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FLEX-WING ROTARY CUTTER OPERATION AND PARTS MANUAL Read and understand the manual. This manual provides information and procedures to safely operate and maintain the 2512 Series Flex-Wing Rotary Cutter. Scan QR code for a digital version of this manual June 2023...
INTRODUCTION 1.1 WELCOME Congratulations on your choice of a IronCraft flex-wing rotary cutter. This equipment has been de- signed and manufactured to meet the needs of discerning users. Many features incorporated into this rotary cutter are the result of suggestions made by customers like you.
1.4 SAFETY SHIELDS Some of the illustrations in this manual may show the equipment with safety shields removed for clarity. Never operate the rotary cutter unless all safety shields are in place. WARNING CUTTING OR ENTANGLEMENT HAZARD Operating the rotary cutter without the safety shields could result in physical injury or death.
1.11 DISPOSAL OF EQUIPMENT The IronCraft rotary cutter has been designed for the specific purpose of cutting grass, weeds, and brush. When this unit is no longer capable of doing its designed purpose, it should be dismantled and scrapped.
Phone: (423) 405-5150 Fax: (423) 405-5904 The manual is also available for download at: www.ironcraftusa.com IronCraft cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this manual and on the unit are, therefore, not all-inclusive. If a method of assembly, operation, or maintenance not specifically recommended by us is used, you must satisfy yourself that it is safe for you and for others.
2.2 SAFETY ALERT SYMBOLS This is the safety alert symbol and will be accompanied with a descriptive pictorial. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. This manual contains DANGERS, SAFETY INSTRUCTIONS, CAUTIONS, IMPORTANT NOTICES, and NOTES which must be followed to prevent the possibility of improper service, damage to the equip- ment, personal injury, or death.
2.3 SAFETY ICON NOMENCLATURE Pictorial icons signal a type of hazard and warn of personal protection issues, prohibited actions, and hazard avoidance. Personal Protection / Explosive separation Rollover protection Important Information hazard Fire hazard Read the manual Wear seat belt Cutter blade contact Damaged hazard label Weight rating...
PROVIDE USER WITH LITERATURE IronCraft rotary cutter owners must provide operator instructions to anyone using the rotary cutter before use, and at least annually thereafter. Refer to “2.6 OSHA Training Requirements”...
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Personal injury or death could result from unauthorized modifications. If the rotary cutter has been altered in any way from the original design, IronCraft does not accept any liability for injury or warranty. DAMAGED PARTS HAZARD Do not use the rotary cutter if any parts are damaged.
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CAUTION The following safety instructions are provided to help prevent potential injury. Not following these instructions may lead to injury. PERSONAL PROTECTION EQUIPMENT When using this rotary cutter, wear appropriate personal protective equipment. This list may include, but is not limited to: •...
OEM manuals, and the safety signs. If you do not understand any information in this manual, see your dealer or contact IronCraft before proceeding. Do not use or allow anyone else to use this rotary cutter until all information has been reviewed.
2.7 FEDERAL LAWS & REGULATIONS IMPORTANT FEDERAL LAWS AND REGULATIONS CONCERNING EMPLOYERS, EMPLOYEES, AND OPERATORS This section is intended to explain in broad terms the concept and effect of the following federal laws and regu- lations. It is not intended as a legal interpretation of the laws and should not be considered as such. U.S.
2.8 SIGN-OFF FORM IronCraft adheres to the general Safety Standards established by the Farm Equipment Manufacturers Association (FEMA) and the American National Standards Institute (ANSI). It is crucial for anyone who will be using and maintaining the rotary cutter to thoroughly read and understand all safety, opera- tion, and maintenance information provided in the manual.
2.9 OPERATION SAFETY Refer to “ 6.1 User Safety Training” on page 29 for safety recommendations related to using the rotary cutter. All applicable safety recommendations in other sections should also be followed. 2.10 TRANSPORTING SAFETY Refer to “ 7.1 Transporting Safety (Road)” on page 43 for safety recommendations related to transport- ing the rotary cutter.
5. Replacement parts must have replacement labels attached during installation and/or before the rotary cutter is used. 6. Labels are available from your authorized dealer or from IronCraft at no charge. 3.2 HOW TO INSTALL REPLACEMENT SAFETY SIGNS Clean and dry the installation area.
ASSEMBLY 5.1 TOOLS REQUIRED Tools Required Wrenches, 1/2”, 5/8”, 3/4”, 1-1/8”, 1-3/8”, 1-1/2” Ratchet with extension and sockets as above 5.2 ASSEMBLY PROCEDURE WARNING CRUSH HAZARD The weight of the hitch can cause serious injury or death if it falls on a person. Do not allow anyone to walk under or stand near the hitch when it is supported by a lifting device.
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Rotate the hitch forward using a suitable Remove the jack from its storage location on lifting device. The lifting device may be at- the left wing and install it on the lug on the tached to the safety chain. left side of the hitch. Use the jack to adjust the hitch to the height Board the tractor and start the engine.
15. Lower the cutter to the ground, set the park- ing brake, shut off the tractor, and remove the key. 16. Align the hole in the hitch with the hole in the front of the leveling rod, and install the pin, washers, and cotter pins previously re- moved in Step 3.
5.2.2 LEVELING THE WING DECKS Each wing section will need adjusting if the wing top is not level with the center deck top when the wings are unfolded. The wing lift hydraulic cylinders are not charged when the cutter is shipped, and must be filled with hydraulic oil before removing the wing locks.
NOTICE The cutter does not have a hydraulic reservoir and therefore can deplete the oil in the tractor’s reservoir during the initial charging of the cylinders. After this initial setup, with the cutter and wings fully lowered, check the tractor’s hydraulic oil reservoir and add oil as necessary. Check the wing tops to see if they are level with the top of the center deck.
Attach the safety chain on the driveline Separate the two halves of the driveline. guard to the gearbox cover. Apply a bead of grease around the end of the Slide the front driveline half over the rear inner drive shaft. half.
If the driveline is too short and does not provide sufficient en- gagement, please contact your IronCraft dealer to obtain a longer driveline. On the other hand, if the driveline is too long, follow the provided instructions for shortening the driveline.
OPERATION 6.1 USER SAFETY TRAINING Refer to “2.4 General Safety” on page 8 for user safety training requirements. WARNING ROLL AWAY HAZARD Before leaving the tractor seat, make sure the engine is stopped, the transmission is placed in park, the key is removed, and the parking brake is set. The weight of the tractor, plus the rotary cutter if it rolls onto a person, could cause serious crushing injury or death.
ENTANGLEMENT HAZARD Operating the rotary cutter without the driveline shields could result in physical injury or death from entanglement. Make sure all shields are properly installed before operating the rotary cutter. This equipment should never be operated with any safety shielding removed.
tor or cutter damage and be a potential danger to the operator and passersby. Always review the “controls” section of the tractor operator’s manual to be familiar with the location, settings, and function of the tractor controls. Be familiar with all controls before using this equipment. 6.2.1 EQUIPMENT AND CAPABILITIES: •...
6.2.4 DRAWBAR The distance between the drawbar hitch pin hole and the end of the tractor PTO shaft must be 14”. The distance from the top of the drawbar to the PTO shaft must be 8”. PTO damage may occur if these dimensions vary more than 1”.
6.3 ATTACHING TO TRACTOR Use caution when connecting the rotary cutter to the tractor. The rotary cutter should be securely rest- ing at ground level or setting on blocks. Keep hands and feet from under the deck and clear of pinch points between the tractor drawbar and rotary cutter hitch.
11. Inspect all the hydraulic hoses to ensure they are in good condition. Route the main lift hy- draulic hose through the hose rack, make sure the fitting is clean, and attach to the tractor’s hydraulic port. Make sure the hose is adequately supported so it cannot come in contact with other parts or the ground.
6.4.1 LEVELING FRONT-TO-BACK Locate the tractor and cutter on a flat, level surface and use the hydraulics to adjust the cutter height until the front skid shoes are two to three inches off the ground. Shorten or lengthen the leveling rods, as needed, to obtain the desired cutting results. Lengthen- ing the leveling rods raises the back of the cutter.
Adjust the lock nuts so that the wing stop bolt contacts the raised wing. Tighten the lock nuts. Repeat Steps 2-4 for the other wing. 6.5 INITIAL SETUP CHECKLIST Efficient and safe operation of the rotary cutter requires that every user read and understand the operational instructions and all related safety instructions outlined in this manual.
6.7 PRE-OPERATION CHECKLIST Before each use of the rotary cutter, the following areas should be checked. Checklist Before Each Use Task Make sure the rotary cutter is positively attached to the tractor drawbar. Refer to “6.3 Attaching to Tractor” on page 33. Make sure the hydraulic hoses are undamaged, are secured on the hose rack, and cannot contact the tractor when turning or drag on the ground.
6.8 GENERAL OPERATING PROCEDURE Although the rotary cutter is easy to use, each operator should review this section to familiarize them- selves with the detailed safety and operating procedures. Operate the rotary cutter only in conditions where you have clear visibility in daylight or with adequate artificial lighting.
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When you get to the end of a pass, slightly raise the rotary cutter (2-4”) before turning. Never raise the rotary cutter entirely while the blades are turning. If the rotary cutter must be raised higher than 12” from ground level, disengage the tractor PTO and wait for all blade rotation to come to a complete stop before raising the rotary cutter.
6.9 CHAIN SHIELDING IronCraft installs full chain shielding as standard equipment on all flex-wing rotary cutters. WARNING PROJECTILE HAZARD The chain shielding is designed to reduce the risk of thrown objects. The rotary cutter deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing condition.
Stop mowing if passersby are within 300 feet unless: All thrown object shielding, including front and rear deflectors, chain shields, steel guards, bands, side skirts, and skid shoes are in place and in good condition when mowing. Mower sections or wings are adjusted to be close and parallel to the ground without exposing blades.
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Disconnect the driveline safety chain and hitch safety chain. Pull back on the collar on the tractor end of the driveline. Slide the driveline off the tractor PTO shaft and secure it up off the ground. 10. Remove the hitch pin and drive the tractor away from the rotary cutter.
TRANSPORTING 7.1 TRANSPORTING SAFETY (ROAD) WARNING Failure to understand and follow these safety instructions could result in serious injury and possibly even death. TRACTOR OWNER/OPERATOR MANUAL Always refer to the tractor owner’s manual to determine its compatibility and maximum safety. OPERATING THE TRACTOR Before attaching the rotary cutter to the tractor, be familiar with its controls and how to stop it quickly in the event of an emergency.
ALLOW EXTRA DISTANCE Apply brakes early. Leave extra distance between your vehicle and the one(s) ahead to provide adequate stopping space. Extra distance will be required to stop the vehicle. CLEAR VISION Remove all objects from the area that would prevent clear vision of the complete work area or would present an obstacle when moving the rotary cutter.
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WARNING THROWN OBJECT HAZARD Operating the PTO with a wing in the folded position could cause the driveline to break and throw objects at the operator or a bystander, causing serious injury or death. Do not engage the PTO with either wing folded up. Make sure the jack stand is secured in its storage location on the left wing deck.
STORAGE 8.1 STORAGE SAFETY At the end of the season, the rotary cutter should be thoroughly inspected and prepared for storage. Repair or replace any worn or damaged components to prevent any unnecessary downtime at the beginning of the next season. WARNING ROLLOVER HAZARD The rotary cutter is top heavy when the wings are raised.
8.3 REMOVING FROM STORAGE Grease all lubrication points. Refer to “9.3 Greasing” on page 50. Attach the rotary cutter to the tractor following the procedure in “6.3 Attaching to Tractor” on page 33. Check for locked blades before lowering the wings. Use a pry bar or similar tool to free any locked blades.
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NO UNAUTHORIZED MODIFICATIONS Do not modify the rotary cutter or safety devices. Do not weld on the unit. Unauthorized modifications may impair the cutter’s function or create safety hazards and will void the warranty. If the rotary cutter has been altered in any way from the original design, the manufacturer does not accept any liability for injury or warranty.
9.2 WELDING REPAIRS Before performing any type of welding repair to the rotary cutter, contact IronCraft for approval. Repair welding must be done with care and with procedures that may be beyond the capabilities of the ordinary welder.
9.3 GREASING See the diagram for the location of all grease zerks. Grease all zerks according to the intervals specified in “9.14 Service Record” on page 57. Use an SAE multipurpose high-temperature grease with extreme pressure (EP) performance. An SAE multipur- pose lithium base grease is also acceptable.
9.4 GEARBOX LUBRICATION The gearboxes are filled at the factory and should require no maintenance. If there is evidence of leak- age, check the grease level and add grease until it reaches the proper level. Recommended lubricant is EP-0 Grease. Splitter gearbox capacity is 58 ounces. Outboard gearbox capacity is 35 ounces. Note: Make sure the rotary cutter is level when checking the gearbox grease.
9.6.1 BLADE REMOVAL To remove the blades for sharpening or replacement, remove the nut and lock washer from the blade bolt through the inspection hole in the deck of the mower near the gearbox. 9.6.2 BLADE INSTALLATION When installing blades, be sure to check the blade bolt pivot diameter for wear.
9.7 BLADE CARRIER REMOVAL Remove the cotter pin and loosen the castle nut on the gearbox shaft. Do not remove the nut until the blade carrier is loosened. Use a suitable two jaw gear puller to pull the carrier off the tapered gearbox shaft. Remove the castle nut and the blade carrier.
Retighten the eight nuts to their original position. NOTICE Incorrect slip clutch torque settings may cause damage to the cutter and/or tractor. Be sure to retighten the nuts to their original position. Note: Check each clutch periodically during the first hour of operation for excessive heat build-up due to unexpected slippage.
9.11 SLIP CLUTCH DISASSEMBLY/ASSEMBLY If the clutch did not slip during the operational check, it will need to be disassembled to separate the clutch plates from the friction discs. Measure and record the compressed (as- sembled) spring length. This dimension will be needed for reassembly.
9.13 BOLT TORQUE REQUIREMENTS It is extremely important to apply and maintain proper torque on all bolts. Use a torque wrench to ensure the proper amount of torque is being applied to the fastener. Start all bolts or nuts by hand to prevent cross-threading. Torque figures indicated in the chart are used for non-greased or non-oiled threads unless otherwise specified.
9.14 SERVICE RECORD The period recommended is based on normal operating conditions. Severe or unusual conditions may require more frequent service. Copy this page to continue record. 9.14 Service Record Ironcraftusa.com...
After one year, seals are considered to be wearing parts, and the replacement is the owner’s re- sponsibility. ii. Gearboxes that are subject to warranty may be replaced with new or rebuilt gearboxes at the discretion of IronCraft iii. Shearbolts must be approved Grade 2 , 1 /2 “ x 3 “ shearbolts.
PARTS Replacement parts are available from your authorized Dealer Parts Department or from IronCraft. The following pages contain a list of serviceable parts for the IronCraft 2512 flex-wing rotary cutter. 12.1 A-FRAME COMPONENTS 12.1 A-Frame Components Ironcraftusa.com...
12.10 540-RPM SPLITTER GEARBOX COMPONENTS Splitter Gearbox Components Item Part # Description 551060 Input Oil Seal 45 x 85 x 10 551061 Input Bearing 6209 - for Thru Shaft 551062 Snap Ring 85 x 88.5 x 3 551063 Output Seal 45 x 80 x 10 551064 Snap Ring 80 x 83.5 x 2.5 551065...
12.11 CENTER & WING GEARBOXES 140 (ISO460) Gearoil Recommended CENTER & LH WING GEARBOX #191304 (RG40-A) RH WING GEARBOX #191306 (RG40-O) Fill level 61-oz. (1.83-qt) 12.11 Center & Wing Gearboxes Ironcraftusa.com...
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Center & Wing Gearboxes Item Part # Description 191320 Double Lip Seal 35 x 72 x 10 191321 Snap Ring 72 x 2.5 191322 Adjusting Washer 62 x 71.8 x 0.1 191323 Adjusting Washer 62 x 71.8 x 0.3 191324 Adjusting Washer 62 x 71.8 x 0.5 191325 Adjusting Washer 62 x 71.8 x 1...
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