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Machete Boom Mower

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1. MOTOR P N 02979881 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 See Figure 32 Set this assembly aside for now a MZ RA S cut ua ym 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 Torque these four bolts using an alternat ing pattern to 75 ft lbs 7 ft lbs See Figure 36 Figure 31 Figure 32 Machete Service Manual 04 04 2004 Alamo Group Inc 128 MOTOR P N 02979881 ASSEMBLY Motor Assembly Co
2. 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 a approximatly 6 seconds and is controlled by the size of the Orfice between the Control valve amp Pump Case Oil under charge pressure is available at the Check Seats of the combination System Relief amp 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 frpm Oil in Port D Oil is forced to go throu
3. 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 T 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 ring that retains the seal carrier item 9 Note Smooth Shaft shown actual shaft is splined in this motor Figure 7 Machete Service Manual 04 04 2004 Alamo Group Inc Figure 121 MOTOR P N 02979881 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 Ring item 8 under seal carrier that you can reach 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
4. 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 If old bushing had any kind of adhesive applied when it was installed it will have to possibly be peeled out and hole cleaned up before new bushing can be installed Cylinder Pin amp Boom Bushing Removal The Old Bushing will need to be driven out this must be done with a suitable Bushing Driver Alamo Industrial Bushing Driver 02972282 shown in Figure 82 Care must be taken when doing this to avoid damage to the Bushings and Bosses that Bushings are in 43 p P N P N 02972281 02972282 Turning Arm Bushing Driver Cylinder and Boom Bushing Driver FIGURE 82 22 Kingpin Bushing Replacement The New Bushing will need to be driven in 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 The Bushings should be installed so that the Top Bushing is Flush with the Bottom of the Frame Bore and The Bottom Bushing is Flush with the Top of the frame Bore as Shown in Figure 83 Note some people use an adhesive Locktite on exterior of Bushing this will not harm anything bu
5. 2004 Alamo Group Inc 40 May 1995 to Dec 1997 Item Part No 02968851 02761100 02822300 02960018 02967201 02968850 02969398 02969399 02969400 63042700 OONOARWDN Qty NWAN AATNN VALVE ASSEMBLY Load Sense to P N 02968851 h S N MB21 01001 S N MB24 01001 S N MB21 01109 S N MB24 01046 Description Valve Asy 5 Spool Load Sense Adapter Elbow 90 Deg Adapter Straight Adaptor Elbow 90 Deg Valve Load sense 5 Spool Adapter Straight Orfice for C2 Port 055 Dia Hole Orfice for C1 Port 040 Dia Hole Adapter Straight Adapter Straight 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 P41 i n VALVE ASSEMBLY S N MB21 01110 S N MB24 01047 Sep 2000 Load Sense SATB eri P N 029721 75 S N MB24 01246 5 6 12 See Detail A 070 56 13 See Detail A 055 See Detail A 040 5 9 10 13 15 See Detail 56 11 A amp B 055 See Detail A 063 Note orientation of notch in plate 6 or9 acm 11 12 13 or 14 To Valve DETAIL A DETAIL B MACHETE Service Manual 04 04 2004 Alamo Group Inc 42 Jan 1998 to Sep 2000 item o 00 UOUN gt VALVE ASSEMBLY S N MB21 01110 S N MB24 01047 Load Sense to P N 02972175 Part No 0297217
6. Aa ix System Relief amp Check Valve FIGURE 41 PUMP Machete Service Manual 04 04 2004 Alamo Group Inc 90 MOTOR 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 their Bores as they follow the Camplate This results in Oil being drawn into the Piston Bore as the Piston is pulled outward The 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 approximately 6 seconds and is controlled by the size of the Orifice between the Control valve amp Pump Case Oil under charge pressure is available at the Check Seats of the combination System Relief amp 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 High
7. HY MACHETE em ALAMO BOOM ARM MOWER PRODUCT SERVICE MANUAL Service Manual P N 02969480 Apr 2004 Alamo Industrial 1502 E Walnut doa Seguin Texas 78155 830 372 1480 2004 Edition 2004 Alamo Group Inc MEMBER OF THE 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 Itis hoped that the information contained in this and other Manuals will provide enough detail to eliminate the need for contact of the Alamo Industrial Technical Service Dept However it should be understood that many instances may arrive wherein correspondence with the Manufacturer is necessary CONTACTING MANUFACTURER Please help us Help You Before You Call Alamo Industrial Service Staff Members are dedicated to helping you solve yours or your customer s service problem as quickly and efficiently as possible Unfortunately we receive entirely to many calls with only a minimum amount of information In some cases the correspondent has never gone out to look at the equipment and merely calls inquiring of the problems described to him by the operator or customer Most calls received by Alamo Industrial Service can be classified into approx 6 general categories Hydraulic or Mechanical Trouble Shooting
8. 04 04 2004 Alamo Group Inc 4 INDEX REPAIRS MOTORP N 02967193 60 HEAD MOTOR Motor End Cover Dis Assembly Motor Parts Location Motor Re Assembly Motor Tool Descriptions Motor Valve Block Dis Assembly Motor Valve Block Re Assembly MOTOR P N 02979881 50 HEAD MOTOR Motor Parts Location Motor Dis Assembly Motor Re Assembly Shaft Seal Replacement SPINDLE Blade Bar Removal Blade Bar Installation Motor Plate Removal Motor Plate Installation Motor Removal From Spindle Motor Installation on Spindle Spindle Removal From Deck Spindle Installation on Deck Spindle Dis Assembly Spindle Re Assembly Spindle Cleaning amp Inspection TROUBLE SHOOTING Problem Cause And Solution Valve Testing Procedures Joystick Control Trouble Shooting Joystick Plug Joystick Wirineg Harness Valve Components Valve Operation Valve Parts Valve Trouble Shooting Wiring Harness General View Wiring Harness Plug Wiring Harness Joystick Hydraulic Flow load Sensing Hydraulic Flow Fixed Displacement Machete Service Manual 04 04 2004 Alamo Group Inc 5 Page 95 thru 114 105 thru 110 111 thru 113 115 thru 130 116 117 118 119 120 122 123 124 thru 129 138 thru 144 See Below 145 thru 178 54 thru 60 15 thru 60 19 20 21 22 23 24 19 22 23 24 25 26 27 28 29 30 40 thru 45 amp 46 thru 52 53 thru 60 DRAWING INDEX THIS INDEX INDICATES FIGURE
9. 06 R Max Break Corner Dim Dim A Stamped Model No Used On Material C R S Harden to Rc 50 55 Model C I D Dim A Dim B 3 3 3 9 4 6 4 0 1 5 5 4 6 4 4 0 1 5 FIGURE 77 Machete Service Manual 04 04 2004 Alamo Group Inc 111 MOTOR P N 02967193 TOOL DESC TOOL Shaft Rotating Seal Puller Available from Owatonna Tool Co No l Qj j CAS 1844 BTR 49 21 Typ 4 Typ Material SAE 1074 Spring Steel 16 Ga X 75 Wide Remove Head amp Grind to Point 5 to 6 Long a IJA 001 Tool Limit E 2 Stop for d E Bearing Cone Installation Tool Headless E j Cap Screw Material Steel al S Built Special 5 16 18 UNC Cap screw 2 Req 1 50 1 70 i 5 UR 00 D a C 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 112 MOTOR P N 02967193 TOOL DESC LOW CLEARANCE BEARING PULLER 3 8 16 UNC 28 Thread 40 Dia 2 Places as Shown 2 Places 760 NOTE Grind Bore to Size After Splitting and Heat treatment Model Number Etched on This Face in 1 letters c 1 913 2 229 2 026 2 324 2 628 2 103 Machete Service Manual 04 04 2004 Alamo Group Inc 113 NOTES Machete Service Manual 04 04 2004 Alamo Group Inc
10. 114 MOTOR P N 02979881 Parts Location amp Service Instructions This Section is for Motor Asy P N 02979881 Machete Service Manual 04 04 2004 Alamo Group Inc 115 MOTOR P N 02979881 PARTS LOCATION A Port Pressure View A 29 A Port Relief 30 B Port Relief B Por 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 Machete Service Manual 04 04 2004 Alamo Group Inc 116 MOTOR P N 02979881 PARTS LOCATION Item Part No 02979881 02980529 02980530 02980536 02980537 02980538 02980539 02980540 02980541 02980542 02980543 02980544 02980545 02980546 02980548 02980549 02980550 02980551 02980552 02980553 02980554 02980555 02980556 02980557 02980558 02980559 02980560 02980561 02980562 02980563 02980564 N a anana nananana na nanana nananana MN 50 Rotary Head Description 50 Motor Asy Barrel Housing Asy Vlalve Plate Nozzle Plug Asy Hexagon Bearing Housing O Ring 7 O Ring 7 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
11. Accidents Operator Change Have all the obvious items been checked Oil Levels Tractor amp Unit Reservoirs Electrical Supply Dead Battery Loose connections etc Does the malfunction affect all circuits one two or more Does malfunction affect both sides of the same function or just one Example Lift amp Lower in or out etc Does malfunction happen when Cold or Hot only Cold or only Hot more when Cold than Hot more when Hot than Cold etc What Conditions What is Unit doing when malfunction occurs running at low RPM High RPM heavy Cutting light Cutting Level Ground Slope Angle etc 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 Replace any missing broken components tighten any loose components repair any Oil Leaks before beginning any further test Machete Service Manual 04 04 2004 Alamo Group Inc 54 TROUBLE SHOOTING TESTING OPERATIONAL TEST Visual
12. Adaptor Elbow 90 Adp Hyd Straight Orifice 063 Orifice 070 Orifice 055 Solenoid Lock Valve Assy Cap Plastic Female Cap Plastic Outer Adp Hyd Stght Adp Hyd Elbow Pol Control Valve Trouble Shooting Section Machete Service Manual 04 04 2004 Alamo Group Inc 53 TROUBLE SHOOTING BEGIN MACHETE CONTROL VALVE 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 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 What is Model Unit Size Type Head Type Tractor it is mounted on etc What is not working correctly In as much detail as possible Has this malfunction existed for some time just start suddenly continuos malfunction or off and on when does malfunctions occur 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
13. Air entrained Oil will have a foamy appearance If Airis present find the Air Leak and correctit 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 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 Engine RPM Too Slow Run Tractor Engine at required Speed to achieve GPM through Pump See Speci fication Section in Repair Manual Excessive Ground Speed For Mowing Conditions Operational Problem 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 distributed across width of Deck These conditions can force t
14. Ask if the Symptom has existed for the life of the machine has been gradually getting worse orifit 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 Machete Service Manual 04 04 2004 Alamo Group Inc 162 POSSIBLE FAILURE CAUSE amp SOLUTION Hydraulic System Overheating continued CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Restrictions Just as indicated an unintentional obstruction 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
15. DRAWING LOCATION PROCEDURE BLADE BAR Removal Rotary Head JOYSTICK KING PIN Boom Mount King Pin Removal King Pin Bushing Driver Bushing Removal amp Replacement King Pin Replacement Circuit Electric Schematic New Style Circuit Pump Engage 65 67 89 91 Circuit Pump Engage End Cover Dis Assembly 56 thru 58 100 101 End Cover Re Assembly 70 thru 73 108 109 Input Seal amp Bearing Removal 102 103 Main Housing Re Assembly Motor Components Torque Specifications Motor Repair Tools Descriptions 111 thru 113 Output Shaft Assembly Removal Rotating Group Dis Assembly Rotating Group Re Assembly Parts Location Shuttle Valve Dis Assembly Shuttle Valve Re Assembly System Hydraulic Schematic Valve Block Dis Assembly Valve Block Re Assembly 52 thru 55 Valve Block O Ring Back Up Ring Replace 76 Motor Plate Dis Assembly Motor Plate Re Assembly Machete Service Manual 04 04 2004 Alamo Group Inc 6 DRAWING INDEX PROCEDURE Circuit Motor Engaged 65 67 89 91 Circuit Motor Disengaged 66 and 90 Charge Pump Adapter Assembly Dis Assembly 72 thru 73 Re Assembly Parts Location 68 thru 70 Port Locations Rotating Kit Parts Location Pump Motor Port Connections SERVO CNTRL Control System Control Assembly Manual Type Old Style 32 Control Assembly Manifold Type New Style Control Electric Control SPINDLE Blade Bar Removal Rotary Head Blade Bar Replace Rotary Head M
16. 0625 Dia X 3 25 ID 1 59 mm Dia X 82 55 mm ID O Ring Molded Nut Used 1997 amp Down Bolt 3 8 16 X 1 25 4 mm Long Lockwasher Washer Plug O Ring 087 Dia X 644 ID 2 21 mm Dia X 16 36 mm ID Plug O Ring 087 Dia X 644 ID 2 21 mm Dia X 16 36 mm ID Plug O Ring 116 Dia X 924 ID 2 95 mm Dia X 23 47 mm ID Plug O Ring 116 Dia X 924 ID 2 95 mm Dia X 23 47 mm ID Key Cover Plate Shaft Seal Charge Pump Adapter Asy Control Arm Used 1997 amp Down Manual Servo Control Asy used 1997 amp down Solenoid Servo Control Manifold Asy Used 1998 amp Up Not Shown Inner Ring Gerotor Outer Ring Gerotor Supply Orfice Control Valve Orfice Control Arm Orfice Dump Valve Actuator of Plug Retaining Ring 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 71 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 TI
17. 4 1600 133 24 1 1 2 2000 167 32 2 2800 233 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 contaminants to enter system through fittings when installing them 10 Special Torque Specifications Rotary Heads Motor to Spindle Housing 100 ft Ibs Spindle to Deck 425 ft Ibs Spindle to Adjusting Nut Bearing Preload 25 in Ibs Rolling Torque Blade Bar Leaf Bolts Old Style 7 8 Bolts 600 ft Ibs New Style 1 1 4 Bolts 2000 ft Ibs Blade Bar to Spindle Bolts 400 ft Ibs Blade Bolts 400 ft Ibs Motor Plate 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 whatis bolted down and the type material Metal that is being bolted together Thread condition and lubrication will vary Torque settings Inche Sizes Metric Sizes ALWAYS CHECK MARKINGS Not Used 10 14 Not Used 20 27 Not Used 35 47 55 75 85 115 120 163 75 102 130 176 175 230 105 142 170 230 240 325 185 251 300 407 425 576 160 217 445 603 685 929 250 339 670 908 1030 1396 330 447 910 1234 1460 1979 480 651 1250 1695 2060 2793 SN Machete Service Manual 04 04 2004 Alamo Group Inc 14 VALVE SE
18. 4 0 2300 psi 10 Seconds B Dipper In 5 5 1000 psi 10 Seconds A Tilt Up 4 0 System 0 050 6 0 Seconds B Tilt Down 4 0 System Lock Valve 8 0 Seconds A Door Open 2 5 System 5 0 Seconds B Door Close 2 5 System 6 0 Seconds ant BRWWNDND Valve Spool Functions amp Specs In the Chart Cycle Times listed above are close approximations of actual times based on machine testing Times indicate 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 be close to above but can vary some from unit to unit Times listed are a guide to show approx what Cycle times for tour Unit should be 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 Continued Next Page Machete Service Manual 04 04 2004 Alamo Group Inc 13 SPECIFICATIONS MACHETE 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 Ibs 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 15 16 1 1200 100 20 1 1
19. 6 Narrow Notch 2 MACHETE Service Manual 04 04 2004 Alamo Group Inc 23 CONTROL VALVE JOYSTICK PLUG Joystick New Style w Push Pull Motor Switch amp Rocker Master Switch Dbl Trigger Switches Danfoss Command Circuit Joystick B fi Positive i Z Output H regie Negatve D FI Wht BIk LEE m B 8 o i g p o E O Actual Pin Location IS SHOWN in this Illustration See Figure 6 Narrow Notch 2 MACHETE Service Manual 04 04 2004 Alamo Group Inc ab ma eme H m FIGURE 8 Motor Push Pull Switch With Momentary Start 24 CONTROL VALVE WIRE HARNESS PLUG Actual Pin Wire Harness Plug New Style FIGURE 9 Location in Plug Narrow Illustrated Notch 2 Start Solenoid Loop Piston Pump Solenoid MACHETE Service Manual 04 04 2004 Alamo Group Inc 25 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 The Hydraulic Control Valve must be compatible with the type Tractor System being utilized There are two types of Tractor Hydraulic System available to be used Note in some cases even these two type systems can vary from Tr
20. C28 PISTON MOTOR Drain Charge Port A From Shuttle Pump Valve to Tank Suction The Motor Circuit is engaged by two Manually Operated Switches See Figures 36 37 amp 38 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 is for a Solenoid to actuate a Pump Control which actuates a Valve to turn on 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 Oilis Pumped and the more oil pumped means faster the motor turns Machete Service Manual 04 04 2004 Alamo Group Inc 88 MOTOR PUMP ACTIONS Note The Servo Control System Changed see Note on Previous Page Pump Output is started by movement of the Variable Displacement Pump Control Lever Figure 40 As the Lever is rotated it moves the Spring centered Servo Control Spool first Movement of the Spool allows Charge Pump Oil past the Spool to one side of the Servo Piston Figure 40 The Pressurized Servo Piston pushed against the Camplate figure 40 causing the Camplate to rotate to a Pre Set Angle Oil from the opposite end of the Servo Piston is exhausted to the Pump Housin
21. Control Arm onto Control Assembly input Arm Retain with Lock Washer and Nut Torque from 4 to 6 ft Ibs 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 Machete Service Manual 04 04 2004 Alamo Group Inc 76 PUMP CHARGE PUMP ADAPTER ASY CHARGE PUMP ADAPTER DIS ASSEMBLY 1 The following instructions apply to Charge Pump Adapter Dis Assembl See Figure 30 amp 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 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 th
22. For Cleaning and inspecting this Bearing Cone should be removed You may need a Bearing Puller to remove Lower Bearing Cone from Shaft Remove Lower Seal from Housing Discard Old Seal Do Not re use it only install new Seals 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 Cleaning Housing Clean the Housing completely No Oil or Grease left in 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 Upper Bearing Tab Washer Adjusting Nut Oil Grease Relief Plug Sec Upper Bearing Cup and Cone Oil Plug Grease Fitting Lower Bearing Adjusting Nut Lower Bearing J Cup and Cone Spindle Shaft Lower Seal Spring around ID of Seal Lip Lower Seal FIGURE 87 Machete Service Manual 04
23. Group Inc 93 MOTOR SERVICE REPAIR Motor Dis Assembly or Assembly Comments The purpose of this Section is to provide Service information and procedures for Dis Assembly and Re Assembly of the Hydrostatic Fixed Displacement Motors Motors with Valve Blocks Motors with integral Shuttle and Low Pressure Relief Valves are covered The Procedures in this Manual will allow better Service of Motors This Manual will show some Components Dis Assembled that are not available as replacement parts Some Sub Assemblies that are to be Dis Assembled for cleaning or inspection only There are Special Tools that may be required SEE BACK PAGES for Tool Drawings Tools Required Recommended Tools for Service Repair Work on Motor Stationary Seal Puller 1 4 X 20 UNC Cap Screw 3 to 4 Long Rotating Seal Puller Special Tool Retaining Ring Pliers No 5 and No 7 Ratchet Wrench or Breaker Bar Drive Size Optional Wrench Box End Open End Combination 1 3 8 Wrench Box End Open End Combination 1 Socket Drive Size Optional Torque Wrench 200 ft Ib Capacity Drive Size Optional Hex Bit Socket 1 4 Hex Key 1 4 Tube Locktite No 271 Pliers Punch Magnetic Base Indicator Dial Hammer Bearing Press or Driver Light Petroleum Jelly Like Vaseline Cleaning Solvent CLEAN UN USED NON CONTAMINATED Non Petroleum Base Two Headless Cap Screws 5 16 X 5 to 6 Long Special Micrometer or
24. Models will Electronic Controllers 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 aboom mower on ofthe boom functions may slowly begin to move The resolution ofthis 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 equipped 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 SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Hoses Routed incorrectly On New or Repaired Units Route hoses per Hose Diagram in Parts Manual Incorrect Valve Operation Plate On New or Repaired Units Replace with correct Plate Wire Harness improperly connected On New or Repaired Units with Joystick 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 Confusion On Direction Travel of Joystick or Switch Application The Function of Joystick is specific to type or combinations of movement that is made to perform that function If the system was
25. Motor Shuttle Valve Figure 44 amp 45 The Shuttle Valve is located in the Motor Housing The purpose of the Shuttle valve is to direct a controlled amount of Oil out of the Hydrostatic Loop and back to the Tank for Cooling The Spool item 3 is centered in its bore by springs on each end While the Pump Shaft is turning and the Camplate is in the neutral Position Figure 44 Both ends of the Shuttle Spool are exposed to a charge pressure When the Camplate Angle is changed The Pressured side if the Spool sees an increased pressure while the opposite end is still seeing the charge pressure return side of circuit Figure 45 This causes the Spool to shift in its bore opening a passage for Oil in the return side of the Loop to go to the Tank through the Case Drain Line The Volume of Oil flowing through the Case drain Line should not exceed the Charge Pump Volume unless excessive internal leakage exists in the Motor The low Pressure relief is designed to prevent the Motor seal from blowing out if excessive pressure should enter case The Case Drain serves to lubricate the Motor approx 3 GPM goes through to Lube motor The volume through case drain should not exceed 8 GPM if it does check the motor for wear or a malfunction Owo Case Pressure System Pressure LOM Charge Pressure NEN Case Pressure E Charge Pressure MEN FIGURE 44 FIGURE 45 Machete Service Manual 04 04 2004 Alamo
26. 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 With Tractor Engine running operate each Circuit Paying close attention to every thing the unit does or does not do The Engine speed should drop the Sound Change when the Valve spool moves and the Pump comes under a load If the Engine sound does not change when the Circuit is activated on a Load Sense System it is an indication that there is a possible malfunction in the Load Sense Circuit 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 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 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 ti
27. 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 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 symptom occurs when the mower is freewheeling or only when the 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 168 POSSIBLE FAILURE CAUSE amp SOLUTION Motor Runs Too SIOW continued CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION C
28. and will be atleast 200 to 250 PSI in order to maintain Pilot Pressure Oil passes through the Pilot Reducing Cartridge andis blocked at each Proportional Control Valve The Pilot Reducing Valve maintains 200 to 250 PSI in the Pilot Circuit The Main Relief is located in the Inlet Section End Cap of the Valve and limits the Pressure in the P Port to a maximum 2700 PSI The Load Sense Circuit is connected to the Return T Circuit when all Spools are in the Neutral centered Position With the Flow Control spools in their Neutral centered position Oil Flows to and from the Cylinder is blocked by the Spool The centering of the Spool connects the Load Sense circuit to the Return T Galley in the Control Valve Since there is no Load Sense Signal being sent to the Pump The Pump only delivers enough Oil to maintain Pilot Pressure MACHETE Service Manual 04 04 2004 Alamo Group Inc 31 CONTROL VALVE LOAD SENSING Pressure Relief Pilot Reducing Valve Return to Tank T Load Sense Signal N N Ny S N Pressure Bypass Bu NN cuc S o ml N Adjustment Spool Valve is Shown In Neutral Centered Position Anti Cavitation Work Port Relief Valve Mechanical e RR SN RD SRE eI YY NN eae SO SI NS y NS E i o 281 OW We M CE JE NN p m Main Spool FIGURE 15 Segment Compensation Spool MACHETE Service Manual 04 04 2004 Alamo Group Inc 32 CONTROL VALVE LOAD SEN
29. 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 Voltage 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 Machete Service Manual 04 04 2004 Alamo Group Inc 153 POSSIBLE FAILURE CAUSE amp 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 L
30. 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 tfallout 1 amp 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 3 note 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 will leave 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 Machete Service Manual 04 04 2004 Alamo Group Inc 120 MOTOR P N 02979881 DISASSEMBLY Motor Disassembly Continued 4 Lift Out Barrel Support Lift the barrel supportout item 16 make certain thatall the parts in barrel support are accounted for See Figure 5
31. 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 Machete Service Manual 04 04 2004 Alamo Group Inc 78 PUMP MANUAL SERVO CONTROL ASY USED 1997 amp Down Metering 4 Notches Wide Band Neutral Spool ID Mark FIGURE 32 Pin is Press Fit NOTE SOLENOID SERVO CONTROL MANIFOLD ASSEMBLY Used 1998 amp Up See Figure 39 The Manual Servo Control Assembly Shown in Figure 32 was used through 1997 at which time it was replaced by a Solenoid Servo Manifold There are not really any repairs to be done to this later version other than replacing the complete manifold assembly or the 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 79 PUMP SERVO CONTROL MANIFOLD ASY USED 1998 amp Up Solenoid Servo Manifold Asy Bolts Here FIGURE 33 Solenoid Servo Control Manifold Assembly Item Part No Qty Description 02970206 Solenoid Servo Control Manifold Kit w items 2 through 7 02970207 Solenoid Manifold Assembly w Solenoid 02970209 Gasket 02970208 Bolt 02970205 Wire Harness Adapter 3 wire to 2 only used if converting old style Manual Servo to Solenoid Type
32. is shown ER for Illustration C RET Only T FIGURE 2 Electric Controller Spool P sitioning Valves Spool Position Transducer MACHETE Service Manual 04 04 2004 Alamo Group Inc 17 CONTROL VALVE OPERATION HYDRAULIC LOCK VALVE Head Tilt Function An Electric Solenoid Operated Hydraulic Lock Valve Figure 3 is incorporated in the Head Tilt Function to prevent excessive Head Lift Cylinder leak down during storage or transportation The Solenoid which operates this valve is normally in the Locked position until Head Lowering function is actuated at Joystick When Joystick is actuated to lower Head an electric signal is sent to solenoid to open Lock valve When the function to raise the Head is activated there is no electric signal from Joystick The pressure against the valve when head is being raised will force Valve open like a relief Valve allowing Oil to pass through it If this valve will not open it could stop head from lifting or dropping The valve is plumbed into the Hydraulic Circuitry of the Head Tilt Function and is located near the Control Valve Hydraulic Lock Valve FIGURE 3 ELECTRIC SIGNALS Electrical Signals are sent to the Controllers etc through a Wiring Harness The Harness is supplied with a one way connector at the Joystick Console Box So it can not be installed Wrong Connectors are supplied for each electric valve controller connection These are labeled with Letter code A B C
33. 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 Machete Service Manual 04 04 2004 Alamo Group Inc 174 POSSIBLE FAILURE CAUSE amp SOLUTION Spindle Leaking at Relief Plug CAUSE Relief Fitting Installed in Wrong Hole SOLUTION 1 First Determine whatis leaking Spindle Oil or Hydraulic Oil If itis 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 of the Housing above Oil Level for the Relief Fitting to be installed a 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
34. 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 39 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 its 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 Wires 2 Wire Control Relief Valve Line To Filter FIG U RE 39 Manifold Return From Filter Servo Port C Servo Piston SERVO CONTROLLED C 2S PISTON MOTOR Drain Charge Port A From Shuttle Pump 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 Th
35. method in next step Note be sure to move any swapped connection back to their original location when diagnosing a problem 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 amp Etc Manually Follow the following steps A Use extreme caution while performing this operation Know where every one around you are at all the time DO NOT do this if you are not experienced with the functions of unit Go back and learn Functions Shut Tractor Engine Off Turn Off Master Switch on Joystick Console This will turn off all electric function including Front Hydraulic Motor Make sure no one is near Tractor Boom or Head Locate Control Valve It will be mounted on Side Rail of earlier models or in Front at Front Pump on later models Remove all covers required to gain access to Valve Restart Tractor Engine DO NOT Turn on Joystick Console Master Switch Go to Valve and look for a Hex Bolt Head sticking out of each valve section on the opposite side of valve from the electrical connection at Valve Older Models this was a 1 2 Wrench size old style Apitech Valve with 10 Plugs at Valve 5 plugs on each side of Valve and on the later models itis a 9 mm Wrench size later Valve has 5 Plug at Valve all 5 are on 1
36. 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 152 POSSIBLE FAILURE CAUSE amp 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 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
37. readings The Tilt and Door Functions are On or Off when checking keep track of which connection is being check as it will make a difference in reading on voltmeter All Connections are marked on plug where they plug onto Valve See Figure 5 Make sure Tractor Engine is off and cannot be started while you are working on it Relieve Any Hydraulic Pressure Make sure any Hydraulic Pressure in any Lines or Cylinders has been relieved and Mower Boom are resting on the Ground completely This should be done by working the Manual Overrides on Valve to be sure pressures are relieved Turn on Ignition Switch of Tractor to the On position But DO NOT Start Engine Switch on the Master Rocker Switch Push Pull on older models to the On position Remove the Din connector from the control Valve Section being tested to check voltage 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 Voltage fromthe No 1 Slot Positive 12 Volt DC Voltage will depend on Battery condition it cannot exceed the amount of the voltage in the battery and should not be less than Battery Voltage when Joystick Switch is activated So always Know what voltage is in Battery See Figure 5 MACHETE Service Manual 04 04 2004 Alamo Group Inc 20 CONTROL VA
38. shown in Figure 13 amp 14 are not on Valves They are shown as Illustration Only On Actual Valve Section there will be a Hex Head sticking out here 1 2 Wrench for older Valves 10 Plug Harness and a 9 mm Wrench for later Valves 5 Plug Harness The Later Style Valve 5 Plug Shown in Figure 13 Segment Compensating Spool Anti Cavitation Check Work Port Relief Valve Manual Over Ride Control Mechanical Flow Limiters Main Flow Control Spool B Shuttle valve Anti Cavitation Manual Control Handle Illustration Only tothe Proportional Control System MS Pilot Pressure ML SS SW ISS Main Spool iye IF WW p 77 li Shuttle KANN D yy SS tm CS Mechanical Pressure Port Flow Limiters Segment Compensation loads C tion Port Spool oad Sense Connection Ports FIGURE 13 SEGMENT COPENSATING SPOOL Pressurized Oil must pass by the segment Pressure Compensating Spool before it is used by the Cylinders The Compensating Spool uses Load Sense and Spring Pressure to maintain constant pressure drop across the Main spool Both when the Load changes and when a Segment with a higher load pressure is activated Anti Cavitation Check Work Port Relief Valves Work Port Relief Valves are installed in the Swing Lift and Dipper Circuits to limit the max pressure in those particular circuits to a lower pressure than the Main System Relief The Anti Cavitation Check Valve allows Oil to be taken from the return Ta
39. 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 21 CONTROL VALVE JOYSTICK PLUG Numbered Slots on DIN Plugs at Valve 5 Only On Units with 5 Plug Harness Late Positive 12 Volts DC Positive Should be 1 2 of voltage of 1 This Slot is not used in this application Negative Common Ground long Slot FIGURE 5 PIN PATTERN OF HARNESS PLUG amp PLUG AT JOYSTICK CONSOLE Below Figure 6 is ths actual Pattern of Pins in Plug at Joystick Console and the Pattern for plug on Wiring Harness In Wire schematic drawing this Pattern is the same for Illustration of Wire Routing Some Wires cross each other in illustration but actualy run along side each other in actual Harness In the illustrations notice some pins are connected together Use Plug patterns in Wire Schematic to Connect plugs is OK ACTUAL PIN PATTERN FIGURE 6 MACHETE Service Manual 04 04 2004 Alamo Group Inc 22 CONTROL VALVE JOYSTICK PLUG Joystick Console Plug Old Style w 2 Push Pull Switches FIGURE 7 Dbl Trigger Switch lt Wht Violet Danfoss Command Circuit Joystick II Push Pull Motor Switch o 7 o oO Push Pull Master Switch Wht Red Actual Pin Location IS SHOWN for Plug in this illustration See Figure
40. the P Pressure Porton the Inlet Section End Cap If there are no other Hydraulic functions being used all of the flow from the Fixed Displacement Pump must go through the Control Valve The Flow of Oil is blocked by the Flow Control Spools in each Valve Section The Main Relief Valve The Proportional Control System valves The Load Sense Passage Plug and the Bypass Adjustment Valve The first Circuit to be charged is the Pilot Circuit Oil passes through the Pilot Reducing Cartridge which limits the Pressure in the Circuit to approximately 200 PSI After the Pilot Circuit is charged Additional Oil being pumped into the Valve increases the pressure in the pressure P Circuit When in Neutral The Pressure in the pressure P Circuit is limited to approximately 215 PSI by the Pressure Bypass Adjustment Valve Spring When the Pressure in the P circuit is enough to overcome the force of the Bypass Spring the Bypass Spool is shifted in its bore Opening a passage between the Pump Oil P Circuit and the Return T Circuit The Bypass Spool maintains enough pressure Pilot Pressure in the System to actuate the Flow Control Spools and returns any surplus Oil to Tank When the Flow Control Spools are centered Neutral the Load Sense Passage works in conjunction with the Bypass Spring to limit the Main System Pressure in Circuit P Since there is no pressure in the Load Sense Passage in Neutral Centered the force of
41. the threads on top of the 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 176 POSSIBLE FAILURE CAUSE amp 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 New Bolts to Long SOLUTION Check that Blade Bar Retaining Bolts are not too 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 Seal Protector Damaged Component Bent The Seal Protector there has been two types
42. the 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 SOLUTION 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 Oil 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 p
43. 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 CAUSE Restrictions in System SOLUTION 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 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 is 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 da
44. up through from Bottom If it does not make sure Turning Arm is supported so as not to be in bind When Pin is installed on the bottom of the Kingpin there is a threaded hole which allows you to screw a long bolt into it to aid in moving pin Insert the Retaining Bolt into Hole See Figure 84 This Bolt will hold Pin in Next Install the Snap Ring into lower Frame Bore up under Kingpin This Snap Ring Holds Kingpin In the event the retaining Bolt Should Break Replace Boom Move Boom back into position with Hoist Bushings should have already been Replaced If not see Steps 21 and 23 Lower Boom down over to Turning Arm aligning Holes in Boom with Hole in top of Turning Arm Align using Hoist Pin should slide through without a great amount of effort Install Retaining Nut and Lock on Pin Replace Swing Cylinder Pin in Rod End and Tube End of Hydraulic Cylinder Install retaining Bolts Reconnect Lift Cylinder Lower Pin if it was removed and Top Pin Rod End Also reconnect any Hoses that were removed If Oil loss refill with Oil Run and Test for operation Note if hoses were disconnected and there was Oil loss Unit may have Air in it and may have to be worked out this can normally be done by cycling Cylinders in and Out Thrust Washer Swing Cylinder Swing Cylinder 2 Rod End Pin Qi Swing Cylinder Tube End Pin Mounting Pivot Pin Hole Lift Cylinder Lower Mounting Main Frame Bushings King Pin Retraining Bolt amp Nut Ho
45. with Grease Older Models had Oil in them These older models can be filled with Grease Fill with Grease till 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 Install Motor Plate Old Style Note This Plate has a front and Back and MUST be installed correctly for the four bolts that go down through the Plate to hold the Valve Block to fit See Figure 91 on next page or read step 3 above If working on an older model where the Four Bolts for the Valve Block went through the Motor Plate see Figure 86 remove the temporary Bolts you installed to hold Valve Block on Install New O Rings and Back up Rings on Valve Block Install Motor Plate down over Tie Rods Install the four Bolts into Motor Plate that goes through Valve Block and tighten them down DO NOT tighten the Nuts on the Tie Rods yet Note to convert old style Motor Plate to new style use a 13 16 Drill Bit and drill out Recess the 4 holes to a depth of 5 8 minimum this will allow plate to sit down over Bolt Heads for Valve Body on top of Motor Install Motor Plate New Style Note This Plate has a front and Back and MUST be installed correctly for the four bolts that go down through Valve Block to fit into the four recessed holes on the under side of Plate See Figure 91 on next page or read step 3 above If working on new Style the
46. 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 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 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 it appear there is no Pressure or val
47. with possibly a suction gun Spi nd le Over Heati ng E 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 SOLUTION 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 Machete Service Manual 04 04 2004 Alamo Group Inc 175 POSSIBLE FAILURE CAUSE amp SOLUTION Spindle Shaft
48. 02970201 1 Decal Instructions Not Shown 02970224 1 Insert Sheet for Conversion Not Shown 02969527 1 Pump Assembly w Item 1 New Pump 02969527RB ref Pump Assembly w Item 1 Re Built Pump NOTE 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 80 PUMP ROTATING KIT ASY ROTATING KIT DIS ASSEMBLY See Figure 34 1 The following instructions apply to Rotating Kit Assembly Dis Assembl Dis Assembly of Rotating Assembly is required for inspection Only There are no repairable Parts that can be replaced See Figure 34 Clean Make Sure that every thing Tools Work Bench Vise and all general conditions are very clean before beginning any work Inspection Examine the outside diameter ofthe Pistons forfinish condition They should not show wear or deep scratches Inspect the shoes for a snug fit on the ball end of the Pistons and aflat smooth surface that comes in contact with the Camplate DO NOTLAP the Piston Shoes Do Not Lap means do not sand file or try to smooth machined surface Piston Shoes If Piston Shoes are rough DO NOT LAP them Spider Examine Spider for wear in the Pivot area Examine Pivot to insure smoothness and no signs of wear Piston Block Inspectthe Piston Block surface th
49. 04 2004 Alamo Group Inc 140 SPINDLE REPAIR Procedures Re Assemble Spindle Spindle Re Assembly See Figure 88 Make sure Housing is Clean and in Good Shape Install Bearing Cups Using a Driver or Press install Upper and Lower Bearing Cups Make sure they are seated completely into Housing 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 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 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 Install Upper Bearing Cone Support Spindle Shaft from Bottom and Press 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 it is seated into Bearing Cup Remember to keep Spindle Shaft supported at bottom Install lower Bearing Adjusting Nu
50. 04 Alamo Group Inc 46 May 1995 to Dec 1997 Item NOOR WD VALVE ASSEMBLY smwe2t0100 S N MB24 01001 Fixed Displ to S N MB21 01109 P N 02968854 S N MB24 01046 Part No 02968854 02761100 02822300 02968533 02968850 63042700 02969398 02969400 MACHETE Service Manual 04 04 2004 Alamo Group Inc Qty MN CO N ND Description Valve Asy 5 Spool OCFD Adapter Elbow 90 Deg Adapter Straight Valve Fixed Displ 5 Spool Adapter Straight Adapter Straight Orfice 055 Dia Hole Adapter Straight P47 S N MB21 01110 Jan 1998 VALVE ASSEMBLY Swezt orrt0 to to PRISE Fixed Displ S N MB21 01571 P N 02972176 15 14 S N MB24 01246 2 3 4 8 9 12 13 See Detail 4 5 10 A amp B 055 See Detail A 063 Note orientation of notch in plate 60r8 10 11 or 12 To Valve DETAIL A DETAIL B MACHETE Service Manual 04 04 2004 Alamo Group Inc 48 Jan 1998 to Sep 2000 item OONOARWDNDN VALVE ASSEMBLY S N MB21 01110 S N MB24 01047 Fixed Displ to P N 02972176 Part No 02972176 02971379 63042700 02761100 02972113 02968850 02972177 02972179 02972180 001654 02972209 02972210 02969398 02972208 02974004 02974005 02974027 02974838 02975598 02975599 MACHETE Service Manual 04 04 2004 Alamo Group Inc S N MB21 01571 S N MB24 01246 Qty Description OAwWnNnNHANH HK HNANWNN gt Val
51. 146 Hydraulic System Overheating 146 147 148 Motor Flange Breaking 148 Motor Inoperative Won t Run 149 Motor Overheating 149 150 151 Motor Shaft Seal Leaking 152 Motor Runs Too Slow or Slows Down Under Load 152 153 154 Motor Stops Stops UnderLoad 155 156 Pump Seizure Pump Locks Up 156 Pump Wear Rapid Excessive Wear 157 Spindle Leaking At Motor 158 Spindle Leaking Around Bottom Seal 158 Spindle Leaking At Relief Vent 159 Spindle Overheating 159 Spindle Shaft Loose or Falls Out 160 Spindle Locks Up Siezes and Won t Turn 161 Starter On Tractor Won t Crank 161 162 Tractor Battery Dead or Low Continous Power Draining 162 Machete Service Manual 04 04 2004 Alamo Group Inc 146 POSSIBLE FAILURE CAUSE amp SOLUTION Boom Breaks Back Too Easily Boom is designed to break back if tomuch resistance is meet for safety reason CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Work Port Relief for Swing Cylinder Malfunction Test for 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 adjust the 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 adjust
52. 5 02971378 63042700 02761100 02972178 02972113 02968850 02972177 02972179 02972180 001654 02972209 02972210 02969398 02969399 02972208 02974004 02974005 02974027 02974838 02975598 02975599 S N MB21 01571 S N MB24 01246 Qty Description UUQN A B2 NoaoBlBl moBoonm mN a Valve Asy 5 Spool Valve 5 Spool CCLS Adaptor Straight Adaptor Elbow 90 Adapter Elbow 90 Adaptor Straight Adapter Straight Adapter Straight Adaptor Straight Adaptor Straight Adaptor Elbow 90 Deg Orifice 063 Orifice 070 Orifice 055 Orifice 040 Solenoid Lock Valve Asy Electric Activation Module Electric Activation Module Seal Kit O Ring Mech Activation Module Coil Cartridge 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 P43 Oct 2000 VALVE ASSEMBLY S N MB21 01572 to Current Load Sense S N m P N 02976688 S NMB24 Current 4 5 11 15 4 5 12 15 0 070 Orfice 0 055 Orfice 6 15 3 E 1 m U a LE P a DESEE 4 5 15 18 T 0 040 Orfice 6 15 4 5 8 12 13 15 16 Ro La 7 0 055 Orfice amp 0 063 Orfice Lock Valve Note Orientation of Notch in Plate must be notch up as shown N 5or8 D 10 11 12 or 18 To Vakve Orfice Plate Solinoid Lock Valve DETAIL A DETAIL B MACHETE Ser
53. AUSE 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 If the 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 Airis 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 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 Kink
54. 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 pupose system Relief and Check Valves Figure 41 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 Motor wanting to run Port D System Relief amp Port C Neutral Check Val To Motor Son Valve From Motor Centering Camplate Gerotor Solenoid i 4 Charge Servo J j Control n E LEA GJ Sina gt p Lj NNSS A b Ks x ES c SS Servo Piston aan System Relief amp Check Valve FIGURE 41 PUMP Servo Control Supply Oil Machete Service Manual 04 04 2004 Alamo Group Inc 66
55. CTION MACHETE Service Manual 04 04 2004 Alamo Group Inc 15 CONTROL VALVE WIRING Used 1998 amp Up Pressure Port Tank Port Inlet Section 5 Spool Val a 3 Handles ad a tee as Illistration Only H SaL Dipper Starter Solenoid Brown Junction Box Joystick Solenoid Lock S Valve X Voltage Supply Lift LB oar FIGURE 1 Tilt Door MACHETE Service Manual 04 04 2004 Alamo Group Inc 16 CONTROL VALVE OPERATION HYDRAULIC FUNCTIONS The Hydraulic Functions of the Machete Boom Mower are controlled by a Pilot operated Electrically Actuated Control Valve GENERAL OPERATION This Section addresses the method of operation of the electrical part of controls The function of the Hydraulic Valve itself will be covered in another Section Three Functions The Lift The Dipper and the Swing are Proportional meaning that the Speed of operation can be slowed down or Sped up according to the position of the Joystick Control The Door and Tilt Functions are On or Off only Meaning that their speed of operation is dependent upon the volume of Oil Flowing through the Circuit and cannot be controlled by the Joystick position In Our application the Oil Volume varies with the Tractor Engine Speed SPECIFIC OPERATION Figure 2 The Electrical Power to operate the Circuits is obtained from a Switched and Fused Tractor Voltage Source This means that the Electrical Power Wire to the Joystick Controller
56. 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 cuase cavitation This must be found and corrected before repairing old Pump ot 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 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 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 i
57. 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 sensitive 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 itis 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 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
58. 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 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 154 POSSIBLE FAILURE CAUSE amp 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 A
59. E CAUSE amp 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 Damage 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 Amajor problem for cylinders is storage when unitis not being used fora 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 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 Cy
60. GHTEN IN VISE with the 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 Lift the 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 Remove the Inner Gerotor Ring and Key from the Drive Shaft or Inner Gerotor Ring and Coupler Assembly from Shaft Lift Back Plate straight up off Shaft and Housing Remove Valve Plate from Back Plate or from rotating Kit Assembly Still in Housing 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 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 Remove Housing Gasket from Housing of Back Plate With Pump Still in Vise remove the six Bolts retaining the Manual Servo Control Asse
61. LVE JOYSTICK JOYSTICK TROUBLE SHOOTING VALVE CONTROLS CONNECTION TROUBLE SHOOTING Continued 10 Voltage from the NO 2 Slot Positive 12 Volt DC Voltage should be 1 2 of what reading at Slot No 1 is With Voltmeter connected to the No 2 Slot of Plug and the Joystick in Neutral Centered position begins moving Joystick and watch Voltmeter be sure you are moving Joystick to Match functions being checked The Voltage should rise as Proportional to the movement of Joystick Proportional Sections Only and on or off on sections without proportional functions See Figure 5 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 Emergency Field Test Can be performed without a Voltage Meter But it is always best to use a Voltmeter for electrical testing NEVER use an extra 12 Volt hot wire to supply current to connections for testing Valve or Joystick connections or components as it would damage components Emergency Field Test if in a remote location and you do not have a Volt Meter You can test the Joystick and Harness by temporally relocating swapping the plugs on the Valve to make another action performs a different function This will tell if the problem is in Joystick or connections Also in an emergency situation this method could be performed to get unit in transport position or use
62. Loose or Falls Out Note When Spindles are properly assembled and lubricated The Shaft should not loosen up inservice 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 replacement 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
63. ON 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 Machete Service Manual 04 04 2004 Alamo Group Inc 178 INDUSTRIAL Machete Boom Service Manual Archive 2004 Edition P N 02969480 Machete Service Manual 04 04 2004 Alamo Group Inc
64. OTING TESTING The Slots are numbered Positive 12 Volts DC Positive Should be 1 2 Voltage of Slot No 1 to Ground 6 Volts if 12 Volts etc because current is being reduced This Slot is not used at all Grd Negative Common Ground A Harness long Slot Not Marked Plug THE ABOVE INFORMATION IS FOR TESTING THE NEW STYLE VALVE ONLY USE A VOLT METER TO TEST THE NEW STYLE CAN BE ID BY THE 5 PLUGSON ONE SIDE WHERE HARNESS CONNECTS TO VALVE THE OLD STYLE HAD 10 PLUGS 5 ON EACH SIDE gt MAKE SURE IF OLD STYLE OR NEW STYLE VALVE IS USED BEFORE TESTING THIS IS IMPORTANT THE INFORMATION ON THE NEXT PAGE IS FOR TESTING OLD STYLE VALVE ONLY To ID Old Style Valve it will have 10 Plugs on Wiring Harness where it plugs on to Valve The Newer Style Only has 5 For testing new Style see Previous Pages DO NOT USE THESE to Test Newr Style Valves with5 Plug Harness Machete Service Manual 04 04 2004 Alamo Group Inc 59 TROUBLE SHOOTING TESTING JOYSTICK WIRING HARNESS TEST See Figure 22 amp 23 Old Style Valve testing 1 Perform this Test when Isolation Test 1 Isolation Test 2 and Solenoid Valve Test have been Completed and indicates that the cause of an inoperative or intermittent complaint is located in the Joystick or Harness A Handy TIP to make a tester is shown in Figure 19 To make this tool use a discarded Plug or purchase one Locally and wire a 12 vol
65. 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 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 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
66. 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 Typeis 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 notto 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 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 Tractorto 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 177 POSSIBLE FAILURE CAU
67. P Pressure Relief J Pilot Reducing Valve Tank Port T S M CEN d Shuttle Valve Circuit Pressure Bypass Adjustment Spool FIGURE 11 When the Tractor is Started and the Main Spool in the 5 Sections ofthe Control Valve are in The Neutral Centered Position Oil Flows from the Pump Through connection P across the pressure bypass adjustment spool to the Tank The Oil Flow which is led across the Pressure Bypass Adjustment Spool determines the Pump Pressure Pump Pressure atthe Neutral Position will be equal to Standby Pressure When one or more ofthe Main Spools are activated the Load Pressure is fed through the Shuttle or Load Sense Valve Circuit to the Spring Chamber behind the Pressure Bypass Adjustment Spool This completely or partially closes the connection to Tank This allows Oil Pressure to flow to Cylinders when needed The Pilot Reducing Valve maintains Standby Pilot Oil Pressure to the Proportional Control System 200 to 250 PSI MACHETE Service Manual 04 04 2004 Alamo Group Inc 27 CONTROL VALVE HYDRAULIC CONTROL VALVE COMPONENTS Load Sensing Valve End Cap The Control Valve for Both Type Systems Load Sense or Fixed Displacement consists of the same basic components The Difference between the Control Valves for the two systems involves the components in the Inlet Section The Inlet Section End Cap of the Load Sensing Closed Center Valve Figure 12 contains the following compone
68. P N 02967193 PARTS LOCATION Motor Assembly P N 02967193 c 3 Description Retaining Ring Stationary Seal Rotating Seal amp O Ring Cap Screw Washer Dowel Pin Plug Pipe Socket Head Case Drain Plug amp O ring COON OA FPF WN SE ID Tag amp Screws Motor Housing Output Shaft Brg Cup amp Cone Retaining Pin Motor Drive Shaft Swash Plate Thrust Plate Piston amp Slipper Asy e m eo IX 9 OY a Slipper Retainer Plate Spacer Retaining Strap Cap Screw NNNM Do cor ER Me oen Cylinder Barrel Asy Dowel Pin 5 16 X 5 8 Long Bearing Plate Valve Plate Brg End Cover Cup amp Cone Shim End Cover Brg Shims Gasket End Cover End Cover Standard Motor Lifting Strap Hex Head Bolt Hex Head Bolt Square Cut seal N N o 1 1 2 2 1 1 1 1 1 1 1 1 1 14 1 1 9 1 4 2 4 1 5 1 1 1 WwowWNNNNN porcos ee pe cS Pe n Machete Service Manual 04 04 2004 Alamo Group Inc Item 33 34 35 36 3f 38 39 40 41 42 43 44 45 46 4T 48 49 50 21 52 53 54 55 56 57 58 59 Qty A NNN AN WwW BW FA NN gt NANa HA NN NM Description Back Up Washer O Ring Valve Block Asy Hex Head Bolt Gauge Port Plug amp O Ring Back Up Ring O Ring O Ring Relief Cartridge Hi Pressure Relief Cartridge Lo Pressure Shuttle Valve Shuttle Spring Shuttl
69. Plate Held Firmly Magnetic in position Base E Indicator Du F IT FIGURE 72 Hold Valve Plate firmly in position Install End Cover on Housing Figure 73 Install Cap Screws in End Cover Slowly and evenly in a star pattern tighten them Torque Cap Screws to 39 ft Ibs Then a di i Standrard End Cover second time go back and recheck Torque CAD or Integral Shuttle amp making sure they are 39 ft Ibs 53 nm Low Pressure Relief using the star pattern y End Cover Install the IMPORTANT Get the New Shaft Seal same The New Shaft Seal is coated with a Rust FIGU RE 73 Preventative that MUST be removed be fore installation Clean the Seal Parts with a suitable solvent then Blow Dry The poa Ring Stationary Seal Asy Metal to Metal Sealing Surfaces are Pp di CRITICAL The Solvent MUST EVAPO SH RATE without leaving a residue DO NOT Rotating Seal touch the Sealing surfaces after clean v d ing Lubricate Inner O Ring of Rotating Seal O Ring Theninstall Rotating Seal with Seal Puller Seal Puller i Owatonna Tool Co No CAS 1844 Ensure that Rotating Seal O Ring is cen placed inside the Rotating Seal before FIGURE 74 assembling onto the Drive Shaft Lubricate O Ring Seal of Stationary Seal assembly Figure 74 Then install Stationary Seal Assembly Use a No 5orNo 7 retaining Ring Pliers to install Retaining Ring Be Sure to install Retaining Ring with Beveled Side Out Machete Service M
70. Request for Technical Information or Specifications Mounting or Fitting Problem Special Service Problem Equipment Application Problems Tractor Problem Inquiries HOW YOU CAN HELP Make sure the call is necessary Most ofthe 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 Ifacallto Alamo Industrial is needed Certain Information should be available and ready forthe Alamo Industrial Service Staff Such information as Machine Model Serial Number Your Dealer Name Your Account Number and Any other information that will be useful This information 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 tofuture problems of a similar nature 3 The technician may be asked to provide detailed information about the problem including the results of any required trouble shooting techniques If the information is not available The technician may be asked to get the information and call back Most recommendations for repairs will be ba
71. Retaining Strap and Cap Screws in Swash Plate remember Loctite Rule in Step 1 Tighten all four Cap Screws 16 to 19 ft Ibs 22 to 26 nm An alternate method of checking fixed clearance is using a Feeler Gauge If using this method make sure Gauge is inserted between Retaining Strap and Slipper Retainer Plate Only Piston Slipper faces could be damaged if Gauge is inserted between Piston Slippers and Thrust Plate 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 106 MOTOR P N 02967193 ASSEMBLY Socket Head Plug Guides Bolts Main Headless Cap Screws qty 2 Housing Cap Screws with Special Washer 2 Guides Bolts Headless Cap Screws qty 2 Output Shaft Sub Asy Cyl amp FIGURE 69 Barrel Asy MAIN HOUSING RE ASSEMBLY Figure 69 1 Install two headless 5 16 Cap Screws 5 to 6 Long in Swash Plate These Cap Screws can be made by sawing off Head and Grinding end to a smooth semi blunt point These Cap Screws will Guide Swash Plate into Pocket of Main Housing These Headless Bolts are for assembly use only When installing Cylinder Barrel and Swash Plate into Housing Align Dowel Pin in with notch in Swash Plate Carefully slide Housing over Output Shaft Sub Assembly S
72. SE amp SOLUTION Starter on Tractor Will Not Crank continuea CAUSE Mower ON OFF Switch or Wiring Malfunction SOLUTION CAUTION MAKE SURE TRACTORIS IN NUETRAL 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 SHORT ORLOOSE CONNECTION YOU MAY MOVE ITAND 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 drain 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 SOLUTI
73. SING ENGINE RUNNING AND VALVE FUNCTION ACTIVATED See Figure 16 When a function is selected and actuated by the controller The Proportional Control System directs the Pilot Pressure Oil to move the Main Spool in its bore Two actions resulting from the Main Spool Shifting in its bore now takes place The Shifting of the Spool opens a passage to connect one end of the selected Cylinder to Pressure P Galley and connect the other end to the Return T Galley The Shifting Spool also connects the Load Sense Circuit to the Pressure P Circuit The Pressure Signal is sent to the Pump Control System which increases the Oil Flow to the Control valve The Pressure present in the P circuit and the Load Sense Circuit is the same and is created by the Load on the Cylinder NOTE The Load Sense Signal Shown in Figure 16 is an internal passage in Valve it is shown here on the outside for illustration onlr and cannot be seen if actually looking at valve Before the Pressurized Oil reaches the Flow Control Spool it must first pass through the Segment Compensation Spool The Compensating Spool uses Load Sense and Spring Pressure to maintain constant pressure drop across the Main spool Both when the Load changes and when a Segment with a higher load pressure is activated The maximum Pressure in the Swing Lift and Dipper Circuits is controlled by the settings of the Work Port Relief Valves of these Circuits These Settings may be
74. Socket Head Item Part No 26 2T 28 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 gt A N NNNNYNY 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 Machete Service Manual 04 04 2004 Alamo Group Inc 117 MOTOR P N 02979881 SPECIFICATIONS Motor P N 02979881 Specifications Displacement Motor Operating Speed Max Intermittent Motor Torque Theor Motor Input Flow Operating Pressure Maximum Case Pressure Max Continous Min Continous Max Intermittent Max Continous Max Intermittent Max Continous Fluid Contamination Level Motor Shipping Weight Specifications Subject To Change Without Notification Machete Service Manual 04 04 2004 Alamo Group Inc European Standards 80 4 Cm Rev 5 200 rpm 4 000 rpm 50 rpm 128 NM at 100 Bar 614 NM at 480 Bar 418 L min 322 L min 480 Bar 420 Bar 10 bar at 1500 rpm 18 13 ISO Code 4406 118 United States Standa
75. URE CAUSE amp SOLUTION Cylinder Rod Came Out of Cylinder continued CAUSE SOLUTION Relief Valve Setting Too High 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 SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Severe Usage Prepare and Repair Weld Grind Down Add Scab Plate and Re Paint Repaired Area Vibration Locate and correct cause of Vibration problem Prepare and Repair Weld Grind Down Add Scab Plate and Re Paint Repair Area Poor or Missing Welds Missing Bracing Prepare and Repair Weld Grind Down Add Scab Plate and Re Paint Repaired Area As this 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 Inadequate Bracing This is a difficult subject It is recommended that you consult with the factory before making modifications of this type Adding additional piec
76. 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 Splined Shaft 11 13 22 Machete Service Manual 04 04 2004 Alamo Group Inc 122 MOTOR P N 02979881 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 itto fallout when pressed and hit the 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 hous
77. Vernier Calipers Small Screwdriver 1 8 Blade Low Clearance Bearing Puller Special Filtered Moisture Free Compressed Air Clean Lint Free Rags IFNOTLINTFREE DO NOT USE THEM ONOAR WN gt GENERAL NOTES DO NOT Dis Assemble anything till everything has been thoroughly cleaned on or around Motor Connections and Head Seal All Opening to Hydraulic System when opened to keep Contamination Out This will include opening in all Fittings Hoses and Motor Whenever a Unit is dis assembled and cleaned lubricate Parts with Clean Lubricant as soon as possible to keep moisture off of them Always use New Seal to Re Assemble and lubricate them with Petroleum Jelly Vaseline 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 94 MOTOR P N 02967193 Parts Location amp 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 95 MOTOR P N 02967193 PARTS LOCATION End Cover with Integral Shuttle and Low Pressure Relief Valve Used on Machete Motor FIGURE 46 Machete Service Manual 04 04 2004 Alamo Group Inc 96 MOTOR
78. Y 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 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 into the Servo Piston cavity of Housing Screw the Cover Plate onto the Servo P
79. actor to Tractor Model and make connections different See original Mount Kit Instruction for Connecting Hydraulic Supply from Tractor to Valve Type 1 Load Sensing Closed Center Constant Pressure with Flow on demand Type 2 Fixed Displacement Open Center Continuos Flow with Pressure on demand Valve Shown Below use 1998 amp Up ithas 5 Plugs on Wire Harness that plug onto Valve Old Style Valve used 1997 amp Down had 10 Plugs on wire Harness 5 on each side of Valve Also the late Model has an added Filter Assembly P N 02976066 which was added to protect Valve from contamina tion from Tractor Hydraulic System This is a Spin on type Filter Pressure Port Tank Port Inlet Section Pressure Gauge Port 5 Spool Valve Handles Shown as Illistration Only This Valve Used 1998 amp Up FIGURE 10 MACHETE Service Manual 04 04 2004 Alamo Group Inc 26 CONTROL VALVE HYDRAULIC CONTROL VALVE COMPONENTS Fixed Displacement Valve End Cap The Control Valve for Both Type Systems Load Sense or Fixed Displacement consists of the same basic components The Difference between the Control Valves for the two systems involves the components in the Inlet Section The Inlet Section End Cap of the Fixed Displacement Open Center Valve Figure 11 contains the following components 1 Pressure Bypass Adjustment Spool i Pilot Reducing Valve 3 Pressure Relief Valve Load Sense Passage Plug FIXED DISPLACEMENT VALVE END CA
80. adjust Your Safety Support Stand under Boom till there is no space between them Leave Hoist connected to Boom for Support Remove the Swing Cylinder Pin on the Rod End Push Cylinder Back out of way Figure 81 Support Turning Arm with another Hoist or suitable Hydraulic Jack Remove the retaining Bolt and Nut located at the Bottom of kingpin See Figure 81 Remove the Retaining Snap Ring for kingpin This Snap Ring is located up inside the Lower boss below kingpin Remove kingpin by moving Turning Arm back and forth to alleviate binding Pin Should Slide out through Bottom If it does not make sure turning arm is supported so as not to be in bind Also on the bottom of the kingpin there is a threaded hole which allows you to screw a long bolt into it to aid in removing pin Use Jack or Hoist to set Turning Arm out of way ThrustWasher Swing Cylinder 2 Rod End Pin Swing Cylinder i i Tube End Pin Boom Mounting Pivot Pin Hole LiftCylinder Lower Mounting Main Frame Hale Bushings King Pin Retraining Bolt amp Nut Turning Arm Snap Ring amp Groove in Bottom Boss FIGURE 81 Machete Service Manual 01 03 2003 Alamo Group Inc 133 KING PIN REPLACEMENT Thrust Washer Be sure to remove the Thrust Washer on top of Upper Pivot Bushing This washer should be replaced when making these repairs There are Bushings in the Boom Pivot Pin Holes The Cylinder Pin Holes and in the Kingpin Pivot holes See Figure 81
81. age Past Control Valve Spool SOLUTION _ If excessive 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 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 Oil 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 sho
82. akage problem in the Cylinder Lines or Valves Travel Hydraulic Cylinder Pressure Rates See Valve Spool Functions amp Specs for Rates Hydraulic Cylinder Repair Specs Cylinder Part No 02967172 02967172A 02967173 02967173A 02967174 02967174A 02967175 02967175A 02961480 02961480A 02970710 02970710A 02971423 02811000 02811000A Cylinder Function Swing 21 amp 24 Swing 21 amp 24 Lift 21 amp 24 Lift 21 amp 24 Dipper 21 amp 24 Dipper 21 amp 24 Tilt 21 amp 24 Tilt 21 amp 24 Door Rotary Door Rotary Door Flail Axe Door Flail Axe Slide Timber Cat Door Ditcher Door Ditcher Machete Service Manual 04 04 2004 Alamo Group Inc Piston Nut Torque ft Ibs 400 500 400 500 400 500 400 500 400 500 400 500 400 500 400 500 150 250 150 250 40 60 40 60 400 500 150 250 150 250 11 Gland Torque ft Ibs 135 149 Cap 80 120 Head 135 149 Cap 80 120 Head 135 149 Cap 80 120 Head 135 149 Cap 80 120 Head 100 120 cap 80 120 Head None Lockwire 80 120 Head 50 60 Tie Rod None Lockwire 80 120 Head Seal Kit Part No 02968612 02975530 02968610 02975527 02968610 02975527 02968612 02975530 02972147 02975528 02972762 02975532 02973505 02840600 02975528 Continued Next Page SPECIFICATIONS MACHETE 6 HYDRAULIC HOSE CODES Hydraulic Hose Band Mark Color Codes Hose
83. alance 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 it is 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 Machete Service Manual 04 04 2004 Alamo Group Inc 145 POSSIBLE FAILURE CAUSE amp SOLUTION SUB INDEX Possible Failure Page Boom Breaks Back Too Easily 131 Boom Drops When Two Functions Actuated 131 Boom Moves On Its Own Under Power w no function actuated 135 Cylinder Boom Positioning 132 Cylinder Excessive Drift 133 134 Cylinder Leaks At Fittings 134 Cylinder Leaks At Rod 135 Cylinder Moves On Its Own Under Power w no function actuated 135 136 Cylinder Moves Wrong Way Not the function that was actuated 136 Cylinder Moves intermittent all functions 137 Cylinder Moves Spongy or Jerky 138 Cylinder Moves Some Functions But Not All 138 139 Cylinder Rod Bent 143 Cylinder Rod Came Out of Cylinder 143 144 Cylinder Won t Move At All No Power 140 Cylinder Won t Move Under Load Low Power 141 142 Deck Cracks 144 Deck Worn On Underside Cutting Head Only 144 145 Hydraulic System Noise Squeal 145
84. alve See Figure 20 for the Valve circuit that is malfunctioning or you want to test Each Section of the Valve has manual override control Manual Override Control use 9 mm HexHead Wrench FIGURE 20 Start the Engine and let the Engine run at least 1000 RPM Using a 9 mm Open Wrench See Figure 20 actuate the manual override controls for the Circuit that is malfunctioning Take note of the reaction of the Circuit to all positions of the control Also take note of the Smoothness of Spool Operation The Spool should move smoothly If it doesn t it can indicate contami nation in the system or something wrong with Spool causing it to bind If the Circuit fails to work with the Joystick and works properly with the manual override control The problem is in the Electrical Control Circuit The Solenoid Valve Joystick or Wiring Harness or Pilot Pressure 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 57 TROUBLE SHOOTING TESTING SOLENOID VALVE TEST See Figure 21 Using this test to determine if the Malfunction is in the Solenoid Valve Assembly after having performed Isolation Test 1 and 2 This test is used when some circuits are operating and one or more are not The Circuit will work manually as descr
85. anual 04 04 2004 Alamo Group Inc 109 MOTOR P N 02967193 ASSEMBLY Low Pressure Relief Valve Shuttle Valve Gauge Port Plugs FIGURE 75 y FIGURE 76 INTEGRAL SHUTTLE AND LOW PRESSURE RELIEF VALVE INSTALLATION Figure 75 If you have not assembled this yet See Figure 56 on previous Pages assemble Shuttle Valve and Low Pressure Relief Valve now See Figure 75 Install the Gauge Port Plug Assemblies The two outer Ports have smaller plugs Torque all three plugs 25 to 31 ft Ibs 18 to 23 nm Lubricate and install the Shuttle Spool Figure 75 it slides into hole between Shuttle Valve Plugs into the End Cover Make sure the Shuttle valves are installed correctly With the smaller ends facing the center of the Spool Install the Shuttle Valve Springs and Plugs Figure 75 Torque Plugs 68 to 82 ft Ibs 92 nm Install the Low Pressure Relief Valve Plunger and Spring Lubricate and insert the Shims in the relief Valve Plug Remember use same amount of Shims that was taken out Install New Lubricated O Ring on Plug Install Plug over Spring making sure the Shims are not dislodged Screw the Plug in and Torque it 68 to 82 ft Ibs 92 nm VALVE BLOCK INSTALLATION Figure 75 1 Valve Block should already be Assembled See Figures 52 53 54 and 55 on previous pages 2 Install O Rings and Back Up Rings on the Valve Block The High Pressure Ports require an O Ring and Back Up Ring The O Ring goes o
86. at makes contact with Valve Plate This surface should be smooth and free of deep scratches DO NOT LAP Piston Block Pistons The Pistons should move freely in Piston Block Bore If they are sticky in the Bore Examine the Bore for scoring or contamination Pins and Spring To inspect Pins and Spring CAUTION should be taken in removing Spring The Spring is highly compressed and the retaining Ring should not be removed without compressing the Spring safely Piston Block Dis Assembly The following Tools will be needed to dis assemble Piston Block A Flat Washers 2ea 3 8 ID X 1 1 8 OD B Bolt 1 ea 3 8 X 3 1 4 NC C Nut 3 8 NC 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 Washer 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 34 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 lu
87. ated completely in End Cover Figure 71 Check Output Shaft Sub Assembly endplay by installing End Cover without installing either Valve or Bearing Plates This removes Cylinder Barrels tension against Output Shaft Install Cap Screws in End Cover and slowly and evenly tighten them Torque Cap Screws to 39 ft Ibs Place and support Motor Assembly on End Cover Gently tap Output Shaftinward with Hammer Install Magnetic Base Indicatoron Mounting Flange with Gauge on Output Shaft end Figure 72 Use Pliers to grip Output Shaft as low as possible Pry Upward to determine Shaft EndPlay Indicator must read 002 to 007 05 to 17 mm Shaft endplay If endplay is incorrect adjust by adding or removing Shims under Bearing Cup in End Cover After adjusting endplay Reposition Motor on mounting flange remove End Cover Figure 73 Install two Dowel Pins in face of Cylinder Barrel Sub Assembly Freely lubricated Bearing Plate with clean Hydraulic Fluid Align Bearing Plate with Dowel Pins Figure 73 and install it on Cylinder Barrel Assembly Install Valve Plate Dowel Pins in face of End Cover Using Petroleum Jelly Lightly coat side of 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 108 MOTOR P N 02967193 ASSEMBLY Valve
88. ation to Motor A Lubricate O Ring with Petroleum Jelly Vaseline for retention during Assembly B Freely Lubricate all Bearings and finished Parts surfaces with Clean Hydraulic Oil Fixed clearance of Piston Slipper Flange and Slipper Retaining Plate See Figure 66 A Measure distance between the bottom of Retainer Strap to top of Thrust Plate this is the height of Spacer B Measure distance from top of Slipper Retainer Flange to top of Thrust Plate C Measure the distance between bottom of Retaining Strap and the top of Slipper Retainer Strap You can also get this by subtracting distance in B from distance in A Fixed Clearance MUST NOT exceed 008 20 mm If fixed displacement exceeds this measure ment replace worn parts Example A Spacer Height B Top of Slipper Retainer Plate to Top of Thrust Plate C Fixed Clearance not to exceed 008 20 mm Clearance C 008 Max 20mm Cap Screw Retaining Swash Plate Thrust Plate FIGURE 66 Lubricate and install Slipper Retainer Plate and Piston Slippers in Cylinder Barrel Assembly After installation Freely lubricate Brass Slipper Faces with Clean Hydraulic Fluid 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 G
89. be tween End Cover Bearing and Cylinder Barrel makes it difficult to use any other type Bearing Puller See Recommended ToolListin previous pages of Motor Section for Bearing Puller information Use Lint free Cloth or other Lint free Material as a coverto prevent contamina tion from getting in while removing Bearing Install Bearing Puller and remove Bearing Cone from Output Shaft Figure 59 Carefully reposition Motor on its side Figure 60 Using 1 4 Hex Bit Socket Remove the two Cap Screws that retain Swash Plate in Housing Remove and discard the Washers on these Cap Screws DO NOT reuse them Always use new Washers Push Output shaft Assembly inward to dislodge Swash Plate from its Pocket in Housing Carefully remove Cylinder Barrel Assembly in the Up position Remove Output Shaft Assembly Figure 61 When Output Shaft Bearing Cone must be replaced Use a Press to remove Cone from Shaft You Must use Special Stop Limit Tool when installing new Bearing Cone on Output Shaft Lint Free Cloth Cap Screw Swash Plate Output Shaft Assembly Socket Bit Plug FIGURE 60 LEE FIGURE 61 Machete Service Manual 04 04 2004 Alamo Group Inc 103 MOTOR P N 02967193 DISASSEMBLY iit Note See Bearing To Drive Out Critical j Cone removel Tool Bearing Cup Sealing HAM Figure 59 Area FIGURE 63 When removing or installing Bearing Cone DO NOT damage Output Shaft Sealing area Stepped area b
90. before beginning any work Make sure all parts are lubricated 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 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 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 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 Wiper Seal Install Wiper Seal item 16 on Input Shaft and seat into Control Housing Valve Spool Plug Install New O Ring item 3 onto Valve Spool Plug item 2 and install Plug Tighten Plug till there
91. bricated with Hydraulic Oil prior to re assembly 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 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 Bolt to compress Spring and retain with 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 81 PUMP ROTATING KIT ASY NO Sy SY pa S J KK Oa CAS VES FIGURE 34 Rotating Kit Assembly Item OMONOABRWNDN gt Machete Service Manual 04 04 2004 Alamo Group Inc Qty k 3 AJ QG Description Piston Assembly Spider Spider Pivot Retainer Piston Block Pins Wsher Spring Retaining Ring 82 Motor Circuit Section Machete Service Manual 04 04 2004 Alamo Group Inc 83 MOTOR ELECTRICAL CONTROL MOTOR CONTROL SWITCH See Wiring Schematic in This section Earlier Model Machetes FIGURE 36 w 1 Push Pull Switch amp 1 Momentary Push Button Switch The Cutting Head Hydraulic Motor circuit is engage
92. cer 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 Figu re 20 Machete Service Manual 04 04 2004 Alamo Group Inc 125 MOTOR P N 02979881 ASSEMBLY Motor Assembly Continued 6 Install Bearing Retaining Ring This is an external snap ring item 23 Use snap ring pliers to Shaft slide snap ring down over shaft See Figure 22 Check Bearing load after snap ring is installed to 22 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 Splined 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 Sie Ring 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
93. ck from top of Deck 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 Vlave Bolck Bolts Under Plate on Later Models ni Moter Hold Down Plate Motor Hold Down Tie Rod Nut C a Hose Connection N FIGURE 86 Machete Service Manual 04 04 2004 Alamo Group Inc 139 SPINDLE REPAIR Procedures Dis Assemble Spindle Spindle Dis Assembly See Figure 87 The Spindle Shaft is 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 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 stuck Using Press push Pin and Shaft Down It will come out through bottom of Housing 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
94. d by two Manually operated Switches lo cated on the Joystick controller One is a Push Pull Switch the other is a Push Button Switch Both Switches must be actuated in sequence before the Motor Circuit will engage Figure 35 Power is taken from the Ignition Switch through a fuse to the normally open contacts on a Push Pull Switch When the Push Pull Switch is pulled out it completes a Circuit to the Hold Coil of the Solenoid located on the Pump The Hold Coil does not have enough pull by itself to move the Control Lever on the Pump so a Pull Coil is employed The Pull Coil takes power from the Hold Coil Circuit downstream of the Push Pull Switch and goes to a manually closed posi tion A Spring Opened Normally Open Switch called a Momentary Switch When this Switch is Pushed after the Push Pull Switch is Pulled The Pull Coil is energized which moves the control Lever on the Pump After the Pump has been engaged the Hold Coil will keep the Control Lever in the engaged position Adjustment of the Solenoid Linkage is Critical to prevent premature burnout of the Sole noid With the Solenoid engaged adjust the Linkage so that the Valve lever is fully actuated Later Model Machetes FIGURE 37 w 2 Push Pull Switches The Cutting Head Hydraulic Motor circuit is engaged by actuating a single On Off Switch located on the Joystick controller The System works in much the same way as the earlier system except that later machi
95. de Bar Type Stacked 3 Leaf Blade Bar Size 1 1 4 Thick X 5 Wide Ea Leaf Blade Bar Material Bottom Leaf Middle amp Top Leaf HRFB Steel Blade Swing 360 Deg Swing Blade Material High Carbon Alloy Steel Cutter Weight Approximate w Rotary Head Cutter Deck Opening amp Closing Hyd Operated Door Older models recommended Universal Tractor Hydraulic Oil This was changed to ISO AW 100 Hyd Oil If changing Oil in Older units switch to New Oil DO NOT Mix types of Oil 2 BOOM SPECIFICATIONS Boom Reach 21 Foot Boom Up 20 3 Out 21 4 Down 12 11 24 Foot Boom Up 23 Out 24 2 Down 14 5 Frame Old Low Frame 4 X 6 Rect Tube New High Frame 4 X 4 Sq Sq Tube formed corners Chromed Bushings Self Lubricating No grease needed Weight vary w size of Boom not include Head 21 ft 2250 lbs 24 ft 2300 lbs Weight Head Only Add to Boom when used 60 Rotary 950 Ibs 48 Flail 770 Ibs FML100H 990 Ibs Boom Rest Tractor Axle Mounted Boom Mounting ROPS or CAB Tractor Optional 3 FILTRATION Control Valve Functions Control functions include All Hydraulic Cylinders These are powered by the Tractor Hydraulic System and are protected by the Tractors Filtration system Maintenance and specification of this should be per Tractor Manufacturer instructions Later Models Had an Inline Filter assembly P N 02976066 added to Filter Tractor System between Valve and Tractor Change Filter every 200 to 250 hrs Operation recomme
96. different for opposite ends of the same Cylinder or Circuit The Cartridge also incorporates Anti Cavitation Check Valves to provide make up Oil if required These Valves will open to allow Oil from the Tank Galley to enter the Cylinder whenever there is no more Oil being demanded by a Cylinder than is supplied Such as with the Lowering Function in order to prevent Cavitation Proportional Control of the Lift Dipper and Swing Functions is achieved through the Proportional Control System of each Section Tilt and Door Functions DO NOT have Proportional Control they are Open or Closed only When an Electrical Signal is sent from the Joystick to the Electric Controller in the Valve The Pilot Pressured Oil is then allowed to flow to either end of the Spool thus causing it to shift The amount Pilot Pressured Oil to either end of Spool is varied with the Pilot Oil Control Valve by the Electric Controller there by controlling the distance the Spool Shifts This in turn controls the volume of Oil sent to the Cylinders and consequently the speed of actuation of the Cylinders The Tilt and Door Functions While not Proportionally Controlled are controlled by Pilot Oil Control Valves However instead of opening or closing based on the Joystick position these valves will fully Open or Close when activated When the Function is returned to Neutral at the Joystick The electrical current to the Valve Controller is stopped Therefore the Pilot Oil Co
97. dle Motor and Blade Carrier 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 Install Spindle Housing Gasket Install Spindle Gasket on top of Spindle Make sure old Gasket was removed and not stuck to Bottom of Motor 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 Look at the four Bolts that hold the Valve Body on Notice two bolts are 2 1 2 center apart and the other two are 2 1 4 apart the two that are 2 1 4 apart goes to the front toward Door 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 till 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 Fill Spindle with Grease Make Sure that Spindle Grease Relief Plug is installed Fill Spindle
98. e MACHETE Service Manual 04 04 2004 Alamo Group Inc 37 CONTROL VALVE FIXED DISPLACEMENT Pressure Relief Pilot Reducing Valve Tank Return T 7 Pressure From Pump P 4 fa d Load Sense Signal Ii es i 7 5 SS Valve Shown with Q ONE A x i 8 Function Activated E S N Position Signal v c E From The Joystick UN Pressure Bypass Plug Adjustment Spool 1 Pilot Pressure Oil me Anti Cavitation Work n B A Port Relief Valve yt AQ 5 Mechanical e E f J a t i 1 A Segment Compensation Spool Main Spool uu FIGURE 18 Load Sense passage is internaly in Valve Shown outside for Illustration MACHETE Service Manual 04 04 2004 Alamo Group Inc 38 NOTES MACHETE Service Manual 04 04 2004 Alamo Group Inc 39 May 1995 VALVE ASSEMBLY S N MB21 01001 S N MB24 01001 Dec 1997 to Load Sense S N MB21 01109 P N 02968851 S N MB24 01046 g o xe UV VERY IMPORTANT oua56s DO NOT Use Solenoids B T A p as Handles 5 6 8 See Detail A L unm VIL T fcu Lo o gt S Y 3 a fa Ny I Load Sense X Port gu D 5 6 8 See Detail A aaa 8 NOTE Make Certain That 5 Orfice Plate 6 Goes to Swing Port C2 Orfice Plate 7 Goes to Swing Port C1 Orfice Plate 6 Goes to Tilt Plate Port C1 DETAIL A otch in Orfice Plate Must Face away from Valve as Shown MACHETE Service Manual 04 04
99. e 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 FIGURE 30 095 2 41 mm Gerotor Pocket CHARGE PUMP ADAPTER RE ASSEMBLY 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 install 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 Q Z Description Chrage Pump Adapter Bearing Press Fit Bushing Press Fit pa Plug 3 Charge Pump O Ring Z Suction Port Shims Spring 3 FIGURE 31 Poppet I l Q X l os IX CX Machete Service Manual 04 04 2004 Alamo Group Inc 7T PUMP MANUAL SERVO CONTROL ASY MANUAL SERVO CONTROL DIS ASSEMBLY Used 1997 amp Down The following instructions apply to Manual Servo Control Dis Assembly See Figure 32 Clean Make Sure that every thing Pump Connections Tools Work Bench Vise and all general conditions are very clean before beginning any work Input Shaft Removal Re
100. e Valve Plug amp O Ring Shuttle Spool End Cover w Integral Shuttle amp Lo Pressure Relief valve Shuttle Valve Plug amp O Ring Shuttle Spring Shuttle Valve Shuttle Spool Gauge Port Plug amp O Ring Gauge Port Plug amp O Ring Bolt Hex Head Bolt Socket Head Plunger Spring Shim Lo Pressure Relief Valve Lo Pressure Relief Valve Plug amp O ring Var Shims Vary in Qty Use as required Item 28 amp 47 used one or the other not both 97 MOTOR VALVE BLOCK DIS ASSEMBLY VALVE BLOCK INTEGRAL SHUTTLE REMOVAL 1 Position the Motor on its mounting Flange as shown in Figure 48 If the Motor has a Integral Shuttle and Low Pressure Relief see Figure 49 Valve Block see Figure 48 loosen all of the Relief Valve Plugs in the Valve Block Keep track of how many Shims are removed with each Relief Plug Remove the four bolts that hold the Integral Shuttle valve or Valve Block to the Motor Remove the Integral shuttle Valve or Valve Block See Figure 48 or 49 Removes O Rings and Back Up Rings f the Motor that is under Valve Block on top of Motor On Motor with Valve Block Figure 48 use 1 3 8 Wrench to remove Valve Block Low Pressure and High Pressure Relief Valve Cartridge The Low Pressure Relief will not have white Back Up Rings only O Ring in lower groove High Pressure Relief Valves will have two white Back Up Rings and one O Ring in lower groove This will help to ID Pressure Relief Valves Low amp Hi
101. e 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 and Motor Pistons 3 Operate Control Functions 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 41 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 Campmate 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 Motor wanting to run Neutral Port D System Relief amp Port C Centering ToMotor Check Valve From Motor Camplate Gerotor Solenoid Servo Control SSNS M xe L
102. eak 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 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 it warms up or move unit To a Building where Oil can warm up before operating CAUSE Faulty Pump Drive SOLUTION Inspect Pump
103. ectronic Controller and the Spool position Transducer are not included in these functions Earlier Model Joysticks Master Switch was a 2 Push Pull Switch type Later Models have one Push Pull Switch with a Momentary Pull Start Switch built in to it and a Lighted Rocker Master Switch Rocker Trigger Switch d Rocker Switch Onl ocker Switch Only Pistol Grip Push Right Tilt Down Motor Start Pesh Left TiltUp Stop Switch Rocker amp Trigger Switch Push Right Door Close Master Push Left Door Open Switch Pistol Grip Handle Switch Push Front Lift Down Pull Back Lift Up Push Right Dipper Up Push Left Dipper Down Rotate Right Swing Out FIG U RE 4 Rotate Left Swing In Joystick Functions MACHETE Service Manual 04 04 2004 Alamo Group Inc 19 CONTROL VALVE JOYSTICK JOYSTICK TROUBLE SHOOTING The Joystick Wiring Harness has 2 wire connections to link Machete to Tractor Power Supply 12 Volt DC One red colored wire for Positive Connection and 1 Black colored wire for Ground Connection These wires will provide power to start the Front Auxilary Pump that runs the Cutting Head Motor Circuit and power to operate the 5 spool Valve Electrical Circuits The Hydraulics to operate 5 Spool valve is furnished from Tractor Hydraulic System through the Tractors Internal Hydraulics The Joystick Wiring Harness also has 2 other wires that must connect to Tractor these are 2 Brown colored wires These wires connect
104. ends of the Servo Piston to equalize 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 FIGURE 40 ON 9 on later Model replaced by PUMP f S Block with Solenoid Y re S Servo Piston Feed Back Servo Piston Follower Camplate F SystemRelief and Check Neutral Valve Centering Port C Port D From Motor To Motor Gerotor Servo Camplate Charge Control Piston Asy Solenoid LLLLEV LLLA i AA L7 Ex Imt iip ral N J e OE ET iis NEON SSNs Charge Pump Relief Valve UNTERTITEL epee Pen System Relief amp Servo Control Supply Oil Check Valve Machete Service Manual 04 04 2004 Alamo Group Inc 65 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 The Canplate 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
105. er pressure in Port D seats the Check Valve for Port D Separating 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 System Relief amp Port C Neutral Port D Check Valve From Motor Centering Camplate To Motor Gerotor Solenoid Spring Piston Asy Servo Control Pump Suction d j 5 1 SIN S S 27 Neutral Adjustment Servo Piston System Relief N Servo Control Supply Oil amp Check Valve Relief Valve Operation FIGURE 42 PUMP 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 Orifice 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 spike pressure encountered during severe operation Machete Service Manual 04 04 2004 Alamo Group Inc 91 MOTOR SYSTEM SCHEMATIC Motor CCW i A Q e e t FIGURE 43 Machete Service Manual 04 04 2004 Alamo Group Inc 92 MOTOR SHUTTLE VALVE
106. es 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 SOLUTION 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 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 a540 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 160 POSSIBLE FAILURE CAUSE amp 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 TheDeck will wear over ti
107. ese Switches have varied from On Off to Momentary Butall have served the same purpose Closingthe Switches completes a Circuitthrough the Solenoid The Purpose ofa 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 faster the motor turns Machete Service Manual 04 04 2004 Alamo Group Inc 64 PUMP CIRCUIT MOTOR ENGAGE Note The Servo Control System Changed see Note on Previous Page Movement of the Variable Displacement Pump Control Lever Figure 40 starts pump Output As Lever is rotated it moves the Spring centered Servo Control Spool first Movement of the Spool allows Charge Pump Oil past the Spool to one side of the Servo Piston Figure 40 The Pressurized Servo Piston pushed against the Camplate figure 40 causes the Camplate to rotate to a 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
108. etc for the function which they are connected The Plug will only fit together one way and should always have right connections BUT ifthe terminals within this Plug are moved around or the connections at the valve end are changed then the Plug would still be connected the same way and be Wrong If any connections are removed they MUST be placed back in the same order they came out of SEE FIGURE 5 and 6 See Figure 6 for Plug Connection Letter Code amp Terminal locations Also the Wiring Schematic BUT NOTE on the Wiring Schematic it WILL NOT be the actual location of Wires Letter Codes ABC etc They are changed to enable the wiring diagram to be drawn with as few lines crossing each other as possible for illustration purposes See Figure 6 for actual Wire locations in Plug DO NOT USE WIRE SCHEMATIC PIN LOCATION IN PLUG TO MAKE CONECTIONS IN ACTUAL PLUG DO NOT CHANGE LOCATIONS OF PINS AND OR WIRES IN PLUGS THEY MUST BE CONNECTEDTHE SAME WHEN REPLACED OR THE SYSTEM WILL MALFUNCTION AND THIS COULD ALSO DAMAGE JOYSTICK CONTROLLER COMPONENTS MACHETE Service Manual 04 04 2004 Alamo Group Inc 18 CONTROL VALVE JOYSTICK JOYSTICK FUNCTIONS Figure 4 To operate a function the following series of events must work 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 Val
109. etween Bearing Journal and Output Shaft Splines This area is critical for sealing Output Shaft Seal Figure 62 Use suitable Bearing Puller or Punch to remove Bearing Cup from Main Housing Figure 63 Reposition Cylinder Barrel and Swash Plate so that Swash Plate is in down position Use 1 4 Hex Key to remove Cap Screws from retaining straps on one side of Swash Plate Loosen Cap Screws on other Retaining Strap this will make it easier to remove Cylinder Barrel from Swash Plate Figure 64 Carefully reposition Cylinder Barrel and Swash plate in the Up position Remove Swash Plate by lifting it slightly and sliding it over to dis engage from retaining Strap Remove Cap Screws retaining Strap Spacers and Thrust Plate from Swash Plate Figure 64 Dis Assemble Cylinder Barrel Assembly Place it on a clean protective surface for inspection and cleaning Retaining Piston Cylinder Strap Slipper Asy Barrel Asy FIGURE 64 Machete Service Manual 04 04 2004 Alamo Group Inc 104 MOTOR P N 02967193 ASSEMBLY ROTATING GROUP RE ASSEMBLY Before re assembly of Fixed Displacement Fixed Clearance Motor Clean all Parts and Assemblies in clean Solvent and Blow Dry with compressed Air Inspect and Replace all Scratched or Damaged Parts When Re Working Parts DO NOT use Coarse Grit Paper Files or Grinders on Parts Assembly Preparations that need to be done prior to Assembly This will provide start up lubric
110. ew 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 not tighten 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 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
111. four Bolts that retain the Valve Block on top of Motor should not have been removed Set Motor Plate down over Tie Rod Bolts Make sure all the Washer are on and Plate is setting square DO NOT tighten the Nuts on the Tie Rods yet Tightening Nuts on Ties Rods will require measuring and adjusting the Upper Nuts under Plate As the Tie Rods were not remove this measurement should not be far off BUT they MUST be correct so using the next two pages and drawings as a guide and instructions Tighten and adjust Plate Retaining Nuts as Shown If you are installing components new then The tightening procedure will have to be done from beginning for the Motor Plate and Tie Rods 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 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 and lock washer must be installed These will torque to 400 ft Ibs After Assembly is completed check all steps to be sure they are completed Test run Head then Stop and recheck all components inc
112. g 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 equalize The Piston and Camplate return to a Neutral position and Oil flow from the Piston Pump ceases Speed of the Camplate movement is controlled by orifices between the Control Valve and the Servo Piston 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 FIGURE 40 PUMP Servo Piston Servo Piston Follower Camplate Neutral Centering S pring Port D To Motor Servo Camplate Control Piston Asy Solenoid z eooo ooe 2 RT ts UY ra d NN Servo Control ASUP Oil Machete Service Manual 04 04 2004 Alamo Group Inc 89 TNS pnt awe on later Model replaced by Block with Solenoid Feed Back System Relief and Check Valve Port C From Motor Gerotor Charge d D Saw AM eng H E Zp Pu bs 222 PAS L C UH CUN CURRUS L FT F Charge Pump Relief Valve System Relief amp Check Valve 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 th
113. ge 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 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 along period and are gradual loss of power and excess heating of Oil This may go unnoticed till itis 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 NOTES Machete Service Manual 04 04 2004 Alamo Group Inc 170 POSSIBLE FAILURE CAUSE amp SOLUTION Motor Stops Mower Quits Under Load CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION 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 Air In Oil Run the System for a few minutes Check for Air in the Oil in the Tank
114. gh 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 M System Relief amp port C Neutral Port D Check Valve From Motor Centering Camplate To Motor Gerotor Solenoid Spring Piston Asy Ec F aiii Servo Piston Meg System Relief Servo Control Supply Oil amp Check Valve Relief Valve Operation FIGURE 42 PUMP 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 spike pressure encountered during severe operation Machete Service Manual 04 04 2004 Alamo Group Inc 67 PUMP PARTS LOCATION See Item 48 the lever Servo Control removed and replaced by a 2 wire Solenoid Block Asy Serial Code and Product Number Location Left FIGURE 25 Machete Service Manual 04 04 2004 Alamo Group Inc 68 PUMP PARTS LOCATION Description Jam Nut Retaining Ring Retaining Ring Seal Washer Bolt 10 24 X 1 25 4
115. gh Pressure Relief Settings are Pre Set at factory The Stampings of three digit codes on Cartridge identifies setting 1 St Digit 1000 Th 2 Nd digit 100 Th and 3 rd digit 10 Th example Low Pressure Codes 061 code 160 PSI 11 Bar 022 220 PSI 15 Bar or High Pressure Codes 500 5000 PSI 344 Bar 400 4000 PSI 275 Bar On Motor with Integral Shuttle Valve Figure 49 Unscrew Low Pressure Relief Valve Note the Shims as you dis assemble Low Pressure Relief Count Shims as this is how many should be re installed during re assembly Valve Block Standard Motor w Valve Block d High Pressure Standard High Pressure f Relief Valve End Cover uc E Relief Valve Low Pressure Relief Valve Back Up RES SF eng FIGURE 48 Ring Q Square Cut Ring Motor w Integral EAN Low Pressure shuttle and Low EX Relief Valve Pressure Relief Valve Builtinto End Cover T D Shuttle Valve SS Gauge Port Machete Service Manual 04 04 2004 Alamo Group Inc 98 MOTOR VALVE BLOCK DIS ASSEMBLY VALVE BLOCK DIS ASSEMBLY On Standard Motor 1 Use 1 Hex Wrench to remove Shuttle Valve Plugs The remove Shuttle valve Plugs Figure 50 2 Remove Shuttle Valves and Shuttle Spools Figure 50 amp 51 3 Remove Gage Port Plug Assemblies Shuttle Valve Plugs Valve Block 7 Valve Block Shuttle Valve Shuttle Valve Springs Shuttle Valve Plugs Shuttle Valves Shu
116. gh the Proportional Control System of each section When an electrical signal is sent from the Joystick to the Electric Controller in the Valve The Pilot Pressured Oil is then allowed to flow to either end of the Spool thus causing it to shift The amount of Pilot Pressured Oil to either end of Spool is varied with the Pilot Oil Control Valve by the Electric Controller there by controlling the distance the Spool Shifts This in turn controls the volume of Oil sent to the Cylinders and consequently the Speed of activation of the Cylinders The Tilt and Door Function While not proportionally controlled are controlled by Pilot Oil Control Valves However instead of opening or closing based on Joystick Position These Valve will fully open or fully closed when activated Tiltand Door Functional are not proportional they are open full or closed full only When the Function is returned to Neutral at the Joystick The Electrical current to the Valve Controller is stopped There fore the Pilot Oil Control Valves return to their normal positions and the Flow of Pilot Pressure Oil to the Main Spool is stopped The Springs on the Main Spool returns the Spool to its centered Neutral Position When the Spool is centered the Load Sense Signal stops With no Load Sense Signal present the Pressure Bypass Adjustment Spool allows most of the Oil inthe Pressure P Port to return to the Tank T The Pilot Reducing Valve retains Pilot Standby Pressure in the Valv
117. h a 11 to 15 Volt Range Valve Port Markings Ports Marked with letter A solid marking hose bands are for Functions Connected to Rod 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 12 SPECIFICATIONS MACHETE Note Old style Valve Apitech 10 Plug Wire Harness type is not shown Below this is the later style 5 Plug Harness type Yel Wht Blue Wht Wht Gm Wht Pressure Door Tilt Lift 2 Yellow Blue Orange Solenoid Side Of Valve Valve Restrictors The Restrictors Vary in size from Spool to Spool Some Ports do not use restrictors at all See parts page for types and sizes Restrictors operate by controlling the rate of flow to or from a Cylinder This is most commonly done by the size of the Hole the Oil is sent through But can be done by Hose Size There are also 1 way and 2 way restrictors Check Parts pages DO NOT Remove Change or Modify Restrictors Valve Spool Funtions amp Specs Port Spool Cyl Cyl Flow Pressure Restrictor Cycle Marked No Function Travel GPM Rating Size Time A Swing Forward 2 3 2000 psi 0 040 8 5 Seconds B Swing Back 3 5 2000 psi 9 0 Seconds A Lift Down 4 5 1000 psi 12 Seconds B Lift Up 6 5 2000 psi 0 070 11 Seconds A Dipper Out
118. harge 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 Machete Service Manual 04 04 2004 Alamo Group Inc 167 POSSIBLE FAILURE CAUSE amp 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 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 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
119. hat it is 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 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 164 POSSIBLE FAILURE CAUSE amp 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 before continuing CAUSE No Oil Flow to Motor Front Pump Inoperative No Pump Pressure reaching Motor SOLUTION OilLevelis 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 agai
120. he Oil Drain and flush the system before installing the new Oil Machete Service Manual 04 04 2004 Alamo Group Inc 166 POSSIBLE FAILURE CAUSE amp SOLUTION Motor Over Heating continues CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Excessive Internal Leakage in Pump Motor 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 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 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 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 Relief Valve Malfunction Perform Flow Pressure Test If Flow is correct and Pressure is Lo
121. he 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 and or Defects in Pump and or Motor Machete Service Manual 04 04 2004 Alamo Group Inc 171 POSSIBLE FAILURE CAUSE amp SOLUTION Motor Stops Mower Quits continued CAUSE Low Relief Valve Setting SOLUTION 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
122. he 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 System 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 at a time using a criss cross pattern The Valve Body can be placed ina bind ifthe mounting bolts are tightened un evenly This can cause the Spool to stick in the bore or cause the Valve to 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 Machete Service Manual 04 04 2004 Alamo Group Inc 148 POSSIBLE FAILURE CAUSE amp SOLUTION Cylinder Excessive Drift NOTE All
123. ibed in Isolation Test 2 but not electrically Start with the Engine OFF and the Control Valve Cover still removed Connect the Solenoid Valves of the inoperative Valve Section to the Harness connections of a Valve section that is known to be operational See Valve Diagram remember some are proportional and some are not Connect for Testing Swing Lift and Dipper Functions Proportional or connect Door to Tilt Non Proportional for testing In other words connect Swap the Harness connection from Questionable Circuit with a good Circuit Operate the Joy stick function for Both swap Circuits NOTE You swapped connections so the movement of Joystick one way will have a different Cylinder movement now KEEP this different movement in Mind If the inoperative circuit begins to work now and the former function is inopera tive The problem most likely is in the Joystick Wiring Harness If the Inoperative Circuit STILL FAILS to operate and the Known operative circuit continues to function properly The problem is most likely in the Solenoid Valve Providing that the Circuit functioned when Manually operated with Manual Override NOTE See Directions above Disconnect connector for malfunctioning circuit and recoonect to a known operational circuit for testing Pressure Port Tank Port 5 Spool Valve Handles Shown as Illistration Only FIGURE 21 Machete Service Manual 04 04 2004 Alamo Group Inc 58 TROUBLE SHO
124. in to form the Safety Link in the Tractor Start Circuit to prevent the Tractor Engine from being started when the Machete Electrical Circuit is energized These wires Brown Colored connect the Starter relay Circuit of the Tractor to the Master On Off Switch Rocker Switch on later models on the Joystick Console of the Machete Caution These 2 wires Brown Colored are to be spliced into Tractor Starter Relay Wire approximately 3 behind Starter Switch normally Key Switch DO NOT splice wires Brown Colored any further from Starter Switch than 3 if further than 3 it may cause electrical interference in other tractor electrical operations when the Motor Circuit is engaged With the Switch Keyed Switch of tractor in the On position and the Rocker Master Switch on Joystick Console in the On position a Green Light on Master Switch should be on Note Early models did not have a Lighted Master Switch only a Push Pull Switch This green light indicates that electrical power is available to the five movement control circuits of the Valve and to the start system of front pump as well as start circuit of Motor To Check this Current at Switch Master or Motor Stop Start Switch it can be done with a test light or Voltmeter VALVE CONTROLS CONNECTION TROUBLE SHOOTING Proportional Controlled Functions Only the Swing Lift and Dipper Functions are Proportional Controlled Therefore only these three functions will show progressive
125. ine RPM Too Slow Run Tractor Engine at required Speed to achieve GPM through Pump See Specification Section in Repair Manual 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 Machete Service Manual 04 04 2004 Alamo Group Inc 158 POSSIBLE FAILURE CAUSE amp SOLUTION Cylinder Rod Bent CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Excessive Load Applied to Cylinder This is an Operational Problem or Operational Accident 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 Misalignment of Cylinder Lugs 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
126. ing Figure 15 Machete Service Manual 04 04 2004 Alamo Group Inc Eb Press Splined b Figure 16 123 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 a tube that will support the gear item 19 Using press on Shaft item 14 Shaft will slide down through the gear and bearing at the same time Make certain to support Shaftin such a way it will not fall through and hit the 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 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 Machete Service Manual 04 04 2004 Alamo Group Inc Press Splined Shaft Figure 17 124 MOTOR P N 02979881 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 Co
127. 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 Figure 24 Machete Service Manual 04 04 2004 Alamo Group Inc 126 MOTOR P N 02979881 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 amp Piston Rings Coat the pistons item 17 with hydraulic oil make certain all 7 pistons have 3 rings item 18 eachonthem See Figure 29 Piston willlay 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 Figure 25 port item 16 is a 4 piece assembly that installs in the center of the 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 Machete Service Manual 04 04 2004 Alamo Group Inc 127 Carrier
128. 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 Machete Service Manual 04 04 2004 Alamo Group Inc 157 POSSIBLE FAILURE CAUSE amp SOLUTION Cylinder Won t Move Under Load continueg CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Piston has come off of Rod 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 The best way to check would be with a Flowmeter in Cylinder Line Check Repair or Replace as required Restrictor Valve Installed in Wrong Line Backwards or Plugged 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 Excessive Internal Leakage in Pump Motor 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 pe
129. ion in Repair Manual Excessive Ground Speed for Mowing Conditions Operational Prob lem 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 Cut is 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 Excessive Ground Contact with Blades Operational Problem Inspect Blades Blade Carrier and 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 Incorrect Oil Installed Incorrect Oil installed may produce internal wear which will overheat the 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 t
130. iston 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 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 Unitis 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 Left Side ii Right Side Install Servo emp l Piston in This Front Flange Drive Adjustto Center Direction Shaft End of Pump Neutral Piston FIGURE 29 Machete Service Manual 04 04 2004 Alamo Group Inc 74 PUMP RE ASSEMBLY Install New Seal Washer Washer and Jam Nut to 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 Ibs 17 to 18 nm Recheck Servo Piston Measurements See Figure 29 If Measurement is OK install Cover Plate and Cover Plate Gasket on Left Side of Servo Piston Retain cover with 4 each of 10 24 B
131. le Turning Arm Snap Ring amp Groove in Bottom Boss FIGURE 84 King Pin Machete Service Manual 01 03 2003 Alamo Group Inc 135 NOTES Machete Service Manual 01 03 2003 Alamo Group Inc 136 Spindle Repair Section Rotary Head Only SPINDLE REPAIR Procedures Remove Blade Bar 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 Move Tractor to Level and Firm Ground Concrete Floor is Best 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 Fully apply the Park Brake on Tractor Place all Gears in Tractor in the Neutral Position Shut Off Tractor remove Key and disable Tractor so it cannot be started till you are ready to have it started 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 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 b
132. lem 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 toa 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 aresult of operation when cutting Heavy Material or hitting stationary object that 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 original 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 b
133. linder Moves On Its 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 Cable Binding or Sticking repair or replace as required Sometimes it may be the Linkage sticking or binding and not the Cable It 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 Machete Service Manual 04 04 2004 Alamo Group Inc 151 POSSIBLE FAILURE CAUSE amp SOLUTION Cylinder Moves On Its Own under power Continued CAUSE SOLUTION CAUSE SOLUTION Controller Not Returning to Center Electronic Joystick Control Models 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 2 Way Radio RF Interference
134. ll Circuits will not work the Problem is mostlikely 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 itis 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 at a time using a criss cross pattern The Valve Body can be 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 res
135. ll 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 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 070tip 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 O 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 W
136. lose the Passage to the Tank T and allows the correct amount of Oil to travel to the Cylinders Based on the Load Sense Pressure The Pressure Bypass Adjustment Spool will allow only the Oil needed at the Cylinder in accordance with the Controllers Position Any excess Oil will be allowed to return to Tank T The Pressure present in the P Circuit and the Load Sense Circuit is the same and is created by the Load on the Cylinder Before the Pressurized Oil reaches the Flow Control Main Spool It must first pass through the Segment Compensation Spool this Spool maintains a constant pressure differential Flow between the Supply Pressure and the Cylinder Pressure at the Flow Control Main Spool Simple Explanation Function of Segment Spool is to keep a constant even pressure to Main Spool so Cylinder cannot suck in Air The maximum Pressure in the Swing Lift and Dipper Circuits is controlled by the settings of the Work Port Relief Valves for these Circuits These settings may be different for opposite ends of the same Cylinder or Circuit The Cartridge also incorporate Anti Cavitation Check Valves to provide make up Oil if required These Valves will open to allow Oil from the tank Galley to enter the Cylinder when ever there is no more Oil being demanded by a Cylinder than is supplied Such as with Lowering function in order to prevent Cavitation Proportional Control of the Lift Dipper and Swing Functions is achieved throu
137. luding 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 142 SPINDLE MOTOR PLATE Hardened Flatwasher 60 MACHETE HEAD MOTOR PLATE ATTACHMENT Jam Nuts Before installing the rods run two nuts on each end of the rods down 2 Place a hardened Flat Washer on each end See FIGURE 89 Placethe straight rods in the holes marked 1 through 4 See FIG Jam Nuts WSE RO Hardened Flatwasher Once the rods are in the holes through the Buck Plate align the rods through the holes on the FIGURE 89 mount plate and place the mount plate on top ofthe relief block The valve block bolts on top of the motor is not equally spaced Make sure the pockets align accordingly See FIGURE 91 Front of Deck Door Opening FIGURE 90 Place thread locking compound on the threads and install the Hardened Wash ers and Toplock Nuts on the Rods ex tending through the bottom of the deck Torque these rods to 230 Ft Lbs See FIGURE 91 Measure the distance that the rods ex f tend through the top mount plate this Front of Deck needs to be 7 8 to 15 16 To get this Door Opening height adjust the two jam nuts by the buck plate Once the required distance is achieved place thread locking com FIGURE 91 pound on the threads and lock the two nuts t
138. m Hex head on Later Version 1 2 on early models located on each Valve Section See Figure 19 The other person will operate the Joystick from the Operators Seat If Manual override is not moving check the electrical connections Manual Override Control use 9mm Hex Head Wrench FIGURE 19 While the malfunction is occurring one person should actuate the Joystick while the other observes the manual override control for that specific function See Figure 19 The Manual Override control should move in relation to the move ment of the Joystick movement Each Valve Section will have one of these Hex Head Overrides 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 56 TROUBLE SHOOTING TESTING ISOLATION TEST 2 This Procedure applies to Units utilizing the Late Model Control Valve Assem blies used 1998 and up Re check to make sure all fluid levels are OK The Control Valve Cover should still be removed Make sure that the Tractor Transmission is in Neutral and the Park Brake is set and Holding Test Park Brake before continuing Make sure that Boom and Cutting Head are resting on the ground Locate the manual override control on Control V
139. maged 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 left in Tank or fallin 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 Machete Service Manual 04 04 2004 Alamo Group Inc 172 POSSIBLE FAILURE CAUSE amp SOLUTION Pump Wear Rapid Excessive Wear CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION 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 component including your source of replacement Oil Supply The Contaminants must be found and completly removed and stopped The Solution is to repair or replace worn parts Completly Flush and
140. mbly or Solenoid Servo Assembly 1998 amp 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 amp Down Refer to Appendix B for Dis Assembly and Inspection of Control Assembly 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 required Lift and remove the Housing and Shaft from Rotating Kit Assembly and Camplate Machete Service Manual 04 04 2004 Alamo Group Inc 72 PUMP DIS ASSEMBLY Remove Camplate from rotating kit Assembly and Servo Piston follower from Camplate Refer to Appendix C for dis assembly and inspection of Rotating Kit Camplate Inspection The Finish on the Piston Shoe Surfaces of the Camplate should show no signs of scoring atall Inspect Camplate Bushing surface for wear and surface for coating transfer from Bushing To remove Servo Piston Assembly from Housing start with the four bolts and washers retaining each cover plate In removing the Cover Plate from the Servo Piston Bolt Remove Jam Nut Washer and Seal Washer H
141. me 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 saa CAUSE Restrictions in System A Squeal 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 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 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 P
142. me Unit has been running Position of Joystick before and during malfunction Position and Condition of Tractor Any other condition you might notice 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 when the malfunction occurred ISOLATION TEST 1 This test must be performed while the malfunction is occurring This Test is used when one or more functions are inoperative either constant or intermittent This procedure applies to units utilizing a general application Read directions as to which series of Valve there are early model versions and late model versions The following is for the late model version Machete Service Manual 04 04 2004 Alamo Group Inc 95 TROUBLE SHOOTING TESTING ISOLATION TEST 1 Continued from previous page 2 Re check to make sure all fluid levels are OK The Control Valve Cover should still be removed Make sure that the Tractor Transmission is in Neutral and the Park Brake is set and Holding Test Park Brake before continuing Make sure that Boom and Cutting Head are resting on the ground With the help of an assistant One Person stand outside the Tractor in a position to observe the Manual override control which is 9 m
143. menentary Push Button Switch S N MB21 01001 to MB21 01107 S N MB24 01001 to MB24 01045 Bat Start AD R g Tractor Starter Ign at amp Soleniod e Start ZOOM 9 N B Tractor Key Switch Ignition Side 12 Volt Supply 12 Bowrn 12 Brown Tractor Key Switch MOTOR CIRCUIT 10 Anp Fuse 16 Red N C gt N C N O N O Push Pull Shown in Normally Closed Position Pushed In N O Momentary Switch 16 Yellow 16 Black 16 Black Hold Coil MEN Piston Pump Solenoid 10 AMPs Max Pull Coil FIGURE 36 Machete Service Manual 04 04 2004 Alamo Group Inc 85 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 Mater Mower Push Pull Push Pull Ign Bat add Mud CN E NS AL p 12 AMPS Mower Solenoid Tractor Starter amp Solenoid FIGURE 37 Machete Service Manual 04 04 2004 Alamo Group Inc 86 MOTOR ELECTRICAL CONTROL Current Model Machete Motor Circuit Wiring Schematic w 1 Push Pull Switch amp 1 Lighted Rocker Switch S N MB21 01482 amp Up S N MB24 01053 amp Up Ign Bat Push Pull Momentary Control Switch Green indicator Power On Master Rocker Switch A Red Indicator Mower On Mower Solenoid Tractor Star
144. mm Long Rotating Kit Asy Servo Piston Asy Servo Piston Follower Cover Plate Gasket Cover Plate Gasket Housing Gasket Control Housing Used 1997 amp Down Gasket Solenoid Servo Asy Used 1998 amp Up Cover Plate Camplate Thrust Race Thrust Bearing Relief Valve For Port C O Ring 097 Dia X 755 ID 2 46 mm Dia X 19 18 mm ID Relief Valve For Port D O Ring 097 Dia X 755 ID 2 46 mm Dia X 19 18 mm ID Bolt 3 8 16 X 2 1 4 57 2 mm Long Bolt 3 8 16 X 3 1 5 88 9 mm Long Bolt 3 8 16 X 4 101 6 mm Long Bolt Valve Plate Housing Asy Includes Following Items Housing Only Bearing Press Fit Plug Sub Asy O Ring 064 Dia X 239 ID 1 63 mm Dia X 6 1 mm ID Cradle Sub Asy Dowel Bushing Bushing Bolt Button Head Bolt Seal Sub Asy Back Plate Asy Bearing Press fit 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 Machete Service Manual 04 04 2004 Alamo Group Inc 69 PUMP PARTS LOCATION Inner Gerotor and 11 tooth Coupler 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 70 PUMP PARTS LOCATION Description Drive Shaft O Ring
145. motor that are screwed on to Motor Hold Down Tie Rods See Figure 86 It may be required to hold Ties Rods This can be done with a Pipe Wrench or other round surface gripping Tool On Older Models remove the four Bolts in the Center of the Motor Hold Down Plate On Later Models the four Bolts are in a recess under Hold Down Plate and are not visible till Plate is removed On the later models these four Bolts will not have to be removed These four bolts hold Valve Block on top of Motor After you Lift the Hold down Plate off you will need to secure this Block to the top of Motor with alternate Bolts or it will fall off on older Models USE EXTREME CAUTION when removing Valve Block make sure no foreign material gets into Ports Also All O Rings and Back Up Rings will have to be replaced if this Valve Block is taken loose See earlier steps about cleaning Remove the four Bolts that Retain Motor to Spindle Working Motor side to side lift it away from Spindle If the Head is standing up on 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 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 de
146. move Wiper Seal item 16 with Screwdriver Remove Set Screw item 13 retaining Input Shaft item 14 and remove it from Control Housing 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 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 Valve Spool Remove Valve Spool item 7 from Housing after Step 5is 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 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 MANUAL SERVO CONTROL RE ASSEMBLY Used 1997 amp Down The following instructions apply to Manual Servo Control Re Assembly See Figure 32 Clean Make Sure that every thing Parts Tools Work Bench Vise and all general conditions are very clean
147. n With Tractor Ignition 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 available to 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 felt or seen in the System trying to run but having to bypass Sometimes the Spindle is not seized but only tight 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 M otor Ove r Heati n g 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 ab
148. n first then the Back Up Ring as shown in Figure 76 Install the Square Cut Ring in Low Pressure Port of Valve Block Note DO NOT damage O Rings and Back Up Rings Use clean Petroleum Jelly to hold O Rings in place during block Installation Install Valve Block on End Cover install four Hex Hex Bolts and Torque them 28 ft Ibs 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 110 MOTOR P N 02967193 TORQUE SPEC S TORQUE SUMMARY SPECIFICATIONS Component Where Used Model C I D 3 3 3 9 4 6 C I D 5 4 6 4 C I D End Cover Bolts 39 ft Ibs 53 nm 63 ft Ibs 85 nm Gauge Port Plugs 25 ft Ibs 34 nm 25 ft Ibs 34 nm Relief Valve Low Pressure 75 ft Ibs 100 nm 75ft Ibs 100 nm Relief Valve High Pressure 25 ft Ibs 34 nm 25 ft Ibs 34 nm Relief Valve Feathering 25 ft lbs 34 nm 25 ft lbs 34 nm Shuttle Valve Cap 68 ft Ibs 92 nm 68 ft Ibs 92 nm Socket Pipe Plug 16 ft Ibs 22 nm 16 ft Ibs 22 nm Swash Plate Cap Screws 24 ft Ibs 32 nm 24 ft Ibs 32 nm Swash Plate Retaining Strap 19 ft Ibs 26 nm 26 ft Ibs 26 nm Valve Block Mountin Bolts 28 ft lbs 38 nm 28 ft lbs 38 nm MOTOR TOOL DESCRIPTION SHAFT BEARING CONE DRIVER End Cover End SHE Begrees Knurl 2 00 from End N
149. ncrease 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 Machete Service Manual 04 04 2004 Alamo Group Inc 163 POSSIBLE FAILURE CAUSE amp SOLUTION Hydraulic System Overheating continued CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION 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 entrained 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 Test System for excessive Pump and Motor Wear or Cavitaion by running Pressure and flow Test Repair or Replace as required Engine RPM Too High Run Tractor Engine at required Speed to achieve GPM through Pump See Specifica tion Section in Repair Manual Malfunctioning Valves Main Relief Priority Valves a
150. nd Logic Valves 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 Operational Problems Cutting Excessively Heavy Material Traveling to Fast for Conditions Improper Cutting Height Make sure Cutting Heightis not solow Blades are hitting Ground Make sure that Travel Speed 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 running 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 SOLUTION CAUSE Insufficient Support on Upper End of Motor 1 Make sure that the Motor Plate is installed on top of Motor and t
151. nded maximum Mower Head Functions Mower Head Functions are operated by Pump which is mounted to the front of the Tractor Engine This will have an inline Filter installed into hydraulic circuit 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 10 SPECIFICATIONS MACHETE 4 HYDRAULIC PUMP CIRCUIT Pump Type Pump Speed Front Engine Mounted Relief Setting at the Pump Pump Flow Front Engine Mounted 1950 RPM Oil Operating Temperature Filter Discharge from Charge Pump Hydraulic Tank Capacity Hydraulic Oil Type Pump amp Motor Circuit Motor Start Stop Time Approximate HYDRAULIC CYLINDERS SPECIFICATIONS Hydraulic Cylinder Drift Rates Cylinder Function Piston Type 1950 RPM 100 deg F above Ambient Temp 10 Micron 17 Gallons ISO AW 100 HYD OIL 6 Seconds Time 8 0 minutes 7 1 minutes Tilt w hyd lock closed No Drift Tilt w hyd lock open 5 8 minutes Measured Cylinder Drift Rates are measured as the amount of time required for the rod to move 1 The times shown represent the nominal times for a new machine The times should be expected to decrease somewhat over time Drift rates exceeding the times given meaning that it takes LESS time for the Rod to move 1 may indicate a le
152. ne 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 must only contact the inner edge of the bearing See Figure 40 at the end of this section for tool dimensions Figure 18 2 Install Bearing Cups into Bearing Hous ing This will need to be done if the bearing cups were removed Install bearing cups 1 2 of item 20 into Press Bearing housing using a press and tube that is 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 Installthe Shaft Assembly Shaft Gearand Bearing into the Bearing housing Slide the Lower Bearing Bearing cone down over Shaft You will need to support shaft Housing while pressing Bearing Cone onto shaft make cer tain to support it with something that will not damage itor get contamination on it Using a tube and a press to push bearing down untilitis seated in Bearing cup Press Bearing Cone on until the proper Bearing Figure 19 preload is achieved Proper Bearing Preload is the removal ofthe slackin the bearing remove end play 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 Spa
153. nes utilize a Solenoid Valve with a single Coil instead of the earlier arrange ment No Momentary Switch is required The Push Pull Switch also acts as a Neutral Start Switch for the motor Circuit The starting Circuit of the Tractor is wired through the Switch so that the Starter Circuit is open when the Motor Circuit is Closed preventing the Operator from starting Tractor while the Motors engaged Current Model Machetes FIGURE 36 w 1 Push Pull Switch amp 1 Lighted Rocker Switch The Cutting Head Hydraulic Motor circuit is engaged by actuating a Push Pull Switch with a built in Momentary Switch The Momentary Switch is actuated by pulling up on Pull Knob after Push Pull Switch has been turned on This is a Spring loaded start and will pull it self back in when released ID Early Model from Late Model 1 Look at Type Switches mounted in Joystick Console 2 Push Pull Switches is Early Old Model and 1 Push Pull Switch with 1 Lighted Rocker Switch is Later New Model 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 UJ FIGURE 35 Lj Later Model Pump Solenoid 3 Wire Plug Corrent Model Pump Solenoid 2 Wire Plug Machete Service Manual 04 04 2004 Alamo Group Inc 84 MOTOR ELECTRICAL CONTROL Early Model Machete Motor Circuit Wiring Schematic w 1 Push Pull Switch amp 1 Mo
154. ng driver to Motor install bearings on motor shaft B Port Relief Seal Carrier Diminsions Remove Old Seal From A Seal Carrier carefully as B shown o Figure 40 2 91 0 04 2 75 2 441 008 0 Machete Service Manual 04 04 2004 Alamo Group Inc 130 King Pin Replacement Section Machete Service Manual 04 04 2004 Alamo Group Inc 131 KING PIN REPLACEMENT King Pin Replacement Procedure Caution Care must be taken when removing and replacing the KingPin to prevent damage to the King Pin Bushings When the Pin is properly aligned it should slide easily in through the Bushing DO NOT align the holes by driving the Pin with a Hammer this will destroy the Bushings NEVER check Hole alignment with your Fingers at any time this would be very dangerous to check alignment on anything that might possibly slip with your fingers in it you could be injured ONLY CHECK alignment of Holes with your EyeSight Tools Required Recommended Combination End Wrench 1 ea 1 2 and 2 ea 3 4 Pry Bar Flat End Hammer 2 approx Over Head Hoist Floor Jack 1 Ton or Larger Support Stand Large enough to Support Boom Procedures 1 Clean all components of Boom and Tractor Remove all Dirt and any other material that may contaminate components as being dis asembled or when dis assembled Move Tractor to Level and Firm Ground Concrete Floor is Best Swing the Boom t
155. nk 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 spoolis 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 thatthe 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 29 CONTROL VALVE HYDRAULIC FIGURE 14 Manual Control Handle f Illustration NS RAW Onl IW Sse y eot LY 25 2773 om n SEN CEN LEA 3 Dr HH 64 RAV IGFEENRY 14 15 16 Description Description Pressure Relief Pilot Pressure Flow Pilot Reducing Valve Anti Cavitaion Work Port Relief Valve Load Sense signal Pilot Pressure Control valve Pressure Gauge Port Main Spool Position Transducer Signal From Joystick Shuttle valve Orfice Closed Center Segment Compenstaion Spool Plug Open Center Pressure Port Pressure Bypass Adj
156. ntinued 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 reliefs item 29 amp 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 Inspectall assembly steps done and make certain every thing is clean all opening should be plugged and remain plug until hoseconnections are attached 20 If only replacing Seal as a repair See Figure 8 amp 9 in disassembly section and Figures 24 25 26 amp 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 Figure 36 Machete Service Manual 04 04 2004 Alamo Group Inc 129 MOTOR P N 02979881 ASSEMBLY Motor Assembly Continued A Port Relief Pressure To Motor P d This tool can be machined from Return d rom tubing to create a beari
157. ntrol Valves return to their normal positions and the flow of Pilot Pressure Oil to the Main Spoolis 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 33 CONTROL VALVE LOAD SENSING Pressure Relief Pilot Reducing Valve Return to Tank T Pump Pressure P Load Sense Signal to Pump Valve is Shown with Valve Function N Ne N s p R Activated G i l N N i S Load Sense p Signal WM p AN e Position Signal inii a Plug Pressure Bypass Closed center Adjustment Spool Pilot Pressure Oil Anti Cavitation Work A Port Relief Valve Mechanical Flow Limiters mU oe Rc EE DADA el l Main Spool Segment Compensation Spool This is internal passage in Valve FIGURE 16 Shown on outside for illustration only MACHETE Service Manual 04 04 2004 Alamo Group Inc 34 CONTROL VALVE FIXED DISPLACEMENT GENERAL INFORMATION Fixed Displacement Valve The Fixed Displacement Open Centered Systems Control Valve is designed to be used on tractors that DO NOT have Load Sense Closed Centered Hydraulic Systems ENGINE RUNNING AND ALL FLOW CONTROL VALVES CENTERED See Figure 17 Oil from the Pump enters the Control Valve at
158. nts 1 Pressure Bypass Adjustment Spool Pilot Reducing Valve 3 Pressure Relief Valve Load Sense Passage Outer Plug 5 Load Sense Orifice LOAD SENSING VALVE END CAP Pressure Relief P Pilot Reducing Valve Tank Port T A Pressure Port P UF Pressure Gauge Port N d q Orfice z dy iod Wj NA FIGURE 12 aig y A Load Sense Signal l Plug Pressure Bypass Adjustment Spool The Load Sensing Valve Closed Center Version An Orifice with an Outer Plug are used in place of the Plug which was used in the Fixed Displacement Open Center Version Therefore the Pressure Adjustment Spool will only open to Tank when the Pressure in the Pressure Port P exceeds the value of the Pressure relief The Load Sense Signal or Load Pressure is led to the Tractor Pump Regulator via the Load Sense Connection In the Neutral Position the Pump Control sets the Displacement so that leakage in the system is compensated for and the Standby Pilot Pressure is maintained approx 200 to 250 PSI When a Main Spool is activated The Pump Regulator will adjust the displacement so that the set differential pressure between the Pressure Port P and the Load Sense Signal pressure is maintained MACHETE Service Manual 04 04 2004 Alamo Group Inc 28 CONTROL VALVE HYDRAULIC CONTROL VALVE COMPONENTS Valve Section Components Eachofthe 5 Valve Sections Figure 13 amp 14 contains the following Components Note Handles
159. o the Side of the Tractor Extend Boom out till fully extended With head still attached to Boom Head helps to stabilize Boom laterally sit Boom Down till Head is flat on the floor Make Sure to relieve all pressure from Cylinders Fully apply the Park Brake on Tractor Place all Gears in Tractor in the Neutral Position Shut Off Tractor remove Key and disable Tractor so it cannot be started till you are ready to have it started Support the Boom with a suitable Hoist Attach Hoist as shown in Figure 80 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 132 KING PIN REPLACEMENT King Pin Replacement Procedure Procedures Continued Make Sure that all pressure has been released from Hydraulic Cylinders before disconnect ing any Hoses or removing any Pins Remove Top retaining Pin from the Lift Cylinder See Figure 80 Once Cylinder has dropped down at top from Pin remove Bottom Cylinder Pin to Move Cylinder Out of way If dis connecting any hoses or Fittings always clean around them first Plug all hoses and Fittings to keep clean Using the Hoist apply enough Pressure to support Boom Set Safety Support under Boom Remove the Boom Pivot Pin See Figure 80 and lift Boom up above Turning Arm Re
160. of Lugs place a side load on Rods that can cause them to bend Usually this alignment is noticeable Work Port Relief Malfunction 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 Reliefs are installed correctly and in the proper places Interference with Another Part of Component Repairor 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 Out of Cylinder CAUSE SOLUTION CAUSE SOLUTION Piston Nut Backed Off of Rod 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 ithas been operated while Nut was loose Wrong Nut On Rod 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 159 POSSIBLE FAIL
161. ogether See FIGURE 92 Machete Service Manual 04 04 2004 Alamo Group Inc 143 SPINDLE MOTOR PLATE 7 8 to 15 16 6 Check to make sure the Flat washer is not contact ing the bottom of the mount plate There should be a 1 4 gap between the Flat Washer and the mount plate See FIGURE 93 Front of Deck Place Thread Locking Door Opening Compound on the threads and install the Hardened Locktite Threads Jam Nuts amp Flat Washers and Toplock amp the 2 Nuts Hardened Nuts Torque these Nuts to 100 Ft Lbs in three in ees n z Flatwashers crements and following the fg ii positions 1 through 4 Hardened JT x Example torque to 35 ft Flatwasher amp Top Loctite amp Torque Ibs 70 ft Ibs then to 100 Lock Nuts to 177 ft Ibs ft lbs Re check torque val ues after reaching the final FIGURE 92 torque See FIGURE 94 Jam Nuts amp Hardened Flatwashers Place Thread Locking Compound on the threads and run the Hardened Flat Washers and Jam Nuts up tight against the bottom of the Mount Plate Lock Jam Nuts together See FIG URE 95 Place Loctite on Threads Top Lock Nut amp Hardened amp Torque to 100 ft Ibs Place Flatwasher Locktite on Threads amp Lock Jam FIGURE 94 FIGURE 95 Machete Service Manual 04 04 2004 Alamo Group Inc 144 Possible Failure Cause and Solution Section NOTE This Section is written to give a POSSIBLE CAUSE ofa prob
162. old the Servo Piston Plate with Hex Key and unscrew Cover Plate off Bolt Remove Servo Piston Assembly and Seal Sub Assemblies Two Sets from Housing Note Dis Assembly of Servo Assembly is not required 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 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 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 Remove Button Head Bolts to remove Bushing from cradle Bushing Inspection Inspect bushing for contamination embodiment within Coating of Bushing surface coming in contact with Camplate Remove All Plugs from Housing This for inspection to make sure contamination is not caught under plugs or in passages 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 73 PUMP RE ASSEMBL
163. olts Torque these Bolts to 40 to 48 in Ibs 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 Bolt on 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 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 Ibs 1 6 to 1 8 nm 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 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 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 To Install Rotation Kit Assembly Leave Housing and Shaft in the Horizontal position Holding Camplate into position with Screw Driver through Controlle
164. olts and screw them in where you removed the 2 retaining bolts This will support Blade carrier while 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 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 itthe 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 2 Short and 2 Long Torque 2000 ft Ibs Middle Blade Bar I gt Blade Bolt Nut Washer gt E bet amp Roll Pin E a non Le Torque 400 ft Ibs Blade Bar Retaining Bolts and Washers Torque 400 ft lbs FIGURE 85 Blade Bolt Machete Service Manual 04 04 2004 Alamo Group Inc 138 SPINDLE REPAIR Procedures Remove Motor and Spindle Remove the Motor Hold Down Tie Rod Nuts on the Top side of
165. orts 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 75 PUMP RE ASSEMBLY 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 Ibs 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 amp Down Units 1998 amp Up have Solenoid Servo Manifold Assembly to install here Retain Servo Control Assembly with six Bolts Torque these Bolts to 40 to 48 in Ibs 4 5 to 5 4 nm Install Control Arm Only applies to units 1997 amp Down with Manual Servo Control Install
166. otor Plate Removal Rotary Head Motor Removal Rotary Head Spindle Dis Mount from Deck Rotary Head 86 Spindle Dis Assembly Spindle Re Assembly Spindle Re Mount to Deck 143 thru144 Motor Plate Installation 143 thru144 VALVE 5 SPLSpecific Section Operation Components 27 thru 30 Hydraulic LocK Valve Operation 32 thru 38 PartNumbers 40 thru 51 56 thru 60 WIRING SYS Harness Schematic Joystick End 23 thru 24 Harness Schematic Vlave End Harness Valve Plug Old Style Harness Valve Plug Old amp New Style Control Valve Wiring Plug Pin Location Machete Service Manual 04 04 2004 Alamo Group Inc 7 Machete Service Manual 04 04 2004 Alamo Group Inc Specifications Section Machete Service Manual 04 04 2004 Alamo Group Inc 9 SPECIFICATIONS MACHETE 1 Cutting Circuit Specifications Hyd Pump Speed Front Aux Pump 1950 RPM Hyd Motor Speed 1220 RPM Hyd Motor Rated 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 Hyd Oil Operating Temperature 95 Deg F Above Ambient Hyd Oil Filtration Discharge f Charge Pump 10 Micron Hyd Tank Capacity Hyd Motor Circuit Oil Type ISO AW 100 Hyd Oil Hyd Motor Start Stop Time Approximate 6 Seconds Cutting Diameter Rotary Head Spindle 4 5 by 9 Heat Treated Alloy Bla
167. ove 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 Machete Service Manual 04 04 2004 Alamo Group Inc 165 POSSIBLE FAILURE CAUSE amp SOLUTION Motor Over Heating continue CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION 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 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 Engine RPM Too High Run Tractor Engine at required Speed to achieve GPM through Pump See Specification Sect
168. perly 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 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
169. r USE CAUTION Internal Parts are Spring Loaded To avoid internal Part Damage Slowly Alter nately from one bolt to the other loosen the remaining 2 Bolts Holding Pressure down on End Cover Slowly remove the other 2 bolts KEEP PRESSURE on End Cover With pressure on End Cover start to release pressure and End Cover should start to rise If it doesn t rise Keep your hand on it and tap it with a hammer lightly to loosen it up from housing Let End Cover rise till there is no Pressure pushing up Remove End Cover 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 101 MOTOR P N 02967193 DISASSEMBLY Motor Dis Assembly GENERAL RULES 1 DONOT Dis Assemble anything till everything has been thoroughly cleaned 2 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 DO NOT SPIN BEARINGS WITH COMPRESSED AIR WHILE CLEANING All Torque specifications are for Clean Good Un Damaged threads Bolts for Gasketed Surfaces should be re torqued a second time Replace All Seal with new ones whenever unit is dis assembled always lubricate Seals except metal
170. r Linkage passage way at the top ofthe 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 Install Gasket on Housing Install New Gasket on Housing now 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 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 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 Apply a small amount of Petroleum Jelly to the Steel Side of Valve Plate to hold itin place for installation Aligning the Index Pin Place the Valve Plate in position onto the Back Plate with the Steel side against Back Plate Install Back Plate Assembly into Housing Assembly Make sure P
171. r Torque Settings and more detailed Assembly instructions See Previous Page Figure 44 45 and 49 on Dis Assembly more details on the End Cover FIGURE 56 Gauge Port Machete Service Manual 04 04 2004 Alamo Group Inc 100 MOTOR P N 02967193 DISASSEMBLY End Cover Standard End Input Cover Shown Rotation Rotation Bearing Shim Bearing Cup Valve Plate lt FIGURE 58 peo Dowel Pins VALVE PLATES Helpful Hint Motor Bearing Cone Shown above Figure 58 is Pump Housing et and Motor Valve Plates for comparison 5 Pump Valve Plate Left has two Meter ing Slots and is Directional Which is Clockwise The Motor Valve Plate Right is bi directional and has four Metering Slots Which allows for Clockwise or Counter Clockwise Rotation Make sure correct Valve Plate is installed in Motor or Pump HANDLE VALVE PLATES amp BEARING PLATES with extreme care Both Plates are lapped to extremely close FIGU RE 57 tolerances for flatness END COVER DIS ASSEMBLY Figure 57 On Standard Motor or Integral Shuttle amp Low Pressure Relief Valve End Cover 1 There are two different End Covers for this Motor The Same procedure to remove the either the Standard End Cover or Integral Shuttle with Low Pressure Relief Valve End Coverfrom the Motor is the same Check which one you have See Figure 57 or Figure 56 Remove 6 of the 8 Hex Bolts from End Cover leave 1 tight at each end of cove
172. rds 4 9 Cu In Rev 5 200 rp 4 000 rp 50 rpm 94 ft lbs at 1450 psi 453 ft Ibs at 6960 psi 110 gpm 85 gpm 6960 psi 6100 psi 145 psi at 1500 rpm 18 13 ISO Code 4406 57 lbs 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 the 50 inch only at this time March 2004 This is a high Torque Motor with heavy duty roller bearings See Figure 1 below for component location Barrel Housing Valve Plate Cylinder Barrel Piston with Piston Ring Timing Gear Tapered Roller Bearing Bearing Housing Shaft Seal Output Input Shaft Figure 1 Motor Assembly Machete Service Manual 04 04 2004 Alamo Group Inc 119 MOTOR P N 02979881 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
173. 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 reqiured 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 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 or equivelant Listen to the Valve Body next to the Work Portthat 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 Machete Service Manual 04 04 2004 Alamo Group Inc 149 POSSIBLE FAILURE CAUSE amp SOLUTION Cylinder Excessive Drift continue CAUSE Leak
174. rench Drive Light Petroleum Jelly Vaseline Locktite 222 and 277 or equivalent Qty 1 tube each Machete Service Manual 04 04 2004 Alamo Group Inc 62 PUMP REPAIR TOOLS RECOMMENDED GAUGES FOR DIAGNOSTICS Inlet Vacuum 30 PSI to 30 in Mercury 207 bar to 0 bar System Pressure Gauge 6 000 PSI 700 bar Charge Pressure Gauge 0 to 500 PSI 0 to 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 number by 10 to get the Valves pressure settings Example 500 stamped in valve is 10 X 500 5000 PSI 345 bar Later Models Lever not Used Replaced by Block w 2 wire Charge Pump Suction Port Electric Solenoid Not Shown m E Vacuum Pressure Ports Tee in Line to Check System Pressure Auxillary Port Check Charge Pressure Drain Port Tee in Line to Check Case drain FIGURE 24 Machete Service Manual 04 04 2004 Alamo Group Inc 63 PUMP CIRCUIT MOTOR ENGAGE Note The Servo Control Valve Lever and Solenoid have been replaced by a
175. ressure is Low remove Relief Valve and inspect for damaged Seals Contamination or other abnormali ties Re Seal Adjustorreplace 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 Machete Service Manual 04 04 2004 Alamo Group Inc 161 POSSIBLE FAILURE CAUSE amp SOLUTION Hydraulic System Noise continued CAUSE Cavitation Cavitation is caused by inadequate amount of fluid reaching the Pump Cavitation will damage Pump so do not run with a Cavitation problem 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
176. riod 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 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 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 Eng
177. roblem 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 147 POSSIBLE FAILURE CAUSE amp 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 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 If the 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 t
178. roup Inc 105 MOTOR P N 02967193 ASSEMBLY BEARING CONE OUTPUT SHAFT ASY amp CYLINDER BARREL amp SWASH PLATE RE ASSEMBLY After checking fixed clearance continue with assembly of Cylinder Barrel Swash Plate Apply 1 or 2 drops of Loctite No 271 or equal in first and second thread in each of the four holes Figure 67 CAUTION Loctited parts must contact only those surfaces intended for assembly Wipe any excess Loctite from Swash plate with Non Petroleum Base Solvent applied to a Lint free Cloth DO NOT apply Loctite to threads more than 15 minutes before installing Cap Screws If Locktite stands for more than 15 minutes Repeat Loctite application It will not be necessary to remove previously applied Loctite Lightly lubricate and then install Thrust Plate Aligning Cap Screw Holes Install Spacers retaining strap and Cap Screws on one side of the Swash Plate DO NOT tighten Cap screws at this time Figure 68 Apply Loctite 4 Threaded Holes FIGURE 67 FIGURE 68 Place Cylinder Barrel Assembly on Clean Flat Surface with Piston Slippers pointing upward Carefully install Swash Plate on Cylinder Barrel by slightly lifting side without Retaining Strap Slide Swash Plate over to engage installed Retaining Strap Slide Swash plate over to engage installed Strap around Piston retainer Carefully reposition Cylinder Barrel and Swash Plate with Swash Plate in down position Install remaining Spacers
179. rt 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 torque to correct specification 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 if using a SemiLiquid 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 Torque Values Machete Service Manual 04 04 2004 Alamo Group Inc 150 POSSIBLE FAILUR
180. s 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 Remove 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 Machete Service Manual 04 04 2004 Alamo Group Inc 169 POSSIBLE FAILURE CAUSE amp SOLUTION Motor Runs Too Slow continued CAUSE Excessive Internal Leaka
181. 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 Stripe DO NOT remove these bands unless you replace them All Bands with Solid Colors connect to Rod End of Cylinder All Bands with Stripes connects to Butt End of Hydraulic Cylinder or connections leading to them AlwaysCheck Hose Size amp Color Code Color Color Tie Hose Hydraulic Tie Abbreviation Size Connection Orange OR Medium Lift Cylinder Rod End Orange OR Large Return Flow from Motor Orange White Stripe OR W Medium Lift Cylinder Butt End Green G Medium Swing Cylinder Rod End Green White Stripe G W Medium Swing Cylinder Butt End Blue B Medium Dipper Cylinder Rod End Blue B Large Case Drain for Motor Blue White Stripe B W Medium Dipper Cylinder Butt End Red R Medium Tilt Cylinder Rod End Red R Large Pressure Flow to Motor Red White Stripe R W Medium Tilt Cylinder Butt End Yellow Y Small Door Cylinder Rod End Yellow White Stripe Y W Small Door Cylinder Butt End 7 VALVE SPECIFICATIONS Valve Type Electrically controlled Pilot Operated 5 Spool Proportional Control Valve Available as Closed Center Load Sense CCLS or Open Center Fixed Displacement OCFD Option depending on Requirements of Tractor Model Series Valve Construction Individual Spool with Tie Rod Bolt together type Valve Controller Electrical Joystick Reaction Time 300 Milliseconds Voltage Rated 12 Volt wit
182. sealing surfaces of Shaft Seal Assembly with Petroleum Jelly Vaseline Use only clean recommended Oil when Re Assembling Motor SHAFT SEAL REMOVAL See Figure 47 Use a Pair of Retaining Ring Pliers to remove Retaining Ring Figure 47 Insert Stationary Seal Puller into threaded hole of Stationary Seal Assembly to pull Seal Assembly from Output Shaft Figure 47 Use Rotating Seal Puller Qwatonna Tool Company Tool No CAS 1844 to grip outside diameter of Bronze Rotting Seal Remove Seal from Output Shaft O Ring may remain in Rotating Seal Recess If O Ring is not found in Recess Remove O Ring from main 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 SS eut Staionary Seal Assembly l Rotating Seal Retaining Ring d P FIGURE 47 Pliers Puller Bolt 1 4 20 a i le M 5 Machete Service Manual 04 04 2004 Alamo Group Inc 102 MOTOR P N 02967193 DISASSEMBLY BEARING CONE OUTPUT SHAFT CYLIN DER BARREL amp SWASH PLATE DIS ASY Bearing Puller and Special Tool Low Clearance Bearing Puller Use of Low Clearance Bearing Puller is recommended for removal of end Cover Bearing Cone Figure 59 The Bearing Puller pulls against Bearing Rollers Not against Inner Race It is designed to pre vent Bearing Cone and Cylinder Barrel Face from being damaged Close clearance
183. sed 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 830 372 2708 Machete Service Manual 04 04 2004 Alamo Group Inc 3 INDEX REPAIRS INTRODUCTION SPECIFICATION Boom Specifications Cutting Circuit Specifications Filtration Specifications Hydraulic Cylinder Specifications Hydraulic Hose Specifications Hydraulic Hose Torque Specifications Hydraulic Pump Specifications Hydraulic Valve Specifications General Speceial Torque Specifications BLADEBAR Blade Bar Assemble amp Dis Assemble Blade Bar Torque Specification Blade Bolt Torque Specifications Blade Bar Installation Instructions KING PIN 132 thru 135 Tools Required List Recommended Tools ToolDescription King Pin Removal Procedure 132 133 134 King Pin Bushing Replacement 134 135 61 thru 82 Pump Charge Pump Adapter Asy Pump Dis Assembly Instructions Pump Introduction Pump Manual Servo Control Asy Pump Motor Engage Requirements Pump Motor Dis Engage Requirements Pump Parts Location Pump Re Assembly Pump Rotaiting Kit Asy MOTOR CIRCUIT 83 thru 94 Motor Electrical Control 84 85 86 87 88 Motor Pump Actions 89 90 91 Motor System Schematic MotorShuttle Valve Location Motor Service amp Repair Motor Component Torque Specification Motor Dis Assembly Machete Service Manual
184. should only be connected to a Wire that has Voltage when the ignition is in the On Position If Connection of the Joystick Controller is to a constant current source it will cause power drain on Battery and eventually Battery Failure Furthermore the Master Switch on the Joystick Console Figure 5 must be in the On position to allow for the operation of any of the Control Functions To achieve Electrical Proportional Actuation The main Spool Position is adjusted so that it corresponds to an Electrical signal sent from the Joystick Controller The Position of the Joystick is Electrically sensed by a Coil and Magnet located in the Joystick Assembly which sends the positioning information to the electric controller in the Valve The Signal from the Joystick is converted by the electronic Controller into Hydraulic Pressure by activating a series of Hydraulic Valves These Valves direct the Standby or Pilot Pressure Oilto the proper end of the Spool to cause it to move Likewise the position of the Spool is converted in the Spool position transducer to feedback signal This Signal is registered by the electronic controller which will activate the series of valves as needed to move the spool in either direction until the spool is positioned in accordance with the location of the Joystick An equilibrium between the Joystick and feedback signal is the end result Electric Signal for Joystick Controller Pilot Pressure Control Valve A Segment X EN Handle
185. t bulb into it If doing a lot of testing might want to consider making one for each connection By making this type tester you will be able to test the positive and negative connection at the same time and this would allow the test to be performed by one person and decrease the chance of making a connection wrong A normal 12 volt test Light can be used as shown in Figure 23 but this method normally requires two people to perform and Test Light Must be connected correctly lt gt FIGURE 22 Disconnect the Wiring Harness Connector at Valve for the inoperative Circuit at the Valve Solenoid Connection Connect the Test Tool you built or 12 Test light to the Harness end of the connector If using a test light to check a positive connection be sure to ground Test Light to a good ground connection if testing a Negative connection it would be required to reverse the to Connection See Figure 22 While actuating the Joystick Test for voltage at the connect if using Tool you Built the Bulb should light up or test light should light up If test light comes on then this circuit is OK If using a normal Test Light see Figure 23 both sides of connection will need to be tested this may require an assistant Connection for Testing Positive Side Shown Below WIRING HARNESS FIGURE 23 Machete Service Manual 04 04 2004 Alamo Group Inc 60 PUMP SECTION Machete Service Manual 04 04 2004 Alamo Gro
186. t if used bushing must be installed before it dries Cylinder Pin amp Boom Bushing Replacement The New Bushing will need to be driven in this must be done with a suitable Bushing Driver Alamo Industrial Bushing Driver 02972282 shown in Figure 82 Care must be taken when doing this to avoid damage to the Bushings and Bosses that Bushings are in The Boom Pivot Bushing should be driven in till the end no longer protrude past Hole Install the Top Bushing Th Wash NOTE Inspect the Fit between Flush with the Bottom of fusi vvaster the Bushings and the Frame the Frame Bore Bore The Fit should be a Press Fit Ifany looseness between the Bushing and frame is Observed Install the Bottom Or if the Frame bores are out of Bushing Flush with the D round further repairs may be necessary Contact Alamo In Toporine Frame Bore dustrial Customer Service dept Machete Service Manual 01 03 2003 Alamo Group Inc 134 KING PIN REPLACEMENT Install Turning Arm Put Turning Arm back on Mainframe using Hoist or suitable Jack to support and align Turning Arm DO NOT USE Fingers to align Holes Make sure Thrust Washer is on top between Turning Arm and Top Bore of Frame See Figure 84 Install Kingpin by moving Turning Arm back and forth to alleviate binding This can be done with a jack or hoist Blocks can be used to support Turning Arm to help with alignment there a numerous ways to align Turning Arm Pin should slide
187. t 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 ability of the Oil will be diminished Machete Service Manual 04 04 2004 Alamo Group Inc 173 POSSIBLE FAILURE CAUSE amp 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 N
188. t 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 be 25 in lbs of rolling Torque Install Tabbed Washer on to Spindle Inner tab in slot and Outer tabs facing up Before Installing Top Nut with chamfer on Nut facing down Make sure Shaftis locked Clamped so it willnot Turn in Spindle Housing Torque this top Nutto 100 ftlbs Bend the Tab of the Locking Washer to fit into one of the Grooves on top nut Recheck Rolling Torque of Shaft it should be 25 in Ibs Rolling Torque 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 Upper Bearing Tab Washer Adjusting Nut Oil Grease Relief Plug X 7 A A un Lower Bearing Upper Bearing Cup and Cone AY Adjusting Nut Oil Plug Grease Fitting Lower Bearing Cup and Cone i Spindle Shaft Lower Seal Spring around ID of Seal Lip Lower Seal FIGURE 88 Machete Service Manual 04 04 2004 Alamo Group Inc 141 SPINDLE INSTALLATION Procedures Install Spin
189. the Spring is the only factor determining System Pressure NOTE The Load Sense Passage shownin figure 17 is an internal passage inside of Valve and cannot be seen if looking at Valve It is shown here outside Valve as lllustration Only MACHETE Service Manual 04 04 2004 Alamo Group Inc 35 CONTROL VALVE FIXED DISPLACEMENT Pressure Relief Return To Tank T Load sense Signal MEM EGE Lee Segment Compensation Spool MACHETE Service Manual 04 04 2004 Alamo Group Inc idi o NE oks Pilot Reducing Valve Pressure From Pump P e A N le Pessure Bypass Adjustment Spool Anti Cavitation Work Port Relief Valve Mechanical Flow Limiters EEE SSS A SSS a Lnd ES Main Spool FIGURE 17 36 CONTROL VALVE FIXED DISPLACEMENT ENGINE RUNNING AND VALVE FUNCTION ACTIVATED See Figure 18 When a function is selected and actuated by the Controller The Proportional Control System directs the Pilot Pressure Oil to move the Main Spool in its bore Two actions resulting from the Main Spool Shifting in its bore now take place The Shifting Spool opens a Passage to connect one end of the selected Cylinder to the Pressure P Galley and connectthe other end to the Return T Galley The Shifting Spool also allows the Load Signal created by gravity acting on the Cylinder to connect to the Spring end of the Pressure Bypass Adjusting Spool This acts with the Spools spring to c
190. tor amp Solenoid FIGURE 38 Machete Service Manual 04 04 2004 Alamo Group Inc 87 MOTOR ELECTRICAL CONTROL Note The Servo Control Valve Lever and Solenoid have been replaced 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 39 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 its own Brake slowing down the Blades and 3 Less Fuel consumed due to No Load condi tion 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 Wires 2 Wire Control Relief Valve Line To Filter FIGURE 39 Manifold A Return From Filter Servo Port C Servo Piston SERVO CONTROLLED
191. ttle Valve Spring FIGURE 50 FIGURE 51 VALVE BLOCK RE ASSEMBLY On Standard Motor 1 Install 3 Gage port Plug Assemblies Torque Plugs to 16 ft Ibs 22 nm Figure 52 2 Install Shuttle Spool and Shuttle Valves in Valve Block Figure 52 3 Install Shuttle valve Plugs and Shuttle Valve Springs Torque to 68 ft Ibs 92 nm Figure 53 Shuttle Shuttle Valve Springs Machete Service Manual 04 04 2004 Alamo Group Inc 99 MOTOR VALVE BLOCK REASSEMBLY Install 2 High Pressure Relief Valves as Shown in Figure 54 Torque to 25 ft Ibs 34 nm Install Low Pressure Relief Valve as Shown in Figure 55 Torque to 75 ft Ibs 100 nm Install Valve Block back on Motor if this all that was being repaired or set it aside for now if more work is being done on motor Valve Block Valve Block Low Pressure Relief Valve Back Up Rings FIGURE 54 ir iQ FIGURE 55 Ring N Square Cut Ring INTEGRAL SHUTTLE LOW PRESSURE RELIEF VALVE END COVER RE ASSEMBLY e On Machete Motor See Figure 56 Low Pressure Shims Relief Valve i 1 Install Low Pressure Relief Valve Make sure to install the same amount of d End Cover Shims back into Relief Valve as was removed Shuttle 3 S Install Shuttle Valves in End Cover Valve Oe Install Gauge Port Plugs DO NOT TIGHTEN ANY of these components at this time unless this is all that is being repair If so go to Figures 75 and 76 later in this Manual fo
192. ult 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 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 155 POSSIBLE FAILURE CAUSE amp SOLUTION Cylinder Won t Move At All wo 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 amp 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
193. up Inc 61 PUMP GENERAL 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 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 SYTEM IF IT IS BEING WORKED ON ANY DIRT OR CONTAMINANTS IN SYSTEM 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 a
194. ustment Spool Mechanical Flow Limiters Plug 1 Main Spool Electric Controller Manual Control Handle illustration Only Spool Position Signal MACHETE Service Manual 04 04 2004 Alamo Group Inc 30 CONTROL VALVE LOAD SENSING GENERAL INFORMATION Load Sensing Valve The Load Sensing Closed Centered Systems are Commonly used on Tractors that may employ either Fixed Displacement or Variable Displacement Pumps The Load Sense Feature may control Pump Output or in the case of the Fixed Displacement Pump Simply control delivery to the control Valve returning surplus Oil to the tank The Goal of either System is to reduce wasted energy wear and tear from pumping Oil under Pressure when there is no demand on the system For the Purposes of this Manual A Load Sense System will be defined as any system that varies the Flow of Oil to Control Valve based on a demand signal sent through a separate Load Sense Circuit Closed Center System may or may not be load sensing systems ENGINE RUNNING AND ALL FLOW CONTROL VALVES CENTERED See Figure 15 Oilfrom the Pump enters the Control Valve atthe P Pressure Porton the Inlet Section End Cap and is available at each Flow Control Spool The Pilot Reducing Cartridge and the Main Relief Valve Oil flow is blocked by the Flow Control Spools The Proportional Control System Valves and the Main Relief Valves Pressure at Neutral will normally be referred to a Standby Pressure
195. ve 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 amp 3 allow Pilot Pressure Oil to flow to the corresponding end of the Spool Thus causing it to move Valves 2 amp 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 The Spool position Transducer sends an electrical signalto the Electronic Controller which indicates the position of the Spool 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 Reaction time from the time the Joystick is moved until the Spool moves is approximately 300 milliseconds The Rocker Type Switch on top of the Joystick is spring centered 3 function switch Figure 4 When used alone the Rocker Switch controls the Head Tilt function When used in conjunction with the Trigger Switch the Rocker Switch opens and closes the Door Both of these functions are NOT controlled Proportionally When the Toggle Switch is activated The electrical signal fully opens either Valve 1 or 3 and fully closes either valve 2 or4 in the correct Valve Section depending on which way the Spool needs to travel The El
196. ve 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 Machete Service Manual 04 04 2004 Alamo Group Inc 156 POSSIBLE FAILURE CAUSE amp SOLUTION Cylinder Won t Move Under Load moves siowy 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 amp 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 Impro
197. ve Asy 5 Spool Valve 5 Spool OCFD Adaptor Straight Adaptor Elbow 90 Adapter Straight Adaptor Straight Adapter Straight Adaptor Straight Adaptor Straight Adaptor Elbow 90 Deg Orifice 063 Orifice 070 Orifice 055 Solenoid Lock Valve Asy Electric Activation Module Electric Activation Module Seal Kit O Ring Mech Activation Module Coil Cartridge P49 og VALVE ASSEMBLY Z2 Current Fixed Displ SINMB21 Current P N 02976533 S NMB24 Current 4 5 11 15 0 070 Orfice 6 15 7 SWING 6 15 17 3 7 14 6 15 4 5 10 15 4 5 8 12 13 15 16 5 0 063 Orfice Uu prod Sheen Note Orientation of Notch in Plate must be 9 15 notch up as shown ET 5or8 E 10 11 or 12 4 To Vakve Orfice Plate Solenoid Lock Valve MACHETE Service Manual 04 04 2004 Alamo Group Inc 50 Oct 2000 to Current VALVE ASSEMBLY sree ag Fixed Displ SNe eee P N 02976533 Item Part No 02976533 1 02971379 2 63042700 3 02976532 4 02972113 5 02968850 6 02972177 7 02972179 8 02962213 9 02968850 10 02972209 11 02972210 12 02969398 13 02972208 14 02957416 15 02963637 16 02975438 17 02976531 S N MB24 Current Qty Description ON NY NY W A I MACHETE Service Manual 04 04 2004 Alamo Group Inc Assembly Valve 5 Spool 5 Spool Valve OCFD Adaptor Straight Adaptor Elbow 90 Adapter Straight Adapter Straight Adapter Straight Adaptor Straight
198. vice Manual 04 04 2004 Alamo Group Inc 44 S N MB24 01247 6 15 17 3 7 14 Oct 2000 to Current VALVE ASSEMBLY 5v Load Sense i P N 02976688 Item PartNo 02976688 1 02971378 2 63042700 3 02976532 4 02972113 5 02968850 6 02972177 T 02972179 8 02962213 9 02968850 10 02972209 11 02972210 12 02969398 13 02972208 14 02957416 15 02963637 16 02975438 17 02976531 18 02969399 19 02972178 S NMB21 Current S NMB24 Current Qty Description i 3 W a ND SB AHP WAU A ol I Assembly Valve 5 Spool 5 Spool Valve CCLS Adaptor Straight Adaptor Elbow 90 Adapter Straight Adapter Straight Adapter Straight Adaptor Straight Adaptor Elbow 90 Adp Hyd Straight Orifice 063 Orifice 070 Orifice 055 Solenoid Lock Valve Assy Cap Plastic Female Cap Plastic Outer Adp Hyd Sight Adp Hyd Elbow Orifice 040 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 P45 vo VALVE ASSEMBLY 22s dd Fixed Displ S N MB21 01109 P N 02968854 S N MB24 01046 VERY IMPORTANT DO NOT Use Solenoids as Handles LS Ll IL ain VI gc at LASS 4 6 7 See Detail A 4 To Valve otch in Orfice Plate Must Face away from Valve as Shown MACHETE Service Manual 04 04 20
199. w remove Relief Valve and inspect for 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 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 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 heat 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 Insufficient Flow From C
200. wash Plate and Cylinder Barrel Assembly Carefully Holding Cylinder Barrel Assembly in position in Housing Reposition Motor on its side and remove the Headless Cap Screw and replace them with the retaining Cap Screw with NEW Special Washers on them Do this by removing ONE Headless Cap Screw and replacing it then the other ONLY snug the two cap Screws Tighten the two Cap Screws in increments alternating from one to the other till they are torqued to 20 to 24 ft Ibs 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 107 MOTOR P N 02967193 ASSEMBLY Shaft M N ia Assemble Driver without Valve or Brg Plate 1 Standrard End Cover or Integral Shuttle amp Low Pressure Relief End Cover Install the same FIGURE 70 END COVER amp END COVER BEARING RE ASSEMBLY 1 Position and support Motor on Mounting Flange as shown in Figure 71 Support the Output Shaft in a slightly raised position Use a Press or Bearing driver and install Bearing Cone onto Output Shaft as shownin Figure 70 Bearing Cone MUST seat against shoulder of Output Shaft REMEMBER Do not install Bearing Cone unless Output Shaft is supported on Bottom Install two Dowel Pins in Main Housing and Install Gasket on End Cover Figure 71 Lubricate and install Bearing Cup Shims and Bearing Cup into End Cover Be sure Bearing Cup and Shims are se
201. 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 Positioning Control Valve must be sethigher than Tractor Relief Valve Otherwise the Oil will bypass continuously and overheat rapidly Leakage This type 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 notleak 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 i

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