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Spearhead ROLLICUT 500 Operator's Instruction Manual

5.0-6.0m cut width, 540 pto input vegetation control folding rotary amenity mower
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8999170EN: v1.1 28/02/2023
Spearhead Machinery
Operator Instruction Manual For
5.0-6.0m cut width, 540 PTO input
1
Original instructions (ENGLISH)
Website: www.spearheadmachinery.com

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Summary of Contents for Spearhead ROLLICUT 500

  • Page 1 8999170EN: v1.1 28/02/2023 Spearhead Machinery Operator Instruction Manual For 5.0-6.0m cut width, 540 PTO input Original instructions (ENGLISH) Website: www.spearheadmachinery.com...
  • Page 2 Verification Of Warranty Registration Dealer Warranty Information & Registration Verification It is imperative that the selling dealer registers this machine with Spearhead before delivery to the end user. Failure to do so may affect the validity of the machine warranty.
  • Page 3 8999170EN: v1.1 28/02/2023 (This page is left blank intentionally) Original instructions (ENGLISH) Website: www.spearheadmachinery.com...
  • Page 4 Any arbitrary modifications carried out to this machine may relieve the manufacturer of liability for any resulting damage or injury. It is potentially hazardous to fit or use any parts other than genuine Spearhead parts. The company disclaims all liability for the consequences of such use which, in addition, voids the machine warranty.
  • Page 5 8999170EN: v1.1 28/02/2023 (This page is left blank intentionally) Original instructions (ENGLISH) Website: www.spearheadmachinery.com...

  • Page 6: Table Of Contents

    8999170EN: v1.1 28/02/2023 Contents List Machine Description ..........................10 Intended Usage ........................10 1.1.1 Allowed Uses ......................10 1.1.2 Improper Uses ......................10 General Arrangement ......................11 Rollicut – Standard Specification................12 1.2.1 1.2.2 Rollicut Proline - Additional Components ..............13 Machine Identification ......................
  • Page 7 8999170EN: v1.1 28/02/2023 4.5.1 Fitting & Removal Of The Input PTO Driveshaft ............60 4.5.2 PTO Driveshaft Specifications .................. 63 Unfolding & Folding The Machine................... 64 4.6.1 Standard ........................64 4.6.2 Proline ........................66 Setting Cutting Height ......................71 Work Site Assessment ......................74 4.8.1 Foreign Debris Hazards ....................
  • Page 8 8999170EN: v1.1 28/02/2023 5.10 Torque Settings ........................128 5.10.1 Nuts & Bolts ......................128 5.10.2 Hydraulic Fittings ..................... 129 5.11 Machine Inspection Record ....................130 5.12 Machine Storage ........................132 5.12.1 Preparing The Machine For Storage ............... 132 5.12.2 Returning The Machine Back To Work ..............133 Troubleshooting ..........................
  • Page 9 8999170EN: v1.1 28/02/2023 (This page is left blank intentionally) Original instructions (ENGLISH) Website: www.spearheadmachinery.com...

  • Page 10: Machine Description

    They are designed for use on level, undulating or inclined ground and for a duty cycle of 1000 hours per annum. They will cut vegetation up to 20mm thickness. Rollicut machines require a tractor with a minimum of 60hp (Rollicut 500) and 70hp (Rollicut 600). 1.1.2...

  • Page 11: General Arrangement

    8999170EN: v1.1 28/02/2023 General Arrangement The layout and naming convention used throughout this manual for each of the machines are shown in the tables below. The numbering and positioning of the Standard specification relevant item can be found in Section 1.2.1 for Standard Rollicut machines.

  • Page 12: Rollicut - Standard Specification

    8999170EN: v1.1 28/02/2023 Rollicut – Standard Specification 1.2.1 Figure 1.2 – Rollicut Standard Specification General Arrangement (600 model illustrated) Original instructions (ENGLISH) Website: www.spearheadmachinery.com...

  • Page 13: Rollicut Proline - Additional Components

    8999170EN: v1.1 28/02/2023 1.2.2 Rollicut Proline - Additional Components Figure 1.3 – Rollicut Proline Specification Additional Features General Arrangement (600 Proline model illustrated) Item No. Description Valve Block Beacon Wing Clutches Wing Sensors Scraper Wire Hydraulic Wing Transport Locks Hydraulic Rear Body Transport Lock Table 1.2 –...

  • Page 14: Machine Identification

    By utilising a smart phone and scanning the Authorised Representative QR scan code found on the right-hand side of the serial plate (ref 8, Figure 1.4) using a suitable QR scanning App, you can find details for Spearhead Machinery authorised representatives for its various territories.

  • Page 15: Rotation Definitions & Conventions

    In order to create a consistent and quality cut and through-flow of material through and out of the machine, Rollicut machines have anti-clockwise rotating rotors which are in turn fitted with right-hand (RH) blades. The rotation direction of each of the rotors is stated in Figure 1.6 for the Rollicut 500 and Figure 1.7 for the Rollicut 600.

  • Page 16: Machine Specification

    Table 1.3 – Rollicut 500/600 Specification – Standard & Proline Notes: (1) Spearhead constantly reviews and improves product designs and reserve the right to change this information. Actual machines may vary from the above specification. Contact your Spearhead Sales representative if you have any queries.
  • Page 17 8999170EN: v1.1 28/02/2023 Figure 1.9 Working Dimensions (600 Proline model illustrated) Figure 1.10 Transport Dimensions (600 Proline model illustrated) Original instructions (ENGLISH) Website: www.spearheadmachinery.com...

  • Page 18: Machine Options

    8999170EN: v1.1 28/02/2023 1.5.2 Machine Options Rollicut machines can be ordered in a variety of different specifications to fit the user’s requirements. Option Picture Tyres Road Turf Option Picture Wing Driveline Standard Proline Automatic Disengage Option Picture Towing Eye Standard Swivel Option Picture...
  • Page 19 8999170EN: v1.1 28/02/2023 Option Picture Body Locking Standard Proline Option Picture Beacon Standard on Rollicut Proline Option Picture Mudguard Kit Original instructions (ENGLISH) Website: www.spearheadmachinery.com...

  • Page 20: Safety

    - even severe - to people or animals. Spearhead declines all responsibility for damage caused by not complying with the safety and injury prevention regulations described below. Spearhead also declines any responsibility for damage caused by improper use of the machine and/or as a result of modifications made without prior authorisation by the manufacturer.

  • Page 21: Safe Use

    Health and Safety Executive (HSE) Safe Stop Campaign In Great Britain, Spearhead Machinery endorses the “Safe Stop” campaign promoted by the Health and Safety Executive (HSE) to give guidance on how to safely prepare the machine and personnel and operate the machine and what to do in emergency cases.

  • Page 22: Operators Manual

    IMPORTANT: Ensure the operator’s manual is complete, readable, and easily accessed by the operator and accompanying personnel. If in doubt replace, by contacting your local Spearhead dealer or Spearhead Machinery directly. DANGER! It is prohibited to use the machine in ways that are different from the indications contained in this operators manual.
  • Page 23 8999170EN: v1.1 28/02/2023 CAUTION! On Proline specification machines, ensure that the Minipilot joystick and control box cables are routed correctly between tractor and machine. Ensure that the cables are placed through the hose guide bracket found on the front of the machine chassis between the tractor and the machine and are distanced from the input PTO driveshaft and anywhere where the operator could potentially trip or entangle themselves potentially causing them to fall or cause injury.

  • Page 24: Tractor And Machine Preparation For Work

    8999170EN: v1.1 28/02/2023 2.3.5 Tractor And Machine Preparation For Work Tractor Preparation IMPORTANT: Before starting, safety checks on tractor and machine must be carried out with regard to functionality, road safety and accident prevention rules. CAUTION! Check that the agricultural tractor on which the machine is installed is of adequate power, weight and configuration, compatible with the model fitted and fitted with a seat belt.
  • Page 25 (PDI) sheet before first use. WARNING! Check all key components. Inspect and replace all damaged components with genuine Spearhead parts and ensure the machine is running correctly again before resuming cutting operations. IMPORTANT: The condition of the blades must be checked before beginning daily work and they must all be replaced if damaged or missing before proceeding to use the machine.
  • Page 26 Ensure that when the machine inspection is carried out that the machine is stationary and not running. Where parts are broken, damaged and deemed not fit for use; replace with genuine Spearhead parts using the online Interactive Parts facility at: https://my.spearheadmachinery.com/parts/public-interactive-parts-database/...
  • Page 27 Driveline IMPORTANT: It is mandatory to use the type of input PTO driveshaft supplied with the machine by Spearhead and for the same type to be sourced again when a replacement is required. IMPORTANT: Ensure that before first use the input PTO driveshaft is the correct item for the...
  • Page 28 Gearbox Oil And Lubrication IMPORTANT: Using the types of lubricating oils indicated by Spearhead and follow the recommended guidelines of the lubricant manufacturer. Check oil levels and grease points daily to ensure the longevity of your components on your machine following the maintenance section of this operators manual.

  • Page 29: Work Site Preparation

    DANGER! It is forbidden to alter, tamper with or bypass any of the components on the machine including the safety devices provided by the manufacturer. e.g. guarding. Spearhead claims no responsibility to damages to operators, personnel or property by the factory fitted guards being not fitted or in poor repair.

  • Page 30: Machine At Work & Observation

    8999170EN: v1.1 28/02/2023 Hazards WARNING! Extreme care should be taken when operating near loose objects such as gravel, rocks, wire, and other debris. Inspect the area before mowing. Foreign objects should be removed from the site prior to beginning work to prevent machine damage to the operator, bystanders or the environment.
  • Page 31 WARNING! Check all key components including blades and blade carriers. Blades can fail from impact and objects can be thrown at great velocity. Inspect and replace all damaged components with genuine Spearhead parts and ensure the machine is running correctly again before resuming cutting operations.

  • Page 32: Transporting The Machine

    IMPORTANT: Stop and do not use the machine when there is vibration in the machine, as this may cause breakage and extended serious damage. Find the cause of the vibration or have it inspected by your local Spearhead dealer and do not use the machine until the cause is identified and eliminated.
  • Page 33 8999170EN: v1.1 28/02/2023 CAUTION! Personnel should take regular breaks during work to minimise fatigue and ensure alertness in work. WARNING! Never carry passengers in the tractor unless it is fitted with an approved seat and seat belt. WARNING! Never carry passengers on the machine. IMPORTANT: When driving on public roads respect other road users and obey the highway laws of the local jurisdiction.

  • Page 34: Machine Storage

    8999170EN: v1.1 28/02/2023 IMPORTANT: Before proceeding to take the machine onto the public highway ensure that the machine bodies are clear of any cut material collected. IMPORTANT: Before proceeding to take the machine onto the public highway ensure that the tractor and machine tyres are clear of mud and dirt build up.

  • Page 35: Safe Maintenance

    Section 3.1 and according to the regulations in force in the country where these operations take place along with the recommendations of Spearhead. DANGER! When raising the machine make sure that personnel are distanced from the machine to ensure they are not hit by falling components;...
  • Page 36 8999170EN: v1.1 28/02/2023 Parts & Components IMPORTANT: Always use genuine Spearhead parts when carrying out repairs and maintenance with thoughts to longevity and reliability of the machine and personnel safety. IMPORTANT: Do not modify or alter implement functions or components.
  • Page 37 Ensure that when the machine inspection is carried out that the machine is stationary and not running. Where parts are broken, damaged and deemed not fit for use; replace with genuine Spearhead parts using the online Interactive Parts facility at: https://my.spearheadmachinery.com/parts/public-interactive-parts-database/...

  • Page 38: Safety & Operational Decals

    Section 2.5.2. The operator must memorise the meaning of these decals. All decals should be kept clean and replaced immediately if they are fully/partially detached or damaged by purchasing them through a local Spearhead dealer. 2.5.1 Definitions Figure 2.2 –...
  • Page 39 8999170EN: v1.1 28/02/2023 Figure 2.3 – Other Safety & Instruction Decals Instruction: - Grease every 8 Placed and pointed towards components of the machine which should be hours greased at least once every 8 hours Instruction: - Designated lifting Placed at positions on machine where safe lifting should be carried out point Instruction: - P65 cancer and Operating, servicing and maintaining this equipment can expose you to...

  • Page 40: Placement

    Safety decals can be purchased readily from a local Spearhead dealer. Spearhead safety decals have the replacement part number found in the bottom right of the decals. For more extensive guidance on ordering spare parts and how to go about finding the correct part number; see Section 7.

  • Page 41: Guards

    DANGER! For safe operation it is essential that that all guards, protection flaps and rollers must be kept in position on the machine whenever the machine is running. Spearhead disclaim all responsibility for any damage or injury arising as a result of guards, protection flaps or rollers being removed, or other than in accordance with these instructions.

  • Page 42: Personal Protective Equipment

    In most instances Spearhead machines can be broken into its constituent parts with the use of basic workshop equipment. Table 2.5 contains a typical list of constituent materials, together with disposal guidelines.

  • Page 43: Proposition 65

    8999170EN: v1.1 28/02/2023 Material Typically found in; Disposal guideline Steel Structural components, fixed guards, Can be dismantled and recycled. Take care fasteners and driveline when handling heavy and/or sharp objects Aluminium Pump and gearbox housings, serial Can be dismantled and recycled. Take care number plates when handling heavy and/or sharp objects.

  • Page 44: Machine Preparation

    8999170EN: v1.1 28/02/2023 Machine Preparation Lifting The Machine WARNING! Do not lift by drawbar or axle alone. Damage may occur which will invalidate warranty. Use recommended lifting point locations. Rollicut machines should be lifted using the four designated lifting loops in each of the four corners of the centre chassis;...
  • Page 45 8999170EN: v1.1 28/02/2023 When transporting the machine with the wings and rear body raised, ensure that the body locks are fully engaged and working correctly to ensure that the wings or rear body don’t suddenly drop and potentially crush personnel, bystanders and cause an accident with other road users in the event of a mechanical or hydraulic failure or inadvertent tractor operator input.

  • Page 46: Post-Delivery/First Use Inspection

    Spearhead machines are tested after manufacture. It is important to assess the machine to ensure that it is of the correct specification ordered from Spearhead or local Spearhead dealer. Information with regards to the specification of the machine can be found on the machines serial plate.

  • Page 47: Bottoming Out Test

    If an input PTO driveshaft is too short then a new longer driveshaft should be fitted. Please contact your local Spearhead dealer for guidance on purchasing a new/replacement input PTO driveshaft.

  • Page 48: Modifying & Shortening The Input Pto Driveshaft

    This is further supported by Spearhead. NOTE: Bondioli & Pavesi and Spearhead declines all responsibility for damage and/or injury caused by modifying ANY of the power take-off driveshafts on Rollicut machines in any other way than described in this manual.

  • Page 49: Fitting The Pto Driveshaft

    8999170EN: v1.1 28/02/2023 Carefully deburr the ends of the tubes with a file and remove any chippings from the tubes. Figure 3.7 Shorten shield tubes one at a time by cutting the same length that was cut from the drive tubes. If the driveshaft is equipped with Single Chain Restraint System, shortening the driveshaft will involve removal of the plastic ring which connects the shield tubes.

  • Page 50: Wheels & Tyre Installation

    8999170EN: v1.1 28/02/2023 Wheels & Tyre Installation There may be on some occasions, dependent on the type of delivery chosen for the machine to be delivered to the dealer/customer where wheels and tyres could be removed from the machine and will be required to be refitted to the machine when it arrives and before its first use.
  • Page 51 8999170EN: v1.1 28/02/2023 (This page is left blank intentionally) Original instructions (ENGLISH) Website: www.spearheadmachinery.com...

  • Page 52: Usage Instruction

    2.5.2. The connecting tractor will also have them as well with information given in the tractor operator’s manual. If any part of the operation safe use of the machine is not completely understood, consult a local Spearhead dealer or Spearhead for complete explanation.

  • Page 53: Tractor Requirements

    (PTO) at the machines rated speed (540 rpm) while travelling at a working ground speed for the conditions and quantity of material of the work site. Operating the machine with a tractor which does not meet the requirements set by Spearhead may cause the tractor and/or machine damage, potentially risking danger to the operator and bystanders.

  • Page 54: Connecting & Disconnecting Hydraulic Hoses & Electric Cables

    This is achieved on Standard machines using the tractors hydraulic control levers/buttons in a back/forth in/out motion. On Proline machines fitted with Spearhead’s Minipilot control system, place each of the cutting bodies into float utilising the Minipilot control box and then switching off the control box; see Section 4.10.5.

  • Page 55: Disconnecting

    8999170EN: v1.1 28/02/2023 Ensuring that the quick couplers are clean; proceed to fit the hydraulic hoses. Rollicut machines can be specified with either standard 3-spool double acting or single spool Minipilot control hydraulic set-ups on the higher specification Rollicut Proline; see Figure 4.3. Under the preference of the operator and which service they wish to use on the tractor, fit the hoses into separate banks of service on the tractor for each of the hoses;...

  • Page 56: Hitching & Unhitching The Machine

    8999170EN: v1.1 28/02/2023 in/out motion. On Proline machines fitted with Spearhead’s Minipilot control system, place each of the cutting bodies into float utilising the Minipilot control box and then switching off the control box; see Section 4.10.5. Rollicut machines feature quick release hydraulic couplers so they can be removed by first pushing in and then pulling out the connections.
  • Page 57 Standard machines using the tractors hydraulic control levers/buttons in a back/forth in/out motion. On Proline machines fitted with Spearhead’s Minipilot control system, place each of the cutting bodies into float utilising the Minipilot control box and then switching off the...
  • Page 58 Check that all lights work correctly before taking the machine onto the public highway. Spearhead offers three different towing hitch options for Rollicut machines; standard, swivel and K80. Standard Swivel Figure 4.10 – Rollicut Towing Eye Options Original instructions (ENGLISH)

  • Page 59: Unhitching

    This is achieved on Standard machines using the tractors hydraulic control levers/buttons in a back/forth in/out motion. On Proline machines fitted with Spearhead’s Minipilot control system, place each of the cutting bodies into float utilising the Minipilot control box.

  • Page 60: Pto Driveshaft

    PTO adaptors also increase the exposed working length increasing the probability of entanglement with external objects. If the driveshaft is incorrect for the tractor; contact your local Spearhead dealer for assistance.
  • Page 61 8999170EN: v1.1 28/02/2023 Figure 4.12 – Rollicut Input Driveshaft Fitting & Removal Fitting - Machine End Equipment Required • Torque wrench (see required settings in Torque Settings section) • 22mm hex socket • NLGI #2 Molybdenum Disulphide grease with paint brush/distributor Proceed as follows: Proceed to remove the taper pin, flat washer and nut from the machine end of the input PTO driveshaft.
  • Page 62 8999170EN: v1.1 28/02/2023 Fitting - Tractor End Figure 4.14 – Fit Input Driveshaft To Tractor Proceed as follows: Pull the input PTO driveshaft yoke collar back and align the grooves and splines with those of the PTO output driveshaft of the tractor; see Figure 4.12 (B). Push the driveshaft yoke onto the tractor output PTO driveshaft, release the locking collar and position the yoke of the input PTO driveshaft until the locking collar balls are seated onto the tractors output PTO driveshaft;...

  • Page 63: Pto Driveshaft Specifications

    PTO adaptors also increase the exposed working length increasing the probability of entanglement with external objects. If the driveshaft is incorrect for the tractor; contact your local Spearhead dealer for assistance.

  • Page 64: Unfolding & Folding The Machine

    8999170EN: v1.1 28/02/2023 Unfolding & Folding The Machine The machine when received from Spearhead is virtually complete and components are set correctly, requiring minimum time to ready the machine for use. WARNING! When operating a fully assembled machine, do not release the body locking mechanism until the hoses are attached to the tractor and each of the wing lift ram cylinders are filled with oil.
  • Page 65 8999170EN: v1.1 28/02/2023 To lower the rear body: Pull and continue to hold the body lock release rope to allow the lock to release from holding the rear body. Use the tractor spool control lever/button controls to place the hydraulics into float to lower the rear body to the ground.

  • Page 66: Proline

    8999170EN: v1.1 28/02/2023 4.6.2 Proline Figure 4.19 Unfolding To lower the wings of the machine, connect the hydraulic hoses and electrical connections of the machine to the tractor; see Section 4.3. Ensure all hoses have been connected and seated properly. If the machine is being fitted to the tractor for the first time, follow the guidance in Section 4.4 to safely hitch the machine to the tractor.
  • Page 67 8999170EN: v1.1 28/02/2023 Fill Hydraulic Ram Cylinders Centre Body Left-hand Wing Body Right-hand Wing Body Figure 4.21 Use the joystick and go through all functions to fill hydraulic ram cylinders of the machines in a manner of if you wanted to raise the machine; see Figure 4.21. •...
  • Page 68 8999170EN: v1.1 28/02/2023 Once all hydraulic rams are filled with oil: Press and hold the body lock button on the control box; see Figure 4.22 (1) to pull the body lock latches open. Press and hold the left-hand button on the joystick and push the joystick to the right at the same time to raise the left-hand wing to its fullest extent;...
  • Page 69 8999170EN: v1.1 28/02/2023 Lowering The Centre Body Figure 4.24 Press and hold the body lock button on the control box; see Figure 4.24 (1) to pull the body lock latches open. Push the joystick forward to raise the centre body to its fullest extent; see Figure 4.24 (2). Pull the joystick back to lower the centre body to its fullest extent;...
  • Page 70 8999170EN: v1.1 28/02/2023 To raise the right-hand wing, press and hold the right-hand button on the joystick and push the joystick to the left at the same time to raise the right-hand wing. The body lock should automatically engage and lock that wing ready for transport. Figure 4.26 Finally raise the centre body by pushing the joystick forward.

  • Page 71: Setting Cutting Height

    8999170EN: v1.1 28/02/2023 Setting Cutting Height Equipment Required • 24mm hex spanner IMPORTANT: Ensure that the PTO is disengaged, tractor engine is stopped and the handbrake is applied before proceeding to adjust the rear rollers of the machine. Figure 4.28 – Rollicut Roller Adjustment (Rollicut 600 Proline Model Illustrated) With reference to Figure 4.28, to alter the minimum height of cut: Unfold all body’s of the machine using the guidance given in Section 4.6.
  • Page 72 8999170EN: v1.1 28/02/2023 Lowest Setting Highest Setting 0mm (0”) cutting height 110mm (4.3”) cutting height Figure 4.29 – Rollicut Roller Cutting Height Adjustment Mark “B” – see Figure 4.28 Cutting Height “D” – see Figure 4.29 0mm (0”) 1 (lowest setting) 10mm (0.3”) 20mm (0.8”) 30mm (1.2”)
  • Page 73 The machine is perfectly manufactured and there is no tolerance variation in components Due to this Spearhead shows the data below as a reference holding no responsibility for the machine not achieving the exact quantities given in the table below. It is important for the operator to try out the machine at the work site with the expectation that they will need to adjust the machine after to get exactly what they require to fit the working conditions.

  • Page 74: Work Site Assessment

    8999170EN: v1.1 28/02/2023 Work Site Assessment 4.8.1 Foreign Debris Hazards The destined work site to use the machine should be thoroughly checked and familiarised following the guidance given in Section 2.3.5 to assess the working area for hazards; removable and fixed. Items should be assessed, removed or clearly marked (e.g.

  • Page 75: Stopping The Machine In An Emergency

    Wait for all machine rotating parts to stop, then raise the mower and move the tractor and machine off the object. Once manoeuvred off the object, on Rollicut Proline machines specified with Spearhead’s Minipilot control system, switch off the power to the control box by pressing the main red centre button to ensure the machine does not unintentionally move;...

  • Page 76: Bystanders

    8999170EN: v1.1 28/02/2023 4.8.3 Bystanders DANGER! Machines are capable under adverse conditions of throwing objects for great distances 90m (300 ft) or more and causing serious injury or death. Follow safety messages carefully. It is of upmost importance that the tractor and machine is stopped immediately if a bystander comes within 90m (300 ft) while operating.

  • Page 77: Safe Driving Practices

    On Rollicut Proline machines specified with Spearhead’s Minipilot control system, when the machine is out of use ensure to switch off the power to the control box by pressing the main red centre button to ensure the machine does not unintentionally move.

  • Page 78: Using The Machine

    It is of upmost importance that safety decals are kept clean and replaced if they are no longer legible, damaged or lost completely. Safety decals can be purchased readily from a local Spearhead dealer. 4.10 Using The Machine 4.10.1 Engaging The Power Take-off (PTO)

  • Page 79: Disengaging The Power Take-Off (Pto)

    8999170EN: v1.1 28/02/2023 Folded (light illuminated) Unfolded (light not illuminated) Rotor Stationary Rotor In Motion Figure 4.36 Slowly increase the engine speed until the PTO is operating at the rated speed. IMPORTANT: If you hear unusual noises or see or feel abnormal vibrations, disengage the PTO immediately. Inspect the implement to determine the cause of the noise or vibration and repair the abnormality before proceeding to use the machine.

  • Page 80: 4.10.3 Minipilot Controls - Rollicut Proline

    8999170EN: v1.1 28/02/2023 4.10.3 Minipilot Controls – Rollicut Proline Rollicut Proline machines come equipped with a higher specification which includes the Spearhead Minipilot control system which gives increased user comfort through the ability to control all the various features of the machine through one control unit called the “control box”.

  • Page 81: 4.10.4 Forward & Power Take-Off Speed

    Spearhead Rollicut machines are designed to cut vegetation up to 20mm (13/16”) diameter. Sharp blades will produce a cleaner cut and require less power. Travel at a speed that allows the mower sufficient time to cut through the vegetation and maintain the PTO operating speed to prevent overloading the mower and tractor.

  • Page 82: 4.10.5 Float

    On Proline machines fitted with Spearhead’s Minipilot control system, with the system already switched on and working, with reference to Figure 4.39 press the left-hand body float button (A), centre body float button (B) and right-hand body float button (C) found on the control box to allow each of the respective hydraulic rams to float in order for the machine bodies to rise and fall with ground contours automatically.

  • Page 83: 4.10.6 Proline Automatic Wing Disengage

    8999170EN: v1.1 28/02/2023 4.10.6 Proline Automatic Wing Disengage Rollicut Proline machines feature automatic wing rotor disengage control via the Proline Minipilot control system. The system works via an electric clutch found on the wings which automatically engages and disengages the rotor without an input from the operator when the wing reaches a specific angle when its raised.

  • Page 84: 4.10.8 Crossing Ditches & Steep Inclines

    8999170EN: v1.1 28/02/2023 4.10.8 Crossing Ditches & Steep Inclines WARNING! Damage resulting from bottoming out the input PTO driveshaft inner profile and its outer housing may allow the input PTO driveshaft to come loose from the tractor which could cause bodily injury to the operator or bystanders and/or extensive damage to the tractor or machine.

  • Page 85: Road Transporting The Machine

    Make sure that the safety tow chain is secured between the tractor and the machine before entering a public road; see Figure 4.45. On Proline machines fitted with Spearhead’s Minipilot control system, switch off the power to the control box by pressing the main red centre button to ensure the machine does not unintentionally move through accidental movement of the joystick and buttons;...

  • Page 86: Transporting The Machine On A Trailer

    8999170EN: v1.1 28/02/2023 4.12 Transporting The Machine On A Trailer Figure 4.47 – Transporting Machine On A Trailer Before transporting a machine (potentially plus tractor), measure the height and width dimensions and gross weight of the complete loaded unit. Ensure that the load will be in compliance with the legal limits set for the areas that will be travelled through during transit.
  • Page 87 8999170EN: v1.1 28/02/2023 (This page is left blank intentionally) Original instructions (ENGLISH) Website: www.spearheadmachinery.com...

  • Page 88: Maintenance

    Inspect for loose or missing fasteners, worn or broken parts, leaky or loose fittings, worn bushes and any other moving parts which are worn or missing. Replace any worn or broken parts with genuine Spearhead parts under the guidance of the specific section stated in Section 5.
  • Page 89 8999170EN: v1.1 28/02/2023 Rollicut 500/600 Centre Splitter Gearbox (A) Rotor Gearbox (B) 1.3 litres (2.28 pints) Table 5.1 – Rollicut Gearbox Oil Capacities Figure 5.1 - Rollicut Gearbox Oil Capacity Locations Changing the oil regularly prevents problems associated with deterioration, moisture build up in the oil and the potential presence of metallic particles which form early in the rotary mowers life.

  • Page 90: Pto Driveshafts

    8999170EN: v1.1 28/02/2023 5.2.2 PTO Driveshafts Equipment Required • Manually operated grease gun supplying NLGI #2 Molybdenum Disulphide Grease to M6/M8 grease nipples IMPORTANT: Proper and correct frequency of lubrication of all the rotating and sliding parts of the various PTO driveshafts fitted to the machine is essential for the correct function, longevity and reliability of the driveshaft.

  • Page 91: Transfer Driveshaft

    8999170EN: v1.1 28/02/2023 WARNING! It is mandatory to switch the combustion engine off and disengage PTO and ensure that the tractor and machine is stopped, the ignition key is removed from the dashboard and the parking brake is engaged before leaving the driver’s seat and proceeding to carry out maintenance on any of the PTO driveshafts.

  • Page 92: General Machine Greasing Point Locations

    8999170EN: v1.1 28/02/2023 Wing/Rear Driveshaft (3) Figure 5.7 – Rollicut Wing Driveshaft Grease Locations Quantity of Pumps (S) – Shield (T) – Telescopic Model PTO Input (C) - Cross Frequency Speed Bearings Members (Driveshaft Size) Rollicut 540 (G4) Every 8 hours Table 5.5 –...

  • Page 93: Greasing Schedule

    8999170EN: v1.1 28/02/2023 5.2.4 Greasing Schedule Equipment Required • Manually operated grease gun supplying NLGI #2 Molybdenum Disulphide Grease to M6/M8 grease nipples With reference to the position of grease points in Figure 5.5, Figure 5.6, Figure 5.7 and Figure 5.8, the following greasing schedule should be adhered to, to ensure reliability and longevity in components.

  • Page 94: Pto Driveshafts

    8999170EN: v1.1 28/02/2023 PTO Driveshafts Spearhead Rollicut machines feature Bondioli & Pavesi gearboxes and PTO driveshafts. PTO driveshafts require routine maintenance and sometimes more demanding maintenance requirements to ensure their longevity and reliability of service. 5.3.1 Size Adjustment & Fitting To The Tractor The input PTO driveshaft supplied with the Rollicut machine will be of standard supply as it came from the original manufacturer.
  • Page 95 8999170EN: v1.1 28/02/2023 Disassembly Equipment Required • Phillips head screwdriver • Flat head screwdriver Remove the screws arranged radially around the circumference of the CV cone Figure 5.10 Remove the screws from the base of the cone Figure 5.11 Remove the base cone and the shield tube Figure 5.12 Remove the CV cone Figure 5.13...
  • Page 96 8999170EN: v1.1 28/02/2023 Spread the bearing rings and remove from their groove Figure 5.15 Reassembly Equipment Required • Phillips head screwdriver • Flat head screwdriver • NLGI #2 Molybdenum Disulphide grease with paint brush/distributor Grease the bearing grooves. Fit the bearing ring into the yoke groove with the grease fitting facing the drive tube Figure 5.16...
  • Page 97 8999170EN: v1.1 28/02/2023 In the case of 50° CV joints only: insert the shield strip, aligning the reference pins and also the additional hole of the shield strip with the grease fitting of the large ring Figure 5.20 Ensure that the radial holes of the CV cone are aligned with the holes on the reference pins of the bearing ring Figure 5.21...

  • Page 98: Wing & Rear Body Pto Driveshaft - Bearing Ring Replacement

    8999170EN: v1.1 28/02/2023 Tighten the 3 screws. The use of an electric screwdriver is not recommended Figure 5.25 5.3.4 Wing & Rear Body PTO Driveshaft - Bearing Ring Replacement Plastic wear bearing rings are found inside the PTO assembly to give a replaceable wearing surface between the metal PTO driveshaft and the outer plastic safety shield/cone.
  • Page 99 8999170EN: v1.1 28/02/2023 Remove the outer cone and the bearing ring Figure 5.29 Reassembly Equipment Required • Phillips head screwdriver • Flat head screwdriver • NLGI #2 Molybdenum Disulphide grease with paint brush/distributor Grease the bearing groove on inner yokes Figure 5.30 Fit the bearing ring into the yoke groove with the grease fitting facing the drive tube...

  • Page 100: Belts

    Each of these circuits should be treated individually and tensioned separately. However, whether the machine has three or four rotors they can be tensioned using an exactly the same technique. Rollicut 500 Rollicut 600 Three rotor wing bodies...

  • Page 101: Belt Replacement

    8999170EN: v1.1 28/02/2023 5.4.1 Belt Replacement Equipment Required • 8mm allen key • 13mm hex spanner/socket Two cogged belts are found on each of the machine bodies which need to be tensioned correctly at first fitment to transfer drive between the body gearbox and each of the rotors. The tensioner device requires adjusting to an angle of 15 degrees in order to set the belts to the correct tension.

  • Page 102: Belt Tensioning

    8999170EN: v1.1 28/02/2023 There is no requirement to replace both belts if the upper belt pulley is the one defective and the lower belt is serviceable. If the belt requiring to be replaced is the lower belt on the pulley, see Figure 5.39, then the other belt tension will be required to be released and the belt removed also.
  • Page 103 8999170EN: v1.1 28/02/2023 Using a 36mm spanner against the flat square sides of the belt tensioner, rotate the belt tensioner against the belt to deflect and add tension to the belt. Figure 5.43 Inspect the marks on the side of the belt tensioner.

  • Page 104: Blades & Rotor

    8999170EN: v1.1 28/02/2023 Blades & Rotor Rollicut machines features three or four high lift free swinging cutting blade rotors per machine body, with a smooth intake and contained cutting area to allow for a smooth input of material into the machine and a strong mulched finish of the ejected material.

  • Page 105: Blade Sharpening & Straightening

    IMPORTANT: Always use genuine Spearhead parts when carrying out repairs and maintenance with thoughts to longevity and reliability of the machine and personnel safety. Spearhead blades are made of special heat- treated alloy steel. Substitute blades may not meet specifications and may fail in a hazardous manner that could cause injury.

  • Page 106: Blade Removal & Replacement

    8999170EN: v1.1 28/02/2023 Spearhead does not recommend sharpening worn blades. It is important that all the blades on a rotor, are of the same weight and length and are all present to ensure the rotor remains balanced. By sharpening blades there is a chance of them overheating, which will affect the hardness of the blades; compromising safety to the operator, machine and bystanders.

  • Page 107: Hydraulic Components

    8999170EN: v1.1 28/02/2023 Blade bolts are prone to getting damaged when coming in contact with foreign or solid objects which can seriously compromise the wellbeing of machine, the operator and bystanders. Neglecting damaged blade bolts can cause serious injury or death. Inspect the heads of blade bolts daily for: •...

  • Page 108: Ram Inspection

    Replace the component at fault if in any doubt before proceeding to use the machine. Hydraulic ram seal spares kits are available. Where parts are broken, damaged and deemed not fit for use; replace with genuine Spearhead parts using the online Interactive Parts facility at: https://my.spearheadmachinery.com/parts/public-interactive-parts-database/...

  • Page 109: Wing Ram Replacement

    On Standard machines using the tractors hydraulic control levers/buttons in a back/forth in/out motion. On Proline machines fitted with Spearhead’s Minipilot control system, place each of the cutting bodies into float utilising the Minipilot control box and then switching off the control box;...
  • Page 110 8999170EN: v1.1 28/02/2023 Proceed to open the front and rear covers on the machine by releasing the spring latches found on both sides of the front and rear covers, see Figure 5.54. Figure 5.54 Check to see that the hydraulic cylinder destined to be removed is not under pressure.
  • Page 111 8999170EN: v1.1 28/02/2023 Ensuring pressure in the ram is gone, slowly loosen the hose connections to the ram. CAUTION! Do not loosen the hydraulic connections to the cylinder until all pressure has been relieved from the system. Ensuring that the hydraulic ram is movable and that the machine wing is supported substantially so it will not in reaction move, remove the cylinder pear pins from each of...

  • Page 112: Rear Body Lift Ram Replacement

    8999170EN: v1.1 28/02/2023 Reconnect the implement hoses to the tractor. Get into the tractor seat and fasten your seat belt. Clear the area of all persons before attempting to raise the wing. From the tractor seat, start the tractor and using the tractor controls or the Minipilot control system operate the control valve for the hydraulic ram and go through all functions to fill the hydraulic ram cylinder with oil.
  • Page 113 On Standard machines using the tractors hydraulic control levers/buttons in a back/forth in/out motion. On Proline machines fitted with Spearhead’s Minipilot control system, place each of the cutting bodies into float utilising the Minipilot control box and then switching off the control box;...
  • Page 114 8999170EN: v1.1 28/02/2023 heavy, use proper lifting techniques to lift and handle the cylinder and if needed get assistance from another person. Figure 5.64 (Double-acting Rollicut Proline model illustrated) Inspect the hydraulic rams condition; see Section 5.6.1. Inspect the hydraulic ram port adaptors and seals to see they are serviceable and able to be used on the replacement ram.

  • Page 115: Hydraulic Wing Body Lock Ram Replacement - Proline Specification

    8999170EN: v1.1 28/02/2023 Hydraulic Wing Body Lock Ram Replacement – Proline Specification 5.6.4 Rollicut Proline specification machines come fitted with hydraulic wing body locks which allow for each of the wing bodies to be secured and released hydraulically using the Minipilot control system. Equipment Required •...
  • Page 116 8999170EN: v1.1 28/02/2023 Proceed to open the front and rear covers on the machine by releasing the spring latches found on both sides of the front and rear covers, see Figure 5.70. Figure 5.70 Check to see that the hydraulic cylinder destined to be removed is not under pressure.
  • Page 117 8999170EN: v1.1 28/02/2023 Inspect the hydraulic rams condition; see Section 5.6.1. Inspect the hydraulic ram port adaptor and seal to see they are serviceable and able to be used on the replacement ram. Measure the distance between the cylinder pin holes on the old ram and extend the new cylinder to that length before installing.

  • Page 118: Hydraulic Rear Body Lock Ram Replacement - Proline Specification

    8999170EN: v1.1 28/02/2023 Hydraulic Rear Body Lock Ram Replacement – Proline Specification 5.6.5 Rollicut Proline specification machines come fitted with a hydraulic rear body lock which allows for the rear body to be secured and released hydraulically using the Minipilot control system. Equipment Required •...
  • Page 119 8999170EN: v1.1 28/02/2023 Proceed to open the front and rear covers on the machine by releasing the spring latches found on both sides of the front and rear covers, see Figure 5.79. Figure 5.79 Check to see that the hydraulic cylinder is not under pressure.
  • Page 120 8999170EN: v1.1 28/02/2023 Refit the hydraulic hoses to the rear spools of the tractor following the guidance given in Section 4.3. Return to the tractor and start the engine. Switch on the Minipilot control box. Press and hold the body lock button on the Minipilot control box to fill the hydraulic ram cylinder until the ram actuates to ready it for work again;...

  • Page 121: Hoses

    8999170EN: v1.1 28/02/2023 5.6.6 Hoses Equipment Required • See Section 5.6 Replace pinched and broken hydraulic hoses at once. Tighten any hydraulic fitting with fluid leaking from it. If fluid still leaks, loosen the fitting, apply a pipe thread compound to the threads and tighten. Care must be exercised when tightening hydraulic fittings.
  • Page 122 8999170EN: v1.1 28/02/2023 Proline Specification Hydraulic Body Locks Set-up Body Lock Left Hand Wing Ram – Rod End Left Hand Wing Ram – Base End Centre Lift Ram – Rod End Centre Lift Ram – Base End Right Hand Wing Ram – Rod End Right Hand Wing Ram –...

  • Page 123: Electrical Components & Wiring Diagrams

    8999170EN: v1.1 28/02/2023 Electrical Components & Wiring Diagrams 5.7.1 Lights Figure 5.86 – Rollicut Lighting Loom 7-pin Durite Plug x2 7-pin Durite Socket x1 see Figure 5.86 (1) see Figure 5.86 (2) Colour Colour Yellow Left-hand Direction Light Yellow Left-hand Direction Light Blue Fog Light Blue...

  • Page 124: Proline

    8999170EN: v1.1 28/02/2023 5.7.2 Proline Figure 5.87 – Rollicut Control Box Diagram Body Lock Right-hand Clutch Flashing Beacon Left-hand Clutch Not Used Clutch Power Supply (To Tractor Battery) Not Used Right-hand Wing Angle Position Sensor Left-hand Wing Ram – Base End Left-hand Wing Angle Position Sensor Left-hand Wing Ram –...

  • Page 125: Wheels, Hubs & Tyres

    Spearhead dealer on Rollicut machines. If you are unsure of the correct wheel/tyre for the machine, or need additional assistance, please contact your local Spearhead dealer, qualified service centre or Spearhead.

  • Page 126: Tyre Pressures

    Manually operated grease gun supplying NLGI #2 Molybdenum Disulphide Grease to M6/M8 grease nipples Spearhead Rollicut wheel hubs feature grease nipples which need to be greased at least once a week (dependant on amount of machine use). They are found on all hubs shown in the position on Figure 5.89.

  • Page 127: Skids

    30mm hex spanner/socket Figure 5.91 – Rollicut Wing Skid Spearhead machine skids are fitted to protect the machine body fabrications from permanent damage. Premature wear can be caused to the skids through allowing the skids to drag along the ground causing an earlier requirement for replacement.

  • Page 128: Torque Settings

    Table 5.13 – Rollicut Specific Fastener Torque Settings Non-specific Fastener Requirements The below tables give reference to the maximum recommended tightening torques for standard, zinc plated finished bolts on Spearhead machines. These settings can be applied to hex, socket countersunk and socket button screws. Size Grade 10.9...

  • Page 129: 5.10.2 Hydraulic Fittings

    8999170EN: v1.1 28/02/2023 5.10.2 Hydraulic Fittings Throughout all Rollicut machines, BSP adaptors and hoses are used. See the relevant headings for adaptors and hoses. Port Adaptors With Bonded Seals The below tables give reference to the maximum recommended tightening torques for standard, BSP port adaptors found on Rollicut machines.

  • Page 130: Machine Inspection Record

    8999170EN: v1.1 28/02/2023 5.11 Machine Inspection Record Select Pre-delivery inspection: MACHINE INSPECTION Select RECORD Installation inspection: (For Rollicut 500/600) Select Daily pre-work inspection: Model: Serial No: Inspector name (print): Inspection date: Company/Position: Inspector signature: Visual Checks Comments Check that an operator’s instruction manual in the correct language for the working territory is in the machine document holder.
  • Page 131 Spearhead claims no responsibility to any machine and/or physical harm caused by anything other than the practice guidelines stated in its specific machine model operators manual.

  • Page 132: Machine Storage

    Many other local operators will be carrying out the same procedure at the same time. Where parts are broken, damaged and deemed not fit for use; replace with genuine Spearhead parts using the online Interactive Parts facility at https://my.spearheadmachinery.com/parts/public-interactive-parts-database/...

  • Page 133: 5.12.2 Returning The Machine Back To Work

    So as not to invalidate the warranty and to avoid problem, use only genuine Spearhead parts and make sure the machine is not driven at a speed in excess of 540rpm on the PTO.

  • Page 134: Troubleshooting

    Vibration Gearbox noise a) Lack of oil Fill to level mark on gearbox b) Worn gears Replace gears with genuine Spearhead part c) Worn bearings Replace bearings with genuine Spearhead part Vibration! a) Lost/broken blades (see Replace all blades on that rotor 6.5)
  • Page 135 8999170EN: v1.1 28/02/2023 Symptom Possible Cause Remedy 6.10 Damage to a) Input PTO driveshaft Shorten the telescopic guard following the input PTO telescopic guard guidance in Section 3.3.4 driveshaft, bottoming out universal joint b) Engaged PTO drive with Ensure a steady engagement into driving the and wide-angle too much speed PTO with a low tractor engine speed...

  • Page 136: Spare Parts

    8999170EN: v1.1 28/02/2023 Spare Parts How To Obtain The Correct Spare Part Numbers For correct part numbers; use the Spearhead interactive online parts books. These are available at https://my.spearheadmachinery.com/parts/public-interactive-parts-database/ You will need to enter the machine serial number; see Figure 1.4.

  • Page 137: Spare Parts Ordering

    For guidance on finding your local Spearhead dealer; see Section 7.3. Dealer Network Spearhead has an extensive dealer network which can offer genuine replacement parts. In order to make it easier to find your local Spearhead dealer, the Spearhead website has a Dealer Locator facility. http://www.spearheadmachinery.com/dealer-locator/ To find your local Spearhead dealer enter your location or postcode into the “Your location”...
  • Page 138 8999170EN: v1.1 28/02/2023 Notes Original instructions (ENGLISH) Website: www.spearheadmachinery.com...
  • Page 139 8999170EN: v1.1 28/02/2023 Notes Original instructions (ENGLISH) Website: www.spearheadmachinery.com...

This manual is also suitable for:

Rollicut 600

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