Spearhead TWIGA
TWIGA Reach Mower
555/600/655T
555FR/600FR
Edition 1.3 – September 2013
PART No. 8999056
0
Spearhead TWIGA
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1
Spearhead TWIGA
General information
CE Declaration of Conformity, Conforming to EU
Machinery Directive
2006/42/EC
We, Spearhead Machinery Ltd, Green View, Salford Priors, Evesham,
Worcestershire, WR11 8SW hereby declare that:
Product ……………………………………………..…………………………
Product Code……………………………………………..…………………………
Serial No……………………………………………..……..………………….
Type……………………………………………..…………………………
Manufactured by: Alamo Manufacturing Services (UK) Limited, Station Road,
Salford Priors, Evesham, Worcestershire, WR11 8SW
Complies with the required provisions of the Machinery Directive 2006/42/EC. The
Machinery Directive is supported by the following harmonized standards:
BS EN ISO 14121-1 (2007) Safety of Machinery – Risk Assessment, Part 1:
Principles Part 2: Practical Guide and Examples of Methods.
BS EN ISO 12100-1 (2010) Safety of Machinery – Part 1: Basic Terminology
and Methodology Part 2: Technical Principles.
BS EN 349 (1993) + A1 (2008) Safety of Machinery – Minimum Distances to
avoid the Entrapment of Human Body Parts.
BS EN 953 (1998) Safety of Machinery – Guards General Requirements for
the Design and Construction of Fixed and Movable Guards.
BS EN 982 (1996) + A1 (2008) Safety Requirements for Fluid Power Systems
and their Components. Hydraulics.
The EC Declaration only applies if the machine stated above is used in accordance
with the operating instructions.
Signed
(On behalf of Spearhead Machinery Ltd)
Status General Manager
Date 01/09/2013
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Spearhead TWIGA
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 machine is resold the Manual must be given to the new owner.)
Introduction
The TWIGA is a very robust high capacity reach mower that is easy to operate and
maintain. To ensure trouble-free operation this manual should be carefully studied.
The term Left and Right hand applies to the machine when coupled to the tractor and
viewed from the rear, this also applies to the tractor.
Important Note
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.
3
Spearhead TWIGA
Indhold
General information ....................................................................................................... 2
CE Declaration of Conformity, Conforming to EU Machinery Directive ................. 2
Introduction ................................................................................................................ 3
Specification MID ...................................................................................................... 6
Specification PRO ...................................................................................................... 7
Safety ............................................................................................................................. 8
Machine Safety Stickers ............................................................................................ 8
Safety Recommendations 1 ............................................................................................ 9
Beware of the following Potential Dangers associated with the use of this machine:
.................................................................................................................................... 9
Always ....................................................................................................................... 9
Never ........................................................................................................................ 10
Overhead Power Lines ................................................................................................. 11
Minimum Heights for Overhead Power Lines ......................................................... 11
Definitions of Exclusion Zones ............................................................................... 12
Risk Assessment ...................................................................................................... 12
Emergency Action for Accidents Involving Electricity ........................................... 12
Safety Recommendations 2 .......................................................................................... 13
Lighting Kits ............................................................................................................ 13
Warning Signs .......................................................................................................... 13
Roadwork guidelines ............................................................................................... 13
Training .................................................................................................................... 13
Tractor Requirements ............................................................................................... 13
Attaching your machine to the tractor – Using Axle mounting ................................... 14
Attaching your machine to the tractor – when using 3 Point Linkage ......................... 17
Running Up Your Machine .......................................................................................... 21
Removing from the tractor ........................................................................................... 22
Subsequent attachment to a different tractor ........................................................... 22
Hydraulic Proportional Controls - 2SV ................................................................... 23
Electric Proportional PRO PILOT Control - 3SV ................................................... 24
PRO PILOT Switch Box .......................................................................................... 25
Cutting Head Set-Up - MP head .................................................................................. 26
Hedge Cutting .......................................................................................................... 28
Grass Cutting ........................................................................................................... 29
Cutting Height Adjustment ...................................................................................... 29
Operation ...................................................................................................................... 30
Operation Warnings ................................................................................................. 30
Moving into transport position ................................................................................. 31
Engaging Head Drive ............................................................................................... 33
Disengage Head Drive ............................................................................................. 33
Break Back ............................................................................................................... 34
Auto Reset ................................................................................................................ 34
Tractor Forward Speed ............................................................................................ 35
Cutting Sequence ..................................................................................................... 35
Wire Trap ................................................................................................................. 36
Oil Cooler ................................................................................................................. 36
Options ......................................................................................................................... 37
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Spearhead TWIGA
Head Float ................................................................................................................ 37
Arm Float ................................................................................................................. 37
Debris Blower .......................................................................................................... 39
Hydraulic Rear Roller .............................................................................................. 40
Autopilot .................................................................................................................. 41
Introduction To The Autopilot ............................................................................. 41
Set-Up: Correct position of micro switches ......................................................... 42
Summary .............................................................................................................. 42
Auto Pilot Switch Alignment ............................................................................... 44
Alternative Settings .............................................................................................. 44
Operation Of The Autopilot ................................................................................. 45
Transport of the machines with Autopilot ........................................................... 45
Quad Saw ..................................................................................................................... 45
Technical Data & Description ................................................................................. 47
Belt Diagram - Quad Saw ........................................................................................ 47
Mounting the Quad Saw .......................................................................................... 47
Quad Saw Operating Instructions ............................................................................ 48
Telescopic Arm ............................................................................................................ 49
Description ............................................................................................................... 49
Operating the Telescopic Arm ................................................................................. 49
Transporting the Telescopic Arm ............................................................................ 49
Forward Reach (FR) & Variable Forward Reach (VFR) ............................................. 50
Description ............................................................................................................... 50
Operating the (Variable) Forward Reach ................................................................. 50
Transporting the (Variable) Forward Reach ............................................................ 50
Service & Maintenance ................................................................................................ 51
Greasing/Lubrication Points .................................................................................... 51
Lubrication Chart ..................................................................................................... 52
Greasing/Lubrication ............................................................................................... 52
Washing your machine ........................................................................................ 52
Gearbox ................................................................................................................ 52
P.T.O. ................................................................................................................... 52
Motor Drive - Direct Drive .................................................................................. 52
Motor Drive - Belt Drive ..................................................................................... 52
Oil requirements ................................................................................................... 52
Hydraulic Hoses ....................................................................................................... 53
Oil Supply ................................................................................................................ 54
Oil ............................................................................................................................ 54
Recommendations .................................................................................................... 54
Filtration Maintenance ............................................................................................. 54
Flail Head ................................................................................................................. 55
Pins & Bushes .......................................................................................................... 56
Storage ..................................................................................................................... 56
Torque Settings ........................................................................................................ 57
Regular Service Chart .............................................................................................. 57
Trouble Shooting ......................................................................................................... 58
Trouble Shooting ......................................................................................................... 59
Pump & Motor Failure ................................................................................................. 60
Warranty ...................................................................................................................... 61
Warranty Conditions ................................................................................................ 61
5
555
600
655T
555FR
600FR
Weight inc. Oil (Kg)
1350
1370
1465
TBC
TBC
Weight of head (Kg)
300
300
300
300
300
Tractor horse power
85-120
95-120
100-140
TBC
TBC
Min. tractor weight (Kg)
3500
3750
4000
TBC
TBC
Oil tank capacity (ltr)
230
230
230
230
230
Reach A (m)
5.5
6.0
6.5
TBC
TBC
Reach B (m)
4.9
5.3
5.9
TBC
TBC
Reach C (m)
3.9
4.2
4.7
TBC
TBC
Reach D (m)
6.5
6.7
7.2
TBC
TBC
Reach E (m)
4.9
5.2
5.7
TBC
TBC
Specification MID
Spearhead TWIGA
6
560
650T
700T
800T
600VFR
650VFR
Weight inc. Oil (Kg)
1500
1650
1720
1850
1700
1750
Weight of head (Kg)
300
300
300
300
300
300
Tractor horse power
100-130
120-150
140-170
160-190
120-150
140-150
Min. tractor weight (Kg)
4500
5000
6000
6500
5000
6000
Oil tank capacity (ltr)
220
220
220
220
220
220
Reach A (m)
5.6
6.5
7.0
8.0
6.0
6.5
Reach B (m)
5.0
5.9
6.4
7.4
5.4
5.9
Reach C (m)
3.8
4.7
5.2
6.0
4.2
4.7
Reach D (m)
6.7
7.6
8.1
8.6
7.1
7.6
Reach E (m)
5.2
6.1
6.6
7.1
5.6
6.1
Specification PRO
Spearhead TWIGA
7
Warning
Danger – flying objects
keep safe distance from
the machine as long as
the engine is running.
Warning
Shut off engine and remove
key before performing
maintenance or repair work.
Warning
Avoid fluid escaping
under pressure. Consult
technical manual for
services procedures.
Warning
Carefully read operator’s
manual before handling this
machine. Observe
instructions and safety rules
when operating.
Warning
Stay clear of mower flails.
Warning
Do not remove / open
guard..
Warning
Beware of overhead
electrical power line.
Warning
Check all nuts and
bolts are tight every
8 hours.
Machine Safety Stickers
Spearhead TWIGA
Safety
8
Spearhead TWIGA
Safety Recommendations 1
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 hitting overhead 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 overbalancing 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. The minimum legal height for 11,000 and 22,000-volt cables is
5.2 metres from the ground. When fully extended, the machine may well
exceed this height so extreme caution should be practised. 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 are fitted correctly 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.
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Spearhead TWIGA
Use clear warning signs to alert others to the type of 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 recommended by the manufacturer, are securely
fitted and are undamaged.
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, 540 R.P.M.
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.
10
Spearhead TWIGA
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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Spearhead TWIGA
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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Spearhead TWIGA
Safety Recommendations 2
Lighting Kits
For additional safety, rear mounted lighting kits are already fitted as standard. For
more detailed information, contact the Department of Transport or your local
Highways Authority.
Warning Signs
You are advised to display clear warning signs to indicate the type of machine when
working in public places. The signs should be carefully placed at either end of the
work site to give advanced warning of the hazard.
Contact your local Highways Authority or Department of Transport for more
information.
Roadwork guidelines
On two-way roads, one set of signs should face the traffic in each direction.
Work should be within 1 mile of the signs.
Work only when visibility is good and at times of low risk, e.g. NOT during rush hour.
Vehicles should show an amber flashing light.
Vehicles should be conspicuously colored.
Debris should be removed from the road or path at regular intervals and the operator
should wear high visibility clothing.
Collect all warning signs promptly when the job is finished.
Training
It is the responsibility of the Spearhead dealer to provide instruction on the safe
installation, operation and maintenance of the machine in the first instance. Further
training is available from Spearhead Machinery Ltd on request, at cost.
Tractor Requirements
Check your tractor size and minimum weight on the Specification table (pg 5).
Before hitching, ensure position control is selected. DO NOT attempt to hitch
in draft control.
Set wheel width as wide as possible.
Front and offside ballast weight is to be fitted within tractor manufacturer’s
recommended requirements.
Check chains and stabilisers must be in good working order
to hold the machine firmly. Do not operate without ensuring
that chains and stabilisers are tight.
Spearhead particularly recommend ‘turn buckle’ type
stabiliser.
Before fitting a front mounted machine to your tractor, seek
advice from your manufacturer or dealer to check it’s
suitability and whether additional linkage, ballast, or weight
requirements may be needed.
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Spearhead TWIGA
Warning
It is most important the operator fully understands the procedure for
attaching/un-attaching the reach mower to/from the tractor. The
following text must be fully understood before attempting to attach the
machine. If there is any doubt please contact your supplying dealer or
Spearhead Service Department. Failure to follow the correct procedure
To attach/unattached the machine could result in personal injury or machine damage. Any
resulting damage to a machine is not covered by warranty.
Always be sure to select a level firm surface, such as concrete before attaching to the tractor.
When operating the tractor or 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.
A linkage isolation facility is necessary for all models. Set linkage lift rods to
an equal length.
All machines require a 12v fused supply. A 30 amp DIN connector is
provided, but if not, the lead should be taken directly to the vehicle battery.
Avoid cigarette lighter plugs as they are unsuitable. The supply cable has a
red wire for positive (+ve) and black wire for negative (-ve)
Spearhead particularly recommend “Category 2” three point linkage of ball
end type, we do not advise the use of claw type hitching. The quick release
latches should be checked, if worn or insecure they may cause accidental
damage or personal injury if the machine becomes detached.
The machine is sold to suit Cat. 2 linkage, some modification may be
necessary before mounting on Category 3 linkage.
Ensure tractor link arms can be isolated from accidental lifting.
Note
For machines fitted with an oil cooler it is important to connect a separate lead direct
from the battery to the oil cooler control box.
Lifting Points for use with pallet forks.
Attaching your machine to the tractor – Using Axle
mounting
14
Spearhead TWIGA
Fitting axle brackets
1. Mount axle brackets as instructed 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 holes.
3. Fit lift-in hitch assembly
Follow instructions from Picture 1. if you have axle mounting.
Follow instructions from Picture 9. if you have 3 point linkage mounting
15
6. Open catch
5. Offer up frame to tractor and adjust 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.
Please Note
The hole sizes may not match the
tractor links, this will not matter as
machine weight is carried on the stabiliser
frame when fully mounted.
7. Ensure top link is fitted to prevent machine
from tipping over before raising. Lift sub frame
until it engages in the catches Note: You may
mount sub frame to the tractor first and follow
procedure in step 9.
8. Insert latch locking pin
Please Note
Spearhead TWIGA
16
Spearhead TWIGA
9. Reverse tractor and attach lower link arms by
inserting lower linkage pins into the bottom set of
holes.
10. Spearhead strongly recommend mounting the
control unit to the seat in place of the armrest to the
head side of the tractor. Modification and additional
bracket may need to be fabricated Consult your local
dealer for advice.
An electric 12-volt supply cable will be needed from a
30-amp source.
To power controls and a separate 12 volt supply
direct from the battery to the oil cooler.
11. Fit stabiliser yoke to the tractor’s top hitch
bracket. Standard bracket Cat 3, use conversion
bush supplied for Cat 2, alternative bracket
available to suit 28mm.
12. Place the stabiliser tubes on to the
machine chassis using the pins. Engage the
stabiliser bars and attach to stabiliser yoke. Be
sure the stabiliser bars are free to slide. Do not
fit locking pins.
Attaching your machine to the tractor – when using 3
Point Linkage
17
Spearhead TWIGA
13. Fit top link between the machine and the
stabiliser yoke.
14. Lift the machine up on the tractor’s
hydraulics until both PTO stub shafts are
approximately in line. PTO angle may vary
between tractor makes - up to 17° above
horizontal is acceptable to ensure there is
enough ground clearance.
15. Check the machine is level, ensuring both
stabiliser bars are of equal length. Fit locking
pins to both stabilisers (use a pry bar to twist
tube if necessary).
Once the stabilising bars are correctly fitted,
lower the tractor hydraulics allowing all the
weight of the machine to be carried by the
stabiliser bars
18
Spearhead TWIGA
16. If fitting the PTO shaft for the first time
measure and cut to the correct length.
Example: A (900mm minus 75mm)
= 825mm
17. Fit the PTO shaft connecting the tractor
output shaft to the machine input shaft.
Warning
Always stop the engine and ensure the PTO
drive is disengaged before fitting the PTO.
Ensure the PTO does not bottom out when raising the
machine, serious damage will result.
Remove slew
locking pin
18. Remove locking pin from slew post before
operating the machine, and slew forward
19. Operate the main arm to bring the frame
horizontal by lowering the head weight to the
ground.
19
Spearhead TWIGA
20. Adjust top link length until the main
frame is vertical.
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 yoke.
21. Warning - fully tighten check chains or
linkage stabilisers to hold the machine rigid.
There must be no sideways movement, it is
very dangerous and may cause damage.
22. Raise parking stands and secure with
locking pin. The machine can not be unhitched
without these stands.
23. 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.
20
Spearhead TWIGA
Warning
The rotor will take a long time to stop. Never leave the cab until PTO
is disengaged, engine stopped and rotor has stopped spinning.
Running Up Your Machine
1. First ensure the rotor is in the ‘off’ position and PTO drive is disengaged, then
start the tractor.
2. Engage PTO into gear and run machine up to low revs, allowing oil to
circulate for about 15 minutes before operating arms.
3. Re-check oil level, - check for oil leaks. All Spearhead machines have been
run-up and checked thoroughly. However, hose connections can become
loose in transit and these should be checked again before the machine is put
to work.
4. Operate the arms through the full amount of travel; check all movements are
functioning correctly.
5. Place flail head near ground in a safe position and with tractor revs low, select
‘start’ position for the flail motor.
6. Once the rotor is settled, slowly increase revs of PTO to 540 R.P.M. and run
for a further 5 minutes. Slowly reduce revs and then disengage PTO.
7. Check all hoses for kinks, pinching, chafing and leaks.
8. Re-check oil level.
21
Spearhead TWIGA
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.
Fig. 1
Fig. 2
Removing from the tractor
1. Select a level firm site such as a concreted surface.
2. Fit parking stands. Place the flail head on the ground approximately 1m 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 care to enable the stabiliser locking
pins to be removed.
7. Lower all weight securely onto parking stands (Fig.2).
8. Stop engine; ensure all weight is off the tractor and machine 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.
Subsequent attachment to a different tractor
Follow the steps for “Attaching your Machine to the Tractor” (page 13).
22
Lift Up
Lift Down
Dipper
LH - Dipper Out
RH - Dipper In
Dipper
LH - Dipper In
RH - Dipper Out
Autopilot Cancel
Power ON/OFF
Power Indicator
Head Crowd
LH - Head Out
RH - Head In
Head Crowd
LH - Head In
RH - Head Out
Reverse Rotor
Hydraulic Roller
Slew
LH - Slew In
RH - Slew Out
Slew
LH - Slew Out
RH - Slew In
Tele
LH - Tele Out
RH - Tele In
Tele
LH - Tele In
RH - Tele Out
Rotor
Auto Reset
Stage 1:
Head Float
Stage 2:
Arm Float or
Autopilot
Spearhead TWIGA
Hydraulic Proportional Controls - 2SV
23
Spearhead TWIGA
Head Float
Autopilot Cancel
Head Crowd
LH - Head Out
RH - Head In
Head Crowd
LH - Head In
RH - Head Out
Slew
LH - Slew In
RH - Slew Out
Slew
LH - Slew Out
RH - Slew In
Tele
LH - Tele Out
RH - Tele In
Tele
LH - Tele In
RH - Tele Out
Head Float On
Dipper
LH - Dipper Out
RH - Dipper In
Dipper
LH - Dipper In
RH - Dipper Out
Lift Up
Lift Down
Electric Proportional PRO PILOT Control - 3SV
24
Spearhead TWIGA
Spare
Autopilot
Arm Float
Power Indicator
Hour Meter
Hydraulic Roller
Power ON/OFF
Rotor
Auto Reset
Spare
Reverse Rotor
PRO PILOT Switch Box
The switch box is supplied with a suction pad to allow the box to be mounted to the
tractor cab window for ease of reach.
25
Spearhead TWIGA
Warning
Never operate the machine with the 140 Ø pulley on the rotor and the
160 Ø pulleys on the motor. This will over-speed the rotor and is very
Dangerous.
Warning
Never attempt to operate the machine without the rear roller correctly
fitted. The roller performs a key safety function should the rotor shaft
pick up wire. It is essential for operator safety that it remains in place.
It is also an essential structural part of the cutting head. Removing it
will cause premature wear on rotor bearings and will lead to
premature wear on the fabrications.
Cutting Head Set-Up - MP head
Direct Drive option minimises weight at the end of a long arm by compact mounting
and benefit of reduced maintenance. Running at a single speed of 2800 rpm.
Belt Drive optimises cutting performance with a choice of rotor speeds.
Fast 3100 rpm to provide extra cutting tip speed for fine finish on annual
hedge trimming (rotor pulley 150 Ø. Motor pulley 160 Ø).
Standard medium speed setting of 2700 rpm for general work in grass and
hedges (rotor pulley 160 Ø. Motor pulley 150 Ø).
Slow 2500 rpm to provide extra torque with more power for grass mowing and
overgrown hedges (rotor pulley 160 Ø. Motor pulley 140 Ø).
Cutting Width
Standard 1.2m is suitable for both grass and hedges, and optimises power to weight
ratio.
Optional 1.5m is best used for hedge trimming to reduce the number of passes.
However, there is less power per flail, and an increased weight penalty, which is not
recommended on long reach machines and especially not for grass cutting.
26
Spearhead TWIGA
27
Spearhead TWIGA
Roller Set-Up
The roller should be raised so that it is clear of the
top of the hedge. The adjustable front guard should
be set as low as possible without restricting the
ability of the hedge to enter the cutting head.
Normal Hedge Cutting
Flail is cutting upwards-reducing flying debris to
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 not good for the hedge and
leaves an untidy finish. Only use this position when
rough cutting in heavy growth.
Warning
Seek advice before reversing
direction of motor.
Optional belt drive rotor - use smaller pulley on
rotor shaft for 3100 rpm.
Do not remove cowling from the head when
cutting “up”.
Hedge Cutting
Recommended for hedge cutting
- 1.2m or 1.5m rotor
- Rear roller dia. 114mm
- T” flails or “Boot” flails
- Rear flap
- Front flap
28
Spearhead TWIGA
1.2 rotor
Rear roller dia. 150mm.
Cowl wear plate
“C” flails or “Back to Back” flails
Optional - “Boot” flails
Front and rear flap
Head float and Angle Float
Auto-pilot
Cutting Height
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.
Warning
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 to
control the cutting height.
Optional Belt Drive Rotor
Use larger pulley on rotor shaft for reduced
speed 2500 rpm.
Grass Cutting
Recommended for grass cutting
Note: The 1.5m head is not recommended for grass cutting.
29
Spearhead TWIGA
Warning
Please read all the following operation warnings carefully
Operation
Operation Warnings
Never drive the tractor with arm out-stretched (except when cutting). When
moving from 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 this 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 range is its ability to
operate within a very narrow space, often within the tractor’s width. This will
mean it is quite possible for the flail head to foul the tractor. When in confined
space the main arm will need to be slightly slewed backwards from normal
working position. Practice all these positions and be very familiar with your
machine before ever attempting work.
Never operate above the recommended PTO speed of 540 R.P.M. Failure to
heed this warning will result in severe damage i.e. reduced belt and pulley life
(when fitted); greatly increased oil temperature; risk of rotor going out of
balance, as well as reduced machine life, and may cause expensive repairs.
Failure to start and stop the rotor at a low PTO speed or to operate at the
correct speed will result very quickly in severe motor and/or pump 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.
Never attempt to operate the machine while going backwards. It will
immediately damage the arms and possibly the flail head. Remember, before
selecting reverse gear always lift the flail head out of work and retract the
arms towards the tractor.
Never change/reverse the rotor rotation until it has come to a standstill,
serious damage will occur leading to premature pump and/or motor failure.
30
Spearhead TWIGA
Warning
Always transport machine with the slew-locking pin
Fitted and their arms closed in their 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 are discharged and
turned off.
Retract arms to bring flail head approx. 1metre from
tractor wheel and 1 metre off the ground (close
telescopic or VFR where applicable).
Slew rearwards to fully close slew ram
2. Gently close reach arm into cradle and bump stop
on main arm.
3. Fold transport stop over.
Moving into transport position
31
Spearhead TWIGA
4. Carefully position main boom over the tractor cab roof until
rubber bump stop meets the flip-over transport bracket, allow
minimum of 300mm.
Warning: Bracket must be in correct position or main
boom may move over centre and damage cab roof, if
positioned too close.
6. Fit slew locking pin to secure slew post to A
frame.
Warning : Do NOT attempt to slew machine
until locking pin has been removed, serious
damage will occur to machine frame.
+300mm
5. Turn main lift ram isolation tap to off.
32
Spearhead TWIGA
Warning
Ensure slew locking pin is removed
or machine damage will occur.
Transport to work position
Remove locking pin from slew post.
Turn lift ram isolation tap to on position.
Ensure rotor/motor switch is off.
Engage PTO low revolutions.
Lower main lift ram only, until main arm is vertical.
Extend dipper arm outward.
Flip transport stop over to clear lift frame.
Slew arm forward through 90°.
Position head till horizontal, just above ground.
Engaging Head Drive
Select 540rpm PTO and run with low engine revs.
With flail head in safe position move rotor control lever (5) to ‘ON’.
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, 540rpm.
Never attempt to start rotor while under load.
Disengage Head Drive
Slowly decrease engine revolutions to a fast idle.
Move rotor control lever (5) to ‘OFF’.
Never increase or decrease PTO speed rapidly, this could seriously damage
pumps and motor.
33
Spearhead TWIGA
Manual
Recommended for
confined areas and on steep hills
The Twiga range of reach mowers have 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.
Auto reset
Recommended for
normal use
This is recommended for normal use either verge
mowing or hedge cutting. When auto reset is
selected the flail head rises as the arm slews back
past an obstacle, once past, the weight of the head
causes the arm to automatically slew forward and
down to the original position. Therefore, when verge
mowing, too much weight on rear roller will cause arm
to break back prematurely, as will too high a forward
speed and a dense crop.
Under certain conditions it may be beneficial to turn
off auto reset and operate break back manually,
especially in confined areas and up steep hills.
Warning
Never attempt to operate the machine when travelling backwards, the
break back will not function and any damage caused will not be considered
warranty.
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.
Break Back
Manual - Yellow Switch “Off” 2SV
Auto Reset
Auto Reset - Yellow Switch “On”2SV
34
Spearhead TWIGA
Too high a forward speed will impair the finish,
leaving it looking ragged, and cause over frequent
use of the break back, 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 as the break-back cannot
function.
Tractor Forward Speed
Cutting Sequence
35
Spearhead TWIGA
Warning
Wire is extremely dangerous and must be
avoided at all times. Inspect work area before
commencing, removing all loose wire and clearly
marking fixed wire
Note
Important to connect a separate lead direct
from the battery to the oil cooler control box.
Ensure the radiator is kept clear of debris
And the air flow is free.
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 P.T.O. and stop engine before leaving cab.
Oil Cooler
Prolongs the life of the hydraulic oil and components
in hot and arduous conditions, it is fitted as standard to
all TWIGA PRO machines.
36
Spearhead TWIGA
Warning
Do not fold the machine up for transport before turning off the head float.
Head Float
Options
Head Float
This option allows the flail head to follow contours of the ground without having to
constantly control the angle of the head.
The centre of balance is the best mounting point for the head if head float is to be
used properly.
Operating The Head Float
Place flail head on the ground and switch on head float control, this opens the head
ram to tank, and allows the ram to float in or out, maintaining full contact with the
ground automatically. Note, the rotor must be switched on and running to provide
electric supply to the head float.
To regain manual control switch off by pressing the green rocker switch.
37
Spearhead TWIGA
Warning
Do not fold the machine up for transport before turning off the arm float.
And discharging the pressure from the lift circuit.
Arm Float
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 pre-charged gas accumulator.
Operating The Arm Float
To select arm float, first lower cutting head to the ground, disengage PTO and stop
tractor engine. To the back of the slew frame is situated the float on/off tap. Turn tap
in line for ‘on’ float, remote electric switching is optional. 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 the use of auto reset - break back.
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.
Debris Blower
Hydraulically driven fan from tractor external services, please quote tractor oil flow
when ordering (maximum 40lt per min).
38
Spearhead TWIGA
Debris Blower
The return oil must go to a free flow connection i.e. filler plug. Avoid quick release
couplings.
Operating The Debris Blower
The fan is suitable for clearing cuttings off the highway; we recommend the Blower is
used on final cut only and not continually on.
Excessive use may cause overheating. The unit can be angled for the best effect.
Transport
The Blower housing protrudes and care should be taken not to damage unit.
39
Spearhead TWIGA
Grease daily
Setup for hedge cutting uses large stops in
either position at bottom of adjustment slot
Setup for grass cutting uses small stops in
either position, with the option of an
Additional stop at the top of the adjustment
slot.
Hydraulic rear roller control switch. Positions depend on
machine options specified.
Attention
When hedge cutter is fitted with reverse rotor direction control the
hydraulic rear roller will not function.
To set rear roller when rotor is reversed, bolts supplied must be fitted to
hold roller in position.
Note
To ensure the roller moves freely its important to keep the roller
Side plates and head cowl clean and lubricated
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.
40
Spearhead TWIGA
Autopilot
Introduction To The Autopilot
The Spearhead 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 degrees
to the horizontal, it is best to switch off the Autopilot and
operate the machine manually until the angle becomes
more normal. The middle position 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).
Ensure you fully understand the operation of the Spearhead Autopilot, which will
reduce machine and operator fatigue and improve hourly output, machine life,
standard of work and comfort to the operator.
41
Spearhead TWIGA
Warning
Ensure the engine has stopped and the key is removed, the PTO is disengaged,
handbrake secure, and the head is firmly on the ground before attempting any
servicing, maintenance or adjustment.
Bolt “A”
Screw “B”
Fig 2
Autopilot
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 removed and PTO disengaged.
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. Remove the fuse mounted in the control panel and start the machine, turn on
the rotor switch (the rotor should not spin) 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.
42
Spearhead TWIGA
Auto Pilot
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.
Auto Pilot
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
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 it’s 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
43
Spearhead TWIGA
Bend lever arm of switch to
align with the middle of each
cam, ensure they don’t
overlap onto the adjacent
cam.
Move cams apart to increase amount
of weight carried on the rear roller,
there by reducing the sensitivity of
the auto-pilot
If the cams are to close together the
switches will constantly be altering
the main arm height causing
unnecessary wear and strain on the
hydraulics
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
Auto Pilot Switch Alignment
Alternative Settings
44
Spearhead TWIGA
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. Inspect machine for fault.
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 Auto slew 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 Spearhead 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 hydraulic joystick and the red 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 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
45
Spearhead TWIGA
Warning
Important Safety Considerations
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 correct speed, See LRS Manual.
Maximum oil pressure of 250 bars in the hydraulic hoses.
Never transport without the blade protection guards 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 540 R.P.M.
46
Spearhead TWIGA
Technical Data & Description
Each shaft is driven by vee belts, and the whole unit is powered by a hydraulic motor.
Branch carriers are placed between the blades.
The Quad saw is supplied with a special bracket enabling mounting on various
vehicles and machines.
Belt Diagram - Quad Saw
It is important that the belts are correctly mounted and tightened. When new belts
are mounted they must be tensioned correct. See LRS Manual for further
information.
After 10 to 15 working hours the belts may have slackened and must be checked.
Mounting the Quad Saw
The blades must be mounted in a downward cut rotation (Fig. 1). Always use the
blades vertically positioned in relation to the direction of travel (Fig. 2).
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. This rotation should be maintained to ensure optimum performance.
47
Spearhead TWIGA
Warning
Take care not bend the blades in storage or during work. The blades
must be inspected daily for signs for fatigue and cracking, do not use t
he 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.
P/T
Plug
P/T
Anticav valve
Drain Port fill
with oil here
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.
Do not use horizontally there is a danger the weight of the cut braches will bend the
blades, however 45’ is permitted for trimming material of smaller diameter.
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
Note
To change rotation of motor exchange the position of the pressure/returns hoses and
the anti-cav valve with the plug.
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Spearhead TWIGA
Description
Telescopic extending arm provides
extra reach, particularly useful for
deep ditches, banks and for reaching
high hedges.
Telescopic Arm
Operating the Telescopic Arm
Use the electric switch to adjust the length of the extending telescopic dipper arm to
suit working conditions and use dipper ram to vary reach as required.
Over frequent use of telescopic arm will cause premature wear of adjustable pads.
Transporting the Telescopic Arm
Always fully retract before folding machine arms into transport position.
49
Spearhead TWIGA
Description
This useful feature provides extra
visibility particularly when topping a
hedge, or verge mowing.
Forward Reach (FR) & Variable Forward Reach (VFR)
Operating the (Variable) Forward Reach
Before operating the arm, ensure the head is one metre off the ground and at least
two metres away from the tractor. To operate the arm, press rocker switch. This will
push the head forward. Likewise press the rocker switch opposite, the head will
retract backwards. When operating the cutting head close to the tractor extreme care
must be taken to avoid contact with the cab.
Transporting the (Variable) Forward Reach
Never attempt transport position without first fully retracting the variable forward
reach arm.
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Spearhead TWIGA
TWIGA machine
Optional - Quad saw
Head Rotor & Roller
Grease 1.2m head every 8 hours (5-10 pumps)
Optional - Autopilot
Service & Maintenance
Greasing/Lubrication Points
All the following grease points need to be greased daily
51
Spearhead TWIGA
Lubrication Chart
Greasing/Lubrication
Washing your machine
Grease all your machine and optional parts after each time you wash your machine.
Gearbox
Gearbox oil level / quantity 380cc. Replace after 50hrs then once a year
with EP90 Note: Do not over tighten filler / drain plugs, as this will
damage gearbox casing.
P.T.O.
Dismantle and clean the input drive shaft sliding surfaces and re-grease, failure to do
this will result in serious damage to the gearbox. Grease both 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 10-30 pumps of grease.
Motor Drive - Belt Drive
Motor drive splines are lubricated via the pulley shaft and should be greased every
40 hours with 5 pumps of grease.
Oil requirements
Fill the tank to centre of sight gauge with
approximately 220 litres of HD46 or
equivalent oil. Do not over fill.
52
Spearhead TWIGA
Recommended torque settings for hose unions
in conjunction with bonded seals
BSP
(size)
Tightening
(Nm)
Torque
(lbs/ft)
1/4 “
24
18
3/8”
33
24
1/2”
44
35
3/4”
84
62
1”
115
85
BSP
(size)
Tightening
(Nm)
Torque
(lbs/ft)
1/4”
34
25
3/8”
75
55
1/2”
102
75
3/4”
183
135
1”
203
150
Warning
Hose is weakened when installed in twisted position. Also, pressure pulses in twisted hose tend to fatigue
wire and loosen fitting connections. Design so that machine motion produces bending rather than torsion.
Recommended torque settings for nut
Hydraulic Hoses
Carefully check condition of all hoses during routine service, paying particular attention to
chafed outer casing. Securely wrap with waterproof adhesive tape to stop the metal braid
from rusting.
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 it is your responsibility to
help ensure a long reliable working life. Spearhead provide a tool kit to enable hoses to be
tightened as part of routine maintenance.
Hoses with damaged metal braid should be replaced.
The Spearhead hydraulic system works at very high pressure. Use only genuine hoses, a
burst hose could be very dangerous.
Always replace hoses in exactly the same way they were removed, and to
avoid twisting during fitting use two spanners to slacken and tighten.
Always check the yellow protective sleeving is in good order, replacing sleeving 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 chaffing, abrasion, cuts or pinching
while in work, or to damaged threads due to over tightening.
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Spearhead TWIGA
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
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 which is starved of oil will be damaged beyond repair.
Replace oil if signs of contamination occur (discoloured)
Contamination can be reduced 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. Any damage or leaks must be
rectified immediately, this is part of the daily maintenance and it is your responsibility
to help maintain a long reliable working life.
When tightening fittings always use two spanners when necessary and do not over
tighten. If a fitting persists in leaking it will need to be replaced.
Oil
Recommendations
Filtration Maintenance
The machine is protected by a suction strainer and a low-pressure full flow return line filter.
1. The suction filter is permanently fixed in the reservoir tank. Should symptoms of
pump cavitation or spongy operation occur the tank must be drained, and the tank
and suction filter thoroughly cleaned and dried before refilling with clean oil.
2. The return line filter element should be replaced after the first 50 hours and thereafter
at 300-hour intervals… or yearly. It is most important to replace the filter within these
intervals because once blocked, oil will bypass the filter element infiltrated, causing
pump & motor damage
3. If any failure or replacement of hydraulic parts have occurred then the return line filter
must be replaced immediately
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Spearhead TWIGA
Warning
When end mounted, head may foul on machine.
Do not slide head mounting bracket past centre stops to extreme
end on 1.5metre head.
Flail Head
Grease all bearings daily.
Check there is no wrapping of string, plastic, grass or other debris on rotor
shaft and rear roller bearings.
Check the condition 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 200Nm.
Flail head is supplied centre mounted to get best travel on crowd ram.
Never operate with any flails missing. This will cause severe vibration and
lead to rapid bearing wear and quickly cause the head to crack.
Blunt flails leave an untidy finish and absorb excessive power, when re-
sharpening always wear protective clothing and goggles.
When flails are showing severe wear, damage or cracking, they must be
replaced immediately. Never attempt to weld the flails, as this will make them
very brittle and extremely dangerous. Do not take risks with the cutting flails, if
in doubt replace.
When replacing flails always replace bolts, nuts and bushes with new.
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. (1hr - 4hrs then
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 adjustment.
55
Spearhead TWIGA
Warning
Before you attempt to do any repair, service, maintenance or
adjustment on your machine, ensure the engine has stopped and t
he key is removed. PTO is disengaged, handbrake secure, and t
he head is firmly on the ground.
Warning
Do not use grease containing Molybdenum disulphide on nylon
bushes and wear pads.
Warning
Regularly inspect the slew post and tank areas and remove any hedge
trimmings which may have become lodged there. Failure to do this may
cause damage to the machine’s main lift ram.
Pins & Bushes
All main pivot points are furnished with replaceable pins and bushes. If there are any
signs of wear, these must be replaced. All parts are available from Spearhead Parts
Department.
The pins are secured with a nut and bolt through the head to prevent turning. A
retaining washer and screw are clamped to the base of the pin to prevent spreading
and must be kept tight (use locking compound).
Storage
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. Slacken rotor drive belts (where fitted).
It is important where possible to store undercover to protect against rain and sunlight.
Always ensure a firm level surface.
Smear grease on all areas vulnerable to corrosion, in particular the chrome on the ramrods.
Remember: regular maintenance will greatly increase the life of the machine.
56
Spearhead TWIGA
Size:
Tensile strength:
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
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
300 hrs
Return line filter element
X
Hydraulic oil if any signs of contamination appears
X X
Torque Settings
The Torque figures given below are recommended maximum settings only.
Regular Service Chart
57
Spearhead TWIGA
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 tractor PTO speed matches
implement
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 UJ failure
Working angle to great
Reduce offset of implements
Shaft incorrect length I.e. 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 tank overheating
Oil level incorrect
Fill tank to correct level
Oil grade incorrect
Drain and refill tank with correct grade
oil
PTO speed too fast
Ensure the tractor's PTO speed
matches implement
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
Weight of machine being carried
upon rear roller
Use Autopilot or head float
Machine not set vertical
Shorten top link
Hydraulics not
responding
Oil level low
Fill oil to correct level
Oil pump suction filter blocked
Replace filter element
Oil leak in pressure line
Check machine of leaks
Drive line broken
Check pump is rotating
Joystick control sluggish
Air in pilot lines from joystick
Slacken off each line of pilot circuit
individually at spool valve whilst
operating. When all air is expelled
retighten the line
Trouble Shooting
58
Spearhead TWIGA
Problem
Cause
Solution
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
Trouble Shooting
59
Spearhead TWIGA
Pump & Motor Failure
There are many reasons for pump and motor failure, cavitations (suction of air), peak
pressure, contamination. These can be avoided by the following:
Never run out of oil
Never run a cold machine straight up to speed, ensure the engine idle speed before
engage/disengage the head motor.
Never increase or decrease engine speed quickly
Regularly check that suction hose and pump fittings are tight.
Never stop or start the rotor at 540r.p.m
Never cause sudden movements to the arms via your controls or bumps in the
ground as pressure spikes will by transmitted back to the pump, resulting in failure.
Avoid striking the rotor on obstacles i.e., road gullies as this causes pressure spikes.
Never transport the machine with the PTO in gear.
Never select 1000 speed gear for economy start up, speed is too high.
Never operate above recommended PTO speed 540r.p.m. and risk over heating.
Remember: pump and motor warranty is limited to replacement due to faulty materials or
manufacture. Cavitations, contamination and peak pressures are easily detected on
inspection, warranty will not be considered if failure is due to misuse.
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Spearhead TWIGA
Warranty
Spearhead warrants that the Spearhead 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 Spearhead dealer, or Spearhead’s Service Department. Any part found to be
defective during this period will be replaced or repaired, at Spearhead’s discretion, by the
dealer or a Spearhead Service Engineer.
Warranty Conditions
1. The Warranty Registration Form must be completed and returned to Spearhead
within 30 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
Spearhead’s instructions (oral or written, including all instructions an recommendation
made in the Operator’s Manual) or alteration or repair of the machinery without
Spearhead’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, tyres, 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
Spearhead, for which the Buyer shall only be entitled to the benefit of any such
warranty or guarantee given by the manufacturer to Spearhead. Only genuine
Spearhead replacement parts will be allowable for warranty claims.
7. All parts replaced by Spearhead under warranty become the property of Spearhead
and must be returned to Spearhead if Spearhead so request. Such parts may only
be disposed of after a warranty claim has been accepted and processed by
Spearhead.
8. Spearhead is not liable under this warranty for any repairs carried out without
Spearhead’s written consent or without Spearhead being afforded a reasonable
opportunity to inspect the machinery the subject of the warranty claim. Spearhead’s
written consent must, therefore, be obtained before any repairs are carried out or
parts replaced. Use of non-Spearhead parts automatically invalidates the.
Spearhead Warranty. Failed components must not be dismantled except as
specifically authorised by Spearhead and dismantling of any components without
authorisation from Spearhead will invalidate this warranty.
9. All warranty claims must be submitted to Spearhead on Spearhead 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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Spearhead TWIGA
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