Alamo 803213C User Manual

This Operator's Manual is an integral part of the safe operation of this machine and must be maintained with the unit at all times. READ,

UNDERSTAND, and FOLLOW the Safety

and Operation Instructions contained in this manual before operating the equipment. C01-

Cover

INTERSTATER

FLAIL MOWER

Published 02/11 Part No. 803213C

OPERATOR’S MANUAL

ALAMO INDUSTRIAL®

1502 E. Walnut Seguin, Texas 78155 830-372-3551 Email: parts@alamo-industrial.com

$0.00

To the Owner/Operator/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.

The video will familiarize and instruct mower-tractor operators in safe practices when using industrial and agricultural mowing equipment. It is important that Every Mower Operator be educated in the operation of their mowing equipment and be able to recognize the potential hazards that can occur while operating a mower. This video, along with the mower operator’s manual and the warning messages on the mower, will significantly assist in this important education.

Your Authorized Alamo Industrial Dealer may have shown this video and presented you a DVD Video when you purchased your mower. If you or any mower operator have not seen this video, Watch the Video, Read this Operator’s Manual, and Complete the Video Guidebook before operating your new mower. If you do not understand any of the instructions included in the video or operator’s manual or if you have any questions concerning safety of operation, contact your supervisor, dealer or Alamo Indus- trial.

If you would like a VHS video tape of the video, please email AEMVideo@alamo-group.com or Fax AEM VHS Video at (830) 372-9529 or mail in a completed copy of the form on the back of this page to AEM VHS Video 1502 E Walnut Street, Seguin, TX 78155. and request the VHS video version. Please include your name, mailing address, mower model and serial number.

Every operator should be trained for each piece of equipment (Tractor and Mower), understand the intended use, and the potential hazards before operating the equipment.

Alamo Industrial Division is willing to provide

one (1) AEM Mower Safety Practices Video

Please Send Me: VHS Format – AEM/FEMA Mower Operator Safety Video

DVD Format – AEM/FEMA Mower Operator Safety Video

Mower Operator’s Manual

AEM Mower Operator’s Safety Manual

Requester Name Phone:

Requester Address:

City

State

Zip Code

Mower Model: Serial Number:

Date Purchased: Dealer Salesperson:

Dealership Name: Dealership Location:

Mail to:

AEM Video Services

1502 E Walnut street

Seguin, TX 78155

Or Fax to:

(830) 372-9529

Or Email to:

AEMVideo@alamo-group.com

SAFETY SECTION

Safety Section 1-1

SAFETY

A 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 responsible and trained, and who know how to do so 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.

Indicates an imminently hazardous situation that, if not avoided, WILL result in DEATH OR VERY SERIOUS INJURY.

Indicates an imminently hazardous situation that, if not avoided, COULD result in DEATH OR SERIOUS INJURY.

Indicates an imminently hazardous situation that, if not avoided, MAY result in MINOR INJURY.

Identifies special instructions or procedures that, if not strictly observed, could result in damage to, or destruction of the machine, attachments or the environment.

NOTE: Identifies points of particular interest for more efficient and convenient operation or repair.

(SG-1)

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.

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)

Si no lee ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad.

(SG-3)

General Safety Instructions and Practices

SAFETY

Operator Safety Instructions and Practices

INTERSTATER 02/11 Safety Section 1-2

SAFETY

The rotating parts of this machine continue to rotate even after the PTO has been turned off. The operator should remain in the operator’s seat for 60 seconds after the brake has been set, the PTO disengaged, the tractor turned off, and all evidence of rotation has ceased.

(S3PT-10)

“Wait a minute...Save a life!”

Never crawl under a raised Implement supported solely by the Tractor 3-Point hitch. Release of the control lever or mechanical failure will result in the Implement falling and possible injury or death. Always securely block up the Implement before crawling underneath to perform repairs and service.

(S3PT-19)

Do not put hands or feet under mower decks. Blade Contact can result in serious injury or even death. Stay away until all motion has stopped and the decks are securely blocked up.

(SFL-2)

Never operate the Tractor or Implement until you have read and completely understand this Manual, the Tractor Operator’s Manual, and each of the Safety Messages found in the Manual or on the Tractor and Implement. Learn how to stop the tractor engine suddenly in an emergency. Never allow inexperienced or untrained personnel to operate the Tractor or Implement without supervision. Make sure the operator has fully read and understood the manuals prior to operation.

(SG-4)

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 that may be thrown by the equipment.

(SG-16)

PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING LOSS! Tractors with or without an Implement attached can often be noisy enough to cause permanent hearing loss. We recommend that you always wear hearing protection if the noise in the Operator’s position exceeds 80db. Noise over 85db over an extended period of time will cause severe hearing loss. Noise over 90db adjacent to the Operator over an extended period of time will cause permanent or total hearing loss. NOTE: Hearing loss from loud noise

[from tractors, chain saws, radios, and other such sources close to the ear] is cumulative over a lifetime without hope of natural recovery.

(SG-I7)

SAFETY

INTERSTATER 02/11 Safety Section 1-3

SAFETY

Always read carefully and comply fully with the manufacturer’s instructions when handling oil, solvents, cleansers, and any other chemical agent.

(SG-22)

KEEP AWAY FROM ROTATING ELEMENTS to prevent entanglement and possible serious injury or death.

(SG-24)

Never allow children to play on or around Tractor or Implement. Children can slip or fall off the Equipment and be injured or killed. Inadvertent contact with controls can cause the Implement to shift or fall crushing themselves or others.

(SG-25)

DO NOT 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)

Prolonged operation may cause operator boredom and fatigue affecting safe operation. Take scheduled work breaks to help prevent these potentially impaired operating conditions. Never operate the Implement and Tractor in a fatigued or bored mental state which impairs proper and safe operation.

(SG-32)

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 ground 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)

DO NOT operate this Implement on a Tractor that is not properly maintained. Should a mechanical or Tractor control failure occur while operating, immediately shut down the Tractor and perform repairs before resuming operation. Serious injury and possible death could occur from not maintaining this Implement and Tractor in good operating condition.

(SG-36)

SAFETY

INTERSTATER 02/11 Safety Section 1-4

SAFETY

Never leave the Tractor and Implement unattended while the Implement is in the lifted position. Accidental operation of lifting lever or a hydraulic failure may cause sudden drop of unit with injury or death by crushing. To properly park the implement when disconnecting it from the tractor, lower the stand and put the retaining pin securely in place, or put a secure support under the A-Frame. Lower the implement carefully to the ground. Do not put hands or feet under lifted components.

(S3PT-1)

Use extreme care when lowering or unfolding the implement’s wings. Make sure no bystanders are close by or underneath the wings. Allow ample clearance around the implement when folding or unfolding the wings. Use extreme caution around buildings or overhead power lines.

(S3PT-05)

This Implement may be wider than the Tractor. Be careful when operating or transporting this equipment to prevent the Implement from running into or striking sign posts, guard rails, concrete abutments or other solid objects. Such an impact could cause the Implement and Tractor to pivot violently resulting in loss of steering control, serious injury, or even death. Never allow the Implement to contact obstacles.

(S3PT-12)

There are obvious and hidden potential hazards in the operation of this Mower. REMEMBER! This machine is often operated in grass and in heavy weeds. The Blades of this Mower can throw objects if shields are not properly installed and maintained. Serious injury or even death may occur unless care is taken to insure the safety of the operator, bystanders, or passersby in the area. Do not operate this machine with anyone in the immediate area. Stop mowing if anyone is within 100 yards of the mower.

(SFL-1)

Do not operate Mower if excessive vibration exists. Shut down PTO and the Tractor engine. Inspect the Mower to determine the source of the vibration. If Mower blades are missing or damaged replace them immediately. Do not operate the mower until the blades have been replaced and the Mower operates smoothly. Operating the Mower with excessive vibration can result in component failure and broken objects to be thrown outward at very high velocities. To reduce the possibility of property damage, serious injury, or even death, never allow the Mower to be operated with blades missing.

(SFL-4)

Equipment Operation Safety Instructions and Practices

SAFETY

INTERSTATER 02/11 Safety Section 1-5

SAFETY

Flail Mowers are capable under adverse conditions of throwing objects for great distances (300 feet or more) and causing serious injury or death. Follow safety messages carefully.

STOP MOWING IF PASSERSBY ARE WITHIN 300 FEET UNLESS:

-Front and Rear Deflectors, Chain Guards, or Bands are installed and in good, workable condition;

-Mower sections or Wings are running close to and parallel to the ground without exposed Blades;

-All areas have been thoroughly inspected and all foreign material such as rocks, cans, glass, and general debris has been removed.

NOTE: Where there are grass and weeds high enough to hide debris that could be struck by the blades, the area should be: inspected and large debris removed, mowed at an intermediate height, inspected closely with any remaining debris being removed, and mowed again at desired final height. (This will also reduce power required to mow, reduce wear and tear on the Mower drivetrain, spread cut material better, eliminate streaking, and make the final cut more uniform.)

(SFL-6)

Operate this Equipment only with a Tractor equipped with an approved rollover-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)

BEFORE leaving the tractor seat lower the implement, set the parking brake and/or set the tractor transmission in parking gear, disengage the PTO, stop the engine, remove the key, and wait for all moving parts to stop. Place the tractor shift lever into a low range or parking gear to prevent the tractor from rolling. Never dismount a Tractor that is moving or while the engine is running. Operate the Tractor controls from the tractor seat only.

(SG-9)

Never allow children or other persons to ride on the Tractor or Implement. Falling off can result in serious injury or death.

(SG-10)

Never allow children to operate, ride on, or come close to the Tractor or Implement. Usually, 16-17 year-old children who are mature and responsible can operate the implement with adult supervision, if they have read and understand the Operator’s Manuals, been trained in proper operation of the tractor and Implement, and are physically large enough to reach and operate the controls easily.

(SG-11)

SAFETY

INTERSTATER 02/11 Safety Section 1-6

SAFETY

Do not mount or dismount the Tractor while the tractor is moving. Mount the Tractor only when the Tractor and all moving parts are completelystopped.

(SG-12)

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)

Do not operate this Equipment with hydraulic oil or fuel leaking. Oil and fuel are explosive and their presence could present a hazard. Do not check for leaks with your hand! High-pressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene. To check for a hose leak, SHUT the unit ENGINE OFF and remove all hydraulic pressure. Wear oil impenetrable gloves, safety glasses and use Cardboard to check for evidence of oil leaks. If you suspect a leak, REMOVE the HOSE and have it tested at a Dealer. If oil does penetrate the skin, have the injury treated immediately by a physician knowledgeable and skilled in this procedure.

(SG-15)

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

(SG-23)

Do not exceed the rated PTO speed for the Implement. Excessive PTO speeds can cause Implement driveline or blade failures resulting in serious injury or death.

(SG-26)

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)

In case of mechanical difficulty during operation, place the transmission in the park position, set the parking brake, shut down all power, including the PTO and the engine and remove the key. Wait until all rotating motion has stopped before dismounting.

(SG-39)

SAFETY

INTERSTATER 02/11 Safety Section 1-7

SAFETY

Do Not operate this equipment in areas where insects such as bees may attack you and/or cause you to lose control of the equipment. If you must enter in such areas, use a tractor with an enclosed Cab and close the windows to prevent insects from entering. If a tractor cab is not available, wear suitable clothing including head, face, and hand protection to shield you from the insects. Attacking insects can cause you to lose control of the tractor, which can result in serious injury or death to you or bystanders. Never dismount a moving tractor.

(SG-40)

Mow only in conditions where you have clear visibility in daylight or with adequate artificial lighting. Never mow in darkness or foggy conditions where you cannot clearly see at least 300 feet (90 m) in front and to the sides of the tractor and mower. Make sure that you can clearly see and identify passersby, steep slopes, ditches, drop-offs, overhead obstructions, power lines, debris and foreign objects. If you are unable to clearly see these type of items discontinue mowing.

(SGM-1)

The rotating parts of this machine have been designed and tested for rugged use. However, the blades could fail upon impact with heavy, solid objects such as metal guard rails and concrete structures. Such impact could cause the broken objects to be thrown outward at very high velocities. To reduce the possibility of property damage, serious injury, or even death, never allow the cutting blades to contact such obstacles.

(SGM-4)

Extreme care should be taken when operating near loose objects such as gravel, rocks, wire, and other debris. Inspect the area before mowing. Foreign objects should be removed from the site to prevent machine damage and/or bodily injury or even death. Any objects that cannot be removed must be clearly marked and carefully avoided by the operator. Stop mowing immediately if blades strike a foreign object. Repair all damage and make certain rotor or blade carrier is balanced before resuming mowing.

(SGM-05)

Many varied objects, such as wire, cable, rope, or chains, can become entangled in the operating parts of the mower head. These items could then swing outside the housing at greater velocities than the blades. Such a situation is extremely hazardous and could result in serious injury or even death. Inspect the cutting area for such objects before mowing. Remove any like object from the site. Never allow the cutting blades to contact such items.

(SGM-06)

Mow at the speed that you can safely operate and control the tractor and mower. The correct mowing speed depends on terrain condition and grass type, density, and height of cut. Normal ground speed range is from 2 to 5 mph(3-8 kph). Use slow mowing speeds when operating on or near steep slopes, ditches, drop-offs, overhead obstructions, power lines, or when debris and foreign objects are to be avoided.

(SGM-07)

SAFETY

INTERSTATER 02/11 Safety Section 1-8

SAFETY

Avoid mowing in reverse direction when possible. Check to make sure there are no persons behind the mower and use extreme care when mowing in reverse. Mow only at a slow ground speed where you can safely operate and control the tractor and mower. Never mow an area that you have not inspected and removed debris or foreign material.

(SGM-08)

Do not mow with two machines in the same area except with Cab tractors with the windows closed.

(SGM-11)

Follow these guidelines to reduce the risk of equipment and grass fires while operating, servicing, and repairing the Mower and Tractor:

-Equip the Tractor with a fire extinguisher in an accesible location.

-Do Not operate the Mower on a Tractor with an underframe exhaust.

-Do Not smoke or have an open flame near the Mower and Tractor.

-Do Not drive into burning debris or freshly burnt areas.

-Ensure slip clutches are properly adjusted to prevent excessive slippage and plate heating.

-Never allow clippings or debris to collect near drivelines, slip clutches, and gearboxes. Periodically shut down the Tractor and Mower and clean clippings and collected debris from the mower deck.

(SGM-12)

The Mower is designed for certain mowing applications and is rated to cut up to a specific size vegetation (see Mower Standard Equipment and Specifications). DO NOT use this mower to cut vegetation above the Mower’s rated capacity or to cut any type of nonvegetative material. Only operate this Mower on a properly sized and equipped Tractor. Operating this Mower in an application for which it is not designed and/or operating the Mower with the wrong size Tractor can cause Mower component damage and equipment failure resulting in possible serious injury or death.

(SGM-14)

Do Not attempt to raise or lower the implement wing unless the Implement tongue is securely attached to the Tractor drawbar. The Implement could tip over and cause equipment damage and possible serious injury or death. Raise or Lower the mower wing only while seated in the Tractor operator’s seat with the seat belt securely fastened.

(SRM-2)

Do not let the Blades turn when the Mower Deck is raised for any reason, including clearance or for turning. Raising the Mower deck exposes the Cutting Blades which creates a potentially serious hazard and could cause serious injury or even death from objects thrown from the Blades.

(SRM-07)

SAFETY

INTERSTATER 02/11 Safety Section 1-9

SAFETY

DO NOT allow any person under a folded wing unless wing is securely

locked up or supported. DO NOT approach the Implement unless the Tractor is turned off and all motion has ceased. Never work under the frame work, or any lifted component unless the implement is securely supported or blocked up. A sudden or inadvertent fall by any of these components could cause serious injury or even death.

(STI-03)

DO NOT use a PTO adapter to attach a non-matching Implement driveline to a Tractor PTO. Use of an adapter can double the operating speed of the Implement resulting in excessive vibration, thrown objects, and blade and implement failure. Adapter use will also change the working length of the driveline exposing unshielded driveline areas. Serious bodily injury and/or equipment failure can result from using a PTO adapter. Consult an authorized dealer for assistance if the Implement driveline does not match the Tractor PTO.

(S3PT-14)

Always shut the Tractor completely down, place the transmission in park, and set the parking brake before you or anyone else attempts to connect or disconnect the Implement and Tractor hitches.

(S3PT-15)

Never operate the Tractor and Mower if the Implement input driveline is directly connected to the Tractor transmission. Tractor braking distances can be substantially increased by the momentum of the rotating Mower blades driving the Tractor transmission even though the Tractor clutch has been disengaged. Install an over running clutch between the Tractor PTO and the Mower driveline to prevent this potentially dangerous situation.

(S3PT-16)

When attaching the Implement input driveline to the Tractor PTO, it is important that the connecting yoke spring activated locking collar slides freely and the locking balls are seated securely in the groove on the Tractor PTO shaft. Push and pull the driveline back and forth several times to ensure it is securely attached. A driveline not attached correctly to the Tractor PTO shaft could come loose and result in personal injury and damage to the Implement.

(S3PT-17)

Before operating the Implement, check to make sure the Implement input driveline will not bottom out or become disengaged. Bottoming out occurs when the inner shaft penetrates the outer housing until the assembly becomes solid-it can shorten no more. Bottoming out can cause serious damage to the Tractor PTO by pushing the PTO into the Tractor and through the support bearings or downward onto the PTO shaft, breaking it off. A broken driveline can cause personal injury.

(S3PT-18)

Each Rear Wheel must have a minimum of 1,000 pounds contact with the surface to prevent lateral instability and possible tip-over which could result in serious bodily injury or even death. Widen the wheel tread and add weights if needed. Refer to the mounting instructions or call customer service if you need assistance with counterweight procedure.

(SFL-3)

Connecting or Disconnecting Implement Safety Instructions and Practices

SAFETY

INTERSTATER 02/11 Safety Section 1-10

Transporting Safety Instructions and Practices

On a fully-assembled unit, do not remove the Wing Retaining Strap until hoses are attached to the tractor and the Wing Cylinders are filled with oil. Lower the Wings slowly and carefully. Keep bystanders away during operations.

(STI-05)

Be particularly careful when transporting the Implement with the Tractor. Turn curves or go up hills only at a low speed and using a gradual steering angle. Rear mounted implements move the center of gravity to the rear and remove weight from the front wheels. Make certain, by adding front ballast, that at least 20% of the tractor’s weight is on the front wheels to prevent rearing up, loss of steering control or Tractor tip-over. Slow down on rough or uneven surfaces to prevent loss of steering control which could result in property damage or possible injury. Do not transport unless 3-Point lift lever is fully raised and in the latched transport position. Dropping implement in transport can cause serious damage to the tractor and/or Implement and possibly cause the operator or others to be injured or killed.

(S3PT-02)

Allow sufficient clearance for the Implement to swing outward while turning. Implements carried behind the Tractor will swing outside the tire path when making turns. Contacting a solid object while turning will cause equipment damage and possible injury.

(S3PT-20)

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.

(SG-6)

SAFETY

INTERSTATER 02/11 Safety Section 1-11

SAFETY

Transport only at speeds where you can maintain control of the

equipment. Serious accidents and injuries can result from operating this equipment at high speeds. Understand the Tractor and Implement and how it handles before transporting on streets and highways. Make sure the Tractor steering and brakes are in good condition and operate properly.

Before transporting the Tractor and Implement, determine the proper transport speeds for you and the equipment. Make sure you abide by the following rules:

Test the tractor at a slow speed and increase the speed slowly. Apply the Brakes smoothly to determine the stopping characteristics of the Tractor and Implement. As you increase the speed of the Tractor the stopping distance increases. Determine the maximum transport speed not to exceed 20 mph (30 kph) for transporting this equipment.

Test the equipment at a slow speed in turns. Increase the speed through the turn only after you determine that the equipment can be operated at a higher speed. Use extreme care and reduce your speed when turning sharply to prevent the tractor and implement from turning over. Determine the maximum turning speed for you and this equipment before operating on roads or uneven ground.

Only transport the Tractor and Implement at the speeds which allow you to properly control the equipment.

Be aware of the operating conditions. Do not operate the Tractor with weak or faulty brakes or worn tires. When operating down a hill or on wet or rain slick roads, the braking distance increases: use extreme care and reduce your speed. When operating in traffic always use the Tractor’s flashing warning lights and reduce your speed. Be aware of traffic around you and watch out for the other guy.

(SG-19)

When the Wings are folded for transport, the center of gravity is raised and the possibility of overturn is increased. Drive slowly and use extreme caution when turning on hillsides. Overturning the Implement could cause the Implement to overturn the Tractor and vice versa resulting in serious injury or even death. Never fold wings on a hillside...the Implement or unit may overturn.

(STI-02)

Only tow the Implement behind a properly sized and equipped Tractor which exceeds the weight of the Implement by at least 20%. DO NOT tow the Implement behind a truck or other type of vehicle. Never tow the Implement and another Implement connected in tandem. Never tow the Implement at speeds over 20 MPH.

(STI-06)

Secure the Implement for transport before traveling on public roads. For pull-type Implements, secure the center axle using cylinder stops or transport pin and properly attach a safety chain between the Implement and Tractor. Secure wings in upright position on folding Implements using wing transport locks.

(STI-7)

SAFETY

Maintenance and Service Safety Instructions and Practices

INTERSTATER 02/11 Safety Section 1-12

SAFETY

Make sure the PTO shield, integral driveline shields, and input shields are installed when using PTO-driven equipment. Always replace any shield if it is damaged or missing.

(S3PT-8)

Relieve hydraulic pressure prior to doing any maintenance or repair work on the Implement. Place the Implement on the ground or securely blocked up, disengage the PTO, and turn off the tractor engine. Push and pull the Remote Cylinder lever in and out several times prior to starting any maintenance or repair work.

(S3PT-09)

Always disconnect the main PTO Driveline from the Tractor before performing service on the Implement. Never work on the Implement with the tractor PTO driveline connected and running. Rotating Parts, Blades or Drivelines could turn without warning and cause immediate entanglement, injury or death.

(S3PT-11)

All Safety Shields, Guards and Safety devices including (but not limited to) - the Deflectors, 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.

(SFL-5)

Always maintain the safety signs in good readable condition. If the safety signs are missing, damaged, or unreadable, obtain and install replacement safety signs immediately.

(SG-5)

Do not modify or alter this Implement. Do not permit anyone to modify or alter this Implement, any of its components or any Implement function.

(SG-8)

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)

Never attempt to lubricate, adjust, or remove material from the Implement while it is in motion or while tractor engine is running.

(SG-20)

SAFETY

INTERSTATER 02/11 Safety Section 1-13

SAFETY

Periodically inspect all moving parts for wear and replace when necessary with authorized service parts. Look for loose fasteners, worn or broken parts, and leaky or loose fittings. Make sure all pins have cotter pins and washers. Serious injury may occur from not maintaining this machine in good working order.

(SG-21)

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)

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)

Replace bent or broken blades with new blades. NEVER ATTEMPT TO STRAIGHTEN, WELD, OR WELD HARDFACING ON BLADES SINCE THIS WILL LIKELY CRACK OR OTHERWISE DAMAGE THE BLADE WITH SUBSEQUENT FAILURE AND POSSIBLY CAUSE SERIOUS INJURY FROM THROWN BLADES.

(SGM-10)

DO NOT weld or repair rotating mower components. Welds and other repairs may cause

severe vibration and/or component failure resulting in part being thrown from the mower

causing serious bodily injury. See your Authorized Dealer for proper repairs.

(SGM-13)

PARTS IN F O RM ATION Alamo Industrial mowers use balanced and matched system components for blade carriers, blades, cuttershafts, knives, knife hangers, rollers, drivetrain components, and bearings. These parts are made and tested to Alamo Industrial specifications. Non-genuine "will fit" parts do not consistently meet these specifications. The use of “will fit” parts may reduce mower performance, void mower warranties, and present a safety hazard. Use genuine Alamo Industrial mower parts for economy and safety.

(SPAM-1)

SEE YOUR ALAMO DEALER

SAFETY

INTERSTATER 02/11 Safety Section 1-14

SAFETY

Always disconnect the main PTO Driveline from the Tractor before performing service on the Mower. Never work on the Mower with the tractor PTO driveline connected and running. Blades or Drivelines could turn without warning and cause immediate

entanglement, injury or death.

(SRM-3)

Always disconnect the main PTO Driveline from the Tractor before performing service on the Mower. Never work on the Mower with the tractor PTO driveline connected and running. Blades or Drivelines could turn without warning and cause immediate

entanglement, injury or death.

(SRM-3)

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)

In addition to the design and configuration of this Implement, including Safety Signs and Safety Equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the machine. Refer also to Safety Messages and operation instruction in each of the appropriate sections of the Tractor and Equipment Manuals. Pay close attention to the Safety Signs affixed to the Tractor and Equipment.

(SG-18)

Concluding Safety Instructions and Practices

SAFETY

INTERSTATER 02/11 Safety Section 1-15

SAFETY

Decal Location

NOTE: Alamo Industrial supplies safety decals on this product to promote safe operation. Damage to the

decals may occur while in shipping, use, or reconditioning. Alamo Industrial cares about the safety of its customers, operators, and bystanders, and will replace the safety decals on this product in the field, free of charge (Some shipping and handling charges may apply). Contact your Alamo Industrial dealer to order replacement decals.

SAFETY

INTERSTATER 02/11 Safety Section 1-16

SAFETY

ITEM PART NO. QTY LEVEL DESCRIPTION

1. 002369 4 DANGER Multiple-Hazard

2. 02988385 6 LOGO Terrain King Logo

3. 1458393 4 REFLECTR Yellow Reflector Decal

4. 02925100 3 INSTRUC Genuine Terrain King Parts

5. 002425 3 DANGER Cutting & Entanglement Hazard

6. 02967668 3 DANGER Thrown Object Keep Away

7. 02965262 3 DANGER Oil Penetration, Leaks

8. 00758194 4 WARNING Belt/Pulley Pinch Point

9. 000678 3 INSTRUC Grease Fitting Inside

10. 02962765 2 DANGER Crushing From Folding Hazard

11. 03200285 1 CAUTION Slipping on Step Hazard

12. 1 SERIAL # Serial Number

13. 000108 3 INSTRUC Flail Operation

14. 02990257 2 LOGO Terrain Master Logo

15. 001829 2 INSTRUC Wing Lube Chart

16. 002023 3 INSTRUC Cutting Height Adjustment

17. 1458392 4 REFLECTR Red Reflector Decal

18. 00725739 3 WARNING Flail Shield Missing

19. 00763977 2 INSTRUC Notice to Owner

20. 00725746 1 PELIGRO Translate in Spanish

21. 001830 1 INSTRUC Rear Unit Lube Chart

22. 00756494 1 DANGER Driveline Hazards

23. 00773723 1 PELIGRO Driveline Manual Spanish

24. D103 1 WARNING Operate at 540 RPM

25. 02966305 1 INSTRUC Hyd Oil and Type

26. 02971123 1 WARNING Pressurized Tank

27. 03200347 * REFLECTR SMV Reflector

28. 1 LOGO Flail King Logo

29. 00756004 1 DANGER Shield Missing Do Not Operate

30. 00756005 1 DANGER Keep Away Rotating Driveline

31. 00753840 2 DANGER Wing Falling

32. 03200328 1 DANGER Transport with Lever in Detent

33. 001412 1 INSTRUC Valve Lever Operating Plate1

34. 00776031 1 Canister (Operator’s Manual)

35. 803213C 1 Terrain Master Operators Manual

36. 10058000 4 Bolt

37. 00017000 4 Lock washer

38. 0024100 4 Flatwasher

39. 001660 2 LOGO Interstater

40. 02979544 2 LOGO Alamo Industrial

41. 00757139 1 LOGO Alamo Industrial

SAFETY

INTERSTATER 02/11 Safety Section 1-17

Decal Description

Danger! Mult-Hazard Warning. Failing to follow these Safety Messages and Operating Instructions can cause serious bodily injury or even death to operator and others in the area.

P/N 30000002369

SAFETY

INTERSTATER 02/11 Safety Section 1-18

SAFETY

Name LOGO - Alamo Industrial

P/N 02979546

Amber Reflector. Keep reflectors clean and visible.

P/N 30001458393

IMPORTANT - Use only Genuine Terrain King replacement parts.

P/N 30002925100

DANGER! Keep Away! If front deflector shield is removed from flail housing, serious injury to or amputation of hands, feet, or limbs may occur from blades contact. Always make sure that all shields are in place at all times.

P/N 30000002425

SAFETY

INTERSTATER 02/11 Safety Section 1-19

SAFETY

DANGER! - Keep Away - Thrown Objects. Inspect area before mowing. Do not let rotating blades contact solid objects. Operate only if all Guards Deflectors are in place. Do not operate with Mower or Wing raised off the ground. Stop mowing if Passerby enter the area. Stay away from rotating blades. Keep hands and feet away from rotating blades. Do not approach mower until all movement has stopped.

P/N 30002967668

WARNING! Failure to INSPECT and REPAIR or REPLACE Hoses may allow worn Hoses to rupture SUDDENLY and VIOLENTLY with resulting serious BODILY INJURY from SCALDING or FIRE with resulting BURN INJURY or DEATH.

P/N 30002965262

WARNING! Do not operate with Belt Shield removed. Finger(s) may be pinched off if get caught between V-Belt and Pulley.

P/N 30000758194

Information that Grease Fitting is present and must apply grease.

P/N 30000000678

SAFETY

INTERSTATER 02/11 Safety Section 1-20

SAFETY

DANGER! Crushing and Pinch Points. Moving machinery parts can pinch or crush or fallwhich may cause injury or death.

P/N 30002962765

CAUTION! Watch your step.

P/N 30003200285

Instructions to properly lubricate and check mower for potential problems prior to operation.

P/N 30000000108

ALAMO INDUSTRIAL LOGO

P/N 001651

SAFETY

INTERSTATER 02/11 Safety Section 1-21

SAFETY

INFORMATION - 8 Hour Lubrication Chart

P/N 30000001829

Cutting Height Adjustment Chart

P/N 30000002023

Red Reflector. Keep reflectors clean and visible.

P/N 30001458392

WARNING! Failure to use and maintain shields and deflectors in good condition may lead to injury or death from entanglement with rotating parts, being hit by objects thrown with great force by blades, or by blade contact.

P/N 30000725739

SAFETY

INTERSTATER 02/11 Safety Section 1-22

SAFETY

Operator's Manual (with repair parts) and warranty was attached to this implement during final inspection.

P/N 30000763977

Peligro Translation, If you do not know how to read English, please find someone who knows how to read English.

P/N 30000725746

INFORMATION - 8 Hour Lubrication Chart

P/N 30000001830

DANGER! Make certain that drivelines are correct length and are securely attached.

P/N 30000756494

SAFETY

INTERSTATER 02/11 Safety Section 1-23

SAFETY

PELIGRO! Spanish Translation for Driveline Safety

P/N 30000773723

WARNING! Avoid Bodily Injury, Use 540RPM PTO Speed Only.

P/N 3000000D103

INFORMATION - Attention - Service Hydraulic System with Universal Tractor Hydraulic Oil. Alamo Group part Number 30002966307.

30002966305

WARNING! Pressurized Tank - Slowly open cap to relieve pressure before completely removing cap. Stay clear to prevent being scalded with hot oil which may cause serious injury to eyes, face and exposed skin.

P/N 30002971123

SAFETY

INTERSTATER 02/11 Safety Section 1-24

SAFETY

ALAMO NAME LOGO.

P/N 001650

Slow Moving Vehicle Decal. Keep SMV reflector clean and visible. DO NOT transport or operate without the SMV.

P/N 30003200347

DANGER! Guard Missing, Do Not Operate. If you see this decal, Do Not Operate the mower until the shield has been replaced.

P/N 30000756004

DANGER! Rotating Driveline Keep Away, Contact can cause death.

P/N 30000756005

SAFETY

INTERSTATER 02/11 Safety Section 1-25

SAFETY

DANGER! Stay clear when lowering or raising wings.

P/N 30000753840

DANGER! - Transport with Lever in Neutral Position to prevent inadvertent unfolding.

P/N 30003200328

Cylinder Controls for Lift and Tilt.

30000001412

Read Operator’s Manual! The operator’s manual is located inside this canister. If the manual is missing order one from your dealer.

P/N 30000776031

SAFETY

INTERSTATER 02/11 Safety Section 1-26

SAFETY

INTERSTATER NAME LOGO.

P/N 001660

Name LOGO - Alamo Industrial

P/N 02979544

Name LOGO - Alamo Industrial

P/N 00757139

SAFETY

INTERSTATER 02/11 Safety Section 1-27

SAFETY

Federal Laws and Regulations

This section is intended to explain in broad terms the concept and effect of federal laws and regulations concerning employer and employee equipment operators. This section is not intended as a legal interpretation of the law and should not be considered as such.

Employer-Employee Operator Regulations

U.S. Public Law 91-596 (The Williams-Steiger Occupational and Health Act of 1970) OSHA

This Act Seeks:

“...to assure so far as possible every working man and woman in the nation safe and healthful working conditions and to preserve our human resources...”

DUTIES

Sec. 5 (a) Each employer(1) shall furnish to each of his employees employment and a place of employment which are free from

recognized hazards that are causing or are likely to cause death or serious physical harm to his employees; (2) shall comply with occupational safety and health standards promulgated under this Act. (b) Each employee shall comply with occupational safety and health standards and all rules, regulations and

orders issued pursuant to this Act which are applicable to his own actions and conduct.

OSHA Training Requirements

Title 29, Code of Federal Regulations Part 1928.57(a)(6). www.osha.gov Operator instructions. At the time of initial assignment and at least annually thereafter, the employer shall

instruct every employee who operates an agricultural tractor and implements in the safe operating practices and servicing of equipment with which they are or will be involved, and of any other practices dictated by the work environment.

Keep all guards in place when the machine is in operation; Permit no riders on equipment Stop engine, disconnect the power source, and wait for all machine movement to stop before servicing,

adjusting, cleaning or unclogging the equipment, except where the machine must be running to be properly serviced or maintained, in which case the employer shall instruct employees as to all steps and procedures which are necessary to safely service or maintain the equipment.

Make sure everyone is clear of machinery before starting the engine, engaging power, or operating the machine.

Employer Responsibilities:

To ensure employee safety during Tractor and Implement operation, it is the employer’s responsibility to:

1. Train the employee in the proper and safe operation of the Tractor and Implement.

2. Require that the employee read and fully understand the Tractor and Implement Operator’s manual.

3. Permit only qualified and properly trained employees to operate the Tractor and Implement.

4. Maintain the Tractor and Implement in a safe operational condition and maintain all shields and guards on the equipment.

5. Ensure the Tractor is equipped with a functional ROPS and seat belt and require that the employee operator securely fasten the safety belt and operate with the ROPS in the raised position at all times.

6. Forbid the employee operator to carry additional riders on the Tractor or Implement.

7. Provide the required tools to maintain the Tractor and Implement in a good safe working condition and provide the necessary support devices to secure the equipment safely while performing repairs and service.

8. Require that the employee operator stop operation if bystanders or passersby come within 300 feet.

Child Labor Under 16 Years of Age

Some regulations specify that no one under the age of 16 may operate power machinery. It is your responsibility to know what these regulations are in your own area or situation. (Refer to U.S. Dept. of Labor, Employment Standard Administration, Wage & Home Division, Child Labor Bulletin #102.)

SAFETY

INTERSTATER 02/11 Safety Section 1-28

INTRODUCTION SECTION

Introduction Section 2-1

INTRODUCTION

This Flail Mower is designed with care and built with quality materials by skilled workers. Proper assembly, maintenance, and operating practices, as described in this manual, will help the owner/operator get years of satisfactory service from the machine.

The purpose of this manual is to familiarize, instruct, and train. The Assembly Section instructs the owner/ operator in the correct assembly of the Mower using standard and optional equipment. The Parts Manual is designed to familiarize the owner/operator with replaceable parts on the Mower and is provided also. This section provides exploded assembly drawings of each mower component illustrating each piece and the corresponding part number.

Careful use and timely service saves extensive repairs and costly downtime losses. The Operation and Maintenance Sections of the manual train the owner/operator how to work the Mower correctly and attend to appropriate maintenance. The Trouble Shooting Guide helps diagnose difficulties with mower and offers solution to the problems.

Safety is of primary importance to the owner/operator and to the manufacturer. 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. Many of the Safety Messages will be repeated throughout the manual. The owner/operator/dealer

INTRODUCTION

should know these Safety Messages before assembly and be aware of the hazards of operating this mower during assembly, use, and maintenance. The Safety Alert Symbol combined with a Signal Word, as seen below, is intended to warn the owner/operator of impending hazards and the degree of possible injury faced when operating this machine.

Indicates an imminently hazardous situation that, if not avoided, WILL result in DEATH OR VERY SERIOUS INJURY.

Indicates an imminently hazardous situation that, if not avoided, COULD result in DEATH OR SERIOUS INJURY.

Indicates an imminently hazardous situation that, if not avoided, MAY result in MINOR INJURY.

Identifies special instructions or procedures that, if not strictly observed, could result in damage to, or destruction of the machine, attachments or the environment.

INTERSTATER 02/11 Introduction Section 2-2

INTRODUCTION

The Interstater is a revolutionary mowing system. Utilizing 2 side wings and 1 rear, you have ability to mow up to 20’ across in on swath. Perfect for large areas of mowing including interstate highways and airport fields. A productive way to get a manicured cut in spaces there is high public visibility.

Unique in-frame cooling system maintains the proper oil temperature while providing constant power flow.

Strong top decks make with 10-gauge steel and end plates that are 1/2” thick for the inboard and 5/16” thick steel for the outboard.

Smart front mount hydraulic pump that drives power from the crankshaft of tractor, while twin piston pumps provide the power for the wing mowing units.

Knife Variety - An array of cutting knife options allows you to tailor the finished appearance to meet your needs.

Cutting Capacity: 1” diameter grass and weeds.

Wing Cutting Widths:

20’ 9” Interstater, 88” Rear Flail, 88” Left and Right Wings

18’ 5” Interstater, 88” Rear Flail, 74” Left and Right Wings

16’ 5” Interstater, 88” Rear Flail, 60” Left and Right Wings

13’ 2” Single-Side Interstater, 88” Rear Flail and 88” Right Wing

12’ 2” Single-Side Interstater, 88” Rear Flail and 74” Right Wing

INTERSTATER 02/11 Introduction Section 2-3

INTRODUCTION

Attention Owner/Operator

BEFORE OPERATING THIS MACHINE:

1. Carefully read the Operator’s Manual, completely understand the Safety Messages and instructions, and know how to operate correctly both the tractor and implement.

2. Fill out the Warranty Card in full. Be sure to answer all questions, including the Serial Number of the implement. Mail within 30 days of delivery date of this implement.

NOTE: Warranties are honored only if completed “Owner Registration and Warranty” forms are received by Alamo Group within thirty days of delivery of the implement.

3. Record the Model and Serial Numbers on the Warranty page at the front of the Operator’s Manual. Keep this as part of the permanent maintenance file for the implement.

INTRODUCTION

INTERSTATER 02/11 Introduction Section 2-4

ASSEMBLY SECTION

Assembly Section 3-1

ASSEMBLY

GENERAL INSTRUCTIONS

To assemble your new INTERSTATER and mount it to your tractor we assist you with drawings, instructions and information, also about experiences of others and when needed just get some information or clarification from our engineering department over the phone.

These instructions are general information and not specifically for your tractor, but in connection with our drawings, they might offer your some valuable assistance.

This section covers the installation procedure of an Alamo Group Interstater mower kit, and includes parts lists for framework, hoses, and miscellaneous parts to be attached to your tractor.

These instructions are for mounting the center mower, right side mower, and left side mower units. For mounting one mower side only, disregard information concerning the opposite side. Hardware quantities shown are for both sides.

1. The hydraulic system must be kept “SURGICALLY CLEAN” to ensure proper operation and long life of the pumps, motors, and valves. All components have protective caps over openings connected to internal spaces to prevent contamination. It is important that care be taken during unpacking, assembly, and other contaminants which will damage parts.

2. After the drive belts are installed, DO NOT start the tractor unless the hydraulic system is filled with

ASSEMBLY

hydraulic oil. Running without oil will damage the pumps.

3. Check the oil level in the reservoir before start-up.

4. Care should be taken when filling the reservoir to prevent contamination of the hydraulic system. Always use new hydraulic fluid when filling the system. USE ONLY TRACTOR HYDRAULIC OIL IN THE HYDRAULIC SYSTEM.Reference to the left or right side of the Interstater is determined while facing the front of the tractor from the drivers seat.

Reference to the left or right side of the Interstater is determined while facing the front of the tractor from the drivers seat.

Assemble the Interstater, step by step, as illustrated on the pages of this section. Small parts (bolts, nuts, etc.) required are packed in numbered plastic bags which correspond to assembly procedures and illustrations in the manual.

The part quantities listed for an illustration pertain only to that phase of assembly. The quantity given corresponds to the number of parts needed. When assembling a single-sided model based on a dual-sided model, the quantity furnished will usually be half the quantity listed.

Large parts are not always listed next to an illustration because they are usually easy to identify.

Whenever reference is made to parts, listed for an illustration or elsewhere in this manual, the following abbreviations are used:

HHCS - hex head capscrew RH - right hand NF - national fine LW - lock washer LH - left MA - mechanical assembly PW- plain washer NC - national coarse WA - welded assembly When installing fasteners, PW and LW (generally installed in that order) are usually on the side of the fixture or

part being fastened that the hex/lock nut is on. When only HHCS, LW and/or PW are required, they are generally installed in that order. Some parts do not require a PW or LW. Refer to illustrations for exceptions. Fasteners should be installed so they cause the least interference with other parts. When securing driveshaft pulley to hub, tighten fasteners to 9 lb-ft torque.

This manual makes reference to individual component parts, some of which may have been pre assembled at the factory.

INTERSTATER 02/11 Assembly Section 3-2

ASSEMBLY

PRELIMINARY TRACTOR PREPARATION

Depending on the make and model of tractor the INTERSTATER is to be mounted on, certain modifications will be illustrated. In some cases special accessory components for the tractor will be required before assembling the INTERSTATER. In these cases, specific mention will be made to the manufacturer, part number and description of required accessory component.

If so equipped, remove drawbar from rear of tractor. In most cases, the main frame rear pad is attached under the rear axle.

If so equipped, remove all objects from exterior of cab (lights, hand rails, etc.) which may interfere with mowers when placed in the transport position. Remove all objects from right front interior of cab structure which may interfere with mounting and operation of sectional control valve.

If so equipped, remove foot step from each side of tractor to which a mower will be mounted.

Front tractor wheels may require a wider adjustment to clear hydraulic tank and tank mounting frame.

SPECIAL TOOLS

Special tools, for installing and servicing INTERSTATER kits, are illustrated on the below. Drawings for these tools are available on request. If desired, tools may be obtained from Alamo on a made to order basis. Prices will be furnished on request. ASM-FL-0001

ASSEMBLY

ITEM PART NO. CODE DESCRIPTION 1 701628 S Lift Frame Assembly Suspension Chain 2 701627 A Cuttershaft Bearing Puller 3 104764 A Lift Frame Alignment Pin (2) 4 104768 A Rubber bushing Support Base 5 104767 A Rubber Bushing Compression Ring 6 104765 A Rubber Bushing Expander (Ford and Kubota Tractors) 7 104766 A Rubber Bushing Expander (I.H.,Massey-Ferguson and Case Tractors) 8 104769 A Driveshaft Installation Collar 9 1047770 A Rubber Bushing Installation Plug 10 103741 A Seal Installation and Setting Tool

- 000802 S Hydraulic Pressure Gauge, 3000 PSI

A - Denotes Special Tools designed by Alamo S - Denotes Standard Tools or Equipment available on the market

INTERSTATER 02/11 Assembly Section 3-3

ASSEMBLY

DRIVE COUPLING ATTACHMENT

Assemble the front coupling to the engine crankshaft pulley using the hardware supplied with the coupling. Due to the variations in the tractor models, it may be necessary to remove some of the sheet metal to facilitate mounting of the coupling.

ASM-FL-0002.

ASSEMBLY

HYDRAULIC TANK, SUPPORTS AND MAINFRAME ATTACHMENT

1. Attach the left hydraulic tank support and step weldment to the tractor with (4) bolts provided in your Mount Kit. Refer to your particular Tractor Installation Drawing for part numbers and quantities. ASM-FL-0003

2. Attach the right hydraulic tank support to the tractor with (4) bolts provided in your Mount Kit. Refer to your particular Tractor Installation Drawing for part numbers and quantities. ASM-FL-0004

3. To make assembly easier, the hard plumbing assembly should be installed on the Mainframe before the Mainframe is installed. Use (2) 1/2” x 1-1/2” bolts, (2) 1/2" Flatwashers, and (2) 1/2" Locknuts. Metal tubing on assembly will need to be loosened to install bolts.

4. Position the mainframe under the tractor. Lift the front of the frame and install the top two 5/8” x 2" bolts. Install a 5/8" flatwasher and a 5/8" locknut on the bolts and tighten enough to hold the frame in place.

ASM-FL-0005

INTERSTATER 02/11 Assembly Section 3-4

ASSEMBLY

5. Lift the rear of the frame and secure with (4) 1/2" x 1 1/2" & (2) 5/8" x 1/3/4" bolts. Install the remaining front hardware. ASM-FL-0006

MOUNTING AND PUMP ASSEMBLY

1. Before mounting tank, attach pipe manifold for return lines to the return filter assembly.

2. Raise bumper with a forklift or hoist and lower onto hydraulic tank supports. Attach the bumper to the tank supports with (4) 1/2” x 2" bolts and (4) 1/2" locknuts. ASM-FL-0007

3. Now tighten all hardware for mainframe, tank support, tank, and bumper.

ASSEMBLY

LIFT CYLINDER FRAME ATTACHMENT

Position the right and left lift cylinder supports and loosely install the (6) 3/4" x 2-1/4" bolts and (6) 3/4"

locknuts to each side. Pull the supports outward and downward to remove the slack, then tighten the hardware. ASM-FL-0008

NOTE: On some applications Cylinder Support will have an extra set of holes. Refer to Installation Drawing for correct mounting.

INTERSTATER 02/11 Assembly Section 3-5

ASSEMBLY

Raise the left lift frame with the hydraulic jack and align frame with ears on main frame. ASM-FL-0009. Insert the upper pivot pins with the lift frame ears on the outside of the mainframe ears. Secure the pins with the (2) 3/ 8"x3/4" NF bolts and (2) 3/8" lockwashers. NOTE: Use Locktight for right side.

R

on bolts. ASM-FL-0010. Repeat procedure

ASSEMBLY

Mount the tilt and lift cylinders. The lift cylinder has a 3" bore diameter and the tilt cylinder has a 3-1/2" bore diameter. Be sure to remove the port caps before extending the cylinders. Attach with (2) cylinder pins and (2) 3/16" x 1-1/2" cotter pins to each side. ASM-FL-0011.

NOTE: Mount cylinder so that hose connections do not interfere when wings are raised and lowered.

For tractors equipped with a cab, a collar may need to be installed on the lift cylinder rod for proper alignment of the transport lock. Remove the cylinder end and the locking collar. Install the extra collar onto the rod and reassemble. ASM-FL-0011.

MOUNTING WING MOWERS

Assemble Skid Shoes on Cutter before mounting the head. With the cutter housing tipped up, attach

housing shoes/wear plate. Carriage bolt attaches to front mounting hole; plow bolts attach to middle and rear holes. ASM-FL-0012

Position the cutter unit so that the outer pivots can be assembled over the pivot pins. Attach the front outer pivot to the lift frame using (4) 5/8 x 2-1/2 bolts and (4) 5/8 locknuts.

Attach switch assembly and rear outer pivot to the lift frame using (2) 5/8 x 3-1/2 bolts and (2) 5/8 locknuts. Install spacer (P/N 107242) between switch assembly and lift arm. ASM-FL-0013

Attach magnet assembly to picot pin using bolts and lockwashers provided. ASM-FL-0014.

INTERSTATER 02/11 Assembly Section 3-6

ASSEMBLY

Right Wing

If it is necessary to loosen the nut on the pivot pin. Re-torque the nut to 400 ft labs. Failure to do so will cause the nut to loosen during use, allowing the pin to come out, thereby causing certain machine damage.

Remove belt guard. Assemble the rod end of the tilt cylinder. Use the pin located in the ears on the end of the housing and secure with the cotter pins. Reinstall belt guard.

ASSEMBLY

Attach the air breather (Item 1) to the hydraulic tank. ASM-FL-0015

Insert driveshaft through the pump mount weldment until it slides into the crank shaft pulley coupling. When using auxiliary hydraulic pump, place the pump drive belt around driveshaft. Place splined pulley weldment on the driveshaft. ASM-FL-0016

NOTE: All splines on driveshaft and pump should have anti-seize applied.

INTERSTATER 02/11 Assembly Section 3-7

ASSEMBLY

Attach the hydraulic pump assemblies to the pump mount plate with (2) 1/2”x1-1/2” Grade 8 bolts and (2) 1/2” lockwashers. ASM-FL-0017

Attach pivot plate to pump mount weldment with (2) 1/2”x1-1/2” bolts, (2) 1/2” flatwashers and (2) 1/2” locknuts. Wrap belt around pulleys, adjust tension and tighten all bolts securely. ASM-FL-0018.

ASSEMBLY

ELECTRICAL WIRING INSTALLATION

To prevent any damage to electrical system during wiring procedures, temporarily remove the negative lead (ground) from battery terminal. Asm-R-0018

Remove ignition switch access panel or ignition switch if panels are not provided in dash. Identify the “IgnitionStart” wire and the “Ignition-Accessory” wire. ASM-FL-0019

INTERSTATER 02/11 Assembly Section 3-8

ASSEMBLY

Using the wire identified as “Ignition-Start” leading from ignition switch to starter solenoid, cut wire approximately 3” from ignition switch. Using the internal and external bullet connectors provided, install the “Line-connector” (internal) onto wire at ignition switch which is 3” long. Install the “Bullet-Terminal” (external) onto the wire leading to starter solenoid.

ASSEMBLY

ELECTRICAL CIRCUIT

Using ASM-FL-20-22 as a guide, install electrical components and wiring.

Wires from the safety switch must be routed close to cutter housing sidesheet and lift frame pivot points. This will prevent wires from being stretched and broken when cutter housing is raised or lowered to maximum positions.

NOTE: Route wires in such a manner to prevent interference with the operation of tractor or INTERSTATER. Ensure that wires DO NOT lay against anything which could wear through insulation and cause a short circuit.

After connecting all wires, wrap wires with flexguard tubing. Neatly gather hydraulic hoses and flexguard tubing and strap together using plastic ties.

NOTE: Be sure to install connector so that larger brown wires are located on bottom poles of switch. This applies to Dual Wing and Single Wing applications.

INTERSTATER 02/11 Assembly Section 3-9

ASSEMBLY

INTERSTATER 02/11 Assembly Section 3-10

ASSEMBLY

CONTROL VALVE

Attach valve stand to the top of the right lift cylinder support with (3) 1/2” x 1-1/2” bolts, and (3) 1/2” locknuts.

ASM-FL-0024

Attach valve stand to the valve mount bracket with (2) 3/8”x1-1/4” bolts and (2) 3/8” locknuts. ASM-FL-0025

Attach control valve to the valve stand with (2) 3/8”x1” bolts, (2) 3/8” locknuts. Attach the top cover and the bottom cover to the valve mount bracket with (8) 3/8”x1” bolts, (8) 3/8” washers and (8) locknuts. ASM-FL-

0026

.

ASSEMBLY

INTERSTATER 02/11 Assembly Section 3-11

ASSEMBLY

HYDRAULICS

Refer the Tractor Manual when connecting hydraulic hoses to the tractor hydraulic system. Not only does the installation procedure vary from tractor to tractor, but numerous precautions should be taken due to the possibility of a pressure buildup within the hydraulic circuit. Relieve the pressure before opening or entering the circuit. FLUID ESCAPING UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SERIOUS INJURY. Ensure that hose fittings are secure before pressurizing the hydraulic systems.

Once pumps and belts are installed, DO NOT start the tractor (which will turn pumps) unless both power circuits are filled with the specified hydraulic fluid. Running pumps without oil will cause non-warrantable damage.

It is important that pipe thread sealant be used only on solid connections of pipe thread; never on connections between swivel fittings and solid male pipe threads or on straight thread "O" ring fittings. Use the pipe thread sealant supplied. Do not substitute with some other type of sealant, i.e., teflon tape, paint, shellac, etc.

Hoses supplied have two types of fittings; solid or swivel. Some hoses have solid fittings on both ends; others

ASSEMBLY

have a solid fitting and a swivel fitting. Hoses with two solid fittings will fit into either a female solid thread, or a swivel adapter union. When installing either type hose, solid fittings must be installed first, then install the swivel end of the hose.

The INTERSTATER hydraulic system incorporates three basic types of hydraulic fittings:

a. Standard pipe (NPT or NPTF) thread fittings. This type requires a small amount of evenly-applied sealant.

b. Swivel fittings. This type does not require any sealant on the swivel end because it seals against an internal flare.

c. “O” Ring fittings. This type does not require any sealant on the “O” Ring end of the fitting.

It is extremely important to avoid getting pipe thread sealant inside the fittings or hoses. KEEP THE INTERIOR OF ALL HYDRAULIC COMPONENTS SURGICALLY CLEAN. Inspect the inside diameter of each hose before assembly. Ensure that no obstruction is present. Dirt, sand, dust, etc., are abrasive and once in the system can cause immediate or early failure.

POWER CIRCUIT

Using the following drawing and your installation drawing as a guide to install the hydraulic hoses and fittings for the power circuit. The power circuit drives the Interstater wing cutter units. The control circuit (for lift and tilt) will be assembled later.

NOTE: Do not strap hoses together until all hoses and wiring are connected. Hoses and wiring should be routed so they do not lay on moving parts, too close to sharp edges, or near excessive heat.

INTERSTATER 02/11 Assembly Section 3-12

ASSEMBLY

1. Attach the two Pump Case Drain hoses p/n

001788 (Item 1 and 2) from the Hydraulic Pump to the Hydraulic Tank. ASM-FL-0029

2. Attach the two Suction hoses p/n 001783

(Items 3 and 4) from the Hydraulic Pump to the vertical suction tubes on the hydraulic tank. ASM-FL-0029 Fit hoses and cut to length so that there is no kink after they are installed.

3. Attach the left wing pressure hose (Item 1) to

the first Hydraulic Pump. ASM-FL-0030

4. Attach the right wing pressure hose (Item 2) to

the second Hydraulic Pump. ASM-0030

5. Slide the Protective Sleeving (Item 3) over

these hoses. ASM-FL-0030 & 0031

ASSEMBLY

INTERSTATER 02/11 Assembly Section 3-13

ASSEMBLY

6. Attach the Return Hose (Item 1) to Left Wing ASM-FL-0032 & 0033 Slide Protective Sleeving (Item 2) over the Return Hose.

INTERSTATER 02/11 Assembly Section 3-14

ASSEMBLY

Slide the left wing pressure hose (Item 1) through the protective sleeving (Item 2) and attach to the left wing hydraulic motor. ASM-FL-0034 & 0035

ASSEMBLY

Slide right wing pressure hose (Item 1 ASM-FL-0036 and 0037) through protective sleeving (Item 4 ASM-FL-

0037) and attach to right wing hydraulic motor.

Attach right wing return hose to hydraulic adapter (Item 3) on right wing (Item 2 ASM-FL-0036) and slide through the sleeving. This sleeving will now have both right wing pressure hose and right wing return hose.

ASM-FL-0037

‘

INTERSTATER 02/11 Assembly Section 3-15

ASSEMBLY

Attach the return hose to the return filter on the hydraulic tank. ASM-FL-0038 Attach the other end of the return hose to the 3-way fitting on the hard plumbing. ASM-FL-0039

NOTE: the nut on the 3-way fitting must be loosened before the return hose can be attached. ASM-FL-0039

ASSEMBLY

Install the vent plug P/N 000696 (Item 1) ASM-FL0040 plug into upper port of each lift cylinder

NOTE: On some model, lift cylinder ports must face forward for proper hose clearance.

Install the 90 deg. elbow fittings P/N 02045200 (Item 2) ASM-FL-0040 into the remaining lift and tilt cylinder ports

INTERSTATER 02/11 Assembly Section 3-16

ASSEMBLY

Attach suction hose (Item 1) ASM-FL-0041 from auxiliary pump to hydraulic tank.

Attach the pressure hose (Item 1) ASM-FL-0042 from the auxiliary pump to the control valve (Item 1) ASM-FL0042

Attach the return hose (Item 2) ASM-FL-0043 from the control valve to the return filter on the hydraulic tank (Item 1) ASM-FL-0044.

ASSEMBLY

INTERSTATER 02/11 Assembly Section 3-17

ASSEMBLY

ITEM PART NO. QTY DESCRIPTION

8* 001775 1 Hose - Control Valve to Pump

7* 001776 1 Hose - Control Valve to Return Filter

6+ 001773 1 Hose - Control Valve to Tilt Cyl. - Live End

5+ 001774 1 Hose - Control Valve to Tilt Cyl. - Dead End

4+ 001772 1 Hose - Control Valve to Lift Cyl. - Live End

3+ 001771 1 Hose - Control Valve to Lift Cyl. - Live End

1+ 001770 1 Hose - Control Valve to Tilt Cyl. - Dead End

2+ 001770 1 Hose - Control Valve to Tilt Cyl. - Live End

+ Hose used with most non-cab tractors

* See Installation Instructions that were shipped with your unit for proper replacement part numbers.

INTERSTATER 02/11 Assembly Section 3-18

ASSEMBLY

CONTROL CABLE CONNECTION TO CONTROL STICK ASSEMBLIES

First remove the Cross-Screw from the bottom of the Control Stick Assembly. DO NOT remove the screws that fasten the two housings halves together. ASMP-FL-0001

Next while holding the housing, fully shift the Handle in the Control Stick Assembly to expose the female-threaded end of the Plunger Rod. ASMP-

FL-0002

Then while holding the Handle to expose the Plunger Rod, thread the Threaded Bead ASMP-FL- 0003 of the Cable into the end of the Plunger Rod and tighten securely. Release the Handle, allowing the Cable to pull into the Control Stick Assembly.

Once Cable is attached to Plunger Rod, slide the silver Conduit Sleeve ASMP-FL-0004 into the bottom of the Control Stick Assembly and align the groove in the Conduit Sleeve with the Cross-Screw Hole.

Finally Reinstall the Cross- Screw and tighten securely.

ASSEMBLY

INTERSTATER 02/11 Assembly Section 3-19

ASSEMBLY

INITIAL START-UP PROCEDURE

1. Check all nuts and hex head capscrews to ensure all are tight and all lock washers are fully compressed

(flattened).

2. Check all hoses and hydraulic connections. Make certain they are secure.

3. Inspect all moving parts and be sure that no wires or hoses will be caught or pinched when the tractor or

the INTERSTATER is in operation. Tie down loose wires and hoses.

4. Thoroughly grease the INTERSTATER and install a lubricap on each grease fitting. Refer to the Operation

and Maintenance Section.

5. Jack front of tractor up enough to allow axle to pivot through its full range. While turning wheels through

their limits, right and left, swing them up and down. Look for interference between tires and any part of the INTERSTATER. If interference occurs, shims (not furnished) must be welded to axle pivot stop or steering arm to limit the movement enough to avoid interference. Tractors with an adjustable front axle may require an outward adjustment of the wheels.

6. To fill the INTERSTATER reservoir with new, clean hydraulic oil, follow the steps below. Refer to the

Operation and Maintenance Section for specifications.

ASSEMBLY

a. With a hydraulic jack raise the right side of the tractor. This will tilt the tank and allow only a minimum amount of air when filling.

b. Avoid hydraulic contamination by filtering the hydraulic oil while filling the hydraulic tank. ASM-FL-0038

INTERSTATER 02/11 Assembly Section 3-20

ASSEMBLY

Filter buggies or carts are commercially available for hydraulic system clean-up. These consist of a high-efficiency, highcapacity filter, a circulating pump, a drive motor, and hoses for connecting the overhauled machine’s hydraulic system.

ASM-FL-0048

After the first 10 hours of operation, replace the hydraulic filter with a new one. An extra Filter Element is provided for you. Refer to the Operation and Maintenance Section for instruction.

7. After the Interstater mower is completely assembled to the tractor and with the wings on the ground, fill the mower hydraulic tank above the oil level sight gauge approximately 5" or 1" below the top of the tank.

8. With mower ON/OFF switches in “ON” position and tractor fuel cut off, crank engine for about 30 to 45 seconds to allow oil to fill pumps and motors. Check the oil level in the sight gauge. If no oil is seen add oil to bring the level up to the sight gauge. NOTE: Do not fill the tank with oil above the level of the sight gauge. Over filling the tank with oil after the initial filling may result in oil being discharged through the air filter on top of the hydraulic tank. Start the tractor and run it for 2 minutes and then turn it off. Again check the oil level in the sight gauge. If the oil level is in the sight gauge, the unit is ready to run. If no oil is seen, add oil to bring the level up to the sight gauge.

Remove all foreign objects and stand clear of cutter units. DO NOT GET NEAR ROTATING KNIVES!

ASSEMBLY

NOTE: On tractor hydraulic powered circuit only, make certain that there is full flow from tractor hydraulic system to control valve. Refer to tractor manual.

9. After hydraulic system is fully charged and functioning properly, switch cutter units on, then speed engine up to 540 RPM PTO speed. Maintain this speed for about 5 minutes. Check complete INTERSTATER, look for any leaks, loose connections, or anything that could cause premature wear or failure.

FINAL CHECK

Run INTERSTATER for about 1/2 hour at full speed. Check for leaks and vibrations. Frequently check oil temperature. Make certain it does not exceed 180 deg.

NOTE: When raising wings, make certain there is no interference with mower, frame, cylinders or tractor. Lift wings slowly.

DO NOT leave unit unattended, and COMPLY WITH ALL WARNING DECALS.

If unit starts to make unusual noise, stop unit and check oil level. Also check for frothy oil which would indicate a leak on suction side of system.

INTERSTATER 02/11 Assembly Section 3-21

ASSEMBLY

INSTALLATION OF REAR MOWER

Before attaching mower to tractor, it will be necessary that each tractor lower hitch arm has freedom of movement so that the mover is completely independent of tractor movement. This will allow the mower to pivot sideways as well as move vertically.

Some tractors provide this “float” by means of an optional slot in the lower end of each lift link, others by lift links which can be made telescopic by changing the position of the pins in the links. Failure to provide “float” may result in failure of the cutterhousing and bearings in the roller, thus voiding the mover warranty. Should your tractor not have a built in “float” option, a flexible lift chain assembly will be required.

On all centered mowers, two flexible lift chain assemblies will be necessary to provide “float” to each lift link.

On all offset mowers, one flexible lift chain assembly will be necessary to provide “float” to the lift link on the same side that the mover is offset. The other lift link should be the adjustable stiff link furnished with the tractor.

After the mower is attached to the tractor’s 3-point hitch, but before the universal slip joint is installed, and with the mover on the ground, adjust the top link of the hitch to make the mower gearbox input shaft parallel to the tractor P.T.O. shaft. This relationship provides optimum operation of the universal joints in the driveline. Driveline that is not parallel to PTO will result in vibration due to the characteristic of a universal joint that

ASSEMBLY

results in the output end speeding up and slowing down twice each revolution of the universal jointed shaft. Adjust the top link whenever the cutting height is changed.

1. Tip cutterhousing back and place a block under roller to safely support unit. Remove shipping skids and drive pulley side belt guard fender. If necessary, install knives, as shown, one row at a time. ALL KNIFE PINS ARE INSTALLED WITH THEIR HEADS FACING AWAY FROM THE CUTTERSHAFT PULLEY. This will locate cotter pins where knives cannot reach them when flexing backward. The housing side sheet has a hole in it which allows knife pins to be inserted into end lugs from outside the cutterhousing. After the cotter pin is installed, bend extended prong at a 45 Degree angle with prong parallel to lug. ASMP-FL-0047

INTERSTATER 02/11 Assembly Section 3-22

ASSEMBLY

With the cutterhousing tipped up, attach housing shoes/wearplate. Carriage bolt attaches to front mounting hole; plow bolts attach to middle and rear holes.

1. Attach overarms to cutterhousing. Secure each in 2 places with 5/8 NC x 1-3/4 Hex Head Capscrew(#1),

and nut.

2. Attach “A” frame arms to front of cutterhousing. Secure each, plus overarms in place with 5/8 NC x 2-1/2"

HHCS, and nut(#2).

3. Attach gearbox mounting frame to overarms and A- frame arms. ASM-FL-0049 a. Secure with 5/8 NC x 1-3/4 HHCS and nut (#3). Torque to 170 ft-lbs.

b. Secure with 3/4 NC x 3-3/4 HHCS, A- frame spacer and nut(#4). Torque to 300 ft-lbs.

ASSEMBLY

INTERSTATER 02/11 Assembly Section 3-23

ASSEMBLY

1. Attach outboard bearing plate to cutterhousing.

FORWARD ROTATION (Bearing plate mounts on left side of cutterhousing.)

a. Secure with 3/8 NC x 7/8 HHCS and nut at front mounting hole. Torque to 35 ft-lbs. (Typ.)

b. Secure with 3/8 NC x 2-1/4 HHCS, nut, lock washer, and second nut at rear mounting hole. The HHCS is used as an anchor for the idler arm spring.

REVERSE ROTATION (Bearing plate mounts on right side of cutterhousing)

a. Secure with 3/8 NC x 2-1/4 HHCS, nut and second nut at front mounting hole. The HHCS is used as an anchor for the idler arm spring.

b. Secure with 3/8 NC x 7/8 HHCS and nut at rear mounting hole.

2. 2. Install gearbox & extension shaft assembly and PTO shield mounting bracket a. Remove existing nuts and lock washer from bearing housing.

NOTE: On forward rotation units, remove only the lower two fasteners.

b. Slide bearing housing HHCS into proper holes in outboard bearing plate.

ASSEMBLY

c. Attach gearbox and mounting bracket to gearbox mounting frame. Secure with 5/8 NC x 1-1/4 HHCS (upper gearbox feet), and 5/8 NC x 1-1/2 HHCS (lower gearbox feet) and Lockwashers. Torque to 170 ft-lbs. (Typ.)

If extension shaft does not line-up with Gearbox, it may be necessary to shim gearbox mounting lugs. To accomplish this, insert one gearbox retaining bolt (Item 1), ASM-FL- 0050 thru the mount plate and into the gearbox housing. Do not tighten this bolt (it should have at least 1/4" free threads to move in and out). Assemble the gearbox, shaft, shaft extension tube and the bearing to the bearing retainer plate mounted on the side sheet. Tighten all fasteners except the one bolt in the gearbox mounting plate. Check the distance between the gearbox mounting lugs and the mount plate. If required, insert shims from shim kit (P/N 000552), ASM-FL-0051 between gearbox mounting lugs and mounting plate to insure the gearbox pulls up evenly on the mounting plate.

INTERSTATER 02/11 Assembly Section 3-24

ASSEMBLY

Install idler arm assembly to bearing plate. Do not secure at this time. ASM-FL-0052

3. Remove fasteners and shaft protector from end of drive shaft and retain. Lightly grease shaft. Install key

and driveshaft pulley. Do not secure at this time.

4. Align all three pulleys. Use spacers and shims provided to achieve alignment, then secure idler arm

assembly with cotter pin #4. Secure driveshaft pulley #1 with fasteners that were retained during previous step.

5. Install drive belt #2.

6. Attach spring. One end is inserted in idler arm spring arm hole; the other end is attached to the long

outboard bearing plate capscrew.

ASSEMBLY

INTERSTATER 02/11 Assembly Section 3-25

1. Properly mount rear mower to tractor and install

driveline. See INSTALLATION AND DRIVELINE SECTIONS.

2. Attach PTO shield to mounting bracket. Snap-

on shield is positioned so lower ears engage holes in bracket; upper ears rest on top of bracket. Bolt-on shield is secured with 3/8 NC x 3/4 HHCS (4 places).

3. Attach belt guard to cutter housing then

reattach belt guard fender.

Belt Guard, FORWARD ROTATION

Three 1/2 NF x 1-1/4 HHCS and nuts.

ASSEMBLY

Belt Guard, REVERSE ROTATION

One 1/2 NF x 1 HHCS (upper attaching pollinator 1/2NF x 1-1/4 HHCS two plain washers, and one nut. Plain washers are located at upper two belt guard attaching points

UNIVERSAL SLIP JOINT (PTO SHAFT): Refer to instructions supplied with shaft.

To install the driveline separates slip joint halves, then install them onto mower gearbox input shaft and tractor PTO driveline according to illustration on PTO shaft shield. Hold halves side by side, then raise and lower the mower to determine that there is no interference between halves when in the shortest position, and that there is a specified minimum amount of overlap (see PTO SHAFT PARTS LIST section) when in the longest position. Once it is determined that the shaft will cause no clearance problems, remove the halves, rejoin them and install the assembled PTO shaft between the tractor and the mower.

After attaching PTO shaft, slowly raise and lower mower to make sure shaft will not make any contact with “A-Frame” or mower head. If a problem exists, change mounting position or lengths of lift chains by removing or adding links.

.

ASSEMBLY

INTERSTATER 02/11 Assembly Section 3-26

OPERATION SECTION

Operation Section 4-1

OPERATION

READ AND UNDERSTAND THE ENTIRE OPERATING INSTRUCTIONS AND SAFETY SECTION OF THIS MANUAL AND THE TRACTOR MANUAL BEFORE ATTEMPTING TO USE THE TRACTOR AND IMPLEMENT. If you do not understand any of the instructions, contact your nearest authorized dealer for a

full explanation. Pay close attention to all safety signs and safety messages contained in this manual and those affixed to the implement and tractor. OPS-U- 0001

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)

Si no lee ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad.

(SG-3)

ALAMO INDUSTRIAL INTERSTATER

OPERATING INSTRUCTIONS

Alamo Industrial Interstater flail mowers are manufactured with quality material by skilled workers. These mowers are designed for cutting grass and small weeds. The mower is equipped with protective deflectors to prevent objects being thrown from the mower by the blades, however, no shielding is 100% effective. All shields, guards, and deflectors equipped on the mower must be maintained in good operational condition.

It is the operator’s responsibility to be knowledgeable of all potential operating hazards and to take every reasonable precaution to ensure oneself, others, animals, and property are not injured or damaged by the mower, tractor, or a thrown object. Do not operate the mower if passersby, pets, livestock, or property are within 100 yards of the unit.

This section of the Operator’s Manual is designed to familiarize, instruct, and educate safe and proper mower use to the operator. Pictures contained in this section are intended to be used as a visual aid to assist in explaining the operation of a Interstater flail mower and are not specific to any model. Some pictures may show shields removed for picture clarity. NEVER operate implement without all shields in place and in good operational condition. The operator must be familiar with the mower and tractor and all associated safety practices before operating the mower and tractor. Proper operation of the mower, as detailed in this manual,

OPERATION

will help ensure years of safe and satisfactory use of the mower.

To avoid mower damage, retorque all bolts after the first 10 hours of operation. Refer to the

Torque Chart at the end of the Maintenance Section to ensure bolts are properly tightened.

INTERSTATER 02/11 Operation Section 4-2

OPERATION

1. Standard Equipment and Specifications

Base Unit Specifications

16’5”,18’5”, or 20’9” Overal Cutting Widths Full-Length Welded Tubular Frame With Transport Lock 19-Gallon Reservoir with 12 Micron Filtration Tandem Piston Pumps Rated @ 48 GPM @ 3800 PSI(Dual Interstater) Tandem Piston Pump Rated @ 24 GPM @ 3800 PSI(Right & Left Hand Interstater) 4-Spool Valve with Detent Position (Dual Wing Interstater) 2-Spool Valve with Detent Position (Right & Left Hand Interstater)

Wing Mower Specification

62”. 74”, or 88” Cutting Widths 1/2” Inboard & 5/16” Outboard Side Plates Replaceable Skid Shoes 4-1/2” x 5/16” Wall Cuttershaft 1-5/16” Bore Greasable, Self-Aligning Cuttershaft Bearings 53 HP Piston Motor Belt Drive From Motor to Cuttershaft with Automatic Spring Tension 6” Adjustable Rear Roller 1/2” to 6” Cutting Height Available in Fine or Coarse-Cut Front and Rear Safety Deflectors Automatic Cut-Off Switch Lift Cylinder Capable of 14” Vertical Lift Tilt Cylinder Capable of 45 Degrees Down & 90 Degrees up 10 Gauge Unitized Cutter Housing

Rear Mower Specifications

88” or 96” Cutting Width (Depending on tractor mount kit) 10-Gauge Unitized Cutter Housing 5/16” Side Plates CAT I or CAT II Three Point Hitch 4-1/2” x 5/16” Wall Cuttershaft 1-5/16” Bore Greasable, Self-Aligning Cuttershaft Bearings 60 HP Gearbox 6” Adjustable Rear Roller 1/2” to 6” Cutting Height Available in Fine or Coarse-Cut Torque Limiter Clutch Front and Rear Safety Deflectors CAT 4 Driveline Belt Drive From Gearbox To Cuttershaft with Automatic Spring Tension

OPERATION

INTERSTATER 02/11 Operation Section 4-3

OPERATION

2.OPERATOR REQUIREMENTS

Safe operation of the unit is the responsibility of a qualified operator. A qualified operator has read and understands the implement and tractor Operator’s Manuals and is experienced in implement and tractor operation and all associated safety practices. In addition to the safety messages contained in this manual, safety signs are affixed to the implement and tractor. If any part of the operation and safe use of this equipment is not completely understood, consult an authorized dealer for a complete explanation.

If the operator cannot read the manuals for themselves or does not completely understand the operation of the equipment, it is the responsibility of the supervisor to read and explain the manuals, safety practices, and operating instructions to the operator.

Safe operation of equipment requires that the operator wear approved Personal Protective Equipment (PPE) for the job conditions when attaching, operating, servicing, and repairing the equipment. PPE is designed to provide operator protection and includes the following safety wear:

PERSONAL PROTECTIVE EQUIPMENT (PPE)

• Always Wear Safety Glasses

•Hard Hat

• Steel Toe Safety Footwear

• Gloves

• Hearing Protection

• Close Fitting Clothing

• Respirator or Filter Mask (depends on operating conditions) OPS-U- 0002

DO NOT 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)

OPERATION

INTERSTATER 02/11 Operation Section 4-4

OPERATION

3.1 ROPS and Seat Belt

The tractor must be equipped with a Roll-Over-Protective-Structure (ROPS) (tractor cab or roll-bar) and seat belt to protect the operator from falling off the tractor, especially during a roll over where the driver could be crushed and killed. Only operate the tractor with the ROPS in the raised position and seat belt fastened. Tractor models not equipped with a ROPS and seat belt should have these life saving features installed by an authorized dealer. OPS-U- 0003

Operate this Equipment only with a Tractor equipped with an approved rollover-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)

3.2 Tractor Safety Devices

If transporting or operating the tractor and implement near a public roadway, the tractor must be equipped with proper warning lighting and a Slow Moving Vehicle (SMV) emblem which are clearly visible from the rear of the unit. Lights and a SMV emblem must be equipped directly on implements if the visibility of the tractor warning signals are obscured.

Maintain all manufacturer equipped safety shields and guards. Always replace shields and guards that were removed for access to connect, service, or repair the tractor or implement. Never operate the tractor PTO with the PTO master shield missing or in the raised position. OPS-U- 0004

3. TRACTOR REQUIREMENTS

In addition to tractor horsepower and size required to operate the boom unit, the tractor must also be properly equipped to provide operator protection, to alert approaching vehicle drivers of the tractor’s presence, and to ensure tractor stability when mowing with the boom fully extended.

Tractor Requirements and Capabilities

• ASAE approved Roll-Over Protective Structure (ROPS) or ROPS cab and seat belt.

• Tractor Safety Devices ..................... Slow Moving Vehicle (SMV) emblem, lighting, PTO master shield

• Tractor Horsepower-Minimum.......... Rear INT 88” 60hp, Rear INT 96” 60hp

• Drawbar............................................ 14” length-measured from end of PTO shaft to hitch pin hole, rated to

carry mower tongue weight, safety chain attachment point

• Hydraulics......................................... 4-Spool Valve & 2-Spool Valve with Detent Position

• Power Take Off................................. 540 RPM

OPERATION

3.3 Tractor Horsepower

The horsepower required to operate the mower depends on many factors including the vegetation to be cut, terrain condition, operator experience, and condition of the mower and tractor. For most mowing condition, the Rear INT 88” & 96”mowers require a tractor with at least 60HP. Operating the mower with a tractor that does not have adequate power may damage the tractor engine.

INTERSTATER 02/11 Operation Section 4-5

OPERATION

DO NOT use a PTO adapter to attach a non-matching Implement driveline to a Tractor

PTO. Use of an adapter can double the operating speed of the Implement resulting in excessive vibration, thrown objects, and blade and implement failure. Adapter use will also change the working length of the driveline exposing unshielded driveline areas. Serious bodily injury and/or equipment failure can result from using a PTO adapter. Consult an authorized dealer for assistance if the Implement driveline does not match the Tractor PTO.

(S3PT-14)

Never operate the Tractor and Mower if the Implement input driveline is directly connected to the Tractor transmission. Tractor braking distances can be substantially increased by the momentum of the rotating Mower blades driving the Tractor transmission even though the Tractor clutch has been disengaged. Install an over running clutch between the Tractor PTO and the Mower driveline to prevent this potentially dangerous situation.

(S3PT-16)

4. GETTING ON AND OFF THE TRACTOR

Before getting onto the tractor, the operator must read and completely understand the implement and tractor operator manuals. If any part of either manual is not completely understood, consult an authorized dealer for a complete explanation. OPS-U- 0007

Do not mount or dismount the Tractor while the tractor is moving. Mount the Tractor only when the Tractor and all moving parts are completelystopped.

(SG-12)

4.1 Boarding the Tractor

Use both hands and equipped handrails and steps for support when boarding the tractor. Never use control levers for support when mounting the tractor. Seat yourself in the operator’s seat and secure the seat belt around you.

Never allow passengers to ride on the tractor or attached equipment. Riders can easily fall off and be seriously injured or killed from falling off and being ran over. It is the operator’s responsibility to forbid all extra riders at all times. OPS-U- 0008

Never allow children to operate, ride on, or come close to the Tractor or Implement. Usually, 16-17 year-old children who are mature and responsible can operate the implement with adult supervision, if they have read and understand the Operator’s Manuals, been trained in proper operation of the tractor and Implement, and are physically large enough to reach and operate the controls easily.

(SG-11)

OPERATION

INTERSTATER 02/11 Operation Section 4-6

OPERATION

Never allow children or other persons to ride on the Tractor or Implement. Falling off can result in serious injury or death.

(SG-10)

Do not mount or dismount the Tractor while the tractor is moving. Mount the Tractor only when the Tractor and all moving parts are completelystopped.

(SG-12)

4.2 Dismounting the Tractor

Before dismounting the tractor, idle the tractor engine down, disengage the head and retract the boom arm to the transport position. Park the tractor on a level surface, place the transmission in neutral and set the parking brake. Shut down the tractor engine, remove the key, and wait for all motion to come to a complete stop before exiting the operator’s seat. NEVER leave the seat until the tractor, its engine, and mower head movement have come to a complete stop.

Use hand rails and extra steps when exiting the tractor. Be careful of your step and use extra caution when mud, ice, snow, and other matter has accumulated on the steps and handrails. Never rush or jump off the tractor. OPS-B- 0002

BEFORE leaving the tractor seat lower the implement, set the parking brake and/or set the tractor transmission in parking gear, disengage the PTO, stop the engine, remove the key, and wait for all moving parts to stop. Place the tractor shift lever into a low range or parking gear to prevent the tractor from rolling. Never dismount a Tractor that is moving or while the engine is running. Operate the Tractor controls from the tractor seat only.

(SG-9)

OPERATION

INTERSTATER 02/11 Operation Section 4-7

OPERATION

5. STARTING THE TRACTOR

The operator must have a complete understanding of the placement, function, and operational use of all tractor controls before starting the tractor. Review the tractor operator’s manual and consult an authorized dealer for tractor operation instructions if needed.

Essential Tractor Controls:

• Locate the ignition key/switch

• Locate the engine shut off control

• Locate the hydraulic control levers

• Locate the light control lever

• Locate the brake pedals and clutch

• Locate the PTO control

• Locate the 3 point hitch control lever

• Locate the boom operating controls (joystick or valve bank)

Before starting the tractor ensure the following:

• Conduct all pre-start operation inspection and service according to the tractor operator’s manual.

• Make sure all guards, shields, and other safety devices are securely in place.

• The parking brake is on.

• The tractor transmission levers are in park or neutral.

• The boom operating controls are in the neutral and off position.

• The PTO control lever is disengaged.

• The hydraulic remote control levers are in the neutral position.

Refer to the tractor owner’s manual for tractor starting procedures. Only start the tractor while seated and belted in the tractor operator’s seat. Never bypass the ignition switch by short circuiting the starter solenoid. After the tractor engine is running, avoid accidental contact with the tractor transmission to prevent sudden and unexpected tractor movement. OPS-B- 0003

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

(SG-23)

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)

6. CONNECTING THE MOWER TO THE TRACTOR

Use extreme caution when connecting the mower to the tractor. The mower should be securely resting at ground level or setting on blocks. Keep hands and feet from under the mower deck and clear of pinch points between the tractor hitch arms and mower pins. OPS-R-0001

OPERATION

INTERSTATER 02/11 Operation Section 4-8

OPERATION

Always shut the Tractor completely down, place the transmission in park, and set the parking brake before you or anyone else attempts to connect or disconnect the Implement and Tractor hitches.

(S3PT-15)

6.2 Safety Tow Chain

If the mower is towed on a public roadway, a safety chain with tensile strength equal to or greater than the gross weight of the mower must be connected between the tractor and mower. This will help control the implement in the event the tongue becomes disconnected from the drawbar. Make sure the chain is attached to a secure location on the tractor and not to an intermediate support.

After connecting both ends of the safety chain, drive the tractor to the right and left to check for proper chain length. Adjust length as necessary and allow only enough slack in the chain to make a maximum turn in both directions. When not in use, store the safety chain to protect it from mud or standing water by wrapping the chain around the tongue. Replace the safety chain if one or more links or end fittings are broken, stretched or otherwise damaged or deformed. OPS-U-0039

6.1 Connecting the Mower A-Frame to the Tractor

1. Make sure the tractor is equipped with the

correct PTO shaft. Change shafts if needed.

2. Shorten or remove the tractor drawbar to avoid

interference when raising and lowering the mower.

3. Board the tractor and start the engine. Position

the tractor to the mower with the 3-point lift arms positioned between the respective set of mower A-frame lift lugs. Note: Set the 3-point lift control to “Position Control” so that the lift arms maintain a constant height when attaching the mower. See the tractor Operator’s Manual for correct settings when attaching 3-point equipment.

4. Turn off the tractor engine and dismount.

5. One lift arm at a time, align arm end hole

between the set of A-frame lift lugs. Insert hitch pin through the lug and arm holes and insert retaining pin into hitch pin.

6. Walk around to opposite side and repeat

procedure for remaining lift arm and hitch pin.

7. Extend or retract 3-point top link to align its end

hole with the holes of the mower’s top link. Insert the top link hitch pin and insert retaining pin into hitch pin.

8. Adjust any lower link check chains, guide

blocks, or sway blocks to prevent the mower from swaying side to side and possible contact with tractor rear tires.

OPERATION

INTERSTATER 02/11 Operation Section 4-9

OPERATION

7. SETTING THE MOWER

Properly setting the cutting height is essential for efficient and safe operation. A properly set mower will make a more uniform cut, distribute clippings more evenly, require minimal tractor work, and follow the contour of uneven terrain. NOTE: Avoid very low cutting heights, striking the ground with the blades gives the most

damaging shock loads and will cause damage to the mower and drive. Blades contacting the ground may cause objects to be thrown out from under the mower deck. Always avoid operating the mower at a height which causes the blades to contact the ground. OPS-U- 0010

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)

OPERATION

INTERSTATER 02/11 Operation Section 4-10

OPERATION

7.1 Roller Height Adjustment

1. The mower’s cutting height is set by positioning

the roller assembly for each mower section. Each section must be set at the same height to ensure an even cut across the entire width of the mower.

2. Place the tractor and mower on a level surface

and completely lower the mower to the ground.

3. Shut down the tractor, place the transmission in

park, and set the parking brake before dismounting.

4. One section at a time, place lifting device

(scissors jack or hydraulic jack) under center of cutter housing.

5. Remove hex nuts, washers and carriage bolts

from bracket at each end of roller. Make certain that roller bracket is free to move once the fasteners are removed. A stuck roller could drop unexpectedly and cause injury.

6. Use lifting device to reposition cutter housing to

desired cutting height. Align bracket holes with cutter housing, then reinstall hardware.

7. Lower cutter housing to the ground and remove

lifting device.

8. Set cutting height according to procedures

above for remaining two cutter sections. Make sure that all three rollers are set at the same height to ensure a even cut across the entire width of the mower.

OPERATION

Hydraulic Cylinder Priming

Hydraulic Cylinders must be filled with hydraulic oil before releasing the wing transport locks to lower the mower. Hydraulic cylinders and lines are filled by holding the valve control levers in the raised position until the cylinders fully extend then place the control lever in the float position. Repeat the process several more times to ensure wings are entirely supported by the hydraulic cylinders before releasing the transport locks and lowering the mower.

INTERSTATER 02/11 Operation Section 4-11

OPERATION

Do not let the Blades turn when the Mower Deck is raised for any reason, including clearance or for turning. Raising the Mower deck exposes the Cutting Blades which creates a potentially serious hazard and could cause serious injury or even death from objects thrown from the Blades.

(SRM-07)

8. DRIVELINE ATTACHMENT

The driveline yoke and tractor PTO shaft must be dirt free and greased for attachment.

To connect the mower driveline to the tractor PTO output shaft, pull the driveline yoke collar back and align the grooves and splines of the yoke with those of the PTO shaft. Push the driveline yoke onto the PTO shaft, release the locking collar, and position the yoke until the locking collar balls are seated onto the PTO shaft. Push and pull the driveline back and forth several times to ensure a secure attachment.

After the driveline is securely attached, place the tractor PTO master shield back in the operating position. OPS-R-0003

Before operating the Implement, check to make sure the Implement input driveline will not bottom out or become disengaged. Bottoming out occurs when the inner shaft penetrates the outer housing until the assembly becomes solid-it can shorten no more. Bottoming out can cause serious damage to the Tractor PTO by pushing the PTO into the Tractor and through the support bearings or downward onto the PTO shaft, breaking it off. A broken driveline can cause personal injury.

(S3PT-18)

7.2 Leveling Deck

To Facilitate a safe and efficient mowing operation, the mower should be operated parallel to the ground at all times. Never operate if front or rear of mower is tilted upward. Objects may be discharged at high speeds causing possible injury or even death.

Adjust Top Link to level mower roller adjustment. Side Skid Shoes should always be parallel to ground throughout the full adjustment range. Adjust cutting height of machine by raising or lowering rear roller as specified in Operation Section.

OPERATION

8.1 Driveline Length Check

INTERSTATER 02/11 Operation Section 4-12

OPERATION

“Bottoming Out” Check Procedure

• Disconnect driveline from the tractor and slide the profiles together until fully compressed.

• Place a mark on the inner shield 1/8” from the end of the outer shield and reattach the driveline to the PTO Shaft.

• With the PTO NOT TURNING, slowly drive the tractor with mower attached through the sharpest turn possible and watch shaft movement. With the PTO NOT TURNING, slowly drive the tractor with the mower attached through the most severe terrain conditions expected and watch shaft movement.

• If the distance between the mark and the outer shield becomes less than 2” at any point there is a potential problem bottoming out the driveline and the driveline should be shortened.

OPS-F-0001

When fitting the mower to the tractor, the telescoping driveline must be inspected to ensure that at its most compressed position, the profiles do not “bottom out”, and when at its farthest extended position, there is sufficient engagement between the profiles to operate safely. At its shortest length, there must be at least a 1” clearance between each profile end and opposite profile universal joint. At its farthest operating extension, a minimum profile engagement of 12” must be maintained.

OPERATION

INTERSTATER 02/11 Operation Section 4-13

OPERATION

Shorten the driveline profiles as follows:

• Remove the driveline from the tractor.

• Position the mower to the point with the shortest distance between the tractor PTO shaft and cutter gearbox. Shut down the tractor and securely block the mower in this position.

• Pull driveline apart and reattach yoke to PTO shaft.

• Hold driveline sections parallel to one another and measure back 1” from yoke of each shaft and place mark on opposite section. Cut this length off with a saw.

• Round off all sharp edges and debur.

• Thoroughly grease then reinstall the driveline.

• Recheck for proper operation.

Engagement Check Procedure

• With the driveline attached, position the mower to the point where the telescoping driveline is at its maximum extension. Completely shut down the tractor and secure in position.

• Mark the inner driveline shield 1/8” from the end of the outer shield.

• Disconnect the driveline from the tractor and separate the two driveline halves.

• Measure the distance from the mark to the end of the inner profile. This length is the amount the driveline profiles were engaged.

• If the engaged length is less than 12” the shaft is considered too short and should be replaced with a longer shaft. Consult an authorized dealer to purchase the required driveline length.

NOTE: If the driveline cannot be shortened and still maintain the required profile engagement, the operator must be made aware of terrain conditions and avoid situations which pose a potential problem to avoid damaging the driveline. OPS-F-0002

9. PRE-OPERATION INSPECTION AND SERVICE

Before each use, a pre-operation inspection and service of the implement and tractor must be performed. This includes routine maintenance and scheduled lubrication, inspecting that all safety devices are equipped and functional, and performing needed repairs. DO NOT operate the unit if the pre-operation inspection reveals any condition affecting safe operation. Perform repairs and replacement of damaged and missing parts as soon as noticed. By performing a thorough pre-operation inspection and service, valuable down time and repair cost can be avoided. OPS-U-0029

Always disconnect the main PTO Driveline from the Tractor before performing service on the Mower. Never work on the Mower with the tractor PTO driveline connected and running. Blades or Drivelines could turn without warning and cause immediate

entanglement, injury or death.

(SRM-3)

Always disconnect the main PTO Driveline from the Tractor before performing service on the Mower. Never work on the Mower with the tractor PTO driveline connected and running. Blades or Drivelines could turn without warning and cause immediate

entanglement, injury or death.

(SRM-3)

OPERATION

INTERSTATER 02/11 Operation Section 4-14

OPERATION

DO NOT allow any person under a folded wing unless wing is securely

locked up or supported. DO NOT approach the Implement unless the Tractor is turned off and all motion has ceased. Never work under the frame work, or any lifted component unless the implement is securely supported or blocked up. A sudden or inadvertent fall by any of these components could cause serious injury or even death.

(STI-03)

Periodically inspect all moving parts for wear and replace when necessary with authorized service parts. Look for loose fasteners, worn or broken parts, and leaky or loose fittings. Make sure all pins have cotter pins and washers. Serious injury may occur from not maintaining this machine in good working order.

(SG-21)

9.1 Tractor Pre-Operation Inspection/Service

Refer to the tractor operator’s manual to ensure a complete pre-operation inspection and scheduled service is performed according to the manufacturers recommendations. The following are some of the items that require daily service and inspection:

• Tire condition/air pressure

• Wheel lug bolts

• Steering linkage

• PTO shield

• SMV sign is clean and visible

• Tractor’s lights are clean and functional

• Tractor Seat belt is in good condition

• Tractor ROPS is in good condition

• ROPS is in the raised position

• No tractor oil leaks

• Radiator free of debris

• Engine oil level and condition

• Engine coolant level and condition

• Power brake fluid level

• Power steering fluid level

• Fuel condition and level

• Sufficient lubrication at all lube points

• Air filter condition OPS-U-0030

OPERATION

INTERSTATER 02/11 Operation Section 4-15

OPERATION

9.2 Mower Pre-Operation Inspection/Service

Before each mower use, a complete inspection and service is required to ensure the mower is in a good and safe working condition. Damaged and/or broken parts should be repaired and/or replaced immediately. To ensure the mower is ready for operation, conduct the following. OPS-R-0007

All Safety Shields, Guards and Safety devices including (but not limited

to) - the Deflectors, 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.

(SFL-5)

Replace bent or broken blades with new blades. NEVER ATTEMPT TO STRAIGHTEN, WELD, OR WELD HARDFACING ON BLADES SINCE THIS WILL LIKELY CRACK OR OTHERWISE DAMAGE THE BLADE WITH SUBSEQUENT FAILURE AND POSSIBLY CAUSE SERIOUS INJURY FROM THROWN BLADES.

(SGM-10)

The operator’s manual and safety signs affixed on the unit contain important instructions on the safe and proper use of the equipment. Maintain these important safety features on the implement in good condition to ensure the information is available to the operator at all times.

• Ensure the manual canister is secured to the equipment with the operator’s manual inside.

• Ensure all safety signs are in place and legible. Replace missing, damaged, and illegible decals. OPS-U- 0011

OPERATION

INTERSTATER 02/11 Operation Section 4-16

OPERATION

• Check that the main driveline securely attached to the tractor and the locking collar is seated in the groove of the PTO Shaft.

• Ensure wing hydraulics are secure at both ends.

• Ensure the mower hitch is securely attached to the tractor drawbar with a proper size bolt and secured nut.

• Ensure that a properly rated safety tow chain is equipped securing the mower to the tractor.

OPS-F- 0003

• Ensure rubber deflectors are in position and not damaged. Replace worn, broken, and missing sections immediately.

• Ensure the rollers are in good condition and rotate freely.

• Ensure the driveline integral shield is in good condition and rotate freely.

• Inspect that all bolts and screws are in position and are properly torqued. OPS-F- 0004

• Inspect the condition of the wings and rear section drive belts.

• Ensure the slip clutch (rear mower section only) is properly adjusted and the friction plates are not frozen together. Reference the Maintenance Section for proper slip clutch maintenance.

• Ensure the slip clutch shield and drive belts shields are in place and in good repair.

• Ensure the tractor PTO master shield is in place, lowered and in good condition.

OPS-F- 0005

OPERATION

INTERSTATER 02/11 Operation Section 4-17

OPERATION

• Inspect oil level in gearbox and replenish if needed. A low oil level is a warning sign that the gearbox may be cracked or its seal is damaged and needs to be replaced.

• Check the oil level in tank and replenish if need. NOTE: Do not fill the tank with oil above the level of the sight gauge. Over filling the tank with oil after initial filling may result in oil being discharged through the air filter on the top of the hydraulic tank.

• Perform scheduled lubrication as specified in the maintenance section. OPS-F- 0006

• Inspect cutter knives and knife pins for looseness and excessive wear. Make sure the mower is securely blocked up before crawling beneath. Replace damaged, worn, and missing knives as complete sets to maintain cuttershaft balance.

• Remove any grass or other debris which may be wrapped around the cuttershafts.

• Inspect the condition of deck skid shoes and hardware. OPS-F- 0007

OPERATION

INTERSTATER 02/11 Operation Section 4-18

OPERATION

Flail Mower PRE-OPERATION Inspection

Mower ID#________________ Make ____________________

Date: ________________ Shift ____________________

Before conducting the inspection, make sure the tractor engine is off, all rotation has stopped and the tractor is in park with the parking brake engaged. Make sure the mower is resting on the ground or securely blocked up and all hydraulic pressure has been relieved.

Operator’s Signature:

Item

Condition at

Start of Shift

Specific Comments if

not O.K.

FLAIL MOWER

The Operator’s Manual is in the canister on the mower

All safety decals are in place and legible

The hitch connection bolts & pins are tight

There are no cracks in hitch

Their mower deck is clear of cut grass and debris

The thrown object guard/deflectors are in place

Their guards/deflectors are in good condition

The driveline/gearbox shields are in good condition

The driveline clutch is in good condition, not frozen

The driveline tubes & u-joints have been lubricated

The driveline yoke is securely attached to the PTO

The gearbox oil level is full

Blades are not broken, chipped, cracked or bent

Blade shackles are in good condition with no cracks

The blade pins are properly retained

The skid shoes are in good condition & tight

The rear roller is in good condition and turns freely

DO NOT OPERATE an UNSAFE TRACTOR or MOWER

OPERATION

INTERSTATER 02/11 Operation Section 4-19

OPERATION

Tractor PRE-OPERATION Inspection

Mower ID#________________ Make ____________________

Date: ________________ Shift ____________________

Before conducting the inspection, make sure the tractor engine is off, all rotation has stopped and the tractor is in park with the parking brake engaged. Make sure the mower is resting on the ground or securely blocked up and all hydraulic pressure has been relieved.

Operator’s Signature:

Item

Condition at

Start of Shift

Specific Comments if

not O.K.

The flashing lights function properly

The SMV Sign is clean and visible

The tires are in good condition with proper pressure

The wheel lug bolts are tight

The tractor brakes are in good condition

The steering linkage is in good condition

There are no visible oil leaks

The hydraulic controls function properly

The ROPS or ROBS Cab is in good condition

The seatbelt is in place and in good condition

The 3-point hitch is in good condition

The drawbar pins are securely in place

The PTO master shield is in place

The engine oil level is full

The brake fluid level is full

The power steering fluid level is full

The fuel level is adequate

The engine coolant fluid level is full

The radiator is free of debris

The air filter is in good condition

DO NOT OPERATE an UNSAFE TRACTOR or MOWER

This Inspection Form may be freely duplicated for extra copies.

OPERATION

INTERSTATER 02/11 Operation Section 4-20

OPERATION

This Implement may be wider than the Tractor. Be careful when operating or transporting this equipment to prevent the Implement from running into or striking sign posts, guard rails, concrete abutments or other solid objects. Such an impact could cause the Implement and Tractor to pivot violently resulting in loss of steering control, serious injury, or even death. Never allow the Implement to contact obstacles.

(S3PT-12)

Transport only at speeds where you can maintain control of the equipment. Serious accidents and injuries can result from operating this

equipment at high speeds. Understand the Tractor and Implement and how it handles before transporting on streets and highways. Make sure the Tractor steering and brakes are in good condition and operate properly.

Before transporting the Tractor and Implement, determine the proper transport speeds for you and the equipment. Make sure you abide by the following rules:

Test the tractor at a slow speed and increase the speed slowly. Apply the Brakes smoothly to determine the stopping characteristics of the Tractor and Implement. As you increase the speed of the Tractor the stopping distance increases. Determine the maximum transport speed not to exceed 20 mph (30 kph) for transporting this equipment.

Test the equipment at a slow speed in turns. Increase the speed through the turn only after you determine that the equipment can be operated at a higher speed. Use extreme care and reduce your speed when turning sharply to prevent the tractor and implement from turning over. Determine the maximum turning speed for you and this equipment before operating on roads or uneven ground.

Only transport the Tractor and Implement at the speeds which allow you to properly control the equipment.

Be aware of the operating conditions. Do not operate the Tractor with weak or faulty brakes or worn tires. When operating down a hill or on wet or rain slick roads, the braking distance increases: use extreme care and reduce your speed. When operating in traffic always use the Tractor’s flashing warning lights and reduce your speed. Be aware of traffic around you and watch out for the other guy.

(SG-19)

10. DRIVING THE TRACTOR AND IMPLEMENT

Safe tractor transport requires the operator possess a thorough knowledge of the model being operated and precautions to take while driving with an attached implement. Ensure the tractor has the capacity to handle the weight of the implement and the tractor operating controls are set for safe transport. To ensure safety while driving the tractor with an attached implement, review the following. OPS-U- 0012

OPERATION

INTERSTATER 02/11 Operation Section 4-21

OPERATION

10.1 Starting the Tractor

The procedure to start the tractor is model specific. Refer to the tractor operator’s manual for starting procedures for your particular tractor. Consult an authorized dealer if the starting procedure is unclear. Ensure the 3-point control lever is in the lowered position and the PTO is disengaged before starting the tractor. OPS-U-0033

10.2 Brake and Differential Lock Setting

Make sure the tractor brakes are in good operating condition. Tractor brakes can be set to operate independently allowing single rear wheel braking action or locked together to provide simultaneous rear wheel braking. FOR MOST DRIVING AND OPERATING CONDITIONS, THE BRAKE PEDALS SHOULD BE LOCKED TOGETHER TO PROVIDE THE MOST EFFECTIVE BRAKING ACTION.

Always disengage the tractor differential lock when turning. When engaged the differential lock will prevent or limit the tractor from turning. During normal cutting conditions, locking the differential provides no benefit and should not be used. OPS-

U- 0013

Be aware of the operating conditions. Do not operate the Tractor with weak or faulty brakes. When operating down a hill or on wet or rain slick roads, the braking distance increases; use extreme care and reduce your speed in these conditions. When operating in traffic, always use the Tractor’s flashing warning lights and reduce your speed. Be aware of traffic around you and watch out for the other guy.

OPERATION

INTERSTATER 02/11 Operation Section 4-22

OPERATION

11. Operating the Mower Wings

Raising to Transport Position

1. With tractor engine running, place ON/OFF switch(s) in "OFF" position and wait for cuttershaft(s) to stop rotating.

2. Pull LIFT control lever rearward until lift frame is as high as it will go.

3. Pull TILT control lever rearward until bracket on unit is above support bar on lift cylinder support. If unit is in the detent “FLOAT”, it will takes some effort to pull TILT lever from "FLOAT" position.

4. Push LIFT control lever forward enough to lower unit slowly. Bar on cylinder support must pass through bracket on unit as shown in Figure 268.

5. Make certain that all control levers are in "HOLD" position when transporting unit.

OPERATION

NOTE: Lift and Tilt cylinder rods may be adjusted to provide proper transport bracket to support bar clearance.

Loosen rod end clamp.

Shorten stroke on LIFT cylinder to raise lift frame. Lengthen stroke on LIFT cylinder to lower lift frame.

and/or

Shorten stroke on TILT cylinder to move transport bracket closer to support bar. Lengthen stroke on TILT cylinder to move transport bracket away from support bar.

Once sufficient clearance is obtained, tighten rod end clamp.

The mower’s center of gravity is raised making the mower more prone to tipping when the wings are in the raised position. Use extreme caution when towing the mower in the transport position and avoid uneven terrain which could upset the mower.

INTERSTATER 02/11 Operation Section 4-23

Lowering into Operating Position

When the Wings are folded for transport, the center of gravity is raised and the possibility of overturn is increased. Drive slowly and use extreme caution when turning on hillsides. Overturning the Implement could cause the Implement to overturn the Tractor and vice versa resulting in serious injury or even death. Never fold wings on a hillside...the Implement or unit may overturn.

(STI-02)

The mower head will start running when lowered if the mower ON/OFF switch is in the ON

position. Make sure the SWITCH is in the OFF positon before lowering mower wing(s).

(SFL-10)

Ensure that ON/OFF switch(es) is (are) in "OFF" position. With tractor engine running, pull LIFT control lever rearward until bracket on cutter unit clears support bar on lift cylinder support. Push TILT control lever forward until cutter unit is level with ground. Push LIFT lever forward enough to slowly lower unit until it touches ground, then push both levers forward to "FLOAT" position.

OPERATION

NOTE: For best mowing results and longer roller

life, both LIFT and TILT levers should be in "FLOAT" position while mowing.

It takes some effort to pull TILT lever from "FLOAT" position because of detent spring.

The mower must be operated with the cutter sections fully lowered and the hydraulic control lever in the float detent to ensure the mower follows the contour of the ground and to prevent sections from creeping up. NEVER attempt to raise the mower while the mower is operating.

INTERSTATER 02/11 Operation Section 4-24

OPERATION

Do not let the Blades turn when the Mower Deck is raised for any reason, including clearance or for turning. Raising the Mower deck exposes the Cutting Blades which creates a potentially serious hazard and could cause serious injury or even death from objects thrown from the Blades.

(SRM-07)

Do not put hands or feet under mower decks. Blade Contact can result in serious injury or even death. Stay away until all motion has stopped and the decks are securely blocked up.

(SGM-09)

11.1 Engaging and Disengaging the Power Take Off (PTO) and Wings

Before engaging the PTO, make certain that the area is clear of bystanders and passersby. The implement must be lowered to the mowing position. NEVER engage the PTO with the implement in the raised position. Set the tractor engine speed at approximately 1,000 RPM before engaging the PTO. Shift the PTO control to the on position.

To start the wings, make sure they are in the lowered position (refer to Lowering Wings into Operating Position of the operation section) and PULL the start/stop button(s) to start the wing motor(s) and slowly increase the engine speed until the PTO is operating at the rated speed. If you hear unusual noises or see or feel abnormal vibrations, lower the engine RPM’s, disengage the PTO and PUSH the wing start/stop button(s) to stop the wing motor(s). Inspect the implement to determine the cause of the noise or vibration and repair the abnormality.

OPERATION

INTERSTATER 02/11 Operation Section 4-25

OPERATION

11.2 Driving the Tractor and Implements

Start off driving at a slow speed and gradually increase your speed while maintaining complete control of the tractor and units. Moving slowly at first will also prevent the tractor from rearing up and loss of steering control. The tractor should never be operated at speeds that cannot be safely handled or which will prevent the operator from stopping quickly during an emergency. If the power steering or engine ceases operating, stop the tractor immediately as the tractor will be difficult to control.

Drive the tractor with the 3-Point lift arms in the raised position and lock the control lever in the transport detent position to prevent damage to the mower driveline and tongue when turning.

Perform turns with the tractor and units at slow speeds to determine how the tractor with an attached blade or rake handles a turn. Determine the safe speed to maintain proper control of the tractor when making turns. When turning with a towed implement, the overall working length of the unit is increased. Allow additional clearance for the units when turning.

To avoid overturns, drive the tractor with care and at safe speeds, especially when operating over rough ground, crossing ditches or slopes, and turning corners. Tractor wheel tread spacing should be increased when working on inclines or rough ground to reduce the possibility of tipping.

Use extreme caution when operating on steep slopes. Keep the tractor in a low gear when going

downhill. DO NOT coast or free-wheel downhill.

OPS-F- 0009

OPERATION

INTERSTATER 02/11 Operation Section 4-26

OPERATION

When confronted with an incline or ditch, do not approach from an angle which is perpendicular or straight on as damaged to over collapse of the driveline may occur.

When crossing such terrain, the implement should be fully lowered for a lower center of gravity and added stability. OPS-R-0021

11.3 Crossing Ditches and Steep Inclines

When crossing ditches with steep banks or going up sharp inclines, it is possible that the main driveline inner profile will penetrate into the outer housing to its maximum depth until the assembly becomes solid (driveline is at its extreme shortest length). This type of abusive operation can cause serious damage to the tractor and mower drive by pushing the PTO into the tractor and through the support bearings or downward onto the PTO shaft, breaking it off.

Damage resulting from over-collapse of the driveline’s inner profile and its outer housing may allow the driveline to come loose from the Tractor which could cause bodily injury to the operator or bystanders and/or extensive damage to the Tractor or Implement. OPS-R-0020

OPERATION

INTERSTATER 02/11 Operation Section 4-27

OPERATION

Inclines and ditches should be approached along a line which is at an angle as shown. This type of path will reduce the possibility of over-collapse of the driveline and resulting damage. If the gradient is so steep that such an approach increases the possibility of a tractor roll-over, select an alternate crossing path.

When operating the tractor and mower across slopes and inclines, through ditches, and other uneven terrain conditions, it is important to maintain sufficient deck to ground clearance. Blade contact with the ground may cause soil, rocks and other debris to be thrown out from under the mower resulting in possible injury and/or property damage. Ground contact also produces a severe shock load on the mower drive and to the mower blades

resulting in possible damage and premature wear.

OPS-R-0022

12. OPERATING THE TRACTOR AND IMPLEMENT

THE OPERATOR MUST COMPLETELY UNDERSTAND HOW TO OPERATE THE TRACTOR AND IMPLEMENT AND ALL CONTROLS BEFORE ATTEMPTING TO OPERATE. The operator must read and

understand the Safety and Operation Sections of the implement and tractor operator’s manuals. These manuals must be read and explained to any operator who cannot read. Never allow someone to operate the implement and tractor without complete operating instructions.

Before starting any operation, the operator must become familiar with the area to be worked in and any obstacles and hazards contained within to ensure safety to the operator, bystanders, and equipment. Special attention should be paid to foreign debris, rough terrain, steep slopes, and passersby and animals in the area.

OPS-U- 0015

Extreme care should be taken when operating near loose objects such as gravel, rocks, wire, and other debris. Inspect the area before mowing. Foreign objects should be removed from the site to prevent machine damage and/or bodily injury or even death. Any objects that cannot be removed must be clearly marked and carefully avoided by the operator. Stop mowing immediately if blades strike a foreign object. Repair all damage and make certain rotor or blade carrier is balanced before resuming mowing.

(SGM-05)

OPERATION

INTERSTATER 02/11 Operation Section 4-28

OPERATION

Many varied objects, such as wire, cable, rope, or chains, can become entangled in the operating parts of the mower head. These items could then swing outside the housing at greater velocities than the blades. Such a situation is extremely hazardous and could result in serious injury or even death. Inspect the cutting area for such objects before mowing. Remove any like object from the site. Never allow the cutting blades to contact such items.

(SGM-06)

12.1 Foreign Debris Hazards

Before mowing, inspect the area to make sure there are no foreign objects that the mower blades could hit or become entangled with. Remove all foreign objects and debris. If objects are too big to remove, mark them clearly and be sure to prevent the mower blades from contacting them.

If you hit a solid object or foreign debris, stop the mower and tractor at once. Immediately idle the engine speed and disengage the PTO. Wait for all mower rotating motion to stop, then raise the mower and move the tractor and implement off the object. Inspect the area and remove, or mark the location of the debris. Inspect the condition of the mower and make any needed repairs immediately. Make sure the blades are not damaged and the carrier is balanced before resuming operation.

Always wear your seat belt securely fastened and only operate the tractor and mower with the ROPS in the raised position. If the tractor or mower hits a tree stump, rock, or bump, a sudden movement could throw you off of the seat and under the tractor and/or mower. The seat belt is your best protection from falling off the tractor and the ROPS provides protection from being crushed during a tractor roll-over. OPS-F-0010

12.2 Bystanders/Passersby Precautions

If a bystander comes within 300 feet of the tractor while the mower is being operated, stop the tractor at once, idle the engine and disengage the PTO. Do not engage the PTO again until all bystanders are well past the 300 foot distance. OPS-R-0024

OPERATION

INTERSTATER 02/11 Operation Section 4-29

OPERATION

Flail Mowers are capable under adverse conditions of throwing

objects for great distances (300 feet or more) and causing serious

injury or death. Follow safety messages carefully.

STOP MOWING IF PASSERSBY ARE WITHIN 300 FEET UNLESS:

-Front and Rear Deflectors, Chain Guards, or Bands are installed and in good, workable condition;

-Mower sections or Wings are running close to and parallel to the ground without exposed Blades;

-All areas have been thoroughly inspected and all foreign material such as rocks, cans, glass, and general debris has been removed.

NOTE: Where there are grass and weeds high enough to hide debris that could be struck by the blades, the area should be: inspected and large debris removed, mowed at an intermediate height, inspected closely with any remaining debris being removed, and mowed again at desired final height. (This will also reduce power required to mow, reduce wear and tear on the Mower drivetrain, spread cut material better, eliminate streaking, and make the final cut more uniform.)

(SFL-6)

12.3 PTO RPM and Ground Speed

Ground speed for mowing will depend upon the height, type, and density of vegetation to be cut. Recommended speed for efficient mower performance is between 2 and 5 mph(3-8 kph). Operate the mower at its full rated PTO speed to maintain blade speed for a clean cut. Refer to the tractor operator’s manual or the tractor instrument panel for the engine speed and gear to provide the required PTO and desired ground speed. Make sure that the mower is operating at its full rated speed before entering the vegetation to be cut. If it becomes necessary to temporarily regulate engine speed, increase or decrease the throttle gradually.

Ground speed is achieved by transmission gear selection and not by the engine operating speed. The operator may be required to experiment with several gear range combinations to determine the best gear and range which provides the most ideal performance from the mower and most efficient tractor operation. As the severity of cutting conditions increase, the ground speed should be decreased by selecting a lower gear to maintain the proper operating PTO speed. OPS-R-0025

Do not exceed the rated PTO speed for the Implement. Excessive PTO speeds can cause Implement driveline or blade failures resulting in serious injury or death.

(SG-26)

Mow at the speed that you can safely operate and control the tractor and mower. The correct mowing speed depends on terrain condition and grass type, density, and height of cut. Normal ground speed range is from 2 to 5 mph(3-8 kph). Use slow mowing speeds when operating on or near steep slopes, ditches, drop-offs, overhead obstructions, power lines, or when debris and foreign objects are to be avoided.

(SGM-07)

OPERATION

INTERSTATER 02/11 Operation Section 4-30

OPERATION

12.4 Operating the Mower

Only operate the mower from the tractor operator’s seat with the seatbelt securely fastened. The tractor must be equipped with a ROPS in the raised position or a ROPS cab.

The mower is designed to cut vegetation up to 1-1/2” in diameter. Sharp blades will produce a cleaner cut and require less power. Travel at a speed that allows the mower sufficient time to cut through the vegetation and maintain the PTO operating speed to prevent overloading the mower and tractor. Choose a driving pattern that provides the maximum pass length and minimizes turning.

Under certain conditions, tractor tires may roll some grasses down preventing them from being cut at the same height as the surrounding area. When this occurs, reduce the tractor ground speed while maintaining the operating speed of the mower. A slower ground speed will permit grasses to at least partially rebound and be cut. Taking a partial cut and/or reversing the direction of travel may also help produce a cleaner cut.

Avoid mowing in the reverse direction when possible. In situations where the mower must be backed to access areas to be cut, make sure there are no persons or other foreign debris behind the mower before mowing in reverse. When mowing in reverse, operate the tractor and mower at a reduced ground speed to ensure tractor and mower control is maintained. OPS-R-0026

Do not mow with two machines in the same area except with Cab tractors with the windows closed.

(SGM-11)

Mow only in conditions where you have clear visibility in daylight or with adequate artificial lighting. Never mow in darkness or foggy conditions where you cannot clearly see at least 300 feet (90 m) in front and to the sides of the tractor and mower. Make sure that you can clearly see and identify passersby, steep slopes, ditches, drop-offs, overhead obstructions, power lines, debris and foreign objects. If you are unable to clearly see these type of items discontinue mowing.

(SGM-1)

Avoid mowing in reverse direction when possible. Check to make sure there are no

persons behind the mower and use extreme care when mowing in reverse. Mow only at a

slow ground speed where you can safely operate and control the tractor and mower.

Never mow an area that you have not inspected and removed debris or foreign material.

(SGM-08)

OPERATION

INTERSTATER 02/11 Operation Section 4-31

OPERATION

Follow these guidelines to reduce the risk of equipment and grass fires while operating, servicing, and repairing the Mower and Tractor:

-Equip the Tractor with a fire extinguisher in an accesible location.

-Do Not operate the Mower on a Tractor with an underframe exhaust.

-Do Not smoke or have an open flame near the Mower and Tractor.

-Do Not drive into burning debris or freshly burnt areas.

-Ensure slip clutches are properly adjusted to prevent excessive slippage and plate heating.

-Never allow clippings or debris to collect near drivelines, slip clutches, and gearboxes. Periodically shut down the Tractor and Mower and clean clippings and collected debris from the mower deck.

(SGM-12)

12.5 Shutting Down the Implement

To shut down the implement, first bring the tractor to a complete stop. Then slow down the implement by reducing the engine speed before disengaging the PTO. Push the stop button to disengage the wings and wait for all motion to stop before

proceeding to drive or shut down the tractor.

Park the tractor on a level surface, place the transmission in park or neutral and apply the parking brake, lower the attached implement to the ground, shut down the engine, remove the key, and wait for all motion to come to a complete stop before exiting the tractor. OPS-F- 0011

OPERATION

INTERSTATER 02/11 Operation Section 4-32

OPERATION

13. DISCONNECTING THE MOWER FROM THE TRACTOR

Before disconnecting the mower, the PTO must be disengaged and all motion at a complete stop. Move the mower to a level storage location and lower both wings to the ground. If the mower will be stored with the sections in the raised position, be sure that the locks are engaged. If the mower is not resting securely on the ground, block the mower up securely before attempting to disconnect it from the tractor. Use extreme care to keep feet and hands from under the mower and clear of any pinch points. OPS-F-0012

After disconnecting the 3 lift points, remove the mower driveline from the tractor PTO shaft. Lay the driveline down carefully to avoid damaging the driveline or its shield. Do not let the driveline fall into mud or dirt, which can contaminate the bearing and shorten the life of the driveline.

OPS-F-0013

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)

OPERATION

INTERSTATER 02/11 Operation Section 4-33

OPERATION

MOWER STORAGE

It is recommended that the mower be stored with the center section and both wings fully lowered to ground level. If the mower is stored with the wings in the raised position, select a level area and install wing transport braces to prevent the wings from falling BEFORE disconnecting the mower hitch from the tractor.

Properly preparing and storing the mower at the end of the season is critical to maintaining its appearance and to help ensure years of dependable service. The following are suggested storage procedures:

• Thoroughly clean all debris off the mower to prevent damage from rotting grass and standing water.

• Lubricate all mower grease points and fill gearbox oil levels as detailed in the maintenance section.

• Tighten all bolts and pins to the recommended torque.

• Check the mower for worn and damaged parts. Perform repairs and make replacements immediately so that the mower will be ready for use at the start of the next season.

• Store the mower in a clean, dry place with the mower housing resting securely on blocks or at ground level.

• Keep the driveline yoke from sitting in water, dirt and other contaminants.

• Use spray touch-up enamel where necessary to prevent rust and maintain the appearance of the mower.

It is critical that driveline clutches slip when an obstacle or heavy load is encountered to avoid mower and/or tractor damage. If the mower sits outside for an extended period of time or is exposed to rain and/or humid air, the clutch lining plates must be inspected to ensure they are not frozen together from rust or corrosion. If the mower has been exposed to such conditions, at the start of each mowing season, and any time it is suspected that the slip clutch plates may be frozen together, readjust the slip clutch as detailed in Seasonal Clutch Maintenance of the maintenance section in this manual. OPS-F-0014

Never allow children to play on or around Tractor or Implement. Children can slip or fall off the Equipment and be injured or killed. Inadvertent contact with controls can cause the Implement to shift or fall crushing themselves or others.

(SG-25)

OPERATION

INTERSTATER 02/11 Operation Section 4-34

Alamo 803213C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTERSTATER

FLAIL MOWER

OPERATOR’S MANUAL

ALAMO INDUSTRIAL®

To the Owner/Operator/Dealer

Table of Contents

Alamo Industrial Division is willing to provide

one (1) AEM Mower Safety Practices Video

SAFETY SECTION

General Safety Instructions and Practices

Concluding Safety Instructions and Practices

Decal Location

1. 002369 4 DANGER Multiple-Hazard

2. 02988385 6 LOGO Terrain King Logo

3. 1458393 4 REFLECTR Yellow Reflector Decal

4. 02925100 3 INSTRUC Genuine Terrain King Parts

5. 002425 3 DANGER Cutting & Entanglement Hazard

6. 02967668 3 DANGER Thrown Object Keep Away

7. 02965262 3 DANGER Oil Penetration, Leaks

8. 00758194 4 WARNING Belt/Pulley Pinch Point

9. 000678 3 INSTRUC Grease Fitting Inside

10. 02962765 2 DANGER Crushing From Folding Hazard

11. 03200285 1 CAUTION Slipping on Step Hazard

12. 1 SERIAL # Serial Number

13. 000108 3 INSTRUC Flail Operation

14. 02990257 2 LOGO Terrain Master Logo

15. 001829 2 INSTRUC Wing Lube Chart

16. 002023 3 INSTRUC Cutting Height Adjustment

17. 1458392 4 REFLECTR Red Reflector Decal

18. 00725739 3 WARNING Flail Shield Missing

19. 00763977 2 INSTRUC Notice to Owner

20. 00725746 1 PELIGRO Translate in Spanish

21. 001830 1 INSTRUC Rear Unit Lube Chart

22. 00756494 1 DANGER Driveline Hazards

23. 00773723 1 PELIGRO Driveline Manual Spanish

24. D103 1 WARNING Operate at 540 RPM

25. 02966305 1 INSTRUC Hyd Oil and Type

26. 02971123 1 WARNING Pressurized Tank

27. 03200347 * REFLECTR SMV Reflector

28. 1 LOGO Flail King Logo

29. 00756004 1 DANGER Shield Missing Do Not Operate

30. 00756005 1 DANGER Keep Away Rotating Driveline

31. 00753840 2 DANGER Wing Falling

32. 03200328 1 DANGER Transport with Lever in Detent

33. 001412 1 INSTRUC Valve Lever Operating Plate1

34. 00776031 1 Canister (Operator’s Manual)

35. 803213C 1 Terrain Master Operators Manual

36. 10058000 4 Bolt

37. 00017000 4 Lock washer

38. 0024100 4 Flatwasher

39. 001660 2 LOGO Interstater

40. 02979544 2 LOGO Alamo Industrial

41. 00757139 1 LOGO Alamo Industrial

Decal Description

Federal Laws and Regulations

INTRODUCTION SECTION

ASSEMBLY SECTION

GENERAL INSTRUCTIONS

3. Check the oil level in the reservoir before start-up.

PRELIMINARY TRACTOR PREPARATION

SPECIAL TOOLS

DRIVE COUPLING ATTACHMENT

HYDRAULIC TANK, SUPPORTS AND MAINFRAME ATTACHMENT

1. Attach the left hydraulic tank support and step weldment to the tractor with (4) bolts provided in your Mount Kit. Refer to your particular Tractor Installation Drawing for part numbers and quantities. ASM-FL-0003

2. Attach the right hydraulic tank support to the tractor with (4) bolts provided in your Mount Kit. Refer to your particular Tractor Installation Drawing for part numbers and quantities. ASM-FL-0004

5. Lift the rear of the frame and secure with (4) 1/2" x 1 1/2" & (2) 5/8" x 1/3/4" bolts. Install the remaining front hardware. ASM-FL-0006

MOUNTING AND PUMP ASSEMBLY

1. Before mounting tank, attach pipe manifold for return lines to the return filter assembly.

2. Raise bumper with a forklift or hoist and lower onto hydraulic tank supports. Attach the bumper to the tank supports with (4) 1/2” x 2" bolts and (4) 1/2" locknuts. ASM-FL-0007

3. Now tighten all hardware for mainframe, tank support, tank, and bumper.

LIFT CYLINDER FRAME ATTACHMENT

MOUNTING WING MOWERS

ELECTRICAL WIRING INSTALLATION

ELECTRICAL CIRCUIT

CONTROL VALVE

HYDRAULICS