Alamo MACHETE User manual

PRODUCT SERVICE
MANUAL
BOOM ARM MOWER
™
© 2004 Alamo Group Inc.
2009Edition
Alamo Industrial
1502 E. Walnut
Seguin, Texas 78155
830-372-1480
Service Manual
P/N02969480
(Jun. 2009)
PUMP
MOTOR
BOOM

©2004Alamo Group Inc. 3
Machete (Service Manual) 04/04
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
ItishopedthattheinformationcontainedinthisandotherManualswillprovideenoughdetailto
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
tomanycallswithonlyaminimumamountofinformation.Insomecases,thecorrespondenthasnever
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.
1. HydraulicorMechanical TroubleShooting.
2. Request for Technical Information or Specifications.
3. Mountingor Fitting Problem.
4. Special Service Problem.
5. Equipment Application Problems.
6. Tractor Problem Inquiries.
HOW YOU CAN HELP:
Makesurethecall is necessary! Mostof thecallsreceivedmaynot be necessary iftheDealer
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
ServiceManuals,manyoftheseareavailableviatheAlamoIndustrial Internetsite(Alamo-Industrial.
Com). Attempt to diagnose or repair problem before calling.
2. IfacalltoAlamoIndustrialisneeded,CertainInformationshouldbeavailableandready
fortheAlamoIndustrialServiceStaff.Suchinformationas, MachineModel,SerialNumber,YourDealer
Name,YourAccountNumberandAnyotherinformationthatwillbeuseful. Thisinformationisvitalfor
the development of a prompt and correct solution to the problem. This will also help to develop a
databaseofproblemsandrelatedsolutions,whichwillexpediteasolutiontofutureproblemsofasimilar
nature. 3. The technician may be asked to provide detailed information about the problem
includingtheresultsofanyrequiredtroubleshootingtechniques.Iftheinformationisnotavailable,The
technician may be asked to get the information and call back. Most recommendations for repairs will
be based on the procedures listed in the Service Manual / Trouble Shooting Guide.
CONTACT ALAMO INDUSTRIAL:
Alamo Industrial, 1502 E. Walnut St. Seguin TX. 78155, Technical Service Dept. PH: 830-372-2708

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©2004Alamo Group Inc. 4
Page
INTRODUCTION........................................................................................ 3
SPECIFICATION......................................................................................... 10 thru 13
BoomSpecifications..................................................... 10
CuttingCircuitSpecifications......................................... 10
FiltrationSpecifications.................................................. 10
HydraulicCylinderSpecifications................................... 11
HydraulicHoseSpecifications........................................ 12
HydraulicHose TorqueSpecifications........................... 14
HydraulicPumpSpecifications...................................... 11
HydraulicValveSpecifications....................................... 12 -13
General / Speceial Torque Specifications..................... 14
BLADEBAR................................................................................................ 121 thru 128
Blade Bar Assemble & Dis-Assemble.......................... 138 - 142
BladeBarTorque Specification..................................... 138
BladeBolt TorqueSpecifications................................... 138
BladeBarInstallationInstructions.................................. 142
KINGPIN..................................................................................................... 132 thru 135
Tools Required List (Recommended Tools)................ 132
ToolDescription............................................................. 134
King Pin Removal Procedure......................................... 132 - 133 - 134
King Pin Bushing Replacement...................................... 134 - 135
PUMP........................................................................................................... 61 thru 82
Pump Charge Pump Adapter Asy.................................. 77
Pump Dis-Assembly Instructions................................... 72 - 73
PumpIntroduction........................................................... 61 - 62 - 63
PumpManualServo Control Asy.................................... 78 - 79 - 80
Pump - Motor Engage Requirements............................. 66
Pump - Motor Dis-Engage Requirements...................... 66 - 67
PumpPartsLocation...................................................... 68 - 69 - 70 - 71
PumpRe-Assembly....................................................... 74 - 75 - 76
PumpRotaitingKitAsy................................................... 81 - 82
MOTOR CIRCUIT........................................................................................ 83 thru 94
MotorElectricalControl.................................................. 84 - 85 - 86 - 87 - 88
Motor-PumpActions.................................................... 89 - 90 - 91
Motor System Schematic.............................................. 92
MotorShuttleValveLocation.......................................... 93
MotorService&Repair.................................................. 94
MotorComponentTorque Specification........................ 111
MotorDis-Assembly....................................................... 101 - 102 - 103
INDEX - REPAIRS

©2004Alamo Group Inc. 5
Machete (Service Manual) 04/04
Page
MOTORP/N02967193 (60" HEADMOTOR)............................................. 95 thru 114
Motor End Cover Dis-Assembly.................................... 101
MotorPartsLocation...................................................... 96 - 97
MotorRe-Assembly........................................................ 105 thru 110
MotorToolDescriptions................................................. 111 thru 113
MotorValveBlockDis-Assembly................................... 98 - 99
MotorValveBlockRe-Assembly.................................... 100
MOTOR P/N 02979881 ( 50" HEAD MOTOR)............................................. 115 thru 130
MotorPartsLocation....................................................... 116 - 117 - 118
MotorDis-Assembly....................................................... 119 - 120 - 122 - 123
MotorRe-Assembly........................................................ 124 thru 129
ShaftSealReplacement................................................ 129
SPINDLE...................................................................................................... 138 thru 144
BladeBarRemoval......................................................... 138
BladeBarInstallation....................................................... 142
MotorPlateRemoval....................................................... 139
MotorPlateInstallation..................................................... 142 - 143 - 144
Motor RemovalFrom Spindle......................................... 139
MotorInstallationonSpindle............................................ 142
Spindle Removal From Deck.......................................... 139
SpindleInstallationonDeck............................................ 142
SpindleDis-Assembly.................................................... 140
SpindleRe-Assembly..................................................... 141
SpindleCleaning&Inspection........................................ 139
TROUBLE SHOOTING.............................................................................. See Below
Problem,CauseAndSolution........................................ 145 thru 178
ValveTestingProcedures.............................................. 54 thru 60
VALVE.......................................................................................................... 15 thru 60
JoystickControl / TroubleShooting................................ 19 - 20 - 21
JoystickPlug................................................................... 22 - 23 - 24
JoystickWiringHarness................................................. 19 - 22 - 23 - 24 - 25
ValveComponents......................................................... 26 - 27 - 28 - 29 - 30
ValveOperation.............................................................. 17-18
ValveParts..................................................................... 40 thru 45 & 46 thru 52
ValveTroubleShooting.................................................. 53 thru 60
WiringHarness,GeneralView....................................... 16
WiringHarness,Plug..................................................... 25
WiringHarness,Joystick............................................... 22 - 23 - 24
HydraulicFlow,loadSensing......................................... 31 - 32 - 33 - 34
Hydraulic Flow, Fixed Displacement.............................. 35 - 36 - 37 - 38
INDEX - REPAIRS

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PROCEDURE Fig.# Pge.#
BLADE BAR...Removal (RotaryHead)............................... 85................. 122
JOYSTICK.....Assembly...................................................... 4................... 19
PlugPinLocation.......................................... 6.................. 22
KING PIN.......Boom Removal............................................. 80................ 132
BoomMount.................................................. 81................. 133
KingPinRemoval......................................... 81................. 133
King Pin Bushing Driver................................ 82................. 134
Bushing Removal & Replacement............... 83................. 134
KingPinReplacement.................................. 84................. 135
MOTOR.........Circuit Electric Schematic (Old Style).......... 36................. 85
Circuit Electric Schematic (Mid Style).......... 37................. 86
Circuit Electric Schematic (New Style)........ 38................. 87
Circuit Pump Engage................................... 40-42............ 65-67-89-91
Circuit Pump Engage................................... 41................. 66-90
End Cover Dis-Assembly............................. 56 thru 58..... 100-101
End Cover Re-Assembly.............................. 70 thru 73...... 108-109
Input Seal & Bearing Removal...................... 47-59............ 102-103
MainHousingRe-Assembly.......................... 69................. 107
Motor Components Torque Specifications... ------ ............. 111
Motor Repair Tools Descriptions.................. 77 thru 79..... 111 thru 113
Output Shaft Assembly Removal................. 60-61............ 103
Rotating Group Dis-Assembly...................... 63-64............ 104
RotatingGroup Re-Assembly....................... 65-66............ 105
PartsLocation............................................... 46................. 96
ShuttleValveDis-Assembly.......................... 44-45.............. 93
ShuttleValveRe-Assembly.......................... 75................... 110
System Hydraulic Schematic....................... 43................... 92
ValveBlock Dis-Assembly............................ 48 thru 51...... 98 thru 99
ValveBlockRe-Assembly............................ 52 thru 55...... 99 thru 100
Valve Block O-Ring/Back-Up Ring Replace. 76................... 110
MotorPlateDis-Assembly............................ 86................... 123
MotorPlateRe-Assembly............................. 89 thru 95...... 127 thru128
THIS INDEX INDICATES FIGURE (DRAWING) LOCATION
DRAWING INDEX

©2004Alamo Group Inc. 7
Machete (Service Manual) 04/04
PROCEDURE Fig.# Pge.#
PUMP.............ElectricControl............................................. 39................... 88
CircuitMotorEngaged.................................. 40-42.............. 65-67-89-91
CircuitMotorDisengaged............................. 41................... 66 and 90
Charge Pump Adapter Assembly................. 30-31.............. 77
Dis-Assembly................................................ 27-28.............. 72 thru 73
Re-Assembly................................................ 29.................. 74
PartsLocation............................................... 25-26.............. 68 thru 70
PortLocations............................................... 24................... 63
Rotating Kit Parts Location........................... 34................... 82
Pump / Motor Port Connections................... 39................... 64
SERVO CNTRL.Control System......................................... 40................... 65
Control Assembly (Manual Type - Old Style)... 32................... 79
Control Assembly (Manifold Type - New Style). 33................... 80
Control Electric Control................................ 39................... 88
SPINDLE....... Blade Bar Removal (Rotary Head)............... 85................... 138
Blade Bar Replace (Rotary Head)................ 85................... 138
Motor Plate Removal (Rotary Head)............. 86................... 139
MotorRemoval(RotaryHead)....................... 86................... 139
Spindle Dis-Mount from Deck (Rotary Head) 86................... 139
SpindleDis-Assembly................................... 87.................. 140
SpindleRe-Assembly................................... 88.................. 141
SpindleRe-Mount toDeck............................ 89 thru 95....... 143thru144
MotorPlateInstallation.................................. 89 thru 95....... 143thru144
VALVE,5SPLSpecific Section Operation........................... 2.................... 17
Components................................................. 11 thru 14.......27 thru 30
HydraulicLocKValve.................................... 3.................... 18
Operation...................................................... 15 thru 18.......32 thru 38
PartNumbers............................................... -----................ 40 thru 51
Testing......................................................... 19 thru 23.......56 thru 60
Type............................................................. 10.................. 26
WIRING SYS. Harness Schematic, Joystick End.............. 7-8................. 23 thru 24
Harness Schematic, Vlave End.................. 9.................... 25
Harness Valve Plug (Old Style)................... 5.................... 22
Harness Valve Plug (Old & New Style)....... 35.................. 84
ControlValveWiring.................................... 1.................... 16
PlugPinLocation........................................ 6.................... 22
DRAWING INDEX

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©2004Alamo Group Inc. 9
Machete (Service Manual) 04/04
Specifications Section

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SPECIFICATIONS - MACHETE
1. Cutting Circuit Specifications
Hyd.PumpSpeed(FrontAuxPump)...................................... 1950RPM
Hyd.MotorSpeed.................................................................. 1220 RPM
Hyd.MotorRatedHP............................................................. 199 HP
Hyd.MotorRotation(asviewedf/TopoftheDeck)................... CW (Clockwise)
ReliefValveSettingAtMotor................................................. 4000PSI
ReliefValveSettingAtPump................................................ 4500PSI
Hyd.Pump Flow(Front Pump @ 1950 RPM).......................... 25.3GPM
Hyd.OilOperatingTemperature.......................................... 95 Deg, (F) Above Ambient
Hyd.OilFiltration,(Dischargef/ChargePump)......................... 10Micron
Hyd.TankCapacity............................................................... 17Gal.
Hyd.MotorCircuitOilType*................................................ ISO AW 100 Hyd Oil
Hyd.Motor Start StopTime (Approximate)........................... 6 Seconds
CuttingDiameter, (RotaryHead).......................................... 58 Inch
Spindle................................................................................... 4.5 “ by 9” Heat Treated Alloy
BladeBarType...................................................................... Stacked 3 Leaf
BladeBarSize....................................................................... 1-1/4” Thick X 5" Wide (Ea. Leaf)
BladeBarMaterial.... BottomLeaf....................................... T1 Steel
Middle&TopLeaf............................. HRFB Steel
BladeSwing........................................................................... 360 Deg Swing
BladeMaterial........................................................................ HighCarbonAlloySteel
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 FootBoom............................... Up20'-3" Out 21'-4" Down 12'-11"
24FootBoom....................................................... Up 23' Out 24'-2" Down 14'-5"
Frame (Old Low Frame)....................................... 4" X 6" Rect, Tube
(NewHighFrame)..................................... 4 X 4 Sq. Sq. Tube (formed corners)
Pins....................................................................... 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 lbs., 48" Flail = 770 lbs.,
FML100H = 990 lbs.
BoomRest............................................................ TractorAxleMounted
BoomMounting..................................................... 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 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), Filter should be replaced with the same Micron and High Pressure rated Filter.

©2004Alamo Group Inc. 11
Machete (Service Manual) 04/04
SPECIFICATIONS - MACHETE
4. HYDRAULIC PUMP CIRCUIT
PumpType.......................................................................... Piston Type
PumpSpeed(FrontEngine Mounted)................................. 1950 RPM
ReliefSettingatthePump................................................... 4500PSI
Pump Flow (Front Engine Mounted @ 1950 RPM)............. 25.3GPM
OilOperatingTemperature.................................................. 100 deg. (F) above Ambient Temp
Filter, Discharge from Charge Pump.................................. 10Micron
HydraulicTankCapacity...................................................... 17Gallons
Hydraulic Oil Type (Pump & Motor Circuit).......................... ISO AW 100 HYD OIL
Motor Start / Stop Time (Approximate)................................ 6 Seconds
5. HYDRAULIC CYLINDERS SPECIFICATIONS
Hydraulic Cylinder Drift Rates:
Cylinder Function Travel Time
Lift............................................. 1"Travel................... 8.0 minutes
Dipper........................................ 1"Travel................... 7.1 minutes
Tilt (w/hyd. lock closed).............1"Travel................... No Drift
Tilt (w/hyd. lock open)................1"Travel................... 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
leakage problem in the Cylinder, Lines or Valves.
Hydraulic Cylinder Pressure Rates:
See Valve Spool Functions & Specs for Rates.
Hydraulic Cylinder Repair Specs:
Cylinder Cylinder Piston Nut Gland Seal Kit
Part No. Function Torque ft. lbs. Torque ft. lbs. Part No.
02967172 Swing (21' & 24') 400-500 135-149 (Cap) 02968612
02967172A Swing (21' & 24') 400-500 80-120(Head) 02975530
02967173 Lift (21' & 24') 400-500 135-149 (Cap) 02968610
02967173A Lift (21' & 24') 400-500 80-120(Head) 02975527
02967174 Dipper (21' & 24') 400-500 135-149 (Cap) 02968610
02967174A Dipper (21' & 24') 400-500 80-120(Head) 02975527
02967175 Tilt (21' & 24') 400-500 135-149 (Cap) 02968612
02967175A Tilt (21' & 24') 400-500 80-120(Head) 02975530
02961480 Door (Rotary) 150-250 100-120 (cap) 02972147
02961480A Door (Rotary) 150-250 80-120(Head) 02975528
02970710 Door (Flail Axe) 40-60 None (Lockwire) 02972762
02970710A Door (Flail Axe) 40-60 80-120(Head) 02975532
02971423 Slide (Timber Cat) 400-500 50-60 (Tie Rod) 02973505
02811000 Door (Ditcher) 150-250 None (Lockwire) 02840600
02811000A Door (Ditcher) 150-250 80-120(Head) 02975528
ContinuedNextPage

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SPECIFICATIONS - MACHETE
6. HYDRAULIC HOSE CODES
Hydraulic Hose Band Mark Color Codes:
Hose's and/or fittings are marked with a Color Coded Plastic Band around it. Some Bands
are a solid Color and some have a Colored Stripe. DO NOT remove these bands unless you
replace them. All Bands with Solid Colors connect to Rod End of Cylinder. All Bands with
Stripesconnects to Butt End of Hydraulic Cylinder (or connections leading to them).
AlwaysCheck Hose Size & 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 with a 11 to 15
VoltRange.
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).
ContinuedNextPage

©2004Alamo Group Inc. 13
Machete (Service Manual) 04/04
SPECIFICATIONS - MACHETE
8. ValveRestrictors:
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 & Specs:
Port Spool Cyl. Cyl. Flow Pressure Restrictor Cycle
Marked No. Function Travel GPM Rating Size Time
"A" 1 Swing Forward 2.3 2000 psi. 0.040" 8.5 Seconds
"B" 1 Swing Back 3.5 2000 psi. 0.050" 9.0 Seconds
"A" 2 Lift Down 4.5 1000 psi. --------- 12 Seconds
"B" 2 Lift Up 6.5 2000 psi. 0.070" 11 Seconds
"A" 3 Dipper Out 4.0 2300 psi. 0.063" 10 Seconds
"B" 3 Dipper In 5.5 1000 psi. ---------- 10 Seconds
"A" 4 Tilt Up 4.0 System 0.050" 6.0 Seconds
"B" 4 Tilt Down 4.0 System LockValve 8.0 Seconds
"A" 5 Door Open 2.5 System ---------- 5.0 Seconds
"B" 5 Door Close 2.5 System ---------- 6.0 Seconds
Valve Spool Functions & 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.
ContinuedNextPage
Door Tilt Dipper Lift Swing
Tank
Pressure
Return
Supply
Yel / Wht Red / Wht Blue / Wht Org / Wht
Green
Yellow Red Blue Orange
Grn / Wht
"A"
"B"
"B"
"B""B"
"B"
"A""A"
"A"
"A"
Solenoid Side Of Valve
Note: Old style Valve (Apitech 10 Plug Wire Harness type) is not shown
Below, this is the later style 5 Plug Harness type.

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©2004Alamo Group Inc. 14
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. lbs. ft .lbs.
-4 1/4" 140 12
-6 3/8" 230 19
-8 1/2" 450 38
-10 5/8" 650 54
-12 3/4" 900 75
-16 1" 1200 100
-20 1-1/4" 1600 133
-24 1-1/2" 2000 167
-32 2" 2800 233
* 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)
MotortoSpindleHousing......................................................... 100 ft. lbs.
SpindletoDeck........................................................................ 425 ft. lbs.
SpindletoAdjusting Nut (Bearing Preload).............................. 25 in. lbs. Rolling Torque
Blade Bar Leaf Bolts Old Style 7/8" Bolts............................... 600 ft. lbs.
NewStyle 1-1/4"Bolts........................... 2000 ft. lbs.
BladeBar toSpindleBolts......................................................... 400 ft. lbs.
BladeBolts................................................................................. 400 ft. lbs.
MotorPlate................................................................................. See Set Up Instructions
11. TORQUE VALUES - BOLTS: Recommended Torque, Ft. lbs. & (Nm)
IMPORTANT! Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE, Component
ApplicationTorquewillvarydependingonwhatisbolteddownandthetypematerial(Metal)thatisbeing
bolted together. Thread condition and lubrication will vary Torque settings.
Bolt
Dia.
mm 4.8 8.8 10.8
6
8
10
12
14
16
18
20
22
24
27
30
33
36
5
11
20
37
60
92
118
160
215
285
450
600
800
900
7
20
40
70
100
155
216
270
330
500
875
1200
1600
2100
12
25
58
105
140
200
280
355
430
700
1000
1700
2300
3000
ALWAYS
CHECK
MARKINGS
ON
TOP
OF
BOLT
HEAD
OR
OTHER
BOLT
DESCRIP-
TIONS
PlainHead 3Dashes 6Dashes
Bolt
Dia.
inch
2(B) 5(D) 8(F)
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
Not Used
Not Used
Not Used
35 (47)
55 (75)
75 (102)
105 (142)
185 (251)
160 (217)
250 (339)
330 (447)
480 (651)
10 (14)
20 (27)
35 (47)
55 (75)
85 (115)
130 (176)
170 (230)
300 (407)
445 (603)
670 (908)
910 (1234)
1250 (1695)
14 (19)
30 (41)
50 (68)
80 (108)
120 (163)
175 (230)
240 (325)
425 (576)
685 (929)
1030 (1396)
1460 (1979)
2060 (2793)
Inche Sizes Metric Sizes

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VALVE SECTION

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CONTROL VALVE - WIRING
A
A
A
A
AB
B
B
B
B
T
P
Pressure Port Tank Port
5 Spool Valve
(Handles Shown
as Illistration Only)
Swing
Lift
Dipper
Tilt
Door
Ground
(Black)
Starter Solenoid
(Brown)
Voltage Supply
(Red)
Solenoid Lock
Valve
HR
1
2
3
451 : Swing
2 : Lift
3 : Dipper
4 : Tilt
5 : Door
Pump Solenoid Connector
Clamp
Junction Box
(Joystick)
(Used 1998 & Up)
FIGURE 1
Inlet Section

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CONTROL VALVE - OPERATION
HYDRAULIC FUNCTIONS:
The Hydraulic Functions of the Machete Boom Mower are controlled by a Pilot operated
ElectricallyActuated ControlValve.
GENERAL OPERATION:
ThisSectionaddressesthemethodofoperationoftheelectricalpartofcontrols.Thefunction
oftheHydraulicValveitselfwillbecoveredinanotherSection.ThreeFunctions, TheLift,The
Dipperandthe Swing are"Proportional"meaning that theSpeedofoperation canbeslowed
downorSpedupaccordingtothepositionoftheJoystickControl.TheDoorandTiltFunctions
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 meansthat the ElectricalPower Wireto the Joystick Controller should
only be connected to a Wire that has Voltage when the ignition is in the "On" Position. If
Connectionofthe JoystickControlleristo a constantcurrentsource it willcausepower drain
on Battery and eventually Battery Failure. Furthermore the Master Switch on the Joystick
Console(Figure5)mustbeinthe"On"positiontoallowfortheoperationofanyoftheControl
Functions.To achieveElectricalProportionalActuation,Themain SpoolPositionisadjusted
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
whichsendsthepositioninginformationtotheelectriccontrollerintheValve.TheSignalfrom
the Joystick is converted by the electronic Controller into Hydraulic Pressure by activating a
seriesofHydraulicValves.TheseValves directtheStandbyorPilotPressureOiltotheproper
endoftheSpooltocauseittomove.LikewisethepositionoftheSpoolisconvertedintheSpool
position transducer to feedback signal. This Signal is registered by the electronic controller
whichwillactivatetheseriesofvalvesasneededtomovethespoolineitherdirectionuntilthe
spoolispositionedinaccordancewiththelocationoftheJoystick. Anequilibriumbetweenthe
Joystick and feedback signal is the end result.
Electric
Controller
Electric Signal for Joystick Controller
Pilot Pressure
BA Control Valve
Segment
Spool Positioning Valves Spool Position Transducer
FIGURE 2
Handle is shown
for Illustration
Only

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©2004Alamo Group Inc. 18
CONTROL VALVE - OPERATION
HYDRAULIC LOCK VALVE: (Head Tilt Function)
AnElectricSolenoidOperatedHydraulicLockValve(Figure3)isincorporatedintheHeadTilt
Functiontopreventexcessive(HeadLiftCylinder)leakdownduringstorageortransportation.
TheSolenoidwhichoperatesthisvalveisnormallyintheLockedpositionuntilHeadLowering
function is actuated at Joystick. When Joystick is actuated to lower Head an electric signal
issentto solenoid to openLockvalve. WhenthefunctiontoraisetheHeadisactivatedthere
isnoelectric signal from Joystick. Thepressureagainstthevalve when headisbeingraised
willforceValveopenlikeareliefValveallowingOiltopassthroughit.Ifthisvalvewillnotopen
itcouldstopheadfromliftingor dropping.Thevalveisplumbed intotheHydraulicCircuitryof
the Head Tilt Function and is located near the Control Valve.
ELECTRIC SIGNALS:
ElectricalSignals aresent tothe Controllers etc. through aWiring Harness,The Harness
issuppliedwithaonewayconnectorattheJoystickConsoleBox(Soitcannotbeinstalled
Wrong).Connectorsaresuppliedforeach electric valve controller connection,These are
labeled (with Letter code A,B,C etc.) for the function which they are connected. The Plug
willonlyfittogetheronewayandshouldalwayshaverightconnections.BUTiftheterminals
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
5and6)SeeFigure6forPlugConnection(LetterCode) &Terminallocations,Alsothe
WiringSchematic,BUTNOTEontheWiringSchematicitWILLNOTbetheactual
locationofWires(Letter Codes ABC etc.),Theyarechangedto enable the wiring
diagramtobedrawnwithasfewlinescrossingeachotheraspossibleforillustration
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.
FIGURE 3
Hydraulic Lock Valve

MACHETE (ServiceManual) 04/04
©2004Alamo Group Inc. 19
CONTROL VALVE - JOYSTICK
JOYSTICK FUNCTIONS: (Figure 4)
To operate a function the following series of events must work.
1. The Joystick Controller is moved in the correct direction the required distance, During its
movementan electrical signalis sent tothe electric Controllerinthe properValveSection
of the Control Valve.
2. The Electric Controller sends an electrical signal, which causes the Proportional Control
Valves to actuate the proper amount based on the signal from the Controller. EXAMPLE:
Valves 1 & 3 allow Pilot Pressure Oil to flow to the corresponding end of the Spool, Thus
causing it to move. Valves 2 & 4 allow the Oil from the opposite end of the Spool to return
to the Tank. (NOTE: Lift, Swing and Dipper functions are Proportional, Door and Tilt
functions are “ON” or “Off” Only, See later section for explanation of Proportional).
3. TheSpoolpositionTransducersendsanelectricalsignaltotheElectronicControllerwhich
indicates the position of the Spool.
4. The Electronic Controller will continue to adjust the Valves (1 - 4) in order to maintain an
equilibrium between the Joystick signal and the feedback signal.
5. Reaction time from the time the Joystick is moved until the Spool moves is approximately
300 milliseconds.
6. TheRockerTypeSwitchontopoftheJoystickisspringcentered3-functionswitch(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
ofthesefunctionsareNOTcontrolledProportionally.WhentheToggleSwitchisactivated,
TheelectricalsignalfullyopenseitherValve1or3andfullycloseseithervalve2or4inthe
correct Valve Section depending on which way the Spool needs to travel. The Electronic
Controller and the Spool position Transducer are not included in these functions.
7. Earlier Model Joysticks Master Switch was a 2 Push/Pull Switch type. Later Models have
onePush/PullSwitchwithaMomentaryPullStartSwitchbuiltintoitandaLightedRocker
Master Switch. Joystick Functions
Rocker Switch Only
Push Right = Tilt Down
Push Left = TiltUp
Rocker & Trigger Switch
Push Right = Door Close
Push Left = Door Open
Pistol Grip Handle Switch
Push Front = Lift Down
Pull Back = LiftUp
Push Right = Dipper Up
Push Left = Dipper Down
Rotate Right = Swing Out
Rotate Left = SwingIn
Rocker
Switch
Trigger
Switch
Pistol Grip
Handle Switch
Fuse
Master
Switch
Motor Start
Stop Switch
FIGURE 4

MACHETE(ServiceManual)04/04
©2004Alamo Group Inc. 20
JOYSTICK TROUBLE SHOOTING:
TheJoystickWiringHarnesshas2wireconnectionstolinkMachetetoTractorPowerSupply
(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 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.
Thesewires(BrownColored)connecttheStarterrelayCircuitoftheTractortotheMaster“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
StarterSwitch(normallyKeySwitch).DONOTsplicewires(BrownColored)anyfurtherfromStarter
Switch than 3”, if further than 3" it may cause electrical interference in other tractor electrical
operations when the Motor Circuit is engaged.
Withthe Switch(Keyed Switch) oftractor inthe“On” positionand the RockerMaster Switch
onJoystickConsoleinthe“On”positionaGreenLight(onMasterSwitch)shouldbeon.(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:
1. Proportional Controlled Functions, Only the Swing, Lift and Dipper Functions are
ProportionalControlled,Thereforeonlythesethreefunctionswillshowprogressivereadings.
TheTiltand Door Functionsare“On”or “Off, when checkingkeeptrackof which connection
is being check, as it will make a difference in reading on voltmeter
2. All Connections are marked on plug where they plug onto Valve (See Figure 5)
3. Make sure Tractor Engine is off and cannot be started while you are working on it.
4. Relieve 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
shouldbedonebyworkingtheManualOverridesonValvetobesurepressuresarerelieved.
5. Turn on Ignition Switch of Tractor to the “On” position (But DO NOT Start Engine)
6. Switch on the Master Rocker Switch (Push / Pull on older models) to the “On” position.
7. Removethe“Din”connectorfromthecontrolValveSectionbeingtestedtocheckvoltage.
8. The Spade type Pins will be on the Section of the Valve and the plug will have slots where it
plugs on, Each of these connectors have numbers at the slot to ID which connections (see
Figure 5) connect where, these plugs cannot be reversed, will only plug on one way.
9. VoltagefromtheNo.1Slot,Positive (12VoltDC),VoltagewilldependonBatterycondition,
itcannotexceed the amount of thevoltageinthebatteryandshouldnotbelessthanBattery
Voltagewhen JoystickSwitch isactivated, Soalways Know what voltage isin Battery.(See
Figure 5)
CONTROL VALVE - JOYSTICK