McConnel Merlin Xtreme 2000 / 2500 / 2800 flail mower service schedule
Hedgecutters and flails · 2009 on (Publication 590, April 2009)
Every maker's service job for the McConnel Merlin Xtreme 2000 / 2500 / 2800 flail mower, counted in hours, with the oils, filters and parts each one needs. Add your implement to Farmyard Workshop and it works out what's due from your hours and dates, and keeps the service history.
Track your Merlin Xtreme 2000 / 2500 / 2800 flail mower for freeVersions: Merlin Xtreme 2000 (2.0 m); Merlin Xtreme 2500 (2.45 m); Merlin Xtreme 2800 (2.65 m)
Service intervals
| Job | When |
|---|---|
| Grease rotor and roller bearings | every 8 hours |
| Gearbox oil change | every year |
| Storage | every year |
| Flails, flail bolts and rotor bearings | when needed |
| Drive belts and taper locks | when needed |
Service jobs and parts
Grease rotor and roller bearings
Rotor · every 8 hours
McConnel says grease the rotor bearings and rear roller points at least every 8 hours, and especially after washing. Clear any string, wire or grass from the rotor shaft and roller ends at the same time.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Grease | 1 | check your handbook |
Step-by-step
- Lower the mower, disengage the PTO, stop the tractor, take the key out and wait for the rotor to stop.
- Grease the rotor bearings, the rear roller bearings and the PTO shaft.
- Remove string, plastic or grass wrapped round the rotor shaft or roller bearings.
- Grease again after every wash to push water out of the bearings.
Tools: Grease gun, Knife or side cutters
Gearbox oil change
Gearbox · every year
McConnel says drain and refill the gearbox after the first 50 hours, then every year, with EP90 (1.8 L). Check the level before first use and every 8 hours after that, and check the gearbox bolts and seals.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| EP90 gear oil | 1 | SAE 90 EP gear oil (EP90). 1.8 L. Aztec Oils match: TRANSMATEC EP-4 90 | check your handbook |
| Gearbox | 0 | For reference only | 5770009 |
Step-by-step
- Lower the mower to the ground on level ground, disengage the PTO, stop the tractor and take the key out.
- Drain the gearbox, refit the drain plug and fill with EP90 until oil just starts to seep from the level plug, the lower centre plug on the aluminium end plate.
- On a new machine do this at 50 hours, then every year.
- Check the gearbox bolts are tight and secured with thread-lock, and look for leaking seals. Replace a leaking seal straight away.
Tools: Drain tray (3 L), Spanners, Funnel
Storage
Storage · every year
McConnel says wash the mower thoroughly at the end of the season, grease every point until fresh grease shows, and store the PTO shaft and belts somewhere dry.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Grease | 1 | check your handbook |
Step-by-step
- Wash off all grass and dirt. Do not hold a pressure washer jet close to the paint or the bearing seals.
- Grease every point until fresh grease shows.
- Store the PTO shaft and drive belts in a dry place.
- Check the skids. Hard-facing rods can be used on skids that wear fast on abrasive ground.
Tools: Pressure washer, Grease gun
Flails, flail bolts and rotor bearings
Rotor · when needed
McConnel says check the flails and bolts regularly, torque flail bolts to 200 Nm, always fit new bolts, nuts and bushes with new flails, never weld flails and never mix flail types. Missing flails cause vibration, rapid bearing wear and a cracked hood.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Flail | 1 | Full set: 48 / 60 / 66; keep the rotor balanced. Corrected: McConnel Merlin Xtreme parts list, rotor page ref 22 (the earlier number 7770699 is the flail bush) | 1777312A |
| Flail bush | 1 | One per flail; always renew with the flail. Per McConnel Merlin Xtreme parts list, ref 24 | 7770699 |
| Flail bolt | 1 | One per flail; always renew. Per McConnel Merlin Xtreme parts list, ref 25 | 1777721 |
| Flail nut | 1 | One per flail; always renew. Per McConnel Merlin Xtreme parts list, ref 26 | 2770600 |
| Rotor/roller bearings | 1 | Bearings listed on the rotor and roller page: 4770872, 4770891, 4770892. Match the position on the diagram | check your handbook |
| Rotor bearing seal | 1 | 4771122 |
Step-by-step
- Disengage the PTO, stop the tractor, take the key out and wait until the rotor has stopped.
- Support the mower on stands if you must reach underneath. Never rely on the tractor linkage alone.
- Check each flail. Replace badly worn, cracked or damaged flails at once, keeping the rotor balanced. Never weld a flail.
- Fit new bolts, nuts and bushes with each new flail and torque the flail bolts to 200 Nm.
- Check the rotor bearing bolts are tight and the bearings run smoothly.
- Sharpen blunt flails wearing goggles and protective clothing.
Tools: Torque wrench (to 200 Nm), Sockets, Stands or blocks, Eye protection and gloves
Drive belts and taper locks
Drive · when needed
McConnel lists belt tension as a daily job: belts must be aligned and correctly tensioned. Check the screws on the pulley taper locks, especially while the machine is new.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Drive belt | 1 | Number in the set: check your handbook | 4770843 |
| Taper lock (250 mm pulley) | 0 | If worn | 4770922 |
| Taper lock (190 mm pulley) | 0 | If worn | 4770921 |
Step-by-step
- Stop the tractor and take the key out. Take both belt guards off.
- Check the belts for wear and cracks and tension them. Check they run in line after adjustment.
- Check the 7 taper lock screws on each pulley are tight (pulley clamps M8 45 Nm). Thread-lock helps once they have bedded in.
- Refit both guards before use.
Tools: Spanners, Allen keys, Straight edge
Oils, fluids and capacities
| System | Oil or spec | Capacity |
|---|---|---|
| Gearbox | EP90 gear oil | 1.8 L. Level with the lower centre plug on the aluminium end plate |
| Rotor, roller and PTO grease points | Grease |
Specifications
| Tractor | 50 hp (2000), 60 hp (2500), 70 hp (2800); Cat 2 linkage; at least 2,500 kg with ballast; live PTO |
| PTO | 1000 rpm, slip clutch protection |
| Weight | 730 kg (2000), 814 kg (2500), 860 kg (2800) |
| Flails | 48 (2000), 60 (2500), 66 (2800), as read from the spec table |
| Rear roller | 168 mm |
| Flail bolt torque | 200 Nm (160 lbf ft) |
| Other torques | Pulley clamps M8 45 Nm; general M10 65 Nm, M12 114 Nm; roller plate bolts M16 280 Nm; headstock bolts M24 950 Nm |
| Belt drive | Pulleys on taper locks (7 screws, 3 jacking holes); 250 mm and 190 mm pulleys |
Known problems
Rotor bearing failure
McConnel lists lack of greasing, water in the bearing, wire or string in the bearing and an out-of-balance rotor as the causes.
Gearbox overheating
Check the oil level and grade, cut slower, and make sure the PTO speed is 1000 rpm.
Repair guides
- Rotor vibration and rotor bearing failure (Moderate, 1–2 hours for flails; 3–5 hours for a rotor bearing): Mower shakes or the hood vibrates, a rotor bearing runs hot, rumbles or has play, grease is thrown out, or the hood has started to crack.
- Drive belts wearing fast or slipping: belts, pulleys and taper locks (Moderate, 1–2 hours): Belts squeal, smell hot, wear quickly, throw off, or the rotor slows in heavy growth while the PTO keeps turning; pulleys loose on their shafts.
- Gearbox running hot or leaking oil (Moderate, 1 hour to check and refill; 2–4 hours to change a seal): Gearbox too hot to touch after work, oil weeping from the input or output seal, oil on the hood or belt guard, or a low level at the level plug.
- PTO shaft wear, UJ failure and slip clutch (Moderate, 1–2 hours): Universal joints knocking or with play, the shaft bottoming out when the mower is raised or lowered, broken guards, or the slip clutch slipping all the time or not slipping at all when the rotor hits something.
The full step-by-step guides are in Farmyard Workshop once you add your implement.
Parts list with genuine part numbers
McConnel MERLIN Xtreme 2000/2500/2800 operator and parts manual (Publication 590, part no. 41571.90, rev. 27.01.15), parts section; plus McConnel Merlin Xtreme 2000/2500/2800 operator and parts manual, rev. 27.01.15
Main Assembly
| Part | Part number | Qty | Notes |
|---|---|---|---|
| Gearbox | 5770009 | ||
| Guard | 5770106 | ||
| Bolt | 2770418 | ||
| Washer | 2770434 | ||
| Shaft | 5770040 | ||
| Shaft Q2800 | 5770115 | ||
| Shaft | 1772211A | ||
| Key | 4772229 | ||
| Bearing | 4770933EC | ||
| Bolt | 2770423 | ||
| Nut | 2440447 | ||
| Washer | 2770454 | ||
| Bracket | 1771513A | ||
| Pulley (250mm) | 4770920 | ||
| Taper Lock | 4770922 | ||
| Pulley (190mm) | 4770918 | ||
| Taper Lock | 4770921 | ||
| Cap | 8777516 | ||
| Guard | 1772231B | ||
| Belt | 4770843 | Wear part | |
| Skid | 1772309 | Wear part | |
| Bolt | 2770422 | ||
| Rubber 2m | 8400201 | ||
| Rubber 2.5m | 8400200 | ||
| Rubber 2.8m | 8400199 | ||
| Bar 2m | 1772290 | ||
| Bar 2.5m | 1772291 | ||
| Bar 2.8m | 1772310 | ||
| Bolt | 2770396 | ||
| Nut | 2770412 | ||
| Plate | 1771520A | ||
| Bolt | 2770493 | ||
| Washer | 2770457 | ||
| Cover – 2m | 1772256B | ||
| Cover – 2.5 & 2.8m | 1772268A | ||
| Washer | 2770469 |
Rotor & Roller Assembly
| Part | Part number | Qty | Notes |
|---|---|---|---|
| LH plate | 1772307 | ||
| RH plate | 1772307R | ||
| Roller assembly 2m | SA 02006 | ||
| Roller assembly 2.5m | SA 02005 | ||
| Roller assembly 2.8m | SA 02007 | ||
| Shaft | 1772305 | ||
| Bearing | 4770872 | ||
| Circlip | 2771109 | ||
| Circlip | 2777512 | ||
| Cover | 1772306 | ||
| Grease Nipple | 2770468 | ||
| Bolt | 2770425 | ||
| Nut | 2770447 | ||
| Washer | 2770454 | ||
| Bearing | 4770891 | ||
| Circlip | 2771610 | ||
| Washer | 1777850 | ||
| Bolt | 2770461 | ||
| Cover | 1777312A | ||
| Flail | 7770699 | Wear part | |
| Bush | 1777721 | ||
| Bolt | 2770600 | ||
| Nut | 05.968.06 | ||
| Bolt | 2770397 | ||
| Grease Nipple | 2770467 | ||
| Housing | 1772303A | ||
| Seal | 4771122 | ||
| Circlip | 2771611 | ||
| Bearing | 4770892 | ||
| Sleeve | 4770893 | ||
| Housing | 1772302A | ||
| C/Sink Bolt | 2770398 | ||
| Seal Housing | 1772311A | ||
| Washer | 4771511 | ||
| Bolt | 2770443 | ||
| 2m Rotor assembly | 1772298A | ||
| 2.5m Rotor assembly | 1772299A | ||
| 2.8m Rotor assembly | 1772301A | ||
| Bolt | 2770450 | ||
| Washer | 2770436 | ||
| Nut | 2770417 | ||
| Spacer | 180470 |
Headstock Assembly
| Part | Part number | Qty | Notes |
|---|---|---|---|
| Standard Headstock | 1772265 | ||
| Front Clamp | 1772266 | ||
| Rear Clamp | 1772267A | ||
| Bolt | 2770403 | ||
| Nut | 2770414 | ||
| Pin | 6310208 | ||
| Washer | 2770470 | ||
| Pin | 00.372.01 | ||
| Pin | 6310203 | ||
| PTO Support | 1777434 | ||
| Clip | 6310194 |
Hydraulic Headstock Assembly
| Part | Part number | Qty | Notes |
|---|---|---|---|
| Hydraulic Headstock | 1772270 | ||
| Bolt | 2770519 | ||
| Nut | 2770414 | ||
| Wear Pad | 4600120 | Wear part | |
| Pin | 6310208 | ||
| Washer | 2770470 | ||
| Pin | 00.372.01 | ||
| Pin | 6310203 | ||
| PTO Support | 1777434 | ||
| Clip | 6310194 | ||
| Ram – 2m | 3580650 | ||
| Ram – 2.5m & 2.8m | 3580663 | ||
| Bolt | 2770424 | ||
| Nut | 2770417 | ||
| Washer | 2770436 | ||
| Bolt | 2770471 | ||
| Grease Nipple | 2770511 | ||
| Hose | 3760261 | ||
| Hose | 3760262 | ||
| Hose | 3760260 | ||
| Adaptor | 3460100 | ||
| Adaptor | 3360080 | ||
| Adaptor | 3460107 | ||
| Washer | 3260070 | ||
| Washer | 3360074 | ||
| Seal | 3260072 | ||
| QR Coupling | 3750153 | ||
| Sleeve | 3870500 | ||
| Tie | 8770639 |
PTO Shaft Assembly
| Part | Part number | Qty | Notes |
|---|---|---|---|
| Outer Bearing | 4770815 | ||
| Chain | 5771020 | Wear part | |
| Inner Bearing | 4770814 | ||
| Cross Journal | 5771301 | ||
| QR Yoke | 5771299 | ||
| Tube Yoke | 5770095 | ||
| Tube Yoke | 5770096 | ||
| Overrun Clutch (R/M) | 5772321 | ||
| Overrun Clutch (F/M) | 5772321L | ||
| Taper Pin | 5771322 | ||
| Roll Pin | 2770542 | ||
| Complete Guard | 5772262 |
Cross Shaft Assembly
| Part | Part number | Qty | Notes |
|---|---|---|---|
| Shaft – 2000 & 2500 | 5770040 | ||
| Shaft - 2800 | 5770115 | ||
| 6 Spline Yoke | 5772279 | ||
| Grease Nipple | 2770467 | ||
| Cross Journal | 5770113 | ||
| Tube Yoke | 5772274 | ||
| Pin | 2770527 | ||
| Clamp Yoke – 35mm | 5772271 | ||
| Bolt | 2770424 | ||
| Nyloc Nut | 2770417 | ||
| Flat Washer | 2770436 |
Gearbox Assembly
| Part | Part number | Qty | Notes |
|---|---|---|---|
| Gearbox Assembly | 5770009 | ||
| Cover | 5772296 | ||
| Bearing | 5772341 | ||
| Circlip | 5772447 | ||
| Seal | 5772343 | ||
| Shaft | 5772297 | ||
| Gearset | 5772344 | ||
| Bearing | 4771606 | ||
| Bearing | 5771435 | ||
| Circlip | 5772299 | ||
| Oil Seal | 4771124 | ||
| Circlip | 5772348 | ||
| Breather | 5771607 | ||
| Oil Seal | 5772343 | ||
| Circlip | 5772347 | ||
| Bearing | 5772340 | ||
| Plug | 5777205 | ||
| Rear Shaft Guard | 1777602 |
Hydraulic headstock
| Part | Part number | Qty | Notes |
|---|---|---|---|
| Ram seal kit | 3570650T,W,HP | 1 | Wear part |
Sources
- MERLIN Xtreme operator manual: gearbox EP90 1.8 L, 50 h then yearly, greasing, flail bolts 200 Nm, belts, storage, torques
- MERLIN Xtreme operator and parts manual: flail, bush, bolt, nut, bearings, belt, taper locks
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