Wessex AF160 User manual

Operation Manual and Parts Book
Wessex AF160 & AFC160 Trailed Flail Mowers
Product Code: L2003
Issue August 2014
GB

CONTENTS
Welcome to your new Wessex Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 3
Important Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Important ATV Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5, 6
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Setting up your Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Using your Wessex Mower / 4 Wheel Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Maintenance / Belt Adjustment / Lubrication / Flail Blades . . . . . . . . . . . . . . . . . . . . . . . . . .10
Troubleshooting / Winter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Parts Illustration - AF & AFC 160 - - Mainframe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .12
Parts List - AF & AFC 160 - Mainframe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Parts Illustration - AF160 Side Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Parts List - AF160 Side Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Parts Illustration - AF & AFC 160 Rear Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Parts List - AF & AFC 160 Rear Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Parts Illustration - AF & AFC 160 Four Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Parts List - AF & AFC 160 Four Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Parts Illustration - AFC160 Side Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Parts List - AFC160 Side Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Parts Illustration - Drive Shaft Assembly (Centre Mount) . . . . . . . . . . . . . . . . . . . . . . . . . .22
Parts List - Drive Shaft Assembly (Centre Mount) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Parts Illustration -Manual Engagement Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Parts List - Manual Engagement Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Parts Illustration / Parts List - Control Arm Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Illustration -AF160 Belt Retainer Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Illustration - Adjusting Screw Mount / Pivot Position for Adjusting Screw Assembly . . . . . .28
CE Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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 CAREFULLY BEFORE USING YOUR MACHINE
AND KEEP THIS MANUAL IN A SAFE PLACE.
THIS SAFETY SYMBOL IS TO ALERT OPERATORS OF A HAZARD
THAT MAY RESULT IN INJURY.
ALWAYS FOLLOW INSTRUCTIONS CAREFULLY

2
SAFETY DECALS
GB ATTENTION Description of pictograms.
FATTENTION Description des pictogrames.
DVORSICH Beschreigung der piktogramme.
GB Read Operating manual before use.
F Lisez Manual D’Opéreration avant l’utilisation.
DVor der Benutzung, Betriebshandbuch lesen.
GB Ear defenders must be worn.
F Défenseurs des oreilles doivent être portés.
D Gehörschutz getragen werden.
GB Never remove guards or attempt adjustment until rotor has stopped.
F Ne retirez jamais les gardes ou d'ajustement tentative jusqu'à ce que toutes les pièces mobiles ont
été interrompus.
D Schutzvorrichtung niemals abnehmen oder einstellung versuchen, bevore der rotor abstellt.
GB Bystanders must be at least 20 metres from machine range of action.
F Des spectateurs doivent s’écarter au moins 20 mètres du rayon d’action de la machine.
D Umstenhenden müßen sich mindestens 20 meter vom maschinenbetriebsraum entfernen.
GB Stand clear. Flying objects possible.
F S’écartez! Possibilité d’objets volants.
D Zurückbleiben! Herumfliegende objekte möglich
GB Examine blades regularly. The operator is responsible for machine damage caused by unbalanced
rotors.
F Examinez des lames régulièrement. L’opérateur est responsable des dommages à la machine
provoqés par des rotors mal equilibrés
D Klingen regelmäßig kontrollieren. Der abeiter ist an den durch unausgewogenen rotoren
maschinenschäden verantwortlich.
GB Keep hands and feet clear
F Garder les mains et les pieds.
D Halten Sie Ihre Hände und Füße.
GB Grease points
F Les points de graissage
D Grease Punkte.
GB Liftt Machine before turning
F Levez la machine avant de la tourner
D Maschine aufheben, bevor man sie umdreht.

3
SAFETY DECALS
GB It is the operators responsibility to ensure that the machine is compatible with the load-
ing capacity of the towing vehicle.
F Il est de la responsabilité des opérateurs afin de s’assurer que la machine est compati-
ble avec la capacité de chargement du véhicule tracteur.
D Es ist den Betreibern dafür zu sorgen, dass die Maschine mit der Belastbarkeit des
Zugfahrzeugs ist.
GB Never carry passengers on implements unless designed to do so.
F Ne jamais transporter des passagers sur instruments sauf s’ils sont conçus pour le
faire.
D Niemals Passagiere implementiert, es sei denn ausgelegt, dies zu tun.
GB ATTENTION: Engage Slowly.
FATTENTION: Engagez Lentement.
D VORSICH: Einschalten Langsam.
GB Lifting Point
F Point de levage
D Anschlagpunkt

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 COMPLETELY at a
standstill.
2. NEVER attempt to clear any obstructions around the mower unless the machine is
COMPLETELY at a standstill.
3. NEVER remove belt guards unless the machine is COMPLETELY at 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 IMMEDIATELY if 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
Wessex AF Flail mower: Approximately 97.5 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.

5
READ THE FOLLOWING CAREFULLY
IMPORTANT SAFETY INSTRUCTIONS ON COUPLING IMPLEMENTS AND
ATTACHMENTS TO ATV’S
TRAINING
!It is most essential that all operators of ATV’s are trained by a certified training organisation.
!It is strictly forbidden that any person under 16 years of age should ride an ATV.
!Any person 17 years of age must have had training before towing a trailer with an ATV.
!Contact your local HSE office for approved training courses.
BODY PROTECTION
!Remember that when riding on an ATV the only form of protection that you have is what you
wear. ALWAYS wear a helmet, eye protection and suitable robust clothing.
!Never operate an ATV or attachments while under the influence of alcohol or non-prescription
drugs.
!Contact your doctor before operation of an ATV or attachments while under the influence of any
prescription drugs.
ATV MANUAL
!Before coupling any implement to your ATV refer to your ATV handbook.
STABILITY
!When using equipment coupled to an ATV it is very important to remember that the handling
characteristics of your ATV will change dramatically, whether the additional load is placed on
the front or rear rack or trailed on the towing ball hitch.
WEIGHT CAPACITY
!Always ensure that the implement or attachment that your are coupling to the ATV is within the
ATV’s drawbar loading or weight carrying capacity. Refer to the ATV manufacturer’s handbook
to obtain information on the specific capacities.
!It is most important that you know the weight of your load, especially when on slopes or
hillsides.
!As a guide, on level ground with an unbraked implement, the weight of the implement should
be approximately no more than twice the unladen weight of the ATV. This should be reduced
on sloping, uneven or rough ground.
WEIGHT TRANSFER
!Always take great care when towing loads which may be subject to weight transfer e.g. liquids
or livestock, especially on hillsides and slopes.
!Always restrict the movement of animals or rolling objects in a trailer.
IMPORTANT ATV SAFETY WARNINGS

6
TOWING
!Never tow loads larger or heavier than recommended for your ATV. (See ATV hand book).
!Never tow or turn across a slope.
!Never tow down a steep slope with a large or heavy load.
!When towing heavy loads there is a significant risk of jack-knifing or overturning.
ROUGH TERRAIN
!Always take care when operating implements on rough terrain or uneven ground.
!Take special care when operating on slippery surfaces especially hill sides or slopes.
!Take extra care when towing on hillsides, slopes or rough terrain.
OPERATING ON ROADS
!Implements are not designed for travelling distances on roads but when crossing or going short
road distances always travel slowly and do not exceed 20 KPH.
!Make sure that your equipment complies with Road Vehicle Lighting Regulations.
!Ensure that you have the correct insurance cover and comply with all relevant laws.
LOAD SECURITY
!Always secure your load firmly with ratchet straps.
!Make sure that your load is evenly; distributed.
!Never stack a high load, high loads increase the risk of overturning.
PASSENGERS
!Never carry passengers on any kind of implement or attachment, especially children.
MAINTENANCE
!Service your ATV and attachments as per the manufacturer’s handbook. Regular servicing of
your ATV will ensure that it will steer, stop and handle to its best ability and your attachment will
operate as safely and effectively as possible. Regular servicing helps ensure the longest
possible working life for your equipment.
EQUIPMENT SAFETY INSPECTION
!Check tyre pressure, incorrect tyre pressure can seriously affect the handling of your ATV.
(See Operators handbook).
!Maintain your equipment regularly to keep it in safe working order.
ROUTE / RISK ASSESSMENT
!Assess and plan the route that you intend to travel to avoid any type of hazards i.e. rocks,
boulders, ditches, hidden fences or wire, pot holes, low hanging branches or any other type of
hazard.
!Where possible stay with a routine route to avoid hazards.
!The risk may change in wet or wintery conditions, avoid slopes where possible.
IMPORTANT ATV SAFETY WARNINGS

7
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.

8
SETTING UP YOUR MOWER
1. Reverse your towing vehicle up to your machine, and connect to the ball hitch. Ensure that it is
locked in position prior to use.
2. Secure the engine cut-off switch to the rear carrier, within easy reach of the operator.
3. Ensure that the rotor is disengaged, and stationary, before using the adjustment handle to adjust
the cutting height.
4. Adjust the rear roller to suit conditions. Set the roller down for large volumes of cut material.
5. In order to obtain full cutting height adjustment, the adjustment handle(s) must be in the correct
position on the adjusting screw mount see Plate 10 (page 28).
USING YOUR WESSEX MOWER
1. Centrifugal Clutch version - The engine on your mower can be started with the throttle set at
either the high or low revs setting, but always ensure that the revs are immediately adjusted so
that the clutch is either completely engaged or disengaged. Running the machine with the
clutch partially engaged will drastically reduce the life of the clutch.
2. Manual Clutch version - Always start the engine with the clutch disengaged.
IMPORTANT - To commence cutting, engage the clutch slowly!
3. Suitable forward speed will be determined by the amount, type, and condition of material to be
cut. In very difficult conditions, better results will be obtained by making two passes, and
adjusting cutting height accordingly.
4. Cutting height is adjusted by turning the adjustment handle in the relevant direction.
4 WHEEL VERSION
1. Both front and rear wheels should be adjusted for cutting height, to keep the machine level.
2. When towing between jobs, it is advisable to adjust cut height to maximum, for smooth running
of front (swivel) wheels.

9
1. Remove Belt Cover.
2. Loosen Jockey Pulley Bracket clamping bolt.
3. Tighten belts using adjusting screw and lock off.
4. Retighten clamp bolt.
5. Replace Belt Cover.
NOTES
1. For Manual version, the clutch lever should be in the drive position for belt adjustment.
2. The belts should be free to move 10mm under moderate thumb pressure.
3. The three belt retainers, should be positioned as shown on Plate 9 (page 27).
4. Check belt tension after 1 hours use, as new belts often slacken while seating in pulleys.
5. For Centrifugal Clutch machines, it is strongly advised not to put the machine to heavy work for
the first 5 hours of use, as this can cause the clutch to overheat, consequently reducing its
useful life.
BELT ADJUSTMENT

10
MAINTENANCE
!IMPORTANT! Check that all fastening sets (bolts and nuts) are tight after the first hour of
operation.
LUBRICATION
DAILY (8-10 working hours)
!Grease Main Rotor bearings (x2).
!Grease Roller bearings (x2).
!Grease Wheel bearings (x2).
FLAIL BLADES
!The condition of the flail blades should be inspected daily. Damaged flail blades cause
imbalance in the rotor and in turn, will cause serious damage to the mower, which is
specifically excluded from our Warranty Conditions.
!If the mower begins to vibrate, stop work immediately and investigate. Almost certainly the
cause will be damaged flail blades, or foreign objects around the flail rotor.
FLAIL BLADES - CHANGING
!When fitting new flail blades, unhitch the mower from the tractor/ATV and lift the mower up
enough to access the blades, (preferably with a hoist or mechanical lifting equipment). Remove
the damaged flail blades and replace.
!It is important that the rotor remains balanced. Always fit new bolts and nuts when replacing
the flails and preferably fit a full set. If only one or two flails are being replaced, they should be
fitted opposite to each other on the rotor, to keep the rotor balanced.
SPARE PARTS
Spare parts for your Wessex Mower can be obtained through our extensive dealer network.
For details of your nearest supplier or technical information, please email
[e-mail] or telephone [phone].

11
WINTER STORAGE
Before winter storage, the 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.
TROUBLESHOOTING
FAULT CAUSE 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.

12
PARTS ILLUSTRATION - AF & AFC160 MAINFRAME ASSEMBLY
PLATE 1

Item No. Part No. Description Qty. per Machine
1 WX-2903 Fastening Set 1
2 WX-9666 Shaft Spacer 1
3 WX-1347 Key 1
4 WX-7262 Taper Lock 1
5 WX-7062 Engine Pulley 1
6 WX-1520 Special Washer 1
7 WX-7462 Centrifugal Clutch 1
8 WX-10977 Fixed Guard 1
9 WX-0103 Fastening Set 1
10 WX-0760 16 HP Engine 1
11 WX-1603 Fastening Set 1
12 WX-10457 Engine Mounting Plate 1
13 WX-1303 Fastening Set 1
14 WX-1860 18 HP Engine 1
15 WX-1060 13 HP Engine 1
16 WX-2803 Fastening Set 1
17 WX-8779 Mainframe 1
18 WX-2360 Cut-out Switch Assembly 1
19 WX-5376 Apron Clamp 2
20 WX-2003 Fastening Set 1
21 WX-9678 Front Apron 1
22 WX-1955 Left Hand Roller Bracket 1
23 WX-0303 Fastening Set 2
24 WX-7866 Rotor 1
25 WX-8270 Flail 44
26 WX-6702 Fastening Set 44
27 WX-1855 Roller 1
28 WX-1755 Right Hand Roller Bracket 1
29 WX-0841 Bearing 2
30 WX-1703 Fastening Set 2
31 WX-4858 Belt Retainer 3
32 WX-1103 Fastening Set 3
33 WX-9566 Bearing Shield 2
34 WX-0941 Bearing 2
35 WX-1803 Fastening Set 2
36 WX-7162 Rotor Pulley 1
37 WX-5962 Taper Lock 1
38 WX-0447 Key 1
39 WX-11077 Belt Cover 1
40 WX-0203 Fastening Set 1
41 WX-3834 Drive Belt 3
13
PARTS LIST AF & AFC160 MAINFRAME ASSEMBLY - PLATE 1

14
PARTS ILLUSTRATION - AF160 SIDE WHEEL ASSEMBLY
PLATE 2

Item No. Part No. Description Qty. per Machine
1 WX-8853A Plastic Cap 2
2 WX-11551 Wheel Mounting Support 2
3 WX-2403 Fastening Set 2
4 WX-9353 Wheel Mounting 1
5 WX-13380 Adjusting Screw Assembly 1
6 WX-0503 Fastening Set 1
7 WX-11251 Adjusting Screw Mount 1
8 WX-0403 Fastening Set 1
9 WX-2029 Drawbar Adjuster 1
10 WX-1129 Adjuster Bar 1
11 WX-1129A Ball Knob 2
12 WX-2356 Tow Hitch 1
13 WX-1503 Fastening Set 1
14 WX-12880 Drawbar 1
15 WX-4503 Fastening Set 1
16 WX-12156 Tow Hitch Swivel Bar 1
17 WX-1403 Fastening Set 1
18 WX-12980 Drawbar Mounting Bracket 1
19 WX-1203 Fastening Set 1
20 WX-5228 Pillar 1
21 WX-5228A Tommy Bar 1
22 WX-3325 Disc Spring 1
23 WX-1352 Wheel 2
24 WX-1538 Wheel Bearing Inner 2
25 WX-1638 Wheel Bearing Outer 2
26 WX-2652 Wheel, HTC 2
27 WX-11651 Wheel Spacer 2
28 WX-9153 Wheel Stud 8
29 WX-9451 Wheel Hub 2
30 WX-2552 Wheel, Flotation 2
31 WX-11751 Wheel Spacer 2
32 WX-9253 Wheel Stud 8
15
PARTS LIST - AF160 SIDE WHEEL ASSEMBLY - PLATE 2

16
PARTS ILLUSTRATION - AF & AFC160 REAR WHEEL ASSEMBLY
PLATE 3

Item No. Part No. Description Qty. per Machine
1 WX-3152 Wheel 2
2 WX-2503 Fastening Set 2
3 WX-13380 Adjusting Screw Assembly 1
4 WX-0503 Fastening Set 1
5 WX-11251 Adjusting Screw Mount 1
6 WX-0403 Fastening Set 1
7 WX-2029 Drawbar Adjuster 1
8 WX-1129 Adjuster Bar 1
9 WX-1129A Ball Knob 2
10 WX-11056 Jack Bracket 1
11 WX-7002 ‘U’ Bolt 2
12 WX-12156 Tow Hitch 1
13 WX-1503 Fastening Set 1
14 WX-12880 Drawbar 1
15 WX-4503 Fastening Set 1
16 WX-2356 Tow Hitch Swivel Bar 1
17 WX-1403 Fastening Set 1
18 WX-10956 Jockey Wheel Assembly 1
19 WX-2303 Fastening Set 1
20 WX-12980 Drawbar Mounting Bracket 1
21 WX-1203 Fastening Set 1
22 WX-5228 Pillar 1
23 WX-5228A Tommy Bar 1
24 WX-3325 Disc Spring 1
25 WX-8753 Rear Wheel Mounting 1
26 WX-11551 Wheel Mounting Support 2
27 WX-2403 Fastening Set 2
28 WX-8853A Plastic Cap 2
17
PARTS LIST - AF & AFC120 REAR WHEEL ASSEMBLY - PLATE 3

18
PARTS ILLUSTRATION - AF & AFC160 FOUR WHEEL ASSEMBLY
PLATE 4