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Woods Equipment DS96 User's Manual

1. driveline 18864 C FALLING OFF OR FAILING TO BLOCK SECURELV CAN RESULT IN SERIOUS INJURV OR DEATH 18865 C 6 PN 18866 A WARNING DO NOT EXCEED PTO SPEED OF 540 RPM PTO speeds higher than 540 RPM can cause equipment failure and personal injurv 18866 D 9 PN 15503 A DANGER ROTATING BLADES AND THROWN OBJECTS m Do not put hands or feet under or into mower when engine is running 7 PN 18877 A WARNING TO AVOID SERIOUS INJURY OR DEATH Read Operator s Manual available from dealer and follow all safety precautions m Before mowing clear area of objects that may be thrown by blade m Keep bystanders away m 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 10 PN 1002940 12 PN 1004114 to operate eguipment AMBER REFLECTOR 9 A DANGER 11 PN 57123 If shaft connection is visible shield FAILURE TO OPERATE SAFELY RED REFLECTOR 9 is missing Replace shield before CAN RESULT IN operating eguipment 4004114 INJURY OR DEATH Do not transport towed or semi mounted units over 20 mph 1 2 Sa fe ty MANO390 Rev 6 30 2006 SAFETY 8 INSTRUCTIONAL DECALS A ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A R
2. CLEANING After Each Use e Remove large debris such as clumps of dirt grass crop residue etc from machine Inspect machine and replace worn or damaged parts Replace any safety decals that are missing or not readable Periodically or Before Extended Storage Clean large debris such as clumps of dirt grass crop residue etc from machine Remove the remainder using a low pressure water spray 1 Be careful when spraying near scratched or torn safety decals or near edges of decals as water spray can peel decal off surface 2 Be careful when spraying near chipped or scratched paint as water spray can lift paint 3 If a pressure washer is used follow the advice of the pressure washer manufacturer Inspect machine and replace worn or damaged parts Sand down scratches and the edges of areas of missing paint and coat with Woods spray paint of matching color purchase from your Woods dealer Replace any safety decals that are missing or not readable supplied free by your Woods dealer See Safety Decals section for location drawing Rev 2 6 2009 MANO390 Rev 4 6 2007 SERVICING TIRES SAFELY Used Aircraft Tires Figure 17 A WARNING m Explosive separa tion of tire and rim parts can cause seri ous injury or death Release all air pressure before loosening bolts Do not attempt to mount a tire unless you have the proper eguipment and experience to pe
3. 1 Make sure vent plug hole is clear installed by A DANGER dealer m Full chain or rubber shielding must be installed when operating in populated areas or other areas 2 R i f box einiove plug Onside of gearbox where thrown objects could injure people or dam 3 Fill gearbox until oil runs out the side plug on age property gearbox Use a high quality gear oil with a viscosity e If this machine is not equipped with full chain index of 80W or 90W and an API service rating of or rubber shielding operation must be stopped GL 4 or GL 5 when anyone comes within 300 feet 92 m e This shielding is designed to reduce the risk of thrown objects The mower deck and protec tive devices cannot prevent all objects from 4 Install side plug and vent plug INSTALL RUBBER SHIELDING escaping the blade enclosure in every mowing l condition It is possible for objects to ricochet to the front of the frame using self tapping screws 6 flat washers 8 and lock washers 7 CD6663 1 Front belt bracket Rear belt strap Front rubber deflector Rear rubber deflector Rear belt strap DS96 only Self tapping screw 3 8 x 1 1 4 Lock washer 3 8 Flat washer 3 8 Front reflector bracket O P NO Ol BN Figure 43 Rubber Shield Installation MANO390 Rev 4 6 2007 Assembly 47 INSTALL CHAIN SHIELDING OPTIONAL The optional chain shielding assemblies are readv for installation when vou receive them 1 Install front and r
4. or 4 1003410 2 29 Used aircraft tire REF PART DESCRIPTION Zl B89 ua 30 1258 1 2 NF x 1 1 8 Wheel bolt 6 d U 1 Schedule 40 pipe x 3 75 31 4119 gt 1 2 NF x 1 Hex head cap screw GR5 7 1004814 1 Transportlocicup 32 855 1 2 Standard lock washer 8 29547 1 3 x 8 Hydraulic cylinder 33 3489 1 2 NC x 3 Hex head cap screw GR5 see page 70 34 11900 1 2 NC Flange lock nut 9 11893 1 1 2 to 1 4 Reducer 10 10290 1 1 4x1 4 90 Elbow w 1 16 35 378 5 8 NC x 5 Hex head cap screw GR5 restricter 36 6239 5 8 NC Lock nut 11 8669 1 1 4x 156 Hose 37 1863 1 Standard flat washer 12 1005020 1 Ratchet adjustment link 38 3132 1 NC Hex nut 13 1009245 1 Springarm 39 23479 1 2 NC x 5 Hex head cap screw GR5 40 1285 1 4 x 1 1 2 Cotter pin Standard hardware obtain locally MANO390 Rev 4 6 2007 Pa rts 57 DS96 MOUNTED ASSEMBLY REF PART QTY DESCRIPTION REF PART DESCRIPTION 2 Tailwheel arm see page 60 30 3097 5 8 NC x 4 1 2 Hex head cap screw GR5 2 1013376 2 Rear A frame link 31 902 5 8 NC x 2 Hex head cap screw GR5 3 1013397 2 Front A frame link 32 6239 5 8 NC Lock nut 4 14012 2 Hitch pin 33 986 5 8 NC x 2 3 4 Hex head cap screw GR5 5 1005790 1 Drive see page 65 34 35124 7 16 x 2 Klik pin 6 27140 1 Sleeve 3 4 x 1 1 4 x 3 35 57262 M12x 1 5 x 65 mm Hex head screw 7 1013375 2 Breaklink 36 57261 M12x 1 5 Hex lock nut 8 14824 1 Sleeve 34x1x3 37 29315 3 4 NC x 5 1 2 Hex head cap screw GR5
5. 1 19914 2 Crossbar puller clevis 6 24881 1 Crossbar puller screw assembly 2 3097 4 5 8NCx4 1 2 7 24885 4 Crossbar puller link Hex head cap screw GR5 3 230 4 5 8NC Hex nut Standard hardware obtain locally 4 24879 1 Crossbar puller pad assembly 72 Pa rts MANO390 Rev 4 6 2007 application BOLT TORQUE CHART Alwavs tighten hardware to these values unless a different torque value or tightening procedure is listed for a specific Fasteners must alwavs be replaced with the same grade as specified in the manual parts list Alwavs use the proper tool for tightening hardware SAE for SAE hardware and Metric for metric hardware Make sure fastener threads are clean and vou start thread engagement properlv All torque values are given to specifications used on hardware defined by SAE J1701 MAR 99 8 J1701M JUL 96 TI SAESERIES SAE Bolt Head CI A TOROUE Identification A CHART SAE Grade 2 SAE Grade 5 SAE Grade 8 No Dashes 3 Radial Dashes 6 Radial Dashes B MARKING ON HEAD Diameter Wrench SAE 2 SAES SAES Inches Size Ibs ft N m Ibs ft N m lbs ft N m 1 4 7 16 6 8 10 13 14 18 5 16 1 2 12 17 19 26 27 37 3 8 9 16 23 31 35 47 49 67 7 16 5 8 36 48 55 75 78 106 1 2 3 4 55 75 85 115 120 163 9 16 13 16 78 106 121 164 171 232 5 8 15 16 110 149 170 230 240 325 3 4 1 1
6. 3 4 NC x 2 1 2 Hex head cap screw GR5 42 2472 5 16 Lock washer 33 57798 3 4 Hardened flat washer 43 35155 5 16 Flat washer 34 302207 3 4 NC Flange lock nut 44 6250 5 16 NC x 1 1 4 Hex head cap screw GR5 35 6100 1 2 NC x 1 1 4 Hex head cap screw GR5 45 24801 M8x1 25P x 20 mm 36 855 1 2 Lock washer Hex head cap screw GR5 37 39323 M30 x 2 Castle nut 46 66840 Knob 3 Prong 3 8 NC 38 B6 x 60 Cotter pin 39 11900 1 2 NC Flange lock nut Rev 2 6 2009 MANO390 Rev 4 6 2007 Standard hardware obtain locally Parts 53 DS96 DS120 PULL TYPE ASSEMBLY FRONT HALF Rev 7 4 2008 5 4 P a r t S MANO390 Rev 4 6 2007 DS96 DS120 PULL TYPE ASSEMBLY FRONT HALF PARTS LIST DS96 DS120 REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 1 1009220 1 Tongue 1 1009220 1 Tongue 2 11940 1 H frame 2 11939 1 H frame 3 1791 2 Sleeve 5 8 x 1 x 9 16 3 1791 2 Sleeve 5 8 x 1 x 9 16 4 10635 2 Cup washer 5 8 x 1 3 4 x 14 Ga 4 10635 2 Cup washer 5 8 x 1 3 4 x 14 Ga 5 19407 1 Safety chain 5 19407 1 Safety chain 6 23790 1 Parking jack 6 23790 1 Parking jack 7 404 1 Clevis pin 1 2 x 5 3 4 7 404 1 Clevis pin 1 2 x 5 3 4 8 40599 1 Front 2 3 drive see page 66 8 40599 1 Front 2 3 drive see page 66 9 1009206 1 Rear 1 3 drive see page 64 9 1009206 1 Rear 1 3 drive see page 64 10 13132 1 3 joint drive bearing housing 10 13132 1 3 joint drive bearing housing includes items 11 12 37 includes items 11 12 37 11 13133 1 Beari
7. BW1620 BW1800 BW2400 8 years BW240HD BW180HD BW180HB BW126HB 7 years BB48X BB60X BB72X BB84X BB600X BB720X BB840X BB6000X BB7200X BB8400X Geatbox DS 1260 DSO1260 DS 1440 TS1680 BW 126 3 BW180 3 BW240 components PHD25 PHD35 PHD65 PHD95 2162 3240 DS96 DS120 RCC42 RM550 2 RM660 2 RD990X PRD6000 PRD7200 PRD8400 SISCD S20CD S22CD S25CD S27CD BW180LH 5 years TC R74 TC R68 TC R60 TBW 144 TBW180 TBW204 6 years 3 years 1 year if used in rental or RDC54 RD60 RD72 TBW150C TS R60 TS R52 TS R44 A dere Commercial applications spindles RM550 2 RM660 2 RD990X PRD6000 PRD7200 PRD8400 TBW144 TBW180 TBW204 3 years BB600 BB720 BB840 BB6000 BB7200 BB8400 BW126 3 BW126HB BW180 3 BW180HB 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 thos
8. MANO390 Rev 4 6 2007 Leakage can occur at the vertical or horizontal gaskets 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 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 5 Carefully press seal into housing avoiding distortion to the metal seal cage 1 Seal 2 Pipe or tube 3 Seal seat 4 Casting Pipe or tube must press at outer edge of seal Incorrect Installation CD1092 Figure 18 Seal Installation Dealer Service 27 VERTICAL SHAFT SEAL REPAIR SPINDLE BOX Refer to Figure 19 1 Remove and Disconnect and remove the driveline from the gearbox Remove vent plug 3 and siphon gear lube from housing through this opening Remove crossbar see Crossbar removal on page 33 Remove vertical shaft seal 16 Replace with new seal see Seal Installation on page 27
9. Rev 3 28 2007 A ASSEMBLY Assemble DS120 Pull Tvpe 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 Tvpe 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 Categorv 2 Standard Hitch 45 Category 3 Standard Hitch 45 Install Driveline 46 Install Height Adjustment Device 45 Install Hydraulic Hoses 45 Install Tailwheel Arms 45 Assemble DS96 Mounted Cutter 43 Install A Frame 43 Install Driveline 43 Install Tailwheel Arms 43 Dealer Set up Instructions 37 Install 3 Joint Driveline 41 Attach Driveline to H Frame 41 Install Drive Shield amp Hose Holder 41 Install Driveline 41 Install Front Drive 41 Install H Frame 41 Install SMV Bracket 41 Install Tongue DS96 8 DS120 Cutters 41 D DEALER CHECK Check Lists 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 Seal Replacement 27 Vertical Shaft Seal Repair Spindle Gearbox Rev 2 6 2009 MANO390 Rev 4 6 2007 INDEX 28 Side Drive Service 32 Spindle Gearbox Repair 28 Assemble Gearbox 29 Disassemble
10. by Xs in Figure 12 under the cutter before working underneath unit Do not position jackstands under wheels axles or wheel supports Components can rotate and cause cutter to fall 2 Consider the overall stability of the blocked unit Just placing jackstands underneath will not ensure your safety Rev 10 5 2007 MANO390 Rev 4 6 2007 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 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 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 LUBRICATION Do not let excess grease collect on or around parts particularly when operating in sandy areas 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
11. hold voke in hand and tap on voke to drive cup up out of voke See Figure 28 CD1386 Figure 28 Remove Cups Rev 5 11 2007 MANO390 Rev 4 6 2007 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 Figure 29 Remove Cups 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 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 Dealer Service 35 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 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 sha
12. 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 ALITEC BMP CENTRAL FABRICATORS GANNON GILL WAIN ROY Im fa WOODS WOT 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
13. 12 1008136 1 Cover 2 1008130 1 Lock nut 13 1008148 2 Bearing cup and cone 3 39274 16 M10x 1 5 x 22 mm Cap screw 14 1008149 1 Input shaft 1 3 4 20 spline 4 1008131 1 Through shaft 1 3 4 20 spline 15 1008151 1 Housing extension 5 57456 1 Shim 45 3 x 65 3 x 2 5 16 39408 2 Bearing cup and cone 6 39325 1 3 8 Vent plug 17 39412 1 Seal 52x 85x10 7 1008132 1 Crown gear 27 teeth 18 58751 3 Shim kit 45 3 x 65 3 8 1008133 1 Pinion gear 18 teeth 19 27326 4 3 8NPT Solid plug 9 1008134 1 Shim 45 3 x 65 3 x 1 20 1008154 1 Spacer 45 3 x 60 3x5 10 39402 1 Key 14x9x40 21 1008155 1 Key 14x9x 35 11 1008135 2 Seal 45x 72x 8 Standard hardware obtain locally MANO390 Rev 4 6 2007 Pa rts 6 1 DS96 DS120 SPINDLE GEARBOX ASSEMBLY 1 Complete Gearbox 62 P ar S MANO390 Rev 4 6 2007 DS96 DS120 SPINDLE GEARBOX ASSEMBLY PARTS LIST REF PART QTV DESCRIPTION 12 39261 1 M30x1 5 Castle nut 1 1008191 1 Complete gearbox DS96 only 13 1009097 1 Pinion gear DS96 only 1 58803 1 Complete gearbox DS120 only 12 99418 JIL SOVA DS tay only 2 57150 6 M8x 1 25 x 14mm Hex head cap 14 STAT ji SE screw 15 39263 2 Bearing cup and cone 3 57076 1 1 2 Vent plug 16 39289 1 Seal50x90x 10 4 57139 1 Cover 17 57338 1 Screen protection 5 57328 1 Shim kit 60 3 x 71 7 18 1 Cotter pin B4 x 55 mm 6 1009096 1 Crown gear DS96 only 19 57191 1 Output shaft 6 39424 1 Crown gear DS120 only 20 39322 1 Flat washer 31 x56x4 7 57462 1 Bearing
14. 2 26 45 Lock nut 3 4 NC 19 SMV Bracket 46 Flat washer 3 4 20 SMV Emblem 47 Washer 3 4 x 2 x 3 8 30 Cap screw 1 4 NC x 1 2 DS120 only 31 Nut 1 4 NC 48 Cotter pin 1 4 x 1 1 2 32 Cap screw 1 2 NC x 1 49 Cotter pin 3 16 x 1 Figure 36 DS96 and DS120 Tongue and Driveline Installation 42 Assembly MAN300 Rev 46 2007 ASSEMBLE DS96 MOUNTED CUTTER Refer to 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 Install A Frame 1 2 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 Torque hex nuts to 400 Ibs ft 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 Attach the two rear A frame bars together at the top rear hole using cap screw 33 spacer sleeve 9 and lock nut 32 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 Place spacer sleeve 6 through front holes of break links Align break links with bottom holes
15. 35 and lock nut 36 Attach rear tether chain of driveline to driveline shield Assembly 43 DS96 Mounted Assembly CD6659 Tailwheel arm Rear A frame bar Front A frame bar Hitch pin Driveline Sleeve 3 4 x 1 1 4 x 3 Break link Sleeve 3 4 x 1 x3 Sleeve 5 8 x 1 x 1 1 4 Headless pin 3 4 x 5 O NO Or R oh ok N49 Washer 5 8 x 2 1 2 x 1 4 Tailwheel adjustment arm 9 Sleeve 1 1 8 x 1 7 16 x 11 16 30 31 32 33 34 35 36 37 38 39 40 41 42 Cap screw 5 8 NC x 4 1 2 Cap screw 5 8 NC x 2 Lock nut 5 8 NC Cap screw 5 8 NC x 2 3 4 Klik pin 7 16 x 2 Cap screw M12 x 1 5P x 65 mm Lock nut M12 x 1 5P Cap screw 3 4 NC x 5 1 2 Lock nut 3 4 NC Cotter pin 1 4 x 1 1 2 Klik pin 1 4 x 1 3 4 Washer 1 1 8 x 2 3 8 x 3 16 Slotted nut 1 1 8 NF Figure 39 DS96 Mounted Assembly 44 Assembly MANO390 Rev 4 6 2007 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 sguare hole of the cutter mast plates Secure using carriage bolts 35 bushing sleeves 19 washers 34 and lock nuts 31 2 Attach rear A frame bars 2 with washers 44 over mounting bolts 33 and secure with lock nuts 32 3
16. 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 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 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 Category 2 Standard Hitch Figure 40 Install top link pin 10 and sleeve 6 into top holes of A frame Secure with cotter pin 41 and klik pin 42 CD6655 2 Figure 40 Category 2 Hitch Arrangement 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 MANO390 Rev 4 6 2007 CD6655 1 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 NOTE Position tailwheel arms on tailwheel to desired location usuallv on row crop centers Install Height Adjustment Device Ratchet Install ratchet 18 between cvlinder lugs on tailwheel and lugs on the deck Secure to lugs on the deck with pin 11 and two cotter pins 41 Se
17. Bolt Thread Sizes 8MM 10MM 12MM 14MM 16MM 18MM ABBREVIATIONS AG E E E r na Agriculture ASABE zni skrinke American Society of Agricultural amp Biological Engineers formerly ASAE ASAE American Society of Agricultural Engineers f IT Automatic Transmission Fluid BSPP a Asia lii British Standard Pipe Parallel BSPTM British Standard Pipe Tapered Male GN EE Constant Velocity COW egeebegseger gn Seege Eege e Counter Clockwise 0 A eebe Clockwise SE Female Ki ON o a Full Thread GA i ke a i Gauge GR 5 DE Grade 5 etc HACS anessin iaae Hex Head Cap Screw e EE Heat Treated JI Joint Industrv Council 377 Degree Flare A Tr Left Hand A Left A a Meter AU ratio koko de Piata io Millimeter DN A d a alle cee sa Male MPd A Mega Pascal Ni ise H a Seay Newton A e asa erta National Coarse NIE ia a a Fe National Fine NPSM en National Pipe Straight Mechanical NET ia bieb bi rn National Pipe Tapered NPT SWF National Pipe Tapered Swivel Female EREM ees bi ek b i em O Ring Boss Male geegent eenegen hee ees Pitch PBN a ee Power Beyond E EE Pounds per Sguare Inch PO GEN Power Take Off QD DEN Quick Disconnect Kl i En Right Hand ROPS tege ed Sec Roll Over Protective Structure RPM i ari kan fen fen Revolutions Per Minute PRD i A ah Right SAB ia cic Society of Automotive Engineers WING A Unified Coarse UNF ii i Unified Fine LEE Unified Special 74 Appendix Bolt Torgue 8 Size Charts
18. Front reflector bracket w reflector 9 1009242 1 Front reflector bracket w reflector Standard Hardware obtain locally Standard Hardware obtain locally 6 8 P ar t S MANO390 Rev 4 6 2007 DS96 DS120 CHAIN SHIELDING OPTIONAL CD6662 DS96 DS120 REF PART QTV DESCRIPTION REF PART QTV DESCRIPTION 1 1009188 2 Front chan shield bracket 1 1008083 2 Frontchain shield bracket 2 1009189 1 Rear chain shield bracket 2 1008084 1 Rear chain shield bracket 3 1007854 2 Front chain pin 3 1007856 2 Frontchain pin 4 1007856 1 Rearchain pin 4 1007856 1 Rear chain pin 5 3994 122 5 16 Chain 5 link 5 3994 151 5 16 Chain 5 link 6 19446 18 3 8 x 1 1 4 Type T self tapping screw 6 19446 20 3 8x1 1 4 Type T self tapping screw 7 838 18 3 8 Standard lock washer 7 838 20 3 8 Standard lock washer 8 565 18 3 8 Standard flat washer 8 565 20 3 8 Standard flat washer 9 1009242 1 Frontreflector bracket with reflector 9 1009242 1 Front reflector bracket with reflector Standard Hardware obtain locally Standard Hardware obtain locally MANO390 Rev 4 6 2007 Pa rts 69 3X8 SINGLE ACTING HYDRAULIC CYLINDER REF PART 1 N A 2 19810 2A t 2B 2C t 2D t 2E 2F t 2G t 3 N A 4 N A 5 34328 6 N A 7 4510 8 N A QTY M N a a P a sch sch M DESCRIPTION Not available Seal Kit 3 In Hyd Cylinder includes items 2A thru 2G Wiper seal Not used 1 1 4 ID U Cup Barrel O ring Not used on this cylinder Piston back up washe
19. Vertical seal should be recessed in housing Hori zontal seal should be pressed flush with outside of housing NOTE Distortion to seal cage or damage to seal lip will cause seal to leak Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug replace any seal damaged in installation HORIZONTAL SHAFT SEAL REPAIR Refer to Figure 19 1 Disconnect and remove the driveline from the gearbox Remove vent plug 3 and siphon gear lube from housing through this opening 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 Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug SPINDLE GEARBOX REPAIR NOTE Replacing gears shafts bearings and seals may not be cost effective Purchasing a complete gear box may be more economical REMOVE GEARBOX FROM CUTTER Refer to Figure 19 1 2 3 Disconnect and remove the driveline from the gearbox Remove vent plug 3 and siphon gear lube from housing through this opening Remove cotter pin washer and nut from vertical shaft and remove crossbar see Crossbar removal page 33 28 Dealer Service 4 Remove the four bolts that attach gearbox to cutter and remove gearbox Gearbox is heavy do not attempt to move with
20. and implement 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 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 4003751 A Safety Decals continued on next page Safety 11 SAFETY 8 INSTRUCTIONAL DECALS A ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED 4A Replace Immediately If Damaged Safety Decals continued from previous page 5 PN 18864 8 PN 18865 A DANGER N te Gef FALLING OFF CAN RESULT IN BEING RUN OVER RO TA TING DRIVELINE Tractor must be eguipped with ROPS or ROPS CAB and seat CONTACT CAN CAUSE DEATH belt Keep foldable ROPS systems in locked up position at all times KEEP A WA VI Buckle Up Keep seat belt securelv fastened Allow no riders DO NOT OPERATE WITHOUT SE RAISED EQUIPMENT CAN DROP AND CRUSH All driveline guards tractor and m Before working underneath follow all instructions and safety rules in equipment shields in place operator s manual and securely block up all corners of equipment z with jack stands Drivelines securely attached at both ends l m Securely blocking prevents equipment dropping from hvdraulic leak Driveline guards that turn freely on down hydraulic system failures or mechanical component failures
21. could result in minor or moderate injury ae Is used to address practices not related to personal injury i i ALITEC NOTE lndicates helpful information BMP CENTRAL FABRICATORS GANNON GILL Ww rar WAIN ROY tr VAI WOODS 2 Introduction Bani EREDI TABLE OF CONTENTS INTRODUCTION 6 sek sp vodn hl doma A A teed gee ene 2 GPECIEICGATIONS ai iaa a r e a teens 4 GENERAL INFORMATION 4 SAFETY VIDEO ORDER FORM LL 5 SAFETY RULES i A A A aa A 7 SAFETY DECALS i ai i b ee ae Lee Ge raa 11 OPERATION iii cis aetna ted Seige el Gee ae BY 14 OWNER SERVICE isa sies sae ene atau tania rahul PN 21 TROUBLESHOOTING ii ia A aiken eae tae eee ade olden 26 DEALER SERVICE s as aera Pag peas A E E e o EE 27 ASSEMBLY INSTRUCTIONS 37 DEALER CHECK LIST tae ce Ged a ae teed eee gees 49 INDEX TO PARTS LIST 51 BOLT TORQUE CHAT 73 BOLT SIZE CHART 8 ABBREVIATIONS 000000 e ee 74 INDEX si oie ija S A yawn nase die ee Rade feste 75 PRODUCT WARRANTY ee eee INSIDE BACK COVER REPLACEMENT PARTS WARRANTY BACK COVER LEA EL INSTRUCTIVO Si no lee Ingles pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad This Operator s Manual should be regarded as part of the machine Suppliers of both new and second hand machines must make sure that this manual is provided with the machine Rev 4 6 2007 MANO990 Rev 6 30 2006 n t ro d uc t i On
22. cup 23 1258 1 2 NF x 1 1 8 Wheel bolt 7 1003411 1 15 0x6 0 Rim half 24 855 1 2 Extra heavy lock washer for 29 aircraft wheel only or 25 4119 1 2 NF x 1 Cap screw GR5 7 1003694 1 10 0x5 0 Rim half solid tire only for 22 aircraft wheel only 26 9 1 6NC x 1 1 4 Cap screw GR5 8 1003412 1 15 0x6 0 Rim half w valve hole 27 9 16 NC Hex lock nut EES 28 19887 38NCx1 Cap screw GR8 8 1003693 1 10 0x 5 0 Rim half w valve hole 29 838 3 8 Standard lock washer for 22 aircraft wheel only 30 835 3 8NC Hex nut plated 9 531 1 Hub cap 31 1972 1 4 28 Tapered thread grease fitting 10 529 1 15 4 Hole rim 10 7428 1 6 00 x9 Solid tire rim A hardware or A Standard hardware obtain locally 10 1003410 1 29x9x 15 Aircraft tire rim 8 hardware or MANO390 Rev 4 6 2007 Pa rts 6 7 DS96 DS120 BELT SHIELDING CD6663 DS96 DS120 REF PART QTV DESCRIPTION REF PART QTV DESCRIPTION 1 1013391 2 Front belt bracket 1 1008091 2 Front belt bracket 2 1013393 1 Rear belt strap 2 1008093 1 Rear belt strap 3 1013392 2 Front rubber deflector 3 1008092 2 Front rubber deflector 4 1013394 1 Rear rubber deflector 4 1008094 1 Rear rubber deflector 5 1013399 2 Rear belt strap outer DS96 only 6 19446 20 3 8 x 1 1 4 Type T self tapping screw 6 19446 18 3 8 x 1 1 4 Type T self tapping screw 7 838 20 3 8 Standard lock washer 7 838 18 3 8 Standard lock washer 8 565 20 3 8 Standard flat washer 8 565 18 3 8 Standard flat washer 9 1009242 1
23. cup and cone 21 39323 1 M30 x 2 0 Castle nut 8 1 Cotter pin B6 x 60 mm 22 27326 1 3 8 NPT Solid plug 9 57466 2 Snap ring 23 20890 1 Ball bearing 10 57463 1 Seal 35 x 72x 10 24 57374 1 Seal 72x10 11 57147 1 Input shaft 1 3 8 6 spline 25 57094 1 Shim 44 x 30 3 x 1 Standard hardware obtain locally DS96 DS120 FLEXIBLE COUPLER REF PART QTY DESCRIPTION CD6661 5 1008140 4 Rubber disc 6 1008141 48 Shaped washer 7 1008142 24 Bushing 63 I D 8 307430 12 M16x2 0x 70 mm HHCS only for 2 REF PART QTV DESCRIPTION disc drives on DS96 1 1019437 Complete drive DS96 only 8 1001042 12 M16x2 0x 90 mm HHCS 1 1009207 Complete drive DS120 only 9 1008146 12 M16x2 0Locknut 2 1 Inner connector yoke 10 ee d Grease fitting 3 1008147 1 Outer connector yoke 1 3 4 20 spline 11 90016031 2 3 8 NC x 3 4 Square head set screw 4 1008143 1 Outer connector yoke 1 3 4 6 spline Standard hardware obtain locally MANO390 Rev 4 6 2007 Pa rts 63 DS96 DS120 PULL TYPE DRIVELINE REAR 1 3 A Complete Drive Assembly REF PART GTY DESCRIPTION REF PART QTV DESCRIPTION 1009206 1 Complete 540 drive 18 40779 1 Grease fitting 2 110 1 Cross and bearing kit 24 1005792 1 Outer guard half 3 40764 1 Spring pin 10 x 80 25 1005793 1 Inner guard half 4 1005791 1 Male drive half complete 31 57438 1 Flange yoke 6 40593 1 Outer profile amp sleeve 32 57432 2 Friction disc 7 40576 1 Inboard yoke 33 57440 1 Hub 1 3 4 20
24. equipment while engine is running Stay clear of all moving parts zu Always comply with all state and local lighting and marking reguirements m Never allow riders on power unit or attachment m 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 m 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 m Operate tractor PTO at 540 RPM Do not exceed E Look down and to the rear and make sure area is clear before operating in reverse m Do not operate or transport on steep slopes m Do not stop start or change directions sud denly on slopes m Use extreme care and reduce ground speed on slopes and rough terrain m Watch for hidden hazards on the terrain during operation m Stop power unit and equipment immediately upon striking an obstruction Turn off engine remove key inspect and repair any damage before resuming operation m Leak down or failure of mechanical or hydraulic system can cause equipment to drop m On pull tvpe or semi mounted units with optional hydraulic cutting height adjustment use a single acting cylinder with a maximum extended length
25. excessive torsional loads occur 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 materia s height type and density 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 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 Rev 2 6 2009 MANO990 Rev 6 30 2006 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 Mowing Tips 4 WARNING E Look down and to the rear and make sure area is clear before operating in reverse m Do not operate or transport on steep slopes m Do not stop start or change directions sud denly on slopes m Use extreme care and reduce ground speed on slopes and rough terrain m Watch for hidden hazards on the terrain during operation A CAUTION m Stop power unit and equ
26. or attachment m Make sure spring activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove m Operate tractor PTO at 540 RPM Do not exceed m Do not allow bystanders in the area when oper ating attaching removing assembling or servic ing equipment m Stop power unit and equipment immediately upon striking an obstruction Turn off engine remove key inspect and repair any damage before resuming operation A CAUTION m 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 14 Operation TRACTOR STABILITY A WARNING m 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 1 Tractor Stability CONNECT CUTTER TO TRACTOR PULL TYPE NOTICE mm 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
27. or bumps in the areas where the seals seat Resurface any damage with emery cloth Inspect housing and caps for cracks or damage Gearbox Lock nut M10 x 1 5 x 22 Cap screw Cross shaft Shim 45 3 x 65 3 x 2 5 Vent plug Crown gear Pinion gear Shim 45 3 x 65 3 x 1 Key 14x 9x 40 Seal Cover Bearing cup amp cone Input shaft Housing input Bearing cup amp cone Seal Shim kit Plug 3 8 NPT Spacer Key BONVDMRKOON Figure 20 Center Gearbox Assembly MANO390 Rev 4 6 2007 Dealer Service 31 ASSEMBLE GEARBOX Refer to Figure 20 1 10 11 12 13 14 15 16 Clean housing paying specific attention to areas where gaskets will be installed Wash housing and all components thoroughiv Select a clean area for gearbox assembly Replace all seals bearings and gaskets All parts must be clean and lightly oiled before reassembling Install new bearing cup 16 in gearbox housing and bearing cup 13 in cover if these parts were previously removed Place bearing 16 and shim 5 on end of cross shaft 4 and insert shaft into housing Install spacer 20 key 21 crown gear 7 shim 18 and bearing 13 on opposite end of cross shaft Place cover 12 over bearings 13 and secure into position using eight cap screws 3 Torque cap screws to 29 Ibs ft Place seal 11 over cross shaft and press into housing Use a round tube the same diamet
28. will increase Please follow the steps as you would for a 3 point hitch to insure proper engagement DRIVELINE INTERFERENCE CHECK 1 Check for clearance between driveline and cutter 5 Cut the shield to the overall dimension deck Figure 8 Determine Shield Length 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 A WARNING m On pull tvpe 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 Figure 9 Cut Shield der or ratchet jack is available for cutting height adjust MANO390 Rev 6 80 2006 Operation 17 ment on pull type units and DS120 mounted units DS96 reguires manual adjustment using holes in the tailwheel arms 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 NOTICE m 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 The bla
29. your dealer has trained service technicians available For your protection read and follow the safety informa tion in this manual A WARNING E Keep all persons away from operator control area while performing adjustments service or maintenance A CAUTION m If you do not understand any part of this manual and need assistance see your dealer m 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 BLOCKING METHOD A WARNING m 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 To minimize the potential hazards of working under neath the cutter follow these procedures 1 Jackstands with a load rating of 1000 Ibs or more are the only approved blocking device for this cutter Install a minimum of four jackstands shown
30. 3 SPECIFICATIONS Cutting Height varies with tire selection Cutting Width Overall Width Tractor HP Tractor PTO rpm Blade Spindle Blade Overlap Number of Blades Center Driveline with Slip Clutch Side Frame Thickness Weight Pull Tvpe approximate Ibs Blade Speed feet per minute Blade Rotation Wheel Size Torsion Protection DS96 DS120 2 15 2 15 96 120 103 127 40 120 40 120 540 540 2 2 4 4 4 4 Cat 4 Cat 4 7 ga 7 ga 1 800 1 930 15 900 16 700 Left Spindle CCW Right Spindle CW 15 Rims or 21 OD Solid Tires 22 or 29 Used Aircraft Tires Slip Clutch and Flex Couplers GENERAL INFORMATION A WARNING m Some illustrations in this manual show the equipment with safety shields removed to provide a better view This equipment should never be operated with any necessary safety shielding removed The purpose of this manual is to assist you in operating and maintaining your 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 4 Introduction may be general in nature due to unknown and varying operating conditions However through experience and these instructions you should be able to develop procedures suitable to your particular situation The illustrations and data u
31. 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 Interference Check 1 Be sure that tractor 3 point lift links do not interfere with hydraulic hoses cutter driveline or cutter frame 2 Check for straight ahead operation and at full turning angles If there is any interference remove the lower lift links 3 Contact between tractor lift links and cutter parts can cause damage especially when turning CONNECT CUTTER TO TRACTOR MOUNTED A WARNING m 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 Rev 2 6 2009 MANO390 Rev 6 30 2006 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 Install tractor front end weights as recommended by the tractor manufacturer to provide 20 of weight on fron
32. 4 1863 1 Standard flat washer 16 10290 1 1 4 x 1 4 90 Elbow w 1 16 restricter 17 8669 1 1 4 x 156 Hose Standard hardware obtain locally 18 1005020 1 Ratchet adjustment link 19 12313 2 Sleeve 5 8 x 1 x 13 16 MANO390 Rev 4 6 2007 Pa rts 59 DS96 DS120 MOUNTED TAILWHEEL ASSEMBLY REF PART 1 OM N A A UO N A o 1013385 or 1009185 15580 12577 15591 15277 309 310 314 15574 15575 15573 GTY M N M MNM NV N N N N A A A DESCRIPTION Tail wheel arm DS96 only or Tailwheel arm DS120 only Tail wheel clevis 4 x 8 Rim and laminated tire Wheel hub with cups includes 2 of item 6 Wheel hub assembiv includes 2 of items 6 7 8 Bearing cup Bearing cone 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 60 Parts REF PART 12 15087 13 1386 14 34279 15 855 16 4119 17 4674 18 2370 19 12296 20 12889 21 12881 QTY N N N FNM O WO HK HL FA DESCRIPTION 1 NC x 9 Hex head cap screw GR5 1 NC Jam nut 1 NC Lock nut 1 2 Standard lock washer 1 2 NF x 1 Hex head cap screw 3 8 x 2 Spirol pin 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 Standard hardware obtain locally MANO390 Rev 4 6 2007 DS96 DS120 SPLITTER GEARBOX ASSEMBLY 1 Complete Gearbox 16 17 CD6664 REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 1 1008192 Complete gearbox
33. 8 192 261 297 403 420 569 7 8 1 5 16 306 416 474 642 669 907 1 1 1 2 467 634 722 979 1020 1383 MA METRIC SERIES Metric Bolt Head A TORQUE Identification TA Metric Metric CHART Grade 8 8 Grade 10 9 COARSE THREAD FINE THREAD A MARKING ON HEAD MARKING ON HEAD A Diameter amp x Diameter amp Thread Pitch Wrench Metric 8 8 Metric 10 9 Metric 8 8 Metric 10 9 Thread Pitch Millimeters Size N m lbs ft N m Ibs ft N m Ibs ft N m Ibs ft Millimeters 6x1 0 10mm 8 6 11 8 8 6 11 8 6x1 0 8 x 1 25 13mm 20 15 27 20 21 16 29 22 8x1 0 10x 1 5 16mm 39 29 54 40 41 30 57 42 10x 1 25 12 x 1 75 18 mm 68 50 94 70 75 55 103 76 12 x 1 25 14 x 2 0 21 mm 109 80 151 111 118 87 163 120 14 x 1 5 16 x 2 0 24 mm 169 125 234 173 181 133 250 184 16x 1 5 18 x 2 5 27 mm 234 172 323 239 263 194 363 268 18x 1 5 20x 2 5 30 mm 330 244 457 337 367 270 507 374 20x 1 5 22x2 5 34 mm 451 332 623 460 495 365 684 505 22x1 5 24 x 3 0 36 mm 571 421 790 583 623 459 861 635 24x2 0 30 x 3 0 46 mm 1175 867 1626 1199 1258 928 1740 1283 30 x 2 0 Typical Washer Flat Washer Installations No Lock Washer N Na acte sod gt yy al to a d mbo o POW Oy VA AD A Bolt Torque 8 Size Charts Rev 3 28 2007 A p p en d X 73 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 00000 MM 100 125 000003 Metric
34. 9 66661 2 Sleeve 5 8 x 1 x 1 1 4 38 2371 3 4 NC Lock nut 10 8327 1 3 4x5 Headless pin 39 1285 1 4 x 1 1 2 Cotter pin 11 28306 2 Sleeve 1 1 8 x 1 7 16 x 11 16 40 62043 1 4 x 1 3 4 Klik pin 12 30278 4 5 8 x 2 1 2 x 1 4 Washer 41 12272 1 1 8 x 2 3 8 x 3 16 Washer 13 1013374 4 Tailwheel adjustment arm 42 14153 1 1 8 NF Slotted hex nut Standard hardware obtain locally 5 8 P ar t S MANO390 Rev 4 6 2007 DS120 MOUNTED ASSEMBLY CD6655a REF PART QTY DESCRIPTION REF PART DESCRIPTION 2 Tailwheel see page 60 30 378 5 8 NC x 5 Hex head cap screw GR5 2 1009214 2 Rear A frame link 31 19025 5 8 NC Flange lock nut 3 1009212 2 Front A frame link 32 34279 1 NC lock nut 4 39064 2 Lower hitch pin 33 39141 1 NC x 12 Hex head cap screw GR5 5 57413 1 Drive see page 65 34 692 5 8 Standard flat washer 6 27140 2 Sleeve 3 4 x 1 1 4 x 38 35 5836 5 8 NC x 2 1 2 Carriage bolt GR5 7 1013375 2 Break link 36 35124 7 16 x 2 Klik pin 8 14824 1 Sleeve 3 4 x1x3 37 57262 M12x 1 5 x 65 mm Hex head screw 9 66661 2 Sleeve 5 8 x 1 x 1 1 4 38 57261 M12 x 1 5 Hex lock nut 10 8327 1 3 4x5 Headless pin 39 29315 3 4 NC x 5 1 2 Hex head cap screw GR5 11 8346 1 1x 4 1 2 Headless pin 40 2371 3 4 NC Lock nut 12 8347 1 1x5 Headless pin 41 1285 1 4 x 1 1 2 Cotter pin 13 1004814 1 Transport lock up 42 62043 1 4 x 1 3 4 Klik pin 14 29547 1 3x 8 Hyd cylinder see page 70 43 986 5 8 NC x 2 3 4 Hex head cap screw GR5 15 11893 1 1 2 to 1 4 Reducer 4
35. 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 35 Disassembly 35 Repair 35 G GENERAL Abbreviations 74 Bolt Size Chart 74 Bolt Torque Chart 73 General Information 4 Introduction 2 Obtaining Replacement Manuals 2 Product Registration 2 Specifications 4 Table of Contents 3 Warrantv Product 71 Replacement Parts 1 O OPERATION Attitude Adjustment Pull Type 18 Normal Mowing 18 Shredding 18 Blade Selection 18 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 Pul Type 14 Hydraulic Connection 15 Interference Check 15 Cutting Height Adjustment 17 Mounted 18 Pull Tvpe 18 Index 75 Driveline Adjustment Pull Type 18 Driveline Attachment Mounted 16 Driveline interference Check 17 Operating Technigue 19 Cutter Operation 19 Mowing Tips 19 Recommended Speed 14 Storage 20 Tractor Operation 19 Tractor Stability 14 Transporting 19 Wheel Spacing DS120 Only 18 OWNER SERVICE Adjusting Slip Clutch 24 Blocking Method 21 Cleaning 25 Jackstand Placement Diagram 22 Lubrication 21 Driveline 21 Gearbox 21 Lubrication Points Diag
36. LL TVPE Normal Mowing 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 slightiv lower Shredding For shredding it is better to set rear of cutter slightiv lower than the front How much lower depends on the material to be shredded Determine the best setting for vour situation bv experimenting Use a slow ground speed for better shredding DRIVELINE ADJUSTMENT PULL TVPE 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 ONLV Wheels mav be adjusted to anv position for row crop shredding BLADE SELECTION There are two blade options standard suction blades and flat double edge blades The standard suction blade is a general use multi pur pose blade 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 Blade rotation viewed from top of cutter is clockwise for the right crossbar and counter clockwise for the left crossbar 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 rotatio
37. NY IMPLIED WARRANTY OF MERCHANTABILITY AND OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE WOODS shall not be liable for any incidental or conseguential 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 generalitv 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 ALITEC Woods Equipment service and locations may be obtained by contacting BMP Company 2606 South Illinois Route 2 CENTRAL FABRICATORS Post Office Box 1000 Oregon Illinois 61061 USA ear 800 319 6637 tel 800 399 6637 fax Ww ra ru WAIN ROY A a VA
38. P oil until it runs out of side level hole Tighten all plugs REINSTALL GEARBOX NOTE Gearbox is heavy do not attempt to move without mechanical assistance Set gearbox on cutter and fasten with bolts and nuts Torque bolts to 300 Ibs ft Attach crossbar see Crossbar removal on page 33 Dealer Service 29 Gearbox housing Cap screw 8 mm x 14 8 8 Vent plug Top cover Shim kit Crown gear Bearing cup amp cone Cotter pin B6 x 60 mm Snap ring Seal Input shaft Castle nut metric M30 x 1 5 Pinion gear Shim kit Bearing cup amp cone Q 359 O Gs Mart 24 Seal 50 x 90x 10 Protective screen Cotter pin Output shaft Flat washer Castle nut metric M3 x 2 0 Plug 3 8 NPT Ball bearing Oil cap Shim 44 x 30 3 x 1 Figure 19 Spindle Gearbox Assembly 30 Dealer Service H E SPLITTER GEARBOX REPAIR NOTE Replacing gears shafts bearings and seals may not be cost effective Purchasing a complete gear box may be more economical REMOVE GEARBOX FROM CUTTER 1 Disconnect driveline from the tractor PTO and remove it from center gearbox Remove vent plug 6 and siphon gear lube from housing through this opening Disconnect and remove flex coupler drivelines from side of gearbox by a Removing cap screws and hex nuts from drive line b Loosen set screws from flex coupler yoke c Slide flex coupler yoke from gearbox shaft Remove the four bol
39. P x 55 mm Cap screw GR8 8 IS aa EES 37 57260 6 M10x1 5P Lock nut w nylon insert 16 OER ey PO 38 57261 2 M12 x 1 5P Lock nut w nylon insert 17 40767 1 Support bearing 39 57262 2 M12x1 5P x65 mm Cap screw GR8 8 18 40779 1 Grease fitting Rev 12 16 2010 MANO390 Rev 4 6 2007 P a r t S 65 DS96 DS120 3 JOINT DRIVE FRONT 2 3 CDS963 REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 1 40599 1 Complete drive assembly 7 40590 1 Guard outer half also includes items 2 40574 1 Yoke 1 3 8 6SP SNE complete with lock collar 8 40591 1 Guard inner half also includes items 3 110 2 Cross and bearing kit 9 10 and 11 cutto length 4 40576 2 Inboard yoke 9 40766 2 Bearing ring package of 2 5 40764 2 Spring pin 10 mm x 80 mm 10 40778 2 Screw package of 10 package of 10 11 40777 2 Anti rotation chain 6 40588 1 Outer profile cut to length 12 40589 1 Lock collar repair kit without yoke 13 15308 1 Yoke 1 3 8 6SP clamp type 6 6 P ar t S MANO390 Rev 4 6 2007 WHEEL 8 TIRE ASSEMBLY 10 Rim for Pneumatic Tire 23 o 28 Aircraft Solid Tire Tire 8 Rim amp Rim REF PART QTV DESCRIPTION REF PART QTV DESCRIPTION 1 1003492 1 Heavy hub assembly 10 1003695 1 22x6 6x10 Aircraft tire 2 530 1 Heavy wheel hub with cups rim amp hardware 3 1003493 1 Axle 20 1257 3 4 Standard flat washer 4 314 1 Seal for 1 1 2 shaft 21 5849 3 4 NF Slotted hex nut 5 310 2 Bearing cone 22 1256 3 16x1 Cotter pin 6 309 2 Bearing
40. S WOODS www WoodsEguipment com F 3079 Rev 2 14 2011 WARRANTV Replacement Parts For All Models Except Mow n Machine M Zero Turn Mowers and Woods Boundary Utility Vehicles 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 discovere
41. SERVICE 8 6 Shaped washer 2 Shaft 7 Bushing 3 Inner yoke 8 Bolt 4 Outer yoke 9 Lock nut 5 Rubber disc 11 Set screw Figure 21 Side Drive Assembly 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 Remove end vokes by removing nuts 9 and sliding bolt 8 inward to clear voke 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 voke can be slid off gearbox shaft The inner yoke is held by two set screws 11 Reassemble shaft as shown in Figure 21 End yokes 3 amp 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 NOTE Crossbar must be re timed anytime a crossbar or a side drive is disconnected MANO390 Rev 4 6 2007 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 re
42. TIONS DEALER SET UP INSTRUCTIONS A DANGER m 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 e If this machine is not equipped with full chain or rubber shielding operation must be stopped when anyone comes within 300 feet 92 m e 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 A WARNING m Make sure spring activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove A CAUTION m Always wear relatively tight and belted clothing to avoid getting caught in moving parts Wear sturdy rough soled work shoes and protective eguipment for eyes hair hands hearing and head and respirator or filter mask where appropriate These instructions are for the assembly of the DS96 and DS120 mounted and pull tvpe cutters Manv of the procedures applv to all units When an instruction applies to a specific unit the section heading will indicate which unit Assembly of options may not applv to all units Assembly of this cutter is the responsibility of the Woods dealer It should be delivered to the owner completely assembled lubricated and adjust
43. Uv INPA Se e O JLw tell o DS96 DS120 WOODS ROTARV CUTTER O6EONVIN TO THE DEALER Assembly and proper installation of this product is the responsibility of the Woods dealer Read manual instructions and safety rules Make sure all items on the Dealer s Pre Delivery and Delivery Check Lists in the Operator s Manual are completed before releasing equipment to the owner The dealer must complete the online Product Registration form at the Woods Dealer Website which certifies that all Dealer Check List items have been completed Please contact vour dealer to complete this form Dealers can register all Woods product at dealer WoodsEquipment com under Product Registration Failure to register the product does not diminish customer s warrantv rights TO THE OWNER Read this manual before operating vour Woods equipment The information presented will prepare vou to do a better and safer job Keep this manual handy for ready reference Require all operators to read this manual carefully and become acquainted with all adjustment and operating procedures before attempting to operate Replacement manuals can be obtained from vour dealer To locate vour nearest dealer check the Dealer Locator at www WoodsEquipment com or in the United States and Canada call 1 800 319 6637 The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactorv use Like all mechanical products it wil
44. ate valve levers to release any hydraulic pres sure set parking brake stop engine remove key and unfasten seat belt m Before performing any service or maintenance disconnect driveline from tractor PTO m 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 m Do not modify or alter or permit anyone else to modify or alter the equipment or any of its compo nents in any way m Your dealer can supply original equipment hydraulic accessories and repair parts Substitute parts may not meet original equipment specifica tions and may be dangerous m 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 m 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 m 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 equipme
45. bricated 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 Raise and lower equipment to make sure air is purged from hydraulic cylinders and hoses 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 Make sure tractor ROPS or ROPS cab and seat belt are in good condition Keep seat belt securely fastened during operation Check that shields and guards are properly installed and in good condition Replace if dam aged 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 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 Make sure tractor 3 point lift links do not interfere with hydraulic hoses or driveline throughout full turning range Rev 4 6 2007 MANO390 Rev 6 30 2006 OWNER SERVICE The information in this section is written for operators who possess basic mechanical skills If you need help
46. ch shield 5 1013377 2 Shield 5 1009202 2 Shield 6 1013378 1 Right skid 6 1009178 1 Right skid 7 1013379 1 Leftskid 7 1009179 1 Left skid 8 1013370 2 Crossbar 8 1009180 2 Crossbar 9 11769KT 1 Right blade CCW 9 19160KT 1 Right blade CCW kit includes 2 blades kit includes 2 blades 10 11768KT 1 Left blade CW 10 19161KT Left blade CW kit includes 2 blades kit includes 2 blades 11 11886KT 2 Double edge blade 11 19162KT 2 Double edge blade kit includes 2 blades kit includes 2 blades 12 1009098 4 Blade pin kit includes item 14 8 15 12 1008190 4 Blade pin kit includes item 14 amp 15 13 13946 4 20ga Shim as required 13 13946 4 20ga Shim as required 14 32603 4 Keyhole plate 14 32603 4 Keyhole plate 15 32604 4 Blade pin lock clip 15 32604 4 Blade pin lock clip 16 10520 4 18 ga Shim as required 16 10520 4 18 ga Shim as required 17 1003828 1 Manual tube 17 1003828 1 Manual tube 18 1019437 2 Flexible drive coupler see page 63 18 1009207 2 Flexible drive coupler see page 63 20 1009203 2 Shield hold down inside 20 1009203 2 Shield hold down inside 21 1009204 2 Shield hold down outside 21 1009204 2 Shield hold down outside 22 1008194 1 Complete decal set 22 1008194 1 Complete decal set 23 1008195 1 Safety decal set 23 1008195 1 Safety decal set Hardware Hardware REF PART DESCRIPTION REF PART DESCRIPTION 30 39141 1 NC x 12 Cap screw GR5 40 14406 1 2 NC x 1 Carriage bolt 31 34279 1 NC Lock nut 41 4529 5 16 NC Hex nut 32 30068
47. ches 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 If driveline is too long please follow the instructions for shortening the driveline SHORTEN DRIVELINE 1 Move cutter up and down to get the shortest possible distance between tractor PTO shaft and gearbox input shaft 2 Separate driveline into two halves and connect them to the tractor PTO and gearbox 3 Place driveline halves parallel to one another to determine how much to shorten the driveline Rev 2 6 2009 MANO390 Rev 6 30 2006 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 x VAN 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 Connect driveline to tractor PTO shaft making sure the spring activated locking collar slides freely and locks driveline to PTO shaft NOTICE m If attaching with quick hitch the distance between the tractor PTO and gearbox input shaft
48. cure to tailwheel with pin 12 and two cotter pins 41 Cvlinder 1 Place hvdraulic cvlinder 14 between lugs on tailwheel and lugs on deck 2 Secure to deck lugs using pin 11 and two cotter pins 41 3 Extend cvlinder rod place transport lock bracket 13 over cvlinder rod end and between lugs on tailwheel 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 A WARNING m 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 m 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 Assembly 45 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 NOTE Mounted units must use a double acting grease Install Driveline 1 Coat input shaft of gearbox with a light coating of 2 Attach slip clutch on driveline 5 to input shaft of cylinder to prevent damage to tailwheels during 38 transport 2 Connect hoses 17 to elbows 16 gearbox Tighten cap screws 37 and loc
49. d 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 11 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
50. d snap ring 9 Secure snap ring 9 on input shaft 11 if not alreadv secure Place gear 6 through top of housing and align gear 6 and gear 13 so that gear teeth are a match MANO390 Rev 4 6 2007 11 12 13 14 15 16 17 18 19 1 2 While holding gear 6 in place slide input shaft 11 through gear 6 and bearing 7 Align splines on shaft 11 and gear 6 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 Slide shim 5 over input shaft 11 and secure with snap ring 9 Check input shaft end float bv 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 bv hand The torque should be less than 2 2 Ibs inch Check that the gear backlash is between 0 006 and 0 016 Vou should not have to adjust the backlash Press in input oil seal 10 using tube of correct diameter Be careful not to damage seal lip Press oil cap 24 on to cover the rear of housing using a tube of the correct diameter 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 Remove gearbox from water and dry off with compressed air Add SAE 80W or 90W E
51. damaged when turning 1 Adjust tractor drawbar to obtain the desired drawbar hitch point distance NOTE On some tractors a drawbar kit must be used to obtain the required dimension Check with your tractor dealer for assistance 2 Install tractor drawbar bracket to the tractor 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 tongue and drawbar 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 MANO390 Rev 6 30 2006 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 8 Remove parking jack from the tongue and attach it to the storage post on the front of the cutter 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 two 3 8 x 1 cap screws and 3 8 lock washers Hydraulic Connection 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
52. de cutting edge is approximately 1 3 4 inches above the bottom of the skid shoes Pull Tvpe Units To adjust cutter for normal mowing select a cutting height example 4 inches Using anv 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 approximatelv 1 4 to 1 2 inches more than position A Refer to Figure 11 N Ground Figure 11 Cutting Height Adjustment Mounted Units 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 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 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 18 Operation 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 ATTITUDE ADJUSTMENT PU
53. direction of rotation Streaks or ragged cut Broken or worn blades Attitude incorrect Ground speed too fast Excessive cutting height Excessive lush and tall vegetation Replace or sharpen blades Level machine Reduce ground speed Lower cutting height Note Set height so blades do not frequentiv hit ground Recut at 90 to first pass Excessive side skid wear Running with skids continuously on ground Raise cutting height or adjust Excessive clutch slippage Clutch out of adjustment Clutch discs worn wear stops contacting opposite plate Blades hitting ground Adjust clutch Replace discs Raise cutting height Vibration Broken blade Bearing failure Hitch length incorrect Universal drive Replace blades in pairs Check gearbox shafts for side plav Reset hitch length Adjust pedestal bearing height to be parallel to ground Blades hitting deck Bent blades or crossbar Replace bent blades or crossbar Blades hitting each other Side drive failure Retime blades or replace rubber coupler disks See page 34 Unit will not raise Low oil Add hvdraulic oil 26 Troubleshooting MANO390 Rev 4 6 2007 DEALER SERVICE The information in this section is written for dealer ser vice personnel The repair described here reguires special skills and tools If your shop is not properly eguipped or your mechanics are not properly
54. e sure blade offset is away from cutter Push blade pin through crossbar Pin should rotate freely prior to installing blade clip 15 Install shims 13 amp 16 over blade pin NOTE Only use enough shims to allow keyhole plate 14 to slide into blade pin groove Install blade clip 15 over keyhole plate and into blade pin groove Secure into position with cap screw 35 Torque cap screw to 85 lbs ft 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 Sharpening Blades NOTICE When sharpening blades grind the same 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 1 Sharpen both blades at the same time to maintain balance Follow original sharpening pattern Do not sharpen blade to a razor edge leave at least a 1 16 blunt edge Do not sharpen back side of blade Follow Original Pattern S Maintain Corner CD1257 2 Flange voke Friction disc Hub 1 3 8 round bore Thrust plate Belleville spring plate 10 mm x 1 35P x 50 mm Cap screw 10 mm x 1 5P Hex nut Figure 15 Slip Clutch Assembly Rev 5 11 2007 MANO390 Rev 4 6 2007 Owner Servic
55. e 23 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 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 3 If clutch does not slip freely disassemble and clean the thrust plate faces 4 flange voke 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 5 If a clutch continues to slip when the spring is compressed to 1 8 check friction discs 2 for excessive wear Discs are 1 8 when new Replace discs after 1 16 wear Minimum disc thickness is 1 16 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 reguire replacement much like slip clutch disks To maximize rubber disk life lower tractor engine speed t
56. e 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 Warrantv does not transfer to the third party purchaser in any way There are no third party beneficiaries of this Warrantv 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 A
57. ear chain shielding as shown using self tapping screws 6 lock washers 7 and flat washers 8 2 Attach front reflector bracket 9 over left front shield A DANGER m 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 e If this machine is not equipped with full chain or rubber shielding operation must be stopped when anyone comes within 300 feet 92 m e 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 Front chain shield bracket Rear chain shield bracket Front chain pin Rear chain pin 5 16 Chain link Self tapping screw 3 8 x 1 1 4 Lock washer 3 8 Flat washer 3 8 Front reflector bracket 1 2 3 4 9 6 7 8 9 Figure 44 Optional Chain Shielding Installation 48 Assembly MANO390 Rev 4 6 2007 DEALER CHECK LISTS PRE 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 NOTICE m Gearb
58. ed for normal cutting conditions The cutter is shipped partially assembled Assembly will be easier if aligned and loosely assembled before tightening hardware Recommended torgue values for hardware are located in the Bolt Torgue Chart page 73 Select a suitable working area A smooth hard surface such as concrete will make assembly much guicker 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 MANO390 Rev 4 6 2007 Complete check lists on page 49 when vou have com pleted the assembiv ASSEMBLE DS96 PULL TVPE CUTTER REAR HALF 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 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 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 Install Attitude Rod Slide attitude rod 5 under left spindle driveline and through p
59. eness 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 TRAINING m 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 the Dealer Locator at www WoodsEquipment com or in the United States and Canada call 1 800 319 6637 Failure to follow instructions or safety rules can result in serious injury or death m If you do not understand any part of this manual and need assistance see your dealer m Know your controls and how to stop engine and attachment quickly in an emergency m 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 E 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 m Make sure that all operating and service person nel know that if hydraulic fluid penetrates skin it must be surgically
60. eplace Immediately If Damaged 13 PN 1004991 A WA R N N G TRANSPORT LOCK AND CYLINDER RAISED CUTTER CAN DROP AND CRUSH REGUIREMENTS Cutters must be eguipped with transport lock SINGLE ACTING FULL Before working underneath transport lock must be in the raised EXTENSION position All corners of cutter must be securely blocked with jack gt A stands All transport components must be functional kept in good 7 condition and stored on equipment Blocking up prevents cutter dropping from hydraulic leak down hydraulic system failures or mechanical component failures FAILURE TO FOLLOW INSTRUCTIONS CAN TRANSPORT 1004991 RESULT IN SERIOUS INJURY OR DEATH LOCK 14 PN 19924 A WARNING HIGH PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN Gen RESULTING IN SERIOUS INJURY GANGRENE OR DEATH m Check for leaks with cardboard never use hand m Before loosening fittings lower load release pressure and be sure oil is cool 19924 B Consult physician immediately if skin penetration occurs GUARD MISSING DO NOT OPERATE A DANGER PN 1006348 A WARNING RELEASE ALL AIR PRESSURE BEFORE LOOSENING BOLTS GUARD MISSING DO NOT OPERATE A DANGER FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY MAX SPEED 20 MPH MAX WEIGHT 4000 LBS MAX AIR PRESSURE 40 PSI BE CAREFUL Use a clean damp cloth to clean safety decals Nese SLOW MOVING VEHICLE EMBLEM Avoid spraying too close to decals when using a
61. er of the seal and a handpress Repeat process on opposite side of gearbox Install new bearing cup 16 8 13 into input housing if these parts were previously removed Place bearing 16 over end of input shaft 14 and insert shaft into front of input housing Place seal 17 over shaft and press into housing Use a round tube the same diameter of the seal and a handpress Install bearing 13 shim 18 pinion gear 8 key 10 shim 9 over opposite end of input shaft 14 Secure parts together using lock nut 2 Tighten lock nut 2 until shaft rolling torgue is 3 to 9 Ibs inch 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 Ibs ft Check gear backlash it should be 006 to 017 at outer tooth Check gearbox housing for leaks bv plugging all holes except one Applv 4 psi compressed air and immerse the gearbox in water to verifv that there are no leaks 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 32 Dealer Service REINSTALL GEARBOX NOTE Gearbox is heavy do not attempt to move without mechanical assistance 1 Install flex coupler driveline between side gearboxes and center gearbox 2 Set gearbox on cutter and fasten with bolts and nuts Torque bolts to 300 Ibs ft SIDE DRIVE
62. es Fig ure 36 shows the DS120 cutter frame 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 4 Secure with second washer 46 and lock nut 45 5 Attach front half of attitude rod to lug on tongue using clevis pin 17 and cotter pin 48 6 Raise front of cutter and install parking jack 6 to 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 INSTALL 3 JOINT DRIVELINE Install Driveline 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 3 Attach rear tether chain on driveline to clip on plastic gearbox shield Install H Frame 1 Place H frame 2 over front of tongue and align holes MANO390 Rev 4 6 2007 2 Secure H frame to tongue using cap screw 42 two sleeve 3 two cup washers 4 and lock nut 43 Attach Driveline to H 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 necessarv when cutter is attached to the tractor Place drive
63. eve The break link must be placed in the lower holes of the A frame See Figure 5 1 1 4 OD Long End 1 1 4 OD Figure 5 DS120 Cat 3 Standard Hitch Connection DS120 Category 3 Quick Hitch 1 Position the hitch pins as shown in Figure 6 2 Place break link and 1 1 4 OD sleeve in the top hole of the A frame and secure 3 Attach tractor with guick hitch to cutter and secure according to quick hitch manufacturer s instructions 16 Operation Figure 6 DS120 Categorv 3 Quick Hitch Connection Hvdraulic Connection DS120 Oniv 1 Inspect hvdraulic hoses to ensure thev are in good condition 2 Clean the fittings before connecting them to the tractor hvdraulic ports 3 Route hoses through hose holder on 3 point mast Be sure hoses can slide freelv in holder Do not allow hose slack to drag on the ground or become caught on tractor protrusions 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 Driveline length must be sufficient to provide at least 1 3 driveline length of engagement during operation There must be at least 4 in
64. ipment immediately upon striking an obstruction Turn off engine remove key inspect and repair any damage before resuming operation 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 Tall material should be cut twice Cut material higher the first pass Cut at desired height at 90 degrees the second pass 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 TRANSPORTING A WARNING m 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 e Loss of control of the implement and tractor e Reduced or no ability to stop during braking e Implement tire failure e Damage to the implement or its components Operation 19 A WARNING m Use additional caution and reduce speed when under adverse surface conditions turning or on inclines m Never tow this implement with a motor vehicle 1 Alwavs transport with cutter in raised locked position 2 Raise cutter with hvdraulic cvlinder 3 Rota
65. is fol lowed 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 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 2 Lower cutter to ground disconnect driveline from tractor PTO shaft and slide halves apart but do not disconnect from each other 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 4 Grease side drive yoke where yoke attaches to side gearbox Owner Service 21 Front U Joint Mid U Joint Carrier Bearing Block Telescoping Shaft Rear U Joint Rotating Drive Shield Side Drive Yoke 2 Places Gearbox Check Oil Level Lower Hole on Center Gearbox Side Hole on Spindle Gearboxs Daily Tailwheel Spindle 20 hrs Caster Wheel Swivel 40 hrs Figure 12 Jackstand Placement and Lubrication Points SERVICING BLADES Removing Blades Figure 13 NOTICE m If blade pin 12 is seized in crossbar and extreme force will be needed to remove it support cr
66. ist e Training Package for Rotary Mowers Cutters English Contains DVD 8 VHS English Guidebook for Rotary Mowers Cutters English AEM Industrial Agricultural Mower Safety Manual English AEM Agricultural Tractor Safety Manual English e Training Package for Rotary Mowers Cutters English Spanish Contains DVD amp 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 aem ulilitho com 800 369 2310 tel 866 541 1668 fax Free Mower Cutter Safety Video Order Form V Select one LI VHS Format VHS01052 Safety Video LI DVD Format DVDO 1052 Safety Video Please send me Name Phone Address Mower Cutter Model Serial Send to ATTENTION DEALER SERVICES WOODS EGUIPMENT COMPANY PO BOX 1000 OREGON IL 61061 1000 USA 6 S a f e t V Safetv Video Order Form Rev 2 6 2006 SAFETY RULES A ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED AA Safety is a primary concern in the design and manufacture of our products Unfortunately our efforts to provide safe equipment can be wiped out by an operator s single careless act In addition to the design and configuration of equipment hazard control and accident preven tion are dependent upon the awar
67. ivot block on the tailwheel Loosely install spacers 6 washers 37 and two hex nuts 36 Install Height Adjustment Device Ratchet Install ratchet 12 between cylinder lug on tail wheel and lug on deck Secure with pins supplied with ratchet Cylinder 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 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 Assembly 37 Install Hydraulic Hose in the cylinder rod end port Use a restricter fitting in the base end port to dampen the cutter lowering action A WARNING 1 Install reducer bushing 9 and restricter swivel m On pull type units with optional hydraulic cut elbow 10 in port at base end of cylinder 8 ting height adjustment use a single acting cylinder Position elbow to point toward front of cutter 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 m If using a cylinder other than the one supplied rod Stroke control kit is used to set cut height by Woods make su
68. k nut 3 Attach rear tether chain of driveline to driveline shield CD6655a Tailwheel arm Rear A frame bar Front A frame bar Lower hitch pin Driveline Sleeve 3 4 x 1 1 4 x 3 Break link Sleeve 3 4 x 1 x3 Sleeve 5 8 x 1 x 1 1 4 Headless pin 3 4 x 5 Headless pin 1 x 4 1 2 Headless pin 1x5 Transport lock up DN DOV H eck lb zc Seck DM oo 14 Hydraulic cylinder 3 x 8 15 Reducer 16 Elbow restricter 17 Hose 156 18 Ratchet 19 Sleeve 5 8 x 1 x 13 16 30 Cap screw 5 8 NC x5 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 37 38 39 40 41 42 43 44 Cap screw M12 x 1 5P x 65 mm Lock nut M12 x 1 5P Cap screw 3 4 NC x 5 1 2 Lock nut 3 4 NC Cotter pin 1 4 x 1 1 2 Klik pin 1 4 x 1 3 4 Cap screw 5 8 NC x 2 3 4 Flat washer 1 46 Assembly Figure 42 DS120 Mounted Assembly MANO390 Rev 4 6 2007 FILL GEARBOXES 2 Attach front reflector bracket 9 over left front shield NOTICE 3 Attach rubber deflector 4 and center deflector H Gearbox is not filled at the factory Prior to strap 2 to the rear of the cutter frame using self delivery to customer make sure gearbox is filled tapping screws 6 flat washers 8 and lock only half full with 80W or 90W API GL 4 or GL 5 washers 7 gear lube Use side plug to remove any excess oil
69. l require cleaning and upkeep Lubricate the unit as specified Observe all safetv information in this manual and safetv decals on the equipment For service vour authorized Woods dealer has trained mechanics genuine Woods service parts and the necessarv tools and equipment to handle all vour needs Use only genuine Woods service parts Substitute parts will void the warrantv and may not meet standards required for safe and satisfactorv operation Record the model number and serial number of vour equipment in the spaces provided Model Date of Purchase Serial Number see Safetv Decal section for location Provide this information to vour dealer to obtain correct repair parts Throughout this manual the term NOTICE is used to indicate that failure to observe can cause damage to equipment The terms CAUTION WARNING and DANGER are used in conjunction with the Safety Alert Symbol a triangle with an exclamation mark to indicate the degree of hazard for items of personal safetv This is the safetv alert svmbol It is used to alert vou to potential personal A injurv hazards Obey all safety messages that follow this symbol to avoid possible injurv or death Indicates a hazardous situation which if not avoided will result in death A hla b or serious injury A WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury A CAUTION Indicates a hazardous situation which if not avoided
70. line bearing carrier between H frame 2 and secure with clevis pin 7 and cotter pin 49 Install Front Drive 1 Slide rear voke of front driveline 8 over shaft of driveline 9 and align with notch on shaft 2 Secure drives together using cap screw 39 and lock nut 38 3 Attach tether chain on front half of driveline 8 to H frame 2 Install Drive Shield amp Hose Holder 1 Attach drive shield 13 to driveline carrier bearing using two cap screws 35 and lock washers 36 2 Attach hydraulic hose holder 15 to the top hole in H frame 2 with cap screw 41 sleeve 14 and lock nut 40 Install SMV Bracket 1 Attach SMV bracket 19 to the top of center gearbox using two cap screws 32 2 Attach SMV emblem 20 to SMV bracket using two round head cap screws 30 and hex nuts 31 Assembly 41 Tongue and Driveline Installation 1 Tongue 2 H Frame 33 Cap screw M12 x 1 5P x 65 mm 3 Sleeve 5 8 x 1 x 9 16 34 Lock nut M12 x 1 5P 4 Cup washer 35 Cap screw 3 8 NC x 1 5 Safety chain 36 Lock washer 3 8 6 Parking jack 37 Grease fitting 7 Clevis pin 1 2 x 5 3 4 38 Lock nut 1 2 NC 8 Driveline front 2 3 39 Cap screw 1 2 NC x 2 9 Driveline rear 1 3 40 Flange lock nut 1 2 NC 13 Shield 41 Cap screw 1 2 NC x 5 1 2 14 Sleeve 1 2 x 3 9 16 42 Cap screw 5 8 NC x 6 15 Hose holder 43 Lock nut 5 8 16 Sleeve 3 4 x 1 1 8 x 5 8 44 Cap screw 3 4 NC x 3 17 Clevis pin 1 x
71. lwheel weldment 30 1258 1 2 NF x 1 1 8 Wheel bolt 2 1003492 2 or 4 Wheel hub see page 67 31 4119 1 2 NF x 1 Hex head cap screw GR5 3 529 2 15 steel rim or 32 855 1 2 Standard lock washer 4 7428 2 21 solid tire or 33 3489 1 2 NC x 3 Hex head cap screw GR5 4 1003695 2 22 Used aircraft tire or 34 11900 1 2 NC Flange lock nut 4 1003695F 2 22 Used aircraft tire foam filled or 35 1285 1 4 x 1 1 2 Cotter pin 4 1003410 2 29 Used aircraft tire 36 3132 1 NC Hex nut 5 1013388 1 Attitude rod 37 1863 1 Standard flat washer 6 27267 1 1 Schedule 40 pipe x 3 75 7 1004814 1 Transport lock up Standard hardware obtain locally 8 29547 1 3x8 Hydraulic cylinder see page 70 9 11893 1 1 2 to 1 4 Reducer 10 10290 1 1 4x1 4 90 Elbow w 1 16 restricter 11 8669 1 1 4x 156 Hose 12 1005020 1 Ratchet adjustment link 13 46605 2 Clevis pin 1 00 x 2 26 14 24098 1 1 1 4 Stroke control kit see page 71 Rev 5 23 2008 56 Pa rts MANO390 Rev 4 6 2007 DS120 PULL TYPE ASSEMBLY REAR HALF CD6653 D REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 1 1009165 2 Tailwheel arm 14 13316 1 Spring 2 1003492 2 or 4 Wheel hub see page 67 15 11493 1 1x3 Headless pin 3 529 2 15 steel rim or 16 8346 1 1x 4 1 2 Headless pin 4 7428 2 21 solid tire or 17 8347 1 1x5 Headless pin 4 1003695 2 22 Used aircraft tire or 18 24098 1 1 1 4 Stroke control kit see page 71 4 1003695F 2 22 Used aircraft tire foam filled
72. 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 m Inspect and clear area of stones branches or other hard objects that might be thrown causing injury or damage OPERATION m 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 e If this machine is not equipped with full chain or rubber shielding operation must be stopped when anyone comes within 300 feet 92 m e 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 m Do not allow bystanders in the area when oper ating attaching removing assembling or servic ing equipment m Never direct discharge toward people animals or property m Do not operate or transport equipment while under the influence of alcohol or drugs Mm Operate only in daylight or good artificial light 8 Safety E Keep hands feet hair and clothing away from
73. move 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 CD6657 1B Figure 22 Blade Removal 3 Remove cotter pin 38 and castle nut 37 from bottom of crossbar Se 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 CD1249A 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 Clevis 5 8 NC x 4 Cap screw 5 8 NC Hex nut Pad assembly Tube assembly Screw assembly 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 Noanwnna fy NOTE Hydraulic jack will not operate if tipped Fu hernie more than 90 degrees Use care to prevent bend ing crossbar during removal Figure 23 Crossbar Removal A O Dealer Se
74. n Blades from the right may be used on the left Blades from the left may be used on the right Rev 2 6 2009 MANO390 Rev 6 30 2006 Blades must be moved in pairs Never use one new blade and one used blade on a crossbar TRACTOR OPERATION Use care when operating around tree limbs and other low objects Use care and reduce ground speed on rough terrain Always watch for hidden hazards Being knocked off or falling off tractor can result in seri ous injury or death Only use a tractor with a Roll Over Protective Structure ROPS and seat belt Securely fasten seat belt before starting tractor 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 Be sure operator is familiar with all controls and can stop tractor and cutter guickly in an emergency The operator should give complete undivided attention to operating tractor and cutter OPERATING TECHNIQUE Power for operating the cutter is supplied by the tractor PTO Operate PTO at 540 rom Know how to stop the tractor and cutter guickly in an emergency 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 Gearbox protection is provided by a slip clutch with replacement fiber disc The slip clutch is designed to slip when
75. ng 11 13133 1 Bearing 12 12128 1 Snap ring 12 12128 1 Snap ring 13 1011760 1 Shield 13 1011760 1 Shield 14 27267 1 Sleeve 1 2 x 3 56 14 27267 1 Sleeve 1 2 x 3 56 15 3443 1 Hose holder 15 3443 1 Hose holder 16 10083 2 Sleeve 3 4 x 1 1 8 x 5 8 16 10083 2 Sleeve 3 4 x 1 1 8 x 5 8 17 46605 1 Clevis pin 1 00 x 2 26 17 46605 1 Clevis pin 1 00 x 2 26 18 1013388 1 Attitude rod 18 39385 1 Attitude rod 19 1009234 1 SMV Bracket 19 1009234 1 SMV Bracket 20 24611 1 Slow moving vehicle emblem 20 24611 1 Slow moving vehicle emblem Hardware Hardware REF PART DESCRIPTION REF PART DESCRIPTION 30 1282 1 4 NC x 1 2 Round head cap screw 41 12305 1 2 NC x 5 1 2 Hex head cap screw GR5 31 5288 1 4 NC Nut 42 12005 5 8 NC x 6 Hex head cap screw GR5 32 25475 1 2 NC x 1 Hex head cap screw GR5 43 6239 5 8 NC Lock nut 33 57262 M12x 1 5 x 65 mm Hex head screw 44 14334 3 4 NC x 3 Hex head cap screw GR5 34 57261 M12 x 1 5 Hex lock nut 45 2371 3 4 NC Lock nut 35 839 3 8 NC x 1 Hex head cap screw GR5 46 1257 3 4 Standard flat washer 36 838 3 8 Standard lock washer 47 8424 Washer 3 4 x 2 x 3 8 37 2985 1 4 28 x 90 Grease fitting 48 1285 1 4 x 1 1 2 Cotter pin 38 765 1 2 NC Lock nut 49 1256 3 16 x 1 Cotter pin 39 19811 1 2 NC x 2 Hex head cap screw GR8 50 14334 3 4NC x 3 HHCS GR5 Standard hardware obtain locally Rev 5 5 2011 o Hey SO Parts 55 DS96 PULL TYPE ASSEMBLY REAR HALF REF PART QTY DESCRIPTION REF PART DESCRIPTION 1 1013380 1 Tai
76. nt 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 m Make sure attachment is properly secured adjusted and in good operating condition E Keep all persons away from operator control area while performing adjustments service or maintenance m Make certain all movement of equipment com ponents has stopped before approaching for ser vice m Frequently check blades They should be sharp free of nicks and cracks and securely fastened m Do not handle blades with bare hands Careless or improper handling may result in serious injury m Your dealer can supply genuine replacement blades Substitute blades may not meet original equipment specifications and may be dangerous m 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 m Make sure all safety decals are installed Replace if damaged See Safety Decals section for location m Make sure shields and guards are properly installed and in good condition Replace if dam aged m Do not disconnect hydraulic lines until machine is securely blocked or placed in lowest position and system pressure is released by operating valve levers m Leak down or failure of mechanical or hydraulic s
77. o an idle when engaging the PTO and avoid striking the ground with cutter blades 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 reguired in the future 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 torgue bolts to 85 Ibs 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 Complete drive Inner connector yoke Outer connector voke 1 3 4 20 spline Outer connector voke 1 3 4 6 spline Rubber disc Shaped washer Bushing 63 ID Hex head cap screw M16 x 2 0 Lock nut Grease fitting 3 8 NC x 3 4 Sguare head set screw Figure 16 Flexible Coupler 24 Owner Service Rev 2 6 2009 MANO390 Rev 4 6 2007 SHIELDING REPAIR A DANGER m 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 dav of operation and replace if bent cracked or broken Repairing Optional Chain Shielding Inspect chain shielding each dav of operation and replace anv broken or missing chains as required
78. of 28 1 4 718 mm from attaching point center to center m 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 TRANSPORTATION m 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 DS96 DS120 Safety Rules Rev 5 11 2007 SAFETY RULES A ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A imum transport speed Doing so could result in e Loss of control of the implement and tractor e Reduced or no ability to stop during braking e Implement tire failure e Damage to the implement or its components m Use additional caution and reduce speed when under adverse surface conditions turning or on inclines m Do not operate PTO during transport m Never tow this implement with a motor vehicle m Do not operate or transport on steep slopes m Do not operate or transport equipment while under the influence of alcohol or drugs m Always comply with all state and local lighting and marking requirements m Never allow riders on power unit or attachment MAINTENANCE m 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 oper
79. on front A frame bars 3 and secure together using cap screw 37 and lock nut 38 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 CD6659 2 Figure 37 Break Linkage Installation MANO390 Rev 4 6 2007 Install Tailwheel Arms Refer to Figure 38 and Figure 39 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 Secure each adjustment brace with a cap screw 31 and lock nut 32 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 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 13 Tailwheel adjustment arm 31 32 5 8 NC Lock nut Tailwheel arm 5 8 NC x 4 1 2 Cap screw Figure 38 Adjustment Arm Installation Install Driveline 1 2 3 Coat input shaft of gearbox with a light coating of grease Attach slip clutch on driveline 5 to input shaft of gearbox Tighten cap screws
80. 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 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 9 9 Dealer Check Lists 49 NOTES 50 Dealer Check Lists Ee WOODS PARTS INDEX Rotary Cutters DS96 8 DS120 MAIN FRAME ASSEMBLV MAIN FRAME ASSEMBLY PARTS LIST ASSEMBLY FRONT HALF PULL TYPE ASSEMBLY FRONT HALF PARTS LIST PULL TYPE ASSEMBLY REAR HALF FLEXIBLE COUPLER PULL TYPE DRIVELINE REAR 1 3 SLIP CLUTCH DRIVE ASSEMBLY 3 JOINT DRIVE FRONT 2 3 WHEEL amp TIRE ASSEMBLY BELT SHIELDING CHAIN SHIELDING OPTIONAL 3 X 8 SINGLE ACTING HYDRAULIC CYLINDER HYDRAULIC CYLINDER STROKE CONTROL KIT PULL TYPE PARKING JACK PULL TYPE CROSSBAR PULLER OPTIONAL MANO390 Rev 4 6 2007 Pa rts 5 1 DS96 DS120 MAIN FRAME ASSEMBLY 22 Complete decal set 23 Safety decal set Rev 2 6 2009 MANO390 Rev 4 6 2007 52 Parts DS96 DS120 MAIN FRAME PARTS LIST DS96 DS120 REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 1 1009230 1 Tailwheel weldment 2 1008191 2 Spindle gearbox see page 62 2 58803 2 Spindle gearbox see page 62 3 1008192 1 Splitter gearbox see page 61 3 1008192 1 Splitter gearbox see page 61 4 1002048 1 Clutch shield 4 1002048 1 Clut
81. or or filter mask where appropriate m Make sure attachment is properly secured adjusted and in good operating condition m Make sure spring activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove m 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 m 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 E Inspect chain shielding before each use Replace if damaged Safety Rules continued on next page Safety 7 SAFETY RULES A ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A Safety Rules continued from previous page m Remove accumulated debris from this equip ment power unit and engine to avoid fire hazard m Make sure all safety decals are installed Replace if damaged See Safety Decals section for location m Make sure shields and guards are properly installed and in good condition Replace if dam aged m Do not put this equipment into service unless all side skids are properly installed and in good condi tion Replace if damaged m A
82. ossbar from below to prevent gearbox damage 8 Crossbar 9 Blade 12 Blade pin 13 Shim 14 Keyhole plate 15 Blade pin lock clip 16 Shim 35 Cap screw CD6657 1 Figure 13 Blade Assembly 22 Owner Service 1 Disconnect driveline from tractor PTO 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 amp 16 Carefully drive blade pin 12 out of crossbar 3 Rotate crossbar 8 and repeat for opposite blade Installing Blades A CAUTION m Your dealer can supply genuine replacement blades Substitute blades may not meet original equipment specifications and may be dangerous NOTICE m Crossbar rotation has counterclockwise rota 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 Rev 10 5 2007 MANO390 Rev 4 6 2007 NOTE Always replace or sharpen both blades at the same time 1 Insert blade pin through the blade 9 Inspect blade pin 12 for nicks or gouges and if vou find any replace the blade pin Blade should swivel on blade pin if it doesn t determine the cause and correct Align crossbar 8 with blade access hole in cutter frame Apply a liberal coating of Never Seez or eguivalent to blade pin and crossbar hole Mak
83. out mechanical assistance DISASSEMBLE GEARBOX Refer to Figure 19 1 11 12 13 14 15 16 17 18 Remove 3 8 plug from side of gearbox and pour out gear oil Remove oil cap 24 to be replaced Remove snap ring 9 and shim 5 from input shaft 11 Support gearbox in hand press and push on input shaft 11 to remove bearing 23 Remove top cover 4 from housing Remove gear 6 from inside housing Remove oil seal 10 from front of housing to be replaced Remove snap ring 9 and shim 5 from front of housing 1 Remove input bearing 7 by using a punch and hammer from outside of housing Support housing in vise in a horizontal position 10 The castle nut 21 cotter pin 8 and washer 20 are already removed with the stump jumper crossbar Remove the protective screen 17 and seal 16 Remove cotter pin 18 castle nut 12 and washer 25 from output shaft 19 Remove output shaft 19 by using a punch and hammer and tap on top to drive down Remove gear 5 and shim 15 from inside housing Remove bearing 15 by using a punch and hammer from the top outside the housing Support housing upside down top cover surface and remove bearing 15 by using a punch and hammer from the bottom side of the housing Inspect gears for broken teeth and wear Some wear is normal and will show on loaded side Forged gear surfaces a
84. ox 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 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 Check that all cotter pins are properly installed and secured Check that PTO shaft is properly installed MANO390 Rev 4 6 2007 DELIVERY CHECK LIST DEALER S RESPONSIBILITY 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 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 Present Operator s Manual and request that cus tomer and all operators read it before
85. pressure washer high pressure water can enter through very small scratches or under edges of decals causing them to peel or come off Replacement safety decals can be ordered free from your Woods dealer To locate your nearest dealer check the Dealer Locator at www WoodsEquipment com or in the United States and Canada call 1 800 319 6637 vre eee Sa f e t V 1 3 OPERATION The operator is responsible for the safe operation of the cutter The operator must be properly trained Operators should be familiar with the cutter the tractor and all safetv practices before starting operation Read the safetv rules and safetv decals on page 7 to page 13 This medium dutv cutter is designed for grass and weed mowing and shredding Recommended mowing speed for most conditions is from 2 to 5 mph A DANGER m 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 e If this machine is not equipped with full chain or rubber shielding operation must be stopped when anyone comes within 300 feet 92 m e 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 A WARNING m Never allow riders on power unit
86. r Piston seal O ring Rod end housing Piston Nut Lock 3 4 NF Cylinder tie rod 1 2 Pipe plug Cylinder butt end 70 Parts REF PART 9 10 11 11893 12 N A 13 14 15 16 23549 17 6698 18 23550 19 N A 20 29547 QTY 1 a1 1 1 h x t N A DESCRIPTION Not used on this cylinder Not used on this cylinder Bushing Pipe Reducing 1 2 x 1 4 Cylinder barrel Not used on this cylinder Not used on this cylinder Tie rod nut Clevis Cylinder Rod Nut Lock 3 8 NC Screw SHCS 3 8 NC x 1 1 2 Cylinder rod Cylinder Hydraulic 3 x 8 Standard hardware obtain locally Included in seal repair kit Not available MANO390 Rev 4 6 2007 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 DB1673 2 2 1 1 2 Segment 3 1 1 1 4 Segment 4 1 1 Segment 5 1 3 4 Segment PARKING JACK PULL TYPE B se IN Se REF PART QTV DESCRIPTION 23790 1 Swivel parking jack 2 25857 1 Jack hitch pin assembly 3 N S 3A N S 4 25859 2 15 Tooth bevel gear 5 25860 2 5 32 x 1 1 4 Drive pin 6 N S 7 25862 1 Thrust bearing N S Not Serviced Separately MAN0390 Rev 4 6 2007 P ar S 7 1 CROSSBAR PULLER OPTIONAL CD1249A REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION A 8811 1 Crossbar puller complete 5 24876 1 Crossbar puller tube assembly
87. ram 22 Servicing Blades 22 Installing Blades 22 Removing Blades 22 Sharpening Blades 23 Shielding Repair Optional Chain Shielding 25 Rubber Shielding 25 P PARTS Index to Parts Lists 51 S SAFETY Blocking Method 21 Check Lists Delivery Dealer s Responsibility 49 Pre Delivery Dealer s Responsibility 49 Pre Operation Owners Responsibility 20 Free Mower Safety Video Order Form 5 6 Safety 8 Instructional Decals 11 Safety Rules 7 8 9 10 Safety Symbols Explained 2 T TROUBLESHOOTING Troubleshooting 26 Rev 2 6 2009 7 6 n d ex MANO990 Rev 4 6 2007 WARRANTY All Models Except Mow n Machine Zero Turn Mowers Please Enter Information Below and Save for Future Reference Date Purchased From Dealer Model Number 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 Duration from date of Condition Model Number delivery to the original Warranted purchaser Gearbox Seals All units listed below 2 years BW1260
88. re a breather fitting is installed Tailwheel Transport lock up Headless pin 1 x 4 Wheel hub Hydraulic cylinder Wheel bolt 1 2 NF x 1 1 8 15 Steel rim Reducer Cap screw 1 2 NF x 1 21 Solid tire or Elbow restricter Lock washer 1 2 22 Aircraft tire or Hose 156 Cap screw 1 2 NC x3 29 Aircraft tire Ratchet Flange lock nut 1 2 NC Attitude rod Clevis pin 1 0 x 2 26 Cotter pin 1 4 x 1 1 2 Spacer Stroke control kit Hex nut 1 NC Headless pin 1 x 4 1 2 Flat washer 1 1 2 3 4 4 4 5 6 Figure 33 DS96 Pull Type Rear Half Installation 3 8 A ssem b l y MANO390 Rev 4 6 2007 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 3 Attach rims and pneumatic tires pneumatic tires are not furnished to wheel hubs using four wheel bolts 30 Install Attitude Rod Slide attitude rod 5 under left spindle d
89. re 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 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 NOTE Make sure there is a breather fitting installed in the rod end port 2 Connect hose 11 to elbow 10 3 Install optional stroke control kit 18 to cvlinder rod Stroke control kit is used to set cut height Assemblv 39 DS120 Pull Type Rear Half Tailwheel arm Wheel hub 15 Steel rim 21 Solid tire or 22 Aircraft tire or 29 Aircraft tire Attitude rod Spacer Transport lock up Hvdraulic cvlinder Reducer Elbow restricter Hose 156 Ratchet Spring arm Spring 15 16 17 18 30 31 32 33 34 35 36 37 38 39 40 Headless pin 1 x 3 Headless pin 1 x 4 1 2 Headless pin 1 x5 Stroke control kit Wheel bolt 1 2 NF x 1 1 8 Cap screw 1 2 NF x 1 Lock washer 1 2 Cap screw 1 2 NC x 3 Flange lock nut 1 2 NC Cap screw 5 8 NC x5 Lock nut 5 8 NC Flat washer 1 Hex nut 1 NC Cap screw 1 2 NC x 5 Cotter pin 1 4 x 1 1 2 Figure 35 DS120 Pull Type Rear Half Installation 40 Assembly MANO390 Rev 4 6 2007 INSTALL TONGUE DS96 8 DS120 CUTTERS Refer to Figure 36 1 Place tongue 1 between inner mast plates NOTE DS96 only has one set of mast plat
90. re rough when new Check that wear pattern is smooth Inspect vertical and horizontal shafts for grooves nicks or bumps in the areas where the seals seat Resurface any damage with emery cloth Inspect housing and caps for cracks or other damage MANO390 Rev 4 6 2007 ASSEMBLE GEARBOX Refer to Figure 19 1 Clean housing paving specific attention to areas where gaskets will be installed Wash housing and all components thoroughiv Select a clean area for gearbox assembly Replace all seals bearings and gaskets All parts must be clean and lightly oiled before reassembling Insert output bearings 15 in the housing using a round tube of the correct diameter and a hand press Slide output shaft 19 through both bearings 15 until it rests against bearing 6 5 Slide shim 5 over output shaft 19 10 Press gear 13 onto output shaft 19 and secure with washer 25 castle nut 12 and cotter pin 18 Applv 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 Press in housing so that seal is recessed Install protective screen 17 and position it together with dual lip seal 16 bv pressing it into position Verifv that snap ring is seated correctiv Press bearing 7 into the housing using a round tube of the correct diameter and a hand press Secure with shim 5 an
91. 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 m Never allow children or untrained persons to operate equipment DS96 DS120 Safety Rules Rev 5 11 2007 PREPARATION m Check that all hardware is properly installed Always tighten to torque chart specifications unless instructed otherwise in this manual m 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 m 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 m 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 respirat
92. rform 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 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 A WARNING RELEASE ALL AIR PRESSURE BEFORE LOOSENING BOLTS FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY MAX SPEED 20 MPH MAX WEIGHT 4000 LBS MAX AIR PRESSURE 40 PSI DECAL PN 1006348 Figure 17 Split Rim Tire Servicing Owner Service 25 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Does not cut Dull blades Worn or broken blades Incorrect PTO speed Ground speed too fast Drive not functioning blades do not turn when PTO is running Gearbox malfunction Excessive clutch slippage Incorrect blade direction Sharpen blades Replace blades Replace in pairs oniv Set at rated PTO speed Reduce ground speed Check drive shaft connection Check gearbox Repair gearbox Adjust clutch Check to be sure blade edge is correct for
93. riveline and through pivot block on the tailwheel Loosely install spacer 6 washer 37 and two hex nuts 38 Install Spring Arm 1 Attach spring arm 13 to cylinder 8 or ratchet 12 using pin 15 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 Install Height Adjustment Device Ratchet Attach ratchet 12 to tailwheel lug and secure with pin 17 and two cotter pins 40 Cvlinder 1 Place hvdraulic cvlinder 8 between lug on tailwheel 2 Extend cvlinder rod place transport lock bracket 7 over cvlinder rod end and between lugs on tailwheel 3 Align holes of cvlinder rod transport lock bracket and lugs on tailwheel Secure assembly using pin 17 and two cotter pins 40 MANO390 Rev 4 6 2007 CD6653 1 13 Spring arm 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 Figure 34 Spring Arm Installation Install Hydraulic Hose A WARNING s On pull tvpe 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 NOTICE m If using a cylinder other than the one supplied by Woods make su
94. rply with a hammer to relieve any tension Repeat until both yokes move in all directions without restriction O CD1389 Figure 31 Install Cups SERVICING TIRES SAFELY Used Aircraft Tires Figure 32 A WARNING m Explosive separa tion of tire and rim parts can cause seri ous injury or death Release all air pressure before loosening bolts 36 Dealer Service Do not attempt to mount a tire unless you have the proper eguipment 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 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 A WARNING RELEASE ALL AIR PRESSURE BEFORE LOOSENING BOLTS FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY MAX SPEED 20 MPH MAX WEIGHT 4000 LBS MAX AIR PRESSURE 40 PSI DECAL PN 1006348 Figure 32 Split Rim Tire Servicing Rev 5 11 2007 MANO390 Rev 4 6 2007 ASSEMBLY INSTRUC
95. rvice 33 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 CD3739 Figure 24 Example of Crossbar and Gearbox Shaft 2 Install crossbar 8 Figure 22 on splined shaft Install castle nut 37 and cotter pin 38 Torgue nut to 450 Ibs ft 3 Install blades reinstall them using existing hardware Torque cap screws to 85 Ibs ft CROSSBAR TIMING Crossbar must be re timed anvtime 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 TI gt Cutting Edge Rotation 90 15 Rotation Cutting Edge Figure 25 Crossbar Timing Bottom View 34 Dealer Service MANO390 Rev 4 6 2007 UNIVERSAL JOINT REPAIR Yoke Cup and bearing ar Snap ring 3 eg 2 Journal cross af 2 CH 4 Figure 26 Universal Joint Parts Breakdown U JOINT DISASSEMBLV 1 Remove external snap rings from vokes in four locations as shown in Figure 27 Figure 27 Remove Snap Ring 2 With snap rings removed support drive in vise
96. sed 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 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 MANO390 Rev 6 30 2006 BE SAFE BE ALERT BE ALIVE BE TRAI NED Before Operating Mowers EM Safety Training mu D009 Make a Difference ASSOCIATION OF EOUIPMENT 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 Eguipment Manufacturers reinforces the proper procedures to follow while operating your mowing equipment The video does not replace the information contained in the Operators Manual so please review this manual thoroughly before operating vour new mowing equipment Safetv Video Order Form 8 2 2005 S a f e t V 5 Also available from the Association of Eguipment Manufacturers A large variety of training materials ideal for groups are available for a nominal charge from AEM Following is a partial l
97. spline 8 57416 2 Friction clutch 34 57434 1 Thrust plate 12 40766 2 Bearing ring 35 57439 1 Bellevile spring 13 40777 1 Anti rotation chain 36 57259 6 M10x1 5P x 55 mm Cap screw 14 18864 2 Decal Danger rotating driveline 37 57260 6 M10 x 1 5P Lock nut w nylon insert 15 33347 1 Decal Danger guard missing 38 57261 2 M12x 1 5P Lock nut w nylon insert 16 40778 2 Screw 39 57262 2 M12x1 5P x 65 mm Cap screw 17 40767 1 Support bearing 64 Pa rts MANO390 Rev 4 6 2007 DS96 DS120 SLIP CLUTCH DRIVE ASSEMBLY A Complete Drive Assembly SSC v REF DAME QTY DESCRIPTION REF PART QTY DESCRIPTION 1009799 JA e SEN 23 40589 1 Slide collar kit 57413 1 Complete 540 Drive assembly 24 1005795 1 Outer guard half DS96 only DS120 only 24 57268 1 Outer guard half DS120 only 1 40574 1 Yoke 1 3 8 Spline ASGE 25 1005796 1 Inner guard half DS96 only 2 110 2 Cross and bearing 25 57269 1 Inner guard half DS120 only 3 40764 2 Spring pin 10 X 80 26 1005794 1 Shaftasv male complete guard 4 40575 1 Inboard yoke DS96 only 5 40587 1 Inner profile 26 57414 1 Gee o complete guard 6 40593 1 Outer profile amp sleeve 31 57438 1 Flange yoke EO 40018 4 Inboard yoke 32 57432 2 Friction disc 8 57416 1 Friction clutch 1340 1 3 4 20 spline 33 57440 1 Hub 1 3 4 20 spline 12 40766 2 Bearing ring SC25 34 57434 1 Thrust plate 13 40777 2 Anti rotation chain 35 57439 1 Belleville spring 14 18864 1 Decal Danger rotating driveline 36 57259 6 M10x 1 5
98. t wheels DS96 Category 2 Standard Hitch 1 Position the tractor 3 point lower lift arms over the hitch pins and secure with 7 16 klik pins 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 Figure 2 DS96 Cat 2 Standard Hitch Connection DS96 Category 2 Quick Hitch An optional Category 2 quick coupler kit 24845 is available for DS96 cutters DS120 Category 2 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 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 Figure 3 DS120 Cat 2 Standard Hitch Connection Operation 15 DS120 Category 2 Quick Hitch 1 Position the hitch pins as shown in Figure 4 2 Attach tractor with guick hitch to cutter and secure according to quick hitch manufacturer s instructions Figure 4 DS120 Categorv 2 Quick Hitch Connection DS120 Categorv 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 2 Connect the tractor top link to the cutter A frame using the upper holes and 1 1 4 OD sle
99. te transport lock over cvlinder rod See Figure 33 on page 38 4 Lower cvlinder against transport lock 5 To lower cutter for operation extend hvdraulic cvlinder Rotate transport lock back awav from cvlinder rod Lower to desired cutting height STORAGE A WARNING m Keep children and bystanders away from stor age area On Mounted and Semi Mounted Cutters m 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 On Pull Tvpe Cutters m 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 PRE OPERATION CHECK LIST OWNER S RESPONSIBILITY Review and follow all safety rules and safety decal instructions on page 7 to page 13 20 Operation Check that all safety decals are installed and in good condition Replace if damaged Check that equipment is properly and securely attached to tractor Make sure driveline spring activated locking pin or collar slides freely and is seated firmly in trac tor PTO spline groove Set tractor PTO at correct rom for your equip ment Lubricate all grease fitting locations Make sure PTO shaft slip joint is lu
100. trained in this type of repair you may be time and money ahead to replace complete assemblies A WARNING m 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 E Keep all persons away from operator control area while performing adjustments service or maintenance A CAUTION m 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 GEARBOX MAINTENANCE NOTE Read this entire section before starting any repair Many steps are dependent on each other 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 SEAL REPLACEMENT Recommended sealant for gearbox repair is Perma tex Aviation 3D Form A Gasket or equivalent
101. ts that attach gearbox to cutter and remove gearbox Gearbox is heavy do not attempt to move without mechanical assistance DISASSEMBLE SPLITTER GEARBOX Refer to Figure 20 1 2 Remove breather plug from top of gearbox Remove plug 19 from side of input housing 1 and pour out gear oil Remove eight cap screws 3 from around input housing 15 Remove input shaft assembly and housing 11 12 13 14 Remove oil seals 11 to be replaced from both sides of cross shaft 4 Remove eight cap screws 3 from around gearbox cover 12 and remove cross shaft 4 from gearbox Disassemble shims 5 amp 18 spacer 20 bearings 16 amp 13 and crown gear 7 from cross shaft Support housing in a vise and remove bearing cones 16 by using a punch and hammer to drive bearing cone out Support cover 12 in a vise and remove bearing cups 13 by using a punch and hammer to drive bearing cone out Remove lock nut 2 from end of input shaft 14 10 Support input housing in a handpress and push input shaft 14 out of housing Support housing in a vise and remove bearing cups 13 amp 16 by using a punch and hammer to drive bearing cones out 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 Inspect input and cross shafts for grooves nicks
102. ystem can cause equipment to drop m Explosive separation of tire and rim parts can cause serious injury or death Release all air pres sure before loosening bolts on wheel SAFETY RULES A ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED AA STORAGE m Keep children and bystanders away from stor age area m Follow manual instructions for storage On mounted and semi mounted cutters m 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 10 Safety inder Disconnect cutter from tractor 3 point hitch and carefully drive tractor away from cutter ON PULL TYPE CUTTERS m 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 e 6 0 DS96 D S120 Safety Rules Rev 5 11 2007 SAFETY 8 INSTRUCTIONAL DECALS A ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED AA Replace Immediately If Damaged MODEL NO SERIAL NO H vr Fi Woods Eguipment Company A Leg JIID Oregon Illinois U S A 2 PN 5669 MANO390 Rev 6 30 2006 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

Woods Equipment DS96 User's Manual

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