INFORMATION & SERVICE BULLETINS

Transcription

1 Interstater Tractor Mounted Flails INFORMATION & SERVICE BULLETINS Manual P/N (01/04) Alamo Industrial P. O. Drawer Alamo Group Inc Edition

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3 BOOK INTRODUCTION INFORMATION & SERVICE BULLETINS This Book is divided into two Sections Section One - Technical Information Bulletins 1. Technical Information Bulletins: Information Bulletins are listed by Bulletin Number (Date). Example the oldest Bulletin will be listed first and the most recent bulletin will be listed last. Bulletin No = first & second digits are the month, the third & fourth digits are the day of the month and the fifth & sixth digits are the year this means, the bulletin was written on Feb, 10, If more than one bulletin was written on that day the a dash with a number will added, example -1, -2 etc. 2. Authorize Repairs: Technical Information Bulletins do not authorize any repairs to be made under warranty or any other circumstance unless specifically instructed to do so. 3. Bulletin Reference: Some Technical Information Bulletins will refer to the corresponding Service Bulletins for repairs and some are for information only. 4. Bulletin Instructions: Technical Information Bulletins should have all the instructions as to what you need, but may not have all the information needed to make an installation complete. In some cases it may be required to refer to other manuals for more complete information, this should be suggested in the Technical Information Bulletin. 5. All Technical Information Bulletins printed in this Manual will void any previously printed Bulletin. Any changes in these bulletins are the final version as of the date of this manual. Section Two - Service Bulletins 1. Service Service Bulletins are listed by Bulletin Number (Date). Example the oldest Bulletin will be listed first and the most recent bulletin will be listed last. Bulletin No = first & second digits are the Year, the third & fourth digits are the day of the month and the fifth & sixth digits are the month, this means the bulletin was written on Apr, 10, If more than one bulletin was written on that day the a dash with a number will added, example -1, -2 etc. 2. Repairs: Service Bulletins are intended to authorize only the repairs listed on It to be made under warranty or any other circumstance unless specifically instructed to do so. 3. Parts: This is the Rate at which compensation will be allowed under warranty for repair parts. 4. Labor: This is the amount of labor (hours) that are allowed to make this repair under warranty. 5. Parts Disposition: Service Bulletins list the disposition of any parts that are removed during the repair. If listed removed parts must be held awaiting return to factory if instructed to do so. 6. Termination Service bulletins show a termination date, this is the date that the Bulletin will be discontinued, Any repairs must be made and all warranty applications filed by the listed date. 7. All Service Bulletins printed in this Manual will void any previously printed Bulletin. Any changes in these bulletins are the final version as of the date of this manual Alamo Group Inc.

4 INDEX Section 1 Technical Information Bulletins Bulletin No. (Old No.) Page Date Description Information Bulletins Introduction (I-94001) /21/94... Rollers & Roller Bearing Identification (940012) /15/94... Motor High Pressure Seal Kit (953101) /31/95... Cuttershaft Bearing Setscrew /28/95... Hydraulic leak between Tank & Filter Housing /04/95... Special Optional Rollers & Bearings Available (5895-1) /08/95... Material wrapping around cuttershaft (5895-2) /08/95... Electric Flail Knife Grinder Instructions /28/95... Push - Pull Power Switch Failure /04/95... Pivot Pin Turning in Bore of Frame /08/96... Oil Leaking from New Hydraulic Cylinders /29/96... New Holland Tractor Dead Battery Problem /21/97... Flow restrictor installation in wing tilt function /29/97... Availability of Flow restrictors for Parts /29/97... Parts Manual Error (manual dated 1994) /12/98... Left Wing Remote Transport / Folding Kit /24/99... Leaking / Expanded Cooling Tubes /23/00... Cuttershaft and Cuttershaft Bearing change /19/00... Low Motor performance on Wing Motors /15/01... Universal Tractor Oil approved for Interstater use /09/01... Rebuilt Parts Availability Change Notice /21/03... Lexan Shield Availability Non-Cab Tractors 2004 Alamo Group Inc. INDEX - 1

5 INDEX Section 2 Service Bulletins Bulletin No. (Old No.) Page Date Description Service Bulletin Introduction (89-005) /15/89... Foot Guard Retaining Bolt Size Increase (89-006) /16/89... Possible Bearing Greasability Problem (89-012) /06/89... Roller Bearing Preload Problem (89-013) /06/89... Front Driveshaft Chain Coupler Installation (JD) (90-002) /13/90... Bearing Spacer on Non-Drive Side of Cuttershaft (90-017) /12/90... Valve Stand Redesign (Non Cab Tractors) (92-009) /29/92... Crankshaft Pulley Adapter Spacers (56,66,7740) (93-008) /04/93... Crankshaft Pulley Adapter Spacer (56,66,7740) (940008) /06/94... Outboard Cutter Shaft Bearing Setscrew (950015) /21/95... Crankshaft Pulley Adapter Bolts (JD 62,63 & 6400) (950005A) /18/97... Restrictors for Wing Lift Function (990003A) /27/99... New Holland T6640 & T7740 A/C Service Notice (990005A) /19/99... New Holland TS Tractor Inspection Service Notice 2004 Alamo Group Inc. INDEX - 2

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7 SECTION 1 TECHNICAL INFORMATION BULLETINS (This Book is divided into two Sections) Section One - Technical Information Bulletins 1. Technical Information Bulletins: Information Bulletins are listed by Bulletin Number (Date). Example the oldest Bulletin will be listed first and the most recent bulletin will be listed last. Bulletin No = first & second digits are the month, the third & fourth digits are the day of the month and the fifth & sixth digits are the year this means, the bulletin was written on Feb, 10, If more than one bulletin was written on that day the a dash with a number will added, example -1, -2 etc. 2. Authorize Repairs: Technical Information Bulletins do not authorize any repairs to be made under warranty or any other circumstance unless specifically instructed to do so. 3. Bulletin Reference: Some Technical Information Bulletins will refer to the corresponding Service Bulletins for repairs and some are for information only. 4. Bulletin Instructions: Technical Information Bulletins should have all the instructions as to what you need, but may not have all the information needed to make an installation complete. In some cases it may be required to refer to other manuals for more complete information, this should be suggested in the Technical Information Bulletin. 5. All Technical Information Bulletins printed in this Manual will void any previously printed Bulletins Any changes in these bulletins are the final version as of the date of this manual Alamo Group Inc. 1-1

8 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: SHD 62", 74" & 88" Flails, Versa Flail 60" & 74" Interstater 62", 74" & 88" Mott Rear Roller Assemblies (old # I-94001) Feb 21, 1994 Mott Flail Rollers & Bearing Identification: Subject: There has been several changes in the rear roller and bearings on the mot flail. Below is some information to help identify which roller and what parts (if any) are available to update the roller and bearings. This is designed to assist in identification but is not intended to replace the parts manual. Models Manufactured prior to Jan. 1987: (See Figure 1) Part No. Qty Description Roller & Brkts (88") Roller & Brkts (74") Roller & Brkts (62") Roller Shell (88") Roller Shell (74") Roller Shell (62") Tie Rod (88") Tie Rod (74") Tie Rod (62") Brg Shield Washer Bracket Roller Nut Bearing Grease Fitting Nut Figure 1 Grease Fitting Tie Rod Bearing Brg Shield Washer Bracket Roller Shell Note: if you order the old tie rod style roller shells or roller assembly with brackets, you will be shipped the current roller and bearings with a Hex Shaft and with the retrofit type bearings and brackets Alamo Group Inc. 1-2 Continued Next Page

9 Information Bulletin Continued from previous Page Models Manufactured from Jan through Oct : (See Figure 2) Part No. Qty Description Roller & Brkts (88") Roller & Brkts (74") Roller & Brkts (62") Roller Shell (88") Roller Shell (74") Roller Shell (62") Roller Nut Roller Bracket Brg & Housing Brg Only Spacer Roller Shell Bearing Bracket Spacer Nut Note: if you order the old tie rod style roller shells or roller assembly with brackets, you will be shipped the current roller and bearings with a Hex Shaft and with the retrofit type bearings and brackets. Figure 2 Retrofit Rollers for Models Manufactured from Oct and Down : (See Figure 3) Part No. Qty Description * 1 Shell Rnd Shaft (88") Shell Hex Shaft (88") * 1 Shell Rnd Shaft (74") Shell Hex Shaft (74") * 1 Shell Rnd Shaft (62") Shell Hex Shaft (62") Roller Bracket L or R Brg & Housing (Rnd) Brg & Housing (Hex) Brg Only (Rnd) Brg Only (Hex) *Note: The roller shown in figure 3 will replace the earlier rollers but the brackets and bearings Figure 3 will have to be changed also. If you are replacing an old style roller (prior to Nov. 1990) you will have to replace the Bearings, Bearing Housings and Brackets. Make certain which you have, the Hex Shaft (later) Roller or the Round Roller (earlier style), hex or round refers to the shaft where the bearings go on. The Hex shaft is the later production Alamo Group Inc. 1-3 Roller Retro-Fit Bracket Bearing & Housing Continued Next Page

10 Information Bulletin Continued from previous Page Models Manufactured Nov through Jan 1994 : (See Figure 4) Part No. Qty Description Roller & Brkt Asy (88") Roller & Brkt Asy (74") Roller & Brkt Asy (62") * 1 Shell Rnd shaft (88") * 1 Shell Rnd Shaft (74") * 1 Shell Rnd Shaft (62") Roller Bracket RH Roller Bracket LH Brg & Housing Brg Only Note: If you order a roller Bracket Assembly (with brackets and bearings), the later Hex Shaft Figure 4 type Roller will be sent. Round rollers are replacement parts only. Models Manufactured Feb and up : (See Figure 5) Part No. Qty Description Roller & Brkts (88") Roller & Brkts (74") Roller & Brkts (62") Shell Hex Shaft (88") Shell Hex Shaft (74") Shell Hex Shaft (62") Roller Bracket RH Roller Bracket LH Brg & Housing Brg Only Note: In Feb 2001 the LH & RH roller Bracket was replaced by one that will work on either side, if replacing LH or RH Bracket use P/N which fits either side TECHNICAL INFORMATION BULLETIN No This Information Bulletin updated 10/30/03 This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-4 Figure 5 Roller with Round keyed Shaft Bearing Housing with Round Bearing Roller with Hex Shaft Bearing Housing with Hex Bearing

11 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Interstaters (in Frame Colling), Versa pro, Grounds Keeper, Grass King & Hydro (old # ) Aug. 15, 1995 Motor High Pressure Seal Kit: Subject: There is a high pressure shaft seal kit available for the piston motors used on above products, kit P/N If the shaft seal has been blowing out, replace with this kit. Note: the new motors shipped in the future will have this high pressure seal already installed. Disassembly: Work in clean area, cleanliness is extremely important when repairing hydraulic components. Before disconnecting any thing, clean the entire motor area, your work area and your tools of any debris that might get into the system. Disconnect and plug hydraulic lines, remove motor from the mower. Cover the spindle where motor was removed to keep it clean. Thoroughly clean the outside of the motor, drain any oil left in mount into proper container. Remove original retaining ring from motor housing. Pry original shaft seal from the housing, take care not to damage shaft or housing. Remove original washer from housing. Assembly: Lubricate new seal adapter, O-ring and fill the snap ring groove in motor housing with lithium based # 2 grease. Install O-Ring and shaft seal into the adapter. (Seal lip should face shoulder of adapter). Install adapter in motor housing, with shaft seal side into housing first, by pressing it into place with finger pressure. Light tapping may be used, however, be careful not to cock the adapter as it is pressed by the snap ring groove, as this would cause O-Ring damage. Install the new retaining ring. Reinstall motor on machine. Run and test for operation. This document does not authorize the repair or replacement of parts under warranty Original Shaft Seal Original Retaining Ring Figure Alamo Group Inc. 1-5 Original Washer O-Ring Shaft Seal Seal Adapter Retaining Ring Seal Kit

12 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Interstaters useing SHD 62", 74", 88" and 96" (old # ) Jan. 31, 1995 New Cuttershaft Bearing Setscrew: Subject; A new square shank setscrew, (P/N ) is available to replace the dog point setscrew (P/ N ) in the Non-Drive side cuttershaft bearing. They should add additional life to the cuttershaft setscrew. They will be standard on all new mowers as soon as the parts become available. The Part Number for the bearing with the new setscrew is P/N , the part number for the bearing and housing is P/N (See Figure 1) Setscrew Outboard Cuttershaft Bearing P/N P/N Figure 1 Cuttershaft This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-6

13 TECHNICAL INFORMATION BULLETIN No Models: Interstaters with Inframe Cooling Alamo Industrial Technical Services Department Apr. 28, 1995 Hydraulic Leak Between Tank and Filter Housing: If you experience an Interstater Tank leaking between the top of the tank and the bottom of the filter housing, you have replaced the O-ring P/N (See Figure 1 item 1) and it does not correct the problem. Check the four mounting bolts P/N (See Figure 1 item 2). These should be no longer than 7/8". If they are longer they will bottom out and you will not be able to draw the housing up tight to the bottom of the tank. If longer bolts are found, select one of the three options for repair. Option # 1. Remove bolts and cut down to 7/8" long maximum. Option # 2. Add a 3/8" Narrow flatwasher under the lock washer to make bolts 7/8" long. Option # 3. Replace the bolts with 3/8" - 16 NC X 7/8" hex head bolts (P/N ). Filter Asy 1 2 Filter Sealing O-Ring Tank Figure 1 This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-7

14 TECHNICAL INFORMATION BULLETIN No Models: All Flail Mowers SHD 74" & 88" And Interstaters Alamo Industrial Technical Services Department May 4, 1995 Optional Rollers and Bearing Available: Some customers in specialized applications have requested an option be made available that would allow them to use rollers with round shafts and bearings with open housings. If the customer specifically request this, the parts that will be needed are as follows: Part No. Qty Description a/r Roller with Round Shaft 88" a/r Roller with Round Shaft 74" Bearing and Housing Asy, for 74" or 88" (bearing Only P/N ) These parts will bolt up in place of the current parts. There are no plans for a whole good option for the round shaft rollers and bearings NOTE: This is for information only. There is no allowance for warranty, labor or shipping charges to make this change. This option should only be used for customers that consider roller bearings as "throw away", expendable items and that have an exceptional maintenance program. These are typically high usage machines such as turf farms. It is believed that other applications would benifit by using the current standard hex shaft design. This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-8

15 TECHNICAL INFORMATION BULLETIN No Models: All Flail Cuttershafts Alamo Industrial Technical Services Department (old # ) May 8, 1995 Cutter Shaft Material Wrapping, Causes and Effects: Wrapping is a condition where the grass or other growth being mowed will wrap around the cuttershaft instead of being cut and mulched. This condition is caused by the cuttershaft speed being too slow. Different grasses, vines etc. cut differently and require different minimum speeds of the cuttershaft to keep it clear and free from wrapping. Tough fibrous growths are the hardest to cut without encountering wrapping and in some instances may require more than the normal cuttershaft speed of 2000 RPM. Usually 2000 RPM cuttershaft speed is enough to cut cleanly without wrapping. The cuttershaft speed may be too slow just because the tractor engine speed (in case of the selfpowered models) is being operated throttled back. The solution in such situations is to increase the throttle to recommended settings and drop to a lower ground speed gear. (See operating instructions for the particular model involved) The Cuttershaft speed may also be too low if not enough power is available to do the job. If the mower is taken into a cut too tough for the power available, the cuttershaft speed will drop. If the speed gets too low, the material will start to wrap. The wound up grass will form a big wad at the end of the cuttershaft pressing against the cutter housing end plate. This wad will act like a big friction brake. It can become so tight that it will be impossible to turn the cuttershaft without first cutting away the wad. Such a wad naturally causes the mower to pull hard. This is a situation where a lack of power is actually causing a need for more power. So much heat can be generated by a wad wrapped around the end of the cuttershaft that the bearing will actually turn blue from the heat. Naturally, such heat will destroy the bearings and seals and result in bearing failure. Even if the bearing does not fail it may get hot enough to melt the grease in the bearing housing. Once the grease is gone (it can happen as little as 15 minutes), there is nothing to keep the bearing from burning up due to a lack pf lubrication even though the bearing was just greased. The type grease recommended for hammer Knife mower bearings has a high temperature (Bulletin No. 3 dated 7/21/56) has a high temperature melting point and will stay with bearing under adverse conditions longer than ordinary greases. Bearings which fail because of above mentioned conditions are not defective in material or workmanship, and are not covered by warranty. This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-9

16 TECHNICAL INFORMATION BULLETIN No Models: Alamo Industrial Technical Services Department All Flail mowers using Mott Flail Knives (old # ) May 8, 1995 Electric Flail Knife Grinder: The Mott (Alamo Industrial) Knife grinder P/N , will sharpen all Mott Knives. The Grinder is shipped complete and ready to use. A word of caution about electrically powered tools: Never use this grinder or any other power toll while standing on a wet surface, even though the grinder has a grounded plug. Always wear and use all Safety Equipment when using power tools. The grinder is easy to use. Following is suggested method to use when sharpening Mott Flail Knives with the Mott Flail Knife Grinder/Sharpener. 1. Support all Heads with stands, Do Not get under any object only supported by hydraulic system or a hoist. Secure Tractor so it cannot be started by anyone. 2. Position the mower so knives are easily accessible and mower is well supported by stands. 3. Prevent the Cuttershaft from rotating, this can be done by clamping a bar to knife lugs and other end of bar to deck. 4. Determine which edges should be sharpened, top or bottom. Forward rotation mowers cut with the rear (Bottom) edge of the knife. Reverse rotation mowers cut with the front (Top) edge of knife. It is necessary to sharpen the edge that is used. 5. Choose proper end and side of grinder. Match the illustration on the grinder with the direction the knife tip points, as you face it. Note: Keep in mind which edge is to be sharpened. If the tip points left, hold the grinder in the left hand, If the tip points right, hold the grinder in the right hand. Note: Refer to Figure 2 for steps 5 & Use your free hand to hold the knife out away from the cuttershaft. Move the grinder so that the knife is inserted into the curved slot. Move the grinding wheel to put light pressure on the knife edge. Move the grinder back and forth, grinding more at the tip of the knife. Note: Refer to Figure 2 for steps 5 & Sharpen the knives in that row which faces the same direction. Note: after several sharpenings the knife should be tapered not notched. 8. Reverse the grinder to the use other slot to sharpen in same row which face the opposite direction. 9. Rotate cuttershaft and repeat procedure for other rows of knives until all knives are sharpened. "A" "B" "C" Sharpen Top Edge of Left Knife Sharpen Top Edge of Right Knife Knife Grinder Serial Number & Manufacturer Name 2004 Alamo Group Inc Continued Next Page

17 Left Knife Information Bulletin Continued from previous Page "B" Sharpen Top Edge of Right Knife "A" Sharpen Top Edge of "C" Mott Hammer Knife Grinder Serial No. Mott Corp. LaGrange ILL "A" Sharpen Top Edge of Left Knife Figure 2 Figure Figure 3 TECHNICAL INFORMATION BULLETIN No This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-11

18 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: All Hydraulic mowers using the Push-Pull Switch Bulletin No Sep. 28, 1995 Failures of the mower push-pull switch: Alamo has recently received reports of failures of the referenced switch. The failures modes are: (a) Knob pulls off rod. (b) Rod and Knob pulls out of switch body. Test performed on numerous switches indicates that the (b) failures are due to excessive force being applied to the knob when shutting off the mower. Specifically, the knobs are usually roughly slapped to turn the mower off. After internal parts of the switch are damaged, the rod can then be pulled out easily. The (a) failures are due to the knobs not being securely tightened. To prevent these failures from occurring, or to replace a damaged switch, use the following procedure to adjust the travel of the switch. (See attached diagram). 1. Install the switch body in the holder and tighten the nut. 2. Screw the Knob on the rod to the bottom of the thread, but do not overtighten. It will probably be necessary to hold the rod with pliers to get the knob tight, if you do use caution not to score the rod with the pliers. 3. Measure the distance (if any) between the knob and the nut. Record the measurement. 4. If a Gap exists between the knob and the nut, remove the knob. 5. Remove the nut and install the same thickness of flat washers that was measured in step 3. Install and tighten the nut> DO NOT install more washers than needed to take up the space. Flat Washer Part No or equivalent can be used. 6. Install the Knob, using Locktite or similar thread locking compound. Thread the knob on the rod all the way. Test to make sure that when the switch is "Off" (with rod pushed in) that the knob can not travel further into the switch Alamo Group Inc Continued Next Page

19 Information Bulletin Continued from previous Page WITH NUT TIGHT AND SWITCH "OFF". MEASURE THIS GAP IF ANY MOUNT PLATE IF GAP EXIST, INSTALL WASHERS OR SHIMS TO EQUAL GAP MEASURED IN STEP MOUNT PLATE KNOB SHOULD LIGHTLY CONTACT NUT WHEN PROPERLY ADJUSTED MOUNT PLATE TECHNICAL INFORMATION BULLETIN No Contact: Alamo Industrial Technical Services Department Ph; Fax; This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-13

20 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Interstater Oct. 4, 1995 Pivot Pin Turn in Bore, Prevent Wing Cutoff Switch from Working: There have recently been reports of the Pivot Pins turning in their bore. The problem seems to be confined to a small number of machines shipped from the factory in mid The problem is caused by an inadequate amount of thread on the pivot pin. The pivot pins that attach the wings to the frame should rotate with the wing as the wing is tilted. Failure of the pin to rotate will prevent the wing cutoff switches from cutting the motors off when the wing is raised. To determine if this problem exist on a machine, Torque the pivot pin retaining nut to approximately 450 ft. lbs. Tilt the wing and observe the movement of the pin. If the pin does not move with the wing, it is likely that the nut has run out of thread before tightening on the plate. If this is the case, the pivot pin will require replacement. If the bushings are also replaced, they will require reaming to fit after they have been installed, use caution not to oversize the bushings when reaming. To determine if a Pin is threaded far enough, measure from the shoulder of the pin to the FIRST FULL THREAD. That dimension must not exceed 3/4" (See Figure 1). After Installation is completed the Pivot Pin Retaining Nut must be torqued to 600 ft. lbs. Figure 1 Pin This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc /16" This Dimension must not exceed 3/4"

21 TECHNICAL INFORMATION BULLETIN No Models: Alamo Industrial Technical Services Department All Models using Single Acting Hydraulic Cylinder Apr. 8, 1996 Oil Leaking from new single Acting Hydraulic Cylinders: There have been numerous cases of the dealers and customers replacing single acting hydraulic cylinders on new machines due to oil leakage out of the vent plug in the cylinder. In many of these instances, no defect could be found in the cylinders. Further investigation has revealed that he manufacture of our cylinders is leaving oil in the cylinders after their testing. The Oil is left to help protect the interior of the cylinders during storage. When the cylinders are fully actuated, they are forcing this oil out the vent plug, causing what appears to be a leaking cylinder through the vent plug. Even the oil is cleaned off the cylinder after testing there is enough oil still inside the cylinder to bleed out when used. If you have a New Cylinder that appears to be leaking from the vent plug, The oil should be cleaned off and unit ran for a few days to a week to determine if the Cylinder is leaking, or if it is the oil that was left in the cylinder to protect it. It has been found that in some cases it has taken as much as a week for this to appear that it is not leaking. If after running and cycling the cylinder during operation and the cylinder continues to leak then the necessary repair should be performed. Cylinders that are attracting dust around them is not considered to be leaking. This dust collecting around them is considered normal. All Cylinder that are returned as leaking will be pressure tested for leakage to determine the condition of the Cylinder and its components. This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-15

22 TECHNICAL INFORMATION BULLETIN No Models: Booms Alamo Industrial Technical Services Department All New Holland Tractors with Alamo Industrial Mounted Apr. 29, 1996 Dead Batteries on New tractors: There have been several reports recently of dealers receiving machines with dead batteries, some of which could not be satisfactorily recharged. Please see the attached copy of a tag which is coming with the new tractors. The "small electrical discharge" being mentioned amounts to a constant drain on the battery. If the battery cable (+ Post) is left connected for a long enough time with the tractor inactive, the battery will become sulfated (permanently damaged) and will not accept a charge. Sulfated batteries are not warranted through the battery manufacturer. At present, the only alternative to removing the battery cable would to be install a battery disconnect switch in the negative cable, which would allow the battery to be easily isolated. These switches are available at most major tractor dealers. USE CAUTION when installing any thing on battery cables, disconnect the positive cable before installing disconnect switch and make sure after switch is installed that it is "OFF" before reconnecting Positive Cable. ATTENTION! BATTERY CARE _ + Your new Tractor has electronics which cause a very small electrical demand on the battery. If the tractor in not in use for an extended period, disconnect battery to avoid damage by excessive discharge. Recharge Battery if voltage is less than 12.3V (S.G. less than 1.140) Lataa Akku uudelleen, jos jannite on alle 12.3V (ominaispaino alle 1.140) Ricaricare la batteria se il voltaggio e inferiore a 12.3V (G.S. inferiore a 1.140) Batteria recarregavel se a voltagem for inferior a 12.3V (Gravidade especifca inferior a 1.140) Laddt de batterijweer op wanneer de voltage lager is dan 12.3V (S.G. Minder dan 1.140) Recharger la batterie si la tension est inferieure a 12.3V (Densite inferieure a 1.140) Batterie wieder aufladen. wenn spanning unter 12.3V (Spez gewicht unter IST) Recarcar la bateria si el voltage es inferior a 12.3V (S.G. inferior a ) Batteriet ma lades opp hvis spenningen er mindre enn 12.3V (Spesifikk vekt under ) Part No This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-16

23 NOTES 2004 Alamo Group Inc. 1-17

24 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Interstater Jan. 21, 1997 Flow Restrictor Orifice Installed in Valve: (Special Note: this bulletin canceled Jan 29, 1997 because of parts unavailable). Subject: Excessive wing tilt lowering speeds can cause damage to the roller bearing and tilt cylinders. To reduce the lowering speed of the wing tilt cylinders, install a one way restrictor as instructed in this bulletin. Caution: 1. Install orifice only in the two locations indicated in this bulletin. 2. Al applicable safety procedures should be followed including the use of safety glasses, reaf the operators manual be fore attempting repairs. Part Required: 2 ea. P/N restrictor Orifice Procedure: 1. Lower both the Left and Right Wings to the ground 2. Turn Tractor off and secure it safely, Engine off and Parking brake set. Tractor secured to where it can not be started without you wanting it to be. 3. Cycle all control levers on control valve to ensure that all pressure is relieved from system. 4. Clean all debris from around valv eand on hose at valve to prevent debris form entering system. 5. Disconnect the Hose that goes to the rod end of the tilt cylinder (left or right wing) at the valve. 6. Alway keep hoses and opened ports pof valve covered when disconnected to keep them clean. 7. Remove adapter from the valve, if thread sealer was used, ensure it doesn't get into system. 8. Using a flat screwdriver, install the orifice into the valve hose port (as shown in figure 1), turn untill snug, do not over tighten orifice. 9. Reinstall hose adapter and hose, tighten them properly. 10. Repaet steps above for both wings if a dual wing unit. 11. Check Oil Level in tank, visually inspect all components, run and test. Note: Check all valves to insure tha float detents are functioning properly when engaged. It is crucial that they work to prevent premature failure of the mainframe. If found to be defective replace with proper parts Alamo Group Inc Continued Next Page

25 Information Bulletin Continued from previous Page Install Orifice Here Aux Pump Return Filter Right Wing Cylinders Toward Valve Left Wing Cylinders Existing Adapter Orifice New Adapter To Tilt Cylinder (Rod End) Existing Adapter Orifice New Adapter To Tilt Cylinder (Rod End) Groove in orifice must point Toward Adapter & Hose Side Figure 1 TECHNICAL INFORMATION BULLETIN No This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-19

26 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Interstater Jan. 29, 1997 Availability of Flow Restrictor Orifice Parts: The orifice P/N which has to be installed in the interstater control valve as per Technical Information Bulletin dated Jan. 21, 1997 is no longer available. A New restrictor arrangement is currently being developed and will be ready shortly. Please disregard the Jan. 21, 1997 Technical Information bulletin regarding the installation of the above mentioned orifice restrictors. A new Technical Information Bulletin will be issued when the parts are available. This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-20

27 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Dual Wing Interstater Mowers Utilizing the Current In Deck Hydraulic Colling System (old # A) Apr 28, 1997 Interstater Parts Book Error: (Parts Book dated 1994 on the cover) The parts book for the interstater (dated 1994 on the cover) may have an error on page labeled "Lift & Tilt Cylinder". This appears on page number 6-10 in some books. The part item "7" is listed as , Plug. This is incorrect, the correct part number is , vented plug. Please change this number & description in your parts book to correct this error. It is important that this be changed because Installation of the non vented plug in the Cylinder, will cause immediate failure of the cylinder. This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-21

28 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Dual Wing Interstater Mowers Utilizing the Current In Deck Hydraulic Colling System May 12, 1998 Left Wing Remote Transport Positioning System: The Kit illustrated in Figure 1 is now available to provide for the remote operation of the left wing and tilt functions on dual wing interstater mowers of the current design. The intent of this system is to allow the operator to exit the cab of the tractor with the left wing in the down position and remotely maneuver the left wing into the transport position. This is intended to allow the unit to be parked with both wing in the folded position. The operation of the system is dependent on the 12 volt power supply of the tractor battery. This system is designed to operated independently of the tractor engine operated hydraulic pump. The system is designed with a lockable keyed switch to prevent being operated when it is parked by unauthorized people. Any future orders of the dual wing interstater mowers may be ordered with this remote system as an option. This system can also be ordered as an add on system to earlier dual wing interstaters. Instructions on the installation of the assembly on earlier units will be shipped with the Kit when ordered. The Kit is P/N , some modifications may be required but these should be illustrated in the installation instruction sheet. Tilt Rod Tilt Base Lift Rod Figure 1 This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-22

29 NOTES 2004 Alamo Group Inc. 1-23

30 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Interstaer Mowers 74" & 88" S/n less than IS and IS Nov. 24, 1999 Leak in Hydraulic Oil & Expanding Cooling Tube: Procedure to repair hydraulic leakage from the Interstater Side mount Mower Hydraulic Cooling Tubes. NOTE: There are photos of the repair procedure in the original Bulletin date 11/24/99, but because of the type and condition of them they cannot be included in this copy. A copy of the original will most likely have to be mailed on a special request basis only. Investigation of reports relating to the leakage from the hydraulic oil cooling tubes of some side mounted Interstater mowers can be the result of either expansion of the tube due to over pressurization or fatigue of the tube at the weld which connects the inner end plate support gusset to the tube on the underside of the mower deck. Over pressurization is normally the result of restrictions in the return circuit or misplacement of the hydraulic lines. The hydraulic lines must be connected so the flow of oil goes through the cooling tubes after it has gone through the motor. Weldments with leaking, expanded tubes will require replacement. However, expanded tubes which do not show indication of leakage will not present a problem. Fatigue at the inner end plate support gusset weld can be repaired with the following procedure. This procedure permanently repairs the problem by eliminating the stress raiser created by the weld which crosses the cooling tube. Procedure: 1. Units must be within the above listed serial number range for this procedure to apply, check all serial numbers prior to starting repair. 2. Prior to performance of this procedure it is necessary to thoroughly clean and inspect the Housing to ensure that the leakage is due to fatigue at the support gusset. Tubes with leakage due to impact damage or expansion cannot be repaired with this procedure. 3. Remove the effected mower deck from the tractor, Plug all hydraulic lines to keep them clean and contamination out. Remove the roller assembly from the mower. Thoroughly clean the deck of all debris and oil, Never weld or cut on mowers with oil on them. 4. Securely support the mower in an upright position with the cylinder mount plate at the lowest point (toward ground). It will not be required to remove the cuttershaft Alamo Group Inc Continued Next Page

31 Information Bulletin Continued from previous Page 5. Inspect the cooling tube for damage and the type of damage. The tube should be rectangular in shape, If it id not it has been over pressurized and cannot and should not be repaired, this expansion will have weakened the tube and it should be replaced. If tube is rectangular proceed with repair. 6. Leaks on cooling tubes emanate from the cross weld of the cylinder mount end plate support bracket. This cross weld produces a stress point which leads to a fatigue fracture due to loads created by repetitive raising and lowering of the head. 7. Carefully remove the welds which retain the gussets such that a 1/2" gap is left between the cooling tube and the gusset. Look on the under side of deck at the motor end of deck and you will see where this gusset is welded to the cooling tube. 8. Pressurize the cooling tube with air (25 lbs. psi maximum air pressure) and cover the area with soapy water solution. Resulting bubbles indicate where leakage is coming from the tube. Mark the leak well so it can be found later. Release the air pressure from the tube. 9. Weld the tube at the leaking areas, grind the welds flat and check again for leaks with air and soapy water solution. Repeat this procedure till all leaks are stopped. 10. Locate the new gusset plate P/N into position in 1/2" gap you made between the existing gusset and the cooling tube, see figure 1 for new gusset. 11. Attach the new gusset by welding up the gusset to the fold of the tube, DO NOT weld across the tube, it will weaken tube. Continue to weld the gussets on both sides BUT not across the tube. Use a 1/4" weld on gussets will be sufficient. 12. After welding is complete pressurize to tube (25 lbs. psi. maximum) and use a soapy water solution to test for leaks. If no leaks are present, reassembly the mower to the tractor frame work. Reinstall any removed components. Run and test mower for operation. Oil Cooling Tube Install New Gusset Here Weld Here On Both Sides DO NOT Weld Here Across Cooling Tube Existing Gusset TECHNICAL INFORMATION BULLETIN No This document does not authorize the repair or replacement of parts under warranty Motor End of Deck Figure 1 Figure Alamo Group Inc New Gusset Existing Gusset

32 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: Interstaer Mowers, Versa Flail Side Mount Mar. 23, 2000 Cutter Shaft and Cutter Shaft Bearing Updates: Alamo Industrial current production cuttershafts and bearings of all Interstater and Versa Flail mowers now utilize a slightly extended shaft and external locking outer bearing which utilizes two setscrews. This is an update to the previous bearing arrangement which provided one locking setscrew behind the bearing located in a keyway machined in the cuttershaft stub (shaft end). This update was initiated in an effort to improve the maintenance procedures and ensure positive retention of the bearing to the cuttershaft. The Old style Bearing (P/N ) one setscrew - bearing insert will be available for a limited time as supplies last. Replacement of the old (shorter) cuttershaft will require an updated to the longer shaft and the replacement of the cuttershaft bearings to the new design bearing (P/N ). Future cuttershaft production will eliminate the keyway required for the old bearing design. All cuttershaft part num- Style Old bers will remain unchanged. Bearing When installing the new bearing it is important that the setscrews are designed to grip onto the radius of the shaft. DO NOT install the setscrews onto a flat portion or machined groove which may be on the shaft surface. Some updated longer shafts may incorporate a keyway groove. When installing the new bearing on these shafts, the keyway should be ignored. The new bearing will not fit on an old shaft at all, the shaft is to short. Figure Alamo Group Inc Continued Next Page

33 Information Bulletin Continued from previous Page NOTES: Listed here are points of bearing difference. Figure 1 and figure 4 shows the old style bearing without the two setscrews. Figure 2 and figure 3 shows the new bearing with the two setscrews. The bearings install in the opposite direction of each other. The new bearing will not work on the old shaft because shaft is to short. New bearings setscrews do not lock into keyway, the lock on the radius of the cuttershaft New Style Bearing New Setscrew Location Figure 2 New Style Bearing This side of bearing faces out This side of bearing faces out Figure 3 Figure 4 Old Style Bearing TECHNICAL INFORMATION BULLETIN No This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-27

34 TECHNICAL INFORMATION BULLETIN No Models: Interstater with Flail Hydraulic powered Mowers Alamo Industrial Technical Services Department Apr 19, 2000 Low Motor Performance on Wing Motors: Some recently reported performance deficiencies with some Interstater wing mowers delivered this year have been diagnosed as being the result of blown pressure valve seals. Investigation revealed a problem with the machining process associated with the pressure relief valve cartridge bore in the manifold block. Symptoms of failure associated with this problem will normally be related to poor performance and loss of mowing efficiency. Diagnoses is performed by removing the pressure relief cartridge and inspecting the seals. Seals are cut during installation of the pressure relief cartridge into the manifold due to incorrect tolerances of the manifold bore. The correct repair requires the complete replacement of the manifold block. Note: Assumption in regard to the cause of reported performance problems should be avoided. A complete and correct diagnosis procedure should be performed in order to ensure the correct repair. Right Side Wing Mower Motor Left Side Wing Mower Motor Pressure Relief Manifold Block Manifold Block Pressure Relief Figure 1 This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-28

35 TECHNICAL INFORMATION BULLETIN No Models: Interstater Alamo Industrial Technical Services Department Mar. 15, 2001 Recommended Oil For Hydraulic System: Alamo Industrial received approval from the hydraulic pump and motor manufactured to use Universal tractor fluid in Interstater Units. Results from testing conducted by Alamo Industrial Engineering showed the Universal tractor Oil provided service and cooling that meets or exceeds requirements set by the hydraulic component manufacturer. All Alamo Industrial Interstaters shipped after September of 2000, were shipped with Universal Tractor Oil. Universal Tractor Oil is now approved for all Interstater Units manufactured after The operators Manual with Parts Listing, printed in 2001, calls for Dextron type II Automatic transmission Fluid. Dextron II fluid may be used, but the Universal Tractor Oil is the preferred Fluid. DO NOT mix the two oils together, This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-29

36 TECHNICAL INFORMATION BULLETIN No Models: Alamo Industrial Technical Services Department All Alamo Industrial Products are affected Apr. 9, 2001 Change in the availability of rebuilt components: This bulletin has been published to inform you of a change in the availability of rebuilt parts. In the past, rebuilt components such as pumps and motors were available for use as spare parts. That will no longer be the case. The major factor in this decision was the lack of cores that are returned from the customer. Since Alamo Industrial will no longer offer rebuilt parts an effort will be made to offer customers a complete parts listing of all components that are needed as service repairs. The most common service parts are pumps and motors will now be available for order through Alamo Industrial Customer Service Department. Likewise, a parts breakdown with Alamo Industrial part numbers will be provided. The Eaton Pumps and Motors, Danfoss Control Valves will be the first components available with such a parts breakdown. It is Our intention to provide a better and more reliable service parts system. This transition will better suit customer, and provide more timely and efficient parts delivery. This document does not authorize the repair or replacement of parts under warranty 2004 Alamo Group Inc. 1-30

37 NOTES 2004 Alamo Group Inc. 1-31

38 TECHNICAL INFORMATION BULLETIN No Alamo Industrial Technical Services Department Models: All Non-Cab Models with Expanded Metal Side Screens Retro Fit Kit P/N Oct. 21, 2003 Lexan (Polycarbonate) Shield Upgrade Kit P/N : (field Install) Alamo Industrial has designed a Lexan ( Polycarbonate) Shield that will install on the expanded metal screen currently used on the Non-Cab models. This is a retro fit kit that is designed to be customer installed over the expanded metal screen. The Lexan Sheets will require trimming and the Holes will have to be drilled in the Lexan sheets as well as through the existing expanded metal screen frame Recommended Tools: 1. Jig Saw or Circular Saw (hand held or table) equipped with plastic cutting blade. 2. Electric Hand Drill, preferably a variable Speed Drill. 3. 3/8" and 1/4" High Speed Steel Drill Bit. (Drill bit should be sharp and in good condition). 4. Measuring Tape or other measuring device. 5. Hand Wrenches for tightening Bolts, do not use air tools to tighten bolts. 6. Straight edge and marker that will write on Lexan. Lexan Shield Kit Components: (Retro-Fit Kit P/N includes: Part No. Qty Description Part No. Qty Description Lexan Sheet, Upper Lexan Sheet, Lower Bolt, Hex Head 1/4" Flatwasher, Std. 1/4" Fender Washer, 1/4" 32901C 20 Locknut, 1/4"-20 Protection of Lexan Sheets: 1. Do not remove protective sheet (Paper) from the Lexan Sheet. This will protect it while you are working with it. You can drill through this protective sheet as well as cut through it. 2. There are two Lexan Sheets sent, an upper and a lower. Identify these and mark them to designate front to rear, inside to outside because once you cut to size to match the existing Expanded Metal Screen, they cannot be turned around. Cutting these is permanent. Installation Procedure: 3. Use the measuring tape to get the measurements around your existing Expanded Metal Screen and write them down, Note there is an Upper and Lower section (See Figure 1). 4. Place the Lexan Sheets (Upper and Lower Sheets) on a clean work suface and transfer your measurements from step 1 to the the Lexan Sheets using a Pen or other marker. RE- CHECK your measurement and when certain they are correct. Cut the sheets out to match your measurements. Lightly sanding the cut edges will smooth them out and round the outer edge slightly helping to protect it. Sheets should look like sheets in Figure 2, note the holes will not be drilled in them yet. Continued Next Page 2004 Alamo Group Inc. 1-32