adjusted, and in good operating condition.
Do not put Mow’n Machine into service unless
clutch is working properly. When the engine is at
full throttle, PTO-driven accessories must stop
within five seconds after the PTO switch is turned
to “OFF.” See your dealer for replacement
clutches.
Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
Do not remove radiator cap while engine is hot.
Do not change engine governor settings or
overspeed engine.
Frequently check blades. They should be sharp,
free of nicks and cracks, and securely fastened.
Do not handle blades with bare hands. Careless
or improper handling may result in serious injury.
Your dealer can supply genuine replacement
blades. Substitute blades may not meet original
equipment specifications and may be dangerous.
.
When using a sunshade and lifting hood for
maintenance, use caution around pinch points.
MM F-Series (Rev. 8/1/2008)
(Safety Rules continued on next page)
Safety 7
Page 8
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
(Safety Rules continued from previous page)
Tighten all bolts, nuts, and screws to torque
chart specifications. Check that all cotter pins are
installed securely to ensure equipment is in a safe
condition before putting unit into service.
Use care to prevent battery acid from contacting
skin.
Make sure all safety decals are installed.
Replace if damaged. (See Safety Decals section for
location.)
Make sure shields and guards are properly
installed and in good condition. Replace if damaged.
Battery posts, terminals, wiring insulation, 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.
STORAGE
Keep children and bystanders away from stor-
age area.
Never store equipment where fuel or fumes
could reach an open flame or spark. Allow engine
to cool before storing in an enclosure.
Never store the machine or fuel container near
an open flame, spark or pilot light such as on a
water heater or other appliance.
Do not run engine indoors. Exhaust gases contain carbon monoxide, an odorless and deadly poison.
Remove key and store in a secure location to
prevent unauthorized persons from operating
equipment.
8 Safety
MM F-Series (Rev. 8/1/2008
Page 9
3 – SERIAL NUMBER PLATE
1 – 72407
(Safety Decals continued on next page)
2 – 72404
SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
MAN0999 (12/4/2012)
Safety 9
Page 10
6 – 70376
5 – 72406
4 – 72408
7 – 72405
9 - 78643
BE CAREFUL!
Use a clean, damp cloth to clean safety decals. Avoid spraying too close to decals when using a pressure
washer; high-pressure water can enter through very small scratches or under edges of decals causing them to
peel or come off. Replacement safety decals can be ordered free from your Woods dealer, or in the United
States and Canada call 1-800-319-6637.
(Safety Decals continued from previous page)
SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
10 Safety
MAN0999 (12/4/2012)
Page 11
OPERATION
WARNING
CAUTION
WARNING
1. Console decal
2. PTO switch
5. Ignition switch
6. Hour meter
7. Throttle control
8. Choke
9. Tilt deck switch
The operator is responsible for the safe operation of
this Mow’n Machine. The operator must be properly
trained. Operators should be familiar with the power
unit, all attachments that will be used, and all safety
practices before starting operation. Read the safety
rules and safety decals on page 5 through page 10.
Operators must be instructed in and be capable
of the safe operation of the equipment, its attachments, and all controls. Do not allow anyone to
operate this equipment without proper instructions.
Do not operate power unit with attachment
removed. Attachment is required for power unit
stability.
Never direct discharge toward people, animals,
or property.
Moving steering levers rapidly from forward to
reverse or reverse to forward could cause loss of
control.
tilt position. Release switch when deck reaches maximum tilt position. To lower the deck, push and hold toggle switch until it cycles to the desired cutting height.
NOTE:
ting in the seat.
Power Tilt™ feature must not be used when sit-
Figure 1
. Console Control Locations
Start engine from operator's seat after disengaging power unit PTO and placing steering levers
in neutral.
Stop power unit and equipment immediately
upon striking an obstruction. Turn off engine,
remove key, inspect, and repair any damage before
resuming operation.
CONTROLS AND SWITCHES
Know your controls and how to stop engine and
attachment quickly in an emergency.
The Control and Indicator console is located on the
right fuel tank. This console contains controls needed
to operate this unit. PTO switch (2) is used to engage
attachments: pull up to engage, push down to disengage.
Deck Height/Power Tilt™
Adjustment Switch
The deck height and Power Tilt™ switch is used with
MXT. Push the toggle switch forward to raise the deck
and pull back to lower the deck to the desired cutting
height. For Power Tilt operation, pull back and hold the
toggle switch to lower the deck and cycle through to the
MAN0999 (12/4/2012)
Hour Meter
The hour meter is programmed to alert the operator at
various service intervals. The change oil light will flash
at 20 hours (initial break in for some models) and every
100 hours after. The light will flash for a period of 4
hours (alternating between hours & change oil) and
then resume normal mode. The hour glass will flash
every second indicating that it’s in running mode.
FZ22K Service Intervals
8 hrs Engine oil change (break in)
100 hrs Engine oil change & filter
40 hrs Hydraulic oil change & filter
(break in)
400 hrs Hydraulic oil change & filter (see
hydraulic transmission - change
oil & filter, page 18.)
Safety Switch System
Several safety switches are incorporated in the unit’s
design to prevent it from being started out of PARK
(handles pivoted outward) or with PTO engaged.
The PTO control must be in the “OFF” position and the
steering handles in the PARK position before unit can
be started.
Operation 11
Page 12
A safety switch in the operator’s seat will cause the
DANGER
WARNING
WARNING
WARNING
engine to stop if the operator leaves the seat with the
PTO or steering handles engaged. The engine will also
stop if the steering handles are moved from PARK if
the deck jumper wire is not connected to the wire harness or the deck safety switch is disengaged.
STARTING ENGINE
Do not run engine indoors. Exhaust gases contain carbon monoxide, an odorless and deadly poison.
To enhance starter life, use short starting cycles not
exceeding 10 seconds. If engine does not start within
10 seconds, stop cranking for 30 seconds; then repeat
starting procedures.
Make sure people and objects are clear of
attachment and discharge area before engaging
PTO.
NOTICE
■
Never engage PTO if the mower blades are
plugged with grass or other material. This may
cause damage to the electric clutch.
1.
With engine running, position throttle at half speed.
2.
Engage PTO by pulling up on the PTO switch.
3.
Move throttle to full speed and begin operation.
NOTE:
help prolong the life of the clutch and transmission
components.
Stopping Mower or Attachment
Starting attachment at lower engine speed will
1.
Position yourself on the power unit seat.
2.
Place steering control handles in the PARK
position (pivoted outward).
3.
Place PTO switch in the “OFF” position (down).
4.
Place choke approximately 1/2 open.
5.
Turn key to “START”.
6.
Warm up engine several minutes at medium
throttle.
NOTE:
starts, release key immediately. Pull choke gradually
back until choke is off and engine is running smoothly.
NOTE:
the season. Loading a cold engine will shorten its life.
Choke as necessary to start. When engine
Allow engine a warm-up period regardless of
Cold Weather Starting Tips
1.
Use proper oil grade for temperature expected.
(Refer to engine manual for oil grade.)
2.
Set throttle half way open.
Push down on PTO switch.
NOTE:
unit requires service.
If attachment does not stop in five seconds, the
PRACTICE OPERATION
Never allow children or untrained persons to
operate equipment.
Operating this unit is not difficult once you are familiar
with the use of the controls. Equip the power unit with
the attachment you will be using and practice in a flat
open area at half throttle setting until you are comfortable with the controls.
Do not operate attachment until you become proficient
with controls.
Uneven Terrain Operation
3.
A warm battery has better starting capacity than a
cold one.
4.
Use fresh fuel, it is better for starting than leftover
fuel.
STARTING MOWER OR ATTACHMENT
12 Operation
Do not operate on slopes greater than 15
degrees (27% grade).
Do not stop, start, or change directions sud-
denly on slopes.
Use extreme care and reduce ground speed on
slopes and rough terrain.
MAN0999 (12/4/2012)
Page 13
the steering handles are moved, the faster the machine
WARNING
WARNING
will move.
Watch for hidden hazards on the terrain during
operation.
Practice steering maneuvers at half throttle.
STEERING HANDLE OPERATION
Moving steering levers rapidly from forward to
reverse or reverse to forward could cause loss of
control.
Do not operate power unit with attachment
removed. Attachment is required for power unit
stability.
NOTE:
ing handles. Pushing handles forward will move power
unit forward. Pulling handles to the rear will move the
power unit in reverse. The further forward or rearward
Speed and direction are controlled with steer-
Steering Handle Positions
NOTICE
■
If you become confused during operation,
return both handles to the center NEUTRAL position and the power unit will stop.
Forward Both handles forward
Reverse Both handles rearward
Gentle Right Left handle further forward than right
Gentle Left Right handle further forward than left
360° Left Left full rearward / right full forward
360° Right Right full rearward / left full forward
NOTE:
dle in NEUTRAL will also result in a 360-degree circle.
However this will cause one drive wheel to dig into the
turf and should be avoided.
Moving one handle forward with the other han-
MAN0999 (12/4/2012)
Figure 2
. Steering Handle Operation
Operation 13
Page 14
STOPPING ENGINE
CAUTION
CD101
NEUTRAL LINK
WARNING
WARNING
Remove key and store in a secure location to
prevent unauthorized persons from operating
equipment.
1.
Place steering handles in PARK (pivoted outward).
2.
Move throttle to 1/3 setting.
3.
Allow engine to idle for several minutes.
4.
Turn key to OFF position and remove.
MOVING DISABLED POWER UNIT
Manually move disabled power unit by following these
steps.
1.
Locate dump valve on neutral link at middle,
underneath frame.
2.
Pull up and back and down to lock in open position.
3.
Pull up and back and then forward and down to
return to operation.
WEIGHT TRANSFER SYSTEM
■
When using weight transfer system, correct
counterweight must be used to maintain stability.
The weight transfer is designed to place an additional
load on the drive wheels, providing additional traction.
1.
Attach mower to power unit and set to desired
cutting height.
2.
Torque bolt on both sides to 35 lbs-in.
NOTE:
stability. Optional coutnerweight kit 78727 is required
with 60" sweeper.
Counterweights are not required when power unit is
equipped with a grass catcher system.
trailer or add power unit ballast with a combined
weight over 200 lbs. Too much weight can cause
loss of traction or stability on a slope. Too much
weight will shorten the hydraulic system life. Never
tow a trailer with a grass collection system
attached to the power unit.
Counterweight is needed to provide adequate
Do not tow a trailer over 200 lbs. Do not tow a
Figure 3
. Left Pump Dump Valve
14 Operation
MAN0999 (12/4/2012)
Page 15
OWNER PRE-OPERATION CHECK LIST
(OWNER'S RESPONSIBILITY)
___ Review and follow all safety rules and safety
decal instructions on pages 5 through 10.
___ Check that all safety decals are installed and in
good condition. Replace if damaged.
___ Check to make sure all shields and guards are
properly installed and in good condition. Be sure
that either the discharge shield or complete vacuum attachment is installed.
___ Check that all hardware and cotter pins are prop-
erly installed and secured.
___ Check that equipment is properly and securely
attached to power unit.
___ Make sure driveline spring-activated locking pin
or collar slides freely and is seated firmly in
power unit PTO spline groove and in gearbox
spline groove.
___ Check for grass wrap on PTO shaft. When mow-
ing long grass, remove key and check for grass
wrap around PTO shaft every 30 minutes of operation.
___ Check to be sure engine is free of dirt and debris.
Pay particular attention to the cooling fins, governor parts and muffler.
___ Do not allow riders.
___ Inspect area and remove stones, branches or
other hard objects that might be thrown, causing
injury or damage.
___ Clean air intake screen. Check air cleaner; ser-
vice if necessary.
___ Clean area around oil fill dipstick. Remove dip-
stick and check to be sure oil is in operating
range (between marks on dipstick). Add oil if necessary but
assembly firmly until cap bottoms out on tube.
Dipstick assembly must always be secured into
fill tube when engine is running.
___ Check all lubrication points and grease as
instructed in the lubrication information, page 16.
___ Perform a functional check of the safety interlock
system each time you operate the unit. Place
both steering levers outward, start engine,
engage PTO and then rise up out of the seat; the
engine should die. If it does not, do not operate
unit until the safety interlock system has been
repaired and operates properly.
Do Not Overfill.
Install Dipstick
MAN0999 (12/4/2012)
Operation 15
Page 16
OWNER SERVICE
WARNING
CAUTION
Before performing any service or maintenance,
lower attachment to ground, turn off power unit
engine, remove key, and disconnect battery
ground cable (negative -).
Before working underneath, read manual
instructions, securely block up, and check stability.
Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system
failure, or mechanical component failure.
Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
Change Engine Oil
NOTICE
■
Use care to prevent hot oil from contacting
bare skin.
Run engine to allow oil to become hot. This will
1.
ensure that most foreign materials are in
suspension and will be flushed out with the oil.
2.
Install hose on drain. Open drain valve.
3.
Remove oil filter.
4.
Install new oil filter.
5.
Close drain valve, remove hose.
NOTE:
tions, capacity, service rating, and proper grade.
Refer to the engine manual for oil specifica-
Always wear relatively tight and belted clothing
to avoid getting caught in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and head;
and respirator or filter mask where appropriate.
SERVICE ENGINE
NOTE:
in engine manual.
Follow engine manufacturer recommendations
Check Engine Oil Level
NOTE:
running. Serious injury or damage to equipment could
result.
Never attempt to check oil level while engine is
1.
Park power unit on a level surface.
2.
Stop engine and clean off dirt and dust from
around dipstick.
3.
Remove dipstick, check oil level. Oil level should
be between marks on dipstick.
4.
Add oil as necessary. See engine owner’s manual
for specifications.
LUBRICATION INFORMATION
1.
Do not let excess grease collect on or around
parts, particularly when operating in sandy areas.
2.
See Figure 4 for lubrication points and frequency or
lubrication based on normal operating conditions.
Severe or unusual conditions may require more
frequent lubrication.
3.
Use a lithium grease of #2 consistency with a
MOLY (molybdenum disulfide) additive for all
locations unless otherwise noted. Be sure to clean
fittings thoroughly before attaching grease gun.
One good pump of most guns is sufficient when the
lubrication schedule is followed.
Lubrication (Service Intervals)
Ref Description Frequency
1. Deck Pivot 8 hours
2. Driveshaft 8 hours
3. Blade Spindles 40 hours
4. Wheels 8 hours
5. Engine Oil Level (check) 8 hours
6. Gearbox (under deck) and tractor 500 hours
7. Front Lift Linkage 40 hours
8. Caster Pivot 40 hours
16 Owner Service
MAN0999 (12/4/2012)
Page 17
Figure 4
1. Tailwheel assembly
2. Dust cap
3. Cotter pin
4. Slotted hex nut
5. Bushing washer 3/4 x 14 GA
6. Bearing cone
7. Bearing cup
8. Seal
9. Spacer
10. Wheel fork
. Lubrication Diagram
TAILWHEEL MAINTENANCE
Once a year, disassemble tailwheel assembly and
inspect roller bearings:
1.
Remove dust cap (2) from top of tailwheel
assembly (1).
2.
Remove cotter pin (3) and slotted hex nut (4).
3.
Remove wheel fork (10), bearing cones (6) and
remaining hardware from assembly.
4.
Inspect bearing cones (6) and bearing cups (7) for
wear and replace if necessary. Replace seals and
washers as necessary.
5.
Pack bearing cones (6) with a good grade wheel
bearing grease.
6.
Install wheel fork (10) bearing cones (6) and
remaining hardware into assembly as shown.
7.
Set bearings by torquing nut to 26 lbs-ft. All bearing
free play should be removed.
NOTE:
bearing life.
If bearings are loose, casters will wobble and/or slap
side-to-side.
If bearings are overtightened, loosen hex nut and rap
shaft with a lead hammer to loosen bearings. Readjust
bearings until proper setting is obtained.
Proper bearing adjustment is essential to good
MAN0999 (12/4/2012)
Figure 5
. Tailwheel Assembly (Typical)
Owner Service 17
Page 18
HYDROSTATIC TRANSMISSION SERVICE
3
1
2
CD103
Service and Maintenance Procedures
NOTE:
or oil additions between regularly scheduled maintenance. Opening expansion tank excessively may introduce dirt and foreign particles shortening hydrostatic
life.
External Maintenance
Regular external maintenance of the transaxle should
include the following:
Hydrostatic system should require no servicing
1.
Check the vehicle operator's manual for the
recommended load ratings. Insure that the current
application does not exceed load rating.
2.
Check oil level in accordance with "Fluid Change
Procedure," step 12, page 19.
3.
Inspect the vehicle drive belt, idler pulley(s), and
idler spring(s). Insure that no belt slippage can
occur. Slippage can cause low input speed to the
transaxle.
4.
Inspect the vehicle control linkage to the directional
control arm on the transaxle. Also insure that the
control arm is securely fastened to the trunnion
arm of the transaxle.
Some of the service procedures presented on the following pages can be performed while the transaxle is
mounted on the vehicle. Any repair procedures as
mentioned in the repair section of this manual must be
performed after the unit has been removed from the
vehicle.
Fluids
The fluids used in Hydro-Gear® products have been
carefully selected, and only equivalent, or better products should be substituted.
Typically, an engine oil with a minimum rating of 9.0
cSt (55 SUS) at 230° F (110° C) and an API classification of SL is recommended. A 20W50 engine oil has
been selected for use by the factory and is recommended for normal operating procedures.
Fluid Volume and Level
Certain situations may require additional fluid to be
added or even replaced.
Purging will be required if oil has been changed. Refer
to the purging procedures on page 19.
5.
Inspect the bypass mechanism on the transaxle
and the vehicle linkage to insure that both actuate
and release fully.
18 Owner Service
Figure 6
. Hydrostat Filter and Guard
MAN0999 (12/4/2012)
Page 19
FLUID CHANGE PROCEDURE
This transaxle is designed with an external filter for
ease of maintenance. To ensure constant fluid quality
levels and longer life, an initial oil and filter change at
75-100 hours, then every 400 hours thereafter is recommended.
13.
Re-install the expansion tank cap by hand. Be
careful to not over tighten.
14.
Proceed to the purge procedure.
PURGING PROCEDURES
The following procedure can be performed with the
transaxles installed in the vehicle, and the vehicle on
level ground. Apply the bypass valve for each transaxle
and lock the vehicle parking brake.
1.
Remove the three 1/4" filter guard screws and filter
guard. Clean any loose debris from around the
perimeter of the filter.
2.
Place an oil drain pan (12" or more diameter and 8
qt. capacity is optimal) beneath the oil filter.
Remove the oil filter from the transaxle.
3.
After the oil has drained, wipe the filter base
surface off and apply a film of new oil to the gasket
of the new replacement filter (part number 78726).
4.
Install the new filter by hand; turn 3/4 to one full
turn after the filter gasket contacts the filter base
surface.
5.
Re-install the filter guard with three 1/4" screws.
Torque each screw to 65 in. lbs. (7.3 Nm).
6.
Repeat steps 1-5 on the opposite side transaxle
drive.
Due to the effects air has on efficiency in hydrostatic
drive applications, it is critical that it is purged from the
system.
Air creates inefficiency because its compression and
expansion rate is higher than that of the oil approved
for use in hydrostatic drive systems.
These purge procedures should be implemented any
time a hydrostatic system has been opened to facilitate
maintenance or the oil has been changed.
The resulting symptoms in hydrostatic systems may
be:
1.
Noisy operation.
2.
Lack of power or drive after short term operation.
3.
High operation temperature and excessive
expansion of oil.
Before starting, make sure the transaxle is at the
proper oil level. If it is not, fill to the specifications outlined in this manual.
7.
Drain old oil filters of all free flowing oil prior to
disposal. Place used oil in appropriate containers
and deliver to an approved recycling collection
facility.
8.
Remove the top port plug from the left side and
right side transaxles prior to filling with oil. This will
allow the transaxles to vent during oil fill.
9.
Remove the cap from the transaxle's expansion
tank located on the vehicle frame.
10.
Fill with 20W50 motor oil until oil just appears at the
bottom of each transaxle's top port (approximately
2 qts. per transaxle, 4 qts. total). Install the top port
plug into each transaxle as the oil level reaches
this port.
11.
Install and torque the top port plugs to 180 in. lbs.
(20.3 Nm).
12.
Continue to fill the transaxles through the
expansion tank until the "Full Cold" line is reached
®
on the Hydro-Gear
.5 qt will be needed to fill expansion tank.
expansion tank. An additional
The following procedures are best performed with the
vehicle drive wheels off the ground. Then repeat under
normal operating conditions. If this is not possible, then
the procedure should be performed in an open area
free of any objects or bystanders.
1.
Disengage the brake if activated.
2.
With the bypass valve open and the engine
running, slowly move the directional control in both
forward and reverse directions (5 or 6 times).
3.
With the bypass valve closed and the engine
running, slowly move the directional control in both
forward and reverse directions (5 to 6 times).
Check the oil level, and add oil as required after
stopping the engine.
4.
It may be necessary to repeat Steps 2 and 3 until
all the air is completely purged from the system.
When the transaxle operates at normal noise
levels and moves smoothly forward and reverse at
normal speeds, then the transaxle is considered
purged.
MAN0999 (12/4/2012)
Owner Service 19
Page 20
SERVICE BATTERY
WARNING
CAUTION
CD104
WARNING
Battery posts, terminals, wiring insulation, 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.
Use care to prevent battery acid from contacting
skin.
Figure 7
Refer to Figure 7.
Clean battery at least once a season by following these
steps:
1.
Remove the seat to access the battery.
2.
Inspect cables for deterioration and loose
connections.
3.
Clean terminals.
4.
Inspect battery to make sure tie-down is tight and
battery is secured in place.
5.
Inspect battery case for cracks or leaks; replace
battery if necessary.
6.
Test battery with hydrometer; recharge battery if
less than 75% charge is indicated.
7.
Add water if necessary.
. Battery Located Under Seat
BURNISH CLUTCH
NOTICE
■
A new clutch or one that has not been used for
three months, will require burnishing to dress drive
surface. The clutch could fail if you do not accomplish the following procedure.
1.
Place steering control handles in PARK (pivoted
outward). Start engine and run at half throttle.
2.
Turn clutch switch (PTO) “ON” 30 seconds and
“OFF” for 30 seconds. Repeat cycle 20 times.
NOTE:
cool.
The 30 seconds “OFF” allows clutch surface to
RETURN TO OPERATION
Make sure shields and guards are properly
installed and in good condition. Replace if damaged.
Make sure all safety decals are installed.
Replace if damaged. (See Safety Decals section for
location.)
CLEANING
After Each Use
●
Remove large debris such as clumps of dirt, grass,
crop residue, etc. from machine.
●
Inspect machine and replace worn or damaged
parts.
●
Replace any safety decals that are missing or not
readable.
Periodically or Before Extended Storage
●
Clean large debris such as clumps of dirt, grass,
crop residue, etc. from machine.
●
Remove the remainder using a low-pressure water
spray.
1.
Be careful when spraying near scratched or torn
safety decals or near edges of decals as water
spray can peel decal off surface.
2.
Be careful when spraying near chipped or
scratched paint as water spray can lift paint.
3.
If a pressure washer is used, follow the advice
of the pressure washer manufacturer.
●
Inspect machine and replace worn or damaged
parts.
●
Sand down scratches and the edges of areas of
missing paint and coat with Woods spray paint of
matching color (purchase from your Woods
dealer).
●
Replace any safety decals that are missing or not
readable (supplied free by your Woods dealer).
See Safety Decals section on page 9 for location
drawing.
20 Owner Service
MAN0999 (12/4/2012)
Page 21
DEALER SERVICE
WARNING
CAUTION
1
CD102
2
The information in this section is written for dealer service personnel. The repair described here requires
special skills and tools. If your shop is not properly
equipped or your mechanics are not properly trained in
this type of repair, you may be time and money ahead
to replace complete assemblies.
Before performing any service or maintenance,
lower attachment to ground, turn off power unit
engine, remove key, and disconnect battery
ground cable (negative -).
Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
Always wear relatively tight and belted clothing
to avoid getting caught in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and head;
and respirator or filter mask where appropriate.
1.
Block up power unit frame so both drive wheels are
off the ground.
2.
Pivot steering arms to center.
3.
Loosen jam nut (1) on linkage rod as shown in
Figure 9.
4.
Place steering handles in the neutral position
(pivoted outward) and start engine.
5.
If drive wheels turn, turn rod out or in until wheel
stops.
6.
Tighten jam nut.
7.
Repeat steps 3 through 6 for other hydrostatic
pump control arm.
TROUBLESHOOTING HYDROSTATIC
PUMP
Loss of Power in Transmission
Make sure transmission fluid is correct.
1.
2.
Make sure hydrostatic pump and fan blades are
clean.
NOTE:
fluid leaks from excess fluid expansion.
3.
Make sure dump valves are tightened down.
Overheating can cause loss of power or
No Positive Neutral Position
If drive wheels try to travel forward or reverse when
steering handles are in the PARK position (pivoted outward), adjustment of hydrostatic pumps is necessary.
Figure 9
. Jam Nut on Linkage Rod
Straight Line Travel
1.
Check tire pressure; tires must have equal air
pressure.
2.
Check travel; drive forward with both steering
handles full forward at half throttle.
• If travel is not straight, adjust steering handle stop
bolt (2) on opposite side of turn.
• If power unit turns to the left, raise steering stop
bolt (2) on the right.
• If power unit turns to the right, raise steering stop
bolt (2) on the left.
MAN0999 (12/4/2012)
Dealer Service 21
Page 22
TROUBLESHOOTING ENGINE
PROBLEM POSSIBLE CAUSE SOLUTION
Engine will not crank
Engine cranks but will not start
PTO switch is “ON” Switch to the “OFF” position
Steering handles are not in “PARK” Pivot steering handles outward
Battery is discharged Charge or replace battery
Starter fuse is blown Replace fuse
Steering handle switches are out of
adjustment
Fuel tank is empty Fill fuel tank
Fuel line or fuel filter is restricted Bleed fuel line or replace fuel filter
Ignition fuse is blown Replace fuse
Loose wires or connections Inspect wire connection and
NOTICE
■
The following test must be performed with an
accurate voltmeter. The amperage in this circuit is
too low for a test light. This circuit is the ground
side of a relay.
Listen for the switch “click” and
adjust as necessary
safety switches
deck switch is open the engine will kill when pulling handles in.
1.
Check seat switch and deck safety switch/jumper.
a.
Raise seat assembly and secure.
b.
Turn key switch “ON”, engage seat switch and
move deck to highest cut height position.
c.
Check voltage at the pink and black wires on the
main wire harness where it connects into the seat
switch wire harness. (2 way Packard 56 series connector located underneath seat pan on the right
side next to steering pivot block.)
• If there is voltage at one wire but not the other,
either the switches/jumper are defective or not
fully engaged. The pink and black wires are part
of a series circuit that includes the seat switch
and deck safety switch (on power tilt deck) or
weatherpack jumper.
• If there is voltage on only one wire check each
switch ((seat switch, deck safety switch, (located
on the deck), or weatherpack jumper)) individually to determine which switch is defective or not
closed. The weatherpack jumper should be connected to the main wire harness, underneath the
seat pan by the left hand steering pivot linkage if
there is not a deck or a standard deck is
attached.
• Check the deck safety switch refer to Figure 10
and troubleshooting deck safety switch. If the
Figure 10
• If there is voltage at both pink/black wires mentioned in the previous paragraph, check voltage
at yellow/red parking brake wires with the park
brake off.
• If voltage is not present, the wire between the
seat relay and parking brake switch is unconnected or the seat relay is defective and must be
replaced.
• If voltage is present at one wire but not the other,
the parking brake switch is defective and must be
replaced.
. Power Tilt Deck Safety Switch Layout
22 Dealer Service
MAN0999 (12/4/2012)
Page 23
Troubleshooting Deck Safety Switch
1.
Pull handlebars in with deck in lowest cutting
height position (1), see Figure 10.
2.
Check that switch is making contact with the height
gauge.
3.
Check that the wires are properly hooked up to
power unit.
4.
Adjust switch bracket location on actuator if
needed (four screws). Make sure height screw
does not bottom out on slot in either direction when
raising or lowering deck.
5.
Check that screws holding switch to bracket are
not too tight and holding lever open.
6.
Adjust safety switch lever or replace switch if
necessary.
7.
After adjustments, check that engine cuts out with
deck partially raised.
HYDROSTAT DRIVE REMOVAL
1.
Place power unit on a level surface and remove
key.
2.
Place power unit on stands to allow access to
bottom of the machine and remove drive wheels.
3.
Remove steering linkage from control arm on
hydrostat.
4.
Remove brake arm actuator and spring from brake
arm.
5.
Remove expansion tank hose from hydro.
6.
Loosen idler spring and remove belt.
7.
Remove two outer screws, washers and nuts.
8.
At front of machine, remove two screws and nuts
attaching small L bracket.
9.
At rear of machine, remove two screws and nuts
attaching small L bracket.
10.
While supporting hydro (each hydro weighs
approximately 33 pounds), remove front and rear
screws and nuts.
11.
Lower hydro down and out from under unit.
12.
For repair parts information, contact Hydro-Gear
at 1-877-728-7410 for nearest authorized dealer.
HYDROSTAT DRIVE INSTALLATION
4.
Install screws and nuts in the front and rear of the
frame finger tight.
5.
With hydro positioned squarely, tighten small L
bracket nuts and then the longer screws through
frame.
6.
Tighten outer nuts.
7.
Install belt and tighten spring to proper belt tension.
8.
Install expansion tank hose.
9.
Install brake arm actuator and spring on brake arm.
No adjustment necessary if arm was not moved.
10.
Install steering linkage from control arm to
hydrostat.
11.
Proceed to oil change maintenance for proper oil
change and pump purging.
BELT REMOVAL
1.
Remove key from switch.
2.
Loosen idler spring bolt, and derail belt from
pulleys.
3.
Remove belts.
ENGINE REMOVAL
1.
Disconnect throttle cable, battery cables, hoses,
fuel line, and electrical wires from engine.
2.
Remove the four engine mounting bolts from
bottom of power unit frame.
3.
Remove belts from the engine pulleys. See Belt
Removal.
4.
Remove exhaust.
5.
Lift engine from the power unit frame.
NOTE:
parts and repairs.
Contact your authorized engine dealer for
PARKING BRAKE ADJUSTMENT
NOTE:
automotive style parking pawl and is not a service
brake. Brake system is for parking of unit and emergency use only. The drive wheel may have to rotate
slightly to engage pawl in locking ring (usually less the
®
3 degrees of wheel rotation).
NOTE:
should require no maintenance unless the system
parts are replaced.
Hydrostatic system parking brake is similar to
Parking brake is adjusted from the factory and
1.
Position hydro under frame and carefully raise up
into position.
2.
Install two outer screws, washers and nuts finger
tight.
3.
Install small L bracket at the front and rear using
long bolts through frame loosely.
MAN0999 (12/4/2012)
NOTE:
Adjust right and left brakes individually.
1.
With drive wheels off of the ground and control
handles in the outward park position, check to see
if drive wheel rotates.
2.
If drive wheel rotates and park brake does not
engage, remove screw from top of park brake
Dealer Service 23
Page 24
release link and free park brake release rod. (If
CD101
1
3
2
WARNING
drive wheel rotates with park brake engaged, there
may be internal hydrostatic problems. Contact
®
authorized Hydro-Gear
3.
Check to see if there is spring tension on hydrostat
brake arm. Hydrostat brake arm should be roughly
horizontal with park brake engaged. Tension
spring to 1/8" past initial tension. Repeat 1.
4.
Loosen lock nut on top of park brake release link.
Reinstall screw and park brake release link.
5.
With control handles in the outer park position,
park brake release link should be at top of slot in
control rod. Adjust rod until park brake release link
is at top of slot with no pressure. Tighten lock nut.
Repeat 1.
6.
Move control arm to neutral drive position, check to
see if drive wheel rotates. Park brake release arm
should be pushing down on hydrostat brake arm,
releasing the parking brake.
7.
Confirm free movement of control arm, park brake
release rod and parking brake spring.
8.
Repeat for opposite side.
dealer).
CLUTCH REPAIR
2.
Loosen PTO idler arm spring and remove belt.
3.
Disconnect electrical wire harness from clutch (1).
4.
Remove screw from end of crank shaft.
5.
Remove clutch from crank shaft. Be sure to
capture spacer between clutch (1) and drive pulley
(2). Drive pulley (2) is held on by drive belt. If no
drive belt is installed at this point, drive pulley (2)
and top spacer (3) will also come off of crankshaft.
Install Clutch
1.
Install spacer (3), drive pulley (2) if previously
removed.
2.
Install spacer (3) between drive pulley (2) and
clutch (1).
3.
Align key on clutch (1) with keyway on crankshaft.
4.
Align anti rotation rod with closed slot of clutch (1).
5.
Install clutch (1) on crankshaft.
6.
Insure that clutch (1) engages anti rotation rod.
7.
Place drop of Loctite 242 (Blue) on threads of
screw.
8.
Install screw and torque to 55-60 FT-LB.
Figure 11
Remove Components
1.
Position unit on level ground and set control
handles in park (pivoted outward), stop engine and
remove key.
. Clutch Assembly
9.
Reinstall belt and retighten idler arm spring to
proper belt tension.
10.
Attach electrical wiring harness. Insure wiring
harness is held out of the way of moving parts and
belts.
11.
Follow Clutch Burnishing instructions on page 20.
RETURN TO OPERATION
When you have completed service and maintenance
functions, read and comply with these safety messages before returning unit to operation.
Make sure all safety decals are installed.
Replace if damaged. (See Safety Decals section for
location.)
Make sure shields and guards are properly
installed and in good condition. Replace if damaged.
24 Dealer Service
MAN0999 (12/4/2012)
Page 25
ASSEMBLY
DP105
1
DP105
1
2
4
3
DEALER SET-UP INSTRUCTIONS
Assembly of this Mow’n Machine is the responsibility of
the Woods dealer. It should be delivered to the owner
completely assembled, lubricated, and adjusted for
normal cutting conditions.
Set up the Mow’n Machine as received from the factory
with these instructions. Complete the Dealer Check
Lists on page 27 when assembly is completed.
Power Unit Preparation
1.
Remove crating from around power unit. Remove
power unit from pallet and place on blocks.
2.
Remove Operator’s Manual from power unit frame
and save for original retail purchaser.
1.
Install drive tires using five lug nuts (1) from bag of
loose parts shipped with machine.
2.
Torque lug bolts to 85 lbs-ft.
Drive Tire Pressure:
Turf Tires 12 psi
Chevron Tires 10 - 12 psi
TAIL WHEEL INSTALLATION
NOTE:
registration card at time of sale.
Dealer must complete and return product
Lubrication
NOTICE
■
Running engine without oil will cause engine
failure.
1.
Check engine oil level (30W).
2.
Check that oil levels (20W-50) in hydro expansion
tank are at correct level.
NOTE:
transmission, and lubrication information.
Fuel
Fill fuel tank with the correct fuel. Refer to engine manual.
INSTALL DRIVE TIRES
See Owner Service section for engine,
Figure 13
. Dual Tail Wheel Installed
Dual Tail Wheel
1.
Attach pivot mount adapter to rear of power unit
frame using 4 flange screws.
2.
Slide tail wheel arm over pivot.
3.
Attach arm with large flat washer (2), lock washer
(3) and screw (4).
4.
Torque hardware to 38 FT-LB.
5.
Inflate tires to 18 psi.
Single Tail Wheel
1.
Attach mount adapter to rear of power unit frame
using 4 flange screws (1).
Figure 12
MAN0999 (12/4/2012)
. Drive Tire Installed
2.
Torque hardware to 38 FT-LB.
3.
Inflate tire to 18 psi.
Assembly 25
Page 26
ADJUST STEERING HANDLES
2
1
DP8
1. 5/16 NC x 1 Whiz bolt
2. 5/16 Flanged lock nut
❖
Figure 14
1.
Remove whiz bolt (1) and lock nut (2) from left
steering lever mount.
. Steering Handle Adjustment
for taller operators and the middle and bottom
holes are for shorter operators. Do not tighten
hardware at this time. Repeat steps 1 and 2 for
right steering handle.
3.
Rotate handles inward. Align handles with one
another. Torque all hardware to 12 lbs-ft. Make
sure handles stay in alignment.
Straight Line Travel
1.
Check tire pressure; tires must have equal air
pressure.
2.
Check travel; drive forward with both steering
handles full forward at half throttle.
• If travel is not straight, adjust steering handle stop
bolt on opposite side of turn.
• If power unit turns to the left, raise steering stop
bolt on the right.
• If power unit turns to the right, raise steering stop
bolt on the left.
• For quick adjustments, access stop bolt throught
front cover.
2.
Position steering handle to desired location on
steering lever mount. The top and middle holes are
I
26 Assembly
MAN0999 (12/4/2012)
Page 27
DEALER CHECK LISTS
❖
PRE-DELIVERY CHECK LIST
(DEALER’S RESPONSIBILITY
Inspect the equipment thoroughly after assembly to
make sure it is set up properly before delivering it to the
customer. The following check list is a reminder of
points to inspect. Check off each item as it is found satisfactory, corrections are made, or services are performed.
___ Check that all safety decals are installed and in
good condition. Replace if damaged.
___ Check that all shields and guards are properly
installed and in good condition. Replace if damaged.
___ Properly attach implement to power unit and
make all necessary adjustments.
___ Check all bolts to be sure they are properly
torqued.
___ Check that all cotter pins and safety pins are
properly installed. Replace if damaged.
___ Check and grease all lubrication points.
___ Check the level of gearbox fluids before delivery.
___ Run unit immediately following set-up to double-
check systems operation including hydrostatic
neutral and safety switch system (page 11).
___ Check all fluid levels. See Lubrication, page 25.
___ Check tire pressure. See Drive Tire Pressure,
page 25.
)
DELIVERY CHECK LIST
(DEALER’S RESPONSIBILITY)
___ Show customer how to make adjustments.
___ Instruct customer how to lubricate and explain
importance of lubrication.
___ Point out the safety decals. Explain their meaning
and the need to keep them in place and in good
condition. Emphasize the increased safety hazards when instructions are not followed.
___ Present Operator's Manual and request that cus-
tomer and all operators read it before operating
equipment. Point out the manual safety rules,
explain their meanings, and emphasize the
increased safety hazards that exist when safety
rules are not followed.
___ Show customer how to make sure driveline is
properly installed and that spring-activated locking pin or collar slides freely and is seated in
groove on power unit PTO shaft.
___ Show customer the safe, proper procedures to be
used when mounting, dismounting, and storing
equipment.
___ Make customer aware of optional equipment
available so that customer can make proper
choices as required.
MAN0999 (12/4/2012)
Dealer Check Lists 27
Page 28
NOTES
28 Dealer Check Lists
MAN0999 (12/4/2012)
Page 29
FZ22K FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30 & 31
Parts Index
Mow’n Machine
FZ22K
ENGINE ASSEMBLY
FZ22K (Kawasaki Gas Engine 22hp) . . . . . . . . . . . . . . . . . . 32
HYDROSTAT DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
PTO, CLUTCH & PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . 34 & 35
PTO GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SEAT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
WIRING DIAGRAM
FZ22K Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 38 & 39
TAILWHEEL ASSEMBLY
Single Tailwheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wide Stance Tailwheel Assembly . . . . . . . . . . . . . . . . . . . . . 40
HEADLIGHT KIT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
COUNTERWEIGHT MOUNT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
MAN0999 (12/4/2012)
Parts 29
Page 30
FZ22K FRAME ASSEMBLY
30 Parts
(Rev. 2/18/2013)
MAN0999 (12/4/2012)
Page 31
FZ22K FRAME ASSEMBLY PARTS LIST
REF PART QTY DESCRIPTION
1 01563700 1 Key switch
2 06517400 1 Panel nut
3 07517700 1 Ignition cap
4 35139 2 Retainer ring
5 70179 1 Plug - 1.25 Sq - Plastic
6 71144 2 Spring assembly
7 71156 2 .375-16 x 6.00 Bolt hook
8 71170 2 Chain-lift
9 71444 2 Rubber bumper
10 72262 1 Toggle 2P DT 2position clch
11 72410 1 Pivot rod
12 72411 2 Foot rest tread
13 73581 2 .5 x .62 x 1.0 Bushing, nylon
14 73827 1 Bracket
15 73891 1 Foot rest assembly
16 73895 2 Weight transfer pin
17 73896 4 Weight transfer sleeve
18 73898 2 Traction arm assembly
19 73902 1 Hour meter
20 75196 1 Key
21 75472 1 Throttle cable
22 75520 1 Switch deck
23 75546 1 Glide
24 75553 1 Boot
25 78069 1 Choke cable
26 78330 1 Fuel tank, RH
27 78331 1 Fuel tank, LH
REF PART QTY DESCRIPTION
28 78333 1 Gas cap
29 78334 1 Grommet
30 78335 1 Remote vent
31 ------- * 1 Battery, 340 CCA
32 78541 1 Front cover
33 78546 1 Skid plate
34 78606 1 Console
35 78607 1 Decal, instruction
36 78610 12 Hose clamp
37 78632 1 Gearbox shield
38 78717 1 Battery hold down
39 78718 7 Weight, 15.6 lb
40 11036 2 3/4x1-1/2x18GA Washer
41 1326 * 2 1/8 x 1/2 Cotter pin
42 16231 8 5/16 NC x 1/2 Flanged cap screw
43 24660 * 2 3/8 NC x 3-1/2 Cap screw FT GR5
44 301300 * 6 1/4NC x 3/4 Truss head screw
45 3598 * 2 1/2 SAE Flat washer
46 62153 4 3/8NC x 1 Flanged Screw SRTD
47 70069 * 8 3/8 NC Flanged whiz nut
48 70070 2 .375 x .75 Clevis pin
49 71630 * 2 1/8 x 3/4 Cotter pin
50 71851 8 5/16 NC x 3/4 Flanged cap screw
51 73163 * 10 5/16 NC Flanged whiz nut
52 73542 * 7 10-24 x .50 Machined screw
53 90001708 * 2 3/8 NC x 4.5 Carriage bolt ZP
54 FA448 * 4 10-24 Nut w/Nylon insert
(Rev. 2/18/2013)
MAN0999 (12/4/2012)
* Standard hardware, obtain locally
Parts 31
Page 32
FZ22K ENGINE ASSEMBLY
REF PART QTY DESCRIPTION
1 75310 1 Solenoid
2 75325 1 Drain valve
3 75364 2 Exhaust gasket
4 75366 1 16mm O-ring
5 78457 1 Kawasaki, FS651V
6 78536 1 Exhaust
7 71812 1 Fuel filter
8 78722 1 Oil filter
9 78723 1 Air filter
32 Parts
REF PART QTY DESCRIPTION
10 78724 1 Air pre-filter
11 78725 1 Engine tune up kit
12 21536100 2 Spark plug
13 78738 4 Nut, Whiz M8 x 1.25P Flange Stainless
14 62153 4 3/8 NC x 1 Flange Head Screw Serated
15 70065 * 4 1/4 NC Whiz nut
16 70068 4 1/4 NC x 3/4 Whiz bolt
* Standard Hardware, Obtain Locally
(Rev. 2/18/2013)
MAN0999 (12/4/2012)
Page 33
HYDROSTAT DRIVE SYSTEM
REF PART QTY DESCRIPTION
1 78454 1 Hydrostat drive, RT
2 78455 1 Hydrostat drive, LT
3 78456 1 Expansion tank
4 78555 2 Neutral link
5 78611 4 Hose clamp, dual wire, .75
6 78612 2 Hose, expansion tank
7 78621 4 Angle, hydro support
8 78726 2 Oil filter, ZT-3400
9 78623 4 5/16NC x 2-1/2 Flanged cap screw,
GR8
10 1010706 10 1/2-20 Wheel nut
11 21363 * 2 1/16 x 1 Cotter hair pin #2
12 35155 * 4 5/16 SAE Flat washer ZP
13 62155 * 4 5/16 NC x 2-3/4 Cap screw GR5
14 70065 * 2 1/4 NC Whiz nut
(Rev. 11/7/2013)
MAN0999 (12/4/2012)
REF PART QTY DESCRIPTION
15 71206 2 1/4-20 Flanged hex screw
16 71851 8 5/16 NC x 3/4 Flanged cap screw
17 73163 * 16 5/16 NC Flanged whiz nut
18 73955 2 23 x 10.50 Turf tire & wheel -or-
18 74093 1 23 x 10.50 Chevron tire & wheel(right)
18 74097 1 23 x 10.50 Chevron tire & wheel(left) -
or-
18 78625 2 23 x 8.50 Turf tire & wheel
18 75101 23 x 10.50 Turf tire
18 75102 23 x 10.50 Chevron tire
18 78731 23 x 8.50 Turf tire
* Standard Hardware, Obtain Locally
®
Note: Contact Hydro-Gear
for repair information.
Parts 33
Page 34
PTO, CLUTCH & PUMP ASSEMBLY
34 Parts
(Rev. 2/18/2013)
MAN0999 (12/4/2012)
Page 35
PTO CLUTCH & PUMP ASSEMBLY PARTS LIST
REF PART QTY DESCRIPTION
78609 CW Gearbox
1 70091 1 Seal, .875 x 1.38
2 70092 1 Gasket, cap
3 70085 2 Bearing, .875
4 78732 1 Output shaft
6 70097 1 Bearing, .ball 75 x 1.62 x .31
7 71984 1 Bearing, ball 25 mm
8 71861 1 Shaft, .875 x 4.60
9 70088 2 Bevel gear, .865 x 8 pitch
10 70084 1 External retainer, .819 x .040
11 70090 1 Cover gasket
12 71862 1 Oil seal
REF PART QTY DESCRIPTION
1 3886 * 1 1/4 x 1/4 x 1-1/4 Key
2 51880 2 Flanged idler
3 62233 1 .187 X .75 Key Woodruff
4 64051 1 5/32 x 5/8 Key Woodruff
5 70005 1 Cupped washer
6 73826 2 Extension spring
7 74076 1 1.135 x 1.500 x 1.000 Sleeve
8 78465 1 Electric clutch
9 78469 1 Engine drive pulley
10 78484 1 V-Belt A 58
11 78493 1 1.0 Stub shaft
12 78530 1 Gearbox pulley
13 78535 1 V-Belt B 50
14 78608 1 1/4 Spacer
15 78609 1 Gearbox RT angle
16 78734 2 .25 x 3.00 Eye bolt
REF PART QTY DESCRIPTION
17 78710 1 Idler arm drive
18 78711 1 Idler arm PTO
19 1033958 2 3/8NC x 1-1/4 Flanged screw
20 14350 * 2 3/8 NC Flanged lock nut
21 19025 * 2 5/8 NC Flanged lock nut
22 2864 * 3 3/4 SAE Hardened flat washer
23 2978 * 2 1/4 NC x 3/4 Socket Head Cap Screw
24 57817 * 3 5/8 SAE Hardenend flat washer
25 5849 * 1 3/4 NF Slotted hex nut
26 62533 * 1 7/16 NF x 2 Cap screw GR5
27 64291 * 1 5/32 x 1 Cotter pin
28 70065 * 4 1/4 NC Whiz nut
29 78188 * 1 3/8NF x 1 Cap screw GR5
30 941 * 2 5/8 NC x 2-1/2 Cap screw GR5
* Standard hardware, obtain locally
PTO GEARBOX
(Rev. 2/18/2013)
MAN0999 (12/4/2012)
Parts 35
Page 36
SEAT ASSEMBLY
REF PART QTY DESCRIPTION
1 1032106 1 ROPS Folding
2 1035001 2 Hinge pin assembly
3 1035002 2 Anti-rattle spring
4 1035003 1 ROPS stop 2.0
5 1035004 1 Post, LH
6 1035005 1 Post, RH
7 1035006 1 Top loop
8 14069 * 2 1/2 NC x 3-1/4 Cap screw
9 765 * 2 1/2 NC Lock nut, plated
10 78468 1 Seat, 13M w/belt
12 78498 1 Bellows, 13M
13 78499 1 Delta plunger, 13M
14 78500 1 Cushion cover, 13M
15 78501 1 Back cover, 13M
16 78502 1 Wiring harness, 13M
17 78504 1 Weight adjust knob, 13M
18 78494 1 Arm rest assembly, RH, 13M
REF PART QTY DESCRIPTION
19 78496 2 Arm rest pad, 13M
20 78495 1 Arm rest assembly, LH, 13M
21 78497 1 2IN Retractable seat belt, 13M
22 78503 1 4IN Track set, 13M
23 78700 1 DCL, Mown Machine
24 78706 2 DCL, Model FZ22K
25 78712 1 Switch shield, RT w/decals
26 78713 1 Switch shield, LT w/decals
27 78714 1 Seat platform w/decals
28 19025 * 4 5/8 NC Flanged lock nut
29 21341 4 5/8 NC x 3-1/4 Bolt GR5 ZP
30 4378 * 4 5/16 Flat washer STD ZP
31 57817 * 4 5/8 SAE Hardened flat washer
32 71632 4 .312-18 x 1 Hex whiz bolt
33 71851 2 5/16 NC x 3/4 Flanged cap screw
34 73163 * 6 5/16 NC Flanged whiz nut
* Standard hardware, obtain locally
36 Parts
MAN0999 (12/4/2012)
Page 37
STEERING ASSEMBLY
REF PART QTY DESCRIPTION
1 09107800 4 5/16 NF LH Female rod end
2 09211400 2 Vinyl cap
3 1017779 * 4 #8-32 x 3/4 Cap screw
4 1282 4 1/4NC x 1/2 Screw RD HD
5 14562 * 4 5/16 NC x 1 Cap screw GR5
6 24408 * 4 5/16 NC x 1-1/2 Cap screw GR5 ZP
7 2472 * 4 5/16 Lock washer ZP
8 30515 * 4 M8 x 1.25P Hex nut
9 33654 * 4 5/16 NF Jam nut
10 3598 * 2 1/2 SAE Flat washer
11 37613 4 5/16 NF RH Female rod end
12 4378 * 14 5/16 STD Flat washer ZP
13 62529 * 4 #8 NC Lock nut
14 62788 * 8 1/4 NC X 1-1/2 GR5
15 6778 * 12 5/16 NC Lock nut
16 70065 * 16 1/4 NC Whiz nut
17 70162 2 Compression spring
18 70284 4 6-32 x 1 Bolt
19 70423 2 .5 x .88 x .065 Nylon washer
20 71313 1 Mount-STRG SW RT
21 71314 1 Mount-STRG SW LT
22 71323 8 .5 Nylon bearing
REF PART QTY DESCRIPTION
23 71632 4 .312-18 x 1 Whiz bolt
24 72886 4 Nylon shoulder washer
25 73023 2 Steering lever
26 73163 * 4 5/16 NC Flanged whiz nut
27 73581 2 .5 x .62 x 1.0 Nylon bushing
28 75105 2 Safety switch
29 75458 1 Control arm RH
30 75459 1 Control arm LH
31 75488 2 Dampener
32 75570 * 4 6-32 Nylock nut ZC
33 765 * 4 1/2 NC Lock nut, plated
34 78492 2 Linkage rod
35 78506 2 Steering arm mount
36 78508 2 Brake arm
37 78511 2 Link
38 78512 4 Brake arm support
39 78514 2 Brake rod
40 78633 2 .25 x 2.00 Eye bolt
41 78705 2 .5-.063-2.5-10 Extension spring
42 78719 2 Handlebar cushion-1.4
* Standard hardware, obtain locally
MAN0999 (12/4/2012)
Parts 37
Page 38
FZ22K WIRING DIAGRAM
38 Parts
MAN0999 (12/4/2012)
Page 39
FZ22K WIRING DIAGRAM PARTS LIST
REF PART QTY DESCRIPTION
A 78613 1 FZ22K Wiring assembly
1 01563700 1 Ignition switch
75196 1 Ignition key
3 -------- 1 Battery 12V L-Terminals 340CCA
(obtain locally)
4 73046 1 Diode assembly
5 72262 1 PTO Switch
6 75105 2 Steering safety switch
8 75502 1 Seat switch
9 73902 1 Hour meter
10 71475 1 Bosch style relay
12 71385 1 Fuse - 30 amp auto
REF PART QTY DESCRIPTION
13 71387 1 Fuse - 7.5 amp auto
14 78043 1 Positive battery cable
w/ terminal boot
15 78042 1 Negative battery cable
16 75310 1 Engine solenoid relay
17 75324 1 Ground wire solenoid
18 75390 1 Positive cable, short
18A 75392 1 Boot (not shown)
19 75309 1 Engine wiring harness jumper
20 78636 1 Jumper
21 78637 1 Deck switch 39"
22 75520 1 Toggle switch
MAN0999 (12/4/2012)
Parts 39
Page 40
TAILWHEEL ASSEMBLY
Single Tailwheel Assembly Wide Stance Tailwheel Assembly
REF PART QTY DESCRIPTION
REF PART QTY DESCRIPTION
1 07147800 1 Wheel and tire assembly, 15 x 6 x 6
2 09231800 1 Spacer wheel
3 1033958 4 3/8NC x 1-1/4 Flanged hex screw
4 11900 * 1 1/2 NC Flanged lock nut
5 29553 2 1/2ID 1-5/8OD 1/4 Thick washer
6 38107 * 1 1/2 NC x 9 Cap screw GR5
7 5849 * 1 3/4 NF Slotted hex nut
8 64291 * 1 5/32 x 1 Cotter pin
9 3585 2 Bearing cup #L44610
10 3586 2 Bearing cone #L44643
11 70086 1 Sleeve, 1.013 x 1.50 x .375
12 70328 1 Seal, 1.5 x 2 x .187
13 70332 1 Dust cap
14 70417 1 Bushing washer
15 73741 1 Pivot housing
16 73818 1 Caster fork
17 78704 1 Spacer
3 3585 4 Bearing cup
4 3586 4 Bearing cone
5 70328 2 Seal, 1.5 x 2 x .187
6 70086 2 Spacer, 1.013 x 1.5 x .375
7 73818 2 Wheel fork
8 05435700 4 Bearing, 25 mm x 52 mm x 15 mm
9 3598 * 4 1/2 Flat washer
10 07147800 2 Wheel & tire assembly tire, 15 x 6-6
11 09231800 2 Spacer - wheel
12 765 * 2 1/2 NC Lock nut
13 38107 2 1/2 NC x 9 HHCS
14 70417 2 Bushing washer
15 5849 2 3/4 NF Slotted hex nut
16 70332 2 Dust cap
17 64291 * 2 Cotter pin, 5/32 x 1
21 62153 * 4 3/8 NC x 1 Flanged screw SRTD
22 70336 1 Axle beam (includes item #22)
23 73740 1 Rear axle pivot
24 74065 2 Oilite bushing
25 70602 1 Washer, 1/2 x 2-1/4
26 855 * 1 1/2 Standard lock washer
27 25475 * 1 1/2 NC x 1 HHCS full thread GR5
* Standard Hardware, Obtain Locally
40 Parts
* Standard Hardware, Obtain Locally
MAN0999 (12/4/2012)
Page 41
HEADLIGHT KIT (OPTIONAL)
REF PART QTY DESCRIPTION
73938 Headlight kit
1 73937 1 Light bracket - left
2 73936 1 Light bracket - right
3 73935 2 Rect. work light with switch
4 07516000 4 Button bumper
5 6096 * 4 5/16 NC x 3/4 HHCS
6 2472 * 4 5/16 Lock washer
REF PART QTY DESCRIPTION
7 4378 * 4 5/16 Flat washer
8 5288 * 2 1/4 NC Hex nut
9 1985 * 2 1/4 Lock washer
10 -------- * 8 Plastic tie
* Standard hardware, obtain locally
NOTES:
steering pivot blocks.
Headlight power outlets are located near the
MAN0999 (12/4/2012)
Parts 41
Page 42
78727 COUNTERWEIGHT MOUNT KIT (OPTIONAL)
REF PART QTY DESCRIPTION
1 -------- 6 Weight, 14.8 lb
2 78728 * 1 3/8 NC x 8 Carriage bolt GR5, ZP
* Standard hardware, obtain locally
42 Parts
(Rev. 11/7/2013)
MAN0999 (12/4/2012)
Page 43
BOLT TORQUE CHART
A
SAE SERIES
TORQUE
CHART
SAE Bolt Head
Identification
SAE Grade 2
(No Dashes)
SAE Grade 5
(3 Radial Dashes)
SAE Grade 8
(6 Radial Dashes)
METRIC SERIES
TORQUE
CHART
Metric Bolt Head
Identification
8.8
Metric
Grade 10.9
10.9
Metric
Grade 8.8
A
A
Typical Washer
Installations
Lock Washer
Flat Washer
8/9/00
Bolt
Always tighten hardware to these values unless a different torque value or tightening procedure is listed for a specific
application.
Fasteners must always be replaced with the same grade as specified in the manual parts list.
Always use the proper tool for tightening hardware: SAE for SAE hardware and Metric for metric hardware.
Make sure fastener threads are clean and you start thread engagement properly.
All torque values are given to specifications used on hardware defined by SAE J1701 MAR 99 & J1701M JUL 96.
A
Diameter
(Inches)
1/4" 7/16" 6 8 10 13 14 18
5/16"1/2"121719262737
3/8"9/16"233135474967
7/16"5/8"3648557578106
1/2" 3/4" 55 75 85 115 120 163
9/16" 13/16" 78 106 121 164 171 232
5/8" 15/16" 110 149 170 230 240 325
3/4" 1-1/8" 192 261 297 403 420 569
7/8" 1-5/16" 306 416 474 642 669 907
1" 1-1/2" 467 634 722 979 1020 1383
A
Diameter &
Thread Pitch
(Millimeters)
6 x 1.0 10 mm 8 6 11 8 8 6 11 8 6 x 1.0
8 x 1.25 13 mm 20 15 27 20 21 16 29 22 8 x 1.0
10 x 1.5 16 mm 39 29 54 40 41 30 57 42 10 x 1.25
12 x 1.75 18 mm 68 50 94 70 75 55 103 76 12 x 1.25
14 x 2.0 21 mm 109 80 151 111 118 87 163 120 14 x 1.5
16 x 2.0 24 mm 169 125 234 173 181 133 250 184 16 x 1.5
18 x 2.5 27 mm 234 172 323 239 263 194 363 268 18 x 1.5
20 x 2.5 30 mm 330 244 457 337 367 270 507 374 20 x 1.5
22 x 2.5 34 mm 451 332 623 460 495 365 684 505 22 x 1.5
24 x 3.0 36 mm 571 421 790 583 623 459 861 635 24 x 2.0
30 x 3.0 46 mm 1175 867 1626 1199 1258 928 1740 1283 30 x 2.0
Wrench
Size
Wrench
Size
Metric 8.8 Metric 10.9 Metric 8.8 Metric 10.9
N-m lbs-ft N-m lbs-ft N-m lbs-ft N-m lbs-ft
SAE 2 SAE 5 SAE 8
lbs-ft N-m lbs-ft N-m lbs-ft N-m
Coarse Thread Fine Thread
Marking on Head Marking on Head
MARKING ON HEAD
Diameter &
Thread Pitch
(Millimeters)
Bolt Torque & Size Charts (Rev. 3/28/2007)
Appendix 43
Page 44
BOLT SIZE CHART
NOTE:
Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts.
SAE Bolt Thread Sizes
5/16 3/8 1/2 5/8 3/4 7/8
IN 1 7
2
34
5
6
MM 25 50 75 100 125 150 175
Metric Bolt Thread Sizes
8MM 18MM14MM12MM10MM 16MM
ABBREVIATIONS
AG .............................................................. Agriculture
ASABE ....................American Society of Agricultural &
Biological Engineers (formerly ASAE)
ASAE....... American Society of Agricultural Engineers
ATF................................Automatic Transmission Fluid
BSPP.............................British Standard Pipe Parallel
BSPTM................ British Standard Pipe Tapered Male
CV ....................................................Constant Velocity
CCW.............................................. Counter-Clockwise
CW .............................................................. Clockwise
F .......................................................................Female
FT.............................................................. Full Thread
GA .....................................................................Gauge
GR (5, etc.)........................................... Grade (5, etc.)
HHCS ........................................ Hex Head Cap Screw
HT ...........................................................Heat-Treated
JIC.................Joint Industry Council 37° Degree Flare
LH................................................................. Left Hand
LT ...........................................................................Left
m ........................................................................ Meter
mm ............................................................... Millimeter
M ..........................................................................Male
MPa ........................................................ Mega Pascal
N ......................................................................Newton
NC...................................................... National Coarse
NF ...........................................................National Fine
NPSM .................... National Pipe Straight Mechanical
NPT...........................................National Pipe Tapered
NPT SWF......... National Pipe Tapered Swivel Female
ORBM ...........................................O-Ring Boss - Male
P .......................................................................... Pitch
PBY.......................................................Power-Beyond
psi ......................................... Pounds per Square Inch
PTO......................................................Power Take Off
QD ................................................... Quick Disconnect
RH.............................................................. Right Hand
ROPS........................... Roll-Over Protective Structure
RPM........................................Revolutions Per Minute
RT ........................................................................Right
SAE..........................Society of Automotive Engineers
UNC ..................................................... Unified Coarse
UNF ..........................................................Unified Fine
UNS ..................................................... Unified Special
44 Appendix
Bolt Torque & Size Charts (Rev. 3/28/2007)
Page 45
INDEX
ASSEMBLY
Dealer Set-Up Instructions
Install Single Tailwheel (Optional)
DEALER CHECK LISTS
Delivery (Dealer’s Responsibility)
Pre-Delivery (Dealer’s Responsibility)
DEALER SERVICE
Belt Removal
Clutch Repair
Align Belt
Install Clutch
Reassemble Components
Remove Components
Engine Removal
Hydrostatic Pump Installation
Hydrostatic Pump Removal
Parking Brake Adjustment
Return to Operation
Troubleshooting Engine
Troubleshooting Hydrostatic Pump
No Positive Neutral Position
Straight Line Travel
22
24
24
22
26
24
23
22
23
25
21
20
22
20
27
28
20
28
Owner Pre-Operation Checklist (Owner’s
Responsibility)
Practice Operation
Uneven Terrain Operation
Safety Switch System
Start Engine
Cold Weather Starting Tips
Start Mower or Attachment
Stop Mower or Attachment
Steering Handle Operation
Steering Handle Positions
Stopping Engine
Weight Transfer System
OWNER SERVICE
Burnish Clutch
Change Engine Oil
Cleaning
Hydraulic Transmission - Change Oil & Filter
Hydrostatic Transmission Service
Lubrication Information
Lubrication Diagram
Lubrication Service Intervals
Return to Operation
15
12
12
11
12
12
12
12
13
13
14
14
19
16
19
18
16
17
16
19
18
GENERAL
Abbreviations
Bolt Size Chart
Bolt Torque Chart
General information
Introduction
Obtaining Replacement Manuals
Product Registration
Specifications
Table Of Contents
Warranty - Product
OPERATION
Brake and Temperature Lights
Controls and Switches
Moving Disabled Power Unit
MAN0326 (12/28/2007)
51
51
50
4
2
2
4
3
53
11
14
11
2
Service Battery
Service Engine
Check Engine Oil Level
Tailwheel Maintenance
PARTS
Parts Index
SAFETY
Dealer Check Lists
Delivery (Dealer’s Responsibility)
Pre-Delivery (Dealer’s Responsibility)
Owner Pre-Operation Checklist (Owner’s
Responsibility)
Safety & Instructional Decals
Safety Rules
Safety Symbols Explained
18
16
16
17
29
15
9, 10
5, 6, 7, 8
2
Index 45
28
28
Page 46
LIMITED WARRANTY
(Mow’n MachineTM Zero-Turn Mower Replacement Parts)
Woods Equipment Company (“WOODS”) warrants replacement parts for Mow’n MachineTM zero-turn
mowers and attachments to be free from defect in material and workmanship for a period of ninety (90)
days from the date of delivery of the product to the original purchaser.
IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR
PURPOSE ARE LIMITED IN DURATION TO A PERIOD OF NINETY (90) DAYS FROM THE
DATE OF DELIVERY OF THE PRODUCT TO THE ORIGINAL PURCHASER. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
This Warranty is extended solely to the original purchaser of the product. Should the original purchaser
sell or otherwise transfer the product to a third party, this Warranty does not transfer to the third party
purchaser in any way. There are no third party beneficiaries of this Warranty.
This Warranty does not cover normal wear or tear, or normal maintenance items, or any damage, failure
or loss caused by improper operation, improper maintenance, misuse, or an accident.
WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement,
free of charge, of the product if the product is defective or in noncompliance with this Warranty. The
product must be returned to WOODS with proof of purchase within thirty (30) days after such
defect or noncompliance is discovered or should have been discovered, routed through the dealer
and distributor from whom the purchase was made, transportation charges prepaid. WOODS
shall complete such repair or replacement within a reasonable time after WOODS receives the product.
WOODS shall not be liable for any incidental or consequential losses, damages or expenses,
arising directly or indirectly from the product, whether such claim is based upon breach of
contract, breach of warranty, negligence, strict liability in tort or any other legal theory. Without
limiting the foregoing, WOODS shall not be liable for any damages relating to (i) lost profits, business,
revenues or goodwill; (ii) any expense or loss incurred for labor, supplies, substitute machinery or rental;
or (iii) any other type of damage to property or economic loss. Some states do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitations may not apply to you.
No agent, representative, dealer, distributor, service person, salesperson, or employee of any company,
including without limitation, WOODS, its authorized dealers, distributors, and service centers, is
authorized to alter, modify, or enlarge this Warranty.
This Warranty gives you specific legal rights, and you may also have other rights which may vary from
state to state.
Answers to any questions regarding warranty service and locations may be obtained by contacting:
Woods Equipment
A Blount International Company
2606 South Illinois Route 2
Post Office Box 1000
Oregon, Illinois 61061 USA
800-319-6637 tel
800-399-6637 fax
woodsequipment.com
©2011 Woods Equipment Company. All rights reserved. WOODS, the Woods logo, Mow’n Machine, and “Tested. Proven. Unbeatable.” are
trademarks of Woods Equipment Company. All other trademarks, trade names, or service marks not owned by Woods Equipment Company that
appear in this manual are the property of their respective companies or mark holders. Specifications subject to change without notice.
F-8495 MM & Boundary Repair Parts (Rev. 2/11/2011)
Page 47
LIMITED WARRANTY
Mow’n MachineTM Zero-Turn Mowers
Please Enter Information Below and Save For Future Reference.
Date Purchased: __________________________ From (Dealer):______________________________________
Model Number: __________________________ Serial Number: _____________________________________
WHAT IS COVERED:
Woods Equipment Company (“WOODS”) warrants Mow’n Machine
material and workmanship for the warranty periods listed below.
FOR HOW LONG:
Mow’n Machine Model #FZ22K, FZ23B, FZ25D, FZ28K & attachments are warranted for two (2) years from the date of delivery to the original
purchaser or 2000 hours of operation, whichever occurs first.
IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION
TO THE DURATION OF THE WRITTEN WARRANTY PERIODS LISTED ABOVE. Some states do not allow limitations on how long an
implied warranty lasts, so the above limitation may not apply to you.
WHO IS COVERED:
This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or otherwise transfer the product to a
third party, this Warranty does not transfer to the third party purchaser in any way. There are no third party beneficiaries of this Warranty.
WHAT IS NOT COVERED:
This Warranty does not cover normal wear or tear, or normal maintenance items, or any damage, failure or loss caused by:
1. Improper operation, improper maintenance, misuse, or an accident;
2. Any modification or repair by someone other than WOODS, a WOODS’ authorized dealer or distributor, and/or a WOODS’
authorized service center; or
3. Repairs made with parts other than those obtained through WOODS.
WOODS makes no warranty, express or implied, with respect to engines, batteries, tires or other parts or accessories with respect to which the
manufacturer provides a separate warranty.
WHAT WOODS WILL DO TO CORRECT PROBLEMS:
WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of charge, of the product if the product
is defective or in noncompliance with this Warranty. The product must be returned to WOODS with proof of purchase within thirty (30) days
after such defect or noncompliance is discovered or should have been discovered, routed through the dealer and distributor from whom the
purchase was made, transportation charges prepaid. WOODS shall complete such repair or replacement within a reasonable time after WOODS
receives the product.
OTHER LIMITATIONS:
WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the
product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal
theory. Without limiting the foregoing, WOODS shall not be liable for any damages relating to (i) lost profits, business, revenues or goodwill;
(ii) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (iii) any other type of damage to property or economic loss.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to you.
No agent, representative, dealer, distributor, service person, salesperson, or employee of any company, including without limitation, WOODS, its
authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty.
HOW STATE LAW APPLIES:
This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
QUESTIONS:
Answers to any questions regarding warranty service and locations may be obtained by contacting:
TM
zero-turn mowers, attachments and accessories to be free from defect in
Woods Equipment
A Blount International Company
2606 South Illinois Route 2
Post Office Box 1000
Oregon, Illinois 61061 USA
800-319-6637 tel
800-399-6637 fax
woodsequipment.com
F-8045 MM (Rev. 4/15/2013)
Page 48
PART NO.
MAN0999
© 2013 Woods Equipment Company. All rights reserved. Woods® and the Woods logo are trademarks of Woods Equipment Company. All other
trademarks, trade names, or service marks not owned by Woods Equipment Company that appear in this manual are the property of their respective companies or mark holders. Specifications subject to change without notice.
Woods Equipment
A Blount International Company
2606 South Illinois Route 2
Post Office Box 1000
Oregon, Illinois 61061
800-319-6637 tel
800-399-6637 fax
woodsequipment.com
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