Woods Equipment Mown Machine Fz25D Users Manual MAN0646
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2015-02-05
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FZ25D Power Unit OPERATOR'S MANUAL (Rev. 3/7/2012) MAN0646 MOW’N MACHINE TO THE DEALER: Assembly and proper installation of this product is the responsibility of the Woods® dealer. Read manual instructions 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: Model: _______________________________ Date of Purchase: _____________________ Serial Number: (see Safety Decal section for location) ____________________________________ Provide this information to your dealer to obtain correct repair parts. Throughout this manual, the term NOTICE is used to indicate that failure to observe can cause damage to equipment. The terms CAUTION, WARNING, and DANGER are used in conjunction with the Safety-Alert Symbol (a triangle with an exclamation mark) to indicate the degree of hazard for items of personal safety. 2 Introduction Gen’l (Rev. 12/5/2011) TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DEALER CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 INDEX TO PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 50 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . INSIDE BACK COVER WARNING WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 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. MAN0646 (7/6/2007) Introduction 3 SPECIFICATIONS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota 3-cylinder, 4-cycle, liquid cooled (See engine manual for complete specifications) Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 HP Fuel Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Standard Tire Size: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 x 10.50 - 12 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . .15 x 6.00 - 6 Rib Recommended Tire Pressure: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 psi Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum 18 psi Power Unit Dimensions: Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50" Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87" Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020 lbs Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.0 Gallons Recommended Mower Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52", 61", 72" GENERAL INFORMATION WARNING Some illustrations in this manual show the equipment with safety shields removed to provide a better view. This equipment should never be operated with any necessary 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 4 Introduction 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. (Rev. 11/5/2007) MAN0646 (7/6/2007) SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 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. PREPARATION 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. 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. It has been said, “The best safety device is an informed, careful operator.” We ask you to be that kind of operator. TRAINING 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 1-800-3196637.) 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. Never allow children or untrained persons to operate equipment. Check that all hardware is properly installed. Always tighten to torque chart specifications unless instructed otherwise in this manual. Make sure attachment is properly secured, adjusted, and in good operating condition. Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove. 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. Inspect and clear area of stones, branches, or other hard objects that might be thrown, causing injury or damage. The machine is not intended for highway or street use. Do not mow on wet grass. While fueling, extinguish all cigarettes, cigars, pipes, and other sources of ignition. Never fuel the machine indoors. (Safety Rules continued on next page) FE-Series Mow”n Machine (12/23/2005) Safety 5 SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 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. 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. Transport power unit facing rearward when equipped with a sunshade. 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. Because a ROPS is not offered with this unit, a seat belt must not be used. Use extreme care when approaching blind corners, shrubs, trees, or other objects that may block your vision. Use care when operating with ROPS or sunshade around shrubs, trees or other objects that can become entangled with power unit. 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. 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. Do not operate or transport on steep slopes. If the tires lose traction on a slope, disengage the blade(s) and proceed slowly straight down the slope. Do not operate or transport equipment while under the influence of alcohol or drugs. Do not stop, start, or change directions suddenly on slopes. Do not operate PTO during transport. Do not make sudden changes in speed or direction which could cause the machine to roll over. OPERATION Keep bystanders away from equipment. Use extreme care and reduce ground speed on slopes and rough terrain. Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator. Installation of a grasscatcher assembly will reduce the stability and maneuverability of the Mow'n Machine when operating on sloping terrain. Be alert and turn machine off if a child enters the mowing area. Watch for hidden hazards on the terrain during operation. Before and while backing, look behind and down for children. Watch for traffic when operating near or crossing roadways. Never direct discharge toward people, animals, or property. Uneven terrain could overturn the machine. 6 Safety Do not try to stabilize the machine by putting your foot on the ground. (Rev. 8/22/2008) FE-Series Mow’n Machine (12/23/2005) SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 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 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. This machine is not equipped for towing. Do not tow any loads. To avoid burns, DO NOT TOUCH the engine or muffler immediately after operation. 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, disengage 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 deck is in a stable position. 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 Do not work on mower in tilt-up position unless lock-up mechanism is in good condition. Replace if damaged. 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 t o “ O FF. ” S e e y o ur d e a l e r f o r r e p l a c e m e n t clutches. Keep all persons away from operator control area while performing adjustments, service, or maintenance. 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. 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. (Safety Rules continued on next page) (Rev. 8/22/2008) FE-Series Mow”n Machine (12/23/2005) Safety 7 SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 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 storage area. 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 8 Safety (Rev. 8/22/2008) FE-Series Mow’n Machine (12/23/2005) SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! 1 - PN 72407 2 - PN 72404 3 - SERIAL NUMBER PLATE MODEL NO. SERIAL NO. Woods Equipment Company Oregon, Illinois, U.S.A. Woods Equipment Company W Oregon, Illinois, U.S.A. (Safety Decals continued on next page) MAN0646 (7/6/2007) Safety 9 SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! (Safety Decals continued from previous page) 5 - PN 72648 4 - PN 72408 CAUTION ENGINE COOLANT (SEE ENGINE MANUAL) DO NOT OPEN WHEN HOT 72648 9 - PN 07754100 10 - PN 72801 07754100 6 - PN 70376 8 - PN 72406 7 - PN 72405 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. 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. 10 Safety MAN0646 (7/6/2007) OPERATION 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. WARNING 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. Make sure attachment is properly secured, adjusted, and in good operating condition. Inspect and clear area of stones, branches, or other hard objects that might be thrown, causing injury or damage. Do not operate power unit with attachment removed. Attachment is required for power unit stability. Make sure shields and guards are properly installed and in good condition. Replace if damaged. 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. Keep bystanders away from equipment. Do not operate or transport equipment while under the influence of alcohol or drugs. Keep hands, feet, hair, and clothing away from equipment while engine is running. Stay clear of all moving parts. Never allow riders on power unit or attachment. Never direct discharge toward people, animals, or property. MAN0646 (7/6/2007) WARNING Moving steering levers rapidly from forward to reverse or reverse to forward could cause loss of control. Look down and to the rear and make sure area is clear before operating in reverse. Do not stop, start, or change directions suddenly on slopes. 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. 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. Do not operate PTO during transport. CAUTION Remove accumulated debris from this equipment, power unit, and engine to avoid fire hazard. 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. 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. Operation 11 CONTROLS AND SWITCHES brake and turn ignition key switch to the “ON” position. Control panel brake light (3) should be on. WARNING Temperature Light Know your controls and how to stop engine and attachment quickly in an emergency. 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. 4 2 3 1 5 6 8 7 NOTICE ■ For overheating, clean radiator grill and check engine coolant level. The temperature light will alert you when the engine temperature is excessive. The temperature light system is not intended to shut the engine off or prevent operation; it is designed to provide notification. If temperature light starts to flash during operation, discontinue operation. The light is programed to flash at 220° fahrenheit and above. NOTE: The radiator and prescreen require regular cleaning to prevent engine overheating. Clean the prescreen daily and the radiator fins every 40 hours. Do not use high pressure on radiator fins to avoid radiator damage. HOUR METER 1. 2. 3. 4. 5. 6. 7. 8. Temperature gauge PTO switch Brake light Oil light Ignition switch Hour meter Throttle control Deck height switch Figure 1. Console Control Locations DECK HEIGHT/POWER TILT™ ADJUSTMENT SWITCH The deck height and Power Tilt™ switch is used with MXT or MX deck equipped with the Power Tilt™ Kit. 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 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: Power Tilt™ feature must not be used when sitting in the seat. BRAKE & TEMPERATURE LIGHTS Brake Light NOTICE ■ Do not operate with parking brake engaged or damage to the brake adjustment will occur. The brake light indicates when the brake is engaged. To ensure light is operating properly, engage parking 12 Operation The hour meter is programed to alert the operator at various service intervals. The change oil light will flash at 20 hours (initial break in) and every 100 hours after. The light will flash for a period of 4 hours (alternating between hours & change oil) and than resume normal mode. The hour glass will flash every second indicating it’s in running mode. Service Intervals 20 hrs Engine oil change (break in) 100 hrs Engine oil change & filter 500 hrs Hydraulic oil change & filter (see hydraulic transmission - change oil & filter, page 19) SAFETY SWITCH SYSTEM Several safety switches are incorporated in the unit’s design to prevent it from being started out of NEUTRAL (handles pivoted outward) or with PTO engaged. The PTO control must be in the “OFF” position and the steering handles in the NEUTRAL position before unit can be started. A safety switch behind the operator’s seat will cause the 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 NEUTRAL while the parking brake is engaged. It will not run if the deck jumper wire (for Power Tilt™ operation) is not connected to the wire harness or the deck safety switch is disengaged. (Rev. 1/7/2010) MAN0646 (7/6/2007) STARTING ENGINE DANGER 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. 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. 1. Position yourself on the power unit seat. NOTE: Starting attachment at lower engine speed will help prolong the life of the clutch and transmission components. 2. Place steering control handles in the NEUTRAL position (pivoted outward). STOPPING MOWER OR ATTACHMENT 3. Place PTO switch in the “OFF” position (down). Push down on PTO switch. 4. Place throttle approximately 1/3 open. 5. Turn key counter-clockwise to “PRE-HEAT” the glow plugs. NOTE: Standard pre-heating time is 5 to 10 seconds. Pre-heat is not required if engine has been running and warmed up. 6. Turn key to “START”. Release key immediately when engine starts. 7. Ensure that the oil pressure light is off. 8. Warm up engine several minutes at medium throttle. NOTE: Allow engine a warm-up period regardless of the season. Loading a cold engine will shorten its life. NOTE: If attachment does not stop in five seconds, the unit requires service. PRACTICE OPERATION WARNING 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. If engine does not start after refueling or has been sitting for a prolonged period, refer to “bleeding the fuel system” in the engine manual. Do not operate attachment until you become proficient with controls. COLD WEATHER STARTING TIPS UNEVEN TERRAIN OPERATION 1. Use proper oil grade for temperature expected. (Refer to engine manual for oil grade.) WARNING 2. Set throttle half way open. Uneven terrain could overturn the machine. 3. A warm battery has better starting capacity than a cold one. Do not operate on slopes greater than 15 degrees (27% grade). 4. Use fresh fuel (winter grade for diesel model); it is better for starting than leftover fuel. Do not stop, start, or change directions suddenly on slopes. STARTING MOWER OR ATTACHMENT WARNING Make sure people and objects are clear of attachment and discharge area before engaging PTO. MAN0646 (7/6/2007) Use extreme care and reduce ground speed on slopes and rough terrain. Watch for hidden hazards on the terrain during operation. Installation of a grasscatcher assembly will reduce the stability and maneuverability of the Mow'n Machine when operating on sloping terrain. Operation 13 CAUTION 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. Practice steering maneuvers at half throttle. STEERING HANDLE OPERATION WARNING 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: Speed and direction are controlled with steering 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 the steering handles are moved, the faster the machine will move. 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: Moving one handle forward with the other handle in neutral will also result in a 360° circle. However this will cause one drive wheel to dig into the turf and should be avoided. Figure 2. Steering Handle Operation 14 Operation (Rev. 3/7/2012) MAN0646 (7/6/2007) STOPPING ENGINE 1. Move throttle to 1/3 setting. 2. Allow engine to idle for several minutes. 3. Turn key to OFF position and remove. CAUTION Remove key and store in a secure location to prevent unauthorized persons from operating equipment. Manually move a disabled power unit by following these steps. 1. Locate dump valves on bottom of both hydraulic pumps. 2. Turn hex head two full revolutions counter-clock wise to open valve, using a 5/8" wrench or round punch. WEIGHT TRANSFER Manual Fuel Shut-Off Valve WARNING A manual fuel shut-off valve is located on top of the fuel filter, on the right side of engine. 1. Place valve in the “ON” position before attempting to start engine. 2. Place valve in the “OFF” position when changing or cleaning the fuel filter. When using weight transfer system, correct counterweight must be used to maintain stability. See counterweight chart in power unit manual or contact dealer. 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: Counterweight is needed to provide adequate stability. Refer to the chart to determine your power unit/mower combination, and the amount of counterweight required. Figure 3. Manual Shut-Off Valve Counterweights are not required when power unit is equipped with a grass catcher system. MOVING DISABLED POWER UNIT With ROPS & Sun Grass Shade Catcher FZ25D With ROPS 52" Deck 0 lbs 50 lbs 100 lbs 0 lbs 61" Deck 0 lbs 50 lbs 100 lbs 0 lbs 72" Deck 50 lbs 100 lbs 150 lbs N/A Snow Thrower 0 lbs 50 lbs 100 lbs N/A Dozer Blade 0 lbs 50 lbs 100 lbs N/A 60" Sweeper 50 lbs 100 lbs 150 lbs N/A Mower DP2 DUMP VALVE Figure 4. Left Pump Dump Valve (Rev. 8/22/2008) MAN0646 (7/6/2007) Figure 5. Counterweight Requirement Chart Operation 15 OWNER PRE-OPERATION CHECK LIST ___ Do not allow riders. (OWNER'S RESPONSIBILITY) ___ Inspect area and remove stones, branches or other hard objects that might be thrown, causing injury or damage. ___ 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 properly 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 mowing 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. ___ Clean air intake screen. Check air cleaner; service if necessary. ___ Clean area around oil fill dipstick. Remove dipstick and check to be sure oil is in operating range (between marks on dipstick). Add oil if necessary but Do Not Overfill. Install dipstick assembly firmly until cap bottoms out on tube. Dipstick assembly must always be secured into fill tube when engine is running. Avoid touching exhaust manifold if unit has been running. ___ Check all lubrication points and grease as instructed. See “Lubrication Service Intervals” on page 18. ___ Check hydrostatic fluid level (refer to Owner Service section). Check to be sure cooling fins on hydrostat are clean. ___ 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. 16 Operation MAN0646 (7/6/2007) OWNER SERVICE The information in this section is written for operators who possess basic mechanical skills. If you need help, your dealer has trained service technicians available. For your protection, read and follow the safety information in this manual. WARNING 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. 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. Avoid touching exhaust manifold if unit has been running. 4. Add oil as necessary. Change Engine Oil NOTICE ■ Use care to prevent hot oil from contacting bare skin. 1. Run engine to allow oil to become hot. This will ensure that most foreign materials are in suspension and will be flushed out with the oil. 2. Remove drain plug and drain crankcase. 3. Remove oil filter. CAUTION 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. RADIATOR AND PRESCREEN NOTICE ■ Clean the prescreen daily and the radiator fins every 40 hours or annually, which ever is less. Do not use high pressure on radiator fins to avoid radiator damage. ENGINE SERVICE NOTE: Follow engine manufacturer recommendations in engine manual. Check Engine Oil Level NOTE: Never attempt to check oil level while engine is running. Serious injury or damage to equipment could result. (Rev 1/7/2010) MAN0646 (7/6/2007) 4. Install new oil filter. 5. Install drain plug and add oil. NOTE: Refer to the engine manual for oil specifications, capacity, service rating, and proper grade. Engine Coolant Refer to the engine manual for the coolant specifications, coolant capacity, service rating, and proper mixture. LUBRICATION INFORMATION 1. Do not let excess grease collect on or around parts, particularly when operating in sandy areas. 2. See Figure 6 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. Owner Service 17 Lubrication Service Intervals 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Hydrostatic Fluid Level (check) 8 hours Deck Pivot 8 hours Driveline 80 hours Driveshaft 8 hours Blade Spindles 40 hours Front Wheels 8 hours Engine Oil Level (check) 8 hours Parking Brake Handle Pivot 80 hours Gearbox (under deck) 500 hours Front Lift Linkage 40 hours Caster Pivot 40 hours Radiator Clean 40 hours/annually Prescreen Clean Daily Figure 6. 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 hex nut to 26 lbs-ft. All bearing free play should be removed. NOTE: Proper bearing adjustment is essential to good bearing life. If bearings are loose, caster wheels 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. 18 Owner Service 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Tailwheel assembly Dust cap Cotter pin Slotted hex nut Bushing washer 3/4 x 14 GA Bearing cone Bearing cup Seal Spacer Wheel fork Figure 7. Tailwheel Assembly (Typical) (Rev 1/7/2010) MAN0646 (7/6/2007) HYDROSTATIC TRANSMISSION SERVICE NOTICE ■ Keep transmission oil clean. When adding fluid take precautions to prevent dirt and other foreign material from entering the system. NOTE: Check fluid level every 8 hours of operation. 1. Place power unit on a level surface. 2. Stop engine; remove key and clean off dirt and dust from around cap on top of hydraulic reservoir, located behind left tire. 3. Remove cap and look inside reservoir to check fluid level. Check oil against notch in center of reservoir; hot oil should be to the top of the divider, cold oil should be to the bottom of the notch. See Figure 8. 4. Add oil as necessary. 5. Check cooling fins and fan blades for debris; they should be free of foreign material. Clean as necessary. 3. Remove case drain hose fitting from bottom of reservoir, located outside of power unit frame. Allow reservoir to completely drain. 4. Remove automotive type filter (Figure 8) by turning counter-clockwise. 5. Replace filter by turning until gasket is seated; then turn an additional 3/4 turn. 6. Replace hose fitting and fill reservoir with 5 quarts of 20W-50 motor oil. NOTE: The transmissions do not need to be individually drained; they will drain through the fluid reservoir. BATTERY SERVICE 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. NOTICE ■ Use care to prevent battery acid from contacting skin. Figure 8. Hydraulic Tank HYDRAULIC TRANSMISSION - CHANGE OIL & FILTER NOTE: Change oil and filter every 1000 hours under normal mowing conditions. NOTE: Change oil and filter every 500 hours when using a grass catcher or when operating in ambient temperature above 100°F for any extended period. 1. Place power unit on a level surface. 2. Stop engine; remove key. MAN0646 (7/6/2007) DP2 Figure 9. Battery Located under Seat Clean battery at least once a season by following these steps: 1. Inspect cables connections. for deterioration and loose 2. Clean terminals. 3. Make sure battery tie-down is tight and battery is secured in place. Owner Service 19 4. Inspect battery case for cracks or leaks; replace battery if necessary. 5. Test battery with hydrometer; recharge battery if less than 75% charge is indicated. 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. 6. Add water if necessary. 7. Check that the positive terminals on the battery, starter and alternator are properly covered with protective boots from exposure to grounding. CLUTCH BURNISHING 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. 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. Place steering control handles in the NEUTRAL position. Start engine and run at half throttle. 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. Turn clutch switch (PTO) “ON” 30 seconds and “OFF” for 30 seconds. Repeat cycle 20 times. 2. Be careful when spraying near chipped or scratched paint as water spray can lift paint. NOTE: The 30 seconds “OFF” allows clutch surface to cool. 3. If a pressure washer is used, follow the advice of the pressure washer manufacturer. RETURN TO OPERATION WARNING Make sure shields and guards are properly installed and in good condition. Replace if damaged. CAUTION Remove accumulated debris from this equipment, power unit, and engine to avoid fire hazard. ● 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 for location drawing. 20 Owner Service MAN0646 (7/6/2007) DEALER SERVICE 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. WARNING 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. 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. 1 CAUTION 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. TROUBLESHOOTING HYDROSTATIC PUMP Loss of Power in Transmission 1. Make sure transmission fluid is correct. 2. Make sure hydrostatic pump and fan blades are clean. NOTE: Overheating can cause loss of power or fluid leaks from excess fluid expansion. 3. Make sure dump valves are tightened down. NOTE: Transmission fluid can leak by the dump valve if by-pass is not tight. Tighten hex head if dump valves are loose. Figure 10. Jam Nut on Linkage Rod, Left Pump Straight Line Travel Adjustment 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. No Positive Neutral Position If drive wheels travel forward or reverse when steering handles are in the NEUTRAL position (pivoted outward), adjustment of hydrostatic pumps is necessary. 1. Block up power unit frame so both drive wheels are off the ground. 2. Release parking brake. 3. Loosen jam nut (1) on linkage rod as shown in Figure 10. MAN0646 (Rev. 11/5/2007) DP4 Figure 11. Left Side Steering Stop Bolts Dealer Service 21 TROUBLESHOOTING ENGINE PROBLEM Engine will not crank Engine cranks but will not start POSSIBLE CAUSE SOLUTION PTO switch is “ON” Switch to the “OFF” position Steering handles are not in “Positive Neutral” Swing steering handle outward Battery is discharged Charge or replace battery Starter fuse is blown Replace fuse Steering handle switches are out of adjustment Listen for the switch “click” and adjust as necessary 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 safety switches Engine Dies when Steering Handles are Engaged 1. Check if parking brake is set. • Release parking brake. NOTE: When parking brake is on, system is designed to kill the engine if either steering handle is engaged. ACAUTION ■ This circuit has a positive voltage with the key on. Jumping the seat switch with exposed wires could short out the main fuse or timer delay. 2. 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 if equipped with power tilt deck. c. Check voltage between the green timer delay wire and red wire at the seat switch connector on the main wire harness side. (See FZ25D Wiring Diagram.) Both wires are located underneath the 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 red and green wires are 22 Dealer Service part of a series circuit that includes the seat switch and deck safety switch (power tilt deck) or weatherpack jumper. • If there is voltage on only one wire check each switch 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. • If using the power tilt option and you need to check the deck safety switch refer to Figure 12 and troubleshooting deck safety switch. If the deck switch is open the engine will kill when pulling handles in. 3. Check park brake switch. • If there is voltage at both red/green wires mentioned in previous paragraph, check voltage at yellow/red parking brake wires with the park brake off. • If voltage is not present, check the yellow/red wire between the seat relay and parking brake; and the pink seat relay/timer delay wire to determine which wire or relay is defective. • If voltage is present at one yellow/red wire but not the other, the parking brake switch is defective and must be replaced. MAN0646 (Rev. 11/5/2007) engine. Push radiator forward until belt clears radiator cowl and engine sheave. Figure 12. Power Tilt Deck Safety Switch Layout Troubleshooting Deck Safety Switch 1. Pull handlebars in with deck in lowest cutting height position (1). 2. Check that switch is making contact with the height gauge. 3. Check that 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. HYDROSTATIC PUMP & BELT REMOVAL NOTE: Removal procedures are the same for both right and left hydrostatic pumps. 1. Place power unit on a level surface and remove key. Figure 13. Rubber Isolator & Radiator Mount 7. Remove hoses from hydrostatic pump. Plug and cap all fittings on hoses and pump to prevent contamination. 8. Remove H-drive that mounts sheave to hydrostatic pump. Use new 1/4 x 3/4 GR5 bolts in holes located 90° from previously occupied holes to separate H-drive from sheave. 9. Remove two bolts holding hydrostatic pump to frame and remove pump from frame. Hydrostatic pump weighs approximately 8 lbs; use care when removing. HYDROSTATIC PUMP INSTALLATION 1. Position hydrostatic pump into power unit frame and secure with two bolts. Apply Loctite® 242 to threads of the two mounting bolts and torque to 35 lbs-ft. 2. Place power unit on stands to allow access to bottom of the machine. 2. Install sheave onto hydrostatic pump and secure H-drive. Alternate tightening each cap screw to 8 lbs-ft. Align sheave with spring idler to allow for proper belt alignment. 3. Drain hydraulic reservoir and hydrostatic pumps. 3. Install hoses to hydrostatic pump. 4. Remove steering linkage from control arm on hydrostatic pump. 4. Install belts and tighten J-bolt for proper belt tension. 5. Loosen J-bolt and remove belt. 5. Install steering linkage hydrostatic pump. 6. If clearance between radiator cowl and engine sheave is too tight, loosen or remove rubber isolator (84) radiator mount located above the MAN0646 (Rev. 11/5/2007) to control arm on 6. Fill hydraulic reservoir with new fluid. Use 20W-50 motor oil. Dealer Service 23 8. Open pump dump valve. 6. Adjust right parking brake pull rod until brake rock shaft lug is perpendicular with the bottom edge of the frame rail. 9. Slowly push steering levers back and forth 5 to 6 times to bleed the hydraulic system. 7. Reconnect parking brake rod. 7. Start engine and disengage parking brake. 10. Close pump dump valve. 11. Adjust NEUTRAL position of steering linkage as necessary. NOTE: Approximately 24 to 26 lbs of force at the top of the handle is needed to apply both brakes. SOLENOID TEST 12. Stop engine. Check level of hydraulic reservoir and check for leaks. 1. Disconnect solenoid from engine and briefly crank engine. 13. Remove power unit from stands. 2. Leave key ON. Fuel solenoid should be engaged (pushed out). PTO BELT REMOVAL 1. Remove key from switch. NOTE: If fuel solenoid will not engage, check inline fuse. If fuse is OK, test the solenoid in this manner: 2. Remove belt shield, if necessary a. Disconnect wires from solenoid terminals. 3. Remove clutch anti-rotation cable, if necessary. b. Set a multi meter to X 1 ohm scale. 4. Loosen idler spring bolt (J-bolt), and derail belts from pulleys. c. Connect leads to “Common” and “Pull” solenoid terminals; meter should indicate 0.1 ohms. 5. Remove belts. d. Connect leads to “Common” and “Hold” solenoid terminals; meter should indicate 10 ohms. 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 front and rear engine pulleys. See belt removal. 4. Lift engine from the power unit frame. NOTE: Contact your authorized engine dealer for parts and repairs. PARKING BRAKE ADJUSTMENT NOTICE ■ Overtightening the brake can cause internal NOTE: If you do not get these readings, or one of the circuits reads “OPEN”, then the solenoid is defective and you will need to replace the defective solenoid. CLUTCH REPAIR Remove Components (Figure 14 & Figure 15) 1. Position Mow’n Machine on a level work area. 2. Set parking brake, stop engine, and remove key. NOTE: Photo in Figure 14 was taken from underneath the power unit for clarification. All work can be performed from above. NOTE: It may be easier to rework clutch if you first remove counterweights from the rear of the power unit. damage to the brake linkage. NOTE: Adjust right and left brakes individually. 16 1. Disconnect clevis from right parking brake and brake handle linkages. 2. Adjust left parking brake pull rod until brake rock shaft lug is perpendicular with the bottom edge of the frame rail. 21 6 8 20 47 3. Readjust and reconnect clevis for parking brake handle linkage. NOTE: Approximately 12 to 13 lbs of force at the top of the handle is needed to apply the single brake. 4. Reconnect right parking brake rod. 5. Disconnect clevis from left parking brake and brake handle linkages. 24 Dealer Service 2 DP9 22 Figure 14. Clutch and Sheave Assembly MAN0646 (Rev. 11/5/2007) A DP10 Figure 16. Clutch Spacer Installed 2. Install clutch onto engine shaft. 3. Secure clutch to engine shaft using 3/8 NF cap screw GR8 (21) and lock washer (8) previously removed (Figure 15). NOTE: Place a drop of Loctite® 242 (blue) on threads of cap screw before installing. A. Clutch spacer 2. PTO Sheave 6. 3/8 NC x 1-3/4 HHCS GR5 8. 3/8 Lock washer 16. Cable, clutch stop 19. Electric clutch, mag-stop 1-1/8 20. 13/32 x 1-1/2 Retaining washer 21. 3/8 NF x 1-1/4 HHCS GR8 22. PTO V-belt set, matched Figure 15. Clutch Assembly 3. Place a 9/16 wrench over cap screw (6) on idler (47) and remove the tension from PTO V-belts (22) by rotating the wrench clockwise. 4. Torque Grade 8 cap screw (21) to 40 lbs-ft. 5. Check belt alignment and if necessary adjust PTO sheave on shaft. See . NOTE: If belt alignment is not necessary, proceed to Reassemble Components. 2. PTO sheave 13. 1/4 NC x 3/4 HHCS GR5 19. Electric clutch, magstop 1-1/8 46. Taper lock 4. Remove PTO V-belts (22) from PTO drive sheave (2). 5. Disconnect electrical wire harness from clutch. Figure 17. Align Clutch & PTO Sheave 6. Disconnect clutch cable (16) from clutch. 7. Remove cap screw (21), lock washer (8) and retaining washer (20) from end of clutch. 8. Remove clutch (19) and clutch spacer (A) from engine shaft. Install Clutch 1. Install clutch spacer (A) over engine shaft with the chamfer side towards the engine. See Figure 16. Align Belt 6. Loosen the taper bolts (13), adjust sheave (2), and tighten bolts to 85 lbs-inch. Reassemble Components 1. Install PTO V-belts (22) over PTO sheave (2) and clutch (19). 2. Attach clutch cable (16) to clutch (19) using hardware previously removed. Make sure nut is inside of loop of cable and between washers. Cable must pivot freely, (see Figure 15). 3. Attach electrical wiring harness to clutch. 4. Replace counterweights if removed. MAN0646 (Rev. 11/5/2007) Dealer Service 25 RETURN TO OPERATION When you have completed service and maintenance functions, read and comply with these safety messages before returning unit to operation. WARNING 19 16 22 2 2. 16. 19. 22. 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. PTO sheave Cable, clutch stop Electric clutch, mag-stop 1-1/8 PTO V-belt set, matched Figure 18. Clutch & Drive Components Reassembled 26 Dealer Service MAN0646 (Rev. 11/5/2007) ASSEMBLY 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. 1. Lug Bolt Set up the Mow’n Machine as received from the factory with these instructions. Complete check lists on page 29 when assembly is completed. Power Unit Preparation 1 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. DP5 NOTE: Dealer must complete and return product registration card at time of sale. Figure 19. Drive Tire Installed ADJUST STEERING HANDLES Battery 1. Connect ground cable to negative battery post and secure. 2 2. Confirm that rubber boot is properly secured over positive battery post. 1 Lubrication/Coolant NOTICE ■ Running engine without oil will cause engine failure. 1. Check oil level (30W) and the engine radiator fluid. 2. Check that oil level (20W-50) in transmission reservoir is full. NOTE: See Owner Service section for engine, transmission, and lubrication information. Fuel Fill fuel tank with the correct fuel. Refer to engine manual. INSTALL DRIVE TIRES 1. Install drive tires using five lug bolts (1) from bag of loose parts shipped with machine. 2. Torque lug bolts to 85 lbs-ft. Drive Tire Pressure: Turf Tires 12 psi Knobby Tires 12 psi Chevron Tires 10 - 12 psi MAN0646 (Rev. 11/5/2007) 3 4 1. 2. 3. 4. Steering lever Steering lever mount DP8 5/16 NC x 1 Whiz bolt 5/16 Flanged lock nut Figure 20. Steering Handle Adjustment The steering handles are shipped loose, inside the foot rest. 1. Remove whiz bolt (3) and lock nut (4) from left steering lever mount (2). 2. Position steering handle (1) to desired location on steering lever mount (2). The top and middle holes are 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. Assembly 27 STRAIGHT LINE TRAVEL INSTALL SINGLE TAILWHEEL (OPTIONAL) 1. Check tire pressure; tires must have equal air pressure. 1. Attach tailwheel spacer (22), and pivot mount adapter (1) to rear of power unit frame using two cap screws (21) and lock nuts (20). 2. Check travel; drive forward with both steering handles full forward at half throttle. 2. Attach pivot housing (2) to pivot mount adapter and power unit frame using four cap screws (18) and lock washers (19). • If travel is not straight, adjust steering handle stop bolt on opposite side of turn. 3. Torque hardware to 35 lbs-ft. NOTE: Rear tire pressure: 18 psi • 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. 1. 2. 18. 19. 20. 21. 22. DP4 Figure 21. Left Side Steering Stop Bolts Pivot mount adapter Pivot housing 3/8 NC x 4-1/2 HHCS GR5 3/8 Lock washer 3/8 Lock nut 3/8 NC x 1-3/4 HHCS GR5 Tailwheel spacer Figure 22. Single Tailwheel Installation ❖ 28 Assembly MAN0646 (Rev. 11/5/2007) DEALER CHECK LISTS PRE-DELIVERY CHECK LIST ___ Check tire pressure. See Assembly section. (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 doublecheck systems operation including hydrostatic neutral and safety switch system (page 12). ___ Check all fluid levels. See Owner Service section. 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 customer 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. ❖ MAN0646 (Rev. 11/5/2007) Dealer Check Lists 29 NOTES 30 Dealer Check Lists MAN0646 (Rev. 11/5/2007) Parts Index Mow’n Machine FZ25D FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 & 33 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 & 35 HYDRAULIC RESERVOIR & HOSES . . . . . . . . . . . . . . . . . . . 36 & 37 HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PTO, PUMP & CLUTCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . 38 & 39 SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 TAILWHEEL ASSEMBLY Single Tailwheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Wide Stance Tailwheel Assembly . . . . . . . . . . . . . . . . . . . . . 41 BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 & 43 WIRING DIAGRAM KUBOTA DIESEL. . . . . . . . . . . . . . . . . . . 44 & 45 STEERING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 COUNTERWEIGHT MOUNT KIT (OPTIONAL). . . . . . . . . . . . . . . . . 47 HEADLIGHT KIT (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 MAN0646 (Rev. 11/5/2007) Parts 31 FZ25D FRAME ASSEMBLY 32 Parts (Rev. 8/22/2008) MAN0646 (Rev. 11/5/2007) FZ25D FRAME ASSEMBLY PARTS LIST REF PART QTY DESCRIPTION 1 78317 1 Fuel tank, LH 2 73894 1 Fuel tank, RH Diesel 3 09239500 2 4 73427 5 6 REF PART QTY DESCRIPTION 38 24660 2 3/8 NC x 3-1/2 HHCS full thread - GR5 Fuel cap 39 73896 4 Weight transfer sleeve 1 Left fender cover 40 73895 2 Weight transfer pin 73428 1 Right fender cover 41 71170 2 5-Link chain 73898 2 Weight transfer arm 42 6698 * 4 3/8 NC Hex lock nut 839 * 4 3/8 NC x 1” HHCS - GR5 2 Bushing sleeve 2 1/2 Flat washer 7 71144 2 Extension spring 43 9 73891 1 Footrest (includes item 44 & 50) 44 10 73827 2 Deck bracket 45 11 -------- * 1 Battery, 12V (details on page 45) 46 72410 1 Pivot rod 71444 2 Rubber bumper 73581 3598 * 12 70274 1 Terminal boot 47 13 70733 1 Battery hold down 48 73217 * 2 1/8 x 3/4 Cotter pin 14 73887 1 Negative battery cable 49 73163 2 5/16 NC Flange whiz nut 15 73888 1 Positive battery cable w/ terminal boot 50 72411 2 Footrest tread 53 3184 * 3 1/4 NC x 1-1/4 HHCS - GR5 1985 * 1 1/4 Standard lock washer 16 73714 1 Seat support channel 54 17 75520 1 Switch, toggle deck 55 78086 2 Battery bolt 18 71475 3 Bosch style relay 56 62155 * 2 5/16 NC x 2-3/4 HHCS - GR5 19 73542 * 8 #10-24 x 1/2 Hex head machine screw 57 6778 * 2 5/16 NC Hex lock nut 58 71314 1 Steering switch mount, left 20 35710 5 #10-24 Nylok nut 59 75105 2 Steering safety switch 21 75518 1 Console (SN 00001 - 00284) 60 75519 1 21 75567 1 Console (SN 00285 & Up) Console decal - FZ25D (SN 00001 - 00284) 22 75522 1 Temp gauge 60 75566 23 73173 1 Key switch, diesel 24 75525 1 Throttle cable, diesel (SN 00001 - 00284) 61 71313 62 78285 1 5/16 NC x 3/4 Button head screw 24 75565 1 Throttle cable, diesel (SN 00285 & Up) 63 75357 1 Ignition cap switch 64 75198 1 Panel nut 25 08841200 2 Indicator light 65 75546 1 Glide, felt 26 75197 1 Key 66 07511400 2 Bushing 27 73902 1 Hour meter 67 75258 2 Fitting, barb 3/16 - RETRUN 28 72262 1 PTO Switch Console decal - FZ25D (SN 00285 & Up) 1 Steering switch mount, right 68 07064500 2 Fitting, barb 5/16" w/screen 29 6096 * 7 5/16 NC x 3/4 HHCS - GR5 69 75560 1 Throttle bracket (SN 00001 - 00284) 30 2472 * 8 5/16 Standard lock washer NS -------- * 6 31 4378 * 10 5/16 Standard flat washer Screw, slotted #8 - 32 x .5 (used with throttle bracket) NS -------- * 6 Nut, self locking #8 - 32 (used with throttle bracket) 32 301300 * 4 1/4 NC x 3/4 Truss head bolt 33 72474 4 1/4-20 U-tapped spring nut 34 70070 2 3/8 x 3/4 Pin NS 75368 1 Decal, Woods 2 1/8 x 1/2 Cotter pin NS 75531 1 Decal, FZ25D 35 1326 * 36 70624 2 3/4 x 18GA Washer 37 71145 2 3/4 External retainer NS Not Shown HHCS Hex Head Cap Screw * Standard hardware, obtain locally (Rev. 6/8/2010) MAN0646 (Rev. 11/5/2007) Parts 33 FZ25D ENGINE ASSEMBLY 34 Parts (Rev. 1/9/2009) MAN0646 (Rev. 11/5/2007) FZ25D ENGINE ASSEMBLY PARTS LIST REF 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 18 18a 18b 18c 19 20 21 22 23 24 25 26 27 28 29 30 30 31 31 32 33 33 34 35 36 37 38 PART QTY 1 DESCRIPTION Kubota diesel engine (Spec No. 16447 - 15000) 70127 1 Oil filter 73432 1 Sheave adapter 75464 1 Front drive sheave 75399 1 Left front engine mount 75400 1 Right front engine mount 75401 1 Rear engine mount 75442 1 Muffler bracket 75490 1 Fuel stop solenoid 71406 1 Stub shaft weldment 73509 1 Clutch spacer 75465 1 Muffler (gasket sold separately) 75529 1 Muffler gasket 78048 1 Clutch shield 75460 1 Air intake hose 75212 1 Air cleaner 75215 1 Air filter - safety element 75214 1 Air filter - element only 75229 1 Rain hat, air filter 09079500 2 Hood latch 75454 1 Air cleaner mount 73672 1 Left hood support 70666 1 Fuel filter - element only 75448 1 Radiator 75509 1 Lower radiator hose 75510 1 Upper radiator hose 75462 1 Radiator screen (includes item # 27) 75463 1 Rubber flap 71087 1 Hose - tank overflow 71882 1 Hose - radiator overflow 72308 1 Expansion tank (SN 00001 - 00284) 75556 1 Expansion tank (SN 00285 & Up) 75451 1 Left radiator support (SN 00001 - 00284) 75555 1 Left radiator support (SN 00285 & Up) -------- * 1 Cable tie 75455 1 Radiator cowl (SN 00001 - 00284) 75564 1 Radiator cowl (SN 00285 & Up) 75450 1 Right radiator support 70659 1 Fuel pre-filter 73951 1 Fuel filter clamp 480263 * 4 1-1/2 Hose clamp -------- * 3 M8 x 1.25 x 15mm Flat head screw REF PART QTY DESCRIPTION 5/16 NC x 1 Socket head cap screw 5/16 Standard lock washer M10 x 1.25 x 20 mm HHCS CL 8.8 3/8 Standard lock washer M8 x 1.25 x 20 mm HHCS CL 8.8 M8 x 1.25 Hex nut 1/4 NC x 3/4 HHCS - GR5 1/4 NC Lock nut #10-24 x 1/2 Pan head machine screw 3/8 NC x 1/2 Hex flange head screw - GR5 1/4 NC x 1-1/2 HHCS - GR5 M8 x 1.25 x 15 mm Socket head cap screw 2” Hose clamp 1/4 Standard flat washer Clamp, throttle 1/4 NC Whiz nut Washer 1/4 x 7/8 x 1/8 Vibration isolator 1/2 NC x 3-1/4 HHCS - GR5 1/2 NC Hex lock nut 1/2 Flat washer M8 x 1.25 x 50 mm HHCS CL 8.8 M8 x 1.25 x 25 mm HHCS CL 8.8 5/16 NC x 1 Whiz bolt 5/16 NC x 1-3/4 HHCS GR5 1” Cushioned P-clip 3/8 NC x 1 Carriage bolt 3/8 NC Hex lock nut Sleeve, isolator Vibration isolator bushing Vibration isolator ring 5/16 Flat washer 1/4 Lock washer Cowl, rear Bracket, radiator Insulator, rubber 5/16 NC Hex nut Lug, Throttle cable (SN 00285 & Up) Throttle clamp #10 - 24 Nut 1/4 NC x 1/2 HHCS GR5 39 -------- * 3 40 41 42 43 44 47 48 50 2472 * -------- * 838 * 307125 * 30515 * 300057 * 6128 * -------- * 16 10 14 6 4 11 15 4 51 -------- * 4 52 53 15041 * -------- * 4 9 54 62259 * 55 5336 * 56 75461 58 70065 * 64 32806 65 73681 66 14069 * 67 765 * 68 3598 * 70 72885 * 71 30577 * 72 71632 73 4528 * 74 74060 75 15028 * 76 6698 * 77 78090 78 78088 79 78089 80 4378 * 81 1985 * 82 75449 83 75453 84 75530 85 4529 * 86 75563 87 06928000 88 -------- * 89 -------- * 2 8 1 2 4 4 4 4 4 1 3 2 1 2 1 1 2 2 2 1 1 1 2 1 1 1 2 HHCS Hex Head Cap Screw * Standard hardware, obtain locally (Rev. 1/9/2009) MAN0646 (Rev. 11/5/2007) Parts 35 HYDRAULIC RESERVOIR & HOSES 36 Parts (Rev. 8/22/2008) MAN0646 (Rev. 11/5/2007) HYDRAULIC RESERVOIR & HOSES PARTS LIST REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 1 75477 1 Hydraulic reservoir 16 315031 2 Adapter, 9/16 ORBM x 3/4 JICM 2 75489 1 Cap w/breather 17 62367 2 Elbow, 9/16 ORBM x 9/16 JIMCM 5 838 * 3 3/8 Lock washer 19 75481 1 Hose - Right, top pump front motor 20 75480 1 Hose - Right, bottom pump back motor 6 59077 * 3 3/8 NC Center lock nut 10 75527 1 Filter, hydraulic oil 11 61 4 Adapter, 3/4 JICM x 3/4 ORBM 21 75478 1 Hose - Left, top pump back motor 12 75482 1 Hose assembly - suction 22 75479 1 Hose - Left, bottom pump front motor 13 75483 1 Hose assembly - Case drain 15 316016 4 Adapter, 3/4 JICM x 7/8 ORBM * Standard hardware, obtain locally HYDRAULIC DIAGRAM MAN0646 (Rev. 11/5/2007) Parts 37 PTO, CLUTCH & PUMP ASSEMBLY 38 Parts MAN0646 (Rev. 11/5/2007) PTO CLUTCH & PUMP ASSEMBLY PARTS LIST REF PART 1 75397 2 75549 4 5 6 3886 * 78044 920 * QTY 1 DESCRIPTION REF Splined power shaft 24 PART QTY 6698 * 5 DESCRIPTION 3/8 NC Center lock nut 1 PTO sheave 25 31138 * 2 3/8 NC x 3-1/2 HHCS - GR5 1 Key 1/4 x 1-1/4 26 73416 2 Idler sleeve 2 1" Pillow block bearing w/set screw 27 75362 1 PTO Idler arm (includes item 42) 6 3/8 NC x 1-3/4 HHCS - GR5 31 75476 1 Sheave, pump idler 7 565 * 16 3/8 Flat washer 32 73826 2 Extension spring 8 838 * 10 3/8 Lock washer 33 75551 1 Spring lug 9 835 * 9 3/8 NC Hex nut 34 75402 1 Drive V-belt 10 -------- * 4 1/4 NF Socket head set screw 35 75543 1 Pump, Left 11 58567 * 2 90° Grease fitting 36 75538 2 Fan 12 73425 1 Bearing guard 37 73964 2 Key 5 mm x 25 mm 13 2457 * 10 1/4 NC x 3/4 HHCS - GR5 41 71156 1 3/8 NC x 6 Hook bolt 14 5336 * 74068 2 Bushing idler arm 4 1/4 Flat washer 42 15 70065 4 1/4 Whiz nut 44 75363 2 Collar set 16 73758 1 Cable, clutch stop 45 75194 2 Bushing, 17 mm 17 75507 1 Drive idler arm (includes item 42) 46 34440 1 Bushing, 1" 18 75403 2 Pump sheave 47 75360 1 Idler 19 74075 1 Electric clutch, mag-stop 1-1/8 48 75537 20 70355 1 13/32 x 1-1/2 Retaining washer 21 71724 1 3/8 NF x 1-1/4 HHCS - GR8 49 75542 1 Pump, right 22 78095 1 PTO V-belt set, matched 50 ----- 2 1/4 Lock washer 23 12169 * 1 3/8 NC x 1-1/4 HHCS - GR5 51 ----- * 1 3/8 NC x 1-1/2 HHCS, GR5 AR Seal kit, for hydraulic pump (items 35 & 49) AR As Required HHCS Hex Head Cap Screw * Standard hardware, obtain locally MAN0646 (Rev. 11/5/2007) Parts 39 SEAT & HOOD ASSEMBLY REF PART QTY DESCRIPTION REF 1 75406 1 Seat pan 23 2 75225 PART QTY -------- * DESCRIPTION 2 #10-24 x 1-1/2 SHCS #10-24 x 1/2 SHCS 2 Suspension seat 24 53110 * 4 4 4378 * 4 5/16 Flat washer 25 75273 — Kit, arm rest (LH and RH included) 5 FA220 * 4 5/16 Nylok nut 26 75501 — Kit, seat cushion 6 73581 2 Pivot bushing 27 75272 — Kit, seat back cushion 7 72410 1 Pivot rod 28 75275 — Kit, track 8 854 * 2 1/2 Flat washer 29 75505 — Arm pad 9 71630 * 2 1/8 x 3/4 Cotter pin 30 75502 1 Switch 10 78098 1 Prop rod 31 75503 1 Plunger Spring 11 07534100 1 Rod clip 32 75504 1 12 07533000 2 Rubber bumper 33 75532 — Trim lock, 41.25" 13 2 5/16 Center lock nut 34 1025871 6778 * — Knob, seat adjustment (NS) 17 75429 1 Hood weldment 35 75368 1 Decal, Woods (NS) 18 75524 2 Rubber cowl seal 36 75534 2 Decal, Mow’n Machine Diesel (NS) 19 73944 1 Foam cowl seal 20 15042 * 8 3/8 NC x 3/4 HHCS GR5 HHCS Hex Head Cap Screw 21 00932300 2 Foam seal 80" SHCS Socket Head Cap Screw 22 09079500 2 Hood latch 40 Parts NS Not Shown * Standard hardware, obtain locally (Rev. 8/22/2008) MAN0646 (Rev. 11/5/2007) TAILWHEEL ASSEMBLY Single Tailwheel Assembly REF PART 1 71126 2 73741 3 3585 4 3586 5 70328 6 70086 7 73818 8 05435700 9 3598 * QTY 1 DESCRIPTION Wide Stance Tailwheel Assembly REF PART QTY DESCRIPTION Pivot mount adapter 3 1 Pivot housing 4 3586 4 Bearing cone 2 Bearing cup 5 70328 2 Seal, 1.5 x 2 x .187 2 Bearing cone 6 70086 2 Spacer, .375 x 1 1 Seal, 1.5 x 2 x .187 7 73818 2 Wheel fork 1 Spacer, .375 x 1 8 05435700 1 Wheel fork 9 2 Bearing, 25 mm x 52 mm x 15 mm 10 2 1/2 Flat washer 11 3585 4 Bearing cup 4 Bearing, 25mm x 52mm x 15mm 4 1/2 Flat washer 07147800 2 Wheel & tire assembly, 15 x 6-6 09231800 2 Spacer - wheel 3598 * 10 07147800 1 Wheel and tire assembly, 15 x 6-6 12 2 1/2 NC Lock nut 11 09231800 1 Spacer - wheel 13 38107 2 1/2 NC x 9 HHCS 1 1/2 NC Lock nut 14 70417 2 Bushing washer 5849 2 3/4 NF Slotted hex nut 12 765 * 765 * 13 38107 1 1/2 NC x 9 HHCS 15 14 70417 1 Bushing washer 16 70332 2 Dust cap 15 5849 1 3/4 NF Slotted hex nut 17 64291 * 2 Cotter pin, 5/32 x 1 16 70332 1 Dust cap 21 839 * 4 3/8 NC x 1 HHCS GR5 17 64291 * 1 Cotter pin, 5/32 x 1 22 70336 1 Axle beam (includes item #24) 18 12915 * 4 3/8 NC x 4-1/2 HHCS GR5 23 73740 1 Rear axle pivot 19 838 * 4 3/8 Lock washer 24 74065 2 Oilite bushing 20 6698 * 2 3/8 NC Lock nut 25 70602 1 Washer, 1/2 x 2-1/4 21 920 * 2 3/8 NC x 1-3/4 HHCS GR5 26 1 1/2 Standard lock washer 2 Tailwheel spacer 27 22 78058 28 855 * 25475 838 * * MAN0646 (Rev. 11/5/2007) 1 1/2 NC x 1 HHCS full thread GR5 4 3/8 Lock washer Standard hardware, obtain locally Parts 41 BRAKE ASSEMBLY 42 Parts MAN0646 (Rev. 11/5/2007) BRAKE ASSEMBLY PARTS LIST REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 1 ----- -- See Tire & Wheel Chart Below 20 5651 * 8 5/16 NC x 5/8 HHCS - GR5 2 06541900 2 1 NF Hex patch lock nut 21 2472 * 8 5/16 Standard lock washer 3 73904 1 Brake assembly - RH (includes items 3A, 3C, 4, 5, 6, 7, 20, 21, 22) 22 5248 8 5/16 NC x 1-1/4 SHCS 23 2985 * 1 1/4-28 Tapered thread grease fitting 24 3145 * 6 3/32 x 1/2 Cotter pin or 3 73903 1 Brake assembly - LH (includes items 3B, 3C, 4, 5, 6, 7, 20, 21, 22) 3A 73972 1 Adjuster kit, Right hand (not shown) 3B 73973 1 Adjuster kit, Left hand (not shown) 3C 73974 1 Push rod assembly (not shown) 4 73948 2 Brake drum 5 73949 2 Spring repair kit 6 73939 2 7 75557 8 ---- * 25 3 Clevis pin 26 70024 3231 * 1 3/8 NC x 2 HHCS - GR5 27 12169 * 7 3/8 NC x 1-1/4 HHCS - GR5 28 6698 * 8 3/8 NC Hex lock nut 29 835 * 1 3/8 NC Hex nut 30 35709 * 2 #10-24 x 3/4 Pan head machine screw Shoe repair kit 31 35710 * 2 #10-24 Nylok nut 2 Adapter plate 32 4115 * 1 3/16 x 1-1/8 Spring pin 2 Key, Woodruff 3/16 x 1 33 6096 * 2 5/16 NC x 3/4 HHCS - GR5 9 73440 2 Brake actuator bar 34 6778 * 2 5/16 NC Hex lock nut 10 70022 3 Adjustable clevis 5/16 - 24 x 2.5 35 2 Wheel motor, 240CC 11 73829 1 Brake rod - RH 36 8 1/2 NC x 2 HHCS GR5 12 73439 1 Brake rod - LH 37 62149 * 1 5/16 NC Hex jam nut 13 74042 1 Brake pull 38 74043 1 5/16 NC x 2-1/2 Hex turnbuckle 14 73710 1 Brake actuator 39 74044 1 Lower link 15 01522000 1 Sintered bushing 40 1 5/16 Flat washer 16 73441 1 Parking brake lever 17 75393 1 Parking brake lever - Grip HHCS Hex Head Cap Screw 18 71148 1 Brake switch SHCS Socket Head Cap Screw 19 73943 10 Wheel bolt, 1/2 NF x 5/8 GR5 75487 3699 * 4378 * * Standard hardware, obtain locally TIRE & WHEEL CHART REF (Rev. 8/22/2008) MAN0646 (Rev. 11/5/2007) PART QTY DESCRIPTION 1 73955 2 23 x 10.50 Turf tire & wheel 1 78055 2 23 x 10.50 Knobby tire & wheel 1 74093 1 23 x 10.50 Chevron tire & wheel - Right 1 74097 1 23 x 10.50 Chevron tire & wheel - Left - 78068 - 12” Spoked drive wheel only - 75101 - 23 x 10.50-12 Turf tire only - 78070 - 23 x 10.50-12 Knobby tire only - 75102 - 23 x 10.50-12 Chevron tire only Parts 43 FZ25D WIRING DIAGRAM KUBOTA 44 Parts (Rev. 8/22/2008) MAN0646 (Rev. 11/5/2007) FZ25D WIRING DIAGRAM KUBOTA DIESEL REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION - 75499 1 FZ25D Wiring assembly 12 71385 * 1 Fuse - 30 Amp auto 1 73173 1 Ignition switch 13 71387 * 1 Fuse - 7.5 Amp auto - 75197 1 Ignition key 15 72314 1 Water temperature sender 2 08841200 2 Indicator light 17 75437 1 Timer delay 3 -------- * 1 Battery 12V, side post, group 70, 450500 CCA (obtain locally) 18 74079 1 Ground strap 4 73046 1 Diode assembly 19 75533 1 Cable, alternator-starter FZ25D 5 72262 1 PTO Switch 20 75521 1 Cable jumper 6 75105 1 Steering safety switch - right 21 75520 1 Switch, deck tilt - 71313 1 Right steering switch mount 22 75535 1 Fuse, 40 amp Auto 7 75105 1 Steering safety switch - left - 73888 1 - 71314 1 Left steering switch mount Positive battery cable w/ terminal boot 8 75502 1 Seat switch - 73887 1 Negative battery cable 9 73902 1 Hour meter 10 71475 3 Relay 11 71148 1 Brake switch (Rev. 6/8/2010) MAN0646 (Rev. 11/5/2007) 17A -------- * #10 x 7/16 Self tapping screw (NS) NS Not Shown * Standard hardware, obtain locally Parts 45 STEERING ASSEMBLY REF PART QTY DESCRIPTION REF 1 73023 2 Steering lever (includes items 5 & 6) 18 2 73030 2 Steering lever mount 20 3 73178 4 5/16 NC x 1.0 Whiz bolt 21 4 73163 4 5/16 NC Flanged lock nut 5 09246800 2 Foam handle grip 6 09211400 2 7 75458 8 9 PART QTY 2 Dampener 4 5/16 Standard lock washer 30515 4 M8 x 1.25P Hex nut 22 75511 2 Steering control link 23 33654 2 5/16 NF Jam nut Vinyl cap 24 08960700 2 5/16 NF RH Female rod end 1 Steering pivot - right 25 09107800 2 5/16 NF LH Female rod end 75459 1 Steering pivot - left 26 24408 * 4 5/16 NC x 1-1/2 HHCS, GR5 71323 8 1/2 Nylon bushing 27 4378 * 8 5/16 Standard flat washer 11 70423 2 Nylon washer 28 6778 * 4 5/16 NC Hex lock nut 12 72886 4 Nylon washer 31 4 2 1/2 SAE Washer 5/16 NC x 1-1/2 HHCS, GR5 full thread 2 Compression spring 4 5/16 NC Hex nut 4 1/2 NC Lock nut 13 14 15 3598 * 70162 765 * 32 75488 DESCRIPTION 2472 * -------4529 * * Standard hardware, obtain locally 46 Parts MAN0646 (Rev. 11/5/2007) COUNTERWEIGHT MOUNT KIT REF PART QTY DESCRIPTION A 70980 1 71063 1 Weight mount 2 71123 1 Weight strap 3 71156 2 .375-16 x 6” Hook bolt 4 3/8 NC x 1 HHCS 4 839 * Counterweight mount kit 5 66885 4 3/8 NC Flange nut 6 71512 ** 50 lb Counterweight A/R 7 565 * 2 3/8 Flat washer 8 838 * 2 3/8 Lock washer * Standard hardware, obtain locally NOTES: * Refer to counterweight requirement chart on page 15 to determine the amount of counterweight required for your mower and equipment. ** Not included in kit. As required. MAN0646 (Rev. 11/5/2007) Parts 47 HEADLIGHT KIT (OPTIONAL) REF PART QTY - DESCRIPTION A 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 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: Headlight power outlets are located near the steering pivot blocks. 48 Parts MAN0646 (Rev. 11/5/2007) BOLT TORQUE CHART 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. SAE Bolt Head Identification SAE SERIES TORQUE CHART A SAE Grade 2 (No Dashes) SAE Grade 8 (6 Radial Dashes) SAE Grade 5 (3 Radial Dashes) MARKING ON HEAD A SAE 2 SAE 5 SAE 8 Diameter (Inches) Wrench Size lbs-ft N-m lbs-ft N-m lbs-ft N-m 1/4" 5/16" 7/16" 1/2" 6 12 8 17 10 19 13 26 14 27 18 37 3/8" 7/16" 9/16" 5/8" 23 36 31 48 35 55 47 75 49 78 67 106 1/2" 9/16" 3/4" 13/16" 55 78 75 106 85 121 115 164 120 171 163 232 5/8" 3/4" 15/16" 1-1/8" 110 192 149 261 170 297 230 403 240 420 325 569 7/8" 1" 1-5/16" 1-1/2" 306 467 416 634 474 722 642 979 669 1020 907 1383 A METRIC SERIES TORQUE CHART A Metric Bolt Head Identification 8.8 Metric Grade 8.8 10.9 Metric Grade 10.9 COARSE THREAD FINE THREAD MARKING ON HEAD MARKING ON HEAD A Diameter & Thread Pitch (Millimeters) Wrench Size N-m lbs-ft N-m lbs-ft N-m lbs-ft N-m lbs-ft 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 10 x 1.5 13 mm 16 mm 20 39 15 29 27 54 20 40 21 41 16 30 29 57 22 42 8 x 1.0 10 x 1.25 12 x 1.75 14 x 2.0 18 mm 21 mm 68 109 50 80 94 151 70 111 75 118 55 87 103 163 76 120 12 x 1.25 14 x 1.5 16 x 2.0 18 x 2.5 24 mm 27 mm 169 234 125 172 234 323 173 239 181 263 133 194 250 363 184 268 16 x 1.5 18 x 1.5 20 x 2.5 22 x 2.5 30 mm 34 mm 330 451 244 332 457 623 337 460 367 495 270 365 507 684 374 505 20 x 1.5 22 x 1.5 24 x 3.0 30 x 3.0 36 mm 46 mm 571 1175 421 867 790 1626 583 1199 623 1258 459 928 861 1740 635 1283 24 x 2.0 30 x 2.0 Typical Washer Installations Bolt Metric 8.8 Lock Washer Metric 10.9 Metric 8.8 Metric 10.9 Flat Washer 8/9/00 Bolt Torque & Size Charts (Rev. 3/28/2007) Appendix 49 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 IN MM 5/8 3/4 7/8 1 2 3 4 5 6 7 25 50 75 100 125 150 175 Metric Bolt Thread Sizes 8MM 10MM 12MM 14MM 16MM 18MM 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 50 Appendix 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 Bolt Torque & Size Charts (Rev. 3/28/2007) INDEX ASSEMBLY Owner Pre-Operation Check List (Owner’s Responsibility) 16 27 Dealer Set-Up Instructions Practice Operation DEALER CHECK LISTS Safety Switch System 12 Delivery (Dealer’s Responsibility) 29 Pre-Delivery (Dealer’s Responsibility) DEALER SERVICE Belt Removal 24 Remove Components Engine Removal Uneven Terrain Operation 25 14 13 Weight Transfer 15 24 Counterweight Requirement Chart 24 Hydrostatic Pump & Belt Removal 23 Hydrostatic Pump Installation 23 Parking Brake Adjustment Cleaning Troubleshooting Engine 20 20 Engine Service 17 22 Change Engine Oil Troubleshooting Hydrostatic Pump No Positive Neutral Position 21 17 Check Engine Oil Level 21 Engine Coolant 21 Straight Line Travel 19 Clutch Burnishing 24 Solenoid Adjustment 17 17 Hydraulic Transmission - Change Oil & Filter Hydrostatic Transmission Service GENERAL 19 17 Lubrication Diagram 18 50 Lubrication Service Intervals Bolt Torque Chart 49 18 Return to Operation 20 4 Service Engine Introduction 2 Obtaining Replacement Manuals Product Registration 19 Lubrication Information Abbreviations 50 General Information 15 OWNER SERVICE Battery Service 24 Return to Operation 26 Bolt Size Chart 14 Stopping Engine 15 25 Reassemble Components Specifications 29 Steering Handle Positions 25 Install Clutch 13 Stop Mower or Attachment 13 Starting Engine 13 Steering Handle Operation 14 Start Mower or Attachment Steering Handle Operation Diagram Clutch Repair Align Belt 13 2 2 17 Tailwheel Maintenance 18 PARTS 4 Index to Parts Lists 31 Table of Contents 3 SAFETY Warranty - Product 53 Dealer Check Lists OPERATION Delivery (Dealer’s Responsibility) Brake & Temperature Lights 12 Cold Weather Starting Tips Controls & Switches 13 12 Manual Fuel Shut-Off Valve 15 Moving Disabled Tractor 15 Safety Symbols Explained (Rev. 11/5/2007) MAN0646 (7/6/2007) 29 Owner Pre-Operation Check List (Owner’s Responsibility) 16 9, 10 Safety Rules 5, 6, 7, 8 Hour Meter 12 29 Pre-Delivery (Dealer’s Responsibility) Safety Decals 2 Index 51 LIMITED WARRANTY Mow’n Machine Zero-Turn Mowers TM 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 MachineTM zero-turn mowers, attachments and accessories to be free from defect in material and workmanship for the warranty periods listed below. FOR HOW LONG: Mow’n Machine Model #CZ2242, CZ2252, CZ2461, CZ2361, MZ2552K, MZ2561K, MZ2661K, MZ3761K, MZ3772K, MZ2661KL & attachments are warranted for two (2) years from the date of delivery to the original purchaser or 2000 hours of operation, whichever occurs first. Purchaser may opt for a warranty of five (5) years from the date of delivery to the original purchaser or 500 hours of operation, whichever occurs first. The dealer must specify the special warranty term on the original, dated bill of sale and a copy must be provided with all warranty claims. Mow’n Machine model numbers CZR2242B and CZR2652B are warranted for residential use for three (3) years from the date of delivery to the original purchaser or for commercial use for 90 days from the date of delivery to the original purchaser. Mow’n Machine Model #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. In addition, Mow’n Machine ME and MZ Series Models, serial number XXXXXXXX300 and above, have a Limited Lifetime Warranty on deck, deck cradle, and engine deck for the life of the machine to the original retail purchaser. 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: Woods Equipment Company 2606 South Illinois Route 2 Post Office Box 1000 Oregon, Illinois 61061 800-319-6637 tel 800-399-6637 fax www.WoodsEquipment.com F-8045 MM (Rev. 2/11/2011) LIMITED WARRANTY (Mow’n Machine Zero-Turn Mower Replacement Parts) TM Woods Equipment Company (“WOODS”) warrants replacement parts for Mow’n Machine 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. TM 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: ©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) Woods Equipment Company 2606 South Illinois Route 2 Post Office Box 1000 Oregon, Illinois 61061 USA 800-319-6637 tel 800-399-6637 fax www.WoodsEquipment.com ©2007 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.
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