Woods DS96 - Manual

S a f e t y 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 VHSor DVD video outlining Industrial and Agricultural Mower Safety Practices . The 22 minute video, developed in cooperation with AEM (Association of Equipment Manu...

6 S a fe ty 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: __________________...

S a f e t y 7 DS96-DS120 Safety Rules (Rev. 5/11/2007) TRAINING Safety instructions are important! Read all a t ta c hm e n t a n d p o w e r u n i t m a n u a l s ; f o l l o w a l lsafety rules and safety decal information. (Replace-ment manuals and safety decals are available fromyour dealer. To ...

8 S a f e t y 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 forlocation.) Mak...

S a f e t y 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 sp...

1 0 S a f e t y 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 g r o u n d . R a i s e c u t t e r w i t h 3 - p o i n ...

S a f e t y 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 a...

1 2 S a f e t y 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 seatbelt. Keep foldable ROPS systems in “locked up” position at alltimes. „ Buckle Up! Keep seat belt securely fastened. „ Allow no riders. RAISED EQ...

S a f e t y 1 3 MAN0390 (Rev. 6/30/2006) SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN RESULTING IN SERIOUS INJURY, GANGRENE OR DEATH. n Check for leaks with cardboard; never us...

1 4 O p e r a t i o n MAN0390 (Rev. 6/30/2006) OPERATION The operator is responsible for the safe operation ofthe cutter. The operator must be properly trained.Operators should be familiar with the cutter, the tractor,and all safety practices before starting operation. Readthe safety rules and safet...

O p e ra t i o n 1 5 MAN0390 (Rev. 6/30/2006) 7. Connect cutter driveline to tractor PTO shaft,making sure the spring-activated lock pin slidesfreely and is seated in tractor PTO splined groove. 8. Remove parking jack from the tongue and attach itto the storage post on the front of the cutter. 9. Ad...

1 6 O p e r a t i o n 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 secureaccording to quick hitch manufacturer’sinstructions. Figure 4 . DS120 Category 2 Quick Hitch Connection DS120 Category 3...

O p e ra t i o n 1 7 MAN0390 (Rev. 6/30/2006) Figure 7 . Drive Halves Placed Parallel 4. Measure from end of the upper shield to the baseof the bell on the lower shield (A). Add 1-9/16" todimension (A). See Figure 8. Figure 8 . Determine Shield Length 5. Cut the shield to the overall dimension. ...

1 8 O p e r a t i o n MAN0390 (Rev. 6/30/2006) ment on pull-type units and DS120 mounted units.DS96 requires manual adjustment using holes in thetailwheel arms. When selecting a cutting height, you should considerthe area of operation. If the ground is rolling and hasmounds the blades could contact,...

O p e ra t i o n 1 9 MAN0390 (Rev. 6/30/2006) Blades must be moved in pairs. Never use one newblade and one used blade on a crossbar. TRACTOR OPERATION Use care when operating around tree limbs and otherlow objects. Use care and reduce ground speed on rough terrain.Always watch for hidden hazards. B...

O w n e r S e r v i c e 2 1 MAN0390 (Rev. 4/6/2007) OWNER SERVICE The information in this section is written for operatorswho 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 m...

2 2 O w n e r S e r v i c e 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, supportcrossbar from below to prevent gearbox dama...

O w n e r S e r v i c e 2 3 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 ifyou find any, replace the blade pin. 2. Insert blade pin through the blade (9). Bladeshould swivel on blade pin; if it doesn’t, deter...

2 4 O w n e r S e r v i c e MAN0390 (Rev. 4/6/2007) ADJUSTING SLIP CLUTCH The slip clutch is designed to slip so that the gearboxand driveline are protected if the cutter strikes anobstruction. A new slip clutch or one that has been instorage over the winter may seize. Before operatingthe cutter, ma...

2 6 Tr o u b l e s h o o t i n g 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. Driv...

D e a l e r S e r v i c e 2 7 MAN0390 (Rev. 4/6/2007) DEALER SERVICE The information in this section is written for dealer ser-vice personnel. The repair described here requiresspecial skills and tools. If your shop is not properlyequipped or your mechanics are not properly trained inthis type of re...

2 8 D e a l e r S e r v i c e MAN0390 (Rev. 4/6/2007) VERTICAL SHAFT SEAL REPAIR (SPINDLE BOX) Refer to Figure 19. 1. Disconnect and remove the driveline from thegearbox. 2. Remove vent plug (3) and siphon gear lube fromhousing through this opening. 3. Remove crossbar (see Crossbar removal on page33...

D e a l e r S e r v i c e 2 9 MAN0390 (Rev. 4/6/2007) ASSEMBLE GEARBOX Refer to Figure 19. 1. Clean housing, paying specific attention to areaswhere gaskets will be installed. 2. Wash housing and all components thoroughly.Select a clean area for gearbox assembly. Replaceall seals, bearings, and gask...

D e a l e r S e r v i c e 3 1 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 andremove it from...

3 2 D e a l e r S e r v i c e MAN0390 (Rev. 4/6/2007) ASSEMBLE GEARBOX Refer to Figure 20. 1. Clean housing, paying specific attention to areaswhere gaskets will be installed. 2. Wash housing and all components thoroughly.Select a clean area for gearbox assembly. Replaceall seals, bearings, and gask...

D e a l e r S e r v i c e 3 3 MAN0390 (Rev. 4/6/2007) CROSSBAR REMOVAL 1. It is necessary to gain access to bottom side ofcutter for crossbar removal. See BLOCKINGMETHOD, page 21. NOTE: You will need to use either the puller screw (Item 6, Figure 23) or a small hydraulic jack toremove the crossbar. ...

3 4 D e a l e r S e r v i c e MAN0390 (Rev. 4/6/2007) CROSSBAR INSTALLATION 1. Using emery cloth (220 or finer), remove surfacerust, and foreign material from hub, splinedgearbox vertical shaft, and crossbar. See Figure24. Figure 24 . Example of Crossbar and Gearbox Shaft 2. Install crossbar (8), Fi...

D e a l e r S e r v i c e 3 5 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 fourlocations as shown in Figure 27. Figure 27 . Remove Snap Ring 2. With snap rings removed, support drive in vise...

3 6 D e a l e r S e r v i c e MAN0390 (Rev. 4/6/2007) 3. Seat cups by placing a drift or socket (slightlysmaller than the cup) on cup and rap with ahammer. See Figure 31. Install snap ring andrepeat on opposite cup 4. Repeat Step 1 and Step 2 to install remaining cupsin remaining yoke. 5. Move both ...

A s s e m b l y 3 7 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 areaswhere thrown objects could injure people or dam-age property. • If this machine is not equipped with full chai...

3 8 A s s e m b l y MAN0390 (Rev. 4/6/2007) Install Hydraulic Hose On pull-type units with optional hydraulic cut- ting height adjustment, use a single-acting cylinderwith a maximum extended length of 28-1/4" (718mm) from attaching point center to center. NOTICE ■ If using a cylinder other than ...

4 2 A s s e m b l y 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, rea...

A s s e m b l y 4 3 MAN0390 (Rev. 4/6/2007) ASSEMBLE - DS96 MOUNTED CUTTER Refer to Figure 39. Place jackstands under cutter to raise it off the groundto provide clearance when assembling cutter. See“BLOCKING METHOD” on page 21 for jackstandplacement. Install A-Frame 1. Attach front A-frame bars (3)...

4 4 A s s e m b l y 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...

A s s e m b l y 4 5 MAN0390 (Rev. 4/6/2007) ASSEMBLE - DS120 MOUNTED CUTTER Refer to Figure 42. Place jackstands under cutter to raise it off the groundto provide clearance when assembling cutter. See“BLOCKING METHOD” on page 21 for jackstandplacement. Install A-Frame 1. Attach front A-frame bars (3...

A s s e m b l y 4 7 MAN0390 (Rev. 4/6/2007) FILL GEARBOXES NOTICE ■ Gearbox is not filled at the factory. Prior to delivery to customer, make sure gearbox is filledonly half-full with 80W or 90W API GL-4 or GL-5gear lube. Use side plug to remove any excess oil. 1. Make sure vent plug hole is clear (...

D e a l e r C h e c k L i s ts 4 9 MAN0390 (Rev. 4/6/2007) DEALER CHECK LISTS PRE-DELIVERY CHECK LIST(DEALER’S RESPONSIBILITY) Inspect cutter thoroughly after assembly to make sureit is set up properly before delivering it to the customer.The following check list is a reminder of points toinspect. C...

5 0 D e a l e r C h e c k L i s ts MAN0390 (Rev. 4/6/2007) NOTES

5 2 P a rts MAN0390 (Rev. 4/6/2007) DS96 / DS120 MAIN FRAME ASSEMBLY 22 - Complete decal set 23 - Safety decal set (Rev. 2/6/2009)

P a r ts 5 3 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...

P a r ts 5 5 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 jac...

5 8 P a rts 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 ...

P a r ts 5 9 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 1482...

6 0 P a rts 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 ite...

P a r ts 6 1 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 100813...

6 2 P a rts MAN0390 (Rev. 4/6/2007) DS96 / DS120 SPINDLE GEARBOX ASSEMBLY

P a r ts 6 3 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 4 571...

P a r ts 6 5 MAN0390 (Rev. 4/6/2007) DS96 / DS120 SLIP CLUTCH DRIVE ASSEMBLY REF PART QTY DESCRIPTION 1005790 1 Complete 540 Drive assembly (DS96 only) 57413 1 Complete 540 Drive assembly (DS120 only) 1 40574 1 Yoke, 1-3/8 Spline ASGE 2 110 2 Cross and bearing 3 40764 2 Spring pin 10 X 80 4 40575 1 ...

P a r ts 6 7 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 o...

P a r ts 7 1 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" Segme...

A p p e n d i x 7 3 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 ...

7 4 A p p e n d i x 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 .............

I n d e x 7 5 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 R...

F-3079 (Rev. 2/14/2011) Woods Equipment Company 2606 South Illinois Route 2 Post Office Box 1000Oregon, Illinois 61061 USA 800-319-6637 tel800-399-6637 faxwww.WoodsEquipment.com WARRANTY All Models Except Mow’n Machine TM Zero-Turn Mowers Please Enter Information Below and Save for Future Reference....

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 othertrademarks, trade names, or service marks not owned by Woods Equipment Company that appear in this manual are the property of their respectivecompa...