Wessex FLC125 User manual

Operation Manual and Parts Book
Country FLC110, FLC125 & FLC140 Flail Mower
Product Code: L2044
Issue September 2012
GB

CONTENTS
Welcome to your new Wessex Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Important Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Linking up to the Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hydraulic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Using your Wessex Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Working Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Side Shift Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Belt Tensioner Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Cutter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Drive Belts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Winter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Parts Illustration - Mainframe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Parts List - Mainframe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Parts Illustration - Mainframe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Parts List - Mainframe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Parts Illustration - Mainframe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Parts List - Mainframe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
P.T.O. Shaft - Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20, 21
Safety Training Induction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Daily Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
CE Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
1

WELCOME TO YOUR NEW WESSEX PRODUCT
Thank you for purchasing a Wessex product. As a Wessex customer, you now number among the
most important people of our business and we will endeavour to give you the best service available
through our dealer network.
Please read this Manual carefully and familiarise yourself and other persons that will be using the
machine with its contents, to ensure the optimum performance and working life of your machine. It
is advisable that a copy of this Manual is kept in the workshop and one copy with the machine.
Further copies are available through your dealer.
On delivery, your dealer should go through the workings of the machine with you, explaining the
setting up procedures, all of which are contained in this manual for further reference. The Warranty
Registration Form must also be completed and returned to us within 7 days of delivery in order
to validate the Warranty.
PLEASE READ THE FOLLOWING PAGES CAREFULLYBEFORE USING YOUR MACHINE
AND KEEP THIS MANUAL IN ASAFE PLACE.
THIS SAFETY SYMBOL IS TO ALERT OPERATORS OF AHAZARD
THAT MAYRESULT IN INJURY.
ALWAYS FOLLOW INSTRUCTIONS CAREFULLY
2

SAFETY DECALS
GB Stand clear. Flying objects possible.
FS’écartez! Possibilité d’objets volants.
DZurückbleiben! Herumfliegende objekte möglich
GB Examine blades regularly. The operator is responsible for machine damage caused by unbalanced
rotors.
FExaminez des lames régulièrement. L’opérateur est responsable des dommages à la machine
provoqés par des rotors mal equilibrés
DKlingen regelmäßig kontrollieren. Der abeiter ist an den durch unausgewogenen rotoren
maschinenschäden verantwortlich.
GB Keep hands and feet clear
FGarder les mains et les pieds.
DHalten Sie Ihre Hände und Füße.
GB Grease points
FLes points de graissage
DGrease Punkte. 3
GB ATTENTION Description of pictograms.
FATTENTION Description des pictogrames.
DVORSICH Beschreigung der piktogramme.
GB Read Operating manual before use.
FLisez Manual D’Opéreration avant l’utilisation.
D Vor der Benutzung, Betriebshandbuch lesen.
GB Ear defenders must be worn.
FDéfenseurs des oreilles doivent être portés.
DGehörschutz getragen werden.
GB Never remove guards or attempt adjustment until rotor has stopped.
FNe retirez jamais les gardes ou d'ajustement tentative jusqu'à ce que toutes les pièces mobiles ont
été interrompus.
DSchutzvorrichtung niemals abnehmen oder einstellung versuchen, bevore der rotor abstellt.
GB Do not use without pto shaft guard.
FNe pas utiliser sans de dispositif de sûreté de l’abre (arbre d’entraînement).
DNicht benutzen ohne p.t.o. (antriebswelle) schutvorrichtung.
GB Bystanders must be at least 20 metres from machine range of action.
FDes spectateurs doivent s’écarter au moins metres du rayon d’action de la machine.
DUmstenhenden müâen sich mindestens 20 meter vom maschinenbetriebsraum entfernen.
GB Liftt Machine before turning
FLevez la machine avant de la tourner
DMaschine aufheben, bevor man sie umdreht.

4
IMPORTANT SAFETY WARNINGS
Wessex machines are guarded for your protection, but you must always observe certain
elementary precautions. Machines are potentially dangerous and should be used with the greatest
respect and ALL OPERATORS MUST read this manual and be are aware of all safety
precautions.
1. NEVER attempt any adjustment whatsoever, unless the machine is COMPLETELYat a
standstill.
2. NEVER attempt to clear any obstructions around the mower unless the machine is
COMPLETELYat a standstill.
3. NEVER remove belt guards unless the machine is COMPLETELYat a standstill.
4. NEVER remove safety guards which are provided for your protection.
5. NEVER operate the mower with people behind, keep everybody (especially children and
animals) at a safe distance, minimum 20 metres.
6. Stand well back from the machine when cutters are spinning.
7. Regularly inspect the BLADES AND FIXING BOLTS to ensure that they are in tip-top
condition. Replace blades IMMEDIATELYif any signs of fracture or excess wear becomes
apparent. Serious damage, which is excluded from our warranty conditions, may result from
using your mower with an unbalanced rotor. When replacing blades, always fit new
mounting bolts and nuts to ensure that the rotor is balanced and running smoothly.
HEALTH AND SAFETY - Noise at Work Regulations
READING AT THE OPERATORS EAR
CM series mowers : 94 D.B.A
Depending on conditions and material being cut, this reading may alter, it is therefore advisable for
users to do their own assessment.
In compliance with the above regulations, Ear Protectors must be worn when
operating machinery.

WARRANTY
Your Wessex product or equipment is warranted free from defect in workmanship
or manufacture for one year from date of purchase. Any parts which appear to us
to be defective, either in material or workmanship shall be replaced or repaired at
no cost to the purchaser, subject to the following conditions:
1. The registration card enclosed with this booklet must be returned to us within seven days of
purchase.
2. Any failure in the machine should be reported in the first instance immediately to your
dealer, who will act on your behalf to resolve the matter to your satisfaction.
3. The defective parts will be returned by your dealer to us, accompanied by a full statement
describing the failure and the circumstances and conditions in which the failure occurred.
4. The following are specifically excluded from our terms of warranty:
a) Fair wear and tear, especially to belts, brushes, blades and spinners.
b) Damage to blades or brushes caused through incorrect positioning of the rotor (see
instructions).
c) Damage caused by neglect or lack of lubrication.
d) Damage caused by misuse or abuse.
e) Damage caused whilst the machine is in transit.
f) Damage caused to the frame of the machine by running the machine with unbalanced
rotors, blades or spinners.
g) Damage caused to the machine by use with loose nuts, bolts, screws or any other type
of fittings.
5. The warranty is for the benefit of the first user only.
6. Wessex International decisions will be final and binding.
Note:
It is recommended that every machine is inspected after one hour of operation to check that
all nuts, bolts, screws or any other types of fixings are tight and any loose fixings or
components should be rectified as appropriate.
Further inspections should be carried out at regular intervals thereafter.
5

LINKING UP TO THE TRACTOR
1. Reverse your tractor up to the machine and connect the lower links, left hand first, to the link
pins on the machine, securing with linch-pins. Adjust the right hand tractor lift arm to ensure that
the mower is level from side to side.
2. Connect the top link. Adjust the top link so that the top of the mower is parallel to the ground.
3. Connect the P.T.O. shaft ensuring the the shaft is not too long for the tractor. If necessary, the
P.T.O. shaft may to be shortened, (see instructions on pages 20 and 21). Always hook the
P.T.O. chains onto the lugs provided.
4. Tighten the tractor check chains to prevent sideways movement of the mower.
HYDRAULIC CONNECTIONS
1. If your machine is equipped with hydraulic side shift, connect the cylinder to the tractor, by
linking the ends of the inlet/outlet pipes - supplied with quick hitch connectors - to the hydraulic
outlet of the tractor. Check the connection stability and familiarise yourself with the controls.
USING YOUR WESSEX MOWER
1. Having linked you mower up to the tractor and connected up the P.T.O. shaft, ensure that the
mower is not too heavy for the tractor, if so you may need to fit front weights to the tractor.
2. Ensure that there are no bystanders or animals within 20 meters before starting the mower up.
3. Never use the mower in P.T.O. speeds in excess of 540 R.P.M.
4. Ensure that there are no objects underneath the mower deck and that there are no bystanders
within 20 meters behind the mower before starting the mower up especially children and
animals.
5. Having set the mower up in accordance with the above instructions engage the P.T.O. and select
a low forward speed and gently move forward. You will establish the optimum forward speed for
your conditions by experience, but on regularly maintained grass you will achieve a good finish
at 5-6 M.P.H.
6. When mowing it is important that you lift the machine on the tractor link arms when turning
sharply. When planning your cutting pattern ensure that you keep the turning whilst mowing to a
minimum. Turning sharply with the mower on the ground will damage the roller bearings.
6

WORKING HEIGHT ADJUSTMENT
The machine’s working height is determined by the vertical position of the rear roller. By lifting the
roller, the blades get closer to the soil, whereas by lowering it you achieve a longer cut. After
adjusting the working height, make sure that the cutters do not hit the ground: Adirect contact
with the ground would cause excessive wear.
To adjust the roller height (picture 2):
= Screw out and remove bolts Bwhich fasten the roller on both sides.
= Loosen nut A.
= Lift or lower the roller, then position it according to the scheme.
= Re-insert and tighten bolts B.
= Tighten nut A.
The skids prevent the machine from sinking too much into the soil while working. The skids
position is fixed.
7
ADJUSTMENTS

Country FLC Flail Mowers are provided with side shift, both manual (picture 3) and hydraulic
(picture 4).
To adjust side shift on the machines provided with manual shift (picture 3).
= Unscrew and remove bolt A.
= Move the AFrame to one of the permitted positions.
= Replace bolt Aand tighten the nut.
If the mower is equipped with hydraulic shift, its position can be adjusted at one’s pleasure after
connecting quick release hoses A(picture 4) to the tractor, by using the controls of the tractor
itself.
8
SIDE SHIFT ADJUSTMENT

To adjust the drive belts tensioner, proceed as follows (picture 5).
= Unscrew nut B.
= Tighten pin Ato tension the belts with roller C.
= Once the belts are adjusted, tighten nut B.
The belts are stretched properly when applying a force of about 10kg on the tension side of the
belts they are deflected by about 10mm.
9
BELT TENSIONER ADJUSTMENT

FIRST CHECK
= Check the correct tension of the driving belt.
= Check that all bolts and nuts are tightened strongly.
= After the first 50 hours of work change oil in the gearbox unit (Oil Type: 80W90)
EVERY8 HOURS OF WORK
= Grease the shaft support (driveline side) through the lubricating nipple A(picture 6).
= Grease the shaft support (external side) through the lubricating nipple A(picture 7).
= Grease the stabilising roller through the lubricating nipple A(picture 8).
EVERY50 HOURS OF WORK
= Check the correct tension of the driving belt.
= Check that all bolts and nuts are tightened strongly.
= Check the cutters/hammers wear state.
= Check the gearbox oil level through plug A.
EVERY500 HOURS OF WORK
= Check that all bolts and nuts are tightened strongly.
= Check oil in the gearbox (Oil Type: 80W90).
EVERY1000 HOURS OF WORK
= Replace the driving belts.
10
ROUTINE MAINTENANCE

To assure a perfect functioning of the machine, check often (at least every 50 hours of work) that the
flails are in good condition and perfectly fixed by the locking bolts; if they are broken or badly worn
replace them with new spare parts.
When a Flail has to be replaced, it is advisable to replace the whole set. The use of non-original
replacements might cause irregular vibrations on the machine.
If replacing operations are carried out with the machine lifted up, do not rely only on the hydraulics of the
machine: It is recommended to place mechanic props or trestle supports between the machine and the
ground, thus preventing the head from suddenly and dangerously falling down.
For any replacement parts please contact the nearest Wessex authorised dealer.
11
CUTTER CHECK
Before starting the inspection of cutters, stop engine, apply parking brake and disengage power
takeoff; lift the mower with the tractor and place it on rests to avoid an accidental fall.

To replace the belts proceed as follows (picture 9)
= Remove roller Cby unfastening its tensioning spring, unscrewing nut Band holding pin Awith
a spanner.
= Remove the damaged belt(s).
= Position the new belt(s).
= Proceed in reversed order to reassemble the tensioning roller, by properly adjusting the tension
of the belts (see section ‘Belt Tensioner Adjustment, page 9).
If a belt gets damaged, it is recommended to replace the whole set, in order to have the drive
tension equally balance on each belt.
12
DRIVE BELTS REPLACEMENT

13
WINTER STORAGE
Before winter storage, the Flail Mower should be thoroughly inspected:-
= Repair or replace any worn or broken parts.
= Take special care to look at the flail blades, rotor and the bearings.
= Remove the belts and ensure that the rotor is free-spinning.
= Make sure that the belts are in good condition before re-fitting.
= Thoroughly wash the machine to remove all oil, grease, debris and materials.
= Grease up all grease points before storage to avoid any corrosion.
= Check or change engine oil depending on hours of use.
SPARE PARTS
Spare parts for your Wessex Mower can be obtained through our extensive dealer network.
For details of your nearest supplier or for technical information, please email
part[email protected] or telephone [phone].
TROUBLESHOOTING
FAULTCAUSE REMEDY
Leaving wheel track uncut 1. Forward speed too fast
2. Cutting height too high
Reduce forward speed
Lower cutting height
Bad quality of cut 1. Forward speed too fast
2. Excessive blade wear
3. Belts slipping
Reduce forward speed
Replace blades
Tighten belts
Narrow strip uncut 1. Possibly missing or broken
blade
Inspect blades and replace as
necessary
Excessive vibration 1. Damaged or missing blades
2. Bent flail rotor
3. Main rotor bearing failed
4. Loose part
Inspect and replace blades
Inspect rotor
Inspect bearing, replace if damaged
Check all nuts and bolts are tight
Excessive scalping 1. Cutting height too low Raise cutting height.

PARTS ILLUSTRATION - FLC MAINFRAME ASSEMBLY- PLATE 1
2
5
10
8
65
1
2
15
14 16
17 18 19
18
107
20
12
23 22
21
13
32
40
41
31 30
29 28
26
3436
35 36
60 43
37
53
44
45 53
47
54
11
46 48
49
13
57
45 48
53 51
47
110
50
40
66
68
53
65
40
40
52
40
67 52
24
2561
39
70
9
52
52
4071
88 89 90 81 91 92 81 79
78
79
80
81
82
83
97
85
86
87
98 96 95 94
19
108
43
69
43
33
106
11
63
76
40 64
52
27
24
3343
40
43
78
12
63
100 101 102 103
99 104 105
5859
38
109
11
73
727475
11
17
16
62
53
11
43
38
84
38
52
77
64
77
3
4
2
7
112
111
111
43
93
14
PLATE 1

PARTS LIST - FLC MAINFRAME ASSEMBLY- PLATE 1
15
Item No. Part No. Description Qty.
1SCA-5005222 A-Frame 1
2WX-0221 ‘R’ Clip 3
3SCA-6304100020 Washer 1
4SCA-5005199 Pin 1
5SCA-4301590 Pin 2
6SCA-3464101012 Nut 1
7SCA-5537015 Spacer 1
8SCA-5535215 Tube 1
9SCA-5005839 Tube 1
10 SCA-5005838 Tube 1
11 SCA-3464101008 Nut 35
12 SCA-5005826 Complete Cylinder 1
13 SCA-3011008040 Bolt 35
14 SCA-6421904 Bolt 2
15 SCA-6470038 Washer 4
16 SCA-64126150 Hose 2
17 SCA-6470012 Washer 2
18 SCA-6037390 Nipple 2
19 SCA-6037683 Quick Release Coupling 2
20 SCA-3021112030 Bolt 1
21 SCA-3625100012 Washer 1
22 SCA-3614000012 Washer 1
23 SCA-4532393 Spacer 1
24 SCA-6363055 Self-Locking Units2
25 SCA-5645266 Driving Pulley 1
25 SCA-5645264 Driving Pulley 1
26 SCA-3011108060 Bolt 2
27 SCA-5005373 Main Frame FLC110 1
27 SCA-5005374 Main Frame FLC125 1
27 SCA-5005375 Main Frame FLC140 1
28 SCA-5205202 Pin 1
29 SCA-4211510 Spring 1
30 SCA-6320032 Circlip 1
31 SCA-6710950 Belt 3
31 SCA-6710800 Belt 3
32 SCA-5005286 Belt Cover 1
33 SCA-5005285 Skid 2
34 SCA-6320020 Circlip 1
35 SCA-5782901 Roller 1
36 SCA-2226204 Bearing 2
37 SCA-5005228 Protection 1

16 PARTS ILLUSTRATION - FLC MAINFRAME ASSEMBLY- PLATE 1
2
5
10
8
65
1
2
15
14 16
17 18 19
18
107
20
12
23 22
21
13
32
40
41
31 30
29 28
26
3436
35 36
60 43
37
53
44
45 53
47
54
11
46 48
49
13
57
45 48
53 51
47
110
50
40
66
68
53
65
40
40
52
40
67 52
24
2561
39
70
9
52
52
4071
88 89 90 81 91 92 81 79
78
79
80
81
82
83
97
85
86
87
98 96 95 94
19
108
43
69
43
33
106
11
63
76
40 64
52
27
24
3343
40
43
78
12
63
100 101 102 103
99 104 105
5859
38
109
11
73
727475
11
17
16
62
53
11
43
38
84
38
52
77
64
77
3
4
2
7
112
111
111
43
93
PLATE 1

17
PARTS LIST - FLC MAINFRAME ASSEMBLY- PLATE 1
Item No. Part No. Description Qty.
38 SCA-3625000010 Spring Washer 3
39 SCA-3011110035 Bolt 4
40 SCA-3604000008 Washer 16
41 SCA-3021108020 Bolt 3
42 SCA-3021110030 Bolt 1
43 SCA-3464101010 Nut 8
44 SCA-5645264 Driving Pulley 1
45 SCA-5005230 Support 2
46 SCA-5005281 Support 1
47 SCA-20300030 Bearing 2
48 SCA-2226306 Bearing 2
49 SCA-5005277 Roller - FLC110 1
49 SCA-5005278 Roller - FLC125 1
49 SCA-5005279 Roller - FLC140 1
50 SCA-5855251 Scraper - FLC110 1
50 SCA-5855252 Scraper - FLC125 1
50 SCA-5855253 Scraper - FLC140 1
51 SCA-5005282 Support 1
52 SCA-3021108020 Bolt 10
53 SCA-3021111020 Bolt 14
54 SCA-5005217 Rotor - FLC110 1
54 SCA-5005218 Rotor - FLC125 1
54 SCA-5005219 Rotor - FLC140 1
57 SCA-5715103 Hammer - FLC110 26
57 SCA-5715103 Hammer - FLC125 30
57 SCA-5715103 Hammer - FLC140 34
58 SCA-3604000022 Washer 1
59 SCA-3646102022 Nut 1
60 SCA-5005284 Lever 1
61 SCA-2000030 Bearing 1
62 SCA-5005283 Shaft 1
63 SCA-80117-01 2PTO Gearbox 1
64 SCA-6330850 Roll Pin 1
65 SCA-5005221 Plate 1
66 SCA-5135254 Guard 1
67 SCA-5135287 Guard 1
68 SCA-5835201 Tie 1
69 SCA-5135253 Guard 1
70 SCA-5135255 Support 1
71 SCA-5135256 Support 1
72 SCA-5135279 Stone Guard 1
73 SCA-5135248 Stone Guard 16

18 PARTS ILLUSTRATION - FLC WHEEL ASSEMBLY- PLATE 1
2
5
10
8
65
1
2
15
14 16
17 18 19
18
107
20
12
23 22
21
13
32
40
41
31 30
29 28
26
3436
35 36
60 43
37
53
44
45 53
47
54
11
46 48
49
13
57
45 48
53 51
47
110
50
40
66
68
53
65
40
40
52
40
67 52
24
2561
39
70
9
52
52
4071
88 89 90 81 91 92 81 79
78
79
80
81
82
83
97
85
86
87
98 96 95 94
19
108
43
69
43
33
106
11
63
76
40 64
52
27
24
3343
40
43
78
12
63
100 101 102 103
99 104 105
5859
38
109
11
73
727475
11
17
16
62
53
11
43
38
84
38
52
77
64
77
3
4
2
7
112
111
111
43
93
PLATE 2