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Alamo 02984405 Lawn Mower User Manual

1. 8 Reinstall LH Rear Tire and Wheel Reinstall the LH rear Tire and Wheel now if it has not already been done Use a hoist to lift and secure the rear tires is recommended as they are very heavy Figure 27 Boom Rest Support Weldment f 24 ft or 30 ft boom Boom Rest Weldment f 24 ft boom Bolts to amp boom rest f 30 ft boom Bolts to top of Figure 28 tractor axle LH side of tractor ipa PA DR 4 e DAN A Boom Rest Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 10 Frame Installation Counter Weight Installation 1 Counter Weight CWT Installation The Counter weight See Figure 1 mounts on the LH side Under Frame Weldment Its is retained with three pins the long pin on top the short pin at the rear and a short pin at the front Using a hoist or other sufficient lifting device align the weight with the frame The Frame for the weight will slide over the under frame until the upper long pin is aligned with the mounting tube of the weight and the mounting tubes of the under frame Install the long mounting pin The front and rear pin holes should be aligned install the short pins front and rear The short pins are retained using a nut and bolt The long pin uses two large cotter pins install cotter pins and bend end of them to secure them See Figure 32 33 amp 34 Weight Attaching Pin LH Counter Weight 24 or Short Pin Rear side 30 Foo
2. 6 Install The new Fuel tank onto Tractor if Mounting required Tabs The new fuel tank with the gauge sending Figure 13 unit slide in on top of the new mounting brackets with the fuel cap to the front See Figure 14 Connect lines to fuel pick up connections connect wiring to fuel gauge sending unit See Figure 14 7 Bolt Tank to the Mounting Brackets _Bolt the tank to the mounting brackets there are two bolts in the front bracket and one bolt in the rear bracket See Figure 15 8 Install New replacement Step The new Replacement step is a bolt on weldment that will bolt to the new fuel tank with four bolts note below the step is painted yellow for clarity only See Figure 16 U Braeket A ma Nam 1 Bolt A RE E EM zh z Figure 15 j Es es ts Ce EN Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 5 Frame Installation Under Mount Frame Asy 24 amp 30 ft are the same except for the LH weight 30 ft model only LH Counter Weight Turret Asy Machined Turret Boom Mount Pin Weight Attaching Pin Long Pin Boom Mount Attaching Pin Long Pin Center Section Frame Weldment Boom Mount Attaching Pin Short Pin Boom Mount Machined Swing Cylinders Swing Cylinder Pivot Bushings Swing Cylinder Trunnion Mount Weldment Swing Cylinder Cover Axtreme Boom Asy Man 07 06 Rev 02 20 07 2
3. Hose Installation Bump Retain 1 Connect Pump Hoses to Cutter control valve a Bots The hoses should be connected after bolting pump to front pump mount plate Pressure Hose To Motor Clean all Hoses and Pump Fitting The tractor must be clean at the pump hoses and hydraulic tank before beginning any installation The Pressure Hoses run down the right side of the tractor and connect to the control valve block which is bolted to the pump on the right hand side See Figure 13 14 amp 15 The small hose is the i pressure to cylinder control valve the larger hose is Figure 13 the pressure hose for the mower motor circuit These hoses should be connected first See Figure Ta 13 Bolt the hose rings to the right side of tractor Control Valve E M a The Suction Hose At Tank The suction hose le gt Ar is connected to the pump next Make certain that suction hose is fastened tightly at the Tank See Figure 14 The Suction Hose At Hydraulic Pump Fillthe hose with clean new hydraulic oil recommended type only This is so when pump is started it will not start up dry Install suction hose to hydraulic pump and tighten hose fitting See Figure 14 Tractor Operation tractor to be started as it could damage the pump and other components if the assembly is not complete com pletely inspect all installation made to make certain Figure 14 js they have been completed and components hav
4. Never work under any raised component or any component that is not securely blocked up or supported WARNING Many components of this mower are very heavy and must be handled by proper material handling equipment Do not lift components that weight over 50lbs by yourself 0 Use an overhead crane forklift or other coworkers to lift heavy items Ensure lifted components are securely supported e Never walk or work under a lifted component Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 3 4 General Information Installation Requirements WARNING Use extreme care when moving handling or adjusting the tractor tires The tires are extremely heavy and could fall and crush you 8 Use an overhead crane or forklift to move the tires Properly fasten the tires to the material handling eguipment to prevent the tire from falling WARNING The hydraulic oil is under high pressure and a hydraulileak can cause oil to be injected under the skin Before starting the tractor ensure all hydraulic connections have bee tightened Never check for leaks with your hands Use a piece of wood or cardboard to check for the leak making sure your hands and face are kept away from the leak area Repair any leaks before operating the eguipments Clean up all oil that has leaked according to the requirements of the oil supplier Oil residue on the ground can result in unjury from slipping or falling TRACTOR PREPA
5. o Torgue in Ibs 140 230 450 650 900 1200 1600 2000 2800 Torgue ft Ibs 12 19 38 54 75 100 133 167 233 Straight Threads do not always seal better when higher torgues are used Too much torgue causes distortion and may lead to leakage DO NOT over torgue fittings and DO NOT allow any contaminants to enter system through fittings when installing them 9 TORQUE VALUES BOLTS Maximum Torque per Bolt Size and Grade Ft lbs 8 Nm IMPORTANT Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE Component Application Torque will vary dependimg on what is bolted down and the type material Metal that is being bolted together Thread condition and lubrication will vary Torque settings Inche Sizes Not Used Not Used Not Used 35 47 55 75 75 102 10 14 20 27 35 47 55 75 85 115 130 176 170 230 300 407 445 603 670 908 910 1234 1250 1695 14 19 30 41 50 68 80 120 163 175 230 240 325 425 576 685 929 1030 1396 1460 1979 2060 2793 Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Metric Sizes ALWAYS CHECK MARKINGS DESCRIP TIONS Section 2 6 Section 3 Axtreme Boom Tractor Preperations NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor components can vary with tractor model See the installation draw
6. 1 for now this will protect battery and cover Figure 3 N Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 2 Exhaust Muffler Relocation Exhaust Muffler Relocation 1 Remove The Exhaust If Required See As sembly Drawings sent with unit The Exhaust relocation kit will include a new mounting bracket Bolting hardware replacement exhaust pipe from turbo to muffler The Muffler needs to be removed first See Figure 5 Remove the Exhaust pipe to turbo See Figure 5 Remove the tractors factory Exhaust pipe mounting bracket See Figure 6 2 Install Exhaust Replacement Mounting Bracket If Required See Assembly Drawings sent with unit The replacement exhaust mounting bracket will bolt in the place of the factory mounting bracket The replacement bracket moves the ex haust inward towards the engine by about 5 to 6 inches This is to give clearance of the boom and exhaust system See Figure 7 3 Install Replacement Exhaust Pipe If Re quired See Assembly Drawings sent with unit In stall the replacement exhaust pipe using the new clamp furnished in kit Fasten the new exhaust pipe to the new exhaust bracket using the two factory u Bolts that were used on the original exhaust pipe See Figure 8 4 Reinstall the muffler If Required See As sembly Drawings sent with unit to the exhaust pipe using the factory bolts and hardware Check all the bolts and components to th
7. Boom Steel Tube To Head Connecting Hose Motor Return From Head Motor Return Dipper Boom Steel Tube Steel Tube Connecting Hose Motor Return From Head To Hyd Tank Motor Return Lift Boom Steel Tube Figure 23 Axtreme Boom Asy Man 07 06 Rev02 20 07 2006 Alamo Industrial Section 6 11 NOTES Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 6 12 Section 7 Axtreme Boom Boom amp Head Installation With Hyd Connections NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor compo nents can vary with tractor model See the installation drawings shipped with the unit for the specific tractor type mount and hardware components IN SOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLA TION DRAWING INSTRUCTION THE INSTALLATION DRAWING INSTRUC TIONS WILL OVERRIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 7 1 Boom Head Installation Boom Installation Boom Hoses 1 Turret Assembly The turret assembly has the cylinders connected and the hoses are connected to the cylinders The end of the hoses will be sticking up through the turret mount weldment between turret and tractor The hoses will need to be connected there and routed to the hydraulic control
8. Boom to Tank Axtreme Boom Asy Man 07 06 Rev02 20 07 2006 Alamo Group Inc Section 7 4 Boom Head Installation Motor Case Drain 12 Hose Blue Tie Door Cyl 4 Hose Yellow White Tie Cyl 4 Hose Green White Tie Motor Tank Return 16 Hose Orange Tie ps ner ee Ores Motor Pressure 16 Hose Red Tie Head Swivel Es ra 1 HeadMount Pin Hole Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Rev 02 20 07 Section 7 5 Boom Head Installation 12 Routing Boom Hoses to Pump Boom hose to pump will be routed on RH Side of tractor They are run through sleeving material and hose support bracket See Figure 15 The Pump hoses must be connected correctly to boom and pump There are 2 Pump to motor hoses and 1 motor case drain return hose for a total of 3 Note Motor Case Drain hose will be run through the Oil Cooler and then return to tank First is the hose with the red plastic tie the lower connection at Boom See Figure 14 this is the pressure supply from pump lower connection at pump See Figure 14 to the motor connection at the boom Second is hose with orange plastic tie upper connec tion at boom See Figure 14 This is the Return hose from the motor upper connection at pump See Figure 14 Third is Hose with blue plastic tie middle connection at boom See Figure 14 which is case drain from moto
9. Slipping and falling can cause serious injury or death 56 33 gt WARNING 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 so 34 gt WARNING Avoid contact with hot surfaces of the engine or muffler Use gloves and eye protection when servicing hot components Contact with a hot surface or fluid can cause serious injury from burns or scalding sa 3s gt Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 1 6 Section 2 Axtreme Boom Model Specifications SPECIFICATIONS AXTREME BOOM READ THIS BEFORE BEGINNING ASSEMBLY The Axtreme Boom has electronic components The electronic components can be damaged if care is not taken when performing repairs testing and or during assembly DO NOT DO NOT short any wires across or allow them to be shorted out DO NOT attempt to jump across any wires or supply them with alternate power source DO NOT install higher rated fuses than are recommended by manufacturer DO NOT do any welding on unit unless the computer modules are unplugged first this is to prevent a power surge going into modules THIS IS VERY IMPORTANT This could also apply to the tractor components Check Tractors repai
10. Specification Motor to Spindle Housing 100 ft Ibs SPindle to Deck 425 ft Ibs Spindle Bearing Pre Load 25 in Ibs Rolling Torque Blade Bar Leaf Bars 1 1 4 Bolts 2000 ft Ibs Blade Bolts 400 ft Ibs Blade Bar to Spindle 400 ft Ibs Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 2 3 SPECIFICATIONS AXTREME BOOM Control Valve 5 Spool used with Rotary Heads w Door Valve Type Open Center 5 Spool Valve Control Manual Standard Remote Cable Control Valve Control Electonic Joystick Optional Joystick Electronic Control Pressure Maximum Flow Maximum Main Relief Direct Acting 3000 PSI Adjustable FilterType Return Side Filter Size 10 Micron Bushings Greasable Steel Valve Ports See Figure 1 8 2 A Port Valve Ports designated as A Ports connect to the Rod End of the Swing and Lift Cyl to the Barrel End of the Dipper Cyl to the Barrel End of Tilt Cyl and to Barrel End of the Door Cyl B Port Valve Ports designated as B Ports connect to the Barrel End of Swing and Lift Cyl to the Rod End of the Dipper Cyl to the Rod End of the Tilt Cyl and to the Rod End of the Door Cyl Mechanical Remote Cable Controled Valve Standard A Port Side 5 A Yellow White Orange White Green White Pressure Supply Port P1 Return Port T2 Note Hose Colored Bands Bands with stripes go to Cylinder Base Solid color bands go to Cylinder rod end Red Wh
11. Ta Sight Gauge Sight Gauge Generic Type A FIGURE 7 i Return Pressure piste 4 Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 10 3 NOTES Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 10 4 Section 11 Axtreme Boom PRE DELIVERY INSPECTION CHECKLIST NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor components can vary with tractor model See the installation drawings shipped with the unit for the specific tractor type mount and hardware components IN SOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLATION DRAWING INSTRUCTION THE INSTALLATION DRAW ING INSTRUCTIONS WILL OVERRIDE THE ASSEMBLY MANUAL IN STRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Manl 07 06 2006 Alamo Group Inc Section11 1 PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See previous pages for component location Saftey Equipment Operators Manual is with Unit The Safety Decals are installed as listed in the Assembly Manual Valve operation plate is installed Operators cage or Tractor Cab is in place Deflectors are installed on the Mower Head Tractor Rops or Cab with seatbels instal
12. a Drive Motor and hoses for connecting to the units hydraulic system When adding Oil always use Clean new Oil from a sealed container If you suspect the Oil of being contaminated don t use it See Figure 2 8 3 It is best to always use a filter system when adding even new oll 4 When adding Oil in the field keeping it clean is critical do not use dirty funnels or hoses Do Not open Hydraulic tank or any containers unless the openings have been cleaned first The outside of the containers mustbe clean If a windy dusty day do notfilland allow dirt to blow into oil Always add Oil using apump system with at least a 10 Micron filter system See Figure 4 a Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 10 2 Fill Hydraulic Tank Fill Hydraulic Tank with Oil 5 Fill Tank Fill the Hydraulic Tank See Figure 4 Fill tank till the Oil is visible in the sight Gauge See Figure 5 amp 7 This will fill tank for the start but it will have to filled again later Read Step 6 a must 6 Fill Suction Hose with Oil This is an important step that must be done Remove the Suction Hose at the pump See Figure 6 and fill the hose with clean oil also oil can be put into the pump This will prevent Dry start up of Pump Dry start up of PUMP will damage the Pump After filling suction Hose reinstall it and tighten down Hose fittings See Figure 6 Suction Hose Pressure Gauge
13. clevis item 7 is retained to the valve spool item 10 with a bolt amp locknut item 8 amp 9 The valve spool will have a hole in it and two flat side for the clevis to slide onto Slide the clevis onto valve spool until the holes in clevis align with the hole in the valve spool Install the clevis retaining bolt amp locknut but do not tighten them at this time Continue this with the other four cables Figure 3 8 Mark Cables For Identification The cable Will be runupthrough the floor of the tractor See Figure 4 as an Example actual routing may vary It is recommended that the ends of the cables be marked before this is done to track which cable is which control function Cable need to be marked as shown from left to right See Figure 5 9 Remote Cable Control Handle The remote control cable handle is a stackable type where they can be bolted together All five of the handles used are the same See Figure 6 Remove the Cable Housing Retaining screw amp Nut See Figure 6 Set the screw and nut aside for now it will be reinstalled Remote Control Handle Straight Up In Neutral Position Handle Remote Control Stacking Cable Handle Asy Mount Holes Cable Housing Retaining Screw amp Nut Cable Housing Figure 5 Mounting ole Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 8 6 Valve Remote Cable Controls 10 Connect Cable to Control Handle Install the cable locking
14. from the diverter valve will continue along the LH side of tractor with sleeving material over them See Figure 10 to the front of the tractor They will have hose support brackets on them that bolt to the side of the tractor See Figure 10 where they will be connected to the valve at the Door Swivel Ports in the correct order See Figure 13 amp 14 The other cylinder hoses from the boom will be inserted into sleeving material and also be routed under the tractor to the LH side See Figure 11 They will continue up the LH side to the front of the tractor where they will connect to the valves ports The hoses will be held to the frame with metal hose holders bolted to the tractor frame See Figure 12 NOTE the hoses must be run through the sleeving material On the LH side there is a hole in the center frame weldment the hoses can be run through it if wanted Connect the hoses to the valve as shown See Figure 11 60 Inch Head with 60 ch Head with Swivel Hitch Mount Swivel Hitch Mount 50 Inch Head w o x Swivel Hitch Mount B ter i hs r 50 Inch Head w o Swivel Hitch Mount i N tay Motor Circuit Hoses to Boom Connections Listed as reference Color Tie Code Hose Size Hyd Function Red R SAE 16 Pressure Flow to Motor Orange OR SAE 16 Return Flow From Motor Blue B SAE 8 Case Flow From Motor to Boom Blue B SAE 12 Case Flow at
15. hydraulic oil leaking Oil is expensive andits presence could present a hazard Do notcheck for leaks with your hand Use apiece of heavy paper or cardboard High pressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene If oildoes penetrate the skin have the injury treated immediately by a physician knowledge able and skilled in this procedure 56 15 WARNING Always read carefully and comply fully with the manufacturers instruc tions when handling oil solvents cleansers and any other chemical agent sG 22 All Safety Shields Guards and Safety devices including but not limited to the Deflectors Chain Guards Steel Guards Gearbox Shields PTO integral shields and Miss Ea ode Retractable Door Shields should be used and main o tained in good working condition All safety devices should be inspected carefully at least daily for missing orbroken 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 sam 3 Defiector Axtreme Boom Asy Man 07 06 2006Alamo Group Inc Section 1 5 Safety Section DANGER NEVER use drugs or alcohol immediately before or while operating the Tractor and Implement Drugs and alcohol will affect an operator s alertness and coordination and therefore affect the operator s ability to operate the equipment safely Bef
16. or Right This will help it clear the Joystick when it is mounted once the desired location of the shifter is reached tighten the black knob back down to secure the tractor shifter lever in position you want it See Figure 11 NOTE Shift Lever is a tracotr Function any reference to the operation of it or the nomenclature should be referenced to the New Hol land Manual or authorized dealer FIGURE 6 Ma Tractor Dash Panelremoved N Existing Bolts pis and Holes Insert the wire harness up through the cab floor from the bottom the wires that connect to tractor wiring will also need to be inserted through the hole Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section9 5 Joystick Mounting Description Flatwasher Lockwasher Bolt Seat Mounting bracket Joystick Seat Cushion remoded for illustration omnly See Assembly drawings shipped with unit for specific joystick mount ing instructions Some Tractor Shift Levers are adjustable h A A 4 P X ka ii UP D i Fe CS ER z A i gt 7 r i wiz 1 Joystick Mount Joystick Mount FIGURE 10 Bracket gt FIGURE 11 Bracket Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 9 6 Joystick Mounting 4 Install Joystick Console Controler Set the Joystick Controller down on top of the mounting bracket and insert the two mounting bolts with flat washer and lock
17. the Yoke as you slide Pump Shaft into the Yoke Once Pump is slid into the Splined Yoke keep the Pump supported DO NOT let the Pump hang on the Yoke unsupported 8 Pump Driveshaft Yoke Gap Adjustment After sliding Pump Shaft into Splined Clamp Yoke the Pump and Yoke mustbe slid apart far enough to allow fora 1 16 to 1 8 Gap between them The Yoke edge cannot touch the Pump Housing it will damage the Housing and the Yoke if it does This is a very critical adjustment See Figure 9 Tube End of Driveshaft Typical Pump Mount Plate Shown Splined Clamp Yoke Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Splined Clamp Yoke Tube End Flange M Shaft End Drive Shaft Assembly Shaft 1 2 Assembly w Flanged Yoke Tractor Radiator Qi Left Hand front side of Tractor Bar to Hold Drive Shaft N A P A I Driveshaft pline SL Clamp Yoke End i Section 6 4 Pump Driveline Hose Installation 9 Tighten Clamp Yoke After Gap between Yoke and Pump has been adjusted tighten the Bolts amp Nuts on the Clamp Yoke See Figure 9 amp 10 Check Pump to Yoke Gap once more Keep Pump Supported do not let it hang on Yoke 10 Mount Pump to Pump Plate Removethe Bar that is slid through the Driveshaft Yoke and push the Pump inward See Figure 11 This will make the two piece Driveshaft slide together allowing the Pump to be pushed towards the tractor Do this untill the
18. the joystick to be mounted to the tractor seat or a stand that bolts to the floor Check which you have before ordering parts check the assembly list for your mount kit Swivel Head Option Wiring Harness Used Only with Swivel Head Mount Asy This Wire Harness only used with the Swivel Head Option Main Wire Harness Connection Diverter Valve Solenoid Connection Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section9 2 Joystick Mounting Wire Harness Side Joystick Resister Wiring Harness Used with Joystick Option Only Pin Numbers Locations PCB Assembly Pin Numbers amp Locations Joystick Side Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 9 3 Joystick Mounting Wiring Harness used with Joystick Valve Controls Only Note Wires are marked with function identification Communications Port X Joystick Connection Ignition Switch 12 VDC P Starter interupt Starter interupt Battery 12 VDC Battery 12 VDC Ground Negative Ground Negative Cutter Switch Connec tion Motor ON OFF Switch Valve B Side Valve A Side Door ni Door be 4H m Tiit Tik Dipper Dipper Lif A LR Swing p Swing Swivel Head Connection nee Optional l kl B A B c Fan Cooler o Connection This wire harness B Inline Fuse only use
19. the swivel head option is installed and share pressure fron the door port of the control valve The Port openings on this diverter valve are marked with letter number codes which show which port is connected to which hose and where that hose connect on other end See Above Diverter Valve Diverter Valve C1 Port to Swivel Cyl Base End Port Green w White Tie Diverter Valve C4 Port to Swivel Cyl Rod End Port Green Tie Valve B Port to Diverter valve P1 Port Green w White Tie 4 Through holes are Diverter Valve C2 Port mounting holes to Door Cyl Base End Port Yellow w White Tie Valve A Port to Diverter valve P2 Port Green Tie FIGURE 17 Valve Sections Function Mechanical Control Vale See Figure 18 Diverter Valve C3 Port to Door Cyl Rod End Port Yellow Tie Spool Cylinder Function Pressure B A A B 1 Swing Back Forward 2750 PSI 2750 PSI 2 Lift Up Down 2750 PSI 1160PSI 3 Dipper Out In 2750 PSI 1160PSI 4 Tilt Up Down 2750PSI Main Relief Main Relief 5 Door In Open Out Closed Main Relief Main Relief Electronic Control Vale See Figure 17 Spool Cylinder Function Pressure B A A B 1 Swing Back Forward 2750 PSI 2750 PSI 2 Lift Up Down 1160 PSI 2750 PSI 3 Dipper Out In 1160 PSI 2750 PSI 4 Tilt Up Down 2750 PSI Main Relief 5 Door In Open Out Closed 2750 PSI 2750 PSI Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 7 8 Rev02 20 07 Hydrauli
20. under the rear axle Stabilizer brackets for three point have been unbolted Install the bolts up and into the three point stabilizer bracket and the tractors rear axle housing and snug the bolts down Support the frame rail with a jack stand or leave the floor jack under it See Figure 17 amp 22 The RH Rear Frame Rail will basically install the same bolts up under the tractor axle housing with the three point stabilizer bolt back up under frame rail See Figure 18 amp 23 The RH Rail looks different at the rear because the boom rest will bolt here later 4 Install Front Frame Mount Rails The Front Frame mount rails will consist of a RH amp LH See Figure 19 20 24 amp 25 These will only fit one way as they have a gusset reinforcement on one side that will be showing to the outside when installed These can be lifted by the technician installing them The LH and RH will install the same way Using 4 bolts each that screw into tractor casting on the side of the tractor See Figure 24 Make certain that all 3 4 and 20 mm bolts have hardened flatwashers on them m 1 RH Front Frame hn lt x Moy 287 tH Frame Meunt Weldmeht 4 k m 8 Point Stabe lizer Bracke Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 8 Frame Installation 5 Install Center Frame Weldment The Center Frame Weldment has a front and a back side LH
21. unit after the installation of the maverick Boom has begun The Maverick Boom uses electronic modules and compo nents that could be damaged by welding Before doing any welding ALL ELECTRONIC MODULES AND DISPLAY COMPONENTS MUST BE UNPLUGGED Check the Tractors Opertion Repair Service or any other manual from the tractor manufacturer of the tractor to find any special electronic or special proedures about the tractor electronics Taking a few minutes to check could save you from a major damage to the electronics xtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 3 7 NOTES Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 3 8 Section 4 Axtreme Boom Battery Exhaust amp Fuel Tank Modification With Main Frame Installation NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor compo nents can vary with tractor model See the installation drawings shipped with the unit for the specific tractor type mount and hardware components IN SOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLA TION DRAWING INSTRUCTION THE INSTALLATION DRAWING INSTRUC TIONS WILL OVERRIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 1 Battery Holder Relocation B
22. valve One hose will have a Green Tie and one agreen and white tie where the come up throught the turret mount weldment See Figure 3 2 Booms Are recieved from the factory with the Sections of Boom Assmebled to together The Boom Sections are assembled with the hydraulic lines and cylinder connected The hose will be connected to the boom that are routed to the control valve and diverter valve and bundled together See Figure 4 The Boom Hoses are protruding out the turret mount end of the boom The Hose connections on the head end will be shipped with metal caps on them these are to protect the lines from contamination and should not be re moved until the hoses are being installed See Figure 4 The hose that attaches to the boom are sent in stalled on the head assembly and the hose will also have plugs in them 3 Boom Lift Cylinder The boom lift cylinder will be connected to the boom at the rod end of the cylinder See Figure 2 amp 4 when it is shipped from factory The hoses will also be connected to the cylinder The retaining pin for the lift cylinder will be located in the turret assembly The Lift Cylinder will be fastened to boom with tie wire It will not be required to remove this tie wire before mounting boom on turret assembly 4 Booms 8 Lift Cylinder Mounting Pins The Boom and lift cylinder mounting pins are shipped in stalled in the turrert assembly Remove both pins in preparation to mounting t
23. 006 Alamo Group Inc Section 4 6 Frame Installation Frame Installation 1 Frame Components The frame will include the rear axle mounts a LH amp RH Frame rail Two front frame mounts a LH amp RH One center frame LH Rear Frame weldment See Figure 17 18 19 20 amp 21 Mount Weldment 2 Install Frame Components The Frame components will only fit one way The Frame com ponents are a Bolt together assembly no welding will be required The Frame components will bolt together and to the tractor using mostly 3 4 and or 20 mm bolts Each 3 4 amp 20 mm bolt will use hardened flat washers one on the head side when bolts go into the tractor castings Two washers used when bolts use a nut and go through the Fi 17 frame These hardened washers are important igure RH Rear Frame Mount Weldment RH Front Frame Mount Weldment Center Frame Weldment LH Front Frame Mount Weldment Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 7 Frame Installation 3 Install Rear Frame Mount Rails Rear frame rails consist of a LH 8 RH We have started with the Left Hand Rail The three point lift stabilizer brackets will need to be unbolted on both sides In the illustra tion for the LH side we installed the frame with the LH rear tire and wheel still removed this was done for clarity not because the wheel needs to be re moved Using a floor jack to lift the rail up
24. 006 Alamo Industrial Section 6 9 Hyd Schematic Mechanical Operated Std Motor Return line Valve Return line Motor Control Valve Block Swing Cyl s Suction Hose Dipper Cyl F mo u E ull Return to Filter to Tank Door Cyl F TT u Motor Pressure Hose Q Q Es mem ol Valve Pressure Hose Oil Cooler amp Fan Asy Valve Return Hose Motor Pressure Lift Boom Steel Tube Motor Pressure Dipper Steel Tube Motor Pressure Boom Steel Tube OAO To Head Connecting Hose o a 39 Motor Return Steel Tube From Head Motor Return Dipper Connecting Hose Boom Steel Tube Motor Return From Head To Hyd Tank Figu re 22 Motor Return Lift Boom Steel Tube Axtreme Boom Asy Man 07 06 Rev 02 20 07 2006 Alamo Industrial Section 6 10 Hyd Schematic Electrically Controlled Opt Valve Return line Motor Control m Valve Block b om al Lift Cyl Hyd Tank L un oll LE 2 ol e Swing Cyl s on Hose Motor Return line Dipper Cyl Tilt Cyl f 2 9 21 E O Return to Filter to Tank Motor Pressure Hose Valve Pressure Hose Cl Pl Diverter Valve A P2 Optional C2 C3 Oil Cooler amp Fan Asy Valve Return Hose fh mo oo ci Head Swivel Cyl Motor Pressure Lift Boom Steel Tube Motor Pressure Dipper Steel Tube Motor Pressure
25. 06 Alamo Group Inc Section 4 16 Section 5 Axtreme Boom Wheel Weight Installation This section show the secondary weight that can be added to the LH rear wheel NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor components can vary with tractor model See the installation drawings shipped with the unit for the specific tractor type mount and hardware components INSOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLATION DRAWING INSTRUCTION THE INSTALLATION DRAWING INSTRUCTIONS WILL OVER RIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 5 1 Rear Wheel Counter Weight Fill Left Rear Wheel with Liquid The Left Rear Wheel must be filled with liquid Alamo Industrial recommends a Calcium Chloride Water Mixture The recommended Ratio of a 30 70 mix 30 Calcium Chloride and 70 Water this mixture will add weight at about 10 5 lbs per gallon Follow the Mixture procedures furnished by the Manufactured of the Brand of Calcium Chloride that you are using It is also recommended that a trained person installs the calcium Chloride Calcium Chloride must be added in addition to the Steel Wheel Weight and the Counter Weight that hangs on the Left Side It is Not recommend
26. 07 06 2006 Alamo Industrial Section 9 12 Section 10 Axtreme Boom Fill Hydraulic Tank amp Start Up Instructions NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor components can vary with tractor model See the installation drawings shipped with the unit for the specific tractor type mount and hardware components INSOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLATION DRAWING INSTRUCTION THE INSTALLA TION DRAWING INSTRUCTIONS WILL OVERRIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 10 1 Fill Hydraulic Tank Fill Hydraulic Tank with Oil 1 DO NOT START TRACTOR until you have filled Hydraulic Oil Tank to a level as shown in Sight Glass gauge and fill the Suction Hose to Pump with Oil 2 Remove Filler Cap Remove Filler cap only when ready to fill hydraulic Tank with Oil Do Notleave the Cap off and the system Open always keep system closed when possible Avoid any oil contamination See Figure 1 3 Avoid Hydraulic Contamination by filtering the Hydraulic Oil while filling the Hydraulic Tank Filter bug gies or carts are commercially available for Hydraulic system cleanup and Oil transfer These consist of high capacity filter a Circulating Pump
27. Cut Tractor Starter harnes should all be under floor Wire to Starter Sole mat of tractor and not visible noid and reroute this is a typical installation and through Joystick will vaey from type tractor to Harness Brown tractor model wires FIGURE 15 Tractor Ignition Switch Harness FIGURE 16 EE Axtreme Boom Asy Man 07 06 O 2006 Alamo Industrial Section 8 10 Hyd Schematic Mechanical Operated Std Motor Returnline Valve Return line Motor Control Valve Block k Lift Cyl p Hyd Tank Le m d E So O Swing Cyl s Suction Hose Dipper Cyl Tilt Cyl pF 1 4 o_o Return to Filter to Tank Door Cyl F mo mao Motor Pressure Hose L Valve Pressure Hose C4 Diverter a Valve A P2 Optional C2 C3 Oil Cooler amp Fan Asy Valve Return dise P L m m i Motor Pressure Lift Head Swivel Cyl Boom Steel Tube Motor Pressure Dipper Steel Tube Motor Pressure To Head Boom Steel Tube onnecingfl Motor Return Steel Tub From Head Motor Return Dipper aes Boom Steel Tube Connecting Hose Motor Return From Head To Hyd Tank Fig ure 18 Motor Return Lift Boom Steel Tube Axtreme Boom Asy Man 07 06 Rev02 20 07 2006 Alamo Industrial Section 8 11 Hyd Schematic Mechanical Operated Std Mechanical Remote Cable Controled Valve Standard A Por
28. Inspection Check List 11 1 to 11 4 Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Index 2 Section 1 Axtreme Boom SAFETY SECTION Safety Section Read these assembly instructions through completely and understand them S ha before proceeding with the assembly of the equipement REA Na A safe and careful operator is the best operator Safety is of primary importance to the manufacturer and should be to the owner operator Most accidents can be avoided by being aware of your equipment your surroundings and observing certain precautions The first section of this manual includes a list of Safety Messages that if followed will help protect the operator and bystanders from injury or death Read and understand these Safety Messages before assembling operating or servicing this Implement This equip ment should only be operated by those persons who have read the Manual who are re sponsible and trained and who know how to do so safely and responsibly The Safety Alert Symbol combined with a Signal Word as seen below is used throughout this manual and on decals which are attached to the equipment The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The Symbol and Signal Word are intended to warn the owner operator of impending hazards and the degree of possible injury faced when operating this equipment Practice all usual and customary safe working precautions and abo
29. Ke ALAMO BOOM ARM MOWER Published 07 06 Rev 02 20 07 Part No 02984405 ASSEMBLY MANUAL STANDARD INSTRUCTIONS Tractors equipped with additional options special equipment tractor manufacturer modi fications new tractor models or Customer alterations may prevent this Mount Kit from being properly mounted to the tractor Alamo Group is not responsible for modifications to the MountKit to accommodate these differences NOTE This manual is designed to be a basic assembly instruction manual and will show some illustration that are intended to be generic Some iluustrations may not reflect the type tractor the mower is being mounted on It is intended to be used with the Assembly Instrucrion Drawings sent for the specific tractor type that the mount kit was designed to fit It is important to keep these assembl drawing with this manual for future reference ALAMO INDUSTRIAL 1502 E Walnut MEMBER OF THE Seguin Texas 78155 dy nen l i ALYY E OF THE CUT EDGE 830 379 1480 2006 Alamo Industrial TO THE OWNER OPERATOR DEALER Allimplements 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 an
30. NTRODUCTION ABOUT THIS MANUAL The intent of this publications to provide the competenttechnician with the information necessary to assemble the Alamo Industrial Product This will in turn provide for complete customer satisfaction This manual is designed to be used as a basic component guide The assembly drawings shipped with the unit will be used as to the assembly of components that are specific to a particular tractor model these assembly drawings should always be kept with the other product manuals for future reference Itis hoped that the information contained in this and other Manuals will provide enough detail to eliminate the need for contact of the Alamo Industrial Technical Service Dept However it should be understood that many instances may arrive where in correspondence with the Manufacturer is necessary CONTACTING MANUFACTURER Please help us Help You Before You Call Alamo Industrial Service Staff Members are dedicated to helping you solve yours or your customer s service problem as quickly and efficiently as possible Unfortunately we receive entirely to many calls with only a minimum amount of information In some cases the correspondent has never gone out to look atthe equipmentand merely calls inquiring of the problems described to him by the operator or customer PART NUMBERS Part numbers listed in this manual are subject to change without notice as designs are made to adaptto the tractor or for a design improv
31. Pump is against the Pump Plate See Figure 12 11 Install Pump Mounting Bolts While holding in on the Pump See Figure 12 start the two Pump Retaining Bolts Make sure both Bolts are started well before you stop supporting pump The Bolts should be snugged untill pump sits level before you stop supporting it See Figure 12 Let go of the Pump it may slide back some and leave a slight gap between Pump and Mounting Plate See Figure 16 Align Splines of Pump Shaft w Splines of Yoke Bar to Hold Driveshaft Lo Clamp Yoke Bolt Splined Clamp Yoke 1 16 to 1 8 Gap between Pump amp Yoke must so P Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 6 5 between Pump 8 drivesahft Pump Driveline Hose Installation 12 Tightening Pump Mounting Bolts There is a shoulder on Pump Flange that mustline up through hole in Pump Mounting Plate See Figure 14 if the Pump is slid back as in figure 11 try to push it inward untill it is against Pump Mount Plate as shown See Figure 12 Slowly and alternating from Left to the Right side tighten the Pump mounting bolts untill they are tight DO NOT FORCE Pump through Pump Mount Plate if it will not freely slide in check for a problem of some kind Excess force could damage Pump Housing See Figure 12 Do Not remove any Plastic caps from Pump inlet or outlet at this time keep all openings plugged and sealed to keep them clean
32. RATION FIGURE 1 amp 2 1 Temporally remove ROPS and fenders from tractor axle Move left rear tire out so that it is 50 inches from the outside of left rear tire to the center of tractor Then move the right rear tire out so that it is 96 inches between the outside of the left and right rear tires Refer to your tractor s Operator s Manual for instructions on Rear Wheel Adjustment for your particular tire FIGURE 1 Hydraflate rear left tire as much as needed for stability but stay in factory recommend limit LE a FIGURE 1 96 WARNING Never operate the tractor with a loose wheel rim or disc Always tighten nuts to the specified torque and at the recommended intervals 2 Extend front wheels out so that it is 55 inches between the inside of the tires This will allow no interference between tire and front mount bracket FIGURE 2 s as sz 5 FIGURE 2 5 Le m W i ili xtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 3 5 General Information Installation Requirements Tractor Area Cleanliness The Tractor all tools and work area must be clean of dirt and debris when assembling any hydraulic components DO NOT leave any hydraulic component open to the elements DO not use any containers for fluids that are not clean and free of any other liquids DO NOT use rags cloth that has lint or fuzz on them when working on hydraulic components Keep all ho
33. TRUCTION MAY VARY FROM THE INSTALLA TION DRAWING INSTRUCTION THE INSTALLATION DRAWING INSTRUC TIONS WILL OVERRIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 6 1 Pump Driveline Hose Removal Pump Driveline Hose Information This Section covers the Pump and Driveline Components Some precautions must be followed during the assembly Process before unitis ever started for the first time See Hyd Schematic in this section for hyd routing Tractor must be disabled to prevent accidental engine start and prevent damge to components All Fittings Hose Cylinders Tank must be kept plugged at all times No part of the Hydraulic System can be left open at any time All Tools Work Area Components and Workers Hands must remain Clean when working on any part of the Hydraulic System All components should be rechecked for tightness at least twice Hose routing also double checked Componets shown here are a general illustration of the pump driveshaft configuration The actual configuration used on a specific tractor may vary See the assembly drawings shipped with the unit when shipped from the factory Keep these drawings with the assembly parts service operators manuals for future reference CAUTION Shown in Figure 1 is a basic pump driveline configuration BUT NOT the only configuration Components will
34. amp RH side The Center frame must be installed with the two openings See Figure 26 toward the front of the tractor These openings are to allow for the movement of the swing cylinders when moving the boom to the boom rest position IMPORTANT NOTE When bolting the center frame up to the front and rear frame mounting rails the bolts on the RH turret side must have the bolts installed from the bottom with the bolt heads on bottom under center under frame and the nuts on top See Figure 27 showing nuts on top The reason the nuts must be on top is so the bolts will not hit the swing cylinders when the turret assembly has been mounted The Bolts that are used to mount center frame are not the same lentgh The 8 bolts for the rear fame bracts bolts that face the rear of the tractor will be 3 4 X 3 1 2 long The other twelve bolts will be 3 4 X 2 1 4 long All 20 Bolts that at are used to mount center frame MUST have hardened flat washers install on both sides one under Bolt Head and one under Nut See Figure 26 amp 27 Using floor jacks or Fork lift position the center frame weldment up under the tractor See Figure 27 The center frame weldment will bolt to the front and rear mounting rails on both sides Make Certain to use hardened flatwashers on all 3 4 and 20 mm bolts when using nut on bolts it will need two hardened washers one on each side See Figure 27 Double check the frame mounting bolt tightness RH Side Rear To
35. an 07 06 Rev02 20 07 2006 Alamo Group Inc Section 7 11 NOTES Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 7 12 Section 8 Axtreme Boom Remote Valve Cable Installation This Control valve is the Standard 5 Spool thatis remote cable controlled withthe 5 Th Spool operating the Door or the Swivel Head Mount Option through a diverter valve The Standard Pump System is used to supply the cylinder valve control circuit NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor compo nents can vary with tractor model See the installation drawings shipped with the unit for the specific tractor type mount and hardware components IN SOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLA TION DRAWING INSTRUCTION THE INSTALLATION DRAWING INSTRUC TIONS WILL OVERRIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 8 1 ON OFF Switch Installation Wire Harness Standard Mechanical Valve 1 Starter Safety Switch Schematic Mechanical Cable Operated Valve Type NOT correct for Optional Joystick Electronic Controls 2 Figure 1 illustrates a common wire harness connection for Boom mowers with mechani cal cable controls If the Joystick Optional controls are used the Wiri
36. attery Holder Relocation 1 The Battery Relocation The battery holder is located on the RH side of the tractor See Figure 1 It will have to be relocated The mount kit will include a battery relocation kit The battery relocation kit includes a mounting bracket See Figure 2 that will relocate the battery tray farther to the rear This is done so the Boom Swing will not hit battery when in the transport position The RH Step Will need to be removed to allow access to relocate battery 2 Remove Factory Battery Cover Battery Bat tery Tray and Battery Tray mount Remove the bat tery cover See Figure 3 Remove the battery cables from the battery Remove the battery from the battery tray Unbolt the battery tray from the tractors factory mount bracket Remove the factory mounting bracket from the tractor See Figure 4 3 Install Replacement Battery Tray Bracket Battery Install the replacement battery tray bracket See Fig Relocation ure 2 using the same bolts and holes as the original Bracket bracket This Bracket is designed to move battery further back Install original battery tray using original hardware Reinstall battery into batter tray See Fig ure 3 DO NOT reconnect battery cables at this time leave them off and make certain they do not make contact with the battery connections as you do not want the battery connected during installation Re place the battery cover See Figure
37. au them that match the colors listed here this is a guide to which hose connects where Cylinder Control Valve Cables To Valve Spools The Remote Control Cables Connection to the valve and the Control Handle assembly See Figure 2 for listing of items 1 thru 8 listed in assembly steps 1 Remove the phillps head screws that are in the valve body next to the spool end 8 There are bolts in kit that will be used to replace these screws when needed See Figure 2 Slide the Bolt flange 8 Thread 750 16 NF jam nut entire length of threaded hub and onto the cable 7 Place flange on sleeve and thread flange sleeve assembly entire length of threaded hub and onto cable 2 amp 6 Thread 250 28 NF jam nut onto cable threaded rod until it bottoms 3 Place connector onto threaded rod and against jam nut Align connector so it will mate with spool terminal and secure jam nut against connector 4 Slide the connector onto spool and align the holes Insert pin through connector and spool holes 5 The control cables will need to inserted through the floor of the tractor cab and the Control Levers will need to be assembled to the cables before continuing with the next assembly steps With cable attached to the valve and control levers turn the flange sleeve assembly onto the threaded hub until it is flush with the valve face When turning the flange sleeve assembly make certain that the control levers remains in the neutral position Tighten
38. c Hose Connections Joystick Electronic 2 E Controled Valve Optional A Port Side Red White Dipper Blue White Lift Orange Pressure Supply Port P1 B Port Side Return Port T2 2 5 eo gt m Figure 18 RE FE RE A ae gt Mechanical Remote Cable Controled Valve Standard A Port Side Note Hose Colored Bands Bands with stripes go to Cylinder Base Solid color bands go to Cylinder rod end Orange White Swing Green White Swing Green White Lift Orange White PEs 2 ZEN SE Es AE Fe a Pressure Supply Port P1 B Port Side ao Bi Return Port T2 4 Note Hose Colored Bands Bands with stripes go to Cylinder Base Solid a 2 2 gt color bands go to Cylinder rod end 58 25 AB s 5 SH EL T as S Figure 19 Ag 5 FS 5 6 ES Axtreme Boom Asy Man 07 06 Rev02 20 07 2006 Alamo Group Inc Section 7 9 Hyd Schematic Mechanical Operated Std Motor Returnline Valve Return line ion Hose Motor Control Valve Block Swing Cyl s Dipper Cyl Return to Filter to Tank Oil Cooler amp Fan Asy Motor Return From Head To Hyd Tank Motor Pressure Hose Valve Pressure Hose Motor Pressure To Head A 5 Valve Ret
39. ck diverts the hydraulic pressure through a bypass by using an electric solenoid so the pressure can be used to operate two functions one atatime as needed This block is bolted to the mainframe on the LH side back from left front wheel and is connected to the door cylinder and the optional head swivel option cylinder Through a toggle switch operation it can be decided which cylinder will function when on the cable control valve system and through button trigger combination on the joystick electronic valve FIGURE 18 control option If the head swivel option is not used this diverter valve will not be used See Figure 17 Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 6 8 Pump Driveline Hose Installation Swivel Cyl Base End Gi Port G W Tie bora vl Hip a swivel l Rod Ed C4 Port G Tie From Valve A e gaa 2 Port to P1 Diverter apio ey fr Port G7 Wilgle v Door Cyl z f an e s4 gt E Valve A Port to TA Div rter Por p A Lad Return to Tank Return Filter Two Wires In Plug 1 Red Wire Pos Connector 1 Black Wire Neg Connector Return From Cyl ControlValve Figure 21 The return oil cooler with fan is inthe cylinder control valve circuit The return oil from the cylinder control valve is going through the cooler as it is being returned to the cutter control valve block See Figure 20 amp 21 Axtreme Boom Asy Man 07 06 2
40. d somewhere else is desired If Mounted somewhere else keep in mind it must be accessible quickly by the operator in case of emergency needs See Figure 10 Door Swivel Cable retaining screw Cable Housing amp nut installed inserted into hamdle asy Axtreme Boom Asy Man 07 06 O 2006 Alamo Industrial Section 8 7 Valve Remote Cable Controls 13 The Arm Rest is bolted to the Control Handles This has some options as to where it is bolted and can be bent to adjust to individual preference See Figure 11 14 Control Handle Stand is bolted to the floor of the Cab under the Floor Mat on the right hand side oir to the cab support post with a fabricated bracket There is a rubber plug in floor under floor mat here Remove and or cut the rubber plug to run the cables and wire harness through it The opening around cables through rubber plug can be sealed using silicone sealer Floor mat will lay back down around cables and leave a smallarea of floor mat opening See Figure 11 Figu re 11 SWING LIFT DIPPER TILT 09834068 15 Cable Handle Control Instructional Decal There will be a decal showing the operation of the spools of the valve that will show you how the handles shoud be placed 13 Control Handle Adjusted to neutral position Adjust the cable control handle to the neutral posi tion Using the two locking nuts on the cable hous ing to adjust the handle to the neutral position Loose
41. d shown in your manual Observe the rules of safety and common sense DANGER FAILING TO FOLLOW SAFETY MESSAGES AND OPERATING INSTRUCTIONS CAN CAUSE SERIOUS BODILY INJURY OR EVEN DEATH TO OPERATOR AND OTHERS IN THE AREA 2 NO RIDERS 3 USE SAFETY SHOES 4 BLOCK UP SECURELY HARD HAT SAFETY BEFORE WORKING GLASSES SEAT UNDER BELTS amp ROPS 1 Study andunderstand oper tor s manual safety signs and Instructional decals for tractor and implement to prevent misuse abuse and accidents Learn how lostop engine suddenly In an emergency Be alert for passer by and especialy chidren 2 Mownochidren on ormear implement or tractor Mownonders on tracio andimplement Falling off may cause sericu sinjury or death from being run over by tractor or culler or contact with rotating i sdes 3 Operate ontywith tractor having Roll Over Protectve Sructure ROPS andwilh seatbelt fastened securely and snugly to prevent mjury and possible death from falling off or tractor overturn Personal Protective Equipment such as Hard Hat Safety Giasses Safety Shoes and Ear Plugs are Recommended 4 Block up or support raised machine and allfted components se curely before putting hands or feet under or working underneath any Medcomponents toprevent crusting Injury or death trom sudden dropping or inadvertent operation of controls Make certain area s clear beforelowenng or folding 5 Before transporting put Lift Lever in detent of full position Secure the mpl
42. d with Joystick 20 amp Optional cyl valve Temperature Sensot controls Connection m lcan Module Connection Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 9 4 Joystick Mounting Joystick Installation 1 Cab Floor Access Hole Raise the floor mat on the RH side of the cap and inspect the floor for an access hole to the under side of cab A 2 diameter hole is needed to run the cables or the wire harness through If there is no hole one will need to be cut with a hole saw Check the under side of the cab floor to make certain you do not hit a brace or any other object under the floor See Figure 5 DO NOT cut the floor mat it will not be required Run the wire harness up through the floor from the bottom and to the left of the floor mat See Figure 6 2 Remove Tractor Dash Panel Remove the plastic panel on the RH side of the dash from the floor up See Figure 7 This will give access to the tractor ignition switch plug for connecting the wire harness to the tractor starter wires See Wire Schematic See the New Holland Manual for the location of the wires to the switch on the tractor 3 Locate the Seat Panel Bolts The Joystick mount ing bracket will bolt the lower seat panel See Figure 8 9 amp 10 If the controls on the RH Fender interfere with the joystick See Figure 11 Loosen the black knob on top of the shift selector This knob allows the shift lever to be moved Left
43. e been tightened Pressure Hose to Cyl Valve a Return Hose amp Return Filter Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 6 6 Pump Driveline Hose Installation Back Pump Side Brake Relief 1875 psi Main Relief 3000 psi Bolts Direct To Pressure Outlet Motor Front Cyl Control Valve Side Of Circuit Pressure Inlet Control Q Block Back V Logic Side Of Control Block Motor Circuit Pressure Inlet Bolts Mounting Control Cartridge Block to Pump Return Oil Return Oil From From Motor Cylinder Control Motor Return to Tank Valve Oil Via Oil ON OFF Via Return Filter Figu re 15 Cooler amp Fan Asy Solenoid Motor Control Valve Block The pump motor control valve block this MotorCircuit bolts to the right hand side of the pump See a Figure 13 14 15 8 16 The pressure andreturn AUALA T hoses are connected to this valve block Return Port 8 The Motor Control Valve Block is used to ks control the on off function of the mower head The control block diverts the hydraulic pressure Gylinider Circuit through a bypass by using an electric solenoid AA pe Oil Supply to Pump Pressure Port Baek side Pump Not L EN cay Seen Ax F q The Brake relief should be pre set at 1875 psi and is located on top of the control block this is a brake to stop the motor from turning when EE Cylindet Circuit moweris shut down If the mow
44. e exhaust for tightness and fit Replacement Exhaust Bracket Figure 5 Factory Exhaust Mount Bracket r d New Exhaust Pipe Figure 8 R E RSS e A Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 3 Fuel Tank Replacement Fuel Tank Replacement 1 Remove RH Rear Tire and Wheel If Required See Assembly Drawings sent with unit Use proper Floor jack to lift the RH Rear Wheel Support the tractor with proper jack stands rated appropri ately for the tractors weight The RH rear tire and wheel should be removed for this installation by using tower head hoist to support and lift the wheel and tire i assembly The tractors factory fuel tank is mounted behind the RH rear tire and wheel See Figure 9 2 Remove Tractors Factory Fuel Tank and Mounting Brackets If Required See Assembl Drawings sent with unit The LH factory step will w have to be removed from the tractor before attempt 1 _Rerflove RH ing to remove the fuel tank the step will not be A Rear Tire amp reused The factory fuel tank will need to drained of Wh el fuel Use an appropriate and safe method for pump 4 ing out tank and for the storage of the fuel removed The Tank is removed by loosening and removing the retaining straps that you will see around the tank from the out side DO NOT Attempt to remove tank with fuel in it Store the fue
45. ed to use straight Water in the Wheel as this would not provide protection against freezing A 30 70 Calcium Chloride Water mixture provides antifreeze to approx 50 deg F below 0 Rotate Washer to Match Bolt Circle dia and Washer fits into 3 Wheel Weight Slot Bolt is shown extra long in drawing for illustration only Item Part No Qty Description 1 02979603 3 Hex Head Bolt 7 8 NC X 16 2 02971569 3 Wheel Weight Washer Special 3 02970758 1 Wheel Weight Casting 1400 Ibs 4 5JRC1490 3 Locknut Top Lock 7 8 NC Note some Older Units used a All Thread Rod with Hex Nuts Lock Nuts with Flat Washer and Lock washer This was replaced with the Bolt Type shown above These Bolt and Nut combinations will replace the old All Thread type Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 5 2 Rear Wheel Counter Weight Installing Wheel Weight 1 This Wheel Weightis 1400 lbs Always use caution when working with it 2 Locate the three Holes in LH Rear Wheel Make sure these holes are 15 16 dia if not they must be reamed out 3 Lift Left Rear Tractor Wheel till it just clears the ground This will allow the Wheel to be rotated when aligning mounting holes for Weight 4 Using a forklift lift Wheel Weight into Wheel When Wheel Weight is centered in Wheel Se cure Forkliftand Set Parking Brake on Forklift Insert one of the three bolts through Weight and Wheel Rotate Wheel to align
46. electrical connection problem is to bypass them this should never be done eliminating the starter safety system is dangerous and hard on the Hydraulic System The Hydraulic System will be trying to start at a low RPM which is not good Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 8 2 Wire Harness Cable Controled Valve Oil Cooler Fan Connection Inline Fuse 20 amp Head Swivel Optional Wire harness P N 02982924 connects a ha here if swivel option is e a used Motor Control Block Solenoid at Pump Ce All Standard Wire Harness have connections for the swivel head harness and the toggle control switch these are not used unless swivel head option is ordered Ground A Starter interupt we Starter interupt Ignition Switch 12 VDC Swivel Cylinder Option Control Switch Toggle Switch is not included with wire harness only used with Head Swivel Cylinder option Inline Fuse 20 amp Cutter Switch Connec tion Motor ON QFE Switch Figure 1 Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 8 3 Valve Remote Cable Controls Hoses have colored plastic ties on them that match the colors listed here this is a guide to which hose connects where Mechanical Remote Cable Controled Valve Standard Yellow White Green White Pressure Supply Port P1 Return Port T2 Hoses have colored plastic ties P
47. ely The set of five will be shipped with a mount kit when using remote cable controls 3 Install Valve Cable Mounting Bracket The valve cable mounting bracket will have 5 holes to mount 5 cables See Figure 2 The cable will be shipped with the components on them or in a separate package 4 Install cable to valve cable mounting bracket Locate the cable amp housing assembly one end the cable housing is threaded See Item 1 Install inner locking adjusting nut See Item 3 on to the cable housing screw it on until it is about 3 4 the way on Slide the lockwasher See Item 2 on to the cable housing until itis seated against the inner locking nut Install the other locking adjusting nut See Item 4 on the cable housing and screw it on until the nut is touching the valve mounting plate but do not tighten the nuts at this time Repeat this procedure with the other four cables 5 Install Locking nut to Cable Install the locking nut to the threaded end of the cable See Item 5 amp 6 Screw the locking nut onto the threads of the cable to about 3 4 of the way Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 8 5 Valve Remote Cable Controls 6 Cable Clevis Installation Screw the cable clevis item 7 onto the threaded cable item 5 until the threads are fully engaged into the clevis If the locking nut item 6 needs to be run further onto cable this is OK 7 Connect Cable Clevis to Valve Spool The cable
48. ement Before ordering parts ALWAYS Measure old part to make certain that is the one you will need This manual is designed to be used along with the Parts and Operators Manual Most calls received by Alamo Industrial Service can be classified into approx 6 general categories Hydraulic or Mechanical Trouble Shooting Request for Technical Information or Specifications Mounting or Fitting Problem Special Service Problem Equipment Application Problems 6 Tractor Problem Inquiries HOW YOU CAN HELP 1 Make certain the call is necessary Most of the calls received may not be necessary if the Dealer Service Technician would do the following 2 Checkthe Service Information at your Dealership provided by Alamo Industrial This would include Service Bulletins Information Bulletins Parts Manuals Operators Manuals or Service Manuals many ofthese are available viathe Alamo Industrial Internet site Alamo Industrial Com Attempt to diagnose or repair problem before calling 3 Ifacallto Alamo Industrial is needed Certain Information should be available and ready for the Alamo Industrial Service Staff Such information as Machine Model Serial Number Your Dealer Name Your Account Number and Any other information that willbe useful This information is vital for the development of a prompt and correct solution to the problem This will also help to develop a database of problems and related solutions which will expedite a solution to fut
49. ement for transport by installing Cyinder Stops or Transport Pin on Pull type implement center axle and Wing Transport Locks on folding implements e Attach Safety Chain to cuter andtowing unit securely See Operator s Manual 5 Make certain that the SMV sign Warming Lights and Refiectors are deary visible Follow local traffic codes 7 Never operate wth Cutting Head raised F passerby bystanders or tratic are in the area to reduce possibilty of injury or death from Objects Brown by Blades under Guard ar cutter structure 8 Before drsmounlin secure mplement in transpor position or lower to ground Put tractor in park of set he brake disengage PTO stop engine and remove key and wail until noise of rotation Has ceased to prevenl entanglement in rotating parts whichcan cause injury or death Never mount or dismountamoving vehicle Crushing from runover may cause injury or death 5 TRANSPORT SAFELY 6 USE SMV LIGHTS amp 7 DO NOT OPERATE 8 DO NOT MOUNT OR LOCK UP REFLECTORS WITH CUTTER OR DISMOUNT WHILE WING RAISED MOVING at 00749117 X WARRANTY INFORMATION Read and understand the complete Warranty Statement found in this Manual Filloutthe Warranty Registration Form in full and return it to within 30 Days Make certain the Serial Number of the Machine is recorded on the Warranty Card and on the Warranty Form that you retain NOTES Axtreme Boom General Assembly 02 06 Rev 02 20 07 2006 Alamo Group Inc I
50. ent Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 2 2 SPECIFICATIONS AXTREME BOOM Fifty Inch 50 Cutting Head Specifications Blade Motor Rotation Looking down from Top of Deck Clockwise Blade Tip Speed 18 850 FPM 210 MPH Blade carrier Type Pan or 3 Leaf bar Option Blade Pan Blade Qty 2 Blade or 3 Blade Option Blade Bar Blade Qty 2 Blades Blade Cutting Width Overall 50 inches Deck Construction Formed and Welded Steel Deck Material 10 Gauge Deck Weight 725 lbs SPINE train ko ek ane den ni S tn 4 5 by 9 Heat Treated Alloy Spindle Bearing Tapered Roller Bearings Spindle Lubrication Grease Pumped In Motor Motor Motor Speed Maximum 2400 RPM Motor Pressure Maximum 3000 PSI Motor Rated Pressure 3000 PSI Motor Rated Flow Motor Displacement Sixty Inch 60 Rotary Mower Head Blade Motor Rotation Looking down from Top of Deck Clockwise Blade Tip Speed 18 000 FPM 205 MPH Blade Carrier Type 2 Leaf bar Option Blade Bar Blade Qty 2 Blades Blade Cutting Width Overall 60 inches Deck Construction Formed and Welded Steel Deck Material Deck Weight Spindle nr Ne RO NTE 4 5 by 9 Heat Treated Alloy Spindle Bearing Tapered Roller Bearings Spindle Lubrication Grease Pumped In Motor Motor Gear Widi eerie i iriri ririri Eren eE EEEE EER 2 25 Motor Speed Maximum Motor Pressure Maximum Motor Rated Pressure Motor Rated Flow Motor Displacement Rotary Head Torque
51. er head does not Pr ssute Port Oil Supply Return i i js Filter stop check this pressure setting k P Return The motor control block has the main relief E a gt onit this relief is set to 3000 psi Max 3000 psi Figure 16 G 0 Valve to Filter Hose and should not be exceeded If a problem in the system this pressure should be tested using an appropriate pressure flow meter DO NOT do any adjusting or modifications to the control block without the proper testing Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 6 7 Pump Driveline Hose Installation Used with Swivel Head Option Only Electric Solenoid Retaining Nut Electric Solenoid These 2 threaded holes on back C1 Port this side side for mounting diverter valve Not Seen to Door to frame Not Seen Cyl Base End Pi Pressure from control Valve Door Head Swivel of control valve Port C4 Port this side Not Seen to Door Cyl Rod End SA disel These 4 holes are through holes more valves together These hol are not used in this application that would be used if this were a stacking valve to stack two or es C2 Port to Head Swivel Cyl Base P2 Port Return to control valve Door End Head Swivel Port of control valve C3 Port to Head Figure 17 Swivel Cyl Rod End Cylinder Diverter Valve Block The Cylinder Diverter Valve Block is used to control the hydraulic head swivel option if used The control blo
52. haft Pulley if they go completely through the adapter Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 6 3 Pump Driveline Hose Installation 4 Driveline timeing means the universal joints are both the same position when driveline half is slid together If they are nottimed it will decrease the life of the universal jointandin some cases could cause a vibration See Figure 2 amp 3 Driveline timing is critical to smooth operation 5 Install Tube End of Driveline Pump End Slide the Tube half of driveshaft through Pump Mount Plate and Tractor Crankshaft Access Hole See Figure 8 You will have to align the Universals when doing this time the Driveshaft Slide the two together where the Universal are in time See Figure 2 3 amp 5 this will help the driveshaft to operate smoothly 6 Loosen Splined Clamp Yoke Insert a bar through the Yoke to hold Driveshaft up and to help loosen the Bolts in the clamp Yoke See Figure 6 This can be loosened with ahand Wrench or a Socket whichever is easier See Figure 6 Sometimes it is easier to test fit the Tube End of Driveshaft to the Pump while the Pumpis onthe bench But this make timing the driveline yokes more difficult 7 Install Pump into Splined Clamp Yoke Coat the Pump Splined Shaft with Anti Sieze Compound Slide the Pump Splined Shaft into the Spline Clamp Yoke See Figure 8 Leave the Bar stuck in through the Yoke as shown this helps to stabilize
53. he boom See Figure 3 5 Lower Boom onto Turret Assembly Using an over head hoist lift the boom by placing a lift strap at the boom hinge point See Figure 2 the boom assem bly will be shipped with the two boom end tie wired together See Figure 3A The wire tie will need to be removed as it is tied through the boom hinge pin hole Lift the boom above the turret assembly and lower it back down onto the turret assembly aligning the boom with the mounting pin hole Install the Mount Pin through the turret and into the boom Make certain the pin is installed correctly as one side of the pin is self locking in design Tighten the pin retaining nut and install cotter pin See Figure 3C Swing Cyl Hose WitaGreen White Tie Swing Cyl Hos y gt with Green Tie Rear of Tractor Lifting Point Figure 2 E i Main Boom MountPin Lift Cyl Base End Mount Pin Axtreme Boom Asy Man 07 06 O 2006 Alamo Group Inc Section 7 2 Boom Head Installation 6 Connect lower end of Lift Cylinder The Base end lower end of lift cylinder will mount into the turret under the boom mount The Cylinder will have to be extended to connect If cylinder has to be extended the best way is to unplug the ends of the lift cylinder hoses where they come out of the boom these will be the 6 hose with the Orange Tie and the 6 hose with the orange White Tie When p
54. hich will not have the swivel attachement See Figure 6 amp 7 If using the 50 head leave the ports for swivel cylinder on boom capped See Figure 8 More types of heads are tobe made available at a later date 10 Connect Hose From Boom to Control Valve The cylinder hoses will connect to the control valve mounted on the front of the tractor with the exception of the Door and Swivel Cylinder hoses they will connect to the diverter valve and then there are two hoses that connect to thediverterr valve to the 6 spool control valve See Figure 11 The hoses for door and swivel will be routed under the tractor along the center under frame weldment to the diverted valve which will be mounted on the LH side of the tractor on the front frame mount bracket oO Sal ay Lift ois a i a AU f Mount Pin Figure 3C Le S Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 7 3 Boom Head Installation 11 Routing Cylinder Hoses from Boom to Valve The Hose from the boom to the valve will be split the four hoses to the door cylinder and swivel cylinder will run together through a section of sleeving material to the RH side of the tractor See Figure 9 On the Right hand side of the tractor the four hoses will connect to the diverter valve in the coded locations See Hose Codes on next pages Tie the hoses to the frame under the tractor See Figure 10 The two hoses
55. holes if needed Install a Hex Lock Nut on inside Insert the other two Bolts through Weight and Wheel and start the other two Locknuts Do not tighten yet See Figure 2 Wheel Weight Mntg Locknuts 5 Looking at the outside al dd Wheel Weight ers Figure 1 Item 2 are aligne with the Slots in the Wheel Weight Special Washers En 1400 Ibs Tighten the three Bolts now You will need an assistant to hold the other Side while you are tightening the Bolts While tightening Bolts check to make sure the three spe cial washers are seated correctly If these Bolts are tightened and washer are not seated into the recess on Wheel Weight dam age will occur See Figure 3 Part 02971569 6 Remove forklift away from Wheel and Weight Recheck tight ness of Wheel Weight retaining Bolts Bolts should torque to 500 ft Ibs Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 5 3 NOTES Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 5 4 Section 6 Axtreme Boom Typical Pump Driveline Hyd Assembly instructions NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor compo nents can vary with tractor model See the installation drawings shipped with the unit for the specific tractor type mount and hardware components IN SOME CASES THE MANUAL INS
56. igure 37 5 i VEM gt Center Section Under Frame Weldment Turret Mount Attaching Pin Long Pin Turret Mount Attaching Pin Long Pin Turret Attaching Pin Short Pin one Front side and one rear side NOTE Turret Assembly shown as diassembled for illustration only Turret will be shipped as an assembly when shipped with mount kit Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Rev02 20 07 Section 4 12 Frame Installation 3 Turret Assembly Installation Theturret assembly mounts on the RH side onto the center section under frame See Figure 36 amp 37 Using a hoist or other lifting device lower the turret assembly until itis level with the underframe Slide the turret assembly inward toward the under frame until the retaining pin tube on under frame an turret assembly align Installthe long upper retaining pin and then the two small front and rear pins The long upper pin is retained with two cotter pins that need to be bent over on the ends The short pins are retained with nuts and bolts See Figure 36 amp 38 ES 4 Turret Assembly Grease Fittings The turret assembly has three grease fittings around the OD of it The grease fittings are 120 apart this is to make certain that the bearing will be greased all the way around because of the large diameter of the bearing This bearing must be greased before unit is pu
57. ings shipped with the unit for the specific tractor type mount and hardware components IN SOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLATION DRAWING INSTRUCTION THE INSTALLATION DRAW ING INSTRUCTIONS WILL OVERRIDE THE ASSEMBLY MANUAL IN STRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 3 1 General Information Installation Requirements General Information The tools you will need at the assembly site are as follows Welding equipment including correct head gear eye shields and protective clothing Impact wrench or socket and ratchet set Rubber mallet Box end Allen and crescent wrenches Alignment pins Phillips and plain head screwdrivers Forklift or hydraulic floor jacks with rolling back boards Over head hoist and floor jacks Jack Stands and or other support devices that are strong enough to support tractor and components 10 Multidirectional Levels 11 Paint Scraper 12 Hydraulic Filter Buggy or Cart 13 Safety shoes safety glasses and gloves 14 A hard hat should be worn by anyone working under any raised component NO 01 8 D gt Remember to follow each step closely and cautiously Be aware of all support personnel at all times Keep the assembly area as clean as possible clean up all spills when they occur An uncluttered assembly area and a crew that
58. is sensitive to the hazards involved in putting this implement together will help prevent accidents Keep all unauthorized personnel from the area Do not allow children near the assembly site nor allow them on or near the tractor after assembly There is no safe place for anyone except the operator on the tractor and those assisting with the assembly To help you assemble your new Unit and mount it to your tractor a detailed assembly instruction Manual is being provided with the mount kit to provide detailed instructions and part numbers Please consult this document for specific information When needed you can get additional information or clarification from Your Dealer or Alamo Group Customer Service This publication provides general information and may not specifically be for your case or tractor but in connection with the assembly drawings that are sent with the mount kit this publication offers you some valuable assistance please read it thoroughly and use it with your assembly drawings and other publications Other publications may include operators manual parts manual service manual or any other publication sent by manufacturer Keep all publications together for future reference These mount kits are made for selected tractors with standard configurations Only the noted options and tire sizes listed in the Mounting Specifications will work with these mount kits Other options front axles or different tire sizes may prevent the moun
59. ite Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 2 4 SPECIFICATIONS AXTREME BOOM Joystick Electronic Controled Valve Optional A Port Side 7 Valve Sections Red White A gt 5 a Function Blue White Orange White Mechanical Control Vale See Figure 1 Spool Cylinder B Swing Back Lift Up Dipper Out Tilt Up Door In Open Function A Forward Down In Down 2750 PSI Out Closed Electronic Control Vale See Figure 2 Spool Cylinder B Swing Back Lift Up Dipper Out Tilt Up Door In Open Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Function A Forward Down In Down Out Closed Section 2 5 Green White Pressure Supply Port P1 Return Port T2 Note Hose Colored Bands Bands with stripes go to Cylinder Base Solid color bands go to Cylinder rod end Pressure A 2750 PSI 2750 PSI 2750 PSI Main Relief Main Relief BN 2750 PSI 1160PSI 1160PSI Main Relief Main Relief Pressure A 2750 PSI 1160 PSI 1160 PSI 2750 PSI 2750 PSI B 2750 PSI 2750 PSI 2750 PSI Main Relief 2750 PSI 8 Dash Size 4 6 8 10 12 16 20 24 32 SPECIFICATIONS AXTREME BOOM Hose End Fitting Torque Specification Hose End Type 37 Degree Angle End Steel Hose End Fittings Nominal Cyl Size in 1 4 3 8 1 2 5 8 3 4 4 1 1 4 1 1 2
60. ith an approved roll over protective system ROPS Always wear seat belts Serious injury or even death could result from falling off the tractor particularly during a turnover when the operator could be pinned under the ROPS 567 Never work under the Implement the framework or any lifted compo nent unless the Implement is securely supported or blocked up to prevent sudden or inadvertent falling which could cause serious injury or even death so 14 WARNING Use caution and wear protective gloves when handling sharp objects such as blades knives and other cutting edges Be alertto worn component surfaces which have sharp edges Sharp surfaces can inflict severe laceration injuries if proper hand protection is not worn sa 37 Axtreme Boom Asy Man 07 06 2006Alamo Group Inc Section 1 3 Safety Section WARNING Many of the parts are heavy and require lifting assistance Do not try to lift the heavy parts by yourself Get help from another employee or from an overhead crane WARNING The operator and all support personnel should wear hard hats safety shoes safety glasses and proper hearing protection at all times for protection from injury including injury from items thrown by the equipment sa 16 L WARNING Always wear safety shoes with steel toes when working on this equipmen t It is recommended that the safety shoes have metatarsal guards N Al 7a WARNING When welding use Welding hood wi
61. itting of hoses to valve See Figure 20 amp 21 lay the Plugs out in the Order they are to be installed starting at the far end terminal Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section9 9 Joystick Mounting Installing Wire Harness To Valve Continued 5 Terminal Connections The Valve is mounted on the left hand side of the hydraulic tank PLUG FUNCTION 1 1stPlug Swing Terminal 2 2nd Plug Lift Terminal 3 3rd Plug Dipper Terminal 4 4th Plug Tilt Terminal 5 5th Plug Door Terminal Always check to make certain that the plugs are securly mounted t mthe valve 6 Wire Harness Completed Pull the Wire harness back toward Cab to remove any ex cess slack only enough to remove slack not to make Wire Harness tight Tie wire harness or hoses to Tractor Frame Rails to prevent them from rubbing or getting caught on something The Wiring Schematic is shown in this book as a reference only the wire harness will come to you assembled and ready to mount The only wires that will have to be altered are the wires inside that connectto the existing Tractor Wires These inside wires are intentionally left long so they can be cut as needed None of the wires with the factory plugs will have to be cut Phillips Screwdriver MT Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 9 10 Hyd Schematic Electrically Controlled Opt Valve Return line Motor Con
62. iveshaft to go into If this is needed most tractors will have a dimple mark in the front to indicated the center point of the engine crankshaft A hole of sufficient size will need to be cut in most cases a 1 1 2 to 2 dia hole will work The drive shaft is atwo piece Assembly an inner and outer shaft assembly See Figure 2 amp 3 The Shaft End has a four bolt flange yokes on it that connectto the Crankshaft Pulley Adapter The Tube end has a splined clamp yoke on itthat connects tothe Pump This Drive Shaft connects to the Pulley Adapter Note that the Universals of the Driveshaft are in time When installed in tractor they should be in time as shown both Yokes the same direction See Figure 2 amp 3 3 Install Shaft End of Driveshaft Engine end Install the Shaft 1 2 Assembly w Flanged Yoke into the Engine compartment of Tractor install it from the LH front Side down and under radiator See Figure 4 This needs to be installed this way because the Flange Yoke will not go through the Crankshaft access hole in the front of the Tractor Bolt the Flange Yoke to the Pulley Adapter using the four Bolts and Lock Washers put Locktite on the threads of the Bolts when installing them into Pulley Adapter To Tighten these four Bolts use along extension and go through the front Crankshaft Pulley access hole in front of Tractor if youcannottighten them from the side Do Notuse bolts longer than the mount kit calls for longer bolts will damage Cranks
63. l All tires must have the proper amount of air in them as per tire and or Tractors manufactures recommendations DO NOT level tractor by over inflating tires The tractor can be leveled by jacking it up and putting it on jack stands if needed Tractor should be kept at ride operation height when mounting unit this will insure that the components are mounted at the correct height xtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 3 3 General Information Installation Requirements Replacement Oil Filter Included in the packing box of this unit is a replacement filter element for filter assembly in the tank This Mower unit s hydraulic components have been carefully cleaned and packaged at the factory to prevent contamination from entering the system However dust and dirt particles may enter into the sealed components through transportation handling rain or just sitting in a dirty or harsh environment Therefore to assure that the hydraulic system is properly clean please prepare the area where the unit is to be assembled The area should be on a hard concrete floor that has been swept clean of all dust and contaminants Unpacked the Mower unit carefully so that the seals on the hydraulic components are not broken or pulled off WARNING Before attempting to assemble the mower to the tractor move the tractor to a clean solid surface preferably a concrete shop surface with an over head crane The crane sho
64. l tank in an appropriate safe place away from flames extreme heat and or dusting dirty con ditions The Fuel Pickup and Gauge sending unit will need to be removed from the factory tank to be installed in the new replacement tank later See Fig ure 10 3 Install Replacement Fuel Tank Mounting Brackets If Required See Assembly Drawings sent with unit Remove the factory fuel tank mounting brackets there are two new mounting brackets that will be supplied to mount the new tank There is a front and a rear bracket See Figure 11 amp 12 Figure 10 Front Fuel Tank Bracket Rear Fuel Tank Bracket Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 4 Fuel Tank Replacement 4 Install Pick Up Tube amp Gauge Sending Unit in new Tank _ The Pickup gauge sending unit from the factory tank will be installed into the new tank This is recommended to be done before mounting the new tank to the tractor See Figure 13 The new tank will have a fuel capacity of 51 gallons 5 Install the new mount brackets to the tractor Pick Up Tube Unit frame The tank mounting brackets will bolt to the tractor the same as the factory brackets that were removed Make certain that the brackets are installed correctly the front bracket will have 2 outer holes same as the tank see Figure 11 amp 13 The rear bracket will have 1 hole in the outer end same as the tank See Figure 12 amp 13
65. led properly Frame and Boom Axle Plate Bolts are torqued Boom Rest Axle Plate Bolts are torqued Front Rail Bolts are torqued Front Support Bolts at tractor are torqued Rear Rail Bolts torque Rotator bolts torque to All Welds inspected toinsure proper welds and locations Hydraulic System Oil Level in Hydraulic Tank is within the sight gauge Hose connections are tight Hoses do not have any kinks or twist in them Front Pump Shaft adapter bolts are tight Front Pump Shaft Coupler Drive Shaft is lubricated and has an anti seize compound on the Splines of Pump and Shafts The Pump Drive Shaft has correct alignment Suction Hose has no leaks or kinks Rotary Mower Head Skid Shoe Bolts are torqued to 120 ft Ibs Spindle Housing Bolts are torqued to 400 ft Ibs The Spindle Housing is properly lubricated Motor Bolts are torqued to 120 ft Ibs Blade Carrier Bar Bolts torque to 400 ft Ibs Blade Bolts are torqued and the retainings Pins are in place Blades Swing freely Boom All Hoses tightened and no leaks All hoses secured to where they will not rub get pinched or hanging down where they may catch on something All Decals installed Pump Primed and Pressure adjusted if needed only applys to Pump for Cylinder control Axtreme Boom Asy Manl 07 06 2006 Alamo Group Inc Section 11 2 PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit
66. n it See Figure 45 Loosen the bolt and locking nut turn the bolt outward 3 Swinging Boom DO NOT Swing Boom until the boom has been run with it sticking out away from tractor and all electronic control adjustments have been done The boom must be working smoothly Slowly with low engine RPM with some one guiding you swing boom inward toward cab until the boom rest lug is aligned with the boom rest pin See Figure 44 Set boom securely down over pin Bottom Turret 4 Final Swing Stop Adjustment Unscrew the stop ne Cover bolt See Figure 45 until the head is against the swing stop lug ofthe turret cylinder link weldment See Figure 45 Hold the bolt so it won t turn tighten the locking nut down against the turret stop swing lug Recheck to make certain the boom will not hit the cab of the tractor It will stop at the turret stop lug when properly adjusted This may have to be adjusted more than once Swing unit to be run if Boom will hit the cab this will damage cab Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 14 Turret Swing Stop Lug with Adjusting Bolt amp Locking Nut Swing Stop Lug Built onto the Turret Cylinder Link Weldment Adjust Boom Swing Stop Turret Assembly as seen from the bottom Swing Cylinders Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc NOTES Axtreme Boom Asy Man 07 06 20
67. n one nut and tighten the other the cable can be moved back and forth in the valve mounting bracket This must be done before operating the mover Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 8 8 ON OFF Switch Installation Solenoid Cutter pees 10Amp Spade Fuse Yellow or Orange Wire Brown Wire Billet Tractor Terminal Starter s Connection of Solenoid Tractor Ignition Figure 14 Switch Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 8 9 ON OFF Switch Installation Wiring Tractor with Remote Cable Cylinder Control Valve 1 Connecting Harness Wires There are 4 wires that must be connected inside Tractor 1 Red Wire power supply 1 Black Wire Ground and 2 Brown Wires Neutral Safety Switch These will have to be spliced into Tractor circuits See Figure 15 2 Ground Wire The Black wire at the harness See Figure Battery 15 can be connected inside the cab floor or it can be run down through the floor and connected to the frame below the cab If grounding to the Cab floor con nect ground now Shown here is typical Ignition ACC Wire connection Your Ignition may vary but the function will not 3 Reinstall Dash Panel Reinstall the dash panel after the wires have been connected to the tractors wiring system See Figure 16 amp 17 The dash panel is attached with screw on fasteners Note All wires for the f trator connection with wire
68. n the ground when the boom is fully extended horizontally with 200 lbs placed on the outside of the mower head Post Operation Inspection Check that the oil in the hydraulic tank has not turned milky in color or has foam on top Check that there are no loose fasteners or hardware Axtreme Boom Asy Manl 07 06 2006 Alamo Group Inc Section11 3 Axtreme Boom Asy Manl 07 06 2006 Alamo Group Inc Section 11 4 MTT PREM Axtreme Boom Assembly Manual P N 02984405 Axtreme Boom Asy Man 07 06 STANDRAD ASSEMBLY INSTRUCTIONS Rev 02 20 07 2006 Alamo Group Inc
69. ng will be different than shown 3 Individual installations may vary and are dependent on the electrical and safety system designs of the tractor to which the mower is mounted 4 Consult the specific mounting instructions to determine the correct wire routing for each specific unit Common Problems 1 The tractor won t start The mower on off switch if left in the on position will not allow the tractor to restart Be sure to push the switch into the off position and account for all the tractor safety interlocks to enable the tractor to start Failure of the tractor starter safety lock system is normally attributed to a failure of the mower on off switch Check continuity atthe switch Check for loose connections 2 Cutter motor won t start Normal causes of this type of malfunction include failure of the push pull switch failure of the solenoid coil loose connections loss of ground or a blown fuse Ifthe mower won t start check continuity of the system with atestlightto find an electrical problem Problems may also exist in the cutter valve and other systems 3 The problem may not be in the electrical system but because there are so many connections that could be malfunctioning it is the best place to start checking If the electrical connections are OK go on to the Tractor connections and or the Tractor components to check for the malfunction Some times the service technician thinks the best way to eliminate the Mower
70. nut onto the threaded cable See Figure Cable Retaining 7 screw the nut on leaving enough threads to fully Screw Groove screw the control handle to the cable Push the handle of the control assembly all the way to one side and the A threaded shaft of the handle will be visible at the bottom See Figure 8 After the handle is screwed l onto the cable tighten the cable locking nut against the Threaded handle control Push the control handle to the straight Cable Cable End position See Figure 9 while pushing the cable into locking Cable Housing the handle asy When the cable is inserted into the Nut handle assembly until the groove in the cable housing is aligned with the retaining screw hole of handle housing assembly insert the retaining screw and nut See Figure 9 Handle Out of 11 Stack Control Handles Each cable control A Neutral Position handle will attach to the cable in the same way The control handles will be stacked together in the proper order See Figure 5 amp 10 These control handles will be stacked with the mounting brackets and electrical switch brackets between them Where the brackets are located in the group can vary Shown in figure 10 is the recommended placement of these brackets The bracket that mounts the control handles is slotted to allow for the adjustment of the angle of the control handle assemblies F 12 The ON OFF Switch is bolted to the Control Handles This is a good place but can be mounte
71. ol Valve to Diverter Valve Green SAE 4 C4 Swivel CW Rod End Green White G W SAE 4 C1 Swivel CCW Base End Yellow SAE 4 Door Open Rod End Yellow White SAE 4 C2 Door Closed Base End Orange SAE 12 Valve Return To Tank Red SAE 12 Pressure to Valve Axtreme Boom Asy Man 07 06 Rev02 20 07 2006 Alamo Industrial Section 8 12 Section 9 Axtreme Boom Optional Electric Hydraulic Joystick Cylinder Control Valve Installation NOTE This shows a basic mount for the frame installation and may not be the same for your tractor model The way the frame mounts to the tractor compo nents can vary with tractor model See the installation drawings shipped with the unit for the specific tractor type mount and hardware components IN SOME CASES THE MANUAL INSTRUCTION MAY VARY FROM THE INSTALLA TION DRAWING INSTRUCTION THE INSTALLATION DRAWING INSTRUC TIONS WILL OVERRIDE THE ASSEMBLY MANUAL INSTRUCTIONS WHICH ARE BASIC THE INSTALLATION DRAWINGS ARE FOR A SPECIIFIED TRACTOR Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 9 1 Joystick Mounting Joystick Optional The joystick is an option and allows the mower amp boom to be operated with electronic control The joystick will be mounted in different ways depending on the type tractor you have Some models bolt to a stand on the floor that is sent with the mower Another style is an arm rest mount that is designed to allow
72. or Codes Hose fittings are marked with Color Coded Plastic Band Some Bands are solid Color some are Colored with Stripe Purpose of colored bands is provide quick reference for hose and port connection Metal band is also attached to hose that band has Alamo Industrial Part Number for reference Boom Cylinder Circuit Hoses Electrical Joystick Controlled Valve Option Color Tie Code Hose Size Port Diverter Hyd Function Green G SAE 6 A Swing Back Rod End Green White G W SAE 6 B Swing Forward Base End Orange OR SAE 6 A Lift Down Rod End Orange White OR W SAE 6 B Lift Up Base End Blue B SAE 6 B Dipper In Rod End Blue White B W SAE 6 A Dipper Out Base End Red R SAE 6 B Head Tilt Up Rod End Red White R W SAE 6 A Head Tilt Down Base End Yellow Y SAE 4 A Door Open Rod End See Option Yellow White Y W SAE 4 B Door Closed Base End See Option Connections w Swivel Head Diverter Valve Option Connects to Door Valve section Green G SAE 4 A P1 Control Valve to Diverter Valve Green White G W SAE 4 B P2 Control Valve to Diverter Valve Green G SAE 4 C4 Swivel CW Rod End Green White G W SAE 4 C1 Swivel CCW Base End Yellow Y SAE 4 C3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Axtreme Boom Asy Man
73. ore operating the Tractor or Imple ment an operator on prescription or over the counter medication must consult a medical professional regarding any side effects of the medi cation 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 sc 27 DANGER Operatethe Tractor and or Implementcontrols 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 56 29 gt WARNING Engine Exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the state of California to cause cancer and birth defects or other reproductive harm SG 30 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the state of California to cause cancer and birth defects or other reproductive harm Wash Hands after handling SG 31 gt WARNING Use extreme caution when getting onto the Implementto perform repairs maintenance and when removing accumulated material Only stand on solid flat surfaces to ensure good footing Use a ladder or raised stand to access high spots which cannot be reached from gound level
74. own Rod End Orange White OR W SAE 6 B Lift Up Base End Blue B SAE 6 B m Dipper In Rod End Blue White B W SAE 6 A Dipper Out Base End Red R SAE 6 B Head Tilt Up Rod End Red White R W SAE 6 A Head Tilt Down Base End Yellow Y SAE 4 A Door Open Rod End See Option Yellow White Y W SAE 4 B Door Closed Base End See Option Connections w Swivel Head Diverter Valve Option Connects to Door Valve section Green G SAE 4 A Pi Control Valve to Diverter Valve Green White G W SAE 4 B P2 Control Valve to Diverter Valve Green G SAE 4 C4 Swivel CW Rod End Green White G W SAE 4 C1 Swivel CCW Base End Yellow Y SAE 4 C3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Axtreme Boom Asy Man 07 06 Rev 02 20 07 2006 Alamo Group Inc Section 7 7 Hydraulic Hose Connections Diverter Valve The Diverter Valve bolts onto the front frame mount bracket on the LH side of the tractor the holes are in the bracket The Diverter valve is aelectrical operated valve that allows the hydraulic pressure to be shared to operate two or more if valves are stacked functions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pressure This valve is only used when
75. p Mounting Holes use 3 4 X 2 1 4 bolts in these 4 places Front Mounting Holes use 3 4 X 2 1 4 bolts in these 8 places Rear of Tractor Install with these openings to front of tractor LH Side of Front of Tractor Tractor Rear Mounting Holes use 3 4 X Center Section Under Mount Frame Wldmnt 3 1 2 bolts in these 8 places 6 Install Boom Rest Weldment The boom rest weldment for the 24 foot boom and the 30 ft boom are not the same See Figure 29 The boom rest weldment bolts to the RH Side on the Rear Frame mount weldment behind the tractor axle weldment See Figure 30 It is recommended that this be installed using an overhead hoist and supported by the hoist until boom rest and support brace See Figure 28 amp 30 are completely installed The Boom Rest Support also serves as the top axle strap for the RH Axle mount See Figure 30 Rear View Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 9 Frame Installation 7 Install LH Axle Strap The Axle Strap bolts down over the top of the Axle LH Side and bolts run through the Rear Frame rails The RH Side the axle strap is part of the boom support brace weldment and also bolts down over the axle with the bolts through the rear frame rail See Figure 30 amp 31 Make certain that all the bolts mounting the frame components and the boom rest are properly torqued see the bolt torque chart
76. ply to Joystick wires From Battery Ignition Tractor Ignition Terminal Tractor Ignition Switch To Tractor Battery VDC Pos 4 To Tractor Starter S z Starter S To Tractor Battery terminal terminal Z 12VDC Neg Interupt Starter S 7 terminal Joystick Wiring Interupt Harness FIGURE 17 7 Connecting Harness Wires There are 5 wires that must be connected to Tractor wiring these wires will be marked with the description of what they are from the factory 1 Power supply to joystick this wire will be connected to the tractors ignition switch wire as close to the ignition switch as possible It is recommended to be not more that 3 away from ignition switch 2 This is the tractor starter interrupt switch It connects to the wire to the tractors starter solenoid marked S this prevents the tractor from being started when the mower is in the on position 3 This is the return for the tractor starter interrupt switch It is connect back into the other end of the cut starter solenoid wire 4 Battery 12 VDC connection which connects direct to the battery terminal This wire will power a relay that will operate the electric cooling fan for the hydraulic oil D Ground wire This connect direct to the negative Battery terminal of the battery It will serve as a ground for the system 8 Reinstall Dash Panel Reinstall any dash panels after the wires have been connected to the tractors wiring system if the
77. r Hose connects to the Oil Cooler Fan Asy mounted under tractor bolster behind hyd tank There is short hose which will not have plastic tie that will connect to oil cooler then goes to tank return See Figure 16 13 Pump Hose Routing at Tank Hose routing at tank is shown as reference to Pump hose routing which most will already be connected when tank and pump asy is shipped from factory All hoses you must disconnect and reconnect during pump and or tank asy refer to this figure for the correct location of hose See Figure 15 Hose Support Bracket L k v za a i No Tie F OilCooler Figure 16 to Tank it das Hose Support Bracket sj A 4 amp vm Et o Sleeving Material for Hoses 7 1 Red Tie Figure 14 pa r JI Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 7 6 Rev 02 20 07 Hydraulic Hose Connections Hyd Hose Codes at Control Valve amp Head Swivel Divertor Valve Option Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some are Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attached to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose Always Check Ho
78. r guide for specific instruction about tractor model and type DO NOT attempt to repair or adjust a component that is not intended to be repaired example sealed components as there are no serviceable components inside DO NOT let anyone attempt any testing or repairs unless they are an experienced and qualified techni cian Technicians must have proper tools gauges meters etc to perform proper diagnosis and or repairs DO NOT perform any assembly or repairs with dirty tools or in dirty work area When working on hydraulic components keeping system clean and free of contamination is important DO NOT start or engage system if the oil level is not at the proper level or condition Never start or run unit low or out of oil DO NOTinstall add any oil unless you know itis the correct type and the container is clean Make certain the oil is not contaminated with dirt or any liquid Pump Specifications Body Construction Castlron Control Valve Type Direct Acting Pilot Operated Control Valve Relief Driveshaft Type 1 X 15 Spline Driveshaft Torque Rating 371 ft lbs Pressure Rating Maximum 3000 PSI Pump Type Pump Gear Width Pump Efficency Flow Rate Approx 85 of G P M is Acceptable Speed Rating Maximum 2400 RPM Nominal Displacement Per Revolution Output 1800 RPM Operating RPM Output 2400 RPM Maximum RPM Horsepower Rating Maximum Conditions 6 Seconds Approx 17 5Gallons See Oil Chart 70 Deg F Above Ambi
79. se Size Color Code amp Part No when ordering parts Boom Cylinder Circuit Hoses Mechanical Cable Controlled Valve Std Color Tie Code Hose Size Port Diverter Hyd Function Green G SAE 6 A Swing Back Rod End Green White G W SAE 6 B Swing Forward Base End Orange OR SAE 6 A Lift Down Rod End Orange White OR W SAE 6 B Lift Up Base End Blue B SAE 6 A Dipper In Rod End Blue White B W SAE 6 B Dipper Out Base End Red R SAE 6 B Head Tilt Up Rod End Red White R W SAE 6 A Head Tilt Down Base End Yellow Y SAE 4 B Door Open Rod End See Option Yellow White Y W SAE 4 A Door Closed Base End See Option Connections w Swivel Head Diverter Valve Option Connects to Door Valve section Green G SAE 4 A P2 Control Valve tor Diverter valve Green White G W SAE 4 B P1 Control Valve to Diverter Valve Green G SAE 4 C4 Swivel CW Rod End Green White G W SAE 4 C1 Swivel CCW Base End Yellow Y SAE 4 C3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Boom Cylinder Circuit Hoses Electrical Joystick Controlled Valve Option Color Tie Code Hose Size Port Diverter Hyd Function Green G SAE 6 A Swing Back Rod End Green White G W SAE 6 B Swing Forward Base End Orange OR SAE 6 A Lift D
80. ses capped until you are ready to connect them Cleaning Boom and mower componets electronics The units Components are designed to be water resistant But the sealing can be damaged by Pressure Washers Steam Cleaners Solvents or any other harsh chemical that would be used to clean the units components It is important to keep all electrical connections and components sealed and dry When washing and cleaning this unit it should be done with a non corrosive soap and low pressure spray of water It is recommended that all exposed electronic components be covered and protected from excess moisture Lay Out Components in Display It is helpful to lay out the component in as neat a display as possible Lay out the Bolts according to size and length Lay out the Nuts and washer by size This will allow you to see how many of each part as you use them and help to identify any missing parts See figure 6 See Mount Kit Specification and Component Identification Section to help ID Components All the component that are received should be check and sorted as to what they are Shown below is a general example of the components laid out this is nota lay out of the components in this mount kit Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 3 6 General Information Installation Requirements WARNING DO NOT WELD On This Unit During or After Installation DO NOT WELD any components or items on this
81. t Boom Weight Mount Attaching Pin Long Pin Center Section Under Frame Weldment Weight Attaching Pin Short Pin front side Figure 32 amp 3 Wheel Counter Weight CWT Installation The Wheel counter weight is in addition to the frame mounted counter weight they both must be used together See Figure 32 Allthese weight are in addition to adding liquid weight into the Left rear tire The proper amount of counter weight is not complete until all these weight have been installed Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 4 11 Frame Installation v 6 4 E A k MN de 247 A Figure 33 SERS a ab Turret Assembly Installation 1 Turret Assembly Theturret assembly is shipped assembled with the hydraulic swing cyl inders hoses pivot bearing assembly boom mount weldment and mounting pins installed See Figure 35 amp 36 2 Under Frame Weldment The Under frame weldment center section is designed for the turret assembly to mount on the RH side Remove the one long mounting pin and the front and back short mounting pins See Figure 36 amp 37 Check to make certain the mounting bolts mounting the center ubder frame weldment are installed with the bolt heads unter frame weldment and nuts are ontop visible looking down if they are in wrong the swing cylinders will hit the bolts causing damge to cylinders and bolts See F
82. t Side Yellow White Orange White Green White Pressure Supply Port P1 Return Port T2 4 Note Hose Colored Bands Bands with stripes go to Cylinder Base Solid color bands go to Cylinder rod end Dipper Blue White Figure 19 Hyd Hose Codes at Control Valve amp Head Swivel Divertor Valve Option Hose Bands Mark Color Codes Hose fittings are marked with Color Coded Plastic Band Some Bands are solid Color some are Colored with Stripe Purpose of colored bands is provide quick reference for hose and port connection Metal band is also attached to hose that band has Alamo Indusirial Part Number for reference v 3 p v Boom Cylinder Circuit Hoses Mechanical Cable Controlled Valve Std Color Tie Code Hose Size Port Diverter Hyd Function Green G SAE 6 Swing Back Rod End Green White G W SAE 6 Swing Forward Base End Orange OR SAE 6 Lift Down Rod End Orange White OR W SAE 6 Lift Up Base End Blue B SAE 6 Dipper In Rod End Blue White B W SAE 6 Dipper Out Base End Red R SAE 6 Head Tilt Up Rod End Red White R W SAE 6 Head Tilt Down Base End Yellow Y SAE 4 Door Open Rod End See Option Yellow White Y W SAE 4 Door Closed Base End See Option PUPUUTPUTPUT Connections w Swivel Head Diverter Valve Option Connects to Door Valve section Green G SAE 4 P2 Control Valve tor Diverter valve Green White G W SAE 4 P1 Contr
83. t into service It is easier to get to grease fittings now than after boom has been installed On the under side of the turret assembly are the grease fittings for the swing cylinder pivot mounts these need to be greased before operating the unit Also there is a bolt on cover on the under side of turret that will be installed See Figure 40 ata later time Greasing the cylinder pivots will need to be done before the cover is installed See Figure 39 and the boom swing stop will need to be adjusted but this cannot be done until a later time making it best to leave this cover of until then After greasing components at assembly of unit operator should consult the operators manual for maintenance requirements N a ea Ni ta Axtreme Boom Asy Man 07 06 O 2006 Alamo Group Inc Section 4 13 Adjust Boom Swing Stop Boom Swing Adjustment 1 Boom Swing Stop Location The boom Stop adjust ment cannot be seen from the top of the turret assembly 6 Turret See Figure 41 If the bottom cover plate See Item 42 is ssefibly not already removed it will need to be itis bolted on from the i rele under side of the turret assembly From the under side you will see the swing cylinders and cylinder pivot mounts See Figure 43 2 The Swing Stop Lug which is part of the Turret Cylinder Link Weldment See Figure 45 On the side toward the rear there will be a lug with a bolt and locking nut i
84. t kit from fitting your nonstandard tractor Alamo Group cannot take responsibility for these problems or any modifications made to the unit Throughout these instructions references are made to right or left directions Right and left are determined by sitting on the tractor seat and facing the direction of travel forward always This is the Safety Alert symbol When you see this symbol on your machine or in these instructions be alert to the potential for personal injury Follow recommended precautions DANGER and safe operating practices A A signal word DANGER WARNING or CAUTION is used with the Safety Alert symbol DANGER DANGER identifies the most serious hazards Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 3 2 General Information Installation Requirements WARNING Safety signs with signal word WARNING are typically used to point out more serious hazards CAUTION General precautions are listed on CAUTION safety sign CAUTION also calls attention to safety messages in these instructions CRUSHING AND PINCH POINTS TET MOVING MACHINERY PARTS CAN PINCH OR CRUSH OR FALL WHICH MAY CAUSE INJURY OR DEATH 02962765 WARMING Disconnect the negative lead ground from the battery terminal to prevent any A damage to the electrical system LEVELING TRACTOR TRACTOR MUST be on level ground before assembly is begun The tractor must be leve
85. th the appropriate OSHA required protective lens welding apron and welding gloves NE 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 sem Never run the tractor engine in a closed building or without adequate ventilation The exhaust fumes can be hazardous to your health SG 23 Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 1 4 Safety Section DANGER Before starting the mower make sure the area is clear and the floor has been swept The mower blade can throw objects several hundred feet Thrown objects could damge property or cause severe bodily injuries even death I WARNING 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 Eguipment use the Tractor flashing warning lights and follow all local traffic regulations so 6 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 sc 13 Start only from seat in park or neutral Starting in gear kills Do not operate this Eguipment with
86. the 750 16 NF jam nut against the sleeve to lock in position 6 Bring flange into position and bolt assembly to valve housing Tighten screws sufficiently to flatten lockwashers secure flange 8 Caution overtightening flange bolts will distort flange Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 8 4 Valve Remote Cable Controls 7 Screw On Cable Clevis 9 Clevis Retaining Nut 6 Cable To Clevis Locking Nut 5 Threaded Cable End 10 Valve Spool 3 amp 4 Cable Housing Locking Nuts amp Adjusting mm Cable Housing Seal Valve Asy 1 Gable 8 Clevis Retaining Bolt Housing Fiaure 2 11 Cable Mounting Bracket 2 Lockwasher REMOTE CABLE OPERATION AND INSTALLATION 1 Remote operation of the boom movement control valve can be achieved with the use of cables and remote actuator handles The remote operation system is standard eguipment on cab tractor and ROPS tractors as well See Figure 2 Cable lengths will vary based on the length reguired to reach from the valve to the Operator s location with out binding or kinking This cable length is determined by which model tractor the boom is mounted on See the tractor mounting instruction for the type tractor being used The Cable lengths are limited to 48 60 72 and 102 inches 2 To install the cables to the valve each valve section will require a cable installation kit 5 kits for a 5 spool valve Each individual valve connection kit can be ordered separat
87. to assure that they are properly assembled Flail Mower Head Skid Shoe Bolts are torqued to 120 ft lbs Motor Bolts are torqued to 120 ft lbs Belt Alignment amp tension adjustment is correct Cutter shaft bearings are properly lubricated Roller bearings are properly lubricated Blades swing freely Tractor Mower Operation Inspection Using all Safety precautions operate the Tractor and Mower unit for 30 minutes and while the unit is running check the following items Note Only make adjustments after the mower has been turned off and all motion has stopped and all hydraulic pressure has been relieved Check for Hydraulic oil leaks at the hose connections Operate the boom and mower head throughout its full range of motion and check for hose s rubbing pinching or kinking Make sure the Return Filter Gauge is reading in the Green after Oil is warm Check the function of the Mower Head On Off Valve and switch for proper function Make sure that the tractor will not start with the mower on off switch in the on position Check the Blade Rotation for the Rotary Mower Head to make sure it is turning Clockwise looking from the top of the mower deck Make sure the control valve boom movements agree with the valve operation decal Make Sure Boom Movement operates as expected and is smooth and under control no air in the control system Look for any unusual or excessive noise or vibrations Make sure the left rear wheel of the tractor stays o
88. trol Valve Block Lift Cyl 2 pty E Swing Cyl s M 5 i ton Hose Dipper Cyl Tilt Cyl Fr TT u Fr TT u po 5 gt mm 56 Eli nf d m al Return to Filter to Tank Motor Pressure Hose Valve Pressure Hose PI WA yr Diverter S 9 Valve Optional C2 C3 Oil Cooler amp Fan Asy Valve Return Hose G OL Head Swivel Cyl Motor Pressure Lift Boom Steel Tube Boom Steel Tube Connecting Hose M S F o gt a S RES O E E Motor Pressure Dipper Steel Tube E O Boom Steel Tube Connecting Hose ed 5 M Motor Return 5 From Head Motor Return Dipper Steel Tube Motor Return Lift Boom Steel Tube Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 9 11 Hyd Schematic Electrically Controlled Opt Joystick E a ai Electronic s a Ee S HE Controled Valve 2 j Optional A Port Side Pressure Supply Port P1 Br Port Side j Return Port T2 Figure 27 A Note Hose Colored Bands Bands with stripes go to Cylinder Base Solid color bands go to Cylinder rod end Yellow White Tilt Red Lift Orange White Swing Green White Hyd Hose Codes at Control Valve amp Head Swivel Divertor Valve Option Hose Bands Mark Col
89. uld have a rated capacity to lift the heaviest component or assembly A 5 ton crane is recommended for the assembly work If a smaller crane is used be sure not to exceed the rated capacity of the crane Always follow all OSHA crane operating and inspection rules regulations inspection requirements and recommended practices when using the crane Never work under any component that is lifted by the crane WARNING Wear personal protective equipment when assembling the mower As a minimum that should include Safety Glasses Safety Shoes Gloves Hard Hat Hearing Protection Welding Helmet WARNING Before attempting to assemble ensure that the tractor engine is off and the tractor transmission is in the park position with the parking brake engaged Remove the engine key and keep it in your pocket to prevent inadvertent starting or movement of the tractor Place wheel blocks in front and behind the tractor wheels to prevent the tractor from moving Never attempt to start the tractor unless properly seated in the tractor seat with the seat belt fastened around you Never attempt to operate the tractor and mower controls unless seated in the tractor seat with the seat belt fastened around vou WARNING Securely block up and support the tractor before attempting to loosen and move the tires Failure to properly block up the tractor can result in the tractor to suddenly move or fall crushing you or another worker
90. ulling extending or collapsing cylinder always put the opened end of the hoses into a clean drain pan as oil will run out of the cylinder when extended or collapsed After installing the cylinder lower mounting pin re plug the hoses that were in the drain pan until ready to connect hoses 7 Connect Head to Boom The mounting pins to in stall the head onto the boom will be shipped installed in the mount weldment Remove the mounting pins Use the hoist to lower boom down over head to connect head Align the upper head mount pin The lower mount pin is the connect the lift link See Figure 4 The Door Cylinder and the Swivel Cylinder are shipped installed on the head with the hoses connected to the cylinder 8 Heads Are received from the Factory with the Cylinder and Head hoses Attached to Head The head will be received with the door cylinder swivel cylinder and Motor attached to the head The Hoses for the cylinders and the motor will connect to the boom There is a decal that is installed on the side of the boom that shows where the hoses connect to the fitting that have the metal caps on them The fittings for the head are located on the side of the main Boom The hoses must be connected in the correct order to make certain of correct operation See Figure 4 5 6 7 amp 8 9 Two Head Options There are two heads available 60 See Figure 4 amp 5 which has the head Swivel attach ment on it The 50 Head w
91. ure problems of a similar nature 4 Thetechnician may be asked to provide detailed information about the problem including the results of any required trouble shooting techniques If the information is not available The technician may be asked to get the information and call back Most recommendations for repairs will be based on the procedures listed in the Service Manual Trouble Shooting Guide and the information as received from the dealer customers These recommendations are based onthe asumption that the proper testing and equipmentinspections have been performed to determine the repairneeded CONTACT ALAMO INDUSTRIAL Alamo Industrial Inc 1502 E Walnut St Seguin TX 78155 Technical Service Dept PH 830 379 1480 Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Index 1 Page Index 1 to Index 2 Section 1 Safety Instructions Section 2 Model Specifications Section 3 Tractor Preperations Section 4 Batteryt Ehaust Fuel Tank Modifications amp Mani Frame Section 5 Wheel Weight Installation Section 6 Pump Driveline and Hydraulic Installation 6 1 to 6 12 Section 7 Boom amp Head Installations with Hydraulic Connections 7 1 to 7 12 Section 8 Valve Installation Mechanical Cable Controlled Standard 8 1 to 8 12 Section 9 Valve Installation Joystick ElectricalControlled Optional 9 1 to 9 12 Section 10 Hydralic Tank Fill amp Start UP 10 1 1 to 10 4 Section 11 Pre Delivery
92. urn Hose Head Swivel Cyl Motor Pressure Lift Boom Steel Tube Motor Pressure Dipper Boom Steel Tube Motor Return From Head Motor Return Dipper Boom Steel Tube G b ull E C1 Oliv M P 5 Diverter i dlc Res Valve P2 S Optional C2 Lift Cyl Door Cyl RO O E l C4 C3 OL Steel Tube Connecting Hose Steel Tube Connecting Hose Motor Return Lift Boom Steel Tube Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 7 10 Rev 02 20 07 Hyd Schematic Electrically Controlled Opt Valve Return line Motor Control r all Valve Block E Lift Cyl Fr DE nm F EE E Hyd Tank Es M E Swing Cyl s 2 5 Suction Hose ae Dipper Cyl Tilt Cyl jam TH o O LA L a A a ci Return to Filter to Tank Door Cyl F mo Motor Pressure Hose L ol Valve Pressure Hose Cl C4 B Pl Diverter Valve A p2 Optional C2 C3 Oil Cooler amp Fan Asy Valve Return Hose F DE m Head Swivel Cyl Motor Pressure Lift Boom Steel Tube Motor Return From Head To Hyd Tank Motor Pressure Dipper Steel Tube Motor Pressure Boom Steel Tube Connecting Hose OAO To Head o o Motor Return Steel Tube o From Head Motor Return Dipper l Boom Steel Tube Connecting Hose Motor Return Lift Boom Steel Tube Figure 21 Axtreme Boom Asy M
93. vary with the type tractor that the Axtreme Boom is mounted on See the Assembly Drawings and or Parts manual that is for the unit mounted to your tractor Some models may reguire modifications to the tractor that are not listed in this manual see the assembly drawing shipped with the unit Existing Tractor Bolts amp Washers Tractor Crankshaft Pulley Tractor Frame Rails Tractor Front Casting Description Front Pump Plate Pulley Adapter Driveline Assembly Bolt Lockwasher Bolt Lockwasher Bolt Lockwasher ODA RA K gt Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 6 2 Pump Driveline Hose Removal Pulley Adpater Use Bolts amp Washers 4 ea Tractor Engine Pulley Time Universal Joints Driveline Asy Clamp Yoke amp Tube End Pump Pressure Ports large port to motor small port to cyl con trol valve supply Pump Mount Bolts amp Washer 4 Suction Port Pump Mount Pump Mount Plate PO M Bolts To Tractor Figure 2 Bolster Pump Driveline Hose Installation 1 Install Pulley Adapter The Pulley adapter is around plate with 4 threaded holes and four non threaded holes in it The Non threaded holes are used to mount the Adapter to the Pulley using 4 bolts amp Lockwasher Do not use longer bolts to mount Pulley Adapter to Pulley than is supplied with mounting kit See Figure 2 2 Driveshaft Assembly Some tractor models may have to have a hole cut in the front for the dr
94. ve all remember safety is up to YOU Only YOU can prevent serious injury or death from unsafe practices CAUTION The lowest level of Safety Message warns of possible injury Decals located on the Equipment with this Signal Word are Black and Yellow WARNING Serious injury or possible death Decals are Black and Orange DANGER Imminent death critical injury Decals are Red and White sc Axtreme Boom Asy Man 07 06 2006 Alamo Group Inc Section 1 2 Safety Section PELIGRO Si no lee Ingles pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad sc 3 ILEA EL INSTRUCTIVO READ UNDERSTAND and FOLLOW the following Safety Messages Serious injury or death may occur unless care is taken to follow the warnings and instructions stated in the Safety Messages Always use good common sense to avoid hazards SG 2 PELIGROBi no lee Ingles pida ayuda a alguien que i LEAEL si lo lea para que le traduzca las medidas k INSTRUCTIVO de seguridad sa 3 WARNING Perform service repairs and lubrication according to the maintenance section Ensure the unit is properly lubricated as specified in the lubrication schedule and all bolts and nuts are properly torqued Failure to properly service repair and maintain this Implement in good operating condition could cause component failure and possible serious injury or even death sa 3s WARNING Operate this Equipment only with a Tractor equipped w
95. washers form the bottom side of the console DO NOT used excessive long bolts to mount the joystick The joystick will have some adjustemnt through the mounting bolts as to where it will sit on bracket Thighten the two mounting bolts for the joystick from the bottom See Figure 12 amp 13 5 Attach Wire Harness to the Joystick DO NOT CUT floor mat it is not required The wire harness will fit between the floor mat and the RH side panel See Figure 14 The Wire harness connects to the joysick through a plug at the bottom of the joystick console This plug will only fit on one way there are three notches of different width that must be aligned befor the plug will fit See Wire Shematic and Figure 15 6 Connect the wire harness to Tractor Connec tions See the wire schematic fot the wire connections to the tractor wiring Make certain that the battery cables are disconnected before attempting to connect any wires See Figure 16 FIGURE 14 Make certain these wires have been feed up through hole in floor and are inside the cab they are the ignition connections s ah lt FIGURE 16 E Axtreme Boom Asy Man 07 06 O 2006 Alamo Industrial Section 9 7 Joystick Mounting Shown here is typical Ignition Cut Tractor Starter connection Your Ignition may Wire to Starter Sole vary but the function will not noid and reroute ACC Wire through Joystick Tractor Ignition Harness Brown Sup
96. y were removed Dash panels will vary with the type and model tractor used the type fasteners will vary Consult tractors manufacturer service repair and or parts manual for removing any fasteners fro the tractor components Note All wires for the tractor connection with wire harness should all be under floor mat of tractor and not visible with the exception of the harness running up to the bottom of the joystick this will prevent damage to the wiring See Figure 18 amp 19 Axtreme Boom Asy Man 07 06 2006 Alamo Industrial Section 9 8 Joystick Mounting FIGURE 18 EZ Installing Wire Harness To Valve 1 Wire Harness From Cab to Front The wire harness runs out the bottom of the Cab on the right hand side Run harness along under RH cab of Tractor to the control valve See Figure 21 Note the wire harness runs bottom of cab and near the exhaust from the Tractor to the Stack Valve to the front of the tractor Make certain to tie the Harness or Hoses to the Tractor for protection 2 Gaskets on Valve Terminals There are 5 wire terminals on Valve 3 Wire Harness Terminal Identification The Wire Harness Terminal Plugs are marked in writing on the plug Swing Lift Dipper Tilt and Door terminal plugs 5 Total The Valve terminals are in this same order starting atthe input cap end and going toward the blank end 4 Wire Harness Terminal Installation You will need to feed wire harness under the f

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