INTRODUCTION

BoxerAgri 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, finish grading, and backfilling 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 efficient 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 BoxerAgri 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 filled 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. 

SAFETY

Safety at all times

Thoroughly read and understand the instructions given in this manual before operation. Refer to the “Safety Decal”, read all instructions noted on them. 
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. 

• Operator should be familiar with all functions of the unit. 
• Operate implement from the driver’s seat only. 
• Make sure all guards and shields are in place and secured before operating the implement. 
• Do not leave tractor or implement unattended with engine running. 
• Dismounting from a moving tractor could cause serious injury or death. 
• Do not stand between tractor and implement during hitching. 
• Keep hands, feet, and clothing away from power-driven parts. 
• Wear snug fitting clothing to avoid entanglement with moving parts. 
• Watch out for wires, trees, etc., when raising implement. Make sure all persons are clear of working area. 
• Turning tractor too tight may cause implement to ride up on wheels. This could result in injury or equipment damage. 

Look For The Safety Alert Symbol 

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. In addition to design and configuration 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. 

Symbols

This booklet contains three "safety graphic symbols" which highlight the relevant danger levels or important information:

WARNING It draws the operator's attention to situations which can jeopardize people's safety.

CAUTION It draws the attention to situations which jeopardize the machine efficiency but not people's safety.

IMPORTANT It highlights general information which does not endanger people's safety or the efficiency of the parts.

For your protection

Thoroughly read and understand the “Symbols” section, read all instructions noted on them. 

Shutdown and storage

• Lower machine to ground, put tractor in park, turn off engine, and remove the ignition key. 
• Detach and store implements in an area where children normally do not play. Secure implement by using blocks and supports. 

Use safety lights and devices

• Slow moving tractors, self-propelled equipment, and towed implements can create a hazard when driven on public roads. They are difficult 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. 

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.

Keep riders off machinery

• 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 off engine, and remove key before performing maintenance. 
• Allow implement to cool completely. 
• Do not grease or implement oil while the machine is in 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 fire starts. 
• Keep a fist aid kit and fire extinguisher handy. 
• Keep emergency numbers for doctor, ambulance, hospital and fire department near phone. 

Wear protective equipment

• Protective clothing and equipment should be worn. 
• Wear clothing and equipment appropriate for the job. Avoid loose fitting clothing. 
• Prolonged exposure to loud noise can cause hearing impairment or hearing loss. Wear suitable hearing protection such as earmuffs or earplugs. 
• Operating equipment safely requires the full attention of the operator. Avoid wearing radio headphones while operating machinery. 

Avoid high pressure fluids hazard

• Escaping fluid 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 fluid 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 dealer or visit www.boxeragri.nl. 
3. Some new equipment installed during repair requires safety labels to be affixed to the replaced component as specified by BoxerAgri. 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: 

1. Clean the area the label is to be placed. 
2. Spray soapy water on the surface where the label is to be placed. 
3. Peel backing from label. Press firmly onto the surface. 
4. Squeeze out air bubbles with the edge of a credit card. 

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

1. 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 first time.
2. Align lower link arms of tractor to hitch clevises on mower. Insert lower hitch pins into lower ball swivels and attach linch pins.
3. Attach tractor top link to upper floating hitch on mower with pin supplied. Secure with lock pin.
4. Adjust tractor top link in or out to place upper hitch pin vertically above or slightly behind lower hitch pins to allow mower flotation. The mower should be run with the back 15 degrees lower than the front.

Driveline Installation

1. Slide driveline end with extended safety cone over splined shaft of gearbox and secure with attaching device.
2. Slide driveline over tractor’s splined PTO shaft and secure with locking device of driveline.
3. Driveline should now be moved back and forth to insure that it is secure on the PTO shaft of the tractor and mower gearbox.
4. Attach chain from the driveline shield to one of the upper hitch braces to ensure that the shield does not rotate.
5. 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 profiles 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 off all sharp edges and remove burrs. Grease sliding profiles.

CAUTION Tractor PTO shield and all mower guards must be in place at all times during operation!

OPERATION

Transporting

NOTE: Always disengage PTO before raising mower to transport position.

1. 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.
2. 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. 
3. 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. 
4. When traveling over rough or hilly terrain, shift tractor to a lower gear.

CAUTION 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.

Mowing Instructions

1. Clear area to be mowed of objects and debris that might be picked up and thrown by the mower blades.
2. Grass is best cut when it is dry. Mowing wet grass can cause plugging resulting in grass clumps behind the mower.
3. Grass should be mowed frequently as shorter clippings deteriorate faster.
4. 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:

1. Check oil level in gearbox. 
2. Check that all plugs in gearbox have been replaced and tightened properly.
3. Be sure all mower knives, bolts and nuts are tight.
4. Be certain all guards and shields are in place and secure.
5. Grease driveline shaft and all other grease fittings.
6. Clear area to be mowed of rocks, branches and other foreign objects.
7. Lower mower to ground. Set tractor throttle at approximately 1/4 open. Engage PTO to start blades rotating. 
8. Operate with 540 rpm PTO tractor.
9. At first begin mowing at a slow forward speed and shift up until the desired speed is achieved - maintaining 540 PTO rpm.
10. Mower knives will cut better at a faster blade speed than at reduced throttle.
11. After mowing the first 50 feet, stop and check to see that the mower is adjusted properly.
12. Do not make sharp turns or attempt to back up while mower is on the ground.
13. Do not engage PTO with mower in the fully raised position. Do not engage PTO at full throttle.

ADJUSTMENTS

Leveling the Mower

NOTE: Tractor and mower should be on level ground.

Leveling can be adjusted at the tractor’s 3-point arms and center link. 

Cutting Height Adjustment

1. The machines cutting height depends upon the position of the rear roller. 
2. Remove the bolts that fix the roller on both sides. 
3. Lift or lower both sides of roller in equal measurements. 
4. Replace bolts and re-tighten. 

3-Point Hitch Adjustments 

The 3-point hitch system on this mower has been designed for front to back flotation when mowing on uneven terrain. Adjust tractor’s top center link to place the upper hitch pin vertically above or slightly behind the lower hitch pins. The mower should be run with the back 15 degrees lower than the front. The hitch can also be adjusted from side to side by turning the adjustment handle. Turn handle until you have achieved your desired location. 

CAUTION Engage parking brake, shut off tractor, remove key and disengage PTO before making any height adjustments!

Belt Tension 

CAUTION Belt drive system under spring tension; use care to avoid bodily harm!

The Belt tension should be checked after the first 20 hours of use. And then every 40 hours of use.

1. Tension on the belt can be adjusted with the belt tension bolt. Turn the bolt until desired tension is achieved. When the belt has the correct tension the gearbox should be adjusted so that the gearbox extension is running straight (parallel) with the flail mower. Loosen bolts at the bottom of the gearbox and move gearbox until gearbox extension is running straight. 
2. Excessive tension on the belt may lead to premature failure of belt and drive components. 

CAUTION Excessive tension on the belt may lead to premature failure of belt and drive components. Excessive tension on the belt may also lead to a safety hazard to the operator or bystanders.

MAINTENANCE

Maintenance

Proper servicing and adjustment is the key to the long life of any farm implement. With careful and systematic inspection, you can avoid costly maintenance, time and repair. 

CAUTION For safety reasons, each maintenance operation must be performed with tractor PTO disengaged, mower lowered completely to ground and tractor engine shut off with ignition key removed.  After using the mower for several hours, check all bolts to be sure they are tight and check drive belt tension.  Replace any worn, damaged or illegible safety decals by obtaining new decals from dealer.

Knife Replacement 

IMPORTANT Make sure that the knife is the same length as the others on the mower. This will keep the rotor rotation balanced.

1. Remove bolt and nut. 
2. Remove old knife. 
3. Install new knife and existing bolt. 
4. Secure with nut. 

V-Belt Installation 

CAUTION Belt drive system under spring tension; use care to avoid bodily harm!

1. Remove belt guard fender and belt cover. 
2. Disengage belt tension by loosening belt tension bolt until belt can be removed. 
3. With tension relieved from belt remove old belt from pulleys. 
4. Tighten belt tension bolt. 
5. Reinstall belt guard and belt guard fender. 

Storage

At the end of the working season or when the mower will not be used for a long period, it is good practice to clean off any dirt or grease that may have accumulated on the mower and any of moving parts.

1. Clean as necessary.
2. Check knives for wear and replace if necessary.
3. Inspect mower for loose, damaged or worn parts and adjust or replace as needed.
4. Store unit inside if possible for longer life.
5. Repaint parts where paint is worn or scratched to prevent rust.
6. Replace all damaged or missing decals.

Lubrication

IMPORTANT Mower should be level when checking oil in gearbox!

TROUBLESHOOTING

CAUTION Do not try to clean rear discharge area when mower is running. Bodily harm may occur!

KDK FLAIL MOWER ASSEMBLY