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TWIGA FLEX 5000
Handbook
68 pgs5.23 Mb0

Spearhead TWIGA FLEX 5000 Handbook

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Important information
TWIGA Flex
Handbook
4. Edition – Dec 2015
The information contained in this manual is correct at the time of publication. However, in the course of constant development, changes in specification are inevitable. Should you find the information given in this book different to the machine it relates to please contact the “After Sales Department” for advice
© GreenTec Machinery Limited 2015
Please ensure that this manual is handed to the operator before using the machine for the first
time. The operator must fully understand the
contents of this manual before using this machine. (If the mac hine is resold the Manual must be given to the new owner.)
Merkurvej 25
DK 6000 Kolding
Danmark
Tlf: +45 75553644
Fax: +45 75554243
Email: info@greentec.eu
http: www.greentec.eu
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Contents
Introduction .................................................................................................................... 4
Useful information ......................................................................................................... 5
CE Declaration of Conformity ....................................................................................... 6
Vehicle/tractor preparation ............................................................................................ 7
Vehicle Ballast ........................................................................................................... 7
Front weights ............................................................................................................. 7
Rear weights ............................................................................................................... 7
Factors that affect stability ......................................................................................... 8
Suggestions to increase stability ................................................................................ 8
Safety Stickers ............................................................................................................... 9
Safety ........................................................................................................................... 10
Potential Dangers associated with the use of this machine ...................................... 10
Additional Safety Advice ......................................................................................... 11
Training ................................................................................................................ 11
Working in Public Places ..................................................................................... 11
Warning Signs ...................................................................................................... 11
Suggested Warning Signs Required ..................................................................... 11
Use of Warning Signs .......................................................................................... 12
Safety Recommendations ............................................................................................. 13
Overhead Power Lines ............................................................................................. 15
Specifications ............................................................................................................... 17
Attaching Machine To The Tractor – 3 Point Linkage ................................................ 18
Attaching Machine To The Tractor – Axle Mounting ................................................. 22
Running Up Your Machine ...................................................................................... 24
Removing from the tractor ........................................................................................... 25
Settings for daily use .................................................................................................... 26
Joystick-type: STD 2010-2012 ................................................................................ 26
Joystik-type: STD. Auto Flex 2013 ......................................................................... 27
Adjusting the Flail Head .......................................................................................... 28
Cutting width ........................................................................................................... 28
Rotation settings ....................................................................................................... 29
Hedge trimming set-up ............................................................................................ 30
Grass cutting ............................................................................................................ 31
Operational Warnings .............................................................................................. 32
Moving into transport position ................................................................................. 33
Operation .................................................................................................................. 35
Engaging head drive ................................................................................................ 35
Disengage head drive ............................................................................................... 35
Break Back ............................................................................................................... 36
Collision safety Function Range .............................................................................. 37
Tractor forward speed .............................................................................................. 38
Cuttingsequence ....................................................................................................... 38
Wire trap .................................................................................................................. 39
Oil cooler ................................................................................................................. 39
Extra equipment ........................................................................................................... 40
Angle float ............................................................................................................... 40
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Operating the head angle float ............................................................................. 40
Arm float .................................................................................................................. 41
Operating the arm float ........................................................................................ 41
Automatic vertical control: Auto Flex ..................................................................... 42
Operating Auto Flex ............................................................................................ 42
Hydraulic rear roller ................................................................................................. 43
Hedge cutting ....................................................................................................... 43
Grass cutting ........................................................................................................ 43
Auto pilot ................................................................................................................. 44
Set-Up: Correct position of micro switches ......................................................... 45
Summary .............................................................................................................. 45
Auto Pilot Switch Alignment ............................................................................... 47
Alternative Settings .............................................................................................. 47
Warning ................................................................................................................ 47
Operation Of The Autopilot ................................................................................. 48
Transport of the machines with Autopilot ........................................................... 48
Warning ................................................................................................................ 48
Quad Saw ..................................................................................................................... 49
Technical Data ......................................................................................................... 50
Tensioning the belts ................................................................................................. 50
Belt diagram ............................................................................................................. 51
Mounting the Quad Saw .......................................................................................... 51
Quad Saw Operating Instructions ............................................................................ 52
Warning .................................................................................................................... 52
Service and maintenance .............................................................................................. 53
Greasing ................................................................................................................... 53
Lubrication chart ...................................................................................................... 54
After washing your machine .................................................................................... 54
Gearbox .................................................................................................................... 54
PTO .......................................................................................................................... 54
Motor drive – direct drive ........................................................................................ 54
Motor drive – belt drive ........................................................................................... 54
Oil requirements ....................................................................................................... 54
Hydraulic hoses ........................................................................................................ 55
Oil Supply ................................................................................................................ 56
Recommended oil ................................................................................................ 56
Filtration Maintenance ............................................................................................. 56
Flail head .................................................................................................................. 58
Pins & Bushes .......................................................................................................... 59
Storage ......................................................................................................................... 59
Torque settings ......................................................................................................... 59
Trouble shooting .......................................................................................................... 60
Regular Services Chart ................................................................................................ 61
Pump & Motor Failure Prevention .......................................................................... 61
Hydraulic and electrical di agram s ............................................................................... 62
GreenTec Warranty ...................................................................................................... 66
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Introduction
Dear customer! Your new Greentec machine is constructed with background in more than 20 years
experience with tractor mounted machines to maintenance of green areas. This machine is produced by the latest technology and recognized safety regulations, standards and regulations.
We want to make a product available in such a way, that neither the use of the machine during transportation or maintenance of the machine causes any damage or misunderstandings.
This manual contains information and instructions that are important and useful for maintaining your Greentec machine's reliability, dependability and value. Please read this manual carefully as it will familiarize you with the installation, use, care and maintenance. Pay particular attention to the instructions regarding safety.
You are welcome to visit our website www.green tec .e u - where the login via the dealer's access gives you the latest updates on instructional and part books on our entire product range. The password for dealer log-in: PUBLI SH E R
We hope, you will be pleased with your new Greentec machine. Best regards,
John Christensen Sales Director GreenTec A/S
GreenTec’s vision is to develop and sell quality machines for the maintenance of green areas, including in agriculture, in industry, at airports and in the local sector. Through innovative product development, we will strive to become a leader in our field.
All machines are developed in a simple and functional design in close cooperation with dealers and end users. It is our goal to cover every need in the market segment with preferably 2 different solutions. In-depth analysis of requirements and serious advice to the customer is offered the best solution, where individual needs can be met through the modularity of the product program . Our goal is also to offer the best possible after sales service, and a quick and efficient spare parts supply.
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Useful information
Before using the machine for the first time, it’s the seller’s responsibility that the buyer is given this manual, and the seller is sure, that the buyer fully understands the manual’s contents. If the machine is resold, the manual must be transferred to the new owner.
Please fill out the list below to ensure that the necessary information is at hand when ordering spare parts etc.
Serial No
Delivery date
Dealer
Tlf./ E-mail
Merkurvej 25
DK 6000 Kolding
Denmark
Tlf: +45 75553644
Fax: +45 75554243
Email: info@greentec.eu
http: www.greentec.eu
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Merkurvej 25, DK-6000 Kolding, Denmark
CE Declaration of Conformity
Adapted EEC directive
EG Guideline 2006/42/EF, 89/392/EEC & 98/37/EC
We, GreenTec A/S, Merkurvej 25, 6000 Kolding, hereby declare that in terms of its design, method of construction and our execution thereof, the item of machinery described below complies with the basic health and safety regulations of the respective EU Directives. The Machinery Directive is supported by the following harmonized standards:
Product: GreenTec Twiga Flex Product code: 998365778 Serial no: Type: Armsystem mower
DS/EN ISO 12100 3rd edition 2011. Safety of Machinery – General
principles for design – Risk assessment and risk reduction.
DS/EN 953+A1 4th edition 2010. Safety of Machinery – Guards-General
requirements for the design and construction of fixed and movable guards.
DS/EN ISO 4413 1th edition 2010. Hydraulic fluid power – General rules
and safety requirements for systems and their components.
The EC Declaration only applies if the machine stated above is used in accordance with the operating instructions.
On behalf of GreenTec A/S
Date: 24.11.2014 Signature:_________________________________ John Christensen Sales Director
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Vehicle/tractor preparation
We recommend vehicles are fitted with cabs using ‘safety glass’ windows and protective guarding when used with our machines. Fit Operator Guard (See drawing) using the hooks provided. Shape the mesh to cover all vulnerable areas. The driver must be looking through mesh and/or poly c ar bon ate glazing when viewing the working tool in any working position - unless the vehicle/ cab manufacturer can demonstrate that the penetration resistance is equivalent to, or higher than, that provided by mesh/polycarbonate glazing. If the tractor has a roll bar only, a frame must be made to carry both mesh and polycarbonate glazing. The operator should also use personal protective equipment to reduce the risk of serious injury such as; eye protection (mesh visor to EN1731 or safety glasses to EN166), hearing protection to EN352, safety helmet to EN297, gloves and high visibility clothing.
Vehicle Ballast
It is imperative when attaching ‘third-party’ equipment to a vehicle that the maximum possible stability of the machine and vehicle combination is achieved – this can be accomplished by the utilisation of ‘ballast’ in order to counter-balance the addi ti onal eq ui pm ent ad d ed.
Front weights
May be required for rear mounted machines to place 15% of total outfit weight on the front axle for stable transport on the road and to reduce ‘crabbing’ due to the drag of the cutting unit when working on the ground.
Rear weights
May be required to maintain a reasonable amount of rear axle load on the opposite wheel from the arms when in work; for normal off-ground work i.e. hedge cutting this should be 20% of rear axle weight or more for adequate control, and for ground work i.e. verge mowing with experienced operators, this can be reduced to 10%. All factors must be addressed in order to match the type and nature of the equipment added to the circumstances under which it will be used – in the instance of Power Arm hedge cutters it must be remembered that the machines centre of gravity during work will be constantly moving and will differ from that during transport mode, therefore balance becomes critical.
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Factors that affect stability
Centre of gravity of the tractor/machine combination. Geometric conditions, e.g. position of the cutting head and
ballast.
Weight, track width and wheelbase of the tractor. Acceleration, braking, turning and the relative position of the
cutting head during these operations.
Ground conditions, e.g. slope, grip, load capability of the
soil/surface.
Rigidity of implement mounting.
Suggestions to increase stability
Increasing rear wheel track; a vehicle with a wider wheel track is
more stable.
Ballasting the wheel; it is preferable to use external weights but
liquid can be added to around 75% of the tyre volume – water with anti-freeze or the heavier Calcium Chloride alternative can be used.
Addition of weights – care should be taken in selecting the
location of the weights to ensure they are added to a position that offers the greatest advantage.
Front axle locking (check with tractor manufacturer).
NOTE: The advice above is offered as a guide for stability only and is not a guide to vehicle strength. It is recommended that you consult your vehicle manufacturer or local dealer to obtain specific advice on this subject, additionally advice should be sought from a tyre specialist with regard to tyre pressures and ratings suitable for the type and nature of the machine you intend to fit.
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Safety Stickers
Warning
Avoid fluid escaping under pressure. Consult technical manual for service procedures
.
Warning
Danger – flying objects. Keep safe distance from the machine as long as the engine is running.
Warning
Stay clear of rotating saw blades / knifes.
Warning
Do not remove / open guard when parts are rotating
Warning
Stop engine and remove key before performing maintenance or repair work.
Warning
Check all nuts and bolts are tight every 8 hours – retighten if required.
Warning
Carefully read operator’s manual before handling this machine. Observe instructions and safety rules when operating.
Warning
The recommended oil flow has been adjusted by the manufacturer. Never exceed this.
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Safety
This machine has the potential to be extremely dangerous - in the wrong hands it can kill or maim; it is therefore imperative that both owner and operator of the machine reads and understands the following section to ensure they are fully aware of the dangers that do, or may exist, and their responsibilities surrounding the use and operation of the machine. The operator of this machine is responsible not only for their own safety but equally for the safety of others who may come into the close proximity of the machine, as the owner you are responsible for both.
All operators must be fully competent in the use of this machine and also the machine to which it is attached and must read and understand the operation manuals for both machines before attempting to attach or operate this equipment.
When the machine is not in use it should be lowered to rest on the ground. In the event of any fault being detected with the machine’s operation it must be stopped immediately and not used again until the fault has been corrected by a qualified technician.
Potential Dangers associated with the use of this machine
▲ Being hit by debris thrown by rotating components. ▲ Being hit by machine parts ejected through damage during use. ▲ Being caught in other moving parts i.e.: belts, pulleys and cutting
heads.
▲ Being hit by cutting heads or machine arms as they move.
▲ Becoming trapped between tractor and machine when hitching or
unhitching.
▲ Tractor overbalancing when machine arm is extended. ▲ Injection of high-pressure oil from hydraulic hoses or couplings. ▲ Machine overbalancing when freestanding (out of use). ▲ Road traffic accidents due to collision or debris on the road.
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Additional Safety Advice
Training
Operators need to be competent and fully capable of operating this machine in a safe and efficient way prior to attempting to use it in any public place. We advise therefore that the prospective operator make use of relevant training courses available such as those run by the Agricultural Training Board, Agricultural Colleges, Deale rs and GreenTec.
Working in Public Places
When working in public places such as roadsides, consideration should be paid to others in the vicinity. Stop the machine immediately when pedestrians, cyclists and horse riders etc. pass. Restart only when they are at a distance that causes no risk to their safety.
Warning Signs
It is advisable that any working area be covered by suitable warning signs and statutory in public places. Signs should be highly visible and well placed in order to give clear advanced warning of the hazard. Contact the Department of Transport or your Local Highways Authority to obtain detailed information on this subject. The latter should be contacted prior to working on the public highway advising them of the time and location of the intended work asking what is required by way of signs and procedure. – ‘Non-authorized placement of
road signs may create offences under the Highways Act’.
Suggested Warning Signs Required
‘Road works ahead’ warning sign with a supplementary ‘Grass cutting’ plate. ‘For 1 km’ or appropriate shorter distance may be added to the plate.‘Road narrows’ warning signs with supplementary ‘Single file traffic’ plate. White on blue ‘Keep left’ (*) arrow sign on rear of machine.
* Note – this applies to EU Market machines where traffic passes to the left of a machine working in the same direction as the traffic flow. The direction, use and colour of the arrow sign will depend on the country of use and the Lo cal Highway Authorities regulations in the locality.
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Use of Warning Signs
▲ On two-way roads one set of signs is needed facing traffic in each direction.
▲ Work should be within 1 km of the signs. ▲ Work only when visibility is good and at times of low risk e.g.: NOT during
‘rush-hour’.
▲ Vehicles should have an amber-flashing be ac on. ▲ Ideally, vehicles should be conspicuously coloured. ▲ Debris should be removed from the road and path as soon as practicable,
and at regular intervals, wearing high visibility clothing and before removing the hazard warning signs. ▲ Collect all road signs promptly when the job is completed.
Safety Gear: It is recommended that the following personal protective equipment is worn when operating and/or maintaining this machine; Coveralls, safety boots, safety glasses, hearing protection, safety helmet, protective gloves.
Although the information stated here covers a wide range of safety subjects it
is impossible to predict every eventuality that can occur under differing circumstances whilst operating this machine. No advice given here can replace ‘good common sense’ and ‘total awareness’ at all times, but will go a long way towards the safe use of your GreenTec machine.
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Safety Recommendations
Beware of the following Potential Dangers associated with the use of this machine:
• Becoming trapped when hitching or unhitching
• Tractor overbalancing when arm is extended
• Electrocution due to hit ti ng ov erhead power lines
• Getting caught on rotating power take off (PTO)
• Being hit or caught by any moving part, e.g. belts, pulleys, arms, cutting
head
• Being hit by flying debris or machine parts due to machine damage
• Machine overbalancin g when not in use
• Injection of high pressure oil from damaged couplings or hydraulic
hoses
• Accidents due to collision with other machines, or debris left on road
Always
• Ensure the operator has read this handbook and has been trained to use the machine.
• Ensure all cab safety guards are in place and all tractor windows closed.
• Before leaving the tractor cab always ensure that the flail head is firmly on the ground, no weight is on the machine’s hydraulics and the rotor has stopped spinning.
• Check that all guards are properly fitted and there are no damaged or loose parts. Particular attention should be given to the flails to ensure they are not damaged, cracked or missing.
• Inspect work area for wire, steel posts, large stones and other dangerous materials and remove before starting work.
• Beware of the danger of overhead power cables. The operator must be aware of the maximum height and reach of the machine when working under power cables. For more information contact the Health and Safety Executive or your local power company.
• Ensure that all warning labels are always visible and that they are not damaged, defaced or missing.
• Lower the head to the ground when parking up
• Fit locking pins to slew and height before transport and before
unhitching when applicable.
• Wear ear defenders if operating without a quiet cab or with the cab windows open.
• Ensure tractor guards ar e fitte d corr ec tl y and are undamaged
• Work at a safe speed, taking into account terrain, passing vehicles and
obstacles
• Ensure that the tractor meets the minimum weight recommendations of the machine manufacturer and that ballast is used if necessary
• Check that machine fittings and couplings are in good condition
• Follow the manufacturer’s instructions for attachment and removal of
machine from the tractor are warning signs to alert others to the type of
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machine working in the vicinity. Signs should be placed at both ends of the work site and should be in accordance with Department of Transport recommendations.
• Ensure flails are of the type recom me nd ed by the manufacturer, are securely fitted and are undam ag ed.
• Ensure hydraulic pipes are correctly routed to avoid damage from chafing, stretching, pinching or kinking.
• Disengage the machine, stop the engine and remove the key before leaving the tractor cab for any reason.
• Clean up any debris left at the work site.
• Ensure that when you remove the machine from the tractor it is
secured in a safe position using the stands provided.
Never
• Never operate the machine with other people present, as it is possible for debris, including stones, to be discharged from the front and rear of the flail head.
• Never operate the machine until you have read and understood the relevant Handbook and are familiar with the controls.
• Never use a machine that is poorly maintained or has guards that are damaged or missing
• Never allow an inexperienced person to operate the machine without supervision.
• Never use or fit a machine onto a tractor if it doesn’t meet the manufacturer’s specification.
• Never use a machine if the hydraulic system shows signs of damage.
• Never attempt to detect a hydraulic leak with your hand, use a piece of
card.
• Never allow children to play on or around the machine at any time.
• Never attempt any maintenance or adjustment without first disengaging
the PTO, lowering the head to the ground, stopping the tractor engine and applying the tractor parking brake.
• Never leave the cab without removing the ignition key.
• Never operate the tractor or any controls from any position other than
from the driving seat.
• Never stop the engine with the PTO engaged.
• Never operate with flails missing.
• Never operate PTO above recommended speed for your machine, 750
or 1000 R.P.M. flail head, 150 R.P.M. cutter-bar.
• Never operate with wire around the rotor. Stop immediately.
• Never use the head at an angle, which may throw debris towards the
cab.
• Never attempt to use the machine for any purpose other than that it was designed for.
• Never transport with the PTO engaged
• Never enter the working area of the machine (risk of injury!)
• Never transport with the controls live, always turn off electrical isolator
switch (red) and disconnect supply.
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Overhead Power Lines
It cannot be stressed enough the dangers involved when working in the vicinity of Overhead Power Lines (OHPLs). Some of our machines are capable of reach in excess of 8 metres (26’); they have the potential to well exceed, by possibly 3 metres (9’ 9”), the lowest legal minimum height of 5.2 metres from the ground for 11,000 and 33,000 volt power lines. Remember electrocution can occur without actually coming into contact with a power line as electricity can ‘flashover’ when machinery gets close to it.
WARNING: All operators must read the following information and be aware of the risks and dangers involved when working in the vicinity of Overhead Power Lines (OHPLs).
Wherever possible the safest option is always to avoid working in areas close to OHPLs. Where unavoidable, all operators must perform a risk assessment and implement a safe procedure and system of work – see following page for details. All operators should perform a risk assessment before operating the machine within 10m horizontal distance of any OHPLs.
Minimum Heights for Overhead Power Lines
Absolute Minimum Exclusion Zones for Specific Overhead Power Lines
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Definitions of Exclusion Zones
Risk Assessment
Before starting to work near OHPLs you should always assess the risks. The following points should be observed;
Know the risks of contacting OHPLs and the risk of flashover. Find out the maximum height and maximum vertical reach of your machine. Find out the location and route of all Power Lines within the work area. Find out the operating voltage of all Power Lines within the work area. Contact the local Distribution Network Operator (DNO) who will be able to advise
you on the operating voltage, safe minimum clearance distance for working and additional precautions required.
Never attempt operate the machine in an exclusion zones. Always work with extreme caution and plan your work ahead to avoid high risk
areas.
If doubt exists do not work in the area – never risk the safety of yourself or others.
Emergency Action for Accidents Involving Electricity
• Never touch an overhead line - even if it has been brought down by machinery, or has fallen. Never assume lines are dead.
• When a machine is in contact with an overhead line, electrocution is possible if anyone touches both the machine and the ground. Stay in the machine and lower any raised parts in contact or drive the machine out of the lines if you can.
• If you need to get out to summon help or because of fire, jump out as far as you can without touching any wires or the machine - keep upright and away.
• Get the electricity company to disconnect the supply. Even if the line appears dead, do not touch it - automatic switching may reconnect the power.
Further information and leaflets on this and other agricultural safety subjects are available on the ‘Health & Safety Executive’ website at the following address: www.hse.gov.uk/pubns/agindex.htm
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Specifications
Type
4000 Flex
5000 Flex
6000 Flex
6000 T Flex
A range m
4,8
5,6
6,3
7,2
B range m (with LRS 2001)
5,5
6,3
7,2
8,1
C range m
3,3
3,9
4,7
5,4
D range m
3,4
4,2
4,6
5,4
E range m
4,1
4,9
5,5
6,3
Type
7000 Flex
7000 LR Flex
7000T Flex
7000 LRT Flex
A range m
6,7
7,5
7,9
9,0
B range m (with LRS 2001)
7,6
8,3
8,9
9,5
C range m
5,1
5,6
6,1
7,1
D range m
5,1
5,9
6,1
7,0
E range m
6,0
6,7
7,2
8,2
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Attaching Machine To The Tractor – 3 Point Linkage
1. Reverse tractor to machine and attach lower links.
2. Fit stabiliser bracket into top link clevis and fit top link. The standard link comes with a Cat III hole plus a Cat III to Cat II reducing bush, a 28mm bracket is available on request.
3. Fit stabiliser tubes between A frame and stabiliser bracket. Ensur e t he tubes are free to slide, do not fit locking pins.
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4. Raise machine to required height. Both P.T.O. shafts should be roughly in-line, an upward angle of up to 17° is acceptable to ensure adequat e clearance.
5. Adjust the top link so that the machine sits vertically.
6. Fit locking pins to stabiliser tubes, then the linkage can be lowered so that the weight of the machine is taken by the stabilisers. It is essential that both tubes are set to equal lengths, more than one attempt may be required to achieve the correct height as the machine settles on the stabilisers.
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7. It is recommended that the controls are mounted in-place of the seat armrest on the side of the cutting head. A pivoting bracket is supplied with every machine, if additional brackets are required contact your local dealer. A 12v/30Amp power supply will be required.
8. Ensure the engine is switched off and then fit the P.T.O. shaft. If fitting for
the first time follow instructions below to cut P.T.O. to length. Ensure both sections are cut to equal lengths
9. Remove slew locking pin.
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9. Raise leg stands to ensure they don't get damaged. Adjust check chains ensure the machine is secure and cannot swing from side to side.
10. Use only tractors with safety glass. If windows are not laminated safety glass, polycarbonate glazing must be fitted between operator and cab meshing. Shape mesh to cover all windows that the driver will look through to view flail head in any operating position. Mesh can be retained by springs and clips supplied, but it is the operators responsibility to ensure guarding is firmly in place.
Warning
Avoid raising the tractor linkage once the stabiliser bars are locked in place. Always lower the tractor linkage and allow all the weight to be carried by the stabiliser frame. Failure to observe this warning will result in bending the stabiliser bracket. When operating the machine’s controls do so only when seated in the tractor cab. Do not allow anyone to stand on or amongst linkage for any reason
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Attaching Machine To The Tractor – Axle Mounting
1. Mount axl e brack ets a s inst ruc te d
on separate fitting sheet specific to your tractor type.
2. Detach tractor draft links.
4. Assemble sub frame to suit axle width
1m or 1.1m, mount sub frame assembly to your machine using bottom pin hol es.
3. Fit lift-in hitch assembly
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Please Note
6. Open catch
5. Offer up frame to tractor and adj ust to
give required length. Distance “X” to be kept to the minimum ensuring the machine is close coupled, as a guide set the same as original. Attach tractor lift links to frame with suitable pins.
Note: The hole sizes may not match the tractor links, this will not matter as the machines weight will be carried on the stabilisers.
7. Ensure top link is fitted to pr event
machine from tipping over before raising. Lift sub frame until it engages in the catches. Note: It is best to mount the sub frame to the tractor first.
8. Insert latch locking pin
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Running Up Your Machine
1. First ensure the rotor is in the ‘off’ position and P.T.O. drive is
disengaged, and then start the tractor.
2. Engage P.T.O. into gear and run machine up to half revs allowing oil to
circulate for about 5 minutes bef or e operating arms
3. Re-check oil level, - check for oil leaks
4. Operate the arms through the full amount of travel, check all
movements are functioni ng corr ect ly
5. Place flail head near ground in a safe position and with tractor revs low
idle, select ‘start’ position for the flail motor
6. Once rotor is settled, slowly increase revs of P.T.O. to 750/1000 R.P.M.
according to model and run for a further 5 minutes. Slowly reduce revs and then disengage P.T.O.
7. Check all hoses for kinks, pinching, chafing and leaks.
8. Re-check oil level.
Warning
The rotor will take a long time to stop. Never leave the cab until P.T.O. is disengaged, engine stopped and rotor has stopped spinning.
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Removing from the tractor
The following steps MUST be followed in exactly the same order in which they appear, with removal of the top link being the last action before driving the tractor away. Do not attempt to operate machine controls through the rear cab window whilst standing on or amongst the linkage.
1. Select a level firm site such as a concreted surface
2. Fit parking stands. Place the flail head on the ground approximately
1.5 m out from machine main assembly, to the rear
3. Ensure head float is discharged and turned off
4. The arms must be slewed back into transport position and the locking
pin fitted to slew post. (Fig. 1
5. Disengage PTO
6. Slightly raise the lower lift arms with great car e to enabl e the s tabi li ser
locking pins to be removed
7. Lower all weight securely onto parking stands (Fig.2).
Fig.1
Fig. 2
8. Stop engine; ensure all weight is off the tractor and machi ne hydraulics.
9. Remove stabiliser bars, lower link pins, PTO shaft and control unit from
the cab.
10. Remove top link.
11. Slowly drive tractor away.
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Settings for daily use
Joystick-type: STD 2010-2012
Power On / Off Head Float Arm Float (Option Autopilot) Available (Option Hydr. parallel handling) Turn Head Available (Option Telescope)
Rotor On / Off
Turn arm Vertical control
Tip head Option: Oversteering Autopil ot
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Joystik-type: STD. Auto Fle x 2 01 3
Power On / Off Head Float Arm Float (Option Autopilot) Auto Flex Vertical control Available (Option Telescope)
Rotor On / Off
Turn arm Turn head
Tip head Option: Oversteering Autopilot
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Adjusting the Flail Head
A flail head with direct flow gives the advantage of minimizing the weight at the end of a long arm thanks to the compact shaping and in the form of reduced maintenance. Runs with a fixed speed of 2800 rpm.
A flail head with a belt drive optimizes the performance because it gives you the choice between different rotor speeds. There are no direct mechanical strains on the engine shaft.
• High speed of 3100 rpm. gives the knives the extra speed for the finishing
touch to the annual hedge cutting (rotor pulley 150 Ø, motor pulley 160 Ø).
• Standard middle speed 2700 rpm. for daily work on grass and hedges (rotor
pulley 160 Ø, motor pulley 150 Ø).
Cutting width
The standard width of 1.2 m is suitable for both grass and hedges and gives the best balance between power and weight. The alternative width of 1.5 m is best suited for reducing the number of passages when cutting hedges. However this will result in reduced power of each flail and a higher weight, which cannot be recommended for machines with long range, especially when cutting grass.
Warning
The machine must never operate with a 140 Ø washer on the rotor and a 160 Ø washer on the engine. This will lead the rotor to run too fast and this is very dangerous.
Warning!
Never attempt to operate the machine without the r ea r roller corr ect ly fitted. The rear roller is an integral part of the machine giving the necessary support and stability to the head. Failure to adhere to this warning may result in metal fat igu e.
Spearhead
Rotation settings
High Speed
Low Speed
Spearhead
Hedge trimming set-up
Recommended set-up
- 1.2m or 1.5m rotor
- Rear roller
- T” flails or “L” flails
- Rear flap
Rear roller settings
Raise to just clear the top of the hedge. The adjustable front hood should be adjusted as low as possible without hindering the hedge getting into the flail head.
Hedge trimm ing
The flails are cutting upwards reducing flying debris to a minimum and leaving a tidy finish. Open adjustable front hood as required.
Rough cutting
Reverse rotation and remove front cowling if necessary. Down cut is no good for the hedge and leaves an untidy finish. Only use this position when rough cutting in heavy growth. Not possible on all models.
Warning!
Seek advice before reversing direction of motor.
Optional belt drive rotor – use smaller pulley on rotor shaft.
Do not remove cowling from the head when cutting
“up”.
Spearhead
Grass cuttin g
Recommended for grass cutting
• 1.2 rotor
• Rear roller
• Cowl wear plate
• Option – “L” flails
Note: 1.5 m head is not recommended for grass cutting
• ”C” flails or ”Y” flails
• Front and rear flap
• Head float
• Auto Pilot
Cutting height adjustment
Grass cutting
Set rear roller down to control cutting height. Have rubber flap fitted to the front and rear of head and close down the adjustable front hood to reduce flying debris to a minimum.
Never remove front cowl.
Do not operate without front and rear flap.
Do not verge mow without a rear roller.
Do not verge mow with rear roller set too high; remember the
rear roller is used for controlling the cutting height.
Warning!
Spearhead
Operational Warnings
• Never drive the tractor with arm out stretched (except when cutting).
When moving at work always first retract arms. Transport with care. Metal fatigue is always caused by careless transportation and misuse. If the ground is uneven or bumpy slow down.
• Read operator’s manual and be fully familiar with all operational
maintenance and safety procedures.
• Practice in open space without rotor running until familiar with controls.
Take care working the head close to the tractor as it may be possible to strike the tractor.
• Remember one of the clever features of the TWIGA Flex is its ability to
operate within a very narrow space, often within the tractors width. This will mean it is quite possible for the flail head to foul the tractor. Practice all these positions and be very familiar with your machine before ever attempting work.
• Never operate above the recommended P.T.O. speed. Failure to heed
this warning will result in severe damage, i.e. greatly increased oil temperature, risk of rotor going out of balance, as well as reduced machine life, and could cause expensive repairs.
• Failure to start and stop the rotor at a low P.T.O. speed or to operate at
the correct speed will result very quickly in severe motor and/or pump damage.
• Be very careful when operating on sloping ground.
• Remember, before selecting reverse gear always lift the flail head out
of work and retract the arms towards the tractor. If something is hit while reversing, the Break-back will still work, as long as you are within the angular range from 450 to 1250. See illustrations in "Collision safety Function Range".
• Never operate with flail rotor facing towards the tractor. This is
potentially dangerous with debris being thrown towards the tractor, and unseen hazards may cause damage.
• Never attempt to slew arms when fully out stretched - always retract
before operating the slew. Be very careful when operating on sloping ground.
• Never attempt to slew arms with the head on the ground, always raise
the head before slewing.
Spearhead
Moving into transport position
Warning
Always transport machine with the slew-locking pin fitted and the arms closed in the transport position on the bump stops. Avoid high transport speeds, which will cause unnecessary strain on machine and tractor. Never travel with the reach arm away from bump stop on the main arm failure to adhere to this warning will cause damage to ram seals and arms.
1. Disengage head motor drive.
Ensure that the lift and head float ar e disch ar ged and turned off.
Retract arms to bring flail head approx. 1metre from tractor wheel and 1 metre off the ground (close telescopic where applicable).
Slew rearwards to fully close slew ram
2. Gently close reach arm into cradle and bump
stop on main arm.
Spearhead
3.
Slowly raise the main arm. Be careful not to hit the cabin –
make sure the gap is at least 300 mm.
4.
Make sure the tool is hanging as protected as possible. The
transport position may vary according to machine and tractor.
5.
Mount the adjustable transportation link. (Kat. 1 Top lever).
6.
Option 2010-2012: Fit slew locking pin.
Transportation
link
Spearhead
Operation
• Remove locking pin from slew post.
• Ensure rotor/motor switch is “OFF”.
• Engage PTO low revolutions
• Position head 45˚ compared to the dipper arm.
• Extend main lift hydraulic cylinder until main arm
is upright.
• Extend dipper arm slightly.
• Slew arm into work position.
• Position head till horizontal, just above ground.
• Engage Auto-Flex. (The unit will settle into
upright position). Engage Float / Auto Pilot and position head on the ground.
Engaging head drive
• Select 750 / 1000 rpm PTO and run with low engine revs.
• With flail head in safe position switch rotor control to “ON”.
• NOTE! Be aware that when engaging the rotor with low PTO/rpm the
operations of the arm will be slower or not operating at all.
• Cold start - it is important not to run at full speed with cold oil. Run at low
speed for at least 15 minutes to allow oil to warm up.
• Afterwards slowly increase engine revs to obtain correct PTO speed.
• Never attempt to start rotor while under load.
Disengage head drive
• Slowly decrease engine revolutions to a fast idle.
• Move rotor control lever to ‘OFF.
• Never increase or decrease PTO speed rapidly, this could seriously damage
pumps and motor.
Warning
Upper Rotorflex must always be kept upright whether working on grass or hedges (Photo above). If put
horizontally there will not be sufficient hydraulic power to
control it and it will lose pressure and the tool will turn in adverse position.
Spearhead
Break Back
Manual - Yellow Switch “Off”
The Twiga Flex has as standard a 3-point break back. The further out the arm is stretched, the higher the pressure. The gauge pressure valves are controlled by micro switches on the In/Out cylinder.
Manual
Recommended for
confined areas and on steep hills
The Twiga Flex has as standard a slew ram to
position the machine from transport to work or any position midway for narrow lane cutting. This ram also acts as the break back ram for machine protection should an obstacle be encountered while travelling forward.
The break back will operate if the machine is overloaded i.e. a dense patch of vegetation, too high a forward speed, and when working uphill. The tractor must be halted and the flail head manoeuvred around the obstacle before the break back is reset via slew control lever / switch.
Remember, before selecting reverse gear always lift the flail head out of work and retract the ar ms towards the tractor. If something is hit while reversing, the Break-back will still work, as lon g as you are within the angular range from 450 to
1250. See illustrations in "Collision safety Function Range".
Warning:
If something is hit while reversing, the Break-back will still work, as long as you are within the angular range from 450 to 1250. See illustrations in "Collision safety Function Range". The break back feature does not excuse the machine operator of their need to be aware of obstacles and to avoid hazards. It is your responsibility to maintain a long reliable working life.
Spearhead
Collision safety Function Range
Please note: There can be worked freely in all angles between 450 – 1550 as illustrated above.
1550 Forward
Normal working position for cutting grass. Can be used for hedgecutting.. Break-Back device works 100% while driving forward. 0% when reversing while the ram is completely out .
900 Forward
Normal working position for hedge cutting. Can be used for grass cutting. Break-Back device works 100% while driving forward, as well as
100% when reversing.
450 Forward
Possible working position for mowing into narrow spaces, such as forest paths and forest roads. Take particular care when driving in this position. Breakaway device works 100% while driving forward, as well as 100%
when reversing.
Spearhead
Tractor forward speed
Cuttingsequence
Too high a forward speed will impair the finish,
leaving it looking ragged and cause over frequent use of the break back, Possible overloading of the motor
which will overheat the oil.
A slower forward speed improves the standard of the
finish.
Cut field side and bottom of hedge first.
Cutting hedge from roadside.
Warning!
Never operate with flail rotor facing towards the tractor. This is potentially dangerous with debris being thrown towards the tractor and unseen
hazards may cause damage
Spearhead
Wire trap
This is located under the front hood. It must not be interfered with in any way. Any wire must be removed immediately. Lower rotor to ground, select rotor control lever to “OFF” and wait until rotor stops
spinning. Disengage PTO and stop engine before leaving cab.
Oil cooler
Prolongs the life of the hydraulic oil and components in hot and arduous conditions. (Not fitted as standard to all models)
Warning!
Wire is extremely dangerous and must be avoided at all times. Inspect work area before commencing, removing all lose wire and clearly marking fixed wire.
Oil Cooler
Spearhead
Extra equipment
Angle float
This extra equipment allows the cutting head to follow the contours of the ground without it being necessary to check the angle of the head regularly.
Operating the head angle float
Lower the cutting head to the ground and engage the head angle float control. This will open the ram to the tank and the ramHead can float in or out. You wil l automatically have full contact with the ground. Disengage to get manual control.
Warning!
The float position must be disengaged before folding the machine up for transportation.
Head float
Spearhead
Arm float
This is only to be used in verge mowing set up, it will reduce weight on the rear roller allowing head to move more easily, following small changes in ground contours in a forward motion, with the aid of a pre­charged gas accumulator.
Operating the arm float
To select arm float, first lower the flail head to the ground before operating the switch. The main lift control lever should be operated to take a proportion of the flail head weight off the rear roller. This is important, as too little weight on the rear roller will leave uncut areas of grass, too much weight on the roller will cause scalping in places and increase flail wear and damage. We strongly recommend to use the Headfloat together with Anglefloat.
When the head is pushed further out more weight will be applied to the accumulator causing the head to drop, reset with control lever
As the ground contours alter it is necessary to reset the pressure within the main lift circuit as above, constantly raising or lowering control lever.
Warning!
Do not fold the machine up for transport before turn ing off the arm float and discharging the pressure from the lift circuit.
Arm float
Spearhead
Automatic vertical control: Auto Flex
This equipment gives you advantages when cutting both grass and hedges. The automatic vertical control constantly monitors that ”Rotor-Flex” remains vertical, enabling you to drive your Twiga Flex more effectively.
Operating Auto Flex
After unfolding the machine to the required work position this function is engaged by pressing the yellow switch. If Rotorflex is not vertical it will now automatically correct itself. Auto-Flex is especially suitable for cutting grass and works the best if connected with Auto Pilot and/or floating positions. When work is finished and the machine has to be folded up for transport, disengage the Auto-Flex. Otherwise you will not be able to put the machine in the transport position.
Rotorflex in vertical position
Spearhead
Hydraulic rear roller
Hedge cutting
Grass cutting
The hydraulic rear roller is controlled by a switch on the control panel. The control of the rear roller is either raised or lowered; there is no in-between height control. Height is set as above for either hedge or grass cutting.
Grease daily
The settings for cutting hedges have large
gaps between the positions at the bottom of the adjustment point.
The settings for cutting grass have small
gaps between the positions.
Warning!
If the hedge cutter is fitted with a control for reverse rotor rotations, the hydraulic rear roller will not function. To secure the rear roller when the rotor is in reverse fix the enclosed bolts keeping the roller in place.
Note
To ensure the roller moves freely it is important to keep the roller linkage clean and lubricated.
Spearhead
Auto pilot
The Autopilot is an automatic control system for use when cutting on the ground. It operates by sensing the weight on the rear roller and maintaining this within a narrow band without the attention of the operator. When the angle of the area being mown is more than 45° to the horizontal, it is best to switch off the Autopilot and operate the machine manually until the angle becomes more normal . Th e middl e pos i ti on of the green switch will allow angle float without autopilot
Autopilot will only operate when the cutting head rear roller is in contact with the ground
If the machine is going to be used for long periods of time at hedge cutting it is recommended to remove the Autopilot assembly between the dipper arm and head and replace with standard head bracket (Part no. 1777315A)
Warning!
Ensure the eng ine has stoppe d and the key is remov ed, the PTO is disengaged, h andbrake sec ured, and the head is firmly on the ground before atte mpting any servi cing, mainten ance or adjust ment.
Spearhead
Set-Up: Correct position of micro switches
1. Place rear roller on the ground
2. Ensure the locking pins (fig.1) are installed into the Auto-pilot with the arm
fully lowered
3. Engine turned off, key remov ed and P TO dis eng ag ed.
4. Slacken bolt (“A” fig 2) and adjust cam plates until they are flush on the top.
5. Slacken screws (“B” fig 2) to adjust switches; the lever arm must rise on the
cam as shown sufficiently to make the circuit. The switch will give an audible click, if necessary bend the lever arm towards the cam to ensure the switch makes a circuit.
6. Remove the locking pin from the Auto-pilot and raise the main arm and rear
roller off the ground 0.5 m, now check the opposite switch has risen up the other cam and the switch has made a circuit.
7. Start the machine and turn on the Autopilot. The arm should rise if the arm
head was fully lowered or drop if the rear roller is off the ground, and the 2 switch arms should come to rest in the valley between each cam peak.
8. The system can be checked for operation by depressing the red isolator
button on the top of the joystick handle, fully lowering the main arm, bring joystick to neutral and releasing the red button. The autopilot should now reset the arm up until the switches rest in the valley.
Summary
You must ensure that the micro switches make and break a circuit as the cams rotate through their arc of travel. It is very important to correctly set the micro switches to ensure the electrical circuit functions, the switch lever arm must follow its own cam and not be influenced by the opposite cam also the lever must be bent towards or away from the cam to allow the electric circuit to open and close in accordance to the cam position
Bolt “A”
Screw “B”
Fig. 2
Spearhead
Autopilot
When both switches are open the main arm will hold position, this is neutral or mid position when they rest in the valley between both cam peaks.
Slacken this bolt before adjusting the position of cams,
increase sensitivity by moving the cam peaks together reduce auto pilot sensitivity by moving them apart. We recommend the cam plates are flush at the top as shown.
Ensure the switch lever
closes the contacts, if not adjust by bending the lever arm towards the cam.
Autopilot
When one of the switches is closed, main arm will either raise or lower dependant on which switch has been triggered.
Fig. 3 Fig. 4
Spearhead
Auto Pilot Switch Alignment
Alternative Settings
Warning
If the working range is altered the spring length on the damper may need adjusting to compensate.
Note: The basic factory setting for the spring length is 200mm
Bend lever arm of switch to
align with the middle of each cam, ensure they don’t overlap onto the adjacent cam.
Move the cams apart to incr ease
amount of weight carried on the rear roller, thereby reducing the sensitivity of the auto-pilot If the cams are too close together the switches will constantly be altering the main arm height causing unnecessary wear and
strain on the hydraulics.
Spearhead
Operation Of The Autopilot
To activate Autopilot first slew the head into work position and lower the head horizontally onto the ground.
Remove the 2 transport pins. Raise the head 300 - 400mm off the ground and ensure AHS is switched on, engage rotor drive and then switch on Autopilot. The head will gently drop to the ground and be ready for work.
Your forward speed will be determined by ground conditions, density of growth, height of cut and generally operating within a safety margin to allow you time to react to any unexpected occurrence.
Once in work the Autopilot will control the head height and angle, allowing the head to accurately follow all the ground contours. The operator will control reach whenever necessary.
The Autopilot will assist you with grass mowing. It does not relieve you of your responsibility to drive with care and understanding for the machine.
When crossing “grips” or drainage gullies, it may be necessary to temporarily lift with the main ram using joystick and the isolator button.
If you approach larger areas not to be mown i.e. road junction, bridges and crash barriers, it will be necessary to switch off the Autopilot, enabling you to raise the head from the ground.
Before switching on the Autopilot please ensure the head is within 300 ­400mm from the ground. Always ensure that the Auto-break-back (AHS) is switched on when operating with the Autopilot.
Transport of the machines with Autopilot
1. Turn off autopilot switch (green
2. Ensure all locking pins are fitted to mainframe, slew, height stop and
auto pilot bracket
3. Ensure machine is folded to the recommended position
4. Turn off isolator switch (red
5. Disconnect electrical supply
6. Disengage PTO
Warning
Autopilot is not suitable in extreme conditions i.e. very steep banks and very wet conditions. Always ensure the rear roller is not “clogged” with mud. If the machine starts to move uncontrolled, isolate by turning off the green switch, place the head on the ground, follow point 4, 5 and 6 above. Turn off the tractor, apply parking brake and remove the ignition key, then insp e ct machi ne for faul t.
Spearhead
Quad Saw
• Never operate the machine with other people present, as it is possible for
debris to be thrown from the saw blades in all directions.
• Always ensure all cab safety guards are in place and all tractor windows are
closed. Never allow an inexperienced person to operate the machine without supervision.
• Never allow children to play on or around the machine at any time.
• Never attempt any maintenance or adjustment without first disengaging the
PTO/ hydraulic pump, lowering the head to the ground, stopping the tractor engine and applying the tractor’s parking brakes. Before leaving the cab remove the ignition key, never stop the engine with the PTO engaged.
• Before leaving the tractor cab always ensure that the saw head is firmly on
the ground no weight is on the tractors hydraulics and blades have stopped spinning.
• Always check that all guards are properly fitted, check there are no
damaged or loose parts.
• Always operate the blades at a speed between 3000 - 3200 R.P.M.
• Maximum oil pressure of 250 bars in the hydraulic hoses.
• Never transport without the blade protection guard mounted.
• Always inspect work area for wire, steel posts, large stones and other
dangerous materials. If such items are found remove them.
• Never attempt to use the machine for any purpose other than that it was
designed for.
• Ensure that all warning labels are always visible and that they are not
damaged, defaced or missing.
• P.T.O. speed 750/1000 R.P.M. depending on choice of hydraulic circuit.
Spearhead
Technical Data
Quadsaw for mounting on hydraulic hedge cutters. Frame with 4 shafts. 500 mm or 590 mm saw blades. Depending on model. Each shaft is driven by vee belts, and the whole unit is powered by a hydraulic motor. Branch deflectors are placed between the blades. Depending on m odel . The Quadsaw is supplied with a special bracket enabling mounting on various vehicles / carriers.
Model
Lrs 2001
Lrs 2401
Working width
2000 mm
2380 mm
Blade speed
3000 – 3200 rpm.
3000 – 3200 rpm.
Blade diameter
500 mm
590 mm
Teeth per blade
72 teeth.
78 teeth.
Material
Hardened steel with
special teeth HM precision
blade
Hardened steel with
special teeth HM precision
blade
Performance
1 – 120 mm branch diameter
1 - 160 mm branch diameter
Application
Vertical
Vertical
Oil flow 15,0 CC
50 Litres. Relief valve 180 bar
50 litres. Relief valve 180 bar
Oil flow 28,0 CC
85 Litres. Relief valve 150 bar
85 litres. Relief valve 150 bar
e. g. Twiga 4-7000
PTO speed 540
PTO speed 540
e. g. Twiga MID
PTO speed 540
PTO speed 540
e. g. Twiga PRO HP
PTO speed 440
PTO speed 440
Twiga Flex
750/1000 PTO rpm
750/1000 PTO rpm
Tensioning the belts
It is utmost importance that the belts are correctly mounted and tightened. When new belts are mounted they must be tensioned to (LRS 2001 700 Nm) (LRS 2401 1100 Nm) for the short and (LRS 2001 900 Nm) (LRS 2401 1300 Nm) for the long belts. After 3-5 working hours the belts may have slackened and must be checked. . Note ! The tension has now changed to (LRS 2001 550 Nm) (LRS 2401 900 Nm) for the short and (LRS 2001 650 Nm) (LRS 2401 1100 Nm) for the long belts.
Contact GreenTec A/S After Sales Department if you have any questions. We might help you with a piece of good advice.
Spearhead
Belt diagram
LRS 2001
LRS 2401
Tool for belt tension control Part no. 200155.0
Mounting the Quad Saw
The blades must be mounted in a downward cut rotation. Always use the blades vertically positioned in relation to the direction of travel.
The hydraulic hoses must be connected correctly to achieve the correct direction of rotation. Drainage hose must be lead directly to the oil reservoir. Daily inspect all hydraulic hoses and fittings for damage or leaks.
When starting for the first time the speed of rotation on the blades must be measured (LRS 2001 3000 - 3200 R.P.M. This rotation should be maintained to ensure optimum performance.
Spearhead
Quad Saw Operating Instructions
It is recommended to travel forward slowly when starting work in order to maintain the correct speed of the blades. Adjust the angle of the saw to present the branches approx 90° to the blades. Always ensure the blades are vertical to allow cut branches to fall away. If a large branch is approaching adjust the working height to ensure it meets the centre of a blade.
In the event of small twigs or debris jamming the saw blades, stop the machine immediately and clear the blockage with a suitable tool.
Ensure there is a skid mounted on the bottom of the saw attachment to protect the lowest blade from striking the ground.
Warning
Be careful not bend the blades in storage or during work. The blades must be inspected daily for signs for fatigue and cracking, do not use the machine with damaged blades they must be replaced immediately. Before starting the saw for the first time after connecting the hoses, you must ensure the hydraulic motor is primed with oil and the case has filled with oil, via the small hose connection. Failure to fill the motor case with oil will lead to seizure due lack of lubrication.
Note:
To change rotation of motor exchange the position of the pressure/returns hoses and the anti-cav valve with the plug.
P/T
Plug
P/T Anticav va lve
Drain Port. Fill
with oil here
Spearhead
Service and maintenance
Greasing
Daily grease points
Twiga Flex
Head rotor & roller
Grease 1.2m head every 8 hours (min. 10 pumps).
Weekly grease it with 40-50 pumps so grease are
comming out at the Rotor.
Optional – Auto pilot
Spearhead
Lubrication chart
Daily
Weekly
Monthly
Rotorbearings
Grease 10 pumps
Grease 40-50 pumps
PTO bearings
Grease
PTO shaft tubes
Grease
Pivot pins
Grease
Roller bearings
Grease
Grease
Oil tank
Check
Oil
Gearbox
Check
Oil
Flail head
Grease
After washing your machine
Grease all your machine and optio nal par t s after each wash.
Gearbox
Check oil level. Change oil after 50 hours. Then once a year or after every 500 hours.
Note:Do not overtighten filler/drain plugs as this will damage the gearbox casing
PTO
Dismantle and clean the input drive shaft sliding surfaces; failure to do this will result in serious damage to the gearbox. Grease U.J. joints every 8 hours.
Motor drive – direct drive
Motor drive splines are lubricated via the rotor bearings and should be greased every 8 hours with 20-40 pumps of grease.
Motor drive – belt drive
Motor drive splines are lubricated via the pulley shaft and should be greased every week with 1-2 pumps of grease. Do not ”over grease” as this leaves pressure on the motor sealing.
Oil requirements
Fill the tank to the centre with approximately 200 l Texaco Rando HD46 or equivalent oil. Do not over fill.
Spearhead
Recommended torque settings for nut
Hydraulic hoses
Carefully check condition of all hoses during routine service paying particular attention to chafed outer casing. Secure wrap with waterproof adhesive tape to stop the metal braid from rusting. Fejl! Bogmærke er ikke defineret. Daily inspect all hydraulic hoses and fittings to be in good order. Any damages or leaks must be rectified immediately; this is part of the daily maintenance and is your responsibility, to unsure a long reliable working life. Hoses with damaged metal braid should be replaced.
The Spearhead hydraulic system works at very high pressure, when replacing hoses use only genuine hoses, a burst hose could be very dangerous.
When replacing hoses to avoid twisting fitting, use two spanners to slacken and tighten.
Always check the black protective sleeve is in good order, to replace sleeve is far cheaper than replacing expensive hoses. Hose warranty is limited to replacement of hoses due to faulty materials or manufacture Warranty will not be considered on hoses damaged by chafing, abrasion, cuts or pinching while in work, or to damaged threads due to over tightening.
BSP (size)
Torque setting
1/4 “
24 Nm
18 ibs/ft
3/8”
33 Nm
24 ibs/ft
1/2”
44 Nm
35 ibs/ft
3/4”
84 Nm
62 ibs/ft
1”
115 Nm
85 ibs/ft
BSP (size)
Torque setting
1/4”
34 Nm
25 ibs/ft
3/8”
75 Nm
55 ibs/ft
1/2”
102 Nm
75 ibs/ft
3/4”
183 Nm
135 ibs/ft
1”
203 Nm
150 ibs/ft
Warning!
Hose is weakened when installed in twisted position. Also, pressure pulses in a twisted hose tend to fatigue wire and loosen fitting connections.
Design so that machine motion produces bending rather than torsion.
Recommended torque settings for ”Parkersoft-seal”
Spearhead
Oil Supply
• Daily before starting up check oil level in tank reservoir.
• It is a good practice to constantly keep an eye on the tank level gauge,
(this can be seen from the tractor seat) as a pipe burst could empty the tank within minutes.
• A pump or motor starved of oil will be damaged beyond repair.
• Replace oil if signs of contamination occur (discoloured)
• Contamination can be reduce d by
• Thoroughly cleaning around reservoir cap before removing
• Using a clean container when replenishing the system
• Regularly servicing the filtration system
• Never allowing oil level to fall below the sight gauge
• Daily inspect all hydraulic connections and fittings to be in good order.
Any damage or leaks must be rectified immediately, this is part of the daily maintenance and is your responsibility, to maintain a long reliable working life.
• When tightening fittings always use two spanners when necessary and
do not over tighten. If a fitting leaks it will need to be replaced
Recommended oil
Filtration Maintenance
The machine is protected by a suction strainer, a low pressure full flow return line filter and a pressurefilter of the type “Absolute”.
1. The suction filter is permanently fixed in the reservoir tank. Should
symptoms of pump cavitation or spongy operation occurs, the tank must be drained, the tank and sucti on filter thoroughly cleaned and dried before refilling with clean oil.
2. The return line filterelement and highpressure filterele ment sho ul d b e
replaced after the first 50 hours and thereafter at 500 hour intervals. It is most important to replace the filter within these intervals because once blocked, oil will bypass the filter element infiltrated.
3. W hen tightening fittings always use two spanners when necessary and
do not over tighten. If a fitting leaks it will need to be replaced
Oil supplier
Description
Texaco
Rando HD 46
Rando HDZ 46
Esso
Univis N 46
Tellus 46
Shell
Tellus T46
Bartran 46
BP
Energol HLP-HM 46
Hyspin AWH-M 46
Castrol
Equivis ZS 46
Total
Hydrelf HV 46
Elf
Hydrelf XV 46
Spearhead
Twiga Flex with Danfoss PVG 32
2006
Fig.
1 P171741 Filter liner 2 K040675 High pressure filter kpl
Twiga Flex is cleaned to 10 My or below before deliverance.
Spearhead
Flail head
• Grease all bearings daily. Grease rotor bearing daily with at least 10 pumps.
Additional greasing will increase the lifespan. Grease rotor bearings weekly until grease shows, at least 40-50 pumps.
• Check for strings, plastic, grass or other debris around the rotor shaft and rear
rollers.
• Check the conditions of flails and ensure all retaining bolts are tight. When
flails are replaced care must be taken to maintain balance of rotor shaft, do not change to a different type.
• Flail retaining bolt and nut torque setting is 140 Nm.
• Flail head is centre mounted to get best travel on hydraulic cylinder.
• Never work if one or more flails are missing. This will cause severe vibration,
lead to faster wear and tear of bearings and the head will crack.
• Blunt flails leave an untidy finish and use way too much power. Always wear
safety googles if sharpening the flails.
• When the flails are showing signs of wear and tear, defects or cracks they
must be replaced immediately. Never attempt to weld the flails. This will leave them very brittle and this is very dangerous. Never take a risk with the flails; if in doubt replace them!
• When replacing flails always replace bolts, nuts and bushings too.
• Regularly check that all rotor bearing bolts and hydraulic motor retaining bolts
are tight.
• With a new machine or if new bolts have been fitted, particular attention
needs to be applied to regular tightening of the new bolts.(Every 1-4 hours, instead of daily)
• Check the condition of drive belts, ensuring they are aligned and properly
tensioned to avoid any unnecessary belt wear. Remove guards for access to both adjusters when tensioning belts, and ensure belts are running in line after adjustm ent.
Rem moment Riemen Vorspannwerte Belt tension
1400 Nm Ny
/ Neu / New
1100 Nm Kontrol / Control
8 PL 1194
Ø140 Ø160
Warning!
Flail head can hit the tractor. Pay attention. Do not slide head mounting bracket past centre stops to extreme end on 1.5 m head.
Spearhead
Pins & Bushes
All main pivot points are furnished with replaceable bushes. If there are any signs of wear, these must be replaced. All bushes are available from the GreenTec Parts Department.
Warning
Do not use grease containing Molybdenum disulphide on nylon bushes and wear pads
Storage
Remember regular maintenance will greatly increase the life of the machine Before storing away, thoroughly wash the machine removing all traces of
grass and dirt. Great Care must be taken when washing with high-pressure hoses, do not hold the water jet close to the paintwork. Use steam cleaners with caution; be sure to remove all detergents to avoid any discolouring or damage to paint. Grease all grease points until fresh grease shows. It is important where possible to store undercover to protect against rain and sunlight. Always ensure a firm level surface.
Smear greaser on all areas vulnerable to corrosion, in particular the chrome on the ramrods.
Before you attempt to do any repairs, service, maintenance or adjustment on your machine, ensure the engine has stopped and the key removed. P.T.O. is disengaged, handbrake secure, and the head is firmly on the ground
Control joysticks and electricbox must be wrapped in plastic sheeting and taped over to keep dry. Or even better; be removed and stored in a safe and dry area. Control joysticks and electricbox are NOT waterproof.
Torque settings
The torque figures given below are recommended maximum settings only.
Size
Tensile strenght
Description
Torque setting
Nm
M8
12.9
Pulley clamps
45
M10
8.8
General fasteners
65
M12
8.8
General fasteners
114
M12
12.9
Head bolts
170
M14
10.9
Flail bolts
200
M16
8.8
Head bracket bolts
280
Spearhead
Trouble shooting
Problem
Cause
Solution
Gearbox overheating
Oil level incorrect
Check oil level
Oil grade incorrect
Check oil grade
Implement overloaded
Reduce forward speed
Wrong PTO speed
Ensure PTO speed matches
Excessive belt wear
Belt and pulley condition
Replace if necessary
Pulley alignment
Check alignment
Incorrect belt tension
Tension belts to spec
Overloading of implement
Reduce forward speed or increase height of cut
P.T.O.. wear U.J. failure Working angle to great
Reduce offset of implements
Shaft incorrect length bottoming out
Resize PTO shaft as recommended
Lack of maintenance
Grease PTO shaft as recommended
Cut Quality Flails worn
Replace worn flails
Rotor speed/direction
Check tractor PTO speed
Crop condition
Look for suitable conditions
Rotor bearing failure
Rotor out of balance
See rotor vibration
Wire/string in bearing
Remove wire/string
Lack of maintenance
Grease bearings to schedule
Water in bearing
Expel water with grease
Rotor vibration
Flails broken or missing
Replace flails
Bearings worn or damaged
Replace bearings
Rotor bend
Re-balance/replace rotor
Build up of debris
Remove debris
Incorrect speed
Check rotor R.P.M.
Oil overheating
Oil level incorrect
Fill tank to correct level
Oil grade incorrect
Refill tank with correct grade oil
PTO speed too fast
Drive correct PTO speed
Ambient temperature too high
Reduce work rate / install oil cooler
Machine overloaded
Reduce forward speed or increase height of cut
Break-back operating
Frequently
Machine overloaded
Reduce forward speed or increase height of cut
Machine being used on excessive incline
Switch off auto reset (AHS)
Weight of machine being carried upon rear roller
Use Autopilot or head float Oil pump suction filter blocked
Replace filter element
Oil leak in pressure line
Check machine of leaks
Drive line broken
Check pump is rotating
Irregular arm movement Spool contacting with housing
Check spool is free moving
Broken spring in spool valve
Check spring
Failed ram seals
Repair ram
Electrically operated
valve not responding
Faulty wiring
Check wiring and switches
Dirt in valve
Check of ingress of dirt
Sticking valve
Replace the valve
Insufficient voltage
Attend to bad connection
Spearhead
Regular Services Chart
Pump & Motor Failure Prevention
• Never run out of oil
• Never run a cold machine straight up to speed, first ensure engine
revolutions are low then engage/disengage the head motor
• Never increase or decrease engine speed quickly
• Never stop or start rotor at high engine speed.
• Never transport with P.T.O. in gear.
• Never operate above or below recommended P.T.O . speed.
• Check that pump fittings are tight.
• If any strange noise occurs from the hydraulics, stop immediately and
investigate.
• Remember, pump and motor warranty is limited to replacement due to
faulty materials or manufacturer. Cavitation and peak pressures are very easily detected on pump inspection.
• Warranty will not be considered if fault is due to misuse.
Service
Hours
Service points
Grease Drain Check Clean Change
1-4 hrs
Bolts are fully tightened
X
Condition of flails
X
Condition of hoses especially for chafing
X
Flail bolts are fully tightened
X
Flail head retaining bolts are fully tightened
X
Gearbox seals (If oil is leaking replace immediately)
X ( X
)
Inspect leaks from fittings and pipes
X
Pins and bushes
X
Rotor bearing bolts are fully tightened
X
8 hrs
Bearings
X
Gearbox & pump bolts are fully tightened
X
Gearbox oil level
X
Grease points & PTO shaft
X
Motor Drive
X
Maintain correct belt tension on head (only with belt drive heads)
X
Oil level in reservoir
X X
U.J. joints
50 hrs
Gearbox oil (use EP 90 oil)
X X
400-500 hrs Return line filter element
X
Hydraulic oil if any signs of contamination appears
X X
Spearhead
Hydraulic and electrical diagrams
Spearhead
Spearhead
Spearhead
Spearhead
GreenTec Warranty
GreenTec warrants that the GreenTec machine referred to in the Warranty Registration Form will be free from defects in materials and workmanship for a period of 12 months from the date of sale. This warranty does not affect your statutory rights, but merely adds to them. Should you have a problem within 12 months from the date of sale please contact your original GreenTec dealer, or GreenTec’s Service Department. Any part found to be defective during this period will be replaced or repaired, at GreenTec’s discretion, by the dealer or a GreenTec Service Engineer.
GreenTec Warranty Conditions
1. The Warranty Registration Form (green page) must be completed and returned to GreenTec within 7 days of the date of sale
2. This warranty does not cover defects arising from fair wear and tear, willful damage, negligence, misuse, abnormal working conditions, use in competition, failure to follow GreenTec’s instructions (oral or written, including all instructions and recommendation made in the Operator’s Manual) or alteration or repair of the machinery without GreenTec’s approval.
3. The machinery must have been serviced in accordance with the Operator’s Manual and the Service Log must have been kept up to date and made available to the dealer should service, repair or warranty work be undertaken.
4. This warranty does not cover claims in respect of wearing parts such as blades, flails, paintwork, tires, belts, hydraulic hoses, bearings, bushes, linkage pins, top links, ball ends unless there is a manufacturing or material defect or the cost of normal servicing items such as oils and lubricants.
5. This warranty does not cover any expenses or losses incurred whilst the machinery is out of use for warranty repairs or parts replacement.
6. This warranty does not extend to parts, materials or equipment not manufactured by GreenTec, for which the Buyer shall only be entitled to the benefit of any such warranty or guarantee given by the manufacturer to GreenTec. Only genuine GreenTec replacement parts will be allowable for warranty claims.
7. All parts replaced by GreenTec under warranty become the property of GreenTec and must be returned to GreenTec if GreenTec so requests. Such parts may only be disposed of after a warranty claim has been accepted and processed by GreenTec.
8. GreenTec is not liable under this warranty for any repairs carried out without GreenTec’s written consent or without GreenTec being afforded a reasonable opportunity to inspect the machinery the subject of the warranty claim. GreenTec’s written consent must, therefore, be obtained before any repairs are carried out or parts replaced. Use of non­GreenTec parts automatically invalidates the GreenTec Warranty. Failed components must not be dismantled except as specifically authorized by GreenTec and dismantling of any components without authorization from GreenTec will invalidate this warranty.
9. All warranty claims must be submitted to GreenTec on GreenTec Warranty Claim Forms within 30 days of completion of warranty work.
Using the machine implies the knowledge and acceptance of these
instructions and the limitations contained in this Manual.
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