Flail Cutter 6903303 EnUS SM 11-08

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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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

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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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

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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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.
Always use the serial number of the flail cutter when

requesting service information or when ordering parts. DELIVERY REPORT

Early or later models (identification made by serial
number) may use different parts, or it may be necessary Figure 4
to use a different procedure in doing a specific service
operation [Figure 1].
MANUAL STORAGE LOCATION
Read and understand the Operation & Maintenance

Manual before operating the flail cutter.
Figure 2
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. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
4].
Earlier Models P-57633
III Flail Cutter Service Manual

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IDENTIFICATION AND MACHINE SIGNS (DECALS)
HYDRAULIC MOTOR
HYDRAULIC CONTROL VALVE

ROLLBACK HOOK
STEPS
7106129 (1)
68156993
68156993 (3)
(3)

7100705 (1)
REAR 7100706 (1)

RUBBER SKIRT
SIDE FRONT
SKID SHOE
RUBBER SKIRT RUBBER SKIRT
7107788 (2)
P-57631
IV Flail Cutter Service Manual

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IDENTIFICATION AND MACHINE SIGNS (DECALS) (CONTD)
MANUAL STORAGE CONTAINER
EARLIER MODELS LATER MODELS

DRIVE PULLEY SHIELD
MOUNTING FRAME

HYDRAULIC QUICK COUPLERS
7107788 (2) 6734443 (2) 68156993
(3)
Drive Pulley Shield has been removed for picture clarity.
P-57633
V Flail Cutter Service Manual

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VI Flail Cutter Service Manual

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SAFETY AND MAINTENANCE SAFETY AND
MAINTENANCE
DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Attachment Mounting Frame . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Bob-Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Checking Mechanical Linkage For Rotor Shut-Off Device. 10-20-7
Checking The Rotor Shut-Off Device. . . . . . . . . . . . . . . . . 10-20-4
Rollback Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
REAR HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Rear Hatch Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
10-01 Flail Cutter Service Manual

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TROUBLESHOOTING
Chart
If the attachment is not working correctly, check the

hydraulic system of the machine thoroughly before
WARNING making any repairs on the attachment. 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.
Instructions are necessary before operating or Connect a flow meter to the machine to check the
servicing machine. Read and understand the hydraulic pump output, relief valve setting and tubelines
Operation & Maintenance Manual, Operators to check flow and pressure. (See the machine Service
Handbook and signs (decals) on machine. Follow Manual for the correct procedure to connect the flow
warnings and instructions in the manuals when meter).
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE CORRECTION

Abnormal machine vibrations. The knife rotor is out of balance. Rebalance the rotor.

One or more of the knives are broken. Replace broken knives.
Loss of a counterweight. Replace counterweight.
Poor Cutting. The rotor does not reach the correct Check belt tension.
working speed.
Machine adjustment does not comply Check transmission rpm.
with the instructions.
Forward speed is too fast. Adjust forward speed.
Worn knives or parts. Replace knives or sharpen uniformly.
DO NOT change their weight and
position on the rotor.
Machine absorbs too much power. Hatch or roller out of adjustment. Adjust the hatch and/or roller.
Too much material and low machine Adjust power and forward speed.
power.
The roller does not turn. Dry roller. Lubricate roller.
Material is fouling the guards. Clean the guards.
Roller is bent. Replace roller.
Sandy soil. Fit roller with larger roller diameter.
Casing is punctured. Worn sheet metal. Replace the casing or scrap the
attachment.
Repair the casing if the rotor is still
operational.
Bearings break frequently. Casing is bent by excessive side loads. Replace casing.
No lubrication. Lubricate bearings.
Attachment overloaded. Adjust power and forward speed.
Rotor installed wrong. Reinstall rotor.
Rotor out of adjustment. Adjust rotor.
10-10-1 Flail Cutter Service Manual

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DAILY INSPECTION
Attachment Mounting Frame
Figure 10-20-5
2
1
P-57632
Inspect the Bob-Tach wedge mounts (Item 1), 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

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.
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.

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DAILY INSPECTION (CONTD) 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. Levers
must be fully down and locked. Failure to secure P-79780
wedges can allow attachment to come off.
W-2715-0208
The wedges must extend through the holes in the
attachment mounting frame, securely fastening the
Figure 10-20-7
attachment to the Bob-Tach [Figure 10-20-8].
NOTE: If the wedge does not contact the lower edge

of the hole, the attachment will be loose and
can come off the Bob-Tach.

Inspect the mounting frame on the attachment. (See the
machine's Operation and Maintenance Manual for
inspecting the Bob-Tach). Replace any parts that are
damaged, bent or missing. Keep all fasteners tight. Look
for cracked welds. Contact your Bobcat dealer for repair
or replacement parts.
P-41502A Lubricate the wedges. (See the machines Operation &

Maintenance Manual for the correct procedure.)
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).
The levers and wedges must move freely [Figure 10-20-

7].

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Bob-Tach (Contd)
Power Bob-Tach
WARNING
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers P-41500A
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
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).
1 Figure 10-20-12

2
B-15993A
Figure 10-20-10
P-79780
Work Machine Switch

The wedges must extend through the holes in the
attachment mounting frame, 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, the attachment will be loose and
can come off the Bob-Tach.
Inspect the mounting frame on the attachment. (See the

machine's Operation and Maintenance Manual for
P-88124 inspecting the Bob-Tach). Replace any parts that are
damaged, bent or missing. Keep all fasteners tight. Look
for cracked welds. Contact your Bobcat dealer for repair
or replacement parts.
Lubricate the wedges. (See the machines Operation &

Maintenance Manual for the correct procedure.)

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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.
NOTE: The rollback hook must swing freely.
Figure 10-20-13
P-70383
Place the flail cutter flat on the ground, fully lower the lift
arm(s) [Figure 10-20-14].
Engage the auxiliary hydraulics. (See the Machine
1 Operation & Maintenance Manual for the correct
procedure.) The rotor should rotate.
Figure 10-20-15

P-60268
Inspect the rollback hook (Item 1) [Figure 10-20-13]. The 2

rollback hook must swing freely. Inspect for cracks, loose
hardware or damage. Replace any parts that are
damaged bent or missing.
P-70370
Checking The Rotor Shut-Off Device
WARNING P-70387
Never operate without rotor shut-off device. Raise the lift arm(s), 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. 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.
Use the following procedures to check the rotor shut-off Lower the lift arm(s) fully to check that the rotor does not
device. restart.
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. (See the Flail Cutter Operation & of the above procedures, see your Bobcat
Maintenance Manual for the correct procedure.) dealer for service.
While in the operator seat, seat belt fastened and seat

bar lowered, start the engine.

18 of 110
DAILY INSPECTION (CONTD) Procedure 3
Checking The Rotor Shut-Off Device (Contd) Figure 10-20-18
Procedure 2
Figure 10-20-16
P-70383
Place the flail cutter flat on the ground, fully lower the lift
arm(s) [Figure 10-20-18].
P-70383
Engage the auxiliary hydraulics. (See the Machine

Place the flail cutter flat on the ground, fully lower the lift Operation & Maintenance Manual for the correct

arm(s) [Figure 10-20-16]. procedure.) The rotor should rotate.
Engage the auxiliary hydraulics. (See the Machine Figure 10-20-19

Operation & Maintenance Manual for the correct
procedure.) The rotor should rotate.
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, when
the mounting frame (Item 1) comes in contact with the
P-70382
shut-off lever (Item 2) [Figure 10-20-19], the rotor must
come to a complete stop within 7 seconds.
Tilt the Bob-Tach back, 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.
10-20-17], the rotor must come to a complete stop within
7 seconds. 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. after the lift arms are fully lowered during any
of the above procedures, see your Bobcat
NOTE: If the rotor does not come to a complete stop dealer for service.
within seven seconds or begins rotating again
after the lift arms are fully lowered during any
of the above procedures, see your Bobcat
dealer for service.

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DAILY INSPECTION (CONTD)
Checking The Rotor Shut-Off Device (Contd)
Restart Rotor Rotation
Disengage the auxiliary hydraulics by taking it out of

detent, re-engage the auxiliary hydraulics into detent.
The rotor should start rotating.
NOTE: Shut-off valve WILL NOT reset unless the

auxiliary hydraulics are cycled off first.

20 of 110
DAILY INSPECTION (CONTD)
Checking Mechanical Linkage For Rotor Shut-Off

Device WARNING
AVOID BURNS
Hydraulic fluid, tubes, fittings and quick couplers
WARNING can get hot when running machine and attachments.
Be careful when connecting and disconnecting quick
couplers.
Never operate without rotor shut-off device. W-2220-0396
Never modify the rotor shut-off device and check
that it is operating properly.
W-2628-0405 Figure 10-20-21
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:

When fluids are under pressure.
Flying debris or loose material is present.
Engine is running. P-57706
Tools are being used.

W-2019-0907
Check for loose or missing bolts mounting the control
valve [Figure 10-20-21] to the frame.
Stop the engine and exit the loader. (See the Flail Cutter
Operation & Maintenance Manual for the correct Check hydraulic hoses for loose connections.
procedure.)
Repair or replace as needed.
Figure 10-20-20
Figure 10-20-22
2
1
3
P-57690
P-57707
Remove the four bolts (Item 1), then remove cover (Item
2) [Figure 10-20-20]. Check the condition of the connector link (Item 1) [Figure
10-20-22].
Check if the pivot bolt (Item 3) [Figure 10-20-20] in the
shut-off lever is loose or missing.

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Follow the flail cutter service schedule for routine

maintenance. It is located on top of the attachment, just
right of the hydraulic control valve.
Check the following items every 8 hours of operation:
Check rotor shut-off device and rollback hook for

proper function. Rollback hook must swing freely.
Check the knives and mounting hardware for cracks

or damage. Replace if necessary.
Check deck, shields and roller. Replace or repair if

damaged.
Check for damaged or missing decals. Replace if

necessary.
Check for damaged or leaking hydraulic hoses or

fittings. Replace if necessary.
Lubricate all grease points.

Check the following every 50 hours of operation:
Check belt tension and adjust if required.
WARNING 7100706

Diesel fuel or hydraulic fluid under pressure can Service schedule decal [Figure 10-20-23].
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
WARNING
Never operate without rotor shut-off device.
Never modify the rotor shut-off device and check
that it is operating properly.
W-2628-0405

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LUBRICATION Figure 10-30-4
Lubricate the following locations after every 8 hours of

operation.
NOTE Always use a good quality lithium based
grease when lubricating the attachment.
1
Figure 10-30-1
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 1) [Figure 10-30-1] Figure 10-30-5

Figure 10-30-2

1 1
1
2 3
P-57687 P-57636
Remove bolts (Item 1), then remove cover plate (Item 2)

[Figure 10-30-2]. 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. pivot arm.
Lubricate fitting (Item 3) [Figure 10-30-2] on the left side Figure 10-30-6
of the mower. Replace cover plate and bolts.
Figure 10-30-3
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. the roller.
Flail Cutter
10-30-1 Service Manual
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Flail Cutter
10-30-2 Service Manual
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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. Power 1
requirements are also affected by the roller
height adjustment. The degree of mulching is
also reduced as the rear hatch is opened
further.
Stop the engine and exit the machine.
P-60552
WARNING Loosen rear hatch pivot bolts (Item 1) [Figure 10-40-1]

on both sides of the flail cutter.
Before you leave the operators seat:
Lower the lift arms, put the attachment flat on the
Figure 10-40-2
ground.
Stop the engine.
Engage the parking brake.
Raise seat bar.

(Foot Pedal Controls) Move pedals until both
lock.
(Advanced Control System-ACS) Move the
hydraulic controls to the NEUTRAL POSITION to
make sure that both lift and tilt functions are
deactivated.
The seat bar system must deactivate the lift and
tilt control functions when the seat bar is up. 1
Service the system if hand controls do not P-60545
deactivate.
(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, move the rear hatch to the
deactivated. desired position.
The seat bar system must deactivate these
functions when the seat bar is up. Service the NOTE: When installing the bolts (Item 1) [Figure 10-
system if controls do not deactivate. 40-2] that hold the rear hatch in position,
W-2463-0603 install them from the inside towards the
outside. Placing the nut on the outside of the
flail cutter.
Re-install the bolts securing the rear hatch in position.

WARNING Tighten bolts (Item 1) [Figure 10-40-2] on both sides of
the flail cutter to 65-70 ft.-lb. (88-94 Nm) torque.
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.-lb. (88-94 Nm) torque.
Engine is running.
W-2019-0907

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REAR HATCH (CONTD) 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.
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.
When the rear hatch is in the fully open position, the cut
material exits the flail cutter over the roller [Figure 10-40-
P-60540 5].

NOTE: Cutting wet grass is difficult and absorbs a lot
The fully closed position is generally used to mulch
of hydraulic power. Adjust travel speed as
prunings and when a fine homogeneous mulch is
needed.
desired.
When the rear hatch is in the fully closed position, the

material being mulched will circulate between the rotor
and the roller [Figure 10-40-3].
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].

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DRIVE BELTS Figure 10-50-3
Adjustment
1
NOTE: Check belt tension every 50 hours of use. 1
WARNING
of the following conditions exist: P-57637 P-57638
Loosen the four bolts (Item 1) [Figure 10-50-3]
Engine is running.
supporting the gear box and extension.
W-2019-0907
Installation: Tighten bolts to 65-70 ft.-lb. (88-95 Nm)
torque.
Figure 10-50-1
Figure 10-50-4
1

1 2
2 P-57634
P-57639
Remove bolts (Item 1) [Figure 10-50-1].
Remove brush guard (Item 2) [Figure 10-50-1].
Loosen jam nut (Item 1), then turn the tension bolt (Item
Installation: Tighten bolts to 65-70 ft.-lb. (88-95 Nm) 2) [Figure 10-50-4] counterclockwise to increase belt
torque. tension. Turn the tension bolt clockwise to decrease belt
tension.
Figure 10-50-2
P-57635
Remove bolts (Item 1) and drive pulley shield (Item 2)

[Figure 10-50-2].

torque.

27 of 110
DRIVE BELTS (CONTD)
Adjustment (Contd)
Figure 10-50-5
BELT TENSION
Check belt tension by pressing forcefully on the belt.
Depending on model and the distance between pulleys,

the belt should move between 0.2-0.4 in. (5-10 mm)
[Figure 10-50-5].
Once the desired belt tension is obtained, tighten jam nut

(Item 1) [Figure 10-50-4].
Install drive pulley shield and brush guard.

28 of 110
HYDRAULIC SYSTEM
HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-10-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1 HYDRAULIC
SYSTEM
HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N
467500163 & BELOW, S/N 467300196 & BELOW) . . . . . . . . 20-20-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N

467500154 & ABOVE, S/N 467300197 & ABOVE). . . . . . . . . 20-21-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4

29 of 110

30 of 110
HYDRAULIC MOTOR Figure 20-10-3
Removal and Installation
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-57714
Figure 20-10-1
Remove the bolts (Item 1) [Figure 20-10-3].
Installation: Tighten the bolts to 90-100 ft.-lb. (125-140
Nm) torque.
1
Remove the hydraulic motor from the shaft housing.

1
P-57928
Mark and remove the hydraulic hoses (Item 1) [Figure

20-10-1].
Figure 20-10-2
P-57714
Cap hydraulic fittings (Item 1) [Figure 20-10-2].

31 of 110
HYDRAULIC MOTOR (CONTD)
Parts Identification
1. Shaft and Bearing

2. Housing
3. Cam Plate and Bronze Bushings
4. Rotating Group
5. Manual Control
6. Valve Plate
7. Distributor
5
3
7
6

2

32 of 110
HYDRAULIC MOTOR (CONTD) Figure 20-10-6
Disassembly and Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-57694
Figure 20-10-4
Remove roll pin (Item 1) [Figure 20-10-6].
Figure 20-10-7

1 1
P-57692
Clean the outside of the hydraulic motor. P-57695
NOTE: Place marks (Item 1) [Figure 20-10-4] on the

housing before beginning disassembly. Remove bolts (Item 1) and plate (Item 2) [Figure 20-10-
7] from the end housing.
Figure 20-10-5 Installation: Tighten the bolts to 180-200 in.-lb. (21-23
Nm) torque.
P-57693
Remove the bolt (Item 1) [Figure 20-10-5].

33 of 110
Disassembly and Assembly (Contd)
Figure 20-10-8 1
P-57700
1
Remove the valve plate (Item 1) [Figure 20-10-10].

P-57696 Figure 20-10-11
Remove gasket from cap (Item 1) [Figure 20-10-8].

Figure 20-10-9

1
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.
should be in this position during assembly before
installing cap.

34 of 110
Figure 20-10-12
1 1
P-57719
Remove divider plate (Item 1) from piston assembly

P-57729
[Figure 20-10-14].
Figure 20-10-15
Remove pivot bushing (Item 1) [Figure 20-10-12].
Figure 20-10-13

1
P-57732
P-57727
Compress washer and spring with a threaded rod and
nut. The remove snap ring (Item 1) [Figure 20-10-15].
Remove three needle bearings (Item 1) and nylon lock

ring (Item 2) [Figure 20-10-13].

35 of 110
Figure 20-10-16
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].

Figure 20-10-17
P-57721
1
Press bearing off shaft [Figure 20-10-19].
P-57735A
Remove O-ring (Item 1) and oil seal (Item 2) [Figure 20-

10-17].

36 of 110
Figure 20-10-20 1
1
P-57737
Installation: When installing the plate on the end

housing, align pegs (Item 1) [Figure 20-10-22] and put
P-57723
into position.
Remove washer (Item 1) [Figure 20-10-20]. Clean all parts in solvent and dry with compressed air.
Figure 20-10-21 Inspect all parts for wear or damage. Replace any worn

or damaged parts.
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
1
P-57724
Remove snap ring (Item 1) [Figure 20-10-21].

37 of 110

38 of 110
HYDRAULIC CONTROL VALVE (S/N A01P00143 & Figure 20-20-2
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW)
Removal And Installation
IMPORTANT
1
damage the system. P-57691
I-2003-0888
Mark all hoses for correct installation.
Remove the hoses (Item 1) [Figure 20-20-2].

IMPORTANT Installation: When installing hoses, inspect the O-ring(s)
on the fitting(s). Replace the O-ring if damaged.

Contain and dispose of any oil leakage in an
environmentally safe manner. Figure 20-20-3
I-2066-0395
Figure 20-20-1
2 P-57707
P-57690
Remove the retaining clip and side link (Item 1) [Figure
20-20-3].
Remove the two bolts (Item 1) from both sides of cover,

then remove cover (Item 2) [Figure 20-20-1].

39 of 110
HYDRAULIC CONTROL VALVE (S/N A01P00143 &
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Removal And Installation (Contd)
Figure 20-20-4
P-57757
Remove the three nuts (Item 1) [Figure 20-20-4] and

bolts.
Installation: Tighten bolts to 180-200 in.-lb. (21-23 Nm)

torque.
Remove the control valve.
Figure 20-20-5
P-57758
Installation: Inspect nylon spacer (Item 1) [Figure 20-

20-5] and replace if damaged.

40 of 110
HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW)
(CONTD)
1. Boot
2. Spool 1
3. Screw
4. Retainer
5. O-Ring
6. Relief Valve
7. Backup Ring 2
8. Housing
9. Seat 3
10. Spring
11. Load Check Valve
12. Ball
13. Plug 3
14. Orifice 6 4
15. Washer
16. Block 4
17. Spool Cover
18. Cap 5
5

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

41 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Disassembly
1
Clean the outside of the valve before disassembly.
Figure 20-20-6
1 1
P-56678
Remove the screws (Item 1) [Figure 20-20-8].
Figure 20-20-9
P-56677

Remove the relief valve (Item 1) [Figure 20-20-6].
1 2
Figure 20-20-7
P-56679
Remove the boot (Item 1) and retainer (Item 2) [Figure

20-20-9].
1
N-17086
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-20-7] from the relief valve.

42 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
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.
P-56680 Figure 20-20-13
Remove the screws (Item 1) [Figure 20-20-10].

Figure 20-20-11
P-56683
Remove the cap (Item 1) [Figure 20-20-13].
P-56681
Remove the retainer (Item 1) [Figure 20-20-11].

43 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
1
Figure 20-20-14
P-56686
1
2 Remove the screws (Item 1) [Figure 20-20-16].
Figure 20-20-17
P-56684
Remove the screws (Item 1) and spool cover (Item 2)

1
[Figure 20-20-14] from the spool.
NOTE: The spool cover is under spring pressure.
Figure 20-20-15
1
P-56687
Remove the block and spool assembly (Item 1) [Figure

20-20-17].
P-56685
Remove the spring (Item 1) [Figure 20-20-15].

44 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
2
Figure 20-20-18
P-56709
Remove the plug (Item 1) and washer (Item 2) [Figure

20-20-20].
P-56688 NOTE: Do Not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.
Separate the spool assembly [Figure 20-20-18].

Figure 20-20-21
Figure 20-20-19
Cut
3.50
1.125
1
3.0 P-56689
1.50 B-14674
Remove the block (Item 1) [Figure 20-20-21].

To remove the plug from the spool a holding fixture will
have to be made from a 1.50 inch thick x 3.50 inch wide x
3.0 inch long (38 mm thick x 89 mm wide x 76 mm long)
piece of hardwood. Drill a 1.125 inch (28.575 mm) hole in
the center of the hardwood block. Cut the block
lengthwise [Figure 20-20-19].
Clamp the spool in the blocks.

45 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
1 2
Figure 20-20-22
P-56692
1
Remove the spring (Item 1) and seat (Item 2) [Figure 20-
20-24].
P-56690 Figure 20-20-25
Remove the O-rings (Item 1) [Figure 20-20-22] from the

block.
Figure 20-20-23
P-56693
Remove the O-ring (Item 1) [Figure 20-20-25].
P-56691
Turn the valve over and remove the load check valve
(Item 1) [Figure 20-20-23].

46 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Figure 20-20-26 1
1 N-17085
Remove the O-ring (Item 1) [Figure 20-20-28] from the

plug.
P-56694 Figure 20-20-29
Remove the plug (Item 1) [Figure 20-20-26].

1
Figure 20-20-27
1
1
2
P-56696
Remove the plugs (Item 1) [Figure 20-20-29].
P-56695
Remove the spring (Item 1) and check ball (Item 2)

[Figure 20-20-27].

47 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Figure 20-20-30
N-17084

plugs.
Figure 20-20-31
P-56697
Remove the orifice (Item 1) [Figure 20-20-31].

48 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Assembly 2
Clean all parts in solvent and dry with compressed air.

1
Inspect all parts for wear or damage. Replace any worn
or damaged parts.

and O-rings with clean hydraulic fluid before installation. 2
Figure 20-20-32
P-56696
Install the plug (Item 1) [Figure 20-20-34]. Tighten the

1 plug to 198 in.-lb. (22,4 Nm) torque.
Install the plugs (Item 2) [Figure 20-20-34]. Tighten the

plugs to 120 in.-lb. (13,6 Nm) torque.

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]. Install the orifice
and tighten to 120 in.-lb. (13.5 Nm) torque.
Figure 20-20-33
N-17085
1
Install the O-ring (Item 1) [Figure 20-20-35] on the plug.
N-17084
Install the O-ring (Item 1) [Figure 20-20-33] on the plugs.

49 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Assembly (Cont'd)
1
Figure 20-20-36
2
1
P-56693
Figure 20-20-39
P-56695
Install the check ball (Item 1) and spring (Item 2) [Figure

2 1
20-20-36].
Figure 20-20-37
P-56692
Install the seat (Item 1) and spring (Item 2) [Figure 20-

20-39].
P-56694

plug to 41 ft.-lb. (56 Nm) torque.

50 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD) 1
Assembly (Cont'd)
Figure 20-20-40
P-56689
Place the spool in the hard wood blocks. Clamp the

blocks (Item 1) [Figure 20-20-42] in the vise.
P-56691 Install the block (Item 2) [Figure 20-20-42] on the spool.
NOTE: Do Not use anything other than hard wood

Install the load check valve (Item 1) [Figure 20-20-40].

blocks to grip the spool, or the spool will be
damaged.
Figure 20-20-41
Figure 20-20-43
1
1
2
P-56690
P-56709
Install the O-rings (Item 1) [Figure 20-20-41] on the

block.
Install the washer (Item 1) and plug (Item 2) [Figure 20-
20-43].
Tighten the plug to 198 in.-lb. (22.4 Nm) torque.
Remove the spool and wood blocks from the vise.

51 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Assembly (Cont'd)
1
Figure 20-20-44
P-56686
Apply the thread lock adhesive (Loctite 242) to the screw

threads. Install the screws (Item 1) [Figure 20-20-46].
Tighten the screws to 108 in.-lb. (12.2 Nm) torque.
P-56688
Figure 20-20-47
Assemble the spool [Figure 20-20-44].

Figure 20-20-45
2
1
P-56685
Install the spring (Item 1) [Figure 20-20-47].

P-56687
Install the spool assembly (Item 1) in the housing (Item 2)

[Figure 20-20-45].

52 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Assembly (Cont'd)
1
the screws.
Figure 20-20-48
P-56682
Install the O-rings (Item 1) [Figure 20-20-50] on the

retainer.
2
1 Figure 20-20-51

P-56684
Install the spool cover (Item 1) and screws (Item 2) 1

[Figure 20-20-48].
Tighten the screws to 108 in.-lb. (12,2 Nm) torque.
Figure 20-20-49
1 P-56681
Install the retainer (Item 1) [Figure 20-20-51].
P-56683
Install the cap (Item 1) [Figure 20-20-49].

53 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Assembly (Cont'd)
1
the screws.
Figure 20-20-52
1
1
P-56678
Install the screws (Item 1) [Figure 20-20-54]. Tighten the

screws to 108 in.-lb. (12.2 Nm) torque.
1
Figure 20-20-55

P-56680
2
Install the screws (Item 1) [Figure 20-20-52]. Tighten the
screws to 108 in.-lb. (12.2 Nm) 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.
P-56679
Install the retainer (Item 1) and boot (Item 2) [Figure 20-

20-53].

the screws.

54 of 110
BELOW, S/N 467500163 & BELOW, S/N 467300196 &
BELOW) (CONTD)
Assembly (Cont'd)
Figure 20-20-56
P-56677
Install the relief valve (Item 1) [Figure 20-20-56]. Tighten

the valve to 25 ft.-lb. (34 Nm) torque.

55 of 110

56 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE)
IMPORTANT
1
damage the system. P-57691
I-2003-0888
Mark all hoses for correct installation.
Remove the hoses (Item 1) [Figure 20-21-2].

IMPORTANT Installation: When installing hoses, inspect the O-ring(s)
on the fitting(s). Replace the O-ring if damaged.

Contain and dispose of any oil leakage in an
environmentally safe manner. Figure 20-21-3
I-2066-0395
Figure 20-21-1
2 P-57707
P-57690
Remove the retaining clip and side link (Item 1) [Figure
20-21-3].
Remove the two bolts (Item 1) from both sides of cover,

then remove cover (Item 2) [Figure 20-21-1].

57 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Figure 20-21-4
P-57757
Remove the three nuts (Item 1) [Figure 20-21-4] and

bolts.
Installation: Tighten bolts to 180-200 in.-lb. (21-23 Nm)

torque.
Remove the control valve.
Figure 20-21-5
P-57758
Installation: Inspect nylon spacer (Item 1) [Figure 20-

21-5] and replace if damaged.

58 of 110
HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE)
(CONTD)
1. Cap 1
2. Spool Cover
3. Bolt 3
4. Spring
5. Spring Guide 2
6. O-ring
7. Lower Cap
8. Spool
9. Housing
10. Plug 4
11. Poppet
12. Check Valve Body
13. Seal
14. Orifice 5
15. Back-up Ring
16. Relief Valve 6
3
17. Compensator
18. Orifice Disc
19. Snap Ring
7

6
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

59 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Disassembly
Clean the outside of the valve before disassembly. 1
Figure 20-21-6
P-71092
Remove the plug (Item 1) [Figure 20-21-8] from the

control valve.
Figure 20-21-9
P-71090

Remove the relief valve (Item 1) [Figure 20-21-6].
Figure 20-21-7
1
P-71093

plug.
1
P-71091
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-21-7] from the relief valve.

60 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Figure 20-21-10 1
1
2
P-71096
Remove the O-ring (Item 1) [Figure 20-21-12] from both

plugs.
P-71094 Figure 20-21-13
Remove the compensator compression spring (Item 1)

and the compensator (Item 2) from the port (Item 3)
[Figure 20-21-10].
2
Figure 20-21-11
1 P-71097
Remove the orifice (Item 1) from the port (Item 2) [Figure

20-21-13].
P-71095
Remove the 2 plugs (Item 1) [Figure 20-21-11] from the

control valve.

61 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
3
Figure 20-21-14
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].
P-71098
Figure 20-21-17
Remove the check valve body (Item 1) [Figure 20-21-14]

from the control valve.
Figure 20-21-15
1
P-71101

control valve.
P-71099

check valve body.

62 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
1
Figure 20-21-18
P-71103
Remove the 2 bolts (Item 1) and spool cover (Item 2)

[Figure 20-21-20].
1
P-71096 NOTE: The spool cover is under spring pressure.
Figure 20-21-21

three plugs.
3
Figure 20-21-19
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].

63 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Figure 20-21-22 1
1
P-71118
Remove the mower spool (Item 1) [Figure 20-21-24]

from the control valve.
P-71105 Figure 20-21-25
Remove the 4 bolts (Item 1) and the lower cap (Item 2)

3
[Figure 20-21-22] from the control valve.
Figure 20-21-23
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].
P-71106
Remove the 2 O-rings (Item 1) [Figure 20-21-23] from

the lower cap.

64 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
1
Figure 20-21-26
P-71109
Remove the plug (Item 1) [Figure 20-21-28] from the

control valve.
P-71114 Figure 20-21-29

load control valve.
Figure 20-21-27
1
P-71096

plug.
1
P-71096
Remove the O-ring (Item 1) [Figure 20-21-27] from the 3

plugs.

65 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Figure 20-21-30
1
2
P-71111
Remove the snap ring (Item 1) and orifice disc (Item 2)

[Figure 20-21-30] from port A of the control valve.

66 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Assembly
1
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear or damage. Replace any worn

or damaged parts.

and O-rings with clean hydraulic fluid before installation.
Figure 20-21-31
P-71109


2
1
P-71111
Install the orifice disc (Item 1) and snap ring (Item 2)

[Figure 20-21-31] into port A.
Figure 20-21-32
P-71093

67 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Assembly (Cont'd) 3
Figure 20-21-34
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.
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.
Install the O-ring (Item 1) [Figure 20-21-34] on the 3

Figure 20-21-37
plugs.
Figure 20-21-35
1
1
P-71118
P-71114 Install the mower spool (Item 1) [Figure 20-21-37] into

the control valve.
Install the 2 plugs (Item 1) [Figure 20-21-35]. Tighten the
plugs to 25 ft.-lb. (34 Nm) torque.


68 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
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

lower cap.
Figure 20-21-39
2
2
1
P-71103
Install the spool cover (Item 1) and 2 bolts (Item 2)

[Figure 20-21-41]. Tighten the 2 bolts to 9 ft.-lb. (12 Nm)
P-71105 torque.
Install the lower cap (Item 1) and 4 bolts (Item 2) [Figure

20-21-39]. Tighten the bolts to 9 ft.-lb. (12 Nm) torque.

69 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Assembly (Cont'd)
1
Figure 20-21-42
P-71101
1
Install the 2 plugs (Item 1) [Figure 20-21-44]. Tighten the
plugs to 25 ft.-lb. (34 Nm) torque.
P-71102 Install the plug (Item 2) [Figure 20-21-44]. Tighten the

Install the plastic spool cover cap (Item 1) [Figure 20-21-

Figure 20-21-45
42].
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.
plugs.

70 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Assembly (Cont'd)
2
Figure 20-21-46
P-71097
Install the orifice (Item 1) into the port (Item 2) [Figure

1 20-21-48].
2
P-71100 Figure 20-21-49
Install the poppet (Item 1) and compression spring (Item

2) into the port (Item 3) [Figure 20-21-46].
Figure 20-21-47
P-71096

plugs.
1
P-71098
Install the check valve body (Item 1) [Figure 20-21-47].

Tighten the check valve to 35 ft.-lb. (48 Nm) torque.

71 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Assembly (Cont'd)
Figure 20-21-50
1
P-71093
2
Figure 20-21-53
P-71095
Install the plug (Item 1) [Figure 20-21-50] into the control

valve. Tighten the plug to 25 ft.-lb. (34 Nm) torque.
1
Install the plug (Item 2) [Figure 20-21-50] into the control
valve. Tighten the plug to 20 ft.-lb. (27 Nm) torque.
Figure 20-21-51
2 1 P-71092

3
P-71094
Install the compensator (Item 1) and the compression

spring (Item 2) into the port (Item 3) [Figure 20-21-51].

72 of 110
ABOVE, S/N 467500154 & ABOVE, S/N 467300197 &
ABOVE) (CONTD)
Assembly (Cont'd)
Figure 20-21-54
P-71091
Install the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-21-54] on the relief valve.
Figure 20-21-55
P-71090
Install the relief valve (Item 1) [Figure 20-21-55]. Tighten

the relief valve to 25 ft.-lb. (34 Nm) torque.

73 of 110

74 of 110
MAIN FRAME
BRUSH DEFLECTOR (EARLIER MODELS) . . . . . . . . . . . . . 30-40-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1
DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 MAIN
FRAME
FLAIL KNIVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
RUBBER SKIRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

RUBBER STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

SKID SHOE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

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


75 of 110

76 of 110
SKID SHOE
WARNING
Engine is running.
W-2019-0907
Figure 30-10-1

1
1 1
2
P-57648
Remove nuts and washers (Item 1) [Figure 30-10-1].

Remove skid shoe (Item 2) [Figure 30-10-1].
Figure 30-10-2
P-57649
Remove remaining bolts (Item 1) [Figure 30-10-2].

Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 Nm)
torque.

77 of 110

78 of 110
ROLLER ASSEMBLY Figure 30-20-2

Remove skid shoe (See Removal and Installation on
Page 30-10-1.)
WARNING 1

of the following conditions exist: P-57650
Flying debris or loose material is present. Remove bolt (Item 1) [Figure 30-20-2] from both sides of
Engine is running. the roller.
W-2019-0907
torque.
Figure 30-20-1 Figure 30-20-3

2 1
P-57653
Remove bolts (Item 1) and the plate (Item 2) [Figure 30-

20-3] on both sides of the roller.
torque.
Figure 30-20-4
P-57651
Chain and lift front until roller is flat on the ground [Figure
30-20-1].
1
P-57654
Remove bearing spacer (Item 1) [Figure 30-20-4].

79 of 110
ROLLER ASSEMBLY (CONTD) Figure 30-20-7
Removal and Installation (Contd) 1
Figure 30-20-5
P-57657
Remove dust cap (Item 1) [Figure 30-20-7].

P-57655 Figure 30-20-8
Remove bearing bolts (Item 1) [Figure 30-20-5].

1
Installation: Tighten the bolts to 80-90 in.-lb. (9-10 Nm)

torque.
Figure 30-20-6
P-57658
Remove pinion nut (Item 1) [Figure 30-20-8] and

bearing.
Installation: Set pinion bearing preload to 15 in.-lb. (17
Nm) rotating torque with used bearings, and 25 in.-lb.
P-57656 (28 Nm) with new bearings. Once preload is set, install
the seal and loctite pinion nut.
Remove bearing (Item 1) [Figure 30-20-6].

80 of 110
RUBBER SKIRT Front Rubber Skirt
Removal and Installation Figure 30-30-2
WARNING
of the following conditions exist: 1
Engine is running.
W-2019-0907
2
P-57659
Rear Rubber Skirt
NOTE: Mounting frame removed for picture clarity. Remove bolts (Item 1), then remove the rubber skirt (Item
2) [Figure 30-30-2] and flat bar.
Figure 30-30-1
torque.

Side Rubber Skirt
Figure 30-30-3
1
2
P-57686
Remove bolts (Item 1), then remove the rubber skirt (Item
2
P-57659
torque.
Remove bolts (Item 1), then remove the rubber skirt (Item
NOTE: The flat bar on the side skirts is mounted on

the inside.

torque.

81 of 110

82 of 110
BRUSH DEFLECTOR (EARLIER MODELS) Figure 30-40-2

NOTE: This section only affects early model Flail
Cutters. Late model Flail Cutters are equipped
with a weld-on front rubber skirt mount and
are not equipped with metal brush deflectors.
Rubber guard removed for clarity.
WARNING P-57662

Wear safety glasses to prevent eye injury when any Remove bolt (Item 1) [Figure 30-40-2].
When fluids are under pressure. Installation: Tighten bolts to 65-70 ft.-lb. (88-95 Nm)
Flying debris or loose material is present. torque.
Engine is running. Figure 30-40-3
W-2019-0907

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, 3] away from the flail cutter.
then remove front rubber skirt mount (Item 2) [Figure 30-
40-1].

torque.

83 of 110
BRUSH DEFLECTOR (EARLIER MODELS) (CONTD)
Figure 30-40-4
P-57664
Slide the brush deflectors (Item 1) [Figure 30-40-4] until

they are free from the deflector mount.

Figure 30-40-5
P-57662
Remove and replace damaged brush deflectors, 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.-lb. (88-95 Nm)

torque.

84 of 110
DRUM Figure 30-50-3

Place attachment flat on the ground.
WARNING
Engine is running. P-57666
W-2019-0907
Raise the front of the attachment to remove the drum
[Figure 30-50-3].
Figure 30-50-1
Figure 30-50-4

1 1
2
P-57665
Remove bolts and lock washers (Item 1) [Figure 30-50-

P-57667
1].
Repeat for other side. Remove bolt and lock washer (Item 1) to remove
alignment plate (Item 2) [Figure 30-50-4].
torque. Repeat for other side.
Figure 30-50-2 Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 Nm)
torque.
P-57651
Install chain to the attachment (Item 1) [Figure 30-50-2].

85 of 110
DRUM (CONTD) Figure 30-50-8
Removal and Installation (Contd)

1
Figure 30-50-5
P-57670

P-57675
Figure 30-50-9
Remove grease seal (Item 1) [Figure 30-50-5].

Figure 30-50-6
1

1
P-57671
P-57668
Remove bearing spacer (Item 1) [Figure 30-50-9].

Figure 30-50-7
P-57669
Remove flange plate (Item 1) [Figure 30-50-7].

86 of 110
DRUM (CONTD)
Removal and Installation (Contd)
Figure 30-50-10

P-57672
Remove bearing with a press [Figure 30-50-10].
Installation: Assembly drum in reverse order. Block

drum up and lower attachment over drum assembly. Use
alignment plates to slide into place. Install bolts and lock
washers.

87 of 110

88 of 110
FLAIL KNIVES

WARNING
Replacing Individual Flail Knives (Broken):
When replacing individual broken flail knives to maintain Wear safety glasses to prevent eye injury when any
rotor balance, 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.
being replaced. Flying debris or loose material is present.
NOTE: This reduces abnormal vibrations and can Engine is running.
prevent damage to the flail cutter. Tools are being used.
W-2019-0907
NOTE: Keep a series of worn flail knives on hand.
Figure 30-60-2
Replacing Multiple Flail Knives (Broken):

4
When replacing multiple flail knives, it is recommended 1
that all the flail knives be replaced. 2
NOTE: The life of the flail knives depends on the type

use and the type of land being worked.

NOTE: When flail knives are broken, worn or
damaged they will cause abnormal vibrations
in the rotor. It is recommended that the flail 3 P-57674
knives be replaced an average of every 200-
300 hours of operation. Remove nut (Item 1), then slide bolt (Item 2) out of the
NOTE: When installing the flail knives, pay close mount until the knife (Item 3) [Figure 30-60-2] is free.
attention to the direction in which they are NOTE: When the knife has been removed, check the
installed. If the knives are installed flail supports for wear, rounded or oval
backwards, they do not cut. shaped holes.
Figure 30-60-1 Installation: Tighten nuts against flail supports (Item 4)
[Figure 30-60-2]. The knife should move freely.
1
Figure 30-60-3
P-57748
Install chains (Item 1) [Figure 30-60-1] to the side arm

linkage on both sides of the flail cutter.
NOTE: Use chains that are in good condition and of P-57756
adequate size to lift the attachment.

Installation: With nut tighten against the flail support,
Raise the flail cutter and rotate the flail cutter clockwise, 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. This must be done
the ground. for both notches. This procedure locks the nuts in place
Replace the worn knives, bolts and nuts. and prevents them from coming loose during operation
[Figure 30-60-3].

89 of 110

90 of 110
RUBBER STOP Rubber Stop With Isolator Support
Removal and Installation Figure 30-70-2
WARNING 2
3
1 2
When fluids are under pressure. P-83020
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].
2 Install the rubber stop and isolator support through the

flail cutter mount.

Install the lock washer and nut (Item 3) [Figure 30-70-2].
Tighten the nut.
1 Repeat procedure on opposite side of the flail cutter.
P-57677
To remove rubber stop (Item 1), remove bolt, nut and

washer (Item 2) [Figure 30-70-1].

91 of 110

92 of 110
LINKAGE Figure 30-80-3

Side Linkage
WARNING
When fluids are under pressure. P-57680
Engine is running.
Remove side link (Item 1) [Figure 30-80-3].
W-2019-0907
Figure 30-80-1 Center Linkage
Figure 30-80-4

1 1
1
1
P-57678 P-57682
Block attachment to raise mounting frame slightly off the

ground.
Remove bolt and nut (Item 1) [Figure 30-80-1].
torque.
Figure 30-80-5
torque.
Figure 30-80-2
1 1
1 1
P-57683
P-57679
Remove pins (Item 1) and remove center link (Item 2)
[Figure 30-80-5].
Remove collar (Item 1) [Figure 30-80-2].

93 of 110

94 of 110
WEAR STRIP
WARNING
Engine is running.
W-2019-0907
Figure 30-90-1

1
P-57685
Remove bolts (Item 1) [Figure 30-90-1] and replace if

necessary.

95 of 110

96 of 110
DRIVE BELTS Installation: Tighten bolts to 25-28 ft.-lb. (34-38 Nm)
torque.
Figure 30-100-3
1
WARNING 1

Engine is running.
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.
1 Installation: Tighten bolts to 65-70 ft.-lb. (88-95 Nm)
torque.
1
Figure 30-100-4

2
2
1
P-57634

Remove brush guard (Item 2) [Figure 30-100-1].
Installation: Tighten bolts to 65-70 ft.-lb. (88-95 Nm) P-57639
torque.
Figure 30-100-2 Loosen jam nut (Item 1), then turn the tension bolt (Item
2) [Figure 30-100-4] counterclockwise to increase belt
tension. Turn the tension bolt clockwise to decrease belt
tension.
P-57635
Remove bolts (Item 1) and drive pulley shield (Item 2)

[Figure 30-100-2].

97 of 110
DRIVE BELTS (CONTD)
Figure 30-100-5
P-57641
Remove and replace belts (Item 1) [Figure 30-100-5].
NOTE: Once the belts have been replaced, adjust belt

tension. For the proper belt tension

adjustment procedure (See Adjustment on
Page 10-50-1.)

98 of 110
SPECIFICATIONS AND SCHEMATICS
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

S/N A01P00143 & Below, S/N 467500153 & Below, S/N
467300196 & Below. . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
S/N A01P00144 & Above, S/N 467500154 & Above, S/N
467300197 & Above . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
SPECIFICATIONS
AND
SCHEMATICS
SPEC-01 Flail Cutter Service Manual

99 of 110
SPEC-02 Flail Cutter Service Manual

100 of 110
SPECIFICATIONS
Dimensions
All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Where applicable, specifications conform to SAE and ISO standards and are subject to change without notice.

D
E
A
B
DESCRIPTION FC155 (Europe Only) FC175 (Europe Only) FC200

Weight 1279 lb. (580kg) 1530 lb. (696 kg) 1640 lb. (746 kg)
Cutting Width (A) 61 in. (1.5 m) 69 in. (1.75 m) 78 in. (2 m)
Total Width (B) 73 in. (1856 mm) 81 in. (2057 mm) 91 in. (2306 mm)
Total Offset (C) 10.9 in. (277 mm) 10.4 in. (264 mm) 15.3 in. (388 mm)
Total Height (D) 26.8 in. (683 mm) 29.7 in. (754 mm) 29.7 in. (754 mm)
Total Length (E) 57.4 in. (1457.4 mm) 56.9 in. (1445 mm) 56.9 in. (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) 3.5 in. ^ 3 (58 cm ^ 3) 3.5 in. ^ 3 (58 cm ^ 3)
Displacement
Minimum Hydraulic Motor 1.8 in. ^ 3 (29 cm ^ 3) 1.8 in. ^ 3 (29 cm ^ 3) 1.8 in. ^ 3 (29 cm ^ 3)
Displacement
Shutoff Float Height 10 in. (254 mm) 10 in. (254 mm) 10 in. (254 mm)
Cutter Capacity Brush material up to 2 in. Brush material up to 3 in. Brush material up to 3 in.
(51 mm) in diameter (76 mm) in diameter (76 mm) in diameter
SPEC-10-1 Flail Cutter Service Manual

101 of 110

102 of 110
HYDRAULIC SCHEMATIC
S/N A01P00143 & Below, S/N 467500153 & Below, S/N 467300196 & Below
ORIFICE
(.030 in.)

[.762 mm]
P-57753

103 of 110
HYDRAULIC SCHEMATIC (CONTD)
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]
P-83972

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).
Printed in U.S.A.
105 of 110
106 of 110
ROUTE TO
ATTENTION
PARTS MANAGER

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.
COVER

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.
107 of 110
108 of 110
ROUTE TO
ATTENTION
PARTS MANAGER

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.

COVER
ALPHABETICAL INDEX

CONTENTS
10-01
10-20
30-70
Printed in U.S.A
109 of 110
110 of 110

Flail Cutter 6903303 EnUS SM 11-08

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Flail Cutter

Dealer Copy -- Not for Resale

6903303 (11-08) Printed in U.S.A. Bobcat Company 2008

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

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

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

HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

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

Dealer Copy -- Not for Resale

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

REAR HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

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

Flail Cutter Service Manual

Flail Cutter Service Manual

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

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

Dealer Copy -- Not for Resale

I Flail Cutter Service Manual

II Flail Cutter Service Manual

Attachment Serial Number

Later Models P-60854

The Operation & Maintenance Manual and Safety

Always use the serial number of the flail cutter when

Dealer Copy -- Not for Resale

MANUAL STORAGE LOCATION

Read and understand the Operation & Maintenance

The delivery report must be filled out by the dealer and

Earlier Models P-57633

III Flail Cutter Service Manual

HYDRAULIC CONTROL VALVE

Dealer Copy -- Not for Resale

REAR 7100706 (1)

IV Flail Cutter Service Manual

MANUAL STORAGE CONTAINER

EARLIER MODELS LATER MODELS

Dealer Copy -- Not for Resale

Drive Pulley Shield has been removed for picture clarity.

V Flail Cutter Service Manual

VI Flail Cutter Service Manual

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

REAR HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Dealer Copy -- Not for Resale

10-01 Flail Cutter Service Manual

10-02 Flail Cutter Service Manual

If the attachment is not working correctly, check the

PROBLEM CAUSE CORRECTION

Dealer Copy -- Not for Resale

10-10-1 Flail Cutter Service Manual

10-10-2 Flail Cutter Service Manual

Attachment Mounting Frame

Inspect the Bob-Tach wedge mounts (Item 1), mounting

Dealer Copy -- Not for Resale

Frequently inspect the flail cutter to ensure that all

Periodically inspect the flail knife bolts (Item 1) and nuts

10-20-1 Flail Cutter Service Manual

Hand Lever Bob-Tach

NOTE: If the wedge does not contact the lower edge

Dealer Copy -- Not for Resale

P-41502A Lubricate the wedges. (See the machines Operation &

The levers and wedges must move freely [Figure 10-20-

10-20-2 Flail Cutter Service Manual

Dealer Copy -- Not for Resale