Alamo 02984405 User Manual

BOOM ARM MOWER

Published 07/06 (Rev 02-20-07) Part No. 02984405

ASSEMBLY MANUAL

(ST ANDARD INSTRUCTIONS)

Tractors equipped with additional options, special equipment, tractor manufacturer modifications, new tractor models, or Customer alterations may prevent this Mount Kit from being properly mounted to the tractor. Alamo Group is not responsible for modifications to the MountKit to accommodate these differences.

NOTE: This manual is designed to be a basic assembly instruction manual and will show some illustration that are intended to be generic. Some iluustrations may not reflect the type tractor the mower is being mounted on. It is intended to be used with the Assembly Instrucrion Drawings sent for the specific tractor type that the mount kit was designed to fit. It is important to keep these assembly drawing with this manual for future reference.

ALAMO INDUSTRIAL

1502 E. Walnut Seguin, T exas 78155 830-379-1480

TO THE OWNER/OPERA T OR/DEALER

All implements with moving parts are potentially hazardous. There is no substitute for a cautious, safe-minded operator who recognizes the potential hazards and follows reasonable safety practices. The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents.

BEFORE YOU START!! Read the safety messages on the implement and shown in your manual.

Observe the rules of safety and common sense!

WARRANTY INFORMATION: Read and understand the complete Warranty Statement found in this Manual. Fill out the Warranty Registration

Form in full and return it to within 30 Days. Make certain the Serial Number of the Machine is recorded on the Warranty Card and on the Warranty Form that you retain.

NOTES

Axtreme Boom General Assembly (02-06) (Rev 02-20-07)

INTRODUCTION

ABOUT THIS MANUAL:

The intent of this publications to provide the competent technician with the information necessary to assemble the Alamo Industrial Product. This will, in turn provide for complete customer satisfaction. This manual is designed to be used as a basic component guide. The assembly drawings shipped with the unit will be used as to the assembly of components that are specific to a particular tractor model, these assembly drawings should always be kept with the other product manuals for future reference.

It is hoped that the information contained in this and other Manuals will provide enough detail to eliminate the need for contact of the Alamo Industrial Technical Service Dept. However, it should be understood that many instances may arrive where in correspondence with the Manufacturer is necessary.

CONTACTING MANUFACTURER: (Please help us Help You! Before You Call! )

Alamo Industrial Service Staff Members are dedicated to helping you solve yours or your customer’s service problem as quickly and efficiently as possible. Unfortunately, we receive entirely to many calls with only a minimum amount of information. In some cases, the correspondent has never gone out to look at the equipment and merely calls inquiring of the problems described to him by the operator or customer.

PART NUMBERS:

Part numbers listed in this manual are subject to change without notice as designs are made to adapt to the tractor or for a design improvement. Before ordering parts ALWAYS Measure old part to make certain that is the one you will need. This manual is designed to be used along with the Parts and Operators Manual. Most calls received by Alamo Industrial Service can be classified into approx. 6 general categories.

1. Hydraulic or Mechanical Trouble Shooting.

2. Request for Technical Information or Specifications.

3. Mounting or Fitting Problem.

4. Special Service Problem.

5. Equipment Application Problems.

6. Tractor Problem Inquiries.

HOW YOU CAN HELP:

1. Make certain the call is necessary! Most of the calls received may not be necessary if the Dealer Service

Technician would do the following.

2. Check the Service Information at your Dealership provided by Alamo Industrial, This would include, Service

Bulletins, Information Bulletins, Parts Manuals, Operators Manuals or Service Manuals, many of these are available via the Alamo Industrial Internet site (Alamo - Industrial. Com). Attempt

to diagnose or repair problem before calling.

3. If a call to Alamo Industrial is needed, Certain Information should be available and ready for the Alamo Industrial Service Staff. Such information as, Machine Model, Serial Number, Your Dealer Name, Your Account Number and

Any other information that will be useful. This information is vital for the development of a prompt and correct solution

to the problem. This will also help to develop a database of problems and related solutions, which will expedite a solution to future problems of a similar nature.

4. The technician may be asked to provide detailed information about the problem including the results of any required trouble shooting techniques. If the information is not available, The technician may be asked to get the information and call back. Most recommendations for repairs will be based on the procedures listed in the Service Manual / Trouble Shooting Guide and the information as received from the dealer / customers. These recommendations are based on the asumption that the proper testing and equipment inspections have been performed to determine the repair needed.

CONTACT ALAMO INDUSTRIAL:

Alamo Industrial Inc. 1502 E. Walnut St. Seguin TX. 78155, Technical Service Dept. PH: 830-379-1480

Axtreme Boom - Asy Man (07/06)

Index -1

INDEX

Section Page

Index.......................................................................................................................... Index-1 to Index 2

Section 1

Safety Instructions..............................................................................1-1 to 1-6

Section 2

Model Specifications...........................................................................2-1 to 2-6

Section 3

Tractor Preperations......................................................................... 3-1 to 3-8

Section 4

Batteryt, Ehaust, Fuel Tank Modifications & Mani Frame..................4-1 to 4-16

Section 5

Wheel Weight Installation...................................................................5-1 to 5-4

Section 6

Pump, Driveline and Hydraulic Installation.........................................6-1 to 6-12

Section 7

Boom & Head Installations with Hydraulic Connections...................7-1 to 7-12

Section 8

Valve Installation, Mechanical Cable Controlled. (Standard)..............8-1 to 8-12

Section 9

Valve Installation, Joystick ElectricalControlled. (Optional).............. 9-1 to 9-12

Section 10

Hydralic Tank Fill & Start UP..............................................................10-1-1 to 10-4

Section 11

Pre-Delivery Inspection Check List....................................................11-1 to 11-4

Axtreme Boom - Asy Man (07/06)

Index -2

Section 1

Axtreme Boom

SAFETY

SECTION

Axtreme Boom (Asy. Man.) 07/06

Section 1 - 1

Safety Section

Read these assembly instructions through completely and understand them before proceeding with the assembly of the equipement.

A safe and careful operator is the best operator. Safety is of primary importance to the manufacturer and should be to the owner/operator . Most accidents can be avoided by being aware of your equipment, your surroundings, and observing certain precautions. The first section of this manual includes a list of Safety Messages that, if followed, will help protect the operator and bystanders from injury or death. Read and understand these Safety Messages before assembling, operating or servicing this Implement. This equipment should only be operated by those persons who have read the Manual, who are re-

sponsible and trained, and who know how to do so safely and responsibly .

The Safety Alert Symbol combined with a Signal Word, as seen below, is used throughout this manual and on decals which are attached to the equipment. The Safety Alert Symbol means: “ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!” The Symbol and Signal Word are intended to warn the owner/operator of impending hazards and the degree of possible injury faced when operating this equipment..

Practice all usual and customary safe working precautions and above all---remember safety is up to YOU. Only YOU can prevent serious injury or death from unsafe practices.

CAUTION! The lowest level of Safety Message; warns of possible injury. Decals

located on the Equipment with this Signal Word are Black and Yellow.

WARNING! Serious injury or possible death! Decals are Black and Orange.

DANGER! Imminent death/critical injury. Decals are Red and White. (SG-1)

Axtreme Boom (Asy. Man.) 07/06

Section 1 - 2

Safety Section

PELIGRO!

Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. (SG-3)

!LEA EL INSTRUCTIVO!

READ, UNDERSTAND, and FOLLOW the following Safety

Messages. Serious injury or death may occur unless care is taken to follow the warnings and instructions stated in the Safety Messages. Always use good common sense to avoid hazards.

(SG-2)

PELIGRO!

Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. (SG-3)

INSTRUCTIVO!

LEA EL

WARNING!

DANGER!

WARNING!

Perform service, repairs and lubrication according to the maintenance section. Ensure the unit is properly lubricated as specified in the lubrication schedule and all bolts and nuts are properly torqued. Failure to properly service, repair and maintain this Implement in good operating condition could cause component failure and possible serious injury or even death. (SG-35)

Operate this Equipment only with a Tractor equipped with an approved roll-over-protective system (ROPS). Always wear seat belts. Serious injury or even death could result from falling off the tractor--particularly during a turnover when the operator could be pinned under the ROPS. (SG-7)

Never work under the Implement, the framework, or any lifted component unless the Implement is securely supported or blocked up to prevent sudden or inadvertent falling which could cause serious injury or even death. (SG-14)

Use caution and wear protective gloves when handling sharp objects such as blades, knives, and other cutting edges. Be alert to worn component surfaces which have sharp edges. Sharp surfaces can inflict severe laceration injuries if proper hand protection is not worn. (SG-37)

Axtreme Boom (Asy. Man.) 07/06

Section 1 - 3

Safety Section

WARNING!

Many of the parts are heavy and require lifting assistance. Do not try to lift the heavy parts by yourself. Get help from another employee or from an overhead crane.

The operator and all support personnel should wear hard hats, safety shoes, safety glasses, and proper hearing protection at all times for protection from injury including injury from items thrown by the equipment. (SG-16)

Always wear safety shoes with steel toes when working on this equipment. It is recommended that the safety shoes have metatarsal guards.

WARNING!

DANGER!

When welding use Welding hood with the appropriate OSHA required protective lens, welding apron, and welding gloves.

Always disconnect the wire leads from the mower valve solenoid before performing service on the Tractor or Mower. Use caution when working on the Tractor or Mower. Tractor engine must be stopped before working on Mower or Tractor. The Mower Blades could inadvertently be turned on without warning and cause immediate dismemberment, injury or death. (SBM-12)

Never run the tractor engine in a closed building or without adequate ventilation. The exhaust fumes can be hazardous to your health.

Axtreme Boom (Asy. Man.) 07/06

(SG-23)

Section 1 - 4

Safety Section

DANGER!

WARNING!

DANGER!

Before starting the mower make sure the area is clear and the floor has been swept. The mower blade can throw objects several hundred feet. Thrown objects could damge property or cause severe bodily injuries even death.

Make certain that the “Slow Moving Vehicle” (SMV) sign is installed in such a way as to be clearly visible and legible. When transporting the Equipment use the Tractor flashing warning lights and follow all local traffic regulations.

Start tractor only when properly seated in the Tractor seat. Starting a tractor in gear can result in injury or death. Read the Tractor operators manual for proper starting instructions. (SG-13)

(SG-6)

DANGER!

WARNING!

DANGER!

Do not operate this Equipment with hydraulic oil leaking. Oil is expensive and its presence could present a hazard. Do not check for leaks with your hand! Use a piece of heavy paper or cardboard. Highpressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene. If oil does penetrate the skin, have the injury treated immediately by a physician knowledgeable and skilled in this procedure. (SG-15)

Always read carefully and comply fully with the manufacturers instructions when handling oil, solvents, cleansers, and any other chemical agent. (SG-22)

All Safety Shields, Guards and Safety devices including (but not limited to) - the Deflectors, Chain Guards, Steel Guards, Gearbox Shields, PTO integral shields , and Retractable Door Shields should be used and maintained in good working condition. All safety devices should be inspected carefully at least daily for missing or broken components. Missing, broken, or worn items must be replaced at once to reduce the possibility of injury or death from thrown objects, entanglement, or blade contact. (SGM-3)

Axtreme Boom (Asy. Man.) 07/06

Section 1 - 5

Safety Section

DANGER!

WARNING!

NEVER use drugs or alcohol immediately before or while operating the

Tractor and Implement. Drugs and alcohol will affect an operator’s alertness and coordination and therefore affect the operator’s ability to operate the equipment safely. Before operating the Tractor or Implement, an operator on prescription or over-the-counter medication must consult a medical professional regarding any side effects of the medication that would hinder their ability to operate the Equipment safely. NEVER knowingly allow anyone to operate this equipment when their alertness or coordination is impaired. Serious injury or death to the operator or others could result if the operator is under the influence of drugs or alcohol. (SG-27)

Operate the Tractor and/or Implement controls only while properly seated in the Tractor seat with the seat belt securely fastened around you. Inadvertent movement of the Tractor or Implement may cause serious injury or death. (SG-29)

Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. (SG-30)

WARNING!

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Wash Hands after handling. (SG-31)

Use extreme caution when getting onto the Implement to perform repairs, maintenance and when removing accumulated material. Only stand on solid flat surfaces to ensure good footing. Use a ladder or raised stand to access high spots which cannot be reached from gound level. Slipping and falling can cause serious injury or death. (SG-33)

Avoid contact with hot surfaces including hydraulic oil tanks, pumps, motors, valves and hose connections. Relieve hydraulic pressure before performing maintenance or repairs. Use gloves and eye protection when servicing hot components. Contact with a hot surface or fluid can cause serious injury from burns or scalding. (SG-34)

Avoid contact with hot surfaces of the engine or muffler. Use gloves and eye protection when servicing hot components. Contact with a hot surface or fluid can cause serious injury from burns or scalding. (SG-38)

Axtreme Boom (Asy. Man.) 07/06

Section 1 - 6

Section 2

Axtreme Boom

Model

Specifications

Axtreme Boom - Asy Man (07/06)

Section 2 - 1

SPECIFICATIONS - AXTREME BOOM

READ THIS BEFORE BEGINNING ASSEMBLY:

The Axtreme Boom has electronic components:. The electronic components can

be damaged if care is not taken when performing repairs, testing and/or during assembly.

DO NOT

1. DO NOT short any wires across or allow them to be shorted out.

2. DO NOT attempt to jump across any wires or supply them with alternate power source.

3. DO NOT install higher rated fuses than are recommended by manufacturer.

4. DO NOT do any welding on unit unless the computer modules are unplugged first, this is to prevent a power

surge going into modules (THIS IS VERY IMPORTANT). This could also apply to the tractor components. Check Tractors repair guide for specific instruction about tractor model and type.

5. DO NOT attempt to repair or adjust a component that is not intended to be repaired, example sealed

components as there are no serviceable components inside.

6. DO NOT let anyone attempt any testing or repairs unless they are an experienced and qualified techni-

cian. Technicians must have proper tools, gauges, meters etc. to perform proper diagnosis and/or repairs.

7. DO NOT perform any assembly or repairs with dirty tools or in dirty work area. When working on hydraulic

components keeping system clean and free of contamination is important.

8. DO NOT start or engage system if the oil level is not at the proper level or condition. Never start or run

unit low or out of oil.

9. DO NOT install / add any oil unless you know it is the correct type and the container is clean. Make certain

the oil is not contaminated with dirt or any liquid.

1. Pump Specifications:

Body Construction.....................................................................Cast Iron

Control Valve Type.................................................................... Direct Acting, Pilot Operated

Control Valve Relief................................................................... 3000 PSI

Driveshaft Type......................................................................... 1" X 15 Spline

Driveshaft Torque Rating............................................................ 371 ft. lbs.

Pressure Rating (Maximum).......................................................3000 PSI

Pump Type...............................................................................Gear

Pump Gear Width..................................................................... 2 inch

Pump Efficency Flow Rate (Approx)............................................85 % of G.P.M. is Acceptable

Speed Rating (Maximum)...........................................................2400 RPM

Nominal Displacement (Per Revolution)....................................... 5.1 Cu. In.

Output @ 1800 RPM.(Operating RPM)........................................37.5 G.P.M.

Output @ 2400 RPM.(Maximum RPM)........................................ 51 G.P.M.

Horsepower Rating (Maximum Conditions)................................... 90 HP

Rotation Direction (Viewed from Top of Deck................................ Clockwise

Motor Start / Stop Time............................................................. 6 Seconds (Approx)

Tank Capacity Required.............................................................17.5Gallons

Oil Type................................................................................... See Oil Chart

Oil Temperature (While Operating).............................................. 70 Deg, (F) Above Ambient

Axtreme Boom - Asy Man (07/06)

Section 2 - 2

SPECIFICATIONS - AXTREME BOOM

2. Fifty Inch (50") Cutting Head Specifications:

Blade / Motor Rotation (Looking down from Top of Deck)...............Clockwise

Blade Tip Speed........................................................................18,850 FPM / 210 MPH

Blade carrier Type..................................................................... Pan or 3 Leaf bar Option

Blade Pan Blade Qty.................................................................2 Blade or 3 Blade Option

Blade Bar Blade Qty.................................................................. 2 Blades

Blade Cutting Width (Overall)......................................................50 inches.

Deck Construction.....................................................................Formed and Welded Steel

Deck Material........................................................................... 10 Gauge

Deck Weight.............................................................................725 lbs.

Spindle ....................................................................................4.5" by 9" Heat Treated Alloy

Spindle Bearing.........................................................................Tapered Roller Bearings

Spindle Lubrication....................................................................Grease (Pumped In)

Motor Type...............................................................................Gear

Motor Gear Width......................................................................2-1/2"

Motor Speed (Maximum)............................................................2400 RPM

Motor Pressure (Maximum)........................................................3000 PSI

Motor Rated Pressure ...............................................................3000 PSI

Motor Rated Flow......................................................................38 GPM

Motor Displacement.................................................................. 6.375 Cu. Inches

3. Sixty Inch (60") Rotary Mower Head:

Blade / Motor Rotation (Looking down from Top of Deck)...............Clockwise

Blade Tip Speed........................................................................18,000 FPM / 205 MPH

Blade Carrier Type.....................................................................2 Leaf bar Option

Blade Bar Blade Qty.................................................................. 2 Blades

Blade Cutting Width (Overall)......................................................60 inches.

Deck Construction.....................................................................Formed and Welded Steel

Deck Material........................................................................... 10 Gauge

Deck Weight.............................................................................818 lbs.

Spindle ....................................................................................4.5" by 9" Heat Treated Alloy

Spindle Bearing.........................................................................Tapered Roller Bearings

Spindle Lubrication....................................................................Grease (Pumped In)

Motor Type...............................................................................Gear

Motor Gear Width......................................................................2.25"

Motor Speed (Maximum)............................................................2500 RPM

Motor Pressure (Maximum)........................................................3250 PSI

Motor Rated Pressure................................................................3000 PSI

Motor Rated Flow......................................................................38 GPM

Motor Displacement.................................................................. 8.1 Cu. Inches

4. Rotary Head Torque Specification:

Motor to Spindle Housing...........................................................100 ft. lbs.

SPindle to Deck........................................................................425 ft. lbs.

Spindle Bearing Pre-Load...........................................................25 in. lbs. Rolling Torque

Blade Bar Leaf Bars. ( 1-1/4" Bolts)............................................ 2000 ft. lbs.

Blade Bolts ..............................................................................400 ft. lbs.

Blade Bar to Spindle..................................................................400 ft. lbs.

Axtreme Boom - Asy Man (07/06)

Section 2 - 3

SPECIFICATIONS - AXTREME BOOM

1234567

123

5. Control Valve: 5 Spool used with Rotary Heads w/ Door

Valve Type................................................................................Open Center 5 Spool

Valve Control (Manual Standard)................................................. Remote Cable Control

Valve Control (Electonic Joystick Optional)..................................Joystick Electronic Control

Pressure (Maximum)................................................................. 3500 PSI

Flow (Maximum)....................................................................... 20 GPM

Main Relief............................................................................... Direct Acting: 3000 PSI: Adjustable

FilterType.................................................................................Return Side

Filter Size.................................................................................10 Micron

Bushings..................................................................................Greasable Steel

6. Valve Ports: ( See Figure 1 & 2)

"A" Port...........Valve Ports designated as "A" Ports connect to the Rod End of the Swing and Lift Cyl, to the

Barrel End of the Dipper Cyl, to the Barrel End of Tilt Cyl and to Barrel End of the Door Cyl.

"B" Port......... Valve Ports designated as "B" Ports connect to the Barrel End of Swing and Lift Cyl, to the

Rod End of the Dipper Cyl, to the Rod End of the Tilt Cyl and to the Rod End of the Door Cyl.

Mechanical Remote Cable Controled Valve (Standard)

"A" Port Side

"B" Port Side

Figure 1

Door

Tilt

(Red)

Dipper

(Y ellow / White)

Tilt

23456

AAAA

234567

Door

(Yellow)

(Red / White)

Lift

(Blue)

(Orange / White)

234567

Dipper

Lift

(Orange)

(Blue / White)

Swing

(Green / White)

234567

Swing

Pressure Supply (Port P1)

Return (Port T2)

Note: Hose Colored Bands, Bands

with stripes go to Cylinder Base. Solid color bands go to Cylinder rod end.

(Green)

Axtreme Boom - Asy Man (07/06)

Section 2 - 4

SPECIFICATIONS - AXTREME BOOM

Joystick Electronic Controled Valve (Optional)

"A" Port Side

"B" Port Side

Figure 2

Door

A A

Tilt

(Yellow)

(Red / White)

B B B

Door

Tilt

(Y ellow / White)

Dipper

(Red)

Lift

(Orange)

(Blue / White)

Lift

(Blue)

Dipper

(Orange / White)

Swing

(Green)

Swing

(Green / White)

Pressure Supply (Port P1)

Return (Port T2)

Note: Hose Colored Bands, Bands

with stripes go to Cylinder Base. Solid color bands go to Cylinder rod end.

7. Valve Sections Function:

Mechanical Control Vale (See Figure 1)

Spool Cylinder Function Pressure

"B" "A" "A" "B" 1 Swing Back Forward 2750 PSI 2750 PSI 2 Lift Up Down 2750 PSI 1160PSI 3 Dipper Out In 2750 PSI 1160PSI 4 Tilt Up Down 2750 PSI Main Relief Main Relief 5 Door In-Open Out-Closed Main Relief Main Relief

Electronic Control Vale (See Figure 2)

Spool Cylinder Function Pressure

"B" "A" "A" "B" 1 Swing Back Forward 2750 PSI 2750 PSI 2 Lift Up Down 1160 PSI 2750 PSI 3 Dipper Out In 1160 PSI 2750 PSI 4 Tilt Up Down 2750 PSI Main Relief 5 Door In-Open Out-Closed 2750 PSI 2750 PSI

Axtreme Boom - Asy Man (07/06)

Section 2 - 5

SPECIFICATIONS - AXTREME BOOM

8. Hose End Fitting Torque Specification:

Hose End Type: 37 Degree Angle End Steel Hose End Fittings*

Dash Nominal Cyl. Torque Torque Size Size (in.) in. lbs. ft .lbs.

-4 1/4" 140 12

-6 3/8" 230 19

-8 1/2" 450 38

-10 5/8" 650 54

-12 3/4" 900 75

-16 1" 1200 100

-20 1-1/4" 1600 133

-24 1-1/2" 2000 167

-32 2" 2800 233 * Straight Threads do not always seal better when higher torgues are used. Too much torque causes distortion and may lead to leakage. DO NOT over torque fittings and DO NOT allow any contaminants to enter system through fittings when installing them.

9. TORQUE VALUES - BOLTS:

Maximum Torque per Bolt Size and Grade, Ft lbs & (Nm) IMPORTANT ! Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE, Component

Application Torque will vary dependimg on what is bolted down and the type material (Metal) that is being bolted together. Thread condition and lubrication will vary Torque settings.

Bolt Dia. inch

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4

Inche Sizes

2 (B)

Plain Head

Not Used Not Used Not Used 35 (47) 55 (75) 75 (102) 105 (142) 185 (251) 160 (217) 250 (339) 330 (447) 480 (651)

5 (D)

3 Dashes

85 (115) 130 (176) 170 (230) 300 (407) 445 (603) 670 (908)

910 (1234)

1250 (1695)

10 (14) 20 (27) 35 (47) 55 (75)

8 (F)

6 Dashes

14 (19) 30 (41) 50 (68) 80 (108) 120 (163) 175 (230) 240 (325) 425 (576) 685 (929) 1030 (1396) 1460 (1979) 2060 (2793)

ALWAYS

CHECK

MARKINGS

TOP

OF BOLT HEAD

OTHER

BOLT

DESCRIP-

TIONS

Bolt Dia. mm

6 8 10 12 14 16 18 20 22 24 27 30 33 36

Metric Sizes

4.8

5 11 20 37 60 92 118 160 215 285 450 600 800 900

8.8

7 20 40 70

100 155 216 270 330 500

875 1200 1600

2100

10.8

12 25 58 105 140 200 280 355 430 700 1000 1700 2300 3000

Axtreme Boom - Asy Man (07/06)

Section 2 - 6

Section 3

Axtreme Boom

Tractor Preperations

NOTE: This shows a basic mount for the frame installation and may not be the same for your tractor model. The way the frame mounts to the tractor components can vary with tractor model. See the installation drawings shipped with the unit for the specific tractor type mount and hardware components. IN

SOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLATION DRAWING INSTRUCTION, THE INSTALLA TION DRAWING INSTRUCTIONS WILL OVERRIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC. THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR.

Axtreme Boom (Asy. Man) 07/06

Section 3 - 1

General Information / Installation Requirements

General Information:

The tools you will need at the assembly site are as follows:

1. Welding equipment (including correct head gear, eye shields, and protective clothing.)

2. Impact wrench or socket and ratchet set.

3. Rubber mallet.

4. Box-end, Allen, and crescent wrenches.

5. Alignment pins.

6. Phillips and plain-head screwdrivers.

7. Forklift or hydraulic floor jacks with rolling back boards.

8. Over head hoist and floor jacks

9. Jack Stands and/or other support devices that are strong enough to support tractor and components

10. Multidirectional Levels.

11. Paint Scraper.

12. Hydraulic Filter Buggy or Cart.

13. Safety shoes, safety glasses, and gloves.

14. A hard hat should be worn by anyone working under any raised component.

Remember to follow each step closely and cautiously. Be aware of all support personnel at all times. Keep the assembly area as clean as possible; clean up all spills when they occur. An uncluttered assembly area and a crew that is sensitive to the hazards involved in putting this implement together will help prevent accidents. Keep all unauthorized personnel from the area. Do not allow children near the assembly site nor allow them on or near the tractor after assembly. There is no safe place for anyone except the operator on the tractor and those assisting with the assembly.

To help you assemble your new Unit and mount it to your tractor, a detailed assembly instruction Manual is being provided with the mount kit to provide detailed instructions and part numbers. Please consult this document for specific information. When needed, you can get additional information or clarification from Your Dealer or Alamo Group Customer Service.

This publication provides general information and may not specifically be for your case or tractor, but, in connection with the assembly drawings that are sent with the mount kit, this publication offers you some valuable assistance - please read it thoroughly and use it with your assembly drawings and other publications. Other publications may include, operators manual, parts manual, service manual or any other publication sent by manufacturer. Keep all publications together for future reference.

These mount kits are made for selected tractors with standard configurations. Only the noted options and tire sizes listed in the Mounting Specifications will work with these mount kits. Other options, front axles, or different tire sizes may prevent the mount kit from fitting your nonstandard tractor. Alamo Group cannot take responsibility for these problems or any modifications made to the unit.

Throughout these instructions, references are made to right or left directions. Right and left are

determined by sitting on the tractor seat and facing the direction of travel forward always.

This is the Safety-Alert symbol. When you see this symbol on your machine or in these instructions, be alert to the potential for personal injury. Follow recommended precautions

DANGER!

and safe operating practices.

DANGER!

A signal word - DANGER, WARNING, or CAUTION - is used with the Safety Alert symbol. DANGER identifies the most serious hazards.

Axtreme Boom (Asy. Man) 07/06

Section 3 - 2

General Information / Installation Requirements

WARNING! Safety signs with signal word WARNING are typically used to point out more

serious hazards.

CAUTION! General precautions are listed on CAUTION safety sign. CAUTION also calls

attention to safety messages in these instructions.

WARNING!

Disconnect the negative lead (ground) from the battery terminal to prevent any damage to the electrical system.

LEVELING TRACTOR:

TRACTOR MUST be on level ground before assembly is begun. The tractor must be level, All tires

must have the proper amount of air in them as per tire and/or Tractors manufactures recommendations.

DO NOT level tractor by over inflating tires. The tractor can be leveled by jacking it up and putting it on

jack stands if needed. Tractor should be kept at ride/operation height when mounting unit, this will insure that the components are mounted at the correct height.

Axtreme Boom (Asy. Man) 07/06

Section 3 - 3

General Information / Installation Requirements

Replacement Oil Filter

Included in the packing box of this unit is a replacement filter element for filter assembly in the tank. This Mower unit's hydraulic components have been carefully cleaned and packaged at the factory to prevent contamination from entering the system. However, dust and dirt particles may enter into the sealed components through transportation, handling, rain, or just sitting in a dirty or harsh environment. Therefore to assure that the hydraulic system is properly clean, please prepare the area where the unit is to be assembled. The area should be on a hard concrete floor that has been swept clean of all dust and contaminants. Unpacked the Mower unit carefully so that the seals on the hydraulic components are not broken or pulled off.

WARNING!

Before attempting to assemble the mower to the tractor, move the tractor to a clean solid surface, preferably a concrete shop surface with an over head crane. The crane should have a rated capacity to lift the heaviest component or assembly. A 5-ton crane is recommended for the assembly work. If a smaller crane is used, be sure not to exceed the rated capacity of the crane. Q Always follow all OSHA crane operating and inspection rules, regulations,

inspection requirements, and recommended practices when using the crane.

Q Never work under any component that is lifted by the crane.

Wear personal protective equipment when assembling the mower. As a minimum that should include:

Q Safety Glasses Q Safety Shoes Q Gloves Q Hard Hat Q Hearing Protection Q Welding Helmet

Before attempting to assemble ensure that the tractor engine is off and the tractor transmission is in the park position with the parking brake engaged.

Q Remove the engine key and keep it in your pocket to prevent inadvertent

starting or movement of the tractor.

Q Place wheel blocks in front and behind the tractor wheels to prevent the tractor

from moving.

Q Never attempt to start the tractor unless properly seated in the tractor seat

with the seat belt fastened around you.

Q Never attempt to operate the tractor and mower controls unless seated in

the tractor seat with the seat belt fastened around you.

WARNING!

Axtreme Boom (Asy. Man) 07/06

Securely block up and support the tractor before attempting to loosen and move the tires. Failure to properly block up the tractor can result in the tractor to suddenly move or fall, crushing you or another worker. Q Never work under any raised component or any component that is not

securely blocked up or supported.

Many components of this mower are very heavy and must be handled by proper material handling equipment. Do not lift components that weight over 50lbs by yourself. Q Use an overhead crane, forklift, or other coworkers to lift heavy items. Ensure

lifted components are securely supported.

Q Never walk or work under a lifted component.

Section 3 - 4

General Information / Installation Requirements

WARNING!

TRACTOR PREPARATION (FIGURE 1 & 2)

1. Temporally remove ROPS and fenders from tractor axle. Move left rear tire out so that it is 50 inches

from the outside of left rear tire to the center of tractor. Then move the right rear tire out so that it is 96 inches between the outside of the left and right rear tires. Refer to your tractor’s Operator’s Manual for instructions on Rear Wheel Adjustment for your particular tire. FIGURE 1. Hydraflate rear left tire as much as needed for stability but stay in factory-recommend limit.

Use extreme care when moving, handling or adjusting the tractor tires. The tires are extremely heavy and could fall and crush you

Q Use an overhead crane or forklift to move the tires. Q Properly fasten the tires to the material handling equipment to prevent the tire

from falling. The hydraulic oil is under high pressure and a hydrauli leak can cause oil to be injected under the skin.

Q Before starting the tractor ensure all hydraulic connections have bee tightened Q Never check for leaks with your hands. Use a piece of wood or cardboard to

check for the leak making sure your hands and face are kept away from the leak area.

Q Repair any leaks before operating the equipments Q Clean up all oil that has leaked according to the requirements of the oil supplier.

Oil residue on the ground can result in unjury from slipping or falling.

FIGURE 1

50"

96"

WARNING: Never operate the tractor with a loose wheel rim or disc. Always tighten nuts

to the specified torque and at the recommended intervals.

2. Extend front wheels out so that it is 55" inches between the inside of the tires. This will allow no interference between tire and front mount bracket. FIGURE 2.

FIGURE 2

55"

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Section 3 - 5

General Information / Installation Requirements

Tractor, Area Cleanliness

The Tractor, all tools and work area must be clean of dirt and debris when assembling any hydraulic components. DO NOT leave any hydraulic component open to the elements. DO not use any containers for fluids that are not clean and free of any other liquids. DO NOT use rags/cloth that has lint or fuzz on them when working on hydraulic components. Keep all hoses capped until you are ready to connect them.

Cleaning Boom and mower componets (electronics)

The units Components are designed to be water resistant. But the sealing can be damaged by Pressure Washers, Steam Cleaners, Solvents or any other harsh chemical that would be used to clean the units components. It is important to keep all electrical connections and components sealed and dry. When washing and cleaning this unit it should be done with a non corrosive soap and low pressure spray of water. It is recommended that all exposed electronic components be covered and protected from excess moisture.

Lay Out Components in Display. It is helpful to lay out the component in as neat a display

as possible. Lay out the Bolts according to size and length. Lay out the Nuts and washer by size. This will allow you to see how many of each part as you use them and help to identify any missing parts. (See figure 6) See Mount Kit Specification and Component Identification Section to help ID Components.

All the component that are received should be check and sorted as to what they are. Shown below is a general example of the components laid out, this is not a lay out of the components in this mount kit.

Axtreme Boom (Asy. Man) 07/06

Section 3 - 6

General Information / Installation Requirements

WARNING

DO NOT WELD On This Unit During or After Installation:

DO NOT WELD any components or items on this unit after the installation of the maverick Boom has begun. The Maverick Boom uses electronic modules and components that could be damaged by welding. Before doing any welding ALL ELECTRONIC MODULES AND DISPLAY COMPONENTS MUST BE UNPLUGGED. Check the Tractors Opertion, Repair, Service or any other manual from the tractor manufacturer of the tractor to find any special electronic or special proedures about the tractor electronics. Taking a few minutes to check could save you from a major damage to the electronics.

Axtreme Boom (Asy. Man) 07/06

Section 3 - 7

NOTES

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Section 3 - 8

Section 4

Axtreme Boom

Battery, Exhaust

Fuel Tank

Modification

With

Main Frame

Inst allation

CASES THE MANUAL INSTRUCTION MAY VAR Y FROM THE INSTALLATION DRA WING INSTRUCTION, THE INSTALLATION DRA WING INSTRUCTIONS WILL OVERRIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC. THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR.

Axtreme Boom (Asy. Man) 07/06

Section 4 - 1

Battery Holder Relocation

Battery Holder Relocation:

1. The Battery Relocation (If Required, See Assembly Drawings sent with unit). The battery holder is

located on the RH side of the tractor (See Figure 1) . It will have to be relocated. The mount kit will include a battery relocation kit. The battery relocation kit includes a mounting bracket (See Figure 2)

that will relocate the battery tray farther to the rear. This is done so the Boom Swing will not hit battery when in the transport position. The RH Step Will need to be removed to allow access to relocate battery.

2. Remove Factory Battery Cover, Battery, Bat-

tery Tray and Battery Tray mount. (If Required, See

Assembly Drawings sent with unit) Remove the bat-

tery cover (See Figure 3), Remove the battery cables from the battery. Remove the battery from the battery tray. Unbolt the battery tray from the tractors factory mount bracket. Remove the factory mounting bracket from the tractor (See Figure 4).

Figure 1

3. Install Replacement Battery Tray Bracket (If

Required, See Assembly Drawings sent with unit).

Install the replacement battery tray bracket (See Figure 2) using the same bolts and holes as the original bracket. This Bracket is designed to move battery further back. Install original battery tray using original hardware. Reinstall battery into batter tray (See Figure 3). DO NOT reconnect battery cables at this time, leave them off and make certain they do not make contact with the battery connections as you do not want the battery connected during installation. Replace the battery cover (See Figure 1) for now this will protect battery and cover.

Battery

Relocation

Bracket

Figure 2

Figure 3

Axtreme Boom (Asy. Man) 07/06

Figure 4

Section 4 - 2

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