Spearhead R Series User manual

R Series R190/R225/R245/R270
1
R Series Flail Mowers
R190/R225/R245/R270
Edition 1.1–August 2016
Part No. 8999047

R Series R190/R225/R245/R270
2
Spearhead
R Series Flail Mowers
R190/R225/R245/R270
Handbook & Parts
Manual
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.)
Spearhead Machinery
Green View
Salford Priors
Evesham
Worcestershire
WR11 8SW
Tel: [phone]
Fax: [phone]
www.spearheadmachinery.com
[email protected]
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.

R Series R190/R225/R245/R270
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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 ………………………………………………

R Series R190/R225/R245/R270
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Contents
Operator Section
General Information
5
Machine Description & Purpose of Use
6
Machine Identification
6
Technical Data
7
Technical Specifications
7
Safety Features
8
Safety Information
9
Safety Decals
10
Vehicle/Tractor Preparation
11
Machine Attachment
12
PTO Shaft
13
Setting Up & Adjustment
14
Offsetting
16
Flails
16
Drive Belts
17
Pre-Operational Checks
18
Operation
19
Detachment and Storage
20
Maintenance
21
Troubleshooting
25
Warranty
26
Parts
Mower Assembly
29

R Series R190/R225/R245/R270
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General Information
Always read this manual before fitting or operating the machine –whenever any
doubt exists contact your dealer or the Spearhead Machinery Service
Department for advice and assistance.
Use only Spearhead Genuine Service Parts on Spearhead Equipment and
Machines
DEFINITIONS –The following definitions apply throughout this manual:
WARNING
An operating procedure, technique etc., which –
can result in personal injury or loss of life if not observed carefully.
CAUTION
An operating procedure, technique etc., which –
can result in damage to either machine or equipment if not observed carefully.
NOTE
An operating procedure, technique etc., which –
is considered essential to emphasis.
LEFT & RIGHT HAND
This term is applicable to the machine when attached to the tractor and is
viewed
from the rear –this also applies to tractor references.
Machine Description & Purpose Of Use

R Series R190/R225/R245/R270
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The R series of machines are ‘3-point linkage’ tractor mounted mid-sized flail
mower/shredders suitable for tractors of 50HP and above. Designed primarily
for the mulching of grasses, brambles, bushes, branches, vines, and general
crop residues their tough construction and choice of working widths of 1.9m,
2.2m, 2.4m or 2.7m with offsetting capability of up to 400mm make them ideal
for both agricultural users and general contractors alike.
These machines should only be used to perform tasks for which they were
designed –use of the machine for any other function may be both dangerous to
persons and damaging to components and is therefore not advisable.
Machine Identification
Each machine is fitted with an identification plate with the following information:
1. Machine (Part Number)
2. Machine Serial No.
3. Machine Weight
When ordering spares or replacement parts from your local dealer it is important to
quote both Part Number and Serial Number as stated on the identification plate so the
machine and model can be quickly and correctly identified.

R Series R190/R225/R245/R270
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Technical Data
Component Identification
1. Frame
2. Gearbox
3. Sliding Tubes
4. 3-Point Linkage
5. Belt Drive / Belt Guard
6. Skid
7. Rear Roller
8. Protection Flaps
9. Stand Leg
Technical Specifications
SPECIFICATION
R190
R225
R245
R270
Working Width (mm)
1920
2270
2420
2720
Tractor Power Requirement (HP)
50
60
74
80
PTO Speed (RPM)
540
540
540
1000
Hammer Blades (No.)
24
28
30
34
Y-Blades (No.)
48
56
60
68
Machine Weight (kg)
410/430
462/487
495/515
525/545
Offset Capability (mm)
400
400
400
400
Linkage (Type)
3-point Cat 2
3-point Cat 2
3-point Cat 2
3-point Cat 2
Machine Width (mm)
2080
2430
2630
2880
Optional Equipment
The following options are available on these machines:
•Front Linkage
•Hammer Flails
•Y-Blade Flails
The cutting capability of the each particular type of flail will be dependant on the
sort and hardness of the material being cut, but in general the following cutting
thicknesses apply:
Y-blade flails –for materials up to a maximum of 30mm diameter.
Hammer flails –for materials up to a maximum of 45mm diameter.
Noise Level
The sound level of this machine, as measured at the operator’s ear, is within the
range of 70 to 90 dB when the rear window of the tractor is open. We
recommend that ear protectors are worn and the tractor windows kept closed at
all times when operating this machine.

R Series R190/R225/R245/R270
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Safety Features
Location Of Machine Safety Features
1. PTO Shaft Shields
2. Drive Belt Guard
3. Side Skids
4. Protection Flaps
5. Safety Decals

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Safety Information
General Safety Rules:
▲Always read and follow the instructions for the use and maintenance of the machine before
carrying out any work operations or servicing tasks.
▲Improper use of the machine is both highly dangerous to persons and damaging to the
machine components –only use the machine for its designated task.
▲Both operators and the maintenance fitters should be familiar with the machine and fully
aware of dangers surrounding improper use or incorrect repairs.
▲Before starting, checks to both tractor and machine must be carried out as regards:
functionality, road safety, accident prevention rules.
▲Even when using the machine correctly, stones or other objects may be thrown a long
distance. Therefore nobody must stand within the danger area. Special attention must be paid
when working near roads or buildings.
▲Use tractor’s fitted with safety cabs.
▲The condition of flails and of machine guards must be checked before beginning the daily
work - they must be replaced if damaged or missing before you use the machine.
▲During checks or repairs, make sure nobody could start the machine by mistake.
▲Never wear loose or fluttering clothes.
▲Never carry passengers on the tractor.
▲Never carry passengers on the machine.
▲Never connect the power takeoff with the engine running.
▲Never approach the machine until the rotor has completely stopped.
▲Do not enter the working zone of the PTO shaft. It is dangerous to approach the rotating parts
of a machine.
▲Keep the PTO shaft guard in good condition.
▲Before starting, check the surrounding area for the likely presence of children and/or animals.
▲Do not stand near the machine when it is operating.
▲The PTO shaft must be assembled and disassembled only with the engine stopped and the
starting key removed.
▲Before connecting the power takeoff, check that the speed and the rotational direction
correspond to those of the machine.
▲Immediately replace missing or damaged safety decals.
▲Before leaving the tractor with the machine attached, proceed as follows:
1. Disconnect the power takeoff,
2. Put the machine steadily on the ground using the tractor’s hydraulic lift.
3. Apply the hand brake and, if the ground is steeply sloping, wedge the tractor.
4. Remove the starting key.

R Series R190/R225/R245/R270
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Transportation Safety
▲In transport, reduce speed, especially on bumpy roads, the weight of the machine may render
driving difficult and damage the machine itself.
▲Ensure the levers that operate the hydraulic lift are locked, to avoid the lowering of the
machine during transport.
▲When driving on public roads, respect all road rules in force.
▲Never transport the machine with the rotor running, even for short distances.
Operating Safety
▲Pay special attention when working with the machine not to touch fixed objects such as road
drain, walls, shafts, kerbs, guard rails, tracks etc. This could cause the breakage of the flails,
which would be thrown out of the machine at very high speed.
▲If wires, ropes or chains should become entangled in the rotor stop immediately to prevent
damage or dangerous situations; stop the rotor and the tractor, take out the starting key. Put
working gloves on; clear the rotor with the aid of pliers or shears. Do not try to disentangle by
inverting the rotational direction of the rotor.
▲Do not use the machine when excessive vibration is experienced, as this may cause breakage
and serious damage - find the cause of the vibration and eliminate it before using the machine
again.
Although the information given here covers a wide range of safety subjects, it is impossible to
predict every eventuality that can occur under differing circumstances whilst operating this
machine. No advice given here can replace ‘good common sense’ and ‘total awareness’ at all times,
but will go a long way towards the safe use of your Spearhead Machinery machine.
Safety Decals
1. Always switch machine off, remove starting key and read instruction manual before
performing service or maintenance work on the machine.
2. Keep a safe distance from the machine at all times - risk from projection of objects.
3. Risk of hand injury –always ensure all guard are fitted and in place when machine is
operating.
4. Risk of feet injury –keep at a safe distance from the machine when it is operating.
5. Never stand or ride on the machine.

R Series R190/R225/R245/R270
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Vehicle/Tractor Preparation
We recommend vehicles are fitted with cabs
using ‘safety glass’ windows and protective
guarding when used with our machines.
Fit Operator Guard (part no. 73 13 324) using
the hooks provided. Shape the mesh to cover
all vulnerable areas.
Remember the driver must be looking through
mesh and/or polycarbonate glazing when
viewing the machine in all positions - unless
the vehicle/ cab manufacturer can demonstrate
that the penetration resistance is equivalent to, or higher than, that provided by
mesh/polycarbonate glazing. If the tractor has a roll bar only, a frame must be made to
carry both mesh and polycarbonate glazing. The operator should also use personal
protective equipment to reduce the risk of serious injury such as; eye protection (mesh
visor to EN1731 or safety glasses to EN166), hearing protection to EN352, safety
helmet to EN297, gloves, filter mask and high visibility clothing.
Vehicle Ballast
It is imperative when attaching ‘third-party’ equipment to a vehicle that the maximum possible
stability of the machine and vehicle combination is achieved –this can be accomplished by the
utilisation of ‘ballast’ in order to counter-balance the additional equipment added.
Front weights may be required for rear mounted machines to place 15% of total outfit weight on
the front axle for stable transport on the road and to reduce ‘crabbing’ due to the drag of the
cutting unit when working on the ground.
Where a machine works to the side of the tractor rear weights may be required to maintain a
reasonable amount of rear axle load on the opposing wheel.
All factors must be addressed in order to match the type and nature of the equipment added to
the circumstances under which it will be used - factors that effect stability are:
•Centre of gravity of the tractor/machine combination.
•Geometric conditions, e.g. position of the cutting head and ballast.
•Weight, track width and wheelbase of the tractor.
•Acceleration, braking, turning and the relative position of the cutting unit during these
operations.
•Ground conditions, e.g. slope, grip, load capability of the soil/surface.
•Rigidity of implement mounting.
Suggestions to increase stability:
•Increasing rear wheel track - a vehicle with a wider wheel track is more stable.
•Ballasting the wheel; it is preferable to use external weights but liquid can be added to around
75% of the tyre volume –water with anti-freeze or the heavier Calcium Chloride alternative
can be used.
•Addition of weights –care should be taken in selecting the location of the weights to ensure
they are added to a position that offers the greatest advantage.
•Front axle locking, check with tractor manufacturer.
The advice above is offered as a guide for stability only and is not a guide to vehicle
strength. It is therefore recommended that you consult your vehicle manufacturer or
local dealer to obtain specific advice on this subject, additionally advice should be
sought from a tyre specialist with regard to tyre pressures and ratings suitable for the
type and nature of the machine you intend to fit.

R Series R190/R225/R245/R270
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Attaching The Machine To The Tractor
Attachment of the machine to the tractor should always be performed on a firm level site.
Before attachment always ensure:
•The machine is in good condition.
•All safety guards are in good working condition and correctly fitted.
•All flails are correctly fitted and undamaged.
•Lubrication points are well greased and the gearbox oil level is correct.
•Drive belts are tensioned correctly.
•The tractor PTO rpm and direction of rotation correspond to that of the machine.
Attachment Of The Mower
Drive the tractor ‘squarely’ up to the machine.
Position the tractors lower linkage at a height where it is approximately in line with the lower linkage
points (A) on the machine –refer to photo below.
Drive tractor slowly towards the machine until the lower linkage points correspond.
Fit linkage pins and secure with spring clips.
Fit top link to upper linkage point (B) –this may be floating or fixed depending on the work terrain - refer
to set up and adjustment page for specific details on this subject.
Raise the machine slightly on the tractors hydraulics –adjust top link to bring the machine into the
perpendicular position.
Fit check chains and/or stabilisers to tractor lower links to centralise and secure the machine in position.
Fit PTO Shaft and attach torque chains –refer to following page for details of shaft measurement.
Attach hydraulic hoses - hydraulic sideshift models only.
Machine Linkage
A –Lower linkage points
B –Upper linkage point

R Series R190/R225/R245/R270
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PTO Shaft
PTO Shaft Management
Measure the PTO shaft and cut to the
dimension shown –the finished length of the
PTO shaft should be 75mm (3”) less than the
measured distance ‘A’ - between tractor
shaft and gearbox stub shaft - to enable
fitting.
NOTE: For subsequent use with different
tractors measure again, there must be a
minimum shaft overlap of 150mm (6”).
Fit PTO in position and attach the torque
chains to a convenient location to prevent
the shaft guards from rotating.
PTO SHAFT LENGTH ADJUSTMENT
1. Shorten outer plastic tube to 40mm
less than the shortest envisaged shaft
length.
2. Remove the marked tube.
3. Remove same length from inner
plastic tube and metal shaft profiles
(inner and outer).
4. De-burr all edges and remove ‘swarf’
to ensure smooth operation.

R Series R190/R225/R245/R270
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Approximate overlap length of PTO shaft with machine lowered to the ground ▲
Approximate gap length of PTO protection tube with machine in working position ▲
Fit torque chains to shaft guards to prevent rotation ►

R Series R190/R225/R245/R270
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Top linkage working positions ►
Top Linkage
The machines top linkage point (B) has two working modes; floating and fixed –
refer to photo below.
Floating position (B1) should always be
used when working on hilly or uneven
terrain to protect the machine and linkage
from damage.
Fixed position (B2) may be used when
working on even level terrain such as
playing fields and other similar areas that
present a lower degree of stress on the
linkage.
WARNING:
Always use top linkage floating position (B1) when working on hilly, sloping or
undulating terrain.
Setting Up & Adjustment
The height of cut is dependent on working
conditions and volume of material. The cutting
height can be regulated with the hydraulic
system on the tractor and/or rear roller
adjustment –see photo opposite.
The minimum height of cut should be between
1 –3cm.
NOTE: The machine must always
run on the rear roller not the side
skids –side skids are a protection
feature and in normal working
conditions remain clear of the
ground.
Do not allow the rotor flails to
contact the ground - set roller
height to allow a minimum flail to ground clearance of 1 to 3cm.

R Series R190/R225/R245/R270
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Hammer Flails Y-Blade Flails
Offsetting
The machine can be placed into an offset position to allow for work beyond the width of the tractor
–depending on the particular specification of the machine offsetting operation will either be
manual or hydraulic.
Manual adjustment is performed by removal of the locking pin and physically sliding the unit
sideways before replacing the pin when the desired offset position is achieved.
On machines fitted with hydraulic offset, adjustment to the required position can be carried out
from the tractor cab by operation of the hydraulic side-shift ram.
In both cases the machines must be raised clear of the ground to allow for free sideways
movement.
DANGER: Ensure the machine is switched off and the rotor stationary when moving manual
machines into the offset position –never attempt to perform this procedure with the machine
running.
Flails
As standard, the machine is equipped with Hammer type flails, but as an option can be fitted with
Y-blade flails. The hammer type flails are more suited to harder working with the ability to cut
materials up to 45mm (1¾”) diameter. Y-blade flails can cut up to 30mm (1¼”) diameter material –
these figures are under normal use and may differ depending on the type and nature of the
material being cut.
The design of the mower is such that during work the rotor unit cuts the material and projects it
upwards into the frame, as the material falls back into the rotor it is cut again several times until it
is small enough to be discharged from the rear of the machine.
The rotor unit should be inspected on a daily basis prior to work to check for damaged or missing
flails –always replace damaged or missing flails immediately. Flail bolts should be checked for
tightness on a regular basis and re-tightened as required before attempting to use the machine.
WARNING: Checking of rotor components should only be carried out with tractors engine switched
off, starting key removed and the PTO shaft disconnected. Always ‘prop up’ the machine using
suitable supports before attempting to inspect or work on components underneath it.
Manual Offset Model –Locking pin
Hydraulic Offset Models –Ram location

R Series R190/R225/R245/R270
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Drive Belts
Belt Tension
It is important for both optimal machine performance and long lasting belt life
that belts are correctly tensioned at all times. Tension is correct when a force of
10 kg exerted on the belts at their mid-point between the upper and lower
pulleys deviates the belts by 15mm.
If the belts require tensioning follow the procedure stated below.
After an initial first 1 hour of work check belt tension and taper locks (indicated 1 & 2 in
the photo below right) –tighten if required.
Taper Locks –check tightness on new
machines after initial 2 hours of work
Belt Tension –15mm deviation under
10kg pressure at mid-point of belt run

R Series R190/R225/R245/R270
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Location of Gearbox Mounting Bolts
Location of Belt Tension Adjusters
Belt Adjustment
Adjustment of the belt tension is performed by loosening the adjuster locking
nut (A) and slackening half-shaft lock bolt (B) along with the four gearbox
mounting bolts (C) –refer to photos below. Adjuster bolt (D) can then be turned
to increase or decrease belt tension until belt deviation matches the required
measurement –see above. Belt tensioning should be performed when the belts
are cold. Re-tighten bolts ‘B’ and ‘C’ and locknut ‘A’ when belt tension is correct.
WARNING: Checking of belts and drive components should only be carried out with
tractors engine switched off, starting key removed and the PTO shaft disconnected.
Never attempt to run the machine with the belt guard removed –Replace guard after
tensioning before starting the machine.
Pre-Operational Checks
Before commencing work with the machine the following checks should be
performed:
•Make a visual inspection of the machine to ensure it is in good operational
condition.
•Check all safety guarding is in position and in full working order.
•Check rotor for missing or damaged flails and replace if required.
•Check all greasing points are well lubricated.
•Check gearbox oil level.
•Check belt tension and adjust if required.
•Check PTO speed and direction match that of the machine.

R Series R190/R225/R245/R270
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Optimal forward working speed 3-8 km/h Raise the machine before turning or reversing
Operation
Ensure that the operator is suitably qualified to use a machine of this nature and
that they have fully read and understood this manual - they should be aware of
all safety aspects relating to the safe use of the machine. It is advisable that all
‘first time’ operators practice using the machine in a clear safe area prior to
work in order to familiarise themselves with its operation.
After the initial first 1 hour of work with a new machine, nuts and bolts should be
checked for tightness and the drive belts inspected and re-tensioned if required –refer to
belt section for details.
Prior to starting work the area should be checked for dangerous objects such as
large stones, wood, wire, glass etc. –hazardous objects should be removed
from the area prior to operation with the machine. The location of unmovable or
natural hazards should be noted, or if necessary ‘marked’, to indicate to the
operator that the area should either be avoided or additional caution adopted
whilst working around the hazard.
Starting Work
With the machine switched off, lower it into a position approximately 10cm
above the ground, start the machine and allow it to build up to the correct
working speed before gently lowering the it onto the ground - the machine is
now in its work position and forward travel can begin.
Forward Speed
The forward working speed will depend on the working conditions and nature of
the material being cut. Optimal speed will be in the region of 3-8 km/h (2-5
mph).
Reversing & Turning
When reversing or turning the unit the machine must always be lifted clear of
the ground to avoid damage.

R Series R190/R225/R245/R270
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Transport
The following must be observed at all times when transporting the machine:
•Machine must always be switched off.
•Machine must be raised.
•Speed must be kept to a minimum especially on bumpy roads or terrain.
•Always abide with local laws and road regulations.
•Be aware of the machines width.
Detachment & Storage
Detaching The Machine
•Removal of the machine should be performed on a firm level site. The
procedure for detachment is as follows:
•Gently lower the machine fully to the ground.
•Switch off the tractor and remove its starting key.
•Remove the PTO driveshaft.
•‘Chock’ the rear roller to prevent movement of the machine during the
detachment procedure and whilst in storage.
•Detach hydraulic hoses where applicable.
•Remove the top link and both pins from the lower attachment points.
•Carefully and slowly drive the tractor clear of the machine.
•Clean and lubricate the machine in preparation for next use.
Storage
For extended periods of storage it is advisable that the machine be kept in a
clean dry environment protected from the elements to avoid risk of corrosion.
The machine should be thoroughly cleaned and lubricated prior to storage. At
this point it is good practice to check the machine for worn or damaged
components - any parts that require replacing should be ordered and fitted at
the earliest opportunity so the machine is fully prepared for the next seasons
work.