COSMO Bully BPF 180, BPF SERIES, BPF 200, BPF 225 Operator And Parts Manual
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OPERATOR'S AND
PARTS MANUAL
BPF SERIES
FLAIL MULCHER
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Congratulation for purchasing your new COSMO BULLY Flail Mulcher!
This machine has been designed and manufactured following all safety and quality requirements needed
for a safe and satisfactory use over time.
A careful reading of this manual will permit you to familiarize with your new equipment and will provide
you all the tools needed to use it safely.
Proper maintenance and knowledge of the safety rules of use will allow obtaining the best performance
and long service life of the machine.
The Safety Alert Symbol used throughout this manual and on safety decals of the
machine indicates the presence of potential hazard to the operator. When you see
this symbol, be alert and carefully read the message that follows it.
The Safety Alert Symbol is used in conjunction with following Signal Words, according to the
degree of possible injuries that may result operating the implement:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and
includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe
practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It
may also be used to alert against unsafe practices.
IMPORTANT
Indicates instructions or procedures that, if not observed, can cause damage to equipment or environment.
NOTE
Indicates helpful information.
READ, UNDERSTAND, and FOLLOW the safety messages following the Safety Alert Symbol and Signal
Words. Failure to comply with safety messages could result in serious bodily injury or death.
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TO THE PURCHASER
This manual contains valuable information about COSMO BULLY FLAIL MULCHER. It
has been carefully prepared to give you helpful suggestions for operating, adjusting,
servicing repair parts.
Keep this manual in a convenient place for quick and easy reference. Study it carefully.
You have purchased a dependable and sturdy Flail Mulcher, but only by proper care
and operation can you expect to get the service and long life designed and built into
it.
RIGHT-HAND AND LEFT-HAND sides are determined by watching from the tractor side.
Sometime in the future, your Flail Mulcher may need new parts to replace those are
worn or broken. If so, go to nearest COSMO BULLY dealer and provide him with the
model and part number.
Customer information
Name ____________________________________________________________
Purchased from_____________________________________________________
Purchased date______________________________________________________
Model No.__________________________________________________________
Serial No.___________________________________________________________
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TABLE OF CONTENT
1. ABOUT THIS MANUAL 6
2. INTRODUCTION 6
2.1. MACHINE IDENTIFICATION 6
2.2. INTENDED USE 7
2.3. MAIN PARTS DESCRIPTION 8
2.4. CONFIGURATION 9
2.5. TECHNICAL SPECIFICATION 10
3. SAFETY 11
3.1. GENERAL SAFETY INSTRUCTIONS 11
3.2. EQUIPMENT SAFETY INSTRUCTIONS 12
3.3. OPERATING SAFETY INSTRUCTIONS 13
3.4. TRANSPORTING SAFETY INSTRUCTIONS 15
3.5. MAINTENANCE SAFETY INSTRUCTIONS 15
3.6. STORAGE SAFETY INSTRUCTIONS 16
3.7. SAFETY LABELS 16
4. SET UP 20
4.1. CONNECTING TO THE TRACTOR 20
4.2. DRIVELINE INSTALLATION 21
4.3. TRACTOR-FLAIL MULCHER STABILITY 23
5. OPERATING 24
_ 5.1. START-UP 24
_5.2. OPERATING INSTRUCTIONS 25
5.3. ADJUSTMENTS _ 25
5.4. STOPPING AND DISCONNECTION __ 31
5.5. TRASPORTATION 31
6. MAINTENANCE 32
6.1. ROTOR TOOLS REPLACEMENT 32
6.2. GEARBOX LUBRICATION 33
6.3. ROTOR BEARINGS LUBRICATION 34
6.4. ROLLER BEARINGS LUBRICATION 35
6.5. DRIVE BELTS REPLACEMENT 35
6.6. DRIVESHAFT MAINTENANCE 35
7. STORAGE 36
8. SCRAPING 36
9. TROUBLESHOOTING 37
10. TORQUE VALUES TABLE 37
11. WARRANTY 38
12. SPARE PARTS 41
13. “EC” DECLARATION OF CONFORMITY 64
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1. ABOUT THIS MANUAL
The operator must read the manual for a correct understanding of the hazards that may present when
operating the Flail Mulcher, as well as for obtaining optimum performance from the machine.
The manual is part of the machine, it must be kept in good condition and remain with the machine even in
case of resale, until its demolition. In case of loss or damage, request a new copy to the Manufacturer or
your Dealer.
The information, descriptions and illustrations in this manual describe the state of the product at the time
of its publication, and may not reflect the product in the future.
The Manufacturer reserve the right to make design improvements or changes in specifications without
incurring any obligation to install them on units previously sold.
Text, illustrations and drawings of this manual cannot be disclosed or transmitted, in whole or in part, to
third parties without the written permission of the Manufacturer. All rights are reserved.
2. INTRODUCTION
2.1. MACHINE IDENTIFICATION
Each Flail Mulcher is provided with a plate for unique identification (see the position in the picture below),
showing the CE
marking together with the following information:
• Manufacturer name and address
• Type of machine (“TYPE”)
• Model of machine (“MODEL”)
• Serial number (“SERIAL No.”)
• Construction year (“YEAR”)
• Machine weight (“MASS”)
It’s recommended to note down all data shown on the plate.
Any request for assistance or information regarding the machine must be directed to the Manufacturer or
Dealer always referring to the model and serial number as shown on the plate affixed to the machine.
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2.2. INTENDED USE
The BPF Flail Mulcher is designed specifically for cutting grass and for shredding fibrous wood stalks, corn
and branches up to a diameter of 7 cm (depending on the type of blade used).
The Flail Mulchers are designed to be mounted on tractors equipped with a hydraulic lift and universal
three-point hitch that can support the implement weight, and driven by the power of the tractor through
the PTO driveshaft.
The tractors used to operate the Flail Mulcher must have the following requirements:
Hitch Category: 3-point hitch, I / II Category standard
PTO: 540 RPM, 6-spline, 1 3/8 Z6
Horsepower: 50-100 HP
DANGER
Any use of the machine other than the intended use is non-intended use and is to be considered as
unauthorized and dangerous. The manufacturer assumes no liability for damage resulting from nonintended use.
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2.3. MAIN PARTS DESCRIPTION
1. Flail Mulcher frame 9. Side transmission case
2. Lower hitch 10. Rakes
3. Lower hitch pin 11. Shredding Chamber
4. Upper hitch pin 12. Roller
5. Upper hitch 13. Parking stand
6. Input Shaft Cover 14. Side skid
7. Implement Input Shaft 15. Hydraulic hoses
8. Gearbox with a free wheel inside
NOTE
To make the illustrations clear, some images of this manual may show machines missing some safety
components. NEVER operate with the safety components (e.g. safety devices and barriers) removed.
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3
4
5
6
7
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9
10
11
13
14
15
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2.4. CONFIGURATIONS
The BPF Flail Mulcher can be set in different configurations.
The standard configuration can be changed by applying one or more optional parts, listed below:
STANDARD CONFIGURATION
• Mobile arc with hydraulic cylinder
• Hammers
OPTIONAL CONFIGURATION
• Mobile arc without hydraulic cylinder
M o b i l e a r c w i t h o u t
s c r e w
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2.5. TECHNICAL SPECIFICATIONS
BPF
180 200 225
Overall size L x W x H
mm
1194 X 2000 X 990
(47 X 79 X 39)
1194 X 2200 X 990
(47 X 87 X 39)
1194 X 2450 X 990
(47 X 96 X 39)
(inch)
Working width mm (inch) 1780 (70) 1980 (78) 2230 (88)
Recommended
tractor HP
HP 50-100 50-100 50-100
3 Point Hitch Type Cat-II Cat-II Cat-II
No. of blades Nos 48 60 60
No. Of Hammer Nos 16 20 20
PTO input speed Rpm 540 540 540
Rotor speed Rpm 2146 2146 2146
Side transmission 4 Belt XPB type 4 Belt XPB type 4 Belt XPB type
Side shift (max) mm 337 437 467
Rotor diameter mm 170 170 170
Rotor swing diameter mm 410 410 410
Approx. Weight Kg/lbs 680(1500) 735(1620) 800(1763)
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3. SAFETY
Proper use of the equipment, a strict observance of the safety messages listed below and application of all
reasonable practices to avoid any risks, prevents accidents or injury, allows the machine to work better
and longer, and minimize the risk of failures.
The manufacturer assumes no liability for any damage resulting from not applying the behavioral rules
indicated into the manual.
3.1. GENERAL SAFETY INSTRUCTION
DANGER
The machine must be used only by authorized and well trained operators. The operator must have read
and understood the instructions of this manual, it must make adequate preparation for the proper use of
the machine and must hold a driving license. In case of doubt about the use of the machine and/or the
interpretation of this manual, the operator must contact the Manufacturer or the Dealer.
WARNING
The manual must always remain with the machine. In case of loss or damage, request a new copy to the
Manufacturer or your Dealer.
WARNING
Follow strictly the rules prescribed by the safety pictograms applied to the machine.
WARNING
Be sure that all safety pictograms are legible. If pictograms are worn, they must be replaced with others
obtained from the Manufacturer, and placed in the position indicated by this manual.
DANGER
Before using the machine, make sure that all safety devices are installed and in good working conditions.
In case of damages of shields, replace them immediately.
DANGER
Is absolutely forbidden to remove or alter safety devices.
DANGER
Before starting, and during operation of the Flail Mulcher, make sure there are no people or animals in
the opera- tion area: the machine can project material from the back, with risks of serious injury or
death.
DANGER
Pay maximum attention to avoid any accidental contact with rotating parts of the machine.
DANGER
During operation, adjustment, maintenance, repairing or transportation of the machine, the operator must
always use appropriate Personal Protective Equipment (PPE).
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DANGER
Do not operate the implement while wearing loose fitting clothing that can give rise to entanglement in
parts of the machine.
DANGER
Do not operate the implement when tired, not in good condition or under the influence of alcohol or drugs.
CAUTION
If the use of the machine is required at night or in conditions of reduced visibility, use the lighting system
of the tractor and possibly an auxiliary lighting system.
3.2. EQUIPMENT SAFETY INSTRUCTION
WARNING
Use the Flail Mulcher for its intended purpose only. Improper use can damage the Flail Mulcher and cause
serious injury to persons, animals, or death.
DANGER
The machine should be used by a single operator driving the tractor.
WARNING
Any unauthorized modification of the machine may cause problems in safety and relieves the Manufacturer
from any liability for damages or injuries that may result to operators, third parties and objects.
WARNING
Before using the machine, familiarize yourself with its controls and its working capacity.
WARNING
Do not leave the Flail Mulcher unattended with tractor engine running.
WARNING
Do not operate Flail Mulcher on too muddy, sandy or rocky soils.
WARNING
Keep the machine clean from debris and foreign objects which may damage functioning or cause injury.
WARNING
Do not use the machine if the category of the connecting pins of the Flail Mulcher does not match that of
the tractor hitch system.
WARNING
Do not use the machine with missing bolts, screws, pins or safety pins, safety guards etc.
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WARNING
Never use the machine to transport or lift people, animals or objects.
WARNING
Make certain, by adding front ballast, that at least 20% of the total weight (tractor, implement and ballast)
is on the front axle of the tractor, to ensure stability.
WARNING
Before engaging the tractor PTO, make sure the tractor PTO speed is set as required for the Flail
Mulcher (540 rpm). Do not over speed PTO or machine breakage may result.
DANGER
Do not operate the Flail Mulcher if the driveshaft is damaged. The driveshaft could be subject to
breakage during operation, causing serious injury or death. Remove the driveshaft and replace it with an
undamaged.
WARNING
With Flail Mulcher disconnected from tractor, rest the driveline on the provided support of the Flail Mulcher.
3.3. OPERATING SAFETY INSTRUCTION
WARNING
Before using the machine, be sure to have cleared the operating area from obstacles (stones, branches,
debris, etc...). Mark all the obstacles that cannot be eliminated (e.g. by means flags).
DANGER
Never engage the tractor PTO in the presence of people close to the driveshaft. The body, hair or clothing
of a person can get caught in rotating parts, causing serious injury or death.
DANGER
Before engaging the PTO and during all operations, make sure that no person or animal is in immediate
area of action of the machine. Never use the Flail Mulcher if people are in his working area.
DANGER
It’s absolutely forbidden to stand near the Flail Mulcher with moving parts.
WARNING
The operator must operate machine lifting/lowering only from the driving seat of the tractor. Do not perform lifting maneuvers on side or behind the tractor.
WARNING
Before making changes in direction, turns or going in reverse, slightly lift the Flail Mulcher from the
ground after disengaging the power take-off, to avoid damage to the machine.
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DANGER
In presence of steep slopes (greater than 15 degrees) the tilling action may cause instability of the tractor
with risk of serious injury or death hazard. Consult the manual for the tractor to determine the maximum
slope that the tractor is able to deal with.
DANGER
Always disengage the PTO before raising the Flail Mulcher, and never engage the PTO with the Flail
Mulcher in the raised position. The machine might throw objects at high speed, causing serious injury or
death.
WARNING
Never leave the driver’s seat when the tractor is turned on. Before leaving the tractor, lower the Flail Mulcher
to
the ground, disengage the PTO, insert the parking brake, stop engine and remove the key from the control
panel.
DANGER
The PTO shields of tractor and implement side, the driveshaft shielding and the driveshaft retaining chains
must be properly installed and in good condition, to avoid risk of entanglement with serious injury or death.
DANGER
Before engaging the PTO of the tractor, always make sure that the driveshaft is mounted in the correct
direction, and that its clamping elements are properly connected both to tractor side and to Flail
Mulcher side.
WARNING
Stop operating immediately if blades strike a foreign object. Repair all damage and make certain rotor and
blades are in good condition before resuming operation.
WARNING
Always disengage the tractor PTO when the driveshaft exceed an angle of 10 degrees up or down while
operating. An excessive angle with driveshaft rotating can break the driveshaft and cause flying projectiles.
CAUTION
Prolonged use of the Flail Mulcher can cause overheating of the gearbox. Do not touch the gearbox during
use and immediately after, it could be extremely hot and cause severe burn.
WARNING
All adjustment operations on the Flail Mulcher must be performed by qualified and trained operators, with
the tractor engine off, the PTO disengaged, the Flail Mulcher lowered to the ground or on security stands,
the ignition key off and the parking brake set.
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3.4. TRANSPORTING SAFETY INSTRUCTION
WARNING
Before transporting the machine, determine the stopping characteristics of the tractor and implement.
WARNING
Transport only at speeds where you can maintain control of the equipment.
WARNING
When driving on roads, the implement must be in transport position adequately raised from the road surface, with tractor lifting hydraulics locked so that the Flail Mulcher cannot be lowered accidentally.
DANGER
The implement may be wider than the tractor. Pay attention during transporting to persons, animals or
obstacles exposed.
WARNING
When turning, use extreme care and reduce tractor speed.
WARNING
Do not operate the tractor with weak or faulty brakes or worn tires.
CAUTION
Always use tractor lighting system and auxiliary lighting system for an adequate warning to operators of
other vehicles, especially when transporting at night or in conditions of reduced visibility.
PERICOLO
In case is required the lifting of the machine, make sure that the lifting device chosen is suitable to perform
the operation safely, and use only the lifting points prescribed on Flail Mulcher.
3.5. MAINTENANCE SAFETY INSTRUCTION
WARNING
All maintenance and repairing operations must be performed by qualified and trained operators, with the
tractor engine off, the PTO disengaged, the Flail Mulcher lowered to the ground or on security stands, the
ignition key off and the parking brake set.
WARNING
Perform repairs and replacements necessary to the machine using only original spare parts provided by the
manufacturer or your Dealer.
DANGER
Perform maintenance operations always using appropriate Personal Protective Equipment (protective eye
glasses, hard hat, hearing protection, safety shoes, overall and work gloves, filter mask).
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CAUTION
Before any maintenance operation, make sure that the parts which may become hot during use (gear box)
have cooled.
WARNING
Do not perform repairs that you do not know. Always follow the manual instructions and in case of doubt
contact the Manufacturer or your Dealer.
DANGER
Do not swallow fuels or lubricants. In case of accidental contact with eyes, rinse well with water and
consult a doctor.
3.6. STORAGE SAFETY INFORMATION
WARNING
Never leave the tractor unattended with the Flail Mulcher in lifted position. Accidental operation of lifting
lever or a hydraulic failure may cause sudden drop of unit with injury or death by crushing.
DANGER
Following operation, or before unhooking the machine, stop the tractor, set the brakes, disengage the PTO,
lower the Flail Mulcher to the ground, shut off the engine, remove the ignition key and wait for all moving
parts to stop.
WARNING
Make sure all parked machines are on a hard, level surface and engage all safety devices.
CAUTION
Place support blocks under Flail Mulcher as needed to prevent unit from tipping over onto a child and/or an
adult. A Flail Mulcher that tips over can result in injury or death.
CAUTION
Store the unit in an area away from human activity.
3.7. SAFETY LABELS
The safety labels on the machine provide key information for use in the safety of the machine.
Make sure all the labels are in good condition. If the labels are deteriorated, they must be replaced as with
others provided by the manufacturer,
and placed in the position shown in this manual. Make sure all the labels are readable. If necessary, clean
them using a cloth with soap and water.
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SAFETY LABELS POSITION AND DESCRIPTION
2 1
5 4 10
7
8
9
12
6
3
3
11
13
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1
Carefully read the operator’s manuals of the
Flail Mulcher, tractor and cardan shaft before
using the machine
2
Disengage the PTO, turn off the tractor engine,
remove the key and ensure that all rotating parts have
stopped before approaching the implement.
Read the operator’s manual before performing any
maintenance operation.
3
Thrown or flying objects hazard.
Keep a safe distance from the machine.
4
Rotating knives: severing of lower limbs hazard.
Keep a safe distance from the machine.
5
Cutting of fingers or hand hazard. Wait
until all machine components have
completely stopped before touching them.
6
Rotating belts: fingers or hand entanglement hazard.
Do not open or remove safety shields
while engine is running.
7
Crushing hazard.
Stay clear of draft link lifting range while in operation.
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8
Implement input driveline: body entanglement hazard.
Do not open or remove safety shields
while engine is running.
9
Before engaging the tractor PTO, check that
rpm rate and sense of rotation are those
prescribed for the implement.
10
Lower limbs crushing hazard.
Keep a safe distance from the machine.
11
Crushing hazard.
Do not stand rear the machine.
12
Hydraulic lines under pressure: keep safe distance.
Before carrying out maintenance operations, ensure the line has
been depressurized and does not contain any hot
fluid.
13
Always wear protective clothing and equipment
appropriate for the job:
hearing protection, safety shoes, safety gloves,
safety glasses and overall.
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4. SET UP
The Flail Mulcher is delivered equipped with a driveshaft and related operating manual.
When the machine is delivered, check that there is no damage to the Flail Mulcher or driveshaft. In case of
damage or missing parts immediately notify the Manufacturer or your Dealer.
Because of his size, the machine could be delivered with some parts to be assembled.
In this case, the assembly of such parts is the dealer’s task, and must be performed carefully, with
reference to the tables of the Spare parts section.
WARNING
For proper tightening torques of bolts and screws, refer to the table in this manual.
4.1. CONNECTING TO THE TRACTOR
The Flail Mulcher is designed to be mounted on tractors equipped with 3-point Hitch Category I (ISO
730 standard).
To connect the Flail Mulcher to the tractor the operator must do the following:
• drive the tractor in reverse, up to align the rear lifting arms to lower hitches of the Flail Mulcher in
parking
(see picture below);
• set the tractor’s parking brake, stop engine, remove the ignition key and get off the tractor;
• connect the lifting arms of the tractor to the lower hitches of the Flail Mulcher, and the 3-point top link to
the
upper hitch of the Flail Mulcher, through the use of the pins and the relative safety split pins;
• raise the Flail Mulcher until PTOs of tractor and machine are at the same height, then adjust the 3-point
top link so that the front of the machine is leveled to the back (the axis of the Flail Mulcher PTO must
be parallel to the ground), in order to limit stress transmitted to the Flail Mulcher through the cardan
shaft;
• make sure that left side of the Flail Mulcher is leveled with the right, by adjusting the tractor lifting arms,
then lock the arms to prevent swinging that could compromise the stability of tractor and machine
• finally adjust the parking stand, placing it at the highest point by means of the related linch pin.
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WARNING
Before connect the Flail Mulcher to the tractor, make sure that tractor and Flail Mulcher are on a flat, stable
and dry surface
4.2. DRIVELINE INSTALLATION
The gearbox unit is equipped with a free wheel inside, able to absorb the rotor inertia during stopping, and
to prevent possible damage to the transmission system machine-tractor that would be caused by an
instantaneous stop of the rotor.
Consequently, the use of a cardan shaft with free wheel is not required.
Before installing the driveshaft, the operator must read the manuals of driveshaft and tractor, checking in
particular that rpm and direction of rotation of the tractor PTO match those of the Flail Mulcher.
If the direction of rotation of the PTO tractor does not match that of the machine, contact the Manufacturer
or your Dealer.
To connect the driveshaft to the tractor and implement, the operator must:
park tractor and Flail Mulcher on a flat surface, with parking brake set, engine off, and ignition key
removed;
check that driveshaft, Flail Mulcher and tractor are in good condition, otherwise provide for their
replacement;
remove the PTO shield of the Flail Mulcher through the fixing screws;
insert the driveline yoke on the implement PTO by first lining up the splines, then ensure its tightening
onto the shaft through its fastener/snap pin;
replace the PTO shield of the Flail Mulcher through the fixing screws;
insert the driveshaft yoke on the tractor PTO, then ensure its tightening onto shaft through its fastener;
hook to the tractor and Flail Mulcher the two retaining chains of the driveline shielding, to prevent
shielding rotation during functioning of the machine.
DRIVELINE LENGTH CHECK
Before operating the Flail Mulcher, ensure that the size of driveshaft is adequate. The driveshaft
supplied with the machine has a standard length, therefore it may need an adaptation of the
length, depending of the tractor which the Flail Mulcher is combined.
The length of the driveshaft must be such to:
• avoid bottom out of the transmission tubes, when the driveshaft is in compressed position (when Flail
Mulcher is raised up off the ground);
• ensure an overlapping of the transmission tubes enough to transmit the torque required, when the
driveshaft is in max extension (when Flail Mulcher is in its lowest position in the ground).
When the driveshaft is at its minimum length (max compressed position), there must be at least a
2 cm of distance between the ends of each transmission tube and the yokes side.
When the driveshaft is at its maximum operational extension, there must be an overlap between
the tubes profiles of 15 cm at least.
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