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Flail Cutter

FC155 - FC175
(Europe Only)
FC200
Service
Manual

Dealer Copy -- Not for Resale
(FC155 Europe Only) S/N A01P00101 & Above
(FC175 Europe Only) S/N 467500101 & Above
(FC200) S/N 467300101 & Above

6903303 (11-08) Printed in U.S.A. © Bobcat Company 2008
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Dealer Copy -- Not for Resale

ALPHABETICAL INDEX

BRUSH DEFLECTOR (EARLIER MODELS) . . . . . . . . . . . . . 30-40-1

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1
DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

FLAIL KNIVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N
467500163 & BELOW, S/N 467300196 & BELOW) . . . . . . . . 20-20-1
HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N
467500154 & ABOVE, S/N 467300197 & ABOVE). . . . . . . . . 20-21-1
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

IDENTIFICATION AND MACHINE SIGNS (DECALS) . . . . . . . . . . . IV

Dealer Copy -- Not for Resale
LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

MANUAL STORAGE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . III

REAR HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
RUBBER SKIRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
RUBBER STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1 ALPHABETICAL
INDEX
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
SKID SHOE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

WEAR STRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1

Flail Cutter Service Manual
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Dealer Copy -- Not for Resale

Flail Cutter Service Manual
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SAFETY AND
CONTENTS
MAINTENANCE
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
Attachment Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
HYDRAULIC
MANUAL STORAGE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . III SYSTEM

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
MAIN
IDENTIFICATION AND MACHINE SIGNS (DECALS) . . . . . . . . . . . IV FRAME

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
SPECIFICATIONS
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 AND
SCHEMATICS
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

SPECIFICATIONS AND SCHEMATICS . . . . . . . . . . . . . . . . SPEC-01

Dealer Copy -- Not for Resale
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects and other reproductive harm.

I Flail Cutter Service Manual
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II Flail Cutter Service Manual
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DELIVERY REPORT Dealer Copy -. MANUAL STORAGE LOCATION Read and understand the Operation & Maintenance Manual before operating the flail cutter. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 4].SERIAL NUMBER LOCATION Figure 3 Attachment Serial Number Figure 1 1 Later Models P-60854 The Operation & Maintenance Manual and Safety P-57630 Manual are stored in a container (Item 1) [Figure 2] & [Figure 3] located on the flail cutter. or it may be necessary Figure 4 to use a different procedure in doing a specific service operation [Figure 1].Not for Resale Early or later models (identification made by serial number) may use different parts. Earlier Models P-57633 III Flail Cutter Service Manual 7 of 110 . Always use the serial number of the flail cutter when requesting service information or when ordering parts. Figure 2 1 P-20022 The delivery report must be filled out by the dealer and signed by the owner or operator when the flail cutter is delivered.

Not for Resale 7100705 (1) REAR 7100706 (1) RUBBER SKIRT SIDE FRONT SKID SHOE RUBBER SKIRT RUBBER SKIRT 7107788 (2) P-57631 IV Flail Cutter Service Manual 8 of 110 .IDENTIFICATION AND MACHINE SIGNS (DECALS) HYDRAULIC MOTOR HYDRAULIC CONTROL VALVE ROLLBACK HOOK STEPS 7106129 (1) 68156993 68156993 (3) (3) Dealer Copy -.

P-57633 V Flail Cutter Service Manual 9 of 110 .Not for Resale HYDRAULIC QUICK COUPLERS 7107788 (2) 6734443 (2) 68156993 (3) Drive Pulley Shield has been removed for picture clarity.IDENTIFICATION AND MACHINE SIGNS (DECALS) (CONT’D) MANUAL STORAGE CONTAINER EARLIER MODELS LATER MODELS DRIVE PULLEY SHIELD MOUNTING FRAME Dealer Copy -.

Not for Resale VI Flail Cutter Service Manual 10 of 110 . Dealer Copy -.

. . . .Not for Resale 10-01 Flail Cutter Service Manual 11 of 110 . . . . . . . . . . . . . . . . . . . 10-20-4 LUBRICATION . . . . . . . . . . . . . 10-50-1 Adjustment . . . . 10-20-2 Checking Mechanical Linkage For Rotor Shut-Off Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1 REAR HATCH . . . . . . . . . . . . . . . . . . 10-40-1 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . 10-40-1 Rear Hatch Positions . . . SAFETY AND MAINTENANCE SAFETY AND MAINTENANCE DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Attachment Mounting Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4 Rollback Hook Inspection . . . . . . . . . . . . . . . . . . . . . . 10-10-1 Dealer Copy -. . . . . . . . . . . . . . . . . . 10-10-1 Chart . . . . . 10-20-7 Checking The Rotor Shut-Off Device. . . . . . . . . . . 10-40-2 TROUBLESHOOTING . . . . . . . . . . . . 10-20-1 Bob-Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dealer Copy -.Not for Resale 10-02 Flail Cutter Service Manual 12 of 110 .

repairs or service. adjustments or servicing. Operator’s to check flow and pressure. Rebalance the rotor. Dealer Copy -. Reinstall rotor. Sandy soil. The rotor does not reach the correct Check belt tension. Casing is bent by excessive side loads. Attachment problems can be affected by a hydraulic system that is not operating to specifications or such problems as a AVOID INJURY OR DEATH plugged fuel filter or hydraulic filter in the machine. Clean the guards. working speed. Read and understand the hydraulic pump output. Machine adjustment does not comply Check transmission rpm. Dry roller. Machine absorbs too much power. Replace the casing or scrap the attachment. Adjust power and forward speed. The knife rotor is out of balance. Bearings break frequently. Instructions are necessary before operating or Connect a flow meter to the machine to check the servicing machine. Rotor out of adjustment. Rotor installed wrong. 10-10-1 Flail Cutter Service Manual 13 of 110 . Untrained operators and failure to follow instructions can cause injury or death. Too much material and low machine Adjust power and forward speed. Roller is bent. Forward speed is too fast.TROUBLESHOOTING Chart If the attachment is not working correctly. (See the machine Service Handbook and signs (decals) on machine. No lubrication. Follow Manual for the correct procedure to connect the flow warnings and instructions in the manuals when meter).Not for Resale One or more of the knives are broken. Material is fouling the guards. Fit roller with larger roller diameter. Adjust rotor. Replace roller. Loss of a counterweight. Check for correct function after adjustments. Repair the casing if the rotor is still operational. W-2003-0807 PROBLEM CAUSE CORRECTION Abnormal machine vibrations. with the instructions. check the hydraulic system of the machine thoroughly before WARNING making any repairs on the attachment. Worn sheet metal. Lubricate roller. Attachment overloaded. DO NOT change their weight and position on the rotor. Replace casing. Worn knives or parts. relief valve setting and tubelines Operation & Maintenance Manual. making repairs. The roller does not turn. Replace counterweight. power. Hatch or roller out of adjustment. Replace broken knives. Poor Cutting. Adjust the hatch and/or roller. Lubricate bearings. Replace knives or sharpen uniformly. Adjust forward speed. Casing is punctured.

Dealer Copy -.Not for Resale 10-10-2 Flail Cutter Service Manual 14 of 110 .

mounting flange (Item 2) [Figure 10-20-5] and all welds on the flail cutter for wear and damage each time the flail cutter is Dealer Copy -. Figure 10-20-6 1 2 P-57674 Periodically inspect the flail knife bolts (Item 1) and nuts (Item 2) [Figure 10-20-6] for tightness. They must be secured thoroughly as loosening could damage the rotor. 10-20-1 Flail Cutter Service Manual 15 of 110 .Not for Resale removed from the loader. Frequently inspect the flail cutter to ensure that all components are secure and that all bolts and nuts are thoroughly tightened.DAILY INSPECTION Attachment Mounting Frame Figure 10-20-5 2 1 P-57632 Inspect the Bob-Tach wedge mounts (Item 1).

) Push down on the Bob-Tach levers until they are fully engaged in the locked position [Figure 10-20-7] (wedges fully extended through the attachment mounting frame holes). Look for cracked welds. the attachment will be loose and can come off the Bob-Tach. Contact your Bobcat dealer for repair or replacement parts. NOTE: If the wedge does not contact the lower edge of the hole.Not for Resale Inspect the mounting frame on the attachment. W-2715-0208 The wedges must extend through the holes in the attachment mounting frame. Levers must be fully down and locked. Keep all fasteners tight. securely fastening the Figure 10-20-7 attachment to the Bob-Tach [Figure 10-20-8]. Dealer Copy -. 10-20-2 Flail Cutter Service Manual 16 of 110 . The levers and wedges must move freely [Figure 10-20- 7]. P-41502A Lubricate the wedges.DAILY INSPECTION (CONT’D) Figure 10-20-8 Bob-Tach Hand Lever Bob-Tach WARNING AVOID INJURY OR DEATH The Bob-Tach wedges must extend through the holes in the attachment mounting frame. (See the machine’s Operation & Maintenance Manual for the correct procedure. Replace any parts that are damaged. Failure to secure P-79780 wedges can allow attachment to come off. bent or missing. (See the machine's Operation and Maintenance Manual for inspecting the Bob-Tach).

Inspect the mounting frame on the attachment. Keep all fasteners tight. bent or missing. securely fastening the attachment to the Bob-Tach [Figure 10-20-12]. 1 2 NOTE: If the wedge does not contact the lower edge of the hole. 1 Figure 10-20-12 Dealer Copy -.DAILY INSPECTION (CONT’D) Figure 10-20-11 Bob-Tach (Cont’d) Power Bob-Tach WARNING AVOID INJURY OR DEATH The Bob-Tach wedges must extend through the holes in the attachment mounting frame. Failure to secure wedges can allow attachment to come off. Lubricate the wedges.) 10-20-3 Flail Cutter Service Manual 17 of 110 . (See the machine’s Operation & Maintenance Manual for the correct procedure. W-2715-0208 Push and hold the BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure 10-20-9] and [Figure 10-20-10] until the Figure 10-20-9 levers are fully engaged in the locked position [Figure 10-20-11] (wedges fully extended through the attachment Loader Switch mounting frame holes). Levers P-41500A must be fully down and locked. Contact your Bobcat dealer for repair or replacement parts.Not for Resale 2 B-15993A Figure 10-20-10 P-79780 Work Machine Switch The wedges must extend through the holes in the attachment mounting frame. (See the machine's Operation and Maintenance Manual for P-88124 inspecting the Bob-Tach). the attachment will be loose and can come off the Bob-Tach. Look for cracked welds. Replace any parts that are damaged.

P-70370 Checking The Rotor Shut-Off Device 1 WARNING P-70387 • Never operate without rotor shut-off device. fully lower the lift arm(s) [Figure 10-20-14]. loose hardware or damage. Replace any parts that are damaged bent or missing. (See the Machine 1 Operation & Maintenance Manual for the correct procedure. 10-20-4 Flail Cutter Service Manual 18 of 110 . NOTE: If the rotor does not come to a complete stop Procedure 1 within seven seconds or begins rotating again after the lift arms are fully lowered during any Enter the machine. start the engine.Not for Resale P-60268 Inspect the rollback hook (Item 1) [Figure 10-20-13].DAILY INSPECTION (CONT’D) Figure 10-20-14 Rollback Hook Inspection A rollback hook is provided to prevent the cutter deck from contacting the frame if the attachment is raised and fully rolled back on some machines. restart. see your Bobcat Maintenance Manual for the correct procedure.) dealer for service. Inspect for cracks. Use the following procedures to check the rotor shut-off Lower the lift arm(s) fully to check that the rotor does not device. Figure 10-20-13 P-70383 Place the flail cutter flat on the ground.) The rotor should rotate. NOTE: The rollback hook must swing freely. with the shut-off lever (Item 2) [Figure 10-20-15]. the W-2628-0405 rotor must come to a complete stop within 7 seconds. The 2 rollback hook must swing freely. when the lower cross member of the • Never modify the rotor shut-off device and check attachment mounting frame (Item 1) comes in contact that it is operating properly. While in the operator seat. Raise the lift arm(s). (See the Flail Cutter Operation & of the above procedures. Engage the auxiliary hydraulics. seat belt fastened and seat bar lowered. Figure 10-20-15 Dealer Copy -.

procedure. see your Bobcat NOTE: If the rotor does not come to a complete stop dealer for service. (See the Machine Figure 10-20-19 Operation & Maintenance Manual for the correct procedure. Tilt the Bob-Tach back. Engage the auxiliary hydraulics. fully lower the lift Operation & Maintenance Manual for the correct Dealer Copy -. when the mounting frame (Item 1) comes in contact with the P-70382 shut-off lever (Item 2) [Figure 10-20-19]. (See the Machine Place the flail cutter flat on the ground. fully lower the lift arm(s) [Figure 10-20-18]. when the mounting frame (Item 1) Lower the lift arm(s) fully to check that the rotor does not comes in contact with the shut-off lever (Item 2) [Figure restart. after the lift arms are fully lowered during any of the above procedures.) The rotor should rotate. see your Bobcat dealer for service. NOTE: If the rotor does not come to a complete stop Lower the lift arm(s) fully to check that the rotor does not within seven seconds or begins rotating again restart.Not for Resale arm(s) [Figure 10-20-16].DAILY INSPECTION (CONT’D) Procedure 3 Checking The Rotor Shut-Off Device (Cont’d) Figure 10-20-18 Procedure 2 Figure 10-20-16 P-70383 Place the flail cutter flat on the ground. the rotor must come to a complete stop within 7 seconds. 10-20-5 Flail Cutter Service Manual 19 of 110 . P-70383 Engage the auxiliary hydraulics. 2 Figure 10-20-17 P-70370 2 1 P-70370 1 P-70385 Raise the lift arm(s) and tilt the Bob-Tach forward. within seven seconds or begins rotating again after the lift arms are fully lowered during any of the above procedures.) The rotor should rotate. the rotor must come to a complete stop within 7 seconds. 10-20-17].

NOTE: Shut-off valve WILL NOT reset unless the auxiliary hydraulics are cycled off first. The rotor should start rotating. Dealer Copy -. re-engage the auxiliary hydraulics into detent.Not for Resale 10-20-6 Flail Cutter Service Manual 20 of 110 .DAILY INSPECTION (CONT’D) Checking The Rotor Shut-Off Device (Cont’d) Restart Rotor Rotation Disengage the auxiliary hydraulics by taking it out of detent.

then remove cover (Item 2) [Figure 10-20-20]. Be careful when connecting and disconnecting quick couplers. Figure 10-20-20 Figure 10-20-22 2 1 3 1 P-57690 P-57707 Remove the four bolts (Item 1). fittings and quick couplers WARNING can get hot when running machine and attachments. • Flying debris or loose material is present. Stop the engine and exit the loader. 10-20-7 Flail Cutter Service Manual 21 of 110 . W-2628-0405 Figure 10-20-21 WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: Dealer Copy -. W-2019-0907 Check for loose or missing bolts mounting the control valve [Figure 10-20-21] to the frame. (See the Flail Cutter Operation & Maintenance Manual for the correct Check hydraulic hoses for loose connections. tubes. procedure. • Never operate without rotor shut-off device. • Engine is running.) Repair or replace as needed. Check if the pivot bolt (Item 3) [Figure 10-20-20] in the shut-off lever is loose or missing. P-57706 • Tools are being used. Check the condition of the connector link (Item 1) [Figure 10-20-22].Not for Resale • When fluids are under pressure.DAILY INSPECTION (CONT’D) Checking Mechanical Linkage For Rotor Shut-Off Device WARNING AVOID BURNS Hydraulic fluid. W-2220-0396 • Never modify the rotor shut-off device and check that it is operating properly.

Not for Resale Check the following every 50 hours of operation: • Check belt tension and adjust if required. Check the following items every 8 hours of operation: • Check rotor shut-off device and rollback hook for proper function. If fluid enters skin or eyes. WARNING 7100706 AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can Service schedule decal [Figure 10-20-23].DAILY INSPECTION (CONT’D) Figure 10-20-23 Follow the flail cutter service schedule for routine maintenance. penetrate skin or eyes. Replace if necessary. Do not use your bare hand. shields and roller. Use a piece of cardboard or wood to find leaks. Replace if necessary. • Never modify the rotor shut-off device and check that it is operating properly. get immediate medical attention from a physician familiar with this injury. • Check for damaged or leaking hydraulic hoses or fittings. • Lubricate all grease points. • Check deck. It is located on top of the attachment. Wear safety goggles. W-2072-0807 WARNING • Never operate without rotor shut-off device. Dealer Copy -. Replace or repair if damaged. Replace if necessary. Fluid leaks under pressure may not be visible. W-2628-0405 10-20-8 Flail Cutter Service Manual 22 of 110 . • Check the knives and mounting hardware for cracks or damage. causing serious injury or death. just right of the hydraulic control valve. • Check for damaged or missing decals. Rollback hook must swing freely.

Not for Resale 1 1 1 2 3 P-57687 P-57636 Remove bolts (Item 1). then remove cover plate (Item 2) [Figure 10-30-2]. Replace cover plate and bolts. pivot arm. the roller. Figure 10-30-3 1 1 P-57650 P-57688 Lubricate fitting (Item 1) [Figure 10-30-3] on the left side Lubricate fitting (Item 1) [Figure 10-30-6] on both ends of of the drum.LUBRICATION Figure 10-30-4 Lubricate the following locations after every 8 hours of operation. P-57682 NOTE: The drive pulley shield has been removed (right frame) [Figure 10-30-2] for picture Lubricate fittings (Item 1) [Figure 10-30-5] on the center clarity. NOTE Always use a good quality lithium based grease when lubricating the attachment. 1 Figure 10-30-1 1 1 P-57678 Lubricate fittings (Item 1) [Figure 10-30-4] on both side P-57637 link arms of the Flail Cutter. Lubricate fitting (Item 3) [Figure 10-30-2] on the left side Figure 10-30-6 of the mower. Flail Cutter 10-30-1 Service Manual 23 of 110 . Lubricate fitting (Item 1) [Figure 10-30-1] Figure 10-30-5 Figure 10-30-2 Dealer Copy -.

Not for Resale Flail Cutter 10-30-2 Service Manual 24 of 110 . Dealer Copy -.

REAR HATCH Figure 10-40-1 Adjustment NOTE: As the rear hatch is progressively opened to one of the seven available positions less hydraulic power is required. (88-94 N•m) torque. • Engine is running. • Tools are being used.-lb. (88-94 N•m) torque.Not for Resale • (Foot Pedal Controls) Move pedals until both lock. The seat bar system must deactivate these functions when the seat bar is up. Re-install the bolts securing the rear hatch in position. Service the NOTE: When installing the bolts (Item 1) [Figure 10- system if controls do not deactivate. 1 Service the system if hand controls do not P-60545 deactivate. Before you leave the operator’s seat: • Lower the lift arms. W-2463-0603 install them from the inside towards the outside. • (Selectable Joystick Controls-SJC) Move the joysticks to the NEUTRAL POSITION to make Remove bolts (Item 1) [Figure 10-40-2] and nuts from sure that travel and hydraulic functions are both sides of the flail cutter. Power 1 requirements are also affected by the roller height adjustment. WARNING Tighten bolts (Item 1) [Figure 10-40-2] on both sides of the flail cutter to 65-70 ft. The degree of mulching is also reduced as the rear hatch is opened further. The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Stop the engine and exit the machine. • Stop the engine. Placing the nut on the outside of the flail cutter. AVOID INJURY OR DEATH Tighten rear hatch pivot bolts (Item 1) [Figure 10-40-1] to Wear safety glasses to prevent eye injury when any 65-70 ft. W-2019-0907 10-40-1 Flail Cutter Service Manual 25 of 110 . • (Advanced Control System-ACS) Move the hydraulic controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated. • Flying debris or loose material is present. Dealer Copy -. put the attachment flat on the Figure 10-40-2 ground. move the rear hatch to the deactivated. • Raise seat bar. of the following conditions exist: • When fluids are under pressure. 40-2] that hold the rear hatch in position. P-60552 WARNING Loosen rear hatch pivot bolts (Item 1) [Figure 10-40-1] on both sides of the flail cutter.-lb. desired position. • Engage the parking brake.

Figure 10-40-3 Fully Closed Position P-60539 The fully open position enables a more efficient cut at high forward speeds. reduces fuel consumption and minimizes the hydraulic power required. Figure 10-40-4 Intermediate Positions P-60541 The intermediate positions allow the operator to adjust the degree of mulching required and discharge the mulched material over the roller [Figure 10-40-4]. 10-40-2 Flail Cutter Service Manual 26 of 110 . the material being mulched will circulate between the rotor and the roller [Figure 10-40-3]. desired. Adjust travel speed as prunings and when a fine homogeneous mulch is needed. Dealer Copy -.Not for Resale NOTE: Cutting wet grass is difficult and absorbs a lot The fully closed position is generally used to mulch of hydraulic power. When the rear hatch is in the fully closed position. the cut material exits the flail cutter over the roller [Figure 10-40- P-60540 5]. When the rear hatch is in the fully open position.REAR HATCH (CONT’D) Figure 10-40-5 Rear Hatch Positions Fully Open Position NOTE: When operating the flail cutter in any of the following positions it is important that the rotor speed of 2200 rpm is maintained during operation.

• Tools are being used. Turn the tension bolt clockwise to decrease belt tension. (34-38 N•m) torque.-lb. • Flying debris or loose material is present. Installation: Tighten bolts to 25-28 ft.-lb. Figure 10-50-1 Figure 10-50-4 1 Dealer Copy -. supporting the gear box and extension.Not for Resale 1 2 1 2 P-57634 P-57639 Remove bolts (Item 1) [Figure 10-50-1]. tension. W-2019-0907 Installation: Tighten bolts to 65-70 ft. 1 WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: P-57637 P-57638 • When fluids are under pressure. (88-95 N•m) 2) [Figure 10-50-4] counterclockwise to increase belt torque. (88-95 N•m) torque. Loosen the four bolts (Item 1) [Figure 10-50-3] • Engine is running. then turn the tension bolt (Item Installation: Tighten bolts to 65-70 ft. Remove brush guard (Item 2) [Figure 10-50-1].-lb. Loosen jam nut (Item 1).DRIVE BELTS Figure 10-50-3 Adjustment 1 NOTE: Check belt tension every 50 hours of use. 10-50-1 Flail Cutter Service Manual 27 of 110 . Figure 10-50-2 2 1 P-57635 Remove bolts (Item 1) and drive pulley shield (Item 2) [Figure 10-50-2].

tighten jam nut (Item 1) [Figure 10-50-4].2-0.4 in. (5-10 mm) [Figure 10-50-5]. Install drive pulley shield and brush guard. Depending on model and the distance between pulleys. 10-50-2 Flail Cutter Service Manual 28 of 110 . Dealer Copy -.Not for Resale the belt should move between 0.DRIVE BELTS (CONT’D) Adjustment (Cont’d) Figure 10-50-5 BELT TENSION Check belt tension by pressing forcefully on the belt. Once the desired belt tension is obtained.

. . . . . . . . . . . 20-20-11 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S/N 467500154 & ABOVE. . . . . . . . . . . . . . . . 20-10-1 Disassembly and Assembly . 20-20-3 Removal And Installation . . . . . . . . . . . S/N 467500163 & BELOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1 HYDRAULIC SYSTEM HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW. . . S/N 467300197 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 Dealer Copy -. . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM HYDRAULIC MOTOR . . . . 20-10-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . 20-20-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3 Removal And Installation . . . . . . . . . . S/N 467300196 & BELOW) . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4 Parts Identification . . . . . . . . . . . . . . . . . . . 20-10-2 Removal and Installation . . . .Not for Resale 20-01 Flail Cutter Service Manual 29 of 110 . . . . . . . . . . 20-21-11 Disassembly. . . 20-21-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 Assembly . . . .

Dealer Copy -.Not for Resale 20-02 Flail Cutter Service Manual 30 of 110 .

20-10-1 Flail Cutter Service Manual 31 of 110 . Installation: Tighten the bolts to 90-100 ft. Figure 20-10-2 1 P-57714 Cap hydraulic fittings (Item 1) [Figure 20-10-2]. clean the work area before disassembly and keep all parts clean. Dirt can quickly 1 damage the system.-lb. Dealer Copy -. Always use caps and plugs on hoses. (125-140 N•m) torque.HYDRAULIC MOTOR Figure 20-10-3 Removal and Installation IMPORTANT When repairing hydrostatic and hydraulic systems. tubelines and ports to keep dirt out. 1 Remove the hydraulic motor from the shaft housing. I-2003-0888 P-57714 Figure 20-10-1 Remove the bolts (Item 1) [Figure 20-10-3].Not for Resale 1 1 P-57928 Mark and remove the hydraulic hoses (Item 1) [Figure 20-10-1].

Distributor 4 5 3 7 6 Dealer Copy -. Shaft and Bearing 2. Rotating Group 5. Valve Plate 7. Housing 3. Manual Control 6.Not for Resale 2 1 20-10-2 Flail Cutter Service Manual 32 of 110 . Cam Plate and Bronze Bushings 4.HYDRAULIC MOTOR (CONT’D) Parts Identification 1.

Figure 20-10-7 2 Dealer Copy -. Figure 20-10-5 Installation: Tighten the bolts to 180-200 in. I-2003-0888 P-57694 Figure 20-10-4 Remove roll pin (Item 1) [Figure 20-10-6].-lb. (21-23 N•m) torque. 1 clean the work area before disassembly and keep all parts clean. Dirt can quickly damage the system.HYDRAULIC MOTOR (CONT’D) Figure 20-10-6 Disassembly and Assembly IMPORTANT When repairing hydrostatic and hydraulic systems. 1 P-57693 Remove the bolt (Item 1) [Figure 20-10-5].Not for Resale 1 1 1 P-57692 Clean the outside of the hydraulic motor. 20-10-3 Flail Cutter Service Manual 33 of 110 . Always use caps and plugs on hoses. tubelines and ports to keep dirt out. Remove bolts (Item 1) and plate (Item 2) [Figure 20-10- 7] from the end housing. P-57695 NOTE: Place marks (Item 1) [Figure 20-10-4] on the housing before beginning disassembly.

should be in this position during assembly before installing cap. 20-10-4 Flail Cutter Service Manual 34 of 110 .HYDRAULIC MOTOR (CONT’D) Figure 20-10-10 Disassembly and Assembly (Cont’d) Figure 20-10-8 1 P-57700 1 Remove the valve plate (Item 1) [Figure 20-10-10]. Figure 20-10-9 Dealer Copy -. P-57696 Figure 20-10-11 Remove gasket from cap (Item 1) [Figure 20-10-8].Not for Resale 1 2 1 P-57728 Remove pistons (Item 1) and plate (Item 2) [Figure 20- P-57697 10-11]. NOTE: It is recommended that the pistons be kept Installation: Control bar (Item 1) [Figure 20-10-9] with their original bores during assembly.

Figure 20-10-13 Dealer Copy -. Figure 20-10-15 Remove pivot bushing (Item 1) [Figure 20-10-12].HYDRAULIC MOTOR (CONT’D) Figure 20-10-14 Disassembly and Assembly (Cont’d) Figure 20-10-12 1 1 P-57719 Remove divider plate (Item 1) from piston assembly P-57729 [Figure 20-10-14]. 20-10-5 Flail Cutter Service Manual 35 of 110 .Not for Resale 1 2 1 P-57732 P-57727 Compress washer and spring with a threaded rod and nut. Remove three needle bearings (Item 1) and nylon lock ring (Item 2) [Figure 20-10-13]. The remove snap ring (Item 1) [Figure 20-10-15].

Dealer Copy -.HYDRAULIC MOTOR (CONT’D) Figure 20-10-18 Disassembly and Assembly (Cont’d) Figure 20-10-16 1 P-57720 Remove snap ring (Item 1) and remove shaft [Figure 20- P-57733 10-18]. Figure 20-10-19 Remove the spring by backing off the nut on the threaded rod [Figure 20-10-16]. P-57735A Remove O-ring (Item 1) and oil seal (Item 2) [Figure 20- 10-17].Not for Resale Figure 20-10-17 2 P-57721 1 Press bearing off shaft [Figure 20-10-19]. 20-10-6 Flail Cutter Service Manual 36 of 110 .

Lubricate all seals and O-rings with clean hydraulic fluid before installation.Not for Resale or damaged parts. Clean all parts in solvent and dry with compressed air. align pegs (Item 1) [Figure 20-10-22] and put P-57723 into position. Replace any worn Dealer Copy -. 20-10-7 Flail Cutter Service Manual 37 of 110 . 1 P-57724 Remove snap ring (Item 1) [Figure 20-10-21]. Remove washer (Item 1) [Figure 20-10-20]. Figure 20-10-21 Inspect all parts for wear or damage. Always install new seals and O-rings.HYDRAULIC MOTOR (CONT’D) Figure 20-10-22 Disassembly and Assembly (Cont’d) Figure 20-10-20 1 1 1 P-57737 Installation: When installing the plate on the end housing.

Not for Resale 20-10-8 Flail Cutter Service Manual 38 of 110 . Dealer Copy -.

Remove the two bolts (Item 1) from both sides of cover. Replace the O-ring if damaged. IMPORTANT Installation: When installing hoses. P-57691 I-2003-0888 Mark all hoses for correct installation. Dirt can quickly damage the system. S/N 467300196 & BELOW) Removal And Installation 1 IMPORTANT 1 When repairing hydrostatic and hydraulic systems. inspect the O-ring(s) on the fitting(s). tubelines and ports to keep dirt out. S/N 467500163 & BELOW. then remove cover (Item 2) [Figure 20-20-1].HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-2 BELOW. clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses. Dealer Copy -. Figure 20-20-3 I-2066-0395 Figure 20-20-1 1 1 1 2 P-57707 P-57690 Remove the retaining clip and side link (Item 1) [Figure 20-20-3]. 20-20-1 Flail Cutter Service Manual 39 of 110 .Not for Resale Contain and dispose of any oil leakage in an environmentally safe manner. Remove the hoses (Item 1) [Figure 20-20-2].

HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW. S/N 467500163 & BELOW. Figure 20-20-5 1 P-57758 Installation: Inspect nylon spacer (Item 1) [Figure 20- 20-5] and replace if damaged. Remove the control valve. Installation: Tighten bolts to 180-200 in. (21-23 N•m) torque. 20-20-2 Flail Cutter Service Manual 40 of 110 .Not for Resale bolts.-lb. S/N 467300196 & BELOW) (CONT’D) Removal And Installation (Cont’d) Figure 20-20-4 1 P-57757 Remove the three nuts (Item 1) [Figure 20-20-4] and Dealer Copy -.

Seat 3 10. Orifice 6 4 15. Cap 5 5 Dealer Copy -. Washer 16.Not for Resale 5 7 5 9 10 5 11 8 12 10 5 13 5 2 14 5 13 13 15 5 13 5 16 10 3 17 3 18 PE2421S 20-20-3 Flail Cutter Service Manual 41 of 110 . Spool Cover 18. Housing 9. S/N 467500163 & BELOW. Boot 2. Screw 4. O-Ring 6.HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW. Block 4 17. Ball 13. S/N 467300196 & BELOW) (CONT’D) Parts Identification 1. Backup Ring 2 8. Retainer 5. Load Check Valve 12. Plug 3 14. Relief Valve 7. Spring 11. Spool 1 3.

1 2 Figure 20-20-7 2 P-56679 Remove the boot (Item 1) and retainer (Item 2) [Figure 20-20-9]. Figure 20-20-9 P-56677 Dealer Copy -.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-8 BELOW.Not for Resale Remove the relief valve (Item 1) [Figure 20-20-6]. S/N 467300196 & BELOW) (CONT’D) Disassembly 1 Clean the outside of the valve before disassembly. S/N 467500163 & BELOW. 20-20-4 Flail Cutter Service Manual 42 of 110 . 1 N-17086 Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-20-7] from the relief valve. Figure 20-20-6 1 1 P-56678 Remove the screws (Item 1) [Figure 20-20-8].

S/N 467300196 & BELOW) (CONT’D) Disassembly (Cont'd) Figure 20-20-10 1 1 1 P-56682 1 Remove the O-rings (Item 1) [Figure 20-20-12] from the retainer. S/N 467500163 & BELOW. P-56681 Remove the retainer (Item 1) [Figure 20-20-11].Not for Resale Figure 20-20-11 1 1 P-56683 Remove the cap (Item 1) [Figure 20-20-13]. Dealer Copy -.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-12 BELOW. 20-20-5 Flail Cutter Service Manual 43 of 110 . P-56680 Figure 20-20-13 Remove the screws (Item 1) [Figure 20-20-10].

S/N 467300196 & BELOW) (CONT’D) Disassembly (Cont'd) 1 Figure 20-20-14 1 1 P-56686 1 2 Remove the screws (Item 1) [Figure 20-20-16].HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-16 BELOW.Not for Resale 1 [Figure 20-20-14] from the spool. S/N 467500163 & BELOW. 20-20-6 Flail Cutter Service Manual 44 of 110 . P-56685 Remove the spring (Item 1) [Figure 20-20-15]. Figure 20-20-15 1 P-56687 Remove the block and spool assembly (Item 1) [Figure 20-20-17]. Figure 20-20-17 P-56684 Remove the screws (Item 1) and spool cover (Item 2) Dealer Copy -. NOTE: The spool cover is under spring pressure.

HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-20 BELOW. P-56688 NOTE: Do Not use anything other than hardwood blocks to grip the spool. Drill a 1. Dealer Copy -.0 inch long (38 mm thick x 89 mm wide x 76 mm long) piece of hardwood.Not for Resale Figure 20-20-21 Figure 20-20-19 Cut 3. To remove the plug from the spool a holding fixture will have to be made from a 1. 20-20-7 Flail Cutter Service Manual 45 of 110 .50” 1.0” P-56689 1. Separate the spool assembly [Figure 20-20-18].125” 1 3.50” B-14674 Remove the block (Item 1) [Figure 20-20-21]. Clamp the spool in the blocks.125 inch (28. or the spool will be damaged.50 inch thick x 3. S/N 467500163 & BELOW. S/N 467300196 & BELOW) (CONT’D) Disassembly (Cont'd) 2 Figure 20-20-18 1 P-56709 Remove the plug (Item 1) and washer (Item 2) [Figure 20-20-20].50 inch wide x 3. Cut the block lengthwise [Figure 20-20-19].575 mm) hole in the center of the hardwood block.

20-20-8 Flail Cutter Service Manual 46 of 110 . P-56691 Turn the valve over and remove the load check valve (Item 1) [Figure 20-20-23]. S/N 467500163 & BELOW.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-24 BELOW. P-56690 Figure 20-20-25 Remove the O-rings (Item 1) [Figure 20-20-22] from the Dealer Copy -.Not for Resale block. Figure 20-20-23 1 1 P-56693 Remove the O-ring (Item 1) [Figure 20-20-25]. S/N 467300196 & BELOW) (CONT’D) Disassembly (Cont'd) 1 2 Figure 20-20-22 1 P-56692 1 Remove the spring (Item 1) and seat (Item 2) [Figure 20- 20-24].

P-56694 Figure 20-20-29 Remove the plug (Item 1) [Figure 20-20-26]. 20-20-9 Flail Cutter Service Manual 47 of 110 . P-56695 Remove the spring (Item 1) and check ball (Item 2) [Figure 20-20-27]. Dealer Copy -.Not for Resale 1 Figure 20-20-27 1 1 2 1 P-56696 Remove the plugs (Item 1) [Figure 20-20-29]. S/N 467500163 & BELOW. S/N 467300196 & BELOW) (CONT’D) Disassembly (Cont'd) Figure 20-20-26 1 1 N-17085 Remove the O-ring (Item 1) [Figure 20-20-28] from the plug.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-28 BELOW.

S/N 467300196 & BELOW) (CONT’D) Disassembly (Cont'd) Figure 20-20-30 1 N-17084 Remove the O-ring (Item 1) [Figure 20-20-30] from the Dealer Copy -. 20-20-10 Flail Cutter Service Manual 48 of 110 . S/N 467500163 & BELOW.HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW. Figure 20-20-31 1 P-56697 Remove the orifice (Item 1) [Figure 20-20-31].Not for Resale plugs.

Replace any worn or damaged parts.6 N•m) torque. Install the orifice and tighten to 120 in. (22.-lb. Dealer Copy -. 2 Figure 20-20-32 P-56696 Install the plug (Item 1) [Figure 20-20-34].Not for Resale Figure 20-20-35 P-56697 1 Apply thread lock adhesive (Loctite 242) to the threads of the orifice (Item 1) [Figure 20-20-32]. 20-20-11 Flail Cutter Service Manual 49 of 110 . (13. Figure 20-20-33 N-17085 1 Install the O-ring (Item 1) [Figure 20-20-35] on the plug. Install the plugs (Item 2) [Figure 20-20-34]. Lubricate all seals and O-rings with clean hydraulic fluid before installation. S/N 467300196 & BELOW) (CONT’D) Assembly 2 Clean all parts in solvent and dry with compressed air. Always install new seals and O-rings.-lb.-lb. S/N 467500163 & BELOW. (13. Tighten the plugs to 120 in. N-17084 Install the O-ring (Item 1) [Figure 20-20-33] on the plugs.5 N•m) torque.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-34 BELOW. 1 Inspect all parts for wear or damage. Tighten the 1 plug to 198 in.4 N•m) torque.

Not for Resale 2 1 20-20-36]. (56 N•m) torque.-lb. S/N 467300196 & BELOW) (CONT’D) Assembly (Cont'd) 1 Figure 20-20-36 2 1 P-56693 Install the O-ring (Item 1) [Figure 20-20-38] on the plug. Figure 20-20-39 P-56695 Install the check ball (Item 1) and spring (Item 2) [Figure Dealer Copy -. 20-20-12 Flail Cutter Service Manual 50 of 110 . Figure 20-20-37 1 P-56692 Install the seat (Item 1) and spring (Item 2) [Figure 20- 20-39]. Tighten the plug to 41 ft. P-56694 Install the plug (Item 1) [Figure 20-20-37]. S/N 467500163 & BELOW.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-38 BELOW.

-lb. or the spool will be damaged. Dealer Copy -.4 N•m) torque. S/N 467300196 & BELOW) (CONT’D) 1 Assembly (Cont'd) Figure 20-20-40 1 2 P-56689 Place the spool in the hard wood blocks. NOTE: Do Not use anything other than hard wood Install the load check valve (Item 1) [Figure 20-20-40]. P-56691 Install the block (Item 2) [Figure 20-20-42] on the spool. S/N 467500163 & BELOW. Figure 20-20-41 Figure 20-20-43 1 1 1 2 P-56690 P-56709 Install the O-rings (Item 1) [Figure 20-20-41] on the block.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-42 BELOW. Install the washer (Item 1) and plug (Item 2) [Figure 20- 20-43]. Clamp the blocks (Item 1) [Figure 20-20-42] in the vise. (22.Not for Resale blocks to grip the spool. Remove the spool and wood blocks from the vise. 20-20-13 Flail Cutter Service Manual 51 of 110 . Tighten the plug to 198 in.

S/N 467500163 & BELOW. P-56688 Figure 20-20-47 Assemble the spool [Figure 20-20-44]. 20-20-14 Flail Cutter Service Manual 52 of 110 . (12. Install the screws (Item 1) [Figure 20-20-46].-lb.2 N•m) torque.Not for Resale Figure 20-20-45 2 1 1 P-56685 Install the spring (Item 1) [Figure 20-20-47]. S/N 467300196 & BELOW) (CONT’D) Assembly (Cont'd) 1 Figure 20-20-44 1 P-56686 Apply the thread lock adhesive (Loctite 242) to the screw threads.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-46 BELOW. Dealer Copy -. Tighten the screws to 108 in. P-56687 Install the spool assembly (Item 1) in the housing (Item 2) [Figure 20-20-45].

Figure 20-20-49 1 P-56681 Install the retainer (Item 1) [Figure 20-20-51]. 20-20-15 Flail Cutter Service Manual 53 of 110 .HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-50 BELOW. S/N 467500163 & BELOW.Not for Resale P-56684 Install the spool cover (Item 1) and screws (Item 2) 1 [Figure 20-20-48]. S/N 467300196 & BELOW) (CONT’D) Assembly (Cont'd) 1 Apply thread lock adhesive (Loctite 242) to the threads of the screws.2 N•m) torque. Figure 20-20-48 1 2 P-56682 Install the O-rings (Item 1) [Figure 20-20-50] on the retainer.-lb. (12. P-56683 Install the cap (Item 1) [Figure 20-20-49]. Tighten the screws to 108 in. 2 1 Figure 20-20-51 Dealer Copy -.

S/N 467500163 & BELOW. S/N 467300196 & BELOW) (CONT’D) Assembly (Cont'd) 1 Apply thread lock adhesive (Loctite 242) to the threads of the screws. 1 Figure 20-20-55 Dealer Copy -.HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-54 BELOW. (12.Not for Resale P-56680 2 Install the screws (Item 1) [Figure 20-20-52].2 N•m) torque. Figure 20-20-53 1 1 2 N-17086 Install the O-rings (Item 1) and backup ring (Item 2) [Figure 20-20-55] on the relief valve.-lb. Figure 20-20-52 1 1 P-56678 Install the screws (Item 1) [Figure 20-20-54].2 N•m) torque. (12. Tighten the screws to 108 in.-lb. Tighten the screws to 108 in. Apply thread lock adhesive (Loctite 242) to the threads of the screws. P-56679 Install the retainer (Item 1) and boot (Item 2) [Figure 20- 20-53]. 20-20-16 Flail Cutter Service Manual 54 of 110 .

HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW. (34 N•m) torque. 20-20-17 Flail Cutter Service Manual 55 of 110 . S/N 467500163 & BELOW. S/N 467300196 & BELOW) (CONT’D) Assembly (Cont'd) Figure 20-20-56 1 P-56677 Install the relief valve (Item 1) [Figure 20-20-56].Not for Resale the valve to 25 ft. Tighten Dealer Copy -.-lb.

Dealer Copy -.Not for Resale 20-20-18 Flail Cutter Service Manual 56 of 110 .

Figure 20-21-3 I-2066-0395 Figure 20-21-1 1 1 1 2 P-57707 P-57690 Remove the retaining clip and side link (Item 1) [Figure 20-21-3]. then remove cover (Item 2) [Figure 20-21-1]. Dealer Copy -. clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses. P-57691 I-2003-0888 Mark all hoses for correct installation. IMPORTANT Installation: When installing hoses. S/N 467500154 & ABOVE. Dirt can quickly damage the system.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-2 ABOVE. Replace the O-ring if damaged. inspect the O-ring(s) on the fitting(s). Remove the hoses (Item 1) [Figure 20-21-2]. Remove the two bolts (Item 1) from both sides of cover. S/N 467300197 & ABOVE) Removal And Installation 1 IMPORTANT 1 When repairing hydrostatic and hydraulic systems. tubelines and ports to keep dirt out.Not for Resale Contain and dispose of any oil leakage in an environmentally safe manner. 20-21-1 Flail Cutter Service Manual 57 of 110 .

Figure 20-21-5 1 P-57758 Installation: Inspect nylon spacer (Item 1) [Figure 20- 21-5] and replace if damaged. Installation: Tighten bolts to 180-200 in.HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE. S/N 467300197 & ABOVE) (CONT’D) Removal And Installation (Cont’d) Figure 20-21-4 1 P-57757 Remove the three nuts (Item 1) [Figure 20-21-4] and Dealer Copy -. (21-23 N•m) torque.-lb. 20-21-2 Flail Cutter Service Manual 58 of 110 . Remove the control valve.Not for Resale bolts. S/N 467500154 & ABOVE.

Orifice 5 15. Orifice Disc 19. Check Valve Body 13. Cap 1 2. O-ring 7. Lower Cap 8. S/N 467500154 & ABOVE. Spool 9.HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE. S/N 467300197 & ABOVE) (CONT’D) Parts Identification 1. Snap Ring 7 Dealer Copy -. Compensator 18. Bolt 3 4. Housing 10. Spring Guide 2 6. Seal 14. Spool Cover 3. Spring 5. Relief Valve 6 3 17. Poppet 12.Not for Resale 6 8 19 18 10 6 6 17 9 10 4 6 6 10 6 15 10 6 14 10 16 6 6 11 6 6 4 12 6 10 10 10 6 13 MS2208S 20-21-3 Flail Cutter Service Manual 59 of 110 . Back-up Ring 16. Plug 4 11.

S/N 467500154 & ABOVE.Not for Resale Remove the relief valve (Item 1) [Figure 20-21-6]. S/N 467300197 & ABOVE) (CONT’D) Disassembly Clean the outside of the valve before disassembly. Figure 20-21-9 P-71090 Dealer Copy -. 20-21-4 Flail Cutter Service Manual 60 of 110 . 1 P-71091 Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-21-7] from the relief valve.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-8 ABOVE. Figure 20-21-7 2 1 P-71093 Remove the O-ring (Item 1) [Figure 20-21-9] from the plug. 1 Figure 20-21-6 1 P-71092 Remove the plug (Item 1) [Figure 20-21-8] from the control valve.

P-71095 Remove the 2 plugs (Item 1) [Figure 20-21-11] from the control valve. P-71094 Figure 20-21-13 Remove the compensator compression spring (Item 1) Dealer Copy -. 20-21-5 Flail Cutter Service Manual 61 of 110 .HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-12 ABOVE. 2 Figure 20-21-11 1 1 P-71097 Remove the orifice (Item 1) from the port (Item 2) [Figure 20-21-13].Not for Resale and the compensator (Item 2) from the port (Item 3) [Figure 20-21-10]. S/N 467500154 & ABOVE. S/N 467300197 & ABOVE) (CONT’D) Disassembly (Cont'd) Figure 20-21-10 1 1 2 3 P-71096 Remove the O-ring (Item 1) [Figure 20-21-12] from both plugs.

P-71098 Figure 20-21-17 Remove the check valve body (Item 1) [Figure 20-21-14] Dealer Copy -.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-16 ABOVE. 20-21-6 Flail Cutter Service Manual 62 of 110 . P-71099 Remove the O-ring (Item 1) [Figure 20-21-15] from the check valve body.Not for Resale from the control valve. Figure 20-21-15 1 1 P-71101 Remove the 3 plugs (Item 1) [Figure 20-21-17] from the control valve. S/N 467300197 & ABOVE) (CONT’D) Disassembly (Cont'd) 3 Figure 20-21-14 2 1 P-7100 Remove the check valve compression spring (Item 1) 1 and poppet (Item 2) from the port (Item 3) [Figure 20-21- 16]. S/N 467500154 & ABOVE.

S/N 467500154 & ABOVE. Figure 20-21-21 Remove the O-ring (Item 1) [Figure 20-21-18] from the Dealer Copy -. 20-21-7 Flail Cutter Service Manual 63 of 110 . 3 Figure 20-21-19 1 2 1 P-71104 Remove the spool compression spring (Item 1) and the P-71102 spring guide (Item 2) from the lower cap (Item 3) [Figure 20-21-21]. Remove the plastic spool cover cap (Item 1) [Figure 20- 21-19]. S/N 467300197 & ABOVE) (CONT’D) Disassembly (Cont'd) 1 Figure 20-21-18 2 P-71103 Remove the 2 bolts (Item 1) and spool cover (Item 2) [Figure 20-21-20].Not for Resale three plugs. 1 P-71096 NOTE: The spool cover is under spring pressure.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-20 ABOVE.

P-71106 Remove the 2 O-rings (Item 1) [Figure 20-21-23] from the lower cap.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-24 ABOVE.Not for Resale 3 [Figure 20-21-22] from the control valve. P-71105 Figure 20-21-25 Remove the 4 bolts (Item 1) and the lower cap (Item 2) Dealer Copy -. 20-21-8 Flail Cutter Service Manual 64 of 110 . S/N 467500154 & ABOVE. S/N 467300197 & ABOVE) (CONT’D) Disassembly (Cont'd) Figure 20-21-22 1 2 1 P-71118 Remove the mower spool (Item 1) [Figure 20-21-24] from the control valve. Figure 20-21-23 1 1 2 1 P-71112 Remove the wiper seal (Item 1) and O-ring (Item 2) from the spool port (Item 3) [Figure 20-21-25].

S/N 467500154 & ABOVE. Figure 20-21-27 1 P-71096 Remove the O-ring (Item 1) [Figure 20-21-29] from the plug. P-71114 Figure 20-21-29 Remove the 3 plugs (Item 1) [Figure 20-21-26] from the Dealer Copy -. 20-21-9 Flail Cutter Service Manual 65 of 110 . 1 P-71096 Remove the O-ring (Item 1) [Figure 20-21-27] from the 3 plugs. S/N 467300197 & ABOVE) (CONT’D) Disassembly (Cont'd) 1 Figure 20-21-26 1 P-71109 Remove the plug (Item 1) [Figure 20-21-28] from the control valve.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-28 ABOVE.Not for Resale load control valve.

20-21-10 Flail Cutter Service Manual 66 of 110 .HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE. S/N 467500154 & ABOVE. S/N 467300197 & ABOVE) (CONT’D) Disassembly (Cont'd) Figure 20-21-30 1 2 P-71111 Remove the snap ring (Item 1) and orifice disc (Item 2) Dealer Copy -.Not for Resale [Figure 20-21-30] from port “A” of the control valve.

Inspect all parts for wear or damage. Dealer Copy -. Always install new seals and O-rings. 20-21-11 Flail Cutter Service Manual 67 of 110 .Not for Resale 2 1 P-71111 Install the orifice disc (Item 1) and snap ring (Item 2) [Figure 20-21-31] into port “A”. S/N 467300197 & ABOVE) (CONT’D) Assembly 1 Clean all parts in solvent and dry with compressed air. Lubricate all seals and O-rings with clean hydraulic fluid before installation.-lb. Figure 20-21-32 1 P-71093 Install the O-ring (Item 1) [Figure 20-21-32] on the plug. (34 N•m) torque. Tighten the plug to 25 ft. Replace any worn or damaged parts.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-33 ABOVE. Figure 20-21-31 P-71109 Install the plug (Item 1) [Figure 20-21-33]. S/N 467500154 & ABOVE.

S/N 467300197 & ABOVE) (CONT’D) Assembly (Cont'd) 3 Figure 20-21-34 2 1 P-71112 Install the O-ring (Item 1) into the second groove of the 1 spool port (Item 3) [Figure 20-21-36] in the control valve. Install the 2 plugs (Item 1) [Figure 20-21-35]. S/N 467500154 & ABOVE. Tighten the plug to 20 ft. Install the O-ring (Item 1) [Figure 20-21-34] on the 3 Dealer Copy -. (27 N•m) torque.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-36 ABOVE. Tighten the plugs to 25 ft. P-71093 Install the wiper seal (Item 2) into the top groove of the spool port (Item 3) [Figure 20-21-36] of the control valve. Figure 20-21-35 2 1 1 P-71118 P-71114 Install the mower spool (Item 1) [Figure 20-21-37] into the control valve.-lb. 20-21-12 Flail Cutter Service Manual 68 of 110 .-lb. Install the plug (Item 2) [Figure 20-21-35]. (34 N•m) torque.Not for Resale Figure 20-21-37 plugs.

Install the lower cap (Item 1) and 4 bolts (Item 2) [Figure 20-21-39]. Tighten the bolts to 9 ft. Tighten the 2 bolts to 9 ft. Figure 20-21-39 2 1 2 1 P-71103 Install the spool cover (Item 1) and 2 bolts (Item 2) [Figure 20-21-41]. 20-21-13 Flail Cutter Service Manual 69 of 110 . (12 N•m) P-71105 torque.-lb. S/N 467500154 & ABOVE.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-40 ABOVE. S/N 467300197 & ABOVE) (CONT’D) Assembly (Cont'd) 3 Figure 20-21-38 1 2 1 P-71104 1 Install the spring guide (Item 1) and spool compression spring (Item 2) into the lower cap (Item 3) [Figure 20-21- 40]. P-71106 Figure 20-21-41 Install the O-rings (Item 1) [Figure 20-21-38] into the Dealer Copy -. (12 N•m) torque.-lb.Not for Resale lower cap.

-lb. (34 N•m) torque. Tighten the plugs to 25 ft. Install the plastic spool cover cap (Item 1) [Figure 20-21- Dealer Copy -.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-44 ABOVE. P-71102 Install the plug (Item 2) [Figure 20-21-44]. S/N 467300197 & ABOVE) (CONT’D) Assembly (Cont'd) 1 Figure 20-21-42 2 P-71101 1 Install the 2 plugs (Item 1) [Figure 20-21-44]. Tighten the plug to 20 ft. 20-21-14 Flail Cutter Service Manual 70 of 110 . S/N 467500154 & ABOVE. (27 N•m) torque.-lb. Figure 20-21-43 1 1 P-71099 P-71093 Install the O-ring (Item 1) [Figure 20-21-45] onto the check valve body.Not for Resale Figure 20-21-45 42]. Install the O-ring (Item 1) [Figure 20-21-43] on the 3 plugs.

2 P-71100 Figure 20-21-49 Install the poppet (Item 1) and compression spring (Item Dealer Copy -. S/N 467300197 & ABOVE) (CONT’D) Assembly (Cont'd) 2 Figure 20-21-46 3 1 P-71097 Install the orifice (Item 1) into the port (Item 2) [Figure 1 20-21-48].-lb.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-48 ABOVE.Not for Resale 2) into the port (Item 3) [Figure 20-21-46]. Figure 20-21-47 1 P-71096 Install the O-ring (Item 1) [Figure 20-21-49] on the 2 plugs. Tighten the check valve to 35 ft. 1 P-71098 Install the check valve body (Item 1) [Figure 20-21-47]. 20-21-15 Flail Cutter Service Manual 71 of 110 . (48 N•m) torque. S/N 467500154 & ABOVE.

-lb. 20-21-16 Flail Cutter Service Manual 72 of 110 . Figure 20-21-51 2 1 P-71092 Install the plug (Item 1) [Figure 20-21-53]. P-71094 Install the compensator (Item 1) and the compression spring (Item 2) into the port (Item 3) [Figure 20-21-51]. Tighten the plug to 20 ft. (34 N•m) torque. S/N 467500154 & ABOVE.-lb.Not for Resale valve.-lb. Tighten the plug to 25 ft. Tighten the 3 plug to 46 ft.HYDRAULIC CONTROL VALVE (S/N A01P00144 & Figure 20-21-52 ABOVE. (62 N•m) torque. S/N 467300197 & ABOVE) (CONT’D) Assembly (Cont'd) Figure 20-21-50 1 1 P-71093 2 Install the O-ring (Item 1) [Figure 20-21-52] on the plug. 1 Install the plug (Item 2) [Figure 20-21-50] into the control valve. (27 N•m) torque. Figure 20-21-53 P-71095 Install the plug (Item 1) [Figure 20-21-50] into the control Dealer Copy -.

S/N 467300197 & ABOVE) (CONT’D) Assembly (Cont'd) Figure 20-21-54 2 1 P-71091 Install the O-rings (Item 1) and back-up ring (Item 2) Dealer Copy -. S/N 467500154 & ABOVE.Not for Resale [Figure 20-21-54] on the relief valve. Tighten the relief valve to 25 ft. (34 N•m) torque.HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE. 20-21-17 Flail Cutter Service Manual 73 of 110 .-lb. Figure 20-21-55 1 P-71090 Install the relief valve (Item 1) [Figure 20-21-55].

Not for Resale 20-21-18 Flail Cutter Service Manual 74 of 110 . Dealer Copy -.

. . . . . . . . . . . . . . . . 30-100-1 Removal And Installation . . . . 30-30-1 Removal and Installation . . . . . . . . . . . . . . . . . . 30-70-1 Removal and Installation . . . . . . . . . 30-50-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1 30-01 Flail Cutter Service Manual 75 of 110 . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1 Removal and Installation . . . . . . . . . . . . . . 30-40-1 DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN FRAME BRUSH DEFLECTOR (EARLIER MODELS) . . . . . . . . . 30-70-1 SKID SHOE. . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 Dealer Copy -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 MAIN FRAME FLAIL KNIVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 Removal And Installation . . . . . . . 30-80-1 RUBBER SKIRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 WEAR STRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1 ROLLER ASSEMBLY . . . 30-10-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 LINKAGE. . . . . . . . . . . . . . . . . 30-20-1 RUBBER STOP. . 30-80-1 Removal and Installation . 30-40-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Not for Resale Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dealer Copy -.Not for Resale 30-02 Flail Cutter Service Manual 76 of 110 .

SKID SHOE Removal and Installation WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. (34-38 N•m) torque. Figure 30-10-2 1 P-57649 Remove remaining bolts (Item 1) [Figure 30-10-2].Not for Resale 1 1 1 2 P-57648 Remove nuts and washers (Item 1) [Figure 30-10-1]. W-2019-0907 Figure 30-10-1 Dealer Copy -. • Engine is running. Remove skid shoe (Item 2) [Figure 30-10-1]. • Flying debris or loose material is present. • Tools are being used.-lb. 30-10-1 Flail Cutter Service Manual 77 of 110 . Installation: Tighten the bolts to 25-28 ft.

Not for Resale 30-10-2 Flail Cutter Service Manual 78 of 110 . Dealer Copy -.

1 P-57654 Remove bearing spacer (Item 1) [Figure 30-20-4].) WARNING 1 AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: P-57650 • When fluids are under pressure. Figure 30-20-1 Figure 30-20-3 Dealer Copy -. (34-38 N•m) torque.-lb.Not for Resale 2 1 P-57653 Remove bolts (Item 1) and the plate (Item 2) [Figure 30- 20-3] on both sides of the roller. 30-20-1 Flail Cutter Service Manual 79 of 110 . W-2019-0907 Installation: Tighten the bolts to 25-28 ft. (34-38 N•m) torque. Figure 30-20-4 P-57651 Chain and lift front until roller is flat on the ground [Figure 30-20-1].-lb.ROLLER ASSEMBLY Figure 30-20-2 Removal and Installation Remove skid shoe (See Removal and Installation on Page 30-10-1. the roller. • Flying debris or loose material is present. Remove bolt (Item 1) [Figure 30-20-2] from both sides of • Engine is running. • Tools are being used. Installation: Tighten the bolts to 25-28 ft.

(17 N•m) rotating torque with used bearings.Not for Resale torque. (9-10 N•m) Dealer Copy -. P-57655 Figure 30-20-8 Remove bearing bolts (Item 1) [Figure 30-20-5]. and 25 in. Installation: Set pinion bearing preload to 15 in. P-57656 (28 N•m) with new bearings. 30-20-2 Flail Cutter Service Manual 80 of 110 .-lb. 1 Installation: Tighten the bolts to 80-90 in.-lb. install the seal and loctite pinion nut.ROLLER ASSEMBLY (CONT’D) Figure 30-20-7 Removal and Installation (Cont’d) 1 Figure 30-20-5 1 P-57657 Remove dust cap (Item 1) [Figure 30-20-7]. Remove bearing (Item 1) [Figure 30-20-6]. Figure 30-20-6 1 P-57658 Remove pinion nut (Item 1) [Figure 30-20-8] and bearing. Once preload is set.-lb.

• Engine is running. 2 Installation: Tighten bolts to 25-28 ft. NOTE: The flat bar on the side skirts is mounted on the inside. (34-38 N•m) torque.RUBBER SKIRT Front Rubber Skirt Removal and Installation Figure 30-30-2 WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: 1 • When fluids are under pressure. • Tools are being used. 30-30-1 Flail Cutter Service Manual 81 of 110 .-lb. Figure 30-30-1 Installation: Tighten bolts to 25-28 ft. then remove the rubber skirt (Item 2) [Figure 30-30-2] and flat bar.-lb. W-2019-0907 2 P-57659 Rear Rubber Skirt NOTE: Mounting frame removed for picture clarity.Not for Resale Side Rubber Skirt Figure 30-30-3 1 1 2 P-57686 Remove bolts (Item 1). Installation: Tighten bolts to 25-28 ft. Dealer Copy -. (34-38 N•m) torque. Remove bolts (Item 1). (34-38 N•m) P-57659 torque.-lb. Remove bolts (Item 1). • Flying debris or loose material is present. then remove the rubber skirt (Item 2) [Figure 30-30-1] and flat bar. then remove the rubber skirt (Item 2) [Figure 30-30-3] and flat bar.

Dealer Copy -.Not for Resale 30-30-2 Flail Cutter Service Manual 82 of 110 .

Installation: Tighten bolts to 65-70 ft.Not for Resale Figure 30-40-1 2 1 1 P-57663 P-57661 Move the brush deflector mount (Item 1) [Figure 30-40- Remove bolts (Item 1) on both sides of the flail cutter. W-2019-0907 Dealer Copy -.-lb. of the following conditions exist: • When fluids are under pressure. Late model Flail Cutters are equipped with a weld-on front rubber skirt mount and are not equipped with metal brush deflectors. 3] away from the flail cutter. Figure 30-40-3 • Tools are being used. 1 WARNING P-57662 AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any Remove bolt (Item 1) [Figure 30-40-2]. Installation: Tighten bolts to 65-70 ft. torque. (88-95 N•m) • Flying debris or loose material is present. 30-40-1 Flail Cutter Service Manual 83 of 110 .-lb. (88-95 N•m) torque. Rubber guard removed for clarity. then remove front rubber skirt mount (Item 2) [Figure 30- 40-1]. • Engine is running.BRUSH DEFLECTOR (EARLIER MODELS) Figure 30-40-2 Removal and Installation NOTE: This section only affects early model Flail Cutters.

(88-95 N•m) torque. then align the brush deflector mount with the flail cutter frame and install bolt (Item 1) [Figure 30-40-5]. Installation: Tighten bolt to 65-70 ft.Not for Resale Figure 30-40-5 1 P-57662 Remove and replace damaged brush deflectors. Dealer Copy -. 30-40-2 Flail Cutter Service Manual 84 of 110 .-lb.BRUSH DEFLECTOR (EARLIER MODELS) (CONT’D) Removal And Installation (Cont’d) Figure 30-40-4 1 P-57664 Slide the brush deflectors (Item 1) [Figure 30-40-4] until they are free from the deflector mount.

1 P-57651 Install chain to the attachment (Item 1) [Figure 30-50-2]. Installation: Tighten the bolts to 25-28 ft. (34-38 N•m) torque. (34-38 N•m) torque. Remove bolt and lock washer (Item 1) to remove alignment plate (Item 2) [Figure 30-50-4].Not for Resale 1 1 2 P-57665 Remove bolts and lock washers (Item 1) [Figure 30-50- P-57667 1]. Figure 30-50-2 Installation: Tighten the bolts to 25-28 ft. W-2019-0907 Raise the front of the attachment to remove the drum [Figure 30-50-3]. 30-50-1 Flail Cutter Service Manual 85 of 110 . P-57666 • Tools are being used. Repeat for other side. Repeat for other side.DRUM Figure 30-50-3 Removal and Installation Place attachment flat on the ground.-lb. WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Engine is running. Figure 30-50-1 Figure 30-50-4 Dealer Copy -.-lb. • Flying debris or loose material is present.

Figure 30-50-6 1 Dealer Copy -. Figure 30-50-7 1 P-57669 Remove flange plate (Item 1) [Figure 30-50-7]. P-57675 Figure 30-50-9 Remove grease seal (Item 1) [Figure 30-50-5].DRUM (CONT’D) Figure 30-50-8 Removal and Installation (Cont’d) 1 Figure 30-50-5 1 P-57670 Remove snap ring (Item 1) [Figure 30-50-8]. Remove snap ring (Item 1) [Figure 30-50-6].Not for Resale 1 P-57671 P-57668 Remove bearing spacer (Item 1) [Figure 30-50-9]. 30-50-2 Flail Cutter Service Manual 86 of 110 .

Installation: Assembly drum in reverse order.DRUM (CONT’D) Removal and Installation (Cont’d) Figure 30-50-10 Dealer Copy -. 30-50-3 Flail Cutter Service Manual 87 of 110 .Not for Resale P-57672 Remove bearing with a press [Figure 30-50-10]. Use alignment plates to slide into place. Block drum up and lower attachment over drum assembly. Install bolts and lock washers.

Not for Resale 30-50-4 Flail Cutter Service Manual 88 of 110 . Dealer Copy -.

This procedure locks the nuts in place Replace the worn knives. 30-60-1 Flail Cutter Service Manual 89 of 110 .Not for Resale NOTE: When flail knives are broken. Figure 30-60-2 Replacing Multiple Flail Knives (Broken): 4 When replacing multiple flail knives.FLAIL KNIVES Removal And Installation WARNING Replacing Individual Flail Knives (Broken): AVOID INJURY OR DEATH When replacing individual broken flail knives to maintain Wear safety glasses to prevent eye injury when any rotor balance. NOTE: Use chains that are in good condition and of P-57756 adequate size to lift the attachment. pay close mount until the knife (Item 3) [Figure 30-60-2] is free. worn or damaged they will cause abnormal vibrations in the rotor. it is best to replace them with worn flail of the following conditions exist: knives that are similar shape and weight to the others not • When fluids are under pressure. • Flying debris or loose material is present. Dealer Copy -. W-2019-0907 NOTE: Keep a series of worn flail knives on hand. bolts and nuts. prevent damage to the flail cutter. use a hammer and punch to deform the side of the nut then lower the flail cutter and position it upside down on into the notches in the end of the bolt. check the installed. Remove nut (Item 1). attention to the direction in which they are NOTE: When the knife has been removed. NOTE: This reduces abnormal vibrations and can • Engine is running. being replaced. • Tools are being used. rounded or oval backwards. Installation: With nut tighten against the flail support. shaped holes. it is recommended 1 that all the flail knives be replaced. This must be done the ground. then slide bolt (Item 2) out of the NOTE: When installing the flail knives. for both notches. If the knives are installed flail supports for wear. The knife should move freely. Raise the flail cutter and rotate the flail cutter clockwise. Figure 30-60-1 Installation: Tighten nuts against flail supports (Item 4) [Figure 30-60-2]. they do not cut. 1 Figure 30-60-3 1 P-57748 Install chains (Item 1) [Figure 30-60-1] to the side arm linkage on both sides of the flail cutter. It is recommended that the flail 3 P-57674 knives be replaced an average of every 200- 300 hours of operation. 2 NOTE: The life of the flail knives depends on the type use and the type of land being worked. and prevents them from coming loose during operation [Figure 30-60-3].

Not for Resale 30-60-2 Flail Cutter Service Manual 90 of 110 . Dealer Copy -.

• Tools are being used. 30-70-1 Flail Cutter Service Manual 91 of 110 . nut and washer (Item 2) [Figure 30-70-1].RUBBER STOP Rubber Stop With Isolator Support Removal and Installation Figure 30-70-2 3 WARNING 2 3 AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any 1 2 of the following conditions exist: • When fluids are under pressure. 2 Install the rubber stop and isolator support through the flail cutter mount. P-83020 • Flying debris or loose material is present. • Engine is running. W-2019-0907 1 P-79962 Figure 30-70-1 Place the rubber stop (Item 1) inside the isolator support (Item 2) [Figure 30-70-2]. remove bolt.Not for Resale Install the lock washer and nut (Item 3) [Figure 30-70-2]. Dealer Copy -. P-57677 To remove rubber stop (Item 1). 1 Repeat procedure on opposite side of the flail cutter. Tighten the nut.

Dealer Copy -.Not for Resale 30-70-2 Flail Cutter Service Manual 92 of 110 .

LINKAGE Figure 30-80-3 Removal and Installation Side Linkage 1 WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Tools are being used.Not for Resale 1 1 1 1 P-57678 P-57682 Block attachment to raise mounting frame slightly off the Remove bolts (Item 1) [Figure 30-80-4]. torque. 30-80-1 Flail Cutter Service Manual 93 of 110 . Remove side link (Item 1) [Figure 30-80-3]. Figure 30-80-2 2 1 1 1 1 P-57683 P-57679 Remove pins (Item 1) and remove center link (Item 2) [Figure 30-80-5]. Installation: Tighten the bolts to 80-90 in. Installation: Tighten the bolts to 80-90 in.-lb. P-57680 • Flying debris or loose material is present. (9-10 N•m) Figure 30-80-5 torque. ground. W-2019-0907 Figure 30-80-1 Center Linkage Figure 30-80-4 Dealer Copy -. • Engine is running. (9-10 N•m) Remove bolt and nut (Item 1) [Figure 30-80-1].-lb. Remove collar (Item 1) [Figure 30-80-2].

Not for Resale 30-80-2 Flail Cutter Service Manual 94 of 110 . Dealer Copy -.

30-90-1 Flail Cutter Service Manual 95 of 110 . • Flying debris or loose material is present.Not for Resale 1 1 P-57685 Remove bolts (Item 1) [Figure 30-90-1] and replace if necessary.WEAR STRIP Removal and Installation WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Engine is running. • Tools are being used. W-2019-0907 Figure 30-90-1 Dealer Copy -.

Dealer Copy -.Not for Resale 30-90-2 Flail Cutter Service Manual 96 of 110 .

Remove brush guard (Item 2) [Figure 30-100-1]. • Flying debris or loose material is present. P-57637 P-57638 W-2019-0907 Figure 30-100-1 Loosen the four bolts (Item 1) [Figure 30-100-3] supporting the gear box and extension. Removal And Installation Figure 30-100-3 1 WARNING 1 AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. Turn the tension bolt clockwise to decrease belt tension.-lb. 2 1 P-57635 Remove bolts (Item 1) and drive pulley shield (Item 2) [Figure 30-100-2]. (88-95 N•m) torque. 30-100-1 Flail Cutter Service Manual 97 of 110 .Not for Resale 2 2 1 P-57634 Remove bolts (Item 1) [Figure 30-100-1]. • Tools are being used. Figure 30-100-2 Loosen jam nut (Item 1). • Engine is running. Installation: Tighten bolts to 65-70 ft. (34-38 N•m) torque.-lb.-lb. 1 Installation: Tighten bolts to 65-70 ft. then turn the tension bolt (Item 2) [Figure 30-100-4] counterclockwise to increase belt tension.DRIVE BELTS Installation: Tighten bolts to 25-28 ft. (88-95 N•m) P-57639 torque. 1 Figure 30-100-4 Dealer Copy -.

Not for Resale adjustment procedure (See Adjustment on Page 10-50-1.) 30-100-2 Flail Cutter Service Manual 98 of 110 .DRIVE BELTS (CONT’D) Removal And Installation (Cont’d) Figure 30-100-5 1 P-57641 Remove and replace belts (Item 1) [Figure 30-100-5]. For the proper belt tension Dealer Copy -. NOTE: Once the belts have been replaced. adjust belt tension.

. . . . . . . . . . . . . S/N 467500154 & Above. . . . SPEC-10-1 SPECIFICATIONS AND SCHEMATICS Dealer Copy -. . . SPEC-20-1 S/N A01P00143 & Below. . . . . . . . . . . . . . . . . . . . SPEC-10-1 Dimensions . S/N 467500153 & Below. SPECIFICATIONS AND SCHEMATICS HYDRAULIC SCHEMATIC . . S/N 467300197 & Above . . . . . . . . . . . . . . . . . .Not for Resale SPEC-01 Flail Cutter Service Manual 99 of 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S/N 467300196 & Below. . . . . . . . . . . . . . . . . . SPEC-20-1 S/N A01P00144 & Above. . . . . . . SPEC-20-2 SPECIFICATIONS. . . . . . . . . . . . . . . .

Dealer Copy -.Not for Resale SPEC-02 Flail Cutter Service Manual 100 of 110 .

(254 mm) 10 in. ^ 3 (29 cm ^ 3) 1. (264 mm) 15. (277 mm) 10.8 in.8 in. (2057 mm) 91 in. (754 mm) Total Length (E) 57. specifications conform to SAE and ISO standards and are subject to change without notice. (254 mm) Cutter Capacity Brush material up to 2 in. (1856 mm) 81 in.4 in. (683 mm) 29. (580kg) 1530 lb. (696 kg) 1640 lb.8 in. ^ 3 (29 cm ^ 3) Displacement Shutoff Float Height 10 in. Brush material up to 3 in.4 mm) 56.4 in. (754 mm) 29.9 in.9 in. ^ 3 (29 cm ^ 3) 1. (1445 mm) 56. (388 mm) Total Height (D) 26.3 in. ^ 3 (58 cm ^ 3) 3. (2306 mm) Total Offset (C) 10. (1445 mm) Maximum Rotor RPM 2200 RPM 2200 RPM 2200 RPM Maximum Hydraulic Flow 40 GPM (151 LPM) 40 GPM (151 LPM) 40 GPM (151 LPM) Minimum Hydraulic Flow 17 GPM (64 LPM) 17 GPM (64 LPM) 17 GPM (64 LPM) Maximum Hydraulic Motor 3.5 in. ^ 3 (58 cm ^ 3) 3. • Where applicable.5 in.5 in.7 in.7 in.5 m) 69 in. Brush material up to 3 in. (2 m) Total Width (B) 73 in.SPECIFICATIONS Dimensions • All dimensions are shown in inches. (1.75 m) 78 in. ^ 3 (58 cm ^ 3) Displacement Minimum Hydraulic Motor 1. (1.9 in. (746 kg) Cutting Width (A) 61 in. (254 mm) 10 in.8 in. (1457. Respective metric dimensions are given in millimeters enclosed by parentheses. (51 mm) in diameter (76 mm) in diameter (76 mm) in diameter SPEC-10-1 Flail Cutter Service Manual 101 of 110 .Not for Resale D E A B DESCRIPTION FC155 (Europe Only) FC175 (Europe Only) FC200 Weight 1279 lb. C Dealer Copy -.

Not for Resale SPEC-10-2 Flail Cutter Service Manual 102 of 110 . Dealer Copy -.

HYDRAULIC SCHEMATIC

S/N A01P00143 & Below, S/N 467500153 & Below, S/N 467300196 & Below

ORIFICE
(.030 in.)

Dealer Copy -- Not for Resale
[.762 mm]

P-57753

SPEC-20-1 Flail Cutter Service Manual
103 of 110

HYDRAULIC SCHEMATIC (CONT’D)

S/N A01P00144 & Above, S/N 467500154 & Above, S/N 467300197 & Above

ORIFICE
ORIFICE (.030 in.)
MODEL FC155 (.348 in.) [.762 mm]
ONLY [8.83 mm]

Dealer Copy -- Not for Resale

P-83972

SPEC-20-2 Flail Cutter Service Manual
104 of 110

ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: Flail Cutter-1
Date: 23 March 2006
Product: Attachment
Model: Flail
Manual No: 6903303 (1-05)

Flail Cutter Service Manual (P/N 6903303) Dated (1-06) contains updated service information which replaces the
previous Flail Cutter Service Manual (P/N 6903303) Dated (1-05).

Dealer Copy -- Not for Resale

Printed in U.S.A.
105 of 110

Not for Resale .106 of 110 Dealer Copy -.

107 of 110 . COVER Dealer Copy -. ROUTE TO ATTENTION PARTS MANAGER SERVICE MANUAL SERVICE MANAGER X REVISION SALES MANAGER NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.Not for Resale ALPHABETICAL INDEX 10-01 10-20 20-01 20-20 Added 20-21 30-01 30-40 SPEC-01 SPEC-10 Added SPEC-20 Printed in U.S.A. Revision No: Flail Cutter-2 Date: 1 November 2006 Product: Attachment Model: Flail Cutter Manual No: 6903303 (11-06) The following sections are a revision to the above Service Manual.

108 of 110 Dealer Copy -.Not for Resale .

S. Revision No: Flail Cutter-3 Date: 1 November 2008 Product: Attachment Model: Flail Cutter Manual No: 6903303 (11-08) The following sections are a revision to the above Service Manual.Not for Resale CONTENTS 10-01 10-20 30-70 Printed in U. ROUTE TO ATTENTION PARTS MANAGER SERVICE MANUAL SERVICE MANAGER X REVISION SALES MANAGER NOTICE Insert This Sheet With The Below Listed Manual For Future Reference. COVER ALPHABETICAL INDEX Dealer Copy -.A 109 of 110 .

110 of 110 Dealer Copy -.Not for Resale .