A-BOOM PRODUCT SERVICE MANUAL BOOM ARM MOWER. Service Manual P/N T (Feb 2003) Alamo Industrial 1502 E. Walnut Seguin, Texas

Transcription

1 A-BOOM BOOM ARM MOWER PRODUCT SERVICE MANUAL Service Manual P/N T (Feb 2003) Alamo Industrial 1502 E. Walnut Seguin, Texas Alamo Group Inc Edition

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3 INTRODUCTION ABOUT THIS MANUAL: The intent of this publications to provide the competent technician with the information necessary to perform the CORRECT repairs to the Alamo Industrial Product. This will, in turn provide for complete customer satisfaction It is 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 wherein correspondence with the Manufacturer is necessary. CONTACTING MANUFACTURER: (Please help us Help You! Before You Call! ) Alamo Industrial Service Staff Members are dedicated to helping you solve yours or your customer s service problem as quickly and efficiently as possible. Unfortunately, we receive entirely to many calls with only a minimum amount of information. In some cases, the correspondent has never gone out to look 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. 1. Hydraulic or Mechanical Trouble Shooting. 2. Request for Technical Information or Specifications. 3. Mounting or Fitting Problem. 4. Special Service Problem. 5. Equipment Application Problems. 6. Tractor Problem Inquiries. 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 or Service Manuals, many of these are available via the Alamo Industrial Internet site (Alamo - Industrial. Com). Attempt to diagnose or repair problem before calling. 2. If a call to Alamo Industrial is needed, Certain Information should be available and ready for the Alamo Industrial Service Staff. Such information as, Machine Model, Serial Number, Your Dealer Name, Your Account Number and Any other information that will be useful. This information is vital for the development of a prompt and correct solution to the problem. This will also help to develop a database of problems and related solutions, which will expedite a solution to 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. If the information is not available, The technician may be asked to get the information and call back. Most recommendations for repairs will be based on the procedures listed in the Service Manual / Trouble Shooting Guide. CONTACT ALAMO INDUSTRIAL: Alamo Industrial, 1502 E. Walnut St. Seguin TX , Technical Service Dept. PH: Alamo Group Inc. Parts Section -3

4 INDEX - REPAIRS Page Introduction... 3 A-Boom Components Blade Bar Assembly (Rotary Head) to-131 Control Valve Operation to- 97 Standard Mechanical Control Valve to- 72 Cylinder Control Schematic Control Valve Illustration (figure 32) Valve Operation to- 68 Control Cable Operation to- 72 Optional Electronic Control Valve to- 97 Control Valve Drawing Control Valve Components to- 89 Control Valve - Load Sense to- 93 Control Valve - Fixed Displacement to- 97 Hydraulic Functions General Operation Specific Operation Hydraulic Lock Valve Electric Signals Joystick Functions Joystick Trouble Shooting Valve Control Connections to- 79 Valve Wiring Schematic Wiring Harness Schematic to- 83 Control Valve Trouble Shooting to- 114 Standard Mechanical Control Valve to- 105 Pump Schematic, Single Pump Pump Schematic, Tandem Pump Valve Testing to- 105 Optional Electronic Control Valve to- 114 Pump Schematic, Single Pump Pump Schematic, Tandem Pump Valve Testing to- 114 Diagnoses Terminolgy... 8 Hydraulic System Operation to- 32 Gear Motor & Gear Pump Operation to- 28 Gear Pump Common Complaints Hydraulic Schematic Drawing Hydraulic Power To Motor Motor Circuit Control Valve Operation to- 32 King Post Assembly Instructions to- 120 King Post Parts Identification King Post Assembly Instructions to Alamo Group Inc. Parts Section -4

5 INDEX - REPAIRS Page Possible Failure Cause & Solution Section to- 171 Boom Breaks Back Too Easly Boom Drops When Two Funtions Acticated Control Valve Spool Sticking Cylinder Boom Positioning Cylinder Excessive Drift to- 142 Cylinder Leaks At Fittings Cylinder Leaks Around Rod Cylinder Moves Intermittent Cylinder Moves Jerky Cylinder Moves On Its Own to- 145 Cylinder Moves Only on Some Functions to- 147 Cylinder Moves Spongy Cylinder Moves Wrong Way Cylinder Rod Came Out of Cylinder to- 152 Cylinder Rod Bent Cylinder Won't Move At All Cylinder Won't Move Under Load to- 150 Deck Cracks Deck Worn On Under Side to- 153 Failure Cause & Solution Index Hydraulic System Overheating to- 156 Hydraulic System Noise (Squeal) to- 154 Motor Flange Breaking to- 157 Motor Overheating to- 159 Motor Runs To Slow or Slows Down Under Load to- 162 Motor Shaft Seal Leaking Motor Stops Under Load to- 165 Pump Seizure, (Pump Seizes Up) Pump Wear Rapid or Excessive Spindle Leaking At Motor Spindle Leaking At Bottom Seal Spindle Leaking At Relief Plug Spindle Locks Up Spindle Overheating Spindle Shaft Loose or Falls Out Tractor Battery Dead or Low Tractor Starter Will Not Crank to Alamo Group Inc. Parts Section -5

6 DRAWING INDEX Page Pump Pressure & Flow Testing to- 39 Pump System Single Pump Schematic Pump System Tandem Pump Schematic Pump Testing Information Collecting Pump Operationa Test Pump Pressure & Flow Testing to- 39 Pump Repair Section to- 55 Pump Dis-Assembly to- 47 Pump Re-Assembly to- 52 Pump Facts to Watch Out For Pump Parts Location Drawing to- 55 Pump Drive Shaft to- 60 Pump Drive Shaft Components Pump Drive Shaft Removal Pump Drive Shaft Installation Pump Drive Shaft Common Problems Specification... 9 Bolt Torque Values Hose Fitting Torque Values Ditcher Head Specifications Manual (Cable) Control Valve Specifications to-15 Pump Start Up Specifications (New or Rebuilt Pump) Pump Technical Specifications Pump Wear Tolerance Specifications to-17 Motor Wear Tolerance Specifications to-17 Rotary Head Component Torque Specifications Test Equipmeent Recommendation " / 60" SHD Flail Cutting Head Specifications " Flail Axe Cutting Head Specifications " Rotary Cutting Head Specifications ', 6' & 7' Sickle Bar Cutting Head Specifications ' & 6' Timber Cat Limb Cutter Head Specifications " Rotary Cutting Head Specifications Spindle Assembly (Rotary Head) to- 131 Spindle Part Identification Spindle Dis-Assembly to- 126 Spindle Re-Assembly to- 130 Wiring Schematic to- 135 Common Problems Wiring Schematic (Neutral Saftey Switch) to Alamo Group Inc. Parts Section -6

7 NOTES 2003 Alamo Group Inc. Parts Section -7

8 DIAGNOSES TERMINOLIGY Diagnosis: The organized study of determining the nature of the problem by a systematic method or process of elimination. Causal Part: The component which is determined through diagnoses and failure analysis to have initiated the overall failure. Note: Many parts may make up a failure - usually only one of those parts is the causal part. Trouble Shooting: The determination through diagnoses which components are functioning within specifications, until the causal part is isolated. Basic Diagnoses Suggestions: 1. Understand the Basic System, Hydraulics, Electrical and etc. 2. Know the components that make up each System. 3. Don t be neglect to use Reference Books and Test Tools. 4. Have the proper Tools and Test Equipment at Hand and know how to use them. 5. Determine what is working in each system and eliminate it as a cause. 6. Use planned systematic, logical steps to diagnose. Don t jump in the middle. 7. Determine cause of failure, just repairing failure is no good if cause is not repaired. Logical Diagnoses Steps: 1. Question the customer (operator) to help in identifying the exact symptoms of problem, When does malfunction occur, What are the conditions when it occurs, What is working and what is not working. Has all the obvious things been check, Fluid levels and etc. 2. Don t sacrifice your safety to determine the problem. Use all the published safety practices and all common sense to operate and test the machine safely. Identify any unsafe conditions of the machine or your surroundings before beginning any repairs. Have the customer or yourself correct any unsafe conditions before beginning any repairs. Inform evryone around you that you are working on Unit and they need to stay away from it. Dis-able Machine so it can not be started unless you want it to. Secure Tractor and Components to make them safe is your responsibility. 3. Make a complete examination. Use all of your senses to closely examine unit. Make sure the proper conditions exist for correct operation, Check Fluid levels, Filters, Linkage, Connections, any leakage, external defects and etc. 4. If possible have the operator simulate the problem, then try to confirm it by operating it your self. While operating the machine, determine and classify all the actual symptoms. Determine which systems are working correctly and which are not. 5. Verify the performance of the major systems. Perform operational tests to eliminate systems. Operate each system to ensure it is functioning within specifications. 6. Perform specific test. Using testing equipment, (Flow & Pressure Gauges, Test Lights & etc.) Determine which component works correctly; eliminate any component that meets specifications. 7. Make repairs, then re-test to verify the repair. Failure Analysis: The in-depth analysis of individual failed components to determine the mode of the failure (fatigue, types of wear, fractures, etc.) is a highly involved and in-depth topic which cannot be properly discussed in this publication. Proper failure analysis can provide valuable information about a failure, and they re fore the proper repair. Many sources exist which can provide information in component failure analysis. Future Alamo Industrial Publications will discuss this topic in detail Alamo Group Inc. 8

9 Specifications Section 2003 Alamo Group Inc. 9

10 SPECIFICATIONS - A-BOOM Pump Specifications: (All Models) Body Construction... Cast Iron Control Valve Type... Direct Acting, Pilot Operated Control Valve Relief PSI Driveshaft Type... 7/8" X 13 Spline Driveshaft Torque Rating ft. lbs. Pressure Rating (Maximum) PSI Pump Type... Gear Pump Gear Width... 2 inch Pump Efficency Flow Rate (Approx) % of G.P.M. is Acceptable Speed Rating (Maximum) RPM Nominal Displacement (Per Revolution) Cu. In RPM.(Operating RPM) G.P.M RPM.(Maximum RPM) G.P.M. Horsepower Rating (Maximum Conditions) HP Rotation Direction (Viewed from Top of Deck... Clockwise Motor Start / Stop Time Seconds (Approx) Tank Capacity Required Gallons Oil Type... Universal Tractor Hydraulic Oil Oil Temperature (While Operating) Deg, (F) Above Ambient Cutting Heads Specifications: (Head Options) 50" Rotary Mower Head Option: Blade / Motor Rotation (Looking down from Top of Deck)... Clockwise Blade Tip Speed... 18,325 FPM / 208 MPH Blade carrier Type... Pan or 2 Leaf bar Option Blade Pan Blade Qty... 2 Blade or 3 Blade Option Blade Bar Blade Qty... 2 Blades Blade Cutting Width (Overall) inches. Deck Construction... Formed and Welded Steel Deck Material Gauge Deck Weight lbs. Spindle Body Material... Unibody Cast Steel Spindle Bearing... Tapered Roller Bearings Spindle Lubrication... Grease (Pumped In) Motor Type... Gear Motor Gear Width /2" Motor Speed (Maximum) RPM Motor Pressure (Maximum) PSI Motor Rated Pressure PSI Motor Rated Flow GPM Motor Displacement Cu. Inches 2003 Alamo Group Inc. 10

11 SPECIFICATIONS - A-BOOM Cutting Head Specifications: (Continued ) 60" Rotary Mower Head Option: Blade / Motor Rotation (Looking down from Top of Deck)... Clockwise Blade Tip Speed... 18,990 FPM / 216 MPH Blade Carrier Type... Pan or 2 Leaf bar Option Blade Pan Blade Qty... 2 Blade or 3 Blade Option Blade Bar Blade Qty... 2 Blades Blade Cutting Width (Overall) inches. Deck Construction... Formed and Welded Steel Deck Material Gauge Deck Weight lbs. Spindle Body Material... Unibody Cast Steel Spindle Bearing... Tapered Roller Bearings Spindle Lubrication... Grease (Pumped In) Motor Type... Gear Motor Gear Width /2" Motor Speed (Maximum) RPM Motor Pressure (Maximum) PSI Motor Rated Pressure PSI Motor Rated Flow GPM Motor Displacement Cu. Inches 48" Flail Axe Mower Head Option: Belt Drive System... Belt Drive F/ Hyd. Motor Belt Drive Type... B Section V - Belt Belt Drive Qty... 2 Drive Belts f. Hyd. Motor Blade Tip Speed... 8,933 FPM / 102 MPH Blade Carrier Type... Welded Vertical Shaft Blade Qty... N/A Blade Cutting Width (Overall) inches. Cutter Shaft Bearings... Tapered Roller Deck Construction... Formed and Welded Steel Deck Material Gauge Deck Weight lbs. Motor Type... Gear Motor Gear Width... 2" Motor Speed (Maximum) RPM Motor Pressure (Maximum) PSI Motor Rated Pressure PSI Motor Rated Flow GPM Motor Displacement Cu. Inches 2003 Alamo Group Inc. 11

12 SPECIFICATIONS - A-BOOM Cutting Head Specifications: (Continued ) 48" and 60" SHD Flail Mower Head Option: Belt Drive System... Belt Drive F/ Hyd. Motor Belt Drive Type... B Section V - Belt Belt Drive Qty... 2 Drive Belts f. Hyd. Motor Blade Tip Speed... 8,234 FPM / 94 MPH Blade Carrier Type... Welded Vertical Shaft Blade Qty... N/A Blade Cutting Width (48" Head Overall) inch Cut (60" Head Overall) Inch Cut Cutter Shaft Bearings... Tapered Roller Deck Construction... Formed and Welded Steel Deck Material Gauge Deck Weight. (48" Model) lbs. (60" Model) lbs. Motor Type... Gear Motor Gear Width... 2" Motor Speed (Maximum) RPM Motor Pressure (Maximum) PSI Motor Rated Pressure PSI Motor Rated Flow GPM Motor Displacement Cu. Inches 5', 6' & 7' Sickle Mower Head Option: Blade Tip Speed... 6,300 FPM / 72 MPH Blade Carrier Type... Slide Bar Blade Attachment... Rivets Blade Qty... Vary w/ Length Blade Option... Smooth or Serrated Edges Drive Housing Type... Cast Steel Drive Housing Bearing... Ball Bearings Drive Housing Lubrication... Grease w/ Sealed Bearings Motor Type... Gear Motor Gear Width... 1" Motor Speed (Maximum) RPM Motor Speed (Working) RPM Motor Pressure (Maximum) PSI Motor Rated Flow... 8 GPM (Governed) Motor Displacement Cu. Inches Weight (Total) 5 ft. Model lbs. (approx) 6 ft. Model lbs. (approx) 7 ft. Model lbs. (approx) 2003 Alamo Group Inc. 12

13 SPECIFICATIONS - A-BOOM Cutting Head Specifications: (Continued ) 5' & 7' Timber Cat Limb Cutter Head Option: Blade Cycles Per Minute Blade Material... T1 Steel Countinously Milled Blade Type... Milled Cutting Edge Blade Bearings... Polyethylene Strips Blade Qty... Upper & Lower Cutting Bars Blade Option... 5 ft. or 6 ft. Models Drive System Type... Mechanical over Hyd. w/ Auto Reversing movment Drive Coupler... Direct to Hyd. Cyl Lubrication... Grease Hydraulic Pressure PSI Weight (Head) 5 ft. Model lbs. (approx) 7 ft. Model lbs. (approx) Rotary Ditcher Head Option: Blade Tip Speed... 2,208 FPM / 25 MPH Blade Type... Forged Steel/ Heat Treated Blade Qty... 3 Spindle Material... Steel Spindle Construction... Welded Assembly Spindle Bearings... Tapered Roller Lubrication Grease Motor Type... Gear Motor Gear Width... 2" Motor Speed (Maximum) RPM Motor Pressure (Maximum) PSI Motor Pressure (Rated) PSI Motor Requirement GPM Weight (Total) lbs. (approx) Rotary Head Torque Specification: Motor to Spindle Housing ft. lbs. SPindle to Deck ft. lbs. Spindle Bearing Pre-Load to 15 in. lbs. Rolling Torque Blade Bar Leaf Bars ft. lbs. Blade Bolts (Leaf Bar Carriers) ft. lbs. Blade Bar to Spindle ft. lbs Alamo Group Inc. 13

14 SPECIFICATIONS - A-BOOM Valve Specifications: Boom Movement Control Valve: 4 Spool Shown, Rotary Heads w/ Optional Door has 5 Spool Valve Valve Type... Open Center, 4 or 5 Spool Pressure (Maximum) PSI Flow (Maximum) GPM Main Relief... Direct Acting: 2000 PSI: Adjustable FilterType... Return Side Filter Size Micron Bushings... Greasable Steel or Non Greasable Self Lubricating, Depends on Machine and Bushing Application Return Pressure One Way Restrictors "B' Side Ports Inlet Cover Handle Swing Lift Dipper Tilt "A" Side Ports End Cap Figure 1 Valve Ports: ( See Figure 1) Valve Ports designated as "B" Ports connect to the Rod End of the Swing and Lift Cylinder, and to the Barrel End of the Dipper and Tilt Cylinder. Valve Ports designated as "A" Ports connect to the Barrel End of Swing and Lift Cylinder, and to the Rod End of the Dipper and Tilt Cylinder. Valve Ports on 5 Spool valve will be "A" and "B" also, The 5 spool valve is used on 28' A-Boom Model and on Models with opening Door on Rotary Head Models Alamo Group Inc. 14

15 SPECIFICATIONS - A-BOOM Valve Specifications: (Continued) One Way Restrictors: (See Figure 1) The one way restrictors operate by restricting the flow returning to the Valve from the Cylinder. The illustration in Figure 1 dipicts a standard 4 Spool Valve. Machines requiring a 5 Spool Valve will have the additional section added between the Tilt and Dipper Sections. Valve Sections Function: (See Figure 1) Spool Cylinder Function Restriction Pressure "A" "B" "A" "B" "A" "B" 1 Swing Back Forward PSI 1500 PSI 2 Lift Up Down PSI 875 PSI 3 Dipper Out In PSI 875 PSI 4 Tilt Up Down Main Relief Main Relief 5 * *Extend (28') In Out 0 0 System System *Door (Rotary) Open Closed 0 0 System System Note: * The 5 th Spool is only used on the 28' Model as the extension Cylinder Control. Or when the Rotary Head Option of Mechanical Door is used on the 17' through 23' models Hose End Fitting Torque Specification: Hose End Type: 37 Degree Angle End Steel Hose End Fittings* Dash Nominal Cyl. Torque Torque Size Size (in.) in. lbs. ft.lbs. -4 1/4" /8" /2" /8" /4" " /4" /2" " * Straight Threads do not always seal better when higher torgues are used. Too much torque causes distortion and may lead to leakage. DO NOT over torque fittings and DO NOT allow any contaminants to enter system through fittings when installing them Alamo Group Inc. 15

16 SPECIFICATIONS - A-BOOM Wear Tolerance for Pump & Motor: This is suggested Wear Tolerance to Keep Assemblies operating as efficient as possible, Not Complete failure rate. Gear Housing: Gear type Pump and Motor Gear Housing Cut-Out Area Gear Wear Area Wear in excess of.007" cut-out necessitates replacement of the Gear Housing. Place a straight edge across the Bore in the cut out area. If you can slip a.007" feeler gage under the straight edge in the cutout area. Replace the Gear Housing. Pressure pushes the Gears against the Housing on the Low-Pressure side. As the Hubs and Bushings wear, the cutout becomes more pronounced. Excessive cutout wear in short period of time indicates excessive pressure or Oil contamination. If the relief Valve Settings are within prescribed limits check for shock pressures or tampering. Withdraw Oil Samples and check it and tank for dirt. Where cut-out is moderate, 0.007" or less, gear housing is in good enough condition and may be reused, understand if you are at 0.007" you are at the upper limits and will not be at peak performance. A pump should always produce at least 85% efficiency (Example: if your Pump is rated at 37 GPM it should produce at least 32 GPM). Gear Teeth Seal Area Splines Gear Hubs Gear Teeth Thrust Plate Gears: Any scoring on Gear Hubs necessitates Replacement. Scoring, Grooving or Burring of Outside diameter of Teeth requires replacement. Nicking, Grooving or Fretting of Teeth surfaces also necessitates replacement. Drive Shaft: (with Built on Gear) If Gear Teeth and Gear Hubs are OK, Inspect Splines on input end (OD) of Shaft and the Splines (ID) Output) Coupler End (Tandem Pump) for condition and Wear. Inspect Wear or damage to Seal Wear Area. If damage at Seal are check for contamination. Note: Some Pumps and/or Motors may have Keyway or Splines. Either will have to be inspected for condition. If Damage in any of these area the Shaft / Gear will have to be replaced. Thrust Plate: The Thrust Plate Seals the Gear Section at the sides of the Gears. Wear will allow internal slippage, which is Oil bypassing within the pump. The Pump and Motor Thrust Plates are different even though they may look very similar. They are built different. They will not interchange. A Maximum of 0.002" wear is allowable. Replace Thrust Plates if they are scored, eroded or pitted. Wear can be checked usually by comparing thickness at outer edges with thickness at Gear contact area. 1. Check center of Thrust Plates where the Gears mesh. Erosion here indicates Oil contamination. 2. Pitted Thrust Plates indicate cavitation or Oil aeration. 3. Discolored Thrust Plates indicate overheating, probably insufficient Oil Alamo Group Inc. 16

17 SPECIFICATIONS - A-BOOM Wear Tolerance: Continued from Previous Page Dowel Pins Dowel Pins: There are Dowel Pins and Dowel Pin Holes in each Pump or Motor Section; these are to align the components. if either the Dowel Pin or the Hole is damaged, the Dowel or the Machined Casting and in some cases both must be replaced. If more than reasonable force is required to seat dowels, the cause may be poorly deburred or dirty parts; cocking of Dowel Pins in the Hole; or improper Pin to Hole Fit. Dowel Pins are a snug fit and must remain that way; the four Retaining Studs will not keep components aligned without the Dowel Pins. Without the Dowel Pins or with improper fit of Dowel Pins, damage of components will occur from an alignment problem. Bushing (Bearing) Shaft Seal Channel Seal Plug Bushing (Bearings): These are the Bushings that keep the Gears aligned and in the proper operating position. If these wear it will cause damage to most of the other components; Thrust Plates, Gear Housing and Gears. A number of conditions can cause these to wear, so always check the fit on Gear Hubs for a good firm fit. Check the Fit of Bushings into Housings, it should have a heavy press fit. If Gears are replaced the Bushings must also be replaced. Never use new Gears and old Bushings. Seals and Gaskets: There are Shaft Seals, Thrust Plate Channel Seals and Gasket Seals (O-Rings). All these Seals should always be replaced when Pump or Motor is reassembled. The Shaft Seals are about the same on Pumps and Motors. The Thrust Plate Channel Seals are different shapes from pump to motor (Pump Seal Shown to Left). But the function is the same, the Thrust Plate will have a groove machined into it, the Channel Seal will have a flat side and an angled side, the angle side must fit into this groove. The gasket Seal is the Seal, which fits into the Groove, machined into the Gear Housing, it is usually square shaped and has the same curved shape as the groove in Housing. Must make sure groove is clean and Seal (O-Ring) is seated in groove during assembly. Plugs: (Pumps Only) Plugs should not have been remove unless the Pump Rotation was being reversed. If they were removed they were staked in, pieces of Metal could come off when they are removed. DO NOT remove the Plugs just to examine them, this only applies if you had to remove them. Examine the Plug in the Shaft Mount Flange Housing End and the one in the Port End Cover. Make sure Plugs are tight and seated properly. Make sure there are no metal slivers from Plugs that could get into system Alamo Group Inc. 17

18 SPECIFICATIONS - A-BOOM Recommended Start-up procedure for New or Rebuilt Pump: Before Installing a New or Rebuilt Pump A. Connect your Flow Meter in Line to test Pressure as unit is started; this is in case the Relief Valve is malfunctioning or has been tampered with. If this is not done you could damage the replacement Pump because you would not Know it till Pump failed from excessive pressure. B. Before connecting any lines to Pump, fill all Ports with clean Oil to provide initial Lubrication. This is especially important is Pump is located at a higher level than Oil Reservoir. C. Check Oil level in reservoir, fill to full level if needed, Reservoir must have more Oil than the Pump GPM capacity. D. After connecting the Lines and mounting the replacement Pump, make sure that Oil is not warmer than Pump temperature. If Oil is warmer than pump run Pump at short intervals till Pump and Oil temperature is equalized. Hot Oil must not be fed into cold Pump. E. Operate the Pump for at least two minutes at no load and at low RPM (400 RPM min and 1400 RPM max.). Watch Flow Meter Pressure (or Pressure Gauge). During this break-in period, the unit should run free and not develop an excessive amount of heat. Heat should not exceed 100 deg F. above ambient Temperature. If the unit operates properly, speed and pressure can then be increased to normal operating settings. Increase Pressure in 500 Lbs. PSI increments from start, this should take 4 to 5 minutes to max. PSI allowing 1 minute between increases to check Oil Pressure and Temperature. F. If normal Pressure and Heat readings are seen then the New or Rebuilt Pump installation should be done, remove Flow Meter (Pressure Gauge) from line, reconnect Line and check all connections. Test Equpment Needed: 1. Flow Meter, The Flow meter should have components to measure: A. Guage to Measure the Oil Temperature. B. Gauge to Measure Oil Pressure PSI (Load and No Load). C. Gauge to Measure Oil Flow in G.P.M. D. A Valve to load system to check operating Pressure (PSI). E. Assortment of Connections to connect to Hydraulic System. 2. Electrical Volt Meter with variable settings and Ohm Meter. 3. Electrical Test Light. 4. Wrenches, Torque Wrench, Socket Wrenches, Open and Boxed End Wrenches Alamo Group Inc. 18

19 SPECIFICATIONS - A-BOOM TORQUE VALUES - BOLTS: Maximum Torque per Bolt Size and Grade, Ft lbs & (Nm) IMPORTANT! Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE, Component Application Torque will vary dependimg on what is bolted down and the type material (Metal) that is being bolted together. Thread condition and lubrication will vary Torque settings. Bolt Dia. inch 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/ /8 1-1/4 Inche Sizes 2 (B) 5 (D) 8 (F) Plain Head 3 Dashes Not Used Not Used Not Used 35 (47) 55 (75) 75 (102) 105 (142) 185 (251) 160 (217) 250 (339) 330 (447) 480 (651) 10 (14) 20 (27) 35 (47) 55 (75) 85 (115) 130 (176) 170 (230) 300 (407) 445 (603) 670 (908) 910 (1234) 1250 (1695) 6 Dashes 14 (19) 30 (41) 50 (68) 80 (108) 120 (163) 175 (230) 240 (325) 425 (576) 685 (929) 1030 (1396) 1460 (1979) 2060 (2793) ALWAYS CHECK MARKINGS ON TOP OF BOLT HEAD OR OTHER BOLT DESCRIP- TIONS Bolt Dia. mm Metric Sizes Alamo Group Inc. 19

20 NOTES 2003 Alamo Group Inc. 20

21 A-Boom Arm Components 2003 Alamo Group Inc. 21

22 A-BOOM ARM COMPONENTS A-Boom Arm Component Location Hose & Hose Sleeving Dipper Arm Dipper Cylinder Tilt Cylinder Steel Tube Lines Cylinder Rod Cover (Not Shown) Linkage Arm Lift Arm Head Attaching Pivot Pin King Post Lift Cylinder 2003 Alamo Group Inc. 22

23 Hydraulic System Operation 2003 Alamo Group Inc. 23

24 HYDRAULIC SYSTEM OPERATION System Schematic (Typical 17' through 23' with 4 Spool Valve) Hyd. Pump Swing Cyl. Lift Cyl Dipper Cyl. Tilt Cyl. Control Valve Motor Control Valve Motor Return 3 Hyd. Tank 5 M 1 M 2 4 Motor Pressure 2 Filter Mainframe Figure 2 Hydraulic Motor 2003 Alamo Group Inc. 24

25 HYDRAULIC SYSTEM OPERATION Hydraulic Power to Motor: The rotation of the cutting blades is accomplished through the use of hydraulic power. Power to drive the pump is typically taken from the tractor engine pulley, or if this is not possible, it is taken from the tractor PTO turning at 540 RPM and stepped up to 2160 RPM with the use of a 4:1 speed increaser. Note: Use of a rear mounted PTO driven Pump requires the Pump to be set up to operate in the reverse rotation. Hydraulic Oil to the pump is supplied from the Hydraulic Tank through a 100-micron suction Filter through hose (6). Oil from the pump flows through hose (1) to the motor control Valve Port (P). If the electrical solenoid valve is activated, the oil flows through M1 port to the Motor via the pressure line (2) and is returned through hose (3) to port M2 on the Motor Control Valve. The oil exits the Valve through port (T) through return line (4) to the Mainframe. From there it travels through return line (5) to the 10 micron Filter and into the Tank. If the Solenoid Valve is not activated, oil flows through the Motor Control Valve, out port (T) through line (4) through the main frame, and back to Tank via the 10 micron Filter. See the Motor Control Valve Section for detailed explanation of the valve operation. A non-adjustable Pressure Relief Valve located on the Motor Control Valve Block and set at 2500 PSI protects the Motor circuit. Note: In System Schematic (Figure 2) the Cylinder Control Valve System is also Shown, This will be discussed in the Cylinder Control valve Section later in this Manual. Cylinder Control System is shown here in schematic to make it as complete as possible. Gear Motor and Tandem Gear Pump Operation: The A-Boom Hydraulic System is powered by the Tractor and produces the desired hydraulic function through the use of an external spur gear - fixed displacement pump (Figure 3 and 4). For every complete revolution of the pump s input shaft, the pump displaces a fixed amount of oil. This pump output flow is proportional to the engine speed. Bearing Carrier Bushings Figure 3 Rear Pump Section for Motor Operation Front Pumping Section for Hydraulic Cylinder Operation 2003 Alamo Group Inc. 25

26 HYDRAULIC SYSTEM OPERATION Tandem Pumps: The Tandem pumps utilized on most A-Booms provide hydraulic oil flow for both, the boom movement / control functions as well as for the operation of the cutter motor circuit. The cutting circuit section is the larger section located closest to the mounting flange, while the boom movement section is the smaller section and is located behind the cutting circuit section (Figure 4). Oil Supply to Pump Motor Section Control Section Motor Circuit Supply Control Circuit Supply Figure 4 Viewing the cross section of one of the gear Sections in Pump (Figure 5) can illustrate the Flow of the Oil through the section along with the physical results. Output Force Force Figure 5 Oil Flow Rotation Direction 2003 Alamo Group Inc. 26

27 HYDRAULIC SYSTEM OPERATION Tandem Pumps: (Continued) The counter rotating gears create a vacuum drawing oil into the inlet (See Figure 5). Oil is trapped in the recess between each gear tooth and carried around the outside of the gear. Oil does not pass through the center. At the point where the gear teeth mesh on the outlet side, the oil is forced from the recess and exits the pump. Each one of the recesses is referred to as a pumping chamber. Forces downstream from the pump such as line restrictions or motor loading will allow pressure to build on the outlet side of the pump. This pressure forces the gears to deflect into the housing on the low-pressure (inlet) side. The contact of the gears to the housing walls prevents the high-pressure output oil from leaking to the input side. Excessive pressure will cause excessive wear to the housing and allow leak back of the pressurized oil and poor performance of the hydraulic system. The hydraulic pumps and motors used on the A-Boom utilize a Pressure Balanced Thrust Plate Design (Figure 6). This design allows the oil pressure to hydraulically balance the thrust plates and squeezes them against the gear faces. This provides a seal between the gear face and the thrust plate surface preventing the high-pressure oil from leaking back to the low-pressure (inlet) side. Mechanical seals on the thrust plate prevent oil from leaking between the plate and the adjoining casting. The seals depicted in the illustration are known as Pocket seals, a channel type seal (Figure 7) may be used on other units with the same results. Pump or Motor Housing Oil Flow Out Thrust Plate Seals Pressure Balanced Thrust Plate Figure 6 Oil Flow In Pressure Balanced Thrust Plate Figure 7 Thrust Plate Channel Seals 2003 Alamo Group Inc. 27

28 HYDRAULIC SYSTEM OPERATION Tandem Pumps: (Continued) The operation of the hydraulic motor is essentially the same as the operation of the pump with the exception that the outlet oil from the pump provides oil under pressure to counter rotate the gears of the motor, and provide for the rotation of the shaft. The oil output from the motor flows directly back to the tank and is pressurized only to the extent of the restriction in the return line. Common Complaints: For the most part, gear pumps and motors fail as a result of, CONTAMINATION, CAVITATION (OR LACK OF LUBE), OR OVER PRESSURIZATION. Contamination damage results from the introduction of foreign material into the hydraulic system. The foreign material may be in the form of nuts and bolts or as fine as small grains of sand or dirt which are undetectable to the human eye. Damage due to contaminants usually takes the form of machined grooves in the thrust plates or damage to the gears. All Alamo Industrial hydraulic machines are protected from some forms of contamination by a suction screen filter and a return filter. Regular maintenance of these filters is vital to the survival of the system. Protect the system from potential contamination during repairs by plugging all ports which are opened during disassembly. Rebuild the components in a dust free environment. CAVITATION is the development and explosion of air bubbles in the hydraulic system at the pump or motor. Cavitation damage is identified as isolated pitting in the thrust plates and results in drastic loss of performance. This type of damage is usually the result of the loss of oil in the tank, or air leaks in the suction line to the pump. It is also possible to cavitate the motor during shut down by completely stopping the tractor motor and front pump while the motor is still turning due to the momentum of the blade bar. The tractor should remain at the rated RPM until the blades come to a stop. Over pressurization is the result of excessive restriction in the return line, or excessive load on the system. All Alamo Industrial hydraulic systems are protected from damage due to over pressurization with the use of pressure relief valves. Over-pressurization usually results in excessive backpressure wear to the pump housing and causes extreme loss of performance. Extreme cases can cause torsional shear of the pump or motor shaft or cracking of the pump or motor housing. In addition to these modes of failure, loss of mower performance may be attributed to the failure of the front pump drive assembly. This is identified as severe wear to the pump input shaft and the shaft coupler splines. This type of damage is almost always attributed to momentary or permanent misalignment of the front pump drive assembly. Motor Circuit Control Valve Operation: The control of the cutting operation of the mower head is obtained through the operation of a motor control valve. This valve is controlled by the operator through a switch located near the operator s position. In most cases the control valve is located below the swing cylinder mount and attached to the main frame of the boom (Figure 8) Alamo Group Inc. 28

29 HYDRAULIC SYSTEM OPERATION Figure 8 Motor Control Valve Motor Circuit Control Valve Operation: (Continued) Shown Below (Figure 9) is Valve operation with the Mower Switch in the OFF position (Solenoid Valve De-energized) Check Valve Logic Valve Piston Solenoid Valve Piston T Pilot Port Figure 9 Pilot Piston P Relief Valve High Pressure Test Port, Use # 6 MB Fitting When the mower switch is in the "OFF" or depressed position (Figure 9), electrical power to the solenoid valve on the motor control valve is interrupted and the solenoid valve is in the open position. Oil from the pump enters the valve at port (P). A small amount of oil is allowed to pass through the pilot port in the logic Valve Piston and allowed to pass through the open Port in the Solenoid Valve. (Continued Next Page) 2003 Alamo Group Inc. 29

30 HYDRAULIC SYSTEM OPERATION Motor Circuit Control Valve Operation: (Continued from previous page) With no trapped oil behind the piston, hydraulic oil under low pressure from the pump counter acts the logic valve spring and displaces the logic valve piston such that a passage is opened to return the oil to tank through port (T). Note: The hydraulic oil from the pump is allowed to reach the motor through the (M1) port, however, any oil returned to the valve from the motor through the (M2) port, is stopped at the check valve due to the 100 PSI spring operating against the check valve piston and closing the return to tank. Therefore, the motor will not turn. VALVE OPERATION WITH MOWER SWITCH IN THE ON POSITION (Solenoid Energized) Check Valve Return to Tank Logic Valve Solenoid Valve Piston T M2 Pilot Port Piston Pilot Piston P M1 High Pressure Test Port, use #6 MB Fitting Figure 10 Relief Valve When the operator pulls the mower switch out or into the on position (Figure 10), electrical current activates the solenoid valve and closes the passage behind the logic valve piston thus blocking the flow of oil to the return tank. Pressure builds up behind the logic valve piston and seats it such that the main passage to the tank is blocked. Left with no alternative, the oil is forced to travel to the motor through the (M1) port. The restriction created due to the load on the motor creates pressure and forces the motor to turn. Oil returns from the motor through the (M2) port. The pilot piston under high pressure from the (M1) port opens the check valve piston, and allows free flow of oil to return to tank. Oil under pressure at the motor is also present at the relief valve. The relief valve remains closed until the pressure in line (M1) reaches the relief setting (2500 PSI). The valve then opens and allows some oil to return to tank until pressure is again below the relief valve setting. When the relief valve is open, the motor may slow or completely stop, depending on the load felt at the motor Alamo Group Inc. 30

31 HYDRAULIC SYSTEM OPERATION Motor Circuit Control Valve Operation: (Continued from previous page) VALVE OPERATION JUST AFTER THE MOWER IS TURNED "OFF" ( Braking) Check Valve Logic Valve Piston Solenoid Valve Piston M2 Pilot Port Pilot Piston Figure 11 P Relief Valve M1 High Pressure Test Port, Use #6 MB Fitting When the mower is turned off after operation (Figure 11), the control valve provides the ability to slow the cutting speed to reduce the wind down time of the mower. As stated earlier, when the electrical power to the solenoid is cut off. The solenoid valve opens the passage behind the logic valve piston, This allows the oil which is holding the logic valve piston on its seat to travel to the tank, thus opening the return passage from the pressure (P) port to tank. Likewise, oil under low pressure is supplied to the motor, which is now operating like a pump due to the rotation caused by the momentum of the turning blades. Since there is no oil under pressure to activate the pilot piston, the check valve now provides 100psi resistance to the return oil through (M2). This reduces the wind down time for the motor. IMPORTANT NOTE: Caution When the Mower is shut off after Operation, The momentum and the resulting wind down of the Blade Carrier creates a situation where the Motor can operate like a Pump. Loss of Oil to the Motor during this wind down period due to loss of Operation of Pump (Turning Tractor Engine OFF ) can result in Cavitation damage to Motor during Shut down and Pump during restart of Tractor Engine. THERE FOR THE TRACTOR ENGINE MUST REMAIN RUNNING AT THE RATED RPM SPEED UNTIL THE MOWER BLADES COME TO A STOP Alamo Group Inc. 31

32 HYDRAULIC SYSTEM OPERATION Motor Circuit Control Valve Operation: (Continued from previous page) COMMON COMPLAINTS: Most technicians seem to blame the motor control valve for most performance problems. However, unless contaminated or abused, the Motor Control Valve will provide very dependable service. There are, however, two basic modes of failure of the valve. 1. No Power or Stops under Load, The mower will turn on when the switch is pulled and cut air adequately. However, any load put on the blades will significantly slow or totally stop the mower from turning. This is attributed to a failure of the O- ring seals on the solenoid valve. Check pump pressures and flows to isolate the problem to the valve. An O-ring seal kit should be ordered to replace all of the seals in the cutter valve. 2. The mower will not turn on at all. Check pump pressures and flows to isolate the problem to the cutter valve. Normally the problem is with either the solenoid coil, wire harness or mower start switch. Replace the affected parts Alamo Group Inc. 32

33 Pump Pressure and Flow Testing Section 2003 Alamo Group Inc. 33

34 PUMP TESTING Single Pump System Schematic (Typical 17' through 23' with 4 Spool Valve Shown, w/ Rotary Head Hydraulic Door Option and the 28' will have a 5 spool Valve ) Single Hyd. Pump Tractor Hydraulic Pressure Supply Line Swing Cyl. Lift Cyl Dipper Cyl. Tilt Cyl. Control Valve Return to Tractor Hydraulic System Motor Control Valve Motor Return 3 Hyd. Tank 5 M 1 M 2 Motor Pressure 2 4 Filter Mainframe Hydraulic Motor 2003 Alamo Group Inc. 34

35 PUMP TESTING Tandem Pump System Schematic (Typical 17' through 23' with 4 Spool Valve Shown, w/ Rotary Head Hydraulic Door Option and the 28' will have a 5 spool Valve ) Tandem Hyd. Pump Swing Cyl. Lift Cyl Dipper Cyl. Tilt Cyl. Control Valve Motor Control Valve Motor Return 3 Hyd. Tank 5 M 1 M 2 4 Motor Pressure 2 Filter Mainframe Hydraulic Motor 2003 Alamo Group Inc. 35

36 PUMP TESTING GEAR PUMP TESTING Tandem or Single / Front Engine Mounted or Rear PTO Mounted NOTE: The A-Boom uses a Gear Type Pump, Tandem or Single, Front mounted and rear mounted Pumps do not rotate in same direction, Front to rear Pumps cannot be swapped unless pump is disassemble and parts changed, See Pump repair section for information to reverse Rotation of the Pump. IMPORTANT NOTE: 1. Safety is the most important beginning of Test. You MUST be totally in control of Tractor and You re surrounding area before beginning any test, there must not be other people in area when Tractor is started and mower is being tested, If you have an assistant always know where your Assistant is before you do anything. Only you should be able to start Tractor, Keep the Key with you, do not leave it in Tractor. 2. Repairing a failed Component is not always repairing the Cause of a failure, When making repairs always check all associated components because one component can be the cause of another component failure. INFORMATION COLLECTION: Any information on Unit from operator will be helpful. 1. What is Model Unit, Size, Type Head, Type Tractor it is mounted on etc? 2. What is not working correctly? In as much detail as possible. 3. Has this malfunction existed for some time, just start suddenly, continuos malfunction or off and on, when does malfunctions occur. 4. Did this malfunction result from an earlier malfunction? What if any repairs, adjustment, modifications or any changes to any components have been made to unit recently. (Repairs - Maintenance - Accidents - Operator Change) 5. Have all the obvious items been checked, Oil Levels (Tractor & Unit Reservoirs), Electrical Supply (Dead Battery, Loose connections, etc.) 6. Does the malfunction affect all circuits, one, two or more? 7. Does malfunction affect both sides of the same function or just one (Example Lift & Lower, in or out, etc) 8. Does malfunction happen when Cold or Hot, only Cold or only Hot, more when Cold than Hot, more when Hot than Cold etc. 9. What Conditions? What is Unit doing when malfunction occurs, running at low RPM, High RPM, heavy Cutting, light Cutting, Level Ground, Slope Angle etc. 10. Any information that will help determine what may be causing the Malfunction or to pin point the location of the malfunction. VISUAL TEST: 1. Do Not Start Tractor till all visual inspections are done. Check All Fluid Levels (Fluid Levels should be checked with oil warm and with all components filled with Oil from operation), Remove any bolt on / Slip on Cover that prevent visual inspection of general condition of components. Look for any Broken Components, Missing Components, Loose Components, Oil Leaks, Damaged Components. Look for any thing that is obvious to cause a problem. 2. Replace any missing / broken components, tighten any loose components, repair any Oil Leaks before beginning any further test Alamo Group Inc. 36

37 OPERATIONAL TEST: PUMP TESTING 1. Visual Test should have been done already, If not go back one page and perform visual test now. Pump and/or Valve covers should be removed. 2. There are two different types of Optional Pump Systems offered, determine which you have. A. One type is a Tandem Pump (Double Pump) where the first section (larger Section) supplies the Heads Motor Hydraulics Pressure and the Second Section (Smaller Section) Supplies the Control Valve Hydraulics Pressure. B. Second type is a Single Pump which only supplies the Head Motor Hydraulic Only, The Control Valve Hydraulic Pressure is supplied using Tractors internal Hydraulic System when Single Pump is used. 3. With Tractor Engine running operate each Circuit, Paying close attention to everything the unit does or does not do. 4. The Engine speed should drop slightly (the Sound Change) when the Valve spool moves and the Pump comes under a load, If the Engine sound does not change when the Circuit is activated, it is an indication that there is no load being placed on Pump. 5. Observe each movement of the Cable controls throughout its complete range of movement. Check the Cylinder speeds; Look for Jerky operation, the Cylinder should respond smoothly to the movement of the control valve controls. Look for time delay between movement of Controls and movement of Cylinders. This could indicate an uneven Pressure Flow. 6. After checking each function, attempt to duplicate the malfunction described by Operator, Using the information gathered in the Operator Interview. If you are not able to get machine to malfunction; see if operator can get the machine to malfunction. 7. When the Malfunction occurs, take note of all conditions that exist during the time of the malfunction, Some things to take note of are, A. Engine Speed or Sound. B. Position of Articulating Members. C. Operating Temperature D. Length of time Unit has been running E. Position of Control Levers before and during malfunction. F. Position and Condition of Tractor G. Any other condition you might notice. 8. Duplicate the conditions that existed when the malfunction occurred to determine if the malfunction would occur every time that the same conditions exist. Try different combinations of conditions to determine which conditions actually affect the malfunction and which ones just happened to be there when the malfunction occurred Alamo Group Inc. 37

38 PUMP TESTING Pressure & Flow Supply Test: Front or Rear Mounted Pump This test will use the Hydraulic Schematic on previous page for reference points. If you have a Tandem (Double) Pump System this test will work for the Front or Rear Tandem Pump. If you have a Single Pump System it will also Work. 1. Perform all the Obvious Test First. Check all oil levels. Check Hose s and Connections to make sure they are not in a bind restricting Oil flow. If repairs have been made that everything was connected correctly. If PTO mounted rear pump make sure PTO is engaging. Make sure Speed Changer is transferring RPM to Pump. If Front mount Engine Pump make sure front drive shaft and its components are installed and installed correctly. If every thing checks OK go on to next step. 3. Use extreme caution if using a Flow Meter, Use Caution when installing a Flow Meter if the System has been run and Oil is hot. Never remove a Hydraulic Line while System is running or while System still has residual Pressure in it. Never connect a Flow Meter in system backwards. Pressure should flow through Gauges and then Restrictor valve. 4. Install Flow Meter in System in Line # 1 (See Pump System Schematic for Line location). This will require all Flow to move through Flow Meter. The purpose of this test is to make sure Pump is producing sufficient Flow and Pressure. Make Sure that Restrictor Valve of Flow Meter is in the Full Open Position and that all line connections are tight. See Fitting Chart in Specification Section for proper Torque for Fittings. Do not over tighten fittings. 5. Safety first, make sure area is clear of danger to other Persons and property before starting any test. Start Tractor, you should have a pressure of 200-PSI (approx.) on Flow Meter Gauge, this is caused by line size, which creates restriction. At 1800 RPM you should have 37 GPM and still 200 PSI through Pressure supply line. It is not unusual for a Spike Pressure to be seen in Flow Meter Gauge if head is started then drop back. If this tests OK go on too next Step. 6. Slowly turn Restrictor Valve of Flow Meter down to create Load on Pump. Close Valve slowly watching Pressure Gauge as you go, increasing Pressure in 500-PSI increments. DO NOT exceed 2000 PSI when doing this test, There is no Relief Valve in the System as Flow Meter By passes it. If you exceed 2000 PSI with Flow Meter Test you will damage System. The 38 GPM will drop when under pressure but should not drop below 32 GPM (this is 85% efficiency rating). If GPM drops below 32 GPM there is something wrong with Pump. If test of Pressure and Flow are OK, Leave Flow Meter Connected and go to next step. 7. With Tractor Engine running, Turn Mower on. With Mower running and not cutting anything (No Load or resistance to Blades other than Air). With Tractor RPM at 1800 you should get a reading of 400 to 600 PSI and 37 GPM, If flow were tested while Cutting this Pressure would increase as blade resistance increased, To test while Cutting would not be necessary. When you first turn Cutter Switch on it is not unusual for the Pressure in flow meter to spike as Cutter first starts and then drop back on pressure. The Spike is due to the resistance encountered to get the Blade Carrier turning. If these test are OK remove Flow Meter from Line # 1 and reconnect lines, tighten lines to specifications.(see Pump System Schematic for line location) Continued Next Page Alamo Group Inc. 38

39 PUMP TESTING Pressure & Flow Supply Test: Continued From Previous Page. 8. Install the Flow Meter in line # 2 (See Pump System Schematic for Line location). Connect Flow Meter in line between Cutting Head Motor and Motor Control Valve on the Pressure Side. Check all connections and tightened to specifications. Safety first, make sure area is clear of danger to other Persons and property before starting any test. Start Tractor, you should not get a reading till you turn the Cutter Control Switch on. With Blades on Head running but not cutting anything (No Load or resistance to Blades other than Air) and Tractor RPM at 1800 you should get a reading of 400 PSI to 600 PSI and 37 GPM. It is not unusual to see a Spike Pressure in Flow Meter Gauge when Motor is first started then drop back. Some times when a load is put on the Hydraulic System during test the Load will cause the Tracror RPM to pull down, 1800 RPM Engine speed must be maintained during test, so watch Tractor Rpm and increase it if required to maintain needed PRM. If This Checks OK leave Flow Meter connected and go on to next Step. If this is not OK check the Logic Valve and relief Valve, They are located in the Cutter Control Valve Assembly. There are Seal Kits available for the Logic Valve and Relief Valve, see Part Manual for Part numbers. 9. With the Flow Meter Connected to Line # 2 (See Pump System Schematic for Line Location) and Motor Control Valve engaged with Motor running, you should be showing 400 PSI to 600 PSI Pressure and 37 GPM Flow. Let the System run till the Oil Temperature reaches a least 100 deg. F. Slowly close Restrictor Valve in Flow Meter watching Flow Meter Gauges till Pressure reaches 1000 PSI, here you may see a slight drop in GPM but this is OK. Record the Pressure, Temperature and GPM reading. Continue this in 500 PSI increments till you reach approx PSI (2400 to 2600 PSI is OK) and your Flow should be at least 32 GPM (85 % Efficiency rate), At approx PSI the Cutter Valves Relief Valve should open and pressure will not increase past Relief Valve Setting. If the Pressure exceeds 2600 PSI stop and back off retsrictor Valve on Flow Meter, replace Cutter Control Valves Relief Valve and and run test again. NEVER EXCEED Pressure Relief Pressure Setting in System when running test. If all checks out the Motor is most likely the problem, see the Motor Repair Section. 10. Remove Flow Meter from System and reconnect the original lines back up. Check to make sure all connects are connected to right place (See Pump System Schematic Drawing for line location). Check to make sure all lines a tightened to correct Torque (See Specification Section for Fitting Torque Specs). 11. Check Pressure Gauge at the return on tank, This gauge measure the pressure (return is Low Pressure) as it is being returned through the system to the return filter, This gauge is marked in Green and Red Zones. Green is acceptable return pressure, Red means return pressure is too high. If to high it can be cause by a dirty Filter or a restriction in return line in tank, But in most cases it is the Filter and it should be changed Alamo Group Inc. 39

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41 Pump Repair Section 2003 Alamo Group Inc. 41

42 PUMP REPAIR FRONT MOUNT PUMP / REAR MOUNT PUMP 2 (BOTTOM) 3 (TOP) 10 1 Outlet Ports (Pressure) * * * ** 12 9 Figure 12 Inlet Port (Suction) IMPORTANT! Service Technician must add Marks and or numbers to Pump Here in 5 places to help in the re-assmbly of Pump ITEM QTY DESCRIPTION 1 1 Hydraulic Pump Assembly Deg. Elbow Deg. Elbow 4 1 Flange Kit 5 1 Hose Bib 6 1 Hose Clamp 7 4 Retaining Nut 8 4 Stud 9 1 Pump Mounting Flange (Part of Pump Assembly) 10 1 Pump Input Shaft (Gear & Shaft) Tandem Pump Shown in Figure 12 with standard rotation shown above, If Pump Rotation is reversed when re-assembled the only Mark you would see from this side is on item 9, Pump Mounting Flange and inlet and Outlet side would be the Opposite of shown and the Pump would be re-assembled to where the Marks would be on the other side Alamo Group Inc. 42

43 PUMP REPAIR READ THIS FIRST Dis-Assembly and Re-Assembly of Pump: (Standard Rotation is front Engine Mounted, Reverse Rotation is Rear PTO Mounted and cannot be swapped unless the Rotation is changed by re-installing parts differently) 1. Close Attention must be paid to the way the Pump is assembled. If the Rotation of the is going to be reversed, The Pump must be dis-assembled to change the direction of Shaft rotation. This would be done if you were converting a front engine mounted pump to a rear PTO (w/ speed Changer) driven pump. If the same rotation of Pump is to be the same as it was when disassembled then it must be assembled the same as it came apart. This only applies to the Gear Type Pumps as used on the A-Boom. 2. The Gear Housings have a specific way they must be installed to match the rotation of Pump, This is very important, as Pump will not operate if assembled wrong. The Gears are matched and must installed the same as they came out, This should not be to difficult as Gears are different Width on the Tandem Pump. The Single Pump is basically the same as the Tandem Pump except it has only one set of Gears and one Gear Housing. Most of the directions in this section reference to the Tandem Pump but can be applied to the single pump. 3. Before any dis-assembly of any component of Pump is dis-assembled, The entire area around Pump, Work Area, Tools and including service mans hands must be completely free of any dirt or any debris that could contaminate Pump and lines. THERE CAN BE NO DIRT ALLOWED TO ENTER HYDRAULIC SYSTEM. When parts are being removed do not leave open lines of components that are removed. 4. When Cleaning Pump Components, Do Not used cloth unless it is totally Lint Free. It is best to use Clean Solvent and Blow-dry components with clean filtered compressed air. DO NOT SPIN components with Compressed Air, it is dangerous and will damage parts. After Cleaning if parts are not to be assembled right away they should be coated with light coat of Hydraulic Oil and stored where they can not collect dust. 5. Caution: During dis-assembly, use extreme caution when prying apart castings. The marring of machined surfaces could cause leakage. Excessive use of force can result in mis-alignment and serious damage to parts. Gears are closely matched and must be kept together as a set, when removed from the Pump. Handle them with care to avoid damage to the Journals, Faces and Teeth. 6. During re-assembly, care must be taken when installing all the parts. If one part, Gear Housing, Bearing Carrier Housing, Thrust Plates, Channel Seals, Gasket Seals, Threaded Passage Plugs or any other part is installed in the wrong place or wrong direction, This would cause pump not to work and/or be severely damaged. Read all directions as listed in the assembly steps, If there is some thing in question as to which way a part should be installed, check it out. Installing a small part wrong can cause major damage. 7. After Assembling Pump and reinstalling it on Tractor, MAKE SURE PUMP IS FULL OF OIL (Pre- Lubed). Never start Engine with New or Re-Built Pump unless it is prelube. On models where Oil Level (Tank) is higher than Pump Gravity will prelube Pump when Tank is filled. This means that Oil level in Tank must be higher than the Suction Line, If any part of the Suction Line is higher than the Oil Level in tank Pre-Lube Pump in addition to coating all components with oil during assembly Alamo Group Inc. 43

44 PUMP REPAIR DIS-ASSEMBLY INSTRUCTIONS: 1. Remove the Shaft Key from the drive shaft. Clean the Shaft and inspect for burrs. If Burrs exist, lightly stone away to prevent the Lip Seal from being damaged during dis-assembly. 2. Place the Pump assembly in a vice with the drive shaft pointing downward (Figure 13). Clamp the Pump on the sides of the mounting Flange only, Do Not clamp on the round pilot diameter of Shaft (Figure 12 item 10) as it would damage shaft which would cause seal surface to be damaged. 3. Match - Mark and/or number each casting piece in the Pump assembly (See Figure 12 & 13). This will help ensure proper location and direction of assembly of each component during re-assembly. This is important because casting must be installed in same direction and order as they came apart. * 4. Use a Socket Wrench to remove 4 Hex Nuts at the top of the Pump (See Figure 14). Some times when removing these, Stud will unscrew and come out instead of the Nut coming off of the stud, if this happens make sure that at least two of the studs stay in at all times, All 4 can stay in it will be OK, (the studs do not have to be removed). Remove the 4 lock washers from the Studs. 5. Removing the Port End Cover, make sure a least 2 Studs are still in the assembly with all the retaining nuts removed. If End cover will not pull up over Studs, Place the point of a wedge (large Screw driver or Chisel) on the parting line between the Port End cover and the Gear Housing. Lightly tap until a slight separation between the castings is detected. Caution must be used when prying Port End Cover off as not to damage the machined surfaces of components. There are Dowel Pins used between the Port End Cover and Gear Housing, these Dowel Pins may stay in either casting which will be important to know when time to re-assemble but do not remove Dowel Pins at this time. Looking at the Machined side of Port End Cover you will see 2 threaded passageways, 1 that has a plug and 1 that will not have a plug. Mark the passage without the Plug so that you will know which one it is later when re-assembling. DO NOT REMOVE THIS THREADED PLUG, even if you are reversing rotation on the Pump from front mounted to a rear mounted. 6. The 1 st. Thrust Plate (See Figure 15) will be on top of Gear Housing between it and the Port End Plate. The Thrust plate has two different sides, Remove the Trust plate by hand, Do Not pry on Thrust Plate. The Channel Seal (facing up) can be left in Thrust Plate Groove, If the unit has a lot of hours operation it will be best to replace these Channel Seals.. Figure 13 * * * * * End Cover Gear Housing Bearing Housing Gear Housing Pump Mounting Flange Vise 2003 Alamo Group Inc. 44

45 * PUMP REPAIR DIS-ASSEMBLY INSTRUCTIONS: (Continued) 7. Match-Mark the Outer Gear Set. before removing them, they must be reinstalled with the Teeth meshed the same way they came out. Wipe (with Lint free cloth) the Oil from Gear Set. Mark the Gear Set with Machinist Ink or Quick Dry Marker. Carefully remove the Gears from the Gear Housing. You should be able to do this by hand. Avoid tapping the gear teeth together or against other hard surfaces. Lift the Gear housing up and off. Be careful if prying Gear Housing. If Gear Housing is stuck, break it free with a wedge as was done in step 5 above. Carefully remove the 2 nd. Thrust Plate off by hand, The Channel Seals will be on the bottom side of thrust plate and may or may not come off with Thrust Plate. (See Figure 15) Note: When looking at Thrust Plate and the Channel Seals, The Smooth side of the Thrust Plate goes against Gears and Channel Seal are on opposite side from Gears. if they are not this way they were installed wrong and will have been destroyed by the gears.. 8. There are Gasket Seals in grooves for the gear Housing (See Figure 17), check to see if these Seals stayed in grooves or fell out, It is not important to remove these Seals unless they have a lot of field time or they are damaged. Replaces Seals if damaged. There are Dowel Pins that will have remained in Gear Housing or Bearing Carrier Housing. Do not remove the Dowel Pins at this time. Note that the Inlet (Suction) Core has a larger opening than Outlet (Pressure) Core. This must be this way, the larger opening must always be on the Suction side of Bearing Carrier Housing. Figure 14 Gear Housings Pump Mounting Flange Retaining Nuts & Studs * * * * Port End Cover Bearing Carrier Housing Vise 9. Lift the Bearing Carrier Housing up and Off. If prying on it be careful with machined surfaces. The Dowel Pins will stay in this Housing or stay in the next Gear Housing. Do Not remove Dowel Pins at this time. 10. Remove the 3 rd. Thrust Plate that will be with the Channel Seal facing up away from Gears in next Gear Housing. (See Figure 15 which is a motor Channel Seal, A Pump Channel Seal is only one sided See Figure 23 & 24) The Thrust Plate should lift off by hand, Do Not Pry on Thrust Plate. Inspect Channel Seal. Thrust Plate Channel Seals Figure Alamo Group Inc. 45

46 PUMP REPAIR DIS-ASSEMBLY INSTRUCTIONS: (Continued) Bearing Carrier Housing Pump Mounting Flange Inner Gear Set Pressure Ports Gear Housing (f/ Cyl. Operation) Bushings End Port Cover Pump Input Shaft and Gear Figure 16 Gear Housing (f/ Motor Operation) Suction Port Outer Gear Set 11. Match-Mark the Inner Gear Set. before removing them, they must stay together and not get mixed with the Outer Gear Set. Wipe (with Lint free cloth) the Oil from Gear Set. Mark the Gear Set with Machinist Ink or Quick Dry Marker. Inspect the Input Shaft that protrudes out through the front of the Pump, make sure there are no damage to Shaft that will damage Seals or flange Housing as gears are removed. (See Pump Breakdown For detailed View). Carefully remove the Gears from the Gear Housing. You should be able to do this by hand. Avoid tapping the gear teeth together or against other hard surfaces. 12. Lift the Gear Housing up and off. Be careful if prying Gear Housing. If Gear Housing is stuck, break it free with a wedge as was done in step 5 earlier. The Gear Housing has Dowel Pins between Gear Housing and Pump Mounting Flange Housing, The Dowel Pins will stay in one or the other housing, do not remove Dowel pins from housing at this time. Carefully remove the 4 th. Thrust Plate off by hand, Some times these thrust Plates will come out with the Gears or can be removed up through Gear Bore in Gear Housing. The Channel Seals will be on the bottom side of Thrust Plate and may or may not come off with Thrust Plate. (See Figure 15) Note: When looking at Thrust Plate and the Channel Seals, The Smooth side of the Thrust Plate goes against Gears and Channel Seal are on opposite side from Gears. If they are not this way they were installed wrong and will have been destroyed by the gears. Inlet (Suction) Core Opening 2003 Alamo Group Inc. 46 Figure 17 Gear Bore Gear Housing Outlet (pressure) Core Opening Gasket Seal

47 PUMP REPAIR DIS-ASSEMBLY INSTRUCTIONS: (Continued) 13. Important! Look at the top of the Pump Mounting Flange you will see two threaded passage ways, one will have a plug in it, the other one will not (See Figure 18). Mark these hole so that you will know which had threaded plug and which did not. DO NOT REMOVE THE PLUG from housing unless you are reversing the Rotation of the Pump from front mounted to a rear mounted. If you are reversing rotation of Pump remove the threaded Plug from the Pump Mounting Flange. Clean the area around the hole where the plug came out, make sure that there are no metal shavings or splinters that came off of threaded plug or hole left on Pump Mounting Flange Housing. Carefully remove any burrs on Housing where Plug came out. 14. Inspect and Clean the Pump Mounting Flange, Inspect and replace the Shaft Lip Seal in housing if needed. If Seal has any damage, nicks or wear is visible it should be replaced. There is a Bearing (Bushing) inside Pump Mounting Flange behind Shaft Lip Seal, Inspect the Bearing condition, There is also a Bearing (Bushing) where Idler Gear runs in this Mounting Flange. If Bering is worn it should not be used. 15. Coat all the parts with a light coat of hydraulic Oil, If parts are going to be around awhile before being re-assembled they should be covered to prevent dust from collecting on them. Never Assemble a Pump if any of the Parts have rust or dirt on them, Pump will be damaged plus you could damage other components of your Unit. The Cleanliness is the most important operation of any hydraulic component repair. The cleanliness during service work is your responsibility Figure 18 Threaded Plug Threaded Passage way (2) Pump Mounting Flange * Vise 2003 Alamo Group Inc. 47

48 PUMP REPAIR ASSEMBLY INSTRUCTIONS: 1. Important! This Step will only apply if you are reversing rotation of Pump to mount it on a Speed increaser on rear of tractor, If NOT Reversing Rotation go on to next Step and do not swap holes with this plug. Apply Loctite to the threads of the Plug that you have removed in Step 13 of disassembly. Screw the Plug tightly into the marked (Hole that had no plug) hole or opposite the one that the plug came in, of Pump Mounting Flange. Stake the Plug with a prick punch at both ends of the screwdriver slot and around the edges. Peen the edge of the hole 1/32" to 1/16" with a 1-1/2" diameter steel ball. After this step the pump must be assembled as started for rotation as this Plug will only work in the correct hole as comparison to the way the rest of components are assembled. 2. Pump Mounting Flange should be checked to make sure it is clean, make sure the Shaft Lip Seal has been replaced or is in good condition. Lightly coat the ID of the Lip Seal with new clean Hydraulic Oil. Pump Mounting Flange should have at least 2 of the 4 studs (all 4 will be OK) screwed into it to hold everything in place as being assembled, For Illustration and clarity purposes the Studs are not shown in drawings. 3. Now is the time to look at the marks that you put on the castings prior to dis-assembling the Pump (See Figure 14). Get the Inner Gear Housing, as it supplies the Motor which needs more volume of Oil it will be the thicker of the two Gear Housings, Inspect the machined surfaces, check Gasket Seals and Seal grooves, If pump is be assembled with the same Rotation slide the Gear Housing with the Gasket Seal in its groove the same way it came off (Your Marks will line up on same side), If you are reversing rotation the Mark on gear housing will be 180 degree turned from the way it came off (See Figure 14). If reversing rotation you may also have to reposition Dowel Pins at this time from housing to housing to get them to be compatible with correct holes. Once everything is lined up, tap Gear Housing with a soft hammer to seat it down over dowel pins. Thrust Plate Gear Bore Gear Housing Relief Groove (High Pressure) Relief Groove (High Pressure) Inlet (Suction) Core Opening Outlet (pressure) Core Opening Gear Side (Smooth Side) Channel Seal Side (Grooved Side) Figure 19 Thrust Plate Installed in Gear Housing Gasket Seal 2003 Alamo Group Inc. 48

49 PUMP REPAIR ASSEMBLY INSTRUCTIONS: (Continued) 4. Install 1 st. of 4 Thrust Plates, Install the Channel Seal into the Groove on Thrust Plate, The Channel Seal has a Flat side and a V shaped side, The V shape goes into groove of Thrust Plate, the Flat side of Seal faces away from Thrust Plate. Gently slip the Thrust Plate with the Channel Seal installed into the Gear Bore of Gear Housing, The Thrust plate must be installed with the Channel Seal Down and the smooth side of the Thrust plate up toward gear, Channel Seal down toward Pump Mount Flange. The Thrust plate also has a notch (lowered Slot) in the smooth side of it. This Notch must always point toward the Outlet (Pressure) side of Gear Housing (See Figure 19). Notice the Openings (core) for Inlet (Suction) Side and Outlet (Pressure) side, The Inlet (Suction) side is always a larger opening (See Figure 19) and must always be installed this way. (See Figure 93 for Channel Seal Description) 5. Coat the Drive Gear input Shaft with light coat of clean Hydraulic Oil; Slide the Shaft down into the Gear Housing, Guiding it through the Thrust Plate, Do not touch Thrust plate with Shaft Splines, Guide Splines through Thrust Plate. Insert Gear Shaft till it protrudes through Shaft Bushing, Shaft Lip Seal and the bottom of Pump Mounting Flange using a gentle Push and twisting motion (See Figure 90), Use caution not to wobble Shaft or push on shaft and damage the Thrust Plate. Coat Idler gear with light coat of Clean Hydraulic Oil and drop it into Gear Housing using caution as it goes through the Thrust Plate. Squirt Clean Hydraulic Oil into cavity around and all over Gears. 6. Mark the position of one of the Tooth points of the Gear on the Out side of the Gear Housing. This Mark will be needed later and used as a reference point during installation of the second Gear Set on a Tandem Pump. 7. Slip the Thrust Plate with Channel Seals installed down over the gear Shafts. Thrust Plate must be installed with the Flat Side toward Gears and the Channel Seal Up. Also the Relief Groove of Flat side of Thrust Plate must be toward Outlet (Pressure) Side core Opening (See Figure 89), The correct installation of Thrust Plate is important. Recheck and make sure Channel Seal is installed with the flat side up. Make sure that Gasket Seal is installed in Groove of Gear Housing. 8. Installing of the Bearing Carrier Housing Must be done correctly. Check Bearings (Bushings) in Housing for condition, Check that Gasket Seal is still in place on the installed Gear Housing. Coat Housing Bearings (Bushings) with Hydraulic Oil. Find the Mark you put on Bearing Carrier Housing when it was dis-assembled (See Figure 13). Line the mark on the Bearing Carrier Housing with the Mark on the previously installed Gear Housing. (If rotation is not being changed then all the marks (3 installed Parts)) you made will be lined (Continued Next Page) Figure 20 Drive Gear Technicians Alignment Marks Pump Mounting Flange * * Drive Gear Connecting Shaft Idler Gear Thrust Plate Gear Housing Vise 2003 Alamo Group Inc. 49

50 PUMP REPAIR ASSEMBLY INSTRUCTIONS: (Continued) 8. (Continued From Previous Page) up on same side, If you are changing Rotation the Pump Mounting Flange mark will be on one side and the other two pieces installed will have their marks on the other side. With the Mark lined up with the mark on the Gear Housing and the Dowel Pins checked (or changed) to align properly, carefully lower the Bearing Carrier Housing down till it is seated against Gear Housing. If needed lightly tap Housing with soft hammer to seat down over Dowel pins. (Check the Bearing Carrier Housing), The size of the Inlet Core and Outlet Core openings a different size and must be installed correctly to Match Gear Housing Core openings. If this is not correct you will have immediate Pump failure. 9. Installing the Second Gear Housing, This applies to the Tandem Pump. The Second (outer Gear Housing is thinner than the first, this is because it supplies the Hydraulic Cylinder Operation and the Volume demand is not as much as the Pump Supply. Inspect the condition of the Gear Housing. Locate the Mark that you put on it during dis-assembly (See Figure 13), If the pump is being assembled with the same rotation as when it was disassembled the Mark will be in its original location (all the marks aligned on the same side). If the pump rotation is beiing change it Large Inlet Core (Suction) Opening Figure 21 Bearings (Bushings) Bearing Carrier Housing Small Outlet Core (Pressure) Opening Dowel Pin Holes will be aligned with the other two housings opposite the Mark on the Pump Mount Flange. Install the Gasket Seals into the grooves on the Gear Housing, Check the Dowel Pins in both housings and move them if needed. Lower Housing down till it rest against the the Bearing Carrier Housing. Tap Gear Housing with a soft Hammer if needed to seat over Dowel Pins. 10. Before continuing check the Inlet and Outlet Core Opening to make sure the Large opening is on the same side as the other Large Inlet Core Opening. Check to make sure that Gasket Seal is still in its groove on Gear Housing. (See Figure 22) 11. Install the 3rd Thrust Plate; make sure that Channel Seal (See Figure 22) is installed into Thrust Plate. When installing Thrust Plate into there are 3 things that must be correct. 1. Make sure Channel Seal is installed with Flat side of Seal out away from groove in Thrust Plate. 2. Install Thrust Plate into Gear Housing with the Channel Seal Down and Facing the Bearing Carrier Housing. 3 rd. Make sure that The Relief Groove in Thrust Plate is pointed toward the Small Outlet Core (Pressure) Opening side (See Figure 22). 12. Install Drive Gear Connecting Shaft (See Figure 20) in to end of Drive Gear that is installed already. The Connector Shaft is a short stub piece of splined Shaft Alamo Group Inc. 50

51 PUMP REPAIR ASSEMBLY INSTRUCTIONS: (Continued) Thrust Plate Gear Bore Gear Housing Relief Groove (High Pressure) Relief Groove (High Pressure) Inlet (Suction) Core Opening Outlet (pressure) Core Opening Gear Side (Smooth Side) Channel Seal Side (Grooved Side) Figure 22 Thrust Plate Installed in Gear Housing Dowel Pin Holes Gasket Seal Thrust Plate Channel Seal Side (Grooved Side) Relief Groove (High Pressure) Channel Seal Cross Section of Channel Seal Gear Side (Smooth Side) Figure 23 Flat Side Figure Slide the Second Driven Gear (this is the gear that will not have Splines in Shaft) through the Gear Housing being careful of Thrust Plate. Align this gear with the Mark you made earlier as described in step six. Align this Gear to where that mark is between two tooth points. This will put the two Gear Sets out of Phase and maximize performance. Phase the Drive Gear into the Housing lining up the marks on the gears from dis-assembly. You will have to rotate Gears to get them to slide together at the Gear Connecting Shaft, But try to keep the Gears a half Tooth out of Phase. Squirt clean Hydraulic Oil over Gears. (Gears installed out of Phase; this will keep the pump operating with smooth constant flow) Alamo Group Inc. 51

52 PUMP REPAIR ASSEMBLY INSTRUCTIONS: (Continued) 14. Slip the Thrust Plate, with Channel Seal over the Journal and into the Gear Housing. Make Sure the Relief Groove (See Figure 22) is down toward Gear Side and pointing toward the Outlet Core Opening (See Figure 92). Make sure the Channel Seal is installed into Thrust Plate facing up. Make sure the Channel Seal has the Smooth side up and the angled side into groove of Thrust Plate (See Figure 23 & 24). 15. All the Studs should be installed at this time if they are not already installed. Make sure that the Gasket Seal is installed into the groove on the Gear Housing (See Figure 22) 16. Install the Port End Cover, The Port End Cover should have your alignment Mark from disassembly. If you are not Reversing Rotation of Pump, put Port End Cover back on the same way it came off, This means that all of your Marks will line up on the same side and the Threaded Plug will be in the same Hole (See Threaded Hole in Figure 25) that it was in originally. If you are Reversing Rotation the Port End Cover will be installed turned 180 degrees and your mark will be on opposite side. The Plug in the Threaded Hole WILL NOT have to be moved to the other Hole from where it was because as cover is turned 180 degrees Plug is being moved. DO NOT MOVE PLUG and if you do move Plug DO NOT ROTATE COVER. Note. You may have to move Dowel pins to line them up. 17. Lightly tap the Port End Cover in the center to seat down over Dowel pins till it rest against Gear Housing. 18. Install the Flat Washers and Nuts on Studs, Tighten these till Nuts and Washers touch End Cover and are snug. Rotate Input shaft of Pump to make sure it is not binding. Now torque these Nuts using an alternating pattern ( See Figure 26) diagonally in increments 1st to 100 ft. lbs, 2 nd 150 ft. lbs and 3 rd to 200 ft. lbs. Re-check to make sure pump turns with out binding between Torque sequence. and after last tightening. Always check Driveshaft components before reinstalling Pump. Bearings (2) (Bushings) Port End Cover Washer and Retaining Nut (4) Threaded Hole (2) Port End Cover Figure 25 Dowel Pin Hole (2) Figure Alamo Group Inc. 52

53 PUMP REPAIR - SUMMARY IMPORTANT FACTS TO WATCH OUT FOR: SUMMARY 1. Always clean Pump, Tools and work are before perform any repairs on Hydraulic System. 2. Mark Each Section of Pump to where you will know how it came apart and in a way that you will know which side id Left or Right, Top or Bottom, This is important for re-assembly. you can mark these as you want but it is best to do it with Punch Marks, Number or Letter Stamps. Marks should be permanent and not wipe off. See figures in this Section for Parts Location and design. 3. The Gears must be marked before being dis-assembled as they must be put back the same as removed, This can be done with machinist Ink or a permanent marker. The Gears on a Tandem Pump has two sets of Gears, The Gears are installed 1/2 tooth out of Phase with each other. 4. Gear Housing must be installed with the Inlet and Outlet Core Openings on the correct side, On Tandem Pump the core opening on all sections must be on the same side, all large one side and all small on other side. 5. Bearing Carrier Housing must be installed with the Inlet and Outlet Core opening on the correct side, they must match the Gear Housings Core Openings. 6. Thrust Plates must always be installed with the smooth side against gears and the Relief Groove toward the Outlet (Pressure) Core Opening. 7. Channel Seals must always be installed on the opposite side of the thrust plates away from Gears (Channel Seals Never go on Gear side of Thrust Plate). The Channel Seals are Flat on one side and peaked on other side, the peaked side always goes against Thrust Plate in the groove on Thrust Plate. The Flat Side goes away from Thrust Plate. 8. Gasket Seals, these are the Gaskets (Rings) that fit into the Grooves on each side of Gear Housings, these must be fit squarely into these grooves to prevent leaking. 9. Pump Mounting Flange, This has two threaded holes in it on the machined side. One hole has a Plug ant the other Hole will not. If Reversing Rotation of Pump is done this plug must be moved to the opposite Hole. If NOT Reversing Pump Rotation DO NOT remove or change this Plug. 10. Port End Cover, The Port End Cover has two threaded holes, one with a plug and one without a plug. This plug WILL NOT need to be removed or changed. The End Cover must be put on in the correct direction to match pump rotation. Always pay attention to how pump was dis-assembled to see which way you need to put cover back on. Put Cover on same for same Rotation or turn 180 degrees if Reversing Rotation Alamo Group Inc. 53

54 PUMP REPAIR - PART LOCATION Figure Alamo Group Inc. 54

55 PUMP REPAIR - PART LOCATION TANDEM PUMP (A-BOOM) ITEM QTY DESCRIPTION -- Pump Assembly, Tandem 1* 1 Seal 2 1 Mounting Flange w/bushings 3 2 Plug 4* 4 Channel Seal 5 1 Gear Set 6 8 Dowel Pin 7 1 Gear Housing 8* 4 Gasket Seal, Square 9 1 Bearing Carrier Housing w/bushings 10 1 Gear Set 11 1 Connector Shaft 12 1 Gear Housing 13** 4 Thrust Plate 14 1 Port End Cover w/bushing 15 4 Washer 16 4 Studs 17 4 Nuts ** included in major rebuild seal kit (includes Minor Seal Kit) * included in Minor Rebuild Seal Kit 2003 Alamo Group Inc. 55

56

57 Front Pump Drive Shaft Components 2003 Alamo Group Inc. 57

58 PUMP DRIVE ASSEMBLY Figure Front Pump Drive Assembly Item Part No. Qty Description 1 Tractor a/r Tractor Engine, at Front Crankshaft 2 1 Tractor Pulley 3. 1 Pulley Adapter Spacer 4. 1 Pulley Adapter 5. 1 Locking Collar Set Screw 6. 1 Locking Collar 7. 1 Drive Shaft 8. 1 Snap Ring 9. 1 Coupler Front Pump Mount Plate Front Pump Front Pump Drive Shown above is generic, Some components may not be used on all models, and some components used may not be shown above. See Parts Manual or Archive Manual for Part Numbers used to fit the Model of Tractor used. Some Models will have a Drive Line Assembly (Not Shown) and use none of the parts above Alamo Group Inc. 58

59 PUMP DRIVE ASSEMBLY The Type of Drive Shaft used will vary with the type of Tractor the A-Boom is mounted on. Shown in this section is for a Front Mounted Engine Driven Pump. This type uses a solid Shaft and Coupler System, some couplers are Splined Sleeve (shown) while others may be a Chain and Sprocket assembly (not shown). Always check the Archive Parts Manual or the original Installation Drawing for Tractor Model for Type drive used. DRIVE SHAFT REMOVAL: 1. Remove the pump from the front of the tractor. If hoses are disconnected from the pump, be sure to cap the fittings to prevent contamination of the hydraulic system. 2. Remove the coupler from the pump shaft and driveshaft. Check all parts for wear. Replace as needed. 3. Remove and inspect the driveshaft. 4. Remove the crankshaft pulley adapter. Check for wear or damage to the internal splines, bolt sleeves and bushings. DRIVE SHAFT INSTALLATION: 1. Attach the pulley adapter hub to the crankshaft pulley. Make sure the hub is flush with the face of the pulley when fasteners are tightened. 2. Insert the splined driveshaft through the front of the tractor until it slides into the pulley adapter hub. Lubricate the spline connection with a good grade graphite grease. 3. Attach the splined coupler to the splined shaft. If your installation is equipped with a snap ring, install the snap ring toward the pump coupler end. Slide the coupler onto the driveshaft until it is flush with the snap ring. 4. Install the front pump plate to the front of the tractor. The plate should fit flush against the front of the tractor. 5. Mount the pump to the mount plate. The pump should also fit flush on the front mount plate. 6. Check that the shaft is free to move back and forth slightly. Slide the shaft as far as possible toward the pump end. Slide the collar against the pulley hub and lock the set screw on the shaft using locktite on the setscrew threads Alamo Group Inc. 59

60 PUMP DRIVE ASSEMBLY COMMON PROBLEMS: 1. Splines on drive shaft, couplers, or pump shaft are worn (See Figure 29 ): This type of damage is normally caused by misalignment of the shaft assembly or lack of engagement of the shaft and coupler splines. Inspect the assembly to ensure that the pump shaft is in line with the splines in the front crankshaft pulley adapter. 2. In some cases it is necessary to install a flexible coupler (Figure 30) in the shaft assembly to compensate for unavoidable shaft misalignment associated with some tractor/ mower designs. Specific mounting instructions for each mower/tractor combination should be consulted for details. 3. Lack of engagement of the shaft to coupler splines is usually indicative of incorrect parts or installation. Consult the mounting instruction and parts list to confirm the problem. IF SPLINE ENGAGE- MENT IS LESS THAN 1-1/ 16 INCH, DO NOT OPER- ATE THE MOWER AS IM- MEDIATE FAILURE CAN RESULT. Contact Alamo Industrial Technical Service for specific details. Note: The Drive components used on your model may not look like the ones that are shown in Figure 30, even though the damage to the Pump Shaft (figure 29) looks like the damage. An alignment problem will damage shaft and couplers. Do not install new shaft w/ damaged coupler or vice versa. Figure 29 Figure Alamo Group Inc. 60

61 Standard Control Valve Operation This Control valve is the Standard 4 Spool that is remote cable Controlled, The 28 ft model used a 5 Spool valve with the 5 Th. Spool operating the Boom Extension. THIS SECTION WILL NOT apply to the OPTIONAL ELECTRONIC JOYSTICK CONTROLS. This Section mostly shows the 4 Spool Valve, The 5 Spool Valve is mainly the same with the 5 Spool operating the Hydraulic Door option on the Rotary head or the Boom Extension Cylinder on the 28-ft Model. The Standard Tandem (Dual) Pump System is Shown, there is a Single Pump System Option available. The Single Pump only supplies the Hydraulics for the Cutter Head Motor and the Tractor Hydraulic System is used to supply the Boom Cylinder movements. The Schematic is very much the same except the Cylinder Control Valve Hose connections are run to and from the tractor instead of the way they are shown in the Schematic on the next page. (See System Schematic drawings for Pump Repair Section) 2003 Alamo Group Inc. 61

62 CYLINDER CONTROL OPERATION System Schematic (Typical 17' through 23' with 4 Spool Valve) Hyd. Pump Swing Cyl. Lift Cyl Dipper Cyl. Tilt Cyl. Control Valve Motor Control Valve Motor Return 3 Hyd. Tank 5 M 1 M 2 4 Motor Pressure 2 Filter Mainframe Figure 31 Hydraulic Motor 2003 Alamo Group Inc. 62

63 CYLINDER CONTROL OPERATION Cylinder Hydraulic Control Circuit: (See Figure 31 & 32) Hydraulic power for the cylinder control circuit is taken from the second (smaller) stage of the hydraulic pump. Oil is supplied through hose 2 to the four (or five) spool control valve where it is directed to the appropriate cylinder through the cylinder hoses. All of the cylinders are double acting. The system is protected from excessive pressure by an adjustable pressure relief valve located on the inlet section of the valve. The pressure relief valve is factory set at 2000 PSI for the 17, 20, & 23 foot booms and to 2500 PSI on the 28 foot booms. In addition, at least 3 individual cylinder circuits are protected by a non-adjustable work port relief valve (See Specifications). One way restrictors are added to the valve sections such that the return flow from the cylinders when performing gravity aided function will slow the flow of return oil and allow for a more controllable movement of the boom. See the specifications for size of restriction and location. Oil is returned from the valve through hose #3 to the main frame where it then passes through hose 4 into the 10-micron return filter and into the tank. The valve utilized on the A-Boom mowers to facilitate the control of the boom movement functions is either a 4 or 5 spool, open center, sectional, manually operated valve. The manual operation is performed with the use of normal directly attached valve handles or through the use of cables and remote mechanical levers. Although similar in appearance, each valve section is specifically designed to perform the specified function for which it is assigned. Some of the major components are shown in figure33. Spool Detent Assembly Control cable Attachment Pressure Work Port Reliefs Main Relief Figure 32 Return 2003 Alamo Group Inc. 63

64 CYLINDER CONTROL OPERATION Return Pressure One Way Restrictors "B' Side Ports Inlet Cover "A" Side Ports Handle Figure 33 Swing Lift Dipper Tilt End Cap Cylinder Hydraulic Control Cicuit: (Continued from previous page) The location and rated pressures of each section relief settings and restrictions are listed in the specifications section. Likewise, each work port relief spring cap is stamped to indicate the pressure setting. Control Valve Spool in Neutral Position Check Valves Pressure Pasage Return Passage (Tank) Return Passage (Tank) Figure 34 Parallel Passage When the spool is in the neutral position (Figure 34), oil from the pump is available at the parallel passage. Oil is also available at the pressure passage, however, its flow is blocked by a plug in the end cap section. The oil travels through all of the valve sections by way of the parallel passage until it reaches the end cap where it is simply directed to the tank passages which travel through the valve sections and back to the oil supply tank. The oil in the system is under very low pressure due to the lack of load or restriction Alamo Group Inc. 64

65 CYLINDER CONTROL OPERATION Control Valve Spool - Spool Function Activated Flow In Check Valves Flow Out Pressure Passage Return Passage To Tank Figure 35 Parallel Passage When the spool is shifted in either direction (Figure 35), the flow of oil through the parallel passage is blocked. This forces the oil to travel through the pressure passage by way of the inlet cap. This pressurized oil overcomes the check valve spring and is allowed to flow to the cylinder. The opposite check valve is prevented from opening due to the closed passage at the spool. Likewise, a passage is opened to the tank cavity to allow the returning oil to flow freely to tank. Work Port Relief Operation: (See Figure 36 & 37) Most of the valve sections of the A-Boom control valve utilize work port relief cartridges (Figure 17) to protect the system while the spool is in the neutral position. When the spool is in neutral, the work port relief proceeds breakaway protection of the circuit from over pressure due to inadvertent loading of the cylinder such as from impact with a solid object. As indicated in figure 36, the pressurized oil is also present at the work port relief when the spool is shifted from the neutral position to operate the cylinder. In this instance the oil will be relieved at the work port relief set pressure rather than the higher main relief pressure. The work port relief is actuated when the pressurized oil overcomes the work port piston spring pressure and unseats the work port piston. The oil is then allowed to pass through the center of the piston and relieve to the tank port. The work port relief pressure adjustment is set at the factory to provide the maximum control of boom movement without sacrificing safety. Adjustment of the work port relief pressure is not recommended. The Work Port Relief components are shown in Figure 37. Note: The figure does not show the check valve piston or spring Alamo Group Inc. 65

66 CYLINDER CONTROL OPERATION Work Port Relief Operation Work Port Relief Spool Spool Detent Assembly Tank Port Figure 36 Spring Cap Spring Shims Piston Spring Work Port Relief Cartridge Figure Alamo Group Inc. 66

67 CYLINDER CONTROL OPERATION Anti-Cavitation Check / Work Port Relief Operation: (See Figure 38 & 39) Both of the Swing Functions of the A-Boom Control Valve utilize Work Port relief Valves which incorporate Anti-Cavitation Check Valves (Figure 38) Cylinder Port Check Valve Tank Port Pressure Port Work Port Relief Figure 38 Anti Cavitation Piston Spring Anti-Cavitation Cartridge Anti-Cavitation Check Valves are used to supply make up Oil from the Return Tank Port to the Cylinder during gravity assisted operation of the Cylinder. This prevents the possibility of the entry of Air into the circuit due to the negative pressure created while the Cylinder is operating. The Negative Pressure created by the movement of the Cylinder overcomes the Anti- Cavitation Spring Pressure and allows the Oil at the Tank Port to travel through the Work Port Relief Piston to the Cylinder Port. Figure 39 shows the Assembled components installed in a cutaway section of the valve. Check Valves One Way Flow Restrictors Work Port Relief Figure 39 Work Port Relief w/ Anti-Cavitation Check Spool 2003 Alamo Group Inc. 67

68 CYLINDER CONTROL OPERATION Control Circuit Main Relief Valve Operation: (See Figure 40) The control circuit is protected from over pressurization with the use of the Main Pressure Relief Valve located in the inlet port of the Control Valve Assembly. (Figure 40) Those sections of the control valve assembly which utilize Work Port Relief s will relieve pressure at the work port setting. The Main Relief is usually set slightly higher than the work port relief s and will protect the entire circuit (rather than an individual section) from the possibility of damage due to over pressurization. Spring Shims Main Relief Cartridge Spring Housing Acorn Nut Lock Nut Figure 40 Piston Spring Adjustment Piston Adjustment Bolt Pressure in excess of the set pressure of the main relief spring will overcome the spring tension and unseat the piston. This allows the pressurized oil to travel directly to tank. Once pressure is reduced to below the set pressure of the spring the piston will reseat to the cartridge and seal the flow of oil to the tank. Main Relief valve assembly utilizes springs which are specifically designed to maintain an ideal pressure setting. All control valve main relief s for the A-Boom mowers are factory pre-set at 2500 PSI. (2400 to 2600 PSI is OK) It is not intended for Relief valve to be reset in the field. Changing Relief Setting can cause serious damage to system from over heating to excessive pressure damage. Main relief pressure can be checked by installing a pressure gauge (at least 6000-PSI Gauge recommended) in the pressure inlet line to the control valve. Pressure in excess of 3000PSI will cause severe damage to the circuit components. The Main relief is factory set to the specified relief pressure to obtain the best possible function of the boom movement without sacrificing safety. Adjustment to the main relief is not recommended Alamo Group Inc. 68

69 CONTROL CABLE OPERATION REMOTE CABLE OPERATION AND INSTALLATION Remote operation of the boom movement control valve can be achieved with the use of cables and remote actuator handles. The remote operation system is standard equipment on cab tractor units and can be installed on ROPS tractors as well (See Figure 41). Four cable lengths are available and should be ordered based on the length required to reach from the valve to the Operator s location with out binding or kinking. Cable lengths are limited to 48,60,72 and 102 inches. To install the cables to the valve, each valve section will require a cable installation kit (4 kits for a 4-spool valve, 5 kits for a 5-spool valve etc.). Each individual valve connection kit can be ordered using part number Figure 41 displays the contents of each kit. Flange Flat Washers Flange Bolts Lock Washers Flange Sleeve Connecting Pin Retaining Pin Spacer Rings Cable Eye Fitting Cable Eye Jam Nut Figure 41 Cable (Valve End Shown - Not included with connection Kit) Turn the Jam Nut and the Flange/ Sleeve Assembly onto the threaded cable end to the entire length of the threads. (See Figure 42) Figure Alamo Group Inc. 69

70 CONTROL CABLE OPERATION Turn the cable eye Jam nut on the threaded cable end until it bottoms. Thread the Cable Eye onto the cable end until it bottoms on the cable. Turn the eye to align with the spool end and secure the jam nut against the cable eye. (See Figure 43). Figure 43 Slide the cable eye into the slot in the spool and align the holes. Insert the connection pin and install the retaining pin into the hole in the connecting pin and secure by bending both ears of the retaining pin back and around the connecting pin. (See Figure 44). Figure 44 With the cable attached to the valve, turn the Flange/Sleeve Assembly back onto the threaded cable end until it is flush with the valve face. When turning on the assembly, make sure that the valve spool remains in the neutral position. (See Figure 45). Figure 45 Tighten the Jam Nut onto the Flange/Sleeve Assembly to lock it into position. (See Figure 46) Figure Alamo Group Inc. 70

71 CONTROL CABLE OPERATION Tighten the Flange into position using the two allen head screws. Use a flat washer to support a lock washer on each bolt. (See Figure 47) Interference will occur between the Flange/Sleeve Assembly and the casting of the Inlet Section on the Valve Section next to the Inlet Section. To compensate, the provided shims should be placed on the Flange/Sleeve Assembly under the flange (See Figure 48) Each cable is controlled by the operator with the use of single axis control handle assemblies. A single control handle assembly is required to operate each individual valve section. The control handle assemblies are ordered as PN Figure 47 Figure 48 Control Assembly - Controller End - Installation Procedure: Each controller assembly comes fully assembled. All required hardware etc. is included. The control cables are not included with the control handles and should be ordered separately (See Figure 49) Figure 49 To attach the cable, manipulate the controller handle so that the attachment nut is exposed as shown. Remove the lower most nut and screw from the controller housing. Thread the cable nut into the controller attachment nut and tighten. (See Figure 50) Figure Alamo Group Inc. 71

72 CONTROL CABLE OPERATION Allow the controller handle to return to neutral. Slide the cable guide tube into the control housing and reinstall and tighten the housing screw. Check the operation of the spool, cable and controller. Some adjustment at the valve end may be required too ensure that the spool returns to neutral when the controller is in the neutral position. (See Figure 51) Figure 51 The control lever assemblies utilize a small spring to make up for free play in the cable to valve connection. The control valve spool spring provides the centering capabilities of the controller and the valve spool. Lack of centering at the controller is normally attributed to poor adjustment at the valve to cable connection or binding of the cables due to poor routing Alamo Group Inc. 72

73 Optional Control Valve / Joystick Control There is a 4 Spool or a 5 Spool Valve Available depending on Model and head Application, ON 28 ft. Model 5 th Spool works Extension Cylinder and on other Models with 5 th Spool it will operate the Optional Hydraulic Door on the Rotary Head. All other Models have a 4 Spool Valve. Most information in this section is directed at the 5 Spool valve, It will apply to the 4 Spool Valve also 2003 Alamo Group Inc. 73

74 CONTROL VALVE - WIRING (Used 1998 & Up) Pressure Port Tank Port Inlet Section P T 5 Spool Valve (Handles Shown as Illistration Only) A A A B B B Swing Lift Dipper A A B B Tilt Door or Boom Ext. Starter Solenoid (Brown) Solenoid Lock Valve 1 H R Voltage Supply (Red) Ground (Black) Clamp Junction Box (Joystick) : Swing 2 : Lift 3 : Dipper 4 : Tilt 5 : Door Pump Solenoid Connector FIGURE Alamo Group Inc. 74

75 CONTROL VALVE - OPERATION HYDRAULIC FUNCTIONS: The Hydraulic Functions of the Machete Boom Mower are controlled by a Pilot operated Electrically Actuated Control Valve. GENERAL OPERATION: This Section addresses the method of operation of the electrical part of controls. The function of the Hydraulic Valve itself will be covered in another Section. Three Functions, The Lift, The Dipper and the Swing are "Proportional" meaning that the Speed of operation can be slowed down or Sped up according to the position of the Joystick Control. The Door and Tilt Functions are "On" or "Off" only, Meaning that their speed of operation is dependent upon the volume of Oil Flowing through the Circuit and cannot be controlled by the Joystick position. In Our application the Oil Volume varies with the Tractor Engine Speed. SPECIFIC OPERATION: (Figure 53) The Electrical Power to operate the Circuits is obtained from a Switched and Fused Tractor Voltage Source. This means that the Electrical Power Wire to the Joystick Controller should only be connected to a Wire that has Voltage when the ignition is in the "On" Position. If Connection of the Joystick Controller is to a constant current source it will cause power drain on Battery and eventually Battery Failure. Furthermore the Master Switch on the Joystick Console (Figure 55) must be in the "On" position to allow for the operation of any of the Control Functions. To achieve Electrical Proportional Actuation, The main Spool Position is adjusted so that it corresponds to an Electrical signal sent from the Joystick Controller. The Position of the Joystick is Electrically sensed by a Coil and Magnet located in the Joystick Assembly which sends the positioning information to the electric controller in the Valve. The Signal from the Joystick is converted by the electronic Controller into Hydraulic Pressure by activating a series of Hydraulic Valves. These Valves direct the Standby or Pilot Pressure Oil to the proper end of the Spool to cause it to move. Likewise the position of the Spool is converted in the Spool position transducer to feedback signal. This Signal is registered by the electronic controller which will activate the series of valves as needed to move the spool in either direction until the spool is positioned in accordance with the location of the Joystick. An equilibrium between the Joystick and feedback signal is the end result. Electric Controller Electric Signal for Joystick Controller Pilot Pressure B A Control Valve Segment Handle is shown for Illustration Only FIGURE 53 Spool Positioning Valves Spool Position Transducer 2003 Alamo Group Inc. 75

76 CONTROL VALVE - OPERATION HYDRAULIC LOCK VALVE: (Head Tilt Function) An Electric Solenoid Operated Hydraulic Lock Valve (Figure 54) is incorporated in the Head Tilt Function to prevent excessive (Head Lift Cylinder) leak down during storage or transportation. The Solenoid which operates this valve is normally in the Locked position until Head Lowering function is actuated at Joystick. When Joystick is actuated to lower Head an electric signal is sent to solenoid to open Lock valve. When the function to raise the Head is activated there is no electric signal from Joystick. The pressure against the valve when head is being raised will force Valve open like a relief Valve allowing Oil to pass through it. If this valve will not open it could stop head from lifting or dropping. The valve is plumbed into the Hydraulic Circuitry of the Head Tilt Function and is located near the Control Valve. Hydraulic Lock Valve FIGURE 54 ELECTRIC SIGNALS: Electrical Signals are sent to the Controllers etc. through a Wiring Harness, The Harness is supplied with a one way connector at the Joystick Console Box (So it can not be installed Wrong). Connectors are supplied for each electric valve controller connection, These are labeled (with Letter code A,B,C etc.) for the function which they are connected. The Plug will only fit together one way and should always have right connections. BUT if the terminals within this Plug are moved around or the connections at the valve end are changed then the Plug would still be connected the same way and be Wrong. If any connections are removed they MUST be placed back in the same order they came out of. (SEE FIGURE 55 and 56) See Figure 6 for Plug Connection (Letter Code) & Terminal locations, Also the Wiring Schematic, BUT NOTE on the Wiring Schematic it WILL be the actual location of Wires (Letter Codes ABC etc.), They are listed to enable the wiring diagram to be drawn with as few lines crossing each other as possible for illustration purposes. See Figure 6 for actual Wire locations in Plug. USE WIRE SCHEMATIC PIN LOCATION IN PLUG TO MAKE CONECTIONS IN ACTUAL PLUG. DO NOT CHANGE LOCATIONS OF PINS AND/OR WIRES IN PLUGS, THEY MUST BE CONNECTEDTHE SAME WHEN REPLACED OR THE SYSTEM WILL MALFUNCTION AND THIS COULD ALSO DAMAGE JOYSTICK CONTROLLER COMPONENTS Alamo Group Inc. 76

77 CONTROL VALVE - JOYSTICK JOYSTICK FUNCTIONS: (Figure 55) To operate a function the following series of events must work. 1. The Joystick Controller is moved in the correct direction the required distance, During its movement an electrical signal is sent to the electric Controller in the proper Valve Section of the Control Valve. 2. The Electric Controller sends an electrical signal, which causes the Proportional Control Valves to actuate the proper amount based on the signal from the Controller. EXAMPLE: Valves 1 & 3 allow Pilot Pressure Oil to flow to the corresponding end of the Spool, Thus causing it to move. Valves 2 & 4 allow the Oil from the opposite end of the Spool to return to the Tank. (NOTE: Lift, Swing and Dipper functions are Proportional, Door and Tilt functions are ON or Off Only, See later section for explanation of Proportional). 3. The Spool position Transducer sends an electrical signal to the Electronic Controller which indicates the position of the Spool. 4. The Electronic Controller will continue to adjust the Valves (1-4) in order to maintain an equilibrium between the Joystick signal and the feedback signal. 5. Reaction time from the time the Joystick is moved until the Spool moves is approximately 300 milliseconds. 6. The Rocker Type Switch on top of the Joystick is spring centered 3-function switch (Figure 55). When used alone the Rocker Switch controls the Head Tilt function, When used in conjunction with the Trigger Switch the Rocker Switch opens and closes the Door, Both of these functions are NOT controlled Proportionally. When the Toggle Switch is activated, The electrical signal fully opens either Valve 1 or 3 and fully closes either valve 2 or 4 in the correct Valve Section depending on which way the Spool needs to travel. The Electronic Controller and the Spool position Transducer are not included in these functions. 7. Earlier Model Joysticks Master Switch was a 2 Push/Pull Switch type. Later Models have one Push/Pull Switch with a Momentary Pull Start Switch built in to it and a Lighted Rocker Master Switch. Trigger Switch Pistol Grip Handle Switch Fuse Master Switch FIGURE 55 Rocker Switch Motor Start Stop Switch Joystick Functions Rocker Switch Only Push Right = Tilt Down Push Left = Tilt Up Rocker & Trigger Switch Push Right = Door Close Push Left = Door Open Pistol Grip Handle Switch Push Front = Lift Down Pull Back = Lift Up Push Right = Dipper Up Push Left = Dipper Down Rotate Right = Swing Out Rotate Left = Swing In 2003 Alamo Group Inc. 77

78 CONTROL VALVE - JOYSTICK JOYSTICK TROUBLE SHOOTING: The Joystick Wiring Harness has 2 wire connections to link Machete to Tractor Power Supply (12 Volt DC). One red colored wire (for Positive Connection) and 1 Black colored wire (for Ground Connection). These wires will provide power to start the Front Auxilary Pump that runs the Cutting Head Motor Circuit and power to operate the 5 spool Valve Electrical Circuits. The Hydraulics to operate 5 Spool valve is furnished from Tractor Hydraulic System through the Tractors Internal Hydraulics. The Joystick Wiring Harness also has 2 other wires that must connect to Tractor; these are 2 Brown colored wires. These wires connect in to form the Safety Link in the Tractor Start Circuit to prevent the Tractor Engine from being started when the Machete Electrical Circuit is energized. These wires (Brown Colored) connect the Starter relay Circuit of the Tractor to the Master On / Off Switch (Rocker Switch on later models) on the Joystick Console of the Machete. Caution: These 2 wires (Brown Colored) are to be spliced into Tractor Starter Relay Wire (approximately 3 ) behind Starter Switch (normally Key Switch). DO NOT splice wires (Brown Colored) any further from Starter Switch than 3, if further than 3" it may cause electrical interference in other tractor electrical operations when the Motor Circuit is engaged. With the Switch (Keyed Switch) of tractor in the On position and the Rocker Master Switch on Joystick Console in the On position a Green Light (on Master Switch) should be on. (Note: Early models did not have a Lighted Master Switch only a Push / Pull Switch). This green light indicates that electrical power is available to the five movement control circuits of the Valve, and to the start system of front pump as well as start circuit of Motor. To Check this Current at Switch (Master or Motor Stop Start Switch) it can be done with a test light or Voltmeter. VALVE CONTROLS CONNECTION TROUBLE SHOOTING: 1. Proportional Controlled Functions, Only the Swing, Lift and Dipper Functions are Proportional Controlled, Therefore only these three functions will show progressive readings. The Tilt and Door Functions are On or Off, when checking keep track of which connection is being check, as it will make a difference in reading on voltmeter 2. All Connections are marked on plug where they plug onto Valve (See Figure 56) 3. Make sure Tractor Engine is off and cannot be started while you are working on it. 4. Relieve Any Hydraulic Pressure, Make sure any Hydraulic Pressure in any Lines or Cylinders has been relieved and Mower / Boom are resting on the Ground completely. This should be done by working the Manual Overrides on Valve to be sure pressures are relieved. 5. Turn on Ignition Switch of Tractor to the On position (But DO NOT Start Engine) 6. Switch on the Master Rocker Switch (Push / Pull on older models) to the On position. 7. Remove the Din connector from the control Valve Section being tested to check voltage. 8. The Spade type Pins will be on the Section of the Valve and the plug will have slots where it plugs on, Each of these connectors have numbers at the slot to ID which connections (see Figure 5) connect where, these plugs cannot be reversed, will only plug on one way. 9. Voltage from the No. 1 Slot, Positive (12 Volt DC), Voltage will depend on Battery condition, it cannot exceed the amount of the voltage in the battery and should not be less than Battery Voltage when Joystick Switch is activated, So always Know what voltage is in Battery. (See Figure 56) 2003 Alamo Group Inc. 78

79 CONTROL VALVE - JOYSTICK JOYSTICK TROUBLE SHOOTING: VALVE CONTROLS CONNECTION TROUBLE SHOOTING: (Continued) 10. Voltage from the NO. 2 Slot, Positive (12 Volt DC) Voltage should be 1/2 of what reading at Slot No. 1 is. With Voltmeter connected to the No. 2 Slot of Plug and the Joystick in Neutral (Centered) position begins moving Joystick and watch Voltmeter, (be sure you are moving Joystick to Match functions being checked). The Voltage should rise as Proportional to the movement of Joystick (Proportional Sections Only) and on or off on sections without proportional functions. (See Figure 56) 11. Tilt Function, The Tilt Section incorporates a Lock Out Solenoid on the down function side that operates on 12 Volts, See previous page (Figure 54) for this Lock Out Solenoid Valve 12. Emergency Field Test, Can be performed without a Voltage Meter, But it is always best to use a Voltmeter for electrical testing. NEVER use an extra 12 Volt hot wire to supply current to connections for testing Valve or Joystick connections or components as it would damage components. Emergency Field Test, if in a remote location and you do not have a Volt Meter, You can test the Joystick and Harness by temporally relocating (swapping) the plugs on the Valve to make another action performs a different function. This will tell if the problem is in Joystick or connections. Also in an emergency situation this method could be performed to get unit in transport position or use method in next step. Note: be sure to move any swapped connection back to their original location when diagnosing a problem. 13. Mechanical Valve Test, This test will tell if problem is in Valve or electrical Circuit. This can also be used to put unit in a transport position or to move unit in emergency situations. There is a manual override on the valve that will allow you to move the Components (Boom, Head & Etc.) Manually. Follow the following steps. A. Use extreme caution while performing this operation, Know where every one around you are at all the time! DO NOT do this if you are not experienced with the functions of unit, Go back and learn Functions. B. Shut Tractor Engine Off. C. Turn Off Master Switch on Joystick Console, This will turn off all electric function including Front Hydraulic Motor. D. Make sure no one is near Tractor, Boom or Head. E. Locate Control Valve, It will be mounted on Side Rail of earlier models or in Front at Front Pump on later models. F. Remove all covers required to gain access to Valve. G. Restart Tractor Engine (DO NOT Turn on Joystick Console Master Switch). H. Go to Valve and look for a Hex Bolt Head sticking out of each valve section on the opposite side of valve from the electrical connection at Valve. Older Models this was a 1/2 Wrench size (old style Apitech Valve with 10 Plugs at Valve, 5 plugs on each side of Valve) and on the later models it is a 9 mm Wrench size (later Valve has 5 Plug at Valve, all 5 are on 1 side of Valve). I. Using Wrench as a Handle move Wrench to activate Valve section needed to move component you want to move, Then go on to the next Valve section and move it Alamo Group Inc. 79

80 CONTROL VALVE - JOYSTICK PLUG # 3 # 1 # 2 Grnd Numbered Slots on "DIN" Plugs at Valve (5) (Only On Units with 5 Plug Harness, Late Model) # 1 = Positive, 12 Volts DC # 2 = Positive, Should be 1/2 of voltage of # 1 # 3 = This Slot is not used in this application Grnd = Negative, Common Ground (long Slot) FIGURE 56 PIN PATTERN OF HARNESS PLUG & PLUG AT JOYSTICK CONSOLE Below (Figure 57) is ths actual Pattern of Pins in Plug at Joystick Console and the Pattern for plug on Wiring Harness. In Wire schematic drawing this Pattern is the same for Illustration of Wire Routing, Some Wires cross each other in illustration but actualy run along side each other in actual Harness. In the illustrations notice some pins are connected together. Use Plug patterns in Wire Schematic to Connect plugs is OK. ACTUAL PIN PATTERN Wide Notch Narrow Notch X W V H G U F J B A E T K C D S L R P M N Narrow Notch 2003 Alamo Group Inc. 80 FIGURE 57

81 CONTROL VALVE - JOYSTICK PLUG B + Positive X-Output Joystick Console Plug (Old Style) w/2 Push / Pull Switches FIGURE 58 W Danfoss Command Circuit (Joystick) 1 J Dbl Trigger Switch - Negative M Y-Output C Z-Output K Violet Red Wht/Violet Rocker Switches Red Wht/Blk 2 S R Grn 3 4 P N Valve B 6 5 M L A D F H X 8 7 Push/Pull Motor Switch G Push/Pull Master Switch B Wht/Red Gry/Blk Org/Blk Brn/Blk T E 12 A Red Actual Pin Location IS SHOWN for Plug in this illustration, See Figure 6 Wide Notch (1) Narrow Notch (2) X W V H G F U J B A E T K C D S L R M P N 2003 Alamo Group Inc. 81

82 Wht/Violet Ign Master Switch Grnd CONTROL VALVE - JOYSTICK PLUG Joystick (New Style) w/ Push/Pull Motor Switch & Rocker Master Switch Dbl Trigger Switches Danfoss Command Circuit (Joystick) B J D C K + Positive B Z-Output Wht/Blk D B X X X 2 5 B - Negatve Y-Output X-Output Wht/Red Violet Red Grey/Blk Rocker Switch Org/Blk S 2 1 R Grn J D C K B T E G 3 Brn/Blk 4 N P 5 Yel 6 D 8 7 B FIGURE 59 Red X D Acc T Pwr Start Motor Relay Motor Push / Pull Switch With Momentary Start D 10 AMP Wide Notch (1) H J B K C L M Actual Pin Location IS SHOWN in this Illustration, See Figure 6 Narrow Notch (2) X W V G F U A E T D S R P N 2003 Alamo Group Inc. 82

83 CONTROL VALVE - WIRE HARNESS PLUG Actual Pin Location in Plug Illustrated B (+) 12V Narrow Notch (2) K L Wire Harness Plug (New Style) J M Wide Notch (1) H C B N X D G A P W R E F V S U T FIGURE 60 T E G Start Solenoid Loop A D (-) Grnd Piston Pump Solenoid H R Blk Red Blk Blk Red Red Blk Red Blk Soleniod Lock Valve Red J L U C F V K M W R H S N X P Grnd Grnd Grnd Grnd Grnd SWING LIFT DIPPER TILT DOOR 2003 Alamo Group Inc. 83

84 CONTROL VALVE - HYDRAULIC CONTROL VALVES: (See Figure 61) The Alamo A-Boom Optional Hydraulic Control Valve is an Electro-Hydraulic (Electric over Hydraulic) Valve. The Valve is designed to utilize Oil from the Tractors Hydraulic System. This is basically considered a Selector Valve. Since the Tractor System is the Source of Hydraulic Supply (Hydraulic Pressure). The Hydraulic Control Valve must be compatible with the type Tractor System being utilized. There are two types of Tractor Hydraulic System available to be used (Note: in some cases even these two type systems can vary from Tractor to Tractor Model, and make connections different. See original Mount Kit Instruction for Connecting Hydraulic Supply from Tractor to Valve). Type 1. Type 2. Load Sensing (Closed Center) Constant Pressure with Flow on demand. Fixed Displacement (Open Center) Continuos Flow with Pressure on demand Valve Shown Below use 1998 & Up, it has 5 Plugs on Wire Harness that plug onto Valve. Old Style Valve used 1997 & Down had 10 Plugs on wire Harness, 5 on each side of Valve. Also the late Model has an added Filter Assembly (P/N ) which was added to protect Valve from contamination from Tractor Hydraulic System. This is a Spin on type Filter. Pressure Port Tank Port Pressure Gauge Port P T Inlet Section 5 Spool Valve (Handles Shown as Illistration Only) A A A A A B B B B B Swing Lift Dipper Tilt Door (This Valve Used 1998 & Up) FIGURE Alamo Group Inc. 84

85 CONTROL VALVE - HYDRAULIC CONTROL VALVE COMPONENTS: Fixed Displacement Valve End Cap The Control Valve for Both Type Systems (Load Sense or Fixed Displacement) consists of the same basic components. The Difference between the Control Valves for the two systems involves the components in the Inlet Section. The Inlet Section (End Cap) of the Fixed Displacement (Open Center) Valve (Figure 62) contains the following components. 1. Pressure Bypass Adjustment Spool 2. Pilot Reducing Valve 3. Pressure Relief Valve 4. Load Sense Passage Plug FIXED DISPLACEMENT VALVE END CAP Tank Port ("T") Pressure Relief Pilot Reducing Valve Pressure Port ("P") Pressure Gauge Port Plug Shuttle Valve Circuit FIGURE 62 Pressure Bypass Adjustment Spool When the Tractor is Started and the Main Spool in the 5 Sections of the Control Valve are in The Neutral (Centered) Position, Oil Flows from the Pump, Through connection P across the pressure bypass adjustment spool to the Tank. The Oil Flow which is led across the Pressure Bypass Adjustment Spool determines the Pump Pressure. (Pump Pressure at the Neutral Position will be equal to Standby Pressure). When one or more of the Main Spools are activated, the Load Pressure is fed through the Shuttle (or Load Sense) Valve Circuit to the Spring Chamber behind the Pressure Bypass Adjustment Spool. This completely or partially closes the connection to Tank; This allows Oil Pressure to flow to Cylinders when needed. The Pilot Reducing Valve maintains Standby (Pilot) Oil Pressure to the Proportional Control System (200 to 250 PSI) 2003 Alamo Group Inc. 85

86 CONTROL VALVE - HYDRAULIC CONTROL VALVE COMPONENTS: Load Sensing Valve End Cap The Control Valve for Both Type Systems (Load Sense or Fixed Displacement) consists of the same basic components. The Difference between the Control Valves for the two systems involves the components in the Inlet Section. The Inlet Section (End Cap) of the Load Sensing (Closed Center) Valve (Figure 63) contains the following components. 1. Pressure Bypass Adjustment Spool 2. Pilot Reducing Valve 3. Pressure Relief Valve 4. Load Sense Passage Outer Plug 5. Load Sense Orifice LOAD SENSING VALVE END CAP Tank Port ("T") Pressure Relief Pilot Reducing Valve Pressure Port ("P") Pressure Gauge Port Orfice FIGURE 63 Load Sense Signal Plug Pressure Bypass Adjustment Spool The Load Sensing Valve (Closed Center) Version, An Orifice with an Outer Plug are used in place of the Plug which was used in the Fixed Displacement (Open Center) Version. Therefore the Pressure Adjustment Spool will only open to Tank when the Pressure in the Pressure Port P exceeds the value of the Pressure relief. The Load Sense Signal or Load Pressure is led to the Tractor Pump Regulator via the Load Sense Connection. In the Neutral Position the Pump Control sets the Displacement so that leakage in the system is compensated for and the Standby (Pilot) Pressure is maintained (approx. 200 to 250 PSI). When a Main Spool is activated, The Pump Regulator will adjust the displacement so that the set differential pressure between the Pressure Port P and the Load Sense Signal pressure is maintained Alamo Group Inc. 86

87 CONTROL VALVE - HYDRAULIC CONTROL VALVE COMPONENTS: Valve Section Components Each of the 5 Valve Sections (Figure 64 & 65) contains the following Components. Note: Handles shown in Figure 13 & 14 are not on Valves, They are shown as Illustration Only, On Actual Valve Section there will be a Hex Head sticking out here, 1/2" Wrench for older Valves (10 Plug Harness) and a 9 mm Wrench for later Valves (5 Plug Harness). The Later Style Valve (5 Plug) Shown in Figure Segment Compensating Spool 2. Anti-Cavitation Check / Work Port Relief Valve 3. Manual Over Ride Control 4. Mechanical Flow Limiters 5. Main Flow Control Spool 6. Shuttle valve B A Pilot Pressure to the Proportional Control System Anti-Cavitation / Work Port Relief Valve Manual Control Handle Illustration Only Main Spool Shuttle Valve Segment Compensation Spool Load Sense Connection Ports Pressure Port FIGURE 64 Mechanical Flow Limiters SEGMENT COPENSATING SPOOL, Pressurized Oil must pass by the segment Pressure Compensating Spool before it is used by the Cylinders. The Compensating Spool uses Load Sense and Spring Pressure to maintain constant pressure drop across the Main spool, Both when the Load changes and when a Segment with a higher load pressure is activated. Anti-Cavitation Check / Work Port Relief Valves, Work Port Relief Valves are installed in the Swing, Lift and Dipper Circuits to limit the max pressure in those particular circuits to a lower pressure than the Main System Relief. The Anti-Cavitation Check Valve allows Oil to be taken from the return (Tank T Port) galley of the Valve when needed to prevent Cavitation of Cylinder. The Tilt and Door Valve Sections do not contain these valves. Main Flow Control Spools, The Flow Control Spools work in conjunction with the Valve Body to direct the flow of Oil to the Cylinders. The spool is actuated by Pilot Oil Pressure, which is controlled by the Proportional Control System. It can also be Mechanically operated with the use of an external Lever or Wrench. Spools cannot be interchanged in the Valve Section due to the special individual designs of Spools. Maximum Stroke Adjusters are pre-set at the factory and will not need Adjusting. Load Sense Shuttle Valve, The Load Sense Shuttle Valve located in each Section insures that the Load Sense Signal from the Valve Section with the highest Pressure is sent through the Load sense Line Alamo Group Inc. 87

88 CONTROL VALVE - HYDRAULIC FIGURE Manual Control Handle f/ Illustration Only B 8 A Alamo Group Inc. 88

89 CONTROL VALVE - HYDRAULIC Item Description 1 Pressure Relief 2 Pilot Reducing Valve 3 Load Sense signal 4 Pressure Gauge Port 5 Signal From Joystick 6 Orfice = Closed Center Plug = Open Center 7 Pressure Bypass Adjustment Spool 8 Plug 9 Electric Controller 10 Spool Position Signal Item Description 11 Pilot Pressure Flow 12 Anti-Cavitaion / Work Port Relief Valve 13 Pilot Pressure Control valve 14 Main Spool Position Transducer 15 Shuttle valve 16 Segment Compenstaion Spool 17 Pressure Port 18 Mechanical Flow Limiters 19 Main Spool 20 Manual Control Handle (illustration Only) 2003 Alamo Group Inc. 89

90 CONTROL VALVE - LOAD SENSING GENERAL INFORMATION: Load Sensing Valve The Load Sensing (Closed Centered) Systems are Commonly used on Tractors that may employ either Fixed Displacement or Variable Displacement Pumps. The Load Sense Feature may control Pump Output or in the case of the Fixed Displacement Pump, Simply control delivery to the control Valve returning surplus Oil to the tank. The Goal of either System is to reduce wasted energy, wear and tear from pumping Oil under Pressure when there is no demand on the system. For the Purposes of this Manual, A Load Sense System will be defined as any system that varies the Flow of Oil to Control Valve based on a demand signal sent through a separate Load Sense Circuit, Closed Center System may or may not be load sensing systems. ENGINE RUNNING AND ALL FLOW CONTROL VALVES CENTERED: (See Figure 66) Oil from the Pump enters the Control Valve at the P (Pressure) Port on the Inlet Section (End Cap) and is available at each Flow Control Spool, The Pilot Reducing Cartridge and the Main Relief Valve. Oil flow is blocked by the Flow Control Spools, The Proportional Control System Valves and the Main Relief Valves. Pressure at Neutral will normally be referred to a Standby Pressure and will be at least 200 to 250 PSI in order to maintain Pilot Pressure. Oil passes through the Pilot Reducing Cartridge and is blocked at each Proportional Control Valve. The Pilot Reducing Valve maintains 200 to 250 PSI in the Pilot Circuit. The Main Relief is located in the Inlet Section (End Cap) of the Valve and limits the Pressure in the P Port to a maximum 2700 PSI. The Load Sense Circuit is connected to the Return T Circuit when all Spools are in the Neutral (centered) Position. With the Flow Control spools in their Neutral (centered) position, Oil Flows to and from the Cylinder is blocked by the Spool. The centering of the Spool connects the Load Sense circuit to the Return T Galley in the Control Valve. Since there is no Load Sense Signal being sent to the Pump, The Pump only delivers enough Oil to maintain Pilot Pressure Alamo Group Inc. 90

91 CONTROL VALVE - LOAD SENSING Pressure Relief Pilot Reducing Valve Return to Tank "T" Load Sense Signal Pressure Bypass Adjustment Spool Plug, Closed Center Pilot Pressure Oil 1 3 B A Valve is Shown In Neutral (Centered) Position Anti - Cavitation / Work Port Relief Valve Mechanical Flow Limiters 2 4 Segment Compensation Spool Main Spool FIGURE Alamo Group Inc. 91

92 CONTROL VALVE - LOAD SENSING ENGINE RUNNING AND VALVE FUNCTION ACTIVATED: (See Figure 67) When a function is selected and actuated by the controller, The Proportional Control System directs the Pilot Pressure Oil to move the Main Spool in its bore. Two actions resulting from the Main Spool Shifting in its bore now takes place. The Shifting of the Spool opens a passage to connect one end of the selected Cylinder to Pressure ( P ) Galley and connect the other end to the Return ( T ) Galley. The Shifting Spool also connects the Load Sense Circuit to the Pressure ( P ) Circuit. The Pressure Signal is sent to the Pump Control System, which increases the Oil Flow to the Control valve. The Pressure present in the ( P ) circuit and the Load Sense Circuit is the same and is created by the Load on the Cylinder. (NOTE: The Load Sense Signal Shown in Figure 16 is an internal passage in Valve, it is shown here on the outside for illustration onlr and cannot be seen if actually looking at valve). Before the Pressurized Oil reaches the Flow Control Spool, it must first pass through the Segment Compensation Spool. The Compensating Spool uses Load Sense and Spring Pressure to maintain constant pressure drop across the Main spool, Both when the Load changes and when a Segment with a higher load pressure is activated. The maximum Pressure in the Swing, Lift and Dipper Circuits is controlled by the settings of the Work Port Relief Valves of these Circuits. These Settings may be different for opposite ends of the same Cylinder or Circuit. The Cartridge also incorporates Anti - Cavitation Check Valves to provide make up Oil if required. These Valves will open to allow Oil from the Tank Galley to enter the Cylinder whenever there is no more Oil being demanded by a Cylinder than is supplied (Such as with the Lowering Function) in order to prevent Cavitation. Proportional Control of the Lift, Dipper and Swing Functions is achieved through the Proportional Control System of each Section (Tilt and Door Functions DO NOT have Proportional Control, they are Open or Closed only). When an Electrical Signal is sent from the Joystick to the Electric Controller in the Valve, The Pilot Pressured Oil is then allowed to flow to either end of the Spool thus causing it to shift. The amount Pilot Pressured Oil to either end of Spool is varied with the Pilot Oil Control Valve by the Electric Controller there by controlling the distance the Spool Shifts. This in turn controls the volume of Oil sent to the Cylinders and consequently, the speed of actuation of the Cylinders. The Tilt and Door Functions (While not Proportionally Controlled) are controlled by Pilot Oil Control Valves. However instead of opening or closing based on the Joystick position, these valves will fully Open (or Close) when activated. When the Function is returned to Neutral at the Joystick, The electrical current to the Valve Controller is stopped. Therefore the Pilot Oil Control Valves return to their normal positions and the flow of Pilot Pressure Oil to the Main Spool is stopped. The Springs on the Main Spool returns the Spool to its Neutral (Centered) position. When the Spool is centered, The Load Sense Circuit is connected to the Tank ( T ) Galley. With no Load Sense Signal, Pump returns to minimum Alamo Group Inc. 92

93 CONTROL VALVE - LOAD SENSING Return to Tank ("T") Pressure Relief Pilot Reducing Valve Pump Pressure ("P") Load Sense Signal to Pump Load Sense Signal Valve is Shown with Valve Function Activated Position Signal From Joystick Plug, Closed center Pilot Pressure Oil B A Pressure Bypass Adjustment Spool Anti - Cavitation / Work Port Relief Valve Mechanical Flow Limiters Segment Compensation Spool This is internal passage in Valve, Shown on outside for illustration only Main Spool FIGURE Alamo Group Inc. 93

94 CONTROL VALVE - FIXED DISPLACEMENT GENERAL INFORMATION: Fixed Displacement Valve The Fixed Displacement (Open Centered) Systems Control Valve is designed to be used on tractors that DO NOT have Load Sense (Closed Centered) Hydraulic Systems. ENGINE RUNNING AND ALL FLOW CONTROL VALVES CENTERED: (See Figure 68) Oil from the Pump enters the Control Valve at the P (Pressure) Port on the Inlet Section (End Cap), If there are no other Hydraulic functions being used; all of the flow from the Fixed Displacement Pump must go through the Control Valve. The Flow of Oil is blocked by the Flow Control Spools in each Valve Section, The Main Relief Valve, The Proportional Control System valves, The Load Sense Passage Plug and the Bypass Adjustment Valve. The first Circuit to be charged is the Pilot Circuit, Oil passes through the Pilot Reducing Cartridge which limits the Pressure in the Circuit to approximately 200 PSI. After the Pilot Circuit is charged, Additional Oil being pumped into the Valve increases the pressure in the pressure ( P ) Circuit. When in Neutral, The Pressure in the pressure ( P ) Circuit is limited to approximately 215 PSI by the Pressure Bypass Adjustment Valve Spring. When the Pressure in the ( P ) circuit is enough to overcome the force of the Bypass Spring, the Bypass Spool is shifted in its bore, Opening a passage between the Pump Oil ( P ) Circuit and the Return ( T ) Circuit. The Bypass Spool maintains enough pressure (Pilot Pressure) in the System to actuate the Flow Control Spools and returns any surplus Oil to Tank. When the Flow Control Spools are centered (Neutral), the Load Sense Passage works in conjunction with the Bypass Spring to limit the Main System Pressure in Circuit ( P ). Since there is no pressure in the Load Sense Passage in Neutral (Centered) the force of the Spring is the only factor determining System Pressure. NOTE: The Load Sense Passage shown in figure 17 is an internal passage inside of Valve and cannot be seen if looking at Valve, It is shown here outside Valve as Illustration Only Alamo Group Inc. 94

95 CONTROL VALVE - FIXED DISPLACEMENT Pressure Relief Return To Tank ("T") Pilot Reducing Valve Pressure From Pump ("P") Load sense Signal Plug Pilot Pressure Oil B A Pessure Bypass Adjustment Spool Anti - Cavitation / Work Port Relief Valve Mechanical Flow Limiters Segment Compensation Spool Main Spool FIGURE Alamo Group Inc. 95

96 CONTROL VALVE - FIXED DISPLACEMENT ENGINE RUNNING AND VALVE FUNCTION ACTIVATED: (See Figure 69) When a function is selected and actuated by the Controller, The Proportional Control System directs the Pilot Pressure Oil to move the Main Spool in its bore. Two actions resulting from the Main Spool Shifting in its bore now take place. The Shifting Spool opens a Passage to connect one end of the selected Cylinder to the Pressure ( P) Galley and connect the other end to the Return ( T ) Galley. The Shifting Spool also allows the Load Signal created by gravity acting on the Cylinder to connect to the Spring end of the Pressure Bypass Adjusting Spool. This acts with the Spools spring to close the Passage to the Tank ( T ), and allows the correct amount of Oil to travel to the Cylinders. Based on the Load Sense Pressure, The Pressure Bypass Adjustment Spool will allow only the Oil needed at the Cylinder in accordance with the Controllers Position. Any excess Oil will be allowed to return to Tank ( T ). The Pressure present in the ( P ) Circuit and the Load Sense Circuit is the same and is created by the Load on the Cylinder. Before the Pressurized Oil reaches the Flow Control Main Spool, It must first pass through the Segment Compensation Spool, this Spool maintains a constant pressure differential (Flow) between the Supply Pressure and the Cylinder Pressure at the Flow Control Main Spool. (Simple Explanation: Function of Segment Spool is to keep a constant even pressure to Main Spool so Cylinder cannot suck in Air). The maximum Pressure in the Swing, Lift and Dipper Circuits is controlled by the settings of the Work Port Relief Valves for these Circuits. These settings may be different for opposite ends of the same Cylinder or Circuit. The Cartridge also incorporate Anti - Cavitation Check Valves to provide make up Oil if required. These Valves will open to allow Oil from the tank Galley to enter the Cylinder when ever there is no more Oil being demanded by a Cylinder than is supplied (Such as with Lowering function) in order to prevent Cavitation. Proportional Control of the Lift, Dipper and Swing Functions is achieved through the Proportional Control System of each section. When an electrical signal is sent from the Joystick to the Electric Controller in the Valve, The Pilot Pressured Oil is then allowed to flow to either end of the Spool thus causing it to shift. The amount of Pilot Pressured Oil to either end of Spool is varied with the Pilot Oil Control Valve by the Electric Controller there by controlling the distance the Spool Shifts. This in turn controls the volume of Oil sent to the Cylinders and consequently, the Speed of activation of the Cylinders. The Tilt and Door Function, While not proportionally controlled are controlled by Pilot Oil Control Valves. However instead of opening or closing based on Joystick Position, These Valve will fully open or fully closed when activated, Tilt and Door Functional are not proportional they are open full or closed full only. When the Function is returned to Neutral at the Joystick, The Electrical current to the Valve Controller is stopped. There fore the Pilot Oil Control Valves return to their normal positions and the Flow of Pilot Pressure Oil to the Main Spool is stopped. The Springs on the Main Spool returns the Spool to its centered (Neutral) Position. When the Spool is centered the Load Sense Signal stops. With no Load Sense Signal present the Pressure Bypass Adjustment Spool allows most of the Oil in the Pressure ( P ) Port to return to the Tank ( T ). The Pilot Reducing Valve retains Pilot (Standby) Pressure in the Valve Alamo Group Inc. 96

97 CONTROL VALVE - FIXED DISPLACEMENT Tank Return ("T") Pressure Relief Pilot Reducing Valve Pressure From Pump ("P") Load Sense Signal Valve Shown with Function Activated Position Signal From The Joystick 1 2 Plug Pilot Pressure Oil B A Pressure Bypass Adjustment Spool Anti - Cavitation / Work Port Relief Valve Mechanical Flow Limiters 3 4 Segment Compensation Spool Load Sense passage is internaly in Valve, Shown outside for Illustration Main Spool FIGURE Alamo Group Inc. 97

98 NOTES 2003 Alamo Group Inc. 98

99 Standard Handle or Remote Cable Operated Control Valve Trouble Shooting Section 2003 Alamo Group Inc. 99

100 VALVE TROUBLE SHOOTING Single Pump System Schematic (Typical 17' through 23' with 4 Spool Valve Shown, w/ Rotary Head Hydraulic Door Option and the 28' will have a 5 spool Valve ) Single Hyd. Pump Tractor Hydraulic Pressure Supply Line Swing Cyl. Lift Cyl Dipper Cyl. Tilt Cyl. Control Valve Return to Tractor Hydraulic System Motor Control Valve Motor Return 3 Hyd. Tank M 1 Motor Pressure 5 M Filter Mainframe Hydraulic Motor 2003 Alamo Group Inc. 100

101 VALVE TROUBLE SHOOTING Tandem Pump System Schematic (Typical 17' through 23' with 4 Spool Valve Shown, w/ Rotary Head Hydraulic Door Option and the 28' will have a 5 spool Valve ) Tandem Hyd. Pump Swing Cyl. Lift Cyl Dipper Cyl. Tilt Cyl. Control Valve Motor Control Valve Motor Return 3 Hyd. Tank 5 M 1 M 2 4 Motor Pressure 2 Filter Mainframe Hydraulic Motor 2003 Alamo Group Inc. 101

102 VALVE TROUBLE SHOOTING - TESTING MECHANICAL CONTROL VALVE HYDRAULIC SYSTEM - POSITIONING - TEST PROCEDURES NOTE: The A-Boom Standard remote Cable Control Valve is equipped Cable Actuated controls for the Control Valve. The Hydraulics is operated manually through the movement in Cables. It must be determined if problem is in Cable Controls, therefore all Cable control components should be checked before the Valve. IMPORTANT NOTE: 1. Safety is the most important beginning of Test. You MUST be totally in control of Tractor and You re surrounding area before beginning any test, there must not be other people in area when Tractor is started and mower is being tested, If you have an assistant always know where your Assistant is before you do anything. Only you should be able to start Tractor, Keep the Key with you, do not leave it in Tractor. 2. Repairing a failed Component is not always repairing the Cause of a failure, When making repairs always check all associated components because one component can be the cause of another component failure. INFORMATION COLLECTION: Any information on Unit from operator will be helpful. 1. What is Model Unit, Size, Type Head, Type Tractor it is mounted on etc? 2. What is not working correctly? In as much detail as possible. 3. Has this malfunction existed for some time, just start suddenly, continuos malfunction or off and on, when does malfunctions occur. 4. Did this malfunction result from an earlier malfunction? What if any repairs, adjustment, modifications or any changes to any components have been made to unit recently. (Repairs - Maintenance - Accidents - Operator Change) 5. Have all the obvious items been checked, Oil Levels (Tractor & Unit Reservoirs), Electrical Supply (Dead Battery, Loose connections, etc.) 6. Does the malfunction affect all circuits, one, two or more? 7. Does malfunction affect both sides of the same function or just one (Example Lift & Lower, in or out, etc) 8. Does malfunction happen when Cold or Hot, only Cold or only Hot, more when Cold than Hot, more when Hot than Cold etc. 9. What Conditions? What is Unit doing when malfunction occurs, running at low RPM, High RPM, heavy Cutting, light Cutting, Level Ground, Slope Angle etc. 10. Any information that will help determine what may be causing the Malfunction or to pin point the location of the malfunction. VISUAL TEST: 1. Do Not Start Tractor till all visual inspections are done. Check All Fluid Levels (Fluid Levels should be checked with oil warm and with all components filled with Oil from operation), Remove any bolt on / Slip on Cover that prevent visual inspection of general condition of components. Look for any Broken Components, Missing Components, Loose Components, Oil Leaks, Damaged Components. Look for any thing that is obvious to cause a problem. 2. Replace any missing / broken components, tighten any loose components, repair any Oil Leaks before beginning any further test Alamo Group Inc. 102

103 VALVE TROUBLE SHOOTING - TESTING OPERATIONAL TEST: 1. Visual Test should have been done already, If not go back one page and perform visual test now. Pump and/or Valve covers should be removed. 2. There are two different types of Optional Pump Systems offered. A. One type is a Tandem Pump (Double Pump) where the first section (larger Section) supplies the Heads Motor Hydraulics Pressure and the Second Section (Smaller Section) Supplies the Control Valve Hydraulics Pressure. B. Second type is a Single Pump which only supplies the Head Motor Hydraulic Only, The Control Valve Hydraulic Pressure is supplied using Tractors internal Hydraulic System when Single Pump is used. You need to determine which type you have. 3. With Tractor Engine running operate each Circuit, Paying close attention to everything the unit does or does not do. 4. The Engine speed should drop slightly (the Sound Change) when the Valve spool moves and the Pump comes under a load, If the Engine sound does not change when the Circuit is activated, it is an indication that there is no load being placed on Pump. 5. Observe each movement of the Cable controls throughout its complete range of movement. Check the Cylinder speeds; Look for Jerky operation, the Cylinder should respond smoothly to the movement of the control valve controls. Look for time delay between movement of Controls and movement of Cylinders. 6. After checking each function, attempt to duplicate the malfunction described by Operator, Using the information gathered in the Operator Interview. If you are not able to get machine to malfunction; see if operator can get the machine to malfunction. 7. When the Malfunction occurs, take note of all conditions that exist during the time of the malfunction, Some things to take note of are, A. Engine Speed or Sound. B. Position of Articulating Members. C. Operating Temperature D. Length of time Unit has been running E. Position of Control Levers before and during malfunction. F. Position and Condition of Tractor G. Any other condition you might notice. 8. Duplicate the conditions that existed when the malfunction occurred to determine if the malfunction would occur every time that the same conditions exist. Try different combinations of conditions to determine which conditions actually affect the malfunction and which ones just happened to be there when the malfunction occurred Alamo Group Inc. 103

104 VALVE TROUBLE SHOOTING - TESTING Pressure & Flow Supply Test: Handle or Cable Operated Control Valve This test should be performed while the malfunction is occurring. This Test is used when one or more functions are inoperative (either constant or intermittent). This test will use the Hydraulic Schematic on previous page for reference points. If you have a Double Pump System this test will work for the Front or Rear Mounted Tandem Pump. If you have a Single Pump System it will be the Tractor Hydraulics you are testing. See Specification Section under Test Equipment Need for type Flow Meter required to perform this test. 1. If only one or some functions of Valve are not working it is easiest to check the Relief Valve for that section, It could be a Relief Valve or an O-Ring Seal of a Relief Valve. See the charts on the next page to determine what Relief Pressures should be and if Section has its own Relief or uses a System Relief. 2. If No Function works, It is easiest to visually check Main Relief Valve on Control Valve, It could be the Relief Valve or an O-Ring Seal for the Relief Valve. If the relief is OK go on to next step. 3. Install Flow Meter in System in Line # 7 (See Pump System Schematic). This will require all Flow to move through Flow Meter. The purpose of this test is to make sure Pump is producing sufficient Flow and Pressure. Make Sure that Restrictor Valve of Flow Meter is in the Full Open Position and that all line connections are tight. See Fitting Chart in Specification Section for proper Torque for Fittings. Do not over tighten fittings. 4. Safety first, make sure area is clear of danger to other Persons and property before starting any test. Start Tractor, you should have a pressure of 100-PSI (approx.) on Flow Meter Gauge, this is caused by line size, which creates restriction. At 1800 RPM you should have 8 GPM and still 100 PSI through supply line. It is not unusual for a Spike Pressure to be seen in Flow Meter Gauge when a Valve Function is first activated then drop back. If this test ok go on too next Step. If no Flow go to Pump Section. 5. Slowly turn Restrictor Valve of Flow Meter down to create Load on Pump. Close Valve slowly watching Pressure Gauge as you go, increasing Pressure in 500-PSI increments. There will be no need to exceed 2000 PSI when doing this test. GPM will drop when under pressure but should not drop below 6.8 GPM (this is 85% efficiency rating) If these test are OK go on to next step. If it is not OK go to Pump Section on Tandem Pump Option or Tractor Hydraulic (See Tractor Manufactures Testing Specifications & Requirements) on Single Section Pump System Option. 6. If only one function of Valve is not working it is easiest to visually check the Relief Valve for that section, It could be a Relief Valve or an O-Ring Seal of a Relief Valve. If Relief Valve visually check OK, you will need to test for Pressure, go on to next step. 7. See the charts on the next page to determine what Relief Pressures should be if Section has its own Relief or uses a System Relief. This can be check by connecting a Pressure Gauge to the hose of the cylinder function you are testing ( A Gauge of 5000 PSI is recommended). The Gauge should reach the recommended Check Valve Pressure If this Relief Checks OK the Problem is in The Cylinder itself, or the Cylinder or a Pivot Point could be in a bind Alamo Group Inc. 104

105 VALVE TROUBLE SHOOTING - TESTING Return Pressure One Way Restrictors "B' Side Ports Inlet Cover Handle Swing Lift Dipper Tilt "A" Side Ports End Cap Valve Ports: ( See Figure 1) Valve Ports designated as "B" Ports connect to the Rod End of the Swing and Lift Cylinder, and to the Barrel End of the Dipper and Tilt Cylinder. Valve Ports designated as "A" Ports connect to the Barrel End of Swing and Lift Cylinder, and to the Rod End of the Dipper and Tilt Cylinder. Valve Ports on 5 Spool valve will be "A" and "B" also, The 5 spool valve is used on 28' A-Boom Model and on Models with opening Door on Rotary Head Models. One Way Restrictors: (See Figure 1) The one way restrictors operate by restricting the flow returning to the Valve from the Cylinder. The illustration in Figure 1 dipicts a standard 4 Spool Valve. Machines requiring a 5 Spool Valve will have the additional section added between the Tilt and Dipper Sections. Valve Sections Function: (See Figure 1) Spool Cylinder Function Restriction Pressure "A" "B" "A" "B" "A" "B" 1 Swing Back Forward PSI 1500 PSI 2 Lift Up Down PSI 875 PSI 3 Dipper Out In PSI 875 PSI 4 Tilt Up Down Main Relief Main Relief 5 * *Extend (28') In Out 0 0 System System *Door (Rotary) Open Closed 0 0 System System Note: * The 5 th Spool is only used on the 28' Model as the extension Cylinder Control. Or when the Rotary Head Option of Mechanical Door is used on the 17' through 23' models 2003 Alamo Group Inc. 105

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107 Optional Joy Stick Control Valve Trouble Shooting Section 2003 Alamo Group Inc. 107

108 TROUBLE SHOOTING - BEGIN JOYSTICK CONTROL VALVE HYDRAULIC SYSTEM - POSITIONING - TEST PROCEDURES NOTE: The A-Boom Joystick Electronic Control Valve is equipped with manual override controls for the Control Valve. In case of Emergency Electrical failure or for testing purposes, The positioning Hydraulics can be operated manually. Refer to Isolation Test 2 for instructions or review Control Valve Section. IMPORTANT NOTE: 1. Repairing a failed Component is not always repairing the Cause of a failure, When making repairs always check all associated components because one component can be the cause of another component failure. INFORMATION COLLECTION: Any information on Unit from operator will be helpful. 1. What is Model Unit, Size, Type Head, Type Tractor it is mounted on etc? 2. What is not working correctly? In as much detail as possible. 3. Has this malfunction existed for some time, just start suddenly, continuos malfunction or off and on, when does malfunctions occur. 4. Did this malfunction result from an earlier malfunction? What if any repairs, adjustment, modifications or any changes to any components have been made to unit recently. (Repairs - Maintenance - Accidents - Operator Change) 5. Have all the obvious items been checked, Oil Levels (Tractor & Unit Reservoirs), Electrical Supply (Dead Battery, Loose connections, etc.) 6. Does the malfunction affect all circuits, one, two or more? 7. Does malfunction affect both sides of the same function or just one (Example Lift & Lower, in or out, etc) 8. Does malfunction happen when Cold or Hot, only Cold or only Hot, more when Cold than Hot, more when Hot than Cold etc. 9. What Conditions? What is Unit doing when malfunction occurs, running at low? RPM, High RPM, heavy Cutting, light Cutting, Level Ground, Slope Angle etc. 10. Any information that will help determine what may be causing the Malfunction or to pin point the location of the malfunction. VISUAL TEST: 1. Do Not Start Tractor till all visual inspections are done. Check All Fluid Levels (Fluid Levels should be checked with oil warm and with all components filled with Oil from operation), Remove any bolt on / Slip on Cover that prevent visual inspection of general condition of components. Look for any Broken Components, Missing Components, Loose Components, Oil Leaks, Damaged Components. Look for any thing that is obvious to cause a problem. 2. Replace any missing / broken components, tighten any loose components, repair any Oil Leaks before beginning any further test Alamo Group Inc. 108

109 TROUBLE SHOOTING - TESTING OPERATIONAL TEST: 1. Visual Test should have been done already, If not go back one page and perform visual test now. Pump and/or Valve covers should be removed. 2. Start Tractor Engine, When starting Machete Boom functions always listen to sound of Engine, Sound should change when Boom Hydraulics are in the working position. 3. With Tractor Engine running operate each Circuit, Paying close attention to every thing the unit does or does not do. 4. The Engine speed should drop (the Sound Change) when the Valve spool moves and the Pump comes under a load, If the Engine sound does not change when the Circuit is activated (on a Load Sense System) it is an indication that there is a possible malfunction in the Load Sense Circuit. 5. Observe each function of the Joystick control throughout its complete range of movement. Check the Cylinder speeds, Look for Jerky operation (the Cylinder should respond smoothly to the movement of the Joystick). Look for time delay between movement of Joystick and movement of Cylinders. 6. After checking each function, attempt to duplicate the malfunction described by Operator, Using the information gathered in the Operator Interview. If you are not able to get machine to malfunction, see if operator can get the machine to malfunction. 7. When the Malfunction occurs, take note of all conditions that exist during the time of the malfunction, Some things to take note of are, A. Engine Speed or Sound. B. Position of Articulating Members. C. Operating Temperature D. Length of time Unit has been running E. Position of Joystick before and during malfunction. F. Position and Condition of Tractor G. Any other condition you might notice. 8. Duplicate the conditions that existed when the malfunction occurred to determine if the malfunction will occur every time that the same conditions exist. Try different combinations of conditions to determine which conditions actually affect the malfunction and which ones just happened to be there when the malfunction occurred. ISOLATION TEST 1: 1. This test must be performed while the malfunction is occurring. This Test is used when one or more functions are inoperative (either constant or intermittent) This procedure applies to units utilizing a general application, Read directions as to which series of Valve, there are early model versions and late model versions. The following is for the late model version Alamo Group Inc. 109

110 TROUBLE SHOOTING - TESTING ISOLATION TEST 1: (Continued from previous page) 2. Re-check to make sure all fluid levels are OK. The Control Valve Cover should still be removed. Make sure that the Tractor Transmission is in Neutral and the Park Brake is set and Holding, Test Park Brake before continuing. Make sure that Boom and Cutting Head are resting on the ground. 3. With the help of an assistant, One Person stand outside the Tractor in a position to observe the Manual override control, which is 9 mm Hex head (on Later Version, 1/2" on early models) located on each Valve Section, (See Figure 70) The other person will operate the Joystick from the Operators Seat. If Manual override is not moving check the electrical connections Manual Override Control use 9 mm Hex Head Wrench 12 FIGURE While the malfunction is occurring, one person should actuate the Joystick while the other observes the manual override control for that specific function (See Figure 70). The Manual Override control should move in relation to the movement of the Joystick movement. Each Valve Section will have one of these Hex Head Overrides. 5. If the Manual Override control moves properly when the Joystick is moved: A. The Joystick is working. B. Wiring Harness is OK. C. Solenoid valve(s) are working. D. Pilot Pressure Oil is Present. E. Valve Spools are moving. F. Cause is most likely in Valves, Hoses or Cylinders Alamo Group Inc. 110

111 TROUBLE SHOOTING - TESTING ISOLATION TEST 2: 1. This Procedure applies to Units utilizing the Late Model Control Valve Assemblies used 1998 and up. 2. Re-check to make sure all fluid levels are OK. The Control Valve Cover should still be removed. Make sure that the Tractor Transmission is in Neutral and the Park Brake is set and Holding, Test Park Brake before continuing. Make sure that Boom and Cutting Head are resting on the ground. 3. Locate the manual override control on Control Valve (See Figure 71) for the Valve circuit that is malfunctioning (or you want to test). Each Section of the Valve has manual override control Manual Override Control use 9 mm Hex Head Wrench FIGURE Start the Engine and let the Engine run at least 1000 RPM 5. Using a 9 mm Open Wrench (See Figure 71) actuate the manual override controls for the Circuit that is malfunctioning. Take note of the reaction of the Circuit to all positions of the control. Also take note of the Smoothness of Spool Operation. The Spool should move smoothly. If it doesn t it can indicate contamination in the system or something wrong with Spool causing it to bind. 6. If the Circuit fails to work with the Joystick and works properly with the manual override control, The problem is in the Electrical Control Circuit, The Solenoid Valve, Joystick or Wiring Harness or Pilot Pressure. 7. If the circuit fails to work using the Manual Override Control, The Problem is in the Control Valve, Hoses or Cylinder. 8. Use this test to determine which components to test and/or trouble shoot Alamo Group Inc. 111

112 TROUBLE SHOOTING - TESTING SOLENOID VALVE TEST: (See Figure 72) 1. Using this test to determine if the Malfunction is in the Solenoid Valve Assembly after having performed Isolation Test 1 and 2. This test is used when some circuits are operating and one or more are not, The Circuit will work manually as described in Isolation Test 2 but not electrically. 2. Start with the Engine OFF and the Control Valve Cover still removed. 3. Connect the Solenoid Valves of the inoperative Valve Section to the Harness connections of a Valve section that is known to be operational (See Valve Diagram), remember some are proportional and some are not. Connect (for Testing) Swing, Lift and Dipper Functions (Proportional) or connect Door to Tilt (Non-Proportional) for testing. In other words connect (Swap) the Harness connection from Questionable Circuit with a good Circuit. 4. Operate the Joy stick function for Both swap Circuits, (NOTE: You swapped connections so the movement of Joystick one way will have a different Cylinder movement now). KEEP this different movement in Mind. 5. If the inoperative circuit begins to work now and the former function is inoperative, The problem most likely is in the Joystick Wiring Harness. 6. If the Inoperative Circuit STILL FAILS to operate, and the Known operative circuit continues to function properly, The problem is most likely in the Solenoid Valve (Providing that the Circuit functioned when Manually operated with Manual Override). NOTE: See Directions above, Disconnect connector for malfunctioning circuit and recoonect to a known operational circuit for testing. Inlet Section Pressure Port P T Tank Port A B Swing 5 Spool Valve (Handles Shown as Illistration Only) A B B Lift Dipper A B Tilt Door A B FIGURE 72 (Used 1998 & Up) 2003 Alamo Group Inc. 112

113 TROUBLE SHOOTING - TESTING No. 1 No. 2 No. 3 The Slots are numbered: Positive, 12 Volts DC Positive, Should be 1/2 Voltage of Slot No. 1 to Ground (6 Volts if 12 Volts etc.) because current is being reduced This Slot is not used at all Grd. Negative, Common Ground, A long Slot, (Not Marked ). No.1 No.3 Grd Harness Plug No.2 FIGURE 73 THE ABOVE INFORMATION IS FOR TESTING THE NEW STYLE VALVE ONLY USE A VOLT METER TO TEST. THE NEW STYLE CAN BE ID BY THE 5 PLUGSON ONE SIDE WHERE HARNESS CONNECTS TO VALVE, THE OLD STYLE HAD 10 PLUGS, 5 ON EACH SIDE> MAKE SURE IF OLD STYLE OR NEW STYLE VALVE IS USED BEFORE TESTING THIS IS IMPORTANT THE INFORMATION ON THE NEXT PAGE IS FOR TESTING OLD STYLE VALVE ONLY To ID Old Style Valve it will have 10 Plugs on Wiring Harness where it plugs on to Valve, The Newer Style Only has 5, For testing new Style see Previous Pages. DO NOT USE THESE to Test Newr Style Valves with5 Plug Harness Alamo Group Inc. 113

114 TROUBLE SHOOTING - TESTING JOYSTICK - WIRING HARNESS TEST: (See Figure 74 & 75) Old Style Valve testing 1. Perform this Test when Isolation Test 1, Isolation Test 2 and Solenoid Valve Test have been Completed and indicates that the cause of an inoperative or intermittent complaint is located in the Joystick or Harness. 2. A Handy TIP to make a tester is shown in Figure 19, To make this tool use a discarded Plug (or purchase one Locally) and wire a 12 volt bulb into it, If doing a lot of testing might want to consider making one for each connection. By making this type tester you will be able to test the positive (+) and negative (-) connection at the same time and this would allow the test to be performed by one person and decrease the chance of making a connection wrong. A normal 12 volt test Light can be used as shown in Figure 23, but this method normally requires two people to perform and Test Light Must be connected correctly. FIGURE Disconnect the Wiring Harness Connector at Valve for the inoperative Circuit at the Valve Solenoid Connection. 4. Connect the Test Tool you built (or 12 Test light) to the Harness end of the connector, (If using a test light to check a positive (+) connection be sure to ground Test Light to a good ground connection, if testing a Negative (-) connection it would be required to reverse the + to - Connection. (See Figure 22) 5. While actuating the Joystick, Test for voltage at the connect (if using Tool you Built the Bulb should light up or test light should light up). If test light comes on then this circuit is OK, If using a normal Test Light see Figure 75 both sides of connection will need to be tested; this may require an assistant (Connection for Testing Positive (+) Side Shown Below) Swing Lift Dipper TO WIRING HARNESS FIGURE Alamo Group Inc. 114

115 King Post Procedures 2003 Alamo Group Inc. 115

116 KING POST ASSEMBLY Figure 76 KING POST PARTS IDENTIFICATION Item Qty Description 1 1 King Post 2 1 Turning Arm 3 1 Main Pin Bushing 4 1 Swing Cylinder Pin 5 2 King Post Bearing, Cup & Cone 6 1 Bottom bearing Plate 7 1 Top Bearing Plate 8 1 Bearing Support Collar 9 1 Upper Bearing Seal Item Qty Description 10 1 Lower Bearing Seal 11 1 Bearing Nut Lock Washer 12 1 Bearing Nut 13 1 Cotter Pin 14 1 Grease Fitting 15 1 Lift Cylinder Pin Bushing 16 1 Swing Cylinder Pin Bushing 17 1 Turning Arm Pin 18 1 Main Frame 2003 Alamo Group Inc. 116

117 KING POST ASSEMBLY King Post Assembly Instructions: Using a suitable driver or bearing press, install the upper bearing cup as shown. (See Figure 77). Install the lower bearing cup from the underside of the king post frame. The tapered surface should face towards the ground. (See Figure 78). Figure 77 Figure 78 Install the lower bearing and Lower Seal. The seal and bearing will need to be installed together. A suitable seal installation tool and press should be utilized to avoid damage to the seal. Seal must install in correct lip direction (See Figure 79 and 80). The lip of the lower seal should face towards the ground. (See Figure 80). Figure 79 Figure Alamo Group Inc. 117

118 KING POST ASSEMBLY King Post Assembly Instructions: (Continued) Use a hoist to lift the king post up through the upper bearing bore as shown. Care should be taken to avoid damage to the king post on the upper bearing race. (See Figure 81). Lift the king post until it reaches the vertical position shown. (See Figure 82). Figure 81 Figure 82 Position the bottom bearing seal ring on top of the lower bearing. Gently lower the king post into the lower bearing and remove the hoist. (See Figure 83). Install the upper bearing seal onto the king post shaft and into the frame with the sealing lip facing towards the ground as shown. (See Figure 84). Figure 83 Figure Alamo Group Inc. 118

119 KING POST ASSEMBLY King Post Assembly Instructions: (Continued) A suitable seal installation tool should be used to avoid damage to the seal. (See Figure 85). Care should be taken to avoid pressing the seal into the housing too far. Proper installation allows the seal to be installed no more than 1/8 below the bearing race. (See Figure 86). Figure 85 Figure 86 Install the top bearing seal plate. (See Figure 87). Install the Turning Arm such that it is oriented in the correct direction to properly attach the swing cylinder. Install the Main Pin Bushing using a suitable bushing installer. Note: IT IS ESSENTIAL THAT THE SERRATED SPLIT IN THE MAIN PIN BUSHING BE ORIENTED SUCH THAT IT IS IN LINE WITH THE GREASE ZERT HOLE AS SHOWN. THIS WILL ALLOW GREASE TO REACH THE PIN DURING OPERATION AND PROVIDE PROTEC- TION FROM WEAR. (See Figure 88). Figure 87 Figure Alamo Group Inc. 119

120 KING POST ASSEMBLY King Post Assembly Instructions: (Continued) Orient the upper bearing seal plate so that the lock tab is in line with a flat surface of the turning arm. Bend the tab with a punch to lock the plate in place. (See Figure 89). Install the bearing support collar into the lower bearing seal. (See Figure 90). Figure 89 Figure 90 Install the bearing nut and locking washer (See Figure 91 & 92).Tighten the bearing nut to provide a bearing preload which allows 20 to 25 pounds of resistance to turning of the king pin. This resistance can be measured by attaching a pull type scale to the king post at the lift cylinder pin bore. The scale can be pulled to turn the king post while reading the force required on the scale. Bend one or more of the lock washer tabs into the slots of the bearing nut to lock the nut in place. Reinstall the Main Pin and the boom assembly. THOROUGHLY GREASE ALL THREE GREASE FITTINGS. Test the operation of the boom and check for problems. Figure 91 Figure Alamo Group Inc. 120

121 Spindle Assembly (Rotary Head) 2003 Alamo Group Inc. 121

122 SPINDLE ASSEMBLY Spindle Housing Assembly Procedure (Rotary Head) Fill with NLGI 000 Grease Alamo Group P/N DO NOT OVERFILL! Figure Item Qty Description 1 1 Housing 2 1 Spindle 3 1 Bearing Ring 4 1 Lower Seal Seal 5 1 Snap Ring 6 1 Lower Bearing, Cup and Cone 7 1 Upper Bearing, Cup and Cone 8 1 Stake Nut 9 1 Plug, Pressure Relief Fitting 10 1 Grease Fitting Plug Gear Oil, 1 Quart (NLGI 000) 2003 Alamo Group Inc. 122

123 SPINDLE ASSEMBLY SPINDLE HOUSING: In order to properly perform repairs to the spindle housing assembly, it must first be removed from the mower deck. (See Figure 94) 1. Remove the Blade Bar or Pan Assembly (See Blade Carrier at the end of Spindle Section) 2. Remove the hydraulic motor. Hoses can be left connected to Motor and lifted off with Motor 3. Remove the Spindle Assembly from the Mower Deck, Unbolt and remove Spindle Retaining Bolts Be certain to clamp or securely support the Spindle Housing and sub-assemblies to prevent injuries to hands and feet due to inadvertent dropping or falling. Always wear safety glasses and gloves to prevent eye and hand injury when chiseling or hammering on metal components. Hardened metal will chip un-expectedly. An assembled spindle housing is quite heavy. Use a hoist or lift to handle them safely. Always use proper lifting techniques when lifting heavy objects. Figure 94 Figure 95 SPINDLE HOUSING DIS-ASSEMBLY: Drain the oil from the Spindle Assembly. Inspect the housing for cracks or other damage, which would deem it unusable. (See Figure 94) Place a 3/16 angled chisel, parallel with and into one of the staking slots in the threaded section of the shaft. Using a hammer, drive the chisel downward until the bent part of the staking flange on the adjusting nut is bent outward and is free of the slot and threads of the shaft. This procedure is done in two places on the shaft. A new nut will be required for reassemble. (See Figure 95) If the Spindle is equipped with a locking washer, use a chisel to bend the locking tang until it is free from the slot in the nut Alamo Group Inc. 123

124 SPINDLE ASSEMBLY SPINDLE HOUSING DIS-ASSEMBLY: (Continued) Use a four pronged socket or a suitable punch and hammer to remove the shaft nut. (See Figure 96) Insert the original blade bar or pan bolts into the threaded spindle shaft. Turn the bolts until they contact the bearing ring. Rotate each bolt in a clockwise pattern 1/4 turn at a time for 2&1/2 revolutions. (See Figure 97) Figure 96 Figure 97 Remove the original bolts and replace them with 4 shanked bolts (PN ). In a clockwise pattern, rotate each bolt 1/4 turn at a time until the spindle shaft is free from the housing. (See Figure 98) In some cases it may be necessary to use a drift punch and hammer to fully dislodge the shaft. Care should be taken to avoid damage to the shaft or housing. (See Figure 99). Figure 98 Figure Alamo Group Inc. 124

125 SPINDLE ASSEMBLY SPINDLE HOUSING DIS-ASSEMBLY: (Continued) Place the housing in a suitable vise with the motor flange facing down as shown. (See Figure 100). Use a flat blade screwdriver to remove the seal retaining ring. (See Figure 101). Figure 100 Figure 101 Pry out the lower seal. BE CAREFUL NOT TO DAMAGE THE SPINDLE HOUSING. A new seal is required for rebuild of the spindle. (See Figure 102). Remove the bearing and check it for damage or excessive wear. (See Figure 103) Figure 102 Figure Alamo Group Inc. 125

126 SPINDLE ASSEMBLY SPINDLE HOUSING DIS-ASSEMBLY: (Continued) Use a suitable drift punch to remove the bearing races. BE CAREFUL NOT TO DAMAGE THE SPINDLE HOUSING. (See Figure 104), Remove and inspect the vent and filler plugs and passageways. Be sure the vent is free from clogs due to debris or paint. Always install the vent plug above the filler plug. (See Figure 105). Figure 104 Figure 105 SPINDLE HOUSING INSPECTION: Inspect the bearings and bearing cups for nicks, pitting, discoloration and wear. If any exist, replace the bearing and bearing cup. Inspect the housing for cracks, wear at the bearing cup bores, or impact damage. Replace if necessary. Inspect the spindle shaft for pulled bolt threads, cracks, adjusting nut thread damage, or machined surface damage. Replace if required. SPINDLE HOUSING ASSEMBLY: Figure 106 Figure Alamo Group Inc. 126

127 SPINDLE ASSEMBLY SPINDLE HOUSING ASSEMBLY: (Continued) If installing new bearings, be sure to install new bearing cups (races). When installing the bearing cups, make sure that they are properly seated into the housing. DO NOT DRIVE AGAINST THE BEARING SURFACE. All parts should be thouroughly cleaned. The bearing nut, the lower seal and the motor flange seal cannot be reused. Therefore, replacements should be ordered. (See Figure 106). Figure 108 Figure 109 Place a thin coat of silicone on the inside (tapered side) of the bearing ring. (See Figure 107). Place the bearing ring on the spindle shaft. The tapered surface should face downward to fit the contour of the spindle shaft. (See Figure 108). Use a piece of 2-3/4 16 gauge tubing, 8 long to drive the bearing ring down on to the spindle until the bearing ring bottoms out against the spindle. (See Figure 109).Remove any excess silicone from the spindle shaft and bearing ring. (See Figure 110). Turn the housing upside down so that the bearing seal and retaining ring may be installed. Lubricate the seal prior to installation. (See Figure 111). Figure 110 Figure Alamo Group Inc. 127

128 SPINDLE ASSEMBLY SPINDLE HOUSING ASSEMBLY: (Continued) Install the lower Bearing race and Bearing. Install the seal to approximately 1/4 from the edge of the Spindle Housing. Place the Retaining Ring in the housing on top of the seal. (See Figure 112). Using a suitable driver, EVENLY press the seal and retaining ring into the housing until the retaining ring snaps into place in the ring groove. Be sure the retaining ring is in the groove all the way around and the seal is against the retaining ring. ( See Figure 113) Figure 112 Figure 113 Place the spindle shaft with the bearing ring installed into the spindle housing. Turn the assembly over so that the housing is sitting upright and the spindle shaft is supporting the housing. (See Figure 114). Use the 2-3/4 tube to drive the lower bearing down onto the bearing ring. BE SURE THAT THE BEARING IS FULLY SEATED ONTO THE SPINDLE. If the bearing ring is not seated, or if the bearing is not properly seated against the bearing ring, the assembly will lose bearing preload and rapidly fail. (See Figure 115) Figure 114 Figure Alamo Group Inc. 128

129 SPINDLE ASSEMBLY SPINDLE HOUSING ASSEMBLY: (Continued) Fill the spindle housing with NLGI000 grease Alamo PN The proper oil level is indicated when the spindle is laying on its side and level (fill plug facing to the side). The oil level should be flush with the bottom of the oil fill hole when in this position. (See Figure 116). Install the upper bearing and race along with the bearing nut. Tighten the new Lock Nut with a 4 prong socket and hand ratchet until tight. Back the nut off until 12 to 15 INCH POUNDS of rolling resistance is achieved (See Figure 117) Figure 116 Figure 117 Use a punch to stake the bearing nut in place. Be sure to stake the nut at both slot locations. (See Figure 118). Install the new motor flange gasket. Apply a thin film of silicone to both sides of the gasket to ensure a good seal. (See Figure 119) Figure 118 Figure Alamo Group Inc. 129

130 SPINDLE ASSEMBLY SPINDLE HOUSING ASSEMBLY: (Continued) Install the spindle so that the vent and fill plugs face towards the front or rear of the mower. Install the blade bar and pan and torque the bolts to 400ftlbs. Use a suitable locking compound on the bolts. (See Figure 120) Figure 120 BLADE CARRIERS: Shown in Figure 121 and 122 are the Blade Carriers that could be used, These Carriers were used on Rotary Heads, This is Not intended to be a source of replacement parts. These are intended to be a general reference as to design and type Carriers, Options of type of Heads and Carriers on the Head makes determination as to type used. Rotary Head 2 Leaf Bar Carrier Rotary Head 1 Leaf Bar Carrier Rotary Head Pan Carrier Figure Alamo Group Inc. 130