VERSA PRO FLAIL MOWER Part No. 803350C Published 03/09 OPERATOR’S MANUAL This Operator's Manual is an integral part of the safe operation of this machine and must be maintained with the unit at all times. READ, UNDERSTAND, and FOLLOW the Safety and Operation Instructions contained in this manual before operating the equipment. C01Cover ALAMO INDUSTRIAL ® 1502 E. Walnut Seguin, Texas 78155 830-372-3551 Email: parts@alamo-industrial.com ©2009 Alamo Group Inc. $0.
To the Owner/Operator/Dealer All implements with moving parts are potentially hazardous. There is no substitute for a cautious, safe-minded operator who recognizes the potential hazards and follows reasonable safety practices. The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents. BEFORE YOU START!!Read the safety messages on the implement and shown in your manual.
In order to reduce accidents and enhance the safe operation of mowers, Alamo Industrial, in cooperation with other industry manufacturers has developed the AEM/FEMA Industrial and Agricultural Mower Safety Practices video and guide book. The video will familiarize and instruct mower-tractor operators in safe practices when using industrial and agricultural mowing equipment.
Alamo Industrial Division is willing to provide one (1) AEM Mower Safety Practices Video Please Send Me: VHS Format – AEM/FEMA Mower Operator Safety Video DVD Format – AEM/FEMA Mower Operator Safety Video Mower Operator’s Manual AEM Mower Operator’s Safety Manual Requester Name Phone: Requester Address: City State Zip Code Mower Model: Serial Number: Date Purchased: Dealer Salesperson: Dealership Name: Dealership Location: Mail to: AEM Video Services 1502 E Walnut street Seguin, TX 78155 Or Fax t
TABLE OF CONTENTS SAFETY SECTION .............................................................................................................. 1-1 General Safety Instructions and Practices ......................................................................................................... 1-2 Operator Safety Instructions and Practices ....................................................................................................... 1-3 Equipment Operation Safety Instructions and Practices .......
STARTING THE TRACTOR .............................................................................................................................. 4-8 SETTING THE MOWER .................................................................................................................................... 4-9 DRIVELINE ATTACHMENT ............................................................................................................................ 4-11 Driveline Length Check ...............................
EXTERNAL COIL SLIP CLUTCH DISK REPLACEMENT ............................................................................... 5-20 TO DISASSEMBLE EXTERNAL COIL SPRING CLUTCH .............................................................................. 5-20 TO CLEAN AND INSPECT .............................................................................................................................. 5-20 TO REASSEMBLE ..........................................................................................
SAFETY SECTION Safety Section 1-1 © 2009 Alamo Group Inc.
SAFETY General Safety Instructions and Practices SAFETY A careful operator is the best operator. Safety is of primary importance to the manufacturer and should be to the owner/operator. Most accidents can be avoided by being aware of your equipment, your surroundings, and observing certain precautions. The first section of this manual includes a list of Safety Messages that, if followed, will help protect the operator and bystanders from injury or death.
SAFETY 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) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. (SG-31) The rotating parts of this machine continue to rotate even after the PTO has been turned off.
SAFETY SAFETY PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING LOSS! Tractors with or without an Implement attached can often be noisy enough to cause permanent hearing loss. We recommend that you always wear hearing protection if the noise in the Operator’s position exceeds 80db. Noise over 85db over an extended period of time will cause severe hearing loss. Noise over 90db adjacent to the Operator over an extended period of time will cause permanent or total hearing loss.
SAFETY Use extreme caution when getting onto the Implement to perform repairs, maintenance and when removing accumulated material. Only stand on solid flat surfaces to ensure good footing. Use a ladder or raised stand to access high spots which cannot be reached from ground level. Slipping and falling can cause serious injury or death. (SG-33) Avoid contact with hot surfaces including hydraulic oil tanks, pumps, motors, valves and hose connections.
SAFETY Use extreme care when lowering or unfolding the implement’s wings. Make sure no bystanders are close by or underneath the wings. Allow ample clearance around the implement when folding or unfolding the wings. Use extreme caution around buildings or overhead power lines. (S3PT-05) SAFETY This Implement is wider than the Tractor.
SAFETY Never allow children to operate, ride on, or come close to the Tractor or Implement. Usually, 16-17 year-old children who are mature and responsible can operate the implement with adult supervision, if they have read and understand the Operator’s Manuals, been trained in proper operation of the tractor and Implement, and are physically large enough to reach and operate the controls easily. (SG-11) Do not mount or dismount the Tractor while the tractor is moving.
SAFETY SAFETY In case of mechanical difficulty during operation, place the transmission in the park position, set the parking brake, shut down all power, including the PTO and the engine and remove the key. Wait until all rotating motion has stopped before dismounting. (SG-39) Do Not operate this equipment in areas where insects such as bees may attack you and/or cause you to lose control of the equipment.
SAFETY Many varied objects, such as wire, cable, rope, or chains, can become entangled in the operating parts of the mower head. These items could then swing outside the housing at greater velocities than the blades. Such a situation is extremely hazardous and could result in serious injury or even death. Inspect the cutting area for such objects before mowing. Remove any like object from the site. Never allow the cutting blades to contact such items.
SAFETY Do not operate or pull the mower into standing water. When uplift or fan type mower blades contact water they can be severely deflected downward causing possible failure of blade resulting in serious boldly injury to the operator or bystanders. (SGM-15) Use extreme caution when raising the Mower above ground level. Stop the Blades from turning when the Mower is raised and passersby are within 100 yards.
SAFETY DO NOT use a PTO adapter to attach a non-matching Implement driveline to a Tractor PTO. Use of an adapter can double the operating speed of the Implement resulting in excessive vibration, thrown objects, and blade and implement failure. Adapter use will also change the working length of the driveline exposing unshielded driveline areas. Serious bodily injury and/or equipment failure can result from using a PTO adapter.
SAFETY Allow sufficient clearance for the Implement to swing outward while turning. Implements carried behind the Tractor will swing outside the tire path when making turns. Contacting a solid object while turning will cause equipment damage and possible injury. (S3PT-20) SAFETY Make certain that the “Slow Moving Vehicle” (SMV) sign is installed in such a way as to be clearly visible and legible.
SAFETY Only tow the Implement behind a properly sized and equipped Tractor which exceeds the weight of the Implement by at least 20%. DO NOT tow the Implement behind a truck or other type of vehicle. Never tow the Implement and another Implement connected in tandem. Never tow the Implement at speeds over 20 MPH. (STI-06) Maintenance and Service Safety Instructions and Practices Make sure the PTO shield, integral driveline shields, and input shields are is installed when using PTO-driven equipment.
SAFETY Never attempt to lubricate, adjust, or remove material from the Implement while it is in motion or while tractor engine is running. (SG-20) SAFETY Periodically inspect all moving parts for wear and replace when necessary with authorized service parts. Look for loose fasteners, worn or broken parts, and leaky or loose fittings. Make sure all pins have cotter pins and washers. Serious injury may occur from not maintaining this machine in good working order.
SAFETY PARTS INFORMATION Alamo Industrial mowers use balanced and matched system components for blade carriers, blades, cuttershafts, knives, knife hangers, rollers, drivetrain components, and bearings. These parts are made and tested to Alamo Industrial specifications. Non-genuine "will fit" parts do not consistently meet these specifications. The use of “will fit” parts may reduce mower performance, void mower warranties, and present a safety hazard.
SAFETY Decal Location SAFETY NOTE: Alamo supplies safety decals on this product to promote safe operation. Damage to the decals may occur while in shipping, use, or reconditioning. Alamo cares about the safety of its customers, operators, and bystanders, and will replace the safety decals on this product in the field, free of charge (Some shipping and handling charges may apply). Contact your Alamo dealer to order replacement decals VERSA PRO 03/09 © 2009 Alamo Group Inc.
SAFETY PART NO. QTY TYPE DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.
SAFETY Decal Description SAFETY Peligro Translation, If you do not know how to read English, please find someone who knows how to read English. P/N 00725746 DANGER! wings. Stay clear when lowering or raising P/N 00753840 DANGER! Guard Missing, Do Not Operate. If you see this decal, Do Not Operate the mower until the shield has been replaced. P/N 00756004 DANGER! Rotating Driveline Keep Away, Contact can cause death. P/N 00756005 VERSA PRO 03/09 © 2009 Alamo Group Inc.
SAFETY WARNING! Keep all safety shielding installed, repaired and replaced when damaged so that machine stays in safe condition. P/N 00756007 P/N 00756059 DANGER! Keep Away - Rotating Blades P/N 00756485 DANGER! Make certain that drivelines are correct length and are securely attached. P/N 00756494 VERSA PRO 03/09 © 2009 Alamo Group Inc. Safety Section 1-19 SAFETY WARNING! Never use your hand to check for oil leaks. Always use paper or cardboard.
SAFETY SAFETY WARNING! Do not operate with Belt Shield removed. Finger(s) may be pinched off if get caught between V-Belt and Pulley. P/N 00758194 DANGER! Crushing and Pinch Points. Moving machiney parts can pinch or crush or fallwhich may cause injury or death. P/N 02962765 DANGER! Keep Away! If front deflector shield is removed from flail housing, serious injury to or amputation of hands, feet, or limbs may occur from blades contact. Always make sure that all shields are in place at all times.
SAFETY Slow Moving Vehicle Decal. Keep SMV reflector clean and visible. DO NOT transport or operate without the SMV. P/N 03200347 SAFETY Red Relector Tape. P/N 99203 Yellow Relector Tape. P/N 99204 INSTRUCTIONS - Use only DEXTRON TYPE A Automatic Transmission Fluid. Maintain ATF Level within the height of the sight glass. P/N 03200286 VERSA PRO 03/09 © 2009 Alamo Group Inc.
SAFETY SAFETY IMPORTANT - Use ALAMO Genuine Flail Parts. P/N 03200432 Cutting Height Adjustment Chart P/N 002023 Instructions to properly lubricate and check mower for potential problems prior to operation. P/N 000108 Information that Grease Fitting is present and must apply grease. P/N 000678 VERSA PRO 03/09 © 2009 Alamo Group Inc.
SAFETY 8 Hour Lubrication Chart INFORMATION - Pull to Start, Push to Stop 02962748 INFORMATION - To prevent premature hydraulic component failure, do not over speed the engine. When using the mower attachment, operate tractor at the engine speed which will deliver 540 PTO RPM on Tachometer. Over speeding the engine and pump when operating the mower will overheat and rapidly ruin the oil which will decrease the life of the hydraulic components.
SAFETY ALAMO NAME LOGO. SAFETY P/N 001650 ALAMO INDUSTRIAL LOGO P/N 001651 NAME LOGO - Alamo Industrial P/N 02960766 NAME - VERSA PRO P/N 002489 VERSA PRO 03/09 © 2009 Alamo Group Inc.
SAFETY Wing Lowering Instructions. Following instructions will assure the safety of the operator and unit. INFORMATION - 8 Hour Lubrication Chart P/N 001830 PELIGRO! Spanish Translation for Driveline Safety P/N 00773723 INSTRUCTIONS - Read Operator’s Manual and U n d e r s ta n d , b e f o r e o p e r a t i n g Tr a c t o r a n d Implement. P/N 02977417 VERSA PRO 03/09 © 2009 Alamo Group Inc.
SAFETY Read Operator’s Manual! The operator’s manual is located inside this canister. If the manual is missing order one from your dealer. SAFETY P/N 00776031 VERSA PRO 03/09 © 2009 Alamo Group Inc.
SAFETY Federal Laws and Regulations This section is intended to explain in broad terms the concept and effect of federal laws and regulations concerning employer and employee equipment operators. This section is not intended as a legal interpretation of the law and should not be considered as such. Employer-Employee Operator Regulations U.S. Public Law 91-596 (The Williams-Steiger Occupational and Health Act of 1970) OSHA This Act Seeks: “...
INTRODUCTION SECTION Introduction Section 2-1 © 2009 Alamo Group Inc.
INTRODUCTION INTRODUCTION This Flail Mower is designed with care and built with quality materials by skilled workers. Proper assembly, maintenance, and operating practices, as described in this manual, will help the owner/operator get years of satisfactory service from the machine. The purpose of this manual is to familiarize, and instruct. The Assembly Section instructs the owner/operator in the correct assembly of the Mower using standard and optional equipment.
INTRODUCTION INTRODUCTION The Versa Pro Flail Mower is designed for medium-duty cutting such as lawn maintenance plus small weed and grass control. With a reasonable amount of preventive maintenance, your mower will provide years of dependable service. For Non-Agricultural use, OSHA, ASAE, SAE, and ANSI standards require the use of Chain Guards, Deflectors, or Solid Skirts at all times.
INTRODUCTION INTRODUCTION Attention Owner/Operator BEFORE OPERATING THIS MACHINE: 1. Carefully read the Operator’s Manual, completely understand the Safety Messages and instructions, and know how to operate correctly both the Mower and Power Unit. 2. Fill out the Warranty Card in full. Be sure to answer all questions, including the Serial Number of the Mower. Mail promptly using the return envelope included with the Operator’s Manual.
ASSEMBLY SECTION Assembly Section 3-1 © 2009 Alamo Group Inc.
ASSEMBLY The hydraulic system must be kept "SURGICALLY CLEAN" to ensure proper operation and long life of the pumps, motors, and valves. All components have protective caps over openings connected to internal spaces to prevent contamination. It is important that care be taken during unpacking, assembly, and other contaminants which will damage parts. DO NOT start the tractor unless the hydraulic system is filled with hydraulic oil. Running without oil will damage the pumps.
ASSEMBLY MAINFRAME TO ATTACHMENT FRAME ASSEMBLY Place Mainframe on a level surface. Raise Mainframe with a forklift or hoist and attach the Jack stands. Raise Jack stands until the Mainframe is raised to approximately 18". Align the Attachment Frame (3) lugs with Mainframe, install the Pins (4) and retain with 1/2 x 1-3/4 bolts (5), flatwashers (6) and locknuts (7). Install the Axle Mount Bars (8) and retain with Pins (9) and Cotter Pins (10).
ASSEMBLY TRACTOR TO ATTACHMENT FRAME ASSEMBLY ASSEMBLY Raise the Attachment Frame Arms(1) to a level height. Drive Tractor into Attachment Frame and align with the Tractor Attachment Frame Mounts (2). Retain with bolt (3) and locknut (4). ASM-FL-0099. Attach the Axle Mount Bars (5) to the Tractor lugs with Pins (6) and Lynch Pins (7). ASM-FL-0100. Attach the Down Links (8) to the Mainframe with Pins (9) and Lynch Pins (10). ASM-FL-0101. NOTE: Adjust down links to 28" pin center.
ASSEMBLY DRIVELINE ATTACHMENT Pull slide collar back and attach one end to the Tractor PTO. Move yoke back and forth until locking collar "clicks" forward and locks the yoke in place. Do the same to the other end of the Driveline on the Speed Increaser shaft. ASSEMBLY CENTER & WING MOWER ASSEMBLY Tip cutterhousing back and place a block under roller to safely support unit. Remove shipping skids and drive pulley side belt guard fender. If necessary, install knives, as shown, one row at a time.
ASSEMBLY ASSEMBLY WING MOWER ATTACHMENT To attach wing mower to mainframe. Align tilt link (1) with actuator (2) and retain with pin (3). Proceed to lift frame (4) and align with lug on mainframe (5), retain with pin (6) and with pin (7). Secure all pins with 1/2" x 1 1/2" bolt and 1/2" nut. ASM-FL-0103. Pin (3) will be secured with bolt that also secures pin for cylinder. LIFT FRAME TO MOWER Align toplink (1) to mower lugs (8), retain with pin (9) and lock with cotter pins (10).
ASSEMBLY ELECTRICAL CONNECTION AT TRACTOR ELECTRICAL CONNECTION AT MOWER Connect terminals on harness to corresponding terminals on safety switch. Continue harness routing with hoses and attach connector at end of harness to solenoid coil on motor. Secure with screw and gasket provided with harness. ASM-FL-0106. Refer to electrical schematic (ASM-FL-0107) for additional help. VERSA PRO 03/09 © 2009 Alamo Group Inc.
ASSEMBLY ASSEMBLY CENTER MOWER ASSEMBLY Attach the right and left Overarms (1) to the cutterhousing. Secure with 5/8 x 1-3/4 bolts (2) and locknuts (3). Attach the A-Frame Weldment (4) to the Overarms with bolts (2) and locknuts (3). ASMFL-0108. VERSA PRO 03/09 © 2009 Alamo Group Inc.
ASSEMBLY CENTER MOWER ASSEMBLY 1. Attach outboard bearing plate to cutterhousing. a. Remove existing nuts and lockwasher from bearing housing. NOTE: On forward rotation units, remove only the lower two fasteners. b. Slide bearing housing Bolt into proper holes in outboard bearing plate. c. Attach gearbox and mounting bracket to gearbox mounting frame. Secure with 5/8 NC x 1-1/4 Bolt (upper gearbox feet), and 5/8 NC x 1-1/2 Bolt (lower gearbox feet) and Lockwashers. Torque to 170 ft.-lbs. (Typ.) d.
ASSEMBLY ASSEMBLY CENTER MOWER ASSEMBLY Install idler arm assembly to bearing plate. Do not secure at this time. ASM-FL-0052. 1. Remove fasteners and shaft protector from end of drive shaft. Lightly grease shaft. Install key and drive shaft pulley. Do not secure at this time. ASM-FL-0052. 2. Align all three pulleys. Use spacers and shims provided to achieve alignment, then secure idler arm assembly with cotter pin. Secure drive shaft pulley with fasteners removed in Step 1, above. 3. Install drive belt.
ASSEMBLY INSTALLATION OF CENTER MOWER ASM-FL-0111 VERSA PRO 03/09 © 2009 Alamo Group Inc. Assembly Section 3-11 ASSEMBLY 1. To properly attach center mower to mainframe, align lower links (1) to overarms (2) and anti-sway bar (3). Attach with 7/8" x 5" bolt and 7/8" locknut (4). 2. Align toplink (5) with top of A-frame (6) on center mower and retain with pin (7), washers (8), and cotter pins. Attach the other end of the toplink to the mainframe.
ASSEMBLY HYDRAULIC CONNECTIONS ASSEMBLY Refer to the Tractor Manual when connecting hydraulic hoses to the tractor hydraulic system. Numerous precautions should be taken due to the possibility of a pressure buildup within the hydraulic circuit. Relieve the pressure before opening or entering the circuit. FLUID ESCAPING UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SERIOUS INJURY. Ensure that hose fittings are secure before pressurizing the hydraulic systems.
ASSEMBLY HOSE CONNECTION AT TRACTOR 1. To properly connect hydraulic hoses to tractor, connect right wing hose P/N 02839000 (1), and left wing hose P/N 02839000 (2). ASM-FL-0112. 2. Connect center lift hose P/N 02964451 (3) to connection at center of tractor. ASM-FL-0112. This should be the remote valve with "Float" position. Always operate front mower in float detent position. ASSEMBLY VERSA PRO 03/09 © 2009 Alamo Group Inc.
ASSEMBLY HYDRAULIC CONNECTIONS TO CYLINDER Connect the Hoses P/N 02965364 and P/N 02961321 from Tee to Center Lift Hydraulic Cylinders at rod end. HYDRAULIC CONNECTIONS TO FILTER ASSEMBLY Connect return hose P/N 002479 from right wing mower to elbow at filter (identified as "A"). Left wing mower will use hose P/N 002477 and will be connected to Tee (identified as "B"). ASM-FL-0113 HYDRAULIC CONNECTIONS TO PUMP Connect right wing hydraulic motor to pump using hose P/N 002480 (identified by "C").
ASSEMBLY HYDRAULIC CONNECTION MOTORS Left Wing Hydraulic Motor To connect hydraulic hoses to left side mower, use hose P/N 002477 (identified as "B"). This hose comes from filter at tank. Hose P/N 002478 from pump to motor (identified as "D"). ASM-FL-0115. ASSEMBLY Right Wing Hydraulic Motor To connect hydraulic hoses to right side mower, use hose P/N 002480 (identified as "C"). ASM-FL-0116. This hose comes from pump. Hose P/N 002479 filter at tank (identified as "A").
ASSEMBLY HYDRAULIC Filter buggies or carts are commercially available for hydraulic system charging. These consist of a highefficiency, high-capacity filter, a pump, a drive motor, and hoses for supplying the machine’s hydraulic system. After the first 10 hours of operation, replace the hydraulic filter with a new one. An extra Filter Element is provided for you. Refer to the Operation and Maintenance Section for instruction.
OPERATION SECTION Operation Section 4-1 © 2009 Alamo Group Inc.
OPERATION OPERATION ALAMO INDUSTRIAL VERSA PRO FLAIL OPERATION INSTRUCTIONS Alamo Industrial Versa Pro flail mowers are manufactured with quality material by skilled workers. These mowers are designed to cut grass, weeds, small brush, and other vegetative material up to 2” in diameter. The mower is equipped with protective deflectors and chain guards to prevent objects being thrown from the mower by the blades, however, no shielding is 100% effective.
OPERATION FRONT MOWER SPECIFICATIONS 96” Cutting Width 10-Gauge Unitized Cutter Housing 5/16” Side Plates 4-1/2” x 5/16” Wall Cuttershaft 1-5/16” Bore Greasable, Self-aligning Cuttershaft Bearings 60 HP Gearbox 6” Adjustable Rear Roller 1/2” to 6” Cutting Height Available in Fine or Coarse Cut Front and Rear Safety Deflectors Belt Drive from Gearbox to Cuttershaft with Automatic Spring Tension The Mower is designed for certain mowing applications and is rated to cut up to a specific size vegetation (see Mo
OPERATION OPERATION 1. OPERATOR REQUIREMENTS Safe operation of the unit is the responsibility of a qualified operator. A qualified operator has read and understands the implement and tractor Operator’s Manuals and is experienced in implement and tractor operation and all associated safety practices. In addition to the safety messages contained in this manual, safety signs are affixed to the implement and tractor.
OPERATION Tractor Requirements and Capabilities • • • • • • ASAE approved Roll-Over Operator Protective Structure (ROPS) or ROPS cab and Seatbelt. Tractor Safety Devices ...............................Slow Moving Vehicle (SMV) emblem, lighting, PTO master shield Tractor Horsepower -Minimum ...................Versa Pro Flail 90 HP Hydraulics...................................................2 piston pumps and motors are used with a 26-gallon hydraulic reservoir Front End Weights.............................
OPERATION 1.3 Tractor Horsepower The horsepower required to operate the mower depends on many factors including the vegetation to be cut, terrain condition, operator experience, and condition of the mower and tractor. For most mowing condition, the Versa Pro flail mower require a tractor with at least 90HP. Operating the mower with a tractor that does not have adequate power may damage the tractor engine. 1.
OPERATION 2. GETTING ON AND OFF THE TRACTOR Before getting onto the tractor, the operator must read and completely understand the implement and tractor operator manuals. If any part of either manual is not completely understood, consult an authorized dealer for a complete explanation. OPS-U- 0007 2.1 Boarding the Tractor Use both hands and equipped handrails and steps for support when boarding the tractor. Never use control levers for support when mounting the tractor.
OPERATION OPERATION BEFORE leaving the tractor seat, always engage the brake and/or set the tractor transmission in parking gear, disengage the PTO, stop the engine, remove the key, and wait for all moving parts to stop. Place the tractor shift lever into a low range or parking gear to prevent the tractor from rolling. Never dismount a Tractor that is moving or while the engine is running. Operate the Tractor controls from the tractor seat only. (SG-9) 3.
OPERATION mower. Always shut the Tractor completely down, place the transmission in park, and set the parking brake before you or anyone else attempts to connect or disconnect the Implement and Tractor hitches. (S3PT-15) 4. SETTING THE MOWER Properly setting the cutting height is essential for efficient and safe operation. A properly set mower will make a more uniform cut, distribute clippings more evenly, require minimal tractor work, and follow the contour of uneven terrain.
OPERATION OPERATION Roller Height Adjustment The mower’s cutting height is set by positioning the roller assembly for each mower section. Each section must be set at the same height to ensure an even cut across the entire width of the mower. 1. Place the tractor and mower on a level surface and completely lower the mower to the ground. 2. Shut down the tractor, place the transmission in park, and set the parking brake before dismounting. 3.
OPERATION Do not let the Blades turn when the Mower Deck is raised for any reason, including clearance or for turning. Raising the Mower deck exposes the Cutting Blades which creates a potentially serious hazard and could cause serious injury or even death from objects thrown from the Blades. (SRM-07) 5.
OPERATION OPERATION “Bottoming Out” Check Procedure” 1. Disconnect driveline from the tractor and slide the profiles together until fully compressed. 2. Place a mark on the inner shield 1/8” from the end of the outer shield and reattach the driveline to the PTO shaft. 3. With the PTO NOT TURNING, slowly drive the tractor with mower attached through the sharpest turn possible and watch shaft movement.
OPERATION 6. PRE-OPERATION INSPECTION AND SERVICE Before each use, a pre-operation inspection and service of the implement and tractor must be performed. This includes routine maintenance and scheduled lubrication, inspecting that all safety devices are equipped and functional, and performing needed repairs. DO NOT operate the unit if the pre-operation inspection reveals any condition affecting safe operation. Perform repairs and replacement of damaged and missing parts as soon as noticed.
OPERATION OPERATION 6.2 Tractor Pre-Operation Inspection/Service Refer to the tractor operator’s manual to ensure a complete pre-operation inspection and scheduled service is performed according to the manufacturers recommendations.
OPERATION The operator’s manual and safety signs affixed on the unit contain important instructions on the safe and proper use of the equipment. Maintain these important safety features on the implement in good condition to ensure the information is available to the operator at all times. • • • • Check that the main driveline is securely attached to the tractor and the locking collar is seated in the groove of the PTO shaft.
OPERATION • • • OPERATION • • • • • • Inspect the condition of the drive belts. Ensure the slip clutch is properly adjusted and the friction plates are not frozen together. Reference the Maintenance Section for proper slip clutch maintenance. Ensure the slip clutch shield and drive belt shields are in place and in good repair. Ensure the tractor PTO master shield is in place, lowered and in good condition. OPS-F-0039 Check the oil level in tank and replenish if needed.
OPERATION • • • • Do not operate this Equipment with hydraulic oil or fuel leaking. Oil and fuel are explosive and their presence could present a hazard. Do not check for leaks with your hand! High-pressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene. To check for a hose leak, SHUT the unit ENGINE OFF and remove all hydraulic pressure. Wear oil impenetrable gloves, safety glasses and use Cardboard to check for evidence of oil leaks.
OPERATION OPERATION Flail-Wing Mower PRE-OPERATION Inspection Mower ID#________________ Make ____________________ Date: Shift ________________ ____________________ Before conducting the inspection, make sure the tractor engine is off, all rotation has stopped and the tractor is in park with the parking brake engaged. Make sure the mower is resting on the ground or securely blocked up and all hydraulic pressure has been relieved. Condition at Start of Shift Item Specific Comments if not O.K.
OPERATION Tractor PRE-OPERATION Inspection Mower ID#________________ Make ____________________ Date: Shift ________________ ____________________ Condition at Start of Shift Item Specific Comments if not O.K.
OPERATION 7. DRIVING THE TRACTOR AND IMPLEMENT OPERATION Safe tractor transport requires the operator possess a thorough knowledge of the model being operated and precautions to take while driving with an attached implement. Ensure the tractor has the capacity to handle the weight of the implement and the tractor operating controls are set for safe transport. To ensure safety while driving the tractor with an attached implement, review the following. OPS-U- 0012 Read all safety instructions.
OPERATION Transport only at speeds where you can maintain control of the equipment. Serious accidents and injuries can result from operating this equipment at high speeds. Understand the Tractor and Implement and how it handles before transporting on streets and highways. Make sure the Tractor steering and brakes are in good condition and operate properly. Before transporting the Tractor and Implement, determine the proper transport speeds for you and the equipment.
OPERATION OPERATION 7.2 Brake and Differential Lock Setting Make sure the tractor brakes are in good operating condition. Tractor brakes can be set to operate independently allowing single rear wheel braking action or locked together to provide simultaneous rear wheel braking. FOR MOST DRIVING AND OPERATING CONDITIONS, THE BRAKE PEDALS SHOULD BE LOCKED TOGETHER TO PROVIDE THE MOST EFFECTIVE BRAKING ACTION. Always disengage the tractor differential lock when turning.
OPERATION terrain which could upset the mower. When the Wings are folded for transport, the center of gravity is raised and the possibility of overturn is increased. Drive slowly and use extreme caution when turning on hillsides. Overturning the Implement could cause the Implement to overturn the Tractor and vice versa resulting in serious injury or even death. Never fold wings on a hillside...the Implement may overturn. (STI-02) Ensure that the PTO Switch is in the OFF position.
OPERATION OPERATION 7.4 Driving the Tractor and Implement Start off driving at a slow speed and gradually increase your speed while maintaining complete control of the tractor and unit. Moving slowly at first will also prevent the tractor from rearing up and loss of steering control. The tractor should never be operated at speeds that cannot be safely handled or which will prevent the operator from stopping quickly during an emergency.
OPERATION When confronted with an incline or ditch, do not approach from an angle which is perpendicular or straight on as damage to over collapse of the driveline may occur. When crossing such terrain, the wings should be fully lowered for a lower center of gravity and added stability. Inclines and ditches should be approached along a line which is at an angle as shown. This type of path will reduce the possibility of over-collapse of the driveline and resulting damage.
OPERATION OPERATION 8. OPERATING THE TRACTOR AND IMPLEMENT THE OPERATOR MUST COMPLETELY UNDERSTAND HOW TO OPERATE THE TRACTOR AND IMPLEMENT AND ALL CONTROLS BEFORE ATTEMPTING TO OPERATE. The operator must read and understand the Safety and Operation Sections of the implement and tractor operator’s manuals. These manuals must be read and explained to any operator who cannot read. Never allow someone to operate the implement and tractor without complete operating instructions.
OPERATION Many varied objects, such as wire, cable, rope, or chains, can become entangled in the operating parts of the mower head. These items could then swing outside the housing at greater velocities than the blades. Such a situation is extremely hazardous and could result in serious injury or even death. Inspect the cutting area for such objects before mowing. Remove any like object from the site. Never allow the cutting blades to contact such items. (SGM-06) 8.
OPERATION OPERATION 8.2 Bystander/Passersby Precautions If a bystander comes within 100 yards of the tractor while the mower is being operated, stop the tractor at once, idle the engine and disengage the PTO. Do not engage the PTO again until all bystanders are well past the 100 yard distance. Flail Mowers are capable under adverse conditions of throwingobjects for great distances (100 yards or more) and causing seriousinjury or death. Follow safety messages carefully.
OPERATION 8.4 PTO RPM and Ground Speed Do not exceed the rated PTO speed for the Implement. Excessive PTO speeds can cause Implement driveline or blade failures resulting in serious injury or death. (SG-26) Mow at the speed that you can safely operate and control the tractor and mower. The correct mowing speed depends on terrain condition and grass type, density, and height of cut. Normal ground speed range is from 2 to 5 mph(3-8 kph).
OPERATION OPERATION Do not mow with two machines in the same area except with Cab tractors with the windows closed. (SGM-11) Mow only in conditions where you have clear visibility in daylight or with adequate artificial lighting. Never mow in darkness or foggy conditions where you cannot clearly see at least 100 yards(90 m) in front and to the sides of the tractor and mower.
OPERATION 9.1 Shutting Down the Implement To shut down attached mower head, first bring the tractor to a complete stop. Decrease engine RPM to idle then disengage cutterhead. The mower head will come to a complete stop within a suitable amount of time. Do not engage or disengage the cutterheads at a high RPM unless there is an emergency situation. 10.
OPERATION OPERATION To disconnect the rear mower, first extend the tractor 3-point hitch top link to remove tension on the top link hitch pin. When the pin is loose and easy to rotate, remove the pin from the mower. Next remove both lower hitch pins. OPS-F-0055 After disconnecting the 3 lift points, remove the mower driveline from the tractor PTO shaft. Lay the driveline down carefully to avoid damaging the driveline or its shield.
OPERATION 11. MOWER STORAGE 12. TRANSPORTING THE TRACTOR AND IMPLEMENT Inherent hazards of operating the tractor and implement and the possibility of accidents are not left behind when you finish working in an area. Therefore, the operator must employ good judgement and safe operation practices when transporting the tractor and implement between locations.
OPERATION OPERATION Before transporting the tractor and mower, idle the tractor engine, disengage the PTO and wait for all mower moving parts to come to a complete stop. Raise the mower section and ensure transport lock is engage. OPS-F-0057 Before transporting the tractor on a public roadway or boarding a trailer for transport, the tractor brake pedals should be locked together. Locking the pedals ensures that both wheels brake simultaneously while stopping, especially when making an emergency stop.
OPERATION 12.1 Transporting on Public Roadways Only tow the Implement behind a properly sized and equipped Tractor which exceeds the weight of the Implement by at least 20%. DO NOT tow the Implement behind a truck or other type of vehicle. Never tow the Implement and another Implement connected in tandem. Never tow the Implement at speeds over 20 MPH. (STI-06) Never allow children or other persons to ride on the Tractor or Implement. Falling off can result in serious injury or death.
OPERATION OPERATION Make sure that all tractor flashing warning lights, headlights, and brake/tail lights are functioning properly before proceeding onto public roads. While newer model tractors have plenty of lighting to provide warning signals and operating lighting, most older models are only equipped with operating lights. Consult an authorized tractor dealer for lighting kits and modifications available to upgrade the lighting on older tractor models.
OPERATION 12.2 Hauling the Tractor and Implement Before transporting a loaded tractor and implement, measure the height and width dimensions and gross weight of the complete loaded unit. Ensure that the load will be in compliance with the legal limits set for the areas that will be traveled through. OPS-U- 0024 Arrange the chains so that when tightened, the chains are pulling downward and against themselves.
OPERATION OPERATION 13. TROUBLESHOOTING GUIDE TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY Mower will not rotate 1. Inline fuse blown. 2. Safety switch not making contact. 3. Broken drive belts. 4. On/Off switch bad. 5. Insufficient voltage through solenoid. 6. Solenoid spool will not shift completely. Replace Fuse. Adjust or replace safety switch. Replace belts. Replace On/Off switch. Check oil and wires. Mower will not stop 1. Solenoid spool will not shift. Clean or replace solenoid cartridge.
OPERATION TROUBLESHOOTING GUIDE (Cont’d) POSSIBLE CAUSE POSSIBLE REMEDY Mower will not raise or raises slowly. 1. Relief valve setting too low. Adjust relief valve. 2. Worn cylinder. 3. Worn control valve. Replace or rebuild. Replace valve section. See tractor manual. 1. Air in system due to low oil level. 2. Loose suction line. 3. Clogged suction filter. 4. Internal pump or motor damage. Fill in reservoir to sight glass. System noisy. Sluggish response to acceleration or deceleration 1.
OPERATION OPERATION TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY Excessive case drain Excessive internal wear Disassemble motor, inspect parts and replace as necessary. Case drain flow should not exceed 1.5 GPM at full pressure. Mower heads scalping. 1. Center unit top link out of adjustment. 2. Cutting height set to low. Level front unit so that skid shoes are level with ground. Raise cutting height. VERSA PRO 03/09 © 2009 Alamo Group Inc.
MAINTENANCE SECTION Maintenance Section 5-1 © 2009 Alamo Group Inc.
MAINTENANCE MAINTENANCE DAILY CHECKS 1. Lubricate the VERSA PRO at the specified intervals as outlined in the lubrication diagram. All mower grease fittings are equipped with lubricaps which snap over the grease fittings to prevent dirt from entering the fittings. Remove the cap and wipe the fitting before greasing. Wipe the outlet of the grease gun then grease the bearing. When finished, place the cap over the fitting and wipe any excess grease from around the cap.
MAINTENANCE LUBRICATION INFORMATION Before operating your Mower, make sure it is properly lubricated and thoroughly inspected. Only a minimum of time and effort is required to regularly lubricate and maintain this machine to provide long life and trouble free operation. Always disengage the PTO before raising the mower for transporting or making adjustments. VERSA PRO 03/09 © 2009 Alamo Group Inc.
MAINTENANCE CHANGING HYDRAULIC SYSTEM FILTER MAINTENANCE A large capacity filter is located on top of the hydraulic oil reservoir. Mnt-FL-0078. The filter will trap particles which are .001 inch or larger. The filter needs to be changed after the first 10 hours of operation and every 200 hours or every 12 months thereafter. VERSA PRO 03/09 © 2009 Alamo Group Inc.
MAINTENANCE CHANGING HYDRAULIC SYSTEM FILTER (Cont’d) 1. Clean the filter cover to prevent dirt from entering tank. 2. Loosen the four bolts on the filter cover. Mnt-FL-0004. Remove one bolt from the filter to aid in removing the filter cover. Mnt-FL-0005. MAINTENANCE 3. Push the filter cover down and slowly twist the filter cover off. Mnt-FL-0006. 4. Remove filter spring. Mnt-FL-0007. VERSA PRO 03/09 © 2009 Alamo Group Inc.
MAINTENANCE CHANGING HYDRAULIC SYSTEM FILTER (Cont’d) MAINTENANCE 5. Remove filter. Inspect material trapped by the filter. It can indicate parts wear in the system. Mnt-FL-0008. 6. Install the new filter. 7. Reinstall filter spring and filter cover. Replace the one bolt which had previously been removed. Tighten all bolts in an even manner. Mnt-FL-0079. VERSA PRO 03/09 © 2009 Alamo Group Inc.
MAINTENANCE GENERAL REPLACING CUTTER UNIT DRIVE BELTS Image Mnt-FL-0020 1. Place unit on ground or support securely. 2. Remove belt guard. 3. Remove idler arm spring. 4. Remove extension shaft housing mounting bracket front bolt and loosen rear bolt. 5. Remove motor mounting bracket front bolt and loosen rear bolt. 6. Pivot motor-mounting bracket assembly. Remove old belts and install new ones. 7. Reinstall front mounting bolt then secure motor mounting bracket to unit. 8.
MAINTENANCE MAINTENANCE ROLLER BEARING REPLACEMENT 1. Remove roller and both bearing and bracket assemblies from mower. Lift the mower only high enough to remove the roller assembly. Securely support mower while removing and installing roller assembly. If installing a roller with preassembled bearing and bracket assemblies, remove the old roller, proceed to step 11. 2. Slide bearing and bracket assemblies off each end of roller. If replacing with new bearing and bracket assemblies, proceed to step 9. 3.
MAINTENANCE CUTTERSHAFT BEARING REPLACEMENT MAINTENANCE OUTBOARD BEARING. (Mnt-FL-0021) 1. Lift cutter unit to maximum horizontal height; then securely support ends of cutterhousing. 2. Remove enough knives to place a floor jack under center of cutterhousing. 3. Securely support cuttershaft. NOTE: The cuttershaft must remain supported while changing bearings. 4. Remove outboard fender. 5. Remove fasteners securing bearing and housing assembly to cutterhousing, then remove bearing and housing assembly.
MAINTENANCE MAINTENANCE CUTTERSHAFT BEARING REPLACEMENT (Cont’d) INBOARD (DRIVE) BEARING. (Mnt-FL-0023 & Mnt-FL-0058) 7. Remove Belt Guard. 8. Remove spring from idler arm. 9. Remove motor mounting bracket fasteners, at the cutterhousing. Pivot motor-mounting bracket assembly and remove drive belts. 10. Remove fasteners that secure pulley to cuttershaft. Remove pulley and key. 11. Remove fasteners securing inboard bearing and housing assembly to cutterhousing, then remove bearing and housing assembly.
MAINTENANCE CUTTERSHAFT REPLACEMENT Changing to Forward or Reverse Rotation WING MOWER The hydraulic wing motors are dual rotation motors which means they will rotate in either direction depending on the inlet port used. An arrow on the flat surface of the motor housing at both ports indicate the direction of rotation. To change rotation, remove the four bolts that mount the manifold block to the motor.
MAINTENANCE HYDRAULICS MAINTENANCE GENERAL VERSA PRO hydraulic system consists of two circuits. The power circuit drives the cuttershaft. The control circuit lifts and tilts the cutter unit. NOTE: It is important that pipe thread sealant be used on solid connections only; never on connections between swivel fittings or fittings with "O" rings and straight threads. Use pipe thread sealing compound. DO NOT substitute other types of sealant, such as teflon tape, paint, shellac, etc.
MAINTENANCE REPLACING HYDRAULIC PUMPS The pump unit for the power circuit is a piston fixed displacement pump (see specifications) and is PTO driven. It is mounted on the mainframe above the hydraulic reservoir. There is a separate pump for each wing. By following the hose routing, the operator can determine each wing mower's supply source. Each pump has a case drain to eliminate excessive fluid in the pump. All excess fluid in the pump is routed back to the reservoir through the case drain.
MAINTENANCE MAINTENANCE RESERVOIR Mnt-FL-0080 The reservoir stores hydraulic system oil. The breather cap which is mounted on top of the reservoir prevents a pressure buildup or vacuum from occurring in the tank as oil level changes. Their is also an oil filler cap which is used to fill the reservoir with oil. To help prevent dirt from entering the tank, clean the top of the reservoir before removing the cap. THE BREATHER CAP HOLDS APPROX 11 PSI PRESSURE IN TANK.
MAINTENANCE SOLENOID CONTROL VALVE (Cont’d) CHECKING SOLENOID VALVE A. With engine running, turn the mower ON/OFF switch in the "ON" position. Check voltage level at the solenoid. B. If it is less than 12 volts, check wiring and ground connections. Checking ground wire is as important as checking the hot wire. If voltage is sufficient, the solenoid valve is bad and will need to be replaced. DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. Disconnect all hydraulic lines. Remove pump assembly from tractor.
MAINTENANCE INSPECTION MAINTENANCE 1. Inspect flat surface of the backplate. The finish on the piston block side should be smooth and free of grooves. DO NOT LAP BACKPLATE WEAR SURFACE. The backplate should be replaced if it shows any of the wear characteristics outlined above. Inspect the needle bearing in the backplate. If the needles are free of excessive play and remain in the bearing cage, there is no need to replace the bearing. 2. Inspect the piston block.
MAINTENANCE MAINTENANCE HYDRAULIC MOTOR DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Clean outside of unit thoroughly. Refer to Hydraulic Motor illustration in the Parts Listing section. Clamp shaft in a protected jaw vise with backplate end up. Remove six bolts from backplate. Use a plastic mallet and tap the backplate to loosen it. Remove o-ring from backplate. Remove the complete piston block assembly from the housing assembly. Remove piston assemblies, spider, and pivot form piston block assembly.
MAINTENANCE INSPECTION MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Wash all parts thoroughly in a suitable solvent. Examine needle bearings in housing and backplate. Inspect thrust washers and thrust bearing. All surfaces should be free of any signs of wear or fretting. Inspect spider and pivot; conical surfaces should be free of wear and score marks. Inspect the pistons: the O.D. surface should be smooth and free of scoring. The shoes should be snug fit to the piston.
MAINTENANCE LIFT CYLINDERS MAINTENANCE DISASSEMBLY OF LIFT CYLINDER For part numbers and illustration, refer to the Parts Listing section. 1. Disconnect hoses at cylinder. Cap all hoses to prevent fluid contamination. Remove cylinder from unit. 2. Remove reducer bushing and snap ring which retains the rod guide. Remove rod guide, rod, and piston. Remove guide and piston from rod. 3. Replace all "O" rings, back-up washers, and rod wiper. Inspect rod, guide, piston, and body for damage. 4.
MAINTENANCE EXTERNAL COIL SLIP CLUTCH DISK REPLACEMENT MAINTENANCE TO DISASSEMBLE EXTERNAL COIL SPRING CLUTCH (Refer to Mnt-FL-0083) Before beginning disassembly, remove or fold shields out of the way and clean off dirt and trash from the area. 1. Remove two Attaching Bolts (6). Remove Clutch Assembly from shaft of Gearbox. Leave Driveline or Driveline Half attached to Clutch. 2. Loosen six Adjusting Bolts (1). LOOSEN EACH BOLT A FEW TURNS AT A TIME - NOT ALL AT ONCE.
MAINTENANCE TO REPLACE SHIELDS 1. Make certain that all Driveline Canopy Shields are in good repair and rotate smoothly on the Drivelines. Replace Bearings and/or Integral Shields if necessary. 2. Re-install Gearbox Canopy Shields with the same hardware and tighten securely. MAINTENANCE ITEM PART NO.
MAINTENANCE TO TEST FOR FROZEN CLUTCHES MAINTENANCE 1. Mark across Clutch Disks and Plates plainly with soft chalk so that you can tell if Clutch slips (would misalign the marks). 2. 2.With mower lifted off the ground, PTO engaged, and tractor engine at half throttle, let the tractor clutch out rapidly to see if all Slip Clutches will slip. 3. If all Clutches slip and provide protection for the drivetrain, you are ready to mow if you have performed all normal maintenance.
MAINTENANCE VERSA PRO TANK FILLING INSTRUCTIONS NOTE: Do not fill the tank with oil above the level of the sight gauge after the first filling. Over-filling the tank with oil after the initial filling may result in oil being discharged through the air filter on top of the hydraulic tank. 4. Start the tractor and engage PTO for 2 minutes and then turn it off. 5. Again check the oil level in the sight gauge.
MAINTENANCE MAINTENANCE STORAGE Your mower represents an investment from which you should get the greatest possible benefit. Therefore, when the season is over, the mower should be thoroughly checked and prepared for storage so that a minimum amount of work will be required to put it back into operation for the next season. The following are suggested storage procedures: 1. Thoroughly clean the mower. 2. Lubricate the cutter as covered in Maintenance Section. 3.
ALAMO-INDUSTRIAL LIMITED WARRANTY 1. 2. LIMITED WARRANTIES 1.01. Alamo Industrial warrants for one year from the purchase date to the original non-commercial, governmental, or municipal purchaser (“Purchaser”) and warrants for six months to the original commercial or industrial purchaser 1.02. Manufacturer will replace for the Purchaser any part or parts found, upon examination at one of its factories, to be defective under normal use and service due to defects in material or workmanship. 1.03.
TO THE OWNER/OPERATOR/DEALER To keep your implement running efficiently and safely, read your manual thoroughly and follow these directions and the Safety Messages in this Manual. The Table of Contents clearly identifies each section where you can easily find the information you need. The OCCUPATIONAL SAFETY AND HEALTH ACT (1928.51 Subpart C) makes these minimum safety requirements of tractor operators: REQUIRED OF THE OWNER: 1.
VERSA PRO - SOM 3/09 Printed in USA P/N 803350C
