Major 12000FW-HD, 18000FW-HD User Manual

MAJOR RANGE OF

FLEX WING TOPPERS

12000FW-HD and 18000FW-HD

Operator Manual

& Parts List

Head Ofce
Major Equipment Intl. Ltd.
Ballyhaunis,
Co. Mayo,
Ireland.

Tel.: [phone]
Fax: [phone]
Email: [e-mail]

UK Ofce

Major Equipment Ltd.
Major Industrial Estate,
Middleton Rd.,
Heysham,
Lancs.
LA3 3JJ

Tel.: [phone]
Fax: [phone]
Email: [e-mail]

NETHERLANDS & GERMANY OFFICE

Major Equipment Intl. Ltd.
Postbus 29,
NL-7700 AA ,
Dedemsvaart,
Nederland.

Tel: [phone]
Email: [e-mail]

Web: www.major-equipment.com

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Disclaimer
While every effort has been made in the production of this manual to ensure that the information
contained herein is full and correct, Major assumes no responsibility for errors or omissions.

Major reserves the right to modify the machinery and the technical data contained within the
manual without prior notice.

Further to this, Major assumes no liability for any damages which may result from the use of the
information contained within this manual.

Contents

Introduction

Thank you 1
Using Your Operator’s Manual 1

Safety Aspects 1

Intended use 1

Product Identication

Machine Serial Numbers 1
Register Your Product and Warranty Online 1
Product Specications 2

Safety

Machine Safety Labels 2

Hazards 3
Operating Safely 4
Workstation 4

Regulations for use of the transmission 4

PTO Shaft Safety 5

Driving Safely on Public Roads 5

Operating the Machine

Inspections before Use 6

Key to Main Parts 7
Starting Regulations 7

Hitching to the Tractor 7
Operating the Machine/Mowing 9

Maintenance

PTO Shaft Maintenance 9

Blade Rotation 10

Maintenance Schedule 10
Trouble Shooting 11

Spare Parts - Flex Wing

Flex Wing Topper Overview 12
12000FW-HD and 18000FW-HD body assembly 13
12000FW-HD wing 14
18000FW-HD wing 14
Castor wheel 15
Blade Systems 16
Gearboxes 18
Flex Wing Hydraulics 22

EEC certicate of conformity for machines

(conforming to Directive 98/37/EEC)

Company: Major Equipment Ltd.
Address: Coolnaha,
Ballyhaunis,
Co. Mayo,
Ireland.
Tel. [phone]
Fax [phone]

declares in sole responsibility that the product:

FLEX WING GRASS TOPPER

When properly installed, maintained and used only for it’s intended purpose, complies with
all the essential Health & Safety requirements of:

• THE SUPPLY OF MACHINERY (SAFETY) REGULATIONS 2008.

• S.I. No. 299 of 2007, Safety, Health and Welfare at Work (General Application)
Regulations 2007 (Ireland).

• Health & Safety at Work, etc. Act 1974 (c.37) (UK).

• EN ISO 14121-1: 2007 ‘Safety of machinery. Principles for risk assessment’.

• EN 745 - Agricultural Machinery - Rotary Mowers and Flail Mowers - Safety.

• EN ISO 13857 - Safety of machinery: Safety distances to prevent hazard zones
being reached by upper and lower limbs.

I certify on behalf of Major Equipment Int. Ltd., that this machine when properly installed
and operated correctly, complies with all the essential Health & Safety requirements of
all legislation referred to above.

Signature : ______________ Date 12/06/2013

Managing Director

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120416

Introduction

Thank you

We appreciate having you as a customer and wish you many years of safe and satised use of your machine.

Using Your Operator’s Manual

This manual is an important part of your machine and should remain with the machine when you buy it. Reading your
operator’s manual will help you and others avoid personal injury or damage to the machine. Information given in this
manual will provide the operator with the safest and most effective use of the machine.

Sections in your operator’s manual are placed in a specic order to help you understand all the safety messages so you
can operate this machine safely. You can also use this manual to answer any specic operating or servicing questions.

Safety Aspects

Your manual contains special messages to bring attention to potential safety concerns, machine damage as well as
helpful operating and servicing information. Please read all the information carefully to avoid injury and machine damage.

Intended use

This machine is a grass cutting machine and designed for cutting grass. Moreover, it must only be used with a suitable

tractor (see “Product Specications” section of this booklet) and driven by an adequate drive-line of the tractor PTO. All

other use is strictly prohibited.

Product Identication

Machine Serial Numbers

If you need to contact MAJOR or your MAJOR dealer for information on servicing or spare parts, always provide the
product model and serial numbers. Model and Serial number can be found on the Serial Plate located on the machine.

We suggest that you record your machine details below:

Model No: ______________________________

Serial No: ______________________________

Date of Purchase: ______________________________

Dealer Name: ______________________________

Dealer Telephone: ______________________________

Register Your Product and Warranty Online

To register your product through the Internet, simply go to the Support section on www.major-equipment.com. Completing
the information, either online or with the product warranty card, will ensure the customer that their product receives all
post sales service and important product information.

This machine is warranted for 12 months with. No warranty is given where the machine is being used as a hire machine.
Warranty is against faulty workmanship or parts.

Warranty covers parts only. All parts must be returned to the manufacturer. No warranty can be considered unless parts
are returned. All replacement parts will be supplied on a chargeable basis until warranty has been accepted.

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Product Specications

Model 12000FW-HD 18000FW-HD

Overall Width 3.8m (12’ 4”) 5.6m (18’ 4”)

Working Width 3.56m (12’) 5.38m (18’)

Transport Width 2.2m (7’ 2”) 2.2m (7’ 2”)

No. of Blades 16 24

No. of Rotors 4 6

Power (HP) 50 - 75 60 -90

PTO (rpm) 540 540

Blade tip speed 74m/s 74m/s

Cutting Height 12-250mm 12-250mm

Weight 1116kg 1395kg

To avoid injury, read the manual Check the tightness of the transmission

Rotating blade hazard

PTO entanglement

hazard - keep clear

of PTO drives.

Safety

Machine Safety Labels

The machine safety labels shown in this section are placed in important areas on your machine to draw attention to
potential safety hazards.

On your machine safety labels, the words DANGER, WARNING, and CAUTION are used with this safety alert symbol.

DANGER identies the most serious hazards.

The operator’s manual also explains any potential safety hazards whenever necessary in special safety messages that
are identied with the word, CAUTION, and the safety-alert symbol .

Grease points

Shaft alignment

High oil pressure

hazard

Moving parts

Maximum speed

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Hazards associated with operating Grass Cutting Machinery

Shear Hazard

Shear hazards are created when the edges of two objects move toward or next to each other closely enough to cut
relatively soft material. This can include the parts of the machine under hydraulic control when operating from transport

to mowing position. Note, the wing units are designed to oat independently of the centre deck & are free to move within

operating limits.

Crush Hazard

Bystanders can be injured when machine is lowered into mowing position. Winged machines have crush points around
the hinge areas & between the wing & main body. Always use transport locking bars when not in use (winged models
only).

Rotating Blade Hazard

All persons are at risk if they place their hands or feet under the machine when it is raised from the ground when the
blades are in motion.

Pinch Hazard

Pinch points are created when two objects move together, with at least one of them moving in a circle. This hazard is
common in power transmission devices such as Belt Drives, Gear Drives & Rollers. Ensure all guarding is present.

Wrap Hazard

Any exposed, rotating machine component is a potential wrap point. Injuries usually occur when loose clothing or long
hair catch on and wrap around rotating parts such as PTO shafts or Drive shafts on the machine. Ensure all guarding
is present.

Free-wheeling parts Hazard

The heavier a revolving part is, the longer it will continue to rotate after power is shut off. This characteristic is called
‘free-wheeling.’ Blades, and various other components, drive shafts etc., will continue to move after power is shut off ­often for several minutes. Injuries occur when:

• Operators shut off equipment, and attempt to clean or adjust a machine before components have completely stopped
moving.

• Shear bolt protection device in PTO shaft shears & the mowing parts are still spinning but the primary PTO shaft is
stationary. Operator awareness is the key to safety around freewheeling parts. Never raise the machine while the
blades are still rotating.

Thrown objects Hazard

Machines throw material as a natural part of doing their job. Foreign objects, such as stones, sticks and other debris,
may be taken into this equipment and expelled at tremendous speed. These objects are contained by the sides of the
machine and by the rear/front rollers / guards / chain guards / rubber skirts depending on model of your machine.
Ensure bystanders are clear from the machine & cannot be hit with debris expelled from the machine. Bystanders or
animals in the path of thrown objects could be seriously injured. Never operate machine with decks raised from the
ground as this makes the front/rear protection redundant.

Hydraulic Hazard (if applicable)
Hydraulic systems store considerable energy. Careless servicing, adjustment, or replacement of parts can result in
serious injury. High pressure blasts of hydraulic oil can injure eyes or other body parts. The following precautions are
crucial:

• Make certain the hydraulic pump is turned off.

• Lower attached equipment to the ground.

• Conrm that load pressure is off the system.

A pinhole leak in an hydraulic hose is a serious hazard. A leak may not be visible, and the only sign may be a few drops

of uid. Never inspect hydraulic hoses with your hands, because a ne jet of hydraulic uid can pierce the skin.

Slips, Trips and Falls Hazard

Slips and falls often result from:

1. Slippery footing on the ground

2. Cluttered steps and work platforms.

The potential for slips and falls can be greatly reduced by using good judgement and practicing good housekeeping on
and around equipment.

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Operating Safely

This MAJOR machine is designed to operate at a PTO rate which is stated in the Product Specications part of this

booklet. Ensure tractor PTO output is set at a correct RPM rate. This MAJOR machine must only be used for purposes
outlined in the Intended Use section of this booklet. All other use is strictly prohibited.

Users should become thoroughly familiar with the contents of this manual before using, servicing and
mounting the implement to the tractor and all other pertinent operations. Never wear jewellery, loose clothing
such as ties, scarves, belts, unbuttoned jackets or dungarees with open zips which could become caught up
in moving parts.

Always wear approved garments complying with accident prevention provisions such as non-slip shoes, ear

muffs, goggles and gauntlets. Wear a jacket with reecting stickers if the implement is used near public

highways.

Consult your retailer, the Labour Health Service or your nearest equivalent authority for the information about

the current safety provisions and specic regulations with in order to ensure personal safety.

ALWAYS DISENGAGE PTO, SWITCH OFF THE TRACTOR ENGINE AND ENGAGE THE PARKING BRAKE
BEFORE MAKING ADJUSTMENT TO THE MACHINE.

NEVER PLACE LIMBS UNDER THE MACHINE WHILE ROTOR(S) ARE TURNING. ROTOR(S) CAN
REMAIN TURNING FOR UP TO 1 MINUTE AFTER DISENGAGING PTO.

Workstation

The operator must remain seated while working the machine. If the machine is a winged unit and the wings need to
be raised/lowered the operator must not leave the tractor. Always ensure the PTO has been turned off and the parking
brake applied before leaving the tractor cab or carrying out maintenance.

NEVER OPERATE THE HYDRAULICS WITH THE TRACTOR SWITCHED OFF

Regulations for use of the transmission

The transmission to the gearboxes is protected throughout the machine by both PTO shafts and bolt down covers. All

guarding should be kept efcient and in good condition. If the condition is poor, the guarding should be renewed before

the implement is used.

UNLESS IT IS CORRECTLY PROTECTED THE TRANSMISSION COULD CAUSE DEATH SINCE IT CAN
CATCH ON PARTS OF THE BODY OR CLOTHING

Ensure retaining chains are correctly anchored on all PTO shafts, preventing them from turning. Ensure drive line can
turn easily within the shield. Keep spline grooves clean and greased so that PTO shaft can connect easily. Besides
being described in this booklet, the method by which the PTO shaft is connected to the tractor must be checked out with
the instructions in the tractor manufacturer’s manual.

Noise Hazard

Please note that the machine is normally used outdoors and that the position of the operator is seated in the driving seat
of the tractor. It is advisable to consult the prescriptions listed in tractor operator and maintenance manuals.
The acoustic pressure at a distance of 2.6m from the centre of the machine and at a height of 2.0m, with the implement
operating in a no load condition can reach 90 dBA. In a loaded condition & a PTO rate of 540 rpm the value can reach
97dBA. Higher rate of PTO input will result in in higher noise levels. Always wear hearing protection.

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PTO Shaft Safety

Maximum PTO input is specied in the Product Specications section of this booklet. Contact your nearest dealer or

a specialised retail outlet if the PTO must be replaced with a longer one, since this must belong to the same power
category and possess the same characteristics. An unsuitable PTO could easily break.

The tractor PTO shaft length may be altered to suit the individual tractor model. When the machine is in operation, the
PTO shaft should have a minimum 1/3 engagement as shown in the diagrams. After the machine has been hitched to
the tractor, it should be checked in various positions that the drive line is the correct length. If the PTO is too short and
tends to slip out of place, it must be replaced with a longer one.

Driving Safely on Public Roads

Check the local Highway Code regulations before driving the tractor on public highways with an implement attached.

Check the reectors, hazard ashers and/or projecting load indicators are installed when required and efcient. These

indicators must be installed correctly and easily seen by the drivers of other vehicles.
Bystanders must not be allowed to lean against or climb onto the machine during transport or while working. Do not
allow bystanders to ride on the machine.

MAXIMUM TRANSPORT SPEED MUST NOT EXCEED 30 km/hr (18 MPH)

If the PTO shaft is too long, it should be shortened in the following way:

• Set the machine at a minimum distance from the tractor, then brake the tractor and
switch off the engine.

• Separate the two halves of the PTO. Insert the female part into the tractor PTO and the
male part into the machine PTO, checking that the position is correct by means of the

xing pins.

• Line up the two halves of the PTO together, keeping them parallel.

• Using a felt tip pen, match mark the place where the two halves must be shortened as
shown.

• First cut shield “1” and use part “2” as a reference to cut the splined shaft.

• Proceed in the same way for the second half.

• Trim and chamfer the two cut ends of the PTO and clean off all swarf and shavings.

• Grease the two proles and join the two halves of the PTO together.

• Mount the PTO shaft and check that its length is correct as before.

General safety instructions

Precautions to be taken while working with the machine:

1. Do not operate the machine when you are tired;

2. Before starting mowing, make sure that the area is clear of people or animals.

3. Before starting adjusting the machine, it is mandatory to disconnect the PTO, to turn off the engine of the tractor, apply
handbrake and wait for the turning parts to become still and placed on the ground.

4. It is mandatory to read all the safety requirements and the operator’s manual of the machine.

5. If you are not sure how to use the machine, please contact the manufacturer or the dealer.

Trailed machine operation.

Ensure that the PTO doesn’t catch the wheel
of the tractor when turning sharply.