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Brahma/Cat Challenger MT465B

1. sneen kk nennen 4 4 Section 5 Pump Driveshaft Hyd Tank Rs 5 1 to 5 9 PU Cal CREA CON eine eee deh era des ou ets 5 2 Install Crankshaft Pulley Adapter rrrrnnnrrnnnnnrrnnnnnvrnnnnrrnrnnnrenrnnnnen 5 2 to 5 3 Install Driveshaft EEE a nenne anne 5 3 HEAR PO PEN 5 3 ASTA DE ae een 5 4 Pump amp Pump Drive Schematic nennen 5 5 to 5 6 HATE 5 7 to 5 8 Section 6 Cylinder Control Valve Installation 6 1 to 6 7 Mo MEN 6 2 Modify Control Valve End Cap 6 2 to 6 3 Connect Remote Cables to Valve 6 4 Mounting Control Valve to Frame kk e rn knrn nn 6 5 to 6 7 Brahma Caterpiller Challenger MT465B Asy Manual 09 05 2005 Alamo Group Inc Index 2 INDEX ASSEMBLY INSTRUCTION Section 7 Page Joystick amp Electrical Controld Mounting RR nn 7 1t0 7 6 Install Joystick MOUNTING Stand 7 2 Joystick Control Instruction D CaAl 22 7 2 to 8 3 Install Cbles amp Wire Harnnes through Cab Floor 7 2 Connect Cables to Joystick 7 3 Connecting Wire Harniessau aaas sen 7 4 to to 7 6 Section 8 Pump Hose c Connections amp Head Installation 8 1 to 8 8 General Information about Hose connections 8 2 to 8 3 Pump to Frame Hose connections 8 4 Hose Retaining Ring EE nee res 8 4 Hose to Pump SONNSLION Seesen 8 4 Head Installation 8 5 to 8 7 Section 9 Tractor Start Up PLFOCE HUNG a ee 9 1 to 9 4 PUTE 9 2 to 9 3 Fa
2. BRAHMA ALAMI Assembly Manual INDUSTRIAL Published 09 05 Part No 02983272 2 ge Ara mil N ei Tractors equipped with additional options special equipment tractor manufacturer modifications new tractor models or Customer alterations may prevent this Mount Kit from being properly mounted to the tractor Alamo Group is not responsible for modifications to the Mount Kit to accommodate these differences ALAMO INDUSTRIAL 1502 E Walnut Seguin Texas 78155 MEMBER OF THE 210 379 1480 her EEE 2005 Alamo Group Inc ALWAYS ON THE CUTTING EDGE TO THE OWNER OPERATOR DEALER All implements with moving parts are potentially hazardous There is no substitute for a cautious safe minded operator who recognizes the potential hazards and follows reasonable safety practices The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents BEFORE YOU START Read the safety messages on the implement and shown in your manual Observe the rules of safety and common sense 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 NO 3 USE SAFETY SHOES 4 BLOCK UP SECURELY TORS HARD HAT SAFETY BEFORE WORKING See OBER GLASSES SEAT BELTS ROPS amp 1 Study and understand Operator s Manuals Safety Decals and Ins
3. 02970202 Position Joystick to connect cables as necessary _ Push Pull Switch Joystick mounting bolt Cable Tilt Valve Cable retainong bolt f Function Note Routing of wire f Gable Lift Valve harness amp control cables Function this hole will most likely require cutting General Illustration Shown for General P information Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 7 3 Joystick amp Electrical Controls Mounting CONTROL WIRING 1 Disconnect the Battery negative lead ground from the battery terminal to prevent any damage to the electrical system 2 Running the Wiring Harness section with the plug on it from the inside of the cab to the Hydraulic tank mounted on front of the tractor The second leg of the wire harness with the wires sticking out of will stay in the cab and Kl connect to the tractor electrical system Make r is 2 certain that the Wiring Harness is free and clear of any moving parts from the Mower or Figure 6 the Tractor or any condition that may sever bind or entangle the cable The wiring harness will run through a protective boot in the floor of the cab If there is not a hole under floor mat to run wiring through the cab floor one will need to be cut with a hole saw 3 Install Push Pull Switch amp Switch Mount ing Bracket The push pull switch bracket will bolt to the side panel i
4. square 1 4 thick P N 02983115 P N 02983119 Support Weldment PP Battery Mount Bracket 1 X 15 Spline Clamp Yoke P N 02975257A P N 02979770 Driveshaft Asy Hose Support Ring Inner amp Outer Half W Yokes Weld On Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 11 Mount Kit Component ID Pump amp Driveshaft Components Tractor Engine Pulley Time Universal Joints Pulley Adpater P N 02979238 w Mounting Bolts amp Washers 4 bolts Pump End Driveline Asy P N Clamp Yoke 02975257A A Mounting Bolts ee Spacers P N 02982085 Pump Reference B Bolts To Mounting Bolts Tractor Bolster Pump Mounting Bolts Pump Mount P N 02977074 Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 12 Base Unit Component ID 2 P N 02979630 PA Under Beam Asy w Hardware Shipped Assembled item Part No Qty Description 02979630 Under Beam Asy Item 1 thru 7 1 00015800 2 Locknut Toplock 3 8 NC PLC 2 00059900 2 Bolt Hex head 3 8 NC X 3 PL 3 00695100 4 Locknut Toplock 5 8 NC PLB 4 00059100 4 Bolt Hex Head 5 8 NC X 6 PL 5 02967987 1 Clamp Plate 6 02979629 2 Pin Cylinder Base 7 02979613 1 Under Beam Machined Asy P N 02979630 Under Beam Asy w Harware Under Beam assembly will be shipped with pins bolts nuts and clamp plate Under beam assembly is
5. 28 02969646 29 02970202 30 02970204 31 02971123 32 02971191 33 02978099 34 00059900 35 00010600 36 02958206 37 02958488 38 02982828 BUMPER WELDMENT DECAL MULTI HAZ OIL TANK amp PUMP ASY ASY BRAHMA OPERATORS amp PARTS ASY BRAHMACANISTER MANUAL JOYSTICK DUAL AXIS REMOTE CONTROL KIT CABLE CONNECTION F VALVE VALVE ASY CONTROL DECAL NAME BRAHMA 20 YELLOW DECAL INST JOYSTICK amp PUMP WIRE HARNESS PUMP CONTROL DECAL WARNING PRESSURIZED TANK WELDMENT SWITCH MOUNT TANK COVER ASY BOLT HEX HEAD 3 8 NC X 3 PL GR5 BOLT HEX HEAD 3 8 NC X 2 PL GR5 QUICK SPLICE 18 14 TO 18 14GA COTTER PIN 1 16 X 1 2 DECAL OIL HYD TEMP RANGE ND ND m dt dt S S NN St Common Box P N 02969093 is included in Base Unit P N 04001000 Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 7 Common Box Component List Tractor Hyd Valve IMPORTANT NOTICE These are parts that are used as Base Unit with each unit that will use tractor hydraulics for Cylinder Control Valve These parts will remain the same no matter which model tractor or head is used DO NOT ORDER any of these parts unless you are certain that that is what you want most of theses are complete assemblies and may contain more prts than are wanted to perform repairs If ordering parts that are listed here it is recommended that you look up the parts in a regular parts manual under the spec
6. Hose Fitting 3 Hydraulic Tank Installation Using a hoist to lift the Hydraulic Tank into position See Figure 19 The Hydraulic Tank will slide in under Pump Align the rear two mounting holes of Hydraulic Tank with the holes inthe Tank Mounting Brackets See Figure 20 These are the two closest to the tractor Snug these two bolts at this time do not tighten them as tank will have to move to align front Bolts Note the front Bolts that mount tank Suction Hose Fitting points also mount Bumper Leave the Tank supported by to Rear of Tractor at approx the Hoist 15 to 20 deg to RH Side 4 Mounting Bumper When installing the frontbumper Tank mount Brackets andthe Bumper must all line up together as they share the same bolts Start with one side or the other in Figures below we started with the LH side See Figure 21 amp 22 There are three bolts on each side total 6 for both sides Insert the Bolts Washers and Nuts but do not tighten untill all 6 are installed Tighten the 2 rear mounting bolts and the 6 front mounting bolts See Figure 20 5 Tightening Tank Makes sure all the Mount ing Bolts for the Tank and Bumper are tightened Make sure that all Fittings and Hoses are plugged to prevent contamination from getting into system Bumper AA Weldment a m ef Tank Mounting Bracket Figure 18 Figure 19 E Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo G
7. Installing Hydraulic Tank E BE iT untin Special Note the photos in this sec tion may not be of the same type tractor as you are mounting but the procedure will be the same These photos are illusrtration only and not for model identification 1 Hydraulic Tank The Hydraulic tank is sent with the Tank Filler cap attached to itand the return Filter Assembly mounted on it The Openings For Hoses are plugged and should remain Plugged Al untill Hoses are connected Never leave a Hose or Fitting unplugged during Assembly See Figure Figure 14 16 amp 17 2 Tank Mounting Brackets amp Bumper In spect the Tank Mounting Brackets Notice the Bends in the Brackets they should be bent to where they are wider atthe Bumper end than atthe Tractor Frame Rail Mounting End The tank rails are installed using the RH frmae rail and LH support frames front 4 bolts Remove the front 4 bolts of frame rail and install the tank rails over the frame these four bolts can be tighten now Test fit Bumper this will make sure thatthe Tank Mounting Brackets are correct and the Bumper will fit Ok Remove Bumper as the Hydraulic Tank cannot be installed with the Bumper installed See Figure 28 Figure 15 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 5 7 Tighten Suction Hose Fitting Pump Hydraulic Tank Assembly Instructions Installing Hydraulic Tank continued Outlet Pressure
8. Sometimes it will be required to extent or retract the cylinder to align this lug If you need to extend or retract the cylinder you can usually do it with a pry bar but you may have to loosen the hoses to let pressure escape The lift lug uses a retaining bolt and nut if you need to align the retaining bolt hole in pin with hole in the mounting frame The pin has a head welded on to it in the front side that can turned by using a large pair of pliers or a pipe wrench Align pin and install re taining nut and bolt See Figure 10 11 amp 12 NOTE The two holes where cylinder can be con nected which hole determines what degrees the head will fold into transport Figure 11 ERA Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 8 6 Connecting Head To Frame Install Cutting Head 5 Check Head mount Frame To Head Con nections The head mounting frame for the flail head is a bolt on clamp type Always check these bolts to make certain they have been tightened See Figure 13 Head Frame Mounting Clamp 6 Connect Hoses from Head to Mounting Arm The hoses are already assembled on to the head and will have the sleeving installed It may be required to loosen some of the fittings at the Motor to allow hose Fitting clearance or for the hoses to run in the direction you need them to These hose will have color coded plastic ties on them Orange Tie the top fitting Red Tie the
9. 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 sc 35 WARNING Operate this Equipment only with a Tractor equipped with an approved roll over protective system ROPS Always wear seat belts Serious injury or even death could result from falling off the tractor particularly during a turnover when the operator could be pinned under the ROPS 6 7 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 56 14 WARNING Use caution and wear protective gloves when handling sharp objects such as blades knives and other cutting edges Be alert to worn component surfaces which have sharp edges Sharp surfaces can inflict severe laceration injuries if proper hand protection is not worn SG 37 Brahma Caterpiller Challenger MT465B Asy Manual 09 05 2005Alamo Group Inc Section 1 3 WARNING Many of the parts are heavy and require lifting assistance Do not try to WARNING WARNING WARNING DANGER DANGER lift the heavy parts by yourself Get help from another employee or from an overhead crane The operator and all support personn
10. buggies or carts are commercially available for hydraulic system cleanup These consist of a high efficiency high ca pacity filter a circulating pump a drive motor and hoses for connecting to the overhauled machine s hydraulic system See Figure 2 amp 3 When adding hydraulic oil use only new oil from a sealed barrel Used oil or oil from an open barrel may contain high levels of contamination Transfer the new oil into the hydraulic tank by using a hydraulic filter pump unit equipped with a properly operating 10 mi cron filter This will insure that the oil being added is clean Do not just pour the oil directly into the hydraulic tank since most oils even from a sealed barrel have contaminants that should be removed before operating the hy draulic system TANK SHIELD ATTACHMENT Failure to INSPECT and REPAIR or REPLACE Hoses may allow worn Hoses to rupture SUDDENLY and VIOLENTLY with resulting serious BODILY INJURY from SCALDING or FIRE with resulting BURN INJURY or DEATH 1 Frayed torn or crimped Hoses may RUPTURE andspray BOILING OIL onto Operator and cause serious BODILY INJURY from scalding 2 Boiling Oil may spray onto HOT TRACTOR PARTS and CATCH FIRE with SEVERE BURN INJURY or DEATH 3 Use Paper or Cardboard to check for leaks NEVER USE YOUR HAND Ifoil penetrates skin gangrene or other serious injury could occur GET IMMEDIATE MEDICAL ATTENTION See Manual KEEP SHIELDS OVER HYDRAULIC COMPONENTS I
11. driveshaft half The shaft half of driveline will have to be slid down and through the bolster from the engine side of radiator The driveshaft has to slide in from the engine side because the hole holes in bolster may be to small for driveline flange yoke to slide through There is a plate that is bolted to the front of tractor that will have to be removed Check hoses for the Oil Cooler and or Air Conditioning condenser these hoses need to be tied up in such away that they will not rub on driveshaft after it has been installed Installing Pump Drive Components le With Front Bolster coverremoved Remove any plastic plugs that are located in the threaded holes in the front and discard them they will not be needed The Casting should already have a hole in it for the driveshaft to slide through Installing Crankshaft Pulley Adapter 1 Install Pulley Adapter The Pulley adapter P N 02979238 is a round plate with 4 threaded holes and four non threaded holes in it Notice this pulley adapter will not have a center hole in it See Figure 1 The four non threaded holes are used to mount the Adapter to the Crankshaft Pulley using 4 bolts and 4 lockwashers that are supplied in mount kit The four threaded holes are used to install the flange yoke of driveline to pulley adapter Do not use longer bolts to mount Pulley Adapter to Pulley or Flange yoke to adapter than are supplied with mounting kit if longer bolts are used they could go through adapter and pulle
12. middle fitting Blue Tie the bottom fitting Orange Tie Hose Returns Flow back to Front Pump Hydraulic Reservoir Red Tie Hose Supplies Pressure Flow From Front Pump Blue Tie Hose is Case drain from Motor back to Hydraulic Tank in front of tractor Make certain that the hoses are connected where they will not rub or get pinched when Head is folded up See Figure 14 T Connecting Rotary Head The rotary head will connect the same as the Flail Head with the exception of the bolt on mounting frame like the Flail has The rotary Head mount is built on the the rotary head The hoses will have the same color coded plastic ties on them as the flail has and will connect in the same order See Figure 15 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 8 7 NOTES Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 8 8 Section 9 BRAHMA Caterpillar Challenger MT465B Cab 4 WD Tractor Tractor Start Up Procedures Tractor Start Up Procedure HYDRAULIC TANK FILLING 1 Remove the Filler Cap and fill the Hydraulic Tank completely full of AW ISO VG100 Fluid however do not over flow or spill over 2 Replace Filler Cap and clear area to start the Tractor and the Hydraulic Pump as outlined in the Operation Section Make certain that the Mower Head is in a clear safe mowing position i e Blades down and the area is clear 3 Check tha
13. shaft Set the tube end of driveshaft aside for now as it will be installed later But always remember the driveline universal joint must be aligned timed when assembling the driveline halves Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 5 2 Pump Driveshaft Assembly Instructions Four Threaded Four Non Threaded Holes Holes Splined Clamp Yoke Tube End Flange Yoke Shaft End Drive Shaft Assembly Installing Pump Mounting Weldment 1 Install Pump Mounting Weldment The Pump Mount Weldment P N 02977074 bolts to the front of the tractor there are four spacers that are used P N 02982085 used to space pump mount plated See Figure 3 P N 002528 Bolt M20 X 7OMM P N 02971158 Lockwasher M20 P N 20982085 Spacers 4 P N 5312316 Hardened Flatwasher 3 4 P N 02977074 Pump Figure 3 Mount Weldment Installing Driveline Half to Pump 1 Install Driveline Half to Pump Coat the Splined Pump Shaft with anti sieze compound before installing driveline Grease the driveshafts universal joints before assembly Install the clamp yoke of the tube half of driveline onto the pump slide the clamp yoke on pump shaft until you have about 1 8 to 1 4 gap between yoke and pump Do not install yoke so far on pump shaft that yoke will rub against pump in anyway Tighten the two bolts and nuts on clamp yoke at this time See Figure 4 Brahma Caterpiller Challenger MT465B Asy Man 09 0
14. transporting the Equipmentuse the Tractor flashing warning lights and follow all local traffic regulations sc s tractor in gear can result in injury or death Read the Tractor operators manual for proper starting instructions 56 13 DANGER Start tractor only when properly seated in the Tractor seat Starting a DANGER 4 Start only from seat in park or neutral Starting in gear kills DANGER Do not operate this Equipment with hydraulic oil leaking Oil is expensive and its presence could presenta hazard Do notcheck for leaks with your hand Use a piece of heavy paper or cardboard High pressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene Ifoildoes penetrate the skin have the injury treated immediately by a physician knowledge able and skilled in this procedure sG 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 DANGER All Safety Shields Guards and Safety devices including but not limited to the Deflectors Chain Guards Steel Guards Gearbox Shields PTO integral shields and ro PT Retractable Door Shields should be used and main 06 tained in good working condition All safety devices should be inspected carefully at least daily for missing or broken components Missing broken or worn items must be replaced at once to red
15. 5 2005 Alamo Group Inc Section 5 3 Pump Driveshaft Assembly Instructions Driveline Tube Half with Clamp Yoke Installing Pump to Pump Mount Weldment 1 Install Pump to Pump Mount Weldment The Pump has the tube half of driveline attached and clamp yoke tightened To install the pump and driveline half it is best to use an assistant or overhead hoist to help you align the drivelines halves as they are slid together the Driveline must be timed universal joints aligned the same as shown inthe pump amp driveline schematic on See Figure 4 thru 12 Slide Driveline half and pump together until the shoulder on the pump slide in the hole onthe pump mount weldment The Driveshaft halves will have to slide together while the two halves must align to keep the universal jionts in time When installing the pump always keep ports sealed to keep them clean and free of contamination The pump MUST be turned correctly This can be done by making certain thatthe pressure filter that is mounted on top of the pump is up Install the two 1 2 X 1 1 2 long pump mount bolts P N 02892000 and two 1 2 lockwashers P N 00001300 Tighten the two pump mounting bolts eo Bolts To Mounting Bolts Tractor Bolster Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 5 4 Pump Driveshaft Assembly Instructions Mount Weldment installed vom to 1 4 gap Pe yoke amp pum F rove Push Pump int
16. 5 X 70MM PL GR10 9 BOLT HEX HEAD M20 P2 5 X 80MM PL GR10 9 FLATWASHER 1 2 HARDENED NON PLTD WASHER 3 4 HARDENED BOLT HEX HEAD 3 8 NG X 2 3 4 PL GR8 BOLT HEX HEAD 3 8 NG X 1 3 4 PL GR8 LOCKWASHER 1 2 BOLT HEX HEAD 7 16 NF X 1 3 4 PL GR8 BOLT HEX HEAD M20 P2 5 X 110MM PL GR10 9 BOLT HEX HEAD 3 8 NG X 1 1 4 PL GR5 BOLT HEX HEAD 3 8 NG X 2 1 2 PL GR5 FLATWASHER 3 8 STD BOLT HEX HEAD M20 P2 5 X 60MM PL GR10 9 Bolt Bag Asy P N 02983165 is included in Mount Kit P N 02983134 Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 5 Common Box Component List Aux Hyd Valve IMPORTANT NOTICE These are parts that are used as Base Unit with each unit that will use Auxillary Cylinder Control Valve These parts will remain the same no matter which model tractor or head is used DO NOT ORDER any of these parts unless you are certain that that is what you want most of theses are complete assemblies and may contain more prts than are wanted to perform repairs If ordering parts that are listed here it is recommended that you look up the parts in a regular parts manual under the specific assembly number 04001000 Base Unit Consist of the Following Items 04001000 is NOT a Replacement Part Number listed here as a reference only Used on Caterpillar Challenger MT465B Cab 4wd w Aux Valve ITEM PART NO QTY DESCRITION 04001000 BRAHMA SIDE MOWER BASE UNIT
17. Caterpiller Challenger MT465B Asy Man 09 05 Section 7 5 2005 Alamo Group Inc Joystick amp Electrical Controls Mounting gt u nn Battery Shown here is typical Ignition ply Wire from wire harness Remove ignition switch access panel or ignition switch if panels are not provided in dash Identify Ignition the Ignition ON OFF Posi tive wire This wire must be connected to a wire that is only charged when ignition switch is on and dead when ignition is off Connect power supply wire as close to the switch as possible Do not connect wire into wire that will be overloaded because something else is connected to ACC Wire connection Your Ignition may vary but the function will not Tractor Ignition Switch it If power supply wire is con Cut Tractor Starter nected to a wire that is positive Wire to Starter Sole when switch is off and operator noid and reroute leaves the push pull switch on it through Joystick will drain the tractor battery See Harness Brown Figure 10 wires 6 Find the Ignition Start wire leading from ignition switch to Joystick Wiring ER Starter solenoid of the tractor Harness cut the wire in two as close to ignition switch as is reasonable and still have room to work Strip off 1 4 to 3 8 of insulation from each wire Connect the two brown wires of harness to this wire Solder the connection and insulate with a good heat shrink tubing See Figure 10 7 Con
18. G Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the state of Califor nia to cause cancer and birth defects or other reproductive harm Wash Hands after handling SG 31 WARNING Use extreme caution when getting onto the Implement to perform repairs maintenance and when removing accumulated material Only stand on solid flat surfaces to ensure good footing Use a ladder or raised stand to access high spots which cannot be reached from gound level Slipping and falling can cause serious injury or death sc 33 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 sc 34 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 sc 38 Brahma Caterpiller Challenger MT465B Asy Manual 09 05 O 2005 Alamo Group Inc Section 1 6 Section 2 BRAHMA Caterpiller Challenger MT465B Cab 4 WD Tractor PRE DELIVERY INSPECTION CHECKLIST BRAHMA PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operat
19. Head or Folding Section raised if passersby bystanders or traffic are in the area to reduce possibility of injury or death from objects thrown by Blades under Guards or mower structure 8 Before dismounting secure implement in transport position or lower to ground e Puttractorin park or set brake disengage PTO stop engine remove key and wait until noise of rotation has ceased to prevent crushing by entanglement in rotating parts which could cause injury or death e Never mount or dismount a moving vehicle Crushing from runover may cause serious injury or death 5 TRANSPORT SAFELY 6 USE SMV LIGHTS amp 7 DO NOT OPERATE WITH 8 DO NOT MOUNT OR LOCK UP REFLECTORS CUTTER OR WING RAISED DISMOUNT WHILE La VE da NNN 02067827 INTRODUCTION ABOUT THIS MANUAL The intent of this publication to provide the competenttechnician with the information necessary to perform the CORRECT Assembly to the Alamo Industrial Product This will in turn provide for complete customer satisfaction 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 correspondence with the Manufacturer is neces sary CONTACTING MANUFACTURER Please help us Help You Before You Call Alamo Industrial Service Staff Members are dedicated to helping you solve yo
20. ITEMS 1 THRU 3 1 02969093 1 COMMON BOX BRAHMA 2 02979630 1 UNDERBEAM ASY BRAHMA 3 02979631 1 MOUNTING ARM BRAHMA Base Unit Includes Valve amp Joystick for Hydraulic Cylinder Control 02969093 Common box Consist of the Following Items ITEM PART NO QTY DESCRITION 1 00001300 2 LOCKWASHER 1 2 2 00001800 8 LOCKNUT TOPLOCK 1 2 NC PLB 3 00002700 8 FLATWASHER 1 2 PL STD 4 00015800 3 LOCKNUT TOPLOCK 3 8 5 00023500 6 FLATWASHER 5 16 PL 6 002369 1 DECAL DANGER MULTI HAZARD 7 00725336 2 STRAP 8 00725337 2 PIN 9 00725746 1 DECAL PELIGRO 10 00726119 2 WASHER BRASS SPECIAL F HINGE 11 00748823 2 BOLT HEX HEAD 1 2 13UNC X 1 1 2 PL GR5 12 00750940 3 LOCKNUT TOPLOCK 5 16 NC PLB 13 02027400 6 BOLT HEX HEAD 1 2 NC X 2 1 4 PL GR5 14 02733700 3 BOLT HEX HEAD 5 16 NC X 4 1 2 PL GR5 15 02776600 2 BOLT HEX HEAD 1 2 13NC X 1 1 4 PL GR8 16 02959010 1 PAMPHLET SAFETY MOUNTING 17 02964028 1 SWITCH PUSH PULL SPDT 10A 12V 18 02965093 1 DECAL PROPER ENGINE OPERATING 19 02965262 1 DECAL WARNING HOSE BURST Continued Next Page Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 6 Common Box Component List Aux Hyd Valve 02969093 Common box Consist of the Following Items Continued From Previous Page ITEM PART NO QTY DESCRITION 20 02966634 21 02967827 22 02981212 23 02968822A 24 02968822CA ed 02969128 26 02969129 27 02969613
21. JX 8FJX90 92 LG BOOT CABLE DRAWING INSTRUCTION BOOT CABLE REMOTE CONTROL 72 LG HOSE 16 16FJX 16FJX 108LG HOSE 16 16FJX 16FJX 108LG HOSE 16 16FJX 16FJX 108LG CORDURA SLEEVING 100 DRIVELINE ASY 1 X15 SPLINE HOSE SUPPORT RING MAINFRAME WELDMENT BRAHMA SUPPORT MOUNT LH TANK RAIL WELDMENT LH TANK RAILWELDMENT RH BATTERY MOUNT BRACKET HOSE 8 8FJX 8FJX90 84 LG HOSE 8 8FJX 8FJX90 112 LG END CAP POWER BEYOND ADAPTER HYD ELBOW 8M J 10MB90 HYDRAULIC FITTING 12MB PLUG ADAPTER HYD 8MJ 8FJX90 ADAPTER HYD STRAIGHT 8MJ 10FJ ADAPTER HYD 8MJ 22MM W SEAL CONTROL STAND WELDMENT BOLT BAG CAT MT465B C 4 BRAHMA PUMP MOUNT PLATE MACHINED SPACER PLATE MACHINED SPACER PUMP PLATE ASSEMBLY MANUAL CAT MT465B Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 4 Mounting Kit Bill of Material 02983165 Bolt Bag Caterpillar Challenger MT465B Cab 4wd Consist of the Following Items Item O oN O O1 R D gt Part No 00015800 00022200 02892000 02971158 02976344 02975738 02976113 00759635 5312316 02970595 02957042 00001300 02975781 002528 00753642 00013900 00011100 02975669 Qty oO Bo ae Seen ee reas sa BUND BASED Description LOCKNUT TOPLOCK 3 8 LOCKWASHER 7 16 PL BOLT HEX HEAD 1 2 13NG X 1 1 2 PL GR8 amp LOCKWASHER 20MM BOLT HEX HEAD 7 16 NG X 1 1 4 PL GR8 BOLT HEX HEAD M20 P2
22. N PLACE Inspect Hoses daily and repair or replace when needed Stop all leaks Repair or replace hoses as indicated to prevent unexpected failure and possible serious injury to operator or bystander 02965262 Attach the Tank Shield to the Bumper and the Straps to the Tank with the Hardware supplied in the Common Box 1 Attach the Tank Straps to the tank with the pin and Cotter pin 2 Place the Special Washer upon the Hinge posts 3 Lower and Slide the Shield in place secure the straps to the rear of the shield Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section9 3 Tractor Start Up Procedure START UP PROCEDURE 1 Read all safety instructions Decals on the Brahma Mower warn you of particular and multiple hazards Many decals are attached close to part of the Brahma Mower where there is a possible hazard Read and make sure you understand the safety messages before you operate the Brahma Mower Keep all decals clean and readable Replace lost or damaged decals 2 Before operating read all the safety and operating instructions in the Operator s Manuals for both the tractor and mower 3 When the hydraulic tank has been filled and the mower unit properly assembled the unit should be started up NOTE Make sure that no materials tools or jacks have been left under the mower head Make sure the front and rear of the mower are properly guarded to prevent any foreign objects from bein
23. a Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 6 8 Section 7 BRAHMA Caterpillar Challenger MT465B Cab AWD Tractor Joystick amp Electrical Connections Jovstick amp Electrical Controls Mountinc Joystick Mount Installation P N 02982176 1 Fitting Joy Stick Mount Stand to Tractor Control Stand Cab The joystick stand is a weldment that will bolt Weldment to the floor of the cab See Figure 1 amp 2 Sit the stand inside cab of tractor and position it for the best reach by the operator sometimes it is best to consult the operator to see what is needed by them once the location is determined use a marker pencil to mark the holes in the stand to the floor mat of cab 2 Bolt in the Joystick stand Once the location has been determined and marked check under the cab to make certain that the other components will not be in the way of the drill or the bolts when installed Drill the four mounting bolt holes and the hole in the center to run the electrical wiring through See figure 3 Joystick amp Motor Control Decal 1 The Joystick and Motor Control operation Decal will need to be installed in the cab of the tractor This is a transparent decal that shows the direction of movement of joystick in relation to the function that is activated Install this decal where it is easily in view by the operator but where it will not interfere with his line of sight of his environ
24. an 09 05 2005 Alamo Group Inc Section 2 2 BRAHMA PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component location Flail Mower Head Skid Shoe Bolts are torqued to 120 ft Ibs Motor Bolts are torqued to 120 ft Ibs 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 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 and facing forward Make sure the control valve boom movements agree with the valve oper
25. ation 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 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 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 2 3 NOTES Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section2 4 Section 3 BRAHMA Caterpiller Challenger MT465B Cab 4 WD Tractor General Information GENERAL INFORMATION The tools you will need at the assembly site are as follows Impact wrench or socket and ratchet set Rubber mallet Box end Allen and adjustable wrenches Alignment pins Forklift or hydraulic floor jacks with rolling back boards Small chain hoist or block and tackle Multidirectional Levels Hydraulic Filter Buggy or Cart Safety shoes safety glasses and gloves hard hat should be worn by anyone working under any raised component IN Remember to follow each step closely and cautiously Be aware of all support personnel at all times Keep the assembly area as clean as possible clean up all spills when they occur An uncluttered assembly area and a crew that is sensitive to the hazards involved in putting this implement together will help prevent accidents Kee
26. ch the oil that will run out Remove this factory hose at both ends and discard the hose it will not be used again 11 Locate the three 8 hoses There are three number 8 hoses that will connect the add on control vale to the tractor hydraulic sys tem See Figure 20 amp 21 Hose P N 02972267 8 8FJX 8FJX90 112 long P N 02960004 8 8FJX 8FJX90 92 long P N 02961853 8 8FJX 8FJX90 84 long Adapters P N 0692300 8MJ 0 22 MM w Seal Qty 1 P N 02861100 8MJ 8FJX90 Qty 2 P N 02961851 8MJ 10 FJ Qty 2 leave any fittings hoses ports or any other opening in hydraulic system during assembly always use compressed air and clean out all new hoses before installing Corner Valve them This will make certain there is nothing in Figure 17 mouhting bolts hoses to contaminate hydraulic system f Fr TTET ie Tractor Pressure m hose to i motes is W ted here Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 6 5 Mounting Cylinders amp Control Valve Hydraulic lines LH Side of Tractor down beside T Tank Return Orange Tie Transmission Lift Cylinder Base End Blue Tie Existing Line New Hose P N 02960004 Install Adapter Here 1 92 long P N 02761100 8MJ 8FJX90 Il Existing Line ANE mn 4 or il N Kunz Install Adapter Here 7 TT P N 02961851 2 ni 8MJ 10FJ N O ze New Ho
27. components down stream It is important that pipe thread sealant be used only on solid connections of pipe thread never on connections between swivel fittings and external pipe threads or on straight thread O ring fittings Use pipe thread sealant suitable for hydraulic service Do not substitute some other type of sealant i e teflon tape paint shellac etc Hoses supplied have two types of Fittings solid or rigid Some Hoses have rigid Fittings on both ends others have a rigid fitting and a swivel fitting Hoses with two rigid fittings will fit into either an internal rigid thread or a swivel adapter union When installing either type hose rigid fittings must be installed first Then install the swivel end of the hose The Brahma hydraulic system incorporates three basic types of hydraulic fittings A Standard pipe NPT or NPTF thread fittings This type requires a small amount of evenly applied sealant B JIC Swivel fittings This type does not require any sealant on the swivel end because it seals against an internal flare C O Ring fittings This type does not require any sealant on the O Ring end of the fitting It is extremely important to avoid getting pipe thread sealant inside the fittings or hoses KEEP THE INTERIOR OF ALL HYDRAULIC COMPONENTS ABSOLUTELY CLEAN Inspect the inside diameter of each hose before assembly Ensure that no obstruction is present Dirt sand dust etc are abrasive and once in the system ca
28. d See Figure 6 There are lift lugs bolted to each end of the flail deck for lifting See Figure 6 amp 7 There are two pins that will need to be removed from the mounting frame before at tempting to install the Cutting head The Tilt cyl Arm Pin and or the Head Pivot Pin The head pivot pin can be in Head Frame or it can be in Mounting Arm depending which one you used to install mounting arm See Figure 7 2 Align Cutting head with Mounting arm The TiftCyl Arm Pin M Head Pivot Pins Cutting Head will have to aligned with the mount ing arm and the tilt lug weldment at the same time This is recommended that two person work on this together When the Head Mounting frame is aligned with the mounting arm install a tempo rary under size pin into the front side to help hold the head in position See Figure 8 From the back side start the pivot pin into the hole make certain to try to keep the retaining bolt hole of pin a closely aligned with the frame as possible DO NOT use excess force to install this pin With the Head suspended by a hoist have your helper nn Se move the head to keep it from binding on pin EU while you install the pin with a minimum amount of force Ifthe Teflon Bushing are damage during this installation you will know it because as pin is installed it will push out pieces of the bushing If this happens the bushing must be replaced Use a Rubber Hammer or a soft piece of metal such as brass or alum
29. d off the tractor and then installed as an assembly to the tractor or they can be installed as components one piece at a time If installing under beam and Lift Arm assembled it is best that you use an overhead hoist and an assistant to help control the components movement The LH Under beam Support Mount WILL be assembled to the tractor be fore the under beam is installed The Clamp plate to mount the under beam to the LH Under beam Support Mount will be installed after the arm bracket and under beam asy are installed See Figure 8 2 Locate Components Locate Lift Arm Assembly See Figure 7 Locate the underbeam weldment See Figure 6 amp 8 These component can be assembled together then mounted on to the tractor These are heavy components you will need an overhead hoist to lift them into position 3 Align components The same pin will connect all three components It works well to have the Mounting Arm Assembly up off the floor a few inches See Figure 8 Align the under beam up with the lift arm using a hoist lower the under beam down and into the frame rail Caution read the section on the previous page about the bearings for these pin this is important that these bearings are not damaged LH Under Beam LH Under Beam RH Frame Clamp Plate Support Mount Weldment Lift Arm Asy Under Beam Weldment EN N Pin EA f l x Figure 8 Bolt Pin NOTE Shown in Figure 8 as disassembled as reference only these components can be con necte
30. d to tractor as an assembly it is the person mounting the unit to decide which method works best for them Pin Lock Nut Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 4 4 Section 5 MACHETE Caterpiller Challenger MT465B Cab 4 WD Tractor Front Pump Driveshaft amp Hydraulic Tank Installation Pump Driveshaft Assembly Instructions Installing Pump Pump Drive Components and Hydraulic Tank This Section covers the installation of Pump Drive Components Pump Assembly and the Hydraulic Tank Some precautions must be followed during the Assembly Process and before unit is ever started for the first time 1 Tractor must be disabled to prevent accidental engine start and prevent damage to components 2 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 during mounting process this will keep system clean 3 All Tools Work Area Components and Workers Hands must remain Clean when working on any part of the Hydraulic System 4 All components should be rechecked for tightness at least twice Hose routing also double checked Prepare Tractor Front Plate Bolster to Slide Driveline in F Engine Side 1 Preparing Tractor On the Left and Right side of Tractor the hood sides will need to be removed also if there are engine protective shields they will have to be removed to install pulley adapter and
31. e Cylinder Hydraulics 1 The Motor Hydraulics consists of the Front Mounted Pump and Tank and the larger hoses and the Motor on the Mowing Head which can vary There are three types of hoses in this system marked with the colored ties Color s Abbreviation Hydraulic Direction Red Tie R Pressure Flow Orange Tie Or Return Flow Blue Tie B Case Drain Note The colored ties do repeat but the motor hoses can be identified by their large size compared to all the other hoses 2 The Hoses for the Brahma are included in the Mount Kit and with the Head each may vary in length 3 Connect the Mount Kit hoses to the marked Tank Ports and route the hoses to the tractor so that they do not interfere with the tractor mowers operation Be especially aware of any pinch points on the tractor or any position where the hoses may become entangled in brush 4 Connect the Mount Kit hoses to the Right Side of the Fittings located on the Middle Rear of the Arm first Red second Orange then Blue 5 Connect the Hoses from the Head to the Left Side of the Arm Fittings in the same order Note the Motor is marked with the same color codes 6 Check each connection by following one hose and checking the color connections Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 8 3 Connecting Hoses To Pump amp Frame Pump To Frame Hose Connections 1 Connect Hoses to the Mounting Arm Bulk head The Mo
32. el should wear hard hats safety shoes safety glasses and proper hearing protection at all times for protection from injury including injury from items thrown by the equipment sG 16 Yan Always wear safety shoes with steel toes when working on this equipment lt is recommended that the safety shoes have metatarsal guards When welding use Welding hood with the appropriate OSHA required protective lens welding apron and welding gloves NZ Always disconnect the wire leads from the mower valve solenoid before performing service on the Tractor or Mower Use caution when working UPA on the Tractor or Mower Tractor engine must be stopped before 2 or death s8M 12 working on Mower or Tractor The Mower Blades could inadvertently be IN A turned on without warning and cause immediate dismemberment injury AN G Never run the tractor engine in a closed building or without adequate ventilation The exhaust fumes can be hazardous to your health SG 23 Brahma Caterpiller Challenger MT465B Asy Manual 09 05 2005 Alamo Group Inc Section 1 4 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 BERND Make certain that the Slow Moving Vehicle SMV sign is installed in such a way as to be clearly visible and legible When
33. g thrown by the mower All other workers should be kept a safe distance from the unit before the mower is started 4 Start the tractor and idle at a slow engine speed until oil is being pumped 5 Engage the Cutter Control Valve at low engine rpm and run the mower slowly for a short period until all air is removed from the hoses Keep all persons WELL CLEAR of mower since Blades can THROW OBJECTS with great velocity for a considerable distance KEEP CLEAR 6 With the area clear of any ground and overhead obstructions work each cylinder on the boom one at a time several times to expel any air in the Hoses and Cylinders 7 Run the Mower Head for 5 minutes While the tractor is idling its tires are blocked and you wearing protective clothing and eye protection CAREFULLY check for leaking hydraulic fittings hoses and ports at this point with a piece of cardboard DO NOT USE YOUR HAND If any are found stop the tractor immediately and correct any leaky connections 8 Check the fluid level in the Hydraulic Tank on the Tractor and add oil if required As the air has been forced out ofthe Cylinders and Hoses it goes into the Hydraulic Tank and reduces the oil level Check you Tractors operators manual for the proper level and type of oil to be used 9 Basic trouble shooting guide for first start up A Electrical solenoid valve does not work check wiring possible faulty switch possible faulty solenoid see the Maintenance Section for p
34. heck for any damage to the bear LH Frame Support ings or any burrs on the pins Replace the bear ing if there is any damage to it and remove any he pins burrs on the pins Toward RH side of 3 DO NOT USE EXCESSIVE FORCE Pins Tractor should slide into the bearing with just hand force If they do not check each bearing and thru hole to make certain that the pin will go into them It they do realign and try again Teflon bearings are not to be Force Fitted The Holes for the pins are align bored DO NOT use force to spread any compo nents as you will misaligned the holes A If the Teflon sheathing is pushed out by a pin the bearing must be replaced immediately 5 DO NOT USE ANY KIND OF LUBRI CANT If problems continue do not use any kind of lubricant to aid the installation of the pin it will only attract dirt becoming liquid sandpaper and definitely destroy the bearing Contact your dealer or Alamo Industrial Technical Services Under Beam Wdf ment or h Fi po Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 4 3 Mounting Main Frame Asy To Tractor 6 Assembled Components The Under Beam and the Lift Assembly will be shipped as sembled The pins and bolts will have to be removed in order to mount them together and to the tractor use caution not to damage pin bearings MOUNTING ARM amp UNDER BEAM INSTALLATION 1 The Under Bear amp Lift arm can be assemble
35. his application See Figure 12 N 9 Locate the Hydraulic Elbow Adapter The Pa end cap will need an adapter installed into it Adapter Hyd Elbow P N 02161300 8MJ 10MB90 as shown See Figure 12 Install the adapter as shown in figure 12 the angle can be changed P N02975061 later if desired or this elbow could be installed Power Beyond later if desired Figure 12 6 Install Power beyond End Cap Make cer P N 02975061 tain all the O Rings are in the proper location if Power Beyond you need to hold an o ring in place use petroleum End Cao jelly vaseline to coat the o ring A light coat of petroleum jelly will hold o ring in place and will not contaminate hydraulic oil See Figure 13 Lower end cap down over the tie rod bolts carefully See Figure 14 the end cap will only fit one way IMPORTANT INFORMATION Start the nuts onto the tie rod bolts and tighten them until they touch the valve end cap only DO NOT tighten beyond that point as damage to the valve could occur SEE STEP 7 for proper valve tightening sequence P N 02161 300 U il I 7 Proper End Cap Tightening Procedure It Figure 13 i is very important that this step be followed when tightening the valve end cap 1 st Tighten the three tie rod nuts 7 to 10 ft lbs torque do this alternating from one nut to the other a little at a time till all three are torqued 2 nd Lay the valve on a flat surface with the ports facing up make certain the co
36. ific assembly number 04101000 Base Unit Consist of the Following Items 04101000 is NOT a Replacement Part Number listed here as a reference only Used on Caterpillar Challenger MT465B Cab 4wd Base Unit when Tractor Hydraulic used for Hydraulic Cylinder Control ITEM PARTNO QTY DESCRITION 04101000 BRAHMA SIDE MOWER BASE UNIT ITEMS 1 THRU 3 1 02982163 1 COMMON BOX BRAHMA 2 02979630 1 UNDERBEAM ASY BRAHMA 3 02979631 1 MOUNTING ARM BRAHMA Base Unit WILL NOT Incl ude Valve or Joystick for Hydraulic Cylinder Control Use Tractor Huydraulic controls 02982163 Common box Consist of the Following Items ITEM PART NO QTY DESCRITION 1 00001300 2 LOCKWASHER 1 2 2 00001800 8 LOCKNUT TOPLOCK 1 2 NC PLB 3 00002700 8 FLATWASHER 1 2 PL STD 4 002369 1 DECAL DANGER MULTI HAZARD 5 00725336 2 STRAP 6 00725337 2 PIN 7 00725746 1 DECAL PELIGRO 8 00726119 2 WASHER BRASS SPECIAL F HINGE 9 00748823 2 BOLT HEX HEAD 1 2 13UNC X 1 1 2 PL GR5 10 02027400 6 BOLT HEX HEAD 1 2 NC X 2 1 4 PL GR5 11 02776600 2 BOLT HEX HEAD 1 2 13NC X 1 1 4 PL GR8 12 02959010 1 PAMPHLET SAFETY MOUNTING 13 02964028 1 SWITCH PUSH PULL SPDT 10A 12V 14 02965093 1 DECAL PROPER ENGINE OPERATING 15 02965262 1 DECAL WARNING HOSE BURST 16 02966634 1 BUMPER WELDMENT Continued Next Page Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 8 Common Box Component List T
37. ing the unit to assure that they are properly assembled 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 Item 1 page 1 4 Deflectors are installed on the Mower Head Item 2 page 1 4 Tractor Rops or Cab with seatbels installed properly Frame Front Support Bolts are torqued Hydraulic Tank mounting Pins Bolts in place correctly All Welds inspected toinsure proper welds and locations Hydraulic System saian 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 Brahma Caterpiller Challenger MT465B Asy M
38. inum to protect the pivot pin if it is hammered on Installing the pivot pin will push the under sized pin outthat you have installed into the front Go slowly as you will need to align the lift lug as the pin starts through and then the outer part of the mount arm Sometimes it is best to put a floor jack under the mounting arm to help align the mounting arm and head Under Sized Short a Pin in front Side to help align the three i componefits Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 8 5 Connecting Head To Frame Install Cutting Head 3 Secure The Head Pivot Pin The head pivot pin uses a bolt and nut to retain the pin You may have to realign the hole in the pin with the hole in mounting frame If you can not see the hole at all you can push the pin back out a short distance till the pin hole is visible not to much or you will lose the alignment of pin and compo nents Using a small punch or bolt insert it into the pin retaining hole using a hammer tap on punch or bolt to rotate pin NEVER USE a tool that will scratch or cut pin It will help if you have you helper rock the head a bit as you align the pin 4 Install the Lift Lug Pin for the Tilt Cyl Start the Lift Pin into the front side of the frame Push pin through while holding the lifting lug into align ment the other end of this lug is connected to the same pivot bracket as the cylinder is connected to
39. is vital for the development of a prompt and correct solution to the problem This will also help to develop a database of problems and related solutions which will expedite a solution to future problems of a similar nature 3 The technician may be asked to provide detailed information about the problem including the results of any required trouble shooting techniques Ifthe 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 Information provided by customer CONTACT ALAMO INDUSTRIAL Alamo Industrial 1502 E Walnut St Seguin TX 78155 Technical Service Dept PH 830 379 1480 Brahma Caterpiller Challenger MT465B Asy Manual 09 05 2005 Alamo Group Inc Index 1 INDEX ASSEMBLY INSTRUCTION Index Page INIFOQUCHOR 9 Se eme ae men ns Index 1 General Ind X eee uns ein Index 2 amp 3 User Assmbly Notes rnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnennnnnnnnnnennnnnen Index 4 Section 1 DONS Le TO a te tique 1 1 to 1 6 Section 2 Pre Dilivery Check List 2 1 to 2 4 Section 3 General Information een 3 1 to 3 3 Fools OUT Oi 3 2 BTG CAR ee seen 3 2 General Statement 3 3 Section 4 Frame Momin Ct ee ee ee 4 1 to 4 4 RH Frame RAILINSIANATIONEE Se 4 2 to 4 3 Pins amp Teflon Bearing Information Warning 4 3 Mounting Arm amp Under Beam
40. ll need to be taken loose See Figure 2 and reinstalled over the frame weldment See Figure 3 The frame weldment will need to be supported while the bolts are being installed this can be done with floor jacks or by using an overhead hoist When lifting the frame weldsment use caution not to damage the cab or other components of the tractor Do not tighten any of the mounting bolts for the frame weldment until all the bolts have been install When tightening the frame weldment do not use the bolts to force the frame up it should go up straight Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 4 2 Mounting Main Frame Asy To Tractor 3 The LH Frame Support will bolt to the LH side of the tractor with the angle end pointing inward toward RH side See Figure 4 5 amp 8 Use 4 bolts P N 02975738 4 Lockwashers P N 02971158 and 4 Hardened Flatwashers P N 5312316 The LH Tank Rail will bolt on with these same bolts front 4 bolts these bolts should be left loose until tank rails are installed There are 2 bolts P N 02975669 2 Flatwashers P N 5312316 and 2 Lockwashers P N 02971158 that will be used in the LH frame rail that can be installed and snugged See Figure 5 PINS AND TEFLON BEARINGS 1 Teflon Bearings and Pins should last a reasonable time on Brahma but only if properly installed 2 Before assembling any points that have P N 02983115 teflon bearings c
41. m 2 Remove End Cap From Valve Asy IMPORTANT INFORMATION The Con trol valve will have to be modified from the way it is received The end cap will need to be changed Turn the valve on its side to where the standard end cap cap with no outlets is show ing See Figure 10 There are three tie rods connecting the valve segments together These valve sections should be left together when tie rods are unbolted remove the nuts off tie rods do not pull tie rods out If the valve sections are separated the O Rings could be moved or fall out from between the sections 3 When the end cap is removed you will notice that there are several O Rings See Fig ure 11 sometimes they will stay on the end cap and sometimes on the valve section Al ways check where these O rings are There is a grooved circle around the holes on the cap or the valve segments The O rings need to be in these grooves If the O Rings need to be held in F place use light coating of petroleum jelly Vaseline to hold them in place The old end cap will not be used again Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 6 2 Mounting Cylinders amp Control Valve 4 Locate New Power Beyond End Cap The new power beyond cap P N 02975061 See Fig ure 12 amp 13 is shipped as a part in the Brahma Mount Kit Kit P N 02983164 and will need to be installed onto the valve to modify the valve to function correctly in t
42. ment See Figure 4 Control Cables amp Wire Harness in stallation 1 Control Cable amp Wire Harness Route through Cab Floor The wire harness and the control cables will be inserted through the cab floor in the same hole See Figure 3 It is best to mark the cables as to which is which Lift or Tilt see Figure 5 for which cable connects to where on joystick and control valve section for which cable is connected to where at the valve These cables must be connected correctly so the joystick will operate as the decal shows See Figure 4 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 7 2 Joystick amp Electrical Controls Mounting CONTROL CABLE TO JOYSTICK When using Alamo Industrial Valve Only 1 Remove the Cable retaining bolt for one of Lift Down the directions Lift shown 2 Position the Joystick so that the Lift Plunger Tilt Up Dom is accessible Check the Joystick for the lt proper direction for each cylinder Connect the cable leading from the left in Float 3 side valve section to the left cable port on the joystick this controls the Lift Cylinders Lift Up motion 4 Repeat the procedure for the Tilt Cylinder PULL UP TO START Di Route both cables up to the Control Valve so they do not interfere with the operation of the tractor or the mower o Install the top cover of joystick using the PUSH TO STOP rubber boot on top See Figure 7 amp 8
43. mponents of the valve are sitting flat on the bench if one or more ofthe feet of the valve are sticking up use a mallet and lightly tap the corners until all four are level and touching the bench This will allow the center segments to hang straight on the center tie rod bolt 3 rd Torque the three nuts to 20 ft lbs alternating from one to the other in 4 to 5 ft lbs increments IMPORTANT STEP If the above procedure is not followed the valve segments could be installed crooked and warp the surfaces and or make the valve leak Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 6 3 Mounting Cylinders amp Control Valve 8 Attach the Control Cables to Valve Cable are included in the mount kit to the valve with the Cable Connecting Kit in the Common Box There should be an instruction sheet included in the cable package A Remove the two screws that are around the spool on the valve B Screw the large jam nut onto the cable past the threads until the jam nut slides down the cable See Figure 15 C Slide the retaining ring 2 screw retaining ring on over the threaded cable housing See Figure 15 D Screw the cable mounting tube onto the cable housing until the tube unscrews off the threads and slides onto the cable outer housing E Screw the Jam Nut onto the threaded cable end followed by the clevis tighten the jam nut down against the clevis to keep the clevis from turning F Inse
44. n cause immediate or early failure CAUTION When assembling the fittings and hoses be careful not to introduce any dust or contaminants into the system Keep all fittings hoses and hydraulic compo nents sealed until installed Do not allow any components to lie open and exposed to dust or contamination Do not lay parts down on the dirt or sand and then assemble them as this will introduce contamination into the system See Figure 1 2 amp 3 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 8 2 Connecting Hoses To Pump amp Frame Refer to your Operator s Manual and Parts Listing for part numbers and Hydraulic Schematic Tighten any leaking Hydraulic Fittings If pipe fittings leak loosen the fitting apply a pipe thread compound to pipe threads and tighten Care must be taken when tightening Hydraulic Fittings Too much tightening can cause the fittings to crack and require replacement Please use recommended hose end torque values WARNING Once Pumps are installed DO NOT start the tractor which will turn the pump unless the hydraulic circuit is filled with AW ISO VG100 hydraulic fluid Running pump without oil will cause nonwarrantable and immediate damage HYDRAULIC HOSE CONNECTIONS FRONT MOUNTED TANK HYDRAULICS On all Hoses and Major Connections colored ties are used to identify the proper flow of hydraulic fluid There are two hydraulic systems The Motor Hydraulics and th
45. n the cab The exact location can vary as long as it is mounted in a convenient location for operator Alamo indus trial recommends mounting bracket as shown The Switch will mount to bracket Plug the wire harness plug to switch See Figure 5 amp 6 4 Install Wire Harness Through Tractor Floor The wire harness will have two leads one stays in the cab to connect to the tractors system the second goes through the floor to connect to the pump solenoid Both will run through the cable boot to where they split up under the floor mat the outside lead will go through the floor and the inside lead will go under floor mat to the tractor control panel See Figure 9 10 amp 11 Figure 8 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 7 4 Joystick amp Electrical Controls Mounting P N 02970204 Wire Harness R en _ 16 Red Push Pull Switch shown turned around for illustration of terminals only ON Off Switch Plug A u gt LL 2 12 Brn Fuse Holder _ with Fuse emp Pte Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply Ground 16 Black 48 long Pump Solenoid Connector Ring Connector to Ground Connecters Shipped Loose in Separate Plastic Bag 16 Red to Ignition Switch Power Supply 16 Red DT 12 Brown Line at front pump S Connector to Figure 9 Starter Solenoid Brahma
46. n turned around for illustration of terminals only ON Off Switch Plug C gt le 1 WY D LL 12 Brn Fuse Holder with Fuse Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply Ground 16 Black 10 Amp Fuse 48 long Pump Solenoid Connector Ring Connector to Ground Connecters Shipped Loose in Separate Plastic Bag 16 Red to Ignition Switch Power Supply 416 Red On Solenoid Connector 12 Brown Line at front pump y Connector to Starter Solenoid Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 16 Blue Tie gt ANE Ne 3 2 ST 3 N Base Unit Component ID LG d Item Part No oo oO R D gt 02969613 02963349 02967150 02967151 02968828 02968830 02968831 02968832 02968833 02968834 02969131 63042700 02969399 02972159 9 Red Tie 1 hk Note orientation of orfice A plate notch points away m NN m dt m IM D from valve as shown Description Valve Asy 1 thru 13 Adapter Hyd Elbow 8MJ 4MJ Adapter Hyd Tee 8MJ 8MJ 8FJX Adapter Hyd Straight 8FJ 4 MJ Plastic Tie 4 LG Red Plastic Tie 4 LG Blue Plastic Tie 4 LG Blue amp White Plastic Tie 4 LG Green Plastic Tie 4 LG Green amp White Plastic Tie 4 LG Orange Valve Only Adapter Hyd Straight 12MB 8MJ Orfice One Way Restric
47. nd tire sizes listed in the model specifications will work with these mount kits Other options front axles or different tire sizes may prevent the mount kit from fitting your nonstandard tractor Alamo Group cannot take responsibility for these problems or any modifications made to the unit Throughout these instructions In the Parts Mnaual Operators Manual and decals on unit you will see the following symbles pay close attenion to them 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 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 and safe operating practices A signal word DANGER WARNING or CAUTION is used with the Safety Alert symbol DANGER identifies the most serious hazards z gt Z Q m WARNING Safety signs with signal word WARNING are typically used to point out more serious hazards General precautions are listed on CAUTION safety sign CAUTION also calls attention to safety messages in these instructions O gt e O Z 4 DANGER CRUSHING AND PINCH POINTS i UR 2 MOVING MACHINERY PARTS CAN PINCH OR CRUSH OR FALL WHICH MAY CAUSE INJURYOR DEATH 02962765 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 3 3 NOTES B
48. nect Wire Harness to the Pump Sole noid The wire harness has a plug that will con nect to the pump solenoid at the pump on front of the tractor See Figure 11 after wire harness has been connected use plastic ties to tie the wire harness to the hoses wunning along side the right side of tractor Tie wires so they will not be pinched or pulled 8 Installation of the wiring harness in now completed Recheck all wires according to color and instructions for that color See Figure 10 amp 11 9 Reconnect the negative lead ground to the battery terminal DO NOT START TRACTOR until the assembly is complete and unit has been inspected as well as filled with oil Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 7 6 Section 8 BRAHMA Caterpillar Challenger MT465B Cab 4 WD Tractor Pump Hose Connections amp Head Installation Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 8 1 Connecting Hoses To Pump amp Frame GENERAL INFORMATION AND WARNINGS HYDRAULICS See Figure 1 Inspect and clean all hydraulic hoses and fittings prior to installing them onto the tractor or Mower If dirt or material is seen in any of the parts they should be washed and cleaned thoroughly with an oil compatible solution Do not blow the material further into a hose since this sometimes does not remove the foreign material and can cause damage to hydraulic
49. nkKSMeldInSAlAUON ete 9 3 Stratup Procedure 9 4 Section 10 MOUNTING SPECMCANONS anni 10 1 to 10 3 Mounting Kit Bills of Materials List 10 4 to 10 9 bom 910 aa NESEN 10 10 to 10 18 Brahma Caterpiller Challenger MT465B Asy Manual 09 05 2005 Alamo Group Inc Index 3 NOTES Brahma Caterpiller Challenger MT465B Asy Manual 09 05 2005 Alamo Group Inc Index 4 Section 1 A BOOM Caterpiller Challenger MT465B Cab 4 WD Tractor SAFETY Read these assembly instructions through completely and understand them before proceeding with the assembly of the equipement A safe and careful operator is the best operator Safety is of primary importance to the manufacturer and should be to the owner operator Most accidents can be avoided by being aware of your equipment your surroundings and observing certain precautions The first section of this manual includes a list of Safety Messages that if followed will help protect the operator and bystanders from injury or death Read and understand these Safety Messages before assembling operating or servicing this Implement This 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 S
50. o Pump F D Install Pump Mount until flush N Mounting Bolts Figure 1 gi Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 5 5 Pump Driveshaft Assembly Instructions Pump amp Driveshaft Components Tractor Engine Pulley Time Universal Joints Pulley Adpater P N 02979238 Pump End Driveline Asy P N w Mounting Bolts amp Washers Clamp Yoke 02975257A 4 bolts ar ja EO Mounting Bolts So _ Pump Mount Spacers P N 02977074 P N 02982085 Pump Reference p Bolts To Figure 12 Pump Mounting Bolts Install Tank Rail Weldments 1 Install Tank Rail Welments P N 02983116 LH and P N 02983118 RH These will bolt on using the holes to the front of the tractor bolster on each side This will need to be done so the hydraulic tank can be mounted See Figure 13 amp 14 Do Not tighten the bolts at this time leave them a bit loose it will help in instaling hydraulic tank and bumper weldment later NOTE There is a left hand and a right hand weldment the best way to determine which is LH and RH is the welded on mount for the rubber hold down These rubber hold downs will always be to the outside See Figure 13 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 5 6 Pump Driveshaft Assembly Instructions Cover Hold down on outside Cover Hold down on outside P N 02983116 P N 02983118 Figure 13
51. p 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 RECOMMENDED TORQUE VALUES CHART RECOMMENDED TORQUE IN FT LBS Nm COARSE AND FINE THREADS 2 B Bolt Plain Three Six Dia Head Dashes Dashes 1 4 Not used 5 16 Not used 3 8 Not used 7 16 35 47 1 2 9 16 5 8 3 4 7 8 fe 1 1 8 1 1 4 Brahma Caterpiller Challenger MT465B Asy 2005 Alamo Group Inc 55 75 75 102 105 142 185 251 160 217 250 339 330 447 480 651 130 176 170 230 300 407 603 908 670 908 910 1234 1250 1695 Man 09 05 Section 3 2 80 108 120 163 175 237 240 325 425 576 685 929 1030 1396 1460 1979 2060 2793 To help you assemble your new Brahma and mount it to your tractor we provide you with drawings instructions and general information When needed you can get information or clarification from Your Dealer or Alamo Group Customer Service This publication provides general information not specifically for your case or tractor but in connection with the drawings and Parts Section this publication offers you some valuable assistance please read it thoroughly The mount kits are made for selected tractors with standard configurations Only the noted options a
52. ractor Hyd Valve 02982163 Common box Consist of the Following Items Continued From Previous Page ITEM PART NO QTY DESCRITION 02967827 1 02968822A 1 02968822CA 1 02969646 1 02970204 1 WIRE HARNESS PUMP CONTROL 02971123 1 DECAL WARNING PRESSURIZED TANK 1 1 2 1 1 DECAL MULTI HAZ ASY BRAHMA OPERATORS amp PARTS ASY BRAHMACANISTER MANUAL DECAL NAME BRAHMA 20 YELLOW 02978099 TANK COVER ASY 02958206 QUICK SPLICE 18 14 TO 18 14GA 02958488 COTTER PIN 1 16 X 1 2 02981212 OIL TANK amp PUMP ASY 02982828 DECAL OIL HYD TEMP RANGE Common Box P N 02982163 is included in Base Unit P N 04101000 Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 9 Mount Kit Component ID I SSR LCR nn SL Le bh a Ke oa P N 02979238 Pulley Adapter Spacer u N has 4 thread holes amp 4 oe non threaded holes sn Ts P N 02977074 Pump Mount Plate Machined 1 1 4 OD a SL N 13 16 ID P N 02982085 Pump Plate Spacer P N 02982176 Control Stand Weldment Cover Hold down on outside Cover Hold down on outside P N 02983116 P N 02983118 Tamk Rail Mount LH Tamk Rail Mount RH Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 10 Mount Kit Component ID P N 02983114 Mainframe Weldment 1 f center hole 5 8 f center to this edge hole to this edge 6 3 8
53. rahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 3 4 Section 4 BRAHMA Caterpiller Challenger MT465B Cab 4 WD Tractor Frame Mounting Mounting Main Frame Asy To Tractor MOUNTING RH FRAME WELDMENT 1 The RH Frame weldment will bolt to the rear axle and the front right hand side of the front of the tractor use bolts flatwashers amp lockwashers furnished See Figure 1 in bolt bag Secure Tractor so that it cannot be started unless you want it started DO NOT Mount any Brackets or components until instructed to do so There are some components that will interfere with mounting others if mounted to soon The RH frame and LH frame support must be mounted under the tank rails as they are retained with the same bolts The front 4 bolts of frame rail should be left loose until the frail rails are installed later Back from the front 4 bolts there are two bolts that can be snugged for now remember these must be tighten later Front of 8 P N 02975669 Bolt M20 X 60MM Tractor P N 02971158 Lockwasher M20 P N 5312316 Hardened Flatwasher 3 4 RH Side of P N 02975738 Bolt M20 X 70MM p Tractor P N 02971158 Lockwasher M20 Im P N 5312316 Hardened Flatwasher 3 4 Rear of P N 02983114 Tractor Mainframe Weldment P N 02976113 Bolt M20 X 80MM P N 02971158 Lockwasher M26 2 The rear of the frame weldment will bolt up under the RH rear axle The stabilizer bracket for the RH side wi
54. roper adjustment of the Motor Solenoid Pump is making noise check for obstruction in suction hose and tank suction assembly check alignment of pump driveshaft Cylinders will not raise hoses from cylinder incorrectly connected to valve bank pump not suppling oil Cylinder raise slowly hoses from cylinder incorrectly connected to valve bank work port reliefs on valve bank set too low replace as required The mower head slows down or stops completely the filter may be clogged replace U O W m Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 9 4 Section 10 Brahma Caterpillar Challenger MT465B Cab 4wd Tractor Mounting Specifications amp Component ID Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 1 Mounting Specifications Caterpillar Challenger MT465B Cab 4wd As Of 08 19 05 Tires amp Wheels 14 9 24 R 1W Max Front Tire 18 4 34 R 1W Max Rear Tire Valve Type Open Center Valve Mount Kit Brahma MOUM nennen a 02983164 Restrictions 1 For proper rotary head pitch we recommend using the maximum tire sizes listed above for 4 wd tractors Other tire combinations may tilt the head in a manner that creates an undesirable cut However flail heads should cut smoothly at any pitch 2 For additional stability a 500 wheel weight or calcium chloride may be added to the left rear wheel at the dealer cus
55. roup Inc Section 5 8 Hydraulic Tank Assembly Instructions Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 5 9 NOTES Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 5 10 Section 6 BRAHMA Caterpiller Challenger MT465B Cab 4 WD Tractor Control Valve Installation Mounting Cylinders amp Control Valve Mounting Cylinders and Control Valve 1 Connect Cylinders to Mounting Bracket If the cylinders are not already connected Con nect the cylinders to the under beam See Fig ure 9 It is easiest to connect the bottom cylin der first the pin can be removed or inserted through the holes in the mounting bracket A hoist can be used to lift the mount arm this will help to align the cylinder pin holes After the lower Tilt cylinder is connected the upper Lift cylinder can be connected this cylinder is con nected to a lift arm on the other end and should allow it to reach the under arm without extend ing the cylinder IF YOU NEED to extend any cylinders unplug the hoses Place the hoses in a clean container as some oil may have been left in the cylinders at the time of testing and or assembling them at the factory Once the cylin ders are extended re plug the hoses to keep contamination out NEVER leave hoses valves pumps motors or any hydraulic component open during assembly ONLY unplug them when ready to assemble the
56. rt the clevis over the valve spool post and insert retaining pin into clevis and through the valve post G Screw the cable mounting tube back onto the threaded portion of the cable housing until the tube touches the valve body H Slide the two screw retaining ring over the mounting tube and down against the valve body install the two screws into valve body but only snug them down for now The retaining screw to be tighten after the cables have been adjusted later I Thread the large jam nut onto the cable housing and screw it down against the cable mounting tube Do not tighten it only snug for now See Figure 16 J DO NOT remove any caps Hex Head Bolt Valve Post Cable Mounting Tube Two screw retaining ring Jam Nut Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 6 4 Mounting Cylinders amp Control Valve 9 Mount Valve w Cables to frame The valve will mount on the frame above the cylinders the mounting holes are already in the frame See Figure 17 Insert the four bolts 1 in each corner of the valve and bolt it to the frame 10 Locate tractor factory Hydraulic Suppl hose to Tractor remotes The tractor has a fac tory hydraulic supply hose that connects on the lower LH side down beside the transmission See Figure 18 The other end connects to the LH side of the tractor remotes this is called the power beyond port Insert a drain pan under the bottom of the hose to cat
57. se d S P N 02972267 112 Long o Existing Hose that will need to be removed D and not used Hose is to be rerouted using new hoses to route hydraulics through add r on cylinder control valve New Hose i P N 02961853 84 long ka re ES FE eS Install Adapter Here P N 02961851 8MJ 10FJ Install Adapter Here P N 0692300 8MJ 22 MM w Seal Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 6 6 a Y G De lt 7 Tilt Cylinder Base End Green Tie Lift Cylinder Rod End Blue White Tie C Tilt Cylinder Rod End Green White Tie Mounting Cylinders amp Control Valve Blue Tie Solid Color Lift Cyl Base End Green Tie Solid Color Tilt Cyl Base End Blue Tie w White Stripe Lift Cyl Rod End Green Tie w White Stripe Tilt Cyl Rod End 12 Connect the Cylinder Hoses to Control Valve The cylinder hoses connect to the control valve as shown in hydraulic diagraham See Figure 20 amp 21 After the hoses have been connected to the valve check all the hoses to make certain they are not kinked rubbing some where or to close to the exhaust sytem If hoses need to be moved tied up to clear then it should be done before unit is run See Figure 22 E Ves Figure 22 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 6 7 NOTES Brahm
58. shipped as part of the base unit Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 13 Base Unit Component ID Blue White Orange Red Blue Asy P N 02979631 Mounting Arm Assembly This is shipped assembled with the above shown components For parts number and parts description for the components in this assembly see the Brahma Parts Manual The Hydraulic Hoses have Color Coded Plastic ties on them these must be connected to matching location for the proper functions to operate as designed Some ties have solid colors and some have white stripes on them Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 14 Base Unit Component ID Red 17 Old style weld on Filter gt mount shown latter tanks this will be a bolt on bracket Asy P N 02981212 Tank amp Pump Asy This is shipped assembled with the above shown components For parts number and parts descrip tion for the components in this assembly see the Brahma Parts Manual The Hydraulic Hoses have Color Coded Plastic ties on them these must be connected to matching location for the proper functions to operate as designed Some ties have solid colors and some have white stripes on them Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 15 Base Unit Component ID P N 02970204 Wire Harness 16 Red IG Red Push Pull Switch show
59. t all the hydraulic connections are complete on the Motor Hydraulic System and the Cylinder Hydraulic System 4 Startthe Tractor and Engage the Mower see the START UP PROCEDURE IN THIS SECTION SAFETY SECTION AND OPERATION SECTION for details Run the Mower Head for 5 minutes While the tractor is running wearing protective clothing and eye protection CAREFULLY check for leaking hydraulic fittings hoses and ports at this point with a piece of cardboard DO NOT USE YOUR HAND 5 Shut down completely the Mower and Tractor And correct any leaking connections 6 The Pump Hydraulic Lines Hoses and Motor should now be filled with the Hydraulic Fluid Check the Sight Gauge and add more AW ISO VG100 Hydraulic Fluid to bring the level up to Halfto Three Quarters up on the Gauge Filler Cap Sight Gauge IMPORTANT Change the return filter in tank and suction filters after the first 200 hours of operation Change the filters again at 800 hours then change the oil and filters at 1600 hours After that continue to change the filter every 800 hours and the oil every 1600 hours Hydraulic oil to be used AW ISO VG100 Alamo P N 00751758 Use the above procedures as part of a good filter maintenance program Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section9 2 Tractor Start Up Procedure 7 Avoid hydraulic contamination by filter ing the hydraulic oil while filling the hydraulic tank Filter
60. tomer s expense 3 This mount kit includes the Neapco style driveline with double U joints 4 Adjustment of the steering stop may be necessary on 4wd models First Cut From Tractor Centerline Rotary 72 1 2 Flail 79 1 2 Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 2 Mounting Specifications 3 Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 3 Mounting Kit Bill of Material Caterpillar Challenger MT465B Cab 4wd IMPORTANT NOTICE The following Part Assembly Numbers are for reference and should not be ordered as replacement parts unless all the components in that assembly are wanted These will break down to bills of material of the components Some of numbers listed are NOT individual Parts but complete assemblies and or box of assemblies Check before ordering 02983164 Brahma Mount Kit Caterpillar Challenger MT465B Cab 4wd Consist of the Following Items Item Part No 02753400 02775500 02960004 02966874 02966873 02969130 02969813 02969814 02969815 02969850 02975257A 02959770 02983114 02983115 02983116 02983118 02983119 02961853 02972267 02975061 02161300 00724357 02761100 02961851 0692300 02982176 02983165 02977074 02979238 02982085 02983272 Qty 3 O JAN NN ND mm d of ND i Ss ja Description PLASTIC TIE 15 LG PLASTIC TIE 21 LG HOSE 8 8F
61. tor Adapter Hyd Elbow 8FB 8MB Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 17 Base Unit Component ID Ped Ca a a Pr a P N 02966634 Bumper Weldment P N 02971191 Switch Mount Weldment P N 02978099 Tank Cover amp Manual Cannister Asy Brahma Cat Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 10 18 Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc INDUSTRIAL Brahma Asy Manual Caterpillar Challenger MT465B Cab 4 wd 2005 Edition P N 02983272
62. tructional Decals for tractor and implement to prevent misuse abuse and accidents Practice before operating in a confined area or near passersby Learn how to stop engine suddenly in an emergency Be alert for passersby and especially children 2 Allow no children on or near folding mower or tractor Allow no riders on tractor or implement Falling off may cause serious injury or death from being run over by tractor or mower or contact with rotating blades 3 Operate only with tractor having Roll Over Protective Structure ROPS and with seat beit securely fastened to prevent injury and possible death from falling off or tractor overturn Personal Protective Equipment such as Hard Hat Safety Glasses Safety Shoes amp Ear Plugs are recommended 4 Block up or support raised machine and ail lifted components sadel before putting hands or feet under or working underneath any lifted component to prevent crushing injury or death from sudden dropping or inadvertent operation of controls Make certain area is clear before lowering or folding 5 Before transporting put Lift Lever in detent or full lift position Install Transport Safety Devices securely on folding mowers Put Booms securely in Transport Rest e Folding and Boom Mowers have raised center of gravity Slow down when turning and on hillsides 6 Make certain that SMV sign warning lights and reflectors are clearly visible Follow local traffic codes 7 Never operate with Cutting
63. uce the possibility of injury or death from thrown objects entanglement or blade contact scm 3 PTO Integral hield Deflector Chain guard Brahma Caterpiller Challenger MT465B Asy Manual 09 05 2005Alamo Group Inc Section 1 5 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 Before 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 Operate the Tractor and or Implement controls only while properly seated in the Tractor seat with the seat belt securely fastened around you Inadvertent movement of the Tractor or Implement may cause serious injury or death 56 29 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 WARNIN
64. unting Arm has a bulkhead fitting lug welded on to on the rear side These lugs are color coded with a plastic tie on the bulkhead fitting See Figure 2 Mounting Arm Assembly Orange Tie the top fitting Red Tie the middle fitting r Blue Tie the bottom fitting Red Tica Sy Blue Fie lt Orange Tied Hose Returns Flow back to Front Pump Hydraulic Reservoir Red Tied Hose Supplies Pressure Flow From Front Pump Blue Tied Hose is Case drain from Motor Figure 2 er back to Hydraulic Tank in front of tractor 2 Run Hoses Along Side RH Frame Rail Bolt On Hose The hoses rub up and over under beam and back WESH ME Ring along the RH side of Tractor Frame Install hoses through the sleeving material furnished See Figure 3 Hoses will be run through a bolt hose ring See Figure 4 Hoses will then be connected to the tank and pump as shown See Figure 5 Caution DO NOT try to start tractor as there is no hydraulic in tank and all hoses are NOT connected i j gt Orange Tie e x Tank Return Bg A 7 ag Brahma Caterpiller Challenger MT465B Asy Man 09 05 2005 Alamo Group Inc Section 8 4 Connecting Head To Frame Install Cutting Head 1 Prepare to Install Cutting Head There is a Flail Head and a Rotary Head option Shown here is the Flail Option The Mounting frame will be shipped already bolted to the Flail Head The Rotary Head the Mounting Frame is part of the hea
65. ur problem or your customer s service problem as quickly and efficiently as possible Unfortunately we receive entirely to many calls with only a minimum amount of information In some cases the correspondent has never gone out to look at the equipment and merely calls inquiring of the problems described to him by the operator or customer 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 Tractor Problem Inquiries oo a HOW YOU CAN HELP Make sure the call is necessary Most of the calls received may not be necessary if the Dealer Service Technician would do the following 1 Check the Service Information at your Dealership provided by Alamo Industrial This would include Service Bulletins Information Bulletins Parts Manuals Operators Manuals Assembly Manual or Service Manual many ofthese are available via the Alamo Industrial Internet site www Alamo Industrial Com Attempt to diagnose or repair problem before calling 2 If a callto Alamo Industrial is needed Certain Information should be available and ready forthe Alamo Industrial Service Staff Such information as Machine Model Serial Number Your Dealer Name Your Account Number and Any other information that will be useful This information
66. y causing damage Tighten the four bolts that retain the pulley adapter to the pulley now it will be easier than trying to tighten them later 2 Install Shaft Half of Driveline with Flange Yoke Note the driveline universal joints should be timed See Figure 2 Slide the two driveline half assemblies apart and lay the tube half aside for now Make certain that the four retaining bolts for the Pulley adapter to the crankshaft pulley have been tightened From the side of the tractor LH or RH side slide the Shaft Half of driveline shaft end first down into the opening below the radiator from engine side insert it through the existing hole until the shaft is pointed toward the front of the tractor and the flange yoke is over far enough to align with the four threaded pulley adapter holes Special Note Some technicians do not connect driveshaft to crank shaft pulley at this time they leave the driveshaft pushed up under radiator This allows them to be able to start and move tractor if needed without damaging the pump due to no oil If you do this use extreme caution that driveshaft is out of way of crankshaft pulley and will not move and hit them Align the four holes in the flange yoke of driveline with the four threaded holes in the pulley adapter Installthe four retaining bolts andlockwasher into flange yoke into adapter tighten them at this time These four bolts can be tightened by using a long socket extension run through along side the driveline
67. ymbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The Symbol and Signal Word are intended to warn the owner operator of impending hazards and the degree of possible injury faced when operating this equipment Practice all usual and customary safe working precautions and above all remember safety is up to YOU Only YOU can prevent serious injury or death from unsafe practices CAUTION The lowest level of Safety Message warns of possible injury Decals located on the Equipment with this Signal Word are Black and Yellow WARNING Serious injury or possible death Decals are Black and Orange DANGER Imminent death critical injury Decals are Red and White sc Brahma Caterpiller Challenger MT465B Asy Manual 09 05 2005 Alamo Group Inc Section 1 2 PELIGRO Si no lee Ingles pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad sc 3 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 PELIGROSi no lee Ingles pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad sc 3 wel i LEAEL INSTRUCTIVO WARNING Perform service repairs and lubrication according to the maintenance section Ensure the unit is properly lubricated

Brahma/Cat Challenger MT465B

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