Major Manufacturing TDR Series Installation and operation manual

MAJOR RANGE OF
TDR ROLLERMOWERS
TDR 16000
TDR 20000
Operator Manual
& Parts List

Head Ofce
Major Equipment Intl. Ltd.,
Ballyhaunis,
Co. Mayo,
Ireland.
Tel.: [phone]
Fax: [phone]
Email: [email protected]
UK Ofce
Major Equipment Ltd.
Major Industrial Estate,
Middleton Rd.,
Heysham,
Lancs.
LA3 3JJ
Tel.: [phone]
Fax: [phone]
Email: [email protected]
NL & GERMANY OFFICE
Major Equipment Intl. Ltd.,
Postbus 29,
NL-7700 AA,
Dedemsvaart,
Nederland.
Tel: [phone]
Email: [email protected]
Web: www.major-equipment.com
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Visit our channel MAJOREQUIPMENT on www.youtube.com
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
Product Identication
Machine Serial Numbers 1
Product Specications 1
Register Your Product and Warranty Online 1
Safety
Machine Safety Labels 2
Operating Safely 2
Workstation 3
Regulations for use of the transmission 3
PTO Shaft Safety 3
Driving Safely on Public Roads 4
Operating the Machine
Inspections before Use 4
Key to Main Parts 5
Starting Regulations 6
Hitching to the Tractor 6
Blade Rotations 9
Maintenance
PTO Shaft Maintenance 9
Belt Adjustment 10
Belt Removal & Fitting 10
Wheel nuts 11
Taper Bush Installation 11
Taper Bush Removal 11
Maintenance Schedule 12
Trouble Shooting 13
Spare Parts
TDR Spare Parts 15
Axles 21
Hose Assemblies 25
Blades 27
PTO Shafts 32
Gearboxes 32

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:
TDR ROLLERMOWER
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 12/01/2012
Managing Director

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230615
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.
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.
We suggest that you record your machine details below:
Model No: _______________ Serial No: _______________ Date of Purchase: ________________
Dealer Name: __________________________________ Dealer Telephone: __________________
Product Specications
Model TDR16000 TDR20000
Working Width 4.9m 6.1m
Overall Width 5m 6.24m
Transport Length 3.66m 3.66m
Transport Width 2.53m 2.53m
Transport Height 2.37m 3m
Wing Float 25° down/10° forward/back/90° up
Cutting Height 12 - 150mm
Blade tip speed 4569 m/min 4569 m/min
Power (HP) 65-90 75-100
Rotors 8 10
Tyre Pressure 40psi 50 psi
Gearbox Oil EP 90 gear oil
Weight 2260kg 2675kg
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.

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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.
Operating Safely
This machine is a result of continuous research, development and quality testing. Please treat it accordingly.
The MAJOR TDR Rollermower is designed to operate at 540 RPM. Ensure tractor PTO output is set at
540 RPM. The MAJOR TDR Rollermower must only be used for cutting grass. Moreover, it must only
be used with a suitable tractor (see product specications) and driven by an adequate drive-line by the
tractor PTO. 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 nonslip 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 ROTORS ARE TURNING. ROTORS CAN REMAIN
TURNING FOR UP TO 1 MINUTE AFTER DISENGAGING PTO.
To avoid injury, read the manual
Fold the PTO stand down before removing the
transport pin to avoid PTO shaft damage
Rotating blade hazard
High oil
pressure hazard
PTO entanglement
hazard - keep clear
of PTO drives.
Moving parts
hazard

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Workstation
The operator must remain seated while working the machine. When the wings need to be raised and lowered the
operator must leave the tractor. Always ensure the PTO has been turned off and the parking brake applied before
leaving the tractor cab. The operator must always apply the parking brake, and turn off the engine before leaving
machine 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 form 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 manual, 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.
PTO Shaft Safety
MAX PTO INPUT 540 RPM 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 TDR Rollermower 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.
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 TDR Rollermower 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.
The shaft must not reach the end of the tube or project from this. Ensure the
PTO does not bottom when turning.

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Driving Safely on Public Roads
Check the local Highway Code regulations before driving the tractor on public highways with a towed
implement. 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 for the implement is 30km/h. DO NOT EXCEED
• Check machine is hitched to the tractor as described. Ensure the tractor parking brake is applied
• Lift the two wings by hydraulic control & lock in position using the wing locking clamps.
• Use the retaining strap to fully secure wings.
• Lift the rear deck by hydraulic control and lock hydraulic pipes via the shutoff taps supplied for the rear deck.
• Attach hydraulic connections (check tractor manual for correct hydraulic layout i.e. open or closed circuits). The
TDR Gang Mower is factory set for ‘open’ hydraulic circuits.
• Attach 12v lighting connection
Operating the Machine
Inspections before Use
Always disengage PTO, Switch off tractor engine and engage the parking brake before making adjustment
to the machine.
Rotor gearbox
Oil ller
plug
Oil level
plug
LF205
Pivot arm
gearbox
T27A
Oil level plug
Oil level plug
Oil ller plug
Oil ller plug
NOTE: TDR hitch is adjustable in length. Adjust the hitch to optimum position before cutting shaft.

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1
1
2
5
6
6
5
2
3
4
1. With the whole machine as level as possible, check the oil level in the Primary Gearbox, top up as required with
SAE EP90 gear oil through the oil ller plug indicated. The correct level is at the oil level plug indicated. Check the
oil level in the Rotor Gearboxes and top up as required with SAE EP 90 gear oil. Put it through the oil ller plugs
indicated. The correct level is at the oil level plug indicated
2. Grease the PTO shaft universal joints, drive shaft bearing and carrying arm pivots.
3. Re-sharpen old blades with a grindstone if necessary. Replace bent blades with new ones.
4. Check the blade mounting bolts are tight
5. Ensure the gearbox shaft nuts are tight and retained in place by split pin.
6. Check tightness of all nuts, bolts and retaining screws after the rst and second hours of work.
7. Ensure safety guards and aps are in place at all times where tted.
8. Due to the corrosive nature of grass when cut, wash down the machine when nished mowing, especially when
the machine is being stored for a long period of time.
Key to Main Parts
Fixed blade system
Swinging blade system
Strap
Rear
Lighting
Pulley
Cover
Hydraulic
top link
Gearbox
Cover
Parking
Jack
PTO stand
Roller
Drawbar
height
adjustment
Height
adjustment
Flashing
beacon
Hitch
adjustment
Hitch
Rotor
Gearbox
Rear deck
1 - Spacer bushings
2 - Blade mount bolts
3 - Blade pivot bush
4 - Blade pivot bolt
5 - Gearbox output shaft
6 - Split pin
7 - Retaining bolt
8 - Bolt

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Starting Regulations
Always check that any imminently dangerous conditions have been eliminated before using the machine. Ensure all
guarding is present & the operator is fully aware of the operations of the machine
Always ensure the pins lock the PTO shaft yoke ends onto the spline shafts on both the tractor and the implement. An
unlocked shaft could slip out of position, causing notable mechanical damage and serious injury to both operator and
bystanders.
Hitching to the Tractor
ALWAYS OPERATE ON LEVEL GROUND WHEN HITCHING/UNHITCHING THE IMPLEMENT. THIS WILL PREVENT
DANGEROUS MOVEMENT. NEVER ALLOW ANYONE TO STAND BETWEEN THE TRACTOR AND THE TDR
ROLLERMOWER.
1. Reverse the tractor, connect the hitch & secure in position with correct size drawbar pin
2. Ensure that the circlip is on top as shown below
3. Ensure the tractor brake is applied
4. Adjust the level of the drawbar until the main body is level.
5. Connect the hydraulic connections to the tractor.
6. Mount the solenoid control box in tractor cab.
7. Fit the PTO shaft & secure the PTO cover chains.
8. Raise the parking jack. Solenoid Control Box Mounting.
9. Adjust drawbar instead of cutting PTO shaft.
Drawbar Height
Adjuster
Drawbar Lateral
Adjustment
Parking
Jack
Circlip
The MAJOR TDR Rollermower is designed to operate at a max 540-720 RPM. Always operate on level ground when
hitching / unhitching the implement. This will prevent dangerous movement.
1. Never allow anyone to stand between the tractor and the machine.
2. Ensure the machine is hitched correctly to the tractor as previously described.
3. Ensure bystanders are clear from the machine & cannot be hit with debris expelled from the machine.
4. Unlock hydraulic arms supporting the rear deck, taking care not to stand between mainframe and rear deck.
5. Ensure cutting decks are lowered to the ground.
6. Place wing locking clamps in position ‘X’ as shown in the photo below.
7. Wing PTO drive will engage automatically selector knob ‘Y’.
8. Start up the tractor PTO at a low RPM.
9. Build up to operating speed, select a suitable forward gear & proceed to cut grass. NOTE: The Selector knob is
tted with a spring ‘Y’ in order to auto stop wing rotors when raised.
10. Tighten both the Top Link Tap ‘B’ & Lower Link Arm tap ‘A’ to lock the rear deck when raised for transport.
NOTE: This machine is factory set to operate with ‘open centre’ hydraulic systems. When connecting to tractors with
‘closed centre’ hydraulics, the Pilot valve spool knob ‘C’ must be closed (screwed ‘in’).