Spearhead STARCUT 730 User manual

Spearhead Star-Cut 500 & 730
1
STARCUT 500/730
Edition 1.4- March 2012
Part No. 8999041

Spearhead Star-Cut 500 & 730
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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 ………………………………………………

Spearhead Star-Cut 500 & 730
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Contents
Safety 4
Recommendations 5
Introductions 7
Tractor Requirements 7
Attaching To The Tractor 8
Setting Up Your Machine 11
Operation 13
Transportation 15
Machine Protection 16
Servicing & Maintenance
Safety First 17
Daily 18
Every 8 Hours 19
Torque Settings 19
Regularly 20
Blades 20
MP6 Blade Carrier Setup 21
Clutch Maintenance and Settings 22
Skids 26
Wheels 26
Storage 27
Trouble Shooting Guide 28
Spearhead Warranty 29

Spearhead Star-Cut 500 & 730
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Safety
Warning
Avoid fluid escaping
under pressure. Consult
technical manual for
services procedures.
Warning
Danger –flying objects
keep safe distance from
the machine as long as
the machine is running.
Warning
Stay clear of mower
blades as long as
machine is running.
Warning
Stay clear of un-proped
wings.
Warning
Shut off engine and remove
key before performing
maintenance or repair work.
Warning
Check all nuts are tight
every 8 hours.
Warning
Carefully read operator’s
manual before handling this
machine. Observe
instructions and safety rules
when operating.

Spearhead Star-Cut 500 & 730
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Recommendations
Beware of the following Potential Dangers associated with the use of
this machine:
Becoming trapped when hitching or unhitching
Machine overbalancing when wing is raised.
Getting caught on rotating power take off (PTO)
Being hit or caught by any moving part, e.g. Blades, drive shaft and
wings.
Being hit by flying debris or machine parts due to machine damage
Machine wing falling if not secured with locking pin & transport strap.
Injection of high pressure oil from damaged couplings or hydraulic
hoses
Accidents due to collision with other machines, or debris left on road
Beware of free-swinging blades over centering and falling when wings
are folding.
ALWAYS:
Ensure the operator has read this handbook and has been trained to
use the machine.
Ensure all safety guards are in place and all tractor windows closed.
Impact resistant shielding to the tractor is recommended
Before leaving the tractor cab always ensures that the wings are 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 blades 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.
Ensure that all warning labels are always visible and that they are not
damaged, defaced or missing.
Fit locking pins to height and to wings 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
Ensure blades are of the type recommended by the manufacturer, are
securely fitted and are undamaged

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Ensure hydraulic pipes are correctly routed to avoid damage from
chafing, stretching, pinching or kinking.
Check condition of tyres and tightness of wheel nuts.
Ensure all blades have stopped spinning before folding wings into
transport position.
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.
Never operate the machine until you have read and understood this
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 wings 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 blades missing.
Never operate PTO above recommended speed, 1000 r.p.m.
Never operate with wire around the rotor. Stop immediately.
Never use the wing raised 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 engage the P.T.O with wings folded.

Spearhead Star-Cut 500 & 730
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Introduction
The Spearhead Starcut 500/Starcut 730 is a heavy-duty rotary mower for a
set-aside, stubble and pasture topping. By carefully following the instructions
in this handbook, the machine will give many years of trouble free operation.
Safety First
Never start using the machine until the handbook has been read and
understood. The Starcut 500/Starcut 730 rotary mower is a potentially lethal
machine if used incorrectly and it is essential that the operator fully
understand the working before starting up.
Tractor Requirements
Spearhead recommend tractors of between 85 and 150hp.
A clevis drawbar must be used,
The tractor should have a minimum weight of 3000 kg.
The tractor should have a 1000rpm P.T.O.
Two external hydraulic services are required, double acting for height
control and single acting for wings with float facility.
Attaching To The Tractor
It is essential to ensure that the tractor lift arms cannot foul the P.T.O. shaft,
even when the tractor is on full lock. It is advisable to remove them altogether
if there is any doubt.
The tractor drawbar should be extended to its maximum not less then 400mm
from the P.T.O. This will enable turning in work without damaging the drive
shaft. Never attach the mower using the
pick-up hitch as this will cause damage to
the drive shaft.
Fit the nylon washer between the mower
drawbar and the tractor clevis, as shown, to
reduce wear between the two parts. The
nylon washer is a replaceable wearing part.
Warning
Do not attach machine to
pick up hook. This will
damage the P.T.O. shaft

Spearhead Star-Cut 500 & 730
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Attaching To The Tractor
Low Drawbar
When attached to the low drawbar
of the tractor always use the
parallel linkage bar attached to
the lower hole on the hitch plate.
High Drawbar
We recommend that the parallel
linkage bar is removed and the
hitch is locked by replacing the pin
in the middle hole.
When using the high drawbar it is
not possible to use the parallel
linkage, as when the machine is
full raised the PTO shaft may be
damaged.

Spearhead Star-Cut 500 & 730
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Attaching To The Tractor
Connect the hydraulic hoses. One to a single acting service, with a float
facility for wings. The other pair to a double acting service for the axle again
with float to lower the wheels. This is particularly important the spool valve
allows the machine to follow the ground contours.
Wings; red banded hose, single acting
spool c/w float
Wheel Axle; blue and yellow banded hose,
double acting spool c/w float

Spearhead Star-Cut 500 & 730
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Attaching To The Tractor
Before fitting the PTO for the first time, it may be necessary to adjust the
length. There should be maximum engagement of the sliding tubes without
bottoming at the shortest operation position. To check, first connect the
mower to the tractor. Pull the PTO shaft apart and connect to the tractor PTO
output shaft and the gearbox input shaft. Hold the half shafts next to each
other in the shortest working position. If necessary, shorten the inner and
outer guard tubes equally (Fig. 1). Shorten the inner and outer sliding profiles
by the same length as the guard tubes. File all sharp edges and remove burrs.
Grease sliding profiles.
To fit the PTO, first clean and grease. Press pins on the yoke and
simultaneously push the PTO drive shaft onto PTO shaft of the tractor until
pins engage.
The PTO shaft is fitted with a non-rotating safety guard. It should be secured
to the machine and tractor with the two retaining chains provided.
Note:
Inspect the tractor PTO stub for damage/wear as this may effect the
attachment/removal of the Spearhead input shaft. Check also for alignment as
any concentricity will cause vibration and premature wear of the CV joint.

Spearhead Star-Cut 500 & 730
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Setting Up Your Machine
When the machine is fitted to the
tractor and set at working height,
the front of the skid should be 10-
20mm higher than the rear of the
skid.
To raise the front of the mower
shorten the adjustable link that is
attached to the rear axle.
To lower the front of the mower,
lengthen the adjustable link.
Adjusting the link is made much
easier by placing the machine’s
weight on the parking stands then
gently lower the machine until the
weight is off the hitch

Spearhead Star-Cut 500 & 730
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Setting Up Your Machine
Sticker Part No. 8770351 is
mounted to the rear of the
Starcut machine to allow easy
and quick reference to cutting
heights.
Height of cut is controlled by varying
the amount of ram stops covering the
ram rod.
Start with 4 ram spacers on all rams.
Cutting height can be increased or
decreased by adding or reducing the
amount of spacers that are down.
(see Recommended Cutting Heights)
Fine adjustment and balance of cut
between the rotors is achieved by
adjusting the length of the base screw
attached to the ram.
Attention
Each ram must have
equal amount of
spacers

Spearhead Star-Cut 500 & 730
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Operation
Once ready for work, raise the mower cutting height and slowly engage the
PTO with the tractor engine at low revs to prevent shock damage to the
machine. Slowly increase the engine revs to achieve the recommended PTO
speed of 1000 r.p.m. As indicated by the decal on top of the centre guard and
not the number of splines on the P.T.O shaft. If at any time serious vibration
occurs, stop the engine immediately and check the blades, following all
safety precautions. Select a sensible forward speed bearing in mind the
density of growth, the terrain, and the available horsepower.
The quality of finish is determined by the forward speed, i.e. a slow speed will
produce a high quality of cut, where as faster forward speeds are used when
high output is first priority.
When in work, always ensure the hydraulic spool valve that operates the
folding of the wings is in float position to enable the wings to freely follow all
contours of ground (Fig. 6).
Fig. 6 contours of the ground
Warning
The maximum working angle the wings can safely be run
is 7.5 degrees below horizontal when the machine is
fitted with double “Star-Cut” blades. If the wings are
allowed to drop more than 7.5 this will result in impact
damage from the rotating blades striking the deck.

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Operation
Whilst operating it is possible to continue working when turning as the Starcut
500/730 is fitted with a constant velocity joint on PTO shaft. However take
care not to run the rear tractor wheel against the mower draw bar as this will
result in serious damage to the tractor, the mower and, in particular, the PTO
shaft.
The constant velocity joint on the input PTO shaft, allows the PTO to be left in
gear whilst turning out of work, e.g. on the headlands. It is important not to
turn sharply when the machine is in work as this will over-strain and
shorten the life of the constant velocity joint.
When operating in confined areas it is possible to cut going backwards, but it
is advisable to slightly raise the machine, particularly if in scrub, where there is
the risk of hitting hidden solid obstacles obscured by dense undergrowth.
Always exercise particular care when operating over uneven ground surfaces.
Do not allow the blades and blade holder to frequently hit the ground.
Do not allow debris to build upon the cutting decks in dry conditions, as this
can be a fire hazard, in wet conditions it will place unnecessary strain on the
machine and may foul the drive shaft causing damage.
Warning
Do not run the machine with the wings raised. The risk of
debris and machine parts being ejected is greater as the
chain skirting is ineffective in this position.

Spearhead Star-Cut 500 & 730
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Transportation
First disengage the PTO drive, fold the wings fully upright and secure with
locking pin and transport pin. Never transport along public highways with the
wings only supported by the hydraulics.
Please observe Public Highway Regulations, concerning the towing of
implements, and securely attach a registration and lighting board.
Warning
Avoid transporting machine at high speed over rough ground
Maximum speed on highway –20mph (25kph).
Centre axle
Both centre axle rams must have
all 10 spacers down covering the
ram rod.
Wing axles
Both wing axle rams must have all
the spacers out.
Then lower the machine and keep
pressurizing the rams until both
the wings rams are fully closed to
give a safe and narrow transport

Spearhead Star-Cut 500 & 730
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Machine Protection
To prevent gearbox damage all rotors are protected by slip clutches fitted to
each of the drive shafts. When cutting in extreme conditions where stumps,
rocks and other such solid objects are likely to be found it is recommended
that the operator reduces the engine revs to allow the blades to pivot more
easily when striking solid objects and proceed with caution.
The clutch settings should not be altered without reference to Service and
Maintenance. Never over-tighten the pressure springs on the slip clutches
(Fig. 8) as this could result in severe damage to the gearbox and drive lines,
as well as invalidating the warranty.
If the machine has been laid up for any length of time, there is a risk of
the clutch plates rusting and seizing together. Never operate the
machine in this condition, as there will be no protection to the driveline and
gearboxes against shock loading. To free the clutch plates first slacken all
pressure spring bolts and run up the machine for a short period, deliberately
try to cause the clutch to slip. Finally re-tighten the tension spring bolts to
their original length, taking great care not to over-tighten.
If in any doubt, consult Spearhead’s Service Department or your local
Spearhead Dealer for further advice.
Fig. 8 Slip Clutch
Warning
Never carry out any servicing or maintenance work without
first disengaging the PTO and then stopping the tractor
engine before leaving the seat.
On delivery of your machine check that the dealer has
completed the P.D.I form, ensure the warranty registration
form is completed and returned.

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Service & Maintenance
Safety First
Never leave the tractor seat without first disengaging the PTO
and stopping the engine.
Ensure all rotating parts have stopped turning.
Never attempt any repairs, maintenance, service or any other
checks with the machine carried on the tractor hydraulics.
Always fully lower to the ground, or securely prop the machine
on substantial servicing stands.
Always replace all guards and retaining chains after
servicing/maintenance completed.
It is imperative that the following checks are carried out in order not
to invalidate your warranty; these are carried out before the first
operation, after the first hour, then after 4 hours.
These checks are:
1. Wheel nuts and tyre pressure (40psi).
2. Gearbox bolts, including the splitter box.
3. Retaining bolts on the drive shafts.
4. Grease all points including drive shaft tubes.
5. After the first 50 hours drain and replace the gearbox oil.
Replace with EP90 gear oil.
6. All other nuts and bolts
Blade rotation
CLOCKWISE
Blade rotation
ANTI CLOCKWISE
Blade rotation
CLOCKWISE
730
500

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Servicing & Maintenance
Daily
Grease all points, including rear axle pivot points (Fig. 9a), axle hinge
(Fig. 9c), wheel arms (Fig. 9b), and front draw bar pivot (Fig. 9f)
Check bolts are tight on all gearboxes.
Check condition of blades and blade bushes; ensure all retaining bolts
are fully tight.
Check wheel nuts are tight.
Check tyre pressures –40 P.S.I.
Check gearbox oil, replenish with EP90 gear oil as necessary to the
correct level line on the dipsticks, provided with each gearbox.
Fig. 9 Greasing points
A Rear axle pivot points - grease points 4 off
B Wheel arm grease points 4 off
C Drive shafts c/w slip clutch 2 off
D Front drawbar grease points 2 off
E Wheel bearings 8 off
F Telescopic shafts 2 off
A
B
C
D
E
F
F

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Every 8 Hours
Dismantle and clean the main input P.T.O shafts sliding surfaces and
re-grease; failure to do this will result in serious damage to the splitter
gearbox.
Grease all universal joints, (Fig. 10) paying particular attention to the
constant velocity joint. If under-greased this constant velocity joint will
soon fail.
Grease the wing drive shaft tubes, (note the hole in the plastic tubing
for access).
Lubricate the retaining collar on all the drive shaft guards (Fig. 10).
Grease PTO inner tube and push pins (Fig. 10).
Check all bolts are tightened to the correct Torque (Fig.11).
Torque Settings
The Torque figures given below are recommended maximum settings only.
Size:
Tensile strength:
Description:
Torque setting:
Nm.
M16
8.8
Gearbox bolts
280
M20
8.8
Blade bolts
425
M24
8.8
Blade bolts
730
Wheel nuts
270
For maximum life and performance, the CV body must be greased regularly. Lubricate
with the driveline in a straight position - up to 30 pumps of grease may be required.
The metal drive tubes must be greased to operate properly.
Shielding is subject to damage from abuse and weathering. Replace all damaged
components and all shielding removed during maintenance.
Do not use PTO adapters with CV drivelines. Replace special taper pin bolts only with
genuine OEM parts, periodically check tightness of nuts.
Fig. 10
Primary input shaft

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Regularly
Check there is no wrapping of string, plastic, grass or other debris
between rotor boss and gearbox oil seal.
Inspect gearbox seals for leaks.
Clear grass and other debris from the deck.
Regularly check the rotor boss retaining castle nut for tightness. First
remove the split pin, select the correct size socket in 3/4” drive and fully
tighten the nut. When replacing the split pin, do not slacken the nut to
align the hole, always tighten. Failure to regularly check this nut will
result in serious wear to hub, which is expensive to repair.
It is most important that all gearbox bolts are regularly checked to
be very tight. When the machine is new there will be a ‘bedding
in’ period where very frequent checking is important.
Blades
Caution! When carrying out maintenance work on or near the blades be
careful of free-swinging blades over-centering and falling. It is
recommended that protective clothing including hard-hat and goggles
are worn.
The blades can be re-sharpened by grinding the cutting edges, care must be
taken that the blades are of the same weight and length after grinding. Do not
overheat when grinding as this will affect the hardness of the blades. All the
blades are free swinging and swivel on hardened steel bushes, which are
replaceable. When replacing blades, it is important that blades are replaced
in sets, in order to retain balance of the rotor. Bushes must be replaced when
new blades are to be fitted.
If the blades are showing any signs of severe wear, damage or cracking, they
must be replaced immediately. Never attempt to weld the blades, as this will
make them very brittle thus extremely dangerous. Do not take risks with the
cutting blades - if in doubt, replace.