diamond mowers FLAIL MOWER User manual

DIAMONDMOWERS.COMDIAMONDMOWERS.COM
OPERATOR’S MANUALOPERATOR’S MANUAL
SKID-STEER / COMPACT TRACK LOADER
FLAIL MOWER

PRODUCT INFORMATION
Record the model and serial number of your unit here. When calling for
warranty, service or parts, you may be asked to provide this information,
in order to ensure fast, accurate service.
MODEL: Flail Mower SIZE: 75”(1905mm) 90”(2286mm) 102”(2591mm)
SERIAL NUMBER:___________________________________________________
© Diamond Mowers, LLC
All rights reserved.
Any failure to read, understand and follow the instructions found in this operator’s
manual could lead to serious injury. Operators who choose to operate this equipment
without following instructions, or who choose to operate this equipment in a manner
inconsistent with the recommendations set forth in this manual, do so at their own
risk and assume the risk of injury. Diamond Mowers will not be liable for an owner
or operator’s loss, damage, or injury due to the misuse of the equipment, failure to
understand the inherent risks, or inability to properly operate the equipment.
Provisional Patents: 62/484,363
(circle one)
2

WELCOME!
Thank you for choosing Diamond Mowers, and welcome to your Skid-Steer /
Compact Track Loader Flail Mower. Before you begin operating, we encourage
you to look through this manual to review the proper maintenance and
operating techniques that will keep you, and your equipment, safe — while
ensuring you the most productive Flail Mower in the market.
We have nothing but respect and admiration for you. Our job at Diamond is
to provide you with the toughest, most reliable and safest equipment that
will allow you to do your job better. That also means being there when you
need us.
CONTACT US:
Parts: 888.960.0361 | [email protected]
Warranty / Service: 888.960.0364 | warr[email protected]
Main Office:800.658.5561 | 605.977.3300
Website: www.diamondmowers.com |Email: inf[email protected]
Your time is important to us.
We guarantee that Genuine Diamond Parts will ship within 72-hours of the
order being placed or the parts and shipping are free.
Your satisfaction is guaranteed.
If you are not completely satisfied with your new Diamond in the first
30-days, we will buy it back. No questions asked.
Thanks again for choosing Diamond.
If at any time your needs are not being met by our team, please feel free
to call me direct.
Tim Kubista
VP Sales & Marketing
651.955.6665

OWNER REGISTRATION
In your welcome packet you should have received a warranty registration
form. Complete and return this form to our main office. It’s a self-mailer,
so no postage is required.
If you’d rather complete this info online, go to:
http://info.diamondmowers.com/register-my-product
Returning your registration information to Diamond will help us process any
warranty claims quickly and efficiently – so you can get back to work, fast.
TRANSFERRED OWNERSHIP
If you have acquired this Flail Mower from a previous owner, we encourage
you to register your equipment online. By registering your Diamond Mowers
unit, you’ll stay informed on product advancements,
offers and service alerts.
Register by going to: http://info.diamondmowers.com/register-my-product
We honor our equipment’s warranty from the date it was put into service,
no matter who’s in charge of running it.
For any questions, contact our Warranty / Service team at:
888.960.0364 or 605.977.3300
warran[email protected]
PRODUCT REGISTRATION
4

INTENDED USE 6
TAKE A LOOK AROUND 7
GETTING STARTED 8
OPERATING YOUR FLAIL MOWER 10
MAINTENANCE 16
TROUBLESHOOTING 27
PARTS BOOK 29
INDEX 39
TABLE OF CONTENTS

INTENDED USE
Do not operate this unit without first reading the safety precautions
and operating instructions in this manual.
This attachment is designed to be used for mowing and light brush
management applications.
This includes:
•Cutting grass.
•Mulching light brush.
•Cutting a maximum of 2” (51mm) material continuously.
This attachment should only be used in an area free of obstructions and
bystanders. Any use on non-vegetative material, or in an area that is not
clear of persons and property, is strictly prohibited. Any use outside of the
aforementioned application is considered contrary to its intended use. Any
damage that may occur as a result of misuse will void warranty as stated in
Diamond Mowers’ warranty policy.
Do not operate this unit without first reading the safety precautions
and operating instructions in this manual.
6

TAKE A LOOK AROUND
KNIVES
The cutting shaft is equipped with
heavy duty brush and grass blades
for a smooth, even cut.
BELT DRIVE
Heavy duty flails use a high
strength belt with an automatic
self-tensioner; no manual
adjustment needed.
HYDRAULIC MOTOR
Flail mowers equipped with a high
flow / high efficiency hydraulic
motor matched to your skid-steer /
compact track loader.
HOSES
Shipped with quick couplers and a
case drain line with both male and
female ends.
BEARINGS
For long life and reliability, flail
cutting shafts and ground rollers
are equipped with the best
bearings in the industry.
7

GETTING STARTED
CONTINUED ON NEXT PAGE
MACHINE FLOW
The case drain line must be properly
connected or you will damage your
hydraulic motor. The case drain line
will come equipped with both male and
female QD couplers.
•Install the QD coupler(s) that
matches the machine.
•Attachment is shipped with 1/2”
flat face connectors, which are a
common size for most skid-steer /
compact track loaders.
•Clean connections before attaching
to prevent contamination.
The Flail Mower will mount onto the
front of the skid-steer / compact track
loader quick attach plate in place of a
bucket or other implements.
SHATTER RESISTANT ENCLOSURE
QUICK ATTACH
QD COUPLERS
Diamond’s Flail Mower must be used on
a high flow machine capable of 32-45
GPM (122-171 LPM) and have a case
drain.
A shatter resistant enclosure is
REQUIRED! This product must not be
used without a shatter resistant cab
enclosure. Debris can fly back at the cab
and cause injury.
8

GETTING STARTED
•The pressure(1), return(2), and case
drain(3) hoses from your flail mower
are identified in the illustration
at left.
•Make sure the hose length outside
of the bracket(4) is long enough for
the head to make a full range of
motion, but not so long that the
hose can pinch.
•Start machine at low idle and verify
that the cutting shaft is spinning in
“Reverse” rotation.
◦NOTE:
“Forward” rotation is defined
as blade rotation the same as
the skid-steer / compact track
loader tires when driving forward.
“Reverse” rotation is
the opposite.
◦If the cutting shaft is spinning in
“Forward” rotation, either inverse
the flow from your machine, or
switch the QD couplers on the
pressure(1) and return(2) hoses.
(4)
(1) (3) (2)
9

OPERATING YOUR FLAIL MOWER
CONTINUED ON NEXT PAGE
Before you operate, note that the primary responsibility for safety on this
equipment falls to the operator. Only trained individuals who have read and
understood this manual should operate this unit.
If any portion of this manual is not understood, contact:
Diamond Mowers’ Service/Warranty at 888.960.0364 or 605.977.3300.
Be sure to read all warnings carefully. They are included for your safety,
and for the safety of others working with you.
SAFETY TIPS
Indicates where SERIOUS injury or death WILL result if instructions
are not followed.
Indicates where SERIOUS injury or death COULD result if instructions
are not followed.
Indicates where MINOR injury COULD result if instructions are
not followed.
Indicates a property damage hazard ONLY, no PERSONAL injury.
•Always wear personal protective equipment (safety glasses, goggles,
etc.), when operating.
•DO NOT operate this unit without a shatter resistant cab enclosure
installed on your skid-steer / compact track loader; this unit will cause
flying debris.
•Block off work area from bystanders, livestock, etc.
•Bystanders must keep a distance of 300ft/100m from the unit
when operating.
•Knives are always sharp and can cause injury, even when not
in motion.
10

•DO NOT use extremities to dislodge debris from the cutting shaft
or knives.
•Operate only from the operator’s station.
•Hydraulic fluid is hot and will heat any exposed steel, hoses, motor, or
spindle in its proximity.
•Route hoses correctly to ensure a full range of motion.
•Make certain hoses are out of the way of tires, tracks or the ground.
•Be certain the cutting shaft has come to a complete stop before exiting
the cab.
When transporting Diamond’s Flail
Mower between operations, make
sure to protect it from collisions and
accidental damages by placing it in the
stowed position.
Failure to place the head in its stowed
position could result in
structural damage.
STOWED POSITION
Contact with the cutting shaft and knives while in motion will cause
serious injury or death. The cutting shaft spins at a very high speed
and can take several minutes to stop. Be sure all personnel are clear
of the machine before engaging the Flail Mower.
11

GRASS AND BRUSH CUT
Use to cut grass or brush.
•Lower the front of the deck slightly to ensure ample room for exhausted
material to be dispersed.
◦If you hear the cutting shaft, or engine slow down, lift up the head
and/or slow your ground speed.
•A second pass may be needed for heavy brush or grass.
◦Complete the initial pass at 12” (305mm) into the material.
◦Complete a second pass at ground level to thoroughly mulch the
remaining material.
OPERATING YOUR FLAIL MOWER
1
2
2
1
12

FINISHED MOW
Use for a finished look.
•Drive straight into the material keeping the deck low and level, or slightly
pitched forward.
•Maintain speed of the cutting shaft and ground speed.
13

TREE CUT
Use to cut small trees or brush without mulching.
•For small trees, start working at the top and cut the tree in
12” (305mm) increments.
•With the Flail Mower lifted slightly, drive straight into the material.
•Allow enough time for the tree section to fall away while cutting.
•Use a smooth, quick action to cut the material completely.
◦NOTE: Never drop the mower straight down on trees. Severe damage
will incur. NO PANCAKING!
Be aware when cutting standing trees as there is a potential for tree
tops to fall onto the operator’s cab.
OPERATING YOUR FLAIL MOWER
14

NO PANCAKING
DO NOT pancake.
•This machine is not built to drop on top of material for cutting or
mulching. Damage will incur to the cutting shaft and bearings as a result
of driving down (pancaking) on top of the material.
Dropping the Flail Mower straight down (pancaking) on heavy
vegetation can cause severe damage to the cutting shaft
and bearings.
For more tips, visit us online at www.DiamondMowers.com
15

MAINTENANCE
Regular maintenance will make certain your unit stays productive and retains
a long operating life. The following chart represents the minimum intervals
recommended for inspection and maintenance.
MAINTENANCE INTERVALS
PROCEDURE
10
HOURS/
DAILY
50
HOURS/
WEEKLY
500 HOURS/
ANNUALLY
AS
NEEDED
BELTS & PULLEYS Adjust
CUTTING SHAFT Grease Inspect
DISCHARGE FLAP Inspect
GROUND ROLLER Oil
HYDRAULIC FITTINGS Inspect
KNIVES Inspect
SHATTER RESISTANT ENCLOSURE Inspect Clean
SKID SHOES Inspect
When replacing parts, use Genuine Diamond Parts. Guaranteed to ship within
72-hours of your order being placed, or the parts and shipping are free.
Call: 888-960-0361 or 605.977.3300 | Email: [email protected]
Order online: www.diamondmowers.com
16

BELTS AND PULLEYS
Belt Replacement:
•Remove the access cover.
•Push the idler pulley(1) away from
the belt(2) with a wrench, pry bar, or
similar tool to relieve pressure on
the belt.
◦DO NOT damage the idler pulley
or other components when
relieving pressure on the belt.
•Remove the belt from the pulleys.
•Reverse the above instructions to
install the new belt(2).
•Replace the access cover.
Pulley Alignment:
•Use a straight edge(5) to confirm the
cutting shaft(3) and motor(4) pulleys
are in the same plane as the
idler pulley(1).
•If pulley misalignment is found,
correct as follows:
◦Loosen the bolts(6) holding the
tapered collar(7) to the out-of-
alignment pulley(8).
◦With a padded mallet, tap the
pulley(8) backwards or forwards
on its shaft to align it with the
idler pulley(1).
◦With the pulley(8) aligned, tighten
the bolts(6) holding the tapered
collar(7) to the pulley.
◦NOTE: This process may be easier
without the belt installed.
•Replace the access cover.
CONTINUED ON NEXT PAGE
(1) (2)
(1)
(2)
(3)
(4)
(5)
(7)
(8)
(6)
17

MAINTENANCE
Reversing Cutting Shaft Rotation:
NOTE: “Forward rotation” is defined as
blade rotation the same as the tractor
tires when driving forward. “Reverse
rotation” is the opposite.
•Remove access cover and belt(2)
from the pulleys as described on the
previous page.
•Remove the idler pulley(1) stop bolt
and main center bolt.
•Reposition the idler pulley(1) as
illustrated (dashed outline).
◦A second location for the idler
position stop bolt will
be exposed.
◦Re-attach the main center bolt to
lock it into position.
•Replace the belt(2) as illustrated
(dashed outline) and access cover.
•Disconnect the pressure(9) and
return(10) hoses from the skid steer /
compact track loader.
◦Clean off dirt and debris prior.
•Swap the pressure(9) and return(10)
QD hose connections, and connect
the hoses to the skid steer /
compact track loader in reverse.
•Install the front shield(11) for reverse
rotation, or remove it for
forward rotation.
•Install the baffle with bolts(12) for
forward rotation, or remove it for
reverse rotation.
◦Reference the parts pages for
additional information.
(1)
(11)
(2)
(12)
(9 OR 10)
18

DISCHARGE FLAP
CUTTING SHAFT
•Grease the cutting shaft bearing
zerks(1) (1 on each side of the flail)
every 10 hours or daily with #2
lithium based grease from a hand
grease gun until grease purges from
the bearing seals.
•Torque the cutting shaft bearing
bolts(2) to 90ft-lbs (122Nm) on each
side of the flail every 50 hours
or weekly.
◦NOTE: The access covers
covering the pulleys and belt
must be removed to gain access
to the cutting shaft bearing bolts
located underneath the bottom
pulley of the flail.
•Inspect the flail head’s rear
discharge flaps(1) every 50 hours
or weekly:
◦Excessive wear
◦Cuts, gouges, excessive damage.
•Replace as needed.
(1)
(2)
(1)
(2)
(1)
19

TORQUE
(Nm)
TORQUE
(ft-lbs)
PART#REQPARTS DESCRIPTIONREF#
10-10492
TAPER BEARING
1
10-10502
TAPER BEARING RACE
2
11-20061
ROLL PIN
3
38.928.711-20656
5/16 X 1-3/4 NC SHCS
4
11-20671
THRUST WASHER 2.00 OD X 1.26 ID
5
11-20741CASTLE NUT6
21-113611/8 NPT PLUG
7
24-02731O RING 2-7/8 OD8
33-00311SEAL TCM 132713TC9
41-17761ASSY GROUND ROLLER SHAFT10
90-70451GROUND ROLLER INSERT11
90-70481GROUND ROLLER END CAP12
10-1067 oil bath replacement bearing assy Rev 000
10
9
1
2
5
1
2
11
3
6
8
12
4
7
MAINTENANCE
CONTINUED ON NEXT PAGE
GROUND ROLLER
Bearing Maintenance:
•Each bearing(1) must have the oil and
O-ring replaced once annually with
7-8oz of synthetic 75-90W oil and a
new O-ring.
•Rest the ground roller(2) on
the ground. Block it from moving.
•Unbolt(3) the ground roller(2) from
each side of the flail.
◦DO NOT reassemble the hardware
from one side of the flail on
the other.
•Lift the flail head for access to the
ground roller.
•Remove the cap screws securing
the bearings(1) to the ground roller(2)
on each side.
•Disassemble each bearing(4).
◦Remove the cap screws, 1/8” NPT
plug, and end cap.
◦Discard the old O-ring.
•Remove the roll pin and castle nut(4).
•Pour out the old oil from the insert(4).
◦Catch and retrieve the thrust
washer and taper bearing.
◦Examine the taper bearing its
race for damage or wear.
-No wear; proceed with the
next step.
-Wear detected; contact
Diamond Mowers for a rebuild
kit with instruction.
•Pour synthetic SAE 75-90W oil(5) into
the ground roller insert(4) until it just
touches the taper bearing race(6).
(6)
(5)
(2)
(1)
(4)
DRIVE BELT SIDE NON-DRIVE BELT SIDE
(1)
(1)
(3) (3)
20