ROTARY CUTTER
DS96
DS120
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TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY VIDEO ORDER FORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DEALER CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INDEX TO PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . INSIDE BACK COVER
REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . . . . . . . .BACK COVER
(Rev. 4/6/2007)
MAN0390 (Rev. 6/30/2006)
Introduction 3
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SPECIFICATIONS
DS96
DS120
2" - 15"
120"
127"
40 - 120
540
Cutting Height (varies with tire selection)
Cutting Width
2" - 15"
96"
Overall Width
103"
40 - 120
540
Tractor HP
Tractor PTO rpm
Blade Spindle
2
2
Blade Overlap
4"
4"
Number of Blades
4
4
Center Driveline with Slip Clutch
Side Frame Thickness
Weight - Pull-Type (approximate lbs.)
Blade Speed (feet per minute)
Blade Rotation
Cat 4
7 ga
1,800
15,900
Cat 4
7 ga
1,930
16,700
Left Spindle: CCW; Right Spindle: CW
Wheel Size
15" Rims or 21" OD Solid Tires
22" or 29" Used Aircraft Tires
Torsion Protection
Slip Clutch and Flex Couplers
GENERAL INFORMATION
may be general in nature due to unknown and varying
operating conditions. However, through experience
and these instructions, you should be able to develop
procedures suitable to your particular situation.
ꢀ 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 illustrations and data used in this manual were cur-
rent 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.
The purpose of this manual is to assist you in operating
and maintaining your cutter. Read it carefully. It fur-
nishes 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
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. Blade rotation is clockwise (right) and counter-
clockwise (left) as viewed from the top of the cutter.
MAN0390 (Rev. 6/30/2006)
4 Introduction
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Safety Video Order Form
BE SAFE!
BE ALERT!
BE ALIVE!
BE TRAINED
Before Operating Mowers!
Safety Training
Does Make a Difference.
ASSOCIATION OF
EQUIPMENT
MANUFACTURERS
Free Mower Safety Video
Fill out and return the order form and we will send you a FREE VHS
or DVD video outlining Industrial and Agricultural Mower Safety
Practices. The 22 minute video, developed in cooperation with
AEM (Association of Equipment Manufacturers), reinforces the
proper procedures to follow while operating your mowing
equipment. The video does not replace the information contained in
the Operator’s Manual, so please review this manual thoroughly
before operating your new mowing equipment.
Safety Video Order Form (8/2/2005)
Safety 5
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Also, available from the Association of Equipment Manufacturers:
A large variety of training materials (ideal for groups) are available for a nominal
charge from AEM. Following is a partial list:
● Training Package for Rotary Mowers/Cutters-English
Contains: DVD & VHS (English)
Guidebook for Rotary Mowers/Cutters (English)
AEM Industrial/Agricultural Mower Safety Manual (English)
AEM Agricultural Tractor Safety Manual (English)
● Training Package for Rotary Mowers/Cutters-English/Spanish
Contains: DVD & VHS (English/Spanish)
Guidebook for Rotary Mowers/Cutters (English/Spanish)
AEM Industrial/Agricultural Mower Safety Manual (English/Spanish)
AEM Agricultural Tractor Safety Manual (English/Spanish)
AEM training packages are available through:
AEM at: www.aem.org
or
Universal Lithographers, Inc.
Email: [email protected]
800-369-2310 tel
866-541-1668 fax
ꢁ
Free Mower/Cutter Safety Video Order Form
3 (Select one)
VHS Format - VHS01052 Safety Video
DVD Format - DVD01052 Safety Video
ꢀ
ꢀ
Please send me
Name: ________________________________________ Phone: __________________
Address: _____________________________________
_____________________________________
_____________________________________
Mower/Cutter Model: ______________________ Serial #: ________________________
Send to:
ATTENTION: DEALER SERVICES
WOODS EQUIPMENT COMPANY
PO BOX 1000
OREGON IL 61061-1000
USA
Safety Video Order Form (Rev. 2/6/2006)
6 Safety
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SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
PREPARATION
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.
ꢀ Check that all hardware is properly installed.
Always tighten to torque chart specifications
unless instructed otherwise in this manual.
In addition to the design and configuration of
ꢀ Air in hydraulic systems can cause erratic oper-
ation and allows loads or equipment components
to drop unexpectedly. When connecting equipment
or hoses or performing any hydraulic maintenance,
purge any air in hydraulic system by operating all
hydraulic functions several times. Do this before
putting into service or allowing anyone to
approach the equipment.
equipment, hazard control and accident preven-
tion are dependent upon the awareness, con-
cern, judgement, and proper training of
personnel involved in the operation, transport,
maintenance, and storage of equipment.
It has been said, “The best safety device is an
informed, careful operator.” We ask you to be
that kind of operator.
ꢀ Make sure all hydraulic hoses, fittings, and
valves are in good condition and not leaking before
starting power unit or using equipment. Check and
route hoses carefully to prevent damage. Hoses
must not be twisted, bent sharply, kinked, frayed,
pinched, or come into contact with any moving
parts. Operate moveable components through full
operational range to check clearances. Replace
any damaged hoses immediately.
TRAINING
ꢀ Safety instructions are important! Read all
attachment and power unit manuals; follow all
safety rules and safety decal information. (Replace-
ment manuals and safety decals are available from
your dealer. To locate your nearest dealer, check
or in the United States and Canada call 1-800-319-
6637.) Failure to follow instructions or safety rules
can result in serious injury or death.
ꢀ 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.
ꢀ 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.
ꢀ Make sure attachment is properly secured,
adjusted, and in good operating condition.
ꢀ Operators must be instructed in and be capable
of the safe operation of the equipment, its attach-
ments, and all controls. Do not allow anyone to
operate this equipment without proper instruc-
tions.
ꢀ Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO
spline groove.
ꢀ If equipped with driveline guard tether chains,
make sure they are attached to the tractor and
equipment as shown in the pamphlet that accom-
panies the driveline. Replace if damaged or broken.
Check that driveline guards rotate freely on drive-
line before putting equipment into service.
ꢀ Keep hands and body away from pressurized
lines. Use paper or cardboard, not hands or other
body parts to check for leaks. Wear safety goggles.
Hydraulic fluid under pressure can easily penetrate
skin and will cause serious injury or death.
ꢀ Make sure that all operating and service person-
nel know that if hydraulic fluid penetrates skin, it
must be surgically removed as soon as possible by
a doctor familiar with this form of injury or gan-
grene, serious injury, or death will result. CON-
TACT A PHYSICIAN IMMEDIATELY IF FLUID
ENTERS SKIN OR EYES. DO NOT DELAY.
ꢀ Power unit must be equipped with ROPS or
ROPS cab and seat belt. Keep seat belt securely
fastened. Falling off power unit can result in death
from being run over or crushed. Keep foldable
ROPS system in “locked up” position at all times.
ꢀ Inspect chain shielding before each use.
Replace if damaged.
ꢀ Never allow children or untrained persons to
operate equipment.
(Safety Rules continued on next page)
DS96-DS120 Safety Rules (Rev. 5/11/2007)
Safety 7
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SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
(Safety Rules continued from previous page)
ꢀ Keep hands, feet, hair, and clothing away from
equipment while engine is running. Stay clear of all
moving parts.
ꢀ Remove accumulated debris from this equip-
ment, power unit, and engine to avoid fire hazard.
ꢀ Always comply with all state and local lighting
and marking requirements.
ꢀ Make sure all safety decals are installed.
Replace if damaged. (See Safety Decals section for
location.)
ꢀ Never allow riders on power unit or attachment.
ꢀ Power unit must be equipped with ROPS or
ROPS cab and seat belt. Keep seat belt securely
fastened. Falling off power unit can result in death
from being run over or crushed. Keep foldable
ROPS system in “locked up” position at all times.
ꢀ Make sure shields and guards are properly
installed and in good condition. Replace if dam-
aged.
ꢀ Do not put this equipment into service unless all
side skids are properly installed and in good condi-
tion. Replace if damaged.
ꢀ Always sit in power unit seat when operating
controls or starting engine. Securely fasten seat
belt, place transmission in neutral, engage brake,
and ensure all other controls are disengaged
before starting power unit engine.
ꢀ A minimum 20% of tractor and equipment
weight must be on the tractor front wheels when
attachments are in transport position. Without this
weight, front tractor wheels could raise up result-
ing in loss of steering. The weight may be attained
with front wheel weights, ballast in tires or front
tractor weights. Weigh the tractor and equipment.
Do not estimate.
ꢀ Operate tractor PTO at 540 RPM. Do not exceed.
ꢀ Look down and to the rear and make sure area
is clear before operating in reverse.
ꢀ Do not operate or transport on steep slopes.
ꢀ Do not stop, start, or change directions sud-
denly on slopes.
ꢀ Inspect and clear area of stones, branches, or
other hard objects that might be thrown, causing
injury or damage.
ꢀ Use extreme care and reduce ground speed on
slopes and rough terrain.
OPERATION
ꢀ Watch for hidden hazards on the terrain during
operation.
ꢀ Full chain or rubber shielding must be installed
when operating in populated areas or other areas
where thrown objects could injure people or dam-
age property.
ꢀ Stop power unit and equipment immediately
upon striking an obstruction. Turn off engine,
remove key, inspect, and repair any damage before
resuming operation.
• If this machine is not equipped with full chain
or rubber shielding, operation must be stopped
when anyone comes within 300 feet (92 m).
ꢀ Leak down or failure of mechanical or hydraulic
system can cause equipment to drop.
• This shielding is designed to reduce the risk
of thrown objects. The mower deck and protec-
tive devices cannot prevent all objects from
escaping the blade enclosure in every mowing
condition. It is possible for objects to ricochet
and escape, traveling as much as 300 feet (92 m).
ꢀ On pull-type or semi-mounted units with
optional hydraulic cutting height adjustment, use a
single-acting cylinder with a maximum extended
length of 28-1/4" (718 mm) from attaching point
center to center.
ꢀ On mounted units with optional hydraulic cut-
ting height adjustment, use a double-acting cylin-
der with a maximum extended length of 28-1/4"
(718 mm) from attaching point center to center.
ꢀ Do not allow bystanders in the area when oper-
ating, attaching, removing, assembling, or servic-
ing equipment.
ꢀ Never direct discharge toward people, animals,
or property.
TRANSPORTATION
ꢀ The maximum transport speed for towed and
semi-mounted machines is 20 mph (32 km/h).
Regardless of the maximum speed capability of the
towing tractor, do not exceed the implement’s max-
ꢀ Do not operate or transport equipment while
under the influence of alcohol or drugs.
ꢀ Operate only in daylight or good artificial light.
8 Safety
DS96-DS120 Safety Rules (Rev. 5/11/2007)
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SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
imum transport speed. Doing so could result in:
ꢀ Never go underneath equipment (lowered to the
ground or raised) unless it is properly blocked and
secured. Never place any part of the body under-
neath equipment or between moveable parts even
when the engine has been turned off. Hydraulic
system leak down, hydraulic system failures,
mechanical failures, or movement of control levers
can cause equipment to drop or rotate unexpect-
edly and cause severe injury or death. Follow Oper-
ator's Manual instructions for working underneath
and blocking requirements or have work done by a
qualified dealer.
• Loss of control of the implement and tractor
• Reduced or no ability to stop during braking
• Implement tire failure
• Damage to the implement or its components.
ꢀ Use additional caution and reduce speed when
under adverse surface conditions, turning, or on
inclines.
ꢀ Do not operate PTO during transport.
ꢀ Never tow this implement with a motor vehicle.
ꢀ Do not operate or transport on steep slopes.
ꢀ Make sure attachment is properly secured,
adjusted, and in good operating condition.
ꢀ Do not operate or transport equipment while
under the influence of alcohol or drugs.
ꢀ Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
ꢀ Always comply with all state and local lighting
and marking requirements.
ꢀ Never allow riders on power unit or attachment.
ꢀ
Make certain all movement of equipment com-
ponents has stopped before approaching for ser-
vice.
MAINTENANCE
ꢀBefore dismounting power unit or performing
any service or maintenance, follow these steps:
disengage power to equipment, lower the 3-point
hitch and all raised components to the ground,
operate valve levers to release any hydraulic pres-
sure, set parking brake, stop engine, remove key,
and unfasten seat belt.
ꢀ 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.
ꢀ Before performing any service or maintenance,
disconnect driveline from tractor PTO.
ꢀ 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.
ꢀ Before working underneath, raise mower, install
transport lock, and block mower securely. Hydrau-
lic system leak down and failure of mechanical or
hydraulic system can cause equipment to drop.
ꢀ Make sure all safety decals are installed.
Replace if damaged. (See Safety Decals section for
location.)
ꢀ Do not modify or alter or permit anyone else to
modify or alter the equipment or any of its compo-
nents in any way.
ꢀ Make sure shields and guards are properly
installed and in good condition. Replace if dam-
aged.
ꢀ Your dealer can supply original equipment
hydraulic accessories and repair parts. Substitute
parts may not meet original equipment specifica-
tions and may be dangerous.
ꢀ Do not disconnect hydraulic lines until machine
is securely blocked or placed in lowest position
and system pressure is released by operating
valve levers.
ꢀ 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.
ꢀ Leak down or failure of mechanical or hydraulic
system can cause equipment to drop.
ꢀ Explosive separation of tire and rim parts can
cause serious injury or death. Release all air pres-
sure before loosening bolts on wheel.
ꢀ Do not allow bystanders in the area when oper-
ating, attaching, removing, assembling, or servic-
ing equipment.
DS96-DS120 Safety Rules (Rev. 5/11/2007)
Safety 9
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SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
inder. Disconnect cutter from tractor 3-point hitch
and carefully drive tractor away from cutter.
STORAGE
ꢀ Keep children and bystanders away from stor-
age area.
ON PULL-TYPE CUTTERS:
ꢀ Follow manual instructions for storage.
ꢀ Raise cutter and block securely. Block wheels
and raise tongue with jack. Disconnect hydraulic
lines to optional cylinder. Disconnect driveline and
secure up off the ground.
On mounted and semi-mounted cutters:
ꢀ Disconnect cutter driveshaft and secure up off
ground. Raise cutter with 3-point hitch. Place
blocks under cutter side skids. Lower cutter onto
blocks. Disconnect hydraulic lines to optional cyl-
ꢂ
10 Safety
DS96-DS120 Safety Rules (Rev. 5/11/2007)
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SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
1 - SERIAL NUMBER PLATE
4 - PN 1003751
WARNING
MODEL NO.
SERIAL NO.
Woods Equipment Company
Oregon, Illinois, U.S.A.
CRUSHING AND PINCHING HAZARD
ꢀ Be extremely careful handling various parts of
the machine. They are heavy and hands, fingers,
feet, and other body parts could be crushed or
pinched between tractor and implement.
2 - PN 5669
ꢀ Operate tractor controls from tractor seat only.
ꢀ Do not stand between tractor and implement
when tractor is in gear.
ꢀ Make sure parking brake is engaged before
going between tractor and implement.
3 - PN 12777
ꢀ Stand clear of machine while in operation or
when it is being raised or lowered.
FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN
SERIOUS INJURY OR DEATH.
1003751-A
(Safety Decals continued on next page)
MAN0390 (Rev. 6/30/2006)
Safety 11
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SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
(Safety Decals continued from previous page)
8 - PN 18865
5 - PN 18864
WARNING
DANGER
FALLING OFF CAN RESULT IN BEING RUN OVER.
ROTATING DRIVELINE
„
Tractor must be equipped with ROPS (or ROPS CAB) and seat
belt. Keep foldable ROPS systems in “locked up” position at all
times.
CONTACT CAN CAUSE DEATH
„
„
Buckle Up! Keep seat belt securely fastened.
Allow no riders.
KEEP AWAY!
DO NOT OPERATE WITHOUT -
RAISED EQUIPMENT CAN DROP AND CRUSH.
„
ꢀ All driveline guards, tractor and
equipment shields in place
Before working underneath, follow all instructions and safety rules in
operator’s manual and securely block up all corners of equipment
with jack stands.
ꢀ Drivelines securely attached at both ends
„
Securely blocking prevents equipment dropping from hydraulic leak-
down, hydraulic system failures or mechanical component failures.
ꢀ Driveline guards that turn freely on
driveline
FALLING OFF OR FAILING TO BLOCK SECURELY CAN
18864-C
RESULT IN SERIOUS INJURY OR DEATH.
18865--C
6 - PN 18866
9 - PN 15503
WARNING
DANGER
540 RPM
18866-D
ROTATING BLADES AND
THROWN OBJECTS
7 - PN 18877
ꢀDo not put hands or feet under or into mower when
engine is running.
WARNING
TO AVOID SERIOUS
INJURY OR DEATH:
ꢀBefore mowing, clear area of objects that may be
thrown by blade.
ꢀKeep bystanders away.
ꢀ
ꢀ
Read Operator's Manual (available
from dealer) and follow all safety
precautions.
ꢀKeep guards in place and in good condition.
BLADE CONTACT OR THROWN OBJECTS CAN
CAUSE SERIOUS INJURY OR DEATH.
15503-C
Keep all shields in place and in good
condition.
ꢀ Operate mower from tractor seat only.
ꢀ Lower mower, stop engine and remove
key before dismounting tractor.
ꢀ Allow no children or untrained persons
to operate equipment.
10 - PN 1002940
AMBER REFLECTOR 9"
12 - PN 1004114
ꢀ Do not transport towed or
semi-mounted units over 20 mph.
DANGER
11 - PN 57123
RED REFLECTOR 9"
If shaft connection is visible, shield
is missing. Replace shield before
operating equipment.
FAILURE TO OPERATE SAFELY
CAN RESULT IN
INJURY OR DEATH.
1004114
18877-C
12 Safety
MAN0390 (Rev. 6/30/2006)
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SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
13 - PN 1004991
TRANSPORT LOCK
AND CYLINDER
REQUIREMENTS
WARNING
Cutters must be equipped with transport lock.
RAISED CUTTER CAN DROP AND CRUSH
SINGLE-ACTING FULL
EXTENSION
stands.
ꢀAll transport components must be functional, kept in good
ꢀBlocking up prevents cutter dropping from hydraulic leak down,
hydraulic system failures, or mechanical component failures.
TRANSPORT
LOCK
FAILURE TO FOLLOW INSTRUCTIONS CAN
RESULT IN SERIOUS INJURY OR DEATH.
1004991
14 - PN 19924
16 - PN 33347
WARNING
Check for leaks with cardboard; never use hand.
Before loosening fittings: lower load, release pressure, and
be sure oil is cool.
Consult physician immediately if skin penetration occurs.
19924-B
PN 1006348
33347E
BE CAREFUL!
17 - PN 24611
SLOW MOVING VEHICLE EMBLEM
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
States and Canada call 1-800-319-6637.
(Rev. 5/11/2007)
MAN0390 (Rev. 6/30/2006)
Safety 13
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OPERATION
The operator is responsible for the safe operation of
TRACTOR STABILITY
the cutter. The operator must be properly trained.
Operators should be familiar with the cutter, the tractor,
and all safety practices before starting operation. Read
the safety rules and safety decals on page 7 to page
13.
ꢀ A minimum 20% of tractor and equipment
weight must be on the tractor front wheels when
attachments are in transport position. Without this
weight, front tractor wheels could raise up result-
ing in loss of steering. The weight may be attained
with front wheel weights, ballast in tires or front
tractor weights. Weigh the tractor and equipment.
Do not estimate.
This medium-duty cutter is designed for grass and
weed mowing and shredding.
Recommended mowing speed for most conditions is
from 2 to 5 mph.
ꢀ Full chain or rubber shielding must be installed
when operating in populated areas or other areas
where thrown objects could injure people or dam-
age property.
• If this machine is not equipped with full chain
or rubber shielding, operation must be stopped
when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk
of thrown objects. The mower deck and protec-
tive devices cannot prevent all objects from
escaping the blade enclosure in every mowing
condition. It is possible for objects to ricochet
and escape, traveling as much as 300 feet (92 m).
Figure 1. Tractor Stability
CONNECT CUTTER TO TRACTOR
(PULL-TYPE)
NOTICE
■
The horizontal distance between the end of the
tractor PTO shaft and the drawbar hitch point
should be 14" for 540 RPM cutters. This distance
must not vary more than plus or minus (1") or the
drive may be damaged when turning.
ꢀ Never allow riders on power unit or attachment.
ꢀ Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO
spline groove.
1. Adjust tractor drawbar to obtain the desired
drawbar hitch point distance.
ꢀ Operate tractor PTO at 540 RPM. Do not exceed.
NOTE: On some tractors, a drawbar kit must be
used to obtain the required dimension. Check with
your tractor dealer for assistance.
ꢀ Do not allow bystanders in the area when oper-
ating, attaching, removing, assembling, or servic-
ing equipment.
2. Install tractor drawbar bracket to the tractor
ꢀ Stop power unit and equipment immediately
upon striking an obstruction. Turn off engine,
remove key, inspect, and repair any damage before
resuming operation.
drawbar using cap screw and hex nut.
3. Attach parking jack to cutter tongue. Raise tongue
to tractor drawbar height.
4. Place special heat-treated washer between cutter
CAUTION
tongue and drawbar.
ꢀ 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.
5. Secure cutter to tractor drawbar with a high-
strength drawbar pin 3/4" or larger. Keep pin in
place during operation.
6. Attach safety tow chain to drawbar support. Leave
enough slack for turning.
(Rev. 2/6/2009)
14 Operation
MAN0390 (Rev. 6/30/2006)
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7. Connect cutter driveline to tractor PTO shaft,
making sure the spring-activated lock pin slides
freely and is seated in tractor PTO splined groove.
Tractor Adjustments
Before attaching tractor to cutter, install sway blocks or
sway chains, or adjust stabilizer bars. Refer to the trac-
tor operator's manual for instructions.
8. Remove parking jack from the tongue and attach it
to the storage post on the front of the cutter.
Install tractor front end weights as recommended by
the tractor manufacturer to provide 20% of weight on
front wheels.
9. Adjust H-frame bearing height so that the front
driveline is parallel to the ground. Secure with 5/8 x
5-21/32 clevis pin and 3/16 x 1-1/2 cotter pin.
10. Attach drive shaft shield to bearing housing using
DS96 Category 2 Standard Hitch
two 3/8 x 1 cap screws and 3/8 lock washers.
1. Position the tractor 3-point lower lift arms over the
hitch pins and secure with 7/16 klik pins.
Hydraulic Connection
2. Connect the tractor top link to the cutter A-frame
using the upper holes and 1" OD sleeve. The break
link must be placed in the lower holes of the A-
frame. See Figure 2.
1. Inspect hydraulic hoses to ensure they are in good
condition.
2. Clean the fittings before connecting them to the
tractor hydraulic ports.
3. Attach the hydraulic hose to the tractor.
4. Route the hose through the hose holder at the
hitch and be sure the hose can slide freely in the
holder. Do not allow hose slack to drag on the
ground or become caught on tractor protrusions.
5. From the operator position, start tractor and raise
and lower deck several times to purge trapped air
from the hydraulic cylinder.
Figure 2. DS96 Cat. 2 Standard Hitch Connection
DS96 Category 2 Quick Hitch
Interference Check
An optional Category 2 quick coupler kit (24845) is
available for DS96 cutters.
1. Be sure that tractor 3-point lift links do not interfere
with hydraulic hoses, cutter driveline, or cutter
frame.
DS120 Category 2 Standard Hitch
2. Check for straight-ahead operation and at full-
turning angles. If there is any interference, remove
the lower lift links.
1. Position the tractor 3-point lower lift arms between
the hitch mast plates and secure with hitch pins
and 7/16 klik pins. Note the hitch pins orientation.
3. Contact between tractor lift links and cutter parts
can cause damage, especially when turning.
2. Connect the tractor top link to the cutter A-frame
using the upper holes and 1" OD sleeve. The break
link must be placed in the lower holes of the A-
frame. See Figure 3.
CONNECT CUTTER TO TRACTOR
(MOUNTED)
ꢀ A minimum 20% of tractor and equipment
weight must be on the tractor front wheels when
attachments are in transport position. Without this
weight, front tractor wheels could raise up result-
ing in loss of steering. The weight may be attained
with front wheel weights, ballast in tires or front
tractor weights. Weigh the tractor and equipment.
Do not estimate.
Figure 3. DS120 Cat. 2 Standard Hitch Connection
(Rev. 2/6/2009)
MAN0390 (Rev. 6/30/2006)
Operation 15
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DS120 Category 2 Quick Hitch
1. Position the hitch pins as shown in Figure 4.
2. Attach tractor with quick hitch to cutter and secure
according
to
quick
hitch
manufacturer’s
instructions.
Figure 6. DS120 Category 3 Quick Hitch Connection
Hydraulic Connection (DS120 Only)
1. Inspect hydraulic hoses to ensure they are in good
condition.
2. Clean the fittings before connecting them to the
tractor hydraulic ports.
Figure 4. DS120 Category 2 Quick Hitch Connection
3. Route hoses through hose holder on 3-point mast.
Be sure hoses can slide freely in holder. Do not
allow hose slack to drag on the ground or become
caught on tractor protrusions.
DS120 Category 3 Standard Hitch
1. Position the tractor 3-point lower lift arms between
the hitch mast plates and secure with hitch pins
and 7/16 klik pins. Note the hitch pins orientation.
DRIVELINE ATTACHMENT
Attach the cutter to the tractor 3-point hitch (or quick
hitch if available). Do not attach driveline. Raise and
lower cutter to determine maximum and minimum dis-
tance between the tractor PTO shaft and the gearbox
input shaft. If the distance is too large, the driveline will
be too short for proper engagement. If distance is too
small, the driveline may bottom out in operation and
damage the cutter or tractor.
2. Connect the tractor top link to the cutter A-frame
using the upper holes and 1-1/4" OD sleeve. The
break link must be placed in the lower holes of the
A-frame. See Figure 5.
Driveline length must be sufficient to provide at least
1/3 driveline length of engagement during operation.
There must be at least 4 inches of engagement at the
cutters lowest possible point of operation. The driveline
must not bottom out when raised to the maximum
height possible.
If driveline is too short please call your Woods dealer
for a longer driveline.
Figure 5. DS120 Cat. 3 Standard Hitch Connection
If driveline is too long please follow the instructions for
shortening the driveline.
DS120 Category 3 Quick Hitch
SHORTEN DRIVELINE
1. Position the hitch pins as shown in Figure 6.
1. Move cutter up and down to get the shortest
possible distance between tractor PTO shaft and
gearbox input shaft.
2. Place break link and 1-1/4" OD sleeve in the top
hole of the A-frame and secure.
2. Separate driveline into two halves and connect
them to the tractor PTO and gearbox.
3. Attach tractor with quick hitch to cutter and secure
according
to
quick
hitch
manufacturer’s
3. Place driveline halves parallel to one another to
instructions.
determine how much to shorten the driveline.
(Rev. 2/6/2009)
16 Operation
MAN0390 (Rev. 6/30/2006)
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6. Place the cutoff portion of the shield against the
end of the shaft and use as a guide. Mark and cut
the shaft.
Figure 7. Drive Halves Placed Parallel
4. Measure from end of the upper shield to the base
of the bell on the lower shield (A). Add 1-9/16" to
dimension (A). See Figure 8.
Figure 10. Cut Shaft to Length
7. Repeat step 6 for the other half of the drive.
8. File and clean cut ends of both drive halves.
Do not use tractor if proper driveline engagement can-
not be obtained through these methods.
A
Connect driveline to tractor PTO shaft, making sure the
spring-activated locking collar slides freely and locks
driveline to PTO shaft.
1-9/16"
NOTICE
■
If attaching with quick hitch the distance
between the tractor PTO and gearbox input shaft
will increase. Please follow the steps as you would
for a 3-point hitch to insure proper engagement.
DRIVELINE INTERFERENCE CHECK
Figure 8. Determine Shield Length
1. Check for clearance between driveline and cutter
5. Cut the shield to the overall dimension.
deck.
2. Slowly lift cutter and observe driveline. If clearance
between driveline and cutter deck is less than 1
inch, shorten top link or limit upper travel of lower
hitch arms. Refer to tractor operator's manual for
instructions.
CUTTING HEIGHT ADJUSTMENT
ꢀ On pull-type units with optional hydraulic cut-
ting height adjustment, use a single-acting cylinder
with a maximum extended length of 28-1/4" (718
mm) from attaching point center to center.
Cutting height range is from 2" to 15". A hydraulic cylin-
der or ratchet jack is available for cutting height adjust-
Figure 9. Cut Shield
(Rev. 2/6/2009)
Operation 17
MAN0390 (Rev. 6/30/2006)
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ment on pull-type units and DS120 mounted units.
DS96 requires manual adjustment using holes in the
tailwheel arms.
DS120 - Using any of the optional height adjustment
devices, raise or lower the tailwheel to obtain 2-1/2 to
2-3/4 inches at position B.
Adjust top link to provide 2 inches of clearance
between the break link (2) and the rear lift links. See
Figure 11. This clearance will allow the cutter to float
over uneven terrain.
When selecting a cutting height, you should consider
the area of operation. If the ground is rolling and has
mounds the blades could contact, set the cutting height
accordingly.
ATTITUDE ADJUSTMENT (PULL-TYPE)
Normal Mowing
NOTICE
■
Avoid ground contact with blades. Striking
ground with blades produces one of the most dam-
aging shock loads a cutter can encounter. If this
occurs repeatedly, the cutter, driveline, and gear-
boxes will be damaged.
For the most economical power use and best cutting
results, the cutter should be from 1/2" to 3/4" higher at
the rear than at the front.
For grass and weed mowing, adjust cutter to run level
or with the front slightly lower.
The blade cutting edge is approximately 1-3/4 inches
above the bottom of the skid shoes.
Shredding
Pull-Type Units
For shredding, it is better to set rear of cutter slightly
lower than the front. How much lower depends on the
material to be shredded. Determine the best setting for
your situation by experimenting. Use a slow ground
speed for better shredding.
To adjust cutter for normal mowing, select a cutting
height (example: 4-inches).
Using any of the optional cutting height mechanisms,
raise or lower the tailwheel and set position A to 2-1/4
inches. Loosen the jam nut on the attitude rod that runs
from the tongue to the tailwheel. Adjust rod in or out
until position B is approximately 1/4 to 1/2 inches more
than position A. Refer to Figure 11.
DRIVELINE ADJUSTMENT (PULL-TYPE)
With the cutting height established, adjust the driveline
carrier bearings in the H-frames so that the front drive-
line is parallel to the ground with cutter in cutting posi-
tion.
WHEEL SPACING (DS120 ONLY)
Wheels may be adjusted to any position for row crop
shredding.
BLADE SELECTION
There are two blade options: standard suction blades
and flat double-edge blades.
Figure 11. Cutting Height Adjustment
The standard suction blade is a general use, multi-pur-
pose blade.
Mounted Units
The double-edge blade requires less power because it
does not mulch or recut material. It is designed for use
in areas where blade wear is a problem. Sandy soils
are extremely hard on blades.
To adjust cutter for normal mowing, select a cutting
height (example: 4").
Adjust tractor 3-point hitch to obtain a distance of 2-1/4
inches at position A. See Figure 11.
Blade rotation, viewed from top of cutter, is clockwise
for the right crossbar, and counter-clockwise for the left
crossbar.
DS96 - Using the various holes in the tailwheel arms,
align the tailwheel brace with tailwheel arm to obtain a
distance greater than 2-1/4 inches at position B.
When one cutting surface of a double-edge blade is
worn, the opposite one may be used by placing the
blade on a crossbar of the opposite rotation. Blades
from the right may be used on the left. Blades from the
left may be used on the right.
Adjust top link to provide 2 inches of clearance
between the break link (2) and the rear lift links. See
Figure 11. This clearance will allow the cutter to float
over uneven terrain.
(Rev. 2/6/2009)
18 Operation
MAN0390 (Rev. 6/30/2006)
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Blades must be moved in pairs. Never use one new
blade and one used blade on a crossbar.
Cutter Operation
When beginning operation of the cutter, make sure that
all persons are in a safe location. Slowly move into the
material with the tractor PTO set at 540 rpm.
TRACTOR OPERATION
Use care when operating around tree limbs and other
low objects.
Mowing Tips
Use care and reduce ground speed on rough terrain.
Always watch for hidden hazards.
ꢀ Look down and to the rear and make sure area
is clear before operating in reverse.
Being knocked off or falling off tractor can result in seri-
ous injury or death.
ꢀ Do not operate or transport on steep slopes.
Only use a tractor with a Roll Over Protective Structure
(ROPS) and seat belt. Securely fasten seat belt before
starting tractor.
ꢀ Do not stop, start, or change directions sud-
denly on slopes.
ꢀ Use extreme care and reduce ground speed on
slopes and rough terrain.
The cutter is operated with tractor controls. Engage the
PTO at a low rpm to prevent excessive loads on the
cutter drive system. Increase throttle to proper PTO
speed (540 rpm).
ꢀ Watch for hidden hazards on the terrain during
operation.
Be sure operator is familiar with all controls and can
stop tractor and cutter quickly in an emergency. The
operator should give complete, undivided attention to
operating tractor and cutter.
CAUTION
ꢀ Stop power unit and equipment immediately
upon striking an obstruction. Turn off engine,
remove key, inspect, and repair any damage before
resuming operation.
OPERATING TECHNIQUE
Power for operating the cutter is supplied by the tractor
PTO. Operate PTO at 540 rpm. Know how to stop the
tractor and cutter quickly in an emergency.
Maximum recommended ground speed for cutting or
shredding is 6 miles per hour. Adjust tractor ground
speed by using higher or lower gears to provide a clean
cut without lugging tractor engine.
Engage PTO at a low engine rpm to minimize stress on
the drive system and gearbox. With PTO engaged,
raise PTO speed to 540 rpm and maintain throughout
cutting operation.
Tall material should be cut twice. Cut material higher
the first pass. Cut at desired height at 90 degrees the
second pass.
Gearbox protection is provided by a slip clutch with
replacement fiber disc. The slip clutch is designed to
slip when excessive torsional loads occur.
Remember, sharp blades produce cleaner cuts and
use less power.
Before entering an area, analyze it to determine the
best procedure. Consider the height and type of mate-
rial to be cut and the terrain type (hilly, level or rough,
etc.).
Move slowly into material. Adjust tractor ground speed
to provide a clean cut without lugging the tractor
engine. Use a slow ground speed for better shredding.
Proper ground speed will depend on the terrain and the
material’s height, type, and density.
TRANSPORTING
Normally, ground speed will range from 2 to 5 mph.
Tall, dense material should be cut at a low speed; thin,
medium-height material can be cut at a faster ground
speed.
ꢀ The maximum transport speed for towed and
semi-mounted machines is 20 mph (32 km/h).
Regardless of the maximum speed capability of the
towing tractor, do not exceed the implement’s max-
imum transport speed. Doing so could result in:
• Loss of control of the implement and tractor
• Reduced or no ability to stop during braking
Always operate tractor PTO at 540 rpm to maintain
blade speed and to produce a clean cut.
Under certain conditions tractor tires may roll down
some grass and prevent cutting at the same height as
the surrounding area. When this occurs, reduce your
ground speed but maintain PTO at 540 rpm. The lower
ground speed will permit grass to rebound partially.
• Implement tire failure
• Damage to the implement or its components.
(Rev. 2/6/2009)
Operation 19
MAN0390 (Rev. 6/30/2006)
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___ Check that all safety decals are installed and in
good condition. Replace if damaged.
___ Check that equipment is properly and securely
attached to tractor.
ꢀ Use additional caution and reduce speed when
under adverse surface conditions, turning, or on
inclines.
___ Make sure driveline spring-activated locking pin
or collar slides freely and is seated firmly in trac-
tor PTO spline groove.
ꢀ Never tow this implement with a motor vehicle.
___ Set tractor PTO at correct rpm for your equip-
ment.
1. Always transport with cutter in raised, locked
position.
___ Lubricate all grease fitting locations. Make sure
PTO shaft slip joint is lubricated.
2. Raise cutter with hydraulic cylinder.
3. Rotate transport lock over cylinder rod. See Figure
___ Check that all hydraulic hoses and fittings are in
good condition and not leaking before starting
tractor. Check that hoses are not twisted, bent
sharply, kinked, frayed, or pulled tight. Replace
any damaged hoses immediately.
33 on page 38.
4. Lower cylinder against transport lock.
5. To lower cutter for operation, extend hydraulic
cylinder. Rotate transport lock back away from
cylinder rod. Lower to desired cutting height.
___ Raise and lower equipment to make sure air is
purged from hydraulic cylinders and hoses.
STORAGE
___ Check that all hardware is properly installed and
secured.
___ Check to ensure blades are sharp, in good condi-
tion, and installed correctly. Replace if damaged.
ꢀ Keep children and bystanders away from stor-
age area.
___ Make sure tractor ROPS or ROPS cab and seat
belt are in good condition. Keep seat belt
securely fastened during operation.
On Mounted and Semi-Mounted Cutters:
___ Check that shields and guards are properly
installed and in good condition. Replace if dam-
aged.
ꢀ Disconnect cutter driveshaft and secure up off
ground. Raise cutter with 3-point hitch. Place
blocks under cutter side skids. Lower cutter onto
blocks. Disconnect hydraulic lines to optional cyl-
inder. Disconnect cutter from tractor 3-point hitch
and carefully drive tractor away from cutter.
___ Check cutting height, front-to-rear attitude, and
top link adjustment.
___ Before starting engine, operator must be in trac-
tor seat with seat belt fastened. Place transmis-
sion in neutral or park, engage brake and
disengage tractor PTO.
On Pull-Type Cutters:
ꢀ Raise cutter and block securely. Block wheels
and raise tongue with jack. Disconnect hydraulic
lines to optional cylinder. Disconnect driveline and
secure up off the ground.
___ Inspect area to be cut and remove stones,
branches, or other hard objects that might be
thrown and cause injury or damage.
___ Check that chain shielding is in good condition
and replace any damaged chain links.
PRE-OPERATION CHECK LIST
(OWNER'S RESPONSIBILITY)
___ Make sure tractor 3-point lift links do not interfere
with hydraulic hoses or driveline throughout full
turning range.
___ Review and follow all safety rules and safety
decal instructions on page 7 to page 13.
ꢂ
(Rev. 4/6/2007)
20 Operation
MAN0390 (Rev. 6/30/2006)
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OWNER SERVICE
The information in this section is written for operators
The working surface must be level and solid to
support the weight on the jackstands. Make sure
jackstands are stable, both top and bottom. Make
sure cutter is approximately level.
who possess basic mechanical skills. If you need help,
your dealer has trained service technicians available.
For your protection, read and follow the safety informa-
tion in this manual.
3. With full cutter weight lowered onto jackstands, test
blocking stability before working underneath.
4. If cutter is attached to tractor when blocking, set
the brakes, remove key, and block cutter before
working underneath.
ꢀ Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
5. Securely block rear tractor wheels, in front and
behind. Tighten tractor lower 3-point arm anti-sway
mechanism to prevent side-to-side movement.
CAUTION
ꢀ If you do not understand any part of this manual
LUBRICATION
Do not let excess grease collect on or around parts,
particularly when operating in sandy areas.
and need assistance, see your dealer.
ꢀ Always wear relatively tight and belted clothing
to avoid entanglement 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.
See Figure 12 for lubrication points and frequency or
lubrication based on normal operating conditions.
Severe or unusual conditions may require more fre-
quent lubrication.
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 fol-
lowed.
BLOCKING METHOD
ꢀ Never go underneath equipment (lowered to the
ground or raised) unless it is properly blocked and
secured. Never place any part of the body under-
neath equipment or between moveable parts even
when the engine has been turned off. Hydraulic
system leak down, hydraulic system failures,
mechanical failures, or movement of control levers
can cause equipment to drop or rotate unexpect-
edly and cause severe injury or death. Follow Oper-
ator's Manual instructions for working underneath
and blocking requirements or have work done by a
qualified dealer.
Gearbox Lubrication
1. Use a high quality gear oil with a viscosity index of
80W or 90W and an API service rating of GL-4 or -
5 in gearboxes.
2. Fill gearbox until oil runs out the the lower hole on
back side of center gearbox or side hole on spindle
gearboxs. Check gearboxs daily for evidence of
leakage, and contact your dealer if leakage occurs.
Driveline Lubrication
To minimize the potential hazards of working under-
neath the cutter, follow these procedures:
1. Lubricate the driveline slip joint every eight
operating hours. Failure to maintain proper
lubrication could result in damage to U-joints,
gearbox, and driveline.
1. Jackstands with a load rating of 1000 lbs. or more
are the only approved blocking device for this
cutter. Install a minimum of four jackstands (shown
by Xs in Figure 12) under the cutter before working
underneath unit.
2. Lower cutter to ground, disconnect driveline from
tractor PTO shaft, and slide halves apart but do not
disconnect from each other.
Do not position jackstands under wheels, axles, or
wheel supports. Components can rotate and cause
cutter to fall.
3. Apply a bead of grease completely around male
half where it meets female half. Slide drive halves
over each other several times to distribute grease.
2. Consider the overall stability of the blocked unit.
Just placing jackstands underneath will not ensure
your safety.
4. Grease side drive yoke where yoke attaches to
side gearbox.
(Rev. 10/5/2007)
Owner Service 21
MAN0390 (Rev. 4/6/2007)
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6. Rotating Drive Shield
10 hrs.
40 hrs.
7. Side Drive Yoke (2 Places)
8. Gearbox (Check Oil Level,
Lower Hole on Center Gearbox
1. Front U-Joint
2. Mid U-Joint
3. Carrier Bearing Block
4. Telescoping Shaft
5. Rear U-Joint
10 hrs.
10 hrs.
40 hrs.
10 hrs.
10 hrs.
Side Hole on Spindle Gearboxs) Daily
9. Tailwheel Spindle
10. Caster Wheel Swivel
20 hrs.
40 hrs.
Figure 12. Jackstand Placement and Lubrication Points
1. Disconnect driveline from tractor PTO.
SERVICING BLADES
Removing Blades (Figure 13)
NOTICE
2. Open blade access cover and align crossbar (8)
with blade access hole in the cutter frame. Remove
cap screw (35), blade pin lock clip (15), keyhole
plate (14), and shims (13 & 16). Carefully drive
blade pin (12) out of crossbar.
■
If blade pin (12) is seized in crossbar and
extreme force will be needed to remove it, support
crossbar from below to prevent gearbox damage.
3. Rotate crossbar (8) and repeat for opposite blade.
Installing Blades
8. Crossbar
9. Blade
CAUTION
12. Blade pin
13. Shim
14. Keyhole plate
15. Blade pin lock clip
16. Shim
ꢀ Your dealer can supply genuine replacement
blades. Substitute blades may not meet original
equipment specifications and may be dangerous.
NOTICE
■
Crossbar rotation has counterclockwise rota-
35. Cap screw
tion on left gearbox and clockwise rotation on the
right gearbox when looking down on cutter. Be
sure to install blade cutting edge to lead in correct
rotation.
Figure 13. Blade Assembly
(Rev. 10/5/2007)
22 Owner Service
MAN0390 (Rev. 4/6/2007)
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NOTE: Always replace or sharpen both blades at the
same time.
Sharpening Blades
NOTICE
1. Inspect blade pin (12) for nicks or gouges, and if
■
When sharpening blades, grind the same
you find any, replace the blade pin.
amount on each blade to maintain balance.
Replace blades in pairs. Unbalanced blades will
cause excessive vibration, which can damage
gearbox bearings. Vibration may also cause struc-
tural cracks to cutter.
2. Insert blade pin through the blade (9). Blade
should swivel on blade pin; if it doesn’t, determine
the cause and correct.
3. Align crossbar (8) with blade access hole in cutter
frame. Apply a liberal coating of Never Seez or
equivalent to blade pin and crossbar hole. Make
sure blade offset is away from cutter. Push blade
pin through crossbar. Pin should rotate freely prior
to installing blade clip (15).
1. Sharpen both blades at the same time to maintain
balance. Follow original sharpening pattern.
2. Do not sharpen blade to a razor edge—leave at
least a 1/16" blunt edge.
3. Do not sharpen back side of blade.
4. Install shims (13 & 16) over blade pin.
NOTE: Only use enough shims to allow keyhole
plate (14) to slide into blade pin groove.
5. Install blade clip (15) over keyhole plate and into
blade pin groove.
6. Secure into position with cap screw (35). Torque
cap screw to 85 lbs-ft.
7. Repeat steps for opposite side.
NOTE: Blade should be snug but should swivel on
pin without having to exert excessive force. Keep
any spacers not used in the installation as replace-
ments or for future installation.
Figure 14. Sharpen Blade Cutting Edge
1. Flange yoke
2. Friction disc
3. Hub, 1-3/8 round bore
4. Thrust plate
5. Belleville spring plate
6. 10 mm x 1.35P x 50 mm Cap screw
7. 10 mm x 1.5P Hex nut
Figure 15. Slip Clutch Assembly
(Rev. 5/11/2007)
Owner Service 23
MAN0390 (Rev. 4/6/2007)
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excessive wear. Discs are 1/8" when new. Replace
discs after 1/16" wear. Minimum disc thickness is
1/16".
ADJUSTING SLIP CLUTCH
The slip clutch is designed to slip so that the gearbox
and driveline are protected if the cutter strikes an
obstruction. A new slip clutch or one that has been in
storage over the winter may seize. Before operating
the cutter, make sure it will slip by performing the fol-
lowing operation:
RUBBER DISK REPLACEMENT
The flexible coupler side drive is designed to flex when
striking heavy objects or during start-up to protect gear-
boxes. The rubber disks will wear out over time and
require replacement much like slip clutch disks. To
maximize rubber disk life, lower tractor engine speed to
an idle when engaging the PTO and avoid striking the
ground with cutter blades.
1. Turn off tractor engine and remove key. Remove
driveline from tractor PTO. Loosen six 10 mm cap
screws (6) to remove all tension from Belleville
spring plate (5).
2. Hold clutch hub (3) solid and turn shaft to make
sure clutch slips.
Periodically inspect the disks for signs of cracking. A
disk may run for some time after a crack starts but this
is the first sign that disk replacement is required in the
future.
3. If clutch does not slip freely, disassemble and clean
the thrust plate faces (4), flange yoke (1), and
clutch hub (3).
4. Reassemble clutch. Tighten Belleville spring (5)
until it is against the thrust plate (4) of the clutch,
and then back off each of the six nuts by two full
revolutions. The gap between Belleville spring and
thrust plate should be 1/8" as shown in Figure 15.
To replace the disks, remove hardware items (6, 7, 8,
and 9). Remove sleeves (7) from old disk and install in
new disk. Reassemble and torque bolts to 85 lbs-ft.
See Figure 16. Take special care not to rotate gearbox
shaft and throw blades out of time. If rubber disks have
failed and blades are hitting, you will need to re-time
the blades per instructions on page 34.
5. If a clutch continues to slip when the spring is
compressed to 1/8", check friction discs (2) for
1. Complete drive
2. Inner connector yoke
3. Outer connector yoke
1-3/4 20-spline
4. Outer connector yoke
1-3/4 6-spline
5. Rubber disc
6. Shaped washer
7. Bushing, .63 ID
8. Hex head cap screw
9. M16 x 2.0 Lock nut
10. Grease fitting
11. 3/8 NC x 3/4 Square head set screw
Figure 16. Flexible Coupler
(Rev. 2/6/2009)
24 Owner Service
MAN0390 (Rev. 4/6/2007)
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SHIELDING REPAIR
SERVICING TIRES SAFELY
Used Aircraft Tires (Figure 17)
WARNING
ꢀ Full chain or rubber shielding is required for all
non-agricultural mowing. Full shielding is also rec-
ommended for all agricultural use to further reduce
the risk of thrown objects.
Repairing Rubber Shielding
Inspect belting and rear bands each day of operation
and replace if bent, cracked, or broken.
Repairing Optional Chain Shielding
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Inspect chain shielding each day of operation and
replace any broken or missing chains as required.
Always maintain the correct tire pressure. Do not inflate
tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure and result in a tire explosion.
Welding can structurally weaken or deform the wheel.
CLEANING
After Each Use
●
●
●
Remove large debris such as clumps of dirt, grass,
crop residue, etc. from machine.
When inflating tires, use a clip-on chuck and an exten-
sion hose long enough to allow you to stand to the side
— not in front of or over the tire assembly. Use a safety
cage if available.
Inspect machine and replace worn or damaged
parts.
Replace any safety decals that are missing or not
readable.
Check wheels for low pressure, cuts, bubbles, dam-
aged rims, or missing lug bolts and nuts.
Never remove split rim assembly hardware (A) with the
tire inflated.
Periodically or Before Extended Storage
●
Clean large debris such as clumps of dirt, grass,
crop residue, etc. from machine.
●
Remove the remainder using a low-pressure water
spray.
1. Be careful when spraying near scratched or torn
safety decals or near edges of decals as water
spray can peel decal off surface.
2. Be careful when spraying near chipped or
scratched paint as water spray can lift paint.
3. If a pressure washer is used, follow the advice of
the pressure washer manufacturer.
A
●
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).
DECAL PN 1006348
●
Replace any safety decals that are missing or not
readable (supplied free by your Woods dealer).
See Safety Decals section for location drawing.
Figure 17. Split Rim Tire Servicing
(Rev. 2/6/2009)
Owner Service 25
MAN0390 (Rev. 4/6/2007)
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TROUBLESHOOTING
PROBLEM
Does not cut
POSSIBLE CAUSE
Dull blades
SOLUTION
Sharpen blades.
Worn or broken blades
Replace blades. (Replace in pairs
only.)
Incorrect PTO speed
Ground speed too fast
Set at rated PTO speed.
Reduce ground speed.
Drive not functioning (blades do
not turn when PTO is running)
Check drive shaft connection.
Check gearbox.
Gearbox malfunction
Repair gearbox.
Adjust clutch.
Excessive clutch slippage
Incorrect blade direction
Check to be sure blade edge is
correct for direction of rotation.
Streaks or ragged cut
Broken or worn blades
Attitude incorrect
Replace or sharpen blades.
Level machine.
Ground speed too fast
Excessive cutting height
Reduce ground speed.
Lower cutting height. (Note: Set
height so blades do not frequently
hit ground.)
Excessive lush and tall vegetation
Recut at 90° to first pass.
Excessive side skid wear
Excessive clutch slippage
Running with skids continuously
on ground
Raise cutting height or adjust.
Clutch out of adjustment
Adjust clutch.
Replace discs.
Clutch discs worn; wear stops
contacting opposite plate
Blades hitting ground
Broken blade
Raise cutting height.
Vibration
Replace blades in pairs.
Bearing failure
Check gearbox shafts for side
play.
Hitch length incorrect
Universal drive
Reset hitch length.
Adjust pedestal bearing height to
be parallel to ground.
Blades hitting deck
Bent blades or crossbar
Side drive failure
Replace bent blades or crossbar.
Blades hitting each other
Retime blades, or replace rubber
coupler disks. See page 34.
Unit will not raise
Low oil
Add hydraulic oil.
26 Troubleshooting
MAN0390 (Rev. 4/6/2007)
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DEALER SERVICE
The information in this section is written for dealer ser-
Leakage can occur at the vertical or horizontal gaskets
vice 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.
and shaft seals.
Leakage at the horizontal gasket or seal can be
repaired without removing the gearbox from the cutter.
SEAL INSTALLATION
NOTE: Proper seal installation is important. An improp-
erly installed seal will leak.
1. Clean area in housing where seal outer diameter
ꢀ Before working underneath, disconnect drive-
line, raise cutter, lock in transport position, and
block cutter securely. Hydraulic system leak down
and failure of mechanical or hydraulic system can
cause equipment to drop.
ꢀ Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
(OD) seats. Apply a thin coat of Permatex.
2. Inspect area of shaft where seal seats. Remove
any burrs or nicks with an emery cloth.
3. Lubricate gear shaft and seal lips.
4. Place seal squarely on housing, spring-loaded lip
toward housing. Select a piece of pipe or tubing
with an OD that will sit on the outside edge of the
seal but will clear the housing. Tubing with an OD
that is too small will bow seal cage and ruin seal.
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.
5. Carefully press seal into housing, avoiding
distortion to the metal seal cage.
1. Seal
2. Pipe or tube
3. Seal seat
4. Casting
GEARBOX MAINTENANCE
NOTE: Read this entire section before starting any
repair. Many steps are dependent on each other.
Pipe or tube must
press at outer
edge of seal.
1. Fill gearbox with SAE 80W or 90W gear lube until it
runs out the side level plug.
NOTE: Repair to this gearbox is limited to replac-
ing bearings, seals, and gaskets. Replacing gears,
shafts, and a housing is not cost effective. Pur-
chasing a complete gearbox is more economical.
2. Inspect gearbox for leakage and bad bearings.
Leakage is a very serious problem and must be
corrected immediately. Bearing failure is indicated
by excessive noise and side-to-side or end-play in
gear shafts.
Incorrect
Installation
SEAL REPLACEMENT
Recommended sealant for gearbox repair is Perma-
tex® Aviation 3D Form-A-Gasket or equivalent.
Figure 18. Seal Installation
Dealer Service 27
MAN0390 (Rev. 4/6/2007)
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4. Remove the four bolts that attach gearbox to cutter
and remove gearbox. Gearbox is heavy; do not
attempt to move without mechanical assistance.
VERTICAL SHAFT SEAL REPAIR
(SPINDLE BOX)
Refer to Figure 19.
DISASSEMBLE GEARBOX
1. Disconnect and remove the driveline from the
gearbox.
Refer to Figure 19.
2. Remove vent plug (3) and siphon gear lube from
1. Remove 3/8" plug from side of gearbox and pour
housing through this opening.
out gear oil.
3. Remove crossbar (see Crossbar removal on page
2. Remove oil cap (24) (to be replaced).
33).
3. Remove snap ring (9) and shim (5) from input shaft
4. Remove vertical shaft seal (16). Replace with new
(11).
seal (see Seal Installation on page 27).
4. Support gearbox in hand press and push on input
Vertical seal should be recessed in housing. Hori-
zontal seal should be pressed flush with outside of
housing.
shaft (11) to remove bearing (23).
5. Remove top cover (4) from housing. Remove gear
NOTE: Distortion to seal cage or damage to seal
(6) from inside housing.
lip will cause seal to leak.
6. Remove oil seal (10) from front of housing (to be
5. Fill gearbox with SAE 80W or 90W gear lube until it
replaced).
runs out the level plug.
7. Remove snap ring (9) and shim (5) from front of
6. Remove and replace any seal damaged in
housing (1).
installation.
8. Remove input bearing (7) by using a punch and
HORIZONTAL SHAFT SEAL REPAIR
hammer from outside of housing.
Refer to Figure 19.
9. Support housing in vise in a horizontal position.
10. The castle nut (21), cotter pin (8), and washer (20)
1. Disconnect and remove the driveline from the
gearbox.
are
already
removed
with
the
stump
jumper/crossbar. Remove the protective screen
(17) and seal (16).
2. Remove vent plug (3) and siphon gear lube from
housing through this opening.
3. If the leak occurred at either end of horizontal shaft
(spindle gearbox), remove oil cap (24) and/or oil
seal (10). For splitter gearbox (Figure 20) use oil
seals (11) and (17). Replace with new one (refer to
Seal Installation, page 27).
11. Remove cotter pin (18), castle nut (12), and
washer (25) from output shaft (19).
12. Remove output shaft (19) by using a punch and
hammer and tap on top to drive down.
13. Remove gear (5) and shim (15) from inside
4. Fill gearbox with SAE 80W or 90W gear lube until it
housing.
runs out the level plug.
14. Remove bearing (15) by using a punch and
SPINDLE GEARBOX REPAIR
hammer from the top, outside the housing.
NOTE: Replacing gears, shafts, bearings, and seals
may not be cost effective. Purchasing a complete gear-
box may be more economical.
15. Support housing upside down (top cover surface)
and remove bearing (15) by using a punch and
hammer from the bottom side of the housing.
REMOVE GEARBOX FROM CUTTER
16. Inspect gears for broken teeth and wear. Some
wear is normal and will show on loaded side.
Forged gear surfaces are rough when new. Check
that wear pattern is smooth.
Refer to Figure 19.
1. Disconnect and remove the driveline from the
gearbox.
17. Inspect vertical and horizontal shafts for grooves,
nicks, or bumps in the areas where the seals seat.
Resurface any damage with emery cloth.
2. Remove vent plug (3) and siphon gear lube from
housing through this opening.
3. Remove cotter pin, washer, and nut from vertical
shaft and remove crossbar (see Crossbar removal,
page 33).
18. Inspect housing and caps for cracks or other
damage.
28 Dealer Service
MAN0390 (Rev. 4/6/2007)
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11. While holding gear (6) in place, slide input shaft
(11) through gear (6) and bearing (7). Align splines
on shaft (11) and gear (6).
ASSEMBLE GEARBOX
Refer to Figure 19.
12. Slide spacer (7) over input shaft (11) and press
bearing onto input shaft (11), using a round tube of
the correct diameter and a hand press.
1. Clean housing, paying specific attention to areas
where gaskets will be installed.
2. Wash housing and all components thoroughly.
Select a clean area for gearbox assembly. Replace
all seals, bearings, and gaskets. All parts must be
clean and lightly oiled before reassembling.
13. Slide shim (5) over input shaft (11) and secure with
snap ring (9).
14. Check input shaft end float by moving the input
shaft (11) by hand. If end float is higher than
0.012", insert shim between input shaft (11) and
rear bearing (7). Repeat until end float is less than
0.012". Check rotational torque by hand. The
torque should be less than 2.2 lbs-inch.
3. Insert output bearings (15) in the housing, using a
round tube of the correct diameter and a hand
press.
4. Slide output shaft (19) through both bearings (15)
until it rests against bearing (6).
15. Check that the gear backlash is between 0.006"
and 0.016". You should not have to adjust the
backlash.
5. Slide shim (5) over output shaft (19).
6. Press gear (13) onto output shaft (19) and secure
with washer (25), castle nut (12), and cotter pin
(18).
16. Press in input oil seal (10), using tube of correct
diameter. Be careful not to damage seal lip.
17. Press oil cap (24) on to cover the rear of housing,
7. Apply grease to lower seal lips (16) and press seal
(16) over output shaft (19), using a tube of the
correct diameter. Be sure not to damage the seal
lip.
using a tube of the correct diameter.
18. Check gearbox housing for leaks by plugging all
holes except one. Apply 4 psi compressed air and
immerse the gearbox in water to verify that there
are no leaks.
Press in housing so that seal is recessed. Install
protective screen (17) and position it together with
dual lip seal (16) by pressing it into position. Verify
that snap ring is seated correctly.
19. Remove gearbox from water and dry off with
compressed air. Add SAE 80W or 90W EP oil until
it runs out of side level hole. Tighten all plugs.
8. Press bearing (7) into the housing, using a round
tube of the correct diameter and a hand press.
Secure with shim (5) and snap ring (9).
REINSTALL GEARBOX
NOTE: Gearbox is heavy: do not attempt to move
without mechanical assistance.
9. Secure snap ring (9) on input shaft (11) if not
already secure.
1. Set gearbox on cutter and fasten with bolts and
nuts. Torque bolts to 300 lbs-ft.
10. Place gear (6) through top of housing and align
gear (6) and gear (13) so that gear teeth are a
match.
2. Attach crossbar (see Crossbar removal on page
33).
Dealer Service 29
MAN0390 (Rev. 4/6/2007)
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1. Gearbox housing
2. Cap screw 8 mm x 14 (8.8)
3. Vent plug
4. Top cover
5. Shim kit
6. Crown gear
7. Bearing cup & cone
8. Cotter pin B6 x 60 mm
9. Snap ring
10. Seal
11. Input shaft
12. Castle nut, metric M30 x 1.5
13. Pinion gear
14. Shim kit
15. Bearing cup & cone
16. Seal 50 x 90 x 10
17. Protective screen
18. Cotter pin
19. Output shaft
20. Flat washer
21. Castle nut, metric M3 x 2.0
22. Plug, 3/8 NPT
23. Ball bearing
24. Oil cap
25. Shim, 44 x 30.3 x 1
Figure 19. Spindle Gearbox Assembly
30 Dealer Service
MAN0390 (Rev. 4/6/2007)
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4. Remove oil seals (11) (to be replaced) from both
SPLITTER GEARBOX REPAIR
sides of cross shaft (4).
NOTE: Replacing gears, shafts, bearings, and seals
may not be cost effective. Purchasing a complete gear-
box may be more economical.
5. Remove eight cap screws (3) from around gearbox
cover (12) and remove cross shaft (4) from
gearbox.
REMOVE GEARBOX FROM CUTTER
6. Disassemble shims (5 & 18), spacer (20), bearings
1. Disconnect driveline from the tractor PTO and
(16 & 13), and crown gear (7) from cross shaft.
remove it from center gearbox.
7. Support housing in a vise and remove bearing
cones (16) by using a punch and hammer to drive
bearing cone out.
2. Remove vent plug (6) and siphon gear lube from
housing through this opening.
3. Disconnect and remove flex coupler drivelines from
8. Support cover (12) in a vise and remove bearing
cups (13) by using a punch and hammer to drive
bearing cone out.
side of gearbox by:
a. Removing cap screws and hex nuts from drive-
line.
9. Remove lock nut (2) from end of input shaft (14).
b. Loosen set screws from flex coupler yoke.
c. Slide flex coupler yoke from gearbox shaft.
10. Support input housing in a handpress and push
input shaft (14) out of housing.
4. Remove the four bolts that attach gearbox to cutter
and remove gearbox. Gearbox is heavy; do not
attempt to move without mechanical assistance.
11. Support housing in a vise and remove bearing
cups (13 & 16) by using a punch and hammer to
drive bearing cones out.
DISASSEMBLE SPLITTER GEARBOX
12. Inspect gears for broken teeth and wear. Some
wear is normal and will show on loaded side.
Forged gear surfaces are rough when new. Check
that wear pattern is smooth.
Refer to Figure 20.
1. Remove breather plug from top of gearbox.
13. Inspect input and cross shafts for grooves, nicks,
or bumps in the areas where the seals seat.
Resurface any damage with emery cloth.
2. Remove plug (19) from side of input housing (1)
and pour out gear oil.
3. Remove eight cap screws (3) from around input
housing (15). Remove input shaft assembly and
housing.
14. Inspect housing and caps for cracks or damage.
1. Gearbox
2. Lock nut
3. M10 x 1.5 x 22 Cap screw
4. Cross shaft
5. Shim, 45.3 x 65.3 x 2.5
6. Vent plug
7. Crown gear
8. Pinion gear
9. Shim, 45.3 x 65.3 x 1
10. Key, 14 x 9 x 40
11. Seal
12. Cover
13. Bearing cup & cone
14. Input shaft
15. Housing, input
16. Bearing cup & cone
17. Seal
18. Shim kit
19. Plug, 3/8 NPT
20. Spacer
21. Key
Figure 20. Center Gearbox Assembly
Dealer Service 31
MAN0390 (Rev. 4/6/2007)
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ASSEMBLE GEARBOX
REINSTALL GEARBOX
Refer to Figure 20.
NOTE: Gearbox is heavy: do not attempt to move
without mechanical assistance.
1. Clean housing, paying specific attention to areas
where gaskets will be installed.
1. Install flex coupler driveline between side
gearboxes and center gearbox.
2. Wash housing and all components thoroughly.
Select a clean area for gearbox assembly. Replace
all seals, bearings, and gaskets. All parts must be
clean and lightly oiled before reassembling.
2. Set gearbox on cutter and fasten with bolts and
nuts. Torque bolts to 300 lbs-ft.
3. Install new bearing cup (16) in gearbox housing
and bearing cup (13) in cover if these parts were
previously removed.
SIDE DRIVE SERVICE
4. Place bearing (16) and shim (5) on end of cross
shaft (4), and insert shaft into housing.
5. Install spacer (20), key (21), crown gear (7), shim
(18), and bearing (13) on opposite end of cross
shaft.
6. Place cover (12) over bearings (13) and secure
into position using eight cap screws (3). Torque cap
screws to 29 lbs-ft.
7. Place seal (11) over cross shaft and press into
housing. Use a round tube the same diameter of
the seal and a handpress. Repeat process on
opposite side of gearbox.
6. Shaped washer
7. Bushing
8. Bolt
9. Lock nut
11. Set screw
2. Shaft
8. Install new bearing cup (16 & 13) into input housing
3. Inner yoke
4. Outer yoke
5. Rubber disc
if these parts were previously removed.
9. Place bearing (16) over end of input shaft (14) and
insert shaft into front of input housing.
Figure 21. Side Drive Assembly
10. Place seal (17) over shaft and press into housing.
Use a round tube the same diameter of the seal
and a handpress.
The drives between the center and side gearboxes
contain rubber shock-absorbing discs. To service or
remove the side drives or remove a gearbox, the flexi-
ble coupling must be disassembled.
11. Install bearing (13), shim (18), pinion gear (8), key
(10), shim (9) over opposite end of input shaft (14).
12. Secure parts together using lock nut (2). Tighten
lock nut (2) until shaft rolling torque is 3 to 9 lbs-
inch.
Remove end yokes by removing nuts (9) and sliding
bolt (8) inward to clear yoke. Do not remove bolt unless
rubber discs (5) are to be serviced. Remove complete
center section by lifting straight up on center shaft (2).
The outer yoke can be slid off gearbox shaft. The inner
yoke is held by two set screws (11).
13. Insert input housing assembly into front of gearbox
housing and align teeth of the two gears. Secure
with cap screws (3). Torque cap screws to 29 lbs-ft.
14. Check gear backlash; it should be .006" to .017" at
Reassemble shaft as shown in Figure 21. End yokes (3
& 4) do not bolt directly to center shaft (2). Use the spe-
cial formed washer (6) and bushings (7) between the
rubber discs (5) and under bolt head or nut near rubber
disc. Tighten the nuts (9) evenly until the formed wash-
ers (6) are slightly embedded into the rubber discs.
Rubber discs (5) will warp and twist if bolts are over-
tightened. Tighten set screw (11).
outer tooth.
15. Check gearbox housing for leaks by plugging all
holes except one. Apply 4 psi compressed air and
immerse the gearbox in water to verify that there
are no leaks.
16. Remove gearbox from water and dry off with
compressed air. Add SAE 80W or 90W EP oil until
it runs out of the lower level hole in front cover.
Tighten all plugs.
NOTE: Crossbar must be re-timed anytime a crossbar
or a side drive is disconnected.
32 Dealer Service
MAN0390 (Rev. 4/6/2007)
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CROSSBAR REMOVAL
1. It is necessary to gain access to bottom side of
cutter for crossbar removal. See BLOCKING
METHOD, page 21.
NOTE: You will need to use either the puller screw
(Item 6, Figure 23) or a small hydraulic jack to
remove the crossbar.
2. To make crossbar removal easier, remove blades
as shown in Figure 22.
8. Crossbar
9. Blade
12. Blade pin
13. Shim
14. Keyhole plate
15. Blade pin lock clip
16. Shim
35. Cap screw
37. Castle nut
38. Cotter pin
Figure 22. Blade Removal
3. Remove cotter pin (38) and castle nut (37) from
bottom of crossbar.
4. Refer to Figure 23. Attach a clevis (1) to each end
of crossbar, using blade pins, spacers, keyhole
plates, and blade pin clips.
5. Position tube assembly (5) with threaded nut
toward crossbar for puller screw removal or down
for hydraulic jack removal.
6. For removal with puller screw, attach tube (5) to
each clevis with screws (2) and nuts (3). Place pad
(4) in nut and thread puller screw (6) into nut from
bottom. Tighten until pad is solid against gearbox
shaft. For best results, strike head of puller screw
with a hammer while tightening with a wrench.
1. Clevis
2. 5/8 NC x 4 Cap screw
3. 5/8 NC Hex nut
4. Pad assembly
5. Tube assembly
6. Screw assembly
7. Puller link
7. For removal with a jack, attach tube to each clevis
with puller links (7), screws (2), and nuts (3). Place
jack on tube with end of jack pressing against
gearbox shaft. Slowly apply force with jack.
NOTE: Hydraulic jack will not operate if tipped
more than 90-degrees. Use care to prevent bend-
ing crossbar during removal.
Figure 23. Crossbar Removal
Dealer Service 33
MAN0390 (Rev. 4/6/2007)
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2. Install crossbar (8), Figure 22, on splined shaft.
Install castle nut (37) and cotter pin (38). Torque
nut to 450 lbs-ft.
CROSSBAR INSTALLATION
1. Using emery cloth (220 or finer), remove surface
rust, and foreign material from hub, splined
gearbox vertical shaft, and crossbar. See Figure
24.
3. Install blades, reinstall them using existing
hardware. Torque cap screws to 85 lbs-ft.
CROSSBAR TIMING
Crossbar must be re-timed anytime a crossbar or a
side drive is disconnected.
1. To re-time crossbars, position bars as shown in
Figure 25.
2. The right crossbar will be at right angles to the front
of the cutter.
3. Measure from the front of the cutter to the blade pin
on each side crossbar.
4. Hold crossbars in position while connecting the
side drivelines.
Figure 24. Example of Crossbar and Gearbox Shaft
Figure 25. Crossbar Timing - Bottom View
34 Dealer Service
MAN0390 (Rev. 4/6/2007)
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3. Clamp cup in vise as shown in Figure 29 and tap
on yoke to completely remove cup from yoke.
Repeat Step 2 and Step 3 for opposite cup.
UNIVERSAL JOINT REPAIR
1. Yoke
2. Cup and bearing
3. Snap ring
4. Journal cross
Figure 26. Universal Joint Parts Breakdown
U-JOINT DISASSEMBLY
Figure 29. Remove Cups
1. Remove external snap rings from yokes in four
locations as shown in Figure 27.
4. Place universal cross in vise as shown in Figure 30
and tap on yoke to remove cup. Repeat Step 3 for
final removal. Drive remaining cup out with a drift
and hammer.
Figure 27. Remove Snap Ring
2. With snap rings removed, support drive in vise,
hold yoke in hand and tap on yoke to drive cup up
out of yoke. See Figure 28.
Figure 30. Remove Cups
U-JOINT ASSEMBLY
1. Place seals securely on bearing cups. Insert cup
into yoke from outside and press in with hand
pressure as far as possible. Insert journal cross
into bearing cup with grease fitting away from
shaft. Be careful not to disturb needle bearings.
Insert another bearing cup directly across from first
cup and press in as far as possible with hand
pressure.
2. Trap cups in vise and apply pressure. Be sure
journal cross is started into bearings and continue
pressure with vise, squeezing in as far as possible.
Tapping the yoke will help.
Figure 28. Remove Cups
(Rev. 5/11/2007)
Dealer Service 35
MAN0390 (Rev. 4/6/2007)
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3. Seat cups by placing a drift or socket (slightly
smaller than the cup) on cup and rap with a
hammer. See Figure 31. Install snap ring and
repeat on opposite cup
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure and result in a tire explosion.
Welding can structurally weaken or deform the wheel.
4. Repeat Step 1 and Step 2 to install remaining cups
in remaining yoke.
5. Move both yokes in all directions to check for free
movement. If movement is restricted, rap on yokes
sharply with a hammer to relieve any tension.
Repeat until both yokes move in all directions
without restriction.
When inflating tires, use a clip-on chuck and an exten-
sion hose long enough to allow you to stand to the side
— not in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, dam-
aged rims, or missing lug bolts and nuts.
Never remove split rim assembly hardware (A) with the
tire inflated.
Figure 31. Install Cups
A
SERVICING TIRES SAFELY
Used Aircraft Tires (Figure 32)
WARNING
DECAL PN 1006348
Figure 32. Split Rim Tire Servicing
(Rev. 5/11/2007)
36 Dealer Service
MAN0390 (Rev. 4/6/2007)
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ASSEMBLY INSTRUCTIONS
Complete check lists on page 49 when you have com-
pleted the assembly.
DEALER SET-UP INSTRUCTIONS
ASSEMBLE - DS96 PULL-TYPE CUTTER
REAR HALF
ꢀ Full chain or rubber shielding must be installed
when operating in populated areas or other areas
where thrown objects could injure people or dam-
age property.
Refer to Figure 33.
Place jackstands under cutter to raise it off the ground
to provide clearance when assembling cutter. See
“BLOCKING METHOD” on page 21 for jackstand
placement.
• If this machine is not equipped with full chain
or rubber shielding, operation must be stopped
when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk
of thrown objects. The mower deck and protec-
tive devices cannot prevent all objects from
escaping the blade enclosure in every mowing
condition. It is possible for objects to ricochet
and escape, traveling as much as 300 feet (92 m).
Install Rear Tailwheel
1. Attach tailwheel (1) to the rear of the cutter using
two clevis pins (13) and cotter pins (35).
2. Insert wheel hubs (2) to the outer mounting tubes
of tailwheel. Secure with cap screws (33) and
flange lock nut (34). NOTE: Inner mounting tubes
are for adding a second set of wheels.
ꢀ Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO
spline groove.
3. Attach solid or aircraft tires to wheel hubs using
four cap screws (31) and lock washers (32).
4. Attach rims and pneumatic tires (pneumatic tires
are not furnished) to wheel hubs using four wheel
bolts (30).
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.
Install Attitude Rod
Slide attitude rod (5) under left spindle driveline
and through pivot block on the tailwheel. Loosely
install spacers (6), washers (37) and two hex nuts
(36).
These instructions are for the assembly of the DS96
and DS120 mounted and pull-type cutters. Many of the
procedures apply to all units. When an instruction
applies to a specific unit, the section heading will
indicate which unit. Assembly of options may not apply
to all units.
Install Height Adjustment Device
Ratchet
Install ratchet (12) between cylinder lug on tail-
wheel and lug on deck. Secure with pins supplied
with ratchet.
Assembly of this cutter is the responsibility of the
Woods dealer. It should be delivered to the owner
completely assembled, lubricated, and adjusted for
normal cutting conditions.
Cylinder
The cutter is shipped partially assembled. Assembly
will be easier if aligned and loosely assembled before
tightening hardware. Recommended torque values for
hardware are located in the Bolt Torque Chart, page
73.
1. Place hydraulic cylinder (8) between lug on
tailwheel and lug on deck.
2. Secure to deck lug using pin (15) and two cotter
pins (35).
3. Extend cylinder rod, place transport lock bracket
Select a suitable working area. A smooth hard surface,
such as concrete, will make assembly much quicker.
Open parts boxes and lay out parts and hardware to
make location easy. Refer to illustrations, accompany-
ing text, parts lists and exploded view drawings.
(7) over cylinder rod end and lug on tailwheel.
4. Align holes of cylinder rod, transport lock bracket
(7) and lug on tailwheel. Secure assembly using
pin (16) and two cotter pins (35).
MAN0390 (Rev. 4/6/2007)
Assembly 37
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in the cylinder rod end port. Use a restricter fitting
in the base end port to dampen the cutter lowering
action.
Install Hydraulic Hose
1. Install reducer bushing (9) and restricter swivel
elbow (10) in port at base end of cylinder (8).
Position elbow to point toward front of cutter.
ꢀ On pull-type units with optional hydraulic cut-
ting height adjustment, use a single-acting cylinder
with a maximum extended length of 28-1/4" (718
mm) from attaching point center to center.
NOTE: Make sure there is a breather fitting
installed in the rod end port.
2. Connect hose (11) to elbow (10).
NOTICE
3. Install optional stroke control kit (14) to cylinder
rod. Stroke control kit is used to set cut height.
■
If using a cylinder other than the one supplied
by Woods, make sure a breather fitting is installed
1. Tailwheel
7. Transport lock-up
8. Hydraulic cylinder
9. Reducer
16. Headless pin, 1 x 4
30. Wheel bolt, 1/2 NF x 1-1/8
31. Cap screw, 1/2 NF x 1
32. Lock washer, 1/2
2. Wheel hub
3. 15" Steel rim
4. 21" Solid tire -or-
4. 22" Aircraft tire -or-
4. 29" Aircraft tire
5. Attitude rod
10. Elbow, restricter
11. Hose, 156"
12. Ratchet
33. Cap screw, 1/2 NC x 3
34. Flange lock nut, 1/2 NC
35. Cotter pin, 1/4 x 1-1/2
36. Hex nut, 1 NC
13. Clevis pin, 1.0 x 2.26
14. Stroke control kit
15. Headless pin, 1 x 4-1/2
6. Spacer
37. Flat washer, 1"
Figure 33. DS96 Pull-Type Rear Half Installation
38 Assembly
MAN0390 (Rev. 4/6/2007)
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ASSEMBLE - DS120 PULL-TYPE CUTTER
REAR HALF
Refer to Figure 35.
Place jackstands under cutter to raise it off the ground
to provide clearance when assembling cutter. See
“BLOCKING METHOD” on page 21 for jackstand
placement.
Install Rear Tailwheel
1. Attach tailwheel arms (1) to the tailwheel using
eight (four per wheel arm) cap screws (35) and
lock nuts (36). NOTE: Position tailwheel arms on
tailwheel to desired location (usually on row crop
centers). Wheel hubs should be positioned to the
outside of the cutter.
2. Attach solid or aircraft tires to wheel hubs using
four cap screws (31) and lock washers (32).
13. Spring arm
3. Attach rims and pneumatic tires (pneumatic tires
are not furnished) to wheel hubs using four wheel
bolts (30).
14. Spring
15. Headless pin, 1 x 3
16. Headless pin, 1 x 4-1/2
34. Flange lock nut, 1/2 NC
39. Cap screw, 1/2 NC x 5
40. Cotter pin, 1/4 x 1-1/2
Install Attitude Rod
Slide attitude rod (5) under left spindle driveline
and through pivot block on the tailwheel. Loosely
install spacer (6), washer (37) and two hex nuts
(38).
Figure 34. Spring Arm Installation
Install Hydraulic Hose
Install Spring Arm
1. Attach spring arm (13) to cylinder (8) or ratchet
(12) using pin (15).
ꢀ On pull-type units with optional hydraulic cut-
ting height adjustment, use a single-acting cylinder
with a maximum extended length of 28-1/4" (718
mm) from attaching point center to center.
2. Place spring arm (13) and spring (14) on deck as
shown. Secure spring arm (13) to spring arm lugs
(on the cutter) using pin (16) and two cotter pins
(40). Install retaining cap screw (39) and flange
lock nut (34).
NOTICE
Install Height Adjustment Device
■
If using a cylinder other than the one supplied
Ratchet
by Woods, make sure a breather fitting is installed
in the cylinder rod end port. Use a restricter fitting
in the base end port to dampen the cutter lowering
action.
Attach ratchet (12) to tailwheel lug and secure with pin
(17) and two cotter pins (40).
Cylinder
1. Install reducer bushing (9) and restricter swivel
elbow (10) in port at base end of cylinder (8).
Position elbow to point toward front of cutter.
1. Place hydraulic cylinder (8) between lug on
tailwheel.
2. Extend cylinder rod, place transport lock bracket
(7) over cylinder rod end and between lugs on
tailwheel.
NOTE: Make sure there is a breather fitting
installed in the rod end port.
2. Connect hose (11) to elbow (10).
3. Align holes of cylinder rod, transport lock bracket
and lugs on tailwheel. Secure assembly using pin
(17) and two cotter pins (40).
3. Install optional stroke control kit (18) to cylinder
rod. Stroke control kit is used to set cut height.
MAN0390 (Rev. 4/6/2007)
Assembly 39
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DS120 Pull-Type - Rear Half
1. Tailwheel arm
15. Headless pin, 1 x 3
16. Headless pin, 1 x 4-1/2
17. Headless pin, 1 x 5
18. Stroke control kit
2. Wheel hub
3. 15" Steel rim
4. 21" Solid tire -or-
4. 22" Aircraft tire -or-
4. 29" Aircraft tire
5. Attitude rod
30. Wheel bolt, 1/2 NF x 1-1/8
31. Cap screw, 1/2 NF x 1
32. Lock washer, 1/2
6. Spacer
33. Cap screw, 1/2 NC x 3
34. Flange lock nut, 1/2 NC
35. Cap screw, 5/8 NC x 5
36. Lock nut, 5/8 NC
7. Transport lock-up
8. Hydraulic cylinder
9. Reducer
10. Elbow, restricter
11. Hose, 156"
12. Ratchet
37. Flat washer, 1"
38. Hex nut, 1 NC
39. Cap screw, 1/2 NC x 5
40. Cotter pin, 1/4 x 1-1/2
13. Spring arm
14. Spring
Figure 35. DS120 Pull-Type Rear Half Installation
40 Assembly
MAN0390 (Rev. 4/6/2007)
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2. Secure H-frame to tongue using cap screw (42),
two sleeve (3), two cup washers (4) and lock nut
(43).
INSTALL TONGUE DS96 & DS120
CUTTERS
Refer to Figure 36.
1. Place tongue (1) between inner mast plates.
Attach Driveline to H-frame
NOTE: DS96 only has one set of mast plates. Fig-
ure 36 shows the DS120 cutter frame.
NOTE: Select holes in H-frame that will allow driveline
to run level. Refer to Operation section for driveline
height. Final adjustment will be necessary when cutter
is attached to the tractor.
2. Place washer (46) and sleeve (16) on cap screw
(44).
3. Place washer (47) between mast plates and
tongue, insert cap screw (44) with washer (46) and
sleeve (16) through mast plate and tongue. NOTE:
Washers (47) are only required on DS120 cutters.
Place driveline bearing carrier between H-frame (2)
and secure with clevis pin (7) and cotter pin (49).
Install Front Drive
4. Secure with second washer (46) and lock nut (45).
1. Slide rear yoke of front driveline (8) over shaft of
5. Attach front half of attitude rod to lug on tongue
driveline (9) and align with notch on shaft.
using clevis pin (17) and cotter pin (48).
2. Secure drives together using cap screw (39) and
6. Raise front of cutter and install parking jack (6) to
lock nut (38).
support tongue.
7. Attach safety tow chain (5) to tongue using cap
screw (44), washer (47), and lock nut (45). Be sure
chain links do not interfere with tractor drawbar.
3. Attach tether chain on front half of driveline (8) to
H-frame (2).
Install Drive Shield & Hose Holder
INSTALL 3-JOINT DRIVELINE
1. Attach drive shield (13) to driveline carrier bearing
using two cap screws (35) and lock washers (36).
Install Driveline
2. Attach hydraulic hose holder (15) to the top hole in
H-frame (2) with cap screw (41), sleeve (14), and
lock nut (40).
Refer to Figure 36.
1. Coat input shaft of gearbox shaft with light coating
of grease.
2. Attach slip clutch on driveline (9) to input shaft of
gearbox. Tighten cap screws (33) and lock nut
(34).
Install SMV Bracket
1. Attach SMV bracket (19) to the top of center
gearbox using two cap screws (32).
3. Attach rear tether chain on driveline to clip on
plastic gearbox shield.
2. Attach SMV emblem (20) to SMV bracket using
two round head cap screws (30) and hex nuts (31).
Install H-Frame
1. Place H-frame (2) over front of tongue and align
holes.
MAN0390 (Rev. 4/6/2007)
Assembly 41
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Tongue and Driveline Installation
1. Tongue
2. H-Frame
33. Cap screw, M12 x 1.5P x 65 mm
34. Lock nut, M12 x 1.5P
35. Cap screw, 3/8 NC x 1
36. Lock washer, 3/8
3. Sleeve, 5/8 x 1 x 9/16
4. Cup washer
5. Safety chain
6. Parking jack
37. Grease fitting
7. Clevis pin, 1/2 x 5-3/4
8. Driveline, front 2/3
9. Driveline, rear 1/3
13. Shield
14. Sleeve, 1/2 x 3-9/16
15. Hose holder
38. Lock nut, 1/2 NC
39. Cap screw, 1/2 NC x 2
40. Flange lock nut, 1/2 NC
41. Cap screw, 1/2 NC x 5-1/2
42. Cap screw, 5/8 NC x 6
43. Lock nut, 5/8
16. Sleeve, 3/4 x 1-1/8 x 5/8
17. Clevis pin, 1 x 2.26
19. SMV Bracket
44. Cap screw, 3/4 NC x 3
45. Lock nut, 3/4 NC
46. Flat washer, 3/4
20. SMV Emblem
30. Cap screw, 1/4 NC x 1/2
31. Nut, 1/4 NC
47. Washer, 3/4 x 2 x 3/8
(DS120 only)
48. Cotter pin, 1/4 x 1-1/2
49. Cotter pin, 3/16 x 1
32. Cap screw, 1/2 NC x 1
Figure 36. DS96 and DS120 Tongue and Driveline Installation
(Rev. 5/23/2008)
MAN0390 (Rev. 4/6/2007)
42 Assembly
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ASSEMBLE - DS96 MOUNTED CUTTER
Install Tailwheel Arms
Refer to Figure 39.
Refer to Figure 38 and Figure 39.
Place jackstands under cutter to raise it off the ground
to provide clearance when assembling cutter. See
“BLOCKING METHOD” on page 21 for jackstand
placement.
1. Attach adjustment arms (13) to lower holes of lugs
on the rear of the cutter. Braces must be placed on
the inside of mounting lugs (Figure 38).
2. Secure each adjustment brace with a cap screw
(31) and lock nut (32).
Install A-Frame
3. Attach tailwheel arms (1) between deck rail and lug
near the middle of the cutter. Secure into position
using cap screws (30), two washers (12), and lock
nut (32). NOTE: See Figure 39 for washers (12)
placement.
1. Attach front A-frame bars (3) to the top of the cutter
mast plates using hitch pins (4), bushing sleeves
(11), washers (41), slotted hex nuts (42), and cotter
pins (39).
2. Torque hex nuts to 400 lbs-ft.
4. Align holes on adjustment arms (13) with a hole in
the tailwheel arm and insert cap screw (30).
Secure with lock nut (32). NOTE: Hole positions in
tailwheel arms determines cutting height. Final
adjustment will be necessary when cutter is
mounted to the tractor.
Refer to Figure 37 and Figure 39
3. Attach rear A-frame bars (2) to the mounting lugs
on the rear of the cutter using cap screws (31) and
lock nuts (32).
4. Attach the two rear A-frame bars together at the
top rear hole using cap screw (33), spacer sleeve
(9), and lock nut (32).
5. Place both break links (7) together and position
between front hole of rear A-frame bars. Secure
rear A-frame bars and break links together using
cap screw (33), pacer sleeve (9), and lock nut (32).
NOTE: Break links must rest on top of rear spacer
sleeve (9).
6. Place spacer sleeve (6) through front holes of
break links. Align break links with bottom holes on
front A-frame bars (3) and secure together using
cap screw (37) and lock nut (38).
1. Tailwheel arm
13. Tailwheel adjustment arm
31. 5/8 NC x 4-1/2 Cap screw
32. 5/8 NC Lock nut
7. Install top link pin (10) and sleeve (8) into top holes
of A-frame. Secure with cotter pin (39) and klik pin
(40). Sleeve (8) is used with category 2 top links.
Figure 38. Adjustment Arm Installation
Install Driveline
1. Coat input shaft of gearbox with a light coating of
grease.
2. Attach slip clutch on driveline (5) to input shaft of
gearbox. Tighten cap screws (35) and lock nut
(36).
3. Attach rear tether chain of driveline to driveline
Figure 37. Break Linkage Installation
shield.
MAN0390 (Rev. 4/6/2007)
Assembly 43
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DS96 Mounted Assembly
1. Tailwheel arm
30. Cap screw, 5/8 NC x 4-1/2
31. Cap screw, 5/8 NC x 2
32. Lock nut, 5/8 NC
2. Rear A-frame bar
3. Front A-frame bar
4. Hitch pin
33. Cap screw, 5/8 NC x 2-3/4
34. Klik pin, 7/16 x 2
5. Driveline
6. Sleeve, 3/4 x 1-1/4 x 3
7. Break link
35. Cap screw, M12 x 1.5P x 65 mm
36. Lock nut, M12 x 1.5P
37. Cap screw, 3/4 NC x 5-1/2
38. Lock nut, 3/4 NC
8. Sleeve, 3/4 x 1 x 3
9. Sleeve, 5/8 x 1 x 1-1/4
10. Headless pin, 3/4 x 5
11. Sleeve, 1-1/8 x 1-7/16 x 11/16
12. Washer, 5/8 x 2-1/2 x 1/4
13. Tailwheel adjustment arm
39. Cotter pin,1/4 x 1-1/2
40. Klik pin, 1/4 x 1-3/4
41. Washer, 1-1/8 x 2-3/8 x 3/16
42. Slotted nut, 1-1/8 NF
Figure 39. DS96 Mounted Assembly
44 Assembly
MAN0390 (Rev. 4/6/2007)
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ASSEMBLE - DS120 MOUNTED CUTTER
Refer to Figure 42.
Place jackstands under cutter to raise it off the ground
to provide clearance when assembling cutter. See
“BLOCKING METHOD” on page 21 for jackstand
placement.
Install A-Frame
1. Attach front A-frame bars (3) to the lower (square)
hole of the cutter mast plates. Secure using
carriage bolts (35), bushing sleeves (19), washers
(34), and lock nuts (31).
Figure 41. Category 3 Hitch Arrangement
Install Tailwheel Arms
Attach tailwheel arms (1) to the tailwheel using eight
(four per arm) cap screws (30) and lock nuts (31).
2. Attach, rear A-frame bars (2) with washers (44)
over mounting bolts (33) and secure with lock nuts
(32).
NOTE: Position tailwheel arms on tailwheel to desired
location (usually on row crop centers).
3. Attach the two rear A-frame bars (2) together at the
top rear hole using cap screw (43), spacer sleeve
(9), and lock nut (31).
Install Height Adjustment Device
Ratchet
4. Place both break links (7) together and position
between front hole of rear A-frame bars. Secure
rear A-frame bars and break links together using
cap screw (43), spacer sleeve (9), and lock nut
(31). NOTE: Break links must rest on top of rear
spacer sleeve (9).
Install ratchet (18) between cylinder lugs on tailwheel
and lugs on the deck. Secure to lugs on the deck with
pin (11) and two cotter pins (41). Secure to tailwheel
with pin (12) and two cotter pins (41).
Cylinder
5. Place spacer sleeve (6) through front holes of
break links. Align break links with bottom holes on
front A-frame bars (3) and secure together using
cap screw (39) and lock nut (40).
1. Place hydraulic cylinder (14) between lugs on
tailwheel and lugs on deck.
2. Secure to deck lugs using pin (11) and two cotter
pins (41).
Category 2 Standard Hitch (Figure 40)
3. Extend cylinder rod, place transport lock bracket
(13) over cylinder rod end and between lugs on
tailwheel.
Install top link pin (10) and sleeve (6) into top holes of
A-frame. Secure with cotter pin (41) and klik pin (42).
4. Align holes of cylinder rod, transport lock bracket
and lugs on tailwheel. Secure assembly using pin
(12) and two cotter pins (41).
Install Hydraulic Hoses
ꢀ On mounted units with optional hydraulic cut-
ting height adjustment, use a double-acting cylin-
der with a maximum extended length of 28-1/4"
(718 mm) from attaching point center to center.
Figure 40. Category 2 Hitch Arrangement
■
If using a cylinder other than the one supplied
by Woods, make sure a breather fitting is installed
in the cylinder rod end port. Use a restricter fitting
in the base end port to dampen the cutter lowering
action.
Category 3 Standard Hitch
Install top link pin (10) and sleeve (8) into top holes of
A-frame. Secure with cotter pin (41) and klik pin (42).
MAN0390 (Rev. 4/6/2007)
Assembly 45
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1. Install a reducer bushing (15) and a restricter
swivel elbow (16) in port at base end and rod end
of cylinder (14). Position elbows to point toward
front of cutter.
Install Driveline
1. Coat input shaft of gearbox with a light coating of
grease.
2. Attach slip clutch on driveline (5) to input shaft of
gearbox. Tighten cap screws (37) and lock nut
(38).
NOTE: Mounted units must use a double acting
cylinder to prevent damage to tailwheels during
transport.
3. Attach rear tether chain of driveline to driveline
2. Connect hoses (17) to elbows (16).
shield.
1. Tailwheel arm
14. Hydraulic cylinder, 3 x 8
37. Cap screw,
M12 x 1.5P x 65 mm
2. Rear A-frame bar
3. Front A-frame bar
4. Lower hitch pin
15. Reducer
38. Lock nut, M12 x 1.5P
39. Cap screw, 3/4 NC x 5-1/2
40. Lock nut, 3/4 NC
16. Elbow, restricter
17. Hose, 156"
5. Driveline
18. Ratchet
41. Cotter pin, 1/4 x 1-1/2
42. Klik pin, 1/4 x 1-3/4
43. Cap screw, 5/8 NC x 2-3/4
44. Flat washer, 1"
6. Sleeve, 3/4 x 1-1/4 x 3
7. Break link
19. Sleeve, 5/8 x 1 x 13/16
30. Cap screw, 5/8 NC x 5
31. Lock nut, 5/8 NC
32. Lock nut, 1" NC
33. Cap screw, 1" NC x 12
34. Flat washer, 5/8
35. Carriage bolt, 5/8 NC x 2-1/2
36. Klik pin, 7/16 x 2
8. Sleeve, 3/4 x 1 x 3
9. Sleeve, 5/8 x 1 x 1-1/4
10. Headless pin, 3/4 x 5
11. Headless pin, 1 x 4-1/2
12. Headless pin, 1 x 5
13. Transport lock-up
Figure 42. DS120 Mounted Assembly
46 Assembly
MAN0390 (Rev. 4/6/2007)
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2. Attach front reflector bracket (9) over left front
FILL GEARBOXES
shield.
NOTICE
3. Attach rubber deflector (4) and center deflector
strap (2) to the rear of the cutter frame using self-
tapping screws (6), flat washers (8), and lock
washers (7).
■
Gearbox is not filled at the factory. Prior to
delivery to customer, make sure gearbox is filled
only half-full with 80W or 90W API GL-4 or GL-5
gear lube. Use side plug to remove any excess oil.
1. Make sure vent plug hole is clear (installed by
dealer).
ꢀ Full chain or rubber shielding must be installed
when operating in populated areas or other areas
where thrown objects could injure people or dam-
age property.
2. Remove plug on side of gearbox.
3. Fill gearbox until oil runs out the side plug on
gearbox. Use a high quality gear oil with a viscosity
index of 80W or 90W and an API service rating of
GL-4 or GL-5.
• If this machine is not equipped with full chain
or rubber shielding, operation must be stopped
when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk
of thrown objects. The mower deck and protec-
tive devices cannot prevent all objects from
escaping the blade enclosure in every mowing
condition. It is possible for objects to ricochet
and escape, traveling as much as 300 feet (92 m).
4. Install side plug and vent plug.
INSTALL RUBBER SHIELDING
1. Attach rubber belting (3) and deflector brackets (1)
to the front of the frame using self-tapping screws
(6), flat washers (8), and lock washers (7).
1. Front belt bracket
2. Rear belt strap
3. Front rubber deflector
4. Rear rubber deflector
5. Rear belt strap (DS96 only)
6. Self tapping screw, 3/8 x 1-1/4
7. Lock washer, 3/8
8. Flat washer, 3/8
9. Front reflector bracket
Figure 43. Rubber Shield Installation
MAN0390 (Rev. 4/6/2007)
Assembly 47
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INSTALL CHAIN SHIELDING (OPTIONAL)
The optional chain shielding assemblies are ready for
installation when you receive them.
ꢀ Full chain or rubber shielding must be installed
when operating in populated areas or other areas
where thrown objects could injure people or dam-
age property.
1. Install front and rear chain shielding as shown
using self-tapping screws (6), lock washers (7),
and flat washers (8).
• If this machine is not equipped with full chain
or rubber shielding, operation must be stopped
when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk
of thrown objects. The mower deck and protec-
tive devices cannot prevent all objects from
escaping the blade enclosure in every mowing
condition. It is possible for objects to ricochet
and escape, traveling as much as 300 feet (92 m).
2. Attach front reflector bracket (9) over left front
shield.
1. Front chain shield bracket
2. Rear chain shield bracket
3. Front chain pin
4. Rear chain pin
5. 5/16 Chain link
6. Self tapping screw, 3/8 x 1-1/4
7. Lock washer, 3/8
8. Flat washer, 3/8
9. Front reflector bracket
Figure 44. Optional Chain Shielding Installation
48 Assembly
MAN0390 (Rev. 4/6/2007)
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DEALER CHECK LISTS
PRE-DELIVERY CHECK LIST
(DEALER’S RESPONSIBILITY)
DELIVERY CHECK LIST
(DEALER’S RESPONSIBILITY
Inspect cutter 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.
___ Show customer how to make adjustments.
Describe the options available for this cutter and
explain their purpose.
___ Explain importance of lubrication to customer and
point out lubrication points on cutter.
___ Point out all guards and shielding. Explain their
importance and the safety hazards that exist
when not kept in place and in good condition.
NOTICE
■
Gearbox was not filled at the factory. It must be
serviced before operating cutter. (See LUBRICA-
TION, page 21). Failure to service will result in dam-
age to gearbox.
___ For mounted units, add wheel weights, ballast in
front tires, and/or front tractor weight to enhance
front end stability. A minimum 20% of tractor and
equipment gross weight must be on front tractor
wheels. When adding weight to attain 20% of
tractor and equipment weight on front tractor
wheels, you must not exceed the ROPS weight
certification. Weigh the tractor and equipment. Do
not estimate!
___ Check that gearbox is properly serviced and
seals are not leaking.
___ Check and grease all lubrication points as identi-
fied in Owner Service, LUBRICATION, page 21.
___ Check that blades have been properly installed.
___ Check all bolts to be sure they are properly
torqued.
___ Present Operator's Manual and request that cus-
tomer and all operators read it before operating
equipment. Point out the manual safety rules,
explain their meanings and emphasize the
increased safety hazards that exist when safety
rules are not followed.
___ Check that all cotter pins are properly installed
and secured.
___ Check that PTO shaft is properly installed.
___ Explain to customer that when equipment is
transported on a road or highway, safety devices
should be used to give adequate warning to oper-
ators of other vehicles.
ꢂ
MAN0390 (Rev. 4/6/2007)
Dealer Check Lists 49
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NOTES
MAN0390 (Rev. 4/6/2007)
50 Dealer Check Lists
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PARTS INDEX
Rotary Cutters
DS96 & DS120
MAIN FRAME ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
MAIN FRAME ASSEMBLY PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ASSEMBLY, FRONT HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PULL-TYPE ASSEMBLY, FRONT HALF PARTS LIST . . . . . . . . . . . . . . . . . . . . . . 55
PULL-TYPE ASSEMBLY, REAR HALF
DS96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
MOUNTED ASSEMBLY
DS96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
MOUNTED TAILWHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SPLITTER GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SPINDLE GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SPINDLE GEARBOX ASSEMBLY PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FLEXIBLE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
PULL-TYPE DRIVELINE, REAR 1/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SLIP CLUTCH DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3-JOINT DRIVE, FRONT 2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
WHEEL & TIRE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
BELT SHIELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CHAIN SHIELDING (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 X 8 SINGLE-ACTING HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 70
HYDRAULIC CYLINDER STROKE CONTROL KIT - PULL-TYPE . . . . . . . . . . . . . 71
PARKING JACK - PULL-TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CROSSBAR PULLER (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
MAN0390 (Rev. 4/6/2007)
Parts 51
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DS96 / DS120 MAIN FRAME ASSEMBLY
22 - Complete decal set
23 - Safety decal set
(Rev. 2/6/2009)
52 Parts
MAN0390 (Rev. 4/6/2007)
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DS96 / DS120 MAIN FRAME PARTS LIST
DS96
DS120
REF PART
QTY
DESCRIPTION
REF PART
QTY
DESCRIPTION
1
2
3
4
5
6
7
8
9
1009230
58803
1
2
1
1
2
1
1
2
1
Tailwheel weldment
Spindle gearbox (see page 62)
Splitter gearbox (see page 61)
Clutch shield
2
3
4
5
6
7
8
9
1008191
1008192
1002048
1013377
1013378
1013379
1013370
11769KT
2
1
1
2
1
1
2
1
Spindle gearbox (see page 62)
Splitter gearbox (see page 61)
Clutch shield
1008192
1002048
1009202
1009178
1009179
1009180
19160KT
Shield
Shield
Right skid
Right skid
Left skid
Left skid
Crossbar
Crossbar
Right blade CCW
Right blade CCW
(kit includes 2 blades)
(kit includes 2 blades)
10 11768KT
11 11886KT
12 1009098
1
2
Left blade CW
(kit includes 2 blades)
10 19161KT
11 19162KT
12 1008190
1
2
Left blade CW
(kit includes 2 blades)
Double edge blade
(kit includes 2 blades)
Double edge blade
(kit includes 2 blades)
4
4
4
4
4
1
2
2
2
1
1
Blade pin kit (includes item 14 & 15)
20 ga Shim (as required)
Keyhole plate
4
4
4
4
4
1
2
2
2
1
1
Blade pin kit (includes item 14 & 15)
20 ga Shim (as required)
Keyhole plate
13
14
15
16
13946
32603
32604
10520
13
14
15
16
13946
32603
32604
10520
Blade pin lock clip
Blade pin lock clip
18 ga Shim (as required)
Manual tube
18 ga Shim (as required)
Manual tube
17 1003828
18 1019437
20 1009203
21 1009204
22 1008194
23 1008195
17 1003828
18 1009207
20 1009203
21 1009204
22 1008194
23 1008195
Flexible drive coupler (see page 63)
Shield hold down, inside
Shield hold down, outside
Complete decal set
Flexible drive coupler (see page 63)
Shield hold down, inside
Shield hold down, outside
Complete decal set
Safety decal set
Safety decal set
Hardware
Hardware
REF PART
DESCRIPTION
REF PART
DESCRIPTION
30
31
32
33
39141 1" NC x 12 Cap screw GR5
34279 1" NC Lock nut
40
41
42
43
44
45
14406 * 1/2 NC x 1 Carriage bolt
4529 * 5/16 NC Hex nut
30068 * 3/4 NC x 2-1/2 Hex head cap screw GR5
57798 3/4 Hardened flat washer
2472 * 5/16 Lock washer
35155 * 5/16 Flat washer
34 302207 * 3/4 NC Flange lock nut
6250 * 5/16 NC x 1-1/4 Hex head cap screw GR5
35
36
37
38
39
6100 * 1/2 NC x 1-1/4 Hex head cap screw GR5
855 * 1/2 Lock washer
24801 M8 x 1.25P x 20 mm
Hex head cap screw GR5
46
66840 Knob, 3-Prong 3/8 NC
39323 M30 x 2 Castle nut
-------- * B6 x 60 Cotter pin
11900 * 1/2 NC Flange lock nut
* Standard hardware, obtain locally
(Rev. 2/6/2009)
MAN0390 (Rev. 4/6/2007)
Parts 53
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DS96 / DS120 PULL-TYPE ASSEMBLY, FRONT HALF
(Rev. 7/4/2008)
54 Parts
MAN0390 (Rev. 4/6/2007)
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DS96 / DS120 PULL-TYPE ASSEMBLY, FRONT HALF PARTS LIST
DS96 DS120
REF PART
QTY
DESCRIPTION
REF PART
QTY
DESCRIPTION
1
2
1009220
11940
1791
1
1
2
2
1
1
1
1
1
1
Tongue
H-frame
1
2
1009220
11939
1791
1
1
2
2
1
1
1
1
1
1
Tongue
H-frame
3
Sleeve, 5/8 x 1 x 9/16
Cup washer 5/8 x 1-3/4 x 14 Ga
Safety chain
3
Sleeve, 5/8 x 1 x 9/16
Cup washer 5/8 x 1-3/4 x 14 Ga
Safety chain
4
10635
19407
23790
404
4
10635
19407
23790
404
5
5
6
Parking jack
6
Parking jack
7
Clevis pin, 1/2 x 5-3/4
Front 2/3 drive (see page 66)
Rear 1/3 drive (see page 64)
7
Clevis pin, 1/2 x 5-3/4
Front 2/3 drive (see page 66)
Rear 1/3 drive (see page 64)
8
40599
1009206
13132
8
40599
1009206
13132
9
9
10
3-joint drive bearing housing
(includes items 11,12, 37)
10
3-joint drive bearing housing
(includes items 11,12,37)
11
12
13133
12128
1
1
1
1
1
2
1
1
1
1
Bearing
11
12
13133
12128
1
1
1
1
1
2
1
1
1
1
Bearing
Snap ring
Snap ring
13 1011760
Shield
13 1011760
Shield
14
15
16
17
27267
3443
Sleeve, 1/2 x 3.56
Hose holder
14
15
16
17
18
27267
3443
Sleeve, 1/2 x 3.56
Hose holder
10083
46605
Sleeve 3/4 x 1-1/8 x 5/8
Clevis pin 1.00 x 2.26
Attitude rod
10083
46605
39385
Sleeve 3/4 x 1-1/8 x 5/8
Clevis pin 1.00 x 2.26
Attitude rod
18 1013388
19 1009234
SMV Bracket
19 1009234
20 24611
SMV Bracket
20
24611
Slow moving vehicle emblem
Slow moving vehicle emblem
Hardware
Hardware
REF PART
DESCRIPTION
REF PART
DESCRIPTION
30
31
32
33
34
35
36
37
38
39
1282 * 1/4 NC x 1/2 Round head cap screw
5288 * 1/4 NC Nut
41
42
43
44
45
46
47
48
49
50
12305 1/2 NC x 5-1/2 Hex head cap screw GR5
12005 5/8 NC x 6 Hex head cap screw GR5
6239 5/8 NC Lock nut
25475 * 1/2 NC x 1 Hex head cap screw GR5
57262 M12 x 1.5 x 65 mm Hex head screw
57261 M12 x 1.5 Hex lock nut
14334 * 3/4 NC x 3 Hex head cap screw GR5
2371 * 3/4 NC Lock nut
839 * 3/8 NC x 1 Hex head cap screw GR5
838 * 3/8 Standard lock washer
1257 * 3/4 Standard flat washer
8424 Washer 3/4 x 2 x 3/8
2985 * 1/4-28 x 90 Grease fitting
1285 * 1/4 x 1-1/2 Cotter pin
765 * 1/2 NC Lock nut
1256 * 3/16 x 1 Cotter pin
19811 * 1/2 NC x 2 Hex head cap screw GR8
14334 3/4 NC x 3 HHCS GR5
* Standard hardware, obtain locally
(Rev. 5/5/2011)
MAN0390 (Rev. 4/6/2007)
Parts 55
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DS96 PULL-TYPE ASSEMBLY, REAR HALF
REF PART
QTY
DESCRIPTION
Tailwheel weldment
REF PART
DESCRIPTION
1
2
3
4
4
4
4
5
6
7
8
1013380
1
30
31
32
33
34
35
36
37
1258 * 1/2 NF x 1-1/8 Wheel bolt
4119 * 1/2 NF x 1 Hex head cap screw GR5
855 * 1/2 Standard lock washer
3489 * 1/2 NC x 3 Hex head cap screw GR5
11900 * 1/2 NC Flange lock nut
1285 * 1/4 x 1-1/2 Cotter pin
1003492 2 or 4 Wheel hub (see page 67)
529
7428
2
2
2
2
2
1
1
1
1
15" steel rim - or-
21" solid tire - or-
1003695
1003695F
1003410
1013388
27267
22" Used aircraft tire - or-
22" Used aircraft tire foam filled - or-
29" Used aircraft tire
Attitude rod
3132 * 1" NC Hex nut
1863 * 1" Standard flat washer
1" Schedule 40 pipe x 3.75
Transport lock-up
1004814
29547
* Standard hardware, obtain locally
3 x 8 Hydraulic cylinder
(see page 70)
9
11893
10290
1
1
1
1
2
1
1/2 to 1/4 Reducer
10
11
12
13
14
1/4 x 1/4 90° Elbow w / 1/16 restricter
1/4 x 156" Hose
8669
1005020
46605
24098
Ratchet adjustment link
Clevis pin 1.00 x 2.26
1-1/4 Stroke control kit (see page 71)
(Rev. 5/23/2008)
MAN0390 (Rev. 4/6/2007)
56 Parts
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DS120 PULL-TYPE ASSEMBLY, REAR HALF
REF PART
QTY
DESCRIPTION
Tailwheel arm
REF PART
QTY
DESCRIPTION
1
2
3
4
4
4
4
5
6
7
8
1009165
2
14
15
16
17
18
13316
1
1
1
1
1
Spring
1003492 2 or 4 Wheel hub (see page 67)
11493
8346
1 x 3 Headless pin
529
7428
2
2
2
2
2
1
1
1
1
15" steel rim - or-
1 x 4-1/2 Headless pin
1 x 5 Headless pin
21" solid tire - or-
8347
1003695
1003695F
1003410
39385
22" Used aircraft tire - or-
22" Used aircraft tire foam filled - or-
29" Used aircraft tire
Attitude rod
24098
1-1/4 Stroke control kit (see page 71)
REF PART
DESCRIPTION
30
31
32
33
34
35
36
37
38
39
40
1258 * 1/2 NF x 1-1/8 Wheel bolt
4119 * 1/2 NF x 1 Hex head cap screw GR5
855 * 1/2 Standard lock washer
3489 * 1/2 NC x 3 Hex head cap screw GR5
11900 * 1/2 NC Flange lock nut
378 * 5/8 NC x 5 Hex head cap screw GR5
6239 * 5/8 NC Lock nut
27267
1" Schedule 40 pipe x 3.75
Transport lock-up
1004814
29547
3 x 8 Hydraulic cylinder
(see page 70)
9
11893
10290
1
1
1/2 to 1/4 Reducer
10
1/4 x 1/4 90° Elbow w / 1/16
restricter
1863 * 1" Standard flat washer
11
12
13
8669
1005020
1009245
1
1
1
1/4 x 156" Hose
Ratchet adjustment link
Spring arm
3132 * 1" NC Hex nut
23479 * 1/2 NC x 5 Hex head cap screw GR5
1285 * 1/4 x 1-1/2 Cotter pin
* Standard hardware, obtain locally
MAN0390 (Rev. 4/6/2007)
Parts 57
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DS96 MOUNTED ASSEMBLY
REF PART
QTY
DESCRIPTION
REF PART
DESCRIPTION
1
2
-------
2
2
2
2
1
1
2
1
2
1
2
4
4
Tailwheel arm (see page 60)
Rear A-frame link
30
31
32
33
34
35
36
37
38
39
40
41
42
3097 * 5/8 NC x 4-1/2 Hex head cap screw GR5
902 5/8 NC x 2 Hex head cap screw GR5
6239 * 5/8 NC Lock nut
1013376
1013397
14012
3
Front A-frame link
4
Hitch pin
986 * 5/8 NC x 2-3/4 Hex head cap screw GR5
35124 * 7/16 x 2 Klik pin
5
1005790
27140
Drive (see page 65)
Sleeve 3/4 x 1-1/4 x 3
Break link
6
57262 M12 x 1.5 x 65 mm Hex head screw
57261 M12 x 1.5 Hex lock nut
7
1013375
14824
8
Sleeve 3/4 x 1 x 3
29315 * 3/4 NC x 5-1/2 Hex head cap screw GR5
2371 * 3/4 NC Lock nut
9
66661
Sleeve 5/8 x 1 x 1-1/4
3/4 x 5 Headless pin
Sleeve 1-1/8 x 1-7/16 x 11/16
5/8 x 2-1/2 x 1/4 Washer
Tailwheel adjustment arm
10
11
12
8327
1285 * 1/4 x 1-1/2 Cotter pin
28306
62043 1/4 x 1-3/4 Klik pin
30278
12272 1-1/8 x 2-3/8 x 3/16 Washer
14153 1-1/8 NF Slotted hex nut
13 1013374
* Standard hardware, obtain locally
58 Parts
MAN0390 (Rev. 4/6/2007)
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DS120 MOUNTED ASSEMBLY
REF PART
QTY
DESCRIPTION
REF PART
DESCRIPTION
1
2
-------
2
2
2
2
1
2
2
1
2
1
1
1
1
1
1
1
1
1
2
Tailwheel (see page 60)
Rear A-frame link
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
378 * 5/8 NC x 5 Hex head cap screw GR5
19025 * 5/8 NC Flange lock nut
1009214
1009212
39064
57413
27140
1013375
14824
66661
8327
3
Front A-frame link
34279 1" NC lock nut
4
Lower hitch pin
39141 1" NC x 12 Hex head cap screw GR5
692 * 5/8 Standard flat washer
5
Drive (see page 65)
Sleeve 3/4 x 1-1/4 x 3
Break link
6
5836 * 5/8 NC x 2-1/2 Carriage bolt GR5
35124 * 7/16 x 2 Klik pin
7
8
Sleeve 3/4 x 1 x 3
57262 M12 x 1.5 x 65 mm Hex head screw
57261 M12 x 1.5 Hex lock nut
9
Sleeve 5/8 x 1 x 1-1/4
3/4 x 5 Headless pin
1 x 4-1/2 Headless pin
1 x 5 Headless pin
10
11
12
29315 * 3/4 NC x 5-1/2 Hex head cap screw GR5
2371 * 3/4 NC Lock nut
8346
8347
1285 * 1/4 x 1-1/2 Cotter pin
13 1004814
Transport lock-up
62043 1/4 x 1-3/4 Klik pin
14
15
16
17
29547
11893
10290
8669
3 x 8 Hyd cylinder (see page 70)
1/2 to 1/4 Reducer
986 * 5/8 NC x 2-3/4 Hex head cap screw GR5
1863 * 1" Standard flat washer
1/4 x 1/4 90° Elbow w/1/16 restricter
1/4 x 156" Hose
* Standard hardware, obtain locally
18 1005020
19 12313
Ratchet adjustment link
Sleeve 5/8 x 1 x 13/16
MAN0390 (Rev. 4/6/2007)
Parts 59
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DS96 / DS120 MOUNTED TAILWHEEL ASSEMBLY
REF PART
QTY
DESCRIPTION
REF PART
QTY
DESCRIPTION
1
1013385
or
2
Tail wheel arm (DS96 only)
or
12
13
14
15
16
17
18
19
20
21
15087
4
4
4
8
8
2
4
2
2
2
1" NC x 9 Hex head cap screw GR5
1" NC Jam nut
1386
1
2
3
4
1009185
15580
12577
15591
2
2
2
2
Tailwheel arm (DS120 only)
Tail wheel clevis
34279
1" NC Lock nut
855 *
1/2 Standard lock washer
1/2 NF x 1 Hex head cap screw
3/8 x 2 Spirol pin
4 x 8 Rim and laminated tire
4119 *
4674
Wheel hub with cups (includes 2 of
item 6)
2370
Washer 1.62 x 3 x .18
1/4-28 Straight grease fitting
3/32 x 1-9/16 O.D. O-ring
Cap washer
5
15277
2
Wheel hub assembly (includes 2 of
items 6, 7, 8)
12296 *
12889
12881
6
7
309
310
4
4
4
2
2
2
Bearing cup
Bearing cone
8
314
Seal for 1-1/2 shaft
Sleeve 1.25 x 1.50 x .903
Sleeve 1.25 x 1.50 x 1.86
Sleeve 1.00 x 1.25 x 5.81
* Standard hardware, obtain locally
9
15574
15575
15573
10
11
60 Parts
MAN0390 (Rev. 4/6/2007)
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DS96 / DS120 SPLITTER GEARBOX ASSEMBLY
REF PART
QTY
-- Complete gearbox
Lock nut
DESCRIPTION
REF PART
QTY
DESCRIPTION
1
2
1008192
1008130
12 1008136
13 1008148
14 1008149
15 1008151
1
2
1
1
2
1
3
4
1
1
Cover
1
Bearing cup and cone
Input shaft 1-3/4 20 spline
Housing extension
Bearing cup and cone
Seal 52 x 85 x 10
3
39274 * 16 M10 x 1.5 x 22 mm Cap screw
4
1008131
57456
1
1
1
1
1
1
1
2
Through shaft 1-3/4 20 spline
Shim 45.3 x 65.3 x 2.5
3/8 Vent plug
5
16
17
18
19
39408
39412
58751
27326 *
6
39325
7
1008132
1008133
1008134
39402
Crown gear, 27 teeth
Pinion gear, 18 teeth
Shim 45.3 x 65.3 x 1
Key, 14 x 9 x 40
Shim kit 45.3 x 65.3
3/8 NPT Solid plug
Spacer 45.3 x 60.3 x 5
Key, 14 x 9 x 35
8
9
20 1008154
21 1008155
10
11 1008135
Seal, 45 x 72 x 8
* Standard hardware, obtain locally
MAN0390 (Rev. 4/6/2007)
Parts 61
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DS96 / DS120 SPINDLE GEARBOX ASSEMBLY
62 Parts
MAN0390 (Rev. 4/6/2007)
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DS96 / DS120 SPINDLE GEARBOX ASSEMBLY PARTS LIST
12
39261
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
M30 x 1.5 Castle nut
Pinion gear (DS96 only)
Pinion gear (DS120 only)
Shim kit 50.3 x 70.3
Bearing cup and cone
Seal 50 x 90 x 10
REF PART
QTY
DESCRIPTION
13 1009097
1
1
2
1008191
58803
1
1
6
Complete gearbox (DS96 only)
Complete gearbox (DS120 only)
12
14
15
16
17
18
19
20
21
22
23
24
25
39418
57471
39263
39289
57338
57150 *
M8 x 1.25 x 14 mm Hex head cap
screw
3
4
57076
57139
57328
1009096
39424
57462
------ *
1
1
1
1
1
1
1
2
1
1
1/2 Vent plug
Cover
Screen protection
5
Shim kit 60.3 x 71.7
Crown gear (DS96 only)
Crown gear (DS120 only)
Bearing cup and cone
Cotter pin B6 x 60 mm
Snap ring
------ *
Cotter pin B4 x 55 mm
Output shaft
6
57191
39322
39323
27326 *
20890
57374
57094
6
Flat washer 31 x 56 x 4
M30 x 2.0 Castle nut
3/8 NPT Solid plug
Ball bearing
7
8
9
57466
57463
57147
10
11
Seal 35 x 72 x 10
Input shaft 1-3/8 6 spline
Seal 72 x 10
Shim 44 x 30.3 x 1
* Standard hardware, obtain locally
DS96 / DS120 FLEXIBLE COUPLER
REF PART
QTY
DESCRIPTION
5
6
7
8
1008140
4
Rubber disc
1008141
1008142
307430
48
24
12
Shaped washer
Bushing, .63 I.D.
M16 x 2.0 x 70 mm HHCS (only for 2
disc drives on DS96)
REF PART
QTY
DESCRIPTION
1
1
2
3
4
1019437
1009207
-------
Complete drive (DS96 only)
Complete drive (DS120 only)
Inner connector yoke
8
9
1001042
1008146
------- *
12
12
1
M16 x 2.0 x 90 mm HHCS
M16 x 2.0 Lock nut
1
1
1
10
Grease fitting
1008147
1008143
Outer connector yoke 1-3/4 20-spline
Outer connector yoke 1-3/4 6-spline
11 90016031 *
2
3/8 NC x 3/4 Square head set screw
* Standard hardware, obtain locally
MAN0390 (Rev. 4/6/2007)
Parts 63
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DS96 / DS120 PULL-TYPE DRIVELINE, REAR 1/3
REF PART QTY
DESCRIPTION
Complete 540 drive
REF PART QTY
DESCRIPTION
Grease fitting
1009206
110
1
1
1
1
1
1
2
2
1
2
1
2
1
18
40779
1
1
1
1
2
1
1
1
6
6
2
2
2
3
Cross and bearing kit
Spring pin 10 x 80
Male drive half, complete
Outer profile & sleeve
Inboard yoke
24 1005792
25 1005793
Outer guard half
40764
1005791
40593
40576
57416
40766
40777
18864
33347
40778
40767
Inner guard half
4
31
32
33
34
35
36
37
38
39
57438
57432
57440
57434
57439
57259
57260
57261
57262
Flange yoke
6
Friction disc
7
Hub, 1-3/4 20-spline
Thrust plate
8
Friction clutch
12
13
14
15
16
17
Bearing ring
Bellevile spring
Anti-rotation chain
Decal, Danger rotating driveline
Decal, Danger guard missing
Screw
M10 x 1.5P x 55 mm Cap screw
M10 x 1.5P Lock nut w/nylon insert
M12 x 1.5P Lock nut w/nylon insert
M12 x 1.5P x 65 mm Cap screw
Support bearing
64 Parts
MAN0390 (Rev. 4/6/2007)
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DS96 / DS120 SLIP CLUTCH DRIVE ASSEMBLY
REF PART QTY
DESCRIPTION
REF PART QTY
DESCRIPTION
Slide collar kit
1005790
Complete 540 Drive assembly
(DS96 only)
1
1
40589
1005795
57268
23
24
24
25
25
26
1
1
1
1
1
1
Outer guard half (DS96 only)
Outer guard half (DS120 only)
Inner guard half (DS96 only)
Inner guard half (DS120 only)
57413
Complete 540 Drive assembly
(DS120 only)
40574
110
Yoke, 1-3/8 Spline ASGE
Cross and bearing
Spring pin 10 X 80
Inboard yoke
1
2
1
2
2
1
1
1
1
1
2
2
1
1
2
1
1
1005796
57269
40764
40575
40587
40593
40576
57416
40766
40777
18864
33347
40778
40767
40779
3
1005794
Shaft asy, male (complete/guard)
(DS96 only)
4
57414
Shaft asy, male (complete/guard)
(DS120 only)
26
1
Inner profile
5
Outer profile & sleeve
Inboard yoke
6
57438
57432
57440
57434
57439
57259
57260
57261
57262
Flange yoke
31
32
33
34
35
36
37
38
39
1
2
1
1
1
6
6
2
2
7
Friction disc
Friction clutch 1340, 1-3/4, 20-spline
Bearing ring SC25
Anti-rotation chain
Decal, Danger rotating driveline
Decal, Danger guard missing
Screw
8
Hub, 1-3/4" 20-spline
12
13
14
15
16
17
18
Thrust plate
Belleville spring
M10 x 1.5P x 55 mm Cap screw GR8.8
M10 x 1.5P Lock nut w/nylon insert
M12 x 1.5P Lock nut w/nylon insert
M12 x 1.5P x 65 mm Cap screw GR8.8
Support bearing
Grease fitting
(Rev. 12/16/2010)
MAN0390 (Rev. 4/6/2007)
Parts 65
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DS96 / DS120 3-JOINT DRIVE, FRONT 2/3
REF PART
QTY
DESCRIPTION
REF PART
QTY
DESCRIPTION
1
2
40599
1
1
Complete drive assembly
7
40590
1
Guard, outer half, also includes items
9, 10 and 11 (cut to length)
40574
Yoke, 1-3/8 - 6SP
(complete with lock collar)
8
40591
1
Guard, inner half, also includes items
9, 10 and 11 (cut to length)
3
4
5
110
40576
40764
2
2
2
Cross and bearing kit
Inboard yoke
9
40766
40778
40777
40589
15308
2
2
2
1
1
Bearing ring (package of 2)
Screw (package of 10)
10
11
12
13
Spring pin 10 mm x 80 mm
(package of 10)
Anti-rotation chain
6
40588
1
Outer profile (cut to length)
Lock collar repair kit (without yoke)
Yoke, 1-3/8 - 6SP clamp type
66 Parts
MAN0390 (Rev. 4/6/2007)
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WHEEL & TIRE ASSEMBLY
REF PART QTY
DESCRIPTION
REF PART QTY
DESCRIPTION
1
2
3
4
5
6
7
1003492
530
1
1
1
1
2
2
1
Heavy hub assembly
Heavy wheel hub with cups
Axle
10 1003695
1
22 x 6.6 x 10 Aircraft tire,
rim & hardware
20
21
22
23
24
25
1257
5849
1256
1258
855
*
3/4 Standard flat washer
3/4 NF Slotted hex nut
3/16 x 1 Cotter pin
1003493
314
Seal for 1-1/2 shaft
Bearing cone
*
*
310
1/2 NF x 1-1/8 Wheel bolt
1/2 Extra-heavy lock washer
309
Bearing cup
1003411
15.0 x 6.0 Rim half
(for 29" aircraft wheel only) -or-
4119
1/2 NF x 1 Cap screw GR5
(solid tire only)
7
8
8
1003694
1003412
1003693
1
1
1
10.0 x 5.0 Rim half
(for 22" aircraft wheel only)
26
27
28
29
30
31
*
*
9-1/6 NC x 1-1/4 Cap screw GR5
9/16 NC Hex lock nut
15.0 x 6.0 Rim half w/valve hole
(for 29" aircraft wheel only) -or-
19887
838
3/8 NC x 1 Cap screw GR8
3/8 Standard lock washer
3/8 NC Hex nut, plated
10.0 x 5.0 Rim half w/valve hole
(for 22" aircraft wheel only)
*
*
*
835
9
531
529
1
1
1
1
Hub cap
1972
1/4-28 Tapered thread grease fitting
10
10
15" 4-Hole rim
7428
6.00 x 9 Solid tire, rim & hardware -or-
*
Standard hardware - obtain locally
10 1003410
29 x 9 x 15 Aircraft tire,
rim & hardware -or-
MAN0390 (Rev. 4/6/2007)
Parts 67
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DS96 / DS120 BELT SHIELDING
DS96
DS120
REF PART QTY
DESCRIPTION
REF PART QTY
DESCRIPTION
1
2
3
4
5
6
7
8
9
1013391
1013393
1013392
1013394
1013399
2
1
2
1
2
Front belt bracket
1
2
3
4
6
7
8
9
1008091
1008093
1008092
1008094
2
1
2
1
Front belt bracket
Rear belt strap
Rear belt strap
Front rubber deflector
Rear rubber deflector
Rear belt strap, outer (DS96 only)
Front rubber deflector
Rear rubber deflector
19446 20* 3/8 x 1-1/4 Type T self-tapping screw
838 20* 3/8 Standard lock washer
19446 18* 3/8 x 1-1/4 Type T self-tapping screw
838 18* 3/8 Standard lock washer
565 20* 3/8 Standard flat washer
565 18* 3/8 Standard flat washer
1009242
1
*
Front reflector bracket w/reflector
Standard Hardware, obtain locally
1009242
1
*
Front reflector bracket w/reflector
Standard Hardware, obtain locally
68 Parts
MAN0390 (Rev. 4/6/2007)
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DS96 / DS120 CHAIN SHIELDING (OPTIONAL)
DS96
DS120
REF PART QTY
DESCRIPTION
REF PART QTY
DESCRIPTION
1
2
3
4
5
6
7
8
9
1009188
1009189
1007854
1007856
2
1
2
1
Front chain shield bracket
Rear chain shield bracket
Front chain pin
1
2
3
4
5
6
7
8
9
1008083
1008084
1007856
1007856
2
1
2
1
Front chain shield bracket
Rear chain shield bracket
Front chain pin
Rear chain pin
Rear chain pin
3994 122 5/16 Chain, 5 link
3994 151 5/16 Chain, 5 link
19446 18 3/8 x 1-1/4 Type T self-tapping screw
838 18* 3/8 Standard lock washer
565 18* 3/8 Standard flat washer
19446 20 3/8 x 1-1/4 Type T self-tapping screw
838 20* 3/8 Standard lock washer
565 20* 3/8 Standard flat washer
1009242
1
*
Front reflector bracket with reflector
Standard Hardware, obtain locally
1009242
1
*
Front reflector bracket with reflector
Standard Hardware, obtain locally
MAN0390 (Rev. 4/6/2007)
Parts 69
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3 X 8" SINGLE-ACTING HYDRAULIC CYLINDER
REF PART
QTY
DESCRIPTION
Not available
REF PART
QTY
DESCRIPTION
1
2
N/A
9
Not used on this cylinder
Not used on this cylinder
Bushing, Pipe Reducing 1/2 x 1/4
Cylinder barrel
19810
1
1
Seal Kit, 3 In Hyd Cylinder
(includes items 2A thru 2G)
10
11
12
13
14
15
16
17
18
19
20
11893
1
1
2A
2B
2C
2D
2E
2F
2G
3
†
Wiper seal
N/A
Not used
Not used on this cylinder
Not used on this cylinder
Tie rod nut
†
†
2
2
1-1/4 ID U-Cup
Barrel O-ring
*
8
1
1
1
1
Not used on this cylinder
Piston back-up washer
Piston seal O-ring
Rod end housing
Piston
23549
Clevis, Cylinder Rod
Nut, Lock 3/8 NC
†
†
2
1
1
1
1
4
1
1
6698 *
23550 *
N/A
Screw, SHCS 3/8 NC x 1-1/2
Cylinder rod
N/A
4
N/A
29547
Cylinder, Hydraulic 3 x 8
5
34328
N/A
Nut, Lock 3/4 NF
Cylinder tie rod
1/2 Pipe plug
6
*
Standard hardware, obtain locally
Included in seal repair kit
7
4510 *
N/A
†
8
Cylinder butt end
N/A Not available
70 Parts
MAN0390 (Rev. 4/6/2007)
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HYDRAULIC CYLINDER STROKE CONTROL KIT (OPTIONAL)
REF PART QTY
DESCRIPTION
1
24098
1
Stroke control set for 1-1/4" cylinder
rod (contains items 2 - 5)
2
3
4
5
– – – –
– – – –
– – – –
– – – –
2
1
1
1
1-1/2" Segment
1-1/4" Segment
1" Segment
3/4" Segment
PARKING JACK
PULL-TYPE
REF PART QTY
DESCRIPTION
1
2
23790
25857
1
1
Swivel parking jack
Jack hitch pin assembly
3
N/S
N/S
2
3A
4
25859
25860
15-Tooth bevel gear
5/32 x 1-1/4 Drive pin
5
2
6
N/S
1
7
25862
Thrust bearing
N/S Not Serviced Separately
MAN0390 (Rev. 4/6/2007)
Parts 71
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CROSSBAR PULLER (OPTIONAL)
REF PART
QTY
DESCRIPTION
REF PART
QTY
DESCRIPTION
A
1
2
8811
1
2
4
Crossbar puller, complete
Crossbar puller clevis
5
6
7
24876
1
1
4
Crossbar puller tube assembly
Crossbar puller screw assembly
Crossbar puller link
19914
3097 *
24881
24885
5/8 NC x 4-1/2
Hex head cap screw GR5
3
4
230 *
4
1
5/8 NC Hex nut
*
Standard hardware, obtain locally
24879
Crossbar puller pad assembly
72 Parts
MAN0390 (Rev. 4/6/2007)
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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
8
lbs-ft
10
N-m
13
lbs-ft
14
N-m
1/4"
5/16"
3/8"
7/16"
1/2"
9/16"
5/8"
3/4"
7/8"
1"
7/16"
1/2"
6
18
37
12
17
19
26
27
9/16"
5/8"
23
31
35
47
49
67
36
48
55
75
78
106
163
232
325
569
907
1383
3/4"
55
75
85
115
164
230
403
642
979
120
171
240
420
669
1020
13/16"
15/16"
1-1/8"
1-5/16"
1-1/2"
78
106
149
261
416
634
121
170
297
474
722
110
192
306
467
METRIC SERIES
TORQUE
CHART
8.8
Metric Bolt Head
Identification
10.9
A
Metric
Grade 8.8
Metric
Grade 10.9
COARSE THREAD
MARKING ON HEAD
Metric 8.8 Metric 10.9
N-m lbs-ft
FINE THREAD
MARKING ON HEAD
Metric 8.8 Metric 10.9
N-m lbs-ft
A
A
Diameter &
Thread Pitch Wrench
(Millimeters)
Diameter &
Thread Pitch
(Millimeters)
Size
N-m
lbs-ft
6
N-m
lbs-ft
6
6 x 1.0
10 mm
13 mm
16 mm
18 mm
21 mm
24 mm
27 mm
30 mm
34 mm
36 mm
46 mm
8
11
27
8
8
11
29
8
6 x 1.0
8 x 1.0
8 x 1.25
10 x 1.5
12 x 1.75
14 x 2.0
16 x 2.0
18 x 2.5
20 x 2.5
22 x 2.5
24 x 3.0
30 x 3.0
20
15
20
21
16
22
39
29
54
40
41
30
57
42
10 x 1.25
12 x 1.25
14 x 1.5
16 x 1.5
18 x 1.5
20 x 1.5
22 x 1.5
24 x 2.0
30 x 2.0
68
50
94
70
75
55
103
163
250
363
507
684
861
1740
76
109
169
234
330
451
571
1175
80
151
234
323
457
623
790
1626
111
173
239
337
460
583
1199
118
181
263
367
495
623
1258
87
120
184
268
374
505
635
1283
125
172
244
332
421
867
133
194
270
365
459
928
Typical Washer
Installations
Bolt
Flat Washer
Lock Washer
8/9/00
Bolt Torque & Size Charts (Rev. 3/28/2007)
Appendix 73
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BOLT SIZE CHART
NOTE: Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts.
SAE Bolt Thread Sizes
5/16
3/8
1/2
5/8
3/4
7/8
IN
1
2
7
3
4
5
6
MM
25
50
75
100
125
150
175
Metric Bolt Thread Sizes
8MM 10MM
12MM
14MM
16MM
18MM
ABBREVIATIONS
AG .............................................................. Agriculture
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
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
Bolt Torque & Size Charts (Rev. 3/28/2007)
74 Appendix
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INDEX
28
A
Side Drive Service 32
Spindle Gearbox Repair 28
Assemble Gearbox 29
Disassemble Gearbox 28
Reinstall Gearbox 29
Remove Gearbox 28
Splitter Gearbox Repair 31
Assemble Gearbox 32
Disassemble Gearbox 31
Reinstall Gearbox 32
Remove Gearbox 31
Universal Joint
ASSEMBLY
Assemble - DS120 Pull-Type Cutter Rear Half 39
Install Attitude Rod 39
Install Height Adjustment Device 39
Install Hydraulic Hose 39
Install Rear Tailwheel 39
Install Spring Arm 39
Assemble - DS96 Pull-Type Cutter Rear Half 37
Install Attitude Rod 37
Install Height Adjustment Device 37
Install Hydraulic Hose 38
Install Rear Tailwheel 37
Assemble DS120 Mounted Cutter 45
Install A-Frame 45
Assembly 35
Disassembly 35
Repair 35
Category 2 Standard Hitch 45
Category 3 Standard Hitch 45
Install Driveline 46
G
Install Height Adjustment Device 45
Install Hydraulic Hoses 45
Install Tailwheel Arms 45
Assemble DS96 Mounted Cutter 43
Install A-Frame 43
GENERAL
Abbreviations 74
Bolt Size Chart 74
Bolt Torque Chart 73
General Information 4
Introduction 2
Install Driveline 43
Install Tailwheel Arms 43
Dealer Set-up Instructions 37
Install 3-Joint Driveline 41
Obtaining Replacement Manuals 2
Product Registration 2
Specifications 4
Attach Driveline to H-Frame 41
Install Drive Shield & Hose Holder 41
Install Driveline 41
Table of Contents 3
Warranty
Product 71
Replacement Parts 1
Install Front Drive 41
Install H-Frame 41
Install SMV Bracket 41
O
Install Tongue DS96 & DS120 Cutters 41
OPERATION
D
Attitude Adjustment - Pull-Type 18
Normal Mowing 18
Shredding 18
Blade Selection 18
DEALER CHECK
Check Lists
Connect Cutter to Tractor - Mounted
DS120 Category 2 Quick Hitch 16
DS120 Category 2 Standard Hitch 15
DS120 Category 3 Quick Hitch 16
DS120 Category 3 Standard Hitch 16
DS120 Hydraulic Connection 16
DS96 Category 2 Quick Hitch 15
DS96 Category 2 Standard Hitch 15
Connect Cutter to Tractor - Pull-Type 14
Hydraulic Connection 15
Delivery (Dealer’s Responsibility) 49
Pre-Delivery (Dealer’s Responsibility) 49
DEALER SERVICE
Crossbar
Crossbar Installation 34
Crossbar Removal 33
Timing Crossbar 34
Gearbox Maintenance 27
Horizontal Shaft Seal Repair 28
Seal Installation 27
Interference Check 15
Cutting Height Adjustment 17
Mounted 18
Seal Replacement 27
Vertical Shaft Seal Repair (Spindle Gearbox)
Pull-Type 18
(Rev. 2/6/2009)
MAN0390 (Rev. 4/6/2007)
Index 75
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Driveline Adjustment - Pull-Type 18
Driveline Attachment - Mounted 16
Driveline interference Check 17
Operating Technique 19
Cutter Operation 19
Rubber Shielding 25
P
PARTS
Mowing Tips 19
Recommended Speed 14
Storage 20
Index to Parts Lists 51
Tractor Operation 19
Tractor Stability 14
S
Transporting 19
Wheel Spacing - DS120 Only 18
SAFETY
Blocking Method 21
Check Lists
OWNER SERVICE
Adjusting Slip Clutch 24
Blocking Method 21
Cleaning 25
Delivery (Dealer’s Responsibility) 49
Pre-Delivery (Dealer’s Responsibility) 49
Pre-Operation (Owner’s Responsibility) 20
Free Mower Safety Video Order Form 5, 6
Safety & Instructional Decals 11
Jackstand Placement Diagram 22
Lubrication 21
Driveline 21
Gearbox 21
Safety Rules 7, 8, 9, 10
Safety Symbols Explained 2
Lubrication Points Diagram 22
Servicing Blades 22
Installing Blades 22
Removing Blades 22
Sharpening Blades 23
Shielding Repair
T
TROUBLESHOOTING
Troubleshooting 26
Optional Chain Shielding 25
(Rev. 2/6/2009)
76 Index
MAN0390 (Rev. 4/6/2007)
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WARRANTY
All Models Except Mow’n MachineTM Zero-Turn Mowers
Please Enter Information Below and Save for Future Reference.
Date Purchased: ____________________________
Model Number: ____________________________
From (Dealer): __________________________________________
Serial Number: __________________________________________
Woods Equipment Company (“WOODS”) warrants this product to be free from defect in material and workmanship. Except as otherwise set forth
below, the duration of this Warranty shall be for TWELVE (12) MONTHS COMMENCING ON THE DATE OF DELIVERY OF THE
PRODUCT TO THE ORIGINAL PURCHASER.
All current model loaders and backhoes are warranted for two (2) years from the date of delivery to the original purchaser.
The warranty periods for specific parts or conditions are listed below:
Part or
Condition
Warranted
Duration (from date of
delivery to the original
purchaser)
Model Number
Gearbox
Seals
All units listed below
2 years
BW1260, BW1620, BW1800, BW2400
8 years
7 years
BW240HD, BW180HD, BW180HB, BW126HB
BB48X, BB60X, BB72X, BB84X, BB600X, BB720X, BB840X, BB6000X, BB7200X, BB8400X,
DS1260, DSO1260, DS1440, TS1680, BW126-3, BW180-3, BW240
6 years
Gearbox
components PHD25, PHD35, PHD65, PHD95, 2162, 3240, DS96, DS120, RCC42, RM550-2, RM660-2,
RD990X, PRD6000, PRD7200, PRD8400, S15CD, S20CD, S22CD, S25CD, S27CD, BW180LH, 5 years
TC/R74, TC/R68, TC/R60, TBW144, TBW180, TBW204
3 years (1 year if used in rental or
commercial applications)
RDC54, RD60, RD72, TBW150C, TS/R60, TS/R52, TS/R44
Blade
spindles
RM550-2, RM660-2, RD990X, PRD6000, PRD7200, PRD8400, TBW144, TBW180, TBW204
BB600, BB720, BB840, BB6000, BB7200, BB8400, BW126-3, BW126HB, BW180-3, BW180HB,
3 years
Rust-through BW180HD, BW1260, BW1800, BW240, BW240HD, 2162, 3240, DS1260, DSO1260, DS1440, 10 years
TS1680
Under no circumstances will this Warranty apply in the event that the product, in the good faith opinion of WOODS, has been subjected to
improper operation, improper maintenance, misuse, or an accident. This Warranty does not apply in the event that the product has been materially
modified or repaired by someone other than WOODS, a WOODS authorized dealer or distributor, and/or a WOODS authorized service center.
This Warranty does not cover normal wear or tear, or normal maintenance items. This Warranty also does not cover repairs made with parts other
than those obtainable through WOODS.
This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or otherwise transfer this 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.
WOODS makes no warranty, express or implied, with respect to engines, batteries, tires or other parts or accessories not manufactured by
WOODS. Warranties for these items, if any, are provided separately by their respective manufacturers.
WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of charge, of the product if WOODS, in
its sole discretion, deems it to be 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. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY.
THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS
MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY
OF MERCHANTABILITY AND/OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
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 generality of the foregoing, Woods specifically disclaims any damages relating to (i) lost profits, business, revenues
or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or
rental; or (v) any other type of damage to property or economic loss.
This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture
replacement parts.
No agent, representative, dealer, distributor, serviceperson, 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.
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 USA
800-319-6637 tel
800-399-6637 fax
F-3079 (Rev. 2/14/2011)
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WARRANTY
(Replacement Parts For All Models Except Mow’n Machine
Zero-Turn Mowers and Woods Boundary Utility Vehicles)
TM
TM
Woods Equipment Company (“WOODS”) warrants this product 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
with the exception of V-belts, which will be free of defect in material and workmanship for a period of 12 months.
Under no circumstances will this Warranty apply in the event that the product, in the good faith opinion of
WOODS, has been subjected to improper operation, improper maintenance, misuse, or an accident. This Warranty
does not cover normal wear or tear, or normal maintenance items.
This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or
otherwise transfer this 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.
WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of
charge, of the product if WOODS, in its sole discretion, deems it to be 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. THERE ARE NO
OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE
SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS
WARRANTY. WOODS MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS
SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND/OR ANY
IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
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 generality of the foregoing,
Woods specifically disclaims any damages relating to (i) lost profits, business, revenues or goodwill; (ii) loss of
crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute
machinery or rental; or (v) any other type of damage to property or economic loss.
This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain
materials or manufacture replacement parts.
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.
Answers to any questions regarding warranty service and locations may be obtained by contacting:
©2005 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.
F-8494 (Rev. 6/23/2005)
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