Machete 2 Service Manual

2014 Alamo Group, Inc.

ALAMO INDUSTRIAL1502 E. WalnutSeguin, Texas 78155830-372-9595

An Operator's Manual was shipped with the equipment in the Manual Canister. This Operator's Manual is an integral part of the safe operation of this machine and must be maintained with the unit at all times. READ, UNDERSTAND, and FOLLOW the Safety and Operation Instructions contained in this manual before operating the equipment. If the Operator's Manual is not with the equipment, contact your dealer or Alamo Industrial (800-356-6286) to obtain a Free copy before operating the equipment.

Rev Part No. 02986941S

SERVICE MANUAL

High-Frame Rotary Boom

04-14

Machete 2 Service Manual Pub 04-14 Page 2


Introduction........................................................................................................................... 3 Contact information......................................................................................................................... 3 How to contact Alamo Industrial...................................................................................................... 3Section 10: Safety................................................................................................................. General safety instructions and practices....................................................................................... 8 Operator safety instructions and practices....................................................................................... 9 Connecting and disconnecting implement safety instructions and practices................................... 12 Equipment operation safety instructions and practices.................................................................... 12 Maintenance and service safety instructions and practices............................................................. 18 Transporting Safety instructions and practices................................................................................ 21 Federal laws and regulations........................................................................................................... 23 Tractor side definition....................................................................................................................... 24 Mounting work site requirements..................................................................................................... 25 Warning: Do not weld...................................................................................................................... 26Section 30: Hydraulics.......................................................................................................... 30-1. Valve Section......................................................................................................................... Control Valve - Wiring............................................................................................................... 28 Control Valve - Operation......................................................................................................... 29 Control Valve - Joystick............................................................................................................ 31 Control Valve - Joystick Plug.................................................................................................... 34 Control Valve - Wire Harness Plug........................................................................................... 36 30-2. Control Valve Hydraulics....................................................................................................... 38 Control Valve - Hydraulics......................................................................................................... 38 Control Valve - Load Sensing................................................................................................... 42 Valve Assembly......................................................................................................................... 60 30-3 Pump Section........................................................................................................................ General..................................................................................................................................... 50 Repair Tools............................................................................................................................. 51 Pump Circuit - Motor Engage................................................................................................... 52

Pump Circuit - Motor Disengage............................................................................................... 54 Motor Circuit - Pump Engage................................................................................................... 55 Parts Location............................................................................................................................ 56 Disassembly............................................................................................................................... 60 Reassembly................................................................................................................................ 62 Charge Pump Adapter As ................................................................ 65 Servo Control Manifold Assembly.............................................................................................. 66 Rotating Kit Assembly................................................................................................................ 67 Pump Boom Circuit ................................................................................................................... 69


Section 60: Motors & Spindles.......................................................................................... 60-1 Motor Circuit Section............................................................................................................ Electrical Control..................................................................................................................... 81 Pump Actions.......................................................................................................................... 84 Pump Disengage.................................................................................................................... 85 Pump Engage......................................................................................................................... 86 System Schematic.................................................................................................................. 87 Shuttle Valve.......................................................................................................................... 88 Service/Repair........................................................................................................................ 89 Parts Location........................................................................................................................ 90 Disassembly........................................................................................................................... 95 Assembly................................................................................................................................ 100 60-2 King Pin Replacment Section............................................................................................. King Pin Replacement........................................................................................................... 107 60-3 Spindle Repair Section (Rotary Head Only......................................................................... Spindle Repair....................................................................................................................... 113Section 80: Testing.............................................................................................................. 80-1 Control Valve Trouble Shooting.......................................................................................... 119Section 90: References....................................................................................................... 90-1 Possible Cause and Solution Section.................................................................................. 127 90-2 Specifications: Machete 2.................................................................................................... 162


Section 10:Safety


PARTS INFORMATION

Alamo Industrial mowers use balanced and matched system components for blade carri-ers, blades, cuttershafts, knives, knife hangers, rollers, drivetrain components, and bear-ings. These parts are made and tested to Alamo Industrial specifications. Non-genu-ine will fit parts do not consistently meet these specifications. The use of will fit parts may reduce mower performance, void mower warranties, and present a safety haz-ard. Use genuine Alamo Industrial mower parts for economy and safety. (SPTK-1)

SEE YOUR Alamo Industrial DEALER


Safety


Safety

ALAMO INDUSTRIAL MOUNTING PROCEDURES DO NOT REQUIRE, AND DO NOT RECOMMEND WELDING ON THE FRAME OR TRACTOR.

Electronic control modules can be damaged duringwelding, and should be unplugged and removedprior to welding.

For Example: The Alamo Industrial Boom useselectronic modules and components that could bedamaged by welding. Before doing any welding,ALL ELECTRONIC MODULES AND CONTROLCOMPONENTS MUST BE UNPLUGGED.

In addition, check the Tractors Operation, Repair,Service or any other manual from the tractormanufacturer to identify any special electroniccomponents or required special procedures prior towelding.

Disconnect the negative lead (ground) from thebattery terminal to help prevent damage.

Consult the specific mounting instructions foryour mower. DO NOT WELD YOUR MOUNTKIT COMPONENTS OR TRACTOR UNLESSSPECIFICALLY TOLD TO DO SO IN THEMOUNTING INSTRUCTIONS PROVIDED.

Contract Alamo Industrial Customer Service priorto performing any modification to the mountingcomponents.


Section 30-1:Hydraulics


Section 30 -2:Control ValveHydraulics.


Section 30-3:


PUMP - BOOM CIRCUIT

Variable Volume Piston Pump:Piggy Back Pump Boom Circuit Supply Pump

The Boom Supply pump is the piggy back pump bolted to the frontpump, shown below is the pump with the end plate (shown on different pump)this is for illustration only and not a true drawing of pump.

This End Plate on this Pump

Tandem Pump

FIGURE 34

Pump Specification:

Pump Delivery @ 3000 psi @ 1800 RPM is = 15.6 GPM @ Max continous Pressure 3000 psi.(207bar)


Cylinder Supply Pump PressureAdjust (If Needed):

Special Note: If after setting the display controls, check to make certain that functions operatecorrectly. If the Boom will not lift. The Pump for the Cylinder supply may have to be adjusted. This is asimple process that will require a 7/16" wrench for this adjustment and a 1/2" wrench for the locking nut.Looking on the LH side of the pump there are two adjustments, one has a 7/16" hex head and the othera ridged round head, Only adjust the one with the hex head. DO NOT adjust or change the round ridgedadjustment as it is set from the factory. Adjust the 7/16" hex one by turning it in till it seats completely (Donot force adjustment after is seats). Then back it back out 1/2 turn, this will give you the 2800 psi required

Pressure Adjust Nut (7/16" Hex)&

Locking Nut (1/2" Hex)

Pressure AdjustControl (7/16" Hex)

FIGURE 34A

FIGURE 34B

to opertate the boom

(See Figure 34A & 34B). Hold the adjusting nut while turning the locking nut so the ad justment nut does not turn with it changing the setting.

PUMP - BOOM CIRCUIT


PUMP - BOOM CIRCUITIntroduction: Variable Piston Pump

Features Controls* High Strength Cast Iron Housing * Pressure Compensation* Built-in Supercharger * Load Sensing* High Speed capacity - 3000 RPM * Horsepower (Torque) Limiting* Sealed Shaft Bearing * Horsepower & Load Sensing* Two Piece design for ease of service * Remote Pressure Compensation* Cartridge Type Controls - Field Changeable * Adjustable Maximum Volume Stop* Replaceable Bronze Clad Port Plate * Electrohydraulic Pressure* Airbleed Standard for Quick Priming * Electrohydraulic Flow & Pressure* Hydrodynamic Barrel Bearing (Servo Controled)* Full Pressure Rating on Water Glycol Fluids * Low Pressure Standby* Pump Case & Shaft Sea - See Inlet * Filter and/or Cool Drain Line (100 psi Max.) Pressure Only

FIGURE 35


PUMP - BOOM CIRCUITGeneral Description: Variable Piston Pump

All control is achieved by proper positioning of the swash plate. This is achieved bythe servo piston acting on one end of the swash plate working against the combined effectof the offsetting forces of the pistons and centering spring on other end. The control spoolacts as a metering valve which varies the pressure behind the servo piston.

As shown in Figure 36 Detail "A", the amount of flow produced by the Piston Pumpis dependent upon the length of the stroke of the pumping pistons. This length of stroke inturn is determined by the position of the swash plate. Maximum flow is achieved at an angleof 17.

The rotating piston barrel, driven by the prime mover, moves the pistons in a circularpath and the piston slippers are supported hydrostatically against the face of the swashplate. When the swash plate is in a vertical position, perpendicular to the center line of thepiston barrel, there is no piston stroke and consequently no fluid displacement. When theswash plate is positioned at an angle, the pistons are forced in and out of the barrel andfluid displacement takes place. The greater the angle of the swash plate, the greater thepiston stroke.

The center line of the pumping piston assembly is offset from the center line of theswash plate. Therefore, as shown in Figure 36 Detail "B", the pistons effective summationforce tends to destroke the swash plate to a vertical (neutral) position. This destroking forceis balanced as the swash plate is angled by the force of the servo piston.

FIGURE 36

Detail "A" Detail "B"

Pressure Compensated Control: Variable Piston PumpSwash Plate angle controls the output flow of the pump. Swash plate angle is controlled by the

force generated against the swash plate by the pumping pistons and the force of the servo piston. Theforce of the servo piston is greater than the force of the pumping pistons when both are at the samepressure (See Figure 37)


PUMP - BOOM CIRCUITPressure Compensated Control: (continued)

By means of internal porting, pressure is connected from the output port to the servo piston viaorifice (E), and to the control spool via passage (D). Also pressure is applied to the control spool chamberthrough orifice (F). As long as the pressures at both ends of the control spool remain equal, the spool willremain offset upward, due to the added force of the spring (See Figure 37)

When pressure reaches the setting of the compensator control, the dart leaves its seat causingthe pressure in the spool chamber to be reduced. The spool now moves downward causing pressurein the servo piston cavity to vent via port "A" (control drain) . The reduced pressure at the servo pistonallows the servo piston allows the servo piston to move to the right. This movement reduces the angleof the swash plate and thereby reduces the pumps output flow (See Figure 37)

As pump pressure on the control spool drops below pressure and spring force in the spoolchamber, the control spool moves upward to maintain an equilibrium on both sides of the spool. If pumppressure falls below compensator control setting, the control spool moves up, bringing the pump tomaximum displacement (See Figure 37)

Adjustment of Pumps Procedure: Standard Pressure Compensated PumpsPumps are shipped from factory with a differential pressure of approximately 150 psi (10 bar) at

50% of maximum swash angle. Differential pressure will not normally change through the life of the pump.If this control has been tampered with, a close approximation of the correct setting can be made asfollows.

Dead head the pump (no flow) with 0-3000 psi (0-207 bar) gauge in the OUTLET port (Not thelow signal "B" port), back the pressure compensator adjustment out (full counterclockwise).

The gauge should read between 325-375 psi (22-26 bar). If the gauge reads different than this,turn the differential adjustment knob (differential option 4) or add/remove shims (omit option) until correctpsi figure is reached (See Figure 37).

FIGURE 37


PUMP - BOOM CIRCUITRemote Pressure Control: Control Type (M)

Remote control of the output pressure can be achieved by controlling the pressure in the lowsignal "B" port when the pump is set up for control type (M). A Manual, hydraulically piloted, pressurecontrol device is installed in the line from the low signal "B" port to tank. The pump will then maintainpressure approximately equal to the pressure in the "B" port plus the pump differential setting.Low Pressure Standby:

This option can be used as an alternative to the load sensing option (A) to achieve low pressurestandby. Minimum standby pressure is somewhat higher than that achieved using option (A). In thecompensating mode there is approximately 3 GPM (1.14 LPM) flow from the low signal "B" port in additionto 9 GPM (3.4LPM) flow from the control drain port "A".Multiple Pressure Standby:

If the pressure in the low signal "B" port is limited by a relief valve, as the desired pump outletpressure is reached, the relief valve in the "B" port will allow the pump to standby at a preset pressure.Adding to this concept, multiple, remotely piloted relief valves plumbed in parallel in the "B" port line canyield multiple, sequential pressure settings.Electrohydraulic Pressure & Flow Control:

A proportional pressure control valve can be used in place of relief valves to give variable pressurecontrol proportional to an electrical input signal to the valve. By combining this arrangement with theswash plate position sensing device, amplifier, and logic circuit, servo control of pressure and/or flow isachieved.

Note: In most systems, a load equivalent to the minimum operating pressure of the pump cannotbe guaranteed. Because of this, a sequence valve is required in the discharge line to maintain servo flowcontrol. Please refer to ordering information in parts/operators manual for servo components.

FIGURE 38


FIGURE 39

PUMP - BOOM CIRCUITPressure & Flow Control (Load Sensing) : Control Type (A)

Flow control is achieved by placing an orifice (fixed or adjustable) in the pump outlet port. Thepressure drop (^ A) across this flow control is the governing signal that controls the pump's output, asexplained below.

Whenever the pressure drop at the flow control increases (indicating an increase in output flow),the pump attempts to compensate by decreasing the output flow. It does this by sensing the lower on thedownstream side of the flow control via line (C), which is balanced against the pump pressure viapassage (D), on the control spool. The control spool is forced down against the control spool spring bydifferential pressure. This vents the servo piston cavity, destroking the pump to a point where the setpressure drop across the orifice is maintained and the flow is obtained.

The converse of this is also true whenever the pressure drop decreases (indicating a decreasein output flow). In this case, the control spool is forced up. This increases pump displacement in anattempt to maintain the predetermined pressure drop or constant flow.

It should be noted that the pump is still pressure compensated and destrokes at the selectedpressure setting. The pressure compensator control will override the flow control whenever the pressurecompensator control setting is reached.Low Pressure Standby:

This arrangement can also be used to provide low pressure standby by venting the "B" portthrough a simple on/off valve suitable for flows of 1-2 GPM (3.8-7.6 LPM). When flow or pressure isrequired, this valve is closed allowing system pressure to build behind the control spool and bringing thepump on-stroke.Load Sensing:

If instead of measuring the pressure drop across the orifice in the pump outlet port, it is measureddownstream of a directional control valve, a constant pressure drop will be maintained across the valvespool. This results in a constant flow for any given opening of the directional control valve regardless ofthe work load downstream or the operating speed of the pump.

The pump "senses" the amount of pressure necessary to move the load and adjust output flowto match the valve opening selected and pressure to overcome the load plus the Preset (^ P) across thevalve spool.

c

c

The benefits of thisarrangement are that ex-cellent , repeatable flowcharacteristics areachieved, and consider-able energy savings arerealized while meteringcompared to using astraight pressure com-pensated system.


PUMP - BOOM CIRCUITPressure & Horsepower Control: Control Type (H)

The horsepower is sensitive to the position of the servo piston. When the servo piston is to theright, the swash plate causes low flow and the power control piston develops maximum spring pressureon its companion poppet (mechanical feedback). When the servo piston is left and the flow is high, thepower control piston reduces spring pressure on the poppet. This allows it to open under less pressurein the control spool chamber. As with the operation of the pressure compensator control, this allows thecontrol spool to move downward, venting the servo piston cavity and causing the servo piston to moveto the right. This reduces output flow and thereby power.

As indicated in drawing (See Figure 40) pressure in the control spool chamber is affected by boththe pressure compensator control and the power control. The resultant pressure in this chamber is afunction of the set points of these two controls. Both set points are adjustable.

FIGURE 40

FIGURE 41

Pressure,Horsepower& Flow Control:Control Type (C)

In addition tothe three controlconfigurations justdiscussed, it is pos-sible to combine allthree control devicesin one pump. In thismode, the position ofthe control spool is afunction of the actionsof the pressurecompensator adjust-ment, horse poweradjustment and flowcontrol. (See Figure41)


Rear View Top View

Front View Side View

PUMP - BOOM CIRCUIT

Outlet Port

Port Sizes

Vent & Fill Plug

Low Signal"B" Port

Torque Control Adjust-ment - 500 in-lb/turn

Pressure compensatoradjustment - 800 psi/turn

Inlet Port, Same Both Sides

Control DrainPort "A"

13 SplineShaft

Air Bleed DrainAdjustable Differential(Sensitivity 200 psi/turn)

Max Volume Stop(2.2 CC/Rev/Turn)

Clockwise Pump Shown, Actual Pump Is Counter Clockwise Which willhave ports and adjustment on the opposite side as shown in drawing

This Plug & Adjustments are opposite side of pumpthan is shown, CW pump shown CCW pump Used

Note:Shown & dimensioned is a clock-wise pump, ports "A'" & "B", deliveryport & pump controls will be on theopposite side for the counter clock-wise pump used on Maverick Boom


PUMP - BOOM CIRCUIT


Pressure, Power & Flow Compensator10

PUMP - BOOM CIRCUIT


Section 60-1:


Section 60-2:


18. Thrust Washer, Be sure to remove the Thrust Washer on top of Upper pivot Bush ing, This washer should be replaced when making these repairs.19. There are Bushings in the Boom Pivot Pin Holes, The Cylinder Pin Holes and in the Kingpin Pivot holes, (See Figure 81)20. Kingpin Bushing Removal, The Old Bushing will need to be driven out, this must be done with a suitable Bushing Driver (Alamo Industrial Bushing Driver #02972281) shown in Figure 82. Care must be taken when doing this to avoid damage to the castings that the Bushings are in. The frame holes must be cleaned up before new bushing can be installed.21. Cylinder Pin & 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.

22. Kingpin Bushing Replacement, The New Bushing will need to be driven in, this must be done with a suitable Bushing Driver. If possible place new bushings into a deep freezer for 12 hours prior to installation. The Bushings should be installed so that the bushings bottom in each bore and the groove hole is aligned with the grease hole in the casting. Check grease flow for each bushing prior to pin installation.

23. Cylinder Pin & 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

NOTE: Inspect the Fit between the Bushings and the Frame Bore. The Fit should be a PressFit. If any looseness between the Bushing and frame is Observed, Or if the Frame bores are out of round, further repairs may be necessary. Contact Alamo IndustrialCustomer Service dept.


Section 60-3:


1.

2.

3.


18-


Section 80:Testing


Section 90-1:References


Section 90-2:References


21. Cutting Circuit Specifications Hyd. Pump Speed (Front Aux Pump)...................................... 1950 RPM Hyd. Motor Speed................................................................... 1220 RPM Hyd. Motor Rated HP................................................................199 HP Hyd. Motor Rotation (as viewed f/ Top of the Deck)................ CW (Clockwise) Relief Valve Setting At Motor................................................... 4000 PSI Relief Valve Setting At Pump................................................... 4500 PSI Hyd. Pump Flow (Front Pump @ 1950 RPM).......................... 25.3 GPM Hyd. Oil Operating Temperature.............................................. 95 Deg, (F) Above Ambient Hyd. Oil Filtration, (Discharge f/ Charge Pump)...................... 10 Micron Hyd. Tank Capacity.................................................................. 17 Gal. Hyd. Motor Circuit Oil Type *.................................................... ISO AW 100 Hyd Oil Hyd. Motor Start Stop Time (Approximate).............................. 6 Seconds Cutting Diameter, (Rotary Head).............................................. 58 Inch Spindle..................................................................................... 4.5 by 9 Heat Treated Alloy Blade Bar Type....................................................................... Stacked 3 Leaf Blade Bar Size......................................................................1-1/4 Thick X 5 Wide (Ea. Leaf) Blade Bar Material.... Bottom Leaf........................................... T1 Steel Middle & Top Leaf................................. HRFB Steel Blade Swing............................................................................ 360 Deg Swing Blade Material......................................................................... High Carbon Alloy Steel Cutter Weight. (Approximate w/ Rotary Head)........................ 950 lbs. Cutter Deck Opening & 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 (New High Frame)..................................... 4 X 4 Sq. Sq. Tube (formed corners) Pins....................................................................... Chromed Bushings............................................................... Hardened (Greaseable) 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 lbs., 48 Flail = 770 lbs., FML100H = 990 lbs. 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 Manufac-turer 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 recommended 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). Fil-ter should be replaced with the same Micron and High Pressure rated Filter.


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6. HYDRAULIC HOSE CODES Hydraulic Hose Band Mark Color Codes: Hoses 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 Sol-id Colors connect to Rod End of Cylinder. All Bands with stripes connects to butt end of Hydraulic Cylinder (or con nections leading to them). AlwaysCheck Hose Size & Color CodeColor Tie Color Tie

AbbreviationHose Size Hydraulic

ConnectionOrange OR Medium Lift Cylinder, Rod EndBlue BL Large Return flow from motorOrange/White Stripe OR/W Medium Lift Cylinder, Butt EndGreen G Medium Swing Cylinder, Rod EndGreen/White Stripe G/W Medium Swing Cylinder, Butt EndBlue BL Medium Dipper Cylinder, Rod EndBlue BL Large Case drain for motorBlue/White Stripe BL/W Medium Dipper Cylinder, Butt EndRed R Medium Tilt Cylinder, Rod endRed R Large Pressure flow to MotorRed/White Stripe R/W Medium Tilt Cylinder, Butt EndYellow Y Small Door Cylinder, Rod EndYellow/White Stripe Y/W Small Door Cylinder, Butt End.

7. VALVE SPECIFICATIONSValve Type: Electrically controlled, Pilot Operated, 5 Spool, Proportional Control Valve, Avaiable as Closed Center Load Sense (CCLS) or Open Center Fixed Displacement (OCFD) Option depending on Requirements of Tractor Model / SeriesValve Construction: Individual Spool with Tie Rod Bolt together type.Valve Controller: Electrical Joystick, Reaction Time = 300 Milliseconds, Volt-age Rated = 12 Volt with a 11 to 15 Volt Range.Valve Port Markings: Ports Marked with letter A (solid marking hose bands) are for Functions Con-nect ed to Rod End of Cylinders. Ports Marked with letter B (Striped mark-ing hose band) are for Functions Connect to Butt End of Cylin-ders. (See Decal # 02969106 Hydraulic Hose Hook-Up on Next Page). Continued Next Page


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Machete 2 Service Manual Pub 04-14 Page 168 2013 Alamo Group Inc.

Machete 2 Service Manual

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