Woods Equipment Ds120 Users Manual MAN0390

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OPER ATOR'S MANUAL

ROTARY CUTTER

MAN0390

(Rev. 5/5/2011)

DS96

DS120

2 Introduction

Gen’l (Rev. 3/5/2010)

TO THE DEALER:

Assembly and proper installation of this product is the responsibility of the Woods® dealer. Read manual instructions

and safety rules. Make sure all items on the Dealer’s Pre-Delivery and Delivery Check Lists in the Operator’s Manual

are completed before releasing equipment to the owner.

The dealer must complete the online Product Registration form at the Woods Dealer Website which certifies that

all Dealer Check List items have been completed. Please contact 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:

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.

Introduction 3

MAN0390 (Rev. 6/30/2006)

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)

4 Introduction

MAN0390 (Rev. 6/30/2006)

SPECIFICATIONS

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

22" or 29" Used Aircraft 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 fur-

nishes information and instructions that will help you

achieve years of dependable performance. These

instructions have been compiled from extensive field

experience and engineering data. Some information

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 cur-

rent at the time of printing but, due to possible inline

production changes, your machine may vary slightly in

detail. We reserve the right to redesign and change the

machines as may be necessary without notification.

Throughout this manual, references are made to right

and left directions. These are determined by standing

behind the equipment facing the direction of forward

travel. Blade rotation is clockwise (right) and counter-

clockwise (left) as viewed from the top of the cutter.

Safety 5

Safety Video Order Form (8/2/2005)

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

6 Safety

Safety Video Order Form (Rev. 2/6/2006)

Free Mower/Cutter Safety Video Order Form

3 (Select one)

VHS Format - VHS01052 Safety Video

DVD Format - DVD01052 Safety Video

Please send me

Name: ________________________________________ Phone: __________________

Address: _____________________________________

_____________________________________

_____________________________________

Mower/Cutter Model: ______________________ Serial #: ________________________

Send to: ATTENTION: DEALER SERVICES

WOODS EQUIPMENT COMPANY

PO BOX 1000

OREGON IL 61061-1000

USA

Also, available from the Association of Equipment Manufacturers:

A large variety of training materials (ideal for groups) are available for a nominal

charge from AEM. Following is a partial list:

●Training Package for Rotary Mowers/Cutters-English

Contains: DVD & VHS (English)

Guidebook for Rotary Mowers/Cutters (English)

AEM Industrial/Agricultural Mower Safety Manual (English)

AEM Agricultural Tractor Safety Manual (English)

●Training Package for Rotary Mowers/Cutters-English/Spanish

Contains: DVD & VHS (English/Spanish)

Guidebook for Rotary Mowers/Cutters (English/Spanish)

AEM Industrial/Agricultural Mower Safety Manual (English/Spanish)

AEM Agricultural Tractor Safety Manual (English/Spanish)

AEM training packages are available through:

AEM at:

www.aem.org

or

Universal Lithographers, Inc.

Email: aem@ulilitho.com

800-369-2310 tel

866-541-1668 fax



Safety 7

DS96-DS120 Safety Rules (Rev. 5/11/2007)

TRAINING

Safety instructions are important! Read all

attachment and power unit manuals; follow all

safety rules and safety decal information. (Replace-

ment manuals and safety decals are available from

your dealer. To locate your nearest dealer, check

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.

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 attach-

ments, and all controls. Do not allow anyone to

operate this equipment without proper instruc-

tions.

Keep hands and body away from pressurized

lines. Use paper or cardboard, not hands or other

body parts to check for leaks. Wear safety goggles.

Hydraulic fluid under pressure can easily penetrate

skin and will cause serious injury or death.

Make sure that all operating and service person-

nel know that if hydraulic fluid penetrates skin, it

must be surgically removed as soon as possible by

a doctor familiar with this form of injury or gan-

grene, serious injury, or death will result. CON-

TACT A PHYSICIAN IMMEDIATELY IF FLUID

ENTERS SKIN OR EYES. DO NOT DELAY.

Never allow children or untrained persons to

operate equipment.

PREPARATION

Check that all hardware is properly installed.

Always tighten to torque chart specifications

unless instructed otherwise in this manual.

Air in hydraulic systems can cause erratic oper-

ation and allows loads or equipment components

to drop unexpectedly. When connecting equipment

or hoses or performing any hydraulic maintenance,

purge any air in hydraulic system by operating all

hydraulic functions several times. Do this before

putting into service or allowing anyone to

approach the equipment.

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.

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 accom-

panies the driveline. Replace if damaged or broken.

Check that driveline guards rotate freely on drive-

line 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 is a primary concern in the design and

manufacture of our products. Unfortunately, our

efforts to provide safe equipment can be wiped

out by an operator’s single careless act.

In addition to the design and configuration of

equipment, hazard control and accident preven-

tion are dependent upon the awareness, con-

cern, judgement, and proper training of

personnel involved in the operation, transport,

maintenance, and storage of equipment.

It has been said, “The best safety device is an

informed, careful operator.” We ask you to be

that kind of operator.

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

8 Safety

DS96-DS120 Safety Rules (Rev. 5/11/2007)

(Safety Rules continued from previous page)

Remove accumulated debris from this equip-

ment, 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 dam-

aged.

Do not put this equipment into service unless all

side skids are properly installed and in good condi-

tion. 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 result-

ing in loss of steering. The weight may be attained

with front wheel weights, ballast in tires or front

tractor weights. Weigh the tractor and equipment.

Do not estimate.

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 dam-

age property.

• If this machine is not equipped with full chain

or rubber shielding, operation must be stopped

when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition.

It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

Do not allow bystanders in the area when oper-

ating, attaching, removing, assembling, or servic-

ing equipment.

Never direct discharge toward people, animals,

or property.

Do not operate or transport equipment while

under the influence of alcohol or drugs.

Operate only in daylight or good artificial light.

Keep hands, feet, hair, and clothing away from

equipment while engine is running. Stay clear of all

moving parts.

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 cut-

ting height adjustment, use a double-acting cylin-

der with a maximum extended length of 28-1/4"

(718 mm) from attaching point center to center.

TRANSPORTATION

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-

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Safety 9

DS96-DS120 Safety Rules (Rev. 5/11/2007)

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 pres-

sure, 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. Hydrau-

lic 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 compo-

nents in any way.

Your dealer can supply original equipment

hydraulic accessories and repair parts. Substitute

parts may not meet original equipment specifica-

tions 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 oper-

ating, attaching, removing, assembling, or servic-

ing 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 under-

neath equipment or between moveable parts even

when the engine has been turned off. Hydraulic

system leak down, hydraulic system failures,

mechanical failures, or movement of control levers

can cause equipment to drop or rotate unexpect-

edly and cause severe injury or death. Follow Oper-

ator's Manual instructions for working underneath

and blocking requirements or have work done by a

qualified dealer.

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 com-

ponents has stopped before approaching for ser-

vice.

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 dam-

aged.

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 pres-

sure before loosening bolts on wheel.

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

10 Safety

DS96-DS120 Safety Rules (Rev. 5/11/2007)

STORAGE

Keep children and bystanders away from stor-

age 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.



SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Safety 11

MAN0390 (Rev. 6/30/2006)

1 - SERIAL NUMBER PLATE

2 - PN 5669

3 - PN 12777

4 - PN 1003751

CRUSHING AND PINCHING HAZARD

 Be extremely careful handling various parts of

the machine. They are heavy and hands, fingers,

feet, and other body parts could be crushed or

pinched between tractor and implement.

 Operate tractor controls from tractor seat only.

 Do not stand between tractor and implement

when tractor is in gear.

 Make sure parking brake is engaged before

going between tractor and implement.

 Stand clear of machine while in operation or

when it is being raised or lowered.

FAILURE TO FOLLOW THESE

INSTRUCTIONS COULD RESULT IN

SERIOUS INJURY OR DEATH.

WARNING

1003751-A

MODEL NO. SERIAL NO.

Woods Equipment Company

Oregon, Illinois, U.S.A.

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

(Safety Decals continued on next page)

12 Safety

MAN0390 (Rev. 6/30/2006)

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 leak-

down, 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

540 RPM

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

DANGER

ROTATING DRIVELINE

CONTACT CAN CAUSE DEATH

KEEP AWAY!

DO NOT OPERATE WITHOUT -

 All driveline guards, tractor and

equipment shields in place

 Drivelines securely attached at both ends

 Driveline guards that turn freely on

driveline 18864-C

10 - PN 1002940

AMBER REFLECTOR 9"

11 - PN 57123

RED REFLECTOR 9"

7 - PN 18877

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

INJURY OR DEATH.

18877-C

12 - PN 1004114

If shaft connection is visible, shield

is missing. Replace shield before

operating equipment.

DA

NG

NG

ER

ER

1004114

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

(Safety Decals continued from previous page)

Safety 13

MAN0390 (Rev. 6/30/2006)

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

Check for leaks with cardboard; never use hand.

Before loosening fittings: lower load, release pressure, and

be sure oil is cool.

Consult physician immediately if skin penetration occurs.

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

rs must be e

q

ui

pp

ed with trans

p

ort lock

.

Cutt

e

ds.

sta

n



r

ansport components must be functional, kept in

g

oodAll t

r





Blocking up prevents cutter dropping from hydraulic leak down,

Bloc

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.

33347E

16 - PN 33347

17 - PN 24611

SLOW MOVING VEHICLE EMBLEM

PN 1006348

(Rev. 5/11/2007)

14 Operation

MAN0390 (Rev. 6/30/2006)

OPERATION

The operator is responsible for the safe operation of

the cutter. The operator must be properly trained.

Operators should be familiar with the cutter, the tractor,

and all 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 dam-

age property.

• If this machine is not equipped with full chain

or rubber shielding, operation must be stopped

when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition.

It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

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 servic-

ing 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.

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 result-

ing in loss of steering. The weight may be attained

with front wheel weights, ballast in tires or front

tractor weights. Weigh the tractor and equipment.

Do not estimate.

Figure 1. Tractor Stability

CONNECT CUTTER TO TRACTOR

(PULL-TYPE)

NOTICE

■ 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 high-

strength drawbar pin 3/4" or larger. Keep pin in

place during operation.

6. Attach safety tow chain to drawbar support. Leave

enough slack for turning.

CAUTION

(Rev. 2/6/2009)

Operation 15

MAN0390 (Rev. 6/30/2006)

7. Connect cutter driveline to tractor PTO shaft,

making sure the spring-activated lock pin slides

freely and is seated in tractor PTO splined groove.

8. Remove parking jack from the tongue and attach it

to the storage post on the front of the cutter.

9. Adjust H-frame bearing height so that the front

driveline is parallel to the ground. Secure with 5/8 x

5-21/32 clevis pin and 3/16 x 1-1/2 cotter pin.

10. Attach drive shaft shield to bearing housing using

two 3/8 x 1 cap screws and 3/8 lock washers.

Hydraulic Connection

1. Inspect hydraulic hoses to ensure they are in good

condition.

2. Clean the fittings before connecting them to the

tractor hydraulic ports.

3. Attach the hydraulic hose to the tractor.

4. Route the hose through the hose holder at the

hitch and be sure the hose can slide freely in the

holder. Do not allow hose slack to drag on the

ground or become caught on tractor protrusions.

5. From the operator position, start tractor and raise

and lower deck several times to purge trapped air

from the hydraulic cylinder.

Interference Check

1. Be sure that tractor 3-point lift links do not interfere

with hydraulic hoses, cutter driveline, or cutter

frame.

2. Check for straight-ahead operation and at full-

turning angles. If there is any interference, remove

the lower lift links.

3. Contact between tractor lift links and cutter parts

can cause damage, especially when turning.

CONNECT CUTTER TO TRACTOR

(MOUNTED)

A minimum 20% of tractor and equipment

weight must be on the tractor front wheels when

attachments are in transport position. Without this

weight, front tractor wheels could raise up result-

ing in loss of steering. The weight may be attained

with front wheel weights, ballast in tires or front

tractor weights. Weigh the tractor and equipment.

Do not estimate.

Tractor Adjustments

Before attaching tractor to cutter, install sway blocks or

sway chains, or adjust stabilizer bars. Refer to the trac-

tor operator's manual for instructions.

Install tractor front end weights as recommended by

the tractor manufacturer to provide 20% of weight on

front wheels.

DS96 Category 2 Standard Hitch

1. Position the tractor 3-point lower lift arms over the

hitch pins and secure with 7/16 klik pins.

2. Connect the tractor top link to the cutter A-frame

using the upper holes and 1" OD sleeve. The break

link must be placed in the lower holes of the A-

frame. See Figure 2.

Figure 2. DS96 Cat. 2 Standard Hitch Connection

DS96 Category 2 Quick Hitch

An optional Category 2 quick coupler kit (24845) is

available for DS96 cutters.

DS120 Category 2 Standard Hitch

1. Position the tractor 3-point lower lift arms between

the hitch mast plates and secure with hitch pins

and 7/16 klik pins. Note the hitch pins orientation.

2. Connect the tractor top link to the cutter A-frame

using the upper holes and 1" OD sleeve. The break

link must be placed in the lower holes of the A-

frame. See Figure 3.

Figure 3. DS120 Cat. 2 Standard Hitch Connection

(Rev. 2/6/2009)

16 Operation

MAN0390 (Rev. 6/30/2006)

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 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.

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 dis-

tance between the tractor PTO shaft and the gearbox

input shaft. If the distance is too large, the driveline will

be too short for proper engagement. If distance is too

small, the driveline may bottom out in operation and

damage the cutter or tractor.

Driveline length must be sufficient to provide at least

1/3 driveline length of engagement during operation.

There must be at least 4 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.

(Rev. 2/6/2009)

Operation 17

MAN0390 (Rev. 6/30/2006)

Figure 7. Drive Halves Placed Parallel

4. Measure from end of the upper shield to the base

of the bell on the lower shield (A). Add 1-9/16" to

dimension (A). See Figure 8.

Figure 8. Determine Shield Length

5. Cut the shield to the overall dimension.

Figure 9. Cut Shield

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 can-

not be obtained through these methods.

Connect driveline to tractor PTO shaft, making sure the

spring-activated locking collar slides freely and locks

driveline to PTO shaft.

NOTICE

■ 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

On pull-type units with optional hydraulic cut-

ting height adjustment, use a single-acting cylinder

with a maximum extended length of 28-1/4" (718

mm) from attaching point center to center.

Cutting height range is from 2" to 15". A hydraulic cylin-

der or ratchet jack is available for cutting height adjust-

1-9/16"

A

(Rev. 2/6/2009)

18 Operation

MAN0390 (Rev. 6/30/2006)

ment on pull-type units and DS120 mounted units.

DS96 requires manual adjustment using holes in the

tailwheel arms.

When selecting a cutting height, you should consider

the area of operation. If the ground is rolling and has

mounds the blades could contact, set the cutting height

accordingly.

NOTICE

■ Avoid ground contact with blades. Striking

ground with blades produces one of the most dam-

aging shock loads a cutter can encounter. If this

occurs repeatedly, the cutter, driveline, and gear-

boxes will be damaged.

The 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.

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.

DS120 - Using any of the optional height adjustment

devices, raise or lower the tailwheel to obtain 2-1/2 to

2-3/4 inches at position B.

Adjust top link to provide 2 inches of clearance

between the break link (2) and the rear lift links. See

Figure 11. This clearance will allow the cutter to float

over uneven terrain.

ATTITUDE ADJUSTMENT (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 drive-

line is parallel to the ground with cutter in cutting posi-

tion.

WHEEL SPACING (DS120 ONLY)

Wheels may be adjusted to any position for row crop

shredding.

BLADE SELECTION

There are two blade options: standard suction blades

and flat double-edge blades.

The standard suction blade is a general use, multi-pur-

pose blade.

The double-edge blade requires less power because it

does not mulch or recut material. It is designed for use

in areas where blade wear is a problem. Sandy soils

are extremely hard on blades.

Blade rotation, viewed from top of cutter, is clockwise

for the right crossbar, and counter-clockwise for the left

crossbar.

When one cutting surface of a double-edge blade is

worn, the opposite one may be used by placing the

blade on a crossbar of the opposite rotation. Blades

from the right may be used on the left. Blades from the

left may be used on the right.

(Rev. 2/6/2009)

Operation 19

MAN0390 (Rev. 6/30/2006)

Blades must be moved in pairs. Never use one new

blade and one used blade on a crossbar.

TRACTOR OPERATION

Use care when operating around tree limbs and other

low objects.

Use care and reduce ground speed on rough terrain.

Always watch for hidden hazards.

Being knocked off or falling off tractor can result in seri-

ous injury or death.

Only use a tractor with a Roll Over Protective Structure

(ROPS) and seat belt. Securely fasten seat belt before

starting tractor.

The cutter is operated with tractor controls. Engage the

PTO at a low rpm to prevent excessive loads on the

cutter drive system. Increase throttle to proper PTO

speed (540 rpm).

Be sure operator is familiar with all controls and can

stop tractor and cutter 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.

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.

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

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 mate-

rial to be cut and the terrain type (hilly, level or rough,

etc.).

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 max-

imum transport speed. Doing so could result in:

• Loss of control of the implement and tractor

• Reduced or no ability to stop during braking

• Implement tire failure

• Damage to the implement or its components.

CAUTION

(Rev. 2/6/2009)

20 Operation

MAN0390 (Rev. 6/30/2006)

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 stor-

age area.

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.

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 all safety decals are installed and in

good condition. Replace if damaged.

___ Check that equipment is properly and securely

attached to tractor.

___ Make sure driveline spring-activated locking pin

or collar slides freely and is seated firmly in trac-

tor PTO spline groove.

___ Set tractor PTO at correct 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.

___ Check that shields and guards are properly

installed and in good condition. Replace if dam-

aged.

___ Check cutting height, front-to-rear attitude, and

top link adjustment.

___ Before starting engine, operator must be in trac-

tor seat with seat belt fastened. Place transmis-

sion in neutral or park, engage brake and

disengage tractor PTO.

___ Inspect area to be cut and remove stones,

branches, or other hard objects that might be

thrown and cause injury or damage.

___ Check that chain shielding is in good condition

and replace any damaged chain links.

___ Make sure tractor 3-point lift links do not interfere

with hydraulic hoses or driveline throughout full

turning range.



(Rev. 4/6/2007)

Owner Service 21

MAN0390 (Rev. 4/6/2007)

OWNER SERVICE

The information in this section is written for operators

who possess basic mechanical skills. If you need help,

your dealer has trained service technicians available.

For your protection, read and follow the safety informa-

tion 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 under-

neath equipment or between moveable parts even

when the engine has been turned off. Hydraulic

system leak down, hydraulic system failures,

mechanical failures, or movement of control levers

can cause equipment to drop or rotate unexpect-

edly and cause severe injury or death. Follow Oper-

ator's Manual instructions for working underneath

and blocking requirements or have work done by a

qualified dealer.

To minimize the potential hazards of working under-

neath the cutter, follow these procedures:

1. Jackstands with a load rating of 1000 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 fre-

quent lubrication.

Use a lithium grease of #2 consistency with a MOLY

(molybdenum disulfide) additive for all locations unless

otherwise noted. Be sure to clean fittings thoroughly

before attaching grease gun. One good pump of most

guns is sufficient when the lubrication schedule is fol-

lowed.

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.

CAUTION

(Rev. 10/5/2007)

22 Owner Service

MAN0390 (Rev. 4/6/2007)

Figure 12. Jackstand Placement and Lubrication Points

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.

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.

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

(Rev. 10/5/2007)

Owner Service 23

MAN0390 (Rev. 4/6/2007)

NOTE: Always replace or sharpen both blades at the

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.

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 replace-

ments or for future installation.

Sharpening Blades

NOTICE

■ When sharpening blades, grind the same

amount on each blade to maintain balance.

Replace blades in pairs. Unbalanced blades will

cause excessive vibration, which can damage

gearbox bearings. Vibration may also cause struc-

tural cracks to cutter.

1. Sharpen both blades at the same time to maintain

balance. Follow original sharpening pattern.

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

Figure 15. Slip Clutch Assembly

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

(Rev. 5/11/2007)

24 Owner Service

MAN0390 (Rev. 4/6/2007)

ADJUSTING SLIP CLUTCH

The slip clutch is designed to slip so that the gearbox

and driveline are protected if the cutter strikes an

obstruction. A new slip clutch or one that has been in

storage over the winter may seize. Before operating

the cutter, make sure it will slip by performing the fol-

lowing operation:

1. Turn off tractor engine and remove key. Remove

driveline from tractor PTO. Loosen six 10 mm cap

screws (6) to remove all tension from Belleville

spring plate (5).

2. Hold clutch hub (3) solid and turn shaft to make

sure clutch slips.

3. If clutch does not slip freely, disassemble and clean

the thrust plate faces (4), flange yoke (1), and

clutch hub (3).

4. Reassemble clutch. Tighten Belleville spring (5)

until it is against the thrust plate (4) of the clutch,

and then back off each of the six nuts by two full

revolutions. The gap between Belleville spring and

thrust plate should be 1/8" as shown in Figure 15.

5. If a clutch continues to slip when the spring is

compressed to 1/8", check friction discs (2) for

excessive wear. Discs are 1/8" when new. Replace

discs after 1/16" wear. Minimum disc thickness is

1/16".

RUBBER DISK REPLACEMENT

The flexible coupler side drive is designed to flex when

striking heavy objects or during start-up to protect gear-

boxes. The rubber disks will wear out over time and

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.

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

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

(Rev. 2/6/2009)

Owner Service 25

MAN0390 (Rev. 4/6/2007)

SHIELDING REPAIR

Full chain or rubber shielding is required for all

non-agricultural mowing. Full shielding is also rec-

ommended for all agricultural use to further reduce

the risk of thrown objects.

Repairing Rubber Shielding

Inspect belting and rear bands each day of operation

and replace if bent, cracked, or broken.

Repairing Optional Chain Shielding

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.

●Replace any safety decals that are missing or not

readable.

Periodically or Before Extended Storage

●Clean large debris such as clumps of dirt, grass,

crop residue, etc. from machine.

●Remove the remainder using a low-pressure water

spray.

1. Be careful when spraying near scratched or torn

safety decals or near edges of decals as water

spray can peel decal off surface.

2. Be careful when spraying near chipped or

scratched paint as water spray can lift paint.

3. If a pressure washer is used, follow the advice of

the pressure washer manufacturer.

●Inspect machine and replace worn or damaged

parts.

●Sand down scratches and the edges of areas of

missing paint and coat with Woods spray paint of

matching color (purchase from your Woods

dealer).

●Replace any safety decals that are missing or not

readable (supplied free by your Woods dealer).

See Safety Decals section for location drawing.

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 exten-

sion hose long enough to allow you to stand to the side

— not in front of or over the tire assembly. Use a safety

cage if available.

Check wheels for low pressure, cuts, bubbles, dam-

aged rims, or missing lug bolts and nuts.

Never remove split rim assembly hardware (A) with the

tire inflated.

Figure 17. Split Rim Tire Servicing

WARNING

A

DECAL PN 1006348

(Rev. 2/6/2009)

26 Troubleshooting

MAN0390 (Rev. 4/6/2007)

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)

Check drive shaft connection.

Check gearbox.

Gearbox malfunction Repair gearbox.

Excessive clutch slippage Adjust clutch.

Incorrect blade direction Check to be sure blade edge is

correct for direction of rotation.

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

height so blades do not frequently

hit ground.)

Excessive lush and tall vegetation Recut at 90° to first pass.

Excessive side skid wear Running with skids continuously

on ground

Raise cutting height or adjust.

Excessive clutch slippage Clutch out of adjustment Adjust clutch.

Clutch discs worn; wear stops

contacting opposite plate

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.

Dealer Service 27

MAN0390 (Rev. 4/6/2007)

DEALER SERVICE

The information in this section is written for dealer ser-

vice personnel. The repair described here requires

special skills and tools. If your shop is not properly

equipped or your mechanics are not properly trained in

this type of repair, you may be time and money ahead

to replace complete assemblies.

Before working underneath, disconnect drive-

line, raise cutter, lock in transport position, and

block cutter securely. Hydraulic system leak down

and failure of mechanical or hydraulic system can

cause equipment to drop.

Keep all persons away from operator control

area while performing adjustments, service, or

maintenance.

Always wear relatively tight and belted clothing

to avoid getting caught in moving parts. Wear

sturdy, rough-soled work shoes and protective

equipment for eyes, hair, hands, hearing, and head;

and respirator or filter mask where appropriate.

GEARBOX MAINTENANCE

NOTE: Read this entire section before starting any

repair. Many steps are dependent on each other.

1. Fill gearbox with SAE 80W or 90W gear lube until it

runs out the side level plug.

NOTE: Repair to this gearbox is limited to replac-

ing bearings, seals, and gaskets. Replacing gears,

shafts, and a housing is not cost effective. Pur-

chasing a complete gearbox is more economical.

2. Inspect gearbox for leakage and bad bearings.

Leakage is a very serious problem and must be

corrected immediately. Bearing failure is indicated

by excessive noise and side-to-side or end-play in

gear shafts.

SEAL REPLACEMENT

Recommended sealant for gearbox repair is Perma-

tex® Aviation 3D Form-A-Gasket or equivalent.

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.

Figure 18. Seal Installation

CAUTION

1. Seal

2. Pipe or tube

3. Seal seat

4. Casting

Pipe or tube must

press at outer

edge of seal.

Incorrect

Installation

28 Dealer Service

MAN0390 (Rev. 4/6/2007)

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).

Vertical seal should be recessed in housing. Hori-

zontal seal should be pressed flush with outside of

housing.

NOTE: Distortion to seal cage or damage to seal

lip will cause seal to leak.

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.

SPINDLE GEARBOX REPAIR

NOTE: Replacing gears, shafts, bearings, and seals

may not be cost effective. Purchasing a complete gear-

box may be more economical.

REMOVE GEARBOX FROM CUTTER

Refer to Figure 19.

1. 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).

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).

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.

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.

Dealer Service 29

MAN0390 (Rev. 4/6/2007)

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).

30 Dealer Service

MAN0390 (Rev. 4/6/2007)

Figure 19. Spindle Gearbox Assembly

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

Dealer Service 31

MAN0390 (Rev. 4/6/2007)

SPLITTER GEARBOX REPAIR

NOTE: Replacing gears, shafts, bearings, and seals

may not be cost effective. Purchasing a complete gear-

box may be more economical.

REMOVE GEARBOX FROM CUTTER

1. Disconnect driveline from the tractor PTO and

remove it from center gearbox.

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.

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.

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.

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.

Figure 20. Center Gearbox Assembly

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

32 Dealer Service

MAN0390 (Rev. 4/6/2007)

ASSEMBLE 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.

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 lbs-

inch.

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.

REINSTALL GEARBOX

NOTE: Gearbox is heavy: do not attempt to move

without mechanical assistance.

1. Install flex coupler driveline between side

gearboxes and center gearbox.

2. Set gearbox on cutter and fasten with bolts and

nuts. Torque bolts to 300 lbs-ft.

SIDE DRIVE 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 flexi-

ble 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 spe-

cial formed washer (6) and bushings (7) between the

rubber discs (5) and under bolt head or nut near rubber

disc. Tighten the nuts (9) evenly until the formed wash-

ers (6) are slightly embedded into the rubber discs.

Rubber discs (5) will warp and twist if bolts are over-

tightened. Tighten set screw (11).

NOTE: Crossbar must be re-timed anytime a crossbar

or a side drive is disconnected.

6. Shaped washer

7. Bushing

8. Bolt

9. Lock nut

11. Set screw

2. Shaft

3. Inner yoke

4. Outer yoke

5. Rubber disc

Dealer Service 33

MAN0390 (Rev. 4/6/2007)

CROSSBAR REMOVAL

1. It is necessary to gain access to bottom side of

cutter for crossbar removal. See BLOCKING

METHOD, page 21.

NOTE: You will need to use either the puller screw

(Item 6, Figure 23) or a small hydraulic jack to

remove the crossbar.

2. To make crossbar removal easier, remove blades

as shown in Figure 22.

Figure 22. Blade Removal

3. Remove cotter pin (38) and castle nut (37) from

bottom of crossbar.

4. Refer to Figure 23. Attach a clevis (1) to each end

of crossbar, using blade pins, spacers, keyhole

plates, and blade pin clips.

5. Position tube assembly (5) with threaded nut

toward crossbar for puller screw removal or down

for hydraulic jack removal.

6. For removal with puller screw, attach tube (5) to

each clevis with screws (2) and nuts (3). Place pad

(4) in nut and thread puller screw (6) into nut from

bottom. Tighten until pad is solid against gearbox

shaft. For best results, strike head of puller screw

with a hammer while tightening with a wrench.

7. For removal with a jack, attach tube to each clevis

with puller links (7), screws (2), and nuts (3). Place

jack on tube with end of jack pressing against

gearbox shaft. Slowly apply force with jack.

NOTE: Hydraulic jack will not operate if tipped

more than 90-degrees. Use care to prevent bend-

ing crossbar during removal. Figure 23. Crossbar Removal

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

34 Dealer Service

MAN0390 (Rev. 4/6/2007)

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

Dealer Service 35

MAN0390 (Rev. 4/6/2007)

UNIVERSAL JOINT REPAIR

Figure 26. Universal Joint Parts Breakdown

U-JOINT DISASSEMBLY

1. Remove external snap rings from yokes in four

locations as shown in Figure 27.

Figure 27. Remove Snap Ring

2. With snap rings removed, support drive in vise,

hold yoke in hand and tap on yoke to drive cup up

out of yoke. See Figure 28.

Figure 28. Remove Cups

3. Clamp cup in vise as shown in Figure 29 and tap

on yoke to completely remove cup from yoke.

Repeat Step 2 and Step 3 for opposite cup.

Figure 29. Remove Cups

4. Place universal cross in vise as shown in Figure 30

and tap on yoke to remove cup. Repeat Step 3 for

final removal. Drive remaining cup out with a drift

and hammer.

Figure 30. Remove Cups

U-JOINT ASSEMBLY

1. Place seals securely on bearing cups. Insert cup

into yoke from outside and press in with hand

pressure as far as possible. Insert journal cross

into bearing cup with grease fitting away from

shaft. Be careful not to disturb needle bearings.

Insert another bearing cup directly across from first

cup and press in as far as possible with hand

pressure.

2. Trap cups in vise and apply pressure. Be sure

journal cross is started into bearings and continue

pressure with vise, squeezing in as far as possible.

Tapping the yoke will help.

1. Yoke

2. Cup and bearing

3. Snap ring

4. Journal cross

(Rev. 5/11/2007)

36 Dealer Service

MAN0390 (Rev. 4/6/2007)

3. Seat cups by placing a drift or socket (slightly

smaller than the cup) on cup and rap with a

hammer. See Figure 31. Install snap ring and

repeat on opposite cup

4. Repeat Step 1 and Step 2 to install remaining cups

in remaining yoke.

5. Move both yokes in all directions to check for free

movement. If movement is restricted, rap on yokes

sharply with a hammer to relieve any tension.

Repeat until both yokes move in all directions

without restriction.

Figure 31. Install Cups

SERVICING TIRES SAFELY

Used Aircraft Tires (Figure 32)

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 exten-

sion hose long enough to allow you to stand to the side

— not in front of or over the tire assembly. Use a safety

cage if available.

Check wheels for low pressure, cuts, bubbles, dam-

aged rims, or missing lug bolts and nuts.

Never remove split rim assembly hardware (A) with the

tire inflated.

Figure 32. Split Rim Tire Servicing

WARNING

A

DECAL PN 1006348

(Rev. 5/11/2007)

Assembly 37

MAN0390 (Rev. 4/6/2007)

ASSEMBLY INSTRUCTIONS

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 dam-

age property.

• If this machine is not equipped with full chain

or rubber shielding, operation must be stopped

when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition.

It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

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, accompany-

ing text, parts lists and exploded view drawings.

Complete check lists on page 49 when you have com-

pleted 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 tail-

wheel and lug on deck. Secure with pins supplied

with ratchet.

Cylinder

1. Place hydraulic cylinder (8) between lug on

tailwheel and lug on deck.

2. Secure to deck lug using pin (15) and two cotter

pins (35).

3. Extend cylinder rod, place transport lock bracket

(7) over cylinder rod end and lug on tailwheel.

4. Align holes of cylinder rod, transport lock bracket

(7) and lug on tailwheel. Secure assembly using

pin (16) and two cotter pins (35).

CAUTION

38 Assembly

MAN0390 (Rev. 4/6/2007)

Install Hydraulic Hose

On pull-type units with optional hydraulic cut-

ting height adjustment, use a single-acting cylinder

with a maximum extended length of 28-1/4" (718

mm) from attaching point center to center.

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.

Figure 33. DS96 Pull-Type Rear Half Installation

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"

Assembly 39

MAN0390 (Rev. 4/6/2007)

ASSEMBLE - DS120 PULL-TYPE CUTTER

REAR HALF

Refer to Figure 35.

Place jackstands under cutter to raise it off the ground

to provide clearance when assembling cutter. See

“BLOCKING METHOD” on page 21 for jackstand

placement.

Install Rear Tailwheel

1. Attach tailwheel arms (1) to the tailwheel using

eight (four per wheel arm) cap screws (35) and

lock nuts (36). NOTE: Position tailwheel arms on

tailwheel to desired location (usually on row crop

centers). Wheel hubs should be positioned to the

outside of the cutter.

2. Attach solid or aircraft tires to wheel hubs using

four cap screws (31) and lock washers (32).

3. Attach rims and pneumatic tires (pneumatic tires

are not furnished) to wheel hubs using four wheel

bolts (30).

Install Attitude Rod

Slide attitude rod (5) under left spindle 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).

Figure 34. Spring Arm Installation

Install Hydraulic Hose

On pull-type units with optional hydraulic cut-

ting height adjustment, use a single-acting cylinder

with a maximum extended length of 28-1/4" (718

mm) from attaching point center to center.

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.

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

40 Assembly

MAN0390 (Rev. 4/6/2007)

DS120 Pull-Type - Rear Half

Figure 35. DS120 Pull-Type Rear Half Installation

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

Assembly 41

MAN0390 (Rev. 4/6/2007)

INSTALL TONGUE DS96 & DS120

CUTTERS

Refer to Figure 36.

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

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. Secure H-frame to tongue using cap screw (42),

two sleeve (3), two cup washers (4) and lock nut

(43).

Attach Driveline to H-frame

NOTE: Select holes in H-frame that will allow driveline

to run level. Refer to Operation section for driveline

height. Final adjustment will be 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).

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).

42 Assembly

MAN0390 (Rev. 4/6/2007)

Tongue and Driveline Installation

Figure 36. DS96 and DS120 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

(Rev. 5/23/2008)

Assembly 43

MAN0390 (Rev. 4/6/2007)

ASSEMBLE - DS96 MOUNTED CUTTER

Refer to Figure 39.

Place jackstands under cutter to raise it off the ground

to provide clearance when assembling cutter. See

“BLOCKING METHOD” on page 21 for jackstand

placement.

Install A-Frame

1. 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).

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 37. Break Linkage Installation

Install Tailwheel Arms

Refer to Figure 38 and Figure 39.

1. Attach adjustment arms (13) to lower holes of lugs

on the rear of the cutter. Braces must be placed on

the inside of mounting lugs (Figure 38).

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.

Figure 38. Adjustment Arm Installation

Install Driveline

1. Coat input shaft of gearbox with a light coating of

grease.

2. Attach slip clutch on driveline (5) to input shaft of

gearbox. Tighten cap screws (35) and lock nut

(36).

3. Attach rear tether chain of driveline to driveline

shield.

1. Tailwheel arm

13. Tailwheel adjustment arm

31. 5/8 NC x 4-1/2 Cap screw

32. 5/8 NC Lock nut

44 Assembly

MAN0390 (Rev. 4/6/2007)

DS96 Mounted Assembly

Figure 39. 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

Assembly 45

MAN0390 (Rev. 4/6/2007)

ASSEMBLE - DS120 MOUNTED CUTTER

Refer to Figure 42.

Place jackstands under cutter to raise it off the ground

to provide clearance when assembling cutter. See

“BLOCKING METHOD” on page 21 for jackstand

placement.

Install A-Frame

1. Attach front A-frame bars (3) to the lower (square)

hole of the cutter mast plates. Secure using

carriage bolts (35), bushing sleeves (19), washers

(34), and lock nuts (31).

2. Attach, rear A-frame bars (2) with washers (44)

over mounting bolts (33) and secure with lock nuts

(32).

3. 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).

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).

Figure 41. Category 3 Hitch Arrangement

Install Tailwheel Arms

Attach tailwheel arms (1) to the tailwheel using eight

(four per arm) cap screws (30) and lock nuts (31).

NOTE: Position tailwheel arms on tailwheel to desired

location (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).

Install Hydraulic Hoses

On mounted units with optional hydraulic cut-

ting height adjustment, use a double-acting cylin-

der with a maximum extended length of 28-1/4"

(718 mm) from attaching point center to center.

■ 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.

46 Assembly

MAN0390 (Rev. 4/6/2007)

1. Install a reducer bushing (15) and a restricter

swivel elbow (16) in port at base end and rod end

of cylinder (14). Position elbows to point toward

front of cutter.

NOTE: Mounted units must use a double acting

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.

Figure 42. DS120 Mounted Assembly

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

Assembly 47

MAN0390 (Rev. 4/6/2007)

FILL GEARBOXES

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 self-

tapping 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 dam-

age property.

• If this machine is not equipped with full chain

or rubber shielding, operation must be stopped

when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition.

It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

Figure 43. Rubber Shield Installation

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

48 Assembly

MAN0390 (Rev. 4/6/2007)

INSTALL CHAIN SHIELDING (OPTIONAL)

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 dam-

age property.

• If this machine is not equipped with full chain

or rubber shielding, operation must be stopped

when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition.

It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

Figure 44. Optional Chain Shielding Installation

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

Dealer Check Lists 49

MAN0390 (Rev. 4/6/2007)

DEALER CHECK LISTS

PRE-DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

Inspect cutter thoroughly after assembly to make sure

it is set up properly before delivering it to the customer.

The following check list is a reminder of points to

inspect. Check off each item as it is found satisfactory,

corrections are made, or services are performed.

NOTICE

■ Gearbox was not filled at the factory. It must be

serviced before operating cutter. (See LUBRICA-

TION, page 21). Failure to service will result in dam-

age to gearbox.

___ 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 oper-

ators of other vehicles.



50 Dealer Check Lists

MAN0390 (Rev. 4/6/2007)

NOTES

Parts 51

MAN0390 (Rev. 4/6/2007)

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

52 Parts

MAN0390 (Rev. 4/6/2007)

DS96 / DS120 MAIN FRAME ASSEMBLY

22 - Complete decal set

23 - Safety decal set

(Rev. 2/6/2009)

Parts 53

MAN0390 (Rev. 4/6/2007)

DS96 / DS120 MAIN FRAME PARTS LIST

DS96 DS120

Hardware Hardware

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

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

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

(Rev. 2/6/2009)

54 Parts

MAN0390 (Rev. 4/6/2007)

DS96 / DS120 PULL-TYPE ASSEMBLY, FRONT HALF

(Rev. 7/4/2008)

Parts 55

MAN0390 (Rev. 4/6/2007)

DS96 / DS120 PULL-TYPE ASSEMBLY, FRONT HALF PARTS LIST

DS96 DS120

Hardware Hardware

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

REF PART QTY DESCRIPTION

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

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)

56 Parts

MAN0390 (Rev. 4/6/2007)

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

(Rev. 5/23/2008)

Parts 57

MAN0390 (Rev. 4/6/2007)

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

58 Parts

MAN0390 (Rev. 4/6/2007)

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

Parts 59

MAN0390 (Rev. 4/6/2007)

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

60 Parts

MAN0390 (Rev. 4/6/2007)

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

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

Parts 61

MAN0390 (Rev. 4/6/2007)

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

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

62 Parts

MAN0390 (Rev. 4/6/2007)

DS96 / DS120 SPINDLE GEARBOX ASSEMBLY

Parts 63

MAN0390 (Rev. 4/6/2007)

DS96 / DS120 SPINDLE GEARBOX ASSEMBLY PARTS LIST

DS96 / DS120 FLEXIBLE COUPLER

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

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

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

64 Parts

MAN0390 (Rev. 4/6/2007)

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

Parts 65

MAN0390 (Rev. 4/6/2007)

DS96 / DS120 SLIP CLUTCH DRIVE ASSEMBLY

REF PART QTY DESCRIPTION

1005790 1Complete 540 Drive assembly

(DS96 only)

57413 1Complete 540 Drive assembly

(DS120 only)

140574 1Yoke, 1-3/8 Spline ASGE

2110 2Cross and bearing

340764 2Spring pin 10 X 80

440575 1Inboard yoke

540587 1Inner profile

640593 1Outer profile & sleeve

740576 1Inboard yoke

857416 1Friction clutch 1340, 1-3/4, 20-spline

12 40766 2Bearing ring SC25

13 40777 2Anti-rotation chain

14 18864 1Decal, Danger rotating driveline

15 33347 1Decal, Danger guard missing

16 40778 2Screw

17 40767 1Support bearing

18 40779 1Grease fitting

REF PART QTY DESCRIPTION

23 40589 1Slide collar kit

24 1005795 1Outer guard half (DS96 only)

24 57268 1Outer guard half (DS120 only)

25 1005796 1Inner guard half (DS96 only)

25 57269 1Inner guard half (DS120 only)

26 1005794 1Shaft asy, male (complete/guard)

(DS96 only)

26 57414 1Shaft asy, male (complete/guard)

(DS120 only)

31 57438 1Flange yoke

32 57432 2Friction disc

33 57440 1Hub, 1-3/4" 20-spline

34 57434 1Thrust plate

35 57439 1Belleville spring

36 57259 6M10 x 1.5P x 55 mm Cap screw GR8.8

37 57260 6M10 x 1.5P Lock nut w/nylon insert

38 57261 2M12 x 1.5P Lock nut w/nylon insert

39 57262 2M12 x 1.5P x 65 mm Cap screw GR8.8

(Rev. 12/16/2010)

66 Parts

MAN0390 (Rev. 4/6/2007)

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

Parts 67

MAN0390 (Rev. 4/6/2007)

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

68 Parts

MAN0390 (Rev. 4/6/2007)

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

Parts 69

MAN0390 (Rev. 4/6/2007)

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

70 Parts

MAN0390 (Rev. 4/6/2007)

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

Parts 71

MAN0390 (Rev. 4/6/2007)

HYDRAULIC CYLINDER STROKE CONTROL KIT (OPTIONAL)

PARKING JACK

PULL-TYPE

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

72 Parts

MAN0390 (Rev. 4/6/2007)

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

Appendix 73

Bolt Torque & Size Charts (Rev. 3/28/2007)

BOLT TORQUE CHART

Always tighten hardware to these values unless a different torque value or tightening procedure is listed for a specific

application.

Fasteners must always be replaced with the same grade as specified in the manual parts list.

Always use the proper tool for tightening hardware: SAE for SAE hardware and Metric for metric hardware.

Make sure fastener threads are clean and you start thread engagement properly.

All torque values are given to specifications used on hardware defined by SAE J1701 MAR 99 & J1701M JUL 96.

Diameter

(Inches)

Wrench

Size

MARKING ON HEAD

SAE 2 SAE 5 SAE 8

lbs-ft N-m lbs-ft N-m lbs-ft N-m

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

Diameter &

Thread Pitch

(Millimeters)

Wrench

Size

COARSE THREAD FINE THREAD

Diameter &

Thread Pitch

(Millimeters)

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

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

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)

A

METRIC SERIES

TORQUE

CHART

Metric Bolt Head

Identification

8.8

Metric

Grade 10.9

10.9

Metric

Grade 8.8

A

A

A

Typical Washer

Installations

Lock Washer

Flat Washer

8/9/00

Bolt

74 Appendix

Bolt Torque & Size Charts (Rev. 3/28/2007)

BOLT SIZE CHART

NOTE: Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts.

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

5/16 3/81/2 5/83/4 7/8

SAE Bolt Thread Sizes

MM 25 50 75 100 125 150 175

IN 1 7

Metric Bolt Thread Sizes

8MM 18MM14MM12MM10MM 16MM

234 56

Index 75

MAN0390 (Rev. 4/6/2007)

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

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)

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

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

(Rev. 2/6/2009)

76 Index

MAN0390 (Rev. 4/6/2007)

Driveline Adjustment - Pull-Type 18

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

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

(Rev. 2/6/2009)

F-3079 (Rev. 2/14/2011)

Woods Equipment

Company

2606 South Illinois Route 2

Post Office Box 1000

Oregon, Illinois 61061 USA

800-319-6637 tel

800-399-6637 fax

www.WoodsEquipment.com

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:

Under no circumstances will this Warranty apply in the event that the product, in the good faith opinion of WOODS, has been subjected to

improper operation, improper maintenance, misuse, or an accident. This Warranty does not apply in the event that the product has been materially

modified or repaired by someone other than WOODS, a WOODS authorized dealer or distributor, and/or a WOODS authorized service center.

This Warranty does not cover normal wear or tear, or normal maintenance items. This Warranty also does not cover repairs made with parts other

than those obtainable through WOODS.

This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or otherwise transfer this product to a

third party, this Warranty does not transfer to the third party purchaser in any way. There are no third party beneficiaries of this Warranty.

WOODS makes no warranty, express or implied, with respect to engines, batteries, tires or other parts or accessories not manufactured by

WOODS. Warranties for these items, if any, are provided separately by their respective manufacturers.

WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of charge, of the product if WOODS, in

its sole discretion, deems it to be defective or in noncompliance with this Warranty. The product must be returned to WOODS with proof of

purchase within thirty (30) days after such defect or noncompliance is discovered or should have been discovered, routed through the

dealer and distributor from whom the purchase was made, transportation charges prepaid. WOODS shall complete such repair or

replacement within a reasonable time after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY.

THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS

MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY

OF MERCHANTABILITY AND/OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the

product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal

theory. Without limiting the generality of the foregoing, Woods specifically disclaims any damages relating to (i) lost profits, business, revenues

or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or

rental; or (v) any other type of damage to property or economic loss.

This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture

replacement parts.

No agent, representative, dealer, distributor, serviceperson, salesperson, or employee of any company, including without limitation, WOODS, its

authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this

Warranty. Answers to any questions regarding warranty

service and locations may be obtained by contacting:

Part or

Condition

Warranted

Model Number

Duration (from date of

delivery to the original

purchaser)

Gearbox

Seals All units listed below 2 years

Gearbox

components

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 6 years

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

5 years

RDC54, RD60, RD72, TBW150C, TS/R60, TS/R52, TS/R44 3 years (1 year if used in rental or

commercial applications)

Blade

spindles RM550-2, RM660-2, RD990X, PRD6000, PRD7200, PRD8400, TBW144, TBW180, TBW204 3 years

Rust-through

BB600, BB720, BB840, BB6000, BB7200, BB8400, BW126-3, BW126HB, BW180-3, BW180HB,

BW180HD, BW1260, BW1800, BW240, BW240HD, 2162, 3240, DS1260, DSO1260, DS1440,

TS1680

10 years

F-8494 (Rev. 6/23/2005)

©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.

WARRANTY

(Replacement Parts For All Models Except Mow’n MachineTM

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.

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: