Woods Equipment DS120, DS96 User Manual

Page 1
ROTARY CUTTER
DS96
DS120
MAN0390
(Rev. 5/5/2011)
Page 2
TO THE DEALER:
Assembly and proper installation of this product is the responsibility of the Woods and safety rules. Make sure all items on the Dealer’s Pre-Delivery and Delivery Check Lists in the Operator’s Manual are completed before releasing equipment to the owner.
The dealer must complete the online Product Registration form at the Woods Dealer Website which certifies that all Dealer Check List items have been completed. Please contact your 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 warranty rights.
TO THE OWNER:
Read this manual before operating your Woods equipment. The information presented will prepare you to do a better and safer job. Keep this manual handy for ready reference. Require all operators to read this manual carefully and become acquainted with all adjustment and operating procedures before attempting to operate. Replacement manuals can be obtained from your dealer. To locate your nearest dealer, check the Dealer Locator at www.WoodsEquipment.com, or in the United States and Canada call 1-800-319-6637.
The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory use. Like all mechanical products, it will require cleaning and upkeep. Lubricate the unit as specified. Observe all safety information in this manual and safety decals on the equipment.
For service, your authorized Woods dealer has trained mechanics, genuine Woods service parts, and the necessary tools and equipment to handle all your needs.
Use only genuine Woods service parts. Substitute parts will void the warranty and may not meet standards required for safe and satisfactory operation. Record the model number and serial number of your equipment in the spaces provided:
®
dealer. Read manual instructions
Model: _______________________________ Date of Purchase: _____________________
Serial Number: (see Safety Decal section for location) ____________________________________
Provide this information to your dealer to obtain correct repair parts.
Throughout this manual, the term NOTICE is used to indicate that failure to observe can cause damage to equipment. The terms CAUTION, WARNING, and DANGER are used in conjunction with the Safety-Alert Symbol (a triangle with an exclamation mark) to indicate the degree of hazard for items of personal safety.
2 Introduction
Page 3
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY VIDEO ORDER FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DEALER CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INDEX TO PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . INSIDE BACK COVER
REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . . . . . . . . BACK COVER
(Rev. 4/6/2007)
MAN0390 (Rev. 6/30/2006)
Introduction 3
Page 4
SPECIFICATIONS
WARNING
DS96 DS120
Cutting Height (varies with tire selection) 2" - 15" 2" - 15"
Cutting Width 96" 120"
Overall Width 103" 127"
Tractor HP 40 - 120 40 - 120
Tractor PTO rpm 540 540
Blade Spindle 2 2
Blade Overlap 4" 4"
Number of Blades 4 4
Center Driveline with Slip Clutch Cat 4 Cat 4
Side Frame Thickness 7 ga 7 ga
Weight - Pull-Type (approximate lbs.) 1,800 1,930
Blade Speed (feet per minute) 15,900 16,700
Blade Rotation Left Spindle: CCW; Right Spindle: CW
Wheel Size 15" Rims or 21" OD Solid Tires
Torsion Protection Slip Clutch and Flex Couplers
GENERAL INFORMATION
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 fur­nishes information and instructions that will help you achieve years of dependable performance. These instructions have been compiled from extensive field experience and engineering data. Some information
22" or 29" Used Aircraft Tires
may be general in nature due to unknown and varying operating conditions. However, through experience and these instructions, you should be able to develop procedures suitable to your particular situation.
The illustrations and data used in this manual were cur­rent at the time of printing but, due to possible inline production changes, your machine may vary slightly in detail. We reserve the right to redesign and change the machines as may be necessary without notification.
Throughout this manual, references are made to right and left directions. These are determined by standing behind the equipment facing the direction of forward travel. Blade rotation is clockwise (right) and counter­clockwise (left) as viewed from the top of the cutter.
4 Introduction
MAN0390 (Rev. 6/30/2006)
Page 5
Free Mower Safety Video
Fill out and return the order form and we will send you a FREE VHS or DVD video outlining
Industrial and Agricultural Mower Safety
Practices
. The 22 minute video, developed in cooperation with AEM (Association of Equipment Manufacturers), reinforces the proper procedures to follow while operating your mowing equipment. The video does not replace the information contained in the Operator’s Manual, so please review this manual thoroughly before operating your new mowing equipment.
Safety Training Does Make a Difference.
BE SAFE! BE ALERT! BE ALIVE! BE TRAINED
Before Operating Mowers!
ASSOCIATION OF EQUIPMENT MANUFACTURERS
Safety Video Order Form
Safety Video Order Form (8/2/2005)
Safety 5
Page 6
Also, available from the Association of Equipment Manufacturers:
A large variety of training materials (ideal for groups) are available for a nominal charge from AEM. Following is a partial list:
Training Package for Rotary Mowers/Cutters-English
Contains: DVD & VHS (English)
Guidebook for Rotary Mowers/Cutters (English) AEM Industrial/Agricultural Mower Safety Manual (English) AEM Agricultural Tractor Safety Manual (English)
Training Package for Rotary Mowers/Cutters-English/Spanish
Contains: DVD & VHS (English/Spanish)
Guidebook for Rotary Mowers/Cutters (English/Spanish) AEM Industrial/Agricultural Mower Safety Manual (English/Spanish) AEM Agricultural Tractor Safety Manual (English/Spanish)
AEM training packages are available through:
AEM at:
or Universal Lithographers, Inc. Email: aem@ulilitho.com
800-369-2310 tel 866-541-1668 fax
www.aem.org
Free Mower/ Cutter Safety Video Order Form
3 (Select one)
VHS Format - VHS01052 Safety Video
Please send me
Name: ________________________________________ Phone: __________________
Address: _____________________________________
_____________________________________
_____________________________________
Mower/Cutter Model: ______________________ Serial #: ________________________
Send to: ATTENTION: DEALER SERVICES
WOODS EQUIPMENT COMPANY
PO BOX 1000 OREGON IL 61061-1000 USA
DVD Format - DVD01052 Safety Video
6 Safety
Safety Video Order Form (Rev. 2/6/2006)
Page 7
TRAINING
Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by an operator’s single careless act.
In addition to the design and configuration of equipment, hazard control and accident preven­tion are dependent upon the awareness, con­cern, judgement, and proper training of personnel involved in the operation, transport, maintenance, and storage of equipment.
It has been said, “The best safety device is an informed, careful operator.” We ask you to be that kind of operator.
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Safety instructions are important! Read all attachment and power unit manuals; follow all safety rules and safety decal information. (Replace­ment manuals and safety decals are available from your dealer. To locate your nearest dealer, check the Dealer Locator at www.WoodsEquipment.com, or in the United States and Canada call 1-800-319-
6637.) Failure to follow instructions or safety rules can result in serious injury or death.
If you do not understand any part of this manual and need assistance, see your dealer.
PREPARATION
Check that all hardware is properly installed. Always tighten to torque chart specifications unless instructed otherwise in this manual.
Air in hydraulic systems can cause erratic oper­ation 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.
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.
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.
Know your controls and how to stop engine and attachment quickly in an emergency.
Operators must be instructed in and be capable of the safe operation of the equipment, its attach­ments, and all controls. Do not allow anyone to operate this equipment without proper instruc­tions.
Keep hands and body away from pressurized lines. Use paper or cardboard, not hands or other body parts to check for leaks. Wear safety goggles. Hydraulic fluid under pressure can easily penetrate skin and will cause serious injury or death.
Make sure that all operating and service person­nel know that if hydraulic fluid penetrates skin, it must be surgically removed as soon as possible by a doctor familiar with this form of injury or gan­grene, serious injury, or death will result. CON­TACT A PHYSICIAN IMMEDIATELY IF FLUID ENTERS SKIN OR EYES. DO NOT DELAY.
Never allow children or untrained persons to operate equipment.
DS96-DS120 Safety Rules (Rev. 5/11/2007)
Make sure attachment is properly secured, adjusted, and in good operating condition.
Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove.
If equipped with driveline guard tether chains, make sure they are attached to the tractor and equipment as shown in the pamphlet that accom­panies the driveline. Replace if damaged or broken. Check that driveline guards rotate freely on drive­line before putting equipment into service.
Power unit must be equipped with ROPS or ROPS cab and seat belt. Keep seat belt securely fastened. Falling off power unit can result in death from being run over or crushed. Keep foldable ROPS system in “locked up” position at all times.
Inspect chain shielding before each use. Replace if damaged.
(Safety Rules continued on next page)
Safety 7
Page 8
(Safety Rules continued from previous page)
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Remove accumulated debris from this equip­ment, power unit, and engine to avoid fire hazard.
Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section for location.)
Make sure shields and guards are properly installed and in good condition. Replace if dam­aged.
Do not put this equipment into service unless all side skids are properly installed and in good condi­tion. Replace if damaged.
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 result­ing 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.
Inspect and clear area of stones, branches, or other hard objects that might be thrown, causing injury or damage.
OPERATION
Full chain or rubber shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or dam­age property.
• If this machine is not equipped with full chain or rubber shielding, operation must be stopped when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk of thrown objects. The mower deck and protec­tive devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).
Do not allow bystanders in the area when oper­ating, attaching, removing, assembling, or servic­ing equipment.
Never direct discharge toward people, animals, or property.
Do not operate or transport equipment while under the influence of alcohol or drugs.
Operate only in daylight or good artificial light.
It is possible for objects to ricochet
Keep hands, feet, hair, and clothing away from equipment while engine is running. Stay clear of all moving parts.
Always comply with all state and local lighting and marking requirements.
Never allow riders on power unit or attachment.
Power unit must be equipped with ROPS or
ROPS cab and seat belt. Keep seat belt securely fastened. Falling off power unit can result in death from being run over or crushed. Keep foldable ROPS system in “locked up” position at all times.
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.
Operate tractor PTO at 540 RPM. Do not exceed.
Look down and to the rear and make sure area
is clear before operating in reverse.
Do not operate or transport on steep slopes.
Do not stop, start, or change directions sud-
denly on slopes.
Use extreme care and reduce ground speed on slopes and rough terrain.
Watch for hidden hazards on the terrain during operation.
Stop power unit and equipment immediately upon striking an obstruction. Turn off engine, remove key, inspect, and repair any damage before resuming operation.
Leak down or failure of mechanical or hydraulic system can cause equipment to drop.
On pull-type or semi-mounted units with optional hydraulic cutting height adjustment, use a single-acting cylinder with a maximum extended length of 28-1/4" (718 mm) from attaching point center to center.
On mounted units with optional hydraulic cut­ting height adjustment, use a double-acting cylin­der with a maximum extended length of 28-1/4" (718 mm) from attaching point center to center.
TRANSPORTATION
The maximum transport speed for towed and semi-mounted machines is 20 mph (32 km/h). Regardless of the maximum speed capability of the towing tractor, do not exceed the implement’s max-
8 Safety
DS96-DS120 Safety Rules (Rev. 5/11/2007)
Page 9
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
imum transport speed. Doing so could result in:
• Loss of control of the implement and tractor
• Reduced or no ability to stop during braking
• Implement tire failure
• Damage to the implement or its components.
Use additional caution and reduce speed when under adverse surface conditions, turning, or on inclines.
Do not operate PTO during transport.
Never tow this implement with a motor vehicle.
Do not operate or transport on steep slopes.
Do not operate or transport equipment while
under the influence of alcohol or drugs.
Always comply with all state and local lighting and marking requirements.
Never allow riders on power unit or attachment.
MAINTENANCE
Before dismounting power unit or performing any service or maintenance, follow these steps: disengage power to equipment, lower the 3-point hitch and all raised components to the ground, operate valve levers to release any hydraulic pres­sure, set parking brake, stop engine, remove key, and unfasten seat belt.
Before performing any service or maintenance, disconnect driveline from tractor PTO.
Before working underneath, raise mower, install transport lock, and block mower securely. Hydrau­lic system leak down and failure of mechanical or hydraulic system can cause equipment to drop.
Do not modify or alter or permit anyone else to modify or alter the equipment or any of its compo­nents in any way.
Your dealer can supply original equipment hydraulic accessories and repair parts. Substitute parts may not meet original equipment specifica­tions and may be dangerous.
Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate.
Do not allow bystanders in the area when oper­ating, attaching, removing, assembling, or servic­ing equipment.
Never go underneath equipment (lowered to the ground or raised) unless it is properly blocked and secured. Never place any part of the body under­neath 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 unexpect­edly and cause severe injury or death. Follow Oper­ator's Manual instructions for working underneath and blocking requirements or have work done by a qualified dealer.
Make sure attachment is properly secured, adjusted, and in good operating condition.
Keep all persons away from operator control area while performing adjustments, service, or maintenance.
Make certain all movement of equipment com­ponents has stopped before approaching for ser­vice.
Frequently check blades. They should be sharp, free of nicks and cracks, and securely fastened.
Do not handle blades with bare hands. Careless or improper handling may result in serious injury.
Your dealer can supply genuine replacement blades. Substitute blades may not meet original equipment specifications and may be dangerous.
Tighten all bolts, nuts, and screws to torque chart specifications. Check that all cotter pins are installed securely to ensure equipment is in a safe condition before putting unit into service.
Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section for location.)
Make sure shields and guards are properly installed and in good condition. Replace if dam­aged.
Do not disconnect hydraulic lines until machine is securely blocked or placed in lowest position and system pressure is released by operating valve levers.
Leak down or failure of mechanical or hydraulic system can cause equipment to drop.
Explosive separation of tire and rim parts can cause serious injury or death. Release all air pres­sure before loosening bolts on wheel.
DS96-DS120 Safety Rules (Rev. 5/11/2007)
Safety 9
Page 10
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
STORAGE
Keep children and bystanders away from stor­age area.
Follow manual instructions for storage.
On mounted and semi-mounted cutters:
Disconnect cutter driveshaft and secure up off ground. Raise cutter with 3-point hitch. Place blocks under cutter side skids. Lower cutter onto blocks. Disconnect hydraulic lines to optional cyl-
inder. Disconnect cutter from tractor 3-point hitch and carefully drive tractor away from cutter.
ON PULL-TYPE CUTTERS:
Raise cutter and block securely. Block wheels and raise tongue with jack. Disconnect hydraulic lines to optional cylinder. Disconnect driveline and secure up off the ground.
10 Safety
DS96-DS120 Safety Rules (Rev. 5/11/2007)
Page 11
1 - SERIAL NUMBER PLATE
2 - PN 5669
3 - PN 12777
4 - PN 1003751
SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
MODEL NO. SER IAL NO.
MAN0390 (Rev. 6/30/2006)
Woods Equipment Company
Oregon, Illinois, U.S.A.
Be extremely careful handling various parts of
Operate tractor controls from tractor seat only. Do not stand between tractor and implement
Make sure parking brake is engaged before
Stand clear of machine while in operation or
WARNING
CRUSHING AND PINCHING HAZARD
the machine. They are heavy and hands, fingers, feet, and other body parts could be crushed or pinched between tractor and implement.
when tractor is in gear.
going between tractor and implement.
when it is being raised or lowered.
FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN
SERIOUS INJURY OR DEATH.
(Safety Decals continued on next page)
1003751-A
Safety 11
Page 12
9 - PN 15503
FALLING OFF CAN RESULT IN BEING RUN OVER.
Tractor must be equipped with ROPS (or ROPS CAB) and seat belt. Keep foldable ROPS systems in “locked up” position at all times.
Buckle Up! Keep seat belt securely fastened.
Allow no riders.
RAISED EQUIPMENT CAN DROP AND CRUSH.
Before working underneath, follow all instructions and safety rules in operator’s manual and securely block up all corners of equipment with jack stands.
Securely blocking prevents equipment dropping from hydraulic leak­down, hydraulic system failures or mechanical component failures.
FALLING OFF OR FAILING TO BLOCK SECURELY CAN RESULT IN SERIOUS INJURY OR DEATH.
WARNING
18865--C
8 - PN 18865
DO NOT EXCEED PTO SPEED OF
540 RPM
PTO speeds higher than 540 RPM can cause
equipment failure and personal injury.
WARNING
18866-D
6 - PN 18866
ROTATING BLADES AND
THROWN OBJECTS
Do not put hands or feet under or into mower when
engine is running.
Before mowing, clear area of objects that may be
thrown by blade.
Keep bystanders away.
Keep guards in place and in good condition.
BLADE CONTACT OR THROWN OBJECTS CAN
CAUSE SERIOUS INJURY OR DEATH.
DANGER
15503-C
5 - PN 18864
10 - PN 1002940 AMBER REFLECTOR 9"
11 - PN 57123 RED REFLECTOR 9"
7 - PN 18877
12 - PN 1004114
DA
NG
ER
SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
(Safety Decals continued from previous page)
DANGER
CONTACT CAN CAUSE DEATH
All driveline guards, tractor and
Drivelines securely attached at both ends
Driveline guards that turn freely on
ROTATING DRIVELINE
KEEP AWAY!
DO NOT OPERATE WITHOUT -
equipment shields in place
driveline
18864-C
WARNING
TO AVOID SERIOUS
INJURY OR DEATH:
Read Operator's Manual (available
from dealer) and follow all safety precautions.
Keep all shields in place and in good
condition.
Operate mower from tractor seat only.
Lower mower, stop engine and remove
key before dismounting tractor.
Allow no children or untrained persons
to operate equipment.
Do not transport towed or
semi-mounted units over 20 mph.
FAILURE TO OPERATE SAFELY
CAN RESULT IN
12 Safety
INJURY OR DEATH.
18877-C
NG
ER
If shaft connection is visible, shield is missing. Replace shield before operating equipment.
MAN0390 (Rev. 6/30/2006)
1004114
Page 13
HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN
RESULTING IN SERIOUS INJURY , GANGRENE OR DEA TH.
n
Check for leaks with cardboard; never use hand.
n
Before loosening fittings: lower load, release pressure, and be sure oil is cool.
n
Consult physician immediately if skin penetration occurs.
WARNING
19924-B
14 - PN 19924
13 - PN 1004991
TRANSPORT LOCK
AND CYLINDER
REQUIREMENTS
1004991
TRANSPORT LOCK
WARNING
RAISED CUTTER CAN DROP AND CRUSH
e
.
e
ds.
sta
r
hydraulic system failures, or mechanical component failures.
FAILURE TO FOLLOW INSTRUCTIONS CAN
RESULT IN SERIOUS INJURY OR DEATH.
28-1/4"
SINGLE-ACTING FULL
EXTENSION
BE CAREFUL!
Use a clean, damp cloth to clean safety decals.
Avoid spraying too close to decals when using a pressure washer; high-pressure water can enter through very small scratches or under edges of decals causing them to peel or come off.
Replacement safety decals can be ordered free from your Woods dealer. To locate your nearest dealer, check the Dealer Locator at www.WoodsEquipment.com, or in the United States and Canada call 1-800-319-6637.
GUARD MISSING.
DO NOT OPERATE.
DANGER
33347E
DANGER
DANGER
GUARD MISSING.
DO NOT OPERATE.
16 - PN 33347
17 - PN 24611 SLOW MOVING VEHICLE EMBLEM
PN 1006348
SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
rs must be equipped with transport lock
Cutt
n
ansport components must be functional, kept in goodAll t
(Rev. 5/11/2007)
MAN0390 (Rev. 6/30/2006)
Safety 13
Page 14
OPERATION
DANGER
WARNING
CAUTION
WARNING
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 safety practices before starting operation. Read the safety rules and safety decals on page 7 to page
13.
This medium-duty cutter is designed for grass and weed mowing and shredding.
Recommended mowing speed for most conditions is from 2 to 5 mph.
Full chain or rubber shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or dam­age property.
• If this machine is not equipped with full chain or rubber shielding, operation must be stopped when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk of thrown objects. The mower deck and protec­tive devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).
It is possible for objects to ricochet
TRACTOR STABILITY
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 result­ing 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
Never allow riders on power unit or attachment.
Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO spline groove.
Operate tractor PTO at 540 RPM. Do not exceed.
Do not allow bystanders in the area when oper-
ating, attaching, removing, assembling, or servic­ing equipment.
Stop power unit and equipment immediately upon striking an obstruction. Turn off engine, remove key, inspect, and repair any damage before resuming operation.
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.
The horizontal distance between the end of the
tractor PTO shaft and the drawbar hitch point should be 14" for 540 RPM cutters. This distance must not vary more than plus or minus (1") or the drive may be damaged when turning.
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 high­strength 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.
14 Operation
(Rev. 2/6/2009)
MAN0390 (Rev. 6/30/2006)
Page 15
7. Connect cutter driveline to tractor PTO shaft,
WARNING
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.
Tractor Adjustments
Before attaching tractor to cutter, install sway blocks or sway chains, or adjust stabilizer bars. Refer to the trac­tor operator's manual for instructions.
Install tractor front end weights as recommended by the tractor manufacturer to provide 20% of weight on front wheels.
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.
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.
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 A­frame. 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.
2. Check for straight-ahead operation and at full­turning 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 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 result­ing 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)
MAN0390 (Rev. 6/30/2006)
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 A­frame. See Figure 3.
Figure 3. DS120 Cat. 2 Standard Hitch Connection
Operation 15
Page 16
DS120 Category 2 Quick Hitch
1. Position the hitch pins as shown in Figure 4.
2. Attach tractor with quick hitch to cutter and secure
according to quick hitch manufacturer’s instructions.
Figure 4. DS120 Category 2 Quick Hitch Connection
DS120 Category 3 Standard Hitch
1. Position the tractor 3-point lower lift arms between
the hitch mast plates and secure with hitch pins and 7/16 klik pins. Note the hitch pins orientation.
2. Connect the tractor top link to the cutter A-frame using the upper holes and 1-1/4" OD sleeve. The break link must be placed in the lower holes of the A-frame. See Figure 5.
Figure 6. DS120 Category 3 Quick Hitch Connection
Hydraulic Connection (DS120 Only)
1. Inspect hydraulic hoses to ensure they are in good
condition.
2. Clean the fittings before connecting them to the tractor hydraulic ports.
3. Route hoses through hose holder on 3-point mast. Be sure hoses can slide freely in holder. Do not allow hose slack to drag on the ground or become caught on tractor protrusions.
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 dis­tance 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.
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 quick hitch to cutter and secure according to quick hitch manufacturer’s instructions.
Driveline length must be sufficient to provide at least 1/3 driveline length of engagement during operation. There must be at least 4 inches of engagement at the cutters lowest possible point of operation. The driveline must not bottom out when raised to the maximum height possible.
If driveline is too short please call your Woods dealer for a longer driveline.
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.
16 Operation
(Rev. 2/6/2009)
MAN0390 (Rev. 6/30/2006)
Page 17
Figure 7. Drive Halves Placed Parallel
1-9/16"
A
WARNING
4. Measure from end of the upper shield to the base of the bell on the lower shield (A). Add 1-9/16" to dimension (A). See Figure 8.
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 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 can­not be obtained through these methods.
Figure 8. Determine Shield Length
5. Cut the shield to the overall dimension.
Connect driveline to tractor PTO shaft, making sure the spring-activated locking collar slides freely and locks driveline to PTO shaft.
NOTICE
If attaching with quick hitch the distance
between the tractor PTO and gearbox input shaft will increase. Please follow the steps as you would for a 3-point hitch to insure proper engagement.
DRIVELINE INTERFERENCE CHECK
1. Check for clearance between driveline and cutter
deck.
2. Slowly lift cutter and observe driveline. If clearance between driveline and cutter deck is less than 1 inch, shorten top link or limit upper travel of lower hitch arms. Refer to tractor operator's manual for instructions.
CUTTING HEIGHT ADJUSTMENT
Figure 9. Cut Shield
(Rev. 2/6/2009)
MAN0390 (Rev. 6/30/2006)
On pull-type units with optional hydraulic cut­ting height adjustment, use a single-acting cylinder with a maximum extended length of 28-1/4" (718 mm) from attaching point center to center.
Cutting height range is from 2" to 15". A hydraulic cylin­der or ratchet jack is available for cutting height adjust-
Operation 17
Page 18
ment on pull-type units and DS120 mounted units. DS96 requires manual adjustment using holes in the tailwheel arms.
DS120 - Using any of the optional height adjustment devices, raise or lower the tailwheel to obtain 2-1/2 to 2-3/4 inches at position B.
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
Avoid ground contact with blades. Striking
ground with blades produces one of the most dam­aging shock loads a cutter can encounter. If this occurs repeatedly, the cutter, driveline, and gear­boxes will be damaged.
The blade cutting edge is approximately 1-3/4 inches above the bottom of the skid shoes.
Pull-Type Units
To adjust cutter for normal mowing, select a cutting height (example: 4-inches).
Using any of the optional cutting height mechanisms, raise or lower the tailwheel and set position A to 2-1/4 inches. Loosen the jam nut on the attitude rod that runs from the tongue to the tailwheel. Adjust rod in or out until position B is approximately 1/4 to 1/2 inches more than position A. Refer to Figure 11.
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 (PULL-TYPE)
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 slightly lower.
Shredding
For shredding, it is better to set rear of cutter slightly lower than the front. How much lower depends on the material to be shredded. Determine the best setting for your situation by experimenting. Use a slow ground speed for better shredding.
DRIVELINE ADJUSTMENT (PULL-TYPE)
With the cutting height established, adjust the driveline carrier bearings in the H-frames so that the front drive­line is parallel to the ground with cutter in cutting posi­tion.
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.
WHEEL SPACING (DS120 ONLY)
Wheels may be adjusted to any position for row crop shredding.
BLADE SELECTION
There are two blade options: standard suction blades and flat double-edge blades.
The standard suction blade is a general use, multi-pur­pose 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 rotation. Blades from the right may be used on the left. Blades from the left may be used on the right.
18 Operation
(Rev. 2/6/2009)
MAN0390 (Rev. 6/30/2006)
Page 19
Blades must be moved in pairs. Never use one new
WARNING
CAUTION
WARNING
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.
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
Being knocked off or falling off tractor can result in seri­ous 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 quickly 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 rpm. Know how to stop the tractor and cutter quickly 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 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.
Look down and to the rear and make sure area is clear before operating in reverse.
Do not operate or transport on steep slopes.
Do not stop, start, or change directions sud-
denly on slopes.
Use extreme care and reduce ground speed on slopes and rough terrain.
Watch for hidden hazards on the terrain during operation.
Stop power unit and equipment 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 mate­rial to be cut and the terrain type (hilly, level or rough, etc.).
Proper ground speed will depend on the terrain and the material’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) MAN0390 (Rev. 6/30/2006)
TRANSPORTING
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 max­imum transport speed. Doing so could result in:
• Loss of control of the implement and tractor
• Reduced or no ability to stop during braking
• Implement tire failure
• Damage to the implement or its components.
Operation 19
Page 20
___ Check that all safety decals are installed and in
WARNING
WARNING
good condition. Replace if damaged.
Use additional caution and reduce speed when under adverse surface conditions, turning, or on inclines.
Never tow this implement with a motor vehicle.
1. Always transport with cutter in raised, locked
position.
2. Raise cutter with hydraulic cylinder.
3. Rotate transport lock over cylinder rod. See Figure
33 on page 38.
4. Lower cylinder against transport lock.
5. To lower cutter for operation, extend hydraulic
cylinder. Rotate transport lock back away from cylinder rod. Lower to desired cutting height.
STORAGE
Keep children and bystanders away from stor­age area.
On Mounted and Semi-Mounted Cutters:
___ 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 trac­tor PTO spline groove.
___ Set tractor PTO at correct rpm for your equip-
ment.
___ Lubricate all grease fitting locations. Make sure
PTO shaft slip joint is lubricated.
___ 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.
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 cyl­inder. Disconnect cutter from tractor 3-point hitch and carefully drive tractor away from cutter.
On Pull-Type Cutters:
Raise cutter and block securely. Block wheels and raise tongue with jack. Disconnect hydraulic lines to optional cylinder. Disconnect driveline and secure up off the ground.
PRE-OPERATION CHECK LIST (OWNER'S RESPONSIBILITY)
___ Review and follow all safety rules and safety
decal instructions on page 7 to page 13.
___ Check that shields and guards are properly
installed and in good condition. Replace if dam­aged.
___ 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 transmis­sion 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.
20 Operation
(Rev. 4/6/2007)
MAN0390 (Rev. 6/30/2006)
Page 21
OWNER SERVICE
WARNING
CAUTION
WARNING
The information in this section is written for operators who possess basic mechanical skills. If you need help, your dealer has trained service technicians available. For your protection, read and follow the safety informa­tion in this manual.
Keep all persons away from operator control area while performing adjustments, service, or maintenance.
If you do not understand any part of this manual and need assistance, see your dealer.
Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate.
BLOCKING METHOD
Never go underneath equipment (lowered to the ground or raised) unless it is properly blocked and secured. Never place any part of the body under­neath 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 unexpect­edly and cause severe injury or death. Follow Oper­ator's Manual instructions for working underneath and blocking requirements or have work done by a qualified dealer.
To minimize the potential hazards of working under­neath the cutter, follow these procedures:
1. Jackstands with a load rating of 1000 lbs. or more are the only approved blocking device for this cutter. Install a minimum of four jackstands (shown by Xs in Figure 12) under the cutter before working underneath unit.
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.
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 fre­quent lubrication.
Use a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive for all locations unless otherwise noted. Be sure to clean fittings thoroughly before attaching grease gun. One good pump of most guns is sufficient when the lubrication schedule is fol­lowed.
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.
(Rev. 10/5/2007) MAN0390 (Rev. 4/6/2007)
Owner Service 21
Page 22
Figure 12. Jackstand Placement and Lubrication Points
6. Rotating Drive Shield 10 hrs.
7. Side Drive Yoke (2 Places) 40 hrs.
8. Gearbox (Check Oil Level, Lower Hole on Center Gearbox Side Hole on Spindle Gearboxs) Daily
9. Tailwheel Spindle 20 hrs.
10. Caster Wheel Swivel 40 hrs.
1. Front U-Joint 10 hrs.
2. Mid U-Joint 10 hrs.
3. Carrier Bearing Block 40 hrs.
4. Telescoping Shaft 10 hrs.
5. Rear U-Joint 10 hrs.
8. Crossbar
9. Blade
12. Blade pin
13. Shim
14. Keyhole plate
15. Blade pin lock clip
16. Shim
35. Cap screw
CAUTION
SERVICING BLADES
Removing Blades (Figure 13)
NOTICE
If blade pin (12) is seized in crossbar and
extreme force will be needed to remove it, support crossbar from below to prevent gearbox damage.
22 Owner Service
Figure 13. Blade Assembly
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 & 16). Carefully drive blade pin (12) out of crossbar.
3. Rotate crossbar (8) and repeat for opposite blade.
Installing Blades
Your dealer can supply genuine replacement blades. Substitute blades may not meet original equipment specifications and may be dangerous.
NOTICE
Crossbar rotation has counterclockwise rota-
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.
MAN0390 (Rev. 4/6/2007)
(Rev. 10/5/2007)
Page 23
NOTE: Always replace or sharpen both blades at the
1. Flange yoke
2. Friction disc
3. Hub, 1-3/8 round bore
4. Thrust plate
5. Belleville spring plate
6. 10 mm x 1.35P x 50 mm Cap screw
7. 10 mm x 1.5P Hex nut
same time.
1. Inspect blade pin (12) for nicks or gouges, and if you find any, replace the blade pin.
2. Insert blade pin through the blade (9). Blade should swivel on blade pin; if it doesn’t, determine the cause and correct.
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 struc­tural cracks to cutter.
3. Align crossbar (8) with blade access hole in cutter
frame. Apply a liberal coating of Never Seez or equivalent to blade pin and crossbar hole. Make sure blade offset is away from cutter. Push blade pin through crossbar. Pin should rotate freely prior to installing blade clip (15).
4. Install shims (13 & 16) over blade pin. NOTE: Only use enough shims to allow keyhole
plate (14) to slide into blade pin groove.
5. Install blade clip (15) over keyhole plate and into blade pin groove.
6. Secure into position with cap screw (35). Torque cap screw to 85 lbs-ft.
7. Repeat steps for opposite side.
NOTE: Blade should be snug but should swivel on
pin without having to exert excessive force. Keep any spacers not used in the installation as replace­ments or for future installation.
1. Sharpen both blades at the same time to maintain balance. Follow original sharpening pattern.
2. Do not sharpen blade to a razor edge—leave at least a 1/16" blunt edge.
3. Do not sharpen back side of blade.
Figure 14. Sharpen Blade Cutting Edge
(Rev. 5/11/2007) MAN0390 (Rev. 4/6/2007)
Figure 15. Slip Clutch Assembly
Owner Service 23
Page 24
ADJUSTING SLIP CLUTCH
1. Complete drive
2. Inner connector yoke
3. Outer connector yoke 1-3/4 20-spline
4. Outer connector yoke 1-3/4 6-spline
5. Rubber disc
6. Shaped washer
7. Bushing, .63 ID
8. Hex head cap screw
9. M16 x 2.0 Lock nut
10. Grease fitting
11. 3/8 NC x 3/4 Square head set screw
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 fol­lowing 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 yoke (1), and clutch hub (3).
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 gear­boxes. The rubber disks will wear out over time and require replacement much like slip clutch disks. To maximize rubber disk life, lower tractor engine speed to an idle when engaging the PTO and avoid striking the ground with cutter blades.
Periodically inspect the disks for signs of cracking. A disk may run for some time after a crack starts but this is the first sign that disk replacement is required in the future.
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
To replace the disks, remove hardware items (6, 7, 8, and 9). Remove sleeves (7) from old disk and install in new disk. Reassemble and torque bolts to 85 lbs-ft. See Figure 16. Take special care not to rotate gearbox shaft and throw blades out of time. If rubber disks have failed and blades are hitting, you will need to re-time the blades per instructions on page 34.
Figure 16. Flexible Coupler
24 Owner Service
MAN0390 (Rev. 4/6/2007)
(Rev. 2/6/2009)
Page 25
SHIELDING REPAIR
DANGER
WARNING
A
DECAL PN 1006348
Full chain or rubber shielding is required for all non-agricultural mowing. Full shielding is also rec­ommended for all agricultural use to further reduce the risk of thrown objects.
Repairing Rubber Shielding
Inspect belting and rear bands each day of operation and replace if bent, cracked, or broken.
Repairing Optional Chain Shielding
Inspect chain shielding each day of operation and replace any broken or missing chains as required.
CLEANING
After Each Use
Remove large debris such as clumps of dirt, grass,
crop residue, etc. from machine.
Inspect machine and replace worn or damaged
parts.
SERVICING TIRES SAFELY
Used Aircraft Tires (Figure 17)
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure and result in a tire explosion. Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and an exten­sion 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.
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).
Check wheels for low pressure, cuts, bubbles, dam­aged rims, or missing lug bolts and nuts.
Never remove split rim assembly hardware (A) with the tire inflated.
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)
MAN0390 (Rev. 4/6/2007)
Figure 17. Split Rim Tire Servicing
Owner Service 25
Page 26
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
Does not cut Dull blades Sharpen blades.
Worn or broken blades Replace blades. (Replace in pairs
only.)
Incorrect PTO speed Set at rated PTO speed.
Ground speed too fast Reduce ground speed.
Drive not functioning (blades do not turn when PTO is running)
Gearbox malfunction Repair gearbox.
Excessive clutch slippage Adjust clutch.
Incorrect blade direction Check to be sure blade edge is
Streaks or ragged cut Broken or worn blades Replace or sharpen blades.
Attitude incorrect Level machine.
Ground speed too fast Reduce ground speed.
Excessive cutting height Lower cutting height. (Note: Set
Excessive lush and tall vegetation Recut at 90° to first pass.
Excessive side skid wear Running with skids continuously
on ground
Excessive clutch slippage Clutch out of adjustment Adjust clutch.
Clutch discs worn; wear stops contacting opposite plate
Check drive shaft connection. Check gearbox.
correct for direction of rotation.
height so blades do not frequently hit ground.)
Raise cutting height or adjust.
Replace discs.
Blades hitting ground Raise cutting height.
Vibration Broken blade Replace blades in pairs.
Bearing failure Check gearbox shafts for side
play.
Hitch length incorrect Reset hitch length.
Universal drive 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 hydraulic oil.
26 Troubleshooting
MAN0390 (Rev. 4/6/2007)
Page 27
DEALER SERVICE
WARNING
CAUTION
1. Seal
2. Pipe or tube
3. Seal seat
4. Casting
Pipe or tube must press at outer edge of seal.
Incorrect Installation
The information in this section is written for dealer ser­vice personnel. The repair described here requires special skills and tools. If your shop is not properly equipped or your mechanics are not properly trained in this type of repair, you may be time and money ahead to replace complete assemblies.
Before working underneath, disconnect drive­line, raise cutter, lock in transport position, and block cutter securely. Hydraulic system leak down and failure of mechanical or hydraulic system can cause equipment to drop. Keep all persons away from operator control
area while performing adjustments, service, or maintenance.
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.
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.
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 replac­ing bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. Pur­chasing 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-
®
Aviation 3D Form-A-Gasket or equivalent.
tex
Figure 18. Seal Installation
MAN0390 (Rev. 4/6/2007)
Dealer Service 27
Page 28
VERTICAL SHAFT SEAL REPAIR (SPINDLE BOX)
Refer to Figure 19.
1. Disconnect and remove the driveline from the
gearbox.
2. Remove vent plug (3) and siphon gear lube from housing through this opening.
3. Remove crossbar (see Crossbar removal on page
33).
4. Remove vertical shaft seal (16). Replace with new seal (see Seal Installation on page 27).
4. Remove the four bolts that attach gearbox to cutter and remove gearbox. Gearbox is heavy; do not attempt to move without mechanical assistance.
DISASSEMBLE GEARBOX
Refer to Figure 19.
1. Remove 3/8" plug from side of gearbox and pour
out gear oil.
2. Remove oil cap (24) (to be replaced).
3. Remove snap ring (9) and shim (5) from input shaft
(11).
Vertical seal should be recessed in housing. Hori­zontal seal should be pressed flush with outside of housing.
NOTE: Distortion to seal cage or damage to seal lip will cause seal to leak.
5. Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug.
6. Remove and replace any seal damaged in installation.
HORIZONTAL SHAFT SEAL REPAIR
Refer to Figure 19.
1. Disconnect and remove the driveline from the
gearbox.
2. Remove vent plug (3) and siphon gear lube from housing through this opening.
3. If the leak occurred at either end of horizontal shaft (spindle gearbox), remove oil cap (24) and/or oil seal (10). For splitter gearbox (Figure 20) use oil seals (11) and (17). Replace with new one (refer to Seal Installation, page 27).
4. Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug.
4. Support gearbox in hand press and push on input shaft (11) to remove bearing (23).
5. Remove top cover (4) from housing. Remove gear (6) from inside housing.
6. Remove oil seal (10) from front of housing (to be replaced).
7. Remove snap ring (9) and shim (5) from front of housing (1).
8. Remove input bearing (7) by using a punch and hammer from outside of housing.
9. 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).
11. Remove cotter pin (18), castle nut (12), and washer (25) from output shaft (19).
12. Remove output shaft (19) by using a punch and hammer and tap on top to drive down.
13. Remove gear (5) and shim (15) from inside housing.
SPINDLE GEARBOX REPAIR
NOTE: Replacing gears, shafts, bearings, and seals
may not be cost effective. Purchasing a complete gear­box may be more economical.
REMOVE GEARBOX FROM CUTTER
Refer to Figure 19.
1. Disconnect and remove the driveline from the
gearbox.
2. Remove vent plug (3) and siphon gear lube from housing through this opening.
3. Remove cotter pin, washer, and nut from vertical shaft and remove crossbar (see Crossbar removal, page 33).
28 Dealer Service
14. Remove bearing (15) by using a punch and
hammer from the top, outside the housing.
15. Support housing upside down (top cover surface) and remove bearing (15) by using a punch and hammer from the bottom side of the housing.
16. Inspect gears for broken teeth and wear. Some wear is normal and will show on loaded side. Forged gear surfaces are rough when new. Check that wear pattern is smooth.
17. Inspect vertical and horizontal shafts for grooves, nicks, or bumps in the areas where the seals seat. Resurface any damage with emery cloth.
18. Inspect housing and caps for cracks or other damage.
MAN0390 (Rev. 4/6/2007)
Page 29
ASSEMBLE GEARBOX
Refer to Figure 19.
1. Clean housing, paying specific attention to areas
where gaskets will be installed.
2. Wash housing and all components thoroughly. Select a clean area for gearbox assembly. Replace all seals, bearings, and gaskets. All parts must be clean and lightly oiled before reassembling.
3. Insert output bearings (15) in the housing, using a round tube of the correct diameter and a hand press.
4. Slide output shaft (19) through both bearings (15) until it rests against bearing (6).
5. Slide shim (5) over output shaft (19).
6. Press gear (13) onto output shaft (19) and secure
with washer (25), castle nut (12), and cotter pin (18).
7. Apply grease to lower seal lips (16) and press seal (16) over output shaft (19), using a tube of the correct diameter. Be sure not to damage the seal lip.
Press in housing so that seal is recessed. Install protective screen (17) and position it together with dual lip seal (16) by pressing it into position. Verify that snap ring is seated correctly.
8. Press bearing (7) into the housing, using a round tube of the correct diameter and a hand press. Secure with shim (5) and snap ring (9).
9. Secure snap ring (9) on input shaft (11) if not already secure.
10. Place gear (6) through top of housing and align gear (6) and gear (13) so that gear teeth are a match.
11. While holding gear (6) in place, slide input shaft (11) through gear (6) and bearing (7). Align splines on shaft (11) and gear (6).
12. Slide spacer (7) over input shaft (11) and press bearing onto input shaft (11), using a round tube of the correct diameter and a hand press.
13. Slide shim (5) over input shaft (11) and secure with snap ring (9).
14. Check input shaft end float by moving the input shaft (11) by hand. If end float is higher than
0.012", insert shim between input shaft (11) and rear bearing (7). Repeat until end float is less than
0.012". Check rotational torque by hand. The torque should be less than 2.2 lbs-inch.
15. Check that the gear backlash is between 0.006" and 0.016". You should not have to adjust the backlash.
16. Press in input oil seal (10), using tube of correct diameter. Be careful not to damage seal lip.
17. Press oil cap (24) on to cover the rear of housing, using a tube of the correct diameter.
18. Check gearbox housing for leaks by plugging all holes except one. Apply 4 psi compressed air and immerse the gearbox in water to verify that there are no leaks.
19. Remove gearbox from water and dry off with compressed air. Add SAE 80W or 90W EP oil until it runs out of side level hole. Tighten all plugs.
REINSTALL GEARBOX
NOTE: Gearbox is heavy: do not attempt to move
without mechanical assistance.
1. Set gearbox on cutter and fasten with bolts and nuts. Torque bolts to 300 lbs-ft.
2. Attach crossbar (see Crossbar removal on page
33).
MAN0390 (Rev. 4/6/2007)
Dealer Service 29
Page 30
16. Seal 50 x 90 x 10
17. Protective screen
18. Cotter pin
19. Output shaft
20. Flat washer
21. Castle nut, metric M3 x 2.0
22. Plug, 3/8 NPT
23. Ball bearing
24. Oil cap
25. Shim, 44 x 30.3 x 1
1. Gearbox housing
2. Cap screw 8 mm x 14 (8.8)
3. Vent plug
4. Top cover
5. Shim kit
6. Crown gear
7. Bearing cup & cone
8. Cotter pin B6 x 60 mm
9. Snap ring
10. Seal
11. Input shaft
12. Castle nut, metric M30 x 1.5
13. Pinion gear
14. Shim kit
15. Bearing cup & cone
30 Dealer Service
Figure 19. Spindle Gearbox Assembly
MAN0390 (Rev. 4/6/2007)
Page 31
SPLITTER GEARBOX REPAIR
1. Gearbox
2. Lock nut
3. M10 x 1.5 x 22 Cap screw
4. Cross shaft
5. Shim, 45.3 x 65.3 x 2.5
6. Vent plug
7. Crown gear
8. Pinion gear
9. Shim, 45.3 x 65.3 x 1
10. Key, 14 x 9 x 40
11. Seal
12. Cover
13. Bearing cup & cone
14. Input shaft
15. Housing, input
16. Bearing cup & cone
17. Seal
18. Shim kit
19. Plug, 3/8 NPT
20. Spacer
21. Key
NOTE: Replacing gears, shafts, bearings, and seals may not be cost effective. Purchasing a complete gear­box may be more economical.
REMOVE GEARBOX FROM CUTTER
1. Disconnect driveline from the tractor PTO and
remove it from center gearbox.
2. Remove vent plug (6) and siphon gear lube from housing through this opening.
3. 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.
4. Remove the four bolts 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. Remove breather plug from top of gearbox.
4. Remove oil seals (11) (to be replaced) from both
sides of cross shaft (4).
5. Remove eight cap screws (3) from around gearbox cover (12) and remove cross shaft (4) from gearbox.
6. Disassemble shims (5 & 18), spacer (20), bearings (16 & 13), and crown gear (7) from cross shaft.
7. Support housing in a vise and remove bearing cones (16) by using a punch and hammer to drive bearing cone out.
8. Support cover (12) in a vise and remove bearing cups (13) by using a punch and hammer to drive bearing cone out.
9. 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.
11. Support housing in a vise and remove bearing cups (13 & 16) by using a punch and hammer to drive bearing cones out.
12. Inspect gears for broken teeth and wear. Some wear is normal and will show on loaded side. Forged gear surfaces are rough when new. Check that wear pattern is smooth.
2. Remove plug (19) from side of input housing (1) and pour out gear oil.
3. Remove eight cap screws (3) from around input housing (15). Remove input shaft assembly and housing.
Figure 20. Center Gearbox Assembly
MAN0390 (Rev. 4/6/2007)
13. Inspect input and cross shafts for grooves, nicks, or bumps in the areas where the seals seat. Resurface any damage with emery cloth.
14. Inspect housing and caps for cracks or damage.
Dealer Service 31
Page 32
ASSEMBLE GEARBOX
6. Shaped washer
7. Bushing
8. Bolt
9. Lock nut
11. Se t screw
2. Shaft
3. Inner yoke
4. Outer yoke
5. Rubber disc
REINSTALL GEARBOX
Refer to Figure 20.
1. Clean housing, paying specific attention to areas
where gaskets will be installed.
2. Wash housing and all components thoroughly. Select a clean area for gearbox assembly. Replace all seals, bearings, and gaskets. All parts must be clean and lightly oiled before reassembling.
3. Install new bearing cup (16) in gearbox housing and bearing cup (13) in cover if these parts were previously removed.
4. Place bearing (16) and shim (5) on end of cross shaft (4), and insert shaft into housing.
5. Install spacer (20), key (21), crown gear (7), shim (18), and bearing (13) on opposite end of cross shaft.
6. Place cover (12) over bearings (13) and secure into position using eight cap screws (3). Torque cap screws to 29 lbs-ft.
7. Place seal (11) over cross shaft and press into housing. Use a round tube the same diameter of the seal and a handpress. Repeat process on opposite side of gearbox.
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 lbs-ft.
SIDE DRIVE SERVICE
8. Install new bearing cup (16 & 13) into input housing
if these parts were previously removed.
9. Place bearing (16) over end of input shaft (14) and insert shaft into front of input housing.
10. Place seal (17) over shaft and press into housing. Use a round tube the same diameter of the seal and a handpress.
11. Install bearing (13), shim (18), pinion gear (8), key (10), shim (9) over opposite end of input shaft (14).
12. Secure parts together using lock nut (2). Tighten lock nut (2) until shaft rolling torque is 3 to 9 lbs­inch.
13. Insert input housing assembly into front of gearbox housing and align teeth of the two gears. Secure with cap screws (3). Torque cap screws to 29 lbs-ft.
14. Check gear backlash; it should be .006" to .017" at outer tooth.
15. Check gearbox housing for leaks by plugging all holes except one. Apply 4 psi compressed air and immerse the gearbox in water to verify that there are no leaks.
16. Remove gearbox from water and dry off with compressed air. Add SAE 80W or 90W EP oil until it runs out of the lower level hole in front cover. Tighten all plugs.
32 Dealer Service
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 flexi­ble coupling must be disassembled.
Remove end yokes by removing nuts (9) and sliding bolt (8) inward to clear yoke. Do not remove bolt unless rubber discs (5) are to be serviced. Remove complete center section by lifting straight up on center shaft (2). The outer yoke can be slid off gearbox shaft. The inner yoke is held by two set screws (11).
Reassemble shaft as shown in Figure 21. End yokes (3 & 4) do not bolt directly to center shaft (2). Use the spe­cial 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 wash­ers (6) are slightly embedded into the rubber discs. Rubber discs (5) will warp and twist if bolts are over­tightened. Tighten set screw (11).
NOTE: Crossbar must be re-timed anytime a crossbar or a side drive is disconnected.
MAN0390 (Rev. 4/6/2007)
Page 33
CROSSBAR REMOVAL
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
1. Clevis
2. 5/8 NC x 4 Cap screw
3. 5/8 NC Hex nut
4. Pad assembly
5. Tube assembly
6. Screw assembly
7. Puller link
1. It is necessary to gain access to bottom side of cutter for crossbar removal. See BLOCKING METHOD, page 21.
NOTE: You will need to use either the puller screw (Item 6, Figure 23) or a small hydraulic jack to remove the crossbar.
2. To make crossbar removal easier, remove blades as shown in Figure 22.
3. Remove cotter pin (38) and castle nut (37) from bottom of crossbar.
4. Refer to Figure 23. Attach a clevis (1) to each end of crossbar, using blade pins, spacers, keyhole plates, and blade pin clips.
5. Position tube assembly (5) with threaded nut toward crossbar for puller screw removal or down for hydraulic jack removal.
6. For removal with puller screw, attach tube (5) to each clevis with screws (2) and nuts (3). Place pad (4) in nut and thread puller screw (6) into nut from bottom. Tighten until pad is solid against gearbox shaft. For best results, strike head of puller screw with a hammer while tightening with a wrench.
7. For removal with a jack, attach tube to each clevis with puller links (7), screws (2), and nuts (3). Place jack on tube with end of jack pressing against gearbox shaft. Slowly apply force with jack.
NOTE: Hydraulic jack will not operate if tipped more than 90-degrees. Use care to prevent bend­ing crossbar during removal. Figure 23. Crossbar Removal
MAN0390 (Rev. 4/6/2007)
Figure 22. Blade Removal
Dealer Service 33
Page 34
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.
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). Torque nut to 450 lbs-ft.
3. Install blades, reinstall them using existing hardware. Torque cap screws to 85 lbs-ft.
CROSSBAR TIMING
Crossbar must be re-timed anytime a crossbar or a side drive is disconnected.
1. To re-time crossbars, position bars as shown in Figure 25.
2. The right crossbar will be at right angles to the front of the cutter.
3. Measure from the front of the cutter to the blade pin on each side crossbar.
4. Hold crossbars in position while connecting the side drivelines.
Figure 25. Crossbar Timing - Bottom View
34 Dealer Service
MAN0390 (Rev. 4/6/2007)
Page 35
UNIVERSAL JOINT REPAIR
1. Yoke
2. Cup and bearing
3. Snap ring
4. Journal cross
Figure 26. Universal Joint Parts Breakdown
U-JOINT DISASSEMBLY
1. Remove external snap rings from yokes in four
locations as shown in Figure 27.
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.
2. With snap rings removed, support drive in vise, hold yoke in hand and tap on yoke to drive cup up out of yoke. See Figure 28.
(Rev. 5/11/2007) MAN0390 (Rev. 4/6/2007)
Figure 27. Remove Snap Ring
Figure 28. Remove Cups
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
Page 36
3. Seat cups by placing a drift or socket (slightly
WARNING
A
DECAL PN 1006348
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 sharply with a hammer to relieve any tension. Repeat until both yokes move in all directions without restriction.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure and result in a tire explosion. Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and an exten­sion 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, dam­aged rims, or missing lug bolts and nuts.
Never remove split rim assembly hardware (A) with the tire inflated.
Figure 31. Install Cups
SERVICING TIRES SAFELY
Used Aircraft Tires (Figure 32)
Figure 32. Split Rim Tire Servicing
36 Dealer Service
(Rev. 5/11/2007)
MAN0390 (Rev. 4/6/2007)
Page 37
ASSEMBLY INSTRUCTIONS
DANGER
WARNING
CAUTION
DEALER SET-UP INSTRUCTIONS
Full chain or rubber shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or dam­age property.
• If this machine is not equipped with full chain or rubber shielding, operation must be stopped when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk of thrown objects. The mower deck and protec­tive devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).
Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove.
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.
These instructions are for the assembly of the DS96 and DS120 mounted and pull-type cutters. Many of the procedures apply to all units. When an instruction applies to a specific unit, the section heading will indicate which unit. Assembly of options may not apply to all units.
Assembly of this cutter is the responsibility of the Woods dealer. It should be delivered to the owner completely assembled, lubricated, and adjusted for normal cutting conditions.
The cutter is shipped partially assembled. Assembly will be easier if aligned and loosely assembled before tightening hardware. Recommended torque values for hardware are located in the Bolt Torque Chart, page
73.
Select a suitable working area. A smooth hard surface, such as concrete, will make assembly much quicker. Open parts boxes and lay out parts and hardware to make location easy. Refer to illustrations, accompany­ing text, parts lists and exploded view drawings.
It is possible for objects to ricochet
Complete check lists on page 49 when you have com­pleted the assembly.
ASSEMBLE - DS96 PULL-TYPE 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 pivot 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 tail­wheel 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).
MAN0390 (Rev. 4/6/2007)
Assembly 37
Page 38
Install Hydraulic Hose
WARNING
1. Tailwheel
2. Wheel hub
3. 15" Steel rim
4. 21" Solid tire -or-
4. 22" Aircraft tire -or-
4. 29" Aircraft tire
5. Attitude rod
6. Spacer
7. Transport lock-up
8. Hydraulic cylinder
9. Reducer
10. Elbow, restricter
11. Hose, 156"
12. Ratchet
13. Clevis pin, 1.0 x 2.26
14. Stroke control kit
15. Headless pin, 1 x 4-1/2
16. Headless pin, 1 x 4
30. Wheel bolt, 1/2 NF x 1-1/8
31. Cap screw, 1/2 NF x 1
32. Lock washer, 1/2
33. Cap screw, 1/2 NC x 3
34. Flange lock nut, 1/2 NC
35. Cotter pin, 1/4 x 1-1/2
36. Hex nut, 1 NC
37. Flat washer, 1"
On pull-type units with optional hydraulic cut­ting height adjustment, use a single-acting cylinder with a maximum extended length of 28-1/4" (718 mm) from attaching point center to center.
NOTICE
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.
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 (14) to cylinder
rod. Stroke control kit is used to set cut height.
38 Assembly
Figure 33. DS96 Pull-Type Rear Half Installation
MAN0390 (Rev. 4/6/2007)
Page 39
ASSEMBLE - DS120 PULL-TYPE CUTTER
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
WARNING
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 driveline 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).
Cylinder
1. Place hydraulic cylinder (8) between lug on
tailwheel.
2. Extend cylinder rod, place transport lock bracket (7) over cylinder rod end and between lugs on tailwheel.
3. Align holes of cylinder rod, transport lock bracket and lugs on tailwheel. Secure assembly using pin (17) and two cotter pins (40).
MAN0390 (Rev. 4/6/2007)
Figure 34. Spring Arm Installation
Install Hydraulic Hose
On pull-type units with optional hydraulic cut­ting height adjustment, use a single-acting cylinder with a maximum extended length of 28-1/4" (718 mm) from attaching point center to center.
NOTICE
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.
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 cylinder
rod. Stroke control kit is used to set cut height.
Assembly 39
Page 40
DS120 Pull-Type - Rear Half
1. Tailwheel arm
2. Wheel hub
3. 15" Steel rim
4. 21" Solid tire -or-
4. 22" Aircraft tire -or-
4. 29" Aircraft tire
5. Attitude rod
6. Spacer
7. Transport lock-up
8. Hydraulic cylinder
9. Reducer
10. Elbow, restricter
11. Hose, 156"
12. Ratchet
13. Spring arm
14. Spring
15. Headless pin, 1 x 3
16. Headless pin, 1 x 4-1/2
17. Headless pin, 1 x 5
18. Stroke control kit
30. Wheel bolt, 1/2 NF x 1-1/8
31. Cap screw, 1/2 NF x 1
32. Lock washer, 1/2
33. Cap screw, 1/2 NC x 3
34. Flange lock nut, 1/2 NC
35. Cap screw, 5/8 NC x 5
36. Lock nut, 5/8 NC
37. Flat washer, 1"
38. Hex nut, 1 NC
39. Cap screw, 1/2 NC x 5
40. Cotter pin, 1/4 x 1-1/2
40 Assembly
Figure 35. DS120 Pull-Type Rear Half Installation
MAN0390 (Rev. 4/6/2007)
Page 41
INSTALL TONGUE DS96 & DS120 CUTTERS
Refer to Figure 36.
2. Secure H-frame to tongue using cap screw (42),
two sleeve (3), two cup washers (4) and lock nut (43).
1. Place tongue (1) between inner mast plates.
NOTE: DS96 only has one set of mast plates. 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
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 necessary when cutter is attached to the tractor.
Place driveline bearing carrier between H-frame (2) and secure with clevis pin (7) and cotter pin (49).
Install Front Drive
1. Slide rear yoke 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 & Hose Holder
1. Attach drive shield (13) to driveline carrier bearing
using two cap screws (35) and lock washers (36).
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.
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).
MAN0390 (Rev. 4/6/2007)
Assembly 41
Page 42
Tongue and Driveline Installation
1. Tongue
2. H-Frame
3. Sleeve, 5/8 x 1 x 9/16
4. Cup washer
5. Safety chain
6. Parking jack
7. Clevis pin, 1/2 x 5-3/4
8. Driveline, front 2/3
9. Driveline, rear 1/3
13. Shield
14. Sleeve, 1/2 x 3-9/16
15. Hose holder
16. Sleeve, 3/4 x 1-1/8 x 5/8
17. Clevis pin, 1 x 2.26
19. SMV Bracket
20. SMV Emblem
30. Cap screw, 1/4 NC x 1/2
31. Nut, 1/4 NC
32. Cap screw, 1/2 NC x 1
33. Cap screw, M12 x 1.5P x 65 mm
34. Lock nut, M12 x 1.5P
35. Cap screw, 3/8 NC x 1
36. Lock washer, 3/8
37. Grease fitting
38. Lock nut, 1/2 NC
39. Cap screw, 1/2 NC x 2
40. Flange lock nut, 1/2 NC
41. Cap screw, 1/2 NC x 5-1/2
42. Cap screw, 5/8 NC x 6
43. Lock nut, 5/8
44. Cap screw, 3/4 NC x 3
45. Lock nut, 3/4 NC
46. Flat washer, 3/4
47. Washer, 3/4 x 2 x 3/8 (DS120 only)
48. Cotter pin, 1/4 x 1-1/2
49. Cotter pin, 3/16 x 1
42 Assembly
Figure 36. DS96 and DS120 Tongue and Driveline Installation
MAN0390 (Rev. 4/6/2007)
(Rev. 5/23/2008)
Page 43
ASSEMBLE - DS96 MOUNTED CUTTER
1. Tailwheel arm
13. Tailwheel adjustment arm
31. 5/8 NC x 4-1/2 Cap screw
32. 5/8 NC Lock nut
Install Tailwheel Arms
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. Attach front A-frame bars (3) to the top of the cutter
mast plates using hitch pins (4), bushing sleeves (11), washers (41), slotted hex nuts (42), and cotter pins (39).
2. Torque hex nuts to 400 lbs-ft.
Refer to Figure 37 and Figure 39
3. Attach rear A-frame bars (2) to the mounting lugs
on the rear of the cutter using cap screws (31) and lock nuts (32).
4. Attach the two rear A-frame bars together at the top rear hole using cap screw (33), spacer sleeve (9), and lock nut (32).
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).
2. Secure each adjustment brace with a cap screw (31) and lock nut (32).
3. Attach tailwheel arms (1) between deck rail and lug near the middle of the cutter. Secure into position using cap screws (30), two washers (12), and lock nut (32). NOTE: See Figure 39 for washers (12) placement.
4. Align holes on adjustment arms (13) with a hole in the tailwheel arm and insert cap screw (30). Secure with lock nut (32). NOTE: Hole positions in tailwheel arms determines cutting height. Final adjustment will be necessary when cutter is mounted to the tractor.
5. Place both break links (7) together and position between front hole of rear A-frame bars. Secure rear A-frame bars and break links together using cap screw (33), pacer sleeve (9), and lock nut (32). NOTE: Break links must rest on top of rear spacer sleeve (9).
6. Place spacer sleeve (6) through front holes of break links. Align break links with bottom holes on front A-frame bars (3) and secure together using cap screw (37) and lock nut (38).
7. Install top link pin (10) and sleeve (8) into top holes of A-frame. Secure with cotter pin (39) and klik pin (40). Sleeve (8) is used with category 2 top links.
Figure 38. Adjustment Arm Installation
Install Driveline
1. Coat input shaft of gearbox with a light coating of
grease.
2. Attach slip clutch on driveline (5) to input shaft of gearbox. Tighten cap screws (35) and lock nut (36).
Figure 37. Break Linkage Installation
MAN0390 (Rev. 4/6/2007)
3. Attach rear tether chain of driveline to driveline shield.
Assembly 43
Page 44
DS96 Mounted Assembly
1. Tailwheel arm
2. Rear A-frame bar
3. Front A-frame bar
4. Hitch pin
5. Driveline
6. Sleeve, 3/4 x 1-1/4 x 3
7. Break link
8. Sleeve, 3/4 x 1 x 3
9. Sleeve, 5/8 x 1 x 1-1/4
10. Headless pin, 3/4 x 5
11. Sleeve, 1-1/8 x 1-7/16 x 11/16
12. Washer, 5/8 x 2-1/2 x 1/4
13. Tailwheel adjustment arm
30. Cap screw, 5/8 NC x 4-1/2
31. Cap screw, 5/8 NC x 2
32. Lock nut, 5/8 NC
33. Cap screw, 5/8 NC x 2-3/4
34. Klik pin, 7/16 x 2
35. Cap screw, M12 x 1.5P x 65 mm
36. Lock nut, M12 x 1.5P
37. Cap screw, 3/4 NC x 5-1/2
38. Lock nut, 3/4 NC
39. Cotter pin,1/4 x 1-1/2
40. Klik pin, 1/4 x 1-3/4
41. Washer, 1-1/8 x 2-3/8 x 3/16
42. Slotted nut, 1-1/8 NF
44 Assembly
Figure 39. DS96 Mounted Assembly
MAN0390 (Rev. 4/6/2007)
Page 45
ASSEMBLE - DS120 MOUNTED CUTTER
WARNING
Refer to Figure 42.
Place jackstands under cutter to raise it off the ground to provide clearance when assembling cutter. See “BLOCKING METHOD” on page 21 for jackstand placement.
Install A-Frame
1. Attach front A-frame bars (3) to the lower (square)
hole of the cutter mast plates. Secure using carriage bolts (35), bushing sleeves (19), washers (34), and lock nuts (31).
Figure 41. Category 3 Hitch Arrangement
Install Tailwheel Arms
2. Attach, rear A-frame bars (2) with washers (44)
over mounting bolts (33) and secure with lock nuts (32).
3. Attach the two rear A-frame bars (2) together at the top rear hole using cap screw (43), spacer sleeve (9), and lock nut (31).
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).
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 (usually on row crop centers).
Install Height Adjustment Device
Ratchet
Install ratchet (18) between cylinder lugs on tailwheel and lugs on the deck. Secure to lugs on the deck with pin (11) and two cotter pins (41). Secure to tailwheel with pin (12) and two cotter pins (41).
Cylinder
1. Place hydraulic cylinder (14) between lugs on
tailwheel and lugs on deck.
2. Secure to deck lugs using pin (11) and two cotter pins (41).
3. Extend cylinder rod, place transport lock bracket (13) over cylinder 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).
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).
MAN0390 (Rev. 4/6/2007)
Install Hydraulic Hoses
On mounted units with optional hydraulic cut­ting height adjustment, use a double-acting cylin­der with a maximum extended length of 28-1/4" (718 mm) from attaching point center to center.
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
Page 46
1. Install a reducer bushing (15) and a restricter
1. Tailwheel arm
2. Rear A-frame bar
3. Front A-frame bar
4. Lower hitch pin
5. Driveline
6. Sleeve, 3/4 x 1-1/4 x 3
7. Break link
8. Sleeve, 3/4 x 1 x 3
9. Sleeve, 5/8 x 1 x 1-1/4
10. Headless pin, 3/4 x 5
11. Headless pin, 1 x 4-1/2
12. Headless pin, 1 x 5
13. Transport lock-up
37. Cap screw, M12 x 1.5P x 65 mm
38. Lock nut, M12 x 1.5P
39. Cap screw, 3/4 NC x 5-1/2
40. Lock nut, 3/4 NC
41. Cotter pin, 1/4 x 1-1/2
42. Klik pin, 1/4 x 1-3/4
43. Cap screw, 5/8 NC x 2-3/4
44. Flat washer, 1"
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 x 5
31. Lock nut, 5/8 NC
32. Lock nut, 1" NC
33. Cap screw, 1" NC x 12
34. Flat washer, 5/8
35. Carriage bolt, 5/8 NC x 2-1/2
36. Klik pin, 7/16 x 2
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 cylinder to prevent damage to tailwheels during transport.
2. Connect hoses (17) to elbows (16).
Install Driveline
1. Coat input shaft of gearbox with a light coating of
grease.
2. Attach slip clutch on driveline (5) to input shaft of gearbox. Tighten cap screws (37) and lock nut (38).
3. Attach rear tether chain of driveline to driveline shield.
46 Assembly
Figure 42. DS120 Mounted Assembly
MAN0390 (Rev. 4/6/2007)
Page 47
FILL GEARBOXES
DANGER
1. Front belt bracket
2. Rear belt strap
3. Front rubber deflector
4. Rear rubber deflector
5. Rear belt strap (DS96 only)
6. Self tapping screw, 3/8 x 1-1/4
7. Lock washer, 3/8
8. Flat washer, 3/8
9. Front reflector bracket
NOTICE
Gearbox is not filled at the factory. Prior to
delivery to customer, make sure gearbox is filled only half-full with 80W or 90W API GL-4 or GL-5 gear lube. Use side plug to remove any excess oil.
1. Make sure vent plug hole is clear (installed by
dealer).
2. Remove plug on side of gearbox.
3. Fill gearbox until oil runs out the side plug on
gearbox. Use a high quality gear oil with a viscosity index of 80W or 90W and an API service rating of GL-4 or GL-5.
4. Install side plug and vent plug.
INSTALL RUBBER SHIELDING
1. Attach rubber belting (3) and deflector brackets (1)
to the front of the frame using self-tapping screws (6), flat washers (8), and lock washers (7).
2. Attach front reflector bracket (9) over left front shield.
3. Attach rubber deflector (4) and center deflector strap (2) to the rear of the cutter frame using self­tapping screws (6), flat washers (8), and lock washers (7).
Full chain or rubber shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or dam­age property.
• If this machine is not equipped with full chain or rubber shielding, operation must be stopped when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk of thrown objects. The mower deck and protec­tive devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).
It is possible for objects to ricochet
MAN0390 (Rev. 4/6/2007)
Figure 43. Rubber Shield Installation
Assembly 47
Page 48
INSTALL CHAIN SHIELDING (OPTIONAL)
DANGER
1. Front chain shield bracket
2. Rear chain shield bracket
3. Front chain pin
4. Rear chain pin
5. 5/16 Chain link
6. Self tapping screw, 3/8 x 1-1/4
7. Lock washer, 3/8
8. Flat washer, 3/8
9. Front reflector bracket
The optional chain shielding assemblies are ready for installation when you receive them.
1. Install front and rear 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.
Full chain or rubber shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or dam­age property.
• If this machine is not equipped with full chain or rubber shielding, operation must be stopped when anyone comes within 300 feet (92 m).
• This shielding is designed to reduce the risk of thrown objects. The mower deck and protec­tive devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).
It is possible for objects to ricochet
Figure 44. Optional Chain Shielding Installation
48 Assembly
MAN0390 (Rev. 4/6/2007)
Page 49
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
Gearbox was not filled at the factory. It must be
serviced before operating cutter. (See LUBRICA­TION, page 21). Failure to service will result in dam­age 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.
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 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 oper­ators of other vehicles.
MAN0390 (Rev. 4/6/2007)
Dealer Check Lists 49
Page 50
NOTES
50 Dealer Check Lists
MAN0390 (Rev. 4/6/2007)
Page 51
PARTS INDEX
Rotary Cutters DS96 & DS120
MAIN FRAME ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
MAIN FRAME
ASSEMBLY PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ASSEMBLY, FRONT HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PULL-TYPE ASSEMBLY, FRONT HALF PARTS LIST . . . . . . . . . . . . . . . . . . . . . . 55
PULL-TYPE ASSEMBLY, REAR HALF
DS96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
MOUNTED ASSEMBLY
DS96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
MOUNTED TAILWHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SPLITTER GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SPINDLE GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SPINDLE GEARBOX ASSEMBLY PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FLEXIBLE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
PULL-TYPE DRIVELINE, REAR 1/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SLIP CLUTCH DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3-JOINT DRIVE, FRONT 2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
WHEEL & TIRE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
BELT SHIELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CHAIN SHIELDING (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 X 8 SINGLE-ACTING HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 70
HYDRAULIC CYLINDER STROKE CONTROL KIT - PULL-TYPE . . . . . . . . . . . . . 71
PARKING JACK - PULL-TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CROSSBAR PULLER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
MAN0390 (Rev. 4/6/2007)
Parts 51
Page 52
22 - Complete decal set
23 - Safety decal set
DS96 / DS120 MAIN FRAME ASSEMBLY
52 Parts
(Rev. 2/6/2009)
MAN0390 (Rev. 4/6/2007)
Page 53
DS96 / DS120 MAIN FRAME PARTS LIST
DS96 DS120
REF PART QTY DESCRIPTION
2 1008191 2 Spindle gearbox (see page 62)
3 1008192 1 Splitter gearbox (see page 61)
4 1002048 1 Clutch shield
5 1013377 2 Shield
6 1013378 1 Right skid
7 1013379 1 Left skid
8 1013370 2 Crossbar
9 11769KT 1 Right blade CCW
(kit includes 2 blades)
10 11768KT 1 Left blade CW
(kit includes 2 blades)
11 11886KT 2 Double edge blade
(kit includes 2 blades)
12 1009098 4 Blade pin kit (includes item 14 & 15)
13 13946 4 20 ga Shim (as required)
14 32603 4 Keyhole plate
15 32604 4 Blade pin lock clip
16 10520 4 18 ga Shim (as required)
17 1003828 1 Manual tube
18 1019437 2 Flexible drive coupler (see page 63)
20 1009203 2 Shield hold down, inside
21 1009204 2 Shield hold down, outside
22 1008194 1 Complete decal set
23 1008195 1 Safety decal set
REF PART QTY DESCRIPTION
1 1009230 1 Tailwheel weldment
2 58803 2 Spindle gearbox (see page 62)
3 1008192 1 Splitter gearbox (see page 61)
4 1002048 1 Clutch shield
5 1009202 2 Shield
6 1009178 1 Right skid
7 1009179 1 Left skid
8 1009180 2 Crossbar
9 19160KT 1 Right blade CCW
(kit includes 2 blades)
10 19161KT 1 Left blade CW
(kit includes 2 blades)
11 19162KT 2 Double edge blade
(kit includes 2 blades)
12 1008190 4 Blade pin kit (includes item 14 & 15)
13 13946 4 20 ga Shim (as required)
14 32603 4 Keyhole plate
15 32604 4 Blade pin lock clip
16 10520 4 18 ga Shim (as required)
17 1003828 1 Manual tube
18 1009207 2 Flexible drive coupler (see page 63)
20 1009203 2 Shield hold down, inside
21 1009204 2 Shield hold down, outside
22 1008194 1 Complete decal set
23 1008195 1 Safety decal set
Hardware Hardware
REF PART DESCRIPTION
30 39141 1" NC x 12 Cap screw GR5
31 34279 1" NC Lock nut
32 30068 * 3/4 NC x 2-1/2 Hex head cap screw GR5
33 57798 3/4 Hardened flat washer
34 302207 * 3/4 NC Flange lock nut
35 6100 * 1/2 NC x 1-1/4 Hex head cap screw GR5
36 855 * 1/2 Lock washer
37 39323 M30 x 2 Castle nut
38 -------- * B6 x 60 Cotter pin
39 11900 * 1/2 NC Flange lock nut
(Rev. 2/6/2009) MAN0390 (Rev. 4/6/2007)
REF PART DESCRIPTION
40 14406 * 1/2 NC x 1 Carriage bolt
41 4529 * 5/16 NC Hex nut
42 2472 * 5/16 Lock washer
43 35155 * 5/16 Flat washer
44 6250 * 5/16 NC x 1-1/4 Hex head cap screw GR5
45 24801 M8 x 1.25P x 20 mm
Hex head cap screw GR5
46 66840 Knob, 3-Prong 3/8 NC
* Standard hardware, obtain locally
Parts 53
Page 54
DS96 / DS120 PULL-TYPE ASSEMBLY, FRONT HALF
54 Parts
(Rev. 7/4/2008)
MAN0390 (Rev. 4/6/2007)
Page 55
DS96 / DS120 PULL-TYPE ASSEMBLY, FRONT HALF PARTS LIST
DS96 DS120
REF PART QTY DESCRIPTION
REF PART QTY DESCRIPTION
1 1009220 1 Tongue
2 11940 1 H-frame
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
5 19407 1 Safety chain
6 23790 1 Parking jack
7 404 1 Clevis pin, 1/2 x 5-3/4
8 40599 1 Front 2/3 drive (see page 66)
9 1009206 1 Rear 1/3 drive (see page 64)
10 13132 1 3-joint drive bearing housing
(includes items 11,12, 37)
11 13133 1 Bearing
12 12128 1 Snap ring
13 1011760 1 Shield
14 27267 1 Sleeve, 1/2 x 3.56
15 3443 1 Hose holder
16 10083 2 Sleeve 3/4 x 1-1/8 x 5/8
17 46605 1 Clevis pin 1.00 x 2.26
18 1013388 1 Attitude rod
19 1009234 1 SMV Bracket
20 24611 1 Slow moving vehicle emblem
1 1009220 1 Tongue
2 11939 1 H-frame
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
5 19407 1 Safety chain
6 23790 1 Parking jack
7 404 1 Clevis pin, 1/2 x 5-3/4
8 40599 1 Front 2/3 drive (see page 66)
9 1009206 1 Rear 1/3 drive (see page 64)
10 13132 1 3-joint drive bearing housing
(includes items 11,12,37)
11 13133 1 Bearing
12 12128 1 Snap ring
13 1011760 1 Shield
14 27267 1 Sleeve, 1/2 x 3.56
15 3443 1 Hose holder
16 10083 2 Sleeve 3/4 x 1-1/8 x 5/8
17 46605 1 Clevis pin 1.00 x 2.26
18 39385 1 Attitude rod
19 1009234 1 SMV Bracket
20 24611 1 Slow moving vehicle emblem
Hardware Hardware
REF PART DESCRIPTION
30 1282 * 1/4 NC x 1/2 Round head cap screw
31 5288 * 1/4 NC Nut
32 25475 * 1/2 NC x 1 Hex head cap screw GR5
33 57262 M12 x 1.5 x 65 mm Hex head screw
34 57261 M12 x 1.5 Hex lock nut
35 839 * 3/8 NC x 1 Hex head cap screw GR5
36 838 * 3/8 Standard lock washer
37 2985 * 1/4-28 x 90 Grease fitting
38 765 * 1/2 NC Lock nut
39 19811 * 1/2 NC x 2 Hex head cap screw GR8
REF PART DESCRIPTION
41 12305 1/2 NC x 5-1/2 Hex head cap screw GR5
42 12005 5/8 NC x 6 Hex head cap screw GR5
43 6239 5/8 NC Lock nut
44 14334 * 3/4 NC x 3 Hex head cap screw GR5
45 2371 * 3/4 NC Lock nut
46 1257 * 3/4 Standard flat washer
47 8424 Washer 3/4 x 2 x 3/8
48 1285 * 1/4 x 1-1/2 Cotter pin
49 1256 * 3/16 x 1 Cotter pin
50 14334 3/4 NC x 3 HHCS GR5
* Standard hardware, obtain locally
(Rev. 5/5/2011)
MAN0390 (Rev. 4/6/2007)
Parts 55
Page 56
DS96 PULL-TYPE ASSEMBLY, REAR HALF
REF PART QTY DESCRIPTION
1 1013380 1 Tailwheel weldment
2 1003492 2 or 4 Wheel hub (see page 67)
3 529 2 15" steel rim - or-
4 7428 2 21" solid tire - or-
4 1003695 2 22" Used aircraft tire - or-
4 1003695F 2 22" Used aircraft tire foam filled - or-
4 1003410 2 29" Used aircraft tire
5 1013388 1 Attitude rod
6 27267 1 1" Schedule 40 pipe x 3.75
7 1004814 1 Transport lock-up
8 29547 1 3 x 8 Hydraulic cylinder
(see page 70)
9 11893 1 1/2 to 1/4 Reducer
10 10290 1 1/4 x 1/4 90° Elbow w / 1/16 restricter
11 8669 1 1/4 x 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)
REF PART DESCRIPTION
30 1258 * 1/2 NF x 1-1/8 Wheel bolt
31 4119 * 1/2 NF x 1 Hex head cap screw GR5
32 855 * 1/2 Standard lock washer
33 3489 * 1/2 NC x 3 Hex head cap screw GR5
34 11900 * 1/2 NC Flange lock nut
35 1285 * 1/4 x 1-1/2 Cotter pin
36 3132 * 1" NC Hex nut
37 1863 * 1" Standard flat washer
* Standard hardware, obtain locally
56 Parts
(Rev. 5/23/2008)
MAN0390 (Rev. 4/6/2007)
Page 57
DS120 PULL-TYPE ASSEMBLY, REAR HALF
REF PART QTY DESCRIPTION
1 1009165 2 Tailwheel arm
2 1003492 2 or 4 Wheel hub (see page 67)
3 529 2 15" steel rim - or-
4 7428 2 21" solid tire - or-
4 1003695 2 22" Used aircraft tire - or-
4 1003695F 2 22" Used aircraft tire foam filled - or-
4 1003410 2 29" Used aircraft tire
5 39385 1 Attitude rod
6 27267 1 1" Schedule 40 pipe x 3.75
7 1004814 1 Transport lock-up
8 29547 1 3 x 8 Hydraulic cylinder
(see page 70)
9 11893 1 1/2 to 1/4 Reducer
10 10290 1 1/4 x 1/4 90° Elbow w / 1/16
restricter
11 8669 1 1/4 x 156" Hose
12 1005020 1 Ratchet adjustment link
13 1009245 1 Spring arm
REF PART QTY DESCRIPTION
14 13316 1 Spring
15 11493 1 1 x 3 Headless pin
16 8346 1 1 x 4-1/2 Headless pin
17 8347 1 1 x 5 Headless pin
18 24098 1 1-1/4 Stroke control kit (see page 71)
REF PART DESCRIPTION
30 1258 * 1/2 NF x 1-1/8 Wheel bolt
31 4119 * 1/2 NF x 1 Hex head cap screw GR5
32 855 * 1/2 Standard lock washer
33 3489 * 1/2 NC x 3 Hex head cap screw GR5
34 11900 * 1/2 NC Flange lock nut
35 378 * 5/8 NC x 5 Hex head cap screw GR5
36 6239 * 5/8 NC Lock nut
37 1863 * 1" Standard flat washer
38 3132 * 1" NC Hex nut
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
MAN0390 (Rev. 4/6/2007)
Parts 57
Page 58
DS96 MOUNTED ASSEMBLY
REF PART QTY DESCRIPTION
1 ------- 2 Tailwheel arm (see page 60)
2 1013376 2 Rear A-frame link
3 1013397 2 Front A-frame link
4 14012 2 Hitch pin
5 1005790 1 Drive (see page 65)
6 27140 1 Sleeve 3/4 x 1-1/4 x 3
7 1013375 2 Break link
8 14824 1 Sleeve 3/4 x 1 x 3
9 66661 2 Sleeve 5/8 x 1 x 1-1/4
10 8327 1 3/4 x 5 Headless pin
11 28306 2 Sleeve 1-1/8 x 1-7/16 x 11/16
12 30278 4 5/8 x 2-1/2 x 1/4 Washer
13 1013374 4 Tailwheel adjustment arm
REF PART DESCRIPTION
30 3097 * 5/8 NC x 4-1/2 Hex head cap screw GR5
31 902 5/8 NC x 2 Hex head cap screw GR5
32 6239 * 5/8 NC Lock nut
33 986 * 5/8 NC x 2-3/4 Hex head cap screw GR5
34 35124 * 7/16 x 2 Klik pin
35 57262 M12 x 1.5 x 65 mm Hex head screw
36 57261 M12 x 1.5 Hex lock nut
37 29315 * 3/4 NC x 5-1/2 Hex head cap screw GR5
38 2371 * 3/4 NC Lock nut
39 1285 * 1/4 x 1-1/2 Cotter pin
40 62043 1/4 x 1-3/4 Klik pin
41 12272 1-1/8 x 2-3/8 x 3/16 Washer
42 14153 1-1/8 NF Slotted hex nut
* Standard hardware, obtain locally
58 Parts
MAN0390 (Rev. 4/6/2007)
Page 59
DS120 MOUNTED ASSEMBLY
REF PART QTY DESCRIPTION
1 ------- 2 Tailwheel (see page 60)
2 1009214 2 Rear A-frame link
3 1009212 2 Front A-frame link
4 39064 2 Lower hitch pin
5 57413 1 Drive (see page 65)
6 27140 2 Sleeve 3/4 x 1-1/4 x 3
7 1013375 2 Break link
8 14824 1 Sleeve 3/4 x 1 x 3
9 66661 2 Sleeve 5/8 x 1 x 1-1/4
10 8327 1 3/4 x 5 Headless pin
11 8346 1 1 x 4-1/2 Headless pin
12 8347 1 1 x 5 Headless pin
13 1004814 1 Transport lock-up
14 29547 1 3 x 8 Hyd cylinder (see page 70)
15 11893 1 1/2 to 1/4 Reducer
16 10290 1 1/4 x 1/4 90° Elbow w/1/16 restricter
17 8669 1 1/4 x 156" Hose
18 1005020 1 Ratchet adjustment link
19 12313 2 Sleeve 5/8 x 1 x 13/16
REF PART DESCRIPTION
30 378 * 5/8 NC x 5 Hex head cap screw GR5
31 19025 * 5/8 NC Flange lock nut
32 34279 1" NC lock nut
33 39141 1" NC x 12 Hex head cap screw GR5
34 692 * 5/8 Standard flat washer
35 5836 * 5/8 NC x 2-1/2 Carriage bolt GR5
36 35124 * 7/16 x 2 Klik pin
37 57262 M12 x 1.5 x 65 mm Hex head screw
38 57261 M12 x 1.5 Hex lock nut
39 29315 * 3/4 NC x 5-1/2 Hex head cap screw GR5
40 2371 * 3/4 NC Lock nut
41 1285 * 1/4 x 1-1/2 Cotter pin
42 62043 1/4 x 1-3/4 Klik pin
43 986 * 5/8 NC x 2-3/4 Hex head cap screw GR5
44 1863 * 1" Standard flat washer
* Standard hardware, obtain locally
MAN0390 (Rev. 4/6/2007)
Parts 59
Page 60
DS96 / DS120 MOUNTED TAILWHEEL ASSEMBLY
REF PART QTY DESCRIPTION
1 1013385 2 Tail wheel arm (DS96 only)
or or
1 1009185 2 Tailwheel arm (DS120 only)
2 15580 2 Tail wheel clevis
3 12577 2 4 x 8 Rim and laminated tire
4 15591 2 Wheel hub with cups (includes 2 of
item 6)
5 15277 2 Wheel hub assembly (includes 2 of
items 6, 7, 8)
6 309 4 Bearing cup
7 310 4 Bearing cone
8 314 4 Seal for 1-1/2 shaft
9 15574 2 Sleeve 1.25 x 1.50 x .903
10 15575 2 Sleeve 1.25 x 1.50 x 1.86
11 15573 2 Sleeve 1.00 x 1.25 x 5.81
60 Parts
REF PART QTY DESCRIPTION
12 15087 4 1" NC x 9 Hex head cap screw GR5
13 1386 4 1" NC Jam nut
14 34279 4 1" NC Lock nut
15 855 * 8 1/2 Standard lock washer
16 4119 * 8 1/2 NF x 1 Hex head cap screw
17 4674 2 3/8 x 2 Spirol pin
18 2370 4 Washer 1.62 x 3 x .18
19 12296 * 2 1/4-28 Straight grease fitting
20 12889 2 3/32 x 1-9/16 O.D. O-ring
21 12881 2 Cap washer
* Standard hardware, obtain locally
MAN0390 (Rev. 4/6/2007)
Page 61
DS96 / DS120 SPLITTER GEARBOX ASSEMBLY
REF PART QTY DESCRIPTION
1 1008192 -- Complete gearbox
2 1008130 1 Lock nut
3 39274 * 16 M10 x 1.5 x 22 mm Cap screw
4 1008131 1 Through shaft 1-3/4 20 spline
5 57456 1 Shim 45.3 x 65.3 x 2.5
6 39325 1 3/8 Vent plug
7 1008132 1 Crown gear, 27 teeth
8 1008133 1 Pinion gear, 18 teeth
9 1008134 1 Shim 45.3 x 65.3 x 1
10 39402 1 Key, 14 x 9 x 40
11 1008135 2 Seal, 45 x 72 x 8
MAN0390 (Rev. 4/6/2007)
REF PART QTY DESCRIPTION
12 1008136 1 Cover
13 1008148 2 Bearing cup and cone
14 1008149 1 Input shaft 1-3/4 20 spline
15 1008151 1 Housing extension
16 39408 2 Bearing cup and cone
17 39412 1 Seal 52 x 85 x 10
18 58751 3 Shim kit 45.3 x 65.3
19 27326 * 4 3/8 NPT Solid plug
20 1008154 1 Spacer 45.3 x 60.3 x 5
21 1008155 1 Key, 14 x 9 x 35
* Standard hardware, obtain locally
Parts 61
Page 62
DS96 / DS120 SPINDLE GEARBOX ASSEMBLY
62 Parts
MAN0390 (Rev. 4/6/2007)
Page 63
DS96 / DS120 SPINDLE GEARBOX ASSEMBLY PARTS LIST
REF PART QTY DESCRIPTION
5 1008140 4 Rubber disc
6 1008141 48 Shaped washer
7 1008142 24 Bushing, .63 I.D.
8 307430 12 M16 x 2.0 x 70 mm HHCS (only for 2
disc drives on DS96)
8 1001042 12 M16 x 2.0 x 90 mm HHCS
9 1008146 12 M16 x 2.0 Lock nut
10 ------- * 1 Grease fitting
11 90016031 * 2 3/8 NC x 3/4 Square head set screw
* Standard hardware, obtain locally
REF PART QTY DESCRIPTION
1 1019437 Complete drive (DS96 only)
1 1009207 Complete drive (DS120 only)
2 ------- 1 Inner connector yoke
3 1008147 1 Outer connector yoke 1-3/4 20-spline
4 1008143 1 Outer connector yoke 1-3/4 6-spline
REF PART QTY DESCRIPTION
1 1008191 1 Complete gearbox (DS96 only)
1 58803 1 Complete gearbox (DS120 only)
2 57150 * 6 M8 x 1.25 x 14 mm Hex head cap
screw
3 57076 1 1/2 Vent plug
4 57139 1 Cover
5 57328 1 Shim kit 60.3 x 71.7
6 1009096 1 Crown gear (DS96 only)
6 39424 1 Crown gear (DS120 only)
7 57462 1 Bearing cup and cone
8 ------ * 1 Cotter pin B6 x 60 mm
9 57466 2 Snap ring
10 57463 1 Seal 35 x 72 x 10
11 57147 1 Input shaft 1-3/8 6 spline
DS96 / DS120 FLEXIBLE COUPLER
12 39261 1 M30 x 1.5 Castle nut
13 1009097 1 Pinion gear (DS96 only)
12 39418 1 Pinion gear (DS120 only)
14 57471 1 Shim kit 50.3 x 70.3
15 39263 2 Bearing cup and cone
16 39289 1 Seal 50 x 90 x 10
17 57338 1 Screen protection
18 ------ * 1 Cotter pin B4 x 55 mm
19 57191 1 Output shaft
20 39322 1 Flat washer 31 x 56 x 4
21 39323 1 M30 x 2.0 Castle nut
22 27326 * 1 3/8 NPT Solid plug
23 20890 1 Ball bearing
24 57374 1 Seal 72 x 10
25 57094 1 Shim 44 x 30.3 x 1
* Standard hardware, obtain locally
MAN0390 (Rev. 4/6/2007)
Parts 63
Page 64
DS96 / DS120 PULL-TYPE DRIVELINE, REAR 1/3
REF PART QTY DESCRIPTION
1009206 1 Complete 540 drive
2 110 1 Cross and bearing kit
3 40764 1 Spring pin 10 x 80
4 1005791 1 Male drive half, complete
6 40593 1 Outer profile & sleeve
7 40576 1 Inboard yoke
8 57416 2 Friction clutch
12 40766 2 Bearing ring
13 40777 1 Anti-rotation chain
14 18864 2 Decal, Danger rotating driveline
15 33347 1 Decal, Danger guard missing
16 40778 2 Screw
17 40767 1 Support bearing
REF PART QTY DESCRIPTION
18 40779 1 Grease fitting
24 1005792 1 Outer guard half
25 1005793 1 Inner guard half
31 57438 1 Flange yoke
32 57432 2 Friction disc
33 57440 1 Hub, 1-3/4 20-spline
34 57434 1 Thrust plate
35 57439 1 Bellevile spring
36 57259 6 M10 x 1.5P x 55 mm Cap screw
37 57260 6 M10 x 1.5P Lock nut w/nylon insert
38 57261 2 M12 x 1.5P Lock nut w/nylon insert
39 57262 2 M12 x 1.5P x 65 mm Cap screw
64 Parts
MAN0390 (Rev. 4/6/2007)
Page 65
DS96 / DS120 SLIP CLUTCH DRIVE ASSEMBLY
REF PART QTY DESCRIPTION
1
2
3
4
5
6
7
8
12
13
14
15
16
17
18
1005790
57413
40574
110
40764
40575
40587
40593
40576
57416
40766
40777
18864
33347
40778
40767
40779
Complete 540 Drive assembly
1
(DS96 only)
Complete 540 Drive assembly
1
(DS120 only)
Yoke, 1-3/8 Spline ASGE
1
Cross and bearing
2
Spring pin 10 X 80
2
Inboard yoke
1
Inner profile
1
Outer profile & sleeve
1
Inboard yoke
1
Friction clutch 1340, 1-3/4, 20-spline
1
Bearing ring SC25
2
Anti-rotation chain
2
Decal, Danger rotating driveline
1
Decal, Danger guard missing
1
Screw
2
Support bearing
1
Grease fitting
1
REF PART QTY DESCRIPTION
23
24
24
25
25
26
26
31
32
33
34
35
36
37
38
39
40589
1005795
57268
1005796
57269
1005794
57414
57438
57432
57440
57434
57439
57259
57260
57261
57262
Slide collar kit
1
Outer guard half (DS96 only)
1
Outer guard half (DS120 only)
1
Inner guard half (DS96 only)
1
Inner guard half (DS120 only)
1
Shaft asy, male (complete/guard)
1
(DS96 only)
Shaft asy, male (complete/guard)
1
(DS120 only)
Flange yoke
1
Friction disc
2
Hub, 1-3/4" 20-spline
1
Thrust plate
1
Belleville spring
1
M10 x 1.5P x 55 mm Cap screw GR8.8
6
M10 x 1.5P Lock nut w/nylon insert
6
M12 x 1.5P Lock nut w/nylon insert
2
M12 x 1.5P x 65 mm Cap screw GR8.8
2
(Rev. 12/16/2010)
MAN0390 (Rev. 4/6/2007)
Parts 65
Page 66
DS96 / DS120 3-JOINT DRIVE, FRONT 2/3
REF PART QTY DESCRIPTION
1 40599 1 Complete drive assembly
2 40574 1 Yoke, 1-3/8 - 6SP
(complete with lock collar)
3 110 2 Cross and bearing kit
4 40576 2 Inboard yoke
5 40764 2 Spring pin 10 mm x 80 mm
(package of 10)
6 40588 1 Outer profile (cut to length)
REF PART QTY DESCRIPTION
7 40590 1 Guard, outer half, also includes items
9, 10 and 11 (cut to length)
8 40591 1 Guard, inner half, also includes items
9, 10 and 11 (cut to length)
9 40766 2 Bearing ring (package of 2)
10 40778 2 Screw (package of 10)
11 40777 2 Anti-rotation chain
12 40589 1 Lock collar repair kit (without yoke)
13 15308 1 Yoke, 1-3/8 - 6SP clamp type
66 Parts
MAN0390 (Rev. 4/6/2007)
Page 67
WHEEL & TIRE ASSEMBLY
REF PART QTY DESCRIPTION
1 1003492 1 Heavy hub assembly
2 530 1 Heavy wheel hub with cups
3 1003493 1 Axle
4 314 1 Seal for 1-1/2 shaft
5 310 2 Bearing cone
6 309 2 Bearing cup
7 1003411 1 15.0 x 6.0 Rim half
(for 29" aircraft wheel only) -or-
7 1003694 1 10.0 x 5.0 Rim half
(for 22" aircraft wheel only)
8 1003412 1 15.0 x 6.0 Rim half w/valve hole
(for 29" aircraft wheel only) -or-
8 1003693 1 10.0 x 5.0 Rim half w/valve hole
(for 22" aircraft wheel only)
95311Hub cap
10 529 1 15" 4-Hole rim
10 7428 1 6.00 x 9 Solid tire, rim & hardware -or-
10 1003410 1 29 x 9 x 15 Aircraft tire,
rim & hardware -or-
REF PART QTY DESCRIPTION
10 1003695 1 22 x 6.6 x 10 Aircraft tire,
rim & hardware
20 1257 * 3/4 Standard flat washer
21 5849 3/4 NF Slotted hex nut
22 1256 * 3/16 x 1 Cotter pin
23 1258 1/2 NF x 1-1/8 Wheel bolt
24 855 * 1/2 Extra-heavy lock washer
25 4119 1/2 NF x 1 Cap screw GR5
(solid tire only)
26 * 9-1/6 NC x 1-1/4 Cap screw GR5
27 * 9/16 NC Hex lock nut
28 19887 3/8 NC x 1 Cap screw GR8
29 838 * 3/8 Standard lock washer
30 835 * 3/8 NC Hex nut, plated
31 1972 * 1/4-28 Tapered thread grease fitting
* Standard hardware - obtain locally
MAN0390 (Rev. 4/6/2007)
Parts 67
Page 68
DS96 / DS120 BELT SHIELDING
DS96 DS120
REF PART QTY DESCRIPTION
1 1013391 2 Front belt bracket
2 1013393 1 Rear belt strap
3 1013392 2 Front rubber deflector
4 1013394 1 Rear rubber deflector
5 1013399 2 Rear belt strap, outer (DS96 only)
6 19446 18* 3/8 x 1-1/4 Type T self-tapping screw
7 838 18* 3/8 Standard lock washer
8 565 18* 3/8 Standard flat washer
9 1009242 1 Front reflector bracket w/reflector
* Standard Hardware, obtain locally
REF PART QTY DESCRIPTION
1 1008091 2 Front belt bracket
2 1008093 1 Rear belt strap
3 1008092 2 Front rubber deflector
4 1008094 1 Rear rubber deflector
6 19446 20* 3/8 x 1-1/4 Type T self-tapping screw
7 838 20* 3/8 Standard lock washer
8 565 20* 3/8 Standard flat washer
9 1009242 1 Front reflector bracket w/reflector
* Standard Hardware, obtain locally
68 Parts
MAN0390 (Rev. 4/6/2007)
Page 69
DS96 / DS120 CHAIN SHIELDING (OPTIONAL)
DS96 DS120
REF PART QTY DESCRIPTION
1 1009188 2 Front chain shield bracket
2 1009189 1 Rear chain shield bracket
3 1007854 2 Front chain pin
4 1007856 1 Rear chain pin
5 3994 122 5/16 Chain, 5 link
6 19446 18 3/8 x 1-1/4 Type T self-tapping screw
7 838 18* 3/8 Standard lock washer
8 565 18* 3/8 Standard flat washer
9 1009242 1 Front reflector bracket with reflector
* Standard Hardware, obtain locally
REF PART QTY DESCRIPTION
1 1008083 2 Front chain shield bracket
2 1008084 1 Rear chain shield bracket
3 1007856 2 Front chain pin
4 1007856 1 Rear chain pin
5 3994 151 5/16 Chain, 5 link
6 19446 20 3/8 x 1-1/4 Type T self-tapping screw
7 838 20* 3/8 Standard lock washer
8 565 20* 3/8 Standard flat washer
9 1009242 1 Front reflector bracket with reflector
* Standard Hardware, obtain locally
MAN0390 (Rev. 4/6/2007)
Parts 69
Page 70
3 X 8" SINGLE-ACTING HYDRAULIC CYLINDER
REF PART QTY DESCRIPTION
1 N/A Not available
2 19810 1 Seal Kit, 3 In Hyd Cylinder
(includes items 2A thru 2G)
2A 1 Wiper seal
2B Not used
2C 2 1-1/4 ID U-Cup
2D 2 Barrel O-ring
2E Not used on this cylinder
2F 2 Piston back-up washer
2G 1 Piston seal O-ring
3 N/A 1 Rod end housing
4N/A1Piston
5 34328 1 Nut, Lock 3/4 NF
6 N/A 4 Cylinder tie rod
7 4510 * 1 1/2 Pipe plug
8 N/A 1 Cylinder butt end
REF PART QTY DESCRIPTION
9 Not used on this cylinder
10 Not used on this cylinder
11 11893 1 Bushing, Pipe Reducing 1/2 x 1/4
12 N/A 1 Cylinder barrel
13 Not used on this cylinder
14 Not used on this cylinder
15 * 8 Tie rod nut
16 23549 1 Clevis, Cylinder Rod
17 6698 * 1 Nut, Lock 3/8 NC
18 23550 * 1 Screw, SHCS 3/8 NC x 1-1/2
19 N/A 1 Cylinder rod
20 29547 Cylinder, Hydraulic 3 x 8
* Standard hardware, obtain locally
Included in seal repair kit
N/A Not available
70 Parts
MAN0390 (Rev. 4/6/2007)
Page 71
HYDRAULIC CYLINDER STROKE CONTROL KIT (OPTIONAL)
REF PART QTY DESCRIPTION
1 24098 1 Stroke control set for 1-1/4" cylinder
rod (contains items 2 - 5)
2 – – – – 2 1-1/2" Segment
3 – – – – 1 1-1/4" Segment
4 – – – – 1 1" Segment
5 – – – – 1 3/4" Segment
REF PART QTY DESCRIPTION
1 23790 1 Swivel parking jack
2 25857 1 Jack hitch pin assembly
3N/S
3A N/S
4 25859 2 15-Tooth bevel gear
5 25860 2 5/32 x 1-1/4 Drive pin
6N/S
7 25862 1 Thrust bearing
N/S Not Serviced Separately
PARKING JACK
PULL-TYPE
MAN0390 (Rev. 4/6/2007)
Parts 71
Page 72
CROSSBAR PULLER (OPTIONAL)
REF PART QTY DESCRIPTION
A 8811 1 Crossbar puller, complete
1 19914 2 Crossbar puller clevis
2 3097 * 4 5/8 NC x 4-1/2
Hex head cap screw GR5
3 230 * 4 5/8 NC Hex nut
4 24879 1 Crossbar puller pad assembly
REF PART QTY DESCRIPTION
5 24876 1 Crossbar puller tube assembly
6 24881 1 Crossbar puller screw assembly
7 24885 4 Crossbar puller link
* Standard hardware, obtain locally
72 Parts
MAN0390 (Rev. 4/6/2007)
Page 73
BOLT TORQUE CHART
A
SAE SERIES TORQUE CHART
SAE Bolt Head
Identification
SAE Grade 2
(No Dashes)
SAE Grade 5
(3 Radial Dashes)
SAE Grade 8
(6 Radial Dashes)
METRIC SERIES TORQUE CHART
Metric Bolt Head
Identification
8.8
Metric
Grade 10.9
10.9
Metric
Grade 8.8
A
A
Typical Washer Installations
Lock Washer
Flat Washer
8/9/00
Bolt
Always tighten hardware to these values unless a different torque value or tightening procedure is listed for a specific application.
Fasteners must always be replaced with the same grade as specified in the manual parts list. Always use the proper tool for tightening hardware: SAE for SAE hardware and Metric for metric hardware. Make sure fastener threads are clean and you start thread engagement properly. All torque values are given to specifications used on hardware defined by SAE J1701 MAR 99 & J1701M JUL 96.
A
Diameter
(Inches)
1/4" 7/16" 6 8 10 13 14 18
5/16"1/2"121719262737
3/8"9/16"233135474967
7/16"5/8"3648557578106
1/2" 3/4" 55 75 85 115 120 163
9/16" 13/16" 78 106 121 164 171 232
5/8" 15/16" 110 149 170 230 240 325
3/4" 1-1/8" 192 261 297 403 420 569
7/8" 1-5/16" 306 416 474 642 669 907
1" 1-1/2" 467 634 722 979 1020 1383
A
Diameter &
Thread Pitch
(Millimeters)
6 x 1.0 10 mm 8 6 11 8 8 6 11 8 6 x 1.0
8 x 1.25 13 mm 20 15 27 20 21 16 29 22 8 x 1.0
10 x 1.5 16 mm 39 29 54 40 41 30 57 42 10 x 1.25
12 x 1.75 18 mm 68 50 94 70 75 55 103 76 12 x 1.25
14 x 2.0 21 mm 109 80 151 111 118 87 163 120 14 x 1.5
16 x 2.0 24 mm 169 125 234 173 181 133 250 184 16 x 1.5
18 x 2.5 27 mm 234 172 323 239 263 194 363 268 18 x 1.5
20 x 2.5 30 mm 330 244 457 337 367 270 507 374 20 x 1.5
22 x 2.5 34 mm 451 332 623 460 495 365 684 505 22 x 1.5
24 x 3.0 36 mm 571 421 790 583 623 459 861 635 24 x 2.0
30 x 3.0 46 mm 1175 867 1626 1199 1258 928 1740 1283 30 x 2.0
Wrench
Size
Wrench
Size
MARKING ON HEAD MARKING ON HEAD
Metric 8.8 Metric 10.9 Metric 8.8 Metric 10.9
N-m lbs-ft N-m lbs-ft N-m lbs-ft N-m lbs-ft
SAE 2 SAE 5 SAE 8
lbs-ft N-m lbs-ft N-m lbs-ft N-m
COARSE THREAD FINE THREAD
MARKING ON HEAD
Diameter &
Thread Pitch
(Millimeters)
Bolt Torque & Size Charts (Rev. 3/28/2007)
Appendix 73
Page 74
BOLT SIZE CHART
NOTE: Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts.
SAE Bolt Thread Sizes
5/16 3/8 1/2 5/8 3/4 7/8
IN 1 7
2
34
5
6
MM 25 50 75 100 125 150 175
Metric Bolt Thread Sizes
8MM 18MM14MM12MM10MM 16MM
ABBREVIATIONS
AG .............................................................. Agriculture
ASABE .................... American Society of Agricultural &
Biological Engineers (formerly ASAE)
ASAE....... American Society of Agricultural Engineers
ATF................................Automatic Transmission Fluid
BSPP.............................British Standard Pipe Parallel
BSPTM................ British Standard Pipe Tapered Male
CV ....................................................Constant Velocity
CCW.............................................. Counter-Clockwise
CW .............................................................. Clockwise
F .......................................................................Female
FT.............................................................. Full Thread
GA ..................................................................... Gauge
GR (5, etc.)........................................... Grade (5, etc.)
HHCS ........................................Hex Head Cap Screw
HT ...........................................................Heat-Treated
JIC.................Joint Industry Council 37° Degree Flare
LH.................................................................Left Hand
LT ...........................................................................Left
m ........................................................................ Meter
mm ............................................................... Millimeter
M .......................................................................... Male
MPa ........................................................ Mega Pascal
N ......................................................................Newton
NC...................................................... National Coarse
NF ...........................................................National Fine
NPSM .................... National Pipe Straight Mechanical
NPT...........................................National Pipe Tapered
NPT SWF......... National Pipe Tapered Swivel Female
ORBM ...........................................O-Ring Boss - Male
P ..........................................................................Pitch
PBY.......................................................Power-Beyond
psi ......................................... Pounds per Square Inch
PTO......................................................Power Take Off
QD ................................................... Quick Disconnect
RH.............................................................. Right Hand
ROPS........................... Roll-Over Protective Structure
RPM........................................Revolutions Per Minute
RT ........................................................................Right
SAE..........................Society of Automotive Engineers
UNC ..................................................... Unified Coarse
UNF .......................................................... Unified Fine
UNS ..................................................... Unified Special
74 Appendix
Bolt Torque & Size Charts (Rev. 3/28/2007)
Page 75
INDEX
A
ASSEMBLY
Assemble - DS120 Pull-Type Cutter Rear Half 39
Install Attitude Rod 39 Install Height Adjustment Device 39 Install Hydraulic Hose 39 Install Rear Tailwheel 39 Install Spring Arm 39
Assemble - DS96 Pull-Type Cutter Rear Half 37
Install Attitude Rod 37 Install Height Adjustment Device 37 Install Hydraulic Hose 38 Install Rear Tailwheel 37
Assemble DS120 Mounted Cutter 45
Install A-Frame 45
Category 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 & Hose Holder 41 Install Driveline 41 Install Front Drive 41 Install H-Frame 41 Install SMV Bracket 41
Install Tongue DS96 & DS120 Cutters 41
28
Side Drive Service 32 Spindle Gearbox Repair 28
Assemble Gearbox 29 Disassemble Gearbox 28 Reinstall Gearbox 29 Remove Gearbox 28
Splitter Gearbox Repair 31
Assemble Gearbox 32 Disassemble Gearbox 31 Reinstall Gearbox 32 Remove Gearbox 31
Universal Joint
Assembly 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 Warranty
Product 71 Replacement Parts 1
O
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) MAN0390 (Rev. 4/6/2007)
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 - Pull-Type 14
Hydraulic Connection 15 Interference Check 15
Cutting Height Adjustment 17
Mounted 18 Pull-Type 18
Index 75
Page 76
Driveline Adjustment - Pull-Type Driveline Attachment - Mounted 16
Driveline interference Check 17
Operating Technique 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 Diagram 22
Servicing Blades 22
Installing Blades 22 Removing Blades 22 Sharpening Blades 23
Shielding Repair
Optional Chain Shielding 25
18
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 (Owner’s Responsibility) 20
Free Mower Safety Video Order Form 5, 6 Safety & Instructional Decals 11 Safety Rules 7, 8, 9, 10 Safety Symbols Explained 2
T
TROUBLESHOOTING
Troubleshooting 26
76 Index
(Rev. 2/6/2009)
MAN0390 (Rev. 4/6/2007)
Page 77
WARRANTY
All Models Except Mow’n MachineTM 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
Condition
Warranted
Gearbox
Seals
Gearbox
components
Blade
spindles
Rust-through
Under no circumstances will this Warranty apply in the event that the product, in the good faith opinion of WOODS, has been subjected to improper operation, improper maintenance, misuse, or an accident. This Warranty does not apply in the event that the product has been materially modified or repaired by someone other than WOODS, a WOODS authorized dealer or distributor, and/or a WOODS authorized service center. This Warranty does not cover normal wear or tear, or normal maintenance items. This Warranty also does not cover repairs made with parts other than those obtainable through WOODS.
This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or otherwise transfer this product to a third party, this Warranty does not transfer to the third party purchaser in any way. There are no third party beneficiaries of this Warranty.
WOODS makes no warranty, express or implied, with respect to engines, batteries, tires or other parts or accessories not manufactured by WOODS. Warranties for these items, if any, are provided separately by their respective manufacturers.
WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of charge, of the product if WOODS, in its sole discretion, deems it to be defective or in noncompliance with this Warranty. The product must be returned to WOODS with proof of
purchase within thirty (30) days after such defect or noncompliance is discovered or should have been discovered, routed through the dealer and distributor from whom the purchase was made, transportation charges prepaid. WOODS shall complete such repair or
replacement within a reasonable time after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND/OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal theory. Without limiting the generality of the foregoing, Woods specifically disclaims any damages relating to (i) lost profits, business, revenues
or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (v) any other type of damage to property or economic loss.
This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture replacement parts.
No agent, representative, dealer, distributor, serviceperson, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this
Woods Equipment
All units listed below 2 years
BW1260, BW1620, BW1800, BW2400 8 years
BW240HD, BW180HD, BW180HB, BW126HB 7 years
BB48X, BB60X, BB72X, BB84X, BB600X, BB720X, BB840X, BB6000X, BB7200X, BB8400X, DS1260, DSO1260, DS1440, TS1680, BW126-3, BW180-3, BW240
PHD25, PHD35, PHD65, PHD95, 2162, 3240, DS96, DS120, RCC42, RM550-2, RM660-2, RD990X, PRD6000, PRD7200, PRD8400, S15CD, S20CD, S22CD, S25CD, S27CD, BW180LH, TC/R74, TC/R68, TC/R60, TBW144, TBW180, TBW204
RDC54, RD60, RD72, TBW150C, TS/R60, TS/R52, TS/R44
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, BW180HD, BW1260, BW1800, BW240, BW240HD, 2162, 3240, DS1260, DSO1260, DS1440, TS1680
Warranty. Answers to any questions regarding warranty service and locations may be obtained by contacting:
Model Number
Company
2606 South Illinois Route 2 Post Office Box 1000 Oregon, Illinois 61061 USA
800-319-6637 tel 800-399-6637 fax www.WoodsEquipment.com
Duration (from date of delivery to the original
purchaser)
6 years
5 years
3 years (1 year if used in rental or commercial applications)
10 years
F-3079 (Rev. 2/14/2011)
Page 78
WARRANTY
(Replacement Parts For All Models Except Mow’n Machine
Zero-Turn Mowers and Woods BoundaryTM 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 discovered or should have been discovered, routed through the dealer and distributor from whom the purchase was made, transportation charges prepaid. WOODS shall complete
such repair or replacement within a reasonable time after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND/OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
TM
WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal theory. Without limiting the generality of the foregoing,
Woods specifically disclaims any damages relating to (i) lost profits, business, revenues or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (v) any other type of damage to property or economic loss.
This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture replacement parts.
No agent, representative, dealer, distributor, service person, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty.
Answers to any questions regarding warranty service and locations may be obtained by contacting:
©2005 Woods Equipment Company. All rights reserved. WOODS and the Woods logo are trademarks of Woods Equipment Company. All other trademarks, trade names, or service marks not owned by Woods Equipment Company that appear in this manual are the property of their respective companies or mark holders. Specifications subject to change without notice.
F-8494 (Rev. 6/23/2005)
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