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Maverick Boom Mower

1. CONTROL DRAIN H zi A CONTROL SPOOL PORT A SPRING CHAMBER HORSEPOWER PRESSURE DIFFERENTIAL TORQUE COMPENSATOR ADJUSTMENT E G U RE 4 1 ADJUSTMENT ADJUSTMENT MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 30 PUMP BOOM CIRCUIT Port Sizes Dimensions Side Port Port Location MEET Outlet Port Inlet Port Control Drain Signal Port TEIT SAE 12 1 1 4 SAE 4 Bolt Flange AE 4 SAE 4 dimensions are shown in 2 Straight Thread 1116 14 Threads Standard straight Thread Straight Threat AME TSUNG Pressure Series Code 51 FO 6 200NC 7 16 20UNC Note l E 506149712 1 1 4 SAE 4 Bolt Flange ISO 6149 4 ISO 6142 4 Shown amp cimen ionen SA a clock straight Thread M10 x 1 5 Threads Standard Straight Thread Straight Threac wise pump ports A amp B delivery M27 x 2 Pressure Series Code 61 M12 x 1 5 M12 x 1 5 port amp pump controls will be on the Vent amp Fill Plug opposite side for the counter clock N P mr di E E E A Top Vie wise pump used on Maverick Boom Outlet Port A Low Signal TLC aya B Port orque Control Adjust ment 500 in Ib turn Pressure compensator adjustment 800 psi turn Inlet Port Same Both Sides This Plug amp Adjustments are opposite side of pump than is shown CW pump shown CCW pump Used 13 Spline Shaft Control Drain Front View Port A Side View A
2. eee nnn nnn nan rie Spindle Dis Assembly cera erea aerea SER SSC IOI a de ae a iin iei Re INStal Motor SS PINO noi o dC Re Install Blade BAS em seciilon Flames BOOIMN ziiso asissuzssi sbuzuzo v dun e vac x sue uc eod eaae uu x cxen d Nuus u eds Under Mount Frame Assembly FP EOIN 30 Ft Boom Hose ROING up Hydraulic Kit Hose ROUTINE ee Swing Cylinder Hose RQUIUINO ssa assa misses asus css li soda Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Index 3 Page 4 1 to 4 32 4 32 4 30 to 4 31 5 1 to 5 17 5 7 to 5 11 5 12 to 5 17 6 1 to 6 5 INDEX section Page Section 7 Possible Failure Cause 8 Solution 8 1 to 8 36 Doom Breaks Back Too ASIN ncia anerosi sis jase sad asimadas 8 4 Boom Drops When Two Functions Actuate 8 4 Boom Moves On Its Own Under Power w no function actuated 8 8 Control Valve Spool Spools Sticking ni isieseerreeerereeemo 8 5 CEBE een 8 5 Cylinder Excessive DPI nn nn end dcus ub areas 8 6 to 8 7 Slo ENKE LEG its O on rata kou Bako 8 7 Elias le oks ARNO meme ons bor es eee ao 8 8 Cylinder Moves On lts Own Under Power w no function actuated 8 8 to 8 9 Cylinder Moves Wrong Way Not the function that was actuated 8 9 Cylinder Moves intermittent all functions 8 10 Cylinder Moves Spongy or Jerky
3. 7 8 amp 7 9 Cylinder Moves Wrong Way Not the function that was actuated 7 9 Cylinder Moves intermittent all functions 7 10 Cylinder Moves Spongy or Jerky LR 7 11 Cylinder Moves Some Functions But Not AIT 7 11 amp 7 12 Cylinder Rod BEN aaa Rm 7 16 Cylinder Rod Came Out of Cylinder ss 7 16 8 7 17 Cylinder Won t Move At All No POWET eee eee eee nenene nn 7 13 Cylinder Won t Move Under Load Low Power 7 14 D CORS Oda denen ence A Ra ii 7 17 Deck Worn On Underside Cutting Head Only 7 17 amp 7 18 Hydraulic System Noise Squeal error serena 7 18 8 7 19 Hydraulic System Overheating 2 2000 0000000 een nennen 7 19 8 7 20 8 7 21 Motor dw z lo le E TTE 21 MotorinoperauvetvVohr TIR datada inicias 7 22 Motor Overheating REE EN 7 22 amp 7 23 amp 7 24 Motor Shaft Seal Leaking eeree rrenan 7 25 Motor Runs Too Slow or Slows Down Under Load 1 25 A 7 26 amp 7 27 Motor SIOPS SIOPS Under Load Je 7 27 amp 7 28 Pump Seizure Pump Locks DD boda rn o aro 7 29 Pump Wear Rapid Excessive Wear 7 30 Spindle Leaking At MOLOT EE 7 31 Spindle Leaking Around Bottom Seal 7 31 Spindle Leaking At Relief Vent 7 32 Spindle Overheating sise 7 32 Spindle Shaft Loose or Falls Out ss 7 33 Spindle Locks Up Siezes and Won t Turn 7 34 Starter On Tractor VVOMLCTAN
4. CAUSE Abrasive Contamination In Oil SOLUTION Abrasive Contaminants Dirt Iron Particles Clutch Disc Material etc in the Oil Sump System is a major contributor to all of the above internal leakage problems It is especially likely if the Positioning Hydraulics are using Cil from the Tractor Hydraulic System If the Tractor Hydraulic System is not properly maintained Materials from Gears Clutch Disc and Etc can enter the Control Valve and Cylinders causing excessive Pre mature Wear If Abrasive material Wear is found the complete system Should be flushed and cleaned On Some Later Models an additional Filter System has been added as additional Filtering of Tractor Hydraulic Oil But even this add on Filter if not maintained will run through the Filter Bypass and contaminate System KEEP FILTERS CLEAN and or Replace on a good Maintenance Schedule CAUSE Electrical Short Circuit SOLUTION Electrical short causing controls to emit electrical current even though controller is in neutral position Check all wire connections and try to determine where electrical short is Repair or replace as needed Usually this type of problem will allow drift to be rapid unless Short is through Joystick controller There should be no electrical current when Valve and Joystick are in centered neutral position Cylinder Leaks At Fittings CAUSE Loose or Wrong Fittings SOLUTION Make sure correct Fittings are installed and are torqued to correct sp
5. D C O gt L 4765 FEI 4050 PST 12 MICRON FILTER SV FILTER BYPASS SWITCH Te HAN SGLENDIO A qe m m l3 n ns and See ae SOLENOID A REAR CYLINDER r E H a aj s i m FRONT CYLINDER de A 1 un 9 12YDC FAW i i bey Lil LLJ LLI SUCTIDN STRAINER SUCTION STRAIMER m 100 MESH LOT MESH LOCK VALVE SOLENDEO E SELECTOR VALVE N ET pur O FLUID TEMERATURE SENSOR De f fi B GH 12 MICRON FILTER lav FILTER BYPASS SWITCH mnn m 8 to SD po MS J SWIVEL Si 5 DOOR SVIVEL DIGITAL Ez SVING PROPORTION LIFT PRIPDET FOMAL MEPER FROPLRYLINAL T LESCOFE PROFORTIONAL HEAD TILT DIGITAL o Service Manual 12 04 MAVERICK 2004 Alamo Group Inc Section 2 14 HYDRAULIC HOSE CONNECTIONS HYDRAULIC HOSE CODES Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some have a Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attachted to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose Always Check Hose Size Color Code a
6. eee 8 11 Cylinder Moves Some Functions But Not AI 8 11 to 8 12 Cylinder RBs 8 16 Cylinder Rod Came Out of Cylinder erre 8 16 to 8 17 Cylinder Won t Move At All No Power 8 13 Cylinder Won t Move Under Load Low Power 8 14 SOK go 01 e oa 8 17 Deck Worn On Underside Cutting Head Only nn 8 17 to 8 18 Hydraulic System Noise Squeal 8 18 to 8 19 Hydraulic System Overhedalllig iucue sosta ori 8 19 to 8 21 MOFFAT 8 21 Motor Inoperative Won t Run 8 22 Motor OVENNEAtNY sia su stonka sn hon kinnene innen a union 8 22 to 8 24 Motor Shaft Seal LEAKNG usan ca sereia nest 8 25 Motor Runs Too Slow or Slows Down Under Loadq 8 25 to 8 27 Motor Stops Stops Under L ST uendrede 8 27 to 8 28 Pump Seizure Pump Locks Up 8 29 Pump Wear Rapid Excessive Wear 8 30 Spindle Leaking ALVIO Otura 8 31 Spindle Leaking Around Bottom Seal 8 31 Spindle Leaking At Relief Vent ss 8 32 Spinde Overheating hiami eE o lo V 8 32 Spindle Shaft Loose or Falls Out 8 33 Spindle Locks Up Siezes and Won t Turn 8 34 Starter On Tractor NN 8 35 amp 8 36 Tractor Battery Dead or Low Continous Power Draining 8 36 Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Index 4 rd Section 1 Model Specifications Maverick Boom SPECIFICATIONS MAVERICK READ THIS BEFORE BEGINNING ASSEMBLY REPAIRS
7. 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 PART NUMBERS Part numbers listed in this manual are subject to change without notice as designs are made to adapter to the tractor or for a design improvement Before ordering parts ALWAYS Measure old part to make certain that is the one you will need This manual is designed to be used along with the Parts and Operators Manual Most calls received by Alamo Industrial Service can be classified into approx 6 general cat
8. POSSIBLE FAILURE CAUSE amp SOLUTIONS MAVERICK Service Manual 12 04 Section 8 1 POSSIBLE FAILURE CAUSE 8 SOLUTION Possible Failure Cause and Solution Section NOTE This Section is written to give a POSSIBLE CAUSE of a problem and the POSSIBLE SOLUTION of a problem it Is also to aid in finding problems and to correct problems There may be more than one cause to a problem as there may be more than one solution Inspection and testing by you at the Unit site can diagnose these problems This section cannot be used as absolute diagnose of a problem as well as not to give the absolute solution It can only suggest where to check and what to repair General Cracks in mowing Decks or Booms can be generally attributed to Severe Usage and or Vibration caused by an imbalance in the rotating parts It should be remembered that vibrations occur as aresultof operation when cutting Heavy Material or hitting stationary objectthat cause a component to bend break or lose pieces etc In some cases it may be the result of a design or application this is something that will have to be determined through investigation of circumstance Simply welding up a Crack will not usually yield a satisfactory repair simply welding may cause another weak spot during welding process The condition that caused crack may still be present It is usually advisable to grind down the weld and add a plate over the weld to span the site of the origina
9. Perform all Operational checks Tank Oil Level Pump Operation Control Valve Circuit Electrical Supply amp Hyd Supply All Circuits affected or only some Circuits If All Circuits will not work the Problem is most likely up stream of the control Valve or an electrical Problem Models with Joystick Controller The Following Causes are based on Only some circuits being affected Not all Circuits Load Sense Signal Not Reaching The Tractor Pump Control Remove Inspect and clean Signal Lines from Control Valve to Priority Valve Check all orfices to make sure they are clear Note it is not unusual for the debris to drain out of system with the Oil when the pressure is released or the lines are removed Everything can appear clear then be pushed back in when pressure is applied or it may never return this can be a difficult malfunction to find as well as correct This means even though it was checked once it does not mean the problem is not there Low Oil Level In Tractor Fill to Proper Level with recommended Oil See Specification Chart for recommended Oil type No Voltage to Joystick Controller Check for Voltage to Controller repair or replace as required Wiring Fuses Switches etc Faulty Joystick Controller Check for Voltage output from Controller With power to Controller and Joystick function actuated Check for Voltage at Harness end of Solenoid Valve Connector for that function that is actuated If there is no Output Vo
10. 3 k B j B f 6 y 4 Y S x E 5 LA j gt he Le SERVO CONTROLLED a PISTON MOTOR Charge Port A From Shuttle Pump l Valve to Tank Suction The Motor Circuit is engaged by two Manually Operated Switches See Figures 36 37 amp 38 in Motor Repair Section for Types Used These Switches have varied from On Off to Momentary But all have served the same purpose Closing the Switches completes a Circuit through the Solenoid The Purpose of a Solenoid is to actuate a Pump Control which actuates a Valve to turn on the Pump this has varied some over the years This movement causes the Camplate in the Pump to move Movement of the Camplate when the Pump is turning causes the length of Piston Stroke to Change Causing Oil to too be moved The Greater the Angle the longer the stroke The longer the stroke the more Oil is Pumped and the more oil pumped means the motor turns faster MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 5 MOTOR CIRCUIT PUMP ENGAGE Note The Servo Control System Changed see Note on Previous Page Movement of the Variable Displacement Pump Control Lever Figure 22 starts pump Output As Lever is rotated it moves the Spring centered Servo Control Spool first Movement of the Spool allows Charge Pump Oil pastthe Spool to one side ofthe Servo Piston Figure 22 The Pressurized Servo Piston pushed against the Camplate figure 22 causes the Camplate to rotate to a
11. BOOM ARM MOWER Published 12 04 Part No 02982288 SERVICE ATT E N C N LEA EL INSTRUCTIVO Si No Lee ingles Pida Ayuda a Alguien a Aue Si Lo Lea Para Aue le Traduzca las Medidas de Seguridad An Operators Manual was shipped with the eguipment in the Manual Canister This Operator s Manual is an integral part of the safe operation of this machine and must be maintained with the unit at all times READ UNDERSTAND and FOLLOW the Safety and Operation Instructions contained in this manual before operating the equipment If the Operator s Manual is not with the equipment contact your dealer or Alamo Industrial 830 379 1480 to obtain a Free copy before operating the eguipment ALAMO INDUSTRIAL 1502 E Walnut Seguin Texas 78155 y a ALAMO GROUP 830 379 1480 ALWAYS ON THE CUTTING EDGE 2004 Alamo Group Inc TO THE OWNER OPERATOR DEALER All implements with moving parts are potentially hazardous There is no substitute for a cautious safe minded operator who recognizes the potential hazards and follows reasonable safety practices The manufacturer has designed this implement to be used with all 1ts safety equipment properly attached to minimize the chance of accidents BEFOREYOUSTART Read the safety messages on the implement and shown in your manual Observe the rules of safety and common sense 44 DANGER FAILING TO FOLLOW SAFETY MESSAGES AND OPERATING INSTURCTIONS CAN CAUSE SERIOUS BODILY INJUR
12. Obstructions Hoses have an inner lining that can turn loose and block a hose If Assembly or Repair work has been performed recheck all connections for correct location Some may not be visible without some dis assembly Unplanned restrictions cause increased backpressure loss of usable power excess Heating of Oil and failure of Shaft Seals Restrictions can sometimes be found by measuring the temperature of the Oil or fittings at various points in circuit as heat will usually be higher atthe restriction The restriction should be located at or upstream of the increased temperature point Restrictions are sometimes caused by foreign objects that get into the system This can happen during servicing maintenance or repairs It is not uncommon to find bolts nuts plastic plugs paper or rags stuck into system when it was being repaired or assembled then forgotten about Restrictions sometimes can be a piece off of a failed component up stream or a Component such as a Hose built wrong MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 14 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Won t Move Under Load continued CAUSE Piston has come off of Rod SOLUTION This can be difficult to find If the Piston comes completely off of Rod it can be pushed to bottom of Barrel below Port Then Oil just circulates through Cylinder with little or no resistance This makes it appear there is no Pressure or valve isn t working Th
13. P1 Hose Hydraulic Pressure from Door Swivel B Port on Control Valve P2 Hose Hydraulic Return to Door Swivel A Port on Control Valve C1 Hose to Head Swivel Cylinder Base End C2 Hose to Door Cylinder Base End C3 Hose to Door Cylinder Rod End C4 Hose to Head Swivel Cylinder Rod End Electric solenoid retaing M Electric Solenoid a o These 2 threaded holes on back side for mounting diverter valve to frame Not Seen C1 Port this side Not Seen to head swivel cyl base end P1 Port Pressure from Control Valve door swivel port of control valve These 4 holes are through holes that would be used if this were a stacking valve to stack two or more valves together These holes are not used in this application C4 Port this side Not Seen to head swivel cyl rod end BS V m 3 46 L SA O JO 0 P2 Port Return to control valve door swivel port of control valve C3 Port to door cyl Rod FIGURE 18 gad MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 9 DIRECTIONAL CONTROL VALVE Control Valve Technical Information See Figure 1 amp 2 Pressures DAC LEE TON gl RR Max 4600 psi 320 bar Service Ports Max 5000 psi 350 bar Tank Connection Max 290 psi 20 bar Flow Rates Recommended Pump Connection Max 40 US gpm 150 l min Service Port with Pressure Compensator Max 2
14. Rotating Kit Assembly tem Qty Description 9 Piston Assembly 1 Spider 1 Spider Pivot 1 Retainer 1 Piston Block 3 Pins 2 Wsher 1 Spring 1 Retaining Ring CO OO YX O O1 ND gt MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 22 PUMP BOOM CIRCUIT Variable Volume Piston Pump Piggy Back Pump Boom Circuit Supply Pump The Boom Supply pump is the piggy back pump bolted to the front pump shown below is the pump with the end plate shown on different pump this is for illustration only and not a true drawing of pump FIGURE 34 Pump Specification Pump Delivery 3000 psi 1800 RPM is 15 6 GPM Max continous Pressure 3000 psi 207bar MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 23 PUMP BOOM CIRCUIT Cylinder Supply Pump Pressure Adjust If Needed opecial Note If after setting the display controls check to make certain that functions operate correctly If the Boom will not lift The Pump for the Cylinder supply may have to be adjusted This is a simple process that will require a 7 16 wrench for this adjustment and a 1 2 wrench for the locking nut Looking on the LH side of the pump there are two adjustments one has a 7 16 hex head and the other a ridged round head Only adjust the one with the hex head DO NOT adjust or change the round ridged adjustment as it is set from the factory Adjust the 7 16 hex one by turning it in till it seats com
15. See Figure 32 Set this assembly aside for now jp ga la A ED v iN 16 Install Valve Plate Coat Valve plate item 2 with a coat of grease See Figure 33 will be to hold valve plate in housing during assembly With the Barrel Hosing assembly in vise install the valve plate into it This plate must be installed with the correct side down and the correct side up See Figure 34 Note the location of the notch in OD of valve plate 17 Install Barrel Housing Clamp Bearing housing and Shaft assembly back into the vice With the barrel housing assembly turned up as shown in figure 35 Make certain the Valve plate item 2 is installed inside the barrel housing and facing the correct direction Make certain the Shims item 24 are still installed on the Bearing housing Sit the barrel housing item 1 down over the bearing housing item 6 Install the four bolts item 25 and Torgue these four bolts using an alternat ing pattern to 75 ft lbs 7 ft Ibs See Figure 36 Figure 31 Figure 32 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 15 MOTOR P N 029 9881 ASSEMBLY Motor Assembly Continued 18 Install Relief Manifold It would not have been required to remove the Relief Manifold item 28 to disassemble the motor it could have been left attached to the Barrel Housing Assembly item 1 If it was re moved inspect the O Rings item 31 and replace if nessacary The rel
16. Straight Threads do not always seal better when higher torques are used Too much torque causes distortion and may lead to leakage DO NOT over torque fittings and DO NOT allow any contami nants to enter system through fittings when installing them Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Section 1 6 SPECIFICATIONS MAVERICK 10 Special Torque Specifications Rotary Heads Motor to Spindle Housing 100 ft Ibs Spindle ODER RR 425 ft Ibs Spindle to Adjusting Nut Bearing Preload 25 in Ibs Rolling Torque Blade Bar Leaf Bolts 1 1 4 Bolts esses 2000 ft Ibs Blade Bal to Spindle BOIS Lenkene 400 ft lbs cs e A a ee eee ee 400 ft Ibs MOTO A PP See Set Up Instructions 11 TORQUE VALUES BOLTS Recommended Torque Ft Ibs amp Nm IMPORTANT Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE Component Application Torque will vary depending on what is bolted down and the type material Metal that is being bolted together Thread condition and lubrication will vary Torque settings Inch Sizes Metric Sizes ALWAYS CHECK Plain Head 3 Dashes 6 Dashes MARKINGS Not Used 10 14 14 19 ON Not Used 20 27 30 41 TOP Not Used 35 47 50 68 OF 35 47 55 75 80 108 55 75 85 115 120 163 BOLT 75 102 130 176 175 230 HEAD 105 142 170 230 240 325 OR 185 251 300 4
17. 4 4MJ 4FJX 76 Lg Yel Wht Tie Door Lift Sect n 02981828 1 Y MJ Z FJX Hose 4 4MJ 4FJX 76 Lg Grn Tie Swivel Lift Sec n 02981829 1 Y MJ Z FJX Hose 4 4MJ 4FJX 76 Lg Grn Wht Tie Swivel Lift Sec n 02981830 1 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Yel Tie Ex n Lift Sec n 02981831 1 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Yel Wht Tie Ex n Lift Sec n 02981832 1 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Red Tie Tilt Lift Sec n 02981833 1 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Red Wht Tie Tilt Lift Sec n 02981834 1 Y MJ O FJX Hose 6 6MJ GFJX 96 Lg Blu Tie Dipper Dipper Sec n 02981835 1 Y MJ P FJX Hose 6 6MJ 6FJX 96 Lg Blu Wht Tie Dipper Dipper Sec n 02981836 1 Z MJ R FJX Hose 6 6MJ GFJX 88 Lg Yel Tie Ext n Dipper Sect n 02981837 1 Z MJ Q FJX Hose 6 6MJ 6FJX 88 Lg Yel Wht Tie Ext n Dipper Sec n 02981838 1 Z MJ V FJX Hose 4 4MJ 4FJX 176 Lg Yel Tie Door Dipper Sec n 02981839 1 Z MJ U FJX Hose 4 4MJ 4FJX 176 Lg Yel Wht Tie Door Dipper Sect n 02981840 1 Z MJ X FJX Hose 4 4MJ 4FJX 176 Lg Grn Tie Swivel Dipper Sec n 02981841 1 Z MJ W FJX Hose 4 4MJ 4FJX 176 Lg Grn Wht Tie Swivel Dipper Sec n 02981842 1 Z MJ T FJX Hose 6 6MJ GFJX 176 Lg Red Tie Tilt Dipper Sec n 02981843 1 ZM S FJX Hose 6 6MJ 6FJX 176
18. 6 Spool 1 02981370 1 Valve Asy w o Fittings 2 02090800 2 Adapter Hyd Elbow 12MB 12MJ 90 3 02972177 11 Adapter Hyd Straight 10MB 6MJ 4 03200284 1 Adapter Hyd Straight 6MB 4MJ 5 02981889 1 Adapter Hyd Straight 10MB 6MJ 6 02972208 1 Valve Solenoid Asy T 02975438 1 Adapter Hyd Straight 8MB 8FJX 8 02981890 1 Adapter Hyd Straight 8MB 6MJ E E E o 3 Q L L Ei Service Connection Port B Port B Testing Port for Pilot Pressure Test PS Pump ank Pressure Return Connection Connection P1 T2 Port Load Sense Signal PL A Port A Service Port Connection MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 5 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 Four Functions The Lift The Dipper Swing and Telescope 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 Tilt and Swivel 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
19. Air in the Cylinders SOLUTION Remove Air from Cylinders by Bleeding the System Operate Cylinders and Hold at maximum stroke for several seconds Repeat several times to purge Air from Cylinder Repeat for other Cylinders till condition no longer exist CAUSE Wrong Type of Oil SOLUTION Fill to Proper Level with recommended Oil See Specification Chart for recom mended Oil type If changing Oil in Old type Unit always use most recent recommended Oil Type but do not mix types of Oil CAUSE Cold Oil SOLUTION Run Unit at low Speed until Oil warms up If Oil is to cold and flows slowly it can cause Cavitation this will damage Pump DO NOT Operate if Oil is so thick that you have this problem wait till itwarms up or move unit To a Building where Oil can warm up before operating CAUSE Faulty Pump Drive SOLUTION Inspect Pump Drive Components for wear and damage or other reason pump May not run smoothly If Pump is not smooth then Pressure will not be steady causing surges in pressure CAUSE Work Port Relief Set Too Low for Application SOLUTION Install proper work Port Relief If the Pressure needed to operate the function Can exceed the setting of the valve in certain positions it will cause the Oil to bypass causing jerky movement of the function Cylinder Moves Some Functions Work But Not All CAUSE Faulty Joystick Controller SOLUTION Check Output voltage at the harness end connector for the affected Function S
20. LC SEGMENT COMPENSATING SPOOL Pressurized Oil must pass by the segment Pres sure 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 Oilto 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
21. NOTES MAVERICK Service Manual 12 04 2004 Alamo Group lnc Section 5 18 Section 6 SPINDLE REPAIR F ROTARY MOWER MAVERICK Service Manual 12 04 Section 6 1 SPINDLE REPAIR Procedures Remove Blade Bar 1 Clean all components of Boom and Head Remove all Dirt and any other material that may contaminate components as being dis assembled or after it has been disassembled 2 Move Tractor to Level and Firm Ground Concrete Floor is Best 3 Swing the Boom to the Side of the Tractor Extend Boom out till fully extended Stand Head Up so Blade Bar is facing out away from Tractor in the folded up position 4 Fully apply the Park Brake on Tractor 5 Place all Gears in Tractor in the Neutral Position 6 Shut Off Tractor remove Key and disable Tractor so it cannot be started till you are ready to have it started 7 This procedure can be done with head connected to Boom or with it removed But if removed you will have to lift Head to remove Blade Carrier Assembly 8 Remove Blade Bar Assembly Use Caution the Blade Bar is very heavy Do Not remove the retaining bolts till it is secure to where it will not fall An easy way to support Blade Bar when removing it is to only remove 2 of the 4 retaining bolts Get 2 long bolts with same size and threads but longer than what was removed cut the heads off of these 2 longer bolts and screw them in where you removed the 2 retaining bolts This will support Blade carrier whi
22. The emergency stop switch Is mounted in the arm rest if it is not mounted in arm rest it must be mounted where operator can have access to it immediately if needed Switch Switch Mounting Nut Wire Fast 4 Depth Control Clip di Knob owitch Asy Complete Knob Plug FIGURE 20 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 16 Hydraulic Schematic P N 02981897 E uiCFON MLTER Ev FILTER ITFA 30 TCH CUTTER CIRCUIT PP om i JE usEEDH MLTCA Ev PILTOR I1PA55 Su iTCH Oo d OB ee 1 I I BE WG TF mil LECTIE 1 WF mide INE CIE IHE SEIN MUY TEuEEATUFE SCH SOK 1 u Ei MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 17 Wire Harness Schematic Exterior P N 02981375 REFERENCE 029313754 SCHEMATIC REFERENCE 02981375B SCHEMATIC MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 18 Wire Harness Schematic Exterior P N 02981375 A PACKARD MALE ROUSING 12010973 PACKARD MALE TERMINAL 12083574 PACKARD WIRE SEAL F 12019325 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 19 Wire Harness Schematic Interior P N 02981375B MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 20 Wire Harness Schematic Interior P N 02981375B Remove console cover tie strap J1 Joys
23. 1 O Ring 087 Dia X 644 ID 2 21 mm Dia X 16 36 mm ID 39 1 Plug 39 1 1 O Ring 087 Dia X 644 ID 2 21 mm Dia X 16 36 mm ID 40 1 Plug 40 1 1 O Ring 116 Dia X 924 ID 2 95 mm Dia X 23 47 mm ID 41 1 Plug 41 1 1 O Ring 116 Dia X 924 ID 2 95 mm Dia X 23 47 mm ID 42 1 Key 43 1 Cover Plate 44 1 Shaft Seal 46 1 Charge Pump Adapter Asy 47 1 Control Arm Used 1997 8 Down 48 1 Manual Servo Control Asy used 1997 8 down 48 1 1 Solenoid Servo Control Manifold Asy Used 1998 8 Up Not Shown 49 1 Inner Ring Gerotor 50 1 Outer Ring Gerotor 51 1 Supply Orfice 52 1 Control Valve Orfice 53 1 Control Arm Orfice 57 1 Dump Valve Actuator of Plug 58 1 Retaining Ring 59 1 Quad Ring 062 Dia X 625 ID 1 59 mm Dia X 15 9 mm ID 60 1 Washer 61 8 Washer 62 3 Washer 63 1 Adapter Wire Harness 3 wire to 2 wire P N 02970201 used only when converting pre 1997 units to later Pumps See Insert Sheet 02970224 for instructions MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 12 MOTOR CIRCUIT PUMP DIS ASSEMBLY PUMP DIS ASSEMBLY The following instructions apply to a single Servo Controlled Piston Pump with or without Gerotor Charge Pump A Tandem Pump Assembly should be separated into individual Pumps before dis assembly 1 Position the Pump into a protected Jaw Vise make sure Vise is Clean Clamping onto the outer portion of the flange DO NOT OVER TIGHTEN IN VISE with th
24. 20 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 12 MOTOR P N 029 9881 ASSEMBLY Motor Assembly Continued 6 Install Bearing Retaining Ring This is an external snap ring item 23 Use snap ring pliers to slide snap ring down over shaft See Figure 22 Check Bearing load after snap ring is installed to make certain shaft has zero end play with bear ings If end play is not correct the snap ring will need to be removed and the quantity of spacer washers will have to be changed 7 Install O Ring Seal Install the O Ring seal item 8 into Bearing housing making certain it is straight and seated into housing See Figure 23 8 Install Seal into Seal Carrier Drive the old Seal out of Seal Carrier See Figure 24 Install new seal item 10 using a seal driver Coat the ID of seal with a light coat of oil See Figure 25 9 Install Seal and Seal Carrier The Seal Carrier item 9 has a shaft seal item 10 that is installed into it This needs to be installed before Seal carrier is installed into Bearing housing See Figure 26 10 Install Seal Carrier Retaining Ring Using Internal Snap Ring Pliers Install the retaining ring item 12 into bearing housing This will complete the lower end assembly See Figure 27 Remove the bearing housing from the vise and turn it over Reinstall it into the vise with the gear end up See Figure 28 Splined Shaft MAVERICK Service Manual 12 04
25. 2004 Alamo Group Inc Splined Shaft Snap Ring Pliers Splined Shaft de hn 23 Z m E ax Figure 22 Figure 24 Section 5 13 MOTOR P N 029 9881 ASSEMBLY Motor Assembly Continued 11 Install O Ring Seal Install the O Ring Seal item 7 into bearing housing See Figure 28 12 Install Pistons 8 Piston Rings Coat the pistons item 17 with hydraulic oil make certain all 7 pistons have 3 rings item 18 each on them See Figure 29 Piston will lay over to the side as shown in figure 29 but will slip down into the holes as shown in Figure 30 13 Install Barrel Support The Barrel Sup port item 16 is a 4 piece assembly that installs inthe center ofthe shaft make certain all components of the barrel support is in stalled See Figure 30 14 Install Shims Install the bearing housing shims item 24 onto bearing hous ing See Figure 31 These shims are various thickness and the quantity required will vary start with the same amount and thickness that was removed Splined Figure 27 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Seal Carrier Section 5 14 MOTOR P N 029 9881 ASSEMBLY Motor Assembly Continued 15 Install Cylinder Barrel When installing the cylinder barrel item 15 it must be timed There are punch marks on the Shaft Gear and the gear of cylinder barrel these marks must be aligned as shown below
26. Assembly with six Bolts Torque these Bolts to 40 to 48 in lbs 4 5 to 5 4 nm Install Control Arm Only applies to units 1997 8 Down with Manual Servo Control Install Control Arm onto Control Assembly input Arm Retain with Lock Washer and Nut Torque from 4 to 6 ft lbs 5 to 8 nm Install Plugs Install new O Ring on all Plugs into Housing Torque 3 4 Plugs from 21 to 24 ft lbs 28 to 32 nm and torque 1 1 4 Plugs from 40 to 45 ft Ibs 54 to 61 nm Check all Assembly Steps before Testing and Re Installing Pump back on Tractor Follow Start Up procedures as outlined in Operators Manual Pump MUST be Pre Lubed prior to starting up or Pump will be damaged This is done by putting recommended Hydraulic Oil into pump See Specification chart for type Oil recom mended On Models Machete where the tank is higher than the pump the suction line will have positive Oil flow and usually Pre Lube itself NOTES MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 17 MOTOR CIRCUIT PUMP CHARGE PUMP ADAPTER ASY CHARGE PUMP ADAPTER DIS ASSEMBLY 1 GI Gerotor Pocket The following instructions apply to Charge Pump Adapter Dis Assembly See Figure 30 8 31 Clean Make Sure that every thing Pump Connections Tools Work Bench Vise and all general conditions are very clean before beginning any work Remove Plug Shims Springs and Poppet from Adapter Assembly Inspect Charge Pump Relief Valve Seat inside
27. BOOM SPECIFICATIONS Boom Reach 24 Foot P ON Out 24 Boom Reach 30 Foot Boom Out 30 mS ENTER E PTT Manufactured Box Sections 1 PERERA EMP Chrome Plated Alloy BUSTI ER raivi picadas Greasable Weight 24 o EE Ek nn Eain 1250 lbs Weight VPN O O O 1450 Ibs BORE A Tractor Axle Mounted BOOMmNIOUNAAOL cassia asda ando des E a E sa ROPS or CAB Tractor Optional 3 FILTRATION Control Valve Functions Control functions include All Hydraulic Cylinders used to manipulate the Maverick Boom The boom and frame cylinders are powered by a self contained hydraulic system The pump is loctated on the front of the tractor There is an in line pressure filter P N 02981371 between the closed center load sense pump and cylinder control valve There is a return filter P N 02981391 mounted to the tank that filters the fluid returning from the control valve to the tank Filter change recommended for every 200 to 250 hours An electronic monitoring system monitors element back pressure for indication of clogged filter prior to element change Mower Head Functions Mower Head Functions are operated by Pump which is mounted to the frontofthe Tractor Engine This willhave an in line Filter installed into hydraulic circuit This filter should be changed on a regular maintenance schedule Filter are rated by Micron size 10 Micron Filters should be replaced with original Alamo Industrial Replacement Filters to make certain the correct rated filter element is installed
28. Blade Bolts for wear Excessive wear could indicate frequent contact with the ground Check cutting Height of Blades above Skid Shoes Check for proper Blades and Skid Shoe condition Repair or Replace as required CAUSE Incorrect Oil Installed SOLUTION Incorrect Oil installed may produce internal wear which will overheatthe motor Use only the recommended Oil for the model being used See Specification Chart for correct Oil type Do not mix Oil Types as the may not be compatible if types of Oil are being changed over completely change the Oil Drain and flush the system before installing the new Oil MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 23 POSSIBLE FAILURE CAUSE 8 SOLUTION Motor Over Heating Continued CAUSE Excessive Internal Leakage in Pump Motor SOLUTION Perform Flow and Pressure Test If results are not within Specifications determine the cause of the internal leakage correct the cause Replace worn ordamaged parts Itis good to replace the Filter any time the Pump and or Motor are repaired or replaced Pump and or Motor wear usually occurs over a long period and are gradual loss of power and excess heating of Oil This may go un noticed until it is severe making the operator think it just started this can make this type of failure hard to determine Pre Mature Pump and or Motor Failure wear occurs guickly The problem for these failures must be found and repaired or the failure w
29. EL be r3 pi 4 B s T SN Et E met 1 A v Dee us h sat m z m Figure 11 Figure 12 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 9 MOTOR P N 029 9881 DISASSEMBLY Motor Disassembly Continued 12 Remove Shaft Remove Bearing housing from Vise and move to a press Set the Housing in press where the bottom is open as the shaft will come out the bottom See Figure 13 Make cer tain you Support the shaft in a way that will not allow ittofall outwhen pressed and hitthe floor It will not take a lot of pressure to remove shaft so you should be able to catch it with your hand 13 Remove Small Lower Bearing Cone The lower bearing cone item 21 will lift out of the housing once the shaft is removed See Figure 14 14 Remove the Bearing Cups from Bearing Housing item 6 This will only need to be done if they are being replace Using a hammer and a mandre tap the small bearing ring off See Figure 15 amp 16 The Bearing Cups will drive out from the opposite side of each other The lower bearing cup is tapped from the top and the upper Bearing cup will be tapped from the bottom side of the housing A Figure 15 Figure 16 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 10 MOTOR P N 02979881 DISASSEMBLY Motor Disassembly Continued 15 Remove Gear and Upper Bearing Re move upper bearing cone and gear at the same time Sit Shaft down over
30. Hole In Side of Lift MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 7 4 24 FOOT BOOM HOSE 8 ROUTING Item PartNo Qty End 1 End 2 Description 1 02981823 1 Y MJ Z FJX Hose 44 4MJ 4FJX 76 Lg Yellow Tie Door Lift Section 2 02981824 1 Y MJ Z FJX Hose 4 4MJ 4F JX 76 Lg Yellow White Tie Door Lift Section 3 02981828 1 Y MJ ZFJX Hose 4 4MJ 4FJX 76 Lg Green Tie Swivel Lift Section 4 02981829 1 Y MJ Z FJX Hose 44 4MJ 4F JX 76 Lg Green White Tie Swivel Lift Section 5 02981830 1 Y MJ Z FJX Hose 46 6MJ 6FJX 76 Lg Yel Tie Ext n Lift Section 6 02981831 1 Y MJ Z FJX Hose 46 6MJ 6F JX 76 Lg Yellow White Tie Ext n Lift Section 7 02981832 1 Y MJ ZFJX Hose 6 6MJ 6F JX 76 Lg Red Tie Tilt Lift Section 8 02981833 1 Y MJ Z FJX Hose 46 6MJ 6F JX 76 Lg Red White Tie Tilt Lift Section 9 02981834 1 Y MJ O FJX Hose 46 6MJ 6F JX 96 Lg Blue Tie Dipper Lift Section 10 02981835 1 Y MJ P FJX Hose 46 6MJ 6F JX 96 Lg Blue White Tie Dipper Lift Section 11 02981836 1 Y MJ R FJX Hose 46 6MJ 6F JX 88 Lg Yellow Tie Ext n Dipper Section 12 02981837 1 Z MJ Q FJX Hose 46 6MJ 6F JX 88 Lg Yellow White Tie Ext n Dipper Section 13 02981838 1 Z MJ X V FJX Hose 4 4MJ 4F JX 176 Lg Yellow Tie Door Dipper Section 14 02981839 1 Z MJ U FJX Hose 44 4MJ 4FJX 176 Lg Yellow White Tie Door Dipper Section 15 02981840 1 Z MJ X FJX
31. Lg Red Tie Tilt Dipper Sec n 02981870 1 Z MJ S FJX Hose 6 6MJ 6FJX 214 Lg Red Wht Tie Tilt Dipper Sec n 02981873 1 C FJX F FJX Hose 16 16FJX 16FJX90 140 Lg Red Tie Motor P Lift Sec n 02981874 1 A FJX D FJX Hose 16 16FJX 16F JX90 140 Lg Org Tie Motor R Lift Sec n 02981875 1 K FJX L FJX Hose 16 16FJX 16FJX 94 Lg Red Tie Motor P Dipper Sec n 02981876 1 H FJX N FJX Hose 16 16FJX 16FJX 98 Lg Org Tie Motor R Dipper Sec n 02981877 1 B FJX E FJX Hose 12 12FJX 12FJX90 140 Lg Blu Tie Case Drain Lift Sec n 02981878 1 J FJX M FJX Hose 12 12FJX 12F JX 96 Lg Blu Tie Case Drain Dipper Sec n NOTE 1 Hose End 1 8 End 2 these are where the ends of that hose connect the letter shows location of that end and show type hose fitting at that end NOTE 2 The hoses have plastic ties on the to show which hose is which The colors are abreviated to YEL Yellow YEL W Yellow with White stripe GRN Green GRN W Green with White Stripe RED Red RED W Red with White Stripe BLU Blue BLU W Blue with White Stripe ORG Orange ORG W Orange with White Stripe NOTE 3 Sec n Location where hose Is located on boom MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc section 2 19 TROUBLE SHOOTING BEGIN MAVERICK CONTROL VALVE HYDRAULIC SYSTEM POSITIONING TEST PROCEDURES NOTE The Maverick is eguipped with manual override controls for the Control Valve In c
32. Lg Red Wht Tie Tilt Dipper Sect n 02981846 1 C FJX F FJX Hose 16 16FJX 16FJX90 102 Lg Red Tie Motor P Lift Sec n 02981847 1 A FJX D FJX Hose 16 16FJX 16FJX90 102 Lg Org Tie Motor R Lift Sec n 02981848 1 K FJX L FJX Hose 16 16FJX 16FJX 54 Lg Red Tie Motor P Dipper Sec n 02981849 1 H FJX N FJX Hose 16 16FJX 16FJX 58 Lg Org Tie Motor R Dipper Sec n 02981850 1 B FJX E FJX Hose 12 12FJX 12FJX90 102 Lg Blu Tie Case Drain Lift Sec n 02981851 1 J FJX M FJX Hose 12 12FJX 12FJX 56 Lg Blu Tie Case Drain Dipper Sec n NOTE 1 Hose End 1 8 End 2 these are where the ends of that hose connect the letter shows location of that end and show type hose fitting at that end NOTE 2 The hoses have plastic ties on the to show which hose is which The colors are abreviated to YEL Yellow YEL W Yellow with White stripe GRN Green GRN W Green with White Stripe RED Red RED W Red with White Stripe BLU Blue BLU W Blue with White Stripe ORG Orange ORG W Orange with White Stripe NOTE 3 Sec n Location where hose is located on boom MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 2 17 HYDRAULIC HOSE CONNECTIONS 30 FT BOOM Z Hole in Side Y Hole intop of Lift MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 18 HYDRAULIC HOSE CONNECTIONS 30 FT BOOM Part No Qty End 1 End 2 Description 02981879 1 Y MJ Z FJX Hose 4 4MJ 4F
33. Measurement is OK install Cover Plate and Cover Plate Gasket on Left Side of Servo Piston Retain cover with 4 each of 10 24 Bolts Torque these Bolts to 40 to 48 in lbs 4 5 to 5 4 nm Note If on Buzz Bar Head units there is Flow Limiter Bolt and Nut added in LH side cover plate this looks like the Adjusting Centering Bolton RH Side This adjusting bolt on the LH side cover is only to limit the Flow to the Buss Bar Head The Left Hand side cover is added as Servo Piston Travel Limiting Adjusting Bolt 7 To Assemble Cradle Sub Assembly Press Dowel Bushing into Cradle and install Bushing into Cradle retaining with Button Bolt Torque Button Bolt to 14 to 16 in lbs 1 6 to 1 8 nm 8 Place Cradle Sub Assembly into Housing making sure Dowel Bushings and Cradle is completely seated into Housing Retain Cradle Sub Assembly with two Bolts that have Locktite 277 or equivalent applied to the end of the threads Torque these Bolts to 25 to 28 in lbs 34 to 38 nm 9 To Install Shaft Components Place Exterior Retaining Ring Thrust Race Thrust Bearing Second Thrust Race and second Retaining Ring onto Shaft Position Washer and Shaft Seal or Spacer onto Shaft 10 Install Servo Piston Follower onto Camplate Dowel Pin Install Camplate carefully onto Bushing Coat Bushing Surface with Hydraulic Oil Aligning Servo Piston Follower with Slot in Servo Piston Assembly Refer to Appendix C for Re Assembly of Rotating Kit Assembly 11 To Inst
34. New Bolts to Long SOLUTION Check that Blade Bar Retaining Bolts are not too long to cause them to bottom outand jam through Spindle damaging Shaft Always make sure same Length Bolts are installed that came out If to long of Bolts have been installed in Spindle it will have to be rebuilt CAUSE Seal Protector Damaged Component Bent The Seal Protector there has been two types Old Type was a Cup type that slid up on to bottom of Shaft This type usually would not stop the Spindle from spinning while running if it got bent butit could preventthe spindle from starting The New Type is a Steel Wing that is welded to Blade Bar it is thicker than old type but it can get bent SOLUTION Check Seal protector type and if damaged repair or replace as required Seal protector can be straighten if damage will allow as long as it does not hit Housing and protect Seal it will be OK Starter on Tractor Will Not Crank Note Most of the problems that will cause the Tractor not to fail to crank will be found in the Tractor However there are some causes that involve the Mower Only those problems that are caused by the Mower are covered here and only mower models that have electrical systems that are tied in with Tractor Electrical system could affect Tractor Starting Circuit CAUSE Mower ON OFF Switch Engaged SOLUTION Move Mower Switch to the Off Position and retry Tractor Starter System Tractor is not supposed to start
35. OR TESTING The Maverick has computerized electronics The electronic components can be damaged If care is not taken when performing repalrs testing and or during assembly DO NOT DO NOT short any wires across or allow them to be shorted out 2 DO NOT attempt to jump across any wires or supply them with alternate power source 3 DO NOT install higher rated fuses than are recommended by manufacturer 4 DO NOT do any welding on unit unless the computer modules are unplugged first this isto preventa power surge going into modules THIS IS VERY IMPORTANT This could also apply tothe tractor components Check Tractors repair guide for specific instruction about tractor model and type 5 DO NOT attempt to repair or adjust a component that is not intended to be repaired example sealed components as there are no serviceable components inside 6 DO NOT let anyone attempt any testing or repairs unless they are an experienced and qualified technician Technicians must have proper tools gauges meters etc to perform proper diagnosis and or repairs 7 DO NOT perform any repairs with dirty tools or in dirty area When working on hydraulic components keeping system clean and free of contamination is important 8 DO NOT start or engage system if the oil level is not at the proper level or condition Never start or run unitlow or out of oil 9 DO NOT install add any oil unless you know it is the correct type and the container is
36. Out of Cylinder CAUSE Piston Nut Backed Off of Rod SOLUTION Replace damaged Parts and Assemble Make sure Piston Nut is Correct and Properly Torqued This problem is usually caused by improper assembly Nut Not Torqued but can also be caused by a faulty Nut and or Rod threads This failure would show Rod Threads that are damaged most likely Some times Threads will show damage from Piston working on Rod because it has been operated while Nut was loose CAUSE Wrong Nut On Rod SOLUTION Replace with correct Piston Nut Check Piston Nut that it is not too Thin Wrong Threads or Insufficient Thread engagement on Rod MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 16 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Rod Came Out of Cylinder continued CAUSE Relief Valve Setting Too High SOLUTION After Replacing the damaged Parts test the Settings of the Relief Valve Test this by slowly pressurizing the Cylinder to determine the Relief Pressure a Pressure Gauge installed inline for testing will show this Relief Pressure If Pressure exceeds what Relief Should be stop Repair or replace Relief Valve and retest IF RELIEF IS TO HIGH DO NOT CONTINUE WITH PRESSURE UNTILL RELIEF IS REPAIRED OR DAMAGE WILL RESULT Note Usually Rods that have Nuts pulled off due to Pressure to high will have Threads pulled off of Rod Deck Cracks CAUSE Severe Usage SOLUTION Prepare and Repair Weld Grind Down Add Scab Pl
37. Parts in Joy Stick Controller See the Repair Section for Testing and repairing the Joystick DO NOT Replace Joystick till all Test have been performed to pin down the problem area There are a number of test to locate problem area that can be used these are listed through out sections of the repair Manual as well as some listed in the Operators Manual CAUSE Oil Contaminated SOLUTION Ifthe Filters are Not Maintained properly on the Tractor Hydraulic System Fine contaminates can get into the Solenoid valves this prevents them from seating Properly This can result in Boom Circuits moving without input from the Joystick Controller When Filters getfull It causes the Bypass valve on the Filter to Open and allow unfiltered Oil to go throughout the System Once this is allowed to happen even though the Filters are later changed it is no guarantee that the malfunction will not re occur because the contamination could be any where in the system waiting to break free and travel on through the system Later Models Machete had an add on filter added which has a lower Micron Rating than Tractor Filter This was added to keep Contamination from Tractor oystem from going through the Boom System Both Tractor and add on Boom Filter will have to be changed an a regular maintance schedule See Operators manual Control Valve Spool or Spools Sticking CAUSE Control Valve Bolted to Mounting Plate Incorrectly SOLUTION Loosen bolts and re tighten 1 turn
38. Piston Bolt Remove Jam Nut Washer and Seal Washer Hold the Servo Piston Plate with Hex Key and unscrew Cover Plate off Bolt 16 Remove Servo Piston Assembly and Seal Sub Assemblies Two Sets from Housing Note Dis Assembly of Servo Assembly is not reguired 17 Remove retaining Ring from the Cover of the Housing Press the Shaft Shaft Seal or Spacer and Washer from Housing Remove Retaining Ring Thrust Washer Thrust Bearing Second Thrust Washer and second Retaining Ring from Shaft 18 Housing Inspection See Figure 28 Check the Bearing Press Fit in Housing If needles remain in cage move freely and set at the dimension shown in Figure 28 Removal of Bearing will not be required Flange End of Housing Numbered End 07 1 78mm FIGURE 28 19 To remove Cradle Sub Assembly remove the two Bolts retaining Cradle inside Housing Move the Cradle Sub Assembly back an forth to release Dowel Bushing and removing Cradle Sub Assemblies from Housing 20 Remove Button Head Bolts to remove Bushing from cradle 21 Bushing Inspection Inspect bushing for contamination embodiment within Coating of Bushing surface coming in contact with Camplate 22 Remove All Plugs from Housing This for inspection to make sure contamination is not caught under plugs or in passages 23 Discard Parts This will include The Shaft Seal and all O Rings from all assemblies Replace with new ones NEVER use old Seals to assemble Pump MAVERICK Servic
39. SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Obvious Causes Check First Check These First Perform all Operational checks Tank Oil Level Pump Operation Control Valve Circuit Electrical Supply 8 Hydraulic Supply All Circuits affected or only some Circuits If All Circuits will not work the Problem is most likely up stream of the control Valve or an electrical Problem Models with Joystick Controller The Following Causes are based on only some circuits being affected Not all Circuits Incorrect Hose Routing Unit has never worked or been repaired Check Hose Routing with Parts Manual and Assembly Guide to make sure Hoses Are routed correctly Move and reconnect Hoses as required Work Port Relief Installed Improperly Unit has never worked or has been repaired or worked on Determine correct positioning of Work Port Relief s If reliefs are incorrectly installed Install correctly and Test Work Port Relief Malfunction Determine if one or both sides are affected Make sure Work Port Relief s are in proper position Swap Hoses with another circuit or swap Work Port relief s with another circuit to determine where problem lies Repair or replace faulty Parts as required Control valve or Remote Control Malfunction Observe actuation of Valve Spool in relation to Control Lever Repair any faults Restrictions in System Check Hoses and Lines for Kinks
40. Seal Install Wiper Seal item 16 on Input Shaft and seat into Control Housing 8 Valve Spool Plug Install New O Ring item 3 onto Valve Spool Plug item 2 and install Plug Tighten Plugtill there is no play in Valve Spool with Input Shaft held stationary Lock in place with Set Screw item 8 Torque Set Screw to 17 to 25 in Ibs 2 to 3 nm MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 19 OTOR CIRCUIT PUMP SERVO CONTROL MANIFOLD AS Solenoid Servo Manifold Asy Bolts Here FIGURE 32 Solenoid Servo Control Manifold Assembly Item Part No Qty Description O 1 Solenoid Servo Control Manifold Kit items 2 through 7 2 02970207 1 Solenoid Manifold Assembly w Solenoid 3 02970209 1 Gasket 4 02970208 6 Bolt 5 02970201 1 Decal Instructions Not Shown 6 02969527 1 Pump Assembly w Item 1 New Pump 02969527RB ref Pump Assembly w Item 1 Re Built Pump NOTE Listed above Item 1 Kit as reference only Also listed as reference is Pump Assembly Complete MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 20 MOTOR CIRCUIT PUMP ROTATING KIT ASY ROTATING KIT DIS ASSEMBLY See Figure 33 1 The following instructions apply to Rotating Kit Assembly Dis Assembly Dis Assembly of Rotating Assembly is required for inspection Only There are no repairable Parts that can be replaced See Figure 33 2 Clean Make Sure that every thing Tools Work Bench Vise
41. Section 7 1 FRAME BOOM 8 HOSE ROUTING Under Mount frame Asy 1 Before beginning any repairs on this section make certain the boom is extended outward to full extend and laying on the floor Before removing the Boom Pivot Pin support the boom with an overhead hoist so as when Pie is removed boom can be lifted out of the way NEVER REMOVE ANY PINS OR BOLTS unless boom is supported at pivot end and head end is resting on the floor 2 The under mount frame asy is made up of the Turret Center Section Frame Weldment Boom Mount Swing Cylinders Swing Cylinder Trunnion Mount Turret Cylinder Link and Counter Weight 3 The Turret Asy will be shipped assembled to the Boom mount with the hoses and cylinders plus attaching hardware assembled to it The Swing Cylinders have replaceable mounting bushing which can be replaced by removing the bottom cover and trunnion mount weldment The Cylinders can be dropped down enough to replace the bushing The replace the Trunnion Mount weldment Also by removing the cylinders the Turret Cylinder link can be removed 9 The Turret assembly has a large bearing assembly bolted to it and then bolted to the Boom Mount This Bearing CANNOT be removed or replaced unless the Boom is disconnected from it first When disconnecting boom make certain the boom is supported as not to fall See Step 1 The Bolts retaining the turret to the bearing and the bolts connecting bearing to the Boom Mount MUST be torq
42. Trigger Dipper Telescope i XX Trigger Swivel Door Joystick Functions Push Buttons Only Top Left Swivel CW Top Right owivel CCW Bottom Left Tilt Up Lift Dipper Tele Botom Right Tilt Down Down Up Out Push Button amp Trigger Switch Top Left Door Open Lift Dipper Down 7 a Top Right Door Close Handle Movement Push Front Lift Down Pull Back Lift Up Push Right Dipper Up Push Left Dipper Down Rotate Right Swing Back Rotate Left Swing Forward SS Trigger amp Handle Movement Push Right Telescope Out FIGURE 1 Push Left Telescope In JOYSTICK Schematic next page The Joystick Schematic shown on next page shows the plugs at the joystick The Joystick is P N 02981374 These plugs are mark with numbers on them and the pin location numbers are cast into the plastic plug The wires are solid color or a color with a stripe If testing any of these wires it is best to use a voltmeter MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 3 12 CONTROL VALVE JOY STICK SCHEMATIC 02981374 NON O u 2 ss q U P 5 OPEN LI 4 OPEN Plugs are marked with numbers on them to identify the pins in that plug these numbers are made onto the plug as shown in illustration above Plug Pin Wire Function Plug Pin Wire ID No Color ID No Color P 1 1 Wht Red Power 5V P 4 1 Red P 1 2 Wht Grn Up P4 2 BIk Wht P 1 3 Wht Yel CW P 4 3 Blu P 1 4 W
43. a tube that will support Splined the gear item 19 Using press on Shaft item 14 Shaft Shaft will slide down through the gear and bearing atthe same time Make certain to support Shaft in such a way it will not fall through and hitthe floor See Figure 17 Figure 16 16 Inspect all parts The Motor is now disas sembled Inspect all of the disassembled part for wear and damage Replace worn and or dam aged parts After cleaning and washing parts keep El gure 1 them in clean area If the motor is to remain disassembled for any period of time lightly coat the surfaces of the parts with hydraulic oil and store them in a closed container to prevent the parts from rusting or becoming contaminated MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 5 11 MOTOR P N 029 9881 ASSEMBLY Motor Assembly 1 Install Gear amp Bearing Cone on Shaft Install Gear item 19 down over shaft item 14 make certain Gear is on in correct direction and the guide pin item 27 is installed Slide Bearing Cone item 20 down onto Shaft with small part of Bearing Cone up as shown in Figure 18 Using a tube sleeve tool shown in last figure of this section press Bearing cone and Gear down onto shaft with a press The tube mustonly contact the inner edge of the bearing See Figure 40 at the end of this section for tool dimensions 2 Install Bearing Cups into Bearing Hous ing This will needto be done ifthe
44. at all times Pressure Filter is P N 02968922 and Return Filter Replacement Element is P N 02968923 Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Section 1 3 SPECIFICATIONS MAVERICK 4 HYDROSTATIC PUMP SPECS Cutter Head Pump Circuit Spec s FAO AV OG tonta cio Piston Type Pump Speed Front Engine Mounted Run Engine to 540 PTO Speed Relief Setting at the Pump 4500 PSI Pump Flow Front Engine Operating Speed 25 3 GPM Boom Cylinder Pump Circuit Spe c s Pump PVC Aer Piston Type Pump SPEe cccsscsscssssscerensersevrscuscnessscerensereususs 1800 RPM Pump Flow Front Engine Operating Speed 15 6GPM Low Pressure Standby 250 PSI High Pressure COMD Sko n kolo snaz 3000 PSI Horse Power at 1850 RPM Engine Speed 28 9 HP o HYDRAULIC HOSE CODES Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some have a Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attachted to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose Always Check Hose Size Color Code amp Part Number Boom Cylinder Circu
45. attempts to compensate by decreasing the output flow It does this by sensing the lower on the downstream side of the flow control via line C which is balanced against the pump pressure via passage D on the control spool The control spool is forced down against the control spool spring by differential pressure This vents the servo piston cavity destroking the pump to a point where the set pressure drop across the orifice is maintained and the flow is obtained The converse of this is also true whenever the pressure drop decreases indicating a decrease in output flow In this case the control spool is forced up This increases pump displacement in an attempt to maintain the predetermined pressure drop or constant flow It should be noted that the pump is still pressure compensated and destrokes at the selected pressure setting The pressure compensator control will override the flow control whenever the pressure compensator control setting Is reached Low Pressure Standby This arrangement can also be used to provide low pressure standby by venting the B port through a simple on off valve suitable for flows of 1 2 GPM 3 8 7 6 LPM When flow or pressure is required this valve Is closed allowing system pressure to build behind the control spool and bringing the pump on stroke Load Sensing If instead of measuring the pressure drop across the orifice in the pump outlet port itis measured downstream of a directional control valve a co
46. bearing cups were removed Install bearing cups 1 2 of item 20 into Press Bearing housing using a press and tube thatis close to the size of the bearing cup Make certain the Bearing cups are completly seated See Figure 19 Bearing Cup Driver 3 Install Shaft Assembly into Bearing Housing Install the Shaft Assembly Shaft Gear and Bearing into the Bearing housing Slide the Lower Bearing bearing cone down over Shaft You will need to supportshaft Housing while pressing Bearing Cone onto shaft make cer tain to support it with something that will not damage it or get contamination on it Using a tube and a press to push bearing down until it is seated in Bearing cup Press Bearing Cone on until the proper Bearing preload is achieved Proper Bearing Preload is the removal ofthe slack in the bearing remove end play Figure 19 4 Remove Bearing Housing with Shaft From Press Remove assembly from press and reinstall it into the vise as was done during disassembly process Install it with the spline end of the shaft pointing up 5 Install The Lower Bearing and Spacer Wash ers Press lower bearing onto shaft until Zero End play is achieved Install Lower bearing spacer washer item 22 Quantity will vary as these shim type spacer washer are used to maintain zero bearing end play Start with the same quantity that was removed and check Adjust quantity as required to achieve proper bearing load See Figure 21 Figure
47. engine RPM is atidle speed Doing this a t high RPM will cause the system pressure to surge sending fluid over the relief and causing excess heat to be introduced into the system At any time the Cutter Head Motor E Stop emergency stop can be pushed to disable the motor circuit If this is done the Switch must be raised in the run position before the motor circuit can be reactivated MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 8 CONTROL VALVE INSTRUMENTATION Maverick Operator Interface continued Cutterhead is On 43 0 F At this time the motor circuit is powered and the mower head motor is active This screen also shows the tank temperature in degrees Fahrenheit To turn off the motor a Turn Urt dous 10h ra feu i to Disable Josst icd Oil Temp The Joystick Master control switch must be off to een accidental movement of boom and cutting head when ever mower is not being operated such as when In transport Cylinder Supply Pump Pressure Adjust If Needed Special Note If after setting the display controls check to make certain that functions operate correctly If the Boom will not lift The Pump for the Cylinder supply may have to be adjusted This is a simple process that will require a 7 16 wrench for this adjustment and a 1 2 wrench for the locking nut Looking on the LH side of the pump there are two adjustments one has a 7 16 hex head and the othe a ridged round he
48. location MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 7 5 30 FOOT BOOM HOSE ROUTING Z Hole in Side Y Hole intop of Lift MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 7 6 30 FOOT BOOM HOSE 8 ROUTING Item PartNo Qty End 1 End 2 Description 1 02981879 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg Yellow Tie Door Lift Section 2 02981880 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg Yellow White Tie Door Lift Section 3 02981855 1 Y MJ ZFJX Hose 4 4MJ 4F JX 115 Lg Green Tie Swivel Lift Section 4 02981856 1 Y MJ Z FJX Hose 4 4MJ 4F JX 115 Lg Green White Tie Swivel Lift Section 5 02981857 1 Y MJ Z FJX Hose 46 6MJ 6FJX 115 Lg Yel Tie Ext n Lift Section 6 02981858 1 Y MJ Z FJX Hose 46 6MJ 6F JX 115 Lg Yellow White Tie Ext n Lift Section f 02981859 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Red Tie Tilt Lift Section 8 02981860 1 Y MJ Z FJX Hose 46 6MJ 6F JX 115 Lg Red White Tie Tilt Lift Section 9 02981861 1 Y MJ O FJX Hose 46 6MJ 6F JX 135 Lg Blue Tie Dipper Lift Section 10 02981862 1 Y MJ P FJX Hose 46 6MJ 6F JX 135 Lg Blue White Tie Dipper Lift Section 11 02981863 1 Y MJ R FJX Hose 46 6MJ 6F JX 125 Lg Yellow Tie Ext n Dipper Section 12 02981864 1 Z MJ Q FJX Hose 46 6MJ 6F JX 125 Lg Yellow White Tie Ext n Dipper Section 13 02981865 1 Z MJ V FJX Hose 4 4MJ 4F JX 214 Lg Yellow Tie Door
49. low pressure stand by of the pump 200 250 PSI the pump will supply flow to the valve to overcome the high pressure low flow situation That flow is then delivered to the valve via the pump and sent to the cylinder work ports and into the cylinder that is requiring flow thus moving the cylinder and lifting the load As the lifting load reaches it s designated stopping point the operator demand is released and the valve spool centered back in neutral The work port pressure is no longer transmitted through the valve amp pump communication line so the pump decreases the flow and rests back at low pressure stand by until further flow demand is required The Maverick hydraulic system is identical to this principle the following sections will outline each of the three main components and their responsibility to the control system as a whole MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 3 DIREC TIONAL CONTROLVALVE AJ B Ports Ports Pump Pressure L Port Load Sense Signal 2 Pl Port a EN oo i di DO por COCO swine Eat CACA vir EE 0099 CEC Dipper 83 BIA GRO OLD CECH Telescope L oito SOON Head Tilt 631 DD eo roa CS Head Swivel Door 1j TL i AI 0 JO Tank Return Port m c PAR an MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 4 DIREC TIONAL CONTROL VALVE Item Part No Qty Description 02981888 Valve amp Fittings Asy
50. m D 10 11 12 Hex Allen Wrench Qty 5 9 16 5 32 5 16 3 32 5 64 Retaining Ring Pliers Qty 3 1 each of Internal Straight O 70 tip internal Straight 090 tip amp 1 each External Straight 0 90 tip Retaining E Ring Applicator Qty 2 1 each 9 32 amp 1 each 1 2 O Ring Pick Qty 1 End Wrench Qty 4 1 each of 7 16 9 16 3 4 1 Torque Wrench Qty 1 0 to 100 ft Ibs 135 6 nm capacity Hammer Soft Face Qty 1 Seal Driver Set Qty 1 Arbor Press Qty 1 Sockets Qty 3 7 16 9 16 3 4 Drive Size should match Torque Wrench Drive Light Petroleum Jelly Vaseline Locktite 222 and 277 or equivalent Qty 1 tube each MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 2 PUMP MOTOR 8 BOOM CIRCUIT RECOMMENDED GAUGES FOR DIAGNOSTICS 1 Inlet Vacuum 30 PSI to 30 in Mercury 207 bar to O bar 2 System Pressure Gauge 6 000 PSI 700 bar o Charge Pressure Gauge O to 500 PSI oto 25 bar SYSTEM CHARGE RELIEF PRESSURE SETTINGS Inlet Vacuum 6 in Mercury 203 bar Case Pressure 25 PSI 1 7 bar Charge Pressure 250 to 300 PSI 17 24 to 20 68 bar System Pressure 4500 PSI Max 3000 PSI Continuos 306 bar Max 207 bar Continuos Motor Relief 4000 PSI 272 bar The High Pressure relief Valves are all Factory Pre Set and Cannot be re adjusted The Pressure Setting is stamped on each valve with a three digit Code number To identify Multiply this stamped
51. module receives input from instrumen tation then provides that information to the network for further utilization See Figure 11 REFER ENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANU FACTURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com he XS The XS is expansion module that provides extra input and output capabilities In order to gain more flexibility on the network The XS is responsible for receiving the signals from the joy stick and other in cab inputs and making them available on the network REFERENCE PROD UCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANUFAC TURER ON THE INTERNET AT www igan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com MAVERICK Service Manual 12 04 XP2 Expansion Power Analog Inputs 4 Prop Output 4x Digital Inputs 4 Digital Outputs 4 Freg Inputs 2 E Gas FIGURE 10 da XT2 Expansion Transmission Analog Inputs 10 Prop Outputs 2x J1909 CAN hub 1 Digital Outputs 6 Freg Inputs 3 E Gas 1 Op 111 XS expansion signal O 2004 Alamo Group Inc Section 3 5 CONTROL VALVE INSTRUMENTATION Maverick Instrumentation Instrumentation The Maverick Boom uti lizes Instrumentation for certain decislon making activities Listed bel
52. of their stroke So the oversize wear could only be in part of the bore When checking Bore size it is recommended to check entire length of Bore if the length of stroke is not known CAUSE Work Port Relief Valves Not Seating Properly SOLUTION Test Cylinders for Bypassing as above If OK Leakage must be occurring in the Control Valve Spool or Work Port Reliefs if Equipped Suspend the Load with the Cylinders and place Valve Lever in Hold Neutral Centered position Use a Stethoscope Tool orequivelant Listen to the Valve Body nextto the Work Port that is suspect The Oil will be making a shrill whistling sound as it leaks past the Work Port Poppet If Leakage is evident Lower the Load and inspect to Work Port Relief Valve replace if needed MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 6 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Excessive Drift continues CAUSE Leakage Past Control Valve Spool SOLUTION Ifexcessive Cylinder Drift is confirmed and the Cylinder and Work Port Relief Valves have been eliminated The possibility is the Control Valve Spool itself If clearance between the Control valve Spool and Body are causing the drift the Only Solution is to replace the Valve Section Keep in mind that the cause for excess clearance must be found and corrected Frequently the cause is pre mature wear from abrasive material Contamination in the Oil If this is not corrected failure will re occur
53. position Swap Hoses with another circuit or swap Work Port relief s with another circuit to determine where problem lies Repair or replace faulty Parts as required Control valve or Remote Control Malfunction Observe actuation of Valve Spool in relation to Control Lever Repair any faults Restrictions in System Look for Kinked Plugged Pinched Hoses or Lines Observe as Cutting Head is moved throughout its range of movement Do not forget the possibility of foreign objects being lodged in Restrictors Hoses Tubes Fittings and or Lines Piston has come off of Rod This can be difficult to diagnose if the Piston comes completely off of Rod it can be pushed to bottom of Barrel below Port Then Oil just circulates around through Piston with little or no resistance This makes itappearthere is no Pressure or valve is not working The best way to check would be with a Flowmeter in Cylinder Line Check Repair or Replace as required Vent Plug Block or Not Installed Power One Way Cylinders This applies to Cylinders that only Stroke in or Out under pressure The return Stroke under gravity Remove Plug Clean or Replace as needed If No Vent Plug is there determine if one is needed and install as required See Parts Operators Manual for Vent Plug requirements MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 13 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Won t Move Under Load moves Slowly CAUSE
54. sense Line MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 7 CONTROL VALVE OPERATION HYDRAULIC LOCK VALVE Head Tilt Function An Electric Solenoid Operated Hydraulic Lock Valve Figure 5 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 sentto 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 3 Hydraulic Lock Valve Item Part No Gty Description E ur i m 02972208 Solenoid Valve Asy si 1 02971425 1 Seal Kit f solenoid Valve 2 02975198 1 Coil 12V DC w Dual i 8 32NF Studs 3 02975199 1 Cartridge Solenoid Valve 4 02975438 1 Adapter Hyd Straight 8MB 6FJX 5 02981890 1 Adapter Hyd Straight 5MB 6MJ ELECTRIC SIGNALS Electrical Signals are sent to the Controllers etc through a Wiring Harness The Harness is supplied with a one way c
55. sequential pressure settings Electrohydraulic Pressure 8 Flow Control A proportional pressure control valve can be used in place of relief valves to give variable pressure control proportional to an electrical input signal to the valve By combining this arrangement with the swash plate position sensing device amplifier and logic circuit servo control of pressure and or flow is achieved Note In most systems a load equivalent to the minimum operating pressure ofthe pump cannot be guaranteed Because ofthis a sequence valve is required in the discharge line to maintain servo flow control Please refer to ordering information in parts operators manual for servo components CONTROL OPTION M SWASHPLAI E AIRBLEED VALVE ASSEMBLY AT CONSTANT SPEED PRESSURE ICE een Gomes T He O fete CONTROL iod pics BE S SPOOL AND SLEEVE CONTROL DRAIN 3 cee CONTROL SPOOL PORT A SPRING CHAMBER PRESSURE F G U RE 38 COMPENSATOR ADS MENE ADJUSTMENT MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 28 PUMP BOOM CIRCUIT Pressure 8 Flow Control Load Sensing Control Type A Flow control is achieved by placing an orifice fixed or adjustable in the pump outlet port The pressure drop 6 A across this flow control is the governing signal that controls the pump s output as explained below Whenever the pressure drop at the flow control increases indicating an increase in output flow the pump
56. system the electronic network instrumentation and hydraulic components 2 System components are The hydraulic System The electronic network The instrumen tation and Operator Interface 3 The Hydraulic System The hydraulic components are responsible for transferring me chanical power into hydraulic power There are two separate hydraulic circuits the boom circuit and the mower head circuit 4 How the boom is controlled The system progression starts with operator input at the joystick Figure 7 A or otherinstrumentation Inputis received atthe CAN module Figure 7 B and joins the network That information is transferred via the network to the valve solenoid Figure 7 C which activates and moves the spool sending hydraulic fluid pressure to the cylinder Figure 7 D and moves the load X5 expansion signal p 107 FIGURE 7 A FIGURE 7 B FIGURE 7 C FIGURE 7 D Maverick Mower Head Circuit 1 The Motor Circuit The motor circuit for the cutting head operation is operated through display Figure 8 A By selecting the activation parameter the coil will shift the servo piston at the hydrostatic pump Figure 8 B stroking the pump into the On position Flow will then be supplied to the hydraulic motor at the cutter head Figure 8 C Activate the motor circuit while the engine RPM is at idle Once activated the engine RPM can be raised to the 540 PTO required speed if the 540 PTO engine speed is not noted on the tractors RP
57. 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 78155 Technical Service Dept PH 830 379 1480 Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Index 1 section Page Section AS 1 1 to 1 8 Do Not Do or Allow Items Read First Thing 1 2 Cutting Circuit Specifications 1 3 Boom SPECNCA ONS sausen O 1 3 Filtration SPECNCAUONS uices ivriuciva DwroavtvEvpdtek Lad Ove eine 1 3 Hydrostatic Pump Specifications Cutter Head 1 4 Hydrostatic Pump Specifications Cylinder Supply 1 4 Hydraulic m 050510 EE TO 1 4 Hydraulic Cylinders Specifications 1 5 Valve Specifications 1 5 Valve Spool FUNCTIONS sucios daa eds 1 6 Hose Fiting Torque Specifications 1 6 Rotary Head Components Torque Specicfications 1 7 Bolt Torque Specifcations Chart 1 7 Section 2 Control Valve Operation amp Joystick Controls 2 1 to 2 21 Cylinder Control Valve 2 2 to 2 3 Control Valve Schematic ee 2 4 to 2 5 Control Valve Operation 2 6 to 2 7 Hydraulic Electric Lock Valve Head Tilt 2 8 Diverter Valve Door Swing Function 2 9 Cylinder Control
58. 0 RPM Tractor the Blade Tip Speed would be way to high and this would create severe amount of Sand and Dust under deck MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 17 POSSIBLE FAILURE CAUSE 8 SOLUTION Deck Worn on Underside continued CAUSE Deck being Worn and Ripped away by Heavy Debris SOLUTION Make sure material being cut is not to heavy large or thick for unit being used This type wear will be accompanied by dents and large scratches The best solution for this is to make sure that Unit is suited for job Make sure job is not over tasking Unit CAUSE Deck Worn from Continuous Use SOLUTION The Deck will wear over time If Deck had severe wear by sand or other debris at one time causing excess premature wear then this will make it wear that much faster and the only solution would be to replace Deck Hydraulic System Noise squea CAUSE Restrictions in System A Sgueal may be normal in some Valves when the lowering function is actuated as Oil is going over restrictors SOLUTION Check Hoses and Lines for Kinks Obstructions Hoses have an inner lining that can turn loose and block a hose If Assembly or Repair work has been performed recheck all connections for correct location Some may not be visible without some disassembly Unplanned restrictions cause increased backpressure loss of usable power and excess heating of Oil Restrictions can sometimes be found by measuring the temperatu
59. 07 425 576 160 217 445 603 685 929 OTHER 250 339 670 908 1030 1396 BOLT 330 447 910 1234 1460 1979 DESCRIP 480 651 1250 1695 2060 2793 1999 2060 0722 TIONS Maverick Boom Service Manual 12 04 2004 Alamo Group Inc section 1 7 NOTES Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Section 1 8 Section 2 VALVE OPERATION amp HOSE ROUTING 24 8 30 BOOM ERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 1 CONTROL VALVE BOOM 8 MOTOR CONTROL Maverick Boom and Motor Control Circuits It is advised that this section be read before proceeding with any repairs or test with the display and electronics used in this application the system will test many components for you This is done by following the prompts on the display screen Visually check all hose connections to make sure valve and cylinders are connected correctly This section will deal with the control valve and hose routing valve function and operation As this is a Elctro Hydraulic unit there are two section to deal with the controls Electric section and the valve section These two sections are closely linked together making it necessary to check both section together See section 2 amp 3 for these test DO NOT pressure wash this system while the components are sealed the soaps acid and high water pressure used in the pressure washer can damage these seals and cause moisture t
60. 19 18 mm ID 22 1 Relief Valve For Port D 22 1 1 O Ring 097 Dia X 755 ID 2 46 mm Dia X 19 18 mm ID 23 4 Bolt 3 8 16 X 2 1 4 57 2 mm Long 24 2 Bolt 3 8 16 X 3 1 5 88 9 mm Long 25 2 Bolt 3 8 16 X 4 101 6 mm Long 26 6 Bolt 27 1 Valve Plate 28 1 Housing Asy Includes Following Items 28 1 1 Housing Only 20 2 1 Bearing Press Fit 28 3 1 Plug Sub Asy 28 3 1 1 O Ring 064 Dia X 239 ID 1 63 mm Dia X 6 1 mm ID 28 4 1 Cradle Sub Asy 28 4 1 2 Dowel Bushing 28 4 2 1 Bushing 28 4 3 1 Bolt Button Head 28 5 2 Bolt 28 6 2 Seal Sub Asy 29 1 Back Plate Asy 29 1 1 Bearing Press fit 1 29 2 Roll Pin ote If replaced with a new Pump it will be the Electric Solenoid Servo Control Type Reference o Insert Sheet 02970224 for Electric Servo Control Manifold Asy MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 10 MOTOR CIRCUIT PUMP PARTS LOCATION Inner Gerotor and 11 tooth Coupler VALVE PLATE IDENTIFICATION Note V Notch Location y LH Rotation RH Rotation Valve Plate Valve Plate Item 27 Item 27 FIGURE 26 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 11 MOTOR CIRCUIT PUMP PARTS LOCATION Item Qty Description 31 1 Drive Shaft 32 1 O Ring 0625 Dia X 3 25 ID 1 59 mm Dia X 82 55 mm ID 33 1 O Ring Molded 34 1 Nut Used 1997 amp Down 35 2 Bolt 3 8 16 X 1 25 4 mm Long 36 1 Lockwasher 37 1 Washer 38 1 Plug 38 1
61. 4 4 MOTOR CIRCUIT PUMP ENGAGE Note The Servo Control Valve Lever and Solenoid have been replaced by a manifold and Solenoid valve Cartridge Please make note on all diagrams and text The Method used on the Machete to transmit Engine Power to the Mowing Head is called a Closed Loop or Hydrostatic System Figure 21 Engine Power is converted to Hydraulic Power by the Variable Displacement Hydraulic Piston Pump Oil is sent to the Fixed Displace ment Motor through the Hoses that run down the Boom Oil passing through the Motor converts the Hydraulic Power Back into Mechanical Power to Rotate the Blades The Shuttle Valve in the Motor returns 8 GPM back to the Tank for Cooling The remain der of the return oil remains in the Closed Loop Some of the advantages of using a Closed Loop System for the Motor Circuit are 1 A Smaller quantity of Oil is required 2 System acts as lts own Brake slowing down the Blades and 3 Less Fuel consumed due to No Load condition when Motor Circuit is disengaged Another feature of the Alamo System is that the Oil is filtered after it leaves the Charge Pump and before it enters the High Pressure Loop Solenoid Activation FIGURE 21 Wires 2 Wire Control Relief Valve Line To Filter Manifold Return From Filter Servo Port C Servo Piston A q a i ji I 1 J Y Y a q y UE 1 k LA AA Ad Cr A Np b Va IV E net 4 i a
62. 4 US gpm 90 l min Service Port without Pressure Compensator Max 33 US gpm 125 l min Return From Service Port Max 40 US gpm 150 l min Stated pressures are absolute shock pressures at 10 bar tank pressure Depending on Spool Varient Feed Reducing valves SER nisso secar aa 725 4800 psi 50 300 bar Internal Pilot Pressure Fixed SENO rra mn 320 or 508 psi 22 or 35 bar Temperature Oil Temperature Function Range Max 225 F Oil Temperature Working Range Max 225 F Filtration Filtration must be arranged so that contamination class 18 14 according to ISO 4406 is not exceeded For the Pilot circuit target contamination class 16 13 according to ISO 4406 is recommended Hydraulic Fluids Oil Type Recommended ISO 100 AW Hydraulic Oil Valve Connection Information Connection Location G Version UN Version P1 Inlet Section G 3 4 1 1 16 12 UN 2B T2 End Section G 3 4 1 1 16 12 UN 2B A B Spool Section G 1 2 7 8 14 UNF 2B PL Inlet Section G 1 4 9 16 18 UNF 2B PS End Section G 1 4 9 16 18 UNF 2B Valve Weights Section Weight ME IN 12 1 Ibs 5 5 kg JA 9 3 lbs 4 2 kg Spool Section w Spool Actuater EC A 11 9 Ibs 5 4 kg MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 10 NOTES MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 11 DIRECTIONAL CONTROL VALVE Hy
63. 70 02981277 Dipper 400 500 80 120 Head 02982068 02981280 Tilt 400 500 80 120 Head 02982071 02961480A Door Rotary 150 250 80 120 Head 02975528 02970710A Door Flail Axe 40 60 80 120 Head 02975532 02971423 Slide Timber Cat 400 500 50 60 Tie Rod 02973505 02811000A Door Ditcher 150 250 80 120 Head 02975528 02981316 Stabilizer 40 60 80 120 Head 02982073 02981315 Swivel Rotary 300 400 80 120 Head 02982072 02981276 Extension 300 400 80 120 Head 02982067 7 VALVE SPECIFICATIONS Valve Type Multi Section Load Sense Pressure Compensated Directional control Valve Features electro hydraulic spool actuators for proportional characteristics Valve Construction Multi Section Individual Spool with electro hydraulic solenoids Tie rod bolt together type Valve Controller Mechanical over Electric 3 axis multi function lever type joystick Valve Porting and Hose Connections Hoses connect to valve as shown by color code See Decal P N 02981986 below Electrical connections connect as shown Reference label on connector and corresponding solenoid Hose 4 Connector Attachment Stripe te LO Cylinder Base Solid to Cylinder Rod 02981984 Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Section 1 5 SPECIFICATIONS MAVERICK 8 Valve Spool Functions 8 Spec s Boom Feature Main Relief at Inlet 3335 psi Valve Spool Functions amp Specs Band Spool Cyl Travel Port Work Port Pressure
64. 80544 02980545 02980546 02980548 02980549 02980550 02980551 02980552 02980553 02980554 02980555 02980556 02980557 02980558 02980559 02980560 02980061 02980562 02980563 02980564 Qty M A AA A I I I I I lI I I lI cl a N alr a r a r a r a r a r a r a r Rotary Head Description Motor Asy Barrel Housing Asy Vlalve Plate Nozzle Plug Asy Hexagon Bearing Housing O Ring 7 O Ring 77 Seal Carrier Shaft Seal Spacer Washer Retaining Ring Retaining Ring Shaft Asy Cylinder Barrel Barrel Support Piston Asy Piston Ring Ring Gear Bearing Roller Bearing Roller Spacer Washer Retaining Ring Shim 0 5 Shim 0 2 Shim 0 4 Shim 0 6 Shim 0 8 Shim 1 0 Shim 0 7 Bolt Socket Head MAVERICK Service Manual 12 04 2004 Alamo Group Inc Item Part No 20 2f 20 29 30 31 33 34 35 36 37 38 39 40 02980565 02980547 02980571 02980570 02960568 02980569 02980237 02980532 02980533 02980534 02980535 02980572 02980573 02980566 02980567 A a M M M DDD Description Safety Valve Guide Pin Relief Manifold Relief Valve Seal Kit Relief Valve 280 Bar A Port Relief Valve 330 Bar B Port O Ring Ball Plug Hexagon O Ring Plug Asy Plug Asy Plug Asy Rebuild Kit Seal Kit These parts are included in Seal Kit These parts are included in Rebuild Kit Se
65. CIRCUIT PUMP DIS ENGAGE Motor Circuit Disengage w Engine Running The Alamo Closed Loop Motor Circuitic considered to be Neutral when there is no output being generated by the Variable Displacement Pump as the Shaft Internal components and Charge Pump are being driven by Tractor Engine The Camplate is in the centered position and the length of Stroke of the Pistons is equal therefore there is no flow being generated by the pump At this point the Charge Pump is drawing Oil through a Suction Screen from the Tank to provide flow to perform the following functions 1 Keep the Circuit Primed and make up internal leakage 2 Maintain Back Pressure on Pump asnd Motor Pistons 3 Operate Control Funtions to Start Pump 4 Maintain Temperature Control to prevent Oil Heating in Pump Oil from the Charge Pump is directed to two dual purpose system Relief and Check Valves Figure 23 Since the Charge Pressure is greater than the pressure in either side of the Closed Loop The Check Valves open and charged Oil at Charge Pressure is available to both sides of the closed Loop When the System is primed any excess Oil is relieved through the Charge Pump relief Valve which maintains a pressure of 250 to 300 PSI The Piston Pump remains in Neutral as long as the Camplate remains in the centered position this is controlled by the Servo Control System If Pump does not stay in neutral check the Neutral Adjusting screw This is usually noticed by M
66. Cable Binding or Sticking repair or replace as required Sometimes it may be the Linkage sticking or binding and not the Cable lt may be required to disconnect Cables from Linkage to determine which is sticking If it is the Linkage repair as needed Cables may stick because of internal abrasion inside calve Housing Some times this damage is not visible MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 8 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Moves On Its Own Under power Continued CAUSE Controller Not Returning to Center Electronic Joystick Control Models SOLUTION Test Joy Stick Controller as shown in Repair Manual Repair or Replace as needed Note Do Not replace Joystick till Test have been performed to eleminate other possible failures Other Malfunctions can appear like Joystick Failures CAUSE 2 Way Radio RF Interference Models will Electronic Controllers SOLUTION Radio Frequency interference is a common problem with all electronic controllers in allequipmentand vehicles Normally keying the microphone ofthe radio will result in some unwanted or unexpected operation In the case of a boom mower on of the boom functions may slowly begin to move The resolution of this problem requires that power to the controller be disconnected when operating the radio To accomplish this simply switch off the power switch on the controller box prior to using the radio This may affect Tractors that are equ
67. Color No Function Direction Relief Rating G W 1 Swing Forward B 3045 psi 2 0 G 1 Swing Back A 3045 psi 2 0 OR 2 Lift Down B 1160 psi 7 92 OR W 2 Lift Up A Plug 7 92 B W 3 Dipper Out B Plug 3 17 B 3 Dipper In A 1160 psi 3 1 YAN 4 Telescope Out B 2030 psi 3 17 Y 4 Telescope In A Plug 3 17 R W 5 Tilt Up A Plug 3 17 R 5 Tilt Down B 2030 psi 3 17 G 6 Swivel CW top A 2 55 psi 6 60 G W 6 Swivel CCW top B 2755 psi 6 60 Valve Spool Functions 8 Specs The Cylinder Cycle has adjustable settings slow medium and fast Time Cylinder cycle of unit Time indicates the time for the Cylinder to travel the full amount of its extension or retraction The lift times up and down are taken with the dipper fully extended and begin with the Deck flat on the ground All Cycle times are measured at the rated Tractor RPM Test Times should vary as accord ing to the setting being used Valve Leakage Maximum internal Valve Leakage from the Cylinder Ports to Tank at any Valve Segment Oil Pressure at 1450 PSI and Oil Viscosity at 102 SSU 1 25 Cubic Inch Minute Standby Pilot Pressure Standby Pilot Pressure 200 to 250 PSI 9 HOSE END FITTING TORQUE SPECS Hose End Type 37 Degree Angle End Steel Hose End Fittings Dash Nominal Cyl Torque Torque Size Size in in lbs ft Ibs 4 1 4 140 12 6 3 8 230 19 8 1 2 450 38 10 5 8 650 54 12 3 4 900 75 16 1 1200 100 20 1 1 4 1600 133 24 1 1 2 2000 167 32 2 2800 233
68. Detail B the pistons effective summation force tends to destroke the swash plate to a vertical neutral position This destroking force is balanced as the swash plate is angled by the force of the servo piston Detail A sm Detail B BARREL SUMMATION OF PISTON FORCES ara lid pr rv do nr fe ol en a i m I CA ze Cr api eH EA rl esses Bete tae OIL FLOW Pressure Compensated Control Variable Piston Pump Swash Plate angle controls the output flow of the pump Swash plate angle is controlled by the force generated against the swash plate by the pumping pistons and the force of the servo piston The force of the servo piston is greater than the force of the pumping pistons when both are at the same pressure See Figure 37 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 26 PUMP BOOM CIRCUIT Pressure Compensated Control continued By means of internal porting pressure is connected from the output port to the servo piston via orifice E andto the control spool via passage D Also pressure is applied to the control spool chamber through orifice F As long as the pressures at both ends of the control spool remain equal the spool will remain offset upward due to the added force of the spring See Figure 37 When pressure reaches the setting of the compensator control the dart leaves its seat causing the pressure in the spool chamber to be reduced The spool now moves downward causing pr
69. Dipper Section 14 02981866 1 Z MJ U FJX Hose 44 4MJ 4FJX 214 Lg Yellow White Tie Door Dipper Section 15 02981867 1 Z MJ X FJX Hose 4 4MJ 4F JX 214 Lg Green Tie Swivel Dipper Section 16 02981868 1 Z MJ W FJX Hose 4 4MJ 4F JX 214 Lg Green White Tie Swivel Dipper Section 17 02981869 1 Z MJ T FJX Hose 6 6MJ 6FJX 214 Lg Red Tie Tilt Dipper Section 18 02981870 1 Z MJ S FJX Hose 6 6MJ 6FJX 214 Lg Red White Tie Tilt Dipper Section 19 02981873 1 C FJX F FJX Hose 16 16FJX 16F JX90 140 Lg Red Tie Mtr Prs r Lift Section 20 02981874 1 A FJX D FJX Hose 16 16FJX 16F JX90 140 Lg Orange Tie Mtr Rtrn Lift Section 21 02981875 1 K FJX L FJX Hose 16 16F JX 16FJX 94 Lg Red Tie Mtr Prs r Dipper Section 22 02981876 1 H FJX N FJX Hose 16 16FJX 16F JX 98 Lg Orange Tie Mtr Rtrn Dipper Section 23 02981877 1 B FJX E FJX Hose 412 12FJX 12FJX 140 Lg Blue Tie Case Drain Lift Section 24 02981878 1 JFJX M FJX Hose 12 12FJX 12F JX 96 Lg Blue Tie Case Drain Dipper Section NOTE Hose end 1 amp hose end 2 These are where the ends of the hose connects the letter shows location of that end and shows type hose fitting on that end of hose The Hoses have plastic ties on then to help show which hose is which the ties are a solid color or they will have a white stripe on them The same color tie may be used twice but should not be used twice on the same size of hose Example a yellow t
70. EED VALVE ASSEMBLY AT CONSTANT SPEED PRESSURE CHORE H H CONTROL DRAIN E si dE CONTROL SPOOL PORT A cB SPRING CHAMBER FIGURE 37 PERS OR DIFFERENTIAL ADJUSTMENT ADJUSTMENT MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 27 PUMP BOOM CIRCUIT Remote Pressure Control Control Type M Remote control of the output pressure can be achieved by controlling the pressure in the low signal B port when the pump is set up for control type M A Manual hydraulically piloted pressure control device is installed in the line from the low signal B port to tank The pump will then maintain pressure approximately equal to the pressure in the B port plus the pump differential setting Low Pressure Standby This option can be used as an alternative to the load sensing option A to achieve low pressure standby Minimum standby pressure is somewhat higher than that achieved using option A In the compensating mode there is approximately 3 GPM 1 14 LPM flow from the low signal B port in addition to 9 GPM 3 4LPM flow from the control drain port A Multiple Pressure Standby If the pressure in the low signal B port is limited by a relief valve as the desired pump outlet pressure is reached the relief valve in the B port will allow the pump to standby at a preset pressure Adding to this concept multiple remotely piloted relief valves plumbed in parallel in the B port line can yield multiple
71. ERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com Make certain that the instructions you refer to is for the MDM system the manufacturer has more than one system The boom and motor control is electronic over hydraulics If these functions are not properly set or working properly the mower can not be operated Also make certain that all fluid levels are OK and with in operating limits The first thing that should be checked is the main electrical power supply to the system this can be checked on the display unit when power is on The set up portion as shown in the next pages should be checked to make certain the joystick and motor functions are set correctly Check all the connections if not operating properly If the settings are not correct the system will not function properly Check the emergency stop E Stop switch if it is in the off position the system will not operate and the system cannot be set properly Never short across any of these components as the type electronics used can be seriously damaged Always use a volt ohm meter to test any circuits MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 2 CONTROL VALVE BOOM CONTROL Maverick Boom Control System 1 Operating the Boom Control functions is done so by means of a load sensing electronic over hydraulic system There are three main areas of that
72. Hose 4 4MJ 4F JX 176 Lg Green Tie Swivel Dipper Section 16 02981841 1 Z MJ W FJX Hose 4 4MJ 4F JX 176 Lg Green White Tie Swivel Dipper Section 17 02981842 1 Z MJ T FJX Hose 46 6MJ 6FJX 176 Lg Red Tie Tilt Dipper Section 18 02961843 1 Z MJ S FJX Hose 46 6MJ 6FJX 176 Lg Red White Tie Tilt Dipper Section 19 02981846 1 C FJX F FJX Hose 16 16FJX 16FJX90 102 Lg Red Tie Mtr Prs r Lift Section 20 02981847 1 A FJX D FJX Hose 16 16FJX 16F JX90 102 Lg Orange Tie Mtr Rtrn Lift Section 21 02981848 1 K FJX L FJX Hose 16 16FJX 16FJX 54 Lg Red Tie Mtr Prs r Dipper Section 22 02981849 1 H FJX N FJX Hose 416 16FJX 16FJX 58 Lg Orange Tie Mtr Rtrn Dipper Section 23 02981850 1 B FJX E FJX Hose 412 12FJX 12FJX 102 Lg Blue Tie Case Drain Lift Section 24 02981851 1 JFJX M FJX Hose 12 12FJX 12FJX 56 Lg Blue Tie Case Drain Dipper Section NOTE Hose end 1 8 hose end 2 These are where the ends of the hose connects the letter shows location of that end and shows type hose fitting on that end of hose The Hoses have plastic ties on then to help show which hose is which the ties are a solid color or they will have a white stripe on them The same color tie may be used twice but should not be used twice on the same size of hose Example a yellow tie may be used on a 4 hose and again on a 6 or larger hose always check the color coded ties and the size of the hose identify the hose and its
73. JX 115 Lg Yel Tie Door Lift Sec n 02981880 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg Yel Wht Tie Door Lift Sec n 02981855 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg Grn Tie Swivel Lift Sec n 02981856 1 Y MJ Z FJX Hose 4 4MJ AFJX 115 Lg Grn Wht Tie Swivel Lift Sec n 02981857 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Yel Tie Ex n Lift Sec n 02981858 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Yel Wht Tie Ex n Lift Sec n 02981859 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Red Tie Tilt Lift Sec n 02981860 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Red Wht Tie Tilt Lift Sec n 02981861 1 Y MJ O FJX Hose 6 6MJ 6FJX 135 Lg Blu Tie Dipper Dipper Sec n 02981862 1 Y MJ P FJX Hose 6 6MJ 6FJX 135 Lg Blu Wht Tie Dipper Dipper Sec n 02981863 1 Z MJ R FJX Hose 6 6MJ 6FJX 125 Lg Yel Tie Ext n Dipper Sect n 02981864 1 Z MJ Q FJX Hose 6 6MJ 6FJX 125 Lg Yel Wht Tie Ext n Dipper Sec n 02981865 1 Z MJ V FJX Hose 4 4MJ 4FJX 214 Lg Yel Tie Door Dipper Sec n 02981866 1 Z MJ U FJX Hose 4 4MJ 4FJX 214 Lg Yel Wht Tie Door Dipper Sect n 02981867 1 Z MJ X FJX Hose 4 4MJ 4FJX 214 Lg Grn Tie Swivel Dipper Sec n 02981868 1 Z MJ W FJX Hose 4 AMJ 4FJX 214 Lg Grn Wht Tie Swivel Dipper Sec n 02981869 1 Z MJ T FJX Hose 6 6MJ 6FJX 214
74. K iness st cast knze nee messes sneonsns eme 7 35 A 7 36 Tractor Battery Dead or Low Continous Power Draining 7 36 MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 8 3 POSSIBLE FAILURE CAUSE 8 SOLUTION Boom Breaks Back Too Easily Boomis designed to break back if to much resistance is meet for safety reason CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Work Port Relief for Swing Cylinder Malfunction Testfor Pressure required to Break Back the Boom If Pressure is lower or higer than Specified Adjust or Replace Work Port Relief Valve Cutting Head Positioned Too Close To The Ground This is an Operational Problem The Operator will be required to adjustthe way the unit is being run and raise the Head Up Operator Running Into Too Heavy Material or Traveling Too Fast This is an Operational Problem The Operator will be required to adjustthe way the unit is being run and Adjust Operating procedures to eliminate this Inadequate Bracing This is a difficult subject It is recommended that you consult with the factory before making modifications of this type Adding additional pieces may change many components functions the weight that would be added changes the balance weight ratio The Hydraulics ability to lift and even lower could be affected Adding weight is not recommended Boom Drops When Two Functions Actuated CAUSE S
75. M NO MATTER HOW SMALL WILL DAMAGE SYSTEM After cleaning around all connections thoroughly Dis connect all connections Lines Hoses Wiring and Remove the Pump Completely from the Tractor Plug all hoses and Lines on Tractor and on Pump DO NOT leave any open Lines NO Contamination Should be allowed into system at all Clean Area Clean all Tools Pans etc The cleaning of Area and Tools MUST be done before moving Cleaned Pump there Drain Oil from Pump Recheck outside of Pump to Make Sure it is Clean After dis assembly of Pump wash all metal components in clean solvent Use compressed Air to dry parts after washing Compressed air must be filtered and moisture free DO NOT wipe them dry with Paper Towels or Cloth as these will leave lint and or dust contamination DO NOT USE Compressed Air to spin any component Such as Bearings or Plates as this will damage them and could be dangerous Always use new Seals when re assembling Hydraulic Pumps Lubricate the new rubber Seals with a Petroleum Jelly Vaseline before installing them DO NOT reinstall worn or damaged Parts back in Pump DO NOT Use a worn or damaged Pump Housing Torque all Bolts over Gasketed Joints Then repeat the Torque sequence to make sure Bolts are tight some times Gaskets can give a Torque reading that is OK but is not so always re check Torque Verifying the accuracy of Pump Repairs on an authorized test stand is essential REQUIRED TOOLS N e Re c OE
76. M gauge consult tractor owners manual to find whatthe required speed is At any time the Emergency stop switch Figure 8 D located on the joystick will deactivate the cutter motor circuit The blade will stop within 6 second when the emergency switch is shut Off MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 3 CONTROL VALVE ELECTRONIC NETWORK Maverick Mower Head Circuit continued from Previous page MDM Master Display Mini Analog inputs Prop Outputs Digital Inputs Digital Outputs 1 Freq Inputa E Gas r FIGURE 8 A FIGURE 8 B FIGURE 8 C FIGURE 8 D Maverick Electronic Network Figure 9 Electronic Network The electronic network is the control and communication network that receives and transmits data to certain components in the boom control system Its purpose is to manage the incoming and outgoing information There are five main components The MDM is an operator Display that is located in the cab The purpose of the display is to house the programming software for the system control and provide an interface between the operator and the Maverick Boom The interface is utilized through a multi screen function that allows the operator to set individual parameters for customized control functions The display also provides tools such as an on board measurement device useful for determin ing short circuits component loss and or power supply issues REFERENCE PRODUCT MANUAL FO
77. OLUTION CAUSE SOLUTION CAUSE SOLUTION Low Oil Level in Tractor Hydraulic System Fill and Bleed all Cylinders Run All Cylinders through thier Cycle Then fill Tractor Hydraulic Oil to Proper Level Run Cylinders through thier Cycle again and recheck Hydraulic Sump Oil Level again If the Cylinders are not Filled then Cil Level brought to Specs the Oil Level could be low during operation causing damage to Tractor Hydraulic System Too Rapid Drop Of Boom Too Rapid Drop in Cylinder Restrictors damaged or removed Check restrictors if they have them Make sure correct size Hoses are installed to cylinders Repair or Replace as needed Defective or Damaged Joy Stick Controller There are very few replaceable Parts in Joy Stick Controller See the Repair Section for Testing and repairing the Joystick DO NOT Replace Joystick till all Test have been performed to pin down the problem area There are a number of tests to locate problem area that can be used these are listed through out sections of the repair Manual as well as some listed in the Operators Manual MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 4 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Boom Positioning Cyl Continue to move after Joy Stick released Boom Moves on its Own Electronic Joystick Joystick does Not return to Neutral CAUSE Defective or Damaged Joy Stick Controller SOLUTION There are very few replaceable
78. OVE RIGHT HAND CW PORT PLATE SHOWN BELOW Section 4 33 MOTOR BOOM PUMP HOSE ROUTING Tee m m l NO EE A y GE CBCE H 909 Item PartNo Qty Description A 02981427 1 Hose 8FJX 8FJX 90 24 Lg w Red Tie Charge Filter to Pump B 02981428 1 Hose 8FJX 8FJX 90 21 Lg w Blu Tie Case Drain to Tank C 02981429 1 Hose 12FJX 12FJX 23 Lg Pump to Suction Filter hose under pump and cannot be seen in drawing D 02981430 1 Hose 12FJX 12FJX 31 Lg w Red Tie Pressure Filter to Supply E 02981431 1 Hose 4FJX 4FJX 90 35 Lg w Red Tie Pump Load Sense to Valve PX F 02981432 1 Hose 4FJX AFJX 90 20 Lg w Blu Tie Pump Regulator to Tank G 02981433 1 Hose 20FJX 12FJX 24 Lg Pump to Suction Filter H 02981462 1 Hose 12FJX 12FJX 90 20 Lg w Org Tie Valve Return to Tank NOTE Hoses are not shown in drawing above this is for clarity The hose routing is for the hoses which connect from one pointto the other Use the instructions and hose description listed to follow hose routing Example Hose A connects to one end marked A and the other end of hose connects to the other item marked A This is done with the other letters as well the hose must connect to the same letter markings on each end as in drawing Some hose will be marked with a colored plastic tie Some hose will have a straight fitting or a 90 fitting This is to allow hoses to be routed to where they cl
79. OYSTICK JOYSTICK TROUBLE SHOOTING The Joystick Wiring Harness has 2 wire connections to link Joystick 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 Spool valve is furnished by the secondary pump system mounted to the front pump With the Switch Keyed Switch of tractor in the On position and the Rocker Master Switch on Display Console in the On position a Light on Master Switch should be on This light indicates that electrical power is available to the control circuits 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 Dipper and Telescopic Functions are Proportional Controlled Therefore only these three functions will show progressive readings The Tilt Door and Swivel Functions are On or Off when checking keep track of which connection is being checked as it will make a difference in reading on voltmeter 2 All Connections are marked on plug where they plug onto Valve See Figure 5 3 Make sure Tractor Engine is off and cannot be started while you are working on it 4 Relieve An
80. Pin Place the Valve Plate in position onto the Back Plate with the Steel side against Back Plate 17 Install Back Plate Assembly into Housing Assembly Make sure Ports are posi tioned correctly Valve Plate and Gasket stay in place If No Gerotor Charge Pump Skip to step 22 MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 16 MOTOR CIRCUIT PUMP RE ASSEMBLY 18 19 20 21 22 23 24 25 Install Key and Inner Ring Gerotor onto Shaft or Coupler Assembly Lubricate Inner Ring Gerotor before Assembly Refer to appendix A for Re Assembly of Charge Relief Valve in Adapter Plate Install O Ring and Outer Ring Gerotor onto Adapter Plate Lubricate both O Ring and outer ring to hold in position during assembly of adapter plate Install adapter plate onto Back Plate Make sure O Ring and Gerotor Ring stay in place Retain Back Plate and Adapter Plate when used with four Bolts Torque these Bolts to 27 to 31 ft lbs 37 to 42 nm refer to Appendix B for Re Assembly of Manual Servo Control Assembly Install Control Housing Gasket onto Housing Install Orifices into Control Assem bly and retain in position with Petroleum Jelly Vaseline Install Manual Servo Control Assembly onto housing making sure feed back link entered small groove in Servo Piston Assembly Manual Servo Control on units 1997 8 Down Units 1998 8 Up have Solenoid Servo Manifold Assembly to install here Retain Servo Control
81. Pin 1 P 3 14 Pin 2 P 3 15 Pin 3 P 3 Pin 4 P 3 16 Pin 1 P 4 17 Pin 2 P 4 18 Pin 3 P 4 Pin 4 P 4 Qty O A X X Cy CX X IX Onnan X3 LX LX ASA ad Description Red Wire Blue Wire Black amp White Stripe Wire Red amp White Stripe Wire Violet Wire Brown amp Black Stripe Wire Black amp Red Stripe Wire Yellow amp Red Stripe Wire Black Wire Red amp White Stripe Wire Brown amp Black Stripe Wire Violet Wire Open No Wire Red Wire Black amp White Stripe Blue Wire Open No Wire Black amp Red Stripe Wire Black Wire Yellow amp Red Stripe Wire Open No Wire NOTE Listed above is the resister wire harness P N 02981990 this harness connects to the joystick and interior wire harness The wire colors indicate which pin is which wire The plugs will have numbers on them to indicate pin location MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 15 Emergency Stop Switch P N 02964028A Emergency Stop E Stop Switch The emergency stop switch also referred to as the E Stop Switch is to stop the head motor from turning It is designed to stop the blades from rotating in 6 second from time switch is activated The E Stop switch will not allow the head to start when activated the Switch is engaged if you are unable to get head to start always check this first Some parts may not be available as replacement parts for this switch available as an assembly only
82. Plug was installed into the lower hole where the relief fill plug was installed as the early spindle only had the one hole Spindle should always be installed with Pressure and Fill Plugs pointing away from Tractor CAUSE Spindle Overfilled SOLUTION Continue running Only continue to Run if sure Leak is because Spindle is Over Filled and clean up the mess until the leakage stops or remove some of the lubricant with possibly a suction gun SPI ndle Over Heati NG spindle will operate up to 200 F which is considered within tolerance range and is not considered over heating DON T Check for over heating with the touch of your Hand The Temperature is to high and will burn you CAUSE Low Oil Level in Spindle SOLUTION Find causes of Low Oil Level and correct it If Spindle was run Low Lubricant it is likely to be Bearing Damage from lack of Lubricant The Spindle should be dis assembled Inspected and reassembled replacing any damaged parts Always use New Seals CAUSE Excessive Bearing Pre load Bearings to Tight SOLUTION Bearing need to be removed and inspected for damage from running too tight Rebuild Spindle replacing Parts as required Always replace with new Seal Set Bearing Pre Load and Lock Adjusting and Locking Nut down as instructed in Spindle repair section to correct Specifications always double check to make sure Nuts are Locked in place CAUSE Bolts Holding Blade Bar to Spindle replaced and New Bolts to Long SOL
83. Pre Set Angle Oil from the opposite end of the Servo Piston is exhausted to the Pump Housing through the Control Valve Spool When the Control Lever Solenoid amp Block on Current Models is returned to the Neutral position The Spool centers itself allowing the Pressure on both ends of the Servo Piston to egualize The Piston and Camplate return to a Neutral position and Oil flow from the Piston Pump ceases Orifices between the Control Valve and the Servo Piston control speed of the Camplate movement Neutral Adjustment Screw is to set Servo in Neutral position to prevent flow to motor a Buzz Bar Head will have a screw on both sides Rotary head shown below Control Lever removed on later Model replaced by Block with Solenoid FIGURE 22 Servo Piston Feed Back Line Servo Piston Follower Camplate System Relief and Check Neutral Valve Centering i Port C Spring Port D From Motor To Motor Gerotor Camplate Charge Servo Control Piston Asy Pump Solenoid ms KK Charge Spool ns x NBS NO 0 C C Q 3 O O D APG 00 0 6 L sa SI U JET 4 amu 4 SONO S LL 94 ma III a Pressure Line Sm ENT gt y Charge Pump Relief Valve oystem Relief amp Check Valve TE TIGRE Servo Control Supply Oil MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 6 MOTOR
84. R MDM DISPLAY THIS MANUAL IS AVAIL ABLE FROM THE MANUFACTURER ON THE INTERNET AT www iqan com viewable and print able with ADOBE ACROBAT READER If you do MDM Master Display Mini not have Adobe Acrobat Reader it can be ob altas Diplo s tained at www adobe com Freq Inputs E Gas Make certain to view the MDM section as this Op 109 is the type used on the maverick boom there are listings at the web site that will not apply to the FIGURE 9 maverick boom MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 4 CONTROL VALVE ELECTRONIC NETWORK Maverick Electronic Network continued The XP2 The XP2 is a controller module that is mounted at the front of the tractor next to the maverick control valve The function of this compo nentis to provide a gateway for incoming and outgo ing information Information is sentvia the network to this module in order to provide control of the sole noids for valve operation See Figure 10 REFER ENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANU FACTURER ON THE INTERNET AT www igan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com The XT2 The XT2 is also a controller mod ule that is mounted at the front of the tractor on the side of the tank The function of this component is to provide a gateway for incoming and outgoing infor mation This
85. RICK Service Manual 12 04 2004 Alamo Group Inc Section 3 10 DOOR SWING CYL DIVERTER VALVE P N 02977622 Diverter Valve The diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two or more if valves are stacked funtions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pressure The Port openings on this diverter valve are marked with letter number codes which show wich port is connected to which hose and where that hose connect on other end See Figure 18 Port Function amp Connection P1 Hose Hydraulic Pressure from Door Swivel B Port on Control Valve P2 Hose Hydraulic Return to Door Swivel A Port on Control Valve C1 Hose to Head Swivel Cylinder Base End C2 Hose to Door Cylinder Base End C3 Hose to Door Cylinder Rod End C4 Hose to Head Swivel Cylinder Rod End Electric solenoid retaing M Electric Solenoid kle T ber o on C1 Port this side for mounting diverter valve cide Not to frame Not Seen Seen to head swivel cyl base end C4 Port this P1 Port Pressure from Control Valve door swivel port of control valve side Not Seen to head swivel cyl rod end N A GI K TI These 4 holes are Through holes that would be used if this were a stacking valve to stack two or more valves together These holes are not used in this application P2 P
86. SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION MAVERICK Service Manual 12 04 2004 Alamo Group Inc Contamination In System Locate and correct source of contaminants This could include the complete system Pump Motor Valves Hoses Tank Oil Filter System or any other componentincluding your source of replacement Oil Supply The Contaminants must be found and removed and stopped The Solution is to repair or replace worn parts Completely Flush and Clean all Hydraulic Components Install New Clean Recommended Oil Cavitation Cavitation Is caused by inadequate amount of Fluid Hydraulic Oil reaching Pump Usually a restriction of some sort in the suction lines but can also be caused by an unvented Tank This will cause a vacuum when the Pump starts demanding Oil The Pump cannot pull Oil out of this vacuum Other Problems such as plugged Suction Screens or very Thick Oil can cause cavitation This must be found and corrected before repairing old Pump or installing new one Air In The Oil Run System for a few minutes Check for Air in the Oil in the Tank Air entrained Oil has a foamy appearance If Air is present find the Air Leak and correct it Air Leak can be in the Suction Line and Oil may not leak out because there may only be Oil in that location when the Pump is sucking it in With the Tractor Engine Off you can find a leak by pressurizing the Tank This will not take b
87. See Figure 32 2 Clean Make Sure that everything Pump Connections Tools Work Bench Vise and all general conditions are very clean before beginning any work 3 Input Shaft Removal Remove Wiper Seal item 16 with Screwdriver Remove Set Screw item 13 retaining Input Shaft item 14 and remove it from Control Housing 4 Valve Spool Plug Remove Set Screw item 8 from Plug item 2 retaining Valve Spool item 7 and remove Plug Remove O Ring item 3 if it did not come out with plug or remove after Valve Spool is removed 5 Feedback Link and Bell Crank Remove E Ring item 11 from Pin item 10 retaining Feedback Link item 9 Remove Feedback Link and Bell Crank from Control Housing Head Pin item 17 is a press fit into Bell Crank Removal of Head Pin is not required as part of repair unless it is damaged 6 Valve Spool Remove Valve Spool item 7 from Housing after Step 5 is done Compress Spring item 6 on Spool and remove E Ring item 4 This allows Spring Retainer item 5 Spring item 6 and other Spring Retainer item 5 to slide off of Valve Spool 7 O Rings and Cleaning Parts Make sure all O Rings are removed from Housing Throw away all old O Rings Inspect and clean all parts clean all Parts with Clean Solvent and Dry with Compressed Air Only See introduction section for more cleaning information Lubricate all parts in preparations for re assembly ANUAL SERVO CONTROL RE ASSEMBLY 1 The following instru
88. UTION Check that Blade Bar Retaining Bolts are not to Long to cause them to bottom out and jam through Spindle damaging Shaft Always make sure same Length Bolts are installed that came Out If to long of Bolts have been installed in Spindle it will have to be rebuilt MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 32 POSSIBLE FAILURE CAUSE 8 SOLUTION Spindle Shaft Loose or Falls Out Note When Spindles are properly assembled and lubricated The Shaft should not loosen up in service Shaft loosening up is an indication of a serious internal problem Merely tightening up the adjusting Nut will not correct the cause of the problem CAUSE Bearing Adjusting Nut Backed Off Not Properly Locked SOLUTION Dis Assemble Spindle and inspect Parts for damage All components have a possibility of being damaged if ran with Bearings Loose Install required replacement parts and re assemble See Spindle repair section for assembly and settings CAUSE Bearing Cups or Bearing Cones Not Seated Properly SOLUTION 1 IF MOWER HAS NOT BEEN RUN since Spindle was assembled Find out why Bearings are not seated and correct problem readjust Bearing Pre load and make sure Bearings are seated properly Fill with Lubricant and Test 2 IF MOWER HAS BEEN RUN since Spindle was assembled Dis Assemble Spindle and inspect Parts for damage All components have a possibility of being damaged if ran with Bearings Loose Install required rep
89. Valve Specifications 2 10 Cylinder Control valve Operations 2 12 to 2 13 Hydraulic STEN easier Ua Ut oi 2 14 Cylinder amp Motor Hose Functions and Color Codes 2 15 Boom Hoses Conctions 8 Functions 2 16 to 2 19 Cylinder Control Valve Trouble Shooting 2 20 to 2 21 Section 3 Joystick Operations 8 Electronic TestingTesting 3 1 to 3 4 PE DOF i RM RETE 3 2 Doom Control SS Musicas 3 3 Mower head Circuit aaa 3 4 Electroni a aa is na ad 3 4 to 3 5 Electronic instrumentation 3 6 to 3 9 Electric Lock Valve Head Tilt Function 3 10 Electric Diverter Valve Door Swing Function 3 11 Joystick Operation 3 12 Joystick SCNSMAL Criar 3 13 Joystick ResisterHarness Schematic 3 14 to 3 15 Emergency Stop VO See ener oap ute o cera ere 3 16 Hydraulic Schematic P N 029818970 3 17 Wire Harness Schematic Exterior P N 02981375 3 18 Wire harness Schematic Exterior P N 02981375A 3 19 Wire Harness Schematic Interior P N 02981375B 3 20 Wire Harness Schematic Interior P N 02981376 3 21 Joystick Trouble Shooting 3 22 to 3 23 Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Index 2 Section Section 4 Pump SECTION inis u dani obojak ai d ln iso il hla a Pump Tan
90. Volume varies with the Tractor Engine Speed SPECIFIC OPERATION Figure 3 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 Harness should only be connected to a Wire that has Voltage when the ignition is in the On Position If Connection of the Harness is to a constant current source it will cause power drain on Battery and eventually Battery Failure Furthermore the Master Switch on the Display Console 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 Potentiometer located in the Joystick Assembly which sends the positioning information to the electric controller 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 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 th
91. Y OR EVEN DEATH TO OPERATOR AND OTHERS IN THE AREA 2 NO RIDERS NO CHILDREN 3 USE SAFETY SHOES HARD 4 BLOCK UP SECURELY OPERATORS HAT SAFETY GLASSES BEFORE WORKING UNDER SEAT BELTS amp ROPS Re TA DES OM 1 Study and understand Operators Manuals Safety Signs and Instructional Decals for tractor amp flail mower to prevent misuse abuse amp accidents Practice before operating mower in a confined area or near passersby Learn how to stop engine suddenly in an emergency Be alert for passersby and especially children 2 Allow no children on or near implement or tractor Allow no riders on tractor or implement Falling off can cause serious injury or death from being runover by tractor or mower or contact with Flail Mower Blades 3 Operate only with tractor having Roll Over Protective Structure ROPS and with seatbelt fastened securely and snugly to prevent injury and possible death from falling off or tractor overturn Personal Protective Equipment such as Hard Hat Safety Glasses Safety Shoes and Ear Plugs are recommended 4 Block up or support raised machine and all lifted components securely before putting hands or feet under or working underneath any lifted component to prevent crushing injury or death from sudden dropping or inadvertent operation of controls Make certain that area is clear before lowering or folding 5 Before transporting put Lift Lever in detent or full lift position Install Transport Safet
92. able at the Check Seats of the combination System Relief a Check Valves As the Piston is drawn outwards in its bore The combination of lower pressure in the Piston Bore and charge pressure in Port C causes the Check Valve for Port C to come off its seat Allowing Oil At Charge pressure to fill the Piston Bore As the Piston Block rotates the Oil is trapped in its bore by the Valve Plate As the Piston Block rotates more the piston is forced back into its bore expelling the Oil into Port D through an opening in the Valve Plate The Higher pressure in Port D seats the Check Valve for Port D Seperating Oil in Port C from Oil in Port D Oil is forced to go through the Motor causing Motor Rotation Any Leakage from the Piston Block Valve Plate Pistons or excess Oil from the Charge Pump Relief Valve is vented to the case and is returned to Tank through the case Drain Port mu oystem Relief amp port C Neutral Port D Check Valve From Motor Centering Camplate ToMotor Gerotor noid Sole Spring Piston Asy NI Charge AT re VON from y warmer ed eel X Charge ON au Ex us i OA E Nims O nm lk m DE Suction am Charge Pump bua gt gt pum ss eZ mio E System Relief amp Check Valve FIGURE 24 Servo Control Supply Oil V Relief Valve O
93. ad Only adjust the one with the hex head DO NOT adjust or change the round ridged adjustment as it is set from the factory Adjust the 7 16 hex one by turning it in till it seats completely Do not force adjustment after is seats Then back it back out 1 2 turn this will give you the 2800 psi required to oprtate the boom See Figure A 8 B F Hold the ad justing nut while turning MN the locking l nut so the be AG A adjustment lk Pressure Adjust nut does not u Control 7 16 Hex 4 turn with it 1 A changing the ar A A Pressure Adjust Nut 7 16 Hex setting I PEE amp A4 x Locking Nut 1 2 Hex MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 9 CONTROL VALVE OPERATION HYDRAULIC LOCK VALVE Head Tilt Function An Electric Solenoid Operated Hydraulic Lock Valve Figure 17 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 sentto 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 co
94. all Rotation Kit Assembly Leave Housing and Shaftin the Horizontal position Holding Camplate into position with Screw Driverthrough Controller Linkage passage way atthe top of the Housing Place Rotating Kit Assembly over shaft and into Housing until Pistons are in against Camplate Make sure all parts are in Housing completely and properly positioned Return the Pump to the Vise with open end of Housing up Clamping Housing on the outer portion of the flange 12 Install Gasket on Housing Install New Gasket on Housing now 13 If necessary Press New Bearing and Roll Pin in to Back Plate to dimension shown in Figure 34 Bearing MUST be installed with the numbered end of Bearing Outward Roll Pin must be installed with split in Roll Pin away from Bearing 14 Install Relief Valve Always Install New O Rings on Relief Valves Install Relief Valves in its original cavity in Back Plate that it was taken out of is recommended but if they are switched it should not affect anything as they are both the same setting Torque Relief Valves Tighten to 100 to 110 ft Ibs 136 to 149 nm 15 Install New Quad Ring on Dump Valve or Plug Install Dump Valve or Plug and retain with Retaining Ring into Back Plate Note Make sure paddle of Dump Valve is perpendicular to relief valve axis prior to installing or damage could occur 16 Apply a small amount of Petroleum Jelly to the Steel Side of Valve Plate to hold itin place for installation Aligning the Index
95. and all general conditions are very clean before beginning any work 3 Inspection Examine the outside diameter ofthe Pistons for finish condition They should not show wear or deep scratches Inspect the shoes for a snug fit on the ball end of the Pistons and a flat smooth surface that comes in contact with the Camplate DONOTLAP the Piston Shoes Do Not Lap means do not sand file or try to smooth machined surface 4 Piston Shoes If Piston Shoes are rough DO NOT LAP them 5 Spider Examine Spider for wear in the Pivot area Examine Pivot to insure smoothness and no signs of wear 6 Piston Block Inspectthe Piston Block surface that makes contact with Valve Plate This surface should be smooth and free of deep scratches DO NOT LAP Piston Block 7 Pistons The Pistons should move freely in Piston Block Bore If they are sticky in the Bore Examine the Bore for scoring or contamination 8 Pins and Spring To inspect Pins and Spring CAUTION should be taken in removing opring The Spring is highly compressed and the retaining Ring should not be removed without compressing the Spring safely 9 Piston Block Dis Assembly The following Tools will be needed to dis assemble Piston Block A Flat Washers 2 ea 3 8 ID X 1 1 8 OD B Bolt 1 ea 3 8 X 3 1 4 NC C Nut 3 8 NC 10 To remove Spring Place one of the Flat Washers over the 3 8 X 3 1 4 NC Bolt Put Bolt through the center of the Piston Block and apply the second Flat Wash
96. ase 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 amp 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 amp 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 W
97. at a time using a criss cross pattern The Valve Body can be placed in a bind ifthe mounting bolts are tightened un evenly This can cause the Spool to stick in the bore or cause the Valveto leak internaly CAUSE Contamination in Valve Spool SOLUTION Find Contamination source and correct it Clean Valve Change Filters Re place Oil if required to remove contamination Re Assemble and Test CAUSE Faulty Valve Spool or Section SOLUTION Replace Valve Section If the valve Section is defective The Malfunction will most likely occur immediately after being placed in service If the Unit has been operating for sometime the problem is most likely to be a failure not a defective partthere fore more checking maybe needed to determine why the Valve Spool failed MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 5 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Excessive Drift NOTE All Cylinder Hydraulic Systems have some amount of drift or leakage in the system All parts have tolerances and all parts Must have clearance in order to function Clearance necessary to allow the part to function also results in some internal leakage Cylinder Drift can also be refered to as Leak Down or Settling In most cases the cause of Cylinder Drift will be found in the Cylinder Valve s or Lines Components have a different leakage rate Reducing the amount of drift also has its drawbacks Tight components are very sensi
98. ate and Re Paint Repaired Area CAUSE Vibration SOLUTION Locate and correct cause of Vibration problem Prepare and Repair Weld Grind Down Add Scab Plate and Re Paint Repair Area CAUSE Poor or Missing Welds Missing Bracing SOLUTION Prepare and Repair Weld Grind Down Add Scab Plate and Re Paint Repaired Area Asthis will usually be found rather quickly from delivery date it should be covered under warranty always take photos of this before any repairs as they may be requested by factory CAUSE Inadequate Bracing SOLUTION This is a difficult subject It is recommended that you consult with the factory before making modifications of this type Adding additional pieces may change many components functions the weight added could affect balance weight ratio and the Hydraulic Functions ability to lift Deck Worn on Underside CAUSE Mowing Over Sand or Other Abrasive Material Under side of deck has Sand Blasted appearance This Sand Blasted appearance will also be visible on Blades and Carrier most severe on Fan Blades Up Lift Blades SOLUTION 1 Run Mower with as low a Tractor RPM as Possible Decreased PTO Speed and still get a satisfactory Mowing job done Use Flat non Up Lift Blades is available Try to do the mowing at a time when the ground is still damp earlier in day 2 Check to make sure mower is operating at correct RPM 540 or 1000 as required by mower components If a 540 RPM mower was connected to a 100
99. ation Executing Set Up The following representations will outline the steps necessary to execute set up Key Escape or back at anytime to revert to the previous screen or restart the set up menu at any time Alamo Industrial Boom Menu Key Fl For Setup SETUP E Key F 1 to access the set up menu Select Boom Operating Speed EM HEM KIN Key the corresponding F key to establish the desired boom speed This parameter is provided for customizable operation MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 7 CONTROL VALVE INSTRUMENTATION Maverick Operator Interface continued Choose Lutterhead for Set Up Fl RI Others F2 Tinbercat Sicklebar TIHBERGAT TT Key the corresponding F key for the head attachment that will be used This is an important step because this parameter chooses which direction the fluid will enterthe motor The Timbercat Sicklebar mower is the only head attachment that currently requires the operator to send reverse flow for all others chose F 1 key for standard directional flow Set Ulb Complete Fl to Enable Joystick T ETA Key F 1 to activate Joystick the Boom will not move until the joystick is activated The Boom function Set up is now complete the boom speed the head attachment has been chosen and the joystick has been activated Motor Power Condition Fl to Enable Cutterhead AT rd Key F 1 to power motor This is best done when the
100. ay be required to drain and replace all the oil See Specification Chart for recommended Oil Type When repairing unit it is recommended that Oil is updated to recommended Oil CAUSE Air In Oil SOLUTION Run the System for a few minutes Check for Air in the Oil in the Tank Air entrained Oil will have a foamy appearance If Air is present find the Air Leak and correct it Air Leak can be in the Suction Line and Oil may not leak out because there may only be Cil in that location when the Pump is sucking it in With the Tractor Engine Off you can find a leak by pressurizing the Tank This will not take but a few pounds of pressure 10 PSI or Less look for leakage in the Suction Lines Because the Oil Pick Up is lower than the Oil Level this will force Oil out the leak Leaks in Hoses and at Fittings can draw Air into System as Oil Flows Past Systems that have had severe or prolonged Air Entry Problems may have Experienced Pump Damage CAUSE Engine RPM Too Slow SOLUTION Run Tractor Engine at required Speed to achieve GPM through Pump See Speci fication Section in Repair Manual MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 27 POSSIBLE FAILURE CAUSE 8 SOLUTION Motor Stops Mower Quits Under Load Continued CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Excessive Ground Speed For Mowing Conditions Operational Problem This will usually also have a Heating P
101. be damaged by foreign material SOLUTION It will be required to replace Seal and refill Spindle with Lubricant Before replacing Seal always check to make sure Shaft Bearings have not lost Pre load Shaft will be loose in Housing as this will make Seal Leak and will damage Seal If Shaft is Loose see next cause Solution Always Check condition of Shaft surface at Seal Area that it is not damaged Always coat ID of Seal with light coat of grease before installing CAUSE Bearings Loose SOLUTION If Bearings are Loose the Bearing Pre Load is lost and Bearings are most likely damaged Remove Motor Dis assemble Spindle clean and Inspect Rebuild and Fill with Lubricant See Spindle Repair Product Service manual MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 31 POSSIBLE FAILURE CAUSE 8 SOLUTION Spindle Leaking at Relief Plug CAUSE Relief Fitting Installed in Wrong Hole SOLUTION 1 First Determine whatis leaking Spindle Oil or Hydraulic Oil Ifitis Spindle Oil continue If it is Hydraulic Oil See Motor Seal Leaking 2 Sometimes the Fill Plug Grease Fitting on Spindles that are filled with Grease and the Relief Fitting are installed in the wrong Holes The relief Fitting should be in the Upper Hole Hole closest to the Motor if there are 2 holes Note There were changes made to Spindle in 1996 to add another Hole near the top ofthe Housing above Oil Level for the Relief Fitting to be installed a
102. before continuing CAUSE No Oil Flow to Motor Front Pump Inoperative No Pump Pressure reaching Motor SOLUTION Oil Level is correct but no Oil Flow to Motor Check Pump connection to Tractor Shafts Couplers and Adapters make sure they are not stripped or broken Check to make sure Pump is ON if equipped with Pump Shut Off Check to make sure Motor is ON when equipped with Shut Off Check for any malfunctions in Drive System and Shut Off Components CAUSE No Voltage to Solenoid Valve If Equipped SOLUTION Check Fuse if used replace if required and try again With Tractor lgnition Switch ON and Mower Switch ON Test for voltage at the Solenoid Valve A quick test is to turn switches on With Tractor Engine Off and see if a small metal object such as a paper clip or washer will stick to the end of the Valve when the mower is turned ON If it does not The Coil is not magnetizing the Valve Test for Voltage at the Wire using a test Light or Voltmeter If no Voltage is present trace the circuit back through the wiring the Mower Switch The Fuse and the Tractor Wiring to locate the faulty part If Currentis availableto the Solenoid but Solenoid won tturn on motor replace Solenoid CAUSE Spindle Locked Up SOLUTION The Spindle can be locked up causing Motor notto Start This can usually be feltor seen in the System trying to run but having to bypass Sometimes the Spindle is not seized but only ti
103. clean Make certain the oil is not contaminated with dirt or any liquid Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Section 1 2 SPECIFICATIONS MAVERICK 1 CUTTING CIRCUIT SPECIFICATIONS Hyd Pump Speed Front AUX P UMP 1950 RPM PVO DOOF DOC EEE O 1220 RPM Hyd Motor Rated AP sita as eee 199 HP Hyd Motor Rotation as viewed f Top of the Deck CW Clockwise Relief Valve Setting At Motor 4000 PSI Relief Valve Setting At Pump 4500 PSI Hyd Pump Flow Front Pump 1950 RPM 25 3GPM Hyd Oil Operating Temperature 100 F Ambient 155 165 F Hyd Oil Filtration Discharge f Charge Pump 10 Micron Ayd rak apaci AAA 17 1 2 Gal Hyd Motor Start Stop Time Approximate 6 Seconds Cutting Diameter Rotary Head 58 Inch 6 6 SORANO OE R P PER 4 5 by 9 Heat Treated Alloy Blade Bar Type Stacked 3 Leaf cs AO O O O eee eae 1 1 4 Thick X 5 Wide Ea Leaf Blade Bar Material Bottom LEAf 11 Steel Middle 8 ToplLeaf esee HRFB Steel 19 ES PS V O O teens 360 Deg Swing Blade Maternal RG RP US DDR E High Carbon Alloy Steel Cutter Weight Approximate w Rotary Head 950 lbs Cutter Deck Opening A Closing esses Hyd Operated Door Recommended Hydraulic Oil ISO AW 100 Hyd Oil Fluid Cleanliness eV coetum erat otn troie ski ion ar ISO 16 14 11 2
104. ction 5 4 MOTOR P N 029 9881 SPECIFICATIONS Motor P N 02979881 Specifications 3 European United States Standards Standards LISPIACEMIEN zauia usszasiadolnocu n n a vysl van lazi 80 4 Cm Rev or 4 9 Cu In Rev Motor Operating Speed Max Intermittent 5 200 rom or 5 200 rp Max Continous 4 000 rpm or 4 000 rp Min Continous 50 rpm or 50 rpm Motor Torque Theor 128 NM at 100 Bar Or 94 ft Ibs at 1450 psi 614 NM at 480 Bar Or 453 ft Ibs at 6960 psi Motor Input Flow Max Intermittent 418 L min Or 110 gpm Max Continous 322 L min or 85 gpm Operating Pressure Max Intermittent 480 Bar Or 6960 psi Max Continous 420 Bar Or 6100 psi Maximum Case Pressure 10 bar at 1500 rpm Or 145 psi at 1500 rpm Fluid Contamination Level 18 13 ISO Code 4406 or 18 13 ISO Code 4406 Motor Shipping Weight 26 kg Or 57 lbs Specifications Subject To Change Without Notification MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 5 MOTOR P N 02979881 PARTS LOCATION General Information The Motor P N 02979881 is Sperical Piston design This motor is used on the Rotary Head This is a high Torque Motor with heavy duty roller bearings See Figure 1 below for component location Valve Plate Piston with Piston Ring Tapered Roller Bearing Shaft Seal Barrel Housing Cylin
105. ctions apply to Manual Servo Control Re Assembly See Figure 32 2 Clean Make Sure that every thing Parts Tools Work Bench Vise and all general conditions are very clean before beginning any work Make sure all parts are lubricated 3 Valve Spool Spring Install Spring Retainer item 5 Spring item 6 and second Spring Retainer item 5 onto Valve Spool item 7 Compress Spring by pushing on outer Spring Retainer and install E Ring item 4 onto Valve Spool 4 Valve Spool Install Valve Spool assembled into Control Housing item 1 making sure that the metering notches See Figure 32 are facing outward and can be seen through the Metering Ports Check the notches at this time if the notches cannot be seen it will not work 5 Feedback Link and Bell Crank Bell Crank item 12 should have Head Pin item 17 already installed Position Bell Crank in Housing Slide Feedback Link item 9 into position between Clevis on Valve Spool aligning holes install Retaining Dowel Pin item 10 and E Ring item 11 6 Input Shaft Install New O Ring item 15 onto Input Shaft item 14 Hold Bell Crank in position with Feedback Link Slot and align Splined Hole of Bell Crank with Input Shaft Cavity Install Input Shaft into Control Housing and Bell Crank Apply Locktite 242 or equivalent to Set Screw item 13 and install it to retain Input Shaft Tighten Set Screw till it bottoms out against Input Shaft and then back it out 1 4 turn F Wiper
106. der Barrel Timing Gear Bearing Housing Output Input Shaft Sa ES Oy e IN Figure 1 Motor Assembly MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 5 6 MOTOR P N 029 9881 DISASSEMBLY Motor Disassembly 1 Clean Outer Surface Motor hose and deck surfaces Before removing any com ponents Motor and hoses must be com pletely clean dry the exterior of the motor and hoses Make certain that you have proper containers to catch any oil that will drain out Plug all hoses that are removed and plug all opening of motor fittings Make certain the work area and all tools are clean No contami nation can be allowed to get into system Refer to the previous parts page for part location in disassembly instructions It works well to print a copy and have it laying to one side as you read these instructions Instruc tions should be read all the way through prior to beginning disassembly 2 Remove Barrel Housing Clamp Mo tor in a vise as shown in figure 1 There are 4 bolts item 25 located on top of the Barrel Housing Assembly item 1 Remove these four bolts Lift Barrel Housing item 1 as shown in Figure 2 Use caution to make 2 under item certain the valve plate Item 2 doesn tfall out 1 8 not seen when lifting the Barrel Housing off By lifting straight up you should be able to use your finger to make certain the valve plate item 2 i does not fall out and get damaged Make a Figure 9 not
107. djustable Differential Air Bleed Drain Sensitivity 200 psi turn Max Volume Stop 2 2 CC Rev Turn Clockwise Pump Shown Actual Pump Is Counter Clockwise Which will have ports and adjustment on the opposite side as shown in drawing MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 31 PUMP BOOM CIRCUIT THESE ITEMS ARE SHOW IN POSITION FOR CONTROL OPTION OMIT SEE SEPARATE DIAGRAM FOROTHER CONTROL OPTIONS 10 FT LBS TORQUE 125 FT LBS ag FT LBS TORGUE ADJUSTABLE DIFFERENTIAL VARIATION 4 oO F T LBS TORQUE NON ADJUSTABLE DIFFERENTIAL VARIATION OMIT 20 FT LBS TORQUE MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 32 PUMP BOOM CIRCUIT Pressure Power 8 Flow Compensator 20 FT LBS TORQUE 10 F L LBS TORQUE M SET MAX PRESSURE PER TEST PP SPEC THEN INSTALL JAM NUT LOCKING i NUT AND LOCKING TAB 1 TRUNNION CAP ASSEMBLY 4 RETAINER DETAIL TD 1 vil pohla AM s er MA an AME MIT ru Er I EE Tris TENE A THRUST WASHER SNAP RING GRING TRUNNION CAP ROLLER BEARING qnn Si PA TO EET STAKE BALL IN PLACE B BEARING SHAFT ASSEMBLY O RING 1 BACK UP RING 9 PORT PLATE SLEEVE o RING 1 BACK UP RING 6 PISTON DIFFERENTIAL CONTROL PISTON BODY RING 1 BACK UP RING MAVERICK Service Manual 12 04 2004 Alamo Group Inc LEFT HAND CCW PORT PLATE SHOWN IN ASSEMBLY AB
108. draulic Circuit Diagram Showing Basic Functions 66 76 75 50 25 TB FIGURE 3 67 60 47 60 31 The item numbers in the hydraulic circuit diagram and table below refer to the valve function areas for which different options are available The valve in the example above is equipped according to the description below For other equipment alternatives see under respective valve function area item number in catalog Item Code Description 15 CFC Inlet w bypass for systems w fixed pump 16 PS Pilot Operated main pressure relief valve 20 KB Prepared for load signal copying 22 BEN Electrically activated pump unloading function that blocks the pump and unloads the signal 20 T1B Tank Connection in inlet plugged 26 PI Pump connection in inlet open 31 LSPB Load signal connection for parallel connected valve plugged 32 P2 Pump Connection 33 MF Counter pressure valve with fixed setting 34 T3 Tank Connection open 37 R Pressure reducing valve with separate safety valve for internal pilot pressure supply 39 S Internal coarse filter for pilot circuit Continued Next Page MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 12 DIREC TIONAL CONTROL VALVE Continued From Previous Page Item 40 47 90 60 66 67 fo 76A 76B Code Description TPB TTT 000 EC CH D K 0 8 N2 Prepared for separate tank connection from pilot circuit Section 1 equipped with pres
109. e Bolts up Mark the relationship of the working Ports for re assembly identification to the Servo Control Assembly with a Scribe Make a Line Remove the four bolts retaining the Back Plate If no Gerotor Charge Pump Skip to Step 6 2 Liftthe Charge Pump Adapter Assembly straight up off Back Plate Shaft and Gerotor Gerotor may stay in adapter or on Back Plate Remove O Ring from Charge Pump Adapter Remove Outer Gerotor Ring from either the Charge Pump Adapter of the Inner Gerotor Ring 5 Remove the Inner Gerotor Ring and Key from the Drive Shaft or Inner Gerotor Ring and Coupler Assembly from Shaft ui s 6 Lift Back Plate straight up off Shaft and Housing Remove Valve Plate from Back Plate or from rotating Kit Assembly Still in Housing f From Back Plate remove Dump Valve Retaining Ring Dump Valve or Plug and Relief Valve Assemblies NOTE Mark the Relief Valve in relationship to the Cavity it was removed from for Re Assembly purposes 8 Back Plate inspection See Figure 27 Check the Bearing Press Fit in Back Plate If Needles remain in cage Move freely and settings is at the Dimension shown in Figure 27 removal of Bearings is not required Check Roll Pin in Back Plate If tight and set to dimensions shown in Figure 27 removal is not required Numbered End 09 2 29mm 173 4 39 mm FIGURE 27 A 9 Remove Housing Gasket from Housing of Back Plate 10 With Pump Still in Vise remove the six Bolts r
110. e Manual 12 04 O 2004 Alamo Group Inc Section 4 14 MOTOR CIRCUIT PUMP RE ASSEMBLY PUMP RE ASSEMBLY The following instructions apply to a single Servo Controlled Piston Pump with or without Gerotor Charge Pump A Tandem Pump Assembly should be separated into individual Pumps before dis assembly and assembled back the same way 1 All Parts should have been cleaned and critical moving parts lubricated as described in Steps below Before Starting Re Assembly Also Listed in Previous Introduction Page A After dis assembly of Pump wash all metal components in clean solvent B Use compressed Air to dry parts after washing Compressed air must be filtered and moisture free DO NOT wipe them dry with Paper Towels or Cloth as these will leave lint and or dust contamination DO NOT USE Compressed Air to Spin any component such as Bearings or Plates as this will damage or Blow them apart Secure any part before using compressed Air to dry it C Always use new Seals when re assembling Hydraulic Pumps Lubricate the new rubber Seals with a Petroleum Jelly Vaseline before installing them D DO NOT reinstall worn or damaged Parts back in Pump DO NOT use a worn or damaged Pump Housing 2 If Bearings are being replaced in Housing Press them in now See Figure 28 for dimension on how far to press them in This is a critical dimension and make sure the numbered end of Bearing is pointing outward Install the two new Seal Sub Assemblies i
111. e Valve and inspect Seals replace if damaged Insufficient Flow From Charge Pump MACHETE SPECIFIC Measure Flow from charge Pump Install Flowmeter in series upstream of Charge Filter If Flow is significantly less than 6 GPM at rated RPM Replace the Pump Assembly and retest for proper Flow MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 26 POSSIBLE FAILURE CAUSE 8 SOLUTION Motor Runs Too Slow continued CAUSE Excessive Internal Leakage in Pump Motor SOLUTION Perform Flow and Pressure Test If results are not within Specifications determine the cause of the internal leakage correct the cause Replace worn or damaged parts It is good to replace the Filter any time the Pump and or Motor are repaired or replaced Pump and or Motor wear usually occurs over along period and are gradual loss of power and excess heating of Oil This may go unnoticed till it is severe making the operator think it just started this can make this type of failure hard to determine Pre Mature Pump and or Motor Failure wear occurs quickly The problem for these failures must be found and repair or the failure will be repetitive The Most common cause of Pre Mature Failure is Cavitation Oil Contamination Oil Aeration and or Defects in Pump and or Motor Motor Stops Mower Quits Under Load CAUSE Incorrect Oil Used SOLUTION Use recommended Hydraulic Oil DO NOT mix Oils that are not compatible in some cases it m
112. e and cause should always be identified and corrected before any repairs are made Repairing the failure and leaving the cause will result in more failure In Some cases a Cylinder Rod can be cleaned up with CROCUS CLOTH a very fine abrasive material DO NOT USE anything more abrasive than crocus cloth A major problem for cylinders is storage when unitis not being used for a while The Rods are a chrome alloy but if subjected to moisture long enough they will rust This is not a problem when being operated as they are to be cleaned with every in and out stroke If Unit is going to be stored for an extended time you can coat Rods Exposed Part with Oil or Grease to protect them But If you do this it must be cleaned off before running to remove the Dust that will have collected on rod from Oil and grease Cylinder Rod Bent Determine and correct cause of bent Rod Replace Rod and Re Seal Cylinder Cylinder Moves On lts Own under Power CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Control Valve Spool Stuck Locate stuck Spool repair or replace Spool Determine why Spool is stuck Debris Foreign Objects Contamination Broken Spool Components and etc If just the Spool is replaced and the reason it failed is not corrected it will fail again Return Spring Broken in Control Valve Repair or Replace Spring Determine why it broke Binding of Control Cables or Linkage Remote Cable Control Models Determine cause of
113. e best way to check would be with a Flowmeter in Cylinder Line Check Repair or Replace as required CAUSE Restrictor Valve Installed in Wrong Line Backwards or Plugged SOLUTION Determine the correct location of installation for Restrictor and make sure it is in correct location Inspect for being Plugged Clean or Replace as needed CAUSE Excessive Internal Leakage in Pump Motor SOLUTION Perform Flow and Pressure Test If results aren t within Specifications determine the cause of the internal leakage correct the cause Replace worn or damaged parts It is good to replace the Filter any time the Pump and or Motor are repaired or replaced Pump and or Motor wear usually occurs over a long period and are gradual loses of power and excess heating of Oil This may go un noticed until it is severe making the operator think it just started this can make this type of failure hard to determine Pre Mature Pump and or Motor Failure wear occurs quickly The problem for these failures must be found and repaired or the failure will be repetitive The Most common cause of Pre Mature Failure is Cavitation Oil Contamination Oil Aeration and or Defects in Pump and or Motor MACHETE SPECIFIC When performing the Flow Test on the Machete The flow going to Motor and either the return from the Motor or the Case drain must be determined These figures will indicate internal leakage in the Motor CAUSE Air in Oil SOLUTION Run the System for a few
114. e end result Spool actuator rM E IM Pressure setting feed A Port relief and or anti pe ERE y reducing valve 75 a cavitation function 76 l v M Cau d re 1 1l Flow setting 72 RA k LY VAR PAC n ie P 7 b 4 S al 2 en ET E a SIT He A D UE 2 k LL D Pilot restriction 55 Spool function 60 i AA JO SSS SS Spool designation 69 UA Ne KALAL SAAE 2 m 77 DE Damping of pressure Z LL LS compensator 67 Pressure compensator 66 FIGURE 4 MAVERICK Service Manual 12 04 2004 Alamo Group lnc Section 2 6 CONTROLVALVE HYDRAULIC CONTROL VALVE COMPONENTS Valve Section Components Each of the Valve Sections contains the following Components 1 Segment Compensating Spool 2 Anti Cavitation Check Work Port Relief Valve 3 Manual Over Ride Control 4 Mechanical Flow Limiters M Main Flow Control Spool 6 Shuttle valve Spool actuator IM Pressure setting feed A Port relief and or anti LB _ IE reducing valve 75 GA cavitation function 76 1 o SE M iS RO ARO HE quu E A AR VEZA ETT EI Z NOME S UIS RA LE h Ho ET Vy p fm as E RODE RS M mmm Z SEAT JEG HY FA EH EMP IS R Ms oi IH Pilot restriction 55 SSH S 3 PRA HC 3 ET EA BEE A aar M a aea asset JA DD A OG y i NE IN F Damping of pressure IA A compensator 67 Pressure compensator 66 FIGURE 7 md A
115. e of which side of Valve plate is up and which side is down this will be important during reassembly 3 Remove Cylinder Barrel Remove the Shim item 24 and set it aside Lift the Cylinder Barrel up and out See Figure 4 This willleave the barrel support components item 16 sticking up out of the shaft Support components item 16 are an assembly of four parts The pistons item 17 will also be sticking up Make certain all the removed components are laid in a clean area Figure 4 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 7 MOTOR P N 029 9881 DISASSEMBLY Motor Disassembly Continued 4 Lift Out Barrel Support Lift the barrel support out item 16 make certain that all the parts in barrel support are accounted for See Figure 5 5 Remove the Pistons item 17 there are 7 pistons and 21 piston rings item 18 that will be removed There are 3 piston rings per piston See Figure 6 6 Remove Bearing Housing Sealing O Ring There is an O Ring item 7 that is used to seal barrel housing assembly item 1 to bearing hous ing item 6 Remove this O ring See Figure 7 This will leave Shaft Assembly item 14 still in Bearing housing item 6 f Remove Retaining Snap Ring Remove the Bearing Housing Assembly from vise and turn it over so the shaft end is pointing upward and re clamp it into vise as shown in figure 8 Using internal Snap Ring pliers to remove the snap rin
116. ear other items when connecting hose put the end on that has the correct fitting as noted in drawing with 90 or the straight fitting if note marked hose routing that is to make hoses clear other items Do Not connect hose to different letter items all hose end must connect to the same letter on both ends TO ID HOSES Always check Size Length Fittings and Color Plastic Tie to identify the hoses Some hoses will have the same color tie but the size length or fittings will be different MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 34 Section 5 MOTOR CIRCUIT 24 8 30 BOOM MAVERICK Service Manual 12 04 Section 5 1 MOTOR P N 02979881 Parts Location amp Service Instructions This Section is for Motor Asy P N 02979881 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 2 MOTOR P N 029 9881 PARTS LOCATION A Port Pressure View A 29 A Port Relief 30 B Port Relief B Port 28 NOTE Item 28 has a B stamped in it the motor has a B stamped in it also these are aligned when installing Item 28 to motor MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 3 MOTOR P N 02979881 PARTS LOCATION Item Part No E lk YS 11 12 18 14 15 16 17 18 19 20 21 22 29 24 25 02979881 02980529 02980530 02980536 02980537 02980538 02980539 02980540 02980541 02980542 02980543 029
117. ecification Boss Fittings may have damaged O Ring Check and repair as required CAUSE Port Cracked at Fitting SOLUTION Repair or Replace Cylinder and or Fitting This type failure is more common on Cylinders with Pipe Fittings than the ones with O Ring Boss Fittings The reason is because the Pipe Thread is tapered and can be over tightened and the tapered thread acts as a wedge Don t over tighten any fittings Don t use Teflon tape at all ifusing a Semi Liquid Pipe Thread Sealer Don t put excessive amount on fitting and Never put sealer into ID of Port It will get into system and contaminate it CAUSE Deformed or Damaged Fitting JIC SOLUTION Replace damaged Fittings and or Hose Over tightening of JIC Fittings can deform the Flares on the Fitting and create leaks See Torque Specification for proper MAVERICK Service MANGA 48704 2004 Alamo Group Inc Section 8 7 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Leaks Around Rod CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Faulty Seals On Cylinder Gland Dis Assemble and Re Seal Gland Seals can be damaged by foreign objects or worn by abrasive material such as Dirt getting into Seal and or Rod Seals can also be damaged during Assembly and this type of damage will almost always show up shortly after being put in service Damage To Cylinder Rod Determine the cause of the Damage Dent Scratch Rust and or something stuck to Rod The Damag
118. ed into the Oil These Air Bubbles will reduce the lubricating ability of the Oil causing adhesive wear to the Pump and Motor and arapid increase in internal leakage Air entrained Oil will have a foamy look after the system has run for a while SOLUTION Test System for excessive Pump and Motor Wear or Cavitaion by running Pressure and flow Test Repair or Replace as required CAUSE Engine RPM Too High SOLUTION Run Tractor Engine at required Speed to achieve GPM through Pump See Specifica tion Section in Repair Manual CAUSE Malfunctioning Valves Main Relief Priority Valves and Logic Valves SOLUTION Test the above Valves they are on the High Pressure Side of the system these act on a pressure differential and are spring loaded The Typical failure is a Leaking Seal between the Valve Cartridge and the Valve Block An improper Low setting of Relief Valve to Low a Pressure can cause rapid Heating as the Oil passes from the High Pressure to the Low Pressure area The same is true for the other Spring Type Valves such as the Priority Valve Governors CAUSE Operational Problems Cutting Excessively Heavy Material Traveling to Fast for Conditions Improper Cutting Height SOLUTION Make sure Cutting Heightis notsolow Blades are hitting Ground Make sure that Travel opeed while cutting does not exceed cutting capacity of Model Design Make sure something too heavy for this model is not being cut Make Sure the Tractor Engine is runnin
119. egories Hydraulic or Mechanical Trouble Shooting Request for Technical Information or Specifications Mounting or Fitting Problem Special Service Problem Equipment Application Problems Tractor Problem Inquiries D 0 e ON gt 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
120. en the malfunction occurred O NMUOD gt MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 21 NOTES MAVERICK Service Manual 12 04 2004 Alamo Group lnc Section 2 22 section 3 JOYSTICK OPERATION ELECTRONIC CONTROLS 24 8 30 BOOM MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 1 CONTROL VALVE BOOM 8 MOTOR CONTROL Maverick Boom and Motor Control Circuits It is advised that this section be read before proceeding with any repairs or test with the display and electronics used in this application the system will test many components for you This is done by following the prompts on the display screen DO NOT pressure wash this system while the components are sealed the soaps acid and high water pressure used in the pressure washer can damage these seals and cause moisture to enter system causing damage DO NOT do any welding around these electronic components If welding is required in a repair the electronic components MUST be disconnected unplugged Un plug all components Joystick Modules Displays and any other electronic component If not unplugged the current from the welded can cause serious damage to electronic components Additional repair and diagnostic procedures for the electrical system is available on the internet web site of the manufacture of this system at REFERENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANUFACTURER ON THE INT
121. er Let the Washer rest on the three Pins and retain with Nut Turning Nut and compressing Spring inside Block Use a pair of Retaining Ring Pliers and remove the Internal Retaining Ring Remove the Nut Bolt and two Flat Washers from Block removing the Washer Spring Second Washer Three Pins and Pin Keeper at the same time ROTATING KIT RE ASSEMBLY See Figure 33 1 The following instructions apply to Rotating Kit Assembly Re Assembly Re Assembly of Rotating Assembly See Figure 34 2 Clean Make Sure that every thing Tools Work Bench Vise and all general conditions are very clean before beginning any work Make sure all parts are lubricated with Hydraulic Oil prior to re assembly 3 To reassemble the rotating Kit Assembly complete the following Compress the Pin Keeper and install in Spline of the Piston Block Install the three Pins with the Head end to the inside of the Block and position in Special grooves of the Piston Block Spline 4 Install the Washer Spring and second Washer into the Piston Block Use the two 3 8 ID Flat Washers the 38 Nut and the 3 8 x 3 1 4 Boltto compress Spring and retain with Retaining Ring Remove the Nut Bolt and two washers 5 Install Pivot onto the three Pins Spider on the Pivot and Piston Assemblies through the opider and into Piston Block resting on Spider MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 21 MOTOR CIRCUIT PUMP ROTATING KIT ASY FIGURE 33
122. ess pressure in the control spool chamber As with the operation of the pressure compensator control this allows the control spool to move downward venting the servo piston cavity and causing the servo piston to move to the right This reduces output flow and thereby power As indicated in drawing See Figure 40 pressure in the control spool chamber is affected by both the pressure compensator control and the power control The resultant pressure in this chamber is a function of the set points of these two controls Both set points are adjustable Pressure Horsepower CONTROL OPTION H amp Flow Co ntrol SWASHPLATE QA Ad VE Control Type C In addition to the three control configurations just discussed it is pos js PERET SS sible to combine all Ame E Riou pc i E CONTROL three control devices IE Let OT Steeve O in one pump In this tasas deteuted BERA EEE Ri Binh mode the position of the control spool is a AT CONSTANT SPEED PRESSURE PISTON function of the actions CONTROL DRAIN i E 3 z CONTROL SPOOL of the pressure PORT A i SPRING CHAMBER mpen r adjust compensator adjust FIGURE 40 HORSEPOWER PRESSURE o p DIFFERENTIAL ment horse power ADJUSTMENT ADJUSTMENT adjustment and flow control See Figure 41 SWASHPLATE AIRBLEED VALVE FLOW CONTROL ASSEMBLY ADJUSTMENT E ul ul EL on E E en o cea CONTROL OPTION C CONTROL PISTOM
123. essure in the servo piston cavity to vent via port A control drain The reduced pressure at the servo piston allows the servo piston allows the servo piston to move to the right This movement reduces the angle of the swash plate and thereby reduces the pumps output flow See Figure 37 As pump pressure on the control spool drops below pressure and spring force in the spool chamber the control spool moves upward to maintain an equilibrium on both sides of the spool If pump pressure falls below compensator control setting the control spool moves up bringing the pump to maximum displacement See Figure 37 Adjustment of Pumps Procedure Standard Pressure Compensated Pumps Pumps are shipped from factory with a differential pressure of approximately 150 psi 10 bar at 50 of maximum swash angle Differential pressure will not normally change through the life of the pump If this control has been tampered with a close approximation of the correct setting can be made as follows Dead head the pump no flow with 0 3000 psi 0 207 bar gauge in the OUTLET port Not the low signal B port back the pressure compensator adjustment out full counterclockwise The gauge should read between 325 375 psi 22 26 bar If the gauge reads different than this turn the differential adjustment knob differential option 4 or add remove shims omit option until correct psi figure is reached See Figure 37 CONTROL OPTION OMIT SYVASHPLATE AIRBL
124. etaining the Manual Servo Control Assembly or Solenoid Servo Assembly 1998 8 Up Remove the Control Assembly and Control Housing Gasket from the Housing remove the Orifice Plates noticing the Location for Re Assembly Remove Nut and Lock Washer from control Arm Note position of Control Arm for Re Assembly on Manual Servo Assembly 1997 8 Down Refer to Appendix B for Dis Assembly and Inspection of Control Assembly 11 To remove Rotating Kit Assembly from housing first remove Pump from Vise holding the Rotating Kit assembly in position Lower Pump so that the Shaft end Flange End is up Set the rear of Housing onto table with Housing flat and Rotating Kit Assembly at rest on table Hole in table for protruding Shaft is reguired Lift and remove the Housing and Shaft from Rotating Kit Assembly and Camplate MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 13 MOTOR CIRCUIT PUMP DIS ASSEMBLY 12 Remove Camplate from rotating kit Assembly and Servo Piston follower from Camplate Refer to Appendix C for dis assembly and inspection of Rotating Kit 13 Camplate Inspection The Finish on the Piston Shoe Surfaces of the Camplate should show no signs of scoring at all Inspect Camplate Bushing surface for wear and surface for coating transfer from Bushing 14 To remove Servo Piston Assembly from Housing start with the four bolts and washers retaining each cover plate 15 In removing the Cover Plate from the Servo
125. g that retains the seal carrier item 9 Note Smooth Shaft shown actual shaft is splined in this motor Figure Figure MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 8 MOTOR P N 029 9881 DISASSEMBLY Motor Disassembly Continued Splined Shaft 8 Remove Seal Carrier Using small pry tool lift seal carrier item 9 up and slide it off of shaft as shown in Figure 9 9 Remove sealing O Ring There is an O Small Pry Ring item 8 under seal carrier that you can reach Tool and pull out See Figure 10 10 Remove External Snap Ring From Shaft Looking down on the shaft as shown in Figure 11 there are spacer washers items 11 13 amp 22 and external snap ring Make certain to make a note of where they are located and how many there are Use snap ring pliers to remove retaining ring do not pry it off of shaft as this would scratch the shaft 11 Remove Spacer Washer Under the Snap Ring Remove any spacer washer under the snap ring noting their quantity and location See Figure 12 Make certain to keep all Spacers in the same order they came off Splined oplined Shaft Shaft 11 13 22 23 M i a T g x P Fu 1 gt a 2 1 a E 1 P m T 1 i 4 n i F 4 3 i 1 ow EM 3 E dx M AA MA ll 4 L 4 je m 5 k K L i z L a T EI Se al aa a PY A LE n T a aer LE bo m e d P La
126. g at the correct RPM to run Hydraulics at the correct Speed All of these can cause Over Heating by forcing the system pressure over relief causing Relief Valves to Open and heating the Oil as it passes across the Valve If the system pressure is going over relief too frequently or for too long at a time The Oil capacity will not be sufficient to maintain the desired operating temperature Travel Speed is always dependent on the material being cut Motor Flange Breaking CAUSE Insufficient Support on Upper End of Motor SOLUTION 1 Make sure that the Motor Plate is installed on top of Motor and that itis installed correctly These Plates must be installed with clearance dimensions and Torque settings See the Spindle repair instruction in the Operators Product Service Manual 2 Some Units built prior to 1996 did not have this Motor Plate on it There was a kit made to add to these early units Kit P N 02970754 can be used to add Motor Plate to Units made prior to 1996 CAUSE Motor to Spindle retaining Bolts not Tight SOLUTION Check and Tighten Motor to Spindle Mounting Bolts MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 21 POSSIBLE FAILURE CAUSE 8 SOLUTION Motor Inoperative Won t Run CAUSE Low Oil Level or No Oil SOLUTION Check and Correct Oil Level If oil level was extremely Low or Empty Pump Damage most likely has occurred This will also have to be checked Repair any cause of Oil loss
127. g it in With the Tractor Engine Off you can find a leak by pressurizing the Tank This will not take but a few pounds of pressure 10 PSI orless look for leakage in the Suction Lines Because the Oil Pick Up is lower than the Oil Level this will force Oil out the leak Leaks in Hoses and at Fittings can draw Air into System as Oil Flows Past Systems that have had severe or prolonged Air Entry Problems may have Experienced Pump Damage Restrictions in System Check Hoses Lines for Kinks Obstructions Hoses have inner linings that can turn loose to block it If Assembly or Repair work has been performed recheck all connections for correct location Some may not be visible without some dis assembly Unplanned restrictions cause increased backpressure loss of usable power and excess Heating of Oil Restrictions can sometimes be found by measuring the temperature of the Oil or fittings at various points in circuit for higher heat The restriction should be located at or upstream of the increased temperature point Foreign objects sometimes cause restrictions in the system This can happen during servicing maintenance or repairs It is not uncommon to find bolts nuts plastic plugs paper or rags stuck into system when it was used as being repaired or assembled then forgotten about Restrictions sometimes can be a piece off of a failed component up stream Component such as a Hose built wrong Damaged O Ring on Solenoid Valve If Equipped Remov
128. ght this can prevent motor from starting right away from a dead Stop or slowly start The tightness is not enough to prevent motor from running once it is started See the Spindle Section for more information Motor Over Heati ng z Motor Over Heating is considered when the Operating temperature exceeds 100 degrees F over ambient Temperature CAUSE Oil Level Too Low SOLUTION Make sure it is filled to proper level with recommended Oil Determine reason for low Oil Level leaks etc and correct problem Run Mower and check temperature it should not exceed 100 degree F above ambient Temperature CAUSE Incorrect Oil Used SOLUTION Use recommended Hydraulic Oil DO NOT mix Oils that are not compatible in some cases it may be required to drain and replace all the oil See Specification Chart for recommended Oil Type When repairing unit it is recommended that Oil be update to recommended Oil MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 22 POSSIBLE FAILURE CAUSE 8 SOLUTION Motor Over Heating Continued CAUSE Air in Oil SOLUTION Run the System for a few minutes Check for Air in the Oil in the Tank Air entrained Oil will have a foamy appearance If Air is present find the Air Leak and correct it Air Leak can be in the Suction Line and Oil may not leak out because there may only be Oil in that location when the Pump is sucking it in With the Tractor Engine Off you can find a leak by pressuriz
129. hat 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 Compo nents Missing Components Loose Components Oil Leaks Damaged Com ponents 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 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 20 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 whe
130. ht BIk CCW P4 4 Open nowire P 1 5 Wht Blu Down P 1 6 Wht Trigger Plug Pin Wire Axis Function P 1 7 Open Open no wire ID No Color P 1 8 Open Open no wire P5 1 Red X Power P 1 9 Open Open nowire P 5 2 Blu X Output 0 5 to 4 5 V P5 3 BIK Wht X Neg P 5 4 Red Wht Y Power 5V Plug Pin Wire P 5 5 Vio Y Output 0 5 to 4 5 V ID No Color P5 6 Brn Blk Y Neg po 4 Red Wht P 5 7 Blk Red Z Power 5V p 2 Brn BIk Po 8 Yel Red Z Output 0 5 to 4 5 V P2 3 Vio P5 9 Bik Z Neg P 2 4 Open no wire SIDE TO SIDE Y AXIS D Por 40 254 em E 25 AA Plug Pin Wire inam 2 CENTER ID No Color 2 SY 2 504 40 250 P 3 1 Red n ROTATION Z AXIS PI 2 PN 4 254 Cn 25 i de n one LP amp DOWN X AXIS 83 2 SOU 30 29 VET Plug P 5 pin function Axis as show above MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 13 RESISTER WIRE HARNESS P N 02981990 P5 Wire Harness Side EZ EBIK Red lA Yel Red Pin Numbers Locations PCB Assembly 02981990 Resistor harness Pin Numbers amp Locations je UN E AN m O MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 14 RESISTER WIRE HARNESS P N 02981990 Item Pin Location 1 Pin 1 P 5 2 Pin 2 P 5 3 Pin 3 P 5 4 Pin 4 P 5 5 Pin 5 P 5 6 Pin 6 P 5 7 Pin 7 P 5 8 Pin 8 P 5 9 Pin 9 P 5 10 Pin 1 P 2 11 Pin 2 P 2 12 Pin 3 P 2 Pin 4 P 2 13
131. i Max Pressure Only MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 25 PUMP BOOM CIRCUIT General Description Variable Piston Pump All control is achieved by proper positioning of the swash plate This is achieved by the servo piston acting on one end of the swash plate working against the combined effect of the offsetting forces of the pistons and centering spring on other end The control spool acts as a metering valve which varies the pressure behind the servo piston As shown in Figure 36 Detail A the amount of flow produced by the Piston Pump is dependent upon the length of the stroke of the pumping pistons This length of stroke in turn is determined by the position of the swash plate Maximum flow is achieved at an angle of 17 The rotating piston barrel driven by the prime mover moves the pistons in a circular path and the piston slippers are supported hydrostatically against the face of the swash plate When the swash plate is in a vertical position perpendicular to the center line of the piston barrel there is no piston stroke and consequently no fluid displacement When the swash plate is positioned at an angle the pistons are forced in and out of the barrel and fluid displacement takes place The greater the angle of the swash plate the greater the piston stroke The center line of the pumping piston assembly is offset from the center line of the swash plate Therefore as shown in Figure 36
132. ident The Mode of failure would be that an excessive load was applied while the Control Valve Spool was in Hold and there was no Work Port Relief in circuit or it was malfunctioning Corrective action is to counsel the operator to avoid conditions that resulted in bending repair or replace Cylinder and any other damaged component A good example would be using Tractor Wheel Power to put pressure against boom and Valve closed so Cylinder can not give Exceeding Break A Way CAUSE Misalignment of Cylinder Lugs SOLUTION make sure something has not been bent Frame Lugs and etc Align Cylinder Lugs may require cutting and Welding or replace faulty Parts as needed Mis Alignment of Lugs place a side load on Rods that can cause them to bend Usually this alignment is noticeable CAUSE Work Port Relief Malfunction SOLUTION Check relief Pressure of Valves that are in the affected circuit Adjust or replace them as needed to bring them to specification See Repair Manual Do not operate with Relief Setting incorrect this will cause damage Also check to make sure that Port Relief s are installed correctly and in the proper places CAUSE Interference with Another Part of Component SOLUTION Repair or Replace the damaged cylinder Slowly actuate the Implement throughout its full range of motion utilizing all possible Cylinders Observe for interference with any other Part Correct cause of interference as needed Cylinder Rod Came
133. ie may be used on a 4 hose and again on a 6 or larger hose always check the color coded ties and the size of the hose identify the hose and its location MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 7 7 HYDRAULIC KIT HOSE ROUTING B 90 C A A 907 Tee E T OS HS KRG e E DAE KR Soo K Item PartNo Qty Description A 02981427 1 Hose 8 8FJX 8FJX90 24 Lg Red Tie Charge Filter to Pump B 02981428 1 Hose 8 8FJX 8FJX90 21 Lg Blue Tie Case Drain to Tank C 02981429 1 Hose 12 12FJX 12FJX 23 Lg Pump to Suction Filter Under Pump Connection Not Shown in Drawing D 02981430 1 Hose 12 12FJX 12FJX 31 Lg Red Tie Pressure Filter to Supply E 02981431 1 Hose 4 4F JX 4F JX90 35 Lg Red Tie Pump Load Sense to Valve PX F 02981432 1 Hose 4 4F JX AF JX90 20 Lg Blue Tie Pump Regulator to Tank G 02981433 1 Hose 20 20FJX 20FJX 24 Lg Pump to Suction Filter H 02981462 1 Hose 12 12FJX 12FJX90 20 Lg Orange Tie Valve Return to Filter NOTE Hoses are not shown in drawing above this is for clarity The Hose routing is for the hoses which connect from one point to the other Use the instructions and hose descriptions listed to follow hose routing Example Hose A connects to one end marked A and the other end connects to the other connection marked A This is done with the other letter as well the hose must connect to the same letter mark on each end Some hose have a plastic c
134. iefs item 29 8 30 would not have had to be removed but if they were make certain to replace them the same way they were removed there is a Relief Valve Seal Kit See item 28 available as repair parts See Figure 37 19 Inspect all assembly steps done and make certain every thing is clean all opening should be plugged and remain plug until hoseconnections are attached 20 Ifonly replacing Seal as a repair See Figure 8 amp 9 in disassembly section and Figures 24 25 26 8 27 in the assembly section It will be required to remove Seal Carrier Retaining Ring Pull Seal Carrier out of pump Bearing Housing and remove seal from seal carrier Make certain to check the O Ring Seal under seal carrier it should be replaced when seal carrier is removed and reinstalled Reverse procedure to reinstall seal carrier See Figure 38 amp 39 Figure 35 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 16 MOTOR P N 029 9881 ASSEMBLY Motor Assembly Continued A Port Relief Pressure To Motor lt This tool can be machined from PSS HI AO tubing to create a bearing driver to Motor i install bearings on motor shaft B Port Figure 37 Relief Seal Carrier Retaining Ring Seal Carrier Diminsions Remove Old Seal From AM 291 0 04 Seal Carrier carefully as p 2 75 shown Be 2 441 008 0 Figure 40 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 5 17
135. ill be repetitive The Most common cause of Pre Mature Failure is Cavitation Oil Contamination Oil Aeration and or Defects in Pump and or Motor MACHETE SPECIFIC When performing the Flow Test on the Machete The flow going to the Motor and either the return from the Motor or the Case drain must be determined These figures will indicate internal leakage in the Motor CAUSE Relief Valve Malfunction SOLUTION Perform Flow Pressure Test If Flow is correct and Pressure is Low remove Relief Valve and inspectfor damaged Seals Contamination or other abnormali ties Re Seal Adjust or replace the Valve as needed Leakage through the Valve from Low Pressure setting or leakage around the Valve from damaged Seals will cause heating of the Oil and Low Power complaints NOTE There may be situations when Pump Flow is insufficient to reach Relief Pressure Therefore it is important the proper Flow be present before con demning the Relief Valve CAUSE Restrictions in System SOLUTION Check Hoses Lines for Kinks Obstructions Hoses have inner linings that can turn loose to block it If assembly or Repair work has been performed recheck all connections for correct location Some may not be visible without some disassembly Unplanned restrictions cause increased backpressure loss of usable power and excess Heating of Oil Restrictions can sometimes be found by measuring the temp of the Oil or fittings at various points in circuit for higher hea
136. ing Control Valve must be sethigherthan Tractor Relief Valve Otherwise the Oil will bypass continuously and overheat rapidly Leakage Thistype Leakage is Internal an External Leak will not cause Heating unless it causes enough Oil loss to effect the Oils cooling Another type leakage would be Air entering the system on the suction side This may not leak externally when system is engaged because it would be a suction Some internal leakage is always present because of tolerance in the components Valve Pump Motor and other components But usually this is compensated for in the design of the system and components Internal leakage will normally increase with wear and age on the system components Heating from normal internal leakage is usually not severe or noticeable until it reaches advanced stages It usually occurs gradually and is accompanied by a gradual loss of power Test System for leakage by running Pressure and flow Test Rebuild or Replace as required MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 20 POSSIBLE FAILURE CAUSE 8 SOLUTION Hydraulic System Overheating continued CAUSE Excessive Pump or Motor Wear These will be accompanied by a Power Loss when Mower Head is Cutting Rapid Pump and or Motor wear can be from damage caused by Cavitation restricted Oil Supply Contamination Aeration or defects in the Pump and Motor Air Leaks Air being sucked into system causes Air Bubbles to be entrain
137. ing the Tank This will not take but a few pounds of pressure 10 PSI or Less look for leakage in the Suction Lines Because the Oil Pick Up is lower than the Oil Level this will force Oil out the leak Leaks in Hoses and at Fittings can draw Air into System as Oil Flows Past Systems that have had severe or prolonged Air Entry Problems may have Experienced Pump Damage CAUSE Engine RPM Too High SOLUTION Run Tractor Engine at required Speed to achieve GPM through Pump See Specification Section in Repair Manual CAUSE Excessive Ground Speed for Mowing Conditions Operational Prob lem SOLUTION This will usually also have a Heating Problem if continuing to mow Observe or Ask Operator mowing conditions Material being Cut etc Correct Ground Speed is always relative to Material and conditions of mowing One indication of Excessive Ground Speed Is considerable wear on tips of blades but this is not exclusive of Excessive Ground Speed as the Wear can be caused by other factors So Blade Wear alone is not definite Travel Speed problem The Cutis Choppy and uneven the material is coming from under deck in Lumps instead of being distributed across width of Deck These conditions can force the Oil to go over relief because of excessive Load on Motor A Change of Ground Speed and or material being cut by unit will cure this problem CAUSE Excessive Ground Contact with Blades Operational Problem SOLUTION Inspect Blades Blade Carrier and
138. ion to normal Oil Flow through the circuit Check for an unwanted increase in pressure The obstruction would be down stream from the Pressure increase so you would want to check pressure going back toward pressure inlet As Oil passes through the obstruction it causes Heat increase a check of temperatures will generally be near restriction a heat sensing gun works well for this Some Examples of Restrictions are Kinked Mashed or Internally Broken Hoses Obstruction by foreign materials in lines Plugged Filter or Wrong Filters installed Open Stuck By Pass Valve Wrong Size Hoses or fittings installed Repair work done and parts assembled wrong The number of possibilities is numerous Do not forget when checking especially for kinks in hoses it may be required to run the cylinders through their complete range of movement to check them Know what repair work or modifications were performed Wrong Type Valve being Used For Tractor Tractor Hydraulics Only Determine type of Control Valve for Tractor Is tractor a Fixed Displacement Open Center System or a Load Sense Closed Center System Make Sure the Valve that is installed is the correct one for the Type Tractor Hydraulics be used If the Wrong System is Used it will cause a Heating problem Spool Valve Stuck In Open or Partially Open Position Repair or Replace Valve components as needed Relief Valve Set to Low Load Sense Closed Center Only Relief Valve for Mower Position
139. ipped with two way radios and when using radio to send When Radio Receives there should be no interference Cylinder Moves Wrong Way Opposite of direction it should per Control Movement CAUSE Hoses Routed incorrectly On New or Repaired Units SOLUTION Route hoses per Hose Diagram in Parts Manual CAUSE Incorrect Valve Operation Plate On New or Repaired Units SOLUTION Replace with correct Plate CAUSE Wire Harness improperly connected On New or Repaired Units with Joystick SOLUTION Change connectors to other solenoid valve on Same Circuit and test Applies to Old Apitech valve Models Ten Connector Wiring harness 5 on each side of Valve CAUSE Confusion On Direction Travel of Joystick or Switch Application SOLUTION The Function of Joystick is specific to type or combinations of movement that is made to perform that function If the system was not connected correctly when first assembled the the movements may not match what is expected See Operators Manual Parts Manual or Repair Manuaul for what action or combination of actions should operate what function MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 9 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Moves Intermittent ai Functions CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Obvious Causes Check First Check These First
140. it Hoses Color Tie Code Hose Size Green G SAE 6 Green White G W SAE 6 Orange OR SAE 6 Orange White OR W SAE 6 Blue B SAE 6 Blue White B W SAE 6 Yellow Y SAE 6 Yellow White Y W SAE 6 Red R SAE 6 Red White R W SAE 6 Green G SAE 4 Green White G W SAE 4 Yellow Y SAE 4 Yellow White Y W SAE 4 Motor Circuit Hoses Color Tie Code Hose Size Red R SAE 16 Orange OR SAE 16 Blue B SAE 8 Blue B SAE 12 Maverick Boom Service Manual 12 04 2004 Alamo Group Inc Hyd Function Swing Back Rod End Swing Forward Base End Lift Down Rod End Lift Up Base End Dipper In Rod End Dipper Out Base End Telescope In Rod End Telescope Out Base End Head Tilt Up Rod End Head Tilt Down Base End Swivel CW Rod End Swivel CCW Base End Door Open Rod End Door Closed Base End Hyd Function Pressure Flow to Motor Return Flow From Motor Case Flow From Motor to Boom Case Flow at Boom to Tank Section 1 4 SPECIFICATIONS MAVERICK 6 HYDRAULIC CYLINDER PRESSURE RATES Cylinder bo RR Welded Cylinders Cylinder Working Pressure 3000 PSI Hydraulic Cylnder Repair Specs Cylinder Cylinder Piston Nut Gland Seal Kit Part No Function Torque ft Ibs Torque ft Ibs Part No 02981275 Swing 400 500 80 120 Head 02982066 02981278 Lift 30 ft 400 500 80 120 Head 02982069 02981279 Lift 24 ft 400 500 80 120 Head 029820
141. k Hose ROUTES eo MOTOR PUMP CICUIT Pages 4 2 through 4 21 Pune xo BOOS EE E E ne Recommended Gauge for testing Charge Relief Pressure Settings Pump Circuit Motor Engage FUNCHON Luse PUP Parts LNM Pump Dis Assembly Instructions Pump Re Assembly Instructions Charge Pump Adapter Dis Assembly amp Re Assembly Manual Servo Control Dis Assembly Re Assembly Manual Servo Control COMPONENTS caseus cnini tid Ro cma xig iur e ani kan Rotating GE c Vv J CYLINDER PUMP CICUIT Pages 4 22 through 4 31 Pump rei og e EE A Pump Operation Feature and Controls eee General DESCI LO id O ET Pressure Compensated Control SSS UTS COMO RR LOW Pressure ANN ee Multiple P ressules Ae Electro Hydraulic Pressure amp Flow Circuit Load Sensing Low Pressure Standby Pressure Horse Power CON de Pump ort Size amp SDECIICANONS needed Pump Torgue Specifications and Assembly Section 5 Motor CIU Lanas Motor Parts NOR en eee nese ane se eee Motor PN ee Motor DIS ASsembIY seas oe bu uc ou nsshu sara na is oni idu bo kick oa o ds des ooo Motor Re Assembly core eerer erre eree acre aeee nneado Section 6 Spindle Repair nn nn nn Blade Bar Removal osn on nn nn nn nn nn nn nr Remove Motor 8 Spindle
142. l crack Adding a reinforcing piece or Extra Brace may not be as good as it sounds a number of reasons this is not advisable Because you could be making an area that needs to flex some to relieve stress is being eliminated the added weight may change the balance of unit or component A good suggestion for future reference is to take photos of cracks Failures before the repairs are made this will aid you in future failures to see what happened in the past ones This is a good idea because the failed area may not always cause the failure it may be caused by something else and itis sometimes hard to explain what the failure looked like before it was repaired Always repaint any area that has been re welded to prevent rust as well as cosmetic appearances MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 2 POSSIBLE FAILURE CAUSE 8 SOLUTION Possible Failure Page Boom Breaks Back Too Easily 7 4 Boom Drops When Two Functions Actuate iii 7 4 Boom Moves On lts Own Under Power w no function actuated 7 8 Control Valve Spool Spools Sticking ice eereeererrrenaea 7 5 Cylinder Boom Positioning erre errar 7 5 Cylinder Excessive Duato docs 7 6 8 7 7 Cylinder Leaks AI 1 7 Cylinder Leaks AtRod eee roer cea cera cera reanana 7 8 Cylinder Moves On Its Own Under Power w no function actuated
143. lacement parts and re assemble See Spindle repair section for assembly instructions and settings CAUSE Shaft Falls Out of Spindle Housing Lost Bearing Pre Load SOLUTION Remove Motor from Spindle Housing and Remove Spindle from Deck Clean and inspect all Parts try to determine what part failed and why Replace Parts as required and re assemble spindle assembly Note Pay close attention to the threads on top ofthe Shaft where Bearing Adjusting Nuts screw on if using old shaft make sure that Shaft and Nut Threads are in good shape and compatible DO NOT use old parts if the fit of them is not correct MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 33 POSSIBLE FAILURE CAUSE 8 SOLUTION Spindle Locks Up Seizes and will not turn CAUSE Low Oil Level in Spindle Causing it to Over Heat SOLUTION This will damage almost all parts in Spindle Assembly the only way to find out is to completely dis assemble the spindle Repair and or Replace as required CAUSE Excessive Bearing Pre load Bearings to Tight SOLUTION Bearing needs to be removed and inspected for damage from running too tight Rebuild Spindle replacing Parts as required Always replace with new Seal Set Bearing Pre Load and Lock Adjusting and Locking Nut down as instructed in Spindle repair section to correct Specifications always double check to make sure Nuts are locked in place CAUSE Bolts Holding Blade Bar to Spindle replaced and
144. lamo Industria s Systems are designed to operate at approximately 100 Degrees F above ambient temperature Ambient Temperature measured close to Tank with the proper Oil Level in tank and System Small variances can be expected due to normal wear in the System and other environmental conditions A System is not considered to be overheating unless it significantly exceeds 100 degree F over ambient temperature This is not to be measured by touching use a temperature measuring device to measure temperature to avoid being burnt 4 When Discussing the Problem with a Customer it is important to determine the condition under which the Symptoms occur For example Ask if the Symptom has existed for the life ofthe machine has been gradually getting worse or if it has occurred suddenly A sudden occurrence might indicate that foreign material entered the system when work was being performed Gradual worsening would indicate internal leakage Wear or Breakage Symptoms that occur with specific operators would indicate a possible operational problem Symptoms that have been present for some time could be any of the above problems MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 19 POSSIBLE FAILURE CAUSE 8 SOLUTION Hydraulic System Overheating continued CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Restrictions Just as indicated an unintentional obstruct
145. le you remove the other 2 bolts this allows the Blade carrier to slide off The four Blade Bar Retaining Bolts are Torqued to 400 ft Ibs and are tight It may be required to hold Blade Bar when removing them This can be done by connecting a Chain to Blade Bar and securing it to Deck Make Note of the length of the four Blade Bar Retaining Bolts in center Blade Bar See Figure 85 Never put Bolts back in that are longer or Shorter they will damage Spindle Shaft 9 It will not be required to dis assemble Blade Bar Carrier Assembly once it has been removed from Spindle But if you do dis assemble it the 4 Blade Bar Assembly Bolts 2 long and 2 short are torqued to 2000 ft Ibs Blade Bolts Torque to 400 ft lbs These Torque Values are based on Clean Lubricated and undamaged threads These Components must be torqued back to these setting when re assembled Blade Bar Asy Bolts amp Washers gt E EG 2 Short and 2 Long Top Blade Bar E Torque 2000 ft Ibs Middle Blade Bar SG El Blade Bolt Nut Washer 8 Roll Pin Bottom Blade Bar Torque 400 ft Ibs Blade Bar Retaining Blade Bolts and Washers Torque 400 ft Ibs FIGURE 85 ET Bolt MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 6 2 SPINDLE REPAIR Procedures Remove Motor and Spindle 1 Remove the four Bolts that Retain Motorto Spindle Working Motor side to side lift it away from Spindle If the Head is standing up on
146. lt 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 nextstep Note be sure to move any swapped connection back to their original location when diagnosing a problem 11 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 8 Etc Manually Follow the following steps A Use extreme caution while performing this operation Know where every one around you is at all the times DO NOT do this if you are not experienced with the functions of unit Go back and learn Functions B With Tractor Engine On and pump engaged C Turn On Master Switch on Joystick Console This will engage pump and all electric functions D Make sure no one is near Tractor Boom or Head E Locate Control Valve It will be mounted in Front at Front Pump F Remove all covers required to gain access to Valve G With Tractor Engine running it is necessary to have pump pressure for this activity H Go to valve and look for activator solenoids unplug the wire harnes
147. ltage from Controller check Controller End of Harness If still no Voltage Repair or Replace Controller as needed If Voltage at Controller then check Harness and Repair or Replace as needed see pages 56 and 57 trouble Shooting Testing Faulty Tractor Hydraulic System Perform Hydraulic Electrical isolation Test If Tractor System is at Fault Trouble Shoot and Repair Tractor per Tractor Manufactures Guidelines No or Low Pilot Pressure Check Pilot Pressure Test Adjust or Replace Pilot Pressure Valve as required MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 10 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Moves Spongy or Jerky CAUSE Air in Oil SOLUTION Run the System for a few minutes Check for Air in the Oil in the Tank Air entrained Oil will have a foamy appearance If Air Is present find the Air Leak and correct it Air Leak can be in the Suction Line and Oil may not leak out because there may only be Oil in that location when the Pump is sucking it in With the Tractor Engine Off you can find a leak by pressurizing the Tank This will not take but a few pounds of pressure 3 to 5 PSI or less Look for leakage in the Suction Lines Because the Oil Pick Up is lower than the Oil Level this will force Oil outthe leak Leaks in Hoses and at Fittings can draw Air into System as Oil Flows Past Systems that have had severe or prolonged Air Entry Problems may have Experienced Pump Damage CAUSE
148. m any more than necessary to check system If Suction side is pulling Air in the Oil will usually cause Oil to Foam after running some SOLUTION Cavitation is usually caused by a restriction of some sort in the suction lines but can also be caused by an un vented tank which creates a vacuum when the pump has a demand for Oil Other problems such as plugged Suction Screens or very thick Oil can cause cavitation The cause must be found and corrected before a new Pump is installed as cavitation will damage a Pump Repair or Replace components a required CAUSE Wrong Oil Oil to Thick or Viscous SOLUTION Make sure correct Oil is used Recommended Hydraulic Oil only should be used Do not mix grades and types of Oil if wrong oil has been used it must be completely remove before adding different types Oil See Specification Chart for recommended Oil type Hydraulic System Overheating Note 1 Overheating of the Hydraulic System can have many individual causes Before going too far into trouble shooting an overheating complaint it would be well to understand exactly the difference between HOT and TO HOT 2 Heat is produced anytime a Hydraulic System is working Heat is generated when the Oil moves from an area of High Pressure to an area of Low Pressure These Pressure drops occur when work is performed by the System and normally occurs in Pumps Motors Hoses and Valves They are expected and allowed for in the design of the System 3 A
149. minutes Check for Air in the Oil in the Tank Air entrained Cil will have a foamy appearance If Air is present find the Air Leak and correct it Air Leak can be in the Suction Line and Oil may not leak out because there may only be Oil in that location when the Pump is sucking it in With the Tractor Engine Off you can find a leak by pressurizing the Tank This will not take but a few pounds of pressure 3 to 5 PSI or Less look for leakage in the Suction Lines Because the Oil Pick Up is lower than the Oil Level this will force Oil out the leak Leaks in Hoses and at Fittings can draw Air into System as Oil Flows Past Systems that have had severe or prolonged Air Entry Problems may have Experienced Pump Damage CAUSE Engine RPM Too Slow SOLUTION Run Tractor Engine at required Speed to achieve GPM through Pump See opecification Section in Repair Manual CAUSE Vent Plug Block or Not Installed Power One Way Cylinders SOLUTION This applies to Cylinders that only Stroke in or Out under pressure The return Stroke under gravity Remove Plug Clean or Replace as needed If No Vent Plug is there determine if one is needed and install as required See Parts Operators Manual for Vent Plug requirements MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 15 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Rod Bent CAUSE Excessive Load Applied to Cylinder SOLUTION Thisis an Operational Problem or Operational Acc
150. mp Part Number Boom Cylinder Circuit Hoses Color Tie Code Green G Green White G W Orange OR Orange White OR W Blue B Blue White B W Yellow Y Yellow White Y W Reg R Red White R W Green G Green White G W Yellow Y Yellow White Y W Motor Circuit Hoses Color Tie Code Red R Orange OR Blue B Blue B Hose Size SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 4 SAE 4 SAE 4 SAE 4 Hose Size SAE 16 SAE 16 SAE 8 SAE 12 MAVERICK Service Manual 12 04 2004 Alamo Group Inc ort W gt U gt U gt gt U0U gt gt 00U gt U Section 2 15 Hyd Function Swing Back Rod End Swing Forward Base End Lift Down Rod End Lift Up Base End Dipper In Rod End Dipper Out Base End Telescope In Rod End Telescope Out Base End Head Tilt Up RodEnd Head Tilt Down Base End Swivel CW Rod End Swivel CCW Base End Door Open Rod End Door Closed Base End Hyd Function Pressure Flow to Motor Return Flow From Motor Case Flow From Motor to Boom Case Flow at Boom to Tank HYDRAULIC HOSE CONNECTIONS 24 FT BOOM Z Hole In Side of Lift MAVERICK Service Manual 12 04 2004 Alamo Group lnc Section 2 16 HYDRAULIC HOSE CONNECTIONS 24 FT BOOM Part No Qty End 1 End 2 Description 02981823 1 Y MJ Z FJX Hose 4 4MJ 4FJX 76 Lg Yel Tie Door Lift Sec n 02981824 1 Y MJ Z FJX Hose
151. n power will be found in the Tractor However there is a cause that involves the Mower Only the problem that could be caused by the Mower is covered here and only mower models that have electrical systems that are tied in with Tractor Electrical system could affect Tractor Battery Circuit CAUSE ON OFF Switch or Joystick Wired Incorrectly SOLUTION Power Wire from Tractor to Mower control system must be wired through the Tractor Ignition Key Switch to where it only has current when Tractor Key Ignition Switch is ON If the Mower Power Source is connected where it has Power Constant Power when Tractor Ignition Key Switch is OFF it will put a constant Drain on Battery This is the only one problem that should be able to affect Tractor Battery from Mower Electrical System Check where Wiring is connected Correct as required See Operators Parts or Repair Manuals for Wiring Schematics MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 35 NOTES MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 36 Maverick Service manaual 12 04 AAA eet INDUSTRIAL Maverick Boom Service Manual 24 ft amp 30 ft 12 04 O 2004 Alamo Group Inc Manual P N 02982288 Printed U S A
152. n 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 9 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 f When the Malfunction occurs take note of all conditions that exist during the time of the malfunction Some things to take note of are Engine Speed or Sound Position of Articulating Members Operating Temperature Length of time Unit has been running Position of Joystick before and during malfunction Position and Condition of Tractor Any other condition you might notice 8 Duplicate the conditions that existed when the malfunction occurred to deter mine 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 wh
153. nd or Defects in Pump and or Motor Low Relief Valve Setting Best Tested with Pressure Flowmeter Some Relief Valve can be Repaired Some Only Replaced See Assembly set up instruction on Relief Valves See Specification Section on Relief valve Settings DON T exceed recommended Relief Settings Before condemning Relief Valve do a Flow and Pressure Test The Pump under some conditions can t build enough pressure to make the relief open and this would appear Relief Valve is stuck A Flowmeter will show when Pressure Relief opens Restrictions in System Check Hoses lines for Kinks Obstructions May not be visible without disassembly Unplanned restrictions cause increased back pressure loss of usable power and excessive heating of Oil Usually at the restriction Restrictions can sometimes be found by checking different locations for the temperature The restriction will generally be upstream of heated spot There are a number of things that can cause this heating problem Most common Problem Contamination Kinked or Damaged Hose MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 28 POSSIBLE FAILURE CAUSE 8 SOLUTION Pump Seizure Pump Locking Up CAUSE Lack of Oil Lubrication SOLUTION This is normally caused by failure to Pre Lube the Pump before starting or cavitation Air or Lack of Oil during operation A Lack of Pre Lube failure will occur soon after start up if Pre Lube is not done when unit i
154. nstant pressure drop will be maintained across the valve spool This results in a constant flow for any given opening of the directional control valve regardless of the work load downstream or the operating speed of the pump The pump senses the amount of pressure necessary to move the load and adjust output flow to match the valve opening selected and pressure to overcome the load plus the Preset P across the valve spool Thebenefits ofthis CONTROL OPTION A arrangement are that ex SWASHPLATE AIRBLEED VALVE FLOW CONTROL cellent repeatable flow ASSEMBLY ADJUSTMENT E characteristics are m 8 achieved and consider A foes 1 i able energy savings are J ds E E realized while metering compared to using a straight pressure com O Sm vx pensated system s servo agro l soa ES AND ES SLEEVE EREE E CONTROL DRAIN iy E CONTROL SPOOL PORT A SPRING CHAMBER FIGURE 39 move orem ADJUSTMENT MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 29 PUMP BOOM CIRCUIT Pressure 8 Horsepower Control Control Type H The horsepower is sensitive to the position of the servo piston When the servo piston is to the right the swash plate causes low flow and the power control piston develops maximum spring pressure on its companion poppet mechanical feedback When the servo piston is left and the flow is high the power control piston reduces spring pressure on the poppet This allows it to open under l
155. nto the Servo Piston cavity of Housing Screw the Cover Plate onto the Servo Piston Assembly Install new Cover Plate Gasket in place on Housing Install Servo Piston Assembly and Cover Plate into Servo Piston bore in right side of housing as shown in Figure 29 Retain Cover Plate with four each Washers and Bolts Torque these Bolts to 40 to 48 in Ibs 4 5 to 5 4 nm 5 Servo Piston Neutral Adjustment Centering the Servo Piston Assembly is required Measure in from the left side and set Servo Piston 5 12 7 mm from the surface of Housing Servo Bore as shown in Figure 29 Final adjustment may be require after Pump is installed and operating to obtain Neutral Special Note if Unit is equipped with Buzz Bar Head it will have a Neutral Centering Adjustment on one side of Servo Piston and piston travel limiting Screw on the other side 1 2 12 7 mm EP p Left Side IT M A Right Side Install Servo lt Piston in This Front Flange Drive Adjust to Center Direction Shaft End of Pump Neutral Piston FIGURE 29 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 15 MOTOR CIRCUIT PUMP RE ASSEMBLY 6 Install New Seal Washer Washer and Jam Nutto Servo Piston Bolt Only do this after Centering of Servo Piston has been done Holding Servo Piston Bolt with Hex Key Wrench Torque Jam Nut to 150 to 160 in lbs 17 to 18 nm Recheck Servo Piston Measurements See Figure 29 If
156. number by 10 to get the Valves pressure settings Example 500 stamped in valve is 10 X 500 5000 PSI 345 bar L ater Models Lever not Used Replaced by Block w 2 wire Charge Pump Suction Port Electric Solenoid Not Shown Tee in Line to Check Inlet Vacuum S Pressure Ports Tee in Line to Check System Pressure Auxillary Port Check Charge Pressure Drain Port Tee in Line to FIGURE 20 Check Case drain MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 3 PUMP MOTOR 8 BOOM CIRCUIT IMPORTANT Pump MUST be PRIMED with Hydraulic Oil prior to operation for the first time this Is very important Prime Hydraulic Pump 1 The Hydraulic Pump MUST be Primed The hydraulic pump is primed by putting oil directly in to the pump Looking at the pump out near the end of the pump there is a Allen plug See Figure 21A Remove this plug and install only approved hydraulic oil See Step 1 through 3 of hydraulic tank filling Fill the cavity completely full up to plug threads IMPORTANT This must be done before the unit is ever started Make certain that the O Ring Seal is on plug and reinstall it after cavity is full of oil now the pump is primed The Unit still will not operate until the step of setting the electronics to operate the system are done Remove This allen god a i plug to Prime Pump E al 7 AN ES Ml M A A MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section
157. o enter system causing damage DO NOT do any welding around these electronic components If welding is required in a repair the electronic components MUST be disconnected unplugged Un plug all components Joystick Modules Displays and any other electronic component If notunplugged the current from the welded can cause serious damage to electronic components Additional repair and diagnostic procedures for the electrical system is available on the internet web site of the manufacture of this system at REFERENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANUFACTURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com Make certain that the instructions you refer to is for the MDM system the manufacturer has more than one system The boom and motor control is electronic over hydraulics If these functions are not properly set or working properly the mower can not be operated Also make certain that all fluid levels are OK and with in operating limits The first thing that should be checked is the main electrical power supply to the system this can be checked on the display unit when power is on See Electronic Control Section The set up portion as shown in the next pages should be checked to make certain the joystick and motor functions are set correctly Check all the connections if not operating properly If
158. olored tie on it to ID hose and location Some hoses will have a elbow on one end these are marked in drawing above with 90 this meads the hose end with the elbow connects to this end To ID hoses always check hose size length and colored plastic tie MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 7 8 SWING CYLINDER HOSE ROUTING 24 30 FT BOOM NOTE Male JIC Hose End To Extend Up Thru Holes Item PartNo Qty Description A1 02981825 Hose 6 6FJX 6FJX 28 Lg B1 02981825 Hose 6 6FJX 6FJX 28 Lg C1 02981826 Hose 6 6FJX 6MJ 16 Lg Geen Tie C2 02981827 Hose 46 6F JX 6MJ 16 Lg Green White Tie 34 02968832 Plastic Tie Green 35 02968833 Plastic Tie Green White hh NOTE Hose are not shown in drawing this is for clarity The hose routing is for hoses which connect from one point to the other Use the instructions and hose descriptions listed to follow hose routing Example Hose A1 connects to one end marked A1 and the other end connects to the other connection marked A1 This is done with the other letters as well the hose must connect to the same letter mark on each end Some hose have a plastic colored tie on it to ID hose and location To ID hoses always check hose size length and colored plastic tie MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 7 9 NOTES MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 7 10 SS Section 8
159. onnectors at the Joystick So it can not be installed Wrong Connectors are supplied for each electric valve controller connection 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 Wireing schematic on the following pages S for Plug Connection Letter Code amp Terminal locations See Figure Schematic for actual Wire locations 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 MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 2 8 DOOR SWING CYL DIVERTER VALVE P N 02977622 Diverter Valve The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two or more if valves are stacked funtions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pressure The Portopenings on this diverter valve are marked with letter number codes which show wich port is connected to which hose and where that hose connect on other end See Figure 18 Port Function 8 Connection
160. ort Return to Control Valve door swivel port of control valve C3 Port to door cyl Rod FIGURE 18 Maie MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 11 CONTROL VALVE JOYSTICK JOYSTICK FUNCTIONS Figure 19 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 8 3 allow Pilot Pressure Oil to flow to the corresponding end of the Spool Thus causing it to move Valves 2 a 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
161. otor wanting to run Neutral Port D system Relief amp Port C Centering ToMotor Check Valve From Motor opring Camplate Gerotor Solenoid Piston Asy sek Charge f Servo Pump Control MA 7 iL po TEM a d NS V r Z HO E ons TB ZL EV le Y U C C o 3 o D TU Aj I i OZN Ds pex WEE Charge Pump Relief Valve Me Servo Piston Neutral Adjustment SEG System Relief Servo Control Supply Oil amp Check Valve FIGURE 23 MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 7 MOTOR CIRCUIT PUMP ENGAGE Motor Circuit Engaged w Engine Running When the Switch and Solenoid are activated The Servo control System moves the Camplate to its Maximum Angle As the Piston Block rotates The Angle of the Camplate causes the Pistons to move in and out of thier Bores as they follow the Camplate This results in Oil being drawn into the Piston Bore as the Piston is pulled outward and Oil being expelled into the other side of the Loop as the Piston is forced back into its bore This creates the flow of Oil necessary to power the Motor Movement of the Camplate angle from the neutral to maximum is set at approximatly 6 seconds and is controlled by the size of the Orfice between the Control Valve amp Pump Case Oil under charge pressure is avail
162. ow are the sensors included on this unit Tank Temperature Sensor Charge Pres sure Filter Switch Valve Pressure Filter Switch and Return Filter Switch Tank Temperature Sensor The tank tem perature sensor monitors the fluid temperature in the area of the pump suction screens the tempera ture is real time and is used on the network to accomplish certain objectives The first is to display on the interface while the cutter circuit is operating The second is to be used to control the electric fan on the hydraulic cooler At any time the fluid level reaches 150 F the fan is activated and remains activated until fluid temperature drops to or below the desired temperature See Figure 13 The Charge Pressure Filter Switch The charge pressure filter switch is located at the filter in the charge loop on the hydrostatic pump See Figure 14 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operator for a filter element change of filter element The Valve Pressure Filter Switch The Valve pressure filter switch is located at the pres sure filter in the valve pressure circuit between the closed center load sense pump and the control valve See Figure 15 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and
163. peration When the pressure in Port D exceeds the setting of the Relief Valve 4500 PSI the large Spring in the Relief Valve is compressed Opening an Orfice allowing excess Oil to relieve into the Charge Circuit Since the Check Valve for Port C is open The Oil is available to the intake side of Pump There is also a relief Valve in the High Pressure side of the Loop at the Motor This Valve is set to relieve at 4000 PSI and is in the circuit to absorb pike pressure encountered during severe operation Servo Piston MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 8 MOTOR CIRCUIT PUMP PARTS LOCATION See ltem 48 the lever Servo Control removed and replaced by a 2 wire Solenoid Block Asy Serial Code and Product Number Location Left Slde FIGURE 25 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 9 MOTOR CIRCUIT PUMP PARTS LOCATION Item Qty Description 2 1 Jam Nut 3 1 Retaining Ring 4 2 Retaining Ring 6 1 Seal Washer T 8 Bolt 10 24 X 1 25 4 mm Long 8 1 Rotating Kit Asy 9 1 Servo Piston Asy 10 1 Servo Piston Follower 11 1 Cover Plate 12 2 Gasket Cover Plate 14 1 Gasket Housing 16 1 Gasket Control Housing Used 1997 amp Down 16 1 1 Gasket Solenoid Servo Asy Used 1998 amp Up 17 1 Cover Plate 18 1 Camplate 19 2 Thrust Race 20 1 Thrust Bearing 21 1 Relief Valve For Port C 21 1 1 O Ring 097 Dia X 755 ID 2 46 mm Dia X
164. pindle Grease Relief Plug is installed Fill Spindle with Grease Fill with grease until it comes out the Relief Plug When grease is cold removing Grease relief Plug will help to prevent Seal from blowing out during filling replace plug after filled with grease Wipe away excess Grease 5 Install Blade Bar Carrier As Bar Blade Carrier was only removed and not dis asembled it should only be a matter of bolting the Assembly on and Torqueing it down If Bar Blade Carrier was Dis Assembled it will have to be assembled and components Torqued as specified See Figure 85 on previous Pages Blade Bar leaf Assembly Bolts MUST be torqued to 2000 ft Ibs There are four of these Bolts 2 long and 2 short They MUST be torqued BEFORE Blade Bar is bolted to Spindle The Blade Bolts must be torqued to 400 ft Ibs and Roll Pin Installed The Blade Bar Retaining Bolts Socket Head Bolts that attaches blade bar to spindle and lock washer must be installed These will torque to 400 ft Ibs 6 After Assembly is completed check all steps to be sure they are completed Test run Head then Stop and recheck all components including Grease Level in Spindle Spindle temperature can reach 200 F after running so do not check the Temperature by touching it MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 6 5 NOTES MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 6 6 Section 7 Frame amp Boom With Hose Routing
165. placed in a bind if the mounting bolts are tightened incorrectly This can cause the Spool to stick in the Bore or results in Internal Valve Leakage Contamination in the Valve Spool Clean Valve Check complete System for contamination Flush and Clean as required Reassemble and Test Faulty Valve Spool or Section Determine what caused Valve Spool to be Faulty is it a failure or a defect A Defect usually shows up soon Failure can be any time If Defect Repair or Replace as needed If Failure determine cause of Failure Repair Failure cause and Repair or replace Spool Section Faulty Control Module electric over hydraulic new style 5 wire valve only Valve control modules may develop one of two modes of failure 1 Water damage In this case condensation will develop in the circuit board cavity of the controller and result in a short With this mode the controller will stop working in one or both directions and will very seldom regain function 2 Thermal Fatigue This failure will be identified as a module which performs adequately when cold but will stop working in one or both directions as the unit warms up This is caused by fatigue of the wire strip located inside the module Identify the signal wire from the joystick attached to the faulty segment of the valve swing lift dipper etc Use a phillips screw driver to remove the wire Remove the wire attached to the module next to the faulty segment and swap the two wires If the
166. pletely Do not force adjustment after is seats Then back it back out 1 2 turn this will give you the 2800 psi required to oprtate the boom See PE iras m FIGURE 34B ms Figure 34A amp Pro dd A ET 34B Hold 1 TRA rw Bi 5 the adjusting Eu ih nut while A turning the la 4 AS locking nut so the ad Pressure Adjust justment nut Ms OTI does not turn in with it chang ing the set ting MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 4 24 PUMP BOOM CIRCUIT Introduction Variable Piston Pump PUMP REPLACEABLE HYDRODYNAMIC HOUSING PORT PLATE BEARING o BER EN He NATH EE UR ANA S SEALED BEARING CYLINDER BARREL PISTON FIGURE 35 Features Controls High Strength Cast Iron Housing Pressure Compensation Built in Supercharger Load Sensing High Speed capacity 3000 RPM Horsepower Torque Limiting Sealed Shaft Bearing Horsepower amp Load Sensing Two Piece design for ease of service Remote Pressure Compensation Cartridge Type Controls Field Changeable Adjustable Maximum Volume Stop Replaceable Bronze Clad Port Plate Electrohydraulic Pressure Airbleed Standard for Quick Priming Electrohydraulic Flow amp Pressure Hydrodynamic Barrel Bearing Servo Controled Full Pressure Rating on Water Glycol Fluids Low Pressure Standby Pump Case amp Shaft Sea See Inlet Filter and or Cool Drain Line 100 ps
167. pper Bearing Cup and Cone NINE Adjusting Nut Oil Plug Grease Fitting Lower Bearing 7 d Z Cup and Cone K 77777 Spindle Shaft Lower Seal Spring around ID of Seal Lip Lower Seal FIGURE 88 Procedures Install Spindle Motor and Blade Carrier 1 Install Spindle on Deck Slide Spindle into Deck from Top Side Install Hardened Washers on Bolts then Insert eight 3 4 Retaining Bolts up from Bottom of Deck Install the eight Locknuts on Bolts Torque these Bolts in an alternating Pattern to 300 to 320 ft Ibs DO NOT leave off hardened Flat Washers Use Lock Nuts only do not use Lock Washers 2 Install Spindle Housing Gasket Install Spindle Gasket on top of Spindle Make sure old Gasket was removed and not stuck to Bottom of Motor 3 Install Motor onto Spindle Housing Set Motor down onto Spindle making sure Motor sets down flat and is fully seated against Spindle Housing Make sure Motor is installed correctly This is important that Motor be installed correctly so Case drain comes out in right place The Valve body bolts torque 25 to 30 ft Ibs in an alternating pattern Insert the four 1 2 retaining Bolts that holds Motor to Spindle Tighten these four Bolts until Motor seats against Spindle Housing If Motor will not sit Flat against Housing DO NOT force it Something is wrong Check everything or you could break Flange off of Motor torque the four 1 2 bolts 100 to 110 ft Ibs 4 Fill Spindle with Grease Make Sure that S
168. problem moves to the new location the problem is in the Joystick or harness If the problem continues in the affected valve segment replace the module MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 12 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Won t Move At All No Power CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Obvious Causes Check First Check These First Perform all Operational checks Tank Oil Level Pump Operation Control Valve Circuit Electrical Supply 8 Hydraulic Supply All Circuits affected or only some Circuits If All Circuits will not work the Problem is most likely up stream of the control Valve or an electrical Problem Models with Joystick Controller The Following Causes are based on only some circuits being affected Not all circuits Incorrect Hose Routing Unit has never worked or been repaired Check Hose Routing with Parts Manual and Assembly Guide to make sure Hoses are routed correctly Move and reconnect Hoses as required Work Port Relief Installed Improperly Unit has never worked or been repaired Determine correct positioning of Work Port Relief s If relief s are incorrectly installed Install correctly and Test Work Port Relief Malfunction Determine if one or both sides are affected Make sure Work Port Relief s are in proper
169. prompt the operator for a filter element change WARNING This filter does not have a by pass The element must be changed at the appropriate time to avoid element danmage and system contamination MAVERICK Service Manual 12 04 ES r E LIIS ME T p 2004 Alamo Group Inc Section 3 6 CONTROL VALVE INSTRUMENTATION Maverick Instrumentation continued The Return Filter Switch The return filter switch is located at the return filter mounted on to the tank top The fluid returning from the cylinder control valve is filtered before returning to tank at this loca tion See Figure 16 The sensor monitors back pressure created by the filter assembly while cylin der circuit is in operation When the back pressure reaches 25 psi the switch will trigger and prompt the operator for a filter element change WARNING This filter does not have a by pass The element must be changed at the FIGURE 16 appropriate time to avoid element damage and FIGURE 16 system contamination Maverick Operator Interface The Operator Interface The operator selects parameters provided by a menu system in the MDM display The parameters are used to establish how the boom unit functions The menu system is comprised of two sections The first section is setup the second section powers up the boom control circuit and cutter head circuit The following steps outline how to successfully page through the menu system to execute oper
170. re of the Oil or fittings at various points in circuit as heat will usually be higher at the restriction The restriction should be located at or upstream of the increased temperature point Foreign objects that get into the system sometimes cause restrictions This can happen during servicing maintenance or repairs It is not uncommon to find bolts nuts plastic plugs paper or rags stuck into system when it was being repaired or assembled then forgotten about Restrictions sometimes can be a piece off of a failed component up stream or a Component such as a Hose built wrong CAUSE Relief Valve Malfunction SOLUTION Perform Flow Pressure Test If Flow is correct and Pressure is Low remove Relief Valve and inspect for damaged Seals Contamination or other abnormali ties Re Seal Adjustor replace the Valve as needed Leakage through the Valve from Low Pressure setting or leakage around the Valve from damaged Seals will cause heating of the Oil and Low Power complaints NOTE There may be situations when Pump Flow is insufficient to reach Relief Pressure Therefore it is important to test for proper Flow before condemning the Relief Valve MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 18 POSSIBLE FAILURE CAUSE 8 SOLUTION 1ydraulic System Noise continued CAUSE Cavitation Cavitation is caused by inadeguate amount of fluid reaching the Pump Cavitation will damage Pump so do not run with a Cavitation proble
171. roblem if continuing to mow Observe or Ask Operator mowing conditions Material being Cut etc Correct Ground Speed is always relative to Material and conditions of mowing One indication of Excessive Ground Speed is considerable wear on tips of blades but this is not exclusive of Excessive Ground Speed as the Wear can be caused by other factors So Blade Wear alone is not definite Travel Speed problem The Cutis Choppy and uneven the material is coming from under deck in Lumps instead of distributed across width of Deck These conditions can force the Oil to go over relief because of excessive Load on Motor A Change of Ground Speed and or application will cure this problem Excessive Internal Leakage in Pump Motor Perform Flow Pressure Test If results are not within Specifications determine cause of the internal leakage correct the cause Replace worn damaged parts It is good to replace the Filter anytime the Pump and or Motor are repaired or replaced Pump and or Motor wear usually occurs over a long period and are gradual loss of power and excess heating of Oil This may go unnoticed till it is severe making the operator think it just started this can make this type of failure hard to determine Pre Mature Pump and or Motor Failure wear occurs quickly The problem for these failures must be found and repaired or the failure will be repetitive The Most common cause of Pre Mature Failure is Cavitation Oil Contamination Oil Aeration a
172. s assembled Obstruction or damage to Intake Suction Side of Pump or Lines can cause this problem The solution would be to determine what Is damaged and why was Oil Low Repair or Replace as required CAUSE Improper Assembly SOLUTION Damage can be caused by over torquing the Pump components incorrect alignment or location of components Improper Torquing or Assembly will normally show up very soon after start up The solution would be to determine what is damaged and why Repair or Replace as required CAUSE Faulty Defective Pump SOLUTION Sometimes Oil passages are not open inside the Pump during Manufacturing These problems will show up as early Bearing failures or Pump not working when installed and very seldom occur after being run for awhile unless there is debris or other contamination blocking something The solution would be to determine damage why and Repair or Replace as required CAUSE Foreign Material Contamination SOLUTION Objects leftin Tank or fall in during service This can include Dirt Pieces of Hose Plugs Rags or any other object can be left or get into system Keep everything clean and account for every thing used when serviced The solution is to determine what is damaged and why Repair Replace as required MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 29 POSSIBLE FAILURE CAUSE 8 SOLUTION Pump Wear Rapid Excessive Wear CAUSE SOLUTION completely CAUSE
173. s connection for the function you want to manually activate In the center of the solenoid you will see a pin depress push this pin inwards the movement of this pin should correspond to the required cylinder and direction USE CAUTION movement may be quick and jerky so as not to damage anything press pin slowly and watch the reaction to get familiar with movement speed MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 24 Section 4 TANDEM PUMP SECTION Motor 8 Cylinder Supply Pumps 24 8 30 BOOM Section 4 1 PUMP MOTOR 8 BOOM CIRCUIT INTRODUCTION The information in this Section of Book is re printed with Permission of the Eaton Corp This Section of Book provides service information for the Servo Controlled Piston Pump P N 02967192 Step by Step instructions for the complete dis assembly and re assembly of the Pump are given In Most diagrams there are no Component Part Numbers Listed Only Item numbers and Descriptions This is because most parts shown as break down in drawings are for location amp identification only and are not available as replacement parts NO Dirt at all should be around Parts during repairs BEFORE STARTING REPAIRS Service Rules READ THIS 1 9 Remove Front Cover Clean Pump and surrounding area completely before removing any connections or Lines NO DIRT OR DEBRIS CAN BE ALLOWED ON OR NEAR HYDRAULIC SYTEMIFITISBEINGWORKED ON ANY DIRT ORCONTAMINANTS IN SYSTE
174. se recommended Hydraulic Oil DO NOT mix Oils that are not compatible in some cases it may be required to drain and replace all the oil See Specification Chart for recommended Oil Type When repairing unit it is recommended that Oil is updated to recommended Oil CAUSE Shaft Seal Worn SOLUTION This is usually visible damage Replace Seal if Shaft is NOT also worn If Shaft is worn Groove or scratches in Shaft it is advisable to replace the Motor Seal and Shaft wear are normally caused by abrasive material dirt getting around the Seal Damage can also occur from damaged Spindle Assembly What ever the cause it must be corrected before new Motor is installed CAUSE Shaft Seal Coming Out of Bore SOLUTION Check Seal retainer if equipped to make sure that retainer is of proper size and installed properly Install New Seal and proper retainer But always try to find the cause of Seal blowing out to correct the problem CAUSE Faulty Motor SOLUTION Motors can leak at the Shaft Seal due to internal wear Damaged Internal Seals or Improper Assembly Repair or Replace as required Motor Runs Too Slow Or Slows Down under Load Note The Motor on the Cutting Head running too slow can be a result of many causes and not all caused by the Motor itself It needs to be determined whether the Symptom occurs by itself or if it is accompanied by other symptoms such as overheating unusual noise etc The question should be asked whether the s
175. side Oil may run out of Spindle when seal of Gasket is broken be ready to catch it in a container It will not be necessary to remove Hoses or connections to motor you will be able to set motor aside with Hoses connected Do not let weight of motor hang on hoses 2 Remove Spindle from deck There are six bolts that hold Spindle down to Deck remove these Bolts and Nuts to remove Spindle from Deck You will need someone on bottom side of Deck to hold the Bolts as you take the Nuts off Spindle will lift off deck from top of Deck 3 Move Spindle to work Bench Older Models used a 000 Grease Thick Oil that will Drain Slowly the later models use a Grease that will not drain at all It is Best to remove grease when Spindle has been dis assembled Procedures Dis Assemble Spindle 1 Spindle Dis Assembly See Figure 87 The Spindle Shaftis held in with 2 notched round Nuts and a Tabbed Locking Washer first use small Blunt Chisel to bend tab out away from Notch on Round Nut Using Tabbed Socket consult your local Tool supplier un screw outer Locking Nut Lift tabbed Washer off Shaft un screw lower Bearing Adjusting Nut It is best to replace Tabbed Washer with new one 2 Remove Spindle Shaft Because of fit of Upper Bearing Cone it will be required to Press Shaft out through bottom of Housing This should not take a great deal of effort but some Put a soft Metal Pin Brass into top hole of Shaft Do Not put one in that will be too big and get s
176. ss New type is press on and Older type pushed on Upper Bearing Cone on to Spindle Shaft Don t press on Bearing Rollers or Cage as this will damage Bearing It is installed till itis seated into Bearing Cup Remember to keep Spindle Shaft supported at bottom 7 Install lower Bearing Adjusting Nut with chamfer up Tighten Nut till it contacts Bearing Cone But do not torque at this time Clamp Spindle to Bench or Vise so that Spindle Shaft can rotate Tighten till it takes 25 in lbs to rotate Spindle Shaft Tap Shaft with a Hammer to make sure Bearings seat straight and recheck Rolling Torque must be 25 in lbs of rolling Torque 8 Install Tabbed Washer on to Spindle Inner tab in slot and Outer tabs facing up 9 Before Installing Top Nut with chamfer on Nutfacing down Make sure Shaftis locked Clamped so itwill not Turn in Spindle Housing Torque this top Nutto 100 ftlbs Bend the Tab ofthe Locking Washer to fit into one of the Grooves on top nut Recheck Rolling Torque of Shaft it should be 25 in lbs Rolling Torque 10 Install Grease Plug in bottom hole and Grease Relief Plug in the upper hole Note When grease is cold it could force bottom Seal out of Housing Let grease warm before filling begins Excessive Pressure of Air Grease Gun could force Seal out Use low Pressure MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 6 4 SPINDLE REPAIR Upper Bearing TabWasher Adjusting Nut AAN RNA Lower Bearing U
177. sure compensator separate feed reducers for A and 8 ports and prepared for port relief valves in both service ports Section 2 without pressure compensator feed reducer or port relief valve Section 1 equipped with proportional electrohydraulic remote control Section 2 equipped for direct with spring centering Sections 1 and 2 equipped with spool for double acting function with service ports blocked in neutral position Pressure compensator with built in check valve function Restriction of load signal to pressure compensator Pressure setting for feed reducers in A and B ports Anti cavitation valve in A Port Pressure setting for combined port relief and anti cavitation valve in B port Valve Spool Functions amp Spec s Boom Feature Main Relief at Inlet 3335 psi Valve Spool Functions amp Specs Band Spool Cyl Travel Port Work Port Pressure Color No Function Direction Relief Rating G W 1 Swing Forward B 3045 psi 2 0 G 1 Swing Back A 3045 psi 2 0 OR 2 Lift Down B 1160 psi 7 92 OR W 2 Lift Up A Plug 7 92 B W 3 Dipper Out B Plug 3 17 B 3 Dipper In A 1160 psi 3 17 Y W 4 Telescope Out B 2030 psi 3 17 Y 4 Telescope In A Plug 3 17 R W 5 Tilt Up A Plug 3 17 R 5 Tilt Down B 2030 psi 3 17 G 6 Swivel CW top A 2755 psi 6 60 G W 6 Swivel CCW top B 2755 psi 6 60 MAVERICK Service Manual 12 04 Section 2 13 2004 Alamo Group Inc N O 00 00 O CN O Z O O fed MO C O U O
178. t The restriction should be located at or upstream of the increased temp point Foreign objects sometimes cause restrictions in the system This can happen during servicing maintenance or repairs It is not uncommon to find bolts nuts plastic plugs paper or rags stuck into system when it was used as being repaired or assembled then forgotten about Restrictions sometimes can be a piece off of a failed component up stream a Component such as a Hose built wrong CAUSE Insufficient Flow From Charge Pump MACHETE SPECIFIC SOLUTION Measure Flow from charge Pump Install Flowmeter in series upstream of Charge Filter If Flow is significantly less than 6 GPM at rated RPM Replace the Pump Assembly and retest for proper Flow MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 24 POSSIBLE FAILURE CAUSE 8 SOLUTION Motor Shaft Seal Leaking CAUSE Excessive Back Pressure on return side of Motor Constant or Intermittent SOLUTION Check for restrictions on the return side of Motor See Overheating in General Check all return Plumbing for kinked hoses or hoses that can Kink in various positions of the Cutting Head or Boom Look for plugged Lines or a Plugged Filter Check also for other Valves or add on components downstream of the motor that can stop or restrict the Flow of Oil Do not just replace the Seal without curing the problem if you do it will likely happen again CAUSE Incorrect Oil Used SOLUTION U
179. the Charge Pump Adapter Check to insure that seat is smooth and free of Burrs or other defects or damage Inspect the Charge Pump Relief Valve Spring Make sure it is not bent or broken Inspect the Bearing or Bushing inside the Charge Pump Adapter The Bearing Needles must remain in the bearing Cage at dimensions shown in Figure 36 The Bushing if used must have no excessive scoring Flange Numbered End of Bearing 095 2 41 mm FIGURE 30 CHARGE PUMP ADAPTER RE ASSEMBLY 1 tem Qty Description 1 2 NO GR GO New Bearing or Bushing in Adapter Assembly If necessary Press New Bearing or Bushing into Adapter Assembly The Bearing must be installed to dimensions as listed in Figure 30 The Numbered end MUST be installed Outward toward Flange as Shown in Figure 30 The Bushing if used must be pressed flush to 010 254 mm recessed Install Poppet Spring Shims and New O Ring on Plug Screw Plug into Adapter Assembly See Figure 37 Torque Plug to 27 to 30 ft Ibs 36 6 to 40 7 nm Gerotor Ring Pocket Chrage Pump Adapter Bearing Press Fit Bushing Press Fit 1 1 1 1 Plug Charge Pump 1 O Ring Suction Port a r Shims 1 Spring 1 Poppet FIGURE 31 MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 4 18 MOTOR CIRCUIT PUMP MANUAL SERVO CONTROLASY ANUAL SERVO CONTROL DIS ASSEMBLY 1 The following instructions apply to Manual Servo Control Dis Assembly
180. the settings are not correct the system will not function properly Check the emergency stop E Stop switch if it is in the off position the system will not operate and the system cannot be set properly Never short across any of these components as the type electronics used can be seriously damaged Always use a volt ohm meter to test any circuits MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 2 2 CONTROL VALVE LOAD SENSING GENERAL INFORMATION Load Sensing Valve Load Sensing Principles The Load sensing Closed Centered principle is just that a hydraulic relationship between components that sense the power required to overcome or sustain a load It is commonly used with a variable displacement pump The load sensing feature will control the fluid delivery from the pump to the valve The goal ofthe system is to reduce wasted energy wear and tear from continuously pumping fluid under pressure when there is no demand on the system How It works A communication line between the pump and the valve transmits a pressure reading between the pump and cylinder control valve When the operator demands boom movement the corresponding valve spool is shifted there is then a fluctuation in pressure of that corresponding cylinder line If a pressure increase is seen lifting load in a cylinder work port at the valve that pressure increase flow demand is communicated to the pump If the pressure raises above the
181. tick Connection 9 Pin XS Module P N 02981538 inside a console D XS Module P1 Joystick Connection 6 Pin Connector EN Can 1 XS Module Connector CC1 Pos Key Switch Connection Can 2 XS rca Module Connector lt lt Ground X1 Control gs K3 Control Box Display Box Display Connection Connection G1 Connects to G2 Plug 7 of Exterior Wire Harness Code Connection Can 1 XS Module Can1 Connection 2 of 3 Connections Can 2 XS Module Can 2 Connection 3 of 3 Connections CCI Positive Key Switch Connection MUST Connect to key switch wire CC2 Negative Chasis Ground D XS Moudule C1 Connection 1 of 3 Connections G1 Exterior Harness G2 Plug coonnects Interior amp exterior Harness J1 Joystick Resister Harness 9 Pin Plug K3 Control Box Display Connection 1 of 2 Connections M1 E Stop Switch use A or B of Switch M2 E Stop Switch use A or B of Switch X1 Control Box Display Connection 2 of 2 Connections Above wire harness is the same as the one on the previous page except that itis overlayed over a tractor drawing to illustrate how the wiring is layed out when installed into the tractor MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 21 Control Box Wire Schematic Interior P N 02981376 RELAY DPDT 12VDZ MINIMUM 10 AMP o AN ae E Hi ABCDEF ABCDEF MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 3 22 CONTROL VALVE J
182. tive to contamination Seizure due to high operating temperatures Seizure due to contamination Valves have a tight clearance restrictors have small openings Leaking External Lines cause Cylinder Drift but this is the easiest problem to correct as it is the easiest type to find There fore most causes listed below will deal with Internal Leakage See Cylinder Drift Rate Chart in Specification Section of Product Repair Manual to determine if drift rate is excessive See Cylinders Leak Section for Cylinder leak Problems CAUSE Cylinder Pistons Seals Bypassing Dual Function Cylinders have 2 lines and have pressure both ends Single Function Cylinders have 1 line and pressure on one end and Vent Plug on other Piston bypass in Single Action Cylinders it will not require this test If they leak the Oil will leak out of Vent Plug SOLUTION Raise load and support it safely Drain Pressure off Line after Load is supported and before removing any lines Drain Pressure can be done with Tractor Off and open valve to lower Load Remove and solidly plug lines to the Cylinder Remove Load Support Hoist will be regiured Document the time it takes for the load to drift down See Cylinder Drift Chart If the Piston Seal is cause of excessive Drift down this will tell you Reseal or Repair Cylinders as required Note Piston Seal bypass can be caused by damaged Seals oversized or worn Cylinder Bores Some Cylinders don t function through out the intire length
183. tuck Using Press push Pin and Shaft Down It will come out through bottom of Housing 3 Remove Bearing Cones Upper Bearing Cone will have stayed in Housing reach in from to top to remove it Lower Bearing Cone should have come out and still be on Spindle For Cleaning and inspecting this Bearing Cone should be removed You may need a Bearing Puller to remove Lower Bearing Cone from Shaft 4 Remove Lower Seal from Housing Discard Old Seal Do Not re use it only install new Seals 5 Remove Bearing Cups Bearing Cups will need to be driven out of Housing with a driver or Pressed out But they do Need to come out straight DO NOT DRIVE them out from one side only keep equal force all the way around them when taking them out or Housing could be damaged 6 Cleaning Housing Clean the Housing completely No Oil or Grease leftin it Completely inspect all areas of Housing Bearing Cup Bore Seal Bore Flanges Inner and Out surface of Housing for scratches cracks Burrs especially Seal Area for Burrs Always Dry Parts after Cleaning Make sure there is no Solvent residue on them that will pollute lubricant After Cleaning if Parts are not to be assembled right a way put a coat of Oil over ID of Housing and over Gasket area at the top to prevent rust Un painted Clean steel will rust very rapidly if left dry of Oil Keep it covered to keep dust and dirt from collecting on oiled surface Procedures Re Assemble Spindle Spindle Re Assembly See Fig
184. ued to the required specification This is very critical See the Bolt Torque Chart in the beginning of this manual 6 DO NOT remove any mount pins and or bolts unless the components are supported properly to prevent them from falling T The Turret Bearing Assembly has 3 grease fittings each 120 apart All three of these grease fittings must be greased because of the diameter of the bearing this to ensure an even distribution of grease though out the diameter of the bearing assembly 8 If the hoses for the swing cylinders are disconnected or replaced make certain that they are reconnected correctly as shown in this section Swing Cylinder Hose Routing If the hoses are not connected correctly the swing will not function correctly MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 7 2 UNDER MOUNT FRAME ASY Under Mount Frame Asy 24 8 30 ftare the same except for the LH weight 30 ft model only LH Counter Weight Turret Asy Machined Turret Boom Mount Pin Weight Attaching Pin Long Pin Boom Mount Attaching Pin Long Pin Turret Cylinder Link Center Section Frame Weldment Boom Mount Attaching Pin Medium Pin Boom Mount Machined Boom Mount Attaching Pin Short Pin Swing Cylinders Swing Cylinder Pivot Bushings Swing Cylinder Trunnion Mount Weldment Swing Cylinder Cover MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 7 3 24 FOOT BOOM HOSE 8 ROUTING Z
185. uld 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 Item Part No ty Description 2 Qty p 02972208 Solenoid Valve Asy E 1 02971425 1 Seal Kit f solenoid Valve 2 02975198 1 Coil 12V DC w Dual 8 32NF Studs 3 02975199 1 Cartridge Solenoid Valve 4 02975438 1 Adapter Hyd Straight 8MB 6FJX 5 02981890 1 Adapter Hyd Straight 5MB 6MJ 4 FIGURE 17 ELECTRIC SIGNALS Electrical Signals are sent to the Controllers etc through a Wiring Harness The Harness is supplied with a one way connectors at the Joystick So it can not be installed Wrong Connectors are supplied for each electric valve controller connection 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 Wireing schematic on the following pages S for Plug Connection Letter Code amp Terminal locations See Figure Schematic for actual Wire locations 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 MAVE
186. ure 88 Make sure Housing is Clean and in Good Shape 2 Install Bearing Cups Using a Driver or Press install Upper and Lower Bearing Cups Make sure they are seated completely into Housing 3 Install Lower Seal Inspect Lower Seal area one more time Make sure there are no burrs around surface Install lower Seal Using a Driver consult your local Tool supplier After installed coat ID of Seal with light coat of Grease h Contnued Next Page MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 6 3 SPINDLE REPAIR Upper Bearin TabWasher PP 9 Lower Bearing Upper Bearing Cup and Cone Adiusting Nut Oil Plug Grease Fitting 22 Z Lower Seal Spring PSE around ID of Seal Lip va Lower Bearing Uj NAN ZZ Lower Seal FIGURE 87 Procedures Re Assemble Spindle continued 4 Install Lower Bearing Cone Inspect Spindle Shaft Condition Lower Bearing Cone is installed on Spindle Shaft and pressed down till seated on bottom lip on Shaft Be careful pressing Bearing on do not damage Bearing Coat lower Bearing with light coat of Grease 5 Install Spindle Shaft Put light coat of Grease on Seal area of Shaft this will help Shaft go into Seal Insert Spindle Shaft with lower Bearing Cone installed on it into Spindle Housing from the Bottom Use Caution when lower part of Shaft reaches lower Seal work shaft into seal carefully 6 Install Upper Bearing Cone Support Spindle Shaft from Bottom and Pre
187. ut a few pounds of pressure 10 PSI or Less look for leakage in the Suction Lines Because the Oil Pick Up is lower than the Oil Level this will force Oil out the leak Leaks in Hoses and at Fittings can draw Air into System as Oil Flows Past Systems that have severe or prolonged Air Entry Problems may have Experienced Pump Damage Pump Not Pre Lubed before Starting Repair or Replace Pump Fill Pump with Oil during Assembly and or before Starting This can be done by pouring Oil into the Suction Hose and letting it run into Pump as you are connecting Suction Hose The Pump should have been Assembled using lubricant as it was assembled The Machete and Brahma this is not required as the Pump is lower than the tank This will make the suction line full of Oil to Pump Incorrect Oil Used Use recommended Hydraulic Oil DO NOT mix Oils that are not compatible in some cases it may be required to drain and replace all the oil See Specification Chart for recommended Oil Type When repairing unit it is recommended that Oil is updated to recommended Oil Water In Oil Moisture in Oil adversely affects the lubricating ability of the Oil The Source of the Moisture entry must be found and corrected The System cleaned and flushed All damaged components replaced DO NOT operate system with moisture in it because the moisture will turn to Steam when heated Steam will pit and damage components of Pump Valves and Motors As well as the Lubricating abilit
188. when Mower Switch is on This is a safety feature and is not to be bypassed When Mower Switch is Off the System is internally bypassed to allow the Tractor to Start Therefore if Switch is Off and Starter circuit is not complete through switch Check Wiring and Switch Repair or Replace as needed MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 34 POSSIBLE FAILURE CAUSE 8 SOLUTION Starter on Tractor Will Not Crank continued CAUSE Mower ON OFF Switch or Wiring Malfunction SOLUTION CAUTION MAKE SURE TRACTORISIN NEUTRAL WITH PARKING BRAKE SET MAKE SURE ENGINE IS DISABLED TO SO THAT IT WILL NOT SUDDENLY START SHOULD IT START CRANKING ALSO MAKE SURE EVERYONE AROUND YOU KNOWS THAT THE TRACTOR ENGINE MAY SUDDENLY START CRANKING THIS BECAUSE WHEN DEALING WITH A SHORTORLOOSE CONNECTION YOU MAY MOVEITAND MAKE IT START TO OPERATE Check for Voltage at Starter Solenoid when Starter Switch is engaged If Voltage is not present make Sure Mower Switch is Off and recheck for Voltage at Starter Solenoid If still no Voltage check through circuit till voltage is found checking must be done with Starter Switch engaged The faulty component is most likely immediately down stream of the point of voltage Repair or Replace as needed and retest system DO NOT BYPASS MOWER SWITCH SAFETY FEATURE Tractor Battery Dead or Low Note Most of the problems that will cause the Tractor Battery to fail drai
189. witch ON Engine OFF Joystick Function Actuated If No Voltage is present Check Harness If Harness is OK Repair or Replace Controller as needed See Page 56 and 57 MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 11 POSSIBLE FAILURE CAUSE 8 SOLUTION Cylinder Moves some Functions Work But Not All Continued CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Obvious Causes Check First Check These First You may have enough Oil to operate one function but not all because Some Cylinders will require more volume than others will Perform all Operational checks Tank Oil Level Pump Operation Control Valves Circuit Electrical Supply and Hydraulic Oil Supply All Circuits affected or only some Circuits If All Circuits will not work the Problem is most likely up stream of the control Valve or an electrical Problem Models with Joystick Controller The Following Causes are based on Only some circuits being affected Not all Circuits Faulty Solenoid Valve If Pilot Pressure Is present with engine running Voltage is delivered to the Coil and or Module the function operates manually but not Electrically it is likely that the valve is the Problem Repair or replace as needed Control Valve Bolted to Mount Plate Incorrectly Loosen Bolts and retighten 1 turn ata time using a criss cross pattern The Valve Body can be
190. y Devices securely on folding implements Slow down when turning and on hillsides Install Restrictor in folding circuit to slow down lowering and unfolding if action is faster than is desirable 6 Make certain that SMV sign Warning Lights and Reflectors are clearly visible Follow local traffic codes 7 Never operate with Flail Mower or Folding Section raised if passersby bystanders or traffic are in the area to reduce possibility of injury or death form objects thrown by Blades under Shields or implement structure 8 Before dismounting secure flail mower in transport position or lower to ground Put tractor in park or set brake disengage PTO stop engine remove key and wait until noise of rotation has ceased to prevent entanglement in rotating parts which may cause injury or death Never mount or dismount a moving vehicle Crushing from runover may cause injury or death 5 TRANSPORT SAFELY 6 USE SMV LIGHTS 8 7 DONOT OPERATE WITH 8 DO NOT MOUNT OR LOCK UP REFLECTORS MOWER OR WING RAISED DISMOUNT WHILE MOVING 002369 Read and understand the complete Warranty Statement found in this Manual Fill out the Warranty Registration Form in full and return it within 30 Days Make certain the Serial Number of the Machine is recorded on the Warranty Card and on the Warranty Form that you retain The use of will fit parts will void your warranty and can cause catastrophic failure with possible injury or death
191. y 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 Activate J s through Display 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 Tilt Function The Tilt Section incorporates a Lock Out Solenoid on the down function side that operates on 12 Volts See previous page Figure 3 for this Lock Out Solenoid Valve MAVERICK Service Manual 12 04 O 2004 Alamo Group Inc Section 3 23 CONTROLVALVE JOYSTICK JOYSTICK TROUBLE SHOOTING VALVE CONTROLS CONNECTION TROUBLE SHOOTING Continued 10 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 ifin a remote location and you do not have a Vo
192. y of the Section 8 30 POSSIBLE FAILURE CAUSE 8 SOLUTION Spindle Leaking at Motor CAUSE Filling Spindle with Hydraulic Oil Motor Seal Leaks SOLUTION Determine and correct cause of Motor Shaft Seal Leaking Re Seal Motor Clean Repack or rebuild Spindle as required Note Be sure to determine what caused Seal to Blow out and repair that problem before considering the repair to be done If you just put in New Motor Seal you have not cured the cause of the Problem See Motor Seal Leaking for possible cause of Seal problems CAUSE Motor Loose or Bolts Missing SOLUTION Tighten Motor to Spindle retaining bolts If they will nottighten check and repair threads Notice this problem will let Spindle Oil Leak but will not let Hydraulic Oil from Motor Leak CAUSE Gasket Torn or Damaged SOLUTION Remove Motor Check surface of Spindle Housing and surface of Motor Clean Surfaces of both Check for Burrs or deep Scratches Burrs can be removed by carefully filing surface If you file surface caution must be taken to keep filings out of Spindle If Scratches they can be filled with a sealer Make Sure Sealer is Oil compatible CAUSE Pressure in Spindle Housing Excess Backpressure SOLUTION Make sure Relief Plug installed or Relief Plug is not clogged Check Spindle Oil level so itis not overfull Notice this will be Spindle Oil leaking out not Hydraulic Oil Spindle Leaking around Bottom Seal CAUSE Seal Damaged Could
193. ymptom occurs when the moweris freewheeling or only whenthe Moweris cutting under aload lightorheavy grass If the Motor only slows when under a load see Motor Stop Section If Mower Loads and not under a Load see the following Section Motor runs to Slow MAVERICK Service Manual 12 04 2004 Alamo Group Inc Section 8 25 POSSIBLE FAILURE CAUSE 8 SOLUTION Motor Runs Too Slow continued CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Engine RPM Too Slow Run Tractor Engine at required Speed to achieve GPM through Pump See Specifica tion Section in Repair Manual Pump Drive Damaged Inspect Pump Drive components for wear or damage If Pump is not being driven properly repair or replaced parts as required Faulty Logic Valve in Motor Control Circuit If Equipped Remove and inspect Logic Cartridge for damaged seals or contamination Repair Reseal or Replace as needed Ifthe Seals on the Logic Valve repeatedly fail it will likely be required to replace the Valve Block due to damage or erosion in the Valve Bore Air in Oil Run the System for a few minutes Check for Air in the Oil in the Tank Air entrained Oil will have a foamy appearance If Air is present find the Air Leak and correct it Air Leak can be in the Suction Line and Oil may not leak out because there may only be Oil in that location when the Pump is suckin

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