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Tandem Pump

1. 5 A Low oil level in hydraulic system Solution 5 A fillto proper oil level Cause 5 B Relief valve setting too high Solution 5 B Check relief valve setting repair and or replace as needed Cause 5 C Obstruction in power circuit extra or wrong parts installed in pump or motor Solution 5 C Find and remove obstruction Check if components have been reassembled lately if they have check for being assembled wrong re installed wrong or wrong parts used Make certain the correct and standard parts were used as replacement parts 6 Possible Failure Pump making load noise Cause 6 A Low oil level in hydraulic system Solution 6 A fill to proper oil level Cause 6 B Vacuum in Reservoir Solution 6 B Check Clean or replace reservoir vent plug Cause 6 C Clogged oil filter or wrong filter installed Solution 6 C Check filter for condition and type replace as needed with original type and size filter Cause 6 D Worn or damaged pump Solution 6 D Check Pump condition and operation repair replace as needed 7 Possible Failure Mower will not raise or raises slowly Wing Mowers Cause 7 A Slow gear pump speed Solution 7 A Check gear pump speed pulleys belts and adjustments Cause 7 B Relief valve setting to low or stuck open Solution 7 B Check relie
2. Tandem Piston Pumps Rated 48 GPM 3800 PSI Single Wing Interstater Tandem Piston Pump Rated amp 24 GPM 3800 PSI Cylinder Control Valve Dual Wing Interstater 4 Spool Valve with Detent Position Single Wing Interstater 2 Spool Valve with Detent Position 2 WING MOWER SPECIFICATIONS Wing Mower cutting Width Options 62 74 or 88 Cutting Widths Cutter Housing Construction 10 Guage Unitized Cutter Housing Deck End Plates 1 2 Inboard amp 5 16 Outboard Thick Side Plates Skid SIGE TE ee Bolt On Replaceable Skid Shoes Cuttershaft SIZB u uu u in 4 1 2 x 5 16 Wall Cuttershaft Bearing Size amp Type 1 5 16 Bore Greasable Self Aligning Cuttershaft Bearings Motor Tpe amp Size 53 HP Piston Motor Me DAVO retirer de Belt Drive F Motor to Cuttershaft w Automatic Spring Tension Cutter Shaft Drive Belt cc ceeeceeeeeeeeeees V Belt w Kevlar Construction Rear Roller Wy 0G 2 a Steel Tube Construction w Bell Ends amp Hex Shaft Rear Roller Bearings unseren ennen Greasable Sealed w Housing and Hex ID Rear Roller Adjustment nennen 6 Adjustable Rear Roller Cutting Height Adjustment 1 2 Down to 6 Up Cutting Height Rear Roller Knife ODIO Sranan enten Available in Fine or Coarse Cut Safety Deflectors an aann neen eneen enen Front and Rear Safety Deflectors Standard Wing Motor Cut Switch Automatic Cut Off
3. Figure 25 Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 28 Auxiliary Pump Dis Assembly 19 DISASSEMBLE AUXILIARY PUMP See Figure 28 amp 29 A Remove Auxiliary Pump Drive Pulley loosen set screw in pulley and slide it off of pump shaft B Remove Pump From Pump Mount Plate Bracket There are two bolts that mount the pump to the mounting plate bracket remove these two bolts C Remove Drive Key From Pump Input Shaft before beginning the disassembly of pump See Figure 28 D Secure Auxiliary Pump in Vice Clamp the pump in a vise with protective devices for the jaws Clamp the pump in the vice at the pump mounting flange use caution DO NOT over tighten the vice and damage pump mounting flange See Figure 28 E Unboltthe pump assembly bolts that hold the two pump halves together See Figure 28 F Remove The Cover half of the pump will lift up and off with out to much resistance do not hammer on pump housing Drive gear and driven gear should remain in lower pump body half Look for any components that may stay in pump cover half or fell out onto the floor such as items 2 7 8 See Figure 29 G Pullthe drive gear and the driven gear form pump body half Note Gear Set is not shown Take notice of items 3 4 5 when pulling gear set from pump body See Figure 29 if item 3 4 amp 5 stay in the pump body half when gear set is removed it is OK remove them now by pulling them upwards
4. 100232 020 10233 007 100234 005 100235 002 quantity as required onto Main Housing over Output Shaft Tighten Bolts 000601 and check Bearing Pre Load Should be from 14 to 16 pounds of rolling torque Shaft should NOT have end play If you have end play it will be required to rearrange shims at Inner Bearing Cup or at Bearing cover till settings are right 4 Install Input Shaft amp Gear into Main Housing 5 Install front Bearing Cone 000328 and rear Bearing Cone 000328 onto Input Shaft and Gear Asy 700492 Gear amp Shaft can only be replaced as an Assembly Gear cannot be pressed off of Shaft Install Input Seal 100054 into Input Bearing Cover 100230 Install outer Bearing Cup 000327 into Main Housing Using Shims 100232 020 100233 007 100234 005 100235 002 quantity as required try same quantity as taken off install Input Bearing Cover on front of Main Housing tightening 4 retaining bolts 6 Install Rear Housing Cover 100229 on rear of Main Housing Use Gasket Sealer on this cover it will not use a Gasket If a Gasket is wanted Gasket 00769800 can be used Install Rear Bearing Cup 000327 into rear Housing Cover Using Shims 100232 020 100233 007 100234 005 amp 100235 002 quantity as required try same quantity as taken off install Rear Bearing Cap 100231 on Rear Housing Cover tightening 4 retaining bolts This will set B
5. Cutter Shaft Rotation I TORQUE TO 20 FT LBS Forward v Rotation Tractor Direction of Travel TD 4 N Cutter Shaft Rotation y Reverse Rotation v FIGURE 23 FIGURE 24 Changing Mower Cutter Shaft Rotation to Forward or Reverse WING MOWERS The hydraulic wing motors are dual rotation motors which means they will rotate in either direction depending onthe inlet port used An arrow on the flat surface of the motor housing at both ports indicate the direction of rotation To change rotation remove the four bolts that mount the manifold block to the motor Remove the case drain hose at the motor but leave it attached in present location at the manifold block Leave all other plumbing as presently installed atthe manifold block Remove the two mounting bolts at the motor mounting plate and rotate the motor 180 deg This changes the present inlet port into the outlet port of the motor Re install manifold block but do not change the position Install case drain hose REAR MOWER To change direction of cutter shaft rotation for the rear mover three left hand parts are required A belt guard an outboard bearing plate and a idler pulley arm Consult parts book for these part numbers Remove the cutter shaft and turn 180 deg Remove the gearbox cutter shaft drive pulley and outboard bearing plate using the proper bearing plate mount the plate to opposite side of mower housing Remove the four bolts that mounts the gearbox and rotat
6. Red to Accessory Terminal Black Ground Tractor Starter Right Wing Safety Cut off Switch Right Wing Motor Solenoid Valve Wing Motor Control Switch Dual Wing LH Wing Push Pull Switch CO 07 Fuse Holder Eker _ with Fus 10 Amp Fuse In 2 TOE I 12 Brown 16 Black gt Line Connector to Starter AO Solenoid g I aa C 3 Jon 16 Red to one Power 3 Terminal Connector 16 Black White Left Wing Motor Solenoid Valve DEREN NE C 16 White Cavity Plug Interstater Service Man 03 06 2006 Alamo Group Inc RH Wing Push Pull Switch 16 Red 16 Yellow RH Wing N 16 White LH Wing ON Off Switch Plug CI C am Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply Ground 16 Black White Solenoid Connector Connecters Shipped Loose in Separate Plastic Bag 1 amp 16 Black White Right Wing Motor Solenoid Valve il noon T poomi I Solenoid Connector at Cutter Valve 16 Yellow Section 11 9 Motor Control Switch RH Wing Only 16 Yellow 16 Red EE L lt i ON Off Push Pull Switch Sue LI Cg I DO mn RS 12 Brn Fuse Holder ET with Fuse In 10 Amp Fuse l j Te Starter Solenoid Wire D Starter Solenoid Wire gt Switched Power Supply Ground un 16 Black Ge Solenoid _ Connector Ring Connector to Ground D Co
7. 2006 Alamo Industrial Section 4 14 Pump amp Motor Hydraulic Schematic Dual Wing Return to Tank from TRACTOR Return to Tank from Wet Tubes of RH Wing REAR Wet Tubes of LH Wing RIGHT WING Mainframe LEFT WING Beiu Tube Cross Over Line Hose Sleeving F EE NAA AR PAGE gt Pressure from Pump to RH Wing Motor Pressure from Pump to LH Wing Motor O H Fl Er re art En TRACTOR LH SIDE TRACTOR RH SIDE Hose Sleeving gt Indicates Direction of Flow IN Return to Tank from Wet Tubes of RH amp LH Wing Pressure from Pump to RH Wing Motor Pressure from Pump IE TRACTOR to LH Wing Motor FRONT Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 15 Pump amp Motor Hydraulic Schematic RH WING ONLY HYDRAULIG MOTOR SHOWN Case Drain from Motor to Motor Return from Motor to Rear Wet Tube and on to Tank NEVER CONNECT HIGH PRESSURE HOSE TO WET TUBES ON DECK High Pressure from Pump to Motor Return from Front Wet Tube to Tank Figure 43 RH Win Tandem Pump Inner Pump for RH Wing Pump ak amp Outer Pump for LH Wing RH Wing LH Wing Ben Only has a single pump Pump Case Drain _RH Wing Pump High Pressure Hose Sleeving Tandem LH Wing Pump High Pressure Line Pump Suction Line RH Wing Pump Suction Cyl System Supply Line Figure 44 Pump Suction Hose Interstater Service Manual
8. Jff INTERSTATER FLAIL MOWER PRODUCT SERVICE MANUAL Publish Date 03 06 Manual P N 803213S An operator s manual parts manual was shipped with the unit shipped from the factory There may also be other information on this product available assembly manual insert sheets and or special instruction sheets This manual is designed to be used in conjunction with these other manuals and or instruction sheets This manual is not designed to replace any of the other manual The information is as of the published date changes may be made to unit without prior notice and or changes to the tractors which will affect the mounting Alamo Industrial will not be responsible for the changes that may affect the unit If manuals are needed contact your local dealer oar Alamo Industrial Alamo Industrial AA ALAMO GROUP 1502 E Walnut sn Seguin Texas 78155 830 372 1480 2006 Edition ALWAYS ON THE CUTTING EDGE 2006 Alamo Industrial Inc TO THE OWNER OPERATOR DEALER All implements with moving parts are potentially hazardous There is no substitute for a cautious safe minded operator who recognizes the potential hazards and follows reasonable safety practices The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents BEFORE YOU START Read the safety messages on the implement and shown in your manual Observe the rules of safety and common sense FAI
9. 2 A Clean or replace solenoid cartridge 3 Possible Failure Intermittent mowing power Cause 3 A Safety switch maladjustment Solution 3 A Adjust safety switch Cause 3 B Electrical Malfunction Solution 3 B Check electric circuit magnetic switches and push pull switch Cause 3 C Bad Solenoid Solution 3 C Check solenoid replace as needed 4 Possible Failure Insufficient cutting power or low cutter shaft speed Cause 4 A Drive belts slipping Solution 4 A Check for correct belts condition of belts check idler pulley and spring tension system for idler pulley replace and or repair as needed Cause 4 B Bound cutter shaft Solution 4 B Free up cutter shaft Cause 4 G Hydraulic Pressure relief stuck open or setting to low Solution 4 C Check setting and condition of hydraulic relief valve Repair replace as needed Cause 4 D Solenoid Spool will not shift completely Solution 4 D Replace solenoid valve cartridge Cause 4 E Worn Pump or Motor Solution 4 E Check pump and motor repair or replace as needed Interstater Service Manual 03 06 2006 Alamo Industrial Section 2 2 Possible Failure Cause Solution MOWER FUNCTION TROUBLE SHOOTING Continued 5 Possible Failure Hydraulic oil over heating mower free to rotate Cause
10. 2006 Alamo Industrial Section 4 1 Hyd Schematic W Aux Pump RH Wing Motor Return Hose Vent Plug Cooling Tube Cyl Control Valve en Cyl Valve Return Line Pressure Line Aux Pump Cooling Tube Motor Return Hose amp Deck Cooling Tanks Tank Return Filter amp Return Pressure Gauge Hydraulic Tank Figure 1 d Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 2 Suction Line Hyd Schematic W Aux Pump Dual Wing RH Wing Tilt Cyl LH Wing Tilt Cyl RH Motor Case Drain LH Motor Case Drain 7 E mec Cyl Valve voor Noo T Pressure JE wa Cyl Valve Return Line LH Motor Pres sure Line Cooling Tube RH Motor Pres sure Line Cooling Tube P Motor Return Hose amp Deck Cooling Tanks Cyl Valve Pressure Line Aux Oyl Pump Tank Return Filter amp Return Pressure Gauge Aux Cyl Pump Pump Case Suction Line Drain Lines Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 3 Tandem Pump Suction Lines Hydraulic Tank Hyd Schematic W O Aux Pump RH Winc Motor Return Hose Vent Plug B gt Cooling Tube Cyl Control Valve Cooling Tube Cyl Valve Return Cyl Valve Pressure Line to Tractor Hyd Line from Tractor Hyd Motor Return Hose amp Deck Cooling Tanks ks Suction Line
11. Cooling Tube Cyl Control Valve Cooling Tube Cyl Valve Return Cyl Valve Pressure Line to Tractor Hyd Line from Tractor Hyd Motor Return Hose amp Deck Cooling Tanks ks Suction Line Filter amp Return Pressure Gauge Figure 42 Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 36 Hydraulic Tan Hyd Schematic W O Aux Pump Dual Wing Vent Vent Plug Plug RH Wing Tilt Gyl LH Wing LH Tilt Gyl Wing Lift Cyl RH Motor Case Drain LH Motor p Case Drain JO L moc Cyl Valve d T Pressure im wd f LH Motor Pres sure Line RH Motor Pressure Line 5 N O Cooling Tube Cooling Tube pg Motor Return Hose amp Deck Cooling Tanks Cyl Valve Pressure from Tank Return Tractor Hyd Filter amp Return Pressure Gauge Cyl Valve Pump Case Tandem Pump oo Drain Lines Suction Lines y Figure 43 Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 37 Hydraulic Tank NOTES Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 38 Section 6 Interstater SERVICE MANUAL Hyd Tank amp Return Filter Remove amp Replace Hydraulic Tank Repairs Preparation 1 Clean the entire area around the hydraulic tank hoses pumps and any other component that is going to be worked on DO NOT disconnect any hydra
12. Fill 1 4 NOTE This G B Asy P N 700493 is replaced by later style P N 702673 as an Asy Parts WILL NOT interchange between them The easiest way to tell which G B you have is by looking were the Shaft goes through the G B Housing The Old Style had Bolt on Caps Here and the new style will not Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 14 Gearbox Asy P N 700493 Asy Instructions Asy instructions Gearbox 700493 540 RPM Used Jan 1991 amp Down ul Install Output Shaft amp Pinion Gear into Main Housing 100228 2 Install Snap Ring 000331 into Main Housing 100228 Install Inner Output Bearing Cone 000329 on Output Shaft 100225 Install Inner Bearing Cup 000327 down over Bearing Cone Make Note of Shims 100236 002 100237 004 100238 006 100239 012 amp 100240 020 quantity will be as required try to put in the same amount as taken out These shims will be on either side of Inner Output Shaft Bearing Cup Slide out put shaft into housing with Inner Bearing Cup with Shims Slide Bearing Spacer 100241 in till it bottoms out against inner Bearing Cup Insert Outer Bearing Cup 4000327 into Main Housing Slide Outer Bearing Cone 000328 over Shaft till it seats against Outer Cup 4000327 Install Snap Ring 4000330 onto output shaft next to outer Bearing Cup 3 Install Output Seal 100055 into Seal Housing 100707 Install Seal Housing using Shims
13. Ifthe needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing asy 3 Inspectthrust washers and thrust bearings item 5 All surfaces should be free of any signs of wear or fretting Should be no sign of distortion or flaking 4 Inspect Spider item 1B and Pivot item 1C Conical surfaces should be free of wear and score marks 5 Inspect Pistons item 1A The O D surface should be smooth and free of scoring The shoes should be snug fit to piston The face of the shoe should be flat and free of scoring and flaking Do Not lap piston shoes 6 Inspectthe Piston Block item 1D The bore should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or metal build up 7 Inspect the Cam Plate Insert item 7 The surface should show no signs of scoring or grooves 8 Inspectthe flat surface on the Back Plate item 2 The back plate surface should be free of excessive scoring or metal build up 9 Inspectthe Drive Shaft item 3 Inspect for fretting in the bearing areas Check spline area for twisted broken or worn splines Check for chips and or cracks in shaft Re Assemble Outer Front Pump For item numbers See Figure 17 1 Coat Moving Parts for Re Assembly All moving parts shoulde be coated with lubricant before and during reassembly If pump is to used immediately after assembly the recommend hydraulic oil for interstater will work If pum
14. Place other flatwasher over bolt and let it rest on the three pins item 1F Screw nut on to compress spring inside piston block Use snap ring pliers to install internal snap ring item 1K Install internal snap ring item 1K make certain it is seated into snap ring groove in piston block Unscrew bolt nut and two washers this will release pressure on spring item 1H allowing it to seat against snap ring item 1K Never Remove snap ring in piston block with out compressing spring first 9 Install Pivot item 10 Spider item 1B and piston assembly item 1A Sit pivot item 1 C down onto piston block with taper rounded side up See Figure 11 Sit spider item 1B down over pivot noting concave hole in center of spider will sit over rounded edge of pivot align holes in the spider with holes in piston block Lower Piston assemblies item 1A through spider holes and into piston block piston assembly can be installed one at a time 10 Install Piston Block Assembly item 1 The piston block assembly needs to be coated with oil Slide piston block assembly into end of pump housing aligning ID of it over driveshaft Push piston block assembly into housing and over driveshaft until piston shoes are in contact with cam plate insert it may require driveshaft to be turned as piston block assembly is being slid in to align splines of shaft with spline of the components of piston block assembly DO NOT use excessive force to install piston block assem
15. Pull driveline apart and reattach yoke to PTO shaft D Hold driveline sections parallel to one another and measure back 1 from yoke of each shaft and place mark on opposite section Cutthis length off with a saw Round off all sharp edges and debur Thoroughly grease then reinstall the driveline Recheck for proper operation O mm Engagement Check Procedure A With the driveline attached position the mower to the point where the telescoping driveline is at its maximum extension Completely shut down the tractor and secure in position B Mark the inner driveline shield 1 8 from the end of the outer shield C Disconnect the driveline from the tractor and separate the two driveline halves D Measurethe distance from the markto the end of the inner profile This length is the amountthe driveline profiles were engaged E Ifthe engaged length is less than 12 the shaft is considered too short and should be replaced with a longer shaft Consult an authorized dealer to purchase the required driveline length NOTE Ifthe driveline cannot be shortened and still maintain the required profile engagement the operator must be made aware of terrain conditions and avoid situations which pose a potential problem to avoid damaging the driveline Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 8 SPECIFICATIONS INTERSTATER 17 HOSE END FITTING TORQUE SPEGIFICATION Hose End Type 37 Degree A
16. Remove enough knives to place a floor jack under center of cuttershaft to support cutter shaft when removing cutter shaft bearing Securely support cuttershaft NOTE The cuttershaft must remain supported while changing bearings Continued Next Page Grease hole in bear ing must be inline with hole in housing to insure correct placement of grease fitting en er FIGURE 19 Interstater Service Man 03 06 2006 Alamo Group Inc DESIRED CUTTING HEIGHT INCHES 4 T DETAILOF P N 002023 Cutting Height Adjustment Instruction ROLLER BEARING Section 12 8 Mower Repairs Rear Mower NON DRIVE END CUTTERSHAFT BEARING See Figure 20 21 amp 22 Contiued From Previous Page 3 Remove outboard fender 4 Remove fasteners securing bearing and housing assembly to cutter housing then remove bearing and housing assembly See Figure 14 NOTE There are two tapped holes in the housing which can be used to pull bearing and housing assembly out by using special tool No 701627 5 Using ajack to align parts install bearing and housing asy to cutter unit amp make certain that bearing setscrew If Used is located in keyway on cuttershaft Grease bearing and install cap over fitting If only the outboard bearing and housing assembly is to be replaced proceed as follows Remove jack and check shaft rotation Reinstall knives which were removed Reinstall outboard fender Remove supports lower unit to gro
17. Right Wing Pump Weldment Most Common Used on Models with Single Wing and Tractor Hydraulic for Cylinder Hydrau lic Supply Cyl cir cuit Figure 9 Driveshaft Bearing installs into pump mount weldment here Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 11 Tandem amp Single Pump Remove Replace IMPORTANT WARNING Once the pump removal process is started tractor CANNOT be started unless both pumps and pump driveshaft is removed Itis the responsibilty of the repair technician to secure the tractor to where is safely secure before beginning any repairs It is recommended that the battery cables be disconnected and a note DO NOT START be place in the tractor operators compartment to prevent others from stating it IF the tractor is started with pumps patially disconnected or drive shaft left in the tractor when tractor is started it will damage the tractor and or other components 11 REMOVE PUMP Pump For Motor Supply See Figure 4 through 16 If both pumps are to be removed for this repair remove both pumps together and disassemble them on the work bench is best If only the outer pump is to be removed it can be removed and the inner pump left mounted NOTE When Unit was originally assembled the technician may have used a pipe sealer in the NPT fitting Use caution when removing these that the sealer doesn t fall into the hydraulic system or any of it ports Clean all oil spills at once
18. Use appropriate seal Bench Vice driver to instal seal Coat the seal with petroleum jelly Vaseline for start up lubrication See Figure 29 Insert Snap Ring into Pump Body Use snap ring pliers Figure 28 to make certain snap ring is seated into groove in pump body See Figure 29 Coat the Anti Extrusion Block with petroleum jelly and insert it into pump body make certain it is installed on the correct side of pump body The Petroleum jelly will hold it in place during assembly Install Seal Asy The seal assembly must be installed with the small hole over the Anti Extrusion Block The grooved side of seal must be installed to the opposite side as the anti extrusion block See Figure 29 Install Wear Plate The wear plate is also referred to as othe thrust plate The wear plate will have one side that is bronze this bronze side must face the gears for proper wear and performance See Figure 29 Install drive gear and driven gear Gear set Check the input shaft of the drive gear around the keyway slot to make certainthere are no burrs or sharp edges that willcutthe seal Coatthe input shaft of drive gear with vaseline at seal wear area Install the drive gear into the pump body using caution when pushing through the input seal Install the driven gear coatthe driven gear shaft with coat of vaseline and insertthe gear into the pump body Inspect gears the upper edge of the gears should be even if they are not check components already installed t
19. Use clean filtered compressed air to dry parts after washing DO NOT use compressed air to spin bearing when drying parts DO NOT use rags or towels that will leave lint to dry parts Parts must be kept clean at all times Work area and place parts are kept during repair process must remain clean and dust free 2 Examine Needle Bearings item 16 and 17 Inspect the needle bearings in the housing item 4 andthe back plate item 2 Ifthe needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing asy 3 Inspect thrust washers and thrust bearings item 5 All surfaces should be free of any signs of wear or fretting Should be no sign of distortion or flaking 4 Inspect Spider item 1B and Pivot item 1C Conical surfaces should be free of wear and score marks Contnued Next Page Interstater Service Manual 03 06 2006 Alamo Industrial section 5 17 Tandem Pump Dis Assembly amp Re Assembly Continued From Previous Page Inner Rear Pump Component Inspection For item numbers See Figure 12 5 6 7 8 9 Inspect Pistons item 1A The O D surface should be smooth and free of scoring The shoes should be snug fit to piston The face of the shoe should be flat and free of scoring and flaking Do Not lap piston shoes Inspect the Piston Block item 1D The bore should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or me
20. the Rear INT 88 amp 96 mowers require a tractor with at least 60HP Operating the mower with a tractor that does not have adequate power may damage the tractor engine 8 TRACTOR 3 POINT HITCH REQUIREMENTS The tractor 3 point hitch must be rated to lift at least 1035 Ibs if attaching a INT 88 and 1170lbs if attaching a INT 90 flail Interstater mowers can attach to tractor s with either a CAT I or Il hitch Refer to the tractor operator s manual for the category of the tractor used If the hitch does not conform to ASAE Cat I or Il dimensions the mower may not Continued Next Page Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 4 SPECIFICATIONS INTERSTATER Continued From previous Page fit or raise properly Consult an authorized dealer for possible modification procedures to mount nonconforming hitches Use the correct hitch pins for the hitch category being used For a Cat I hitch 7 8 lower and 3 4 upper diameter hitch pins are used and Cat II hitches require 1 1 8 lower and 1 upper diameter hitch pins CAT I Implement Hitch Specification Width from outside to outside A frame 26 7 8 gt Quick Hitch width inside lug to lug 27 1 8 LZ lt P dd Height from bottom hitch pin to top pin 18 hue Lower pin diameter 7 8 Attach Here Upper pin diameter E
21. 03 06 2006 Alamo Industrial Section 4 16 Pump amp Motor Hydraulic Schematic Tank Return Filter Assembly amp Tank Return Pressure Gauge Tank Return Hose from Cylinder Control Valve to Tank ank Return Hose from Wet Tubes on LH amp RH Wing Decks Oil Level Sight Glass Oil Temperature Gauge Upper Connection Always Main Frame Cross Over from Pump To Wing Motors Bracket amp Tubes RH NEVER TO WET TUBES Side Shown note Tee HIGH PRESSURE Fitting in lower fittings Lower Connection Always from Deck Wet Tubes to Filter Tank Return Line LOW PRESSURE Nut on Bulkhead Fittings Figure 46 Interstater Service Manual 03 06 2006 Alamo Industrial section 4 17 Pump amp Motor Hydraulic Schematic Wings have a front and a rear wet tube for cooling the oil At the outer end of the decks there is a cross over hose which allows the oil to cross from the rear tube to the front tube The Tubes and the cross over hose are in the oil return to tank circuit which has to be low pressure Figure 47 Tractor Remote Hoses for the Hyd Outlets Lift and Tilt Connecting Cylinders To AD cylinders are Tractor Control Valve for Hydrau the same size lic Supply Qty 3 of Hose P N 02905100 When the tractor hydraulics are used to supply and operate the cylinders 4 4FJX u there will not be a control valve shipped 4FUX X 114 with the mower The hydraulic cylinders will connect direct to
22. 19E 1 Pin Keeper iF 3 Pin 19F 3 Pin 1G 1 Washer 19G 1 Washer IH 1 Spring 19H 1 Spring 1 1 Washer 19J 1 Washer 1K 1 Snap Ring 19K 1 Snap Ring 2 1 Back Up Plate Asy w Brg 20 1 Back Up Plate Asy w Brg 3 1 Driveshaft 21 1 Driveshaft 4 1 Housing Not Furnished as Parts 22 1 Housing Not Furnished as Parts 5 1 Thrust Race amp Bearing 23 1 Thrust Race amp Bearing 6 1 Shaft Seal 24 1 Shaft Seal 7 1 Cam Plate Insert 25 Cam Plate Insert 8 1 O Ring 26 1 O Ring 9 6 Bolt 27 6 Bolt 10 1 Washer 28 1 Washer 11 1 Retaining Ring 29 1 Retaining Ring 12 2 Retaining Ring 30 2 Retaining Ring 13 1 Coupler ot Bearing Backplate 14 1 Lock Ring 32 1 Bearing Housing 15 1 O Ring 33 d Roll Pin 16 1 Bearing Backplate 33A 1 Seal kit Outer Pump in Seal Kit 17 1 Bearing Housing 18 1 Roll Pin 18A 1 Seal kit Inner Pump in Seal Kit Refer To Pump ID Numbers Stamped In Flange To Identify Pump Flange No AsyNo Description 73498 LAA O 001840 Inner Pump Section 2 77 CID Closest to Engine 73425 LAA O1 001734 Inner Pump Section 2 28 CID Closest to Engine FSA2B EE in 001841 Outer Pump Section 2 77 CID Furthermost from Engine 73425 LAB O 001733 Outer Pump Section 2 28 CID Furthermost from Engine NOTE When Replaceing Pump Assembly Complete it is important to Know which Pump CID is being worked on the best way to tell is look at the stamped number in
23. Aux Pump Drive Pulley With The aux pump mount f plate firmly tightened and the drive belt on the pulley but not adjusted tight Slide the pump drive pulley but not adjusted tight Slide the pump drive pulley onthe pumpshaft Fr until the upper pulley is aligned with the lower one once the pulleys are aligned tightren the retaining set screw in the upper pulley to secure it to the pump shaft See Figure 33 E Install Aux Pump Belt Cover The belt cover will mount on the same two bolts that mounts the aux pump mount plate to the main pump mount plate Do not tighten the mount ing bolts yet See Figure 34 Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 31 Removal Repair amp Replace F Adjust Drive Belt on Small Auxiliary Pump The small pump mount plate has a 3 8 square hole that is designed to be used with a 3 8 drive ratchet or breaker bar to ad just the belt Snug the pump mounting bolts and put a 3 8 drive ratchet into the hole Pull up until belt has about the same tension as an automotive belt Tighten the mounting ad justing bolts See Figure 32 amp 35 Auxiliary Pump Drive Belt __ 3 8 square hole Small Hyd Pump for Hyd Cy Ze Supply m G Recheck All Bolts and Components that have been installed The bolts and components that have been installed should be checked before moving on the next step Make certain that all bolts have been ti
24. Cap all hoses immediately to prevent contamination of the hydraulic system Remove Outer amp Inner Pump From Mower Tractor A Disconnect the outer Pump Suction Hose item 4 Figure 4 this hose is retained with hose clamps It is easier to remove the fitting at the pump than the hose clamp Cap all hoses and pump ports immediately B Disconnect the Outer Pump Case Drain Hose item 6 Figure 4 at the pump fittings Cap all hoses and pump ports immediately C Disconnect the Outer Pump pressure hose item 8 Figure 4 at the pump Cap all hoses and pump ports immediately D Remove the two bolts which attach the outer pump item 2 figure 4 to the inner pump flange Remove the outer pump by pulling outward on it Once outer pump is removed cover the opening between the two pumps to keep it clean E lfrepairing pump go to pump repair section for pump repair procedures If installing a new pump or rebuilt pump lightly oil new O Ring and place on inner pump flange Install the new pump rebuilt pump with the pump drain ports facing Hydraulic Tank Right hand side of tractor With your hands push the outer pump into the inner pump until the two pump flanges are touching align the two flange bolt holes and install the retaining bolts CAUTION When working with aluminum castings DO NOT force these pumps together with the bolt it will damage the pumps F Reinstall hydraulic hoses item 4 6 amp 8 Figure 4 Tighten hose fittings to their
25. Connect your Flow Meter in Line to test Pressure as unit is started this will test the Relief Valve this is not required this is only to test the relief valve setting If this is not done you could damage the replacement Pump because you would what the relief is set at until Pump failed from possible excessive pressure 2 Before connecting any lines to Pump fill all Ports with clean Oil to provide initial Lubrication This is especially important is Pump is located at a higher level than Oil Reservoir 3 Check Oil level in reservoir fill to full level if needed Reservoir must have more Oil than the Pump GPM capacity If system has been completely drained of oil or if it is a new system without oil circulated through it The oil level of tank will drop from full to lower level when started and ran 4 After connecting the Lines and mounting the replacement Pump make sure that Oil is not warmer than Pump temperature If Oil is warmer than pump run Pump at short intervals till Pump and Oil temperature is equalized Hot Oil should not be fed into cold Pump If oil is cold do not operate pump at high RPM until oil warms up 5 Operate the Pump for at least two minutes at no load and at low RPM 400 RPM min and 1400 RPM max Watch Flow Meter Pressure or Pressure Gauge During this break in period The unit should run free and not develop an excessive amount of heat Heat should not exceed 100 deg F above ambient Temperature If the unit operates pr
26. Control Switches The power supply wire must be connected to a wire that only has current when the tractors ignition switch is in the ON position ht Figure 49 NA Figure 50 Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 13 Wire Harness Connections CAB amp ROPS 3 Check g mo allWire Har N LH Wing Shown ness Rout ASE From Front ing Inspect melf all ofthe wire harness be fore con necting them Make certain that all portions of wire har ness that have been installed is tied up and out of the way of Battery Shown here is typical folding components or any thing that may ACC Ignition connection Your damage them See Figure 46 thru 58 Wire Ignition may vary Pu function will not 4 Wires from the safety switch must be routed close to cutter housing side sheet and lift frame pivot points This will prevent wires from being stretched and broken when cutter housing is raised or lowered to maximum positions See Fig ure 52 Tractor Ignition 5 Route Wires for Cut Off Switches Switch The wire harnes for the magnetic cut off switches mounted on the wing hinges will Cut be ran through a piece of square tubing welded to the lift frame this is to protect the wires from be hung up on object while mowing Tractor Starter Wire to Starter Solenoid and reroute through Joystick l Harness Brown 6 Wire Harness Components The wire se harness w
27. Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 6 Wing Mower Decks Connecting Mower Motor Hoses 1 Connect Motor Pressure amp Return Hoses Presaure Hose to Mower Deck Connecting the Motor Hoses is Bd kote very critical that they are connected to the correct fittings If these hose are connected backwards it will damage the cooling tubes on the deck the cooling tubes cannot take the pressure it will make them swell up and bulge IMPORTANT FACT When connecting the hoses to the fittings on the mainframe crossmember remember the top hose is always re gt thew pressure hose and will only connect to the me J bottom u motor never the cooling tubes on the deck The hose D Return Ho e ram bottom hoses are the return hoses and will always Figure 18 Colling tue connect to the cooling tubes on the mower deck See Figure 18 amp 19 The RH wing will connect the same as the LH mower Shown IMPOR TANT On the RH Wing the top hose is pressure f 14 sie and connect to the Motor and the bottom hose 4 Pressure connects to the Tank return US 2 Hose w 90 degree at 2 Double Check all Hose Connections Be fore operating the mower make certain all hydrau lic hoses are connected correctly IT IS MOST critical that you make certain NO HIGH PRES SURE hoses are connected to the wet tubes of the mower deck The wet tubes will expand swell up and be damage if the High Pressure h
28. Red to Switched Power Supply 16 Yellow On Solenoid Connector gt 12 Brown Line at Cutter Valve J Connector to Starter Solenoid Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 17 Wing Wire Harness RH Wing Single Wing Wire Harness P N 002496 Note RH Wing Only Single Cap C Wing will use P N 002496 Wire ap Connector used on RH Harness only Only Wing Connector to Main Harness nonne Yellow Outer Connector Con nects to White Wire IN White To LH Wing or Plugged L I Connector to Main Harness Yellow gt JOO Wires connect LD to wing magnet p switch gt Black White Connector to Wing Motor Solenoid Black White Inner Connector Connects to Black Wire Connector to Wing Motor Solenoid Schematic P N 002496 Connector OD bal Connector Gasket Fastening Screw Figure 58 Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 18 BIN mmm Wing Wire Harness LH Wing Dual Wing Wire Harness P N 002497 Connector to Main ae IE White Outer Connector Con nects to White Wire AB EA connect to wing magnet Kann Black White Inner Connector Con nects to Black Wire Connector to Wing Motor Solenoid Connector Fastening Screw c Interstater Service Manual 03 06 2006 Alamo Ind
29. Switch When Wings Raised Lift Cylinder Capacity aaneen Lift Cylinder Capable of 14 Vertical Lift Tilt Cylinder 1G ors ie nn Tilt Cylinder Capable of 45 Degrees Down amp 90 Degrees Up 3 REAR MOWER SPECIFICATIONS Rear Mower cutting Width Options 88 or 96 Cutting Width Depending on tetr mnt kit Cutter Housing Construction 10 Guage Unitized Cutter Housing Deck End Plates annen venen ennven 5 16 Thick Side Plates Both Ends OKE SHOE TN NE Bolt On Replaceable Skid Shoes Cuttershaft SIZE een 4 1 2 x 5 16 Wall Cuttershaft Cullershatt DIVE seem Belt Drive f Gearbox to Cuttershaft w Automatic Spring Tension Cutter Shaft Drive Belt cc eeecceeeeeeeeeeees V Belt w Kevlar Construction Bearing Size amp Type 1 5 16 Bore Greasable Self Aligning Cuttershaft Bearings Cuttershaft DFVE ss 60 HP Gearbox Shielded Driveline Driven Gearbox EV era Cat IV Shielded Driveline PTO Driven Gearbox Driveline Connection nen Adjustable Torque Limiter Clutch Rear Roller TVpe us Steel Tube Construction w Bell Ends amp Hex Shaft Rear Roller Bearings unsure ennen Greasable Sealed w Housing and Hex ID Rear Roller Adjustment nennen 6 Adjustable Rear Roller Cutting Height Adjustment 1 2 Down to 6 Up Cutting Height Rear Roller Me TN Available in Fine or Coarse Cut Safety Deflectors ananas aaneen enen enn Front and Rear Safety Deflectors Standard Rear Mower Cut Off e
30. The To RH E pl i i on RH Only hose for the RH Wing should be Wing Motor marked with a red plastic tie on it Connect these two hoses at the pump now See Figure 19 When single wing there will only Case one suction port of tank used gi From p re dekan See sell Suction igure 19 Port 14A TANDEM PUMP amp Figure 19 dre DUAL WINGS The Pump for the dual wing is atandem pump and will be connected different than the single wing The tandem pump has two suction hoses two case drain hoses and two pressure hoses See Figure 20 15 SUCTION HOSES From e pen or Pressure MOTOR SUPPLY PUMPS e NR EN Out Port The suction hose is used for each pump section aar Le RE To RH Single or Dual as shown When single pump ka Eu EN H ON Wing Motor is used one of the suction ports of the pump will LL VA remain plugged See Figure 5 amp 19 16 AUXILIARY PUMP OPERA TION The AUXILIARY pump is used to supply hydraulics to the cylinder control valve This pump is powered by the tractor engine through a pulley and belt system off of the mn driveshaft to the main pumps See Figure 4 5 Pressure Out 6 8 20 amp 21 If the model you have was set Port To LH Wing up to utilize the tractor hydraulic system to Motor operate the hydraulic cylinder circuit you will not have this pump See Figure 7 amp 9 17 REMOVE AUXILIARY PUMP HOSES AND BELT GUARD Remove the Suction hose and the pressure hose
31. This is inherent in the design On a closed loop or propulsion system the motor will not free wheel as long as charge pressure IS maintained to and from the motor 7 Possible Failure Excessive case drain flow Cause A Excessive internal wear in motor Solution A Disassemble motor inspect parts and replace as necessary Case drain flow should not exceed 1 5 GPM at full pressure Interstater Service Manual 03 06 2006 Alamo Industrial Section 2 4 Possible Failure Cause Solution MOTOR CIRCUIT TROUBLE SHOOTING Continued 8 Possible Failure System will not operate in either direction Cause A Oil supply low Solution A Check oil level and fill as needed Cause B Oil filter clogged Solution B Replace filter element Cause C Oiltoo heavy Solution C Use proper viscosity oil Cause D Drive coupling broken Solution D Inspect coupling for sheared spline or key 9 Possible Failure System noisy Cause A Air in system due to low oil level Solution A Fillin reservoir to sight glass Cause B Loose suction line Solution B Tighten fittings Cause C Clogged suction filter Solution C Replace filter element Cause D Internal pump or motor damage Solution D Disassemble inspect and repair 10 Possible Failure Sl
32. UP HOLD and DOWN amp FLOAT The TILT section has four positions UP HOLD OUT and FLOAT A pressure relief valve is mounted in the inlet section of the valve When a cylinder is bottomed the relief valve will open and allow oil from the gear pump to return to the reservoir Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 23 Mower Repairs Wing Mower Decks CHECKING RELIEF VALVE PRESSURE 1 Tocheck the relief valve pressure setting remove inlet hose at the control valve Install a tee fitting and reconnect the hose to a pressure gauge 2 Check for proper tension on front drive belts 1 4 inch play at midpoint 3 Start engine and run at low idle 4 Raise the Tilt cylinder and note the pressure when the cylinder bottoms 5 The pressure should be the same on both circuits 1200 psi If the pressure is 1200 psi on one and not on the other the relief valve and the pump are working fine Problem would be somewhere else 6 Ifpressureis low on both circuits adjust relief valve Remove hex cap loosen lock nut if present and turn adjusting screw clockwise 7 Ifthe pressure does not increase remove the relief valve and inspect it If the valve is good the gear pump is worn Control valve is only usedto raise and lower the wing mowers only the rear mower will be lifted and lowered by the tractors three point hydraulic system Figure 57 Shows ROPS Tractor mounting with the control handles c
33. X 1 1 8 OD Flatwasher lea 3 8 NC X 3 1 4 Bolt Hex Head 1ea 3 8 NC Hex Nut Place one of the flatwashers over the 3 8 X 3 1 4 bolt and place this through the center of the piston block Place the other flatwasher over the bolt and let it rest on the three pins item 19F Screw the nut on and compress the spring inside the piston block Use a pair of snap ring pliers and remove the internal snap ring item 19K Unscrew the bolt nut and two washers this will release pressure on spring item 19H Remove the spring item 19K the three pins item 19F and the pin keeper item 19E 8 Remove Cam Plate Insert item 25 from housing item 22 The cam plate item 25 should be lying inside the housing item 22 Reach into the housing and the cam plate item 25 should pull out without much effort In some cases because of the oil creating suction it may require that housing be tilted up and cam plate dumped out of housing if this is the case catch the cam plate do not let it drop 9 Remove Snap Ring item 29 Using internal snap ring pliers remove internal snap ring item 29 from front side of housing item 22 10 Remove Input Seal item 24 from housing item 22 The input seal will be remove from the housing using a seal puller Use caution when removing the input seal so you don t scratch or damage the interior seal seat area 11 Remove Seal Washer item 28 which is located behind input seal It may require to lift the housing and dum
34. and laws 10 REMOVE PUMP COVER Remove the Pump Cover by unscrewing the four thumb screws which hold it in place lift cover upward and off lf the area under this cover is dirty it must be cleaned before any dissembling starts this will include all metal surfaces hoses and hose fittings See Figure 2 FIGURE 3 N DA F ba amt Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 5 Tandem Pump w Tank amp Aux Pump Item Qty Description 1 1 Hydraulic Tank and Pump Cover Weldment 2 1 Tandem Pump Asy Outer Half LH Wing Inner Half RH Wing 3 1 Auxillary Pump Asy 4 1 Suction Hose F Tank to LH Wing Pump 5 1 Suction Hose F Tank to RH Wing Pump 6 1 Case Drain Hose F LH Wing Pump to Tank 7 1 Case Drain Hose F RH Wing Pump to Tank 8 1 Pressure Hose to LH Wing Motor 9 1 Pressure Hose to RH Wing Motor 10 1 Suction Hose to Auxilliary Pump 11 1 Pressure Hose F Auxillairy Pump to Cyl Control Valve 12 1 Return Hose F Cylinder Control valve to Tank Return Filter 13 1 Return Hose F Wing Motors to Tank Return Filter 14 1 Hydraulic Tank Temperature Gauge 15 1 Hydraulic Oil Level Sight Glass 16 1 Hydraulic Tank Breather Filler Cap 17 1 Hydraulic Tank Filler Cap 18 1 Hydraulic Oil Return Pressure Gauge 19 1 Hydraulic Oil Return Filter Asy Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 6 Single Pump w Tank amp Aux Pump Item Qty Description 1 1 Hydraulic Tan
35. are assembled This is common but may not be shown on the type tractor you have This tractor model is used for illustration only and should match your application in function and design Some mounting components brackets and the way they connect to the tractor may vary Consult the instructions and or assembly manual for the tractor model the unit is mounted on Interstater Service Manual 03 06 O 2006 Alamo Industrial Section 9 1 Install Main Frame RH Only amp Dual Wing NOTE Frame and componets in this section are for illustration only and is not intended to be the components for any particular model Each tractor model mainframe will connect to tractor using some different components and bolt sizes This section is reference only SEE ASSEMBLY MANUAL AND OR ASSEMBLY INSTRUCTIONS SHIPPED WITH YOUR MODEL TRACTOR FOR SPECIFIC FRAME MOUNT SPECIFICATIONS Steps 6 through 9 will be mostly common on all tractors 1 Identify and locate the frame rail See Figure 1 Sub frame Weldment The tractor drawbar retainer and drawbar will have to be removed The rear of the frame will bolt into the same holes the drawbar was removed from See Figure 3 The frame will be slid under the tractor and lifted up under the tractor The Dual wing mainframe shown below the single wing mainframe will look like the dual wing with the exception there are no wing mounting lugs on the H side of frame 2 Remove RH Side Steps The steps on the RH side of the
36. before beginning any repairs or service to mower allmower must be lowered and resting on ground or supports and NOT lifted by hydraulic system Secure tractor as directed by tractor manufactures instruction for parking Secure tractor to prevent it from being started while being repaired 2 Remove roller and both bearing and bracket assemblies from mower Liftthe mower only high enough to remove the roller assembly Ifinstalling a roller with pre assembled bearing and bracket assemblies remove the old roller proceed to step 12 3 Slide bearing and bracket assemblies off each end of roller If replacing with new bearing and bracket assemblies proceed to step 10 4 Removeroller bearing and housing assembly attaching hardware Remove assembly from bracket Inspect seal between assembly and bracket for brittleness cracks wear and tear Replace if necessary If replacing with new roller bearing and housing assemblies proceed to step 9 5 Remove grease fitting from the top of bearing housing 6 Remove bearing form housing By Rotating Bearing 90 sideways and line up with notches in Bearing Housing then pull out 7 Installnew bearing into housing Bearing must be installed with grease hole in bearing aligned with grease fitting hole in housing 8 Reinstall grease fitting to housing Grease fitting must be tight and seated in grease hole in bearing to prevent bearing from rotating in housing 9 Attach roller bearing and housing assembly to
37. block but do not change the position Install case drain hose REAR MOWER To change direction of cutter shaft rotation for the rear mover three left hand parts are required A belt guard an outboard bearing plate and a idler pulley arm Consult parts book for these part numbers Remove the cutter shaft and turn 180 deg Remove the gearbox cutter shaft drive pulley and outboard bearing plate using the proper bearing plate mount the plate to opposite side of mower housing Remove the four bolts that mounts the gearbox and rotate gearbox 180 deg to new position Install cutter shaft pulley gearbox output pulley idler arm pulley assembly and belt REPLACE EXISTING BELT GUARD WITH PROPER GUARD LIFT AND TILT CYLINDERS See Figure 56 To assist in identification of the cylinders Lift Cylinder measure 3 1 4 O D and Tilt Cylinder measure 3 3 4 O D See Figure 56 Hydraulic cylinders change the position of the cutter unit The lift cylinder raises and lowers the unit by changing position of the lift frame To lift unit oil is supplied to rod side of cylinder Gravity lowers unit when lift levers are in DOWN position Thetiltcylinder changes the angle of the cutter unit Oil is supplied to both ends of the cylinder and provides power to tilt the unit up or down The unit can be tilted to the full vertical position for transport DIS ASSEMBLY amp ASSEMBLY OF LIFT OR TILT CYLINDER See Figure 56 For part numbers and illustration refer t
38. bracket with seal between housing and bracket 10 Slide bearing and bracket assemblies on each end of roller 11 Check bearing for proper installation in housing by gently rocking bearing and bracket assembly in end of roller Play should be slight to none at all 12 Install roller and bearing and bracket assemblies on mower 13 Lubricate roller bearing until lubricant can be seen coming out between roller and bearing housing 14 When reinstalling roller bearing amp mount bracket make certain to bolt at the desired height Desired height will normally be the same bolt holes as before the repair See Previous pages for adjust roller height Grease hole in bear ing must be inline with hole in housing to insure correct placement of grease fitting DETAILOF ROLLER BEARING FIGURE 51 OUTBOARD CUTTERSHAFT BEARING See Figure 52 amp 53 1 Lift cutter unit to maximum horizontal height then securely support ends of cutter housing with jack stands or strong blocks do not use just a jack or hoist 2 Remove enough knives to place a floor jack under center of cuttershaft to support cutter shaft when removing cutter shaft bearing Securely support cuttershaft NOTE The cuttershaft must remain supported while changing bearings 3 Remove outboardfender Continued Next Page Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 20 Mower Repairs Wing Mower Decks OUTBOARD CUTTERSHAFT BEAR
39. cage or Tractor Cab is in place Deflectors are installed on the Mower Head Tractor Rops or Cab with seat belts installed properly All Foot Guards and safety switch are installed and functional Frame Axle Plate Bolts are torqued Head Mounting Bolts tightened Frame attaching Bolts tightened Front Support Bolts are torqued Hydraulic Tank mounting Pins Bolts in place correctly All Welds inspected to insure proper welds and locations Hydraulic System Oil Level in Hydraulic Tank is within the sight gauge Item 5 page 1 4 Hose connections are tight Hoses do not have any kinks or twist in them Front Pump Shaft adapter bolts are tight Front Pump Shaft Coupler Drive Shaft is lubricated and has an anti seize compound on the Splines of Pump and Shafts The Pump Drive Shaft has correct alignment Suction Hose has no leaks or kinks Flail Mower Head Skid Shoe Bolts are torqued to 120 ft Ibs Motor Bolts are torqued to 120 ft Ibs Belt Alignment amp tension adjustment is correct Cutter shaft bearings are properly lubricated Roller bearings are properly lubricated Blades swing freely All Pins and Clips for Rear Mower are installed Clutch on Rear Mower has been checked for proper adjustment and conditions per parts book requirements All Belt guards are installed correctly Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 2 INTERSTATER DELIVERY INSPECTION CHECKLIST Pre Operat
40. connector so that larger brown wires are located on bottom poles of switch This applies to Dual Wing and Single Wing applications See Figure 34 35 40 amp 43 MOWER ON OFF F Interstater Service Manual 03 06 MN Ti r iF 77 N en ULA VE AR a ea Z D ZI I DN Cd syl Er Vu Fa r en T gt RQ A EN N Pa Trans Left or Right Plug as seen from back where wires plug in White for LH Wing Switch OR Figure 35 Yellow for RH Wing Switch 2006 Alamo Industrial Section 8 10 Valve Connections ROPS Tractor 5 Install Valve Supply and return hoses Attach Valve pressure and return hoses to the valve See Figure 10 amp 41 These hoses must be connected according to the schematic shown in figure 10 Do not remove the caps from the ends of the hoses or the valve connections until hoses are being connected 6 Install cylinder hoses to Valve Attach the cylinder hose to the cylinders If a single wing see figure 29 and if a dual wing see figure 30 these hose must be connected as shown in order for the control handles of the valve to match the valve operation instruction decal 7 Connect cylinder hoses to valve The hose will con nectto the control valve from the bottom These hose must be connected correctly in order forthe valve handle to function as designed See Figure 29 30 amp 42 8 Install lower Valve cover The lower v
41. cylinder control DOWD Tande CE sf Suctio Hoses To Control Valve Pressure Ling P Port on Valve ji nil F j As Figure 40 Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 33 Hyd Schematic W Aux Pump RH Wing Motor Return Hose Vent Plug Cooling Tube Cyl Control Valve ae Cyl Valve Return Line Pressure Line Aux Pump Cooling Tube Motor Return Hose amp Deck Cooling Tanks Tank Return Filter amp Return Pressure Gauge Hydraulic Tank Figure 41 d Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 34 Suction Line Hyd Schematic W Aux Pump Dual Wing RH Wing Tilt Cyl LH Wing Tilt Cyl RH Motor Case Drain LH Motor Case Drain 7 E mec Cyl Valve voor Noo T Pressure JE wa Cyl Valve Return Line LH Motor Pres sure Line Cooling Tube RH Motor Pres sure Line Cooling Tube P Motor Return Hose amp Deck Cooling Tanks Cyl Valve Pressure Line Aux Oyl Pump Tank Return Filter amp Return Pressure Gauge Aux Cyl Pump Pump Case Suction Line Drain Lines Figure 41 Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 35 Tandem Pump Suction Lines Hydraulic Tank Hyd Schematic W O Aux Pump RH Winc Motor Return Hose Vent Plug B gt
42. from the auxiliary pump See Figure 22 make certain to cap plug all Hydraulic opening when hoses and fittings are disconnected The belt guard is retained by the same bolts that retain the auxiliary pump mount plate to the main pump mount plate There are two bolts remove the belt adjusting bolt first then the pump plate mounting bolt The pump will remain bolted to the pump mounting plate See Figure 23 amp 24 Figure 24 shows the auxiliary pump with out the tank installed for illustration only The tank will not require removalto remove the auxiliary pump When Auxiliary pump is removed the spline drive coupler and pulley weldment will remain on the main pump driveshaft See Figure 25 amp 26 Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 27 Remove amp Replace 18 REMOVE AUXILIARY PUMP Remove the two auxiliary pump mount plate bolts See Figure 24 amp 25 this will release the adjustment to the V belt Slip the v belt off of the auxiliary pump pulley and leave the belt hanging on the spline coupler pulley weldment See Figure 17 amp 18 below pump The hoses for the auxiliary pump should be disconnected now if they have not been make certain to cap all hoses and pump ports immediately when opened To Control Valve Pressure Line P Port on Valve Splined upler aux pump drive pulley weldment and K ps drive belt remains on M RE drivesahft when ag x is removed I a
43. i before the hoses can be connected Always use 4 Be new O Rings on manifold Manifold must be ori entated as shown in figure 6 in order for hoses to connect correctly 14 Reconnect RH WING ONLY HYDRAULIC MOTOR SHOWN Hoses and Wire Harness The Cross Over Hose at a Case Drain from aps de a the outer end of deck NEVER CONNECT Motor to Motor to Rear Wet Tube should not have been re HIGH PRESSURE Valve and on to Tank moved check it for condi tion and make certain itis still connected Reconnect the hoses to motor CAU TION Make certain that you DO NOT connect the de N high pressure hose to Motor Control deck tubes The high pres NS ze S Mainfold sure WILL DAMAGE St TS TUBES ONDECK ONLY al Er 3 the return pressure from Stk High Pressure from motor can be run through 7 Pump to Motor the deck tubes See Fig ure6 Return from Front Wet Tube to Tank Interstater Service Manual 03 06 2006 Alamo Industrial Section 10 5 Motor Manifold Re Move Repair amp Re Place MOTOR CONTROL MANIFOLD RE MOVE REPAIR amp REPLAGE 1 Motor Control Manifold Motor control manifold components can be replace d block test port plug Machining port plug Pressure Relief Valve Solenoid Valve and or Solenoid Valve Components Reference to parts manual for replacement part numbers See Figure 7 8 amp 9 The Motor manifold can be removed and or replace without removing motor or it can be remo
44. in that order Some parts do not require a PW or LW Refer to illustrations for exceptions Fasteners should be installed so they cause the least interference with other parts When securing driveshaft pulley to hub tighten fasteners to 9 Ib ft torque Interstater Service Manual 03 06 2006 Alamo Industrial Section 1 2 INTRODUCTION TO REPAIRS INTRODUCTION In Most diagrams there are no Component Part Numbers Listed Only ltem numbers and Descriptions This is because most parts shown as breakdown in drawings are for location amp identification only and if available as replacement parts will be listed in the Parts Operators Manual NO Dirt at all should be around Parts during repalrs BEFORE STARTING REPAIRS Service Rules READ THIS 1 Remove Front Cover Clean Pump and surrounding area completely before removing any connec tions or Lines NO DIRT OR DEBRIS CAN BE ALLOWED ON OR NEAR HYDRAULIC SYSTEM IF IT IS BEING WORKED ON ANY DIRT OR CONTAMINANTS IN SYSTEM NO MATTER HOW SMALL WILL DAMAGE SYSTEM 2 After cleaning around all connections thoroughly Disconnect 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 3 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 outsid
45. in the special grooves of the spline area of the piston block with the head end of pin toward inside of block 5 Install Washers item 19G amp 19J and Spring item 19H into Piston Block item 19D install Washer item 19G or 19J are the same into the piston block Install Spring item 19H into piston block and against washer item 19G Install second washer item 19J into piston block and against spring CAUTION See Step 6 for spring compression instructions 6 Compress Spring item 19H and install retaining snap ring item 19K CAUTION The following procedure should be used if the spring has been removed from the piston block The spring item 19H will have to be compressed The following parts will be needed to assemble the piston block 2ea 3 8 ID X 1 1 8 OD Flatwasher lea 3 8 NC X 3 1 4 Bolt Hex Head 1ea 3 8 NC Hex Nut Place one flatwasher over 3 8 X 3 1 4 bolt place this through center of piston block Place other flatwasher over bolt and let itrest on the three pins item 19F Screw nutonto compress spring inside piston block Use snap ring pliers to install internal snap ring item 1K Install internal snap ring item 19K make certain it is seated into snap ring groove in piston block Unscrew bolt nut and two washers this will release pres sure on spring item 19H allowing it to seat against snap ring item 19K Never Remove snap ring in piston block without compressing spring first 7 Install Pivot item
46. is against the clip from the bottom side tightening this nut against clip will lock the other nut inside of clip See Figure 12 2 Connect Clip to Valve Spool Turnthe clip and the valve spool to where the hole in the clip and the hole in the clip are aligned Using a hammer drive the roll pin through the hole in the spool and through the other side of clip See Figure 13 Make certain to keep the clip aligned when driving pin in Turn the clip and spool as shown See Figure 14 Continue this with the other 4 cables and clips See Figure 15 3 Connect Cylinder Hosesto Valve There are six cylinder hoses for dual wing and three for single wing that connect to Control Valve One Pressure P hose and one Tank T hose These hoses are connected as follows See Figure 15 17 Tilt Cyl Rod End RH Wing Tilt Cyl Butt End RH Wing Lift Cyl Rod End RH Wing Tilt Cyl Rod End LH Wing Tilt Cyl Butt End LH Wing Lift Cyl Rod End LH Wing P Pressure Hose from Pump T Return Hose To Tank Connect hoses with elbow pointing down See Figure 16 ON O O1 W D 4 4 Control Valve Information Shown Below is the valve used on the dual wing models this is for illustration only and will not be the same as the single valve used on the RH only model the cable connectins will connect the same The two right sections of the valve as shown in Figure 13 amp 14 are the same as the single valve and will g connect the same way See
47. out of pump body H Remove Pump Shaft Input Seal Using the appropriate snap ring pliers remove the seal retaining snap ring Using a seal removing tool remove the input seal use caution not to damage the pump body housing when removing seal l Cleanall pump components Clean the pump components with clean solvent do not use any abrasive cleaning pads or powders as these would damage pump housing components Completely dry all pump components with clean compressed air Do not dry parts with rags or towels that will leave lent or fuzz on components If cleaned parts are going to be left for long period before re assembly parts should be coated with hydraulic oil to prevent rust and stored in such away as not to allow dust and dirt it contaminate them When these parts are assembled it is recommended that they be washed and cleaned again J Layout Pump components for inspection Lay all the components of the pump out on a clean dry surface this will include all seals gaskets O Rings bolts washer or any other component that is part of the auxiliary pump It is very important that all components be inspected for wear and or damage All replacement parts should be laid out and compared to the old parts to make certain they are the same Some components cannot be re placed as parts they can only be replaced as complete pump assembly Check the pump body and pump cover for wear and or damage this pump will not have shaft Splined Co
48. pin will connect to top three point adjustable Link with pin and click pin Top Link is furnished with tractor not with mower Top Link is adjustable in length and is used to level the mower See Figure 8 5 Connect Driveline Driveline is tied to the mower See Figure 6 amp 9 Cut the ties loose from mower Connect the clutch end of the driveline to the mower the clutch is retained to the gearbox input shaft by a clamp yoke on clutch hub Slip the clutch onto the input shaft until holes in clamp yoke are aligned with the grooves in the input shaft Install and tighten the two bolts and nuts The QD Yoke end connect to the Tractor PTO 6 Leveling the Rear Mower The Rear Mower is leveled with the top Three Point Link The Cutting Height is adjusted by moving the Roller up or down by change the bearing bracket mounting hole There is a decal on the deck next the Operators parts manual cannister See Figure 10 amp 11 7 Rear Mower Completely Connected With the rear mower completely connected Check all Oil levels and grease mower components See Figure 14 before running mower Also DO NOT start tractor if the rest of the assembly to the interstater is not done Make certain that all hoses com ponents wiring is completed and Oil Tank for interstater has been filled with oil Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 3 Mower Repairs Rear Mower 8 Sl
49. pump is used to supply the hydraulic cylinders and cylinder control valve See Figure 3 4 Single Pump without Auxiliary Hydraulic Pump The Single Pump is used for the dual wing model mower and the tractors hydraulics are used to supply the hydraulic cylinders and cylinder control valve See Figure 4 PUMP DRIVE TYPES USED The pump drives system is basically the same on on most interstater mowers The part numbers will vary some from tractor types used The size and or part sizes will vary The best way to determine which drive component you have for your tractor model is consult the interstater assembly manual for the tractor used 1 Tandem Pump with Auxiliary Hydraulic Pump The Tandem Pump is used for the dual wing model mower and the auxiliary pump is used to supply the hydraulic cylinders and cylinder control valve See Figure 1 2 Tandem Pump without Auxiliary Hydraulic Pump The Tandem Pump is used for the dual wing model mower and the tractors hydraulics are used to supply the hydraulic cylinders and cylinder control valve See Figure 2 Test Equpment Recommented 1 Flow Meter The Flow meter should have components to measure A Guage to Measure the Oil Temperature B Gauge to Measure Oil Pressure PSI Load and No Load C Gauge to Measure Oil Flow in G P M D A Valve to load system to check operating Pressure PSI E Assortment of Connections to connect to Hydraulic System Electrical Volt Meter with variable setti
50. rear so you can use a grease gun to grease the splined coupler inside Make certain that all snap rings item 6 amp 8 are installed on shaft and seated into snap ring grooves of shaft Make certain that the shims item 9 are installed these shims are to align the drive pulley with the cutter shaft and idler pulley Remove or add shims as needed Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 13 Gearbox Asy P N 700493 di EN GY Gn AZ FN Y Wd S AE NS UZ ANA 13 14 12 4110 LY EQ 5 17 13 14 10 LAY N N Ver En ENG N zz Finn NN gt gt ER zz ET OX N _N DN G Nie EN GJER an 15 Item Part No Qty Description ID qh 700793 Gearbox Asy 1 100225 1 Pinion Shaft 2 100055 1 seal Output a 3 000330 1 Retaining Ring ltem Part No Qty Description 4 100707 1 Seal Housing 5 100232 a r Shim 020 11 000328 3 Bearing Cone 100233 a r Shim 007 12 100231 1 Bearing Cap 100234 a r Shim 005 13 000354 16 Bolt 100235 a r Shim 002 14 000019 20 Lockwasher 6 100241 1 Spacer 15 100228 1 GiearHousing 7 100237 ar Shim 002 16 700495 1 Shaft amp Gear Asy 100238 a r Shim 004 17 100229 1 Housing Cover 100239 a r Shim 006 18 100054 1 Seal Input 100240 a r Shim 020 19 100230 1 Seal Housing 8 000331 1 Retainer Ring 20 000601 4 Bok 9 000329 1 Bearing Cone 21 000054 1 Pipe Plug Level 1 2 10 000327 4 Bearing Cup 22 000055 1 Pipe Plug
51. test on hydraulic system 3 Possible Failure Motor turns but cutter shaft will not Cause Broken drive belts pulley keys or pulley retaining hardware Solution Inspect belts keys pulley and mounting hardware replace repair as required 4 Possible Failure Motor turns if unloaded slows down or stops as load is applied CauSe A Scored back plate Solution A Remove back plate and examine surface condition of flat area if scored replace back plate DO NOT LAP back plate Cause B Scored or worn piston shoes Solution B Disassemble motor examine condition of shoes on pistons replace pistons as a complete set if necessary DO NOT LAP Cause C Lowrelief valve pressure Solution C Check relief valve for proper pressure setting adjust or replace relief valve 5 Possible Failure Motor will not turn CauSe A Severely scored back plate Solution A Disassemble motor completely Inspect all parts clean all parts replace all worn parts and flush hydraulic system 6 Possible Failure Motor free wheels Cause A Oil flow and pressure shut off going to motor Solution A When the hydraulic system is shut off either by shutting off the engine on a closed loop system or returning the control valve spool to neutral on an open center system the motor will free wheel after it has leaked off
52. that the oil in the hydraulic tank has not turned milky in color or has foam on top Check that there are no loose fasteners or hardware Operator Customer Orientation Details discussed with operator customer any variance pointed out and discussed Operator customer aware of all aspects of repairs Notes Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 3 INTERSTATER DELIVERY INSPECTION CHECKLIST Tractor Mower Component Location For Check List Pumps Hyd Tank amp Cover ET Right Wing Flail MT Lift Fold Control Valve y RH SIDE OF TRACTOR ryt LH SIDE OF TRACTOR Rear Mower Driveline Rear Center Flail Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 4 INDUSTRIAL Insterstater Service Manual 2006 Edition P N 80321385 Interstater Service Man 03 06 2006 Alamo Group Inc
53. the lug and arm holes and insert retaining pin into hitch pin F Walk around to opposite side and repeat procedure for remaining lift arm and hitch pin G Extendor retract 3 point top link to align its end hole with the holes of the mower s top link Insert the top link hitch pin and insert retaining pin into hitch pin H Adjust any lower link check chains guide blocks or sway blocks to prevent the mower from swaying side to side and possible contact with tractor rear tires Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 5 SPECIFICATIONS INTERSTATER 10 LEVELING REAR MOWER To Facilitate a safe and efficient mowing operation the mower should be operated parrallel to the ground at all times Never operate if front or rear of mower is tilted upward Objects may be discharged at high speeds causing possible injury or even death Adjust Top Link to level mower roller adjustment Side Skid Shoes should always be parallel to ground throughout the full adjustment range Adjust cutting height of machine by raising or lowering rear roller as specified in Operation Section 11 TRACTOR HYDRAULICS The wing mowers are raised and lowered with 2 hydraulic cylinders a till and lift cylinders for each wing section Hydraulic lines are plumbed together and controlled by a 4 spool or 2 spool control valve The tractor must be equipped with either a 4 spool valve or 2 spool valve open center system with m
54. the pump flange Most of the parts on the inner and the outer pump are the same the parts on the 2 28 CID pump and the 2 77 CID pump are the same except for item number 4 the pump housing Item number 4 determines which CID pump you have also item number 4 is not avalable as a replacement part If the housing needed to be replaced it would require the pump assembly to be replace as an assembly This is when it is so importanrt to identify the pump by checking the number stamped in the pump flange Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 15 Tandem Pump Dis Assembly amp Re Assembly 12 Tools Required for Pump Dis Assembly and Re Assembly 1 ea Ratchet Wrench 1 ea 1 2 Socket 1 ea Seal driver or Similar Tool 1 ea Torque Wrench 68 N m 50 ft Ibs 1 ea Soft Face Hammer 1 ea Petrolium Jelly Vaseline 1 ea Internal Snap Ring Pliers straight 2 3mm 090 in Tip 1 ea External Snap Ring Pliers straight 1 8mm 070 in Tip 13 Tandem Pump Dis Assembly Inner Rear Pump The following instruction are based on the presumption the pumps have been disconnected from tractor unit and are ready for the work bench All Ports and pump openings are still capped plugged The Inner Rear pump and the Outer Front pump have NOT been unbolted and separated For Replacement Part Numbers to repair or replace these pumps see the Parts manual for the Interstater For a Specific tractor Mounting Components see the A
55. the splined area of the piston block Install the three pins in the special grooves of the spline area of the piston block with the head end of pin toward inside of block 5 Install Washers item 1G amp 1J and Spring item 19H into Piston Block item 1D install Washer item 1G or 1J are the same into the piston block Install Spring item 19H into piston block and against washer item 1G Install second washer item 1J into piston block and against spring CAUTION I See Step 6 for spring compression instructions 6 Compress Spring item 1H and install retaining snap ring item 1K CAUTION The following procedure should be used if the spring has been removed from the piston block The spring item 1H will have to be compressed The following parts will be needed to assemble the piston block 2ea 3 8 ID X 1 1 8 OD Flatwasher lea 3 8 NC X 3 1 4 Bolt Hex Head tea 3 8 NC Hex Nut Contnued Next Page Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 25 Single Pump Dis Assembly amp Re Assembly Continued From Previous Page Re Assemble Single Pump For item numbers See Figure 17 6 Continued From Previous Page Place one flatwasher over 3 8 X 3 1 4 bolt place this through center of piston block Place other flatwasher over bolt and let it rest on the three pins item 1F Screw nut on to compress spring inside piston block Use snap ring pliers to install internal snap ring item 1K Install i
56. this is something the technician will need todecide as they assemble the unit Alamo Industrial recommends connecting the wires at thetractor ignition switch See Figure 7 thru 9 Also see the wire harness schematic on the following pages Consult Tractor Repair Manual for wiring schematic of Tractor to determine what wire is what on the tractor ignition switch 2 Connect Power Supply for Motor Control Switches N 1 a J The power supply wire must be connected to a wire that only has currentwhen the tractors ignition switch is in the ON position r Figure 10 Figure 11 fs vy Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 7 Wire Harness Connections CAB amp ROPS 3 Check all Wire Har si LH Wing S5hown ness Routing ER Inspect all of AUSH From Front the wire har ness before connecting them Make certain that all portions of wire harness that have beeninstalled is tied up and out ofthe way folding components or any thing that may damage them See Figure 7 thru 9 Shown here is typical Igni tion connection Your Igni 4 Wires from the safety switch must be tion may vary but the func routed close to cutter housing side sheet and Ignition lift frame pivot points This will prevent wires from being stretched and broken when cutter housing is raised or lowered to maximum positions See Figure 13 5 Route Wires for Cut Off Switches The wire ha
57. 1 701628 S Lift Frame Asy Suspension Chain 2 701627 A Cuttershaft Brg Puller 3 104764 A Lift Frame Alignment Pin 2 4 104768 A Rubber Bushing Support Base 5 104767 A Rubber Bushing Compression Ring 6 104765 A Rubber Bushing Expander f Ford amp Kubota Tractor 7 104766 A Rubber Bushing Expander f Case I H MF amp Case Tractors 8 104769 A Drive Shaft Installation Collar 9 104770 A Rubber Bushing Installation Plug 10 103741 A Seal Installation amp Seating Tool 000802 S Hyd Pressure Gauge 3000 PSI A Denotes special tools designed by Alamo S Denotes std tools equipment available on market 4 RECOMMENDED GAUGES FOR DIAGNOSTICS A Inlet Vacuum 30 PSI to 30 in Mercury 207 bar to 0 bar B System Pressure Gauge 6 000 PSI 700 bar C Charge Pressure Gauge 0 to 500 PSI oto 25 bar 5 POWER CIRCUIT The pump unit assembly is made up ofthe oilreservoir and hydraulic pump The pump is driven by the engine crankshaft through a drive shaft Therefore oil is being pumped whenever the engine is running When the mower is off oil is directed to the reservoir by the solenoid motor control valve and does not flow to the cutter motor Cooling is provided by patented in frame cooling tubes in the wing mowers gt 6 PUMP TYPE The pump unit for the wing mower rotorshaft drivepower circuit is a piston fixed displacement pump see pump repair and is engine driven Itis mounted on the front of the tractor abovethehydrau
58. 19C Spider item 19B and piston assembly item 19A Sit the pivot item 19C down onto the piston block with the taper rounded side up See Figure 12 Sitthe spider item 1B down over the pivot noting the concave hole in the center of the spider will sit over the rounded edge of the pivot align the holes in the spider with the holes in the piston block Lower the Piston assemblies item 19A through the spider holes and into the piston block the piston assembly can be installed one at time Contnued Next Page Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 21 Tandem Pump Dis Assembly amp Re Assembly Re Assemble Inner Rear Pump Continued From Previous Page 8 9 10 11 12 13 Install Cam Plate Insert item 25 Lubricate cam plate insert item 25 well and install it into pump housing item 22 until it seats down into housing This is best done with pump housing lying on its side on work bench Install Piston Block Assembly item 19 Coat piston block asy with oil Slide piston block asy into end of pump housing aligning ID of it over driveshaft Push piston block asy into housing over driveshaft until piston shoes are in contact with cam plate insert it may require driveshaft to be turned as the piston block asy is being slid in to align splines of shaft with spline of the components of piston block asy DO NOT use excessive force to install piston block asy if it will not slide tog
59. 1D The piston assembly will pull upward and out of piston block 9 Remove Spider item 1B and Pivot item 1C The spider item 1B will be left lying on the piston block when the piston assembly is removed the Pivot item 1C will also be left on the piston block and can be removed 10 Piston Block Dis Assembly item 1D The Piston block assembly need not be dis assembled unless the pins item 1F or the Spring item 1H is damaged CAUTION The following procedure should be used if the spring is to be removed from the piston block The spring item 1H is highly compressed and the snap ring item 1K should NOT be removed without compressing the spring The following parts will be needed to dis assemble the piston block 2ea 3 8 ID X 1 1 8 OD Flatwasher tea 3 8 NC X 3 1 4 Bolt Hex Head lea 3 8 NC Hex Nut Place one of the flatwashers over the 3 8 X 3 1 4 bolt and place this through the center of the piston block Place the other flatwasher over the bolt and let it rest on the three pins item 1F Screw the nut on and compress the spring inside the piston block Use a pair of snap ring pliers and remove the internal snap ring item IK Unscrew the bolt nut and two washers this will release pressure on spring item 1H Remove the spring item 1K the three pins item 1F and the pin keeper item 1E 11 Remove Cam Plate Insert item 7 from housing item 4 The cam plate item 7 should be lying inside the housing item 4 Re
60. 4 ar ae F ii f hm nen Tat un Nie 9 RSS NG ar 18 2 13 Item Part No Qty Description Item Part No Qty Description 702673 Gearbox Asy 11 001724 1 Seal 1 001718 1 Pinion 12 001725 1 Shaft amp Gear 2 001719 1 Seal 13 00754459 1 Bearing Ball 3 001717 1 Nut 14 001708 8 Bolt 4 001720 1 Spring Washer 15 001710 1 Cover 5 00754757 2 Bearing Roller 16 00755633 2 Plug 6 001716 1 Spacer 17 000055 2 Plug Drain 7 00754752 2 Circlip Internal 18 002516 1 Housing 8 001722 1 Bearing Roller 19 00769800 1 Gasket See NOTE 9 00753222 2 Shim NOTE Some Models Used Gaskets Cur 10 00754761 1 Shim rently All Models Use Sealant or Form A Gasket NOTE This G B Asy P N 702673 Can replace earlier style P N 700493 as an Asy but parts WILL NOT interchange between them The easiest way to tell which G B you have is by looking were the Shaft goes through the G B Housing The Old Style had Bolt on Caps Here and the new style will not Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 16 Gearbox Asy P N 702673 Asy Instructions Assembly Instructions Gearbox 702673 Used Feb 1991 amp Up Install Output Shaft amp Pinion Gear into Main Housing 002516 2 Install Snap Ring 00754752 into Main Housing 002516 Install Shims 00753222 on Output Shaft next to Gear Install Inner Output Bearing Cone 001722 Cup amp Cone on Output Shaft 001718 Install Inner Bearin
61. CT EEE 12 Bm Fuse Holder with Fuse 10 Amp Fuse Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply Ground 16 Black m Solenoid mn Connector Ring Connector to Ground Vi Connecters Shipped Loose in Separate Plastic Bag y OOO lt N N 16 Red to Switched Power Supply 16 Yellow gt On Solenoid Connector gt 12 Brown Line at Cutter Valve wy Connector to Figure 17 Starter Solenoid Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 11 Wing Wire Harness R Wing Single Wing Wire Harness P N 002496 Note RH Wing Only Single Cap C i Wing will use P N 002496 Wire ap Connector used on RH Harness only Only Wing Connector to Main Harness JUUN To LH Wing or Plugged M I Connector to Main Yellow Harness Outer Connector Con nects to White Wire Wires connect to wing magnet switch Black White Inner Connector Connects to Black Wire Yellow gt gt u JUDO J Black White Connector to Wing Motor Solenoid Connector to Wing Motor Solenoid Schematic P N 002496 Connector OD Lal Connector Gasket Fastening Screw Figure 18 Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 12 EN Wing Wire Harness L amp R Wing Dual Wing Wire Harness P N 002497 Connector
62. D Forward Rotation Drive Belt is to the Left Side Reverse Rotation Drive Belt is on Right Side Standing Behind Unit looking toward Tractor Item 3 amp 4 Lengths are from End to End Item 4 includes welded on round Flanges on Ends in measurement To ID which Unit you have measure the Extension Shafts or Housings see interstater Archive Parts Manual for lengths of shafts amp housings 2 Gearbox Asy amp Extension Shaft Asy Identification The rear mowers are mechanical driven through a driveline and gearbox assembly The gearbox has a extension shaft connected to it These shafts will not all be the same they will be different lengths depending on the size Width of the mower the cutter shaft rotation forward or reverse and the amount and direction of the offset of the A Frame on the mower The mower will need to be identified before ordering shaft tube See Interstater Archive Parts Manual for extension shaft ID There were two different gearbox assemblies used See Gearbox Repair in next pages to ID gearbox 3 Remove Drive belt Guard Remove the drive belt guard item 19 itis retained by two bolts One bolt to the front and one to the rear of the deck Set the belt cover aside as it will not be need until repair is finished 4 Remove Gearbox amp Extension Shaft as an Assembly Itis recommended gearbox and cutter shaft be removed as an assembly this will keep oil from being spilled on mower deck and component drive pulleys and belts
63. Figure 16 and step 3 Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 4 Joystick Valve amp Control Cables Cab F AN s r 3 Figure 15 ontrol Valve Hoses Figure 16 Dual VAM Valve Vent Plug r A d AN 131 2 rg el j Figure 17 k jle Wing Valve Figure 18 Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 5 Joystick Valve amp Control Cables Cab Remote Control Cable Connections to Control Handles Cab Tractor 1 Drill Hole IN Floor Mat and Cab of Tractor to Install Remote Cable Control cables and wire harness into Cab of Tractor Thereis one 1 1 2 minimum size holes that will need to be drilled into the floor mat completely through the floor of tractor See Figure 19 This hole is best cut with round hole saw Looking at the pictures note the location of hole as compared the ribs that run across the floor mat this will give you indication of the location of this holes in floor mat a m i r Er EF re 5 FO 2 Install Remote Control Assembly Mounting Bracket The mounting bracket for the remote control levers will boltto the front cab post in two existing threaded holes See Figure 20 This bracket should be tighten before mounting anything to it 3 Install Wire Harness through floor Mat The Wire harness will come to you with the on off switches attached these switches will need to be removes to Push t
64. Figure 28 amp 29 The Hydraulic hoses must be connected correctly to the cylinders and the Valve or the control functions will not be correct according to the operation instruction decal See Figure 29 amp 30 Em Figure 26 fl kat Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 8 Valve to Cylinder Hose Connections Cab amp ROPS go 0000000000000000000 P Pressure Port T Tank Return Port RH Wing Only Use with Aux Pump gg 000000000000000000 P Pressure Port T Tank Return Port Dual Wing Use with Aux Pump Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 9 Valve Connections ROPS Tractor Valve Connections ROPS Tractor 1 Install Valve Stand to Tractor on ROPS Tractor only Attach Valve Stand to the top of the Right Lift Cylinder Support with 3 1 2 x 1 1 2 bolts and 3 1 2 locknuts See Figure 31 amp 34 2 Attach Valve Stand to Valve Mount Bracket Attach Valve Stand to the Valve Mount Bracket with 2 3 8 x 1 1 4 bolts and 2 3 8 locknuts See Figure 32 37 amp 38 3 Attach Control Valve to the Valve Stand Attach Control Valve to the Valve Stand with 2 3 8 x 1 bolts 2 3 8 locknuts Attach the Top Cover andthe Bottom Cover to the Valve Mount Bracket with 8 3 8 x 1 bolts 8 3 8 washers and 8 3 8 locknuts See Figure 33 amp 38 4 Install Mower Wing ON Off Switches Make certain to install
65. Filter amp Return Pressure Gauge Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 4 Hydraulic Tan Hyd Schematic W O Aux Pump Dual Wing LH Wing Tilt Cyl RH Wing Tilt Cyl RH Motor Case Drain LH Motor Case Drain 7 L moc Cyl Valve voor Noo T Pressure imi v LH Motor Pres sure Line RH Motor Pressure Line y X O Cooling Tube Motor Return Hose amp Deck Cooling Tanks Cooling Tube CylValve Pressure from Tank Return Tractor Hyd Filter amp Return Pressure Gauge CylValve Pump Case Tandem Pump oo Drain Lines Suction Lines y Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 5 Hydraulic Tank Valve to Cylinder Hose Connections Cab amp ROPS goo00000000000000000E P Pressure Port T Tank Return Port RH Wing Only Use with Aux Pump goo00000000000000000E P Pressure Port T Tank Return Port Plug 0000000000000000000000 Dual Wing Use with Aux Pump ey Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 6 Wire Harness Connections CAB amp ROPS Wire Harness Connections 1 Connect Wire Harness to Tractor Starter Activation Wires The wires to the starter from the motor control switches will need to be connected to the tractor near the ignition switch connections Or they can be connected near the starter solenoid
66. Hose Connections Cab amp Rops 4 6 Wire Harness Connections Cab amp Rops 4 7 to 4 8 Wire Harness Schematic Cab amp Rops 4 9 Motor Control Switch Dual Wing 4 10 Motor Control Switch RH Wing Only unne 4 11 Wing Wire Harness RH Wing Only nnen eneen 4 12 Wing Wire Harness Dual Wing 4 13 Pump amp Motor Hyd Schematic RH Wing Only 4 14 Pump amp Motor Hyd Schematic Dual Wing 4 15 Pump amp Motor FANd Sch matie ade 4 16 to 4 18 Interstater Service Manual 03 06 2006 Alamo Industrial Index 1 2 INDEX Section Page NOE rn Index 2 of Index 3 Section 5 Hydraulic Pumps Tandem Single Auxiliary Remove Repair Replace u nn 5 1 to 5 37 Tandem amp Single Pump Removal sauna enne eenens 5 2 to 5 3 Tandem amp Single Pump Repair Replace en 5 4 to 5 5 Tandem Pump W Tank amp Aux Pump 5 6 Single Pump W Tank amp Aux PUumMpP 5 7 Tandem Pump amp Driveshaft Asy W Aux Pump 5 8 Tandem Pump amp Driveshaft Asy W O Aux Pump 5 9 Single Pump amp Driveshaft Asy W Aux Pump 5 10 Single Pump amp Driveshaft Asy W O Aux Pump 5 11 Tandem amp Single Pump Remove Replac b 12t0 5 13 Tandem Pump Disassembly amp Reassembly 5 14to 5 22 Single Pump D
67. Housing Not Furnished as Parts 18A 1 Seal kit Inner Pump in Seal Kit D 1 Thrust Race amp Bearing Refer To Pump ID Numbers Stamped In Flange To Identify Pump Flange No AsyNo Description 73428 LAF 00755650 Single Pump 2 77 CID LE 7 720 LAG moeren Sane 001827 Single Pump 2 28 CID NOTE When Replaceing Pump Assembly Complete it is important to Know which Pump CID is being worked on the best way to tell is look at the stamped number in the pump flange Most of the parts on the inner and the outer pump are the same the parts on the 2 28 CID pump and the 2 77 CID pump are the same except for item number 4 the pump housing Item number 4 determines which CID pump you have also item number 4 is not avalable as a replacement part If the housing needed to be replaced it would require the pump assembly to be replace as an assembly Thisiswhenitis so importanrt to identify the pump by checking the number stamped in the pumpflange Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 23 Single Pump Dis Assembly amp Re Assembl Dis Assemble Single Pump For item numbers See Figure 17 1 10 11 12 13 Clamp Single Pump in Vice with Jaw Protectors See Figure 15 Single pump can be clamped in vice or it can be disassembled while on work bench Remove Back Plate Item 2 The backplate is mounted with six hex head bolts item 9 remove these six bolts It will require a s
68. ING Continued From Previous Page 4 Remove fasteners securing bearing and housing assembly to cutter housing then remove bearing and housing assem bly See Figure 46 NOTE There are two tapped holes in the housing which can be used to pull bearing and housing assembly out by using special tool No 701627 5 Using a jack to align parts install bearing and housing asy to cutter unit amp make certain that bearing setscrew If Used is located in keyway on cuttershaft Grease bearing and install cap over fitting If only the outboard bearing and housing assembly is to be replaced proceed as follows Remove jack and check shaft rotation Reinstall knives which were removed Reinstall outboard fender Remove supports lower unitto ground and test unit Ifthe inboard drive bearing is to be replaced proceed to step 6 INBOARD CUTTERSHAFT BEARING See Figure 52 amp 53 6 Remove spring from idler arm 7 Remove motor mounting bracket fasteners at the cutter housing Pivot motor mounting bracket assembly and remove drive belts 8 Remove fasteners that secure pulley to cuttershaft See Figure 53 item 2 Remove pulley and key See Figure 53 amp item 2 9 Removefasteners securing inboard bearing and housing assembly to cutter housing then remove bearing and housing assembly Refer to Illustration 9 NOTE There are two tapped holes in the housing which can be used to pull bearing and housing assembly out by using special t
69. Industrial Section9 5 NOTES Interstater Service Manual 03 06 2006 Alamo Industrial Section 9 6 Section 10 Interstater SERVICE MANUAL Hydraulic Motors Motors for Wing Mowers Remove Repair Replace Motor Removal amp Replace GENERAL MOTOR REPAIR REPLACEMENT INFORMATION A Todisassemble repair your INTERSTATER this manual is designed to assist you with drawings instructions and information This manual is designed to be used in conjunction with the parts manual operators manual and assembly manuals If additional information or clarification is needed contact your Alamo Industrial factory representative B Some ofthese instructions are general information and not specifically for your tractor but in connection with our drawings they may not show the exact application and tractor you have In many cases reference to assembly manual for your mower to tractor application will clarify some clarity to exact applications C This section covers the removal repair and reinstallation of the hydraulic motors procedure for the Alamo Industrial Interstater mower it also includes instruction for hoses and miscellaneous parts to be attached the hydraulic motor to mower head D These instructions are for working on the motors used to power wing mower mowers right side mower and left side mower units if dual wing model For mounting one mower side only disregard information concerning the opposite side Hardware quant
70. LING TO FOLLOW SAFETY MESSAGES AND OPERATING INSTRUCTIONS CAN CAUSE SERIOUS BODILY INJURY OR EVEN DEATH TO OPERATOR AND OTHERS IN THE AREA 2 NO RIDERS USE SAFETY SHOES 4 BLOCK UP SECURELY NO CHILDREN OPERATORS HARD HAT SAFETY BEFORE WORKING GLASSES SEAT UNDER BELTS A ROPS 1 Study andundersis nd operator sans safety signs and Instructional decals for race and implement la prevent m use abuse andarccidents Leann how 6 alop engine suddenly l 8 emergency Be alert f r passer by and espedaly chi dren 2 Allow no children on or near implement or tractor Al ow nonders on tractor andimplement Falling of may cause senousinjury or dea from being run Gar by rader or Gutler or contact wilh rotengblades 2 Operate ondatih tractor heving Kolk Over Protective Slructure RF Sj en datth seabbelt fastened securely and nano bo prevent injury ard possible dean from fallng of or tractor verten Personal Protective Equipment such 85 Hard Hat Salty Glasses Safety Shoes and Ear PAS ae REDT En ded 4 Block up or support raised machine and alliftedcomgpanents s curehy before putting hands or te et under or working underneath a ny Med components bo prevent crusting Injury or death from sudden dropping or inadvertent operation of controls Make certain areas dew before lowering or folding 2 Before transooting put Lift Lever in delen or full poskon Secure Me implement tor bansport by installing Cylinder Stops or Transport Fin on Pull type i
71. Line P Port on Valve To Control Valve Pressure IE 2 A W ONM VV To Control Valve P U ik A ET Ea tx Hose Sleeving Ar An Material 1 P Tank r Ad lg Suction 7 BeWe ldnient PIN F i Line Figure 9 n Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 3 Joystick Valve amp Control Cables Cab Remote Control Cable Connections to Control Valve Cab Tractor 1 Control Valve Cable Clips Locate the four cable g mounting clips and four roll pins shown laying on muffler pue Woenting Clips8 bracket for illustration only in Figure 10 Start the roll pins Roll Pins into the clips as shown through one side only See Figure 10 Insert the Remote Cable through the Control Valve Mount Bracket See Figure 3 Install the large cable retaining Adjusting nut onto threaded portion of cable housing See Figure 11 DO NOT tighten this large nut until later On the tip of the threaded end of the cable there is a 1 4 nut Screw this nut down onto cable Insert the cable clip down overthreaded cable end See Figure 12 Findthe four for dual wing and two for single wing 1 4 nut supplied install one onto end of cable down into clip This nut should be screwed onto cable at least the thickness of the nut do not screw it on so far that it will interfere with the operation of the cable Using the nut that was already on the cable screw the nut out until it
72. Motor Hydraulic Schematic ala i Sn I C3 BL DE sth i LEAS r a AT _ 8 i Pr Ceara E y hi Ur i x 1 ds p a ER Wings have a front and a rear wet tube for cooling the oil Atthe outer end of the decks there is a cross over hose which allows the oilto cross from the rear tube to the front tube The Tubes and the cross over hose are in the oil return to tank circuit which has to be low pressure Figure 32 Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 17 1 Mower Repairs Wing Mower Decks GENERAL Mower should be in the lowered position mowers resting on the ground Tractor shutdown and parked safely according to tractor manufactures instructions NEVER work on or repair mowers with tractor running and mowers supported by hydraulic system Mowing is accomplished by a series of knives which rotate athigh speed on a shaft On Wing Mowers the shaftis driven by a hydraulic motor through a set of drive belts Belttension is maintained by a spring loaded idler pulley The cutter unit is mounted to the lift frame by two mounting pins and held in place by a hydraulic cylinder This cylinder is usedto tilt the cutter unit to allow mowing on an angle and tilting to the vertical position for transporting Another hyd raulic cylinder is mounted to the lift frame andthe lift cylinder support This cylinder is used to raise the cutter unit via the liftframe Th
73. P HANDLE AT ALL TIMES Typical Torque Wrench Shown If an adapter is attached to the drive of a torque wrench the wrench will not give actual torque indicated by the setting of the handle A simple formula however allows you to figure out what the setting should be to deliver a predetermined amount of torque at the end of any adapter to the fastener The following letters are defined as Length of the torque wrench when set at the middle scale setting inches Length of adapter inches from center hex bolt to center of torque wrench square shaft Desired torque at end of extrusion Setting for accuracy within or 6 OOWP I Here is a typical problem You have an adapter that adds 10 0 inches to a torque wrench length dimension B What should the setting be to obtain 320 ft lbs of torque at the end of the adapter A 22 57 inches length from adapter mounting point torque wrench to center of grip handle B 10 0 inches Length from adapter mounting point of torque wrench to center of hex slot C 320 ft lbs torque desired torque at end of extension D Unknown setting you need to set torque wrench to 320 ft lbs for accuracy A 22 57 22 57 C nn or 320 320 320 X 222 ft lbs A B 22 57 10 0 32 57 Your Answer D is a setting of 222 ft Ibs on the torque wrench will give 320 ft Ibs of torque at the bolt By using the above formula an ac
74. Problems Tractor Problem Inquiries oo ON HOW YOU CAN HELP 1 Make sure the callis necessary Most of the calls received may not be necessary if the Dealer Service Technician would do the following 2 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 3 fa callto 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 to future problems of a similar nature 4 The technician may be asked to provide detailed information about the problem including the results of any required trouble shooting techniques Ifthe information is not available The technician may be asked to getthe 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 Indust
75. Remove the bolts that connect the cutter shaft bearing housing item 7 2 to the idler bearing extension shaft mount plate item 16 is may be easier to remove these bolts by removing the upper drive pulley item 10 and drive belt item 11 Toremove drive pulley item 10 remove the pulley retaining bolt item 15 lockwasher item 14 flatwasher item 13 Pull the drive pulley off note the pulley key item 12 may come off with pulley or stay in shaft Remove key now so as not to lose it Note how many shims washers item 9 are on the extension shaft behind the pulley quantity can vary so it is best to count them and use the same amount when reass embling the shaft With the bearing housing bolts removed go to the gearbox end and remove the 4 bolts mounting the gearbox item 1 to the a frame mounting plate This will allow the gearbox extension shaft assembly to be lifted up off the deck Bearing housing item 7 2 should slide off extension shaft 5 Remove Bearing Retaining Ring Remove bearing retaining ring item 8 from the extension shaft This can be done with external snap ring pliers 6 Remove extension shaft housing Extension shaft housing item 4 is mounted to the gearbox with 4 mounting bolts removing these four bolts will allow the housing to be slid away from gearbox Note the extension housing can be removed from gearbox with the extension shaft inside housing and bearing item 7 left on shaft The extension shaft item 3
76. S 3 4 Linch pin diameter unne nennen een 15 32 Height from bottom hitch pin to top pin 19 CAT Il Implement Hitch Specification Lower pin diameter nnen eneen 1 1 8 Width from outside to outside A frame 32 3 8 Upper pin diameter 1 Quick Hitch width inside lug to lug 33 5 8 Linch pin diameter nnen 15 32 9 CONNECTING REAR MOWER TO TRACTOR Use extreme caution when connecting the mower to the tractor The mower should be securely resting at ground level or on blocks Place a block in front of and behind the tires to prevent the mower from moving Keep hands and feet out from under the mower and clear of pinch points between the tractor and mower A Make sure the tractor is equipped with the correct PTO shaft Change shafts if needed B Shorten or remove the tractor drawbar to avoid interference when raising and lowering the mower C Boardthetractor and startthe engine Position the tractor to the mower with the 3 point lift arms positioned between the respective set of mower A frame lift lugs Note Setthe 3 point lift control to Position Control so thatthe lift arms maintain a constant height when attaching the mower See the tractor Operator s Manual for correct settings when attaching 3 point equipment D Turnoffthe tractor engine and dismount E Oneliftarmatatime align arm end hole between the set of A frame lift lugs Insert hitch pin through
77. Schematic at end of this section B Tandem Pump without Auxiliary Hydraulic Pump The Tandem Pump is used for the dual wing model mower and the tractors hydraulics are used to supply the hydraulic cylinders and cylinder control valve See Hydraulic Schematic at end of this section C Single Pump with Auxiliary Hydraulic Pump The Single Pump is used for the Single wing model mower and the auxiliary pump is used to supply the hydraulic cylinders and cylinder control valve See Hydraulic Schematic at end of this section D Single Pump without Auxiliary Hydraulic Pump The Single Pump is used for the dual wing model mower and the tractors hydraulics are used to supply the hydraulic cylinders and cylinder control valve See Hydraulic Schematic at end of this section E Pumps with different Cubic Inch Displacement CID There are two size pumps used a 2 28 CID pump and a 2 77 CID pump The Higher 2 77 CID pump is used on tractors that operate with a lower RPM engine speed 2000 RPM and below to acheave PTO Speed Tractor using 2000 RPM and above use the larger 2 77 CID Pump are tractor that use a High Engine RPM above 2000 RPM to achieve the PTO Speed will us the lower 2 28 CID pump DO NOT use the 2 77 CID pump on tractors with higher than 2000 RPM engine speed See Below for ID numbers that will be stamped on pump flange Flange No AsyNo Description 73498 LAA 0O1 001840 Inner Pump Section 2 77 CID Closest to En
78. T LIONMUO RECOMMENDED GAUGES FOR DIAGNOSTICS A Inlet Vacuum 30 PSI to 30 in Mercury 207 bar to 0 bar B System Pressure Gauge 6 000 PSI 700 bar C Charge Pressure Gauge 0 to 500 PSI 0 to 25 bar Interstater Service Manual 03 06 2006 Alamo Industrial Section 10 3 Removal amp Replace MOTOR REMOVAL FROM WING DECK 1 Secure tractor amp Mowers Lower Wing and rear Mowers down until they are resting on the ground DO NOT MAKE REPAIRS with mowers lifted or folded Secure Tractor as to tractors manufactures specification for parking tractor Secure tractor so it cannot be started Alamo Industrial recommends that battery cables be dis connected from tractor battery 2 Remove Drive Belt Cover on Wing Mowers Remove y Motor Drive Belt drivebelt cover See Figure 1 which will allow access to the PS and Pulley motor drive belt and pulley See Figure 2 2 SS _ Cover 3 Dis connect Hoses from Wing Motor The hoses on AR the wing will need to be dis connected from motor Cap Plug ES these hoses and all openings in motor immediately when you Bi disconnect them See Figure 2 4 Disconnect Wire Harness From Motor Control Block Unplug wire harness connection at the motor solenoid on the motor control block It will not require that wire harness be completely removed only unplugged and lay it aside See Figure 3 5 Remove Motor Drive Pulley on Wing Mower The drive pulley is retained
79. Wing Wire Harness RH Wing Only 8 18 Wing Wire Harness LH Wing Dual Wing 0 gt 8 19 Hyd Supply From Tractor Hyd To Control Valve 8 20 Interstater Service Manual 03 06 2006 Alamo Industrial Index 1 3 INDEX Section Page pe DP GREENE Index 3 of Index 3 Section 9 Main Frame amp Wing Lift Arm Weldment 9 1 to 9 5 Install Main Frame RH Only amp Dual Wing 9 2 TO9 5 Section 10 Hydraulic Motors for Wing Mowers Remove Repair Replace Vs 10 11 Motor Removal amp Replace anannsens ennen rennen 10 2TO10 5 Motor Manifold Remove Repair amp Replac 10 6 to 10 7 Motor Disassembly amp Reassembly nnen 10 8 to 10 11 Section 11 Wing Mower Remove Repair Replace 11 1 to 11 25 Mower Repairs Wing Mower DeckS annen eneen 11 2TO11 7 Wing Cut Off Switch Schematic Dual Wing 11 8 Wing Motor Control Switch Dual Wing 11 9 Motor Control Switch RH Wing Only uaa eenn 11 10 Pump amp Motor Hyd Schematic RH Wing Only 11 11 Pump amp Motor Hyd Schematic Dual Wing 11 12 Pump amp Motor Hyd Schematic RH Wing 11 13 Pump amp Motor Hyd Schematic Dual Wing 11 14 Pump amp Motor Hyd Schematic 11 15t0 11 17 Mower Repairs Wing Mower DeckS annees 11 18 TO 11 25 Section 12 Rear Mower FA 12 1 to 12 20 Mower Repairs Rear Mower 12 2 TO 12 11 G B amp Ex
80. a use at a latter date it is required that pumps moving components by coating with something that will withstand the time pump is sitting STP or Petroleum Jelly which is vaseline purchased local will work excellent for this as it will stick to the pump components while spare pump is sitting on parts shelf 2 Install Snap Rings item 30 and Thrust Race amp Bearing on Driveshaft Install the inner snap ring item 30 onto driveshaft from the input end Install one Thrust Race part of item 23 onto driveshaft sliding it down against snap ring Install the Thrust Bearing part of item 23 onto driveshaft until it is against the Thrust race Install Second Thrust Race part of item 23 onto driveshaft until it is against thrust bearing Install second snap ring item 30 onto driveshaft until seated in snap ring groove of driveshaft and seated against thrust race 3 Replace Needle Bearing item 31 into Pump Housing item 22 Install needle bearing asy into the pump housing If necessary install driveshaft item 21 into pump housing item 22 and install Washer item 28 Coat the I D of Shaft Seal item 24 and drive it into the pump housing item 22 Installthe outer snap ring item 29 into pump housing until it is seated into snap ring groove of housing 4 Install Pin Keeper item 19E and Pins item 19F into spline area of piston block item 19D Compress Pin Keeper and install it in the splined area of the piston block Install the three pins
81. ach into the housing and the cam plate item 7 should pull out without much effort In some cases because of the oil creating suction it may require that housing be tilted up and cam plate dumped out of housing if this is the case catch the cam plate do not let it drop 12 Remove Snap Ring item 11 Using internal snap ring pliers remove internal snap ring item 11 from front side of housing item 4 13 Remove Input Seal item 6 from housing item 4 The input seal will be remove from the housing using a seal puller Use caution when removing the input seal so you don t scratch or damage the interior seal seat area 14 Remove Seal Washer item 10 which is located behind input seal It may require to lift the housing and dump the washer out 15 Remove Driveshaft item 3 from housing item 4 The driveshaft must be pulled out of housing to the front side The driveshaft will have the retaining rings item 12 and thrust race and bearing item 5 still on itwhen itis pulled out of housing 16 Remove Snap Ring item 12 and Thrust Race amp Bearing item 5 from drive shaft Use Snap Ring Pliers to remove the outer snap ring item 12 from the end of the driveshaft Slide the Trust Race amp Bearing item 5 from the driveshaft Remove the second snap ring item 12 from the driveshaft using snap ring pliers Inner Rear Pump Component Inspection For item numbers See Figure 12 1 Wash All Parts Wash all parts in suitable clean solvent
82. ain pressure relief and detent position During operation the tractor hydraulics must be set in the float detent to enable the mower sections to follow the contour of the terrain The oil returning from the cutter unit motor flows through the oil cooler tubes Under normal mowing conditions the knives blow air against the cooling tubes to maintain oil temperature approximately 60 deg above ambient temperature Should the cutter unit become overloaded the oil temperature will rise very quickly Under no circumstances should the unit be operated if the oil temperature is above 180 deg F If the oil reaches this temperature raise the mower and let the tractor run without the cutter load 12 FRONT END WEIGHT Maintain a minimum of 20 total tractor weight on the tractor front end at all times Front end weight is critical to maintain steering ability and to prevent the front end from rearing up Consult your authorized tractor dealer for front weights and carriers 13 TRACTOR POWER TAKE OFF PTO Only operate the mower on a tractor equipped to operate at 540 rom PTO speed Tractors operating at 540 rpm will have a 1 3 8 diameter 6 spline PTO shaft stub Refer to the tractor operator s manual for operating the PTO at the proper speed If operating an older model tractor where the tractor s transmission and PTO utilize one master clutch an over running clutch must be used between the PTO output shaft and the driveline of the mower Consult an
83. alve cover will cover the hose connections to the valve This is a safety item and unit must not be operated without this cover installed at all times See Figure 42 9 Install upper valve cover Install the upper valve switch cover on the top of the valve See Figure 41 10 Install operation decal for Valve The decal with handle function will be installed on the lower valve cover and the decal for the motor switch will install on the top valve cover under the switches See Figure 43 Interstater Service Manual 03 06 O 2006 Alamo Industrial Section 8 11 Valve Connections ROPS Tractor Ei Figure 40 Ef u Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 12 Wire Harness Connections CAB amp ROPS Wire Harness Connections 1 Connect Wire Harness to Tractor Starter Activation Wires The wires to the starter from the motor control switches will need to be connected to the tractor near the ignition switch connections Or they can be connected near the starter solenoid this is something the technician will need todecide as they assemble the unit Alamo Industrial recommends connecting the wires at thetractor ignition switch See Figure 46 thru 58 Also see the wire harness schematic on the following pages Consult Tractor Repair Manual for wiring schematic of Tractor to determine what wire is what on the tractor ignition switch 2 Connect Power Supply for Motor
84. and any part of the INTERSTATER If interference occurs shims not furnished must be welded to axle pivot stop or steering arm to limit the movement enough to avoid interference Tractors with an adjustable front axle may require an outward adjustment of the wheels 6 To fill the INTERSTATER reservoir with new clean hydraulic oil follow the steps below Refer to the Operation and Maintenance Section for specifications See Figure 16 A With a hydraulic jack raise the right side of the tractor This will tilt the tank and allow only a minimum amount of air when filling B Avoid hydraulic contamination by filtering the hydraulic oil while filling the hydraulic tank C Filter buggies or carts are commercially available for hydraulic system cleanup These consist of a high efficiency high capacity filter a circulating pump a drive motor and hoses for connecting the overhauled machine s hydraulic system D After the first 10 hours of operation replace the hydraulic filter with a new one An extra Filter Element is provided for you Refer to the Operation and Maintenance Section for instruction 7 After the Interstater mower is Lf Tr completely assembled to the Sa ART tractor and with the wings on memmen JA the ground fill the mower hy draulic tank above the oil level sight gauge approximately 5 or 1 below the top of the tank 8 With mower ON OFF switches in ON position and tractor fuel cut off cr
85. and dump the Piston E Figure 15 Vice Jaw Protective Pads Block assembly out If you do Contnued Next Page Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 19 Tandem Pump Dis Assembly amp Re Assembl Continued From Previous Page Dis Assemble Outer Front Pump For item numbers See Figure 12 catch the block with you hand don t let it fall out on the floor or bench DO NOT remove the spring snap Ring item 19K from the piston block assembly as the spring item 19H has compression on it this compression will require relieving before snap ring is removed this can be done later 5 Remove the Piston Assembly item 19A from the Piston Block item 19D The piston assembly will pull upward and out of piston block 6 Remove Spider item 19B and Pivot item 196 The spider item 19B will be left lying on the piston block when the piston assembly is removed The Pivot item 19C will also be left on the piston block and can be removed 7 Piston Block Dis Assembly item 19D The Piston block assembly need not be dis assembled unless the pins item 19F orthe Spring item 19H is damaged CAUTION The following procedure should be used if the spring is to be removed from the piston block The spring item 19H is highly compressed and the snap ring item 19K should NOT be removed without compressing the spring The following parts will be needed to dis assemble the piston block 2ea 3 8 ID
86. and the back plate item 15 Ifthe needles are free of excessive play and remain inthe bearing cage there is no need to replace the bearing asy Inspect thrust washers and thrust bearings item 5 All surfaces should be free of any signs of wear or fretting Should be no sign of distortion or flaking Inspect Spider item 1B and Pivot item 1C Conical surfaces should be free of wear and score marks Inspect Pistons item 1A The O D surface should be smooth and free of scoring The shoes should be snug fit to piston The face of the shoe should be flat and free of scoring and flaking Do Not lap piston shoes Inspect the Piston Block item 1D The bore should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or metal build up Inspect the Cam Plate Insert item 17 The surface should show no signs of scoring or grooves Inspect the flat surface on the Back Plate item 15 The back plate surface should be free of excessive scoring or metal build up Inspect the Drive Shaft item 7 Inspect for fretting in the bearing areas Check keyed area for twisted broken or worn spots Check for chips and or cracks in shaft Re Assemble Motor For item numbers See Figure 11 1 Coat Moving Parts for Re Assembly All moving parts should be coated with lubricant before and during re assembly If pump is to used immediately after assembly the recommend hydraulic oil for interstater will work If p
87. ank Filter Change amp Repairs RE INSTALL NEW HYD SYSTEM FILTER 1 Remove filter Inspect material trapped by the filter It can indicate parts wear in the system See Figure 16 2 Clean Filter Canister If filter cannister needs cleaning it CAN NOT be done with any type of solvent as it would run into oil tank It cleaning is something that cannot be done with lint free towels the filter assembly will need to be removed from tank assembly for cleaning 3 Install the new filter Install the new filter into the filter canister See Figure 16 It will not be required to fill filter cannister with oil as the filter is on the supply return line DO NOT operate system with out a filter and do not operate with incorrect Filter Use only the correct Micron Size Filter that is designed for this system See Figure 16 4 Reinstall filter spring and filter cover Drop spring in on top of new filter See Figure 17 5 Replace Filter Cover Sit the filter cover down onto the spring Push cover down and turn counter clockwise until the three bolts slide into the slots See Figure 18 6 Replace Bolt in filter cover and tighten the 4 bolts Replace the one bolt that was removed previously See Figure 19 Tighten the four bolts in increments until the cover is seated evenly all the way around do not force cover down with bolts if it offers resistance Tighten the bolts in an even manner See Figure 20 7 Check and Fill Oil System It is recommended t
88. ank engine for about 30 to 45 seconds to allow oil to fill pumps and motors Check LE the oil level in the sight gauge pr If no oil is seen add oil to bring r the level up to the sight gauge NOTE Do not fill the tank with oil above the level of the sight Figure 27 gauge Over filling the tank with tm oil after the initial filling may re sult in oil being discharged through the air filter on top of the hydraulic tank Start the tractor and run it for 2 minutes and then turn it off Again check the oil level in the sight gauge If the oil level is in the sight gauge the unit is ready to run If no oil is seen add oil to bring the level up to the sight gauge Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 19 Initial Start Up Procedure CAUTION ROTATING KNIVES Remove allforeign objects and stand clear of 1 cutter units DO NOT GET NEAR NOTE On tractor hydraulic powered circuit only make certain that there is full flow from tractor hydraulic system to control valve Refer to tractor manual 9 After hydraulic system is fully charged and functioning properly switch cutter units on then speed engine up to 540 RPM PTO speed Maintain this speed for about 5 minutes Check complete INTERSTATER look for any leaks loose connections or anything that could cause premature wear or failure FINAL CHECK Run INTERSTATER for about 1 2 hour at full speed Check for leaks and vibrations Frequently ch
89. ant to note which holes these last two bolts come out of as they must go back in same holes when re assembled Remove remaining two bolts It may require a small amount of force to free back plate loose from pump housing Use soft faced hammer tap sides of backplate T his will break backplate loose from pump housing do not hit back plate with excess force it will damage backplate and pump housing Lift Back plate up and out of motor housing Remove amp needle brg item 13 4 Remove O Ring from Backplate Remove the O Ring Seal item 12 from backplate O ring groove item 15 5 Remove Complete Piston Block Assembly item 1 from Motor Housing item 11 Lift Piston Block asy upward and out of pump housing It will require you to remove pump from vice and dump Piston Block asy out Catch the block with hand don t let it fall out on floor or bench DO NOT remove the spring snap Ring item 1K from piston block assembly as spring item 1H has compression on it this compression will require relieving before snap ring is removed this can be done later 6 Remove the Piston Assembly item 1A from the Piston Block item 1D The piston assembly will pull upward and out of piston block 7 Remove Spider item 1B and Pivot item 1C The spider item 1B will be left lying on the piston block when the piston assembly is removed The Pivot item 1C will also be left on the piston block and can be removed 8 Piston Block Dis Assembly item 1D T
90. arts Terminology Whenever reference is made to parts listed for an illustration or elsewhere in this manual the following abbreviations may be used ASY Assembly 2 ASSY Assembly 3 AUX Auxiliary BRG Bearing 5 BRKT Bracket 6 CYL Cylinder CW Clockwise 8 CCW Counter Clockwise 7 EXT Extreme EXT N Extend Extension 9 F For or From 10 FM Female Boss FP Female Pipe 12 FSTNR Fastener 13 FT Foot Feet GB G B Gearbox 15 GR Grade 16 HD Heavy Duty HHCS Hex Head Capscrew 18 HRDND Hardened 19 HYD Hydraulic IN Inch 21 LB Pound 22 LH Left Hand LW Lock Washer 24 M Metric 25 MB Male Boss MM Millimeters 27 MNT Mount 28 MP Male Pipe MTR Motor 30 N A Not Applicable 31 NC National Coarse NF National Fine 33 NLA No Longer Available 34 NLF No Longer Furnished NPT National Pipe Thread 36 P1 5 Thread Pitch 37 P2 0 Thread Pitch P2 5 Thread Pitch 39 PL Plated 40 PLT Plate PMP Pump 42 PTO Power Take Off 43 PW Plain Washer REV Reverse 45 RH Right Hand 46 ROT Rotation RPM Revolutions Per Minute 48 SCKT Socket 49 SD Severe Duty SRV Service 51 STD Standard 52 SVR Severe W With 54 W O With Out 55 WLDMNT Weldment When installing fasteners PW and LW generally installed in that order are usually on the side of the fixture or part being fastened that the hex lock nutis on When only HHCS LW and or PW are required they are generally installed
91. authorized tractor dealer to purchase and install an over running clutch if needed 14 SETTING MOWER CUTTING HEIGHT Properly setting the cutting height is essential for efficient and safe operation properly set mower makes a more uniform cut distributes clippings more evenly increases tractor efficiency and follows the contour of uneven terrain Note Avoid very low cutting heights striking the ground with the blades gives the most damaging shock loads and will cause damage to the mower and drive Blades contacting the ground may cause objects to be thrown out from under the mower deck DANGER Never work under the Implement the framework or any lifted compo nent unless the Implement is securely supported or blocked up to prevent sudden or inadvertent falling which could cause serious injury or even death 6611 2 Continued NextPage Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 6 SPECIFICATIONS INTERSTATER Continued From Previous Page Roller Height Adjustment The mower s cutting height is set by positioning the roller assembly for each mower section Each section must be set at the same height to ensure an even cut across the entire width of the mower A Place the tractor and mower on a level surface and completely lower the mower to the ground B Shut down the tractor place the transmission in park and set the parking brake before dismounting C One section at a time
92. block 2ea 3 8 ID X 1 1 8 OD Flatwasher lea 3 8 NC X 3 1 4 Bolt Hex Head lea 3 8 NC Hex Nut Place one of the flatwashers over the 3 8 X 3 1 4 bolt and place this through the center of the piston block Place the other flatwasher over the bolt and let it rest on the three pins item 1F Screw the nut on and compress the spring inside the piston block Use a pair of snap ring pliers and install the internal snap ring item 1K Install the internal snap ring item 1K and make certain itis seated into the snap ring groove in the piston block Unscrew the bolt nut and two washers this will release pressure on spring item 1H and allow it seat against snap ring item 1K Never Remove snap ring in piston block with out compressing spring Install Pivot item 1C Spider item 1B and piston assembly item 1A Sit the pivot item 1C down onto the piston block with the taper rounded side up See Figure 12 Sitthe spider item 1B down over the pivot noting the concave hole in the center of the spider will sit over the rounded edge of the pivot align the holes inthe spider with the holes in the piston block Lower the Piston assemblies item 1 A through the spider holes and into the piston block the piston assembly can be installed one at time Contnued Next Page Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 18 Tandem Pump Dis Assembly amp Re Assembly Continued From Previous Page Re Assemble Inner Rea
93. bly if it will not slide together with the force of your hand there is something wrong 10 Install Needle Bearing item 13 into Back Plate Asy item 15 The needle bearings will install into center opening of back plate Coat this bearing with oil as you slide it into back plate Install Bearings into back plate with number end of bearing up and visible Bearing will be slightly higher 09 than back plate See Figure 13 11 Back Plate item 15 amp Sealing O Ring item 12 The back plate is sealed with an O Ring that is inserted into a groove on back plate item 15 make certain this O Ring is seated into this groove lubricate the OD of O Ring to aid inserting of Back Plate into motor housing item 11 12 Back Plate Asy item 15 Roll Pin item 14 and Alignment The backplate has a Roll Pin installed into it This roll pin item 14 isto align back plate on pump housing so front flange of housing and back plate ports will be in the correct orientation roll pin should not be more that 173 higher than surface of back plate This alignment is important and must be correct Make certain the roll pin is in the back plate Lower the Back Plate item 15 down onto the pump Housing item 11 aligning the back plate down over driveshaft until the sealing O Ring item 12 inserts into pump housing Back plate should slide down until it is inside of pump housing If back plate can not be pushing completely down without a lot of force check it for
94. bove ambient Temperature If the unit operates properly speed and pressure can then be increased to normal operating settings Increase Pressure in 500 Lbs PSI increments from start this should take 4 to 5 minutes to max PSI allowing 1 minute between increases to check Oil Pressure and Temperature F lfnormal Pressure and Heat readings are seen then the New or Rebuilt Pump installation should be done remove Flow Meter Pressure Gauge from line reconnect Line and check all connections Test Equpment Needed 1 Flow Meter The Flow meter should have components to measure A Guage to Measure the Oil Temperature B Gauge to Measure Oil Pressure PSI Load and No Load C Gauge to Measure Oil Flow in G P M D A Valve to load system to check operating Pressure PSI E Assortment of Connections to connect to Hydraulic System Electrical Volt Meter with variable settings and Ohm Meter Electrical Test Light Wrenches Torque Wrench Socket Wrenches Open and Boxed End Wrenches nn Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 11 NOTES Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 12 Section 4 interstater SERVICE MANUAL Hydraulic amp Electrical Schematics This section shows the Schematics for the hydraulic system of the pump motor and cylinder circuit The Schematic for the electrical Wing Motor Shut Off System Interstater Service Manual 03 06
95. c system Check the oil level in the reservoir before start up after repair K Care should be taken when filling the reservoir to prevent contamination of the hydraulic system Always use new hydraulic fluid when filling the system USE ONLY APPROVED HYDRAULIG OIL IN THE HYDRAULIG SYSTEM 3 RECOMMENDED TOOLS A Hex Allen Wrench Qty 5 9 16 5 32 5 16 3 32 5 64 B Retaining Ring Pliers Qty 3 1 each of Internal Straight 070 tip internal Straight 090 tip amp 1 each External Straight 0 90 tip Retaining E Ring Applicator Qty 2 1 each 9 32 amp 1 each 1 2 O Ring Pick Qty 1 End Wrench Qty 4 1 each of 7 16 9 16 3 4 1 Torque Wrench Qty 1 0 to 100 ft lbs 135 6 nm capacity Hammer Soft Face Qty 1 Seal Driver Set Qty 1 Arbor Press Qty 1 Sockets Qty 3 7 16 9 16 3 4 Drive Size should match Torque Wrench Drive Light Petroleum Jelly Vaseline Locktite 222 and 277 or equivalent Qty 1 tube each Petroluim Jelly Vasoline Samll Jar SPASTIOMMUO Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 3 Tandem amp Single Pump Repair Replace 3A Prices will be furnished on request SPECIAL TOOLS AVAILABLE Specialtools for installing and servicing INTERSTATER kits are illustrated on the below Drawings for these tools are available on request If desired tools may be obtained from Alamo on a made to order basis Item Part No Code Description
96. checked for overheating After this first check the slip clutch should be checked weekly or anytime there is overheating To adjust the slip clutch tighten the spring bolts 1 8 maximum turn atatime Bolts should NEVER be adjusted to the point where the springs are compressed solid The slip clutch should be checked periodically and adjusted to compensate for wear The lining plates are 1 8 thick when new Replace after 1 32 wear If the mower has been idle for an extended period of time or in wet weather before operating check to be sure the friction lining plates are not frozen or rusted together Should this freezing occur refer to the procedure described in the Seasonal Clutch Maintenance on the next page There are 4 friction disc the slip clutch These should be checked weekly for oil or grease wear and moisture which could cause corrosion on the drive plates See Step 8 NOTE Above information is listed as a reference and is listed in the operators manual as well Interstater Service Man 03 06 O 2006 Alamo Group Inc Section 12 4 Mower Repairs Rear Mower 9A IMPORTANT CLUTCH ADJUST IN FORMATION There have been three dif ferent clutches used 1 The First amp earlier clutch had 6 small springs and would adjust to a length of 1 1 16 long this early clutch could be identified by the small springs r which are about 1 3 16 long un compressed N 2 The Next clutch had 8 springs as LINING N shown in f
97. ck plate down Install 6 Retaining Bolts item 27 into pump housing item 22 to fasten back plate item 20 Inspect bolts make certain all threads of bolts are in good condition The bolts need to be installed in a staggered pattern alternating from side to side until snug These bolts must be TORQUED to 15to 18 ft lbs Do this in increment and staggered pattern also Bolt Inner Rear to Outer Front Pump 1 Clamp Inner Rear Pump in Vice See Figure 16 With inner front pump pointing down ward See Figure 16 Make certain splined coupler item 13 is installed into rear of the inner pump also make certain sealing O Ring item 15 is installed on inside of inner pump backplate item 2 Coat sealing o ring with oil or vaseline Lower outer pump down into inner pump aligning outer pump driveshaft with spline coupler item 13 Inner and outer pump must be aligned do this by making certain ports are aligned the same The larger port will be suction port See Figure 16 when tandem pumps are bolted together these ports must be on same side Install tandem pump connecting bolts See Figure 16 It may require a small amount of force Outer Front to push outer pump in inner pump but no more than pushing Pump Suction it together with hands If it will not push together by hand Tandem Pump check for alignment problem DO NOT use bolts to force the two pump halves together this will damage pumps With tiger aa inner amp outer pum
98. cket to unit 7 Reinstall idler arm spring and belt guard ADJUSTING CUTTING HEIGHT See Figure 14 15 16 amp 17 1 Lower cutter unit amp Roller to ground and place control A DN A valve levers in FLOAT position XA S Cuttershaft 2 Place lifting device scissors jack hydraulic jack ISJ Pulley under center of cutter housing or use an over head hoist ee When lifting mower deck always use jack stands to support the object being lifted When working underamower always use safety glasses 3 Remove hex nuts washers and carriage bolts from bracket at each end of roller Make certain that roller bracket is free to move up and down once the fasteners are FIGURE 12 Ao removed stuck roller could drop suddenly and cause an injury While Lifting Deck Roller should be slid down or pushed up to change mowing height DO NOT lift mower very high with bolts removed from roller mounting bracket a stuck roller could drop suddenly and cause an injury 4 Use lifting device to reposition cutter housing to desired cutting height Align bracket holes with cutter housing holes then reinstall fasteners Refer to cutting height decal on mower or Safety Section 5 Lower cutter unit to ground then remove lifting device jack or hoist 6 When adjusting cutting height on interstater chose the desired hole by reading the decal shown in Figure 50 which should be on the mower decks of the interstater showing the adjusting steps and procedur
99. curacy of or 6 of the desired torque will result at the end of the adapter due to length change during grip adjustment Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 10 SPECIFICATIONS INTERSTATER Recommended Start up procedure for New or Rebuilt Pump Before Installing a New or Rebuilt Pump A Connect your Flow Meter in Line to test Pressure as unit is started this is in case the Relief Valve is malfunctioning or has been tampered with If this is not done you could damage the replacement Pump because you would not Know it till Pump failed from excessive pressure B Before connecting any lines to Pump fill all Ports with clean Oil to provide initial Lubrication This is especially important is Pump is located at a higher level than Oil Reservoir C Check Oil level in reservoir fill to full level if needed Reservoir must have more Oil than the Pump GPM capacity D After connecting the Lines and mounting the replacement Pump make sure that Oil is not warmer than Pump temperature If Oil is warmer than pump run Pump at short intervals till Pump and Oil temperature is equalized Hot Oil must not be fed into cold Pump E Operate the Pump for at least two minutes at no load and at low RPM 400 RPM min and 1400 RPM max Watch Flow Meter Pressure or Pressure Gauge During this break in period the unit should run free and not develop an excessive amount of heat Heat should not exceed 100 deg F a
100. don t scratch or damage the interior seal seat area of the seal adapter 11 Remove Seal Washer item 3 which is located behind input seal adapter It may require to lift the housing and dump the washer out 12 Remove Driveshaft item 7 from housing item 11 The driveshaft must be pulled out of housing to the front side The driveshaft will have the retaining rings item 4 amp 6 and thrustrace and bearing item 5 still on it when itis pulled out of housing 13 Remove Snap Ring item 4 and Thrust Race amp Bearing item 5 from drive shaft Use Snap Ring Pliersto remove the outer snap ring item 4 from the end of the driveshaft Slide the Trust Race amp Bearing item 5 from the driveshaft Remove the second snap ring item 6 from the driveshaft using snap ring pliers Interstater Service Manual 03 06 2006 Alamo Industrial section 10 9 Motor Dis Assembly amp Re Assembly Motor Component Inspection For item numbers See Figure 11 1 sa D Wash All Parts Wash all parts in suitable clean solvent Use clean filtered compressed air to dry parts after washing DO NOT use compressed air to spin bearing when drying parts DO NOT use rags or towels that will leave lint to dry parts Parts must be kept clean at all times Work area and place parts are kept during repair process must remain clean and dust free Examine Needle Bearings item 9 and 13 Inspect the needle bearings in the housing item 11
101. drau a pump to pull the oil from the ME EE To RH tank Most will usually have filtra i gt i ee ZV Wing Motor tion system for pumping the oil KR VAA out of the oil buggy system Alamo Industrialrecommends using only new oil when putting oil back into hydraulic tank 4 Disconnect Motor Case Drain Hoses The hoses for the motor Case drain will be discon nected at the tank but can be left attached to the motor See Fig tk ure 1 amp 2 Cap these hose after Pressure Out disconnecting them Figure 2 u Port To LH Wing pe Motor 5 Disconnect the Pump Suction Hoses The suction hose to the Auxiliary pump is best to remove it completely Disconnect it at the pump end and then the tank end Cap the pump and the tank immediately after removing hose to keep contamination out of the oil The suction hose s to the Main Pump s remove the fitting at the pump and cap the hose s and the pump s See Figure 1 amp 2 Interstater Service Manual 03 06 2006 Alamo Industrial Section 6 2 Hydraulic Tank Repairs 4 Disconnect Oil tank Return Hoses The oil return hoses from the wing s motor s and the cylinder control valve system is returned on the RH side of the tractor to the front and to through the oil return filter If the interstater was ordered as model to use the tractor hydraulic oil system for supply to the control valve for the cylinders there will be no return hose from the cylinder control valv
102. draulic Schematic RH WING ONLY HYDRAULIC MOTOR SHOWN Case Drain from Motor to Motor Return from Motor TT Valve to Rear Wet Tube and on to Tank NEVER CONNECT HIGH PRESSURE HOSE TO WET TUBES ON DECK High Pressure from Return from Front Pump to Motor Wet Tube to Tank Figure 28 Tandem Pump Inner Pump for RH Wing Pump Case amp Outer Pump for LH Wing RH Wing LH Wing Grain Only has a single pump Pump Case Drain _RH Wing Pump High Pressure Hose Sleeving Tandem Pump LH Wing Pump High Pressure Line LH Wing Pump Suction Line RH Wing Pump Suction Cyl System Supply l Line Figure 29 Pump Suction Hose Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 15 Pump amp Motor Hydraulic Schematic 7 Tank Return Hose from Cylinder Control Valve to Tank m EN Rn elf ss LE Upper Connection Always from Pump To Wing Motors NEVER TO WET TUBES HIGH PRESSURE Figure 31 Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 16 Tank Return Filter Assembly amp Tank Return Pressure Gauge DCN ank Return Hose from Wet Tubes on LH amp RH Wingi Decks Oil Level Sight Glass Oil Temperature Gauge Main Frame Cross Over Bracket amp Tubes RH Side Shown note Tee Fitting in lower fittings Lower Connection Always from Deck Wet Tubes to Filter Tank Return Line LOW PRESSURE Nut on Bulkhead Fittings Pump amp
103. e Idler Pulley Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 6 Mower Repairs Rear Mower 23 Le Le a a i og FIGURE 13 ROLLER BEARING REPLACEMENT See Figure 19 1 Securely support mower before beginning any repairs or service to mower all mower must be lowered and resting on ground or supports and NOT lifted by hydraulic system Secure tractor as directed by tractor manufactures instruc tion for parking Secure tractor to prevent it from being started while being repaired Tg Roller 2 Removerollerandbothbearingandbracketassemblies zE from mower Liftthe mower only high enough to remove the Bearing amp roller assembly If installing a roller with pre assembled Housing bearing and bracket assemblies remove the old roller Assembly proceed to step 12 Ke 3 Slide bearing and bracket assemblies off each end of FIGURE 15 roller If replacing with new bearing and bracket assemblies proceed to step 10 4 Removeroller bearing and housing assembly attaching hardware Remove assembly from bracket Inspect seal between assembly and bracket for brittleness cracks wear and tear Replace if necessary If replacing with new roller bearing and housing assemblies proceed to step 9 5 Remove grease fitting from the top of bearing housing 6 Remove bearing form housing By Rotating Bearing 90 sideways and line up with notches in Bearing Housing th
104. e C The pump will slide out of the pump mount plate the driveshaft may slide back with it or it may stay in tractor the splined coupler that connects the pump to the driveshaft may stay on driveshaft or it may stay on pump D Check driveshaft crankshaft pulley adapter amp splined coupler for wear and condition If any of these parts are to be changed it is important to check the length of the new and old part to make certain they are the same Do Not use coupler pulley adapter or driveshaft that is worn or damaged Do Not use driveshaft that is to long or to short E Make certain that driveshaft is installed into crankshaft pulley adapter correctly Make certain drive shaft is inserted through driveshaft bearing and lock collar correctly Make certain spline coupler or splined coupler pulley weldment w Auxiliary Pump is installed correctly Note do not tighten auxiliary pump pulley to driveshaft until later Make certain that auxiliary pump drivebelt is installed on pulley if Auxiliary pump is used F Ifthe pump is to be repaired see pump repair section If pump is being replaced bolt the inner and outer pump together onthe bench or bolt inner pump to pump mount plate and then bolt the two pumps together Dual Wings w Tandem Pump Install new pump to inner pump making certain both case drain ports are facing hydraulic reservoir RH Side of Tractor G Reconnecting hoses to the two pumps or SinglePump Single Wing Connect the case dra
105. e see the hydraulic schematic for system using tractor hydraulics See Figure 3 The fittings at the hydraulic tank for the return hoses will not need to be removed to remove the hydraulic tank See figure 4 5 Remove Front Tank Bumper Weldment The front m Yoga Ref Hose Batur bumper weldment bolts to the tank mounting rails See Figure msn AE from Wi 5 Removethefrontbumper a MeturnHose rom Ving ressure from 4 Spool Motora fauo 6 Remove Tank Use an overhead hoistto supportthe Wersi to AIE hydraulic tank while itis being unbolted In figure 6 belowthe Dort Marked Te 7 r main and auxiliary pumps are not installed This is for Sn 7 PR N Bin illustration only the pumps can be leftmounted tothe tractor ORE VE LC WT en Remove the bolts on the side of the tank on both sides See SRE LEGE T Figure 7 With the tank supported by the overhead hoist slide sa f gt WE the tank outward away from the pumps and then upward Oil Temperature m T Replace Tank Toreplace the tank reverse the disas Gauge sembly procedure and hose connections Refill hydraulic tank Fi gure 3 with new clean oil using a filtered oil buggy system is recommended Tank Return Reducer Filter 3 Fittting TN vi Interstater Service Manual 03 06 2006 Alamo Industrial Section 6 3 Hydraulic Tank Repairs Recommended Start up procedure for New or Rebuilt Pump or Tank Replacement 1
106. e auxiliary pump and some will not When possible consult the assembly instructions and or assembly manual that was shipped with the unit to match the tractor model you have Pump Mount Weldment Small Pump Removal amp Replace mem Pressure Port Port Small 1 Hoses amp Pumps The Hoses and i pump will require being unbolted from the Pressure Ma gt A r pump mount weldment use the steps in Out Port u ME Leave Capped the pump repair replacement section To RH M TEA on RH Only Wing Motor 2 Pumps Removed The pumps re nn moved the model using the auxiliary pump pn will have the drive pulley and belt still onthe Case driveshaft Model that do not have the Drain From auxiliary pump will have a spline coupler Pump See Figure 3 3 Remove Drive Pulley from Driveshaft The drive pulley weldment or splined coupler will slide off of driveshaft through the hole for the main pump See Figure 4 D e Pressure f Out Port 4 Driveshaft Carrier Bearing amp Lock M el zel ee To RH Collar The drive shaft has carrier bearing EM ET hr k Poa rk Wing Motor and locking collar on it This locking collar MM EE A locks down onto the driveshaft Toremove the pump mount weldment it will not require the removal of the bearing and collar The driveshaft can be removed with the pump mount plate or the driveshaft can be re moved now If you are repairing the crank shaft pulley or pulley adapt
107. e cutter unit rides on a large roller assembly The position of this roller is adjustable and will determine the cutting height of the knives REPLACE DRIVE BELTS ae om or 6 7 NOTE Belts must be replaced as a matched set DO NOT replace just one belt See Figure 44 amp 45 Place unit on ground or support securely Remove belt guard Remove idler arm spring Remove motor mounting bracket front bolt and loosen rear bolt Pivot motor mounting bracket assembly Remove old belts and install new ones Reinstall front mounting bolt then secure motor mounting bracket to unit Reinstall idler arm spring and belt guard ADJUSTING CUTTING HEIGHT See Figure 46 47 48 amp 49 Lower cutter unit amp Roller to ground and place control valve levers in FLOAT position Place lifting device scissors jack hydraulic jack under center of cutter housing or use an over head hoist When lifting mower deck always use jack stands to support the object being lifted When working under a mower always use safety glasses Remove hex nuts washers and carriage bolts from bracket at each end of roller Make certain that roller bracket is free to move up and down once the fasteners are removed stuck roller could drop suddenly and cause an injury While Lifting Deck Roller should be slid down or pushed up to change mowing height DO NOT lift mower very high with bolts removed from roller mounting bracket A stuck roller could d
108. e gearbox 180 deg to new position Install cutter shaft pulley gearbox output pulley idler arm pulley assembly and belt REPLACE EXISTING BELT GUARD WITH PROPER GUARD Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 11 G B amp Ext n Shaft Asy Rear Mower Gearbox amp Extension Shaft Asy 4 Drawing Show Cutter Shaft Bearing removed this is for illustration only and will not need to be removed to remove Figure 25 Item Qty Description Item Qty Description 1 Gearbox amp Extension Shaft Asy 7 4 4 Bolt 1 1 Gearbox Asy 08 90 amp Down 7 5 4 Nut 1 1 1 Gearbox Asy 09 90 amp Up 8 1 Bearing Retaining Ring 2 1 Spline Coupler Asy w Grease Fitting 9 3 Pulley Shim Use Qty As Needed 2 1 4 Counter Bore Screw 10 1 Pulley Top Shaft Drive 2 2 4 Lockwasher 11 1 Drive Belt 3 1 Extension Shaft 12 1 Key 4 1 Extension Shaft Hsg 13 1 Heavy Flat Washer D 1 Bevel Ring 14 1 Lockwasher 6 1 Snap Ring 15 1 Bolt 7 1 Bearing amp Hsg Asy w Items below 16 1 Idler Brg Ext n shaft Mount Plate 7 1 1 Bearing Only 17 1 Idler Pulley Arm 7 2 1 Bearing Housing Only 18 1 Idler Pulley 7 3 1 Lubricap 19 1 Belt Guard Shield Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 12 G B amp Ext n Shaft Asy Rear Mower Gearbox amp Extension Shaft Assembly Remove Repair amp Replace See Figure 25 for component location and identification 1 Offset Models are Offset to Right To I
109. e mounting bolts that are installed through the mounting brackets The first cable to be installed will be the Right Wing Lift Cylinder the next controller is the Right wing tilt cylinder The controls need to be installed this way to match the operation instruction decal See Figure 26 Figure 24 Figure 25 Interstater Service Manual 03 06 2006 Alamo Industrial Section8 7 Joystick Valve amp Control Cables Cab 14 Install Electrical Control Switch The push pull switch mounts onto the switch mount bracket and the bracket is mounted between the control cable levers See Figure 26 Note this switch can be mount on either side of handles it is customers choice 15 Adjust Cable Control Handles The handles will have some adjustment Left and Right up and down by loosening the mounting bolts of the pivot mount These adjustments will usually be changed after assembly to suit the individual operator It is helpful when possible to get the operator to test fit these adjustments with you See Figure 26 The handles of controllers are adjusted at the valve mount plate See Figure 14 16 Tie Cables and Wire Harnesstogether Tie the cables and Wire Harness together with plastic ties inside the cab and outside the cab This will keep them from moving around See Figure 21 17 Check Hydraulic Hose Routing Shown below is the routing of the hydraulic Cylinder amp Control Valve Double check these before running Unit See
110. e of Pump to Make Sure it is Clean 4 After disassembly of Pump wash all metal components in clean solvent 5 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 6 Always use new Seals when reassembling Hydraulic Pumps Lubricate the new rubber Seals with a Petroleum Jelly Vaseline before installing them 7 DO NOT reinstall worn damaged Parts in Pump DO NOT Use a worn damaged Pump Housing 8 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 recheck Torque 9 Verifying the accuracy of Pump Repairs on an authorized test stand is essential RECOMMENDED TOOLS 1 Hex Allen Wrench Qty 5 9 16 5 32 5 16 3 32 5 64 2 Retaining Ring Pliers Qty 3 1 each of Internal Straight 070 tip internal Straight 090 tip amp 1 each External Straight 0 90 tip Retaining E Ring Applicator Qty 2 1 each 9 32 amp 1 each 1 2 O Ring Pick Qty 1 End Wrench Qty 4 1 each of 7 16 9 16 3 4 1 Torque Wrench Qty 1 0 to 100 ft lbs 135 6 nm capacity Hammer Soft Face Qty 1 Seal Driver Set Qty 1 Arbor Press Qty 1 10 S
111. e placing of wing mower will be the reverse of the Re moval steps Mower Repairs Wing Mower Decks General Information For Repairs A Todisassemble repair your INTERSTATER this manual is designed to assist you with drawings instructions and information This manual is designed to be used in conjunction with the parts manual operators manual and the assembly manuals If additional information or clarification is needed contact your Alamo Industrial factory representative B Some of these instructions are general information and not specifically for your tractor In connection with our drawings they may not show the exact application and tractor you have In many cases refer to assembly manual for your mower to tractor application will clarify some information to exact applications C This section covers the removal repair and reinstallation of the wing mowers for the Alamo Industrial Interstater Mower These instructions are for working on the pumps used to power wing mower mowers right side mower and left side mower units if dual wing model For mounting one mower side only disregard information concerning the opposite side Hardware quantities shown are for both sides E The Auxiliary pump is used to supply the lift and tilt hydraulic cylinder circuit This auxiliary pump will not be used on all units some will use the tractor hydraulic system to supply cylinder circuit F Reference to the left or right side of the Interstater is det
112. earing Pre Load It should be at 14 to 16 pounds of rolling torque It may be required to remove shims from Bearing Caps or add Shims 7 Set Gear Back Lash with Bearing Cap Shims Gear Back Lash should be from 014 to 017 This is very critical By moving shims from front cover to back cover or vice versa gear is moved inward or outward DO NOT add or delete shims as this will change your Bearing Pre Load 8 Fill Gearbox with Oil till Oil flows out of Oil Level hole Install Oil Level Plug 4000054 and Oil Fill Plug 4000055 Check all Seals and Gasket areas for leaks After Running Mower 1 2 to 1 hour recheck Oil Level and check for any leaks HELP There were TWO GEARBOXES used that looked very much the same but they are not The earlier model 700493 till approx Jan 1991 this gearbox can be identified by the round 4 bolt cover at the input shaft and small 4 bolt round cover in the middle of the larger 8 bolt cover in the rear There is a 4 bolt cover at the Output Shaft also These covers are to adjust the Bearing pre load and Gear backlash This gearbox will also have Roller Bearings on Input Shaft and Output Shaft The Later Type 702673 Feb 1991 amp up has Ball Bearings on Input shaft and will replace the 4 700493 G B as an assembly Parts WILL NOT interchange between these two gearboxes Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 15 Gearbox Asy P N 702673 TITT CS ae lt
113. eated into this groove lubricate the OD of the O Ring to aid the inserting of the Back Plate into the pump housing 12 Back Plate Asy item 2 Roll Pin and Alignment The backplate has a Roll Pin installed into it This roll pin item 18 isto align the back plate on the pump housing so front flange of housing and back plate ports will be in the correct orientation roll pin should not be more that 1 73 highe than surface of back plate This alignment is important and must be correct Make certain the roll pin is in the back plate Lower the Back Plate item 2 down onto the pump Housing item 4 aligning the back plate down over driveshaft until the sealing O Ring item 8 inserts into pump housing Back plate should slide down until it is inside of pump housing If back plate can not be pushing completely down without alot of force check it for something wrong DO NOT use excessive force or use the bolts to pull back plate down 13 Install 6 Retaining Bolts item 9 into pump housing item 4 to fasten back plate item 2 Inspect bolts make certain threads are in good condition The bolts need to be installed in a staggered pattern alternating from one side to the other until snug These bolts must be TORQUED to 15 to 18 ft Ibs Do this in increment and staggered pattern also 14 Install Snap Ring item 14 and spline coupler item 13 into Back Plate Install the snap ring into the opening of the back plate and onto the driveshaft This snap rin
114. eck it for something wrong DO NOT use excessive force or use the bolts to pull back plate down 13 Install 6 Retaining Bolts item 9 into pump housin item 4 to fasten back plate item 2 Inspect the bolts make certain all threads are in a The bolts need to be installed in a staggered pattern alternating from one side to the other until snug These bolts must be TORQUED to 15 to 18 ft lbs Do this in increment and staggered pattern 4 39 173 y Roll Pin 26 y Bearing 2 i 1 09 E also 14 Fill Pump Case with Oil when connecting rebuilt or new pump The pump should be filled half full with oil this can be done by pouring clean oil through the ports of pump When Pump is installed on mower Connect pump pressure hose pump case drain hose and install pump suction elbow fitting into pump Pour oil into the elbow fitting this will put oil into pump so it will not be started dry Roll Pin amp Bearing Installation Figure 18A Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 26 Auxiliary Pump Remove amp Repair 14 SINGLE PUMP amp SINGLE WING Case Auxiiary Pump Tank Suction The Pump forthe RH Wing Only Drain To a Pressure Port Port Small Single Pump has one pressure er A Pump hose The Rear closestto Trac i IN tor Engine it the supply for the Pressure MG LCR 3 RH Wing Motor The LH fitting is Out Port Pa ON cave Capped the Motor Pressure Supply
115. eck oil temperature Make certain it does not exceed 180 deg NOTE When raising wings make certain there is no interference with mower frame cylinders or tractor Lift wings slowly CAUTION DO NOT leave unit unattended and COMPLY WITH ALL WARNING DECALS If unit starts to make unusual noise stop unit and check oil level Also check for frothy oil which would indicate a leak on suction side of system Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 20 Section 12 INTERSTATER DELIVERY INSPECTION CHECKLIST It is recommended a complete inspection of mower tractor and all components be done before mower is returned to customer after repairs This section contains suggestions of some things that should be inspected on the mower components and operation Make certain all safety instruction material decals manuals and etc are present and in good condition The tractor should be checked using the tractor manufacturers guidelines and or recommendations Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 1 INTERSTATER DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component location Safety Equipment Operators Manual is with Unit The Safety Decals are installed as listed in the Assembly Manual Valve operation plate is installed Operators
116. ed to ensure that at its most compressed position the profiles do not bottom out and when at its farthest extended position there is sufficient engagement between the profiles to operate safely At its shortest length there must be at least a 1 clearance between each profile end and opposite profile universal joint At its farthest operating extension a minimum profile engagement of 12 must be maintained Bottoming Out Check Procedure A Disconnect driveline from the tractor and slide the profiles together until fully compressed B Placeamark onthe inner shield 1 8 from the end of the outer shield and reattach the driveline to the PTO shaft C With the PTO NOT TURNING slowly drive the tractor with mower attached through the sharpest turn possible and watch o shaft movement With the PTO NOT TURNING slowly drive Priveline in maximum compressed position the tractor with the mower attached through the most severe terrain conditions expected and watch shaft movement D Ifthe distance between the mark and the outer shield becomes less than 2 at any point there is a potential problem bottoming out the driveline and the driveline should be shortened Shorten the driveline profiles as follows A Removethe driveline fromthe tractor B Position the mower to the point with the shortest distance between the tractor PTO shaft and cutter gearbox Shut down the tractor and securely block the mower in this position C
117. eing discharged through the air filter on top of the hydraulic tank 4 Start the tractor and run it for 2 minutes and then turn it off 5 Again check the oil level in the sight gauge If the oil level is in the sight gauge the unit is ready to run If no oil is seen add oil to bring the level up to the sight gauge 6 Repeat steps 4 and 5 as required until the oil level stabilizes at the level of the sight gauge Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 24 Mower Repairs Wing Mower Decks INFORMATION ON FLAIL MOWER VIBRATION EXCESSIVE VIBRATION Vibration is aMONSTER and if allowed to continue unchecked can cause the complete break up of a machine in a very short time A properly operated Flail Mower will produce very little vibration If vibration does occur the mower should be STOPPED IMMEDIATELY and CORRECT THE TROUBLE NOTE warranty does not cover failures resulting from continued operation after something happens to cause the mower to vibrate excessively Vibration is caused by a rotating part which is out of balance This could be the cutter shaft or on those models rear Mower having a universal slip joint assembly drive shaft from the drive shaft If the two extreme ends of the drive shaft the splined yokes which fit on the tractor power take off shaft and on the mower gear box driven shaft are not parallel vibration will be evident This is because of the mechanics of a universal drive
118. emove Back Plate Item 2 The backplate is bolted on with six hex head bolts item 9 remove these six bolts It may re quire a small amount of force to free the backplate loose from pump housing If needed use a small plastic mallet to tap the sides of the backplate This will break the backplate loose from the pump housing do not hit backplate with excessive force as it will damage backplate and pump housing 6 Remove O Ring from Backplate Remove the O Ring Seal item 8 from backplate item 2 Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 16 Outer Front Pump Inner Rear Pump Vice Jaw En 1 8 Protective i i Pads AGE all D Bench Vice Figure 1 Outer Front Pump Tandem Pump Gonnecting__ Bolts Inner Rear Pump Vice Jaw Protective Tandem Pump Dis Assembly amp Re Assembly 7 Remove Complete Piston Block Assembly item 1 from Pump Housing item 4 Liftthe Piston Block assembly upward and out of the pump housing It may require you to remove pump from vice and dump the Piston Block assembly out If you do catch the block with you hand don t let it fall out on the floor or bench DO NOT remove the spring snap Ring item 1K from the piston block assembly as the spring item 1H has compression on it this compression will require relieving before snap ring is removed this can be done later 8 Remove the Piston Assembly item 1A from the Piston Block item
119. en pull out r Bi 0 ee pel FIGURE 16 Lt FIGURE 17 Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 7 Mower Repairs Rear Mower ROLLER BEARING REPLACE MENT See Figure 19 7 Install new bearing into housing Bearing must be installed with grease hole in bearing aligned with grease fitting hole in housing 8 Reinstall grease fitting to housing Grease fitting must be tight and seated in grease hole in bearing to prevent bearing from rotating in housing 9 Attach roller bearing and housing assembly to bracket with seal between housing and bracket 10 Slide bearing and bracket assemblies on each end of roller 11 Check bearing for proper installation in housing by gently rocking bearing and bracket assembly in end of roller Play should be slight to none at all 12 Install roller and bearing and bracket assemblies on mower 13 Lubricate roller bearing until lubricant can be seen coming out between roller and bearing housing 14 When reinstalling roller bearing amp mount bracket make certain to bolt at the desired height Desired height will normally be the same bolt holes as before the repair See Previous pages for adjust roller height NON DRIVE END CUTTERSHAFT BEARING See Figure 20 21 amp 22 1 Lift cutter unit to maximum horizontal height then securely support ends of cutter housing with jack stands or strong blocks do not use just a jack or hoist 2
120. ent that is not intended to be repaired example sealed components as there are no serviceable components inside 6 DO NOT let anyone attempt any testing or repairs unless they are an experienced and qualified technician Technicians must have proper tools gauges meters etc to perform proper diagnosis and or repairs 7 DO NOT perform any repairs with dirty tools or in dirty area When working on hydraulic components keeping system clean and free of contamination is important 8 DO NOT start or engage system if the oil level is not atthe proper level or condition Never start or run unit low or out of oil 9 DO NOT install add any oil unless you know it is the correct type and the container is clean Make certain the oil is not contaminated with dirt or any liquid 10 DONOT Operate any mowers that have a vibration when running cause of vibration must be fond and repaired before running Vibrating Flail Mower running will damage them Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 2 SPECIFICATIONS INTERSTATER Standard Equipment and Specifications 1 BASE UNIT SPECIFICATIONS Overal Cutting Wide 16 5 18 5 or 209 Overal Cutting Widths Frame Construction Full Length Welded Tubular Frame With Transport Lock Reservoir CapaOYsrsnnersernsernsenntenenenser sean 19 Gallon Reservoir with 12 Micron Filtration Pump Type amp Rating Dual Wing Interstater
121. er Brown gan Terminal Right Wing Safety Cut off Switch Right Wing Motor Solenoid Valve Section 8 15 Motor Control Switch Dual Wing LH Wing Push Pull Switch RH Wing Push Pull Switch 16 Yellow e L da RH Wing N 16 White I LH Wing nn I 3 Switch Plug CI LE Sd DI DO SS 12B Fuse Holder LS m __T with Fuse __ 10 Amp Fuse In 35 Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply He nes Wo 16 Black White a en 16 Black Line Connector Solenoid iene AO Connector Ne D gud Connecters Il Q es 16 Red to Shipped Loose in Il Switched Power Supply 3 Terminal Separate Plastic O Connector Bag IR 16 Black White 16 Black White Left Wing Motor Solenoid Valve ps Solenoid Valve LJ nono H Tan il C C 16 White 16 Yellow Cavity Plug Solenoid Connector at Cutter Valve OS Right Wing Motor Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 16 Motor Control Switch RH Wing Only 16 Yellow Push Pull Switch LL ON Off I oo Switch Plug lm CL co mn 12 Brn LT EI Fuse Holder with Fuse 10 Amp Fuse p Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply Ground 16 Black Solenoid CC Connector Ring Connector to Ground J Connecters Shipped Loose in Separate Plastic Bag 16
122. er you can loosen the locking collar and pull driveshaft VI he out or you can remove the four bolts in the u A pump mount weldment and pull the suction driveshaft out with the pump mount Figure 2 weldment See Figure 5 u Pressure Out Port From Port To LH Wing Tank Motor Interstater Service Manual 03 06 2006 Alamo Industrial Section 7 2 Pump Mount Weldment Remove amp Replace 5 Remove Pump Mount Weldment Thepump mount weldment has four mounting bolts Thes bolt screw into the front bolster of the tractor See Figure 6 amp 7 Figure 6 show with driveshaft removed andfigure 7 show with driveshaft left in carrier bearing Removal can be either way Remove the four mounting bolts for the pump mount weldment use caution when all bolts are removed mount weldment will drop if it is not secured Some tractor models will have spacer blocks installed between pump mount weldment andtractor bolster If your model has spacer blocks this should be noted and spacer blocks should be identified and marked Pump mount weldment with spacer blocks will used longer bolts than model that do not have spacer blocks See Figure 7 Pull pump mount weldment away from tractor bolster If the carrier bearing was removed the driveshaft should stay through bolster See Figure 8 amp 9 Driveshaft Bearing amp Lock Coller Drive Pulley amp Drive Belt ee Let Y N 1 4 Dri
123. ermined while facing the front of the tractor from the drivers seat G The part quantities shown for an illustration pertain only to that phase of repair The quantity given corresponds to the number of parts needed When repairing a single sided model based on a dual sided model the quantity furnished will usually be half the quantity listed H Large parts may not always be listed next to an illustration because they are usually easy to identify them from name or description l This manual makes reference to individual component parts some of which may have been pre assembled at the factory Abbreviation of Parts Terminology Whenever reference is made to parts listed for an illustration or elsewhere in this manual some of the following abbreviations may be used 1 ASY Assembly 2 ASSY Assembly 3 AUX Auxiliary 4 BRG Bearing 5 BRKT Bracket 6 CYL GCylinder r CW Clockwise 8 CCW Counter Clockwise 7 EXT Extreme 8 EXT N Extend Extension 9 F For or From 10 FM Female Boss 11 FP Female Pipe 12 FSTNR Fastener 13 FT Foot Feet 14 GB G B Gearbox 15 GR Grade 16 HD Heavy Duty 17 HHCS Hex Head Capscrew 18 HRDND Hardened 19 HYD Hydraulic 20 IN Inch 21 LB Pound 22 LH Left Hand 23 LW Lock Washer 24 M Metric 25 MB Male Boss 26 MM Millimeters 27 MNT Mount 28 MP Male Pipe 29 MTR Motor 30 N A Not Applicable 31 NC National Coarse 32 NF National Fine 33 NLA No Longe
124. ervice Man 03 06 2006 Alamo Group Inc Section 11 3 Wing Mower Decks Wing Cut Off Switch continued 4 Install Mower Rear Mounting Brackets amp Magnetic Switches The Mower Hinge Linkhasa the fi LH amp RH See Figure 7 These brackets will slide I tg VE over the Hinge Pin which is bolted to the mower 1 hi deck at the factory There are two Threaded holes in the end of the hinge pin See Figure 7 These two holes serve dual purpose First they hole the hinge bracket on and the Magnetic Activator Bracket on Some times you will need to loosen the Hinge pin to align the two holes so the bracket will bolt on See Figure 8 amp 9 Tighten the two mounting bolts in to the hinge pin The Hinge bracket will still turn free LH Wing Rear Hinge Bracket TWO Threaded Holes in Hinge Pin Always use overhead JR hoist to position mower I AN LH Wing Shown Magnetic Activato Switch Bracket Hinge Pin Bracket Figure 9 Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 4 Mower Repairs Wing Mower Decks Wing Cut Off Switch continued 5 Install Mower Front Mounting Brackets The Mower Hinge Front Bracket has a has a LH amp RH See Figure 10 These brackets will slide over the Hinge Pin which is bolted to the mower deck at the factory This bracket will be bolted to the Lift frame with four bolts This hinge Pin WILL NOT have threaded holes as the rea
125. ese pin must be installed with the head and cotter pins a certain way see below for installing pin depending on cutter shaft rotation Continued Next Page Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 10 Mower Repairs Rear Mower REPLAGING CUTTER BLADES KNIVES Continued from Previous Page B Type B is used on fine cut cutter shaft and is a Ring amp Clip mounted knife This Knife is retained with a bolt and nut This bolt and nut must be torqued to 20 ft Ibs C Type C is used on the course cut cutter shaft It is the standard course cut knife and retained with a D Ring hardened Pin with a hardened cotter pin Knife must have the pin and cotter pin installed in the right direction See Below FOR FORWARD ROTATION On the right wing and rear unit all knife pins must be installed with their heads facing away form the cuttershaft pulley On the left wing the heads of the knife pins must face the cuttershaft pulley FOR REVERSE ROTATION Onthe right wing and rear unit all knife pins must be installed with their heads facing toward the cuttershaft pulley On the left wing and rear unit the heads of the knife pins must face away from the cuttershaft pulley NOTE Rotation is the direction of the cuttershaft in relation to the direction of travel of the mower The blades will not need to be reversed as they are double sided and designed to cut on either side Tractor Direction of Travel JE
126. ether with force of your hand there is something wrong Install Needle Bearing item 32 into Back Plate Asy item 20 The needle bearings will install into center opening of back plate Coat this bearing with oil as you slide it into back plate Install Bearings into back plate with number end of bearing up and visible Bearing will be slightly higher 09 than back plate Back Plate item 20 amp Sealing O Ring item 26 The back plate is sealed with an O Ring that is inserted into a groove on back plate item 20 make certain this O Ring is seated into this groove lubricate OD of O Ring to aid the inserting of the Back Plate into the pump housing Back Plate Asy item 2 Roll Pin and Alignment The backplate has a Roll Pin installed into it This roll pin item 33 isto align the back plate on the pump housing so front flange of housing and back plate ports will be in the correct orientation roll pin should not be more that 173 higher than surface of back plate This alignment is important and must be correct Make certain the roll pin is in the back plate Lower the Back Plate item 20 down onto the pump Housing item 22 aligning the back plate down over driveshaft untilthe sealing O Ring item 26 inserts into pump housing Back plate should slide down until it is inside of pump housing If back plate can not be pushing completely down without alot of force check it for something wrong DO NOT use excessive force or use the bolts to pull ba
127. ewhere in this manual the following abbreviations may be used 1 ASY Assembly 2 ASSY Assembly 3 AUX Auxiliary 4 BRG Bearing 5 BRKT Bracket 6 CYL Cylinder 7 CW Clockwise 8 CCW Counter Clockwise 7 EXT Extreme 8 EXT N Extend Extension 9 F For or From 10 FM Female Boss 11 FP Female Pipe 12 FSTNR Fastener 13 FT Foot Feet 14 GB G B Gearbox 15 GR Grade 16 HD Heavy Duty 17 HHCS Hex Head Capscrew 18 HRDND Hardened 19 HYD Hydraulic 20 IN Inch 21 LB Pound 22 LH LeftHand 23 LW Lock Washer 24 M Metric 25 MB Male Boss 26 MM Millimeters 27 MNT Mount 28 MP Male Pipe 29 MTR Motor 30 N A Not Applicable 31 NC National Coarse 32 NF National Fine 33 NLA No Longer Available 34 NLF No Longer Furnished 35 NPT National Pipe Thread 36 P1 5 Thread Pitch 37 P2 0 Thread Pitch 38 P2 5 Thread Pitch 39 PL Plated 40 PLT Plate 41 PMP Pump 42 PTO Power Take Off 43 PW Plain Washer 44 REV Reverse 45 RH Right Hand 46 ROT Rotation 47 RPM Revolutions Per Minute 48 SCKT Socket 49 SD Severe Duty 50 SRV Service 51 STD Standard 52 SVR Severe 53 W With 54 W O With Out 55 WLDMNT Weldment When installing fasteners PW and LW generally installed in that order are usually on the side of the fixture or part being fastened that the hex lock nut is on When only HHCS LW and or PW are required they are generally installed in that order Some par
128. f using tractor hydraulics for cylinder skip this section 1 Remove standard control Handles When using remote control cables and handles the standard handles must be removed and discarded This is done by removing the C Clips and pins that hold the handles to the valve body and the C clips and pins that hold handles to the spools See Figure 1 2 Install The Cylinder Control Valve to Valve Bracket The control valve is mount to the valve bracket using two bolts These two bolts is all that will be needed to mount valve to valve bracket See Figure 2 3 Connect Remote Control Cablesto Valve Bracket Shown here are cables being connected tthe valve mount bracket while it is lying on the bench See Figure 3 It can be done after bolting it to the tractor as well 4 Bolt Valve Mounting Bracket to Mainframe The valve mounting bracket is bolted to the Right Hand side of the tractor It is bolted to the mainframe There are two different sets of hole in valve mounting bracket this allows the location of the valve to Figure 1 be varied See Figure 4 Figure 4 Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 2 Joystick Valve amp Control Cables Cab 5 Install sleeving over the return hoses from heads Pressure Hose Return Hose to RH Winge from Wing Motoi LO if and control valve and Control valve Pressure Hose Slide the three hoses through the sleeving Slide the hoses
129. f valve setting repair or replace as needed Cause 7 C Worn Gear Pump Solution 7 C Check pump pressure and flow repair or replace as needed Cause 7 D Worn or damaged cylinder Solution 7 D Check cylinder repair or replace as needed Cause 7 E Worn or damaged control valve Solution 7 E Check valve sections and repair or replace as needed Interstater Service Manual 03 06 2006 Alamo Industrial Section 2 3 Possible Failure Cause Solution MOTOR CIRCUIT TROUBLE SHOOTING 1 Possible Failure Motor turns but in wrong direction Cause Motor manifold block is installed wrong on motor Solution Motor manifold block must be refitted to motor to achieve correct rotation See motor change rotation page 7 22 in mower repair section 2 Possible Failure Motor fails to engage when electric switch activated Cause Electrical connection failure Switch solenoid or wire harness Solution Test Switch for current and activation test solenoid coil for current and activation Cause Pump driveshaft malfunction Solution Inspect pump driveshaft for damage to splines or drive components Make certain pump is turning if not inspect splined coupler at pump and drive shaft Repair as required Cause Lack of sufficient hydraulic pressure and volume Solution Perform a pressure and flow
130. g Cup 001722 Cup amp Cone down over Bearing Cone Slide out put shaft into housing Insert Snap Ring 400754752 into Main Housing Slide Bearing Spacer 001716 in till it bottoms out against Snap Ring 3 Insert Outer Bearing Cup 400754757 Cup amp Cone into Main Housing till it is against Bearing Spacer Slide Outer Bearing Cone 00754757 Cup amp Cone over Shaft till it seats against Outer Cup Install Tabbed Lock Washer 001720 onto output shaft next to outer Bearing Cone Make sure Inner Tab of locking washer is in keyway of Shaft Install Notched Locking Nut 00171 7 by screwing it onto Output Shaft Tighten Nut till Bearing Pre Load is set at 14 to 16 lbs of rolling Torque When Bearing Pre Load is correct DON T BEND Locking Washer Tabs into Notches on Locking Nut and DON T INSTALL OUTPUT SEAL AT THIS TIME this is important 4 Install Input Shaft amp Gear into Main Housing 002516 5 Install front Bearing 00754459 into Main Housing 002516 Using Shims 00754761 quantity as required try same quantity as taken out install Snap ring 00754752 into Main Housing DO NOT INSTALL INPUT SEAL AT THIS TIME this is important 6 Install Input Shaft and Gear Assembly 001725 into rear of Main Housing and through front input Bearing Install Rear Bearing Cone 00754757 Cup amp Cone onto back of input Shaft Install Rear Bearing Cup 00754757 Cup amp Cone into Rear Housing Cover 001710 make sure cup i
131. g prevents the spline coupler item 13 from moving around This step will only apply to the tandem pump this single pump will not use these 15 Install O Ring item 15 Seal into Back Plate item 2 The O Ring will fit into a groove cut into ID of back plate pump mounting flange item 2 Make certain groove is clean in back plate Insert O Ring item 15 into Groove in ID of back plate Coat O Ring with coating of oil or vaselene Dis Assemble Outer Front Pump For item numbers See Figure 12 1 Clamp Outer Front Pump in Vice with Jaw Protectors See Figure Outer Front Half of Tandem Pump 15 Outer front pump can be clamped in vice fordis assembly but it can also be disassembled while on the work bench Pressure 2 Remove Back Plate Item 20 The backplate is bolted on with six hex PO head bolts item 27 remove these six bolts Itrequire a small amount Outer Front Suction of force to free the backplate loose from pump housing If neededuse Pump small plastic mallet to tap the sides of the backplate This will break the backplate loose from the pump housing do not hit back plate with excessive force as it will damage backplate and pump housing 3 Remove O Ring from Backplate Remove the O Ring Seal item 8 from backplate item 26 4 Remove Complete Piston Block Asy item 19 f Pump Hsg item 22 Bench Liftthe Piston Block assembly upward and out of the pump housing Vice It may require you to remove pump from vice
132. gh Pressure Test Port Plug This port is to enable technician to connect gauge to test the high pressure from the pump This port isto always remain plugged and only used when testing pressure Do Not install a pressure gauge here and leave it H Manifold Mounting bolts There are four mounting bolts that are inserted into the manifold these bolts will go through the motor back plate and screw into the motor housing The torque of these four bolts are critical These bolts must be TORQUED at 15 to 18 ft Ibs 10 Reinstall Motor and Manifold Assembly to mower deck See the previous section for instructions on how to connect motor and manifold assembly to mower USE EXTREME CAUTION Do Not connect the High Pressure hose to the cooling tubes of the deck the high pressure will damage these tubes they will expand from the high pressure and in some cases crack and leak ONLY the return hose from the motor return outlet port can be connected to the cooling tubes as the return line is low pressure See Figure 10 11 Re Connect Wire Harness When reconnect ing wire harness make certain the wire harness is Figure 10 routed and tied so it will not catch or rub on anything while being operated or folded for transport Oil High Pressure Port Motor Asy Vg A Vice Jaw Protective Pads Interstater Service Manual 03 06 2006 Alamo Industrial section 10 7 Motor Single or Dual Wing Model Motor Dis Assembly amp Re As
133. ghten It is a good practice to mark the bolts and nuts with some mark such as a dab of paint from a paint marker or anyway that you want so you will know that bolt has been tightened H The small cylinder hydraulic Supply Pump will have a short hose that connects to the small pump and to the tank suction port that is in the tank exclusively for the small pump The suction hose will need to be cut to length make certain suction hose is not kinked See Figure 37 amp 38 which shows these ports Make certain the Elbow pressure port of outer tandem pump See Figure 37 38 amp 39 is installed and tightened pointing to the rear of the pump this is the pressure port to the cylinder control valve l Re install any Engine Guards and or Screens that were removed to gain access to any component Some tractor and or mower models may have guards in place replace any of these that may have been removed See Figure 40 as example Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 32 Removal Repair amp Replace 22 Hydraulic Schematics Figure 41 Hyd Schematic Single Pump for single Wing with Auxiliary hydraulic pump for cylinder control Figure 42 Hyd Schematic Dual Pump for Dual Wing with Auxiliary hydraulic pump for cylinder control Figure 43 Hyd Schematic Single Pump for single Wing using tractor hydraulic pump for cylinder control Figure 44 Hyd Schematic Dual Pump for Dual Wing using tractor hydraulic pump for
134. gine 73425 LAA 01 001734 Inner Pump Section 2 28 CID Closest to Engine 73428 LAG n 001841 Outer Pump Section 2 77 CID Furthermost from Engine 73425 LAB O 001733 Outer Pump Section 2 28 CID Furthermost from Engine 13420 LAF ia ia 00755650 Single Pump 2 77 CID TN LAU nen Bin 001827 Single Pump 2 28 CID 8 TYPE HYDRAULIC RESERVOIR USED The Hydraulic reservoir for the Interstater is the same for the Tandem Pump Dual Wing Model or the Single Pump Single Wing Model When the Single Pump is being used some of the ports on the tank are not used and will remained plugged 9 DRAIN HYDRAULIC RESERVOIR Secure Tractor so it cannot be started while repairing the pump It will re quire the oil to be drained form the system and the tractor MUST NEVER be started without proper level of oil in the system To drain the tank it is recommended that only a filter buggy be used if you intend on reusing the oil Filter buggies or carts are commercially available for hydraulic sys tem clean up These consist of a high efficiency high capacity filter a circulating pump a drive motor and hoses for connect ing the overhauled machine s hydraulic sys tem See Figure 3 When disposing of or storing re moved oil make certain oil to be used is properly stored to keep it clean and in a clean container Make certain Oil that is to be disposed of is done by following your local regulations
135. hat only proper type oil be added or installed and that all oil be installed using a filtered buggy system these system are available on the market Figure 21 af MI CS ITS Interstater Service Manual 03 06 2006 Alamo Industrial Section 6 6 Section 7 interstater SERVICE MANUAL Pump Mount Weldment amp Driveshaft Remove amp Replace Pump Mount Weldment Remove amp Replace Preparation 1 Items to be removed in preparation to remove pump mount weldment Main Pump Single or Tandem some hoses will need to be disconnected and or will need to be removed in order to remove the pump s The pump will need to slide back away from pump mount weldment approx 2 Some hoses may not have enough length to the to allow the pumps to slide outward See Pump Remove and Replace instruction section if hoses are to be disconnected see tankremovalandreplace section Itis recommended oil be drained before disconnecting any hoses See Tank Remove and replace section IMPORTANT Cap all hydraulic components immediately after disconnecting them DO NOT leave hydraulic system open DO NOT work on hydraulic system under dirty conditions Hydraulic System MUST be cleaned before disconnecting hoses and or components Work area and tools MUST be clean at all times See Figure 1 amp 2 2 There are different models of tractors which will have varying components designs Some may use spacers some may not Some will use th
136. he Piston block assembly need not be dis assembled unless the pins item 19F or the Spring item 1H is damaged CAUTION The following procedure should be used if the spring is to be removed from the piston block The spring item 1H is highly compressed and the snap ring item 1K should NOT be removed without compressing the spring The following parts will be needed to dis assemble the piston block 2 ea 3 8 ID X 1 1 8 OD Flatwasher 1 ea 3 8 NC X 3 1 4 Bolt Hex Head amp 1 ea 3 8 NC Hex Nut Place one flatwashers over 3 8 X 3 1 4 bolt place this through center of piston block Place other flatwasher overtbolt and let it rest on the three pins item 1F Screw the nuton and compress the spring inside piston block Use snap ring pliers and remove the internal snap ring item 1K Unscrew bolt nut amp two washers this will release pressure on spring item 1H Remove spring item 1K three pins item 1F and the pin keeper item 1E 9 Remove Snap Ring item 10 Using internal snap ring pliers remove internal snap ring item 10 from front side of housing item 11 Seal Adapter item 2C has an O ring around the OD of it and may make it difficult to remove The motor shaft can be pushed from the back plate side of housing to push the seal adapter out 10 Remove Input Seal item 2B Seal adapter item 2C The input seal will be remove from the adapter from the back side of the seal adapter Use caution when removing the input seal so you
137. he Wire E Harness up through the floor and boot cover See Figure 19 amp 21 4 Insert Cables up through Boot Cover Markthe cables as to which is which on the control valve as they need to be connected in the same order on the inside of the cab as they are connected to the control valve See Figure 21 an Figure 20 5 Reinstall switches and Switch mounting bracket Reconnect the switches and the mounting brackets back to the wire harness See Figure 25 28 amp 29 6 Mark Which Cable is Which Itis important that each cable be marked as to which one it is in relation ship to the valve Start with the cable closest to the engine and mark it 1 next mark 2 See Figure 22 These marked cables will make a difference when mounting the control cable handle assem blies to the mounting bracket 7 Each controller assembly comes fully assembled All required hardware etc is included The control cables are not included with the control handles and should be ordered en separately The Controller must face forward as shown or Mn MN controls will be backward See Figure 23 Figure 21 A Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 6 Joystick Valve amp Control Cables Cab 8 Toattachthe cable manipulate the controller handle so that the attachment nut is exposed as shown Remove the lower most nut and screw from the controller housing Thread the cable nut
138. ide These brackets will bolt to the sub frame with two bolts and nuts each All the mounting bolts should be installed before tightening the bolts Tighten all the bolts in sub frame front and rear now See Figure 4 5 amp 6 Typical But Not The Only Main Frame Weldment Dual Wing Cab or ROPS Tractor LH Side Interstater Service Manual 03 06 2006 Alamo Industrial Section 9 2 Install Main Frame RH Only amp Dual Wing 6 Install Cylinder Support Weldment The cylinder support weldment bolts to the frame rail See Figure 6 Tighten the mounting bolts once installed On dual wing units the LH will install the same as the RH The LH support will not have the mount with the 4 holes welded to the top of it See Figure 7 amp 8 sr _ 7 Install Wing Lift frame The RH wing lift frame pivots on two hinge pins one to the front and one to the rear When installing these pins they must be aligned in a way that will allow the retaining bolt to be installed See Figure 9 10 amp 11 On dual wing models the LH Lift frame will install the same as the RH 8 Install Hydraulic Cylinders Install the hydraulic cylinders as shown Theendswillhavetobeinstalledon EYE the rod ends Note the collars on the cylinders These Steps collars have locking bolts in them and must be installed with the bolts to the top where they are accessible after assembly is complete See Figure 11 Figure 2 AN LH Front Frame a RH Fr
139. ider item 19B and Pivot item 19C Conical surfaces should be free of wear and score marks Contnued Next Page Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 20 Tandem Pump Dis Assembly amp Re Assembly Continued From Previous Page Outer Front Pump Component Inspection For item numbers See Figure 12 5 Inspect Pistons item 19A The O D surface should be smooth and free of scoring The shoes should be snug fit to piston The face of the shoe should be flat and free of scoring and flaking Do Not lap piston shoes 6 Inspectthe Piston Block item 19D The bore should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or metal build up 7 Inspectthe Cam Plate Insert item 25 The surface should show no signs of scoring or grooves 8 Inspect the flat surface on the Back Plate item 20 The back plate surface should be free of excessive scoring or metal build up 9 Inspectthe Drive Shaft item 21 Inspect for fretting in the bearing areas Check spline area for twisted broken or worn splines Check for chips and or cracks in shaft Re Assemble Outer Front Pump For item numbers See Figure 12 1 Coat Moving Parts for Re Assembly It is recommended that all moving parts be coated before and during re assembly If pump is to used immediately after assembly the recommend hydraulic oil for the interstater will work If pump is to set aside for
140. igure 10 and spring are tightenedto PLATE NM 1 5 16 long 3 The newest clutch has 6 springs and the springs will be tighten to 1 9 16 long when adjusted The clutch are easily identified by the springs Always check before adjusting clutch The different clutches are in stalled on different series universal joint driv elines and can not be interchange among driv elines When repairing the clutches the correct type must be identified to enable the correct parts be ordered a good source of identification is the Interstater Archive Manual 10 Check All Shields Make certain any shields that were removed during as sembly are reinstalled DO NOT oper ate mower or tractor with any shields or guards missing X EE EEE EEE HAT 1 1 16 Standard See Step 9A gt IK J r 7 ENE EEE SER NE 7 DB 4 px Style Clutch with 6 Small springs shown see Step 9A for other clutches Figure 10A Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 5 FE f Figure 10B 1 5 16 Standard 1 3 16 Min See Step 9A ann NN Ch SPRING BOLT WITH NUT Style Clutch with 8 large springs shown Figure 10 see Step 9A for other clutches 1 9 16 Standard See Step 9A Style Clutch with 6 large springs shown see Step 9A for other clutches Mower Repairs Rear Mower GENERAL 1 Mower should be in the lowered position mowers resting on the ground Tractor sh
141. ill be received in sections The 4 main wire harness Single or dual wings and the wing harness a RH harness and a LH harness The RH and LH harness Motor Control will both be used for a dual wing unit and FIGURE 54 Wiring Harness onlythe RH harness for a single wing unit NOTE Route wires in such a manner to prevent interference with the operation of tractor or INTERSTATER Ensure that wires DO NOT lay against anything which could wear through insulation and cause a short circuit After connecting all wires wrap wires with flex guard tubing Neatly gather hydraulic hoses and flex guard tubing and strap together using plastic ties Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 14 Wiring Harness Schematic CAB amp ROPS Figure 55 Left z Switch Left Wing Motor Cavity Solenoid Valve Plu a Bug E i Fuse Red White lt Yellow 3 Terminal Connector White h EER Yellow Left Wing Safety Cut off Switch Left Wing Motor Solenoid Valve Black Interstater Service Manual 03 06 2006 Alamo Industrial White Black White z Right Switch DOUBLE WING MOWER SHOWN Single Wings have only the Right Wing Motor Solenoid Valve harness Connector Right Wing Motor Solenoid Valve EL 1 Yellow Sch Right saga Switch Switch Brown Brown Starter Solenoid Red to Accessory Terminal Black Ground Tractor Start
142. in hose and the pump pressure hose first The suction hose port will have an elbow connected to it Fill this elbow with new clean hydraulic oil before connecting the hose this will prevent pump from starting dry when tractor is started later H Fillthe hydraulic system with oil to the correct level always use a 10 micron max filter system to install oil Filter buggy system are commercially available Inspect oil sight gauge and temperature gauge to make certain they are not damaged Start Tractor and run system checking for leaks l Return Filter pressure gauge watch the return filter gauge When the oil is cold the gauge may show in the red and as oil gets up to normal operating temperature the gauger should drop to the green zone If gauge pressure doesn t drop to green zone check filter for being plugged and or check all hoses to make certain they are not crimped shut or in a bind J Re adjustthe Auxiliary pump drive belt if model uses auxiliary pump Reinstall all guards that were removed Do not leave guards off when running mower or tractor Single and Tandem Pump The single pump Is used on single wing interstaters only The pump can be identified by the location of the inlet and outlet port they are located in the end plate facing outward See Figure 10 The dual pump inner and Outer pump will have the inlet and outlet ports to the sides of the pump See Figure 11 The inner pumps end plate has a flange built on to it to al
143. into the controller attachment nut and tighten See Figure 24 9 Allow the controller handle to return to neutral Slide the cable guide tube into the control housing and reinstall and tighten the housing screw 10 Check the operation of the spool cable and controller Some adjustment at the valve end may be required too ensure that the spool returns to neutral when the controlle ris in the neutral position See Figure 14 vi 11 Thecontrolleverassemblies utilizes a small spring to O E to reference make up for free play in the cable to valve connection The F MAS whichit IS On control valve spool spring provides the centering capabilities m the comtr l of the controller and the valve spool Lack of centering at vr the controller is normally attributed to poor adjustment at the valve to cable connection or binding of the cables due to poor routing 12 The control lever assemblies will bolt together to form a group of handles there will be 4 handles bolted together along with the switch mounting brackets See Figure 22 amp 23 The switches will mount to these brackets Dual Wings models will have two switches The switch for the left wing mount on the left and switch for the right wing mounts on the right See Figure 22 amp 23 The same two long bolts that go through cable control handles will go through switch brack ets 13 Install Cable control Handle Assembly The control cable assemblies slide over the thre
144. ion 4 9 Right Switch DOUBLE WING MOWER SHOWN Single Wings have only the Right Wing Motor Solenoid Valve harness Connector Right Wing Motor Solenoid Valve 4 Yellow Sch Right saga Switch Switch Brown Brown Sat Terminal Brown Starter Solenoid Red to Accessory Terminal Black Ground Tractor Starter Right Wing Safety Cut off Switch Right Wing Motor Solenoid Valve Motor Control Switch Dual Winc LH Wing Push Pull Switch C Fuse Holder 10 Amp Fuse OOO 12 Brown 16 Black a Line Connector S gt Solenoid a Ges a _ a DE 16 Red to Switched Power 3 Terminal en Connector 16 Black White Left Wing Motor Solenoid Valve um Hong 16 White Cavity Plug Interstater Service Manual 03 06 2006 Alamo Industrial RH Wing Push Pull Switch 16 Yellow ESE RH Wing N 16 White LH Wing ON Off Switch Plug C C l am Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply Ground 16 Black White Solenoid C Connector Connecters Shipped Loose in Separate Plastic Bag 1 Ra 16 Black White Right Wing Motor Solenoid Valve foon JF non fi Solenoid Connector at Cutter Valve 16 Yellow Section 4 10 Motor Control Switch RH Wing Onl 16 Yell rn 16 Red ON Off Switch Plug Push Pull Switch CI 02 Bamm DI
145. ion Inspection Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component location Tractor Mower Operation Inspection Using all Safety precautions operate the Tractor and Mower unit for 30 minutes and while the unit is running check the following items Note Only make adjustments after the mower has been turned off and all motion has stopped and all hydraulic pressure has been relieved Check for Hydraulic oil leaks at the hose connections Operate the boom and mower head throughout its full range of motion and check for hose s rubbing pinching or kinking Make sure the Return Filter Gauge is reading in the Green after Oil is warm Check the function of the Mower Head On Off Valve and switch for proper function Make sure that the tractor will not start with the mower on off switch in the on position Check the Blade Rotation for the Rotary Mower Head to make sure it is turning Clockwise looking from the top of the mower deck Make sure the control valve boom movements agree with the valve operation decal Make Sure Boom Movement operates as expected and is smooth and under control no air in the control system Look for any unusual or excessive noise or vibrations Make sure the left rear wheel of the tractor stays on the ground when the boom is fully extended horizontally with 200 Ibs placed on the outside of the mower head Post Operation Inspection Check
146. ip clutch is incorporated in the PTO driveline It is designed to slip absorb the shock load and protect the driveline It is important that the clutch lining plates slip when an obstacle or load heavier than clutch setting is encoun tered Therefore if the machine sits outside longer than 30 days and is exposed to rain and or humid air it is important to make sure that the clutch lining plates are not rusted cor a roded together Before using the mower use the following U ee Se procedure to make sure the clutch will slip and give the pan hk overload protection required See Figure 13 This is a re Figure 6 quired step because the driveline has been sitting and may IT be stuck A Loosen nuts on springs until the springs can freely rotate yet remain secure on bolts B Attach mower to tractor and start the tractor Set the engine speed at 1200 RPM C Mark outer plates with marker paint or any form that will work for you to tell if the components of the clutch slipped D Engage the PTO approximately one second and then quickly disengage it The friction lining plates should break loose check the mark E Turn tractor off and tighten the nuts on the springs to their original position of 1 5 16 compressed spring length 9 Slip clutch is incorporated in the PTO driveline It is designed to slip absorb the shock load and protect the driveline After the first hour of operation the slip clutch should be
147. isassembly amp Reassembly 5 23 to 5 26 Auxiliary Pump Remove amp Repair 5 27 Auxiliary Pump Remove amp Replac se snaneere neen 5 28 Auxiliary Pump Disassembly 5 29 Auxiliary Pump Reassembly annen enn en enenneenen 5 30 Auxiliary Pump Reassembly amp Reinstall 9 31 Auxiliary Pump Removal Repair amp Replace 5 3210 5 33 Hyd Schematic W Aux Pump RH Wing 5 34 Hyd Schematic W Aux Pump Dual Wing 5 35 Hyd Schematic W O Aux Pump RH Wing 5 36 Hyd Schematic W O Aux Pump Dual Wing 5 37 Section 6 Hyd Tank amp Return Filter Remove amp Replac nnn sananersenenenn 6 1 to 6 6 Hyd Tank Repairs ennnensenensennen 6 2 to 6 4 Hyd Tank Filter Change amp Repairs een 6 5 to 6 6 Section 7 Pump Mount Weldment amp Driveshaft Remove amp Replace 7 1 to 7 4 Pump Mount Weldment Remove amp Replace Remove 7 2 to 7 4 Section 8 Cable Control Valve Connections 8 1 to 8 20 Joystick Valve amp Control Cables Cab 8 8 Valve to Cylinder Hose Connections Cab amp Rops 8 9 Valve Connections Rops Tractor annen eneen ennen enen 8 10 to 8 12 Wire Harness Connections Cab amp Rops enen 8 13 to 8 15 Motor Control Switch Dual Wing 8 16 Motor Control Switch RH Wing Only eee 8 17
148. ities shown are for both sides F Reference to the left or right side of the Interstater is determined while facing the front of the tractor from the drivers seat G The part quantities shown for an illustration pertain only to that phase ofrepair The quantity given corresponds to the number of parts needed When repairing a single sided model based on a dual sided model the quantity furnished will usually be half the quantity listed H Large parts may not always be listed next to an illustration because they are usually easy to identify them from name or description Il This manual makes reference to individual component parts some of which may have been pre assembled at the factory Abbreviation of Parts Terminology Whenever reference is made to parts listed for an illustration or elsewhere in this manual the following abbreviations may be used 1 ASY Assembly 2 ASSY Assembly 3 AUX Auxiliary 4 BRG Bearing 5 BRKT Bracket 6 CYL GCylinder 7 CW Clockwise 8 CCW Counter Clockwise 7 EXT Extreme 8 EXT N Extend Extension 9 F For or From 10 FM Female Boss 11 FP Female Pipe 12 FSTNR Fastener 13 FT Foot Feet 14 GB G B Gearbox 15 GR Grade 16 HD Heavy Duty 17 HHCS Hex Head Capscrew 18 HRDND Hardened 19 HYD Hydraulic 20 IN Inch 21 LB Pound 22 LH LeftHand 23 LW Lock Washer 24 M Metric 25 MB Male Boss 26 MM Millimeters 27 MNT Mount 28 MP Male Pipe 29 MTR Mo
149. k and Pump Cover Weldment 2 1 Single Pump Asy RH Wing 3 1 Auxillary Pump Asy 4 1 Suction Hose F Tank to RH Wing Pump 7 1 Case Drain Hose F RH Wing Pump to Tank 9 1 Pressure Hose to RH Wing Motor 10 1 Suction Hose to Auxilliary Pump 11 1 Pressure Hose F Auxillairy Pump to Cyl Control Valve 12 1 Return Hose F Cylinder Control valve to Tank Return Filter 13 1 Return Hose F Wing Motors to Tank Return Filter 14 1 Hydraulic Tank Temperature Gauge 15 1 Hydraulic Oil Level Sight Glass 16 1 Hydraulic Tank Breather Filler Cap 17 1 Hydraulic Tank Filler Cap 18 1 Hydraulic Oil Return Pressure Gauge 19 1 Hydraulic Oil Return Filter Asy Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 7 Tandem Pump amp Driveshaft Asy w Aux Pump Driven Drive Used on Models with Dual Wings and Aux Hyd Pump Pulley Belt Shield Auxillary Hydraulic Pump for Cylinder Cyl Circuit Hydraulic Supply Cyl circuit Pulley Adapter Locknut Mounting Bolts 4 Tractor Engine FT Pulley Mounting Driveshaft Bolt amp Washer Bearing u Pulley Drive Pulley amp Adapter Splined Sleeve Driveshaft Weldment Bearing Tandem Pump for Dual Wings N Pump Mount Weldment Left Wing Pump Right Wing Pump Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 8 Driveshaft Bearing installs into pump mount weldment here andem Pump amp Driveshaft Asy w o Aux Pu
150. lation of the hydraulic pump procedure for the Alamo Industrial Interstater mower it also includes instruction for driveshaft hoses and miscellaneous parts to be attached the hydraulic pumps to the tractor D These instructions are for working on the pumps used to power wing mower mowers right side mower and left side mower units if dual wing model For mounting one mower side only disregard information concerning the opposite side Hardware quantities shown are for both sides E The Auxiliary pump is used to supply the lift and tilt hydraulic cylinder circuit This auxiliary pump will not be used on all units some will use the tractor hydraulic system to supply cylinder circuit F Reference to the left or right side of the Interstater is determined while facing the front of the tractor from the drivers seat G The part quantities shown for an illustration pertain only to that phase of repair The quantity given corresponds to the number of parts needed When repairing a single sided model based on a dual sided model the quantity furnished will usually be half the quantity listed H Large parts may not always be listed next to an illustration because they are usually easy to identify them from name or description Il This manual makes reference to individual component parts some of which may have been pre assembled at the factory Abbreviation of Parts Terminology Whenever reference is made to parts listed for an illustration or els
151. licreservoir Thereisaseparatepumpforeach wing By following the hose routing the operator can determine each wing mower s supply source Each pump has a case drain to eliminate excessive fluid in the pump All excess fluid in the pump is routed back to the hydraulic reservoir through the case drain Hydraulicreservoir There is a separate pump for each wing Tandem for dual wings and single pump for single wings By following the hose routing the operator can determine each wing mower s supply source Each pump has acase drain to eliminate excessive fluid in the pump All excess fluid in the pumps is routed back to the reservoir through the case drain m FIGURE 2 7 TYPE PUMP CONFIGURATIONS USED There are different configurations of pumps used depending on how mower unit was ordered and how it is being used on the tractor as weel as which tractor All Below will used the same hydraulic tank which means not all ports on hydraulic tank will be used some will remained plugged The connections on the tank will remain the same for the connections needed leave all ports plugged until ready to connect the fittings Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 4 Tandem amp Single Pump Repair Replace A Tandem Pump with Auxiliary Hydraulic Pump The Tandem Pump is used for the dual wing model mower and the auxiliary pump is used to supply the hydraulic cylinders and cylinder control valve See Hydraulic
152. low the outer pump to bolt to the inner pump The disassembly process for the inner and outer pump is basically the same for the inner outer tandem and the single pump The large difference is inthe end plates and the shafts for the tandem pump The Single and the tandem pump has two different cu in sizes It will be required to know which pump before ordering parts for them this is important as the wrong pump used will cause problems because of oil volume Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 13 Tandem Pump Dis Assembly amp Re Assembly Tandem Pump Dual Wing Model Pump ID Reference ande ump Dua g No is Stamped Here Inner Rear Pump P N 001840 2 77 CID P N 001734 2 28 CID Tractor Engine Pump ID Reference This End No is Stamped Here Outer Front Pump P N 001841 2 77 CID P N 001733 2 28 CID Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 14 Tandem Pump Dis Assembly amp Re Assembly Outer Front Pump Assembly P N 001841 2 77 Cu In Disp P N 001733 2 28 Cu In Disp Inner Front Pump Assembly P N 001840 2 77 Cu In Disp P N 001734 2 23 Cu In Disp Items 1 Thru 18 Items 19 Thru 33 Item Qty Descrition Item Part No Qty Descrition 1 1 Rotating Kit Asy 19 1 Rotating Kit Asy 1A 1 Piston Asy 19A 1 Piston Asy 1B 1 Spider 19B 1 Spider 1C 1 Pivot 19C 1 Pivot 1D 1 Piston Block 19D 1 Piston Block 1E 1 Pin Keeper
153. lter A large capacity filter is located on top of the hydraulic oil reservoir Figure 2 The filter will trap particles which are 001 inch or larger The filter needs to be changed after the first 10 hours of operation and every 200 hours thereafter 2 Clean the filter cover and all componets around filter assembly This is to prevent dirt or other contamination from entering filter and tank See Figure 10 amp 11 3 Loosenthe four bolts on the filter cover Never loosen these four bolt until you have made certain all hydraulic pressure has been relieved from system Make certain no hydraulic cylinders are suporting any weght work the control valves to release any pressure Make certain tractor has been shut down and sit long enough that all pressure is relieved Remove one bolt from the filter to aid in removing the filter cover loosen the other three bolts See Figure 12 amp 13 4 Push the filter cover down and slowly twist the filter cover clockwise to lift it off and up lift it up slowly as there is a spring under this cover See Figure 14 5 Remove filter spring Pull the filter spring up out of filter housing See Figure 15 Pull old fiter up and out of filter housing use caution the housing may still have oil in it See Figure 16 Return Filter _____ RETURNOIL FILTER Assembly hd amme eT leo Figure 14 C2 Interstater Service Manual 03 06 2006 Alamo Industrial Section 6 5 Hyd T
154. mall amount of force to free the backplate loose from pump housing Use softfaced hammer tap sides of backplate This will break the backplate loose from pump housing do not Suction hit back plate with excessive force it will damage backplate Port and pump housing lii Remove O Ring from Backplate Remove the O Ring Seal item 8 from backplate item 2 Vice Jaw N Remove Complete Piston Block Assembly item 1 from Pump Protective at I Housing item 4 Lift Piston Block asy upward and out of pump Pads housing Itwill require youto remove pump from vice and dump Piston Block asy out Catch the block with hand don t let it fall out on floor or bench DO NOT remove the spring snap Ring item 1K from piston block assembly as spring item 1H has Fig ure 18 compression on it this compression will require relieving before snap ring is removed this can be done later Remove the Piston Assembly item 19A from the Piston Block item 1D The piston assembly will pull upward and out of piston block Remove Spider item 1B and Pivot item 1C The spider item 1B will be left lying on the piston block when the piston assembly is removed The Pivot item 1C will also be left on the piston block and can be removed Piston Block Dis Assembly item 1D The Piston block assembly need not be dis assembled unless the pins item 19F or the Spring item 1H is damaged CAUTION The following procedure should be used if the spring is to be re
155. mo 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 PART NUMBERS Part numbers listed in this manual are subject to change without notice as designs are made to adapter to the tractor or for a design improvement Before ordering parts ALWAYS Measure old part to make certain that is the one you will need This manual is designed to be used along with the Parts and Operators Manual Most calls received by Alamo Industrial Service can be classified into approx 6 general categories Hydraulic or Mechanical Trouble Shooting Requestfor Technical Information or Specifications Mounting or Fitting Problem Special Service Problem Equipment Application
156. moved from the piston block The spring item 19H is highly compressed andthe snap ring item 1K should NOT be removed without compressing the spring The following parts will be needed to dis assemble the piston block 2ea 3 8 ID X 1 1 8 OD Flatwasher tea 3 8 NC X 3 1 4 Bolt Hex Head lea 3 8 NC Hex Nut Place one flatwashers over 3 8 X 3 1 4 bolt place this through center of piston block Place other flatwasher overtboltandletitrestonthethreepins item 1F Screw the nuton and compressthe spring inside piston block Use snap ring pliers and remove the internal snap ring item 1K Unscrew bolt nut and two washers this will release pressure on spring item 1H Remove spring item 1K three pins item 1F andthe pin keeper item 1E Remove Cam Plate Insert item 7 from housing item 4 The cam plate item 7 should be lying inside the housing item 4 Reach into the housing and the cam plate item 7 should pull out without much effort In some cases because of the oil creating suction it may require that housing be tilted up and cam plate dumped out of housing if this is the case catch the cam plate do not let it drop Remove Snap Ring item 11 Using internal snap ring pliers remove internal snap ring item 11 from front side of housing item 4 Remove Input Seal item 6 from housing item 4 The input seal will be remove from the housing using a seal puller Use caution when removing the input seal so you don t scratch or damage
157. mp Used on Models with Dual Wings Hydraulic Supply Tractor hydraulic supply used for cylinders and cylinder control valve Cyl circuit Pulley Adapter Mounting Bolts Tractor Engine Pulley Driveshaft Bearing In Driveshaft Bearing Tandem Pump for Dual Wings Pump Mount Weldment Left Wing Pump Right Wing Pump Driveshaft Bearing installs into pump mount weldment here Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 9 Single Pump amp Driveshaft Asy w Aux Pump Driven Drive Used on Models with Single Wing and Aux Hyd Pump Pulley Belt Shield Auxillary Hydraulic Pump for Cylinder Cyl Circuit Hydraulic Supply Cyl circuit Pulley Adapter Locknut Mounting Bolts 4 A Tractor Engine Pulley Weldment Bearing Mounting Driveshaft Bolt amp Washer Bearing u ee 4 Drive Pulley amp Pulley Splined Sleeve Driveshaft Adapter L Small Cyl Hyd Pump Mount Plate mounts here Single Pump for One Wing Only Pump Mount Weldment Right Wing Pump Most Common Driveshaft Bearing installs into pump mount weldment here Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 10 Single Pump amp Driveshaft Asy w o Aux Pump Pulley Adapter Mounting Bolts ij mem Splined Sleeve Driveshaft Pulley Bearing Drivesha t Adapter Bearing Tractor Single Pump for One Wing Only Pump Mount
158. mp has a 90 Fitting Connects here Pressure Hose Motor has a 90 Fitting Connects here NOTE The Pressure hose will always be connected to the top fitting and the return will always connect to the bottom Return Hose to Tank Return Filter has a 90 Fitting Connects here Return Hose from Cutter Head Cooling Tanks has a 45 Fitting Connects here Main Frame w hose bulkhead fitting RH side of tractor looking from front to rear of tractor Single Wing Shown Dual Wing has metal cross over pipe with a Tee in it for the return Note 45 elbow on bulkhead fitting that hose connects to must be turned as shown AR r A i Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 13 Pump amp Motor Hyd Schematic Dual Wing Return to Tank from TRACTOR Return to Tank from Wet Tubes of RH Wing REAR Wet Tubes of LH Wing RIGHT WING Mainframe Ben Tube Cross Over LEFT WING Line Te Hose Sleeving Bi plat ag Tee ir nan FER Hose Sleeving 4 tji H P 1 gt Pressure from Pump to RH Wing Motor Pressure from Pump to LH Wing Motor TRACTOR TRACTOR LH SIDE RH SIDE Hose Sleeving gt Indicates Direction of Flow Return to Tank from Wet Tubes of RH amp LH Wing Pressure from Pump to RH Wing Motor TRACTOR oi Wing Motor FRONT Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 14 Pump amp Motor Hy
159. mplement center axle and Ving Transpod Locks on tfoldinginplemenis k Aath Safety Chain to cuter and bring unit securely Ser Operabors Manual amp Maine certain that the SMA sign Naming Lights and Refectors are dearty visible Folie local traffic codes 7 Never operate with Cufing Headralsed I passerby bystanders or trac are in he ar ea ie reduce poss bility ofinjury ar death fram Objects Frown by Bladesunder Guardar cutter structure Before amount secure mplementin ranspert postion order bo ground Put r char in park of sel Me brake dere PTO dap engine and remove key ard wil und pase of rotalion Has case le prevent erlangemer in mist ng parts wrichean causes jury r death Hever mount ar desmeunt a moving venice Cru shin gp iran runcver man cause injuryor death 5 TRANSPORT SAFELY 6 USE SMV LIGHTS amp T DO HOT OPERATE DO HOT MOUNT OR REFLECTORS WITH GUTTER OR DISMOUNT WHILE WING RAISED hy 3 D 1 as LE F i Es EL i NE Fr Va 00749117 WARRANTY INFORMATION Read and understand the complete Warranty Statement found in this Manual Filloutthe Warranty Registration Form in full and return it to within 30 Days Make certain the Serial Number of the Machine is recorded on the Warranty Card and on the Warranty Form that you retain INDEX ABOUT THIS MANUAL The intent of this publications to provide the competent technician with the information necessary to perform the CORRECT repairs to the Ala
160. neen Tractor PTO Controls Controled By Tractor Operator Reat Mower to Tractor Connection CAT lor CAT II Three Point Hitch Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 3 SPECIFICATIONS INTERSTATER 4 TRACTOR REQUIREMENTS The tractor used to operate the mower must have the power capacity and required equipment to safely operate the mower at a ground speed between 2 and 5 MPH Operating the mower with a tractor that does not meet the following requirements may cause tractor or mower damage and could be a potential danger to the operator and passersby Tractor Requirements and Capabilities gt ASAE approved Roll Over Protective Structure ROPS or ROPS cab and seat belt gt Tractor Safety Devices Slow Moving Vehicle SMV emblem lighting PTO master shield gt Tractor Horsepower Minimum neen Rear INT 88 60hp Rear INT 96 60 hp DANN 14 length measured from end of PTO shaft to hitch pin hole rated to carry mower tongue weight safety chain attachment point 6100 e een nn teen E 4 Spool Valve amp 2 Spool Valve with Detent Position Fou End Vri As needed to maintain 20 weight on tractor front axle PYTTEN 540 RPM 5 ROPS and Seatbelt A Roll Over Protective Structure ROPS and seat belt are essential to protect the operator from falling off the tractor especially during a roll over where the driver could be crushed and killed The ROPS and seat belt mu
161. ngle 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 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 torgues 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 18 TORQUE VALUES BOLTS Maximum Torque per Bolt Size and Grade Ft Ibs amp Nm IMPORTANT Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE Component Application Torque will vary dependimg on what is bolted down and the type material Metal that is being bolted together Thread condition and lubrication will vary Torque settings 330 480 447 651 Inche Sizes Metric Sizes ALWAYS CHECK MARKINGS Not Used 10 14 ON Not Used 20 27 TOP Not Used 35 47 OF 35 47 55 75 55 75 85 115 BOLT 75 102 130 176 HEAD 105 142 170 230 OR 185 251 300 407 160 217 445 603 OTHER 250 350 670 908 1030 1396 BOLT 651 910 1234 1460 1979 DESCRIP 1250 1695 2060 2793 TIONS Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 9 SPECIFICATIONS INTERSTATER How To Compute Torque When Using An Adapter LOAD MUST BE APPLIED AT CENTER OF KNURLED GRI
162. ngs and Ohm Meter Electrical Test Light Wrenches Torque Wrench Socket Wrenches Open and Boxed End Wrenches m Interstater Service Manual 03 06 2006 Alamo Industrial Section 1 4 Section 2 Interstater SERVICE MANUAL Trouble Shooting Information This section list possible failures causes and solutions All possible failures cannot be listed only some of the most common problems Interstater Service Manual 03 06 2006 Alamo Industrial Section 2 1 Possible Failure Cause Solution MOWER FUNCTION TROUBLE SHOOTING 1 Possible Failure Mower will note rotate Cause 1 A Inline fuse on Wire harness failed Solution 1 A Replace fuse as required Cause 1 B Magnetic Safety Switch not making contact Solution 1 B Adjust or replace switch as required Cause 1 C Broken or worn drive belts Solution 1 C Replace drive belts as needed Cause 1 D ON OFF Switch defective or broken Solution 1 D Inspect test switch and replace as required Cause 1 E Insufficient Voltage through solenoid Solution 1 E Check solenoid coil and wiring replace repair as needed Cause 1 F Solenoid Spool will not shift completely Solution 1 F Clean or replace solenoid cartridge 2 Possible Failure Mower will not stop Cause 2 A Solenoid Spool will not shift Solution
163. nnecters Shipped Loose in Separate Plastic Bag fo 9 16 Black 16 Red to Switched Power GS x Supply 16 Yellow G On Solenoid Connector gt 12 Brown Line at Cutter Valve P Connector to Starter Solenoid Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 10 Pump amp Motor Hyd Schematic RH Wing Only Motor Return Hose Vent Plug B Cooling Tube Cyl Control Valve Cyl Valve Val Return Line Oyl Valve Pressure Line Aux Pump Cooling Tube Motor a Return Hose Suction Line Tank Return Filter Hydraulic Figure 24A Tank Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 11 Pump amp Motor Hyd Schematic Dual Wing LH Wing RH Wing Tilt Cyl Tilt Cyl RH Motor Case Drain Cyl Valve Pressure Line LH Motor Case Drain Hel LH Motor Pres Cyl Valve Return Line LH Motor Pres sure Line gt amp sure Line Cooling Tube Cooling Tube Motor Return Hose amp Deck Cooling Tanks Cyl Valve Pressure Line Aux Cyl Pump Tank Return Filter amp Return Pressure Gauge Aux Cyl Pump Suction Line Pump Case Tandem Pump Drain Lines Suction Lines Hydraulic Tank Figure 24B Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 12 Pump amp Motor Hyd Schematic RH Wing Pressure Hose From Pu
164. nst thrust bearing Install second snap ring item 12 onto driveshaft until seated in snap ring groove of driveshaft and seated against thrust race Replace Needle Bearing item 16 into Pump Housing item 4 Install needle bearing asy into the pump housing If necessary install driveshaft item 3 into pump housing item 4 and install Washer item 10 Coat the I D of Shaft Seal item 6 and press it into the pump housing item 4 Install the outer snap ring item 11 into pump housing until it is seated into snap ring groove of housing Install Pin Keeper item 1E and Pins item 1F into spline area of piston block item 1D Compress Pin Keeper and install it in the splined area of the piston block Install the three pins in the special grooves of the spline area of the piston block with the head end of pin toward inside of block Install Washers item 1G amp 1J and Spring item 1H into Piston Block item 1D install Washer item 1G or 1J are the same into the piston block Install Spring item 1H into piston block and against washer item 1G Install second washer item 1J into piston block and against spring CAUTION I See Step 6 for spring compression instructions Compress Spring item 1H and install retaining snap ring item 1K CAUTION The following procedure should be used if the spring has been removed from the piston block The spring item 1H will have to be compressed The following parts will be needed to assemble the piston
165. nternal snap ring item 1K make certain it is seated into snap ring groove in piston block Unscrew bolt nut and two washers this will release pressure on spring item 1H allowing it to seat against snap ring item 1K Never Remove snap ring in piston block with out compressing spring first 7 Install Pivot item 1C Spider item 1B and piston assembly item 1A Sit pivot item 1C down onto piston block with taper rounded side up See Figure 17 Sit spider item 1B down over pivot noting concave hole in center of spider will sit over rounded edge of pivot align holes in the spider with holes in piston block Lower Piston assemblies item 1A through spider holes and into piston block piston assembly can be installed one at a time 8 Install Cam Plate Insert item 7 Lubricate cam plate insert item 7 well and install it into pump housing item 4 until it is seated down into housing This is best done with pump housing lying on its side on work bench 9 Install Piston Block Assembly item 1 The piston block assembly all assembled needs to be coated with oil Slide piston block assembly into end of pump housing aligning ID of it over driveshaft Push piston block assembly into housing and over driveshaft until piston shoes are in contact with cam plate insert it may require driveshaft to be turned as piston block assembly is being slid in to align splines of shaft with spline of the components of piston block assembly DO NOT use excessi
166. o ensure a secure attachment Do not let the Blades turn when the Mower Deck is raised for any reason including clearance or for turning Raising the Mower deck exposes the Cutting Blades which creates a potentially serious hazard and could cause serious injury or even death from objects thrown from the Blades srm 7 WARNING WARNING When attaching the Implement input driveline to the Tractor PTO it is important that the connecting yoke spring activated locking collar slides freely and the locking balls are seated securely in the groove on the Tractor PTO shaft A driveline not attached correctly to the Tractor PTO shaft could come loose and result in personal injury and damage to the Implement sser 17 Interstater Service Manual 03 06 2006 Alamo Industrial Section 3 7 SPECIFICATIONS INTERSTATER 16 DRIVELINE LENGTH CHECK WARNING EEE ET SEERE ee eee OTTE Before operating the Mower check to make sure the Implement input driveline will not bottom out or become disengaged Bottoming out occurswhenthe inner shaft penetrates the outer housing until the assembly becomes solid it can shorten no more Bottoming out can cause serious damage to the Tractor PTO by pushing the PTO into the Tractor and through the support bearings or downward onto the PTO shaft breaking it off A broken drive line can cause personal injury s3Pr 18 When fitting the mower to the tractor the telescoping driveline must be inspect
167. o make certain they are seated correctly DO not attempt to continue assembly if gears are not even in height Pump Mounting Flange Anti Extrusion Block Gasket Insert Bridging Insert Pump Body Pump Cover Seal Assembly Wear Plate Bronze Side Toward Gears tractor facing Figure 29 Pressure Side of Pump RH Side when forward sitting on tractor facing forward Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 30 Auxiliary Pump Re Assembly amp Re Install H Install Gasket Insert and Bridging Insert The Pump Cover will have the Bridging insert and the gasket insert installed into it See Figure 29 Coat the bridging insert with a coat of vaseline Insert the bridging insert as shown in figure 29 with the lip toward cover and the square edge toward the center Coat the gasket insert with vaseline and install it into the pump cover making certain that it seats against the bridging insert l Install O Ring into Pump Cover Coat O Ring with vaseline which will hold the O Ring in the pump cover for asy Insert it in grooved space around hole in pump cover apposite where bridging insert installs See Figure 29 J Install the Pump Cover to Pump Body Install pump cover over the gear set make certain that the o ring gasket insert and bridging insert don t slip out The pump cover should slid down over the gear set until the pump body and the pump cover are touching If the pump cover and pum
168. o the Parts Listing section 1 Disconnect hoses at cylinder Cap all hoses to prevent fluid contamination Remove cylinder from unit 2 Remove reducer bushing and snap ring which retains the rod guide Remove rod guide rod and piston Remove guide and piston from rod 3 Replace all O rings back up washers and rod wiper Inspect rod guide piston and body for damage 4 Clean inside of cylinder with mineral spirits DO NOT wipe dry air dry instead Lint dirt and grit can cause immediate or premature failure 9 Lubricate all parts with clean hydraulic oil and reassemble 1 Lift Cyl FIGURE 56 2 Tilt Cyl SECTIONAL CONTROL VALVE The control valve directs oil flow from the gear pump to the hydraulic cylinders Inthe HOLD position the spoolblocks oil flow to the cylinders which prevents movement and directs oil through the valve back to the reservoir When the spool is shifted oil flows to one side of the cylinder while the other side is opened to the return line The cylinder rod then moves in or out and changes the cutter unit s position Inthe FLOAT position the spool will open both sides of the cylinder to the return line The cylinder rod is then free to move since oil can enter or leave either side of the cylinder There are two valve sections for each side of the tractor One is for TILT one is for LIFT The sections are bolted together between an inlet and an outlet section The LIFT section has three positions
169. ockets Qty 3 7 16 9 16 3 4 Drive Size should match Torque Wrench Drive 11 Light Petroleum Jelly Vaseline 12 Locktite 222 and 277 or equivalent Qty 1 tube each RECOMMENDED GAUGES FOR DIAGNOSTICS 1 Inlet Vacuum 30 PSI to 30 in Mercury 207 bar to 0 bar 2 System Pressure Gauge 6 000 PSI 700 bar 3 Charge Pressure Gauge 0 to 500 PSI 0 to 25 bar NO O1 pw Interstater Service Manual 03 06 2006 Alamo Industrial Section 1 3 INTRODUCTION TO REPAIRS PUMP TYPES USED There are different configurations of pump used depending on how mower unit was ordered and how it is being used on the tractor All Below will used the same hydraulic tank which means not all ports on hydraulic tank will be used some will remained plugged The connections on the tank will remain the same for the connections needed leave all ports plugged until ready to connect the fittings 1 Tandem Pump with Auxiliary Hydraulic Pump The Tandem Pump is used for the dual wing model mower and the auxiliary pump is used to supply the hydraulic cylinders and cylinder control valve See Figure 1 2 Tandem Pump without Auxiliary Hydraulic Pump The Tandem Pump is used for the dual wing model mower and the tractors hydraulics are used to supply the hydraulic cylinders and cylinder control valve See Figure 2 3 Single Pump with Auxiliary Hydraulic Pump The Single Pump is used for the Single wing model mower and the auxiliary
170. onnected direct to the valve within the operators reach Figure 58 Shows Cab Tractor with the valve mounted in a remote location out side the tractor cab The valve is operated by remote cables mounted to remote handle assemblies which FIGURE 58 are mounted in cab TANK FILLING INSTRUCTIONS USE Tractor Hydraulic Oil only A double wing Interstater with 74 wing mowers will require approximately 26 gallons of oil to fill the hydraulic tank hoses cylinders and cooling tubes in the mower deck An Interstater with 60 wings will require less oil and with 88 wings will require more oil The Hydraulic tank only holds 15 gallons of oil and you can not add enough oil to the tank the first time to completely fill the system Therefore the following filling instructions must be carefully followed to prevent pump cavitation and instant pump failure 1 After the Interstater mower is completely assembled to the tractor and with the wings on the ground fill the mower hydraulic tank above the oil level sight gauge approximately 5 or 1 below the top of the tank Use Tractor Hydraulic Oil only 2 Start the tractor and run it for 30 to 45 seconds and then turn it off 3 Check the oil level in the sight gauge If no oil is seen add oil to bring the level up to the sight gauge NOTE Do not fill the tank with oil above the level of the sight gauge after the first filling Overfilling the tank with oil after the initial filling may result in oil b
171. ont Frame Mounting Bracket Mounting Bracket Figure 5 Figure 6 Interstater Service Manual 03 06 O 2006 Alamo Industrial Section 9 3 Install Main Frame RH Only amp Dual Wing 9 Check the Lift and Tilt Cylinders check to make certain that when the Lift cylinder and the Tilt Cylinder were installed the grease fittings and the locking collars are pointed in the right direction See Figure 14 amp 15 When installing these they must be installed with the rod end clevis grease fitting facing up and out See Figure 11 12 amp 13 Do not remove any shipping plugs from cylinders or hoses until you DV i are ready to install the hoses this will keep the he JAN system and components clean while unit is being Figure 7 i RH Lift Cylinde assembled _ Support Weldment _ Support Weldment Pre LP Fins RH Lift Frame Figure 9 RH Lift Frame Frame Hinge Pins CylinderLocking Collars 4 F ri k i JE Tallaler i Mn Figure 10 Retaining A Figure 11 LEE Interstater Service Manual 03 06 O 2006 Alamo Industrial Section 9 4 Install Main Frame RH Only amp Dual Wing Cyl Clevis amp Hose ports must point in the correct direction Install with Hyd fittings 1 Grease to rear fi Fittings I must face Wing Fold Remove Steps if nc already removec EN h Interstater Service Manual 03 06 2006 Alamo
172. ool P N 701627 10 Using a jack to align parts install inboard bearing and FIGURE 53 housing assembly to cutter unit Grease bearing and install cap over fitting 11 Reinstall key and pulley Secure with cuttershaft fasteners 12 Removejack and check shaft rotation Reinstall knives which were removed 13 Reinstall drive belts then secure motor mounting bracket to cutter housing 14 Reinstall idler arm spring 15 Reinstall belt guard 16 Remove supports lower unit to ground and test unit Reinstall outboard fender if not already installed Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 21 Mower Repairs Wing Mower Decks CUTTERSHAFT REPLACEMENT L 3 NOTE It is recommended that cuttershaft bearing and housing assemblies be replaced when replacing cutter shaft Use caution when changing cutter shaft it is heavy and the cutting blades on it can be sharp It is recommended that blades be removed for dis assembly and re assembly Place Mower Units resting on the ground or securely support at a convenient height Remove cuttershaft bearing and housing assemblies as outlined in Paragraph Cutter shaft Bearing repair replace section on previous pages After removing both inboard and outboard bearing assemblies the cuttershaft can be removed and a new one installed It may be necessary to remove two sets of knives nearest the drive end of cutter shaft to allow cuttershaft to slide inward far en
173. operly speed and pressure can then be increased to normal operating settings Increase Pressure in 500 Lbs PSI increments from start this should take 4 to 5 minutes to max PSI allowing 1 minute between increases to check Oil Pressure and Temperature 6 lfnormal Pressure and Heat readings are seen then the New or Rebuilt Pump installation is ok and it is ok to run unit remove Flow Meter Pressure Gauge from line reconnect Line and check all connections for leaks Check oil level and refill if needed Unit is ready for service Replacement of Return Filter Pressure Gauge 1 Return Filter Pressure Gauge The Return filter pressure gauge See Figure 8 amp 9 is a Glcerin filled gauge which give it a smother movement The gauge is color coded Green 0 psi to 15 psi Red 16 psi to 60 psi The return pressure when oil is warm and at operating temperature shoild not move out of the green area It is not unusual for pressure to be high when oil is cold If pressure is inthe read at operating temperature 100 deg F above ambient temperature check the return filter it may need changing Red Area Vent Cut Off Top Replace Filter 16 psi to 60 psi Green Area Good 0 psi to 15 psi P N 02962963 Fiaure 8 Return Pressure Gauge 9 Glycerin Filled Figure 9 Interstater Service Manual 03 06 2006 Alamo Industrial Section 6 4 Hyd Tank Filter Change amp Repairs REMOVE OLD HYD SYSTEM FILTER 1 Hyd Return Fi
174. ose is connected to the deck wet cooling tubes See Figure 21 22 23 24 25 26 amp 27 Looking at al Figure 19 these figure before going on to next step is impor tant Return hose 3 Install Pump Cover The front pump cover will bolt to the tank this cover will cover pumps and all hoses and or fittings connected to the pump See Figure 20 Set the cover down over the pumps Align the hove in cover with the tabs welded to the tank See Figure 20 4 Install Rear Mower Go onto the Install rear mower section which will also include the Initial Start up procedures DO NOT START Tractor until you have completed the initial start up sec tion Figure 20 E Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 7 Wing Cut Off Switch Schematic Dual Wing Left i Switch Figure 21 Left Wing Motor Cavity Solenoid Valve Plug Fuse Red White Se Yellow 3 Terminal Connector i NH White Yellow Left Wing Safety Cut off Switch Left Wing Motor Solenoid Valve Black Interstater Service Man 03 06 2006 Alamo Group Inc White Black White Section 11 8 Right Switch DOUBLE WING MOWER SHOWN Single Wings have only the Right Wing Motor Solenoid Valve harness wm 3 Terminal Connector Right Wing Motor Solenoid Valve 4 Yellow ch Right Switch cal Switch Brown Brown era Terminal Brown Starter Solenoid
175. ot parallel vibration will be evident This is because of the mechanics of a universal drive wherein the rotational speed through a universal joint is not uniform If the ends of a universal drive shaft are parallel the uneven rotation effect is cancelled out and the machine being driven will be driven at a uniform rate of speed However if the ends are not parallel the uneven rotation effect may be multiplied resulting in a speeding up and slowing down of the entire mower system gear box extension shaft pulleys belt and cutter shaft each revolution This effect can be readily noticed if the mower while running Is raised to an extreme height on the tractor lift For smoothest operation the tilt of the mower should be adjusted on a 3 point hitch by adjusting the length of the top link between the tractor and the mower so that the ends of the drive shaft are parallel when the mower is down in operating position Raising the mower while running to extreme heights on the lift should be avoided To check where the vibration is originating first be sure the ends of the universal drive shaft are parallel Then if vibration is still present remove the drive belt and run the mower If vibration is still present it most likely is coming from and caused by a bent drive shaft If so the shaft should be replaced or straightened If the vibration is gone the drive portion of the mower is running smoothly then the vibration is probably coming from
176. ough for other end to drop down Install new bearing and housing assemblies as outlined in inboard and outboard bearing repair on previous pages REPLACING CUTTER BLADES KNIVES The cutter knives are attached to the cutter shaft in three different ways depending on the cuttershaft application there is fine cut and course cut These cuttershafts use different types of blades and different type blade hangers Toremove existing knives remove and replace hanger components See Figure 54 Type A is used on fine cut cuttershaft and is the standard fine cut knife It is retained with a hardened pin and hardened cotter pin These pin must be installed with the head and cotter pins a certain way see below for installing pin depending on cutter shaft rotation Type B is used on fine cut cutter shaft and is a Ring amp Clip mounted knife This Knife is retained with a bolt and nut This bolt and nut must be torqued to 20 ft Ibs Type C is used on the course cut cutter shaft It is the standard course cut knife and retained with a D Ring hardened Pin with a hardened cotter pin This knife must have the pin and cotter pin installed in the right direction See Below FOR FORWARD ROTATION On the right wing and rear unit all knife pins must be installed with their heads facing away form the cuttershaft pulley On the left wing the heads of the knife pins must face the cuttershaft pulley FOR REVERSE ROTATION FIGURE 54 Interstater Se
177. p Pump Mount body has a gap between them there is something wrong do not install bolts or try to force them together as it will cause i bolts to Aux A uxiliary damage Recheck the assembly to see what is preventing An Pumpflange 7 mp them from sliding together See Figure 29 K Bolt pump cover and pump body together There are four Waes GUA bolts and lockwasher used to boltthe pump together These Rate drive bolts screw into the aluminum pump body DO NOT over MIA ZIEN tighten these bolts 21 RE INSTALL AUXILIARY PUMP A Re install Pump Mount plate The pump mount plate will be install with the two retaining bolts through the pump mount flange that was removed during disassembly DO NOT over tighten these bolts they are through the aluminum pump flange and excessive tightening will damage the pump flange and pump See Figure 30 B Install Aux Pump Drive Pulley Install drive pulley on aux pump using the key that was removed Do Not tighten A pulley onto the pump shaft as it will have to slide later to align the pump pulley with the drive shaft coupler pulley C Bolt Pump Mount Plate to Main Pump Mounting Plate The aux pump mount plate installs with two mount bolts and nuts See Figure 31 The hole on the RH Sitting on Tractor Seat has a slotted hole for adjustment of the drive belt Make certain to install a flat washer on the bolt that goes through the slotted hole See Figure 32 D Align
178. p the washer out 12 Remove Driveshaft item 21 from housing item 22 The driveshaft must be pulled out of housing to the front side The driveshaft will have the retaining rings item 30 and thrust race and bearing item 23 still on itwhen itis pulled out of housing 13 Remove Snap Ring item 30 and Thrust Race amp Bearing item 23 from drive shaft Use Snap Ring Pliersto remove the outer snap ring item 30 from the end of the driveshaft Slide the Trust Race amp Bearing item 23 from the driveshaft Remove the second snap ring item 30 from the driveshaft using snap ring pliers Outer Front Pump Component Inspection For item numbers See Figure 12 1 Wash All Parts Wash all parts in suitable clean solvent Use clean filtered compressed air to dry parts after washing DO NOT use compressed air to spin bearing when drying parts DO NOT use rags or towels that will leave lint to dry parts Parts must be kept clean at all times Work area and place parts are kept during repair process must remain clean and dust free 2 Examine Needle Bearings item 31 and 32 Inspectthe needle bearings in the housing item 22 andthe back plate item 20 If the needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing asy 3 Inspectthrust washers and thrust bearings item 23 All surfaces should be free of any signs of wear or fretting Should be no sign of distortion or flaking 4 Inspect Sp
179. p bolted together you are finished with pump rebuild repair See Figure 13 Continued with reinstalling pump onto mower Tractor See Inner Rear Step 14 and 15 of re assemble tandem inner Pump Fill Pump Case with Oil when connecting rebuilt or new pump The pump should be filled half full with oil this can be done by pouring clean oil through the ports of pump When Pump is installed on mower Connect pump pressure hose pump case drain hose and install pump suction elbow fitting into pump Pour oil into the elbow fitting this will put oil into pump so it will not be started dry Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 22 Single Pump Dis Assembly amp Re Assembly Single Pump Single Wing Model Pump ID Reference 2 P 9 9 No is Stamped Here Single Pump P N 00755650 2 77 CID P N 001827 2 28 CID N Single Pump Assembly 11 P N 00755650 2 77 Cu In Disp Tractor P N 001827 2 28 Cu In Disp Engine Items 1 Thru 18 This End N Item Qty Descrition Item Qty Descrition 1 1 Rotating Kit Asy 6 Shaft Seal 1A 1 Piston Asy 1 Cam Plate Insert 1B 1 Spider 8 d O Ring ic 4 Pivot 9 6 Bolt iD 1 Piston Block 10 1 Washer 1E 1 Pin Keeper 11 1 Retaining Ring IF 3 Pin 12 2 Retaining Ring 1G 1 Washer 1H 1 Spring 14 1 Lock Ring 1J 1 Washer 15 1 O Ring 1K 1 Snap Ring 16 1 Bearing Backplate 2 1 Back Up Plate Asy w Brg 17 1 Bearing Housing 3 1 Driveshaft 18 1 Roll Pin 4 1
180. p is to set aside for use at latter date pumps moving components should be coating with something that will withstand the time pump is sitting Petroleum Jelly vaseline which can be purchased local This will work excellent for this as it will stick to the pump components while spare pump is sitting on parts shelf If parts are to be assembled later the parts should be rewashed and cleaned 2 Install Snap Rings item 12 and Thrust Race amp Bearing on Driveshaft Install inner snap ring item 12 onto driveshaft from input end Install one Thrust Race part of item 5 onto driveshaft sliding it down against snap ring Install Thrust Bearing part of item 5 onto driveshaft until itis against Thrust race Install Second Thrust Race part of item 5 onto driveshaft until it is against thrust bearing Install second snap ring item 12 onto driveshaft until seated in snap ring groove of driveshaft and seated against thrust race 3 Replace Needle Bearing item 16 into Pump Housing item 4 Install needle bearing asy into the pump housing If necessary install driveshaft item 3 into pump housing item 4 and install Washer item 10 Coat the I D of Shaft Seal item 6 and press it into the pump housing item 4 Install the outer snap ring item 11 into pump housing until it is seated into snap ring groove of housing 4 Install Pin Keeper item 1E and Pins item 1 F into spline area of piston block item 1D Compress Pin Keeper and install it in
181. place lifting device scissors jack or hydraulic jack under center of cutter housing D Remove hexnuis washers and carriage bolts from bracket at each end of roller Make certain that roller bracket is free to move once the fasteners are removed A stuck roller could drop unexpectedly and cause injury E Uselifting device to reposition cutter housing to desired cutting height Align bracket holes with cutter housing then reinstall hardware F Lower cutter housing to the ground and remove lifting device G Set cutting height according to procedures above for remaining two cutter sections Make sure that all three rollers are set at the same height to ensure a even cut across the entire width of the mower Adjust Roller to Set 4 Mowing Height a a DESIRED CUTTING ADJUSTMENT MOWER END HEIGHT INCHES BRACKET HOLE PLATE HOLE 1 2 1 1 1 2 2 bubuh WPP WP 0 en 15 DRIVELINE ATTACHMENT The driveline yoke and tractor PTO shaft must be dirt free and greased for easy and secure attachment To connect the mower driveline to the tractor PTO output shaft pull the driveline yoke collar back and align the grooves and splines of the yoke with those of the PTO shaft Push the driveline yoke onto the PTO shaft release the locking collar and position the yoke until the locking collar is securely attached to the PTO shaft Push and pull the driveline back and forth several times t
182. proper torque Refer to Torque Chart in specifications section If only the outer pump is being replace or repaired fill system with proper type and amount of oil Run Unit and check for leaks Reinstall Pump Cover and tighten the four thumb screws securely Pump Case Auxiliary Pump Auxiliary Pump SS Auxiliary Pump Drain To Tank EN Suction Port ES Suction Port E gt gt si i Pressure Port amd Leave Capped ale Wing Motor Only Model Pressure Out iu eee Port To RH Ei f ln mn Wing Motor A Ti Es Ba 1 From Tank sjel Pressure Port Suction Port Figure 10 LH Wing Motor Figure 11 From Tank Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 12 Tandem amp Single Pump Remove Replace Replace Outer amp Inner Pump to Mower Tractor See Figure 4 through 16 A Toreplace or rebuild inner pump both inner and outer pumps must be removed from tractor Follow same procedure as for outer pump above plus instruction for inner pump below NOTE Clean spills at once Cap all hoses immediately to prevent contamination of the hydraulic system B Separate the outer pump from the inner This is done by disconnecting hoses to inner pump item 5 7 and 9 Figure 4 amp 5 Remove the tow bolts holding the outer pump the inner pump or they can be left together and unbolted on the work bench Remove the two retaining bolts that mount the pump pumps to the pump mount plat
183. que sequence to make sure Bolts are tight some times Gaskets can give a Torque reading that is OK but is not so always recheck Torque I Verifying the accuracy of Motor Repairs on an authorized test stand is essential J DO NOT start the tractor unless the hydraulic system is filled with hydraulic oil all components have been connected and all safety equipment hase been reinstalled Running without oil will damage the pumps and hydraulic system Check the oil level in the reservoir before start up after repair K Care should be taken when filling the reservoir to prevent contamination of the hydraulic system Always use new hydraulic fluid when filling the system USE ONLY APPROVED HYDRAULIG OIL IN THE HYDRAULIG SYSTEM RECOMMENDED TOOLS A Hex Allen Wrench Qty 5 9 16 5 32 5 16 3 32 5 64 B Retaining Ring Pliers Qty 3 1 each of Internal Straight 070 tip internal Straight 090 tip amp 1 each External Straight 0 90 tip Retaining E Ring Applicator Qty 2 1 each 9 32 amp 1 each 1 2 O Ring Pick Qty 1 End Wrench Qty 4 1 each of 7 16 9 16 3 4 1 Torque Wrench Qty 1 0 to 100 ft lbs 135 6 nm capacity Hammer Soft Face Qty 1 Seal Driver Set Qty 1 Arbor Press Qty 1 Sockets Qty 3 7 16 9 16 3 4 Drive Size should match Torque Wrench Drive Light Petroleum Jelly Vaseline Locktite 222 and 277 or equivalent Qty 1 tube each Petroluim Jelly Vasoline Samll Jar EAS
184. r Pump For item numbers See Figure 12 8 Install Cam Plate Insert item 7 Lubricate the cam plate insert item 7 well and install it into the pump housing item 4 until it is seated down into the housing This is best done with the pump housing lying on its side on the work bench 9 Install Piston Block Assembly item 1 The piston block assembly all assembled needs to be coated with oil Slide the piston block assembly into the end of the pump housing aligning the ID of it over driveshaft Push piston block assembly into housing and over driveshaft until piston shoes are in contact with the cam plate insert it may require the driveshaft to be turned as the piston block assembly is being slid in to align the splines of the shaft with the spline of the components of the piston block assembly DO NOT use excessive force to install piston block assembly if it will not slide together with the force of your hand there is something wrong 10 Install Needle Bearing item 17 into Back Plate Asy item 2 The needle bearings will install into the center opening of the back plate Coat this bearing with oil as you slide it into the back plate Install Bearings into back plate with number end of bearing up and visible Bearing will be slightly higher 09 than back plate 11 Back Plate item 2 amp Sealing O Ring item 8 The back plate is sealed with an O Ring that is inserted into a groove on the back plate item 2 make certain this O Ring is s
185. r The later type used a Snap ring behind seal to hold bearings in where the earlier type had bolt on covers If you have these bolt on covers see G B 700493 These gearboxes DID NOT use vent plugs at all Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 17 Lubrication Points LUBRICATE ALL POINTS BEFORE OPERATING MOWER FIRST TIME Rear Mower Idler Arm Banjo Bearings Banjo Coupling Driveline Yoke Driveline slip Lift Frame Pivot Pin Wing Mower Belt Idler Arm Cuttershaft Bearings Tilt Cylinder Rod Ends Lift Cylinder Rod Ends Roller Bearings TN MOOX gt FAG TO Figure 26 Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 18 Initial Start Up Procedure INITIAL START UP PROCEDURE 1 Check all nuts and hex head bolts to ensure all are tight and all lock washers are fully compressed flattened 2 Check all hoses and hydraulic connections Make certain they are secure 3 Inspect all moving parts and make certain that no wires or hoses will be caught or pinched when the tractor or the INTERSTATER is in operation Tie down loose wires and hoses 4 Thoroughly grease the INTERSTATER and install a lubricap on each grease fitting Refer to the Operation and Maintenance Section 5 Jack front of tractor up enough to allow axle to pivot through its full range While turning wheels through their limits right and left swing them up and down Look for interference between tires
186. r Available 34 NLF No Longer Furnished 35 NPT National Pipe Thread 36 P1 5 Thread Pitch 37 P2 0 Thread Pitch 38 P2 5 Thread Pitch 39 PL Plated 40 PLT Plate 41 PMP Pump 42 PTO Power Take Off 43 PW Plain Washer 44 REV Reverse 45 RH Right Hand 46 ROT Rotation 47 RPM Revolutions Per Minute 48 SCKT Socket 49 SD Severe Duty 50 SRV Service 51 STD Standard 52 SVR Severe 53 W With 54 W O With Out 55 WLDMNT Weldment When installing fasteners PW and LW generally installed in that order are usually on the side of the fixture or part being fastened that the hex lock nut is on When only HHCS LW and or PW are required they are generally installed in that order Some parts do not require a PW or LW Refer to illustrations for exceptions Fasteners should be installed so they cause the least interference with other parts When securing driveshaft pulley to hub tighten fasteners to 9 Ib ft torque Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 2 Wing Mower Decks Wing Cut Off Switch NOTE This section will show Dual Wing installation The LH and RIGHT hand wing will assemble the same except in a mirror image 1 Assemble Brackets amp Magnetic Switches Locate the Magnetic switch mounting bracket dual wings there will be two of these See Figure 1 If Dual wings the two brackets will have the switches mounted on the opposite side See Figure 2 Once these have EN the swi
187. r hinge pin did 6 Install Wing Mower to Lift Frame Using the over head hoist position the Mower Deck See Figure 10 to where the front hinge bracket will align with the lift frame Install at least two of the mounting bolts and snug them down T Install the wire harness to wings The Wire harness will have a lead to each wing These can be determined by the length the longer lead will go to the left wing There is apiece of square tube welded to the lift frame on the back for the wire harness to be run through See Figure 11 The wire harness will be run down and under the round bar of lift frame Leave harness here for now 8 Install Magnetic Switch Pickup amp Bracket as well as the rear hinge bracket The Rear hinge Bracket will install similar to the way the front does but not the same because the Magnetic switches and brackets bolt on with it Before installing the rear Hinge bracket locate the mag netic Switch Bracket See Figure 12 There are two spacers about 3 4 long that must be installed between the magnetic switch bracket and the hinge Bracket See Figure 12 Also the wire harness must be run between these two spacers and between these two brackets See Figure 13 amp 14 Install the remaining two bolts and tighten all the hinge bracket bolts this will include the front hinge bracket bolts See Figure 21 9 Plug Magnetic Switch into Wire Harness The wire harness should have a plug that aligns with
188. rial 1502 E Walnut St Seguin TX 78155 Technical Service Dept PH 830 379 1480 Interstater Service Manual 03 06 2006 Alamo Industrial Index 1 1 INDEX Section Page Index 1 of Index 3 Section 1 Ho TO FR ee ee 1 1 to 1 4 General Repair Replacement Information 1 2 Abbreviation of Parts Terminology 1 2 Before Starting Repairs ss 1 3 Recommended Tools 1 3 Recommended Gauges For Diagnostics 1 3 Pump Types CSS na ne 1 4 Pump DAVE Types USE ee 1 4 Test Equipment Recommended aanrennen ennen 1 4 Section 2 Trouble Shooting Information Possible Failure Cause SOIUUON starende ae 2 1 to 2 5 Mower Function Trouble Shooting 2 2 to 2 3 Motor Circuit Trouble Shooting 2 4 to 2 5 Section 2 General SEAN 3 1 to 3 11 Read This Before Beginning Repairs or Testing 3 2 The Interstater Has Electric Components nennen 3 2 DONE Nr 3 2 Standard Equipment Anad Specifications 3 3 to 3 9 How To Compute Torque When Using An Adapter 3 10 Recommended Start up Procedure For New or Rebuilt Pump 3 11 Test Equipment Needed aaan ennen en nennen venen eenenens 3 11 Section 4 Hydraulic amp Electrical Schemallos aaret 4 1 to 4 18 Hyd Schematic W Aux Pump RH Wing 4 2 Hyd Schematic W Aux Pump Dual Wing 4 3 Hyd Schematic W O Aux Pump RH Wing 4 4 Hyd Schematic W O Aux Pump Dual Wing 4 5 Valve to Cylinder
189. rnes for the magnetic cut off switches Tractor mounted on the wing hinges will be ran through Ignition a piece of square tubing weldedtothe liftframe this is to protect the wires from be hung up on object while mowing 4 Cut Tractor 6 WireHarness Components The wire har f Starter Wire to ness will be received in sections The mainwire harness Single or dual wings and the wing harness a RH harness and a LH harness The RH and LH harness will both be used for a dual wing unit and only the RH harness for a single wing unit Starter Solenoid and reroute through Joystick Harness Brown NOTE Route wires in such a manner to Motor Control prevent interference with the operation oftrac Wirina Har tor or INTERSTATER Ensure that wires DO NOT lay against anything which could wear through insulation and cause a short circuit After connecting all wires wrap wires with flex guard tubing Neatly gather hydraulic hoses and flex guard tubing and strap together using plastic ties Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 8 Wiring Harness Schematic CAB amp ROPS Figure 15 Left 3 Switch Left Wing Motor Solenoid Valve Fuse Red White Yellow 3 Terminal Connector h HE White Yellow Left Wing Safety Cut off Switch Left Wing Motor Solenoid Valve Black Interstater Service Manual 03 06 2006 Alamo Industrial White Black White Sect
190. rop suddenly and cause an injury Continued Next Page Interstater Service Man 03 06 2006 Alamo Group Inc FIGURE 44 Section 11 18 Motor Drive Pulley Idler Pulley Cuttershaft Pulley Uy IN 5 OST der SL HE a Q Adjusting Spring FIGURE 46 Mower Repairs Wing Mower Decks ADJUSTING CUTTING HEIGHT Roller Mounting Height Continued From Previous Page p Adjustng Bracket Fn 4 Use lifting device to reposition cutter housing to desired cutting height Align bracket holes with cutter housing holes then reinstall fasteners Refer to cutting height decal on mower or Safety Section 5 Lower cutter unit to ground then remove lifting device F Roller jack or hoist a 6 When adjusting cutting height on interstater chose the amp Housing desired hole by reading the decal shown in Figure 50 Assembly which should be on the mower decks of the interstater showing the adjusting steps and procedure Er LI B DESIRED CUTTING ADJUSTMENT MOWER END HEIGHT INCHES BRACKET HOLE E HOLE h es 2 1 2 BB gt O A O A O 3 1 2 3 O A A 5 8 A 3 4 he 5 7 FIGURE 49 P N 002023 Cutting Height Adjustment Instruction FIGURE 50 2006 Alamo Group Inc Section 11 19 Interstater Service Man 03 06 Mower Repairs Wing Mower Decks ROLLER BEARING REPLACEMENT see Figure 51 1 Securely support mower
191. rvice Man 03 06 On the right wing and rear unit all knife pins must be installed with their heads facing toward the cuttershaft pulley On the left wing and rear unit the heads of the knife pins must face away from the cuttershaft pulley NOTE Rotation is the direction of the cuttershaft in relationtothe direction oftravelofthemower The blades will TractorDiresiianat Tavel not need to be reversed as they are double sided and designed to cut on either side ur E Cutter Shaft N Rotation TORQUE TO 20 FT LBS Forward VW Rotation Tractor Direction of Travel 1 f y Cutter Shaft Rotation y Reverse Rotation 2006 Alamo Group Inc Section 11 22 Mower Repairs Wing Mower Decks Changing Mower Cutter Shaft Rotation to Forward or Reverse WING MOWERS The hydraulic wing motors are dual rotation motors which means they will rotate in either direction depending onthe inlet port used An arrow on the flat surface of the motor housing at both ports indicate the direction of rotation To change rotation remove the four bolts that mount the manifold block to the motor Remove the case drain hose at the motor but leave it attached in present location at the manifold block Leave all other plumbing as presently installed at the manifold block Remove the two mounting bolts at the motor mounting plate and rotate the motor 180 deg This changes the present inlet port into the outlet port of the motor Re install manifold
192. s bottomed out in Cover Install Rear Cover using Gasket Sealer onto Main Housing and Tighten Bolts Some rear covers may use a Gasket some sealed with Sealer If Gasket wanted Gasket 00769800 will fit and can be used for rear cover T Set Bearing Pre load on Input Shaft to remove end Play Only this is because outer Bearing is a Ball Bearing Do this by adding or removing Shims between Front input Bearing and Snap Ring 8 Set Gear Back Lash with Shims on output shaft next to output Pinion Gear Add or remove shims Gear Back Lash should be from 016 to 019 This is very critical After Gear Back Lash is correct reset Bearing Pre Load on Output shaft 9 Install Input Seal 0017240 and Output Seal 001719 Inspect all opening for seals to make sure there are no Burrs or Scratches to damage seals when installed Always coat ID of Seals with light coat of grease this helps to prevent damage to ID of seals when being installed 10 Fill Gearbox with Oil till Oil flows out of Oil Level hole Install Oil Level plug and Oil Fill Plug Check all Seals and Gasket areas for leaks After Running Mower for 1 2 to 1 hour recheck Oil Level Looking for any leaks HELP I This Later Gearbox 702673 will only have a large 8 bolt cover on rear of gearbox without the small cover in center of it There is a Ball bearing on front of input shaft the old style had all Roller Bearings Input Seals are different Older Gearbox seal is a bit larger than the late
193. s thoroughly Disconnect all connections Lines Hoses Wiring and Remove the Pump Completely from the Tractor C Cleanall 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 before disassembly D After disassembly of Pump wash all metal components in clean solvent E Usecompressed 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 F Always use new Seals when reassembling Hydraulic Pumps Lubricate the new rubber Seals with a Petroleum Jelly Vaseline which will hold them in place during assembly G DO NOT reinstall worn damaged Parts in Pump DO NOT Use a worn damaged Pump Housing H 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 recheck Torque Verifying the accuracy of Pump Repairs on an authorized test stand is essential J DONOT start the tractor unless the hydraulic system is filled with hydraulic oil all components have been connected and all safety equipment hase been reinstalled Running without oil will damage the pumps and hydrauli
194. sembly ltem Qty Descrition 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 Figure 11 Interstater Service Manual 03 06 2006 Alamo Industrial Item Qty Descrition Rotating Kit Asy items 1A thru 1K 4 1 Piston Asy 5 1 Spider 6 1 Pivot 7 1 Piston Block 8 1 Pin Keeper 9 1 Pin 10 1 Washer 11 1 Spring 12 1 Washer 13 1 Snap Ring 14 1 High Pressure Seal Kit items 2A thru 2C 15 4 O Ring 16 2 High Pressure Seal 4 Seal Adapter 47 Washer 18 4 Section 10 8 Snap Ring Thrust Race amp Bearing Snap Ring Motor Shaft Keyed Key Needle Bearing f Housing Snap reing Housing Not Furnished As Parts O Ring Needle Bearing f Backplate Roll Pin Backplate Asy w Bearing Bolt Short Bolt Bolt Long Bolt Cam Plate Insert Seal kit in Seal Kit Motor Dis Assembly amp Re Assembl Dis Assemble Motor For item numbers See Figure 11 1 Motor Dis Assembly w o Manifold Manifold should already beremoved before starting to dis assemble motor See Previ Motor Assembly ous section for instruction to remove amp replace motor manifold block 2 Clamp Single Motor in Vice with Jaw Protectors Motor can be clamped in vice with protective covers for vise jaws See Figure 12 or it can be dis assembled while on work bench 3 Remove Back Plate Item 15 The backplate is mounted with 6 hex head bolts item 16 4 of these bolts will already be removed as they mounted the manifold block Itis import
195. something wrong DO NOT use excessive force or use the bolts to pull back plate down 13 Install 2 Retaining Bolts item 16 into motor housing item 11 to fasten back plate item 15 Inspect the bolts make certain allthreads are good condition The bolts need to be installed in same holes they were removed from tighten these 2 bolts from one side to the other until snug These bolts must be TORQUED to 15 to 18 ft Ibs Do this in increment and staggered pattern also 14 Re install Motor Manifold Now The motor manifold installation is shown in previous pages under pump manifold section When installing motor manifold always install the two O ring between manifold and motor with new O rings Use petroleum Jelly to hold O rings in position during mounting of manifold to motor 4 39 173 15 Fill Motor Case with Oil when connecting rebuilt or new y Roll Pin 26 Bearing A ve 4 Motor The pump should be filled half full with oil this can be done by pouring clean oilthrough the pressure port of motor manifold When motoris installed on mower Connect motor high pressure hose motor case drain hose to motor manifold and install motor return hose Roll Pin amp Bearing Installation Figure 13 Interstater Service Manual 03 06 O 2006 Alamo Industrial Section 10 11 Interstater Service Manual 03 06 2006 Alamo Industrial Section 10 12 Section 11 INTERSTATER Wing Mower Remove Repair Replace The R
196. ssembly Manual and or the assembly instruction that were shipped with unit Unbolt Outer Pump from Inner Pump 1 Cleanthe outside of pump assembly thoroughly if this was not done before it was removed from tractor Make certain all pump openings are sealed during cleaning Make certain work area and all tools are clean 2 Clamp Pump in Vice with Jaw Protectors with the outer front pump pointing upward See Figure 13 Remove the two conn ecting bolts connecting outer pump to inner pump See Figure 14 It may require a small amount of force to free outer pump from inner pump if needed use a soft faced hammer to tap sides of outer pump This will break outer pump loose from inner pump do not hit pump with excessive force it will dam age pump housing and pump With inner amp outer pump sep arated set outer pump aside for now See Figure 14 Dis Assemble Inner Rear Pump For item numbers See Figure 12 1 Clamp inner Pump in Vice with Jaw Protectors See Figure 14 Inner pump can be left clamped in vice for dis assembly 2 Remove Inner Pump to Outer Pump Coupler Pump Shaft cou pler item 13 may have stayed on outer pump input shaft or it may have stayed in backplate item 2 of inner pump Check for coupler and remove it 3 Remove O Ring Seal item 15 it seals between the outer and inner pump it will be on back plate and should be removed now 4 Remove Lock Ring item 14 Remove lock Ring from backplate 5 R
197. st be used in conjunction with one another Only operate the tractor with the ROPS in the raised position and seat belt fastened Tractor models not equipped with a ROPS and seat belt should have these life saving features installed by an authorized dealer SIR Operate this Equipment only with a Tractor equipped with an approved roll over ou protective system ROPS Always wear seat belts Serious injury or even death could result from falling off the Tractor particularly during a turnover when the operator could be pinned under the ROPS sc 7 6 TRACTOR SAFETY DEVICES If transporting or operating the tractor and mower near a public roadway the tractor must be equipped with proper warning lighting and a Slow Moving Vehicle SMV emblem which are clearly visible from the rear of the unit Lights and a SMV emblem must be equipped directly on implements if the visibility of the tractor warning signals are obscured Maintain all manufacturer equipped safety shields and guards Always replace shields and guards that were removed for access to connect service or repair the tractor or mower Never operate the tractor PTO with the PTO master shield missing or in the raised position 7 TRACTOR HORSEPOWER REQUIREMENTS The horsepower required to operate the mower depends on many factors including the vegetation to be cut terrain condition operator experience and condition of the mower and tractor For most mowing condition
198. system must be kept SURGICALLY CLEAN to ensure proper operation and long life of the pumps motors and valves All components must have protective caps over openings connected to internal spaces to prevent contamination Itis important that care be taken during unpacking parts and assemblies to make certain no other contaminants which will damage parts are introduced to hydraulic system B After cleaning around all connections thoroughly Disconnect all connections Lines Hoses Wiring and Remove the Motor Completely from the mower head C Cleanall Tools Pans etc The cleaning of Area and Tools MUST be done before moving Cleaned motor there Drain Oil from motor Recheck outside of motor to Make Sure it is Clean before dis assembly D After dis assembly of motor wash all metal components in clean solvent E Usecompressed 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 F Always use new Seals when reassembling Hydraulic Motors Lubricate the new rubber Seals with a Petroleum Jelly Vaseline which will hold them in place during assembly G DONOT reinstall worn damaged Parts in Motor DO NOT Use a worn damaged motor housing H Torque all Bolts over Gasketed Joints Then repeat the Tor
199. t Plugged Control Solenoid Port block using filtered compressed air to remove all solvent This cleaning is critical to make certain the passage ways and ports are cleaned 8 Holding Manifold for Re assembly If mani fold is clamped in a vise extreme caution must be Manifold Mounting taken to not damage aluminum manifold block with O Rings aty 2 vise Itis recommended that the manifold be bolted to the motor after it has been bolted to the deck or while motor is still clamped in vise See Figure 9 9 Re assembly of Manifold With manifold secure re install components to the manifold See Figure 7 8 amp 9 Bench Vice A Pressure Relief This is preset at 4000 psi and is not adjustable B Oil High Pressure Port Fitting This is a hose fitting that will screw directly into the manifold block for inlet pressure high pres Wing Motor Assembly sure supply to motor C Control Solenoid assembly The solenoid will consist multiple components that may D Machine Access Port Plug This port has no function other than it was required during the manufacturing process and should always remain plugged E OilRe turn Port Fitting This is a hose fitting that will screw directly into the manifold block and is for oil leaving the motor This is a low pressure line F Motor Case Drain Port Fitting This is a hose fitting that will screw directly into the manifold block and is for case drain of the motor This is a low pressure line G Hi
200. t Notes 1 Make certain driveshaft is seated into the splined pulley adapter 2 Coat driveshaft with anti seize compound where it goes through the carrier bearing 3 Make certain to install drive pulley splined coupler weldment w drive belt on models w auxiliary pump or splined coupler on the end of driveshaft Do these before installing pump 4 Itis recommended that the Main pump shaft and the Auxiliary pump shaft be coated with anti seize compound before installation See Figure 12 Coat pump shafts with Anti Sieze Compound Interstater Service Manual 03 06 2006 Alamo Industrial Section 7 4 Section 8 interstater SERVICE MANUAL Cable Control Valve Connections NOTE Shown here is a typical illustration of the way that the control valve remote cables cable handles and the electrical harness is connected This is common but may not be shown on the type tractor you have This tractor model is used for illustration only and should match your applica tion in function and design Some mounting components brackets and they way they connect to the tractor may vary Consult the instructions and or assembly manual for the tractor model the unit is mounted on Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 1 Joystick Valve amp Control Cables Cab Control Valve amp Hose Installation NOTE This section only Applies if using the Auxillary Pump for cylindercontrol i
201. t motor key into motor shaft Slide the drive pulley onto motor shaft Inserttaper lock pulley hub onto motor shaft and into drive pulley The pulley on motor will require alignment with the idler and cutter shaft pulley This may require moving and tightening pulley more than once Align motor pulley with other two pulleys as close as possible The taper lock mounting bolts will pull the pulley into the lock hub and sometimes may mis align the pulley if this happens loosen taper lock hub and reposition it and try again When pulley is aligned and taper lock hub tighten the three pulleys should be aligned Check alignment with a straight edge sighting across the three pulleys 11 Install Drive Belts Drive belts should be a matched set of belts Check to make certain belts are in serviceable condition The drivebelts install over the top drive pulley and then idler pulley this will leave the belts hanging Using a bar to pry the idler pulley back slip the belts over the cutter shaft pulley Release pressure on the idler pulley Belt tension is self adjusting through the idler pulley spring See Figure 4 12 Reinstall Belt Cover Installthe belt cover back onto the end of the mower deck and reinstall the retaining bolts Do not operate any mower with shields or guard damaged or missing See Figure 1 through 4 13 Motor Control Manifold The motor con trol manifold bolts to the top of the motor If manifold was removed it will need to be installed
202. t n Shaft Asy Rear Mower unne nennen 12 13 Gearbox Asy P N 700498 82 penses 12 14 Gearbox P N 700493 Asy Instructions 12 15 Gearbox Asy P N 702673 tie 12 16 Gearbox P N 702673 Asy Instructions 12 17 EDEN PA 12 18 Initial Start Up Procedure 12 19to 12 20 section 13 Delivery Inspection Sheet ss 13 1 to 13 4 Interstater Delivery Inspection Checklist nnn 13 2 TO 13 4 Interstater Service Manual 03 06 2006 Alamo Industrial Index 1 4 Section 1 Interstater SERVICE MANUAL Introduction To Repairs This section is the Introduction to making repairs on Interstater model Recommended procedures amp tools recommended Interstater Service Manual 03 06 2006 Alamo Industrial Section 1 1 INTRODUCTION TO REPAIRS GENERALREPAIR REPLACEMENT INFORMATION A Todisassemble repair your INTERSTATER this manual is designed to assist you with drawings instructions and information This manual is designed to be used in conjunction with the parts manual operators manual and the assembly manuals If additional information or clarification is needed contact your Alamo Industrial factory representative Some ofthese instructions are general information and not specifically for your tractor but in connection with our drawings they may not show the exact application and tractor you have In many cases to assembly manual for your mower to tractor application will clarify some clarit
203. tal build up Inspect the Cam Plate Insert item 7 The surface should show no signs of scoring or grooves Inspect the flat surface on the Back Plate item 2 The back plate surface should be free of excessive scoring or metal build up Inspect the Drive Shaft item 3 Inspect for fretting in the bearing areas Check spline area for twisted broken or worn splines Check for chips and or cracks in shaft Re Assemble Inner Rear Pump For item numbers See Figure 12 1 Coat Moving Parts for Re Assembly Itis recommended that all moving parts be coated before and during re assembly If pumpis to used immediately after assembly the recommend hydraulic oil for the interstater will work If pump is to set aside for a use at a latter date it is required that pumps moving components by coating with something that will withstand the time pump is sitting STP or Petroleum Jelly which is vaseline purchased from your preferred supplier will work excellent for this as it will stick to the pump components while spare pump is sitting on parts shelf Install Snap Rings item 12 and Thrust Race amp Bearing on Driveshaft Installthe inner snap ring item 12 onto driveshaft from the input end Install one Thrust Race part of item 5 onto driveshaft sliding it down against snap ring Install the Thrust Bearing part of item 5 onto driveshaft until it is against the Thrust race Install Second Thrust Race part of item 5 onto driveshaft until it is agai
204. tches bolted on lay the brackets aside for now Slotted Hole for See Figure 20 Small Screw Hole switch wires 2 Assemble Magnetic Switch Activators This magnetic switch activator has a magnet inside and a cover that must be installed See Figure 4 There are merkt EEE brackets that these bolt to With dual wings there is a LH and RH bracket Bolt the Magnetic activators to the brackets See Figure 5 LH Bracket Shown Note there are two sets of mounting holes In figure 5 the set that have the bolts through them is used to shut wing off at 45 degree up If the other set of holes are used wing mower will shut off at 90 degrees up The 45 degree setting is recommended for standard applica tions Magnetic Switch 3 Install Switch Brackets amp Head Mounting Brack ets Use a hoist to lift the Wing Mower and position it for mounting DO NOT get under Mower while lifted on a hoist See Figure 6 Mower is only be positions so that switch brackets and hinge brackets can be installed to head this must be done before mower can be mounted to lift frame su Magnetic LH Wing Magnetic Switch amp Bracket Stich Magnet CRR E Activator Inside Case Cover ee DD En a y KAT h ul N 7 N 4 1 VV J VVII IC i NEL VELING se SS 2 NET iE wi y VVic en O i NATO QO q I m pr n igure er P a 2 Sn i m gt Interstater S
205. that cuttershaft bearing and housing assemblies be replaced when replacing cutter shaft Use caution when changing cutter shaft it is heavy and the cutting blades on it can be sharp Itis recommended that blades be removed for dis assembly and re assembly 1 Place Mower Units resting on the ground or securely support at a convenient height 2 Remove cuttershaft bearing and housing assemblies as outlined in Paragraph Cutter shaft Bearing repair replace section on previous pages After removing both inboard and outboard bearing assemblies the cuttershaft can be removed and a new one installed It may be necessary to remove two sets of knives nearest the drive end ofcut ter shaft to allow cuttershaft to slide inward far enough for other end to drop down 3 _Installnew bearing and housing assemblies as outlined in inboard and outboard bearing repair on previous pages Non Drive End Bearing Coarse Cut Cutter Shaft Fine Cut Cutter Shaft Drive End Bearing REPLACING CUTTER BLADES KNIVES The cutter knives are attached to the cutter shaft in three different ways depending on the cuttershaft application there is fine cut and course cut These cuttershafts use different types of blades and different type blade hangers To remove existing knives remove and replace hanger components See Figure 23 A Type A is used on fine cut cuttershaft and is the standard fine cut knife It is retained with a hardened pin and hardened cotter pin Th
206. the bare mani Pressure Test Port 12 ee fold in clean solvent and blow dry with filtered compressed air Inspect manifold for any Figure 7 Low Pressure Return Tubeto Tank debris or damage to block replace as needed Oil to Deck Tube Port Manifold Return Oil Port Machining Port to Deck Cooling Tubes Plugged St deu High Pressure rene e aty 4 Relief Valve Port Manifold Inlet Port Manifold Oil Return High Pressure Test from Motor Port Port P Motor ort Plugged Case Drain Wire Harness to Control Solenoid Motor Control Solenoid High Pressure Control Solenoid Port High Pressure Control gn Manifold Return Oil Port tg to Deck Cooling Tubes ort Control achini ng Manifold Mountin Solenoid High Pressure Port g Figure 8 Manifold Inlet Port Bolt Holes qty 4 Port Plugged Interstater Service Manual 03 06 2006 Alamo Industrial Section 10 6 Motor Manifold Re Move Repair amp Re Place 6 Motor Dis assembly and or Repair If the motor is to be dis assembled go on motor repair Relief Valve 4000 psi section and return to here when it is time to reinstall Motor Manifold manifold block assembly Pressure Test Port 7 Installing New Manifold Block Always wash Motor Case Drain Port a new manifold block with clean solvent the same as Mounting Bolt qty 4 when re installing an existing one Dry the manifold mif F Oil Return Port lt Q Machining Access Por
207. the cutter shaft it could be a pulley out of balance or a faulty belt with a varying cross section but this is not likely The cutter shaft will run out of balance if 1 Wire rope string rags etc around the cutter shaft are holding the knives in a folded back position Remove such foreign objects and be sure all knives are free to swing to the extended position 2 a Knives are missing or broken Replace missing or broken knives b Knife hanger lugs are broken off shaft This condition usually results from continued operation in contact with large hard objects where the knife hanger lugs themselves are hitting the hard objects Lugs should be replaced using arc welding equipment so as not to direct too much heat in one area of the shaft 3 Cutter shaft ball bearings are worn enough to have radial play in them Replace ball bearing and other worn parts to eliminate play 4 Shaftis bent Shafts are straight within a couple of thousandths of an inch when they are made It is possible that they will become bent in use such as if the shaft is hooked on a stump while the tractor is moving forward at a good speed 5 Shafts are operated at improper speed Rotating shafts have what is known as a natural period of vibration The same is true of the cutter shafts on the Flail Mowers The actual speed at which the harmonic will occur will vary with each mower and each installation To avoid this harmonic vibration when operating the mo
208. the interior seal seat area Remove Seal Washer item 10 which is located behind input seal It may require to lift the housing and dump the washer out Remove Driveshaft item 3 from housing item 4 The driveshaft must be pulled out of housing to the front side The driveshaft will have the retaining rings item 12 and thrust race and bearing item 5 still on it when itis pulled out of housing Remove Snap Ring item 12 and Thrust Race amp Bearing item 5 from drive shaft Use Snap Ring Plierstoremove the outer snap ring item 12 from the end of the driveshaft Slide the Trust Race amp Bearing item 5 from the driveshaft Remove the second snap ring item 12 from the driveshaft using snap ring pliers Single Pump Assembly Pressure Port Bench Vice Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 24 Single Pump Dis Assembly amp Re Assembly Single Pump Component Inspection For item numbers See Figure 17 1 Wash All Parts Wash all parts in suitable clean solvent Use clean filtered compressed air to dry parts after washing DO NOT use compressed air to spin bearing when drying parts DO NOT use rags or towels that will leave lint to dry parts Parts must be kept clean at all times Work area and place parts are kept during repair process must remain clean and dust free 2 Examine Needle Bearings item 16 and 17 Inspect the needle bearings in the housing item 4 and the back plate item 2
209. the magnetic switch wire Plug these to gether now and continued to run wire harness up behind the hinge and on up to the mower decks motor See Figure 21 Interstater Service Man 03 06 2006 Alamo Group Inc LH Wing Shown From Front i i m a wu i al um vi F 5 i LES ky N Eas LH Wing Front Hinge Figure 10 Pin Bracket LH WingsShown From Front Le X Figure 1 Section 11 5 Wing Mower Decks Wing Cut witch continuec 10 Connect Tilt Cylinder to Mower Deck The Tilt Cylinder connects to the mower head See Figure 15 amp 16 Note you will need to remove the belt guard to connect this cylinder so you will have room for the cylinder mounting pin to be installed See Figure 16 When connecting the cylinder the grease fitting on the rod end must face up the locking collar on the cylinder must face up and be tightened on rod end The RH Wing and the LH Wing will mount the same Install the RH wing the same as the LH wing Reinstall Belt Guard 11 Install Wire Harness to Motor Solenoid j LH Wind Shown The thumb nut on top of the solenoid will allow the NA on Rear solenoid to be turnedto different direction if needed A See Figure 17 amp 21 _ Wire Harm ss to own win From Front Motor t 4 gt Clevis rm a ER Rod Collar REET Wire Harness to Magnetic Swithc LH Wing Shown From Rear RH Wing Shown FronfRear Figure 16 ke
210. the tractors remote outlets and the tractor controls will be used See Figure 14 When using the Auxiliary front pump for the cylinder hydraulic system there will be a control valve and compo Make certain lift nents shipped See the section for install control spacer was ing the auxiliary pump and control valve Long Vent 000000006000 0 0 installed on Lift cyl See Figure 12 amp 13 RH Wing RH Wing Tilt Cylinder Lift Cylinder Figure 48 Interstater Service Manual 03 06 2006 Alamo Industrial Section 4 18 Section 5 Interstater SERVICE MANUAL Hydraulic Pumps Tandem Single Auxiliary Remove Repair Replace Tandem amp Single Pump Removal GENERAL PUMP REPAIR REPLAGEMENT INFORMATION A Todisassemble repair your INTERSTATER this manual is designed to assist you with drawings instructions and information This manual is designed to be used in conjunction with the parts manual operators manual and the assembly manuals If additional information or clarification is needed contact your Alamo Industrial factory representative B Some of these instructions are general information and not specifically for your tractor but in connection with our drawings they may not show the exact application and tractor you have In many cases to assembly manual for your mower to tractor application will clarify some clarity to exact applications C This section covers the removal repair and reinstal
211. tion but this is not likely The cutter shaft will run out of balance if 1 Wire rope string rags etc around the cutter shaft are holding the knives in a folded back position Remove such foreign objects and be sure all knives are free to swing to the extended position 2 a Knives are missing or broken Replace missing or broken knives b Knife hanger lugs are broken off shaft This condition usually results from continued operation in contact with large hard objects where the knife hanger lugs themselves are hitting the hard objects Lugs should be replaced using arc welding equipment so as not to direct too much heat in one area of the shaft 3 Cutter shaft ball bearings are worn enough to have radial play in them Replace ball bearing and other worn parts to eliminate play 4 Shaft is bent Shafts are straight within a couple of thousandths of an inch when they are made It is possible that they will become bent in use such as if the shaft is hooked on a stump while the tractor is moving forward at a good speed 5 Shafts are operated at improper speed Rotating shafts have what is known as a natural period of vibration The same is true of the cutter shafts on the Flail Mowers The actual speed at which the harmonic will occur will vary with each mower and each installation To avoid this harmonic vibration when operating the mower it may be necessary to adjust the engine speed of the tractor up or down Some units ha
212. to Main Har NESS White Outer Connector Con nects to White Wire LIN Wires connect to wing magnet switch Black White Inner Connector Con nects to Black Wire Connector to Wing Motor Solenoid Connector Fastening Screw Interstater Service Manual 03 06 2006 Alamo Industrial Cm pomme Note Dual Wing will use both P N 002496 amp P N 002497 Wire Harness Connector to Main Harness White Connector to Main Harness White Black White Connector to Wing Motor Solenoid Black Schematic P N 002496 Connector Gasket Section 4 13 Pump amp Motor Hydraulic Schematic RH Wing Only Pressure Hose From Pump has a 90 Fitting Connects here Pressure Hose Motor has a 90 Fitting Connects here NOTE The Pressure hose will always be connected to the top fitting and the return will always connect to the bottom Return Hose to Tank Return Filter has a 90 Fitting Connects here Return Hose from Cutter Head Cooling Tanks has a 45 Fitting Connects here YD Main Frame w hose bulkhead fitting RH side of tractor looking from front to rear of tractor Single Wing Shown Dual Wing has metal cross over pipe with a Tee in it for the return Note 45 elbow on bulkhead fitting tha hose connects to j i i Pr N m Tk Figure 41 P tA Le a Interstater Service Manual 03 06
213. to pump housing until itis seated into snap ring groove of housing Install Pin Keeper item 1E and Pins item 1F into spline area of piston block item 1D Compress Pin Keeper and install it in the splined area of the piston block Install the three pins in the special grooves of the spline area of the piston block with the head end of pin toward inside of block Install Washers item 1G amp 1J and Spring item 19H into Piston Block item 1D install Washer item 1G or 1J are the same into the piston block Install Spring item 19H into piston block and against washer item 1G Install second washer item 1J into piston block and against spring CAUTION See Step 7 for spring compression instructions Compress Spring item 1H and install retaining snap ring item 1K CAUTION The following procedure should be used if the spring has been removed from the piston block and is being re installed The spring item 1H will have to be compressed The following parts will be needed to assemble the piston block 2ea 3 8 ID X 1 1 8 OD Flatwasher tea 3 8 NC X 3 1 4 Bolt Hex Head Tea 3 8 NC Hex Nut Contnued Next Page Interstater Service Manual 03 06 2006 Alamo Industrial Section 10 10 Motor Dis Assembly amp Re Assembly Continued From Previous Page Re Assemble Motor For item numbers See Figure 11 8 Continued From Previous Page Place one flatwasher over 3 8 X 3 1 4 bolt place this through center of piston block
214. tor 30 N A Not Applicable 31 NC National Coarse 32 NF National Fine 33 NLA No Longer Available 34 NLF No Longer Furnished 35 NPT National Pipe Thread 36 P1 5 Thread Pitch 37 P2 0 Thread Pitch 38 P2 5 Thread Pitch 39 PL Plated 40 PLT Plate 41 PMP Pump 42 PTO Power Take Off 43 PW Plain Washer 44 REV Reverse 45 RH Right Hand 46 ROT Rotation 47 RPM Revolutions Per Minute 48 SCKT Socket 49 SD Severe Duty 50 SRV Service 51 STD Standard 52 SVR Severe 53 W With 54 W O With Out 55 WLDMNT Weldment When installing fasteners PW and LW generally installed in that order are usually on the side of the fixture or part being fastened that the hex lock nut is on When only HHCS LW and or PW are required they are generally installed in that order Some parts do not require aPW or LW Refer to illustrations for exceptions Fasteners should be installed so they cause the least interference with other parts When securing driveshaft pulley to hub tighten fasteners to 9 Ib ft torque Interstater Service Manual 03 06 2006 Alamo Industrial Section 10 2 Motor Removal amp Replace BEFORE STARTING REPAIRS Service Rules READ THIS A Clean motor and surrounding area completely before removing any connections or Lines NO DIRT OR DEBRIS CAN BE ALLOWED ON OR NEAR HYDRAULIC SYSTEM IF IT IS BEING WORKED ON ANY DIRT OR CONTAMINANTS IN SYSTEM NO MATTER HOW SMALL WILL DAMAGE SYSTEM The hydraulic
215. tractor will be removed and not used so as not to interfere with the clearance of the mower head Any factory options that mount on RH side if equipped will need to be removed also for clearance It will be dealer and or customers choice on where and if the optional equipment is remounted somewhere else for use See Figure 2 On the dual wing units the LH step will also need to be removed 3 Install Main Frame to Tractor The frame rail See Figure 1 will be slid under the tractor on the From the rear See Figure 3 Do NOT tighten the frame mounting bolts until all the bolts have been installed as frame will need to be moved slightly for alignment as the bolts are installed The frame can be installed by balancing the frame on a floor jack if using this method it is recommended two people perform this to prevent the frame from falling Raise the frame up to the tractor frame See Figure 3 4 Raise the frame rail up under the tractor Until the rear mounting plate is under the rear axle and aligned with factory holes in the center of rear axle housing Using the jack raise the frame up until it is against the rear axle housing Install the new bolts and lockwashers Do not tighten these bolts until all bolts are installed into the frame 5 Install Front Frame Mounting Brackets The front frame mounting brackets will consist of a RH and a LH Bracket See Figure 4 5 amp 6 Bolt these mounting brackets to the tractor frame with two bolts on each s
216. ts do not require aPW or LW Refer to illustrations for exceptions Fasteners should be installed so they cause the least interference with other parts When securing driveshaft pulley to hub tighten fasteners to 9 Ib ft torque Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 2 Tandem amp Single Pump Removal 1 INTRODUCTION In Most diagrams there are no Component Part Numbers Listed Only Item numbers and Descriptions This is because most parts shown as breakdown in drawings are for location identification or if available as parts Replacement parts will be listed in the Parts Operators Asy Manual This Manual is designed to be used with these other manuals 2 BEFORE STARTING REPAIRS Service Rules READ THIS A Remove FrontCover Clean Pump and surrounding area completely beforeremoving any connections or Lines NO DIRT OR DEBRIS CAN BE ALLOWED ON OR NEAR HYDRAULIC SYSTEM IF IT IS BEING WORKED ON ANY DIRT OR CONTAMINANTSINSYSTEMNO MATTER HOW SMALL WILL DAM AGE SYSTEM The hydraulic system must be kept SURGICALLY CLEAN to ensure proper operation and long life of the pumps motors and valves All components must have protective caps over openings connected to internal spaces to prevent contamination Itis important that care be taken during unpacking parts and assemblies to make certain no other contaminants which will damage parts are introduced to hydraulic system B After cleaning around all connection
217. uggish response to acceleration or deceleration Cause A Air in system Solution A Check oil level and fill Check for loose suction line and or fittings Check for clogged suction filter and replace as needed Oil to heavy change to proper viscosity oil Cause B Internal pump or motor wear or damage Solution B Disassemble inspect and repair Interstater Service Manual 03 06 2006 Alamo Industrial Section 2 5 NOTES Interstater Service Manual 03 06 2006 Alamo Industrial Section 2 6 Section 3 interstater General Specifications SPECIFICATIONS INTERSTATER READ THIS BEFORE BEGINNING ASSEMBLY REPAIRS OR TESTING The Interstater has electric components The electric compo nents can be damaged if care Is not taken when performing repairs testing and or during assembly DO NOT DO NOT short any wires across or allow them to be shorted out 2 DO NOT attempt to jump across any wires or supply them with alternate power source 3 DO NOT install higher rated fuses than are recommended by manufacturer 4 DO NOT do any welding on unit unless the computer modules are unplugged first If equipped with electronics this is to prevent a power surge going into modules THIS IS VERY IMPORTANT This could also apply to the tractor components Check Tractors repair guide for specific instruction about tractor model and type 5 DO NOT attempt to repair or adjust a compon
218. ulic system in any way before completely cleaning the area and all tools to be used Keeping every thing clean work area tools drain pans and components to be repaired is very important 2 Toremove the Hydraulic Tank will require the removal disconnection of hydraulic lines andfittings All hoses fittings and ports must be capped Sealed immediately after they are disconnected NO hydraulic component should be left open this would allow contamination of the hydraulic system which will damage the system Hydraulic Tank Case WE sma Pump MR ENT Drain To Pressure Port Port Small 1 Same hydraulic tank Tank a rs Used Single or Tandem Pump gt The same hydraulic tank is used sn on the single and tandem pump Pressure L i r 7 i models When used with the Out Port ka an Leave Capped single pump Single Wing Model To RH ns T ri on RH Only some of the ports will remain Wing Motor capped See Figure 1 amp 2 2 There are not many re Case pairs to the hydraulic tank that Drain From are required Usually the tank is Pump removed to gain access to an Suction other component of the tractor Port From Figure 1 lic Tank To remove the oil from the hydraulic tank it is recom mended thatan oil buggy be used MR Case P Tank Suction se e these are available on the com eee Drain To G Port Small Pressure mercial market Oil buggies use ao Tank N of Out Port 3 Remove Oil from Hy
219. ump is to set aside for use at latter date pumps moving components should be coating with something that will withstand the time pump is sitting Petroleum Jelly vaseline which can be purchased local This will work excellent for this as it will stick to the pump components while spare pump is sitting on parts shelf If parts are to be assembled later the parts should be rewashed and cleaned Install Snap Rings item 6 and Thrust Race amp Bearing item 5 on Driveshaft Install inner snap ring item 12 onto driveshaft from input end Install one Thrust Race part of item 5 onto driveshaft sliding it down against snap ring Install Thrust Bearing part of item 5 onto driveshaft until it is against Thrust race Install Second Thrust Race part of item 5 onto driveshaft until it is against thrust bearing Install second snap ring item 4 onto driveshaft until seated in snap ring groove of driveshaft and seated against thrust race Replace Needle Bearing item 9 into Pump Housing item 11 Installneedle bearing asy into the pump housing If necessary install driveshaft item 7 into pump housing item 11 and install Washer item 3 Install Input Seal Seal Adapter Kit Replace the O ring Seal item 2A on seal adapter item 20 Install input seal item 2B into seal adapter Coat the I D of Shaft Seal item 2B and O ring item 2A of seal adapter Press seal adapter assembly into the pump housing item 11 Install the outer snap ring item 10 in
220. und and test unit If the inboard drive bearing is to be replaced proceed to step 6 DRIVE END CUTTERSHAFT BEARING See Figure 20 21 amp 22 6 Remove spring from idler arm 7 Remove motor mounting bracket fasteners atthe cutter housing Pivot motor mounting bracket assembly and remove drive belts 8 Remove fasteners that secure pulley to cuttershaft See Figure 21 item 2 Remove pulley and key See Figure 21 amp item 2 9 Remove fasteners securing inboard bearing and housing assembly to cutter housing then remove bearing and housing assembly Refer to Illustration 9 NOTE There are two tapped holes in the housing which can be used to pull bearing and housing assembly out by using special tool P N 701627 10 Using a jack to align parts install inboard bearing and housing assembly to cutter unit Grease bearing and install cap over fitting 11 Reinstall key and pulley Secure with cuttershaft fasteners 12 Remove jack and check shaft rotation Reinstall knives which were removed 13 Reinstall drive belts then secure motor mounting bracket to cutter housing 14 Reinstall idler arm spring 15 Reinstall belt guard 16 Remove supports lower unit to ground and test unit Reinstall outboard fender if not already installed FIGURE 20 Interstater Service Man 03 06 2006 Alamo Group Inc Section 12 9 Continued Next Page Mower Repairs Rear Mower CUTTERSHAFT REPLACEMENT NOTE Itis recommended
221. upler Splined Coupler Only Pulley Weldment Use when Tractor bearings that are replaceable if shaft and or gear wear Use w Aux Hyd Hyd System is used surface is damaged or worn the pump will need to be Pump System to supply cylinders replaced as an assembly Check the mating edges of the pump body and cover with a straight edge to make Figure 27 certain the edges are flat and not warped The gear set the pump body and pump cover are not replaceable as parts these will only be replaceable by replacing the complete pump assembly The Shaft Seal Seal Plate O Ring Seal Asy Anti extrusion Block Wear Plate Gasket Insert Bridging Insert are available as replace ment parts in the form of a pump repair kit Interstater Service Manual 03 06 2006 Alamo Industrial Section 5 29 Auxiliary Pump Re Assembly 20 ASSEMBLE AUXILIARY PUMP NOTE To assemble and dis assmble the auxilary steps are basically the same inreverse Use Dis assembly and Re Assembly section A See Figure 28 amp 29 Auxiliary Pump Pump Een Assembly I Bolts iit Place Pump Body into Vice Clamp the pump body in a vise with protective devices for the jaws See Figure 19 Clamp the pump body in the vice at the pump Vice Jaw Pro mounting flange use caution DO NOT over tightenthe tective Pads vice and damage pump mounting flange Install Shaft Seal into Pump Body the seal is installed with seal lip inward toward gears
222. ustrial Osona Note Dual Wing will use both P N 002496 amp P N 002497 Wire Harness Connector to Main Harness White Connector to Main Harness White P Black White Connector to Wing Motor Solenoid Black Schematic P N 002496 Connector Gasket Section 8 19 Hyd Supply From Tractor Hyd To Control Valve Tractor Remote Hoses for the Hyd Outlets Lift and Tilt Connecting Gylinders To A cylinders are Tractor Control Valve for Hydrau the same size lic Supply Qty 3 of Hose P N 02905100 When the tractor hydraulics are 4 4FJX used to supply and operate the cylinders AFJXX 114 there will not be a control valve shipped with the mower The hydraulic cylinders will connect direct to the tractors remote outlets and the tractor controls will be used See Figure 14 When using the Auxiliary front pump for the cylinder hydraulic system there will be a control valve and compo Make certain lift nents shipped See the section for install control spacer was ing the auxiliary pump and control valve Long so Vent installed on Lift cyl See Figure 12 amp 13 RH Wing RH Wing Tilt Cylinder Lift Cylinder Figure 60 Interstater Service Manual 03 06 2006 Alamo Industrial Section 8 20 Section 9 Interstater SERVICE MANUAL Main Frame amp Wing Lift Arm Weldment NOTE Shown here is a typical illustration of the way the mainframe and wing lift weldments
223. ut down and parked safely according to tractor manufactures instructions NEVER work on or repair mowers with tractor running and mowers supported by hydraulic system 2 Mowing is accomplished by a series of knives which rotate at high speed on a shaft On Wing Mowers the shaft is driven by a hydraulic motor through a set ofdrive belts Belt tension is maintained by a spring loaded idler pulley drive belts Belt tension is maintained by a spring loaded idler pulley 3 The cutter unit is mounted to the lift frame by two mounting pins and held in place by a hydraulic cyl This cylinder is used to tilt the cutter unit to allow mowing on an al and tilting to the vertical position for transporting Another hydraulic cylinder is mounted to the lift frame and the lift cylinder support This cyl is used to raise the cutter unit via the lift frame 4 The cutter unit rides on a large roller assembly The position of this roller is adjustable and will determine the cutting height of the knives REPLAGE DRIVE BELTS NOTE Belts must be replaced as a matched set DO NOT replace just one belt See Figure 12 amp 14 1 Place unit on ground or support securely 2 Remove belt guard 3 Remove idler arm spring 4 Remove motor mounting bracket front bolt and loosen rear bolt 5 Pivotmotor mountingbracket assembly Remove old belts and install new ones 6 Reinstall front mounting bolt then secure motor PEN Motor Drive Pulley mounting bra
224. v shaft Bearing amp LoBkColler ss Figure 5 i Pump Mount Weldment Mounting Bolts 4 EMi mee Ge A Foue o Je Interstater Service Manual 03 06 2006 Alamo Industrial Section 7 3 Pump Mount Weldment Remove amp Replace 6 Pump Mount Weldment Removed The pump mount weldment removed only the driveshaft will remain showing if it was left in bolster below figure 9 amp 10 show the pump mount plate removed Figure 9 shows where driveshaft runs under batter through the tractors front bolster Figure 10 shows with the battery for this model tractor removed this is for illustration only The battery or battery tray will not have to be removed to remove the driveshaft Driveshaft will be sticking out under battery tray as shown in figure 9 T Crankshaft Pulley adapter The crankshaft pulley will have a pulley adapter bolted to it This adapter will have a splined center that the driveshaft will slide into If the pulley adapter is to be removed or replace make certain that the bolts and washers that are removed are replaced with the same length as the old ones If longer bolts are used the crankshaft pulley as well as the tractor engine will be damaged gg DO NOT modify this adapter unless instructed to do so by Alamo Spacer Blocks Industrial See Figure 11 8 Pump Mount Weldment Replacement The procedure to replace the pump mount weldment will be the reverse of the disassembly procedure Importan
225. ve a harmonic which occurs below the nominal operating speed On these units it will be noticed that there is always a little vibration at a particular RPM as the mower is being sped up to operating speed This occurs as the shaft passes through its normal harmonic vibration point As long as the mower is opened at the proper speed then harmonic vibration will not be an issue Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 25 NOTES Interstater Service Man 03 06 2006 Alamo Group Inc Section 11 26 Section 12 INTERSTATER Rear Mower Repairs Mower Repairs Rear Mower INFORMATION ON FLAIL MOWER VIBRATION EXCESSIVE VIBRATION Vibration is a MONSTER and if allowed to continue unchecked can cause the complete break up of a machine in a very short time A properly operated Flail Mower will produce very little vibration If vibration does occur the mower should be STOPPED IMMEDIATELY and CORRECT THE TROUBLE NOTE warranty does not cover failures resulting from continued operation after something happens to cause the mower to vibrate excessively Vibration is caused by a rotating part which is out of balance This could be the cutter shaft or on those models rear Mower having a universal slip joint assembly drive shaft from the drive shaft If the two extreme ends of the drive shaft the splined yokes which fit on the tractor power take off shaft and on the mower gear box driven shaft are n
226. ve force to install piston block assembly if it will not slide together with the force of your hand there is something wrong 10 Install Needle Bearing item 17 into Back Plate Asy item 2 The needle bearings will install into center opening of back plate Coat this bearing with oil as you slide it into back plate Install Bearings into back plate with number end of bearing up and visible Bearing will be slightly higher 09 than back plate See Figure 18A 11 Back Plate item 2 amp Sealing O Ring item 8 The back plate is sealed with an O Ring that is inserted into a groove on back plate item 2 make certain this O Ring is seated into this groove lubricate the OD of O Ring to aid inserting of Back Plate into pump housing 12 Back Plate Asy item 2 Roll Pin and Alignment The backplate has a Roll Pin installed into it This roll pin item 18 isto align back plate on pump housing so front flange of housing and back plate ports will be in the correct orientation roll pin should not be more that 173 higher than surface of back plate This alignment is important and must be correct Make certain the roll pin is in the back plate Lower the Back Plate item 2 down onto the pump Housing item 4 aligning the back plate down over driveshaft until the sealing O Ring item 8 inserts into pump housing Back plate should slide down until it is inside of pump housing If back plate can not be pushing completely down without a lot of force ch
227. ved with the motor The procedure to remove repair and or replace will be the same For illustration it will be assumed the manifold was removed with the motor 2 Remove Hoses from Manifold If hoses are still connected to manifold and only manifold is being removed see step 3 in previous section Make Certain all motor components and area around motor have been cleaned before disconnecting any components Make certain to cap or plug all opened hydraulic connections immediately after opened to prevent contamination from getting in system Make certain all work areas and tools are cleaned 3 Clamp Pump and Manifold in Vise Clamp the motor and manifold in vise with Motor Case Drain Port protective caps on jaws of vise See Figure 9 Pressure Relief High Pressure with the manifold up 4000 psi InletPort 4 Remove Manifold from Motor Re move the four manifold mounting bolts See Figure 9 Lift the manifold up off of motor There are two O Rings between manifold and motor make certain these O rings did not Motor stick to motor back plate or to the manifold Manifold Locate these O rings andremove them now 5 Repair Manifold The Motor Control Manifold will not have alot of components that will need repairing The most important thing ne 4 about manifold is cleaning and inspecting Motor Case ne BEY This is best done by removing all the compo Drain Port QK a SX Low Pressure i Return Oil nents from the manifold Wash
228. wer it may be necessary to adjust the engine speed of the tractor up or down Some units have a harmonic which occurs below the nominal operating speed On these units it will be noticed that there is always a little vibration at a particular RPM as the mower is being sped up to operating speed This occurs as the shaft passes through its normal harmonic vibration point As long as the mower is opened at the proper speed then harmonic vibration will not be an issue Interstater Service Man 03 06 O 2006 Alamo Group Inc Section 12 2 Rear Mower Rear Three Point Mower Connection 1 Install Rear Lift Chains Option Rear lift chains will replace three point lift links using the same pins you removed from lift links These chains allow mower to float with contour of the ground These are optional equipment and may or may not have been ordered See Figure 1 2 amp 3 Note Shown below is a New Holland Tractor in figure 1 2 amp 3 The John Deere check chains will mount the same 2 The Rear Mower is a standard Three Point Hitch mounted mower that is PTO driven through driveline It is sent already assembled with driveline tied to it See Figure 1 3 Connect Lower Hitch Pins Lower hitch pins connect to lift arms of the tractor with click pins pins are furnished with mower See Figure 5 amp 7 It s best to connect lower arms of three point first You will use the lower arms of tractor 4 Connect Upper Hitch Pin Upper hitch
229. wherein the rotational speed through a universal joint is not uniform Ifthe ends of a universal drive shaft are parallel the uneven rotation effect is cancelled out and the machine being driven will be driven at a uniform rate of speed However if the ends are not parallel the uneven rotation effect may be multiplied resulting in a speeding up and slowing down of the entire mower system gear box extension shaft pulleys belt and cutter shaft each revolution This effect can be readily noticed if the mower while running is raised to an extreme height on the tractor lift For smoothest operation the tilt of the mower should be adjusted on a 3 point hitch by adjusting the length of the top link between the tractor and the mower so that the ends of the drive shaft are parallel when the mower is down in operating position Raising the mower while running to extreme heights on the lift should be avoided To check where the vibration is originating first be sure the ends of the universal drive shaft are parallel Then if vibration is still present remove the drive belt and run the mower If vibration is still present it most likely is coming from and caused by a bent drive shaft If so the shaft should be replaced or straightened If the vibration is gone the drive portion of the mower is running smoothly then the vibration is probably coming from the cutter shaft it could be a pulley out of balance or a faulty belt with a varying cross sec
230. will be removed out of extension shaft housing on the gearbox end The best way to do this is to hold the housing up and drop the shaft down on to apiece of wood lying on the work bench This will force the shaft back up into the housing and at the same time push the bearing down the shaft If extension shaft is removed the snap ring item 6 and bevel ring item 5 must be replaced in the same order as removed when re assembled 7 Remove Splined Coupler The splined coupler item 2 that connects extension shaft to gearbox will slide off There is a grease fitting in this coupler that allows the coupler to be greased 8 Cleanandinspectall parts Clean allthe parts removed except the bearing item 7 Caution must be taken when cleaning bearing item 7 be careful not to use any cleaner or cleaning method that will damaged the seals in the bearing as this is asealed bearing Inspect the splined coupler and grease fitting make certain the splines in the coupler on the shaft and on the gearbox shaft are in good conditions 9 Rebuild Gearbox Assembly See gearbox rebuild steps in this section for gearbox assembly instruction and gearbox identification Next Pages 10 Re Assemble Gearbox Extension Shaft Asy To re assemble gearbox extension shaft assembly to deck reverse the dis assembly steps listed above The extension shaft housing item 4 has a hole in the tube part of it This hole will always be at the gearbox end and will be installed to the
231. with the sleeving through the hose supportring boltedtothe side Eeg B ofthe tractor Tie the sleeving using plasticties aroundthe amp NU hoses to keep it from moving See Figure 9 Tie the sleeving with plastic ties around the pressure hose on the LH side of tractor See Figure 9 6 Install return hose to cross member and Hoses to Control Valve Connect the return hose to the cross member on right hand side of main frame crossmember See Figure 6 The other end will connect to the return filter gt fi S rd ee Tee fitting See Figure 7 amp 10 Note These hose are run RH Wina Deck through a sleeving material and a hose support weldment Fig ure 6 codling Tanke P N 02978281 which bolts to the tractor bolster See Figure 9 this must be done before hoses are connected or they will need to be removed to install them Je JM En Ps Return Hose from 7 Connect Pressure amp Return Hose to Cylinder E Mee CAN ge o Control valve Connectthe pressure hose running fromthe H aN 1 RH side of small pump to RH Top side of control valve The port will be marked with a P cast into it the other end is connected to the small supply pump See Figure 7 amp 8 Connectthereturnhosethatisconnectedtothe Tee Fitting of the return filter to the Return side of the control valve with 1 a T cast into it See Figure 2 amp 5 g m a j J a if _ Return Ho i eg rame Cre Figure 7 LO N er x
232. with a taper lock pulley Remove the bolts and start them in the other holes in the hub This will force the pulley inward off the tapered hub Hub should pull off the pump shaft See Figure 4 j M M Returnf frontwettube High Pressure eee to hydraulic Tank Hose si Anbau Motor Return rear Wet tube Pump Drive Pulley vg Taper Lock Hub VO LR O An fe Key TRIAL D i 5 Drive Belts a Belt ie Cover Br R nel me i ie Figure 3 ai dh al Interstater Service Manual 03 06 2006 Alamo Industrial Section 10 4 Motor Removal amp Replace 6 Remove Motor Asy from Wing Mowers Remove bolts retaining motor mount plate to deck and lift motor off and away from deck 7 Remove Motor Mount Plate From Motor Motor Mount Plate bolts to motor flange Remove these bolts and mount flange will pull off front of motor If Motor mount plate was unbolted from mower with the drive pulley attached to motor Motor pulley will need removal before mount plate can be removed 8 Motor Replace or Repair The motor is being replace continue to next step If motor is being repaired go to motor repair dis assembly assembly section in next pages 9 Reinstall Motor Mount Plate The motor mount plate bolts to the motorflange Motor mount plate bolts to deck of mower The mount plate will not require any adjustment as it bolts to deck in predetermined holes See Figure 4 10 Install Motor Drive Pulley Inser
233. y to exact applications This section covers the removal repair and reinstallation of the hydraulic pump procedure for the Alamo Industrial Interstater mower it also includes instruction for driveshaft hoses and miscellaneous parts to be attached the hydraulic pumps to the tractor These instructions are for working on the pumps used to power wing mower mowers right side mower and left side mower units if dual wing model For mounting one mower side only disregard information concerning the opposite side Hardware quantities shown are for both sides The Auxiliary pump is used to supply the lift and tilt hydraulic cylinder circuit This auxiliary pump will not be used on all units some will use the tractor hydraulic system to supply cylinder circuit F Reference to the left or right side of the Interstater is determined while facing the front of the tractor from the drivers seat The part quantities shown for an illustration pertain only to that phase of repair The quantity given corresponds to the number of parts needed When repairing a single sided model based on a dual sided model the quantity furnished will usually be half the quantity listed Large parts may not always be listed next to an illustration because they are usually easy to identify them from name or description This manual makes reference to individual component parts some of which may have been pre assembled at the factory Abbreviation of P

Tandem Pump

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