IronCraft FRF Series Application guide

FRF SERIES
OFFSET FLAIL MOWER
OPERATION & PARTS MANUAL
Read and understand the manual. is manual provides information and procedures to
safely operate and maintain the FRF Series Oset Flail Mower.
August 2023

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TABLE OF CONTENTS
Start Here. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section 1: Assembly and Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 2: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section 3: Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 4: Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 5: Specications & Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 7: Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 8: Parts illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table of COntents

Ironcraftusa.comStart Here 3
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START HERE
Never carry out maintenance or cleaning work unless the PTO has been disengaged,
the engine switched off, the hand brake engaged, and the tractors wheels chocked
in position by a block or stone under the wheels.
Congratulations! You’ve just added an IronCra attachment to your arsenal. If you
have any questions about how to use your new oset ail mower - don’t hesitate to reach
out to your local IronCra dealer!
Tractor Check
Before starting the machine, check that your tractor matches the
required horsepower to run properly. You’ll be glad you did.
Register Your warranty
Help us help you in case of a manufacturing defect or meteor strike* using
the information on page #4. * = meteor strike not covered by warranty.
After the rst 2 operating hours,
check that all screws and bolts are correctly torqued.
Check the condition of the machine
Check all parts (cardan shaft, hammers, knives, belts) to make sure they
haven’t been damaged during transport and that the accessories are
complete and in good condition.
01
02
03
05
Check the greasing points and oil levels
Refer to gure #1 (page #5) for grease points, oil type, and greasing
frequency.
Enjoy!
You’re now ready to make the toughest terrain bow to your will.
04
06

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Important Safety Information 4
In addition to design and conguration of equipment, hazard control and accident prevention are
dependent upon the awareness, concern, prudence and proper training of personnel involved in the
operation, transport, maintenance and storage of equipment.
IMPORTANT SAFETY INFORMATION
SAFETY ALERTS
Do not allow anyone to operate this equipment who has not fully read and
comprehended this manual and who has not been properly trained in the safe
operation of the equipment.
The SAFETY ALERT SYMBOL indicates there is a potential hazard to personal safety
involved and extra safety precaution must be taken. When you see this symbol, be alert
and carefully read the message that follows it.
1. Operator should be familiar with all functions of the unit.
2. Operate implement from the driver’s seat only.
3. Make sure all guards and shields are in place and secured before operating the implement.
4. Do not leave tractor or implement unattended with engine running.
5. Dismounting from a moving tractor could cause serious injury or death.
6. Do not stand between tractor and implement during hitching.
7. Keep hands, feet, and clothing away from power-driven parts.
8. Wear snug tting clothing to avoid entanglement with moving parts.
9. Watch out for wires, trees, etc., when raising implement. Make sure all persons are clear of
working area.
10. Turning tractor too tight may cause implement to ride up on wheels. This could result in injury
or equipment damage.
Thoroughly read and understand the instructions given in this manual before operation.
Refer to the “Safety Decal”, read all instructions noted on them.
DANGER
WARNING
CAUTION

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SHUTDOWN AND STORAGE
USE SAFETY LIGHTS AND DEVICES
• Lower machine to ground, put tractor in park, turn o engine, and remove the ignition key.
• Detach and store implements in a area where children normally do not play. Secure implement
by using blocks and supports.
• Slow moving tractors, self-propelled equipment, and towed implements can create a hazard
when driven on public roads. They are dicult to see, especially at night.
• Flashing warning lights and turn signals are recommended whenever driving on public roads.
Use lights and devices provided with implement.
BE AWARE OF SIGNAL WORDS
A signal word designates a degree or level of hazard seriousness. The signal words are:
Indicates an imminently hazardous situation which, if not
avoids, will result in death or serious injury. This signal
word is limited to the most extreme situations, typically
for machine components that, for functional purpose,
cannot be guarded.
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury, and
includes hazards that are exposed when guards are
removed. It may also be used to alert against unsafe
practices.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
DANGER
WARNING
CAUTION
For your protection Thoroughly read and understand the “safety label” section,
read all instructions noted on them.

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Important Safety Information 6
TRANSPORT MACHINERY SAFELY
• Comply with state and local laws.
• Maximum transport speed for implement is 20 mph. Do not exceed. Never travel at a speed
which does not allow adequate control of steering and stopping. Some rough terrain require a
slower speed.
• Sudden braking can cause a towed load to swerve and upset. Reduce speed if towed load
is not equipped with brakes.
• Use the following maximum speed - tow load weight ratios as a guideline:
20 mph when weight is less than or equal to the weight of tractor.
10 mph when weight is double the weight of tractor.
• IMPORTANT: Do not tow a load that is more than double the weight of tractor.
TRANSPORT MACHINERY SAFELY
• Riders obstruct of operator’s view, they could be struck by foreign objects or thrown from the
machine.
• Never allow children to operate equipment.
PRACTICE SAFE MAINTENANCE
• Understand procedure before doing work. Use proper tools and equipment. refer to
Operator’s Manual for additional information.
• Work in a clean dry area.
• Lower the implement to the ground, put tractor in park, turn o engine, and remove key
before performing maintenance.
• Allow implement to cool completely.
• Do not grease or oil implement while it is operation.
• Inspect all parts. Make sure parts are in good condition and installed properly.
• Remove buildup of grease, oil or debris.
• Remove all tools and unused parts from implement before operation.
PREPARE FOR EMERGENCIES
• Be prepared if a re starts.
• Keep a st aid kit and re extinguisher handy.
• Keep emergency numbers for doctor, ambulance, hospital and re department near phone.
WEAR PROTECTIVE EQUIPMENT
• Protective clothing and equipment should be worn.
• Wear clothing and equipment appropriate for the job. Avoid loose tting clothing.
• Prolonged exposure to loud noise can cause hearing impairment or hearing loss. Wear
suitable hearing protection such as earmus or earplugs.
• Operating equipment safely requires the full attention of the operator. Avoid wearing
radio headphones while operating machinery.

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AVOID HIGH PRESSURE FLUIDS HAZARD
• Escaping uid under pressure can penetrate the skin causing serious injury.
• Avoid the hazard by relieving pressure before disconnecting hydraulic lines.
• Use a piece of paper or cardboard, not body parts, to check for suspected leaks. Wear
protective gloves and safety glasses or goggles when working with hydraulic systems.
• If an accident occurs, see a doctor immediately. Any uid injected into the skin must be
treated within a few hours or gangrene may result.
SAFETY LABELS
Your Flail Mower comes equipped with all safety labels in place. They were designed to help you
safely operate your implement. Read and follow their directions.
1. Keep all safety labels clean and legible.
2. Replace all damaged or missing labels. To order new labels go to your nearest Ironcraft dealer or
visit our dealer locator at IroncraftUSA.com.
3. Some new equipment installed during repair requires safety labels to be axed to the replaced
component as specied by Cosmo. When ordering new components make sure the correct safety
labels are included in the request.
4. Refer to this section for proper label placement. To install new labels:

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Introduction 8
INTRODUCTION
IronCraft welcomes you to the growing family of new product owners. This implement has been
designed with care and built by skilled workers using quality materials. Proper assembly, maintenance,
and safe operating practices will help you get years of satisfactory use from the machine.
APPLICATION
The Flail Mowers are designed for Category 1 - three point hitch or Quick-Hitch System mounting.
These Fixed Bar Flail Mowers are ideal for ripping, leveling, nish grading, and backlling applications
at feedlots, outdoor arenas, building sites, and maintenance operations on farm and ranch lanes or
roadways.
USING THIS MANUAL
• This Operator’s Manual is designed to help familiarize you with safety, assembly, operation,
adjustments, troubleshooting, and maintenance. Read this manual and follow the
recommendations to help ensure safe and ecient operation.
• The information contained within this manual was current at the time of printing. Some parts
may change slightly to assure you of the best performance.
• To order a new Operator’s or Parts Manual contact your authorized dealer. Manuals can also be
printed from the Cosmo Service & Support Center by your dealer.
TERMINOLOGY
“Right” or “Left” as used in this manual is determined by facing the direction the machine will
operate while in use unless otherwise stated.
DEFINITIONS
“Note:” A special point of information that the operator must be aware of before continuing.
“Important:” A special point of information related to its preceding topic. The intention is that this
information should be read and noted before continuing.
OWNER ASSISTANCE
The Warranty Registration card should be lled out by the dealer at the time of purchase. This
information is necessary to provide you with quality customer service. If customer service or repair
parts are required contact a dealer. A dealer has trained personnel, repair parts and equipment
needed to service the machine.
The parts on your machine have been specially designed and should only be replaced with genuine
parts.
SERIAL NUMBER PLATE
For prompt service always use the serial number and model number when ordering parts from your
dealer. Be sure to include your serial and model numbers in correspondence also.

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SECTION 1: ASSEMBLY AND SET-UP
TRACTOR REQUIREMENTS
This mower is designed with a 3-Point category I hitch. Tractor horse power rating should not exceed
80 PTO horse power.
ASSEMBLY
Refer to the parts illustration.
TRACTOR HOOK-UP
• Be certain that tractor draw bar will not interfere. Move draw bar ahead or remove if
required. Draw bar should also be checked for clearance when unit is being raised for the
rst time.
• Align lower link arms of tractor to hitch clevises on mower. Insert lower hitch pins into
lower ball swivels and attach linch pins.
• Attach tractor top link to upper oating hitch on mower with pin supplied. Secure with
lock pin.
• Adjust tractor top link in or out to place upper hitch pin vertically above or slightly behind
lower hitch pins to allow mower otation. The mower should be run with the back 15
degrees lower than the front.
DRIVELINE INSTALLATION
• Slide driveline end with extended safety cone over splined shaft of gearbox and secure
with attaching device.
• Slide driveline over tractor’s splined PTO shaft and secure with locking device of driveline.
• Driveline should now be moved back and forth to insure that it is secure on the PTO shaft
of the tractor and mower gearbox.
• Attach chain from the driveline shield to one of the upper hitch braces to ensure that the
shield does not rotate.
• Should driveline require shortening:
• Hold the half-shafts next to each other in the shortest working position and mark them.
• Shorten inner and outer guard tubes equally.
• Shorten inner and outer sliding proles by the same length as the guard tubes.
• Proper overlap is a minimum of one-half the length of each tube, with both tubes being
of equal length.
• Round o all sharp edges and remove burrs. Grease sliding proles.
Tractor PTO shield and all mower guards must be
in place at all times during operation!
CAUTION

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Section 2: Operating Instructions 10
SECTION 2: OPERATING INSTRUCTIONS
TRANSPORTING
NOTE: Always disengage PTO before raising mower to transport position.
• When raising the mower to transport position, be sure that driveline does not contact
tractor or mower. Adjust and set the tractor’s 3-point hitch lift height so that the driveline
does not contact mower deck in the fully raised position.
• Be sure to reduce tractor ground speed when turning, leaving enough clearance so that the
mower does not contact obstacles such as buildings, trees or fences.
• Select a safe ground travel speed when transporting from one area to another. When
traveling on roadways, transport in such a way that faster moving vehicles may pass safely.
• When traveling over rough or hilly terrain, shift tractor to a lower gear.
When traveling on public roads, whether at
night or during the day, use accessory lights and
devices for adequate warning to operators of
other vehicles. Comply with all Federal, State,
and local laws.
CAUTION
MOWING INSTRUCTIONS
• Clear area to be mowed of objects and debris that might be picked up and thrown by the
mower blades.
• Grass is best cut when it is dry. Mowing wet grass can cause plugging resulting in grass
clumps behind the mower.
• Grass should be mowed frequently as shorter clippings deteriorate faster.
• If mowing extremely tall grass, it is best to raise cutting height and mow the area, then
lower cutting height and mow a second time at the desired height.
OPERATING INSTRUCTIONS
Proper servicing and adjustments are the key to the long life of any machine. With careful and
systematic inspection of the mower, costly maintenance, time and repair can be avoided.
Before beginning to mow, the following inspection should be performed:
• Check oil level in gearbox.
• Check that all plugs in gearbox have been replaced and tightened properly.
• Be sure all mower knives, bolts and nuts are tight.
• Be certain all guards and shields are in place and secure.
• Grease driveline shaft and all other grease ttings.
• Clear area to be mowed of rocks, branches and other foreign objects.
• Lower mower to ground. Set tractor throttle at approximately 1/4 open. Engage PTO to