Major TURF MAJOR 800T User manual

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OPERATORS MANUAL
&
PARTS BOOK
TURF MAJOR
800T, 900T &1200T

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UK Office
Major Equipment Ltd.
Major Industrial Estate.
Walkers,
Middleton Rd.,
Heysham,
Lancs. LA3 3JJ
Tel.: 01524 - 850 501
Fax: 01524 - 850 502
E-mail [e-mail]
Ireland Office
Major Equipment Ltd.
Ballyhaunis,
Co. Mayo,
Ireland
Tel.: 094 - 96 - 30572
Fax: 094 - 96 - 30788
E-mail [email protected]
Web: www.major-equipment.com
Write in Your Dealers Address & Tel. No. for your convenience.
Dealer ……………………........................
Address …………………..........……..........
……………………..........…..........
……………………..........…..........
……………………..........…..........
……………………..........…..........
Tel. No.……………………..........………..
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.
Please return warranty card provided with this manual to register your Warranty and retain receipt as
proof of purchase.

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CONTENTS
SAFETY LABELS 3
INTRODUCTION 4
FOREWORD 4
WARRANTY 4
WORK STATION 5
KEY TO MAIN PARTS 5
GENERAL SAFETY REGULATIONS 7
REGULATIONS IN THE USE OF THE TRANSMISSION 7
PTO SHAFT LENGTH 8
STARTING REGULATIONS 9
HITCHING TO THE TRACTOR 9
TRANSPORT AND MOWING 10
MAINTENANCE 12
FOREWORD 12
INSPECTION BEFORE USE 12
MAINTENANCE SCHEDULE 13
BLADE ROTATION 14
SPECIFICATIONS
PTO SHAFT MAINTAINENCE 15
PARTS BOOK 16
WARRANTY PROCEEDURE 30
TROUBLE SHOOTING 31

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SAFETY LABELS
The Major Trailed Topper comes equipped with all safety labels in place. They are intended to help you operate
your machine safely. Read and follow the safety label directions. Keep safety labels clean and legible.
Replace damaged or missing safety labels.
Thoroughly read and understand the manual.
High Oil Pressure Hazard
Rotating Blade Hazard - Keep clear from
blades while machine is in operation.
Moving Parts Hazard - Keep clear while operating
wings. (1200T MODEL)
Driveline Entanglement Hazard -
Keep clear of PTO drives
Maintenance Warning –
Keep wheel bearing bolts tight.

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INTRODUCTION
The Major Trailed Topper that you have purchased is the result of costly development and extensive field-
testing. It is an engineering product, backed by a dealer distribution network designed to offer you an efficient
after sales service.
Please follow the instructions given in this manual. You will then obtain the best results from your new machine
at the lowest cost.
Lack of maintenance will induce excessive power consumption. This waste of power will not only induce a heavy
load on the machine, but will also cause breakdowns and expensive repairs.
FOREWORD
An exact description of the machine model and year of manufacture will ensure quick and pertinent answers
from our Technical Assistance Service. Always state the machine model when contacting our offices or your
nearest dealer.
We suggest you write the data pertaining to your machine in the following space.
Year of manufacture Model
Serial Number Date of purchase
WARRANTY
The Major Trailed Topper is guaranteed for 1 season. No warranty is given where the machine is being used as
a hire machine. Warranty is against faulty workmanship or parts, with the exception of components not of
Major’s manufacture or design, i.e. hydraulic components, Universally jointed shafts, blades and tyres, etc.,
which are subject to the original manufacturers conditions.
No warranty is considered unless the faulty parts have been returned. All replacement parts will be supplied on
a chargeable basis until warranty has been accepted. Major cannot accept liability for injury or damage caused
by our machines resulting from operational negligence.
Major reserve the right to withdraw warranty if:
- Non-original parts have been fitted.
- The machine is not maintained correctly
- The machine is overloaded, or operated incorrectly
- The machine is used for purposes other than those for which it has been designed
Major and importers do not accept liability if non-Major parts have been fitted. Please read warranty procedure
on page .
IRELAND USERS
Health, Safety and Welfare at Work Act (1989).
UNITED KINGDOM USERS
Health and Safety at work Act (1974)
Both Acts require that all operators must be given instruction on the safe operation, maintenance and
repair of all machinery. This booklet forms part of the instruction for the MAJOR TRAILED TOPPER and
must be read by all operators and repairers before operating the machine. The supplier must also instruct
the customer and user regarding the operation, adjustment and explain all necessary safety precautions

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WORK STATION
The operator must remain seated while working the machine. Always ensure that the PTO has been turned off
and the parking brake applied before leaving the tractor cab.
The operator must always apply parking brake, and turn off engine before leaving machine or carrying out maintenance.
!
CAUTION
Never operate tractor hydraulics’ with the tractor switched off
Never allow hydraulic hoses inside the tractor cab
KEY TO MAIN PARTS
1200T
800T & 900T

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MACHINE SET-UP
AXLE STOPPER SETUP

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GENERAL SAFETY REGULATIONS
The Major TRAILED TOPPER must only be used for cutting grass. Moreover, it must only be used with a
suitable tractor (see specifications on page 20) 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 non-slip shoes, ear muffs, goggles and gauntlets. Wear a jacket with reflecting
stickers if the implement is used near public highways.
Consult your retailer, the Labour Health Service or your nearest equivalent authority for information about the
current safety provisions and specific regulations to comply with in order to ensure personal safety
!
CAUTION
Ensure the PTO does not bottom when turning,or when tractor front axle is
raised or lowered while climbing or descending a sharp incline.
REGUALTIONS FOR THE USE OF THE TRANSMISSION
The transmission to the gearboxes is protected throughout the machine by both guarded PTO shafts and bolt
down covers. All guarding should be kept efficient and in good condition. If the condition is poor, the guarding
should be renewed before the implement is used
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
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.
!
IMPORTANT
The correct rotational speed of the tractor PTO input is 540 rpm.
!
WARNING
Unless it is correctly protected, the transmission could cause death since it
can catch on parts of the body or clothing

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PTO SHAFT LENGTH
.
After the TRAILED TOPPER 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.
!
CAUTION
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
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
TRAILED TOPPER PTO, checking that the position is correct by means of the fixing pins.
Lay 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 profiles
and join the two halves of the PTO together again. 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.
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 across

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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
!
WARNING
Always ensure the PTO shaft yoke ends are locked onto the splined 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
Reverse the tractor, connect the hitch & secure in position with correct size drawbar pin.
Ensure the tractor parking brake is applied.
Adjust the hitch eye to suit the tractor drawbar height, paying particular attention to keep the bolts on the
adjuster plate as spread as far as possible.
Connect the machine to the tractor, The drawbar spring adjuster should now be tensioned ensuring the
front of the skids are raised approx 25mm (1”) higher than the rear.
Before connecting the PTO shaft to the tractor, check for length as previously described in this manual.
Ensure PTO check chains are anchored to prevent PTO guarding from rotating.
Connect the hydraulic hoses to the appropriate connection.
CUTTING HEIGHT
Adjust the skids by lifting the machine and removing the four skid retaining bolts & relocating the skid to
the desired height.
The axle stop should now be adjusted, it should be set to that the wheels are taking as much weight as
possible while the skids are maintaining ground contact.

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TRANSPORT & MOVING
Check the local Highway Code regulations before driving the tractor on public highways with a towed implement
Check the reflectors, hazard flashers and/or projecting load indicators are installed when required and efficient.
These indicators must be installed correctly and easily seen by the drivers of other vehicles.
!
WARNING
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.
TRANSPORT POSITION
Check machine is hitched to the tractor as described. Ensure the tractor parking brake is applied
Lift the body clear from the ground by activating the axle hydraulic ram
Transform the machine into transport position by hydraulic control. The Drawbar ram should be full
closed. On the 1200T model, continue to hold the spool in this position & the wing will lift up into a
vertical position.
Lock the wing into transport position & retain pin with clip (1200T model only)
Adjust the axle height stopper to the highest position.
Operate the tractor hydraulics to pull in the wing ram
1200T TRANSPORT LOCKING BAR LOCATIONS
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WARNING
Maximum transport speed for the implement is 30km/h.

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MOWING POSITION
Check machine is hitched to the tractor as described. Ensure the tractor parking brake is applied
Ensure the body is clear from the ground by activating the axle hydraulic ram.
Transform the machine into mowing position by hydraulic control.
800T and 900T models sequence: The drawbar ram will push out the cutting deck fully into operating
position.
1200T model sequence: The wing will drop first fully to the ground. Continue to hold the spool in position
and the drawbar ram will push out the body into mowing position.
Lock the wing into mowing position & retain pin with clip (1200T only).
Adjust the axle height stopper to the desired position. On the 1200T model adjust the threaded bar to
equalise the machine.
Operate the tractor hydraulics on the axle spool to lower the body against the axle stops.
MOWING
!
WARNING
Never place limbs under the machine while rotors are turning.
Rotors can remain turning for up to 1 minute after disengaging PTO
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IMPORTANT
Ensure drawbar ram is fully extended before operating PTO.
The MAJOR Trailed Topper is designed to operate at a max 540 rpm. 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 TRAILED TOPPER Ensure the machine is
hitched correctly to the tractor as previously described
Ensure cutting decks are lowered to the ground.
Start up the tractor PTO at a low RPM.
Build up to operating speed, select a suitable forward gear & proceed to cut grass.

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MAINTENANCE
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IMPORTANT
Maintenance must be carried out by qualified personnel
The TRAILED TOPPER must always be disconnected from the tractor before any cleaning, lubricating
and servicing operations can be carried out. If emergency operations are required whilst the machine is
connected to the tractor, switch off the engine, engage the parking brake and disengage the PTO.
Good, regular maintenance and correct use are essential if the TRAILED TOPPER is to remain safe
and long lasting.
INSPECTIONS BEFORE USE
!
WARNING
Always disengage PTO, Switch off tractor engine and engage the parking brake
before making adjustment to the machine
1. With the wing lowered (1200T) and 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 filler 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 through the oil filler plugs indicated. The correct level is at the oil level plug indicated.
PRIMARY GEARBOX ROTOR GEARBOX
2. Grease the PTO shaft universal joints, drive shaft bearing and axle bushings daily.
3. Grease the drawbar pivot bush daily.
4. Re-sharpen old blades with a grindstone if necessary. Replace bent blades with new ones.
5. Check the blade mounting bolts are tight.
6. Ensure the gearbox shaft nuts are tight and retained in place by split pin.
7. Check tightness of all nuts, bolts and retaining screws after the first and second hours of work.
8. Ensure safety guards and flaps are in place at all times where fitted.
9. Due to the corrosive nature of grass when cut, wash down the machine when finished mowing,
especially when the machine is being stored for a long period of time.

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MAINTENANCE SCHEDULE
Grease the following:
Initially 8 Hours
1 PTO Shaft yoke ends (8)
2 Drawbar drive Bearings (12)
3Drawbarpivot(1)
4AxlePivot(2)
1200T only
5 Wing Pivots (2)
6 Wing Axle (2)
All nuts and bolts in the transmission including Rubber Couplings, Star Drives, PTO Shafts, Gearboxes & wheel
nuts should be checked for tightness after mowing at the following intervals:
1
st 50 acres,
1
st 100 acres
1
st 250 acres,
And every 250 acres thereafter. Lubricate moveable mechanical joints when required.
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IMPORTANT
Ensure blade rotation and timing is correct after servicing transmission
SHEAR BOLT REPLACEMENT
Slide yoke shield back.
Drive out sheared bolt with hammer and punch.
Align holes and install new shear bolt.
Use only genuine MAJOR replacement shear bolts.
M10X60 BZP -8.8
Slide yoke shield securely in place
IMPORTANT
Fit PTO shaft with the shearbolt end connected to the
Topper as directed on the PTO guarding

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BLADE ROTATION
Blades must always be timed at 90oto each other. Failure to do so can cause the blades to foul & in turn may
damage the transmission.
MAJOR 1200T BLADE ROTATION – PLAN VIEW
MAJOR 800T & 900T BLADE ROTATION – PLAN VIEW

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SPECIFICATIONS
SPECIFICATIONS 800 T 900 T 1200 T
Transport Width 2538 2943 2641
Overall Width 2538 2943 3760
Cutting Width 2399 2694 3569
Cutting Range 12-205 12-205 12-205
No. of Blades 8 8 12
Blade Tip Speed 13685 15298 13685
Power Requirements 35-60 35-60 40-90
Tyre Pressure 2 BAR 2 bar 2 bar
Gearbox oil EP 90 EP 90 EP 90
Weight 550 kg 650 kg 1100 kg
PTO SHAFT MAINTAINANCE
Guard Removal & Yoke End Greasing.
1. Prise back locking tabs
2. Pull back PTO Guard
3. Grease points as shown
4. Push Guard into position
5. Click into place
6. Tie check chain
PTO GUARD GREASING INTERVALS

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PARTS LISTING
Use only MAJOR spare parts for the best results.
!DANGER!! !
SAFETY FIRST!
A moment's lack of attention can result in an accident, as can failure to observe certain
elementary precautions. Do take time to ensure your safety and others are not put at risk.
Essential Do’s and Don’ts.
Don’t allow any spilt oil or grease to remain on the floor - wipe it up straight away, before
someone slips on it.
Don’t use ill-fitting spanners or other tools, which may slip and cause injury.
Don’t attempt to lift a heavy component, which may be beyond your capacity - get assistance.
Don’t rush finish a job, or risks by taking shortcuts.
Do wear eye protection when using power tools such as drills, grinders, etc.
Do keep loose clothing (cuffs, tie, etc.) and long hair well out of the way of moving mechanical
parts. If possible wear overalls.
Do remove rings, wristwatches etc. before working on a machine.
Do keep your work area tidy - it is only too easy to fall over articles left lying around.
Do ensure that any lifting tackle that has a safe working load rating adequate for the job.
Do carry out work in a logical sequence and check that everything is correctly assembled and
tightened afterwards.
Do ensure that all guarding is fitted after servicing the machine.
Do remember that your machines safety affects that of yourself and others.
If in doubt contact your local MAJOR dealer.

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TRAILED TOPPER DRAWBAR &AXLE

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TRAILED TOPPER DRAWBAR
Item Part No. Description Qty
1 8SM11-4 PTO Guard (Oval) 2
2 SF1-12 Flange Bearing 2
3 8T3-1 Dummy Shaft (Drawbar) 1
4 58X3FBZP Bolt 8
5 58FN Nyloc Nut 16
6 FWM16 Flat Washer 16
7 8SM9-3 Spacer 8
8 M16 Nyloc Nut 1
9 8T19 Spacer Plate 2
10 MOT10 BUFFER 1
11 M20 M20 Nyloc Nut 2
12 8T-AD1 Drawbar Hinge 1
13 8T-AD2 Drawbar Toe 1
14 M12X35BZP Bolt 8
15 M12NN Nyloc Nut 12
16 M20X150B Bolt 1
17 12T-SPR Drawbar Spring 1
18 8T15 Spring Tensioner 1
19 M20HEX Nut Plain 2
20 S-272 Lock Pin 1
21 P575 Topper Jack 1
22 12TWTDRAM Drawbar Ram (1200T Model) 1
22 GRAS10/1 Hydraulic Ram (800T & 900T Model) 1
23 M20X120BZP Bolt 1
24 8T3 Drawbar 1
25 M12X150BZP Bolt 4
26 9T3/1 Dummy shaft bolt-on mounting. 1
27 1X8FBZP Pivot Bolt 1
28 V60WA 1100 Tractor primary PTO Shaft
1200 Model 1
28 V60 -1100 Tractor primary PTO Shaft
800 & 900 Model 1
29 RTE01 Rotary Toe Eye 1
30 12TWTDSM Double Spring Mount 1
31 M12X50BZP Bolt 1
32 12TWTDST 1200 Trailed Topper Spring Tensioner 1
33 12TSTDTB Drawbar Double Spring Adjuster 1
34 12TWTDSGA Double Spring Assembly
TRAILED TOPPER AXLE
Drawing
No Part No Description Qty
35 M12x120 BZP Bolt And Nyloc Nut 4
36 8T12 Axle Clamp 5
37 M20x110 BZP Bolt And Nyloc Nut 1
38 9TGTA-1 Axle (12T Model & 900T Model) 1
38 8T7 Axle (800T Model)
39 105x 153 W1 Wheel 800T Model 2
39 Wheel 900T Model 2
39 Wheel 1200 T Model 3
40 S2220 Wheel Nut 8
41 9TGTA-R1 Axle Ram 12T Wing & (Older models). 1
42 9TGTA-R1N Axle Ram New Type 1
43 9TGTA-TB Axle Ram Stop 1
44 9TGT-AP1 Ratchet Height Adjuster 1
45 8SM9/4 Bush 1

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