Flail Mower Attachments for Mini Excavators (1–5 Ton)
REVIEW
How flail mowers function
Required hydraulic setup
Routine maintenance and inspection
Safe operating procedures and troubleshooting
This guide excludes hydraulic hose installation and excavator-specific control setup — refer to your excavator’s auxiliary circuit manual for connection instructions.
2. SYSTEM OVERVIEW
A flail mower (also called a mulching head or brush cutter) is a hydraulic-powered cutting attachment that uses rotating knives or hammers mounted on a horizontal drum to cut vegetation, grass, and light scrub.
The attachment is powered by the excavator’s auxiliary hydraulic circuit, making it ideal for:
Verge and embankment mowing
Clearing undergrowth, brambles, or shrubs
Maintaining ditches and slopes
Orchard, vineyard, and forestry maintenance
3. OPERATING PRINCIPLE
Hydraulic oil from the excavator’s auxiliary circuit flows into the hydraulic drive motor on the mower.
The motor drives a belt or direct-coupled rotor drum that spins flails (knives or hammers) at high speed — typically 2,000–3,000 RPM.
The rotating flails strike vegetation repeatedly, cutting and mulching material.
A protective hood and debris curtain contain the discharge, ensuring controlled cutting.
The excavator arm allows positioning on slopes, ditches, or overhead vegetation.
4. MAIN COMPONENTS
Component
Description
Function
Hydraulic Motor
Orbital or piston motor powered by excavator flow.
Drives the rotor drum.
Rotor Drum
Cylindrical drum fitted with flail blades or hammers.
Performs cutting action.
Flails (Knives or Hammers)
Swinging or fixed cutting elements.
Shred vegetation by impact.
Drive Belt / Coupling
Transmits motor torque to rotor.
Protects motor from shock loads.
Housing / Deck
Heavy-duty steel casing around rotor.
Provides structure and debris containment.
Front and Rear Guards
Chains or rubber curtains.
Prevent debris ejection.
Mounting Bracket
Attaches to excavator dipper arm or quick coupler.
Provides stability and positioning.
Skids / Rollers
Adjustable ground-following supports.
Maintain cutting height.
5. FLAIL TYPES & APPLICATIONS
Flail Type
Description
Best For
Material Thickness
Y-Blades (Grass Flails)
Lightweight double “Y” blades.
Grass, weeds, fine vegetation.
Up to 15 mm.
Hammer Flails
Heavy solid hammers.
Brush, saplings, rough scrub.
Up to 50 mm.
Reversible Knives
Sharpened on both edges.
Mixed vegetation, agricultural work.
Up to 25 mm.
Tip: Hammer flails are best for forestry or heavy brush, while Y-blades give a cleaner finish for landscaping or grass cutting.
6. HYDRAULIC REQUIREMENTS
Excavator Size
Flow Range (L/min)
Pressure (bar)
Cutting Width (mm)
Rotor Speed (RPM)
1–2 Ton
20–35
100–150
800–1000
2000–3000
2–3 Ton
30–50
120–170
1000–1200
2000–3000
3–5 Ton
40–75
150–210
1200–1500
1800–2600
Always ensure the excavator’s flow and return lines are clean and pressure relief valves are within the mower’s rated pressure range.
7. DRIVE SYSTEMS
7.1 DIRECT DRIVE
Motor connects directly to rotor shaft.
Compact, low-maintenance design.
Best for light vegetation and smaller excavators.
7.2 BELT DRIVE (Most Common)
Hydraulic motor drives rotor via V-belts or toothed belts.
Belts act as shock absorbers, protecting motor seals.
Allows torque multiplication for heavy cutting.
7.3 GEAR REDUCTION DRIVE (Heavy-Duty)
Uses internal planetary reduction gears.
High torque output for forestry or thick brush.
Typically found on 3–5 ton excavators.
8. MOUNTING CONFIGURATIONS
Mount Type
Description
Use
Direct Top-Mount
Fixed bracket connects directly to dipper arm or coupler.
Most compact and common setup.
Tilt Bracket Mount
Allows ±45° to ±90° tilt via hydraulic cylinder.
Slopes, banks, or verge mowing.
Side-Mount Offset Arm
Extends mower outward from boom.
Ditch, hedge, or roadside work.
Quick-Hitch Mount
Uses excavator’s standard coupler for fast attachment.
Multi-attachment operations.
When tilting or offsetting, ensure auxiliary hoses are long enough and routed safely to prevent kinking.
9. OPERATIONAL GUIDELINES
Pre-checks: Verify hydraulic flow, pressure, and correct rotation direction.
Lower mower gently to the surface; do not drop from height.
Engage hydraulics at low flow until rotor reaches stable speed.
Maintain steady arm movement — avoid rapid swinging.
Keep RPM consistent; avoid stalling in heavy vegetation.
Operate in short passes, overlapping by 10–20% for uniform cut.
Always work away from bystanders and structures.
Lift the mower before reversing or turning sharply.
Stop rotor and allow full stop before leaving the cab or adjusting.
10. INSPECTION & MAINTENANCE
10.1 Daily / Pre-Use
Check
Purpose
Hydraulic hoses and couplers
Detect leaks or abrasion.
Rotor and flails
Inspect for cracks, bending, or missing blades.
Belt tension and alignment
Maintain torque transmission efficiency.
Mount bolts and brackets
Ensure all fasteners are tight.
Guards and chains
Confirm they are intact and functional.
10.2 Periodic Maintenance (Every 250 Hours)
Task
Description
Replace drive belt(s) if worn or cracked.
Grease rotor bearings and tilt pivot points.
Check gearbox (if equipped) oil level and quality.
Inspect motor shaft seals for oil leaks.
Torque all bolts to manufacturer’s specifications.
10.3 Annual Service
Task
Description
Replace rotor bearings and seals as preventive maintenance.
Replace hydraulic hoses showing wear.
Balance rotor assembly to reduce vibration.
Repaint and re-label worn safety decals.
Perform full hydraulic flow and leak test.
11. SAFETY INFORMATION
Only trained operators may use the attachment.
Never operate near people, vehicles, or windows — debris can be ejected.
Ensure protective guards and curtains are installed before use.
Keep clear of the rotor while running or coasting.
Operate at manufacturer-specified flow and pressure only.
Avoid contact with the ground at full RPM — reduce speed when lowering.
Disconnect hydraulics and relieve pressure before maintenance.
Always wear PPE: hard hat, visor, gloves, hearing protection, steel-toe boots.
Store clean and dry. Ensure rotor is free of debris. Disconnect hoses and fit dust caps.
Long-Term (Over 3 Months)
Grease bearings, coat exposed steel with anti-corrosion oil, and store indoors at 5–25 °C.
Transport
Secure mower horizontally on pallet or cradle. Lock rotor with wooden block. Protect hoses and fittings.
14. MAINTENANCE RECORD TEMPLATE
Date
Technician
Hours
Inspection
Observations
Action Taken
15. TECHNICAL SUMMARY
Category
Specification
Machine Compatibility
Mini Excavators (1–5 Ton)
Drive Type
Hydraulic Motor (Direct or Belt Drive)
Flow Range
20–75 L/min
Pressure Range
100–210 bar
Cutting Width
800–1500 mm
Rotor Speed
1800–3000 RPM
Flail Options
Y-Blades, Hammers, Reversible Knives
Lubrication
Grease every 10 hrs; gearbox oil every 250 hrs
Noise Level
85–95 dB typical
Mounting Options
Top, Tilt, Side, or Quick-Hitch Mount
Maintenance Interval
250-hour check; annual overhaul
Safety Compliance
EN ISO 12100 / ISO 4413 Hydraulic Systems
Flail mower attachments turn mini excavators into powerful vegetation management tools. When properly matched to the excavator’s hydraulic system, they deliver efficient, safe, and reliable cutting for a wide range of terrain. Routine inspection, correct belt tension, and balanced rotors ensure long-term performance and operator safety.
Flail mower attachments turn mini excavators into powerful vegetation management tools.