Iron Baltic ATV Series User manual

ATV SERIES
FLAIL MOWER
OPERATOR’S MANUAL
ATV SEERIA
HOOLDUSNIIDUK
KASUTUSJUHEND
READ AND FOLLOW ALL SAFETY AND OPERATING INSTRUCTIONS!
LOE JA JÄLGI KÕIKI OHUTUS- JA KASUTUSJUHISEID !
KEEP THIS MANUAL FOR FUTURE REFERENCE!
HOIDKE KÄESOLEV JUHEND EDASPIDISEKS KASUTAMISEKS ALLES !

REGISTRATION BROCHURE / REGISTREERIMISE BLANKETT
Add the serial number and purchase date for your flail mower to the fields below. The distributor
needs this information in order to be able to service your equipment quickly and efficiently when
ordering spare parts. If parts need to be replaced, use only original spare parts.
In case repairs are required under the terms of the guarantee, submit this registration brochure
together with the initial sales invoice to the distributor to order servicing under the terms of the
guarantee.
Märkige niiduki seerianumber ja ostukuupäev allpool toodud väljadele. Müüja vajab seda teavet,
et teenindada teid varuosade tellimise korral kiiresti ja tõhusalt. Kui osi on tarvis vahetada,
kasutage ainult originaalvaruosi.
Garantiiremondi vajaduse korral esitage see registreerimise blankett koos algse müügiarvega
garantiiteenuse tellimiseks müüjale.
IRON BALTIC OÜ
Põldmäe tee 1
Vatsla 76915
ESTONIA
Tel. [phone]
[email protected]
www.ironbaltic.com
Type / Tüüp: ......................................... No / Nr: ..............................
Date / Kuup: .........................................
Belts / Rihmad: ............................................ / .................................................
Manufacturer / Tootja Dimensions / Mõõdud
NOTE: Standard lengths of the belts may vary in between belt manufacturers!
MÄRKUS: Rihmade standard pikkused võivad erinevatel tootjatel erineda!

2
INDEX ( ENGLISH )
Section: Description: Page No:
1
Introduction
3
HSE information sheet
4
2
In the interest of safety: DO NOT
6
3
In the interest of safety: DO
6
4
Instruction & Warning Decals
7
5
Operating Instructions And Adjustments
8
5.1 Initial Check
8
5.2 Drawbar Adjustment
9
5.3 Mower Cutting Height
10
5.4 Starting The Engine
10
5.5 Forward Speed
11
5.6 Stopping The Mower
12
5.7 Transport Position
12
5.8 Anti-scalping roller / Side skid′s
12
6
Maintenance Schedule
13
6.1 Engine
13
6.2 Excess Crop Build Up
13
6.3 Visual Check
14
6.4 Tyre Pressures
14
6.5 Rotor Bearing Inspection
14
6.6 Wheel Bearing Inspection
14
6.7 Oil Coupling / Bush Wear
15
6.8 General Inspection
15
6.9 Rotor Flail Maintenance
15
6.10 Changing the Belts
16
6.11 Replacing the Clutch
17
Spare Parts
37

3
With the purchase of your FLAIL MOWER you have made an excellent choice.
This machine should give first class service for a long time, if used correctly, and maintained as
described in this manual.
Fitted with an easy to start engine it has been designed to cope with a wide range of conditions. Flail
mower incorporates easy height adjustment, range of engine options and a full width anti-scalping
roller to avoid damage to machine.
The mower is constructed from 4mm steel for added strength; all fittings are of high quality to ensure
years of trouble free use.
Engines used may vary, but all are accompanied by the engine manufacturers standard warranty.
1
INTRODUCTION

4
Selecting and using equipment for all terrain Vehicles (ATVs)
Introduction
This information sheet gives advice to users on how to use all Terrain vehicles(ATVs) safely with
towed and mounted equipment.
Plan the use of an ATV carefully and take particular note of ground conditions and slopes, as these
may vary considerably, depending on the terrain, weather conditions, ground surface and the crop
under the wheels.
Towed equipment
Choose equipment which matches your ATV. Stability of towed equipment is affected by:
Weight ratios
1The safe ratio between the trailed laden maximum weight and unladen weight of the ATV
must be assessed for each operation.
2Always take note of information given in the manufacture′s handbook when making this
assessment.
3As a guide research shows that on level ground, 4 x unladen weight of the ATV for braked
trailed equipment and 2 x unladen weight of the ATV for unbraked trailed equipment are the
appropriate maximum ratios.
Note: For work on slopes or uneven ground the ratio will need to be reduced.
Braking
Fit:
1Brakes to trailed equipment. This helps prevent jack-knifing when braking or traveling
downhill;
2Over-run brakes which come into action whenever the ATV brakes are applied;
3A manually operated parking brake operable from the driving position. This provides control
for use when going up slopes.
Hitching and loads
Stability is also improved if:
1Some weight is transferred from the trailer onto the ATV draw-bar;
2The draw-bar has a swivel hitch and the ATV a ball hitch having a large head to neck ratio.
This makes it easier for the draw-bar hitch to swivel and cope with undulating ground;
3The load is positioned as near to the centre of the trailer as possible.
Tyres and wheels
1Check tyre pressures regularly with a pressure gauge capable of reading low pressures
accurately;
2Check tyres regularly for damage and wear;
3Select equipment which has tyres and wheels that can cope with speeds over 20mph and
occasional higher speeds;
4Use wheels with bead locks on the rims if the main use is going to be on sloping ground.
This prevents tyre run-off on side slopes.

5
Maximum towed weight
Follow the advice given by manufacturers on the maximum trailed weight. This will be found on the
equipment or in the instruction handbook.
Note: Universal road going trailers will normally have the maximum gross weight stated on a
separate notice.
Mounted equipment
ATVs using mounted equipment are safer if the equipment has:
·a low centre of gravity. This improves stability.
·a gross weight within the limits approved by ATV manufacturer.
·no dangerous projections to injure the operator or bystanders;
·no forward projections which stop head protection being worn;
·controls which are easy to work and which do not create a hazard to the operator;
Instructions for mounted and trailed equipment
Take note of the manufacturer′s instructions on:
·operating on slopes;
·where to place loads so as to give fore/aft and lateral stability;
·the risks of using equipment with negative drawbar nose weight, ie loss of traction;
·the maximum operating speed;
·securing loads;
·the use of ballast, if any, to improve stability;
·the need to select and use safe routes.
Using an ATV
·read the manufacturer′s instruction book and take note of the safety advice given;
·Choose an ATV with enough power for the work you want it to do. Four-wheel driver will give
better traction and mobility and may provide a margin of safety;
·Choose a safe route;
·Be aware that increased speed greatly increases the risk of instability and risk of and
overturn;
Training
Train everyone who has to use an ATV whether with mounted or trailed equipment or as a solo
machine. The training should emphasis the factors affecting stability, the need for care and
concentration, and how to recognize the conditions which may affect the safety of operation, It is
important for trainees to familiarize themselves with the handing and control of the machine on level
open ground before tackling rough hill terrain.
.
Helmets
Wear head protection which protects the head and neck. Helmets are suitable. Some users find
open faced helmets more suitable than full face helmets.
This symbol means WARNING or CAUTION Personal safety or damage will be at risk
if these instructions are ignored. Most accidents are caused by neglect of carelessness;
Avoid needless accidents by following the safety precautions listed below.

6
1DO NOT － Operate the mower without all the correct guards fitted.
2DO NOT － Alter engine settings unless stated by Engine manufacturer.
3DO NOT － Touch any moving or rotating parts, during working conditions
4DO NOT － Stop the engine immediately after heavy use, (See section 5.6)
5DO NOT － Operate the mower without suitable ear and eye protection
6DO NOT － Allow passengers.
7DO NOT － Leave machine un-attended while operating
8DO NOT － Run the engine in an enclosed area, exhaust gases contain Carbon Monoxide
and are fatal if inhaled.
9DO NOT － Operate the mower on excessively steep slopes.
10 DO NOT － Operate the mower unless all safety features are fitted to the mower and are
used correctly
11 DO NOT － Operate the mower until you have read and understood the entire operators
manual
12 DO NOT － Wear loose fitting clothing, to avoid catching on parts of the machine
13 DO NOT － Try to remove blockages while the engine is running. Ensure engine is stopped
and the rotor has finished rotating, before any servicing takes place to your mover.
14 DO NOT － Operate the mower in Dark conditions unless suitable artificial light is used.
15 DO NOT － Operate if excessive vibration occurs, stop the machine immediately and view
maintenance chart.
16 DO NOT － Climb on the mower.
1DO － Follow Engine manufactures guideline.
2DO － Ensure all spectators are a safe distance away when operating.
3DO － Carry out regular servicing and checks before use.
4DO － Clear cutting area from potential damaging components.
5DO － Reduce speeds when working on hillsides or rough terrain
6DO － Be aware components can be hot after operation
7DO － Follow any towing guidelines stated by ATV manufacturer.
8DO － Show some caution when filling the tank with petrol, especially if engine components
are hot.
9DO － Ensure all safety decals are in good condition, replace any that are damaged.
10 DO
－ Keep hands and feet away from rotating blades
11 DO – Ensure mower is in transport position before transporting from workplace
2
IN THE INTEREST OF SAFETY:
DO NOT
3
IN THE INTEREST OF SAFETY:DO

7
KEEP WHEEL NUTS TIGHT CHECK DAILY REFER TO THE OPERATORS MANUAL FOR
CORRECT TYRE INFLATION PRESSURE
OBSERVE TOWING VEHICLE MAX TOWING LIMITS OR TRAILER MAX WEIGHTS
ATTENTION
Your responsibilities before operating this machine are:
· Read Understand and Follow the safety procedures manual
· Train operators before using & review safety procedures regularly
· Ensure that all guards are in place before operating
· Keep Hand, Feet, Hair and Clothing away from all moving parts
·Avoid waring loose clothing whenever possible
· Maintain as per schedule in the safety procedures. Especially Blades and Securing Hardwar, due to
hazard they present should any part break loose during operation
· During maintenance, use suitable support stands
· DO NOT allow any persons to ride on the equipment
4
INSTRUCTION / WARNING DECALS

8
FLAIL MOWER is designed to give safe and dependable service if operated according to instructions
and intended use. Read and understand this manual before operating the mower, as failure to do so
could result in personal injury or equipment damage.
When used with and ATV or compact tractor, ear defenders should be worn. Under
normal working conditions a noise level of 83 decibels would be usual, in the case protection
is advised.
The above decals should be located on your Flail Mower. If any of the above decals are not
located on your Mower or are da aged in da aged in any way contact for so e replace ent decals
before use.
5
OPERAT
ING INSTRUCTIONS

9
1Make sure that all nuts, bolts and fittings are securely fixed, and that all packaging materials
e.g. wire bands, tape etc have been removed. (Remove tape from the front stone deflectors
from the underside of the body)
2Check there is oil in the engine and petrol in the tank.
3Check tyre pressures.
The drawbar attachment height of the towing vehicle can vary. To accommodate adjustment, a screw
link is located beneath the drawbar. This should be lengthened or shortened so that the cutting deck
is horizontal to level ground. (This ensures a better cutting efficiency)
TO ADJUST
1Unlock the locking nut (A)
2Lengthen the link to lower the front of the deck or shorten to raise the deck.
3Once the deck is level, re-tighten locking nut (A).
A
ADRAWBAR Unlock the nut and screw slide the drawbar to the desired position and release the
screw into the securing hole then lock the nut, as shown.
5.1 INITIAL CHECK
5.2 DRAWBAR ADJUSTMENT

10
The main cutting height adjustment is achieved by using the screw jack, to raise or lower the
cutting deck as necessary.
CUTTING HEIGHT ADJUSTMENT:
Turn the handle to raise or lower as necessary.
READ AND UNDERSTAND THE ENGINE OPERATORS MANUAL BEFORE USE
Observe all safety precautions; keep hands and feet away from rotor and other
moving parts. Keep spectators at a safe distance.
1Make sure there is a gap between the blades and the ground / crop.
2Select an area clear of loose debris that could be picked up.
3Set the engine choke, and suitable idling speed with the throttle.
4Place one foot on top of the deck body to give a firm and balanced position. Pull the
starter cord firmly, allowing the cord to return to return to the housing slowly (one or
two strong pulls should start the engine).
5After a few seconds warming up at idling speed, move the throttle to the factory pre-set
working position to give a normal/working engine R.P.M of 3600 max.
5.3 MOWER CUTTING
HEIGHT
5.4 STARTING THE ENGINE
NOTE If the throttle is altered to increase the engine R.P.M beyond the
reco ended level, the guarantee ay beco e invalid. In addition to this, cutting
efficiency will be reduced, fuel consu ption will increase and excessive vibration
could be caused, resulting in a potential danger to personnel and da age to
co ponents.

11
ELECTRIC START
Push button electric start engine options can be supplied if required. Simply hitch up the mower,
connect the electrical supply plug to the ATV socket and turn the ignition key to start the mover.
Observing all the precautions mentioned above in ‘Starting the mower’.
The amount of grass or weeds to be cut dictates the forward speed; slow forward
speeds give better results in most cases. Ensure you follow the procedure below.
NORMAL FORWARD SPEED (1 kph－
－－
－very heavy use－
－－
－10 kph －
－－
－very light use)
Start off in the slowest speed possible, ensure the mower is working efficiently
with the engine set at maximum RPM and not labouring. (If this is not possible due
to very heavy cutting conditions, raise cutting height of blades and be prepared to
go over twice with machine set lower on 2nd pass, leave at least 24 hours in
between 1st and 2nd cut to allow grass to dry out).
Increase forward speed until the RPM of the engine starts to slow down (This is
working the engine too hard for conditions) – slow down, let the engine regain full
RPM and go through the same process but stop short of speed which made
engine labour previously. It is important always to listen to note of engine to
ensure engine and mower are working efficiently, slow down or stop once engine
starts to labour.
When moving from normal working conditions to
heavier cutting, it may be evident that the engine dies
down and loses revs. SLOW DOWN IMMEDIATELY to
allow the engine revs to build up again to normal
working speed. Follow the procedure detailed above in
“Normal Forward Speed”. Expected forward speed will
be much lower in heavy conditions.
FAILURE TO DO THIS WILL RESULT IN CLUTCH SLIP
AND ULTIMATELY SEVERE DAMAGE TO THE CLUTCH
AND DRIVE BELTS.
5.5 FORWARD SPEED

12
When stopping the mower after a period of heavy use run the machine at half working speed in a
stationary position, for at least 4 minutes, to allow the drive belts to cool down.
1Show caution to hot parts e.g. engine exhaust, belts etc after engine is switched off.
2Ensure the mower drawbar has been adjusted to allow the mower to run directly behind the
towing vehicle and is not in an offset position
3When the mower has cooled down (Min 1hr after last used) ensure all grass has been
removed from engine cooling fins, drive belt area, and rotors before operating again.
When the mower is being moved from one site to another it is advisable to raise the deck to
the highest position (Transport position, See section 5.3 “Mower cutting height”)
The engine must be stopped and the blades at a standstill before adjusting to the transport
position.
Remove any crop debris from the deck before leaving the field.
Never move from one site to another with the engine running.
Please note the AT – Flail Mower is not road legal, and should not be used on public
roadways
The main purpose of the anti scalping roller is to prevent damage. If a wheel drops into a hole,
or there is uneven ground between the wheels, the roller takes the weight of the mower,
avoiding the flails scalping the ground; combined with the side skids the mower provides good
protection to the rotor.
The anti scalping roller has the added advantage of-enabling kerb side grass to be cut with no
difficulty, by allowing the wheel to hang over the kerb edge.
The factor pre-set position of the anti scalping roller and side skids are suitable for most
situations.
However, if the mover is used in rough conditions or regularly in heavy crops, the roller and
side skids should be lowered, to increase the clearance between the flail and the ground
when the roller comes into use.
In circumstances where the mower is being used as a “Finishing Mower” and a striped appearance is
desired, the roller can be set down using the various hole positions to give the required cutting height,
then the wheels can be lifted clear of the ground.
5.6 STOPPING THE MOWER
5.7 TRANSPORT POSITION
5.8 ANTI-SCALPING ROLLER/SIDE SKIDS

13
Maintenance Schedule
Maintenance Operation: Hourly Daily Weekly Seasonal
Engine (See Engine manufacturers manual)
● ● ● ●
Remove excess crop gathered on deck
● ● ● ●
Remove excess crop wrapped around rotor
ends
● ● ● ●
Visual check to ensure nothings loose
● ● ●
Grease Height Adjuster
● ● ●
Grease Rear Roller
● ● ●
Grease Rotor Bearings
● ● ●
Tyre Pressures
● ●
Drive belt inspection
● ●
Rotor Bearing inspection
● ●
Wheel bearing inspection
● ●
Oil 50mm coupling
● ●
Swivel hitch Bush Wear
● ●
Check All Fasterner′s are tight and intact
● ●
Safety Chain Guard inspection
● ●
Safety Decals intact
● ●
Safety Guards Intact
● ●
Check Blade wear / condition
●
Check Metal Fatigue
●
Clutch Wear / Function
●
6.1 ENGINE
Refer to engine manufacturers manual, for servicing and maintenance of the engine.
6.2 EXCESS CROP BUILD UP
Remove all crop deposits from the deck, and engine area. Build up of crop deposits could result in
heat build and fires Disconnect the spark plug lead. Remove any crop that is wrapped around the end
of the rotor (A) or on the underside of the deck. Raise the deck to its max height to assist access to
the rotor shaft.
MAINTENANCE
6
A

14
6.3 VISUAL CHECK
Make a visual check around the mower, check for missing / loose parts or damaged / worn
components. All faults must be repaired and missing parts replaced.
6.4 TYRE PRESSURES
6.5 ROTOR BEARING INSPECTION
Rotate rotor shaft by hand and feel for any roughness in the bearings. Also try to pull the shaft from
side to side to see if any movement is found. If symptoms persist strip down the rotor-housing unit
and inspect bearings.
6.6 WHEEL BEARING INSPECTION
Jack one side of the mower body up, so the wheel is just off the ground. Rotate the wheel by hand,
and check the wheel alignment. To check the bearing, try to move the wheel from left to right and feel
for any play in the bearings (A), ensure the wheel-locking bolt is tight before you start and follow any
jacking procedures. If any play is found, remove the wheel and inspect bearings. Replace any faulty
bearings.
6.7 GREASING 50mm COUPLING / BUSH WEAR
Check coupling for signs of damage or wear, swivel the coupling 360 degrees and check that
the bushes are not too worn. Replace any worn or damaged parts.
Grease the coupling regularly!
6.8 GENERAL INSPECTION
Check the mower to ensure all fasteners are tight and all safety guards / chains are intact and fitted
securely. Check all safety-warning decals, Replace any defective guards or damaged decals.

15
6.9 ROTOR FLAIL MAINTENANCE
When breaking or losing a knife, it is important to replace it immediately. Failure to do this can cause
serious unbalancing problems. At the time of replacement, the opposite knife on the rotor should be
checked for wear. If it is partially or well worn then if should be replaced to maintain an accurate
weight balance. When the first cutting edge is becoming blunt, the whole set of flails should be turned
around. (Using blunt knives will reduce the cutting efficiency and increase fuel consumption).
Replacing or reversing the knives follows this simple procedure:
(A) Ensure mower engine has stopped and the knives have stopped rotating. Switch off the
fuel tap and let the machine cool down for 5 minutes. Disconnect the spark plug cap to
ensure the engine cannot be started.
(B) Raise the mower to its max cutting height.
(C) Carefully raise the drawbar to an incline position, so that height adjuster bar at the rear of
the mower takes the weight. NB; Do not attempt this with the wheels behind version; raise the
front jack to its max height.
(D) Slacken and take out the shackle bolt.
(E) Replace or turn around blades (Note the direction of rotation)
(F) Replace shackle bolt securely, but still allowing the shackle to swing on the fixing bush.
Never use cracked or repaired shackles when replacing
knives. If the shackle fixing has become damaged or worn,
replace with new parts.

16
6.10 CHANGING THE BELTS
Belts changing instructions;
1. Remove cover off the belts housing. 2. Release the locknut of the
tensioner arm.
3. Un-tighten the belts by turning the tensioning pulley arm.
Check belts wear and tension regularly.
Over- and under-tensioning will cause premature wear of the belts.

17
4. Remove and replace the worn belts. Put / turn the belts on to the wheels one at
a time.
5. Tighten the belts by turning the tensioning pulley arm back until belts tightened
up to a position where they still can be compressed 10-15mm by hand
(measured in between pulley and the counter run belt).
Specifications / measurement of the
belts used can be found on the belts
housing cover or on the first page of
this manual.

18
6. Fix the pulley in position with the locknuts.
7. Fit the belts housing cover.

19
6.11 REPLACING THE CLUTCH
Clutch replacing instructions;
1. Remove the belts (see pt 6.10, step 1-4).
2. Remove the locknut of the clutch assembly.
3. Pull the clutch assembly off the engine crankshaft, use additional tools (e.g. puller
tool) if needed and then install a new clutch.
Worn clutch will cause premature wear of the belts!
Check the clutch friction pads against the wear regularly,
replace the clutch assembly if pads worn out!