Alamo 803213C User Manual
Interstater, Operator’s manual, Flail mower
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©2011 Alamo Group Inc.
$0.00
Published 02/11
Part No. 803213C
OPERATOR’S MANUAL
ALAMO INDUSTRIAL
®
1502 E. Walnut
Seguin, Texas 78155
830-372-3551
Email: [email protected]
FLAIL MOWER
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
Advertising
Table of contents
Document Outline
- INTERSTATER
- OPERATOR’S MANUAL
- To the Owner/Operator/Dealer
- Table of Contents
- Alamo Industrial Division is willing to provide
- one (1) AEM Mower Safety Practices Video
- 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 Plate 1
- 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 SECTION
- Decal Description
- Federal Laws and Regulations
- GENERAL INSTRUCTIONS
- 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 impo...
- 2. After the drive belts are installed, DO NOT start the tractor unless the hydraulic system is filled with 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...
- 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
- 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 loos...
- 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
- 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
- HYDRAULIC TANK, SUPPORTS AND MAINFRAME ATTACHMENT
- CONTROL VALVE
- HYDRAULICS
- 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
- 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
- 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
- Attach suction hose (Item 1) ASM-FL-0041 from auxiliary pump to hydraulic tank.
- CONTROL CABLE CONNECTION TO CONTROL STICK ASSEMBLIES
- 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 ...
- 6. To fill the INTERSTATER reservoir with new, clean hydraulic oil, follow the steps below. Refer to the Operation and Maintenance Section for specifications.
- FINAL CHECK
- INSTALLATION OF REAR MOWER
- ALAMO INDUSTRIAL INTERSTATER
- OPERATING INSTRUCTIONS
- 1. Standard Equipment and Specifications
- 3. TRACTOR REQUIREMENTS
- Tractor Requirements and Capabilities
- 3.1 ROPS and Seat Belt
- 3.2 Tractor Safety Devices
- 3.3 Tractor Horsepower
- 4. GETTING ON AND OFF THE TRACTOR
- 5. STARTING THE TRACTOR
- 6. CONNECTING THE MOWER TO THE TRACTOR
- 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 ar...
- 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.
- 6.2 Safety Tow Chain
- 6.1 Connecting the Mower A-Frame to the Tractor
- 7. SETTING THE MOWER
- 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.
- 7.2 Leveling Deck
- 7.1 Roller Height Adjustment
- 8. DRIVELINE ATTACHMENT
- 9. PRE-OPERATION INSPECTION AND SERVICE
- 10. DRIVING THE TRACTOR AND IMPLEMENT
- 11. Operating the Mower Wings
- 16. TROUBLE SHOOTING GUIDE
- Problem Possible Cause Remedy
- Check for missing knives on Replace missing knives
- cutter shaft.
- Check to see if knives are Free knives so they swing.
- free swinging.
- Blade broken or bent. Replace blades.
- Cuttershaft bent. Replace cuttershaft.
- Drivelines not phased correctly. Replace driveline.
- Implement & Tractor yokes must
- be in line.
- Improper type lubricant. Replace with proper lubricant.
- Excessive trash build-up Remove trash.
- around gearbox.
- Bearing or gears set up Consult your Dealer.
- improperly.
- Worn Bearing. Replace bearing.
- Noise Damaged Belt Shield Straighten or replace Shields.
- (Rubbing on pulleys or belt).
- Worn Bearing or Gear. Replace Bearing or Gear.
- Bent shaft. Replace oil seal and shaft.
- Shaft rough in oil seal area. Replace or repair shaft.
- Oil seal installed wrong. Replace seal.
- Oil seal not sealing in the housing. Replace seal or use a sealant on
- OD of Seal.
- Oil level too high. Drain oil to proper level.
- Sand hole is casting. Replace castings or gearbox.
- Gasket damaged. Replace gasket.
- Bolts loose. Tighten bolts.
- plates warped. section of manuals.
- Too much power for clutch. Reduce ground speed and material
- intake.
- Oil on facings. Replace facings.
- Friction facings glazed. Clean with emery cloth.
- Cutting in rocky conditions. Increase cutting height.
- Soft “will fit” knives. Use genuine Alamo Industrial knives.
- Quick coupler not completely Complete connection.
- connected.
- Piston “O” Ring worn. Replace piston “O” Ring.
- Cylinder wall scored or pitted. Replace cylinder.
- Wrong piston ring on piston. Use correct piston ring.
- Blades dull. Check blades for sharpness.
- Grass too wet. Wait for grass to dry.
- Grass too long. Mow at 3-1/2” and recut lower.
- Travel speed too fast. Use a lower tractor gear.
- PTO RPM too low. Mow at engine RPM to match 540
- PTO RPM.
- Rough, uneven ground. Use a slower speed.
- Lower rollers.
- Turning Tractor too fast. Slow down when turning.
- Mower deck not level. Level the mowing deck.
- Blades dull or unbalanced. Sharpen or balance blades.
- Deck underside plugged. Clean underside of deck.
- Grass too high. Mow at 3-1/2” and recut lower.
- Housing plugged. Clean underside of deck.
- Spring broke & belt off idler. Replace spring or adjust belt.
- Housing plugged. Clean underside of housing.
- Debris around pulleys. Remove deck belt shield and clean
- out debris.
- Grass too high. Mow at 3-1/2” and recut lower.
- OPERATION SECTION
- MAINTENANCE SECTION
- DAILY CHECKS
- ADJUSTING TENSION OF DRIVEBELTS
- 1. Remove Pump Cover.
- 2. Loosen Pump Mount Plate bolt item 1 and 2. Mnt-FL-0010
- 3. Loosen Belt Tension Bracket bolt item 3. Mnt- FL-0010
- 4. Move pump unit outwards to increase tension on the belt. Belts should have no more than 1/4 inch play at midpoint between drive pulley and pump pulley. Tighten mounting bolts.
- 5. Replace Pump Cover.
- CHANGING HYDRAULIC SYSTEM FILTER
- CUTTER UNIT
- GENERAL MAINTENANCE
- REPLACING CUTTER UNIT DRIVEBELTS
- 1. Place unit on ground or support securely.
- 2. Remove belt guard.
- 3. Remove idler arm spring.
- 4. Remove motor mounting bracket front bolt and loosen rear bolt.
- 5. Pivot motor-mounting bracket assembly. Remove old belts and install new ones.
- 6. Reinstall front mounting bolt then secure motor mounting bracket to unit.
- 7. Reinstall idler arm spring and belt guard.
- ADJUSTING CUTTING HEIGHT
- 1. Lower cutter unit to ground and place control valve levers in "FLOAT" position.
- 2. Place lifting device (scissors jack, hydraulic jack) under center of cutter housing.
- 3. 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 suddenly and cause an injury.
- 4. Use lifting device to reposition cutter housing to desired cutting height. Align bracket holes with cutterhousing holes, then reinstall fasteners. Refer to cutting height decal on mower or Safety Section.
- 5. Lower cutter unit to ground; then remove lifting device.
- ROLLER BEARING REPLACEMENT
- 1. Remove roller and both bearing and bracket assemblies from mower. Lift the mower only high enough to remove the roller assembly. If installing a roller with pre assembled bearing and bracket assemblies, remove the old roller, proceed to step 11.
- 2. Slide bearing and bracket assemblies off each end of roller. If replacing with new bearing and bracket assemblies, proceed to step 9.
- 3. Remove roller bearing and housing assembly attaching hardware. Remove assembly from bracket. Inspect seal between assembly and bracket for brittleness, cracks, wear and tear. Replace if necessary. If replacing with new roller bearing and housing a...
- 4. Remove grease fitting from the top of bearing housing.
- 5. Remove bearing form housing. By Rotating Bearing 90deg. sideways and line up with notches in Bearing Housing: then pull out.
- 6. Install new bearing into housing. Bearing must be installed with grease hole in bearing aligned with grease fitting hole in housing.
- 7. Reinstall grease fitting to housing. Grease fitting must be tight and seated in grease hole in bearing to prevent bearing from rotating in housing.
- 8. Attach roller bearing and housing assembly to bracket with seal between housing and bracket.
- 9. Slide bearing and bracket assemblies on each end of roller.
- 10. Check bearing for proper installation in housing by gently rocking bearing and bracket assembly in end of roller. Play should be slight to none at all.
- 11. Install roller and bearing and bracket assemblies on mower.
- 12. Lubricate roller bearing until lubricant can be seen coming out between roller and bearing housing.
- CUTTERSHAFT BEARING REPLACEMENT
- Outboard Bearing
- 1. Lift cutter unit to maximum horizontal height; then securely support ends of cutterhousing.
- 2. Remove enough knives to place a floor jack under center of cuttershaft.
- 3. Securely support cuttershaft.
- 4. Remove outboard fender.
- 5. Remove fasteners securing bearing and housing assembly to cutterhousing, then remove bearing and housing assembly.
- 6. Using a jack to align parts, install bearing and housing assembly to cutter unit and make certain that bearing setscrew is located in keyway on cuttershaft. Grease bearing and install cap over fitting.
- Inboard (Drive) Bearing
- CUTTERSHAFT REPLACEMENT
- Outboard Bearing
- CHANGING TO FORWARD OR REVERSE ROTATION
- HYDRAULICS
- POWER CIRCUIT
- CONTROL CIRCUIT
- External Coil Slip Disk Replacement
- Slip Clutch
- SEASONAL CLUTCH MAINTENANCE
- 1. Loosen nuts on springs until the springs can freely rotate, yet remain secure on bolts.
- 2. Attach mower to tractor and start the tractor. Set the engine speed at 1200 RPM.
- 3. Mark outer plates as shown in.
- 4. Engage the PTO (approximately one second) and then quickly disengage it. The friction lining plates should break loose (check the mark).
- 5. Turn tractor off and tighten the nuts on the springs to their original position of 1-5/16" compressed spring length.
- Proper Torque for Fasteners
- Problem Possible Cause Remedy
- TO THE OWNER/OPERATOR/DEALER
- ALAMO-INDUSTRIAL
- LIMITED WARRANTY
- 1. LIMITED WARRANTIES
- 1.01. Alamo Industrial warrants for one year from the purchase date to the original non-commercial, governmental, or municipal purchaser (“Purchaser”) and warrants for six months to the original commercial or industrial purchaser
- 1.02. Manufacturer will replace for the Purchaser any part or parts found, upon examination at one of its factories, to be defective under normal use and service due to defects in material or workmanship.
- 1.03. This limited warranty does not apply to any part of the goods which has been subjected to improper or abnormal use, negligence, alteration, modification, or accident, damaged due to lack of maintenance or use of wrong fuel, oil, or lubricants, ...
- 1.04. Except as provided herein, no employee, agent, Dealer, or other person is authorized to give any warranties of any nature on behalf of Manufacturer.
- 2. REMEDIES AND PROCEDURES.
- 2.01. This limited warranty is not effective unless the Purchaser returns the Registration and Warranty Form to Manufacturer within 30 days of purchase.
- 2.02. Purchaser claims must be made in writing to the Authorized Dealer (“Dealer”) from whom Purchaser purchased the goods or an approved Authorized Dealer (“Dealer”) within 30 days after Purchaser learns of the facts on which the claim is based
- 2.03. Purchaser is responsible for returning the goods in question to the Dealer.
- 2.04. If after examining the goods and/or parts in question, Manufacturer finds them to be defective under normal use and service due to defects in material or workmanship, Manufacturer will:
- (a) Repair or replace the defective goods or part(s) or
- (b) Reimburse Purchaser for the cost of the part(s) and reasonable labor charges (as determined by Manufacturer) if Purchaser paid for the repair and/or replacement prior to the final determination of applicability of the warranty by Manufacturer.
- 2.05. Purchaser is responsible for any labor charges exceeding a reasonable amount as determined by Manufacturer and for returning the goods to the Dealer, whether or not the claim is approved. Purchaser is responsible for the transportation cost for...
- 3. LIMITATION OF LIABILITY.
- 3.01. MANUFACTURER DISCLAIMS ANY EXPRESS (EXCEPT AS SET FORTH HEREIN) AND IMPLIED WARRANTIES WITH RESPECT TO THE GOODS INCLUDING, BUT NOT LIMITED TO, MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
- 3.02. MANUFACTURER MAKES NO WARRANTY AS TO THE DESIGN, CAPABILITY, CAPACITY, OR SUITABILITY FOR USE OF THE GOODS.
- 3.03. EXCEPT AS PROVIDED HEREIN, MANUFACTURER SHALL HAVE NO LIABILITY OR RESPONSIBILITY TO PURCHASER OR ANY OTHER PERSON OR ENTITY WITH RESPECT TO ANY LIABILITY, LOSS, OR DAMAGE CAUSED OR ALLEGED TO BE CAUSED DIRECTLY OR INDIRECTLY BY THE GOODS INCLU...
- 3.04. NO ACTION ARISING OUT OF ANY CLAIMED BREACH OF THIS WARRANTY OR TRANSACTIONS UNDER THIS WARRANTY MAY BE BROUGHT MORE THAN TWO (2) YEARS AFTER THE CAUSE OF ACTION HAS OCCURRED.
- 4. MISCELLANEOUS.
- 4.01. Proper Venue for any lawsuits arising from or related to this limited warranty shall be only in Guadalupe County, Texas.
- 4.02. Manufacturer may waive compliance with any of the terms of this limited warranty, but no waiver of any terms shall be deemed to be a waiver of any other term.
- 4.03. If any provision of this limited warranty shall violate any applicable law and is held to be unenforceable, then the invalidity of such provision shall not invalidate any other provisions herein.
- 4.04. Applicable law may provide rights and benefits to purchaser in addition to those provided herein.