Page 1 ™ BOOM ARM MOWER PRODUCT SERVICE MANUAL PUMP MOTOR BOOM Service Manual P/N 02969480 (Jun. 2009) Alamo Industrial 1502 E. Walnut Seguin, Texas 78155 830-372-1480 2009 Edition © 2004 Alamo Group Inc.
Page 3: Introduction
ABOUT THIS MANUAL: The intent of this publications to provide the competent technician with the information necessary to perform the CORRECT repairs to the Alamo Industrial Product. This will, in turn provide for complete customer satisfaction It is hoped that the information contained in this and other Manuals will provide enough detail to eliminate the need for contact of the Alamo Industrial Technical Service Dept.
Page 4 Motor - Pump Actions............ 89 - 90 - 91 Motor System Schematic..........92 Motor Shuttle Valve Location.......... 93 Motor Service & Repair..........94 Motor Component Torque Specification......111 Motor Dis-Assembly............101 - 102 - 103 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 5 Wiring Harness, Plug............. 25 Wiring Harness, Joystick..........22 - 23 - 24 Hydraulic Flow, load Sensing......... 31 - 32 - 33 - 34 Hydraulic Flow, Fixed Displacement......35 - 36 - 37 - 38 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 6 Valve Block Dis-Assembly......48 thru 51..98 thru 99 Valve Block Re-Assembly......52 thru 55..99 thru 100 Valve Block O-Ring/Back-Up Ring Replace. 76....110 Motor Plate Dis-Assembly......86....123 Motor Plate Re-Assembly......89 thru 95..127 thru128 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 7 Harness Schematic, Vlave End....9....25 Harness Valve Plug (Old Style)....5....22 Harness Valve Plug (Old & New Style)..35....84 Control Valve Wiring........1....16 Plug Pin Location........6....22 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 10: Boom Specifications
This filter should be changed on a regular maintenance schedule. Filter are rated by Micron size (10 Micron), Filter should be replaced with the same Micron and High Pressure rated Filter. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 11: Hydraulic Cylinder Specifications
80-120 (Head) 02975532 (Flail Axe) 02971423 Slide 400-500 50-60 (Tie Rod) 02973505 (Timber Cat) 02811000 Door 150-250 None (Lockwire) 02840600 (Ditcher) 02811000A Door 150-250 80-120 (Head) 02975528 (Ditcher) Continued Next Page Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 12: Alamo Group Inc
End of Cylinders. Ports Marked with letter "B" (Striped marking hose band) are for Functions Connect to Butt End of Cylinders. (See Decal # 02969106 Hydraulic Hose Hook-Up on Next Page). Continued Next Page Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 13: Alamo Group Inc
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. Continued Next Page Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 14 685 (929) 1000 BOLT 250 (339) 670 (908) 1030 (1396) 1200 1700 1-1/8 330 (447) 910 (1234) 1460 (1979) DESCRIP- 1600 2300 1-1/4 480 (651) 1250 (1695) 2060 (2793) TIONS 3000 2100 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 16 (Brown) Junction Box (Joystick) Solenoid Lock Valve Clamp Voltage Supply (Red) Pump Solenoid Connector 1 : Swing 2 : Lift FIGURE 1 3 : Dipper 4 : Tilt 5 : Door MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 17 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.
Page 18 CONECTIONS IN ACTUAL PLUG. DO NOT CHANGE LOCATIONS OF PINS AND/OR WIRES IN PLUGS, THEY MUST BE CONNECTEDTHE SAME WHEN REPLACED OR THE SYSTEM WILL MALFUNCTION AND THIS COULD ALSO DAMAGE JOYSTICK CONTROLLER COMPONENTS. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 19 Pistol Grip Handle Switch Push Front Lift Down Pull Back Lift Up Push Right Dipper Up Push Left Dipper Down Rotate Right = Swing Out FIGURE 4 Rotate Left Swing In MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 20 These wires (Brown Colored) connect the Starter relay Circuit of the Tractor to the Master “On” / “Off” Switch (Rocker Switch on later models) on the Joystick Console of the Machete. Caution: These 2 wires (Brown Colored) are to be spliced into Tractor Starter Relay Wire (approximately 3 “) behind Starter Switch (normally Key Switch).
Page 21 Valve, all 5 are on 1 side of Valve). Using Wrench as a Handle move Wrench to activate Valve section needed to move component you want to move, Then go on to the next Valve section and move it. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 22 Harness. In the illustrations notice some pins are connected together . Use Plug patterns in Wire Schematic to Connect plugs is OK. ACTUAL PIN PATTERN Wide Notch Narrow Narrow Notch Notch FIGURE 6 MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 23 Dbl Trigger Switch Danfoss Valve Command Circuit (Joystick) Wht/Blk Push/Pull Master Switch Org/Blk Brn/Blk Wide Notch Actual Pin Location IS SHOWN for Plug in this illustration, See Figure 6 Narrow Notch (2) MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 24 Danfoss Command Circuit (Joystick) Motor Relay Wht/Blk Wht/Red Motor Push / Pull Switch With Momentary Start Wide Notch Actual Pin Location IS SHOWN in this Illustration, See Figure 6 Narrow Notch (2) MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 25 FIGURE 9 Location in Plug Narrow Illustrated Notch (2) Start Solenoid Loop Wide Notch (1) Piston Pump Solenoid Grnd Soleniod Lock Valve Grnd Grnd Grnd Grnd Grnd DOOR DIPPER TILT LIFT SWING MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 26 CONTROL VALVE - HYDRAULIC CONTROL VALVES: (See Figure 10) The Alamo Machete Hydraulic Control Valve is an Electro-Hydraulic (Electric over Hydrau- lic) Valve. The Valve is designed to utilize Oil from the Tractors Hydraulic System. This is basically considered a Selector Valve. Since the Tractor System is the Source of Hydraulic Supply (Hydraulic Pressure).
Page 27 This completely or partially closes the connection to Tank; This allows Oil Pressure to flow to Cylinders when needed. The Pilot Reducing Valve maintains Standby (Pilot) Oil Pressure to the Proportional Control System (200 to 250 PSI) MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 28 When a Main Spool is activated, The Pump Regulator will adjust the displacement so that the set differential pressure between the Pressure Port “P” and the Load Sense Signal pressure is maintained. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 29 Load Sense Shuttle Valve, The Load Sense Shuttle Valve located in each Section insures that the Load Sense Signal from the Valve Section with the highest Pressure is sent through the Load sense Line. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 30 Segment Compenstaion Spool Orfice = Closed Center Pressure Port Plug = Open Center Mechanical Flow Limiters Pressure Bypass Adjustment Spool Main Spool Plug Manual Control Handle (illustration Only) Electric Controller Spool Position Signal MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 31 Return “T” Galley in the Control Valve. Since there is no Load Sense Signal being sent to the Pump, The Pump only delivers enough Oil to maintain Pilot Pressure. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 32 Valve is Shown In Neutral (Centered) Plug, Closed Center Position Pilot Pressure Oil Anti - Cavitation / Work Port Relief Valve Mechanical Flow Limiters Main Spool Segment Compensation Spool FIGURE 15 MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 33 Pilot Pressure Oil to the Main Spool is stopped. The Springs on the Main Spool returns the Spool to its Neutral (Centered) position. When the Spool is centered, The Load Sense Circuit is connected to the Tank (“T”) Galley. With no Load Sense Signal, Pump returns to minimum. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 34 Pilot Pressure Oil Anti - Cavitation / Work Port Relief Valve Mechanical Flow Limiters Main Spool Segment Compensation Spool FIGURE 16 This is internal passage in Valve, Shown on outside for illustration only MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 35 NOTE: The Load Sense Passage shown in figure 17 is an internal passage inside of Valve and cannot be seen if looking at Valve, It is shown here outside Valve as Illustration Only. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 36 Pump ("P") Load sense Signal Pessure Bypass Plug Adjustment Spool Pilot Pressure Oil Anti - Cavitation / Work Port Relief Valve Mechanical Flow Limiters Main Spool FIGURE 17 Segment Compensation Spool MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 37 With no Load Sense Signal present the Pressure Bypass Adjustment Spool allows most of the Oil in the Pressure (“P”) Port to return to the Tank (“T”). The Pilot Reducing Valve retains Pilot (Standby) Pressure in the Valve. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 38 Pilot Pressure Oil Anti - Cavitation / Work Port Relief Valve Mechanical Flow Limiters Main Spool Segment Compensation Spool FIGURE 18 Load Sense passage is internaly in Valve, Shown outside for Illustration MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 40 Orfice Plate # 7 Goes to Swing Port C1 Orfice Plate # 6 Goes to Tilt Plate Port C1 DETAIL A 6 or 7 To Valve Notch in Orfice Plate Must Face away from Valve as Shown MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 41 NOTE: To help ID Valve, The Wiring Harness on this valve has 10 Plugs, 5 on each side of the valve, The later version will only have 5 plugs and they are only on one side of the valve MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 42 See Detail A (.040) See Detail 5,6,11 A & B(.055) See Detail A (.063) Note orientation of notch in plate 6 or 9 11,12,13 or 14 5,9,13 To Valve DETAIL A DETAIL B MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 43 NOTE: To help ID Valve, The Wiring Harness on this valve has only 5 Plugs, 5 only on 1 side of the valve, The Earlier version will have 10 plugs, and they are 5 on each side of the valve. MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 44 *Note: Orientation of Notch in Plate must be 9,15 notch up as shown 5 or 8 4,12 10, 11, 12 or 18 To Vakve Orfice Plate Solinoid Lock Valve DETAIL A DETAIL B MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 45 02969399 1 Orifice, .040 02972178 1 Adp Hyd Elbow NOTE: To help ID Valve, Note the difference in detail B from earlier Valve, The location of components in detail B. Lock Valve MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 46 P/N 02968854 S/N MB24--01046 VERY IMPORTANT DO NOT Use Solenoids as Handles 4,6,7 See Detail A DETAIL A To Valve Notch in Orfice Plate Must Face away from Valve as Shown MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 47 Valve Asy. 5 Spool, OCFD 02761100 Adapter, Elbow, 90 Deg. 02822300 Adapter, Straight 02968533 Valve,Fixed Displ., 5 Spool 02968850 Adapter, Straight 63042700 Adapter, Straight 02969398 Orfice, .055 Dia. Hole 02969400 Adapter, Straight MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 48 SWING LIFT DIPPER TILT 4,8,9,12,13 See Detail 4,5,10 A & B(.055) See Detail A (.063) Note orientation of notch in plate 6 or 8 10,11,or 12 4,8,12 To Valve DETAIL A DETAIL B MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 49 02972208 1 Solenoid Lock Valve Asy 02974004 2 Electric Activation Module 02974005 3 Electric Activation Module 02974027 5 Seal Kit, O-Ring 02974838 5 Mech. Activation Module 02975598 1 Coil 02975599 1 Cartridge MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 50 0.063 Orfice* Valve *Note: Orientation of Notch in Plate must be 9,15 notch up as shown 5 or 8 4,12 10, 11, or 12 To Vakve Orfice Plate Solenoid Lock Valve MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 51 Orifice, .070 02969398 2 Orifice, .055 02972208 1 Solenoid Lock Valve Assy 02957416 2 Cap, Plastic Female 02963637 8 Cap, Plastic Outer 02975438 1 Adp Hyd Stght 02976531 1 Adp Hyd Elbow MACHETE (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 54 HYDRAULIC SYSTEM - POSITIONING - TEST PROCEDURES NOTE: The Machete is equipped with manual override controls for the Control Valve. In case of Emergency Electrical failure or for testing purposes, The positioning Hydraulics can be operated manually. Refer to Isolation Test 2 for instructions or review Control Valve Section.
Page 55 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. 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.
Page 56 If the Manual Override control moves properly when the Joystick is moved: The Joystick is working. Wiring Harness is OK. Solenoid valve(s) are working. Pilot Pressure Oil is Present. Valve Spools are moving. Cause is most likely in Valves, Hoses or Cylinders. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 57 If the circuit fails to work using the Manual Override Control, The Problem is in the Control Valve, Hoses or Cylinder. Use this test to determine which components to test and/or trouble shoot. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 58 Pressure Port Tank Port Inlet Section Swing 5 Spool Valve Lift (Handles Shown as Illistration Only) Dipper Tilt Door FIGURE 21 (Used 1998 & Up) Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 59 To ID Old Style Valve it will have 10 Plugs on Wiring Harness where it plugs on to Valve, The Newer Style Only has 5, For testing new Style see Previous Pages. DO NOT USE THESE to Test Newr Style Valves with5 Plug Harness. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 60 OK, If using a normal Test Light see Figure 23 both sides of connection will need to be tested; this may require an assistant (Connection for Testing Positive (+) Side Shown Below) Swing WIRING Lift HARNESS Dipper FIGURE 23 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 62 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) Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 63 Tee in Line to Check Inlet Vacuum Pressure Ports Tee in Line to Check System Pressure Auxillary Port Check Charge Pressure Drain Port Tee in Line to FIGURE 24 Check Case drain Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 64 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 39). Engine Power is converted to Hydraulic Power by the Variable Displacement Hydraulic Piston Pump.
Page 65 Piston Asy. Pump Control Solenoid Charge Spool Pump Suction Servo Pressure Case Drain Line Neutral Adjust Screw Charge Pump Servo Piston Relief Valve System Relief & Servo Control Supply Oil Check Valve Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 66 PUMP CIRCUIT - MOTOR DIS-ENGAGE Motor Circuit Disengage (w/ Engine Running) The Alamo Closed Loop Motor Circuit ic 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.
Page 67 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 spike pressure encountered during severe operation. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 68 2 wire Solenoid Block Asy. 28-3 28-3-1 38-1 28-4-3 28-6 28-4 28-4-1 28-4-2 28-5 40-1 39-1 Serial Code and 28-6 Product Number Location, Left Side 41-1 28-2 28-1 48-1 FIGURE 25 16-1 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 69 29-2 Roll Pin Note: If replaced with a new Pump it will be the Electric Solenoid Servo Control Type, Reference to Insert Sheet # 02970224 for Electric Servo Control Manifold Asy. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 70 29-1 Inner Gerotor and 11 tooth Coupler 22-1 VALVE PLATE IDENTIFICATION Note "V" Notch Location LH Rotation RH Rotation Valve Plate Valve Plate Item # 27 Irem # 27 FIGURE 26 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 71 Quad Ring .062" Dia. X .625" ID (1.59 mm Dia. X 15.9 mm ID) Washer Washer Washer 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 72 (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 required). Lift and remove the Housing and Shaft from Rotating Kit Assembly and Camplate. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 73 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 74 1/2" (12.7 mm) Left Side Right Side Install Servo Adjust to Center Front Flange - Drive Piston in This (Neutral) Piston Shaft End of Pump Direction FIGURE 29 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 75 Back Plate with the Steel side against Back Plate. 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 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 76 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.
Page 77 Assembly (See Figure 37). Torque Plug to 27 to 30 ft. lbs. (36.6 to 40.7 nm) Bearing Gerotor Ring Pocket Item Description Bushing Chrage Pump Adapter Bearing (Press Fit) Bushing (Press Fit) Charge Pump Plug Suction Port O-Ring Shims FIGURE 31 Spring Poppet Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 78 Plug, Tighten Plug till 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. lbs. (2 to 3 nm) Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 79 Solenoid. Also many of the earlier units were upgraded to this later Manifold by using up-grade Kit # 02970206 See Pump Conversion Kit Insert Sheet # 02970224 (See Figure 33 on next pages). Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 80 Listed above (Item 1) is a Conversion Kit to convert old style Manual Servo Control to New Style Solenoid Control Servo, Also listed is Pump Assembly Complete, To Convert over and use the Wire adapter will have to be used. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 81 Retaining Ring. Remove the Nut, Bolt and two washers. Install Pivot onto the three Pins, Spider on the Pivot and Piston Assemblies through the Spider and into Piston Block, resting on Spider. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 82 PUMP - ROTATING KIT ASY FIGURE 34 Rotating Kit Assembly Item Description Piston Assembly Spider Spider Pivot Retainer Piston Block Pins Wsher Spring Retaining Ring Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 84 2. The Pump Solenoid Connection changed from 3 Wire Connection to 2 Wire, (See Figure 35) Below for Plug Design at Pump Solenoid). The early Model Did Not use Plug. FIGURE 35 Later Model Pump Solenoid 3 Wire Plug Corrent Model Pump Solenoid 2 Wire Plug Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 85 MOTOR - ELECTRICAL CONTROL Early Model Machete Motor Circuit Wiring Schematic w/ 1 Push / Pull Switch & 1 Momenentary Push Button Switch S/N MB21-01001 to MB21-01107 S/N MB24-01001 to MB24-01045 Bat. Start Ign. Tractor Starter Bat. & Soleniod Start...
Page 86 MOTOR - ELECTRICAL CONTROL Later Model Machete Motor Circuit Wiring Schematic w/ 2 Push / Pull Switches Only S/N MB21-01108 to MB21-01481 S/N MB24-01046 to MB24-01052 Tractor Key Switch Mower Mater Push / Pull Push / Pull Bat. Switch Start...
Page 87 MOTOR - ELECTRICAL CONTROL Current Model Machete Motor Circuit Wiring Schematic w/ 1 Push / Pull Switch & 1 Lighted Rocker Switch S/N MB21-01482 & Up S/N MB24-01053 & Up Start Bat. Push / Pull / Momentary Control Switch Green...
Page 88 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 39). Engine Power is converted to Hydraulic Power by the Variable Displacement Hydraulic Piston Pump.
Page 89 Piston Asy. Pump Control Solenoid Charge Spool Pump Suction Servo Pressure Case Drain Line Neutral Adjust Screw Charge Pump Servo Piston Relief Valve System Relief & Servo Control Supply Oil Check Valve Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 90 MOTOR - PUMP DIS-ENGAGE Motor Circuit Disengage (w/ Engine Running) The Alamo Closed Loop Motor Circuit is 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.
Page 91 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 spike pressure encountered during severe operation. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 93 1 2 3 4 5 6 7 8 9 0 1 Case Pressure 1 2 3 4 5 6 7 8 9 0 1 1 2 3 4 5 6 7 8 9 0 1 Charge Pressure FIGURE 45 FIGURE 44 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 94 Cleanliness is extremely important when repairing ANY HYDRAULIC Components. The Work Area, Tools and anything that comes in contact with components. Always clean parts in clean Solvent and Blow Dry with filtered moisture free Air is best. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 95 MOTOR P/N 02967193 Parts Location & Assembly Instructions This Section is for Motor Asy P/N 02967193 Used on 60 inch Rotary Head Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 96 MOTOR P/N 02967193 - PARTS LOCATION End Cover with Integral Shuttle and Low Pressure Relief Valve (Used on Machete Motor) 13 14 45 44 38 39 FIGURE 46 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 97 Hex Head Bolt Var. - Shims Vary in Qty, Use as required, Item # Hex Head Bolt 28 & # 47 used one or the other not both. Square Cut seal Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 98 Square Cut Ring FIGURE 48 Motor w/ Integral Low Pressure Shims shuttle and Low Relief Valve Pressure Relief Valve (Built into Shuttle End Cover) Type Valve Gauge Port Plugs FIGURE 49 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 99 Install Shuttle valve Plugs and Shuttle Valve Springs. Torque to 68 ft. lbs. (92 nm) Figure 53 Shuttle Valve Plug Valve Shuttle Valve Block Valve Shuttle Block Valve Plug Shuttle Valve Springs FIGURE 52 FIGURE 53 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 100 FIGURE 55 FIGURE 54 Ring INTEGRAL SHUTTLE / LOW PRESSURE RELIEF VALVE (END COVER) RE-ASSEMBLY: (On Machete Motor) See Figure 56 Low Pressure Shims Relief Valve Install Low Pressure Relief Valve Make End Cover sure to install the same amount of...
Page 101 Carefully remove Gasket and two End Cover Dowel Pins, DON’T drop any parts (See Valve Plate Above Comment), Valve Plate, Bearing Cup or Shims which May or May Not stick to End Cover. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 102 Motor Shaft. You don’t want this O-Ring left un-accounted for as this could cause a problem during re-assembly later. Retaining Ring Staionary Seal Assembly Rotating Seal O-Ring Retaining Ring FIGURE 47 Pliers Puller Bolt (1/4-20) Seal Puller Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 103 You Must use Special Stop Limit Tool when installing new Bearing Cone on Output Shaft. Cap Screw Swash Plate / Output Shaft Assembly Washer Socket Bit Plug FIGURE 60 FIGURE 61 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 104 13. Dis-Assemble Cylinder Barrel Assembly; Place it on a clean protective surface for inspection and cleaning. Bolts Retaining Piston / Cylinder Swash Thrust Strap Slipper Asy Barrel Asy Plate Plate Spacers FIGURE 64 FIGURE 63 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 105 Before assembling Motor any further, You MUST check Fixed Clearance of Unit as shown in Figure 66, Do this by measuring Height of Retaining Strap Spacer with a Micrometer or Vernier Calipers. Spacers are critical to the unit design and may not be adjusted. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 106 Carefully reposition Cylinder Barrel Assembly and Swash Plate so that Cylinder Barrel Face is on Clean Flat Surface. Lubricate and install Output Shaft Sub-Assembly (Figure 62) in Barrel Sub-Assembly (Figure 68). Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 107 Tighten the two Cap Screws in increments alternating from one to the other till they are torqued to 20 to 24 ft. lbs. (27 to 33 nm). After Assembly keep this Component covered to keep Dust or other Contaminates out. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 108 Valve Plate facing End Cover. This will retain plate during Assembly. Install Valve Plate over Bearing Cup, Aligning it with Dowel pins, Valve Parts must rest flat and be flush with End Cover. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 109 15. Lubricate O-Ring Seal of Stationary Seal assembly (Figure 74). Then install Stationary Seal Assembly . 16. Use a No. 5 or No. 7 retaining Ring Pliers to install Retaining Ring, Be Sure to install Retaining Ring with Beveled Side Out. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 110 Install Valve Block on End Cover, install four Hex Hex Bolts, and Torque them 28 ft. lbs. (38 nm) There is a Valve Block Seal Kit # 02972094 that will included these O-Rings and Back-Up Rings in it, These need to be replaced any time the Motor is removed. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 111 (Used On) Material C.R.S. Harden to Rc 50 - 55 Model (C.I.D) Dim. A Dim. B Dim. C Dim. D 3.3, 3.9, 4.6 1.01 1.25 5.4, 6.4 1.30 1.48 FIGURE 77 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 112 5.00/6.00 Dia. Model Dim. A Dim. B Dim.C Dim.D C.I.D. + or - .001 3.3, 3.9, 4.6 5.803 1.00/1.20 2.20/2.30 3.00 Min. FIGURE 78 5.4, 6.4 6.682 1.30/1.32 2.25/2.35 3.00 Min. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 113 F Dia. C Dia. .135 .141 G Dia. .129 .135 13 deg. 20 deg. Section A - A 1.907 2.223 1.913 2.229 2.020 2.318 2.026 2.324 2.622 2.747 FIGURE 79 2.628 2.753 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 115 MOTOR P/N 02979881 Parts Location & Service Instructions This Section is for Motor Asy P/N 02979881 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 116 Return VIEW "A" 11,13 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 117 Shim 0.5 02980558 Shim 0.2 (*) These parts are included in 02980559 Shim 0.4 Rebuild Kit 02980560 Shim 0.6 02980561 Shim 0.8 02980562 Shim 1.0 02980563 Shim 0.7 02980564 Bolt, Socket Head Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 118 Maximum Case Pressure......10 bar (at 1500 rpm) 145 psi (at 1500 rpm) Fluid Contamination Level......18/13 (ISO Code 4406) or 18/13 (ISO Code 4406) Motor Shipping Weight........ 26 kg 57 lbs. Specifications Subject To Change Without Notification Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 119 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 P/N 02979881 Figure 1 Motor Assembly Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 120 (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 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 121 Snap Ring pliers to remove the snap ring that retains the seal carrier (item 9). Note: Smooth Shaft shown, actual shaft is splined in this motor. Figure 6 Splined Shaft Figure 8 Figure 7 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 122 (See Figure 12). Make certain to keep all Spacers in the same order they came off. Figure 10 Splined Splined Shaft Shaft 11, 13, 22 Figure 11 Figure 12 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 123 The lower bearing cup is tapped from the top and the upper Bearing cup will be tapped from the bottom side of the housing. Figure 14 Figure 16 Figure 15 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 125 Start with the same quantity that was removed and check. Adjust quantity as required to Figure 20 achieve proper bearing load. (See Figure 21) Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 126 Figure 22 Reinstall it into the vise with the gear end up. (See Figure 28) Splined Shaft Figure 23 Figure 24 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 127 (See Figure 31), These shims are various Shaft thickness and the quantity required will vary, start with the same amount and thickness that was removed. 9 & 10 Figure 26 Splined Shaft Figure 27 Figure 28 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 128 (item 6). Install the four bolts (item 25), and Torque these four bolts using an alternat- Figure 30 ing pattern to 75 ft. lbs. +/- 7 ft lbs (See Figure 36) Figure 32 Figure 31 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 129 O-Ring Seal under seal carrier, it should be Figure 34 replaced when seal carrier is removed and reinstalled. Reverse procedure to reinstall seal carrier. (See Figure 38 & 39) Figure 35 Figure 36 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 130 Seal Carrier Diminsions Remove Old Seal From "A" 2.91" + 0 / -.04 Seal Carrier carefully as "B" 2.75" shown "C" 2.441" + .008 / - 0 Figure 40 Figure 39 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 132 Put Support Stand under Boom for safety support before beginning any removal of parts. Keep This Safety Stand under Boom at all times. Approximate Lift Point FIGURE 80 Support Here With Safety Stand Machete (Service Manual) 01/03 © 2003 Alamo Group Inc.
Page 133 Mounting Pivot Pin Hole Lift Cylinder Main Frame Lower Mounting Bushings Hole King Pin Retraining Bolt & Nut Turning Arm Snap Ring & Groove in Bottom Boss FIGURE 81 King Pin Machete (Service Manual) 01/03 © 2003 Alamo Group Inc.
Page 134 20. Kingpin Bushing Removal, The Old Bushing will need to be driven out, this must be done with a suitable Bushing Driver (Alamo Industrial Bushing Driver # 02972281) shown in Figure 82. Care must be taken when doing this to avoid damage to the Bushings and Bosses that Bushings are in.
Page 135 Mounting Pivot Pin Hole Lift Cylinder Main Frame Lower Mounting Bushings Hole King Pin Retraining Bolt & Nut Turning Arm Snap Ring & Groove in Bottom Boss FIGURE 84 King Pin Machete (Service Manual) 01/03 © 2003 Alamo Group Inc.
Page 137 Spindle Repair Section (Rotary Head Only)
Page 138 Blade Bolt Nut, Washer Middle Blade Bar & Roll Pin Bottom Blade Bar (Torque 400 ft. lbs.) Blade Bar Retaining Blade Bolts and Washers (Torque 400 ft.lbs.) FIGURE 85 Blade Bolt Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 139 Vlave Bolck Bolts (Under Plate on Later Models) Moter Hold Down Plate Motor Hold Down Tie Rod Nut Hose Motor Hold Down Connection Tie Rods Motor Motor Retaining Bolt Hose Connection Deck FIGURE 86 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 140 Upper Bearing Cup and Cone Adjusting Nut Oil Plug / Grease Fitting Lower Bearing Cup and Cone Spindle Shaft Lower Seal (Spring around ID of Seal Lip) Lower Seal FIGURE 87 Spindle Shaft Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 141 Upper Bearing Cup and Cone Adjusting Nut Oil / Plug Grease Fitting Lower Bearing Cup and Cone Spindle Shaft Lower Seal (Spring around ID of Seal Lip) Lower Seal FIGURE 88 Spindle Shaft Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 142 9. 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 143 SPINDLE - MOTOR PLATE Hardened 2" Flatwasher 60" MACHETE HEAD MOTOR PLATE 1 2 3 1 2 3 1 2 3 ATTACHMENT 1 2 3 1 2 3 Jam Nuts 1 2 3 1 2 3 1 2 3 1 2 3...
Page 144 FIGURE 93 Place Loctite on Threads Top Lock Nut & Hardened Place & Torque to 100 ft. lbs. Flatwasher Locktite on Threads & Lock Jam Nuts To- gether FIGURE 95 FIGURE 94 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 145 Always repaint any area that has been re-welded to prevent rust as well as cosmetic appearances. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 146 Spindle Leaking At Relief Vent............... Spindle Overheating................Spindle Shaft Loose or Falls Out............Spindle Locks Up (Siezes and Won't Turn)........... Starter On Tractor Won't Crank............. 161-162 Tractor Battery Dead or Low (Continous Power Draining)....Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 147 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 148 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...
Page 149 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 150 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 Torque Values. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 151 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 152 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 153 Perform Hydraulic ? Electrical isolation Test. If Tractor System is at Fault, Trouble Shoot and Repair Tractor per Tractor Manufactures Guidelines. CAUSE: No or Low Pilot Pressure? SOLUTION: Check Pilot Pressure. Test, Adjust or Replace Pilot Pressure Valve as required Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 154 Check Output voltage at the harness end connector for the affected Function, (Switch 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) Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 155 If the 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 156 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). Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 157 Restrictions sometimes can be a piece off of a failed component up stream or a Component such as a Hose built wrong. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 158 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.
Page 159 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 160 If a 540 RPM mower was connected to a 1000 RPM Tractor the Blade Tip Speed would be way to high and this would create severe amount of Sand and Dust under deck. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 161 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 162 Pumps, Motors, Hoses and Valves. They are expected and allowed for in the design of the System. Alamo Industrial’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.
Page 163 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 164 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 165 See Specification Chart for recommended Oil Type. When repairing unit it is recommended that Oil be update to recommended Oil. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 166 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 167 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.
Page 168 Mower is cutting under a load (light or heavy 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 169 SOLUTION: Remove Valve and inspect Seals, replace if damaged. 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.
Page 170 The Most common cause of Pre-Mature Failure is Cavitation, Oil Contamination, Oil Aeration and/or Defects in Pump and/or Motor. NOTES: Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 171 The Most common cause of Pre-Mature Failure is Cavitation, Oil Contamination, Oil Aeration and/or Defects in Pump and/or Motor. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 172 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 173 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...
Page 174 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). Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 175 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 176 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 177 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 178 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. Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.
Page 180 Machete Boom Service Manual Archive 2009 Edition P/N 02969480 Machete (Service Manual) 04/04 © 2004 Alamo Group Inc.

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Page 3: Introduction

Page 10: Boom Specifications

Page 11: Hydraulic Cylinder Specifications

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